SC900

Service Manual
Advance Model Numbers:
56115201 SC900-28D
56115202 SC900-34D
56115203 SC900-32C

English

07/2016 Form No. 56043175

Service Manual – SC900 Contents ii

Contents
03 - General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
General Machine Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Service Manual Purpose and Application . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Other Reference Manuals and Information Sources . . . . . . . . . . . . . . . . . . . . . 5
Parts And Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Diagnostic and Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Property Damage Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Lifting or Transporting the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Know Your Machine — Major components: . . . . . . . . . . . . . . . . . . . . . . . . 11
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Lubricating the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

14 - Wheel System, Non-Traction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

20 - Wheel System, Traction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Forward and Reverse Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Speed Limiting Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Drive Motor PWM Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Drive Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Circuit Description (Idle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Circuit Description (Driving) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Drive Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Follow-up Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Motor Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Transaxle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Shop Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Curtis Programmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

24 - Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Battery Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Maintenance and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Setting Onboard Charger Battery Profile . . . . . . . . . . . . . . . . . . . . . . . 32
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Electrical Bay Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Squeegee and Brush Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Service Manual – SC900 Contents iii

Drive Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Switches and Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Drive Handle Reassembly Notes . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Connector Pinouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
TrackClean Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
EcoFlex Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Operator’s Handle Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Drive Controller Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Harness Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

30 - Solution System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Non-Detergent Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Detergent Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Detergent Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Scrub System, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
No Solution Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
No EcoFlex Detergent Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Scrub Skirt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Solution Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Solution Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Solution Control Panel and Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
EcoFlex Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

34 - Scrub System, Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Circuit Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Scrub System, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
One Brush Not Working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Both Brush Motors Not Working . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Scrub Skirt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Scrub Brush Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Brush Motor Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

34 - Scrub System, Cylindrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Circuit Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Scrub System, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
One Brush Not Working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Both Brush Motors Not Working . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Scrub Skirt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Scrub Brush Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Brush Motor Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Service Manual – SC900 Contents iv

38 - Squeegee System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Squeegee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Maintenance and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Squeegee Blade Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . 69
Squeegee Tilt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Squeegee Blade Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

40-Recovery System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Vacuum Motor and Recovery Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Circuit Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
No Vacuum Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Poor Suction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Vacuum Suction Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Vacuum Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Vacuum Motor Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

90 - Options and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Onboard Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
TrackClean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
EcoFlex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Battery Watering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Service Manual – SC900 5

03 - General Information

General Machine Description

The SC900 machine is a battery-powered, walk-behind, self-propelled commercial floor scrubbing machine
with either a disc or cylindrical scrub system, and suitable for use in hotels, schools, hospitals, factories,
shops, offices, rental businesses and similar applications. The SC900-28D has a 28" disc deck. The SC900-
34D has a 34" disc deck. The SC900-32C has a 32" cylindrical deck.

The machine is powered by six, 6-volt batteries connected in series, to provide 36 VDC to the motors and
controls.

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.

Other Reference Manuals and Information Sources

Document Name Document Document Type
Number
Instructions for Use 56091183 Operator’s Manual
Parts List 56042634 Parts List

Parts And Service

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

Call the Advance Dealer named below for repair parts or service. Please specify the Model Number (same as
the Part Number) and Serial Number when discussing your machine.

Diagnostic and Service Tools

In 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 Advance commercial floor cleaning equipment.

• Digital voltmeter (DVM) with DC current clamp

• Hydrometer
• Battery load tester for checking batteries
• Set of torque wrenches

These tools are also available from Nilfisk-Advance, Inc.:

• Curtis 1311 hand held programmer, p/n 56409441,

• Vacuum water lift gauge, p/n 56205281.

Conventions
All references to right, left, front and rear in this manual are as seen from the Operator’s position.
Service Manual – SC900 03 - General Information 6

Modifications
Modifications and additions to the cleaning machine which affect capacity and safe operation shall not
be performed by the customer or user without prior written approval from Nilfisk, Inc. Unapproved
modifications will void the machine warranty and make the customer liable for any resulting accidents.

Nameplate
The nameplate contains important
identification information which will be
needed when ordering parts: The Model
Number (Part No.) and Serial Number of the
machine are shown on the Nameplate located
on the inside of the battery compartment.

This information is needed when ordering

repair parts for the machine.
Service Manual – SC900 03 - General Information 7

Safety
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.

Note: Indicates an important informational message.

General Safety Instructions

These safety instructions are included to warn you of potential bodily injury or property damage.

CAUTION: Read and understand all safety warnings and instructions. Failure to follow the
warnings and instructions may result in electric shock, fire, and/or serious injury.

−− To avoid personal injury, this machine should be used only by properly trained and
authorized persons.

−− Do not operate the machine near toxic, dangerous, flammable and/or explosive
materials. This machine is not suitable for collecting dangerous or hazardous
materials.

−− In case of fire, use a powder fire extinguisher, not a water-based extinguisher.

−− 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.

−− Disconnect the power source and/or 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.

−− When using floor cleaning detergents, follow all safety and handling instructions of the
respective manufacturer.

−− Battery charging may produce highly explosive hydrogen gas. Charge the batteries
only in well-ventilated areas and away from ignition sources or open flames.

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

−− Take precautions to prevent hair, jewelry, or loose clothing from becoming caught in
moving parts.
Service Manual – SC900 03 - General Information 8

Property Damage Messages

−− Storage and operation temperature must be above 32°F (0°C) and a humidity between
30% and 95%, non-condensing.

−− Before use, all doors and hoods should be properly latched.

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

−− This machine is only approved for hard surface use.

−− Use brushes and pads supplied with the machine or those specified in the User
Manual. Using other brushes or pads could reduce safety.

−− Do not wash the machine with direct or pressurised water jets, or with corrosive
substances.

−− Do not allow the brush/pad to operate while the machine is stationary to avoid
damaging the floor.

−− Use only factory authorized parts and accessories.

−− This machine must be properly disposed of in accordance with local laws and
regulations.
Service Manual – SC900 03 - General Information 9

Lifting or Transporting the Machine

CAUTION: Never work under a machine without safety stands or blocks to support the machine.
−− Drain the recovery and solution tanks to prevent sloshing water from unbalancing the
machine.
−− Lift only from the subframe of the machine, as shown below.
−− Secure the machine to the transport using the tie down points shown below.

The actual procedure for transporting the machine will vary depending on the mode of transport. Follow
these general guidelines as applicable to the situation.
• Remove the squeegee from the machine. This is required to access the rear hold down points and also
protects the squeegee during loading, unloading, and transport.
• If transport will occur below freezing temperatures, place a small amount of environmentally friendly
antifreeze in the recovery tank, solution tank, and solution lines.
• Make sure all doors, panels, and covers are secure.
• Secure the machine to the transport using both front and both rear tie down points.

Tie Downs

Tie Downs &

Rear Lift Points
Service Manual – SC900 03 - General Information 10

Technical Specifications
Model SC900 28D SC900 34D SC900 32C
Model No. 56115201 56115202 56115203
Voltage, Batteries 36V (6 x 6V)
Battery Capacity 310 Ah
Protection Grade na
S P L IEC 60335-2-72: 2002 Amend. 1:2005,
66.4 dB(A)/20µPa 66.4 dB(A)/20µPa 68.8 dB(A)/20µPa
ISO 11201
S P L – KpA (IEC 60335-2-72, ISO 11201)
< 70 dB(A)
Uncertainty
Vibrations at the Hand Controls (ISO 5349-1) 0.510 m/s2 0.381 m/s2 0.476 m/s2
Vibrations at the Hand Controls (ISO 5349-1)
< 2.5 m/s2
Uncertainty
Maximum Wheel Floor Loading (right front) 147 psi / 1.0 N/mm2 128 psi / 0.89 N/mm2 155 psi / 1.1 N/mm2
Maximum Wheel Floor Loading (left front) 107 psi / 0.74 N/mm2 132 psi / 1.0 N/mm2 128 psi / 0.88 N/mm2
Maximum Wheel Floor Loading (right rear) 205 psi / 1.4 N/mm2 432 psi / 3.0 N/mm2 245 psi / 1.7 N/mm2
Maximum Wheel Floor Loading (left rear) 521 psi / 5.6 N/mm2 640 psi / 4.4 N/mm2 416 psi / 2.9 N/mm2
Machine Width (chasis) 30.3” / 77.0 cm 30.3” / 77.0 cm 30.6” / 77.7 cm
Machine Width with Squeegee 41.8” / 106.2 cm 41.8” / 106.2 cm 41.8” / 106.2 cm
Machine Height 44.8” / 113.8 cm
MachineLength 65.4” / 166 cm 67.4” / 171 cm 63.1” / 160.3 cm
Solution Tank Capacity 29.5 Gal / 111.7 L
Recovery Tank Capacity 32 Gal / 121 L
Battery Compartment Size (approximate) Height (maximum) 15 in / 38 cm
Width (maximum) 26 in / 66 cm
Length (maximum) 27.5 in / 70 cm
Scrub brush size (2 per machine) 5.5 x 31 Inch
Ø 14 inch / 35.5 cm Ø 17 inch / 43.1 cm
13.9 x 78.7 cm
Scrub Brush Speed ( Left / Right ) 255 / 259 RPM 256 / 260 RPM 820 / 735 RPM
Cleaning Path Width (scrubbing path) 28 inch / 71.1 cm 34 inch / 86.3 cm 31 inch / 78.7 cm
Gross Weight* 1189 Lbs. 539,3kg 1205 Lbs. 546,8kg 1235 Lbs. 560,2kg
Transport Weight** 942 lbs / 427 kg 979 lbs / 444 kg 1006 lbs / 456 kg
Vacuum Motor Size 710 watts max HP 0.95
Drive Motor Size .5 HP
Brush Motor Size 0.75 HP
Maximum Scrub Speed 3.2
Maximum Transport Speed 3.2
Gradeability Transport 16% (9.1°)
Gradeability Cleaning 8.3% (4.75°)

*Gross Weight: Standard machine without options, full solution tank and empty recovery tank, with removable
scrub brushes and 310 AH batteries installed.
**Transportation Weight: Standard machine without options, empty solution and recovery tanks, with batteries
installed and no operator.
Service Manual – SC900 03 - General Information 11

Know Your Machine — Major components:

Recovery
Cover

Recovery
Tank

Control
Handle
Solution
Tank

Disk Deck

Cylindrical
Deck

Chassis
& Drive

Squeegee
Service Manual – SC900 03 - General Information 12

Maintenance Schedule
Maintenance intervals given are for average operating conditions. Machines used in severe operational
environments may require service more often.
Interval
Maintenance Item
Daily Weekly Monthly Yearly
Charge Batteries •
Check/Clean Tanks & Hoses •
Check/Clean/Rotate the Brushes/Pads •
Check/Clean the Squeegee •
Check/Clean Vacuum Shut-Off Float •
Clean Hopper on Cylindrical System •
Empty/Clean Debris Catch Tray in Recovery Tank •
Check Battery Cell Water Level (does not apply to gel cell batteries) •
Inspect Scrub Housing Skirts •
Inspect and Clean Solution Filter •
Clean Solution Manifolds on Cylindrical System •
Purge Detergent System (AXP and EcoFlex) •
Lubricate the Machine •
Check Vacuum Motor Carbon Brushes 300 hours
Check Brush Motor Carbon Brushes 500 hours
Check Drive Motor Carbon Brushes 500 hours

Note: See the individual machine system sections for maintenance information.

Carbon Brush Notes:

−− The original (new) length of each carbon brush is 1” (25.4mm) on brush and wheel drive motors.

−− All motors: Replace carbon brushes when shorter than 3/8” (9.5mm) to obtain the same motor
efficiency as new brushes.

D C
Lubricating the Machine
D
Once a month, apply light machine oil to
lubricate the:

• General Pivot Points for the Squeegee

Linkage (A). B

• Squeegee end wheels (B).

A

• Scrub deck bumper wheel (C).

• General Pivot Points for the Brush

Linkage (D). E

Once per quarter, Grease the following B

• Rear Caster Wheel Swivels (E).

Service Manual – SC900 13

14 - Wheel System, Non-Traction

Functional Description
The SC900 machine is propelled by the drive
wheels. The rear caster wheels add stability and
ease of turning.

Caster
Wheels
Removal and Installation
WARNING: Never work under machine without safety stands or
blocking to support the machine.

1. To reduce the weight of the machine, drain both the recovery and solution tanks.

2. Raise the rear of the machine and place blocking under the rear lifting points.

3. Remove the four screws and washers that secure the caster to the chassis, and remove the caster.
Service Manual – SC900 14

20 - Wheel System, Traction

Functional Description
The SC900 machine is driven by an electrically Control
Handle
powered transaxle. The transaxle is an open
differential powered by a 1/2 hp, permanent
magnet, 36V motor. A Curtis 1228 solid
state speed controller regulates the speed
and direction of the wheel drive motor. The
motor speed controller is located in the
electrical compartment of the battery bay.
The potentiometer (R1) on the control handle,
controls the speed setting of the machine. The
control handle also contains two forward and one
reverse drive buttons.

Forward and Reverse Switches Transaxle

Functionally, there are two forward and one

reverse buttons on the control handle. However,
electrically, there are actually three “Go”
switches and a single “Reverse” switch. The
distinction is because the reverse button actually
contains two switches internally, where one
switch is reverse and the second switch is a third
Go switch. The three Go switches are in parallel, so they all act the same.

The three Go switches signal the drive controller to move, and the reverse switch just changes its direction.
The reverse switch by itself will not make the machine move.

The incoming side of the Go switches is connected to the Pot-Lo output from the drive controller, which is at
0 volts. The output side of the switches is connected to the throttle input of the drive controller, and also the
low side of the speed limit potentiometer.

The incoming side of the reverse switch is connected to the key switch output. When the key switch is turned
on, the reverse switch receives 36 volts. When the reverse switch is also closed, this 36 volts is provided to
the “Reverse” input of the drive controller, which signals the controller that when it operates, it should be in
the reverse direction.

Speed Limiting Potentiometer

The speed limiting potentiometer (R1 pot) is a 3-wire variable resistor connected to the Speed Limit input
of the drive controller. This pot sets the upper speed limit of the controller so that when any Go switch is
closed, the machine is set to full-throttle, but this potentiometer limits the speed.

As a 3-wire potentiometer, the Drive Controller sets the bias voltage to the potentiometer. However, The
normal “Pot Low” bias voltage first passes through the Go switches. So the speed limit potentiometer is out
of the circuit until one of the Go switches is closed. When the Go switches are open, the Speed Limit wiper
voltage will be nearly 5 volts, but as soon as one of the switches closes and the pot is properly biased, the
wiper voltage will immediately drop to its expected voltage via voltage division between Pot-Lo and Pot-Hi.
Service Manual – SC900 20 - Wheel System, Traction 15

Drive Motor PWM Function

The drive motor is controlled from a Curtis 1228 controller, which is 1-Cycle
a pulse-width-modulation speed controller designed specifically for (15kHz)
permanent magnet DC motors. Pulse-width-Modulation (PWM) is a form
of motor speed control that alters the power to a motor by rapidly turning
the power on and off. The ratio (also called “duty cycle”) between the
25% PWM Duty Cycle

On and Off states determines how much power the motor receives. The
shorter the “off-time” the closer to full power the motor will receive. This
switching occurs so fast (15kHz for this controller) that the motor simply 50% PWM Duty Cycle
sees it as a reduction in power (voltage) instead of the rapid on/off. PWM
is a standard motor control technique because it is easier to turn power
all the way on and all the way off, than it is to vary the magnitude of the 75% PWM Duty Cycle
power. Varying the magnitude would create a lot of heat that would need
to be dissipated.
100% PWM Duty Cycle

Drive Controller
The primary purpose of the drive controller is, of course, to control the drive motor. However, it also provides
some ancillary control of the other functions of the machine, which will be discussed in greater detail in the
applicable chapters. As a motor controller, it delivers PWM-varying power to the drive motor in both positive
and negative polarities for forward and reverse motor operation.

Even though the machine does not utilize an electromechanical brake system, the drive controller possesses
the output control for one. This is used for ancillary machine control. This is more aptly referred to as a
Brake-Release versus a brake control. Whenever the machine is not commanded to move, the brake outputs
are inactive, and if a brake was present, it would be mechanically engaged. The brake outputs are active
only when the machine is commanded to move. This feature is used to activate the scrub functions of the
machine only when the machine is commanded to move (even if the speed is set to zero).

The controller is powered directly from the batteries, but through a 30-amp circuit breaker. The drive
controller remains inactive (inhibited) until the KSI input receives positive battery power through the main
key switch. When KSI is active, the drive is ready to operate, and awaiting a throttle command to move.

Note: The drive controller is configured for an inverted throttle input from typical. Instead of the
throttle being active-high, it is active-low. When the throttle input is at 5 volts, the throttle is
off. When the throttle input is at 0 volts, the drive is commanded for full throttle.

In addition to the throttle being inverted, it is also limited to just two states: Off and Full. Because the
throttle input is either off or full, the speed of the machine is controlled by the speed limit potentiometer
input. This input ranges from 0 to 5 volts, with 0 volts equaling no speed, and 5 volts equaling maximum
speed. The bias voltage of 0 and 5 volts for the potentiometer is provided by the speed controller from the
Pot-Lo and Pot-Hi outputs.
Service Manual – SC900 20 - Wheel System, Traction 16

Circuit Description (Idle)

S1 36 VDC
Main battery power is always
+ -

present at the speed controller

Key Switch

from the battery, but the controller

remains inhibited until the KSI Closed
input is brought to positive battery
voltage. When the main key switch

BLK
RED
5V
is closed, positive battery power is
P1

B+

B-
provided to the KSI input on the VIO 5
KSI 3 WHT
drive controller, and also enables the
POT HI
36V S3 R1
GRA/VIO 17
positive side of the reverse switch on S, REV REV SPD POT
18 ORN POT.
5K OHM
the drive handle.
CURTIS 1228
PNK 14 4 BLU
THR POT
BRAKE+
In this state, the drive controller is 36V POT LO
13 YEL
S6

enabled, but is not active until one

PNK/BLU 6
BRAKE- S2
GO LEFT
of the drive switches is closed. When 36V GO MID
the drive controller is enabled but
S7 GO RT

M2
M2

M1
M1
not active, its outputs are set as BRUSH + -
M
follows: Detergent Pump RED/GRN YEL/BLK 0V
• Pot-Lo = 0V Solution Solenoid M1
MOTOR, DRIVE
• Pot-Hi = 5V Off
Open
• Brake+ = 36V
• Brake- = 36V

Because there isn’t a voltage difference between Brake+ and Brake-, none of the scrub system components
will be energized.

Because all of the Go switches are open, no current will flow through the Speed Pot (R1), and therefore it
will have no voltage drop. This causes all of the R1 terminals to be equal to the 5 volts of the Pot-Hi output.
Specifically, the Throttle-Pot input is high (5V), which is the command for “No Throttle”. (Note that the
throttle input is inverted, as described previously.)

Even though this open circuit results in the Speed Limit to be commanded to maximum speed, the throttle
input remains off. So no motion is commanded.
Service Manual – SC900 20 - Wheel System, Traction 17

Circuit Description (Driving)

S1 36 VDC
+ -
When any of the three Go switches
is closed, it connects the Pot-Lo
Key Switch

output (0V) from the controller back

to the Throttle-Pot input. The drive Closed ?V
5V
controller sees this as a full-throttle 0V
command and initiates the drive

BLK
RED
P1
function. If the Reverse switch closes,

B+

B-
the drive will decelerate (if moving VIO 5
KSI 3 WHT
POT HI
forward) and re-accelerate in the 36V S3
GRA/VIO 17
R1
reverse direction. S, REV REV SPD POT
18 ORN POT.
5K OHM
CURTIS 1228
4 BLU
Because the drive is receiving a full- PNK 14
BRAKE+
THR POT

throttle command, the actual drive 36V POT LO

13 YEL
S6
PNK/BLU 6
speed is set by controlling the speed BRAKE- S2
GO LEFT
limit input. When the Go switch 0V GO MID
S7 GO RT
closes, the speed limit potentiometer

M2
M2

M1
M1
is properly biased with 0 and 5 volts, Brush + -
M
and the pot wiper voltage drops from Detergent Pump RED/GRN YEL/BLK 0V
its previous of 5 volts to somewhere Solution Solenoid M1
MOTOR, DRIVE
between 0 and 5 volts, depending on Enabled
Closed
where the pot is positioned.

As a result of the open-circuit to closed-circuit condition of the Go switch closing, two things happen with the
controller at once: The speed limit drops from maximum to its set position, and the throttle goes from zero to
maximum. Even though this may seem like a conflict, there is enough delay in the motor ramp-up function
that the motor does not momentarily receive a full speed command (unless the speed is set for maximum).

Brake Output (Scrub Enable)

When the drive controller is commanded to move, it activates its “brake release” function by bringing the
Brake- output to battery-negative voltage. This results in both positive and negative voltages being available
to the various scrub circuits. Previously the scrub circuits were disabled, because both sides of the circuits
were at the same battery-positive voltage, and no current could flow.

This Brake- power passes through the K1 relay, and if closed, through the Brush Switch. This activates the
brush relay to drive the brush motors. It also passes to the optional detergent module to enable the solution
solenoid and detergent pump.

Refer to the “24 - Electrical System” on page 28 for a further description of the circuits affected by the
Brake output.
Service Manual – SC900 20 - Wheel System, Traction 18

Troubleshooting
The primary tool for troubleshooting the drive controller
is the Curtis handheld programmer. This tool interfaces
with the drive controller to report back error codes,
control status, and other functions. The Curtis manual
will describe this in greater detail, but the primary
troubleshooting functions are under the Monitor and
Diagnostics menus.

The diagnostics menu displays a list of either current or

past error codes. These are used in conjunction with the
table below to isolate possible causes of malfunction.

The monitor menu displays real-time values of inputs,

outputs, and controls. This is very helpful for troubleshooting
the drive system’s prerequisite conditions for operation, such
as throttle inputs. Additionally, if the brake output isn’t
active, it will cause the scrub system to not function.

Error Codes
Because most drive system failures will be accompanied by a drive controller error code, troubleshooting
is generally error code driven. Those few exceptions that would not be error code drive, are covered in the
electrical chapter.
Status Led Fault Codes
Code Name / Explanation Possible Cause
1,1 THERMAL CUTBACK • Temperature >92°C or < -25°C
• Excessive load on vehicle
Over/under-temperature
• Operation in extreme environments
cutback
• Electromagnetic brake not releasing
1,2 THROTTLE FAULT 1 • Throttle input wire open or shorted
• Throttle pot defective
• Wrong throttle type selected
1,3 SPD LIMIT POT FAULT • Speed limit pot wire(s) broken or shorted
• Broken speed limit pot
Speed limit pot fault
1,4 LOW BATTERY VOLTAGE • Battery voltage <17 volts
• Bad connection at battery or controller
Battery voltage too low
1,5 OVERVOLTAGE • Battery voltage >48 volts
• Vehicle operating with charger attached
Battery voltage too high
• Intermittent battery connection
2,1 MAIN OFF FAULT • Main contactor driver failed open
Main contactor driver Off fault
Service Manual – SC900 20 - Wheel System, Traction 19

Status Led Fault Codes

Code Name / Explanation Possible Cause
2,3 MAIN CONT FLTS • Main contactor welded or stuck open
• Main contactor driver fault
Main contactor fault
• Brake coil resistance too high
2,4 MAIN ON FAULT • Main contactor driver failed closed
Main contactor driver On fault
3,1 PROC/WIRING FAULT • Misadjusted throttle
• Broken throttle pot or throttle mechanism
Fault present for >10 sec.
• The keyswitch must be cycled before this fault can clear
3,2 BRAKE ON FAULT • Electromagnetic brake driver shorted
• Electromagnetic brake coil open
Brake On fault
3,3 PRECHARGE FAULT • Low battery voltage
• Throttle engaged when KSI (keyswitch input) turned on
Precharge fault
3,4 BRAKE OFF FAULT • Electromagnetic brake driver open
• Electromagnetic brake coil shorted
Brake Off fault
3,5 HPD • Improper sequence of throttle and KSI (keyswitch input)
• Misadjusted throttle pot
HPD (High Pedal Disable)
4,1 CURRENT SENSE FAULT • Short in motor or in motor wiring
• Controller failure
Current sense fault
• The keyswitch must be cycled before this fault can clear
4,2 HW FAILSAFE • Motor voltage does not correspond to throttle request
• Short in motor or in motor wiring
HW Failsafe
• Controller failure
(hardware failsafe)
• The keyswitch must be cycled before this fault can clear
4,3 EEPROM FAULT • EEPROM failure or fault
• The keyswitch must be cycled before this fault can clear
EEPROM fault
4,4 POWER SECTION FAULT • EEPROM failure or fault
• Short in motor or in motor wiring
Power section fault
• Controller failure
• The keyswitch must be cycled before this fault can clear
Service Manual – SC900 20 - Wheel System, Traction 20

Removal and Installation

Drive Controller
WARNING: Unswitched battery power is present at the drive controller. Disconnect the battery
connector before servicing the machine.

Note: Drive controllers are factory pre-programmed for the specific machine. Use only factory
authorized replacement controllers.

1. Drain the recovery tank and open the

recovery tank to access the battery bay.

2. Turn off the key and disconnect the main

battery connector.

3. Remove the Electrical Bay Cover described A

on page 33.

4. Disconnect the logic connector (A) from the

drive controller.

5. Disconnect the high power wires as follows:

M- M+ B- B+
• Two motor-negative (Yellow/Black)

• Two motor-positive (Red/Green) C

• Battery-negative (Black)

• Battery positive (Red)

6. Remove the two mounting screws (C), and remove the module.

7. Reverse the steps to install a new module.

Follow-up Testing

After replacing the drive controller, perform this follow-up testing procedure to ensure safe operation of the
controller.

1. Before reconnecting the battery, either block the wheels off the ground or move the machine to an open
area without obstructions.

2. Turn the speed dial all the way to its lowest speed.

3. Reconnect the battery connector and turn on the key switch.

4. While holding any of the drive switches, slowly increase the speed limit dial up and back down to verify
complete speed range.

5. Test both forward and reverse directions.

6. Lower the scrub deck and verify the scrub function, which is controlled by the drive controller.
Service Manual – SC900 20 - Wheel System, Traction 21

Wheels
WARNING: To avoid unexpected movement, disconnect the battery connector before servicing
the machine.

−− Never work under the machine without safety stands or blocking to support the
machine.

−− To avoid instability of the lifted machine, block the rear (caster) wheels so that the
weight of the machine is not on the caster wheels, which can pivot unexpectedly.

1. Drain both the recovery and solution tanks

to reduce the weight of the machine.

2. Turn off the key and disconnect the

batteries.

3. Slightly raise the rear of the machine, and

place rigid blocking below the frame so the
caster wheels are slightly off the ground.

4. Raise the front of the machine, and place

rigid blocks under the lifting points.

5. Remove the three lug nuts that secure the

wheel to the transaxle, and remove the
wheel. Lift Points

Lift Points
Service Manual – SC900 20 - Wheel System, Traction 22

Drive Motor

WARNING: To avoid unexpected movement, disconnect the battery connector before servicing the
machine.
−− Never work under the machine without safety stands or blocking to support the
machine.
−− To avoid instability of the lifted machine, block the rear (caster) wheels so that the
weight of the machine is not on the caster wheels, which can pivot unexpectedly.

1. Drain the recovery and solution tanks to

reduce the weight of the machine.

2. Disconnect the main battery connector. A

3. You will find that access to the motor is

much easier with the right wheel removed
from the machine. Raise the right side of the
machine, and remove the drive wheel.

4. Disconnect the motor connector (A) and the C

ground wire (B).

5. Using a 3/16" hex key, remove the two

screws (C) that secure the motor to the
B
transaxle.

• Due to the tight quarters, you may find it easier to remove the upper screw first.

• Support the motor before completely removing the last screw.

Replacement Notes

• Apply a small amount of grease to the drive coupling (D).

• The drive coupling is 2 pieces. Install the washer-side of

the coupling onto the motor shaft.

• Inspect the O-ring (F) to make sure it isn’t damaged, and

is in position in the O-ring groove.

• While inserting the motor back into the transaxle, rotate

the right axle (without the wheel) to align the spline on
the transaxle with the drive coupling.

D
E
F
Service Manual – SC900 20 - Wheel System, Traction 23

Motor Brushes
It is possible to replace the motor brushes without removing the motor from the transaxle, if you wish. This
is a decision you should make before you start, however, because one method requires removing the right
wheel and the other method removes the left wheel. Replacing the brushes is a relatively easy task, with the
exception being the access to the upper-front brush.

This procedure is written from the standpoint of leaving the motor in place.

WARNING: To avoid unexpected movement, disconnect the battery connector before servicing the
machine.
−− Never work under the machine without safety stands or blocking to support the
machine.
−− To avoid instability of the lifted machine, block the rear (caster) wheels so that the
weight of the machine is not on the caster wheels, which can pivot unexpectedly.

1. Drain the recovery tank and disconnect the

main battery connector.

2. Optional, but recommended: Raise the left

side of the machine and remove the left
wheel for easier access to the brush motor.

3. Unscrew the brush cap (A), and remove the

spring-loaded brush. A

• For the upper 2 brush caps, you will need

to use a right-angle screw driver. If you
don’t have one compact enough for the
task, you can try using a coin in the cap’s
slot.

4. During replacement, fit the brush all the

way into the motor and hold the contact (B)
with your finger. Then slide the cap (A) in
from the side, replacing your finger with the
cap to hold the brush. Carefully thread cap to prevent cross threading.

• Hint: To reduce the likelihood of cross threading, unscrew the cap slightly first before screwing it in.

5. Repeat this for all 4 brushes.

B A
Service Manual – SC900 20 - Wheel System, Traction 24

Transaxle
WARNING: To avoid unexpected movement, disconnect the battery connector before servicing the
machine.
−− Never work under the machine without safety stands or blocking to support the
machine.
−− To avoid instability of the lifted machine, block the rear (caster) wheels so that the
weight of the machine is not on the caster wheels, which can pivot unexpectedly.

1. Drain both the recovery and solution tanks

to reduce the weight of the machine.

2. Turn off the key and disconnect the

batteries.

3. Slightly raise the rear of the machine, and

place rigid blocking below the rear lifting
points so the caster wheels are slightly off
the ground. Make sure these blocks are
stable and cannot tip over.

Lift Points

4. Remove the Scrub Skirt described on page

55.

5. Remove the brush skirt or hopper,

depending on whether it is a disk or Lift Points
cylindrical deck.

6. Insert a small floor jack between the scrub deck and

the drive wheel on the right-hand side of the machine,
and carefully jack the front of the machine about 1 to 2
inches (25-50mm).

7. Place rigid blocks under the frame.

Block
Block
Lift
Service Manual – SC900 20 - Wheel System, Traction 25

8. Remove the three lug nuts that secure each wheel to the transaxle, and remove both wheels.

9. Remove the ground wire (A) from the transaxle.

10. Disconnect the motor connector (B).

11. To prevent the transaxle from falling to the floor, place supports or cushioning under the transaxle.

12. Remove the 4 bolts (C) and nuts (D) securing the right and left retaining plates (E) to the frame.

• It’s best to first loosen all 4 bolts, and then remove them when you are prepared for the transaxle to
be lowered.

13. With the retaining plates removed, lower the transaxle to the floor. Note the orientation, with the motor
toward the rear of the machine.

E C

A
Service Manual – SC900 20 - Wheel System, Traction 26

Specifications

Shop Measurements

Drive Controller Connector

Pin Terminal Wire Color Circuit Voltage (DC Volts to GND)
1 N/A
2 N/A
3 Pot-Hi White 5 Volt bias to the speed limit pot 4.95 V
4 Thrtl Pot Blue Input from the Go switches 4.95 V @ Off
0 V @ On
5 KSI Violet Key Switch Input 36.5 V @ On
6 Brake- Pink/Blue Scrub Enable 34.5 V Parked
0 V Drive
7 N/A
8 N/A
9 Status None Unused Status LED Rapid Pulse
10 N/A
11 N/A
12 N/A
13 Pot-Lo Yellow 0 Volt bias to the speed limit pot 0V
14 Brake+ Pink Positive power to the scrub functions 36.5 V
15 N/A
16 N/A
17 Rev In Gray/Violt Input from the reverse switch
18 Spd Pot Orange Speed limit pot input 4.95 V @ Parked
Variable 0-5 V @ Drive
Service Manual – SC900 20 - Wheel System, Traction 27

Special Tools

Curtis Programmer
The Curtis 1313, 1311, or 1307 generation Programmers may be used to display drive controller error
codes and program the drive controller. The programmer presents complete diagnostic information in plain
language without codes to decipher. Faults are displayed in the Diagnostic Menu, and the status of the
controller inputs/outputs is displayed in the Test Menu.

The handheld programmer can also be used to access the drive controller’s diagnostic history file. This file
contains the history of cleared error codes, which may be helpful in determining the functional status of the
machine between service intervals.

Refer to the Curtis Programmer manual for further information regarding the use and operation of the
handheld programmer.
Service Manual – SC900 28

24 - Electrical System
Functional Description

EcoFlex
Control

Battery
Detergent
Charger
Pump

Electrical
Box

Battery
Disconnect

The SC900 machine is powered using six, 6-volt

batteries connected in series, for a total system
nominal voltage of 36 volts. To protect the batteries
150 A
from over discharge, the system is protected with Fuse
a 150 amp fuse located on the positive battery
terminal.

There are 5 circuit breakers that protect the

electronics. A 25A circuit breaker protects each of the two
brush motors, a 20A circuit breaker protects the vacuum
motor, a 30A circuit breaker protects the drive controller
(and therefore the scrub system controls), and a 2.5A circuit
breaker protects all logic circuits downstream from the key
switch. If these circuit breakers trip, their respective button
will pop up. Pressing the button back in after the overload
has cleared will reset the breaker.
Service Manual – SC900 24 - Electrical System 29

On the operator’s handle is a combination battery indicator and hour

meter. The hour meter increments whenever the scrub system is
active. The LED bar graph on the battery indicator represents the
battery charge.

The hour meter (battery indicator) also serves as a low-voltage

cutout for the scrub system. When the battery voltage is above the
cutout threshold, the hour meter grounds its FET (Field Effect
Transistor) Drain output, which permits the K1 relay to be energized
(when the key switch is on). When the battery voltage drops below
this threshold, the FET opens, and the K1 relay is disabled.

K1 Relay TrackClean
The electrical box contains the majority of the K2 Relay Jumper
machine’s electrical controls.

• The K1 relay, located on the front wall,

serves as a “Scrub Enable” when the key K3 Relay
switch is on and the battery voltage is above
the cutout threshold (via the hour meter).

• The K2 relay controls the two brush motors,

but first passes through the two 25 amp
circuit breakers. The K2 relay is enabled
only when the drive controller activates the
“Brake Release” output, and is active only if
the brush switch (deck lower lever) is closed.

• The K3 relay controls the vacuum motor, Drive

Circuit
but first passes through the 20 amp circuit
Breakers
Controller
breaker. The relay is active whenever the
keyswitch is on and the vacuum switch
(squeegee lower handle) is closed.

• When the optional TrackClean module is not present, a jumper is installed at the TrackClean electrical
connector. This jumper is required for machine operation, and is a series connection of the key switch.
The purpose of the circuit is so that a TrackClean module with a SmartKey reader can disable the
operation of the machine if no authorized SmartKey is present.

When the optional on-board battery charger is present, the battery-side of the key switch is replaced with
an interlock circuit from the charger. (Power to the 2.5A circuit breaker comes through the charger.) This
interlock feature allows the charger to disable all control of the machine when the charger is plugged into a
wall outlet and the battery is being charged. The charger doesn’t disable all power to the machine; just the
control power.

The charger contains a normally-closed relay. When the charger isn’t plugged in to facility power, the relay
is closed, and the key switch circuit is enabled. When the charger is plugged in, the relay opens, and the key
switch circuit is disabled.
Service Manual – SC900 24 - Electrical System 30

Troubleshooting
The SC900 machine architecture is based on a hybrid of “Relay Logic” with limited control logic from the
Curtis Drive Controller. This causes a lot of the system troubleshooting to be interrelated between the
standard relay-logic components and the drive system controller. Most of the troubleshooting scenarios will
be listed here, unless they are specific solely to the drive controller.

Problem Cause Notes & Correction

No system function. Main 150A fuse is This is almost the equivalent of disconnecting the main
• No Drive blown battery connector, except that the optional onboard battery
• No Brush charger would also show as not being connected.
• No Vac • If the optional charger indicates that the battery is present,
• No Hour Meter LED then this is not the cause.
• Replace the 150A fuse module on the positive battery
terminal.
KSI circuit is disabled The KSI circuit is the equivalent of not turning the key switch
on, but can have a couple of different causes. The most
notable symptom is that the hour meter indicators will not
illuminate, nor will the vacuum run.
• If the vacuum motor runs, then this is not the problem.
• Reset the 2.5A circuit breaker
• If the onboard charger is present, make sure the interlock
wire is connected to the 2.5A breaker.
• If the onboard charger is not present, make sure the red
battery wire is connected to the 2.5A breaker.
• If the optional TrackClean module is not installed, make
sure the shunt connector is in place.
• Check for 36 Volts at pin-5 of the Curtis controller. If not
present, work back upstream to locate the break.
Limited System Drive Controller Fault Because the vacuum runs, this is most likely related to a
Function drive controller fault. There can be many causes to a drive
• No Drive controller fault. Refer to the Drive Controller “Troubleshooting”
• No Scrub on page 18. Two exceptions that would not be error code
• But Vacuum Runs drive:
• A break in the KSI input directly at the drive controller
• Open circuit for the Go switches
No Drive, but all other Drive motor or throttle This condition indicates that the drive controller has activated
systems functional fault. the brake release, but is not driving the transaxle without a
• No Drive drive controller fault. The most likely cause is a speed limit
• Brush active fault.
• Vacuum active • Because the scrub system is functional, it is known that the
Go switches are functional.
• The most likely cause is a broken speed limit pot wiper wire
connection. The drive is active, but at zero speed.
Service Manual – SC900 24 - Electrical System 31

Problem Cause Notes & Correction

No Scrub system, but K1 circuit fault The K1 circuit controls all of the scrub functions, and is related
drive and vacuum to the low-voltage cutout feature, which is controlled by the
operational. hour meter.
• No Brush • Check the K1 relay:
• No Solution −−If the relay is open, either the relay is faulty, or the hour
• No Detergent meter is faulty.
• Drive active −−If the relay is closed, then the brush switch is faulty.
• Vacuum active Hour Meter Failure If the hour meter does not provide “ground” to the K1 relay, it
will disable all scrub functions as though the battery voltage is
too low for operation
No Solution, but brush Solution circuit or The solution solenoid and optional detergent pump are
motors run optional module enabled only when the brush is active.
• For all models, make sure that the solution shutoff valve is
not closed.
• For non-EcoFlex models, make sure the shunt jumper
below the solution lever is in place. If so, then check the
solenoid.
• For EcoFlex models, if both solution and detergent
solenoids are non-functional, the module is likely faulty.
No Brush function, but Brush circuit failure Because solution is flowing, you can eliminate the K1 and S4
solution flows circuits as a cause.
• If both brush motors are off, then the most likely cause is
the K2 power relay.
• If only one motor has failed, first check its circuit breaker,
and then check the motor. Swap the two motor connectors
to isolate whether it is before or after the connector.
No vacuum, but all Vacuum circuit If any other systems are running, then you know the KSI
other systems function circuit is functional. This leaves solely the vacuum circuit itself
as the cause.
• Check the vacuum switch at the squeegee lever
• Check the vacuum relay (K3)
• Check the vacuum breaker (CB4)
• Check the motor

Battery Testing
A battery problem is usually recognized by the machine operator as a decrease in the machine’s running
time. This condition is usually caused by one or more “dead cells” in the battery system.

There are 2 ways to find a dead cell:

• Use a hydrometer to check the specific gravity (or “state of charge”) of the fluid in each cell. A dead cell is
one that reads 50 points (or more) lower than the other cells.

• Use a volt meter to check the voltage of each battery. Look for a battery with a voltage that is 1 or 2 volts
less than the other batteries. Check under the following conditions:

–– With the batteries fully charged,

–– With the scrub and drive motors running,

–– With the batteries discharged, but still above the voltage cutoff threshold.

If the batteries in the machine are more than 1 year old, it’s usually best to replace the whole set, rather
than replacing just one battery.
Service Manual – SC900 24 - Electrical System 32

Maintenance and Adjustment

Setting Onboard Charger Battery Profile

The machine may be equipped with the optional onboard battery charger. If the charger is just being
installed, or the batteries have been replaced with a different type, it will be necessary to program the
charger to properly charge the batteries according to their type.

Batteries operate on chemical reactions that produce an electrical charge. Charging a battery reverses these
chemical reactions so they can produce power again. Because these chemical reactions are complex, their
reversal is also complex, at least from the standpoint of maintaining good health of the battery. This process
is referred to as a charging algorithm. During the charging algorithm, various stages of the charging process
are handled differently, depending on the chemical makeup of the battery.

Battery charging occurs in various phases, such as an initial charge, to a bulk charge, to an equalization or
gassing phase. During each of these phases, the method and rate of charge is varied to optimize the reverse
chemical reaction. Some may be constant-current, some constant-voltage, and some may be other methods.
The Delta-Q charger is an intelligent charger that incorporates these various charging algorithms for
multiple battery types.

Charging Profiles
Nilfisk Model Charge Voltage
The Delta-Q charger contains many charging profiles, Part No. Profile
which are identified by number. The table to the right
56206079 WET 6V 242AH 11 6
lists those profiles that are applicable to SC900 battery
system options. 56391391 WET 6V 310AH 72 6
56112545 AGM 6V 255AH 43 6
The Delta-Q instruction manual explains how to set
these profiles. There are two options for programming
this information into the charger.

One option uses a laptop, QuiQ software, and a special USB interface connector kit. This method is the
easiest, but it does require obtaining the QuiQ Program Kit (Pn 56315732). The QuiQ Program kit will
contain instructions for use.

The second option, although more complex, doesn’t require any special tools. It communicates to the charger
by disconnecting the battery terminal and “tapping” the terminal back to the battery to signify which
numerical algorithm code to use. These instructions are included with the charger.

Bulk Charge Indicator

Ammeter If solid: Bulk charge phase complete (80% charged); in absorption phase.
If solid: Displays If flashing: Displays charge profile number if no battery is connected.
scale of output Displays charge profiles 7 and above.
during bulk phase.
If flashing: Output Charge Completion Indicator (Green Light)
has been reduced If solid: Charging complete and maintenance mode is active.
due to high internal If flashing: Absorption phase complete, in finishing phase.
charger temperature.
AC Indicator
Displays charge
profiles 1-6 for 11 If solid: AC power is present.
seconds if no battery If flashing: Low AC voltage. Check electrical source and cord length.
is connected.
Fault Indicator (Red Light)
Charger error.
Service Manual – SC900 24 - Electrical System 33

Removal and Installation

Electrical Bay Cover
CAUTION: Risk of Arc flash. The A
electrical bay contains
exposed high-amperage B
electrical components. Take
care to not allow tools to
come in contact with exposed
components.

The electrical bay contains the majority of the

machine’s electrical components. The cover
protects the components from debris and
incidental contact.

To remove the cover, use an 8mm socket with a

long extension remove the 4 screws that secure it
to the body of the solution tank.

Squeegee and Brush Switches

1. With the deck fully raised, place blocking under the C
E
scrub brushes to prevent the deck from lowering.

2. Move the deck lift lever (D) out of the raised position, B
and allow the blocking to support the deck.
A
3. Lower the squeegee (C).

4. Using a 10mm socket, remove the 4 screws (B) that

secure the lift plate (A) to the solution tank. Tilt the
lift plate downward to expose the switches.
B
5. Remove the two screws and nuts (F), and remove the
switch.

6. When replacing the switch, make sure the switch lever

(G) is properly positioned.
D

F
G
Service Manual – SC900 24 - Electrical System 34

Drive Handle
Removing and disassembling the drive handle
is a prerequisite to other procedures for
servicing the hour meter, drive switches, and
potentiometer.

1. Using a 14mm socket and extension,

unscrew the 5 screws (A) that secure the
drive handle to the machine.

• Make sure to support the handle as you

loosen the last screw. A
• It is best to leave the screws and washers
in place, versus removing them. This
reduces the likelihood of dropping any
of them in the cavity below the solution
control.

2. Move the handle away, and disconnect the

harness connector (B).

3. Remove the 11 screws (C) that hold the two

halves of the handle together.

4. With the handle laying face-down, gently

separate the front and rear halves. There are
6 springs associated with the Go switches.

C
Service Manual – SC900 24 - Electrical System 35

Switches and Harness

Key Switch

Hour Meter
Go Switch
Go Switch

Setscrew

Reverse
Go Switch
Switch

1. Disconnect the 2 wires from the key switch, and the connector from the hour meter.

2. If the new harness does not contain a potentiometer, then free up the wires and cut them at the longest
length you can. (You can trim their length later.)

3. If the new harness does contain a potentiometer, then loosen the setscrew on the dial, transfer the dial
to the new potentiometer, and remove the old potentiometer from the handle.

4. Make note of the wire routing through the handle, and replace each of the original switches with the
new harness/switch. Note that the reverse switch uses violet and gray wires.
Left/Right Go Switches
5. When replacing any of the switches, note the terminal
locations. Each switch contains a normally-open and
normally-closed contact, but only the normally-open
contacts are used.

6. If the potentiometer was previously cut, splice the wires

using crimp connectors.

7. Reassemble the handle, and follow the Drive Handle Reassembly Notes described on page 36.

Reverse Switches Go Switch Wires

Service Manual – SC900 24 - Electrical System 36

Hour Meter

When replacing the hour meter, if possible, record the previous hours for maintenance tracking. The
hour meter can neither be reset nor changed, but the previous hour meter value should be recorded in an
equipment log.

1. Disconnect the wiring plug (D) from the hour

meter. D

2. Press outward on the latch tabs (G) while pressing

downward on the main body of the hour meter (E).

G
The hour meter is held in place with a ratcheting
retaining ring. Make sure to firmly press the two
together when reinstalling the meter. E
F

After you have completed the reassembly (continued below), verify the function of the hour meter with the
following observations:

• Key on → Battery LEDs on, hourglass steady.

• Scrub on → Battery LEDs on, hourglass blinking.

• Scrub off → Battery LEDs on, hourglass steady.

• Key off → Battery LEDs off, hourglass steady.

Drive Handle Reassembly Notes

1. To prevent the reverse button from falling out of

the handle as you are assembling the two halves,
use tape to hold the button in place.

J
H
Service Manual – SC900 24 - Electrical System 37

2. Place the main handle face-down, and inspect to make sure:

• All 6 springs are in place
• All wires are in their grooves/clips
• All switches are in place

3. Feed the harness connector through the back handle, and carefully align the two handle halves.

4. Install all 11 screws.

5. Inspect the movement of the drive switches and speed pot to make sure they move freely.

Key Switch

Hour Meter
Go Switch
Go Switch

Setscrew

Reverse
Go Switch
Switch

6. Reconnect the wiring harness.

7. Reposition the handle and get the first screw started.

• Get the threads started by just one turn.

• Tug on the handle to make sure the threads are engaged,

before moving on to the next screw.

• Start with the lower screws and work upward. This

way, there will be enough gap between the handle and
solution tank to detect when a screw has engaged or not,
by wiggling the handle. Note the gap in the picture to the
right.

8. When you are sure all 5 screws are started, tighten all 5
screws.
Service Manual – SC900 24 - Electrical System 38

Batteries
CAUTION: Use extreme caution when working with batteries. Sulfuric acid in batteries can cause severe
injury if allowed to contact the skin or eyes.
• Explosive hydrogen gas is vented from the batteries through openings in the battery caps. Do not
smoke while servicing the batteries.
• Remove all jewelry. Wear safety glasses, rubber gloves and a rubber apron
• Do not allow tools to touch more than one battery terminal at a time
• Electrical components in this machine can be severely damaged if the batteries are not installed and
connected properly.
• The batteries are extremely heavy and may require a lifting device or assistance to remove and
replace into the machine.

1. Turn the off the machine and C

disconnect the main battery
connector (A).

2. Pull back the insulating boot (B) B

H A
and disconnect the main battery
connector’s positive terminal at
(E). Do not disconnect at lug (F)
because that secures the 150 amp
fuse.
D
3. In a similar manner, remove the
main battery connector’s negative
terminal (C). However, there is no fuse at the G
negative terminal.
F
4. Taking care to not short across the battery
E
terminals, remove each of the interconnecting
cables (H) from the batteries.

5. Make sure the battery straps (D) are not

damaged or cut, and then lift out each of the
batteries from the battery bay.

6. Install the new batteries into the compartment.

Note the orientation of the batteries shown
above.

7. Reconnect the battery cables.

–– All cables are connected positive-to-negative for a series connection between all 6 batteries.

–– Position the cables so the battery caps can be easily removed for battery service.

–– Take care to not over torque the cable connector, as this may damage the battery post.

8. Coat the terminals with spray-on battery terminal coating (available at most auto parts stores).
Service Manual – SC900 24 - Electrical System 39

Specifications

Connector Pinouts

TrackClean Connector
Pin # Name Wire Color, ID
1 Interlock VIO, W093
2 Interlock BRN/VIO, W026

3 Batt+ RED, W040

4 Vacuum GRAY, W035
5 Scrub VIO/WHT, W031
8

6 Drive PINK/BLUE, W023

7 Key Switch BRN/VIO, W026

8 Batt- BLACK, W030 1

EcoFlex Connector
Pin # Name Wire Color, ID
1 Batt+ VIO, W095 1
6
2 Solution In VIO/WHT, W060
3 Solution Out VIO/RED, W062
4 Detergent Out VIO/GRN, W061
5 Batt- BLK, W063
6 Brake+ PINK, W138

Operator’s Handle Connector

Pin # Name Wire Color, ID
1 Pot High WHT, W019
2 Go In YEL, W058
3 Go Out/ Pot Low BLU, W059
4 Speed Limit ORN, W020
5 Reverse Out GRY-VIO, W018
6 Key Switch In BRN, W069
7 Key Switch Out BRN-VIO, W026 12

8 Batt- BLK, W053

9 Hour Meter Run- VIO-WHT, W034
10 Hour Meter Run+ PNK, W141
11 Low Voltage Drain PNK-WHT, W044
1
12 Hour Meter Enable VIO, W096
Service Manual – SC900 24 - Electrical System 40

Drive Controller Connector

Pin # Name Wire Color, ID
1
2
3 Pot High WHT, W019
4 Throttle Pot BLU, W059
5 KSI VIO, W011
6 Brake- PNK-BLU, W023
7
8
9
10
1
11
12
13 Pot Low YEL, W058
14 Brake+ PNK, W137
18
15
16
17 Reverse GRY-VIO, W018
18 Speed Pot ORN, W020
Service Manual – SC900 24 - Electrical System 41

Wiring Diagram Drawing: 56115276 Rev E

A B C D E F G
CONFIDENTIAL
THIS DRAWING AND THE DESIGN REPRESENTED HEREON IS THE PROPERTY OF NILFISK-ADVANCE, INC.,
PLYMOUTH, MINNESOTA AND IT HAS BEEN ISSUED WITH THE UNDERSTANDING THAT IT WILL NOT BE REPRO-
DUCED NOR COPIED NOR USED FOR ANY PURPOSE OTHER THAN FOR WHICH IT WAS ISSUED AND RECIPIENT
AGREES TO RETURN IT UPON REQUEST.
DWG. NO. SHEET

X5a3 X4a3 F1 36 VDC X4b3 X5b3 56115276 1 OF 1 REVISIONS

RED RED RED + - BLK BLK BLK REV ECO DATE DFTM APPD
FUSE, 150A A-11009 2-4-15 PMO WCR
RED TELEMATICS CONNECTOR A RELEASE
RED X44 X44A A-11244 3-18-15 PMO WCR
BLK8 8 8 B- B UPDATE: X44,X44A P3, P1
1 BLK A-11389 5-19-15 PMO WCR 1
E1
B+ B-
RED 3 3 3 B+ C UPDATE: S2,S6,S7,R1
BRN 7 7 7 KEY A-11576 8-18-15 WCR WCR
D UPDATE: S2,S6,S7,R1,P1,P2,K2,D2,L1,L2
~ GND BRN/VIO BRN 2 2 2 INTERLOCK A-11876 1-20-15 WCR WCR
VIO1 1 1 INTERLOCK E UPDATE: P1, P2, P3

fi PNK/BLU 6 6
fl
6 DRIVE
CHARGER, VIO/WHT 5 5 5 SCRUB
DELTA Q
36V, 21A GRA 4 4 4 VAC

PNK/BLU
CB1
30A
RED RED BLK

BLK
RED
CB5 S1
GRN E P1
BRN

B+

B-
RED 2.5A SW, SPST KEY
fi PNK/BLU 6 3 WHT
2 BRAKE- POT HI
R1 2
VIO 5 18 ORN POT.
KSI SPD POT 5K OHM
S3 CURTIS 1228
VIO GRA/VIO 17 4 BLU
S, REV REV THR POT
S6
PNK 14 13 YEL
BRAKE+ POT LO
S2
SW, GO LEFT
SW, GO MID

M2
M2

M1
M1
S7 SW, GO RT
+ M -
RED/GRN YEL/BLK
M1
VIO MOTOR, DRIVE

E P3 DETERGENT MODULE (OPTIONAL)

BRN

PNK 1 5 BLK
B+ B-
3 X87A 3
L2 6
BRAKE+ 1
PNK 1 2 VIO/RED
4 2
L1 PUMP, DETERGENT DET- OUT
3
PNK 1 2 VIO/GRN 3
SOL- OUT 4 K1
COIL, SOLENOID 1
2
SOL IN 5 2
D2 
S4 3
6
4 PNK/BLU
PNK K2 VIO/WHT VIO/WHT RED/YEL 5
SW, BRUSH 6
D3 RELAY, LVC
S5
COIL, BRUSH
VIO K3 GRA BLK
SW, VAC

COIL, VAC
PNK
4
4
K1 RELAY, LVC E
P2
VIO D1 PNK/WHT 3 7
FET DRAIN HM1
VIO 2 6 VIO/WHT
ENABLE HM2
BRN 8 4 BLK BLK
B+ B-
BATTERY GAUGE WITH HOURMETER

M2
WHT/RED CB2 RED/GRN - M + BLK
30A MOTOR, BRUSH LEFT

M3
K2
RED WHT/RED WHT/RED CB3 RED/BRN + M - BLK
BRUSH CONTACT 30A MOTOR, BRUSH RIGHT

K3 1 2 5
5 RED GRA/RED CB4 ORN/VIO BLK BLK
VAC CONTACT 20A
M4
NOTES UNLESS OTHERWISE
4. REFERENCE WIRING DIAGRAM 56115277. M SPECIFIED DRAWN 2-4-15 PMO NILFISK-ADVANCE, INC.
1. ALL DIMENSIONS IN INCHES. CHECKED
2. DO NOT SCALE DRAWING.
3. IF TELEMATICS UNIT IS NOT INSTALLED, X44A CONNECTS TO X44. 3. ALL DIMENSIONS APPLY AFTER PROJ ENG 2-4-15 WCR PLYMOUTH, MINNESOTA 55447-3408
MOTOR, VAC PLATING AND HEAT TREATING,
BUT BEFORE PAINTING. APPROVED TITLE
DIAGRAM-LADDER
4. REMOVE ALL BURRS AND SHARP
2. IF A DETERGENT MODULE IS NOT INSTALLED, X87A WILL CONNECT TO HARNESS. EDGES. APPROVED
DIM. IN [ ] ARE MM. APPROVED
UNITS IN [ ] ARE ISO METRIC SIZE CODE DWG. NO. REV.
1. IF CHARGER IS INSTALLED, THE GREEN INTERLOCK WIRE CONNECTS TO CB5 INSTEAD OF RED B+ WIRE.
56115276
AS NOTED.

ORCAD D E
NOTES: FIRST USED ON
SC900 SCALE
NONE ASSY.
56115277 SHEET
1 OF 1
A B C D E F G
Service Manual – SC900 24 - Electrical System 42

Harness Diagram Drawing: 56115277 Rev E

8 7 6 5 4 3 2 1
CONFIDENTIAL
THIS DRAWING AND THE DESIGN REPRESENTED HERON IS THE PROPERTY OF NILFISK INC.,
BROOKLYN PARK, MINNESOTA AND IT HAS BEEN ISSUED WITH THE UNDERSTANDING THAT IT WILL NOT BE REPRO-
DUCED NOR COPIED NOR USED FOR ANY PURPOSE OTHER THAN FOR WHICH IT WAS ISSUED AND RECIPIENT
AGREES TO RETURN IT UPON REQUEST.
DWG NO SHEET
56115277 1
REVISIONS
REV ECO DATE DFTM APPD
A-11876 12-25-16 AAO WCR
ADD: SPL-20, SPL-21, SPL-22, W138
56115326 W139, W140, W141, W142, W143
H P2
E
DEL: X14, X16, X66, X74, SPL-11,
W027, W051, W068, W069
H
MOD: X13, X62, X65, SPL-9,
BATTERY GUAGE & HOURMETER SPL-19, W030, W040, W042, W045,
PNK-WHT,18,W044 W049, W051, W053, W058, W059,
X79
1 0 W063, W073, W075, W083, W085
VIO,18,W093

3 FET DRAIN
X81 VIO,18,W091
R1

2 ENABLE
6 8 P1
POTENTIOMETER

7 HM 1
CURTIS 1228

6 HM2
X80

8 B+
4 B-
P HI P LOW 2 4 18 ORN,18,W020
1
RED-YEL,18,W084 PNK-BLU,18,W024
WIPER 3

5
X82 17 GRY-VIO,18,W018
K1
BT1 36 VDC
2

B-
SPEED LIMIT POT 18 PNK,18,W092
LCV RELAY BLK,10,W083 16 SPL-19

X46
+ - REVERSE 17

8
X68 PNK,18,W137
15 PNK,18,W012
HORN 16 PNK,18,W141 E

X40

X37
PNK,18,W013

VIO,18,W048
ORN,18,W086

BDI 15 14
PNK,18,W138 E
G X69
PROGRAMMER BRAKE+ 14 13 YEL,18,W058 E G

56115358
RED-GRN,10,W078 POT LOW 13

M2
RED,4,W039 12
INHIBIT 12

RED,4,W089
RED-GRN,10,W077
11
WHT,18,W087

SPL-10 X70 B+ 11
X63
SW6 SW7 X15 4 2
WHT-RED,10,W064 WHT-RED,12,W065 B+ 10 10
GO LEFT GO RIGHT
SW1 3 1
1 2
BLK,18,W054

WHT-RED,12,W066 STATUS 9 9 PNK-BLU,18,W024

X71
BLU,18,W114

8
VIO-WHT,18,W052

SW3 KEY MODE(M1, M2) PNK-BLU,18,W023

M1
YEL-BLK,10,W081 8
X78

X77

X76

X86

S REV VIO-WHT,18,W032 PUSH 7

3 4
PNK,18,W092
YEL-BLK,10,W080
SW2 SPL-9 X25 X18 BRAKE- 6
7

56115357
3 1 X72
SPL-5

DETERGENT MODULE

X49
GO MIDDLE

BLK,4,W004
KSI 5 PNK-BLU,18,W022 VIO,18,W090
BRN,18,W139 X57

6
X55

X56

X58

K2

2
POT WIPER 4 5 VIO,18,W006 VIO,18,W011
BRUSH CONTACTOR

F1
E

4 DET OUT
3 SOL OUT
X60

POT HIGH 3
X59

E SPL-1
PNK-WHT,18,W050
BRN-VIO,18,W046
GRY-VIO,18,W056

2 SOL IN
PNK,18,W049

4
BLU,18,W097

YEL,18,W102

B+
E B- 2
VIO,18,W094

P3
BRN,18,W140

RED,10,W082
VIO,18,W047

1
B- 1 3
F F
BLU,18,W098

BLU,18,W099

X73

X38
E

1 B+
5 B-
YEL,18,W088

2
SPL-20
YEL,18,W101

1
E E

RED,4,W005
E RED,18,W040 X13 X64 BLU,18,W059
E RED,16,W042 X30 WHT,18,W019
BRN,18,W045

RED,10,W041 GRA-RED,12,W067
BLK,18,W134 1 2

E E
L1
X87A

L2 SOL SEL
SPL-14

SPL-3

X62
VIO,18,W090
6

BLU,18,W057 GRY,18,W037 DETERGENT PUMP

3 4

X12 X17 VIO,18,W091

X47 X48

X87
6

X36 X35
1

10

11

12

X29
E

X28
10

11

12

YEL,18,W103

BLK,18,W143
K3
1

VIO,18,W095

- VACUUM CONTACTOR E

56115356

X83
X43
X65
VIO-WHT,18,W060

SPL-2
VIO-GRN,18,W061

VIO-RED,18,W062

BLK,10,W083

1
E
PNK,18,W138

BLK,18,W063
PNK-WHT,18,W044
VIO-WHT,18,W034
GRY-VIO,18,W018

BRN-VIO,18,W026

VIO-GRN,18,W061
ORN,18,W020

E E
WHT,18,W019

BRN,18,W069

PNK,18,W141

SPL-21
BLU,18,W059
YEL,18,W058

BLK,18,W053

VIO,18,W096

PNK,18,W013
RED,4,W039

BLK,4,W038

VIO-RED,18,W062
SPL-22

PNK,18,W012
BLK,18,W142
VIO,18,W096

BLK,18,W030
BLK,12,W073
BLK,12,W072
BLK,12,W075
BLK,18,W063
VIO,18,W011

BLK,4,W038
BLK,18,W053
BLK,18,W085

BLK,18,W142
E E E E E E E E E E
GRN-YEL,16,W105

GRN-YEL,16,W104
RED-GRN,10,W077

YEL-BLK,10,W080

E1
VIO-WHT,18,W033

RED-YEL,18,W084

RED-GRN,10,W078

YEL-BLK,10,W081

GRN-YEL,16,W104
GRN-YEL,16,W105
E E B+ B-
GRY,18,W036

BLK,18,W085

DELTA Q

~
RED-GRN,12,W070
RED-BRN,12,W071
ORN-VIO,12,W074

GND
BLK,12,W075

BLK,12,W073

BLK,12,W072

D X90 X89 D
SPL-13
SPL-12
X84

X85
1

X91
SW4 SW5
BRUSH VACUUM X1 X11
1 2
BLU-YEL,12,W079

DECK GND CHASSIS GND RED,16,W042 BRN,18,W069 E GRN,18,W001

RED-GRN,12,W076

TRANSAXLE GND X2
CB5
X34

X32

2.5A
X33
1

KEY SWITCH
CONN CONN CONN
X31

56115278
2
1

- + - +
X3
M M CONN
GRA-RED,12,W067 1 2 ORN-VIO,12,W074
X44 X44A
X4
C CB4 20A
VIO,18,W093
C
M3 20A M2 SPL-6
1 1

VACUUM MOTOR BRN-VIO,18,W026 BRN,18,W028 2 2 BLK,18,W133

BRUSH MOTOR RIGHT BRUSH MOTOR LEFT
M
M - + GRY,18,W037
RED,18,W040 3 3

15A GRY,18,W036 GRY,18,W035 4 4

M4 14A VIO-WHT,18,W032SPL-8
X5 VIO-WHT,18,W034 VIO-WHT,18,W031 5 5
VACUUM MOTOR M1 56384169 WHT-RED,12,W066 1 2 RED-BRN,12,W071
VIO-WHT,18,W033 SPL-7
VIO-WHT,18,W060
DRIVE MOTOR X6
PNK-BLU,18,W023 6 6

HARNESS-SC900 W/READER BRN,18,W029 7 7

CB3 25A
56384170 RED,18,W124
BRUSH MOTOR RIGHT
BLK,18,W030 8 8

LCV RELAY
K4
X98
1 0
HARNESS-SC900 W/O READER YEL,20,WIRE9
X92 X93 X96 X7
B WHT-RED,12,W065 1 2 RED-GRN,12,W070 56115381 B
INLINE FIUE X99
1 BLK,16,W106 WHT,18,W110 1
X94 ORN,16,W122
6 8
X95
X8 JUMPER-MOLEX CONNECTOR
CB2 25A
2 BRN,18,W112 2 X97
2 4 X102 RED,12,W131 2
1 WHT,20,WIRE 1 1
BRUSH MOTOR LEFT
3 3
X103 BLK,12,W132 1
2 BRN,16,W123 BRN,20,WIRE 2 2
4 1 2 BLU,18,W113 4
1 2
3 RED,20,WIRE 3 3 X101
5 5
SPL-18 X9
6 6
4 BLU,20,WIRE 4 4
RED,10,W041 1 2 RED,10,W082
5 5 X10
7 7
6 6
CB1 30A
8 8
7 7 SPEED CONTROLLER
9
8 8
10

A GRY,18,W109 11
9 MATERIAL: SEE CREO BOM
FINISH/COLOR:NONE
A
10 NOTES UNLESS OTHERWISE DRAWN 8-10-15 TAG NILFISK, INC.
PNK,18,W111 12 SPECIFIED
1.ALL DIMENSIONS IN INCHES. CHECKED BROOKLYN PARK, MN
GRY,20,WIRE 11 11 2.DO NOT SCALE DRAWING.
PROJ ENG 8-10-15 WCR SPRINGDALE, AR 72764
3.ALL DIMENSIONS APPLY AFTER

1. REFERENCE LADDER DIAGRAM 56115276 PNK,20,WIRE 12 12

PLATING AND HEAT TREATING,
BUT BEFORE PAINTING.
4.REMOVE ALL BURRS AND SHARP
APPROVED
APPROVED
TITLE
DIAGRAM-WIRING
EDGES.
APPROVED SIZE DWG NO REV
-NOTES- DIM. IN [ ] ARE MM.
56115277 E
UNITS IN [ ] ARE ISO METRIC
AS NOTED.
CREO DATA E
SCALE
FUO SC900 N/A ASSY 56115276 SHEET 1 OF 1

8 7 6 5 4 3 2 1
Service Manual – SC900 43

30 - Solution System

Functional Description
The SC900 machine has a 29.5-gallon (112 liter) solution tank incorporated into the main body of the
machine. A clear tube on the right side of the machine below the fill cap serves as a water level indicator
for the tank. At the outlet of the solution tank, under the machine, is a manual shutoff valve followed by a
serviceable solution filter that prevents debris from entering the rest of the solution system.

Non-Detergent Models
36 VDC
+ -
All machines use gravity feed and a solution S1
solenoid to provide solution to the scrub deck. For
non-detergent machines, the flow rate of solution SW, SPST KEY

is controlled mechanically with a cable connected VIO 5

CURTIS 1228

between the solution lever, down to the solution KSI

shutoff valve. The solution solenoid is either all- PNK 14 6

BRAKE+
on or all-off, and is controlled by the same circuit
BRAKE-

that activates the brush motors. A circuit jumper

replaces the connector where the optional EcoFlex 1
L1
2 VIO/GRN
control board connects in the solution panel. JUMPER
COIL, SOLENOID

For the solution circuit to be active, the machine RELAY, LVC

K1
must be in motion, and the scrub brushes be active. 2
1

When the machine is in motion, the Curtis drive

D2
S4 3
4 PNK/BLU
controller makes the Brake- output equal to battery PNK K2 VIO/WHT 5
negative. This passes through the K1 relay, through
6
SW, BRUSH

the brush switch (foot lever), through the jumper COIL, BRUSH
(non-EcoFlex), and energizes the solution solenoid.

The solution solenoid receives 36-volt, non-PWM K1 RELAY, LVC

(Pulse Width Modulated) power, to be either all-on VIO PNK/WHT 3 4 BLK
D1
or all-off.
FET DRAIN B-

BATTERY GAUGE WITH HOURMETER

Service Manual – SC900 30 - Solution System 44

Detergent Models
36 VDC
+ - BLK
Machines that have on-board detergent S1
mixing (EcoFlex Models) have a solution
control circuit board, detergent pump, SW, SPST KEY

and detergent bottle. From an enabling VIO 5

CURTIS 1228

standpoint, the detergent module (circuit KSI

board) has the same prerequisite control PNK 14 6 PNK/BLU

BRAKE+
that a non-detergent solution solenoid has.
BRAKE-

The machine must be in motion, and the

scrub brushes be active. P3 DETERGENT MODULE

However, instead of battery negative

VIO 1
B+

passing straight to the solution solenoid, 6 5 BLK

BRAKE+
it passes into the detergent control board.
B-
L2
This signal serves as an “Enable” function 1 2 VIO/RED 4 DET- OUT

for the detergent and solution outputs. L1 PUMP, DETERGENT

VIO/GRN 3
1 2
SOL- OUT
Within the detergent module control board COIL, SOLENOID 2
SOL IN
is a micro controller that generates PWM
outputs for both the detergent pump and K1 RELAY, LVC
1
the solution solenoid. This is a battery- D2 2
S4 3
negative PWM, and applies negative PNK VIO/WHT 5
4 PNK/BLU
K2
voltage to the coils. SW, BRUSH
6

COIL, BRUSH
The two duty cycles of the PWM outputs
are controlled by onboard potentiometers.
The Burst of Power switch will K1 RELAY, LVC
temporarily increase both detergent and
VIO PNK/WHT 3
solution flow rates for 60 seconds. D1 FET DRAIN B-
4 BLK

BATTERY GAUGE WITH HOURMETER

Detergent Pump
Solenoid
The detergent pump is a solenoid-driven
diaphragm with one-way check valves. As Neg
the solenoid oscillates in and out, it drives Diaphragm
a flexible diaphragm that draws fluid in
during the retraction stroke, and drives
Pos

fluid out during the compression stroke. The

check valves allow fluid to enter only though
the inlet port, and exit only through the Outlet

outlet port.

Unlike an AC solenoid that moves its

plunger the same direction regardless of the
electrical polarity, a DC solenoid changes
Inlet
its direction of travel depending on the
electrical polarity of the coil. This is an
important distinction because if the pump is
connected with the wrong polarity, it will not pump liquid.

The solenoid plunger is actively driven in only one direction (intake), but passively returned via the return
spring (exhaust). If the wiring polarity is reversed, the solenoid plunger will be driven in the same direction
that the return spring has already pushed the plunger. So the plunger will never move.
Service Manual – SC900 30 - Solution System 45

Troubleshooting

Scrub System, General

One of the first things about troubleshooting any part of the scrub system, is to make the scrub system
active, so you can make observations. It is possible to active the scrub system without the machine moving,
and without the brushes contacting the floor.

1. To avoid getting water on the floor, you may wish to close B

the solution shutoff valve. If the machine is equipped
with EcoFlex, remove the suction hose from the detergent
bottle. A

2. If you need to inspect the solution solenoid, rotate the top

of the solenoid counterclockwise about 1/8-turn, and lift
the solenoid body (A) out of the valve body (B). Take care
to not lose the plunger (C), spring, or sealing washer.

3. Set the speed limit dial to zero speed.

E
4. Carefully position the scrub deck lever (D) out of F
its retracted slot, but resting on the adjacent tab
D
(E). This should permit the switch (F) to close
without lowering the scrub deck.

CAUTION: Always be prepared for the scrub

deck to unexpectedly drop. Keep
hands and feet away from the
scrub deck when it is raised in
this manner.

5. If the machine is equipped with the EcoFlex

system, set both detergent and solution flow
rates to maximum.

6. Turn the key switch to the on position.

7. Press one of the Go switches to confirm that the machine won’t move. If the machine doesn’t move, you
can tape the switch down or have an assistant hold it for you.

CAUTION: Make sure the Go switch can be released quickly in the event the machine starts to
move.

8. To examine the function of the solution solenoid, hold the plunger (C) as shown above, but not all the
way into the solenoid body (A). The plunger should be pulled into the solenoid when the solenoid is
active. For an EcoFlex machine, this will happen every second or two, and then release.

9. To examine the detergent pump, you should be able to hear or feel the detergent pump cycling a couple
of times a second (at max flow).
Service Manual – SC900 30 - Solution System 46

No Solution Flow
• Make sure the solution shutoff valve is open.

• For a non-EcoFlex machine, make sure the solution cable is connected to the valve and moves through its
full cycle as the solution lever is moved.

• Inspect and clean the solution Filter.

• Inspect the function of the solution solenoid as described in the “Scrub System, General” on page 45

• With the solution solenoid disassembled from the step above, inspect the valve body for foreign materials.

• If the brush motors are active, then you know the drive controller is not the cause.

• For non-EcoFlex machines, make sure the jumper is present on the electrical connector under the solution
panel.

• Test the solenoid itself by applying battery voltage to the terminals.

• For EcoFlex machines, if the solenoid itself is functional, and the brush motor runs, then the detergent
module is likely at fault.

No EcoFlex Detergent Flow

• Inspect the function of the detergent pump as described in the “Scrub System, General” on page 45. If
the pump does not appear to be functioning, check the polarity of the wires.

• Verify the function of the pump by connecting it to the battery and listening for the plunger to move.

• If the pump itself is functional, and the brush motor runs, then the detergent module is likely at fault.
Service Manual – SC900 30 - Solution System 47

Removal and Installation

Scrub Skirt
Removing the scrub skirt (B) allows easy access to
the scrub deck components. It is held in place with 4 B
screws (A) on the sides, and a tab in the center.

1. Using a 3mm hex key, remove the 4 screws and

washers (A). A
2. Slide the skirt toward the front to free the center
tab from the solution tank.

Solution Solenoid
If the solution solenoid is being serviced for
the purposes of inspection and cleaning,
you can rotate the upper solenoid body (B) A
counterclockwise and remove it from the valve B
body (C).

1. Disconnect the solenoid electrical connector

(A).
D
2. Loosen the hose clamp (E) and remove the
supply hose from the solenoid.
E
3. Using a 2.5mm hex key, remove the two
screws (D) that secure the solenoid bracket
to the scrub deck.

4. Loosen the delivery tube hose clamp (not

shown), and lift the solenoid body (C) out of
the delivery tube and remove the solenoid. C
Service Manual – SC900 30 - Solution System 48

Solution Filter
1. Shutoff the solution valve (B).
B
2. Unscrew the solution filter (A). There will
likely still be some liquid in the line that will
spill out.

3. Clean the filter bowl and screen (C). Note that the C
screen is not removable from the bowl.
Service Manual – SC900 30 - Solution System 49

Solution Control Panel and Cable

The solution control panel is located to the right A B
of the operator’s handle, and the cable passes
down through the machine to the solution shutoff
valve.

1. Remove the cable clamp (A).

2. Remove the screw, nut, and washer (B) that

secures the cable to the solution shutoff
valve.

C
3. Remove the 4 screws (C) that secure the
control panel to the solution tank, and lift the
control panel upward, and free up the cable
through the machine.

While you have the solution control panel off, it is a

good idea to check that the solution jumper (D) is in
place.

D
Service Manual – SC900 30 - Solution System 50

EcoFlex Control Panel

For machines equipped with the option EcoFlex A
system, the standard solution control panel is
replaced with the EcoFlex control panel.

1. Remove the 4 screws that secure the control

panel to the solution tank, and lift the panel
away from the tank.

2. Disconnect the electrical connector, and

B
remove the control panel.

Specifications

Parameter Range
Solution Solenoid 105 Ω
Coil Resistance
Detergent Pump Coil Resistance 37 Ω
Service Manual – SC900 51

34 - Scrub System, Disc

Functional Description
The scrub system consists of a scrub deck that
is raised and lowered with a foot pedal at the
rear of the machine. The two counter rotating
brushes are driven by independent motors with
integral speed reduction gear boxes.

The scrub deck is supported by a parallelogram

linkage to maintain level with the floor at any
height. The deck lift lever can be set in a raised
position, float, medium, or heavy scrub.

The brush motors are counter-rotating DC

motors with integral gear reduction. They are
relay controlled without variable speed or soft
start.
Service Manual – SC900 34 - Scrub System, Disc 52

Circuit Overview
36 VDC
+ - BLK
The brush circuit has several prerequisites S1
to operate. All of the following must to be
true for the brushes to run: SW, SPST KEY
CURTIS 1228
• Key switch on VIO 5
KSI
• Battery Voltage not low 6 PNK/BLU
PNK 14
BRAKE+ BRAKE-
• Machine in motion (even if zero speed)
• Brush deck lowered.

Starting at the motors and working back

toward the batteries; the brush motors are
connected directly to battery negative. On K1 RELAY, LVC
1
the positive side, each motor has its own D2 2
3
circuit breaker, which is downstream from
S4
4 PNK/BLU
PNK VIO/WHT 5
the K2 relay contact. K2
SW, BRUSH
6

COIL, BRUSH
The control coil of the K2 relay is in series
with the brush (deck lift) switch and the
K1 relay. This circuit receives power from
K1 RELAY, LVC
the Drive Controller’s Brake output, which
is active only when the drive controller is VIO D1 PNK/WHT 3
FET DRAIN B-
4 BLK

commanding motion. The positive side is BATTERY GAUGE WITH HOURMETER

always energized when the controller is
enabled, and the negative side is switched
to ground voltage when the machine is in MOTOR, BRUSH LEFT

motion.
M2
WHT/RED CB2 RED/GRN - M +
25A

This circuit of the K2 coil, Brush Switch,

and K1 relay, along with the Drive MOTOR, BRUSH RIGHT
M3
Controller’s Brake output, provides the
K2
WHT/RED CB3 RED/BRN + M -
25A
fundamental control of the brush motor. BRUSH CONTACT

This circuit is active only when all 4 of the prerequisite conditions mentioned above have been met.

The control coil for the K1 relay is in series with the hour meter. This aspect of the circuit provides the
low-voltage cutout feature to disable the scrub system when the batteries are running low. The hour meter
contains a Field Effect Transistor (FET), which is active (conducting) when the battery voltage is sufficient
for operation. The FET acts like a switch which connects the negative side of the relay coil to ground.

When the key switch is off, it disables the drive controller and also the K1 relay. This effectively disables all
machine functions.
Service Manual – SC900 34 - Scrub System, Disc 53

Troubleshooting

Scrub System, General

One of the first things about troubleshooting any part of the scrub system, is to make the scrub system
active, so you can make observations. It is possible to active the scrub system without the machine moving,
and without the brushes contacting the floor.

1. To avoid getting water on the floor, you may wish to close B

the solution shutoff valve. If the machine is equipped
with EcoFlex, remove the suction hose from the detergent
bottle. A

2. If you need to inspect the solution solenoid, rotate the top

of the solenoid counterclockwise about 1/8-turn, and lift
the solenoid body (A) out of the valve body (B). Take care
to not lose the plunger (C), spring, or sealing washer.

3. Set the speed limit dial to zero speed.

E
4. Carefully position the scrub deck lever (D) out of F
its retracted slot, but resting on the adjacent tab
D
(E). This should permit the switch (F) to close
without lowering the scrub deck.

CAUTION: Always be prepared for the scrub

deck to unexpectedly drop. Keep
hands and feet away from the
scrub deck when it is raised in
this manner.

5. If the machine is equipped with the EcoFlex

system, set both detergent and solution flow
rates to maximum.

6. Turn the key switch to the on position.

7. Press one of the Go switches to confirm that the machine won’t move. If the machine doesn’t move, you
can tape the switch down or have an assistant hold it for you.

CAUTION: Make sure the Go switch can be released quickly in the event the machine starts to
move.

8. To examine the function of the solution solenoid, hold the plunger (C) as shown above, but not all the
way into the solenoid body (A). The plunger should be pulled into the solenoid when the solenoid is
active. For an EcoFlex machine, this will happen every second or two, and then release.

9. To examine the detergent pump, you should be able to hear or feel the detergent pump cycling a couple
of times a second (at max flow).
Service Manual – SC900 34 - Scrub System, Disc 54

One Brush Not Working

If only one brush is not working, you know it is not related to the drive controller, nor the power relay (K2).
The problem is isolated between the 25 amp circuit breaker and the motor.

• Swap the two motor connectors at the scrub deck. If the same motor is inoperable, you know its the motor.
If the other motor becomes inoperable, you know it is in the wiring or the circuit breaker.

• If the problem is at the motor, inspect/replace the motor brushes. If the brushes are not worn, replace the
motor.

Both Brush Motors Not Working

B
• If solution flows, you can eliminate the drive
Batt+ A
controller and K1 relay as a possible cause.
Troubleshoot the K2 relay.

–– Activate the scrub system as described on

page 53. C

–– Check the voltage from (A) to (Batt-). If Batt-

it’s 36V, then the problem lies between the
relay and the circuit breakers, or a broken
ground at the (Batt-) lug.

–– Check the voltage across the coil from (B) K2 Relay

to (C). If the voltage is 36V, then the relay
is defective. If the voltage is zero, trace the
Pink and Violet wires to locate a break.

• If neither solution nor optional detergent

flows, check the following:

–– Check the continuity of the brush (deck

lower) switch.

–– Check the function of the K1 relay.

A
◦◦ Move the Pink/Blue wire from the top
(A) terminal to the lower (C) terminal. B
If the brush motors run, you can
eliminate the Drive Controller as a
cause, but you know that the relay is C
not closing. (Make sure to move the wire
back.)
K1 Relay
◦◦ If the brush motors did not run in the
previous step, the drive controller is the
most likely cause.
E
◦◦ If the brush motors ran in the previous D
step, check the voltage between (D) and
(E). If 36 volts is present, then the relay
is faulty.

◦◦ If 36 volts was not present in the previous step, then it is likely that the hour meter is faulty.
Service Manual – SC900 34 - Scrub System, Disc 55

Removal and Installation

Scrub Skirt
Removing the scrub skirt (B) allows easy access to
the scrub deck components. It is held in place with 4 B
screws (A) on the sides, and a tab in the center.

1. Using a 3mm hex key, remove the 4 screws and

washers (A). A
2. Slide the skirt toward the front to free the center
tab from the solution tank.

Scrub Brush Motor

1. Remove the Scrub skirt as described above.

2. Remove the two halves of the brush housings.

3. With the scrub deck fully raised, remove both

scrub brushes (even if only one motor is being
removed). D
4. Using a 1/4” hex key, remove the socket head cap
screw (A) that secures the brush plate (B) to the
motor shaft.

5. Slide the brush plate off the motor shaft.

• If you need to pry it off, try to pry evenly.
• Lubricant may help if it is corroded.
• Take care not to lose the motor shaft key.

6. Using a 9/16” socket, remove the 4 screws that

secure the motor to the scrub deck.

7. Slowly lower the scrub deck so the motor doesn’t

C
tip over. (The deck can be lowered farther when
both brushes are removed.)

8. Disconnect the motor connector, and remove the B

motor from the scrub deck.
A
Service Manual – SC900 34 - Scrub System, Disc 56

Brush Motor Brushes

Unless you need to remove the motor(s), it is easier to complete this procedure with the motor(s) installed in
the machine. As long as you disconnected the main battery connector, you don’t even need to disconnect the
motor connector. But if desired, remove the Scrub Brush Motor described on page 55.

1. Drain the recovery tank and disconnect the

main battery connector.
C
2. Remove the Scrub Skirt described on page
55.

3. Remove both scrub brushes. B

4. Lower the scrub deck as far as you can.

5. Important: Using a marker or paint pen,

mark the alignment (A) of the top and D
A
bottom end caps with respect to the motor
housing (D).

6. If necessary, disconnect the motor electrical

connector.

7. Using an 11mm socket, remove the two

screws (B) that secure the top cap (C),
through the motor housing (D), and down to
the bottom cap. The screws are very long.

8. Carefully pry up the top cap (C) away from the motor housing (D). Note the following:
• The rotor’s bearing is a light press into the top cap. It will come free fairly easily, but care must be
taken to not skew the cap in the process.
• A very light tap on the side of the cap with a plastic deadblow hammer should be enough to loosen
the cap enough to begin prying with a small screw driver.
• Taking care not to damage the aluminum cap, work the small screw driver around the cap enough to
be able to get two medium sized screw drivers in 180° apart, and then pry up on both sides evenly.

9. Slowly and gently, lift the top cap up until C

the 4 brushes clear the commutator and
rotor bearing.

For reference, the picture to the right shows the

components of the top cap.

(C) Top Cap E

(E) Bearing Pocket

(F) Carbon Brush

G
(G) Brush Holder

(H) Coil Spring (Brush Spring) F

H
(J) Terminal Screw

J
Service Manual – SC900 34 - Scrub System, Disc 57

10. Remove the terminal screw (J) from the brush wire.

11. Pull the brush (F) outward and remove it from the
brush holder (G).

12. While holding the coil spring out of the way, insert the
new brush into the brush holder. Note that the brush
wire is away from the phenolic base.

13. Re-secure the brush wire to the contact with the screw
(J).

14. After replacing all 4 brushes, retract the brushes away

from the center so the end cap can be placed back over
the commutator without damaging them. In the picture
to the right, note how the brush is retracted far enough
for the coil spring to be pressing against the side of the
brush. This will hold the brush retracted, but can easily
be pushed forward later.

15. Before replacing the end cap, inspect the interior

of the motor:
• Inspect the commutator for missing or
damaged bars. Replace the motor if any of
Bearing

the bars are missing.

• Inspect the rotor bearing for wear. Replace
the motor if worn.
• Inspect the permanent magnets for metallic
Rotor
Windings
debris and clean off as needed.

16. Place the wave washer (L) in the bearing

pocket (E). Use a Rare Earth magnet (K) on the
opposite side of the cap to hold the washer in
place. (A less powerful magnet can be used, but
a Rare Earth magnet is powerful enough to hold
itself in place.)
Commutator Permanent
Magnet
17. After reinstalling the end cap, reach in through
the air vents in the motor housing and push
inward on the brushes until you hear them “click”
against the commutator.

K
E
Service Manual – SC900 34 - Scrub System, Disc 58

Specifications

Parameter Range
K2 Brush Relay Coil Resistance 118 Ω
Service Manual – SC900 59

34 - Scrub System, Cylindrical

Functional Description
The scrub system consists of a scrub deck that
is raised and lowered with a foot pedal at the
rear of the machine. The two counter rotating
cylindrical brushes are driven by independent
motors and belt drives.

The scrub deck is supported by a parallelogram

linkage to maintain level with the floor at any
height. The deck lift lever can be set in a raised
position, float, medium, or heavy scrub.

The brush motors are counter-rotating DC

motors. They are relay controlled without
variable speed or soft start.
Service Manual – SC900 34 - Scrub System, Cylindrical 60

Circuit Overview
36 VDC
+ - BLK
The brush circuit has several prerequisites S1
to operate. All of the following must to be
true for the brushes to run: SW, SPST KEY
CURTIS 1228
• Key switch on VIO 5
KSI
• Battery Voltage not low 6 PNK/BLU
PNK 14
BRAKE+ BRAKE-
• Machine in motion (even if zero speed)
• Brush deck lowered.

Starting at the motors and working back

toward the batteries; the brush motors are
connected directly to battery negative. On K1 RELAY, LVC
1
the positive side, each motor has its own D2 2
3
circuit breaker, which is downstream from
S4
4 PNK/BLU
PNK VIO/WHT 5
the K2 relay contact. K2
SW, BRUSH
6

COIL, BRUSH
The control coil of the K2 relay is in series
with the brush (deck lift) switch and the
K1 relay. This circuit receives power from
K1 RELAY, LVC
the Drive Controller’s Brake output, which
is active only when the drive controller is VIO D1 PNK/WHT 3
FET DRAIN B-
4 BLK

commanding motion. The positive side is BATTERY GAUGE WITH HOURMETER

always energized when the controller is
enabled, and the negative side is switched
to ground voltage when the machine is in MOTOR, BRUSH LEFT

motion.
M2
WHT/RED CB2 RED/GRN - M +
25A

This circuit of the K2 coil, Brush Switch,

and K1 relay, along with the Drive MOTOR, BRUSH RIGHT
M3
Controller’s Brake output, provides the
K2
WHT/RED CB3 RED/BRN + M -
25A
fundamental control of the brush motor. BRUSH CONTACT

This circuit is active only when all 4 of the prerequisite conditions mentioned above have been met.

The control coil for the K1 relay is in series with the hour meter. This aspect of the circuit provides the
low-voltage cutout feature to disable the scrub system when the batteries are running low. The hour meter
contains a Field Effect Transistor (FET), which is active (conducting) when the battery voltage is sufficient
for operation. The FET acts like a switch which connects the negative side of the relay coil to ground.

When the key switch is off, it disables the drive controller and also the K1 relay. This effectively disables all
machine functions.
Service Manual – SC900 34 - Scrub System, Cylindrical 61

Troubleshooting

Scrub System, General

One of the first things about troubleshooting any part of the scrub system, is to make the scrub system
active, so you can make observations. It is possible to active the scrub system without the machine moving,
and without the brushes contacting the floor.

1. To avoid getting water on the floor, you may wish to close B

the solution shutoff valve. If the machine is equipped
with EcoFlex, remove the suction hose from the detergent
bottle. A

2. If you need to inspect the solution solenoid, rotate the top

of the solenoid counterclockwise about 1/8-turn, and lift
the solenoid body (A) out of the valve body (B). Take care
to not lose the plunger (C), spring, or sealing washer.

3. Set the speed limit dial to zero speed.

E
4. Carefully position the scrub deck lever (D) out of F
its retracted slot, but resting on the adjacent tab
D
(E). This should permit the switch (F) to close
without lowering the scrub deck.

CAUTION: Always be prepared for the scrub

deck to unexpectedly drop. Keep
hands and feet away from the
scrub deck when it is raised in
this manner.

5. If the machine is equipped with the EcoFlex

system, set both detergent and solution flow
rates to maximum.

6. Turn the key switch to the on position.

7. Press one of the Go switches to confirm that the machine won’t move. If the machine doesn’t move, you
can tape the switch down or have an assistant hold it for you.

CAUTION: Make sure the Go switch can be released quickly in the event the machine starts to
move.

8. To examine the function of the solution solenoid, hold the plunger (C) as shown above, but not all the
way into the solenoid body (A). The plunger should be pulled into the solenoid when the solenoid is
active. For an EcoFlex machine, this will happen every second or two, and then release.

9. To examine the detergent pump, you should be able to hear or feel the detergent pump cycling a couple
of times a second (at max flow).
Service Manual – SC900 34 - Scrub System, Cylindrical 62

One Brush Not Working

If only one brush is not working, you know it is not related to the drive controller, nor the power relay (K2).
The problem is isolated between the 25 amp circuit breaker and the motor.

• Swap the two motor connectors at the scrub deck. If the same motor is inoperable, you know its the motor.
If the other motor becomes inoperable, you know it is in the wiring or the circuit breaker.

• If the problem is at the motor, inspect/replace the motor brushes. If the brushes are not worn, replace the
motor.

Both Brush Motors Not Working

B
• If solution flows, you can eliminate the drive
Batt+ A
controller and K1 relay as a possible cause.
Troubleshoot the K2 relay.

–– Activate the scrub system as described on

page 61. C

–– Check the voltage from (A) to (Batt-). If Batt-

it’s 36V, then the problem lies between the
relay and the circuit breakers, or a broken
ground at the (Batt-) lug.

–– Check the voltage across the coil from (B) K2 Relay

to (C). If the voltage is 36V, then the relay
is defective. If the voltage is zero, trace the
Pink and Violet wires to locate a break.

• If neither solution nor optional detergent

flows, check the following:

–– Check the continuity of the brush (deck

lower) switch.

–– Check the function of the K1 relay.

A
◦◦ Move the Pink/Blue wire from the top
(A) terminal to the lower (C) terminal. B
If the brush motors run, you can
eliminate the Drive Controller as a
cause, but you know that the relay is C
not closing. (Make sure to move the wire
back.)
K1 Relay
◦◦ If the brush motors did not run in the
previous step, the drive controller is the
most likely cause.
E
◦◦ If the brush motors ran in the previous D
step, check the voltage between (D) and
(E). If 36 volts is present, then the relay
is faulty.

◦◦ If 36 volts was not present in the previous step, then it is likely that the hour meter is faulty.
Service Manual – SC900 34 - Scrub System, Cylindrical 63

Removal and Installation

Scrub Skirt
Removing the scrub skirt (B) allows easy access to B
the scrub deck components. It is held in place with 4
screws (A) on the sides, and a tab in the center.

1. Using a 3mm hex key, remove the 4 screws and A

washers (A).

2. Slide the skirt toward the front to free the center

tab from the solution tank.

Scrub Brush Motor

1. Lower the scrub deck and remove the Scrub skirt as
described above.

2. Using a 3/8” socket, remove the screw (A) that secures

the belt cover (B) to the scrub deck, and remove the
cover.
B
3. Walk the stretch belt (D) off the pulleys.

4. Remove the three screws (C) that secure the motor to

the scrub deck.

5. Disconnect the motor connector, and remove the motor

from the scrub deck.
A
6. During replacement, to aid in walking the stretch belt
back on the pulleys, use a 3/8” socket extension to rotate
the pulley.

D
B

C
Service Manual – SC900 34 - Scrub System, Cylindrical 64

Brush Motor Brushes

1. Drain the recovery tank and disconnect the main battery connector.

2. Remove the Scrub Skirt described on page 63.

3. Remove the Scrub Brush Motor described on page 63.

Remove both scrub brushes.

4. Important: Using a marker or paint pen, mark the

alignment (A) of the top and bottom end caps with
respect to the motor housing (D). C

5. Remove the two screws (B) that secure the top cap (C),
through the motor housing (D), and down to the bottom
cap. The screws are very long.

6. Carefully pry up the top cap (C) away from the motor
housing (D). Note the following:
• The rotor’s bearing is a light press into the top cap. B
It will come free fairly easily, but care must be
taken to not skew the cap in the process.
• A very light tap on the side of the cap with a plastic
deadblow hammer should be enough to loosen the
cap enough to begin prying with a small screw
driver.
A
• Taking care not to damage the aluminum cap, work D
the small screw driver around the cap enough to be
able to get two medium sized screw drivers in 180°
apart, and then pry up on both sides evenly.

7. Slowly and gently, lift the top cap up until the 4

brushes clear the commutator and rotor bearing. D
8. Remove the nut from the terminal screw (E),
and lift the brush wire off the screw.

9. Slide the brush toward the center to remove the

brush and coil spring.

D
Service Manual – SC900 34 - Scrub System, Cylindrical 65

Note: When placing the coil spring and brush back

into position, note the direction the coil spring
faces so that it uncoils properly.

Note: You will need 4 temporary retaining pins, such

as straightened out paperclips. Have them
ready before completing the next steps.

10. While holding the brush (F) and coil spring

(G) together, feed the brush wire through
the brush holder.

F
G

11. Insert the brush and coil spring into the

brush holder. The brush wire should be
toward the top, away from the brush cap.

12. Compress the brush all the way in to the F

brush holder, and insert the temporary
retaining pin.

• Insert the pin from the opposite side of

the end cap, through the bottom of the
brush holder, in front of the brush, and
up through the top of the brush holder. H G

• Make sure the pin is inserted in such

a way that it can be removed after the
motor is completely reassembled.

• The purpose of the pin is to hold the

brush retracted while you install the end
cap back onto the motor.
Service Manual – SC900 34 - Scrub System, Cylindrical 66

Note: The wave washer (J) fits between the rotor J

bearing and the end cap. When placing it in
the end cap before assembly, note that the
fingers (K) face toward the bearing.

The picture to the right is only for reference.

It is easier to place the washer in the end
cap than it is to leave it on the bearing.
K

13. Place the wave washer (J) in the bearing

pocket of the end cap with the fingers (K)
facing toward the bearing. Use a Rare Earth
magnet (L) on the opposite side of the cap
to hold the washer in place. (A less powerful L
magnet can be used, but a Rare Earth
magnet is powerful enough to hold itself in
place.)

14. Place the end cap over the top of the motor,
and lower it until the coil springs prevent
you from lowering it any farther. H

• Make sure to realign the marks (A)

that you made on the motor before
disassembly.

• When the brushes are compressed in A

this manner, they are too wide to fit
the cap all the way into the motor. The
coil springs will catch on the edge of the
motor housing.

15. With the end cap on the motor as far as it

will go, begin removing the pins (H) to allow
the brushes to move toward the commutator.

16. Press the end cap down on to the bearing.

17. Install the two long screws (B) that secure the top cap to the bottom cap.

18. Remove the permanent magnet.

Service Manual – SC900 34 - Scrub System, Cylindrical 67

Specifications

Parameter Range
K2 Brush Relay Coil Resistance 118 Ω
Service Manual – SC900 68

38 - Squeegee System
Functional Description
The squeegee tool collects wastewater from the
floor for the recovery system to lift the water
into the recovery tank. The floor squeegee is
wider than the swath of the scrub deck to ensure
collection of all wastewater from the perimeter
of the scrubbing area. The squeegee also pivots
to the side to permit operation near walls and
to keep the squeegee within the scrubbing path
while turning the machine.

Squeegee
The squeegee tool has a front and rear squeegee blade,
creating a vacuum area in between where water can be drawn
up from the fast moving airflow. The squeegee tool attaches to
the lift/pivot assembly with two knobs.
Service Manual – SC900 38 - Squeegee System 69

Maintenance and Adjustment

Squeegee Blade Cleaning and Inspection
Periodically clean and inspect the squeegee
assembly and blades.

1. Loosen the two thumb nuts (A), and slide the

squeegee assembly off the lift mechanism.
A
2. Clean the squeegee blades (B&C) and suction
area between the blades (D) with soap and
water.

3. Inspect the squeegee blades for nicks, tears,

and worn leading edges. If a squeegee blade
is worn or damaged, it may be turned around
with a fresh edge facing down/forward
up to four times before complete blade
replacement is required.

D B C

Squeegee Tilt Adjustment

Shorten
The squeegee tilt should be adjusted when the
squeegee blades are replaced, or if the squeegee is
not fully wiping the floor. Misadjustment symptoms
include water streaks at the center or edges of the
squeegee path.
Gaps
1. Park the machine on a flat, even surface and
lower the squeegee.
Lengthen
2. Without moving the machine (which will cause
the rear squeegee blade to bend backward),
inspect the interface between the edge of the
rear squeegee blade and the floor. Inspect for
gaps at either the center or the edges.
Gap

3. If adjustments are necessary, loosen the turnbuckle jam

nut (B).
A
4. Lengthen (clockwise) or Shorten (counterclockwise) the
squeegee tilt Turnbuckle (A) to level the squeegee across
its length.
B
• If there is a gap in the center, lengthen the
turnbuckle.

• If there are gaps at the outside, shorten the

turnbuckle.

5. Retighten the jam nut.

Service Manual – SC900 38 - Squeegee System 70

Removal and Installation

Squeegee Blade Replacement

1. Remove the squeegee assembly from the
machine. B
2. Release the rear (main) squeegee latch (B)
by pushing back on the latch release (A) and
pulling the latch outward.

A
3. Remove the tension strap (C) from the end
hooks, and remove the squeegee blade (D).

4. The squeegee blade has 4 working edges. Turn

D
the blade so a clean, undamaged edge points
toward the front of the machine. Replace the
blade if all 4 edges are nicked, torn or worn to a
large radius.
C
5. Reinstall the rear squeegee blade and tension
strap, and tighten the latch.

6. To replace the front squeegee blade, loosen both

thumbscrews (E) that hold the retaining strap (F),
remove the strap and remove the squeegee blade (G).

7. After replacing both blades, rest the squeegee on a

flat surface and look for any waves in the height of the
blades.
G
8. After installing the squeegee assembly back on the F
machine, check the Squeegee Tilt Adjustment described
on page 69. E
Service Manual – SC900 71

40-Recovery System

Functional Description
Recovery
The recovery system extracts wastewater from Tank
the floor and deposits it into the on-board Suction
Inlet
recovery tank.

Vacuum Motor and Recovery Tank

The vacuum motor generates airflow through the
recovery tank and suction hose to the squeegee.
The high velocity air at the squeegee pulls the
wastewater off the floor and up through the
suction hose. As the mixture of air and water
Exhaust
enters the recovery tank, the airflow slows down
Vacuum
due to the larger space, and the water drops out Motor
of the airflow and into the tank.

The airflow passes through an inlet screen to

prevent debris from entering the impeller of
the vacuum motor. The exhaust air is expelled
inside the machine so it can be dispersed without
blowing directly on the operator or the work
environment.

To prevent wastewater from entering the vacuum

motor, a float valve blocks the vacuum when the
recovery tank is full.
Service Manual – SC900 40-Recovery System 72

Circuit Overview
36 VDC
+ - BLK
Unlike other machine functions, the vacuum
circuit is not dependant on the drive function S1
nor the low voltage cutout of the hour meter.
The only prerequisite for the vacuum circuit is SW, SPST KEY
TELEMATICS
the main key switch. JUMPER
VIO

The vacuum motor is controlled by the K3

relay, which in turn, is controlled by the
vacuum switch at the squeegee lift lever. D3
S5
VIO VIO/WHT
K3
SW, VACUUM
COIL, VACUUM

Troubleshooting
K3 MOTOR, VACUUM
GRA/RED CB4 ORN/VIO
No Vacuum Motor 20A
VACUUM CONTACT M4
If the vacuum motor is not functioning, but
all other machine functions are unaffected, M
The problem is limited to the vacuum switch,
relay, circuit breaker, and the motor itself. Begin troubleshooting at the K3 relay.

• Check the voltage from relay out (A) and

battery-negative (Batt-). If 36 volts is present, B Batt+
then the problem is isolated to the circuit A
breaker or motor itself.

–– Check for 36 volts at both terminals of the

circuit breaker.
Batt-
–– Check for 36 volts at the vacuum motor
connector.

–– If 36 volts is reaching the motor, then K3 Relay C

inspect/replace the motor brushes described
on page 75.

• If 36 volts was not present at (A), then check

the voltage between (B) and (C). If 36 volts is
present, then the relay is defective.

• If 36 volts is not present between (B) and (C), then the vacuum switch is likely the cause.

Poor Suction
• Inspect the recovery tank cover seal. If the cover is not well sealed, the squeegee will have very low
vacuum.

• Inspect the vacuum motor inlet screen and clean any built-up debris from the screen.

• Inspect the squeegee and suction hose for obstructions or leaks.

• Replace the squeegee blades if they are nicked or torn.

• Make sure that the recovery tank drain hose cap seals airtight.
Service Manual – SC900 40-Recovery System 73

Vacuum Suction Test

Use this procedure to verify that the vacuum system is performing within factory specifications. This
procedure can also be used to isolate the cause of a vacuum problem between a clog or leak. It is a two-part
procedure that verifies both static pressure and flow rate. This procedure requires a vacuum gauge (PN
56205281), a piece of 2” PVC (or similar) tube, a 1” hole saw, and some duct tape (or similar, for a seal).

1. Remove the suction hose (A) from the squeegee

and then turn on the vacuum.
B
2. Place the vacuum gauge (B) on the hose so the
taper (C) seals against the end of the hose.

3. Record the vacuum pressure reading from the

gauge. This is the static pressure.

4. Turn the vacuum off while constructing and

fitting the PVC restricter tube (D).
C

5. Cut a piece of 2” PVC approximately 6” long, and

clean off the burs. The outer diameter of the tube
should be close to, but not larger than 2½”.

6. Drill a 1” hole (E) approximately in the middle of

the PVC tube, and clean off the burs.

7. As necessary, wrap duct tape around the tube so

it fits snugly in the end of the end of the suction
hose with no leaks. D

8. Turn the vacuum on and place the vacuum gauge

on the restricter tube. E

9. Record the vacuum pressure reading from the

gauge. This is the restricted flow pressure.

Results Summary

The first part of this procedure determined the static pressure of the vacuum system, and the second part
determined the flow rate (by calculation). The flow rate through a restriction is determined by the pressure
differential across the restriction. These two parameters may be used to determine if the vacuum system is
functioning properly, and may also be used to isolate a possible cause for a problem.

• If the static pressure is at least 57 inches H2O, then the vacuum motor(s) are functioning properly and
there are no significant leaks in the system.

• If the 1” restricted flow pressure is at least 20 inches H2O, then there are no significant clogs in the
system.

• If both parameters are below specifications, then one or both vacuum motors may be failing, or there may
be a significant leak in the system.
Service Manual – SC900 40-Recovery System 74

Removal and Installation

Vacuum Motor
1. Drain the recovery tank and move it to the
open position.

2. Disconnect the vacuum motor cable

connector (C). E

3. Loosen the hose clamp (A) on the exhaust

hose, and remove the hose.
D
A
4. Remove the three screws and washers (B)
that secure the vacuum retaining plate (D),
and remove the plate and motor. Take care
not to lose the three vibration mounts (E).

5. Inspect the main vacuum gasket (F) for

damage and compressibility, and replace if C
necessary. Leaks in this gasket will reduce
recovery system suction.

6. During replacement, make sure the three

vibration mounts (E) are in place on the
motor’s tabs.

E
F
Service Manual – SC900 40-Recovery System 75

Vacuum Motor Brushes

1. Remove the Vacuum Motor described on page 74.
A
B
2. Remove the two screws (A) that secure the motor cover
to the motor, and remove the cover.

3. Remove the two screws (C) that secure the

contact strap (D), and remove the strap.
Take care to not bend the wire any more
than necessary.

4. Lift the outer end of the brush (E) up, and

slide the brush out of the motor housing.

5. Repeat for the second brush.

C D

6. When installing a new brush, tilt the brush

assembly downward at the front so the carbon
bar contacts the commutator bars, and then
compress the spring to fully insert the brush.
Service Manual – SC900 40-Recovery System 76

Specifications

Parameter Range
K3 Vac Relay Coil Resistance 105 Ω

Special Tools
Vacuum Pressure Gauge 1-inch open hole adapter
part number 56205281 Fabricated from PVC
Service Manual – SC900 90 - Options and Accessories 77

90 - Options and Accessories

The SC900 machine may be equipped with optional accessories depending on the needs of the owner. Some
of these accessories don’t directly impact servicing the machine, but some may. So it is good to know what
accessories you may encounter and how they impact the machine.

Onboard Charger
The onboard battery charger is located in front of the battery bay. The charger connects directly to the
batteries. It also adds (replaces) an interlock wire to the main key switch to prevent machine activation
when the batteries are being charged.

When the charger is not present, a red battery-positive wire is connected to the input of the 2.5-amp circuit
breaker. When the charger is present, this wire is replaced with the green interlock wire from the charger.
When the charger is plugged in, this wire has no power, and therefore, the machine is inoperable.

Refer to the “24 - Electrical System” on page 28 for additional information on the charger.

TrackClean
The TrackClean module adds a telemetry module at the front-
left of the battery bay. This module receives discrete inputs
from various circuits in the machine and reports them via
cellular network to the machine’s administrator. The module
also receives GPS information for the machine’s location and
reports this as well.

The TrackClean module may also incorporate a Smartkey

reader, located on the solution control panel. If this option is
present, the machine will be inoperable without an authorized
Smartkey.

EcoFlex
The EcoFlex option adds a detergent control board behind the operator’s handle, and also a detergent system
with pump in the battery bay. Refer to the “30 - Solution System” on page 43 for additional details.

Battery Watering
Adds a watering manifold and fill valves to the battery fill caps. It also includes a removable hand pump. It
is not covered by the service manual.