VacRide XL, 3400, 3400C, BRV900 - Nilfisk · 8 Hard (printed) copies of service manuals for all regularly serviced machines (available at and other Nilfisk-Advance websites) 9 6”

VacRide™ XL, 3400, 3400C, BRV900

04/12 Form No. 56043149

English

Service ManualAdvance VacRide™ Models:

• 56602000

• 56602001

Nilfisk ER 1300 and ER 1600 Models:

• 56602002

ii - FORM NO. 56043149 - VacRide / 3400, 3400C, BRV900

CONTENTSINTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Service Manual Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Service Manual Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6General Machine Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Parts and Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Cautions and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Related Reference Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Diagnostic and Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Transporting The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Tie-Down Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Towing the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Jacking Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Emergency Stop Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Know Your Machine - Front RH View. . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Know Your Machine - Rear LH View . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Know Your Machine Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Know Your Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Basic Machine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19How to read Error/FAULT BLINK Codes. . . . . . . . . . . . . . . . . . . . . . . . . . 19Main Controller and Speed control Error/FAULT Codes - diagnostics . . . . . . . . . . 20

DECK SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Deck Removal Cylindrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Brush Motor Removal - Cylindrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

VACUUM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Vacuum System Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Troubleshooting vacuum system issues . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Measure Vacuum Water Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Replacing a Vacuum Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

WHEEL DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Speed Control Fault Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Troubleshooting Drive Wheel Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Curtis Speed Control Installation Checkout Procedure . . . . . . . . . . . . . . . . . . 33Drive Pedal and Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Replacing the Drive Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .37Replacing the Drive Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Inspecting/Replacing the Drive Wheel Assembly Carbon Brushes . . . . . . . . . . . . 39Replacing the Rear Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Steering Column Assembly Shroud Removal . . . . . . . . . . . . . . . . . . . . . . . . 42

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Electric panel: charger interlock, fuses, contactors. . . . . . . . . . . . . . . . . . . . . 43BRV900 Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Control Board, J2 and J3 Pin Outs and Test Points . . . . . . . . . . . . . . . . . . . . 47Replacing the Operator Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

PROGRAMMING FUNCTIONS (Hidden Menu) . . . . . . . . . . . . . . . . . . . . . 50Mandatory Programing Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Additional Programing Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51SERVICE TEST MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

iii - FORM NO. 56043149 - VacRide / 3400, 3400C, BRV900

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

WIRING DIAGRAM 56602076 Rev . F . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

INPUT OUTPUT TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

4 - FORM NO. 56043149 - VacRide / 3400, 3400C, BRV900

INTRODUCTION SERVICE MANUAL PURPOSEThis manual is a technical resource that Nilfisk-Advance expects to be utilized while a VacRide / 3400, 3400C is being serviced. It contains information deemed necessary to provide basic troubleshooting, maintenance, and repairs within a timeframe of 2-3 hours maximum. If your repair involves multiple visits to repair the same problem or the repair cannot be completed within 3 hours, a call to Nilfisk-Advance Technical Support is needed, whether to alert the factory to potential issues or to provide the customer with an acceptable level of service. Refer to the website www.advance-us.com for additional information not contained here-in, as well as updates or expanded instructions to procedures noted here.

Note: Bold numbers in parentheses in the text indicate an illustrated item.

Note: All references to right, left, front and rear in this manual are as seen from the operator's position.

SERVICE MANUAL REVISION HISTORYApril 2012•Replaced Photo showing how to manually release parking brake

•Updated Programming Functions and Service Test Mode sections

•Replaced wiring diagram with Rev. F

•Updated Vacuum System circuit descriptions

GENERAL MACHINE DESCRIPTIONThe VacRide / 3400, 3400C, BRV900 machines are commercial automatic rider vacuums.


PARTS AND SERVICERepairs should be performed by an Authorized Nilfisk-Advance Service Center that employs factory-trained service personnel and maintains an inventory of Nilfisk-Advance original replacement parts and accessories.

NAMEPLATEThe Model Number and Serial Number of the machine are shown on the Nameplate located on the inside of the steering column in front of the driver seat.

Model and Serial Numbers are required when ordering repair parts for the machine or contacting Nilfisk-Advance Technical Support.

CAUTIONS AND WARNINGSSYMBOLSAdvance uses the symbols below to signal potentially dangerous conditions. Always read this information carefully and take the necessary steps to protect personnel and property.

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

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

Caution!Is used to call attention to a situation that could cause minor personal injury or damage to the machine or other property.


Read all instructions before using.GENERAL SAFETY INSTRUCTIONSSpecific Cautions and Warnings are included to warn you of potential danger of machine damage or bodily harm.

Warning!* This machine shall be used only by properly trained and authorized persons.* 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.* Keep sparks, flame and smoking materials away from batteries. Explosive gases are vented during normal operation.* Charging the batteries produces highly explosive hydrogen gas. Charge batteries only in well-ventilated areas, away from open

flame. Do not smoke while charging the batteries.* Remove all jewelry when working near electrical components.* Turn the key switch off (O) and disconnect the batteries before servicing electrical components.* Never work under a machine without safety blocks or stands to support the machine.* Do not dispense flammable cleaning agents, operate the machine on or near these agents, or operate in areas where flammable

liquids exist.* Do not clean this machine with a pressure washer.* Only use the brushes provided with the appliance or those specified in the instruction manual. The use of other brushes may

impair safety.

Caution!* This machine is not approved for use on public paths or roads.* This machine is not suitable for picking up hazardous dust.* When operating this machine, ensure that third parties, particularly children, are not endangered.* Before performing any service function, carefully read all instructions pertaining to that function.* Do not leave the machine unattended without first turning the key switch off (O), removing the key and applying the parking

brake.* Turn the key switch off (O) and remove the key, before changing the brushes, and before opening any access panels.* Take precautions to prevent hair, jewelry, or loose clothing from becoming caught in moving parts.* Use caution when moving this machine in below freezing temperature conditions* 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 use on surfaces having a gradient exceeding that marked on the machine.* All doors and covers are to be positioned as indicated in the instruction manual before using the machine.

SAVE THESE INSTRUCTIONS


RELATED REFERENCE SOURCESNilfisk-Advance provides Operator Manuals, Sales literature, Parts Lists, Technical Service Bulletins, and Instruction Sheets on our website www.advance-us.com for 24/7 availability of information to order parts, operate, troubleshoot, or repair all current production and most discontinued machine models.

For the VacRide / 3400, 3400C, BRV900 please refer to the following documents for additional information:

Parts List - Form Number 56042521

Operation Manual - Form Number 56041798 (English, Spanish)

Curtis Programmer Manual 56043101

TSB US2008-984 Batteries and Chargers

TSB US2008-979 QuiQ Delta-Q Battery Charger Reprogramming Kit 56315732 Instructions

DIAGNOSTIC AND SERVICE TOOLSIn addition to a full set of metric and standard tools, the following items are required in order to successfully and quickly perform troubleshooting and repair of Nilfisk-Advance commercial floor cleaning equipment.1 Laptop computer loaded with current version of EZParts, Adobe Reader, and (preferably cellular) internet access2 Digital voltmeter (DVM) with DC current clamp3 Hydrometer 4 Battery load tester for checking 6V batteries5 Bearing puller6 Static control wrist strap7 Set of torque wrenches8 Hard (printed) copies of service manuals for all regularly serviced machines (available at www.advance-us.com and

other Nilfisk-Advance websites)9 6” section of 1 1/2” PVC pipe with a 1” hole drilled into one side to check vacuum system against 1” lift spec

Additional tools available from Nilfisk-Advance, Inc.:

56407502 Actuator Power Cord Adapter56205281 Water Lift Gauge56206921 Timer Bypass Kit (used to bypass timing function when troubleshooting shelf chargers)56409441 Curtis Handheld Programmer56409823 Curtis Adapter Cable (Quad Plug)56315732 Delta-Q QuiQ Onboard Charger Interface Module56422174 Tire Puller Kit for Drive Wheel Assembly


TECHNICAL SPECIFICATIONS

GENERAL

Machine Voltage 24 VDCDimensions (without Deck)

Length: 52.25 in (132.7cm)

Width (body): 27.5 in (70 cm)

Height: 51.25 in (130.2 cm)Vacuum Deck Width 31.75 in (80.6 cm) Cylindrical Style

Gross Weight (standard machine w/o options; w/on-board charger, heaviest batteries installed, and w/clean recovery bag)

1026 lbs (465.4 kg)

Net Weight (standard machine w/o options, batteries or removable brushes)

536 lbs (243.1 kg)

Static Wheel Loading (no rider) Front: 423 lbs (191.9 kg)

Rear (max on RR): 335 lbs (152.0 kg)

Static Wheel Pressure (no rider) Front: 129.12 psi (9.08 kg/cm2)

Rear (max on RR): 100.69 psi (7.08 kg/cm2)

Sound Pressure Level (IEC 60704-1)

67.0 dB(A) (extreme vacuuming), 64.0 dB(A) (quiet mode)

Vibrations at the Hand Controls (ISO 5349-1) .25 m/s2 (.05 m/s2 uncertainty)

Vibrations at the Seat (EN 1032) .01 m/s2 (.002 m/s2 uncertainty)

Gradability Transport: 16 percent 9 degrees

In operation: 9 percent 5 degrees

Battery Compartment Dimensions

Maximum Battery Compartment

25" L X 15.5" W X 21" H

Without the Box:

26.25" X 16" X 21"


TECHNICAL SPECIFICATIONS

Electrical SpecificationsBatteries Number of Batteries 4 Battery Voltage 6V 305 Ah wet

Number of Batteries 4 Battery Voltage 6V 415 Ah wetNumber of Batteries 4 Battery Voltage 6V 255 Ah AGMNumber of Batteries 4 Battery Voltage 6V 315 Ah AGMStandard Battery Capacity: 238 amp-hours @ 20-hour rate

Wet Acid Battery Available AGM Battery Available

Onboard Battery Charger 24 -volt Manufacturer: Delta Q Model: 912-2400-N1 Output 25-amps Gel Compatible

Drive SystemDrive Wheel Diameter: 9.84 in (25 cm) Width: 3.15 in (80 cm)

Type/Material: Blue UrethaneDrive Motor 1.05 HP (780 watts)Max. Transport Speed Fwd: 3.93 mph (6.33 kph) vacuuming speed has 5 settings

Rev: 2.87 mph (4.62 kph)

Deck System Deck Motors Right-hand Motor: .5 HP 373 watts

Left-hand Motor: .5 HP 373 watts Head Speed(s) Right-hand Motor: 1500 RPM Left-hand Motor: 1500 RPM

Vacuum SystemPrimary (Large) Motor 438-watt @ 2” single stage

Auxiliary (Small) Motor .75 HP (560-watt) -stage

Vacuum Performance

One Motor (Quiet Mode) Sealed: 20.18” of water (5.03 Kpa)

1” Open-hole Aperture: 7.69” of water (1.92 Kpa)

Max Airflow: 56 CFM

With Auxiliary Motor

Sealed: 48.9” of water (12.18 Kpa)

1” Open-hole Aperture: 8.5” of water (2.12 Kpa)

Max Airflow: 50 CFM

Minimum Aisle Turn Around Radius = Turning Left: 63.5 inches (1.61 m)

Door Pass-thru Width Width: 32 inches (.81 m)


TRANSPORTING THE MACHINE

Caution!Before transporting the machine on an open truck or trailer:1 Secure the Deck Assembly (9).2 Tie the machine down securely at the Locations (A) shown in FIGURE 2.3 Tape and strap all access doors and covers as necessary.4 Do not drive machine onto a ramp grade exceeding 16% (9 degrees) or damage to the machine may occur.

TIE-DOWN POINTS

TOWING THE MACHINE

Caution!The Drive Wheel (3) has a built in electromagnetic brake that is engaged whenever the Key Switch is Off or the Drive Pedal (2) is in the Neutral position, i.e. there is no power to the Brake. This Brake can be manually over ridden if necessary by inserting a medium to large screwdriver behind the Yoke (B) as shown in FIGURE 3. (A rubber door stop can also be used). This should only be done in the event you need to push or pull the machine.

Tow the machine for short distances only.

FIGURE 2AA

FIGURE 3

B


JACKING POINTS

Front - When facing the front of the machine and underneath looking up, place the jack to the right of the chain on the frame member, inside the shroud notch (A) as shown in FIGURE 4.

Rear – Lift or remove rubber flap (if equipped) to access these locations. Use a bottle jack at these points (B) as shown in FIGURE 5.

EMERGENCY STOP KNOB

WARNING!The Emergency Stop Knob (6) disconnects power from the Speed Control and Drive Wheel.

It does not disconnect the batteries, but will continue to power the control board . Do not use the Emergency Stop Knob as a substitute for disconnecting the red Anderson battery connector inside the battery compartment.

FIGURE 4

A

FIGURE 5

B

FIGURE 6


KNOW YOUR MACHINE - FRONT RH VIEW1 Operator’s Seat2 Drive Pedal, Directional/Speed3 Drive Wheel4 Drive Wheel Circuit Breaker (70 Amp)5 Control Circuitry Circuit Breaker (10 Amp)6 Emergency Stop7 Hour meter (optional)8 Side Broom Circuit Breaker (5 AMP)9 Deck10 Battery Compartment (under seat)11 Deck Raise/Lower Lever12 Side broom Height Adjustment Knob13 Rear Wheel14 Seat Adjustment Knob15 Front Roller Bumper16 Right Side Broom Assembly17 Wand18 Wand Control Lever19 Spare Bag Tray (behind driver seat)20 Side Broom Release Latch


17-Wand

10-Battery compartment 4, 5, 6 - 70 AMP and 10 AMP circuit breakers with E-stop

6, 7, 8 - E-stop, Hour Meter, 5 AMP circuit breaker

11-Deck raise/lower lever

12, 20 - Side broom Ht. adjustment knob and release latch

9, 16 - Deck and Side Broom assy

3-Drive Wheel assembly

15, 16 - Front Roller Bumper and Side Broom assy

Knob

Latch

KNOW YOUR MACHINE - FRONT RH VIEW, CONTINUED


KNOW YOUR MACHINE - REAR LH VIEW22 Steering Wheel Tilt Adjust Knob23 Control Panel24 Battery Charger Access Door25 Battery Charger (3400-C only)26 Machine Battery Connector27 Seat Prop-Rod28 HEPA Filter Access Door29 Vacuum Motor Foam Filter30 Filter Bag Access Door31 Filter Bag


KNOW YOUR MACHINE - REAR LH VIEW, CONTINUED

23-Control Panel 22-Steering Wheel Tilt Adjust Knob

31-Filter Bag installed position

30, 31 - Filter Bag Access door with full Filter Bag.

24, 25 - Battery Charger access door (open) and Battery Charger

26, 27 - Machine Bat-tery Connector and Seat Prop Rod (in stored position)

29-Vacuum Motor Foam Filter

27-Seat Prop Rod (in prop position)

28-HEPA Filter access door (removed)


KNOW YOUR MACHINE CONTROL PANELA Key SwitchB Battery IndicatorC Quiet Mode ButtonD Quiet Mode IndicatorE HornF Wand ButtonG Wand Button IndicatorH Bag Full IndicatorI Fault Indicator

NOTE 1: The display will go into Sleep Mode to save power if the machine is turned on, in Neutral pedal, and idle for more than 10 minutes. Closing the seat switch (if applicable), moving the drive pedal, or pressing a control panel button will refresh the LEDs.

NOTE 2: Recovery Bag FULL (H) status allows machine transport but disables all active systems and disables the control panel switches except for the Horn Switch (E). To reset, empty/replace the bag and cycle the key switch.

NOTE 3: Battery Low (Low Voltage Cutout) Indicator (B) triggers at 20.55V on the Wet Acid Battery setting.

Refer to “Changing Program Settings - VacRide / 3400, 3400C” to change battery type programming.

B

E

I

D

F

G

A

C

H


KNOW YOUR MACHINEAs you read this manual, you will occasionally run across a bold number in parentheses – example: (2). A bold number refers to an item shown on the Know Your Machine pages unless otherwise noted (bold letters refer to items on the same page). Refer back to the Know Your Machine pages whenever necessary to pinpoint the location of an item mentioned in the text.

BASIC MACHINE OPERATIONRefer to Operator Manual #56041798 (English and Spanish) for detailed information regarding how to operate the machine.

1 Turn on the key to turn on the graphical display showing battery condition, hour meter, and vacuum bag level. Lowering the Vacuum Deck with the Vacuum Deck Raise/Lower lever (11) and lowering the Side Broom Release

Lever (20) will enable regular vacuum mode. 2 Depress the foot pedal forward to begin vacuuming. The brushes and vacuum will turn on.3 When the machine stops, the brushes will stop. The vacuum will continue to run for 10 seconds and then stop.4 To stop all functions and transport the machine, return the Vacuum Deck and Side Broom control levers to the up

position. The brushes will stop and the vacuum will shut off after a 10 second delay.

See the Operator Manual #56041798 to use the side WAND system and the operator’s CONTROL PANEL

HOW TO READ ERROR/FAULT BLINK CODES

The error and fault codes are displayed on the operator’s control panel. The FAULT INDICATOR LED (A) will blink in various sequences indicating codes relating to specific settings or conditions.If fault codes are activated during normal machine operation, the fault LED (A) will display the appropriate blink code (see table on next page).

The fault LED blink code operates as follows:

1. The first part of the code blinks for a 500ms period per flash with 250ms ON and 250ms OFF.2. Then there is a 700ms OFF period.3. The second part of the code flashes again for 500ms with 250ms ON and 250ms OFF.4. Then a 2 second LED OFF period occurs. This ends the blink sequence.5. The sequence repeats if necessary until the key switch is turned off and on again to clear the condition.6. If multiple faults are present, the codes will appear in order until all are displayed. Then the entire sequence repeats.

EXAMPLE - - CODE 1, 2LED - ON 250msLED - OFF 700msLED - ON 250msLED - OFF 250msLED - ON 250msLED - OFF 2 seconds (2000ms)REPEAT

A


MAIN CONTROLLER AND SPEED CONTROL ERROR/FAULT CODES - DIAGNOSTICS

Included in this table are fault blink codes, consequences and possible solutions for each error code. This will assist you in understanding machine response to error code status.Service LED Blink Code

Fault Description Consequences Action / Response / Solutions

1,1 Speed control fault Side broom, Brush motors, vacuum1 and 2 disabled

1. Verify connector at Drive Pedal is connected

2. Refer to “Speed Control Flash Codes” section

3. Repair

4. Reset machine via key switch.

1, 2 Brush motor overload Brush motors disabled

1. Check for binding in rotation of brushes or improper brush lift actuator operation.

2. Check for mechanical interference of the brushes with the side skirts.

3. Check the negative supply cable at the brush motor for a wiring problem, improper modifications, or poor connections at the YEL/VIO sense wire.

4. Check that the deck is set correctly in the control board programming.

1, 3 Vacuum motor overload Vacuum motors and Brush motors disabled

1. Check for debris in vac motor

2. Check for worn carbon brushes

3. Check for defective/corroded motor bearings

4. Check for short circuit in vac motor or wiring.

5. Check the negative supply cable at the vac motor for a wiring problem, improper modifications, or poor connections at the BRN/RED sense wire.

Repair or replace.

1, 4 Side broom contactor overload Side broom disabled

2, 1 Vacuum contactor coil overload

Vacuum1, Side broom, Brush motors disabled

Check for short circuit in wiring or K1 contactor coil.

Repair or replace

2, 2 Brush motor contactor coil overload Brush motors disabled Check for short circuit in wiring or K2 contactor coil.

Repair or replace.2, 3 Side broom contactor open Side broom disabled


2, 4 Brush motor circuit open Brush motors disabled

1. Check for motor wiring open or defective motor

2. Check the negative supply cable at the brush motor for a wiring problem or improper modifications (this is a special cable and must be replaced with original OEM due to sense wire).

3. Check K2 contacts – if open circuit replace K2.

4. Verify brushes are installed.

5. Verify the brushes are touching the floor and there is no interference between the deck and the floor.

3, 1 Vacuum motor circuit open Vacuum1 & 2, Side broom, Brush motors disabled

1. Check for motor wiring open or defective motor,

2. Check the negative supply cable at the vac motor for a wiring problem or improper modifications (this is a special cable and must be replaced with original OEM due to sense wire).

3. Check K1 contacts - if open circuit while vac is turned on (0V at J3-12), replace K1.

3, 2 Brush motor contactor coil open Brush motors disabled

1. Check coil resistance (see chart below)

2. Check for tight connections at contactor and WHT/RED wire to control board.

Repair or replace.

3, 3 Vacuum motor contactor coil open

Vacuum1, Side broom, Brush motors disabled

1. Check coil resistance (see chart below).

2. Check for tight connections at contactor and GRA/BLK wire to control board. Repair or replace.

3, 4 Brush motor circuit contacts stuck closed

With no power to circuit, if contacts measure 0 ohms they’re stuck. Replace K2.

4, 1 Vacuum motor circuit contacts stuck closed

With no power to circuit, if contacts measure 0 ohms they’re stuck. Replace K1.

4, 3 Brush contactor coil control fault probable board failure

1. If J3-13 is 24V referenced to B+ when Scrub switch is Off, replace control board.

2. If J3-13 is 0V referenced to B+ when Scrub switch is Off, disable fault via Hidden Menu. Refer to “Control Board, J2, and J3 Pin Outs and Test Points” section.

4, 4 Vacuum1 contactor coil control fault probable board failure

1. If J3-12 is 24V referenced to B+ when Vacuum switch is Off, replace control board.

2. If J3-12 is 0V referenced to B+ when Vacuum switch is Off, disable fault via Hidden Menu. Refer to “Control Board, J2, and J3 Pin Outs and Test Points” section.

5,1 Vacuum2 contactor coil overload

Vacuum2, Brush motors, Side broom disabled

5,2 Vacuum2 contactor coil stuck closed

5,3 Vacuum2 contactor coil open Vacuum2, Brush motors, Side broom disabled


DECK SYSTEMSDECK REMOVAL CYLINDRICAL

WARNING!DISCONNECT BATTERIES BEFORE SERVICING.Deck Removal / Re-installation1 Removebothdecksideskirt(NoiseDampeningflap)assemblies.Theskirts(flaps)usepush-infasteners.Youmay

needtoreplacethesefastenerswithnewonesforre-installation.2 LowerthedeckmanuallyusingtheRaise/Lowerdecklever.Thebrushescanremaininstalled.3 See Figure 7. 4 Disconnectbothbrushmotorwiringharnessconnectors(A).5 Removethetwo(B)HitchPinsthatattachthedecktothemachinechassislinkagearmweldment.6 Fromtherightsideofthemachinepullthedeckoutfromunderthemachinetocompletetheremoval.7 Toinstallthedeckandrollerbumper(ifapplicable),followthepreviousstepsinreverseorder.

FIGURE 7

B (pins removed)

A

Deck removed from machine

NOTE: The VacRide 3400 series deck casters are NOT adjustable


BRUSH MOTOR REMOVAL - CYLINDRICAL

1 SeeDECKREMOVAL-CYLINDRICALtoremovethedeckassembly.2 See Figure 8. RemovetheBeltCover(A)oneachside.RemovethePlugCap(B)theBelt(C).3 RemovethewiringatboththePos.&Neg.brushmotorterminalstudsandnotethecorrectwiringconnections(forre-

installation).Thenremovethe(3)Screws(D)andliftthemotoroutfromthedeck.4 Reassembleinreverseorder,installingmotorswithwirespointingtotherearofthemachine.5 Applyanti-seizetothemotorshafts.

*Rotationfromshaftend..

FIGURE 8

B

C

D (1 of 3 screws)

Motor

Brush

Motor Type

Nominal Current (A)

+/- 3AOverload Current (A) Wire Colors

Cylindrical

Single motor - 20

Dual motors - 40

Single motor - 30

Dual motors - 60

Red

&

BlackBrush

Contactor CoilNominal Current Overload Current Wire Colors

K2 200 mA +/- 100 mA 750 mA

Brown

&

White/Red

A


BRUSH MOTOR REMOVAL - CYLINDRICAL, CONTINUEDThebrushdrivebeltsmustbemanuallytensionedafterthemotorisreplacedandre-assembled.Removethebeltcover(ifinplace)andloosenthethree(D-previouspage)motormountingscrews.Thereisaslotinthebottomofthemotorbracket(E).Inserttheendofalongscrewdriverthroughtheslotprovided,pryonthemotorshafttoprovidetensiononthebelt,andtightenthemotormountingscrews.

ETurn deck over - viewed from bottomViewed from top of deck with cover

removed

Brush pulley and belt viewed from underneath the deck

Brush pulley (with belt) removed from deck

For proper brush alignment and height the mounting block must be positioned with score marks facing the bottom of the deck.


VACUUM SYSTEMGENERAL DESCRIPTIONThe Vacuum System works in conjunction with the Deck Brushes, the Side Broom and the Wand. After the Vacuum System is activated by the operator at the control panel, the Deck brushes will spin when the deck is lowered, the side broom will spin when it is manually lowered and the Wand will operate when the Wand switch is set. For the Vacuum System to function properly, the following conditions must be met for the vacuum motors to turn on unless by-passed through the Service Test Mode (for troubleshooting purposes).

1. The KEY SWITCH S1 on the operator’s CONTROL PANEL must be ON.2. The operator’s seat must be down and the SEAT SWITCH S2 closed.3. The EMERGENCY STOP switch S4 must be open (E-stop released).4. The BAG FULL switch S3 must be open (bag cannot be full).5 The deck and/or broom must be lowered via DECK RAISE/LOWER lever and/or SIDE BROOM RAISE/LOWER lever that closes DECK SWITCH S5 and/or BROOM SWITCH S7.6. Operator uses foot pedal (accelerator) to move the machine via A2 SPEED CONTROLLER and motor M1 allowing the brushes to turn. Vacuum brush activation is dependent upon the machine movement forward and/or reverse.

Use the simplified wiring diagram provided (next page) to follow the descriptions of the Vacuum System functions. Also see the full machine wiring diagram located at the end of this manual.

BRUSH ACTIVATIONTo activate the Brush motors the A1 CONTROL BOARD energizes the K1 contactor by switching the J3-13 output to Battery negative when the Operator has lowered the deck and begun acceleration. This closes the K1 contacts to supply Battery positive to the brush motor.

VACUUM 1 ACTIVATIONVacuum 1 activates when the A1 CONTROL BOARD energizes the K2 contactor by switching the J3-12 output to Battery negative when the operator has lowered the deck. The K2 contacts close supplying Battery positive to the Vacuum 1 motor.

VACUUM 2 ACTIVATIONVacuum 2 activates when the A1 CONTROL BOARD energizes the K3 contactor by switching the J3-3 output to Battery negative when the operator has lowered the deck. The K3 contacts close supplying Battery positive to the Vacuum 2 motor. If the operator pushes the quiet mode button, the A1 CONTROL BOARD de-energizes the K3 contactor.

BROOM ACTIVATIONThe Side Broom activates when the A1 CONTROL BOARD energizes the K4 contactor by switching the J3-11 output to Battery negative when the operator has lowered the Broom and begun acceleration. The K3 contacts close supplying Battery positive to the Broom motor. SEE SIMPLIFIED WIRING DIAGRAM ON NEXT PAGE


VACUUM SYSTEM MEASUREMENTSVacuum

MotorSingle/Dual

Nominal Current (A)

+/- 3AOverload Current (A) Wire Colors

M5 Single 20 30 White & Black

M5 + M6 Dual 40 60 White & Black

Vacuum

Contactor Coil

Nominal

ResistanceNominal Current Overload Current Wire Colors

K1 100 ohms 240 mA +/- 50 mA 750 mA

Brown

&

Gray/Black


TROUBLESHOOTING VACUUM SYSTEM ISSUES

Problem Possible CauseThe contol board doesn’t indicate the recovery bag is full before the circuit shuts off the vacuum motor

Check the vacuum motor sense wire (BRN / RED) for break or poor connection (mV signal).

Display shows the recovery bag is FULL but it’s not Disable the BAG FULL automatic shut-off via the HIDDEN MENU.Vacuum motors do not turn ON 1. Check that all preliminary conditions have been met .

2. Is the deck down?3. Check voltage outputs at A1 and inputs to K2 and K3..

One vacuum motor does not turn ON 1. Check that all preliminary conditions have been met .2. Is the deck down?3. Check voltage outputs at A1 and inputs to K2 or K3..

Vacuum seems insufficient 1. Check that recovery BAG is not FULL.2. Check for obstructions in hoses and debris around brushes.3. Measure the VACUUM WATER LIFT. See instructions below.

MEASURE VACUUM WATER LIFTMeasuring the Vacuum Water Lift is an effective way to determine the functionality and efficiency of the vacuum system. The photo below shows the method being used at the vacuum hose for the brush deck. Insert the device into the end of the vacuum hose and measure the vacuum with the machine vacuum system activated.


MEASURED VACUUM PERFORMANCE

MOTOR CONDITIONS MEASURE VALUES

One Motor in QUIET MODESealed 20.18” of water (5.03 Kpa)1” Open-hole Aperature 7.69” of water (1.92 Kpa)Max Airflow 56 CFM

Two Motors (QUIET MODE disabled)

Sealed 48.9” of water (12.18 Kpa)1” Open-hole Aperature 8.5” of water (2.12 Kpa)Max Airflow 50 CFM

REPLACING A VACUUM MOTOR WARNING!

DISCONNECT BATTERIES BEFORE SERVICING.

1 See Figure 9 (numbers in the following instructions apply to this figure ONLY). Refer to Parts List document #56042521 for more detail of the Vacuum Fan Assembly components.

2 Remove the rear shroud from the back of the machine.3 Lift the left rear wheel with a bottle jack and remove the wheel. Be sure to loosen the wheel fasteners before lifting the

wheel off the ground. 4 From inside the VAC PANEL (14) (near the deck), Remove the four (2) fastener screws for the Vacuum Motor Cover

(12) and remove the cover. Check or replace the filter (21) on the end of the cover.5 Remove Gaskets (7 and 8). Locate the motor mounting bolts (4) and remove each of the three bolts.6 Disconnect the vacuum motor wiring from the main harness (A). NOTE: The wires should be protruding up through the

hole and not from around the edge of the plate. If they are coming from under the plate, examine for damage and repair if cut.

7 Remove the Tie Cable (10) and remove the Tube Assembly (19) from the motor. 8 To remove the motor, slide it from under the machine and place on bench.


VACUUM MOTOR ASSEMBLY INSTALLATION9 Attach gaskets (7) and (8) to the new vacuum motor; attach gasket (20) where the motor slides into the VAC PANEL,

and insert motor into place.10 Reassemble in reverse order, paying attention to route wires up through the hole, out towards the back and through the

notch provided in the Vac Motor Cover (12).

FIGURE 9

A


WHEEL DRIVE SYSTEMThe drive wheel assembly is directly connected to the Curtis 1228 speed control, which not only provides an output signal of 24V to the drive wheel for forward and reverse movement, but also monitors current and temperature, and controls the electromagnetic brake. It is the same for both the VacRide / 3400, 3400C models. The speed control is programmable through, and can be monitored via, the Curtis Handheld Programmer 56409441 and Curtis Adapter Cable with Quad Plug 56409823, listed in the recommended “Diagnostic and Service Tools” section of this manual. For information on how to use the Curtis programmer, please refer to the Curtis Programmer Manual 56043101.

The 5.7k Ohm throttle pot R1 in the foot pedal controls drive speed and forward/reverse movement. The throttle pot input to the main control board also determines whether or not the vacuum system will engage and is therefore critical to machine performance When the vacuum system is enabled, the brushes are energized and cleaning begins. If the control board senses a Neutral position of the foot pedal, it will not engage these systems unless placed in Service Test Mode or one of the vacuuming modes.

The Electromagnetic Brake is engaged whenever the foot pedal is in Neutral. When the Brake is released, Forward/Reverse is enabled and the drive wheel is energized.

Speed Controller in Electrical Enclosure


SPEED CONTROL FAULT CODESThewandindicatorLEDflashesoutcurrentspeedcontrolfaultcodes. SPEED CONTROL FAULT CODES (TABLE 1)

LED STATUS LIGHT EXPLANATION POSSIBLE CAUSE CODE DISPLAY

1,1 O O Speed control fault-over/under - temperature cutback 1. Temperature >97°C (206°F) or < -25°C (-13°F).

2. Excessive load on vehicle. 3. Operation in extreme environments.

4. Electromagnetic, foot or parking brake not

releasing properly.

1,2 O OO throttle fault 1. Throttle input wire open or shorted. 2. Throttle pot defective. 3. Wrong throttle type selected.

1,3 O OOO speed limit pot fault 1. Speed limit pot wire(s) broken or shorted. 2. Broken speed limit pot.

1,4 O OOOO battery voltage too low 1. Battery voltage <17 volts. 2. Bad connection at battery or controller.

1,5 O OOOOO battery voltage too high 1. Battery voltage >36 volts. 2. Vehicle operating with charger attached. 3. Intermittent battery connection.

2,1 OO O main contactor driver Off fault 1. Main contactor driver failed open.

2,3 OO OOO main contactor fault 1. Main contactor welded or stuck open. 2. Main contactor driver fault. 3. Brake coil resistance too high.

2,4 OO OOOO main contactor driver On fault 1. Main contactor driver failed closed.

3,1 OOO O HPD fault present for >10 sec. 1. Misadjusted throttle. 2. Broken throttle pot or throttle mechanism.

3,2 OOO OO brake On fault 1. Electromagnetic brake driver shorted. 2. Electromagnetic brake coil open.

3,3 OOO OOO precharge fault 1. Low battery voltage. 2. KS1 and Throttle turned ON at the same time

3,4 OOO OOOO brake Off fault 1. Electromagnetic brake driver open. 2. Electromagnetic brake coil shorted.

3,5 OOO OOOOO HPD (High Pedal Disable) fault 1. Improper sequence of throttle and KSI*, push, or inhibit inputs. 2. Misadjusted throttle pot

4,1 OOOO O current sense fault 1. Short in motor or in motor wiring. 2. Controller failure.

4,2 OOOO OO motor voltage fault (hardware 1. Motor voltage does not correspond to failsafe) throttle request. 2. Short in motor or in motor wiring. 3. Controller failure.

4,3 OOOO OOO EEPROM fault 1. EEPROM failure or fault.

4,4 OOOO OOOO power section fault 1. EEPROM failure or fault. 2. Short in motor or in motor wiring. 3. Controller failure.

*NOTE: A KSI (key switch input) system problem is a specific HPD (high pedal disable) type operational fault, caused by the operator activating the Fwd/Rev drive pedal before turning on the main key switch or activating the throttle before sitting on the seat. This can be cleared by returning the operator’s drive pedal to neutral and cycling the key switch OFF and ON.


Wheel Drive Motor

Typical Current (AMPS)

Transport, Full ThrottleWire Colors

M1 15 - 20 Red/Green and Yellow/Black

TROUBLESHOOTING DRIVE WHEEL ISSUESGENERAL TROUBLESHOOTINGWhen troubleshooting various problems related to the DRIVE WHEEL system it is best to approach the issues with some fundamental steps:

1. If the machine isn’t responding to the drive pedal inputs, forward or reverse, visually inspect that all connections are intact, such as the potentiometer connection.

2. Check and test the batteries for proper charge.

3. Check for any Fault codes. If codes are present, repair malfunction if possible.

4. Be sure the key switch is correctly inserted and/or reset the machine by turning the key off and then ON again.

If these basic checks do not reveal the nature of the problem then check the table below. See simplified wiring diagram on page 25. to use with the table

Problem Possible Cause

Machine will still not move forward or reverse.

1. Wheel Drive Motor Circuit Breaker (CB1) tripped (reset 70A circuit breaker)

2. Control Board Circuit Breaker (CB2) tripped (reset circuit breaker)

3. Emergency Stop Knob (6) tripped (pull out and twist)

4. Safety Switch (S2) in seat not closed (check seat switch)

5. Defective Wheel Drive Motor (replace motor)

6. Defective Throttle Potentiometer (R1) (replace)

The wheel drive motor will only run in either

forward or reverse.

1. Test the Fwd & Rev (R1) wiring outputs (pins 3, 4 & 13) at the

speed control for an open. Repair wiring or replace the R1 pot.

2. Controller can’t change electrical polarity to wheel motor -

replace the (A2) speed control.


CURTIS SPEED CONTROL INSTALLATION CHECKOUT PROCEDUREAfter installing a controller and before operating the vehicle, carefully complete the following checkout procedure. If you find a problem during checkout, refer to the Curtis programmer manual for more information.

The installation checkout can be conducted with or without the handheld programmer. The checkout procedure is easier with a programmer otherwise observe the Status LED for codes (located on operator panel wand indicator light).

WARNING!Put the vehicle up on blocks to get the drive wheel off the ground before beginning these tests.

Turn the key switch off and make sure that the seat switch is open, and the throttle (pedal) is in neutral.

Do not stand, or allow anyone else to stand, directly in front of or behind the vehicle during the tests.

Remove the electrical panel to access the controller.1 Observe the error status fault indicator on the operator control panel. If a programmer is available, connect it to the programmer plug-in port 2 Sit on the seat and turn the key switch on. The programmer should “power up” with an initial display. If neither happens, check for continuity in

the key switch circuit and controller ground.3 If you are using a programmer, put it into diagnostic mode by pressing the DIAGNOSTICS key.

• If there is no error detected, the display should indicate “No Faults Found”. Note: Before pressing the diagnostics key, wait until model # screen appears, if the throttle is activated prior to this screen appearing the controller will shut down.

• If there is a problem, the control panel will flash a diagnostic code and the programmer will display a diagnostic message. If you are conducting the checkout without a programmer, refer to the Status LED Fault Codes table in “Speed Control Error Flash Codes” to diagnose the cause.

4 When the problem has been corrected, it may be necessary to cycle the key or seat switch to clear the fault code.5 While sitting on the seat, operate the throttle. The motor should begin to turn in the selected direction. If it does not, verify the wiring to the

controller, and the motor. The motor should run proportionally faster with increasing throttle. If not, refer to the Curtis manual. 6 Put the programmer into test mode by pressing the TEST key. Scroll down to observe the status of the forward, reverse and brake switch.

Cycle each switch in turn, observing the programmer. Each input should show the correct state on the programmer.7 Take the vehicle off the blocks and drive it in an open area. It should have smooth acceleration and good top speed.

Pin Function Wire Color3 5.7k Ohm Pot High YEL4 5.7k Ohm Pot Wiper GRA5 Seat Switch GRA/BLK6 Brake - RED/WHT9 Error Status ORN/BLU13 5.7k Ohm Pot Low VIO14 Brake + ORN16 Reverse Alarm BLU/BLK18 Speed Limit BLK/WHT


DRIVE PEDAL AND POTENTIOMETERTESTING AND ADJUSTING THE DRIVE PEDAL POTENTIOMETERThe Wheel Drive system is controlled by the operator from the DRIVE PEDAL. The DRIVE PEDAL controls the speed and direction of the machine via the Curtis Speed Controller. The potentiometer attached to the pedal assembly is preset at the factory for certain values to control Forward /Reverse speeds and provide a Neutral position. The potentiometer may need readjustment if the pedal is loosened or moved. If the pedal assembly (includes potentiometer) is replaced, the replacement unit will come preset and requires no adjustments. The following instructions will aid in replacing the pedal, adjusting and testing the potentiometer if necessary.

WARNING!Open the Electrical Access Panel carefully per step 2 above.

Batteries must be connected to perform this measurement so extreme caution should be observed.

Caution!Use only insulated test probes designed to backprobe. SPEED CONTROL IS POWERED during these tests.

Referenced to the negative battery standoff, the wiper voltage should read:

Neutral: 2 - 3V

Reverse: < 2V (engage pedal in reverse to measure)

Forward: > 3V (engage pedal forward to measure)

THROTTLE POTENTIOMETER WIPER MEASUREMENT (NEUTRAL POSITION)Use a DVM and extended insulated probe tips (shown in FIGURE 9a next page) to measure the throttle potentiometer Neutral voltage at the wiper (pin 4, the GRA wire) referenced to the B- standoff (green wires).

Drive Pedal Assembly

Potentiometer


POTENTIOMETER TESTINGThe Potentiometer is part of the drive pedal assembly. It is not serviced separately and does not require adjustmentTesting the PotentiometerNote: The pot doesn’t have to be removed from the drive pedal assembly to test.1 Jack the front drive wheel off the fl oor and support the machine with jack stands and wheel chocks.2 Do not remove the the throttle potentiometer.3 Test the pedal signal with a volt meter with the harness connected and the pedal installed on the machine.4 See Figure 9a. Connect the meter leads to each of the outside connections on the potentiometer. The meter should read approximately 4.6V

to 5.02V.5 Next move the test leads to the number two and number three terminals as shown in the lower picture in Figure 9a to validate the signal

voltage. (The range of readings for the signal voltage should be 2.19 V to 2.4 V at neutral , .8 V to 5 V over the entire range of travel , .87 V to 2.19 V in reverse and lastly 2.19 volts to 4.1 volts in forward.NOTE: The drive pedal is shown without the machine wiring harness connector for clarity. Do not disconnect the drive pedal harness connector.

123

4.7 VDC

1 = VCC2 = WIPER3 = GND

123

1 = VCC2 = WIPER3 = GND

.8 VDC - 5 VDC

FIGURE 9a


POTENTIOMETER ADJUSTMENT

WARNING!The potentiometer should not normally need adjustment because it is pre-set by the factory when it is mounted on the drive pedal However, if the potentiometer is loosened or removed it can be readjusted using an ohmmeter. The wiper should be perfectly “centered” when in the neutral position.1 Connect an ohmmeter between the brown and black wire connection points on the potentiometer. Write down the resistance value.2 Connect an ohmmeter between the brown and red wire connection points on the potentiometer. Write down the resistance value.3 Compare the resistance values recorded in step one with step two. They should be exactly the same. If not, loosen the mounting screws, and

rotate the potentiometer, lock it down and repeat steps one and two until both values are equal.

DRIVE PEDAL REPLACEMENT

WARNING!Disconnect the machine’s battery pack connector (13) before servicing.1 See Figure 9b. Remove the 5 Screws (BB) securing the Drive Pedal (CC) to the ? oor.2 Disconnect the Potentiometer electrical connector and remove the Drive Pedal (CC) from the machine.3 Install new pedal in reverse order. NOTE: The Potentiometer does not require adjustment.

FIGURE 9b


REPLACING THE DRIVE WHEEL ASSEMBLY

WARNING!Park the machine on a dry flat surface, turn the main key switch (J) to the Off position and disconnect the battery pack at the red Anderson connectors inside the battery compartment.1 Block the rear wheels.2 Jack up the front of the machine as shown in “Jacking Points” section or use a hoist to lift up the front end of the machine.3 See Figure 10 Using a 17mm socket, loosen but don’t remove the four bolts (A) at the steering sprocket to allow the chain to release some.4 Using a 3/8” magnetic socket, remove the four bolts holding the charger in place, and remove the charger and bottom plate.5 See Figure 11 Using a 1 7/16” socket, remove the hex nut (B) at the top of the Spindle Weldment.6 See Figure 12. Turn the Drive Wheel to the right and remove the motor wiring cover (C).7 Using a 13mm and a 7mm socket, remove the nuts and wires from the drive motor. 8 See Figure 13. Turn the motor towards the left. Using a 7/16” socket and wrench, remove the P-clamp (D).9 Jack up the front end of the machine enough to allow the wheel to slip free from the machine.10 See Figure 10. Using a 17mm socket, remove the four bolts (A) at the top to free the motor from the Steering Plate.

FIGURE 13

FIGURE 12

FIGURE 11

FIGURE 10

Charger bottom plate covering spindle nut

B

A


REPLACING THE DRIVE WHEEL ASSEMBLY (CONTINUED))11 Reassemble the drive wheel in reverse order,

attaching the motor wires as shown (FIGURE 14).

CAUTION!Use a Torque Wrench set at 20 ft-lb to retighten the 1 7/16” hex nut at the top of the steering spindle.

NOTE:

Orient the wires in such a way as to minimize bending at the crimps for optimum motor performance.

There are (2) each YEL/BLK and RED/GRN going to each post.

REPLACING THE DRIVE TIRE The Drive Wheel is assembled as shown in FIGURE 15:

WHITE BLACK

ORANGERED/WHITE

RED/GREENYELLOW/BLACK


In addition to carbon brushes, parts available for replacement are:

• tire with hub 56601472 (A)

• tire 56601471 (B)

• motor 56601473 (C)

• parking brake 56601507 (D)

• motor cover 56601506 (E).1 To replace the tire, follow steps 1-3 of “Replacing the Drive Wheel Assembly.”2 Remove the six metric socket head screws.3 Use Tire Puller Kit 56422174 to replace the tire.Reassemble in reverse order.INSPECTING/REPLACING THE DRIVE WHEEL ASSEMBLY CARBON BRUSHES

important!To remove/replace/inspect the Carbon Brushes, observe the following:1 The motor must come off of the machine.2 The motor assembly must be kept vertical while being disassembled to prevent

loss of gear oil.

WARNING!Park the machine on a dry flat surface, turn the main key switch to the Off position and disconnect the battery pack at the red Anderson connectors inside the battery compartment.1 Follow the instructions in “Replacing the Drive Wheel Assembly”.2 Place the motor assembly upright, motor side up, as shown.

Caution!To prevent gear oil from draining from the gearbox, disassemble the motor with the Drive Wheel assembly in a vertical position. If some oil is lost, drain completely and refill the oil as indicated at the bottom of the page.

3 See Figure 16. Remove the four metric socket head cap screws (A) securing the electric motor to the casting.

4 Use a hard piece of wood or a brass drift punch to tap the motor mounting flange (3 notched locations (B)) to loosen.

5 Grip the motor/brake end bell and pull the motor (C) up and out of its housing.6 Inspect the 4 carbon brushes and springs. A new carbon brush measures 3/4”.

If less than 1/4”, replace.7 Clean the foam filters, and blow out the motor.


8 If gear oil has been lost, drain and replace with 4.5856 oz (130 g) of Mobilgear 600 XP 150 or AGIP BLASIA 150 gear oil.9 When placing the motor back into the housing, the brushes can be spring-flexed aside for easy insertion. Release the spring tension on the

brushes after the motor is in place.

Motor brush (1 of 4)


REPLACING THE REAR WHEELS

WARNING!Park the machine on a dry flat surface, turn the main key switch Off and disconnect the battery pack at the red Anderson connectors in the battery compartment. 1 Block the front Drive Wheel (3).2 Raise the Rear Wheel (13) to be replaced per the instructions at the front of this manual in “Jacking Points” section.3 To prevent injury, if the rear wheel bearing has frozen, replace the bottle jack with blocks or a jack stand before pounding the wheel.4 See Figure 17. Use a 17mm socket to remove bolt (A), washer (B) and wheel (C).5 If the bearing has seized, pound off the wheel and use a bearing puller to remove the inner race from the axle. 6 Apply anti-seize to the inner bearing surface of the new wheel; then replace wheel on axle.7 Apply anti-seize to the bolt threads before refastening bolt, washer and wheel.

FIGURE 17


CSteering nut, washer and Woodruff shaft alignment key

D Battery charger lid lifted for access to lower shroud Lift shroud upward

and off

Shroud removed and inner steering parts exposed

AB & C

STEERING COLUMN ASSEMBLY SHROUD REMOVAL1 Remove the 4 screws fastening the Lower Column Shroud (A) to the Lower Column Weldment.2 Using a flat bladed screwdriver, pry off the steering wheel plastic center cap.3 Using a 3/4” socket, remove the hex nut from the steering wheel center.4 Pound the steering wheel (C) off from behind using a mallet, observing the Woodruff key as it may fall out in the process.5 Pull accordian Steering Boot (D) from the upper steering column.6 Lift the battery charger cover.7 Pry the plastic Lower Column Shroud off the weldment by starting on the left side (away from knob) so shroud can clear the

weldment linkage bump on the right side.

Reassemble in reverse order, applying a light coat of SIlicone Spray or water to the inside of the Steering Boot. This will permit free travel over the shaft.


C

FIGURE 18B

A

ELECTRICAL SYSTEMELECTRIC PANEL: CHARGER INTERLOCK, FUSES, CONTACTORS

WARNING!1 Open battery compartment and disengage the red Anderson battery connectors.2 Remove the 4 screws fastening the electrical panel cover to the front of the machine.3 See FIGURE 18. Inside are found the following: Curtis Speed Controller (A) with drive wheel motor and logic connections. K1 Brush contactor and K2 Vacuum1 contactor (B). Fuses (C) - as shown with onboard charger interlock wire connected.

SPEED CONTROL INFORMATION IS AVAILABLE IN WHEEL SYSTEM SECTION.


ELECTRIC PANEL: CHARGER INTERLOCK, FUSES, CONTACTORS, SPEED CONTROL, CONTINUED

The electrical cabinet components are located as per the following photo. The battery charger interlock connection is also shown.

K1 Contactor 24 VdcBrush

K2 Contactor 24v 100 AmpVacuum 1

K3 Contactor 24V 100 AmpVacuum 2

K4 Relay, Spst 24vBroom

A2 Speed Controller

Battery charger interlock connector - connected

Battery charger interlock connector - disconnected


BRV900 ELECTRICAL COMPONENTSThe following information applies to the Euro model BRV900 only. Shown are additional electrical components for this system. The significant components are:

1. Left deck ferrite bead (Fig. BRV-1) for noise reduction.

2 Deck ferrite bead (Fig. BRV-2) for noise reduction

3 The traction drive controller (BRV-3) and locations within the electrical compartment (BRV-4).

FIGURE BRV-1

Left deck ferrite bead

FIGURE BRV-2

Deck ferrite bead

Clamp

Continued on next page


BRV900 ELECTRICAL COMPONENTS, CONTINUED

FIGURE BRV-3

Traction drive controller in the electrical compartment.

FIGURE BRV-4

Electrical compartment com-ponents (for noise reduction) exclusive to the BRV900 unit only.


1

12111098765432

J2

VAC2_CONT24V

GND

BR_CONT24VVAC_CONT24V

GND

IBRUSH_LINEIVAC_LINE

BRUSH_DECK_SW

SLP_POT_HI

SLP_POT_OUTPUTSLP_POT_LO

HORN+HORN-

F/R_INPUTDIR_INPUT

SCS_INPUT

SEAT_SWITCH

KEY_SWITCHED

B+

VACUUM MOTOR SENSEBRUSH MOTOR SENSEBRUSH DECK SWITCHSIDE BROOM SWITCH

SPEED LIMIT

POT HIPOT LOW

B-B-

BRUSH CONTACTORVACUUM CONTACTOR

SEAT SWITCHVACUUM CONTACTOR 2

HORN -HORN +

DIRECTIONFORWARD / REVERSE

STATUS

KEY SWITCHED

B+

B-1

111098765432

121314

J3

GND

B-B-

BAG FULL SENSE BAG FULL SENSE

SBROOM_SWITCH

SBROOM_CONT24SIDE BROOM CONTACTOR

J2 and J3 Pin Connections

CONTROL BOARD, J2 AND J3 PIN OUTS AND TEST POINTS

Caution!Always take measurements at the end connectors for troubleshooting purposes. If readings tken there do not indicate the problem, check the control board as a last resort as damage to the board may occur (see CAUTION staements in “Replacing Operator Control Panel” section.

Use a DVM and extended insulated probe tips (shown) to take the following measurements.

Caution!Use only insulated test probes designed to backprobe. CONTROL BOARD IS POWERED during these tests.Perform steps in section for “Replacing Operator Control Panel” observing noted CAUTION statements


A BTwo additional screws on opposite side - 4 total

Connectors and wiring removed from Control Board Control Board with disconnected wiring mounted inside Operator’s Control Panel

Continued on next page

REPLACING THE OPERATOR CONTROL PANEL

WARNING!DISCONNECT BATTERIES BEFORE SERVICING.

Caution!To prevent damage to the new control panel assembly due to static electricity (ESD), wear a properly grounded static control wrist strap before removing the new assembly from its protective static shielding bag and throughout the entire installation process until the four screws attaching the assembly to the machine have been fastened.

CONTROL PANEL REMOVAL1 Flip the seat forward and prop it in place. Remove the 4 screws (A) from the Control Panel Assembly (B) then lift and tilt the Control Panel Assembly (B) to access the underside. 2 Take note of all wiring connections for reassembly and then disconnect all wiring.


AAB

B

B

1, 2

C

REPLACING THE OPERATOR CONTROL PANEL, CONTINUEDCONTROL PANEL DISASSEMBLY, ASSEMBLY AND INSTALLATION1 Remove the Key Switch (A) from the panel assembly.2 Remove the 5 screws (B), the Circuit Board (C) and the tab (D-not shown in photo) from the panel assembly. Save items (A-D) and discard the panel assembly.3 Follow all previous steps in reverse order to assemble and install the control panel assembly using the new panel assembly (1 & 2) from the kit.

NOTE: See section on CHANGING CONTROL BOARD PROGRAM SETTINGS for new programming instructions.

Caution!To prevent damage to the new control panel assembly due to static electricity (ESD), wear a properly grounded static control wrist strap before removing the new assembly from its protective static shielding bag and throughout the entire installation process until the four screws attaching the assembly to the machine have been fastened.The ribbon cable(s) and membrane switch grounding film are fragile - do not scratch or crease during assembly or they may be damaged.


PROGRAMMING FUNCTIONS (HIDDEN MENU)Programming the VacRide 3400/3400C is achieved by pressing specific buttons on the operator’s control panel so you can enter a HIDDEN MENU. The HIDDEN MENUs allow you to inform (set) the controller as to how the machine is equipped so that it knows how to properly control the machine functions. When the A1 Control board is replaced, you must program the LOW VOLTAGE CUTOUT setting before the machine will be allowed to operate.

HOW TO CHANGE SETTINGS WITH HIDDEN MENUSThe following instructions are a general overview of how to set functions in the HIDDEN MENU. Specific setting information is available in each setting description in this section.1 Turn the key switch (A) to the OFF position.2 Press and hold the appropriate button or combination of buttons for the menu you wish to

enter. .3 While holding the button(s), turn the key switch (A) to the ON position.4 Continue to hold the button(s) for 2 seconds until the appropriate indicators turn ON to

confirm you entered the expected menu.5 Release the button(s).6 The Fault code LED will blink at the same rate as the fault code display to show what the

current setting is. NOTE: See the KNOW YOUR MACHINE section for “How to read Error/Fault Blink Codes” (page 14).7 To change settings use the WAND button (F). 8 Press the HORN button (E) to SAVE the settings and then all the LEDs turn ON. The program

waits for the operator to turn off the key switch and all buttons are disabled.

MANDATORY PROGRAMING FUNCTIONSThe control board must know the correct low voltage cut out setting to use before it will allow the machine to operate. If the control board is replaced, the first time the key is turned on, the machine will not operate but will go directly to the hidden menu function for setting the low voltage cut out (battery type). When this happens, all three battery indicator LEDs will be illuminated.

Low Voltage Cutout (Battery Type) The purpose of the special low battery voltage cutout function is to prolong battery life. The brush motors and the vacuum motors will turn OFF automatically and cease to function when the batteries discharge to the selected cutout level. The cutout level is adjustable between two settings; the standard setting (wet cell/lead acid) is 20.55 volts and the alternate setting is (gel/maintenance free) is 21.75 volts.

Turn the KEY SWITCH (A) off. Press and hold the QUIET MODE (C) and WAND (F) buttons to enter the menu mode and hold. Turn the KEY SWITCH (A) on. The RED, YELLOW and GREEN LEDs are on. Release the buttons. Then press the WAND (F) button to select between the options. The FAULT LED will blink once for the wet battery selection or twice for the gel battery selection. Press the HORN (E) button to save the setting and all the LEDs turn ON. Turn the KEY SWITCH (A) off.

C

D

EF

B

A

G

H

I


ADDITIONAL PROGRAMING FUNCTIONSRestore DefaultsThis selection will allow you to restore the “Factory Defaults.” In the event that the machine needs “re-booting”, this function will return all the preset factory conditions to all your machine functions. All parameters stored in memory are reset.

Turn the KEY SWITCH (A) off. Press the QUIET MODE (C), WAND (F) and HORN (E) buttons at the same time and hold. Turn the power ON. Continue to hold the buttons for 2 seconds. The WAND, BAG FULL and QUIET MODE LEDs will be ON. Release the buttons. Use the WAND (F) button to select RESTORE FACTORY DEFAULTS –Yes or No. If you select YES the Fault LED blinks two times (twice). If you select NO, the LED blinks once. Press the HORN (E) button to save your selection. Turn the KEY SWITCH (A) off

Fault RecallWhenever the Control unit detects an electrical system fault, one or more error codes are displayed and stored in memory. An error code from a previous machine operation can be recalled for troubleshooting purposes. If the HORN (E) button is pressed while in the Fault Recall menu, the memory is ERASED.

Turn the KEY SWITCH (A) off. Press the WAND (F) button and hold. Turn the power ON. Continue to hold the button for 2 seconds. The WAND and BAG FULL LEDs are ON. Release the button. The Fault codes will blink on the Fault code LED (See section “How to Read Error/Fault Blink Codes, Page 14) to determine what faults may be present. Press the HORN (E) button to ERASE all codes. Turn the KEY SWITCH (A) off.

Fault Detection (default is DISABLED)If a fault occurs in a particular system, the system (and possibly others) will be shut down. This can make troubleshooting the system difficult. This option allows service personnel to disable some of the default detection checks to facilitate troubleshooting.Note: This will not disable the over-current protection on any of the systems.

Turn the KEY SWITCH (A) off. Press the WAND (F) and HORN (E) buttons and hold. Turn the power ON. Continue to hold the buttons for 2 seconds. BAG FULL and QUIET MODE LEDs will be ON. Release the buttons. The Fault LED blinks once for Fault Detection ENABLED and twice for DISABLED. Press the WAND (F) button to toggle between the choices. Press the HORN (E) button to save the setting. Turn the KEY SWITCH (A) off.

Maximum Cleaning Speed (default is 80%)The Control system is programmed to limit the maximum speed while cleaning to a value less than that allowed for simply driving when not cleaning; 100%, 90%, 80%, 65%, 50%, and 35%.

Turn the KEY SWITCH (A) off. Press QUIET MODE (C) and HORN (E) buttons and hold. Turn the power ON. Continue to hold the buttons for 2 seconds. The WAND and QUIET MODE LEDs are ON. Release the buttons. Use the WAND (F) button to select one of the six speed options shown in the table below. Note how many Fault LED blinks for each speed choice. Press the HORN (E) button to save the selection. Turn the KEY SWITCH (A) off.

MAX SPEED – 100% LED blinks = 6MAX SPEED – 90% LED blinks = 5MAX SPEED – 80% LED blinks = 4MAX SPEED – 65% LED blinks = 3MAX SPEED – 50% LED blinks = 2MAX SPEED – 35% LED blinks = 1


HORN VOLUMEThere are two setting modes available in this selection. Backup Alarm Volume and Forward Annunciation. Use the QUIET MODE (C) button to toggle between Backup alarm volume setting mode and Forward Annunciation volume setting mode.

Backup (REVERSE) Alarm volume (default is Medium)Backup Alarm volume can be set to HIGH, MEDIUM, LOW or be turned off.To set the Reverse volume, turn OFF the key switch (A). Press and hold the HORN (E) button. Turn ON the power. Continue to hold for 2 seconds until the QUIET MODE and the RED LOW BATTERY VOLTAGE LEDs turn ON. Release the HORN (E) button. Use the WAND (F) button to select the volume. The Fault Code LED will blink according to the volume. For LOW volume the Fault LED blinks once (1). For MEDIUM volume, the Fault LED blinks twice (2). For HIGH volume the Fault LED blinks three times (3). If the volume is OFF, the Fault LED blinks four times (4). The factory default is MEDIUM. Press the HORN (E) button to save your selection. Turn the KEY SWITCH (A) off.

FORWARD Annunciation volume (default is OFF)The Forward Annunciation volume can be set to HIGH, MEDIUM, LOW or be turned off.To set the forward annunciation volume, turn OFF the key switch (A). Press and hold the HORN (E)button. Turn ON the key switch (A). Hold the button for 2 seconds until the QUIET MODE and LOW BATTERY LEDs turn ON. Release the HORN button. NEXT press the QUIET MODE (C) button once to toggle from the Back up Alarm adjustment mode to the Forward Annunciation volume adjustment mode. The QUIET MODE LED remains ON but the MEDIUM BATTERY VOLTAGE LED turns ON and the LOW BATTERY LED turns OFF. Use the WAND button to select the volume. For LOW volume the Fault LED blinks once (1). For MEDIUM volume, the Fault LED blinks twice (2). For HIGH volume the Fault LED blinks three times (3). If the volume is OFF, the Fault LED blinks four times (4).OFF is the default condition. Press the HORN switch to save the selection and all the LEDS should turn ON. Turn the KEY SWITCH (A) off.

SERVICE TEST MODEThe SERVICE TEST MODE allows you to conveniently test many output circuits independently of the inputs that are normally required for them to function.

To Enter Service Test Mode:1. Turn the key switch (A) to OFF.2. Press and hold the Quiet Mode (C) button.3. Turn the key switch on while continuing to hold the quiet mode button.4. Wait approximately 3 seconds until all indicator lights turn on and then go off.5. Release the quiet mode button.6. Use the control panel buttons to directly control various output functions and monitor the Indicators to confirm operation modes and inputs. See Table below.

BUTTON USED FUNCTION CONTROLLEDHORN Controls the brush motor contactor (ON or OFF)WAND Controls the side broom motor contactor (ON or OFF)QUIET MODE Controls the vacuum motor contactors (ON or OFF)

LED INDICATORS INFORMATION PROVIDED (Displayed)WAND Displays current state of the side broom motor contactor (ON or OFF)BAG FULL Displays current state of the brush motor contactor (ON or OFF)QUIET MODE Displays current state of the vacuum motor contactors (ON or OFF)FAULT Displays current fault codesRED BATTERY Displays current state of the Speed Control Status Input to the A1 control boardYELLOW BATTERY Displays current state of the Speed Control FOR/REV input to the A1 control board GREEN BATTERY Displays current state of the Speed Control REV input to the A1 control board.


TESTING OUTPUTS

To test/control vacuum motor contactors K2 / K3Once in the service test mode, press the QUIET MODE (C) button to turn on the vacuum motor contactors. The quiet mode indicator light will turn on to confirm that you have requested that the vacuum motor contactors be turned on. Press the quiet mode button again to turn off the contactors. On a normally functioning machine, both vacuum motors will be running.

To test/control side broom motor contactor K4Once in the service test mode, press the WAND (F) button to turn on the side broom motor contactor. The wand indicator light will turn on to confirm that you have requested that the side broom motor contactor be turned on. Press the wand button again to turn off the contactor. On a normally functioning machine, the side broom motor will be running.

To test/control brush motor contactor K1Once in the service test mode, press the HORN (E) button to turn on the brush motor contactor. The bag full indicator light will turn on to confirm that you have requested that the side broom motor contactor be turned on (The horn button does not have an indicator LED). Press the horn button again to turn off the contactor. On a normally functioning machine, the brush motor will be running.

TESTING INPUTS

To test the Speed Controller Status InputOnce in the service test mode, monitor the red battery indicator LED.OFF = normal input conditionON = Status input from speed controller is missingFlashing = Speed Controller is communicating a fault code to the A1 control board

To test the Speed Controller FOR/REV InputOnce in the service test mode, monitor the yellow battery indicator while changing the drive pedal position. Keep in mind that the machine will move in response to the drive pedal movement.Off = NeutralOn = Forward or Reverse

To test the Speed Controller REV InputOnce in the service test mode, monitor the green battery indicator while changing the drive pedal position. Keep in mind that the machine will move in response to the drive pedal movement.Off = ReverseOn = Neutral or Forward

Summary of Normal Speed Control inputs by Drive Pedal PositionOnce in the service test mode, If the Speed Control inputs to the A1 Control board are all normal you should see the following when moving the drive pedal:Neutral = Green OnlyForward = Yellow and GreenReverse = Yellow Only


MAINTENANCE SCHEDULESOPERATOR PREVENTIVE MAINTENANCE – MACHINE IN USE

MAINTENANCE ITEM Daily Weekly MonthlyCharge Batteries ●

Check/Clean Bags ●

Check/Clean/Rotate Brushes ●●

Charge Batteries – full charge cycle 12-15 hrs ●

Check Each Battery Cell’s Water Level (wet batteries) ●

Check/Clean/Adjust Deck parts ●

Lubricate Steering Chain ●

Lubricate Pivot Points for Deck Linkage ●

Lubricate Steering Wheel Shaft Universal Joint ●

Lubricate Front Roller Bumper (15) ●

MAINTENANCE


MAINTENANCE SCHEDULES

OPERATOR PREVENTIVE MAINTENANCE – MACHINE IN STORAGEMAINTENANCE ITEM Daily Weekly Monthly Yearly

Check Each Battery Cell’s Water Level (wet) ●

Charge Batteries – full charge cycle 12-15 hrs ●

SERVICE TECHNICIAN SUGGESTED MAINTENANCEMAINTENANCE ITEM Quarterly Yearly

Clean battery tops and posts with baking soda solution ●●

Perform hydrometer battery check (wet batteries) to identify bad cells ●Perform voltmeter check of individual batteries (gel/AGM) to identify bad cells ●Perform battery load test to identify degraded batteries resulting in poor run time ●Inspect vacuum motor carbon brushes for wear(Replace if 9.5mm (3/8 inches) or shorter) 300 Op Hrs

Inspect brush motor carbon brushes(Replace if 9.5mm (3/8 inches) or shorter) 500 Op Hrs

While brush motor being checked, also check for wear at Motor Gimbal inside Brush Plate. Remove and replace if worn. 500 Op Hrs

Inspect drive motor carbon brushes(Original carbon brush length is 19.1mm (3/4 inches). Replace when shorter than 6.3 500 Op Hrs

RECOMMENDED MAINTENANCE MATERIALSTypical adhesives and lubricants used on VacRide / 3400, 3400Cinclude Loctite(R) Silver Grade Anti-Seize, Loctite formulas 242, 680, 414, 409, and No More Leaks(TM) 80724 sealant; Uniroyal M6325 Adhesive, CRC WhiteLithium Grease, Sprayon S00206 All-Purpose SiliconeLube, light machine oil such as 10W-30 motor oil, Mobil SHC 634 lube and Mobilgear 600 XP 150 (EU: AGIP BLASIA 150) gear case oil.

To clean wet batteries, baking soda will also be needed.


Advance VacRide 3400, 3400CCylindrical

PM Checklist

Defect CodesCustomer A needs adjustment

B bindingAddress C dirty or contaminated

D damaged, bent or tornCity St Zip L leaks

M missingModel Serial Hours W worn out

Ref OPERATIONAL INSPECTION ITEMS OK orN/A

Defect Codes(circle)

DoesNotWork

1 Steering A B

2 Drive Pedal Operational (check for Fwd/Rev Drive & any neutral creep) A B D

3 Seat Switch D

4 Electrical Parking Brake (Brake releases when the key is turned on and the drive pedal is engaged. Brake engages when machine is at rest.) A B W

5 Drive System Performance (refer to Curtis Programmer Manual SM56043101 for speed control changes)

Noisy Sluggish

9a Vacuum Performance Single Motor C L W

9b Vacuum Performance Dual Motor C L W

11 Emergency Stop Knob B D

12 Tilt Steering Mechanism and Seat A B D

13 Optional Accessories D

14 Main Control Board Special Program Options and Fault Recall Mode– check all applicable program settings per Changing Program Settings section and examine stored fault codes.

15 Battery Charger Programmed Correctly for Battery A

16 Battery Charger Operation D


Ref VISUAL INSPECTION ITEMS Comments OK or N/A

DefectCodes(circle)

DoesNotWork

17 Brushes (check for wear and rotate) A B D W

18 Brush Motor Carbon Brushes Wear Limit 3/8” B L W

19 Brush Motor Gimbals In Brush Plates W

20 Auto Tension Belt – Wear and Tension (cylindrical) A D W

21 Spring Retainers On Brush Plates D

25 Vacuum Motor Carbon Brushes Wear Limit 3/8” W

26 Vacuum Motor Gaskets & Filters L W

28 Vacuum Bag Lid Gasket C D L

35 Battery Condition (clean & water) Load Test C W

36 Front Drive Wheel Motor Carbon Brushes Wear Limit 1/4” C W

37 Drive Pedal Linkage Neutral Return A C

38 Steering Chain Lube & Tension A B C

39 Steering Column Universal Joint A D

40 Rear Wheels C

WORK COMPLETED BY: ACKNOWLDEGED BY:

__________________________________ _________ ________________________________ ________Service Technician Signature Date Customer Signature Date

WIRING DIAGRAM 56602076 REV. F

Designation VacRide Pin ID Description Signal Characteristic Nominal Value

Reference To: Range Comments

INPUTSKEY SWITCH J3-14 Key Switch DC Voltage 24 V B- (Ground) 20 -26 Digital inputSEAT SWITCH J3-4 Seat Switch DC Voltage 24 V B- (Ground) 20 -26 Digital input Speed Control DIRECTION J3-5 Reverse Signal DC Voltage 24 V B- (Ground) forward is Low ( 1 to 0V), reverse is High (20 to 26 V)

Speed Control MOTION J3-6FWD/REV and (Brake)

Signal DC Voltage 24 V B- (Ground) Neutral is Low ( 1 to 0V), Moving is High (20 to 26 V)

Speed Control STATUS J3-7 Speed Control Status DC Voltage 24 V B- (Ground)Pulsed signal equal to the fault code flashed by the speed controllers built-in status LED

BRUSH CURRENT FEEDBACK J2-10Monitor Main Broom

Overload Analog Volatge 0 - 200 mV B- (Ground) Analog input

VACCUM CURRENT FEEDBACK J2-9Monitor Vaccum Motor

Overload Analog Volatge 1 - 200 mV B- (Ground)Nominal Voltage for single vac : 110mV (+/-20%) Nominal Voltage for dual vac : 220mV (+/-20%)

Side Broom Switch J2-12Side Broom On/Off

Switch Digital 5 B- (Ground) 0 or 5

Brush Deck Switch J2-11Brush Deck On/Off

Switch Digital 5 B- (Ground) 0 or 5 DC voltage

Bag Full Switch J2-3 Bag Full Switch Digital 5 B- (Ground) 0 or 5 Digital inputGround J2-1 ground DC voltage 24 V B+ 20-26 DC voltage

Ground J2-8 ground DC voltage 24 V B+ 20-26 DC voltage

Not connected J2-2

Not connected J3-2Not connected J3-1OUTPUTSSC POT LOW J2-5 Power supply DC voltage 0 B- (Ground) 0 Digital inputSPEED LIMIT J2-4 Speed limit output Analog Volatge 0-5 B- (Ground) 0 - 5 Analog inputSC POT HIGH J2-6 Power supply Ground 5 B- (Ground) 5 Digital inputHORN- J3-9 Horn output (+) DC Voltage 15V B- (Ground) 0-15V DC voltageHORN+ J3-10 Horn output (-) DC Voltage 15V B- (Ground) 0-15V DC voltageBRUSH CONTACTOR J3-13 Control Brush Motor PWM (5KHz, 80% duty cycle ) 24 V B- (Ground) 18-24V DC voltageVACCUM 1 CONTACTOR J3-12 Control Vacuum Motor PWM (5KHz, 80% duty cycle ) 24 V B- (Ground) 18-24V DC voltageVACCUM 2 CONTACTOR J3-3 Control Vacuum Motor PWM (5KHz, 80% duty cycle ) 24 V B- (Ground) 18-24V DC voltageSIDE BROOM CONTACTOR J3-11 Side Broom Motor PWM (5KHz, 80% duty cycle ) 24 V B- (Ground) 18-24V DC voltageMembrane Switch LED'sPOWER J6-1 Membrane Switch DC Voltage 5V B- (Ground) 0 or 5 POWERLow Voltage LED J6-2 Membrane Switch Digital 5V B- (Ground) 0 or 5 Digital OutputMedium Voltage LED J6-3 Membrane Switch Digital 5V B- (Ground) 0 or 5 Digital OutputHigh Voltage LED J6-4 Membrane Switch Digital 5V B- (Ground) 0 or 5 Digital OutputFault LED J6-5 Membrane Switch Digital 5V B- (Ground) 0 or 5 Digital OutputWand LED J6-6 Membrane Switch Digital 5V B- (Ground) 0 or 5 Digital OutputVacuum LED J6-7 Membrane Switch Digital 5V B- (Ground) 0 or 5 Digital OutputBag Full LED J6-8 Membrane Switch Digital 5V B- (Ground) 0 or 5 Digital OutputNot Connected J6-9Power J6-10 Membrane Switch DC Voltage 5V B- (Ground) 0 or 5 POWERNot Connected J6-11Not Connected J6-12Membrane Switch InputsGROUND J5-1 Membrane Switch Ground 5V Vcc 0 or 5 POWERHORN SWITCH J5-2 Membrane Switch Digital 5V B- (Ground) 0 or 5 Digital inputVACUUM SWITCH J5-3 Membrane Switch Digital 5V B- (Ground) 0 or 5 Digital inputWAND SWITCH J5-4NOT CONNECTED J5-5NOT CONNECTED J5-6NOT CONNECTED J5-7NOT CONNECTED J5-8NOT CONNECTED J5-9NOT CONNECTED J5-10NOT CONNECTED J5-11NOT CONNECTED J5-12

VacRide Input/Output Table for Machine Controller

INPUT OUTPUT TABLE

Documents

VacRide XL, 3400, 3400C, BRV900 - Nilfisk · 8 Hard (printed) copies of service manuals for all regularly serviced machines (available at and other Nilfisk-Advance websites) 9 6”