ez rider t · led – light emitting diode pwm (pulse width modulation) – a method of using...

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


1

6


1

7


3

4)

8

EZ Rider HP Wire Harnesses Group (10143033-- ) Page 1 of 4

1

22 2 2

9


1

10


1

11


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


01

23456789

TanPinkBrown


PurpleGrayWhite


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


1

3

36VDCWith

Key ONi


01

23456789

TanPinkBrown


PurpleGrayWhite


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


01

23456789

TanPinkBrown


PurpleGrayWhite


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+


1

3

SIGNAL OUTPUT

36VDCWith

Key ONi


01

23456789

TanPinkBrown


PurpleGrayWhite


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)


+ -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+


SIGNAL OUTPUT

36VDCWith

Key ONi


01

23456789

TanPinkBrown


PurpleGrayWhite


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


+ -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+


SIGNAL OUTPUT

36VDCWith

Key ONi


01

23456789

TanPinkBrown


PurpleGrayWhite


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)



+ -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+


SIGNAL OUTPUT

36VDCWith

Key ONi


01

23456789

TanPinkBrown


PurpleGrayWhite


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)


+ -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+


SIGNAL OUTPUT

36VDCWith

Key ONi


01

23456789

TanPinkBrown


PurpleGrayWhite


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


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)


+ -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+


SIGNAL OUTPUT

36VDCWith

Key ONi


01

23456789

TanPinkBrown


PurpleGrayWhite


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)


+ -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+


SIGNAL OUTPUT

36VDCWith

Key ONi


01

23456789

TanPinkBrown


PurpleGrayWhite


Color of Wire

PIN P3-1627

SCRUB &VACUUM

PIN P3-19

5VDC REFERENCE

0VDC REFERENCE22

PIN P3-116

SCRUB MODESWITCH

6


X

6

VACUUMONLY

SCRUBONLY

1

2

4

SIGNAL INPUT









25

EZ Rider HP – Scrub Mode Switch (Scrub Only)


+ -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+


SIGNAL OUTPUT

36VDCWith

Key ONi


01

23456789

TanPinkBrown


PurpleGrayWhite


Color of Wire

PIN P3-1627

SCRUB &VACUUM

PIN P3-19

5VDC REFERENCE

0VDC REFERENCE22

PIN P3-116

SCRUB MODESWITCH

6


X

6

VACUUMONLY

SCRUBONLY1

2

4

SIGNAL INPUT









26

EZ Rider HP– Scrub Head Configuration Connection

CONDITIONS: Key OFF to change configuration setting


+ -6 VDC+ -6 VDC

+ -6 VDC+ -6 VDC

MACHINE CONTROLLER

FU-1 125 A

NEG - 13 BLK1 REDPOS+

PIN P3-1627

BRUSH PRESSURESIGNAL INPUT


01

23456789

TanPinkBrown


PurpleGrayWhite


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


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


+ -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+


SIGNAL OUTPUT

36VDCWith

Key ONi


01

23456789

TanPinkBrown


PurpleGrayWhite


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


+ -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+


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


01

23456789

TanPinkBrown


PurpleGrayWhite


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


+ -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+


1

3

SIGNAL OUTPUT

36VDCWith

Key ONi


01

23456789

TanPinkBrown


PurpleGrayWhite


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


+ -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+


1

3

SIGNAL OUTPUT

ES SWITCH

36VDCWith

Key ONi


01

23456789

TanPinkBrown


PurpleGrayWhite


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


+ -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+


1

3

SIGNALOUTPUT

36VDCWith

Key ONi


01

23456789

TanPinkBrown


PurpleGrayWhite


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


+ -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


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


01

23456789

TanPinkBrown


PurpleGrayWhite


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


+ -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+


1

3

SIGNAL OUTPUT

36VDCWith

Key ONi


01

23456789

TanPinkBrown


PurpleGrayWhite


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


+ -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+


1

3

SIGNAL OUTPUT

36VDCWith

Key ONi


01

23456789

TanPinkBrown


PurpleGrayWhite


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


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


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


40

EZ Rider HP – Horn, Back-up Alarm & Hazard Light Systems

CONDITIONS: Key ON, operator on seat & reverse travel (for back-up alarm)


+ -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+


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


01

23456789

TanPinkBrown


PurpleGrayWhite


Color of Wire

41

EZ Rider HP – Solution Flow Control (00000000-10143032)



+ -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+


SIGNAL OUTPUT

36VDCWith

Key ONi


01

23456789

TanPinkBrown


PurpleGrayWhite


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


42

EZ Rider HP – Solution Flow Control (10143033- )



+ -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+


SIGNAL OUTPUT

36VDCWith

Key ONi


01

23456789

TanPinkBrown


PurpleGrayWhite


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*



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

of

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

of

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

of

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

of

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

of

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

of

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

of

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

of

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

of

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

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

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

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

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

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

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

67

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

Optional On-board Charger Setup InstructionsPage 1 of 2

68

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

Optional On-board Charger Setup InstructionsPage 2 of 2

69

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