Nilfisk-Advance ConvertaMAX 28 User manual

5/00 revised 12/02 Form Number
56043057
ConvertaMAX™28/34
I-MAX™28HD/34HD
BA 750/850
SERVICE MANUAL
Advance MODELS (Active 56396015, 56396019,
56396016, 56396020) (Obsolete 56396000,
56397200, 56396001, 56397201)
Nilfisk MODELS (Active 56396017, 56396018)
(Obsolete 56396002, 56396003)

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FORM NO. 56043057 / ConvertaMAX
™
28/34, I
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MAX
™
28HD/34HD, BA 750/850
TABLE OF CONTENTS
GENERAL INFORMATION .................................................................................................................................................. 2
SAFETY INSTRUCTIONS....................................................................................................................................................3
SPECIFICATIONS & MAINTENANCE ............................................................................................................................. 4-6
PM CHECKLIST ...................................................................................................................................................................7
KNOW YOUR MACHINE ............................................................................................................................................... 9-13
SOLUTION SYSTEM ................................................................................................................................................... 14-19
FUNCTIONAL OVERVIEW .............................................................................................................................................. 14
TROUBLESHOOTING GUIDE & SYSTEM MAINTENANCE ........................................................................................... 15
SOLUTION SOLENOID VALVE REMOVAL (BEFORE SN BREAK) ...............................................................................15
SOLUTION VALVE DISASSEMBLY AND CLEANING (BEFORE SN BREAK) ...............................................................16
SOLUTION FILTER REMOVAL (BEFORE SN BREAK) ..................................................................................................16
SOLUTION FLOW CONTROL VALVE REMOVAL (BEFORE SN BREAK ......................................................................16
SOLUTION SOLENOID VALVE REMOVAL (AFTER SN BREAK) ..................................................................................18
SOLUTION VALVE DISASSEMBLY AND CLEANING (AFTER SN BREAK) ..................................................................18
SOLUTION FILTER REMOVAL (AFTER SN BREAK) .....................................................................................................18
SOLUTION FLOW CONTROL VALVE REMOVAL (AFTER SN BREAK) ........................................................................19
SCRUB BRUSH SYSTEM............................................................................................................................................ 20-24
GENERAL BRUSH SYSTEM FUNCTIONAL OVERVIEW ...............................................................................................20
SCRUB BRUSH SYSTEM TROUBLESHOOTING .......................................................................................................... 22
28/34 BRUSH DECK REMOVAL .....................................................................................................................................23
SCRUB BRUSH LIFT ACTUATOR REMOVAL................................................................................................................ 23
SCRUB BRUSH MOTOR/GEARBOX REMOVAL ............................................................................................................ 23
RECOVERY SYSTEM.................................................................................................................................................. 25-27
FUNCTIONAL OVERVIEW .............................................................................................................................................. 25
VACUUM/RECOVERY SYSTEM MAINTENANCE CHECKLIST .....................................................................................26
TROUBLESHOOTING GUIDE ......................................................................................................................................... 26
MAINTENANCE OF FLOAT CAGE AND FLOAT DUCT ................................................................................................. 26
VACUUM MOTOR REMOVAL .........................................................................................................................................26
RECOVERY TANK REMOVAL ........................................................................................................................................ 26
SQUEEGEE SYSTEM.................................................................................................................................................. 28-31
SQUEEGEE SYSTEM LIFT MOTOR OVERVIEW ..........................................................................................................28
OPERATIONAL OVERVIEW OF THE SQUEEGEE LIFT MOTOR REVERSE FUNCTION ............................................28
REVERSE SWITCH INSTALLATION AND ADJUSTMENT .............................................................................................29
SQUEEGEE LIFT ACTUATOR MOTOR REMOVAL .......................................................................................................30
SQUEEGEE TOOL BLADE(S) REPLACEMENT .............................................................................................................30
SQUEEGEE ADJUSTMENT ............................................................................................................................................ 30
WHEEL DRIVE SYSTEM ............................................................................................................................................. 32-43
GENERAL FUNCTIONAL OVERVIEW ...................................................................................................................... 32-33
TROUBLESHOOTING GUIDE ................................................................................................................................... 34-36
PARKING BRAKE OPERATION ......................................................................................................................................37
BRAKE ASSEMBLY REMOVAL ......................................................................................................................................37
BRAKE CALIPER ADJUSTMENT ....................................................................................................................................37
DRIVE MOTOR REMOVAL.............................................................................................................................................. 37
DRIVE WHEEL REMOVAL .............................................................................................................................................. 38
CHAIN REMOVAL AND ADJUSTMENT .................................................................................................................... 38-39
POTENTIOMETER (5K) TESTING AND REMOVAL (FOR MACHINES BUILT BEFORE DEC. 1 2000) ....................... 40
POTENTIOMETER INSTALLATION AND ADJUSTMENT (MACHINES BEFORE DEC. 1, 2000) ................................. 41
POTENTIOMETER (5K) TESTING AND REMOVAL (FOR MACHINES BUILT AFTER DEC. 1, 2000) ......................... 42
POTENTIOMETER INSTALLATION AND ADJUSTMENT (MACHINES AFTER DEC. 1, 2000) .............................. 42-43
POTENTIOMETER (100K) WHEEL DRIVE SPEED LIMIT TESTING (ALL MODELS) ...................................................43
revised 12/02

FORM NO. 56043057 / ConvertaMAX
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28/34, I
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MAX
™
28HD/34HD, BA 750/850
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1
TABLE OF CONTENTS
ELECTRICAL SYSTEM................................................................................................................................................ 44-67
BATTERIES / CHARGERS .............................................................................................................................................. 44
INSTALL THE BATTERIES ..............................................................................................................................................44
DESCRIPTION OF LOW VOLTAGE CUTOUT FEATURE ..............................................................................................44
DESCRIPTION OF THE BATTERY CONDITION INDICATORS .....................................................................................45
BATTERY CHARGING, MAINTENANCE AND TESTING ...............................................................................................45
ACTUATOR DRIVE NUT ADJUSTMENT .................................................................................................................. 46-47
CURTIS SPEED CONTROL ...................................................................................................................................... 48-49
FUNCTIONAL OVERVIEW OF MAIN CONTROL BOARD ..............................................................................................50
MAIN CONTROL BOARD TROUBLESHOOTING GUIDE ...............................................................................................50
MAIN CONTROLLER ERROR CODES ..................................................................................................................... 50-52
MAIN CONTROLLER DIAGNOSTIC SERVICE TEST MODE ................................................................................... 53-56
MAIN CONTROL BOARD SPECIAL PROGRAM OPTIONS ..................................................................................... 57-62
ELECTRICAL COMPONENT LOCATION ........................................................................................................................ 63
WIRING DIAGRAM (OBSOLETE MODELS) ...................................................................................................................64
WIRING SCHEMATIC (OBSOLETE MODELS) ...............................................................................................................65
WIRING DIAGRAM (ACTIVE MODELS) ..........................................................................................................................66
WIRING SCHEMATIC (ACTIVE MODELS) .....................................................................................................................67
Note: All references to right, left, front, or rear in this manual are as seen from the operator’s stand-point.
revised 12/02

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FORM NO. 56043057 / ConvertaMAX
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28/34, I
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MAX
™
28HD/34HD, BA 750/850
INTRODUCTION
This manual will help you get the most from your ConvertaMAX™28/34, I-MAX™28HD/34HD & BA 750/850. Read it thoroughly before servicing
the machine.
Note: Bold numbers in parentheses indicate an item illustrated on pages 9-10.
PARTS AND SERVICE
Repairs, when required, should be performed by your Authorized Nilfisk-Advance Service Center, who employs factory trained service personnel,
and maintains an inventory of Nilfisk-Advance original replacement parts and accessories.
Call the NILFISK-ADVANCE DEALER named below for repair parts or service. Please specify the Model and Serial Number when discussing
your machine.
(Dealer, affix service sticker here.)
NAME PLATE
The Model Number and Serial Number of your machine are shown on the Nameplate on the machine. This information is needed when ordering
repair parts for the machine. Use the space below to note the Model Number and Serial Number of your machine for future reference.
MODEL NUMBER
SERIAL NUMBER
TRANSPORTING THE MACHINE
CAUTION!
Before transporting the machine on an open truck or trailer, make sure that . . .
•The machine is tied down securely - see tie-down locations in Know Your Machine section.
• All access doors and covers are secured (tape and strap as needed).
TOWING
CAUTION!
If the machine must be towed or pushed, make sure the Master On/Off Key Switch (20) is in the OFF position and do not move the
machine faster than a normal walking pace (2-3 mph, 3-5kph) and for short distances only.
OTHER MANUALS AVAILABLE FOR YOUR MACHINE
The following manuals are available from the Nilfisk-Advance Literature Service Department (order according to model name, number and
machine’s serial number):
• A Parts List and Operation Manual are available for each machine (request by your machine’s “Model Number” and “Serial Number”).
• Operation Manuals for the BA 750 / BA 850 are multi-language; (Danish, Norwegian, Swedish, Finnish), (English, German, French,
Netherlands) or (Spanish, Portuguese, Italian, Greek)
GENERAL INFORMATION
revised 12/02

FORM NO. 56043057 / ConvertaMAX
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28/34, I
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MAX
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28HD/34HD, BA 750/850
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3
CAUTIONS AND WARNINGS
SYMBOLS
Nilfisk-Advance uses the symbols below to signal potentially dangerous conditions. Read this information carefully and take the
necessary steps to protect personnel and property.
DANGER!
Is used to warn of immediate hazards that will cause severe personal injury or death.
WARNING!
Is used to call attention to a situation that could cause severe personal injury.
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 should only be used 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 a 9.5 degree angle.
CAUTION!
•This machine is not approved for use on public paths or roads.
•This machine is not suitable for picking up hazardous dust.
•Use care when using scarifier discs and grinding stones. Nilfisk-Advance will not be held responsible for any damage to floor
surfaces caused by scarifiers or grinding stones.
•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 securing the machine’s
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.
• The batteries must be removed from the machine before the machine is scrapped. The disposal of the batteries should be safely
done in accordance with your local environmental regulations.
SAVE THESE INSTRUCTIONS
GENERAL INFORMATION

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FORM NO. 56043057 / ConvertaMAX
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28/34, I
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MAX
™
28HD/34HD, BA 750/850
Model designation: (A)=ConvertaMAX 28 & BA 750, (B)=I-MAX 28HD, (C)=BA 850, (D)=ConvertaMAX 34, (E)=I-MAX 34HD
General Specifications
ABCDE
Machine Length (English) 64 in. 65 in. 67.5 in. 67.5 in. 67.5 in.
Metric 163cm 165cm 172 cm 172 cm 172 cm
Machine Width with Squeegee (English) 36.25 in. 36.25 in. 45 in. 45 in. 45 in.
Metric 92cm 92cm 114cm 114cm 114cm
Machine Width w/out Squeegee (English) 30 in. 30 in. 30 in. 35.5 in. 35.5 in.
Metric 76cm 76cm 76cm 90cm 90cm
Machine Height 44 in. (112cm) 44 in. (112cm) 44 in. (112cm) 44 in. (112cm) 44 in. (112cm)
Machine Net Weight* (English) 495 lbs. 535 lbs. 556 lbs. 579 lbs. 619 lbs.
Metric 225 kg 243 kg 252 kg 263 kg 281 kg
Machine Gross Weight** (English) 1,100 lbs. 1,140 lbs. 1,120 lbs. 1,350 lbs. 1,435 lbs.
Metric 499 kg 518 kg 508 kg 612 kg 651 kg
Cleaning Width (scrubbing path) (English) 28 in. 28 in. 33.5 in. 33.5 in. 33.5 in.
Metric 71cm 71cm 85 cm 85 cm 85 cm
Coverage Rate Per Hour (theory) (English) 37,100 ft237,100 ft244,388 ft244,388 ft244,388 ft2
Metric 3,447m23,447m24,124m24,124m24,124m2
Coverage Rate Per Hour (actual) (English) 16,900 ft216,900 ft220,475 ft220,475 ft220,475 ft2
Metric 1,570m21,570m21,902m21,902m21,902m2
Brush Diameter (qty of 2) (English) 14.5 in. 14.5 in. 17 in. 17 in. 17 in.
Metric 37cm 37cm 43cm 43cm 43cm
Brush Speed (RPM) 220 220 220 220 220
Brush Pressure Variable, (English) 25-250 lbs. 25-300 lbs. 25-250 lbs. 25-250 lbs. 25-300 lbs.
Metric 11-113 kg 11-136 kg 11-113 kg 11-113 kg 11-136 kg
Solution Tank Capacity 24 gal. (91l.) 24 gal. (91l.) 24 gal. (91l.) 30 gal. (114l.) 30 gal. (114l.)
Recovery Tank Capacity 24 gal. (91l.) 24 gal. (91l.) 24 gal. (91l.) 30 gal. (114l.) 30 gal. (114l.)
Vacuum Water Lift (Sealed) 56 in. 56 in. 56 in. 68 in. 68 in.
(Open Hole Adapter 1") 9 in. 9 in. 9 in. 13 in. 13 in.
Sound power level
as per ISO 3744 (at operator) 74 dB(A) 74 dB(A) 74 dB(A) 74 dB(A) 74 dB(A)
Transport Speed (Fwd. Maximum) 265 FPM 265 FPM 265 FPM 265 FPM 265 FPM
Metric 81 m/min 81 m/min 81 m/min 81 m/min 81 m/min
Transport Speed (Rev. Maximum) 140 FPM 140 FPM 140 FPM 140 FPM 140 FPM
Metric 43 m/min 43 m/min 43 m/min 43 m/min 43 m/min
Power Source (Batteries) STD (4) 6V/238AH (4) 6V/238AH (4) 6V/238AH (6) 6V/238AH (6) 6V/238AH
Battery Weight (each) 66lbs. (29.9kg) 66lbs. (29.9kg) 66lbs. (29.9kg) 66lbs. (29.9kg) 66lbs. (29.9kg)
Battery Compartment Size
Height (Max.) 13 in. (33cm) 13 in. (33cm) 13 in. (33cm) 15 in. (38 cm) 15 in. (38 cm)
Width (Max.) 15 in. (38cm) 15 in. (38cm) 15 in. (38cm) 21.37 in. (54 cm) 21.37 in. (54 cm)
Length (Max.) 24 in. (61cm) 24 in. (61cm) 24 in. (61cm) 23.5 in. (59 cm) 23.5 in. (59 cm)
Battery Chargers – see Electrical System Battery Section
Wheel Drive Motor (all models) .75 hp, 560 watt .75 hp, 560 watt .75 hp, 560 watt .75 hp, 560 watt .75 hp, 560 watt
Vacuum Motor (all models) .75 hp, 570 watt .75 hp, 570 watt .75 hp, 570 watt .75 hp, 570 watt .75 hp, 570 watt
Brush Drive Motors (2 each) .75 hp, 560 watt 1 hp, 746 watt .75 hp, 560 watt .75 hp, 560 watt 1 hp, 746 watt
Machine Current (Average) 65 Amps 81 Amps 65 Amps 60 Amps 65 Amps
*Net Weight: Standard machine without options, empty solution and recovery tanks, without removable scrub brushes and no batteries installed.
**Gross Weight: Standard machine without options, full solution tank and empty recovery tank, with removable scrub brushes and 305 AH batteries.
SPECIFICATIONS

FORM NO. 56043057 / ConvertaMAX
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28/34, I
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MAX
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28HD/34HD, BA 750/850
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5
SPECIFICATIONS
TOP VIEW
SIDE VIEW
Length
Height
Width
Squeegee
Width

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FORM NO. 56043057 / ConvertaMAX
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28/34, I
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MAX
™
28HD/34HD, BA 750/850
MAINTENANCE
MAINTENANCE SCHEDULE
Maintenance intervals given are for average operating conditions. Machines used in severe operational environments may require
service more often.
MAINTENANCE ITEM Daily Weekly Monthly Yearly
Charge the Batteries X
Drain / Clean and Check Tanks & Hoses X
Check / Clean / Rotate the Brushes/Pads X
Check / Clean / Adjust the Squeegee X X
Check / Clean Vacuum Shut-Off Float X
Check Each Battery Cell’s Water Level X
Inspect and Clean Solution Filter X
*Check Parking Brake For Wear & Adjustment X
Lubricate the Machine X
**Check Motor(s) Carbon Brushes X
*If machine is equipped with the optional parking brake.
**Note: See the individual machine system sections for maintenance information.
WARNING!
Turn the key switch off and disconnect the battery before servicing the machine.
• Check vacuum motor carbon brushes (Qty 2) once a year or after 300 operating hours.
• Check brush and wheel drive motor(s) carbon brushes (Qty 4 per motor) once a year or after 500 operating hours.
• The original (new) length of each carbon brush is 1" (25.4mm) on all machine models 24 volt and 36 volt motors.
• Replace carbon brushes when shorter than 3/8" (9.5mm) to obtain the same motor efficiency as new brushes.
IMPORTANT!
Motor damage resulting from failure to service the carbon brushes is not covered under warranty. See the Limited Warranty
Statement.
BATTERIES AND CHARGERS
Attention: See the electrical system manual section for battery installation, battery maintenance and charger system requirements.
LUBRICATING THE MACHINE
Once a month, pump a small amount of grease into each grease fitting on the machine until grease seeps out around the bearings.
Grease fitting locations are:
• Rear Caster Wheel Axle & Swivel (2) per Assembly
Once a month, apply light machine oil to lubricate the:
• Drive Chain
• Squeegee Tool Adjustment Knob, Wheels & Rollers
• Pivot Points For the Squeegee & Scrub Brush Linkage
revised 12/02

FORM NO. 56043057 / ConvertaMAX
™
28/34, I
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MAX
™
28HD/34HD, BA 750/850
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7
Copyright 2001 Nilfisk-Advance. 8/09/01
Advance ConvertaMAX 28/34, I-MAX 28HD/34HD
Models 56396000, 56397200, 56396001, 56397201, 56396015, 56396019, 56396016, 56396020
Nilfisk BA 750/850 Models 56396002, 56396003, 56396017, 56396018
PM Checklist
Defect Codes
Customer A needs adjustment
Bbinding
Address C dirty or contaminated
Ddamaged, bent or torn
City St Zip Lleaks
Mmissing
Model Serial Hours Wworn out
Ref
OPERATIONAL INSPECTION ITEMS
OK
Defect Codes
(circle)
Does
Not
Work
1 Drive Paddle Operation (check for Fwd/Rev Drive & any neutral creep) A B D
2 Drive System Performance (Speed Changes Min/Max) noisy sluggish
3 Scrub System (Raise/Lower, Brush Motor On/Off, Brush install & Remove Feature) A B D
4 Scrub Brush (pressure settings Normal & Heavy) A B
5 Squeegee System (Raise/Lower & Squeegee Tool pickup Performance) A B D
6 Vacuum Performance (Sealed water lift 56" for 24V, 68” for 36V and 1- inch open
hole adapter 9” for 24V, 13” for 36V)
CLW
7 Solution Control (On/Off Manual /Auto and Flow Volume Min/Max) A B L
8 Battery Charger (Auto turn ON & OFF) D
Ref
VISUAL INSPECTION ITEMS
Comments OK
Defect Codes
(circle)
Does
Not
Work
9 Scrub Brushes, check for wear and rotate DMW
10 Scrub Brush Motors, check for carbon brush wear 500 Hours B C W
11 Scrub Brush Motors, check gearboxes B D L
12 Brush Drive Plate Retainer Clips & flex couplers C D M
13 Scrub Deck Skirts and Side Wheel(s) D M W
14 Solution Solenoid Valve C D L W
15 Solution Flow Control Valve and Linkage A B D W
16 Solution Tank, Delivery Hoses & Filter Clean filter screen C L
17 Vacuum Motor Carbon Brushes (wear limit 3/8”) 300 Hours B C W
18 Vacuum Motor Gaskets CDL
19 Vacuum Float Ball & Cage Assembly Clean float C D M
20 Recovery Tank Cover Gasket L M W
21 Recovery Tank Drain Hose & Cap C D L
22 Squeegee Pick-Up Hose Back flush C D L
23 Squeegee Tool & Blades (clean & rotate) A D W
24 Squeegee Tool Wheels (lubricate) 2 side and 2 floor A D W
25 Battery Condition (load test, clean & water) C W
26 Front Drive Wheel Motor Check Carbon Brushes 500 Hours B C W
27 Front Drive Tire tread wear W
28 Drive wheel Motor Chain (Lubricate and tension) A B C W
29 Rear chassis Caster Wheels (Lubricate) tread wear W
NOTE: For additional service information see service manual form number 56043057 and
operators manual form numbers 56041463, 56041464, 56041465 / 56041479 / 56041515, 56041516,
56041517.
WORK COMPLETED BY: ACKNOWLEDGED BY:
revised 12/02

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FORM NO. 56043057 / ConvertaMAX
™
28/34, I
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MAX
™
28HD/34HD, BA 750/850
BLANK
revised 12/02