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Nilfisk-Advance BA 625, Service Manual

The Nilfisk-Advance BA 625 is a powerful cleaning machine designed to effortlessly tackle dirt and grime. Ensure optimal performance and effective use of this equipment by downloading the Instructions For Use Manual from our website. Accessible, free, and easy-to-follow, it provides comprehensive guidance for getting the most out of your BA 625.

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FORM NO. 56043098 - Convertamatic

™

 24, 26, 28, 32 / BA 625, 725, 825 - 

1

TABLE OF CONTENTS

INTRODUCTION .......................................................................................................................................................................................... 2
CAUTIONS AND WARNINGS ...................................................................................................................................................................... 3
SPECIFICATIONS & MAINTENANCE....................................................................................................................................................... 4-6
PM CHECKLIST ........................................................................................................................................................................................... 7
KNOW YOUR MACHINE ......................................................................................................................................................................... 8-12
SOLUTION SYSTEM ............................................................................................................................................................................. 13-19
  FUNCTIONAL OVERVIEW ....................................................................................................................................................................... 13
  CIRCUIT OVERVIEW SOLUTION AUTO MODE ..................................................................................................................................... 14
  SOLUTION SYSTEM MAINTENANCE .................................................................................................................................................... 15
  TROUBLESHOOTING GUIDE ............................................................................................................................................................ 16-17
  SOLUTION SOLENOID VALVE REMOVAL .............................................................................................................................................. 18
  SOLUTION VALVE DISASSEMBLY AND CLEANING.............................................................................................................................. 18
  SOLUTION FILTER AND BALL VALVE REMOVAL .................................................................................................................................. 19
  SOLUTION PUMP REMOVAL .................................................................................................................................................................. 19
SCRUB SYSTEM .................................................................................................................................................................................. 20-27
  GENERAL BRUSH SYSTEM FUNCTIONAL OVERVIEW ....................................................................................................................... 20
  SPECIAL SCRUB SYSTEM FUNCTIONS .......................................................................................................................................... 20-21
  SCRUB BRUSH DECK REMOVAL (DISC) ......................................................................................................................................... 22-23
  SCRUB BRUSH LIFT ACTUATOR REMOVAL (DISC) ........................................................................................................................ 22-23
  SCRUB BRUSH MOTOR/GEARBOX REMOVAL (DISC) ................................................................................................................... 22-23
SCRUB BRUSH DECK LEVELING ............................................................................................................................................................ 24
  SCRUB BRUSH DECK REMOVAL (CYLINDRICAL) .......................................................................................................................... 26-27
  SCRUB BRUSH MOTOR(S) REMOVAL (CYLINDRICAL) .................................................................................................................. 26-27
  SCRUB BRUSH BELT REPLACEMENT (CYLINDRICAL) .................................................................................................................. 26-27
  SCRUB BRUSH SYSTEM MAINTENANCE (CYLINDRICAL).................................................................................................................. 26
  SCRUB BRUSH REMOVAL AND INSTALLATION (CYLINDRICAL) ........................................................................................................ 26
  SCRUB BRUSH LIFT ACTUATOR REMOVAL (CYLINDRICAL) ......................................................................................................... 26-27
RECOVERY SYSTEM ........................................................................................................................................................................... 28-34
  FUNCTIONAL OVERVIEW ....................................................................................................................................................................... 28
  VACUUM MOTOR CONTROL CIRCUIT OVERVIEW (AUTO MODE) ..................................................................................................... 29
  VACUUM/RECOVERY SYSTEM MAINTENANCE CHECKLIST ............................................................................................................. 30
  MAINTENANCE OF RECOVERY TANK FLOAT SWITCHES .................................................................................................................. 31
  MAINTENANCE OF VACUUM MOTOR INLET SCREEN ........................................................................................................................ 32
  VACUUM MOTOR REMOVAL .................................................................................................................................................................. 33
  RECOVERY TANK REMOVAL ................................................................................................................................................................. 34
SQUEEGEE SYSTEM ........................................................................................................................................................................... 35-38
  SQUEEGEE LIFT LINKAGE ADJUSTMENT ............................................................................................................................................ 35
  SERVICING THE SQUEEGEE ................................................................................................................................................................. 36
  ADJUSTING THE SQUEEGEE ................................................................................................................................................................ 36
  SQUEEGEE MOUNT ASSEMBLY REMOVAL ......................................................................................................................................... 37
  CASTER WHEEL REMOVAL ................................................................................................................................................................... 38
WHEEL DRIVE SYSTEM ...................................................................................................................................................................... 39-47
  GENERAL FUNCTIONAL OVERVIEW ................................................................................................................................................ 39-41
  WHEEL DRIVE TROUBLESHOOTING GUIDE ........................................................................................................................................ 42
  DRIVE MOTOR TRANSAXLE REMOVAL ........................................................................................................................................... 43-44
  DRIVE WHEEL REMOVAL ....................................................................................................................................................................... 45
  (5K) POTENTIOMETER (R1) TESTING AND REMOVAL ........................................................................................................................ 46
  (5K) POTENTIOMETER (R1) INSTALLATION AND ADJUSTMENT ................................................................................................... 46-47
  (100K) POTENTIOMETER (R2) TESTING AND REMOVAL .................................................................................................................... 47
ELECTRICAL SYSTEM ......................................................................................................................................................................... 48-75
  BATTERIES .............................................................................................................................................................................................. 48
  DESCRIPTION OF THE LOW VOLTAGE CUTOUT FEATURE ............................................................................................................... 49
  DESCRIPTION OF THE BATTERY CONDITION INDICATORS .............................................................................................................. 49
  BATTERY CHARGING, MAINTENANCE AND TESTING ................................................................................................................... 50-51
  ACTUATOR DRIVE NUT ADJUSTMENT ............................................................................................................................................ 52-53
  CURTIS CONTROLLER ...................................................................................................................................................................... 54-57
  FUNCTIONAL OVERVIEW OF MAIN CONTROL BOARD ...................................................................................................................... 58
  MAIN CONTROLLER ERROR CODES ................................................................................................................................................... 59
  MAIN CONTROLLER DIAGNOSTIC SERVICE TEST MODE ............................................................................................................ 60-64
  MAIN CONTROL PROGRAMING OPTIONS ...................................................................................................................................... 65-70
  ELECTRICAL COMPONENT LOCATION ................................................................................................................................................ 71
  WIRING DIAGRAM ................................................................................................................................................................................... 72
  WIRING SCHEMATIC............................................................................................................................................................................... 73
APPENDIX ............................................................................................................................................................................................. 74-76
  DETERGENT (AXP / EDS) SYSTEM PLUMBING SCHEMATIC ............................................................................................................. 74
  EXTENDED SCRUB SYSTEM PLUMBING SCHEMATIC ....................................................................................................................... 75
  DETERGENT (AXP / EDS) SYSTEM PREPARATION AND USE ............................................................................................................ 76

Note: 

 All references to right, left, front, or rear in this manual are as seen from the operator’s stand-point.

revised 5/07

Summary of Contents for BA 625

Page 1: ...6315000 24D C 56315001 26D 56315002 28D 56315003 24C C 56315004 28D C 56315005 28C C 56315006 X24D C 56315007 X24C C 56315008 26D C 56315009 X26D C 56315010 26C C 56315011 X26C C 56315012 X28D C 56315013 X28C C 56315804 32D C 56315805 X32D C Nilfisk Models 56315800 625 56315801 725 56315802 725C 56315803 825 ...

Page 2: ......

Page 3: ... MAINTENANCE OF RECOVERY TANK FLOAT SWITCHES 31 MAINTENANCE OF VACUUM MOTOR INLET SCREEN 32 VACUUM MOTOR REMOVAL 33 RECOVERY TANK REMOVAL 34 SQUEEGEE SYSTEM 35 38 SQUEEGEE LIFT LINKAGE ADJUSTMENT 35 SERVICING THE SQUEEGEE 36 ADJUSTING THE SQUEEGEE 36 SQUEEGEE MOUNT ASSEMBLY REMOVAL 37 CASTER WHEEL REMOVAL 38 WHEEL DRIVE SYSTEM 39 47 GENERAL FUNCTIONAL OVERVIEW 39 41 WHEEL DRIVE TROUBLESHOOTING GUI...

Page 4: ...__ SERIAL NUMBER ______________________________________________ TRANSPORTING THE MACHINE CAUTION Before transporting the machine on an open truck or trailer make sure that The machine is tied down securely All access doors and covers are secured tape and strap as needed TOWING CAUTION If the machine must be towed or pushed make sure the Master On Off Key Switch A is in the OFF position and do not ...

Page 5: ...uids exist Do not clean this machine with a pressure washer Do not operate this machine on ramps or inclines of more than a 2 percent gradient Only use the brushes provided with the appliance or those specified in the instruction manual The use of other brushes may impair safety CAUTION This machine is not approved for use on public paths or roads This machine is not suitable for picking up hazard...

Page 6: ...62 m hr 1598 m hr 1598 m hr 1719 m hr Scrub Head Size Type 2 12 in 30 5 cm brushes or pad holders 2 13 in 33 cm brushes or pad holders 2 14 in 35 5 cm brushes or pad holders 2 16 in 40 64 cm brushes or pad holders 2 23 in 58 cm brushes 2 25 in 64 cm brushes 2 27 in 69 cm brushes Scrub Pressure Regular Scrub max 80 lbs max 60 lbs Heavy Scrub max 130 lbs max 80 lbs Extreme Scrub max 160 lbs max 100 ...

Page 7: ...FORM NO 56043098 Convertamatic 24 26 28 32 BA 625 725 825 5 SPECIFICATIONS revised 5 07 ...

Page 8: ...ck every 500 hours or once a year WARNING Turn the key switch off and disconnect the batteries before servicing the machine Check vacuum motor carbon brushes Qty 2 once a year or after 300 operating hours Check brush and wheel drive motor s carbon brushes Qty 4 per motor once a year or after 500 operating hours The original new length of each carbon brush is 1 25 4mm on all 24 volt machine models ...

Page 9: ...fect Codes circle Does Not Work 10 Scrub Brushes check for wear and rotate D M W 11 Scrub Brush Motor s check for carbon brush wear 500 Hours B C W 12 Scrub Brush Motor s check gearboxes disc B D L 13 Brush Drive Plate Retainer Clips flex couplers disc C D M 14 Scrub Deck Lift Motor Skirt Side Wheel D M W 15 Solution Solenoid Valve C L W 16 Solution Pump Hoses C L W 17 Solution Tank Delivery Hoses...

Page 10: ...oint the location of an item mentioned in the text NOTE Refer to the service manual for detailed explanations of each item illustrated on the next 3 pages 1 Solution Tank Fill 2 Operator Control Handle 3 Bottle Holders 4 Vacuum Motor Inlet Screen 5 Recovery Tank Cover 6 Detergent AXP EDS Cartridge Access Cover 6a Detergent AXP EDS Cartridge AXP EDS models only 7 Scrub Deck 8 Scrub Deck Skirt 9 Scr...

Page 11: ...ut 21 Squeegee Adjustment Knob 22 Recovery Tank Drain Hose 23 Debris Hopper Cylindrical Models Only 24 Idler Assembly Cylindrical Models Only 25 Battery Pack Connector non onboard charger models only 25a Battery Pack Connector onboard charger models only 26 Squeegee Blade Tension Strap 27 Squeegee Blade Alignment Pins 28 Recovery Hose 29 Control Panel 30 Drive Paddle 31 Speed Limit Control Knob 32...

Page 12: ...uum Switch D Display Panel Solution Flow Indicator AXP EDS Indicator Hour Meter Battery Indicator Scrub Pressure Indicator Recovery Tank FULL Indicator Fault Indicator E Wand Switch Dealer Installed Option F Detergent System AXP EDS models only G Extended Scrub System Dealer Installed Option H Scrub OFF I Scrub ON revised 5 07 ...

Page 13: ...ed the scrub pressure will increase to the heavy scrub mode If the switch is held for 5 seconds the pressure will change to the extreme scrub mode At the same time the panel display will show the correct changed scrub pressure setting Wand Switch E This switch is used when an external vacuum scrub wand is used Pressing this switch will turn the vacuum on continuously without regard to the throttle...

Page 14: ...e and the machine is moving in either direction This indicator will be off if the scrub system has been turned OFF Extreme Scrub ON Indicators K L Both of these indicators will be yellow if the scrub system is enabled in Extreme scrub mode but the drive paddle is in neutral Both of these indicators will be green if the scrub system has been turned on in Extreme scrub mode and the machine is moving...

Page 15: ...ectrical Diagram Figure 2 The electrical circuit that turns on energizes the solenoid coil and water pump is activated through the A1 control panel s solution switch button input and the FWD REV A2 Speed Controller voltage output signals Note See the Know Your Machine section in this manual for a complete explanation of the solution operation modes During normal machine scrubbing the solution syst...

Page 16: ...ton enabled Anegative voltage output from theA2 speed controller s pin 6 Red Blk wire to theA1 control board Red Blk wire terminal J1 5 Note TheA2 speed controls brake output pin 6 occurs whenever the R1 direction throttle pot is moved off its neutral setting A negative voltage output from the A1 board s terminal J1 8 Grn Blk wire is direct to the M7 Solution Pump turning it on to allow flow to th...

Page 17: ...hassis panel No tools are needed to remove the filter hand tighten only Service Tip The solution filter ball valve must be placed in the OFF Closed position This prevents loss of solution when servicing the filter strainer with a partial or full tank Solution Delivery Trough On the cylindrical scrub deck clean the holes in the delivery trough to assure even distribution of solution TROUBLESHOOTING...

Page 18: ...NG GUIDE ELECTRICAL Possible Symptoms 1 No solution flow while in the scrub auto solution mode 2 Solution Pump will not operate SYMPTOM ONE Note Activate the Service Test Mode Program See optional program section for instructions All testing will be performed in the Service Test Mode Program ...

Page 19: ...2 BA 625 725 825 17 SOLUTION SYSTEM TROUBLESHOOTING GUIDE ELECTRICAL CONTINUED SYMPTOM TWO Note Activate the Service Test Mode Program See optional program section for instructions All testing will be performed in the Service Test Mode Program ...

Page 20: ...et Hose Clamps 5 D that secure the hoses to the valve body Separate pry the solution outlet hose off from its valve body barbed fitting 6 Remove the 2 Hex Screws 7 E that secure the valve to the Mount Bracket F then pull the valve body to the front separating it from the solution inlet Hose G completing the part removal SOLENOID VALVE DISASSEMBLY AND CLEANING 1 Remove the solenoid valve See the So...

Page 21: ... from the machine FIGURE 4 SOLUTION PUMP REMOVAL Drain the solution tank or turn the solution filter ball valve to the off position to prevent solution loss 1 See Figure 4 2 Loosen the 2 Hose Clamps P and pry off inlet Hose M and outlet Hose Q from Solution Pump R Remove the 2 10 24 nuts 3 S that secure the Solution Pump to the Chassis Disconnect the Solution Pump Electrical Connector 4 T A tie st...

Page 22: ...tral setting A negative voltage output from the A1 board s terminal J1 14 Vio Blk wire completes the K1 solenoid coil circuit Pos Neg and pulls in the load contact making the brush motors run The Neg M2 and M3 load voltage is supplied from the battery Neg M5 Scrub Brush Actuator Lift Motor Function The A1 control board outputs a controlled motor voltage polarity change wires J2 1 and J2 8 that rai...

Page 23: ...re When K1 is de energized the neg voltage from the K3 relay is connected to the Brush Motors Positive Wht wires through a Red Wht jumper wire connected to the K1 N C With two battery ground inputs at the brush motors this circuit causes a short to ground and the motors stop abruptly The built up brushes inertia easily spins the brushes off the motors drive disc lugs FIGURE 1 COIL BRUSH MOTOR CONT...

Page 24: ...ith scrub brushes installed lower the scrub deck turn the key off and disconnect the battery pack Note If the lift actuator motor will not run go to step 2 and perform the following shim up the brush deck to remove the weight on the lower deck Actuator Pin C to remove 2 Remove the front nose cone by firmly grasping the lower part and lifting straight up 3 Disconnect the actuator motor wiring harne...

Page 25: ...FORM NO 56043098 Convertamatic 24 26 28 32 BA 625 725 825 23 FIGURE 2 SCRUB SYSTEM ...

Page 26: ...ctory follow the steps below 1 With the scrub deck connected to the machine pre assemble the turnbuckle and hardware as shown using the 1 1 8 inch dimension as a starting point Note Leave the lock nut S loose 2 Press the scrub on button to lower the deck move the drive paddle to start the scrub brushes This allows the actuator to lower brushes to a correct operating pressure 3 Turn the center hex ...

Page 27: ...FORM NO 56043098 Convertamatic 24 26 28 32 BA 625 725 825 25 NOTES ...

Page 28: ...lly roll it onto the Lower Brush Pulley FF NOTE Be sure the belt grooves and pulley grooves match up Aligned SCRUB BRUSH SYSTEM MAINTENANCE CYLINDRICAL The scrubbing system must be serviced at regular intervals to maintain good scrubbing performance Follow the maintenance steps listed below 1 Rinse clean built up debris from the debris hopper drain holes daily 2 Clean drain holes in the solution d...

Page 29: ...FORM NO 56043098 Convertamatic 24 26 28 32 BA 625 725 825 27 SCRUB SYSTEM revised 7 07 FIGURE 5 ...

Page 30: ...ft the wastewater off of the floor The air and wastewater move through the squeegee hose at high speed until it reaches the recovery tank There the air slows down because of the increased volume large size of tank With the decreased air speed the heavier water falls to the bottom of the recovery tank Then at the same time the airflow continues through the tank vacuum fan inlet screen vacuum motor ...

Page 31: ...wheel drive motor in Fwd or Rev The recovery tank float switch S4 must be closed in order for a negative voltage output from the A1 board s terminal J1 12 Blk Yel wire to complete the K2 solenoid coil circuit Pos Neg and pulls in the solenoid load contact making the vacuum motor run Electrical Diagram For complete description of all callouts see Electrical System Wiring Diagram F1 FUSE 150A R1 POT...

Page 32: ... recovery tank drain hose cap seals airtight TROUBLESHOOTING GUIDE If water flows around the ends of the squeegee tool instead of being pulled into the tool the vacuum system is not working properly When a vacuum system performs poorly it is usually because of one of the following problems Vacuum Leak s Air flowing into the vacuum system past a bad gasket or leaky hose damaged tank or a leaky drai...

Page 33: ... when the tank is full Dirty extended scrub system switches can prevent the optional extended scrub system from functioning properly If daily rinsing of the recovery tank does not suffice to keep the switches clean you may need to remove the float arms for cleaning The float arms can be removed easily by grasping them as shown below and twisting to remove It is very important that they be reassemb...

Page 34: ...CUUM MOTOR INLET SCREEN The Vacuum Motor Inlet Screen 4 should be cleaned on a daily basis DO NOT run water down the screen in an attempt to clean it If you do this you will be running water directly into the vacuum motor Remove the Screen 4 from the machine to clean and then reinstall FIGURE 4 ...

Page 35: ...e vacuum motor Shroud Cover A secured to the bottom of the recovery tank qty 4 screws Loosen the exhaust hose clamp and remove Acoustic Foam 5 B from the vacuum motor discharge tube and completely remove the Vacuum Motor C from its mount cavity NOTE Take care not to loose the 3 D Vibration Mounts Inspect the condition of the Vacuum Motor Gasket 6 E inside the vacuum motor mount cavity Make service...

Page 36: ... NOTE Disconnect any other options installed on the tank 2 See Figure 6 Remove the Screw F and Tank Cable G and allow the tank to swing down to the side of the battery compartment box 3 Remove the Recovery Tank Drain Hose H 4 Disconnect the Squeegee Hose I from the tank 5 Support the tank and remove the 3 J Screws that attach the tank to the hinge and pull the tank free from the machine FIGURE 6 ...

Page 37: ...are adjustable To adjust Lower the squeegee assembly to the floor 1 See Figure 1 2 The Squeegee Mount Bracket has 3 Mount Holes A for changing the lift cable length Remove the Hardware Items 3 B from the Squeegee Mount Bracket and place in the one of the other holes Observe when the lever is lowered that the squeegee lift cable has ample free play 4 Note This allows the tool the proper movement to...

Page 38: ...everse or Replace the Front Squeegee Blade 1 Raise the squeegee tool off the floor loosen the 2 Thumb Nuts 20 disconnect the Recovery Hose 28 and remove the Squeegee Assembly 12 from the mount 2 Remove both rear Tension Straps 26 first 3 Remove all the wing nuts that hold the front blade in place and then remove the tension strap and blade 4 The squeegee blade has 4 working edges Turn the blade so...

Page 39: ... the machine 2 Lower the Squeegee Lever 15 and disconnect the Squeegee Lift Cable C from the squeegee mount bracket 3 Refer to Caster Wheel Removal section to remove the rear Caster D 3 Remove Screw E and slide the Squeegee Mount Assembly F away from the chassis 4 Service Note It may be necessary to remove the Squeegee Level Wheel from the Squeegee Mount Assembly for reinstallation FIGURE 3 ...

Page 40: ...nd recovery tanks Remove the squeegee assembly and have the scrub deck in the up stored position with the scrub brushes installed 2 See Figure 4 Place Wood Blocking G in front of the drive wheels to prevent the machine from rolling 3 Jack the machine in the location shown until the caster wheel is approximately 1 off the ground 4 Place Blocking H under the chassis tab as shown 5 Remove the 4 Screw...

Page 41: ...rol circuits operational powering it up The F3 circuit breaker 30 Amp supplies the positive load circuit voltage input to the B controller terminal Wht Yel wire The black wire from the battery negative standoff supplies the NEG input to the B controller terminal Moving the 5K Ohm R1 pot off its centered balanced neutral setting of approximately 2500 Ohms activates the operator input to the speed c...

Page 42: ... BLK BLK ORN BLU ORN BLU BLU BLK BRN WHT BLU BLK BRN WHT BLK FOR REV REVERSE J1 5 A2 B B 1210SPEEDCONTROLLER M1 M2 PIN3 POT HI PIN4 POT WIPER PIN13 POT LO PIN5 KSI PIN16 REV PIN6 BRAKE 1228FOR36V STATUS PIN9 STATUS PIN18 SPEEDLIMITPOT J1 4 F1 FUSE 150A S3 SW SPSTKEY F2 CIRCUITBREAKER 5AMP 1 2 1 2 GRN BRN RED RED RED BT1 BATTERY BLK A1 J1 6 Partial A1 Control Board Electrical Diagram For complete d...

Page 43: ...troller logic circuits 6 Red Blk Auxiliary Driver Battery output to main controller E1 to turn on activate all auto scrub functions 7 Open not used 8 Open not used 9 Orn Blu Status Fault Speed controller fault output to main control panel fault indicator light accessory wand 10 Open not used 11 Open not used 12 Open not used 13 White Throttle Pot R1 pot low input 14 Open not used 15 Open not used ...

Page 44: ...otor replace motor Defective Throttle Potentiometer R1 replace Wheel drive in one direction only loss of either forward or reverse Test the Fwd Rev R1 wiring outputs pins 3 4 13 at the speed control for an open Repair wiring or replace the R1 pot Controller can t change electrical polarity to wheel motor Replace the A1 speed control Display LED panel shows an error 03 fault code Speed controller h...

Page 45: ...vicing machine WARNING Never work under machine without safety stands or blocking to support the machine Drain both the solution and recovery tanks and remove the squeegee 1 Remove the Scrub deck by following the Scrub Deck Removal instructions in this manual 2 Block the rear of the machine See 3 Figure 4 for proper placement of the wood blocking FIGURE 4 ...

Page 46: ...machine from this location until the drive wheels are approximately 1 off the ground Remove the 8 Locknuts 5 A and then remove the 2 Drive Wheels B from the transaxle Disconnect the drive motor wiring connector 6 Remove the 4 Motor Mount Bolts and Nuts 7 C and carefully slide the Motor Transaxle D away from the machine Reinstall in reverse order 8 FIGURE 5 ...

Page 47: ...hine without safety stands or blocking to support the machine Remove the squeegee and place wood blocking in front and rear of the opposite drive wheel that you are removing to prevent the machine from rolling 1 Using a scissors jack raise the machine until the wheel is off the ground 2 See Figure 6 for jack placement Remove the 4 Locknuts 3 E and Drive Wheel F Reinstall in reverse order 4 FIGURE ...

Page 48: ... 2 wiper and outside rear 1 low Fwd reading 2 420 ohms to 4 700 ohms Rev 2 420 ohms to 230 ohms 5 Testing Summary The above tests are to show the increase and decrease of the pot through its working range If you do not get similar readings replace the Potentiometer R1 FIGURE 7 R1 Potentiometer Removal 6 See Figure 9 Loosen the pot shaft anchor nut and unthread it to the end of the shaft 7 Back out...

Page 49: ...ervicing Note The potentiometer pot doesn t have to be removed from the drive paddle cover to test Test Procedure FIGURE 8 FIGURE 9 1 See Figure 7 Remove the front drive paddle Cover G from the rear housing H held together with 4 item I Screws Note the cover will have the speed limiting pot R2 mounted to it observe the 3 wires to reassemble and then separate them to complete the removal of the cov...

Page 50: ...hen Servicing Batteries Remove all jewelry Do not smoke Wear safety glasses rubber gloves and a rubber apron Work in a well ventilated area Do not allow tools to touch more than one battery terminal at a time ALWAYS disconnect the negative ground cable first when replacing batteries to prevent sparks ALWAYS connect the negative cable last when installing batteries CAUTION Electrical components in ...

Page 51: ... higher cutout voltage Special Service Note On all the 24V machines a minimum recharge voltage of 2 13 volts per cell must be reached to allow the scrub brush and solution system to reset function again A 24V battery pack must increase to a 25 6 volt minimum DESCRIPTION OF THE BATTERY CONDITION INDICATORS The Battery Condition Indicator will give an indication of the state of charge of the batteri...

Page 52: ...ighten the vent caps Wash the tops of the batteries with a solution of baking soda and water 2 tablespoons of baking soda to 1 liter of water CHARGING GEL VRLA BATTERIES Charge the batteries each time the machine is used or when the Battery Indicator D is reading less than full WARNING Charge batteries in a well ventilated area Do not smoke while servicing the batteries When Servicing Batteries Re...

Page 53: ...ing Almost all battery caps are vented so there s no need to loosen or remove them for charging Keep the Batteries Clean Monthly Use a damp cloth to wipe dirt from the top of the batteries Battery terminals must be clean and tight If the tops of the batteries are wet after charging the batteries have probably been over filled or over charged Note If there is acid on the batteries wash the tops of ...

Page 54: ...all the plastic Drive Nut B as shown with the nut pin pocket away from the motor Then finish assembly of remaining parts long compression spring Spring Housing D and mounting hardware 2 Hold onto the spring housing assembly and press the rocker switch to run the drive motor and retract the spring housing towards the motor housing its IN limit 3 Measure the position of the spring housing assembly o...

Page 55: ...FORM NO 56043098 Convertamatic 24 26 28 32 BA 625 725 825 53 FIGURE 4 ...

Page 56: ...nnections 2 Connect the programmer put it in diagnostic mode and read the displayed fault information In this example the display shows No Faults Present indicating that the controller has not detected anything out of the norm 3 Put the programmer in test mode and observe the status of inputs and outputs in the forward direction In this example the display shows that the forward input did not acti...

Page 57: ...FORM NO 56043098 Convertamatic 24 26 28 32 BA 625 725 825 55 FIGURE 5 ELECTRICAL SYSTEM ...

Page 58: ...000 00000 HPD High Pedal Disable fault 1 Improper sequence of throttle and KSI push or inhibit inputs 2 Misadjusted throttle pot 4 1 0000 O current sense fault 1 Short in motor or in motor wiring 2 Controller failure 4 2 0000 00 motor voltage fault hardware failsafe 1 Motor voltage does not correspond to throttle request 2 Short in motor or in motor wiring 3 Controller failure 4 3 0000 000 EEPROM ...

Page 59: ...cessary to cycle the key or seat switch to clear the fault code 4 Move the drive paddle to operate the throttle The motor should begin to turn in the selected direction If it does not verify the wiring to the controller and the motor The motor should run proportionally faster with increasing throttle If not refer to the DIAGNOSTICS section of this chapter Table 1 5 If you are using a programmer pu...

Page 60: ...tion of the main control is to detect any system failures and display an error code on the display LED panel or store it in the main control board s recall memory mode The error code s are used to help the serviceperson determine the fault and to quickly guide in repairing a specific system malfunction Note See the Troubleshooting Guide for further information An additional special feature of the ...

Page 61: ...disc Repair or replace 7 Inspect scrub brush drive bearings drive belts for excessive wear cyl 07 Vacuum motor overload Normal current load 24V 23 25 Amps 1 Check for debris in the vacuum motor 2 Worn carbon brushes 3 Defective motor bearings 4 Check for short circuit in vacuum motor or wiring Repair or replace 5 Check for an open in the small ORG current sense wire 08 Solenoid Coil Bank Overload ...

Page 62: ...ll flash the fault code produced by the speed control Refer to the speed control section for details on these codes If SCS does not display following the troubleshooting procedure below Disconnect the Org Blu wire from the speed controller and main controller and check the continuity of the wire If the wire tests open repair or replace the wire or plug If wire tests ok replace the speed controller...

Page 63: ...FORM NO 56043098 Convertamatic 24 26 28 32 BA 625 725 825 61 FIGURE 6 ELECTRICAL SYSTEM ...

Page 64: ...Brief On Green Flash Brush motor output is off and brush motor current is being sensed abnormal condition Check for voltage at the Wht wire on K1 contactor to battery ground If any voltage is present replace K1 contactor NO voltage replace the Main control board Brief Off Green Flash Brush motor output is on and brush motor current is not being sensed abnormal condition Check brush motor wiring pl...

Page 65: ... is not at its down limit When the output is in state 4 the actuator output is turned on The scrub pressure decrease indicator should be green or flashing green The indicator will be a steady green if the control senses current flow through the actuator It will flash green if no actuator current flow is sensed actuator at limit open circuit open output driver The wand switch has no effect in this ...

Page 66: ...il overload has occurred Extended Scrub Switch G This switch is used to toggle the sate of the recycle pump and recycle valve If available Pressing and releasing this switch will alternately turn the recycle pump and recycle valve on and off The indicator provides the following status information Off Recycle pump and valve off Steady Green Recycle output is on and valve is open Detergent Switch F ...

Page 67: ...tandard cutout level factory default select 20 6V For the alternate cutout level select 21 6V 8 To save the new setting press scrub off switch Scrub off indicator will turn to Green and display will show key switch icon to reset the machine Turn the main key switch to the off position 9 The new setting will be saved and will remain in effect until it is changed again Recall of Stored Error Codes W...

Page 68: ...ntil light scrub indicator turns yellow 5 Release both switches The scrub OFF indicator will turn red and the display will display current deck size and type disc or cylindrical 24 26 or 28 NOTE The 28 selection is also used for the 32 deck The chemical option and recycle option can be selected here while selecting scrub deck 6 To select chemical option press chemical switch Chemical indicator wil...

Page 69: ...n in effect until it is changed again Displaying the Control Unit Revision Level If it is desired to view the revision level of the control unit perform the following steps 1 Turn the main power key switch to the off position 2 Press and hold the scrub off switch and chemical switch 3 While holding both switches until scrub off and chemical indicators turn green 4 Release both switches 5 The displ...

Page 70: ... solution rate setting 7 The display will now show solution icon with gauge Light scrub indicator will now turn green and solution indicator will turn yellow Pressing solution switch will now select new solution rate Pressing scrub off switch will save the new setting and move to chemical setting If available 8 The display will now show chemical bottle with current chemical setting Solution indica...

Page 71: ...y 9 Turn the main power key switch to the off position 10 The new settings will be saved and will remain in effect until it is changed again Extreme Scrub Setting Adjustment FACTORY DEFAULT SCRUB PRESSURE 3 SOLUTION THREE BARS CHEMICAL 0 IF AVAILABLE The extreme scrub pressure solution rate and chemical rate can be programmed depending on its application where high solution rate is need with extre...

Page 72: ... Turn the main power key switch to the off position 2 Press and hold the recycle switch 3 While holding the recycle switch turn the main key switch to the on position 4 Continue to hold the recycle switch until the recycle indicator turns yellow 5 Release the recycle switch 6 The display will display current deck setting low voltage cutout setting and error checking setting 7 To exit this mode tur...

Page 73: ...ional M1 Motor Wheel Drive M2 Motor Left Brush M3 Motor Right Brush M4 Motor Vac M5 Motor Brush Actuator M8 Pump Solution M9 Pump Recycle Optional M10 Chemical Pump Optional R1 Potentiometer 5K Ohm Throttle R2 Potentiometer 100K Ohm Speed Limit S1 Part of M8 S2 Part of M9 S3 Switch Key S4 Switch Float Recovery Tank Full S5 Switch Float Optional Recycle Start S6 Switch Float Optional Recycle Stop X...

Page 74: ...1 11 J1 10 REVERSE OPTIONAL RECYCLE STOP SWITCH RECYCLE START SWITCH NOTE SWITCH IS PART OF PUMP ASSEMBLY NOTE SWITCH IS PART OF PUMP ASSEMBLY B 1 SOL PUMP RECYCLE PUMP BRUSH ACTUATOR 1 BRUSH ACTUATOR 2 B 3 B 4 B 2 A1 CONTROL BOARD J1 5 J2 5 J2 10 J1 6 J1 2 J1 1 J2 4 J1 7 J1 8 J2 12 J2 8 J2 1 J2 6 J1 9 J2 9 OPTIONAL RECOVERY TANK FULL SENSE RELAY COMMON RELAY N O BRUSH REMOVE BRUSH REMOVE CHEMICAL...

Page 75: ... TO B ON BATTERY PACK NOTE DISCONNECT RED 16 1 WIRE FROM F2 AND CONNECT GRN WIRE TO F2 OPTIONAL CHEMICAL RATIO SENSOR SUPPLY OUTPUT B F G G TERMINAL BLOCK X4 TERMINAL BLOCK X4 1 2 3 CONTACTOR BRUSH MOTOR K1 CONTACTOR BRUSH MOTOR K1 1 2 3 4 5 6 S3 SW SPST KEY S3 SW SPST KEY 1 2 SP2 SP2 1 1 2 2 X10 X10 K2 CONTACTOR VACUUM MOTOR K2 CONTACTOR VACUUM MOTOR 1 2 3 4 SP3 SP3 1 2 2 X8 X8 A B X33 X33 A B F2...

Page 76: ...STEM PLUMBING SCHEMATIC Item Description 1 Solution Tank 2 Shut Off Valve 3 Inline Solution Filter 4 Solution Pump 5 Check Valve 6 Detergent Pump 7 Reducer Tee 8 Reducer Coupler 9 Solution Solenoid Valve 10 Detergent Tank 11 Reducer Coupler 12 Solution Manifold Cylindrical Models 13 Tee ...

Page 77: ...on The purge will run for 20 seconds NOTE This is to flush any debris from the system If you do not do this the extended pump and or solenoid valve could become plugged up with debris revised 8 05 Item Description 1 Solution Tank 2 Shut Off Valve 3 Inline Solution Filter 4 Recovery Tank 5 Extended Scrub Filter 6 Extended Scrub Stop Switch 7 Extended Scrub Start Switch 8 Vacuum Shut Off Switch 9 Ex...

Page 78: ...easuring NOTE Only reset the system when the cartridge is full When switching cartridges the Low Detergent indicator is only accurate if the replacement cartridge is at the same level as the cartridge being replaced To Reset 1 Turn the Key Switch A ON and hold the Detergent Switch F down for 2 seconds See illustration on next page for Detergent System indicators NON REFILLABLE CARTRIDGE SPECIFIC I...

Page 79: ...www nilfisk advance com 2008 ...

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