Nilfisk-Advance 56397010 Service Manual Download Page 53

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ELECTRICAL SYSTEM

52 - FORM NO. 56043056 / CONVERTAMAX™ 20/26 / BA 550/650

WIRING DIAGRAM / SCHEMATIC

Item

Qty Description

Speed Control

A2*

Timer Module Assy

Battery, 24V

Diode

Circuit Breaker, 10 Amp (Auxiliary)

Circuit Breaker, 40 Amp (20” model / Brush Motor)

Circuit Breaker, 60 Amp (26” model / Brush Motor)

Circuit Breaker, 30 Amp (Wheel Drive Motor)

Circuit Breaker, 30 Amp (Vac Motor)

Contactor, 24V SPDT (Brush Motor)

Contactor, 24 VDC (Vacuum Motor)

Solenoid Valve Assy

Vac Motor Assembly

Wheel Drive Motor

Motor (20” model)

Motor / Gear Unit (26” model)

Fuel Gauge, Battery

Hourmeter

Potentiometer, 25K

Potentiometer, 5K

Switch, Toggle (Main Power)

Switch, Rocker (Solution)

Switch, Rocker SPST (Brush Remove)

Switch, Vacuum

Switch, Interlock

Switch, Brush

*Terminal Identification of A2 Timer Module Assembly

Relay Common

Pad Contactor Coil (+)

Pad Contactor Coil (-)

Speed Control Input

Battery (-)

Relay Normally Open

Relay Normally Closed

Brush Switch Input

Remove Switch Input

Battery (+)

revised 7/02

VIO

RED 25

RED

BRN/BLK

VIO

BRN/RED

RED/BLK

GRA

RED/WHT

VIO

B+

B-

B+
B-

(T2)

(T1)

(T3)

WHT/YEL

VIO

BLK

P2 2

VIO/BRN

+ WHEN

FORWARD

(T4)

GRN

RED/BLU

ORN

YEL

BLK

26 BLK

BLK

VIO/BLK

YEL/WHT

BLK

YEL/BLK

WHT/RED

ORN/BLK

VIO/BLK

BLK

BRN

BLK

BRN/WHT

BRN

BLK

WHT/RED

BLK

BLK/YEL

BRN/WHT

BLK

VIO

GEL.

LIQ.

BATTERY

GRA

SWITCH

BLK

VIO/BLK

RED/GRN

VIO/BLK

BLU

RED

BLK

Summary of Contents for 56397010

Page 1: ...1 00 revised 7 02 Form Number 56043056 ConvertaMAX 20 26 BA 550 650 SERVICE MANUAL Advance MODELS 56397010 56397011 56397580 56397581 Nilfisk MODELS 56397012 56397013 56397582 56397583 ...

Page 2: ... VACUUM MOTOR REMOVAL 35 RECOVERY TANK REMOVAL 35 VACUUM SWITCH REPLACEMENT AND ADJUSTMENT 35 SQUEEGEE SYSTEM 36 37 SQUEEGEE TOOL BLADE REPLACEMENT 36 SQUEEGEE TOOL ANGLE ADJUSTMENT 36 WHEEL DRIVE SYSTEM 38 45 FUNCTIONAL OVERVIEW 38 TROUBLESHOOTING GUIDE 39 41 CHAIN MAINTENANCE 42 CHAIN REMOVAL AND ADJUSTMENT 42 WHEEL DRIVE MOTOR REMOVAL 42 DRIVE WHEEL REMOVAL 42 POTENTIOMETER 5K TESTING AND REMOV...

Page 3: ...ne 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 26 All access doors and covers are secured tape and strap as needed TOWING CAUTION If the machine must be...

Page 4: ... servicing electrical components Never work under a machine without safety blocks or stands to support the machine Donotdispenseflammablecleaningagents operatethemachineonorneartheseagents oroperateinareaswhereflammable liquids exist Do not clean this machine with a pressure washer Do not operate this machine on ramps or inclines of more than a 2 percent gradient CAUTION This machine is not approv...

Page 5: ... High 110 lbs 50kg Solution Tank Capacity 20 gal 76l Recovery Tank Capacity 20 gal 76l Vacuum Water Lift 63 inches sealed 14 inches open hole adapter 1 Ramp Climbing Ability gradeability 2 grade Sound power level as per ISO 3744 at operator 70 dB A 20µPa Transport Speed Maximum 3 3 mph 5 3KPH Scrubbing Speed Maximum 3 mph 4 8KPH Power Source 24VDC Battery Pack 4 6V 238 AH batteries Battery Weight ...

Page 6: ...056 ConvertaMAX 20 26 BA 550 650 5 SPECIFICATIONS TOPVIEW SIDEVIEW 30 5in 77cm 20 Models 64in 162cm 20 Models 59in 149cm 26 Models 42 5in 108cm 26 5in 67 3cm 20 Models 28 5in 72 4cm 26 Models 36 25in 92cm 26 Models ...

Page 7: ...once a year or after 300 operating hours Note if the vacuum or brush motor carbon brushes are 9 5mm 3 8 inches or shorter replace them Check brush motor carbon brushes Qty 4 once a year or after 500 operating hours Check wheel drive motor carbon brushes every 500 operating hours The original length of each brush is 20mm 25 32 inches Replace when shorter than 9 5 mm 3 8 inches to obtain the same mo...

Page 8: ...Work 9 Scrub Brushes check for wear and rotate D M W 10 Scrub Brush Motor s check for carbon brush wear 500 Hours B C W 11 Scrub Brush Motor s check gearboxes B D L 12 Brush Drive Plate Retainer Clips flex couplers C D M 13 Scrub Deck Skirts and Side Wheels 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 filte...

Page 9: ...8 FORM NO 56043056 ConvertaMAX 20 26 BA 550 650 BLANK PAGE revised 9 01 ...

Page 10: ...Squeegee 11 Battery Charger Connector 12 Battery Fuel Gauge 13 Hour Meter 14 Solution Switch ON Momentarily ON OFF 15 Brush Remove Switch 16 Solution Flow Control Knob 17 Speed Limit Control Knob 18 Master Key Switch 19 Auxiliary Circuit Breaker 20 Vacuum Motor Circuit Breaker 21 Brush Motor Circuit Breaker 22 Wheel Drive Circuit Breaker 23 Scrub Pressure Lever 24 Brush Deck 25 Operator Control Ha...

Page 11: ...10 FORM NO 56043056 ConvertaMAX 20 26 BA 550 650 3 5 6 8 9 11 13 16 18 19 20 22 21 23 7 1 KNOW YOUR MACHINE revised 9 01 ...

Page 12: ...t will stop after the machine is stationary for 1 second Solution Drain Hose Level Indicator 6 Used to empty the solution tank and show current level of solution in tank graduations are marked on the side of the solution tank next to the hose Recovery Drain Hose 7 Used to empty the recovery tank Squeegee Adjustment Knob 8 Used to adjust the tilt of the squeegee Turn knob clockwise to tilt the sque...

Page 13: ... trips repeatedly have the machine serviced Vacuum Motor Circuit Breaker 20 Provides overload protection to machine s vacuum motor If it trips it will pop out To reset wait one minute and press the button back in If any breaker trips repeatedly have the machine serviced Brush Motor Circuit Breaker 21 Provides overload protection to machine s brush motor s If it trips it will pop out To reset wait ...

Page 14: ... at 1 75 volts per cell and the alternate setting cuts out at 1 83 volts per cell The cutout level is selected by momentarily depressing the pushbutton switch located on the module circuit board Important Note See the Low Voltage Cutout Level Selection manual section in the Electrical System and follow the instructions for setting the low voltage cutout threshold DESCRIPTION OF THE BATTERY FUEL GA...

Page 15: ...spensed onto the floor The Knob A located on the control panel operates the Main Solution Valve B that controls the needed flow volume demanded by the scrub brushes The electrical solenoid valve L1 C and control panel mounted solution switch S2 start and stop the solution flow See Electrical Diagram During normal machine operation the S2 solution switch when turned ON works in conjunction with the...

Page 16: ...N Position For complete description of all callouts see Electrical System Wiring Diagram TROUBLESHOOTING GUIDE Problem Possible Cause Inadequate or no solution flow No solution in the tank Main solution flow control valve knob is in the off position Clogged solution filter valves and hoses Defective solution solenoid valve L1 Defective control panel solution switch S2 See Solenoid Troubleshooting ...

Page 17: ...inputwire ontheS2solution switch Testcontinuityof theBlk Yel 12 wiresfromtheK1 solenoidtotheS2 solutionswitch Repairorreplace ReplacetheS2 solutionswitch Checkfor24V Neg fromthe Yel BlkL1harness feedwiretoa Pos batterystandoff Checkfor24V Neg atthe Vio Blkinputwire ontheS2solution switch ReplacetheS2 solutionswitch CheckdiodeD2 forcontinuityin onedirectiononly Ifdiodechecks openreplacethe D2diode ...

Page 18: ...Yes L1 solenoid will not open when the S2 switch is in the momentary on position no solution flow See Figure 3 Check for the 24V input at the S2 solu tion switch Vio Blk wires Check for 24V Pos from the Vio S2 switch wire to a Neg battery standoff Replace the S2 solution switch Check for 24V Neg from the Blk S2 switch wire to a Pos battery standoff Repair or replace the Blk wire Repair or replace ...

Page 19: ...rom the Elbow Fitting F as shown 3 Loosen the G Hose Clamp and remove the H solution feed hose from the I solenoid valve barb 4 Loosen the solenoid valve mount anchor connector and then disconnect the valves wiring harness connector 5 Pull out from underneath the machine the combined valve and strainer assembly Make service repairs as required and re install in reverse order FRONT H I F E M D G FI...

Page 20: ...6324247 SOLUTION FLOW CONTROL VALVE REMOVAL 1 Drain the solution tank and also remove the squeegee tool from the machine this allows the needed room to work on the valve 2 See Figure 4 Loosen the Hose Clamp D and pull the Hose E off the valve elbow fitting F 3 Remove the Screw M that holds together both the water valve shaft arm and the solution valve arm 4 Separate the control arms and work the s...

Page 21: ...setting Note See the battery system section for instructions for selecting setting the two different thresholds wet cell lead acid or gel maintenance free Special Service Note On all the 24V and 36V machines a minimum recharge voltage of 2 09 volts per cell must be reached to allow the scrub brush and solution systems to reset function again A 24V battery pack must increase to a 25 1 volt minimum ...

Page 22: ...it double flashing Recharge battery pack the low voltage cutout is functioning Test the machine s battery pack voltage under load Is it less than 22 volts Voltage test reading is above 22 volts See the scrub brush system troubleshoot ing Symptom Two parts A B Part A The machine s low voltage cutout is functioning Check to see that the correct voltage cutout threshold setting has been selected batt...

Page 23: ...erminal Check for 24V at brush motor s M3 and M4 the model C 26 uses two motors Repair or replace the brush motor s See part B scrub brush control circuit troubleshooting Check continuity on both the 8 neg 16 pos wires to the M3 M4 brush motor s Repair or replace wiring SYMPTOM TWO Brush Motor s Don t Turn Note Do all testing with the key switch on brush switch closed scrub deck lowered and the dr...

Page 24: ...le Check for a Neg 24V at pin 9 on the A2 timer module Yes Yes Yes No No No Replace the K1 brush motor solenoid Repair or replace the Brn K1 coil wire Yes No No Yes Yes No No Yes Yes No Check for a Neg 24V at the Gra P1 wire on the A1 speed controller Replace the A1 speed controller Repair or replace the P1 controller output wire Replace the A2 timer module assembly Check for 24V at the Blk wire o...

Page 25: ...hootingstepsshownabovetesttheS6brushswitchwithanOhmmetertoconfirmanopen circuit Also check the switch for proper adjustment raised open lowered closed Special Service Note This will be a brief pulse not a continuous voltage Yes No Yes No Yes No Scrub brush auto removal function does not work See Figure 1 Check for 24V Neg at pin 10 found on the A2 timer module Note The S3 Switch must be activated ...

Page 26: ... 2 G Mount Pins from the upper scrub head lift linkage 7 Pull the scrub head forward 12 inches 30 cm to access the motor wiring terminal block 8 Removethemotorwiringattheterminalblockandthenpullthebrushheadassemblycompletelyfromthemachine Note SeeFigure4forthecorrectwiring for the single scrub brush motor FIGURE 2 SCRUB BRUSH MOTOR GEARBOX RE MOVAL CONVERTAMAX 20 BA 550 1 Follow steps 1 8 of the S...

Page 27: ... scrub brush motors MODEL CONVERTAMAX 26 BA 650 SCRUB BRUSH MOTOR GEARBOX REMOVAL 1 Follow steps 1 6 in the Model ConvertaMAX 26 BA 650 Scrub Deck Removal section 2 Turn the brush deck over top of the motors down 3 Remove the scrub brushes from the brush holders then markthelocationofthemotortothebrushdeckforproper re assembly 4 SeeFigure3 Removethe 3 U HexScrewsand 3 V Nuts from each Flexible Cou...

Page 28: ... Motor Left Brush Motor Without Jumper Plates WithJumper Plates Jumper Plates CWrotation fromshaft end CCWrotation fromshaft end CWrotation fromshaft end CCWrotation fromshaft end Negativeleadfromright motor Negativeleadfromleft motor Positiveleadfromright motor Negativeleadfromright motor Negativeleadfromleft motor Pos leadfromrt motor Right and left are identified as seen from the rear of the ma...

Page 29: ...age position B brush install position and C normal scrub position 3 With the key OFF scrub deck raised place scrub brush es underneath the drive disc s and lower deck for the automatic brush installation 4 With the brush switch mounted loosely position the switch on the corner of the switch striker plate as shown in figure B Note The switch is mounted with the roller not compressed and is in its n...

Page 30: ...in it s UP stored position 2 See Figure 6 Position the switch arm roller on the corner of the striker bracket as shown 3 Push the switch and roller down to compress the switch you will hear a click then tighten the mounting screws to secure the switch adjustment Note the switch is now properly adjusted for an open circuit brush motors Off function 4 Install scrub brush es lower the scrub deck turn...

Page 31: ...d air speed the heavier water falls to the bottom of the recovery tank Then at the same time the airflow continues throughthetank shutofffloat vacuumhose vacuummotorandisexhaustedoutofthevacuummotorhousing Nowastewatereveractuallymoves through the vacuum motor just clean air The vacuum system uses a shutoff float to prevent the tank from being overfilled and stops any water from being sucked into ...

Page 32: ...lve seals airtight TROUBLESHOOTING GUIDE Ifwaterflowsaroundtheendsofthesqueegeetool insteadofbeingpulledintothetool thevacuumsystemisnotworkingproperly Whenavacuum system performs poorly it is usually because of one of the following problems Vacuum Leak s Air flowing into the vacuum system past a bad gasket or leaky hose damaged tank or a leaky drain valve A vacuum leak below the water line will c...

Page 33: ...he blue wire output terminal on the K2 vac motor solenoid to a Neg battery standoff Check for 24V at the M1 vac motor Repair or replace the M1 vac motor See part B vac motor control circuit troubleshooting guide Repair or replace wiring to vac motor TROUBLESHOOTING GUIDE ELECTRICAL Possible Symptom 1 Vacuum motor will not run SYMPTOM ONE Note Do all testing with the master key switch ON vac switch...

Page 34: ...e 2 Check for 24V at the Red Wht and Blk wires on the K2 vac motor solenoid small terminals Check for 24V at the Pos K2 Red Wht solenoid coil wire to a Neg battery standoff Replace the K2 vac motor solenoid Check for 24V at the Neg K2 Blk solenoid coil wire to a Pos battery standoff Check for 24V at Vio wire on the S4 vac switch to a Neg battery standoff Repair or replace the Blk wire back to the ...

Page 35: ...e lid and lay it to the side remove the two A Screws and pull the Float Duct B and float cage assembly C from vac motor spacer D 2 Snap apart the two float cage halves C and flush clean the float ball and cage pieces 3 Inspect the Gasket E and clean any debris from the inside of the float duct housing Then re install all parts in reverse order FIGURE 3 revised 9 01 ...

Page 36: ...he hose clamp for the tank drain hose J and pull the hose free 4 Remove the Tank End Panel K 3 screws and remove the Squeegee Hose L from the tank connection 5 Supportthetankandremovethe 4 screwsfromthehingethatattachesthetanktothetopofthesolutiontankedgeandpull thetankfreefromthemachine VACUUM SWITCH REPLACEMENT AND ADJUSTMENT 1 With the key switch OFF remove the back Electrical Panel N secured w...

Page 37: ...or Replace the Front Squeegee Blade 1 Raise the squeegee tool off the floor then loosen the 2 Thumb Nuts E on top of the squeegee and remove the squeegee tool from the mount 2 Remove all the Hex Nuts F that hold the Front Blade G in place then remove tension strap and blade 3 The squeegee blade has 4 working edges Turn the blade so a clean undamaged edge points toward the front of the machine Repl...

Page 38: ...56 ConvertaMAX 20 26 BA 550 650 37 SQUEEGEE SYSTEM FRONT H F B C C E A B E D G FIGURE 1 FIGURE 2 G D Note the 20 squeegee tool is shown the 26 squeegee tool is similar in adjustment and blade replacement revised 9 01 ...

Page 39: ...theT1orB controllerterminal Brn Blkwire TheblackwirefromthebatteryNegative standoff supplies the Neg 24V power input to the T2 or B controller terminal Moving the 5K Ohm R2 speed pot off its centered balanced neutral setting activates the operator input to the speed control Forward or reverse movement of the drive paddle rotates the pot shaft and its variable resistance changes causing internal vo...

Page 40: ... ON auto dead man return to neutral components Repair or replace needed parts The R2 drive pot is out of adjustment Reset to neutral the 5000 Ohm drive paddle potentiometer During normal machine transporting with the 5K The R1 25 000 Ohm speed limiting pot wiper is either open drive paddle pot activated the operator also adjusts where the machine runs at minimum speed or the pot wiper the control ...

Page 41: ...d in the lower rear of the machine frame between the caster wheels No Fwd or Rev wheel drive see Figure 1 1 Try resetting the F3 drive motor circuit breaker 30 Amp 2 Still no drive check the F3 breakers continuity Replace the F3 30 Amp wheel drive circuit breaker No Check for 24V at the A1 speed controllers Battery Pos Battery Neg terminals Repair or replace the battery input wiring to the A1 spee...

Page 42: ...heck the total resistance of the drive paddle R2 pot Remove wires and measure across the two outside terminals should read 4500 5500 Ohms Test shows an open infinity replace the R2 potentiometer with P N 56397029 Check the total resistance of the speed limit R1 pot Remove wires and measure across the two outside terminals should read approximately 25000 Ohms Separate the motor wiring harness disco...

Page 43: ... Disconnect the drive motor wiring connector 4 See Figure 4 Loosen the Lock Nut A and back out Bolt B several turns to loosen the drive chain tension 5 Remove the retainer clip from the chains master link separate and remove the chain from the sprockets 6 Remove both the Setscrews D from the Drive Motor Sprocket E then remove the sprocket from the motor shaft 7 Support the Drive Motor F then remov...

Page 44: ...FORM NO 56043056 ConvertaMAX 20 26 BA 550 650 43 WHEEL DRIVE SYSTEM J I K E D C B A G F FRONT H FIGURE 4 revised 9 01 ...

Page 45: ...nd pull the rear cover to turn the shaft in both directions The readings should be approximately half the total resistance 2500 ohms towards 5000 ohms and 2500 ohms towards 0 ohms Example A total resistance of pot 4840 ohms 1 high 3 low test connections Example B test middle connection 2 wiper and outside rear 3 low Fwd reading 2420 ohms to 4700 ohms Rev 2420 ohms to 230 ohms 5 Testing Summary The...

Page 46: ...e shaft to approximately 2300 ohms 3 Observe the molded rib inside the Fork Q position it to align with the slot on the end of the pot shaft then assemble together and tighten the P Screw 4 Then without turning the pot shaft thread the anchor nut to seat the pot to its mount bracket 5 Reconnect the ohmmeter test leads to the pot wiper and low terminal connections and adjust turn the pot to obtain ...

Page 47: ...est connections Example B test middle connection 2 wiper and outside rear 3 low Fwd reading 2420 ohms to 4700 ohms Rev 2420 ohms to 230 ohms 5 Testing Summary The above tests are to show the increase and decrease of the pot through its working range If you do not get similar readings replace the Potentiometer O Potentiometer Removal 6 See Figure 10 Loosen the pot shaft anchor nut and unthread it t...

Page 48: ... at the battery pack before servicing Testing the 25K Potentiometer Note The potentiometer pot doesn t have to be removed from the instrument panel to test FIGURE 11 1 See Figure 11 Remove the Setscrew R if used from the Solution Control Knob S then pull the knob off from the water valve shaft 2 Remove the instrument panel to access the speed adjustment pot T secured with 4 item U Screws as shown ...

Page 49: ... to touch more than one battery terminal at a time CAUTION Electrical components in this machine can be severely damaged if the batteries are not installed and connected properly Batteries should be installed by Nilfisk Advance or by a qualified electrician 1 Remove the batteries from their shipping crate and carefully inspect them for cracks or other damage If damage is evident contact the carrie...

Page 50: ...board Observe the LED indicator light on the circuit board which gives the following indications Light OFF No battery power key is off or module not functioning Light ON Slow Flash Alternate maintenance free battery voltage threshold selected 22 volt setting Light ON Fast Flash Standard lead acid battery voltage threshold selected 21 volt setting Light On Continuous Module is in low voltage cutout...

Page 51: ...e batteries Do not add acid to batteries Keep the Batteries Charged Weekly Batteries should be charged each time that a machine is used for more than 1 hour Machine operators should open the battery compartment cover for charging to avoid a concentrated build up of hydrogen gas Operators should follow the instructions provided with theirspecificbatterycharger todeterminehowlongthebatteriesshouldbe...

Page 52: ...t Breaker 10 Amp Auxiliary 10 Contactor 24 VDC Vacuum Motor 11 Contactor 24V SPDT Brush Motor 12 Charge Connector Assy 13 Potentiometer 25K 14 Potentiometer 5K 15 Switch Rocker SPST Brush Remove 16 Switch Vacuum 17 Switch Toggle Main Power 18 Switch Rocker Solution 19 Switch Interlock 20 Switch Brush 21 Motor DC 1 2 HP Wheel Drive 22 Motor 20 model Brush 23 Motor 26 model Brush 24 Motor Assembly V...

Page 53: ...S3 1 Switch Rocker SPST Brush Remove S4 1 Switch Vacuum S5 1 Switch Interlock S6 1 Switch Brush Terminal Identification of A2 Timer Module Assembly 1 Relay Common 2 Pad Contactor Coil 3 Pad Contactor Coil 4 Speed Control Input 5 Battery 6 Battery 7 Relay Normally Open 8 Relay Normally Closed 9 Brush Switch Input 10 Remove Switch Input 11 Battery 12 Battery revised 7 02 NO C VIO VIO RED 25 RED RED ...

Page 54: ...ON SWITCH BRUSH OFF SWITCH MAXIMUM THROTTLE POTENTIOMETER R1 S3 CONTROL MODULE A2 BLK 0I B BRN WHT 19A B VIO BLK 70B B VIO BLK 70D A GRN 5B A GRN 5B B GRN 5A B WHT 9A A BATTERY 24 Vdc VACUUM MOTOR STAND OFF STAND OFF WHEEL DRIVE MOTOR M4 26 ONLY SCRUB BRUSH MOTORS BRUSH MOTOR SWITCH INTERLOCK SWITCH VACUUM SWITCH THROTTLE POTENTIOMETER RED BLU 26A A WHT YEL 94A A BRN BLK 10A B BLK 0A B GRA 8A A VI...

Page 55: ...r Lorong 19 1A 46300 Petaling Jaya Selangor Darul Ehsan 03 7568188 03 7568189 03 7568388 Fax03 7566828 NEDERLAND Nilfisk Advance B V Flevolaan 7 Postbus 341 1380 AH Weesp 0294 462121 Fax 0294 430053 NEW ZEALAND Nilfisk Advance Limited 477 Great South Road Penrose Auckland 09 525 0092 Fax 09 525 6440 SCHWEIZ SUISSE Nilfisk Advance AG Ringstrasse 19 9533 Kirchberg Wil 719 23 52 83 Fax 719 23 84 44 S...

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