Convertamatic 28/32/38LX Hydro-Retriever 280/320/380HD BA 700/800/1000

Transcription

1 Convertamatic 28/2/8LX Hydro-Retriever 280/20/80HD BA 700/800/000 SERVICE MANUAL Advance MODELS , , , , , Nilfisk MODELS 56972, , /95 revised /0 Form Number

2 TABLE OF CONTENTS SAFETY... SPECIFICATIONS & MAINTENANCE KNOW YOUR MACHINE SOLUTION SYSTEM MAINTENANCE... FLOW CONTROL VALVE REPLACEMENT - BA 700 / 28LX / 280HD FLOW CONTROL VALVE REPLACEMENT - BA 800, 000 / 2, 8LX / 20, 80HD... 2 SOLUTION CABLE REPLACEMENT - BA 700 / 28LX / 280HD... SOLUTION CABLE REPLACEMENT - BA 800, 000 / 2, 8LX / 20, 80HD... SOLUTION SOLENOID VALVE REMOVAL - BA 700 / 28LX / 280HD...5 SOLUTION SOLENOID VALVE REMOVAL - BA 800, 000 / 2, 8LX / 20, 80HD... 6 SOLUTION SOLENOID VALVE DISASSEMBLY AND CLEANING... 7 TROUBLESHOOTING...8 BRUSH DRIVE SYSTEM BRUSH DRIVE SYSTEM MAINTENANCE...9 BELT TENSION ADJUSTMENT - BA 700 / 28LX / 280HD BELT TENSION ADJUSTMENT - BA 800, 000 / 2, 8LX / 20, 80HD BRUSH LIFT LIMIT SWITCHES LIMIT SWITCH ADJUSTMENT LIMIT SWITCH REPLACEMENT... 2 BRUSH LIFT ACTUATOR REPLACEMENT...2 TROUBLESHOOTING...25 VACUUM SYSTEM VACUUM SYSTEM MAINTENANCE VACUUM MOTOR REMOVAL - BA 700 / 28LX / 280HD...27 VACUUM MOTOR REMOVAL - BA 800, 000 / 2, 8LX / 20, 80HD SQUEEGEE MAINTENANCE...29 SQUEEGEE ADJUSTMENT (BEFORE SN 08) SQUEEGEE ADJUSTMENT (AFTER SN 080)...0 TROUBLESHOOTING WHEEL DRIVE SYSTEM WHEEL DRIVE SYSTEM MAINTENANCE... CHAIN REMOVAL AND ADJUSTMENT... - DRIVE MOTOR REPLACEMENT... DRIVE WHEEL REPLACEMENT...5 TROUBLESHOOTING...6 POTENTIOMETER ADJUSTMENT... 7 BATTERY SYSTEM BATTERY MAINTENANCE...8 BATTERY TESTING...9 ELECTRICAL SYSTEM ELECTRICAL COMPONENT LOCATION... WIRING DIAGRAMS / SCHEMATICS Note: All references to right, left, front, or rear in this manual are as seen from the operator s stand-point. FORM NO / BA 700, 800, 000 / 28LX, 2LX, 8LX / 280HD, 20HD, 80HD -

3 SAFETY CAUTIONS AND WARNINGS SYMBOLS Nilfisk-Advance uses the symbols below to signal potentially dangerous conditions. Always read this information carefully and take the necessary steps to protect personnel and property. DANGER! Is used to warn of immediate hazards that will cause severe personal injury or death. WARNING! Is used to call attention to a situation that could cause severe personal injury. CAUTION! Is used to call attention to a situation that could cause minor personal injury or damage to the machine or other property. GENERAL SAFETY INSTRUCTIONS Specific Cautions and Warnings are included to warn you of potential danger of machine damage or bodily harm. WARNING! This machine shall be used only by properly trained and authorized persons. Keep sparks, flame and smoking materials away from batteries. Explosive gases are vented during normal operation. Charging the batteries produces highly explosive hydrogen gas. Charge batteries only in well-ventilated areas, away from open flame. Do not smoke while charging the batteries. Remove all jewelry when working near electrical components. Turn the key switch off (O) and disconnect the batteries before servicing electrical components. Never work under a machine without safety blocks or stands to support the machine. Do not dispense flammable cleaning agents, operate the machine on or near these agents, or operate in areas where flammable liquids exist. Do not clean this machine with a pressure washer. Do not operate this machine on ramps or inclines of more than an 8.7 percent gradient. CAUTION! This machine is not approved for use on public paths or roads. This machine is not suitable for picking up hazardous dust. Do not use scarifier discs and grinding stones. Nilfisk-Advance will not be held responsible for any damage to floor surfaces caused by scarifiers or grinding stones (can also cause damage to the brush drive system). When operating this machine, ensure that third parties, particularly children, are not endangered. Before performing any service function, carefully read all instructions pertaining to that function. Do not leave the machine unattended without first turning the key switch off (O), removing the key and applying the parking brake. Turn the key switch off (O) before changing the brushes, and before opening any access panels. Take precautions to prevent hair, jewelry, or loose clothing from becoming caught in moving parts. Use caution when moving this machine in below freezing temperature conditions. Any water in the solution or recovery tanks or in the hose lines could freeze, causing damage to valves and fittings. Flush with windshield washer fluid. SAVE THESE INSTRUCTIONS - FORM NO / BA 700, 800, 000 / 28LX, 2LX, 8LX / 280HD, 20HD, 80HD

4 SPECIFICATIONS SPECIFICATIONS - BA 700 / 28LX / 280HD Dimensions English (Metric) Scrub Brush Diameter.5 inches (6 cm) Scrub Brush Path 28 inches (7 cm) Scrub Brush Pressure 0 lbs. (6.5 kg) Scrub Brush Speed 55 rpm (55 rpm) Squeegee Size inches (08 cm) Machine Length 59 inches (50 cm) Machine Width 0.25 inches (77 cm) Machine Height 5.75 inches (6 cm) Drive Wheel 0 inch (25 cm) solid, traction tire Solution Tank Capacity (US) gal (25 l) Recovery Tank Capacity (US) gal (8 l) Coverage Rate 25,500 sq. ft (2,69 m 2 ) per hour Machine Weight 520 lbs. (690 kg) Gross Vehicle Weight (GVW) GVW Standard machine without options, maximum size batteries, full solution tank, empty recovery tank and brushes 770 lbs. (9 kg) shipping weight General Specifications Brush Motor 6 volt, 2 / hp dc motor Wheel Drive Motor 6 volt, / hp dc motor Vacuum Motor 6 volt, hp dc motor Brush Drive Dual worm gear 0 to reduction gear box Squeegee Type sided, curved, self tracking Speed Control Electronic, fully variable forward/reverse Batteries (6) 6 volt 2 AH (std) FORM NO / BA 700, 800, 000 / 28LX, 2LX, 8LX / 280HD, 20HD, 80HD - 5

5 SPECIFICATIONS SPECIFICATIONS - BA 800 / 2LX / 20HD Dimensions English (Metric) Scrub Brush Diameter 7 inches ( cm) Scrub Brush Path 2 inches (8 cm) Scrub Brush Pressure 60 lbs. (72.5 kg) Scrub Brush Speed 20 rpm (20 rpm) Squeegee Size 5 inches ( cm) Machine Length 62.5 inches (59 cm) Machine Width 7 inches (9 cm) Machine Height 6.75 inches (9 cm) Drive Wheel 0 inch (25 cm) solid, traction tire Solution Tank Capacity gal (25 l) Recovery Tank Capacity gal (8 l) Coverage Rate 2,500 sq. ft (,09 m 2 ) per hour Machine Weight,78 lbs. (779 kg) Gross Vehicle Weight (GVW) GVW Standard machine without options, maximum size batteries, full solution tank, empty recovery tank and brushes 825 lbs. (7 kg) shipping weight General Specifications Brush Motor 6 volt, 2 / hp dc motor Wheel Drive Motor 6 volt, / hp dc motor Vacuum Motor 6 volt, hp dc motor Brush Drive Dual worm gear 0 to reduction gear box Squeegee Type sided, curved, self tracking Speed Control Electronic, fully variable forward/reverse Batteries (6) 6 volt 50 AH (std) 6 - FORM NO / BA 700, 800, 000 / 28LX, 2LX, 8LX / 280HD, 20HD, 80HD

6 SPECIFICATIONS SPECIFICATIONS - BA 000 / 8LX / 80HD Dimensions English (Metric) Scrub Brush Diameter 20 inches (50 cm) Scrub Brush Path 8 inches (97 cm) Scrub Brush Pressure 60 lbs. (72.5 kg) Scrub Brush Speed 20 rpm (20 rpm) Squeegee Size 5 inches ( cm) Machine Length 62.5 inches (59 cm) Machine Width 0 inches (02 cm) Machine Height 6.75 inches (9 cm) Drive Wheel 0 inch (25 cm) solid, traction tire Solution Tank Capacity gal (25 l) Recovery Tank Capacity gal (8 l) Coverage Rate 5,000 sq. ft (,25 m 2 ) per hour Machine Weight,77 lbs. (792 kg) Gross Vehicle Weight (GVW) GVW Standard machine without options, maximum size batteries, full solution tank, empty recovery tank and brushes 878 lbs. (98 kg) shipping weight General Specifications Brush Motor 6 volt, 2 / hp dc motor Wheel Drive Motor 6 volt, / hp dc motor Vacuum Motor 6 volt, hp dc motor Brush Drive Dual worm gear 0 to reduction gear box Squeegee Type sided, curved, self tracking Speed Control Electronic, fully variable forward/reverse Batteries (6) 6 volt 50 AH (std) FORM NO / BA 700, 800, 000 / 28LX, 2LX, 8LX / 280HD, 20HD, 80HD - 7

7 MAINTENANCE MAINTENANCE SCHEDULE Maintenance intervals given are for average operating conditions. Machines used in severe operational environments may require service more often. Once a Once a Once a MAINTENANCE ITEM Daily Week Month Year Clean and inspect the tanks and hoses X Clean the brushes and pads X Clean the squeegee X Charge the batteries X Check battery water level X Lubrication X *Vacuum motor carbon brushes X *Have your Nilfisk-Advance Dealer check the motors carbon brushes once a year or after 00 operating hours. AFTER EACH USE Raise the brushes (or pads) and raise the squeegee. Move the machine to a service area. 2 Turn the Master Key Switch () OFF and remove the key. To empty the solution tank, take the Solution Drain Hose off its hanger. Direct the hose to a designated DISPOSAL SITE and remove the plug. Rinse the tank with clean water. Inspect the solution hoses; replace if kinked or damaged. To empty the recovery tank, take the Recovery Drain Hose (2) off its hanger. Direct the hose to a designated DISPOSAL SITE and remove the plug. Rinse the tank with clean water. Inspect the recovery and vacuum hoses; replace if kinked or damaged. 5 Remove the brushes or pad holders. Rinse the brushes or pads with warm water and hang them up to dry. Allow buffing pads to dry completely before using again. 6 Remove the Squeegee (), rinse it with warm water and hang it up to dry. 7 Check the Maintenance Schedule above and perform any required maintenance before storing the machine in a clean, dry place. LUBRICATING THE MACHINE Once a month, pump grease into each grease fitting on the machine until grease seeps out around the bearings. Grease fittings locations are: One on the front wheel One on each rear caster swivel Apply light machine oil to lubricate the following: Solution tank hinge Recovery tank hinge Brush skirt locks Squeegee lever pivot linkage Solution lever pivot points Brake lever pivot points Drive Chain Pivot points for the squeegee and scrub brush lift linkage 8 - FORM NO / BA 700, 800, 000 / 28LX, 2LX, 8LX / 280HD, 20HD, 80HD

8 KNOW YOUR MACHINE As you read this manual, you will occasionally run across a bold number in parentheses - example: (2). These numbers refer to an item on this or the following page. Refer back to these pages whenever necessary to pinpoint the location of an item mentioned in the text. Solution Lever 2 Twist Grip Solution Tank Cover Brake Lever 5 Power Connector 6 Circuit Breaker (80 Amp) 7 Circuit Breaker (25 Amp) 8 Circuit Breaker (25 Amp) 9 Circuit Breaker (5 Amp) 0 Squeegee Lever Master Key Switch 2 Recovery Tank Drain Hose Squeegee Squeegee Blade Latch 5 Recovery Tank Cover 6 Skirt FORM NO / BA 700, 800, 000 / 28LX, 2LX, 8LX / 280HD, 20HD, 80HD - 9

9 KNOW YOUR MACHINE CONTROL PANEL 7 Battery Meter 8 Brush Switch 9 Solution ON Light 20 Solution Switch, ON - Momentarily ON OFF 2 Power ON Light FORM NO / BA 700, 800, 000 / 28LX, 2LX, 8LX / 280HD, 20HD, 80HD

10 SOLUTION SYSTEM MAINTENANCE The solution system should be flushed every day to prevent a build-up of soap residue in the solution valve. To flush the system... Park the machine near a designated DISPOSAL SITE and drain the solution tank. 2 Put clean, warm water into the solution tank and let it drain through the drain hose. When the tank is empty, re-cap the drain hose and put about 2 inches (5 cm) of clean, warm water in the tank. Put the machine controls in the following positions: Key Switch () - ON Solution Switch (20) - ON Brush Drive (8) - Lowered Twist Grips (2) - Forward slightly Solution Flow Control Lever () - Pulled Back 5 Let all of the clean water flow from the tank. This will flush dirt and soap residue from the electric solenoid valve and the flow control valve. FLOW CONTROL VALVE REPLACEMENT - BA 700 / 28LX / 280HD Drain the solution tank at a designated DISPOSAL SITE. 2 See Figure. Remove the (A), (B), and (C) Hoses from the solution valve fittings and mark them to ensure proper reassembly. Remove Ball Joint (D) from the valve arm. Be careful not to lose the bushings. Remove the valve mounting bolts and remove the valve from the machine. 5 Remove the fittings from the old valve and remove the valve from the mount, (note the positioning of the fittings for reassembly). 6 Install the new valve on the mount and install the fittings. FIGURE FORM NO / BA 700, 800, 000 / 28LX, 2LX, 8LX / 280HD, 20HD, 80HD -

11 SOLUTION SYSTEM FLOW CONTROL VALVE REPLACEMENT - BA 700 / 28LX / 280HD (continued) 7 Follow steps - 5 in reverse order to reassemble. Make sure that the valve mount is in the forward two holes as shown. 8 Check for leaks and proper operation. FLOW CONTROL VALVE REPLACEMENT - BA 800, 000 / 2, 8LX / 20, 80HD Drain the solution tank at a designated DISPOSAL SITE. 2 Remove the left splash guard. See Figure 2. Remove the (E), (F), and (G) Hoses from the solution valve fittings and mark them to ensure proper reassembly. FIGURE 2 Remove Ball Joint (H) from the valve arm. Be careful not to lose the bushings. 5 Remove the valve mounting bolts and remove the valve from the machine. 6 Remove the fittings from the old valve and remove the valve from the mount, (note the positioning of the fittings for reassembly). 7 Install the new valve on the mount and install the fittings. 8 Follow steps - 5 in reverse order to reassemble. 9 Check for leaks and proper operation. 2 - FORM NO / BA 700, 800, 000 / 28LX, 2LX, 8LX / 280HD, 20HD, 80HD

12 SOLUTION SYSTEM SOLUTION CABLE REPLACEMENT - BA 700 / 28LX / 280HD Drain the solution tank at a designated DISPOSAL SITE. FIGURE 2 See Figure. Disconnect Ball Joint (I) from the valve arm. Be careful not to lose the bushings. Remove Ball Joint (I) from the cable, then remove the cable from the chassis cable mount, (note the cable position in the mount). See Figure. Remove Panel (J). FIGURE 5 Disconnect Ball Joint (K) from the lever, and then remove the balljoint from the cable. K 6 Remove the cable from the control handle cable mount, (note the cable position in the mount). 7 Before removing the cable, take note of the cable routing. Pull the cable up and out through the control handle. 8 Follow steps -8 in reverse order to reassemble. Test the new cable for proper operation before reinstalling the panels. J FORM NO / BA 700, 800, 000 / 28LX, 2LX, 8LX / 280HD, 20HD, 80HD -

13 SOLUTION SYSTEM SOLUTION CABLE REPLACEMENT - BA 800, 000 / 2, 8LX / 20, 80HD Drain the solution tank at a designated DISPOSAL SITE. 2 Remove the left splash guard. FIGURE 5 See Figure 5. Disconnect Ball Joint (L) from the valve arm. Be careful not to lose the bushings. Remove the cable from the chassis cable mount (note the cable position in the mount), then remove Ball Joint (L) from the cable. 5 See Figure. Remove Panel (J). 6 Disconnect Ball Joint (K) from the lever, and then remove the balljoint from the cable. 7 Remove the cable from the control handle cable mount, (note the cable position in the mount). 8 Before removing the cable, take note of the cable routing. Pull the cable down and out through the bottom of the control handle, and then pull it out through the rear of the chassis. 9 Follow steps -8 in reverse order to reassemble. Test the new cable for proper operation before reinstalling the handle panel and splash guard. - FORM NO / BA 700, 800, 000 / 28LX, 2LX, 8LX / 280HD, 20HD, 80HD

14 SOLUTION SYSTEM SOLUTION SOLENOID VALVE REMOVAL - BA 700 / 28LX / 280HD FIGURE 6 Drain the solution and recovery tanks at a designated DISPOSAL N SITE and disconnect one of the battery cables. M 2 Tip the solution tank over to the side of the machine. See Figure 6. Remove the () (M) Screws and remove Cover (N) from the machine. See Figure 7. Disconnect Hoses (O), (P), (Q) and then disconnect the solenoid valve wiring connector. FIGURE 7 O W FRONT T X R U Q V S P 5 Remove the (2) (R) Screws, remove the Solenoid Valve (S) and Bracket (T) from the machine. 6 Remove the fittings from the solenoid valve only if you are replacing the solenoid valve (remove Fittings (U), (V), (W), and (X) as a one piece unit to avoid snapping them off inside the Tee Fitting (X). 7 Reassemble in reverse order and test for leaks and proper operation. FORM NO / BA 700, 800, 000 / 28LX, 2LX, 8LX / 280HD, 20HD, 80HD - 5

15 SOLUTION SYSTEM SOLUTION SOLENOID VALVE REMOVAL - BA 800, 000 / 2, 8LX / 20, 80HD Drain the solution and recovery tanks at a designated DISPOSAL SITE and disconnect one of the battery cables. Z FIGURE 8 2 Tip the solution tank over to the side of the machine. Y See Figure 8. Remove the () (Y) Screws and remove Cover (Z) from the machine. See Figure 9. Disconnect Hoses (AA), (BB), (CC) and then disconnect the solenoid valve wiring connector. FIGURE 9 FRONT AA EE GG HH BB DD JJ FF CC II 5 Remove the (2) (DD) Screws, remove the Solenoid Valve (EE) and Bracket (FF) from the machine. 6 Remove the fittings from the solenoid valve only if you are replacing the solenoid valve (remove Fittings (GG), (HH), (II), and (JJ) as a one piece unit to avoid snapping them off inside the Tee Fitting (JJ). 7 Reassemble in reverse order and test for leaks and proper operation. 6 - FORM NO / BA 700, 800, 000 / 28LX, 2LX, 8LX / 280HD, 20HD, 80HD

16 SOLUTION SYSTEM SOLUTION SOLENOID VALVE DISASSEMBLY AND CLEANING Remove the solenoid valve (do not remove the fittings from the solenoid valve unless you are replacing the valve!). Refer to the Solution Solenoid Valve Removal sections of this chapter. 2 See Figure 0. Remove the (2) (KK) Screws and Nuts and disassemble the valve (be careful not to lose any internal parts). FIGURE 0 KK LL MM KK Thoroughly wash any dirt from Block (LL) and Diaphragm (MM). Reassemble in reverse order and test for leaks and proper operation. FORM NO / BA 700, 800, 000 / 28LX, 2LX, 8LX / 280HD, 20HD, 80HD - 7

17 SOLUTION SYSTEM TROUBLESHOOTING PROBLEM: NO SOLUTION FLOW Possible Cause & Remedy: Machine controls not positioned properly - in order for solution to flow, the controls must be positioned as follows: Key Switch - ON Solution Switch - ON Brush Switch - ON Twist Grips - Forward Flow Control Lever - Pulled Back 2 Clogged solution filter - drain solution tank, using the clear plastic drain hose at the back of the machine. This automatically flushes loose dirt from the solution filter. If solution still does not flow, remove and disassemble the teefitting (attached to the solenoid valve) and remove and clean the filter thoroughly. Clogged solenoid valve - remove, disassemble and clean the solenoid valve. See the Solenoid Valve Disassembly and Cleaning section for instructions. Defective speed control - replace the speed control. PROBLEM: SOLUTION LEAKS IN THE OFF POSITION Possible Cause & Remedy: Dirt in solenoid valve - remove, disassemble and clean the solenoid valve. See the Solenoid Valve Disassembly and Cleaning section for instructions 2 Defective solenoid valve - replace the solenoid valve. See the Solution Solenoid Valve Removal sections for instructions. 8 - FORM NO / BA 700, 800, 000 / 28LX, 2LX, 8LX / 280HD, 20HD, 80HD

18 BRUSH DRIVE SYSTEM MAINTENANCE Every years... Check the carbon brushes in the brush motor. Replace the brushes if they are worn to a length of /8 inch (0 mm) or less. 2 Remove the fill plug from the top of the gear box and check the oil level. The oil should be -/2 inches (.8 cm) from the top of the gear box. Use 0W gear lube only. Check the belt tension. There should be about /2 inch (2 mm) of belt deflection when -/ pounds of pressure is applied between the pulleys. BELT TENSION ADJUSTMENT - BA 700 / 28LX / 280HD Remove the actuator from the machine (see the Brush Lift Actuator Replacement section). 2 Remove the access panel from the right side of the machine. See Figure. Loosen the () screws in the (A) Belt Guards. FIGURE FORM NO / BA 700, 800, 000 / 28LX, 2LX, 8LX / 280HD, 20HD, 80HD - 9

19 BRUSH DRIVE SYSTEM BELT TENSION ADJUSTMENT - BA 700 / 28LX / 280HD (continued) Loosen the (B) Bolts and Nuts. 5 Loosen the (C) Lock Nuts and turn the (D) Bolts to adjust the belt tension. There should be about /2 inch (2 mm) of belt deflection when -/ pounds of pressure is applied between the pulleys. 6 Follow steps -5 in reverse order to reassemble. 7 After the adjustment is complete, test to make sure the belt does not slip. BELT TENSION ADJUSTMENT - BA 800, 000 / 2, 8LX / 20, 80HD Drain and tip the solution tank to the side of the machine. 2 See Figure 2. Loosen the (E) Bolts and Nuts. Loosen the lock nuts and turn the (F) Bolts to adjust the belt tension. There should be about /2 inch (2 mm) of belt deflection when -/ pounds of pressure is applied between the pulleys. After the adjustment is complete, test to make sure the belt does not slip. BA 800 / 2LX / 20HD E FIGURE 2 BA 000 / 8LX / 80HD E E E F F FRONT FRONT 20 - FORM NO / BA 700, 800, 000 / 28LX, 2LX, 8LX / 280HD, 20HD, 80HD

20 BRUSH DRIVE SYSTEM BRUSH LIFT ACTUATOR LIMIT SWITCHES LIMIT SWITCH ADJUSTMENT Remove the brushes, lower the brush drive and jack up the front of the machine about 2 inches. Put wood blocks under the brush holders and lower the jack enough to take the weight of the brush drive assembly off the actuator. 2 Drain and tip the solution tank to the side of the machine. See Figure. Loosen the (2) (G) Bolts and Nuts until the plastic nut on the actuator slips out of the brackets. Remove Ring (H) and Pin (I), lift the actuator up, but leave it plugged in. FIGURE BA 700 / 28LX / 280HD BA 800, 000 / 2, 8LX / 20, 80HD FRONT H I I G G G H G FRONT FORM NO / BA 700, 800, 000 / 28LX, 2LX, 8LX / 280HD, 20HD, 80HD - 2

21 BRUSH DRIVE SYSTEM LIMIT SWITCH ADJUSTMENT (continued) 5 See Figure. Measure the position of the plastic nut on the actuator shaft. 6 Manually turn the plastic nut to the DOWN position given below. FIGURE Adjuster Cover Plastic Nut Down Up Machine DOWN Position UP Position BA 700 / 28LX / 280HD 5-/2 inches 8 inches (0 mm) (20 mm) BA 800, 000 / 2LX / 8LX 5-/ inches 0 inches 20HD / 80HD (6 mm) (25 mm) 7 Hold the plastic nut, put the brush lift switch in the UP position and wait until the actuator stops. 8 Measure the position of the plastic nut on the actuator shaft and compare your measurement with the UP position given above. 9 Remove the adjuster cover from the top of the actuator and adjust the UP position. To increase the travel of the plastic nut, turn the adjuster clockwise. To decrease the travel of the plastic nut, turn the adjuster counter-clockwise. Note: Each click of the adjuster will change the nut travel /6 inch (.6mm). 0 After each adjustment, hold the plastic nut, run the actuator up and down and check the UP and DOWN position of the plastic nut again. After adjustment is complete, replace the adjuster cover and follow steps - in reverse order to reassemble. 2 Test the actuator to make sure the brushes raise and lower properly FORM NO / BA 700, 800, 000 / 28LX, 2LX, 8LX / 280HD, 20HD, 80HD

22 BRUSH DRIVE SYSTEM BRUSH LIFT LIMIT SWITCHES (continued) LIMIT SWITCH REPLACEMENT Remove the actuator from the machine (see the Brush Lift Actuator Replacement section). 2 See Figure 5. Remove the (J) Screws and Cover (K), be careful not to lose the spring and washers. Note the position of the Adjuster (L) for reassembly. Remove the (M) Diodes from the switches. FIGURE 5 L N J K M Remove the (N) Screws, the switches and the switch shroud. 5 Follow steps 2- in reverse order to reassemble the actuator. 6 After reassembling the actuator and before reinstalling the actuator in the machine, adjust the UP and DOWN limits (see the Brush Lift Limit Switch Adjustment section). FORM NO / BA 700, 800, 000 / 28LX, 2LX, 8LX / 280HD, 20HD, 80HD - 2

23 BRUSH DRIVE SYSTEM BRUSH LIFT ACTUATOR REPLACEMENT Remove the brushes, lower the brush drive and jack up the front of the machine about 2 inches. Put wood blocks under the brush holders and lower the jack enough to take the weight of the brush drive assembly off of the actuator. 2 Drain and tip the solution tank to the side of the machine, and disconnect the batteries. See Figure 6. Loosen the (2) (O) Bolts and Nuts until the plastic nut on the actuator slips out of the brackets, do not turn this nut if you are reinstalling the same actuator. BA 700 / 28LX / 280HD FIGURE 6 BA 800, 000 / 2, 8LX / 20, 80HD Q FRONT P O Q O P O O FRONT Unplug the actuator cord. Remove Nut (P), and Bolt (Q). Remove the actuator from the machine. 5 Follow steps - in reverse order to reassemble. To set UP and DOWN limits (see the Brush Lift Limit Adjustment section). 2 - FORM NO / BA 700, 800, 000 / 28LX, 2LX, 8LX / 280HD, 20HD, 80HD

24 BRUSH DRIVE SYSTEM TROUBLESHOOTING Before troubleshooting the brush drive circuit, check the reset button on the 80 amp brush motor circuit breaker, reset if necessary. Problem: Squealing noise when brushes are lowered. Possible Cause & Remedy: Loose belt - adjust belt tension. Problem: Brush motor will not start when twist grips are turned. Possible Cause & Remedy: Tripped brush motor circuit breaker (see Figures 7A & 7B) - press the reset button, check the circuit breaker for continuity. 2 Defective brush switch (on top of control handle) - replace switch. Defective brush motor solenoid (see Figures 7A & 7B) - replace solenoid. Defective brush motor - remove motor, repair or replace. 5 Defective speed control (see Figures 7A & 7B) - replace speed control. FIGURE 7A FIGURE 7B BA 700 Before SN BA 800, BA 000 Before SN 08 Drive Motor Solenoid BA 700 After SN BA 800, BA 000 After SN 080 All 28LX / 280HD All 2LX, 8LX / 20HD, 80HD Drive Motor Solenoid Speed Control Speed Control Brush Solenoid Down Solenoid Brush Motor Solenoid Actuator Control Module Up Solenoid Brush Circuit Breaker Brush Circuit Breaker FRONT FRONT Problem: Brushes will not go up or down. Possible Cause & Remedy: Defective brush switch (on top of control handle) - replace switch. 2 Defective drive nut or actuator - replace drive nut or actuator. Defective up or down solenoid (see Figure 7A) - replace solenoid(s), for machines with up and down solenoids. Defective Actuator Control Module (see Figure 7B) replace control module, for machines with actuator control module. FORM NO / BA 700, 800, 000 / 28LX, 2LX, 8LX / 280HD, 20HD, 80HD - 25

25 VACUUM SYSTEM MAINTENANCE Whenever the vacuum system does not perform properly, the entire system should be cleaned and inspected, following the maintenance checklist below. Remove the squeegee from the machine and clean it thoroughly. 2 Inspect the squeegee blades. If the wiping edge of the rear blade is damaged or worn to a radius, turn it around or over so a new edge with a sharp corner faces toward the front of the machine. See Figure. Disconnect Squeegee Hose (A) from the recovery tank cover. Park the machine near a designated disposal site and use a garden hose to back flush dirt down and out of Squeegee Hose (A). A FIGURE B C E D 26 - FORM NO / BA 700, 800, 000 / 28LX, 2LX, 8LX / 280HD, 20HD, 80HD

26 CAUTION! Do not flush hose (C) unless it is disconnected from the vacuum motor. VACUUM SYSTEM MAINTENANCE (continued) Remove Cover (B) from the recovery tank (see Figure ). Rinse all dirt from Cage (E) and the ball float inside. 5 Check the gasket on recovery tank Cover (B). It must seal air-tight against the top of the tank. 6 Check drain hose Plug (D). Replace the plug if it does not seal air-tight. If the machine still does not pick up after completing this checklist, see the Troubleshooting section of this chapter for additional information. VACUUM MOTOR REMOVAL - BA 700 / 28LX / 280HD FIGURE Disconnect one of the battery cables. 2 Drain the solution tank and tip it to the side of the machine. H See Figure 2. Remove the () (F) Screws and remove Cover (G) from the machine. See Figure. Remove the () (H) Screws and disconnect the vacuum motor wiring connector. Remove the vacuum motor from the machine. FIGURE 2 FRONT G F FORM NO / BA 700, 800, 000 / 28LX, 2LX, 8LX / 280HD, 20HD, 80HD - 27

27 VACUUM SYSTEM VACUUM MOTOR REMOVAL - BA 800, 000 / 2, 8LX / 20, 80HD Disconnect one of the battery cables. FIGURE 5 2 Drain the solution tank and tip it to the side of the machine. K See Figure. Remove the () (I) Screws and remove Cover (J) from the machine. See Figure 5. Remove the () (K) Screws and disconnect the vacuum motor wiring connector. Remove the vacuum motor from the machine. FRONT FIGURE J I FRONT 28 - FORM NO / BA 700, 800, 000 / 28LX, 2LX, 8LX / 280HD, 20HD, 80HD

28 VACUUM SYSTEM SQUEEGEE MAINTENANCE If the squeegee leaves narrow streaks of water, the blades may be dirty or damaged. Remove the squeegee, rinse it under warm water and inspect the squeegee blades. Reverse or replace the blades if they are cut, torn, wavy or worn. To Reverse or Replace the Rear Squeegee Wiping Blade... Unsnap the center Latch on the squeegee tool. 2 Remove the Wing Nut from each end of the squeegee, then remove the Tension Straps. Slip the rear blade off the Alignment Pins. The rear squeegee blade has working edges. Turn the blade so a clean, undamaged edge points toward the front of the machine and against the floor. Replace the blade if all edges are nicked, torn or worn. 5 Install the blade, following steps - in reverse order. FIGURE 6 Adjustment Knob Thumb Nut Squeegee Mount Wing Nut Rear Squeegee Blade Alignment Pin Retaining Strap Vacuum Hose Connection Latch To Reverse or Replace the Front Squeegee Blade... Put the Squeegee Lever in the UP position and remove the vacuum hose from the squeegee tool. 2 Loosen the two thumb screw on top of the squeegee, and slide the squeegee tool off of the squeegee mount. Remove the nuts that hold the front blade in place, then remove the blade. The front squeegee blade has working edges. Turn the blade so a sharp 90 edge points toward the front of the machine and against the floor. Replace the blade if all edges are nicked, torn or worn. 5 Install the blade, following steps - in reverse order. 6 Put the squeegee tool back on the machine, connect the vacuum hose, and adjust the squeegee. SQUEEGEE ADJUSTMENT (BA 700 BEFORE SN & BA 800/000 BEFORE SN 08) The squeegee should be adjusted whenever the squeegee is not wiping the floor dry. To Adjust the Squeegee Tool... Park the machine on a flat, even surface. 2 Turn the Master Switch () OFF and lower the Squeegee Lever (0). Turn the Adjustment Knob until the rear squeegee blade touches the floor across its entire width. FORM NO / BA 700, 800, 000 / 28LX, 2LX, 8LX / 280HD, 20HD, 80HD - 29

29 VACUUM SYSTEM SQUEEGEE ADJUSTMENT (BA 700 AFTER SN & BA 800/000 AFTER SN 080) ALL 28, 2, 8LX / 280, 20, 80HD Park the machine on a flat, even surface. 2 Lower the squeegee. Loosen the (horizontal) squeegee-mount lock bolt (found on right side next to the recovery hose tube). Loosen the locking nut on the (vertical) tilt adjustment bolt on the squeegee tongue. 5 Turn the adjustment bolt with a wrench to tilt the tool forward or backwards, until the rear squeegee wiping blade touches the floor across its entire width. 6 Re-tighten both the adjustment nut and mount lock bolt. FIGURE 7 Tilt Adjustment Bolt Locking Nut Squeegee Mount Lock Bolt Rear Squeegee Wiping Blade 0 - FORM NO / BA 700, 800, 000 / 28LX, 2LX, 8LX / 280HD, 20HD, 80HD

30 VACUUM SYSTEM TROUBLESHOOTING Problem: Machine will not pick up water, water flows around ends of squeegee Possible Cause & Remedy: Plug for recovery tank drain hose not sealing air-tight install plug properly or replace if damaged. 2 Recovery tank cover not installed properly push cover down all the way, so it seals air-tight against the top of the tank. Damaged gasket on recovery tank cover replace gasket. Low battery voltage charge or replace batteries. 5 Vacuum motor defective repair or replace vacuum motor. Problem: Water in vacuum motor Possible Cause & Remedy: Operator using high-sudsing detergent use low-sudsing detergent or add a defoaming chemical to the recovery tank. 2 Vacuum leak in recovery tank drain hose or plug replace hose or plug. Vacuum shut-off float ball not closing clean or replace float ball and cage (mounted on recovery tank cover). Problem: Float closes before tank is full Possible Cause & Remedy: Foam in recovery tank use low-sudsing detergent or add a defoaming chemical to the recovery tank. 2 Cage around vacuum shut-off float clogged disconnect hoses from recovery tank cover, remove the cover and clean or replace the float cage. FORM NO / BA 700, 800, 000 / 28LX, 2LX, 8LX / 280HD, 20HD, 80HD -

31 VACUUM SYSTEM TROUBLESHOOTING (continued) Problem: Vacuum motor will not run when squeegee is lowered Possible Cause & Remedy: Tripped vacuum motor circuit breaker (see Figures 8A and 8B) press reset button, check circuit breaker for continuity. 2 Defective vacuum switch (see Figure 9) remove cover panel from back of control handle, adjust or replace switch. Defective vacuum motor remove motor, repair or replace. Defective vacuum motor solenoid (see Figures 8A and 8B) replace solenoid. FIGURE 8A BA 700 Before SN BA 800, BA 000 Before SN 08 FIGURE 9 FRONT Vac Motor Solenoid Vac Motor Circuit Breaker FIGURE 8B Vacuum Switch BA 700 After SN BA 800, BA 000 After SN 080 All 28LX / 280HD All 2LX, 8LX / 20HD, 80HD Vac Motor Solenoid FRONT Vac Motor Circuit Breaker 2 - FORM NO / BA 700, 800, 000 / 28LX, 2LX, 8LX / 280HD, 20HD, 80HD

32 WHEEL DRIVE SYSTEM MAINTENANCE Lubricate the drive wheel bearings once per month. For access to the grease fitting, open the left splash guard, raise the brushes and remove the left scrub brush from the machine. CHAIN REMOVAL OR ADJUSTMENT CHAIN REMOVAL: Drain and remove the solution and recovery tanks, disconnect and remove the batteries and squeegee. 2 Remove the left splash guard and scrub brush. Then tip the machine over on its left side. See Figure. Loosen Lock Nut (A) and back out Bolt (B) several turns to loosen tension on the drive chain, then remove the chain from the motor sprocket. Disconnect the master link in the drive chain and remove the chain from the machine. 5 Follow steps - in reverse order to reassemble. Adjust the chain tension. See the Chain Adjustment instructions follow step 2. 6 Test the drive system for proper operation. FIGURE D E F G C B A FRONT FORM NO / BA 700, 800, 000 / 28LX, 2LX, 8LX / 280HD, 20HD, 80HD -

33 WHEEL DRIVE SYSTEM CHAIN REMOVAL OR ADJUSTMENT (continued) CHAIN ADJUSTMENT: Follow steps & 2 from the Chain Removal section above. 2 See Figure. Loosen Lock Nut (A), turn Bolt (B) to adjust chain tension. There should be about /2 inch (2 mm) of deflection between the sprockets when moderate pressure is applied to the chain. Follow steps & 2 in reverse order to reassemble. Test the drive system for proper operation. DRIVE MOTOR REPLACEMENT Drain and remove the solution and recovery tank, disconnect and remove the batteries and squeegee. 2 Remove the left splash guard and scrub brush. Then tip the machine over on its left side. See Figure. Cut the plastic tie strap holding the vac hose and wiring onto motor mount Bracket (C). Then disconnect the (2) motor wires from the red terminals. Note that the positive motor wire and the blue wire from the machine wiring harness are connected to the same terminal. Remove the Bolt (D) and Washer (E) from the end of the motor shaft. 5 Loosen Lock Nut (A) and back out Bolt (B) several turns to loosen the tension on the drive chain, then remove the chain from the motor sprocket. 6 Loosen the (2) set screws in Motor Sprocket (F) and pull the sprocket off the motor shaft. 7 Put a wood block under the motor so that it will not fall. Then remove the () Bolts (G) and separate the motor from Bracket (C). 8 Follow steps - 7 in reverse order to re-assemble. Note: Install a new plastic tie strap to hold the wiring and vac hose away from any moving parts. - FORM NO / BA 700, 800, 000 / 28LX, 2LX, 8LX / 280HD, 20HD, 80HD

34 WHEEL DRIVE SYSTEM DRIVE WHEEL REPLACEMENT Drain and remove the solution and recovery tank, disconnect and remove the batteries and squeegee. 2 Remove the left splash guard and scrub brush. Then tip the machine over on its left side. See Figure 2. Loosen Lock Nut (H) and back out Bolt (I) several turns to loosen the tension on the drive chain, then remove the chain from the motor sprocket. FIGURE 2 I H FRONT J Remove the () (J) Bolts (2 at each end of the axle) and pull the wheel assembly away from the machine frame. 5 Remove the (6) bolts that hold the brake disc and sprocket on the wheel. 6 Using a rubber mallet or brass drift, drive the axle and one of the bearings out of the wheel. Then drive the other bearing out of the wheel. 7 Follow steps -6 in reverse order to reassemble. 8 Refer to the Chain Adjustment section for proper chain tension. 9 Test the drive system for proper operation. FORM NO / BA 700, 800, 000 / 28LX, 2LX, 8LX / 280HD, 20HD, 80HD - 5

35 WHEEL DRIVE SYSTEM TROUBLESHOOTING Problem: No wheel drive - forward or reverse Possible Cause & Remedy: Tripped wheel drive circuit breaker - press reset button and check circuit breaker for continuity. 2 Defective wheel drive motor - follow instructions below to test. Jack up the front of the machine to lift the drive wheel off the floor. Turn Key Switch () OFF. Disconnect one of the battery cables. Remove the back panel from control handle. Disconnect the white/green wire from the M2 terminal on the speed control. Connect this wire to one of the B+ terminals (also on the speed control). Disconnect the blue wire from the M terminal on the speed control. Connect this wire to one of the B- terminals (also on the speed control). Reconnect the battery cable and then turn key ON. If the wheel motor turns, go to steps. If the wheel motor does not turn, remove the tanks and batteries, tip the machine on its side and repair or replace the wheel drive motor. Defect in potentiometer mechanism - follow instructions below to test. Make sure that the white, green and black wires are firmly connected to the potentiometer. The white wire should be on the potentiometer terminal closest to the front of the machine, the green wire on the center terminal and the black wire on the terminal closest to the back of the machine. Disconnect the potentiometer plug (the one with the green, black and white wires) from the speed control. Connect an ohmmeter to the green and white wires. NOTE: Inserting a paper clip into the plug end will help in the attachment of the test leads. Meter should read ohms in neutral and increase to 5000 ohms when the twist grips are turned to the full-forward position. If you do not get these readings, follow potentiometer adjustment instructions. If you do get these readings, go to the next test. Connect an ohmmeter to the green and black wires. Meter should read ohms in neutral and decrease to ohms when the twist grips are turned to the full-forward position. If you do not get these readings, follow potentiometer adjustment instructions. If you do get these readings, the potentiometer is OK replace the speed control. 6 - FORM NO / BA 700, 800, 000 / 28LX, 2LX, 8LX / 280HD, 20HD, 80HD

36 WHEEL DRIVE SYSTEM POTENTIOMETER ADJUSTMENT Adjust the potentiometer if the machine has no drive, or if it moves with the twist grips in neutral. To adjust the potentiometer... Remove the back panel from the control handle. 2 Carefully inspect the potentiometer belt and pulley mechanism for a mechanical defect, correct defects before proceeding. Carefully pull the potentiometer connector (the one with the green, black and white wires) off of the speed control. Connect an ohmmeter (on 0 x 00 scale) to the green and white wires on the connector. The meter should read between 200 and 2600 ohms. If it does not, go to the next step. 5 Loosen the (2) set screws (using a 5/6 Allen wrench) in the potentiometer pulley and slide it off of the potentiometer shaft (if the potentiometer shaft does not have a slot in the end of it) (if it does, use a screw driver to adjust the potentiometer after loosening the pulley set screws). 6 Turn the potentiometer shaft until the ohmmeter reads between 200 and 2600 ohms. 7 Slide the pulley back onto the potentiometer shaft, being careful not to turn the shaft. 8 Test the drive system for proper operation before reinstalling the back panel. FORM NO / BA 700, 800, 000 / 28LX, 2LX, 8LX / 280HD, 20HD, 80HD - 7

37 BATTERY SYSTEM WARNING! Use extreme caution when working with batteries. Sulfuric acid in batteries can cause severe injury if allowed to contact skin or eyes. Explosive hydrogen gas is vented from inside the batteries through openings in the battery caps. This gas can be ignited by any electrical arc, spark or flame. When working with batteries: Remove all jewelry. Wear chemical goggles, rubber gloves and a protective apron. Do not smoke. Do not allow tools to touch more than one battery terminal at a time. Work in a well-ventilated area. Do not fill the batteries before charging. BATTERY MAINTENANCE Proper maintenance of electric vehicle batteries can greatly extend their life. Well-maintained batteries may last up to years, but failure after year is common if maintenance has been poor. There are simple rules for good battery maintenance: Maintain Proper Electrolyte Level Check the electrolyte level of the batteries at least once a week. Use distilled water in batteries whenever possible. If batteries are discharged, add just enough water to cover the plates in each cell. After batteries are fully charged, fill each cell to the bottom of the filler tube. Do not over-fill the batteries! Do not add acid to batteries! Keep the Batteries Charged - Batteries should be charged each time that a machine is used for more than hour or when the Battery Meter (7) indicates batteries are empty. Machine operators should tip the solution and recovery tank to the side of the machine for charging, to avoid a concentrated build-up of hydrogen gas. Push the connector from the charger into the Power Connector (5). Operators should follow the instructions provided with their specific battery charger, to determine how long the batteries should be charged. Even when a machine is stored, the batteries should be charged once a month to prevent the batteries from sulfating. Almost all battery caps are vented, so there s no need to loosen or remove them for charging. Keep the Batteries Clean - Use a damp cloth to wipe dirt and liquid from the top of the batteries. Battery terminals must be clean and tight. If the top of the batteries are wet after charging, the batteries have probably been over-filled. Always wipe water and acid from the top of the batteries after charging. If there is acid on the batteries, wash the tops of them with a solution of baking soda and water (2 tablespoons of baking soda to liter of water). 8 - FORM NO / BA 700, 800, 000 / 28LX, 2LX, 8LX / 280HD, 20HD, 80HD

38 BATTERY SYSTEM BATTERY TESTING A battery problem is usually recognized by the machine operator, as a decrease in the machine s running time. This condition is usually caused by one (or more) dead cell in the battery system- that is, one (or more) cell that is putting out less voltage than the other cells. Note: Always charge batteries before testing. There are 2 ways to find a dead cell: Use a hydrometer to check the specific gravity (or state of charge ) of the fluid in each cell. A dead cell is one that reads 50 points (or more) lower than the other cells. Use a volt meter to check the voltage of each battery with the brush and vac motors running. The battery with the dead cell will read or 2 volts lower than the other batteries in the system. If the batteries in the machine are more than year old, it s usually best to replace the whole set, rather than replacing just one battery. FIGURE BLACK 6V 95 AH USA / ESPANOL / NIPPON 05 AH ITALIANO / FRANCAIS / 28 AH Proper installation and cable routing of (6) 6 Volt batteries FORM NO / BA 700, 800, 000 / 28LX, 2LX, 8LX / 280HD, 20HD, 80HD - 9

39 NOTES 0 - FORM NO / BA 700, 800, 000 / 28LX, 2LX, 8LX / 280HD, 20HD, 80HD

40 2 ELECTRICAL SYSTEM COMPONENT LOCATION Item Description Speed Controller 2 Actuator Control Module Circuit Breaker 5 Amp (Control Circuit) Circuit Breaker 25 Amp (Wheel Drive) 5 Circuit Breaker 25 Amp (Vacuum Motor) 6 Circuit Breaker 80 Amp (Brush Motor) 7 Solenoid (Vac Motor) 8 Solenoid (Brush Motor) 9 Solenoid (Wheel Drive Motor) 0 Solution Solenoid Valve Vacuum Motor 2 Actuator Motor (Brush Lift) Wheel Drive Motor Brush Motor 5 Potentiometer 5K Ohm 6 Charger Interlock Switch 7 Main Key Switch 8 *Solenoid (Brush Down) 9 *Solenoid (Brush Up) 20 *Solenoid (Brush Motor) 2 *Time Delay,.5 sec. 22 *Circuit Breaker, 70 Amp (Brush Motor) *Electrical Panel used only on BA 700 s before SN & BA 800/000 s before SN 08 FORM NO / BA 700, 800, 000 / 28LX, 2LX, 8LX / 280HD, 20HD, 80HD -

41 ELECTRICAL SYSTEM BA 700 Before SN BA 800, BA 000 Before SN 08 X8 BT + - X9 6 Vdc F /BRN S BLU/WHT S X R H /BRN P 2 P2 K5 D S BRN/ K D UP S2 5 6 BRN/WHT 2 DOWN YEL GRN/BLU WHT/ K2 D2 K F2 D5 BRN BRN/WHT K S5 5 2 YEL/ YEL/WHT 6 WHT/ X7 + R BRN BLU H2 B- B+ M M2 D F5 E 2 5 K2 6 L - X6 M / WHT/ORN R2 K5 FWD. OFF REV. X WHT/GRN YEL /GRN GRN WHT WHT M2 + P2 - P A K ORN/ F YEL/BRN K YEL/ X5 X5 M 2 F 27 K X2 M + - X 2 - FORM NO / BA 700, 800, 000 / 28LX, 2LX, 8LX / 280HD, 20HD, 80HD

42 WIRING DIAGRAM / SCHEMATIC BA 700 s Before SN BA 800/000 Before SN 08 S R H 5 S2 2 6 P2 2 P 2 R H2 5 2 S5 6 ELECTRICAL SYSTEM Item A BT Description Speed Controller Batteries 7F-B 7E-B /BRN 2A-A 7A-B 7B-B 0N-B 7E-A 7C-B BRN/WHT 9C-A BRN/WHT 9A-A YEL A-A WHT/ 92A-A GRN/BLU 56A-A 7C-B 7J-A 0G-B 0M-B /BRN 7B-B 7J-B 7B-A 0M-B 0H-B YEL/WHT 9A-B 0H-B 0N-B BRN/WHT 9D-A BRN/WHT 9D-B BRN/WHT 9C-B WHT/ 90A-B WHT/ 90B-B WHT/ 90B-A YEL/WHT 9B-B YEL/WHT 9B-A YEL/WHT 9A-A D D2 D D D5 E F F2 F F F5 H H2 K K2 K K K5 L M M2 M M P P2 R R2 R S S2 S S S5 X X2 X X X5 X6 X7 X8 X9 Suppression Diode Suppression Diode Suppression Diode Suppression Diode Regenerative Feedback Diode Time Delay Module (on break) 5 Amp Circuit Breaker 25 Amp Circuit Breaker 25 Amp Circuit Breaker 70 Amp Circuit Breaker Amp Fuse Green Lamp Blue Lamp Vacuum Motor Solenoid Actuator Motor Up Solenoid Actuator Motor Down Solenoid Brush Motor Solenoid Wheel Drive Motor Solenoid Solenoid Valve Vacuum Motor Actuator Motor Wheel Drive Motor Brush Motor Battery Fuel Gauge Hourmeter (Optional) 0 Ohm Resistor 5K Ohm Potentiometer 0 Ohm Resistor Main Switch Brush Switch Vacuum Motor Switch Charger Interlock Switch Solution Switch Charger Connector Brush Motor + Terminal Stud Brush Motor - Terminal Stud Actuator Motor Connector Vacuum Motor Connector Wheel Drive Motor - Terminal Stud Wheel Drive Motor + Terminal Stud + Terminal Stud - Terminal Stud YEL/ 7A-B 7A-A 7D-A X2 S E BLU/WHT 69A-B BRN/WHT 9B-B M X9 0J-A 0B-A 0A-A 0K-A X F5 S K BT 6 Vdc M2 R2 OFF REV. FWD. WHT GRN 0L-A /GRN 25A-A /GRN 25B-A BRN/WHT 9B-B D BLU/WHT 69A-A /BRN 7A-B - + K5 X + - WHT/ 90A-A WHT L WHT/GRN 95A-A YEL/ 7A-A X X8 + D 0J-B 7D-B BRN/ 2A-B YEL/BRN A-B YEL/ 0A-A 0B-B 2D-A 2C-A 2B-A 2A-A 0A-B 0L-B BRN A-A 2D-B BLU 6A-A WHT/GRN 95A-B YEL A-B /GRN 25A-B 7H-A GRN WHT WHT/ 92A-B F /GRN 25B-B / 20B-A ORN/ 0B-A WHT/ORN 9A-A D5 BRN/WHT 9A-B 0G-B 0F-B ORN/ 0B-B K 0A-B 27 ORN/ 0A-A 0F-A 0E-A OC-B 7H-B 7G-B GRN/BLU 56A-B 0E-B 0D-B / 20B-B 20A-B / 20A-A 0D-A 0C-A 7G-A 7F-A 2A-B WHT/ORN 9A-B BLU 6A-B 0K-B /BRN 7B-A /BRN 7A-A YEL/ 0A-B 2B-B F2 X6 X7 B- B+ M M2 P2 P D D2 X5 BRN A-A 2C-B M A F K K2 YEL/BRN A-A M F FORM NO / BA 700, 800, 000 / 28LX, 2LX, 8LX / 280HD, 20HD, 80HD -

43 ELECTRICAL SYSTEM X8 Convertamatic 28/2/8LX Before SN 0829 Hydro Retriever 280/20/80HD Before SN 0829 BA 700 between SN and SN 0829 BA 800, BA 000 between SN 08 and SN 0829 BT Vdc X9 F /BRN S BLU/WHT S X R H /BRN P 2 P2 K5 D S BRN/ K D S2 5 2 UP 6 DOWN /GRN /YEL WHT/ M2 WHT X ORN/ / X0 IN 2 IN TIMER OUT DIR MOTOR - MOTOR + B - B + E BRN/WHT K F2 D5 BRN /WHT S5 5 2 WHT/ 6 D2 YEL/WHT L X7 + - X6 R H2 BRN BLU M K5 WHT/ORN WHT/GRN /GRN + B- B+ M M2 P2 - A F5 R2 FWD. OFF REV. GRN WHT P F YEL/BRN K YEL/ X5 X5 M 2 F 27 K X2 M + - X - FORM NO / BA 700, 800, 000 / 28LX, 2LX, 8LX / 280HD, 20HD, 80HD

44 WIRING DIAGRAM / SCHEMATIC Convertamatic 28/2/8LX Before SN 0829 Hydro Retriever 280/20/80HD Before SN 0829 BA 700 between SN and SN 0829 BA 800, BA 000 between SN 08 and SN 0829 Item A BT D D2 D D5 E F F2 F F F5 H H2 K K K5 L M M2 M M P P2 R R2 R S S2 S S S5 X X2 X X X5 X6 X7 X8 X9 X0 Description Speed Controller Batteries Suppression Diode Suppression Diode Suppression Diode Regenerative Feedback Diode Actuator Control Module 5 Amp Circuit Breaker 25 Amp Circuit Breaker 25 Amp Circuit Breaker 80 Amp Circuit Breaker Amp Fuse Green Lamp Blue Lamp Vacuum Motor Solenoid Brush Motor Solenoid Wheel Drive Motor Solenoid Solenoid Valve Vacuum Motor Actuator Motor Wheel Drive Motor Brush Motor Battery Fuel Gauge Hourmeter (Optional) 0 Ohm Resistor 5K Ohm Potentiometer 0 Ohm Resistor Main Switch Brush Switch Vacuum Motor Switch Charger Interlock Switch Solution Switch Charger Connector Brush Motor + Terminal Stud Brush Motor - Terminal Stud Actuator Motor Connector Vacuum Motor Connector Wheel Drive Motor - Terminal Stud Wheel Drive Motor + Terminal Stud + Terminal Stud - Terminal Stud Actuator Control Module Connector 7F-B 7E-B S 7G-A 7A-A 7D-A X2 BRN/ 2A-A S 7A-B 7B-B M On 28 IN. (700 MM) Models Connect Cable to (-). 0n 2 & 8 IN. (800 & 000 MM) Models Connect Cable to (+). BLU/WHT 69A-B X9 R X H 0C-A 0J-A 0B-A 0A-A 0K-A 0N-B F5 0D-B 0C-B 7E-A S K BT 6 Vdc M2 R2 S2 OFF REV. FWD. WHT D K5 X + - WHT/ 90A-A 7C-B L X D2 BLU/WHT 69A-A /BRN 7A-B GRN WHT 6 BRN/WHT 9C-A BRN/WHT 9A-A WHT/ 92A-A WHT/GRN 95A-A X8 + D 7C-A 7J-A K 0J-B P2 7D-B /WHT 9A-B /YEL 0A-A 27 0G-B BRN/ 2A-B YEL/BRN A-B YEL/ 0A-A 0B-B 0A-B BRN A-B 2D-B BLU 6A-A WHT/GRN 95A-B P 2 /GRN 25A-B 7F-A GRN WHT /GRN 25A-A /GRN 25B-A /YEL 0A-B WHT/ 92A-B ORN/ 0B-B / 20B-B 0D-A 7G-B X6 X7 8 X5 E IN 2 IN TIMER OUT DIR MOTOR - MOTOR + B - B + 2D-A 2C-A 2B-A 2A-A F F2 F F /GRN 25B-B / 20B-A ORN/ 0B-A 2 WHT/ORN 9A-A 0GA 0M-A D5 /BRN 7B-B 7J-B 7B-A 2A-B WHT/ORN 9A-B BLU 6A-B 0K-B /BRN 7B-A /BRN 7A-A YEL/ 0A-B 2B-B 0M-B X 0H-B X0 B- B+ M M2 P2 P BRN A-A YEL/WHT 9A-B 2C-B R M A H2 0H-A 0N-A YEL/BRN A-A M BRN/WHT 9D-A BRN/WHT 9D-B BRN/WHT 9C-F 5 2 ELECTRICAL SYSTEM S5 6 WHT/ 90A-B WHT/ 90B-B WTH/ 90B-A YEL/WHT 9B-B YEL/WHT 9B-A YEL/WHT 9A-A FORM NO / BA 700, 800, 000 / 28LX, 2LX, 8LX / 280HD, 20HD, 80HD - 5