Nilfisk-Advance 56509001 Manuals

Manuals and User Guides for Nilfisk-Advance 56509001. We have 1 Nilfisk-Advance 56509001 manual available for free PDF download: Service Manual

Nilfisk-Advance 56509001 Service Manual

Nilfisk-Advance 56509001 Service Manual (440 pages)

Brand: Nilfisk-Advance | Category: Floor Machine | Size: 46.87 MB

Table of Contents

Service Manual
1
Table of Contents
2
General Information

13
- General Machine Description
  13
- Service Manual Purpose and Application
  13
- Revision History
  13
- Other Reference Manuals and Information Sources
  14
  - Nilfisk-Advance Publications
    14
  - Engine Manufacturers' Technical Manuals
    15
- Conventions
  15
- Parts and Service
  15
- Nameplate
  15
- Cautions and Warning Symbols
  16
- General Safety Instructions
  16
- Hopper Prop Rod
  18
  - To Engage the Hopper Prop Rod
    18
  - To Disengage the Hopper Prop Rod
    18
- Jacking the Machine
  19
- Transporting the Machine
  19
- Towing the Machine
  20
- Diagnostic and Service Tools
  21
- Technical Specifications
  22
  - General Specifications
    22
  - Fastener Torque Specifications
    25
  - Overall Dimensions
    26
- Maintenance
  27
- PM Checklist
  33
- Machine Controls
  35
  - Control Panel - General Layout
    35
  - Miscellaneous Controls
    35
  - Miscellaneous Indicators
    36
  - Scrub Controls
    37
  - Scrub Indicators
    38
  - Sweep Controls
    38
  - Sweep Indicators
    39
  - Hopper Controls
    40
- LCD Displays
  40
  - General Displays
    40
    
    Battery Machine
    40
    
    LPG Machine
    40
    
    Diesel Machine
    41
    
    Broom Adjustment (Battery, LPG and Diesel)
    41
    
    Battery Charge Indicator
    41
  - Fault, Caution and Warning Displays
    42
    
    Fault Displays
    42
    
    Caution Displays
    42
    
    Warning Displays
    43
- Steering Wheel
  44
- Foot Pedals
  44
Chassis System

45
- Component Locations - Battery Machine (Major Components)
  45
- Component Locations - LPG and Diesel Machine (Major Components)
  46
Control System

47
- Functional Description
  47
  - CAN Bus Circuit
    48
  - CAN BUS Message Routing
    49
    
    Control Panel
    49
    
    Main Machine Controller
    49
    
    Drive Controller
    49
    
    Steering Controller
    50
- Component Locations
  51
- Troubleshooting
  52
  - Fault Codes
    52
  - Fault Code Table (Main Machine Controller)
    53
  - Hidden Menus
    57
    
    Configuration Display
    57
    
    Configuration Menu
    59
    
    User Options Menu
    63
- Service Mode
  68
  - To Operate
    71
  - Control Panel Leds All Stay Lit - CAN Bus Problems
    75
- Removal and Installation
  76
  - Main Machine Controller
    76
  - Control Panel
    77
- Specifications
  78
  - Shop Measurements - Main Machine Controller
    78
    
    J2 Connector (White)
    78
    
    J3 Connector (Gray)
    79
    
    J7 Connector (Black)
    81
Dust Control/Dustguard™ Systems

83
Electrical System

101
- Functional Description
  101
  - Overview
    101
  - Wiring Harnesses
    104
  - Circuit Protection
    105
  - Current Sensors
    105
  - Volt Alternator (Generator)
    105
  - Lighting
    105
  - Low Voltage Cutout
    106
  - 42 Volt Generator
    106
  - Headlights
    107
    
    Incandescent Headlights
    107
    
    LED Headlights
    107
- Component Locations
  108
- Electrical Panel Contactor/Relay Location
  110
- Harness to Harness Connector Locations
  111
- Connector Pin-Outs
  112
  - Component ID to Connector ID Look up Table
    112
- Wiring Connections
  134
  - K14 Safety Relay and K15 Auxiliary Relays
    134
  - Early Style K14 Safety Relay
    134
    
    Early Style K15 Auxiliary Relay
    134
    
    Late Style K14 Safety Relay and K15 Auxiliary Relay
    135
- Maintenance and Adjustments
  136
  - Charging the Battery (Battery Model)
    136
  - Generator Drive Belt
    136
- Troubleshooting
  136
- Removal and Installation
  137
  - 42 Volt Generator Drive Belt
    137
  - 42 Volt Generator
    139
  - Generator Drive Belt Tensioner
    139
  - Head Light Bulb - Standard 12V Halogen
    140
- Specifications
  141
  - Battery (Battery Model)
    141
  - Low Voltage Cut out
    141
  - Battery Run Time (Battery Powered Machine)
    141
  - Current Sensors
    142
- Wiring Diagrams
  146
- LEV Engine Side Wiring 56511576_REV_A_LEV_ENG Sheet 1 of 1
  156
Engine System - LPG

157
- Functional Description
  157
  - Circuit Descriptions
    158
    
    Ignition System
    158
    
    Engine Starter Control
    160
  - Throttle Control Modes
    161
    
    Ignition off
    161
    
    Ignition on
    162
    
    Cranking
    163
    
    Normal Running
    164
    
    Engine RPM Control
    164
  - Normal Engine Shut off
    165
    
    Step One
    165
    
    Step Two
    166
    
    Engine Overheat Shutdown
    167
    
    Lost Oil Pressure Shutdown
    168
- Component Locations
  169
- Maintenance and Adjustments
  173
  - Maintenance Checklist
    173
  - Change Engine Oil and Oil Filter
    174
  - Change Engine Coolant
    175
  - Inspect Air Filter
    175
  - Replace Air Filters
    175
- Troubleshooting
  176
- Removal and Installation
  180
  - Engine RPM Sensor Installation
    180
  - Engine Assembly
    180
- Specifications
  181
  - Fuel System
    181
  - Engine Oil
    181
  - Engine Coolant
    181
  - Shop Measurements
    181
    
    Ignition System
    181
    
    Spark Controller Measurements
    182
    
    Governor Control System
    182
    
    Woodward L Series Actuator Measurements
    182
    
    Fuel System
    183
    
    Engine
    183
- Special Tools
  184
Engine System - LPG LEV

185
- Functional Description
  185
  - Circuit Descriptions
    186
    
    Engine Starter Control
    186
    
    Engine RPM Control
    187
  - Normal Engine Shut off
    187
  - Engine Protection Modes
    187
- Component Locations
  188
- Maintenance and Adjustments
  190
  - Maintenance Checklist
    190
  - Change Engine Oil and Oil Filter
    190
  - Change Engine Coolant
    190
  - Inspect Air Filter
    191
  - Replace Air Filters
    191
- Troubleshooting
  192
- Engine Management System
  192
  - Checking Spark
    192
  - Checking LPG Primary Pressure
    193
- Removal and Installation
  194
  - Engine Assembly
    194
- Specifications
  195
  - Fuel System
    195
  - Engine Oil
    195
  - Engine Coolant
    195
  - Shop Measurements
    195
    
    Ignition System
    195
    
    Fuel System
    196
    
    Engine
    196
- Special Tools
  197
Engine System - Petrol (Gasoline)

199
- Functional Description
  199
  - Kubota WG972-GL-E3-NFK-1 Petrol (Gasoline)
    199
  - Circuit Descriptions
    200
    
    Ignition System
    200
    
    Engine Starter and Carburetor Choke Control
    202
  - Throttle Control Modes
    203
    
    Ignition off
    203
    
    Ignition on
    204
    
    Cranking
    205
    
    Normal Running
    206
    
    Engine RPM Control
    206
  - Normal Engine Shut off
    207
    
    Engine Overheat Shutdown
    208
    
    Lost Oil Pressure Shutdown
    209
- Component Locations
  210
- Maintenance and Adjustments
  214
  - Maintenance Checklist
    214
  - Change Engine Oil and Oil Filter
    215
  - Change Engine Coolant
    215
  - Inspect Air Filter
    216
  - Replace Air Filters
    216
- Troubleshooting
  217
- Removal and Installation
  220
  - Engine RPM Sensor Installation
    220
  - Engine Assembly
    220
- Specifications
  221
  - Engine Oil
    221
  - Engine Coolant
    221
  - Shop Measurements
    221
    
    Ignition System
    221
    
    Spark Controller Measurements
    222
    
    Governor Control System
    222
    
    Woodward L Series Actuator Measurements
    222
    
    Fuel System
    223
    
    Engine
    223
- Special Tools
  224
Engine System, Diesel

225
- Functional Description
  225
  - Engine Starter Control
    225
  - Fuel Pump Control
    226
  - Engine Protection
    227
    
    Over Temperature Shutdown
    228
    
    Low Oil Pressure Shutdown
    229
  - Engine RPM Control
    230
  - Glow Plug Control
    232
- Component Locations
  233
- Maintenance and Adjustments
  236
  - Diesel Engine Maintenance Schedule
    236
  - Change Engine Oil and Oil Filter
    237
  - Change Engine Coolant
    237
  - Replace Fuel Filter
    237
  - Bleed Fuel System
    238
  - Inspect Air Filter
    238
  - Replace Air Filters
    239
- Troubleshooting
  240
- Removal and Installation
  245
  - Engine RPM Sensor Installation
    245
  - Engine Assembly
    245
- Specifications
  246
  - Fuel Pump
    246
  - Glow Plugs
    246
  - Engine Compression
    246
  - Engine Oil Capacity
    246
  - Engine Oil Type
    246
  - Engine Oil Viscosity
    247
  - Cooling System
    247
    
    Engine Coolant
    247
    
    Radiator Cap
    247
  - Shop Measurements
    247
    
    Engine RPM Sensor
    247
    
    Actuator
    247
    
    Engine Compression
    248
    
    Fuel System Return Fuel Flow
    248
    
    Starter
    248
    
    Glow Plug Relay
    248
- Special Tools
  249
Hopper System

250
- Functional Description
  250
  - Overview
    250
  - Hopper System Wiring Diagram
    251
  - Hopper Hydraulic System Circuit Details
    252
    
    Hopper at Rest
    252
    
    Hopper Being Raised
    252
    
    Hopper Being Lowered
    253
  - Circuit Description
    253
- Component Locations
  254
  - Upper and Lower Hopper
    254
  - Hydraulic Power Pack Assembly
    255
  - Hopper Dump Door
    256
  - Hopper Dump Door Actuator
    256
  - Dump Door Extend and Retract Limit Switches
    256
  - Hopper Interlock Switch
    257
  - Hopper Prop Rod and Pull Rod
    257
- Troubleshooting
  258
- Removal and Installation
  260
- Specifications
  277
Options and Accessories

278
Recovery System

288
- Functional Description
  288
  - Overview
    288
  - Recovery System Wiring Diagram
    289
  - Circuit Description
    290
- Component Locations
  291
  - Recovery Tank
    291
  - Recovery Tank Cover and Debris Basket
    291
  - Vacuum Fan Cover Assembly
    292
  - Vacuum Motors
    292
  - Float Cage and Ball Assemblies
    292
- Maintenance and Adjustments
  293
  - To Clean the Vacuum Filter and Filter Screen
    293
  - To Clean the Debris Basket
    294
- Troubleshooting
  295
- Removal and Installation
  296
- Specifications
  300
- Special Tools
  300
Scrub System

301
- Functional Description
  301
  - Overview
    301
  - Scrub Pressure Control
    301
  - Scrub System Wiring Diagram
    302
  - Circuit Description
    303
    
    The Following Conditions Must be Met for the Scrub System to Operate
    303
    
    Scrub Deck Actuator Motor
    303
    
    Brush Current Sensor
    304
- Component Locations
  304
  - Scrub Motor Assemblies
    304
  - Right Scrub Arm Gas Spring and Lever Arm Bracket
    304
  - Side Squeegee Assemblies
    305
  - Scrub Deck Actuator
    305
- Maintenance and Adjustments
  306
  - To Replace a Leading Deck Blade
    306
  - To Replace a Trailing Deck Blade
    306
- Troubleshooting
  307
- Removal and Installation
  308
- Specifications
  316
- Special Tools
  317
Solution System

318
Squeegee System

344
- Functional Description
  344
  - Overview
    344
  - Squeegee System Wiring Diagram
    344
  - Circuit Description
    345
- Component Locations
  345
- Maintenance and Adjustments
  346
- Troubleshooting
  350
- Removal and Installation
  351
- Specifications
  353
- Special Tools
  353
Steering System

354
- Functional Description
  354
  - Summary
    354
    
    Steering Wheel Rotation Sensor
    354
    
    Steering Actuator
    355
    
    Steering Travel Limit Switches
    356
  - Steering Controller
    356
  - Steering System Wiring Diagram
    357
  - Circuit Description
    358
- Component Locations
  362
- Maintenance and Adjustments
  363
- Troubleshooting
  363
- Removal and Installation
  369
  - Steering Wheel Assembly
    369
  - Steering Wheel Rotation Sensor
    370
  - Steering Controller
    373
  - Steering Actuator
    373
- Specifications
  375
  - Shop Measurements
    375
    
    Steering Wheel Rotation Sensor Voltage Measurements
    375
    
    Steering Controller Voltage Measurements
    376
    
    J5 Connector
    376
    
    Motor U, V and W Terminal Pair Voltages
    377
    
    Motor U, V and W Terminal Pair Frequency
    377
    
    System Current Draw
    377
    
    Steering Contactor
    377
    
    Safety Relay
    377
- Special Tools
  377
Sweep System, Main

378
- Functional Description
  378
  - Overview
    378
  - Main Sweep System Wiring Diagram
    379
  - Circuit Description
    380
    
    The Following Conditions Must be Met for the Main Sweep System to Operate
    380
    
    Main Broom Actuator Motor
    380
    
    Broom Current Sensor
    381
- Component Locations
  381
  - Main Broom and Drive Components
    381
- Maintenance and Adjustments
  382
  - To Adjust the Main Broom Height
    382
  - To Adjust the Main Broom Tilt
    383
- Inspecting/Replacing Main Broom Motor Carbon Brushes
  384
- Troubleshooting
  387
- Removal and Installation
  388
- Specifications
  393
Sweep System, Side Broom

394
- Functional Description
  394
  - Overview
    394
  - Side Broom System Wiring Diagram
    395
    
    Side Broom Actuator Motor
    395
  - Circuit Description
    396
- Component Locations
  397
  - Side Brooms
    397
  - Side Broom Motor Assemblies
    397
  - Side Broom Actuator
    397
- Maintenance and Adjustments
  398
  - To Remove and Reinstall a Side Broom
    398
- Inspecting/Replacing Side Broom Motor Carbon Brushes
  399
- Troubleshooting
  401
- Removal and Installation
  402
- Specifications
  407
- Special Tools
  407
Wheel System, Traction

408
- Functional Description
  408
  - Drive Pedal
    408
- Drive Controller
  408
  - Drive Wheel Motor
    409
  - Gear Box
    409
  - Circuit Description
    409
    
    Powering up the Drive Controller
    410
    
    Drive Pedal Sensor
    410
    
    CAN Bus
    413
- Component Locations
  414
- Maintenance and Adjustments
  415
  - Drive Controller
    415
  - Drive Pedal Position Sensor
    415
  - Gear Box
    415
- Troubleshooting
  416
  - Fault Codes
    416
  - Summary of LED Display Formats
    417
  - Troubleshooting Chart
    418
  - Fault History
    428
- Removal and Installation
  429
  - Drive Pedal Assembly
    429
  - Drive Motor and Gearbox Assembly
    429
  - Drive Wheel
    433
  - Drive Controller
    433
- Specifications
  434
  - Shop Measurements
    434
    
    Drive Controller Voltage Measurements
    434
    
    Low Current 35 Pin Connector (J4)
    434
    
    Motor U, V and W Terminal Pair Voltages
    435
    
    Motor U, V and W Terminal Pair Frequency
    435
    
    System Current Draw - Driving Only with no Cleaning Functions
    436
    
    Wheel Drive Contactor
    436
- Special Tools
  436
Wheel System, Non-Traction

437
- Functional Description
  437
- Maintenance and Adjustments
  438
  - To Adjust the Brakes
    438
- Troubleshooting
  439
- Removal and Installation
  439
  - To Remove and Reinstall a Wheel
    439
  - To Remove and Reinstall a Brake and Spindle Assembly
    440

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