Service manual

ManualsBrandsRPS Corporation ManualsFloor Machine2023 Series

ELECTRICAL SERVICE GUIDE

R.P.S. Corporation Phone: 1-800-450-9824

P.O. Box 241 Fax: 1-866-632-6961

Racine, Wisconsin

www.factorycat.com

www.tomcatequip.com

ELECTRICAL

SERVICE GUIDE

VERSION 4.0

Summary of content (142 pages)

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ELECTRICAL SERVICE GUIDE ELECTRICAL SERVICE GUIDE VERSION 4.0 R.P.S. Corporation P.O. Box 241 Racine, Wisconsin Phone: Fax: 1-800-450-9824 1-866-632-6961 www.factorycat.com www.tomcatequip.
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CAUTION! To reduce the chance of personal injury and/or property damage, the following instructions must be careful observed: Proper service and repair are important to the safety of the service technician and the safe reliable operation of all cleaning equipment. If part replacement is necessary, the part must be replaced with one of the same part number or with an equivalent part.
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FOREWORD Factory Cat/Tomcat service manuals are intended for use by professional, qualiﬁed technicians. Attempting repairs or service without the appropriate training, tools, and equipment could cause injury to you or others and damage to your piece of equipment that may cause it not to operate properly This manual should be kept in a convenient place for easy reference. When properly used, it will meet the needs of technicians and equipment owners.
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SAFETY SAFETY MESSAGE Your safety and the safety of others is very important and operating this unit safely is an important responsibility. To help you make informed decisions about safety, we have provided operation procedures and other safety information in this manual. This information informs you of potential hazards that could hurt you or others. It is not practical or possible to warn you of all the hazards associated with operating this unit. You must use your own good judgement.
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SAFETY SAFETY PRECAUTIONS • Hazardous voltage. Shock, Burns or electrocution can result. ALWAYS disconnect the batteries before servicing machine. • Batteries emit hydrogen gases, explosion or ﬁre can result. Keep sparks and open ﬂame away.! • Charge unit in a well ventilated area and keep battery compartment open when charging or explosion or ﬁre could result. • Battery acid can cause burns. Wear protective face-shield and gloves when servicing batteries. • Do not store outdoors or pressure wash.
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TABLE OF CONTENTS TOC CONTENTS CENTRAL COMMAND I 1-1 IDENTIFICATION ........................................................................... 1-1 MACHINE COVERAGE ....................................................................... 1-1 CONTROLLER IDENTIFICATION ................................................. 1-1 1203A .................................................................................................... 1-1 1213 ......................................................................
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TOC TABLE OF CONTENTS MAGNUM ............................................................................................1-13 250/GTX ..............................................................................................1-13 XR........................................................................................................1-13 200 ......................................................................................................1-13 255/275 ...............................................
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TABLE OF CONTENTS TOC CHECK VOLTAGE TO THE CONTROLLER ................................4-4 CONNECTIONS ............................................................................. 4-6 BATTERY ..............................................................................................4-6 POWER SWITCH..................................................................................4-6 THROTTLE............................................................................................4-6 REVERSE SWITCH ..
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TOC TABLE OF CONTENTS DOWN PRESSURE CONTROL ...........................................................6-4 BATTERY METER ................................................................................6-5 OUTPUT NAMES & OPERATION: .......................................................6-5 CONNECTIONS ....................................................................................6-6 MOLEX MINI FIT JR. ....................................................................6-6 AMP TERMINALS ...............
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TABLE OF CONTENTS TOC SWITCHES ......................................................................................... 11-1 ROCKER SWITCHES ............................................................... 11-2 TOGGLE SWITCHES ................................................................. 11-2 LIMIT SWITCHES ....................................................................... 11-2 RELAYS ...................................................................................... 11-3 DIODES ..............
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TOC TABLE OF CONTENTS BLANK THIS PAGE WAS INTENTIONALLY LEFT BLANK toc - 6 Electrical Service Manual V4.
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CENTRAL COMMAND I CENTRAL COMMAND I The Central Command I system refers to all of our equipment manufactured utilizing a Curtis speed control system. This system was used an all our equipment with a speed controller from 1994 to 2002. In 2002 Central Command II was released and while some machines were migrated to Central Command II others retained the Central Command I system.
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1 CENTRAL COMMAND I 1213 Used on models: Factory Cat: 38, 40, 48, 52 Tomcat: 3700, 4700, 5100 Deﬁnitive characteristics: Is labelled Curtis 1213 on the face label, Sliding door that covers 3 micro potentiometers. Has only one 16 pin molex and 4 lug style connectors.
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CENTRAL COMMAND I 1228 Used on models: Factory Cat: 2000 series Tomcat: 2000 Series, 200 Burnishers Deﬁnitive characteristics: Blue in color Small package DIAGNOSTICS See Chapter 5 HOW CENTRAL COMMAND I SYSTEMS WORK The Curtis system is a solid state speed controller that replaces the old style resistor-based speed control systems. The solid state system eliminates runaway machines and burnt electrical components while conserving energy and making the machine operate more smoothly.
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1 CENTRAL COMMAND I GENERAL DIAGNOSIS OF THE CURTIS SYSTEM The Curtis system diagnosis is performed in many cases by the substitution of known good parts into the system. This system of diagnosis, although seemingly crude, is very effective from a time management stand point. Some Curtis systems uses a “ﬂash code” system to assist in diagnosing it. There is either an LED on the controller itself or an LED located on or around the control panel of the machine.
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CENTRAL COMMAND I THROTTLE SIGNAL The throttle signal originates at the high and low throttle signal outputs of the Curtis Control. The high and low output are sent to the coil circuit of a 5K ohm hermetically sealed potentiometer. The potentiometer sums the signals and outputs a varied voltage signal from 0.2 volts (+/- 0.2 volts) to 4.8 volts (+/- 0.2 Volts) on the center terminal of the potentiometer.
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1 CENTRAL COMMAND I #2 Relay contact test – This test checks to make sure there is no continuity from one side of the relay’s contact to the other. This ensures that the relay is in an open stat before applying power to it. Once these two relays have passed the internal test of the Curtis control the controller will then turn on and apply power to the drive motor.
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CENTRAL COMMAND I BRUSH CIRCUIT BREAKERS All of our machines with Central Command 1 have in line brush motor protection. The protection is in line auto resetting circuit breaker(s) These breakers will open in the event of an over load and reset themselves when they cool. These breakers can burn out in the event of a huge overload and weaken over time if they are tripped repeatedly. The following is a list of the machines and what circuit breakers are used on each one.
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1 CENTRAL COMMAND I DOWN PRESSURE GAUGE The scrubbers that were equipped with Central Command 1 used an active down pressure readout. This readout would convert the amp draw of the brushes into brush deck pressure and show it on the control panel mounted brush pressure gauge. For this to work it utilized the down pressure gauge, a control module and a shunt. The shunt is wired in series with the brush deck motor(s).
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CENTRAL COMMAND I SOLID STATE VACUUM TIMER TIMER CONNECTIONS The timer is a solid state device that has 6 terminals.
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1 CENTRAL COMMAND I TIMER BASED VACUUM SYSTEMS The following model machines had timer based vacuum systems: 29, 35, 38, 40, 52, 3700 & 5100 There 2 different systems, 1 system for walk behind machines and another for rider machines. WALK BEHIND MACHINES The walk behind timer circuit is very straight forward. Pin #5 on the timer receives +24 Volts from the limit switch that is actuated by the squeegee lift bar.
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CENTRAL COMMAND I If there is not battery voltage (+/- 1.5 volts) repair the ground wire to the coil of the vacuum motor solenoid. With a volt meter measure from the negative buss bar to the left load terminal on the contactor. If there is battery voltage go to the next step If there is not battery voltage there is a battery or battery cable problem. Measure from the negative (-) buss bar to the right side load contact on the solenoid.
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1 CENTRAL COMMAND I �� Early versions of the Model 40 scrubber were equipped with a ﬂoat switch that was in the recovery tank. This ﬂoat switch would interrupt the power from the center terminal on the “down” limit switch to pin # 5 of the electronic vacuum delay timer. 1-12 Electrical Service Manual V4.
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CENTRAL COMMAND I SPECIAL NOTES BY MACHINE 34/3300 38/40/3700 52/5100 29/35 20/2000 30/3000 290/350 2023 MINIMAG MAGNUM 250/GTX XR 200 255/275 Electrical Service Manual V4.
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1 CENTRAL COMMAND I BLANK THIS PAGE WAS INTENTIONALLY LEFT BLANK 1-14 Electrical Service Manual V4.
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CURTIS 1203A CONTROLLER CURTIS 1203 The Curtis 1203A controller was used on our model 29 & 35 walk behind scrubbers. This controller was a non programmable controller we used on all of these machines built with Central Command I. This controller has true regenerative and dynamic braking providing complete downhill and deceleration speed control. The traction control parts are all housed internally including the forward, reverse and power contactors.
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2 CURTIS 1203A CONTROLLER CONNECTIONS BATTERY The connections from the controller to the battery are made via 0.25” quick connects (Spade terminals). The positive battery cable connects from the main circuit breaker to any one of the 3 terminals labeled “B+”. The negative battery cable connects to any one of the 3 terminals labeled “B-”. POWER SWITCH The power switch is a very simple circuit.
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CURTIS 1203A CONTROLLER DIAGNOSIS Machine will not turn on Attach a DC Volt meter to the B+ and B- terminals on the controller Charge or replace batteries Was there at least 23.5 volts between B+ and B- Was there at least 23.5 volts at the battery pack Measure the voltage at the battery pack Repair battery cables or mail breaker Replace the controller Attach the (-) lead of a DC voltmeter to the B(-) terminal.
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2 CURTIS 1203A CONTROLLER Machine will not move. Suspected bad throttle system Remove the tape from the handle bar buttons and remeasure for voltage YES Raise machine drive wheels and support with suitable stands. Did the meter display a sweeping voltage from about 0 volts to 5 volts? Turn the machine power on and THEN tape down handle bar button(s). Attach the (-) lead of a DC voltmeter to the B(-) terminal.
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CURTIS 1203A CONTROLLER �� CURTIS PMC WIRING �� Electrical Service Manual V4.
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CURTIS 1213 CONTROLLER CURTIS 1213 The Curtis 1213 controller was used on our model 48 sweepers until 1997. The controller is an adjustable controller that has true regenerative braking that also provides complete downhill deceleration and speed control. This controller required no forward and reverse contactor due to its full bridge design. �� FEATURES - Full bridge power MOSFET design.
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3 CURTIS 1213 CONTROLLER CONNECTIONS BATTERY The connections from the controller to the battery are made using ring terminals that are fastened to the lug style terminals on the controller. It is important to tighten theses terminals with two wrenches using one to hold the nut and one to turn the bolt so undo stress is not put on the terminals. The POWER SWITCH The power switch is a very simple circuit.
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CURTIS 1213 CONTROLLER DIAGNOSIS Machine will not turn on Attach a DC Volt meter to the B+ and B- terminals on the controller Charge or replace batteries Was there at least 23.5 volts between B+ and B- Was there at least 23.5 volts at the battery pack Measure the voltage at the battery pack Repair battery cables or mail breaker Replace the controller Attach the (-) lead of a DC voltmeter to the B(-) terminal.
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3 CURTIS 1213 CONTROLLER Machine will not move. Suspected bad throttle system The potentiometer system is working properly YES Raise machine drive wheels and support with suitable stands. Turn the machine power on. Attach the (-) lead of a DC voltmeter to the B(-) terminal. With the (+) lead measure the voltage at Pin #6 on the 16 pin connector on the Curtis control. Depress and release the foot pedal slowly.
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CURTIS 1213 CONTROLLER WIRING M- A2 B- B+ M- output to motor armature (-) B- Negative battery connection B+ Positive connection to battery A2 Output to motor armature Electrical Service Manual V4.
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3 CURTIS 1213 CONTROLLER BLANK THIS PAGE WAS INTENTIONALLY LEFT BLANK 3-6 Electrical Service Manual V4.
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CURTIS 1227 CONTROLLER CURTIS 1227 CONTROLLER The Curtis 1227 controller replaced the Curtis 1213 controller in the models 38, 40, 48, 3700 & 4700. The 1227 is more modern control with more adjustable parameters. The controllers are fully programmable with the use of a Curtis 1307 or 1311 hand programmer or a Curtis PC Programmer with special interface cord.
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4 CURTIS 1227 CONTROLLER DIAGNOSTICS FLASH CODES To assist in the diagnosis of problems the controller has an LED that ﬂashes diagnostic codes. During normal operation, with no faults present, the status LED is steadily on. If the controller detects a fault, the status LED provides two types of information. First, it displays a slow ﬂash (2 Hz or 2X a second) or a fast ﬂash (4Hz or 4X a second) to indicate the severity of the fault.
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CURTIS 1227 CONTROLLER Table 8 TROUBLESHOOTING CHART LED CODE PROGRAMMER LCD DISPLAY EXPLANATION POSSIBLE CAUSE HARDWARE F A I L SA F E 2 �� HARDWARE F A I L SA F E 4 �� HARDWARE F A I L SA F E 1 �� HARDWARE F A I L SA F E 3 �� PRECH
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4 CURTIS 1227 CONTROLLER CHECK VOLTAGE TO THE CONTROLLER Machine will not turn on Attach a DC Volt meter to the B+ and B- terminals on the controller Charge or replace batteries Was there at least 23.5 volts between B+ and B- Was there at least 23.5 volts at the battery pack Measure the voltage at the battery pack Repair battery cables or mail breaker Replace the controller Attach the (-) lead of a DC voltmeter to the B(-) terminal.
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CURTIS 1227 CONTROLLER Raise machine drive wheels and support with suitable stands. Machine will not move. Suspected bad throttle system The potentiometer system is working properly YES Turn the machine power on. Attach the (-) lead of a DC voltmeter to the B(-) terminal. With the (+) lead measure the voltage at Pin #2 on the 16 pin connector on the Curtis control. Depress and release the foot pedal slowly.
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4 CURTIS 1227 CONTROLLER CONNECTIONS BATTERY The connections from the controller to the battery are made via 0.25” quick connects (Spade terminals). The positive battery cable connects from the main circuit breaker to any one of the 3 terminals labeled “B+”. The negative battery cable connects to any one of the 3 terminals labeled “B-”. POWER SWITCH The power switch is a very simple circuit.
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CURTIS 1227 CONTROLLER 4 WIRING 1227/37 High Current Connections M- B- A2 B+ �� B-� B+��M-� A �� M- = Drive Motor (-) B- = Battery (-) B+ = Battery (+) A2 = Drive Motor (+) 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 ��
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CURTIS 1228 CONTROLLER CURTIS 1228 CONTROLLER �� The Curtis 1228 controller was used on the 20/2000 series of walk behind auto scrubbers and the 200 burnishers. The 1228 is a fully programmable controller and comes in 24 and 36 volt versions. This controller has regenerative breaking which provides downhill and deceleration speed control.
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5 CURTIS 1228 CONTROLLER CONNECTIONS BATTERY The connections from the controller to the battery are made via 0.25” quick connects (Spade terminals). The positive battery cable connects from the main circuit breaker to any one of the 3 terminals labeled “B+”. The negative battery cable connects to any one of the 3 terminals labeled “B-”. POWER SWITCH The power switch is a very simple circuit.
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CURTIS 1228 CONTROLLER DIAGNOSTICS FLASH CODES To assist in the diagnosis of problems the controller has a remote LED indicator that ﬂashes diagnostic codes. This LED is located either on the side or on the bottom of the central command. During normal operation, with no faults present, the status LED is steadily on. If the controller detects a fault, the status LED provides two types of information.
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5 CURTIS 1228 CONTROLLER Table 3 TROUBLESHOOTING CHART LED CODE PROGRAMMER LCD DISPLAY EXPLANATION POSSIBLE CAUSE ��
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CURTIS 1228 CONTROLLER Machine will not turn on Attach a DC Volt meter to the B+ and B- terminals on the controller Charge or replace batteries Was there at least 23.5 volts between B+ and B- Was there at least 23.5 volts at the battery pack Measure the voltage at the battery pack Repair battery cables or mail breaker Replace the controller Attach the (-) lead of a DC voltmeter to the B(-) terminal.
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5 CURTIS 1228 CONTROLLER Machine will not move. Suspected bad throttle system Remove the tape from the handle bar buttons and remeasure for voltage YES Raise machine drive wheels and support with suitable stands. Did the meter display a sweeping voltage from about 0 volts to 5 volts? Turn the machine power on and THEN tape down handle bar button(s). Attach the (-) lead of a DC voltmeter to the B(-) terminal.
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CURTIS 1228 CONTROLLER WIRING B+ B- M2 M1 B+ = Battery Positive (+) B- = Battery Negative (-) M2 = Traction Drive Motor M1 = TRACTION DRIVE MOTOR 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 J10 Pin 1 J10 Pin 2 J10 Pin 3 J10 Pin 4 J10 Pin 5 J10 Pin 6 J10 Pin 7 J10 Pin 8 J10 Pin 9 J10 Pin 10 J10 Pin 11 J10 Pin 12 J10 Pin 13 J10 Pin 14 J10 Pin 15 J10 Pin 16 J10 Pin 17 J10 Pin 18 Electrical Service Manual V4.
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CENTRAL COMMAND II CENTRAL COMMAND II The Central Command II control system implemented on majority our machines in September of 2002. This new control system utilized a controller Manufactured by P&G Drives of the UK. The new P&G controller is feature-rich and simpliﬁed our control systems. IDENTIFICATION Machines built with the Central Command II system are easily identiﬁable by the LCD display on the control panel. All machine that are equipped with Central Command II have this display.
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6 CENTRAL COMMAND II CONTROLLER OVERVIEW The controller used in the Central Command II system is manufactured by P&G drives and is much more than a standard speed controller. The controllers heart is an industrial micro computer. The P&G series of controllers used in the Central Command II is the “Trio” series that was designed primarily for the commercial and industrial cleaning equipment segment.
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CENTRAL COMMAND II ON-OFF (CENTER OFF) For the controller to switch a connected component on and off it must receive an input signal from one of the switches on the machine. The controller knows to turn components on and off based on the signal it receives from that switch . These switches are part of a tri-state logic system that the controller uses to interpret the input from the switches. The switches for the inputs are fed a reference voltage that is created by the controller.
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6 CENTRAL COMMAND II CONTINUITY TESTS The controller in our Central Command II system has onboard testing capabilities that test the ﬁtness of different circuits on the machine. These circuits are the Drive Motor, Brush Motor, Vacuum Motor and Parking Brake. To do this the controller sends out voltage on one of the output terminals for a circuit and watches to assure the voltage is returned on the other terminal of the output circuit.
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CENTRAL COMMAND II TIMED CIRCUITS The controller has the capability to control a circuit with a certain amount of logic. We can customize the operation of a component beyond the simple on off operation. Timers are used for our vacuum motors and our squeegee actuators to make the machine operation more user friendly. The timer settings are changed through the controller programming.
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6 CENTRAL COMMAND II Aux 3 = Solution solenoid circuit The solution solenoid output is turned on and off 2 times per second (2 Hz). The length of the “On Cycle” is determined by the position of the potentiometer on the control panel if the machine is so equipped.
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CENTRAL COMMAND II LCD DISPLAY The LCD display is a multi-function display that conveys machine information to the operator about the operation state of the machine and diagnostic information in the event of a malfunction. The LCD display communicates to the controller on a serial data connection that is made via the 6 wire connector running from the display to the controller. The LCD display has 4 different screens with different information presented on each. There are four versions of the LCD display.
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6 CENTRAL COMMAND II SCREEN 2 To access screen 2, push the green page button on the control panel once. 7: KEY SWITCH HOUR METER This hour meter represents the total number of hours the machine has been powered on. This does not mean, however, that the machine has been used this long, just that it has had the power on for the time indicated. 8: BATTERY METER This meter shows the charge level of the batteries in the machine.
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CENTRAL COMMAND II VERSION 2 SCREEN 1 Screen 1 is the default screen that appears after the machine has powered up. 1: BATTERY METER - This meter shows the charge level of the batteries in the machine. This gauge is designed to read properly while the machine is in use and therefore will vary both up and down during usage of the machine. 2: WATER VOLUME - This icon shows when the output volume that the controller has set.
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6 CENTRAL COMMAND II SCREEN 2 To access screen 2, push the green page button on the control panel once. 7: KEY SWITCH HOUR METER This hour meter represents the total number of hours the machine has been powered on. This does not mean, however, that the machine has been used this long, just that it has had the power on for the time indicated. 8: BATTERY METER This meter shows the charge level of the batteries in the machine.
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CENTRAL COMMAND II VERSION 3 SCREEN 1 Screen 1 is the default screen that appears after the machine has powered up. 1: BATTERY METER - This meter shows the charge level of the batteries in the machine. This gauge is designed to read properly while the machine is in use and therefore will vary both up and down during usage of the machine. 2: WATER VOLUME - This icon shows when the output volume that the controller has set.
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6 CENTRAL COMMAND II SCREEN 2 To access this from screen 1, press the green page button twice. 9: BATTERY METER - This meter shows the charge level of the batteries in the machine. This gauge is designed to read properly while the machine is in use and therefore will vary during usage of the machine. 10: SCRUB HOURS - The hour total listed here indicates the total number of hours the brush deck has been operated on the machine. 9. BATTERY GAUGE 10. SCRUB HOURS 11. TRACTION HOURS 12.
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CENTRAL COMMAND II VERSION 4 SCREEN 1 Screen 1 is the default screen that appears after the machine has powered up. 1: BATTERY METER - This meter shows the charge level of the batteries in the machine. This gauge is designed to read properly while the machine is in use and therefore will vary both up and down during usage of the machine. 2: WATER VOLUME - This icon shows when the output volume that the controller has set.
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6 CENTRAL COMMAND II SCREEN 2 To access this from screen 1, press the green page button twice. 9: BATTERY METER - This meter shows the charge level of the batteries in the machine. This gauge is designed to read properly while the machine is in use and therefore will vary during usage of the machine. 10: SCRUB HOURS - The hour total listed here indicates the total number of hours the brush deck has been operated on the machine. 9. BATTERY GAUGE 10. SCRUB HOURS 11. TRACTION HOURS 12.
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CENTRAL COMMAND II ON-BOARD DIAGNOSTICS The Central Command II control system utilizes a Diagnostic Code system that displays diagnostic codes on the LCD display should a malfunction of the machine occur. The diagnostic code can be looked up in the diagnostic code chart and it will assist you in determining the cause of malfunction. The diagnostic codes are slightly different from the V.2 to the V.3 controller, while the diagnostic codes are the same for the V.3 and V.4 controllers.
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6 CENTRAL COMMAND II PROGRAMMING We use the same controllers on nearly all of our machines. The controller’s embedded computer needs a set of instructions to operate the machine. The instructions are the program the computer runs and we can modify this program by changing it’s “parameters”. This is what makes it possible to use the same controller in most of our machines but have each one of them react differently. By changing these parameters we can make the piece of equipment function in different ways.
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TRIO CONTROLLER TRIO CONTROLLER - V.2 The Trio controller was the ﬁrst controller manufactured by P&G Drives of the UK that we used in our machines. This controller is identiﬁable by the l”ime green” colored circuit board that it is built on. This Trio controller with the “lime green” circuit board is called the V.2. The V.2 controller was used from September 2002 until March 2004 across our full line and was used on the 390/420 line of machines until June of 2007. The V.
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7 TRIO CONTROLLER Central Command II V. 2 Fault Codes Code 0003 0100 0204 0705 Probable Cause Service Action Memory corrupt Replace Controller if not cleared by disconnecting batteries for 1 min All 070x codes -Wiring short circuit between Tiller Check for wiring short circuits on the 20 way connector on the Trio, the 16 way connector on the LCD (if used) Hi and Lo Ref and the wiring to the front panel switches & controls and those switches & controls themselves.
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TRIO CONTROLLER All 70xx codes – Check wiring of brake and freewheel switch Check for wiring short circuits on the 20 way connector on the Trio, the 16 way connector on the LCD (if used) and the wiring to the ffreewheel switch and the switch itself.. Check the Traction motor connection on the Trio and check the wiring from this connector down to the electromagnetic brake on the Traction motor and check connections all the way.
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TRIO PLUS CONTROLLER TRIO PLUS CONTROLLER - V.3 The Trio Plus controller was put into our production in March of 2004. The Trio Plus controller is called the V.3 Controller and is readily identiﬁed buy the Blue circuit board that it is built on. The V.3 controller replaced all controllers used across our entire line with Central Command II with the exception of the 390/420 line which still used the V.2 controller. The V.
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8 TRIO PLUS CONTROLLER CENTRAL COMMAND II V.3 SYSTEM DIAGNOSTIC CODES Code 0700 0701 0702 0704 0705 0706 0810 0811 0812 0813 0814 0815 0816 0817 0818 0A01 1310 Fault Description Bias Voltage Error Mid Rail Voltage High Mid rail bias voltage high 12V supply failure 2.
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TRIO PLUS CONTROLLER CENTRAL COMMAND II V.
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TRIO PLUS HD CONTROLLER TRIO PLUS HD CONTROLLER - V.4 The Trio Plus HD controller called the V.4. This controller is easily identiﬁed by all of the high amp terminals being the lug style terminals. The V.4 controller was another evolutionary design from the V.2 and V.3 controls with marked improvement. Improvements Boost Mode- The V.4 controller has new software that allows the machine to safely climb ramps better than the V.2 or V.3 controller.
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9 TRIO PLUS HD CONTROLLER CENTRAL COMMAND II V.3 SYSTEM DIAGNOSTIC CODES Code 0700 0701 0702 0704 0705 0706 0810 0811 0812 0813 0814 0815 0816 0817 0818 0A01 1310 Fault Description Bias Voltage Error Mid Rail Voltage High Mid rail bias voltage high 12V supply failure 2.
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TRIO PLUS HD CONTROLLER CENTRAL COMMAND II V.
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TRIO PROGRAMMING TRIO PROGRAMMING We use the same controllers on nearly all of our machines. The controller’s embedded computer needs a set of instructions to operate the machine. The instructions are the program the computer runs and we can modify this program by changing it’s “parameters”. This is what makes it possible to use the same controller in most of our machines but have each one of them react differently.
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10 TRIO PROGRAMMING BLANK THIS PAGE WAS INTENTIONALLY LEFT BLANK 10-2 Electrical Service Manual V4.
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TRIO PROGRAMMING PROGRAMMING THE CONTROLLER 1. Start your computer. 2. Plug in the Belkin USB adapter with the programming cable attached 3. Move your cursor over “My Computer” 4. [Right Click] your mouse button while your cursor is over “My Computer” 5. [Left Click] on “Properties” from the bottom of the drop down menu. Electrical Service Manual V4.
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10 TRIO PROGRAMMING 6. The “System Properties” windows will appear [Left Click] on the “Hardware Tab” 7. [Left Click] on the “Device Manager” button. 8. [Left Click] on the “+” symbol on the left side of the word “Ports (COM & LPT)” 10-4 Electrical Service Manual V4.
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TRIO PROGRAMMING 9. Observe the COM port number listed next to the words “Belkin F5U409 Serial Port” 10. If the port listed is “(COM6)” or lower, record the COM# and close out all windows and then proceed to step 23. 11. If the port listed is higher than (COM6) you must manually reset the port number as follows. 12. Double “Left Click” on words “Belkin F5U409 Serial Port (COM#)” 13. The “Belkin F5U409 Serial Port (Com#) Properties” window will show. Electrical Service Manual V4.
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10 TRIO PROGRAMMING 14. [Left Click] on the “Port Settings” tab. 15. [Left Click] on the “Advanced...” button. 16. The “Advanced Settings for Com#” window will show. 17. [Left Click] on the drop down arrow next to the com port listing. 10-6 Electrical Service Manual V4.
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TRIO PROGRAMMING 18. The following drop down list will appear. [Left Click] on “COM1” It may or may not be followed by “(in use)” 19. The window will then look like below. [Left Click] on the “OK” button. 20. The following window may or may not appear. “Communications Port Properties” 21. If it does appear [Left Click] on the “Yes” button. Electrical Service Manual V4.
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10 TRIO PROGRAMMING 22. Close out all remaining windows. 23. Open INDUSTRIAL/PC Programmer 24. When you open INDUSTRIAL/PC Programmer you may get an error window that says “Can’t open Serial port” click the “OK” button. 25. When the “Industrial Programmer” window opens up click on the “Conﬁgure” tab on the top of the window. 26. You do not want the check mark next to the “Standard COM Enumeration”. If there is a check mark there click on the check mark and it will go away. 27.
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TRIO PROGRAMMING 28. [Left Click] on “Options” on the drop down menu. 29. The following window will show after the [Left Click]. Observe the “Com port” listed in this window. If the “Com port” listed is the same as the one you recorded earlier then [Left Click] on the “OK “ button. If it does not match then [Left Click] on the drop down arrow to the right of the “Com port” listed. [Left Click] on the corresponding COM # to the one you recorded earlier. Then [Left Click] on the “OK” button. 30.
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10 TRIO PROGRAMMING 32. Watch at the bottom of the Industrial Programmer window for the place where it says “Comms lost” to change to OK. When this occurs the link is established between the computer and the controller. 33. If the controller will not link up to your computer call the factory @ 1-800-634-4060 10-10 Electrical Service Manual V4.
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ELECTRICAL COMPONENTS COMPONENTS SWITCHES We use a number of different switches on our machines. Many of them look very similar on the outside but it is the conﬁguration of the contacts inside that makes them function differently. Switches are deﬁned in 3 ways; poles, throws and action. A POLE refers to the number of cirrcuits in a switch. A THROW refers to the number of ways a pole can connect. The ACTION is how a switch responds to being moved.
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11 ELECTRICAL COMPONENTS ROCKER SWITCHES TOGGLE SWITCHES LIMIT SWITCHES �� 11-2 Electrical Service Manual V4.
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ELECTRICAL COMPONENTS 11 RELAYS In our machines we use relays which are also refered to as contactors and solenoids. �� BOSCH �� Electrical Service Manual V4.
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11 ELECTRICAL COMPONENTS DIODES Diodes are devices that only allow electricity to ﬂow in one dorection. We use 2 types of diodes on our equpment. Supression diodes and bridge rectiﬁer diodes. Testing diodes. There are two methods of testing diodes. The ﬁrst is with a meter with a diode checking function and the second is with a meter without a integrated diode checker. For meters with a Diode Checker: Set the meter to the diode checker range. Test the diode in one direction and then the other direction.
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BATTERY CHRARGERS BATTERY CHARGERS A number of different types of battery chargers are used on our equipment. They are Ferro Resonnant, Linear Wound, SCR and High Frequency chargers. Each one has it’s own virtues and therefore is used is different scenarios. FERRO- RESONANT These are Ferro-Resonant Brands Power Cat Lester Ferro Five M.A.C. LINEAR These are Linear Wound Quick Charge SCR These are Lester Electric HIGH-FREQUENCY These are SPE Magnum Service Manual V1.
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12 BATTERY CHARGERS 12-2 Magnum Service Manual V1.
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BATTERY CHRARGERS POWER CAT LESTER 7-243 CHARGER PARTS LIST WIRING DIAGRAM PARTS LIST FOR POWERCAT CHARGER PART# 7-243 115 VAC / 60 HZ 24 VDC 36A PART NO. QTY. 7-244A 7-224TR 7-244B 7-244H 7-244F 7-244G 7-244T 7-244C 7-244D 7-244E 7-244J 7-244K 1 1 1 2 1 1 1 1 1 1 1 1 �� Magnum Service Manual V1.
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12 BATTERY CHARGERS 7-244 CHARGER PARTS LIST WIRING DIAGRAM PARTS LIST FOR POWERCAT CHARGER PART# 7-243 115 VAC / 60 HZ 24 VDC 36A �� 12-4 PART NO. QTY.
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BATTERY CHRARGERS 7-251 CHARGER PARTS LIST WIRING DIAGRAM black red 230 Vac INPUT black red or white 1 5 3 2 black green white DIODE tan 4 TO BATTERIES FUSE ASSEMBLY black 2 or red black - AMMETER 3 ELECTRONIC TIMER KIT + 4 tan DIODE CAPACITOR TRANSFORMER PARTS LIST FOR POWER CAT CHARGER PART# 7-251 230 VAC 50 HZ 24 VDC 40 A �� 7-251TR 7-251HS 7-251N 7-251G 7-251T 7-244B 7-251C 7-251D 7-244D 7-251L 7-244S 7-244F 1 1 1 1 1 1 1 1 1 1 1 1 ��
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12 BATTERY CHARGERS 21-2440 CHARGER PARTS LIST WIRING DIAGRAM PARTS LIST FOR POWERCAT CHARGER PART# 21-2440 115 VAC / 60 HZ 24 VDC 25 A PART NO. 21-2446 21-2447 21-2445 21-2448 21-2440T * 7-244M ** 7-244RE 7-244B 21-2444 7-244C 21-2449 21-2450 21-2451 S/O 4-257 5-260 QTY. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 DESCRIPTION CASE ASSEMBLY TRANSFORMER ASSEMBLY HEATSINK ASSEMBLY, W/ DIODES AMMETER ELECTRONIC TIMER ASSEMBLY RELAY, FOR TIMER ASSEMBLY RELAY, FOR TIMER ASSEMBLY CAPACITOR, 6.
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BATTERY CHRARGERS 21-2441 CHARGER PARTS LIST WIRING DIAGRAM PARTS LIST FOR POWERCAT CHARGER PART# 21-2441 115 VAC / 60 HZ 24 VDC 25 A PART NO. QTY. 21-2446 21-2447 21-2445 21-2448 21-2440T 7-244B 21-2444 7-244C 21-2449 21-2450 21-2451 S/O 4-257 5-260 1 1 1 1 1 1 1 1 1 1 1 1 1 1 �� Magnum Service Manual V1.0 DESCRIPTION CASE ASSEMBLY TRANSFORMER ASSEMBLY HEATSINK ASSEMBLY, W/ DIODES AMMETER ELECTRONIC TIMER ASSEMBLY CAPACITOR, 6.
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12 BATTERY CHARGERS 21-2442 CHARGER PARTS LIST WIRING DIAGRAM PARTS LIST FOR POWERCAT CHARGER PART# 21-2442 230 VAC / 50 HZ 24 VDC 25 A �� 12-8 �� S/O S/O 7-244B 21-2445 21-2440F S/O 21-2440E 7-244C 21-2451 S/O 1 1 1 1 1 1 1 1 1 1 �� CASE ASSEMBLY TRANSFORMER ASSEMBLY CAPACITOR, 6MFD, 660VAC/70C, 600VAC/90C HEATSINK ASSEMBLY, W/ DIODES FUSE ASSEMBLY AMMETER, 0-30 AMP, CORNER MOUNTING STATUS ELECTRONIC TIMER KIT, 24 VDC INSULATOR BUSHING FO
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BATTERY CHRARGERS 190-2440 CHARGER PARTS LIST WIRING DIAGRAM PARTS LIST FOR POWERCAT CHARGER PART# 190-2440 115 VAC / 60 HZ 24 VDC 18 A �� S/O S/O 21-2440F S/O 21-2445 S/O 7-244C 21-2449 S/O S/O 21-2451 S/O 1 1 1 1 1 1 1 1 1 1 1 1 �� CASE ASSEMBLY POWER CAT TRANSFORMER ASSEMBLY FUSE ASSEMBLY ELECTRONIC TIMER ASSEMBLY HEATSINK ASSEMBLY W/ DIODES AMMETER, 25 AMP, CORNER MOUNT BUSHING, 7W-2, INSULATOR FOR DC CORD BUSHING, 7K-2, INSULATOR FOR AC CORD CAPACITOR, 4.
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12 BATTERY CHARGERS 190-2442 CHARGER PARTS LIST WIRING DIAGRAM PARTS LIST FOR POWERCAT CHARGER PART# 190-2442 250 VAC / 50 HZ 24 VDC 25 A �� S/O 1 TRANSFORMER ASSEMBLY 7-244B 21-2445 21-2440F S/O S/O 244-C 21-2451 S/O 1 1 1 1 1 1 1 1 CAPACITOR, 6MFD, 660VAC/70C, 600VAC/90C HEATSINK ASSEMBLY, W/ DIODES FUSE ASSEMBLY AMMETER, 0-30 AMP, CORNER MOUNTING STATUS ELECTRONIC TIMER KIT, 24 VDC INSULATOR BUSHING FOR DC CORDSET DCCORDSET, 12/2, 108", SB50 RED DCCORDSET, 12/2, 108", S
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BATTERY CHRARGERS 250-2440 CHARGER PARTS LIST WIRING DIAGRAM PARTS LIST FOR POWERCAT CHARGER PART# 250-2440 115 VAC / 60 HZ 36 VDC 25A PART NO. QTY. S/O 7-244B 21-2444 21-2440F S/O S/O 7-244C 21-2450 S/O S/O 4-260 390-2575 1 1 1 1 1 1 1 1 1 1 1 1 �� Magnum Service Manual V1.0 DESCRIPTION TRANSFORMER ASSEMBLY CAPACITOR, 6.
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12 BATTERY CHARGERS 390-2440 CHARGER PARTS LIST WIRING DIAGRAM PARTS LIST FOR POWERCAT CHARGER PART# 390-2440 115 VAC / 60 HZ 36 VDC 36A �� 390-2443 S/O 7-244B 7-244HS 7-244F 7-244G 390-2440T 7-244C 7-244D 7-251D S/O S/O 7-244H 7-244L S/O �� 12-12 �� 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 �� CASE ASSEMBLY FOR 10/2 DC CORD TRANSFORMER ASSEMBLY CAPACITOR, 6 MFD, 660 VAC HEATSINK ASSEMBLY W/ 2 DIODES IN PARALLEL FUSE ASSEMBLY AMMETER, 50 AMP, W/ CORNER MO
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BATTERY CHRARGERS 390-2441 CHARGER PARTS LIST WIRING DIAGRAM PARTS LIST FOR POWERCAT CHARGER PART# 390-2441 115 VAC / 60 HZ 36 VDC 36 A �� 390-2443 S/O 7-244B 7-244HS 7-244F 7-244G 390-2440T 7-244C 7-244D 7-251D S/O S/O 7-244H 7-244L S/O �� 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 �� Magnum Service Manual V1.
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12 BATTERY CHARGERS BLANK THIS PAGE WAS INTENTIONALLY LEFT BLANK 12-14 Magnum Service Manual V1.
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APPENDIX A APPENDIX A METERS Meters come in varius style and conﬁgurations. They come in both analog (with a needle type indicator) and digital (with a digital readout). DO NOT use an analog meter on the controll systems of the machine or you can destroy the controller instantaneously. We recomened a high quality non auto ranging “High Imedance” Multi-Meter with an integral DC AMP clamp such as the Fluke 336. As a basic rule of thumb do not use a meter that cost less than $50.
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APPENDIX A Electrical Service Manual V4.
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A B C - M1 + 5 MOTOR, BRUSH DRIVE BLACK #57 - PINK #62 BLACK #17 DELTROL VALVE 1 2 MOTOR, BRUSH ACCTUATOR RED #57 M3 2 1 1 2 4 4 RED #49 4 1 2 M2 2 MOTOR, VACUUM 1 RELAY, VACUUM 5 RELAY, BRUSH BLACK #2 5 RED #59 CIRCUIT BREAKER, MAIN BLACK #2 + RED #26 3 ORANGE #16 RED #59 ORANGE #18 BATTERY 12 VOLT RED #5 - - BATTERY 12 VOLT GREEN #110 + PINK #62 RED #49 D 2 PINK #63 2 2 A-1 Date: Size A Title YELLOW #48 RED #26 RED #58 METER, HOUR H RED #3 METER,
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A B C D BLACK BLACK YELLOW 2 RED RED 5 6 4 3 1 BLACK ORANGE YELLOW BLACK SW2 3 2 BLACK BLACK 5 SWITCH, SOLUTION 1 BLUE PINK WHITE ORANGE ORANGE SWITCH, BRUSH DECK 5 2 6 4 3 1 RED BLACK SWITCH, REVERSE SW6 WHITE 2 3 2 SWITCH, POWER 1 RED RED YELLOW POT, THROTTLE GREEN 1 1 ORANGE SW SPST 2 SW SPST 2 CIRCUIT BREAKER 2 BLACK RED M2 4 1 2 YELLOW BLACK RED YELLOW RED RED PURPLE DIODE BLACK 1 1 YELLOW WHITE BLACK RED M2 M1 BAT + BAT - M1 1 BLA
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A B C 1 1 1 1 1 1 1 1 1 LED LED D9 LED D8 LED D7 LED D6 LED D5 LED D4 LED D3 LED D2 D1 M MG6 2 M RED A-3 5 RED Brush Motor Left 1 MG7 2 Brush Motor Right 1 BLACK 2 2 2 2 2 2 2 2 2 LED STRIP RED + + D BLACK - - RED PINK - M + 1 2 - M + 1 2 BLACK MG9 Drive Motor LS3 ORANGE BLACK + - M RED 2A BLACK BLACK 1 1 6A 1 2 BLACK YELLOW 2 2 4 BATTERY BT2 BATTERY BT1 RED 1 1 1 2 BLACK BLACK BLACK BLACK CIRCUIT BREAKER 2 CIRC
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A B C M 2 M 2 RED 5 Brush Motor Left 1 Brush Motor Right 1 + + RED PINK - M + + - M BLACK Drive Motor Actuator Motor WHITE + - M RED 2A BLACK BLACK 1 1 6A 1 2 BLACK YELLOW 2 2 4 BATTERY BT2 BATTERY BT1 RED 1 1 1 2 BLACK BLACK BLACK CIRCUIT BREAKER 2 BLACK BLACK BLACK GREEN BLACK DK BLUE 3 RED 6A BLACK - 2 DRIVE MOTOR 2 1 2 J2 BLACK + MAIN POWER Brush Motor J3 BUSS RELAY RED CIRCUIT BREAKER 1 87 87A YELLOW WHITE BLACK YELLOW PI
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APPENDIX B BLANK THIS PAGE WAS INTENTIONALLY LEFT BLANK Electrical Service Manual V4.
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A B 10 Ga. RED TO BRUSH MOTOR C 10 Ga. RED TO VACUUM MOTOR 1 RED #132 1 1 5 SWITCH, SPRAY JET 10 Ga. RED 10 Ga. RED CONNECTOR, BODY MOLEX 12 PIN RED #182 RED #183 CIRCUIT BREAKER, BRUSH 2 CIRCUIT BREAKER, VACUUM 2 GREEN #107 RED #224 YELLOW #26 H/V 4 RED #35 BLACK #184 BLACK #72 WHITE #131 CONNECTOR, COMMAND MOLEX 12 PIN PINK #130 10 Ga. RED RED #132 RED #298 RED #182 10 Ga. RED 10 Ga. RED BLACK #72 WHITE #131 PINK #130 1 2 4 1 2 4 BLACK #184 RELAY, BRUSH 5 10 Ga.
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A B C D - MOTOR, BRUSH ACCTUATOR + - M3 - M2 + - M1 + 1 4 10 Ga. BLACK 10 Ga. BLACK 5 10 Ga. RED 3 BLACK #184 BLACK #184 BLACK #72 ORANGE #71 RED #183 WHITE #131 WHITE #131 RED #183 PINK #130 PINK #130 SOLUTION, SOLENOID 1 2 BT3 A-7 Date: Size A Title 2 Tuesday, December 05, 2006 Sheet 1 1 of 1 Rev 1.
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A B 5 2 6 4 3 1 2 BLACK #23 BLACK #23 4 RED #27 S5 SW SPDT 4 5 6 1 2 3 MOLEX 14 PIN 1 2 3 4 5 6 7 RED #182 WHITE #131 BLACK #184 CONNECTOR, COMMAND MOLEX 12 PIN YELLOW #201 MOLEX 6 PIN 8 9 10 11 12 13 14 RED/WHT #220 RED #20 GREEN #221 BLACK/WHT #243 RED/WHT #241 RED #183 CONNECTOR, BODY MOLEX 12 PIN SWITCH, SPRAY JET 1 RED #182 SWITCH, MAIN POWER 2 1 SWITCH, REVERSE 5 2 BLACK 22 GAUGE RED 22 GAUGE 3 POT, SOLUTION 2 ORANGE #243 ORANGE #242 MOLEX 3 PIN WHITE #131
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A B C D - M4 + 1 MG4 MOTOR, SPRAY JET MOTOR, BRUSH ACCTUATOR + - M3 - M2 + MOTOR, VACUUM 4 - M1 + 4 10 Ga. BLACK 5 10 Ga. RED 10 Ga. BLACK 3 BLACK #184 BLACK #184 SOLUTION, SOLENOID 1 2 RED #183 WHITE #131 WHITE #131 RED #183 PINK #130 BLACK #72 ORANGE #71 - M4 + PINK #130 10 Ga.
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A B C D 2 RED #202 RED #27 1 3 YELLOW YELLOW RED #183 5 SWITCH, PRUSH PRESSURE LOCK OUT 2 SWITCH, SPRAY JET 1 YELLOW #201 SWITCH, MAIN POWER 1 2 BLACK #233 BLACK #233 BLACK #233 5 2 1 6 4 3 BLACK #260 BLACK #233 SWITCH, REVERSE 1 POT, SPEED 3 CON2 - WHITE #234 BLACK #233 GREEN #232 BLACK #233 2 + 4 GREEN #232 BLACK #233 WHITE #234 TO BATTERIES TO BATTERIES YELLOW #28 BLACK #29 CON2 CON2 BLACK #260 RED/WHT #220 WHITE #261 GREEN #221 WHITE #234 BLACK #233 GREEN #2
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A B C 75A ANDERSEN 75A ANDERSEN 5 1 2 1 2 MOTOR, BRUSH WHITE #131 PINK #130 MOTOR, TRACTION RED #183 4 MOTOR, SPRAY JET BLACK #184 MOTOR, DECK ACTUATOR MOTOR, BRUSH 4 TO CONTROLLER TO CONTROLLER MOTOR, VACUUM 1 2 1 2 1 2 TO CONTROLLER TO CONTROLLER 1 2 1 2 1 2 Electrical Service Manual V4.
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A B C 1 2 ORANGE #79 ORANGE #79 BLACK #78 BLACK #78 BLACK #78 ORANGE #79 2 1 2 3 5 MOLEX 3 PIN MOLEX 6 PIN 1 2 SWITCH, PAGE 1 HORN, HIGH VACUUM ORANGE #79 BLACK #78 D YELLOW #60 GREEN #11 GREEN #11 1 2 3 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 MOLEX 6 PIN 4 5 6 YELLOW #60 YELLOW #64 MAIN KEY SWITCH MOLEX 14 PIN MOLEX 16 PIN YELLOW #64 RED #56 RED #3 SWITCH, BRUSH PRESSURE 1 2 3 BLACK #57 4 5 6 RED #56 BLACK #57 RED #65 ORANGE #58 6 4 6
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A B C 1 2 PARKING BRAKE RL4 BLACK #50 PURPLE #51 5 BLACK #50 PURPLE #51 2 H 1 2 BLUE BLACK #36 PURPLE #51 RED #30 RED #35 MOLEX 14 PIN WHITE #37 BLACK #38 GREEN #39 TO CONTROLLER TO CONTROLLER CHARGING PLUG FRONT DRIVE DELTROL VALVE 1 2 BLACK #46 HOUR METER RED #45 BLACK #38 WHITE #37 HORN SWITCH BACK UP ALARM 1 2 HORN 1 2 SWITCH, CHARGER INTERLOCK BLUE #47 BLUE #47 2 1 WHITE #37 BLACK #38 HEAD LIGHT BLUE #55 BLACK #58 BLUE #55 BLACK #57 BLACK #46 RED #45 BLACK #46 R
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A B C 5 LAMP LP1 J10 CON2 + LS5 SPEAKER 4 ORANGE #79 BLACK #78 - CONTROLLER J14 CON2 J13 CON2 1 2 4 BLACK #78 BLACK 10 Gauge RED 10 Gauge BLACK #78 ORANGE #25 ORANGE #25 D 5 1 2 RED 10 Gauge BLACK 10 Gauge 1 2 ORANGE #79 BLACK #82 3 3 BLACK #78 P13 MOLEX 20 PIN RED #26 VACUUM SWITCH BLACK 10 Gauge 2 Tuesday, December 05, 2006 Document Number 000-000 Sheet 250 High Vacuum Shut Off Date: Size A 1 1 VAC MOTOR MG14 1 1 of 1 Rev 1.
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APPENDIX B BLANK THIS PAGE WAS INTENTIONALLY LEFT BLANK Electrical Service Manual V4.
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WHITE 5 6 3 4 2 1 1 9 8 16 C.R. MAIN #1 RECHARGE SAFETY SWITCH RED BLACK WHITE RED RED 16 PIN MOLEX RED DIODE MAIN RELAY BLACK 5K POT WHITE D RE FWD /REV SWITCH DIODE BLU 50 AMP BREAKER 200 AMP MAIN BREAKER RED A-16 E GREEN RED 50 RED BLUE YELLOW BA2 BLACK 87 85 86 RELAY 87A HELLA 30 M- CURTIS 1227 B+ 24 VOLTS BLUE BLACK RED NO. 2 RELAY BLACK BLACK BLACK MOTOR TRACTION BRAKE SOL.
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#2 PEDAL RELAY RED GREEN 15 AMP POSITIVE BUSS BREAKER (OPTIONS) BREAKER 15 AMP KEY SWITCH RED RED 4 5 6 2 3 85 1 RED 30 WHITE 87 WHITE WHITE DIODE BRIDGE +REVERSE 6 3 4 5 - GREEN RED BLACK 25 OR 50 AMP BREAKER 2 1 WHITE BLACK CURTIS PIN #13 BLUE RED VAC DIODE BRIDGE SQUEEGEE SWITCH WHITE + VAC RELAY COIL FWD/REV SWITCH HELLA 86 WHITE VAC SWITCH VAC C.H.
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RED 15 AMP POSITIVE BUSS BREAKER KEY SWITCH RED A-18 WHITE RED 30 HELLA 87 YELLOW RED 6 5 2 3 4 BLUE 1 6 AMP BREAKER BLUE RED SCRUB SWITCH SCRUBHEAD LIMIT SWITCH NO.
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RED ACCESSORY CONNECTOR RED 50 BLACK (OPTION) 15 AMP BREAKER RED KEY SWITCH PUMP HORN RED RED RED YELLOW HORN BUTTON HOUR METER RED RED RED 2 4 2 BLACK FLOJET SOLUTION SWITCH RED 1 BATTERY RED 3 87 15 AMP BREAKER POSITIVE BUSS RED 1 #12 RELAY A 30 PUMP SWITCH RED RED MAIN BREAKER 200 AMP 5 6 2 3 BLACK 4 5 AMP CARTRIDGE FUSE 1 RED RED BLACK YELLOW BLACK HEAD LIGHT HIGH RECOVERY LIGHT RED AMBER LOW SOLUTION LIGHT FWD/REV SWITCH RECOVERY SWITCH ORANGE
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A B C 1 2 LCD DISPLAY 1 2 3 MOLEX 3 PIN MOLEX 6 PIN 1 2 YELLOW #64 YELLOW #27 ORANGE #25 MAIN KEY SWITCH SW2 5 1 2 3 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 MOLEX 14 PIN 8 9 10 11 12 13 14 9 10 11 12 13 14 15 16 MOLEX 16 PIN MOLEX 6 PIN 4 5 6 RED #65 RED #3 RED #56 BLACK #57 BLACK #57 BLACK #57 RED #56 BRUSH PRESSURE SW9 BLACK #6 YELLOW #27 RED #56 PINK #62 SW1 PAGE SWITCH YELLOW #60 SQUEEGEE SWITCH RED #56 RED #6 SOLUTION POT BLACK #63 R1 RED #56 SCRUB SWITCH GREEN #10 PI
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A B 5 BLUE #14 WHITE #14 1 2 RED #14 BLACK #14 A-21 2 1 2 BLUE #55 BLACK #54 PAGE SWITCH BLACK #50 RESISTOR TO CONTROLLER TO CONTROLLER RED #26 RED #36 RED #28 RED #30 GREEN #34 PURPLE #32 GREEN MOLEX 20 PIN ORANGE #25 YELLOW #27 BLACK #29 BLACK #35 WHITE BLACK BLACK #33 BLACK #31 BLUE #55 ORANGE #53 PURPLE #51 BLACK #49 BLUE #47 RED #45 PINK #43 GREEN #41 ORANGE #40 MOLEX 16 PIN WHITE #42 WHITE #44 BLACK #46 BLACK #52 BLACK #50 BLACK #54 50A ANDERSON (WHITE) BLACK #46 HOUR METER H
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A B C 1 2 BLACK #76 1 2 BLACK #75 2 2 1 2 3 5 MOLEX 3 PIN MOLEX 6 PIN 1 2 SWITCH, PAGE 1 RESISTOR 1 YELLOW #60 GREEN #11 GREEN #11 RESISTOR 2 1 DS2 LAMP 1 2 3 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 MOLEX 6 PIN 4 5 6 YELLOW #60 YELLOW #64 MAIN KEY SWITCH BLACK #76 BLACK #75 RED #16 BLACK #16 MOLEX 14 PIN MOLEX 16 PIN YELLOW #64 RED #56 RED #3 SWITCH, BRUSH PRESSURE 1 2 3 BLACK #57 4 5 6 RED #56 BLACK #57 RED #65 D ORANGE #25 YELLOW #2
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A B C BLUE #14 BLACK #14 BLACK #14 1 2 WHITE #14 1 5 BLUE #14 WHITE #14 RED #14 BLACK #14 A-23 2 1 2 BLACK #50 RESISTOR TO CONTROLLER TO CONTROLLER RED #26 RED #36 RED #28 RED #30 GREEN #34 PURPLE #32 GREEN MOLEX 20 PIN WHITE BLACK BLACK #33 BLACK #31 ORANGE #25 YELLOW #27 BLACK #29 BLACK #29 BLUE #55 ORANGE #53 PURPLE #51 BLACK #49 BLUE #47 RED #45 PINK #43 GREEN #41 ORANGE #40 MOLEX 16 PIN RED #30 PAGE SWITCH BACK UP ALARM 1 2 WHITE 42 WHITE #44 BLACK #46 BLACK #52 BLACK #50 BLA
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A B C 1 2 5 LCD DISPLAY 1 2 3 MOLEX 3 PIN MOLEX 6 PIN 1 2 MAIN KEY SWITCH SW2 BLUE #133 BLACK #134 RED #202 BLACK #134 BLUE #133 YELLOW #201 1 2 1 2 3 BLACK #303 RED #300 1 2 3 4 5 6 7 MOLEX 14 PIN 8 9 10 11 12 13 14 RED/WHT #294 GREEN #295 1 2 3 4 5 6 7 8 MOLEX 16 PIN 9 10 11 12 13 14 15 16 RED #27 6 4 3 1 5 2 SWITCH, PAGE RESISTOR METER, AMP A M1 BLACK #301 RED #300 FILTER ALARM RED #202 YELLOW #201 MOLEX 6 PIN 4 5 6 RED #300 RED #300 BLACK #301 BLACK #301 RED #
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A B C D 5 BLUE #67 BLACK #66 RED 10 GAUGE BLACK 10 GAUGE BLUE #67 BLACK #66 BLACK #171 BLACK #171 RED 10 GAUGE BLACK 10 GAUGE BLUE #67 BLACK #66 2 A-25 TO CONTROLLER TO CONTROLLER TO CONTROLER TO CONTROLLER GREEN #297 BLACK #173 WHITE #131 BLACK #134 BLACK GREEN BLACK #178 MOLEX 20 PIN PINK #130 BLUE #133 WHITE RED #172 BLACK #173 4 BLACK/WHT #296 GREEN #297 HEAD LIGHT RED #175 GREEN BLACK RED #175 BLACK #174 BLACK #174 HOUR METER H BLACK #174 SWITCH, HORN BACK UP ALARM 1 2 2
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B APPENDIX B BLANK THIS PAGE WAS INTENTIONALLY LEFT BLANK A-26 Electrical Service Manual V4.
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INDEX Electrical Service Manual V4.
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INDEX IND-2 INDEX Electrical Service Manual V4.
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INDEX Electrical Service Manual V4.
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INDEX Electrical Service Manual V4.