Nilfisk-Advance 56381032, X4030D-EcoFlex, 56381037, X4830C-EcoFlex w/Side Broom, 56381033 Service Manual

...

Download

Condor™ EcoFlex™, BR 1100 S/SC EcoFlex™, BR 1300 S/SC EcoFlex

™

Service Manual

Advance Models:

56381032 (X4030D-EcoFlex) 56381037 (X4830C-EcoFlex w/Side Broom)

56381033 (X4030C-EcoFlex w/Side Broom) 56381043 (X4030C-EcoFlex w/o Side Broom)

56381034 (X4530D-EcoFlex) 56381044 (X4530C-EcoFlex w/o Side Broom)

56381035 (X4530C-EcoFlex w/Side Broom) 56381045 (X4830C-EcoFlex w/o Side Broom)

56381036 (X4830D-EcoFlex)

Nilfisk Models:

56413006 (BR1000 S EcoFlex w/o Side Broom) 56413007 (BR1000 S C EcoFlex w/Side Broom)

56413010 (BR1300 S EcoFlex w/o Side Broom) 56413011 (BR1300 S C EcoFlex w/Side Broom)

English

7/11 Form No. 56043154

Contents

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Parts and Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Transporting the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Other Manuals Available for Your Machine . . . . . . . . . . . . . . . . . . . . . . . . . 5

Caution and Warning Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Emergency-stop Switch/Battery Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . 8

Technical Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

General Machine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Chassis System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Major Chassis Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Main Control Programming Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Service Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

I/O Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

™

2Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Low-voltage Cut-out Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Battery Condition Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

Battery Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Options and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Recovery System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

Scrub System, Cylindrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78

Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92

™

Scrub System, Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Solution System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Contents 3Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Squeegee System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 122

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

Specications . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . 129

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Sweep System, Side Broom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

Wheel System, Non-traction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

Wheel System, Traction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

Electrical Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

Ladder Diagram, Rev. G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Wiring Diagram, Rev. I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

Detergent (EcoFlex™) System Plumbing Schematic . . . . . . . . . . . . . . . . . . . . 169

Detergent (EcoFlex™) System Preparation and Purging . . . . . . . . . . . . . . . . . 170

™

General Information

Introduction

This manual will help you get the most from your Advance rider scrubber. Read it thoroughly before servicing the machine.

Parts and Service

Repairs should be performed by your Authorized Advance Service Center, which employs factory-trained service personnel and maintains an inventory of Advance original replacement parts and accessories.

Call the Advance dealer named below for repair parts or service. Please specify the Model and Serial Number when discussing your machine.

4Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

(Dealer, afx service sticker here.)

Nameplate

The Model Number and Serial Number of your machine are shown on the machine nameplate. This information is needed when ordering repair parts for the machine. Use the space below to note the Model Number and Serial Number of your machine for future reference.

Model Number:

Serial Number:

Note that the Nameplate is attached to the rear of the steering column.

Nameplate

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).

• The battery/batteries are disconnected.

Towing

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

in the Off position. Do not move the machine faster than a normal walking pace (2-3 mph, 3-5 kph) and for short distances only.

Note: Disconnecting the wheel drive motor wiring connector will make a disabled machine easier

to push.

™

General Information 5Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Other Manuals Available for Your Machine

Electronic Databases

The manuals listed below can be found on Advance’s electronic supported databases. They are:

• Advance Dealer Customer Zone

• EzParts service / parts CD-ROM

• Nilsk-Advance website: www.nilsk-advance.com

Manuals

• Parts List - Form Number 56042467

• Instructions for Use - Form Number 56041986 (English, Spanish)

• Curtis Programmer Manual Number 56043101

™

General Information 6Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Caution and Warning Symbols

Advance uses the symbols below to signal potentially dangerous conditions. Read this information carefully

and take the necessary steps to protect personnel and property.

Danger! Is used to warn of immediate hazards that will cause severe personal injury or death.

Warning! Is used to call attention to a situation that could cause severe personal injury.

Caution! Is used to call attention to a situation that could cause minor personal injury or

damage to the machine or other property.

Read all instructions before using.

General Safety Instructions

Specic Cautions and Warnings are included to warn you of potential danger of machine damage or bodily

harm.

Warning!

• This machine is to be used only by correctly trained and authorized persons.

• Avoid sudden stops while on ramps or inclines when the tanks are full. Avoid abrupt sharp turns. Use low speed down hills. Clean only while ascending (driving up) the ramp.

• Keep sparks, flame 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 flame. Do not smoke while charging the batteries.

• Remove all jewelry when working near electrical components.

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

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

• Do not dispense flammable cleaning agents, operate the machine on or near these agents, or operate in areas where flammable liquids exist.

• Only use the brushes provided with the machine or those specified in the instruction manual. The use of other brushes may impair safety.

™

General Information 7Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Caution!

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

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

• Do not use scarifier discs and grinding stones. Advance will not be held responsible for any damage to floor surfaces caused by scarifiers or grinding stones. (This can also damage the brush drive system.)

• When operating this machine, ensure that third parties, particularly children, are not endangered.

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

• Do not leave the machine unattended without first turning the key switch off (O), removing the key and applying the parking brake.

• Turn the key switch off (O) and remove the key before changing the brushes, and before opening any access panels.

• Take precautions to prevent hair, jewelry or loose clothing from becoming caught in moving parts.

• 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 fittings. Drain the tanks and purge with windshield washer fluid.

• The batteries must be removed from the machine before the machine is scrapped. The disposal of the batteries should be done safely and in accordance with your local environmental regulations.

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

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

Caution! Do not pressure-wash the operator control panel, circuit breaker panel or any

electrical areas of the machine.

™

Emergency-stop Switch/Battery Disconnect

The Emergency-stop/Battery Disconnect is the red lever located to the right of the Operator’s seat. In the event of an emergency, press the Emergency-

stop/Battery Disconnect

the machine) to disconnect the battery from the machine. This will stop all machine functions.

in (toward the rear of

General Information 8Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Emergency-stop/

Battery Disconnect

Save These Instructions

™

Technical Specifications

General Specifications Common to All Models

Machine Length 73.5 in. [187 cm] Machine Height 58.5 in. [148.6 cm] Machine Height (w/overhead guard 84 in. [213 cm] Machine Body Width 40 in. [101.6 cm] Solution Tank Capacity 70 gal. [265 L.] Recovery Tank Capacity 70 gal. [265 L.] Sound pressure level as per IEC 60704-1 (at operator) 72 dB(A) Vibrations at the Hand Controls (ISO 5349-1) 1.12 m/s Vibrations at the Seat (EN 1032) 0.35 m/s Transport Speed (Fwd. Maximum) 5.5 mph [8.9 kph] Transport Speed (Rev. Maximum) 4.8 mph [7.7 kph] Gradeability (Transport) 14.5% / 8° Gradeability (Working –Scrubbing) 10.5% / 6° Wheel Drive Motor 1.75 HP, 1300 watt Vacuum Motor (3 stage) .75 HP, 560 watt

Vacuum Water Lift for one motor

Vacuum Water Lift for two motors

(Sealed) 68 in. (Open Hole Adapter 1”) 14 in. (Sealed) 74 in.

(Open Hole Adapter 1”) 27 in. Power Source (Batteries) Battery Weight (395 amp) STD (6) 6 volt @ 20 hour rate 121 lbs. [55 kg] Battery Weight (450 amp) Opt. (1) Mono-block @ 20 hour rate 919 lbs. [417 kg] Battery Compartment Size (approximate)

Height (Max.) 19 in. [48.2 cm] Width (Max.) 20 in. [50.8 cm]

Length (Max.) 31.75 in. [80.6 cm] Maximum Wheel Floor Loading (Center Front) 116 psi / 119.9 kg/cm Maximum Wheel Floor Loading (Left Rear) 86 psi / 88.9 kg/cm Maximum Wheel Floor Loading (Right Rear) 81 psi / 83.7 kg/cm

Battery Chargers – see the Electrical System/Specifications section.

General Information 9Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

™

General Information 10Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Specifications Common to Deck Size

Model designations: 40” = Condor 4030 D/C; 45” = Condor 4530 D/C; 48” = Condor 4830 D/C

40” 45” 48”

Machine Width with Squeegee

Scrub Brush Size Brush Diameter - Disc (2) 20 in. [50.8 cm] (3) 16 in. [40.6 cm] (3) 17 in. [43 cm] Outside Scrub Brush Diameter -

Cylindrical (inside core is 5 in.) Scrub Brush Length (two per

machine) Scrub Brush

Motors Scrub Brush

Speed Minimum Aisle Turn Width 84 in. [214 cm] 84 in. [214 cm] 84 in. [214 cm] Machine Net

Weight* Machine Gross

Weight** Cleaning Width

(scrubbing path)

Coverage Rate Per Hour

English 49 in. “F” 54 in. “G” 57 in. “H” Metric 78 cm “F” 87 cm “G” 91 cm “H”

8.5 in. [21.6 cm] 8.5 in. [21.6 cm] 8.5 in. [21.6 cm]

38.37 in. [97.4 cm] 43.62 in. [110.8 cm] 46.62 in. [118.4 cm]

Disc

(1) 3.0 HP

2240 watts

(3) 1.5 HP

1120 watts

(3) 1.5 HP

1120 watts Cylindrical All Cylindrical Models use (2) 1.5 HP 1120 watts Disc 240 RPM 225 RPM 225 RPM Cylindrical 630 RPM 630 RPM 630 RPM

English 1,845 lbs. 1,845 lbs. 1,845 lbs. Metric 837 kg 837 kg 837 kg English 3,545 lbs. 3,545 lbs. 3,545 lbs. Metric 1608 kg 1608 kg 1608 kg English 40 in. 45 in. 48 in. Metric 101 cm 114 cm 122 cm English @ 3.5

mph Metric @ 5.6

kph

61,600 ft

5722 m

69,300 ft

6438 m

73,920 ft

6867 m

*Net Weight: Standard machine without options, empty solution and recovery tanks, without removable

scrub brushes and no batteries installed.

** Gross Weight: Standard machine without options, full solution tank and empty recovery tank, with

removable scrub brushes and 450 AH batteries.

*** Listings for watts are maximum values.

Dimensions

™

General Information 11Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

General Machine Overview

Major Machine Components

Recovery

Tank Lid

Operator’s

Seat

Operator’s

Seat

Adjustment

Lever

™

Solution Tank Fill

Cover

Control

Panel

General Information 12Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Battery

Compartment

(underneath

recovery tank)

Machine

Battery

Connector

Emergencystop Switch/

Battery

Disconnect

Squeegee

Rear

Wheel

Scrub

Deck

Side

Access

Panel

Circuit

Breakers

Steering

Wheel

Tilt/Adjust

Knob

Brake

Pedal/

Parking

Brake

Drive/Steer

Wheel

Drive Pedal,

Direction/

Speed

™

Top

Cover

Assembly

General Information 13Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Recovery

Tank

Shutoff

Valve

Squeegee

Vacuum

Hose

Hopper

(cylindrical

models

only)

Solution

Filter

Solution

Shutoff

Valve

Solution

Tank Drain Hose

Recovery

Tank

Drain Hose

Squeegee

Height

Adjust Knob

Squeegee Tilt

Adjust Knob

Squeegee Assembly

Squeegee

Height

Adjust Knob

™

General Information 14Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Control Panel

Switch and Button Functions

The controls on your rider scrubber were designed with one-touch operation in mind. For single-pass scrubbing, the user can simply depress one switch and all systems on the machine will be ready to go. For most single-pass scrubbing operations, the operator should only need to use the middle switches on the control panel. These are the red Scrub Off and the green Scrub On/Pressure Increase Switches.

Horn

Button

Solution

Switch

Detergent

Switch

EcoFlex™

Button

Scrub

Off

Switch

Control

Panel

Display

Scrub On/

Pressure

Increase

Switch

Vacuum/

Wand

Switch

Side

Broom

On/Down

Switch

Scrub

Speed

Switch

Traction

Control

Switch

Key

Switch

• Key Switch – main power switch; controls the battery input to the machine’s main control board and the wheel drive speed control.

• Scrub On/Pressure Increase Switch – functions as follows:

If the scrub system is off, pressing this switch once will put the machine into the Auto Scrub mode. The following will occur:

– The scrub system will be enabled with the scrub pressure set to the #1 normal setting.

Note: Press the switch twice for #2 heavy scrub setting, and three times for the #3 extreme scrub

setting. Pressing the switch a fourth time will return the system to the normal scrub setting.

– The scrub deck and squeegee will automatically be lowered. On cylindrical models equipped with side

brooms, the side brooms will be lowered.

– The vacuum system will be enabled.

– The solution and detergent systems will be enabled. Note that both the solution and detergent ow

rates will correspond to the selected scrub pressure mode.

– As soon as the drive pedal is moved from its neutral position, the scrub brushes and side brooms (if

installed) will start turning, and the solution, detergent and vacuum systems will switch on.

™

General Information 15Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

◦ If the direction is forward, the solution and detergent ow will also start automatically.

◦ If the direction is reverse, the solution and detergent ow will be stopped and the squeegee will be

raised just enough to clear the oor surface.

Note: The solution, vacuum and detergent systems are automatically enabled when the Scrub On

Switch

is pressed to put the machine into the Auto Scrub mode. Any individual system can be toggled off and on by simply pressing the corresponding system switch at any time during scrubbing.

If the machine is already scrubbing, pressing the Scrub On/Pressure Increase Switch will increase the scrub pressure to the next higher setting (toggling from regular to heavy, heavy to extreme, then back to normal). The Scrub Pressure Indicator will show the selected scrub pressure (one, two or three bars) in the

Control Panel Display.

• Scrub Off Switch – Pressing this switch when the machine is in the scrub mode will cause the following to occur:

– The scrub brushes will turn off and the scrub deck will be raised to the up position. On cylindrical

models equipped with side brooms, the side brooms will shut off and be raised.

– The solution and detergent ow will be stopped.

– Once forward machine motion stops, the vacuum/wand switch indicator light will start to blink. After

a user-programmable time delay, the squeegee will be raised and the vacuum motors will shut off. Pressing the switch a second time before the vacuum time delay is complete will raise the squeegee

and turn off the vacuum motors immediately.

• Solution Switch – functions as follows:

– If the scrub system is off, pressing and holding this switch will switch on the solution ow to pre-

wet the oor. The solution ow will stop when the switch is released. Note this must be done prior to

pressing the Scrub On Switch and putting the machine into the Auto Scrub mode.

– If the machine is in the Auto Scrub mode, pressing this switch will disable the solution system. This is

used if you wish to scrub without adding additional solution to the oor.

– If the machine is in the Auto Scrub mode, you can use the Solution Switch to actuate the solution ow

override function. This override function allows you to select a different solution ow rate without

changing the scrub pressure. Note that the machine is programmed for two additional higher solution

ow rates plus the three normal default ow rates, for a total of ve solution ow rates.

To actuate the solution ow override function, press and hold the Solution Switch for three seconds until the Solution System Indicator ashes, then release it. You’ll have three seconds to select the desired solution ow rate by pressing the Solution Switch. The Solution Flow Indicator will show the selected solution ow rate (one through ve bars) in the Control Panel Display. Note that if any scrub pressure change is made while in the solution override mode, the solution ow will return to its default solution ow rate.

• Detergent Switch – functions as follows:

– If the solution system is enabled, pressing this switch will toggle the detergent system off and on.

When the detergent system is on, the detergent pumps will be activated at a specic rate when the

drive pedal is actuated. The detergent pump will turn off when the drive pedal is in neutral or reverse.

– If the solution system is off, the detergent pump will not turn on.

™

General Information 16Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

• Vacuum/Wand Switch – functions as follows:

– If the machine is in the Auto Scrub mode, pressing this switch once will raise the squeegee. The

vacuum motors will run for a short time delay, then shut off. If you press the switch twice, the vacuum motors will shut off immediately. This is used if you wish to double-scrub (scrub without recovering the solution).

– If the scrub system is off, the Vacuum/Wand Switch functions differently depending on whether the

seat switch is open (no operator in the seat) or closed (operator in the seat).

◦ If the operator is in the seat, pressing the switch will lower the squeegee and switch on the vacuum

motors. When the machine is moved into reverse, the squeegee will be raised, then lowered when the machine is again moved forward. This mode is used to pickup water from the oor without

scrubbing or adding solution.

◦ If the operator is not in the seat, pressing the switch will toggle the vacuum motors on and off

to allow use of the vacuum wand. In this mode, the squeegee will not move up or down and the recovery tank full indicator is ignored.

• Scrub Speed Switch – When the machine is operating in any one of its scrub settings, the machine’s

travel speed is reduced to 80 percent of the maximum transport speed pre-programmed into the speed controller. Pressing the Scrub Speed Switch overrides the 80 percent of transport speed limit and increases the scrub speed to 100 percent of transport speed.

• Traction Control Switch – regulates the drive wheel motor torque to minimize drive wheel slippage and

provide better traction.

• Side Broom On/Down Switch – lowers and raises the side brooms (only functional on cylindrical models equipped with side brooms). Note that when the scrub system is switched on, the side brooms are lowered

to the same position they were in when the scrub system was last turned off (auto memory operating position).

Note: You can raise or lower the side broom height to maintain the correct broom contact patterns

and compensate for normal broom wear. Refer to the Sweep System, Side Broom section for instructions on setting the side broom height.

• EcoFlex

™

Button – The EcoFlex™ Button functions differently depending on whether the EcoFlex

™

mode is

set to Mode 1 or Mode 2. (Also refer to the Control System/Main Programming Options/ EcoFlex™ Mode

Selection section.) Note that in Mode 1 the detergent concentration is displayed as a ratio. In Mode 2 the

detergent concentration is displayed as a percent.

– In EcoFlex™ Mode 1, the detergent ratio is preset to 1:400. Pressing the EcoFlex

™

Button in Mode 1 will

do the following:

◦ The detergent ratio will change to the programmed ratio. (Also refer to the Solution System/

Maintenance and Adjustments/To Program the Detergent Ratio section.)

◦ The scrub pressure will increase to the next highest pressure.

◦ The solution ow rate will increase to the next highest rate.

After 60 seconds, or after you press the EcoFlex and the scrub pressure and solution rate will return to their previous settings.

™

Button again, the detergent ratio will revert to 1:400,

™

General Information 17Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

– In EcoFlex™ Mode 2, the default detergent ratio will be the programmed ratio. Pressing the EcoFlex

Button

in Mode 2 will do the following:

◦ The detergent concentration will change to the next highest (richest) concentration. For example,

if the programmed concentration is 0.4%, pressing the EcoFlex

™

Button will change it to 0.5%. (Also

refer to the Solution System/Maintenance and Adjustments/To Program the Detergent Ratio section.)

◦ The scrub pressure will increase to the next highest pressure.

◦ The solution ow rate will increase to the next highest rate.

After 60 seconds, or after you press the EcoFlex

™

Button again, the detergent ratio will revert to the

programmed ratio, and the scrub pressure and solution rate will return to their previous settings.

• Horn Button – sounds the horn when pressed.

• Control Panel Display – displays the various icons that indicate scrub pressure, solution ow rate, detergent ratio, battery charge state and a recovery tank full condition. The display also shows any error

conditions detected by the main control board.

Control Panel Indicators

™

In general the following guidelines apply to the control panel indicators:

• When the key switch is rst turned on all of the blue control panel indicator lights will turn on for one

second for an operational test.

• A blue indicator means that a system is on and running, or has been enabled and is ready to switch on when the drive pedal is moved into forward or reverse.

• The indicators will be off when the system is disabled or switched off.

• The green EcoFlex

™

Indicator will be on when the system is in the low-concentration mode, and ash when

the 60-second burst of power function is active.

Solution

System

Indicator

Detergent

System

Indicator

Vacuum/

Wand

Indicator

Maximum

Scrub

Speed

Indicator

EcoFlex

Indicator

Scrub Off

Indicator

Scrub On/

Scrub Mode

Select

Indicators

Side

Broom On/Down Indicator

Traction

Control

Indicator

™

General Information 18Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

• Scrub On/Scrub Mode Select Indicator:

– The left side indicator will light when the normal scrub mode is selected.

– The right side indicator will light when the heavy scrub mode is selected.

– Both the right and left indictors will light when the extreme scrub mode is selected.

– Both the right and left indictors will be off when the scrub system is off.

• Scrub Off Indicator:

– The indicator will light to indicate that the scrub system is off and is ready to be activated.

– The indicator will be off when the scrub system is enabled and/or switched on.

• Solution System Indicator:

– The indicator will light when the solution system is enabled and/or is switched on.

– The indicator will be off when the solution system is off.

– The indicator will ash when the solution tank (liquid level) oat switch senses a low solution level.

• Detergent System Indicator:

– The indicator will light when the detergent system is enabled and/or is switched on.

– The indicator will be off when the detergent system is off.

Note: The control board automatically recognizes that the machine has an operational detergent

system through its wiring harness connection.

• Vacuum/Wand Indicator:

– The indicator will light when the vacuum system is enabled and/or is switched on.

– The indicator will be off when the vacuum system is off.

– The indicator will ash when the vacuum system is operating in the time delay shutdown mode

(normally ve to 10 seconds).

• Maximum Scrub Speed Indicator:

– The indicator will light when the maximum 100% transport speed during scrubbing is enabled.

– The indicator will be off when normal scrub speed is enabled.

• Traction Control Indicator:

– The indicator will light when the traction control mode is enabled.

– The indicator will be off when the traction control mode is disabled.

™

General Information 19Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

• Side Broom On/Down Indicator:

– The indicator will be on when the side brooms are in the down working position, enabled and switched

on.

– The indicator will be off when the scrub system is switched off and the brooms are in the raised

position.

• EcoFlex Indicator:

– The (green) indicator will be on when the EcoFlex™ low-concentration detergent mode is enabled.

– The (green) indicator will ash when the EcoFlex™ burst of power mode is enabled.

– The (green) indicator will be off when the EcoFlex™ full-concentration detergent mode is enabled.

Note: When the recovery tank becomes full (when in the auto scrub mode), the vacuum motors and

all other systems shut off except the drive motor. The LCD on the dash panel will display the full tank icon.

Control Panel Display

The control panel display is a liquid

crystal display (LCD) that shows the hour meter, battery charge indicator,

solution ow rate and scrub pressure.

Hour

Meter

If the detergent system is enabled, the display will also show the detergent system indicator and the current detergent/solution ratio.

If an A2 Control Board error occurs, the display will show a wrench icon

Error

Indicator

Error Code

Number

Ø .4

to indicate an error, and display a two-digit error code number. If more than one error exists, the display will

sequence through the error codes at

Regular

Solution

Flow

one-second intervals. (Refer to the

Control System section for a list of the

A2 Control Board error codes.)

Caution Displays

If the recovery tank is full, the display will show a caution symbol and the tank full icon.

Ratio

Heavy

Solution

Flow

Detergent

System

Indicator

Extreme Solution

Flow

Normal

Scrub

Pressure

Battery

Indicator

Heavy Scrub

Pressure

Extreme

Scrub

Pressure

If the battery charge level falls to a critical level, the display will show a caution symbol and the battery-low icon.

™

Circuit Breakers

The machine circuit breakers are located on the panel to

the left of the Operator seat.

General Maintenance

Maintenance After Use

General Information 20Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

1. When nished scrubbing, press the Scrub Off Switch. This will automatically raise the scrub deck and squeegee, and switch off the solution, detergent and vacuum systems.

2. Drive the machine to a service area for daily maintenance, and check the machine for any additional maintenance or service that may be needed.

3. To empty and clean the solution tank:

a. Remove the Solution Tank Drain

Hose

from its storage clamp.

b. Direct the Solution Tank Drain Hose

to a designated disposal site and remove the Solution Tank Drain

Hose Plug

Recovery Tank

Drain Hose Plug

c. Rinse the tank with clean water.

4. To empty and clean the recovery tank:

a. Pull the Recovery Tank Drain Hose

from its storage area.

b. Direct the

Hose

Recovery Tank Drain

to a designated disposal site

Recovery Tank

Drain Hose

and remove the Recovery Tank

Drain Hose Plug

. (Hold the end of

the Recovery Tank Drain Hose above

the water level in the tank to avoid

sudden, uncontrolled wastewater

ow.) The Recovery Tank Drain Hose can be squeezed to regulate the ow.

c. Rinse the recovery tank with clean

water.

Hopper

Solution Tank

Drain Hose

Solution Tank

Drain Hose Plug

Vacuum

Hose

™

General Information 21Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

d. Inspect the Solution Tank Drain Hose, Recovery Tank Drain Hose and Vacuum Hose for wear or damage.

Replace the if kinked or damaged.

5. Remove the brushes or pad holders. Rinse the brushes or pads in warm water and hang up to dry.

6. Remove the squeegee, rinse it with warm water, then reinstall.

7. Remove the Hopper on cylindrical systems and clean thoroughly. You can remove the Hopper from either side of the machine by removing the skirt, tilting the Hopper up and away from housing, then pulling the

Hopper out.

8. Check the following maintenance schedule and perform any required maintenance before you store the machine.

Maintenance Schedule

Maintenance Item Daily Weekly Monthly Yearly

Charge Batteries X

Check/Clean Tanks and Hoses X

Check/Clean/Rotate the Brushes/Pads X

Check/Clean the Squeegee X

Check/Clean Vacuum Shutoff Float X

Check/Clean the Vacuum Motor Foam Filter(s) X

Clean Hopper on Cylindrical System X

Check the Water Level in each Battery Cell X

Inspect Scrub Housing Skirts X

Inspect and Clean Solution Filter X

Check Foot/Parking Brake For Wear and Adjustment X

Clean Solution Trough on Cylindrical System X

Purge Detergent System X

Side Broom Maintenance X

Lubrication - Grease Fittings X

* Check Carbon Brushes X

* Inspect the vacuum motor carbon brushes every 300 operating hours. Check the brush and drive motor

carbon brushes every 500 operating hours.

Note: Refer to the individual machine sections in this manual for more detail on maintenance and

service repairs.

9. Store the machine indoors in a clean, dry place. Keep the machine from freezing. Leave the tanks open to air them out.

10. Turn the key switch off (O) and remove the key.

Caution! Do not pressure-wash the operator control panel, circuit breaker panel or any

electrical areas of the machine.

Machine Lubrication

™

General Information 22Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Once a month:

• Pump a small amount of grease into each grease

tting on the machine as shown until grease

seeps out around the bearings.

• Apply light machine oil to the components

shown.

Apply grease to:

• Squeegee Caster Wheel Axle and Pivot

Grease

• Steering Wheel Shaft Universal joint

• Steering Chain

• Squeegee mount angle adjustment knob threads

Apply light machine oil to:

• Squeegee tool end wheels

• Recovery Tank release latch

• Brake Pedal (parking brake) linkage

Lubrication Points

Oil

Grease

Oil

Grease

Advance Condor EcoFlex™, Nilfisk BR 1100/1300 EcoFlex™

Disc and Cylindrical

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

1 Steering 2 Drive Pedal Operation (check for Fwd/Rev drive and any neutral creep) A B D 3 Seat Safety Switch (when operator stands up machine is to stop) A D 4 Brakes (service and parking) A B W

Drive System Performance (reference Service Manual for Curtis drive

programmer speed changes)

6 Scrub System (Raise/Lower and auto scrubbing functions) A B

Scrub Brush Pressure Settings (see Service Manual programming, 3 different

modes)

8 Squeegee System (Raise/Lower and auto lift in reverse function) A B

Vacuum Performance (sealed water lift 70" and 1-inch open hole adapter 15

inches) 10 Solution Control (On/Off and flow volume Min/Max) A B L 11 Emergency Battery Disconnect Control Lever B D

Side broom Sweep System, Raise/Lower and auto sweep functions 12

(cylindrical only) 13 Tilt Steering Mechanism and Seat A B D 14 Optional Accessories (headlight, safety beacon, etc.) D

Main Control Board Special Program Options (check all applicable program 15

settings, reference Service Manual 56043154); Example, Fault Recall Mode,

etc. 16 Battery Charger Operation D 17 Chemical Detergent System Functions C L

Ref

18 Scrub Brushes, check for wear and rotate A B D W 19 Scrub Brush Motor(s) and disc machine gearboxes Carbon Brushes B L W 20 Scrub Brush Drive Belt, wear (cylindrical only) A D W 21 Scrub Brush Deck Actuator Motor A B D W

Brush Driver Plates (flex coupler and retainer clips) 22

(disc only) 23 Brush Idler Bearing Plate and Driver (cylindrical only) C W 24 Scrub Deck Skirts A B W 25 Solution Solenoid Valve C L 26 Solution Tank, Delivery Hoses and Filter Clean Filter Screen C L 27 Vacuum Motor Carbon Brushes Wear Limit 3/8" W 28 Vacuum Motor Cover Gasket and Filters L W 29 Vacuum Float Ball and Cage Assembly Clean Float C M

Operational Inspection Items

Visual Inspection Items

Comments OK

D M

Defect Codes

(circle)

noisy sluggish

A B

C L W

A B D

Program as needed

A B

Defect Codes

(circle)

Does

Not

Work

Does

Not

Work

Ref

Visual Inspection Items (continued)

30 Recovery Tank Cover Gasket C D L 31 Recovery Tank Drain Hose and Cap Flush C L 32 Squeegee Pick-Up Tool and Hose Back flush C L 33 Squeegee Blades (clean and rotate) A C D W 34 Squeegee Mount Wheels (lubricate) 4 Grease Fittings A C W 35 Squeegee Lift Actuator Motor and Lifting Bar A B D 36 Battery Pack Condition (clean and water) Load Test C W 37 Front Drive Wheel Motor Carbon Brushes C W 38 Front Drive Tire Tread Wear W 39 Rear Brake Rotors and Disc Wear Adjust Free Play A B W 40 Drive Pedal Linkage (neutral return) Torsion Spring A B 41 Steering Chain (lubricate and tension) 1/4" Deflection A B C

Steering Column (knob and plunger spring) also 42

Universal Joint 43 Rear Wheels (bearing wear) Tread Wear C W 44 Sweep Debris Tray (cylindrical only) Rinse C

Comments OK

Grease A D

Defect Codes

(circle)

Does

Not

Work

Defect Codes A needs adjustment C dirty or contaminated M missing B binding D damaged, bent or torn W worn out L leaks

Note: For additional service information see Service Manual form number 56043154 and Instructions for

Use form number 56041633.

Work Completed By: Acknowledged By:

Service Technician Signature Date Customer Signature Date

Chassis System

Major Chassis Components

Side Rear

Panel

™

25Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Chassis Support

Side Panel

Assembly

Conduit (2)

Chassis

Weldment

Pin Plate

Weldment

Support

Edge

Trim

™

Control System

Functional Description

Overview

The control system consists of the A2 Control Board Assembly, the A3 Switch/Display Panel Assembly and associated sensors and circuitry.

A2 Control Board Assembly

The A2 Control Board Assembly, sometimes referred to the main controller, communicates with the Curtis A1 Speed

Controller

and the A3 Switch/Display Panel Assembly to coordinate the operation of the various machine systems. The A2 Control Board Assembly is fastened to the Electrical

Mount

behind the electrical panel cover assembly to the

left of the Operator seat.

A2 Control Board

Assembly

Electrical

Mount

26Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

One primary function of the A2 Control Board Assembly is

to position the scrub brushes relative to the oor surface

using a lift actuator motor. The A2 Control Board Assembly continuously monitors the brush motor current draw to

maintain the desired scrub pressure on the oor.

Curtis A1

Speed

Controller

• If the brush motor current drops below the desired

range, the A2 Control Board Assembly switches on the

lift actuator motor to move the scrub deck downward

until the brush motor current draw is within the correct range for the scrub pressure selected.

• If the brush motor current rises above the desired

range, the A2 Control Board Assembly switches on the

lift actuator motor to lift the scrub deck upward until

the brush motor current draw is again within the correct range for the scrub pressure selected.

Note: Refer to the Scrub System section in this

manual for a complete explanation of scrub deck operation.

A secondary function of the A2 Control Board Assembly is to detect any system failures and display the corresponding error code on the display panel, or store it in the control board’s recall memory mode. The

error codes are used to help service technicians determine the fault and to guide in repairing a specic system malfunction quickly.

Note: See the Troubleshooting section for further information.

The A2 Control Board Assembly also allows you to change program settings for a set of specic machine functions. See the Main Control Programming Options section in this manual for further information.

A3 Switch/Display Panel Assembly

The A3 Switch/Display Panel Assembly is the user interface that includes the various system switches and buttons, and the control panel display. The A3 Switch/ Display Panel Assembly sends the operator inputs via a CAN BUS to the A2 Control Board Assembly.

Control System Wiring Diagram

™

Control System 27Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Circuit Breaker, 3 Amp

Circuit Breaker, 15 Amp

B+

Fuse, 250 A

Key Switch Seat Switch

Diode

Battery Interlock Switch

(for roll-out Battery)

36V Battery

Speed

Controller

B-

Bat -

Bat +

A2 Control

Board

Assembly

B+

Motion

Direction

Bat + 8V

Bat -

CAN H

CAN L

Battery Ground

Switch/Display

Panel Assembly

B-

Circuit Description

The A2 Control Board Assembly is connected by several inputs to battery negative:

The A2 Control Board Assembly gets positive battery voltage from two inputs:

• When the key switch, seat switch and battery interlock are closed, positive voltage is supplied to the A2

Control Board Assembly.

• When the key switch is closed, positive voltage is supplied to the coil side of contactor K5. When K5

contacts close, positive voltage is supplied to the A2 Control Board Assembly.

The A3 Switch/Display Panel Assembly gets voltage from two outputs on the A2 Control Board Assembly. The A3 Switch/Display Panel Assembly communicates with the A2 Control Board Assembly via a CAN BUS connection (CAN H and CAN L).

™

Control System 28Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Main Control Programming Options

Fault Recall Mode

Whenever the A2 Control Board Assembly detects an electrical system error or fault, one or more error codes are displayed and stored by the A2 Control Board Assembly. You can recall error codes (if any) from

previous machine operation for troubleshooting purposes, To recall stored error codes:

1. Turn the key switch off.

2. Press and hold the solution switch.

3. While holding the solution switch, turn the key switch on.

4. Continue to hold the solution switch until the solution system indicator turns on.

5. Release the solution switch. The solution system indicator turns off and the scrub off indicator will light.

The display will show a wrench icon indicating that you are in fault recall mode.

• If there are no previous error codes stored, the display will show the no-fault wrench icon asking you to reset the machine (no fault). Skip to step 7.

• If error codes have been stored, the display will show the wrench icon and error number(s) next to the

wrench. If more than one error code is stored, the display will toggle through all the errors stored.

6. • If you want to save the codes, skip to step 7.

• To clear the stored error codes, press the scrub off switch. The display will now show key switch icon asking you to reset the machine.

7. To exit the fault recall mode, turn the key switch off.

To Restore the Scrub Pressures to the Factory Default Settings

1. Turn the key switch off.

2. Press and hold the scrub on switch.

3. While holding the scrub on switch, turn the key switch on.

4. Continue to hold the scrub on switch until the display shows key switch icon. The factory default scrub pressures have now been restored.

5. Turn the key switch off.

To Enable/Disable the Fault Detection

Note that the factory default for fault detection is ON.

Normally the main control unit will perform checks of the electrical system during operation. 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. To turn the fault checking on or off:

1. Turn the key switch off.

2. Press and hold both the scrub off switch and solution switch.

™

Control System 29Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

3. While holding both switches, turn the key switch on.

4. Continue to hold both switches until both switch indicators turn on. The display will show a wrench icon indicating fault detection mode.

5. Release both switches. The solution system indictor light will blink and the scrub off indicator will stay on.

6. Press the solution switch to toggle the fault detection between enabled/on (wrench icon with no cross) or disabled/off (wrench icon with cross).

7. Press the scrub off switch to save the new setting and display the key switch icon.

8. Turn the key switch off. The new setting will be saved until changed again.

To Display the Control Board Revision Level

1. Turn the key switch off.

2. Press and hold both the scrub off switch and traction control switch.

3. While holding both switches, turn the key switch on.

4. Continue to hold both switches until the scrub off and traction control indicators light.

5. Release both switches. The scrub off and traction control indicators will switch off. The display will show

MAIN REVISION of the A2 control board assembly, the DISPLAY REVISION of the A3 switch/display

the

panel assembly and the key switch icon.

6. Turn the key switch off.

Monitor Mode

The control system allows the ve machine settings listed below to be quickly checked in the monitor mode to view the machine’s specic setup. To enter the monitor mode and view the current machine settings:

1. Turn the key switch off.

2. Press and hold the detergent switch.

3. While holding the detergent switch, turn the key switch on.

4. Continue to hold the detergent switch until the detergent system indicator switches on.

5. Release the detergent switch. The display will show the following current machine programmed settings:

• Scrub deck type and size,

• Detergent mode on/off,

• Fault detection on/off,

• Vacuum motor selection – VACUUM–SINGLE (one motor) or VACUUM–DUAL (two motors).

6. To exit the monitor mode, turn the key switch off.

™

Control System 30Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Scrub Deck Down Time Adjustment

Note that the factory default deck down time is two seconds.

When scrub on switch is pressed, the control board will automatically lower the deck for two seconds. The time that the deck is lowered is adjustable from one second to three seconds in 0.1-second increments.

To adjust the scrub deck down time:

1. Turn the key switch off.

2. Press and hold the scrub on and solution switches.

3. While holding both switches, turn the key switch on.

4. Continue to hold both switches until both switch indicators turn on.

5. Release both switches. The display will now show a clock icon in the upper left corner with a number

indicating the scrub deck down time period.

6. Press the scrub on switch to increment the time period. Each press of the switch increments the scrub

deck down time 0.1 seconds. For example, the time will increment from 2.0 seconds to 2.1 seconds, and so on. The deck down times range from 1.0 to 3.0 seconds.

7. Press the scrub off switch to save the new setting and display the key switch icon.

8. Turn the key switch off. The new setting will be saved until changed again.

Normal (Light) Scrub Setting Adjustment

Note that the factory default settings for the normal scrub setting are: Scrub pressure – one bar, Solution

ow rate – one bar.

The scrub pressure and solution ow rate for the normal scrub setting can be programmed to better suit a particular application. This allows you to select a higher solution ow rate with normal scrub pressure, or

a normal solution rate with heavier scrub pressure, etc., as the normal scrub setting. To change the normal scrub settings:

1. Turn the key switch off.

2. Press and hold the scrub on and scrub speed switches.

3. While holding both switches, turn the key switch on.

4. Continue to hold both switches until the scrub speed indicator turns on and the normal scrub on

indicator blinks.

5. Release both switches. The display will now show a scrub icon (either disc or cylindrical) with the current scrub pressure setting.

6. Press the scrub on switch to increment the scrub pressure setting as shown by the number of bars in the display.

7. Press the scrub off switch to save the new scrub pressure setting and move to the solution ow rate setting. The display will now show the solution icon with gauge. The normal scrub indicator will stop

blinking and the solution system indicator will blink.

8. Press the solution switch to increment the solution ow rate as shown by the number of bars in the display.

™

Control System 31Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

9. Press the scrub off switch to save the new solution ow rate setting and move to the detergent concentration setting. The display will now show the detergent icon with a 0, + or – next to it. The

solution system indicator will stop blinking and the detergent indicator will blink.

10. Press the detergent switch to scroll through and select the 0, + or – character in the display.

• Selecting 0 will not change the detergent concentration in the detergent ratios.

• Selecting + will increase the detergent concentration in the detergent ratios by 10 percent.

• Selecting – will decrease the detergent concentration in the detergent ratios by 10 percent.

11. Press the scrub off switch to save the detergent concentration setting and display the key switch icon.

12. Turn the key switch off. The new settings will be saved until changed again.

Heavy Scrub Setting Adjustment

Note that the factory default settings for the heavy scrub setting are: Scrub pressure – two bars, Solution

ow rate – two bars.

The scrub pressure and solution ow rate for the heavy scrub setting can be programmed to better suit

a particular application. This allows you to select a higher solution rate with heavy scrub pressure, or a normal solution rate with heavy scrub pressure, etc., as the heavy scrub setting. To change the heavy scrub settings:

1. Turn the key switch off.

2. Press and hold the scrub on and detergent switches.

3. While holding both switches, turn the key switch on.

4. Continue to hold both switches until the detergent indicator turns on and the heavy scrub indicator

blinks.

5. Release both switches. The display will now show a scrub icon (either disc or cylindrical) with the current scrub pressure setting.

6. Press the scrub on switch to increment the scrub pressure setting as shown by the number of bars in the display.

7. Press the scrub off switch to save the new scrub pressure setting and move to the solution ow rate setting. The display will now show the solution icon with gauge. The solution system indicator will

blink.

8. Press the solution switch to increment the solution ow rate as shown by the number of bars in the display.

solution system indicator will stop blinking and the detergent indicator will blink.

10. Press the detergent switch to scroll through and select the 0, + or – character in the display.

• Selecting 0 will not change the detergent concentration in the detergent ratios.

• Selecting + will increase the detergent concentration in the detergent ratios by 10 percent.

• Selecting – will decrease the detergent concentration in the detergent ratios by 10 percent.

11. Press the scrub off switch to save the detergent concentration setting and display the key switch icon.

™

Control System 32Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

12. Turn the key switch off. The new settings will be saved until changed again.

Extreme Scrub Setting Adjustment

Note that the factory default settings for the extreme scrub setting are: Scrub pressure – three bars, Solution

ow rate – three bars.

The scrub pressure and solution ow rate for the extreme scrub setting can be programmed to better suit

a particular application. This allows you to select a higher solution rate with extreme scrub pressure, or a normal solution rate with extreme scrub pressure, etc., as the extreme scrub setting. To change the extreme scrub settings:

1. Turn the key switch off.

2. Press and hold the scrub on and vacuum/wand switches.

3. While holding both switches, turn the key switch on.

4. Continue to hold both switches until the vacuum/wand indicator turns on, and the normal and heavy

scrub indicators blink.

5. Release both switches. The display will now show a scrub icon (either disc or cylindrical) with the current scrub pressure setting.

6. Press the scrub on switch to increment the scrub pressure setting as shown by the number of bars in the display.

7. Press the scrub off switch to save the new setting and move to the solution ow rate setting. The display

will now show the solution icon with gauge. The normal and heavy scrub indicators will stop blinking and the solution indicator will blink.

8. Press the solution switch to increment the solution ow rate as shown by the number of bars in the display.

9. Press the scrub off switch to save the new solution ow rate setting and move to the detergent concentration setting. The display will now show the detergent icon with a

0, + or – next to it. The

solution system indicator will stop blinking and the detergent indicator will blink.

10. Press the detergent switch to scroll through and select the 0, + or – character in the display.

• Selecting 0 will not change the detergent concentration in the detergent ratios.

• Selecting + will increase the detergent concentration in the detergent ratios by 10 percent.

• Selecting – will decrease the detergent concentration in the detergent ratios by 10 percent.

11. Press the scrub off switch to save the detergent concentration setting and display the key switch icon.

12. Turn the key switch off. The new settings will be saved until changed again.

™

Control System 33Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Scrub Speed Switch Lockout

Note that the factory default setting for the scrub speed switch is FAST/SLOW - ENABLE.

The control system is programmed to limit the maximum travel speed while scrubbing to a value less than that allowed when driving and not scrubbing. Pressing the scrub speed switch on the control panel will override this speed limiting feature and allow scrubbing at a the higher speed. If you wish to prevent scrubbing at this faster speed, you can disable the scrub speed switch override feature. To disable the scrub speed switch override feature:

1. Turn the key switch off.

2. Press and hold the scrub speed switch.

3. While holding the scrub speed switch, turn the key switch on.

4. Continue to hold the scrub speed switch until the scrub speed and scrub off indicators both turn on.

5. Release the scrub speed switch. The scrub speed indictor light will blink.

6. Press the scrub speed switch to enable or disable the scrub speed switch override feature. FAST/SLOW

- ENABLE

high-speed scrub feature is turned off.

means that the high-speed scrub feature is turned on. FAST/SLOW - DISABLE means that the

7. Press the scrub off switch to save the setting and display the key switch icon.

8. Turn the key switch off. The new setting will be saved until changed again.

Detergent System Selection Mode

1. Turn the key switch off.

2. Press and hold the scrub off switch and the detergent switch.

3. While holding both switches, turn the key switch on.

4. Continue to hold both switches until both switch indicators turn on.

5. Release both switches. The scrub off indicator will stay lit and the detergent system indicator will blink. The display will now show a detergent bottle in the upper left corner indicating the detergent selection mode.

6. Press the detergent switch to select between a normal detergent bottle icon indicating that the detergent system is activated, or a detergent bottle with a cross through it indicating that the detergent system is not activated.

7. Press the scrub off switch to save the new setting and display the key switch icon.

8. Turn the key switch off. The new setting will be saved until changed again.

EcoFlex™ Mode Selection

Note that the factory default setting for the EcoFlex™ Mode is OFF.

1. Turn the key switch off.

2. Press and hold the EcoFlex™ button.

3. While holding the button, turn the key switch on.

™

Control System 34Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

4. Continue to hold the button for two seconds until the EcoFlex™ and scrub off indicators turn on.

5. Release the EcoFlex™ button. The display will now show the ECOFLEX MODE/

OFF

, ECOFLEX MODE/MODE 1 and ECOFLEX MODE/MODE 2 menu.

6. Press the EcoFlex™ button to scroll through the menu and select the desired

ECOFLEX MODE.

ECOFLEX MODE OFF

ECOFLEX MODE MODE 1

ECOFLEX MODE

7. Press the scrub off switch to save the setting and display the key switch icon.

MODE 2

8. Turn the key switch off. The new setting will be saved until changed again.

Vacuum Motor Configuration Option

Note that the factory default setting for the vacuum motor conguration is SINGLE (one vacuum motor).

All rider scrubber models covered in this manual can be equipped with optional dual vacuum motors. The A1

control board assembly must be programmed for the number of vacuum motors installed so that the current

overload protection will function correctly. To select the vacuum motor conguration:

1. Turn the key switch off.

2. Press and hold the scrub system off and vacuum/wand switches.

3. While holding both switches, turn the key switch on until the scrub off and vacuum/wand indicators light.

4. Release both switches. The vacuum/wand indictor will ash. The control panel display will now indicate the vacuum motor setting.

5. Press the vacuum/wand switch to toggle between

VACUUM - DUAL for two vacuum motors.

VACUUM - SINGLE for a single vacuum motor or

6. Press the scrub off switch to save the setting and display the key switch icon.

7. Turn the key switch off. The new setting will be saved until changed again.

Recovery Tank Full Detection Enable/Disable

Note that the factory default setting for the recovery tank full detection is ENABLE.

The Condor is equipped with a feature that will automatically shut off the vacuum and scrub systems and display a recovery tank full icon on the control panel display when the recovery tank becomes full. If

problems are encountered with the vacuum shutoff feature, such as the vacuum shutting off even when the

recovery tank is not full, this feature can be turned off. To turn this feature on (enable) or off (disable):

1. Turn the key switch off.

2. Press and hold the vacuum/wand switch.

3. While holding the vacuum/wand switch, turn the key switch on.

4. Continue to hold the vacuum/wand switch until the vacuum/wand indicator turns on.

5. Release the vacuum/wand switch. The vacuum/wand indictor will blink and the scrub off indicator will turn on. The display will now show a text message REC TANK FULL DETECT/ENABLE or DISABLE.

6. Press the vacuum/wand switch to toggle between ENABLE or DISABLE. ENABLE means that the automatic shutoff feature is turned on. DISABLE means that the automatic shutoff feature is turned off.

™

Control System 35Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

7. Press the scrub off switch to save the setting and display the key switch icon.

8. Turn the key switch off. The new setting will be saved until changed again.

Solution Flow in Reverse Enable/Disable

Note that the factory default setting for the solution ow in reverse option is ENABLE.

The solution ow is programmed to dispense solution when the machine backing up. To disable solution ow

when the machine moves in reverse:

1. Turn the key switch off.

2. Press and hold the EcoFlex™ button and the solution switch.

3. While holding both the button and switch, turn the key switch on.

4. Continue to hold the button and switch until the solution system and vacuum/wand indicators turn on.

5. Release the button and switch. The vacuum/wand indicator will turn off, the solution system indictor

will blink and the scrub off indicator will turn on. The display will now show the message

REVERSE

/ENABLE or DISABLE.

SOLUTION IN

6. Press the solution switch to toggle between SOLUTION IN REVERSE ENABLE or DISABLE. If you select

ENABLE, the solution ow will stay on when the machine is moving in reverse. If you select DISABLE,

solution ow will stop when the machine is moving in reverse.

7. Press the scrub off switch to save the setting and display the key switch icon.

8. Turn the key switch off. The new setting will be saved until changed again.

Indicator LED Intensity Selection Option

Note that the factory default setting for the indicator LED intensity is normal.

To change the intensity of the LEDs in the control panel indicators.

1. Turn the key switch off.

2. Press and hold the vacuum/wand and scrub speed switches.

3. While holding both switches, turn the key switch on.

4. Continue to hold both switches until the vacuum/wand and scrub speed indicators turn on. The display will now show a light bulb icon in the upper left corner indicating the LED light intensity selection.

5. Release both switches. The scrub speed and scrub off indicators will light and the vacuum/wand

indicator will blink.

6. Press the vacuum/wand switch to select between the normal intensity or extra bright intensity levels.

7. Press the scrub off switch to save the setting and display the key switch icon.

8. Turn the key switch off. The new setting will be saved until changed again.

™

Control System 36Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Detergent and Solution Pump Purge

The EcoFlex™ detergent system has two purge (ush) programs to ensure that the detergent delivery hoses

and related components are kept open and clean. A general operational description in how the system

functions is found in the Solution System section. To activate the maintenance purge functions:

Method 1

1. Turn the key switch off.

2. Press and hold both the detergent and solution switches.

3. While holding the switches, turn the key switch on. The display will show the purge icon, the detergent and solution pumps will run for approximately 20 seconds, then the pumps will shut off.

4. When the purge cycle is complete, turn the key switch off.

Method 2 (as described in the Instructions for Use)

1. Turn the key switch on.

2. Press and hold both the detergent and solution switches for three seconds. The detergent and solution pumps will run for approximately 10 seconds.

3. When the purge cycle is complete, turn the key switch off.

Side Broom Function

1. Turn the key switch off.

2. Press and hold the side broom on/down switch.

3. While holding the switch, turn the key switch on.

4. Continue to hold the switch until the side broom on/down indicator turns on.

5. Release the switch. The display will now show SIDE BROOM/ENABLE or DISABLE.

6. Press the side broom on/down switch to toggle between SIDE BROOM ENABLE or SIDE BROOM DISABLE.

7. Press the scrub off switch to save the setting and display the key switch icon.

8. Turn the key switch off. The new setting will be saved until changed again.

Side Broom Height Adjustment

The height of the side brooms is determined by the length of time the side broom actuator runs as it lowers the side brooms. Note that:

• Increasing the side broom actuator run time lowers the side broom height.

• Decreasing the side broom actuator run time raises the side broom height.

To adjust the side broom height:

1. Turn the key switch off.

™

Control System 37Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

2. Press and hold the side broom on/down and scrub off switches.

3. While holding the switches, turn the key switch on.

4. Continue to hold the switches until the side broom on/down indicator, scrub off indicator and both scrub on indicators turn on.

5. Release the switches. The indicators will stay on and the display will now show the side broom actuator down run time in seconds.

6. • Press the scrub on switch to increase the side broom actuator run time and lower the position of side

brooms.

• Press the side broom on/down switch to decrease the side broom actuator run time and raise the

position of side brooms.

Note that the side broom actuator run times range from 1.0 to 3.0 seconds.

7. Press the scrub off switch to save the side broom height. The actuator will raise the brooms to their up

position and the display will show a key switch icon.

8. Turn the key switch off. The machine is now reprogrammed to work with the new side broom height

setting.

Display Mode Selection

1. Turn the key switch off.

2. Press and hold the detergent switch and EcoFlex™ button.

3. While holding the detergent switch and EcoFlex™ button, turn the key switch on.

4. Continue to hold the button and switch for two seconds until the EcoFlex™ and detergent system indicators turn on.

5. Release the button and switch. The EcoFlex™ indicator will blink and the display will show DISPLAY

MODE

6. Press the EcoFlex™ button to toggle between 1. US DISPLAY and 2. GLOBAL DISPLAY.

7. Press the scrub off switch to save the new setting and display the key switch icon.

8. Turn the key switch off. The new setting will be saved until changed again.

Service Test Mode

The purpose of the service test mode is to assist the service technician with numerous quick shortcut

troubleshooting procedures. The service test mode allows you to control individual system components independent of the normal machine operator inputs.

To Enter the Service Test Mode

1. Turn the key switch off.

2. Press and hold the scrub speed and traction control switches.

3. While holding the scrub speed and traction control switches, turn the key switch on.

™

Control System 38Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

4. Continue to hold the scrub speed and traction control switches until the traction control indicator lights.

5. Release the scrub speed and traction control switches. The scrub speed indicator will turn off and the display will show NEUTRAL/SC-NO FAULT (speed controller - no fault). The display, switch and indicator functions in the service test mode are described below.

6. To exit the service test mode, turn the key switch off.

Service Test Mode Display

• Speed Control Status

– This indicator will read SC–NO FAULT (speed controller - no fault) if the status signal from the speed

control is normal.

– If a speed control fault exists, this indicator will read SC-FAULT (speed control fault). Refer to the

Wheel System, Traction section for details on these codes.

• Speed Control Foot Throttle Status

– The control panel display will read NEUTRAL when the operator foot pedal is at rest.

– The control panel display will read FORWARD when the foot pedal is depressed in the forward direction

to activate its forward drive mode functions.

– The control panel display will read REVERSE when the operator foot pedal is depressed in the reverse

direction to activate its reverse drive mode functions.

Control Panel Switch and Button Functions

• Scrub System Off Switch – This switch controls the scrub brush motor(s). Pressing and

releasing this switch will alternately turn the brush motor(s) on and off. The scrub off indicator provides the following status information:

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

– Steady Blue - Brush motor output is on and there is normal brush motor current

sensed.

• Scrub ON/Pressure Select Switch – This switch controls the scrub deck lift actuator as

follows:

– Pressing the switch the rst time will switch on the actuator to lower the scrub

deck. The normal scrub indicator (left blue LED) will light as the actuator is running. Once the deck reaches the down position, the normal scrub indicator will blink.

– Pressing the switch a second time will switch off the normal scrub indicator.

– Pressing the switch a third time will switch on the actuator to raise the scrub deck. The normal scrub

indicator will light as the actuator is running. Once the deck reaches the up position, the normal scrub indicator will blink.

– Pressing the switch a fourth time will switch off the normal scrub indicator.

™

• Vacuum/Wand Switch – This switch controls the squeegee lift actuator and vacuum

motor(s) as follows:

– Pressing the switch the rst time will switch on vacuum motor(s) and switch on

the actuator to lower the squeegee. The vacuum/wand indicator will light as the actuator is running. Once the squeegee reaches the down position, the vacuum/ wand indicator will blink.

– Pressing the switch a second time will switch off the vacuum/wand indicator.

– Pressing the switch a third time will switch off the vacuum motor(s) and switch on the actuator

to raise the squeegee. The vacuum/wand indicator will light as the actuator is running. Once the squeegee reaches the up position, the vacuum/wand indicator will blink.

– Pressing the switch a fourth time will switch off the vacuum/wand indicator.

• Side Broom On/Down Switch – This switch controls the side broom motors and side

broom lift actuator as follows:

– Pressing the switch the rst time will switch on side broom motors and switch on

the actuator to lower the side brooms. The side broom on/down indicator will light as the actuator is running. Once the side brooms reach the down position, the side

broom on/down indicator will blink.

Control System 39Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

– Pressing the switch a second time will switch off the side broom on/down indicator.

– Pressing the switch a third time will switch off the side broom motors and switch on the actuator to

raise the side brooms. The side broom on/down indicator will light as the actuator is running. Once the

side brooms reach the up position, the side broom on/down indicator will blink.

– Pressing the switch a fourth time will switch off the side broom on/down indicator.

• Solution Switch – This switch controls the solution solenoid and solution control pump.

Pressing and releasing this switch will alternately turn the solution solenoid and solution pump on and off. The solution system indicator provides the following status information:

– Off – Solenoid and solution pump outputs are off.

– Steady Blue – Solenoid and solution pump outputs are on.

• Detergent Switch – This switch controls the detergent pumps. Pressing and releasing

this switch will alternately turn the detergent pumps on and off. The detergent system indicator provides the following status information:

– Off – Detergent pump output is off.

– Steady Blue – Detergent pump output is on.

Troubleshooting

Error Indicator and Error Code Display

Any error codes detected by A2 Control Board Assembly will be displayed on the control panel display as they occur. If more than one error exists, the display

will sequence through the error

codes at one-second intervals. The error will display as a mechanical

wrench symbol followed by a two-digit code. For example, 29

as shown in the adjacent drawing would be an open vacuum motor error.

™

Error

Indicator

Two-digit

Error Code

Control System 40Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Error Codes

Display

Code

Error/Fault Description Correction

Scrub deck sense R2 resistor fault A fault will occur if scrub deck sensor resistor is

unplugged or damaged. Check the resistor wiring for an open and substitute a new resistor and test scrub deck for correct operation. Note that there are four different resistor values used on the different deck types. See the

electrical diagram decal for the correct specication for

the resistor to replace.

Speed control fault Observe the blue ashing light detergent indicator light,

then refer to the Wheel Drive, Traction section to troubleshoot the drive system.

Scrub motor overload

1. Check for binding in the rotation of the brushes and incorrect brush deck lift actuator operation.

Note that some models use one, two or three scrub motors. Refer to the

Specifications section for detailed

load current values for the different decks.

2. Check the negative supply cable at the brush motor for a wiring problem, and also the small BRN current sense wire in the harness and A2 pin J2-2.

3. Check for a short circuit* in the brush motor or wiring. On cylindrical models check for excessive belt tension and the condition of the idler bearing.

™

Control System 41Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Display

Code

Error/Fault Description Correction

Left brush motor contactor coil overload

Contactor

K4 is for the left motor on

the three-motor decks. The nominal

1. Check for a K4 coil wiring problem or a short circuit* (wire colors VIO and GRA/RED).

2. Check the coil resistance. If the resistance is below 75 ohms, replace the coil.

coil resistance is 94 ohms for all three motor contactors.

Center brush motor contactor coil overload

Contactor

K3 is for the center motor

on three-motor decks. K3 is for the

1. Check for a K3 coil wiring problem or a short circuit* (wire colors VIO and WHT/VIO).

2. Check the coil resistance. If the resistance is below 75 ohms, replace the coil.

left motor on two-motor decks. Right brush motor contactor coil

overload Contactor

K2 is for the right motor

on two- or three-motor decks. K2 is

1. Check for a K2 coil wiring problem or a short circuit* (wire colors VIO & YEL/BLU).

2. Check the coil resistance. If the resistance is below 75 ohms, replace the coil.

the only contactor on a single-motor decks.

Scrub deck actuator overload

1. Check for binding or a frozen brush lift linkage and excessive weight on the brush deck.

• Normal current load is 1-3 amps.

• Max current load is 6 amps.

• Max current with no load is 1.4

amps.

2. Check for a short circuit* in the actuator motor and wiring. Repair or replace.

To test the actuator, disconnect the motor plug and attach the actuator power cord adapter (p/n 56407502) and perform an amp draw test. Compare readings to the

current load specications.

Vacuum motor overload Normal current load for one motor is

16-20 amps. Normal current load for two motors is 32-40 amps.

1. Check for debris in the vacuum motor(s).

2. Check for worn carbon brushes - replace brushes.

3. Defective motor bearings - repair or replace.

4. Check for a short circuit* in the vacuum motor or wiring - repair or replace.

K1 Vacuum motor contactor

coil overload. The nominal coil resistance is 100 ohms.

1. Check for a K1 coil wiring problem or short circuit* (wire colors VIO and BLU).

2. Check the coil resistance. If the coil resistance is below 80 ohms, replace the coil.

Squeegee actuator overload

1. Check for binding or frozen squeegee lift linkage and excessive weight on the squeegee mount.

• Normal current load is 1-2 amps.

• Max current load is 6 amps.

• Max current with no load is 1.4

amps.

2. Check for a short circuit* in the actuator motor and wiring. Repair or replace.

To test the actuator, disconnect the motor plug and attach the actuator power cord adapter (p/n 56407502) and perform an amp draw test. Compare readings to the

current load specications.

L1 Solution solenoid overload

The nominal coil resistance is 74 ohms.

1. Check for a wiring problem or short circuit*.

2. Check the coil resistance. Replace the solution solenoid if the coil resistance is lower than 58 ohms.

™

Control System 42Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Display

Code

Error/Fault Description Correction

Solution control pump overload

1. Check for short circuits* in the wiring and in the

M12

pump motor.

• The normal current load is 0.8-1.8 amps.

• A current load of 3.2 amps or over will generate code 13 pump motor overload.

K6 Side broom motor contactor coil

overload The nominal coil resistance is 100

ohms. Side broom actuator overload

2. Disconnect the solution pump motor and run the machine to see if the wiring is shorted.

3. Check the current draw and compare to the

specications. If the motor shows high current draw

replace the motor.

1. Check for a K6 coil wiring problem or short circuit* (wire colors VIO and BRN/BLK).

2. Check the coil resistance. If the resistance is below 80 ohms, replace the contactor.

1. Check for binding or frozen side broom lift linkage and excessive weight on the lifting arms.

• Normal current load is 1-2 amps.

• Max current load is 6 amps.

• Max current with no load is 1.4

amps.

2. Check for a short circuit* in the actuator motor and wiring. Repair or replace.

To test the actuator, disconnect the motor plug and attach the actuator power cord adapter (p/n 56407502) and perform an amp draw test. Compare readings to the

current load specications.

K5 Auxiliary contactor coil overload

1. Check for a K5 coil wiring problem or short circuit* (wire colors YEL/BRN & BLK/ORN).

The nominal coil resistance is 100 ohms.

Back-up alarm overload

2. Check the coil resistance. If the resistance is below 80 ohms, replace the contactor.

1. Check for a back-up alarm wiring problem or short

circuit* (wire colors: positive ORN/BRN; negative

Specications:

• 5-15 VDC

• Current load 100 ma

Horn output fault

BLU/WHT).

2. Disconnect the back-up alarm and test to see if the wiring is shorted. If not, replace the back-up alarm.

1. The horn or horn wiring’s +36V power feed is shorted to ground (wire colors VIO and BLU/RED).

Current load spec. 1.2 amps

2. Disconnect the horn and test to see if the wiring is shorted. If not, replace the horn.

Scrub motor open 1. Check for an open circuit in the motor wiring or for a

defective motor.

2. Check for 36 volts at the scrub motor that is not running. If you get 0 Volts, replace the brush motor contactor.

Left brush motor contactor coil open 1. Check for an open circuit in the

K4 coil and wiring

(wire colors VIO and GRA/RED).

2. Test for 36V at the K4 coil. If you get 0 Volts, check the A2 control board assembly.

™

Control System 43Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Display

Code

Error/Fault Description Correction

Left brush motor contactor coil short to ground

1. Disconnect the

K4 coil wiring (wire colors VIO and

GRA/RED) and check to see if the code disappears.

− If the code disappears, replace the brush contactor.

− If the code does reappear, test the wiring for a short back to the battery ground. Repair or replace the defective wire.

2. If the above test doesn’t remove the code, substitute a new A2 control board assembly.

Center brush motor contactor coil open

1. Check for an open circuit in the (wire colors VIO and WHT/VIO).

K3 coil and wiring

2. Test for 36V at the K3 coil. If you get 0 Volts, check the A2 control board assembly.

Center brush motor contactor coil short to ground

1. Disconnect the

K3 coil wiring (wire colors VIO and

WHT/VIO) and check to see if the code disappears.

− If the code disappears, replace the brush contactor.

− If the code does reappear, test the wiring for a short back to the battery ground. Repair or replace the defective wire.

2. If the above test doesn’t remove the code, substitute a new A2 control board assembly.

Right brush motor contactor coil open

1. Check for an open circuit in the (wire colors VIO and YEL/BLU).

K2 coil and wiring

2. Test for 36V at the K2 coil. If you get 0 Volts, check the A2 control board assembly.

Right brush motor contactor coil short to ground

1. Disconnect the

K2 coil wiring (wire colors VIO and

YEL/BLU) and check to see if the code disappears.

− If the code disappears, replace the brush contactor.

− If the code does reappear, test the wiring for a short back to the battery ground. Repair or replace the defective wire.

2. If the above test doesn’t remove the code, substitute a new A2 control board assembly.

Scrub deck actuator open 1. Check for disconnected lift actuator wiring.

2. Check for an open circuit in the motor wiring or for a defective motor.

3. Check for output voltage from the A2 control board assembly at the actuator wiring plug. It should be 36 volts. If 0 Volts, check the A2 control board assembly.

Vacuum motor open 1. Check for disconnected vacuum motor wiring.

2. Check for an open circuit in the vacuum motor wiring or for a defective motor.

3. Check for 36 Volts at the vacuum motor. If 0 Volts, replace the vacuum motor contactor

K1.

™

Control System 44Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Display

Code

Error/Fault Description Correction

Vacuum motor contactor coil open 1. Check for an open circuit in the

K1 coil and wiring

(wire colors VIO and BLU).

2. Test for 36V at the K1 coil. If 0 Volts, check the A2 control board assembly.

K1 Vacuum motor contactor coil

short to ground

1. Disconnect the K1 coil wiring (wire colors VIO and BLU) and check to see if the code disappears.

− If the code disappears, replace the motor contactor.

− If the code does reappear, test the wiring for a short back to the battery ground. Repair or replace the defective wire.

2. If the above test doesn’t remove the code, substitute a new A2 control board assembly.

Squeegee actuator open 1. Check for disconnected squeegee actuator motor

wiring or plug connection.

2. Check for an open circuit in actuator motor wiring (WHT/GRN and BLU/BRN) or for a defective motor

M3.

3. Check for 36 Volts at the actuator motor. If 0 Volts, check the A2 control board assembly.

L1 Solution solenoid open 1. Check for an open circuit in the L1 coil and wiring

(wire colors VIO and YEL/GRN).

2. Test for 36V at the L1 coil. If 0 Volts, check the A2 control board assembly.

L1 Solution solenoid short to ground 1. Disconnect the L1 solenoid coil wiring (wire colors

VIO and YEL/GRN) and check to see if the code disappears.

− If the code disappears, replace the solenoid valve.

− If the code does reappear, test the wiring for a short back to the battery ground. Repair or replace the defective wire.

2. If the above test doesn’t remove the code, substitute a new A2 control board assembly.

Solution control pump open 1. Check for an open circuit in the

M12 pump motor and

wiring (wire colors VIO and BLU/ORN).

2. Test for 36V at the pump motor. If 0 Volts, check the A2 control board assembly.

Side broom motor contactor coil open

1. Check for open circuit in the colors VIO and BRN/BLK).

K6 coil and wiring (wire

2. Test for 36V at the K6 coil. If 0 Volts, check the A2 control board assembly.

™

Control System 45Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Display

Code

Error/Fault Description Correction

K6 Side broom motor contactor coil

short to ground

1. Disconnect the K6 coil wiring (wire colors VIO and BRN/BLK) and check to see if the code disappears.

− If the code disappears, replace the K6 contactor.

− If the code does reappear, test the wiring for a short back to the battery ground. Repair or replace the defective wire.

2. If the above test doesn’t remove the code, substitute a new A2 control board assembly.

Side broom actuator motor open 1. Use an ohmmeter to check for an open circuit in the

M4 side broom actuator and its wiring (wire colors

GRA/VIO and GRN/ORN). If defective, repair or replace.

2. Test for 36V at side broom actuator. If 0 Volts, check the A2 control board assembly.

Auxiliary motor contactor coil open 1. Check for an open circuit in the

(wire colors YEL/BRN and BLK/ORN).

K5 coil and wiring

2. Test for 36V at the K5 coil. If 0 Volts, check the A2 control board assembly.

K5 Auxiliary motor contactor coil

short to ground

1. Disconnect the K5 coil wiring (wire colors YEL/ BRN and BLK/ORN) and check to see if the code disappears.

− If the code disappears, replace the K5 contactor.

− If the code does reappear, test the wiring for a short back to the battery ground. Repair or replace the defective wire.

2. If the above test doesn’t remove the code, substitute a new A2 control board assembly.

Back-up alarm open 1. Use an ohmmeter to check for an open circuit in the

H1 back-up alarm and its wiring (wire colors ORN/

BRN and BLU/WHT). If defective, repair or replace.

2. Test for 36V at the back-up alarm. If 0 Volts, check the A2 control board assembly.

Back-up alarm short to ground 1. The Back-up alarm and/or its +36V power feed is

shorted to ground. Test the positive wire to ground for short circuit* (wire colors ORN/BRN battery + and BLU/WHT battery -). Repair or replace the defective wiring.

2. Disconnect the alarm and test to see if the circuit wiring is still causing an error code (shorted). If not, replace the back-up alarm.

* Short Circuit denition:

• A short circuit is a parallel path of very low resistance, often caused accidentally.

• With low resistance there is an excessive amount of current.

• The excessive current will either melt the wires or open a fusible link.

** See Service Test Mode in this manual for further troubleshooting information.

*** See the Main Control Programming Options section to activate the Brush Type Selection function.

Removal and Installation

Warning! Before removing or reinstalling any machine components, disconnect the battery

pack by pushing in the emergency-stop switch/battery disconnect, and make sure the parking brake is engaged.

A2 Control Board Assembly

1. Remove the electrical panel cover assembly (located to the left of the

operator position). Make sure to

unplug the fan assembly before removing the electrical panel cover assembly from the machine.

2. Disconnect the electrical connectors from the A2 Control Board Assembly.

3. Remove the ve Screws holding the A2

Control Board Assembly Mount

and remove the A2 Control

Board Assembly

from the machine.

to the Electrical

™

Screw (5)

Control System 46Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Control Board

Assembly

Electrical

Mount

4. Install the A2 Control Board Assembly by following the above steps in reverse order.

™

Control System 47Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Specifications

Scrub Pressure and Current Load (Amps) Specifications

Scrub Mode Scrub

Pressure Indicator

Disc 40” Cyl. 40” Disc 45”/48” Cyl. 45”/48” Normal Scrub 1 bar (#1) 40 amps 35 amps 50 amps 35 amps Heavy Scrub 2 bars (#2) 50 amps 45 amps 60 amps 45 amps Extreme Scrub 3 bars (#3) 65 amps 55 amps 80 amps 55 amps

Solution Flow Rates

Standard flow rates Override flow rates

1 bar 2 bars 3 bars 4 bars 5 bars

40” Disc 0.84 GPM 1.00 GPM 1.50 GPM 2.00 GPM 2.50 GPM 40” Cylindrical 0.70 GPM 0.84 GPM 1.00 GPM 1.50 GPM 2.50 GPM 45”/48” Disc 1.00 GPM 1.50 GPM 2.00 GPM 2.25 GPM 2.50 GPM 45”/48” Cylindrical 0.84 GPM 1.00 GPM 1.50 GPM 2.00 GPM 2.50 GPM

Deck Type

Control System 48Service Manual – Condor™ EcoFlex

™

I/O Tables

A2 Control Board Assembly

• Ladder Diagram: 56015372-G • Main PCB Assy: 56381049 • Main PCB Schematic: 56381059

• UI Panel Assy: 56381083 • UI PCB Schematic: 56381061

Designation Pin ID

Wire ID/

Color

Description

Signal

Characteristics

Nominal

Value (when

activated)

Reference

To:

Acceptable

Range

Comments

Output J1-1 BLU/GRA

Detergent

Pump2 (+)

Pulsed Voltage 0 or 36V B- (ground)

see comment

below *

Complex pulsed PWM signal

Bidirectional J1-2 BRN/BLU CAN-L

Digital

Communication

see comment see comment

Protocol analyzer needed to verify connection

Bidirectional J1-3 GRN/BLU CAN-H

Digital

Communication

see comment see comment

Protocol analyzer needed to verify connection

Input J1-4 ORN/RED

Speed Control

- Fault

Voltage see comment B- (ground) see comment

Pulsed signal equal to the fault code ashed

by the speed controllers built-in status LED

Input J1-5 GRN Battery + Voltage +36V B- (ground) 31V - 38V

Downstream of circuit breaker F1, Key switch S1, Diode D1, Seat Switch S2 and Battery Interlock Switch S3

Output J1-6 TAN/BRN

Detergent Pump1 (-)

Pulsed Voltage 0 or 36V B- (ground)

see comment

below *

Line should alternate between 0V and 36V when detergent pump is activated

Output J1-7 BLK/GRA

Detergent

Pump1 (+)

Pulsed Voltage 0 or 36V B- (ground)

see comment

below *

Line should alternate between 0V and 36V when detergent pump is activated

Input J1-8 ORN Battery + Voltage +36V B- (ground) 31V - 38V

Downstream of circuit breaker F1, switched through key switch S1

Output J1-9 ORN/GRA

Detergent Pump2 (-)

Pulsed Voltage 0 or 36V B- (ground)

see comment

below *

Line should alternate between 0V and 36V when detergent pump is activated

Input J1-10 BLK Battery - Voltage 0V B- (ground) 0 - 1V

Input J1-11 RED/WHT

Speed Control -

Motion

Voltage

0V (moving),

36V (not

moving)

B- (ground)

0 - 1V

(moving),

31 - 38V (not

moving)

Input J1-12 YEL/RED

Speed Control -

Direction

Voltage

0V (reverse), 36V (forward)

B- (ground)

0 - 1V

(reverse),

31 - 38V

(forward)

Control System 49Service Manual – Condor™ EcoFlex

™

Designation Pin ID

Wire ID/

Color

Description

Signal

Characteristics

Nominal

Value (when

activated)

Reference

To:

Acceptable

Range

Comments

Output J1-13 GRA

UI Panel -

Ground

Voltage 0V B- (ground) 0 - 1V Provides ground to User Interface panel Input J1-14 BLK Battery - Voltage 0V B- (ground) 0 - 1V Input J1-15 VIO Battery + Voltage 36V B- (Ground) 31V - 38V

Downstream of circuit breaker F2, switched through contactor K5

Output J1-16 WHT/VIO

Center Brush

Contactor

Voltage 0V B- (ground) 0 - 1V

Output J1-17 GRA/RED

Right Brush

Contactor

Voltage 0V B- (ground) 0 - 1V

Output J1-18 YEL/GRN Solenoid Valve Pulsed Voltage 0 or 36V B- (ground) see comment

Line should alternate between 0V and 36V when solenoid is activated

Output J1-19 YEL/BLU

Left Brush

Contactor

Voltage 0V B- (ground) 0 - 1V

Output J1-20 BLU/RED Horn (-) Voltage 0V B- (ground) 0 - 1V Output J1-21 BLU/ORN

Solution Pump

(-)

PWM 0 or -36V B+

see comment

below **

Pulsed PWM signal. Switched ground return for pump.

Output J1-22 WHT/BRN

UI Panel -

Power Supply

Voltage +8V B- (ground) 7 - 9V Provides power to User Interface panel

Input J1-23 VIO Battery + Voltage 36V B- (Ground) 31V - 38V

Downstream of circuit breaker F2, switched through contactor K5

Output J2-1 WHT/GRN

Squeegee Actuator +

Voltage 36V J2-9 see comment +36V while lowering, -36V while raising

Input J2-2 BRN

Scrub Brush Motor Shunt

Voltage .03 - .3V B- (ground) .03 - .3V

Input J2-3 ORN/BLU

Vacuum Motor

Shunt

Voltage

.10V (Single

Vac)

.20V (Dual

Vac)

B- (ground)

.07 - .12V

(Single Vac.

Motor)

.15 - .24V

(Dual Vac.

Motor)

Recovery Tank Full voltage = .083V (Single Vacuum Motor)

Recovery Tank Full voltage = .166V (Dual Vacuum Motor)

Output J2-4 ORN/BLK Battery - Voltage 0V B- (ground) 0 - 1V Return path for Scrub Deck Resistor Output J2-5 YEL/GRA

Brush

Actuator -

Voltage 36V J2-6 see comment

-36V while lowering, +36V while raising

Output J2-6 RED/BLK

Brush Actuator

Voltage 36V J2-5 see comment

+36V while lowering,

-36V while raising

Control System 50Service Manual – Condor™ EcoFlex

™

Designation Pin ID

Wire ID/

Color

Description

Signal

Characteristics

Nominal

Value (when

activated)

Reference

To:

Acceptable

Range

Comments

Output J2-7 GRN/ORN

Side Broom

Actuator -

Voltage 36V J2-8 see comment -36V while lowering, +36V while raising

Output J2-8 GRA/VIO

Side Broom

Actuator +

Voltage 36V J2-7 see comment +36V while lowering, -36V while raising

Output J2-9 BLU/BRN

Squeegee

Actuator -

Voltage 36V J2-1 see comment -36V while lowering, +36V while raising Input J2-10 BLK Battery - Voltage 0V B- (ground) 0 - 1V

Input J2-14 BLK Battery - Voltage 0V B- (ground) 0 - 1V

Output J2-15 BRN/BLK

Side Broom

Contactor

Voltage 0V B- (ground) 0 - 1V

Input J2-16 GRN/WHT

Scrub Deck

Sense Resistor

Voltage

1.78V, 2.5V,

3.0V, 3.57V

B- (ground)

1.78V = 40” Disk

2.50V = 40” Cylindrical

3.0V = 45”/48” Disk

3.57V = 45”/48” Cylindrical

Input J2-17 VIO/YEL

Solution Empty

Switch

Voltage 0V B- (ground) 0 - 1V Active when tank is empty

Output J2-18 ORN/BRN

Backup Alarm

(+)

Voltage +15V B- (ground)

Output J2-19 BLU/BLK

Speed Control -

Mode Sel 1

Voltage 0 or 36V B- (ground)

Depends on which mode the speed controller is in

Output J2-20 BLK/WHT

Speed Control -

Mode Sel 2

Voltage 0 or 36V B- (ground)

Depends on which mode the speed controller is in

Output J2-21 BLK/ORN

Auxiliary

Contactor

Voltage 0V B- (ground) 0 - 1V

Output J2-22 BLU

Vacuum

Contactor

Voltage 0V B- (ground) 0 - 1V

Output J2-23 BLU/WHT

Backup Alarm

(-)

Voltage 0V B- (ground)

* The signal controlling the detergent pump is extremely complex and eld troubleshooting should a take a functional approach. Substitute with a known

good detergent pump to check operation. If the known good pump does not operate, and the wiring and control inputs to the EcoFlex™ system is correct, the EcoFlex™ system is probably defective. Check the resistance of the detergent pump before replacing the EcoFlex™ system so as not to damage it if the pump is defective.

** The Solution Pump (-) line provides a switched ground return for the pump. When the solution pump is on, a 5KHz signal with a varying duty cycle and

a peak voltage of 36 volts will appear between this pin and B+. Measuring with a DC voltmeter will give a signal in the range of 6 to 27 volts. Changing

the ow rate solution bars on the LCD should produce a relative increase or decrease of the meter reading.

Control System 51Service Manual – Condor™ EcoFlex

™

EcoFlex PCB Assembly

• EcoFlex™ PCB Ass’y: 56316110-B

• EcoFlex™ PCB Schematic: 56314929-B

Designation Pin ID Wire ID/Color Description

Signal

Characteristics

Nominal

Value (when

activated)

Reference

To:

Acceptable

Range

Comments

Input J1-1 GRN/GRA

EcoFlex

™

Board

Power

Voltage +5V B- (ground) 4.5 - 5.5V Supplied by control board

Input J1-2 ORN/WHT

EcoFlex

™

Board

Ground

Voltage 0V B- (ground) 0 - 1V Supplied by control board

unused J1-3 unused

Output J1-4 GRA/WHT

EcoFlex

™

Chemical

Ratio

Analog Voltage B- (ground) 1 - 5V

Signal is sent to main control board

™

Electrical System

Functional Description

Overview

This section includes information on battery installation and maintenance, a description of the low-voltage cut-out function, and descriptions of the battery condition displays.

• For information on the A2 Control Board Assembly, refer to the Control System section.

• For information on the A1 (Curtis) Speed Controller, refer to the Wheel System, Traction section.

52Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Condor EcoFlex™ Ladder Wiring Diagram

CONFIDENTIAL

NOTES UNLESS OTHERWISE

SPECIFIED

1. ALL DIMENSIONS IN INCHES.

2. DO NOT SCALE DRAW ING.

3. ALL DIMENSIONS APPLY AFTER PLATING AND HEAT TREATING,

CHECKED

DRAWN

PROJ ENG

U/MQTY. CODE DES CRIPTION

ITEM

1 2

FUSE, 250 A.

RED/BLK WHT /YEL

F1 F2

A1 A2

MOTOR, TRACTION

RED

1 2

CONTACT N.O.

RED

1 2

CIRCUIT BREAKER, 3 AMP

1 2

CIRCUIT BREAKER, 15 AMP

RED WHT/RED

1 2

CIRCUIT BREAKER, 20 A.

YEL/BRN

RED

B1 3

SWITCH, KEY

1 2

CONTACTOR, AUX.

RED 4-A1

RED

ORN

DIODED1DIODE

VIORED GRN/BLU

VIO

CONTACTOR, VACUUM

VIO

CONTACTOR, RIGHT BRUSH

VIO

CONTACTOR, CENTER BRUSH

VIO

CONTACTOR, LEFT BRUSH

VIO

CONTACTOR, SIDE BROOMS

VIO BLU/RED

1 2

HORNH4HORN

BACK UP ALARM

M12

VIO BLU/ORN

PUMP, SOLUTION CONT ROL (OPTIONAL)

VIO

1 2

VALVE, SOLENOID

M13

PUMP, CHEMICAL METERING (OPT IONAL)

M16

PUMP, CHEMICAL METERING (OPT IONAL)

1 2

CONTACTOR, VACUUM

1 2

CONTACTOR, SIDE BROOMS

1 2

CONTACTOR, RIGHT BRUSH

1 2

CONTACTOR, CENTER BRUSH

1 2

CONTACTOR, LEFT BRUSH

ORN

SWITCH, SEAT

YEL/BRN BLK/ORN

(OPTIONAL)

BLU/GRN

WHT/RED

123

POT. 5 OHM

ORN BLK

1 2

LAMP, FLASHING

(OPTIONAL)

GRA/ORN

1 2

SWITCH, BAT. INTERLOCK

(FOR ROLL OUT BATTE RY)

CONTACTOR, AUX.

WHT/ORN

GRA/BLK

BLU/YEL

REDRED

A1 SPEED CONTROLLER

SPEED CONTROLLER

WHT/BLK

BRN/RED

VIO/BLK

FOR.REV.

BLK 4-A2

GRN

ORN

VIO

BLU

YEL/BLU

WHT /VIO

GRA/RED

BRN/BLK

ORN/BRN

BLU/WHT

YEL/GRN

BLK/GRA

TAN/BRN

BLU/GRA

ORN/GRA

VIO BLK

BLU/GRNRED

BLU/GRN

WHT/RED

™

BT1

BLKRED

+ -

BATTERY, 36 Vdc

+ -

X1X1

X2X2

+ -

B-

M-

BLK

J1-5

J1-8

J2-21

J1-15

J1-23

J2-22

J1-19

J1-16

J1-17

J2-15

J1-20

J2-18

J2-23

J1-21

J1-18

J1-7

J1-6

J1-1

J1-9

1 2

(+ ON 40" DISK) (- ON 40" DISK)

MOTION

DIRECTION

MODE 2J2-2 0

MODE 1

A2 CONTROL BOARD ASSEMBLY

M14

FAN, COOLING

M15

ZENER TVSD2ZENER TVS

PUMP, ACCESSORY

1 2

LAMP, HEAD

1 2

MOTOR, VACUUM

1 2

MOTOR, VACUUM

BLK RED

MOTOR, SIDE BROOM

BLK RED

MOTOR, SIDE BROOM

- +

M10

MOTOR, RIGHT BRUSH

- +

(LEFT MOTOR ON 2 MOT OR DECKS)

M11

MOTOR, CENTER BRUSH

(ON 3 MOTOR DECKS)

MOTOR, LEFT BRUSH

FAULT

+8V

B-

CAN H

+5V

B-

(OPTIONAL)

BLK

ORN

GRN

BLU/BLK

BLK/WHT

9101112131415

X6X6

1234567

ORN/RED YEL/RED BLK/YEL ORN

RED/WHT

B+

RED

RED/WHT

J1:11

YEL/RED

J1-12

ORN/RED

J1-4

BLK/WHT

BLU/BLK

J2-19

J2-10

J2-14

J1:10

J1-14

WHT/BRN

J1-22

GRA

J1-13

GRN/BLU

J1-3

BRN/BLU

J1-2CAN L

RED/BLK

J2-6

YEL/GRA

J2:5

WHT/GRN

J2-1

BLU/BRN

J2-9

GRA/VIO

J2-8

GRN/ORN

J2-7

J2-17

GRN/WHT

J2-16

ORN/BLK

J2-4

GRN/GRA

J2-12

ORN/WHT

J2-13 J4-2

GRA/W HT

J2-11 J4-4

BRN

J2-2

ORN/BLU

J2-3

BLKVIO

BLK

COIL, MAIN CONTACTOR

ORN/BLU

BRN

BLK

J3:1

SWITCH/DISPLAY

J3:2

PANEL

J3:3

ASSEMBLY

J3:4

SWITCH, SOLUT ION EMPTY

1 2

J4-1

A4 CHEMICAL SENSING BOARD

A4 NOT USED WITH ECOFLEX

Electrical System 53Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

BLKRED

BRUSH ACTUATOR

BLKRED

SQUEEGEE ACTUATOR

BLKRED

SIDE BROOM ACTUATOR

(CLOSES WHEN EMPTY)

RESISTOR, SCRUB DECK SENSING

1K OHM FOR 40" DISK 10K OHM FOR 40" CYL. 20K OHM FOR 45" & 48" DISK 40K OHM FOR 45" & 48" CYL.

BLK

BLKVIO/YEL

™

Electrical System 54Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Low-voltage Cut-out Feature

All models discussed in this manual are equipped with a low-voltage cutout feature to prevent overdischarging of the batteries. When a machine’s battery pack voltage falls below a specically dened

threshold (voltage settings), the scrub system automatically shuts down. The drive motor will still operate in the low-voltage cut-out mode to allow the machine to be driven to a charging location.

The low-voltage cut-out level is adjustable. The standard lead-acid battery (wet cell) setting is 1.72 volts per cell. The alternate maintenance-free battery (gel cell) setting is 1.81 volts per cell. The standard lead-acid

battery setting is factory-selected and should be used unless the battery manufacturer species the higher

cut-out voltage.

Service Note: A minimum recharge voltage of 2.13 volts per cell must be reached to allow the

scrub and solution systems to function again (reset). A 36-volt battery pack must increase to a 38.6-volt minimum.

Battery Condition Indicator

The battery indicator displays the state of battery charge. Five vertical bars indicates a fully-charged

battery after a complete charging cycle. The battery indicator will retain the state-of-charge even if the key

switch has been turned off. The state-of-charge indicator is reset to full charge when the batteries have been recharged. It is also possible to choose between two different low-voltage thresholds depending on whether

maintenance-free or standard (lead-acid) batteries are being used (Have a qualied service engineer perform

this selection*.)

Note: The following percentages are based on usable battery capacity, not total battery capacity.

Therefore, 100% discharge = 80% of total battery capacity for standard wet-cell batteries, or 70% of total battery capacity for maintenance-free batteries.

Battery Indicator Standard Alternate

5 vertical indicator bars 36.1+ 36.1+ 4 vertical indicator bars 35.5-36.1 35.5-36.1 3 vertical indicator bars 34.4-35.5 34.4-35.5 2 vertical indicator bars 33.9-34.4 33.9-34.4 1 vertical indicator bars 32.2-33.9 33.3-33.9 0 vertical indicator bars 30.9-32.2 32.8-33.3 Low-voltage Cut-out <30.9 <32.8

Battery Location

The Batteries are located in the battery compartment behind the operator seat and

underneath the recovery tank.

The Battery Disconnect is mounted on the right side of the operator seat.

™

Electrical System 55Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Battery (6)

Battery

Disconnect

Maintenance and Adjustments

Warning! Before performing any machine maintenance or adjustments, make sure the key

switch is off and the key is removed from the machine.

Wet-cell Battery Maintenance

Correct maintenance of electric vehicle batteries can greatly extend their life. Well-maintained batteries may

last up to three years, but failure after one year is common if maintenance has been inadequate.

There are three simple rules for good battery maintenance:

• Maintain the correct electrolyte level (check weekly). Use distilled water in batteries whenever possible.

If batteries are discharged, add just enough water to cover the plates in each cell. 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 (charge weekly). Batteries should be charged each time that a machine is

used for more than one hour. The battery compartment cover should be open during charging to avoid a concentrated buildup 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”. Almost all battery caps are vented, so there’s no need to loosen or remove them for charging.

• Keep the batteries clean (check and clean monthly). 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 overcharged.

Note: If there is acid on the batteries, wash the tops of the batteries with a solution of two

tablespoons of baking soda to one quart/liter of water.

™

Electrical System 56Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Checking the Battery Water Level

1. Check the water level of the batteries at least once a week.

2. After charging the batteries, remove the vent caps and check the water level in each battery cell. Use

distilled or demineralized water in a battery lling dispenser (available at most auto parts stores) to ll

each cell to the level indicator (or to approximately 3/8” [10 mm] over the top of the separators). Do not

overll the batteries!

Caution! Acid can spill onto the floor if the batteries are overfilled.

3. Tighten the vent caps.

4. Wash the tops of the batteries with a solution of baking soda and water. Use a mixture of two

tablespoons of baking soda to one quart/liter of water).

Charging Wet-cell Batteries

Charge the batteries each time the machine is used, or when the battery indicator is reading less than full.

To Charge the Batteries

1. Disconnect the machine battery connector.

2. Open the side access panel and push the connector from the charger into the battery connector.

3. Follow the instructions on the battery charger.

4. After charging the batteries, check the uid level in all battery cells. Add distilled water if necessary to

bring the uid level up to the bottom of the ller tubes.

Warning!

• Do not fill the batteries before charging.

• Charge the batteries in a well-ventilated area.

• Do not smoke while servicing the batteries.

When Servicing Batteries

• Remove all jewelry.

• Do not smoke.

• Wear safety glasses, rubber gloves and a rubber apron.

• Work in a well-ventilated area.

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

• ALWAYS disconnect the negative (ground) cable rst when replacing batteries to prevent sparks.

• ALWAYS connect the negative cable last when installing batteries.

™

Electrical System 57Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Caution! To avoid damage to floor surfaces, wipe water and acid from the top of the batteries

after charging.

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 – that is, one or more cells that are putting out less voltage than the other cells.

Note: Always charge batteries before testing.

There are two ways to nd a dead cell:

• Use a voltmeter to check the voltage of each battery with the scrub and drive motors running. The battery

with the dead cell will read 1 or 2 volts lower than the other batteries in the system.

• Use a hydrometer to check the specic gravity

Approximate State of Charge Corresponding to

(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.

State of Charge Specific Gravity

If the batteries in the machine are more than one year old, it’s usually best to replace the whole set rather than replacing just one battery.

Discharged 1.120

General Troubleshooting

Problem Cause Correction

No Power to the Machine

Short machine run time.

The emergency stop switch/battery disconnect by the Operator seat is not connected.

There is a problem on the battery wiring or connections.

The 250-amp fuse (

F4) is blown. Replace the fuse.

Weak batteries or battery/batteries with a dead cell.

Connect the emergency stop switch/battery disconnect.

Check the wiring and connections and clean/ repair as necessary.

Charge and test the batteries. Replace as necessary.

Electrolyte Specific Gravity

Charged 1.265 Initial Full Charge

100% 1.265

75% 1.225 50% 1.190 25% 1.155

Removal and Installation

Warning! Before removing or reinstalling any machine components, make sure the key switch

is off and the key is removed from the machine.

To Install the Batteries

Warning!

• 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. This gas can be ignited by any spark, flame or electrical arc. Do not install any lead-acid battery in a sealed container or enclosure. Hydrogen gas from overcharging must be allowed to escape.

™

Electrical System 58Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Caution!

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

• The batteries must be installed only by an Advance representative or dealer, a qualified electrician or the battery manufacturer.

1. Remove the batteries from their shipping crate and carefully inspect them for cracks or other damage. If damage is evident, contact the carrier that delivered them, or the battery manufacturer, to le a damage

claim.

2. Turn the key switch off and remove the key.

3. Remove the recovery tank from the machine. (Refer to the Recovery System/Removal and Installation/

Recovery Tank section.)

4. Your machine comes from the factory with enough battery cables to install six 6-volt batteries. Using at least two people and an appropriate lifting

Battery

Disconnect

strap, carefully lift the batteries into the battery compartment and arrange them exactly as shown. Secure the batteries as close to the front of the machine as possible. If installing a

monoblock battery, use an overhead

hoist.

5. Install the battery cables as shown. Position the cables so the battery caps can be removed easily for battery service.

™

6. Carefully tighten the nut in each battery terminal until the terminal will not turn. Do not overtighten

the terminals or they will be very difcult to remove for future service.

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

8. Put one of the black rubber boots over each of the terminals and connect the Battery Disconnect.

Electrical System 59Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Specifications

Component Specifications

Use a combination of multiple 2-volt cell units to construct a 36-volt DC battery pack system.

Wet Cell Batteries

Wet Cell Battery Charger

Advance-recommended battery pack capacity is a 395 AH @ 20 Hour Rate

deep cycle battery system. Note that the battery pack must t the battery

compartment size listed in the Technical 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 correct charger DC output amperage to the amp-hour rating batteries being installed. This will prevent the battery pack from being overcharged or undercharged.

The recommended 395 AH battery should be matched to a 36-volt, 36-amp output charger on machines using six 6-volt batteries.

The optional 450 AH battery should be matched to the Advance 36-volt, 38amp output charger.

Special Tools

A hydrometer can be used to check the specic

gravity of the battery electrolyte. A typical example is shown here.

™

Options and Accessories

Brush Selector Guide

• ProLite: Light-duty polypropylene for general scrubbing.

• Prolene: Medium-duty scrubbing on concrete, terrazzo and vinyl oor tile.

• Union Mix: Used for polishing oors.

• Soft Nylon: For use on light dust coated oors where long life is required.

• Hard Nylon: For general use on concrete oors where long life is required.

• AgLite Grit: General scrubbing of urethane coated, sealed or other hard surfaces.

• MidGrit: Lighter action general purpose scrubbing on sealed or unsealed concrete.

• MidLite Grit: General purpose scrubbing of sealed or unsealed concrete oors.

• Dyna Grit: Heavy-duty scrubbing on concrete oors.

60Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

• Magna Grit: Extreme heavy-duty scrubbing on concrete oors.

4030D Pad Holders and Disc Brushes (two required)

Description

Short trim pad holder with pad retainer, 20 inch [51 cm] Pad retainer/centering device only, snap lock Prolite disc brush, 20 inch [51 cm] Prolene disc brush, 20 inch [51 cm] Union Mix disc brush, 20 inch [51 cm] AgLite Grit 500 disc brush, 20 inch [51 cm] MidGrit 240 disc brush, 20 inch [51 cm] MidLite Grit 180 disc brush, 20 inch [51 cm] Dyna Grit 80 disc brush, 20 inch [51 cm] Magna Grit 46 disc brush, 20 inch [51 cm]

4030C Cylindrical Brushes and Side Brooms (two of each required)

Description

Soft nylon cylindrical brush, 40 inch [102 cm] Hard nylon cylindrical brush, 40 inch [102 cm] Prolene cylindrical brush, 40 inch [102 cm] MidLite 180 cylindrical brush, 40 inch [102 cm] Dyna Grit 80 cylindrical brush, 40 inch [102 cm] Side broom, polypropylene, all-purpose

Side broom, polypropylene, ner bristles for delicate surfaces

™

4530D Pad Holders and Disc Brushes (three required)

Description

Short-trim pad holder with pad retainer, 16 inch [41 cm] Pad retainer/centering device only, snap lock ProLite disc brush, 16 inch [41 cm] Prolene disc brush, 16 inch [41 cm] Union Mix disc brush, 16 inch [41 cm] AgLite Grit 500 disc brush, 16 inch [41 cm] MidGrit 240 disc brush, 16 inch [41 cm] MidLite Grit 180 disc brush, 16 inch [41 cm] Dyna Grit 80 disc brush, 16 inch [41 cm] Magna Grit 46 disc brush, 16 inch [41 cm]

4530C Cylindrical Brushes and Side Brooms (two of each required)

Description

Soft nylon cylindrical brush, 45 inch [114 cm] Hard nylon cylindrical brush, 45 inch [114 cm] Prolene cylindrical brush, 45 inch [114 cm] MidLite 180 cylindrical brush, 45 inch [114 cm] Dyna Grit 80 cylindrical brush, 45 inch [114 cm] Side broom, polypropylene, all-purpose

Side broom, polypropylene, ner bristles for delicate surfaces

Options and Accessories 61Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

4830D Pad Holders and Disc Brushes (three required)

Description

Short-trim pad holder with pad retainer, 17 inch [43 cm] Pad retainer/centering device only, snap lock ProLite disc brush, 17 inch [43 cm] Prolene disc brush, 17 inch [43 cm] Union Mix disc brush, 17 inch [43 cm] AgLite Grit 500 disc brush, 17 inch [43 cm] MidGrit 240 disc brush, 17 inch [43 cm] MidLite Grit 180 disc brush, 17 inch [43 cm] Dyna Grit 80 disc brush, 17 inch [43 cm] Magna Grit 46 disc brush, 17 inch [43 cm]

™

4830C Cylindrical Brushes and Side Brooms (two of each required)

Description

Soft nylon cylindrical brush, 48 inch [122 cm] Hard nylon cylindrical brush, 48 inch [122 cm] Prolene cylindrical brush, 48 inch [122 cm] MidLite Grit 180 cylindrical brush, 48 inch [122 cm] Dyna Grit 80 cylindrical brush, 48 inch [122 cm] Side broom, polypropylene, all-purpose

Side broom, polypropylene, ner bristles for delicate surfaces

4030C/D Squeegee Kits

Description

46 inch [117 cm] squeegee blade kit, gum rubber, includes front and rear blade 46 inch [117 cm] squeegee blade kit, Linatex 46 inch [117 cm] squeegee blade kit, polyurethane, includes front and rear blade Cylindrical deck side skirt, gum rubber, 1 each (2 required per deck) Cylindrical deck side skirt, Linatex

, 1 each (2 required per deck) Cylindrical deck side skirt, polyurethane, 1 each (2 required per deck) Disc deck skirt kit, gum rubber, includes left and right blades Disc deck skirt kit, Linatex

, includes left and right blades

Disc deck skirt kit, polyurethane, includes left and right blades

, includes front and rear blade

Options and Accessories 62Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

4530C/D Squeegee Kits

Description

52 inch [131 cm] squeegee blade kit, gum rubber, includes front and rear blade 52 inch [131 cm] squeegee blade kit, Linatex 52 inch [131 cm] squeegee blade kit, polyurethane, includes front and rear blade Cylindrical deck side skirt, gum rubber, 1 each (2 required per deck) Cylindrical deck side skirt, Linatex

, 1 each (2 required per deck) Cylindrical deck side skirt, polyurethane, 1 each (2 required per deck) Disc deck skirt kit, gum rubber, includes left and right blades Disc deck skirt kit, Linatex

, includes left and right blades

Disc deck skirt kit, polyurethane, includes left and right blades

, includes front and rear blade

™

4830C/D Squeegee Kits

Description

55 inch [140 cm] squeegee blade kit, gum rubber, includes front and rear blade 55 inch [140 cm] squeegee blade kit, Linatex

, includes front and rear blade 55 inch [140 cm] squeegee blade kit, polyurethane, includes front and rear blade Cylindrical deck side skirt, gum rubber, 1 each (2 required per deck) Cylindrical deck side skirt, Linatex

, 1 each (2 required per deck) Cylindrical deck side skirt, polyurethane, 1 each (2 required per deck) Disc deck skirt kit, gum rubber, includes left and right blades Disc deck skirt kit, Linatex

, includes left and right blades

Disc deck skirt kit, polyurethane, includes left and right blades

Options and Accessories

Description

Heavy duty front bumper Deluxe Grammer seat kit (in lieu of standard)

Rellable detergent cartridge, 2.5 gallons [9.5 L]

Onboard Scrub, Spray and Vacuum kit includes: mounting bracket, vacuum hose w/ solution line, 2 piece stainless steel heavy duty wand with hard oor and soft oor shoes.

CoolTool spray and scrub wand kit Recovery tank drain hose extension - 11.5 ft [3.5 m] Floor mat kit 2nd vacuum motor kit Warning beacon kit Front headlight kit Back-up alarm kit Seat belt kit Overhead guard Operator foot guard kit Battery exchange cart

Solution auto-ll kit

Two position roller battery charger station (charger not included) Battery tray for (6) 420 AH batteries (batteries not included) Battery roll out kit (batteries not included)

Options and Accessories 63Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

™

Batteries and Chargers

Description

375 AH C6 monoblock battery 375 AH C6 monoblock battery with roll on roll off kit 450 AH C6 monoblock battery Shelf charger, single phase 230 VAC / 36 VDC, 38A, for 375 AH C6 battery Shelf charger, single phase SCR 240/480 VAC / 36 VDC, 96A max, for 450 AH C6 battery Shelf charger, three phase SCR 240/480 VAC / 36 VDC, 88A max, for 450 AH C6 battery

Deck Kits (includes deck and squeegee, brushes sold separately)

Description

40 inch [102 cm] disc deck (ts disc units only)

40 inch [102 cm] cylindrical deck (ts cylindrical units only)

45 inch [114 cm] disc deck (ts disc units only)

45 inch [114 cm] cylindrical deck (ts cylindrical units only)

48 inch [122 cm] disc deck (ts disc units only)

48 inch [122 cm] cylindrical deck (ts cylindrical units only)

Options and Accessories 64Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Extended Warranty

Description

3 year / 3000 hours parts and labor from in-service date 4 year / 4000 hours parts and labor from in-service date

Recovery System

Functional Description

Overview

The recovery system picks up the scrubbing solution from the squeegee

tool and directs it to the Recovery Tank.

Recovery Tank

The Recovery Tank holds 70 gallons [265 l] of wastewater and supports the

Vacuum Motor, Recovery Tank Lid and Top Cover Assembly.

Recovery

Tank Cover

Cover

Gasket

Recovery

Tank

™

Float Cage

and Ball

65Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Top Cover

Assembly

Vacuum Motor

The Vacuum Motor draws air from the

Recovery Tank to create a vacuum in

Squeegee

Hose

Vacuum

Hose

the tank and at the Squeegee.

The Vacuum Motor switches on automatically when the scrub system is enabled and the machine moves

Drain Hose

Squeegee

forward. The Vacuum Motor will switch off after a predetermined time delay once machine motion stops.

The Vacuum Motor can also be switched on independent of the scrub system by pressing the vacuum/wand switch. This is used to pick up solution already on the oor, or when using a wand on the Squeegee Hose.

A current sensor monitors the Vacuum Motor current and will display a fault if the Vacuum Motor current draw is too high.

Squeegee and Squeegee Hose

The wastewater and air enter the vacuum system at the Squeegee tool through small openings (notches) located in the front Squeegee blade. The small openings are the entrance points for the water and air and

help speed up the airow, producing the suction to lift the wastewater off of the oor. The solution travels

through the Squeegee Hose at high speed and into the Recovery Tank. The airow continues through the

Recovery Tank, vacuum fan inlet screen and Vacuum Motor, then is exhausted out of the Vacuum Hose. No

wastewater ever actually moves through the Vacuum Motor, just the working air.

™

Recovery System 66Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Float Cage and Ball

A shutoff Float Cage and Ball prevent the Recovery Tank from being overlled and stops any water from being

sucked into the Vacuum Motor. When the Float Ball rises (to full-tank level) it will seat itself inside the Cage assembly and block off the Vacuum Motor airow. This causes a reduced Vacuum Motor current load which is

sensed by the A2 control board which automatically shuts off the vacuum and scrub systems.

The LCD will then display the recovery tank full indicator icon to alert the operator that the recovery tank needs to

be drained.

Recovery System Wiring Diagram

Circuit Breaker, 3 Amp

Circuit Breaker, 15 Amp

Fuse, 250 A

Key Switch Seat Switch

Diode

Battery Interlock Switch

(for roll-out Battery)

36V Battery

Speed

Controller

B-

Bat -

Bat +

A2 Control

Board

Assembly

Bat -

Motor Shunt

B+

Motion

Direction

CAN H

CAN L

Vacuum

Battery Ground

Switch/Display

Panel Assembly

B+

Vacuum Motor

B-

™

Recovery System 67Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Circuit Description

Vacuum Motors M5 and M6 get positive voltage from the Battery when the load sides of contactors K5 and K1

are closed. Contactors K5 and K1 close when the A2 Control Board Assembly connects the K5 and K1 contactor coils to battery ground. Vacuum Motors M5 and M6 are connected directly to battery ground.

The A2 Control Board Assembly connects the K5 and K1 contactor coils to battery ground when:

• The A3 Switch/Display Panel Assembly sends the A2 Control Board Assembly a signal via the CAN BUS that the vacuum system has been switched on, or,

• The A1 Speed Controller sends the A2 Control Board Assembly a signal that the wheel drive is switched on, the scrub system is enabled and the vacuum system has not been switched off.

Note: The A2 Control Board Assembly monitors the voltage input from the Vacuum Motor Shunt

wire connected to the ground side of Vacuum Motors M5 and M6. If the voltage is out of the acceptable range (.07 - .12 volts for a single vacuum motor or .15 - .24 volts for dual vacuum motors), the A2 Control Board Assembly will sense that the oat ball is sealed against the oat cage and that the recovery tank is full. The A2 Control Board Assembly will then shut down the vacuum and scrub systems and display a recovery tank full icon on the LCD.

Component Locations

Vacuum Motor and Vacuum Hose

The Vacuum Motor sits in a cavity in the

Recovery Tank. To access the Vacuum Motor

, remove the ve Phillips screws and

washers holding the top cover assembly

on the recovery tank and remove the top

cover assembly.

Note that there is room in the

Recovery Tank for an optional second Vacuum Motor.

The Vacuum Hose is clamped to the outlet side of the Vacuum Motor and

exhausts the airow from the Vacuum

Motor

through to the underside of the

machine.

Vacuum

Motor

Vacuum

Hose

Recovery

Tank

Top Cover Assembly

The Top Cover Assembly is fastened to the top

of the recovery tank and includes the Vacuum

Filter Lid Top

, Filter, Filter Screen and Recovery Tank

. The Vacuum Cover Plate, Float Cage and

contained Float Ball attach to the bottom of the

Recovery Tank Top. The Vacuum Fan Top Gasket

seals the Top Cover Assembly to the recovery

tank.

Float Cage and Ball

™

Wire

Rope

Recovery System 68Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Vacuum

Filter Lid

Filter

Screen

The Float Ball is retained inside the two-piece interlocking Float Cage. The assembled Float

Cage

and Float Ball attach to the bottom of the

Recovery Tank Top.

Recovery

Tank Top

Vacuum

Cover Plate

Vacuum Fan Top

Gasket

Float Cage

Float

Cage

Float Ball

Recovery Tank Lid

™

Recovery System 69Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

The Recovery Tank Lid is hinged and opens to allow access to the

Recovery Tank.

Squeegee and Drain Hoses

The Squeegee Hose and Drain

Hoses

are mounted on the rear of

the Recovery Tank.

The Squeegee Hose connects the

squeegee to the inlet port on the

Recovery Tank.

The Drain Hose allows you to drain the Recovery Tank by removing the

Drain Hose Cap.

Recovery

Tank Lid

Recovery

Tank

Drain Hose

Cap

Drain Hose

Squeegee

Hose

™

Maintenance

Warning! Before performing any machine maintenance or adjustments, make sure the key

switch is off, the key is removed from the machine and the parking brake is engaged.

To Inspect and Clean the Vacuum Filter and Inlet Screen

1. Open the tethered Vacuum Filter Lid.

2. Remove the Filter and Filter Screen by pulling them

out of the recess in the Recovery Tank Top.

Recovery System 70Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Vacuum

Filter Lid

3. Clean the Filter and Filter Screen with vacuum or by

washing them in warm water.

4. When the Filter and Filter Screen are clean and dry,

reinstall them into the Recovery Tank Top.

Service Note: The Filter and Filter Screen

must be completely dry before reinstalling.

5. Replace the Vacuum Filter Lid.

To Inspect and Clean the Vacuum Motor Float Cage

1. Lift the Recovery Tank Lid to access the Float Cage and

captive oat ball. The Float Cage is attached to the underside of the Top Cover Assembly.

2. Carefully remove the Float Cage from the Top Cover

Assembly

design and can be snapped apart to separate for cleaning.

. Note that the Float Cage is a two-piece

Recovery

Tank Lid

Float Cage

Filter

Screen

Recovery Tank Top

Top Cover Assembly

3. Clean any debris from the Float Cage slots with a rag,

or by ushing the Float Cage with water. The Float

Cage

slots must be kept clean to prevent any airow

restriction.

4. Reassemble the Float Cage and captive oat ball and

reinstall into the Top Cover Assembly.

5. Inspect the Recovery Lid Gasket to make sure it is not

damaged and is sealing correctly.

Recovery

Lid

Gasket

™

Recovery System 71Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Troubleshooting

If water ows around the ends of the squeegee tool instead of being pulled into the tool, the vacuum system is not working correctly. This is usually due to either vacuum leaks, or restrictions in the squeegee tool, vacuum hoses or oat cage.

Problem Cause Correction

Poor water pickup * Vacuum leak(s) due to:

• Leaky drain hose cap

• Leaky hose

• Bad gasket

• Damaged tank

Restrictions due to built-up debris in the squeegee tool,

vacuum hoses or oat cage

Vacuum motor(s) will not run.

Vacuum motor overload (error code

09 displayed)

Vacuum motor contactor coil overload (error code displayed)

Vacuum motor open (error code

29 displayed)

Vacuum motor contactor coil open (error code

displayed)

K1 Vacuum motor contactor

coil short to ground (error code 31 displayed)

• Check the drain hose cap and tighten/replace as necessary.

• Check the squeegee and recovery tank hoses and tighten/replace as necessary.

• Check the gaskets and replace as necessary.

• Check the recovery tank for damage.

1. Check the squeegee tool, vacuum hoses and oat cage for any accumulated dirt or debris and clean as necessary.

2. Check the vacuum system airow pathway

wherever the airow is forced to make a sharp

turn for any accumulated dirt or debris and clean as necessary.

1. Check for debris in the vacuum motor(s).

2. Check for worn carbon brushes - replace brushes.

3. Defective motor bearings - repair or replace.

4. Check for a short circuit in the vacuum motor or wiring - repair or replace.

1. Check for a K1 coil wiring problem or short circuit (wire colors VIO and BLU).

2. Check the coil resistance. If the coil resistance is below 80 ohms, replace the coil.

1. Check for disconnected vacuum motor wiring.

2. Check for an open circuit in the vacuum motor wiring or for a defective motor.

3. Check for 36 Volts at the vacuum motor. If 0 Volts, replace the vacuum motor contactor K1.

1. Check for an open circuit in the K1 coil and wiring (wire colors VIO and BLU).

2. Test for 36V at the K1 coil. If 0 Volts, check the A2 control board assembly.

1. Disconnect the K1 coil wiring (wire colors VIO and BLU) and check to see if the code disappears.

− If the code disappears, replace the motor contactor.

− If the code does reappear, test the wiring for a short back to the battery ground. Repair or replace the defective wire.

2. If the above test doesn’t remove the code, substitute a new A2 control board assembly.

* A vacuum leak below the waterline will create turbulence in the recovery tank, causing water to enter the

vacuum motor(s).

™

Recovery System 72Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Removal and Installation

Warning! Before removing or reinstalling any machine components, disconnect the battery

pack by pushing in the emergency-stop switch/battery disconnect, and make sure the parking brake is engaged.

Recovery Tank

1. Drain the recovery tank.

2. Disconnect the squeegee hose from the squeegee tool, and from the top of the recovery tank (twist the hose to remove).

Note: Removing the squeegee tool at the mount will allow more room to maneuver when removing

the recovery tank.

3. Disconnect the Vacuum Motor Wiring Connector located underneath the left rear bottom of the

recovery tank.

4. Release the Tank Latch and tilt the tank toward the rear.

Vacuum Motor

Wiring Connector

Tank

Latch

5. Disconnect the Tank Tether from the back of the operator seat.

Caution: Maintain a good grip on the

recovery tank and control the tank as you lower it. Do not allow the tank to fall to the floor on its own.

6. Carefully lower the tank to the oor level.

7. Note that the tank is attached to the chassis

by two pins. Lift up on the tank ends to separate and pull the tank free from the

machine.

Caution: Be careful not to crush or damage the drain hose when pulling the tank from the

chassis.

8. To reinstall the tank:

™

Recovery System 73Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Tank

Tether

a. Align each side of the tank bracket with the chassis pins one at a time.

b. Grip the opening of the tank cover at the rear and quickly lift up to set (engage) the tank in its

upright position.

c. Reconnect the Tank Tether to the back of the operator seat.

d. Swing the tank up to the vertical position to reengage the Tank Latch.

e. Reconnect the vacuum motor wiring connector and squeegee hose.

Vacuum Motor

1. Drain the recovery tank.

2. Release the Tank Latch and tilt the tank to the rear.

Tank

Latch

3. Remove the ve Screws from the Top Cover

Assembly

, then lift the Top Cover Assembly,

straight up while guiding the oat cage up through the opening in the recovery tank.

4. Disconnect the Vacuum

(exhaust) Hose Vacuum Motor.

from the

Vacuum Filter

Lid Gasket

5. Disconnect the wiring harness connector from the Vacuum

Motor

and lift the Vacuum

Motor

out from its mounting

cavity.

RS Strip

Gasket

6. Inspect the following vacuum

system gaskets and replace as

necessary:

Vacuum Fan

Top Gasket

Filter

Screen

™

Screw (5)

Top Cover Assembly

Filter

Recovery System 74Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Vacuum

Motor

Vacuum

Fan

Gaskets

• Vacuum Filter Lid Gasket

• Vacuum Fan Top Gasket

• RS Strip Gasket

• Vacuum Fan Gaskets

7. Clean the vacuum motor

Filter, Filter Screen and Vacuum (exhaust) Hose

8. Inspect the carbon motor brushes. If the carbon brushes are less than 3/8” (10 mm) in length, replace the brushes.

9. Reinstall the Vacuum Motor by following the above steps in reverse order.

Vacuum

(exhaust)

Hose

Specifications

Component Specifications

Vacuum Motor 36 VDC, Insulation Class: A

™

Recovery System 75Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

One Vacuum Motor

Vacuum Lift

Two Vacuum Motors

Special Tools

Vacuum water lift gauge, Nilsk-Advance part number 56205281

(Sealed) 68 in. H

(Open Hole Adapter 1”) 14 in. H (Sealed) 74 in. H

(Open Hole Adapter 1”) 27 in. H

™

Scrub System, Cylindrical

Functional Description

Overview

The Condor EcoFlex™ cylindrical scrub deck models use two cylindrical brushes that counter-rotate to sweep up light debris into a removable hopper, and scrub at the same time. The two scrub brushes are powered on opposing ends by 1-1/2 HP permanent-magnet motors and drive belts.

The scrub deck actuator raises and lowers the scrub deck, and automatically adjusts the deck height while

scrubbing to maintain the desired scrub pressure.

Cylindrical Scrub System Wiring Diagram

76Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Circuit Breaker, 3 Amp

Circuit Breaker, 15 Amp

B+

Fuse, 250 A

Key Switch Seat Switch

Diode

Right Brush Contactor

Center Brush Contactor

Battery Interlock Switch

(for roll-out Battery)

36V Battery

Speed

Controller

B-

Bat -

Bat +

A2 Control

Board

Assembly

Bat -

B+

Motion

Direction

CAN H

CAN L

J2-2

BRN

Battery Ground

Switch/Display

Panel Assembly

RED BLK

Brush Actuator

Solution Empty Switch

(closes when empty)

Scrub Deck Sensing Resistor 10K Ohm for 40" Cyl.

40K Ohm for 45" & 48" Cyl.

Right Brush Contactor

Left Brush Contactor

B+

Right Brush Motor

M10

Left Brush Motor

B-

™

Scrub System, Cylindrical 77Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Circuit Description

The coil sides of contactors K2 and K3 get positive voltage from the Battery when the load side of contactor

K5 is closed. Contactor K5 closes when the A2 Control Board Assembly connects the K5 coil to battery ground.

Contactors K2 and K3 are connected to battery ground through the A2 Control Board Assembly.

The Right Brush Motor M9 and Left Brush Motor M10 get positive voltage from the Battery when the load sides of contactors K2 and K3 are closed respectively. Contactors K2 and K3 close when the A2 Control Board Assembly connects the K2 and K3 coils to battery ground. The Right Brush Motor M9 and Left Brush Motor M10 are connected directly to battery ground.

The Brush Actuator M2 gets voltage from the A2 Control Board Assembly which switches the polarity to move the scrub deck up or down. When the A2 Control Board Assembly receives a signal from the A3 Switch/Display

Panel Assembly Assembly

position.

The Scrub Deck Sensing Resistor R2 senses the deck size so the operator does not need to program the deck size into the hidden menu.

As the brush motor current passes through the BRN current sense wire, which is in effect a low-value resistor, a small voltage drop is developed across it which is proportional to the motor current. This voltage change is inputted to pin J2-2 on the A2 Control Board Assembly. Any surrounding temperature change in the BRN current sense wire affects its resistance, so the temperature is sensed by a thermistor built into the A2 Control Board Assembly. This allows error correction for the temperature resistance changes in the

BRN current sense wire. When A2 Control Board Assembly senses a current draw out of the desired range it

automatically turns on the M2 actuator motor to raise or lower the scrub deck. This process is ongoing in maintaining the operator’s selected scrub motor current load setting to sustain the desired brush working

pressure.

via the CAN BUS that the operator has pressed the scrub on switch, the A2 Control Board

sends the appropriate voltage to the Brush Actuator M2 to lower the scrub deck to the operating

Component Locations

The 1-1/2 HP permanent-magnet Scrub

Motors

that drive the broom drive lug assemblies coupled to the brushes.

drive Poly V Sheaves and Drive Belts

™

Scrub System, Cylindrical 78Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

The Scrub Deck Actuator Assembly

raises and lowers the scrub deck and automatically adjusts the deck height

during scrubbing to maintain the correct scrub pressure.

The Hopper Assembly holds the dust and debris swept up by the scrub brushes, and can be removed for dumping and cleaning.

The Side Skirts direct the waste water to

the squeegee and help keep the water conned within the cleaning path. The

Side Skirt height is adjustable, and the Side Skirts can be removed for cleaning or

replacement.

Scrub Deck

Actuator

Assembly

Scrub

Motor (2)

Hopper

Assembly

Poly V Sheave/

Drive Belt (2)

(under

Belt Guard)

Side

Skirt (2)

Maintenance and Adjustments

Warning! Before performing any machine maintenance or adjustments, make sure the key

switch is off, the key is removed from the machine and the parking brake is engaged.

General Scrub System Maintenance

The scrubbing system must be serviced at regular intervals to maintain good scrubbing performance. Follow the maintenance steps listed below.

Daily Maintenance

• Dump the sweeping debris from the hopper.

• Rinse and clean any built-up debris from the hopper drain holes.

™

Scrub System, Cylindrical 79Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Weekly Maintenance

• Clean the drain holes in the solution delivery trough on top of the scrub deck.

• Clean any built-up dirt from the inside of the scrub brush housing.

• Remove any string wrapped around the scrub brushes, drive hubs and idler hubs.

• Remove both the scrub brushes and rotate end-for-end. Refer to the Removal and Installation/Scrub

Brushes section.

Monthly Maintenance

• Inspect the scrub brush bristles for wear, the brushes should be replaced when the bristle length is 1 inch

(26 mm) or less.

Scrub Brush Belt Replacement

1. Remove the Side Skirt

Assembly

belt replacement.

2. Remove the two hex nuts (10

mm socket) and Phillips screw

holding the Belt Guard, then remove the Belt Guard.

3. Loosen the Flat Head Screw and Hex Screw holding the Belt

Idler Arm Assembly

to release the tension on the belt, then roll the belt off the pulleys to remove.

on the side needing

in position

Hex

Screw

Belt

Idler Arm

Assembly

Flat

Head

Screw

4. Install a new belt onto the pulleys.

Belt Guard

Side Skirt

Assembly

5. Rotate the 1” wide Idler Arm with an adjustable wrench so the Idler Arm is centered between the two holes drilled into the motor mount plate. This will provide a good preliminary tension setting.

6. Tighten the Flat Head Screw.

7. Remove the adjustable wrench from the Idler Arm and tighten the Hex Screw (shown in the

gure on the preceding page).

8. Check for 1/8” deection at the belt midpoint and make

any additional belt tension adjustments as necessary. This will ensure the correct belt performance and belt/ bearing life.

™

Scrub System, Cylindrical 80Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Idler Arm

Flat Head

Screw

9. Reinstall the Belt Guard and

Side Skirt Assembly, then test

the scrub system for correct operation.

Lift Actuator Adjustment

This section explains the steps for adjusting the actuator drive nut (Spring Housing Assembly) setting for the

scrub deck actuator motor.

Using the Actuator Power Cord Adapter

The adjacent drawing shows the special actuator power cord adapter (p/n 56407502) that is needed to connect the machine’s

battery pack and actuator motor for setting

the actuator drive nut limit settings. To connect the actuator power cord adapter:

1. Open the machine battery compartment and disconnect the battery connector. The

battery pack is needed to power the scrub deck actuator motor to correctly set the

and OUT limit switches.

2. Connect the actuator motor to be tested to the power cord adapter end.

3. Connect the alligator clips from the cord adapter (red clip to the positive and black to negative) to

battery connector or battery posts. Use the rocker switch on the actuator power cord adapter to change

the motor rotation when setting the correct actuator drive nut dimensions.

™

Scrub System, Cylindrical 81Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Service Note: You can also use the above actuator power cord adapter to help position the drive

nut/spring housing assembly (in or out) for ease in actuator motor installations.

Drive Nut Adjustment

1. • If you’re installing a new scrub deck actuator motor, begin with step 2 below.

• If you’re adjusting the Drive Nut on the existing scrub deck actuator, skip to step 5 on the following

page.

2. Remove (spin-off) the plastic Drive

Nut

and install the Upper Housing

Spring

onto the actuator lead

screw shaft.

3. Reinstall the Drive Nut as shown

with the nut pin pocket away from

the motor.

4. Assemble the Lower Housing

Spring

, Spring Housing, Nut

Retainer

(two-piece) and mounting

hardware.

Lower Housing Spring

Nut

Retainer

Upper Housing Spring

Drive Nut

Nut

Retainer

Spring

Housing

5. Hold onto the Spring Housing

Assembly

and press the rocker

switch on the actuator power cord adapter to run the drive motor and retract the Spring

Housing Assembly

toward the motor housing (its Retracted limit).

6. Measure the position of the

Spring Housing Assembly on

the actuator shaft. Manually turn the Spring Housing

Assembly Retracted position shown in

to the appropriate

the table below.

Service Note: The Inner Spring (upper housing spring) is set at a pre-loaded compressed setting.

It will be necessary to slightly override the manual adjustment after running the

Spring Housing Assembly in and turning it by hand. A small problem is observed in

the retracted position as the pin mounting bracket interferes with the motor.

Cam

Adjuster

Cover

™

Scrub System, Cylindrical 82Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Nut

Retainer

Part # Actuator Motor Spring Housing

Retracted Position

Spring Housing Extended Position

Models

56413700 Scrub Brush Lift* 4-1/8” [10.48cm] 4” [10.16cm] All

* The

Retracted dimension reference point is the edge of the gearbox case to the center pin weldment of the

assembled Nut Retainer. The Extended dimension reference point is the edge of the gearbox to the edge of the plastic Spring Housing Assembly as shown in the above drawing.

Note: All adjustment settings are measured out of the machine (not attached).

7. After making the initial adjustment, hold the Spring Housing Assembly and run it out enough so that the

Nut Retainer can be turned in to make up difference from the dimension targeted. For example: the rst Retracted dimension measures 4-1/2” minus the 4-1/8 target dimension the difference is 3/8”. Turn the Spring Housing Assembly manually 3/8”, then run the Spring Housing Assembly in under power until the

inner limit stops the motor. Readjust until the Retracted Position is as shown in the above table.

8. Hold the Spring Housing Assembly, then press the rocker switch on the actuator power cord adapter to run the drive motor to the Extended position (wait until the motor stops).

9. Measure the position of the Spring Housing Assembly on the shaft and compare the measurement with the Extended position shown in the above table.

10. If the measurement doesn’t match the dimension shown in the table, remove the Cam Adjuster Cover and adjust the Extended position as follows:

• To increase the travel of the spring housing assembly, turn the adjuster clockwise.

• To decrease the travel of the assembly, turn the adjuster counterclockwise.

™

Scrub System, Cylindrical 83Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Note: Use a 1/2” (13mm) socket to turn the adjuster. Each click of the adjuster will change the

spring housing assembly travel 1/16 inch (1.6mm).

11. After each adjustment, hold the Spring Housing Assembly, run the actuator in and out and check both dimensions.

12. After checking that the Spring Housing Assembly limits are set correctly, replace the Cam Adjuster Cover.

13. After adjusting the actuator

Spring Housing Assembly

dimensions, refer to the Removal

and Installation/Scrub Deck Lift Actuator section to reassemble

it in the machine. Refer to the adjacent drawing to correctly mount the top of actuator motor to the chassis by model size.

Service Note: Note the correct orientation of the Spring Housing Assembly when installing the

complete motor assembly and also run the Spring Housing Assembly to the Retracted (in) position before you install it in the machine.

Side Skirt Replacement and Adjustment

During normal use the side skirt blades will wear in time. The operator will notice a small amount of water leaking out underneath the side skirts. You can easily adjust the side skirt height to lower the blades to allow the squeegee to pick up the water more effectively.

™

To reverse or replace the scrub system side skirt blade(s):

1. Loosen the two side skirt Retainer

Knobs

(two per side) and remove

the Side Skirt Assemblies from the

scrub deck. Remove the Side Skirt

Assemblies

forward, then pulling them off.

by rst sliding them

Retainer Knob (2)

2. Remove all the hardware that holds the Skirt Blades to the

Bracket Weldments. Note that the Skirt Blade is held on with tool-less

retainers. Simply loosen the large

Thumb Nuts, then turn the Knobs

on the outside of the Skirt Strap until they are horizontal, then push them through the slots.

3. The main Skirt Blade has four

working edges as shown. Turn the

Skirt Blade so a clean, undamaged

edge faces toward the center of the machine. Replace the Skirt

Blades

as a set if all four edges are

nicked, torn or worn beyond their

ability to be adjusted.

4. Reinstall the Side Skirt Assemblies

onto the machine and check the

Skirt

Strap

height of the Skirt Blades for

correct contact on the oor when the brush deck is lowered to the

scrub position. The Skirt Blades should fold over just enough when scrubbing that all the waste water

is contained inside the skirting. If

necessary, adjust the height of the

Side Skirt Assemblies as follows:

a. Loosen the Retainer Knobs.

Scrub System, Cylindrical 84Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Front

Height

Adjusting

Knob (2)

Side Skirt

Assembly

Bracket

Weldment

Thumb

Nut (typical)

Knob

(typical)

Skirt

Blade

b. Rotate the Height Adjusting

Knobs

to raise or lower the Side Skirt Assembly as necessary.

Note: Make small adjustments to obtain good blade wiping. Do not lower the blades too much to

where they fold over excessively as this can cause excessive blade wear.

c. When the Skirt Blade contact is correct, tighten the Retainer Knobs.

™

Troubleshooting

Problem Cause Correction

The scrub system will not operate

Scrub deck sense R2 resistor fault (error code

displayed)

Scrub motor overload (error code

04 displayed)

Center brush motor contactor coil overload (error code

06 displayed)

Right brush motor contactor coil overload (error code

displayed)

Scrub motor open (error code

21 displayed)

Center brush motor contactor coil open (error code

24 displayed)

Center brush motor contactor coil short to ground (error code

displayed)

Scrub deck sensor resistor is unplugged or damaged.

1. Check the resistor wiring for an open.

2. Substitute a new resistor and test the scrub deck for correct operation.

Note that there are four different resistor values used on the different deck types. See the electrical

diagram decal for the correct specication of the

resistor to replace.

1. Check for binding in the rotation of the brushes and incorrect brush deck lift actuator operation.

2. Check the negative supply cable at the brush motor for a wiring problem, and also the small BRN current sense wire in the harness and A2 pin J2-2.

3. Check for a short circuit in the brush motor or wiring. Check for excessive belt tension and the condition of the idler bearing.

1. Check for a K3 coil wiring problem or a short circuit (wire colors VIO and WHT/VIO).

2. Check the coil resistance. If the resistance is below 75 ohms, replace the coil.

Note that the nominal coil resistance is 94 ohms for both motor contactors.

1. Check for a K2 coil wiring problem or a short circuit* (wire colors VIO & YEL/BLU).

2. Check the coil resistance. If the resistance is below 75 ohms, replace the coil.

1. Check for an open circuit in the motor wiring or for a defective motor.

2. Check for 36 volts at the scrub motor that is not running. If you get 0 Volts, replace the brush motor contactor.

1. Check for an open circuit in the K3 coil and wiring (wire colors VIO and WHT/VIO).

2. Test for 36V at the K3 coil. If you get 0 Volts, check the A2 control board assembly.

1. Disconnect the K3 coil wiring (wire colors VIO and WHT/VIO) and check to see if the code disappears.

2. If the above test doesn’t remove the code, substitute a new A2 control board assembly.

Scrub System, Cylindrical 85Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

− If the code disappears, replace the brush contactor.

− If the code does reappear, test the wiring for a short back to the battery ground. Repair or replace the defective wire.

™

Problem Cause Correction

The scrub system will not operate (continued)

Right brush motor contactor coil open (error code

displayed)

1. Check for an open circuit in the K2 coil and wiring (wire colors VIO and YEL/BLU).

2. Test for 36V at the K2 coil. If you get 0 Volts, check the A2 control board assembly.

Right brush motor contactor coil short to ground (error code

27 displayed)

1. Disconnect the K2 coil wiring (wire colors VIO and YEL/BLU) and check to see if the code disappears.

− If the code disappears, replace the brush contactor.

− If the code does reappear, test the wiring for a short back to the battery ground. Repair or replace the defective wire.

2. If the above test doesn’t remove the code, substitute a new A2 control board assembly.

The scrub deck actuator doesn’t raise or lower the scrub deck

Scrub deck actuator overload (error code

displayed)

• Normal current load is 1-3 amps.

• Max current load is 6 amps.

1. Check for binding or a frozen brush lift linkage and excessive weight on the brush deck.

2. Check for a short circuit in the actuator motor and wiring. Repair or replace.

To test the actuator, disconnect the motor plug and attach the actuator power cord adapter (p/n

56407502) and perform an amp draw test. Compare

readings to the current load specications to the left.

• Max current with no load

is 1.4 amps.

Scrub deck actuator open (error code

28 displayed)

1. Check for disconnected lift actuator wiring.

2. Check for an open circuit in the motor wiring or for a defective motor.

3. Check for output voltage from the A2 control board assembly at the actuator wiring plug. It should be 36 volts. If 0 Volts, check the A2 control board assembly.

Scrub System, Cylindrical 86Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Removal and Installation

Warning! Before removing or reinstalling any machine components, make sure the key switch

is off, key is removed from the machine and the parking brake is engaged.

Scrub Brushes

1. Make sure the scrub deck is in the raised position and the

key switch is off.

2. Loosen the Retainer Knobs, then slide the Side Skirt

Assembly

then off of the scrub deck.

forward slightly,

™

Scrub System, Cylindrical 87Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

3. Loosen the Thumb Nut on top of the Broom Idler Assembly until the Broom Idler Assembly drops down far enough to disengage it from the Notches, then remove the Broom Idler

Assembly

4. Remove the Brush from the housing.

5. To reinstall a Brush, slide it into the housing, lift it slightly, then push and turn the Brush until it seats.

6. Reinstall the Broom Idler

Assembly Assembly

and Side Skirt .

Notch

Brush

Retainer Knob (2)

Thumb Nut

Broom Idler

Assembly

Side Skirt

Assembly

Scrub Brush Deck

Warning! Engage the parking brake and chock both rear wheels so the machine can’t roll.

™

Scrub System, Cylindrical 88Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

1. Loosen the four side skirt Retainer Knobs (two per side) and remove the Side Skirt

Assemblies

from the

deck.

2. Slide out the Hopper.

3. With the scrub brushes installed in

the deck, press the

Scrub On button to

lower the deck to the oor.

ID Resistor

Plug

Retainer

Knob (4)

Solution

Feed Hose

Side Skirt

Assembly

Hopper

Cotter

Hair Pin

Scrub Deck

Actuator

Spring Housing

Assembly

Retainer

Pivot

Support

Arm (4)

Hex

Nut (4)

Service Note: Once the brush deck is in the lowered position, don’t turn the key switch off until

you disconnect the battery pack (push in the Emergency Disconnect). This will prevent the scrub deck from automatically rising when the key is turned off.

4. Turn the key switch off.

5. Remove the Solution Feed Hose at the solution solenoid valve located underneath the left side of the machine ahead of the rear wheel.

6. Remove bottom lift actuator Cotter Hair Pin, then push the Retainer Pin from its housing and mount

bracket holes.

7. Disconnect the actuator wire harness connector. Note that this will prevent the actuator from being

switched on and rising when it is disconnected from its deck mount.

Service Note: Connect the Advance power cord adapter (p/n 56407502) to the lift motor harness,

then position (relieve the pressure on) the Retainer Pin for ease of removal.

8. Note the correct brush motor wire connections at each individual motor, then remove all the wiring from the motor terminals.

9. Locate the ID (identication) Resistor Plug on the scrub brush deck and separate its connector.

™

Scrub System, Cylindrical 89Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

10. Remove the four Hex Nuts, hex screws and bushings from the left and right front deck supports, then swing the Pivot Support Arms away from their mounting holes.

Service Note: Removing both the left and right side brooms and both front chassis corner rollers

will allow easier access to the mounting hardware on the four front scrub deck support arms.

Warning! Safely jack up the front of the machine 1-1/2 to 2 inches (38-50 mm) and put a wood

block (2 x 4) underneath the drive wheel for a safety support.

11. Run the Scrub Deck Actuator to its retracted (up) position to get the clearance needed to pull the scrub

deck assembly out from underneath the machine.

Service Note: Connect the power cord adapter (p/n 56407502) to the actuator motor and use the

adapter to shorten the Scrub Deck Actuator length. Hold the Spring Housing Assembly when you run the Scrub Deck Actuator motor to maintain the correct retracted and extended position settings. See the Lift Actuator Adjustment section in this manual for additional details.

An alternate method to get the needed actuator clearance to slide the deck out from under the machine would be to safely jack up the front of the machine.

Warning! Support both front corners with adequate jack stands or blocking before working

underneath the machine.

12. Carefully slide the complete deck assembly out from underneath the machine from either side.

Note: Observe the position of the disconnected lift actuator housing and swing it to the rear to clear

its mount bracket pocket.

™

Scrub Deck Lift Actuator

Note: All new replacement actuator motors are not shipped with the lift nut pre-adjusted for any

specic machine model application.

Note: The scrub deck must be removed to access the top mount bracket on the scrub deck lift motor.

1. Remove the scrub deck by following the steps in the Scrub Brush Deck section.

2. Locate and remove the upper Cotter

Hair Pin

of the machine.

3. Slide the actuator Mount Pin from the

housing and frame mounting bracket

holes allowing the motor to drop down completing its removal.

4. Refer to the Drive Nut Adjustment section for instructions on how to install a new drive nut and set the extended and retracted positions.

from underneath the middle

Cotter

Hair Pin

Mount

Scrub System, Cylindrical 90Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Cotter

Hair Pin

5. Install the scrub deck actuator by following the above steps in reverse order.

Service Note: You can use the actuator power cord adapter (p/n 56407502) to help position

(extend or retract) the lift actuator housing for ease in installing the bottom Mount (clevis) Pin.

Scrub Brush Motor

Note: It is not necessary to remove the complete scrub deck assembly from the machine to service

an individual scrub brush motor.

1. Remove the Side Skirt Assembly

on the side of the deck

that needs the scrub motor replaced.

2. Slide out the Hopper.

3. With the scrub brushes

installed in the deck, press the

Scrub On button to lower the

deck to the oor.

Service Note: Once

the brush deck is in the lowered position, don’t turn the key switch off until you disconnect the battery pack (push in the Emergency Disconnect). This will prevent the scrub deck from automatically rising when the key is turned off.

4. Turn the key switch off.

Hopper

™

Clamp (2)

Scrub

Motor

Assembly

Scrub System, Cylindrical 91Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Gear

Motor

Shroud (2)

Screw (4)

Belt Guard

Side Skirt

5. Loosen both worm Gear Clamps that fasten the inboard and outboard Motor Shrouds to the motor housing, then remove both Motor Shrouds from the motor.

6. Remove the two hex nuts (10 mm socket) and Phillips screw holding the Belt Guard and remove the Belt

Guard

7. Remove the four motor mount Screws holding the Scrub Motor to its deck mount. Also note that the Scrub

Motor

may stick to the motor mount, so be careful and watch your ngers as the motor will drop.

8. Turn the Scrub Motor clockwise to access the motor terminal studs. Note the wire connections for correct reassembly, then remove both motor wires.

9. Lower the deck assembly to the deck actuator’s maximum down position (travel) to get the clearance needed to remove the motor from the machine. You can do this either of two ways:

• Reconnect the battery, then lower the scrub deck in the service test mode. (Refer to the Control

System/Service Test Mode section.)

• Connect the actuator power cord adapter to the deck actuator motor and run (lower) the deck housing.

(Refer to the Drive Nut Adjustment section for details.)

10. Pull and push the Scrub Motor back toward the rear of the machine to clear the chassis supports and remove it at the Hopper.

™

11. To install a Scrub Brush Motor:

a. Follow the above steps in reverse order with the exception that the drive belt tension must be

reduced to allow the installation of the four motor mount Screws.

b. Refer to the Scrub Brush Belt Replacement section and follow the instructions on how to replace or

tension the belt.

Scrub System, Cylindrical 92Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Specifications

Component Specifications

Voltage – 36 VDC

Power – 1100 Watt

Scrub Brush Motor

Deck Actuator Motor

Speed – 2200 RPM

Current – 30 Amps

UP Rating – 55

Type – permanent magnet, 36 VDC, 1/5 HP, reversible

Motor-to-drive-screw ratio – 19.1:1

Performance Data

No Load – Thrust 0 lbs., Speed 36 ±4 in/min, 1.0 ±0.5 Amps

Full Load – Thrust 600 lbs., Speed 29 ±3 in/min, 5.0 ±1 Amps

Stall Current – 25 Amps max.

Start Thrust – 600 lbs. min.

Special Tools

Actuator Power Cord Adapter, p/n 56407502

™

Scrub System, Disc

Functional Description

Overview

The Condor EcoFlex™ disc models use rotary brushes powered by permanent-magnet motors and gearbox

assemblies. The 40” decks have two scrub brushes that are both powered by one 3 HP motor/gearbox assembly. The 45” and 48” decks have three brushes, each powered by a separate 1-1/2 HP motor/gearbox

assembly.

The scrub deck lift actuator raises and lowers the scrub deck, and automatically adjusts the deck height

while scrubbing to maintain the desired scrub pressure.

Disc Scrub System Wiring Diagram

93Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Circuit Breaker, 3 Amp

Circuit Breaker, 15 Amp

B+

Fuse, 250 A

Key Switch Seat Switch

Right Brush Contactor

Center Brush Contactor

Left Brush Contactor

Diode

Right Brush Contactor

Center Brush Contactor

Left Brush Contactor

Battery Interlock Switch

(for roll-out Battery)

36V Battery

Speed

Controller

(+ on 40" Disc) (- on 40" Disc )

B-

Bat -

Bat +

A2 Control

Board

Assembly

Bat -

Right Brush Motor

M10

Center Brush Motor

M11

Left Brush Motor (three-motor decks)

Direction

B+

Motion

CAN H

CAN L

J2-2

BRN

Battery Ground

Switch/Display

Panel Assembly

RED BLK

Brush Actuator

Solution Empty Switch

(closes when empty)

Scrub Deck Sensing Resistor

1K Ohm for 40" Disc

20K Ohm for 45" & 48" Disc

B+

B-

™

Scrub System, Disc 94Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Circuit Description

The coil sides of contactors K2, K3 and K4 get positive voltage from the Battery when the load side of contactor

K5 is closed. Contactor K5 closes when the A2 Control Board Assembly connects the K5 coil to battery ground.

Contactors K2, K3 and K4 are connected to battery ground through the A2 Control Board Assembly.

The Right Brush Motor M9, Center Brush Motor M10 and Left Brush Motor M11 get positive voltage from the

Battery when the load sides of contactors K2, K3 and K4 are closed respectively. Contactors K2, K3 and K4 close

when the A2 Control Board Assembly connects the K2, K3 and K4 coils to battery ground. The Right Brush Motor

, Center Brush Motor M10 and Left Brush Motor M11 are connected directly to battery ground.

Panel Assembly Assembly

position.

The Scrub Deck Sensing Resistor R2 senses the deck size so the operator does not need to program the deck size into the hidden menu.

BRN current sense wire. When A2 Control Board Assembly senses a current draw out of the desired range it

pressure.

via the CAN BUS that the operator has pressed the scrub on switch, the A2 Control Board

sends the appropriate voltage to the Brush Actuator M2 to lower the scrub deck to the operating

Component Locations

On the 45” and 48” decks, three 1-1/2 HP

Gearmotors drive the scrub brushes directly. The

40” decks have a single 3 HP Gearmotor with two gearboxes (one on either end) that power the two scrub brushes.

™

Scrub System, Disc 95Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

The Scrub Deck Actuator Assembly raises and

lowers the scrub deck, and automatically adjusts the deck height during scrubbing to maintain the

correct scrub pressure.

The Side Skirts direct the waste water to the

squeegee and help keep the water conned

within the cleaning path. The Side Skirt height is adjustable and the Side Skirts can be removed for cleaning or replacement.

Scrub Deck

Actuator

Assembly

Gearmotor (3)

Side

Skirt (2)

™

Scrub System, Disc 96Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Maintenance and Adjustments

Warning! Before performing any machine maintenance or adjustments, make sure the key

switch is off, the key is removed from the machine and the parking brake is engaged.

Lift Actuator Adjustment

This section explains the steps for adjusting the actuator drive nut (Spring Housing Assembly) setting for the lift actuator motor.

Using the Actuator Power Cord Adapter

The adjacent drawing shows the special actuator power cord adapter (p/n 56407502) that is needed to connect the machine’s

battery pack and actuator motor for setting

the actuator drive nut limit settings. To connect the actuator power cord adapter:

1. Open the machine battery compartment and disconnect the battery connector. The

battery pack is needed to power the lift

actuator motor to correctly set the IN and

OUT limit switches.

2. Connect the actuator motor to be tested to the power cord adapter end.

3. Connect the alligator clips from the cord adapter (red clip to the positive and black to negative) to

battery connector or battery posts. Use the rocker switch on the actuator power cord adapter to change

the motor rotation when setting the correct actuator drive nut dimensions.

Service Note: You can use the above actuator power cord adapter to help position the drive nut/

spring housing assembly (in or out) for ease in actuator motor installations.

™

Scrub System, Disc 97Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Drive Nut Adjustment

1. • If you’re installing a new scrub deck lift actuator motor, begin with step 2 below.

• If you’re adjusting the Drive Nut on the existing scrub deck lift actuator, skip to step 5 on the following

page.

2. Remove (spin-off) the plastic Drive

Nut

and install the Upper Housing

Spring

onto the actuator lead

screw shaft.

3. Reinstall the Drive Nut as shown

Upper Housing Spring

with the nut pin pocket away from

the motor.

Drive Nut

4. Assemble the Lower Housing

Spring

, Spring Housing, Nut

Retainer

(two-piece) and mounting

hardware.

Nut

Retainer

Lower

Housing

Spring

Housing

5. Hold onto the Spring Housing

Assembly

and press the rocker

switch on the actuator power cord adapter to run the drive motor and retract the Spring

Housing Assembly

toward the motor housing (its Retracted limit).

6. Measure the position of the

Spring Housing Assembly on

the actuator shaft. Manually turn the Spring Housing

Assembly Retracted position shown in

to the appropriate

the table below.

Service Note: The Inner Spring (upper housing spring) is set at a pre-loaded compressed setting.

It will be necessary to slightly override the manual adjustment after running the

Spring Housing Assembly in and turning it by hand. A small problem is observed in

the retracted position as the pin mounting bracket interferes with the motor.

Cam

Adjuster

Cover

™

Nut

Retainer

Scrub System, Disc 98Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Part # Actuator Motor Spring Housing

Retracted Position

Spring Housing Extended Position

Models

56413700 Scrub Brush Lift* 4-1/8” [10.48cm] 4” [10.16cm] All

* The

Retracted dimension reference point is the edge of the gearbox case to the center pin weldment of the

assembled Nut Retainer. The Extended dimension reference point is the edge of the gearbox to the edge of the plastic Spring Housing Assembly as shown in the above drawing.

Note: All adjustment settings are measured out of the machine (not attached).

7. After making the initial adjustment hold the Spring Housing Assembly and run it out enough so that the

inner limit stops the motor. Readjust until the Retracted Position is as shown in the above table.

8. Hold the Spring Housing Assembly, then press the rocker switch on the actuator power cord adapter to run the drive motor to the Extended position (wait until the motor stops).

9. Measure the position of the Spring Housing Assembly on the shaft and compare the measurement with the Extended position shown in the above table.

10. If the measurement doesn’t match the dimension shown in the table, remove the Cam Adjuster Cover and adjust the Extended position as follows:

• To increase the travel of the spring housing assembly, turn the adjuster clockwise.

• To decrease the travel of the assembly, turn the adjuster counterclockwise.

™

Scrub System, Disc 99Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Note: Use a 1/2” (13mm) socket to turn the adjuster. Each click of the adjuster will change the

spring housing assembly travel 1/16 inch (1.6mm).

11. After each adjustment, hold the Spring Housing Assembly, run the actuator in and out and check both dimensions.

12. After checking that the Spring Housing Assembly limits are set correctly, replace the Cam Adjuster Cover.

13. After adjusting the actuator

Spring Housing Assembly

dimensions, refer to the Removal

and Installation/Scrub Brush Lift Actuator section to reassemble

it in the machine. Refer to the adjacent drawing to correctly mount the top of lift motor to the chassis by model size.

Service Note: Note the correct orientation of the Spring Housing Assembly when installing the

complete motor assembly and also run the Spring Housing Assembly to the Retracted

(in) position before you install it in the machine.

Side Skirt Replacement and Adjustment

™

To reverse or replace the scrub system side skirt blade(s):

1. Loosen the two side skirt Retainer

Knobs

(two per side) and remove

the Side Skirt Assemblies from the

scrub deck. Remove the Side Skirt

Assemblies

by rst sliding them

Retainer Knob (2)

forward, then pulling them off.

2. Remove all the hardware that holds the Skirt Blades to the Skirt

Weldments Blade

. Note that the Skirt

is held on with tool-less

Height

Adjusting

Knob (2)

retainers. Simply loosen the large

Thumb Nuts, then turn the Knobs

on the outside of the Skirt Strap until they are horizontal, then push them through the slots. The small Inside Blade is held on by two screws and nuts and has two

working edges.

Side Skirt Assembly

3. The main Skirt Blade has four

working edges as shown. Turn the

Skirt Blade so a clean, undamaged

edge faces toward the center of the machine. Replace the Skirt

Blades

as a set if all four edges are

nicked, torn or worn beyond their

ability to be adjusted.

Scrub System, Disc 100Service Manual – Condor™ EcoFlex™, BR 1100/1300 EcoFlex

Front

Skirt

Strap

Thumb

Nut (typical)

Knob

(typical) Inside Blade

4. Reinstall the Side Skirt Assemblies

onto the machine and check the

height of the Skirt Blades for

correct contact on the oor when the brush deck is lowered to the

scrub position. The Skirt Blades should fold over just enough when scrubbing that all the waste water

is contained inside the skirting. If

necessary, adjust the height of the

Side Skirt Assemblies as follows:

Skirt

Weldment

a. Loosen the Retainer Knobs.

b. Rotate the Height Adjusting

Knobs

to raise or lower the Side Skirt Assembly as necessary.

Note: Make small adjustments to obtain good blade wiping. Do not lower the blades too much to

where they fold over excessively as this can cause excessive blade wear.

c. When the Skirt Blade contact is correct, tighten the Retainer Knobs.

Skirt

Blade

Nilfisk-Advance 56381032, X4030D-EcoFlex, 56381037, X4830C-EcoFlex w/Side Broom, 56381033 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual