Nilfisk-Advance Advolution 2710 Service Manual Download Page 1

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7/06 revised 6/08 FORM NO. 56043107

Advolution

™

2710

UHR 70-1700

Service Manual

Advance Models: 56422000, 56422002

Nil

sk Model: 56422001

Summary of Contents for Advolution 2710

Page 1: ...7 06 revised 6 08 FORM NO 56043107 Advolution 2710 UHR 70 1700 Service Manual Advance Models 56422000 56422002 Nilfisk Model 56422001 ...

Page 2: ... DRIVE DECK LEVEL ADJUSTMENT 18 INSTALLATION OF THE BURNISHING PAD 19 INSTALLATION OF THE DUST COLLECTION BAG 20 TROUBLESHOOTING GUIDE ELECTRICAL 21 WHEEL DRIVE SYSTEM 25 GENERAL FUNCTIONAL OVERVIEW 25 DRIVE MOTOR SYSTEM CONTROLLER FUNCTION OVERVIEW 25 DRIVE MODE SELECTION OPERATION OVERVIEW 25 WHEEL DRIVE TROUBLESHOOTING GUIDE 28 WHEEL DRIVE ASSEMBLY REMOVAL 30 WHEEL DRIVE MOTOR REMOVAL 31 DRIVE ...

Page 3: ... SPEED CONTROLLER 47 PROGRAMMING VEHICLE SPEED CHANGES 47 FUNCTIONAL OVERVIEW OF MAIN CONTROL BOARD 48 MAIN CONTROLLER ERROR CODES 48 ADVOLUTION PROGRAMMING MODES 49 FAULT RECALL MODE REVISION DISPLAY 49 SERVICE TEST MODE 49 STATUS DISPLAY 50 OUTPUT CONTROLS 50 HORN SWITCH 50 PAD SWITCH 50 LOW VOLTAGE CUTOUT THRESHOLD SELECTION MODE 51 FAULT DETECTION ENABLE DISABLE MODE 51 PAD PRESSURE ADJUSTMENT...

Page 4: ... the space below to note the Model and Serial Number of your machine for future reference MODEL ________________________________________________ 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 All access doors and covers are secured tape and strap as ...

Page 5: ...s or operate in areas where flammable liquids exist Do not clean this machine with a pressure washer This machine is not approved for use on public paths or roads Do not put any object into openings Do not use with any opening blocked keep free of dust lint hair and anything that may reduce air flow Do not use on surfaces having a gradient exceeding that marked on the machine When operating this m...

Page 6: ... 72 PSI Rear Left Wheel Pressure w six 395 AH batteries 105 PSI Average Coverage Rate 41 580 sq ft 3 862m2 per hour Average Run Time 3 hours per battery charge Batteries Recommended Six 6 volt 395 A H 20 hour rate 120 lbs 54 4 kg each Battery Compartment Size 25 inches 63 50 cm long 22 5 inches 57 15 cm wide 17 50 inches 44 45 cm high Battery Charger Recommendation 25 or 36 Amp output 36 volt char...

Page 7: ...FORM NO 56043107 Advolution 2710 UHR 70 1700 7 TECHNICAL SPECIFICATIONS ...

Page 8: ...ar or after 500 operating hours The original new length of each carbon brush is 1 3 32 27 76mm on all 36 volt machine models brush and wheel drive motors All motors Replace carbon brushes when shorter than 3 8 9 5mm to obtain the same motor efficiency as new brushes IMPORTANT Motor damage resulting from failure to service the carbon brushes is not covered under warranty See the Limited Warranty St...

Page 9: ...Headlight Safety Beacon Active Dust Control System Etc 11 Battery Charger auto turn ON OFF 12 Main Control Board Special Program Options Reference SVR Manual 56043107 and check all applicable program settings Examples stored error fault codes diagnostic SVR test mode pad pressure settings etc A Ref VISUAL INSPECTION ITEMS Comments OK Defect Codes circle Does Not Work 13 Pad Motor Carbon Brushes ch...

Page 10: ...ust Control Shroud 3 Burnishing Pad 4 Pad Retainer 5 Dust Collection Bag 6 Machine Tie Down 7 Battery Connector Assembly 8 FWD REV Drive Pedal 9 Tilt Steering Wheel Adjuster 10 Emergency Power Disconnect 11 Steering Wheel 12 Operator s Seat W Safety Switch 13 Battery Compartment Cover 14 Drive Steer Wheel 15 Circuit Breakers 40 Amp Wheel Drive 5 Amp Control Circuit 16 Deck Latch 17 I O Panel Indic...

Page 11: ...ution 2710 UHR 70 1700 11 KNOW YOUR MACHINE AA Master Key Switch BB Battery Condition Indicator CC Hour Meter Error Display DD Pad Drive Indicator Light EE Pad Drive Raise Lower Switch FF Horn Indicator Light GG Horn Switch ...

Page 12: ...ontrol system default parameters Service Note Have a qualified Service Technician reference the Service Manual for explanations about Error Codes and Control Fault Parameter Changes A description of Error Codes can be found in the electrical section of this manual Pad Drive Indicator Light DD Indicator will be blank off when deck is in the raised position Indicator will be light Green when lowerin...

Page 13: ...BRN GRN BLK GRN BLK ORN BLK ORN BLK GRA BLK VIO BLK GRA WHT BRN WHT ORN BLU BLK WHT BLU WHT RED BLK BLK YEL RED BLK BLK RED WHT BLK WHT VIO RED BLK BLK BLK GRA BLU PINK ORN WHT BLU BLK BRN YEL WHT YEL WHT GRN YEL WHT ORN J2 4 ACC J3 1 B J3 9 SEAT SW J3 2 KEY SW J3 10 F R MODE J2 2 STATUS J3 4 I O PANEL B J2 10 B J3 8 SENSE J3 3 ACT 1 J2 12 ACT 2 J2 6 HORN J2 7 HORN J2 1 J2 11 PAD CONT J2 5 PAD CON...

Page 14: ...p position will also make it easier less tension 3 Attach the Advance actuator adapter cord P N 56407502 to the deck Actuator E and lower deck This step is done to gain service access to the motor wiring and lift linkage mount hardware 4 Disconnect the deck s Safety Switch G at its harness connector 5 Remove the 2 pad motor wires NOTE Mark the Red Black wire locations Service Tip Measure the heigh...

Page 15: ...FORM NO 56043107 Advolution 2710 UHR 70 1700 15 FIGURE 1 ...

Page 16: ...ve the 4 Screws E and the Dust Shroud F 6 Remove the 4 Screws G that fasten the motor to the deck plate Lift the remaining Deck Assembly H off the Motor I to complete its removal NOTE Mark motor terminal location for reassembly 7 Follow the above steps in reverse order to reinstall the Pad Drive Motor FIGURE 2 DUST SHROUD REMOVAL 1 See Figure 2 Remove the Dust Bag A 2 Remove the Pad Retainer B pad...

Page 17: ...oud B 2 To install start at the rear of the Shroud B with one end of the new Edging A so that the seam is hidden Push U channel onto Shroud B work edging assembly around Shroud B 3 Check that Edging A U channel is firmly in place all around Shroud B NOTE Pinch the U channel every 3 to 4 inches with a vise grips to ensure it is securely fastened to the shroud FIGURE 3 ...

Page 18: ...ft to Right Pad Contact Adjustment See Figure 4 1 Loosen the 2 Nuts A on the Adjustable Bracket B 2 Turn the 2 Lock Nuts C on the Carriage Screw D either down to increase or up to decrease Dimension X Decreasing Dimension X will increase the pad pressure at the 3 O clock position Increasing Dimension X will increase the pad pressure at the 9 O clock position FIGURE 4 NOTE As a general rule the mea...

Page 19: ...machine Front to Back Pad Contact Adjustment See Figure 5 1 Loosen Lock Nut A and turn the Adjustment Screw B clockwise to increase or counter clockwise to decrease Dimension X Increasing Dimension X will increase the pad pressure to the front of the pad assembly at the 12 O clock position Decreasing Dimension X will increase the pad pressure to the rear of the pad assembly at the 6 O clock positi...

Page 20: ...d 2 and remove the Pad Retainer 4 from the flexible pad holder assembly NOTE Grip the retainer firmly and turn clockwise to the right as the retainer uses a Left Hand thread 3 Select a 27 inch 68 cm Dia Burnishing Pad A See your local Nilfisk Advance Distributor for a complete selection of pads and accessories 4 Insert the plastic Pad Retainer 4 into the center of the Pad A Then reinstall by turni...

Page 21: ...hine NOTE Never operate the Advolution 2710 UHR 70 1700 without a Dust Collection Bag 5 or the optional Active Dust Control Kit 21 PN56422083 installed Failure to do so will allow the burnishing dust to become airborne The Active Dust Control Kit 21 is operational when ever the vacuum switch on the vacuum is in the ON position the Master Key Switch A is ON the Pad Drive Deck 1 is down and the FWD ...

Page 22: ...SHING SYSTEM TROUBLESHOOTING GUIDE ELECTRICAL Symptom Burnishing deck will not raise or lower Part A Chart 1 Control Circuit Note Do all testing with key switch on and seat switch activated Have Pad R L switch activated and deck in the burnishing position ...

Page 23: ... Chart 2 Control Circuit Note Do all testing with key switch on and seat switch activated Have Pad R L switch activated and deck in the burnishing position Symptom Burnishing deck will not raise or lower Part B Load Circuit Note Do all testing with key switch on and seat switch activated Have Pad R L switch activated and deck in the burnishing position ...

Page 24: ...SHING SYSTEM TROUBLESHOOTING GUIDE ELECTRICAL Symptom Pad drive motor will not run Part A Control Circuit Note Do all testing with key switch on and seat switch activated Have Pad R L switch activated and deck in the burnishing position and drive engaged ...

Page 25: ...y switch on and seat switch activated Have Pad R L switch activated and deck in burnishing ready position and drive pedal engaged BURNISHING SYSTEM TROUBLESHOOTING GUIDE ELECTRICAL Symptom Active dust control not working Note Do all testing with the key switch ON emergency switch closed seat switch activated pad switch activated drive pedal engaged and the vac motor switch turned ON ...

Page 26: ...tery voltage On and Off PWM which varies the motor speed KSI Key Switch Input PWM Pulse Width Modulation also called chopping is a technique that switches battery voltage to the motor ON and OFF very quickly thereby controlling the speed of the motor DRIVE MODE SELECTION OPERATION OVERVIEW The A1 speed Controller allows operation in two distinct modes mode 1 M1 mode 2 M2 Mode 1 M1 is the transport...

Page 27: ...FORM NO 56043107 Advolution 2710 UHR 70 1700 27 WHEEL DRIVE SYSTEM FIGURE 2 ...

Page 28: ...00 WHEEL DRIVE SYSTEM R1 Voltage Values 0 2 5V Reverse 2 5 5V Forward This drawing shows additional controller input circuit detail The R1 pot is shown in the neutral position Resistance is measured between pot low and pot wiper FIGURE 3 FIGURE 4 ...

Page 29: ...mit pot input connection Note in this application it is tied to the pot high pin 3 WHEEL DRIVE TROUBLESHOOTING GUIDE Problem Possible Cause Wheel drive motor will not run in forward and reverse Batteries need charging low battery voltage recharge batteries Wheel Drive Motor Circuit Breaker CB2 tripped reset 40A circuit breaker Control Circuit Breaker CB1 tripped reset 5A circuit breaker Y1 parking...

Page 30: ...ove the master link and separate the chain from the Steering Shaft Sprocket F NOTE Reassemble the master link clip back onto the end of the chain so that it is not lost 7 Remove the Steering Spindle Retainer Nut B with the use of a 1 7 16 inch socket WARNING Never work under machine without safety stands or blocking to support the machine 8 Safely jack up the front of the machine 16 18 inches 40 4...

Page 31: ...3 Remove the 4 Socket Head Cap Screws A that secure the electric drive motor to the motor housing casting 4 Use a hard piece of wood or a brass drift punch to tap the motor mounting flange 3 notched locations B to loosen 5 Grip the motor brake end bell C and pull the motor up and out of its housing 6 Inspect the 4 carbon brushes springs A new carbon brush measures 3 4 If less than 1 4 replace NOTE...

Page 32: ...r wheels 2 See Figure 7 Using a 5mm hex key wrench remove the 4 Screws A that secure the Tire Hub Assembly B to the gearbox out put flange 3 Safely lift or jack the front of the machine 1 2 inches 25 50 mm and block both sides of the machine body in front of the burnishing deck 4 While rotating the Tire Hub Assembly B tap on the tire with a block of wood or dead blow hammer until tire hub separate...

Page 33: ...Disconnect battery and block rear wheels so that the machine will not roll when the brake is removed 2 See Figure 8 Remove the 2 Nuts A then the Brake Cover B 3 Remove brake wiring at motor terminal block secured by 2 hex nuts 4 Remove the 3 Screws C using a 4mm socket key wrench 5 Separate the 3 parts that make up the brake assembly items D Electromagnetic Housing E Brake Rotor and F Brake Backin...

Page 34: ... front of the machine This is done to separate the Chain B from the Steer Sprocket C Service Note Use a 17mm socket with 3 extension to loosen screws 3 Remove both Master Links D that secure the chain to the steer plate then remove the Chain B from the machine 4 Reassemble parts in reverse order and adjust chain tension so that there is about 3 16 1 4 4 7 6 4mm total deflection with moderate press...

Page 35: ...r located in the operator s compartment POTENTIOMETER INSTALLATION AND ADJUSTMENT WARNING The adjustment of the potentiometer is to set the drive pedal for a neutral drive motor operation If the pot is not adjusted properly the machine will creep in either FWD or REV 1 See Figure 10 Install the pot into the Mount Housing J and tighten the attachment nut 2 Connect together loosely both the Link Rod...

Page 36: ...36 FORM NO 56043107 Advolution 2710 UHR 70 1700 FIGURE 10 FIGURE 11 ...

Page 37: ...w back into the pedal frame slot to increase spring tension and eliminate pedal free play Then tighten the screw nut being careful not to pull on the linkage connection to the pot shaft and disturb move its neutral setting To Replace Pedal or Spring 3 Position the torsion spring ends O P as shown This is with the Bushing N and Screw L not installed 4 Place the bushing inside the pedal channel pilo...

Page 38: ...38 FORM NO 56043107 Advolution 2710 UHR 70 1700 WHEEL DRIVE SYSTEM TROUBLESHOOTING GUIDE ELECTRICAL Symptom Wheel drive motor will not run Part A load circuit ...

Page 39: ...FORM NO 56043107 Advolution 2710 UHR 70 1700 39 WHEEL DRIVE SYSTEM TROUBLESHOOTING GUIDE ELECTRICAL Symptom Wheel drive motor will not run Part B control circuit ...

Page 40: ... the negative ground cable first when replacing batteries to prevent sparks ALWAYS connect the negative cable last when installing batteries CAUTION Electrical components in this machine can be severely damaged if the batteries are not installed and connected properly Nilfisk Advance a qualified electrician or the battery manufacturer should install batteries 1 Remove the batteries from their ship...

Page 41: ... batteries CAUTION Acid can spill onto the floor if the batteries are overfilled Tighten the vent caps Wash the tops of the batteries with a solution of baking soda and water 2 tablespoons of baking soda to 1 liter of water Service Note There is a drain plug in the bottom of the battery compartment BATTERY MAINTENANCE Proper maintenance of electric vehicle batteries can greatly extend their life W...

Page 42: ...h the pad drive motor running The battery with the dead cell will read 1 or 2 volts lower than the other batteries in the system If the batteries in the machine are more than 1 year old it s usually best to replace the whole set rather than replacing just one battery BATTERY SPECIFICATIONS Use a combination of multiple 2 volt cell units to construct a 36 Volt DC battery pack system Nilfisk Advance...

Page 43: ...ad lift actuator motor first install the Compression Spring B then slide on the Spring Housing Guide A followed by the Mounting Hardware C 2 Hold onto the spring housing assembly and press the rocker switch to run the drive motor and retract the spring housing towards the motor housing its IN limit 3 Measure the position of the spring housing assembly on the actuator shaft Manually turn the spring...

Page 44: ...44 FORM NO 56043107 Advolution 2710 UHR 70 1700 FIGURE 5 ...

Page 45: ... Connect the programmer put it in diagnostic mode and read the displayed fault information In this example the display shows No Faults Present indicating that the controller has not detected anything out of the norm 3 Put the programmer in test mode and observe the status of inputs and outputs in the forward direction In this example the display shows that the forward input did not activate when f...

Page 46: ...age 2 KSI and throttle turned on at same time 3 4 000 0000 brake Off fault 1 Electromagnetic brake driver open 2 Electromagnetic brake coil shorted 3 5 000 00000 HPD High Pedal Disable fault 1 Improper sequence of throttle and KSI push or inhibit inputs 2 Misadjusted throttle pot 4 1 0000 O current sense fault 1 Short in motor or in motor wiring 2 Controller failure 4 2 0000 00 motor voltage fault...

Page 47: ...cycle the key switch to clear the fault code 4 Move the drive pedal to operate the throttle The motor should begin to turn in the selected direction If it does not verify the wiring to the controller and the motor The motor should run proportionally faster with increasing throttle If not refer to the DIAGNOSTICS section of this chapter Table 1 5 If you are using a programmer put it into the test m...

Page 48: ...eacon accessory systems wiring and components SVR Tip Disconnect each component separately and observe if the code goes away then check that specific component Repair or replace defective part or wiring Err 03 Speed control System Faults 1 Check for a tripped 40Amp CB2 breaker and reset if needed 2 Next investigate the reason for the mechanical overload Examples prolonged ramp climbing exceeding t...

Page 49: ...ch 12 If the pad down switch was pressed the display will now show NONE 13 To exit this mode turn the key switch off Service Test Mode To assist in the troubleshooting and servicing of the electrical system and related components on the Advolution burnishers a special test mode which allows independent control of the various outputs and monitoring of the various inputs has been incorporated To ent...

Page 50: ...ent flow through the pad motor or the pad motor output is on and there is no current flow through pad motor Pad Switch This switch is used to control the output to the pad lift actuator Pressing and releasing this switch will cycle the actuator output through 4 states These are 1 output off direction up 2 output on direction down 3 output off direction down 4 output on direction up NOTE THE ACTUAT...

Page 51: ...e troubleshooting the system difficult This option will allow service personnel to disable some of the fault detection checks to facilitate troubleshooting This will not disable the over current protection on any of the systems To enable or disable fault checking 1 Press and hold the horn switch while turning the key switch on 2 Continue holding the horn switch until the status display is scrollin...

Page 52: ...al in the reverse direction will activate the alarm so that the appropriate sound level can be selected 1 Press and hold the horn switch while turning the key switch on 2 Continue holding the horn switch until the status display is scrolling the word SELECT 3 Release the horn switch 4 Press and release the horn switch five times The status display should now be scrolling HORN R 5 Press and release...

Page 53: ...ymptom No machine functions work control circuit Machines without onboard battery charger Note Do all testing with the 5 amp circuit breaker reset key switch on emergency switch closed and seat switch activated Check condition of batteries cables and make sure battery pack is fully charged ...

Page 54: ...0 UHR 70 1700 ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE Symptom No machine functions work control circuit Machines with onboard battery charger Note The onboard charger must be unplugged from the AC wall outlet for the machine to operate ...

Page 55: ...on Drive F1 Fuse 150 Amp H1 Horn Back Up Alarm K1 Contactor 36V Pad Motor LP5 Headlight Optional LP6 Beacon Warning Optional M1 Motor Drive Wheel M2 Motor Pad Drive M3 Actuator Motor M4 Dust Control Vac Motor Optional R1 Potentiometer 5K S1 Switch Key Main S2 Switch Seat S3 Sensor Proximity S10 Disconnect Emergency COMPONENT LOCATION ELECTRICAL SYSTEM ...

Page 56: ... 1 J2 11 PAD CONT J2 5 PAD CONT J3 7 INTERLOCK B J3 5 INTERLOCK CONTROL BOX ON BOARD BATTERY CHARGER OPTIONAL 56015612 REV E B J2 9 J4 6 PAD SW J4 1 SDA J4 2 SCL J4 3 5 V J4 5 B J4 4 HORN SW PAD SW J1 6 B J1 5 5 V J1 3 SCL J1 2 SDA J1 1 HORN SW J1 4 REV J3 6 M M2 MOTOR PAD M M2 MOTOR PAD K1 K1 1 2 PLUG AC MALE PLUG AC MALE S5 SW SPST S5 SW SPST 1 2 CB2 CIRCUIT BREAKER 40 AMP CB2 CIRCUIT BREAKER 40...

Page 57: ...BLU BLK 20 1 BLK GRA 20 1 BLK 16 3 BLK 16 3 ORN 18 2 RED WHT 18 3 YEL WHT 20 1 YEL WHT 20 1 GRN 18 1 WHT ORN 18 1 YEL 18 1 ON BOARD BATTERY CHARGER OPTIONAL NOTE WHEN ON BOARD BATTERY CHARGER IS NOT USED CONNECT X4 TO X5 56015613 REV E FERRITE FERRITE M M3 MOTOR ACTUATOR M M3 MOTOR ACTUATOR X14 X14 A B CB2 CIRCUIT BREAKER 40 AMP CB2 CIRCUIT BREAKER 40 AMP 1 2 X2 X2 BT1 BATTERY 36 Vdc BT1 BATTERY 3...

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