Service manual

FORM NO. 56043098 - Convertamatic
™
24C, 24D, 26C, 26D, 28C, 28D - 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 .................................................................................................................................................................................. 20-25
GENERAL BRUSH SYSTEM FUNCTIONAL OVERVIEW ....................................................................................................................... 20
SPECIAL SCRUB SYSTEM FUNCTIONS .......................................................................................................................................... 20-21
SCRUB BRUSH DECK REMOVAL (DISC) .............................................................................................................................................. 22
SCRUB BRUSH LIFT ACTUATOR REMOVAL (DISC) ............................................................................................................................. 22
SCRUB BRUSH MOTOR/GEARBOX REMOVAL (DISC) ........................................................................................................................ 23
SCRUB BRUSH DECK REMOVAL (CYLINDRICAL) .......................................................................................................................... 24-25
SCRUB BRUSH MOTOR(S) REMOVAL (CYLINDRICAL) .................................................................................................................. 24-25
SCRUB BRUSH BELT REPLACEMENT (CYLINDRICAL) .................................................................................................................. 24-25
SCRUB BRUSH SYSTEM MAINTENANCE (CYLINDRICAL) ................................................................................................................. 24
SCRUB BRUSH REMOVAL AND INSTALLATION (CYLINDRICAL) ........................................................................................................ 24
SCRUB BRUSH LIFT ACTUATOR REMOVAL (CYLINDRICAL) ......................................................................................................... 24-25
RECOVERY SYSTEM ........................................................................................................................................................................... 26-32
FUNCTIONAL OVERVIEW ....................................................................................................................................................................... 26
VACUUM MOTOR CONTROL CIRCUIT OVERVIEW (AUTO MODE) ..................................................................................................... 27
VACUUM/RECOVERY SYSTEM MAINTENANCE CHECKLIST ............................................................................................................. 28
MAINTENANCE OF RECOVERY TANK FLOAT SWITCHES .................................................................................................................. 29
MAINTENANCE OF VACUUM MOTOR INLET SCREEN ........................................................................................................................ 30
VACUUM MOTOR REMOVAL .................................................................................................................................................................. 31
RECOVERY TANK REMOVAL ................................................................................................................................................................. 32
SQUEEGEE SYSTEM ........................................................................................................................................................................... 33-36
SQUEEGEE LIFT LINKAGE ADJUSTMENT ............................................................................................................................................ 33
SERVICING THE SQUEEGEE ................................................................................................................................................................. 34
ADJUSTING THE SQUEEGEE ................................................................................................................................................................ 34
SQUEEGEE MOUNT ASSEMBLY REMOVAL ......................................................................................................................................... 35
CASTER WHEEL REMOVAL ................................................................................................................................................................... 36
WHEEL DRIVE SYSTEM ...................................................................................................................................................................... 37-45
GENERAL FUNCTIONAL OVERVIEW ................................................................................................................................................ 37-39
WHEEL DRIVE TROUBLESHOOTING GUIDE ........................................................................................................................................ 40
DRIVE MOTOR TRANSAXLE REMOVAL ........................................................................................................................................... 41-42
DRIVE WHEEL REMOVAL ....................................................................................................................................................................... 43
(5K) POTENTIOMETER (R1) TESTING AND REMOVAL ........................................................................................................................ 44
(5K) POTENTIOMETER (R1) INSTALLATION AND ADJUSTMENT ................................................................................................... 44-45
(100K) POTENTIOMETER (R2) TESTING AND REMOVAL .................................................................................................................... 45
ELECTRICAL SYSTEM ......................................................................................................................................................................... 46-73
BATTERIES .............................................................................................................................................................................................. 46
DESCRIPTION OF THE LOW VOLTAGE CUTOUT FEATURE ...............................................................................
................................ 47
DESCRIPTION OF THE BATTERY CONDITION INDICATORS .............................................................................................................. 47
BATTERY CHARGING, MAINTENANCE AND TESTING ................................................................................................................... 48-49
ACTUATOR DRIVE NUT ADJUSTMENT ............................................................................................................................................ 50-51
CURTIS CONTROLLER ...................................................................................................................................................................... 52-55
FUNCTIONAL OVERVIEW OF MAIN CONTROL BOARD ...................................................................................................................... 56
MAIN CONTROLLER ERROR CODES ................................................................................................................................................... 57
MAIN CONTROLLER DIAGNOSTIC SERVICE TEST MODE ............................................................................................................ 58-62
MAIN CONTROL PROGRAMING OPTIONS ...................................................................................................................................... 63-68
ELECTRICAL COMPONENT LOCATION ................................................................................................................................................ 69
WIRING DIAGRAM ................................................................................................................................................................................... 70
WIRING SCHEMATIC .............................................................................................................................................................................. 71
APPENDIX ............................................................................................................................................................................................. 72-74
DETERGENT (AXP) SYSTEM PLUMBING SCHEMATIC ........................................................................................................................ 72
EXTENDED SCRUB SYSTEM PLUMBING SCHEMATIC ....................................................................................................................... 73
DETERGENT (AXP) SYSTEM PREPARATION AND USE ...................................................................................................................... 74
Note: All references to right, left, front, or rear in this manual are as seen from the operator’s stand-point.
revised 8/05