Convertamatic™ 285LX, 325LX, 385LX Hydro

SERVICE
M
A
N
U
A
L
Convertamatic™
285LX, 325LX, 385LX
Models 391007, 392700, 392701
Hydro-Retriever™
285HD, 325HD, 385HD
Models 391008, 392703, 392702
Lynx™
285, 325, 385
Models 391008, 392703, 392702
revised 7/97 Form Number 043018
30 - FORM NO. 043018 / 285, 325, 385 Service Manual
TABLE OF CONTENTS
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Batteries .........................................................................................................28
Brush Drive Belt Tension Adjustment - 285 ....................................................12
Brush Drive Belt Tension Adjustment - 325, 385 ............................................13
Brush Drive System Maintenance..................................................................12
Brush Drive System Troubleshooting.............................................................18
Brush Lift Actuator Replacement ...................................................................17
Brush Lift Limit Switches - Adjustment & Replacement .................................14
Drive Wheel Replacement .............................................................................25
Potentiometer Adjustment ..............................................................................27
Safety .............................................................................................................. 2
Solution Cable Replacement - 285 ..................................................................9
Solution Cable Replacement - 325, 385 ........................................................10
Solution System Maintenance .........................................................................7
Solution System Troubleshooting .................................................................. 11
Solution Valve Replacement - 285 ...................................................................7
Solution Valve Replacement - 325, 385 .......................................................... 8
Specifications & Maintenance ..........................................................................3
Squeegee Adjustment ....................................................................................21
Vacuum Motor Removal.................................................................................20
Vacuum System Maintenance .......................................................................19
Vacuum System Troubleshooting ..................................................................21
Wheel Drive Chain - Removal & Adjustment .................................................23
Wheel Drive Motor Replacement ...................................................................24
Wheel Drive System Maintenance .................................................................23
Wheel Drive System Troubleshooting ............................................................26
Note: All references to right, left, front, or rear in this manual are as seen from the operator’s stand-point.
285LX, 285HD Service Manual A-1
FORM NO. 043018 / 285, 325, 385 Service Manual - 1
SAFETY
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SYMBOLS
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
WARNING!
Keep sparks, flame and smoking materials away from the batteries. Explosive gasses are vented during
normal operation.
Remove all jewelry when working near electrical components.
Disconnect one of the battery terminals when servicing electrical components.
Never work under a machine without safety stands or blocks to support the machine.
CAUTION!
Take precautions to prevent hair, jewelry, or loose clothing from becoming caught in moving parts.
2 - FORM NO. 043018 / 285, 325, 385 Service Manual
SPECIFICATIONS
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SPECIFICATIONS - 285
Dimensions
Scrub Brush Diameter
Scrub Brush Path
Scrub Brush Pressure
Scrub Brush Speed
Squeegee Size
Machine Length
Machine Width
Machine Height
Drive Wheel
Solution Tank Capacity
Recovery Tank Capacity
Coverage Rate
Machine Weight
General Specifications
Brush Motor
Wheel Drive Motor
Vacuum Motor
Brush Drive
Squeegee Type
Speed Control
Batteries
English (Metric)
14.5 inches (36 cm)
28 inches (71 cm)
140 lbs (63.5 kg)
155 rpm (155 rpm)
33 inches (108 cm)
59 inches (150 cm)
30.25 inches (77 cm)
45.75 inches (116 cm)
10 inch (25 cm) solid, traction tire
32 gal (121 l)
29 gal (109 l)
25,500 sq ft (2,369 m2) per hour
650 lbs (295 kg) net w/o batteries
1,075 lbs (488 kg) net w batteries
770 lbs (349 kg) shipping weight
36 volt, 2 1/4 hp dc motor
36 volt, 3/4 hp dc motor
36 volt, 1 hp dc motor
Dual worm gear 10 to 1 reduction
gear box
4 sided, curved, self tracking
Electronic, fully variable
forward/reverse
(6) 6 volt 244 AH (std)
285LX, 285HD Service Manual A-3
FORM NO. 043018 / 285, 325, 385 Service Manual - 3
SPECIFICATIONS
________________________________________________________________________________________________________________________________________________
SPECIFICATIONS - 325
Dimensions
Scrub Brush Diameter
Scrub Brush Path
Scrub Brush Pressure
Scrub Brush Speed
Squeegee Size
Machine Length
Machine Width
Machine Height
Drive Wheel
Solution Tank Capacity
Recovery Tank Capacity
Coverage Rate
Machine Weight
General Specifications
Brush Motor
Wheel Drive Motor
Vacuum Motor
Brush Drive
Squeegee Type
Speed Control
Batteries
4 - FORM NO. 043018 / 285, 325, 385 Service Manual
English (Metric)
17 inches (43 cm)
32 inches (81 cm)
160 lbs (72.5 kg)
120 rpm (120 rpm)
45 inches (114 cm)
62.5 inches (159 cm)
37 inches (94 cm)
46.75 inches (119 cm)
10 inch (25 cm) solid, traction tire
32 gal (121 l)
29 gal (109 l)
32,500 sq ft (3,019 m2) per hour
705 lbs (320 kg) net w/o batteries
1,586 lbs (719 kg) net w batteries
825 lbs (374 kg) shipping weight
36 volt, 2 1/4 hp dc motor
36 volt, 3/4 hp dc motor
36 volt, 1 hp dc motor
Dual worm gear 10 to 1 reduction
gear box
4 sided, curved, self tracking
Electronic, fully variable
forward/reverse
(6) 6 volt 350 AH (std)
SPECIFICATIONS
________________________________________________________________________________________________________________________________________________
SPECIFICATIONS - 385
Dimensions
Scrub Brush Diameter
Scrub Brush Path
Scrub Brush Pressure
Scrub Brush Speed
Squeegee Size
Machine Length
Machine Width
Machine Height
Drive Wheel
Solution Tank Capacity
Recovery Tank Capacity
Coverage Rate
Machine Weight
General Specifications
Brush Motor
Wheel Drive Motor
Vacuum Motor
Brush Drive
Squeegee Type
Speed Control
Batteries
English (Metric)
20 inches (50 cm)
38 inches (97 cm)
160 lbs (72.5 kg)
120 rpm (120 rpm)
45 inches (114 cm)
62.5 inches (159 cm)
40 inches (102 cm)
46.75 inches (119 cm)
10 inch (25 cm) solid, traction tire
32 gal (121 l)
29 gal (109 l)
35,000 sq ft (3,251 m2) per hour
753 lbs (341 kg) net w/o batteries
1,627 lbs (738 kg) net w batteries
878 lbs (398 kg) shipping weight
36 volt, 2 1/4 hp dc motor
36 volt, 3/4 hp dc motor
36 volt, 1 hp dc motor
Dual worm gear 10 to 1 reduction
gear box
4 sided, curved, self tracking
Electronic, fully variable
forward/reverse
(6) 6 volt 350 AH (std)
285LX, 285HD Service Manual A-5
FORM NO. 043018 / 285, 325, 385 Service Manual - 5
MAINTENANCE
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MAINTENANCE CHART
MAINTENANCE ITEM
Clean and inspect the tanks and hoses
Clean the brushes and pads
Clean the squeegee
Charge the batteries
Check battery water level
Lubrication
Vacuum motor carbon brushes
6 - FORM NO. 043018 / 285, 325, 385 Service Manual
Daily
X
X
X
X
Once a
Week
Once a
Month
Once a
Year
X
X
X
SOLUTION SYSTEM
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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...
1
Park the machine outdoors or near a floor drain and open the solution tank drain valve.
2
When the tank is empty, close the drain valve and put about 2 inches (5 cm) of clean, warm water in the
tank.
4
Pull the solution lever (on the control panel) all the way back, to the full-on position. Allow all of the warm
water to drain through the valve.
5
Close the solution valve before refilling the tank.
________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
SOLUTION VALVE REPLACEMENT - 285
1
Drain the solution tank.
2
Remove the access panel from the right side of the machine.
3
See figure 1. Remove the “A”, “B”, and “C” hoses from the solution valve fittings and mark them to
ensure proper reassembly.
4
Remove ball joint “D” 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.
A
Front
FIGURE 1
D
B
C
285LX, 285HD Service Manual A-7
FORM NO. 043018 / 285, 325, 385 Service Manual - 7
SOLUTION SYSTEM
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SOLUTION VALVE REPLACEMENT - 285 (continued)
8
Follow steps 1 - 5 in reverse order to reassemble. Make sure that the valve mount is in the forward two
holes as shown.
9
Check for leaks and proper operation.
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SOLUTION VALVE REPLACEMENT - 325, 385
1
Drain the solution tank.
2
Remove the left splash guard.
3
See figure 2. Remove the “E”, “F”, and “G” hoses from the solution valve fittings and mark them to
ensure proper reassembly.
4
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 1 - 5 in reverse order to
reassemble.
9
FIGURE 2
E
Front
H
G
Check for leaks and proper operation.
8 - FORM NO. 043018 / 285, 325, 385 Service Manual
F
SOLUTION SYSTEM
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SOLUTION CABLE REPLACEMENT - 285
FIGURE 3
1
Drain the solution tank.
2
Remove the access panel from the right
side of the machine.
3
See figure 3. Disconnect balljoint “I” from
the valve arm. Be careful not to lose the
bushings.
4
Remove balljoint “I” from the cable, then
remove the cable from the chassis cable
mount, (note the cable position in the
mount).
5
See figure 4. Remove panel “J”.
Front
FIGURE 4
I
6
Disconnect balljoint “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 up and
out through the control handle.
9
Follow steps 1-8 in reverse order to
reassemble. Test the new cable for
proper operation before reinstalling the
panels.
K
J
Front
285LX, 285HD Service Manual A-9
FORM NO. 043018 / 285, 325, 385 Service Manual - 9
SOLUTION SYSTEM
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SOLUTION CABLE REPLACEMENT - 325, 385
1
Drain the solution tank.
2
Remove the left splash guard.
3
See figure 5 Disconnect balljoint “L” from the valve arm. Be careful not to lose the bushings.
FIGURE 5
Front
L
4
Remove the cable from the chassis cable mount (note the cable position in the mount), then remove
balljoint “L” from the cable.
5
See figure 4. Remove panel “J”.
6
Disconnect balljoint “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 1-8 in reverse order to reassemble. Test the new cable for proper operation before reinstalling the handle panel and splash guard.
10 - FORM NO. 043018 / 285, 325, 385 Service Manual
SOLUTION SYSTEM
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TROUBLESHOOTING
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Problem: Not Enough Solution Flow to The Scrub Brushes
Possible Cause & Remedy:
1
Kinked solution hoses - check all solution hoses for kinks.
2
Solution valve not opening all the way - adjust solution valve cable.
________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
Problem: Solution Leaks With The Control Lever in The Off Position
Possible Cause & Remedy:
1
Solution valve not closing all the way - adjust solution valve cable.
2
Defective solution valve - replace solution valve.
________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
Problem: Uneven Solution Flow
Possible Cause & Remedy:
1
Kinked solution hoses - check solution hoses between the valve and brushes for kinks.
285LX, 285HD Service Manual A-11
FORM NO. 043018 / 285, 325, 385 Service Manual - 11
BRUSH DRIVE SYSTEM
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MAINTENANCE
Every 3 years...
1 Check the carbon brushes in the brush motor. Replace the brushes if they are worn to a length of 3/8
inch (10 mm) or less.
2
Remove the fill plug from the top of the gear box and check the oil level. The oil should be 1-1/2 inches
(3.8 cm) from the top of the gear box. Use 140W gear lube only.
3
Check the belt tension. There should be about 3/32 inch (2 mm) of belt deflection when 3-1/4 pounds of
pressure is applied between the pulleys.
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BELT TENSION ADJUSTMENT - 285
1
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.
3
See figure 1. Loosen the (4) screws in the “A” belt guards.
FIGURE 1
Front
B
C
D
A
A
12 - FORM NO. 043018 / 285, 325, 385 Service Manual
BRUSH DRIVE SYSTEM
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BELT TENSION ADJUSTMENT - 285 (continued)
4
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 3/32
inch (2 mm) of belt deflection when 3-1/4 pounds of pressure is applied between the pulleys.
6
Follow steps 1-5 in reverse order to reassemble.
7
After the adjustment is complete, test to make sure the belt does not slip.
________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
BELT TENSION ADJUSTMENT - 325, 385
1
Drain and tip the solution tank to the side of the machine.
2
See figure 2. Loosen the “E” bolts and nuts
3
Loosen the lock nuts and turn the “F” bolts to adjust the belt Tension. There should be about 3/32 inch (2
mm) of belt deflection when 3-1/4 pounds of pressure is applied between the pulleys.
4
After the adjustment is complete, test to make sure the belt does not slip.
E
FIGURE 2
F
E
Front
285LX, 285HD Service Manual A-13
FORM NO. 043018 / 285, 325, 385 Service Manual - 13
BRUSH DRIVE SYSTEM
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BRUSH LIFT LIMIT SWITCHES
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LIMIT SWITCH ADJUSTMENT
1
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.
3
See figure 3. Loosen the (2) “G” bolts and nuts until the plastic nut on the actuator slips out of the
brackets.
4
Remove ring “H” and pin “I”, lift the actuator up, but leave it plugged in.
285
FIGURE 3
325, 385
G
Front
H
H
I
I
I
G
G
14 - FORM NO. 043018 / 285, 325, 385 Service Manual
G
Front
BRUSH DRIVE SYSTEM
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LIMIT SWITCH ADJUSTMENT (continued)
5
See figure 4. Measure the position of the plastic nut on the actuator shaft.
FIGURE 4
Plastic Nut
Adjuster Cover
Down
Up
6
Manually turn the plastic nut to the DOWN position given below.
Machine
285
325, 385
DOWN Position
5-1/2 inches
(140 mm)
5-3/4 inches
(197 mm)
UP Position
8 inches
(203 mm)
10 inches
(254 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 1/16 inch (1.6mm).
10 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.
11 After adjustment is complete, replace the adjuster cover and follow steps 1-4 in reverse order to reassemble.
12 Test the actuator to make sure the brushes raise and lower properly.
285LX, 285HD Service Manual A-15
FORM NO. 043018 / 285, 325, 385 Service Manual - 15
BRUSH DRIVE SYSTEM
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BRUSH LIFT LIMIT SWITCHES (continued)
________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
LIMIT SWITCH REPLACEMENT
1
Remove the actuator from the machine (see the Brush Lift Acuator Replacement section).
2
See figure 5. Remove the “J” screws and cover “K”, be carefull not to lose the spring and washers. Note
the position of the adjuster “L” for reassembly.
FIGURE 5
L
N
M
J
K
3
Remove the “M” diodes from the switches.
4
Remove the “N” screws, the switches and the switch shroud.
5
Follow steps 2-4 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).
16 - FORM NO. 043018 / 285, 325, 385 Service Manual
BRUSH DRIVE SYSTEM
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BRUSH LIFT ACTUATOR REPLACEMENT
1
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.
3
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.
285
FIGURE 6
325, 385
O
Front
P
P
Q
Q
O
O
Front
O
4
Unplug the actuator cord. Remove retainer ring “P”, and pin “Q”. Remove the actuator from the machine.
5
Follow steps 1-4 in reverse order to reassemble. To set UP and DOWN limits (see the Brush Lift Limit
Adjustment section).
285LX, 285HD Service Manual A-17
FORM NO. 043018 / 285, 325, 385 Service Manual - 17
BRUSH DRIVE SYSTEM
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TROUBLESHOOTING
Before troubleshooting the brush drive circuit, check the reset button on the 70 amp brush motor circuit
breaker, reset if necessary.
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Problem: Squealing noise when brushes are lowered.
Possible Cause & Remedy:
1
Loose belt - adjust belt tension
________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
Problem: Brush motor will not start when twist grips are turned.
FIGURE 7
Possible Cause & Remedy:
1
2
Tripped brush motor circuit breaker (see figure
7) - press the reset button, check the circuit
breaker for continuity.
Defective brush switch (on top of control handle)
Brush
- replace switch.
Solenoid
3
Defective brush motor solenoid (see figure 7) replace solenoid.
4
Defective brush motor - remove motor, repair or
replace.
5
Defective speed control (see figure 7) - replace
speed control.
Speed
Control
Down
Solenoid
Up
Solenoid
Brush
C. B.
________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
Problem: Brushes will not go up or down.
Possible Cause & Remedy:
1
Defective brush switch (on top of control handle) - replace switch.
2
Defective drive nut or actuator - replace drive nut or actuator.
3
Defective up or down solenoid (see figure 7) - replace solenoid(s).
18 - FORM NO. 043018 / 285, 325, 385 Service Manual
VACUUM SYSTEM
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MAINTENANCE
Whenever the vacuum system does not perform properly, the entire system should be cleaned and inspected,
following the maintenance checklist below.
1
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.
3
See Figure 1. Disconnect squeegee hose “A” from the right side of recovery tank. Park the machine
outside or near a floor drain and use a garden hose to “back flush” dirt down and out of squeegee hose
“A”.
FIGURE 1
Front
B
F
C
E
A
D
285LX, 285HD Service Manual A-19
FORM NO. 043018 / 285, 325, 385 Service Manual - 19
VACUUM SYSTEM
________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
MAINTENANCE (continued)
CAUTION!
Do not flush hose “C” unless it is disconnected from the vacuum motor.
4
Remove cover “B” from the recovery tank (see Figure 1). Rinse all dirt from cage “E” and ball “F”.
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.
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VACUUM MOTOR REMOVAL
1
Disconnect one of the battery cables.
2
Drain the solution tank and tip it to the side of
the machine.
3
See Figure 2. Remove the (3) “G” screws and
disconnect the vacuum motor wiring connector.
4
FIGURE 2
Front
Remove the vacuum motor from the machine.
G
20 - FORM NO. 043018 / 285, 325, 385 Service Manual
VACUUM SYSTEM
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SQUEEGEE ADJUSTMENT
1
Adjust the large knob on the back of the squeegee mount until both front and rear blades touch the floor
equally.
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TROUBLESHOOTING
________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
Problem: Machine will not pick up water, water flows around ends of squeegee
Possible Cause & Remedy:
1 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.
3
Damaged gasket on recovery tank cover — replace gasket.
4
Low battery voltage — charge or replace batteries.
5
Vacuum motor defective — repair or replace vacuum motor.
________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
Problem: Water in vacuum motor
Possible Cause & Remedy:
1 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.
3
Vacuum shut-off float ball not closing — clean or replace float ball and cage (mounted on recovery tank
cover).
285LX, 285HD Service Manual A-21
FORM NO. 043018 / 285, 325, 385 Service Manual - 21
VACUUM SYSTEM
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TROUBLESHOOTING (continued)
________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
Problem: Float closes before tank is full
Possible Cause & Remedy:
1 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.
________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
Problem: Vacuum motor will not run when squeegee is lowered
Possible Cause & Remedy:
1 Tripped vacuum motor circuit breaker (see figure 3) — press reset button, check circuit breaker for
continuity.
2
Defective vacuum switch (see figure 4) — remove cover panel from back of control handle, adjust or
replace switch.
3
Defective vacuum motor — remove motor, repair or replace.
4
Defective vacuum motor solenoid (see figure 3)— replace solenoid.
FIGURE 3
FIGURE 4
Vacuum
Switch
Vac Motor
Solenoid
Vac Motor
Circuit
Breaker
22 - FORM NO. 043018 / 285, 325, 385 Service Manual
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
_________________________________________________________________________________________________________________________________________________________________________________________________________________________
REMOVAL:
1
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 it’s left side.
3
See Figure 1. Loosen locknut “A” and back out bolt “B” several turns to loosen tension on the drive
chain, then remove the chain from the motor sprocket.
4
Disconnect the master link in the drive chain and remove the chain from the machine.
5
Follow steps 1-4 in reverse order
to reassemble.
6
FIGURE 1
Front
Test the drive system for proper
operation.
C
G
D, E
A
B
F
285LX, 285HD Service Manual A-23
FORM NO. 043018 / 285, 325, 385 Service Manual - 23
WHEEL DRIVE SYSTEM
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CHAIN REMOVAL OR ADJUSTMENT (continued)
_________________________________________________________________________________________________________________________________________________________________________________________________________________________
ADJUSTMENT:
1
Follow steps 1 & 2 from the Chain Removal section above.
2
See Figure 1. Loosen locknut “A”, turn bolt “B” to adjust chain tension. There should be about 1/2 inch
(12 mm) of deflection between the sprockets when moderate pressure is applied to the chain.
3
Follow steps 1 & 2 in reverse order to reassemble.
4
Test the drive system for proper operation.
_________________________________________________________________________________________________________________________________________________________________________________________________________________________
DRIVE MOTOR REPLACEMENT
1
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.
3
See Figure 1. 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.
4
Remove the “D” bolt and “E” washer from the end of the motor shaft.
5
Loosen locknut “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 (4) “G” bolts and separate the
motor from the bracket “C”.
8
Follow steps 1 - 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.
24 - FORM NO. 043018 / 285, 325, 385 Service Manual
WHEEL DRIVE SYSTEM
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DRIVE WHEEL REPLACEMENT
1
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.
3
See Figure 2. Loosen locknut “H” and back out bolt “I” several turns to loosen the tension on the drive
chain, then remove the chain from the motor sprocket.
Front
FIGURE 2
H
I
J
4
Remove the (4) “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 1-6 in reverse order to reassemble.
8
Refer to the Chain Adjustment section for proper chain tension.
9
Test the drive system for proper operation.
285LX, 285HD Service Manual A-25
FORM NO. 043018 / 285, 325, 385 Service Manual - 25
WHEEL DRIVE SYSTEM
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TROUBLESHOOTING
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Problem: No wheel drive - forward or reverse
Possible Cause & Remedy:
1
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 of the floor.
•
Disconnect the battery connector at the right rear of the machine.
•
Remove back panel from control handle.
•
Disconnect the white/orange 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 M1 terminal on the speed control. Connect this wire to one of the Bterminals (also on the speed control).
•
Reconnect the battery connector. If the wheel motor turns, go to steps 3. 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.
3
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 2400 - 2600 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.
26 - FORM NO. 043018 / 285, 325, 385 Service Manual
WHEEL DRIVE SYSTEM
________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
TROUBLESHOOTING (continued)
•
Connect an ohmmeter to the green and black wires. Meter should read 2400 - 2600 ohms in neutral and
decrease to 100 - 300 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.
_________________________________________________________________________________________________________________________________________________________________________________________________________________________
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...
1
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.
3
Carefully pull the potentiometer connector (the one with the green, black and white wires) off of the speed
control .
4
Connect an ohmmeter (on 0 x 100 scale) to the green and white wires on the connector. The meter
should read between 2400 and 2600 ohms. If it does not, go to the next step.
5
Loosen the (2) set screws (using a 5/64 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 2400 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.
285LX, 285HD Service Manual A-27
FORM NO. 043018 / 285, 325, 385 Service Manual - 27
BATTERIES
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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 battery caps. This gas can be ignited by any electrical arc,
spark, or flame.
When working with batteries:
•
Remove all jewelry
•
Wear safety glasses
•
Do not smoke
•
Do not allow tools to touch more than one battery terminal at a time
•
Work in a well ventilated area
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BATTERY MAINTENANCE
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 - Use distilled water in batteries whenever possible. If batteries are
discharged, add just enough water to cover the plates in each cell. If 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 1 hour. 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. 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.
27
28 - FORM NO. 043018 / 285, 325, 385 Service Manual
BATTERIES
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BATTERY MAINTENANCE (continued)
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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 1 or 2 volts lower than the other batteries in the system.
If the batteries in the machine are more than 1 year old, it’s usually best to replace the whole set, rather than
replacing just one battery.
285LX, 285HD Service Manual A-29
FORM NO. 043018 / 285, 325, 385 Service Manual - 29
Nilfisk-Advance, Inc.
14600 21st Avenue North
Plymouth, MN, 55447-3408
www.nilfisk-advance.com
Phone:
800-989-2235
Fax:
800-989-6566
©2000 Nilfisk-Advance, Inc.,
Plymouth, MN 55447-3408
Printed in the U.S.A.