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 Informaon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Service Manual Purpose and Applicaon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Other Reference Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Convenons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Transporng the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cauons and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
General Safety Instrucons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Know Your Machine — Major components: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Specicaons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Lubricang the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Chassis System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Funconal Descripon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Front Nose Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Funconal Descripon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Control Panel Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Scrub Mode Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Baery 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 Detecon On or O: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Low-voltage Cutout Threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Scrub Deck Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Chemical Opon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Extended Scrub Opon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Scrub Deck Down Time Period Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Scrub Deck Pressure, Soluon Flow Rate, and Chemical Flow Rate Adjustments . . . . . . . . . . . . . 24
Restoring the Scrub Pressures to Factory Default Sengs . . . . . . . . . . . . . . . . . . . . . . . 24
Regular Scrub Seng Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Heavy Scrub Seng Adjustment: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Extreme Scrub Seng Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Recovery Tank-Full Switch Orientaon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
LCD Style Selecon (Warrior AXP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Monitor Mode (Warrior AXP/EcoFlex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Chemical User Rao Selecon (Warrior AXP/EcoFlex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Troubleshoong Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Main Controller Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Service Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Test Mode Input Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Page ii
Service Manual – Warrior ST, AXP, EcoFlex
Baery Voltage (AXP/Ecoex Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Speed Controller Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Forward/Reverse Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Reverse Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Test Mode Output Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Descripon of Output Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Sample Voltage Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Funconal Descripon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Descripon Of The Low-Voltage Cutout Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Descripon Of The Baery Condion Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Charging Baeries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Extending Baery Life. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Troubleshoong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Baery Tesng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Removal and Installaon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Baeries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Specicaons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Wet Cell Baery specicaons: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Wet Cell Baery Charger Specicaons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Opons and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Recovery System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Funconal Descripon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Vacuum Motor and Recovery Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Float Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Vacuum Motor Control Circuit Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Troubleshoong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Removal and Installaon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Vacuum Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Float Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Specicaons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Scrub System, Cylindrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Funconal Descripon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Brush Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Brush Li Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Circuit Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Maintenance and Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Li Actuator Limit Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Removal and Installaon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Scrub Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Li Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Brush Motor Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Page iii
Service Manual – Warrior ST, AXP, EcoFlex
Scrub Brush Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Scrub System, Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Funconal Descripon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Brush Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Brush Li Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Circuit Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Maintenance and Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Li Actuator Limit Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Removal and Installaon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Scrub Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Li Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Brush Motor Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Scrub Brush Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Soluon System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Funconal Descripon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Non-detergent Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Detergent Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Extended Scrub Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Circuit Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Solenoid Valve Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Soluon Pump Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Detergent (Chemical) Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Soluon System Schemac. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Troubleshoong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Removal and Installaon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Soluon Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Squeegee System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Funconal Descripon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Squeegee. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Squeegee Li/Pivot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Maintenance and Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Squeegee Blade Cleaning and Inspecon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Squeegee Trim Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Squeegee Li Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Removal and Installaon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Rear Squeegee Blade Reversal or Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Front Squeegee Blade Reversal or Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Wheel System, Non-Tracon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Funconal Descripon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Removal and Installaon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Wheel System, Tracon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Funconal Descripon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Throle Posion Potenometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Speed Liming Potenometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Drive Motor System Funcon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Page iv
Service Manual – Warrior ST, AXP, EcoFlex
Speed Control Potenometer Funcon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Speed Controller J10 Pinout Funcons
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Troubleshoong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Drive Controller (Curs 1228)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Throle Potenometer Tesng and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Removal and Installaon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Throle Potenometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Drive Controller
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Follow-up Tesng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Drive Motor and Transaxle
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Curs 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 Nilsk-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 specication value for 28” Disc. .
6
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.
7
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 specied in the instruction manual.
The use of other brushes may impair safety.
◦ Refer to the battery charger OEM product manual for additional specic battery charger
warnings.
Caution!:
◦ This machine is not approved for use on public paths or roads.
◦ Use care when using abrasive brushes, scarier 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
8
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 conguration 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 relling the solution tank,
by reusing a portion of the recovered solution from the oor surface.
Nameplate
The nameplate contains important
identication 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.
9
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
10
Operator
Controls
Squeegee
Cylindrical
Scrub Deck
Disc Scrub
Deck
Drive
Assembly
Lift/Pivot
Squeegee
Specifications
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)
B=
41.9 in (106 cm)
C=61.5 in (156 cm)
D=45 in (114 cm)
A=31 in (79 cm)
B=
41.9 in (106 cm)
C=62.5 in (159 cm)
D=45 in (114 cm)
A=33.5 in (85cm)
B=
41.9 in (106 cm)
C=61.75 in (157 cm)
D=45 in (114 cm)
A=35 in (89cm)
B=
41.9 in (106 cm)
C=61.75 in (157 cm)
D=45 in (114 cm)
11
CC CC
BAA
D
D
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
12
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
efciency 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.
OK
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
OK
: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
© 2011 Nilfisk-Advance Revised 09/12/11
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.
G
F
J
E
K
D
C
B
15
A
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.
H
G
H
B
E
F
E
I
K
Ø.4
03
K
Ø.4
03
J
D
C
B
J
D
C
F
A
A
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 relling
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.
16
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
17
Scrub ON Indicators (L & M):
• For Regular scrub mode, the (L) LED will be active.
N
M
L
• 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
B
Extreme
Heavy
Regular
K
2
O
Ø.4
03
Solution Scrub
18
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
P
2
R
Ø.4
03
Q
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 specic 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 specic 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 specic 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.
19
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
conguration. 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.
H
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.
E
20
3. Hold both switches until Scrub Off and Wand indicators turn green.
F
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.
E
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 difcult. 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).
21
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 specications. 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 identied 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 congures 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)
N
E D
L
22
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.
N
E D
L
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.
H
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.
N
E D
23
L
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.
G
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
B
D
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
24
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.
N
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.
25
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.
F
D
E
B
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.
H
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:
H
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.
D
C
D
26
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.
E
B
H
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:
D
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.
G
27
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).
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.
D
I
E
B
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.
H
Loading...