Clarke Focus II Rider Autoscrubber Nilfisk-Alto Scrubtec R6 Rider Autoscrubber Service Manual Clarke® model numbers: Nilfisk-Alto model numbers: 56114000 Focus II Rider 28 D Base 56114004 Scrubtec R 6-71 28D 56114001 Focus II Rider 34 D OBC Base 56114005 Scrubtec R 6-71C 28C 56114002 Focus II Rider 34 D Base 56114006 Scrubtec R 6-86 34D 56114003 Focus II Rider 28 B Base 56114008 Scrubtec R 6-100 40D 56114009 Focus II Rider 28 B OBC Base 56114010 Focus II Rider 28 D OBC Base English 08/12 Updated 08/14 Form No. 56043159 Service Manual – Focus II / Scrubtec R6 Rider Autoscrubber Contents ii Contents General Information 6 Service Manual Purpose and Application 6 Revision History 6 Other Reference Manuals and Information Sources 6 Conventions 6 Cautions and Warnings 6 Symbols 6 General Safety Instructions 7 Transporting the Machine 8 Nameplate 9 Know Your Machine — Major components: 9 General Specifications 10 Fastener Torque Specifications 11 Maintenance Schedule 11 Lubricating the Machine 12 Diagnostic and Service Tools 12 Chassis System 15 Functional Description 15 Control System 16 Functional Description 16 Control Panel 16 Main Machine Controller 17 Component Locations 18 Main Machine Controller Programming 19 Programming Menu Outline 19 Quick Start: Navigating the Hidden Menus 20 Deck Type 20 Battery Charger 20 Chemical (Detergent) Selection 20 Detergent Mode 20 Vacuum Selection 21 Low Voltage Cutout 21 Max (Maximum) Scrub Speed 21 Lockout Brush Pre (Pressure) 21 Lockout Sol (Solution) Flows 21 Chemical (Detergent) Rate Bias 21 Deck Down Time 21 Restore Defaults 21 Display Rev Level 22 Fault Recall 22 Fault Detection 22 Service Test Mode 22 Backup Alarm Vol (Volume) 22 FWD Alarm Vol (Forward) 22 Horn Volume 22 Panel Test 22 Troubleshooting Guide 22 Main Controller Error Codes 23 Service Manual – Focus II / Scrubtec R6 Rider Autoscrubber Contents iii Service Test Mode 25 Test Mode Display 25 Test Mode Functions 25 Sample Shop Voltage Measurements 26 Controller I/O Table 28 Removal and Installation 29 Main Control Board 29 Electrical System 30 Functional Description 30 Safety Circuit 30 Description Of The Low-Voltage Cutout Feature 31 Onboard Battery Chargers 31 Interlock Circuit 31 S.P.E. Charging Profiles and Charging Progress 31 Delta-Q Charging Profiles and Charging Progress 32 Delta-Q Battery Charging Profile Table 32 Component Locations 34 Maintenance and Adjustments 35 Charging Batteries 35 Extending Battery Life 35 Troubleshooting 36 Battery Testing 36 Removal and Installation 36 Batteries 36 Electrical Panel Cover 37 Specifications 37 Wet Cell Battery Specifications: 37 Wet Cell Battery Charger Specifications 37 Wiring Diagrams 37 Wiring (Ladder) Diagram: 56114061 Rev C (Early, before machine SN 3000167142) 38 Sheet 1 of 2 38 Sheet 2 of 2 39 Wiring (Ladder) Diagram 56114404 Rev A (Late, beginning with machine SN 3000167142) 40 Sheet 1 of 2 40 Sheet 2 of 2 41 Wiring Harness Diagram: 56114062 Rev B (Early, before machine SN 3000167142) 42 Wiring Harness Diagram: 56114405 Rev A (Late, beginning with machine SN 3000167142) 43 Connector Pinouts 44 Options and Accessories 47 Recovery System 48 Functional Description 48 Vacuum Motor and Recovery Tank 48 Vacuum Motor Control Circuit Overview 49 Troubleshooting 50 Vacuum Suction Test 51 Removal and Installation 52 Recovery Tank 52 Vacuum Motor 53 Specifications 54 Special Tools 54 Service Manual – Focus II / Scrubtec R6 Rider Autoscrubber Contents iv Scrub System: Disc, Cylindrical, & Boost 55 Functional Description 55 Deck Lift 55 Drive Motors 55 Disc Deck 55 Cylindrical Deck (Nilfisk-Alto models only) 56 Boost Deck (Clarke models only) 56 Circuit Overview 56 Scrub Deck Motors 56 Deck Lift Actuator 57 Maintenance and Adjustment 58 Lift Actuator Limit Adjustment 58 Removal and Installation 59 Scrub Deck 59 Deck Lift Actuator 61 Lead Nut and Spring Orientation 62 Brush Motor Contactor 63 Disc Deck Motor 64 Cylindrical Deck Motor 64 Boost Deck Motor 65 Specifications 66 Special Tools 66 Solution System 67 Functional Description 67 Solution Solenoid 67 Detergent Models 67 Circuit Overview 68 Solenoid Valve Circuit 68 Detergent Pump 68 Solution System Schematic 68 Removal and Installation 69 Solution Valve, Filter, and Solenoid 69 Detergent Pump 70 Specifications 70 Squeegee System 71 Functional Description 71 Squeegee Lift Actuator 71 Squeegee 71 Maintenance and Adjustment 72 Squeegee Blade Cleaning and Inspection 72 Squeegee Trim Adjustment 72 Actuator Limit Adjustment 73 Removal and Installation 74 Rear (main) Squeegee Blade Reversal or Replacement 74 Front Squeegee Blade Reversal or Replacement 75 Squeegee Lift Actuator 76 Specifications 76 Wheel System, Non-Traction 77 Functional Description 77 Removal and Installation 77 Service Manual – Focus II / Scrubtec R6 Rider Autoscrubber Contents v Wheel System, Traction 78 Functional Description 78 Drive Pedal Sensor 78 Speed Limiting Potentiometer 78 Drive Motor System Function 79 Wheel Drive Controller J10 Pinout Functions 80 Troubleshooting 81 Wheel Drive Controller Error Codes 82 Removal and Installation 83 Drive Controller 83 Drive Wheel Assembly 84 Drive Motor, Brushes, and Electromechanical Brake 87 Carbon Brushes 88 Drive Tire 89 Steering Chain 91 Specifications 92 Special Tools 93 Curtis 1311 Programmer PN 56409441 93 Tire “Puller” Kit PN 56422174 93 Service Manual – Focus II / Scrubtec R6 Rider Autoscrubber General Information 6 General Information Service Manual Purpose and Application This Service Manual is a resource for professional service technicians. It provides information for understanding how the machine operates, where components are located, basic troubleshooting, maintenance and mechanical service operations. The cover page of this manual lists each machine part number that the manual applies to. Compare the part number of the machine you are working on to the model numbers listed on the cover page to be sure you are using the correct manual. Revision History • 11/13 • Electrical System: Updated wiring diagram 56114061 Rev B to Rev C. • Control System: Explained that Main Machine Controller code 07 can be caused by failing to program controller after installing a second vacuum motor. • General Information, General Specifications: Added metric values • Wheel System, Traction, Special Tools: Added Tire Puller Kit part number and photo. • 07/14 • Control System: Clarified programming options for S.P.E charger VS Delta-Q • Electrical System: Added information for Delta-Q IC650 onboard battery charger and added wiring diagrams. Other Reference Manuals and Information Sources The following documents contain parts information and instructions for machine operation: • Instructions for Use: OM56091040 through OM56091046 • Parts List: PL56042589 and PL56042590 Conventions Forward, backward, front, rear, left or right are intended with reference to the operator’s position, that is to say in operating position with the hands on the handlebar. Cautions and Warnings Symbols It is important for you to read and understand this manual. The information it contains relates to protecting your safety and preventing problems. The symbols below are used to help you recognize this information. Danger: Indicates a potentially hazardous situation which, if not avoided, will result in death or serious injury. Warning: Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. Caution: Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury. Caution: When used without the Safety Alert Symbol, indicates a potential situation which, if not avoided, could result in property or machine damage. Service Manual – Focus II / Scrubtec R6 Rider Autoscrubber General Information 7 General Safety Instructions Warning! • This machine should be used only by properly trained and authorized persons. • Never work under a machine without safety blocks or stands to support the machine. • Keep sparks, flame and smoking materials away from batteries. Explosive gases are vented during normal operation. • Charging the batteries produces highly explosive hydrogen gas. Charge batteries only in well- ventilated areas away from open flame. Do not smoke while charging the batteries. • Remove all jewelry when working near electrical components. • Do not dispense flammable cleaning agents, operate the machine on or near these agents, or operate in areas where flammable liquids exist. Caution!: • When operating this machine, ensure that third parties, particularly children, are not endangered. • Turn the key switch off (O) and disconnect the batteries before servicing electrical components. • Turn the key switch off (O) and remove the key, before changing the brushes, and before opening any access panels. • This machine is not suitable for picking up hazardous dust. • Do not use on surfaces having a gradient exceeding that marked on the machine. • While on ramps or inclines, avoid sudden stops when loaded. Avoid abrupt sharp turns. Use low speed down hills. Clean only while ascending (driving up) the ramp. • Before performing any service function, carefully read all instructions pertaining to that function. • Do not leave the machine unattended without first turning the key switch off (O), removing the key and securing the machine. • Take precautions to prevent hair, jewelry, or loose clothing from becoming caught in moving parts. • Only use the brushes provided with the appliance or those specified in the instruction manual. The use of other brushes may impair safety. • Refer to the battery charger OEM product manual for additional specific battery charger warnings. Caution!: • This machine is not approved for use on public paths or roads. • Do not use scarifier discs or grinding stones. These can damage the machine and the floor surface. • Turn the key switch off (O) and remove the key, before changing the brushes, and before opening any access panels. • Use caution when moving this machine at or below freezing temperature conditions. Any water in the solution, recovery or detergent tanks or in the hose lines could freeze, causing damage to valves and fittings. Flush with windshield washer fluid. • The batteries must be removed from the machine before the machine is scrapped. The disposal of the batteries should be safely done in accordance with your local environmental regulations. • Do not clean this machine with a pressure washer. • All doors and covers are to be positioned as indicated in the instruction manual before using the machine. Service Manual – Focus II / Scrubtec R6 Rider Autoscrubber General Information 8 Transporting the Machine Caution: Before transporting the machine on an open truck or trailer, make sure that the machine is tied down securely and all access doors and covers are secured (tape and strap as needed). The actual procedure for transporting the machine will vary depending on the mode of transport. Follow these general guidelines as applicable to the situation. • If the machine is not operational or cannot be moved under its own power, you must manually release the brake. To release the brake, move the release handle (27) outward and insert an object, such as a screw driver, behind the lever to keep it deactivated. • Drain the recovery and solution tanks. • If transport will occur below freezing temperatures, place a small amount of environmentally friendly 27 antifreeze in the recovery tank, solution tank, and solution lines. After transport, make sure to dispose of the used antifreeze according to local regulations. • Remove the squeegee from the machine (page 74). This is required to access the rear hold down points and also protects the squeegee during loading, unloading, and transport. • If the loading, unloading, or transport operations pose a risk for damage to the scrub deck, then remove the scrub deck (page 59). • Make sure the recovery tank is securely fastened in place, or removed from the machine and transported separately. • Make sure the recovery tank cover is securely held closed or removed from its hinges. • Secure the machine to the transport using the anchor points shown below. General Machine Description The Clarke Focus II Rider/Scrubtec 6 is a compact battery power ride on floor scrubber. The machine can be equipped with a 28 inch (71 cm) disc, 34 inch disc, 28 cylindrical, 28 inch BOOST or 38 inch Disc scrub deck. The machine may also be equipped with Front Anchor an onboard detergent mixing system. This system Rear Anchor Points stores concentrated detergent on the machine and Points meters the appropriate quantity of concentrated detergent and mixes it on the machine with water from the solution tank. The machine can be equipped with wet acid (flooded) or AGM (maintenance free) batteries and charged with either shelf or on board battery chargers Service Manual – Focus II / Scrubtec R6 Rider Autoscrubber General Information 9 Nameplate The nameplate contains important identification information which will be Sample needed when ordering parts: Model (Name), Part No. (Part number of the machine which is often referred to as the “Model Number”), and Serial Number. Know Your Machine — Major components: Recovery Tank Operator’s Seat Solution Tank Electrical Panel Squeegee Steering Column Subframe Scrub Deck Drive Wheel and Motor Service Manual – Focus II / Scrubtec R6 Rider Autoscrubber General Information 10 General Specifications Specifications Model Category 28” Disc 28” Boost 28” Cyl. 34” Disc 38” Disc Focus II 28 D Focus II 28 B Focus II 34 D Model Name Scrubtec R 6 71 Scrubtec R 6 71C Scrubtec R 6 86 Scrubtec R 6 100 56114000 56114002 56114003 Model Number 56114010 56114005 56114001 56114008 56114009 56114004 56114006 Battery Voltage 24 Volts Protection Grade IPX3 Sound Pressure Level 68.3dB LpA 68.6dB LpA 68.3dB LpA 68.3dB LpA 68.3dB LpA IEC 60335-2-72: 2002 Amend. 1:2005, 3dB KpA 3dB KpA 3dB KpA 3dB KpA 3dB KpA ISO 11201 1,341 lbs 1,371 lbs 1,359 lbs 1,350 lbs 1,603 lbs Gross Weight 608 kg 622 kg 616 kg 613 kg 727 kg Maximum Wheel Floor Loading (front) 152 psi (1.05 N/mm2) Maximum Wheel Floor Loading (right rear) 193 psi (1.33 N/mm2) Maximum Wheel Floor Loading (left rear) 154 psi (1.06 N/mm2) Vibrations at the Hand Controls 0.181 m/s2 0.386 m/s2 0.181 m/s2 0.181 m/s2 0.181 m/s2 (ISO 5349-1) Vibrations at the Seat (EN 1032) 0.014 m/s2 0.132 m/s2 0.014 m/s2 0.014 m/s2 0.014 m/s2 Gradeability Transport 12.5% (7.1°) Gradeability Cleaning 7.9% (4.5°) Height 54.8” (139 cm) Length 60.5” (154 cm) Width at Deck 32.1” (82 cm) 32.1” (82 cm) 32.8” (83 cm) 36.6” (93 cm) 42.1” (107 cm) Width at Squeegee 32.5” (83 cm) 32.5” (83 cm) 32.5” (83 cm) 41.3” (105 cm) 46.3” (118 cm) All Models 28” & 34” Models 38” Models Length Squeegee Width Squeegee Width t h g ei H Deck Width Deck Width