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R 253 9087362020

Nilfisk-Advance R 253 9087362020, R 253 9087365020, RA40 9087363020, SC2000 Service Manual

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Page 1
SCRUBTEC R 253 - RA40
Service Manual
Nilsk R 253, 9087362020 - 9087365020
Clarke RA40, 9087363020
English
01/2015 revised 03/2016 (2)
Form No. 9100000402
Page 2
Contents
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Machine General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Service Manual Purpose and Field of Application . . . . . . . . . . . . . . . . . . . . . 5
Other Reference Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Service and Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Serial Number Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Visible Symbols on the Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Machine Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Machine Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Machine Nomenclature (know your machine) . . . . . . . . . . . . . . . . . . . . . . . 11
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Service and Diagnostic Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Scheduled Maintenance Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Contents iiService Manual – Scrubtec R 253 - RA40
Chassis System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Frame (main parts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Functional Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Function Electronic Board (EB1) Alarm Codes. . . . . . . . . . . . . . . . . . . . .22
Super User Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Alarm Log Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Setting Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Hours Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
System for Flow Rate Adjustment as Function of Speed. . . . . . . . . . . . . . . .32
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Function Electronic Board (EB1) Removal/Replacement . . . . . . . . . . . . . . . 33
Display Board (EB2) and Dashboard Instrument Board (EB4) Removal/Replacement 35
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Function Electronic Board (EB1) Connectors. . . . . . . . . . . . . . . . . . . . . .37
Display Electronic Board (EB2) Connectors . . . . . . . . . . . . . . . . . . . . . . 43
Shop Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Shop Measurements - Function Electronic Board (EB1) . . . . . . . . . . . . . . . 44
Shop Measurements - Display Electronic Board (EB2) . . . . . . . . . . . . . . . . 51
Page 3
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Functional Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Battery Charge State Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Setting the Installed Battery Type . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Battery installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Checking/Replacing Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Options and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Recovery System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Functional Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Recovery Tank Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Vacuum System Motor Amperage Test . . . . . . . . . . . . . . . . . . . . . . . . .73
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Vacuum System Motor Unit Disassembly/Assembly. . . . . . . . . . . . . . . . . .74
Container and Vacuum System Motor Disassembly/Assembly . . . . . . . . . . . . 75
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
Contents iiiService Manual – Scrubtec R 253 - RA40
Scrub System, Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Functional Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
RPM Brush Reduction Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Brush Installation/Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Brush Motor Amperage Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Brush Deck Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Checking/Replacing Brush Motor Carbon Brushes . . . . . . . . . . . . . . . . . .88
Brush Motor Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Brush Deck Actuator Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . .90
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Page 4
Solution System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Functional Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Water Level Sensor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
Cleaning the Solution Tank and Filter . . . . . . . . . . . . . . . . . . . . . . . . . 97
Cleaning the Chemical Mixing System Detergent Tank . . . . . . . . . . . . . . . .98
Draining the Chemical Mixing System . . . . . . . . . . . . . . . . . . . . . . . . .99
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Checking the Water Level Sensor Operation . . . . . . . . . . . . . . . . . . . . . 102
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Solenoid Valve Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . . . 103
Detergent Pump Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . . 104
Water Level Sensor Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . 105
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Squeegee System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Functional Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Squeegee cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Checking/Replacing the Squeegee Blades . . . . . . . . . . . . . . . . . . . . . . 110
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Squeegee Lifting Actuator Disassembly/Assembly . . . . . . . . . . . . . . . . . . 112
Squeegee Tie Rod Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . 113
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Contents ivService Manual – Scrubtec R 253 - RA40
Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Functional Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Wheels, Drive System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
Functional Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Drive System Gearmotor Amperage Test. . . . . . . . . . . . . . . . . . . . . . .122
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Drive Pedal Potentiometer Disassembly/Assembly . . . . . . . . . . . . . . . . . 123
Drive System Gearmotor Disassembly/Assembly . . . . . . . . . . . . . . . . . . 124
Gearmotor Carbon Brushes Check/Replacement. . . . . . . . . . . . . . . . . . . 125
Drive System Motor Electromagnetic Brake Disassembly/Assembly . . . . . . . . 126
Drive System Motor Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . 127
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Page 5
Service Manual – Scrubtec R 253 - RA40
General Information
General Information
Machine General Description
The Scrubtec R 253 and Clarke RA40 are a “man on-board” industrial machine designed to wash and dry oors in one pass. The machine is powered by on-board batteries, models can be equipped with chemical mixing sys-
tem. The machine features a variable oor pressure disc brush, controlled solution dosing and a rear squeegee with rubber blades that vacuums and dries the oor.
Service Manual Purpose and Field of Application
The Service Manual is a technical resource intended to help service technicians when carrying out mainte­nance and repairs on the scrubbers, to guarantee the best cleaning performance and a long working life for the machine. Please read this manual carefully before performing any maintenance and repair procedure on the machine.
5
Other Reference Manuals
Model Product Code User Manual Spare Parts List
Nilsk Scrubtec R 253 9087362020
Nilsk Scrubtec R 253 full PKG 9087365020
Clarke RA40 9087363020 9100000394
Assembly Instructions Instruction Code Machines concerned
Chemical Mixing System Kit 9100000953 Scrubtec R 253 - RA40
Battery charger kit 9100001068 Scrubtec R 253
Waste basket kit 9100001067 Scrubtec R 253
Broom holder kit 9100000985 Scrubtec R 253
Enhanced vacuum system motor kit 9100000968 Scrubtec R 253
Water ller hose kit 9100001072 Scrubtec R 253 - RA40
Stop water kit 9100000984 Scrubtec R 253 - RA40
Beacon light kit 9100000982 Scrubtec R 253 - RA40
USB kit 9100000983 Scrubtec R 253 - RA40
Trackclean kit 9100001061 Scrubtec R 253 - RA40
These manuals are available at:
• Local Nilsk or Clarke retailer
• Nilsk website: www.nilsk.com
• Clarke website: www.clarkeus.com
9100000391 9100000392
Page 6
Service Manual – Scrubtec R 253 - RA40
General Information
Conventions
Forward, backward, front, rear, left or right are intended with reference to the operator’s position, that is to say in driving position.
Service and Spare Parts
Service and repairs must be performed only by authorised personnel or Nilsk or Clarke Service Centers. The authorised personnel is trained directly at the manufacturer’s premises and has original spare parts and ac­cessories. Contact Nilsk or Clarke Retailer indicated below for service or to order spare parts and accessories, specify­ing the machine model and serial number.
(Apply Retailer label here)
6
Serial Number Label
Reference to Figure 1 The machine serial number and model name are marked on the plate (see the example to the side). Product code and year of production are marked on the same plate. This information is useful when requiring ma­chine spare parts. Use the following table to
write down the machine identication data.
Figure 1
Scrubber-Dryer RA40 B R
Model:
Prod. Nr: 9087363020
GVW: 342 kg/754 lb 26 A
Type E SCRUBBER DRYER
A Nilfisk-Advance Brand
Charg.100-240Vac 50-60 Hz
UL 583
CSA C22.2 N.68-92
IPX4
Control Nr:
3084826
Serial No: ..................
Date code: .......
LpA = 68 dB(A)
Battery 24 Vdc
2%
“Made in Hungary” 14600 21st Ave N Plymouth, MN, USA www.clarkeus.com
MACHINE model .............................................................................................
PRODUCT code ..............................................................................................
MACHINE serial number .................................................................................
Page 7
Service Manual – Scrubtec R 253 - RA40
max.2%
General Information
Safety
The following symbols indicate potentially dangerous situations. Always read this information carefully and take all necessary precautions to safeguard people and property.
Visible Symbols on the Machine
Warning! Carefully read all the instructions before performing any operation on the
machine.
Warning! Do not wash the machine with direct or pressurized water jets.
Warning! Do not use the machine on slopes with a gradient exceeding the
specications.
7
Symbols
Note: It indicates a remark related to important or useful functions.
Danger! It indicates a dangerous situation with risk of death for the operator.
Warning! It indicates a potential risk of injury for people or damage to objects.
Caution! It indicates a caution related to important or useful functions.
Page 8
Service Manual – Scrubtec R 253 - RA40
General Information
General Instructions
Specic warnings and cautions to inform about potential damages to people and machine are shown below.
Warning! Make sure to follow the safety precautions to avoid situations that may lead to
serious injuries.
• Before performing any maintenance, repair, cleaning or replacement procedure, remove the ignition key and disconnect the battery connector.
• This machine must be used by properly trained operators only.
• Do not wear jewels when working near electrical components.
• Do not work under the lifted machine without supporting it with safety stands.
• Do not operate the machine near toxic, dangerous, ammable and/or explosive powders, liquids or vapors. This machine is not suitable for collecting dangerous powders.
• When using lead (WET) batteries, keep sparks, ames and smoking materials away from the batteries. During the normal operation explosive gases are released.
• When using lead (WET) batteries, battery charging produces highly explosive hydrogen gas. During bat­tery charging, lift the recovery tank and perform this procedure in well-ventilated areas and away from
naked ames.
Caution! Make sure to follow the safety precautions to avoid situations that may lead to
serious injuries, damages to materials or equipments.
8
• Carefully read all the instructions before performing any maintenance/repair procedure.
• Before using the battery charger, ensure that frequency and voltage values, indicated on the machine se­rial number plate, match the electrical mains voltage.
• Do not pull or carry the machine by the battery charger cable and never use the battery charger cable as a handle. Do not close a door on the battery charger cable, or pull the battery charger cable around sharp edges or corners. Do not run the machine on the battery charger cable.
• Keep the battery charger cable away from heated surfaces.
• Do not charge the batteries if the battery charger cable or the plug are damaged.
• To reduce the risk of re, electric shock, or injury, do not leave the machine unattended when it is plugged in. Before performing any maintenance procedure, disconnect the battery charger cable from the electrical mains.
• Do not smoke while charging the batteries.
• To avoid any unauthorized use of the machine, remove the ignition key.
• Do not leave the machine unattended without being sure that it cannot move independently.
• Always protect the machine against the sun, rain and bad weather, both under operation and inactivity condition. This machine must be used in dry conditions, it must not be used or kept outdoors in wet condi­tions.
• Before using the machine, close all doors and/or covers as shown in the User Manual.
• This machine is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the machine by a person responsible for they safety.
• Children should be supervised to ensure that they do not play with the machine.
• Close attention is necessary when used near children.
• Use only as shown in this Manual. Use only Nilsk or Clarke recommended accessories.
Page 9
Service Manual – Scrubtec R 253 - RA40
• Check the machine carefully before each use, always check that all the components have been properly assembled before use. If the machine is not perfectly assembled it can cause damages to people and prop­erties.
• Take all necessary precautions to prevent hair, jewels and loose clothes from being caught by the machine moving parts.
• Do not use the machine on slopes.
• Do not tilt the machine more than the angle indicated on the machine itself, in order to prevent instabil­ity.
• Do not use the machine in particularly dusty areas.
• Use the machine only where a proper lighting is provided.
• If the machine is to be used where there are other people besides the operator, it is necessary to install the beacon light (optional).
• While using this machine, take care not to cause damage to people or objects.
• Do not bump into shelves or scaffoldings, especially where there is a risk of falling objects.
• Do not lean liquid containers on the machine, use the relevant can holder.
• The machine operating temperature must be between 32 °F and 104 °F (0 °C and +40 °C).
• The machine storage temperature must be between 32 °F and 104 °F (0 °C and +40 °C).
• The humidity must be between 30 % and 95 %.
• When using oor cleaning detergents, follow the instructions on the labels of the detergent bottles.
• To handle oor cleaning detergents, wear suitable gloves and protections.
• Do not use the machine as a means of transport.
• Do not allow the brush/pad to operate while the machine is stationary to avoid damaging the oor.
• In case of re, use a powder re extinguisher, not a water one.
• Do not tamper with the machine safety guards and follow the ordinary maintenance instructions scrupu­lously.
• Do not allow any object to enter into the openings. Do not use the machine if the openings are clogged. Always keep the openings free from dust, hairs and any other foreign material which could reduce the air
ow.
• Do not remove or modify the plates afxed to the machine.
• To manually move the machine, the electromagnetic brake must be disengaged. After moving the ma­chine manually, engage the electromagnetic brake again. Do not use the machine when the electromag­netic brake handwheel is screwed down.
• When the machine is to be pushed for service reasons (missing or discharged batteries, etc.), the speed must not exceed 2.5 mi/h (4 km/h).
• This machine cannot be used on roads or public streets.
• Pay attention during machine transportation when temperature is below freezing point. The water in the recovery tank or in the hoses could freeze and seriously damage the machine.
• Use brushes and pads supplied with the machine or those specied in the User Manual. Using other brushes or pads could reduce safety.
• In case of machine malfunctions, ensure that these are not due to lack of maintenance. If necessary, re­quest assistance from the authorised personnel or from an authorised Service Center.
• If parts must be replaced, require ORIGINAL spare parts from an Authorised Dealer or Retailer.
• To ensure machine proper and safe operation, the scheduled maintenance shown in the relevant chapter of this Manual, must be performed by the authorised personnel or by an authorised Service Center.
• Do not wash the machine with direct or pressurised water jets, or with corrosive substances.
• The machine must be disposed of properly, because of the presence of toxic-harmful materials (batteries, etc.), which are subject to standards that require disposal in special centres (see Scrapping chapter).
General Information
9
Page 10
Service Manual – Scrubtec R 253 - RA40
Machine Lifting
Warning! Do not work under the lifted machine without supporting it with safety stands.
Machine Transportation
Warning! Before transporting the machine, make sure that:
All covers are closed.
The recovery tank and the detergent tank are empty.
The batteries are disconnected.
The ignition key is removed.
General Information
10
The machine is securely fastened to the means of transport.
Page 11
Service Manual – Scrubtec R 253 - RA40
Machine Nomenclature (know your machine)
General Information
11
Steering wheel
with control panel
Can holder
Battery charger
cable
Battery charger
cable housing
and document
holder
Seat Battery connector Recovery tank
EMERGENCY
push-button
cover
Squeegee hook
Dumping recovery
tank assembly
Solution tank
Solution drain and
level check hose
Squeegee bumper
wheels
Drive pedal
Front steering
wheel
Figure 2
Squeegee
Solution valveBrush deckSolution lterSolenoid valve
Electromagnetic brake
locking/unlocking lever
Page 12
Service Manual – Scrubtec R 253 - RA40
Machine Nomenclature (Continues)
General Information
12
Electronic
component
compartment
cover
Vacuum grid with auto-
matic shut-off oat
Container with debris col-
lection grid
Recovery water drain hose
Chemical mix-
ing system
detergent tank
Batteries Tank assembly sup-
port rod
Lifted recovery tank
assembly and driver’s
seat
Recovery water
tank cover (open)
Serial number plate/
technical data
Solution tank ller neck
Squeegee vacuum hose
Squeegee adjusting knob
Squeegee mounting hand-
wheels
Squeegee support wheel
Figure 3
Tank assembly and
seat lifting handle
Battery charger
Brush deck bumper
wheel
Rear driving wheels
Page 13
Service Manual – Scrubtec R 253 - RA40
Control Panel
Multifunction display and
operating information
General Information
13
Horn button
Detergent percentage
adjustment button
Solution ow
adjustment button
Figure 4
max.2%
Machine ignition key
Reverse gear button
1s
One-Touch Scrub ON/
OFF push-button
Vacuum system
button
Page 14
Service Manual – Scrubtec R 253 - RA40
General Information
Service and Diagnostic Equipment
Besides a complete set of standard meters, the following instruments are necessary to perform fast checks and repairs on
Nilsk Clarke machines:
• Laptop computer charged with the current version of EzParts, Adobe Reader and (if possible) Internet
connection
• Digital Volt Meter (DVM)
• Amp clamp with possibility of making DC measurements
• Hydrometer
• Battery charge tester to check 12V batteries
• Static control wrist strap
• Dynamometric wrench set
• A copy of the User Manual and Spare Parts List of the machine to be serviced (provided with the machine
or available at www.nilsk.com and www.clarkeus.com or other Nilsk Clarke websites).
The following equipment is also available at Nilsk Clarke Centers:
• Vacuum water lift gauge, P/N 56205281
14
Figure 5
Page 15
Service Manual – Scrubtec R 253 - RA40
Technical Data
General Information
15
Description / Model
Solution tank capacity 18,5 US gal (70 liters)
Recovery tank capacity 18,5 US gal (70 liters)
Machine length 50 in (1270 mm)
Machine width with squeegee 28.3 in (720 mm)
Machine width without squeegee 21.6 in (550 mm)
Machine height 40.1 in (1020 mm)
Turning space for U-turns 71 in (1800 mm)
Cleaning width 21 in (530 mm)
Rear driving wheel diameter 10 in (254 mm)
Rear driving wheel specic pressure on the oor (*) 145 psi (1,0 N/mm2)
Front steering wheel diameter 7.9 in (200 mm)
Front wheel specic pressure on the oor (*) 189 psi (1,3 N/mm2)
Brush/pad diameter 21 in (530 / 508 mm)
Brush pressure 33 lb (15 kg)
Brush pressure (extra pressure on) 66 lb (30 kg)
Solution ow values 0,75 cl/m / 1,5 cl/m / 3,0 cl/m / (2,8 l/min, if enabled)
Chemical Mixing System detergent percentage Ratio 1:500 ÷ 1:33 (0,25% ÷ 3%)
Sound pressure level at workstation (ISO 11201, ISO 4871, EN 60335-2-72) (LpA) 68 ±3 dB(A)
Machine sound power level (ISO 3744, ISO 4871, EN 60335-2-72) (LwA) 84 dB(A)
Vibration level at the operator’s arms (ISO 5349-1, EN 60335-2-72) 130 in/s2 (3,3 m/s2)
Vibration level at the operator’s body (ISO 5349-1, EN 60335-2-72) 35.4 in/s2 (0,9 m/s2)
Maximum gradient when working 2%
Drive system motor power 0.53 hp (400 W)
Drive speed (variable) 0 - 3.7 mi/h (0 - 6 km/h)
Vacuum system motor power 0.4 hp (310 W)
Vacuum system circuit capacity 39 in H2O (1000 mm H2O)
Brush motor power 0.6 hp (450 W)
Brush rotation speed 155 rpm
Total power draw (EN 60335-2-72) 26 A (620 W)
IP protection class X4
Protection class (electric) III (I for the battery charger)
Battery compartment size 13.8x14.2x11 in (350x360x280 mm)
System voltage 24 V
Standard batteries (2) Discover 12V-105Ah
Battery charger 100-240Vac 50-60Hz, 24Vdc 13A
Operating time (standard batteries) (EN 60335-2-72) 2,5 h
Weight without batteries and with empty tanks 262 lb (119 kg) 267 lb (121 kg)
Gross vehicle weight (GVW) 754 lb (342 kg)
Shipping weight 342 lb (152 kg)
Nilsk
Scubtec R253
Scubtec R253 full PKG
502 lb (228 kg) Nilsk 342
Nilsk
Clarke RA40
lb (155 kg) Clarke
(*) Machines have been tested under the following conditions:
◦ Battery maximum size ◦ Maximum brush and squeegee size ◦ Full detergent tank ◦ Optional equipment installed ◦ Wheel weight checked ◦ Print on the oor checked on cement for each single wheel ◦ Result expressed as maximum value for both front and rear wheels
Page 16
Service Manual – Scrubtec R 253 - RA40
21.6 in (550 mm)
Dimensions
40.1 in (1020 mm)
General Information
16
Figure 6
28.3 in (720 mm)
50.0 in (1270 mm)
Page 17
Service Manual – Scrubtec R 253 - RA40
General Information
Maintenance
The lifespan of the machine and its maximum operating safety are ensured by correct and regular maintenance.
Warning! Read carefully the instructions in the Safety chapter before performing any
maintenance procedure.
The following tables provides the scheduled maintenance. The intervals shown may vary according to particular working
conditions, which are to be dened by the person in charge of the maintenance.
For instructions on maintenance procedures, see the following paragraphs.
Scheduled Maintenance Table
17
Procedure
Battery Charging
Squeegee Cleaning
Brush/pad cleaning
Recovery tank and debris tray cleaning, and cover gasket check
Chemical Mixing System cleaning and draining
Squeegee blade check
Solution lter cleaning
Battery (WET) uid level check
Squeegee blade replacement
Electromagnetic brake efciency check
Brush motor carbon brush check or replacement
Drive system motor carbon brush check or replacement
Daily, after using the
machine
Weekly
Every six
months
Yearly
Page 18
Service Manual – Scrubtec R 253 - RA40
Chassis System
Frame (main parts)
Reference to Figure 1
• Steering assembly/column support plate and deck mount
• Main support side member
• Gearmotor support plate and squeegee system mount
Steering assembly/column support
plate and deck mount
Chassis System 18
Gearmotor support plate and
squeegee system mount
Figure 1
Main support side member
Page 19
Service Manual – Scrubtec R 253 - RA40
Control System
Functional Description
The architecture of the electronic control system for the machine’s electrical components is composed of a function electronic board (EB1) and a display elec­tronic board (EB2), in turn connected to a dashboard instrument electronic board (EB4) which represents the main user interface.
The function electronic board (EB1)
Control System 19
The display electronic board (EB2)
Flat cable from (EB2) to (EB4)
Display electronic board (EB2)
serves mainly as an aggregator for all input signals (buttons) and outputs (LEDs) from the dashboard in­strument electronic board (EB4),
Function electronic board (EB1)
manages all components and drives the following components directly:
- Brush motor (M1)
- Vacuum system motor (M2)
- Drive system motor (M3) with the relevant Electromagnetic brake (BRK)
- Detergent pump (M4)
- Deck actuator (M5)
- Squeegee actuator (M6)
- Solution ow solenoid valve (EV1)
The horn and the beep reverse is an integral part of the function electronic board (EB1).
Dashboard electronic board (EB4)
which it is connected to via 2 at cables.
The ignition key (SW1) is inserted in relevant slot on the steering column,
The display electronic board (EB2) sends all the in­put signals from the Dashboard instrument electronic board (EB4) to the function electronic board (EB1) us­ing 2-wire 2-way serial communications protocol.
The system is completed by the on-board battery charger (see the Electrical System chapter) which also uses a proprietary serial protocol to communicate with the function electronic board (EB1), in order to display its operating status (charging phase) to the operator on the LCD display.
Page 20
Service Manual – Scrubtec R 253 - RA40
Wiring Diagram
Control System 20
DASHBOARD ELECTRONIC BOARD (EB4)
IGNITION KEY (SW1)
BATTERY CHARGER (CH)
DISPLAY BOARD (EB2)
Dashboard power supply +
Dashboard power supply -
FCI DUFLEX (2.54 pitch) 6-way, male pins
J3
FCI DUFLEX (2.54 pitch) 9-way, male pins
J2
Enabling input
Dashboard serial +
Dashboard serial -
Key electronic board power supply +
J1.1
Return from USER key
J1.2
J1.3 (+5V)
J1.5
J4.1
J4.2
J4.4
Key reader power supply circuit
Key Identification
J1.4
External power supplies -
Enabling from battery charger
Power supply from battery charger
Battery charger enabling power supply
J4.3
Battery charger data communication
FUNCTION BOARD (EB1)
Display electronic board power supply +
J1.1
J1.2
J1.3
J1.4
J1.5
ANTI-SKID CONTROL SENSOR (SW4) (SEE THE STEERING SYSTEM CHAPTER)
J1.6
Enabling input from display electronic board
J1.7
Display electronic board serial +
J1.8
Display electronic board serial -
J1.9
Return from steering microswitch
J1.12
Electronic board power supply +
SIGNAL CIRCUIT FUSE (F2)
Microprocessor
Electronic board power supply -
B+
B -
Figure 1
Page 21
Service Manual – Scrubtec R 253 - RA40
Component Locations
• Function electronic board (EB1)
• Display electronic board (EB2)
• Dashboard instrument electronic board (EB4)
Control System 21
• Flat cables from (EB2) to (EB4)
• Ignition Key (SW1)
Function electronic
board (EB1)
Figure 2
Flat cables from (EB2) to (EB4)
Dashboard instrument elec-
tronic board (EB4)
Ignition
key(SW1)
Display electronic board (EB2)
Figure 3
Page 22
Service Manual – Scrubtec R 253 - RA40
Control System 22
Troubleshooting
Function Electronic Board (EB1) Alarm Codes
The function electronic board indicates a series of alarms in case of malfunction of one or more systems, and in case of abnormal conditions detected in the input signals. The alarms are shown on the display in the following format (Figure 4).
Figure 4
In case the display is malfunctioning, the alarms are also repeated by the yellow and red diagnostic LEDs (Figure 5) on the function electronic board (EB1), as indicated in the following tables.
Figure 5
General alarms
Alarm on function electronic board - FLASHING YELLOW + RED LEDS
Alarm code
-------------------------­Description
G2
----------------------­EEPROM ERROR
No.
Flashes
Meaning Condition Effect
2 EEPROM error EEPROM error Function block
+ Default setting reset
Service Suggestions
If the machine continues to function after G2 has been displayed, this may have been caused by a signicant external electromagnetic disturbance.
1. Check that the settings and parameters (see page 30) are correct (they may have returned to their defaults). If the error persists, the board must be replaced.
Page 23
Service Manual – Scrubtec R 253 - RA40
Function Electronic Board (EB1) Alarm Codes (Continues)
General alarms
Alarm on function electronic board - FLASHING YELLOW + RED LEDS
Alarm code
-------------------------­Description
G3
----------------------­MAIN FUSE FAILURE
No.
Flashes
Meaning Condition Effect
3 Blown F1 fuse. Blown F1 fuse.
Broken battery.
Function block.
Control System 23
Service Suggestions
F1 is a safety fuse primarily included to prevent a short circuit or serious damage to the electronic board causing currents such as to melt cables and/or cause smoke or re. If F1 has blown, this is usually indicative of serious damage to the electronic board.
1. Removing the cover should allow you to understand the extent of the damage, but the solution in any case should be to replace the electronic board.
2. Try replacing fuse F1 only if there is no clear damage to the electronic board and wiring.
3. Ensure you tighten the fuse contacts correctly.
G4
----------------------­BATTERY LOW VOLTAGE
G5
----------------------­BATTERY OVERVOLTAGE
G6
----------------------­HARDWARE FAILURE
G7
----------------------­HARDWARE FAILURE
4 Undervoltage. The battery voltage
5 Excessive
battery voltage.
6 Serial
communication error with dashboard instrument electronic board.
7 General relay
fault.
remains below 18.4V for over 10 seconds (for WET CELL batteries,
19.6V for GEL-AGM batteries).
Battery voltage over 32V. Function block.
No signal or error in communications decoding between the function electronic board (EB1) and the display electronic board (EB2).
Relay closes or closed at start-up.
Function block.
No block.
Function block.
It could happen also if a battery is broken: Check the battery voltage under load.
1. Check the battery voltage under no-load conditions and under load. Replace the faulty battery/batteries if necessary.
2. Recharge the batteries by performing a complete charging cycle.
Check the voltage of the installed batteries and that the terminals are correctly tightened.
1. Check the 5 cables from the 6-way dashboard instrument electronic board connector to connector J3 pins 1, 2, 3, 4.
2. If there is continuity, the dashboard instrument electronic board must be replaced.
Replace the electronic board.
Page 24
Service Manual – Scrubtec R 253 - RA40
Function Electronic Board (EB1) Alarm Codes (Continues)
Function electronic board alarms
Alarm on function electronic board - FLASHING RED LED
Alarm code
-------------------------­Description
F2
----------------------­BRUSH MOTOR OVERLOAD
F3
----------------------­VACUUM MOTOR OVERLOAD
F4
----------------------­DECK ACTUATOR FAILURE
F5
----------------------­SQUEEGEE ACTUATOR FAILURE
F6
----------------------­HARDWARE FAILURE
F7
----------------------­OVERHEATING
F8
----------------------­BRUSH MOTOR FAILURE
F9
----------------------­VACUUM MOTOR FAILURE
No.
ashes on
electronic
board
Meaning Condition Effect
2 BRUSH motor
amperometric protection.
3 VACUUM
SYSTEM amperometric protection.
4 DECK
ACTUATOR overcurrent.
5 SQUEEGEE
ACTUATOR overcurrent.
5 Short circuit on
the vacuum or brush motor drive MOSFET.
7 Motor drive
section thermal cut-out.
8 Brush motor
output short circuit.
9 Vacuum system
motor output overcurrent.
The voltage drop measured on fuse F1 is greater than the value of the parameter (see page
29) VS1
The amperage of the vacuum system motor is greater than 30A for over 10 seconds.
Current greater than 4A detected for more than 1 second.
Current greater than 4A detected for more than 1 second.
MOSFET short circuit. Function block.
The heatsink on the electronic board has reached a temperature of 194 °F (90 °C).
I > 150A for 20µsec. Function block.
I > 150A for 20µsec. Function block.
Brush electromagnetic switch output block.
Vacuum system block.
Brush function block.
Vacuum function block.
Function block.
Control System 24
Service Suggestions
Check the amperage of the brush motor. It should remain below the value set in the parameter “VS1” during operation.
1. Check for any debris in the vacuum system motor.
2. Check that the motor rotor turns freely.
3. Replace the vacuum system motor if necessary.
1. Check that there is no friction on the brush deck linkage; lubricate if necessary.
2. Check that the actuator and deck travel is not blocked by mechanical obstructions.
3. If the problem persists, replace the actuator.
1. Check that there is no friction on the brush deck linkage; lubricate if necessary.
2. Check that the actuator and deck travel is not blocked by mechanical obstructions.
3. If the problem persists, replace the actuator.
1. Check that there are no short circuits in the motor wiring.
2. Replace the electronic board.
Check the vacuum system and brush motor amperage; also check that the openings of the electrical compartment are not blocked.
Check for short circuits in the wiring or motor.
Check for short circuits in the wiring or motor.
Page 25
Service Manual – Scrubtec R 253 - RA40
Function Electronic Board (EB1) Alarm Codes (Continues)
Drive system alarms
Alarm on function electronic board - FLASHING YELLOW LED
Alarm code
-------------------------­Description
T2
----------------------­DRIVE MOTOR OVERLOAD
T3
----------------------­RELEASE THE PEDAL !
T4
----------------------­PEDAL INPUT FAILURE
T5
----------------------­HARDWARE FAILURE
No.
ashes on
electronic
board
Meaning Condition
2 Amperometric
protection intervention.
3 Pedal not in rest
position when the electronic board is turned on.
4 Incorrect voltage
measured at the pedal potentiometer input.
5 Drive system
power section damage
Drive system motor amperage greater than the parameter (see page
28) “INOM” for more than the parameter (see page
30) “TMAX”.
Voltage on J1.2 of EB2 electronic board above the value of “DEADL” parameter.
Voltage on J1.2 of electronic board EB2 above 6V.
MOSFET short circuit.
Effect
Drive blocked. Check the drive system motor amperage
Drive blocked. Check that the pedal moves correctly,
Drive blocked. 1. Check the connection of the
Drive blocked. 1. Check that the cables of the
Control System 25
Service Suggestions
(this should be around 6-8A without load and remain below 10/12A during operation).
lubricating if necessary; check the linkage and potentiometer.
potentiometer to the electronic board.
2. Replace the pedal potentiometer.
gearmotor are not short circuited (try disconnecting the connectors from contacts M1 and M2) and try starting the machine and pressing the pedal again
2. If the alarm persists, replace the electronic board
T6
----------------------­DRIVE MOTOR FAILURE
T7
----------------------­OVERHEATING
T8
----------------------­ELETTROBRAKE FAILURE
6 Overcurrent
(motor D.C.)
7 Drive system
motor drive section thermal cut-out.
8 Drive system
motor electromagnetic brake failure
Drive system motor amperage greater than
1.5 times the value of the parameter (see page 28) “IMAX”.
The heatsink on the electronic board has reached a temperature of 194 °F (90 °C).
Electromagnetic brake resistance above 1 kΩ.
Drive blocked. 1. Check that the gearmotor cables are
not short circuited
2. Check that the motor of the gearmotor unit is not short circuited (the impedance of the motor should be around 0.6 – 0.8 Ohm)
3. If necessary, replace the gearmotor unit motor
Drive blocked. 1. Check the drive system motor
amperage and that the openings of the electrical compartment are not blocked.
2. If everything is within normal parameters, this may simply have been caused by extreme working conditions such as: ambient temperature over 86 °F (>30 °C), sloping working sections. Simply leave the system to cool and turn the machine back on.
Drive blocked. 1. Check the electromagnetic brake
connection.
2. Replace the electromagnetic brake.
All alarms of the drive system operate by cutting the power supply to the gearmotor unit motor until the KEY input is reset (with the exception of alarm T3 which is reset as soon as the input voltage of the paddle potentiometer returns within the values corresponding to “machine stopped”). In case of simul-
taneous errors, the one with greater priority is shown rst (priority order is opposite to the number of ashes).
Page 26
Service Manual – Scrubtec R 253 - RA40
Function Electronic Board (EB1) Alarm Codes (Continues)
On-board Battery Charger Alarms
Alarm code
-------------------------­Description
C1
----------------------­CHARGER
COMMUNICATION
C2
----------------------­BATTERY OVERVOLTAGE
C4
----------------------­CHARGING TIME I EXPIRED
C5
----------------------­CHARGING TIME II EXPIRED
C6
----------------------­CHARGER FAULT
Meaning Condition
Communication problem between the battery charger and function electronic board.
Battery overvoltage.
Charging phase I expired.
Charging phase II expired.
Battery charger internal short circuit.
No signal from battery charger via gate J4.4 for over 3 seconds.
Battery voltage over 32V.
Battery excessively discharged or at end of life cycle.
Battery excessively discharged or at end of life cycle.
Battery charger internal short circuit.
Effect
The battery charger is performing the standard recharging cycle for generic GEL/AGM batteries.
Battery charger block.
Battery charger block.
Battery charger block.
Battery charger block.
Control System 26
Service Suggestions
Check the wiring between the battery charger and function electronic board.
1. Check the connections of the batteries and the voltage of the installed batteries.
2. Disconnect and reconnect the battery charger.
If the problem persists, replace the batteries.
If the problem persists, replace the batteries.
Replace the battery charger.
Page 27
Service Manual – Scrubtec R 253 - RA40
Control System 27
Super User Screen
The alarms activated during normal machine operation are stored and can be read in the corresponding log (Alarm Log Screen).
Alarm Log Screen
The alarms log screen (F, Figure 6) function allows you to check any alarms stored on the machine.
1. Turn the ignition key to “I” holding down both the horn button (A) together with the adjustment percentage detergent button (B).
2. Press hold 1 second the reverse button (C) to switch to the screen menu (D).
3. Press the vacuum system button (E) to access the alarm log screen (F).
4. To return to the menu screen (D) repeatedly press the One-Touch button (G).
C
A
>1sec
B
Figure 6
G
E
F D
Each alarm (See table of alarms in the Function Electronic Board Alarm Codes paragraph) is stored along with the working hour (machine operating time counter) at which it occurred and all alarms are recorded in the order in which they occurred, from the most recent to the oldest. The memory holds up to 20 alarm records, after which the oldest are overwritten when new alarms occur.
Page 28
Service Manual – Scrubtec R 253 - RA40
Alarm Log Screen (continues)
Improper uses of the batteries or battery charger are also recorded, as in the following table:
On-board Battery Charger Alarms
Alarm code
-------------------------­Description
GB-N
----------------------­CONTINUOUS LOW BATTERY VOLTAGE
GC
----------------------­CHARGER DISCONN BEFORE END CYCLE
GD-N
----------------------­CHARGING TIME LESS THAN 4 HOURS
Meaning Condition
Time of continuous use with discharged batteries
Charging cycle interrupted before completion
Charging phase duration
“N” is the number of hours from key on to off when the battery level is below 18.4V for WET CELL (19.6 for AGM) batteries. This event is not recorded if the usage time is below 10 minutes.
Disconnection of battery charger before stage IV = battery symbol with 3 segments lit steadily.
N = Number of hours from battery charger connection to completion of PHASE II (red LED on) if < 4
Effect
Incorrect use by customer. Risk of reduced battery life.
Incorrect use by customer. Risk of reduced battery life.
Incorrect use by customer. Risk of reduced battery life.
Control System 28
Press the One-Touch button to skip to the next Alarm logged.
Press and keep pressed for 3 seconds the vacuum button to reset the memory log.
Page 29
Service Manual – Scrubtec R 253 - RA40
Control System 29
Setting Screen
The machine function parameters screen (C, Figure 7) allows you to customise some parameters described in
the following table of modiable parameters.
1. Turn the ignition key to “I” holding down both the horn button (A) together with the adjustment percentage detergent button (B).
2. Press the One-Touch button (D) to increase the value of the current parameter.
3. Press the vacuum system button (E) to decrease the value of the current parameter.
4. To move to the next parameter press the reverse button (F), or hold it for 1 second to return to the screen menu (G).
A
B
C
E
F
D
G
>1sec
Figure 7
MODIFIABLE PARAMETERS
Code Description Min. Value Factory Setting Max. Value
P1/P3
P2/P3
P3 Level 3 solution ow rate 1.0 cl/m 3.0 cl/m 5.0 cl/m
P4 Level 4 enabling (2.8 l/min regardless of speed) OFF OFF ON
XPRES Brush deck extra pressure enabling OFF ON ON
FVMAX Maximum forward speed 10 % 100 % 100 %
RVMAX Maximum reverse speed 10 % 40 % 50 %
WSMIN Minimum working speed 10 % 25 % 100 %
WSMAX Maximum working speed 10 % 100 % 100 %
BRK Electromagnetic brake activation delay 0 sec. 3 sec. 5 sec.
BAT Installed battery type 0 1 5
TOFF Automatic shut-off time 0 (disabled) 300 sec. 600 sec.
BRGH Display contrast 5 15 50
RPM (*) Reduced brush rpm activation threshold 5 9 20
RESET (**) Restore factory settings for all parameters OFF OFF ON
Level 1 solution ow rate in relation to level 3 (see “System for Flow Rate Regulation as Function of Speed” paragraph)
Level 2 solution ow rate in relation to level 3 (see “System for Flow Rate Regulation as Function of Speed” paragraph)
0 % 25 % 100 %
0 % 50 % 100 %
(*) Increase the value of this parameter to reduce the brush motor speed in a wider range of applications and vice versa
(**) The RESET function acts only on “MODIFIABLE PARAMETERS” and not on “HIDDEN PARAMETERS”.
Page 30
Service Manual – Scrubtec R 253 - RA40
Control System 30
Setting Screen (Continues)
The following parameters are displayed only when, on reaching the last RESET parameter, the reverse but-
ton is pressed together with the detergent percentage adjustment button and the solution ow
adjustment button .
Otherwise at the reverse button pressed, the system will return to the rst parameter P1/P3.
HIDDEN PARAMETERS
Code Description
TSERV Service advisory timer (hours)
AR
DR
IR
AMAX
KG
VS1
VS2
DEADL Drive pedal bottom dead area (V) 0.0 0.1 1.0 DEADH Drive pedal top dead area (V) 0.0 0.8 1.0
INOM Drive system rated current (A) 10 22 25
IMAX
TMAX
Maximum acceleration ramp (sec.)
Maximum deceleration ramp (sec.)
Maximum deceleration ramp in reverse (sec.)
Maximum lateral acceleration (g/100)
Lateral acceleration control constant
Brush 1 motor protection threshold (A)
Brush 2 motor protection threshold (A)
Drive system maximum current (A)
Protection trip time for IMAX (sec.)
Min.
Value
0 0 1000
0.5 1.5 5
0.5 0.6 3
0.5 0.5 1
1 5 100
1.0 1.6 2.0
20 30 50
20 40 50
10 60 70
0 10 60
Factory
Setting
Max.
Value
Meaning
Set to a value X greater than 0 if you wish the “Service Advisory” icon to be displayed every X hours of machine running time (according to the main operating time counter). To reset the time counter for the icon display countdown (until the next service advisory), press the BURST and vacuum buttons for 10 seconds with the display on the “SERVICE MENU” page.
Increase to obtain a less abrupt response when accelerating, and vice versa.
Increase to obtain a less abrupt response when decelerating, and vice versa.
WARNING: increasing this value increases the braking distance.
Increase to obtain a less abrupt response when decelerating doing a reverse gear, and vice versa.
WARNING: increasing this value increases the braking distance.
It is the maximum lateral acceleration allowed to the machine. With this value, the drive system reduces the power to the driving wheel to keep the stability of the machine.
WARNING: increasing this value increases the risk of machine overturning.
Engineering parameter connected to AMAX.
- Do not change.
This is the maximum current which can be supplied to the disc brush deck.
WARNING: increasing this value increases the risk of motor overheating.
This is the maximum current which can be supplied to the cylindrical brush deck (not used).
WARNING: increasing this value increases the risk of motor overheating.
Pedal output voltage when the pedal is released. Pedal output voltage when the pedal is fully pressed. This is the maximum continuous current which can be
supplied to the driving wheel unit.
WARNING: increasing this value increases the risk of motor overheating.
This is the maximum instantaneous current which can be supplied to the driving wheel unit.
WARNING: increasing this value increases the risk of motor overheating.
This is the reaction time of the driving wheel unit protection device when overloaded: this parameter is used in conjunction with IMAX to obtain the most appropriate response curve for the overload protection motor actuation system.
WARNING: increasing this value increases the risk of motor overheating.
Page 31
Service Manual – Scrubtec R 253 - RA40
Control System 31
Hours Screen
1. Turn the ignition key to “I” holding down both the horn button (A, Figure 8) together with the adjustment percentage detergent button (B).
2. Press hold 1 second the reverse button (C) to switch to the screen menu (D).
3. Press the horn button (A) to access the operating time counter screen (E).
The operating time counter screen (E) function allows you to check the total accumulated hours of work for each machine subsystem:
• (F) TOTAL counter (machine running time)
• (G) DRIVE counter (drive system usage time)
• (H) BRUSH counter (brush rotation system usage time)
• (I) VACUUM counter (vacuum system usage time)
4. To return to the screen menu (D) press the One-Touch button (J).
A
B
F
G
H
I
J
E
C
>1sec
D
Figure 8
Page 32
Service Manual – Scrubtec R 253 - RA40
Control System 32
System for Flow Rate Adjustment as Function of Speed
Solution ow levels 1, 2 and 3 regulate the ow of solution on the basis of the machine speed so as to keep the quantity of solution dispensed per square metre of oor treated constant.
The reference ow level is level 3: based on the setting of the corresponding parameter P3, the opening time of the solenoid valve (and of the detergent pump when tted) is regulated so that the quantity of solution in
centiliters per metre travelled by the machine is constant and equal to the value set in the parameter.
For example, for P3 = 3.0, the machine will dispense 3 centiliters of solution per metre travelled, which equates
(for the standard deck width of 530mm) to 5.7 centiliters per square metre of oor treated.
Levels 1 and 2 are dened via the corresponding parameters P1 and P2 as a % of level 3. For example, for P1 = 25 and P2 = 50, P1 and P2 are respectively ¼ (25 %) and ½ (50 %) of the reference ow
rate P3.
The default values (the same as in the example above) are summarized in the table, with the corresponding
ow rate values in liters per minute, dependent on machine speed, given as a reference.
Detergent ow (as a function of speed) (standard setting)
Level 1 Level 2 Level 3
Liters/minute @ 1 km/h 0.2 0.3 0.5
Liters/minute @ 3 km/h 0.4 0.8 1.5
Liters/minute @ 5 km/h 0.6 1.3 2.5
Centiliters per metre cleaned (constant) 0.75 1.5 3
Centiliters per meter2 cleaned (Ø530 deck) 1.4 2.8 5.7
Level 4 (when enabled) is independent of any parameter and supplies the maximum possible quantity of solu­tion as it keeps the solenoid valve of the supply system constantly open (with the brush rotating).
Detergent ow rate
Level 4
Liters/minute - Tank full 3.5
Liters/minute - Average 2.5
Page 33
Service Manual – Scrubtec R 253 - RA40
Removal and Installation
Function Electronic Board (EB1) Removal/Replacement
1. Drive the machine on a level oor and remove the operator key.
2. Disconnect the red battery connector by pressing the emergency push-button.
3. Lift the recovery tank assembly and the driver’s seat.
4. Remove the 3 screws and remove the upper cover.
5. Remove the 2 screws and remove the function electronic board front cover.
6. Disconnect the following connections (Figure 9):
◦ (A) and (B) Electronic board power supply connection (B+) and (B-). ◦ (C) and D) Brush motor connection (BR+) and (BR-).
Control System 33
C
D
B
A
Figure 9
7. Disconnect the following connections (Figure 10):
◦ (E) and (F) Drive system motor connection (M1) and (M2). ◦ (G) and (H) Vacuum system motor connection (VA+) and (VA-).
GE F H
C
D
B
A
Figure 10
E F G H
Page 34
Service Manual – Scrubtec R 253 - RA40
Function Electronic Board (EB1) Removal/Replacement (Continues)
8. Disconnect the following connections (Figure 11):
◦ (I) Key, accelerator and steering wheel electronic board connection (J1). ◦ (J) Squeegee actuator, beacon light and driver’s seat sensor connection (J3). ◦ (K) Battery charger connection (J4). ◦ (L) Brush deck actuator connection (J2). ◦ (M) Accessory connection (J8).
K
L MM JJ
II
K
Control System 34
L
Figure 11
9. Unscrew the 4 retaining screws (N) and carefully remove the function electronic board (Figure 12).
N
N
Figure 12
N
N
N
N
N
N
10. Assemble the components in the reverse order of disassembly.
Page 35
Service Manual – Scrubtec R 253 - RA40
Control System 35
Display Board (EB2) and Dashboard Instrument Board (EB4) Removal/Replacement
Display Board (EB2)
1. Drive the machine on a level oor.
2. Remove the operator key and disconnect the red battery connector
3. Remove the steering wheel mounting screws (A, Figure 13).
4. Lift the steering wheel group and disconnect the wiring harness connection (B).
5. At the workbench, remove the 6 screws (C, Figure 14).
A
6. Lift the cover of the dashboard instrument board
(D, Figure 15) and recover the gasket (E).
7. Remove the screws (F) and remove the display electronic board (G).
8. Disconnect the connection (H, Figure 16).
9. Disconnect the at connections (I) and (J) from the display electronic board (EB2).
F
G
Figura 13
E
D
B
Figura 15
I
J
C
H
Figura 14
Figura 16
Page 36
Service Manual – Scrubtec R 253 - RA40
Control System 36
Display Board (EB2) and Dashboard Instrument Board (EB4) Removal/Replacement (Continues)
Dashboard Instrument Board (EB4)
10. Perform points 1 to 6 for removal of the display electronic board (EB2).
11. Disconnect the at connections (K, Figure 17) and (L) from the display electronic board (EB2).
12. Carefully lift the dashboard instrument electronic board (M, Figure 18) and remove it from the cover (N).
Assembly
13. Assemble the components in the reverse order of disassembly and note the following:
◦ Install the display electronic board (EB2) and
check the proper operation and function.
◦ By carefully, install the dashboard electronic
board (EB4) on the cover, paying attention
to the routing of the at connections in the
cover slots.
M
K
Figura 17
L
N
Figura 18
Warning! The rst batch of Display electronic board (EB2) are equipped with an 8-way male
pins on the right side connection (N) instead of a 6-way male pins. Pay attention and mount the connector leaving in sight 2 male pins on the right side as show in the
gure:
N
Page 37
Service Manual – Scrubtec R 253 - RA40
Specications
Function Electronic Board (EB1) Connectors
(Figure 19) Power connections (Ø6mm male RADSOK terminals - AMPHENOL SK 200800532 101 or equivalent)
Ref. Description
B+ Electronic board power supply + in 24V 125A BAT+
B- Electronic board power supply - in 24V 125A BAT-
Electronic board
in/out
V ref. I max. Connected to
Control System 37
Figure 19
(Figure 20) Drive connections (Ø3.6mm male RADSOK terminals - AMPHENOL P/N N01 036 6501 001 or equivalent)
Ref. Description
BR+ Brush motor + out 24V 50A M1+
BR- Brush motor - out 24V 50A M1-
Electronic board
in/out
V ref. I max. Connected to
Figure 20
Page 38
Service Manual – Scrubtec R 253 - RA40
Function Electronic Board (EB1) Connectors (Continues)
(Figure 21) Drive connections (Ø3.6mm male RADSOK terminals - AMPHENOL P/N N01 036 6501 001 or equivalent)
Ref. Description
M1 Drive system motor + out 0-24V 70A M3+
M2 Drive system motor - out 0-24V 70A M3-
Electronic board
in/out
V ref. I max. Connected to
Control System 38
Figure 21
(Figure 22) Vacuum connections (2-way male parallel faston connectors, 6.3x0.8 – spacing 6.5mm)
Ref. Description
VA+ Vacuum system power supply + out 16-24V 30A M2+
VA- Vacuum system power supply - out 0V 30A M2-
Electronic board
in/out
V ref. I max. Connected to
Figure 22
Page 39
Service Manual – Scrubtec R 253 - RA40
Function Electronic Board (EB1) Connectors (Continues)
(Figure 23) J1: MOLEX MINIFIT type, 12-ways vertical
PIN Description Electronic board
1 Key electronic board power supply + out 24V 3A SW1
2 Return from USER key in 24V 3A SW1
3 Key reader power supply circuit out 12V <1A -
4 Key Identication in 0-5V <1A -
5 External power supplies - out 0V <1A -
6 Display electronic board power supply + out 24V 3A EB2.1
7 Enabling input from display electronic
board
8 Display electronic board serial + in/out 5V <1A EB2.3
9 Display electronic board serial - in/out 0V <1A EB2.4
10 Pedal power supply + out 24V <1A PED.1
11 Return from pedal in 0-5V <1A PED.2
12 Return from steering microswitch in 0V <1A SW4
in/out
in 24V 3A EB2.2
V ref. I max. Connected to
Control System 39
Figure 23
(Figure 24) J2: MOLEX MINIFIT type, 2-ways vertical
PIN Description Electronic board
Deck actuator power supply +/- out 0/24V 8A M5
1
Deck actuator power supply -/+ out 0/24V 8A M5
2
in/out
Figure 24
V ref. I max. Connected to
Page 40
Service Manual – Scrubtec R 253 - RA40
Function Electronic Board (EB1) Connectors (Continues)
(Figure 25) J3: MOLEX MINIFIT type, 6-ways vertical
PIN Description Electronic board
Squeegee actuator power supply +/- out 0/24V 8A M6
1
Driver’s seat microswitch power supply out 0V <1A SW3
2
Auxiliary power supply - out 0V 1A BE1
3
Squeegee actuator power supply -/+ out 0/24V 8A M6
4
Return from driver’s seat microswitch In 0V <1A SW3
5
Auxiliary power supply + out 24V 1A BE1
6
in/out
V ref. I max. Connected to
Control System 40
Figure 25
(Figure 26) J4: MOLEX MINIFIT type, 4-ways vertical
PIN Description Electronic board
Enabling from battery charger in 24V <1A CH.1
1
Power supply from battery charger in 24V <1A CH.2
2
Battery charger enabling power supply out 24V <1A CH.3
3
Battery charger data communication in/out 5V <1A CH.4
4
in/out
V ref. I max. Connected to
Figure 26
Page 41
Service Manual – Scrubtec R 253 - RA40
Function Electronic Board (EB1) Connectors (Continues)
(Figure 27) J5: JST VHR-3N type, 3-way vertical
PIN Description Electronic board
in/out
1 Power supply for water level sensor + out 24V <1A S1.1
2 Water level sensor return in 0V <1A S1.2
3 Power supply for water level sensor - out 0V <1A S1.3
V ref. I max. Connected to
Control System 41
Figure 27
Figure 28
(Figure 28) J6: JUMPER, 2-ways vertical
Page 42
Service Manual – Scrubtec R 253 - RA40
Function Electronic Board (EB1) Connectors (Continues)
(Figure 29) J7: TYCO MODU II type, 6-ways vertical
PIN Description Electronic board
1
2
3
4
5
6
+24V power supply out 24V <1A TRK.RD
+5V power supply out 5V <1A -
iButton input in (out) 0V (0-5V) <1A TRK.YE
External time counter enabled (in) out 0V (0-24V) <1A TRK.WH
Power supply - out 0V <1A TRK.BU
Machine on signal out 24V <1A TRK.BN
in/out
V ref. I max. Connected to
Control System 42
Figure 29
(Figure 30) J8: TYMOLEX MINIFIT type, 10-ways vertical
PIN Description Electronic board
1
2
3
4
5
6
7
8
9
10
Solenoid valve power supply - out 0V 1A EV1
Detergent pump power supply - out 0V <1A M4
Electromagnetic brake output out 0V 1A BRK
Opt power supply - out 0V 1A USB -
DECK congurator return in 0V <1A J4.10
Solenoid valve power supply + out 24V 1A EV1
Detergent pump power supply + out 24V <1A M4
Electromagnetic brake output + out 24V 1A BRK
Opt power supply + out 24V 1A USB +
Power supply for DECK congurator out 0V <1A J4.4
in/out
V ref. I max. Connected to
Figure 30
Page 43
Service Manual – Scrubtec R 253 - RA40
Display Electronic Board (EB2) Connectors
(Figure 31) J1: MOLEX MINIFIT type, 6-ways vertical
Ref. Description
1 Power supply + in 24V 3A CFG2.J1.6
2 Machine startup enabling out 24V 3A CFG2.J1.7
3 Display electronic board serial + in/out 5V <1A CFG2.J1.8
4 Display electronic board serial - in/out 0V <1A CFG2.J1.9
5 Power supply - in 0V <1A CFG2.J1.5
6 Power supply repetition - out 0V <1A -
(Figure 31) J2: FCI DUFLEX (2.54 pitch) 9-way, male pins
Ref. Description
1 Power supply - common out 0V <1A
2 HORN button (P3) in 0V <1A
3 EDS button (P2) in 0V <1A
4 DETERGENT MIX button (P1) in 0V <1A
5 BRUSH / EXTRAPR. button (P4) in 0V <1A
6 VACUUM button (P5) in 0V <1A
7 BRUSH RELEASE button (P6) in 0V <1A
8 ON/OFF button (P0) in 0V <1A
9 REVERSE GEAR button (P7) in 0V <1A
10 INCREASE SPEED button (P8) in 0V <1A
11 DECREASE SPEED button (P9) in 0V <1A
12 Dashboard congurator in 0V <1A
Electronic
board in/out
Electronic
board in/out
V ref. I max. Connected to
V ref. I max.
Control System 43
(Figure 31) J3: FCI DUFLEX (2.54 pitch) 6-way, male pins
Ref. Description
1 Power supply – common out 0V <1A
2 BRUSH RELEASE function LED (LD3) out 5V <1A
3 VACUUM function LED (LD2) out 5V <1A
4 BRUSH / EXTRAPR funct. LED (red) (LD1R) out 5V <1A
5 BRUSH / EXTRAPR funct. LED (green) (LD1V) out 5V <1A
6 SPOT function LED (LD4) out 5V <1A
Electronic
board in/out
V ref. I max.
REAR FRONT
J1
J2
Figure 31
J3
Page 44
Service Manual – Scrubtec R 253 - RA40
Control System 44
Shop Measurements
The following tables contain some “real world” shop voltage measurements to help you recognize what “nor­mal” looks like. All voltage values were measured with the black (Negative) voltmeter lead connected to the
main battery negative unless otherwise specied.
Shop Measurements - Function Electronic Board (EB1)
Battery volts at battery, key on = 24.55V (23.5V Vac on high).
Power Supply
Figure 32
PIN Color Description Measured Comments
B+ Red Electronic board power supply + 23.4V Measured B+ to B-, Vac on high
B- Black Electronic board power supply - 23.4V Measured B+ to B-, Vac on high
Brush Motor
Figure 33
PIN Color Description Measured Comments
BR+ Red Brush motor + 23.5V Measured to BR-, normal scrub
BR- Blue Brush motor - 23.5V Measured to BR+, normal scrub
Page 45
Service Manual – Scrubtec R 253 - RA40
Shop Measurements - Function Electronic Board (EB1) (continues)
Drive System Motor
Figure 34
Control System 45
Specify if with operator on board or drive motor without load (machine lifted). The values seem a little bit low.
PIN Color Description Measured Comments
M1 White Drive system motor + 21.7V FWD Measured M1 to M2 at Max speed
9.7V REV
M2 Black Drive system motor - 21.7V FWD Measured M1 to M2 at Max speed
9.7V REV
Vacuum Motor
Figure 35
PIN Color Description Measured Comments
VA+ Red Vacuum system power supply + 23.2V Measured VA+ to VA-
VA- Blue Vacuum system power supply - 23.2V Measured VA+ to VA-
Page 46
Service Manual – Scrubtec R 253 - RA40
Shop Measurements - Function Electronic Board (EB1) (continues)
J1 - 12 Ways
Figure 36
PIN Color Circuit Description Measured Comments
1 Red Key electronic board power supply + 24.4V Off or On
2 Orange Return from USER key 0.02V Key not in slot
23.7V With either gray or yellow key in slot
3 Or/Blk Key reader power supply circuit 8.65V With either gray or yellow key in slot
4 Wh/Blk Key Identication 0V Key not in slot
1.45V Gray Operator Key
1.21V Yellow Super User Key
5 Black External power supplies - 0.03V Vac On
6 White Display electronic board power supply +23.1V Key In (all condition)
Control System 46
7 Brown Enabling input from display electronic
board
8 Green Display electronic board serial + 4.5V
9 Yellow Display electronic board serial - 4.0V
10 Violet Pedal power supply + 23.7V
11 Vi/Blk Return from pedal 0.01V Pedal at rest
12 Blue Return from steering microswitch 4.98V Straight ahead (switch pressed)
0V Power Off (Timed out)
22.7V Power On
4.82V Pedal pressed full forward
0.003V Sharp turn (Switch released)
Page 47
Service Manual – Scrubtec R 253 - RA40
Shop Measurements - Function Electronic Board (EB1) (continues)
J2 - 2 Ways
Figure 37
PIN Color Circuit Description Measured Comments
1 Black 2 Deck actuator power supply +/- 24.4V At rest
0.04V Extending (deck down)
24.3v Retracting (deck up)
2 Black 1 Deck actuator power supply -/+ 24.4V At rest
23.7V Extending (deck down)
0.07V Retracting (deck up)
Control System 47
J3 - 6 Ways
Figure 38
PIN Color Circuit Description Measured Comments
1 Br/Blk Squeegee actuator power supply +/- 23V At rest
23.7V Extending (Squeegee down)
0.07V Retracting (Squeegee up)
2 Or/Blk Driver’s seat microswitch power
supply
3 Wh/Blk Auxiliary power supply - Beacon 0V
4 Bl/Blk Squeegee actuator power supply -/+ 0V At rest
5 Or/Blk Return from driver’s seat microswitch 4.98V Off seat
6 White Auxiliary power supply + Beacon 24.39V
0.02V On or off seat
0.08V Extending (Squeegee down)
23.9V Retracting (Squeegee up)
0.003V On seat
Page 48
Service Manual – Scrubtec R 253 - RA40
Shop Measurements - Function Electronic Board (EB1) (continues)
J4 - 4 Ways
Figure 39
PIN Color Circuit Description Measured Comments
1 White Enabling from battery charger 24.4V Not Charging
0.013V Charging
2 Yellow Power supply from battery charger 0.032V Not Charging
24.4V Charging
3 Brown Battery charger enabling power
supply
4 Green Battery charger data communication 0.01V Not Charging
24.4V Not Charging
26V Charging
4.59V Charging
Control System 48
J5 - 3 Ways
Figure 40
PIN Color Circuit Description Measured Comments
1 Brown Power supply for water level sensor + 21.6V
2 Black Water level sensor return 4.9V < 1/2 solution tank level
0.03V > 1/2 solution tank level
3 Blue Power supply for water level sensor - 0.001V
Page 49
Service Manual – Scrubtec R 253 - RA40
Shop Measurements - Function Electronic Board (EB1) (continues)
J6 - 2 Ways
Figure 41
Control System 49
Two way vertical jumper.
• What is this for? The J6 Jumper is used to congure the function board for the EcoFlex option.
• What does it mean if it is jumped? The function board is set for no EcoFlex
• What does it mean if it is open? The function board is set for EcoFlex
• Is there a measurable voltage on either of the pins when not jumped? Yes. 4.98v on pin near the LEDS on the board.
J7 - 6 Ways
Measured machine did not have a wiring connector. Measurements were taken at each pin on the board.
Figure 42
PIN Color Circuit Description Measured Comments
1 Red +24V power supply 24.6V
2 - +5V power supply 5.00V
3 Yellow iButton input 4.98V
4 Blue External time counter enabled 24.6V
5 White Power supply - 0.001V
6 Brown Machine on signal 23.68V
Page 50
Service Manual – Scrubtec R 253 - RA40
Shop Measurements - Function Board (EB1) (continues)
J8 - 10 Ways
Figure 43
PIN Color Circuit Description Measured Comments
1 Blue Solenoid valve power supply - 24.2V When off
0.08v When on (momentary)
2 Black Detergent pump power supply - 24.2V When off
3 Wh/Blk Electromagnetic brake output 24.1V Not energized (stationary)
0.7V Energized (moving)
4 Black Opt power supply - No wire
5 Green DECK congurator return 0V Loop not cut
6 Brown Solenoid valve power supply + 24.2V
7 Grey Detergent pump power supply + 24.2V
8 White Electromagnetic brake output + 24.2V
9 Red Opt power supply + No wire
10 Green Power supply for DECK congurator 0V Loop not cut
Control System 50
Page 51
Service Manual – Scrubtec R 253 - RA40
Control System 51
Shop Measurements - Display Electronic Board (EB2)
Measure and record the voltage at each of the function board pins. Always use battery negative as your refer­ence point for your black voltmeter lead.
J1 - 6 Ways
REAR
J1
Figure 44
PIN Color Circuit Description Measured Comments
1 White Power supply + 23.1V Key In (all condition)
2 Brown Machine startup enabling 0V Power Off (Timed out)
22.7V Power On
3 Green Display electronic board serial + 4.5V
4 Yellow Display electronic board serial - 4.0V
5 Grey Power supply - 0.03V Vac On
6 Power supply repetition - No wire
Page 52
Service Manual – Scrubtec R 253 - RA40
Shop Measurements - Display Electronic Board (EB2) (continues)
J2 12 way ribbon connector
FRONT
J2
Figure 45
Control System 52
PIN Color Circuit Description Measured Comments
1 Power supply - common 0.007V
2 HORN button (P3) 3.1V Not pressed
0.03V Pressed
3 EDS button (P2) Solution Button 3.1V Not pressed
0.03V Pressed
4 DETERGENT MIX button (P1) 3.1V Not pressed
0.1V Pressed
5 BRUSH / EXTRAPR. button (P4) 3.1V Not pressed
0.07V Pressed
6 VACUUM button (P5) 3.1V Not pressed
0.06V Pressed
7 BRUSH RELEASE button (P6) 3.1V Not pressed
0.04V Pressed
8 ON/OFF button (P0) 22.1V Not pressed
0.02V Pressed
9 3.1V
10 3.1V
11 REVERSE GEAR button (P7) (Blue
models only)
12 Dashboard congurator 3.1V Gray model
3.1V Not pressed
0.06V Pressed
0.01V Blue model
Page 53
Service Manual – Scrubtec R 253 - RA40
Shop Measurements - Display Electronic Board (EB2) (continues)
J3 6 way ribbon connector
FRONT
J3
Figure 46
Control System 53
PIN Color Circuit Description Measured Comments
1 Power supply – common 0.007V
2 BRUSH RELEASE function LED
(LD3)
3 VACUUM function LED (LD2) 0.01V Off
4 BRUSH / EXTRAPR funct. LED (red)
(LD1R)
5 BRUSH / EXTRAPR funct. LED (green)
(LD1V)
6 SPOT function LED (LD4) 2.0V Steady green
0.01V Off
0.9V When ashing red
2.0V Steady green
0.01V Off
2.0V Steady red
0.01V Off
Page 54
Service Manual – Scrubtec R 253 - RA40
Electrical System
Functional Description
Electrical System 54
The batteries (2 x 12V) are connected together in se­ries by the cables. The battery charger (CH) is connected to the machine by two connectors (C) (power connection to the batter­ies) and C3 (4-way signal connection). The grey and white cables (1 and 2 of connector C3) are short circuited inside the battery charger (CH) when this is not connected to the electrical mains. If this connection is not made, all machine functions are disabled.
If the optional battery charger has not been installed, the relevant bridge must be used on connector C3. The “bridge” is installed at the function board J4 lo­cation as shown in a photo below.
J4 bridge connector
The green cable (terminal 4 of connector C3) is the data cable between electronic board (EB1) and bat­tery charger (CH). This connection allows the battery charger charging curve to the be set directly from the machine dash­board and to view the operational state of the battery charger during charging directly on the dashboard display.
Battery Charger
When the battery charger (CH) is connected to the power supply, it provides a + 24V on J4.2: in this con­dition the electronic board (EB1) disables all the con­trol and functions except the battery status indicator on the display electronic board (EB4).
Battery Charge State Display
Low voltage cut out
The Function electronic board shuts off electrical loads to protect the batteries from damage caused by over discharging. The voltage threshold where loads are turned off depends on the battery type. See table below.
(Signicant levels for machine operation)
INDICATION
1 22V 22.2V Little remaining run time, no block.
2 20.4V 21.6V Brush OFF
3 19.4V 20.6V Vacuum system OFF
4 18.4V 19.6V Drive system OFF
TRANSITION THRESHOLD (VOLT)
WET GEL
CONSEQUENCE
Page 55
Service Manual – Scrubtec R 253 - RA40
Wiring Diagram
C1+
MAIN BATTERY CONNECTOR
BATTERY CONNECTOR
J4.1
Enabling from battery charger
Electrical System 55
B+
J4.1
C2.A
24V BATTERIES (BAT)
24V
(*)
BATTERY CHARGER (CH) BATTERY CONNECTOR
C1-
Figure 1
(*) Optional for BASIC version (**) Version without on-board battery charger
SIGNAL CIRCUIT FUSE (F2)
J4.2
Power supply from battery charger
J4.3
Battery charger enabling power supply
J4.4
Battery charger data communication
(**)
J4.3
FUNCTION ELECTRONIC BOARD FUSE (F1)
B-
FUNCTION ELECTRONIC BOARD (EB1)
Page 56
Service Manual – Scrubtec R 253 - RA40
Component Locations
• Function electronic board (EB1)
• Signal circuit fuse (F2)
• Function electronic board fuse (F1)
• Battery charger (CH)
• Battery connections
• Batteries (BAT)
• Battery connector (C1)
Battery connections
Electrical System 56
Batteries (BAT)
Battery connector (C1)
Figure 2
Function electronic board
(EB1)
Function electronic
board fuse (F1)
Figure 3
Signal circuit fuse (F2)
Battery charger (CH)
Page 57
Service Manual – Scrubtec R 253 - RA40
Component Locations (continues)
• On board battery charger connector (C2)
• J4 Bridge for without or broken on board battery charger
Electrical System 57
On board battery charger connector (C2)
Figure 4
J4 bridge connector for without or
broken on board battery charger
Figure 5
Page 58
Service Manual – Scrubtec R 253 - RA40
Electrical System 58
Maintenance and Adjustments
Setting the Installed Battery Type
Set the machine and the on-board battery charger (where tted) on the basis of the type of battery to be in­stalled by modifying the BAT parameter as shown.
1. Turn the ignition key to “I” holding down both the horn button (A, Figure 6) together with the
adjustment percentage detergent button (B) to going at the function parameters screen (C).
2. Press the reverse button (F) until you reach the BAT parameter.
A
B
C
E
F
D
G
>1sec
Figure 6
MODIFIABLE PARAMETERS
Code Description Min. Value Factory Setting Max. Value
BAT Installed battery type 0 1 5
3. Press the One-Touch button (D) or the vacuum system button (E) to modify the value of the BAT
parameter as per the following table:
Code BAT
Value Installed battery type
0 WET Wet cell batteries
1 GEL / AGM Generic GEL or AGM batteries
2 GEL DISCOVER DISCOVER® brand GEL batteries
3 GEL OPTIMA OPTIMA™ brand GEL batteries
4 GEL EXIDE EXIDE®/SONNENSHINE brand GEL batteries
5 GEL FULLRIVER FULLRIVER® brand GEL batteries
4. Press the reverse button (F) for more than 1 second to conrm the chosen parameter and return to the
screen menu (G).
5. To return to the work screen press the adjustment percentage detergent button (B).
Page 59
Service Manual – Scrubtec R 253 - RA40
Electrical System 59
Battery Charging (Continues)
Warning! When using lead (WET) batteries, battery charging produces highly explosive
hydrogen gas. Charge the batteries in well-ventilated areas and away from naked
ames. Do not smoke while charging the batteries. Keep the recovery tank lifted until
the battery charging cycle is over.
Warning! Pay close attention when charging WET CELL batteries, as there may be battery uid
leakages. The battery uid is corrosive. If it comes in contact with skin or eyes, rinse
thoroughly with water and consult a physician.
1. (For WET CELL batteries only) Check the level of electrolyte inside the batteries. If necessary, unscrew
the caps and top up.
2. When the correct level is restored, close the caps and clean the tops of the batteries.
Charging the Batteries with an External Battery Charger
1. Check that the external battery charger is
suitable by referring to the relevant Manual. The battery charger voltage rating must be 24V.
2. Press the emergency push-button, disconnect
the red battery connector and connect it to the external battery charger.
3. Connect the battery charger to the electrical
mains.
4. After charging, disconnect the battery charger
from the electrical mains and from the battery red connector.
5. Connect the battery connector to the machine.
6. Disengage the support rod, then grasp the
handle and carefully lower the recovery tank assembly.
Battery charging with battery charger installed on the machine
1. When the rst or second segment from the left in the battery symbol is ashing, this means that
the battery charger is charging the batteries.
2. When the third segment from the left in the
battery symbol is ashing, this means that the battery charger is nishing the battery charging
cycle.
3. When all segments of the battery symbol are steadily lit, the battery charging cycle is complete.
4. Disconnect the battery charger plug from the electrical mains and place it in its holder.
5. Disengage the support rod, then grasp the handle and carefully lower the recovery tank assembly.
Note: For further information about
the operation of the battery charger, see the relevant Manual.
7. Plug the battery charger into the electrical mains (the mains voltage and frequency must be compatible with the battery charger values shown on the machine serial number plate).
Note: When the battery charger is
connected to the electrical mains, all machine functions are automatically cut off.
Page 60
Service Manual – Scrubtec R 253 - RA40
Electrical System 60
Battery installation
1. Remove the operator key.
2. Disconnect the battery connector by pressing the emergency push-button.
3. Lift the recovery tank cover and check that it is empty; if not, empty it using the drain hose.
4. Grasp the handle and carefully lift the recovery tank assembly and the driver’s seat.
5. The machine is supplied with cables suitable to install 2 12V batteries.
6. Carefully lift the batteries until the relevant compartment, then place them properly.
7. Route and install the battery cable as shown in the diagram (Figure 7), then carefully tighten the nut on each battery terminal.
8. Place the protection cap on each terminal.
9. Connect the red battery connector.
10. Disengage the support rod, then grasp the handle and carefully lower the recovery tank assembly.
11. Perform a complete battery charging cycle.
Battery Charging
Note: Chargethebatterieswhenthereisonlyoneashingsegmentdisplayedinthebattery
Caution! When the batteries are discharged, charge them as soon as possible, as that
Caution! If the machine is not equipped with on-board battery charger, choose an external
BACK
Figure 7
symbol, or at the end of each shift. Keeping the batteries charged make their life last longer.
condition makes their life shorter. Check for battery charge at least once a week.
battery charger suitable for the type of batteries installed.
FRONT
Page 61
Service Manual – Scrubtec R 253 - RA40
Electrical System 61
Checking/Replacing Fuses
1. Drive the machine on a level oor and remove the operator key.
2. Disconnect the red battery connector by pressing the emergency push-button.
3. Lift the recovery tank.
4. Remove the 3 screws and remove the upper cover.
5. Remove the 2 screws and remove the electronic board front cover.
6. Check/replace the following fuses (Figure 8):
◦ (F1) 100A midi fuse - Function electronic board (A). ◦ (F2) 3A blade fuse - Signal circuits (B).
7. Place the function electronic board assembly in its housing, tighten the mounting screws and install the electronic component compartment cover.
B
B
A
Figure 8
A
Page 62
Service Manual – Scrubtec R 253 - RA40
Electrical System 62
Troubleshooting
See the other chapters for previously provided instructions for other electrical system components.
Trouble Possible Causes Remedy
The machine is not working Batteries (BAT) at or connections faulty Charge the battery or clean the
The batteries (BAT) are broken Check the battery no-load voltage
The battery charger (CH) is broken Replace
The wiring harness is cut or pressed or short circuited Repair
The ignition key (SW1) is broken Replace
Note: A damage to the battery charger or its connections can prevent the machine from
operating properly.
connections
To restore the machine functioning, disabling the on board battery charger with sthe bridge connector on the J4 connection placed on the function electronic board (EB1)
Page 63
Service Manual – Scrubtec R 253 - RA40
Electrical System 63
Specications
Description / Model
Battery compartment size (length x width x height) 13.7x14.1x11 in (350x360x280 mm)
Standard batteries (2) Discover 12V-105Ah
Standard battery run time (capacity) 2.5 h
Input voltage 100-240Vac 50-60Hz, 24Vdc 13A
Nilsk
Scubtec R253
Scubtec R253 full PKG
Nilsk
Clarke RA40
Battery charger
Charging procedure by microprocessor
Efciency > 85 %
Environmental protection class IP30
Page 64
Electrical System 64
Service Manual – Scrubtec R 253 - RA40
Wiring Diagram
J3J2FCI DUFLEX (2.54 pitch) 6-way, male pins
FCI DUFLEX (2.54 pitch) 9-way, male pins
Dashboard power supply +
Dashboard serial +
Dashboard serial -
Dashboard power supply -
Return from key J1.5
J1.1
J1.2
J1.3 (+5V)
J1.4
J1.5
J1.6
J1.7
J1.8
J1.9
J1.12
J4.1
J4.2
J4.3
J4.4
J7.1
J7.2
J7.3
J7.5
J7.4
J7.6
J4.1
J4.3
J6
OUT
-
+
J3.5
J3.6
J3.4
J3.2
J8.5
J3.1
J8.3
J8.9
J8.2
J8.8
J8.1
J8.7
J2.2
J8.6
M2
J2.1
BR -
BR+
B+
B -
Electronic board power supply +
Electronic board power supply -
M1
J8.4
J8.10
J3.3
J5.1
J5.2
J5.3
J1.10
J1.11
Key electronic board power supply +
Return from key USER
External power supplies -
Display electronic board power supply +
Enabling input from display electronic board
Display electronic board serial +
Display electronic board serial -
Return from steering microswitch
Enabling from battery charger
Power supply from battery charger
Battery charger enabling power supply
Battery charger data communication
+24V power supply
+5V power supply
iButton input
Power supply -
External time counter enabled
Machine on signal
Power supply for water level sensor +
Water level sensor return
Power supply for water level sensor -
Pedal power supply +
Return from pedal
J1.1
J1.2
J1.3
VA -
VA+
Return from driver’s seat microswitch
Auxiliary power supply +
Squeegee actuator power supply -/+
Driver’s seat microswitch power supply
DECK configurator return
Squeegee actuator power supply +/-
Electromagnetic brake output -
Opt power supply +
Detergent pump power supply -
Electromagnetic brake output +
Solenoid valve power supply -
Detergent pump power supply +
Deck actuator power supply -/+
Solenoid valve power supply +
Drive system motor -
Deck actuator power supply +/-
Brush motor -
Brush motor +
Drive system motor +
Opt power supply -
Power supply for DECK configurator
Auxiliary power supply -
Vacuum system power supply -
Vacuum system power supply +
J1.4
J1.3
J1.2
J1.1
Versions without battery charger
Microprocessor
DASHBOARD INSTRUMENT ELECTRONIC BOARD (EB4)
FUNCTION ELECTRONIC BOARD (EB1)
FUNCTION ELECTRONIC BOARD FUSE (F1)
SIGNAL CIRCUIT FUSE (F2)
BATTERY CHARGER CONNECTOR (C2)
BATTERY CHARGER CONNECTOR (C2)
24V BATTERIES (BAT)
BATTERY CONNECTOR (C1)
BATTERY CONNECTOR (C1)
TRACKCLEAN (TC)
SOLENOID VALVE (EV1)
BATTERY CHARGER (CH)
DRIVE PEDAL POTENTIOMETER (RV1)
DISPLAY ELECTRONIC BOARD (EB2)
BEACON LIGHT (BE)
ELECTROMAGNETIC BRAKE (BRK)
BRUSH MOTOR (M1)
VACUUM SYSTEM MOTOR (M2)
DRIVE SYSTEM MOTOR (M3)
CHEMICAL MIXING SYSTEM PUMP (M4)
DECK ACTUATOR (M5)
SQUEEGEE ACTUATOR (M6)
SOLUTION LEVEL SENSOR (S1)
DRIVER’S SEAT MICROSWITCH (SW3)
ANTI-SKID CONTROL SENSOR (SW4)
5V POWER UNIT (EB5)USB PORT
(USB)
IGNITION KEY (SW1)
Key reader power supply circuit
Key Identification
Figure 8
https://harrissupplyind.com - To Order Parts Call 608-268-8080
Page 65
Options and Accessories
Description Illustration
CHEMICAL MIXING SYSTEM KIT
(EU model only)
Insert-dry brake Cap Rell cap Hose Pump chemical mix Sensor water level Support sensor Hardware
BATTERY CHARGER KIT
(EU model only)
Charger extention UK / EU Cable tie plug Charger battery Support battery charger Hardware
Options and Accessories 65Service Manual – Scrubtec R 253 - RA40
WASTE BASKET KIT
(EU model only)
Support Basket Hardware
Page 66
Description Illustration
BROOM HOLDER KIT
(EU model only)
Support mop Spacer for support Tool holder Hardware
ENHANCED VACUUM SYSTEM MOTOR KIT
(EU model only)
Vacuum motor assembly Hardware
Options and Accessories 66Service Manual – Scrubtec R 253 - RA40
WATER FILLER HOSE KIT
Support rubber for lling hose Hose lling Hardware
Page 67
Description Illustration
STOP WATER KIT
Solution cap Fitting quick 1/2 gas Valve water stop Support Hardware
BEACON LIGHT KIT
Options and Accessories 67Service Manual – Scrubtec R 253 - RA40
Support Beacon Hardware
USB KIT
USB cable Plate Hardware
Page 68
Description Illustration
TRACKCLEAN KIT
Trackclean sensor assy
Mounting cradle
Trackclean system (IButton)
Trackclean reader kit (reader, 2 keys)
Trackclean system RDR
Options and Accessories 68Service Manual – Scrubtec R 253 - RA40
Page 69
Service Manual – Scrubtec R 253 - RA40
Recovery System
Functional Description
Recovery System 69
The recovery system removes the dirty water from
the oor and pipes it to a recovery tank. When the machine is running, the dirty water on the oor is col-
lected by the squeegee blades and collected through the slots in the same, piped through the vacuum hose
and into the tank by the airow created by vacuum
system motor (M2). The dirty water is piped into the recovery tank, while the airow continues to the vac­uum fan. A tank with a grid collects the largest debris going through the recovery tank hose.
The automatic oat in the vacuum grid stops vacuum
system motor (M2) from collecting any liquids. The vacuum duct for connecting the vacuum grid to the vacuum system motor (M2) is inside the recovery tank cover.
Wiring Diagram
When the automatic oat closes and shuts down the
vacuum system, the vacuum system motor noise will
increase and the oor will not be dried.
The gasket on the input of the vacuum system motor
allows full functionality of the system, while the lter
built-in the gasket prevents the passage of dirt and debris. When the recovery tank is full it can be emptied through the drain hose.
Figure 1
FUNCTION ELECTRONIC BOARD (EB1)
B+
Vacuum system power supply +
Vacuum system power supply -
B-
VA+
VA -
VACUUM SYSTEM MOTOR (M2)
M2
Page 70
Service Manual – Scrubtec R 253 - RA40
Component Locations
• Recovery tank
• Recovery tank cover
• Cover gasket
• Vacuum system motor lter
• Recovery water drain hose
• Squeegee vacuum hose
Recovery System 70
• Vacuum system motor (M2)
• Container with debris collection grid
• Vacuum grid with automatic shut-off oat
Cover gasket
Container with debris col-
lection grid
Figure 2
Recovery tank cover
Vacuum grid with auto-
matic shut-off oat
Recovery tank
vacuum hose
Figure 3
Squeegee
Vacuum system motor
(M2)
Motor protection case
Recovery water drain
hose
Page 71
Service Manual – Scrubtec R 253 - RA40
A
Maintenance and Adjustments
Recovery Tank Cleaning
1. Drive the machine to the appointed disposal area.
2. Drain the water from the tank using the drain hose.
Recovery System 71
Note: The gasket (E) creates the
vacuum in the tank that is necessary to vacuum up the recovery water.
3. Lift the recovery tank cover.
4. Clean the vacuum grid (B) (Figure 4), release the fasteners (A), open the grid (B) and recover
the oat (C), then clean carefully and reinstall.
5. Remove the debris collection tank (D) and open its cover, then clean it carefully.
6. Reinstall it on the vacuum hose.
7. Reinstall the debris collection tank on the rigid tube in the tank.
8. Check the condition of the tank cover gasket (E).
E
G
9. If necessary, replace the gasket (E) by removing
it from its housing (F). When tting the new
gasket, position the joint (G) in the area shown
in the gure.
10. Check that the seating surface (H) of the gasket (E) is in good condition, clean and suitable to form a seal with the gasket itself.
11. Close the cover.
E
D
Figure 4
H
F
A
B
C
Page 72
Service Manual – Scrubtec R 253 - RA40
Troubleshooting
Trouble Possible Causes Remedy
Recovery System 72
The vacuum system motor will not turn onWiring between function electronic board (EB1) and
Suction of dirty water is insufcient or non-existent
vacuum system motor (M2) damaged
Dashboard instrument electronic board (EB4) faulty Replace
Vacuum system motor faulty Check the amperage
Activation of automatic oat shut-off Drain the recovery tank
Debris collection lter dirty Clean
Vacuum grid with automatic shut-off oat dirty Clean
Tank cover not correctly positioned Adjust
Tank cover gasket damaged or not working correctly Clean or replace
Vacuum system motor container dirty Clean
Vacuum seals damaged or not working correctly Repair or replace
Repair
Page 73
Service Manual – Scrubtec R 253 - RA40
Recovery System 73
Vacuum System Motor Amperage Test
Warning! This procedure must be performed by qualied personnel only.
1. Lift the recovery tank assembly and the driver’s seat.
2. Apply the amp clamp (A) to a cable (B) near the vacuum unit (Figure 5).
3. Insert the operator key in its slot.
4. Activate the vacuum by pressing the vacuum button .
5. Check that the vacuum system motor amperage is between 13 and 17A at 24V.
6. If the amperage is higher, remove the vacuum system motor (see the procedure in the Vacuum System Motor Disassembly/Assembly paragraph), and check the condition of all its components to detect and correct the abnormal amperage:
If the above-mentioned procedures do not produce the correct readings for the vacuum system motor amperage, the motor must be replaced.
Figure 5
B
A
Page 74
Service Manual – Scrubtec R 253 - RA40
Removal and Installation
Vacuum System Motor Unit Disassembly/Assembly
Disassembly
1. Remove the operator key.
2. Disconnect the red battery connector.
3. If present, drain the recovery tank, then lift it.
4. Disconnect the connector (A) (Figure 6) and remove the fastening clamp.
5. Unscrew the 3 screws (B) and remove the vacuum system motor unit (C).
Recovery System 74
B
A
Figure 6
Assembly
6. Assemble the components in the reverse order of disassembly.
B
C
B
Page 75
Service Manual – Scrubtec R 253 - RA40
Recovery System 75
Container and Vacuum System Motor Disassembly/Assembly
Disassembly
1. Disassemble the vacuum system motor unit as shown in the previous paragraph.
2. At the workbench, remove the terminals lock (A) (Figure 7) from the connector (B).
3. With a little screwdriver (C) move the splane lock (D) for disengaging the terminals from the connector.
4. Remove the two terminals (E).
5. Carefully, slightly lift the splane lock (D), previously pressed, to restore it.
A
D
Figure 7
B
E
D
C
Page 76
Service Manual – Scrubtec R 253 - RA40
Container and Vacuum System Motor Disassembly/Assembly (Continues)
6. Remove the clamp (F) (Figure 8).
7. Remove the 4 screws (G) and remove the cover (H).
G
F
Recovery System 76
H
Figure 8
8. Remove the soundproong (I) (Figure 9) and (J).
9. Remove the protection (K) to reach the vacuum system motor (L).
I
K
J
Figure 9
L
Page 77
Service Manual – Scrubtec R 253 - RA40
Recovery System 77
Container and Vacuum System Motor Disassembly/Assembly (Continues)
10. Clean the inside of the containers from any dirt that has settled and check all gaskets (J) (Figure 10) for wear; replace if necessary.
J
J
J
Figure 10
Assembly
11. Check that all components are reassembled with the correct polarity and orientation.
12. Assemble the components in the reverse order of disassembly.
Page 78
Service Manual – Scrubtec R 253 - RA40
Specications
Description / Model
Recovery tank capacity 18.5 US gal (70 liters)
Power 0.4 hp (310 W)
Insulation Class H
Nilsk
Scubtec R253
Scubtec R253 full PKG
Recovery System 78
Nilsk
Clarke RA40
Vacuum system motor technical data
Vacuum circuit capacity 39 in H2O (1000 mm H2O)
Voltage VDC 24V
Bearing impeller side CW (chemically resistant sealing)
Insulation materials and wires “UL” recognized
Page 79
Service Manual – Scrubtec R 253 - RA40
Scrub System, Disc
Functional Description
Scrub System, Disc 79
The disc brush system can be started by the operator. The disc brush turn counter-clockwise. The rotating brush system cleans the surface of the
oor. The main component of the brush system is the
deck where the brush or the pad-holder with pad suit­able for the type of surface to be cleaned is installed. The brush deck is installed on a frame to which the electrical actuator and the four levers for connection to the frame integrated with the brush motor is cou­pled. The electrical actuator (M5), with limit microswitches, lifts and lowers the deck. The operating and washing pressure depends on the weight of the deck. The ac­tuator also permits the extra pressure function. Extra pressure is selected via the button on the dashboard. Brush rotation occurs only when the brush motor (M1) is driven by the function electronic board follow­ing activation of the accelerator pedal microswitch.
The brush system uses the solution to wash the oor.
In case of brush motor overload, a safety system stops the brushes after about one minute of continuous overload. If the overload takes place when the extra pressure function is on, the system automatically turns the ex­tra pressure function off. If the overload persists, the brush stops.
The overload is detected by monitoring the current ow sum on the brush motor. The current is mea­sured by verifying the voltage drop through the brush system fuse (F1). If the voltage drop reaches the val­ue stored in the parameter “VS2” (default = 70 mV), the display shows the alarm message: WARNING ALARM F2, and if the overload persists, the brush motor will stop following a delay which varies on the basis of the extent of the overload. To start scrubbing again after a brush stop due to overload, turn the machine off. Then restart the ma­chine by turn the ignition key to “I”. To work properly, the brush motor (M1) needs the fol­lowing:
• Driver’s seat microswitch closed
• Brush function on
• Forward pedal pressed
• Battery level not critical, display icon without
segments and ashing outline.
RPM Brush Reduction Function
This function, controlled by the function board, ad­justs the brush motor speed and prevents (example:
on very smooth oors) the excessive brush rotation
speed causes water splashing outside of the cleaning area. If the brush motor current remains below the param­eterized threshold with the RPM parameter, the mo­tor is powered by reduced voltage of 20,0V. If the brush motor current exceeds the value of pa­rameterized threshold, the motor is supplied at 100% by the battery voltage.
Page 80
Service Manual – Scrubtec R 253 - RA40
Wiring Diagram
Scrub System, Disc 80
Electronic board power supply +
B+
Brush motor +
BR+
BRUSH
MOTOR (M1) FUNCTION ELECTRONIC BOARD (EB1)
Brush motor -
Deck actuator power supply +/-
Deck actuator power supply -/+
Power supply for DECK configurator
DECK configurator return
B -
Electronic board power supply -
BR -
J2.1
J2.2
J8.10
J8.5
DECK ACTUATOR (M5)
Figure 1
Brush Deck Actuator System
The brush deck actuator is a new generation actuator developed by SIR and ITALSEA and it is controlled directly by the main board without electromechanical limit switches. ITALSEA patented the system to control
the actuator. Basically the system uses deeply measurements of the current ow in the actuator to know its
position in real time. The actuator is mechanically proof of the end of stroke because of it reaches the end of stroke with limited volt­age applied and so with a limited speed and force.
The actuator moves and stops in 3 dened positions:
1) RETRACTED: fully retracted end of stroke (deck lifted)
2) WORK: intermediate position (deck on the oor, normal work condition)
3) EXTRAPRESSURE: fully extended end of stroke (deck on the oor with extra pressure given pressing
the actuator integrated spring)
The actuator is powered at 50 % PWM (about 12Vdc) near the end of strokes or during the machine switch-on reset feature, otherwise at 100 % PWM (24Vdc) The machine switch-on reset feature moves the actuator from the position where it was the last time the ma­chine was switched off to the retracted position. The quotes of the actuator strokes, with a tolerance of ±2mm are: Stroke RETRACTED-WORK = 3.3 in (85 mm), stroke RETRACTED-EXTRAPRESSURE (end to end) = 4.7 in (120 mm). There are time out limits and amperometric limits related to the different phases of the movement as follow:
Movement from: To: PWM AMP limit Alarm if AMP limit is
Extrapressure Work 100 % (=24Vdc) 4A per Time>1sec. Yes 7.5 sec.
Work Retracted –
Retracted –
0.4 in (10 mm)
Reset (switch on) 50 %(=12Vdc) 2A per Time>1sec. No (The electronic board
0.4 in (10 mm)
Retracted 50 %(=12Vdc) 2A per Time>1sec. No (The electronic board
100 %(=24Vdc) 4A per Time>1sec. Yes 15 sec.
reached
assumes the actuator reaches the end of stroke)
assumes the actuator reaches the end of stroke)
Timeout
25 sec.
Page 81
Service Manual – Scrubtec R 253 - RA40
Component Locations
Scrub System, Disc 81
• Brush motor (M1)
• Disc brush deck
• Deck raising levers
Brush motor (M1)
Disc brush deck
• Brush deck support
• Drive hub
Deck raising levers
Brush deck support
Figure 2
Drive hub
Figure 3
Page 82
Service Manual – Scrubtec R 253 - RA40
Component Locations (Continues)
• Brush deck lifting/lowering actuator (M5)
• Function electronic board (EB1)
• Actuator system wiring connection
Scrub System, Disc 82
Brush deck lifting/
lowering actuator (M5)
Figure 4
Function electronic board
(EB1)
Actuator system
wiring connection
Figure 5
Page 83
Service Manual – Scrubtec R 253 - RA40
Maintenance and Adjustments
Brush Installation/Removal
Scrub System, Disc 83
1. According to the kind of cleaning to be performed, the machine can be equipped either with the brush (A) (Figure 5) or the pad-holder (B) with pad (C) together with the appropriate deck.
2. Place the brush (A) or the pad-holder (B) under the deck.
3. Turn the ignition key to “I”.
4. Press the One-Touch button to lower the deck onto the brush.
5. To engage the brush, press the drive pedal shortly, if necessary repeat the procedure until the brush is engaged.
6. To remove the brush, lift the deck by pressing
the One-Touch button , then manually release the brush from the hub by turning it abruptly in its normal rotation direction.
Figure 5
A
B
C
Page 84
Service Manual – Scrubtec R 253 - RA40
Troubleshooting
Trouble Possible Causes Remedy
The brush does not clean properly The brush is excessively worn Replace
Scrub System, Disc 84
One brush does not turn See the chapter Control System,
Brush motor carbon brushes worn Replace
Presence of bulky debris or string around the brush or between the brush and attachment ange
Faulty brush motor Repair or replace
Wiring damaged Repair
It is not possible to lift/lower the brush See the chapter Control System,
Deck lifting/lowering actuator (M5) broken Replace
Break in actuator wiring Check the connections according
Function electronic board (EB1) damaged Replace
The brush disengagement system does not work
Function electronic board (EB1) faulty Replace
Function Electronic Board (EB1) Error Codes
Remove the brush and clean it
Function Electronic Board (EB1) Error Codes
to the instructions in the Electrical System chapter, Troubleshooting paragraph
Page 85
Service Manual – Scrubtec R 253 - RA40
Brush Motor Amperage Check
Scrub System, Disc 85
Warning! This procedure must be
performed by qualied
personnel only.
1. Drive the machine on a level oor.
2. Remove the brush.
3. Lift the recovery tank assembly and the driver’s seat.
4. Disassemble the electronic component compartment cover and the function electronic board panel.
5. Disconnect the drive system connector (A) (Figure 6) on the function electronic board (B) to disable machine movement.
6. Turn the ignition key to “I”.
7. Press the One-Touch button to lower the brush deck.
8. Apply the amp clamp (C) to an electrical cable (D) of the brush motor.
Note: Use a jumper wire to disable
the driver’s seat sensor.
9. Activate the brush by pressing the accelerator pedal, then check that the brush motor amperage is between 3 and 4A at 20V(*).
10. Deactivate the brush by releasing the accelerator pedal and raise the brush deck by
pressing the One-Touch button .
11. Remove the amp clamp (C).
12. If the amperage is higher, perform the following procedures to detect and correct the abnormal amperage:
◦ Check the brush motor carbon brushes. ◦ Remove the brush motor then check the con-
dition of its components.
13. If the above-mentioned procedures do not lead to a correct amperage, it is necessary to replace the brush motor.
B
A
C
D
Figure 6
(*) Voltage value supplied by the electronic board to the brush gearmotor when the gearmotor amperage is
less than the value of the RPM parameter.
Page 86
Service Manual – Scrubtec R 253 - RA40
Scrub System, Disc 86
Removal and Installation
Brush Deck Disassembly/Assembly
Disassembly
1. Drive the machine on a level oor or on a hoisting system to facilitate the disassembly procedures.
2. Remove the brush.
3. Place two wooden shims (B, Figure 7), at least 4 cm thick, under the brush deck (A).
4. Turn the ignition key to “I”.
5. Lower the brush deck by pressing the One-Touch button , then press it again and hold it for more than 1 second to activate the brush extra pressure function.
6. Lift the recovery tank assembly and the driver’s seat.
7. Switch off the machine and disconnect the battery connector.
8. Disassemble the electronic component compartment cover and the function electronic board panel.
9. Remove the 4 screws (C) and remove the actuator plate (D).
C
A
D
B
Figure 7
10. Remove the screw (E, Figure 8) and release the actuator lower pin (F).
11. Disconnect the electrical connection (G) and the detergent hose (H) from the solenoid valve (I).
G
E
Figure 8
F
I
H
Page 87
Service Manual – Scrubtec R 253 - RA40
Scrub System, Disc 87
Brush Deck Disassembly/Assembly (Continues)
Warning! To easly remove the brush deck, lift the machine body at the front side as shown
(L, Figure 9). Use extreme caution and follow the safety regulations using proper
equipment or safety xed supports suitable for the purpose.
12. Remove the 4 screws (J, Figure 9) from the raising levers (K).
13. Lift the machine body (L) and disconnect the electrical wiring harness (M) from the brush motor, then remove the brush deck (N) under the machine body.
M
J
K
L
N
Figure 9
Assembly
14. Assemble the components in the opposite order they were removed in, ensuring the brush motor power supply cable polarities are correct.
Page 88
Service Manual – Scrubtec R 253 - RA40
Checking/Replacing Brush Motor Carbon Brushes
Check
1. Remove the brush deck.
2. Remove any dust and dirt from around the brush motor carbon brushes.
3. Remove the four protective covers (A) (Figure 10) by disconnecting the clips.
4. Remove the carbon brush nuts (B) with the lead-in wires.
5. Disengage the tabs (C) and remove the carbon brushes (D).
6. Check the carbon brushes (D) for wear. The carbon brushes are worn out when:
◦ They do not make sufcient contact with the armature of the brush motor due to their wear ◦ When their contact surface is not intact ◦ When the residual stroke is below 0.12 in (3 mm) ◦ When the thrust spring etc. is broken
7. Replace the carbon brushes as an assembly.
Reassembly
Scrub System, Disc 88
8. Assemble the components in the reverse order of disassembly.
A
A
B
C
D
C
C
D
Figure 10
Page 89
Service Manual – Scrubtec R 253 - RA40
Brush Motor Disassembly/Assembly
Scrub System, Disc 89
Disassembly
1. Remove the brush deck.
2. At the workbench, remove the screw (A) (Figure
11) of the brush motor.
3. Use a puller to remove the brush hub (B).
4. Remove the screws (C).
5. Remove the brush motor (D).
6. Recover the key (E).
E
Assembly
7. Assemble the components in the reverse order of disassembly.
Note: For further information on deck
components see the Spare Parts List.
D
Figure 11
C
B
A
Page 90
Service Manual – Scrubtec R 253 - RA40
Brush Deck Actuator Disassembly/Assembly
Disassembly
1. Drive the machine on a level oor.
2. Place two wooden shims (B, Figure 12), at least 4 cm thick, under the brush deck (A).
3. Turn the ignition key to “I”.
4. Lower the brush deck by pressing the One-
Touch button , then press it again and hold it for more than 1 second to activate the brush extra pressure function.
Scrub System, Disc 90
5. Lift the recovery tank assembly and the driver’s seat.
6. Switch off the machine and disconnect the battery connector.
7. Disassemble the electronic component compartment cover and the function electronic board panel.
8. Disconnect the actuator connection (C) on the function electronic board (D).
9. Remove the 4 screws (E) and remove the actuator plate (F).
D
A
C
B
Figure 12
E
10. Remove the screw (G, Figure 13) and release the actuator lower pin (H).
11. Disassemble the actuator (H) by unscrewing the upper pin (I).
I
F
G
Figure 13
Assembly
12. Assemble the components in the reverse order of disassembly, by paying attention to the detergent hose (J).
H
J
Page 91
Service Manual – Scrubtec R 253 - RA40
Specications
Scrub System, Disc 91
Description / Model
Cleaning width 21 in (530 mm)
Brush/pad diameter 21 in (530 / 508 mm)
Brush pressure 33 lb (15 kg)
Brush pressure (extra pressure on) 66 lb (30 kg)
Brush deck right/left offset 65 / 15 mm (2.5 / 0.6 in)
Brush distance from the oor (when lifted) 1.6 in (40 mm)
Brush motor power 0.6 hp (450 W)
Brush rotation speed 155 rpm
Protection class IP 20
Insulation class F
Spring load
Regulated travel
Total travel
Maximum speed
Voltage
Actuator technical data
No load current Amps max
Nilsk
Scubtec R253
Scubtec R253 full PKG
Clarke RA40
105 ÷ 155 N
2.6 in (66 mm)
3.6 in (98 mm)
16 mm/s
24V
0,5 A
Nilsk
Full load current Amps max
Stall Amps
Protection class
Insulation class
3 A
5,5 A
IP 44
A
Page 92
Service Manual – Scrubtec R 253 - RA40
Solution System
Functional Description
Solution System 92
The solution system supplies water and detergent to
the brush when cleaning the oor. The solution tank is
also the main machine body. There is a manual valve on the left side of the tank, just under the rear wheel, to close the water supply whenever maintenance must
be performed on the machine. The solution ows from the tank to the valve, through the lter and solenoid
valve (EV1) and then to the brush deck. The detergent pump (M4), present only on Chemical Mixing System, controls the ow of detergent from the Chemical Mixing System tank which is then
transported to the ow in the main tube just before
the solution enters the brush deck. The Chemical Mixing System can be selected with the specic detergent percentage adjustment button
.
The quantity of detergent is dened by the operator
via the buttons on the dashboard instrument elec­tronic board (EB4).
Solution ow levels 1, 2 and 3 regulate the ow of so­lution on the basis of the machine speed so as to keep the quantity of solution dispensed per square metre of oor treated constant (for further details and modi­cations, see the corresponding paragraph in the chap­ter Control System). Located centrally, below the solution tank, there is also a hole for draining any liquid in the battery com­partment.
The solution ow is regulated by various timed ON /
OFF cycles, according to:
• Water ow rate adjustment (0 - 4)
• Solution tank level Both the solenoid valve and detergent pump (when the Chemical Mixing System is enabled) follow the same timings. The solenoid valve and detergent pump operate only with the following inputs/conditions:
• Driver’s seat microswitch closed
• Brush function on
• Forward pedal pressed
• Battery level not critical, display icon without
segments and ashing outline.
Page 93
Service Manual – Scrubtec R 253 - RA40
Full ½Empty
Solution tank
With sensor
Without sensor
Solution ow
to the brush
(Litre/min)
J5.1
J5.2
J5.3
FUNCTION ELECTRONIC BOARD (EB1)
WATER LEVEL SENSOR (SW1)
24V(B+)
0V(B-)
Power Supply
Input
5V
Solution System 93
Water Level Sensor Operation
The water level sensor (SW1) is positioned about half the height of the solution tank so as to provide the in­formation to the electronic system on the level of water present in the tank (more than half, less than half). Through this information the times of opening of the solenoid valve (EV1) and the detergent pump (M4) are
adjusted to maintain this ow more constant (Figure 1). The water level sensor is capacitive with NPN output (output 0 Volt with water, oating without water).
Figura 1
Figura 2
Page 94
Service Manual – Scrubtec R 253 - RA40
Wiring Diagram
FUNCTION ELECTRONIC BOARD (EB1)
Electronic board power supply +
B+
Solution System 94
SOLENOID VALV E
J8.6Solenoid valve power supply +
(EV1)
Figure 3
Solenoid valve power supply -
Detergent pump power supply +
Detergent pump power supply -
Power supply for water level sensor +
Water level sensor return
Power supply for water level sensor -
B -
Electronic board power supply -
SOLUTION LEVEL SENSOR (SW1)
J8.1
J8.7
J8.2
J5.1
J5.2
J5.3
CHEMICAL MIXING SYSTEM PUMP (M4)
+
OUT
-
Page 95
Service Manual – Scrubtec R 253 - RA40
Component Locations
Solution System 95
• Solution tank
• Solution tank ller plug
• Water removable ller hose
• Solution drain and level check hose
• Solution valve
Solution drain and
level check hose
• Solution lter
• Solenoid valve (EV1)
Solution tank ller plug
Water removable ller
hose
Figure 4
Solution valve
Solution tank
Solution lter
Solenoid valve
(EV1)
Figure 5
Page 96
Service Manual – Scrubtec R 253 - RA40
Component Locations (Continues)
Solution System 96
• Chemical Mixing System detergent tank
• Plug with detergent supply hose
• Chemical Mixing System detergent pump (M4)
Chemical Mixing Sys-
tem detergent tank
• Water level sensor (S1)
• Battery compartment liquid drain hole
Water level sensor (S1)
Chemical Mixing Sys-
tem detergent pump
(M4)
Plug with detergent
supply hose
Figure 6
Battery compartment
liquid drain hole
Page 97
Service Manual – Scrubtec R 253 - RA40
Maintenance and Adjustments
Cleaning the Solution Tank and Filter
Solution System 97
1. Drive the machine on a level oor.
2. Ensure that the machine is off and the operator key has been removed.
3. Close the solution tank valve.
4. Remove the transparent cover (A, Figure 7),
retrieve the gasket (B), then remove the lter
strainer (C).
5. Wash and rinse them with water, then ret
them carefully onto the lter support (D).
6. Open the solution tank valve.
Figure 7
D
B
C
A
Page 98
Service Manual – Scrubtec R 253 - RA40
Cleaning the Chemical Mixing System Detergent Tank
Solution System 98
1. Drive the machine to the appointed disposal area.
2. Ensure that the machine is off and the operator key (41) has been removed.
3. Lift the recovery tank cover and check that it is empty; if not, empty it using the drain hose.
4. Close the recovery tank cover.
5. Lift the recovery tank assembly and the driver’s seat.
6. Unscrew the plug (A, Figure 8) from the detergent tank (B).
A
7. Remove the tank.
8. Rinse and wash out the tank with clean water in the appointed disposal area.
9. Replace the detergent tank (B) as shown in the
gure, then ret the plug (A).
10. When the detergent tank has been drained, it may be necessary to drain the Chemical Mixing System too (see procedure in Draining the Chemical Mixing System paragraph).
Figure 8
B
Page 99
Service Manual – Scrubtec R 253 - RA40
C JI
D
Draining the Chemical Mixing System
Clean the detergent tank as shown in the previous section. To remove residual detergent from the detergent hoses and pump, proceed as follows.
1. Turn the ignition key to “I”.
Solution System 99
2. Press the One-Touch button . Check that the detergent quantity indicator has at least one segment lit.
3. Press the solution ow adjustment button and the detergent percentage adjustment button
together, until the screen appears on the display (after approximately 5 seconds).
4. Release buttons and and wait for the countdown timer on the display to nish and the vacuum system to be activated.
5. Collect the detergent remained on the oor.
6. Remove the operator key.
7. Lift the recovery tank assembly and the driver’s seat, then check that the detergent tank hose is empty, otherwise perform steps 2 to 6 again.
Note: The draining cycle lasts about 30 seconds, then the vacuum function automatically
turns on, which allows to remove the detergent remained. The draining cycle can also be performed with the detergent tank full of water, thus cleaning the system thoroughly. It is advisable to perform this type of draining to clean the Chemical Mixing System from dirt and deposits if the machine has not been used/cleaned for a long time. The draining cycle
canalsobeperformedtoquicklyllthedetergentsupplyhosewhenthetank isfullbut
the system is still empty. If necessary, the draining cycle can be performed several times in succession.
on the display
Page 100
Service Manual – Scrubtec R 253 - RA40
Troubleshooting
Trouble Possible Causes Remedy
Solution System 100
Small amount of solution or no solution reaches the brush
The solution reaches the brush also when the machine is off
The solution lter is clogged/dirty Clean the lter
Solution supply valve locked in (semi) closed position Replace the valve
Solenoid valve (EV1) broken or electrical connection interrupted
Presence of debris in solution tank blocking the outlet hole
Presence of debris in the solution hose, blocking the passage of the liquid
Function electronic board (EB1) faulty Replace
Display electronic board (EB2) faulty Replace
Dashboard instrument electronic board (EB4) faulty Replace
Presence of dirt or scale in solenoid valve (EV1) Clean the solenoid valve
Solenoid valve (EV1) broken Replace the solenoid valve
Replace the solenoid valve/repair the electrical connection
Clean the tank
Clean the hoses
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