MACHINE OPERATION

Pre-cleaning Check List:

1. Check battery condition gauge on the Central Command II LCD screen. Make sure batteries are fully charged before using.

2. Check the condition of pads or brushes.

3. Check the condition of the squeegee blades.

4. Transport the machine to the filling station. Raise the scrub head and squeegee when transporting.

5. Turn machine off.

6. Open solution fill door on the top of the tank and fill the tank up with clean water or "approved" detergent. For help call Powercat Solutions at 414-745-9337. Foam in the recovery tank is usually an indication of excessive soap.

7. Add cleaning chemical. Use the proper dilution ratio indicated on the bottle.

Note: Use only nonflammable commercial cleaning chemicals.

One Pass Scrubbing:

Steps: See picture below

1. Turn machine on with the key switch.

2. Lower squeegee by pressing the switch.

3. Lower scrub head to the floor, use the top half of the brush switch.

4. Adjust the solution +/- to the desired setting. (Start at half way)

5. Begin scrubbing by depressing the foot pedal slowly and then to the speed required. (Not shown)

6. Start scrubbing at the #1 or # 2 marks, do not use the #4 or #5 marks without management's approval.

7. To operate machine in reverse, simply switch the reverse switch to the reverse position, back up alarm may sound and your reverse speed is set to roughly 70% of forward.

8. To stop the machine, let off of the foot pedal and the machine will stop automatically. (Not shown)

9. Depressing the "uni-touch" button activates the solution, vacuum, and brushes simultaneously.

Double Scrubbing:

Steps: See picture below

1. Turn machine on with the key switch.

2. Lower scrub head to the floor, use the top half of the brush switch.

3. Adjust the solution to the desired setting. (Set half way)

4. Begin scrubbing by depressing the foot pedal slowly and then to the speed required. (Not shown)

5. Start scrubbing with the brush pressure at 1 or 2 marks, do not use the 4 or 5 marks without management's approval.

6. To operate machine in reverse, simply switch the reverse switch to the reverse position, back up alarm may sound and your reverse speed is set to roughly 70% of forward.

7. To stop the machine, let off of the foot pedal, and the machine will stop automatically. (Not shown)

Vac Only Scrubbing:

Steps: See picture below

1. Turn machine on with the key switch.

2. Lower squeegee by pressing the switch.

3. Begin vacuuming by depressing the foot pedal slowly and then to the speed required. (Not shown)

4. To operate machine in reverse, simply switch the reverse switch to the reverse position, back up alarm may sound and your reverse speed is set to roughly 70% of forward.

5. To stop the machine, let off of the foot pedal, and the machine will stop automatically. (Not shown)

Operating Hints:

1. Observe the amount of solution the machine is dispensing on the floor and adjust to the desired flow. To increase the solution flow rate, push solution switch (A) +, to decrease push solution switch (A) -. (See picture below)

2. Keep an eye on the "red" recovery full light (B) to make sure there is not foamy buildup in the recovery tank. If excess foam begins to develop, pour a recommended foam control solution into the recovery tank. (See picture below)

3. Always operate at lower speeds when scrubbing around walls and objects. You should reduce the speed, to maintain control when turning.

4. If squeegee starts to streak, raise and wipe the blades with a clean cloth. If the problem continues, check the blades for wear or damage, and rotate if needed.

5. Change or turn over pads when dirty. Rotate the scrub brushes every week.

6. Stay clear of objects protruding from the floor, such as sockets, grates, for they will damage the pads and squeegee blades.

7. During brief stops you should turn everything off, the brushes and solution will automatically stop when the foot pedal is released.

8. Always keep an eye on your gauges. They let you know the status of a particular system at a glance. If your battery gauge is reading low, you must stop immediately, and recharge. Running the batteries dead, will result in damage to the batteries.

9. When you run out of solution, raise the brushes, and continue to vacuum the remaining water until it is consumed. The "yellow" low solution light (C) will light up when the solution is low and the sight tube on the back of the tank tells you how much solution is left in the tank, (See picture above)

10. When you are ready to stop, pick up the brushes, turn off the solution switch, pick up the squeegee, and drive the machine back to the charging area.

Drain Solution Tank:

To drain left over cleaning solution from the solution tank, perform the following steps.

1. Pull the clear sight tube/drain hose (A) off barbed fitting. (See picture below)

2. Rinse out tank and solution flow system with clean water.

Drain Recovery Tank:

Always empty recovery tank when refilling the solution tank. To drain the recovery tank, perform the following steps.

1. Remove drain hose "B" and unscrew cap. Open the top "recovery access lid" and flush out with fresh water to keep tank clean. (See picture below)

2. Remove cap and begin draining, squeeze "C" to control flow. (See picture below)

It is the customer’s responsibility to verify that discarded water is in compliance with local, state, and federal laws. DO NOT DRAIN INTO "STORM DRAINS”!

3. Open the top "recovery tank lid" and flush out with fresh water to keep tank clean. Rinse the recovery tank after every use. This will prevent heavy build up on the bottom of the tank, foul odors and clogging of the drain hose. Empty "Drain Saver".

4. Once tank is empty, put the cap back on and place hose back on hook.

Override Parking Brake:

The parking brake must be released "prior" to attempting to "push/pull" the machine manually. Perform the following steps in any order.

1. Disconnect both positive and negative leads (1 & 2) from the traction motor. (See picture below)

2. Turn wing nut (3) clockwise to release the parking brake. (See picture below)

Recovery Tank Float Shut-Off:

When water is no longer being vacuumed from the floor and the vacuum fan is operating, the ball float has engaged the red high recovery light (1) will come on. (See picture below)

The vacuum motor will not vacuum water with recovery tank full. The recovery tank must be drained

1. The float shut-off (2) screen can be cleaned in or out of the machine.

2. To clean the float shut-off while it is inside the machine wipe material off screen then rinse. Check that the ball is also clean and moves freely.

3. To remove the float shut-off, remove the white clamp (3) grasp the screen with one hand and pull down to remove.

4. Screens, gaskets, and shutoff balls must be in place.

Recovery Tank Drain Saver:

The recovery tank drain saver will help prevent the drain from becoming clogged with debris.

1. The drain saver screen should be emptied and cleaned after you drain the tank.

2. To clean, pull hose (4) out of drain saver and remove screen. Empty screen into trash, wipe material off screen and then rinse the screen.

3. When finished place screen back into the recovery tank and re-insert hose into screen (5).

4. The screen saver must always be in place when the machine is in use to prevent clogging of drain.

Standard Battery Charging:

Charger Specifications:

DC Output voltage of 36 volts. (Standard)

Output current of 36 amps max. (Standard)

AC Input voltage of 110 volts/60 Hz. (Standard)

Automatic shut off circuit.

Made for deep cycle batteries.

Danger: always charge batteries in a well ventilated area. Batteries emit hydrogen gas. Explosion or fire can result. Keep sparks and flame away. Shield eyes when servicing batteries and avoid contact with battery acid. Leave access panel open when charging!

Standard Charger

Caution: the following instructions are intended for the 36v charger supplied with the machine. Do not use any non OEM charger with this machine.

1. Transport machine to a well ventilated area for charging.

2. Turn the machine off.

3. Tip the operator’s seat to expose batteries. (See picture below)

Caution: (always wear eye protection when batteries are exposed)

4. Check the water level in each battery. Do not charge the machine unless the water is slightly higher than the plates. If needed, add enough distilled water to 1/2” above the plates. Do not over fill. Batteries can overflow during charging. Replace caps before charging.

5. With the grey (50) charger plug disconnected from the machine, plug the charger power cord into a grounded 110 volt standard wall outlet.

6. Connect the grey charger plug into the battery charging port (A) located on the seat pedestal.

7. The charger will automatically begin charging, and automatically shut off when fully charged (Check gauge)

8. After the charger has turned off, unplug the grey charger plug from the machine and disconnect the charger from the wall outlet.

9. Recheck the cell level after charging. If needed, add distilled water up to the correct level. Be certain to replace the caps securely and to wipe off the top of the batteries.

Optional Battery Charging:

Charger Specifications

Output voltage of 36 volts. (optional)

Output current of 30 amps max.

Input voltage of 110 volts/60 Hz.

Automatic shut off circuit.

Made for deep cycle batteries, wet or sealed.

On-Board Charger

Caution: the following instructions are intended for the 36v "optional" on-board charger.

1. Transport machine to a well ventilated area for charging.

2. Turn the machine off.

3. Tip the operator’s seat to expose batteries. Caution: (always wear eye protection when batteries are exposed)

5. Plug the extension cord into a grounded 110 volt/60 Hz standard wall outlet & flip switch.

NOTE: MUST HAVE 20 AMP SERVICE.

6. The charger will automatically begin charging, and automatically shut off when fully charged (Check gauge)

7. After the charger has turned off, unplug the extension cord from the machine and disconnect from the wall outlet.

8. Recheck the cell level after charging. If needed, add distilled water up to the correct level. Be certain to replace the caps securely and to wipe off the top of the batteries.

Changing Batteries:

Stop machine in a clean area next to the charger. Turn off machine.

For safety: Before leaving or servicing the machine; stop on level surface, turn off machine and remove key. Use eye protection.

1. Tip the operator’s seat to expose batteries

2. Disconnect main battery cables from machine.

3. Use the proper size wrench to disconnect main ground wire first and secure cable terminal away from batteries.

4. Disconnect main positive lead and secure cable and remove one at a time.

5. Loosen both terminals on each jumper cable and remove one at a time, and place away from machine.

6. Prepare a suitable site to place the batteries, store on a wood pallet, not on concrete.

7. Attach suitable battery lifting device and lift batteries from the machine

Warning!

Batteries are a possible environmental hazard & extremely heavy. Consult your battery supplier for safe removal & disposal methods. Use a hoist; batteries are heavy use caution!

Note: orientation of the positive and negative posts is critical for cables to reach.

Do not lift from battery posts, which cannot support the weight. (See below)

Figure 6 - Front of Machine to the Right

Side Broom System:

1. Flip side broom switch (A) up to lower and engage broom. (See picture below)

2. To adjust side broom height, loosen locking nut located behind screw head (B) of screw that is in front of scrub deck just inside the side wall of frame on each side of the machine. Use 1/2" wrench to loosen locking nut. (See picture below)

3. Turn adjustment screw (B) counter-clockwise (loosens) to lower side brooms. Turn screw clock-wise (tightens) to raise side brooms.

4. Retighten locking nut.

5. Side broom adjustment slot (C). (See picture below)

6. Picture below shows brooms to high.

7. Picture below shows brooms to low.

8. Picture below shows brooms just right.

MACHINE OPTIONS

Overhead Guard:

1. Your machine may be equipped with an "optional" "Overhead Guard" (A) that helps protect the operator from falling objects that are above the operators head. (See picture below)

MACHINE OPTIONS

Overhead Guard:

1. Your machine may be equipped with an "optional" "Overhead Guard" (A) that helps protect the operator from falling objects that are above the operators head. (See picture below)

HD Side Doors:

1. Your machine may be equipped with "optional" "Heavy Duty Side Doors" (C) that helps protect the machine's scrub deck from collision damage. (See picture below)

Non-Marking Tires:

1. Your machine may be equipped with non marking (D) tires, which may have reduced traction on some floors (See picture above)

Industrial Battery:

1. Your machine may be equipped with optional “Heavy Duty Industrial Battery” and charger that provides longer machine runtime. (See picture below)

Pre-treat Soap:

1. Your machine may be equipped with an optional “Pre-treat Soap” (B). It helps remove stains that a normal detergent cannot get out of the floor (See picture below)

Spray Hose:

(A) Your machine may be equipped with "optional" Spray hose. Permits cleaning in remote areas. (See picture below)

Stainless Recovery Tank:

(B) Your machine may be equipped with "optional" stainless steel recovery tank. (See picture above)

Diffuser Exhaust:

(C) Your machine may be equipped with "optional" diffuser exhaust which helps reduce noise and assist in drying the floor by dispersing air evenly to the floor. (See picture above)

Vac Wand:

(D) Your machine may be equipped with "optional" Vacuum wand which allows you to vacuum up water in hard to reach places. (See picture below)

Stainless Solution Tank:

(E) Your machine may be equipped with "optional" Stainless steel Solution tank. (See picture above)

Figure 7 - Control Box

On-Board Soap:

1. Switch toggle switch up once for normal soap distribution and up twice for heavy duty soap distribution. (See “A” in Figure 7)

Spray Hose:

1. Turn on spray jet pump using the toggle switch on the central command. (See Figure 7 Item "B")

2. Detach spray hose from back of machine and squeeze handle.

Vac Wand:

1. Detach vac hose from squeegee and attach it to the vac wand. (See picture below)

2. Turn on vac motors using the toggle switch on the central command. (See Figure 7 Item "C")

MAINTENANCE

Daily Maintenance:

1. Remove and clean pads or brushes. Never use soiled pads when cleaning. Replace pads when they become packed with residue.

2. Remove and clean debris from the float shut‐off screen and drain saver located inside the recovery tank.

3. Drain and rinse tanks thoroughly

4. Inspect vacuum hose for any objects obstructing the air flow.

5. Raise squeegee and wipe blades with a clean cloth. Store squeegee in the raised position to prevent damage or setting of the blades.

6. Wipe down machine if needed. Use a nonabrasive, non solvent cleaner, or a clean damp cloth.

7. Recharge the batteries if needed.

Weekly Maintenance:

1. Check battery water level in each cell of the batteries, and fill as needed. Always use distilled water to refill batteries. Batteries should be filled approximately 3/4" to 1" above the plates. Overfilling will cause the batteries to leak during charging. The charging process creates gas bubbles inside the battery, which effectively increases the volume of the electrolyte.

2. Clean battery tops to prevent corrosion.

3. Rotate brushes. Rotate the left to the right and right to left. For cylindrical models rotate from front to back, or end to end if using different materials.

4. Drain and rinse tanks thoroughly. To thoroughly flush out any solution chemicals in solution line and valves, refill solution tank with a few gallons of warm clean water and run machine until tank is empty.

Monthly Maintenance:

1. Check scrub head and squeegee lifting cables for wear and spring tension.

2. Check machine for water leaks and loose nuts and bolts.

3. Check to see if battery cables are tightened (Tighten if needed)

4. Check parking brake

Yearly Maintenance:

1. Call your local dealer for yearly maintenance

Storing Machine:

1. Make sure to flush the tanks out completely. To thoroughly flush out any solution chemicals in solution line and valves, refill solution tank with a few gallons of warm clean water and run machine until tank is empty.

2. Open the recovery tank lid to promote air circulation.

3. Raise brushes and squeegee.

Checking Battery Specific Gravity:

Use a hydrometer to check the battery specific gravity.

Checking Gravity

A. Hydrometer

B. Battery

Note: Do not take readings immediately after adding distilled water, if water and acid are not thoroughly mixed, the reading may not be accurate.

Check the hydrometer against this chart:

Specific Gravity @ 80° F (27°C)	Battery Condition
1.265	100% CHARGED
1.225	75% CHARGED
1.190	50% CHARGED
1.155	25% CHARGED
1.120	DISCHARGED

Note: if the readings are taken when the battery electrolyte is any temperature other than 80vF (27vC), the reading must be temperature corrected.

To find the corrected specific gravity reading when the temperature of the battery electrolyte is other than 80vF (27vC): add (+) to the specific gravity reading 0.004 (4 points), for each 10vF (6vC) above 80v (27vC). Subtract (‐) from the specific reading 0.004 (4 points), for each 10vF (6vC) below 80vF (27vC).

Preventative Maintenance Records:

CUSTOMER INFORMATION
CUSTOMER
ADDRESS
CITY			STATE		ZIP CODE

MACHINE INFORMATION
MODEL #			SERIAL #
WORK ORDER#			HOUR METER:

BATTERY CONDITION		Cell #1	Cell #2	Cell #3	Cell #4		Cell #5	Cell #6
Battery # 1 Hydrometer
Battery # 1 Water Condition
Battery # 2 Hydrometer
Battery # 2 Water condition
Battery # 3 Hydrometer
Battery # 3 Water Condition
Battery # 4 Hydrometer
Battery # 4 Water condition

Clean Battery tops. Check Battery Cable and Terminal Condition
NOTES:

BRUSH CONDITION
Scrub Brush Fiber Length		Rota ted Brushes
Brush Drive Sockets	Good Worn Needs Replacement
Drive Hubs	Good Worn Needs Replacement
Side Broom Condition	Good Worn Needs Replacement Rotated Side to Side

CHECK OPERATION AND CONDITION OF:		IN SPEC	REPAIR			PROBLEM
Steering wheel Tilt Mechanism
Key Switch
Horn
Head Light
LCD Display
Page Button
Brush Pressure Button
Brush Pressure Managers Lock Out
Foot Pedal
Reverse Switch
Back Up Alarm
One Touch Switch
Brush Switch
Solution Potentiometer
Solution Solenoid
Solution Drain Valve
Low Solution Light
Brush Deck Lift System
Brush Motors & Motor Brushes
Vacuum Switch
Vacuum Motor performance
Off-Board Vac Switch
Squeegee Lift System
Squeegee Adjustment
Squeegee Blades
High Recovery Light
High Recovery Alarm
Drain Hose and Plug
Side Broom Operation
Spray Jet Switch
Spray Jet Pump, Hose & Nozzle
Strobe Light
Battery Charger Connectors
Battery Charger

CLEAN AND/OR LUBRICATE	IN SPEC	REPAIR	PROBLEM
Solution Filter
Squeegee Pivot Points & Knobs
Scrub Deck Linkage
Squeegee Knob Threads
Squeegee Pivot Points
Brush Head Pivot Points

VISUALLY INSPECT	IN SPEC	REPAIR	PROBLEM
Solution Tank Condition
Recovery Tank & Lid Condition
Drain Saver
Vacuum Float
Vacuum Motor Brushes
Vacuum Hoses
Vacuum Filter
Solution Hoses
Squeegee Tool and Throat
Squeegee Blades
Blade retainers & Hardware
Squeegee Wheels
Brush Skirts
Brush Motor Brushes
Brush or Pa d Driver Condition
Drive Wheel Condition
Caster Condition

Technician's Name: ___________________________

Technician's Signature: ___________________________ Date:_______________

Customer's Name: ___________________________

Customer's Signature: ___________________________ Date:_______________

TROUBLESHOOTING

Troubleshooting Central Command:

1. 7601 and 7602 Error. Scrub deck current over load. This can occur when driving over a bump in the floor. To restart, turn off the key and turn it on again. To avoid this error, either slow down on bumpy parts of the floor, or reduce down pressure on the pads.

2. 1500 Error. There is an open in the parking brake circuit. Check the parking brake wiring and the parking brake coil to find the open circuit.

3. 7700, 7701, 7702, and 7703 Error. The vacuum motor has exceeded their authorized power limits. Turn off key and turn on again to clear.

4. BOOST ON Allows front wheel drive to draw more power when needed to climb ramps for 30 seconds.

5. Throttle error. You pressed the foot pedal before turning on the key. Turn off the key and try again, leaving foot off of the pedal.

6. 2C00 and 2C01 error. Low voltage warning. Voltage has dropped down below the minimum required to operate the machine. If you wait a few minutes, the batteries may come up in voltage, allowing you to drive very slowly to the recharge station. If not, you will have to release the parking brake (on the front wheel, pull lever toward the front of the machine to release) and push the machine to recharging station. You must disconnect the traction motor! (+ cable first)

7. 7802 error. The traction motor pulled excessive current perhaps running a ramp for more than the 60 seconds allowing for this. Turn off the key, turn on again, and continue. You should not use this machine to climb ramps so steep and so long that this code comes up repeatedly, or you could overheat the traction motor.

9. All other error codes. Turn off the key, and disconnect the positive battery cable from the batteries for more than one minute (the time is needed to drain the controller on-board capacitor). Reconnect cables, being sure that it is tight. Too loose and you will burn battery. If you over tighten the cables you can damage the battery lead terminal. Try again.

10. If the problems cannot be solved by any of this solution, call your local dealer service department.

Troubleshooting Central Command II V4

Code	Fault Description	Course of Correction
0700	Bias Voltage Error High reference signal is grounded	Bias Voltage Error High reference signal is grounded
0701	Mid Rail Voltage High
0702	Mid Rail Bias Voltage High
0704	12V supply failure
0705	2.5V reference error
0706	High reference ground fault	5 Volt reference is Contacting 0 Volt Reference
0810	Throttle High reference error	For all Throttle Diagnostic Codes
0811	Throttle Max Wiper Difference Error	Check throttle wiring for shorts or opens. Repair or replace as necessary
0812	Throttle Max Pull Down Difference Error	If diagnostic code is not cleared, then replace the throttle potentiometer
0813	Throttle Max Pull Safe Difference Error
0814	Throttle Reference Error
0815	Throttle Lo Reference Error
0816	Throttle Hi Reference ISO Error
0817	Throttle Lo Reference ISO Error
0818	Throttle Error: Both have Readings
0A01	Power down error	Check the wiring to the main power switch. This code indicates rapid power cycling
1310	Excessive Current Trip	Current Draw on Control exceeds maximum limit of 250 amps Resistance in the machine’s Main Breaker and/or battery cable to control Gives a false reading to the controller.
1311	Brush head actuator, excessive current	Device connected to the brush head actuator has exceeded maximum limit of 21 amps surge value and 7 amps continuous. Check that the arms are not too tight (torque = 25 inch lbs, almost finger loose). Check that actuator system is not binding
1312	Squeegee actuator, excessive current	Device connected to squeegee actuator (on riders) has exceeded max limit of 21 amps surge value and 7 amps continuous load. Check that the arms are not too tight (torque = 25 inch lbs, almost finger loose). Check that actuator system is not binding.
1313	Solution valve circuit, excessive current	Current exceeded seven amps max. Check valve operation. Coil may be corroded, or short in wires.
1314	Soft Aux 4 Over current Occurred	Aux 4 is not used by us at this time.
1318	Soft Brake light Over current Occurred	Brake light circuit not used by us at this time.
131C	Backup Alarm Over current occurred	Backup alarm drew more than 2 amps max allowed. Check inline resistor on some models. If resistor is bad, remove it, and put piece of duct tape over speaker of alarm. (Reverse EMF from the echo is causing the problem)
1321	Aux 1 (Brush Actuator) Over current 2 Occurred	Brush actuator exceeded 12 amps for less than 0.1 sec. See notes for 1311
1322	Aux 2 (Squeegee Actuator) Over current 2 Occurred	Squeegee actuator exceeded 12 amps for less than 0.1 sec. See notes for 1312
1400	Bridge Fault 1 - Brush or traction motor not in correct voltage range.	Possible short between B+ and the high amperage outputs
1401	Bridge Fault 2 - Voltage difference on traction bridge too great
1402	Brush Bridge Fault - Battery/Brush bridge voltage difference too great
1411	Brush actuator positive wire is shorting	Find appropriate wire and remove short.
1412	Brush actuator negative wire is shorting	Find appropriate wire and remove short.
1413	Squeegee actuator positive wire is shorting	Find appropriate wire and remove short.
1414	Squeegee actuator negative wire is shorting	Find appropriate wire and remove short.
1500	Brake Fault - Solenoid brake circuit is open	Parking Brake is disconnected or coil of brake is open.
1501	Brake Fault - Solenoid brake circuit is shorted	Parking Brake coil or wiring is shorted.
1502	Brake Fault - Brake Over Current Error	Parking brake coil is shorted internally or wiring too it is shorted
1503	Solenoid brake driver fault
1504	Solenoid brake interlock fault
1507	Brake Over current	Parking Brake is drawing too much power. Check wiring and brake.
1600	High Battery Error	Battery voltage is too high. Batteries hooked up wrong, or still on charger.
1D02	Spec Change Trip	This is normal--comes up when you reprogram the control. Turn key off and on to reset the program.
1E03	Inhibit activated	Inhibit is power signal intended to turn off control. We don't use it.
1E04	Inhibit Activated 2	Inhibit is power signal intended to turn off control. We don't use it.
1E06	Inhibit Input Out of Range	Inhibit circuit voltage is too low or high to work. We don't use Inhibit.
2C00	Low Battery Error	Voltage in battery is too low (18 volts min on 24V system; 28V on 36V system)
2C01	Low Battery Error--2	Recharge the battery in either case. check voltage under load to see if bad
2C02	Battery lockout occurred	cell is pulling down voltage.
2C03	Battery Lockout occurred--2
2F01	Throttle Displaced Error	Pedal was pushed before key turned on. Not a problem. Restart machine.
3A00	Bad Program Settings	You reprogrammed the control with settings that are not authorized.
3100	Low bridge voltage	Probable short circuit of output device or wiring
3101	Traction bridge fault
3102	Brush/Vac bridge fault
3103	Waiting for bridge to charge
7000	Startup With Push Selected	Freewheel input signal selected at startup. Disconnect freewheel switch.
7001	Push Activated in Drive Mode	Freewheel input signal activated while driving. Disconnect freewheel switch. NOTE: As of this reading, we do not use Freewheel. This permits pushing machine more easily by disconnecting traction motor from control.
7500	Throttle Comms Time Out	Problem with LCD dash module or with wiring to it. Check and replace as necessary.
7501	LCD Module settings corrupt	Disconnect batteries and wait 2 minutes to reconnect
7600	Brush motor not connected	Check for open circuit
7601	Soft Brush Current Fold back	Too much load on brush motor. May be from hitting a bump or wire tangled in brush drive mechanism. Possible wiring or brush motor short.
7602	Soft Brush Current Foldback--2	Same as above.
7603	Soft Brush Current Foldback--3	Same as above.
7604	Brush Inhibit is on	We do not use Brush Inhibit at this time.
7605	Brush startup over current detection	You may have started brushes on carpet or rubber or other high resistance material. This may have stalled motor before actuator could react to lift brush head up. If chronic problem, call Factory to discuss reprogramming machine for application.
7700	Soft Vacuum Motor Disconnected Error	Check wiring to vac motor. On 390, check wiring to Hella relay for vac motor
7701	Vac Motor Current Fold back	Too much amp load on vac circuit. Check wiring. May come from picking up large column of water.
7702	Soft Vacuum Current Foldback--2	Same as above
7703	Soft Vacuum Current Foldback--3	Same as above
7800	Traction Motor Fault No. 1	Check traction motor wiring and connectors. Include connector at steering pivot under floor cover!
7801	Traction Motor Over current Error	Too much current due to bad motor or wiring to motor
7802	Soft Traction Motor in Fold back State	Traction motor being overloaded, or ramp climbing that took longer than 60 seconds. (Fold back means normal low amp setting to motor. There is one minute ramp climbing surge that may be 4 times as high as the fold back rate).
7803	Motor Line Voltages Instability Timeout	May be loose wire at motor or at control. Possible motor problem
7880	Traction Speed Input Out of Range	Throttle setting wrong for motor speed. Check throttle pot and wiring.
7900	Emergency Stop Error	Emergency Stop Button is Actuated when you try to move. Optional button.
7901	Soft Belly Button Actuated	Belly Button Switch activated. We don’t use this.
8000	Service Mode	Service Timer Limits have been reached. We don’t normally use them; they are a dealer option
9000	Brushes not fitted	Check brush deck to make sure brushes are on and on securely
0003	Possible terminal short in system	For all of these diagnostic codes:
0100		1. Turn off key switch and disconnect battery for two minutes, using your watch to measure time.
0204		2. When you reconnect the battery, you must see a spark. This shows the control’s on-board capacitor has been discharged and has been refilled.
0A01		3. Restore the battery connection. Make sure the battery cable is on tight before trying machine or you could burn battery posts and cable
0B02		4. Turn on machine. If diagnostic code still shows, then replace the control
1704
1705
1706

Troubleshooting:

Problem

Cause

Solution

No power, nothing operates

Faulty power switch

Batteries need charging

Faulty battery

Loose battery cable

Main circuit breaker tripped

Contact local servicing dealer

See charging batteries

Replace battery

Tighten loose cable

Wait 5 minutes for auto reset

Determine cause and correct

Brush motor(s) do not operate

Brush deck is not down

Foot pedal is not depressed

Brush circuit breaker tripped

Carbon brushes worn

Faulty brush motor or wires

Put brush deck down

Engage foot pedal

Wait 5 minutes for auto reset

Determine cause and correct

Contact local servicing dealer

Drive motor does not operate

Recharge switch misadjusted

Faulty speed controller or wires

Faulty drive motor

Faulty wiring

Carbon brushes worn

Contact local servicing dealer

Vacuum motor does not operate

Squeegee is in the up position

Faulty vacuum switch

Vacuum circuit breaker tripped

Faulty vacuum motor

Rotate squeegee lift lever down

Try operating "white” toggle

Wait 5 minutes for auto reset

Determine cause and correct

Contact local servicing dealer

Drive motor runs incorrectly

Faulty speed controller or wires

Faulty potentiometer

Loose wires

Contact local servicing dealer

Insufficient solution flow

Solution tank low

Flow knob turned down

Solution filter clogged

Solution line clogged

Solution valve clogged

Refill solution tank, drain recovery tank

Move lever to on

Remove cover and clean

Remove and blow out with compressed air

Remove cover and clean

No solution flow

No solution in tank

Solution valve off

Solution switch off

Solution screen clogged

Faulty solution solenoid

Faulty solution switch

Fill solution tank

Rotate lever to on

Turn solution switch on

Remove and clean screen

Contact local servicing dealer

Poor water recovery

Recovery tank is full

Ball/screen in recovery

Tank is clogged

Vacuum hose is clogged

Squeegee is clogged

Squeegee blade is worn

Faulty vacuum hose

Vacuum motor gasket torn

Tank gasket faulty

Drain plug loose

Vac motor faulty

Battery charge low

Empty recovery tank

Remove screen and clean

Remove debris

Rotate or replace blades

Contact local servicing dealer

Tighten lid

Contact local servicing dealer

Charge batteries overnight

Poor water recovery on turns

Wipers worn

Wipers chatter

Squeegee swing is binding

Incorrect squeegee size

Replace wiper material

Tighten pivot points

Contact local servicing dealer

Tires noisy

Bearing dry

Faulty hubs

Grease bearings

Contact local servicing dealer

Poor traction

Excessive brush pressure

Worn drive tire

Heavy soap concentration

Reduce pressure with switch

Replace tires

Contact local servicing dealer

Short run time

Batteries run down

Batteries still down

Batteries low on water

Batteries over cycled

Charge batteries twice

Contact local servicing dealer

Fill with distilled water to ¾” above the lead plates

Contact local servicing dealer

Battery Maintenance Guide

SAFETY:

Always wear protective clothing, gloves and goggles when handling batteries

If acid contacts your skin or eyes, flush with water immediately

Keep flames, sparks and metal objects away from batteries

Charge batteries in a well-ventilated area

To avoid short circuits do not lay objects on top of battery

Check that all cable connections to the terminal are properly tightened; connections that are too tight or too loose could result in post breakage, meltdown or fire

INSPECTION & CLEANING:

Keep batteries clean and dry from residue

Check that all vent caps are tight

Use a solution of baking soda and water to clean if there is acid residue on batteries or corrosion on the terminals

Protective spray or petroleum jelly should be applied to terminals to reduce corrosion

STORAGE:

Batteries should be fully charged prior to and during storage

Never store discharged batteries

Store batteries in a cool, dry place

Recharge batteries before putting them back into service

WATERING:

ADD WATER, NEVER ACID, TO CELLS (distilled water recommended)

DO NOT OVERWATER

Before charging the batteries, only add water if the plates are exposed. Add just enough water to cover the plates, and then charge the batteries. Once fully charged, add water to the proper level as indicated below

For fully charged standard deep cycle batteries, add water to level of 1/8" (3 mm) below bottom of vent well (see diagram A)

For fully charged Plus Series batteries, add water to the maximum water level indicator (see diagram B)

After watering, secure vent caps back on batteries

Diagram A

Diagram B

Maximum Battery Size for Replacement
Standard 245AH Batteries			Upgraded 325AH Batteries
Dimensions Inches (mm)			Dimensions Inches (mm)
Length	Width	Height	Length	Width	Height
12 1/4” (311)	7” (178)	14 3/8” (365)	11 5/8” (295)	7” (178)	16 3/4” (424)