Convertamatic™ 24D, 26D, 28D Convertamatic™ 24C, 26C, 28C Service Manual Advance Models 56315000(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) 2/05 revised 8/06 FORM NO.
TABLE OF CONTENTS INTRODUCTION .......................................................................................................................................................................................... 2 CAUTIONS AND WARNINGS ...................................................................................................................................................................... 3 SPECIFICATIONS & MAINTENANCE ........................................................................
INTRODUCTION This manual will help you get the most from your Convertamatic. Read it thoroughly before servicing the machine. Note: Bold numbers and letters in parentheses indicate an item illustrated on pages 8-10. PARTS AND SERVICE Repairs, when required, should be performed by your Authorized Nilfisk-Advance Service Center, who employs factory trained service personnel, and maintains an inventory of Nilfisk-Advance original replacement parts and accessories.
CAUTIONS AND WARNINGS SYMBOLS Nilfisk-Advance uses the symbols below to signal potentially dangerous conditions. 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.
4 - FORM NO. 56043098 - Convertamatic™ 24C, 24D, 26C, 26D, 28C, 28D 32.6 in (83 cm) Smart Solutions AXP 32:1, 50:1, 64:1, 100:1, 128:1, 150:1, 200:1, 256:1, & 300:1 Standard Available Dilution Rates Low Detergent Warning Refillable Cartridge Capacity 1.25 gal (4.75 L) 780 lb (354 kg) 780 lb (354 kg) 780 lb (354 kg) Weight w/ Batteries 780 lb (354 kg) W=27.5 in (70 cm) W=30 in (76 cm) W=27 in (69 cm) L=55 in (140 cm) L=55.
SPECIFICATIONS FORM NO.
MAINTENANCE SCHEDULE Maintenance intervals given are for average operating conditions. Machines used in severe operational environments may require service more often.
Advance Convertamatic™ 24/26/28 C/D Models Cylindrical and Disc PM Checklist Customer A B C D L M W Address City St Model Serial Zip Hours OPERATIONAL INSPECTION ITEMS Ref 1 2 3 4 5 6 7 8 9 OK Drive Paddle Operation (check for Fwd/Rev Drive & any neutral creep) Drive System Performance (Speed Changes Min/Max) Scrub System (Raise/Lower, Brush Motor On/Off & Optional Brush Remove Feature) Scrub Brush Pressure settings (1-3) Squeegee System (Raise/Lower & Squeegee Tool pickup Performance) Vac Performan
KNOW YOUR MACHINE As you read this manual, you will occasionally run across a bold number or letter in parentheses - example: (2). These numbers refer to an item shown on this page unless otherwise noted. Refer back to this page whenever necessary, to pinpoint 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.
KNOW YOUR MACHINE 14 15 16 17 18 19 20 21 22 23 24 Solution Drain Hose / Level Indicator Squeegee Raise / Lower Lever Onboard Battery Charger (Not found on all models) Wheel Drive Circuit Breaker Control Circuit Circuit Breaker Squeegee Blade Latch Squeegee Mount Thumb Nut Squeegee Adjustment Knob Recovery Tank Drain Hose Debris Hopper (Cylindrical Models Only) Idler Assembly (Cylindrical Models Only) 25 25a 26 27 28 29 30 31 32 33 34 Battery Pack Connector (non onboard charger models only) Battery Pack
KNOW YOUR MACHINE A B C D E F G H I Key Switch (Main Power) Solution Switch Vacuum Switch Display Panel Solution Flow Indicator AXP Indicator Hour Meter Battery Indicator Scrub Pressure Indicator Recovery Tank FULL Indicator Fault Indicator Wand Switch (Dealer Installed Option) Detergent System (AXP models only) Extended Scrub System (Dealer Installed Option) Scrub OFF Scrub ON 10 - FORM NO.
KNOW YOUR MACHINE FUNCTIONAL DESCRIPTION OF CONTROL PANEL: The controls on the Convertamatic were designed with one touch operation in mind. For single pass scrubbing the user can simply depress one switch and all systems on the machine will be ready to go. For most single-pass scrubbing operations, the operator should only need to use the middle switches on the control panel. These are the Scrub System OFF and Scrub system ON switches.
KNOW YOUR MACHINE DESCRIPTION OF INDICATORS ON THE CONTROL PANEL: In general, the following guidelines apply to the control panel indicators: A flashing green or yellow indicator means that a fault has occurred in the particular system. An example of this would be an over-current fault. A yellow indicator means that the particular function has been enabled but is not currently on.
SOLUTION SYSTEM FUNCTIONAL OVERVIEW See Figure 1. The Convertamatic models have a solution tank fill capacity of 20-gallons (76 liters). All models use one right rear tank fill opening, which offers ease of filling. Plumbed into the manual solution shut off valve outlet is a serviceable Solution Filter (C), to keep debris from entering the solenoid valve. Also fitted to the tank is a flexible Clear Hose (B) used to indicate the solution level and to drain the tank for system maintenance.
SOLUTION SYSTEM CIRCUIT OVERVIEW SOLUTION AUTO MODE (SOLENOID VALVE CIRCUIT) See Figure 2. + (Positive) circuit input starts with: • A closed S3 key switch will direct the needed positive voltage (BRN wires) to the L1 solenoid coil and A1 control board terminal #J1-13. - (Negative) circuit input starts with: • A battery negative ground input at the A1 control board terminal #B2 (J1-9) • The A1 control board solution button enabled.
SOLUTION SYSTEM SOLUTION SYSTEM MAINTENANCE • Solution Tank: See Figure 1. Weekly empty the solution tank; remove the solution Drain Hose (B) from its storage area (located on the right rear control handle compartment). Direct the hose to a designated “Disposal Site” and flush the tank with clean water. • Solution Filter: Remove and clean the inline Solution Filter (C). To access the filter housing for removal, work underneath the middle left side chassis panel.
SOLUTION SYSTEM TROUBLESHOOTING 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. 16 - FORM NO.
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. FORM NO.
SOLUTION SYSTEM SOLENOID VALVE REMOVAL 1 2 3 4 5 6 7 Drain the solution tank or turn the solution filter ball valve to the off position to prevent solution loss. Lower the deck and disconnect the battery supply to the machine. Remove the front Nose Cone from the machine by firmly grasping the lower part and lifting straight up. See Figure 3. Unplug the L1 solenoid valve wire assembly connection from the machine harness. Unscrew the inlet Hose Clamps (D) that secure the hoses to the valve body.
SOLUTION SYSTEM SOLUTION FILTER AND BALL VALVE REMOVAL 1 2 3 Drain the solution tank using the solution drain hose (B). See Figure 4. Loosen the (2) Hose Clamps (K) and pry off the inlet Solution Hose (L) and Solution Hose (M). Remove the Nut (N) that secures the Filter Mount Bracket (O) to the chassis and remove the assembly from the machine. FIGURE 4 SOLUTION PUMP REMOVAL 1 2 3 4 Drain the solution tank or turn the solution filter ball valve to the off position to prevent solution loss. See Figure 4.
SCRUB SYSTEM FUNCTIONAL OVERVIEW • Disc Brush System Overview See Figure 2. The machine models Convertamatic™ 24D, 26D, 28D use the disc type scrub system powered by (2) 1/2 hp motor gearbox assemblies. • Cylindrical Brush System Overview See Figure 4. The machine models Convertamatic™ 24C, 26C, 28C use two cylindrical brushes that counter rotate to sweep up light debris and scrub at the same time.
SCRUB SYSTEM • Scrub Brush Removal Function (Continued / Disc only) • Control and Load circuit detail. - A closed S3 key switch supplies the needed positive voltage to the K1 brush solenoid coil, A1 control board (J1-13) Brn wire and K3 brush remove coil relay (Part of A1 Control Board). The brush remove circuit sequence starts when the operator depresses the control panel scrub off button (H) for 2-3 seconds activating the A1 board’s brush remove function.
SCRUB SYSTEM SCRUB BRUSH DECK REMOVAL (DISC) 1 2 3 4 5 6 7 8 With scrub brushes installed lower the scrub deck, turn the key off and disconnect the battery pack. Remove the front Nose Cone by firmly grasping the lower part and lifting straight up. Disconnect the Solution Hose from the scrub deck. Unplug both brush motor wire assemblies. Note: Cable ties may need to be cut. See Figure 2. Remove the lower Actuator Mount Pin (A). Note: Lift up on the scrub deck to take pressure off the Pin (A).
SCRUB SYSTEM SCRUB BRUSH MOTOR/GEARBOX REMOVAL (DISC) 1 2 3 4 5 6 7 Follow the steps in the Scrub Brush Deck Removal (Disc) section. Turn the brush deck on its back. Remove the scrub brushes from the brush holders. If removing both motor/gearboxes mark the location of the holders and motors to the brush deck for proper re-assembly. See Figure 3. Remove the (3) (E) Hex Screws from the flexible coupler that attaches the brush holder to the drive Hub (F) of the Motor/Gearbox Assembly you want to remove.
SCRUB SYSTEM SCRUB BRUSH DECK REMOVAL (CYLINDRICAL) 1 2 3 4 5 6 7 8 With scrub brushes installed lower the scrub deck, turn the key off and disconnect the battery pack. Remove the front nose cone by firmly grasping the lower part and lifting straight up. See Figure 4. Disconnect the Solution Hose from the scrub deck. Unplug both brush motors wire assembles. Note: cable ties may need to be cut. Remove the lower Actuator Mount Pin (J). Note: Lift up on the scrub deck to take pressure off the Pin (J).
SCRUB SYSTEM FIGURE 4 FORM NO.
RECOVERY SYSTEM FUNCTIONAL OVERVIEW Vacuum / Recovery System General Dirt and water are lifted off the floor into the recovery tank by airflow, created by a 3-Stage 24V vacuum motor. The wastewater and air enter the vacuum system at the squeegee tool, through small openings (notches) located in the front squeegee blade. The small openings are the entrance points for the water and air, and help speed up the airflow producing the suction to lift the wastewater off of the floor.
RECOVERY SYSTEM VACUUM MOTOR CONTROL CIRCUIT OVERVIEW (AUTO MODE) See Figure 2. + (Positive) Circuit input starts with: • A closed S3 key switch supplies the needed positive voltage to the K2 vacuum solenoid coil and the A1 control board J1-13 (Brn wire). Note: The A1 control board scrub-on button must also be depressed (enabled). This operator command lowers the brush deck.
RECOVERY SYSTEM VACUUM / RECOVERY SYSTEM SERVICE MAINTENANCE CHECKLIST Whenever there is a vacuum problem, it’s best to check over the entire system. Use the checklist below as a guide, to thoroughly check the vacuum system. □ □ □ □ □ □ Inspect and clean the vacuum motor float switch. (If the switch is open [tipped up] the vacuum motor will not operate) Clean built-up dirt from the inside of the squeegee tool. Replace the squeegee blades if they are nicked or torn.
RECOVERY SYSTEM MAINTENANCE OF RECOVERY TANK FLOAT SWITCHES If the recovery tank float switch(es) become dirty it can impair their proper operation. A dirty vacuum shut off switch can cause the vacuum motor to not function at all or to not shut off when the tank is full. Dirty extended scrub system switches can prevent the optional extended scrub system from functioning properly.
RECOVERY SYSTEM MAINTENANCE OF VACUUM 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 30 - FORM NO.
RECOVERY SYSTEM VACUUM MOTOR REMOVAL 1 2 3 4 5 6 7 Drain the recovery tank using the drain hose. Turn the key off and disconnect the battery pack Swing open the recovery tank and disconnect the vacuum motor harness connector. See Figure 5. Remove the vacuum motor Shroud Cover (A) secured to the bottom of the recovery tank (qty 4 screws). Loosen the exhaust hose clamp and remove Hose (B) from the vacuum motor discharge tube and completely remove the Vacuum Motor (C) from its mount cavity.
RECOVERY SYSTEM RECOVERY TANK REMOVAL 1 2 2 3 4 5 Follow steps 1-5 in the Vacuum Motor Removal section. Disconnect Recovery Tank float switch(es). NOTE: Disconnect any other options installed on the tank. 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. Remove the Recovery Tank Drain Hose (H). Disconnect the Squeegee Hose (I) from the tank.
SQUEEGEE SYSTEM SQUEEGEE LIFT LINKAGE ADJUSTMENT See “Know Your Machine”. The squeegee pick-up tool is raised and lowered manually by a rear control panel mounted Lever (15). Squeegee Lift Lever Adjustment The squeegee tool’s storage and operating positions are adjustable. To adjust: 1 Lower the squeegee assembly to the floor. 2 See Figure 1. The Squeegee Mount Bracket has (3) Mount Holes (A) for changing the lift cable length.
SQUEEGEE SYSTEM SERVICING THE SQUEEGEE If the squeegee leaves narrow streaks or water, the blades may be dirty or damaged. Remove the squeegee, rinse it under warm water and inspect the blades. Reverse or replace the blades if they are cut, torn, wavy or worn. To Reverse or Replace the Rear Squeegee Wiping Blade... 1 See Figure 2. Raise the squeegee tool off the floor, and then unsnap the Center Latch (19) on the squeegee tool. 2 Remove the Tension Straps (26).
SQUEEGEE SYSTEM SQUEEGEE MOUNT ASSEMBLY REMOVAL 1 2 3 3 4 See Figure 3. Disconnect Squeegee Hose (28) and remove the Squeegee Assembly (12) from the machine. Lower the Squeegee Lever (15) and disconnect the Squeegee Lift Cable (C) from the squeegee mount bracket. Refer to Caster Wheel Removal section to remove the rear Caster (D). Remove Screw (E) and slide the Squeegee Mount Assembly (F) away from the chassis.
SQUEEGEE SYSTEM CASTER WHEEL REMOVAL WARNING! Disconnect the battery pack connector before servicing machine. WARNING! Never work under machine without safety stands or blocking to support the machine. 1 2 3 4 5 6 Drain both the solution and recovery tanks. Remove the squeegee assembly and have the scrub deck in the up (stored) position with the scrub brushes installed. See Figure 4. Place Wood Blocking (G) in front of the drive wheels to prevent the machine from rolling.
WHEEL DRIVE SYSTEM GENERAL FUNCTIONAL OVERVIEW See Figures 1 and 2. A 300 watt (.4 HP) permanent magnet (24V) motor transaxle (M1) is used for the wheel drive on all machines. A Curtis PMC solid state speed controller (A2) regulates the variable speed and Fwd/Rev wheel drive motor functions. Location of the controller is in the rear handle housing electrical compartment (accessible by removing the 4 screws securing the rear electrical panel).
WHEEL DRIVE SYSTEM FIGURE 2 BT1 2 + RED FUSE,150A. BRN REVERSE S3 FOR/REV. 1 2 GRN RED CIRCUITBREAKER,5AMP BATTERY Partial A1 Control Board F2 BLK - STATUS F1 1 RED A1 BLK B+ B- 1210SPEEDCONTROLLER (1228FOR36V) M + YEL/RED M2 WHT MOTOR,WHEELDRIVE BLU POT.100KOHMSPEEDLIMIT *For complete description of all callouts see Electrical System Wiring Diagram. 38 - FORM NO.
WHEEL DRIVE SYSTEM R2 Voltage Values 0V = Minimum Speed 5V = Maximum Speed FIGURE 3 WHEEL DRIVE SYSTEM R1 Voltage Values 0 – 2.5V Forward 2.5V – 5V Reverse R1 Throttle 5K Ohms A1 Speed Control Pin Connection WHT 1 BLU POT HIGH 2 BLK STATUS KSI BRAKE 3 5 4 6 POT LOW 9 16 13 POT WIPER 3 BLK R2 Speed Limit 100K Ohms WHT 18 REV. SPEED LIMIT POT WHT 1 BRN 3 BLK 2 This drawing shows additional controller input circuit detail.
WHEEL DRIVE SYSTEM WHEEL DRIVE TROUBLESHOOTING GUIDE Problem • Wheel drive motor will not run in forward and reverse. Possible Cause • Wheel Drive Motor Circuit Breaker (F32) tripped (reset 30A circuit breaker) • Control Circuit Circuit Breaker (F2) tripped (reset circuit breaker) • Defective Wheel Drive Motor (replace motor) * • Defective Throttle Potentiometer (R1) (replace) * • Wheel drive in one direction only, loss of either forward or reverse.
WHEEL DRIVE SYSTEM DRIVE MOTOR TRANSAXLE REMOVAL WARNING! Disconnect the battery pack before servicing machine. WARNING! Never work under machine without safety stands or blocking to support the machine. 1 2 3 Drain both the solution and recovery tanks and remove the squeegee. Remove the Scrub deck by following the Scrub Deck Removal instructions in this manual. Block the rear of the machine. See Figure 4 for proper placement of the wood blocking. FIGURE 4 FORM NO.
WHEEL DRIVE SYSTEM DRIVE MOTOR TRANSAXLE REMOVAL CONTINUED 4 5 6 7 8 See Figure 5. Jack the front of the machine from this location until the drive wheels are approximately 1” off the ground. Remove the (8) Locknuts (A) and then remove the (2) Drive Wheels (B) from the transaxle. Disconnect the drive motor wiring connector. Remove the (4) Motor Mount Bolts and Nuts (C) and carefully slide the Motor Transaxle (D) away from the machine. Reinstall in reverse order. FIGURE 5 42 - FORM NO.
WHEEL DRIVE SYSTEM DRIVE WHEEL REMOVAL WARNING! Disconnect the battery pack connector before servicing machine. WARNING! Never work under machine without safety stands or blocking to support the machine. 1 2 3 4 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. Using a scissors jack, raise the machine until the wheel is off the ground. See Figure 6 for jack placement.
WHEEL DRIVE SYSTEM (5K) POTENTIOMETER (R1) TESTING AND REMOVAL WARNING! Disconnect batteries at the battery pack disconnect before servicing. Testing the 5KDirectional/Throttle Potentiometer R1 Note: The potentiometer (pot) doesn’t have to be removed from its housing mount to test. 1 See Figure 7. Remove the front Drive Paddle Cover (G) from the Rear Housing (H) held together with (4) (I) Screws.
WHEEL DRIVE SYSTEM (5K) POTENTIOMETER (R1) INSTALLATION AND ADJUSTMENT (CONTINUED) 5 6 7. Reconnect the ohmmeter test leads to the pot wiper and low terminal connections and adjust (turn the pot) to obtain half of pot’s total resistance. This will accurately set the true neutral drive paddle operator position. Tighten the anchor nut secure. Note: Do not turn the potentiometer shaft when tightening. Next re-attach all the wiring to both the pots and re-install the cover.
ELECTRICAL SYSTEM BATTERIES If your machine shipped with batteries installed do the following: • Check that the batteries are connected to the machine (25 / 25a). • Turn ON the Key Switch (A) and check the Battery Indicator (D). If the gauge is completely filled, the batteries are ready for use. If the gauge is less than full, the batteries should be charged before use. See the “Charging The Batteries” section.
ELECTRICAL SYSTEM SPECIFIC WET CELL BATTERY INFORMATION Wet Cell Battery specifications - Use a combination of multiple 2-volt cell units to construct a 24 Volt DC battery pack system. - Nilfisk-Advance recommended battery pack capacity is a 238 AH @ 20 Hour Rate deep cycle battery system. Note: The battery pack must fit the battery compartment size listed in Specifications.
ELECTRICAL SYSTEM CHARGING WET BATTERIES Charge the batteries each time the machine is used or when the Battery Indicator (D) is reading less than full. WARNING! Do not fill the batteries before charging. Charge batteries in a well ventilated area. Do not smoke while servicing the batteries. When Servicing Batteries...
ELECTRICAL SYSTEM BATTERY MAINTENANCE WET CELL BATTERIES 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 (Weekly) - Use distilled water in batteries whenever possible. If batteries are discharged, add just enough water to cover the plates in each cell.
ELECTRICAL SYSTEM ACTUATOR DRIVE NUT ADJUSTMENT This manual section explains the steps for adjusting the drive nut (spring housing) setting for all the models’ scrub brush lift actuator motor. Reference the chart below to find the IN & OUT dimensional specification for an actuator motor needing adjustment. Part # 56393303 Actuator Motor Scrub Brush Lift (ALL) Spring Housing IN Position 1/16”(1.6mm) - 3/16”(4.76mm) Spring Housing OUT Position 4-1/8”(10.47cm) - 4-1/4”(10.
FIGURE 4 FORM NO.
ELECTRICAL SYSTEM CURTIS CONTROLLER DIAGNOSTICS: Diagnostics Method A: Uses the machine’s control display LED panel and wand switch indicator. FUNCTION OF THE SPEED CONTROLLER STATUS LIGHT AND DISPLAY The Curtis 1210- (24V) speed control will output a fault code if there is a problem associated with the speed control and wheel drive system. See Figure 5. If a speed control fault occurs, the display LED panel (D) will indicate 03.
ELECTRICAL SYSTEM FIGURE 5 FORM NO.
ELECTRICAL SYSTEM STATUS LED FAULT CODES (TABLE 1) LED CODE 1,1 STATUS LIGHT DISPLAY 0 0 EXPLANATION POSSIBLE CAUSE over-/under-temperature cutback 1. Temperature >92°C or < -25°C. 2. Excessive load on vehicle 3. Operation in extreme environments. 4. Electromagnetic brake not releasing. 1,2 0 00 throttle fault 1. Throttle input wire open or shorted 2. Throttle pot defective. 3. Wrong throttle type selected.
ELECTRICAL SYSTEM INSTALLATION CHECKOUT FOR THE CURTIS SPEED CONTROLLER SAFETY! The 1210 controller is inherently a high power device. When working around any battery powered vehicle, proper safety precautions should be taken. These include, but are not limited to: proper training, wearing eye protection, avoiding loose clothing and jewelry, and using insulated wrenches. After installing a controller and before operating the vehicle, carefully complete the following checkout procedure.
ELECTRICAL SYSTEM FUNCTIONAL OVERVIEW OF MAIN CONTROL BOARD The primary function of the main control board A1 is to position the scrubbing brush(s) with respect to the floor surface using a lift actuator motor to maintain the correct brush pressure and current draw of the brush motor(s). When the scrub ON switch is depressed this will lower the scrub deck to the operating position and by activating the drive paddle start the brush motors.
ELECTRICAL SYSTEM MAIN CONTROLLER ERROR CODES Display Code Fault Description Drive system fault. Troubleshooting Action 1. Check for a tripped drive motor circuit breaker (30 amp). Investigate reason for possible mechanical over load. Examples: Debris wrapped around the drive wheels, defective differential and prolonged ramp climbing. 2.
ELECTRICAL SYSTEM SERVICE TEST MODE: To assist in the troubleshooting and servicing of the electrical system and related components on the CONVERTAMATIC scrubbers, a special test mode that allows independent control of the various outputs and monitoring of the various inputs has been incorporated. To enter the service test mode perform the following step: 1 Turn the main power Key Switch (A) to the off position. 2 Press and hold the Wand Switch (E).
ELECTRICAL SYSTEM FIGURE 6 FORM NO.
ELECTRICAL SYSTEM BATTERY STATUS DISPLAY: The display will show the battery voltage. This display is accurate to within +/- 0.15 volts. Therefore, the voltage displayed may not correlate precisely to a highaccuracy, calibrated voltmeter. OUTPUT CONTROLS: The control panel switches are used to control various output functions of the main control unit. Below is a list of each switch and the function it controls. Following the list is a detailed description of each function.
ELECTRICAL SYSTEM OUTPUT CONTROLS (CONTINUED): Scrub On Switch (I): This switch is used to control the output to the scrub deck lift actuator. Pressing and releasing this switch will cycle the actuator output through 4 states. These are: 1 – Output off, direction = up 2 – Output on, direction = down (Display will show down arrow) 3 – Output off, direction = down 4 – Output on, direction = up (Display will show up arrow) When the output is in state 1, the actuator output is turned off.
ELECTRICAL SYSTEM OUTPUT CONTROLS (CONTINUED): Solution Switch (B): This switch is used to toggle the state of the solution solenoid. Pressing and releasing this switch will alternately turn the solution solenoid on and off. The indicator provides the following status information: Off - Solution output is off. Steady Green - Solution output is on. (solution pump is on and valve is open) Flashing Yellow – Solution solenoid / contactor coil overload has occurred.
ELECTRICAL SYSTEM MAIN CONTROL PROGRAMMING OPTIONS Selection of Low Voltage Cutout Threshold: FACTORY DEFAULT: 20.6V (STANDARD) The CONVERTAMATIC is equipped with a low voltage cutout feature to prevent over-discharging the batteries. This feature will automatically shut down the scrub system when the battery voltage falls to the selected threshold. The cutout level is adjustable. The Standard setting is 20.6 volts (1.72 volts per cell) and the alternate (Gel Cell) setting is 21.6 volts (1.
ELECTRICAL SYSTEM MAIN CONTROL PROGRAMMING OPTIONS (CONTINUED) Restoring the scrub pressures to factory default settings: If it is desired to restore the scrub pressures to factory default setting, perform the following steps: 1 2 3 4 5 6 7 Turn the main power key switch to the off position. Press and hold the scrub on switch. While holding the scrub on switch, turn the main power key switch to the on position. Continue to hold the scrub on switch until the scrub off indicator turns green.
ELECTRICAL SYSTEM MAIN CONTROL PROGRAMMING OPTIONS (CONTINUED) Turning Fault Detection On or Off: FACTORY DEFAULT: ON Normally, the main control unit will perform checks of the electrical system during operation. If a fault occurs in a particular system, that system (and possibly others) will be shut down. This can make troubleshooting the system difficult. This option will allow service personnel to disable some of the fault detection checks to facilitate troubleshooting.
ELECTRICAL SYSTEM MAIN CONTROL PROGRAMMING OPTIONS (CONTINUED) Light Scrub Setting Adjustment: FACTORY DEFAULT: SCRUB PRESSURE =1, SOLUTION = ONE BAR, CHEMICAL = 0 (IF AVAILABLE). The light scrub pressure, solution rate and chemical rate can be programmed depending on its application where high solution rate is need with light scrub pressure or low solution rate with heavy scrub pressure.
ELECTRICAL SYSTEM MAIN CONTROL PROGRAMMING OPTIONS (CONTINUED) Heavy Scrub Setting Adjustment: FACTORY DEFAULT: SCRUB PRESSURE =2, SOLUTION = TWO BARS, CHEMICAL = 0 (IF AVAILABLE). The heavy scrub pressure, solution rate and chemical rate can be programmed depending on its application where high solution rate is need with light scrub pressure or low solution rate with heavy scrub pressure.
ELECTRICAL SYSTEM MAIN CONTROL PROGRAMMING OPTIONS (CONTINUED) LCD Style Selection: FACTORY DEFAULT: RECTANGULAR SHAPE WITH THREE BARS LCD graphic style can be programmed to different style. There are two different styles and to change LCD graphic style, perform the following steps: 1 2 3 4 5 6 7 8 Turn the main power key switch to the off position. Press and hold the scrub on and vacuum switch. While holding both switches, turn the main power key switch to the on position.
ELECTRICAL SYSTEM COMPONENT LOCATION revised 8/05 Item Description A1 A2 BT1 F1 F2 F3 K1 K2 L1 L2 M1 M2 M3 M4 M5 M8 M9 M10 R1 R2 S1 S2 S3 S4 S5 S6 X9 X10 Control Board Speed Control Battery Fuse, 150 Amp Circuit Breaker, 5 Amp Circuit Breaker, 30 Amp Contactor, Brush Motor Contactor, Vac Motor Solenoid, Solution Solenoid, Recycle Solution (Optional) Motor, Wheel Drive Motor, Left Brush Motor, Right Brush Motor, Vac Motor, Brush Actuator Pump, Solution Pump, Recycle (Optional) Chemical Pump (Optional) P
1 L2 2 YEL/GRN COIL, RECYCLE SOLUTION SOLENOID (OPTIONAL) RED/BLK B+ A2 1210 SPEED CONTROLLER (1228 FOR 36V) M + M2 BLU/WHT RED + WHT - M3 M + BLK J2-2 SUPPLY B- B-1 WHT/GRN M MOTOR, BRUSH ACTUATOR RELAY N.O.
NO BLACK BLUE BLUE BLACK 4 WHITE WHITE BROWN BROWN ELECTRICAL SYSTEM 1 2 3 WHT 22-1 1 2 3 BLK 16-1 CONTACT N.O. R1 POT.
APPENDIX DETERGENT (AXP) SYSTEM PLUMBING SCHEMATIC Item 1 2 3 4 5 6 7 8 9 10 11 12 13 Description Solution Tank Shut Off Valve Inline Solution Filter Solution Pump Check Valve Detergent Pump Reducer Tee Reducer Coupler Solution Solenoid Valve Detergent Tank Reducer Coupler Solution Manifold (Cylindrical Models) Tee 72 - FORM NO.
APPENDIX EXTENDED SCRUB SYSTEM PLUMBING SCHEMATIC Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Description Solution Tank Shut Off Valve Inline Solution Filter Recovery Tank Extended Scrub Filter Extended Scrub Stop Switch Extended Scrub Start Switch Vacuum Shut Off Switch Extended Scrub Pump Solution Pump Reducer Coupler Solution Solenoid Valve Reducer Coupler Tee Extended Scrub Solenoid Valve Solution Manifold (Cylindrical Models) Tee Service Note: 1 2 revised 8/05 After each use, drain and rinse the
APPENDIX DETERGENT (AXP™ / ECO+Solution™) SYSTEM PREPARATION AND USE Fill the detergent cartridge with a maximum of 1.25 gallons (4.73 Liters) of detergent. SERVICE NOTE: Remove the detergent cartridge from the detergent box prior to filling to avoid spilling detergent on the machine. It is recommended that a separate cartridge be used for each detergent you plan to use. The detergent cartridges have a white decal on them so you can write the detergent name on each cartridge to avoid mixing them up.
