Page 1
Service Manual
for the
E Ride 30
Training
Trouble Shooting
A
djustments
Page 2
Contents
1. Remarks 4
2. General 5
2.1 Settings 6
2.2 Brief description 7
2.2.1 Vacuuming OFF/soiled water tank full 8
2.2.2 Initial position of machine
3
.
Check and set machine type, LDS and options
,
view and delete last error 11
3.1 Check and set machine type 15
3.2 Check and set options 16
3.3 Check and set LSD
18
3.4 View and delete last error in display 20
4. Program variuous cleaning cycles as a function of drive
potentiometer setting (check and set) 21
5. Pro
g
ram functions 23
g
2
Page 3
Contents
6. Particular settings according to customer’s requirements
(last error display and water stage selection)
33
6.1 Display of last error 36
6.2 Water stage when start scrubbing 37
6.3 Water stage when start cleaning with green H Minuteman key 38
6.4
Water stage when start cleaning with green bordered key
(increased brush pressure) 39
7. Settings on power electronic (A2) 40
8. Water pump 41
8.1 Water pump standstill recognition 43
9. Diagnosis LED for drive module 44
9.1 Signal measuring at the drive control unit 50
9.2 Settings at the accelerator pedal 57
9.2 A4:X51 plug assignment 62
10. Error reference chart with information on service display
65
11. Adjustment of disk brake 76
12. Wiring Diagrams 77
13. Notes 81
3
Page 4
1. Remarks
• Caution:
• Before working at the machine make sure that the batteries are disconnected
(disconnect battery plug); except for cases of current and voltage measurements.
• When replacing the stripe fuses only loosen the screws. Do not remove them
completely to avoid short-circuit hazard.
Place the new stripe fuses completely i.e. evenly under the screws.
• Measure starting and operating voltage after any repair action to detect any
eventual defect.
•
The applicable safety and accident prevention guide lines should be followed
when servicing the machine.
4
Page 5
2. General
•The Minuteman E Ride 30 uses a service display integrated in the hour meter
display. When turning the key switch ON, a 4-digit display will appear for about 3
seconds, describing the software version (e.g. 3.017), then another 4-digit display may
appear which repeats the last error, followed by the hour meter display.
•In case of malfunction during operation, a red error LED alights and a buzzer sounds.
The actual error code (4-digit number in the service display) with flashing dots
between the numbers will appear in the service display. Only if these criteria are
fulfilled the error is actual
.
5
Page 6
2.1 Settings
The following settings on the control unit (A1)/control panel of each machine must be
defined and checked:
1. Machine type
2.LDS (l
ow discharge signal sender
)
3. Options
4. Delete last error display after elimination
5. Program variants with a given drive potentiometer position
6.Settings via control panel which
may
be defined by the customer:
a. Display of the last (eliminated) error when turning the machine
ON.
b. Water stage selection when start cleaning
7.
Settings on power electronic module
8. DIP-switch for electronic circuit breakers
6
Page 7
2.2 Brief Description
The following electronic modules control the machine:
• Control Unit (A1)
• Power Electronic (A2), referred to as ”module 1” in the diagrams
•
Dri
ve Control Unit
(A4)
• Control Panel (A3)
•The control unit (A1) ensures all control and monitoring functions in the machine
except for the drive control unit
.
•There isn’t any error code is displayed on the dash board display, when an error
occurs at the drive control unit since it is equipped with it’s own diagnosis display
(flashing LED at the drive control unit) (see chapter 9).
•The keys for scrubbing, vacuuming and the green Minuteman key for combined
cleaning can be used autonomously, only the selected function being active.
7
Page 8
2.2.1 V acuuming OFF/
Soiled Water Tank Full
•The vacuuming function is turned OFF either by operator’s key action or
automatically when the signal “Dirty (Recovery) water tank is full” applies.
•Operator turns vacuuming OFF:
•
th
e squeegee is
lifted
• the vacuum motor turned OFF with a delay of 15 seconds
•Turned OFF when tank full:
“
”
•
the soiled water tank full switch opens as soon as the tank is filled
• If the switch opens 3 seconds or longer (spill protection) the squeegee is lifted and
the suction motor turned off with a delay of 15 seconds.
8
Page 9
2.2.2 Initial Position of Machine
•After turning ON the machine, all components are set to “initial position” after the seat
contact switch has closed.
•The lifting elements will lift if they have not been turned OFF in top final position by
the micro switch integrated in the lifting element.
•The motors are turned OFF and the LEDs on the control panel for cleaning elements
extinguish.
•The seat contact switch is connected to the control unit A1 at A1:X7:11+12.
•The A1 control unit’s reaction to activation (opening) of the seat contact switch is
delayed by 2 seconds i.e. if, during operation, the contact is opened for more than 2
seconds, the motors stop and brush head and the squeegee is lifted.
•If the switch is closed again within this delay, operation is not interrupted.
•When the machine is switched ON without the seat switch being closed or when the
switch is opened for more than 2 seconds all functions (driving and cleaning) are now
inhibited.
9
Page 10
2.2.2 Initial Position of Machine
•Test the seat contact switch, its wiring and the module’s input by means of the
dia
g
nosis device: Under code no. 3151 the switch status is displayed (open or closed)
gpy(p)
as detected by the module.
•The drive control unit is equipped with an individual diagnosis and self test function.
•Operation of this unit is thus inhibited if the machine is switched ON but the
potentiometer is not in
NEUTRAL
pos
iti
on or its
NEUTRAL
pos
iti
on is not detected.
•The same applies after the seat contact switch has opened and closed again. The
neutral position of the potentiometer is required as well when actuating the seat
contact switch i.e. the drive control unit has to detect a neutral position of the
potentiometer.
•If the potentiometer position detected by the drive control unit is not
neutral, the LED
at the drive control unit flashes. Refer to the chapter on drive control unit test.
10
Page 11
3.Checking and Setting the Machine Type
•Check and set machine type, LDS and options,
view and delete last erro
r
•The settings described in this paragraph must by all means be checked and modified
if required and in particular after replacing the electronic module.
•
Figure 1 shows the control panel for Minuteman E Ride with the disk brush
.
11
Page 12
3. Check and the Set Machine Type
•Entering the Program Viewing Mode This will display the dip switch settings and
can be used to clear the last recorded error.
•
The dip switches must manually changed, if a change is required
.
•1. Turn OFF machine with the key switch.
•2. Depress "G" and "H" keys the same time and hold, turn ON with the key switch.
•
3
. Hold both k
eys u
ntil a number
(so
ftware version)
appears
in the displ
ay,
then
3
o d bo eys u a u be (so a e e s o ) appea s e d sp ay, e
release both keys.
•The set machine type is displayed automatically. Use the “N” key to scroll the display
of option and LDS settings or thereafter for display of the last (eliminated) error. Use
“
”
the L key to step back for display of previous codes
.
•Quit the session by turning key switch OFF.
12
Page 13
3. Check and Set the Machine Type
“N”
Software version, next display
appears automatically
Machine type setting: 9 stands for E Ride 30
O
p
tion settings
pg
LDS setting (in relation to the battery type)
Displ
ay of last error and rese
t
“L”
13
Page 14
3.1 Check and Set the Machine Type
Changing the settings: This will require changing the dip switch positions.
1. Setting the correct machine type with the Dip switches is absolutely necessary.
T
o change, use the
DIP
-switch A on the control unit
(A1)
.
2. For the Minuteman E Ride 30, the first and the last bar have to be
positioned in the top line and the second and third bar in the bottom line.
This setting results in the displayed in chapter 9 on the display menu.
See below
.
3. If the display does not correspond with these parameters, correct the DIP-switch
settings.
=
E Ride 30
1: ON (
bars in top line)
2: OFF (= bars in bottom line)
3: OFF (= bars in bottom line)
4: ON (= bars in top line)
Chapter 9
14
Page 15
3.2 Check and Set the Options
1. The setting of all options on the DIP-Switch B of the control unit (A1) is absolutely
necessary.
2. The DIP-switches are assigned as follows:
1 -3
: unassigned, i.e.
“OFF”
4: OFF
5: OFF
6: OFF
“
”
7 -8:
unassigned, i.e. OFF
Option Settings
Dip Switch B
15
Page 16
3.2 Check and Set the Options
Control unit (A1)
See Page 15
LSD
Machine
(C) Adjustment of battery type, LSD
DIP-switches S3:
Switch No.: 1 See cha
p
ter 3.3
(A) Adjustment of machine type,
DIP-switches S2:
Switch No.: 1 on
16
p
Switch No.: 2 See chapter 3.3
Switch No.: 3 See chapter 3.3
Switch No.: 4 on =24 volt off = 36 volt
Switch No.: 2 off
Switch No.: 3 off
Switch No.: 4 on
Page 17
3.2 A1 Dip Switch Locations
(B) Adjustment of
options,
DIP-switches S1:
without options
Switch no.: 1 off
Switch no.: 2 off
Switch no.: 3 off
Switch no.: 4 off
Switch no.: 5 off
Switch no.: 6 off
Switch no.:
7
off
Switch no.: 8 off
(A) Adjustment of machine type,
DIP-switches S2:
Switch No.: 1 on
(C) Adjustment of battery type, LSD
DIP-switches S3:
Switch No.: 1 See cha
p
ter 3.3
Switch No.: 2 off
Switch No.: 3 off
Switch No.: 4 on
p
Switch No.: 2 See chapter 3.3
Switch No.: 3 See chapter 3.3
Switch No.: 4 on =24 volt off = 36 volt
17
Page 18
3.2 Options and Machine Type
Adjustment
of options,
o opt o s,
DIP-switches
S1:
(B) Adjustment of
options
,
DIP-switches S1:
without options
Switch no.: 1 off
Switch no.: 2 off
Switch no.:
3
off
Switch no.: 4 off
Switch no.: 5 off
Switch no.: 6 off
Switch no.: 7 off
Switch no.: 8 off
Adjustment of machine type,
(A) Adjustment of machine type,
DIP-switches S2:
Switch No.: 1 on
DIP
-switches S2:
18
O
n
Off
Switch No.: 2 off
Switch No.: 3 off
Switch No.: 4 on
Page 19
3.2 Dip Switches Battery Type
Adjust
ment of battery type
and voltage
DIP-switches S3:
See pages 20-21
19
Page 20
3.3 Check and Set LDS
1. The LDS must be set to the correct battery type.
2. If different batteries are installed, modify the LDS setting as described below. Use
-
the DIP
switch C on the control unit (A1)
.
3. The LDS is set by following this chart. (0= off, 1= on) See next the page for
definitions.
Displayed2 34567
code →
Di
p
- GIS GIS PzS PzS Gel Gel
p
switch foreign foreign (Sonnen- (Deta)
schein)
1 0 (off) 1 (on) 0 (off) 1 (on) 0 (off) 1(on)
2 1 (on) 1 (on) 0 (off) 0 (off) 1 (on) 1(on)
3 0 (off) 0 (off) 1 (on) 1 (on) 1(on) 1(on)
4 (1) ON = 24 V
20
Page 21
3.3 Check and Set the LDS
•“1” means ON; “0” means OFF
•“Foreign” means all after market batteries.
•Reset voltage: approx. 25.5V.
•Caution: The maintenance-free Gel batteries are no longer
diff
erentiated by the
manufacturer (Sonnenschein or Deta). The setting is related to the type of battery
used e.g. setting 6 for GIV batteries and setting 7 for PzV batteries, irrespective of the
manufacturer. (For historic reasons, the denominations Sonnenschein and Deta are
not eliminated in the documents
.
•Battery Definitions
•GiS Battery - Is a flooded wet acid battery with grid plates
•
-
PzS Battery
Is a
tubular plate wet battery
•GiV Battery - Is a grid plate Gel battery
•PzV Battery - Is tubular plate Gel battery
21
Page 22
3.4 View and Delete
Last Error in Display
V
iewing
1. Enter into the Program Viewing mode (See Section 3: Entering Program Viewing
Mode
2. D
epress
“N” key three tim
es,
the 4-digit error
code
with flashing dots will
appea
r
ep ess ey ee es, e
d g e o code as g do s appea
(last and eliminated error).
3. Quit the session by turning the key switch OFF (must not be executed when
passing to “deleting”).
Deleti
ng the Last Error
1. Depress “O” key and hold until 0.0.0.0. is displayed
2. Release key, turn key switch OFF and ON.
3. 0.0.0.0. will a
pp
ear (after display of software version) for approx. 3 seconds
pp ( p y ) pp
followed by the hour meter display.
4. You may view the last error in the menu as described under “View”, since such data
cannot be deleted in the menu.
5. Quit the session by turning the key switch OFF
22
Page 23
4. Program V ariations
•Program Variations
The scrubbing and vacuuming features may be adjusted on the E Ride 30 scrubber
when in the programming mode. See the following for details:
•Checking the Programming Settings
1. Turn machine OFF with key switch.
2. De
p
ress "N" and "O" key the same time and hold, turn key switch ON
py y
3. Hold both keys until a number (software version) appears in the display,
thereafter release both keys.
4. The programs may also be viewed by depressing the “L” key (down)
or the “N” key (up).
5. Th
e active program is marked by a dash and the number.
23
Page 24
4. Program V ariations
•Changing the Settings
1. Select the required program with the “L” or “N” key (when in the
programming mode)
2. Depress “O” key and hold until the dash appears with the number.
The
prog
ram is now saved and active.
pg
•Note: To quit the session, turn the key switch OFF.
Page 25
5. Program Functions
Use for all software versions up to 3.017
The d
escription of program functions requires the “brush motor” and/or “vacuuming”
function being turned ON. All programs allow normal cleaning or vacuuming in the
‘forward’ drive potentiometer position. The following chart shows the differences for
‘neutral’ and ‘reverse’ drive potentiometer position ( up to software version 3.017
).
Program Drive Function is activated by driving or stoppin
g
g
ygppg
code potentiometer
setting
Brush head Squeegee
Neutral Brushes and water ON Vacuuming remains ON
1
Reverse Brushes and water ON Squeegee OFF + lifted
25
Page 26
5. Program Functions
Use for all software versions up to 3.017
Program Drive Function activated by driving or stopping
codes Potentiometer
setting
B
rush head
S
queegee
Neutral Brushes and water ON Squeegee OFF + lifted
2
Reverse Brushes and water ON Squeegee OFF + lifted
Neutral Brushes and water OFF Vacuuming remains ON
3
Reverse Brushes and water ON Squeegee OFF + lifted
26
Page 27
5. Program Functions
Use for all software versions up to 3.017
Program Drive Function is activated by driving or stopping
codes potentiometer
setting
B
rush head
S
queegee
Neutral Brushes and water OFF Squeegee OFF + lifted
brush head lifted
(3 seconds delay for
brushes to prevent
brushes from being
4 turned OFF when
switching from forward
to reverse mode)
Reverse Brushes and water ON Squeegee OFF + lifted
27
Page 28
5. Program Functions
Use for all software versions up to 3.017
Program Drive Function is activated by driving or stopping
codes potentiometer
setting
B
rush head
S
queegee
Neutral Brushes and water OFF Squeegee OFF + lifted
(3 Sec. delay)
5
Reverse Brushes and water ON Squeegee OFF + lifted
and lowered
Neutral
Brushes and water OFF
, Vacuuming remains ON
brush head remains
lowered
6
Reverse Brushes and water Squeegee OFF + lifted
28
remain OFF
Page 29
5. Program Functions
Use for software version 3.018 and Higher
On f
rom software version 3.
018
a
dditi
onal program functions are implemented to the
machine control. This allows to work on sensitive floor without leaving marks on the
floor. Remark: as a result of this short switch off times, the life time of brush motor and
lifting element will decrease.
Program Drive Function is activated by driving or stoppin
g
g
ygppg
code potentiometer
setting
Brush head Squeegee
Neutral Brushes and water ON Vacuuming remains ON
1
Reverse Brushes and water ON Squeegee OFF + lifted
29
Page 30
5. Program Functions
Use for software version 3.018 and Higher
Program Drive Function is activated by driving or stopping
codes potentiometer
setting
B
rush head
S
queegee
Neutral Brushes ON, water OFF Vacuuming remains ON
2
Reverse Brushes and water ON Squeegee OFF + lifted
Neutral Brushes and water OFF Vacuuming remains ON
3
Reverse Brushes and water ON Squeegee OFF + lifted
30
Page 31
5. Program Functions
Use for software version 3.018 and Higher
Program Drive Function is activated by driving or stopping
codes potentiometer
setting
B
rush head
S
queegee
Neutral Brushes and water OFF Squeegee OFF + lifted
brush head lifted
(3 seconds delay for
brushes to prevent
brushes from being
4 turned OFF when
(long
switching from forward
switch Off to reverse mode)
time)
Reverse Brushes and water ON Squeegee OFF + lifted
31
Page 32
5. Program Functions
Use for software version 3.018 and Higher
Program Drive Function activated by driving or stopping
codes potentiometer
setting
B
rush head
S
queegee
Neutral Brushes and water OFF Vacuuming remains ON
5 (3 Sec. delay)
(long
brush head lifted
switch OFF Reverse Brushes and water ON Squeegee OFF + lifted
time) and lowered
Neutral
Brushes and water OFF
, Vacuuming remains ON
6 brush head remains
(medium lowered
switch OFF
time) Reverse Brushes and water Squeegee OFF + lifted
32
remain OFF
Page 33
5. Program Functions
Use for software version 3.018 and Higher
Program Drive Function is activated by driving or stopping
codes Potentiometer
setting
B
rush head
S
queegee
Neutral Brushes and water OFF Vacuuming remains ON
7 (less than 1 sec)
(short
switch OFF Reverse Brushes ON Squeegee OFF + lifted
time) water OFF
Neutral
Brushes and water OFF
, Vacuuming remains ON
8
(long
switch OFF
time) Reverse Brushes and water ON Squeegee OFF + lifted
33
Page 34
5. Program Functions
The water supply, brush or vacuuming function LED or the Minuteman E Ride key
(green key) is flashing if the selected function is turned OFF due to the drive
potentiometer setting.
*The brush motors switch off with a delay of 3 seconds. This delay precludes
switching off in case of direction alteration but allows it in neutral drive potentiometer
position.
34
Page 35
6. Optional Settings
’
Optional settings can be set according to customer s requirements
(last error display and water stage selection)
The settings described in this paragraph may be modified following the customer’s
re
q
uirements. The settings made in the factory may be altered.
qgyy
35
Page 36
6. Particular Settings
Entering the Programming Mode
1. Turn machine OFF with key switch.
2. Depress “G” and “O” key the same time and hold, turn key switch ON.
3. Hold both t
ouch pads buttons un
til
a number (software version) appears in the display,
then release both keys.
The following programmed settings will appear automatically in the display:
• last (eliminated) error display when turning ON: yes/no
water stage when start cleaning (scrubbing only): last selected stage or middle
stage
• water stage when start cleaning (with green Minuteman key): last selected stage
or stage 2
• water stage when cleaning has started(with green bordered key for increased brush
pressure): last selected stage or stage 6
36
Page 37
6. Particular Settings
•
currently programmed setting
water stage setting
error display
37
Page 38
6.1 Display of Last Error
1. Select required setting with “L” and “N” keys.
2. The bar of the setting to be modified is flashing.
3.M
ove the bar up or down w
ith “M” k
ey.
Up = ON = error code (of eliminated error) will appear for
approx. 3 seconds in the display after turning ON
Down = OFF = error code (of eliminated error) is not displayed
(will not be displayed during start up)
.
4. The setting is saved by pressing the green key (“O” key) until the dot appears in
the display at the right bottom.
38
Page 39
6.2 Water Stage When
Start Scrubbing
1. Select required setting with “L” and “N” keys.
2. The bar of settings to be modified is flashing.
3. M
ove the bar up or down w
ith “M” k
ey.
Up = ON = last selected stage is set
Down = OFF = middle stage is always set
“
”
4.The setting is saved by pressing the green key (O key) until the dot appears in
the display at the right bottom.
39
Page 40
6.3 Water Stage
Water stage when start cleaning with green Minuteman key
1. Select required setting with “L” and “N” keys.
2. The b
ar of se
tti
ngs to be mo
dified is flashi
ng.
3. Move the bar up or down with “M” key.
Up = ON = last selected stage is set
Down =
OFF
= 2ndstage is always set
4. The setting is saved by pressing the green key (“O” key) until the dot appears in
the display at the right bottom.
40
Page 41
6.4 Water Stage When
Start Cleaning
Water stage when start cleaning with green bordered key
(increased brush pressure)
1. Select required setting with “L” and “N” keys.
2. The bar of settings to be modified is flashing.
3. Move the bar up or down with “M” key.
Up =
ON = last selected stage is set
Down = OFF = 6thstage is always set
4. The setting is saved by pressing the green key (“O” key) until the dot appears in
the display at the right bottom.
41
Page 42
7. Settings on the
Power Electronic Module (A2)
The correct DIP-switch settings on the power electronic module (A2) are necessary
since they have an influence on the electronic circuit breaker values for the lifting
elements (brush head and squeegee).
DIP
-switch se
tti
ngs:
1: OFF
2: ON
Circuit breaker values:
Brush head: 5.7 A
Squeegee: 1.9 A
42
Page 43
8. Water Pump
For check purpose of the water pump function, the voltage of the different stages can
be measured on power electronic module (A2:X2:6+7). In case of measurement with
measuring device Fluke 87, water in tank but suction turbine turned OFF, the result is:
Disk Brush ____________
stage 1: xxx V
(cannot be evaluated because of
value variation caused by the pulses)
stage 2: xxx V
(cannot be evaluated because of
value variation caused by the pulses)
stage 3: approx. 5.0 V
stage 4: approx. 6.7 V
stage 5: approx. 8.7 V
sta
g
e 6: approx. 13.2 V
g
pp
stage 7: approx. 17.8 V
When not using the indicated measuring device the result may vary since the voltage
is pulsed. The value depends on the battery voltage as well. In the present case
measurement was executed w
ith ch
arged battery and three green
LED
s alight.
43
Page 44
8. Water Pump
A good basis is measuring the water quantities.
Let th
e pump run and measure the delivered quan
tit
y of water per minute.
The quantities are indicated in the operating instructions as follows:
Stage1234567
Disk 1,0 1,3 1,6 2,0 2,4 3,6 5,2
Brush
Water quantity l/min
If voltage supply of the pump is as required but the measured water quantity does not
correspond with the indicated parameters, check the hoses for clogging or damage;
check the solenoid valve for opening correctly, and the function of the diaphragms of
the valve plate in the pump.
44
Page 45
8.1 Water Pump
Standstill Recognition
If the pump does not deliver water to the brushes
due to clogging of the hoses. The Standstill Recognition is Activated.
Automatic standstill recognition for water pump:
•
The electronic module allows for protection of the water pump, if the pump does not
deliver correctly. This means if the pump takes in water from the tank and cannot
deliver it to the brushes, because of possible kinked hose, faulty water solenoid or
spray tubes. The pressure will build at the pump. Without being protected by the
electronic module the pump would deliver against this pressure and could be damaged.
•A restricted water flow to the pump such as a clogged filter, empty tank or kinked hose,
could also activate the protection.
•
The electronic module detects the blocked delivery and automatically switches the
pump off for 2 seconds. After this delay, the pump is briefly switched on again and it
is simultaneously measured whether delivery of water to the brushes is free or blocked.
If delivery is as required, the pump remains ON in the selected stage. If the pressure
45
still exists, the pump is switched off again for 2 seconds. This procedure is repeated
until the error is remedied.
Page 46
9. Diagnosis LED for the
Drive Module
The LED is located on the drive module
LED shows Malfunction Remarks
OFF
Dri
ve module is
Volt
age supply interrupte
d
inoperable Check fuses and wiring;
No release signal at A4:X51:2
ON
Drive module is
Drive module function OK
serviceable
2 flashes Wrong start sequence Accelerator actuated and
direction selected, then ON
with key switch = no reaction;
return to neutral position
46
Page 47
9. Diagnosis LED for the
Drive Module
LED shows Malfunction Remarks
3 flashes “M” and “B-” Check cable to drive motor;
short-circuite
d
check carbon brushes;
Check chassis of the
machine for potential, if OK
but error code displayed,
replace the drive module
47
Page 48
9. Diagnosis LED for the
Drive Module
LED shows Malfunction Remarks
4 flashes Direction contactor Do contactors switch and do
stuc
k
th
e correct direction selection
signals apply at the drive
control unit?
Check motor connections for
short circuit or contact to
chassis and remedy if required
since chassis has to be free of
potential; Check for leakage
current between battery and
chassis.
Check cable to drive motor;
check carbon brushes; if OK
but error code displayed,
replace the drive module
48
Page 49
9. Diagnosis LED for the
Drive Module
LED shows Malfunction Remarks
5 flashes Direction contactors do Do contactors switch and do
not close or no
th
e correct direction selection
connection to drive signals apply at the drive
motor control unit?
Check cable to drive motor;
check carbon brushes; if OK
but error code displayed,
replace the drive module
6 flashes
Drive potentiometer or cable
Check drive the potentiometer
and connection interrupted
wiring, possible loose contact
at the plug connectors
Is drive potentiometer not in
neutral position when machine
is turned ON?
49
Page 50
9. Diagnosis LED for the
Drive Module
LED shows Malfunction Remarks
7 flashes Battery low, Measure battery voltage
l
ess than 13 Voltsun
d
er load
(measure at input of the drive
control unit as well),
Check connections and fuses
50
Page 51
9. Diagnosis LED for the
Drive Module
LED shows Malfunction Remarks
8 flashes Excessive tem
p
erature Is travel drive smooth?
p
of drive module Correct position of parking
(70 °C or more) brake?
Excessive uphill riding?
Measure operating voltage of
the motor line “A2” at full
throttle on level ground using
a clip-on current transformer
(approx. 26A max. at transport
ride and 30A max. at cleaning
ride)
Check correct mounting of
drive control unit in the
machine
51
Page 52
9.1 Signal Measuring at
the Drive Control Unit
•
Check the following items when testing the drive control unit. If the respective signals
do not apply, the drive control unit does not work sufficiently.
In the circuit diagram the drive control unit is designated with A4.
When testing the drive control unit, be supported by the circuit diagram and check the
connections there since the complete procedure became more complex by releasing
via A1, closing the drive rheostat switch, the direction switch and the K4 relay. There
is function interaction and the switches and the relay are connected in series.
Note
: The red drive control unit cable with integrated fuse is not connected and
remains free even after replacement of the drive control unit.
52
Page 53
9.1 Signal Measuring at
the Drive Control Unit
1. Self
-
test
Before the drive control unit is operable, it executes a self-test. This self-test starts
automatically after switching on the machine with key switch.
If, during this self-test, the drive control unit detects an error, the LED on the unit
-
flashes to signal non
operability. The machine will then not start riding
.
Key switch ON -> the battery + signal has to apply at A4:X51:2.
Then the self-test starts and the result is signalled by the LED of the drive control unit.
Onl
y
if the LED lights permanently, the drive control unit is operable. If the LED
ygpy p
flashes, check for possible causes of error with the table below.
53
Page 54
9.1 Signal Measuring at
the Drive Control Unit
2.Drive direction
The drive direction is set via the direction selector switch S7 but closing of this switch
alone is not sufficient for signalling the selection to the drive control unit.
Simultaneous releasing of A1, closing of the drive rheostat switch S8 and the K4
relay switching contact is required.
Release on A1
The control unit A1 monitors the seat contact switch and all other functions of the
machine. The control unit releases driving only after all conditions (= seat contact
switch closed) have been met. Releasing means that the contacts A1:X4:3 and
A1:X3:1 are connected on the A1 module to initiate transfer of the battery minus
signal from the A1:X4:3 contact to the A1:X3:1 contact. Only if the battery minus
signal applies at A1:X3:1 release is given as first condition for the drive control unit
to detect the dri
ve direction.
54
Page 55
9.1 Signal Measuring at
the Drive Control Unit
Drive potentiometer switch S8:
Thi
s switch is located at the accelerator and is closed after pedal actuation. Then
the battery plus signal is transferred to the coil of the K4 relay and the relay closes
the switching contact.
Relay K4:
After the drive potentiometer switch S8 has closed, the battery plus signal applies at the
K4 relay’s coil and closes the switching contact. This contact is located in series with
the direction switch S7 between the control unit A1:X3:1 and S7.
Now the batter
y
minus signal can be transferred from A1:X3:1 via the switching
yg g
contact of K4 and the direction selector switch S7 to the drive control unit.
Battery minus at A4:X51:4 -> forward
Battery minus at A4:X51:5 -> reverse
Now the direction contactors of the drive control unit close contact.
Result for drive direction:
If the drive control unit does not switch the direction contactors after drive direction
has been selected and the accelerator actuated, check the above mentioned signals/
55
voltages, connections, switches etc
.
Page 56
9.1 Signal Measuring at
the Drive Control Unit
3. Speed
The speed attained directly depends on the drive potentiometer which is actuated
via the accelerator pedal.
The max. speed with full throttle is:
Forward ride: approx. 7.1km/h
Reverse ride: approx. 3.8 km/h.
-
With a free
wheeling drive wheel (jacked machine and cold drive motor)
,
the parameters are as follows:
Forward ride: I ≈ 12.5A ; drive wheel speed: n ≈ 230 rpm
Reverse ride: I ≈ 11.5A ; drive wheel speed: n ≈ 130 rpm
To attain a higher final speed in forward ride than in reverse ride, a signal is
transferred to the drive control unit.
56
Page 57
9.1 Signal Measuring at
the Drive Control Unit
Forward ride: attaining 100% of the final speed:
In order to attain 100% of the final speed in forward ride, the battery minus signal has
to be transferred from the A1:X3:3 contact of the control unit to the drive control unit
contact A4:X51:1 1.
Therefore, the contacts A1:X4:4 and A1:X3:3 on the A1 are connected. This link
initiates transfer of the battery minus signal from A1:X4:4 contact to the A1:X3:3
contact. Before these transfers may happen, the battery plus signal has to be
transferred via the direction switch S7 to the control unit A1.
Information about drive direction to A1:
The S7 drive direction switch is connected to the control unit at the A1:X8:9 and
A1:X8:10 contacts. This link allows transfer of the information about the selected
drive direction (forward or reverse) to the control unit. This transfer only works if
the drive rheostat switch S8 has closed such that the battery plus signal can be
transferred to the control unit.
Then the A1:X4:4 and A1:X3:3 contacts on A1 are connected in forward ride
(= 100% of the max. speed) and re-opened in reverse ride
(
= 50% of the max. speed).
57
(p)
Page 58
9.1 Signal Measuring at the
Drive Control Unit
50% of the speed apply if:
Driving in reverse mode
The LDS displays low battery status (red LED of LDS lights)
The thermal switch of the drive motor has opened, i.e. the motor is overheated
(error code 3.4.5.1. displayed)
Result for speed:
If the machine should only ride slowly at full speed in forward mode, check the signal
transfer/voltages from the direction switch S7 to the control unit and from the control
unit to the drive control unit.
58
Page 59
9.2 Settings at the Accelerator Pedal
•
Setting the drive potentiometer switch S8 and the drive potentiometer ‘R1‘ at the
Accelerator pedal is required.
Caution:
Bef
ore proceeding to se
tti
ngs at the drive control unit make sure that the drive wheel
rotates freely and has no contact with the ground. The setting work has to be
executed with the greatest precaution possible to preclude injuries of persons or a
movement of the machine, since otherwise the wheels may suddenly start rotating.
Make sure that garments, hair, measuring cables or other are not caught in the
rotating wheel (risk of injury!).
Before starting work, set the direction limit switch ‘S7‘ to ”0”.
59
Page 60
9.2 Settings at the Accelerator Pedal
The ‘S8’ drive potentiometer switch has to be set such that it is not activated in neutral
pedal position, i.e. a small gap between the actuation roller of the switch and the
eccentric disk of the accelerator is required.
If the accelerator pedal is pressed down, the switch should be actuated
(clicki
ng sound) but w
ithout bendi
ng the actuation lever.
After the switch has been actuated, the resistance between the connections
1 and 4 is approx. 0
Ω
.
(Caution: Disconnect battery plug before this measurement!).
60
Page 61
9.2 Settings at the Accelerator Pedal
Before further setting of the drive potentiometer use a voltmeter to measure
at the drive control unit between X51 Pin 3 and Pin 9.
When the accelerator pedal is not pressed down, the voltage has to amount to
U ≈ 0 V and increase continuously up to U ≈ 6.5 V as the pedal is pressed down to
stop. In order to guarantee a perfect operation, the minimum voltage attained when
pressing down the pedal has to be U = 4.5 V.
After the pedal has attained its limit position, the drive potentiometer must not
Positioned at a stop. A clearance of 2mm is required between the final position of the
‘
’
Accelerator and the potentiometer stop (check at the adjusting lever of the R1
potentiometer if required).
If the stop position of the drive potentiometer has already been attained with the
Accelerator pedal, the drive potentiometer may be turned in its oblong holes.
Irrespective of the pedal position, a voltage of approx. U ≈10,5 V
applies between X51 Pin 3 and Pin 8.
61
Page 62
9.3 A4:X51 Plug Assignment
PIN Plug assignment (measured to battery minus) (X51
)
•
gg ( y )()
1 not connected
2 Drive control unit release; U = 24V or battery voltage if key switch has
closed
3 Drive potentiometer; U = 0V
4
Forward drive direction;
U
= 0V after forward mode has been selected
and ‘S8’ drive potentiometer switch and contact on control unit A1 have
closed.
=
5
Reverse drive direction;
U 0V
after reverse mode has been selected
and ‘S8’ drive potentiometer switch and contact on control unit A1 have
closed.
6 not connected
62
Page 63
9.3 A4:X51 Plug Assignment
•
PIN Plug assignment (measured to battery minus) (X51)
7 not connected
8
Dri
ve potentiometer
PIN 8
; approx. 10.7 V
9 Drive potentiometer, voltage modification of approx. U = 0 V to 6.7 V
depending on the accelerator pedal position
10 not connected
11 Slowing down speed, U = 0V, after contact on control unit A1 has closed
(activated with reverse ride)
12 not connected
63
Page 64
9.3 A4:X51 Plug Assignment
•
PIN Plug assignment (measured to battery minus) (X51)
13 not connected
14not
connecte
d
15 not connected
64
Page 65
10. Error Reference Chart With
Information on Service Display
Error code Malfunction Remarks
in display
1.2.5.2.
Thermal protector of
Brush motor fan ok?
brush motor Wire broken (break contact
circuit)?
Measure operating current
(approx. 36.5A max; to
preclude motor overload due
to uneven ground conditions,
32A max. should not be
exceeded during operation)
Check carbon brushes
1.2.6.1 Block protection of Measure operating current
brush motor (36.5A max.; refer to
code 1.2.5.2.)
65
Page 66
10. Error Reference Chart With
Information on Service Display
Error code Malfunction Remarks
in display
1.2.6.3.
Block protection of
Jammed?
brush head lifting Measure operating current
element (5.0A max.)
Correct Dip switch setting on
power electronic module (A2)?
1.4.6.1 Block protection of Jammed?
squeegee lifting Measure operating current
element
(1.5A max.)
Correct Dip switch setting on
power electronic module (A2)?
66
Page 67
10. Error Reference Chart With
Information on Service Display
Error code Malfunction Remarks
in display
3.1.6.1.
Fuse of power
Check all fuses,
electronic module (A2) If the code for blocking
protection of lifting element
for brushes or squeegee
appears, check these;
Check water pump and wate
r
valve if 10A/80V fuse was
defective
3.1.6.7
.
Fuse of control unit (A1)
Check 7.5 A / 32 V fuse
Check connection with
control unit
67
Page 68
10. Error Reference Chart With
Information on Service Display
Error code Malfunction Remarks
in display
3.2.1.1. LDS defective Measure approx. battery
voltage on control unit A1.X2
PIN 1 and 4 , if voltage is
not ok check plug
contacts for corrosion etc.
and cable connection up
to battery plug;
check Dip-switch setting
for battery type if voltage and
connection are ok replace
control unit (A1)
3.4.1.1. Error of drive Check drive potentiometer
potentiometer switch switch S7
68
Page 69
10. Error Reference Chart With
Information on Service Display
Error code Malfunction Remarks
in display
3.4.5.1
.
Th
ermal protector of
Is dri
ve motor fan
OK? D
oes
drive motor travel drive respond smoothly?
Parking brake setting ok?
Did you perform an extended
uphill ride? Wire broken
(wiring to thermal switch or
connectors badly plugged?
Measure operating current in
”
”
-
A2 motor line using a clip
on
current transformer at full
throttle on level ground
(approx. 26A max. at transport
ride and 30A max. at cleaning
ride)
69
Page 70
10. Error Reference Chart With
Information on Service Display
Error code Malfunction Remarks
in display
4.1.2.1
.
P
ower electronic
Check
connection between
module (A2) not control unit (A1) and power
recognised electronic module (A2) control
unit A1:X10:PIN 1 and PIN 2
and power electronic module
(A2:X22:PIN 1 and 2); Check
voltage supply of power
electronic module (A2)
70
Page 71
10. Error Reference Chart With
Information on Service Display
Error code Malfunction Remarks
in display
4.1.3.1
.
P
ower electronic
Check
connection between
module (A2) no control unit (A1) and power
response (timeout) electronic module (A2) control
unit A1:X10:PIN 1 and PIN 2
and power electronic module
(A2:X22:PIN 1 and 2);
Check voltage supply of
power electronic module (A2)
4.6.1.1. Internal control unit Check contacts for corrosion
error and plugs, check voltage
supply, if ok but still error
code displayed replace
control unit
71
Page 72
10. Error Reference Chart with
Information on Service Display
Error code Malfunction Remarks
in display
CAN bus error Check 2 A / 32 V circuit
-
4.6.2.1.
(no response
timeout)
breaker of control unit (A1),
check wiring between A1:X10:PIN
1 and PIN 2 and power electronic
module (A2:X22:PIN 1 and 2)
as well as the contacts and plugs,
check voltage supply of powe
r
electronic module (A2) and
control unit (A1); check
resistors (120 Ω) (60 Ω caused
b
y parallel connection) If
thi
s
error occurs in connection
with code 4.1.2.1. or 4.1.3.1.
first check as indicated there;
if required, replace the power
electronic module (A2)
72
Page 73
10. Error Reference Chart with
Information on Service Display
Error code Malfunction Remarks
in display
4.6.3.1
.
CAN b
us error
Check wiri
ng between
(bus error) A1:X10:PIN 1 and PIN 2 and
power electronic module
(A2:X22:PIN 1 and 2) as well
as the contacts and plugs
,
check voltage supply of power
electronic module (A2) and
control unit (A1); check
resistors (120
Ω
)
(60 Ω caused by parallel
connection)
73
Page 74
10. Error Reference Chart With
Information on Service Display
Error code Malfunction Remarks
in display
4.6.3.2
.
CAN b
us error
Check wiri
ng between
(overrun) A1:X10:PIN 1 and PIN 2 and
power electronic module
(A2:X22:PIN 1 and 2) as well
as the contacts and plugs
,
check voltage supply of power
electronic module (A2) and
control unit (A1); check
resistors (120
Ω
)
(60 Ω caused by parallel
connection)
74
Page 75
10. Error Reference Chart With
Information on Service Display
Error code Malfunction Remarks
in display
4.6.5.1
.
I
ncorrect machine
Check
machine type se
tti
ng o
f
type setting Dip switch A on control unit A1
4.6.5.2
.
Set option impossible
Too many options set at Dip
switch B on control unit A1?
4.6.5.3. Too man
y
modules
A
re all options set at Dip
y
pp
in the machine switch B on control unit A1?
Have all codes been correctly
set at all electronic modules?
75
Page 76
11. Adjustment of the Disk Brake
76
Page 77
Page 78
Page 79
Minuteman E Ride 30 Wiring Diagram
g
)
)
)
Ω
Valid from: March 20 06
Ref. Designation Path
-A1 Control unit (electronic module only) /1.29
-A2 Module 1 /2.24
-A3 Standard control panel (electronic module only) /1.23/1.32
- Complete control panel for plate brush comprising: control unit (A1 electronic
module), and control panel (A3 electronic module, plate and foil) or
- Complete control panel for cylinder brush comprising: control unit (A1
electronic module), and control panel (A3 electronic module, plate and foil)
-A4 Drive controller /2.12
-B1 Piezo buzzer /1.36
-E1 Working flood light (working floodlight OPTION) /1.14
-E2 Flashlight (forward ride warning element OPTION) /1.17
-F1 10A fuse, control voltage /1.7
-F2 125A main fuse /1.2
-F3 7.5A horn /1.11
-F6 10A fuse working floodlight (working floodlight OPTION) or forward ride
warnin
-G1 24V battery /1.2
-G2 On board charger unit (VARIANT with on board charger unit) /1.5
-H1 Horn /1.11
-K1 Power contactor (VARIANT with on board charger unit) /1.8
-K2 Relay (forward ride warning element OPTION) /1.20
-K3 Flasher relay (forward ride warning element OPTION
-K4 Relay /2.3
-M1 Drive motor /2.16
-M2 Suction turbine /2.32
-M3 Plate brush motor (plate brush VARIANT) /2.36
-M3.S1 Thermal protector of plate brush motor (plate brush VARI ANT) /2.37
-M5 R-h cylinder brush motor (cylinder brush VARIANT
-M5.S1 Thermal protector of r-h cylinder brush motor (cylinder brush VARIANT) /2.37
-M6 L-h cylinder brush motor (cylinder brush VARIANT) /2.36
-M6.S1 Thermal protector of l-h cylinder brush motor (cylinder brush VARIANT) /2.37
-M7 Squeegee lifting element /2.34
-M8 Water pump /2.21
-M9 Plate brush or cylinder brush lifting element /2.34
-R1 Drive potentiometer /2.6
-R2
-R3
-S1 Key switch /1.8
-S2 Horn button /1.11
-S3 Working floodlight switch (working floodlight OPTION) or /1.14
-S3 Forward ride warning element (forward ride warning element OPTION) /1.19
-S4 Soiled water sensor /1.25
-S5 Seat switch /1.23
-S6 Parking brake switch /1.26
-S7 Direction switch /2.6
-S8 Drive potentiometer switch /2.6
-V1 Recovery diode for horn /1.13
-V2 Diode (forward ride warning element OPTION) /1.20
-Y1 Water valve /2.21
CAN bus terminating resistor 120Ω
CAN bus terminating resistor 120
element (forward ride warning element OPTION
/1.32
/1.23
/1.14
/1.18
/2.36
/1.25
/2.21
Page 80
13. Notes
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