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CLARKE

FOCUS WALK-BEHIND SCRUBBER


TROUBLESHOOTING GUIDE

PREVIOUS REVISION: June 2, 2005


REVISION:
Change T.O.C.
Insert Important Note Page
Removed page 19 blank note page
Renumber all pages

Table of contents
Page
Important Notes----------------------------------------------------------------------------3
P-3 Trio Connector--------------------------------------------------------------------------4
P-2 Trio Connector--------------------------------------------------------------------------5
P-1 LCD Interface Trio connector--------------------------------------------------------5
C-1 PGDT Display Connector-------------------------------------------------------------6
C-2 PGDT Display Connector-------------------------------------------------------------6
C-3, C-4 and C-5 PGDT Display Connector--------------------------------------------6
Overview:
Functions controlled directly by the PGDT Trio Controller---------------------------7
Functions controlled independently or in conjunction with the
PGDT Trio Controller-----------------------------------------------------------------------7
Operator Inputs / Switches are wired directly to the PGDT Trio Controller - -7
System Power Up/Down Critical Components and Control Operation--------------8
Brush Motor(s) Scrub Deck Critical Components and Control Operation----------9
Solution Water Flow Critical Components and Control Operation-----------------10
Vacuum Motor/Sq. Actuator Critical Components and Control Operation--------11
Traverse Transaxle Drive Critical Components and Control Operation------------12
Fault codes on the LCD Display for the Trio Controller-------------------------13-16
Troubleshooting the PGDT SOLO Traverse Controller ------------------------------17
Delta Q Battery Charger Scrubber System Fault Codes-----------------------------18
Delta Q Battery Charger Scrubber System Operation Codes------------------------18
Delta Q Battery Charger Scrubber System Algorithms------------------------------ 18
Clarke Flow Chart Information----------------------------------------------------------19
System will not power up Flow Chart--------------------------------------------------20
Parking Brake Flow Chart--------------------------------------------------------------21
LCD Display Flow Chart-----------------------------------------------------------------22
Brush Motor(s) will not run Flow Chart------------------------------------------------23
Scrub Deck will not Raise / Lower properly Flow Chart-------------------------24-25
Solution Flow, Flow Chart----------------------------------------------------------------26
Recovery Vacuum Motor will not run Flow Chart------------------------------------27
Traverse Drive System not functioning Flow Chart----------------------------------28
Squeegee will not Raise or Lower Flow Chart-----------------------------------29

IMPORTANT NOTES

ANY time any of the electronic connectors are unplugged or serviced, electronic grease
Clarke P/N 94822A (or equivalent) must be applied to the connector pins prior to reconnecting the plugs. Failure to add the grease could cause random signal lose between
connectors. This grease is silica thicken, medium viscosity, synthetic hydrocarbon grease for
lubrication and protection of tin-lead electrical connectors. Two manufactures are Syn-TechNS-50040-GC and NYE- Nyogel 760G

P-3 TRIO Connector:


P-3

WIRE

Function

Guide

Pin 1
Pin 2
Pin 3
Pin 4
Pin 5

Not Used
Not Used
Traction Speed Input
Not Used
N/C Reserved / One Touch Switch

Pin 6
Pin 7
Pin 8
Pin 9
Pin 10

Soap mixture status


Not Used
ON/OFF Reference (B+)
Throttle Low Reference
Throttle Wiper

Pin 11

Vacuum Mode Input

Pin 12

Brush Mode Input

Pin 13
Pin 14

Reverse Select Input


Inhibit (High Recovery Tank Input)

Pin 15
Pin 16

Not Used
Hi Switch Reference 5V

Pin 17
Pin 18

Alarm Output
ON/OFF Input (KSI)

Pin 19

Lo Switch Reference 0V

Pin 20

Throttle Hi Reference

Not Used
Not Used
5.0V (High Speed).
Not Used
Upon power up, Input = 2.5V, then 5V with
Momentary One Touch Switch depressed.
5 second timer based on time of the water valve
Not Used
36V At All Time / Battery Power.
OV for Traverse Potentiometer Input.
0V to 5V Traverse Potentiometer Wiper Input in
series with Forward Switches.
Upon power up, Input = 2.5V AUTO Mode, 0V with
Vac/Sq. Switch ON, 5V with Vac/Sq. Switch OFF.
Upon power up, Input = 2.5V AUTO Mode, 0V with
Brush Switch UP, 5V with Brush Switch DOWN.
2.5V in Neutral and Forward, 0V with the Reverse
button depressed.
2.5V until Recovery Tank Float Switch is activated,
then 0V.
Not Used
5V Used for Vac/Sq. Sw. & Brush Sw. & One Touch
Sw. Inputs.
Not Used.
36V with Key Switch turned ON and Inhibit Relay
ON.
0V Used for Vac/Sq. Sw. & Brush Sw. & Rev. Switch
& Recovery Float Switch.
5V for Traverse Potentiometer Input.

P-2 TRIO Connector:


P-2

WIRE

Function

Guide

Pin 1
Pin 2
Pin 3
Pin 4
Pin 5

Switched (B+)
Aux 4 Output
Aux 2 Output
Aux 1 Output
Low Switch reference 0V

Pin 6

Aux 1 Input

Pin 7

Aux 3 Input

Pin 8
Pin 9
Pin 10
Pin 11
Pin 12

Switched (B+)
Aux 3 Output
Aux 2 Output (+)
Aux 1 Output (+)
HI Switch Reference 5V

Pin 13

Aux 2 Input

Pin 14

Aux 4 Input

36V for Soap Dispenser Pump Option.


0V for Soap Dispenser Pump Option.
36V / 0V Output for Sq. Actuator Motor.
36V / 0V Output for Brush Head Actuator Motor.
0V for Brush Head Actuator Linear Potentiometer &
Water Flow Sw. & Soap Sw. Option.
0V to 5V from Brush Head Actuator Linear
Potentiometer.
Upon power up, Input = 2.5V, 0V with Water Flow
Switch INC., 5V with Water Flow Switch DEC.
36V Output for Water Valve.
Pulsed 36V / 0V Output for Water Valve.
36V / 0V Output for Sq. Actuator Motor.
36V / 0V Output for Brush Head Actuator Motor.
5V for Brush Head Actuator Linear Potentiometer &
Water Flow Sw. & Soap Sw. Option.
Not Used.
Upon power up, Input = 2.5V, 0V with Soap Switch
Option INC., 5V with Soap Switch Option DEC.

P-1 LCD Interface TRIO Connector:


P-1
Pin 5
Pin 6
Pin 3
Pin 1
Pin 4
Pin 2

WIRE

Function

Guide

ON/OFF Input (KSI)


ON/OFF 0V Reference (KSI)
0V
TX
RX
B+

36V with Key Switch turned ON.


0V with Key Switch turned ON.
0V at all times / Battery Power.
?????
?????
36V at all times / Battery Power.

C-1 PGDT Display Connector:


P-1

WIRE

Pin 5
Pin 6
Pin 3
Pin 1
Pin 4
Pin 2

Function

Guide

ON/OFF Input (KSI)


ON/OFF 0V Reference (KSI)
0V
TX
RX
B+

36V with Key Switch turned ON.


0V with Key Switch turned ON.
0V at all times / Battery Power.
?????
?????
36V at all times / Battery Power.

C-2 PGDT Display Connector:


C-2

WIRE

Function

Guide

Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
Pin 8
Pin 9
Pin 10
Pin 11
Pin 12

Not Used
Not Used
Not Used
Not Used
Not Used
Not Used
Not Used
Not Used
Not Used
Not Used
Not Used
LCD Mode

Pin 13
Pin 14
Pin 15
Pin 16

Not Used
Not Used
Not Used
HI Switch Reference 5V

Not Used
Not Used
Not Used
Not Used
Not Used
Not Used
Not Used
Not Used
Not Used
Not Used
Not Used
5V (Momentary) when Display Switch is
depressed.
Not Used
Not Used
Not Used
5V for Display Switch to toggle LCD Screen Display.

C-3 PGDT Display Connector: Not Used


C-4 PGDT Display Connector: Not Used
C-5 PGDT Display Connector: Not Used

Overview

The LCD Display only functions as a display of the functions that are being used and also displays various
Hourmeter measurements with the use of the Display (Momentary) Switch. This switch will allow you to
toggle the LCD Display back and forth between the LCD displays. In case of Trio fault, the LCD will display
the Trio Fault code on the LCD (diagnostic display).

The following functions on the Scrubber are controlled directly by the PGDT Trio controller.
Traction Drive
Electromechanical Parking Brake (Optional)
Brush Head Actuator
Brush Head Motors
Solution Water Control
Squeegee Actuator
Solution Vacuum Motor

The following functions are controlled independently or in conjunction with the PGDT Trio controller.
Recovery Tank Full Shutdown
Electromechanical Parking Brake (Optional)
Recycle Pump Option
Off Aisle Pump Option
The following Operator Inputs / Switches are wired directly to the PGDT Trio Controller.
Vacuum/Squeegee Switch
Brush Head Up/Down Switch
Water Flow (Solution Increase / Decrease) Switch
Soap Switch Option
One Touch (Default Controller Program) Switch
Forward / Reverse Traverse Control with Forward and Reverse Switches
Traverse Speed Potentiometer

System Power Up/Down:

Critical Components:
Key switch
Inhibit Relay
Key Circuit Breaker (5 Amp)
PGDT Trio Controller
PGDT LCD Display

Control Operation:
Operator turns Key Switch to ON.
The main (B+/36V) and (B-/0V) are always connected to the Trio Controller. The (B-/0V) is
always connected to all other modules and controllers at all times. The Inhibit Relay turns
ON. Upon the contacts closing on the Inhibit Relay, (B+/36V) is provided to (P-3 / Pin-18) on
the Trio Controller. This provides input power to the Trio Controller and the LCD Display.
There is an Internal Programmable Power down timer that will shut off the TRIO if the
Key switch is on with no activity. This is factory set at 20 minutes.
Note: This shut down function should not be used as an alternative to the key switch for
proper powering down the machine. Only functions controlled by the Trio are shut down
by the shutdown timer.

Brush Motor(s) Scrub Deck:

Critical Components:
Brush Head Actuator
Brush Head Actuator Linear Potentiometer
Brush Motor(s)
Brush Mode Switch (rocker switch)
PGDT LCD Display
PGDT Trio Controller
Brush Motor Circuit Breakers (35Amps each) / (2each)
Control Operation:
There are (2) two ways to lower the brush head scrub deck to the floor.
The first way is to use the brush momentary switch and toggle the switch in the + mode. By
depressing the switch the brush head scrub deck will lower to the 1st scrub pressure setting. You
can then increase the scrub pressure by toggling the brush momentary switch in the + mode.
The second way is to use the one touch button on the Control Panel. This button is green color.
By depressing the switch the brush head scrub deck will lower to the programmed scrub pressure
setting. You can then increase the scrub pressure by toggling the brush momentary switch in the
+ mode. Each time you toggle the brush momentary switch the brush pressure will increase
one level of brush pressure, to a total of (5) five brush pressure settings. If you continue to
toggle the brush momentary switch to increase past the 5th programmed brush pressure setting,
the brush pressure setting will not change. If in one touch mode, the pressure is too great for the
setting selected, the Brush deck will automatically notify the operator. If the operator does not
raise the brush deck- the machine will automatically raise the deck to maintain maximum
pressure.
With the linear potentiometer on the brush head actuator, the brush pressure setting will maintain
a constant brush pressure on the floor. The voltage input from the linear potentiometer to the
Trio controller will allow the brush head actuator to maintain a constant brush pressure over the
surface of the floor.
The brush motor(s) will operate when the scrubber is put into motion with the Forward and
Reverse Traverse Switches to traverse in Forward or Reverse. The brush motor(s) will stop when
the Forward and Reverse switches are released and the traverse is returned to neutral after
approximately 1 second.
To reset the HOME brush deck position:
Insure the brush deck is in the up most position. Hold the brush UP switch until you see
a Code 0002 on the LCD Module. This is approximately 30 seconds. This will reset the
HOME and maintain the same five brush pressure settings.

Solution Water Flow

Critical Components:
Solution water flow control valve
PGDT LCD Display
PGDT Trio Controller
Water Flow Switch
Control Operation:
Solution water flow is enabled by the Trio when the scrub deck motors are running (see brush
motor(s) scrub deck). The solution water flow stop valve is powered by P&G Trio controller (P-2
/ Pins 8 & 9). The valve is energized (Open) while the brush motor(s) are running & de energized
(closed) while the brush motor(s) are OFF.
The solution water flow control valve is controlled by a pulse width modulated output from the
Trio controller. The solution water flow control output is only enabled while the scrub decks are
running and the flow is determined by the setting of the solution water flow bar graph on the
PGDT LCD display. The rate of solution flow is adjusted by the water flow switch, by
depressing the switch either in the (+) or (-) direction. The solution rate selected is displayed on
the PGDT LCD Display as a Bar Graph.

Vacuum Motor / Squeegee Actuator:

10

Critical Components:
Vacuum Motor
Squeegee Actuator
Recovery Full Float Switch
PGDT LCD Display
PGDT Trio Controller
Control Operation:
There are (2) two ways to turn ON the vacuum motor and lower the squeegee to the floor.
The first way is to use the Vac / Sq. Switch and toggle the switch in the Down position. By
toggling the switch the vacuum motor will turn on and the squeegee will lower to the floor via
the squeegee actuator. Depressing the switch in the Up position turns the vacuum motor off
and the squeegee will raise up (after a programmed delay)
The second way is to use the one touch button (green color) on the Control Panel. By
depressing the switch the brush head scrub deck and squeegee will be lowered to the floor and
the vacuum motor will turn ON. NOTE: The Vac/Sq. Switch must be placed in the center
position for the squeegee function to operate correctly with the one touch feature.
With either means of starting the vacuum / squeegee, you can depress the one touch button again
when you have completed your job and the brush head scrub deck and squeegee will raise and
the vacuum will turn OFF after a programmed delay.
If you used the Vac /Sq. Switch to turn ON the vacuum and lower the squeegee, you can use
the Vac / Sq. Switch and toggle it to the Up position to raise the squeegee and turn OFF the
vacuum with the same programmed delay as in the One Touch Mode.
When the Recovery tank float switch is tripped the P&G Trio controller is given an Inhibit signal
of 0V on (P-3 / Pin-14). The LCD display switches to the diagnostic screen and the vacuum
motor icon starts to flash. At the same time the vacuum motor is shut Off after a programmed
delay.

Traverse Transaxle Drive:

11

Critical Components:
Traverse Transaxle Drive
Electromechanical Parking Brake (Optional)
Traverse Potentiometer
Forward and Reverse Switches
PGDT LCD Display
PGDT Trio Controller
Control Operation:
The Potentiometer and Forward and Reverse Switches control the Forward / Reverse direction
and speed of the Transaxle Motor and Drive. The Forward Switches are wired in series with the
Wiper of the Potentiometer. The input of the Potentiometer and Forward Switches goes into the
input of (P-3 / Pin-10) of the Trio Controller. The voltage at this input is 0V to 5V, with 0V as
Neutral. When both of the Forward Switches are not activated or depressed by the Operator the
scrubber will not traverse and the brush(s) will not run.
Electromechanical Parking Brake (Optional)
The Parking Brake can be used in one of two ways.
(1.) The Parking Brake is only applied when the Key Switch is turned OFF. When the Key
Switch is turned ON the Electromechanical Parking Brake is released.
Note: The scrubber will not power ON with the Key Switch ON, if the Override Lever
is engaged on the side of the Electromechanical Parking Brake.
(2.) The Parking brake is power with 36V from the Trio controller approximately 2 seconds after
the scrubber is returned to Neutral.

12

Fault codes on Trio LCD Display


The following are Fault Codes from the Trio Controller that may appear on the LCD display in case of a
fault. If a Fault code occurs, use the following chart in conjunction with the CLARKE Flow Charts to
aid in Diagnosing & correcting the problem.
TRIO Scrubber System Diagnostic Codes
Code
0003
0100
0204

PGDT Technical
Description
EEPROM program
checksum error 2
Running Checksum 1
EEPROM program
checksum error 1

0705

2.5V reference error

0706

High switch reference


error

0810
0811
0812
0813
0814
0815
0816
0817
0818

Tiller Fault 1
Tiller maximum wiper
difference error
Tiller maximum pulldown difference error
Tiller maximum pullsafe difference error
Tiller reference error
Tiller lo reference error
Tiller hi reference ISO
error
Tiller lo reference ISO
error
Tiller error both have
readings

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 Hi and Lo
Ref

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 front panel switches & controls and those
switches & controls themselves.

All 081x codes Throttle wiring


short or open circuits
0816 and 0817 can be caused
by incorrect programming of
the ISO test parameter

Check for wiring short circuits or broken wires on the 20


way connector on the Trio, the 5 way connector on the
LCD (if used) and the wiring to the front panel speed /
throttle control and the speed / throttle control itself.

Replace Controller if not cleared by disconnecting batteries


for 1 min
Replace Controller if not cleared by disconnecting batteries
for 1 min
Replace Controller if not cleared by disconnecting batteries
for 1 min

0A01

Power down error

Possible Controller fault

0B0B

EEPROM Q Overflow

Possible Controller fault

1310

Excessive current trip

Possible Controller fault

1311

Excessive current trip

Aux 1 over current

Check to see if the load is binding

1500

Brake fault 1

1501

Brake fault 2

1507

Brake over current


error

All 150x codes - Check brake &


wiring for open or short circuit

Check the Traction motor connection on the Trio and check


the wiring from this connector down to the Traction motor
and checking connections all the way. Otherwise possible
fault in electro brake on traction motor or possible
Controller fault.

1600

High battery voltage

Voltage exceeds maximum

Can be caused by poor or corroded connections to the


batteries or a battery charger being connected.

13

1704
1705
1706
1800
1802
1B20
1B21
1D02
1E03

Relay monitor failure


Relay fault 1
Relay fault 2
Watchdog error
Watchdog voltage ref
error
Both clamps
measuring current
Traction phase
overflow error
Front end spec
change

Inhibit activated2

2102

Progress counter error

2C00
2C01
2C02

Progress counter error


2
Low battery error
Low battery error 2
Soft battery lockout
occurred

2D01

No output drive

2F01

Tiller displace error

3100
3101
3102

Bridge fault 1
Traction bridge fault
Brush/Vac bridge fault
Soft waiting for bridge
to charge
Traction bridge fault 2
Bridge fault 2
Mine field mismatch
No internal timers
Internal timer out of
range
A to D readings not
finished before next
read
Unknown mux channel
ADC module not ready
error

3103
3104
3105
3201
3210
3211
3212
3213
3214
3601
3602
3603
3608

Replace Controller if not cleared by disconnecting batteries


for 1 min

Tiller settings updated in


programming

Cycle the power via the key switch

Inhibit inputs - Exact usage


dependent on programming

Remove or correct what is causing the inhibit fault.


Otherwise check for wiring short circuits or broken wires on
the 20 way connector on the Trio and the wiring elsewhere
on the machine. Otherwise incorrect programming or
operation of machine.

Possible Controller fault

Replace Controller if not cleared by disconnecting batteries


for 1 min

Low voltage warning

Recharge batteries immediately

Dependent on programming

Recharge batteries immediately

Inhibit activated

1E04

2103

Possible Controller fault

Test trip latch 1


Test trip latch 2
Test trip latch 3
Test trip latch 8

Possible Controller fault

Throttle in drive position during


switch on

Replace Controller if not cleared by disconnecting batteries


for 1 min
Incorrect operation of machine. Otherwise check the
mechanical condition of the throttle mechanism. Otherwise
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 front panel switches & controls and those
switches & controls themselves.

All 310x codes - Probable short


circuit of output device or wiring
- can sometimes cause
permanent Controller fault.

Check the Traction, Brush and Vac motor connections on


the Trio and check the wiring from these connectors down
to the Traction, Brush and Vac motors checking
connections all the way and also checking for short
circuits. Check for wiring short circuits or broken wires on
the 14 way connector on the Trio and the wiring elsewhere
on the machine. Otherwise replace Controller.

Possible Controller fault

Replace Controller if not cleared by disconnecting batteries


for 1 min

Possible Controller fault

Replace Controller if not cleared by disconnecting batteries


for 1 min

14

3609
360A
360B
360C
360D
360E

Test trip latch 9


Test trip latch 10
Test trip latch 11
Test trip latch 12
Test trip latch 13
Test trip latch 14

7000

Startup with push


activated

7001

7500
7501

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 freewheel 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. Can be caused by excessive pushing or rolling down
a slope or incorrect operation of the machine.

Wiring fault on 6-way serial link


between Trio and LCD

Check the wiring and connectors on the 6 way connections


on the Trio and LCD

Push activated in drive


mode
LCD Module
communications
timeout
LCD Module settings
corrupt

LCD memory corrupt

7600

Soft brush motor


disconnected error

Open circuit on brush motors or


brush motor wiring

7601

Soft brush current fold


back

Brush current overload


(thermal trip)

7602

Soft brush current fold


back 2

Brush current overload


(magnetic trip)

7603

Soft brush current fold


back 3

Possible short circuit on brush


motors or wiring

7604

Brush inhibit active

7605

Brush inhibit active

7700

Soft vacuum motor


disconnected error

Open circuit on vac motors or


vac motor wiring

7701

Soft vacuum current


fold back

Vacuum current overload


(thermal trip)

7702

Soft vacuum current


fold back 2

Vacuum current overload


(magnetic trip)

7703

Soft vacuum current


fold back 3

Possible short circuit on


vacuum motors or wiring

7800

Motor fault 1

Dependent on programming
Non-Programmable fault

Open circuit on traction motor


or traction motor wiring

15

Disconnect batteries and wait for 1 min before re-applying


power
Check the Brush motor connection on the Trio and check
the wiring from this connector down to the Brush motor and
checking connections all the way. Otherwise possible
Brush motor fault.
Incorrect programming, incorrectly specified Brush motor,
Brush motor developing a fault, excessive resistance on
brushes or brushes pushing down too hard on floor. This is
a result of current being over 33% of factory default and
over the factory default time limit
Incorrectly specified Brush motor, Brush motor developing
a fault Current has been over 200 amps for longer than 3
milliseconds
Check the Brush motor connection on the Trio and check
the wiring from this connector down to the Brush motor and
checking connections all the way. Otherwise possible
Brush motor fault. The brush current has exceeded 400
amps
Incorrect software program - check program, otherwise
possible controller fault.
Dead-Short in wiring or motors
Check the Vac motor connection on the Trio and check the
wiring from this connector down to the Vac motor and
checking connections all the way. Otherwise possible Vac
motor fault.
Incorrect programming, incorrectly specified Vac motor,
Vac motor developing a fault, debris in Vac motor or
airways blocked by debris
Incorrectly specified Vac motor, Vac motor developing a
fault
Check the Vac motor connection on the Trio and check the
wiring from this connector down to the Vac motor and
checking connections all the way. Otherwise possible Vac
motor fault.
Check the Traction motor connection on the Trio and check
the wiring from this connector down to the Traction motor
and checking connections all the way. Otherwise possible
Traction motor fault.

7801

Traction over current


error

Possible short circuit on


Traction motor or wiring

Check the Traction motor connection on the Trio and check


the wiring from this connector down to the Traction motor
and checking connections all the way. Otherwise possible
Traction motor fault.

7802

Traction motor in fold


back state

Traction motor current has


exceeded current limit for the
fold back time

Excessive driving up an incline, or machine driven up


against an obstacle or step.

7900

Emergency stop error

E-stop input active or wiring


fault

7901

Belly button switch


activated

E-stop input active or wiring


fault (programmed as belly
button)

9000

Brushes not fitted

Dependent on programming

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 emergency stop switch and the
emergency stop switch itself. Otherwise incorrect operation
of machine.
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 belly button stop switch and the belly
button switch itself. Otherwise incorrect operation of
machine.
Brushes not fitted or incorrectly adjusted brush deck
actuator

Troubleshooting the Penny & Giles (PGDT) Traverse Controller (Solo):


NOTE: All voltage measurements are in reference to (B-), unless otherwise specified in the instruction.
(1.) Do you have 36Vdc between the (B+) / (White) and (B-) / (Black) terminals on the Traverse Controller?
If these voltages are not present the possible problems are a defective Key Switch, Main Solenoid or

16

wiring.
(2.) Pin 1 will be 4.75Vdc with the Key Switch switched ON. If these voltages are not
present the possible problems are a defective Key Switch or the Potentiometer or wiring.
(3.) Pin 2 will be 0.25Vdc with the Key Switch switched ON. If these voltages are not
present the possible problems are a defective Key Switch or the Potentiometer or wiring.
(4.) Pin 3 will be 0.25Vdc to 4.75Vdc as you vary the position of the Traverse Speed knob, with the Key
Switch and Control Panel switched ON. If these voltages are not present the possible problems are a
defective Key Switch, Control Panel or the potentiometer, or traverse switch or wiring.
(5.) Pin 4 will be 0Vdc at all times.
(6.) Pin 5 will be 36Vdc with the Key Switch turned ON. If these voltages are not present
the possible problems are a defective Key Switch or wiring.
(7.) Pins 6 and Pin 7 and are not used.
(8.) Pin 9 will be 12.0Vdc until Reverse Traverse is selected at which time it will drop to 0Vdc. The Key
Switch must be switched ON. If these voltages are not present the possible problems
are a defective Key Switch or the Reverse traverse switch or wiring.
(9.) Pins 10, 11 and 12 are not used.
(10.) Pin 13 and pin 14 will be used to power the Parking Brake, if the Parking Brake Option is installed.
(12.) Do you have 0Vdc to 36Vdc between the (M+) / (Yellow) and (M-) / (Brown) wires on the Traverse
Controller in the Forward direction?
Do you have 0Vdc to 24Vdc between the (M+) / (Yellow) and (M-) / (Brown) wires on the Traverse
Controller in the Reverse direction? If no, defective Traverse Controller.

Delta Q Battery Charger Scrubber System Fault Codes:


Display
Codes
(1) Flash
(2) Flashes

Alarm Description

Service Action

Battery Voltage High


Battery Voltage Low

Auto Recover
Auto Recover

17

(3) Flashes

Charge Timeout

(4) Flashes

Check Battery

(5) Flashes

Over Temperature

(6) Flashes

Delta QuiQ Fault

The charger did not complete in the allowed time.


This may indicate a problem with the battery pack, or
the charger output was reduced due to high ambient
temperatures.
The battery could not be trickle charged up to the
minimum level required for the charge to be started.
This may indicate that one or more cells in the battery
pack are shorted or damaged.
Auto Recover. Charger has shut down due to high
internal temperature which typically indicates there is
not sufficient airflow for cooling. Charger will restart
and charge to completion if temperature comes within
accepted limits.
An internal fault has been detected. If this fault is
displayed after interrupting the AC power for at least
10 seconds, the charger must be replaced or
repaired.

Delta Q Battery Charger Scrubber System Operation Codes:


Display Codes
AC Power ON
AC Power Low
Thermal Cutback
< 80% Charge Indicator
> 80% Charge Indicator
100% Charge Indicator
Fault Indicator

Operation Description
LED Active.
LED Flash Yellow
LED Flash Yellow
LED Short Flash Green
LED Long Flash Green
LED Solid Green
LED Flash Red

Delta Q Battery Charger Scrubber System Algorithms:


If you have replaced your battery pack with something different than
the original battery pack, please contact your Clarke Service
Representative for instructions on how to change the charging xxx
algorithms in the Delta Q Battery Charger.
CLARKE Flow Charts:
The following are Troubleshooting Flow Charts for the Main Systems & Functions.
These are Guides ONLY & provide tests & checking procedures to resolve most
errors. The Flow Charts DO NOT reference TRIO Fault codes. Any Fault codes

18

that appear on the LCD display should be used in conjunction with the Flow Charts
to identify the problem & the appropriate resolution.
Some understanding of Electrical troubleshooting techniques terminology may be
required.

19

System will not power up

No

Check to see if you have 36


Volts at B+ and B- of Trio

Yes

No
Check Battery Connections

No
With key switch ON is
there 36V at P3-pin 18

Check each cable


and connection

No

With key switch ON is


there 36V at P3-pin 8

Replace Trio

No

Yes
Is there 36 Volts at Terminal
#2 (wire color yellow) on the
Inhibit Relay?

Yes

Yes

No

Check wiring
No

Contact Service
Representative.

Is there 36 Volts at Terminal #4 (wire


color yellow) on the Inhibit Relay?
Yes

Is there 36Volts on the coil


wires of the Inhibit Relay?
No
Is the Key Circuit Breaker Closed?
Is the Charger plugged into A.C.?
Is the Charger inhibit switch of the
charger closed
Is the key switch contacts closed?
Check associated wiring

20

Yes
Check Wiring.

Parking Brake Trouble shooting


No

Does the brake hold the machine normally


when the battery is disconnected?
Yes

Verify the brake manual disable


lever is not engaged. Also check
brake to transaxle connection.
Yes

Does the brake hold the machine


normally when the battery is connected
& the key switch is OFF?

Yes

No
Brake pads or springs are worn
Replace parts or Entire brake

Move lever to engage position or


tighten the brake connections

No

Refer to the section for the


Traverse Transaxle Drive for the
different ways of wiring the
Parking Brake Option.

Does the brake hold the machine


normally when the battery is connected
& the key switch is ON & the
machine is stopped?

Yes

Does the brake release


when the battery is
connected & the key switch
is ON & the machine is
moving?

No
Yes
No

No
Do all the other functions
operate normally?

Jack up a wheel on the transaxle.


Activate the forward or reverse
direction and check Voltage at brake
connections

Call
Authorized
Service
Center
Yes

No

Yes
Replace the TRIO controller
or check wiring. Refer to
the section for the Traverse
Transaxle Drive for the
different ways of wiring the
Parking Brake Option.

L.C.D. Display
21

Follow troubleshooting
guide for any
malfunctions.

Replace the
brake

No

Check to see if you have 36


Volts at B+ and B- of Trio

Yes

No
Check Battery Connections.

No
With key switch ON is
there 36V at P3-pin 18

Check each cable


and connection

See Power-Up Section

Yes

No

Is there 36 Volts between P1


/ Pins 2 & 3 and P1/ Pins 5
&6

Yes

No
Contact Service
Representative.

Replace Trio
Controller

No

Is there 36 Volts between C1 / Pins 2 &


3 and C1 / Pins 5 & 6
Yes

Check wiring between Trio


and LCD Display.

Is there 5 Volts between


C2/ pins 12 & 16

No
Replace LCD Display.
Yes

Yes
LCD should toggle display screens

Check between C2/pin 12 and C2/pin 1 for


5 Volts when the display Switch is
depressed
No
Check wiring and Display Switch

Brush Motor Will Not Run


22

Is Brush deck in the down position? If not lower


Is the traverse direction selected? If not select

No
Yes
No

Is there approximately 0.7 Volts at P2-pin 6 in ref to


P2-pin 5 with the head in the down position?

Yes
Check Brush Actuator
potentiometer or wiring
Or Scrub Deck chart

No

Is there 36 Volts at the Trio


Brush Motor connector P6?

Replace Trio

No
No
Contact Service
Representative.
encountered

Check Wiring

Is there 36 Volts at the


Brush motor connectors
when the motors should
operate?
run?
Yes

Check Brush Motor carbon


brushes. If brushes are OK,
replace the motor

23

Scrub deck will not raise/lower properly

No

Check to see if you have 36


Volts at B+ and B- of Trio

Yes

No
Check Battery Connections.
No
Check each cable
and connection

With key switch ON is


there 36V at P3-pin 18

See Power-Up Section

No

Yes
Is there 5 Volts between
P3 16 and P3-19?
Yes

No

Replace Trio
N
o
Check wiring between P3
and Brush Switch.

Contact Service
Representative.

Is there 5V between the Red and Gray


wires on the Brush Momentary Switch?
Yes
Is there 2.5V at P3 Pin 19?

N
o
Replace Trio
N
o
Check wiring between P3
and Brush Switch.

Yes
Is there 2.5V at the Yellow wire on the
Brush Momentary Switch?
Yes
Does P3-Pin 12 Toggle from 0-5
Volts when you activate the
Brush up/down switch

Yes

No
Replace the Brush switch

SEE NEXT PAGE

24

Scrub deck will not raise/lower properly (Continued)

From Previous Page


Is there 0 to 5 Volts at P2-pin 6 in ref to P2-pin 5?
If the Brush deck is in the full up position, reading
should be approximately 0.6 Volts
Other wise it will be between 0.6 and 5 Volts

Yes
No

Check for 5 Volts between P2pin 5 and pin 12

No
Yes

Replace Trio

Check Brush Actuator


potentiometer or wiring

Is there 36 Volts at P2-pin 4 and pin 11?


Ref. power for Brush head actuator motor

Yes

No
Replace Trio

Check actuator motor connections for 36


Volts when Brush switch is activated
N
o

Yes
Check wiring
Replace Actuator

25

Solution Flow

No

No

Is Brush deck in the down position? If not lower


Is the traverse direction selected? If not select
Is there solution in the tank? If not fill
Is the solution flow switch setting selected? If not select solution setting
Check solution water Filter, if clogged clean
Check solution flow piping

Unable to select desired


solution flow

Is there 5 Volts between P2-pin 5 and pin 12?


Yes
No

Does the Voltage on P2-pin 7 and P2-pin 5


toggles between 0 or 5 Volts?

Yes

Replace Trio

No

Is there 5 Volts between


the violet and blue wires
on the Water Flow
Switch?

Yes

Replace Water Flow


switch

Is there pulsating 36 Volts at


P2-pin 8 and P2-pin 9?

Yes
No
Yes

No
Check wiring between P2pin 5 and pin 12 and
Water Flow Switch

Is there 2.5 Volts between


P2-pin 7 and pin 5?

Replace Trio
Yes

No

Is there pulsating 36 Volts at


the Water Valve?
No
Yes

Replace Trio

Is there 2.5 Volts between P2pin 5 and the brown wire on


the Water Flow switch?

No
Check wiring between P2pin 7 Water Flow Switch

26

Check wiring

Replace Water
Flow Valve

Recovery Vacuum Motor Will Not Run

No

Is recovery Tank Empty

Yes

Empty Recovery Tank

Is there 5 Volts between


P3-pin16 and P3-pin 19?

No

Yes

Replace Trio

No

Is there 5 Volts between


the red and gray wires on
the Vacuum / Squeegee
Switch?

Check wiring

Yes

Is there 2.5 Volts between


P3-pin 11 and pin 19?

No
Yes
No

When it toggles to 0 Volts,


Then there should be 36 Volts
on P5 output

Yes
Replace Trio

Is there 2.5 Volts between the


orange and gray wires on the
Vacuum / Squeegee switch?

Yes
No

Between P3-pin 14 and P3-pin 19


should be 2.5 Volts. If 2.5 Volts then
the Vacuum Motor is not in the
inhibit mode

Check to see if there is 36


Volts at Vacuum motor
connections

No
Replace Trio

Yes
Check wiring

No
Does the Voltage toggle
between 0 and 5 Volts between
P3-pin 11 and pin 19

Yes
No
With Recovery FULL float switch
not activated, there should be 2.5
volts between P3-pin 14 and 19

Check
wiring
NOTE
When P3-pin 11and pin 19
toggles to 5 volts, the vacuum
motor will turn off after the
programmed OFF DELAY

With Recovery FULL float switch


activated, there should be 0 volts
between P3-pin 14 and 19
Yes

No

Replace Vacuum / Squeegee switch


Check Vacuum Motor carbon
brushes. If brushes are OK,
replace the motor

27

Traverse Drive System Not Functioning


Is there 5 Volts between
P3-pin 20 and pin 9?
With Forward Traverse
selected is there 0-5 Volts
between P3-pin 10 and
pin 9.

Yes
Replace Trio

No
No

Check wiring

Yes

Check Traverse
Potentiometer and
Forward Traverse
Switches.

With Traverse selected:


There should be 0-36 Volts at P9
Traction plug M+ and M- and
0Volts between P9 brake outputs

No

Yes
With Traverse selected:
There should be 0-36 Volts at
Traverse Motor connections
output

Replace Trio

No
Check
wiring

28

Yes
Check Traverse Motor carbon
brushes. If brushes are OK,
replace the motor

Squeegee will not Raise or Lower

Is there 5 Volts between


P3-pin16 and P3-pin 19?

No

Replace Trio
No

Yes
Is there 5 Volts between
the red and gray wires on
the Vacuum / Squeegee
Switch?

Check wiring

No

No
Check wiring

Check to see if there is 36


Volts at Squeegee motor
connections.

Is there 2.5 Volts between the


orange and gray wires on the
Vacuum / Squeegee switch?

Yes
Does the Voltage toggle
between 0 and 5 Volts between
P3-pin 11 and pin 19

No

NOTE
When P3-pin 11and pin 19 toggles
to 0 volts, the vacuum motor will
turn off and the Squeegee will raise
after the programmed OFF
DELAY

Yes
Check
wiring

Yes

Replace Trio

Yes

NOTE
The voltage polarity will
reverse when the squeegee is
selected to raise or lower.

Is there 2.5 Volts between


P3-pin 11 and pin 19?

No

When it toggles to 0 or 5
Volts, then there should be
Yes
36Volts at P2-Pin 3 to P2Pin 10

Replace Trio

Yes

Replace the Squeegee


Actuator Motor.

29

No

Replace Vacuum /
Squeegee switch

END OF MANUAL

30