Nilfisk-Advance 56104501 Manuals

Manuals and User Guides for Nilfisk-Advance 56104501. We have 1 Nilfisk-Advance 56104501 manual available for free PDF download: Service Manual

Nilfisk-Advance 56104501 Service Manual

Nilfisk-Advance 56104501 Service Manual (350 pages)

Brand: Nilfisk-Advance | Category: Scrubber | Size: 29 MB

Table of Contents

Table of Contents

2
- Drive Controller Error Code Index
  3
- 03 - General Information
  
  8
  - General Machine Description
    8
  - Service Manual Purpose and Application
    8
  - Other Reference Manuals and Information Sources
    8
  - Parts and Service
    8
  - Diagnostic and Service Tools
    8
  - Conventions
    9
  - Revision History
    9
  - Parts and Service
    9
  - Modifications
    9
  - Nameplate
    9
  - Safety
    10
    
    General Safety Instructions
    10
    
    Symbols
    10
    
    Lithium-Ion Battery Specific Safety Instructions
    11
    
    Property Damage Messages
    11
  - Lifting or Transporting the Machine
    12
  - Moving a Disabled Machine
    13
  - Control Cover Prop Rod
    13
  - Specifications
    14
    
    General Specifications
    14
    
    Overall Dimensions
    15
    
    Fastener Torque Specifications
    16
  - Maintenance
    16
    
    Maintenance Schedule
    16
    
    Lubrication Locations
    17
    
    Maintenance Procedure References
    17
    
    Preventive Maintenance Checklist - Liberty SC50
    18
  - Major Machine Components
    24
- 04 - Control System
  
  25
  - Functional Description
    25
    
    Functional Block Diagram
    25
    
    Onboard Charger
    27
    
    Power Module
    27
    
    Wheel Drive Controller
    28
    
    Main Machine Controller
    29
    
    Control Panel
    30
    
    CAN Bus Communication
    31
    
    CAN Bus Information
    32
  - Component Locations
    33
  - Main Machine Controller Menus
    34
    
    Menu Navigation
    34
    
    Service Mode Access (from Power-Off)
    34
    
    Service Mode Access (While Powered-On)
    34
    
    Menu Outline
    35
    
    Authorizing User Keys
    37
    
    Deauthorizing User Keys
    37
    
    Faults Menu
    37
    
    Hours Menu
    37
    
    Keys Menu
    37
    
    A1 Main Machine Controller
    38
    
    Service Menu
    38
    
    A2 Power Module
    39
    
    A3 Drive Controller
    39
    
    A4 Steering Controller
    40
    
    A5 Autonomy
    40
    
    A8 Battery Charger
    41
    
    B1 Li-Ion Battery Menu
    42
    
    Output Test
    44
    
    Factory Resets
    45
    
    Panel Test
    45
    
    Options Menu
    46
    
    Autonomous Cleaning Menu
    49
    
    Configuration Menu
    49
  - Maintenance and Adjustments
    50
    
    MMC Firmware Update Via USB
    50
  - Troubleshooting
    51
    
    Rebooting
    51
    
    Terminology
    51
    
    Error Code Index
    52
    
    Main Machine Controller (E2) Error Codes
    54
    
    Power Module (A2) Error Codes
    71
  - Removal and Installation
    89
    
    Control Panel/Main Machine Controller
    89
  - Specifications
    90
    
    Sample Shop Voltage Measurements
    90
    
    Device Resistances
    93
    
    Motor Amp Draw Measurements
    93
- 05 - Autonomous System
  
  95
  - Functional Description
    95
    
    Functional Block Diagram
    95
    
    LED Status Bar
    96
    
    Drive Wheel Angle Sensor
    97
    
    IOT (Communication) Module
    97
    
    Wheel Encoders
    97
    
    3D Vision Sensor
    98
    
    Pattern Projector
    98
    
    Drop-Off Sensors
    99
    
    Mapping Sensor (Laser)
    99
    
    Safety Sensors (Lasers)
    102
    
    Area Address Selection
    103
    
    Warning and Protection Zones
    103
    
    Master-Slave Communication
    104
    
    Outputs and LED Indicators
    104
  - Component Locations
    105
  - Maintenance and Adjustment
    106
    
    Wheel Encoder Gap
    106
    
    Drive Wheel Angle Sensor Centering
    107
    
    Drop-Off Sensor Calibration
    108
    
    3D Vision Sensor (Camera) Calibration
    109
    
    2D Mapping (Sensor) Laser Calibration
    110
    
    2D Mapping Sensor Level Check and Adjust
    110
    
    Checking Laser Level
    113
    
    Left Safety Sensor Level Check and Adjust
    113
    
    Right Safety Sensor Level Check and Adjustment
    116
    
    Right Safety Sensor - Check Maximum Laser Height
    119
    
    Safety Sensor Rotational Position Check (Right and Left)
    121
    
    Safety Sensor Rotational Position Adjustment
    122
    
    Autonomous Controller and Main Machine Controller Software Update
    125
    
    Connect to Wifi
    126
    
    Downloading and Installing Software Updates
    126
  - Autonomous System Safety Testing
    127
    
    Locking Machine out of Autonomous Operation
    127
    
    Static Test of Drop-Off Sensors
    127
    
    Dynamic Floor Drop-Off Simulation
    129
    
    Safety (Laser) Sensor Performance Tests
    132
    
    Straight-Line Test Setup
    132
    
    High Speed Stop
    133
    
    Stay-Put Test
    133
    
    Forward Low Speed Stop
    135
    
    Right Turning Low Speed Stop
    139
    
    Left Turning Low Speed Stop
    140
  - Troubleshooting
    142
    
    Troubleshooting Flow Chart
    142
    
    Drive Wheel Angle Sensor
    143
    
    Sensor Input Validation Testing
    143
    
    Safety Sensors (Left and Right)
    144
    
    2D Mapping Sensor
    145
    
    Vision Sensor (Camera)
    145
    
    Drop-Off Sensors
    146
    
    Rear Wheel Encoders
    147
    
    Rebooting
    147
    
    Safety Sensor Error Codes
    148
    
    Autonomous System Error Code Reference
    149
  - Removal and Installation
    150
    
    Autonomy Module
    150
    
    3D Vision Sensor
    152
    
    2D Mapping Sensor
    154
    
    Left Safety Sensor
    156
    
    Right Safety Sensor
    157
    
    Drop-Off Sensors
    158
    
    Drive Wheel Angle Sensor
    159
  - Specifications
    161
    
    Sample Shop Voltage Measurements
    161
  - Special Tools
    164
- 10-Chassis System
  
  165
  - Functional Description
    165
  - Removal and Installation
    166
    
    Tipping the Machine
    166
- 20 - Wheel System - Traction
  
  168
  - Functional Description
    168
    
    Wheel Drive Controller
    169
    
    Drive Control
    170
    
    Manual Speed Control
    170
  - Component Locations
    171
  - Maintenance and Adjustment
    172
    
    Wheel Motor Brushes
    172
    
    Drive Chain Maintenance and Adjustment
    173
  - Troubleshooting
    174
    
    Terminology
    174
Drive Controller Error Code Index 3-001

175
- Drive Controller Error Codes
  176
- Excess M1 Drv Whl Mtr Current
  176
- A3 Calibration Reset
  177
- Internal Clock Failure
  177
- Driver 1Or2 Ovrcrnt
  178
- K3 Cntctr Coil Open
  178
- A3 EEPROM Fault
  179
- Emrgcy Reverse Fault
  179
- K3 Contact Not Closing
  180
- K3 Contactor Closed
  181
- M1/M2 Outputs Shorted
  181
- Lost Comm-A1 Mn Cntrlr
  182
- A3 Supervisor Comm
  183
- A3 Supervisor Watchdog
  183
- Auto OK Input Fault
  183
- Go Pedal (POT 1) Fault
  183
- Output Fault
  183
- S1 Operator Pr Sw Flt
  183
- S2 E-Stop Fault
  183
- Spd Lmt (POT 2) Fault
  183
- Steer Ready Input Flt
  183
- Supervisor Pot3 Fault
  183
- EM Brake Open
  184
- External Supply Fault
  184
- Brake Driver on
  185
- Pot 1 Range
  185
- Pot 2 Range
  185
- Pot 3 Fault
  186
- Very Low Cntrlr Temp
  186
- Very Low Voltage
  186
- K3 Cntr/Y1 Brk Shorted
  187
- Low B+ Power Input
  187
- Very High Cntrlr Temp
  187
- Correlation Fault
  188
- Driver3 Fault
  188
- Driver3 Overcurrent
  188
- Driver4 Fault
  188
- Driver4 Overcurrent
  188
- Driver5 Fault
  188
- Driver5 Overcurrent
  188
- Driver6 Fault
  188
- Driver6 Overcurrent
  188
- Go Pedal Switch Closed
  188
- A3 Drive Motor Hot
  189
- A3 NV Memory Fault
  189
- Parameter Change
  189
- M1 Drive Motor Open
  190
- M1 Drive Motor Short
  190
- High Voltage
  191
- Low Temperature Cutback
  191
- Stall Detected
  191
- A3 Drv Cntrl Temp High
  192
- High Voltage
  192
- Removal and Installation
  194
  - Drive Assembly
    194
  - Drive Wheel Motor
    196
  - Drive Wheel and Wheel Bearings
    197
- Specifications
  199
  - Sample Shop Voltage Measurements
    199
- 22 - Steering System
  
  201
  - Functional Description
    201
    
    Steering Controller
    202
    
    Steering Actuator
    204
    
    Steering Wheel Position Sensor
    204
  - Maintenance and Adjustment
    205
    
    Steering Spindle Bearings
    205
    
    Steering Chain Maintenance and Adjustment
    207
    
    Drive Wheel Angle Sensor Centering
    208
  - Troubleshooting
    209
    
    Rebooting
    209
    
    Terminology
    209
    
    Steering Controller Error Codes
    210
  - Removal and Installation
    225
    
    Steering Controller Module
    225
    
    Steering Sensor
    225
    
    Steering Controller and Actuator
    226
    
    Sample Shop Voltage Measurements
    228
    
    Specifications
    228
- 24 - Electrical System
  
  229
  - Functional Description
    229
    
    Fuses and Circuit Breakers
    229
    
    K2 and K3 Relays
    230
    
    KSI Relay
    230
    
    E-Stop Switch
    231
    
    Low Voltage Cutout
    231
    
    Onboard Battery Charger
    231
    
    DC/DC Converter
    232
    
    Li-Ion Technical Data
    232
    
    Lithium-Ion Battery Option
    232
    
    Ultraviolet Germicidal Irradiation (UVGI) Option
    232
  - Component Locations
    233
  - Maintenance and Adjustments
    234
    
    Battery Charging Profile (Algorithm) Setting
    234
  - Troubleshooting
    235
    
    Back-Probing Connector Voltages
    235
    
    General Electrical Troubleshooting
    235
    
    Testing Cables
    236
    
    Connector Probe Kit
    237
    
    Battery Charger Error Codes
    238
    
    Finding LL-Codes
    248
    
    Lithium-Ion Battery Error Codes
    248
    
    Lower-Level Codes (0X##)
    248
    
    Machine-Level Codes (10-1Xx)
    248
    
    Upper-Level Codes (10-2Xx)
    248
  - Removal and Installation
    261
    
    Operator Platform
    261
    
    Platform Switches
    262
    
    Batteries (Lead-Acid)
    263
    
    Batteries (Lithium Ion)
    264
    
    Battery Charger
    267
  - Wiring Diagrams
    268
    
    Understanding the Features of the Electrical Circuit Diagram
    268
    
    Splice Points
    270
    
    Using the Wiring Harness Diagram
    270
    
    Wire Numbers
    270
    
    Acrobat Search to Trace a Circuit
    271
    
    Connector Numbers
    271
    
    Electrical Circuit Diagram
    272
    
    Sheet 1, Main Machine Controller
    272
    
    Sheet 2, Power Module
    273
    
    Sheet 3, Drive Controller
    274
    
    Sheet 4, Steering Controller
    275
    
    Sheet 5, Autonomy Controller
    276
    
    Sheet 6, Autonomy Breakout Box
    277
    
    Sheet 7, UVGI Option, Generation 2
    278
    
    Sheet 8, UVGI Option, Generation 3
    279
    
    Sheet 9, Battery Connection Options
    280
    
    56104984, Rev F, for Legacy Models
    281
    
    Wiring Harness Diagrams
    281
    
    56104911, Rev B, for Focus Release Models
    286
    
    3D Harness Diagrams
    291
    
    Main Harness, Autonomy Bay
    292
    
    Main Harness, Main Machine Controller
    292
    
    Main Harness, Electrical Bay
    293
    
    Power Connections, Electrical Bay
    293
    
    Main Harness, Lower Electrical Bay
    294
    
    Main Harness, Rear Platform
    295
    
    Main Harness, Scrub Deck
    295
    
    Autonomy Cables, Autonomy Bay
    296
    
    Autonomy Cables, Mapping and Safety Lasers
    297
    
    Autonomy Cables, Dropoff Sensors
    298
    
    Electrical Connector Pin-Out Assignments
    299
- 30 - Solution System
  
  315
  - Functional Description
    315
    
    Circuit Description
    316
    
    Detergent Pump
    317
    
    Solution Flow Meter
    317
  - Maintenance and Adjustments
    318
    
    Cleaning the Solution Filter
    318
    
    Draining the Solution Tank
    318
    
    Clean and Inspect the Solution Solenoid
    319
  - Removal and Installation
    320
    
    Solution Pump
    320
    
    Detergent Pump
    321
  - Specifications
    321
    
    Component Specifications
    321
    
    Nominal Solution Flow Rates
    321
- 34-Scrub System
  
  322
  - Functional Description
    322
    
    Functional Diagram
    322
    
    Deck Lift Actuator
    323
    
    Deck Types
    323
  - Maintenance and Adjustment
    325
    
    Scrub Deck Actuator Adjustment
    325
  - Troubleshooting
    327
    
    Uneven Cleaning Path
    327
  - Removal and Installation
    328
    
    Scrub Deck
    328
    
    Scrub Deck Actuator Assembly
    330
    
    Motor Brushes (Disc Deck)
    332
    
    Motor Brushes (Rev Deck)
    333
    
    Rev Deck Bearing and Motor
    335
  - Specifications
    337
- 38-Squeegee System
  
  338
  - Functional Description
    338
  - Maintenance and Adjustment
    339
    
    Squeegee Blade Replacement
    339
  - Troubleshooting
    340
- 40-Recovery System
  
  341
  - Functional Description
    341
    
    Circuit Description
    342
  - Troubleshooting
    343
    
    General Troubleshooting
    343
    
    Vacuum Suction Test
    345
  - Removal and Installation
    346
    
    Recovery Tank
    346
    
    Recovery Tank Float Switch
    347
    
    Vacuum Motor
    348
    
    Vacuum Motor Brushes
    349
  - Specifications
    350
  - Special Tools
    350

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