Nilfisk-Advance GD 5 BATTERY User manual

ENGLISH
GD 5 Battery
Service manual
26.06.2017
GD 5 Battery variants: EU, UK, CH, AUS, CN, US.

2
2
Index
A. Preface 3
B. Technical data 5
C. Troubleshooting 6
D. Service / repair 7
E. Spare parts 16
F. Electrical diagram 20

3
3 A
Preface
In this manual you will find
the essentials you need to
know when repairing the GD5
Battery.
When carrying out repairs,
make sure you have a suitable
workbench or the like with the
necessary tools and power
supply available.
If you determine an error in
operation, be sure to refer the
customer to the user manual.
A fault in the equipment
can have a number of causes.
Chapter C Troubleshooting
will help you here.
Use the illustrated spare
parts lists for your repairs.
These show you the location
of the individual parts and the
sequence in which they are
assembled.
Read the technical infor-
mation sheets. These will tell
you about any technical modi-
fications made after publica-
tion of this repair manual.
Technical information sheets
are a supplement to the spare
parts list until a follow-on publi-
cation.
Repair manuals and technical
information sheets should be
available at the site where re-
pairs are carried out.
It is not permitted to give the
repair manuals to third parties.
Use original Nilsk spare
parts only!
Safety instructions marked
with this symbol in this man-
ual must be observed to
prevent danger to persons.
This symbol is used to
mark safety instructions
that must be observed to
prevent damage to the
equipment and degradation
of performance.
This symbol indicates tips
and instructions to simplify
work and to ensure safe
operation.
Symbols used to mark
instructions


4
4 A
Safety issues
Observe national safety
directives and regulations
for the electrical engineer-
ing trade, in particular:
IEC 60335-2-69
EN 60335-2-69
DIN VDE 105 part 1:
operation of electrical
power installations.
DIN VDE 0701/0702:
repair, modification and
testing of electrical installa-
tions.
Before starting the equip-
ment, be sure to read the
accompanying user
manual, and keep it close
as reference.
The equipment should
only be used by persons
who have been instructed
in its use and are author-
ized to do so.
Repairs should only be made
by someone who has re-
ceived proper instrucons
for the job or who is a quali-
ed electrician
WARNING:
The upper secon of the ma-
chine contains live compo-
nents. Contact with live
components leads to serious
or even fatal injuries.
Always disconnect the mains
plug before disassembly.
For your own safety
ESD (electrostac discharge)
Observe the following ESD precautions before any
repair of or near electronic parts:
• Touch the protective conductor to discharge your own body.
• Possibly wear an anti-static wrist strap.
• Use a conducting floor or tabletop.
• Never touch a circuit board or electronic components - always hold them by the
plastic or insulation.
• Transport electronic parts in conductive packaging (e.g. special ESD packages).


5
5 B
Technical data
GD 5 Battery specifications - all variants

6
6 C
Troubleshooting
Check:
- Is the battery working correctly (i.e. no
yellow or red LED on)?
- Is there power on the battery (light in
green LED when pushing battery button)?
Is power (≥30V) coming through
the battery connector?
Connect the motor directly to the
battery connector on the PCB.
Is motor running?
Yes
Yes
Yes
No
No
No
Machine does not start
Yes
Replace motor unit.
Check connections and
replace PCB if needed.
Check if complete machine
is working correctly.
No
Job done!! 
Yes
If the machine does start but
it is not possible to switch
between eco and power
boost setting test the re-
sistance on the switch.
If switch is ok the PCB ne-
eds to be replaced.
TIP: Use a Multimeter to
measure voltage and
ohm.
Is adequate resistance present on
switch (open state: ∞Ω; closed
state: <10Ω)?
Yes
No Replace switch + cord.
Is adequate resistance present on
NTC (50KΩ-150KΩ)?
NOTE:
Is power
(≥30V)
present
at the
battery?
Replace
battery.
Yes
Does battery connector
and cable appear in
good condition?
Replace
battery
connector.
No
No
Yes
Check connections and
replace PCB if needed.

7
7
D
1. Change motor unit 9
0. Disassembly 8
3. Change PCB 13
Service / repair
2. Change switch + cord 12
4. Change battery connector 14
5. Change battery lock 15

8
8
D.0
Disassembly
WARNING: The electric section of the machine
contains live components.
Always disconnect the battery before disassembly.
2
1
3Loosen the on/off switch to not be
connected to the harness; use a
TX10 bit (fig.1).
Unscrew the harness (fig.2).
Unscrew and remove the backco-
ver (fig.3)
TIP: Unless otherwise
stated a TX20 bit is nee-
ded for the screws.

9
9
D.1
Change motor unit
Disassemble the unit following
guide in previous section D.0.
Unscrew the cable relief (fig.1) and
disconnect the motor wires from the
PCB (fig.2+3).
1
23
WARNING: The electric section of the machine
contains live components.
Always disconnect the battery before disassembly.

10
10
D.1
Change motor unit
Loosen the latches fixing the motor
unit (fig.4).
Unscrew and remove the outer co-
ver (fig.5) and the motor cover
(fig.6).
Make notice of how the motor is
turned.
4
56
WARNING: The electric section of the machine
contains live components.
Always disconnect the battery before disassembly.

11
11
D.1
Change motor unit
Unscrew the cable relief (fig.7). Make notice of
the cable position in the cable guide and pull
out the cable.
Assemble the machine backwards. Take spe-
cial notice that the motor housing is placed cor-
rectly (fig.8).
7
8
It may be more easy
to put the motor co-
ver back on if the ex-
haust filter is taken
off. Remember to put
it back in place.
WARNING: The electric section of the machine
contains live components.
Always disconnect the battery before disassembly.

12
12
D.2
Change switch + cord
1
Disassemble the unit following guide in previous section D.0.
Unscrew the cable relief (fig.1) and disconnect the switch wires from the
PCB (fig.2).
Carefully pull out the cord and replace it.
Reassemble the machine backwards.
2
WARNING: The electric section of the machine
contains live components.
Always disconnect the battery before disassembly.

13
13
D.3
Change PCB
1
Disassemble the unit following guide in previous section D.0.
Making good notice of how the wires are connected to the PCB disconnect
all wires and unscrew the PCB; use a TX10 bit (fig.1).
Change the PCB and repeat the process backwards to assemble the ma-
chine.
WARNING: The electric section of the machine
contains live components.
Always disconnect the battery before disassembly.

14
14
D.4
Change battery connector
Disassemble the unit following guide
in previous section D.0.
Unscrew the brackets holding the
battery connector (fig.1).
Disconnect the wires from the battery
connector on the PCB (fig.2 + 3).
Replace the battery connector and
reassemble the machine.
1
2
3
WARNING: The electric section of the machine
contains live components.
Always disconnect the battery before disassembly.

15
15
D.5
Change battery lock
1Disassemble the unit following guide
in previous section D.0.
Unscrew the battery lock (fig.1).
Change the battery lock and reas-
semble the machine.
WARNING: The electric section of the machine
contains live components.
Always disconnect the battery before disassembly.

16
16
E
Spare parts
Cassette and electronics

17
17
E
Spare parts
Motor parts

18
18
E
Spare parts
Container parts

19
19
E
Spare parts
Harness

20
20
F
Electrical diagram
GD5 Battery wiring diagram