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EZ Rider HPt
330825Rev. 00
Service Information
*330825*
Patents Pending
The safe scrubbing alternativet
This manual provides service information for the NOBLES Model EZ Rider HP.
This machine will provide excellent service. However, the best results will be obtained at minimumcosts if:
D The machine is operated with reasonable care.D The machine is maintained regularly -- per the maintenance instructions provided.D The machine is maintained with NOBLES supplied or equivalent parts.
Manual Number -- 330825
Revision: 00
Published: 6--05
FaSTt and “The safe scrubbing alternativet” are United States trademarks of Tennant Company.
Copyright E 2005 NOBLES, Printed in U.S.A.
BEFORE CONDUCTING TESTS:
DURING TESTS:
ELECTRICALTroubleshooting Information
* Read and Follow ALL Safety Warnings and Precautions in Operator's Manual
* Always use an ESD (Electrostatic Discharge) strap when working near the Control Board
* Be cautious when working near Control Board – Battery voltage is always present, even with Key OFF
* Always unplug Battery Connector when removing or replacing components
* Call Technical Services if Diagnostic Time Exceeds One Hour With Unknown Cause or Course of Action
NOTE:Troubleshooting charts may be shown with optional equipment. The optional equipment may not be specified in these charts. Some machines may not be equipped with all components shown.
2005.05.11 EZHPETI REV 00
EZ Rider HP
Table of Contents
4Electrical Schematic Addendum for Models with FaST System
13 - 14Wire Harness Drawings Addendum for Models with FaST System
68Specifications (Chart # 2)
3Electrical Schematic for Models with On-board Charger
37 - 41Scrub Head Actuator Removal & Installation Instructions
46 - 59Machine Controller (Trio) Information
69 - 70On-board Charger Setup Instructions
67Test Points (Chart # 1)
61 - 66Troubleshooting Flowcharts
61 - 68FaST System Information
59 - 60Battery Discharge Indicator (BDI) Information
42Horn, Back-up Alarm, & Hazard Light Systems
43 - 44Solution Flow Control
45Fuses & Circuit Breakers
46 - 55Troubleshooting Flowcharts
56Pin Configurations
57Pin Inputs & Outputs
31Extended Scrub (ES) System
32 - 33FaST System
34Signal Resistor (FaST Only)
35Squeegee Actuator
36Scrub Head Actuator
58Battery Cable Connections
29 - 30Recovery Tank Level Switches
28Vacuum Fan Motor
27Scrub Head Configuration Connection
24 - 26Scrub Mode Switch
22 - 23Scrub & Brush Pressure Switches
19Emergency Stop Switch
21Scrub Brush Motors
20Propel System
16 - 18Key Switch & Seat Switch
16 - 44Troubleshooting Sub-system Diagrams (Breakout Schematics)
1Electrical Schematic (00000000-10143032)
2Electrical Schematic (10143033- )
15Commonly Used Electrical Symbols & Terms
9 - 12Wire Harness Drawings (10143033- )
5 - 8Wire Harness Drawings (00000000-10143032)
DESCRIPTION PAGE(S)
EZ Rider HP Electrical Schematic (00000000--10143032)
41/GRY
NOT USED
NOT USED
SEAT SWITCH FAULT
1
EZ Rider HP Electrical Schematic (10143033-- )
41/GRY
NOT USED
NOT USED
SEAT SWITCH FAULT
2
(01--05)
ON--BOARDCHARGER(OPTION)
FU-6
FUSE #393149
FUSE #393149
FUSE #393149
FUSE #393149
FUSE #393149
FUSE #392895
DIAGNOSTIC LED FAULT CODES
I
DIAGNOSTIC MESSAGE:NUMBER OF BARS FLASHINGLOW BATTERY VOLTAGETRACTION MOTOR FAULTBRUSH MOTOR FAULTONE FLASH = SCRUB HEAD ACTUATOR FAULTTWO FLASH = SQUEEGEE ACTUATOR FAULT
1 =2 =3 =4 =
5 = VACUUM MOTOR FAULT6 = SEAT SWITCH OPEN7 = ONE FLASH = THROTTLE FAULT
TWO FLASH = IMPUT SWITCH FAULT8 = CONTROL SYSTEM FAULT9 = ONE FLASH = RECOVERY TANK FULL SENSOR FAULT
TWO FLASH = BACK UP ALAM FAULT
FOUR FLASH = ES PUMP FAULTFIVE FLASH = HOUR METER FAULTHIGH BATTERY VOLTAGE
RIPPLE UP/ON = PEDAL NOT IN NEUTRAL
THREE FLASH = SOLUTION VALVE FAULT
10 =
EZ Rider HP Electrical Schematic for Models with Optional On-board Charger
3
EZ Rider HP Electrical Schematic Addendum for Models with FaST System
4
EZ Rider HP Wire Harnesses Group (00000000--10143032) Page 1 of 4
1
2
2 2 2
5
EZ Rider HP Wire Harnesses Group (00000000--10143032) Page 2 of 4
1
6
EZ Rider HP Wire Harnesses Group (00000000--10143032) Page 3 of 4
1
7
EZ Rider HP Wire Harnesses Group (00000000--10143032) Page 4 of 4
3
4)
8
EZ Rider HP Wire Harnesses Group (10143033-- ) Page 1 of 4
1
22 2 2
9
EZ Rider HP Wire Harnesses Group (10143033-- ) Page 2 of 4
1
10
EZ Rider HP Wire Harnesses Group (10143033-- ) Page 3 of 4
1
11
EZ Rider HP Wire Harnesses Group (10143033-- ) Page 4 of 4
3
4
5
12
1
2
EZ Rider HP Wire Harnesses Group Addendum for Models with FaST System Page 1 of 2
13
3
EZ Rider HP Wire Harnesses Group Addendum for Models with FaST System Page 2 of 2
14
Commonly Used Electrical Symbols & Terms
+ -
Battery
Fuse
Normally OpenSwitch
Motor SolenoidValve
Horn or Alarm
Wires ConnectedTogether
Wiring Color Codes(Unless otherwise marked)
01
23456789
TanPinkBrown
OrangeYellowGreenBlue
PurpleGrayWhite
Right Most Digitof Wire Number
Color of Wire
Example of Wiring Numbers & Colors:
1 RED 25 7 13 BLK
Normally ClosedLimit Switch
Componentis Energized
Plug-inConnection
NOTE: The term “NORMALLY” refers to the component’s “at rest” or “de-energized” position
Diode
Wires Not Connected Together
Terms & AbbreviationsBDI – Battery Discharge IndicatorLED – Light Emitting DiodePWM (Pulse Width Modulation) – A method of using controlled on/off times to regulate the voltage and current
supplied to an electrical device
Movement fromNormal Position
Component in PositionOther than Normal
Normally OpenPush-Button Switch
Normally ClosedPush-Button Switch
Chassis Ground (Static Drain)
Battery Positive or Positive Output
Battery Negativeor Logic Ground
Output that canChange Polarity
Normally ClosedSeat Switch
Normally OpenLiquid Level Switch
LED
Hour Meter
Potentiometer(Variable Resistor)
Lamp(Light Bulb)
M2A
Normally OpenPressure Switch
Circuit Breaker
Relay Coil with spike suppression diode
Fixed valueresistor
Relay Contacts
Open Closed
iInformation
!Warning!
Information Box
Assembly
15
1 RED 13 BLK
EZ Rider HP - Key OFF
+ -6 VDC+ -6 VDC
+ -6 VDC+ -6 VDC
KEYSWITCH
Wiring Color Codes(Unless otherwise marked)
01
23456789
TanPinkBrown
OrangeYellowGreenBlue
PurpleGrayWhite
Right Most Digitof Wire Number
Color of Wire
+ -6 VDC+ -6 VDC
FU-5 10 A
BDI
STATIC DRAIN(Connected to metal frame of machine)
1
3
2
4
3
3
3
2 37
7
22SWITCHEDGROUND
3
MACHINE CONTROLLER
FU-1 125 A
PIN P3-8
PIN P3-6
PIN P3-19
NEG -
PIN P3-18
13 BLK1 REDPOS+
BATTERY VOLTAGEPRESENT AT ALL TIMES!
Be cautious when working near Control Board –Battery voltage is always present, even with Key OFF
!
16
1 RED 13 BLK
EZ Rider HP - Key ON, Operator on Seat
+ -6 VDC+ -6 VDC
+ -6 VDC+ -6 VDC
KEYSWITCH
+ -6 VDC+ -6 VDC
FU-5 10 A
BDI
2
4
3
3
3
2 37
7
22
SWITCHEDGROUND
3
MACHINE CONTROLLER
FU-1 125 A
PIN P3-8
PIN P3-6
PIN P3-19
NEG -
PIN P3-18
13 BLK1 REDPOS+
22 22
22PIN P3-15
SEAT SWITCH
12
SIGNAL OUTPUT
STATIC DRAIN(Connected to metal frame of machine)
1
3
36VDCWith
Key ONi
Wiring Color Codes(Unless otherwise marked)
01
23456789
TanPinkBrown
OrangeYellowGreenBlue
PurpleGrayWhite
Right Most Digitof Wire Number
Color of Wire
BDI should display the state of charge of the batteries if no faults are found; Refer to Machine Controller troubleshooting if BDI LED’s are flashing
i
17
1 RED 13 BLK
EZ Rider HP - Key ON, Operator NOT on Seat
+ -6 VDC+ -6 VDC
+ -6 VDC+ -6 VDC
KEYSWITCH
+ -6 VDC+ -6 VDC
FU-5 10 A
BDI
2
4
3
3
3
2 37
7
22
SWITCHEDGROUND
3
MACHINE CONTROLLER
FU-1 125 A
PIN P3-8
PIN P3-6
PIN P3-19
NEG -
PIN P3-18
13 BLK1 REDPOS+
22 22
22PIN P3-15
12
SEAT SWITCHSTATIC DRAIN
(Connected to metal frame of machine)
1
3
SIGNAL OUTPUT
36VDCWith
Key ONi
Wiring Color Codes(Unless otherwise marked)
01
23456789
TanPinkBrown
OrangeYellowGreenBlue
PurpleGrayWhite
Right Most Digitof Wire Number
Color of Wire
BDI should display 6 rapidly flashing LED’s, indicating that theoperator is not sitting on seat; Refer to Machine Controller troubleshooting for more information
i
18
EZ Rider HP– Emergency Stop Switch
CONDITIONS: Key ON
Emergency Stop Switch is normally closed; Activating the Emergency Stop Switch opens the switch and removes the 0VDC reference voltage to PIN P3-4
Machine will function normally if a 0VDC reference voltage is sensed at pin P3-4
All machine functions will shut off if no reference voltage is sensed at pin P3-4
If the Emergency Stop Switch has been activated, the BDI should display 8 rapidly flashing LED’s; Refer to Machine Controller troubleshooting for more information
i
1 RED 13 BLK+ -6 VDC+ -6 VDC
+ -6 VDC+ -6 VDC
KEYSWITCH
+ -6 VDC+ -6 VDC
FU-5 10 A
BDI
2
4
3
3
3
2 37
7
22
SWITCHEDGROUND
3
MACHINE CONTROLLER
FU-1 125 A
PIN P3-8
PIN P3-6
PIN P3-19
NEG -
PIN P3-18
13 BLK1 REDPOS+
STATIC DRAIN(Connected to metal frame of machine)
1
3
SIGNAL OUTPUT
36VDCWith
Key ONi
Wiring Color Codes(Unless otherwise marked)
01
23456789
TanPinkBrown
OrangeYellowGreenBlue
PurpleGrayWhite
Right Most Digitof Wire Number
Color of Wire
22 22
22PIN P3-4
5SIGNALINPUT
PIN P3-19
EMERGENCYSTOP SWITCH
0VDC REFERENCE
19
EZ Rider HP – Propel System
CONDITIONS: Key ON, operator on seat & travel (forward or reverse)
1 RED 13 BLK+ -6 VDC+ -6 VDC
+ -6 VDC+ -6 VDC
KEYSWITCH
+ -6 VDC+ -6 VDC
FU-5 10 A
BDI
1
3
2
4
3
3
3
2 37
7
22
SWITCHEDGROUND
3
MACHINE CONTROLLER
FU-1 125 A
PIN P3-8
PIN P3-6
PIN P3-19
NEG -
PIN P3-18
13 BLK1 REDPOS+
STATIC DRAIN(Connected to metal frame of machine)
SIGNAL OUTPUT
36VDCWith
Key ONi
Wiring Color Codes(Unless otherwise marked)
01
23456789
TanPinkBrown
OrangeYellowGreenBlue
PurpleGrayWhite
Right Most Digitof Wire Number
Color of Wire
A1 WHT A2 BLK
PROPELMOTOR
HOUR METER
FOOT THROTTLEPOTENTIOMETER
PIN P3-20
PIN P3-10
PIN P3-98
9
10
0VDC REFERENCE
5VDC REFERENCE
THROTTLE SIGNAL INPUT
TRA
CTI
ON
A1 WHT
A2 BLK
A2 BLK
5152
51
52
51
*PWM*
i
Typical Propel Motor Current Draw: 1 to 25 Amps in motion, higher at start-up
Maximum NO-LOAD current: 6 Amps (wheel raised off floor)
Maximum current allowed to Propel Motor by controller: 63 Amps
Propel Motor Voltage: 0 to 36 VDC - FORWARD0 to approx. 27 VDC - REVERSE
Propel Motor is controlled by PWM (Pulse Width Modulation)
Throttle Signal Input will vary from approximately 0 to 5VDC as propel pedal is moved from full forward to full reverse, with neutral being approximately 2.5VDC
6.5K Ohm (+/- 10%) Potentiometeri
Disconnect Traction connector when testing Foot Throttle Potentiometer or
voltage output to Propel Motor!
20
EZ Rider HP – Scrub Brush Motors
1 RED 13 BLK+ -6 VDC+ -6 VDC
+ -6 VDC+ -6 VDC
KEYSWITCH
+ -6 VDC+ -6 VDC
FU-5 10 A
BDI
1
3
2
4
3
3
3
2 37
7
22
SWITCHEDGROUND
3
MACHINE CONTROLLER
FU-1 125 A
PIN P3-8
PIN P3-6
PIN P3-19
NEG -
PIN P3-18
13 BLK1 REDPOS+
STATIC DRAIN(Connected to metal frame of machine)
SIGNAL OUTPUT
36VDCWith
Key ONi
Wiring Color Codes(Unless otherwise marked)
01
23456789
TanPinkBrown
OrangeYellowGreenBlue
PurpleGrayWhite
Right Most Digitof Wire Number
Color of Wire
LEFT BRUSH MOTOR
BR
USH
i
Maximum Brush Motor Current Draw: Standard-duty DISC brush motors – 15 Amps Maximum EACHHeavy-duty DISC brush motors – 23 Amps Maximum EACHCYLINDRICAL brush motors – 22 Amps Maximum EACH
A reversing wire harness is used to change the direction of one motor onmachines equipped with a CYLINDRICAL scrub head (see diagram above)
32
32
32
31 WHT 31 WHT
31 WHT
32
RIGHT BRUSH MOTOR
REVERSING WIRE HARNESS FOR CYLINDRICAL SCRUB HEAD –
LOCATED AT & CONNECTED TO REAR SCRUB BRUSH MOTOR
i
CONDITIONS: Key ON, operator on seat, forward travel, One Step switch ON, scrub modeswitch in “scrub only” or “scrub & vacuum” position
21
EZ Rider HP – Scrub & Brush Pressure Switches (Normal Brush Pressure)
CONDITIONS: Key ON, operator on seat, forward travel, One Step switch ON, scrub modeswitch in “scrub only” or “scrub & vacuum” position
1 RED 13 BLK+ -6 VDC+ -6 VDC
+ -6 VDC+ -6 VDC
KEYSWITCH
+ -6 VDC+ -6 VDC
FU-5 10 A
BDI
1
3
2
4
3
3
3
2 37
7
22
SWITCHEDGROUND
3
MACHINE CONTROLLER
FU-1 125 A
PIN P3-8
PIN P3-6
PIN P3-19
NEG -
PIN P3-18
13 BLK1 REDPOS+
STATIC DRAIN(Connected to metal frame of machine)
SIGNAL OUTPUT
36VDCWith
Key ONi
Wiring Color Codes(Unless otherwise marked)
01
23456789
TanPinkBrown
OrangeYellowGreenBlue
PurpleGrayWhite
Right Most Digitof Wire Number
Color of Wire
PIN P3-1627 NORMAL
PIN P3-19
5VDC REFERENCE
0VDC REFERENCE22
PIN P3-3 4
PIN P3-124
BRUSHPRESSURE
SWITCH
HEAVY
174
17
ONE STEPSWITCH
iNormal brush pressure will be applied if a 5VDC reference voltage is sensed at pins P3-12 and P3-3
Heavy brush pressure will be applied if a 0VDC reference voltage is sensedat pins P3-12 and P3-3
Scrub Functions will be disabled if NO reference voltage is sensed at pins P3-12 and P3-3
SIGNALINPUT
22
EZ Rider HP – Scrub & Brush Pressure Switches (Heavy Brush Pressure)
1 RED 13 BLK+ -6 VDC+ -6 VDC
+ -6 VDC+ -6 VDC
KEYSWITCH
+ -6 VDC+ -6 VDC
FU-5 10 A
BDI
1
3
2
4
3
3
3
2 37
7
22
SWITCHEDGROUND
3
MACHINE CONTROLLER
FU-1 125 A
PIN P3-8
PIN P3-6
PIN P3-19
NEG -
PIN P3-18
13 BLK1 REDPOS+
STATIC DRAIN(Connected to metal frame of machine)
SIGNAL OUTPUT
36VDCWith
Key ONi
Wiring Color Codes(Unless otherwise marked)
01
23456789
TanPinkBrown
OrangeYellowGreenBlue
PurpleGrayWhite
Right Most Digitof Wire Number
Color of Wire
PIN P3-1627 NORMAL
PIN P3-19
5VDC REFERENCE
0VDC REFERENCE22
PIN P3-3 4
PIN P3-124
BRUSHPRESSURE
SWITCH
HEAVY
174
17
ONE STEPSWITCH
SIGNALINPUT
CONDITIONS: Key ON, operator on seat, forward travel, One Step switch ON, scrub modeswitch in “scrub only” or “scrub & vacuum” position
iNormal brush pressure will be applied if a 5VDC reference voltage is sensed at pins P3-12 and P3-3
Heavy brush pressure will be applied if a 0VDC reference voltage is sensedat pins P3-12 and P3-3
Scrub Functions will be disabled if NO reference voltage is sensed at pins P3-12 and P3-3
23
EZ Rider HP – Scrub Mode Switch (Scrub & Vacuum)
1 RED 13 BLK+ -6 VDC+ -6 VDC
+ -6 VDC+ -6 VDC
KEYSWITCH
+ -6 VDC+ -6 VDC
FU-5 10 A
BDI
1
3
2
4
3
3
3
2 37
7
22
SWITCHEDGROUND
3
MACHINE CONTROLLER
FU-1 125 A
PIN P3-8
PIN P3-6
PIN P3-19
NEG -
PIN P3-18
13 BLK1 REDPOS+
STATIC DRAIN(Connected to metal frame of machine)
SIGNAL OUTPUT
36VDCWith
Key ONi
Wiring Color Codes(Unless otherwise marked)
01
23456789
TanPinkBrown
OrangeYellowGreenBlue
PurpleGrayWhite
Right Most Digitof Wire Number
Color of Wire
PIN P3-1627
SCRUB &VACUUM
PIN P3-19
5VDC REFERENCE
0VDC REFERENCE22
PIN P3-116
SCRUB MODESWITCH
6
CONDITIONS: Key ON, operator on seat, forward travel, One Step switch ON
X
6
VACUUMONLY
SCRUBONLY
1
2
4
iScrub system and Vacuum/Squeegee system will operate if a 5VDC reference voltage is sensed at pin P3-11
Vacuum/Squeegee system ONLY will operate if NO reference voltage is sensed at pin P3-11 (Default state)
Scrub system ONLY will operate if a 0VDC reference voltage is sensed at pin P3-11
SIGNAL INPUT
Scrub operations only – No vacuum or squeegee operations0VDCScrub Only
Vacuum & Squeegee operations only – No scrubbingNONEVacuum Only
All scrub, vacuum, & squeegee operations5VDCScrub & Vacuum
Switch PositionReference Voltage
to P3-11 System Functions
24
EZ Rider HP – Scrub Mode Switch (Vacuum Only)
1 RED 13 BLK+ -6 VDC+ -6 VDC
+ -6 VDC+ -6 VDC
KEYSWITCH
+ -6 VDC+ -6 VDC
FU-5 10 A
BDI
1
3
2
4
3
3
3
2 37
7
22
SWITCHEDGROUND
3
MACHINE CONTROLLER
FU-1 125 A
PIN P3-8
PIN P3-6
PIN P3-19
NEG -
PIN P3-18
13 BLK1 REDPOS+
STATIC DRAIN(Connected to metal frame of machine)
SIGNAL OUTPUT
36VDCWith
Key ONi
Wiring Color Codes(Unless otherwise marked)
01
23456789
TanPinkBrown
OrangeYellowGreenBlue
PurpleGrayWhite
Right Most Digitof Wire Number
Color of Wire
PIN P3-1627
SCRUB &VACUUM
PIN P3-19
5VDC REFERENCE
0VDC REFERENCE22
PIN P3-116
SCRUB MODESWITCH
6
CONDITIONS: Key ON, operator on seat, forward travel, One Step switch ON
X
6
VACUUMONLY
SCRUBONLY
1
2
4
SIGNAL INPUT
iScrub system and Vacuum/Squeegee system will operate if a 5VDC reference voltage is sensed at pin P3-11
Vacuum/Squeegee system ONLY will operate if NO reference voltage is sensed at pin P3-11 (Default state)
Scrub system ONLY will operate if a 0VDC reference voltage is sensed at pin P3-11
Scrub operations only – No vacuum or squeegee operations0VDCScrub Only
Vacuum & Squeegee operations only – No scrubbingNONEVacuum Only
All scrub, vacuum, & squeegee operations5VDCScrub & Vacuum
Switch PositionReference Voltage
to P3-11 System Functions
25
EZ Rider HP – Scrub Mode Switch (Scrub Only)
1 RED 13 BLK+ -6 VDC+ -6 VDC
+ -6 VDC+ -6 VDC
KEYSWITCH
+ -6 VDC+ -6 VDC
FU-5 10 A
BDI
1
3
2
4
3
3
3
2 37
7
22
SWITCHEDGROUND
3
MACHINE CONTROLLER
FU-1 125 A
PIN P3-8
PIN P3-6
PIN P3-19
NEG -
PIN P3-18
13 BLK1 REDPOS+
STATIC DRAIN(Connected to metal frame of machine)
SIGNAL OUTPUT
36VDCWith
Key ONi
Wiring Color Codes(Unless otherwise marked)
01
23456789
TanPinkBrown
OrangeYellowGreenBlue
PurpleGrayWhite
Right Most Digitof Wire Number
Color of Wire
PIN P3-1627
SCRUB &VACUUM
PIN P3-19
5VDC REFERENCE
0VDC REFERENCE22
PIN P3-116
SCRUB MODESWITCH
6
CONDITIONS: Key ON, operator on seat, forward travel, One Step switch ON
X
6
VACUUMONLY
SCRUBONLY1
2
4
SIGNAL INPUT
iScrub system and Vacuum/Squeegee system will operate if a 5VDC reference voltage is sensed at pin P3-11
Vacuum/Squeegee system ONLY will operate if NO reference voltage is sensed at pin P3-11 (Default state)
Scrub system ONLY will operate if a 0VDC reference voltage is sensed at pin P3-11
Scrub operations only – No vacuum or squeegee operations0VDCScrub Only
Vacuum & Squeegee operations only – No scrubbingNONEVacuum Only
All scrub, vacuum, & squeegee operations5VDCScrub & Vacuum
Switch PositionReference Voltage
to P3-11 System Functions
26
EZ Rider HP– Scrub Head Configuration Connection
CONDITIONS: Key OFF to change configuration setting
1 RED 13 BLK+ -6 VDC+ -6 VDC
+ -6 VDC+ -6 VDC
+ -6 VDC+ -6 VDC
MACHINE CONTROLLER
FU-1 125 A
NEG - 13 BLK1 REDPOS+
PIN P3-1627
BRUSH PRESSURESIGNAL INPUT
Wiring Color Codes(Unless otherwise marked)
01
23456789
TanPinkBrown
OrangeYellowGreenBlue
PurpleGrayWhite
Right Most Digitof Wire Number
Color of Wire
PIN P3-2
PIN P3-19
5VDC REFERENCE
0VDC REFERENCE
38
22
Refer to information below for proper
configuration settingi
i
Configuration Settings:
For Standard-duty DISC scrub brush motors:MAKE NO CONNECTIONS
For CYLINDRICAL or Heavy-duty DISC scrub brush motors:CONNECT WIRES 22 & 38 (0VDC reference & signal input)
For applications requiring EXTRA-LIGHT down pressure:CONNECT WIRES 27 & 38 (5VDC reference & signal input)
KEYSWITCH FU-5 10 A
BDI
STATIC DRAIN(Connected to metal frame of machine)
1
3
2
4
3
3
3
2 37
7
22SWITCHEDGROUND
3
PIN P3-8
PIN P3-6
PIN P3-19
PIN P3-18
36VDCWith
Key ONi
27
EZ Rider HP – Vacuum Fan Motor
1 RED 13 BLK+ -6 VDC+ -6 VDC
+ -6 VDC+ -6 VDC
KEYSWITCH
+ -6 VDC+ -6 VDC
FU-5 10 A
BDI
1
3
2
4
3
3
3
2 37
7
22
SWITCHEDGROUND
3
MACHINE CONTROLLER
FU-1 125 A
PIN P3-8
PIN P3-6
PIN P3-19
NEG -
PIN P3-18
13 BLK1 REDPOS+
STATIC DRAIN(Connected to metal frame of machine)
SIGNAL OUTPUT
36VDCWith
Key ONi
Wiring Color Codes(Unless otherwise marked)
01
23456789
TanPinkBrown
OrangeYellowGreenBlue
PurpleGrayWhite
Right Most Digitof Wire Number
Color of Wire
VACUUM FAN MOTOR
VAC
UU
M
i Maximum Vacuum Fan Motor Current Draw: 20 Amps
Typical Vacuum Fan Motor Current Draw: 16 to 18 Amps
34
3433 33
34
CONDITIONS: Key ON, operator on seat, One Step switch ON, scrub modeswitch in “vacuum only” or “scrub & vacuum” position
28
EZ Rider HP– Recovery Tank Full Level Switch
CONDITIONS: Key ON
Recovery Tank Full Switch closes when recovery tank is full
Recovery Tank Full Lamp is lit when recovery tank is full
Recovery Tank Full Switch is in the OPEN position with low or empty tank
Recovery Tank Full Switch is in the CLOSED position with full tank
i
1 RED 13 BLK+ -6 VDC+ -6 VDC
+ -6 VDC+ -6 VDC
KEYSWITCH
+ -6 VDC+ -6 VDC
FU-5 10 A
BDI
2
4
3
3
3
2 37
7
22
SWITCHEDGROUND
3
MACHINE CONTROLLER
FU-1 125 A
PIN P3-8
PIN P3-6
PIN P3-19
NEG -
PIN P3-18
13 BLK1 REDPOS+
STATIC DRAIN(Connected to metal frame of machine)
1
3
SIGNAL OUTPUT
RECOVERYTANK FULL
LEVEL SWITCH
PIN 3-7
PIN P2-1
FU-2 10 A
39 11
29 11
36VDCWith
Key ONi
36VDCWith
Key ONi
Wiring Color Codes(Unless otherwise marked)
01
23456789
TanPinkBrown
OrangeYellowGreenBlue
PurpleGrayWhite
Right Most Digitof Wire Number
Color of Wire
22 22
22PIN P3-14
25
3
3
B C
AX
SIGNALINPUT
PIN P2-5
Orange wire # 3 is found in
connector body, but
is not used
i
3
0VDC REFERENCE
RECOVERYTANK FULL
LAMP
29
EZ Rider HP– Recovery Tank Half Full Level Switch (ES Only)
CONDITIONS: Key ON
Recovery Tank Half Full Switch closes when recovery tank is half full or higher
Recovery Tank Half Full Level Switch is in the OPEN position with low or empty tank
Recovery Tank Half Full Level Switch is in the CLOSED position with at least a half full tank
If wire # 26 (PIN P2-13) is grounded or shorted to the 0VDC reference, the Machine Controller will assume the ES system is installed and the recovery tank is at least half full
i
1 RED 13 BLK+ -6 VDC+ -6 VDC
+ -6 VDC+ -6 VDC
KEYSWITCH
+ -6 VDC+ -6 VDC
FU-5 10 A
BDI
2
4
3
3
3
2 37
7
22
SWITCHEDGROUND
3
MACHINE CONTROLLER
FU-1 125 A
PIN P3-8
PIN P3-6
PIN P3-19
NEG -
PIN P3-18
13 BLK1 REDPOS+
STATIC DRAIN(Connected to metal frame of machine)
1
3
SIGNAL OUTPUT
36VDCWith
Key ONi
Wiring Color Codes(Unless otherwise marked)
01
23456789
TanPinkBrown
OrangeYellowGreenBlue
PurpleGrayWhite
Right Most Digitof Wire Number
Color of Wire
22 22
22PIN P2-13
26
3
3
B C
AX
SIGNALINPUT
PIN P2-5
Orange wire # 3 is found in connector
body, but is not usedi
3
RECOVERYTANK HALF FULLLEVEL SWITCH
0VDC REFERENCE
30
EZ Rider HP– Extended Scrub (ES) System
Recovery Tank must be at least half full for ES pump to operate
ES system will be active anytime ES Switch is ON, regardless if scrub system is ON or not
ES Pump current draw: 3.4 Amps at full load
i
1 RED 13 BLK+ -6 VDC+ -6 VDC
+ -6 VDC+ -6 VDC
KEYSWITCH
+ -6 VDC+ -6 VDC
FU-5 10 A
BDI
2
4
3
3
3
2 37
7
22
SWITCHEDGROUND
3
MACHINE CONTROLLER
FU-1 125 A
PIN P3-8
PIN P3-6
PIN P3-19
NEG -
PIN P3-18
13 BLK1 REDPOS+
STATIC DRAIN(Connected to metal frame of machine)
1
3
SIGNAL OUTPUT
ES SWITCH
36VDCWith
Key ONi
Wiring Color Codes(Unless otherwise marked)
01
23456789
TanPinkBrown
OrangeYellowGreenBlue
PurpleGrayWhite
Right Most Digitof Wire Number
Color of Wire
2222
22PIN P2-7
28
3
SIGNAL INPUT
PIN P2-5
3
0VDC REFERENCE
CONDITIONS: Key ON, operator on seat, recovery tank at least half full
PIN P2-2
PIN P2-1
FU-2 10 A
39 11
14 11
36VDCWith
Key ONi
ES PUMP MOTOR
3
13 BLK
36
36
4
8
10
2
6
9
31
EZ Rider HP– FaST System
1 RED 13 BLK+ -6 VDC+ -6 VDC
+ -6 VDC+ -6 VDC
KEYSWITCH
+ -6 VDC+ -6 VDC
FU-5 10 A
BDI
2
4
3
3
3
2 37
7
22
SWITCHEDGROUND
3
MACHINE CONTROLLER
FU-1 125 A
PIN P3-8
PIN P3-6
PIN P3-19
NEG -
PIN P3-18
13 BLK1 REDPOS+
STATIC DRAIN(Connected to metal frame of machine)
1
3
SIGNALOUTPUT
36VDCWith
Key ONi
Wiring Color Codes(Unless otherwise marked)
01
23456789
TanPinkBrown
OrangeYellowGreenBlue
PurpleGrayWhite
Right Most Digitof Wire Number
Color of Wire
2222
22PIN P2-7
28
3
SIGNAL INPUT
PIN P2-5
3
0VDC REFERENCE
CONDITIONS: Key ON, operator on seat, forward travel, scrub system active
PIN P2-2
PIN P2-1
FU-2 10 A
39 11
14 11
36VDCWith
Key ONi
3
13 BLK
36
36
4
8
10
2
6
9FaST SWITCH
xx
M1A5556 AB
M2A13 BLK3 3
M2B
TIMERMODULE
WATER PRESSURE
SWITCHDETERGENT PUMP
SOLENOID VALVE
AIR PUMP
WATER PUMPD1
D2
CB-3 10 A
13 BLK
54
1 RED
57 57 52
52
52 52
52
52 52
52
52 52
5454
54
5454
54
53 58
3
2 1M1B
13 BLK
Approximately 35 pulses per minutei
Normally OPEN pressure switch –held closed with water pressurei
Activated by
Machine Controller
i
32
EZ Rider HP– Signal Resistor (FaST Only)
CONDITIONS: Key ON
1 RED 13 BLK+ -6 VDC+ -6 VDC
+ -6 VDC+ -6 VDC
KEYSWITCH
+ -6 VDC+ -6 VDC
FU-5 10 A
BDI
1
3
2
4
3
3
3
2 37
7
22
SWITCHEDGROUND
3
MACHINE CONTROLLER
FU-1 125 A
PIN P3-8
PIN P3-6
PIN P3-19
NEG -
PIN P3-18
13 BLK1 REDPOS+
22 22
22PIN P2-13
26
STATIC DRAIN(Connected to metal frame of machine)
3 3
3
B C
AX
FaST SIGNALINPUT
Resistor connects to “Recovery Tank Half Full” connectori
SIGNAL OUTPUT
5.6K OHMRESISTOR
Orange wire # 3 is found in connector
body, but is not usedi
36VDCWith
Key ONi
Wiring Color Codes(Unless otherwise marked)
01
23456789
TanPinkBrown
OrangeYellowGreenBlue
PurpleGrayWhite
Right Most Digitof Wire Number
Color of Wire
PIN P2-50VDC REFERENCE
The 5.6K Ohm resistor connected as shown above will tell the Machine Controller that the FaST system is installed
If the 5.6K Ohm resistor is not installed, the Machine Controller will assume there is no FaST system installed and the recovery tank is not at least half full
If wire # 26 (PIN P2-13) is grounded or shorted to the 0VDC reference, the Machine Controller will assume the ES system is installed and the recovery tank is at least half full
i
33
EZ Rider HP– Squeegee Actuator
Squeegee Actuator limit switches are both normally closed, and the respective switch will open at the end-of-travel when extending or retracting
Both limit switches will be closed during actuator travel
Diodes are used to allow current flow around the open switch at the beginning of actuator movement (until switch closes)
Squeegee Actuator current draw: 5.0 Amps at full load
i
1 RED 13 BLK+ -6 VDC+ -6 VDC
+ -6 VDC+ -6 VDC
KEYSWITCH
+ -6 VDC+ -6 VDC
FU-5 10 A
BDI
2
4
3
3
3
2 37
7
22
SWITCHEDGROUND
3
MACHINE CONTROLLER
FU-1 125 A
PIN P3-8
PIN P3-6
PIN P3-19
NEG -
PIN P3-18
13 BLK1 REDPOS+
STATIC DRAIN(Connected to metal frame of machine)
1
3
SIGNAL OUTPUT
36VDCWith
Key ONi
Wiring Color Codes(Unless otherwise marked)
01
23456789
TanPinkBrown
OrangeYellowGreenBlue
PurpleGrayWhite
Right Most Digitof Wire Number
Color of Wire
40 24
PIN P2-323
PIN P2-10
SQUEEGEE LIFT/LOWER ACTUATOR
CONDITIONS: Key ON, operator on seat, engage or disengage One Step switch with Vacuum Fan active
FU-3 10 A
23
TVS
Surge Suppressor (Transient Voltage
Suppressor)i
EXTEND
RETRACT
34
EZ Rider HP– Scrub Head Actuator
Scrub Head Actuator limit switches are both normally closed, and the respective switch will open at the end-of-travel when extending or retracting
Machine controller will turn OFF Scrub Head Actuator when either PIN P2-14 or P2-6 no longer receives the 0VDC reference signal
Both limit switches will be closed during actuator travel
Scrub Head Actuator current draw: 5.0 Amps at full load
i
1 RED 13 BLK+ -6 VDC+ -6 VDC
+ -6 VDC+ -6 VDC
KEYSWITCH
+ -6 VDC+ -6 VDC
FU-5 10 A
BDI
2
4
3
3
3
2 37
7
22
SWITCHEDGROUND
3
MACHINE CONTROLLER
FU-1 125 A
PIN P3-8
PIN P3-6
PIN P3-19
NEG -
PIN P3-18
13 BLK1 REDPOS+
STATIC DRAIN(Connected to metal frame of machine)
1
3
SIGNAL OUTPUT
36VDCWith
Key ONi
Wiring Color Codes(Unless otherwise marked)
01
23456789
TanPinkBrown
OrangeYellowGreenBlue
PurpleGrayWhite
Right Most Digitof Wire Number
Color of Wire
41 GRY 19
PIN P2-418
PIN P2-11
SCRUB HEAD LIFT/LOWER ACTUATOR
CONDITIONS: Key ON, operator on seat, engage or disengage One Step switch with scrub system active
FU-4 10 A
EXTEND
RETRACT
18
22
15
16PIN P2-14
PIN P2-6
PIN P2-50VDC REFERENCE
A
B
C
D
E
16
15
22
35
IB 340570 (3-04) Page 1 of 5
DESCRIPTION:Instructions to remove and reinstall the scrub head lift actuator on the model EZ Rider HP
SPECIAL TOOLS / CONSIDERATIONS: None(Estimated time to complete: 1 hour)
FIG. 1 -- Scrub Head Lift Group
EZ Rider HP–Scrub Head Actuator Removal & Installation
36
Removal:1. Unplug the seat switch.
2. Unplug the traction plug from the P&G controller.
3. Remove the scrub brushes or pad drivers.
4. Loosen the four bolts holding actuator plate.
5. Put the vacuum fan/squeegee switch into thevacuum off position. Put the one--step (scrub)switch into the on position.
6. Turn the key switch on and activate the pedal inthe forward direction. The scrub deck will begin tolower and the brush motors will turn on.
IB 340570 (3-04) Page 2 of 5
EZ Rider HP–Scrub Head Actuator Removal & Installation
37
7. When the scrub deck makes contact with the floorand begins to raise the actuator plate, turn thepower off at the key switch or by using the powerkill switch.
8. Remove the four bolts holding the plate in place.
9. Power on and activate forward propel until theactuator reaches full extension, then power off.
10.Remove the clevis pin at the lower channel.
11.Unplug the actuator and lift out the assembly.
12.Remove the lower bracket assembly.
IB 340570 (3-04) Page 3 of 5
EZ Rider HP–Scrub Head Actuator Removal & Installation
38
13.Lay some cardboard or other non--conductivematerial across the batteries and lay the actuatorassembly down on it.
FOR SAFETY: To prevent shock orsparks, do not lay actuator or metaltools on battery cables.
14.Plug the actuator into the harness, power on andallow the actuator to turn freely until the upper limitswitch in the actuator opens and turns the motoroff.
15.Power off. Turn the tube by hand until the gapbetween the gear--box and tube is 11 mm (7/16 in).
16.Hold onto the tube, power on, activate forwardpropel until the actuator reaches full extension,then power off. HOLD ON TO THE TUBE ALLTHE WAY. If it slips, repeat steps 13 & 14.
17.Unplug the actuator and reinstall the lower bracket
18.Remove the cardboard and place the actuatorback into position.
19.Connect the actuator to the machine by installingthe lower clevis pin.
IB 340570 (3-04) Page 4 of 5
Installation:EZ Rider HP–Scrub Head Actuator Removal & Installation
39
20.Start the two rear bolts into the actuator plate. 21.Power on, and allow the actuator to retract and pullthe upper plate into position.
FOR SAFETY: Keep hands clear ofpinch points while retractingactuator.
22.Install and tighten all four plate bolts and plug inthe actuator.
23.Plug in the seat switch and the traction plug.
24.Install scrub brushes or pad drivers.
IB 340570 (3-04) Page 5 of 5
EZ Rider HP–Scrub Head Actuator Removal & Installation
40
EZ Rider HP – Horn, Back-up Alarm & Hazard Light Systems
CONDITIONS: Key ON, operator on seat & reverse travel (for back-up alarm)
1 RED 13 BLK+ -6 VDC+ -6 VDC
+ -6 VDC+ -6 VDC
KEYSWITCH
+ -6 VDC+ -6 VDC
FU-5 10 A
BDI
1
3
2
4
3
3
3
2 37
7
22
SWITCHEDGROUND
3
MACHINE CONTROLLER
FU-1 125 A
PIN P3-8
PIN P3-6
PIN P3-19
NEG -
PIN P3-18
13 BLK1 REDPOS+
STATIC DRAIN(Connected to metal frame of machine)
SIGNAL OUTPUT
3 3
PIN 3-17
PIN P2-1
FU-2 10 A
39 11
30
3
3 20
13 BLK
13 BLK
35
HORNHORN SWITCH
HAZARDLIGHT SWITCH
30
Back-up Alarm sounds only during reverse traveli
HAZARDLIGHT
BACK-UPALARM
Pulsed Battery Ground with
Reverse Traveli
36VDCWith
Key ONi
36VDCWith
Key ONi
Wiring Color Codes(Unless otherwise marked)
01
23456789
TanPinkBrown
OrangeYellowGreenBlue
PurpleGrayWhite
Right Most Digitof Wire Number
Color of Wire
41
EZ Rider HP – Solution Flow Control (00000000-10143032)
CONDITIONS: Key ON, operator on seat, forward travel, One Step switch ON, scrub modeswitch in “scrub only” or “scrub & vacuum” position
1 RED 13 BLK+ -6 VDC+ -6 VDC
+ -6 VDC+ -6 VDC
KEYSWITCH
+ -6 VDC+ -6 VDC
FU-5 10 A
BDI
1
3
2
4
3
3
3
2 37
7
22
SWITCHEDGROUND
3
MACHINE CONTROLLER
FU-1 125 A
PIN P3-8
PIN P3-6
PIN P3-19
NEG -
PIN P3-18
13 BLK1 REDPOS+
STATIC DRAIN(Connected to metal frame of machine)
SIGNAL OUTPUT
36VDCWith
Key ONi
Wiring Color Codes(Unless otherwise marked)
01
23456789
TanPinkBrown
OrangeYellowGreenBlue
PurpleGrayWhite
Right Most Digitof Wire Number
Color of Wire
SOLUTIONFLOW CONTROLPOTENTIOMETER
PIN P3-1
PIN P3-1627
42
22
0VDC REFERENCE
5VDC REFERENCE
SIGNAL INPUT
iNot all machines use electronic Solution Flow Control – some machines use a mechanical device to control the amount of solution applied to the floor
If electronic Solution Flow Control is used, the Solution Valve is controlled by Pulse Width Modulation
The Solution Valve and Solution Flow Control Potentiometer is used only during conventional scrubbing – they are NOT used during FaST scrubbing
Typical Solution Valve current draw: 0.3 to 0.5 Amps
PIN P2-9
PIN P2-1
FU-2 10 A
39 11
21 11
36VDCWith
Key ONi
SOLUTION VALVE
22
22
22
27
42
*PWM*
Used for conventional scrubbing ONLYi
Used for conventional scrubbing ONLYi
42
EZ Rider HP – Solution Flow Control (10143033- )
CONDITIONS: Key ON, operator on seat, forward travel, One Step switch ON, scrub modeswitch in “scrub only” or “scrub & vacuum” position
1 RED 13 BLK+ -6 VDC+ -6 VDC
+ -6 VDC+ -6 VDC
KEYSWITCH
+ -6 VDC+ -6 VDC
FU-5 10 A
BDI
1
3
2
4
3
3
3
2 37
7
22
SWITCHEDGROUND
3
MACHINE CONTROLLER
FU-1 125 A
PIN P3-8
PIN P3-6
PIN P3-19
NEG -
PIN P3-18
13 BLK1 REDPOS+
STATIC DRAIN(Connected to metal frame of machine)
SIGNAL OUTPUT
36VDCWith
Key ONi
Wiring Color Codes(Unless otherwise marked)
01
23456789
TanPinkBrown
OrangeYellowGreenBlue
PurpleGrayWhite
Right Most Digitof Wire Number
Color of Wire
SOLUTIONFLOW CONTROLPOTENTIOMETER
PIN P3-5
PIN P3-1627
42
22
0VDC REFERENCE
5VDC REFERENCE
SIGNAL INPUT
PIN P2-9
PIN P2-1
FU-2 10 A
39 11
21 11
36VDCWith
Key ONi
SOLUTION VALVE
22
22
22
27
42
*PWM*
Used for conventional scrubbing ONLYi
Used for conventional scrubbing ONLYi
iNot all machines use electronic Solution Flow Control – some machines use a mechanical device to control the amount of solution applied to the floor
If electronic Solution Flow Control is used, the Solution Valve is controlled by Pulse Width Modulation
The Solution Valve and Solution Flow Control Potentiometer is used only during conventional scrubbing – they are NOT used during FaST scrubbing
Typical Solution Valve current draw: 0.3 to 0.5 Amps
43
EZ Rider HP – Fuses & Circuit Breaker
fuse # rating circuit protected location
FU-1 125 Amps Machine Controller
On Machine Controller where Battery (+) cable attaches
FU-2 10 Amps Solution Valve; ES Pump; Recovery Tank Full Lamp; Back-up Alarm
FU-3 10 Amps Squeegee Lift Actuator
FU-4 10 Amps Scrub Head Actuator
FU-5 10 Amps Key Switch; BDI; Machine Controller
circuit breaker # rating circuit protected location
CB-3 10 AmpsFaST Detergent, Air, & Water Pumps; FaST Solenoid Valve;
FaST Timer Module
On the lower part of the operator console
Fuses
Near the two multi-pin connectors on the Machine
Controller
Circuit Breaker
44
Page
1of
15
This
gui
de w
as p
repa
red
to h
elp
you
diag
nose
and
repa
ir th
e m
achi
ne c
ontro
ller.
It is
re
com
men
ded
that
you
beg
in y
our t
roub
lesh
ootin
g at
the
STA
RT
poin
t on
page
2. T
he
follo
win
g ch
art l
ists
the
cont
ents
of t
his
troub
lesh
ootin
g gu
ide
Trou
bles
hoot
ing
Gui
de fo
r the
P
G D
rives
“Trio
” Con
trolle
r
TRIO
BD
I cha
rts &
dia
gram
s14
-15
TRIO
bat
tery
cab
le c
onne
ctio
ns d
iagr
am13
TRIO
con
nect
ors P
2 &
P3
pin
inpu
ts a
nd o
utpu
ts c
harts
12
TRIO
pin
con
figur
atio
ns d
iagr
am11
Cov
ers t
ract
ion
mot
or a
nd fo
ot th
rottl
e10
TEST
3:
Prop
ellin
g Tr
oubl
esho
otin
g9
ES sy
stem
, rec
over
y ta
nk fu
ll lig
ht, h
orn,
& so
lutio
n flo
w c
ontro
l (if
elec
trica
lly c
ontro
lled)
8
Cov
ers t
he fo
llow
ing
func
tions
:7
TEST
2:
Oth
er S
yste
ms T
roub
lesh
ootin
g6
Scru
b br
ush
mot
ors,
scru
b he
ad a
nd sq
ueeg
ee a
ctua
tors
, and
vac
uum
fan
5
Cov
ers t
he fo
llow
ing
func
tions
:4
TEST
1:
Scru
bbin
g Fu
nctio
ns T
roub
lesh
ootin
g3
STA
RT
poin
t for
trou
bles
hoot
ing
2
desc
riptio
npa
ge
45
Page
2of
15
Con
trol
ler
Syst
em T
roub
lesh
ootin
g
Yes
No
Wha
t is B
DI s
tatu
s?W
ith m
eter
lead
s on
the
Trio
’s b
atte
ry c
able
bol
ts, i
s bat
tery
volta
ge m
easu
red?
Y
esN
o
With
met
er le
ads o
n th
eba
ttery
cab
le e
nds a
t the
Trio
, is
batte
ry v
olta
ge m
easu
red?
Yes
No
With
key
on,
do
any
BD
I seg
men
ts li
ght u
p?
STA
RT
With
key
on
or o
ff, i
s the
reba
ttery
vol
tage
at T
rio
conn
ecto
r P3
pin#
8?
Yes
Yes
Yes
Yes
No
No
No
No
Ver
ify p
robl
em is
repa
ired
-ret
est
from
STA
RT
Res
et o
r rep
lace
em
erge
ncy
stop
switc
h, c
heck
all
fuse
s, ch
eck
all w
iring
con
nect
ions
, re
chec
k fu
ses &
wiri
ng,
repl
ace
Trio
if n
eede
d
Rep
lace
mai
n fu
se o
nTr
io a
t B+
conn
ectio
n Rep
air o
r rep
lace
ba
ttery
cab
les,
char
ge o
rre
plac
e ba
tterie
s
With
key
on,
is th
ere
batte
ryvo
ltage
at B
DI p
in#
1?
Che
ck/re
plac
e Fu
se#
5(1
0 am
ps),
chec
k/re
plac
eig
nitio
n sw
itch
With
key
off
, is t
here
con
tinui
tybe
twee
n B
DI p
in#
3 &
Trio
conn
ecto
r P3
pin#
19?
Rep
air/r
epla
ce w
ireor
con
nect
ions
With
key
off
, is t
here
con
tinui
tybe
twee
n B
DI p
in#
2 &
Trio
conn
ecto
r P3
pin#
6?
Ver
ify p
robl
em is
repa
ired
-ret
est
from
STA
RT
Rep
lace
BD
I
Segm
ents
“rip
plin
g”up
and
dow
n
Stea
dy o
r fla
shin
g se
gmen
ts
Go
toT
EST
3Pa
ge 9
Wha
t sys
tem
isno
t wor
king
pro
perly
?
Scru
bbin
gsy
stem
Prop
elsy
stem
Oth
ersy
stem
s
Go
toT
EST
1Pa
ge 3
Go
toT
EST
2Pa
ge 6
Not
e: F
or in
form
atio
n on
the
Trio
pin
co
nfig
urat
ions
, go
to p
ages
11
& 1
2
Not
e: R
efer
to
Page
13,
Fig
ure
1N
ote:
Ref
er to
diag
ram
on
page
14
Not
e: R
efer
todi
agra
m o
n pa
ge 1
4
Ver
ify p
robl
em is
repa
ired
-ret
est
from
STA
RT
Driv
e w
heel
off
gro
und,
bac
k w
heel
s blo
cked
Safe
ty &
Tes
t Req
uire
men
ts:
Key
switc
h “o
n” &
unp
lug
seat
switc
h
Dis
conn
ect t
ract
ion
mot
or p
lug
on T
rio
Be
sure
to h
ave
adeq
uate
bat
tery
cha
rge
“BD
I” is
Bat
tery
Dis
char
ge In
dica
tor
Con
trolle
r will
be
refe
rred
to a
s “TR
IO”
TR
IO C
ontr
olle
r N
otes
Dis
conn
ect t
ract
ion
mot
or
plug
from
Trio
bef
ore
cond
uctin
g th
ese
test
s!!
Not
e: R
efer
toPa
ge 1
3, F
igur
e 2
46
Page
3of
15
TE
ST 1
Scru
b Sy
stem
Wha
t sys
tem
isno
t wor
king
pro
perly
?Sc
rub
brus
h m
otor
s
Scru
b he
ad a
ctua
tor
Vac
uum
fan
Sque
egee
act
uato
r
Doe
s eith
er
brus
h m
otor
op
erat
e?
Yes
No
Yes
Yes
Yes
No
No
No
Rep
air/r
epla
ce w
ire o
rco
nnec
tions
, rep
air/r
epla
ceno
n-w
orki
ng m
otor
(s)
Ver
ify p
robl
em is
repa
ired
-ret
est
from
STA
RT
Rem
ove
“Bru
sh”
conn
ecto
rfr
om T
rio –
is th
ere
batte
ry v
olta
geat
Bru
sh(+
) and
Bru
sh(-
) on
Trio
?
Unp
lug
seat
switc
hTh
rottl
e pe
dal d
epre
ssed
(for
war
d)
Safe
ty &
Tes
t Req
uire
men
ts:
Key
& S
crub
switc
h “o
n”
Driv
e w
heel
off
gro
und,
bac
k w
heel
s blo
cked
Rec
over
y ta
nk le
vel b
elow
floa
t sw
itche
s
Dis
conn
ect t
ract
ion
mot
or p
lug
on T
rio
Not
e: S
crub
M
ode
Switc
h m
ust b
e in
“S
crub
Onl
y”
or
“Scr
ub/V
ac”
posi
tion
Not
e: S
crub
M
ode
Switc
h m
ust b
e in
“V
acO
nly”
or
“S
crub
/Vac
” po
sitio
n
Unp
lug
reco
very
tank
“Fu
ll” f
loat
switc
h –
is th
ere
batte
ry v
olta
ge a
t B
rush
(+) a
nd B
rush
(-) o
n Tr
io?
Rep
air/r
epla
ce fl
oat
switc
h, w
iring
, or
conn
ecto
rs
Go
to APa
ge 4
Is th
ere
batte
ry v
olta
ge a
t Trio
P3
pins
4 &
11,
and
doe
s it s
witc
h po
larit
y w
hen
scru
b sw
itch
is to
ggle
d “o
n” &
“of
f”?
Rep
air/r
epla
ce F
use
4,re
pair/
repl
ace
wiri
ng &
con
nect
ions
,re
pair/
repl
ace
scru
b he
ad a
ctua
tor Ver
ify p
robl
em is
repa
ired
-ret
est
from
STA
RT
Go
to BPa
ge 4
Not
e: R
efer
to T
rio p
in
conf
igur
atio
ns, p
ages
11
& 1
2G
o to C
Page
5
Go
to DPa
ge 5
Scru
bbin
g Sy
stem
Tro
uble
shoo
ting
Dis
conn
ect t
ract
ion
mot
or
plug
from
Trio
bef
ore
cond
uctin
g th
ese
test
s!!
Not
e: T
his t
est w
ill c
over
scru
b br
ush
mot
ors,
scru
b he
ad a
nd sq
ueeg
ee a
ctua
tors
, and
vac
uum
fan
47
Page
4of
15
A(C
ontin
ued
from
pag
e 3)
With
vol
tmet
er le
ads o
n Tr
ioP3
pin
16
and
P3 p
in 1
9, is
ther
e 4.
5 to
5 vo
lts?
(pol
arity
uni
mpo
rtant
)
Not
e: R
efer
to T
rio p
in
conf
igur
atio
ns, p
ages
11
& 1
2
Yes
Yes
No
No
With
key
off
, scr
ub m
ode
switc
hin
“Sc
rub
Onl
y”, b
rush
pre
ssur
e sw
itch
“Hea
vy”-
is th
ere
cont
inui
ty b
etw
een
ALL
Trio
P3
Pins
3, 1
1, 1
2, &
19?
Che
ck a
ll fu
ses,
chec
k al
l wiri
ng &
co
nnec
tions
, rec
heck
fu
ses &
wiri
ng,
repl
ace
Trio
if n
eede
d
Ver
ify p
robl
em is
repa
ired
-ret
est
from
STA
RT
With
key
off
, scr
ub m
ode
switc
hin
“Sc
rub
& V
ac”,
bru
sh p
ress
ure
switc
h “N
orm
al”-
is th
ere
cont
inui
ty b
etw
een
ALL
Trio
P3
Pins
3, 1
1, 1
2, &
16?
Rep
air/r
epla
ce fa
ulty
switc
hes
or re
pair/
repl
ace
wiri
ng&
con
nect
ions
Yes
Yes
No
No
Che
ck a
ll fu
ses,
chec
k al
l wiri
ng
& c
onne
ctio
ns, r
eche
ck fu
ses &
w
iring
, rep
lace
Trio
if n
eede
d
With
met
er le
ads o
n Tr
io P
3pi
n 16
and
P2
pin
5, is
ther
e 4.
5 to
5 v
olts?
(pol
arity
uni
mpo
rtant
)
B(C
ontin
ued
from
pag
e 3)
Rep
air/r
epla
ce w
iring
from
act
uato
r to
Trio
P2
pins
5, 6
, or 1
4, re
pair/
repl
ace
actu
ator
, rec
heck
all
wiri
ng &
conn
ecto
rs, r
epla
ce T
rio if
nee
ded C
heck
all
Trio
wiri
ng &
conn
ectio
ns, r
epla
ceTr
io if
nee
ded
Ver
ify p
robl
em is
repa
ired
-ret
est
from
STA
RT
Unp
lug
seat
switc
hTh
rottl
e pe
dal d
epre
ssed
(for
war
d)
Safe
ty &
Tes
t Req
uire
men
ts:
Key
& S
crub
switc
h “o
n”
Driv
e w
heel
off
gro
und,
bac
k w
heel
s blo
cked
Rec
over
y ta
nk le
vel b
elow
floa
t sw
itche
s
Dis
conn
ect t
ract
ion
mot
or p
lug
on T
rio
Scru
bbin
g Sy
stem
Tro
uble
shoo
ting
48
Page
5of
15
No
Yes
Yes
Yes
No
No
Yes
No
C(C
ontin
ued
from
pag
e 3)
Is th
ere
batte
ry v
olta
ge a
tTr
io P
2 pi
ns 3
& 1
0?
Rep
air/r
epla
ce F
use
# 3
,re
pair/
repl
ace
wiri
ng &
con
nect
ions
,re
pair/
repl
ace
sque
egee
act
uato
r
Unp
lug
reco
very
tank
“Fu
ll” f
loat
switc
h –
does
act
uato
r fun
ctio
n?
Ver
ify p
robl
em is
repa
ired
-ret
est
from
STA
RT
Rep
air/r
epla
ce fl
oat
switc
h, w
iring
, or
conn
ecto
rs
Go
to APa
ge 4
D(C
ontin
ued
from
pag
e 3)
Is th
ere
batte
ry v
olta
geat
Trio
Vac
uum
(+) a
nd
Vac
uum
(-)?
Rep
air/r
epla
ce v
acuu
m fa
nor
wiri
ng a
nd c
onne
ctor
s
Ver
ify p
robl
em is
repa
ired
-ret
est
from
STA
RT
Unp
lug
reco
very
tank
“Fu
ll” f
loat
switc
h –
does
act
uato
r fun
ctio
n? Go
to APa
ge 4
Rep
air/r
epla
ce fl
oat
switc
h, w
iring
, or
conn
ecto
rs
Not
e: R
efer
to T
rio p
in
conf
igur
atio
ns, p
ages
11
& 1
2
Unp
lug
seat
switc
hTh
rottl
e pe
dal d
epre
ssed
(for
war
d)
Safe
ty &
Tes
t Req
uire
men
ts:
Key
& S
crub
switc
h “o
n”
Driv
e w
heel
off
gro
und,
bac
k w
heel
s blo
cked
Rec
over
y ta
nk le
vel b
elow
floa
t sw
itche
s
Dis
conn
ect t
ract
ion
mot
or p
lug
on T
rio
Scru
bbin
g Sy
stem
Tro
uble
shoo
ting
49
Page
6of
15
Oth
er S
yste
ms T
roub
lesh
ootin
g
Not
e: T
his t
est w
ill c
over
the
ES sy
stem
, rec
over
y ta
nk fu
ll lig
ht, h
orn,
& so
lutio
n flo
w c
ontro
l (if
elec
trica
lly c
ontro
lled)
Yes
Yes
Yes
Yes
No
No
No
No
Wha
t sys
tem
isno
t wor
king
pro
perly
?
ES sy
stem
Rec
over
y ta
nk fu
ll lig
ht
Hor
n
Solu
tion
flow
con
trol
Not
e: T
o te
st E
S sy
stem
, hav
e 1/
2 to
3/4
full
reco
very
tank
& E
S sw
itch
“on”
Not
e: T
o te
st so
lutio
n co
ntro
l sys
tem
, hav
ean
em
pty
reco
very
tank
& so
lutio
n ta
nk fi
lled
With
key
off
, is t
here
cont
inui
ty b
etw
een
ALL
Trio
P2
pins
5 &
7 a
nd 1
3?
With
vol
tmet
er o
n Tr
io P
2 pi
ns1
& 2
, is t
here
bat
tery
vol
tage
?
Che
ck F
use
# 2,
repa
ir/re
plac
eES
pum
p, w
iring
or c
onne
ctor
s
Ver
ify p
robl
em is
repa
ired
-ret
est
from
STA
RT
Che
ck a
ll fu
ses,
chec
k al
l wiri
ng
conn
ectio
ns, r
eche
ck fu
ses &
w
iring
, rep
lace
Trio
if n
eede
d
Rep
air/r
epla
ce re
cove
ry ta
nk h
alf
full
switc
h, re
pair/
repl
ace
ES sw
itch,
repa
ir/re
plac
e w
iring
& c
onne
ctor
s
Ver
ify p
robl
em is
repa
ired
-ret
est
from
STA
RT
Mov
e ta
nk fu
ll sw
itch
float
up
& d
own
–do
es li
ght g
o on
& o
ff?
Cle
an o
r rep
air/r
epla
cere
cove
ry ta
nk fu
ll flo
at sw
itchWith
key
off
, is t
here
con
tinui
tybe
twee
n Tr
io P
2 pi
n 1
& P
3 pi
n 7?
Che
ck F
use
# 2,
repa
ir/re
plac
ere
cove
ry ta
nk fu
ll lig
ht, r
epai
r/re
plac
e w
iring
& c
onne
ctor
s
Go
to EPa
ge 7
Ver
ify p
robl
em is
repa
ired
-ret
est
from
STA
RT
Go
to FPa
ge 7
Go
to G Page
8
Not
e: R
efer
to T
rio
pin
conf
igur
atio
ns,
page
s 11
& 1
2
Not
e: R
efer
to
Trio
pin
co
nfig
urat
ions
, pa
ges 1
1 &
12
Unp
lug
seat
switc
hTh
rottl
e pe
dal d
epre
ssed
(for
war
d)
Safe
ty &
Tes
t Req
uire
men
ts:
Key
& S
crub
switc
h “o
n”
Driv
e w
heel
off
gro
und,
bac
k w
heel
s blo
cked
Rec
over
y ta
nk le
vel b
elow
floa
t sw
itche
s
Dis
conn
ect t
ract
ion
mot
or p
lug
on T
rio
Dis
conn
ect t
ract
ion
mot
or
plug
from
Trio
bef
ore
cond
uctin
g th
ese
test
s!!
TE
ST 2
Oth
er S
yste
ms
50
Page
7of
15
Yes
No
With
key
off
, is t
here
cont
inui
ty b
etw
een
Trio
P2
pin
5 &
P3
pin
14?
Che
ck a
ll fu
ses,
chec
k al
l wiri
ng
conn
ectio
ns, r
eche
ck fu
ses &
w
iring
, rep
lace
Trio
if n
eede
d
Rep
air/r
epla
ce re
cove
ry ta
nk fu
ll sw
itch,
repa
ir/re
plac
e w
iring
& c
onne
ctor
s,re
plac
e Tr
io if
nee
ded
Ver
ify p
robl
em is
repa
ired
-ret
est
from
STA
RT
With
key
on
& v
oltm
eter
on w
ires a
t hor
n sw
itch,
is th
ere
batte
ry v
olta
ge?
Yes
Yes
No
No
Rep
air/r
epla
ce h
orn
switc
h or
hor
n
Ver
ify p
robl
em is
repa
ired
-ret
est
from
STA
RT
With
key
off
, is t
here
con
tinui
tybe
twee
n ho
rn sw
itch
wire
20/
Tan
and
Trio
Bat
tery
(-)?
Rep
air/r
epla
ce h
orn
switc
h or
hor
n,re
pair/
repl
ace
wiri
ng &
con
nect
ors
from
Trio
P3
pin
18 to
hor
n sw
itch.
Rep
air/r
epla
ce h
orn,
repa
ir/re
plac
e w
iring
& c
onne
ctor
sfr
om T
rio B
atte
ry(-
) to
horn
.
Ver
ify p
robl
em is
repa
ired
-ret
est
from
STA
RT
Oth
er S
yste
ms T
roub
lesh
ootin
g
Unp
lug
seat
switc
hTh
rottl
e pe
dal d
epre
ssed
(for
war
d)
Safe
ty &
Tes
t Req
uire
men
ts:
Key
& S
crub
switc
h “o
n”
Driv
e w
heel
off
gro
und,
bac
k w
heel
s blo
cked
Rec
over
y ta
nk le
vel b
elow
floa
t sw
itche
s
Dis
conn
ect t
ract
ion
mot
or p
lug
on T
rio
F(C
ontin
ued
from
pag
e 6)
E(C
ontin
ued
from
pag
e 6)
51
Page
8of
15
Yes
Yes
No
No
With
key
off
, is t
here
cont
inui
ty b
etw
een
Trio
P2 p
in 1
& 9
?
With
key
on,
doe
s the
vol
tage
at T
rio
P3 p
ins 1
& 1
9 va
ry st
eadi
ly fr
om 0
to 5
vol
tsas
solu
tion
flow
con
trol p
oten
tiom
eter
is sl
owly
turn
ed fr
om lo
w to
hig
h flo
w?
(pol
arity
uni
mpo
rtant
)
Rep
air/r
epla
ce F
use
# 2,
repa
ir/re
plac
e so
lutio
nva
lve,
repa
ir/re
plac
ew
iring
& c
onne
ctor
s
Ver
ify p
robl
em is
repa
ired
-ret
est
from
STA
RT
Ver
ify p
rope
r ope
ratin
g so
lutio
n va
lve,
che
ck a
ll fu
ses,
chec
k al
l w
iring
con
nect
ions
, rec
heck
fuse
s &
wiri
ng, r
epla
ce T
rio if
nee
ded
Ver
ify p
robl
em is
repa
ired
-ret
est
from
STA
RT
Dis
conn
ect p
lug
at so
lutio
n flo
wco
ntro
l pot
entio
met
er –
mea
sure
resi
stan
ce b
etw
een
whi
te &
ora
nge
wire
s of p
oten
tiom
eter
–is
it a
ppro
x 5k
ohm
s?
No
No
Yes
Yes
Rep
air/r
epla
ce so
lutio
nflo
w c
ontro
l pot
entio
met
er
Ver
ify p
robl
em is
repa
ired
-ret
est
from
STA
RT
Che
ck v
olta
ge a
t pot
entio
met
er o
nw
ires 2
2P/G
reen
& 2
7A/P
urpl
e –
is it
app
rox
4.5
to 5
vol
ts?
(pol
arity
uni
mpo
rtant
)
Ver
ify p
rope
r ope
ratin
g so
lutio
n flo
w c
ontro
l pot
entio
met
er, c
heck
al
l fus
es, c
heck
all
wiri
ng
conn
ectio
ns, r
eche
ck fu
ses &
w
iring
, rep
lace
Trio
if n
eede
d
Rep
air/r
epla
ce w
ires f
rom
P3
pin
16or
pin
19
to p
oten
tiom
eter
, ch
eck
all f
uses
and
wiri
ng &
conn
ectio
ns, r
epla
ce T
rio if
nee
ded
Ver
ify p
robl
em is
repa
ired
-ret
est
from
STA
RT
Oth
er S
yste
ms T
roub
lesh
ootin
g
Unp
lug
seat
switc
hTh
rottl
e pe
dal d
epre
ssed
(for
war
d)
Safe
ty &
Tes
t Req
uire
men
ts:
Key
& S
crub
switc
h “o
n”
Driv
e w
heel
off
gro
und,
bac
k w
heel
s blo
cked
Rec
over
y ta
nk le
vel b
elow
floa
t sw
itche
s
Dis
conn
ect t
ract
ion
mot
or p
lug
on T
rio
G(C
ontin
ued
from
pag
e 3)
52
Page
9of
15
Doe
s mac
hine
pro
pel w
ithse
at sw
itch
unpl
ugge
d an
d tra
ctio
npl
ug p
lugg
ed in
to T
rio?
Yes
Yes
Yes
No
No
No
No
No
Yes
Yes
Rep
air/r
epla
ce se
at sw
itch,
repa
ir/re
plac
e w
iring
and
conn
ecto
rs, r
epla
ce T
rio if
nee
ded
Ver
ify p
robl
em is
repa
ired
-ret
est
from
STA
RT
Is B
DI “
rippl
ing”
up
and
dow
n?
Mea
sure
NEU
TRA
L vo
ltage
at T
rioP3
pin
s 9 &
10
-Is i
t app
rox.
2.25
to 2
.5 v
olts?
(p
olar
ity n
ot im
porta
nt)
With
lead
s stil
l con
nect
ed, p
ress
thro
ttle
peda
l slo
wly
to fu
ll fo
rwar
d, th
en sl
owly
to fu
ll re
vers
e –
Is th
ere
a st
eady
rise
/fall
from
Neu
tral v
olta
ge to
0 v
olts
in o
nedi
rect
ion,
and
to a
ppro
x. 5
vol
ts in
the
othe
r dire
ctio
n?(p
olar
ity n
ot im
porta
nt)
Go
to HPa
ge 1
0
Go
to HPa
ge 1
0
Adj
ust o
r rep
air/r
epla
ceth
rottl
e po
tent
iom
eter
With
key
off
, unh
ook
conn
ecto
r P3
–m
easu
re re
sist
ance
on
conn
ecto
r plu
g w
ires o
npi
ns 9
& 2
0 –
is it
app
rox.
10k
ohm
s?
Ver
ify p
robl
em is
repa
ired
-ret
est
from
STA
RT
Rep
lace
thro
ttle
pote
ntio
met
er.
With
P3
conn
ecte
d &
key
on
,ch
eck/
adju
st p
oten
tiom
eter
toge
t 2.2
5 to
2.5
vol
ts a
tTr
io P
3 pi
ns 9
& 1
0
Prop
ellin
g T
roub
lesh
ootin
g
Unp
lug
seat
switc
hK
ey sw
itch
“on”
Safe
ty &
Tes
t Req
uire
men
ts:
Driv
e w
heel
off
gro
und,
bac
k w
heel
s blo
cked
Dis
conn
ect t
ract
ion
mot
or p
lug
on T
rio
Dis
conn
ect t
ract
ion
mot
or
plug
from
Trio
bef
ore
cond
uctin
g th
is te
st!
!
TE
ST 3
Prop
el S
yste
m
Not
e: T
his t
est w
ill c
over
the
tract
ion
mot
or &
foot
thro
ttle
Not
e: R
efer
to T
rio
pin
conf
igur
atio
ns,
page
s 11
& 1
2
53
Page
10
of 1
5
At t
ract
ion
conn
ectio
n on
Trio
(con
nect
orun
plug
ged)
, is t
here
a st
eady
rise
to n
ear b
atte
ryvo
ltage
whe
n th
rottl
e is
pre
ssed
slow
ly to
full
forw
ard,
and
app
rox.
20
volts
full
reve
rse?
(pol
arity
uni
mpo
rtant
)
Yes
No
Rep
air/r
epla
ce tr
actio
nm
otor
, wiri
ng, o
r con
nect
ors
Ver
ify p
robl
em is
repa
ired
-ret
est
from
STA
RT
Che
ck a
ll fu
ses,
chec
k al
l wiri
ng &
co
nnec
tions
, rec
heck
fu
ses &
wiri
ng,
repl
ace
Trio
if n
eede
d
Prop
ellin
g T
roub
lesh
ootin
g
Not
e: R
efer
to
Trio
pin
co
nfig
urat
ions
, pa
ges 1
1 &
12
Unp
lug
seat
switc
hK
ey sw
itch
“on”
Safe
ty &
Tes
t Req
uire
men
ts:
Driv
e w
heel
off
gro
und,
bac
k w
heel
s blo
cked
Dis
conn
ect t
ract
ion
mot
or p
lug
on T
rio
H(C
ontin
ued
from
pag
e 9)
54
Page
11
of 1
512
34
56
78
910
1112
1314
12
34
56
78
910
1112
1314
1516
1718
1920
Tri
o Pi
n C
onfig
urat
ions
NO
TE
: As v
iew
ed fr
om r
ear
of c
onne
ctor
s (w
ire
side
)
55
Page
12
of 1
5
Tri
o Pi
n In
puts
& O
utpu
ts
pin
inpu
t/out
put
desc
riptio
nP2
-1O
UTP
UT
SWIT
CH
ED B
ATTE
RY
(+) F
RO
M K
EY S
WIT
CH
P2-2
OU
TPU
TES
PU
MP
[BAT
TER
Y (-
)]P2
-3O
UTP
UT
SQU
EEG
EE A
CTU
ATO
R [B
ATTE
RY
(+) O
R (-
)]P2
-4O
UTP
UT
SCR
UB
HEA
D A
CTU
ATO
R [B
ATTE
RY
(+) O
R (-
)]P2
-5O
UTP
UT
0 VD
C R
EFER
ENC
EP2
-6IN
PUT
SCR
UB
HEA
D A
CTU
ATO
R R
ETR
ACT
P2-7
INPU
TES
SW
ITC
HP2
-8X
NO
T U
SED
P2-9
OU
TPU
TSO
LUTI
ON
VAL
VE [B
ATTE
RY
(-)]
P2-1
0O
UTP
UT
SQU
EEG
EE A
CTU
ATO
R [B
ATTE
RY
(+) O
R (-
)]P2
-11
OU
TPU
TSC
RU
B H
EAD
AC
TUAT
OR
[BAT
TER
Y (+
) OR
(-)]
P2-1
2X
NO
T U
SED
P2-1
3IN
PUT
REC
OVE
RY
TAN
K H
ALF
FULL
SW
ITC
HP2
-14
INPU
TSC
RU
B H
EAD
AC
TUAT
OR
EX
TEN
D
Con
nect
or P
2pi
nin
put/o
utpu
tde
scrip
tion
*P3-
1IN
PUT
SOLU
TIO
N F
LOW
CO
NTR
OL
(0 T
O 5
VD
C)
P3-2
INPU
TSC
RU
B H
EAD
TYP
E (T
RI-S
TATE
)P3
-3IN
PUT
SCR
UB
ON
/OFF
& B
RU
SH P
RES
SUR
EP3
-4IN
PUT
EMER
GEN
CY
STO
P SW
ITC
H**
P3-5
INPU
TSO
LUTI
ON
FLO
W C
ON
TRO
L (0
TO
5 V
DC
)P3
-6O
UTP
UT
BATT
ERY
DIS
CH
ARG
E IN
DIC
ATO
RP3
-7O
UTP
UT
REC
OVE
RY
TAN
K FU
LL L
AMP
[BAT
TER
Y (-
)]P3
-8O
UTP
UT
CO
NST
ANT
BATT
ERY
(+)
P3-9
OU
TPU
T0
VDC
REF
EREN
CE
P3-1
0IN
PUT
THR
OTT
LE P
OSI
TIO
N (0
TO
5 V
DC
)P3
-11
INPU
TSC
RU
B M
OD
E SW
ITC
H (T
RI-S
TATE
)P3
-12
INPU
TSC
RU
B O
N/O
FF &
BR
USH
PR
ESSU
RE
P3-1
3X
NO
T U
SED
P3-1
4IN
PUT
REC
OVE
RY
TAN
K FU
LL S
WIT
CH
P3-1
5IN
PUT
SEAT
SW
ITC
HP3
-16
OU
TPU
T5
VDC
REF
EREN
CE
P3-1
7O
UTP
UT
BAC
K-U
P AL
ARM
[BAT
TER
Y (-
)]P3
-18
INPU
TSW
ITC
HED
BAT
TER
Y (+
) FR
OM
KEY
SW
ITC
HP3
-19
OU
TPU
T0
VDC
REF
EREN
CE
P3-2
0O
UTP
UT
5 VD
C R
EFER
ENC
E
Con
nect
or P
3
* P3-
1 no
t use
d on
mac
hine
s w
ith s
eria
l num
bers
101
4303
3 an
d ab
ove
** P
3-5
not u
sed
on m
achi
nes
with
ser
ial n
umbe
rs 0
0000
000
to 1
0143
032
56
Page
13
of 1
5
Tri
o B
atte
ry C
able
Con
nect
ions
Fuse
. . .
. . .W
ashe
rB
olt
Bol
t Neg
ativ
eB
atte
ryC
able
Posi
tive
Bat
tery
Cab
le
. . .Sh
ould
erW
ashe
r. . .
Insu
lato
r
Trio
Con
trolle
r
36 v
olts
??
Mul
timet
er
V
+-
Mul
timet
er
V
+-
This
will
che
ck fo
rba
ttery
vol
tage
to th
e Tr
ioi 36
vol
ts ?
?
FIG
UR
E
1
FIG
UR
E
2
This
will
che
ck fo
r a b
low
n fu
se. I
f bat
tery
vol
tage
is m
easu
red
on th
e Tr
io’s
bat
tery
cab
le h
old-
dow
n bo
lts, f
use
is O
K.
i
57
Page
14
of 1
5
Tri
o B
DI I
nfor
mat
ion
y
BD
I sid
e vi
eww
ith c
able
& p
lug
BD
I top
vie
w
Indi
cato
rD
escr
iptio
nR
ed, y
ello
w, a
nd g
reen
LE
D's
lit (
not f
lash
ing)
Syst
em O
K, n
o fa
ults
foun
d, a
dequ
ate
char
ge in
bat
terie
sO
nly
red
and
yello
w L
ED's
lit (
not f
lash
ing)
Batte
ries
will
soon
nee
d to
be
char
ged
Onl
y re
d LE
D's
lit (
not f
lash
ing)
Cha
rge
batte
ries
imm
edia
tely
LED
's ri
pple
up
only
(not
dow
n)B
atte
ries
are
bein
g ch
arge
dB
DI b
links
on
ever
y 5
seco
nds
Con
trolle
r has
ent
ered
sle
ep m
ode
afte
r 20
min
utes
of i
nact
ivity
BD
I fla
shin
g ra
pidl
yFa
ult h
as b
een
sens
ed; R
efer
to B
DI D
iagn
ostic
Cod
es b
elow
Rip
ple
Up
& D
own
Thro
ttle
peda
l dep
ress
ed a
t sta
rt-up
BD
I Sta
tus
Indi
cato
rs
# B
ars
Flas
hing
Des
crip
tion
of F
ault
Pos
sibl
e C
ause
s1
LOW
BA
TTER
Y V
OLT
AG
EBa
tterie
s ne
ed c
harg
ed; B
ad c
onne
ctio
n to
bat
terie
s2
TRA
CTI
ON
MO
TOR
FA
ULT
Bad
conn
ectio
n to
pro
pel m
otor
3SC
RU
B BR
USH
MO
TOR
FAU
LTBa
d co
nnec
tion
to s
crub
bru
sh m
otor
s4 5
VAC
UU
M M
OTO
R F
AULT
Bad
conn
ectio
n to
vac
uum
fan
mot
or6
SE
AT
SW
ITC
H F
AULT
Ope
rato
r not
on
seat
; Fau
lty s
eat s
witc
h7
THR
OTT
LE F
AULT
Thro
ttle
depr
esse
d be
fore
sta
rt-up
8C
ON
TRO
L S
YSTE
M F
AU
LTEm
erge
ncy
Sto
p S
witc
h ac
tivat
ed; W
iring
issu
e; F
aulty
Trio
con
trolle
r9 10
EXC
ESSI
VE B
ATTE
RY
VOLT
AGE
Bad
conn
ectio
n to
bat
terie
s
NO
T U
SED
NO
T U
SED
NO
TE: R
ippl
e U
p &
Dow
n in
dica
tes
thro
ttle
peda
l dep
ress
ed a
t sta
rt-up
BD
I Dia
gnos
tic C
odes
NO
TE: A
s vie
wed
from
rear
of
con
nect
or (w
ire si
de)
58
Page
15
of 1
5
Tri
o B
DI I
nfor
mat
ion
for
Mod
els w
ith O
ptio
nal O
n-bo
ard
Cha
rger
BD
I top
vie
w
Indi
cato
rD
escr
iptio
nR
ed, y
ello
w, a
nd g
reen
LE
D's
lit (
not f
lash
ing)
Syst
em O
K, n
o fa
ults
foun
d, a
dequ
ate
char
ge in
bat
terie
sO
nly
red
and
yello
w L
ED's
lit (
not f
lash
ing)
Batte
ries
will
soon
nee
d to
be
char
ged
Onl
y re
d LE
D's
lit (
not f
lash
ing)
Cha
rge
batte
ries
imm
edia
tely
LED
's ri
pple
up
only
(not
dow
n)B
atte
ries
are
bein
g ch
arge
dB
DI b
links
on
ever
y 5
seco
nds
Con
trolle
r has
ent
ered
sle
ep m
ode
afte
r 20
min
utes
of i
nact
ivity
BD
I fla
shin
g ra
pidl
yFa
ult h
as b
een
sens
ed; R
efer
to B
DI D
iagn
ostic
Cod
es b
elow
Rip
ple
Up
& D
own
Thro
ttle
peda
l dep
ress
ed a
t sta
rt-up
BD
I Sta
tus
Indi
cato
rs
y
BD
I sid
e vi
eww
ith c
able
& p
lug
NO
TE: A
s vie
wed
fr
om re
ar o
f con
nect
or
(wire
side
)
# B
ars
Flas
hing
# of
Fla
shes
Des
crip
tion
of F
ault
Pos
sibl
e C
ause
s1
1LO
W B
ATT
ERY
VO
LTA
GE
Batte
ries
need
cha
rged
; Bad
con
nect
ion
to b
atte
ries
21
TRA
CTI
ON
MO
TOR
FAU
LTBa
d co
nnec
tion
to p
rope
l mot
or3
1S
CR
UB
BR
US
H M
OTO
R F
AU
LTBa
d co
nnec
tion
to s
crub
bru
sh m
otor
s1
SC
RU
B H
EA
D A
CTU
ATO
R F
AU
LTFa
ulty
act
uato
r; A
ctua
tor u
nplu
gged
2SQ
UEE
GEE
AC
TUAT
OR
FAU
LTFa
ulty
act
uato
r; Ac
tuat
or u
nplu
gged
51
VA
CU
UM
MO
TOR
FA
ULT
Bad
conn
ectio
n to
vac
uum
fan
mot
or6
1SE
AT S
WIT
CH
FAU
LTO
pera
tor n
ot o
n se
at; F
aulty
sea
t sw
itch
1TH
RO
TTLE
FAU
LTTh
rottl
e de
pres
sed
befo
re s
tart-
up2
INP
UT
SW
ITC
H F
AULT
Inco
rrec
t thr
ottle
ped
al s
igna
l; O
pen
thro
ttle
pote
ntio
met
er8
1C
ON
TRO
L S
YSTE
M F
AULT
Emer
genc
y S
top
Sw
itch
activ
ated
; Wiri
ng is
sue;
Fau
lty T
rio c
ontro
ller
1R
ECO
VER
Y TA
NK
FULL
FAU
LTFa
ulty
leve
l sen
sor;
; Lev
el s
enso
r unp
lugg
ed2
BAC
K-U
P AL
ARM
FAU
LTFa
ulty
bac
k-up
ala
rm; S
horte
d ba
ck-u
p al
arm
or f
aulty
wiri
ng3
SOLU
TIO
N V
ALVE
FAU
LTIn
corr
ect s
olut
ion
valv
e si
gnal
; Ope
n so
lutio
n va
lve
pote
ntio
met
er4
ES P
UM
P FA
ULT
Faul
ty E
S pu
mp;
Sho
rted
ES p
ump
or fa
ulty
wiri
ng5
HO
UR
ME
TER
FAU
LTFa
ulty
hou
r met
er; S
horte
d ho
ur m
eter
or f
aulty
wiri
ng10
1EX
CES
SIVE
BAT
TER
Y VO
LTAG
EBa
d co
nnec
tion
to b
atte
ries
NO
TE: R
ippl
e U
p &
Dow
n in
dica
tes
thro
ttle
peda
l dep
ress
ed a
t sta
rt-up
9
BD
I Dia
gnos
tic C
odes
4 7
59
Ove
rall
Syst
em T
roub
lesh
ootin
g
Yes
FaST
FaST
No
Wha
t is t
he so
lutio
n flo
w o
utpu
t per
m
inut
e?
LESS
than
sp
ecifi
catio
ns
Is w
ater
pu
mp
oper
atin
g?
Yes
No
Is a
ir pu
mp
oper
atin
g?
Yes
No
Go
to
TE
ST#
3
Go
to
TE
ST#
1
Go
to
TE
ST#
2
Go
toT
EST
# 1
Go
to
TE
ST#
4
NO
TE
:For
ex
cess
foam
ing
issue
s, ve
rify
that
onl
y Fa
ST
dete
rgen
t is
bein
g us
ed
and/
or th
e w
ater
ta
nk h
as b
een
drai
ned
and
rinse
d be
fore
Fa
STsc
rubb
ing
WA
RN
ING
!Unp
lug
elec
trica
l co
nnec
tors
to p
rope
l mot
or a
nd sc
rub
brus
h m
otor
s be
fore
serv
icin
g!ST
AR
TFa
ST O
pera
tiona
l Req
uire
men
ts:
Igni
tion
switc
h on
FaST
/con
vent
iona
l sw
itch
set t
o Fa
ST
Wat
er ta
nk su
ffici
ently
full
FaST
-Pak
suffi
cien
tly fu
ll &
con
nect
ed
Forw
ard
prop
el e
ngag
ed -
besu
re to
read
war
ning
atS
TA
RT
Ade
quat
e ba
ttery
cha
rge
Scru
b he
ad lo
wer
ed &
bru
shes
eng
aged
Ver
ify F
aST
oper
atio
nal r
equi
rem
ents;
Rem
ove
hose
at T
est P
oint
L, (
Ref
er to
CH
AR
T #
1),
enga
ge fo
rwar
d pr
opel
–Is
any
foam
or
liqui
d be
ing
disc
harg
ed?
Che
ck so
lutio
n flo
w p
er m
inut
e:To
che
ck o
utpu
t by
wei
ght,
dire
ct fo
am o
r liq
uid
disc
harg
e in
to c
onta
iner
and
w
eigh
on
scal
e (R
efer
to C
HA
RT
# 2
for s
olut
ion
flow
wei
ght p
er m
inut
e)
To c
heck
out
put b
y vo
lum
e, d
irect
foam
or l
iqui
d di
scha
rge
into
con
tain
er,
allo
w ti
me
for f
oam
to c
olla
pse
into
a li
quid
stat
e, a
nd m
easu
reliq
uid
volu
me
(Ref
er to
CH
AR
T #
2fo
r sol
utio
n flo
w v
olum
e pe
r min
ute)
MO
RE
than
sp
ecifi
catio
nsO
K p
er
spec
ifica
tions
Go
to
TE
ST#
5
NO
TE
: If
custo
mer
is
com
plai
ning
of
too
muc
hde
terg
ent u
sage
, ch
eck
pulse
rate
pe
r min
ute
of
dete
rgen
t pum
p (R
efer
to
CH
AR
T #
2)
If
not w
ithin
sp
ecifi
catio
ns,
go to
TE
ST #
4
Page
1of
8
60
FaST
FaST
Tro
uble
shoo
ting
-TE
ST #
1T
EST
# 1
(Low
/no
wat
er o
r foa
m)
FaST
Ope
ratio
nal R
equi
rem
ents
:
Igni
tion
switc
h on
FaST
/con
vent
iona
l sw
itch
set t
o Fa
ST
Wat
er ta
nk su
ffici
ently
full
FaST
-Pak
suffi
cien
tly f
ull &
con
nect
ed
Forw
ard
prop
el e
ngag
ed -
besu
re to
read
war
ning
atS
TA
RT
Ade
quat
e ba
ttery
cha
rge
Scru
b he
ad lo
wer
ed &
bru
shes
eng
aged
WA
RN
ING
!Unp
lug
elec
trica
l co
nnec
tors
to p
rope
l mot
or a
nd sc
rub
brus
h m
otor
s be
fore
serv
icin
g!
Rem
ove
hose
at T
est P
oint
G (R
efer
to C
HA
RT
# 1
),
ch
eck
wat
er fl
ow p
er m
inut
e (a
fter o
rific
e):
-To
chec
k ou
tput
by
wei
ght,
dire
ct li
quid
disc
harg
e in
to c
onta
iner
and
wei
gh o
n sc
ale
(Ref
er to
CH
AR
T #
2fo
r wat
er fl
ow w
eigh
t per
min
ute)
-To
chec
k ou
tput
by
volu
me,
dire
ct li
quid
disc
harg
e in
to c
onta
iner
and
mea
sure
liq
uid
volu
me
(Ref
er to
CH
AR
T #
2fo
r wat
er fl
ow v
olum
e pe
r min
ute)
Wha
t is t
he w
ater
flo
w o
utpu
t per
m
inut
e?
LESS
than
sp
ecifi
catio
ns
Go
to
TE
ST#
2
MO
RE
than
sp
ecifi
catio
ns
Che
ck sy
stem
from
Tes
tPo
int G
to sc
rub
head
-C
heck
for b
lock
age
inho
ses o
r mix
ing
cham
ber;
repa
irsy
stem
as n
eede
d
Ver
ify p
robl
em is
repa
ired
-rer
un te
stfro
m S
TA
RT
-If
OK
, rec
onne
ct p
rope
l&
bru
sh m
otor
s
DO
NE
OK
per
sp
ecifi
catio
nsR
emov
e ho
se a
t Tes
t Poi
nt D
-Is
flow
rate
OK
per
spec
ifica
tions
liste
din
CH
AR
T #
2 (a
fter o
rific
e)?
Yes
No
Che
ck fo
r blo
ckag
e in
hos
esfro
m fi
lter/o
rific
e to
Tes
t Poi
nt G
;ve
rify
oper
atio
n &
orie
ntat
ion
ofch
eck
valv
e; v
erify
bat
tery
vol
tage
at F
aST
sole
noid
val
ve; c
heck
for r
estri
ctio
n in
FaS
Tso
leno
idva
lve;
repa
ir sy
stem
as n
eede
d
Ver
ify p
robl
em is
repa
ired
-rer
un te
stfro
m S
TA
RT
-If
OK
, rec
onne
ct p
rope
l&
bru
sh m
otor
s
DO
NE
Yes
No
Che
ck fo
r blo
ckag
e in
hos
esfro
m w
ater
tank
to w
ater
pum
p, c
heck
80
mes
h fil
ter f
or b
lock
age
-Is f
low
rate
at
Test
Poin
t C O
K p
er sp
ecifi
catio
ns li
sted
inC
HA
RT
# 2
(bef
ore
orifi
ce)?
No
Go
to T
EST
# 4
Che
ck fo
r blo
ckag
e at
fil
ter/o
rific
e, o
r hos
es
from
wat
er p
ump
to
orifi
ce a
ssem
bly;
repa
ir sy
stem
as n
eede
d
Rem
ove
hose
at T
est P
oint
C-
Is fl
ow ra
te O
K p
er sp
ecifi
catio
ns li
sted
in C
HA
RT
# 2
(bef
ore
orifi
ce)?
Yes
NO
TE
:The
orif
ice
is a
thin
roun
d m
etal
di
sc w
ith a
ver
y sm
all h
ole
in th
e ce
nter
. Use
ON
LY
bras
s or s
ofte
r m
ater
ial t
o cl
ean
hole
in o
rific
e
NO
TE
:A
rrow
on
chec
k va
lve
(if u
sed)
sh
ould
poi
nt
away
from
w
ater
pum
p
Page
2of
8
61
FaST
FaST
Disa
ssem
ble
filte
r/orif
ice
near
Te
st Po
int D
(Ref
er to
CH
AR
T #
1) -
Is o
rific
e cl
ean
& in
pla
ce?
Yes
No
DO
NE
Cle
an o
r ins
tall
new
orif
ice
DO
NE
Tro
uble
shoo
ting
-TE
ST #
2
Rem
ove
wire
s fro
m
conv
entio
nal s
yste
m
sole
noid
val
ve &
che
ck
outp
ut a
t Tes
t Poi
nt L
-Is
foam
now
bei
ng
disc
harg
ed?
Ver
ify p
robl
em is
repa
ired
-rer
un te
stfro
m S
TA
RT
-If
OK
, rec
onne
ct p
rope
l&
bru
sh m
otor
s
Yes
Insp
ect w
iring
at F
aST/
Con
vent
iona
lSw
itch;
test
switc
h; re
pair
wiri
ng o
r re
plac
e Fa
ST/C
onve
ntio
nal s
witc
h
No
Rem
ove
hose
from
out
put s
ide
of c
onve
ntio
nal s
yste
m so
leno
id
valv
e to
ver
ify le
akag
e; re
plac
e co
nven
tiona
l sys
tem
sole
noid
val
ve
Ver
ify p
robl
em is
repa
ired
-rer
un te
stfro
m S
TA
RT
-If
OK
, rec
onne
ct p
rope
l&
bru
sh m
otor
s
TE
ST#
2
(Too
muc
h w
ater
and
low
/no
foam
)
Ver
ify p
robl
em is
repa
ired
-rer
un te
stfro
m S
TA
RT
-If
OK
, rec
onne
ct p
rope
l&
bru
sh m
otor
s
NO
TE
:The
orif
ice
is a
thin
roun
d m
etal
disc
w
ith a
ver
y sm
all h
ole
in th
e ce
nter
. Use
ON
LYbr
ass o
r sof
ter m
ater
ial t
o cl
ean
hole
in o
rific
e
NO
TE
:The
co
rrect
ord
er fo
r as
sem
bly
of
filte
r/orif
ice
is (in
di
rect
ion
of w
ater
flo
w):
filte
r, w
ashe
r, or
ifice
.
DO
NE
FaST
Ope
ratio
nal R
equi
rem
ents
:
Igni
tion
switc
h on
FaST
/con
vent
iona
l sw
itch
set t
o Fa
ST
Wat
er ta
nk su
ffici
ently
full
FaST
-Pak
suffi
cien
tly f
ull &
con
nect
ed
Forw
ard
prop
el e
ngag
ed -
besu
re to
read
war
ning
atS
TA
RT
Ade
quat
e ba
ttery
cha
rge
Scru
b he
ad lo
wer
ed &
bru
shes
eng
aged
WA
RN
ING
!Unp
lug
elec
trica
l co
nnec
tors
to p
rope
l mot
or a
nd sc
rub
brus
h m
otor
s be
fore
serv
icin
g!
Page
3of
8
62
FaST
FaST
Yes
No
No
Yes
Tro
uble
shoo
ting
-TE
ST #
3
Is a
ir pu
mp
wor
king
pro
perly
as p
er
spec
ifica
tions
?
Yes
Che
ck fo
r blo
ckag
e fro
m
Test
Poin
ts It
o G
, che
ck
for p
rope
r orie
ntat
ion
&
oper
atio
n of
che
ck v
alve
, re
pair
or re
plac
e ite
ms a
s ne
eded
No
TE
ST#
3
(Wat
er O
K, n
o fo
am)
Go
to T
EST
# 4
NO
TE
:Air
pum
p m
easu
rem
ents:
Inle
t -A
ppro
x. 2
0 to
25
inch
es H
g(5
1 to
63.
5 cm
Hg)
Out
let -
App
rox.
20
to 3
0 PS
I(1
38 to
270
kPa
)
Insp
ect f
low
thro
ugh
mix
ing
cham
ber –
Is
mix
ing
cham
ber
clog
ged
with
deb
ris?
Yes
Cle
an o
r re
plac
e m
ixin
g ch
ambe
r
No
Ver
ify p
robl
em is
repa
ired
-rer
un te
stfro
m S
TA
RT
-If
OK
, rec
onne
ct p
rope
l&
bru
sh m
otor
s
DO
NE
NO
TE
:Arro
w o
n ch
eck
valv
e sh
ould
poi
nt
away
from
air
pum
p
FaST
Ope
ratio
nal R
equi
rem
ents
:
Igni
tion
switc
h on
FaST
/con
vent
iona
l sw
itch
set t
o Fa
ST
Wat
er ta
nk su
ffici
ently
full
FaST
-Pak
suffi
cien
tly f
ull &
con
nect
ed
Forw
ard
prop
el e
ngag
ed -
besu
re to
read
war
ning
atS
TA
RT
Ade
quat
e ba
ttery
cha
rge
Scru
b he
ad lo
wer
ed &
bru
shes
eng
aged
WA
RN
ING
!Unp
lug
elec
trica
l co
nnec
tors
to p
rope
l mot
or a
nd sc
rub
brus
h m
otor
s be
fore
serv
icin
g!
Rem
ove
hose
at T
est P
oint
F (R
efer
to C
HA
RT
# 1)
, che
ck d
eter
gent
flow
per
min
ute:
To c
heck
out
put,
dire
ct li
quid
disc
harg
e in
to c
onta
iner
and
mea
sure
liqu
id v
olum
e (R
efer
to
CH
AR
T #
2fo
r det
erge
nt fl
ow v
olum
e pe
r min
ute)
Is d
eter
gent
flow
rate
OK
per
spec
ifica
tions
liste
din
CH
AR
T #
2?
Che
ck fo
r blo
ckag
e in
ho
ses f
rom
FaS
Tde
terg
ent p
ack
to T
est
Poin
t F; r
epai
r or
repl
ace
item
s as n
eede
d
Is d
eter
gent
flow
rate
OK
per
spec
ifica
tions
liste
din
CH
AR
T #
2?
Go
to T
EST
# 4
Ver
ify p
robl
em is
repa
ired
-rer
un te
stfro
m S
TA
RT
-If
OK
, rec
onne
ct p
rope
l&
bru
sh m
otor
s
DO
NE
Page
4of
8
63
FaST
FaST
Do
com
pone
nts h
ave
the
corre
ct in
put
volta
ge re
adin
gs a
s lis
ted
belo
w?
Yes
No
DO
NE
Tro
uble
shoo
ting
-TE
ST #
4
Rep
air o
r rep
lace
fa
ulty
com
pone
nt
TE
ST#
4
(Indi
vidu
al c
ompo
nent
test
ing)
Ver
ify p
robl
em is
repa
ired
-rer
un te
stfro
m S
TA
RT
-If
OK
, rec
onne
ct p
rope
l&
bru
sh m
otor
s
Go
to T
EST
# 5
Normal operating voltages at FaST components
24 vDC systems
36 vDC systems
Water
pump
Air
pump
Battery vo
ltage
26 to 28 vD
C
Soleno
id
valve
Timer
mod
ule
22 ohm
resistor
Not use
d8 to 12 vD
C
Voltage drop ac
ross res
istor
Con
stan
t battery voltage at p
osts 1 & 3;
Pulsed battery voltage at p
osts 1 & 2
(Refer to CHART # 2for p
ulse rate)
Deterge
nt
pump
Battery vo
ltage
Battery vo
ltage
Pulsed battery voltage
(Refer to CHART # 2 fo
r pulse rate)
FaST
Ope
ratio
nal R
equi
rem
ents
:
Igni
tion
switc
h on
FaST
/con
vent
iona
l sw
itch
set t
o Fa
ST
Wat
er ta
nk su
ffici
ently
full
FaST
-Pak
suffi
cien
tly f
ull &
con
nect
ed
Forw
ard
prop
el e
ngag
ed -
besu
re to
read
war
ning
atS
TA
RT
Ade
quat
e ba
ttery
cha
rge
Scru
b he
ad lo
wer
ed &
bru
shes
eng
aged
WA
RN
ING
!Unp
lug
elec
trica
l co
nnec
tors
to p
rope
l mot
or a
nd sc
rub
brus
h m
otor
s be
fore
serv
icin
g!
Page
5of
8
64
FaST
FaST
Is F
aST
circ
uit b
reak
er
tripp
ed?
Yes D
ON
E
Tro
uble
shoo
ting
-TE
ST #
5
Ver
ify p
robl
em is
repa
ired
-rer
un te
stfro
m S
TA
RT
-If
OK
, rec
onne
ct p
rope
l&
bru
sh m
otor
s
Che
ck w
iring
in F
aST
harn
ess f
or
shor
t circ
uit o
r loo
se c
onne
ctio
ns –
repa
ir or
repl
ace
as n
eede
d
No
TE
ST#
5
(Ove
rall
elec
trica
l tes
ting)
Normal operating amperages of FaST com
ponents
Water
pump
Deterge
nt
pump
Air
pump
Soleno
id
valve
Timer
mod
ule
22 ohm
resistor
System
Total
App
rox. 2.5 to 4.0 Amps
App
rox. 400 to 450 m
A (if u
sed)
App
rox. 1.8 to 2.5 Amps
App
rox. 250 to 750 m
A
App
rox. 100 to 200 m
A
App
rox. 5 to 75 mA
App
rox. 400 to 600 m
A
Res
et c
ircui
t bre
aker
–U
sing
the
ampe
rage
cha
rt, c
heck
cur
rent
draw
of F
aST
com
pone
nts –
Do
com
pone
nts t
est O
K?
Yes
FaST
Ope
ratio
nal R
equi
rem
ents
:
Igni
tion
switc
h on
FaST
/con
vent
iona
l sw
itch
set t
o Fa
ST
Wat
er ta
nk su
ffici
ently
full
FaST
-Pak
suffi
cien
tly f
ull &
con
nect
ed
Forw
ard
prop
el e
ngag
ed -
besu
re to
read
war
ning
atS
TA
RT
Ade
quat
e ba
ttery
cha
rge
Scru
b he
ad lo
wer
ed &
bru
shes
eng
aged
Doe
s co
nven
tiona
l sy
stem
wor
k pr
oper
ly?
Yes
No
Rep
air o
r rep
lace
co
mpo
nent
s as
need
ed
Con
nect
jum
per w
ire o
n Fa
STsw
itch
from
cen
ter p
ost t
o ou
ter p
ost (
lead
ing
to F
aST
rela
y) –
Doe
s FaS
T sy
stem
wor
k?
Yes
Rep
lace
FaS
T/
Con
vent
iona
l sw
itch
No
Con
nect
jum
per w
ire o
n Fa
STsw
itch
from
cent
er p
ost t
o ou
ter p
ost (
lead
ing
to c
onve
ntio
nal s
olen
oid
valv
e) D
oes c
onve
ntio
nal s
yste
m w
ork?
No
Rep
lace
FaS
T re
lay
or
repa
ir w
iring
to re
lay
DO
NE
Ver
ify p
robl
em is
repa
ired
-rer
un te
stfro
m S
TA
RT
-If
OK
, rec
onne
ct p
rope
l&
bru
sh m
otor
s
Yes
No
Be su
re to
follo
w F
aST
oper
atio
nal
requ
irem
ents
–if
OK
, the
n re
pair
elec
trica
l sys
tem
bef
ore
FaST
syste
m
Ver
ify p
robl
em is
repa
ired
-rer
un te
stfro
m S
TA
RT
-If
OK
, rec
onne
ct p
rope
l&
bru
sh m
otor
s
WA
RN
ING
!Unp
lug
elec
trica
l co
nnec
tors
to p
rope
l mot
or a
nd sc
rub
brus
h m
otor
s be
fore
serv
icin
g!
Page
6of
8
65
80 M
esh
Filte
rW
ater
Pu
mp
Filte
r/O
rific
e
Det
erge
nt P
ump
(Pul
sed
by T
imer
)Q
uick
Dis
conn
ect
w/c
heck
val
ves
Air
Com
pres
sor
Che
ckV
alve
Mix
ing
Cha
mbe
r
FaST
-Pak
Det
erge
nt
FaST
FaST
Scru
bH
ead
CD
F
H
G
IJ
K
AB
Tes
t Poi
nts -
CH
AR
T #
1
Wat
erTa
nkC
heck
Val
veE
L
Con
vent
iona
l Sol
utio
n Sy
stem
N
OTE
: Hos
e pa
th v
arie
s by
mod
el
Con
vent
iona
l So
leno
id S
hut
Off
Val
ve
Sole
noid
Shu
tO
ff V
alve
**
** S
olen
oid
loca
tion
vari
esby
mod
el n
umbe
r (m
ay b
elo
cate
d be
fore
or a
fter t
he
dete
rgen
t “Te
e”)
Item
indo
tted
line
not u
sed
onal
l mod
els
NO
TES
Flow
Dir
ectio
nar
row
Page
7of
8
66
FaST
FaST
Spec
ifica
tions
-C
HA
RT
# 2
FaS
T w
ater
and
det
erge
nt fl
ow s
peci
ficat
ion
char
t
Des
crip
tion
/ Mea
sure
men
tSp
ecifi
catio
n
Wat
er P
ump
part
#10
0586
6W
ater
Pum
p pr
essu
re b
efor
e or
ifice
(psi
)40
-45
(inte
rnal
ly re
lieve
d)W
ater
pre
ssur
e af
ter o
rific
e (p
si)
3.0
Wat
er P
ump
head
par
t #39
1433
Wat
er fl
ow b
efor
e or
ifice
(L/m
in)
5.3
Wat
er fl
ow b
efor
e or
ifice
(GPM
)1.
4W
ater
flow
bef
ore
orifi
ce (k
g/m
in)
5.3
Wat
er fl
ow b
efor
e or
ifice
(lb/
min
)11
.66
Liqu
id fl
ow a
fter o
rific
e (L
/min
)1.
13Li
quid
flow
afte
r orif
ice
(GPM
)0.
3Li
quid
flow
afte
r orif
ice
(kg/
min
)1.
13Li
quid
flow
afte
r orif
ice
(lb/m
in)
2.5
Orif
ice
& bo
dy p
art #
1014
675
Orif
ice
plat
e pa
rt #
1014
011
Orif
ice
diam
eter
(inc
hes)
0.04
5D
eter
gent
pum
p pu
lse
rate
per
min
34.7
Det
erge
nt fl
ow (m
l/min
)1.
25
Page
8 o
f 8
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DESCRIPTION:
The charger is set at the factory to match the batteries supplied with your machine. These instructionsexplain how to change the charger settings if the charger is purchased as an aftermarket part or if thecharger settings need to be changed for different type or size of batteries.Please follow step-by-step instructions.
SPECIAL TOOLS / CONSIDERATIONS: NONE
(Estimated time to complete: 5 minutes)
PREPARATION:
This charger has nine settings for various types ofbatteries. Always make sure the charger is atthe proper setting BEFORE chargingbatteries.
The green indicator light flashes (when thecharger is first plugged into an AC outlet) to showthe charger setting . DONOT plug the charger intoa battery at this point. Count thenumber of flashesseparated by a pause to determine the chargersetting (i.e.,three flashes, pause, three flashes,pause, etc. means the charger is in the thirdsetting). Refer to Fig. 1.
Fig. 1
Tennant uses only two of the charger settings;
1. Setting 3 (3 flashes) is for 36 VDC systemswith battery ratings between 200--250Ah.
2. Setting 7 (7 flashes) is for 36 VDC systemswith battery ratings more than 250Ah.
NOTE: If charging batteries not supplied byTennant, use the charger manufacturer’sinstructions to determine which setting to use.
3. Read the instructions provided by the chargermanufacturer and the instructions and safetymessages (Refer to Fig. 2) mounted on thecharger for installation/operation instructionsand safety information.
Fig. 2
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TO CHANGE CHARGER SETTING:
1. Plug the charger into the an AC outlet. Thecharger will run through a self test for about 2seconds. Then the green indicator light willflash for 11 seconds to show the charger’scurrent setting. (See previous page). Thecharger setting must be changed during this11 second time span.
NOTE: If you waited more than 11 seconds tochange the setting, the red indicator light will turnon. When this happens, unplug the charger fromthe AC outlet, wait a few seconds, then replug itinto the outlet to start the cycle over.
2. During the 11 second time span, connect thecharger to the battery connector for 3seconds, and then unplug the charger fromthe battery (Refer to Fig. 3). The charger willadvance to the next setting.
Fig. 3
3. Repeat previous step until the desired settingis displayed.
4. After the desired setting is reached, plug thecharger connector into the battery connectoruntil the output relay clicks (this happens 10seconds after it is plugged in). The indicatorlight will flash red and the setting is saved inthe charger memory.
NOTE: To change to a setting for another sizebattery, unplug the charger from the AC outlet,wait a few seconds, then replug the charger backinto the AC outlet. Follow Steps 2 through 4 tochange the setting.
5. The charger can now be used to chargebatteries. (See Machine Operation manualsfor charging instructions).
TENNANT COMPANYP. O. Box 1452
Minneapolis, MN 55440-1452
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