Convertamatic™ 28/32/38LX Hydro-Retriever™ 280/320

Transcription

Convertamatic™ 28/32/38LX
Hydro-Retriever™ 280/320/380HD
BA 700/800/1000
SERVICE MANUAL
Advance MODELS 56392290, 56392210,
56392220, 56392230, 56392240, 56392270
Nilfisk MODELS 56391372, 56392823,
56392824
9/95 revised 3/01 Form Number 56043025
TABLE OF CONTENTS
SAFETY ............................................................................................................................................................................... 4
SPECIFICATIONS & MAINTENANCE ............................................................................................................................. 5-8
KNOW YOUR MACHINE ............................................................................................................................................... 9-10
SOLUTION SYSTEM ................................................................................................................................................... 11-18
MAINTENANCE ............................................................................................................................................................... 11
FLOW CONTROL VALVE REPLACEMENT - BA 700 / 28LX / 280HD ..................................................................... 11-12
FLOW CONTROL VALVE REPLACEMENT - BA 800, 1000 / 32, 38LX / 320, 380HD ................................................... 12
SOLUTION CABLE REPLACEMENT - BA 700 / 28LX / 280HD ...................................................................................... 13
SOLUTION CABLE REPLACEMENT - BA 800, 1000 / 32, 38LX / 320, 380HD .............................................................. 14
SOLUTION SOLENOID VALVE REMOVAL - BA 700 / 28LX / 280HD ............................................................................ 15
SOLUTION SOLENOID VALVE REMOVAL - BA 800, 1000 / 32, 38LX / 320, 380HD .................................................... 16
SOLUTION SOLENOID VALVE DISASSEMBLY AND CLEANING ................................................................................. 17
TROUBLESHOOTING ..................................................................................................................................................... 18
BRUSH DRIVE SYSTEM ............................................................................................................................................. 19-25
BRUSH DRIVE SYSTEM MAINTENANCE ...................................................................................................................... 19
BELT TENSION ADJUSTMENT - BA 700 / 28LX / 280HD ........................................................................................ 19-20
BELT TENSION ADJUSTMENT - BA 800, 1000 / 32, 38LX / 320, 380HD ...................................................................... 20
BRUSH LIFT LIMIT SWITCHES ................................................................................................................................ 21-23
LIMIT SWITCH ADJUSTMENT ................................................................................................................................ 21-22
LIMIT SWITCH REPLACEMENT ................................................................................................................................... 23
BRUSH LIFT ACTUATOR REPLACEMENT .................................................................................................................... 24
VACUUM SYSTEM ...................................................................................................................................................... 26-32
VACUUM SYSTEM MAINTENANCE ......................................................................................................................... 26-27
VACUUM MOTOR REMOVAL - BA 700 / 28LX / 280HD ................................................................................................ 27
VACUUM MOTOR REMOVAL - BA 800, 1000 / 32, 38LX / 320, 380HD ........................................................................ 28
SQUEEGEE MAINTENANCE .......................................................................................................................................... 29
SQUEEGEE ADJUSTMENT (BEFORE SN 1081111) ..................................................................................................... 29
SQUEEGEE ADJUSTMENT (AFTER SN 1081110) ........................................................................................................ 30
TROUBLESHOOTING ............................................................................................................................................... 31-32
WHEEL DRIVE SYSTEM ............................................................................................................................................. 33-37
WHEEL DRIVE SYSTEM MAINTENANCE ...................................................................................................................... 33
CHAIN REMOVAL AND ADJUSTMENT .................................................................................................................... 33-34
DRIVE MOTOR REPLACEMENT .................................................................................................................................... 34
DRIVE WHEEL REPLACEMENT ..................................................................................................................................... 35
POTENTIOMETER ADJUSTMENT ................................................................................................................................. 37
BATTERY SYSTEM ..................................................................................................................................................... 38-39
BATTERY MAINTENANCE .............................................................................................................................................. 38
BATTERY TESTING ........................................................................................................................................................ 39
ELECTRICAL SYSTEM ................................................................................................................................................ 41-46
ELECTRICAL COMPONENT LOCATION ........................................................................................................................ 41
WIRING DIAGRAMS / SCHEMATICS ....................................................................................................................... 42-46
Note: All references to right, left, front, or rear in this manual are as seen from the operator’s stand-point.
FORM NO. 56043025 / BA 700, 800, 1000 / 28LX, 32LX, 38LX / 280HD, 320HD, 380HD - 3
SAFETY
CAUTIONS AND WARNINGS
SYMBOLS
Nilfisk-Advance uses the symbols below to signal potentially dangerous conditions. Always read this information carefully and take
the necessary steps to protect personnel and property.
DANGER!
Is used to warn of immediate hazards that will cause severe personal injury or death.
WARNING!
Is used to call attention to a situation that could cause severe personal injury.
CAUTION!
Is used to call attention to a situation that could cause minor personal injury or damage to the machine or other property.
GENERAL SAFETY INSTRUCTIONS
Specific Cautions and Warnings are included to warn you of potential danger of machine damage or bodily harm.
WARNING!
•
•
•
•
•
•
•
•
•
This machine shall be used only by properly trained and authorized persons.
Keep sparks, flame and smoking materials away from batteries. Explosive gases are vented during normal operation.
Charging the batteries produces highly explosive hydrogen gas. Charge batteries only in well-ventilated areas, away from open
flame. Do not smoke while charging the batteries.
Remove all jewelry when working near electrical components.
Turn the key switch off (O) and disconnect the batteries before servicing electrical components.
Never work under a machine without safety blocks or stands to support the machine.
Do not dispense flammable cleaning agents, operate the machine on or near these agents, or operate in areas where flammable
liquids exist.
Do not clean this machine with a pressure washer.
Do not operate this machine on ramps or inclines of more than an 8.7 percent gradient.
CAUTION!
•
•
•
•
•
•
•
•
•
This machine is not approved for use on public paths or roads.
This machine is not suitable for picking up hazardous dust.
Do not use scarifier discs and grinding stones. Nilfisk-Advance will not be held responsible for any damage to floor surfaces
caused by scarifiers or grinding stones (can also cause damage to the brush drive system).
When operating this machine, ensure that third parties, particularly children, are not endangered.
Before performing any service function, carefully read all instructions pertaining to that function.
Do not leave the machine unattended without first turning the key switch off (O), removing the key and applying the parking
brake.
Turn the key switch off (O) before changing the brushes, and before opening any access panels.
Take precautions to prevent hair, jewelry, or loose clothing from becoming caught in moving parts.
Use caution when moving this machine in below freezing temperature conditions. Any water in the solution or recovery tanks
or in the hose lines could freeze, causing damage to valves and fittings. Flush with windshield washer fluid.
SAVE THESE INSTRUCTIONS
4 - FORM NO. 56043025 / BA 700, 800, 1000 / 28LX, 32LX, 38LX / 280HD, 320HD, 380HD
SPECIFICATIONS
_________________________________________________________________________________________________________________
SPECIFICATIONS - BA 700 / 28LX / 280HD
Dimensions
Scrub Brush Diameter
Scrub Brush Path
Scrub Brush Pressure
Scrub Brush Speed
Squeegee Size
Machine Length
Machine Width
Machine Height
Drive Wheel
Solution Tank Capacity
Recovery Tank Capacity
Coverage Rate
Machine Weight
General Specifications
Brush Motor
Wheel Drive Motor
Vacuum Motor
Brush Drive
Squeegee Type
Speed Control
Batteries
English (Metric)
14.5 inches (36 cm)
28 inches (71 cm)
140 lbs. (63.5 kg)
155 rpm (155 rpm)
33 inches (108 cm)
59 inches (150 cm)
30.25 inches (77 cm)
45.75 inches (116 cm)
10 inch (25 cm) solid, traction tire
33 (US) gal (125 l)
31 (US) gal (118 l)
25,500 sq. ft (2,369 m2) per hour
1520 lbs. (690 kg) Gross Vehicle Weight (GVW)
GVW – Standard machine without options, maximum size
batteries, full solution tank, empty recovery tank and brushes
770 lbs. (349 kg) shipping weight
36 volt, 2 1/4 hp dc motor
36 volt, 3/4 hp dc motor
36 volt, 1 hp dc motor
Dual worm gear 10 to 1 reduction gear box
4 sided, curved, self tracking
Electronic, fully variable forward/reverse
(6) 6 volt 244 AH (std)
SPECIFICATIONS
_________________________________________________________________________________________________________________
Dimensions
Scrub Brush Path
Scrub Brush Speed
Squeegee Size
Machine Length
Machine Width
Machine Height
Drive Wheel
Coverage Rate
Machine Weight
Brush Motor
Wheel Drive Motor
Vacuum Motor
Brush Drive
Squeegee Type
Speed Control
Batteries
English (Metric)
17 inches (43 cm)
32 inches (81 cm)
160 lbs. (72.5 kg)
120 rpm (120 rpm)
45 inches (114 cm)
37 inches (94 cm)
46.75 inches (119 cm)
33 gal (125 l)
31 gal (118 l)
32,500 sq. ft (3,019 m2) per hour
1,718 lbs. (779 kg) Gross Vehicle Weight (GVW)
(6) 6 volt 350 AH (std)
SPECIFICATIONS
______________________________________________________________________________________________
Dimensions
Scrub Brush Path
Scrub Brush Speed
Squeegee Size
Machine Length
Machine Width
Machine Height
Drive Wheel
Coverage Rate
Machine Weight
Brush Motor
Wheel Drive Motor
Vacuum Motor
Brush Drive
Squeegee Type
Speed Control
Batteries
English (Metric)
20 inches (50 cm)
38 inches (97 cm)
160 lbs. (72.5 kg)
120 rpm (120 rpm)
45 inches (114 cm)
40 inches (102 cm)
46.75 inches (119 cm)
33 gal (125 l)
31 gal (118 l)
35,000 sq. ft (3,251 m2) per hour
1,747 lbs. (792 kg) Gross Vehicle Weight (GVW)
(6) 6 volt 350 AH (std)
MAINTENANCE
______________________________________________________________________________________________
MAINTENANCE SCHEDULE
Maintenance intervals given are for average operating conditions. Machines used in severe operational environments may
require service more often.
MAINTENANCE ITEM
Clean and inspect the tanks and hoses
Clean the brushes and pads
Clean the squeegee
Charge the batteries
Check battery water level
Lubrication
*Vacuum motor carbon brushes
Daily
X
X
X
X
Once a
Week
Once a
Month
Once a
Year
X
X
X
*Have your Nilfisk-Advance Dealer check the motors’ carbon brushes once a year or after 300 operating hours.
_________________________________________________________________________________________________________________
AFTER EACH USE
1
Raise the brushes (or pads) and raise the squeegee. Move the machine to a service area.
2
Turn the Master Key Switch (11) OFF and remove the key.
3
To empty the solution tank, take the Solution Drain Hose off its hanger. Direct the hose to a designated “DISPOSAL SITE” and
remove the plug. Rinse the tank with clean water. Inspect the solution hoses; replace if kinked or damaged.
4
To empty the recovery tank, take the Recovery Drain Hose (12) off its hanger. Direct the hose to a designated “DISPOSAL SITE”
and remove the plug. Rinse the tank with clean water. Inspect the recovery and vacuum hoses; replace if kinked or damaged.
5
Remove the brushes or pad holders. Rinse the brushes or pads with warm water and hang them up to dry. Allow buffing pads
to dry completely before using again.
6
Remove the Squeegee (13), rinse it with warm water and hang it up to dry.
7
Check the “Maintenance Schedule” above and perform any required maintenance before storing the machine in a clean, dry
place.
______________________________________________________________________________________________________
LUBRICATING THE MACHINE
Once a month, pump grease into each grease fitting on the machine until grease seeps out around the bearings.
Grease fittings locations are:
•
One on the front wheel
•
One on each rear caster swivel
Apply light machine oil to lubricate the following:
•
Solution tank hinge
•
Recovery tank hinge
•
Brush skirt locks
•
Squeegee lever pivot linkage
•
Solution lever pivot points
•
Brake lever pivot points
•
Drive Chain
•
Pivot points for the squeegee and scrub brush lift linkage
KNOW YOUR MACHINE
_________________________________________________________________________________________________________________
As you read this manual, you will occasionally run across a bold number in parentheses - example: (2). These numbers refer to an item on this or the following
page. Refer back to these pages whenever necessary to pinpoint the location of an item mentioned in the text.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Solution Lever
Twist Grip
Solution Tank Cover
Brake Lever
Power Connector
Circuit Breaker (80 Amp)
Squeegee Lever
Master Key Switch
Recovery Tank Drain Hose
Squeegee
Squeegee Blade Latch
Recovery Tank Cover
Skirt
3
15
2
11
10
16
14
13
1
12
4
6
9
8
7
5
KNOW YOUR MACHINE
CONTROL PANEL
17
18
19
20
21
Battery Meter
Brush Switch
Solution ON Light
Solution Switch, ON - Momentarily ON – OFF
Power ON Light
18
17
20
19
21
SOLUTION SYSTEM
_________________________________________________________________________________________________________________
MAINTENANCE
The solution system should be flushed every day to prevent a build-up of soap residue in the solution valve. To flush the
system...
1
Park the machine near a designated “DISPOSAL SITE” and drain the solution tank.
2
Put clean, warm water into the solution tank and let it drain through the drain hose.
3
When the tank is empty, re-cap the drain hose and put about 2 inches (5 cm) of clean, warm water in the tank.
4
Put the machine controls in the following positions:
•
•
•
•
•
Key Switch (11) - ON
Solution Switch (20) - ON
Brush Drive (18) - Lowered
Twist Grips (2) - Forward slightly
Solution Flow Control Lever (1) - Pulled Back
5
Let all of the clean water flow from the tank. This will flush dirt and soap residue from the electric solenoid valve and
the flow control valve.
______________________________________________________________________________________________
FLOW CONTROL VALVE REPLACEMENT - BA 700 / 28LX / 280HD
1
Drain the solution tank at a designated
“DISPOSAL SITE”.
2
See Figure 1. Remove the (A), (B), and (C)
Hoses from the solution valve fittings and
mark them to ensure proper reassembly.
3
Remove Ball Joint (D) from the valve arm.
Be careful not to lose the bushings.
4
Remove the valve mounting bolts and remove the valve from the machine.
5
Remove the fittings from the old valve and
remove the valve from the mount, (note the
positioning of the fittings for reassembly).
6
Install the new valve on the mount and
install the fittings.
FIGURE 1
SOLUTION SYSTEM
_____________________________________________________________________________________________________________________________
FLOW CONTROL VALVE REPLACEMENT - BA 700 / 28LX / 280HD (continued)
7
Follow steps 1 - 5 in reverse order to reassemble. Make sure that the valve mount is in the forward two holes as shown.
8
Check for leaks and proper operation.
______________________________________________________________________________________________
FLOW CONTROL VALVE REPLACEMENT - BA 800, 1000 / 32, 38LX / 320, 380HD
1
Drain the solution tank at a designated “DISPOSAL SITE”.
2
Remove the left splash guard.
3
See Figure 2. Remove the (E), (F), and (G) Hoses from the solution valve fittings and mark them to ensure proper
reassembly.
4
Remove Ball Joint (H) from the valve
arm. Be careful not to lose the
bushings.
5
Remove the valve mounting bolts
and remove the valve from the machine.
6
Remove the fittings from the old
valve and remove the valve from
the mount, (note the positioning of
the fittings for reassembly).
7
Install the new valve on the mount
and install the fittings.
8
Follow steps 1 - 5 in reverse order to
reassemble.
9
Check for leaks and proper operation.
FIGURE 2
SOLUTION SYSTEM
______________________________________________________________________________________________
SOLUTION CABLE REPLACEMENT - BA 700 / 28LX / 280HD
1
Drain the solution tank at a designated
“DISPOSAL SITE”.
2
See Figure 3. Disconnect Ball Joint (I)
from the valve arm. Be careful not to
lose the bushings.
3
Remove Ball Joint (I) from the cable,
then remove the cable from the chassis
cable mount, (note the cable position in
the mount).
4
See Figure 4. Remove Panel (J).
FIGURE 3
FIGURE 4
5
Disconnect Ball Joint (K) from the lever,
and then remove the balljoint from the
cable.
6
Remove the cable from the control
handle cable mount, (note the cable
position in the mount).
7
Before removing the cable, take note of
the cable routing. Pull the cable up and
out through the control handle.
8
Follow steps 1-8 in reverse order to
reassemble. Test the new cable for
proper operation before reinstalling the
panels.
K
J
SOLUTION SYSTEM
______________________________________________________________________________________________
SOLUTION CABLE REPLACEMENT - BA 800, 1000 / 32, 38LX / 320, 380HD
1
Drain the solution tank at a designated “DISPOSAL SITE”.
2
Remove the left splash guard.
FIGURE 5
3
See Figure 5. Disconnect Ball Joint (L) from the valve arm. Be careful not to lose the bushings.
4
Remove the cable from the chassis cable mount (note the cable position in the mount), then remove Ball Joint (L)
from the cable.
5
See Figure 4. Remove Panel (J).
6
Disconnect Ball Joint (K) from the lever, and then remove the balljoint from the cable.
7
Remove the cable from the control handle cable mount, (note the cable position in the mount).
8
Before removing the cable, take note of the cable routing. Pull the cable down and out through the bottom of the
control handle, and then pull it out through the rear of the chassis.
9
Follow steps 1-8 in reverse order to reassemble. Test the new cable for proper operation before reinstalling the handle
panel and splash guard.
SOLUTION SYSTEM
______________________________________________________________________________________________
SOLUTION SOLENOID VALVE REMOVAL - BA 700 / 28LX / 280HD
1
Drain the solution and recovery
tanks at a designated “DISPOSAL
SITE” and disconnect one of the
battery cables.
2
Tip the solution tank over to the
side of the machine.
3
See Figure 6. Remove the (4) (M)
Screws and remove Cover (N) from
the machine.
4
See Figure 7. Disconnect Hoses
(O), (P), (Q) and then disconnect
the solenoid valve wiring connector.
FIGURE 6
N
M
FIGURE 7
O
FRONT
W
T
X
R
U
Q
V
S
P
5
Remove the (2) (R) Screws, remove the Solenoid Valve (S) and Bracket (T) from the machine.
6
Remove the fittings from the solenoid valve only if you are replacing the solenoid valve (remove Fittings (U), (V), (W),
and (X) as a one piece unit to avoid snapping them off inside the Tee Fitting (X).
7
Reassemble in reverse order and test for leaks and proper operation.
SOLUTION SYSTEM
______________________________________________________________________________________________
SOLUTION SOLENOID VALVE REMOVAL - BA 800, 1000 / 32, 38LX / 320, 380HD
1
Drain the solution and recovery
tanks at a designated “DISPOSAL
SITE” and disconnect one of the
battery cables.
2
Tip the solution tank over to the
side of the machine.
3
See Figure 8. Remove the (4) (Y)
Screws and remove Cover (Z) from
the machine.
4
See Figure 9. Disconnect Hoses
(AA), (BB), (CC) and then disconnect the solenoid valve wiring connector.
FIGURE 8
Z
Y
FIGURE 9
FRONT
AA
HH
EE
GG
DD
BB
JJ
FF
CC
II
5
Remove the (2) (DD) Screws, remove the Solenoid Valve (EE) and Bracket (FF) from the machine.
6
Remove the fittings from the solenoid valve only if you are replacing the solenoid valve (remove Fittings (GG), (HH),
(II), and (JJ) as a one piece unit to avoid snapping them off inside the Tee Fitting (JJ).
7
SOLUTION SYSTEM
______________________________________________________________________________________________
SOLUTION SOLENOID VALVE DISASSEMBLY AND CLEANING
1
Remove the solenoid valve (do not remove the fittings from the solenoid valve unless you are replacing the valve!).
Refer to the Solution Solenoid Valve Removal sections of this chapter.
2
See Figure 10. Remove the (2) (KK) Screws and Nuts and disassemble the valve (be careful not to lose any internal
parts).
FIGURE 10
KK
LL
MM
KK
3
Thoroughly wash any dirt from Block (LL) and Diaphragm (MM).
4
SOLUTION SYSTEM
______________________________________________________________________________________________
TROUBLESHOOTING
______________________________________________________________________________________________
PROBLEM: NO SOLUTION FLOW
Possible Cause & Remedy:
1
Machine controls not positioned properly - in order for solution to flow, the controls must be positioned as follows:
•
•
•
•
•
Key Switch - ON
Solution Switch - ON
Brush Switch - ON
Twist Grips - Forward
Flow Control Lever - Pulled Back
2
Clogged solution filter - drain solution tank, using the clear plastic drain hose at the back of the machine. This
automatically flushes loose dirt from the solution filter. If solution still does not flow, remove and disassemble the teefitting (attached to the solenoid valve) and remove and clean the filter thoroughly.
3
Clogged solenoid valve - remove, disassemble and clean the solenoid valve. See the Solenoid Valve Disassembly
and Cleaning section for instructions.
4
Defective speed control - replace the speed control.
______________________________________________________________________________________________
PROBLEM: SOLUTION LEAKS IN THE “OFF” POSITION
1
Dirt in solenoid valve - remove, disassemble and clean the solenoid valve. See the Solenoid Valve Disassembly and
Cleaning section for instructions
2
Defective solenoid valve - replace the solenoid valve. See the Solution Solenoid Valve Removal sections for
instructions.
BRUSH DRIVE SYSTEM
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MAINTENANCE
Every 3 years...
1 Check the carbon brushes in the brush motor. Replace the brushes if they are worn to a length of 3/8 inch (10 mm)
or less.
2
Remove the fill plug from the top of the gear box and check the oil level. The oil should be 1-1/2 inches (3.8 cm) from
the top of the gear box. Use 140W gear lube only.
3
Check the belt tension. There should be about 3/32 inch (2 mm) of belt deflection when 3-1/4 pounds of pressure
is applied between the pulleys.
_____________________________________________________________________________
BELT TENSION ADJUSTMENT - BA 700 / 28LX / 280HD
1
Remove the actuator from the machine (see the Brush Lift Actuator Replacement section).
2
Remove the access panel from the right side of the machine.
3
See Figure 1. Loosen the (4) screws in the (A) Belt Guards.
FIGURE 1
BRUSH DRIVE SYSTEM
_____________________________________________________________________________________________________________________________
BELT TENSION ADJUSTMENT - BA 700 / 28LX / 280HD (continued)
4
Loosen the (B) Bolts and Nuts.
5
Loosen the (C) Lock Nuts and turn the (D) Bolts to adjust the belt tension. There should be about 3/32 inch (2 mm)
of belt deflection when 3-1/4 pounds of pressure is applied between the pulleys.
6
Follow steps 1-5 in reverse order to reassemble.
7
After the adjustment is complete, test to make sure the belt does not slip.
_____________________________________________________________________________
BELT TENSION ADJUSTMENT - BA 800, 1000 / 32, 38LX / 320, 380HD
1
Drain and tip the solution tank to the side of the machine.
2
See Figure 2. Loosen the (E) Bolts and Nuts.
3
Loosen the lock nuts and turn the (F) Bolts to adjust the belt tension. There should be about 3/32 inch (2 mm) of belt
deflection when 3-1/4 pounds of pressure is applied between the pulleys.
4
After the adjustment is complete, test to make sure the belt does not slip.
BA 800 / 32LX / 320HD
BA 1000 / 38LX / 380HD
FIGURE 2
E
E
E
E
F
F
FRONT
FRONT
BRUSH DRIVE SYSTEM
_____________________________________________________________________________
BRUSH LIFT ACTUATOR LIMIT SWITCHES
_____________________________________________________________________________
LIMIT SWITCH ADJUSTMENT
1
Remove the brushes, lower the brush drive and jack up the front of the machine about 2 inches. Put wood blocks
under the brush holders and lower the jack enough to take the weight of the brush drive assembly off the actuator.
2
Drain and tip the solution tank to the side of the machine.
3
See Figure 3. Loosen the (2) (G) Bolts and Nuts until the plastic nut on the actuator slips out of the brackets.
4
Remove Ring (H) and Pin (I), lift the actuator up, but leave it plugged in.
FIGURE 3
BA 700 / 28LX / 280HD
BA 800, 1000 / 32, 38LX / 320, 380HD
I
H
FRONT
I
H
G
G
G
G
FRONT
BRUSH DRIVE SYSTEM
_____________________________________________________________________________________________________________________________
LIMIT SWITCH ADJUSTMENT (continued)
5
See Figure 4. Measure the position of the plastic nut on the actuator shaft.
6
Manually turn the plastic nut to the DOWN position given below.
FIGURE 4
Plastic Nut
Adjuster Cover
Down
Up
Machine
DOWN Position
UP Position
BA 700 / 28LX / 280HD
5-1/2 inches
(140 mm)
8 inches
(203 mm)
BA 800, 1000 / 32LX / 38LX
320HD / 380HD
5-3/4 inches
(146 mm)
10 inches
(254 mm)
7
Hold the plastic nut, put the brush lift switch in the UP position and wait until the actuator stops.
8
Measure the position of the plastic nut on the actuator shaft and compare your measurement with the UP position
given above.
9
Remove the adjuster cover from the top of the actuator and adjust the UP position. To increase the travel of the plastic
nut, turn the adjuster clockwise. To decrease the travel of the plastic nut, turn the adjuster counter-clockwise.
Note: Each click of the adjuster will change the nut travel 1/16 inch (1.6mm).
10 After each adjustment, hold the plastic nut, run the actuator up and down and check the UP and DOWN position of
the plastic nut again.
11 After adjustment is complete, replace the adjuster cover and follow steps 1-4 in reverse order to reassemble.
12 Test the actuator to make sure the brushes raise and lower properly.
BRUSH DRIVE SYSTEM
_____________________________________________________________________________________________________________________________
BRUSH LIFT LIMIT SWITCHES (continued)
_____________________________________________________________________________
LIMIT SWITCH REPLACEMENT
1
Remove the actuator from the machine (see the Brush Lift Actuator Replacement section).
2
See Figure 5. Remove the (J) Screws and Cover (K), be careful not to lose the spring and washers. Note the position
of the Adjuster (L) for reassembly.
3
Remove the (M) Diodes from the switches.
FIGURE 5
L
N
M
J
K
4
Remove the (N) Screws, the switches and the switch shroud.
5
Follow steps 2-4 in reverse order to reassemble the actuator.
6
After reassembling the actuator and before reinstalling the actuator in the machine, adjust the UP and DOWN limits
(see the Brush Lift Limit Switch Adjustment section).
BRUSH DRIVE SYSTEM
______________________________________________________________________________________________
BRUSH LIFT ACTUATOR REPLACEMENT
1
Remove the brushes, lower the brush drive and jack up the front of the machine about 2 inches. Put wood blocks
under the brush holders and lower the jack enough to take the weight of the brush drive assembly off of the actuator.
2
Drain and tip the solution tank to the side of the machine, and disconnect the batteries.
3
See Figure 6. Loosen the (2) (O) Bolts and Nuts until the plastic nut on the actuator slips out of the brackets, do not
turn this nut if you are reinstalling the same actuator.
FIGURE 6
BA 700 / 28LX / 280HD
BA 800, 1000 / 32, 38LX / 320, 380HD
Q
P
FRONT
Q
P
O
O
O
O
FRONT
4
Unplug the actuator cord. Remove Nut (P), and Bolt (Q). Remove the actuator from the machine.
5
Follow steps 1-4 in reverse order to reassemble. To set UP and DOWN limits (see the Brush Lift Limit Adjustment
section).
BRUSH DRIVE SYSTEM
_____________________________________________________________________________
TROUBLESHOOTING
Before troubleshooting the brush drive circuit, check the reset button on the 80 amp brush motor circuit breaker, reset if
necessary.
____________________________________________________________________________________________________________________
Problem: Squealing noise when brushes are lowered.
1
Loose belt - adjust belt tension.
____________________________________________________________________________________________________________________
Problem: Brush motor will not start when twist grips are turned.
1
2
3
4
5
Tripped brush motor circuit breaker (see Figures 7A & 7B) - press the reset button, check the circuit breaker for continuity.
Defective brush switch (on top of control handle) - replace switch.
Defective brush motor solenoid (see Figures 7A & 7B) - replace solenoid.
Defective brush motor - remove motor, repair or replace.
Defective speed control (see Figures 7A & 7B) - replace speed control.
FIGURE 7B
FIGURE 7A
BA 700 Before SN 1082069
BA 800, BA 1000 Before SN 1081111
Speed Control
Drive Motor
Solenoid
BA 700 After SN 1082068
BA 800, BA 1000 After SN 1081110
All 28LX / 280HD
All 32LX, 38LX / 320HD, 380HD
Drive Motor
Solenoid
Speed Control
Brush
Solenoid
Brush Motor
Solenoid
Down Solenoid
Actuator Control Module
Up Solenoid
Brush Circuit
Breaker
Brush Circuit
Breaker
FRONT
FRONT
____________________________________________________________________________________________________________________
Problem: Brushes will not go up or down.
1
2
3
Defective brush switch (on top of control handle) - replace switch.
Defective drive nut or actuator - replace drive nut or actuator.
Defective up or down solenoid (see Figure 7A) - replace solenoid(s), for machines with up and down solenoids. Defective
Actuator Control Module (see Figure 7B) – replace control module, for machines with actuator control module.
VACUUM SYSTEM
______________________________________________________________________________________________
MAINTENANCE
Whenever the vacuum system does not perform properly, the entire system should be cleaned and inspected, following
the maintenance checklist below.
1
2
3
Remove the squeegee from the machine and clean it thoroughly.
Inspect the squeegee blades. If the wiping edge of the rear blade is damaged or worn to a radius, turn it around or over so a
new edge with a sharp corner faces toward the front of the machine.
See Figure 1. Disconnect Squeegee Hose (A) from the recovery tank cover. Park the machine near a designated disposal
site and use a garden hose to “back flush” dirt down and out of Squeegee Hose (A).
A
B
FIGURE 1
C
E
D
VACUUM SYSTEM
_____________________________________________________________________________________________________________________________
MAINTENANCE (continued)
CAUTION!
Do not flush hose (C) unless it is disconnected from the vacuum motor.
4
Remove Cover (B) from the recovery tank (see Figure 1). Rinse all dirt from Cage (E) and the ball float inside.
5
Check the gasket on recovery tank Cover (B). It must seal air-tight against the top of the tank.
6
Check drain hose Plug (D). Replace the plug if it does not seal air-tight.
If the machine still does not pick up after completing this checklist, see the Troubleshooting section of this chapter for
additional information.
______________________________________________________________________________________________
VACUUM MOTOR REMOVAL - BA 700 / 28LX / 280HD
1
Disconnect one of the battery cables.
2
Drain the solution tank and tip it to the side of
the machine.
3
See Figure 2. Remove the (4) (F) Screws and
remove Cover (G) from the machine.
4
See Figure 3. Remove the (3) (H) Screws and
disconnect the vacuum motor wiring connector.
4
Remove the vacuum motor from the machine.
FIGURE 3
H
FRONT
FIGURE 2
G
F
VACUUM SYSTEM
______________________________________________________________________________________________
VACUUM MOTOR REMOVAL - BA 800, 1000 / 32, 38LX / 320, 380HD
1
Disconnect one of the battery cables.
2
Drain the solution tank and tip it to the side of the
machine.
3
See Figure 4. Remove the (4) (I) Screws and
remove Cover (J) from the machine.
4
See Figure 5. Remove the (3) (K) Screws and
disconnect the vacuum motor wiring connector.
4
Remove the vacuum motor from the machine.
FIGURE 4
FIGURE 5
K
FRONT
J
I
FRONT
VACUUM SYSTEM
______________________________________________________________________________________________
SQUEEGEE MAINTENANCE
If the squeegee leaves narrow streaks of water, the blades may be dirty or damaged. Remove the squeegee, rinse it under warm
water and inspect the squeegee blades. Reverse or replace the blades if they are cut, torn, wavy or worn.
To Reverse or Replace the Rear Squeegee Wiping Blade...
1
Unsnap the center Latch on the squeegee tool.
2
Remove the Wing Nut from each end of the squeegee, then remove the Tension Straps.
3
Slip the rear blade off the Alignment Pins.
4
The rear squeegee blade has 4 working edges. Turn the blade so a clean, undamaged edge points toward the front of the
machine and against the floor. Replace the blade if all 4 edges are nicked, torn or worn.
5
Install the blade, following steps 1-3 in reverse order.
Thumb Nut
Adjustment Knob
FIGURE 6
Squeegee Mount
Vacuum Hose
Connection
Latch
Wing Nut
Alignment Pin
Retaining Strap
Rear Squeegee Blade
To Reverse or Replace the Front Squeegee Blade...
1
Put the Squeegee Lever in the UP position and remove the vacuum hose from the squeegee tool.
2
Loosen the two thumb screw on top of the squeegee, and slide the squeegee tool off of the squeegee mount.
3
Remove the nuts that hold the front blade in place, then remove the blade.
4
The front squeegee blade has 4 working edges. Turn the blade so a sharp 90° edge points toward the front of the machine
and against the floor. Replace the blade if all 4 edges are nicked, torn or worn.
5
Install the blade, following steps 1-3 in reverse order.
6
Put the squeegee tool back on the machine, connect the vacuum hose, and adjust the squeegee.
______________________________________________________________________________________________
SQUEEGEE ADJUSTMENT (BA 700 BEFORE SN 1082069 & BA 800/1000 BEFORE SN 1081111)
The squeegee should be adjusted whenever the squeegee is not wiping the floor dry.
To Adjust the Squeegee Tool...
1
Park the machine on a flat, even surface.
2
Turn the Master Switch (11) OFF and lower the Squeegee Lever (10).
3
Turn the Adjustment Knob until the rear squeegee blade touches the floor across its entire width.
VACUUM SYSTEM
______________________________________________________________________________________________
SQUEEGEE ADJUSTMENT (BA 700 AFTER SN 1082068 & BA 800/1000 AFTER SN 1081110) ALL 28, 32, 38LX
/ 280, 320, 380HD
1
2
3
4
5
6
Park the machine on a flat, even surface.
Lower the squeegee.
Loosen the (horizontal) squeegee-mount lock bolt (found on right side next to the recovery hose tube).
Loosen the locking nut on the (vertical) tilt adjustment bolt on the squeegee tongue.
Turn the adjustment bolt with a wrench to tilt the tool forward or backwards, until the rear squeegee wiping blade touches the
floor across its entire width.
Re-tighten both the adjustment nut and mount lock bolt.
FIGURE 7
Tilt Adjustment Bolt
Locking Nut
Squeegee Mount
Lock Bolt
Rear Squeegee
Wiping Blade
VACUUM SYSTEM
______________________________________________________________________________________________
TROUBLESHOOTING
______________________________________________________________________________________________
Problem: Machine will not pick up water, water flows around ends of squeegee
1 Plug for recovery tank drain hose not sealing air-tight — install plug properly or replace if damaged.
2
Recovery tank cover not installed properly — push cover down all the way, so it seals air-tight against the top of the
tank.
3
Damaged gasket on recovery tank cover — replace gasket.
4
Low battery voltage — charge or replace batteries.
5
Vacuum motor defective — repair or replace vacuum motor.
______________________________________________________________________________________________
Problem: Water in vacuum motor
1 Operator using high-sudsing detergent — use low-sudsing detergent or add a defoaming chemical to the recovery
tank.
2
Vacuum leak in recovery tank drain hose or plug — replace hose or plug.
3
Vacuum shut-off float ball not closing — clean or replace float ball and cage (mounted on recovery tank cover).
______________________________________________________________________________________________
Problem: Float closes before tank is full
1 Foam in recovery tank — use low-sudsing detergent or add a defoaming chemical to the recovery tank.
2
Cage around vacuum shut-off float clogged — disconnect hoses from recovery tank cover, remove the cover and
clean or replace the float cage.
VACUUM SYSTEM
_____________________________________________________________________________________________________________________________
TROUBLESHOOTING (continued)
______________________________________________________________________________________________
Problem: Vacuum motor will not run when squeegee is lowered
1 Tripped vacuum motor circuit breaker (see Figures 8A and 8B) — press reset button, check circuit breaker for
continuity.
2
Defective vacuum switch (see Figure 9) — remove cover panel from back of control handle, adjust or replace switch.
3
Defective vacuum motor — remove motor, repair or replace.
4
Defective vacuum motor solenoid (see Figures 8A and 8B)— replace solenoid.
FIGURE 8A
BA 800, BA 1000 Before SN 1081111
FIGURE 9
FRONT
Vac Motor Solenoid
Vac Motor
Circuit Breaker
FIGURE 8B
Vacuum
Switch
BA 700 After SN 1082068
BA 800, BA 1000 After SN 1081110
All 28LX / 280HD
All 32LX, 38LX / 320HD, 380HD
Vac Motor
Solenoid
FRONT
Vac Motor
Circuit Breaker
WHEEL DRIVE SYSTEM
______________________________________________________________________________________________
MAINTENANCE
Lubricate the drive wheel bearings once per month. For access to the grease fitting, open the left splash guard, raise
the brushes and remove the left scrub brush from the machine.
______________________________________________________________________________________________
CHAIN REMOVAL OR ADJUSTMENT
______________________________________________________________________________________________
CHAIN REMOVAL:
1
Drain and remove the solution and recovery tanks, disconnect and remove the batteries and squeegee.
2
Remove the left splash guard and scrub brush. Then tip the machine over on its left side.
3
See Figure 1. Loosen Lock Nut (A) and back out Bolt (B) several turns to loosen tension on the drive chain, then
remove the chain from the motor sprocket.
4
Disconnect the master link in the drive chain and remove the chain from the machine.
5
Follow steps 1-4 in reverse order to reassemble. Adjust the chain tension. See the “Chain Adjustment” instructions
follow step 2.
6
Test the drive system for proper operation.
FIGURE 1
C
F
G
FRONT
E
A
B
D
WHEEL DRIVE SYSTEM
_____________________________________________________________________________________________________________________________
CHAIN REMOVAL OR ADJUSTMENT (continued)
______________________________________________________________________________________________
CHAIN ADJUSTMENT:
1
Follow steps 1 & 2 from the Chain Removal section above.
2
See Figure 1. Loosen Lock Nut (A), turn Bolt (B) to adjust chain tension. There should be about 1/2 inch (12 mm)
of deflection between the sprockets when moderate pressure is applied to the chain.
3
Follow steps 1 & 2 in reverse order to reassemble.
4
______________________________________________________________________________________________
DRIVE MOTOR REPLACEMENT
1
Drain and remove the solution and recovery tank, disconnect and remove the batteries and squeegee.
2
3
See Figure 1. Cut the plastic tie strap holding the vac hose and wiring onto motor mount Bracket (C). Then disconnect
the (2) motor wires from the red terminals. Note that the positive motor wire and the blue wire from the machine wiring
harness are connected to the same terminal.
4
Remove the Bolt (D) and Washer (E) from the end of the motor shaft.
5
Loosen Lock Nut (A) and back out Bolt (B) several turns to loosen the tension on the drive chain, then remove the
chain from the motor sprocket.
6
Loosen the (2) set screws in Motor Sprocket (F) and pull the sprocket off the motor shaft.
7
Put a wood block under the motor so that it will not fall. Then remove the (4) Bolts (G) and separate the motor from
Bracket (C).
8
Follow steps 1 - 7 in reverse order to re-assemble.
Note: Install a new plastic tie strap to hold the wiring and vac hose away from any moving parts.
WHEEL DRIVE SYSTEM
______________________________________________________________________________________________
DRIVE WHEEL REPLACEMENT
1
Drain and remove the solution and recovery tank, disconnect and remove the batteries and squeegee.
2
3
See Figure 2. Loosen Lock Nut (H) and back out Bolt (I) several turns to loosen the tension on the drive chain, then
remove the chain from the motor sprocket.
FIGURE 2
FRONT
H
I
J
4
Remove the (4) (J) Bolts (2 at each end of the axle) and pull the wheel assembly away from the machine frame.
5
Remove the (6) bolts that hold the brake disc and sprocket on the wheel.
6
Using a rubber mallet or brass drift, drive the axle and one of the bearings out of the wheel. Then drive the other
bearing out of the wheel.
7
Follow steps 1-6 in reverse order to reassemble.
8
Refer to the Chain Adjustment section for proper chain tension.
9
WHEEL DRIVE SYSTEM
______________________________________________________________________________________________
TROUBLESHOOTING
______________________________________________________________________________________________
Problem: No wheel drive - forward or reverse
1
Tripped wheel drive circuit breaker - press reset button and check circuit breaker for continuity.
2
Defective wheel drive motor - follow instructions below to test.
• Jack up the front of the machine to lift the drive wheel off the floor.
• Turn Key Switch (11) OFF.
• Disconnect one of the battery cables.
• Remove the back panel from control handle.
• Disconnect the white/green wire from the M2 terminal on the speed control. Connect this wire to one of the B+
terminals (also on the speed control).
• Disconnect the blue wire from the M1 terminal on the speed control. Connect this wire to one of the B- terminals
(also on the speed control).
• Reconnect the battery cable and then turn key ON. If the wheel motor turns, go to steps 3. If the wheel motor does
not turn, remove the tanks and batteries, tip the machine on its side and repair or replace the wheel drive motor.
3
Defect in potentiometer mechanism - follow instructions below to test.
• Make sure that the white, green and black wires are firmly connected to the potentiometer. The white wire should
be on the potentiometer terminal closest to the front of the machine, the green wire on the center terminal and the
black wire on the terminal closest to the back of the machine.
• Disconnect the potentiometer plug (the one with the green, black and white wires) from the speed control.
• Connect an ohmmeter to the green and white wires. NOTE: Inserting a paper clip into the plug end will help in the
attachment of the test leads. Meter should read 2400 - 2600 ohms in neutral and increase to 5000 ohms when the
twist grips are turned to the full-forward position. If you do not get these readings, follow potentiometer adjustment
instructions. If you do get these readings, go to the next test.
• Connect an ohmmeter to the green and black wires. Meter should read 2400 - 2600 ohms in neutral and decrease
to 100 - 300 ohms when the twist grips are turned to the full-forward position. If you do not get these readings, follow
potentiometer adjustment instructions. If you do get these readings, the potentiometer is OK — replace the speed
control.
WHEEL DRIVE SYSTEM
______________________________________________________________________________________________
POTENTIOMETER ADJUSTMENT
Adjust the potentiometer if the machine has no drive, or if it moves with the twist grips in neutral. To adjust the
potentiometer...
1
Remove the back panel from the control handle.
2
Carefully inspect the potentiometer belt and pulley mechanism for a mechanical defect, correct defects before
proceeding.
3
Carefully pull the potentiometer connector (the one with the green, black and white wires) off of the speed control.
4
Connect an ohmmeter (on 0 x 100 scale) to the green and white wires on the connector. The meter should read
between 2400 and 2600 ohms. If it does not, go to the next step.
5
Loosen the (2) set screws (using a 5/64 Allen wrench) in the potentiometer pulley and slide it off of the potentiometer
shaft (if the potentiometer shaft does not have a slot in the end of it) (if it does, use a screw driver to adjust the
potentiometer after loosening the pulley set screws).
6
Turn the potentiometer shaft until the ohmmeter reads between 2400 and 2600 ohms.
7
Slide the pulley back onto the potentiometer shaft, being careful not to turn the shaft.
8
Test the drive system for proper operation before reinstalling the back panel.
BATTERY SYSTEM
______________________________________________________________________________________________
WARNING!
Use extreme caution when working with batteries. Sulfuric acid in batteries can cause severe injury if allowed to contact
skin or eyes. Explosive hydrogen gas is vented from inside the batteries through openings in the battery caps. This gas
can be ignited by any electrical arc, spark or flame.
When working with batteries:
•
Remove all jewelry.
•
Wear chemical goggles, rubber gloves and a protective apron.
•
Do not smoke.
•
Do not allow tools to touch more than one battery terminal at a time.
•
Work in a well-ventilated area.
•
Do not fill the batteries before charging.
______________________________________________________________________________________________
BATTERY MAINTENANCE
Proper maintenance of electric vehicle batteries can greatly extend their life. Well-maintained batteries may last up to 3
years, but failure after 1 year is common if maintenance has been poor.
There are 3 simple rules for good battery maintenance:
•
Maintain Proper Electrolyte Level – Check the electrolyte level of the batteries at least once a week. Use distilled
water in batteries whenever possible. If batteries are discharged, add just enough water to cover the plates in each
cell. After batteries are fully charged, fill each cell to the bottom of the filler tube. Do not over-fill the batteries! Do
not add acid to batteries!
•
Keep the Batteries Charged - Batteries should be charged each time that a machine is used for more than 1 hour
or when the Battery Meter (17) indicates batteries are empty. Machine operators should tip the solution and recovery
tank to the side of the machine for charging, to avoid a concentrated build-up of hydrogen gas. Push the connector
from the charger into the Power Connector (5). Operators should follow the instructions provided with their specific
battery charger, to determine how long the batteries should be charged. Even when a machine is stored, the batteries
should be charged once a month to prevent the batteries from “sulfating”. Almost all battery caps are vented, so
there’s no need to loosen or remove them for charging.
•
Keep the Batteries Clean - Use a damp cloth to wipe dirt and liquid from the top of the batteries. Battery terminals
must be clean and tight. If the top of the batteries are wet after charging, the batteries have probably been over-filled.
Always wipe water and acid from the top of the batteries after charging. If there is acid on the batteries, wash the
tops of them with a solution of baking soda and water (2 tablespoons of baking soda to 1 liter of water).
BATTERY SYSTEM
______________________________________________________________________________________________
BATTERY TESTING
A battery problem is usually recognized by the machine operator, as a decrease in the machine’s running time. This
condition is usually caused by one (or more) “dead cell” in the battery system- that is, one (or more) cell that is putting out
less voltage than the other cells.
Note: Always charge batteries before testing.
There are 2 ways to find a dead cell:
•
Use a hydrometer to check the specific gravity (or “state of charge”) of the fluid in each cell. A dead cell is one that
reads 50 points (or more) lower than the other cells.
•
Use a volt meter to check the voltage of each battery with the brush and vac motors running. The battery with the
dead cell will read 1 or 2 volts lower than the other batteries in the system.
If the batteries in the machine are more than 1 year old, it’s usually best to replace the whole set, rather than replacing
just one battery.
FIGURE 1
BLACK
RED
36V
395 AH USA / ESPANOL / NIPPON
305 AH ITALIANO / FRANCAIS /
238 AH DEUTSCH
@20HR
Proper installation and cable
routing of (6) 6 Volt batteries
NOTES
ELECTRICAL SYSTEM
COMPONENT LOCATION
11
12
Item
17
15
16
1
2
10
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Speed Controller
Circuit Breaker 5 Amp (Control Circuit)
Circuit Breaker 25 Amp (Wheel Drive)
Circuit Breaker 25 Amp (Vacuum Motor)
Circuit Breaker 80 Amp (Brush Motor)
Solenoid (Vac Motor)
Solenoid (Brush Motor)
Solenoid (Wheel Drive Motor)
Solution Solenoid Valve
Vacuum Motor
Actuator Motor (Brush Lift)
Wheel Drive Motor
Brush Motor
Potentiometer 5K Ohm
Charger Interlock Switch
Main Key Switch
18
19
20
21
22
*Solenoid (Brush Down)
*Solenoid (Brush Up)
*Solenoid (Brush Motor)
*Time Delay, 1.5 sec.
*Circuit Breaker, 70 Amp (Brush Motor)
1
9
6
14
18
9
21
13
19
5
8
3
20
4
22
7
7
3
5
4
*Electrical Panel used only on
BA 700‘s before SN 1082069 &
BA 800/1000’s before SN 1081111
ELECTRICAL SYSTEM
BA 800, BA 1000 Before SN 1081111
X8
+
RED
BT
-
X9
BLK
36 Vdc
RED
F1
RED
BLK
X1
S1
VIO/BRN
S4
H1
R1
VIO
BLU/WHT
P1
1
VIO/BRN
VIO
BLK
2
4
BLK
3
P2
VIO
BLK
K5
VIO
BLK
D4
K1
S3
BLK
BRN/RED
VIO
D1
S2
UP
5
4
BRN/WHT 2
6
1
3
VIO
K2
GRN/BLU
BLK
WHT/RED
D2
YEL
DOWN
K3
BRN/WHT
BLK
D3
5
6
1
3
2
R3
YEL/WHT
S5 4
H2
BLK
WHT/BLK
BLK
F2
RED
BRN
K4
D5
BRN
BLU
X7
YEL/VIO
+
M3
L
3
E 4
BB+
M1
M2
2
5
1
6
X6
-
WHT/ORN
K5
WHT/GRN
YEL
RED/GRN
+
A
P2
- 1
VIO
BLK
R2
P1
GRN
WHT
1
FWD. OFF REV.
F5
X4
RED/BLK
VIO
BLK
WHT
K2
M2
VIO
ORN/BLK
BLK
K3
RED
F3
RED
YEL/BRN
K1
X5
X5
YEL/BLK
BLK
M1
F4
2
27
K4
3
X2
M4
+
-
X3
4
ELECTRICAL SYSTEM
R2
OFF
WHT
REV.
Battery Fuel Gauge
Hourmeter (Optional)
R1
R2
R3
330 Ohm Resistor
5K Ohm Potentiometer
330 Ohm Resistor
S1
S2
S3
S4
S5
Main Switch
Brush Switch
Vacuum Motor Switch
Solution Switch
X1
X2
X3
X4
X5
X6
X7
X8
X9
Charger Connector
Brush Motor + Terminal Stud
Brush Motor - Terminal Stud
Actuator Motor Connector
Vacuum Motor Connector
Wheel Drive Motor - Terminal Stud
Wheel Drive Motor + Terminal Stud
+ Terminal Stud
- Terminal Stud
FWD.
1
6
27
BLK OC-B
D1
BRN/RED 12A-B
YEL/BRN 41A-B
YEL/BLK 40A-A
BLK 0B-B
K1
BLK 0J-A
BLK 0B-A
BLK 0A-A
BLK 0K-A
YEL/WHT 49B-B
YEL/WHT 49B-A
YEL/WHT 49A-A
WHT/BLK 90A-B
WHT/BLK 90B-B
WHT/BLK 90B-A
BRN/WHT 19D-A
BRN/WHT 19D-B
BRN/WHT 19C-B
BLK 0H-B
BLK 0N-B
YEL/WHT 49A-B
BLK 0M-B
BLK 0H-B
M1
WHT/GRN 95A-B
M2
YEL 4A-B
RED/GRN 25A-B
VIO 7H-A
+
P2
1
P3
1
D3
BLK 0G-B
BLK 0F-B
ORN/BLK 30B-B
K3
30A-B
ORN/BLK 30A-A
BLK 0F-A
BLK 0E-A
VIO 7H-B
VIO 7G-B
GRN/BLU 56A-B
D2
BLK 0E-B
BLK 0D-B
RED/BLK 20B-B
K2
20A-B
RED/BLK 20A-A
BLU/WHT 69A-A
VIO/BRN 71A-B
X9
X8
S4
X1
4
BLK
+
RED
BLK
-
BT
RED 2D-A
RED 2C-A
RED 2B-A
RED 2A-A
2
BLK 0D-A
BLK 0C-A
VIO 7G-A
VIO 7F-A
F2
F1
WHT/ORN 93A-B
X6
BLU 6A-B
X7
RED/GRN 25B-B
M4
-
X3
L
4
WHT
WHT/BLK 90A-A
X4
RED/BLK 20B-A
BLK 0K-B
ORN/BLK 30B-A
YEL/BLK 40A-B
M2
M
27
M3
M
X5
M
BLK
F4
F3
2
RED
+
36 Vdc
M
VIO/BRN 71B-B
VIO 7J-B
VIO 7B-A
RED
BLK 0G-B
BLK 0M-B
K4
BRN/WHT 19B-B
RED
YEL/VIO 47A-A
+
B+
RED 2D-B
BLU 6A-A
WHT/RED 92A-B
BRN/WHT 19A-B
3
D5
BLK
GRN
WHT
BLK 0L-A
RED/GRN 25A-A
RED/GRN 25B-A
BRN/WHT 19B-B
3 X2
B-
YEL/BRN 41A-A
P1
P2
A
RED 2C-B
Vacuum Motor
Actuator Motor
Wheel Drive Motor
Brush Motor
K5
WHT/ORN 93A-A
F5
Solenoid Valve
M1
M2
M3
M4
VIO 7C-B
VIO 7J-A
YEL 4A-A
VIO 7D-B
RED
2
5
6
1
3
BRN 1A-A
E
3
4
2
3
BLK 0A-B
BLK 0L-B
D4
WHT/GRN 95A-A
S1
4
RED 2A-B
L
3
4
5
R3 H2
BRN 1A-A
Vacuum Motor Solenoid
Actuator Motor Up Solenoid
Actuator Motor Down Solenoid
Brush Motor Solenoid
Wheel Drive Motor Solenoid
h
V
RED 2B-B
K1
K2
K3
K4
K5
4
1
P1 2
VIO/BRN 71B-A
VIO/BRN 71A-A
Green Lamp
Blue Lamp
P2 2
BLK 0J-B
5 Amp Circuit Breaker
4 Amp Fuse
H1
H2
1
6
1
3
GRN
BLK
Time Delay Module (on break)
VIO 7E-A
VIO 7C-B
BRN/WHT 19C-A
BRN/WHT 19A-A
E
BLK 0N-B
Suppression Diode
Suppression Diode
Suppression Diode
Suppression Diode
Regenerative Feedback Diode
VIO 7A-B
VIO 7B-B
D1
D2
D3
D4
D5
BLU/WHT 69A-B
Batteries
VIO 7A-A
VIO 7D-A
Speed Controller
BT
F1
F2
F3
F4
F5
RED/BRN 12A-A
Description
VIO 7F-B
VIO 7E-B
A
5
2
YEL/VIO 47A-B
Item
S5
S2 4
R1 H1
S3
WHT/RED 92A-A
GRN/BLU 56A-A
WIRING DIAGRAM / SCHEMATIC
BA 700’s Before SN 1082069
BA 800/1000 Before SN 1081111
M1
ELECTRICAL SYSTEM
• Convertamatic 28/32/38LX Before SN 1082119
• Hydro Retriever 280/320/380HD Before SN 1082119
• BA 700 between SN 1082069 and SN 1082119
• BA 800, BA 1000 between SN 1081111 and SN 1082119
X8
BT
+
RED
-
X9
BLK
36 Vdc
RED
F1
RED
BLK
X1
S1
VIO/BRN
S4
H1
R1
VIO
BLU/WHT
P1
1
VIO/BRN
2
4
VIO
BLK
BLK
3
P2
VIO
BLK
K5
BLK
VIO
D4
K1
S3
BLK
BRN/RED
VIO
D1
BLK
X10
S2
VIO
5
4
2
6
1
3
IN 2
IN 1
TIMER OUT
DIR
MOTOR MOTOR +
BB+
RED/GRN
BLK/YEL
WHT/RED
UP
BLK
WHT
M2
X4
DOWN
ORN/BLK
RED/BLK
BLK
VIO
RED/WHT
BRN/WHT
K4
D2
5
S5 4
R3
YEL/WHT
2
BRN
BLK
BB+
M1
M2
BRN
BLU
X7
+
WHT/BLK
D5
H2
6
1
3
F2
RED
E
M3
X6
-
WHT/ORN
K5
WHT/GRN
+
L
A
P2
- 1
RED/GRN
VIO
BLK
R2
P1
GRN
WHT
1
FWD. OFF REV.
F5
RED
F3
RED
YEL/BRN
K1
X5
X5
YEL/BLK
BLK
M1
F4
2
27
K4
3
X2
M4
+
-
X3
4
ELECTRICAL SYSTEM
Battery Fuel Gauge
R1
R2
R3
330 Ohm Resistor
330 Ohm Resistor
X1
X2
X3
X4
X5
X6
X7
X8
X9
X10
YEL/WHT 49B-B
YEL/WHT 49B-A
YEL/WHT 49A-A
WHT/BLK 90A-B
WHT/BLK 90B-B
WTH/BLK 90B-A
BRN/WHT 19D-A
BRN/WHT 19D-B
BRN/WHT 19C-F
BLK 0H-A
BLK 0N-A
YEL/WHT 49A-B
BLK 0H-B
BLK
GRN
WHT
BLK 0G-B
D1
K1
P3
1
X11
K4
BLK/YEL 04A-A
27
RED
3
BRN/RED 12A-B
YEL/BRN 41A-B
YEL/BLK 40A-A
BLK 0B-B
RED/GRN 25A-A
RED/GRN 25B-A
BLK/YEL 04A-B
WHT/RED 92A-B
ORN/BLK 30B-B
RED/BLK 20B-B
BLK 0D-A
VIO 7G-B
X10
E
8
IN 2
IN 1
TIMER OUT
DIR
MOTOR MOTOR +
BB+
1
BLK 0C-A
BLK 0J-A
BLK 0B-A
BLK 0A-A
BLK 0K-A
BLU/WHT 69A-A
VIO/BRN 71A-B
X9
X8
S4
X1
Main Switch
Brush Switch
Vacuum Motor Switch
Solution Switch
Charger Connector
+ Terminal Stud
- Terminal Stud
Actuator Control Module Connector
RED/GRN 25A-B
VIO 7F-A
4
BLK
+
RED
BLK
-
BT
RED 2D-A
RED 2C-A
RED 2B-A
RED 2A-A
2
3 X2
M
-
X3
L
4
On 28 IN. (700 MM) Models
Connect Cable 3 to (-).
0n 32 & 38 IN. (800 & 1000 MM)
Models Connect Cable 3 to (+).
WHT/ORN 93A-B
X6
BLU 6A-B
X7
RED/GRN 25B-B
M4
+
F3
WHT
WHT/BLK 90A-A
X4
RED/BLK 20B-A
BLK 0K-B
ORN/BLK 30B-A
YEL/BLK 40A-B
M2
M
27
M3
M
X5
M
BLK
F4
2
RED
+
36 Vdc
F2
F1
YEL/BRN 41A-A
P1
P2
M2
+
P2
1
-
RED 2C-B
Vacuum Motor
Actuator Motor
Wheel Drive Motor
Brush Motor
S1
S2
S3
S4
S5
D2
Solenoid Valve
M1
M2
M3
M4
FWD.
M1
WHT/GRN 95A-B
BRN 1A-A
L
OFF
REV.
K5
BLK/WHT 19A-B
B+
RED 2B-B
K1
K4
K5
D5 RED 2D-B
RED 2A-B
Green Lamp
Blue Lamp
R2
WHT/ORN 93A-A
H1
H2
F5
WHT/GRN 95A-A
4 Amp Fuse
A
BLU 6A-A
GRN
BLK
F1
F2
F3
F4
F5
6
1
3
BVIO 7D-B
WHT
2
BRN 1A-B
RED
E
S1
4
5
H2
3
D4
BLU/WHT 69A-B
Suppression Diode
Suppression Diode
Suppression Diode
VIO 7G-A
VIO 7A-A
VIO 7D-A
D1
D2
D4
D5
Batteries
R3
BLK 0A-B
BLK 0J-B
BT
V
VIO/BRN 71B-B
VIO 7J-B
VIO 7B-A
RED
Speed Controller
4
P1 2
BLK 0M-B
h
1
3
BLK 0GA
BLK 0M-A
4
BRN/WHT 19C-A
BRN/WHT 19A-A
WHT/RED 92A-A
BLK 0D-B
BLK 0C-B
VIO 7E-A
VIO 7C-B
BLK 0N-B
VIO 7A-B
VIO 7B-B
BRN/RED 12A-A
1
6
1
3
P2 2
VIO/BRN 71B-A
VIO/BRN 71A-A
A
Description
4
5
2
VIO 7F-B
VIO 7E-B
Item
S5
S2
R1 H1
S3
VIO 7C-A
VIO 7J-A
•Convertamatic 28/32/38LX Before SN 1082119
•Hydro Retriever 280/320/380HD Before SN 1082119
•BA 700 between SN 1082069 and SN 1082119
•BA 800, BA 1000 between SN 1081111 and SN 1082119
M1
ELECTRICAL SYSTEM
All Models After SN 1082118
X8
+
RED
BT
-
X9
BLK
36 Vdc
RED
F1
RED
BLK
X1
S1
VIO/BRN
S4
H1
BLU/WHT
BLK
VIO
P1
1
VIO/BRN
VIO
2
4
BLK
3
P2
VIO
BLK
K5
VIO
BLK
D4
K1
S3
BLK
BRN/RED
VIO
D1
BLK
X10
S2
5
4
2
6
1
3
IN 2
IN 1
TIMER OUT
DIR
MOTOR MOTOR +
BB+
RED/GRN
BLK/YEL
WHT/RED
UP
BLK
WHT
M2
X4
DOWN
ORN/BLK
RED/BLK
BLK
VIO
E
K4
VIO
D2
D5
RED
RED/WHT
5
VIO
S5 4
H2
YEL/WHT
6
2
1
3
F2
RED/WHT
BRN
BLU
BRN
VIO
L
X7
WHT/BLK
RED
BLK
BLK
BB+
M1
M2
+
M3
X6
-
WHT/ORN
K5
WHT/GRN
+
A
P2
- 1
GRN/BLU
VIO
BLK
GRN/BLU
R2
P1
GRN
WHT
X11
FWD. OFF REV.
1
F5
RED
F3
RED
YEL/BRN
K1
X5
X5
YEL/BLK
BLK
M1
F4
2
27
K4
3
X2
M4
+
-
X3
4
ELECTRICAL SYSTEM
S5
Battery Fuel Gauge
R2
S1
S2
S3
S4
S5
Main Switch
Brush Switch
Vacuum Motor Switch
Solution Switch
X1
X2
X3
X4
X5
X6
X7
X8
X9
X10
X11
Charger Connector
+ Terminal Stud
- Terminal Stud
Actuator Control Module Connector
Speed Controller Connector
D2
RED
3
GRN/BLU 56A-B
VIO 7G-B
BLK
GRN
WHT
K4
VIO 7K-A
VIO 7L-A
BLK 0B-B
K1
RED/GRN 25A-A
RED/GRN 25B-A
BLK 0F-A
BLK 0G-A
YEL/WHT 49B-B
YEL/WHT 49B-A
YEL/WHT 49A-A
VIO 7C-B
VIO 7E-A
WHT/BLK 90A-B
BLK 0E-B
BLK 0F-B
P3
1
X11
RED/WHT 29A-B
RED 2D-B
D5
27
D1
YEL/WHT 49A-B
RED
BLK 0E-A
RED/GRN 25A-B
WHT/RED 92A-A
BLK 0H-B
BLK 0J-B
GRN/BLU 56A-A
BLK 0D-A
M2
BRN/RED 12A-B
YEL/BRN 41A-B
YEL/BLK 40A-A
BLK 0A-B
+
P2
1
-
X10
E
8
IN 2
IN 1
TIMER
OUT DIR
MOTOR MOTOR +
BB+
RED/GRN 25B-B
BLK/YEL 04A-B
WHT/RED 92A-B
ORN/BLK 30B-B
RED/BLK 20B-B
BLK 0J-A
VIO 7H-B
1
BLK 0A-A
BLK 0H-A
BLK 0K-A
BLK 0L-A
BLU/WHT 69A-A
VIO/BRN 71A-B
X9
X8
S4
X1
4
BLK
+
RED
BLK
-
BT
RED 2D-A
RED 2C-A
RED 2B-A
RED 2A-A
2
3 X2
M
-
X3
L
4
On 28 IN. (700 MM) Models
Connect Cable 3 to (-).
0n 32 & 38 IN. (800 & 1000 MM)
Models Connect Cable 3 to (+).
WHT/ORN 93A-B
X6
BLU 6A-B
X7
VIO 7L-B
M4
+
F3
WHT
WHT/BLK 90A-A
X4
RED/BLK 20B-A
BLK 0K-B
ORN/BLK 30B-A
YEL/BLK 40A-B
M2
M
27
M3
M
X5
M
BLK
F4
2
RED
+
36 Vdc
F2
F1
YEL/BRN 41A-A
P1
P2
FWD.
M1
WHT/GRN 95A-B
RED 2C-B
Vacuum Motor
Actuator Motor
Wheel Drive Motor
Brush Motor
OFF
REV.
K5
BLK/YEL 04A-A
Solenoid Valve
M1
M2
M3
M4
R2
BRN 1A-A
B+
RED 2B-B
K1
K4
K5
B-
RED/WHT 29A-A
BLU 6A-A
F5
6
1
3
A
VIO/BRN 71B-A
VIO/BRN 71A-A
Green Lamp
Blue Lamp
2
3
BRN 1A-B
RED 2A-B
H1
H2
S1
V
4
4
5
H2
BLK 0L-B
WHT/ORN 93A-A
4 Amp Fuse
1
3
VIO 7J-B
VIO 7K-B
WHT/GRN 95A-A
F1
F2
F3
F4
F5
h
P1 2
D4
GRN
BLK
4
BLK 0C-A
BLK 0B-A
WHT
E
BLK 0G-B
Suppression Diode
Suppression Diode
Suppression Diode
RED
D1
D2
D4
D5
VIO 7A-B
VIO 7B-B
Batteries
BLU/WHT 69A-B
BT
L
BRN/RED 12A-A
Speed Controller
VIO 7B-A
VIO 7C-A
A
Description
VIO 7A-A
VIO 7J-A
VIO 7H-A
Item
1
6
1
3
2
P2 2
VIO/BRN 71B-B
VIO 7F-A
VIO 7G-A
4
5
BLK 0C-B
BLK 0D-B
S2
H1
S3
VIO 7E-B
VIO 7F-B
All Models After SN 1082118
M1
DANMARK
Nilfisk-Advance Nordic A/S
Myntevej 3, 8900 Randers
86 42 84 33 – Fax 86 41 19 55
HONG KONG
Nilfisk-Advance Ltd.
2001, 20/F HK Worsted Mills
Industrial Building
31-39 Wo Tong Tsui Street
Kwai Chung, N.T.
2427 59 51 – Fax 2487 5828
UNITED KINGDOM
Nilfisk-Advance Limited
Newmarket Road
Bury St. Edmunds
Suffolk IP 33 3SR
(01284) 763163 – Fax (01284) 750562
TAIWAN
1 F, No.23, Lane 132, Sec. 2
Ta An Road, Taipei
700 22 68 – Fax 784 08 43
GREECE
Embiom S.A.
§ÂˆÊ. µÔ˘ÏÈ·ÁÌ¤ÓË˜ 60
∞ÚÁ˘ÚÔ‡ÔÏË
164 52 ∞ı‹Ó·
☎ 9950613 - Fax 9951680
Institutionen und Gebäudereiniger: 0180 500 11 70
FRANCE
Nilfisk-Advance S.A.
BP 246
91944 Courtaboeuf Cedex
(01) 69.59.87.00 Télécopie (01) 69.59.87.01
www.nilfisk-advance.com
© 2001 Printed in USA
NORGE
Nilfisk-Advance AS
Enebakkvn, 119, 0680 Oslo, Postboks 196, Manglerud,
USA
0612 Oslo
Nilfisk-Advance Inc.
IRELAND
22 08 63 50 – Fax 22 08 63 63
14600 21st Avenue North
Distriktsrepresentanter over hele landet
Plymouth, MN 55447-3408
28 Sandyford Office Park
+1 800 989 2235 – Fax 1 800 989 6566
Dublin 18
SVERIGE
+353 1 2943838 – Fax +353 1 2943845
Nilfisk-Advance AB
Nilfisk-Advance of America, Inc.
Sjöbjörnsvägen 5, 117 67 Stockholm
300 Technology Drive
JAPAN
085 55 944 00 – Fax 085 55 944 30
Malvern, PA 19355
Nilfisk-Advance Inc.
(610) 647 647-6427
3-4-9 Chigasaki Minami
FINLAND/ SUOMI
Tsuzuki-Ku Yokohama 224
Oy Tecalemit AB
ÖSTERREICH
045-942-7741 – Fax 045-942-6545
Hankasuontie 13, 00390 Helsinki
Nilfisk-Advance GmbH
(89) 547 701 – Fax (89) 547 1779
Vorarlberg Allee 46
MALAYSIA
1230 Wien
Nilfisk-Advance Sdn Bhd
AUSTRALIA
1 616 58 30 – Fax 1 616 58 30 40
Lot 2, 1st. Floor
Nilfisk-Advance Pty. Ltd.
Lorong 19/1A
ACN 003 762 623
ESPAÑA
46300 Petaling Jaya
Head office: 17 Leeds Street, Rhodes, N. S. W. 2138
Selangor Darul Ehsan
Nilfisk-Advance, S.A.
(02) 9736 1244 – Fax (02) 9736 3910
03-7568188 / 03-7568189 / 03-7568388 – Fax 03-7566828 Torre D’Ara
Customer Responce Centre:
Passeig del Rengle, 5 PI.9-10
1 800 011 013
E-08302 – Mataró (Barcelona)
NEDERLAND
Tel. 93 741 24 00 – Fax: 93 757 80 20
Nilfisk-Advance B.V.
Central atención al cliente: 902 200 201
BELGIQUE / BELGIË/ LUXEMBOURG
Flevolaan 7, Postbus 341
Nilfisk-Advance s.a./n.v.
[email protected] – www.nilfisk-advance.com
1380 AH Weesp
Doornveld/ Sphere Business Park
Distribuidores y Servicio Técnico en toda España y
0294-462121 – Fax 0294-430053
Andorra
Industrie Asse 3, nr 11 – bus 41
1731 Zellik-Asse
NEW ZEALAND
ITALIA
Nilfisk-Advance Limited
(02) 467.60.50 Fax (02) 463.44.16
Nilfisk-Advance Italia Spa
477 Great South Road, Penrose
Località Novella Terza
CANADA
Auckland
26862 Guardamiglio (LO)
(09) 525 0092 – Fax (09) 525 6440
Italy
396 Watline Avenue
+39 0377 414021 – Fax +39 0377 414097
SCHWEIZ / SUISSE
Mississauga, Ontario L4Z 1X
www.nilfisk-advance.com
Nilfisk-Advance AG
(905) 712-3260 – Fax (905) 712-3255
Ringstrasse 19, 9533 Kirchberg/Wil
719 23 52 83 – Fax 719 23 84 44
PORTUGAL
DEUTSCHLAND
Nilfisk-Advance Lda.
Nilfisk-Advance AG
Rua Cândido de Figueiredo, 91-i, 1500-133 LISBOA
SINGAPORE
Siemensstraße 25-27
Nilisk-Advance Pte. Ltd.
01/7784142 – Fax 01/7785613
25462 Rellingen
10, Woodlands Loop
Porto 02/526766 – Fax 02/520739
(041 01) 3990 – Fax ( 04101) 399191
Singapore 738388
Açores 096/628092/3 – Fax 096/628129
Zentraler Kundenservice
(65) 759 9100 – Fax (65) 759 9133
Madeira 091/228965 – Fax 091/228796
für die Industrie: 0180 535 67 97

Convertamatic™ 28/32/38LX Hydro-Retriever™ 280/320

Transcription

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