Nilfisk-Advance Warrior ST, Warrior AXP, Warrior EcoFlex Service Manual

Warrior ST, Warrior AXP, Warrior EcoFlex

Service Manual

Nilfisk-Advance Warrior™ ST, Warrior™ AXP, Warrior™ EcoFlex™ model number: 56315040 (X28D-C), 56315041(X32D-C), 56315541(X28C-C), 56315542(X32C-C), 56307250(X28D-C), 56315786 (32D-C), 56315036 (28D), 56307250(X28D-C), 56315037(32D), 56315038(28C) 56315538(28D-C), 56315539(32D-C), 56315540(28C-C) 56315039(32C-C), 56381014(X28D-C), 56381015 (X32D-C), 56381023(X32D-C), 56381024(X28C-C), 56381028(X32C-C), 56381017 WARRIOR X32D-C W/STRAINER, 56315584 WARRIOR 32D-C WAL-MART, 56381023 (X32D-C W/STRAINER)

English

09/11 Revised 06/12 Form No. 56043156

Service Manual – Warrior ST, AXP, EcoFlex

Contents

General Informaon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Service Manual Purpose and Applicaon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Other Reference Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Convenons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Transporng the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Cauons and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

General Safety Instrucons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Know Your Machine — Major components: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Specicaons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Lubricang the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Chassis System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Funconal Descripon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Front Nose Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Funconal Descripon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Control Panel Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Scrub Mode Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Baery Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Warrior Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Main Control Board Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Displaying the Control Board Revision Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Recall of Stored Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Turning Fault Detecon On or O: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Low-voltage Cutout Threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Scrub Deck Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Chemical Opon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Extended Scrub Opon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Scrub Deck Down Time Period Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Scrub Deck Pressure, Soluon Flow Rate, and Chemical Flow Rate Adjustments . . . . . . . . . . . . . 24

Restoring the Scrub Pressures to Factory Default Sengs . . . . . . . . . . . . . . . . . . . . . . . 24

Regular Scrub Seng Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Heavy Scrub Seng Adjustment: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Extreme Scrub Seng Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Recovery Tank-Full Switch Orientaon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

LCD Style Selecon (Warrior AXP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Monitor Mode (Warrior AXP/EcoFlex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Chemical User Rao Selecon (Warrior AXP/EcoFlex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Troubleshoong Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Main Controller Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Service Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Test Mode Input Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

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Baery Voltage (AXP/Ecoex Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Speed Controller Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Forward/Reverse Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Reverse Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Test Mode Output Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Descripon of Output Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Sample Voltage Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Funconal Descripon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Descripon Of The Low-Voltage Cutout Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Descripon Of The Baery Condion Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Charging Baeries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Extending Baery Life. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Troubleshoong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Baery Tesng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Removal and Installaon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Baeries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Specicaons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Wet Cell Baery specicaons: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Wet Cell Baery Charger Specicaons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Opons and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Recovery System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Funconal Descripon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

Vacuum Motor and Recovery Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Float Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Vacuum Motor Control Circuit Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Troubleshoong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Removal and Installaon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Vacuum Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Float Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Specicaons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Scrub System, Cylindrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Funconal Descripon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Brush Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Brush Li Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Circuit Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Maintenance and Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Li Actuator Limit Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Removal and Installaon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Scrub Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Li Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Brush Motor Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

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Scrub Brush Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Scrub System, Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Funconal Descripon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Brush Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Brush Li Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Circuit Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Maintenance and Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Li Actuator Limit Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Removal and Installaon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Scrub Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Li Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Brush Motor Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Scrub Brush Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Soluon System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

Funconal Descripon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

Non-detergent Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Detergent Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Extended Scrub Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Circuit Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Solenoid Valve Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Soluon Pump Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Detergent (Chemical) Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Soluon System Schemac. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Troubleshoong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Removal and Installaon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Soluon Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Squeegee System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72

Funconal Descripon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72

Squeegee. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Squeegee Li/Pivot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Maintenance and Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Squeegee Blade Cleaning and Inspecon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Squeegee Trim Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Squeegee Li Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Removal and Installaon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Rear Squeegee Blade Reversal or Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Front Squeegee Blade Reversal or Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Wheel System, Non-Tracon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Funconal Descripon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

Removal and Installaon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Wheel System, Tracon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Funconal Descripon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

Throle Posion Potenometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Speed Liming Potenometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Drive Motor System Funcon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

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Speed Control Potenometer Funcon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Speed Controller J10 Pinout Funcons

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Troubleshoong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Drive Controller (Curs 1228)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Throle Potenometer Tesng and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Removal and Installaon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Throle Potenometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Drive Controller

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Follow-up Tesng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Drive Motor and Transaxle

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Curs 1311 Programmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Page v

General InformationService Manual – Warrior ST, AXP, EcoFlex

General Information

Service Manual Purpose and Application

This Service Manual is a resource for professional service technicians. It provides information for understanding how the machine operates, where components are located, basic troubleshooting, maintenance and mechanical service operations.

This manual covers the Nilsk-Advance models Warrior™ ST, Warrior™ AXP, and Warrior™ EcoFlex™. The cover page of this manual lists each

machine part number that the manual applies to. Compare the model

number of the machine you are working on to the model numbers listed on

the cover page to be sure you are using the correct manual.

The Warrior machine has three primary machine feature levels. The easiest

way to identify a machine for feature level is the decal on the side of the

recovery tank. These decals are shown to the right. The basic machine is the Warrior ST. The two advanced feature machines are the AXP and EcoFlex

models.

Revision History

• 6/2012

• Correct extreme scrub amperage specication value for 28” Disc. .

Other Reference Manuals

The following documents contain parts information and instructions for machine operation:

• Instructions for Use Form # 56041972 applies to the following models: 56315036, 56307250(28D), 56315037(32D), 56315038(28C), 56315538(28D-C), 56315539(32D-C), 56315540(28C-C) 56315039(32C-C), 56381014(X28D-C), 56381015, 56381023(X32D-C), 56381024(X28C-C), 56381028(X32C-C).

• Parts List Form # 56042463 applies to the following models:

Standard Models: 56315036(28D), 56315037(32D), 56315038(28C), 56315039(32C-C), 56307250(28D-C), 56315538(28D-C), 56315539, 56315786(32D-C), 56315540(28C-C)

Obsolete AXP Models: 56315040(X28D-C),56315041(X32D-C), 56315541(X28C-C), 56315542(X32C-C)

EcoFlex Models: 56381014(X28D-C), 56381015, 56381023(X32D-C), 56381024(X28C-C), 56381028(X32C-C)

SAVE THESE INSTRUCTIONS

General InformationService Manual – Warrior ST, AXP, EcoFlex

Conventions

Forward, backward, front, rear, left or right are intended with reference to the operator’s position, that is to

say in operating position with the hands on the handlebar.

Transporting the Machine

Caution! Before transporting the machine on an open truck or trailer, make sure that

• The machine is tied down securely.

• All access doors and covers are secured (tape and strap as needed).

Caution! If the machine must be towed or pushed, make sure the Master On/Off Key Switch

(A) is in the OFF position and do not move the machine faster than a normal walking pace (2-3 mph, 3-5kph) and for short distances only. Note: Disconnecting the wheel drive motor wiring connector will make a disabled machine easier to push.

Cautions and Warnings

Symbols

It is important for you to read and understand this manual. The information it contains relates to protecting your safety and preventing problems. The symbols below are used to help you recognize this information.

Danger! Indicates a potentially hazardous situation which, if not avoided, will result in

death or serious injury.

Warning! Indicates a potentially hazardous situation which, if not avoided, could result in

death or serious injury.

Caution! Indicates a potentially hazardous situation which, if not avoided, could result in

minor or moderate injury.

Caution! When used without the Safety Alert Symbol, indicates a potential situation which,

if not avoided, could result in property or machine damage.

General Safety Instructions

Warning!

◦ This machine should be used only by properly trained and authorized persons.

◦ Never work under a machine without safety blocks or stands to support the machine.

◦ Keep sparks, ame and smoking materials away from batteries. Explosive gases are vented

during normal operation.

◦ Charging the batteries produces highly explosive hydrogen gas. Charge batteries only in well-

ventilated areas away from open ame. Do not smoke while charging the batteries.

◦ Remove all jewelry when working near electrical components.

◦ Do not dispense ammable cleaning agents, operate the machine on or near these agents, or

operate in areas where ammable liquids exist.

Caution!:

◦ When operating this machine, ensure that third parties, particularly children, are not

endangered.

◦ Turn the key switch off (O) and disconnect the batteries before servicing electrical components.

◦ Turn the key switch off (O) and remove the key, before changing the brushes, and before

opening any access panels.

◦ This machine is not suitable for picking up hazardous dust.

◦ Do not use on surfaces having a gradient exceeding that marked on the machine.

◦ While on ramps or inclines, avoid sudden stops when loaded. Avoid abrupt sharp turns. Use low

speed down hills. Clean only while ascending (driving up) the ramp.

◦ Before performing any service function, carefully read all instructions pertaining to that

function.

◦ Do not leave the machine unattended without rst turning the key switch off (O), removing the

key and securing the machine.

◦ Take precautions to prevent hair, jewelry, or loose clothing from becoming caught in moving

parts.

◦ Only use the brushes provided with the appliance or those specied in the instruction manual.

The use of other brushes may impair safety.

◦ Refer to the battery charger OEM product manual for additional specic battery charger

warnings.

Caution!:

◦ This machine is not approved for use on public paths or roads.

◦ Use care when using abrasive brushes, scarier discs, or grinding stones. Advance will not be

held responsible for any damage to oor surfaces.

◦ Turn the key switch off (O) and remove the key, before changing the brushes, and before

opening any access panels.

◦ Use caution when moving this machine in below freezing temperature conditions. Any water

in the solution, recovery or detergent tanks or in the hose lines could freeze, causing damage to valves and ttings. Flush with windshield washer uid.

◦ The batteries must be removed from the machine before the machine is scrapped. The disposal

of the batteries should be safely done in accordance with your local environmental regulations.

◦ Do not clean this machine with a pressure washer.

◦ All doors and covers are to be positioned as indicated in the instruction manual before using the

machine.

General InformationService Manual – Warrior ST, AXP, EcoFlex

General Machine Description

The Warrior machine is a battery-powered, walk-behind, self-propelled oor scrubber with either a disc or cylindrical scrub system. The Warrior ST is a conguration with a gravity-fed, pre-mix solution system. The Warrior AXP and EcoFlex machines utilize on-board chemical (detergent) injection of the solution. The Extended Scrub option (available only on AXP models) reduces the frequency of relling the solution tank, by reusing a portion of the recovered solution from the oor surface.

Nameplate

The nameplate contains important

identication information which

will be needed when ordering parts:

Model (Name), Part No. (Part

number of the machine which is often referred to as the “Model

Number”), and Serial Number.

Know Your Machine — Major components:

Warrior Disc model Warrior Cylindrical Model

Know Your Machine — Major components:

Chemical

Injection Cover

Recovery

Tank

General InformationService Manual – Warrior ST, AXP, EcoFlex

Solution

Tank

Operator Controls

Squeegee

Cylindrical

Scrub Deck

Disc Scrub

Deck

Drive

Assembly

Lift/Pivot

Squeegee

Specifications

Voltage 36 Volt Power Source (6) 6 volt batteries (wet acid and gel cell available) Optional Onboard

Battery Charger Solution Control Precision-ow electric pump - EcoFlex system (Pulse-control gravity feed -Warrior ST) Solution Tank 30 gal. (114 L) Recovery Tank 30 gal. (114 L) Scrub Motors (2) .75 hp (560 watt) Vacuum Motor 0.75 hp (560 watt) 3-stage Sound Level 69 dB(A) with sound suppression kit or 71dB(A) standard Drive System 0.5 hp (375 watt) variable forward and reverse, max speed = 3 mph (4.83 km/hr) Drive Wheels (2) 13 in. (33 cm) dia. foam-lled, black non-marking Gradeability 16% transport, 5% scrubbing

36 volt, 25 amp Wet/Gel Compatible

General InformationService Manual – Warrior ST, AXP, EcoFlex

Specifications (continued)

Warrior 28D Warrior 32D Warrior 28C Warrior 32C Scrub Head Type Disc Disc Cylindrical Cylindrical Scrub Path 28 in (71cm) 32 in (81cm) 28 in (71cm) 32 in (81cm)

Max Productivity @ 3 mph

Max Productivity @ 1.5mph

Scrub Head Size & Type (2) 14 in (36 cm)

Scrub Pressure Regular Scrub Heavy Scrub

Extreme Scrub

Scrub Head Speed 220 rpm 220 rpm 900 rpm 900 rpm

Solution Flow Rate

Regular Scrub Heavy Scrub

Extreme Scrub

Dimensions (See images below)

Weight w/ Std Batteries 914 lb (415 kg) 914 lb (415 kg) 946 lb (430 kg) 946 lb (430 kg)

Chemical Dispensing (AXP and EcoFlex models)

Cartridge Capacity 1.25 gal (4.75 L) Dilution Rates 32:1, 50:1, 64:1, 100:1, 128:1, 150:1, 200:1, 256:1, & 300:1

36,960 ft²/hr

(3,434 m²/hr)

18,480 ft²/hr

(1,717 m²/hr)

brushes/pad holders

42,240 ft²/hr

(3,924 m²/hr)

21,120 ft²/hr

(1,962 m²/hr)

(2) 16 in (41 cm)

brushes/pad holders

36,960 ft²/hr

(3,434 m²/hr)

18,480 ft²/hr

(1,717 m²/hr)

(2) 27 in (69 cm)

brushes

42,240 ft²/hr

(3,924 m²/hr)

21,120 ft²/hr

(1,962 m²/hr)

(2) 31 in (79 cm)

brushes

max 90 lbs (41 kg) max 90 lbs (41 kg) max 80 lbs (36 kg) max 80 lbs (36 kg)

max 175 lbs (79 kg) max 175 lbs (79 kg) max 100 lbs (45 kg) max 100 lbs (45 kg)

max 250 lbs (113 kg) max 250 lbs (113 kg)

max 120 lbs (54 kg) max 120 lbs (54 kg)

.30 gal/min (1.1 L/min) or 100 minutes per solution tank

.60 gal/min (2.3 L/min) or 50 minutes per solution tank .90 gal/min (3.4 L/min) or 33 minutes per solution tank

A=30.5 in (77cm)

41.9 in (106 cm)

C=61.5 in (156 cm)

D=45 in (114 cm)

A=31 in (79 cm)

41.9 in (106 cm)

C=62.5 in (159 cm)

D=45 in (114 cm)

A=33.5 in (85cm)

41.9 in (106 cm)

C=61.75 in (157 cm)

D=45 in (114 cm)

A=35 in (89cm)

41.9 in (106 cm)

C=61.75 in (157 cm)

D=45 in (114 cm)

CC CC

BAA

General InformationService Manual – Warrior ST, AXP, EcoFlex

Maintenance Schedule

Maintenance intervals given are for average operating conditions. Machines used in severe operational

environments may require service more often.

Maintenance Item

Charge Batteries • Check/Clean Tanks & Hoses (clean recovery tank switches & vacuum

inlet screen) Check/Clean/Rotate the Brushes/Pads • Check/Clean the Squeegee • Clean Hopper on Cylindrical System •

Purge Extended Scrub System (if installed) •

Check Battery Cell Water Level (does not apply to gel cell batteries) • Inspect Scrub Housing Skirts •

Inspect and clean Solution Filter •

Clean Solution Manifolds on Cylindrical System •

Purge Detergent System (AXP and EcoFlex) •

Lubricate the Machine • Check Vacuum Motor Carbon Brushes 300 hours

Daily Weekly Monthly Yearly

•

Interval

Check Brush Motor Carbon Brushes 500 hours Check Drive Motor Carbon Brushes 500 hours

Note: See the individual machine system sections for maintenance information.

Carbon Brush Notes:

− The original (new) length of each carbon brush is 1” (25.4mm) on brush and wheel drive motors.

− All motors: Replace carbon brushes when shorter than 3/8” (9.5mm) to obtain the same motor

efciency as new brushes.

− Important: Motor damage resulting from failure to service the carbon brushes is not covered under

warranty. See the Limited Warranty Statement.

Lubricating the Machine

Once a month, apply light machine oil to lubricate the:

• General Pivot Points For the Squeegee Linkage (A).

• Squeegee mount angle adjustment knob threads (B).

• Squeegee Tool end wheels (C).

• General Pivot Points For the Brush Linkage (D).

• Scrub Deck Bumper Wheels.

Once per quarter Grease the Rear Caster Wheel Swivels (E).

Warrior ST, Warrior AXP, Warrior EcoFlex

Cylindrical and Disc

PM Checklist

Defect Codes

Customer A needs adjustment

B binding

Address C dirty or contaminated

D damaged, bent or torn

City St Zip L leaks

M missing

Model Serial Hours W worn out

Ref

3 Scrub System (raise/lower, Brush Motor on/off and optional Brush remove feature) A B D

9 Main Controller Special Program Options (see Service Manual 56043103). Check all

applicable machine settings. Examples: Scrub mode pressure settings, SVR test mode, low voltage cutout, etc.

OPERATIONAL INSPECTION ITEMS

Defect Codes

(circle)

D B A )peerc lartuen yna dna evird esrever/drawrof rof kcehc( noitarepo elddaP evirD1

hsigguls ysion )xaM/niM segnahc deeps( ecnamrofrep metsyS evirD2

B A )3-1( sgnittes erusserp hsurB burcS4

D B A )ecnamrofrep pukcip looT eegeeuqS dna rewol/esiar( metsyS eegeeuqS5

W L C )21/07 :V63 ,retpada eloh-nepo ”1 dna tfil retaw delaes( ecnamrofreP muucaV6

L B A )3 dna 2,1 sgnittes emuloV wolf dna otua/launam ffo/no( lortnoC noituloS7 D )ffo dna no nrut otua( regrahC yrettaB8 A

Does

Not

Work

Does

Ref

11 Scrub Brush Motor(s), check for carbon brush wear 500 Hours B C W

13 Brush Drive Plate Retainer Clips and Flex Couplers (disc deck) C D M

16 Solution Solenoid Valve C L W

19 Vacuum Motor Carbon Brushes (wear limit 3/8”) 300 Hours B C W 20 Vacuum Motor Inlet Filter (located in recovery tank) clean screen C D M

25 Squeegee Tool mount bottom wheels, Squeegee Tool end

wheels (lubricate)

27 Drive Wheel Transaxle Motor - check Carbon Brushes 500 Hours B C D W

Note: For additional service information see service manual, form number 56043103, and operator manual, form number 56041619 (English).

Comments

two side and two floor A D W

:yb degdelwonkcA :yb detelpmoC kroW

VISUAL INSPECTION ITEMS

Defect Codes

(circle)

W M D etator dna raew rof kcehc ,sehsurB burcS01

L D B )kced csid( sexobraeg kcehc ,)s(rotoM hsurB burcS21

W D )kced lacirdnilyc( stleB evirD rotoM hsurB burcS41

W M D leehW ediS dna trikS ,rotoM tfiL kceD burcS51

W L C sesoH dna pmuP noituloS71

L C neercs retlif naelc retliF dna sesoH yrevileD ,knaT noituloS81

W M L teksaG revoC knaT yrevoceR12 L D C paC dna esoH niarD knaT yrevoceR22 L D C hsulf kcab esoH pukciP eegeeuqS32

W D A )tsujda dna etator ,naelc( sedalB dna looT eegeeuqS42

W C )retaw dna naelc ,tset daol( noitidnoC yrettaB62

W raew daert seriT evirD elxasnarT82 W raew daert )etacirbul( leehW retsaC sissahC raeR92

Not

Work

etaD erutangiS remotsuC etaD erutangiS naicinhceT ecivreS

Chassis System

Functional Description

Chassis System 14Service Manual – Warrior ST, AXP, EcoFlex

Recovery

Tank

Solution

Tank

The main component of the chassis system is the solution tank, to which the rest of the machine components attach. The recovery tank is connected to the solution tank with a hinge so that it may be opened to access the battery compartment of the machine. The front nose is attached to the solution tank with 4 lift-off studs for access to the scrub deck components. The front nose on a basic machine (Warrior ST) is a one-piece component. For machines with detergent systems (Warrior AXP and EcoFlex), the front nose contains a

hinged detergent cover for accessing the detergent bottle.

Detergent

Cover

Front Nose

Basic Nose

Front Nose Removal

To remove the front nose, lift it up until the studs are clear of the keyhole slots, and pull it away from the machine. To replace the front nose, insert all 4 studs through the keyhole slots and press the nose down until locked in place.

Keyhole

Slots

Studs

Control SystemService Manual – Warrior ST, AXP, EcoFlex

AXP Display

EcoFlex Display

ST Display

Control System

Functional Description

Within the Warrior system there are two primary controllers: the Warrior Controller (A1) and the Curtis Drive controller (A2). The Warrior controller controls the primary machine functions, and the Curtis controller controls the drive functions. The Curtis controller communicates with the Warrior controller to inform the Warrior controller of machine movement status.

Control Panel

There are three versions of the main control

panel depending on the machine type: ST, AXP, and EcoFlex. The functions of the control panel

are similar for each model, and are shown to

the right and summarized below. (Also see the

Control Panel Indicators section for descriptions

of the various indicator lights and displays.) The

control panel is an integral component with the Warrior controller (A1) circuit board.

Key Switch (A): The keyswitch serves as

a main control switch to enable or disable

operation of the machine. The key is removable

to prevent unwanted operation when not in use.

The keyswitch doesn’t disconnect any power

circuits, but instead, sends a signal to both the

Warrior controller and Curtis Drive controller to

indicate the On/Off function.

Solution Switch (B): This switch turns the solution system on, off, or change the solution

rate (regular, heavy, extreme). The solution ow will turn on only when the throttle is

moved from the neutral position in the forward

direction. The solution ow will turn off if

the throttle returns to neutral or is moved to

reverse. Pressing this switch when the scrub

system is off will momentarily turn the solution

ow on to allow pre-wetting of the scrub

brushes.

Vacuum Switch (C): This switch is used

to turn the vacuum system on or off. Pressing

this switch will alternate between on and off. The vacuum will only turn on when the throttle is moved from the neutral position. It will remain on for 10 seconds after the throttle returns to neutral. The vacuum also has an automatic shutoff feature that will

turn the vacuum and scrub systems off if the recovery tank becomes full.

Ø.4

Scrub ON Switch (D): If the scrub system is off, pressing this switch once will cause the following:

• The scrub system will be enabled with the scrub pressure set to the regular setting and the scrub deck will be lowered. Note: press twice for the heavy scrub pressure mode and hold this switch for 5 seconds to enter the extreme scrub mode.

• The vacuum system and solution system will be enabled.

• As soon as the throttle (operator drive paddle) is moved from the neutral position the scrub brushes will start turning and the vacuum will turn on. If the direction is forward the solution ow will start. If the direction is reverse, the solution ow will be stopped. If the scrub system is already enabled when this switch is pressed, the scrub pressure will increase to the heavy scrub mode. If the switch is held for 5

Control SystemService Manual – Warrior ST, AXP, EcoFlex

seconds the pressure will change to the extreme scrub mode. At the same time the panel display will show

the correct changed scrub pressure setting.

Scrub OFF Switch (E): Pressing this switch when the unit is in a scrub mode will cause the following:

• The scrub brushes will turn off. the scrub deck will be raised to the up position, and the solution ow will

be stopped

• The rst time that this switch is pressed, the vacuum system will NOT be turned off. This is so that any remaining water may be picked up without having to turn the vacuum back on. If this switch is pressed a second time (pressed after the scrub system has been turned off) the vacuum will shut off after a 10

second delay.

Wand Switch (F): This switch is used when an external vacuum/scrub wand is used. Pressing this switch

will turn the vacuum on continuously without regard to the throttle position. If the scrub system was on it

will be turned off. This includes turning off the scrub brushes and turning the solution ow off (to the scrub deck). Note: automatic shutoff of the vacuum motor when the recovery tank is full is disabled when

the wand is enabled.

Extended Scrub (Recycle) Switch (G): Extended Scrub is available only on Warrior ST and AXP models. Pressing this switch will turn on or off the extended scrub option. When extended scrub is active, a portion of the solution to the scrub deck will come from the recovery tank. By recycling some of the used solution with some new solution, the overall scrubbing time of the machine can be extended before relling the solution tank or emptying the recovery tank. See the main programming options in this manual to select (activate) the recycle option. Purge Function: To prevent buildup of debris in the recycling lines and pump, the system should be purged after use. Drain the recovery tank and ll with clean water, and then push and hold the extended scrub switch for 3 seconds to initiate the purge function. The purge will run for 20 seconds to ush the lines. Note: Failure to purge the recycle system after use may cause the extended scrub

pump and/or solenoid valve to become fouled.

Chemical Switch (H): The chemical (detergent mixing) option is available only on Warrior AXP and EcoFlex models. Pressing this switch will turn on or off the chemical option. When active, a small pump will inject chemical (detergent) into the solution line upstream from the scrub deck. The chemical pump

is disabled any time the solution system is inactive. See the main programming options in this manual to

select (activate) the onboard chemical distribution system.

EcoFlex Switch (I): This option is available only on EcoFlex models. By default, the EcoFlex cleaning mode is active during normal operation to conserve solution and detergent. Press this switch for 2 seconds to override the EcoFlex cleaning mode and temporarily increase scrub pressure, solution ow, and the detergent ratio. See the main programming options in this manual to select (activate) the EcoFlex option.

Control Panel Indicators

Each of the switches on the control panel have an indicator LED adjacent to the switch. Most LEDs are dual channel and provide two colors within the same LED. In general, the following guidelines apply to the control panel indicators, and various exceptions to this rule are listed separately:

A steady green

A ashing green indicator means that the particular system is in a delayed-off condition. An example of this is when a scrub mode is selected and the throttle goes from forward or reverse to neutral. When this happens the vacuum indicator will ash green indicating that the vacuum is still on but that it will be

turning off after the delay period.

A steady yellow indicator means that the particular function has been enabled and in a ready state, but is not currently on. For example, if a scrub mode is selected and the throttle is in neutral, the scrub system,

vacuum, and solution indicators will all be yellow indicating that the systems are enabled and ready to turn on when the throttle is moved to forward and/or reverse.

A ashing yellow indicator means that a fault has occurred in the particular system. An example of this would be an over-current fault on one of the motors.

indicator means that the particular system or function is on.

Control SystemService Manual – Warrior ST, AXP, EcoFlex

Scrub ON Indicators (L & M):

• For Regular scrub mode, the (L) LED will be active.

• For Heavy scrub mode, the (M) LED will be active.

• For Extreme scrub mode, both (L&M) LED’s will be active.

• When a scrub mode (regular, heavy, or extreme) is active and the drive paddle is in the neutral position, the LED’s (L and/or M) will be solid yellow.

• When a scrub mode (regular, heavy, or extreme) is active and the drive paddle is in the drive position, the LED’s (L and/or M) will be solid green.

• Both indicators will be off if the scrub system has been turned off.

Scrub OFF Indicator (N):

• This indicator has green and red colors.

• The indicator will be green if the scrub system is off and ready to be activated.

• The indicator will be red if the scrub system has been turned off and the scrub deck is not up yet.

• The indicator will ash red if there is a fault in the scrub system.

• The indicator will be off if the scrub system has been activated.

Wand Switch (F) Indicator:

• This indicator uses green color only.

• This indicator will be green if the Wand Switch has been turned ON.

• This indicator will be off if the Wand Switch has been turned OFF.

• This indicator is also the Status LED indicator, and will ash green with an error code from the Curtis Drive controller (See the Wheel System, Traction chapter for details).

Vacuum Switch (C) Indicator:

• This indicator will be off if the vacuum is disabled and turned off.

• This indicator will be green if the vacuum is on.

• This indicator will ash green if the vacuum is in the 10 second delayed-off condition.

• This indicator will be yellow if the vacuum is enabled but the drive pedal is in neutral.

• This indicator will ash yellow if there is a vacuum system fault.

Solution Switch (B) Indicator:

• This indicator will be off if the solution is disabled and turned off.

• This indicator will be green if the solution is on.

• This indicator will be yellow if the solution is enabled but the drive paddle is in neutral.

• This indicator will ash yellow if there is a solution system fault.

Chemical Switch (H) Indicator:

• This Indicator will be green if the chemical system is on.

• This indicator will be yellow if the chemical system is enabled but the drive paddle is in neutral.

• This indicator will be off if the chemical system is disabled and turned off.

Extended Scrub Switch (G) Indicator:

• This indicator will be green if the Extended Scrub system is on or if the “Purge” function has been started.

• This indicator will be yellow if the Extended Scrub system is enabled but the recovery tank switches haven’t been activated.

• This indicator will be off if the Extended Scrub system is disabled and turned off.

EcoFlex Switch (I) Indicator:

• This indicator will be green if the EcoFlex system is on.

• This indicator will ash green if the EcoFlex system is in a temporary override state.

• This indicator will be off if the EcoFlex system is disabled and turned off.

Scrub Mode Indicators

The Solution system and Scrub system have three scrub

modes (regular, heavy, and extreme). These scrub modes

are jointly controlled when the Scrub On Switch (D) is pressed, but the Solution system can be controlled separately by pressing the Solution Switch (B).

• Pressing the Scrub On Switch (D) once will set both the scrub mode and solution mode to regular (and clear any solution system overrides).

• Pressing the Scrub On Switch (D) twice will set both the scrub mode and solution mode to heavy (and clear any solution system overrides).

• Pressing the Scrub On Switch (D) for 5 seconds will set both the scrub mode and solution mode to extreme (and clear any solution system overrides).

• Pressing the Solution Switch (B) once, twice, or for 5

seconds; will change the solution mode accordingly, but without changing the scrub mode.

Warrior ST Display: The solution mode is displayed in a bar graph adjacent to the solution switch (B), and the scrub mode is indicated in the display (K) with a number representing the mode.

(1 = regular, 2 = heavy, 3 = extreme).

Control SystemService Manual – Warrior ST, AXP, EcoFlex

Extreme

Heavy

Regular

Ø.4

Solution Scrub

Warrior AXP and EcoFlex Display: The solution mode and scrub mode are both shown in bar graphs on the main display (O).

Battery Indicator

The charge state of the battery is shown in the main display area of the

control panel. For Warrior ST models, this is indicated by three colored LED’s (P). For Warrior AXP and EcoFlex models, this is shown with a bar

graph (Q) in the main display. For AXP and EcoFlex models, when the battery is depleated and needs to be charges, the charge indicator (R) will be displayed.

Also note that for AXP and EcoFlex models,

when in Service Mode, the actual battery voltage will be displayed numerically in the lower left corner of the main display.

Regular

Heavy

Extreme

Warrior Controller

The Warrior controller (A1), which includes the control board and the display, is the primary

electronic control for the Warrior machine and its functions (except drive control). The control board is the basic input/output device and contains a micro-

contoller chip to regulate function. The controller receives and interprets user inputs, sensor inputs, and even some motor amperage readings, and controls device output for the user display, solenoid operation, and motor control. Most low and medium

power outputs are controlled with power MOSFET

Regular

Heavy

Extreme

Ø.4

Control SystemService Manual – Warrior ST, AXP, EcoFlex

transistors, with some moderately high power devices controlled with micro-relays, and very high power devices (vacuum and brush motors) controlled with external motor contactors.

Another function of the main controller is to detect any system failures and display an error code on the display panel or store it in the main control board’s memory. The error code(s) are used to help the service person determine the fault and to quickly guide in repairing a specic system malfunction. Note: See the Troubleshooting Guide for further information. An additional special feature of the main control board is to change program settings for a set of specic machine functions. See the Main Control Board Programing

section in this chapter for further information.

Main Control Board Programming

The Warrior controller is programmable for machine specic functions and parameters. This is a required task when replacing the controller with a new controller. The table below and following sections describe the

parameters to be programmed.

Programming Option

Button(s) to Hold While Turning Key Switch to On

Warrior EcoFlex Warrior AXP Warrior ST

Enter Service Test Mode Wand Switch (F) Wand Switch (F) Wand Switch (F) Low-voltage Cut-out Threshold Scrub OFF Switch (E) Scrub OFF Switch (E) Scrub OFF Switch (E)

Enable/Disable Fault Detection

Scrub OFF Switch (E)

Solution Switch (B)

Scrub OFF Switch (E)

Solution Switch (B)

Scrub OFF Switch (E)

Solution Switch (B)

Recall/Clear Stored Error Codes Solution Switch (B) Solution Switch (B) Solution Switch (B)

Controller Software Revision

Level Scrub Deck Down Time

Regular Scrub Setting

Heavy Scrub Setting

Extreme Scrub Setting

Scrub OFF Switch (E)

Chemical Switch (H) Scrub ON Switch (D)

Solution Switch (B) Scrub ON Switch (D)

Wand Switch (F) Scrub ON Switch (D)

Chemical Switch (H) Scrub ON Switch (D)

EcoFlex Switch (I)

Scrub OFF Switch (E)

Chemical Switch (H) Scrub ON Switch (D)

Solution Switch (B) Scrub ON Switch (D)

Wand Switch (F) Scrub ON Switch (D)

Chemical Switch (H) Scrub ON Switch (D)

Recycle Switch (G)

Scrub OFF Switch (E)

Wand Switch (F) Scrub ON Switch (D)

Solution Switch (B) Scrub ON Switch (D)

Wand Switch (F) Scrub ON Switch (D)

Vacuum Switch (C) Scrub ON Switch (D)

Recycle Switch (G)

Restore Factory Default Scrub Settings Scrub ON Switch (D) Scrub ON Switch (D) Scrub ON Switch (D) Scrub Deck Type/Size

Chemical Option

Scrub OFF Switch (E)

Scrub ON Switch (D)

Scrub OFF Switch (E)

Scrub ON Switch (D)

Recycle Option N/A

Recovery Tank-full Switch Orientation

Scrub OFF Switch (E)

Vacuum Switch (C)

LCD Style Selection N/A

Scrub OFF Switch (E)

Scrub ON Switch (D)

Scrub OFF Switch (E)

Scrub ON Switch (D)

Scrub OFF Switch (E)

Scrub ON Switch (D)

Scrub OFF Switch (E)

Vacuum Switch (C) Scrub ON Switch (D)

Vacuum Switch (C)

Scrub OFF Switch (E)

Scrub ON Switch (D)

Scrub OFF Switch (E)

Scrub ON Switch (D)

Scrub OFF Switch (E)

Scrub ON Switch (D)

Scrub OFF Switch (E)

Vacuum Switch (C) N/A

Machine Setting Monitor Mode Vacuum Switch (C) Recycle Switch (G) N/A Chemical Ratio Selection Chemical Switch (F) Chemical Switch (F) N/A

Control SystemService Manual – Warrior ST, AXP, EcoFlex

Displaying the Control Board Revision Level

During machine service, it may be helpful to know the control board revision level to determine machine conguration. To view the control board revision level:

AXP & EcoFlex Models:

1. Turn the key switch to the off position.

2. While holding the Scrub Off (E) and Chemical (H) switches depressed, turn on

the key switch.

3. Hold both switches until Scrub Off and Chemical indicators turn green.

4. The display will show the revision level (letter) of the control unit. Chemical

indicator will blink in revision display mode.

5. To exit this mode, turn the main power key switch to the off position.

ST models:

1. Turn the key switch to the off position.

2. While holding the Scrub Off (E) and Wand (F) switches depressed, turn on the

key switch.

3. Hold both switches until Scrub Off and Wand indicators turn green.

4. The LED display will show the revision level (letter) of the controller software.

5. To exit the revision level recall mode, turn the key switch to the off position.

Recall of Stored Error Codes

To assist with service troubleshooting, the Warrior controller maintains a list of past error codes. To recall

and/or clear the stored error codes perform the following steps:

1. Turn the key switch to the off position.

2. While holding the Solution Switch (B) depressed, turn the key switch to the on position.

3. Continue to hold the solution switch until the solution indicator turns green.

• On AXP/EcoFlex models:

◦ If there are no error codes stored, the display will show the key switch icon.

◦ If any error codes are stored, the display will show the wrench icon and error number right next to

the wrench. If more than one error code is stored, it will cycle through all the error codes stored.

• On ST models:

◦ If there are no error codes stored, the display will show “—”.

◦ If any error codes are stored, the scrub off indicator will be red and the display will show the error

code number(s). If more than one error code is stored, the display will scroll through the error codes in sequence.

4. To clear the stored codes, press the scrub off switch. (It is recommended that error codes are cleared

after servicing so that future error codes represent only errors that occur between service intervals.)

• On AXP/EcoFlex models, the display will now show the key switch icon.

• On ST models, the display will now show “—”.

7 To exit the error code recall mode, turn the key switch to the off position.

Control SystemService Manual – Warrior ST, AXP, EcoFlex

Turning Fault Detection On or Off:

If a fault occurs in a particular system, that system (and possibly others) will be shut down. This can make troubleshooting the system difcult. This option will allow service personnel to disable some of the fault detection checks to facilitate troubleshooting. This will not disable the over-current protection on any of the systems. Important: Make sure to turn Fault Detection back on before returning the machine to normal operation. To turn the fault checking on or off:

1. Turn the key switch to the off position.

2. While holding the Scrub System Off (E) and the Solution (B) switches depressed, turn on the key

switch.

3. Continue to hold both switches until the solution indicator turns yellow.

4. Release both switches. The scrub off indicator will turn red.

5. Pressing the solution switch will toggle between fault detection enabled and disabled.

• On AXP/EcoFlex models, the display will show the normal wrench icon for Fault Detection enabled or a wrench with a cross for Fault Detection disabled.

• On ST models, the LED display will toggle between “E” (enabled) and “d” (disabled).

6. To save the setting, press the scrub off switch.

• AXP/EcoFlex models will display the key switch icon asking user to reset the machine.

• On ST models, the scrub off indicator will turn green.

7. Turn the key switch to the off position. The new setting will be saved and will remain in effect until it is

changed again.

Low-voltage Cutout Threshold

The Warrior is equipped with a low-voltage cutout feature to prevent over-discharging the batteries.

This feature will automatically shut down the scrub system when the battery voltage falls to the selected

threshold. The cutout threshold has two levels: Standard and Alternate. The Standard setting is 30.96 volts (5.16 volts per battery), and is for standard lead acid batteries. The Alternate setting is 32.58 volts (5.43 volts per battery), and is for typical gelled electrolyte batteries. Select the proper cutout level based on the battery manufacturer’s specications. Factory Default: 30.96V (Standard Battery)

To select between the two cutout levels:

1. Turn the key switch (A) to the off position.

2. While holding the Scrub Off switch (E) turn the key switch (A) to the on position.

3. Continue to hold the Scrub Off switch until the Scrub Off indicator (N) turns red, and then release the Scrub Off switch.

4. To toggle between Standard and Alternate, press the Scrub On switch (D). The two modes are identied by the following indicators:

• The Scrub On Regular (M) and Heavy (L) LED’s will toggle green and yellow,

as shown to the right.

• On AXP/EcoFlex models, the status display will now show “30.96V” or “32.58V.”

• On ST models, the status display will show an “S” (standard) or an “A” (alternate).

Alternate

Standard

LDM

5. To save the new setting, press the scrub off switch. The scrub off indicator will turn green. On AXP/ EcoFlex models, the display will show key switch icon to reset the machine.

6. Turn the key switch to the off position to commit the settings to permanent memory.

Control SystemService Manual – Warrior ST, AXP, EcoFlex

Scrub Deck Type

Note: This procedure may be completed concurrently with the Chemical Option and Extended Scrub Option procedures.

Warrior models can be equipped with numerous scrub deck options. This function congures the Warrior controller for each of the scrub deck types. Important: Improper setting of the deck type may result in

motor damage due to overloading.

1. Turn the key switch to the off position.

2. While holding the Scrub Off (E) and Scrub On (D) switches depressed,

turn the key switch to the on position.

3. Continue to hold both switches until the Regular Scrub indicator (L) turns yellow.

4. Release both switches. The Scrub Off indicator (N) will turn red.

• For AXP and EcoFlex models, the display will show the current scrub brush type icon and scrub deck size (28" cylindrical, 32" cylindrical, 28" disc, or 32" disc).

• For the ST model, the LED display will scroll through the deck types (C_2_8, C_3_2, d_2_8, or d_3_2)

E D

5. Press the Scrub On (D) switch to toggle between the four settings.

6. Once the proper scrub deck size is selected, press the Scrub Off switch (E) to save this setting.

7. The AXP/EcoFlex display will show the key switch icon asking user to reset the machine.

8. Turn the key switch to the off position to commit the setting.

Chemical Option

Note: This procedure may be completed concurrently with the Scrub Deck Type and Extended Scrub Option procedures.

Warrior AXP and EcoFlex models are equipped with the chemical (detergent) system. To enable or disable

this option, do the following:

1. Turn the key switch to the off position.

2. While holding the Scrub Off (E) and Scrub On (D) switches depressed,

turn the key switch to the on position.

3. Continue to hold both switches until the Regular Scrub indicator (L) turns yellow.

4. Release both switches. The Scrub Off indicator (N) will turn red.

5. Press the Chemical switch (H) to toggle the chemical option between enabled and disabled.

The Chemical indicator will turn green for enabled and be off for disabled.

E D

6. Press the Scrub Off switch (E) to save this setting. The display will show the key switch icon asking user to reset the machine.

7. Turn the key switch to the off position to commit the setting.

Control SystemService Manual – Warrior ST, AXP, EcoFlex

Extended Scrub Option

Note: This procedure may be completed concurrently with the Scrub Deck Type and Chemical Option procedures.

Warrior ST and AXP models may be equipped with the extended scrub system. To enable or disable this

option, do the following:

1. Turn the key switch to the off position.

2. While holding the Scrub Off (E) and Scrub On (D) switches depressed,

turn the key switch to the on position.

3. Continue to hold both switches until the Regular Scrub indicator (L) turns yellow.

4. Release both switches. The Scrub Off indicator (N) will turn red.

5. Press the Recycle switch (G) to toggle the extended scrub option between enabled and

disabled. The Recycle indicator will turn green for enabled and be off for disabled.

E D

6. Press the Scrub Off switch (E) to save this setting. The display will show the key switch icon asking user to reset the machine.

7. Turn the key switch to the off position to commit the setting.

Scrub Deck Down Time Period Adjustment

The initial lowering of the scrub deck is timed, because there will not be any brush motor amperage to monitor for determining when to stop lowering the deck. The time that the deck is lowered is adjustable from 3.5 seconds to 4.4 seconds in 0.1-second increments. To adjust the scrub deck down time, perform the

following steps:

1. Turn the key switch to the off position.

2. While holding the Scrub On (D) and the Solution (B) switches depressed, turn

the key switch to the on position.

3. Continue to hold both switches until the regular and heavy scrub on indicators and solution indicator turn green.

4. Release both switches. The Regular and Heavy Scrub On indicators will turn

yellow and the Scrub Off indicator will turn red.

• On AXP/EcoFlex models, the display will show the scrub deck icon on right top corner and clock icon

with number.

• On ST models, the LED display will show the number corresponding to the deck down time as listed in the table shown on the right.

5. Press the Scrub On (D) switch to toggle through the deck down time

period values. These values represent the times shown in the table to the right.

6. To save the new setting, press scrub off switch.

• On AXP/EcoFlex models, the key switch icon will appear on the

display.

• On ST models, the scrub off indicator will turn green.

7. Turn the key switch to the off positions.

Number in

Display

0 3.5 sec 1 3.6 sec 2 3.7 sec 3 3.8 sec 4 3.9 sec 5 4.0 sec 6 4.1 sec 7 4.2 sec 8 4.3 sec 9 4.4 sec

Scrub Deck

Down Time

Control SystemService Manual – Warrior ST, AXP, EcoFlex

Scrub Deck Pressure, Solution Flow Rate, and Chemical Flow Rate Adjustments

Each of the scrub settings (Regular, Heavy, and Extreme) affects the scrub deck pressure, solution ow rate, and chemical ow rate (if equipped). These settings are adjustable. The default values are shown in the tables below. The scrub pressures are determined by examining the amperage through the brush motors.

Scrub Pressure & Amperage Specifications Chart

Scrub Mode

Default Pressure

Indicator

Disc 28” Cyl. 28” Disc 32” Cyl. 32”

Regular Scrub 1 bar(#1) 14 AMPS 22 AMPS 16 AMPS 24 AMPS Heavy Scrub 2 bars(#2) 22 AMPS 31 AMPS 24 AMPS 33 AMPS Extreme Scrub 3 bars(#3) 36 AMPS 40 AMPS 38 AMPS 42 AMPS

Default Solution Flow Rate Chart Chemical Chart

Solution Flow Indicator Flow Rate 0 Normal chemical setting

One bar gauge(#1) 0.3 g/m - 10% less than normal chemical setting

Two bar gauge(#2) 0.6 g/m + 10% more than normal chemical setting

Three bar gauge(#3) 0.9 g/m

Deck Type

Restoring the Scrub Pressures to Factory Default Settings

Use this procedure to restore all of the scrub deck pressure settings to their factory default values.

1. Turn the key switch to the off position.

2. While holding the Scrub On switch (D) depressed, turn the key switch to the on position.

3. Continue to hold the Scrub On switch until the Scrub Off indicator (N) turns green, then release the Scrub On switch.

E D

◦ On AXP/EcoFlex models, the display will show pressure icon on the

right top corner indicating you are in pressure restoring mode and the factory default pressures

have been restored. Now display will show key switch icon asking you to reset the machine.

◦ On ST models, the display will show ”d” to indicate that the factory default scrub pressures have

been restored.

4. Turn the key switch to the off position.

Control SystemService Manual – Warrior ST, AXP, EcoFlex

Regular Scrub Setting Adjustment

Use this procedure to adjust the scrub deck pressure, solution rate, and chemical rate that are used for the

Regular scrub mode.

1. Turn the key switch to the off position.

2. While holding the Scrub On (D) and Wand (F) switches depressed, turn the key switch to the on position.

3. Continue to hold the both switches until the Wand and Regular Scrub indicators turn green.

4. Release both switches. The scrub off indicator will turn red and the regular scrub indicator will turn yellow. Also:

• AXP/EcoFlex models: The display will now show the cylinder/disc deck icon with current scrub

pressure setting.

• ST model: The LED display will show the level number of the current scrub pressure setting.

5. Pressing the Scrub On switch (D) will scroll through the 3 scrub pressure settings.

6. Pressing Scrub Off switch (E) will save the pressure setting and move to solution rate setting.

7. Solution Rate Setting: The Regular Scrub indicator (L) will turn from yellow to green and the Solution indicator will turn yellow. For AXP/EcoFlex, the display will show the

solution icon with gauge.

8. Press the Solution switch (B) to scroll through the 3 solution rate settings.

9. Press the Scrub Off switch (E) to save the new setting and move to the chemical rate setting (or the end of the program mode for Warrior ST).

10. Chemical Rate Setting: (Not available on Warrior ST) The display will now show chemical bottle with current chemical setting. Solution indicator will turn green and chemical indicator will turn green.

11. Press the Chemical switch (H) to scroll through the 9 chemical settings.

12. Press the Scrub Off switch (E) to save the new setting and display key switch icon on display.

13. Turn the key switch to the off position. The new settings will be saved and will remain in effect until they are changed again.

Control SystemService Manual – Warrior ST, AXP, EcoFlex

Heavy Scrub Setting Adjustment:

Use this procedure to adjust the scrub deck pressure, solution rate, and chemical rate that are used for the Heavy scrub mode.

1. Turn the key switch to the off position.

2. For AXP/EcoFlex models:

a. While holding the Scrub On (D) and Chemical (H) switches depressed,

turn the key switch to the on position.

b. Continue to hold the both switches until the Wand and Heavy Scrub indicators turn green.

3. For ST models:

a. While holding the Scrub On (D) and Vacuum (C) switches depressed, turn

the key switch to the on position.

b. Continue to hold both switches until the heavy scrub on indicator turns

green and the red battery indicator light switches on.

4. Release both switches. The scrub off indicator will turn red and the heavy scrub indicator (M) will turn yellow. Also:

• AXP/EcoFlex models: The display will now show the cylinder/disc deck icon with current scrub

pressure setting.

• ST model: The LED display will show the level number of the current scrub pressure setting.

5. Press the Scrub On switch (D) to scroll through the 3 scrub pressure settings.

6. Press the Scrub Off switch (E) to save the pressure setting and move to solution rate setting.

7. Solution Rate Setting: The Heavy Scrub indicator (L) will turn from yellow to green and the Solution indicator will turn yellow. For AXP/EcoFlex, the display will show the solution

icon with gauge.

8. Press the Solution switch (B) to scroll through the 3 solution rate settings.

9. Press the Scrub Off switch (E) to save the new setting and move to the chemical rate setting (or the end of the program mode for Warrior ST).

10. Chemical Rate Setting: (Not available on Warrior ST) The display will now show the chemical bottle with current chemical setting. Solution indicator will turn green and chemical indicator will turn green.

11. Press the Chemical switch (H) to scroll through the 9 chemical settings.

12. Press the Scrub Off switch (E) to save the new setting and display key switch icon on display.

13. Turn the key switch to the off position. The new settings will be saved and will remain in effect until they are changed again.

Control SystemService Manual – Warrior ST, AXP, EcoFlex

Extreme Scrub Setting Adjustment

Use this procedure to adjust the scrub deck pressure, solution rate, and chemical rate that are used for the Extreme scrub mode.

1. Turn the key switch to the off position.

2. For ST/AXP models:

a. While holding the Scrub On (D) and Recycle (G) switches depressed, turn

the key switch to the on position.

b. Continue to hold the both switches until the Recycle, Regular Scrub, and Heavy Scrub indicators

turn green.

3. For EcoFlex models:

a. While holding the Scrub On (D) and EcoFlex (I) switches depressed, turn

the key switch to the on position.

b. Continue to hold both switches until the EcoFlex, Regular Scrub, and

Heavy Scrub indicator turn green.

4. Release both switches. The scrub off indicator will turn red and the Regular and Heavy scrub indicators will turn yellow. Also:

• AXP/EcoFlex models: The display will now show the cylinder/disc deck icon with current scrub

pressure setting.

• ST model: The LED display will show the level number of the current scrub pressure setting.

5. Press the Scrub On switch (D) to scroll through the 3 scrub pressure settings.

6. Press the Scrub Off switch (E) to save the pressure setting and move to solution rate setting.

7. Solution Rate Setting: The Heavy Scrub indicator (L) will turn from yellow to green and the Solution indicator will turn yellow. For AXP/EcoFlex, the display will show the solution

icon with gauge.

8. Press the Solution switch (B) to scroll through the 3 solution rate settings.

9. Press the Scrub Off switch (E) to save the new setting and move to the chemical rate setting (or the end of the program mode for Warrior ST).

11. Press the Chemical switch (H) to scroll through the 9 chemical settings.

12. Press the Scrub Off switch (E) to save the new setting and display key switch icon on display.

13. Turn the key switch to the off position. The new settings will be saved and will remain in effect until they are changed again.

Recovery Tank-Full Switch Orientation

Control SystemService Manual – Warrior ST, AXP, EcoFlex

Use this procedure if installing a new control board on an older

Warrior machine that uses the recovery tank full switch in the normally closed orientation. All current Warrior machines use the

normally open orientation, which is also the default option for the control board setting. You may also use this option when changing

the orientation of an existing sensor to the normally open direction

during a sensor replacement procedure.

Note: This feature may not be available on older ST/AXP control

board versions. If the main controller on your machine does not have the switch orientation programming option available (below Revision level I for AXP machines, and below Revision level E for ST machines), you must run the machine with the switch in

the normally-closed conguration. Refer to the Displaying the Control Unit Revision Level section for

instructions on how to view the software revision level of your controller.

1. Turn the key switch to the off position.

2. While holding the Scrub System Off (E) and Vacuum (C) switches depressed,

turn the key switch to the on position.

3. Continue to hold both switches until only the vacuum indicator is lit

(approximately 2 seconds).

4. Release both switches. The status or LED display will now indicate “0” or “1” and the scrub off indicator

will be red.

Normally Closed

(former orientation)

Normally Open

(Default)

5. Press the Vacuum switch (C) to toggle between “1” for the normally closed conguration or “0” for the normally open conguration.

6. To save the new setting, press the scrub off button. The scrub off indicator will change from red to green.

7. Turn the main power key switch to the off position. The new setting will be saved and will remain in

effect until it is changed again.

LCD Style Selection (Warrior AXP)

Factory Default: Rectangular Shape With Three Bars LCD graphic style can be programmed to different style. There are two different styles and to change LCD graphic style, perform the following steps:

1. Turn the key switch to the off position.

2. While holding the Scrub System On (D) and Vacuum (C) switches depressed,

turn the key switch to the on position.

3. Continue to hold both switches until the vacuum indicator and scrub on indicator turn yellow.

4. Release both switches. The display will now show current graphic style. The scrub off switch will turn red.

5. Pressing scrub on switch will now select between two different graphic styles and the display will be

updated with new graphic style.

6. Press scrub off switch to save the setting. Turn the main power key switch to the off position.

7. The new setting will be saved and will remain in effect until it is changed again.

Control SystemService Manual – Warrior ST, AXP, EcoFlex

Monitor Mode (Warrior AXP/EcoFlex)

The Warrior is equipped with a monitor mode where the current deck setting, low-voltage cutout setting, and error checking setting can be quickly checked for the machine’s specic set up.

1. Turn the key switch to the off position.

2. For AXP: While holding the Recycle switch (G) turn the main key switch to the on position.

3. For EcoFlex: While holding the Vacuum switch (C) turn the main key switch to the on position.

4. Continue to hold the switch until the indicator turns yellow (AXP: Recycle, EcoFlex: Vacuum).

5. The display will display current deck setting, low-voltage cutout setting and error checking setting.

6. To exit this mode, turn the main power key switch to the off position.

Chemical User Ratio Selection (Warrior AXP/EcoFlex)

Factory Default: 8

1. Turn the key switch to the off position.

2. Press and hold the chemical switch.

3. While holding the Chemical switch (H) turn the key switch to the on position.

4. Continue to hold the chemical switch until the chemical indicator turns yellow. The Chemical indicator will then turn green.

5. The display will show the chemical bottle with the current user ratio.

6. Press the Chemical switch to scroll through the chemical settings (32, 50,

64, 100, 128, 150, 200, 256, 300).

7. Press Scrub Off switch (E) to save new setting. The display will show key

switch icon.

8. Turn the main power key switch to the off position.

9. The new setting will be saved and will remain in effect until it is changed again.

Note: Program to the desired ratio needed when not using a chemical container (cartridge) that uses the

magnetic slider.

Troubleshooting Guide

Control SystemService Manual – Warrior ST, AXP, EcoFlex

Any error codes detected by the main control board will be displayed on the display panel as they occur. If more than one error exists the display will sequence through the error codes at one-second intervals. On AXP/EcoFlex

models the error (T) will display as a mechanical wrench symbol followed

by a two-digit code. On standard models the hour meter / error display will ash an “E” and 2 numbers one at a time.

When troubleshooting any “Fault Description” noted with a double asterisk (**) follow the instructions for entering the Service Test Mode in the control

boards special programs. See the Main Control Board Special Program Options section in this manual.

Ø.4

Main Controller Error Codes

Error Description Comments

E03 Drive system fault. The Wand indicator (F) will ash out a specic Curtis Drive controller

error code. See the Wheel System, Traction chapter troubleshooting

section for a list of error codes.

E04 Scrub deck lift actuator overload.

E05 Solution pump overload.

E06 Scrub motor overload

E07 Vacuum motor overload

• Inspect the scrub deck for obstruction.

• Measure the actuator amperage with and without the scrub deck

connected.

• No-load current = 1.4 amps

• Normal current = 1.0-2.5 Amps

• Maximum current = 6 Amps

• If the no-load current remains high, then the actuator or wiring is faulty.

• Inspect for downstream obstructions in the solution line.

• Measure the pump amperage with and without solution ow

• Normal current = 0.8-1.8 Amps

• Maximum current = 3.2 Amps

• If the no-load current remains high, then the pump or wiring is faulty.

• Check the scrub setting adjustments described previously in this

chapter.

• Check for binding in rotation of brushes or improper deck lift

actuator operation.

• Inspect the ground wire supplying the brush motors for poor or

corroded connections. The voltage drop across this wire is used to measure the amperage to the motors.

• Inspect the current sense wire (white/gray) for continuity.

• Make sure the correct scrub deck is specied in the control board

settings (cylindrical versus disc).

• Inspect the vacuum motor impeller for obstruction.

• Check the vacuum discharge for obstruction (inlet obstruction will

reduce the amperage).

• Normal current load 17-19 Amps.

• Inspect the vacuum motor brushes

• Defective motor bearings.

• Inspect the current sense wire (orange) for continuity

Control SystemService Manual – Warrior ST, AXP, EcoFlex

E08 Solenoid Bank Coil Circuit

Overload

• Brush Motor Contactor (K1)

• Vacuum Motor contactor (K2)

• Solution Solenoid (L1)

• Recycle Solenoid (L2)

The sum of the currents through these coils is too high

• Inspect the “B-3” ground bus (J2-9 wire) at the controller

for negative battery voltage. This error will occur is B-3 is

disconnected.

• If this error occurs when no coils are active (and J2-9 wire is good), the control board is defective

• Operate various combinations of coils to identify which coil is

causing the problem.

• Check for wiring problems on the coil circuit(s) and repair wiring.

• Check resistance on all contactor/solenoid coils. If the value is less than 20% of the values below, replace the contactor/solenoid

• Brush motor contactor coil (K1): 98 to 120 Ω

• Vacuum motor contactor coil (K2): 102 to 120 Ω

• Solution solenoid coil (L1): AXP, EcoFlex 128 Ω

• Solution solenoid coil (L1): ST 76 Ω

• Recycle solenoid coil (L2): ST 128 Ω

E017 Scrub deck lift actuator circuit

open (**)

The controller’s internal circuitry is not seeing any voltage change.

• Inspect the B+2 bus (J2-7) and fuse (F2) for positive battery

voltage.

• Check for disconnected actuator wiring or defective actuator

motor.

• Check controller’s actuator output voltage. This is a switched ground PWM, so one terminal will be 36 volts (B+2 bus) to

Battery-Negative and the other should be non-zero (PWM of B-2) to Battery-Negative. If both remain near 36 volts, it indicates a controller failure.

E018 Scrub deck lift actuator short The controller’s internal circuitry is seeing maximum voltage in the

current sensing circuit.

• Inspect the B-2 bus (J1-9) for connection to ground

• Inspect the actuator wiring for short circuit(s)

• Inspect the scrub deck for obstructions to movement

• Check the lift actuator limit adjustment

E021 Brush motor circuit open (**) The controller’s internal circuitry is not seeing any voltage change.

• Inspect the current sense wire (white/gray) for continuity.

• Inspect the brush motor contactor for proper operation.

• Inspect the motor power circuit and cable connectors for open

circuits

E022) Scrub motor short The controller’s internal circuitry is seeing maximum voltage in the

current sensing circuit.

• Same troubleshooting as E06

E023) Vacuum motor circuit open (**) The controller’s internal circuitry is not seeing any voltage change.

• Inspect the current sense wire (orange) for continuity.

• Check the vacuum motor contactor for proper operation

• Inspect the motor’s power wiring for open circuit

E024) Vacuum motor short The controller’s internal circuitry is seeing maximum voltage in the

current sensing circuit.

• Same troubleshooting as E07

Control SystemService Manual – Warrior ST, AXP, EcoFlex

Service Test Mode

To assist in the troubleshooting and servicing of the electrical system and related components, a special test mode allows independent control of the various outputs and monitoring of the various inputs. To enter the service test mode perform the following step:

1. Turn the key switch to the off position.

2. While holding the Wand (F) switch depressed, turn the key switch to the on position.

3. Continue to hold the Wand switch until the Wand indicator turns green.

4. ST model: The Display will show “t” for Test Mode.

5. AXP/EcoFlex models: The Display will show “SVCTEST” (AXP/EcoFlex models) or “t” (ST models)

6. To exit Service Test Mode, turn the key switch to the off position.

Test Mode Input Indicators

Battery Voltage (AXP/Ecoflex Models)

The battery voltage, as detected by the controller, is displayed below the “SVCTEST” indicator. If this displayed voltage differs signicantly from the actual battery voltage, it indicates a poor connection between

the batteries and the controller.

Speed Controller Status

This is a Warrior controller input from the Curtis Drive controller. The indicator is passed through the Warrior controller without interpretation, and represents the error code from the Drive controller.

• On ST models, the green light in the battery indicator will light whenever the key is on. If there is a speed control fault, the indicator will ash the

fault code produced by the speed controller.

• On AXP / EcoFlex models, the SCS will be displayed whenever the key is on. If there is a speed control fault, this indicator will ash the fault code

produced by the speed control.

SVCTEST

36.5V F/R REV

SCS

Refer to the speed control section for details on these codes. If the indicator

does not display, disconnect the Orn/Blu wire from the speed controller and main controller and check the

continuity of the wire. If the wire tests open repair or replace the wire or plug. If wire tests OK, the fault is

likely with the Drive controller.

Forward/Reverse Status

This indicator comes from the Curtis Drive controller, and indicates that the drive paddle is moved out of the neutral position (either forward or reverse). The indicator is active when the signal is low.

• On AXP/EcoFlex models, F/R will be shown in the display.

• On ST models, the indicator is the yellow light in the battery status.

Reverse Status

This indicator comes from the Curtis Drive controller and indicates when the drive paddle is in the reverse direction (pulled low in reverse, high in neutral and forward).

• On AXP/EcoFlex models, REV will be displayed if this signal is active.

• On ST models, the red battery indicator will light when the throttle is in the reverse position.

Control SystemService Manual – Warrior ST, AXP, EcoFlex

Test Mode Output Controls

The control panel switches are used to control various output functions of the Warrior controller while in Test Mode. Below is a list of each switch and the function it controls. Following the list is a detailed

description of each function.

Scrub off Switch (H): Controls the brush motor.

Scrub on Switch (I): Controls the scrub deck lift actuator.

Vacuum Switch (C): Controls the vacuum motor.

Wand Switch (E): Jogs the scrub deck lift actuator.

Solution Switch (B): Turns on the solution pump (if so equipped) and solenoid valve.

Extended Scrub Switch (G): Turns on the recycle pump (If available).

Detergent System Switch (F): Turns on the chemical pump (If available).

Description of Output Controls

Scrub System Off Switch (H):

This switch is used to toggle the state of the brush motor contactor. Pressing and releasing this switch

will alternately turn the brush motor contactor on and off. The indicator provides the following status information:

Off – Brush motor output is off and there is no brush motor current sensed.

Steady Green – Brush motor output is on and there is normal brush motor current sensed.

Brief On Green Flash – Brush motor output is off and brush motor current is being sensed (abnormal condition).

• Check for voltage at the Wht wire on K1 contactor to battery ground.

• If any voltage is present, replace K1 contactor.

• NO voltage, replace the Main control board.

Brief Off Green Flash – Brush motor output is on and brush motor current is not being sensed (abnormal condition).

• Check brush motor wiring plugs.

• Check one of the Blk wires of the main harness connector at the brush motor to battery Positive. If no

voltage repair or replace wire.

• Check one of the Wht wires of the main harness connector at the brush motor to battery Neg. If no voltage

repair or replace wire.

• Check for voltage at the Red wire on K1 contactor to battery ground. If no voltage is present repair the

Red wire.

• Check for voltage at the Wht wire on K1 contactor to battery ground. If no voltage is present replace the

K1 contactor.

Flashing Red – Brush motor overload has occurred.

• Check to see that the proper brush programming type is selected (disc or cyl).

• Check for binding in rotation of brushes or improper scrub brush type installed. (Amp. Test) See Pressure

Chart in this Manual.

• Check the negative supply cable at the brush motor for a wiring problem or improper modications.

• Check for open in the small WHT/GRA current sense wire.

Control SystemService Manual – Warrior ST, AXP, EcoFlex

• Check for short circuit* in brush motor or wiring.

• Inspect gearbox for failure (disc). Repair or replace.

• Inspect scrub brush drive bearings for excessive wear (cyl.).

Scrub On Switch (I)

This switch is used to control the output to the scrub deck lift actuator. Pressing and releasing this switch will cycle the actuator output through 4 states. These are:

1 – Output off, direction = up

2 – Output on, direction = down

• AXP / EcoFlex models - display will show down arrow.

• ST models – the normal scrub on indicator will be green.

3 – Output off, direction = down

4 – Output on, direction = up

• AXP / EcoFlex models - display will show up arrow.

• ST models – the normal scrub on indicator will be yellow.

When the output is in state 1, the actuator output is turned off. The scrub pressure decrease indicator should be off. If the indicator is ashing green, this indicates that the control is sensing current ow through the actuator (shorted output driver, control error). If the scrub pressure decrease switch was the last switch

pressed, it is possible to momentarily activate the actuator output using the wand switch. This can be used to jog the actuator to allow precise positioning of the actuator. Note: the actuator can only move in this situation if it is not at its up limit.

When the output is in state 2, the actuator output is turned on. The scrub pressure decrease indicator should be green or ashing green. The indicator will be a steady green if the control senses current ow through the actuator. It will ash green if no actuator current ow is sensed (actuator at limit, open circuit, open output driver). The wand switch has no effect in this state.

When the output is in state 3, the actuator output is turned off. The scrub pressure decrease indicator should be off. If the indicator is ashing green, this indicates that the control is sensing current ow through the actuator (shorted output driver, control error). If the scrub pressure decrease switch was the last switch

When the output is in state 4, the actuator output is turned on. The scrub pressure decrease indicator should be green or ashing green. The indicator will be a steady green if the control senses current ow through the actuator. It will ash green if no actuator current ow is sensed (actuator at limit, open circuit, open output driver). The wand switch has no effect in this state.

Vacuum Switch (C)

This switch is used to toggle the state of the vacuum motor. Pressing and releasing this switch will

alternately turn the vacuum motor on and off. The indicator provides the following status information:

Off - Vacuum motor output is off and there is no vacuum motor current sensed.

On Steady Green - Vacuum motor output is on and there is normal vacuum motor current sensed.

Brief On Green Flash – Vacuum motor output is off and vacuum motor current is being sensed (abnormal condition).

• Check for voltage at the Blu wire on K2 contactor to battery ground.

• If any voltage is present, replace K2 contactor.

Control SystemService Manual – Warrior ST, AXP, EcoFlex

• NO voltage, replace the Main control board.

Brief Off Green Flash – Vacuum motor output is on and vacuum motor current is not being sensed (abnormal condition).

• Check Vacuum Motor wiring plug, disconnection.

• Check for voltage at the Red wire on K2 contactor to battery ground. If no voltage is present repair the

Red wire.

• Check for voltage at the Blu wire on K2 contactor to battery ground. If no voltage is present replace the

K2 contactor.

• Check the Blu wire of the main harness connector at the vacuum motor to battery Negative. If no voltage

repair or replace wire.

• Check the Blk wire of the main harness connector at the vacuum motor to battery Positive. If no voltage

repair or replace wire.

Flashing Yellow – Vacuum motor overload has occurred.

• Check for an open in the small ORG current sense wire.

• To conrm an overload, disconnect the motor plug from the main harness, run a 30 amp fused test leads from the batteries to the motor and perform an Amp draw test. Normal current load 36V 16-19 Amps.

• Check for debris in the vacuum motor.

• Worn carbon brushes.

• Defective motor bearings.

• Check for short circuit* in vacuum motor or wiring. Repair or replace.

Solution Switch (B)

This switch is used to toggle the state of the solution pump and/or solution solenoid. Pressing and releasing this switch will alternately turn the solution solenoid (L1) on and off (ST models), or turn the solution pump (M7) and solution solenoid (L1) on and off (AXP/EcoFlex models). The indicator provides the following status

information:

Off - Solution output is off.

Steady Green - Solution output is on (solution pump is on and/or solenoid valve is open).

Flashing Yellow – Solution solenoid/contactor coil overload has occurred.

Extended Scrub Switch (G)

This switch is used to toggle the state of the recycle pump and recycle valve (if the machine is so equipped). Pressing and releasing this switch will alternately turn the recycle pump and recycle valve on and off. The

indicator provides the following status information:

Off – Recycle pump and valve off.

Steady Green – Recycle output is on and valve is open.

Detergent Switch (F)

This switch is used to toggle the state of the chemical pump (if the machine is so equipped). Pressing and

releasing this switch will alternately turn the chemical pump on and off. The indicator provides the following status information:

Off – Chemical pump and valve off.

Steady Green – Chemical output is on.

Control SystemService Manual – Warrior ST, AXP, EcoFlex

Sample Voltage Measurements

Examining signals sent and received at the control board can be very effective in determining if external components are functioning as expected or if the control board is processing them as expected. The tables below show sample voltage measurements taken from a Warrior machine. Actual voltages will vary from

machine to machine, and with battery charge level.

The majority of voltage measurements will be dependant on the battery voltage of the machine at the time. The nominal battery voltage is 36 volts, but depending on the charge state of the battery, the actual voltage

may be higher or lower. With regard to digital logic signals, the terms “High (voltage)” and “Low (voltage)” mean a voltage value equal (or close to) BatteryPositive and Battery-Negative, respectively. VCC is a special voltage value that is independent of the battery voltage, and is regulated to be close to 5.0 volts by the Warrior controller’s circuit board.

Probe Wire

T-Pin

Some signals are Pulse-Width Modulated (PWM) (See the Wheel System, Traction chapter for more information on PWM). This means that these signals

are being turned On and Off at a high rate. Even though their instantaneous voltage jumps from 36V to 0V, your voltmeter will average these On/Off jumps into an equivalent voltage somewhere in between 36 and 0 volts.

To aid in taking voltage measurements from the cable connectors without removing the connector, a T-shaped push pin connected to the voltmeter probe wire works well (see image to the right).

Warrior Controller Sample Voltage Measurements at the J1 Connector

Pin # Name Voltage Ref. Comments

J1-1 Rec-start 4.99 B- Sensor input from recycle start sensor. Should be slightly less than V J1-2 Rec-stop 4.99 B- Sensor input from recycle stop sensor. Should be slightly less than V J1-3 V

5.00 B- Output from internal 5-volt power supply for logic circuitry and semiconductors.

This measurement should always be very close to 5.0 volts.

J1-4 SC-Status A 36.5 B- Input of status indicator from Drive controller. The actual voltage seen for the

I 3.20

Inactive state will be non-zero due to internal circuitry in the Drive controller.

J1-5 F/R A 0.01 B- Input of F/R from Drive controller. Results should be close to B+ and B-, but will

I 31.9

be slightly less due to internal circuitry in the Drive controller.

J1-6 Rev A 1.80 B- Input of Reverse from Drive controller. Results should be close to B+ and B-,

I 36.3

but will be slightly less due to internal circuitry in the Drive controller.

J1-7 Bat- NL 0.004 B- Measured with Load (Vacuum motor) and No-Load. Any non-zero result

represents the voltage drop in the wiring between battery and control board.

duty cycle of the PWM signal.

J1-8 Solution

Pump

L 0.040

A 25.0 B- PWM output to Solution Pump. The Active voltage will vary depending on the

I 36.8

J1-9 B-3 Bus 0.00 B- Negative bus for solenoids and contactors (brush, vacuum, solution, recycle) J1-10 Recycle N/A B- Obsolete, not recorded. Output to Recycle solenoid (should be similar to J11) J1-11 Solution

Solenoid

J1-12 Vacuum

Contactor

J1-13 Key Switch A 36.9 B- Switched battery power that drives the internal V

J1-14 Brush

Contactor

A 0.177 B- Active voltage may be higher on ST models due to PWM control of the

I 36.9

solenoid. AXP/EcoFlex solenoids are On/Off w/o PWM control.

A 7.5 B- A PWM output to the coil. The PWM is to reduce the effective voltage and

I 36.9

I 0.00

reduce the load in the solenoid coil.

off, so is V

power supply. When this is

A 7.60 B- A PWM output to the coil. The PWM is to reduce the effective voltage and

I 36.9

reduce the load in the solenoid coil.

A = Active I = Inactive NL = No Load

Control SystemService Manual – Warrior ST, AXP, EcoFlex

Warrior Controller Sample Voltage Measurements at the J2 Connector

Pin # Name Voltage Ref. Comments

J2-1 Lift Actuator U 0.20 B- A DPDT relay inside the control board reverses polarity for Up and Down. J2-1

D 36.9

I 0.00

and J2-8 should have mirrored voltages. High voltage should be close to bat+

(voltage drop in wire). Inactive voltage should be equal to Bat- (mirror J2-8).

Active low voltage represents voltage drop across internal switching MOSFET.

J2-2 B- (Output) NL0.004 B- Electrically connected to J1-7 as battery negative output. Measured with Load

(Vacuum motor) and No-Load (see J1-7).

due

to pull-up resistor in controller. Analog hall effect sensor with voltage range

dependant on Top to Bottom position of magnet on chemical bottle.

when Open (down

position), and close to Bat- when Closed (up position).

Motor Amps Input Voltage

Battery negative wire to the brush motors with

a wire resistance of approximately 0.006 Ω. From Ohm’s Law, V = I * R. The values to the right follow closely with the calculated results.

8 0.046

10 0.060

J2-3 Chemical

Ratio

Sensor

J2-4 Recovery

Tank Full

J2-5 Brush

Current

L 0.040 U 5.00 B- Input from chemical ratio sensor. When Unplugged, the voltage is V B 4.78

T 1.83 C 0.01 B- Hall effect sensor. The voltage should be close to V O 4.997

A table B- Represents the voltage drop across the

I 0.0 4 0.025

27 0.187 30 0.199

J2-6 B-4 bus NL0.004 B- Negative battery bus for the pump motors (Recycle, Solution, Chemical).

L 0.040

Measured with Load (Vacuum motor) and No-Load (see J1-7).

J2-7 B+2 bus 36.9 B- Positive battery bus for Lift Actuator motor. Also a reference voltage (no-load

pull-up) for most other switching MOSFET’s that are active-low.

J2-8 Lift Actuator U 36.9 B- A DPDT relay inside the control board reverses polarity for Up and Down. J2-1

D 0.30

I 36.9

and J2-8 should have mirrored voltages. High voltage should be close to bat+

(voltage drop in wire). Inactive voltage should be equal to Bat+ (mirror J2-1).

Active low voltage represents voltage drop across internal switching MOSFET.

J2-9 B-2 bus NL0.004 B- Negative battery bus for Lift Actuator motor. Measured with Load (Vacuum

motor) and No-Load (see J1-7).

motor. At Idle: 14A = 0.085V; Blocked Exhaust: 17A = 0.105V

cycle. The lower the voltage, the more active (faster) the pump.

J2-10 Vacuum

Current

J2-11 Chemical

Pump

J2-12 Recycle

Pump

L 0.040

Varies B- Represents the voltage drop across the Battery negative wire to the vacuum

A PWM B- Active-low PWM signal to chemical pump. The voltage will vary with PWM duty

I 36.9

A PWM B- Active-low PWM signal to chemical pump. The voltage will vary with PWM duty

I 36.9

A = Active I = Inactive NL = No Load U/D = Up/Down O/C = Open/Closed

Electrical SystemService Manual – Warrior ST, AXP, EcoFlex

Electrical System

Functional Description

The Warrior machine is powered using six, 6-volt batteries connected in series, for a total

system nominal voltage of 36 volts. To protect the batteries from over discharge, the system

is protected with a 150 amp fuse (F1). With the exception of the optional on-board battery

charger, all other connections are downstream from this main fuse.

There are 2 circuit breakers that protect the electronics. The keyswitch (S3), Warrior

controller (A1), Brush motor contactor coil (K1), Vacuum motor contactor coil (K2),

Solution solenoid (L1), and optional Recycle solenoid (L2) are protected with a 5 amp resettable circuit breaker (F2). The Curtis Drive controller is

protected with a 30 amp resettable circuit breaker (F3). If these circuit breakers trip, their respective button will pop up. Pressing the button back in after the overload has cleared will reset the breaker.

When the optional on-board battery charger is present, the battery-side of the (F2) fuse is replaced with an interlock circuit from the charger. (Power to the fuse comes through the charger.) This interlock feature

allows the charger to disable all control of the machine when the charger is plugged into a wall outlet and

the battery is being charged. The charger doesn’t disable all power to the machine; just the control power.

Description Of The Low-Voltage Cutout Feature

The warrior machine is equipped with a low-voltage cutout feature to prevent over-discharging of the batteries. When the machine’s battery voltage falls below the dened threshold, the scrub system is

automatically shut down. The voltage cutout level is adjustable for different battery types. The standard

lead acid battery (wet cell) setting is 30.96 volts, and the alternate (gel cell) setting is 32.58 volts. The standard setting is factory selected and should be used unless the battery manufacturer species the higher

cutout voltage. Note: A minimum recharge voltage of 38.6 volts must be reached to allow the low-voltage cutout system to reset once activated.

Description Of The Battery Condition Indicators

The Battery Condition Indicator will give an indication of the state of charge

of the batteries based on the voltage of the batteries. The Warrior ST display has three colored LED’s (3) showing 5-levels of voltage. The Warrior AXP/ EcoFlex display has 5 vertical bars (1) showing 6-levels of voltage. When the low-voltage cutout is active, the charge symbol (2) will be shown, or the red LED will ash. These levels are summarized in the tables below.

AXP/EcoFlex Display ST Display

Display Standard Alternate Display Standard Alternate

5 bars 36.1+ 36.1+ Grn 34.0+ 34.5+ 4 bars 35.5-36.1 35.5-36.1 Grn & Y el 33.0-34.0 34.0-34.5 3 bars 34.4-35.5 34.4-35.5 Yel 32.0-33.0 33.5-34.0 2 bars 33.9-34.4 33.9-34.4 Yel & Red 31.5-32.0 33.0-33.5 1 bars 32.2-33.9 33.3-33.9 Red 31.0-31.5 32.5-33.0 0 bars 30.9-32.2 32.8-33.3 Flash Red <31.0 <32.5 Cutout <30.9 <32.8

Ø.4

Electrical SystemService Manual – Warrior ST, AXP, EcoFlex

Maintenance and Adjustments

Charging Batteries

Charge the batteries each time the machine is used or when the battery indicator (1 or 3) is reading less than full. Note: Refer to the algorithm chart in Advance Technical Service Bulletin TSBUS2008-984 for the

correct charging algorithm for your battery type and model.

Caution!

• Charge batteries in a well-ventilated area.

• Do not smoke while servicing the batteries.

• Remove all jewelry

• Wear safety glasses, rubber gloves and a rubber apron

• Do not allow tools to touch more than one battery terminal at a time

• To avoid damage to floor surfaces, wipe water and acid from the top of the batteries after charging.

If your machine shipped with an onboard battery charger, turn the Key Switch off. Unwind the electrical cord from the side of the onboard charger and plug it into a properly

grounded outlet. Refer to the OEM product manual for more

detailed operating instructions.

If your machine uses an external battery charger, unplug the

battery connector (4) from the machine connector (5), and plug the

battery connector into the charger. Follow the instructions on the

battery charger. Note: Make sure you plug the battery charger into the connector (4) with the handle attached to it.

Extending Battery Life

Proper maintenance of electric vehicle batteries can greatly extend their life. The following information will help extend the life of your batteries.

• Your battery will deliver superior performance and life if it is recharged properly. Excessive charging

or discharging will shorten battery life and limit performance. Be sure to follow proper charging instructions.

• Make sure you have an appropriate charger for the type of battery. Use only “voltage-regulated” or “voltage-limited” chargers. Standard constant-current or taper current chargers must not be used. A temperature-sensing charger is recommended.

• Important! Do not attempt to open sealed gel batteries or add water. Doing so will damage the battery

and void the warranty.

• For wet batteries, maintain proper electrolyte level and check weekly. Use distilled water in batteries

whenever possible. If the batteries are discharged, add just enough water to cover the plates in each cell,

and recheck the level after charging (this prevents over-lling the battery). If batteries are fully charged, ll each cell to the bottom of the ller tube. Do not over-ll the batteries! Do not add acid to batteries!

• Keep the Batteries Charged. Batteries should be charged each time that a machine is used for more

than 1 hour. Machine operators should open the battery compartment cover for charging, to avoid a

concentrated build-up of hydrogen gas. Operators should follow the instructions provided with their specic battery charger, to determine how long the batteries should be charged. Even when a machine is stored, the batteries should be charged once a month to prevent the batteries from “sulfating”. Most battery caps are vented, so there’s no need to loosen or remove them for charging.

• Keep the Batteries Clean. Use a damp cloth to wipe dirt from the top of the batteries. Battery terminals

must be clean and tight. If the tops of the batteries are wet after charging, the batteries have probably

been overlled or over-charged. Note: If there is acid on the batteries, wash the tops of the batteries with a solution of baking soda and water (2 tablespoons of baking soda to 1 quart of water).

Electrical SystemService Manual – Warrior ST, AXP, EcoFlex

Troubleshooting

Battery Testing

A battery problem is usually recognized by the machine operator as a decrease in the machine’s running time. This condition is usually caused by one or more “dead cells” in the battery system.

There are 2 ways to nd a dead cell:

• Use a hydrometer to check the specic gravity (or “state of charge”) of the uid in each cell. A dead cell is one that reads 50 points (or more) lower than the other cells.

• Use a volt meter to check the voltage of each battery. Look for a battery with a voltage that is 1 or 2 volts less than the other batteries. Check under the following conditions:

• With the batteries fully charged,

• With the scrub and drive motors running,

• With the batteries discharged, but still above the voltage cutoff threshold.

If the batteries in the machine are more than 1 year old, it’s usually best to replace the whole set, rather

than replacing just one battery.

Removal and Installation

Batteries

Caution!

• Use extreme caution when working with batteries. Sulfuric acid in batteries can cause severe injury if allowed to contact the skin or eyes.

• Explosive hydrogen gas is vented from the batteries through openings in the battery caps. Do not smoke while servicing the batteries.

• Remove all jewelry. Wear safety glasses, rubber gloves and a rubber apron

• Do not allow tools to touch more than one battery terminal at a time

• Electrical components in this machine can be severely damaged if the batteries are not installed and connected properly.

1. Turn the Key Switch to the off position and open the

recovery tank.

2. Remove the cables from the batteries, and remove the

batteries. Make note of the battery polarity and cable

locations.

3. Install the new batteries into the compartment. Note the orientation of the batteries shown to the right. Not all of the batteries are oriented the same way.

4. Put a rubber boot over each end of the battery cables.

5. Connect the battery cables.

• There are 3 short cables (S), 2 long cables (L), and

the main positive (Bat+) and negative (Bat-) cables leading to the machine.

• All cables are connected positive-to-negative for a

series connection between all 6 batteries.

• Position the cables so the battery caps can be easily

removed for battery service.

• Take care to not over torque the cable connector, as this may damage the battery post.

−

BAT+ BAT-

−

6. Coat the terminals with spray-on battery terminal coating (available at most auto parts stores).

Electrical SystemService Manual – Warrior ST, AXP, EcoFlex

Specifications

Wet Cell Battery specifications:

• Use a combination of multiple 6-volt units to construct a 36 Volt DC battery pack system.

• Advance recommended battery pack capacity is a 305 AH @ 20 Hour Rate deep cycle battery system.

Note: The battery pack must t the battery compartment size listed in Specications.

Wet Cell Battery Charger Specifications

• Use a 36 Volt DC output charger matching the DC battery pack voltage and the input AC line voltage

supply being used.

• When selecting a battery charger always follow the recommendation of the battery supplier to match the

proper charger DC output amperage to the amp/hour rating batteries being installed. This will prevent the battery pack from being over or under charged.

• The recommended 305 AH battery should be matched to a 36V, 20-25 Amp output charger on machines

using (6) 6V batteries.

Electrical SystemService Manual – Warrior ST, AXP, EcoFlex

Wiring Diagram

The wiring diagram below is a general representation of the wiring within all Warrior machine models up

to the publication date of this manual. This diagram and actual machine wiring are subject to change. Some components are optional and may not be present on all machines. Some components are no longer offered on current machines, but are shown for reference to aid in servicing earlier machines.

Note: When the on-board battery charger is present, the red wire leading to the F2 circuit breaker is replaced

with the green wire from the battery charger’s interlock. This disables the system during charging.

BATTERY

RED

NOTE: CONNECT GRN WIRE TO F2 AND DISCONNECT RED WIRE FROM F2 FOR CHARGER OPTION

RED

CIRCUIT BREAKER, 5 AMP

1 2

(OPTIONAL)

RED

1 2

GRN

BRN BRN

EM BRAKE

+ -

WHT/YEL

CIRCUIT BREAKER, 30 AMP

1228 SPEED

CONTROLLER

BRN/BLK

YEL/RED

MOTOR, WHEEL DRIVE

BLU/WHT

RED WHT

1 2

FUSE, 150 A.

SW, SPST KEY

RED/BLK YEL/BLU

B+ B-

PIN 18 - SPEED LIMIT POT

Polarity For Disc Brushes

RED

BRN

COIL, BRUSH MOTOR CONTACTOR

BRN

COIL, VAC MOTOR CONTACTOR

BRN

1 2

COIL, SOLUTION SOLENOID

BRN

COIL, RECYCLE SOLUTION SOLENOID

1 2

(OPTIONAL)

BLK

PIN 14 - BRAKE (+)

PIN 9 - STATUS

PIN 6 - BRAKE (-)

PIN 16 - REV

PIN 5 - KSI

PIN 13 - POT.LO

PIN 4 - POT.WIPER

PIN 3 - POT.HI

POT. 100K OHM SPEED LIMIT

MOTOR, LEFT BRUSH

- +

WHT

MOTOR, RIGHT BRUSH

36 VDC

+ -

(OPTIONAL)

ONBOARD BATTERY

CHARGER

B+

INTERLOCK

BRN

VIO/BLK

BLK/YEL

RED/GRN

YEL/GRN

BRN

ORN/BLU

RED/BLK

BLU/BLK

WHT

BLU

BLK

BRN

Polarity For Cylindrical Brushes

BLK

BLK/WHT

B-

BLU

BRN

WHT

BLK

CONTROL BOARD

J2-7

B+2

J1-13

B+1

J1-14

BRUSH CONTACTOR

J1-12

VACUUM CONTACTOR

J1-11

SOLUTION

J1-10

RECYCLE SOLUTION

WHT

3 1

WHT/GRA

STATUS

FOR/REV.

BRUSH MOTOR SENSE

J1-5

J2-5

J1-4

RED/BLK

ORN/BLU

WHT/GRA

BLK

VACUUM MOTOR SENSE

J2-10

ORN

RECYCLE STOP SWITCH

REVERSE

RECYCLE START SWITCH

J1-6

J1-2

J1-1

J2-4

BLU/BLK

GRA/WHT

YEL/BLU

WHT/BLK

R1 POT. 5K OHM THROTTLE

(OPTIONAL)

BLK

(OBSOLETE)

CHEMICAL RATIO SENSOR

SUPPLY OUTPUT B-

RED/WHT

BLK

BRN/BLK

J2-3

J2-2

J1-3

INPUT

SUPPLY

BRUSH ACTUATOR 2 BRUSH ACTUATOR 1

BRUSH REMOVE BRUSH REMOVE RECYCLE PUMP

CHEMICAL PUMP

RECOVERY TANK FULL SENSE

J2-11

B-

SOL. PUMP

J1-9

B-2

J2-9

B-3

J2-6

B-4

J2-1 J2-8

MOTOR, BRUSH ACTUATOR

RELAY N.O. RELAY COMMON J2-12 J1-8 J1-7

B-1

BLK

VIO/YEL

WHT/GRN

YEL/VIO

SWITCH, FLOAT

(OBSOLETE)

BLK

BLU/WHT BLK

BLK

CHEMICAL PUMP

YEL/VIO

M10

BLK

BLK BLK BLK

GRN/BLK

YEL/VIO

BLK

BLU/WHT

ORN/RED

RED

RED BLU

K2K2

MOTOR, VAC

1 2

S1S1

1 2

(OBSOLETE)

S2S2

1 2

Internal Pressure Switch

TION PUMP

SOLU

RECYCLE PUMP

ORN/RED

Internal Pressure Switch

BLK

GRN/BLK

Options and Accessories 43Service Manual – Warrior ST, AXP, EcoFlex

Options and Accessories

The Warrior machine is available in three basic congurations, ST, AXP, and EcoFlex. It also has a few options that may be added to these congurations, such as different sized scrub decks and squeegee assemblies. Refer to the parts manual for a complete list of accessories and components. The Wand option is an add-on accessory that may be added to any machine, and provides for spot cleanup in areas where the

machine may not be able to reach.

Wand

Storage

Recovery System

Functional Description

The recovery system extracts wastewater from the oor and deposits it into the on-board 30 gallon recovery tank. The oor squeegee is wider than the swath of the scrub deck to ensure

collection of all wastewater from the perimeter of the scrubbing

area. The squeegee also pivots to

the side to permit operation near

walls and to keep the squeegee

within the scrubbing path while turning the machine.

Recovery

Tank Cover

Vacuum Exhaust

Recovery System 44Service Manual – Warrior ST, AXP, EcoFlex

Vacuum

Inlet Screen

Recovery

Tank

Float

Switch

Vacuum

Motor

Squeegee

Suction Hose

Vacuum Motor and Recovery Tank

The vacuum motor generates airow through the recovery tank and suction hose to the squeegee. The high velocity air at the squeegee pulls the wastewater off the oor and up through the suction hose. As the mixture of air and water enters the recovery tank, the airow slows down due to the larger space, and the water drops out of the airow and into the tank.

The airow passes through an inlet screen to prevent

debris from entering the impeller of the vacuum

motor. The exhaust air is expelled inside the machine

so it can be dispersed without blowing directly on the

operator or the work environment.

To prevent wastewater from entering the vacuum

motor, a oat switch shuts off the vacuum when the recovery tank is full.

Squeegee

Airflow

Wastewater

Float Switches

Depending on the machine conguration, there will be 1 or 3 oat switches in the recovery tank. The recovery tank full switch is present on all machines

and senses when water reaches the upper limit in

the tank. The lower two switches are present only on machines equipped with the Extended Scrub option.

When the Extended Scrub option is present, the middle switch is for “Extended Scrub Start” which

tells the machine there is enough solution to utilize

the extended scrub function. The bottom switch is for “Extended Scrub Stop” which tells the machine there is not enough solution to utilize the extended scrub

function.

The sensor arm of the oat switch contains a noncontact reed switch. The oat arm contains an embedded magnet. As the oat arm moves upward into proximity to the sensor arm, the reed switch is

magnetically pulled closed.

Recovery System 45Service Manual – Warrior ST, AXP, EcoFlex

Sensor Arm

Float Arm

Recovery Tank Full

Extended

Scrub Start

Extended

Scrub Stop

Recovery System 46Service Manual – Warrior ST, AXP, EcoFlex

Vacuum Motor Control Circuit Overview

Contactor Coil Circuit:

Positive voltage is always present at the contactor coil (K2) through the F2 circuit breaker. The contactor coil is controlled by the switching of the negative terminal via the J1-12 terminal of the Warrior control board (A1). The output of the J1-12 terminal is PWM controlled to reduce the effective voltage on the contactor’s coil. This PWM signal does not impact the actual vacuum motor voltage, only the coil’s voltage.

Functional Conditions of the J1-12 Terminal Control:

• During Normal Scrub Mode:

• The key switch (S3) must be in the on position and the Scrub On switch has been pressed.

• The oat switch (S4) must be open (recovery tank not full).

• The drive paddle must be moved out of the neutral position. This causes the Curtis Drive controller (A2) to set the J1-5 terminal to ground.

• During Accessory Mode:

• The key switch (S3) must be in the on position and the Accessory (Wand) switch has been pressed.

• The oat switch (S4) must be open (recovery tank not full).

Note: Earlier machines used a normally-closed recovery tank oat switch conguration. In these machines,

the recovery tank oat switch (S4) must be closed in order for the vacuum motor to run.

RED

1 2

RED

CIRCUIT BREAKER, 5AMP

1 2

RED

CIRCUIT BREAKER, 30AMP

1210 SPEED CONTROLLER

MOTOR, WHEEL DRIVE

BRN

(1228 FOR 36V)

BRN/BLK

YEL/RED

RED

1 2

FUSE,150A.

SPST KEY

WHT/YEL

RED

BRN

VACUUM MOTOR

BLK

B+ B-

PIN 6-BRAKE(-)

PIN 5-KSI

PIN 13-POT.LO

PIN 4-POT.WIPER

PIN 3-POT.HI

PIN 18-SPEED LIMIT POT

BLU

BATTERY

24VDC OR 36VDC

BRN

BLK/YEL

COIL

CONTACTOR

BRN

RED/BLK

WHT BLU BLK BRN

POT.100K OHM SPEED LIMIT

BT1

+ -

BLU

BRN

WHT

BLK

CONTROL BOARD

J1-13

B+1

J1-12

VACUUMCONTACTOR

J1-5

RED/BLK

WHT

BLK

FOR/REV.

VACUUMMOTOR SENSE

J2-10

ORN

POT.5KOHM THROTTLE

ORN

MOTOR, VAC

J2-4

RECOVERYTANK FULL SENSE

GRA/WHT

B-2

SWITCH, FLOAT

J1-9

BLK

BLK BLK

BLK

Recovery System 47Service Manual – Warrior ST, AXP, EcoFlex

Troubleshooting

Whenever there is a vacuum problem, it’s best to check over the entire system. Use the checklist below as a guide to thoroughly check the vacuum system.

• Inspect and clean the vacuum motor oat switch. Note that on current models, if the switch is closed (tipped up) the vacuum motor will not operate.

• Inspect the vacuum motor inlet screen and clean any built-up debris from the screen.

• Clean built-up dirt from the inside of the squeegee tool.

• Replace the squeegee blades if they are nicked or torn.

• Inspect the hose between the squeegee tool and the recovery tank and rinse any built-up dirt from the hose. Replace the hose if it is kinked or damaged.

• Inspect and make sure the gasket on the recovery tank cover is sealing and not damaged.

• Make sure that the recovery tank drain hose cap seals airtight.

Problem Cause Correction

No suction Vacuum motor not running

Poor suction Clogged vacuum

Vacuum leaks

• Inspect the recovery tank oat switch for proper

operation

• Check the vacuum motor circuit breaker

• Check the vacuum motor contactor for proper

operation

• Inspect and clean the vacuum motor inlet lter

• Inspect the suction hose between the squeegee tool and the recovery tank

• Inspect and clean the squeegee tool

• Inspect the gasket on the recovery tank cover

• Inspection the suction hose between the squeegee tool and recovery tank for loose

connection, holes, or damage

• Inspect the squeegee blades for nicks, cuts, and

damage

• Inspect the recovery tank drain hose and cap for leaks

• Inspect the vacuum motor mount for leaks

Removal and Installation

Vacuum Motor

1. Turn off the key and disconnect the batteries.

2. Drain the recovery tank and move it to the open position.

3. Disconnect the vacuum motor cable connector.

4. Remove the screw and washer from the discharge hose clamp (23).

Recovery System 48Service Manual – Warrior ST, AXP, EcoFlex

5. Remove the four screws (20) and washers (19) that secure the vacuum motor housing (18) to

the recovery tank, and remove the housing. Be

careful not to let the motor fall, as the housing is what holds it in place.

6. Remove the vacuum motor (15) and discharge hose (22). Take care not to lose the three vibration mounts (16).

7. If necessary, remove the cable tie (21) that secures the discharge hose to the motor outlet.

8. Inspect the main vacuum gasket (14) for damage and compressibility, and replace if necessary. Leaks in

this gasket will reduce recovery system suction.

9. Inspect the motor ventilation gasket (17) for damage and compressibility. This gasket holds the vacuum motor assembly in position against the recovery tank.

10. Make service repairs to the vacuum motor as needed, and re-install by reversing the procedure steps.

Recovery T ank

in Open Position

Cable

Connector

Recovery System 49Service Manual – Warrior ST, AXP, EcoFlex

Float Switches

Use this procedure to replace the oat switches in the Recovery Tank. All machines will have a Recovery Tank Full switch. Machines with the Extended Scrub option will also have two additional switches (located below the tank-full switch) for Recycle Start and

Recycle Stop.

On some older machines, the recovery tank full oat switch operated in the Normally Closed conguration (upper image to the right). When the tank is empty, the switch is in the closed position. For increased

reliability, this switch orientation was later changed

to operate in the Normally Open conguration (lower image to the right).

If the Warrior controller software revision level is above Revision level I for AXP machines, above Revision level E for ST machines, and for all EcoFlex machines, this switch orientation is congurable. If the machine being serviced is congurable for switch orientation, then it is recommended that the switch be installed in the Normally Open conguration with the Float Arm located below the sensor arm as shown. Make sure to check the setting as described in the Recovery Tank-Full Switch Orientation procedure in the Control

System chapter.

Float Arm Orientation

for Older Machine

Float Arm Orientation

for Newer Machine

For newer machines, and for all Extended Scrub sensors, orient the mechanical oat to be below the sensor as shown in the lower image. To replace the oat switch:

1. Turn off the key on the machine.

2. Disconnect the sensor cable connector.

3. Remove the nut and washer that secures the oat

switch to the recovery tank bulkhead, and remove the switch from inside the recovery tank.

4. When installing the switch, make sure the gasket is on the inside of the recovery tank, and the

sensor is oriented correctly as described above.

5. If necessary, complete the Recovery Tank-Full Switch Orientation procedure described in the

Control System chapter.

Float Arm

Nut and

Washer

Gasket

Sensor Arm

Specifications

Parameter Range

Vacuum Lift Blocked: 64 in.-H2O

1-inch Orice: 13 in.-H

Scrub System, Cylindrical

Brush Retainer

Functional Description

The scrub system consists of a motorized scrub deck

that is raised and lowered with a lift actuator. The two counter rotating brushes are driven by independent

motors with integral speed reduction gear boxes.

Brush Motors

Unlike most other motors in the Warrior system, the Brush motors are not PWM speed controlled, but are either full-on or full-off. The primary on/off function is

controlled with the brush motor contactor (K1) located in the main electrical panel in front of the operator

controls. (The contactor coil is PWM controlled to

reduce the effective voltage, but this does not impact

the speed of the motor.)

The Warrior controller measures the current through the motors by examining the voltage drop across

the ground wire between the battery and the motor.

(Wires are not perfect conductors, and will have a voltage drop.) This allows the controller to know how

much scrub pressure is being applied.

Scrub System, Cylindrical 50Service Manual – Warrior ST, AXP, EcoFlex

Brush Motor

Contactor

Lift

Accuator

Cylindrical

Scrub Deck

Hopper

Drive Hub

Idler Hub

Brush

Scrub Deck

Housing

Brush Motor

Scrub System, Cylindrical 51Service Manual – Warrior ST, AXP, EcoFlex

Brush Lift Actuator

The scrub deck is raised and lowered with a motorized

actuator. The top of the actuator connects to the Solution

Tank, and the bottom of the actuator connects to the scrub deck. A series of link arms connects the scrub deck to the drive chassis and solution tank to permit vertical

movement while limiting lateral movement.

The electric motor rotates the leadscrew. Because the leadscrew nut is constrained to not rotate, it threads up and down the leadscrew as the leadscrew turns. Slots in the spring housing allow the leadscrew nut to move vertically without turning, however, the upper and lower pressure springs constrain the leadscrew nut to remain

in the middle of the housing. When the scrub deck is lowered to the oor, the leadscrew continues turning for

a short distance, compressing the down pressure spring.

This maintains pressure on the scrub deck without being rigidly locked to the leadscrew nut position.

Inside the drive motor are two limit switches. These

limit switches control the maximum travel of the

leadscrew nut by limiting the number of revolutions that

the leadscrew is permitted to make.

The controller monitors the scrub motor current

(described above) and raises or lowers the scrub deck

accordingly, to maintain the desired brush pressure. The lift actuator motor is controlled directly by the

Warrior controller. An on-board relay is used to reverse the polarity to the motor for direction control. The

controller also monitors the amperage of the lift motor and displays an error message if the amperage

exceeds a maximum limit.

Limit Switch

Access

Motor

Spring

Housing

Deck Mount

Leadscrew

Up Pressure

Spring

Leadscrew Nut

Down Pressure

Spring

Circuit Overview

5 Amp

Circuit Breaker

Brush Motor

Contactor Coil

Maintenance and Adjustment

Lift Actuator Limit Adjustment

Scrub System, Cylindrical 52Service Manual – Warrior ST, AXP, EcoFlex

To protect the lift actuator from traveling too far, it contains two internal limit switches for minimum and

maximum travel. The minimum travel is adjusted by turning the leadscrew nut, and the maximum travel (or length) is adjusted by turning the dial at the top of the leadscrew motor. This adjustment requires the use of the Actuator Power Cord Adapter (1) (PN 56407502) shown to the right.

1. Remove the front nose from the machine.

2. Connect the Power Cord Adapter (1) to the positive and negative battery terminals of the

Warrior machine.

3. Disconnect the power cable of the lift actuator from the machine, and connect the Power Cord Adapter into the cable leading to the lift actuator motor.

4. Press the For/Rev switch on the Adapter (1) to lower the lift actuator until the scrub deck is resting on the oor in a neutral position (no tension/pressure on the actuator).

5. Remove the retaining key (2) and link pin (3)

that secures the spring housing (4) to the scrub

deck to permit the actuator to swing freely.

6. While holding the spring housing (4) from turning, press the For/Rev switch on the Adapter

(1) to raise the spring housing (4) toward the actuator gear housing (5) until the motor stops

(minimum limit switch engaged).

7. Rotate the spring housing (4) until the distance

between the spring housing and gear housing

(5) is within the Upper Limit range listed in the

table below.

• The “Old Style” spring housing (4) is identiable as a one-piece housing.

• The “New Style” spring housing (4) is identiable as split down the center.

Motor

Battery

Negative

Battery

Positive

Disk Deck Shown

Cylinder Deck Similar

For/Rev

Switch

Housing Distances

Upper Limit Lower Limit

New Style

Old Style

⁄" - ⁄"

(21 - 23 mm)

⁄" - ⁄"

(2 - 5 mm)

4 ⁄" - 5"

(124 - 127 mm)

4 ⁄" - 4 ¼"

(105 - 108 mm)

Housing Distance

Scrub System, Cylindrical 53Service Manual – Warrior ST, AXP, EcoFlex

8. Hold the spring housing from rotating, and press the For/Rev button of the Adapter (1) to lower the actuator to its lowest position until the motor stops (maximum limit switch engaged).

9. Measure the Housing Distance as described above, but for the Lower Limit position, and compare this to

the values shown in the table. If necessary, adjust the lower limit as described below.

10. Remove the dust cap (6) from the top of the gear housing (5) using your ngers or a small screw driver.

11. Place a 1/2" socket (9) over the limit adjustment nut (7) to turn the nut, and increase or decrease the lower limit as follows:

• Important: Even though the center of the adjustment nut looks like it will accept a screwdriver blade, this is the retainer for the adjustment nut. Do Not try to turn the retainer!

• Each “click” of the adjuster nut changes the Housing Distance by 1/16".

• To increase the Housing Distance, turn the nut clockwise.

• To decrease the Housing Distance, turn the nut counterclockwise.

• If you need to make large adjustments, it is recommended to move the actuator away from its limit position rst.

Turn Outer

Nut Only

Do Not

Turn!

12. To check your adjustments, you must rst raise the actuator away from the limit position before lowering it back to the limit position and re-measuring the Housing Distance for the Lower Limit.

13. After adjusting the Lower Limit, it is a good practice to conrm both limits by cycling the actuator to the upper and then lower limit.

14. Before disconnecting the Adapter cord (1), lower the lift actuator down to the scrub deck to make it easier to reinsert the link pin (3) and retaining key (2).

15. Reassemble the machine.

Scrub System, Cylindrical 54Service Manual – Warrior ST, AXP, EcoFlex

Removal and Installation

Scrub Deck

1. Remove the front nose from the machine.

2. Put the scrub deck in a neutral position by either lowering it to the oor or blocking it up to remove the weight.

3. Disconnect the main battery connector in the battery compartment.

4. Loosen the hose clamp and remove the solution line from the front of the scrub deck.

5. Disconnect the scrub brush motor power connectors, and free up the cables from any cable ties.

6. Remove the retaining key (2) and link pin (3) that secures the lift actuator to the scrub deck.

7. Remove the retaining key (10) and washer (11) that secure the scrub deck to the upper linkage.

8. Remove the two retaining keys (12) and link pins (13) that secure the scrub deck to the drive frame link arms.

Lift Actuator

Scrub System, Cylindrical 55Service Manual – Warrior ST, AXP, EcoFlex

1. Remove the front nose from the machine.

2. Put the scrub deck in a neutral position by either

lowering it to the oor or blocking it up to remove

the weight.

3. Disconnect the main battery connector in the battery compartment.

4. Disconnect the lift actuator power cable.

5. Remove the retaining key (2) and link pin (3)

that secures the spring housing (4) to the scrub

deck.

6. Remove the retaining key (14) and link pin (15) that secures the lift actuator to the upper mount, and remove the actuator.

Disk Deck Shown

Cylinder Deck Similar

7. If the replacement actuator is not pre-assembled,

insert the smaller spring (18) onto the leadscrew, followed by the leadscrew nut (17) and larger spring (19), and then install the two halves of the spring housing (4) around the leadscrew nut.

8. Perform the Lift Actuator Limit Adjustment described earlier in this chapter. The limit adjustment may be performed before installing the actuator.

Brush Motor Contactor

Warning: Disconnect the battery connector before servicing machine.

Scrub System, Cylindrical 56Service Manual – Warrior ST, AXP, EcoFlex

1. Turn off the key and disconnect the main battery connector.

2. Free the drive paddle control wire from the wire clamp (37) on the front of the electrical cover (32).

3. Remove the four screws (34) and washers (33) that secure the electrical cover to the solution

tank, and remove the cover.

4. Remove the four screws (36) that secure the

control panel (35) to the solution tank, and gently move the control panel to the side.

5. Disconnect the following wires from the contactor

(38):

• Power to the motors (white bundle) (20)

• Power from the battery (red wire) (21)

• Control from the Warrior controller (violet/ black wire) (23)

• Control from the battery (brown wire) (22)

• Shunt Brake from the Warrior controller (blue/ white wire) (This wire is located on the bottom

of the contactor and is not accessible until the

contactor is partially removed.)

6. Remove the two screws (24) that secure the contactor to the electrical enclosure, and remove the contactor.

Scrub Brush Motor

1. Turn off the key and disconnect the main battery connector.

Scrub System, Cylindrical 57Service Manual – Warrior ST, AXP, EcoFlex

2. Disconnect the motor cable connector and free up any cables from cable ties.

3. Remove the screw and washer that secure the drive belt cover

(25) to the scrub deck, and remove the cover.

4. Remove the drive belt (26) by walking it off the motor pulley (27), and then off the brush pulley. Hint: When replacing the drive belt, use a screwdriver to assist you walking it back onto

the motor pulley, as shown in the two images to the right.

5. Loosen the two setscrews that secure the motor pulley (27) to the motor shaft, and remove the pulley.

6. Remove the three bolts (28) that secure the brush motor (29) to

the scrub deck, and remove the motor.

Special Tools

The Actuator Power Cord Adapter (1) (PN 56407502) is used to

manually control the brush lift actuator.

Motor

Battery

Negative

Battery

Positive

For/Rev

Switch

Scrub System, Disc

Functional Description

Scrub System, Disc 58Service Manual – Warrior ST, AXP, EcoFlex

Brush Motor

Contactor

Lift

Accuator

Scrub Deck,

Disc T ype

The scrub system consists of a motorized scrub deck that is raised and lowered with a lift actuator. The two counter rotating brushes are driven by independent motors with integral speed reduction gear boxes.

Brush Motor

Gear Box

Scrub Deck

Housing

Brush Plate

Brush

Brush Motors

Unlike most other motors in the Warrior system, the Brush motors are not PWM speed controlled, but are either full-on, full-off, or a special shunt-brake function to remove the brushes. The primary on/off function

is controlled with the brush motor contactor (K1) located in the main electrical panel in front of the operator controls. This is a special motor contactor that also includes a set of normally closed contacts that are used

for the “Brush Remove” function. This is a Single-Pole, Double-Throw (SPDT) relay. (A motor contactor is a name used for a relay that has high-power handling contacts necessary for the high amperage of a motor

circuit.)

During normal operation, the brush remove relay (KBR) is not active and its contacts are normally open. When the scrub motor is turned

off, it coasts to a stop.

When the brush remove function is active, the KBR relay closes, which connects to ground. When the scrub motor is turned off, both of its inputs are connected to ground. This is a short-circuit of the motor windings, which acts as a magnetic brake, bringing the motor to a stop very quickly. (An intentional short-circuit is called a shunt, so this is referred to as shunt-braking.) This rapid deceleration of the

brushes causes them to spin off the brush plates.

The Warrior controller measures the current through the motors by examining the voltage drop across the ground wire between the battery and the motor. (Wires are not perfect conductors, and will have a voltage drop.) This allows the controller to know how much

scrub pressure is being applied.

Bat+

Brush Remove

Bat+

Brush Run

KBR

(SPST)

(SPDT)

Scrub Motor

Bat+

Brush Lift Actuator

The scrub deck is raised and lowered with a motorized

leadscrew actuator. The top of the actuator connects

to the Solution Tank, and the bottom of the actuator connects to the scrub deck. A series of link arms connects the scrub deck to the drive chassis and solution tank

to permit vertical movement while limiting lateral movement.

in the middle of the housing. When the scrub deck is lowered to the oor, the leadscrew continues turning for

a short distance, compressing the down pressure spring.

This maintains pressure on the scrub deck without being rigidly locked to the leadscrew nut position.

Inside the drive motor are two limit switches. These

limit switches control the maximum travel of the

leadscrew nut by limiting the number of revolutions that

the leadscrew is permitted to make.

Limit Switch

Access

Motor

Spring

Housing

Deck Mount

Scrub System, Disc 59Service Manual – Warrior ST, AXP, EcoFlex

Leadscrew

Up Pressure

Spring

Leadscrew Nut

Down Pressure

Spring

The controller monitors the scrub motor current

(described above) and raises or lowers the scrub deck accordingly, to maintain the desired brush pressure

depending on the loading of the scrub brush motor. The lift actuator motor is controlled directly by the

Warrior controller. An on-board relay is used to reverse the polarity to the motor for direction control. The

controller also monitors the amperage of the lift motor and displays an error message if the amperage

exceeds a maximum limit.

Circuit Overview

5 Amp

Circuit Breaker

Brush Motor

Contactor Coil

Maintenance and Adjustment

Lift Actuator Limit Adjustment

Scrub System, Disc 60Service Manual – Warrior ST, AXP, EcoFlex

To protect the lift actuator from traveling too far, it contains two internal limit switches for minimum and

1. Remove the front nose from the machine.

2. Connect the Power Cord Adapter (1) to the positive and negative battery terminals of the

Warrior machine.

3. Disconnect the power cable of the lift actuator from the machine, and connect the Power Cord Adapter into the cable leading to the lift actuator motor.

4. Press the For/Rev switch on the Adapter (1) to lower the lift actuator until the scrub deck is resting on the oor in a neutral position (no tension/pressure on the actuator).

5. Remove the retaining key (2) and link pin (3)

that secures the spring housing (4) to the scrub

deck to permit the actuator to swing freely.

6. While holding the spring housing (4) from turning, press the For/Rev switch on the Adapter

(1) to raise the spring housing (4) toward the actuator gear housing (5) until the motor stops

(minimum limit switch engaged).

7. Rotate the spring housing (4) until the distance

between the spring housing and gear housing

(5) is within the Upper Limit range listed in the

table below.

• The “Old Style” spring housing (4) is identiable as a one-piece housing.

• The “New Style” spring housing (4) is identiable as split down the center.

Motor

Battery

Negative

Battery

Positive

For/Rev

Switch

Housing Distances

Upper Limit Lower Limit

New Style

Old Style

⁄" - ⁄"

(21 - 23 mm)

⁄" - ⁄"

(2 - 5 mm)

4 ⁄" - 5"

(124 - 127 mm)

4 ⁄" - 4 ¼"

(105 - 108 mm)

Housing Distance

Scrub System, Disc 61Service Manual – Warrior ST, AXP, EcoFlex

8. Hold the spring housing from rotating, and press the For/Rev button of the Adapter (1) to lower the actuator to its lowest position until the motor stops (maximum limit switch engaged).

9. Measure the Housing Distance as described above, but for the Lower Limit position, and compare this to

the values shown in the table. If necessary, adjust the lower limit as described below.

10. Remove the dust cap (6) from the top of the gear housing (5) using your ngers or a small screw driver.

11. Place a 1/2" socket (9) over the limit adjustment nut (7) to turn the nut, and increase or decrease the lower limit as follows:

• Important: Even though the center of the adjustment nut looks like it will accept a screwdriver blade, this is the retainer for the adjustment nut. Do Not try to turn the retainer!

• Each “click” of the adjuster nut changes the Housing Distance by 1/16".

• To increase the Housing Distance, turn the nut clockwise.

• To decrease the Housing Distance, turn the nut counterclockwise.

• If you need to make large adjustments, it is recommended to move the actuator away from its limit position rst.

Turn Outer

Nut Only

Do Not

Turn!

12. To check your adjustments, you must rst raise the actuator away from the limit position before lowering it back to the limit position and re-measuring the Housing Distance for the Lower Limit.

13. After adjusting the Lower Limit, it is a good practice to conrm both limits by cycling the actuator to the upper and then lower limit.

14. Before disconnecting the Adapter cord (1), lower the lift actuator down to the scrub deck to make it easier to reinsert the link pin (3) and retaining key (2).

15. Reassemble the machine.

Scrub System, Disc 62Service Manual – Warrior ST, AXP, EcoFlex

Removal and Installation

Scrub Deck

1. Remove the front nose from the machine.

2. Put the scrub deck in a neutral position by either lowering it to the oor or blocking it up to remove the weight.

3. Disconnect the main battery connector in the battery compartment.

4. Loosen the hose clamp and remove the solution line from the front of the scrub deck.

5. Disconnect the scrub brush motor power connectors, and free up the cables from any cable ties.

6. Remove the retaining key (2) and link pin (3) that secures the lift actuator to the scrub deck.

7. Remove the retaining key (10) and washer (11) that secure the scrub deck to the upper linkage.

8. Remove the two retaining keys (12) and link pins (13) that secure the scrub deck to the drive frame link arms.

Lift Actuator

1. Remove the front nose from the machine.

2. Put the scrub deck in a neutral position by either

lowering it to the oor or blocking it up to remove

the weight.

Scrub System, Disc 63Service Manual – Warrior ST, AXP, EcoFlex

3. Disconnect the main battery connector in the battery compartment.

4. Disconnect the lift actuator power cable.

5. Remove the retaining key (2) and link pin (3)

that secures the spring housing (4) to the scrub

deck.

6. Remove the retaining key (14) and link pin (15) that secures the lift actuator to the upper mount, and remove the actuator.

7. If the replacement actuator is not pre-assembled,

insert the smaller spring (18) onto the leadscrew, followed by the leadscrew nut (17) and larger spring (19), and then install the two halves of the spring housing (4) around the leadscrew nut.

8. Perform the Lift Actuator Limit Adjustment described earlier in this chapter. The limit adjustment may be performed before installing the actuator.

Brush Motor Contactor

Warning: Disconnect the battery connector before servicing machine.

Scrub System, Disc 64Service Manual – Warrior ST, AXP, EcoFlex

1. Turn off the key and disconnect the main battery connector.

2. Free the drive paddle control wire from the wire clamp (37) on the front of the electrical cover (32).

3. Remove the four screws (34) and washers (33) that secure the electrical cover to the solution

tank, and remove the cover.

4. Remove the four screws (36) that secure the

control panel (35) to the solution tank, and gently move the control panel to the side.

5. Disconnect the following wires from the contactor

(38):

• Power to the motors (white bundle) (20)

• Power from the battery (red wire) (21)

• Control from the Warrior controller (violet/ black wire) (23)

• Control from the battery (brown wire) (22)

• Shunt Brake from the Warrior controller (blue/ white wire) (This wire is located on the bottom

of the contactor and is not accessible until the

contactor is partially removed.)

6. Remove the two screws (24) that secure the contactor to the electrical enclosure, and remove the contactor.

Scrub Brush Motor

1. Turn off the key and disconnect the main battery connector.

2. Disconnect the motor cable connector and free up any cables from cable ties.

3. You may nd it easier to access the mounting

screws with the scrub deck removed, as described

earlier in this chapter.

4. Remove the scrub brushes.

5. Using a 1/4" hex key, remove the bolt (25) that secures the brush holder (26) to the gearbox shaft. Take care not to lose the shaft key.

Scrub System, Disc 65Service Manual – Warrior ST, AXP, EcoFlex

6. Using a 9/16" wrench, remove the four bolts (27) and washers (28) that secure the motor/gearbox

to the scrub deck, and remove the motor.

28 27

Special Tools

The Actuator Power Cord Adapter (1) (PN 56407502) is used to manually control the brush lift actuator.

Motor

Battery

Negative

Battery

Positive

For/Rev

Switch

Solution System

Functional Description

Detergent

Option

Solution System, 66Service Manual – Warrior ST, AXP, EcoFlex

Solution Out

To Scrub Deck

Detergent Tank

Non-detergent

Chemical

Pump

Solution Out

To Scrub Deck

Solution Solenoid

Shutoff Valve

Solution Pump

The Warrior machine has a 30-gallon (114 liter) solution tank incorporated into the main body of the machine. A clear tube on the right side of the machine below the ll cap serves as a water level indicator for the tank. At the outlet of the solution tank, under the machine, is a manual shutoff valve followed by a serviceable solution lter that prevents debris from entering the rest of the solution system.

Solution Filter

Solution Solenoid

Solution Filter

Option

Shutoff Valve

Water Level

Sight Tube

Non-detergent Models

Machines that do not have detergent mixing (Warrior ST Model) use a gravity-fed solution system to the scrub deck. A solution solenoid, located downstream from the solution lter, activates to allow solution to ow to the scrub deck. To prevent pooling of excess water on the oor when the machine is stationary, the solenoid

output from the controller is disabled when the wheel drive is

not active (via pin 6 from the Curtis Controller). The rate of solution ow is controlled by cycling the solution solenoid on and off at varying duty cycles with a 6-second cycle period.

Detergent Models

Machines that have on-board detergent mixing (AXP and EcoFlex Models) use a pump driven solution system to the scrub deck. The solution pump’s 3 speeds are controlled by Pulse Width Modulation (PWM) from the Warrior controller. Positive power is always present at the solution pump terminal, and the Warrior controller switches the battery negative power at 3 varying duty cycles (13%, 38%, 59%) at a cycle rate of 5kHz.

Solution

Indicator

One Bar 0.3 gpm 2 sec 4 sec

Two Bars 0.6 gpm 4 sec 2 sec

Three Bars 0.9 gpm 6 sec 0 sec

Flow Rate Solenoid

On-Time

Solenoid

Off-Time

Solution System, 67Service Manual – Warrior ST, AXP, EcoFlex

Downstream from the solution pump is the chemical (detergent) injection system. The detergent is stored in the removable detergent tank, which has a suction hose from the chemical pump. The chemical pump draws the liquid from the detergent tank and injects it into the solution line between the solution pump and the solution solenoid. The ow rate of the detergent is controlled by the Warrior controller using PWM.

Downstream from the chemical injection system is the solution solenoid. Unlike the non-detergent system, this solenoid does not need to meter the solution ow rate, and is operated in a simple On/Off manner. The solution then passes on to the solution deck for application.

Extended Scrub Models

Extended scrub was an option that was available on early models. It increases the operation time of the machine by recycling a portion of the spent solution that has been recovered from the oor. Two additional oat sensors are added to the recovery tank. The Start switch (G) is active when there is sufcient solution in the recovery tank to operate extended scrub. The Stop switch (F) turns off extended scrub when there is insufcient solution in the tank to operate. The previously used solution is drawn through a lter (E) and into the Extended Scrub Pump (J). The ow rate is metered at the pump by PWM control. A solenoid valve (N) turns the solution on and off. The recycled solution is mixed with the fresh solution before passing on to the scrub deck.

A Solution Tank B Shut Off Valve C Inline Solution Filter D Recovery Tank E Extended Scrub Filter F Extended Scrub Stop Switch G Extended Scrub Start Switch H Vacuum Shut Off Switch J Extended Scrub Pump K Solution Pump L Chemical Injection Line M Solution Solenoid N Extended Scrub Solenoid

Solution System, 68Service Manual – Warrior ST, AXP, EcoFlex

Circuit Overview

Solenoid Valve Circuit

The positive terminal (brown wire) of the solution solenoid receives unswitched +36V battery power through the 5 amp circuit breaker (F2). The negative terminal (red/green wire) of the solution solenoid is connected to the Warrior controller at J1-11. The solenoid is active when the controller forces the J1-11 terminal to GND.

The solenoid output (J1-11) is inhibited unless the Warrior controller (A1) receives a GND signal on the Forward/Reverse (J1-5) terminal from the Curtis Drive Controller. This prevents solution from owing

when the machine is not in motion.

Solution Pump Circuit

The positive terminal (red wire) of the solution pump receives unswitched +36V battery power through the 5 amp circuit breaker (F2). The negative terminal (green/black wire) of the solution pump is connected to the Warrior controller at J1-8. The solution pump is active when the controller forces the J1-8 terminal to GND.

The solution pump output (J1-8) is inhibited unless the Warrior controller (A1) receives a GND signal on the Forward/Reverse (J1-5) terminal from the Curtis Drive Controller. This prevents solution from owing

when the machine is not in motion.

The solution pump also contains an over-pressure cutout switch (S1) that is integral to the pump. This switch opens during an over-pressure condition, and self-resets when the over-pressure condition is removed.

Detergent (Chemical) Pump

The positive terminal (red wire) of the detergent (chemical) pump receives unswitched +36V battery power through the 5 amp circuit breaker (F2). The negative terminal (yellow/violet wire) of the detergent pump is connected to the Warrior controller at J2-11. The detergent pump is active when the controller forces the J2-11 terminal to GND.

The detergent pump output (J2-11) is inhibited unless the Warrior controller (A1) receives a GND signal on the Forward/Reverse (J1-5) terminal from the Curtis Drive Controller. This prevents detergent/solution from owing when the machine is not in motion. The ow rate of the detergent pump is controlled by PWM at varying rates depending on the desired mixing ratio.

Solution System Schematic

Solution System, 69Service Manual – Warrior ST, AXP, EcoFlex

Troubleshooting

Solution System, 70Service Manual – Warrior ST, AXP, EcoFlex

While in the Service Test Mode, activate the Solution button.

No Flow

Are other system functions affected? Check for Recovery Vacuum function.

Vacuum OK

Remove the solution hose from the solution solenoid valve outlet. Activate the Solution button.

No Flow

Remove the solution hose from the solution solenoid valve inlet. Activate the Solution button.

Flow

No Vacuum

Flow

Exit Service mode. If solution doesn’t flow in normal operation, the Curtis drive controller is likely not communicating with the Warrior controller. Check the voltage on For/Rev (J1-5) terminal.

• 36V = Neutral, 0V = Transport

Check the B-2 Ground Bus on the Warrior controller. Voltage from J2-9 to Battery positive = 36V

Inspect and clean the solution tubing to the scrub deck

With the solution system active, check the solenoid terminals for 36 volts.

Yes

Yes No

Yes

Replace the solenoid Replace the Warrior controller

Replace the Curtis drive controller

Replace the Warrior

drive controller

Repair the J2-9 ground wire

Replace the Warrior drive controller

No Flow

Remove the wire terminal cover from the solution pump, and with the solution system active, check for voltage between the two terminals of at least 5 to 20 volts.

Voltage

No Voltage

Replace the Pump

Replace the Warrior controller

Solution Pump Terminals

Screw

Solution

Pump

Terminal Cover

Removal and Installation

Solution Pump

1. Turn off the key and disconnect the battery.

2. Free up the wire bundle from around the

solution pump and disconnect the pump’s power

connector.

3. Loosen the two hose clamps (4) that secure the infeed (5) and outfeed (6) hoses to the solution pump, and remove the hoses.

4. Remove the three screws (2) and washers (3) that secure the solution pump to the machine frame, and remove the pump.

Solution System, 71Service Manual – Warrior ST, AXP, EcoFlex

Wire Bundle

3 2

Squeegee System

Squeegee System 72Service Manual – Warrior ST, AXP, EcoFlex

Functional Description

The squeegee tool collects wastewater from the oor for

the recovery system to lift the

water into the recovery tank. The oor squeegee is wider than the swath of the scrub deck to ensure

collection of all wastewater from the perimeter of the scrubbing

area. The squeegee also pivots to

the side to permit operation near

walls and to keep the squeegee

within the scrubbing path while turning the machine.

Squeegee

The squeegee tool has a front and rear squeegee

blade, creating a vacuum area in between where

water can be drawn up from the fast moving airow. The squeegee tool attaches to the lift/pivot assembly with two knobs.

Squeegee Pivot

Squeegee Lift

Squeegee

Suction Hose

Squeegee

Lift Lever

Squeegee

Tilt Knob

Squeegee Lift/Pivot

Because the squeegee is curved, it is important for it to remain parallel to the oor as it moves up and down. This is accomplished with a 4-link parallelogram linkage system. To adjust the squeegee to be parallel to the oor, the tilt knob changes the pitch of the forward 4-link mounting plate, which also translates to the squeegee’s pitch.

Because the squeegee is wider than the machine, and to keep the squeegee positioned within the wetted area during turning, the squeegee pivots about a vertical axis. .Because this pivot point is approximately 14 inches away from the squeegee, it allows the squeegee to rotate to the side without striking the wheels or

appreciably increasing the swath on the pivoted side.

Lift Linkage

Squeegee Blades

Tension Straps

Maintenance and Adjustment

Squeegee Blade Cleaning and Inspection

Periodically clean and inspect the squeegee tool (4)

and blades (5&6). Remove the squeegee tool from the pivot/lift assembly (2) by removing the suction hose (1) and loosening the two thumb nuts (3).

Clean the squeegee blades (5&6) and suction area with soap and water.

Inspect the squeegee blades for nicks, tears, and worn leading edges. If a squeegee blade is worn or

damaged, it may be turned around with a fresh edge facing down/forward up to four times before complete

replacement is required.

When reinstalling the squeegee tool (4) to the pivot/

lift assembly (2), tighten the two thumb nuts (3) only hand tight.

Squeegee System 73Service Manual – Warrior ST, AXP, EcoFlex

Squeegee Trim Adjustment

The squeegee trim needs to be checked or adjusted whenever the squeegee blades are replaced, or if the squeegee is not fully wiping the oor. Misadjustment symptoms include water streaks at the center or edges of the squeegee path.

1. Park the machine on a at, even surface.

2. Gradually lower the squeegee tool until the blade

is barely making contact with the oor surface,

and inspect for gaps at either the center or edges.

3. Tighten (clockwise) or loosen (counterclockwise)

the squeegee trim adjustment knob (12) to level the squeegee across its length.

• If there is a gap in the center, loosen the adjustment knob.

• If there are gaps at the outside, tighten the adjustment knob.

Knob T oo

Tight

Gap

Knob T oo

Loose

Gap

Squeegee Lift Adjustment

The squeegee tool’s storage and operation positions are adjustable. In the operation (down) position the lifting cable should be slacked, yet still have sufcient travel to lift the squeegee too off the oor when not in

use.

1. Lower the squeegee tool to the oor.

2. Remove the cable mount (13) and reposition the cable in one of the 3 mounting holes to raise or lower the position as needed.

Removal and Installation

Rear Squeegee Blade Reversal or Replacement

Squeegee System 74Service Manual – Warrior ST, AXP, EcoFlex

Cable

Positions

1. Raise the squeegee off the oor and release the squeegee center latch (7) by pulling back on the latch handle and freeing the latch hook from the tension strap (8).

2. Remove the two tension straps from the end hooks, and remove the squeegee blade (5).

3. The squeegee blade has 4 working edges. Turn the blade so a clean, undamaged edge points toward the

front of the machine. Replace the blade if all 4 edges are nicked, torn or worn to a large radius.

4. Reinstall the squeegee blade and tension straps,

and tighten the center latch.

5. After installing the squeegee blade, check the Squeegee Tilt and Height Adjustments described

in this section.

Alignment Pins

End Hooks

Latch Hook

Latch Handle

Front Squeegee Blade Reversal or Replacement

Squeegee System 75Service Manual – Warrior ST, AXP, EcoFlex

1. Raise the squeegee off the oor and remove the squeegee tool (4) from the pivot/lift assembly (2)

by removing the suction hose (1) and loosening the two thumb nuts (3).

2. It is necessary to remove the rear tension straps (8) in order to remove the front tension strap (9)

because the end hooks are connected together. Release the squeegee center latch (7) by pulling back on the latch handle and freeing the latch hook from the tension strap (8), and remove the

two rear tension straps (8) from the end hooks of the front tension strap (9).

3. Remove the 8 wing nuts that secure the front tension strap (8), and remove the strap and front

squeegee blade (10).

4. The squeegee blade has 4 working edges. Turn the

blade so a clean, undamaged edge points toward the

front of the machine. Replace the blade if all 4 edges are nicked, torn or worn to a large radius.

5. Reinstall the squeegee blade, front tension strap, and

wing nuts.

Latch Hook

Latch Handle

6. Reinstall the rear tension strap.

7. After installing the squeegee blade, check the Squeegee Tilt and Height Adjustments described in

this section.

End Hooks

Alignment Pins

Wheel System, Non-Traction

Functional Description

The Warrior machine is propelled by the

drive wheels. The rear caster wheels add stability and ease of turning.

Removal and Installation

Warning: Never work under machine without safety stands or

blocking to support the machine.

Wheel System, Non-Traction 76Service Manual – Warrior ST, AXP, EcoFlex

Caster Wheels

1. To reduce the weight of the machine, drain both

the recovery and solution tanks.

2. Block both sides of the machine at the rear lifting points (1) near the casters to keep the machine stable and prevent it from rolling.

3. Remove the four bolts (3) and nuts (4) that secure the caster to the frame, and remove the caster.

Wheel System, Traction

Functional Description

The Warrior machine is driven by an electrically powered transaxle. A 1/2 hp, permanent magnet, 36V motor drives the transaxle. A Curtis PMC solid state speed controller (A2) regulates the speed and

direction of the wheel drive motor. The motor speed controller is located in the electrical compartment of the rear handle

(operator controls) housing. There are

two potentiometers that control the speed parameters of the drive controller. The

rst potentiometer (R1), controls both the speed setting of the machine (throttle) and

direction, as the operator pushes or pulls the control paddle. This potentiometer is located inside the paddle assembly. The

second potentiometer (R2) controls the maximum speed setting (speed limit). This

potentiometer is located on the front of the operator controls and is set by the operator.

Wheel System, Traction 77Service Manual – Warrior ST, AXP, EcoFlex

Control Paddle

Drive Controller

Motor and

Transaxle

Drive System

Throttle Position Potentiometer

The throttle position potentiometer (R1 pot) is a variable resistor connected to the Pin-4 input of the speed controller. As the resistance changes,

the speed controller increases or decreases

drive motor speed. (See Speed Controller Potentiometer Function below for additional description.)

The body of the potentiometer is mounted to

a xed bracket on the frame supporting the operator controls. When the operator moves the control paddle, it rotates a link arm connected to

the potentiometer, changing the resistance.

Neutral Plunger

R2 Pot

R1 Pot

Throttle

Position Link

Speed Limiting Potentiometer

The speed limiting potentiometer (R2 pot) is a variable resistor connected to the pin-18 input of the speed

controller. This pot sets the upper speed limit of the controller so the operator can press the paddle at full

deection but limit the machine speed to the desired speed for the task, such as scrubbing versus transport

speeds..

Wheel System, Traction 78Service Manual – Warrior ST, AXP, EcoFlex

Drive Motor System Function

1-Cycle

(15kHz)

The drive motor is controlled from a Curtis PMC 1228 controller, which is a pulse-width-modulation speed controller designed specically for permanent magnet DC motors. Pulse-width-modulation (PWM) is a form

25% PWM Duty Cycle

of motor speed control that alters the power to a motor by rapidly turning

the power on and off. The ratio (also called “duty cycle”) between the

On and Off states determines how much power the motor receives. The

50% PWM Duty Cycle

shorter the “off-time” the closer to full power the motor will receive. This switching occurs so fast (15kHz for this controller) that the motor simply sees it as a reduction in power (voltage) instead of the rapid on/off. PWM

75% PWM Duty Cycle

is a standard motor control technique because it is easier to turn power

all the way on and all the way off, than it is to vary the magnitude of the

power. Varying the magnitude would create a lot of heat that would need

100% PWM Duty Cycle

to be dissipated.

Drive power (B+, B-) is always present at the speed controller (A2) from the battery, but the positive battery input (B+) is fused through the circuit breaker (F3) at 30 amps. When the key switch (S3) is closed, 36V

control power is provided to the speed controller via the Brown wire (Pin 5-KSI).

The two potentiometers (R1 and R2) control the internal “clock” of the controller, which determines the PWM duty cycle described above and also the polarity to the motor outputs (M1 and M2). (Refer to the discussion and diagram on the following page for further information).

When the drive is active (either forward or reverse) the Curtis controller pulls the “Brake” output (Forward/ Reverse at the Warrior controller) to GND. To signify the direction of travel, the “Reverse” output is at GND for reverse, and at +Battery when either moving forward or in neutral.

RED

CIRCUIT BREAKER, 5AMP

RED

CIRCUIT BREAKER, 30AMP

1 2

(OPTIONAL)

EM BRAKE

36V ONLY

1 2

SPEED CONTROLLER

(1228 FOR 36V)

BRN/BLK

YEL/RED

BRN

1 2

FUSE,150A.

SW, SPST KEY

WHT/YEL

RED

Brake & Rev. Truth Table

BRN

RED/BLK YEL/BLU

BLK

B+ B-

PIN 14 - BRAKE (+)

PIN 9-STATUS

PIN 6-BRAKE(-)

PIN 16-REV

PIN 5-KSI

PIN 13-POT. LO

PIN 4-POT. WIPER

PIN 3-POT. HI

PIN 18-SPEED LIMIT POT

Forward

Neutral

Reverse

Brake Rev.

0 1 0

BRN

WHT BLU BLK BRN

BT1

+ -

BATTERY

1 1 0

ORN/BLU RED/BLK BLU/BLK

BLK

A1 Control Board

STATUS

FOR/REV.

J1-5

WHT

BLK

J1-6

J1-4

BLU

REVERSE

POT. 5K OHM

THROTTLE

WHT

MOTOR, WHEEL DRIVE

BRN

POT. 100K OHM SPEED LIMIT

BLK

Wheel System, Traction 79Service Manual – Warrior ST, AXP, EcoFlex

Speed Control Potentiometer Function

The two potentiometers on the operator control paddle are set up in a voltage-division scheme across the Pot-Low (0V) and Pot-High (5V) outputs of the speed controller. As the potentiometer wiper moves through its resistance range, the wiper voltage varies from 0V to 5V. This wiper signal is returned to the speed controller for Throttle and Speed Limit control. (The actual voltages will be slightly less than 5.0 Volts.)

When the throttle potentiometer is in the center position, the wiper voltage is 2.5 volts. The speed controller interprets this voltage as neutral (midway between 0 and 5 volts) and the output to the motor will be zero. Forward or Reverse movement of the drive paddle rotates the potentiometer shaft and the wiper voltage is

increased for forward travel, or decreased for reverse travel. The magnitude of the voltage difference away from the neutral point also determines the speed that the motor will be driven.

The speed limit potentiometer operates in a similar manner

except there is no signicance of

seulaV egatloV 1R seulaV egatloV 2R

esreveR

V5.2 – 0 deepS muminiM = V0

V5 – V5.2 deepS mumixaM = V5

drawroF

R1 Throttle

5K Ohms

the middle/neutral position. The speed limit potentiometer scales the machine throttle across the full range of throttle positions to

limit the upper speed. When the potentiometer is in its maximum position (clockwise rotation), the wiper voltage will be 5 volts, and the speed range will be maximum. In the full counterclockwise

A1 Speed Control

Pin Connection

WHT

BLU

BLK

R2 Speed Limit

WHT

100K Ohms

position, the wiper voltage will be 0 volts, and the speed range will be at minimum.

WHT

BRN

Speed Controller J10 Pinout Functions

Pin# Wire Color Controller Description & Function

1 - Open not used 2 - Open not used 3 Black Throttle Pot R1 pot high input 4 Blue Throttle Pot R1 pot wiper input 5 Brown KSI (key switch input): Battery (+) powers up controller logic circuits 6 Red/Blk Auxiliary Driver: Battery (-) output to main controller (E1) to turn on all auto scrub functions 7 - Open not used 8 - Open not used 9 Orn/Blu Status Fault: Speed controller output to main control panel indicator light (accessory wand)

10 - Open not used

11 - Open not used 12 - Open not used 13 White Throttle Pot R1 pot low input 14 Yel/Blu Drive wheel brake release: Battery (+) output to the parking brake (optional) 15 - Open not used 16 Blu/Blk Rev/Alarm Driver output Battery (-) command turns off solution Valve. 17 - Open not used 18 Brown Speed limit pot input connection.

BLK

Troubleshooting

Problem Cause Correction

Wheel drive motor will not

run in either forward or

reverse.

Wheel drive motor will run in only one direction but not the other

Display LED panel shows

an error 03 fault code.

Wheel drive motor circuit

breaker (F3) tripped

Control circuit circuit

breaker (F2) tripped ()

Defective wheel drive

motor

Throttle potentiometer (R1) problem

Drive controller problem

Throttle potentiometer (R1) problem

Drive controller problem

• Reset the 30A circuit breaker

• Reset the 5A circuit breaker

• Check motor connections

• Inspect motor brushes

• Replace motor

• Make sure the paddle is in the neutral position and

cycle the keyswitch

• Inspect the potentiometer wires and mechanical linkage

• Check the potentiometer neutral adjustment

• Check the Status LED for a fault code and refer to

the Drive Controller Troubleshooting below

• Inspect the potentiometer wires and mechanical linkage

• Make sure the linkage clamping screw (21) is tight

• Controller can’t change electrical polarity to wheel

motor. Replace the speed control (A1).

• Refer to the Drive Controller Troubleshooting below

Wheel System, Traction 80Service Manual – Warrior ST, AXP, EcoFlex

Drive Controller (Curtis 1228)

The Warrior machine controller (A1) communicates with the Curtis drive controller (A2) through the Brake (For/Rev), Status, and

Reverse outputs of the Curtis controller. The Warrior controller

interprets these signals and passes them on to the operator through the display interface.

When the Curtis controller presents an error to the Warrior controller, the display will indicate an “E03” error designated as a

drive controller error. On a standard display, the single character display (44) will ash out E...0...3 to indicate a drive controller error. On an advanced display, the error symbol (43) (wrench) will be

succeeded by “03” to indicate a drive controller error.

When an error is present, the Status LED (42) will ash out the 2-digit code for the specic type of error. The LED will ash a number of times representing the rst digit, then a short pause before ashing

a number of times representing the second digit, and then a longer

pause before repeating the sequence.

This ash code is generated by the Curtis Controller (pin-9), and is passed directly to the Status LED (42)

when an error is present. There may be multiple faults, but only one fault is indicated at a time.

Ø.4

Status Led Fault Codes

Code Explanation Possible Cause

1,1 Over/under-temperature

cutback

• Temperature >92°C or < -25°C

• Excessive load on vehicle

• Operation in extreme environments

• Electromagnetic brake not releasing

1,2 Throttle fault

• Throttle input wire open or shorted

• Throttle pot defective

• Wrong throttle type selected

1,3 Speed limit pot fault

• Speed limit pot wire(s) broken or shorted

• Broken speed limit pot

1,4 Battery voltage too low

• Battery voltage <17 volts

• Bad connection at battery or controller

1,5 Battery voltage too high

• Battery voltage >48 volts

• Vehicle operating with charger attached

• Intermittent battery connection

2,1 Main contactor driver Off fault 2,3 Main contactor fault

• Main contactor driver failed open

• Main contactor welded or stuck open

• Main contactor driver fault

• Brake coil resistance too high

2,4 Main contactor driver On fault 3,1 Fault present for >10 sec.

• Main contactor driver failed closed

• Misadjusted throttle

• Broken throttle pot or throttle mechanism

• The keyswitch must be cycled before this fault can clear

3,2 Brake On fault

• Electromagnetic brake driver shorted

• Electromagnetic brake coil open

3,3 Precharge fault

• Low battery voltage

• Throttle engaged when KSI (keyswitch input) turned on

3,4 Brake Off fault

• Electromagnetic brake driver open

• Electromagnetic brake coil shorted

3,5 HPD (High Pedal Disable)

fault

4,1 Current sense fault

• Improper sequence of throttle and KSI (keyswitch input)

• Misadjusted throttle pot

• Short in motor or in motor wiring

• Controller failure

• The keyswitch must be cycled before this fault can clear

4,2 Motor voltage fault (hardware

failsafe)

• Motor voltage does not correspond to throttle request

• Short in motor or in motor wiring

• Controller failure

• The keyswitch must be cycled before this fault can clear

4,3 EEPROM fault

• EEPROM failure or fault

• The keyswitch must be cycled before this fault can clear

4,4 Power section fault

• EEPROM failure or fault

• Short in motor or in motor wiring

• Controller failure

• The keyswitch must be cycled before this fault can clear

Wheel System, Traction 81Service Manual – Warrior ST, AXP, EcoFlex

Wheel System, Traction 82Service Manual – Warrior ST, AXP, EcoFlex

Throttle Potentiometer Testing and Adjustment

The drive motor speed controller has several safety protocols to prevent unwanted drive operation in the event of faulty input signals from the throttle potentiometer (16). If the total resistance of the throttle potentiometer is out of range, the drive controller will fault. If the potentiometer is not at a midpoint

resistance when the drive paddle is in the neutral position, when the key switch is turned on, the controller

will fault. These conditions can be tested with an ohmmeter.

Note: Use this procedure for ne tuning the position of the potentiometer without disconnecting the wires.

Refer to the replacement procedure later in this chapter for the coarse adjustment procedure that is

used when removing or replacing the potentiometer.

1. Turn off the key while disassembling the paddle to avoid unexpected machine movement.

2. Turn the speed limit potentiometer to its lowest

setting. (Part of this procedure is completed with the key turned on, and the machine may move unexpectedly.)

3. Remove the four screws (12) that secure the paddle front cover (14) to the paddle back housing (13), and remove the front cover. Be careful with the wires to the speed limit potentiometer.

4. Using a small instrument screwdriver, gently pry the three wire terminals (17, 18, 19) slightly off the potentiometer (16) to expose enough of the potentiometer posts to connect a volt meter.

5. Turn the key on. Make sure there is ample room

in front of and behind the machine in case it

moves unexpectedly.

Note: Take care when using the voltmeter on active

circuits. However, accidently shorting the potentiometer terminals with the voltmeter will not damage the drive controller.

6. Using a voltmeter, measure the total voltage across the potentiometer at the outside pins (17

& 19). This voltage should be approximately 5

volts, but will vary from controller to controller.

7. Divide this voltage reading by 2. This is the target voltage that you will adjust the potentiometer wiper

voltage to achieve.

8. With The drive paddle in the neutral position, measure the voltage from the center wiper terminal (18) to either of the outside terminals (17 or 19). This voltage should be 1/2 the voltage you recorded between terminals 17 and 19. (Alternatively, the voltage between 17 and 18 should be equal to the voltage between 18 and 19.)

Slight Gap

9. To adjust the potentiometer, loosen the clamping screw (21) and turn the potentiometer shaft (20) with a small screwdriver. Hint: turn the potentiometer shaft toward the terminal (17 or 19) that had the highest voltage.

10. Verify that the voltage readings are centered (equal) within 0.1 volts or less, and reassemble the

machine. (The actual Neutral Deadband range is ±0.35 Volts, but your adjustment should be as close to center as possible.)

Removal and Installation

Throttle Potentiometer

1. Turn the key switch to the off position.

2. Remove the four screws (12) that secure the paddle front cover (14) to the paddle back housing (13), and remove the front cover. Be careful with the wires to the speed limit potentiometer.

3. Disconnect the 3 wires from the speed limit potentiometer (15), and set the paddle front cover (14) aside.

• Hint: Use a small instrument screwdriver to

gently pry the three wire terminals off the potentiometer.

• Make note of the wire colors for replacement.

Wheel System, Traction 83Service Manual – Warrior ST, AXP, EcoFlex

White

Brown

Black

4. Remove the two screws (26) and washers (27) that secure the cam controller (25) to the paddle

back cover, and remove the cam controller.

5. Loosen the clamping screw (21) that secures the potentiometer fork (24) to the potentiometer’s shaft, and slide the fork off the shaft.

6. Disconnect the three wires from the throttle potentiometer (16).

• Hint: Use a small instrument screwdriver to

gently pry the three wire terminals off the potentiometer.

• Make note of the wire colors for replacement.

7. Remove the nut (22) and lockwasher (23) that

secure the potentiometer to the handlebar frame, and remove the potentiometer.

White

Blue

Black

2627

Wheel System, Traction 84Service Manual – Warrior ST, AXP, EcoFlex

Before installing the potentiometer, it is necessary to locate the shaft midpoint position, where the resistance between the wiper and outer

terminals is equal. This coarse adjustment makes it easier to set the

neutral point of the drive controller later.

8. Using an ohmmeter, measure the resistance between the outer terminals (28 & 30). This is the total resistance of the

potentiometer. This value must be between 4.5 kΩ and 7.0 kΩ.

If the total resistance is outside of these bounds, then replace the potentiometer.

9. Divide the total resistance of the potentiometer by 2. This value

is used to set the midpoint position of the potentiometer.

10. Rotate the potentiometer shaft (31) until the resistance between the center terminal (29) and either (both) of the outer terminals

(28 & 30) equals the total resistance divided by 2 from above. Mark this position of the shaft for reference.

11. With the potentiometer in its midpoint position, reassemble the control paddle. If desired, re-conrm the midpoint position with an ohmmeter before connecting the wires to the potentiometer (you cannot check resistance after the wires are connected).

12. Before reinstalling the paddle front cover (14), perform the nal adjustment procedure (or conrmation) described previously in this chapter.

Wheel System, Traction 85Service Manual – Warrior ST, AXP, EcoFlex

Drive Controller

Warning: Disconnect the battery connector before servicing

machine.

Note: Drive controllers are factory pre-programmed for the Warrior machine. Use only factory authorized

replacement controllers.

1. Turn off the key and disconnect the main battery connector.

2. Free the drive paddle control wire from the wire clamp (37) on the front of the electrical cover (32).

3. Remove the four screws (34) and washers (33) that secure the electrical cover to the solution

tank, and remove the cover.

4. Remove the four screws (36) that secure the

control panel (35) to the solution tank, and gently move the control panel to the side.

5. Disconnect the controls cable connector

(39) from the J10 connector on the drive controller (38).

6. Remove the four power/motor wires (40) from the drive controller terminals. Note the color coding for later replacement.

7. Remove the two screws (41) that secure the drive controller (38) to the electrical panel, and remove the drive controller.

N/C Brn/Blk Yel/Red N/C

Black Wht/Yel

Wheel System, Traction 86Service Manual – Warrior ST, AXP, EcoFlex

Follow-up Testing

After replacing the drive controller, perform this follow-up testing procedure to ensure safe operation of the

controller.

1. Before reconnecting the battery, either block the wheels off the ground or move the machine to an open area without obstructions.

2. Reconnect the battery connector and turn on the key switch.

3. Check the display for a drive controller error.

• Machines with the advanced display will show the wrench symbol and code “03” (43). Machines with a standard display will ash out the code E_0_3 on the status display (44).

4. If a drive controller error exists, the accessory wand indicator LED (42) will ash out the specic error code. Refer to the Status LED Fault Code Table in the Troubleshooting section of this chapter for

interpretation of the fault code.

5. If no drive controller error is present, then operate the machine to test for proper function.

a. With the speed limit potentiometer set to its lowest setting,

operate the paddle in the forward and reverse directions, and make sure the machine accelerates, decelerates, and stops as expected. Make sure the speed for the minimum setting is acceptable.

Ø.4

b. With the speed limit potentiometer set to its highest setting, operate the paddle in the forward and

reverse directions, and make sure the machine accelerates, decelerates, and stops as expected. Make sure the speed for the maximum setting is acceptable.

c. With the paddle in the forward direction and the speed limit potentiometer at its lowest setting,

ramp the speed limit potentiometer to its maximum setting and return to its minimum setting. Make

sure the machine accelerates smoothly through its entire range. Repeat this for the reverse direction.

Wheels

Warning: Disconnect the battery connector before servicing

machine.

Warning: Never work under machine without safety stands or

blocking to support the machine.

1. Turn off the key and disconnect the batteries.

2. To reduce the weight of the machine, drain both the

recovery and solution tanks.

3. Block both sides of the machine at the rear lifting points (1) near the casters to keep the machine stable and

prevent it from rolling.

Wheel System, Traction 87Service Manual – Warrior ST, AXP, EcoFlex

4. Raise the front of the machine by jacking at the center

front lifting point (2).

5. Remove the three lug nuts (3) that secure the wheel (4) to the transaxle, and remove the wheel..

Drive Motor and Transaxle

Warning: Disconnect the battery connector before servicing

machine.

Warning: Never work under machine without safety stands or

blocking to support the machine.

Wheel System, Traction 88Service Manual – Warrior ST, AXP, EcoFlex

1. Turn off the key and disconnect the batteries.

2. To reduce the weight of the machine, drain both

the recovery and solution tanks.

3. Block both sides of the machine at the rear lifting points (1) near the casters to keep the machine stable and prevent it from rolling.

4. Depending on the height that you are able to

raise the machine, you may wish to remove the

scrub deck for easier access to the transaxle

components. Refer to the procedure in the scrub system chapter of this manual.

5. Raise the front of the machine by jacking at the

center front lifting point (2).

6. Remove the six lug nuts (3) and both wheels (4)

from the axle.

7. Disconnect the motor connector (10) from the main wiring harness.

8. Remove the ground wire (11) from the transaxle housing.

Note: During reassembly, make sure all wires

are secured and not dragging below the machine.

Wheel System, Traction 89Service Manual – Warrior ST, AXP, EcoFlex

9. Support the transaxle from below so it does not

fall when the mounting bolts are removed.

10. Remove the two bolts (6), nuts (8), and retaining plate (7) that secure each side of the transaxle at the urethane vibration mounts (9).

11. Carefully lower the transaxle to the oor and then slide it out from under the machine.

Special Tools

Curtis 1311 Programmer

The Curtis 1311 Programmer (or the 1307 predecessor) may be

used to display drive controller error codes and program the drive

controller. With a programmer, diagnostics and troubleshooting is more direct than with the Warrior display alone. The programmer

presents complete diagnostic information in plain language

without codes to decipher. Faults are displayed in the Diagnostic

Menu, and the status of the controller inputs/outputs is displayed in the Test Menu.

The handheld programmer can also be used to access the drive

controller’s diagnostic history le. This le contains the history

of cleared error codes, which may be helpful in determining the functional status of the machine between service intervals.

Refer to the Curtis 1311 Programmer manual for further

information regarding the use and operation of the handheld programmer.

Wheel System, Traction 90Service Manual – Warrior ST, AXP, EcoFlex

Nilfisk-Advance Warrior ST, Warrior AXP, Warrior EcoFlex Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual