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Nilfisk-Advance BA 750/850ST, Service Manual

The Nilfisk-Advance BA 750/850ST is a high-performance floor scrubber designed for optimal cleaning results. To ensure easy maintenance and efficient use, we provide a comprehensive Service Manual that can be downloaded for free from our website. Enhance your cleaning experience with our user-friendly manual available at manualshive.com.

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FORM NO. 56043071  CMAX

™

 28/34ST / I-MAX

™

 28/32C, BA 750/850ST, BA 750C - 

1

GENERAL INFORMATION .................................................................................................................................................. 2
  SAFETY INSTRUCTIONS .................................................................................................................................................. 3
SPECIFICATIONS & MAINTENANCE ............................................................................................................................. 4-6
PM CHECKLIST ............................................................................................................................................................... 7-8
KNOW YOUR MACHINE ............................................................................................................................................... 9-13
SOLUTION SYSTEM ................................................................................................................................................... 14-19
  FUNCTIONAL OVERVIEW .............................................................................................................................................. 14
  CIRCUIT OVERVIEW SOLUTION AUTO MODE ............................................................................................................ 15
  SOLUTION SYSTEM MAINTENANCE ............................................................................................................................ 16
  TROUBLESHOOTING GUIDE ................................................................................................................................... 16-17
  SOLUTION SOLENOID VALVE REMOVAL .................................................................................................................... 18
  SOLUTION VALVE DISASSEMBLY AND CLEANING .................................................................................................... 18
  SOLUTION FILTER REMOVAL ....................................................................................................................................... 18
  SOLUTION FLOW CONTROL VALVE REMOVAL .......................................................................................................... 18
SCRUB BRUSH SYSTEM ............................................................................................................................................ 20-32
  GENERAL BRUSH SYSTEM FUNCTIONAL OVERVIEW ............................................................................................... 20
  SPECIAL SCRUB SYSTEM FUNCTIONS ................................................................................................................. 20-21
  SCRUB BRUSH SYSTEM TROUBLESHOOTING .................................................................................................... 22-26
  SCRUB BRUSH DECK REMOVAL (DISC) ...................................................................................................................... 27
  SCRUB BRUSH LIFT ACTUATOR REMOVAL (DISC) .................................................................................................... 27
  SCRUB BRUSH MOTOR/GEARBOX REMOVAL (DISC) ................................................................................................ 27
  SCRUB BRUSH DECK ASSEMBLY REMOVAL (CYLINDRICAL) .................................................................................. 30
  SCRUB BRUSH MOTOR(S) REMOVAL (CYLINDRICAL) .............................................................................................. 30
  SCRUB BRUSH BELT REPLACEMENT (CYLINDRICAL) .............................................................................................. 30
  SCRUB BRUSH SYSTEM MAINTENANCE (CYLINDRICAL) ......................................................................................... 30
  SCRUB BRUSH REMOVAL AND INSTALLATION (CYLINDRICAL) .............................................................................. 30
  SCRUB BRUSH LIFT ACTUATOR REMOVAL (CYLINDRICAL) .............................................................................. 30-31
RECOVERY SYSTEM .................................................................................................................................................. 33-39
  FUNCTIONAL OVERVIEW ........................................................................................................................................ 33-34
  VACUUM/RECOVERY SYSTEM MAINTENANCE CHECKLIST ..................................................................................... 35
  TROUBLESHOOTING GUIDE ................................................................................................................................... 35-37
  MAINTENANCE OF FLOAT CAGE AND FLOAT DUCT ................................................................................................. 38
  VACUUM MOTOR REMOVAL ......................................................................................................................................... 38
  RECOVERY TANK REMOVAL ........................................................................................................................................ 38
SQUEEGEE SYSTEM .................................................................................................................................................. 40-41
  SQUEEGEE LIFT LINKAGE ADJUSTMENT ................................................................................................................... 40
  SQUEEGEE TOOL BLADE(S) REPLACEMENT ............................................................................................................. 40
  SQUEEGEE ADJUSTMENT ............................................................................................................................................ 40
WHEEL DRIVE SYSTEM ............................................................................................................................................. 42-51
  GENERAL FUNCTIONAL OVERVIEW ............................................................................................................................ 42
  TROUBLESHOOTING GUIDE ................................................................................................................................... 43-45
  DRIVE MOTOR REMOVAL (ALL MODELS) .................................................................................................................... 47
  DRIVE WHEEL REMOVAL (CYLINDRICAL) ................................................................................................................... 47
  DRIVE WHEEL REMOVAL (DISC) .................................................................................................................................. 48
  CHAIN MAINTENANCE, REMOVAL AND ADJUSTMENT ........................................................................................ 48-49
  OPTIONAL PARKING BRAKE OPERATION ................................................................................................................... 49
  OPTIONAL BRAKE ASSEMBLY REMOVAL / CALIPER ADJUSTMENT ........................................................................ 49
  POTENTIOMETER (5K) TESTING AND REMOVAL ....................................................................................................... 50
  POTENTIOMETER INSTALLATION AND ADJUSTMENT ........................................................................................ 50-51
  POTENTIOMETER (25K) WHEEL DRIVE SPEED LIMIT TESTING ............................................................................... 51
ELECTRICAL SYSTEM ................................................................................................................................................ 52-65
  BATTERIES / CHARGERS .............................................................................................................................................. 52
  DESCRIPTION OF LOW VOLTAGE CUTOUT FEATURE .............................................................................................. 52
  DESCRIPTION OF THE BATTERY CONDITION INDICATORS ..................................................................................... 53
  BATTERY CHARGING, MAINTENANCE AND TESTING ......................................................................................... 53-54
  ACTUATOR DRIVE NUT ADJUSTMENT .................................................................................................................. 54-55
  FUNCTIONAL OVERVIEW OF MAIN CONTROL BOARD .............................................................................................. 56
  DESCRIPTION OF CONTROL PANEL SYSTEM OVERLOAD INDICATORS ................................................................ 56
  MAIN CONTROLLER DIAGNOSTIC SERVICE TEST MODE ................................................................................... 57-59
  MAIN CONTROL BOARD SPECIAL PROGRAM OPTIONS ..................................................................................... 60-62
  ELECTRICAL COMPONENT LOCATION ........................................................................................................................ 63
  WIRING DIAGRAM .......................................................................................................................................................... 64
  WIRING SCHEMATIC ...................................................................................................................................................... 65

Note: 

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

TABLE OF CONTENTS

Summary of Contents for BA 750/850ST

Page 1: ...6 02 revised 12 04 Form Number 56043071 CMAX 28 34ST I MAX 28 32C BA 750 850ST BA 750C SERVICE MANUAL Advance MODELS 56396010 56397403 56397400 56397401 Nilfisk MODELS 56396011 56396012 56397402 ...

Page 2: ...UBLESHOOTING GUIDE 35 37 MAINTENANCE OF FLOAT CAGE AND FLOAT DUCT 38 VACUUM MOTOR REMOVAL 38 RECOVERY TANK REMOVAL 38 SQUEEGEE SYSTEM 40 41 SQUEEGEE LIFT LINKAGE ADJUSTMENT 40 SQUEEGEE TOOL BLADE S REPLACEMENT 40 SQUEEGEE ADJUSTMENT 40 WHEEL DRIVE SYSTEM 42 51 GENERAL FUNCTIONAL OVERVIEW 42 TROUBLESHOOTING GUIDE 43 45 DRIVE MOTOR REMOVAL ALL MODELS 47 DRIVE WHEEL REMOVAL CYLINDRICAL 47 DRIVE WHEEL...

Page 3: ...mber and Serial Number of your machine for future reference MODEL NUMBER 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 see tie down locations 21 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 Of...

Page 4: ...or stands to support the machine Donotdispenseflammablecleaningagents operatethemachineonorneartheseagents oroperateinareaswhereflammable liquids exist Do not clean this machine with a pressure washer Do not operate this machine on ramps or inclines of more than a 2 degree angle CAUTION This machine is not approved for use on public paths or roads This machine is not suitable for picking up hazard...

Page 5: ...114l 30 gal 114l 30 gal 114l Recovery Tank Capacity 24 gal 91l 24 gal 91l 30 gal 114l 30 gal 114l 30 gal 114l Vacuum Water Lift Sealed 56 in 56 in 68 in 68 in 68 in Open Hole Adapter 1 9 in 9 in 13 in 13 in 13 in Sound pressure level as per ISO 3744 at operator 70 dB A 70 dB A 70 dB A 70 dB A 70 dB A Transport Speed Fwd Maximum 265 FPM 265 FPM 265 FPM 265 FPM 265 FPM Metric 81 m min 81 m min 81 m ...

Page 6: ...FORM NO 56043071 CMAX 28 34ST I MAX 28 32C BA 750 850ST BA 750C 5 SPECIFICATIONS TOPVIEW SIDEVIEW Length Height Width Squeegee Width ...

Page 7: ... 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 machine models 24 volt and 36 volt brush and wheel drive motors All motors Replace carbon brushes when shorter than 3 8 9 5mm to obtain th...

Page 8: ...ode low voltage cutout etc A Ref VISUAL INSPECTION ITEMS Comments OK Defect 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 B D L 13 Brush Drive Plate Retainer Clips flex couplers C D M 14 Scrub Deck Skirts and Side Wheels D M W 15 Solution Solenoid Valve C D L W 16...

Page 9: ...utout etc A Ref VISUAL INSPECTION ITEMS Comments OK Defect Codes circle Does Not Work 10 Scrub Brushes check for wear and rotate Cylindrical brushes D M W 11 Scrub Brush Motor s check for carbon brush wear 500 Hours B C W 12 Scrub Brush Motor s check drive belts idler assy s A B D 13 Scrub Deck clean debris hopper C D M 14 Scrub Deck Skirts and Side Wheels D M W 15 Solution Solenoid Valve C D L W ...

Page 10: ...egee 9 Machine Battery Connector 10 Solution Flow Control Knob 11 Speed Limit Control Knob 12 Wheel Drive Circuit Breaker 30 Amp 13 Control Circuit Circuit Breaker 5 Amp 14 Brush Deck 15 Operator Control Handle 16 Operator Hand Brake optional 17 Squeegee Lever 18 Solution Filter 19 Hopper Cylindrical Only 20 Idler Assembly Cylindrical Only 21 Tie Down Locations 4 KNOW YOUR MACHINE 1 1 2 3 4 5 7 8 ...

Page 11: ...EL A Scrub Pressure Hourmeter Display B Master On Off Key Switch C Solution System Indicator D Solution Button E Vacuum Button F Vacuum System Indicator G Scrub ON Pressure Increase Button H Scrub OFF Pressure Decrease Button I Scrub OFF Indicator J Battery Condition Indicator J A B C D E F G H I ...

Page 12: ... Circuit Circuit Breaker 13 Provides overload protection If it trips it will pop out To reset wait one minute and press the button back in If any breaker trips repeatedly have the machine serviced Brush Deck 14 Contains brush drive motors and brushes Operator Control Handle 15 Operator holds onto this to control the machine Operator Hand Brake optional 16 Use to prevent machine from rolling Squeeg...

Page 13: ...e vacuum system will NOT be turned off This is so that any remaining water may be picked up without having to turn the vacuum back on If this button is pressed a second time pressed after the scrub mode has been turned off the vacuum will shut off after a 10 second delay NOTE Reducing the pad pressure to 1 and then pressing this button one more time will also turn the scrub system OFF In this case...

Page 14: ...l Refer to the Electrical System Main Control Board Special Program Options to disable System Overload Indications Ifthescrubmotorsorthescrubdeckliftactuatorbecomeoverloaded thescrubandsolutionsystemswillturnoffandthescrub off pressure decrease indicator will flash red at a fast rate four times per second If the vacuum motor becomes overloaded the scrub vacuum and solution systems will turn off an...

Page 15: ...the scrub brushes The L1 electrical solenoid valve stops and starts the solution flow to the scrub brushes see electrical diagram The electrical circuit that turns on energizes the solenoid coil is activated through the A1 control panel s solution switch button and the A2 operation wheel drive controller assembly Note See the Know Your Machine section in this manual for a complete explanation of t...

Page 16: ...e A2 speed controls auxiliary output pin 1 occurs whenever the R1 direction throttle pot is moved off its neutral setting A negative voltage output from the A1 board s terminal 7 Red Grn wire is direct to the L1 solenoid coil turning it on to allow flow through the valve body FIGURE 2 Electrical Diagram For complete description of all callouts see Electrical System Wiring Diagram BLK A1 CONTROLBOA...

Page 17: ...he filter hand tighten only Service Tip The manual solution control knob must be placed in the full OFF 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 GUIDE Problem Possible Cause Inadequate or ...

Page 18: ...chtotheL1 solutionsolenoid Repair or replace defectivewiring Checkfor 24Vor 36V Neg fromthe Red GrnL1harness feedwiretoa Pos batterystandoff Test continuityof theRed Grnwire fromtheA1 board s 7pin connectiontothe L1solenoid Test for 24Vor 36V Neg fromtheYel A1board s 3wire toa Pos battery standoff Repair or replace theNeg solution solenoidRed Grn supplywire ReplacetheA2 speedcontrol Yes Replacethe...

Page 19: ...disassemble the valve be careful not to lose any internal parts 3 Thoroughly wash dirt from block K and diaphragm L 4 After reassembling test the solenoid valve for proper operation SOLUTION FILTER REMOVAL 1 Drain the solution tank using the solution drain hose or put the flow control valve knob in the full off position to prevent solution loss 2 See Figure 4A or 4B Loosen the 2 Hose Clamps M and ...

Page 20: ...CMAX 28 34ST I MAX 28 32C BA 750 850ST BA 750C 19 SOLUTION SYSTEM FRONT M P M O S N U R T V P N M M U T S V O N N FRONT Q W H Q W H R FIGURE 4B I MAX 28C I MAX 32C BA 750C CMAX 34ST FIGURE 4A CMAX 28ST BA 750ST BA 850ST ...

Page 21: ...5 Vio Blk wire completes the K1 solenoid coil circuit Pos Neg and pulls in the load contact making the brush motors run Scrub Brush Actuator Lift Motor Function TheA1controlboardoutputs terminals11 12 activate raiseandlower thescrub deckforinstalling removingandcontrollingthescrubbrushes selected current load The large BLK negative scrub brush motor wire is specially designed so that it has a know...

Page 22: ...h Remove Optional BRN ORN BLK K3 BLK The brush remove circuit sequence starts when the operator depresses the control panel scrub off brush pressure decrease button H activating the A1 board s brush remove function This triggers starts an internal timer relay closing the K1 coil ground circuit pin 5 Vio Blk wire turning on momentarily the brush solenoid to run the brush motors Simultaneously with ...

Page 23: ...crub brush motors solution solenoid valve do not work See Control Panel in Know Your Machine section The scrub motor or scrub deck lift actuator is over loaded Inspect the brushes and lift actuator motor for any possi ble mechanical or electrical high current draw Examples Short circuit motor s Worn carbon brushes Frozen lift linkage Restriction on rotation of brush output drive plate gear box etc...

Page 24: ...art B Yes Test for an open circuit in each brush motor Repair or replace wiring or motor s No Test for voltage on both load wires WHT Pos to a battery ground and BLK Neg to a battery Pos Repair or replace defective wiring Scrub brush motors do not work See Figure 1 SYMPTOM TWO Scrub Brush Motors Do Not Work Note Do all testing with key switch on scrub on switch activated scrub deck lowered and dri...

Page 25: ...otor solenoid Check for 24 36V at the Pos K1 BRN coil wire to a battery ground standoff Check for 24 36V Neg at the pin 3 YEL wire on the A1 control board Note The drive paddle must be activated Fwd or Rev for the speed control to close the P1 output circuit to battery ground Test BRN coil wiring continuity Repair or replace the defec tive wiring Yes No Check for 24 36V at the Neg K1 VIO BLK coil ...

Page 26: ...rvice Test Mode Program in the Electrical System manual section for alternate machine troubleshooting procedures Part A Scrub Brush Auto Remove Load Circuit Troubleshooting Guide TROUBLESHOOTING GUIDE CONTINUED No Yes Scrub brush auto removal function does not work See Figure 1 Check circuit continu ity across the K3 relay motor load contact remove the BLU WHT BLK wires before testing Note the K3 ...

Page 27: ...ated check for 24 36V across the K3 brush remove relay coil Wire colors BRN pos ORN BLK neg Check for 24 36V at the neg K3 ORG BLK coil wire to a pos battery standoff Yes No Using an Ohm meter test resistance spec is 400 ohm for 24V and 830 ohm for 36V if infinity coil open Yes Yes Check continuity of the ORN BLK wire repair or replace Test BRN pos relay coil wire continuity Repair or replace wiri...

Page 28: ...e s battery pack and lift actuator motor pig tail connector 4 Pressthecordadapterrockerswitchtomomentarilyrun jog theactuatoroutput upanddown toapositionwherethebottomdeckActuator Pin H is loose see Figure 2 Remove the Cotter Pin I from the lower Actuator Pin H and pull the pin from the mount bracket 5 Remove the Hex Screw J and Nut K that secures the upper Actuator Yoke L at the frame mount 6 Til...

Page 29: ...ST BA 750C SCRUB BRUSH SYSTEM FRONT K L J E A D H G F I C B Remove D Remove C B F G P M R O N S T Q U Brush Rotation FIGURE 2 Note Figure 2 shows the scrub brush components of the CMAX 28ST BA 750ST and BA 850ST Similar components are found on the CMAX 34ST ...

Page 30: ... 850ST Right and left are identified as seen from the rear of the machine FIGURE 3 Right Brush Motor Left Brush Motor TheseTwoTerminals areConnectedwitha Jumper Plate inset TheseTwoTerminals areConnectedwitha Jumper Plate inset Jumper Plate WHT BLK FRONT Negativelead fromright motor Negativelead fromleft motor Positiveleadfromright motor ...

Page 31: ...ACEMENT CYLINDRICAL 1 SeeFigure4 FirstremovetherearscrubdeckSideSkirts AD heldby 3 screws Nextremovethebeltguardsheldinplaceby 4 screws 2 Important Service Tip The left and right side drive belts are not the same lengths they must be ordered individually P N 56407465 left side P N 56407466 right side 3 LoosenthescrubbrushbelttensionhardwareontheBeltIdlerPulley AE usinga5 8 wrench Pulltheidlerwheel...

Page 32: ...of the machine from the front of the brush deck 7 See Important Service Note below Note If the lift actuator motor will not run it will be necessary to jack up the front of the machine or shim up the brush deck to remove the weight on the lower deck Actuator Pin W to remove Important Service Note After removing any actuator motor and before installing a new motor or drive nut the IN and OUT limit ...

Page 33: ...ST I MAX 28 32C BA 750 850ST BA 750C SCRUB BRUSH SYSTEM FRONT Belt Brush Brush Right Motor Left Motor Belt Counter clockwise rotationfrom shaft end Counter clockwise rotationfrom shaft end FIGURE 6 FIGURE 5 13 16 to7 8 20 22mm FRONT ...

Page 34: ...ion to lift 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 shutoff float vacuum motor a...

Page 35: ...he R1 directional throttle pot is moved off its neutral setting This operator command happens when the drive paddle is pushed or pulled to run the wheel drive motor in Fwd or Rev A negative voltage output from the A1 board s terminal 6 Blk Yel wire completes the K2 solenoid coil circuit Pos Neg and pulls in the solenoid load contact making the vacuum motor run FIGURE 2 Electrical Diagram For compl...

Page 36: ... drain hose cap seals airtight TROUBLESHOOTING GUIDE Ifwaterflowsaroundtheendsofthesqueegeetool insteadofbeingpulledintothetool thevacuumsystemisnotworkingproperly Whenavacuum 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 drain valve A vacuum leak below the water...

Page 37: ...Figure 1 Yes Repair or replace wiring to vac motor The vacuum motor is overloaded Inspect motor for possible mechanical or electri cal high current draw If the vacuum motor becomes overloaded the scrub vacuum and solution systems will turn off and the indicator light will flash yellow at a fast rate four times per second TROUBLESHOOTING GUIDE ELECTRICAL Possible Symptom 1 Vacuum motor will not run...

Page 38: ...id Check for 24 36V at the Pos K2 BRN coil wire to a battery ground standoff Check for 24 36V Neg at the pin 3 YEL wire on the A1 control board Note The drive paddle must be activated Fwd or Rev for the speed control to close the P1 output circuit to battery ground Test BRN coil wiring continuity Repair or replace the defec tive wiring Yes No Check for 24 36V at the Neg K2 BLK YEL coil wire to a P...

Page 39: ...the vacuum motor Duct Cover F secured to the bottom of the recovery tank qty 4 screws 4 Loosen the exhaust hose clamp and remove Hose G from the vac motor discharge tube and completely remove the motor from its mount cavity 5 Inspect the condition of the vac motor Gasket H inside the vac motor mount cavity 6 Make service repairs to the vac motor and re install by following steps in reverse order R...

Page 40: ...FORM NO 56043071 CMAX 28 34ST I MAX 28 32C BA 750 850ST BA 750C 39 RECOVERY SYSTEM FRONT A B E K L J I F H D G C FIGURE 3 ...

Page 41: ... Latch B on the squeegee tool 2 Remove the Wing Nut C from each end of the squeegee then remove the Tension Straps D 3 Slip the Rear Blade E off the alignment pins 4 The squeegee blade has 4 working edges Turn the blade so a clean undamaged edge points toward the front of the machine Replace the blade if all 4 edges are nicked torn or worn to a large radius 5 Install the blade following the steps ...

Page 42: ...BA 750C 41 SQUEEGEE SYSTEM FRONT A I C F G H E C B D D FIGURE 2 Note Figure 2 shows the squeegee tool for the CMAX 28ST I MAX 28C BA 750ST and BA 750C the squeegee tool for the CMAX 34ST I MAX 32C and BA 850ST are similar in adjustment and blade replacement ...

Page 43: ...ounted on the top surface of the handle housing and controls the machine s maximum transport and scrub speeds Drive Motor System Function See Figures 1 and 2 With the key switch S3 closed the Brn wire inputs 24V or 36V to the A2 speed controller terminal 3 to make its internal control circuits operational powering it up The F3 circuit breaker 30 Amp supplies the positive load circuit voltage input...

Page 44: ...ice reverse with only the key switch ON auto dead man return to neutral components Repair or replace needed parts The R1 drive pot is out of adjustment Reset to neutral the 5000 Ohm drive paddle potentiometer During normal machine transporting the operator The R2 25 000 Ohm speed limiting pot wiper is either open adjusts the R2 speed limit pot and there is no effect where the machine runs at minim...

Page 45: ...6V machines should have 36V Fwd 28V in Rev Repair or replace the M1 wheel drive motor Yes See part B wheel drive control circuit troubleshooting guide No Yes No Yes TROUBLESHOOTING GUIDE ELECTRICAL Possible Symptom 1 No forward and no reverse wheel drive SYMPTOM ONE Note Do all testing with control panel R2 speed limiting pot in the maximum position the drive wheel jacked up off the floor key swit...

Page 46: ...ave 36V in Fwd 28V in Rev Test shows an open infinity replace the R2 potentiometer with P N 56397123 Replace the A2 speed controller Check the functional operation of the wiper resistance circuits see Note A for both the 5K R1 pot the 25K R2 pot Test measurements should show a variable resistance within spec for each individual pot when the pot shaft is turned in both directions Replace the specif...

Page 47: ...46 FORM NO 56043071 CMAX 28 34ST I MAX 28 32C BA 750 850ST BA 750C WHEEL DRIVE SYSTEM I FRONT J H G C B A D A E F E Motor Sprocket if optional brakeis installed FIGURE 4 ...

Page 48: ...imate dimensions 3 1 2 wide 2 1 4 thickand15 long 9cmx5 7cmx38cm Note Astandard2x4and1x4stackedontopofeachother together willmatch the proper thickness height needed 6 Next read the instructions for using the Service Test Mode steps 1 5 located in the electrical system manual section Then enter the main controller diagnostic Service Test Mode 7 See the Know Your Machine section control panel drawi...

Page 49: ...Mode don t press activate the Scrub Off Pressure Decrease Switch H when the wood blocking is positioned under the scrub brushes as it will turn on the brush motors 9 Make needed service repairs and re install the drive wheel following the above steps in reverse order Note You must re enter the Service Test Mode to raise the scrub deck up away from the floor 10 Test drive the machine for proper ope...

Page 50: ...e left side chassis panel to access the parking brake components 2 Remove the bolt and nut that secure the brake cable at the brake caliper arm 3 Separate the drive chain by removing the master link 4 See Figure 4 Rotate the brake rotor sprocket assembly E to a working position to access the 2 1 4 20 set screws Loosen both the Set Screws D using a 1 8 Hex socket then pull the caliper and rotor ass...

Page 51: ...wiper and outside rear 1 low Fwd reading 2420 ohms to 4700 ohms Rev 2420 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 P Potentiometer Removal 6 See Figure 10 Loosen the pot shaft anchor nut and unthread it to the end of the shaft 7 Back out the Screw Q from ...

Page 52: ...rvicing Note The potentiometer pot should be removed from the handle housing to easily test FIGURE 9 FIGURE 11 FIGURE 10 POTENTIOMETER INSTALLATION AND ADJUSTMENT CONTINUED 1 See Figure 11 Remove the Set Screw S 5 64 wrench andpullofftheAdjustmentKnob T from the stem of the pot 2 Removetherearelectricalaccesspanelsecured with 6 Screws U 3 Remove the pot s anchor nut 1 2 inch wrench then pull the P...

Page 53: ...ct the carrier that delivered them or the battery manufacturer to file a damage claim 2 Turn the Master Key Switch B OFF and remove the key 3 Tip the recovery tank to the side locked position Remove the battery cables from inside the battery compartment 4 Your machine comes from the factory with enough battery cables to install four or six 6 volt 305 Amp hour batteries Carefully lift the batteries...

Page 54: ... tank setting the prop rod Locate the machine battery pack connector assembly 9 2 Pull up separate the top removable battery pack connector half then push together both the battery charger and battery pack connectors 3 Follow the instructions on the battery charger 4 Check the fluid level in all the battery cells after charging the batteries Add distilled water if necessary to bring the fluid leve...

Page 55: ...eneral Instructions for All Actuator Motors 1 See Figure 2 This shows the special actuator power cord adapter PN 56407502 that is needed to connect the machine s battery pack and actuator motor for setting the drive nut limit settings Instructions for Scrub Brush Lift Actuator Drive Nut Adjustment 1 See Figure 3 and 4 On a new scrub lift actuator motor remove spin off the Drive Nut A and first sli...

Page 56: ...heck both dimensions After checking that the spring housing limits are set correctly then replace the ad justercover ServiceTipNote Usethe above power cord adapter to help posi tion the spring housing assembly in or out for ease in actuator motor installa tions 9 Afteradjustingtheactuatorspringhous ing dimensions follow the Scrub Brush Lift Actuator Removal Disc or Cylindri cal manual section to r...

Page 57: ...rs are shut off The controller also manages the other supportive systems such as the solution on off and vacuum motor Note See the Know Your Machine section in this manual for a complete explanation of the machine s operation DESCRIPTION OF CONTROL PANEL SYSTEM OVERLOAD INDICATORS Ifthescrubmotorsorthescrubdeckliftactuatorbecomeoverloaded thescrubandsolutionsystemswillturnoffandthescrub off pressu...

Page 58: ...rease and Scrub On Pressure Increase buttons H G 3 While holding both switches turn the master on off key switch to the on position 4 Continue to hold both switches until the hourmeter status display shows t 5 Release both switches 6 The function of each switch and indicator is described in the following pages 7 To exit this mode turn the master on off key switch to the off position CONTROL PANEL ...

Page 59: ...is used to turn the brush motor on and off as well as turning the remove relay on and off Upon entering the service test mode pressing and releasing this switch will alternately turn the brush motor on and off The indicator I provides the following status information Off Brush motor output is off and there is no brush motor current flow Green Brush motor output is on and there is normal brush moto...

Page 60: ... on If the power indicator is flashing this indicates that the control is sensing current flow through the actuator control failure or wiring problem When the output is in state 4 the actuator output is turned on The actuator power indicator battery yellow L should be on or flashing and the actuator direction indicator battery green M will be off The power indicator will be on steady if the contro...

Page 61: ... off key switch to the off position 2 Press and hold the scrub off switch 3 While holding the scrub off switch turn the master on off key switch to the on position 4 Continue to hold the scrub off switch until the scrub off indicator turns green and the hourmeter status display shows S standard or A alternate 5 Release the scrub off switch 6 Pressingandreleasingthescruboffswitchwillnowselectbetwee...

Page 62: ...lues given are approximate Restoring the Scrub Pressure Limit to Default FACTORY DEFAULT 9 MAXIMUM If it is desired to restore the scrub pressure setting back to the factory default perform the following steps 1 Turn the master on off key switch to the off position 2 Press and hold the scrub on pressure increase and vacuum switches 3 While holding both switches turn the master on off key switch to...

Page 63: ...off position 2 Press and hold the solution switch 3 While holding the solution switch turn the master on off key switch to the on position 4 Continue to hold the solution switch until the solution indicator turns green and the hourmeter status display shows d C or 1 5 Release the solution switch 6 Pressing and releasing the solution switch will now select between the three options For the cylindri...

Page 64: ... Speed Control 2 Display Panel Assembly 3 Fuse 150 Amp 4 Circuit Breaker 5 Amp Control 5 Circuit Breaker 30 Amp Wheel Drive 6 Contactor Vac Motor 7 Contactor Brush Motor 8 Solution Solenoid Valve 9 Actuator Motor Brush Lift 10 Vac Motor Assembly 11 Motor and Gear Unit Disc 12 Motor Cylindrical 13 Motor Wheel Drive 14 Potentiometer 5K Forward Reverse 15 Potentiometer 25K Speed Control 16 Switch Key...

Page 65: ...SC BRUSHES 1 2 M4 M MOTOR VAC BLU RED K2 R1 POT 5K OHM THROTTLE POLARITY FOR CYLINDRICAL BRUSHES M3 M M2 M MOTOR RIGHT BRUSH MOTOR LEFT BRUSH WHT GRA BLK WHT WHT RED K1 K3 BLU WHT CONTACT BRUSH REMOVE OPTIONAL A2 1208 SPEED CONTROLLER M1 M MOTOR WHEEL DRIVE BRN BLK YEL RED B T2 B T1 B B P2 T3 M1 T4 M2 WHEN FORWARD P1 1 2 1 2 3 4 5 6 OUTPUT OUTPUT KEYSWITCH REVERSE WIPER FORWARD VIO BRN WHT GRN YEL...

Page 66: ...ON WHT RED 16 1 WHT 6 2 BRN 16 3 BRN 16 4 BRN 16 5 WHT RED 16 1 BLU WHT 16 1 NO CONNECTION VIO BLK 18 1 NO CONNECTION 1 2 3 4 BRN 16 4 BLU WHT 16 1 BLK 16 1 ORN BLK 18 1 WITH BRUSH REMOVE OPTION WHT RED 16 1 WHT 6 2 BRN 16 3 BRN 16 4 BRN 16 5 WHT RED 16 1 BLU WHT 16 1 VIO BLK 18 1 1 2 3 4 BRN 16 4 BLU WHT 16 1 BLK 16 1 ORN BLK 18 1 5 6 RED 6 1 K1 CONTACTOR BRUSH MOTOR K3 RELAY BRUSH REMOVE OPTIONA...

Page 67: ...Advance A E Tel 30 8 Thoukididou Str 210 963 3443 Argioupoli Fax 30 Gr 164 52 Athens 210 965 0975 Greece Holland Sales Sub Nilfisk Advance B V Phone 31 Camerastraat 9 2e verdieping 36 546 07 00 1322 BB Almere Fax 31 Postbus 60112 36 523 51 48 1320 AC Almere www nilfisk advance nl Ireland Sales Sub Nilfisk Advance Limited Phone 35 28 Sandyford Office Park 3 12 94 38 38 Sandyford Dublin 18 Fax 35 Ir...

Page 68: ...42 Fuitian Free Trade Zone Fax 86 755 518038 Shenzhen 8359 1063 P R China China Suzhou Nilfisk Advance Professional Phone 86 512 Cleaning Equipment Suzhou Co Ltd 8918 5656 306 Su Hong Zhong Road Build 2 Fax 86 512 Suzhou Industrial Park 8918 5666 215021 Suzhou P R China Hong Kong Sales Sub Nilfisk Advance Ltd Phone 852 2001 HK Worsted Mills Ind l Bldg 2427 5951 31 39 Wo Tong Tsui St Fax 852 Kwai C...

Page 69: ...www nilfisk advance com 2004 Printed in USA ...

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