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2800ST & 3400ST Service Manual - Industrial Cleaning Equipment

1. 80 56043121 28005 34005 755 855 ELECTRICAL SYSTEM 1 8 TO BE CONNECTED WHEN BATTERY ROLLOUT OPTION 002 BRN BLK 10 003 ERA BLK 18 1 004 RED WHT 18 80 5 9 9 x15 X16 LI x CURTIS 1228 MOLEX SPEED CONTROLER 006 ORN 18 COMM MINIFIT JR DR18 2 2 007 RED WHT 18 hs 009 BLK WHT 18 iS sereo
2. BAT F1 RED RED Bl FUSE 150 A BATTERY 24 VOC RED nl A CIRCUIT BREKER 70 ON BOARD b gt BATTERY CHARGER OPTIONAL oh Kas RFD B B Bl INTERLOCK fC OPTIONAL FLASHING 5 Sh 25 Hl BRN HT BRN GRA BI K L SW SPST KEY CIRCUIT BREAKER 10 AMP SEN ORN E 5 n EM BRAKE t P 504 2 amp o FOR RE 6 BRAKE B BRN _ 3788 sw STATUSQJ3 7 IRNZBLU fpi 9 status REV SS PIN 16 REV ALARM M1 di GRA BLK J3 1 vacuum CONTACTOR Peo MODE CONTACTOR VACUUM A2 P K2 T CURTIS 1228 SPEED CONTROLLER MI MOTOR WHEEL DRIVE WHT RED gos BRUSH CONTACTOR CONTACTOR BRUSH DA BLK PED 212 4 18 SPEED LIMIT 2 ELLK n TN VIU BLK gt 27 SOLUTION 13 POT LOW VALVE SOLENOID H 95 Al 4 POT WIPER 1 CONTROL BOARD por LB SK OHM THROTTLE H2 d J3 10 qu ORN RED HORN BACKUP ALARM T T 5 GRN BI 33 9 peck DRNZRETI ic BLK a4 56 5 SQUEEGEE K YFI p BLK 52 Bl 63 pert BLK BRUSH MOTOR 82 10 VACUUM MOTOR sENsg 2 9 BRNZRED
3. NOTES DISCONNECT RED WIRE ON AND REPLACE WITH GREEN WIRE FROM CHARGER WHEN ON BOARD CHARGER IS USED RFD RED FUSE 150 BATTERY 24 VOC CB2 RED nr CIRCUIT BREKER 70 AMP ON BOARD BATTERY CHARGER OPTIONAL p RE B Bl INTERLOCK IC OPTIONAL Dw LAMP FLASHING CB1 S1 PACA Une Wn ues n A BRN ZYFI lt BRN BRENT HT BE GRA I SW SPST KEY EMERGENCY STOP CIRCUIT BREAKER 10 AMP EAT Y1 E M BRAKE D 53 4 p a wo FU R REYJ3 6 RED WHT PIN 6 BRAKE B BL B BRN 374 yey sw STATUS US 7 PIN 9 STATUS REV 1J3 9 BLUZBLI PIN 16 REV ALARM 1 REDZGEN K GRA BLK 33718 vacuum CONTACTOR PIN 8 MODE CONTACTOR VACUUM A2 GS 3 13 CURTIS 1228 SPEED CONTROLLER M MOTOR WHEEL DRIVE WHT RED CONTACTOR AUS BRUSK SPEED 22 4 PIN Ta LIMIT M2 ZRI J3 11 VIO BLK 13 POT LOW VALVE SOLENOID Al PIN 4 POT WIPER CONTROL BOARD PIN 3 POT HI POT SK OHM THROTTLE H2 d 13 10 eA ORN RED bore HORN BACKUP ALARM 5 H 33 9 HORN peck surrcu 22 DIRNZRET BE m BL SQUEEGEE SWITCH SE aL p 2 8 B
4. AY EMERGENCY STOP KNOB A WARNING Emergency Stop Knob 7 disconnects power from the Speed Control and Drive Wheel It does not disconnect the batteries but will continue to power the control board Do not use the Emergency Stop Knob as a substitute for disconnecting the red Anderson battery connector inside the battery compartment FIGURE 6 FORM NO 56043121 Advenger 2800ST 3400ST BR 755 BR 855 9 KNOW YOUR MACHINE MACHINE FRONT RH VIEW Operator s Seat Solution Tank Drain Hose Drive Pedal Directional Speed Drive Wheel Drive Wheel Circuit Breaker 70 Amp Control Circuit Circuit Breaker 10 Amp Emergency Stop Scrub Deck Rear Wheel 10 Battery Compartment under seat 11 Squeegee Assembly 12 Detergent Cartridge Access Cover AXP EDS models only 13 Detergent Cartridge AXP EDS models only 14 Scrub Deck Raise Lower Lever ST models only 15 Deck Skirt Removal Knobs 16 Battery Charger Access Door 17 Battery Charger optional 18 Seat Adjustment Knob optional on ST models 19 Deck Skirt Height Adjustment Knob 20 Front Roller Bumper ON OO R amp D 2 ai ot 7 D b Nu SF Y Y LN EN o 10 FORM 56043121 Advenger 28005 34005 755 BR 855 34 Machine Battery Connect
5. SCRUB BRUSH MOTOR REMOVAL DISC 5 See Figure 22 Mark the bolt locations A before removing them because one deck is used for all deck sizes and there are multiple configurations 6 Figure 23 Extract the solution hose from the motor bracket C 7 Remove the bolts and nuts D and remove the motor assembly E from the deck 8 Disassemble the existing scrub brush motor from the bracket 9 Apply Loctite 242 to the motor bolts before fastening the new motor to the bracket 10 Feed the hose back into the bracket making sure that the hose is pointed towards the shaft Z CAUTION If the hose is not positioned correctly the scrub brush will be damaged melted due to lack of water 11 Reattach the motor bracket assembly to the deck making sure to use the correct holes If position is not correct brushes will either interfere with each other or with the deck sides 12 Lubricate the Motor Gimbal and apply anti seize to the socket head bolt before reassembly 13 Press the Brush Plate firmly onto the motor shaft If it is not pressed in completely the deck will not be level causing one motor to prematurely burn out see Caution A CAUTION ST the control board monitors total current drawn by both motors combined It cannot differentiate if one is bound and pulling D high current or if one is forced into the floor while the T other is barely making contact To verify proper
6. VACUUM MOTOR 2 9 BRN RE D DU T EI xe P3 Ah Keer HOURMETER l gt RFD CONTACTOR VACUUM MOTOR VAC C ME T MOTOR VAC KUPTIDNAD _7 A a ee Eee nee sah M7 RED RFD M CONTACTOR BRUSH MOTOR BRUSH 8 Nom MOTOR BRUSH 30 FORM NO 56043121 Advenger 28005 34005 BR 755 BR 855 BRUSH MOTOR CONTROL AND LOAD CIRCUIT ERROR CODES AND MEASUREMENTS Advenger BR 755 855 Display ST Service LED Fault Description Troubleshooting Action Blink Code Check for binding rotation of brushes or improper brus lift actuator operation 2 Check for mechanical interference of the brushes with the side skirts 5 1 2 Brush motor circuit overload 3 Check the negative supply cable at the brush motor for a wiring problem improper modifications or poor connections at the YEL VIO sense wire 4 Check that the deck is set correctly in the control board programming eck for short circuit in wiring or K2 contactor coil Repair 10 2 2 Brush motor K2 contactor coil overload or replace Check for motor wiring open or defective motor 2 Check the negative supply cable at the brush motor for a wiring problem or improper modifications this is a special 2 4 cable and must be replaced with original OEM due to sense wire Visible Brush motor circuit
7. operation of each motor monitor them individually with a current clamp while the machine is scrubbing 14 Firmly tighten the socket head screw without over torquing as damage to Motor Gimbal may occur e Q SS Ss 1 S 1 FIGURE 22 9 FIGURE 23 FORM NO 56043121 Advenger 28005 3400ST BR 755 BR 855 37 1 2 NO 4 FIGURE 24 SCRUB DECK REMOVAL CYLINDRICAL A WARNING DISCONNECT BATTERIES BEFORE SERVICING Scrub Deck Removal Re installation Remove both deck side skirt assemblies and the debris tray Lower the scrub deck with brushes installed STD AXP EDS SERVICE NOTE Don t turn the key switch off until after disconnecting the battery pack This procedure is done to prevent the scrub deck from automatically raising when the key is turned off See Figure 24 Disconnect the solution system water line located on top of the scrub deck Disconnect both brush motor wiring harness connectors A under right side of machine Remove the two B Hitch Pins that attach the scrub deck to the machine chassis linkage arm weldment From the right side of the machine pull the deck out from under the machine to complete the removal To install a scrub deck and roller bumper if applicable follow the previous steps in reverse order 38 FORM NO 56043121 Advenger 28005 3400ST BR 755 BR 855 PEREP BR
8. E P3 Ah BLK me ES Keep Door Open While Charging HOURMETER CGPTIONAL Mantenga la puerta abierta K1 RED HI a 2 mientras que carga CONTACTOR VACUUM _ MOTOR VAC T Pia ry s MOTOR VAC SS kOPTIONALy NA d 7 FD 2 RED gt CONTACTOR BRUSH Ml MOTOR BRUSH N MOTOR BRUSH NOTES DISCONNECT RED WIRE ON AND REPLACE WITH GREEN WIRE FROM CHARGER WHEN ON BOARD CHARGER IS USED REF DRAWING 56601179 DIAGRAM ST WIRING 56601178 REV D FORM NO 56043121 Advenger 2800ST 34005 BR 755 BR 855 41 RECOVERY SYSTEM ERROR CODES AND MEASUREMENTS Advenger T I BR 755 A Service LED Fault Description Troubleshooting Action 855 Display Blink Code 3 debris vac motor 2 Check for worn carbon brushes 3 Check for defective corroded motor bearings 4 Check for short circuit in vac motor or wiring 5 Check the negative supply cable at the vac motor for a wiring problem improper modifications or poor connections at the BRN RED sense wire Repair or replace eck for short circuit in wiring or K1 contactor coil 2 1 Vacuum K1 contactor coil overload Repair or replace Check for motor wiring open or defective motor 2 Check the negative supply cable at the vac motor for a wiring problem or improper modifications this is a special cable and must Visible Vacuum motor circuit open
9. Air leak at hose connection to pressure sensor 2 Air leak at Pressure Sensing Tube fitting 3 Small clear hose at pressure sensor on Interface Control Panel is kinked y control board installed Panel Completely drain the solution tank and the pressure differential should work properly again 2 Check for air leaks at re connected hose fittings emical rate doesnt match manufacturer eck that pump Is wired correctly and that the polarity isnt reversed specifications FORM 56043121 Advenger 28005 34005 BR 755 BR 855 47 SOLUTION SYSTEM DIAGRAM FIGURE 28 Pressure Sensor on Control Board Short clear hose inside Control board compartment If kinked solution level reading Chemical Pump will be off throwing off flow rate and chemical dispensing if equipped Pressure sensing tube that provides column pressure to sensor proportional to liquid level in tank Solution Drain Hose 4 6 Solution Tank 8 _ ai Solution feed hose to scrub brushes ST MODELS p a Be e Valve Tee fitting for hose from Manual Ball Valve 58 Solution Filter chemical pump Solution Tank 48 FORM 56043121 Advenger 2800ST 34005 BR 755 BR 855 SOLUTION SYSTEM CONTROL Advenger BR 755 855 The control board output of pulsed voltage signals driving the Solution System is control
10. CONTACTOR UM 032 BRN 1 aa PEU OE 8 gt 77 MOLEX X J2 CONN MINIF T JR 12DR T 031 WHT BRN 18 2 s mi 3 9 ag E E SW SPDT DI 2 4 S ga 50 EMERGENCY STOP SEAL SWITCH D A ur E 5 2 T 037 BRN 18 5 7 SP8 912 88 3 X76 75 7 5 515 045 YEL 18 5 58 K2 T T T T 044 VIO 18 7 CONTACTOR BRUSH 2 052 WHT BRN 18 085 GRA BLK 18 MO 1 1 E 050 BRN 18 051 WHT BRN 18 CONN MINIFIR JR 10DR sp spt H 3 2 J1 2 2 HE 075 Vio 18 054 BRN 18 jv E 4 s 4 9 7 X0 a a 5 10 No lt OPTIONAL gt m 133 X 2 1 X57 056 RED YEL 18 gt amp 85 xn CHEMICAL PUMP 1AMP cR in E m AN AS onsen apne pn ona 4 gt oss RT 053 BLK 18 lt p 065 BLK YEL 18 X8 o 29 X28 Lti E 1 2 gt la xj7 E1 2 R1 VALVE SOLENOID i ON BOARD 8 7 BATTERY CHARGER o gt 2 28 POT 5K OHM THROTTLE BE lt OPTIONAL gt Be pT z 060 RED 1 X44 5 5 067 REDI INTERLOCK 5 11 70 E 015 GRN YEL 16 M 8 8 5 1 gi 2 gt 5 5 lt X47 ri 3246 OP BRN YEL 16 712 3 B 086 RED 16 1 12 xs 19 4 042 WHT RED 18 2 X56 016 BLK 10 55 034 WHT 10 HORN BACKUP ALARM xB 7 SPh E 2 x35 ER x gt M
11. Tilt Angle Setting Wheel Height FIGURE 8 Factory setting is 0 87 nominal 6 2 5 FIGURE 8 22 FORM NO 56043121 Advenger 28005 34005 BR 755 855 SQUEEGEE ACTUATOR REPLACEMENT ADVENGER BR 755 855 A CAUTION The Recovery Tank is heavy and care should be taken in removing it Two people recommended or battery roll out unit 1 Lower the squeegee tool to the floor and then disconnect the battery pack at the red Anderson connector in the battery compartment Drain the recovery tank using the Recovery Tank Drain Hose 31 Disconnect the squeegee hose from the squeegee tool and remove the tool from its mount Lift up the seat and unplug vacuum motor and warning beacon if equipped connectors located in battery compartment Open the hinged recovery tank cover and grip the top inside edge of the tank then pull straight up to free it from the solution tank platform Guide the tank off the rear of the machine to the floor See Figure 9 From the back of the machine remove the Retainer Ring A securing the lift cable Pin B and separate the pin and cable from the motor drive tube housing and chassis mounts Note Don t lose the two plastic cable spacers positioned in motor drive tube Locate the wire tie that attaches the motor wiring to the chassis and then disconnect the motor harness From underneath the machine remove the Hairpin securing the lift motor Pin 0 a
12. mode X XXX EU mode DETERGENT MODE Mode 1 Mode 2 no a aan US Evergreen On EU or non Evergreen preset i eser LOW VOLTAGE CUTOUT WE battery 80 Gel AGM Battery 7096 LOCK OUT BRUSH PRES High Low amp Medium Low amp displayed pressure is locked out High High amp Medium LOCK OUT SOLUTION High Low amp Medium Low amp displayed rate is locked out High High amp Medium RECOVERY TANK FULL ENABLED DISABLED automatic shutoff turned on Br CHEMICAL RATE BIAS NONE equal 10 MORE CHEM 10 LESS CHEM ENG DECK DOWN TIME Incremental from 1 to 5 seconds in 0 1 second intervals uH pos FACTORY DEFAULTS BEN YES NAE NN BEN faults To erase history press the Solution switch while SEGUE display in this mode mgrum DETECTION eren eee pope mm 66 FORM NO 56043121 Advenger 28005 34005 BR 755 BR 855 CHANGING PROGRAM SETTINGS ST 1 To enter this Hidden Menu turn key switch Off then press and hold the buttons shown in the table below simultaneously 2 Turn key switch back On and hold for 2 seconds until the indicated LEDs for the desired function turn On then release the switches 3 Use the Solution or switches to change the setting The fault code LED will blink at the same rate as the fault code display to show what the current setting is Press the Solution On Off switch to save the setting then turn key switch Off to
13. 2 1 BRUSH MOTOR sENsHE IO VACUUM MOTOR 9 2 2 BRNZRED q P3 i Ah o NE e Keep Door Open While Charging HOURMETER OPTIONAL Mantenga la puerta abierta 1 mientras que carga CONTACTOR VACUUM MOTOR VAC M MOTOR VAC COP TIONAL Bec IL 1 7 RED M CONTACTOR BRUSH MOTOR BRUSH 8M MOTOR BRUSH Item Ref No Qty Description A1 56601566 1 Control PCB Assy A2 56601061 1 Speed Control BAT N A Battery F1 56412089 1 Fuse 150 Amp CB1 56454429 1 Circuit Breaker 70 Amp CB2 56507644 1 Circuit Breaker 10 Amp H1 56307166 1 Beacon Warning optional H2 56412177 1 Horn Backup Alarm K1 56601183 1 Contactor 24v 100 Amp K2 56412179 1 Contactor 24v L1 56601064 1 Solenoid Valve Assy 1 56601050 1 Motor Drive Wheel M5 56601132 1 Motor Vac 24vdc M6 56601132 1 Motor Vac 24vdc optional M7 56601134 2 Motor Gearbox Assy M8 56601134 2 Motor Gearbox Assy R1 N A 1 Part of 56601052 S1 56303553 1 Key Switch 56303526 AR Replacement Key Set 52 7 82 00050 1 Squeegee Switch 54 56407130 1 Disconnect Emergency 5 56305053 1 Deck Switch S6 56601160 1 Squeegee Switch Y1 56601507 1 Brake Electromagnetic 56315124 1 Charger On Board 24v TSBUS2008 984 FORM NO 56043121 Advenger 28005 34005 BR 755 BR 855 79
14. 56422174 Tire Puller Kit for Drive Wheel Assembly 4 FORM NO 56043121 Advenger 2800ST 34005 BR 755 855 TECHNICAL SPECIFICATIONS GENERAL Machine Voltage 24 VDC Length W squeegee 60 in 152 4 cm Dimensions without Squeegee and wigth body 27 5 in 70 cm Scrub Deck Height Recovery tank 51 7 in 131 3cm Scrub Deck Width Squeegee Width Scrub Deck and 30 3 in 77 cm 28 disc 32 6 in 82 8 cm Squeegee Widths 36 3 in 92 2 cm 34 disc 414 in 105 2 cm 31 6 in 80 3 cm 28 32 6 in 82 8 cm Solution Tank 28 gal 106 Tank Capacities Recovery Tank dynamic 25 gal 95 I static 28 gal 106 Gross Weight standard machine w o options w full solution tank empty recovery tank and heaviest batteries installed Net Weight standard machine w o options batteries or removable brushes w empty solution and recovery tanks 1451 Ibs 658 kg 536 Ibs 244 kg Static Wheel Loading Front 615 Ibs 279 kg Rear 836 Ibs 379 kg Static Wheel Pressure Front 174 7 psi 12 3 kg cm Rear 124 7 psi 8 8 kg cm Ingress Protection Code IPX3 Sound Pressure Level IEC 60704 1 Vibrations at the Hand Controls ISO 5349 1 26 m s Vibrations at the Seat EN 1032 05 m s Transport 16 9 degrees Gradeability Cleaning 9 5 degrees Battery Compartment Dimensions Advance Models FIGURE 1 Nilfisk Models Maximum Battery Compartment 420
15. 9 RED 4 3 WHT BLK 59 CONTACTOR VACUUM 21 5 43 Ti MOTOR VAC o 99 S 5 377 6 REY ce ia MOTOR VAC 9 M MER I RED 4 RED BLK CONTACTOR BRUSH A DISCONNECT RED WIRE ON CB2 AND REPLACE WITH GREEN WIRE MOTOR BRUSH FROM CHARGER WHEN BOARD CHARGER IS USED REF DRAWING 56601177 DIAGRAM AXP WIRING ed MOTOR BRUSH ELECTRICAL SYSTEM
16. In addition to a full set of metric and standard tools the following items are required in order to successfully and quickly perform troubleshooting and repair of Nilfisk Advance commercial floor cleaning equipment 1 Laptop computer loaded with current version of EZParts Adobe Reader and preferably cellular internet access Digital voltmeter DVM with DC current clamp Hydrometer Battery load tester for checking 6V batteries Bearing puller Static control wrist strap Set of torque wrenches Hard printed copies of service manuals for all regularly serviced machines available at www advance us com and other Nilfisk Advance websites 9 6 section of 1 1 2 PVC pipe with a 1 hole drilled into one side to check vacuum system against 1 lift spec 10 1 1 2 and 2 3 8 drill bit or hole cutter if a Dual Vac Kit is to be installed Also these tools available from Nilfisk Advance Inc Danish Norwegian Swedish Finnish German French Nederlands Russian Spanish Portuguese Italian Greek Estonian Latvian Lithuanian Slovenian Slovakian Czech Polish Hungarian English Turkish COND FB 56407502 Actuator Power Cord Adapter 56205281 Water Lift Gauge 56206921 Timer Bypass Kit used to bypass timing function when troubleshooting shelf chargers 56409441 Curtis Handheld Programmer 56409823 Curtis Adapter Cable Quad Plug 56315732 Delta Q QuiQ Onboard Charger Interface Module
17. parking brake 56601507 D motor cover 56601506 To replace the tire follow steps 1 3 of Replacing the Drive Wheel Assembly Remove the six metric socket head screws Use Tire Puller Kit 56422174 to replace the tire Reassemble in reverse order gt 54 FORM 56043121 28005 34005 BR 755 BR 855 INSPECTING REPLACING THE DRIVE WHEEL ASSEMBLY CARBON BRUSHES A IMPORTANT To remove replace inspect the Carbon Brushes observe the following 1 The motor must come off of the machine 2 The motor assembly must be kept vertical while being disassembled to prevent loss of gear oil A WARNING Park the machine on a dry flat surface turn the main key switch J to the Off position and disconnect the battery pack at the red Anderson connectors inside the battery compartment 1 Follow the instructions in Replacing the Drive Wheel Assembly 2 Place the motor assembly upright motor side up as shown AN CAUTION To prevent gear oil from draining from the gearbox disassemble the motor with the Drive Wheel assembly in a vertical position If some oil is lost drain completely and refill the oil as indicated at the bottom of the page 3 SeeFigure 37 Remove the four metric socket head cap screws A securing the electric motor to the casting 4 Use ahard piece of wood or a brass drift punch to tap the motor mounting flange 3 notched locations
18. 20HR RATE 420AH 20HR RATE 25 LX 15 5 WX 21 H Without the Box 26 25 X 16 X 21 CAUTION Before changing batteries consult CAUTION Before changing batteries TSBUS2008 984 or call Technical Service at consult TSBUS2008 984 USA 800 989 2235 Canada 800 668 8400 or visit http www nilfisk advance com Mexico 52 55 2591 1002 ext 228 FORM NO 56043121 Advenger 28005 34005 BR 755 BR 855 5 Batteries Onboard Battery Charger DRIVE SYSTEM Drive Wheel Drive Motor Max Transport Speed SOLUTION SYSTEM Solution Control 1 Regular Scrub Advenger BR 755 855 Solution 2 Heavy Scrub Flow Rates 3 Extreme Scrub 1 Regular Scrub ST Solution Flow Rates 2 Heavy Scrub Average 3 Extreme Scrub AXP EDS System Available Detergent Ratios Available Recycle System Available RECOVERY SYSTEM Vacuum Motor s Vacuum Water One Motor Lift measured at recovery hose Two Motors TECHNICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Number of Batteries 4 Battery Voltage 6V 310 Ah wet Number of Batteries 4 Battery Voltage 6V 420 Ah wet Number of Batteries 4 Battery Voltage 6V 312 Ah AGM Standard Battery Capacity 305 amp hours 0 20 hour rate 24 volt Model 912 2400 N1 Output 25A Manufacturer Delta Q Gel Compatible Yes Diameter 9 84 in 25 cm Width 3 15 in 80 cm Type Material Blue Urethane 1 05 HP 780 watts Fwd 3 91 mph 6 30
19. SOLENOID ids zer er SE ON BOARD i C BATTERY CHARGER POT 5K OHM THROTILE OPTIONAL gt a eB 060 RED 1 X44 ri 5245 INTERLOCK 50 069 RED 10 OTE 1 2 B lt X47 7246 471 BRN YAL 5 1 9 086 RED 16 i 63 CIRCUIT BREKER 70 015 GRN YEL 16 2 016 BLK 10 X96 ALARM SP4 043 WHT 10 M7 M8 ae 084 WHT 10 VA S BRUSH BRUSH 11 108 BLK 10 _ xs X6 41 x X69 x MS LY X Filion S ER 1 E E 16 RED 10 MOTOR VAC 078 RED 10 TS USED Ss 2 CONNECT Ji AND TO CONTROL BOARD 029 RED 8 1 2 081 BLK 10 SP3 O77 BLK 10 Nilfisk Advance setting standards www nilfisk advance com 2008
20. SQUEEGEE LIFT ACTUATOR CIRCUIT ERROR CODES AND MEASUREMENTS ADVENGER 755 855 TROUBLESHOOTING SQUEEGEE ISSUES SQUEEGEE ADJUSTMENTS SQUEEGEE ACTUATOR REPLACEMENT ADVENGER BR 755 855 23 SQUEEGEE ACTUATOR DRIVE NUT ADJUSTMENT ADVENGER 755 855 SQUEEGEE LIFT CABLE REPLACEMENT ADVENGER BR 755 855 SQUEEGEE LIFT CABLE REPLACEMENT ST SQUEEGEE LIFT CABLE ADJUSTMENT ST STEERING COLUMN ASSEMBLY SHROUD REMOVAL SCRUB SYSTEM 29 BRUSH MOTOR CONTROL AND LOAD CIRCUIT ERROR CODES AND MEASUREMENTS 31 SCRUB DECK LIFT ACTUATOR ERROR CODES AND MEASUREMENTS ADVENGER BR 755 855 TROUBLESHOOTING SCRUB SYSTEM ISSUES SCRUB DECK LIFT ACTUATOR REPLACEMENT ADVENGER BR 755 855 433 SCRUB DECK LIFT ACTUATOR DRIVE NUT ADJUSTMENT ADVENGER BR 755 855 234 SCRUB DECK REMOVAL DISC 295 SCRUB BRUSH MOTOR REMOVAL DISC SCRUB DECK REMOVAL CYLINDRICAL 238 SCRUB BRUSH MOTOR 39 RECOVERY SYSTEM RECOVERY SYSTEM ERROR CODES AND MEASUREMENTS TROUBLESHOOTING RECOVERY SYSTEM ISSUES REPLACING A VACUUM MOTOR TABLE OF CONTENTS SOLUTION SYSTEM SOLUTION a
21. 058 BLK 8 002 BRN BLK 10 vi 003 GRA BLK 18 i 004 RED WHT 18 X80 699 5 X9 E M BRAKE MIS 15 x10 T 1 CURTIS 1228 MOLEX SPEED CONTROLER 006 ORN 18 COMM MINIFIT JR DR18 x2 P2 En 007 RED WHT 18 Bayo 009 BLK WHT 18 5 um 47 17 REVERSE 17 REVERSE LJ 043 GRN YEL 16 5 BLU BLK 18 16 HORN 16 HORN 2 se 19801 3 vr 1 011 ORN BLU 18 TA BRAKE T l 5 3 1 Low 13 Low PROGRAMMER M amp B 1 8 MOLEX aliel E 18 CONN MINIFIT JR 14DR eligo e P 458 5 STATUS 3 status a 8 8 1 2 mBo 1 s 112 ub wae 7 PUSH HE 035 BLK 18 2 9 021 GRNTBLK e Elano 022 BLK 18 10 023 ORN RED 8 lt 5 ks 3 Ate J 4 POT WIPER 4 POT WIPER sa 071 GRA BLK 18 3 Por 3 POT HIGH 2 42 2 O46 BLK 1 1 OPTIONAL gt p 1 7 030 BRN 18 Tle RED BLK 024 GRA BLK 18 por x2 ie LL 1 LAMP FLASHING dar
22. B to loosen 5 Grip the motor brake end bell and pull the motor C up and out of its housing 6 Inspectthe 4 carbon brushes and springs A new carbon brush measures 3 4 If less than 1 4 replace 7 Clean the foam filters and blow out the motor 8 _ If gear oil has been lost drain and replace with 4 5856 oz 130 g of Mobilgear 600 XP 150 or AGIP BLASIA 150 gear oil FIGURE 37 FORM NO 56043121 Advenger 2800ST 34005 755 BR 855 55 REPLACING THE REAR WHEELS Z WARNING Park the machine on a dry flat surface turn the main key switch Off and disconnect the battery pack at the red Anderson connectors in the battery compartment Block the front Drive Wheel 4 Jack the Rear Wheel 9 to be replaced per the instructions at the front of this manual in Jacking Points section To prevent injury if the rear wheel bearing has frozen replace the bottle jack with blocks or a jack stand before pounding the wheel See Figure 38 Use a 17mm socket to remove bolt A washer and wheel If the bearing has seized pound off the wheel and use a bearing puller to remove the inner race from the axle Apply anti seize to the inner bearing surface of the new wheel then replace wheel on axle Apply anti seize to the bolt threads before refastening bolt washer and wheel NOOR WD FIGURE 38 WAY 56 FORM 56043121 Advenger 28005 34005
23. BR 755 BR 855 ELECTRICAL SYSTEM FIGURE 39 ACCESS TO PANEL CHEMICAL PUMP CHARGER INTERLOCK FUSES CONTACTORS SPEED CONTROL A WARNING Open the battery compartment and disengage the red Anderson battery connectors 2 Remove the 3 AXP EDS 4 screws fastening the electrical panel to the front of the machine 3 See Figure 39 Inside are found the following e Curtis speed control A with Drive Wheel motor and logic connections e and K2 contactors e Fuses as shown with onboard charger green interlock wire connected If no charger red wire shown would be connected there instead e Chemical pump D below fuses THROTTLE POTENTIOMETER WIPER MEASUREMENT NEUTRAL POSITION Use a DVM and extended insulated probe tips shown to measure the throttle potentiometer Neutral voltage at the wiper pin 4 the GRA wire referenced to the B standoff green wires A WARNING Open the Electrical Access Panel carefully per step 2 above Batteries must be connected to perform this measurement so extreme caution should be observed A CAUTION Use only insulated test probes designed to backprobe SPEED CONTROL IS POWERED during these tests Cc WU SR Es Referenced to the negative battery standoff the wiper voltage should read Neutral 2 3V Reverse 2V engage pedal in reverse to measure Forward gt 3V engage pedal forward to measure FIGURE
24. CA ce Pen 1 CB2 51 lt RED 5 BRN YEL BRN YEL 2 1 BRN BRN 7 52 GRA BLK bs WHT BRN SWITCH SEAT CIRCUIT BREAKER 10 EMERGENCY STOP ORN 5 2 Z z BRN YEL 43 SEAT 5 3 E i m a wo J3 Bp FUR REVJ3 6 RED WHT PIN 6 BRAKE E BRN 43 10 5 STATUS J3 7 ORN BLU PIN 9 STATUS B BLK z REV 3 9 BLU BLK PIN 16 REV ALARM BRN GRA BLK J3 18 ACUUM CONTACTOR Mig mde MP RED GRN CONTACTOR VACUUM A2 K2 BRN WAT RED 23 1 RUSH CONTACTOR CURTIS 1228 SPEED CONTROLLER 2 MIT MOTOR WHEEL DRIVE CONTACTOR BRUSH S CEN Je 4 BLK WHT PIN 18 SPEED LIMIT 1 BRN a 2 VIO BLK eater M2 YEL BLK Je eYEL VALVE SOLENOID PUT GRA 1 4 WIPER H2 CONTROL BOARD 2 RI D ORN RED inry por 11 2 5 0 YEL ow POT Hi HORN BACKUP 5K OHM THROTTLE GRAPBLK J3 P 142252202515 71 P lt OPTIONAL D ON RED YEL CHEMICAL PUMP mo E J1 8 BLU CRA Ji 9 CHEMICAL PUMP BLK 2 8 BLK 8152 7 8112 1 BLK 3 2 M3 Bu SQUEEGEE LIFT ACTUATOR 35 SQUEEGEE J1 10 WHT GRN Mh 9 Seueri aet liad 69 Ro BRUSH LIFT ACTUATOR 25 oO BRUSH act 125 ORN BLK 3 2 BRUSH MOTOR sensple 10 YEL VIO 5 9 VACUUM MOTOR sENSEJ8 9ERN RED 2 2 os S
25. CONTACTOR BRUSH MOTOR BRUSH MB MOTOR BRUSH FORM NO 56043121 Advenger 2800ST 34005 755 BR 855 29 SCRUB SYSTEM ST with the seat switch closed lowering the squeegee and brush deck and pressing the drive pedal forward causes the brush and vacuum contactors to energize The 24V brush and vacuum motors turn on the pulsed solution solenoid turns on Combined brush motor current is monitored via the YEL VIO sense wire Reversing the drive pedal turns off the solution solenoid but the brush motors stay on for double scrub BRN 3 14 4 KEY SW K1 GRA BLK 43 12 4 VACUUM CONTACTOR CONTACTOR VACUUM K2 WHT RED 3 13 BRUSH CONTACTOR CONTACTOR BRISU i VIO BLK 23 11 VALVE SOLENOID H2 a ORN RED 53 10 7 SOLUTION Al HORN BACKUP ALARM HORN CONTROL BOARD STATUS 37 REV47375 9 STATUS PIN 16 REV ALARM SPEED PIN 8 MODE A2 CURTIS 1228 SPEED CO 4 LIMIT H LaJ2 XTLI PIN 18 SPEED LIMIT PIN 13 POT LOW PIN 4 POT WIPER 5K OHM THROTTLE PIN 3 POT HI OF 23 9 5 GRN BL 1 HORN peck svi Jer cee BL L 5 BL SQUEEGEE SWITCHE BI KZ YE SE Eu p Je 8 B pWe 1 BRUSH MOTOR 5 2
26. CURTIS 1228 SPEED CONTROLLER D M MOTOR WHEEL DRIVE E Je 4 BLK WHT 18 SPEED LIMIT PIN 15 LO 2 YEL BLK J2 6YEL POT HI Al Es PIN 4 POT WIPER CONTROL BOARD R1 enr L0 2 9V0 RR POT 5K OHM THROTTLE FORM NO 56043121 Advenger 28005 34005 755 BR 855 51 Advenger ST Service Fault Description BR 755 855 LED Display Blink Code Error Code Speed control fault Menu Wheel Drive Typical Current A Motor Transport Full Throttle Advenger BR 755 855 the LCD indicates E03 and the chemical LED flashes a code ST the Fault Indicator LED is blinking 1 1 and the Extreme Solution Flow LED flashes a code drive motor will only run in either forward or reverse drive motor will not run in forward or reverse WHEEL DRIVE CIRCUIT ERROR CODES AND MEASUREMENTS Troubleshooting Action 1 Verify connector at Drive Pedal is connected will disable all systems unless fault 2 Refer to Speed Control Flash Codes section detection is disabled in the Hidden 3 Repair 4 Reset machine via key switch Typical Current A Scrub Mode Level Floor Mie Colors Red Green and Yellow Black 2 wires combined required to prevent overheating if rotor locks 1 Verify connector at Drive Pedal is connected 2 Refer to Speed Control Flash Codes section 3 Repair 4 Reset machine via k
27. Program Settings ST section Then verify fault by entering Service Test Mode FORM NO 56043121 Advenger 2800ST 34005 BR 755 BR 855 15 SPEED CONTROL ERROR FLASH CODES STATUS LED FAULT CODES TABLE 1 STATUS LIGHT EXPLANATION POSSIBLE CAUSE DISPLAY over under temperature cutback 1 Temperature gt 97 C 206 F or lt 25 C 13 F 2 Excessive load on vehicle 3 Operation in extreme environments 4 Electromagnetic foot or parking brake not releasing properly throttle fault Throttle input wire open or shorted Throttle pot defective Wrong throttle type selected 0 000 speed limit pot fault Speed limit pot wire s broken or shorted Broken speed limit pot 0 0000 battery voltage too low Battery voltage lt 17 volts Bad connection at battery or controller 0 00000 battery voltage too high Battery voltage gt 36 volts Vehicle operating with charger attached Intermittent battery connection main contactor driver Off fault Main contactor driver failed open main contactor fault Main contactor welded or stuck open Main contactor driver fault Brake coil resistance too high 00 0000 main contactor driver fault Main contactor driver failed closed 000 0 HPD fault present for gt 10 sec Misadjusted throttle Broken throttle pot or throttle mechanism 000 00 brake On fault Electromagnetic brake driver shorted Electro
28. deck lift actuator overload Check for disconnected actuator wiring open in wiring actuator motor or drift in motor current draw to less than 100mA Scrub deck lift actuator open call factory for instructions Repair or replace Lift Actuator Nominal Current A Overload Current 2 00 028 88 3 5 SAfor gt 4 seconds for gt 4 seconds Blue amp Blue amp Orange Black TROUBLESHOOTING SCRUB SYSTEM ISSUES It is unlikely that the scrub system will malfunction without generating an error code so most issues will be found on the preceding tables A few more machine specific items are listed here Advenger BR755 855 000002 BR 755 855 2 deck lift actuator overload RR interference between the deck and the ground E worn internal components of actuator e a motor overload location is too aggressive on the deck linkage for the floor brush combination 32 FORM NO 56043121 Advenger 28005 34005 BR 755 BR 855 SCRUB DECK ACTUATOR REPLACEMENT ADVENGER BR 755 855 1 2 gt Lower the scrub deck per the instructions found in Service Test Quickly disconnect the batteries at the red Anderson battery connector inside the battery compartment This is done not only for safety but to keep the deck from rising Unplug the Deck Lift Actuator connector Remove the Cotter Hairpins from the both ends of the actuator Remove the Deck Act
29. open 3 Check K2 contacts if open circuit while scrub is on in Fault replace K2 Recall Mode 4 Verify brushes are installed 5 Verify the brushes are touching the floor and there is no interference between the deck and the floor 3 2 i Visible 2 Check for tight connections at contactor and WHT RED 35 in Fault Brush motor K2 contactor coil open wire to control board Recall Mode Repair or replace Brush motor circuit contacts stuck closed With no power to circuit if contacts measure 0 ohms they re 3 4 stuck Replace K2 Of replace control board 2 If J3 13 is OV referenced to B when Scrub switch is Off disable fault via Hidden Menu Refer to Control Board J1 J2 and J3 Pin Outs and Test Points section Scrub Nominal Current A 27 32 Disc 40 23 30 Cylindrical 35 48 prast 4 Nominal Nominal Current Overload Current Contactor Coil Resistance 2 120 ohms 200 mA 100 mA 750 mA White Red FORM NO 56043121 Advenger 2800ST 34005 BR 755 BR 855 31 SCRUB DECK LIFT ACTUATOR ERROR CODES AND MEASUREMENTS ADVENGER BR 755 855 Advenger ST BR 755 855 Service LED Display Blink Code Fault Description Troubleshooting Action Check for improper actuator adjustment refer to Actuator Nut Adjustment section 2 Check for binding or frozen brush deck lift linkage and excessive weight on brush deck 3 Check for short circuit in brush motor and wiring Repair or repla Scrub
30. out function of the normal control system of components that are in an error state and allow those components to be manually turned on and off for troubleshooting purposes Components in an overload error state will still be locked out for safety reasons ST To enter Service Test Mode turn key switch Off then press and hold the three buttons shown below simultaneously Turn key switch back On and hold for 2 seconds until the red yellow and green LEDs turn On then release the switches Switch ON OFF Activate solution solenoid L1 Activate brush motor contactor K2 B ENERGIZED DE ENERGIZED Solution High Activate vacuum motor contactor K1 D ENERGZED DEENERGZED Other Status Indicators Indication Forward Battery YELLOW ON Drive pedal Reverse Battery GREEN ON 64 FORM NO 56043121 Advenger 28005 34005 BR 755 BR 855 CHANGING CONTROL BOARD PROGRAM SETTINGS Although the Advenger BR 755 855 and ST are delivered with a standard factory preset configuration there will be times such as when a control board is replaced when battery type is changed or a different size scrub deck is installed when some parameters in the control system software will need to be changed Most programmable functions are outlined below For more details call the Technical Service Department at Nilfisk Advance A IMPORTANT For field control board replacements critical settings are highl
31. the Drain Hose B 2 Disconnect the Recovery Hose from the squeegee 3 Disconnect the vacuum motor wiring from the main harness NOTE Also disconnect optional Beacon wiring if installed 4 Remove the Recovery Tank A from the machine FIGURE 26 44 FORM 56043121 Advenger 2800ST 34005 BR 755 BR 855 REPLACING A VACUUM MOTOR VACUUM MOTOR ASSEMBLY REMOVAL 5 Figure 27 Lay the Recovery Tank A on it s back 6 Remove the 6 Screws and remove the Vacuum Motor Cover C from the tank 7 Remove Plate and Gaskets D and Vacuum Motor NOTE The wires should be protruding up through the hole and not from around the edge of the plate If they are coming from under the plate examine for damage and repair if cut VACUUM MOTOR ASSEMBLY INSTALLATION 8 Attach gaskets and G to the new vac motor attach gasket to the Vac Motor Cover and insert motor into base 9 Reassemble in reverse order paying attention to route wires up through hole and out towards the back in the groove of Vac Motor Cover FIGURE 27 FORM NO 56043121 Advenger 2800ST 34005 755 BR 855 45 SOLUTION SYSTEM BRN K BRN 1 2 GRA BLK J3 K2 BRN 1 2 CONTACTOR VACUUM WHT RED 43 1 c G ACUUM CONTACTOR The Solution System i
32. to run for 10 seconds and then stop At any time the scrub mode can be changed to regular heavy or extreme scrub by using the SCRUB or SCRUB button At any time the solution flow rate can be changed by using the SOLUTION or SOLUTION button If the scrub mode and solution flow rate are at different positions they can be reset or aligned using two methods A Usethe SOLUTION or SOLUTION buttons to change the solution flow rate to match the scrub mode setting B Change the scrub mode using the SCRUB or SCRUB buttons The scrub pressure and solution flow will automatically be aligned for optimized results 7 To stop all scrubbing functions and transport the machine ADVENGER BR 755 855 press the red SCRUB ON OFF button or ST return the scrub deck and squeegee control levers to the up position The solution and brushes will stop ADVENGER BR 755 855 the deck and squeegee will raise and the vacuum will shut off after a 10 second delay DMI W 14 FORM NO 56043121 Advenger 2800ST 34005 BR 755 BR 855 MAIN CONTROLLER ERROR CODES ADVENGER 755 855 AND ST Advengery ST Service n LED Blink Fault Description Kiel ode Code hp REE a c oo omar toute oo NN s Vacuum contactor coil control fault Probable board failure ST open circuit errors are only visible in Fault Recall Mode accessible via the Hidden Menu Refer to Changing
33. 40 Pin Function Wire Color 3 5kOhm Pot High YEL 4 5kOhm Pot Wiper GRA 5 Seat Switch GRA BLK 6 Brake RED WHT 9 Error Status ORN BLU 13 5kOhm Pot Low VIO 14 Brake ORN s 16 Reverse Alarm BLU BLK C 18 Speed Limit BLK WHT FORM NO 56043121 Advenger 28005 34005 BR 755 BR 855 57 CONTROL BOARD J1 J2 AND J3 PIN OUTS AND TEST POINTS Z CAUTION Always take measurements at the end connectors for troubleshooting purposes If readings taken there do not indicate the problem check the control board as a last resort as damage to the board may occur see Caution statements in Replacing Operator Control Panel section Use a DVM and extended insulated probe tips shown to take the following measurements A CAUTION Use only insulated test probes designed to backprobe CONTROL BOARD IS POWERED during these tests 4 Perform steps 2 and 3 of Replacing Operator Control Panel section observing noted Caution statements J1 Advenger BR 755 855 only Brush deck lift actuator squeegee lift actuator chemical pump To backprobe J1 for voltages leave J1 connected to the control board 24V to 4 for 3 sec deck OV to M3 for 3 sec downward travel squeegee down travel OV to M4 for 3 sec 24V to for 3 sec deck upward travel squeegee up travel OV to 4 for 3 sec deck 24V to for 3 sec downward travel sq
34. 412089 56454429 56507644 56307166 56412177 56601183 56412179 56601064 56601050 56315241 56601147 56601432 56601132 56601132 56315061 56601134 56315061 56601134 N A 56303553 56303526 7 82 00050 56407130 56601507 56315124 4 4 Control PCB Assy Controller Speed Battery Fuse 150 Amp Circuit Breaker 70 Amp Circuit Breaker 10 Amp Beacon Warning optional Horn Backup Alarm Contactor 24v 100 Amp Contactor 24v Solenoid Valve Assy Motor Drive Wheel Pump Chemical Actuator Motor 24v Lift Actuator Assembly Motor Vac 24vdc Motor Vac 24vdc optional Motor 24 Vdc 5 Hp 1800 Rpm cylindrical Motor Gearbox Assy disk Motor 24 Vdc 5 Hp 1800 Rpm cylindrical Motor Gearbox Assy disk Part of 56601052 Key Switch Replacement Key Set Switch Seat Disconnect Emergency Brake Electromagnetic Charger On Board 24v TSBUS2008 984 BAT RED d RED J BLK FUSE 150 A BATTERY 24 VDC rep BSA gt BRN BLK CIRCUIT BREAKER 70 AMP ON BOARD BATTERY CHARGER OPTIONAL p RED p BLK CEPHDNALO RED BLK BLK iN 60 SW SPST KEY a LAMP FLASHING RNG are
35. Advenger 2800ST 3400ST BR 755 BR 855 QUICKSTART SERVICE MANUAL Advance MODELS 56601000 56601001 56601002 56601003 56601004 56601005 56601006 56601007 56601008 56601009 56601010 56601011 56601012 56601013 56601019 56601020 Nilfisk MODELS 56601014 56601015 56601016 Nilfisk Advance setting standards 9 09 FORM NO 56043121 TABLE OF CONTENTS INTRODUCTION QUICK START SERVICE MANUAL PURPOSE GENERAL MACHINE DESCRIPTION PARTS AND NAMEPLATE sese CAUTION AND WARNING SYMBOLS GENERAL SAFETY INSTRUCTIONS RELATED REFERENCE SOURCES DIAGNOSTIC AND SERVICE TOOLS TECHNICAL SPECIFICATIONS TRANSPORTING THE MACHINE TIE DOWN POINTS TOWING THE MACHINE JACKING POINTS EMERGENCY STOP KNOB mainos cr di es vade E eti 9 CO CO 4 NM PY KNOW YOUR MACHINE MACHINE FRONT RH VIEW MACHINE REAR LH VIEW CONTROL PANEL ADVENGER BR 755 855 CONTROL PANEL BASIC MACHINE OPERATION MAIN CONTROLLER ERROR CODES ADVENGER BR 755 855 AND ST SPEED CONTROL ERROR FLASH CODES UNDERSTANDING CONTROL OF SQUEEGEE SCRUB AND RECOVERY SYSTEMS VIA MODES SQUEEGEE SYSTEM M 20
36. Cable Bracket 8 Remove the Cotter and Clevis pins at the white plastic roller to permit cable eyelet clearance as the cable is later pulled through from the front of the machine FRONT 1 Follow the steps outlined in Steering Column Assembly Shroud Removal to allow access to Squeegee Lift Cable in the Steering Column 2 Use a 1 2 wrench to loosen the cable nuts from the Linkage Arm to free the cable Note condition of plastic bushing in eyelet and replace if worn 3 Loosen Adjustment Nut to free cable from slotted Cable Bracket 4 Using a 3 8 socket remove charger and charger bracket underneath exposing cavity though which cable passes 5 Pull the cable through the machine from the front To reinstall the cable reverse this procedure Follow instructions found in Squeegee Lift Cable Adjustment ST to correctly set the Squeegee Lift Cable tightness FIGURE 13 26 FORM NO 56043121 Advenger 28005 34005 BR 755 BR 855 SQUEEGEE LIFT CABLE ADJUSTMENT ST REAR Figure 14 Factory setting is 0 25 Follow steps 1 6 of Squeegee Lift Actuator Replacement Advenger BR 755 855 e Ifthe cable is too long and the squeegee doesn t lift off the ground move the nut closest to the squeegee away from the machine decreasing the distance from the nut to the reference end Figure 14 e Ifthe cable is too short squeegee doesn t reach the ground back the nut towards the machine increasin
37. ICE TECHNICIAN SUGGESTED MAINTENANCE 269 RECOMMENDED SERVICE MATERIALS 269 PM CHECKLIST EXPANDED ELECTRICAL 5 5 da FAN 13 78 COMPONENT LOCATION ADVENGER BR 755 855 73 WIRING DIAGRAM ADVENGER BR 755 855 ELECTRICAL SCHEMATIC ADVENGER 755 855 COMPONENT LOCATION ST x WIRING DIAGRAM ST TT ELEGTRIGAE SCHEMATIG 78 INTRODUCTION QUICK START SERVICE MANUAL PURPOSE This manual is a technical resource that Nilfisk Advance expects to be utilized while Advenger BR 755 855 or ST is being serviced It contains information deemed necessary to provide basic troubleshooting maintenance and repairs within a timeframe of 2 3 hours maximum If your repair involves multiple visits to repair the same problem or the repair cannot be completed within 3 hours a call to Nilfisk Advance Technical Support is needed whether to alert the factory to potential issues or to provide the customer with an acceptable level of service Refer to the website www advance us com for additional information not contained here in as well as updates or expanded instructions to procedures noted here Note Bold num
38. LK eras Pulsed 24V ORN RED Output to horn 15V GRN BLK Output to horn 15V Advenger BR 755 855 Ground 24V Advenger BR 755 855 Power BRN YEL 24V test point for brush motor contactor coil control error 63 test point for vacuum contactor coil control error 64 test point for solution solenoid control error 62 FORM NO 56043121 Advenger 28005 34005 BR 755 BR 855 59 CURTIS SPEED CONTROL INSTALLATION CHECKOUT PROCEDURE After installing a controller and before operating the vehicle carefully complete the following checkout procedure If you find a problem during checkout refer to the Curtis programmer manual for more 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 wand indicator light 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 seat switch is open and the throttle pedal is in neutral Do not stand or allow anyone else to stand directly in front of or behind the vehicle during the tests Remove the electrical panel to access the controller 1 Observe the error status fault indicator on the operator control panel If a programmer is available connect it to the programmer plug in port 2 Sit on the seat and t
39. MT T MOTOR WHEEL DRIVE CONTACTOR BRUSH 2 4 IT 5 42 4 BLK WHT 18 SPEED LIMIT pen 03 1 vio BRN 1 VO BLK NET eB ENT VALVE SOLENOID POT HI Al PIN 4 POT WIPER H2 Ej CONTROL BOARD 2 5 4 ORN RED J3 M npn R RD LgJe S Vo CO EE HORN BACKUP SK OHM THROTTLE CRAPBLK 23 9 aU ENS PTIONAL Mye RED YEL CHEMICAL PUMP cet PUMP i __ BLU GRA 51 3 CHEMICAL PUMP 1 8 BLK 8 BLK JIK p We 1 3 J1 9BLK YEL WP SQUEEGEE LIFT ACTUATOR X SQUEEGEE act 1 10 WHT GRN z 2 BRUSH 43174 BLU 69 BRUSH LIFT ACTUATOR x 59 prusy acr BES ORN BLK 3 5 g BRUSH MOTOR 2 10 YEL VIO So 2 3 9 vacuum MOTOR 2 e eig bre K 5 RED WHE 59 CONTACTOR VACUUM 21 5 43 5 E 4 9 gt w MOTOR VAC e D 5 gt w Sa 3 se EN 5 46 E MOTOR vac d TW t rs RED RED BLK CONTACTOR BRUSH A DISCONNECT RED WIRE ON CB2 AND REPLACE WITH GREEN WIRE MOTOR BRUSH FROM CHARGER WHEN ON BOARD CHARGER IS USED M8 56601176 REV 40 FORM NO 56043121 Advenger 280057 34005 BR 755 855 ST
40. OTOR VAC 7 8 084 WHT 10 GR E MT ee e M3 SP6 MOTOR BRUSH MOTOR BRUSH 5 E 1T2 008 BLK 19 SQUEEGEE LIFT ACTUATOR M X3 rip d x32 Cup X AGI xa EI MS SY SY ce Se Ca x RN Mt 716 RED 10 NS NOTE MOTOR VAC 1 X8 BE CONNECTED WHEN BATTERY ROLLOUT OPTION 011 BRN RED 18 BRUSH LIFT ACTUATOR set 029 RED 8 112 2 CONNECT Jl Je AND J3 CONTROL BOARD SP3 077 BLK 10 112 FORM NO 56043121 Advenger 280057 34005 BR 755 BR 855 77 ELECTRICAL SYSTEM COMPONENT LOCATION 2800ST 3400ST Item Description A1 Control PCB Assy A2 Controller Speed F1 Fuse 150 Amp Circuit Breaker 70 Amp CB2 Circuit Breaker 10 Amp H1 Beacon Warning optional H2 Horn Backup Alarm K1 Contactor Vacuum Motor K2 Contactor Brush Motor L1 Solenoid Valve M1 Motor Drive Wheel M5 Motor Vacuum M6 Motor Vacuum Optional M7 Motor Brush M8 Motor Brush R1 Potentiometer 5K 1 Switch Key 52 Switch Seat 4 Emergency Disconnect 5 Deck Switch 56 Squeegee Switch Y1 Electromagnetic Brake 78 FORM NO 56043121 Advenger 28005 34005 BR 755 BR 855 Onboard Charger ELECTRICAL SYSTEM WIRING DIAGRAM SCHEMATIC 2800ST 3400ST
41. USI MOTOR REMOVAL CYLINDRICAL See SCRUB DECK REMOVAL CYLINDRICAL to remove the scrub deck assembly See Figure 25 Remove the Belt Cover on each side With an operator the driver s seat with the key switch On and the increase scrub function selected press the drive pedal to start the scrub brushes and observe which brush motor needs to be replaced Remove the Belt B 3 Remove the wiring at both the Pos amp Neg brush motor terminal studs and note the correct wiring connections for reinstallation Then remove the 3 Screws C and lift the motor D out from the scrub deck 4 Reassemble in reverse order installing motors with wires pointing to the rear towards the hopper 5 Apply anti seize to the motor shafts Rotation from shaft end NOTE the belts are self tensioning FIGURE 25 FORM NO 56043121 Advenger 28005 34005 BR 755 BR 855 39 RECOVERY SYSTEM ADVENGER 755 855 The recovery system is controlled via the control board output to contactor K1 coil turning on one or both if equipped vac motors 5 M6 with control board feedback provided via the BRN RED vac motor current monitoring sense wire Refer to the section Understanding Control of Squeegee Scrub and Recovery Systems via Modes for details about functionality of the Recovery System due to multiple systems operating in tandem under various seat switch an
42. YEL VIO VACUUM MOTOR ses 9BRI RED ST HORN BACKUP ALARM GRN BI 939 URN peck 2 1 ORN RE BL _ 56 75 BL SQUEEGEE swrrcu 2 1281 pecs i 2 1 E BRUSH MOTOR 5 5 2 10 VACUUM MOTOR sENSR BRNZRE D ac SARI ty CDU Data P3 Ah 1 3 HOURMETER EMEN 1 OPTIONAL love ete nd A Ki RED HT CONTACTOR VACUUM MOTOR VAC MOTOR VAC RED M RED CONTACTOR BRUSH ey MOTOR BRUSH pi K 20 FORM 56043121 Advenger 2800ST 34005 BR 755 BR 855 SQUEEGEE LIFT ACTUATOR CIRCUIT ERROR CODES AND MEASUREMENTS ADVENGER BR 755 855 Advenger STService Fault Description Troubleshooting Action BR 755 855 LED Display Blink Code Error Code Check for binding or frozen squeegee lift linkage and excessive weight on squeegee NA Squeegee lift actuator overload 2 Check for short circuit in wiring or actuator motor Repair or replace Check for disconnected actuator wiring open in wiring or 34 NA Squeegee lift actuator open defective actuator motor Repair or replace 2 Check controller output voltage at BLK YEL wire 2 5 3 5 5A for gt 4 seconds BLK YEL amp WHT GRN TROUBLESHOOTING SQUEEGEE ISSUES Problem Possible Cause Not enough adjustment of squeegee tool by turning adjustment Squeegee Mount Weldment Bracket is bent Replace knob Squeegee is hopping Wheel isn t making contact with the floor repositi
43. accordance with your local environmental regulations Donotuse on surfaces having a gradient exceeding that marked on the machine All doors and covers are to be positioned as indicated in the instruction manual before using the machine SAVE THESE INSTRUCTIONS FORM NO 56043121 Advenger 28005 34005 BR 755 BR 855 3 RELATED REFERENCE SOURCES Nilfisk Advance provides Operator Manuals Sales literature Parts Lists Technical Service Bulletins and Instruction Sheets on our website www advance us com for 24 7 availability of information to order parts operate troubleshoot or repair all current production and most pruned machine models For the Advenger and ST please refer to the following documents for additional information Parts List Form Number 56042495 Operation Manual Form Number 56041735 English Spanish For the BR 755 855 please refer to the following documents for additional information Parts List Form Number 56042496 Operation Manual Form Number 56041738 Operation Manual Form Number 56041739 Operation Manual Form Number 56041740 Operation Manual Form Number 56041741 Operation Manual Form Number 56041742 Operation Manual Form Number 56041743 Curtis Programmer Manual 56043101 TSB US2008 984 Batteries and Chargers TSB US2008 979 QuiQ Delta Q Battery Charger Reprogramming Kit 56315732 Instructions DIAGNOSTIC AND SERVICE TOOLS
44. arger in place and move the charger over to the side See Figure 32 Using a 1 7 16 socket remove the hex nut B at the top of the Spindle Weldment See Figure 33 Turn the Drive Wheel to the right and remove the motor wiring cover C Using a 13mm and 7mm socket remove the nuts and wires from the drive motor See Figure 34 Turn the motor towards the left Using a 7 16 socket and wrench remove the P clamp D Jack up the front end of the machine enough to allow the wheel to slip free from the machine See Figure 31 Using a 17mm socket remove the four bolts A at the top to free the motor from the Steering Plate ON DO 4 FIGURE 32 FIGURE 33 FORM 56043121 Advenger 28005 34005 BR 755 BR 855 53 REPLACING THE DRIVE WHEEL ASSEMBLY CONTINUED 11 Reassemble the drive wheel in reverse order attaching the motor wires as shown A CAUTION Use a Torque Wrench set at 20 ft lb to the 1 1 2 hex nut at the top of the steering spindle NOTE Orient the wires in such a way as to minimize bending at the crimps for optimum motor performance There 2 each YEL BLK RED GRN going to each post FIGURE 35 REPLACING THE DRIVE TIRE The Drive Wheel is assembled as shown FIGURE 36 In addition to carbon brushes parts available for replacement are tire with hub 56601472 A tire 56601471 B motor 56601473 C
45. atio turn the Detergent Mode to Off and set the chemical ratio by pressing and holding the AXP EDS On Off switch E 12 Brush Pressure lock out during normal operation the pressure settings that are locked out will not be selectable 13 Chemical rate bias AXP EDS control set to 10 more or less chemical than the user programmed ratio 14 Deck down time time for which the control system applies 24V to the deck actuator to raise or lower the scrub deck after the Scrub On switch is pressed adjustable from 1 to 5 seconds 15 Backup Alarm volume 16 Horn volume 50700 D OY OT P Cor Ny ct FORM NO 56043121 Advenger 28005 34005 BR 755 BR 855 65 HANGING PROGRAM SETTINGS ADVENGER BR 755 855 To enter this Hidden Menu turn the key switch Off then press and hold the Scrub and Vacuum switches together Turn key switch back On and hold the switches for 2 seconds until the Solution and Scrub indicators both turn on 3 Release both switches the display will now read Programming Options Scroll through the menus using the Solution or switches and enter the program number corresponding to the needed function 4 Toenter a submenu press the Solution switch 5 To save and go back to the main menu press the Scrub switch 6 To exit the hidden menu turn the key switch off DECK TYPE 28 disc 28 Cyl 34 disc BR 755 BR 755 C BR 855 CHEMICAL SELECTION AXP EDS On AXP EDS Off
46. be replaced with original OEM due to sense wire in Fault 3 Check K1 contacts if open circuit while vac is turned on OV at Recall Mode J3 12 replace K1 Vacuum motor circuit overload 3 3 Visible in Fault Recall Mode 61 m Vacuum K1 contactor contacts stuck With no power to circuit if contacts measure 0 ohms they re stuck i closed Replace K1 12 Is 24V t ff B when Vacuum switch Is O 1 Check coil resistance see chart below Vacuum 1 contactor coil open 2 Check for tight connections at contactor and GRA BLK wire to control board Repair or replace replace control board Vacuum contactor coil control fault 2 If J3 12 is OV referenced to B when Vacuum switch is Off disable fault via Hidden Menu Refer to Control Board J1 J2 and J3 Pin Outs and Test Points section Vacuum Nominal Current A Vacuum Overload Current Wire Colors Contactor Coil Resistance Brown K1 100 ohms 240 mA 50 mA 750 mA amp ray Black 42 FORM 56043121 Advenger 2800ST 34005 BR 755 BR 855 TROUBLESHOOTING RECOVERY SYSTEM ISSUES Misadjusted squeegee tool refer to Squeegee Alignments section 2 Worn or damaged blades refer to Operating Manual for instructions 3 Leak in vacuum system check for bad gasket leaky hose damaged tank leaky drain Poor water pickup from squeegee tool valve 4 Restriction in vacuum system check for debris in squeeg
47. bers in parentheses in the text indicate an illustrated item Note All references to right left front and rear in this manual are as seen from the operator s position GENERAL MACHINE DESCRIPTION The Advenger BR 755 855 and ST machines are commercial automatic floor scrubbers available with multiple deck sizes multiple corresponding squeegee blade sizes and materials and variable scrub pressure and solution flow rates Models equipped with AXP EDS detergent systems default into the EverGreen cleaning mode 1 400 detergent ratio a patented new Green cleaning technology designed to reduce chemical use environmental impact and the cost of cleaning PARTS AND SERVICE Repairs should be performed by an Authorized Nilfisk Advance Service Center that employs factory trained service personnel and maintains an inventory of Nilfisk Advance original replacement parts and accessories NAMEPLATE The Model Number and Serial Number of the machine are shown on the Nameplate located on the chassis under the left rear corner as shown This information is required when ordering repair parts for the machine or contacting Nilfisk Advance Technical Support 2 FORM NO 56043121 Advenger 28005 34005 BR 755 BR 855 CAUTIONS AND WARNINGS SYMBOLS Advance uses the symbols below to signal potentially dangerous conditions Always read this information carefully and take the necessary steps to protect personnel and pr
48. code Status or Fash ctor ejdsiq uonduoseq ejqesiq 919291 SJOJOW Usnug e qesiq e qesiq jqes q yr1x eq usnig 21 Joop usnig Jojeoipu ETT FIC NO OC E I 8 Soluion solenoid solenoid overload Brush contactor overload a EIER 32 Brush deck lift actuatoropen deck Brush deck actuator open actuator open epee uM LIC NAME ENS EN EY DDR DN 8 LIC NM 60 Brush motor circuit contacts stuck closed motor circuit contacts stuck closed 14 62 Solution solenoid coil control faut solenoid control fault 9 Vacuum contzctorcoitcontoifaut ____ FORM NO 56043121 Advenger 28005 34005 755 855 17 UNDERSTANDING CONTROL SQUEEGEE SCRUB AND RECOVERY SYSTEMS VIA MODES Due to the unique One Touch functions of the new Advenger BR 755 855 and ST multiple systems are engaged via one action defined by the Mode that is chosen Scrub Mode Vacuum Mode or Wand Mode The following tables outline the various components of the systems that are controlled in tandem by pressing a particular button or engaging the Drive Pedal in Forward Neutral or Reverse under normal machine ope
49. d button configurations For the Recovery System to function properly the systems mentioned above in addition to the Wheel Drive System must be operating properly in order for the vac motors to turn on unless by passed by entering Service Test Mode for troubleshooting purposes REF DRAWING 56601177 DIAGRAM AXP WIRING MOTOR BRUSH T RED RED Die BLK FUSE 150 BATTERY 24 VDC BI BRN BLK CIRCUIT BREAKER 70 AMP ON BOARD BATTERY CHARGE OPTIONAL RED 3d BLK OPTIONAL 5 RED E SW SPST KEY Y 5 LAMP FLASHING E kar amp Ar E EE RED n x BRN YEL BRN YEL 1 BRN BRNY Fa gt 52 GRA BLK WHT BRN SWITCH SEAT CIRCUIT BREAKER 10 AMP EMERGENCY STOP ORN amp 5 7 de BRN YEI 3 SEAT swiTcw3 BRAKE 3 i a 3 8 rFUR aEVJ3 6 JRED WHT PECORA 2 BRN J3 1 Key wiren STATUS J3 7 ORN BLU PIN 9 STATUS B E BI Rey ars BLUZBLK BRN GRA BLK 23 18 CONTACTOR Mi RED GRN CONTACTOR VACUUM A2 N _ BRN WHIZRED J3 1B RUSH CONTACTOR CURTIS 1228 SPEED CONTROLLER ND
50. e hex head bolt and associated hardware A to free other end of lift cable Reassemble in reverse order and test for proper raise and lower functions When lifting the recovery tank back onto the machine pay attention to the location of the foam tubes Route them into the battery tray otherwise they will crush FIGURE 12 FORM NO 56043121 Advenger 28005 34005 BR 755 BR 855 25 SQUEEGEE LIFT CABLE REPLACEMENT ST Z CAUTION The Recovery Tank is heavy and care should be taken in removing it Two people recommended or battery roll out unit REAR 1 Lower the Squeegee Tool to the floor and then disconnect the battery pack at the red Anderson connector in the battery compartment 2 Drain the recovery tank using the Recovery Tank Drain Hose 31 3 Disconnect the Squeegee Hose from the Squeegee Tool and remove the tool from its mount via the two thumbscrews 4 Liftupthe seat and unplug the vacuum motor and warning beacon if equipped connectors located in the battery compartment 5 Open the hinged recovery tank cover and grip the top inside edge of the tank then pull straight up to free it from the solution tank platform Guide the tank off the rear of the machine to the floor 6 Figure 13 Using 7 16 wrenches remove the hex head bolt and associated hardware A from the Squeegee Pivot Bracket Weldment to free this end of the lift cable 7 Loosen the Adjustment Nut to free the cable from the slotted
51. ee tool vacuum hoses float cage or wherever air is forced to make a sharp turn Iquid 15 being pulled into vac motor due to excessive foam In recovery tank Recommend Vacuum motor keeps corroding and failing defoamer and don t fill until shuts off automatically V tor llvd Vacuum leak below the water line creating turbulence in the recovery tank causing water ead motor is normally dry now it s wet an ailing The control board doesn t indicate the recovery 1 Check the vacuum motor sense wire BRN RED for break or poor connection m tank is full before the ball valve shuts off the vac signal motor 2 Check that cage for ball float is clean Display shows the recovery tank is full but it s not Disable Recovery Tank Full automatic shut off via Hidden Menu sooo 1 Go into Fault Recall mode and check for error code 3 1 for vac motor circuit problem 2 Check limit switch S6 in steering column Moving the handle to the down position should move squeegee cable down and close switch S6 turning on the vac motor circuit if operating properly Vacuum motor contactor doesn t energize Go into Fault Recall mode and check for error 3 3 Vacuum motor doesn t turn on FORM NO 56043121 Advenger 28005 34005 BR 755 BR 855 43 REPLACING A VACUUM MOTOR A WARNING DISCONNECT BATTERIES BEFORE SERVICING RECOVERY TANK REMOVAL 1 See Figure 26 Drain the Recovery Tank A using
52. eft hand Motor 64 HP 480 watts Right hand Single Motor 215 260 RPM Left hand Motor 215 260 RPM Right hand Motor 5 HP 373 watts Left hand Motor 5 HP 373 watts Right hand Motor 900 RPM Left hand Motor 900 RPM 1 Regular Scrub 75 85 Ibs 32 7 37 0 kg 2 Extreme Scrub factory setting 170 180 Ibs 77 1 81 6 kg 1 Regular Scrub 95 105 Ibs 41 4 45 7 kg 2 Extreme Scrub factory setting 195 205 Ibs 88 5 93 0kg 1 Regular Scrub 70 90 Ibs 31 8 39 2kg 2 Heavy Scrub 120 150 16 52 3 65 3kg 3 Extreme Scrub 180 220 Ibs 78 4 95 8 kg 1 Regular Scrub 45 60 Ibs 20 4 27 2 kg 2 Heavy Scrub 70 80 Ibs 31 8 36 3 kg 3 Extreme Scrub 90 100 Ibs 40 8 45 4 kg MINIMUM AISLE TURN AROUND RADIUS TURNING LEFT 28 deck Advenger BR 755 855 and ST 34 deck Advenger BR 755 855 and ST Cylindrical Advenger BR 755 855 63 inches 1 63 m 67 5 inches 1 71 m 63 inches 1 63 m MINIMUM DOOR PASS THRU WIDTH SIDE SKIRTS ON SQUEEGEE OFF 28 deck Advenger BR 755 855 and ST 34 deck Advenger BR 755 855 and ST Cylindrical Advenger BR 755 855 31 inches 79 m 36 5 inches 93 m 32 inches 81 m FORM NO 56043121 Advenger 28005 34005 BR 755 BR 855 7 TRANSPORTING THE MACHINE Z CAUTION Before transporting the machine on an open truck or trailer 1 Remove the Squeegee Assembly 11 and secure Tie the machine down securely at the Loca
53. exit the hidden menu 1 2 3 SWITCHES PRESSED INITIAL LED INDICATION BLINKS LOW MED HIGH Low Voltage Cutout Scrub Deck Size 28 34 Single Dual Vac Motor 5 Max Scrub Speed of Transport Speed Recovery Tank Full Shutoff Restore Factory Defaults Fault Recall Fault Detection Solution Flow Rate Lockout 70 100 are 3 to 6 blinks respectively Medium High Low amp Medium Low amp High Medium amp High are 3 to 7 blinks respectively FORM NO 56043121 Advenger 28005 34005 BR 755 BR 855 67 MAINTENANCE SCHEDULES OPERATOR PREVENTIVE MAINTENANCE MACHINE IN USE eck Each Battery Cell s Water Level wet batteries eck Clean Adjust Scrub Deck Side Skirts ubricate Pivot Points for Squeegee amp Scrub Deck Linkage eck for Squeegee Cable Bushing wear inside Steering Column Wear indicates need for replacement and cable adjustment too tight FIGURE 43 68 FORM NO 56043121 Advenger 28005 34005 BR 755 BR 855 MAINTENANCE SCHEDULES OPERATOR PREVENTIVE MAINTENANCE MACHINE IN STORAGE MAINTENANCE ITEM Weekly Monthly SERVICE TECHNICIAN SUGGESTED MAINTENANCE ERE Perform hydrometer battery check wet batteries to identify bad cells NM NN buds LM EI BN nspect vacuum motor carbon brushes for wear Replace if 9 5mm 3 8 inches or sh
54. ey Switch 2 Refer to Speed Control Flash Codes section 3 Repair 4 Reset machine via key switch 1 Batteries need charging low battery voltage recharge batteries 2 Wheel Drive Motor Circuit Breaker CB1 tripped reset 70A circuit breaker 3 Control Board Circuit Breaker CB2 tripped reset circuit breaker 4 Emergency Stop Knob 7 tripped pull out and twist 5 Safety Switch 62 in seat not closed check seat switch 6 Defective Wheel Drive Motor replace motor 7 Defective Throttle Potentiometer R1 replace 1 Test the Fwd amp Rev 1 wiring outputs pins 3 4 amp 13 at the speed control for an open Repair wiring or replace the R1 pot 2 Controller can t change electrical polarity to wheel motor replace the A2 speed control 52 FORM 56043121 Advenger 28005 34005 BR 755 BR 855 REPLACING THE DRIVE WHEEL ASSEMBLY A WARNING Park the machine on a dry flat surface turn the main key switch J to the Off position and disconnect the battery pack at the red Anderson connectors inside the battery compartment 1 Block the rear wheels Jack up the front of the machine as shown in Jacking Points section or use a hoist to lift up the front end of the machine See Figure 31 Using a 17mm socket loosen but don t remove the four bolts A at the steering sprocket to allow the chain to release some Using a 3 8 magnetic socket remove the four bolts holding the ch
55. f until after disconnecting the battery This procedure is done to prevent the scrub deck from automatically raising when the key is turned off See Figure 20 Disconnect the solution system water line located on top of the scrub deck Disconnect both brush motor wiring harness connectors A under right side of machine Remove the two B Hitch Pins that attach the scrub deck to the machine chassis linkage arm weldment From the right side of the machine pull the deck out from under the machine to complete the removal To install a scrub deck and roller bumper if applicable follow the previous steps in reverse order FORM NO 56043121 Advenger 28005 34005 BR 755 BR 855 35 SCRUB BRUSH MOTOR REMOVAL DISC also needed for Carbon Brush check 1 2 3 4 FIGURE 21 See SCRUB DECK REMOVAL DISK to remove the scrub deck assembly See Figure 21 After removing the deck turn it over so the Brush Plates are on top Remove the hex socket screw A from the Motor Gimbal located at the Brush Plate center Remove the Brush Plate Assembly B NOTE It may be necessary to pry the assembly off the motor shaft Do not pry on the outer edge of the Brush Plate Assembly B as this could damage the plate Pry using a flat screw driver C against the aluminum gimbal shoulder underneath the Brush Plate 36 FORM 56043121 Advenger 28005 3400ST BR 755 BR 855
56. g the distance from the nut to the reference end Figure 14 To check the adjustment lift up on the Squeegee Lift Lever It should not require excessive force Too much force needed to move the handle means that the cable is too tight short and the nut should be adjusted accordingly FIGURE 14 FRONT Figure 15 Factory setting is 0 50 Follow the steps outlined in Steering Column Assembly Shroud Removal e Ifthe cable is too long and the squeegee doesn t lift off the ground move the upper nut away from the machine decreasing the distance from the nut to the reference end Figure 15 e Ifthe cable is too short squeegee doesn t reach the ground back the nut towards the machine increasing the distance from the nut to the reference end Figure 15 FIGURE 15 EU 277 FORM 56043121 Advenger 28005 34005 BR 755 BR 855 27 STEERING COLUMN ASSEMBLY SHROUD REMOVAL See Figure 16 Remove the 4 screws fastening the Lower Column Shroud A to the Lower Column Weldment ST Using a 7 16 socket remove Squeegee Lift Knob and Linkage Arm B Using a flat bladed screwdriver pry off the steering wheel plastic center cap Using socket remove the hex nut from the steering wheel center Pound the steering wheel C off from behind using a mallet observing Woodruff key as it may fly off in the process Pull off accordion Steering Boot D from the uppe
57. gee Scrub and Recovery Systems via Modes REV 53 5 BLU BLK PIN 16 REV ALARM BRN 1 1 3 CONTACTOR CONTACTOR VACUUM 2 K2 BRN WHT RED J3 1 RUSH CONTACTOR CURTIS 1228 SPEED CONTRO CONTACTOR BRUSH 4 SEMI Je 4 BLK WHT PIN 18 SPEED LIMIT EE BRN f2 VO BLK J3 M m VO 13 pot 10 VALVE SOLENOID HI 1 4 POT WIPER H2 z CONTROL BOARD M BUE ORN RED Lp e S VIO YEL ow POT HI HORN BACKUP be R K J3 9 POT SK OHM THROTTLE HORN I au OPTIONAL D e RED YEL CHEMICAL PUMP CHEMICAL PUMP 3 pe eon GRA 51 3 CHEMICAL PUMP 1 8 x g J2 8 852 7 022 BLK 2032 3 JA 9BLK YEL 2 7 SQUEEGEE LIFT ACTUATOR 55 SQUEEGEE pJic10 WHIT GRM Mh 9 BRUSH act 21 4 BLU N 9 BRUSH LIFT ACTUATOR G5 59 BRUSH 2125 s BRUSH MOTOR sENsQJe 10 YEL VIO VACUUM MOTOR SENS2 9BRN RED 6 PE 00 69 RED 4 CONTACTOR VACUUM 5 21 5 43 9 69 E um e S 0 EN 9 e MOTOR VAC 89 S A dodo 0 ______ m cmt 5i M6 amp cR d 5 E MOTOR VAC MAN RED 2 ve RED
58. hat are error state and allow those components to be manually turned on and off for troubleshooting purposes Components in an overload error state will still be locked out for safety reasons Advenger BR 755 855 Service Test Mode is accessed via the Hidden Menus To enter turn the key switch Off then press and hold the Scrub and Vacuum switches together Turn key switch back On and hold the switches for 2 seconds until the Solution and Scrub indicators both turn on Release both switches the display will now read Programming Options Scroll through the menus using the Solution or switches and enter program 16 for Service Test Mode Advenger BR 755 855 Desired Action Press Toggles LCD Display Indication Switch ON OFF Raise lower scrub deck lift actuator M4 287 OFF DOWN OFF UP Raise lower squeegee lift actuator M3 OK OFF DOWN OFF UP SQG Activate solution solenoid L1 ENERGIZED DE ENERGIZED SOL Activate vacuum motor contactor K1 ENERGIZED DE ENERGIZED VAC Activate AXP EDS pump 2 ON OFF Activate brush motor contactor K2 ENERGIZED DE ENERGIZED BRUSH LCD also displays SPD speed control ON OFF actual battery voltage measured and any error codes AN LT FORM NO 56043121 Advenger 28005 34005 755 BR 855 63 PROGRAMMING FUNCTIONS SERVICE TEST MODE ST The purpose of Service Test Mode is to by pass the lock
59. he Retracted setting shown below 8 Holdthe metal nut and press the rocker switch running the motor until it stops If the measurement doesn t match 13 25 33 65cm as shown below pry off the black cover B to access the Cam Adjuster 9 Using a 1 2 socket gently turn the adjuster CW to increase travel CCW to decrease travel of the Drive Nut Each click of the adjuster will change the nut travel by 0 09 2 29mm or just under 3 32 10 After each adjustment re check the travel by holding the metal nut and running the actuator IN and OUT checking against the values below 11 Repeat until it is set correctly and replace the Cam Adjuster cover 12 DO NOT TURN THE NUT before mounting mark the position on the shaft if helpful FIGURE 10 Actuator Setting mounting hole center to center Retracted 9 00 06 Extended 13 25 06 It s not practical to measure center to center of the holes so an outer edge to inner edge of the pins measurement is suggested FIGURE 11 9 00 RETRACTED POSITION 13 25 EXTENDED POSITION 24 FORM NO 56043121 Advenger 2800ST 34005 BR 755 855 SQUEEGEE LIFT CABLE REPLACEMENT ADVENGER 755 855 1 Follow steps 1 6 of Squeegee Lift Actuator Replacement Advenger BR 755 855 to disengage front end of lift cable under machine NOTE the motor does not need to be disconnected for this procedure See Figure 12 Using 7 16 wrenches remove th
60. ighted below in bold letters Advenger BR 755 855 and ST settings that can be changed per the following tables are Low Voltage Cutout Depth of Discharge 20 55V wet battery or 21 75V gel AGM battery Scrub Deck size 28 or 34 Number of Vacuum Motors installed single or dual configuration to prevent over current detection malfunction Maximum speed while scrubbing as a percentage of travel speed 50 90 Recovery Tank Full automatic shut off disable enable Restore factory defaults Fault Recall of previous error codes to aid in troubleshooting Fault Detection over ride disable Fault Detection so systems shut down while in error state exception is overload Solution Flow Rate lock out Advenger BR 755 855 models allow these additional programming changes to be made via the Hidden Menu NOTE Replacement control boards come with Evergreen OFF and AXP EDS disabled 10 Chemical Selection Turn AXP EDS Off or On with display indicating US or European ratio or format 11 Detergent Mode Turn on Mode 1 machine factory preset for US market to enable standard Evergreen mode in which pressing the Evergreen button enables preset ratio for 60 seconds on Mode 2 factory preset for the EU market to run at a preset ratio In this mode pressing the Evergreen button increments the ratio solution concentration to the next stronger level for 60 seconds NOTE To run the machine in a constant user defined r
61. km h Rev 2 61 mph 4 20 km h Pulse control Solenoid Valve 38 gal min 1 44 L min or 70 minutes per solution tank 62 gal min 2 35 L min 40 minutes per solution tank 92 gal min 3 48 L min 23 minutes per solution tank 30 gal min 1 13 L min or 60 minutes per solution tank 48 gal min 1 82 L min or 45 minutes per solution tank 88 gal min 3 33 L min or 30 minutes per solution tank Advenger BR 755 855 only 400 1 25 200 1 5 100 1 1 32 1 3 300 1 3 150 1 66 64 1 1 5 256 1 4 128 1 8 50 1 296 No 5 HP 560 watt 3 stage Sealed 63 0 in of Water 15 7 kPa 1 Open hole Aperture 10 3 in of Water 2 6 kPa Sealed 65 0 in of Water 16 2 kPa 1 Open hole Aperture 18 5 in of Water 4 6 kPa 6 FORM NO 56043121 Advenger 28005 34005 BR 755 BR 855 TECHNICAL SPECIFICATIONS SCRUB SYSTEM Scrub Deck Types Scrub Brush Pad Sizes and Types Scrub Motors Disc Scrub Head Speeds Disc Scrub Motors Cylindrical Scrub Head Speeds Cylindrical Scrub Force 28 ST Scrub Force 34 ST Scrub Force Advenger BR 755 855 Disc Scrub Force Advenger BR 755 855 Cylindrical Disc and Cylindrical Disc 2 14 in 35 6 Scrub Path 28 in 71 1 cm Disc 2 17 in 43 2 Scrub Path 34 86 4 cm Cylindrical 2 27 in 68 6 cm Scrub Path 28 in 71 1 cm Number of Motors 2 Right hand Single Motor 64 HP 480 watts L
62. lean this machine with a pressure washer Only use the brushes provided with the appliance or those specified in the instruction manual The use of other brushes may impair safety CAUTION This machine is not approved for use on public paths or roads This machine is not suitable for picking up hazardous dust Do not use discs and grinding stones Advance will not be held responsible for any damage to floor surfaces caused by scarifiers or grinding stones can also cause damage to the brush drive system 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 Donotleave the machine unattended without first turning the key switch off O removing the key and applying the parking brake Turn the key switch off and remove the key before changing the brushes and before opening any access panels Take precautions to prevent hair jewelry or loose clothing from becoming caught in moving parts Use caution when moving this machine in below freezing temperature conditions Any water in the solution recovery or detergent tanks or in the hose lines could freeze causing damage to valves and fittings Flush with windshield washer fluid The batteries must be removed from the machine before the machine is scrapped The disposal of the batteries should be safely done in
63. led by the following three parameters 1 The deck size and type factory set but selectable via Hidden Menu 2 The Solution Flow Rate chosen by the operator through the user interface 3 TheLiquid Level Sensor The liquid level in the Solution Tank is measured by the Pressure Sensor through the Pressure Sensing Tube As the liquid level decreases the pulsed feedback of the Pressure Sensor drives the control board to compensate for this drop in maximum output by adjusting the duty cycle of the solution solenoid thereby keeping the flow rate constant FIGURE 29 User Interface Control Amount of liquid Panel dispensed to brushes solution flow rate pulsed voltage output Chemical Pump Amount of detergent Pressure Sensor AXP dispensed to Solution measuring tank Hose Deck Configuration liquid level full tank 5V empty tank OV A malfunction of either the Pressure Sensor the Control Panel or an air leak in the pressure sensing system may affect the performance of either the Chemical Pump or the Solution Solenoid or both ST The pulsed 24V output of the control board that controls duty cycle of the Solution Solenoid is driven by 1 Control board programming of deck size and type factory set but selectable via the Hidden Menu 2 The Solution Flow Rate chosen by the operator through the user interface ST machines don t have a Pressure Sensor that monitors liquid level in the Solution Tank Since the maximum outpu
64. magnetic brake coil open 000 000 precharge fault Controller failure Low battery voltage 000 0000 brake Off fault Electromagnetic brake driver open Electromagnetic brake coil shorted 000 00000 HPD High Pedal Disable fault Improper sequence of throttle and KSI push or inhibit inputs Misadjusted throttle pot 0000 0 current sense fault Short in motor or in motor wiring Controller failure 0000 00 motor voltage fault hardware Motor voltage does not correspond to failsafe throttle request 2 Short in motor or in motor wiring 3 Controller failure 0000 000 EEPROM fault 1 EEPROM failure or fault 0000 0000 power section fault 1 EEPROM failure or fault 2 Short in motor or in motor wiring 3 Controller failure NOTE AKSI key switch input system problem is a specific HPD high pedal disable type operational fault caused by the operator activating the Fwd Rev drive pedal before turning on the main key switch or activating the throttle before sitting on the seat This can be cleared by returning the operator s drive pedal to neutral and cycling the key switch OFF and ON 16 FORM NO 56043121 Advenger 2800ST 34005 BR 755 BR 855 ERROR CODE SYSTEM DIAGNOSTICS ADVENGER 755 855 AND ST The following table describes the systems that are disabled for each error code to assist you in understanding machine response to error
65. mp AXP EDS SYSTEM ERROR CODES AND MEASUREMENTS ADVENGER BR 755 855 AND ST TROUBLESHOOTING SOLUTION amp AXP EDS SYSTEM ISSUES SOLUTION SYSTEM DIAGRAM SOLUTION SYSTEM CONTROL REPLACING THE SOLUTION SOLENOID VALVE 5 2er e Ue E De ier 50 WHEEL DRIVE SYSTEM WHEEL DRIVE CIRCUIT ERROR CODES AND MEASUREMENTS 252 TROUBLESHOOTING DRIVE WHEEL 550 252 REPLACING THE DRIVE WHEEL ASSEMBLY 253 REPLACING THE DRIVE TIRE 54 INSPECTING REPLACING THE DRIVE WHEEL ASSEMBLY CARBON BRUSHE REPLACING THE REAR WHEELS ELECTRICAL SYSTEM ACCESS TO PANEL CHEMICAL PUMP CHARGER INTERLOCK FUSES CONTACTORS SPEED CONTROL THROTTLE POTENTIOMETER WIPER MEASUREMENT NEUTRAL POSITION CONTROL BOARD 41 J2 AND J3 PIN OUTS AND TEST POINTS 258 CURTIS SPEED CONTROL INSTALLATION CHECKOUT PROCEDURE REPLACING THE OPERATOR CONTROL 61 PROGRAMMING FUNCTIONS SERVICE TEST MODE x CHANGING CONTROL BOARD PROGRAM SETTINGS 266 CHANGING PROGRAM SETTINGS ADVENGER 755 855 266 CHANGING PROGRAM SETTINGS ST ED a i a arten E a ttes 67 MAINTENANCE SCHEDULES OPERATOR PREVENTIVE MAINTENANCE MACHINE IN USE 268 OPERATOR PREVENTIVE MAINTENANCE MACHINE STORAGE 269 SERV
66. nabled Foot Pedal Neutral Solution Solenoid Off but enabled olution Solenoid Off Lift Scrub Deck Brush motor circuits Off Lift Vacuum motor circuit Off after 10 seconds Squeegee Seated Lower Squeegee Vacuum motor circuit enabled Press Foot Pedal Forward Wand Mode Vacuum motor circuit On Press Foot Pedal Reverse Lift Squeegee to prevent damage Vacuum motor circuit Off after 10 seconds Foot Pedal Neutral Vacuum motor circuit On for 10 seconds then enabled Lower Squeegee Vacuum motor circuit On Raise Squeegee Vacuum motor circuit Off after 10 seconds FORM NO 56043121 Advenger 28005 34005 BR 755 BR 855 19 Refer to the section Understanding Control of Squeegee Scrub and Recovery Systems Modes for explanation of control due to functionality of multiple systems in tandem Advenger BR 755 855 SOLUTION VO 13 por Lo M2 YEL BLK PDT HI 1 4 CONTROL BOARD 40RN Ld PIN 3 POT POT SK OHM THROTTLE HORN CHEMICAL PUMP CHEMICAL PUMP pies s J2 8 BLK 8152 7 sJe 1 JIK p J3 28 M3 J1 9BLK YEL Bw SQUEEGEE LIFT ACTUATOR SQUEEGEE act 1 1210 WHI GRN BRUSH 124 BLU En DE BRUSH LIFT ACTUATOR BRUSK act 12175 ORN BLK BRUSH MOTOR sENsQJE 10
67. nd disassemble the motor from the chassis mount Then pull the motor towards the machine front to remove it completely NOTE New replacement lift actuator motors do not come with the lift nut pre adjusted Follow the Squeegee Lift Actuator Drive Nut Adjustment procedure using 56407502 Actuator Power Cord Adapter to set the new lift actuator to the correct settings When finished reassemble in reverse order FIGURE 9 FORM NO 56043121 Advenger 2800ST 34005 BR 755 BR 855 23 SQUEEGEE LIFT ACTUATOR DRIVE NUT ADJUSTMENT ADVENGER BR 755 855 Z WARNING 1 Open the battery compartment and disengage the red Anderson battery connectors 2 Connect the Scrub Deck Lift Actuator completely assembled to the Actuator Power Cord Adapter 56407502 Figure 10 see Diagnostic and Service Tools 3 Connect the red alligator clip to the positive battery terminal 4 Connectthe black alligator clip to the negative battery terminal 5 See Figure 11 Hold onto the metal nut A and press the rocker switch to run the motor and retract the nut towards the motor housing the IN or Retract Limit 6 With the motor laying on a flat surface place a 3 8 pin or bolt through the top mounting holes C and the bottom nut mounting holes D because you will be measuring the distance between them 7 Manually turn the metal nut A until the distance between the outer edge of one pin and the inner edge of the other pin matches t
68. oblem 3 solenoid if coil is shorted eck for a wiring problem CNN wiring or open in solenoid see below Visible in Solution solenoid open 2 Repair or replace Fault Recall Voltage at control board should be 24V referenced to B plug or open in wiring 2 Repair or replace Chemical pump open When the pump is On it makes a clicking noise If the board output is correct it should appear as a pulsed signal to a DVM 1 If J3 11 is 24V referenced to B when Solution switch is Off replace control board Solution solenoid control fault 2 If J3 11 is OV referenced to when Solution switch is Off disable fault via Hidden Menu Refer to Control Board J1 J2 and J3 Pin Outs and Test Points section Solution Nominal Nominal Current Overload Current Wire Colors ohms mA mA BRN VIO BLK Chemical Pump Nominal Current Overload Current PWM Mt int amp AXP EDS SYSTEM ISSUES nadequate or no solution flow No solution the tank Red Solution Shutoff Valve 21 is in the Off position Clogged Solution Filter 20 valve L1 or hoses L1 Solution Solenoid Valve defect er fault Advenger BR 755 855 olution tank level indicator shows empty even mall clear hose at pressure sensor on control board 15 kinked refer to Replacing the though the tank is full Operator Control Panel for instructions
69. off the blocks and drive it in an open area It should have smooth acceleration and good top speed 60 FORM NO 56043121 Advenger 28005 34005 BR 755 BR 855 REPLACING THE OPERATOR CONTROL PANEL A WARNING DISCONNECT BATTERIES BEFORE SERVICING AN CAUTION To prevent damage to the new control panel assembly due to static electricity ESD wear a properly grounded static control wrist strap before removing the new assembly from its protective static shielding bag and throughout the entirety of the installation process until the four screws attaching the assembly to the machine have been re fastened CONTROL PANEL REMOVAL 1 See Figure 41 Flip the seat forward and prop Remove the 4 Screws from the Control Panel Assembly B then lift and tilt the Control Panel Assembly B to access the underside 2 Take note of the wiring connections for reassembly and then disconnect all wiring and the small clear hose Advenger BR 755 855 Completely drain the solution tank to prevent e water squirting out of the fitting at the control board when the hose is removed e erroneous pressure reading due to a loss of pressure differential in Pressure Sensing Tube after the new control board is installed A CAUTION DO NOT disconnect the small clear hose from the circuit board because this is connected to the pressure sensor and may damage the sensor and board It should only be disconnected from the fitting on the top of
70. on wheel in slot on squeegee tool Refer to Squeegee Adjustments section Squeegee tips are being driven into the floor Adjust squeegee using Adjustment Knob turning CW to raise tips Lift motor runs in both directions but does not raise or lower 1 Threads the moveable lift motor assembly drive tube are damaged the squeegee tool assembly stripped 2 Lift cable damaged stretched or broken Lift motor does not run and the display shows an error fault Lift motor electrical system failure refer to chart in Main Controller Error code Codes for service actions Squeegee lift Linkage Arm at steering column keeps bending Squeegee Lift Cable is too tight follow instruction in Squeegee Lift Cable or breaking Adjustment ST section Squeegee lift Linkage Arm Knob doesn t raise or lower Cable Bushing under Eyelet of Squeegee Cable in Steering Column is worn or squeegee Weldment Linkage is bent sheared because Squeegee Lift Cable is too tight Follow instruction in Squeegee Lift Cable Adjustment ST section FORM NO 56043121 Advenger 28005 34005 BR 755 BR 855 21 SQUEEGEE ADJUSTMENTS Correct squeegee alignment is critical to water pickup performance and life of squeegee blades If the squeegee is not angled correctly or hops use the following settings as nominal and adjust as necessary to achieve the required performance Tilt FIGURE 7 Factory setting is 0 625 nominal FIGURE 7
71. operty A DANGER Is used to warn of immediate hazards that will cause severe personal injury or death A WARNING Is used to call attention to a situation that could cause severe personal injury CAUTION Is used to call attention to a situation that could cause minor personal injury or damage to the machine or other property 8 Read all instructions before using GENERAL SAFETY INSTRUCTIONS Specific Cautions and Warnings are included to warn you of potential danger of machine damage or bodily harm WARNING This machine shall be used only by properly trained and authorized persons While on ramps or inclines avoid sudden stops when loaded Avoid abrupt sharp turns Use low speed down hills Clean only while ascending driving up the ramp Keep sparks flame and smoking materials away from batteries Explosive gases are vented during normal operation Charging the batteries produces highly explosive hydrogen gas Charge batteries only in well ventilated areas away from open flame Do not smoke while charging the batteries Remove all jewelry when working near electrical components Turn the key switch off O 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 c
72. or 35 Rear Squeegee Blade Removal Latch 36 Hopper Cylindrical models only 37 Recovery Hose 38 Solution Solenoid Valve 39 Front Squeegee Blade Removal Thumb Nut 40 Solution Filter 33 Seat Prop Rod 22 Squeegee Raise Lower Lever ST models only 23 Steering Wheel Tilt Adjust Knob 24 Control Panel 28 Strainer Basket optional on ST models 29 Recovery Tank Shutoff Float 30 Squeegee Storage Hook 32 Squeegee Tilt Adjustment Knob KNOW YOUR MACHINE MACHINE REAR LH VIEW 21 Solution Shutoff Valve 25 Solution Tank Fill Cover 26 Recovery Tank Cover 27 Vacuum Motor Filter Housing 31 Recovery Tank Drain Hose P ney SS OD 24 7 FORM NO 56043121 Advenger 2800ST 34005 755 BR 855 11 KNOW YOUR MACHINE CONTROL PANEL ADVENGER 755 855 MODELS A B C D E F Key Switch Solution Increase Switch Solution ON OFF Switch C1 Solution Flow Indicators Normal Heavy amp Extreme Solution Decrease Switch AXP EDS ON OFF Switch Display F1 Hour Meter F2 Solution Tank Level Indicator F3 Fault Codes AXPIEDS Indicator if so equipped F5 Detergent Ratio Indicator F6 Battery Indicator F7 Recovery Tank FULL Indicator F8 Battery Low Indicator Scrub Pressure Increase Switch Scrub ON OFF Switch H1 Scrub Pressure Indicators N
73. ormal Heavy and Extreme Scrub Pressure Decrease Switch J EverGreen Switch Horn Switch Vacuum Wand Switch NOTE 1 The display will go into Sleep Mode to save power if the machine is turned on in Neutral pedal and idle for more than 10 minutes Closing the seat switch moving the drive pedal or pressing a control panel button will refresh the LCD display and LEDs NOTE 2 Recovery Tank FULL F7 status allows machine transport but disables all active systems and disables the control panel switches except for the Horn Switch K To reset empty the tank and cycle the key switch NOTE 3 Battery Low Low Voltage Cutout Indicator F8 triggers at 20 55V on the wet setting and at 21 75V on the gel setting Refer to Changing Program Settings Advenger BR 755 855 to change battery type programming 12 FORM 56043121 Advenger 28005 34005 BR 755 BR 855 KNOW YOUR MACHINE CONTROL PANEL ST MODELS A Key Switch NOTE 1 Recovery Tank FULL status is indicated by the Solution Flow B Solution Increase Switch Indicator LED C1 turning Off This status allows machine transport but C Solution ON OFF Switch disables all active systems and disables the control panel switches except C1 Solution Flow Indicators Normal Heavy amp Extreme for the Horn Switch K To reset empty the tank and cycle the key switch D Solution Decrease Switch NOTE 2 Battery Low Low Vol
74. orter nspect brush motor carbon brushes Replace if 9 5mm 3 8 inches or shorter While brush motor being checked also check for wear at Motor Gimbal inside Brush Plate Remove and replace if worn nspect Original carbon brush length is 19 1mm 3 4 inches Replace when shorter than 6 3 mm 1 4 inches to obtain the same motor efficiency as a new brush RECOMMENDED MAINTENANCE MATERIALS Typical adhesives and lubricants used on Advenger BR include Loctite R Silver Grade Anti Seize Loctite formulas 242 680 414 409 and No More Leaks TM 80724 sealant Uniroyal M6325 Adhesive CRC White Lithium Grease Sprayon 500206 All Purpose Silicone Lube light machine oil such as 10W 30 motor oil Mobil SHC 634 lube and Mobilgear 600 XP 150 EU AGIP BLASIA 150 gear case oil To clean wet batteries baking soda will also be needed FORM NO 56043121 Advenger 28005 34005 BR 755 BR 855 69 Advance Advenger 2805 2905 3405 Advance 2800ST 3400ST Nilfisk BR 755 855 Disc and Cylindrical PM Checklist Defect Codes Customer A needs adjustment 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 OK or Defect Codes Does N A circle Not Work Drive Pedal Operational check for Fwd Rev Drive amp any neutral creep eat Switc Noisy Sluggish 4 engaged Brake engages when machine i
75. provides an output signal of 24V to the drive wheel for forward and reverse movement but also monitors current and temperature and controls the electromagnetic brake It is the same for both the Advenger BR 755 855 and ST models The speed control is programmable through and can be monitored via the Curtis Handheld Programmer 56409441 and Curtis Adapter Cable with Quad Plug 56409823 listed in the recommended Diagnostic and Service Tools section of this manual For information on how to use the Curtis programmer please refer to the Curtis Programmer Manual 56043101 The 5k Ohm throttle pot R1 in the foot pedal controls drive speed and forward reverse movement The throttle pot input to the main control board also determines whether or not the scrub and vacuum systems will engage and is therefore critical to machine performance If the control board senses a Neutral position of the foot pedal it will not engage these other systems unless placed in Service Test Mode or one of the vacuuming only modes The Electromagnetic Brake is engaged whenever the foot pedal is in Neutral and released for forward or reverse motion S x GRA BLK p SWITCH SEAT l e M 2 g gt E FOR REWJ3 6 JRED WHT PIN 6 BRAKE sTATUS J3 7 ORN BLU PIN 9 STATUS 3 5 BLU BLK PIN 16 REV ALARM MS PIN 8 MODE M1 PEDIR A2 2
76. r Retract Limit Measure the position of the Spring Housing Guide B in reference to the shoulder as shown in the figure below Manually turn the plastic Spring Housing F assembly until the position measure matches the figure below Hold the Spring Housing and press the rocker switch running the motor until it stops but no further than 4 from the shoulder as shown in the figure below or damage to the Housing may occur If the measurement doesn t match 3 94 100 08mm as shown below pry off the black cover H to access the Cam Adjuster Using a 1 2 socket gently turn the adjuster CW to increase travel CCW to decrease travel of the Drive Nut Each click of the adjuster will change the nut travel by 0 09 2 29mm or just under 3 32 10 After each adjustment re check the travel by holding the Spring Housing Drive Nut assembly and running the actuator IN and OUT checking against the values below Repeat until it is set correctly and replace the Cam Adjuster cover 1 00 06 RETRACTED NO LOAD 3 94 06 EXTENDED NO LOAD 34 FORM NO 56043121 Advenger 28005 34005 BR 755 BR 855 SCRUB DECK REMOVAL DISC A WARNING DISCONNECT BATTERIES BEFORE SERVICING Scrub Deck Removal Re installation 1 2 NO 4 FIGURE 20 Remove both deck side skirt assemblies Lower the scrub deck with brushes pads installed STD AXP EDS SERVICE NOTE Don t turn the key switch of
77. r steering column Lift the battery charger cover Pry the plastic Lower Column Shroud off of the weldment by starting on the left side away from knob so shroud can clear the Weldment Linkage bump on the right side ST you may want to tap the linkage in a bit to permit clearance CONDOR Reassemble in reverse order applying a light coating of Silicone Spray or water to the inside of the Steering Boot to permit free travel over the shaft FIGURE 16 28 FORM 56043121 Advenger 2800ST 34005 BR 755 BR 855 SCRUB SYSTEM Advenger BR 755 855 pressing the Scrub On button with the seat switch closed causes the scrub deck and squeegee to drop The control board provides 24V to the deck lift actuator M4 this signal is DVM measureable for 3 seconds and then becomes a pulsed signal while the deck is down Pressing the drive pedal forward causes the brush and vacuum contactors K2 and K1 to energize The 24V brush and vacuum motors 7 8 5 M6 turn on the pulsed solution solenoid 11 and chemical pump M2 turn on Combined brush motor current is monitored via the YEL VIO sense wire Reversing the drive pedal turns off the solution solenoid and chemical pump but the deck remains down and the brush motors stay on for double scrub Because multiple systems are engaged via one button a further summary is provided in the section Understanding Control of Squee
78. ration To bypass these systems refer to the Service Test Mode section Advenger BR 755 855 Operator Seat Switch Position Status r 4 seconds adjustable Closed Press Scrub On Scrub deck lowers 24V to 4 for 3 sec then pulsed signal Vacuum motor circuit On Press Foot Pedal Scrub motor circuit On Forward Solution Solenoid On Chemical Pump On if equipped olution Solenoid O Chemical Pump Off if equipped Squeegee raises reverse 24V to M3 for 4 seconds Press Foot Pedal Pulsed voltage to M4 deck actuator maintaining down position Brush motor circuit On Vacuum motor circuit off after 10 seconds continuous in reverse Scrub Mode Seated Reverse Vacuum motor circuit Off after 10 sec but Enabled Pulsed voltage to M4 deck actuator maintaining down position Foot Pedal in Neutral S Squeegee in down position Brush motor circuit Of Scrub deck raises reverse 24V to 4 for 3 sec Squeegee raises after 10 sec reverse 24V to M3 for 4 seconds Vacuum motor circuit On for 20 seconds total Solution Solenoid Off Chemical Pump Off if equipped Brush motor circuit Off Scrub deck raises reverse 24V to 4 for 3 sec Press Scrub Off Foot Pedalin Squeegee raises reverse 24V to M3 for 4 seconds Neutral gt 10 sec Vacuum motor circuit Off Solution Solenoid Off Chemical Pump Off if equipped Closed Press Vac Wand On Squeegee lowers 24V to M3 for 4 seconds Press Foot Redal Vacuum motor circuit On Forward Sq
79. s clean amp rotate queegee Liit Cable Plastic Bushing Steering Column abe too tight Worn Dina Pollo RN NNNM ERN NN 15 77 WORK COMPLETED BY ACKNOWLDEGED BY Service Technician Signature Date Customer Signature Date FORM 56043121 Advenger 28005 34005 BR 755 BR 855 71 ELECTRICAL SYSTEM COMPONENT LOCATION Advenger BR 755 855 Item Description A1 Control PCB Assy A2 Controller Speed F1 Fuse 150 Amp Circuit Breaker 70 Amp CB2 Circuit Breaker 10 Amp H1 Beacon Warning optional H2 Horn Backup Alarm K1 Contactor Vacuum Motor K2 Contactor Brush Motor L1 Solenoid Valve M1 Motor Drive Wheel M2 Pump Chemical AXP EDS only M3 Squeegee Lift Actuator 4 Brush Lift Actuator M5 Motor Vacuum M6 Motor Vacuum Optional M7 Motor Brush M8 Motor Brush R1 Potentiometer 5K 1 Switch Key 52 Switch Seat 54 Emergency Disconnect Y1 Electromagnetic Brake Onboard Charger FORM NO 56043121 Advenger 28005 34005 BR 755 BR 855 75 ELECTRICAL SYSTEM WIRING DIAGRAM SCHEMATIC Advenger BR 755 855 Ref No Qty Description 2 F1 CB1 CB2 H1 H2 K1 K2 L1 M1 M2 M3 M4 M5 M6 8 R1 1 52 54 Y1 76 FORM NO 56043121 Advenger 28005 34005 BR 755 BR 855 56601565 56601061 N A 56
80. s at rest Drive System Performance refer to Curtis Programmer Manual SM56043101 for speed control changes crub System Raise Lower auto scrubbing functions Vacuum Performance Dual Motor sealed water lift sealed water lift 65 1 inch open hole aperture 18 0 olution Control On Off Increase amp Decrease for Normal Heavy Extreme mergency Stop Knob B ilt Steering Mechanism and Sea Optional Accessories P e 4 Main Control Board Special Program Opt ault Recall check all app program settings per Changing Program Settings section and examine stored fault codes Battery Charger Programmed Correctly for Battery 7 B ABD D ABW AB W W D ABD D D 6 Battery Charger Operation Vacuum Performance Single Motor sealed water lift 63 1 inch open hole aperture 10 70 FORM NO 56043121 Advenger 2800ST 3400ST BR 755 BR 855 VISUAL INSPECTION ITEMS Comments OK or Defect NIA Codes Sa crub Brushes check for wear and rotate D W crub Brush Motor Carbon Brushes Wear Limit crub Brush Motor Gimbals n Brush Plates Auto Tension Belt Wear and Tension cylindrica pring Retainers On Brush Plates crub Deck Skirt Position ight Flare olution Solenoid Valve olution Tank Delivery Hoses amp Filter ean Filter Screen Vacuum Float Ball amp Cage Assembly ean Float Recovery Tank Strainer Basket queegee Pick Up Tool and Hose queegee Blade
81. s controlled via a pulsed 24V signal from the control board at J3 11 to the Solution Solenoid valve On Advenger 755 855 machines the solution flow rate is also controlled via feedback provided by a pressure sensor on the control board For more details refer to the Solution System Control section in this chapter To avoid clogging and malfunction of solution system components it is recommended to avoid using chemicals that are known in the industry to cause performance degradation in commercial auto scrubbers These chemicals include d limonene frequently found in orange type cleaners and not listed on the MSDS and in hard water areas carbonates silicates and phosphates which are listed on the MSDS KEY SWITCH 5 NTACTUR CONTACTOR BRUSH BRN 4H WO BLK 23 1 SOLUTION VALVE SOLENOID 1 H2 CONTROL BUARD Hh ORN RED 3 o HORN BACKUP 2 CRAP BLK J3 9 OPTIONAI 2 RED YEL Ji 1 m BLU GRA J1 3 CHEMICAL PUMP CHEMICAL PUMP 46 FORM NO 56043121 Advenger 2800 T 34005 755 BR 855 SOLUTION amp AXP EDS SYSTEM ERROR CODES AND MEASUREMENTS ADVENGER BR 755 855 AND ST Advenger BR 755 855 Display ST Service Fault Description Troubleshooting Action LED Blink Code Check for wiring pr
82. t of the Solution Solenoid varies with liquid level as the level drops in the tank the output of the Solution Solenoid will also drop As the tank empties this results in a decrease in solution output to the brushes from the full rate FORM NO 56043121 Advenger 28005 34005 BR 755 BR 855 49 REPLACING THE SOLUTION SOLENOID VALVE 1 Advenger BR 755 855 follow instructions found in Service Test Mode to lower the scrub deck ST manually lower the scrub deck Z WARNING 2 Quickly disconnect the batteries at the red Anderson connectors in the battery compartment done for safety and to keep the deck from rising back up Reach under the front left side of the machine and manually close the red Solution Shutoff Valve 21 adjacent to the Solution Filter 20 4 Usinga flat blade screwdriver or 5 16 socket loosen the two hose clamps on the valve and remove the black Solution Hose A from the inlet side and the clear hose B coming from the deck manifold 5 Usinga 7 16 socket remove the bolt fastening the Solution Solenoid to the machine 6 Unplug the valve body at the connector 7 Replace the valve and reassemble in reverse order FIGURE 30 50 FORM 56043121 Advenger 28005 3400ST BR 755 BR 855 WHEEL DRIVE SYSTEM The drive wheel assembly is directly connected to the Curtis 1228 speed control which not only
83. tage Cutout status is indicated by the red battery LED flashing It triggers at 20 55V on the wet setting and M Battery Indicator 21 75V on the gel setting Refer to Changing Program Settings ST to Fault Indicator change battery type programming FORM NO 56043121 Advenger 28005 34005 BR 755 BR 855 13 KNOW YOUR MACHINE As you read this manual you will occasionally run across a bold number in parentheses example 2 A bold number refers to an item shown on the Know Your Machine pages unless otherwise noted bold letters refer to items on the same page Refer back to the Know Your Machine pages whenever necessary to pinpoint the location of an item mentioned in the text BASIC MACHINE OPERATION refer to Operator Manuals such as 56041735 56041743 English for detailed information regarding how to operate the machine 1 on the key to turn on the graphical display showing battery condition hour meter solution tank level and AXP EDS dilution ratio if so equipped ADVENGER BR 755 855 Pressing the red SCRUB ON OFF button once will enable regular scrub mode The deck and rear squeegee will be lowered to the floor ST Manually lower the scrub deck and squeegee using levers 14 and 22 Depress the foot pedal forward to begin scrubbing The brushes water and vacuum will turn on When the machine stops the brushes and water will stop The vacuum will continue
84. the tank FIGURE 41 FORM NO 56043121 Advenger 2800ST 3400ST BR 755 BR 855 61 REPLACING THE OPERATOR CONTROL PANEL CONTROL PANEL DISASSEMBLY ASSEMBLY AND INSTALLATION 1 See Figure 42 Remove the Key Switch A from the panel assembly 2 Remove the 5 Screws B the Circuit Board C and the Tab D from the panel assembly NOTE Save Items A D and discard the panel assembly 3 Follow all previous steps in reverse order to reassemble and install the control panel assembly using the new panel assembly 1 amp 2 from the kit NOTE the clear hose must not be kinked otherwise the Solution System will not function properly A CAUTION To prevent damage to the new control panel assembly due to static electricity ESD wear a properly grounded static control wrist strap before removing the new assembly from its protective static shielding bag and throughout the entirety of the installation process until the four screws attaching the assembly to the machine have been re fastened The ribbon cable s and membrane switch grounding film are fragile do not scratch or crease during assembly or they may be damaged FIGURE 42 62 FORM NO 56043121 Advenger 28005 34005 BR 755 BR 855 PROGRAMMING FUNCTIONS SERVICE TEST MODE ADVENGER 755 855 The purpose of Service Test Mode is to by pass the lock out function of the normal control system of components t
85. tions A shown in FIGURE 2 Tape and strap all access doors and covers as necessary In temperatures below freezing remove all water from the machine and flush with windshield washer fluid to prevent damage to valves and fittings 5 Do not drive machine onto a ramp grade exceeding 16 9 degrees or damage to the machine may occur TIE DOWN POINTS gt FIGURE 2 TOWING THE MACHINE N CAUTION The Drive Wheel 4 has a built in electromagnetic brake that is engaged whenever the Key Switch is Off or the Drive Pedal 3 is in the Neutral position i e there is no power to the Speed Control This brake can be manually over ridden if necessary by inserting a medium to large screwdriver behind the Yoke A as shown in FIGURE 3 A rubber door stop can also be used This should only be done in the event you need to push or pull the machine FIGURE 3 Tow the machine for short distances only 8 FORM NO 56043121 Advenger 2800ST 3400ST BR 755 BR 855 FIGURE 4 JACKING POINTS Front When facing the front of the machine and underneath looking up place the jack to the left of the chain on the frame member A as shown in FIGURE 4 Rear Remove Squeegee Assembly 11 to access these locations Use bottle jack at these points B as shown in FIGURE 5 VAT EN LA 44
86. uator Using the Actuator Power Cord Adapter 56407502 from your Nilfisk Advance service tool kit set the Extend and Retract limit switch positions as shown in the Scrub Deck Lift Actuator Drive Nut Adjustment section CAUTION Failure to set the lower stop correctly may result in damage to the Spring Housing F 7 Then reassemble in reverse order after drive nut position has been set NOTE to replace a portion of this assembly items A G follow these instructions as they apply noting component position in the diagram at ri ght and set limit switch end stops in accordance with the instructions found in Scrub Deck Lift Actuator Drive Nut Adjustment section FIGURE 17 FORM NO 56043121 Advenger 28005 34005 BR 755 BR 855 33 A 1 2 gt 7 8 9 11 FIGURE 19 SCRUB DECK LIFT ACTUATOR DRIVE NUT ADJUSTMENT ADVENGER BR 755 855 WARNING FIGURE 18 Open the battery compartment and disengage the red Anderson battery connectors Connect the Scrub Deck Lift Actuator completely assembled to the Actuator Power Cord Adapter 56407502 see Diagnostic and Service Tools Connect the red alligator clip to the positive battery terminal Connect the black alligator clip to the negative battery terminal Hold onto the plastic Spring Housing F Drive Nut assembly and press the rocker switch to run the motor and retract the nut towards the motor housing the IN o
87. ueegee down travel 24V to 4 for 3 sec OV to M3 for 3 sec deck upward travel squeegee up travel Not measurable AM DVM BLU GRY Not measurable using DVM RED YEL Range of 24V measurements is 20 26 V 58 FORM NO 56043121 Advenger 28005 34005 BR 755 BR 855 Backprobe J2 Speed Control outputs ST deck and squeegee lever position and sense wires J2 connected at control board oe mm adn ST squeegee lever switch S6 BLK YEL Closed sq down Open sq up 5V ST deck lever switch S5 ORN RED Closed deck up 0V Open deck down 5V M7 amp M8 sense YEL VIO monitor brush heights for deck actuator feedback 0 200 mV M5 amp M6 sense BRN RED monitor vac motors to determine when tank is full 1 200 mV Advenger BR 755 B 855 B ground input to board Backprobe J3 Output to Contactors Solution Solenoid Horn Speed Control error status EM Brake reverse status J3 connected at control board 24V 24 flashed speed control status ORNI BLU Key switch 241 error code Speed control EM brake signal WHT 42A for 2 sec to K2 24 RED WHT then 18 pulsed voltage moving on neutral Speed control reverse GRAIBLK 24V for 2 sec to K1 direction 24V BLU BLK then 18V pulsed voltage reverse off forward on Advenger BR 755 855 BLK B ground Input to board 24V Advenger BR 755 855 24V Seat switch 24V GRA B
88. ueegee raises until Foot Pedal in Neutral or Forward again reverse 24V to M3 for 4 sec Vacuum motor circuit On for 10 seconds Vac Mode Seated Press Foot Pedal Reverse Squeegee raises after 10 sec reverse 24V to M3 for 4 seconds Vacuum motor circuit On for 20 seconds total If drive pedal in Neutral gt 10 sec squeegee will raise and vac motor circuit will be Off immediately with no delay Press Vac Wand Off Squeegee raises immediately reverse 24V to M3 for 4 seconds Vacuum motor circuit Off immediately Press Vac Wand On Squeegee lowers 24V to M3 for 4 seconds Vacuum motor circuit On Press Vac Wand Off Squeegee raises reverse 24V to M3 for 4 sec Vacuum motor circuit Off Press Vac Wand Off Twice Wand Mode lt D m n c re m LA 18 FORM NO 56043121 Advenger 280057 34005 BR 755 855 UNDERSTANDING CONTROL OF SQUEEGEE SCRUB AND RECOVERY SYSTEMS VIA MODES ST Operator Seat Switch Position Status Seated Lower Scrub Deck Brush motor circuit enabled Lower Squeegee Vacuum motor circuit enabled V t On acuum motor circul Scrub Mode Press Foot Pedal Brush motor circuit On Forward Solution Solenoid On Press Foot Pedal Brush motor circuit On Reverse Vacuum motor circuit On for 10 seconds Lift Squeegee to prevent damage Vacuum motor circuit On for 10 seconds then e
89. umr f TT reverse T REVERSE 010 BLU BLK 18 16 HORN 18 HORN 011 ORN BLU 18 E m 4 414 BRAKE 14 19 Low 19 Low MOLEX 63 femmer FE REN E 046 BLK 18 ue ules CONN MINIFIT JR 1 4DR Bir dd EM PL J3 5 status 5 status zu 8 18 MODE M1 2 8 2 Fl puen ub 5 021 GRN BLK 18 ah eine S 18 10 023 ORN RED 18 3 ksi 3 ksi a 4 eor weer por weer 512 027 GRA BLK 18 3 3 24 1 gE 63 e 2 1 OPTIONAL 2g 030 BRN 18 ate Te U gls RED BLK 024 GRA BLK 18 baa xa EE Dp emm K1 le e a E AJ6X P CONTACTOR VACUM LL Eu s De MOLEX EX 032 BRN 18 42 CONN MINIFIT JR 12DR 8 i 031 WHT BRN 18 5 9 SW SPDT KEY id Y 25 10 080 YEL VIO 18 amp X24 51 EMERGENT eS TOP SEAT SWITCH sin NIE 037 BRN 18 SP7 SP8 52 6112 58 XR 3 X76 X75 AE 7 045 YEL 18 S8 uz f T TM 044 VIO 18 5 CONTACTOR BRUSH ae 2 051 WHT BRN 18 049BRN1B E HOUR METER 085 GRA BLK 18 1 5 P1 DECK SWITCH SPE s 2 x8 x7 2 t h S8 047 ORN 18 075 Vio 18 054 BRN 18 A 19 x20 082 YEL 18 2 x21 Av 19 amp xn al M a 8 x26 S7 SQUEEGEE SWITCH CEA X18 5 020 BLK 5 X29 X28 LL gt im 1 2 FANGE c VALVE
90. urn the key switch on The programmer should power up with an initial display If neither happens check for continuity in the key switch circuit and controller ground 3 If you are using a programmer put it into diagnostic mode by pressing the DIAGNOSTICS key e If there is no error detected 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 e If there is a problem the control panel will flash a diagnostic code and the programmer will display a diagnostic message If you are conducting the checkout without a programmer refer to the Status LED Fault Codes table in Speed Control Error Flash Codes to diagnose the cause 4 When the problem has been corrected it may be necessary to cycle the key or seat switch to clear the fault code 5 While sitting on the seat operate the throttle The motor should begin to turn in the selected direction If it does not verify the wiring to the controller and the motor The motor should run proportionally faster with increasing throttle If not refer to the Curtis manual 6 Put the programmer into 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 7 the vehicle

2800ST & 3400ST Service Manual - Industrial Cleaning Equipment

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2800ST &amp; 3400ST Service Manual - Industrial Cleaning Equipment

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2800ST & 3400ST Service Manual - Industrial Cleaning Equipment