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Advolution™ 2710 UHR 70-1700

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1. WHT 8 RED 1 ELECTRICAL SYSTEM BLK BINS B BLK 18 3 BATTERY 36 Vdc X19 x20 BK 59 n e EE f 5 5 i z I W SPST amp To id M4 8 9 0 Y CBI gt 2 lt NOTE gt T 1 2 T ur 5 EMERGENCY STOP SWITCH SEAT MOTOR DUST CONTROL M CIRCUIT BREAKER 5 CIRCUIT BREAKER 40 AMP OPTIONAL CURTIS 1228 SPEED CONTROLLER 1 A1 SWITCH KEY z 33 4 ae Bet xx 8 BRN 20 1 4 1 PINK 20 1 EE 835 mm BLK GRA 20 1 5 2 ORN WHT 20 1 5 5425 22 5 5 BLU 20 1 6 3 BLU BLK 20 1 Sage 9 gt zz olei wiser ed of 1 LO CO NI LI 8 9 4 4 5 5 5 9 994949959 5 E NOTE WHEN ON BOARD aid gt 5 9 5 3 9 25 BATTERY CHARGER IS NOT 5 8 8 8 gt USED CONNECT X4 TO X5 x5 X E xo x7 8 8 5 ZZ 6 x 6 a ES S ES gt x e 0 5 8 Lg 8 SS T X25 X24 Gus E i ORN 18 1 51 Nos 58 m z ORN 18 2 5L z T
2. FORM NO 56043107 Advolution 2710 UHR 70 1700 7 MAINTENANCE SCHEDULE MAINTENANCE ITEM Daily Weekly Monthly Yearly Charge Batteries X Check Clean Replace Burnishing Pad X Check Replace Dust Collection Bag X Check Battery Water Level s X Check Replace Pad Shroud Skirt X Chain Tension Steering X Lubrication Grease Fittings X Check Carbon Brush Wear On Pad Drive Vacuum Motors X Note See the individual machine system sections for maintenance information Have Nilfisk Advance check the vacuum motor carbon motor brushes once a year or after 300 operating hours The pad and drive motor carbon brushes check every 500 hours or once a year A WARNING Turn the key switch off and disconnect the batteries before servicing the machine Check vacuum motor carbon brushes Qty 2 once a year or after 300 operating hours Check pad and wheel drive motor s carbon brushes Qty 4 per motor once a year 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 A IMPORTANT Motor damage resulting from failure to service the carbon brushes is not covered under warranty See the Limited Warranty Statement BATTERIES AND CHARGERS
3. 20 TROUBLESHOOTING GUIDE ELEGTRIGAL nico ge ti o rni 21 WHEEL STEM toti iato Dope 25 25 DRIVE MOTOR SYSTEM CONTROLLER FUNCTION OVERVIEW 25 DRIVE MODE SELECTION OPERATION 25 WHEEL DRIVE TROUBLESHOOTING GUIDE ss 28 WHEEL DRIVE ASSEMBLY 30 WHEEL DRIVE MOTOR REMOVAL 31 DRIVE WHEEE REMOVAL 32 ELECTROMAGNETIC BRAKE ASSEMBLY REMOVAL 33 STEERING CHAIN REMOVAL AND TENSIONING gt ee 34 POTENTIOMETER REMOVAL AND eene 35 POTENTIOMETER INSTALLATION AND 35 ALTERNATE METHOD FOR THROTTLE ADJUSTMENT 35 DRIVE PEDAL NEUTRAL ADJUSTMENT 8 PEDAL REPLACEMENT 37 TROUBLESHOOTING GUIDE ELECTRICAL 5 neptem 38 2 FORM NO 56043107 Advolution 2710 UHR 70 1700 TABLE OF CONTENTS CONTINUED 27 40 UE DU E NS 40 CHARGING THE BATTERIES 41 CHECKING THE BATTERY WATER LEVEL 41 BATTERY MAINTENANCE A 41 CHARGING THE
4. AN gt Advolution 2710 UHR 70 1700 POS 56422002 Advance Models 56422000 Nilfisk Model 56422001 Service Manual 7 06 revised 6 08 FORM NO 56043107 setting standards Ifi QA TABLE OF CONTENTS INTRODUCTION ag 4 IMPORTANT SAFETY INSTRUCTIONS 4 5 5 TECHNICAL SPEGIFIGATIONS entere ehe ro niat Br hee pernicies 6 MAINTENANCE SCHEDULE arie ttes 8 KNOW YOUR MACHINE titii ris de eas te A 10 11 FUNCTIONAL DESCRIPTION OF CONTROL 12 BURNISHING SYSTEM 13 FUNCTIONAL OVERVIEW reto erae REM rv uper 13 PAD LIFT ACTUATOR REMOVAL AND 14 PAD DRIVE DECK REMOVAL 52556 RUP PTOL e abest 14 PAD DRIVE MOTOR CARBON BRUSH 14 PAD DRIVE MOTOR REMOVAL i11 15 dete 15 DUST SHROUD EDGING REPDAGEMENT iint more rotor tatus 16 PAD DRIVE DECK LEVEL ADJUSTMENT cti tte estere 17 PAD DRIVE DECK LEVEL ADJUSTMENT patere cose crie tepore 18 INSTALLATION OF THE BURNISHING requete eoi bi op 19 INSTALLATION OF THE DUST COLLECTION
5. nenne 52 TROUBLESHOOTING GUIDE 2 bn cipe 53 COMPONENT LOCATION 2 55 WIRING DIAGRAM 66 6 56 57 Note All references to right left front or rear in this manual are as seen from the operator s standpoint FORM NO 56043107 Advolution 2710 UHR 70 1700 3 INTRODUCTION This manual will help you get the most from your Nilfisk Advance Advolution 2710 UHR 70 1700 Read it thoroughly before operating the machine Note Bold numbers in parentheses indicate an item illustrated on pages 10 11 This product is intended for commercial use only PARTS AND SERVICE Repairs when required should be performed by Nilfisk Advance service personnel using Nilfisk Advance original replacement parts and accessories Call Nilfisk Advance for repair parts or service Please specify the Model and Serial Number when discussing your machine NAME PLATE The Model and Serial Number of your machine are shown on the Nameplate on the machine This information is needed when ordering repair parts for the machine Use the space below to note the Model and Serial Number of your machine for future reference MODEL SERIAL NUMBER TRANSPORTING THE MACHINE A 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 needed TOWING Reference page 8 for tow
6. speed control fault exists this indicator will flash the fault code from the speed control Refer to the speed control section for details on these codes FORM 56043107 Advolution 2710 UHR 70 1700 49 ELECTRICAL SYSTEM ADVOLUTION PROGRAMMING MODES Status Display If no over current faults are present the status display will show the battery voltage This display is accurate to within 0 15 volts Therefore the voltage displayed may not correlate precisely to a high accuracy calibrated voltmeter The leftmost digit of the display is used to indicate the state of the seat switch and the deck interlock switch inputs The top segment of the display will be on if the deck interlock switch is open deck in pad change position otherwise it will be off This segment will flash if the deck interlock switch is open and the actuator is turned on see output control section below The bottom segment of the display will be on if the seat switch is closed otherwise it will be off If over current faults are present the status display will indicate the fault codes The format will be E xx where xx is a two digit fault code Output Controls The pad and horn switches are used to control the output functions of the main control unit Below is a detailed description of each switch function Horn Switch This switch is used to toggle the state of the pad motor Pressing and releasing this switch will alternately turn the pad
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8. Attention See the ELECTRICAL SYSTEM section for battery installation battery maintenance and charger system requirements LUBRICATING THE MACHINE e Locations requiring periodic oiling are Qty 1 Steering Wheel Shaft Universal Joint oil hole or port TOWING THE MACHINE A CAUTION The Drive Steer Wheel Assembly 14 has a built in electromagnetic brake that is engaged whenever the Master Key Switch AA is OFF or the FWD REV Drive Pedal 8 is in the neutral position This brake can be manually over ridden if necessary by inserting a medium to large screwdriver behind the Yoke A as shown This should only be done in the event you need to push or pull the unit 8 FORM NO 56043107 Advolution 2710 UHR 70 1700 Advance Advolution 2710 amp Nilfisk UHR 70 1700 Rider Burnisher PM Checklist Defect Codes Customer A needs adjustment B binding Address C dirty or contaminated D damaged bent or torn City St Zip L leaks M missing Model Serial Hours W worn out OPERATIONAL INSPECTION ITEMS engaged Note machine should not move when machine is at rest Burnishing System Deck amp Motor Operation pad deck raise lower amp pad motor auto functions 25 nm noisy sluggish 7 Bumishing Sytem perfomance even shiny 0 Optional Accessories Headlight Safety Beacon Active Dust Sytem Banery Charger mo wm ON Orp Main Control Boa
9. Go to Part B Load Circuit Troubleshooting 22 FORM NO 56043107 Advolution 2710 UHR 70 1700 BURNISHING SYSTEM TROUBLESHOOTING GUIDE ELECTRICAL Symptom Burnishing deck will not raise or lower Part A 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 The Control Panel Indicator is blank not lit when the pad switch is pressed Yes Check Circuit Inputs Listed Below Test the function of the Pad Switch J1 6 amp J1 5 circuit input at the Control Box If no continuity across BLK GRY amp BLU wires when activated Replace or repair the Panel or wiring Yes Pad Indicator is Green but actuator does not function No Go to Part B Yes Load Circuit Troubleshooting Indicator is still blank Replace the Control Box Does the Lift Actuator function 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 The Panel Green Indicator Light is ON Test motor wiring Test for 36V at Actuator Motor Repair or Replace No Replace the Control BoX Wire colors WHT RED amp ORG BLU Is actuator functional Y Yes c Replace the M3 Actuator Motor FORM NO 560
10. stop switch and the S2 seat switch Repair or replace the switches or wiring Test the resistance of R1 pot spec is red light should be 4500 to 5500 To measure separate the 18 pin connector at the A1 speed controller Insert test leads into pin 3 Vio Brn wire and pin 13 Brn Blk wire Repair the wiring or replace the R1 Throttle pot Yes Replace the Speed Controller No gt FORM NO 56043107 Advolution 2710 UHR 70 1700 39 ELECTRICAL SYSTEM BATTERIES If your machine shipped with batteries installed do the following e Check that the batteries are connected to the machine 7 e ON the Key Switch AA and check the Battery Indicator BB If the green light is ON the batteries are ready for use If the green light is OFF the batteries should be charged before use See the Charging The Batteries section If your machine shipped without batteries installed do the following e Consult your Authorized Nilfisk Advance dealer for recommended batteries e Install the batteries by following the instructions below DO install three 12 volt batteries in your machine This affects the stability of the machine A WARNING Use extreme caution when working with batteries Sulfuric acid in batteries can cause severe injury if allowed to contact the skin or eyes Explosive hydrogen gas is vented from the batteries through openings in the battery caps
11. 5 Installthe battery cables as shown Position the cables so the battery caps can be easily removed for battery service 6 Carefully tighten the nut in each battery terminal until the terminal will not turn Do not over tighten the terminals or they will be very difficult to remove for future service 7 Coat the terminals with spray on battery terminal coating available at most auto parts stores 8 Putone ofthe black rubber boots over each of the terminals and connect the Battery Connector Assembly 7 NOTE Secure rubber boots with supplied tie 36V X 395A H 20 RATE 40 FORM 56043107 Advolution 2710 UHR 70 1700 ELECTRICAL SYSTEM CHARGING THE BATTERIES Charge the batteries each time the machine is used for 1 hour or longer or whenever the Battery Condition Indicator Lights BB light up red To Charge the Batteries 1 IMPORTANT Open the Battery Compartment Cover 13 to provide proper ventilation 2 Disconnect the Battery Connector Assembly 7 and plug the battery charger into the plug connected to the batteries 4 Follow the instructions on the battery charger 5 Check the fluid level in all battery cells after charging the batteries Add distilled water if necessary to bring the fluid level up to the bottom of the filler tubes A WARNING Do not fill the batteries before charging Charge batteries in a well ventilated area Do not smo
12. To save the setting and exit this mode turn the key switch off gt 4 Reverse Motion Alarm Back Up Alarm Volume Level Adjustment Mode FACTORY DEFAULT 2 LOW VOLUME The control system has the ability to activate a reverse alarm signal to alert personnel of the approach of the machine The volume of this alarm is adjustable from 0 to 9 0 is off and 9 is the maximum volume setting To adjust the volume of this alarm perform the following steps Note while in this mode activating the foot pedal in the reverse direction will activate the alarm so that the appropriate sound level can be selected Press and hold the horn switch while turning the key switch on Continue holding the horn switch until the status display is scrolling the word SELECT Release the horn switch Press and release the horn switch five times The status display should now be scrolling HORN R Press and release the pad switch to enter the reverse motion alarm volume adjustment mode The status display will now show to indicate the reverse alarm mode as well as a number from 0 to 9 To select the desired volume level press and release the horn switch This will scroll through the available settings To save the setting and exit this mode turn the key switch off 64 Burnishing Speed Limit Enable Disable Mode FACTORY DEFAULT LO REDUCED BURNISHING SPEED The control system has t
13. it is recommended that the controller exterior be cleaned periodically and if a handheld programmer is available this periodic cleaning provides a good opportunity to check the controller s diagnostic history file FORM NO 56043107 Advolution 2710 UHR 70 1700 47 ELECTRICAL SYSTEM FUNCTIONAL OVERVIEW OF MAIN CONTROL BOARD The primary function of the main control board A1 is to position the burnishing pad with respect to the floor surface using a lift actuator motor to maintain the correct pad pressure and current draw of the pad motor When the pad drive switch EE is depressed this will lower the pad deck to the operating position and by activating the drive pedal start the pad motor The controller is continuously monitoring the current to the pad motor and when it senses a current draw out of the desired range it automatically raises or lowers the pad deck by turning on the pad lift actuator motor This process is repeated until the pad motor is shut off The controller also manages the other supportive systems such as the optional active dust control Note See the Know Your Machine section in this manual for a complete explanation of the machine s operation The secondary function of the main control box is to detect any system failures and display an error code on the display panel or store it in the main control board s recall memory mode The error code s are used to help the service person determine the fault and to quickly g
14. 10 amp 12 Before making any adjustments inspect the Torsion Spring K for defects and the correct positions of both spring ends repair or replace To Adjust Pedal Spring 1 Loosen the Screw L amp Nut M the screw with Bushing N is positioned between both Fwd amp Rev torsion spring ends Its placement controls the needed pre load pressure to eliminate excessive pedal free play and a balanced spring rate to return the pedal to a centered neutral position 2 Pushthe screw back into the pedal frame slot to increase spring tension and eliminate pedal free play Then tighten the screw amp 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 Position the torsion spring ends O amp P as shown This is with the Bushing N and Screw L not installed Place the bushing inside the pedal channel pilot it into position using a scratch awl or a pin punch Then pivot press the pedal and insert the screw from the opposite side pushing the guide tool out Use a screwdriver to tap and pry the bushing back in the pedal slot to increase spring tension Work the bushing back amp forth on both sides of the pedal to obtain equal spacing Then tighten the screw and nut A correctly adjusted drive pedal will have minimal amount of free play when selecting a drive direction Reconnect the batteries and test the machine to make sure it does not creep forward o
15. Assembly 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 DUST SHROUD REMOVAL 1 See Figure 2 Remove the Dust 2 Remove the Pad Retainer pad if installed and the Motor Shaft FIGU RE 2 Screw C that fastens the Pad Driver Assembly D to the motor shaft Remove the Pad Driver Assembly D from the motor shaft NOTE Do not lose the motor shaft key 4 Remove the 4 Screws E and the Dust Shroud 16 FORM NO 56043107 Advolution 2710 UHR 70 1700 BURNISHING SYSTEM DUST SHROUD EDGING REPLACEMENT 1 See Figure 3 Remove existing Edging pulling it away from the Shroud 2 To install start at the rear of the Shroud B with one end of the new Edging so that the seam is hidden Push U channel onto Shroud B work edging assembly around Shroud B 3 Check that Edging U channel is firmly in place all around Shroud B NOTE Pinch the U channel every to 4 inches with a vise grips to ensure it is securely fastened to the shroud FIGURE 3 U Channel Cross Section FORM NO 56043107 Advolution 2710 UHR 70 1700 17 BURNISHING SYSTEM Left to Right Pad Contact Adjustment Figure 4 PAD DRIVE DECK LEVEL ADJUSTMENT 1 Loosen the 2
16. Briefly run the pad drive motor to get a pattern on the floor A CAUTION Do not run pad motor for an extended period without moving machine Front to Back Pad Contact Adjustment See Figure 5 FIGU RE 5 1 Loosen Lock Nut A and turn the Adjustment Screw B clockwise to increase or counter clockwise to decrease Dimension X B Increasing Dimension X will increase the pad pressure to the front of the pad assembly at the 12 O clock position il Decreasing Dimension X will increase the pad pressure to the rear of the pad assembly at the 6 O clock position 2 hE n IM 5 Dimension Should be approximately 1 1 8 28 44mm n n NOTE As general rule the pad should be approximately 3 8 higher at the 12 o clock position than at the 6 o clock NEN position 4 sition FX 2 174 lt OR ED t HE FORM NO 56043107 Advolution 2710 UHR 70 1700 19 BURNISHING SYSTEM INSTALLATION OF THE BURNISHING PAD A WARNING Disconnect the machines Battery Pack Connector 7 when ever servicing the machine CAUTION Turn the key switch off and remove the key before changing the pad and before
17. F G U RE 3 1 Instructions for Pad Drive Deck Lift Actuator Drive Nut Adjustment 1 2 3 56407502 that is needed to connect the machine s battery pack and actuator motor for setting the drive nut limit settings Open the machine battery compartment and disconnect the battery connector The battery pack is needed to power the lift actuator motor to properly set the IN amp OUT limit switches Connect the actuator motor to be tested to the power cord adapter end Then connect the alligator clips from the cord adapter red clip to the positive and black to negative to battery connector or battery posts The rocker switch is used to change the motor rotation in setting the correct drive nut dimension See Figure 3 This shows the special actuator power cord adapter PN See Figure 4 and 5 new pad lift actuator motor first install the Compression Spring then slide on the Spring Housing Guide followed by the Mounting Hardware C 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 Measure the position of the spring housing assembly on the actuator shaft Manually turn the spring housing assembly to the appropriate IN position shown in the chart above Hold the spring housing assembly then press the adapter cord rocker switch to run the drive motor to the OUT position wait until th
18. Nuts A on the Adjustable Bracket 2 Turnthe 2 Lock Nuts C on the Carriage Screw D either NOTE Install a new pad before performing this adjustment down to increase or up to decrease Dimension X 1 Putthe pad drive deck in the down position Decreasing Dimension X will increase the pad pressure at 2 Briefly run the pad drive motor to get a pattern on the floor the 3 O clock position Increasing Dimension X will increase the pad pressure at the AN CAUTION 9 O clock position Do not run pad motor for an extended period without moving machine Q NOTE As a general rule the measurement at the 3 o clock and the 9 o clock position should be the same when measured from the floor to the edge of the dust shroud CY 0 N 9 o clock position 3 o clock position lae 2 18 FORM 56043107 Advolution 2710 UHR 70 1700 revised 6 08 BURNISHING SYSTEM PAD DRIVE DECK LEVEL ADJUSTMENT NOTE Install a new pad before performing this adjustment 1 Put the pad drive deck in the down position 2
19. 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 Panel Indicator Operation Panel 18 Spare Dust Bag Storage 19 Beacon Optional 20 Headlight Optional 21 Active Dust Control Optional 22 Onboard Charger Optional 23 Serial Plate qty of 2 10 FORM NO 56043107 Advolution 2710 UHR 70 1700 Raise Lower Switch FF Horn Indicator Light GG Horn Swi Indicator Light CC Hour Meter Error Display ch DD Pad Driv BB Battery Condition Indicator EE Pad Driv KNOW YOUR MACHINE AA Master Key Switch FORM NO 56043107 Advolution 2710 UHR 70 1700 1 FUNCTIONAL DESCRIPTION OF CONTROL BUTTONS Key Switch AA Main Power Switch when turned on controls battery input to machine s main control board and wheel drive speed control Battery Condition Indicator BB The Battery Condition Indicator will give an indication of the state of charge of the batteries Three lights make up the Indicator Display Red Yellow Green See the electrical system in this manual for discharge percentage details of each indicator light Hour Meter Error Display CC The 5 character display on the I O Panel is primarily used as a display for the
20. batteries Wheel Drive Motor Circuit Breaker CB2 tripped reset 40A circuit breaker Control Circuit Breaker CB1 tripped reset 5A circuit breaker e Y1 parking brake electromagnetic not releasing Note Check system voltage at brake a reading of O volts brake is set and at 36 volts brake is released with foot pedal activated Emergency Stop Switch 810 tripped Turn knob CW to reset Safety Switch 2 in seat not closed check seat switch Defective Wheel Drive Motor replace motor Defective Throttle Potentiometer R1 replace Test the Fwd amp Rev R1 wiring outputs pins 3 4 amp 13 at the speed control for an open Repair wiring or replace the R1 pot Check potentiometer Controller can t change electrical polarity to wheel motor replace the A1 speed control Speed controller has sensed an operation error code fault System See Curtis Speed Control Troubleshooting Section FORM NO 56043107 Advolution 2710 UHR 70 1700 29 WHEEL DRIVE SYSTEM WHEEL DRIVE ASSEMBLY REMOVAL A WARNING Disconnect the battery pack by separating the battery connectors 7 whenever servicing the machine 1 Disconnect the battery pack by separating the battery connectors 7 located underneath the drivers seat 2 See Figure 5 Pull or pry off the Cover Plate A to access the Steering Spindle Retainer Nut B 3 From underneath the front of the machine loosen the 4 s
21. hour meter function When the Key Switch A is activated pad pressure setting 1 2 or 3 will appear briefly in the right corner of the display Followed by five 8 s to show functionality of the L E D Display then switching to hours on the unit This display is also used to display the following information depending upon which mode the control is in e Error Codes e Pressure Settings 1 2 and 3 e Display of control system default parameters Service Note Have a qualified Service Technician reference the Service Manual for explanations about Error Codes and Control Fault Parameter Changes 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 lowering the deck as the pad drive raise lower switch is activated Indicator will be dark Green when the Drive Pedal is engaged in Forward or Reverse activating the pad motor Indicator will be Red when raising the deck as the pad drive raise lower switch is activated At full raised position the Red light will go out Pad Drive Raise Lower Switch EE Pressing this switch will activate turn on the Lower Raise burnishing deck lift actuator functions see indicator lights description for further information Horn Indicator Light FF Indicator Light will turn Green when Horn Switch is depressed And also displays fau
22. wall outlet for the machine to operate Test the continuity of the F1 150 Amp fuse Test the continuity and wiring of the F1 150 Amp Fuse Is the Fuse Good Repair or Replace YES Test for 36V at the RED wire for the CB1 5 amp circuit breaker Check CB1 5 amp circuit breaker and wiring for continuity Repair or Replace YES Located in the Electrical Panel are WHT to VIO and BLK to VIO wires Connect the 2 VIO wires together to bypass the onboard charger Test for 36V at the VIO wire at the Control Box Pin J3 1 Does the machine operate with charger wires bypassed YES Check the 20 amp fuse on the charger If defective replace If itis good replace the onboard charger Go to the electrical system troubleshooting guide No Machine Functions Work machines without onboard battery charger 54 FORM NO 56043107 Advolution 2710 UHR 70 1700 4 ane amp Control gt p ti onal Onboard Battery Charger ELECTRICAL SYSTEM COMPONENT LOCATION Description A1 Speed Controller CB1 Circuit Breaker 5 Amp Control CB2 Circuit Breaker 40 Amp Traction 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 Optio
23. 07 Advolution 2710 UHR 70 1700 ELECTRICAL SYSTEM CURTIS CONTROLLER DIAGNOSTICS Diagnostics Method A Uses the machine s control display LED panel and Horn Indicator Light FF FUNCTION OF THE SPEED CONTROLLER STATUS LIGHT AND DISPLAY The Curtis 1228 36V speed control will output a fault code if there is a problem associated with the speed control and wheel drive system See Figure 6 If a speed control fault occurs the display LED panel CC will indicate Err 03 When the Err 03 error code is displayed and detects a fault the Red Horn Indicator FF will flash a special error code sequence until the fault is corrected See Table 1 for a description of the fault indications Service Note Instructions on how to read the error code status light Example OO O two light flashes a short pause One flash long pause and the code will be repeated This indicates a fault code 2 1 Diagnostics Method B Uses the optional hand held Curtis programmer model 1307 or the new model 1311 MP1101 PROGRAMMER DIAGNOSTICS With a programmer diagnostics and troubleshooting is more direct than with the LED status light alone The programmer presents complete diagnostic information in plain language no codes to decipher Faults are displayed in the Diagnostic Menu and the status of the controller inputs outputs is displayed in the Test Menu The following 4 step process is generally used for diagnosing and troubleshooting an inoperative vehic
24. 43107 Advolution 2710 UHR 70 1700 23 BURNISHING 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 Test for 36V on the RedMht wire at the 1 speed control No Control Replace A1 Speed Test for 36V on the Red Wht wire at No _ gt the Control Box board pin J3 10 6 Yes Yes Yes m Repair or Replace Red Wht wire Check for 36V at K1 Solenoid coil on the BIKWht and BluM ht wires Does the pad motor run If no see part B of troubleshooting Test K1 Coil for open circuit spec 118 Is the 3 Interlock Switch Replace ohms Is coil open No good closed test continuity of 53 the 3 at the Control Box on the Wht Gry switch or and Vio BIk wires pins J3 7 and repair J3 5 wiring Yes Replace the K1 Solenoid Yes Replace the Control Box Does the pad motor run If no see part B of troubleshooting 24 FORM NO 56043107 Advolution 2710 UHR 70 1700 BURNISHING SYSTEM TROUBLESHOOTING GUIDE ELECTRICAL Symptom Pad drive motor will not run 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 burnishing ready position and drive pedal engaged
25. AL HORN 42 7 GRAWHT HORN j 42 1 BRNWHT GRABLK 13 7 INTERLOCK BJ HORN BACK UP ALARM VIO BLK 13 5 INTERLOCK WHT RED SWITCH DECK INTERLOCK ACT 1 J2 12 ACT 2 J2 6 ORN BLU K1 BK ACTUATOR BLK WHT B 12 9 J2 5 PAD CONT B 2 10 BLK BLK COIL RELAY BLUWHT 32 41 PAD CONT CIS KVEL SENSE J3 3 K1 RED RED BLK MOTOR PAD 59 WHT 1 2 BLK SW SPST M4 MOTOR DUST CONTROL VAC OPTIONAL 56015612 REV F FORM NO 56043107 Advolution 2710 UHR 70 1700 13 BURNISHING SYSTEM PAD LIFT ACTUATOR REMOVAL AND INSTALLATION A WARNING Disconnect the battery pack by separating the battery connectors 7 whenever servicing the machine 1 Disconnect the battery pack by separating the battery connectors 7 located underneath the drivers seat 2 Disconnect the actuator wiring harness at the actuator lift motor 3 See Figure 1 Remove the 2 Hex Screws A that fasten the actuator Mount Bracket B 4 Remove the Retainer Ring C NOTE Remove the retainer closest to the front of the machine Then slide the mount pin D to the rear to allow removal of the Actuator E from the machine 5 To re install follow the above instructions in reverse order NOTE See the Actuator Lift Nut Adjustment section in this manual for correct lift nut adjustment setting as new actuators do not come pre set PAD DRIVE DECK REMOVAL A WARNING Disconnect the battery pac
26. BATTERIES 00 42 42 0 42 BATTERY CHARGER SPECIFICATIONS e 42 ACTUATOR DRIVE NUT tette e 43 CURTIS CONTROLLER DIAGNOSTICS 0 44 FUNCTION OF THE SPEED CONTROLLER STATUS LIGHT AND DISPLAY 44 PROGRAMMER DIAGNOSTICS 44 DIAGNOSTIC HISTORY m en eer EI iu em 44 SPEED CONTROL PROGRAMMING 0 s 45 INSTALLATION CHECKOUT FOR THE CURTIS SPEED CONTROLLER 47 PROGRAMMING VEHICLE SPEED CHANGES e 47 FUNCTIONAL OVERVIEW OF MAIN CONTROL BOARD 48 MAIN CONTROLLER ERROR CODES 48 ADVOLUTION PROGRAMMING MODES 49 FAULT RECALL MODE REVISION DISPLAY sesenta 49 SERVIGE TEST MODE m cot timet aH N 49 STATUS DISPLAY t er ett entente tente een Sot e e d tee Ml uet dn 50 QUTPUT CONTROLS e Pee ce oh ee ote dra kd en 50 terere te tate ede 50 PAD SWITCH eio edes 50 LOW VOLTAGE CUTOUT THRESHOLD SELECTION MODE eene 51 FAULT DETECTION ENABLE DISABLE MODE eene 51 PAD PRESSURE ADJUSTMENT MODE eene tents 51 FORWARD MOTION ALARM VOLUME LEVEL ADJUSTMENT MODE 52 REVERSE MOTION ALARM BACK UP ALARM VOLUME LEVEL ADJUSTMENT MODE 52 BURNISHING SPEED LIMIT ENABLE DISABLE MODE
27. ER 40 AMP 0 YEL WHT 9 a x c gt Mi PLUG AC MALE ON BOARD Z BATTERY CHARGER RED OPTIONAL 2 MOTOR 10 52 Yi EMERGENCY STOP SWITCH SEAT RED WHT 2 1 4 YEL 12 2 GRN BRAKE WHT ORN CB1 Ar RED WHT 33 40 F R RED 2 VIO 1 2 WHT ORN GAN 13 9 SEAT SW REV J3 6 YELWHT CIRCUIT BREAKER 5 AMP SHREK STATUS 13 4 WHT ORN 33 2 KEY SW MODE J2 2 GRN BLK dd SDA J1 1 4 1 SDA 4851 Bt SCL J1 2 J4 2 SCL 95 LP5 45 V J1 3 BLU BLK 44 3 45 V VO PANEL vo 1 21 2 WHT BRN 2 4 ACC HORN SW J1 4 J4 4 HORN SW SW SPST OPTIONAL BJ 1 5 J4 5 B T PAD SW J1 6 BLU J4 6 PAD SW a VIO 1 WHT BRN CONTROL BOX G LAMP FLASHING OPTIONAL HORN J2 7 GRAWHT pees HORN 42 1 BN WHT HORN BACK UP ALARM 1 2 GRA BLK 33 7 INTERLOCK B M3 VIO BLK SWITCH DECK INTERLOCK J3 5 INTERLOCK ACT 1 J2 12 WHT RED ACT 2 2 6 ORN BLU Ki ACTUATOR BLK WHT 429 B J2 5 PAD CONT 82 2 10 BLK COIL RELAY BLK BLUWHT 2 11 PAD CONT B 8 SENSE J3 3 K1 M2 RED 1 2 RED OM BLK MOTOR 59 WHT 1 2 1 2 BLK SW SPST 7 56015612 REV
28. ICLE SPEED CHANGES The M1 transport and M2 burnish High Low and Forward Reverse speeds can be changed electronically using the handheld programmer To change a parameter using the programmer press the PROGRAM key and scroll down the Program Menu until the desired parameter is the top line of the display Press the appropriate CHANGE VALUE key or down until the desired number is reached The parameter is now set at the desired value All programming occurs in real time In other words the parameters can be changed while the vehicle is in operation The upper and lower limits of parameters are set at the factory Some parameters have dependencies on other parameters When the programmer is being used to adjust a parameter and a limit is reached the display will stop changing To see why the display has stopped changing press the MORE INFO key If the limit is related to another parameter that information will be displayed changing the value of the related parameter may allow the original parameter to be adjusted further Otherwise the display simply says Max Limit or Min Limit NOTE Use of the programmer models 1307 old style and 1311 new style is described more fully in the Curtis Programmer manual 56043101 MAINTENANCE There are no user serviceable parts inside the Curtis PMC 1228 controller No attempt should be made to open the controller Opening the controller may damage it and will void the warranty However
29. NSTALLATION CHECKOUT FOR THE CURTIS SPEED CONTROLLER A SAFETY The 1228 controller is inherently a high power device When working around any battery powered vehicle proper safety precautions should be taken These include but are not limited to proper training wearing eye protection avoiding loose clothing and jewelry and using insulated wrenches After installing a controller and before operating the vehicle carefully complete the following checkout procedure If you find a problem during the checkout refer to the DIAGNOSTICS section of this chapter for further information The installation checkout can be conducted with or without the handheld programmer The checkout procedure is easier with a programmer otherwise observe the Status LED for codes located on operator panel horn indicator light The part number of the handheld programmer is 56409441 A WARNING Put the vehicle up on blocks to get the drive wheel off the ground before beginning these tests Turn the key switch off and make sure that the throttle is in neutral Do not stand or allow anyone else to stand directly in front of or behind the vehicle during the tests 1 Remove electrical panel to access controller then observe LED status light on touch pad operator panel horn indicator light If a programmer is available connect it to the programmer plug in port 2 Turn the key switch on The programmer should power up with an initial display If neither happens c
30. OXX 5888 015 919 20 1 ale X22 gt lt REDWHT 20 2 5599 4919 GROUND RED WHT 18 3 J J2 J3 o BLK CHARGER LEAD 1 BLK2 2 dad dddtdq4 dada DO BLK 10 1 ele E Fi RED CHARGER LEAD ol ob 4 25 4 9 zzS din as 538803 150 3 5 235 532 xt 62 0 55 5 aoa om gt a 8 108 8 8 5 339 X2 8 RED CHARGER LEAD 85 RED 21 RED 2 2 PN BOARN BLK CHARGER LEAD 5 wus 5 5 5 BATTERY CHARGER a a S OPTIONAL INTERLOCK 1 INTERLOCK 2 Hi LJ i 2 FERRITE Ao BLK YEL 18 1 BLK 4 1 CONTACTOR HORN BACK UP ALARM MOTOR PAD PES X17 X16 OM 4 ORN BLU 18 1 MET B S B WHT RED 18 1 BRN BLK 20 1 MOTOR ACTUATOR 4 2 GRA20 1 X15 4 POT 5K OHM 7 B GRA BLK 20 1 8 VIO BRN 20 3 1 2 VIO BLK 20 1 GRN YEL 18 3 MEN SWITCH DECK INTRLOCK LP1 X9 X8 FERRITE JL VIO 18 4 RED GRN 10 1 QE Bi WHT BRN 18 2 M1 GROUND LANP FLASHING X23 M YEL BLK 10 1 OPTIONAL Od MOTOR TRACTION S5 Yi onm 260 WHT BRN 18 2 o 1 2 RED WHT 18 3 CT WHT BRN 18 1 18 1 HEAD LAMP BRAKE ORN 18 2 OPTIONAL VIO 18 4 E VIO 18 3 5 56015613 REV FORM NO 56043107 Advolution 2710 UHR 70 1700 57 Nilfisk Advance setting standards www nilfisk advance com
31. RED OPTIONAL m MOTOR TRACTION S10 92 EMERGENCY STOP SWITCH SEAT RED WHT 2 1 24 YEL 1 92 GRN BRAKE WHT ORN B1 REDWHT 33 40 F R RED 1 2 vio 1 2 WHT ORN GRN js o SEAT SW REV J3 6 YELWHT CIRCUIT BREAKER 5 AMP SWITCH KEY STATUS Ja4 55 KEY SW MODE J2 2 GRNBLK 26 FORM 56043107 Advolution 2710 UHR 70 1700 FIGURE 2 WHEEL DRIVE SYSTEM Panel lt 7 A 5 44 YH 77 OPEL IL LATED FORM NO 56043107 Advolution 2710 UHR 70 1700 27 WHEEL DRIVE SYSTEM FIGURE 3 R1 Voltage Values 0 2 5V Reverse 2 5 5 Forward View Non stem end MOBIN 1 Speed Control Pin Connection VIO BRN BRN BLK 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 4 AUXILIARY DRIVER POT WIPER pad motor brake M 1 2 POT LOW AUXILIARY DRIVER brake Used 10 pins AUXILIARY DRIVER rev alarm Not Used 8 pins SPEED LIMIT POT 28 FORM 56043107 Advolution 2710 UHR 70 1700 WHEEL DRIVE SYSTEM Low Current A1 Speed Contr
32. Rate 41 580 sq ft 3 862m per hour Average Run Time 3 hours per battery charge Batteries Recommended Six 6 volt 395 A H 20 hour rate 120 Ibs 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 charger Burnisher Pad Motor 36 volt 3 25 hp 85 Amp Wheel Drive Motor 36 volt 1 hp 27 Amp Pad Lift Motor 36 volt 1 6 hp 6 7 Amp Drive System Speed Control Electronic fully variable Fwd Rev Max Transport Speed 396 FT min Max Burnish Speed 308 FT min Turning Radius 72 inches 182 88 cm Wheels 9 75 inch 24 76 cm drive wheel 12 inch 30 48 cm rear wheels Ramp Climbing Ability 12 396 grade Sound Pressure Level IEC 60704 1 69 dB A 20yPa at operator s ear 6 FORM NO 56043107 Advolution 2710 UHR 70 1700 TECHNICAL SPECIFICATIONS 2315 Jag Q Machine d Width AN Length Machine Height
33. Test for 36V on the load side at the Test for 36V at the K1 K1 solenoid Test point is the Red solenoid load input Red wire Repair or Replace wire wire 4 2 to battery ground 4 1 to a battery ground Replace the K1 Pad Motor Test for 36V at the Pad Motor M2 on solenoid the Red and Black wires Repair or replace the M2 Pad Motor Test for 36V at both wires Red to battery ground and Black to battery pos Repair or replace the defective wire 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 Test S9 switch for 36V NO Check continuity of the S9 switch amp wiring If at the 2 terminal open repair or replace switch amp or wiring YES Check for continuity of the Test for 36V atthe M4 NO Test for 36V at the NO BLK vac motor ground wire vac motor vac motor to battery Repair Wire YES Replace the M4 Vac Motor FORM NO 56043107 Advolution 2710 UHR 70 1700 25 WHEEL DRIVE SYSTEM GENERAL FUNCTIONAL OVERVIEW See Figures 1 amp 2 A700 watt 9 HP permanent magnet 36V motor gear transmission combination wheel M1 unit is used to propel all machines A Curtis model 1228 PMC solid state speed controller A1 regulates outputs the variable speed Fwd Rev
34. This gas can be ignited by any electrical arc spark or flame Do not install any lead acid battery in a sealed container or enclosure Hydrogen gas from overcharging must be allowed to escape When Servicing Batteries Remove all jewelry Do not smoke Wear safety glasses rubber gloves and a rubber apron Work in a well ventilated area Do not allow tools to touch more than one battery terminal at a time ALWAYS disconnect 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 shipping crate and carefully inspect them for cracks or other damage If damage is evident contact the carrier that delivered them or the battery manufacturer to file a damage claim 2 Turn the Master Key Switch AA OFF and remove the key 3 Open and prop the Battery Compartment Cover 13 Remove the battery cables from inside the battery compartment 4 Your machine comes from the factory with enough battery cables to install six 6 volt batteries Carefully lift the batteries into the battery compartment and arrange them exactly as shown in FIGURE 1 Secure the batteries as close to the back of the machine as possible
35. UHR 70 1700 41 ELECTRICAL SYSTEM CHARGING THE BATTERIES CONTINUED The following lights indicate the percentage of discharge in the battery pack Battery Voltage Indication Standard Alternate Green 33 5 33 7 FIGURE 2 Green Yellow 33 4 33 6 Yellow 32 8 33 4 Yellow Red 31 9 33 2 Flashing 30 6 32 8 BATTERY TESTING battery problem is usually recognized by the machine operator decrease in the machine s running time This condition is usually caused by one or more dead cell in the battery system that is one or more cell that is putting out less voltage than the other cells Note Always charge batteries before testing There are 2 ways to find a dead cell Use ahydrometer to check the specific gravity or state of charge of the fluid in each cell A dead cell is one that reads 50 points or more lower than the other cells Usea voltmeter to check the voltage of each battery with 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 recommended battery pack capacity is a 395 AH 20 Hour R
36. ance has been poor There are 3 simple rules for good battery maintenance Maintain Proper Electrolyte Level Weekly Use distilled water in batteries whenever possible If batteries are discharged add just enough water to cover the plates in each cell If batteries are fully charged fill each cell to the bottom of the filler tube Do not over fill the 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 60 minutes 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 their specific battery charger to determine how long the batteries should be charged Even when a machine is stored the batteries should be charged once a month to prevent the batteries from sulfating Almost all battery caps are vented so there s no need to loosen or remove them for charging Keep the Batteries Clean Monthly Use a damp cloth to wipe dirt from the top of the batteries Battery terminals must be clean and tight If the tops of the batteries are wet after charging the batteries have probably been over filled or over charged Note If there is acid on the batteries wash the tops of the batteries with a solution of baking soda and water 2 tablespoons of baking soda to 1 quart of water FORM NO 56043107 Advolution 2710
37. ate deep cycle battery system Note The battery pack must fit the battery compartment size listed below Battery compartment size Height 17 1 2 inches 44 cm Width 22 1 2 inches 57 cm Length 25 inches 63 cm BATTERY CHARGER SPECIFICATIONS Use a 36 Volt DC output charger matching the AC input line voltage supply to be used Always when selecting a battery charger follow the recommendation of the battery supplier to match the proper charger DC output amperage to the amp hour rating batteries being installed This will prevent the battery pack from being over or under charged The recommended 395 AH battery should be matched to a 36V 25 or 36 Amp output charger 42 FORM NO 56043107 Advolution 2710 UHR 70 1700 ELECTRICAL SYSTEM ACTUATOR DRIVE NUT ADJUSTMENT This manual section explains the steps for adjusting the drive nut spring housing setting for all the pad drive lift actuator motor Reference the chart below to find the IN amp OUT dimensional specification for an actuator motor needing adjustment Part Actuator Motor Spring Housing IN Position Spring Housing OUT Position Models 56393303 Pad Drive Lift 3 3 8 8 58cm 6 3 8 16 200 ALL Spring Housing IN OUT Position dimensions are measured when completely assembled Reference points are the gear box step to the edge of the Spring Housing Assembly A as shown in Figure 4 amp 5 General Instructions
38. 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 amp mode 2 M2 Mode 1 M1 is the transport speed range and is automatically selected when the burnishing system is OFF deck up This allows maximum variable vehicle speed operation Mode 2 M2 is the reduced slower burnishing speed range and is automatically selected when the burnishing mode is ON deck down Note The maximum machine drive wheel speed setting for the two drive modes 1 amp 2 can be changed by using the Curtis handheld programmer Reference the Curtis programmer instructions found in the electrical system manual section to change speed settings from their original factory specifications FIGURE 1 RED 2 FL 4 RED B BLK FUSE 150 A BATTERY 36 VDC Al CURTIS 1228 SPEED CONTROLLER VIO BRN GRA 2 Por sk OHM RED WHT GRN BLK ORN BLK 7 1 H H ED 4 5 3 5 34939343994 VIO BRN 5 gas 4 ee RED 1 2 GRN WHT BRN BLK YELIWHT CIRCUIT BREAKER 40 AMP BLK RED GRN YEL BLK PLUG AC MALE ON BOARD BATTERY CHARGER
39. coil energized if OV replace the K1 contactor 48 FORM NO 56043107 Advolution 2710 UHR 70 1700 ELECTRICAL SYSTEM ADVOLUTION PROGRAMMING MODES Fault Recall Mode Revision Display Whenever an electrical system fault is detected by the main control unit one or more error codes are displayed and stored by the control unit If it is desired the error code if any from the previous operation of the machine can be recalled for troubleshooting purposes To recall the last stored error codes perform the following steps Press and hold the horn switch while turning the key switch on Continue holding the horn switch until the status display is scrolling the word SELECT Release the horn switch The status display should now be scrolling FAULT RECALL Press the pad switch to enter the fault recall mode The display will change to Err x where x is a letter indicating the revision level of the control box This is not a control error code Release the pad switch If there are no error codes stored the status display will show NONE Go to step 13 If error codes have been stored the display will now show the error code s To clear the stored error codes press and release the horn switch The display will now show ERASE To clear the error codes press and release the horn switch one more time To return to the error code display press and release the pad switch 12 If the pad down switch
40. e motor stops Measure the position of the spring housing assembly on the shaft and compare the measurement with the OUT position shown in the chart If the measurement doesn t match the dimension shown in the chart it is necessary to remove the Adjuster Cover D and adjust the OUT position To increase the travel of the spring housing assembly turn the adjuster clockwise To decrease the travel of the assembly turn the adjuster counter clockwise NOTE Use a 1 2 13mm socket to turn the adjuster FIGU RE 4 Each click of the adjuster will change the spring housing assembly travel 1 16 inch 1 6mm Spring Housing Assembly After each adjustment hold the spring housing assembly run the actuator IN amp OUT and check both dimensions After checking that the spring housing limits are set correctly replace the adjuster cover Service Tip Use the above power cord adapter to help D position the spring housing assembly in or out for ease in actuator motor installations After adjusting the actuator spring housing dimensions follow the Pad Lift Actuator Removal And Installation section to reassemble dl IN 6 3 8 16 20cm FORM NO 56043107 Advolution 2710 UHR 70 1700 43 44 FORM 560431
41. el is displayed turn off the key switch to save the setting and exit this mode WwW TABLE 2 Pad Motor Pressure Settings amp Currents Pressure Setting Target Current amps 2 75 3 80 FORM NO 56043107 Advolution 2710 UHR 70 1700 51 ELECTRICAL SYSTEM ADVOLUTION PROGRAMMING MODES Forward Motion Alarm Volume Level Adjustment Mode FACTORY DEFAULT 0 OFF The control system has the ability to activate a forward alarm signal to alert personnel of the approach of the machine The volume of this alarm is adjustable from 0 to 9 0 is off and 9 is the maximum volume setting To adjust the volume of this alarm perform the following steps Note while in this mode activating the foot pedal in the forward direction will activate the alarm so that the appropriate sound level can be selected Press and hold the horn switch while turning the key switch on Continue holding the horn switch until the status display is scrolling the word SELECT Release the horn switch Press and release the horn switch four times The status display should now be scrolling HORN F Press and release the pad switch to enter the forward motion alarm volume adjustment mode The status display will now show F to indicate the forward alarm mode as well as a number from 0 to 9 To select the desired volume level press and release the horn switch This will scroll through the available settings
42. emove the motor Brush Cover M secured by 4 Phillips head screws N Inspect carbon brushes and springs NOTE New carbon brushes measure 1 3 32 28mm If the brushes are less than 3 8 10mm long they should be replaced Important Maintenance Tip Always blow out motor before reassembling Motor wiring tip The Red cable goes to NEGATIVE Stand off on the motor and the Black cable goes to the POSITIVE Stand off on the motor gt 14 FORM NO 56043107 Advolution 2710 UHR 70 1700 FIGURE 1 Tap Shaft out toward rear tire Measure distance between shaft and deck Should be approximately 1 1 8 28 44mm 15 FORM 56043107 Advolution 2710 UHR 70 1700 BURNISHING SYSTEM PAD DRIVE MOTOR REMOVAL 1 Follow instructions for Pad Drive Deck Removal 2 See Figure 2 Remove the Dust Bag 3 Tip the deck assembly over and remove the Pad Retainer pad if installed and the Motor Shaft Screw C that fastens the Pad Driver Assembly D to the motor shaft 4 Remove the Pad Driver Assembly D from the motor shaft NOTE Do not lose the motor shaft key Remove the 4 Screws E and the Dust Shroud F 6 Remove the 4 Screws that fasten the motor to the deck plate Lift the remaining Deck
43. entiometer is to set the drive pedal for a neutral drive motor operation Ifthe 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 D to the Pedal E and the Throttle Lever I to the potentiometer input shaft Then tighten only the Link Rod D pedal mounting Hardware F Note Check the movement of the Foot Pedal E it must move freely in both Fwd and Rev 3 See Figure 10 inset Attach test leads from a volt ohm meter to the VIO BRN and BRN BLK wire connection points on the potentiometer to check it s total resistance example 4800 Ohms 4 Nextconnect the ohmmeter test leads to the VIO BRN and potentiometer connection points Then using a small screwdriver turn the shaft end on the pot to half the total resistance previously measured Example 4800 Ohms divided by 2 2400 Ohms Then without turning the shaft tighten the Screw H and Nut G to secure the setting at the Throttle Lever I 5 Follow steps 1 2 in reverse order see Potentiometer Removal steps to finish the installation Then test drive the machine for proper speed and FWD REV directional control ALTERNATE METHOD FOR THROTTLE ADJUSTMENT The throttle adjustment is easier and more accurately adjusted by measuring the throttle potentiometer wiper voltage with respect to B To set throttle neutral 1 See Figu
44. ging the batteries produces highly explosive hydrogen gas Charge batteries with seat cover open in well ventilated areas away from open flame Do not smoke while charging the batteries Remove all jewelry when working near electrical components e Turn the key switch off and disconnect the batteries before servicing electrical components Never work under a machine without safety blocks or stands to support the machine Do not dispense flammable cleaning agents operate the machine on or near these agents 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 machine ensure that third parties particularly children are not endangered Before performing any service function carefully read all instructions pertaining to that function Do not leave the machine unattended without first turning the key switch and removing the key The parking brake is automatically activated at this time Turm the key switch and remove the key before changing the brushes and before opening any access panels e Take precautions to prevent hair jewelry or loose cloth
45. he ability to limit the burnishing speed to a level programmed into the Curtis speed control This limit can be overridden to allow burnishing at full speed To enable or disable this speed limiting feature perform the following steps Press and hold the horn switch while turning the key switch on Continue holding the horn switch until the status display is scrolling the word SELECT Release the horn switch Press and release the horn switch six times The status display should now be scrolling BURNISH SPEED Press and release the pad switch to enter the speed limit enable disable mode The status display will now show or LO to indicate the selected burnishing speed limit Selecting LO will limit the burnishing speed to the programmed limit in the speed control Selecting HI will allow full speed burnishing To select the desired speed limit press and release the horn switch This will alternate between the two settings To save the setting and exit this mode turn the key switch off gt 4 52 FORM 56043107 Advolution 2710 UHR 70 1700 ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE Symptom 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 f
46. he word SELECT Release the horn switch Press and release the horn switch three times The status display should now be scrolling FAULT DETECT Press and release the pad switch to enter the fault detection enable disable mode The status display will now show either or OFF depending on whether the error checking is turned on or off To select the desired option press and release the horn switch This will alternate between the two options To save the setting and exit this mode turn the key switch off COND OO FB Pad Pressure Adjustment Mode FACTORY DEFAULT 1 The amount of pressure applied to the burnishing pad can be adjusted over a limited range by adjusting the pad pressure setting in the control unit The control unit does not set an absolute pressure rather it controls the amount of power used by the pad motor which results in a relative pressure change The range of adjustment is from a setting of 1 least pressure to 3 most pressure 1 is the factory default Having the pressure setting at 1 will result in the maximum run time from the batteries To change the pressure level perform the following steps 1 Press and hold the pad switch while turning the key switch on Continue holding the pad switch until the status display is scrolling the word ADJUST Release the pad switch Pressing and releasing the pad switch will now scroll through the pad pressure options Once the desired lev
47. heck for continuity in the key switch circuit and controller ground 3 If you are using a programmer put it into the diagnostic mode by pressing the DIAGNOSTICS key The display should indicate No Faults Found Note Before pressing the diagnostics key wait until model screen appears if the throttle is activated prior to this screen appearing the controller will shut down Ifthere is a problem the Horn LED will flash a diagnostic code and the programmer will display a diagnostic message If you are conducting the checkout without a programmer look up the LED diagnostic code in the DIAGNOSTICS section of this chapter Table 1 When the problem has been corrected it may be necessary to 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 DIAGNOSTICS section of this chapter Table 1 5 Ifyou are using a programmer put it into the test mode by pressing the TEST key Scroll down to observe the status of the forward reverse and brake Switch Cycle each switch in turn observing the programmer Each input should show the correct state on the programmer 6 the vehicle off the blocks and drive it in an open area It should have smooth acceleration and good top speed PROGRAMMING VEH
48. ing from becoming caught in moving parts Do not use without dust bag and or filters in place Do not stand on the pad housing e This machine is not suitable for picking up health endangering dust The batteries must be removed from the machine before the machine is scrapped The disposal of the batteries should be safely done in accordance with your local environmental regulations All doors and covers are to be positioned as indicated in the instruction manual before using the machine Refer to the battery charger OEM product manual for additional specific battery charger warnings SAVE THESE INSTRUCTIONS FORM NO 56043107 Advolution 2710 UHR 70 1700 5 TECHNICAL SPECIFICATIONS General Specifications English Metric Burnishing Pad Diameter 27 inches 68 58 cm Machine Length 65 5 inches 166 37 cm Machine Width 32 inches 81 28 cm Machine Height 54 inches 137 16 cm 484 Ibs 219 53 kg net w o batteries Machine Weight 1 379 Ibs 626 kg gross w six 395 AH batteries Front Wheel Weight w six 395 AH batteries 308 Ibs 139 7 kg Rear Right Wheel Weight w six 395 AH batteries 445 Ibs 201 8 kg Rear Left Wheel Weight w six 395 AH batteries 451 Ibs 204 5 kg Front Wheel Pressure w six 395 AH batteries 128 PSI Rear Right Wheel Pressure w six 395 AH batteries 72 PSI Rear Left Wheel Pressure w six 395 AH batteries 105 PSI Average Coverage
49. ing instructions OTHER MANUALS AVAILABLE FOR YOUR MACHINE The manuals listed below can be found via Nilfisk Advance s two electronic supported databases They are e Nilfisk Advance Dealer Customer Zone e Ezparts service parts CD Rom Parts List Form Number 56042468 Instructions for Use Form Number 56041634 English Spanish 56041635 Danish Norwegian Swedish Finnish 56041636 German French Dutch Russian 56041637 Spanish Portuguese Italian Greek 56041638 Estonian Latvian Lithuanian Slovenian 56041639 Slovakian Czech Polish Hungarian 56041655 Turkish 4 FORM NO 56043107 Advolution 2710 UHR 70 1700 IMPORTANT SAFETY INSTRUCTIONS This machine is only suitable for commercial use for example in hotels schools hospitals factories shops and offices other than normal residential housekeeping purposes A Read all instructions before using WARNING To reduce risk of fire electric shock or injury Use only as described in this manual Use only manufacturer s recommended attachments e This machine shall be used only by properly trained and authorized persons This machine is for dry use only and shall not be used or stored outdoors in wet conditions e Do not allow to be used as a toy Close attention is necessary when used by or near children Keep sparks flame and smoking materials away from batteries Explosive gases are vented during normal operation Char
50. ith 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 pressure applied at the Mid point E as shown Service Note Use a pry bar or shims between the chassis and steer column to help secure the tension adjustment when tightening the 4 steering column mounting screws FIGURE 9 D FRONT 222 mE ts SS gt 4 lt S 5 pe N EC NOT gt 9 SN My BA WWW ym View Bottom View BN M og d WA 9 EB 6 X JA m E Aeaee MT Te c 34 FORM NO 56043107 Advolution 2710 UHR 70 1700 WHEEL DRIVE SYSTEM POTENTIOMETER REMOVAL AND TESTING A WARNING Disconnect the battery pack by separating the battery connectors 7 whenever servicing the machine Potentiometer Removal 1 See Figure 10 Remove the 5 Screws securing the drive pedal mount assembly to the chassis then carefully lift the pedal assembly up and lay it on its side 2 Observe the 3 wires connected to the Drive Pedal Potentiometer pot B and also the single GRN YEL throttle ground wire note the proper wire colors and their terminal c
51. k by separating the battery connectors 7 whenever servicing the machine 1 Disconnect the battery pack by separating the battery connectors 7 located underneath the drivers seat 2 See Figure 1 Remove the 2 Deck Springs F from the right side of the lower deck housing NOTE Use a pliers to assist in disconnecting the springs Having the deck in the up 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 amp Black wire locations Service Tip Measure the height of the Front to Back Deck Level Adjustment Screw H before disassembling should be approximately 1 1 8 28 44mm 6 Loosen Lock Nut I and thread it down At the same time remove the Adjustment Screw from the Pivot Shaft J 7 Tap the Shaft J toward the rear tire to complete its removal Service Tip The shaft is spaced with 2 Nylon Washers K note their location for reassembly 8 Slide the deck assembly out from under the machine PAD DRIVE MOTOR CARBON BRUSH INSPECTION Follow instructions for Pad Drive Deck Removal See Figure 1 Remove the Motor Air Filter L NOTE Inspect the condition of the filter band and clean or replace as needed R
52. ke while servicing the batteries When Servicing Batteries Remove all jewelry Do not smoke Wear safety glasses rubber gloves and a rubber apron Work well ventilated area Do not allow tools to touch more than one battery terminal at a time ALWAYS disconnect the negative ground cable first when replacing batteries to prevent sparks ALWAYS connect the negative cable last when installing batteries CAUTION To avoid damage to floor surfaces wipe water and acid from the top of the batteries after charging CHECKING THE BATTERY WATER LEVEL Check the water level of the batteries at least once a week After charging the batteries remove the vent caps and check the water level in each battery cell Use distilled or demineralized water in a battery filling dispenser available at most auto parts stores to fill each cell to the level indicator or to 10 mm over the top of the separators DO NOT over fill the 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 Well maintained batteries may last up to 3 years but failure after 1 year is common if mainten
53. le 1 visually inspect the vehicle for obvious problems 2 diagnose the problem using the programmer 3 test the circuitry with the programmer and 4 correct the problem Repeat the last three steps as necessary until the vehicle is operational Example A vehicle that does not operate in forward is brought in for repair 1 Examine the vehicle and its wiring for any obvious problems such as broken wires or loose connections 2 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 Putthe 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 forward was selected which means the problem is either in the electronic throttle or the throttle wiring 4 Check or replace the electronic throttle and wiring and repeat the test If the programmer shows the forward switch closing and the vehicle now drives normally the problem has been corrected Refer to the Status Fault Codes Table 1 for suggestions covering a wide range of possible faults DIAGNOSTIC HISTORY The handheld programmer can be used to access the controller s diagnostic history file Connect the programmer press the MORE INFO key and then while continuing to hold the MORE INFO key pres
54. load on vehicle 3 Operation in extreme environments 4 Electromagnetic brake not releasing 1 2 0 00 throttle fault T Throttle input wire open or shorted 2 Throttle pot defective 3 Wrong throttle type selected 7 1 3 0 000 speed limit pot fault T Speed limit pot wire s broken or shorted 2 Broken speed limit pot 14 0 0000 battery voltage too low 1 Battery voltage 17 volts 2 Bad connection at battery or controller 15 0 00000 battery voltage too high 1 Battery voltage gt 36 volts 2 Vehicle operating with charger attached 3 Intermittent battery connection 2 1 00 0 main contactor driver Off fault 1 Main contactor driver failed open 23 00 000 main contactor fault T Main contactor welded or stuck open 2 Main contactor driver fault 3 Brake coil resistance too high 24 00 0000 main contactor driver On fault T Main contactor driver failed closed 3 1 000 0 fault present for gt 10 sec Misadjusted throttle 2 Broken throttle pot or throttle mechanism 32 000 00 brake On fault 1 Electromagnetic brake driver shorted 2 Electromagnetic brake coil open 3 3 000 000 fault Low battery voltage 2 KSI and throttle turned on at same time 3 4 000 0000 brake Off fault T Electromagnetic brake driver open 2 Electromagnetic brake shorted 35 000 00000 HPD High Pedal Disable fault Improper sequence of throttle and KSI push or inhibit in
55. lt flash codes NOTE See electrical system Curtis Control diagnostics in this manual Horn Indicator Switch GG Pressing this switch will activate turn on the horn causing a horn like sound to emanate from the machine 12 FORM NO 56043107 Advolution 2710 UHR 70 1700 BURNISHING SYSTEM FUNCTIONAL OVERVIEW The machines Advolution 2710 UHR 70 1700 Model numbers 56422000 56422001 amp 56411002 use the disk type burnishing system The pad driver assembly is directly attached to a single 3 25hp 36v DC permanent magnet motor The burnishing deck is raised and lowered by a horizontally mounted electric lift actuator motor The operation of the machine s burnishing functions are activated when the operator presses the main I O Panel s pad drive raise lower switch EE NOTE See the Electrical System Advolution programming modes section of this manual for more detailed operation and instructions to change the burnishing pad pressure setting The machines main burnishing system input and output operating functions are regulated managed by the I O Panel and the Control Box For the Pad motor to function the operator must turn on energize the K1 pad motor solenoid by pressing the Pad drive Raise Lower switch EE on the I O Panel and press the drive pedal moving it off it s neutral position These two operator functions deliver the required A1 Speed control and Control Box circuit inputs and outputs for the bur
56. motor on and off The switch indicator provides the following status information Off Pad output is off and there is no current flow through the pad motor Green Pad output is on and there is normal current flow through the pad motor Flashing red Either the pad motor output is off and there is current 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 ACTUATOR WILL NOT OPERATE IF THE DECK INTERLOCK SWITCH IS OPEN DECK IN PAD CHANGE POSITION OR IF THE DECK INTERLOCK SWITCH IS DISCONNECTED IF THE ACTUATOR IS COMMANDED ON AND THE DECK INTERLOCK SWITCH IS OPEN THE PAD SWITCH INDICATOR AND THE DECK INTERLOCK SWITCH INDICATOR WILL FLASH When the output is in state 1 the actuator output is turned off The pad switch indicator should be off If the switch indicator is flashing red this indicates that the control is sensing abnormal current flow through the actuator When the output is in state 2 the actuator output is turned on The pad switch indicator should be green or flashing green The indicator will be a steady green if the control senses current flow through the actua
57. nal R1 Potentiometer 5 S1 Switch Key Main S2 Switch Seat S3 Sensor Proximity S10 Disconnect Emergency FORM NO 56043107 Advolution 2710 UHR 70 1700 55 ELECTRICAL SYSTEM WIRING DIAGRAM SCHEMATIC Item Description A1 Speed Controller CB1 Circuit Breaker 5 Amp Control CB2 Circuit Breaker 40 Amp Traction 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 4 Dust Control Vac Motor Optional R1 Potentiometer 5 S1 Switch Key Main S2 Switch Seat S3 Sensor Proximity S10 Disconnect Emergency 56 FORM NO 56043107 Advolution 2710 UHR 70 1700 MOTOR DUST CONTROL VAC OPTIONAL RED 2 h 4 RED EN BLK FUSE 150 A BATTERY 36 VDC Ai CURTIS 1228 SPEED CONTROLLER x VIO BRN 3 GRN GRA 2 RED WHT GRN BLK POT 5K OHM ORN BLK J7 1 H sided of p CB2 8 5 5 esie ede VIO BRN a m RED 1 252 GRN WHT BRN BLK CIRCUIT BREAK
58. ng 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 separates from the gear box FIGURE 7 32 FORM NO 56043107 Advolution 2710 UHR 70 1700 WHEEL DRIVE SYSTEM ELECTROMAGNETIC BRAKE ASSEMBLY REMOVAL A WARNING Disconnect the battery pack by separating the battery connectors 7 whenever servicing the machine Disconnect battery and block rear wheels so that the machine will not roll when the brake is removed See Figure 8 Remove the 2 Nuts A then the Brake Cover B Remove brake wiring at motor terminal block secured by 2 hex nuts Remove the 3 Screws C using a 4mm socket key wrench Separate the 3 parts that make up the brake assembly items D Electromagnetic Housing E Brake Rotor and F Brake Backing Ring gt FIGURE 8 FORM NO 56043107 Advolution 2710 UHR 70 1700 33 WHEEL DRIVE SYSTEM STEERING CHAIN REMOVAL AND TENSIONING A WARNING Disconnect the battery pack by separating the battery connectors 7 whenever servicing the machine 1 Turn the master key switch off and separate the Battery Connector Assembly 2 See Figure 9 From underneath the front of the machine loosen the 4 Screws and push the lower steering column toward the front of the machine This is done to separate the Chain B from the Steer Sprocket C Service Note Use a 17mm socket w
59. nishing operation NOTE See troubleshooting page 22 section for more details RED Fh RED ET BLK FUSE 150 A BATTERY 36 VDC CURTIS 1228 SPEED CONTROLLER VIO BRN GRN GRA R1 RED WHT GRN BLK 27 5K OHM ORN BLK 5 8 5 8 5 VIO BRN qp RED 2 GRN WHT BRN BLK YEL WHT CIRCUIT BREAKER 40 AMP x 5 al E EC PLUG AC MALE ON BOARD BATTERY CHARGER RED OPTIONAL BLK MOTOR TRACTION S10 2 RED WHT VG EMERGENCY SWITCH SEAT t 2 YELT 4 GRN BRAKE WHT ORN op REDWHT F R RED 3 vio WHT ORN GBN SEAT SW EUNT CIRCUIT BREAKER 5 SWITCH KEY STATUS J3 4 ORNBLK WHT ORN 33 2 KEY SW MODE J2 2 GBN BLK SDA J1 1 NK J4 1 SDA B SDA 41 1 ORNWHT SCL 1 2 242 SCL 5 4 i vol WHTIBRN 42 4 ACC 98 V J13 4 2 05 I O PANEL HORN SW J1 4 24 4 HORN SW SW SPST LAMP HEAD B j s ELKGRA SPOR OPTIONAL 8 J 5 gj 91 PAD SW J1 6 J4 6 PAD SW vio m WHT BRN CONTROL BOX idi LAMP FLASHING OPTION
60. ol Pin Key Detail Pin Wire Color Controller Pin Description amp Function 1 Opennotused 2 Opennotused 3 Throttle Pot R1 pot high input 4 Throttle Pot R1 pot wiper input 5 KSI key switch input Battery powers up controller logic circuits Auxiliary Driver Battery output to main control box to turn on activate the pad motor amp release 6 the electromagnetic parking brake Pin 6 will read approximately 36 volts when the foot pedal is in Fwd or Rev 7 8 e 0 volts MT open max transport speed selected 9 Status Fault Speed controller fault output to the main Panel indicator light horn LED 10 Open not used 11 Open not used 12 Open not used 13 Throttle Pot R1 pot low input 14 Orn Electromagnetic Brake Parking brake output 15 Open not used 16 Rev Alarm Driver output Battery command turns on back up alarm 17 Open not used 18 Vio Brn Speed limit pot input connection Note in this application it is tied to the pot high pin 3 WHEEL DRIVE TROUBLESHOOTING GUIDE Wheel drive motor will not run in forward and reverse Wheel drive in one direction only loss of either forward or reverse Hour meter status display shows an error 03 fault code see the Status LED Fault Codes Table 1 in the Electrical i Batteries need charging low battery voltage recharge
61. on 2710 UHR 70 1700 WHEEL DRIVE SYSTEM WHEEL DRIVE MOTOR REMOVAL A WARNING Disconnect the battery pack by separating the battery connectors 7 whenever servicing the machine 1 Follow the Wheel Drive Assembly Removal Instructions 2 See Figure 6 Place motor assembly upright tire side down as shown 3 Remove the 4 Socket Head Cap Screws A that secure the electric drive motor to the motor housing casting 4 Usea 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 amp springs new carbon brush measures 3 4 If less than 1 4 replace NOTE Clean foam filters blow out motor amp inspect the oil level in the gear case Gear case oil is 130GR Gear case capacity is approx 4 5 oz FIGURE 6 0 FORM NO 56043107 Advolution 2710 UHR 70 1700 1 WHEEL DRIVE SYSTEM DRIVE WHEEL REMOVAL A WARNING Disconnect the battery pack by separating the battery connectors 7 whenever servicing the machine 1 Disconnect battery and block rear 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 burnishi
62. onnections for re assembly Then disconnect wiring and remove the pedal mount assembly from the machine 3 Remove the Link Rod D from the Pedal E Note Be careful not to lose the link rod mounting hardware items F 4 Loosen the Nut G and Screw at the drive pedal Throttle Lever I Then pry the lever off from the end of the item B potentiometer shaft Next remove the pot from the Mount Housing J Testing the Potentiometer Note The pot doesn t have to be removed from the housing to test 1 Testthe potentiometer using an Ohmmeter the pot specification is 5K Ohms 2 Connect the meter leads to each of the outside connections on the potentiometer The meter should read approximately 5000 Ohms plus or minus 500 Ohms 3 Next move one of the test leads to the middle connection and turn the stem in both directions The range of the readings should be approximately 1300 2500 Ohms or 2500 3700 Ohms increasing and decreasing through its full range 4 If you do not get these readings replace the potentiometer Technical Service Tip A simple short cut method for testing and adjusting the pot resistance values is at the speed controller s 18 pin plug Just disconnect plug and back probe pins 3 4 8 13 wire colors VIO BRN GRA and BRN BLK The controller can be easily accessed by removing the electrical panel door located in the operator s compartment POTENTIOMETER INSTALLATION AND ADJUSTMENT A WARNING The adjustment of the pot
63. opening any access panels 1 See Figure 6 Grab hold of the right side of the Pad Drive Deck 1 and lift up until it Latches 16 in place as shown 2 Place your hand underneath the Dust Control Shroud 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 Insertthe plastic Pad Retainer 4 into the center of the Pad A Then reinstall by turning the retainer counter clockwise to the left NOTE Important Turn the retainer in until you hear a clicking ratchet sound this insures proper tightening of the pad by properly compressing the pad material and drawing up the retainer so it will not strike the floor FIGURE 6 20 FORM 56043107 Advolution 2710 UHR 70 1700 BURNISHING SYSTEM INSTALLATION OF THE DUST COLLECTION BAG Advolution 2710 UHR 70 1700 uses dust collection bag PN 56391185 sold 6 to a Package See Figure 7 Unfold the Dust Collection Bag 5 and while holding onto the Card Board Retainer A insert it over the Collection Tube B found on the top of the Pad Drive Deck 1 on the left side of the machine NOTE Never operate the Advolution 2710 UHR 70 1700 without Dust Collection Bag 5 or the o
64. ptional Active Dust Control Kit 21 56422083 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 REV Drive Pedal 8 is off the neutral position Extra Dust Collection Bags can be stored in the Spare Dust Bag Storage 18 box as shown Install the Rubber Strap C as shown to secure the bags FIGURE 7 FORM NO 56043107 Advolution 2710 UHR 70 1700 21 BURNISHING 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 Indicator Blank Pad Indicator RED EE See A Chart 2 Yes Check Circuit Inputs Indicator is Green amp lit Go to Part B Load Circuit actuator functions Troubleshooting If OV Re par green wire on seat switch Is RED light still ON Yes Yes Test the 63 Deck Interlock switch amp wiring The Indicator is still RED for Replace the Control Box Continuity Repair or Replace board Is the Green Light ON Does Actuator Function The Indicator is Green amp Actuator function
65. puts 2 Misadjusted throttle pot 41 0000 O current sense fault 1 Short in motor or in motor wiring 2 Controller failure 42 0000 00 motor voltage fault hardware 1 Motor voltage does not correspond to throttle failsafe request 2 Short in motor or in motor wiring ontroller failure 43 0000 000 EEPROM fault allure or fault 44 0000 0000 power section fault EEPROM failure or fault 2 Short in motor or in motor wiring 3 Controller failure Jack up vehicle and retest to confirm diagnosis Clean connections inspect system wiring and retest SPEED CONTROL PROGRAMMING OPTIONS The following is a list of the speed control parameters that can be adjusted using a Curtis hand held programmers M1 MAX SPEED Transport Burnish speed maximum limit 96 of full throttle M2 MAX SPEED Burnishing speed factory default is 80 M1 MIN SPEED Transport Burnish speed maximum limit with the speed limit pot in minimum position 96 of full throttle limited by speed limit pot M2 MIN SPEED Burnishing speed factory default is 30 M1 REVERSE MAX SPEED Reverse Transport Burnish speed maximum limit 96 of full throttle M2 REVERSE MAX SPEED Default is 7096 REVERSE MIN SPEED Transport Burnish speed maximum limit with the speed limit pot in minimum position 96 of full throttle limited by speed limit pot 46 FORM 56043107 Advolution 2710 UHR 70 1700 ELECTRICAL SYSTEM I
66. r reverse when the pedal returns to neutral oO RAR FIGURE 12 Right Side View Front View FORM NO 56043107 Advolution 2710 UHR 70 1700 37 WHEEL DRIVE SYSTEM TROUBLESHOOTING GUIDE ELECTRICAL Symptom Wheel drive motor will not run Part A load circuit Locate the RED GRN amp YEL BLK wires at Try resetting the CB2 40 amp the 1 speed controller Test output drive motor circuit breaker If No gt voltage by activating the drive pedal Max No still no drive then check CB2 forward voltage is 36V and Max reverse continuity voltage is 28V Varied pedal movement will vary the output voltage 0 36V Yes Replace the CB2 40 Amp breaker Repair or replace the input wiring to the A1 Board Check for 36V at the A1 speed controller battery and battery inputs Repair or replace the M1 wheel drive motor or wiring Yes i See Part B wheel drive control circuit troubleshooting 38 FORM NO 56043107 Advolution 2710 UHR 70 1700 WHEEL DRIVE SYSTEM TROUBLESHOOTING GUIDE ELECTRICAL Symptom Wheel drive motor will not run Part B control circuit E03 See fault table Is the pad switch indicator light red Check and repair or replace the Grn 51 Test for 36 at the A1 Speed No Input Wire Control on the Grn wire Pin 5 Yes Yes Troubleshoot both the 10 emergency
67. rd 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 VISUAL INSPECTION ITEMS Ref Comments Pad Motor Carbon Brushes check for wear Wheel Drive Motor Carbon Brushes check for wear Pad Deck Actuator Motor and Pad Drive Deck Levelness Perform a pad pattern test 2 Steer Chain Tension Drive and Steer wheels thread wear PF NOTE For additional service information see service manual form number 56043107 and operators manual English amp Spanish form number 56041634 Eg 14 3 5 0 1 18 1 1 7 19 WORK ACKNOWLEDGED Service Technician Signature Date Customer Signature Date FORM NO 56043107 Advolution 2710 UHR 70 1700 9 KNOW YOUR MACHINE you read this manual you will occasionally run across bold number or letter in parentheses example 2 These numbers refer to an item shown on these pages unless otherwise noted Refer back to these pages whenever necessary to pinpoint the location of an item mentioned in the text 1 Pad Drive Deck 2 Dust 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
68. re 11 Connect a voltmeter to B on the speed controller and the GRA wire A thin probe can be inserted into the connector at pin 4 on the speed controller or an insulation piercing probe can be used on the GRA wire 2 Adjustthe throttle potentiometer to 2 50 05 volts with the throttle pedal in neutral This will insure that the throttle is centered on neutral and there is 100 throttle when the pedal is fully depressed in the forward direction A Curtis programmer can be used to check that there is 10096 throttle in forward FORM NO 56043107 Advolution 2710 UHR 70 1700 35 FIGURE 10 FIGURE 11 VIO BRN BRN BLK VIOIBRN R1 GRA 2 GRNIBLK POT 5K OHM ORN BLK M 60 LI _ 5 VIO BRN BRN BLK x YEL WHT a 5 8 i m a gt 1 MOTOR TRACTION 36 FORM 56043107 Advolution 2710 UHR 70 1700 WHEEL DRIVE SYSTEM DRIVE PEDAL NEUTRAL ADJUSTMENT amp PEDAL REPLACEMENT If the drive pedal has been removed or replaced the neutral position for the pedal will have to be set Follow the steps below to accomplish this WARNING Disconnect the machine s battery pack connector 7 before servicing Note See Figures
69. s the DIAGNOSTICS key The programmer will read out all the faults that the controller has experienced since the last time the diagnostic history file was cleared The faults may be intermittent faults faults caused by loose wires or faults caused by operator errors Faults such as HPD or over temperature may be caused by operator habits or by overloading After a problem has been diagnosed and corrected clearing the diagnostic history file is advisable This allows the controller to accumulate a new file of faults By checking the new diagnostic history file at a later date you can readily determine whether the problem was indeed completely fixed To clear the diagnostic history file go to the Special Program Menu by pressing and holding the MORE INFO key and then pressing the PROGRAM key scroll through the menu until Clear Diagnostic History is the top line in the display and then press MORE INFO again The programmer will prompt you to acknowledge or cancel See the Curtis programmer manual 56043101 for more detail on programmer operation FIGURE 6 gt 5 FORM 56043107 Advolution 2710 UHR 70 1700 5 ELECTRICAL SYSTEM STATUS LED FAULT CODES TABLE 1 LED STATUS LIGHT EXPLANATION POSSIBLE CAUSE CODE DISPLAY A 00 over under temperature cutback T Temperature gt 92 lt 25 2 Excessive
70. t Actuator Motor Overload Check for binding or frozen lift linkage and excessive weight on Note Normal current load is1 2 5 Amps burnishing deck 2 Perform a current draw test To test disconnect Max current load 6 Amps amp Max current no the motor plug and attach the actuator test cord 56407502 and load 1 4 Amps compare readings to the fault description table to the left 3 Test for Err 06 Pad Motor Overload ing tn Repair De Note See Table 2 burnishing pad pressure also improper pad pressure lift motor operation 2 check for an open settings in the Pad Pressure Programming circuit in the small Black Yellow pad motor current sense wire and section for detailed load current values for repair wire if open 3 Check for short circuit in pad motor or wiring Err 08 or ere Caan open circuit in the coil wiring wire colors Black White Note Coil resistance spec is 120 Ohms amp Blue White 2 Test coil winding resistance for an open circuit plus or minus 10 Replace if defective 3 Check controller coil output voltage for 36V if Err 17 Pad Lift Actuator Motor Open n TEE TE ED wiring open in wiring or defective actuator motor Repair or replace 2 Check controller actuator output voltage for 36V if OV main controller failure replace Err 21 Pad Motor Open eck for open circuits in the pad motor n Me wiring Repair or replace 2 Test for 36V at the K1 load contact output red wire 2 with its
71. teering column base mount Screws C Service Tip Use a 17mm socket wrench 4 Observe and mark the drive motor wiring connections then remove the two large wires from their motor terminals 5 Remove the P Clamp D that fastens the drive motor wiring harness to the Steer Plate E 6 Temporarily disconnect one end of the steering chain remove 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 A 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 45 cm to remove the wheel motor spindle assembly by carefully guiding it down through the bottom of the frame opening and out from underneath the machine NOTE Be careful not to damage the threads and bearing surfaces when dropping the spindle through the frame when removing 9 Inspect bearings and seal replace as needed Remove the 4 Screws G to separate the Steer Plate E from the spindle weldment 10 To make further service repairs see the Wheel Drive Motor Removal section 11 Re assemble in reverse order and tighten the Steering Spindle Retainer Nut B just enough to eliminate any bearing free play FIGURE 5 30 FORM NO 56043107 Advoluti
72. ting To select between the two types Press and hold the horn switch while turning the key switch on Continue holding the horn switch until the status display is scrolling the word SELECT Release the horn switch Press and release the horn switch twice The status display should now be scrolling BATTERY TYPE Press and release the pad switch to enter the battery type selection mode The status display will now show either STD or ALT The standard setting has a cutout level of 1 75 volts per cell and the alternate setting has a cutout level of 1 84 volts per cell 7 To select the desired option press and release the horn switch This will alternate between the two options 8 save the setting and exit this mode turn the key switch off Fault Detection Enable Disable Mode FACTORY DEFAULT ON Normally the main control unit will perform checks of the electrical system during operation If a fault occurs in a particular system that system and possibly others will be shut down This can make 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 Continue holding the horn switch until the status display is scrolling t
73. tor It will flash green if no actuator current flow is sensed actuator at limit or abnormal condition When the output is in state 3 the actuator output is turned off The pad switch indicator should be off If the switch indicator is flashing green this indicates that the control is sensing abnormal current flow through the actuator When the output is in state 4 the actuator output is turned on The pad switch indicator should be red or flashing red The indicator will be a steady red if the control senses current flow through the actuator It will flash red if no actuator current flow is sensed actuator at limit or abnormal condition 50 FORM NO 56043107 Advolution 2710 UHR 70 1700 ELECTRICAL SYSTEM ADVOLUTION PROGRAMMING MODES Low Voltage Cutout Threshold Selection Mode FACTORY DEFAULT STD The Advolution is equipped with a low voltage cutout feature to prevent over discharging the batteries This feature will automatically shut down the pad motor when the battery voltage falls to the selected threshold The cutout level is adjustable The standard setting is 31 5 volts 1 75 volts per cell and the alternate setting is 33 12 volts 1 84 volts per cell The standard setting should be used unless the battery manufacturer specifies the higher cutout voltage It is important to note that some maintenance free batteries including some gelled electrolyte cells are capable of safely being used with the standard set
74. uide in repairing a specific system malfunction Note See the Troubleshooting Guide for further information An additional special feature of the main control board is to change program settings for a set of specific machine functions See the Main Control Board Special Program Options section in this manual for further information TROUBLESHOOTING GUIDE Any error codes detected by main control board will be displayed on the display panel CC as they occur If more than one error exists the display will sequence through the error codes at one second intervals The error will display as Err followed by a two digit code EX Err 06 would be a Pad Motor Overload MAIN CONTROLLER ERROR CODES Display Fault Description Troubleshooting Action En Oe Accessory Circuit Overload Check for a short circuit in the LP5 headlight and LP6 flashing warning beacon 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 Err 03 Speed control System Faults deep m ru CB2 breaker and reset if needed 2 Next investigate the reason for the mechanical overload Examples prolonged ramp climbing exceeding the machines grad ability limit and the electric parking brake not releasing 3 Then see Curtis drive motor controller section to further troubleshoot the drive system M Err 04 Pad Deck Lif
75. ully charged Test continuity of F1 150 Amp fuse Check wiring amp 150 Amp F1 Fuse for continuity Is fuse good Repair or Replace Yes Test for 36V at the RED feed wire No Check wiring amp 5 Amp breaker for continuity for the CB1 5 Amp breaker Repair or Replace Yes Test for 36 on the Violet wire at On machines without an the Control Box pin 13 1 Onboard charger repair the VIO wire Test for 36V on the wht org wire at the Control Box pin J3 2 Check continuity of 1 key No gt Repair wiring or replace key switch switch Yes Test for 36V on the Negative black ground wires at the Control Box pins No gt Repair damaged wire s J2 9 J2 10 and J3 8 m Install a new touch pad I O display No gt Replace the main Control Box panel do the lights work re the Panel indicator lights on If yes see the following 5 Lift Motor will not Padimotar wil nat Active Dust Control raise lower Vac Motor not working See Wheel See Burnishing Drive System See Burnishing System System See Burnishing System FORM NO 56043107 Advolution 2710 UHR 70 1700 53 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
76. was pressed the display will now show NONE 13 To exit this mode turn the key switch off gt CON 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 enter the test mode perform the following steps Press and hold the horn switch while turning the key switch on Continue holding the horn switch until the status display is scrolling the word SELECT Release the horn switch Press and release the horn switch once The display status display should now be scrolling the word TEST Press and release the pad switch to enter the service test mode To exit this mode turn the key switch off gt Following is detailed description of the service test mode functions Input Indicators Battery status red indicator Speed control reverse signal This indicator will be lit if the reverse signal from the speed control is active Battery status yellow indicator Speed control forward reverse signal This indicator will be lit if the forward reverse signal from the speed control is active Battery status green indicator Speed control status signal This indicator will be lit if the status signal from the speed control is active
77. wheel drive motor functions The controller unit is located underneath the front of the operator seat behind the electrical access panel The potentiometer R1 mounted to the operator s foot pedal inputs to the A1 controller the machine operator s desired speed and directional demands DRIVE MOTOR SYSTEM CONTROLLER FUNCTION OVERVIEW See Figure 1 To make the A1 speed controllers internal control circuits operational power it up the three switches S1 key S2 seat and S10 emergency stop knob must be closed This circuit inputs a positive 36V to the A1 speed controls pin terminal 5 KSI The CB2 circuit breaker 40 Amp supplies the positive high current load circuit input to the B controller terminal Grn Wht wire The black wire from the negative battery standoff supplies the battery ground input to the B terminal for both the control and load circuits See Figure 3 Depressing the foot pedal in either Fwd or Rev will move the 5K Ohm R1 potentiometer shaft off its centered balanced neutral setting of approximately 2500 Ohms With this pot shaft movement the pot s resistance value changes which generates a variable voltage signal 0 5 volts These control board voltage input signals are what energizes the Fwd amp Rev directional relays which selects the motor polarity and also switches the battery voltage On and Off PWM which varies the motor speed Key Switch Input PWM Pulse Width Modulation also called

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