Related Manuals for Nilfisk-Advance whirlamatic 2700 BHS 7014
Summary of Contents for Nilfisk-Advance whirlamatic 2700 BHS 7014
- Page 1 ™ Whirlamatic 2700 BHS 7014 SERVICE MANUAL Advance MODEL 56420000 Nilfisk MODEL 56420161 8/97 revised 2/02 FORM NO. 56043042...
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Page 2: Table Of Contents
TABLE OF CONTENTS _______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ SAFETY ............................2 SPECIFICATIONS & MAINTENANCE ..................3-4 PM CHECKLIST ..........................5 BURNISHING SYSTEM ......................7-16 ACTUATOR LIFT NUT ADJUSTMENT ..................7 PAD DRIVE DECK LEVEL ADJUSTMENT ..................8 PAD DRIVE BELT TENSION ADJUSTMENT ................9 PAD PRESSURE ADJUSTMENT .................... -
Page 3: Safety
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. -
Page 4: Specifications & Maintenance
SPECIFICATIONS ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ General Specifications English (Metric) Burnishing Pad Diameter 27 inches (68.5 cm) Machine Length 81.5 inches (207 cm) Machine Width 32 inches (81 cm) Machine Height 46.75 inches (116 cm) Machine Weight 580 lbs. (263 kg) net w/o batteries 1,300 lbs. -
Page 5: Maintenance Schedule
MAINTENANCE ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ MAINTENANCE SCHEDULE MAINTENANCE ITEM Daily Weekly Monthly Yearly Charge Batteries Check/Clean/Replace Burnishing Pad Check/Replace Dust Collection Bag Check Battery Water Level(s) Check/Replace Pad Shroud Skirt Check Foot/ Parking Brake for Wear & Adjustment Check Tire Pressure (50 PSI) Chain Tension - Steering and Drive Lubrication - Grease Fittings Check Pad Motor Belt Wear &... -
Page 6: Pm Checklist
NOTE: For additional service information see service manual form number 56043042 and operators manual form number 56041380. WORK COMPLETED BY: ACKNOWLEDGED BY: Service Technician Signature Date Customer Signature Date Copyright 2002 Nilfisk-Advance. 1/3/02 revised 2/02 FORM NO. 56043042 / Whirlamatic ™ 2700 / BHS 7014 - 5... - Page 7 BLANK PAGE 6 - FORM NO. 56043042 / Whirlamatic ™ 2700 / BHS 7014 revised 2/02...
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Page 8: Burnishing System
BURNISHING SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ ACTUATOR LIFT NUT ADJUSTMENT Remove the Pad Lift Actuator from the machine. Follow steps 1-6 of the Pad Lift Actuator Removal and Installation section. The original actuator power cord assembly can not be used to set the actuator nut and limit switch settings since the power output is time controlled through the main electronic control board. -
Page 9: Pad Drive Deck Level Adjustment
BURNISHING SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ PAD DRIVE DECK LEVEL ADJUSTMENT NOTE: Install a new pad before performing this adjustment. Put the pad drive deck in the DOWN position. Briefly run the pad drive motor to get a pattern on the floor. CAUTION! Do not run pad motor for an extended period without moving machine. -
Page 10: Pad Drive Belt Tension Adjustment
BURNISHING SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ PAD DRIVE BELT TENSION ADJUSTMENT See Figure 3. Remove Cover (A). See Figure 4. Release tension on the Idler Pulley (B) by loosening Inner Bolt (C) while holding the Outer Nut (D). Turn outer nut until mark lines up with third line from right (40lbs). Tighten Inner Bolt (C) while holding the Outer Nut (D). -
Page 11: Pad Pressure Adjustment
BURNISHING SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ PAD PRESSURE ADJUSTMENT Functional Overview The amount of pressure applied to the burnishing pad can be adjusted over a defined limited range by changing (programming) the pad “pressure” setting in the control unit. The main control unit does not set an absolute pressure; rather it controls the amount of electrical power (maximum amperage) used by the pad motor which results in a relative pressure change (weight to the pad). -
Page 12: Pad Lift Actuator Removal And Installation
BURNISHING SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ PAD LIFT ACTUATOR REMOVAL AND INSTALLATION Place the pad deck assembly in the down position and disconnect the battery pack. Disconnect the pad lift actuator motor electrical cord assembly. See Figure 6. Remove the (2) (A) Screws and the Mount Weldment (B) from the Main Lift Linkage (C). Remove the Retainer Ring (D) and slide the Pin (E) out to remove the Lift Actuator Motor (F) from the machine. -
Page 13: Pad Drive Deck Removal
BURNISHING SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ PAD DRIVE DECK REMOVAL Remove pad from pad holder (the Pad Grab Assembly (A) is a right hand thread). See Figure 7. To remove the Pad Holder (B), first remove the pad grab base, remove the four screws (C) to get pad holder off the Adapter (D). -
Page 14: Pad Drive Belt Replacement
BURNISHING SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ PAD DRIVE BELT REPLACEMENT See Figure 8. Remove the Cover (A). Release tension on the Idler Pulley (B) by loosening Inner Bolt (C) while holding outer nut. Remove the Idler Pulley (B) from the pad drive deck. Remove the lower belt from the Motor Pulley (D). -
Page 15: Pad Drive Motor Replacement
BURNISHING SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ PAD DRIVE MOTOR REPLACEMENT FIGURE 9 Follow steps 1-11 of the Pad Drive Deck FRONT Removal section and steps 1-6 of the Pad Drive Belt Replacement section. See Figure 9. Tip the pad drive deck assem- bly back onto the motor to gain access to the four (A) motor bolts. -
Page 16: Dust Shroud Removal
BURNISHING SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ DUST SHROUD REMOVAL See steps 1-3 of the Pad Drive Deck Removal section. ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ DUST SHROUD EDGING REPLACEMENT FIGURE 11 See Figure 11. Remove existing Edging (A) by pulling it away from the Shroud (B). Start at the rear of the Shroud (B) with one end of the new Edging (A) so that the seam is hidden. -
Page 17: Pad Drive Deck Bearing And Shaft Replacement
BURNISHING SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ PAD DRIVE DECK BEARING AND SHAFT REPLACEMENT Disassembly: FIGURE 12 NOTE: Do not try to remove the shaft and bearings by hammering. Use a hydraulic press with proper blocking and tooling. The press frame opening must be able to accept the 31.50” Dia. deck housing casting. -
Page 18: Wheel Drive System
WHEEL DRIVE SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ WHEEL DRIVE CHAIN ADJUSTMENT Lift the battery cover. Remove the master link from steering chain and move chain for easier accessibility. See Figure 1. Remove the Electrical Box (A) by removing the two (B) nuts and (C) bolts. See Figure 2. -
Page 19: Wheel Drive Chain Removal
WHEEL DRIVE SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ WHEEL DRIVE CHAIN REMOVAL Follow steps 1-6 in Wheel Drive Chain Adjustment section. Remove the batteries, see the Switching Battery Packs (Battery Removal) section in the Electrical System of this manual for further information. Tip the machine onto its Left side (be careful not to damage the pad drive deck). Locate the master link on the chain and remove chain. -
Page 20: Differential Replacement
WHEEL DRIVE SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ DIFFERENTIAL REPLACEMENT Removal: Follow steps 1-4 in the Wheel Drive Chain Removal section. See Figure 4. Remove the six (A) bolts from the three (B) Pillow Blocks. Remove the Differential (C) from the machine. Remove both drive wheels and spacers (if used) from the differential. See Figure 5. -
Page 21: Differential Replacement
WHEEL DRIVE SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ DIFFERENTIAL REPLACEMENT (CONTINUED) Differential Installation: See Figure 4. Slide each pillow block bearing onto the axle shaft. Make sure that the (3) outside bearing locking collars (E) are positioned to the outside of the unit (as shown). Install the differential into the chassis. - Page 22 WHEEL DRIVE SYSTEM FIGURE 6 0“ to 1/16” (0 to 1.6 mm) Shims (if needed) Old Style Before SN 1489668 New Style After SN 1489667 Hub up against Washer revised 2/02 FORM NO. 56043042 / Whirlamatic ™ 2700 / BHS 7014 - 21...
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Page 23: Potentiometer Removal And Testing
WHEEL DRIVE SYSTEM POTENTIOMETER REMOVAL AND TESTING FIGURE 7 WARNING! Disconnect the machines battery pack connector before servicing. See Figure 7. Observe the 3 wires connected to the drive pedal potentiometer (pot) and disconnect. Note the proper wire colors and their terminal connections for re-assembly. -
Page 24: Curtis Speed Control
WHEEL DRIVE SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ CURTIS SPEED CONTROL FIGURE 9 The Whirlamatic 2700 / BHS 7014 is driven by a one horsepower motor. The speed and direction of the motor is regulated by a Curtis Model 1235 solid state controller, the speed control is located in the rear steering wheel systems compartment (remove triangle cover). -
Page 25: Steering / Braking System
STEERING / BRAKING SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ STEERING CHAIN ADJUSTMENT Both the upper and lower steering chains should be adjusted so that they have about 1/4” (6.35 mm) to 1/2” (12.7 mm) total deflection with moderate pressure applied at the points shown in Figure 1. Move the idler sprockets in their slots to adjust chain tension. FIGURE 1 Upper Chain total deflection should be 1/4"... -
Page 26: Brake Caliper Replacement
STEERING / BRAKING SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ BRAKE ADJUSTMENT (CONTINUED) Brake Pedal Lever Position: See Figure 3. Remove the Brake Return Spring (A) and loosen the Lock Nut (B). Adjust the Turnbuckle (C) in or out until the Brake Pedal Lever (D) is 1/2 inch (12.7 mm) down from the top of slot in the chassis. NOTE: Brake Arm (E) must not bottom out against slot in the caliper. -
Page 27: Electrical System
Electrical components in this machine can be severely damaged if the batteries are not installed and connected properly. Batteries should be installed by your local Nilfisk-Advance Distributor or by a qualified electrician. Avoid short circuiting the charged stand-by battery pack. Keep any metal conductor(s) from making direct contact with the battery cables and connectors. -
Page 28: Battery Maintenance
ELECTRICAL SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ 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: •... -
Page 29: Battery Testing
Use a combination of multiple 2-volt cell units to construct a 36 Volt DC battery pack system. Nilfisk-Advance recommended battery pack capacity is a 395 AH @ 20 Hour Rate deep cycle battery system. Note: The battery pack must fit the battery compartment size listed below. - Page 30 ELECTRICAL SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ NEW BATTERY PACK SET-UP See Figure 1. Pull the Battery Tray (A) and the Battery Box (B) out of the machine chassis and center the assembly on a pallet jack with the side rails of the Battery Box (B) parallel to the pallet jack forks. IMPORTANT: The Battery Box (B) must be on the pallet jack before placing the batteries in the Battery Tray, or you will not be able to get a pallet jack under the Battery Box.
- Page 31 ELECTRICAL SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ SWITCHING BATTERY PACKS (BATTERY REMOVAL) Turn the key switch OFF and Disconnect the Battery Connector. Open the battery access door. Roll a pallet jack (NOTE: A 27” (68.58 cm) or narrower pallet jack is required, a pallet jack any wider will not work!) under the battery box (make sure the forks do not come out from under the other side of the chassis or you will raise the entire machine).
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Page 32: Electrical Control Systems
ELECTRICAL SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ ELECTRICAL CONTROL SYSTEMS The Whirlamatic 2700 / BHS 7014 has two different electrical control systems. One is a main control system, which consists of a main control microprocessor and a display board. This system will control the pad motor and the actuator motor. Refer to the Main Control Board section of this manual for further information. -
Page 33: Main Control Board
ELECTRICAL SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ MAIN CONTROL BOARD The primary function of the main control is to position the burnishing head to maintain a specific current draw by the pad motor. When the down/on switch is depressed the actuator will run for approximately two seconds, this will lower the burnishing deck to the operating position. - Page 34 ELECTRICAL SYSTEM _________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ MAIN CONTROL ERROR CODES BEFORE SN 1507059 (CONTINUED) Error Code Fault Description Troubleshooting Action Err07 Pad motor overload 1. Turn key switch off. 2. Wait for display to go off. 3. Check for binding in rotation of pad or improper actuator operation. 4. Verify that 3 position connector on the main board is properly installed.
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Page 35: Troubleshooting Guide (After Sn 1507058)
ELECTRICAL SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ TROUBLESHOOTING GUIDE (AFTER SN 1507058) Error codes for the main control will be displayed on the hour meter display as they occur. If more than one error exists the display will sequence through the error codes at one-second intervals. The error display will show on the hour meter as the letters Err followed by a two-digit code. - Page 36 ELECTRICAL SYSTEM _________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ MAIN CONTROL ERROR CODES AFTER SN 1507058 (CONTINUED) Error Code Fault Description Troubleshooting Action Err09 Pad motor open circuit (**) 1. Turn key switch off. 2. Wait for display to go off. 3. Check for disconnected pad motor, open in wiring or defective pad motor. 4.
- Page 37 ELECTRICAL SYSTEM _________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ MAIN CONTROL ERROR CODES AFTER SN 1507058 (CONTINUED) ADDITIONAL ERROR CODE TROUBLESHOOTING INFORMATION When entering the main controller error fault recall mode after a fault 1or 2 has been detected, the service person will see a second set of error codes.
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Page 38: Special Program Options
ELECTRICAL SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ SPECIAL PROGRAM OPTIONS ERROR RECALL MODE (ALL MODELS) If a fault occurs during the operation of the machine, the fault code(s) will be stored for recall at a later time. Only the error code(s) from the last time the machine was operated will be saved. To enter the error code recall mode perform the following steps: Turn the key switch off Press and HOLD the pad down/on switch while turning the key switch on. - Page 39 ELECTRICAL SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ SPECIAL PROGRAM OPTIONS (CONTINUED) ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ PAD PRESSURE ADJUSTMENT MODE: (ALL MODELS) FACTORY DEFAULT: 0 The amount of pressure applied to the burnishing pad can be adjusted over a defined limited range by changing (programming) the pad “pressure” setting in the control unit. The main control unit does not set an absolute pressure; rather it controls the amount of electrical power (maximum amperage) used by the pad motor which results in a relative pressure change (weight to the pad).
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Page 40: Special Control Modes For Machines After Sn 1507058
ELECTRICAL SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ SPECIAL CONTROL MODES FOR MACHINES AFTER SN 1507058 SERVICE TEST MODE To assist in the troubleshooting and servicing of the electrical system and related components on the 2700/BHS7014 burnishers, a special test mode which allows independent control of the various outputs and monitoring of the various inputs has been incorporated. To enter the test mode perform the following steps: Press and hold pad down switch while turning the key switch on. -
Page 41: Special Control Modes (For Machines After Sn 1507058)
ELECTRICAL SYSTEM ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ SPECIAL CONTROL MODES FOR MACHINES AFTER SN 1507058 ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ SERVICE TEST MODE (CONTINUED) OUTPUT CONTROLS: The pad up/down switch is used to control the output functions of the main control unit. Below is a detailed description of each switch function. -
Page 42: Electrical Component Location
ELECTRICAL SYSTEM ______________________________________________________________________________________________________________________________________________ COMPONENT LOCATION Item Description Speed Controller, 36V Battery Connector (Connected to Batteries) Connector Assembly (Frame Mounted) Control Box Assembly Rocker Switch (Pad UP / DOWN) Switch, Key (Main) Circuit Board (Display) Switch (Charger Interlock) Charger Plug Assembly Switch, Horn Horn, 36V Circuit Breaker, 5 Amp (Control) -
Page 43: Wiring Schematic (Before Sn 1507059)
ELECTRICAL SYSTEM 395 A/H @ 20HR. Rate BRN 1A-A YEL 4A-A BLK 0B-A 10 9 15 14 YEL/BLK 40A-A RED 2A-A 10 5 VIO 7A-A ORN 3A-A BLK 0A-A BLU 6A-A FRONT GRN 5A-A GND 1 2 3 R2 T YEL/BLU 46B-B YEL/BLU 46B-A WHT/BRN 91D-B... -
Page 44: Wiring Diagram (Before Sn 1507059)
ELECTRICAL SYSTEM ____________________________________________________________________________________________________________________________________________________________ WIRING DIAGRAM / SCHEMATIC (before SN 1507059) Speed Controller, 36V Control Box Assembly Display Batteries Diode BLU/YEL WHT/BLK Circuit Breaker, 5 Amp (Control) Circuit Breaker, 40 Amp (Wheel Drive) Fuse, 1.5 Amp (Optional W/Strobe Light Kit) WHT/ORN Horn Back-Up Alarm Kit (Optional) CURTIS PMC... -
Page 45: Wiring Schematic (After Sn 1507058)
ELECTRICAL SYSTEM 395 A/H @ 20HR. RATE CURTIS 1225 FRONT CABLE ASSEMBLY 56420190 YEL/BLU 46B-B YEL/BLU 46B-A WHT/BRN 91D-B WHT/BRN 91D-A RED BLK 44 - FORM NO. 56043042 / Whirlamatic™ 2700 / BHS 7014 revised 2/02... -
Page 46: Wiring Diagram (After Sn 1507058)
ELECTRICAL SYSTEM ______________________________________________________________________________________________________________________________________________ WIRING DIAGRAM / SCHEMATIC (after SN 1507058) Speed Controller, 36V WHT/BLK BLU/YEL Control Box Assembly Display Batteries WHT/ORN Diode CURTIS 1225 BRN/BLK Circuit Breaker, 5 Amp (Control) Circuit Breaker, 40 Amp (Wheel Drive) Fuse, 1.5 Amp (Optional W/Strobe Light Kit) Horn Back-Up Alarm Kit (Optional) GRN/BLU... - Page 47 ¤ +1 800 989 2235 – Fax 1 800 989 6566 Distriktsrepresentanter over hele landet Dublin 18 ¤ +353 1 2943838 – Fax +353 1 2943845 SVERIGE Nilfisk-Advance of America, Inc. Nilfisk-Advance AB JAPAN 300 Technology Drive Sjöbjörnsvägen 5, 117 67 Stockholm Nilfisk-Advance Inc.