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Adgressor™ BR 850S, 850CS, 950S, 950CS BR 1050S

1. ORNIRED 20 1 ORN J4 1 a 2 BRN 18 1 RH Fo Mos BRN 16 1 BLUIBLK 20 1 SW SPST KEY RE oe BRN YEL 16 1 YELMO 18 1 LC ORN 20 2 REDIBLK 20 1 REVEL ID 2 1 GRN YEL 16 3 202 E1 VU E z GRNIBLK 20 L CONTROL BOARD BONDING WARED TED 2 CONTROL BOARD VIOIBLK 18 1 VOR TET ate X3 xu BLK 16 2 BLK 16 2 jamg Sys lat gt qeu APA A X 5 2 16 4 BRNIYEL T5 ATERN IET M5 m LV oJ BRN YEL 16 3 BRN YEL 16 3 J3 S cs BRNE TES REDWET 16 1 REDIWHT 16 1 o amp WHTIGRN 16 1 WHTIGRN 16 1 9 e S BLKIYEL 16 1 BLKIYEL 16 1 F2 F3 amp RUM MOTOR VACUUM 3 BLK 163 X40 x ER 12 amp em BLUIBLK 20 1 B B BLK122
2. RED 1 AWG Bn BLK FUSE 150 A BATTERY 36 Vdc F2 K3 RED L2 8AWG BRN BLK 1 2 CIRCUIT BREAKER 70 AMP CONTACTN O F3 46AWG 51 52 RED 150 BRNYEL 192 BRN 12 2 ORN it ORN E CIRCUIT BREAKER 10 AMP SW M1 M2 SW SEAT FUSE 1 E SPST KEY BRUSH LIFT SQUEEGEE LIFT g ACTUATOR ACTUATOR ORN Z MAINCONTAGTOR E M Amps 3 M Amps 2 9 4 2 E E x ORN BLU n 2 E z 9 2 z E RED BLK 5 o a z 5 5 lt g 8 5 8 8 3 x 3 BLU BLK gt HORN BACKUP ALARM amp 8 gt 52608 28 4 H1 S 5865 6823 BLK x O CC Bc C x 2 22 AWG THERMISTOR 928 gt Zw RED GRN 2 ORNIRED ED amp p 2 C gt g INTERFACE 9 HORN 3 SPEED LIMII 29 WHDYEL PIN 4 SPEED LIMIT 2 YEUBLK E FA J4 9 YEL PIN 1 POT HI 3 mps 16AwG WHT BRN J28 cc _ BOARD POT LO GRA P2 S BOT WIPER 1 MOTOR 85 65 g 2 pot non 43 VID 1 443 YEL WHEEL DRIVE agg T4 lt o o R1 M aes Sata POT 5K OHM SPEED CONTROLLER 11 mI 3 3 465 5 WHT BRN 2 gt VALVE SOLENOID El gt 2 L ra WHT BRN GRA BLK C 33 CONTACTOR VACUUM K1
3. RIGHT SIDE VIEW General Specifrations common to All Models Machine Length Machine Height Machine Chassis Width Solution Tank Capacity Recovery Tank Capacity Sound pressure level as per IEC 60704 1 at operator Vibrations atthe Hand Controls ISO 5349 1 Vibrations atthe Seat EN 1032 Transport S peed Fwd Maximum Transport S peed Rev Maximum Grade Ability Transport Grade Ability Working Scrubbing Wheel Drive Motor Vacuum Motor 3 stage Vacuum Water Lift for one motor Sealed Open Hole Adapter 1 Vacuum Water Lift for two motors Sealed Open Hole Adapter 1 Power Source Batteries Battery Weight 305 amp STD Battery Weight 395 amp Opt Battery Compartment Size approx Height Max Width Max Length Max Battery Chargers see Electrical System Battery Section 4 Dip S Ss TY 8 Length gt Hei ght Squeegee Chassis Width Width TOP VIEW 61 155cm 54in 137 5cm 32 in 82cm 42 gal 1571 42 gal 1571 68 dB A 1 12 m s 0 35 m s 4 5 mph 7 3 kphm 3 15 mph 5 1 kphm 20 11 5 deg 8 4 6 deg 1 5 hp 1100 watt 15 hp 560 watt 68 in 18 78 in 25 in 6 6 volt 20 hour rate 90 Ibs 198kg 121 Ibs 266kg 16 5 in 42cm 22 25 in 56 5cm 25 25 in 64 1cm 4 FORM NO 56043097 Adgressor BR 8505 850CS 9505 950 5 1
4. Reference the Main Control Board Troubleshooting Guide in the Electrical System of this manual for further information SOLUTION SYSTEM MAINTENANCE Solution Tank See Figure 1 Weekly empty the solution tank remove the solution Drain Hose A from its storage area located underneath the left side brush skirt frame Direct the hose to a designated Disposal Site and fish the tank with clean water Solution Filter Remove and clean the inline Solution Filter B To access the fiter housing for removal work underneath the middle front of the solution tank see molded FILTER callout No tools are needed to remove the hand tighten only Service Tip The manual solution control lever must be placed in the full OFF position This prevents loss of solution when servicing the fiter strainer with a partial or full tank Solution Delivery Trough Note on the cylindrical scrub deck clean the holes in the delivery trough to assure even distribution of solution SOLUTION SOLENOID REMOVAL 1 Drain the solution tank or put the Flow Control Valve C in the closed position to prevent solution loss 2 See Figure 3 Locate the solenoid valve it s on the right side of the machine under the solution tank Unplug the L1 solenoid valve wire assembly connection from the machine harness 3 Loosen both the inlet and outlet Hose Clamps D and E that secure the hoses to the valve body 4 Separate pry the solution outlet ho
5. E Ler 33 z amp E 8 5 sl ec zo d a at La E E 5 E al O 5 a god m FORM NO 56043097 Adgressor BR 8505 850CS 9505 950 5 10505 1050 5 29 SCRUB BRUSH SYSTEM SCRUB BRUSH DECK REMOVAL DISC amp CYLINDRICAL SH On gt Remove both deck side skirt assemblies NOTE This step is optional you may fnd deck removal easier with the skirts removed Lower the scrub deck with brushes pads installed ATTENTION Don t turn the key switch off until after disconnecting the battery pack by pushing in activating the Emergency Disconnect 13 This procedure is done to prevent the scrub deck from automatically raising when the Key is turned off See Figure 2 Separate the solution system water line quick disconnect fitings located on top of the scrub deck Grip the bottom movable Sleeve A the quick disconnect fiting assembly and pull on the top Fitting B to separate the hoses Unplug the brush motor wiring harness C under left side of machine Remove the lower Hitch Pin D that secures the brush deck lift actuator to the scrub deck Remove the two E Hitch Pins that attach the scrub deck to the machine chassis linkage arm weldment From the right side of the machine swing the lower actuator housing forward to clear the deck mount bracket Then pull the deck out from under the machine to complete the removal Service Note It is important that the ac
6. 9 496 5 2 4 E z gt x z z zz 9 amp m m E x 2 S e 550 TE amp gs J gs 5 EE a 2 0 7 e Q s H 0MMM904 E 3 Br E Lu 2 8 calor Teor MS was a ser gr nivis gt or zer 2 amp HSnag a Wie w amp rer 2 8 26 c uo x ui E z tl E E osons na ormsa HSsnde HZ rr x eer 59 NOWMOS 2 9 T3ANH8 Lor a z Fs 54 S 95 8 R m ye J J s 3 E 1 48 g il x s ee 8 E 5 c 2 gt o C al CI WHEEL DRIVE SYSTEM R1 Voltage Values FIGURE 3 0 2 5V Reverse 2 5 5V Forward A1 Speed Control T Pin Connection View Non stem end 5 i as Main Control Board Partial Speed Limit This drawing shows additional controller input circuit detail The R1 potis shown in the neutral position Resistance is measured between pot low and pot wiper FIGURE 4 PROGRAM2 POWER DRIVER ENABLE MULTI KSI 15 ri MAIN PROGRAM 1 DRIVER POTLOW SPEED POT LIMIT WIPER POT HIGH Us
7. 4 revised 9 05 FORM NO 56043097 Adgressor BR 8505 850CS 9505 950CS 1050S 1050CS 75 ELECTRICAL SYSTEM WIRING DIAGRAM SCHEMATIC FOR Ackgyessor BR 8505 850CS 9505 S50CS 10505 1050CS after Serial Number Chart kem Description Al 1 2 F1 F2 F3 55553553 E BHA 588 BB 51 52 S3 54 S5 S6 CONTROLLER BATTERY CONTROL PANEL ASSEMBLY CONTROLASSEMBLY AXP EDS FUSE 150AMP CIRCUIT BREAKER 10 AMP CONTROL CIRCUIT CIRCUIT BREAKER 7 WHEEL DRIVE FUSE 1 CIRCUIT BREAKER 5 AMP SIDE BROOM OPTIONAL HORN BACKUP ALARM HEADLIGHT OPTIONAL STROBE LIGHT OPTIONAL CONTACTOR BRUSH MOTOR CONTACTOR VAC MOTOR CONTACTOR WHEEL DRIVE SOLENOID VALVE LIFT ACTUATOR BRUSH LIFT ACTUATOR SQUEEGEE MOTOR DRIVE WHEEL MOTOR PUMP OPTIONAL MOTOR VACUUM 36VDC MOTOR VACUUM 36VDC MOTOR GEARBOX ASSY DISC OR MOTOR BRUSH 36VDC CYLINDRICAL MOTOR BRUSH 36VDC CYLINDRICAL MOTOR SIDE BROOM OPTIONAL MOTOR BRUSH PUMP SOLUTION PUMP CHEMICAL AXP EDS POTENTIOMETER 5K SWATCH KEY SWITCH SEAT SWATCH PUMP SWITCH HEADLIGHT SWATCH SIDE BROOM SWATCH PUMP PART OF M11 Wiring diagramfor Machines built after this Serial Number Chart 1863250 BR 850 1863255 BR 950 1863260 BR 1050 ard all Adgressor rrodels F1 BT1 RED 1 2 RED FUSE 150 A BATTERY 36 Vdc BLK K3
8. An ylindrical Decks Note Terminals X53 X54 Are Used On Only MOTOR BRUSH MOTOR BRUSH Cylinderical Decks revised 9 05 FORM NO 56043097 Adgressor BR 8505 850CS 9505 950CS 1050S 1050CS 77 gt 1 j uU i tibt KEY CC NM 45 ee 44 SD SAS revised 5 06 LZ AA 22 7 78 FORM NO 56043097 Adgressor BR 8505 850CS 9505 950CS 10505 1050CS For Machines after Serial Number Chart SERIAL NUIVBER CHART 1863250 BR 850 1863260 BR 1050 ard all Adgressor rrodels 1863255 BR 950 Nilfisk Advance setting standards www nilfisk advance com 2006
9. 080202 RN204 _ im T 2 WHT 12 2 CIRCUIT CIRCUIT BREAKER ORNIBLU 20 1 H3 Is Optional M6 BREAKER 10 AMP Y BRNIWHT 20 1 70 AMP F4 YELIGRN 16 1 LAMP FLASHING FUSE 1A REDIBIK 20 1 16 1 WHT YEL 16 1 H3 MOT R VACUUM YEL202 pid Note SEU YEL 20 1 16 6 Is Optional GRN 16 1 GRA 20 1 VI 20 2 VI0 20 1 xs PT CONTACTOR _ 4 i MAIN 1 BRN BLK 8 1 x j E C 1 2 8L 0IM81 XI CI IIIIIIIIIIILII a ZSechtBa 22H om BLU ORN 16 1 7L BS 2 5 Inm 23 o WHTIBRN 16 1 2 g a s 95 BLK 12 4 WHTIBRN 16 2 7 a d Hz SPEED CONTROLLER 1 RED82 zelo K1 BLU 2 2 9 LI BLU 14 1 xa AJB IC 3 vvv WHT RED 18 2 x CYCY D JE F SET WHTIBRN 16 2 WHT BRN 16 2 WHT BRN 16 3 WHT 25 CONTACTOR 5 YELIBLK 8 1 4 VIII24 VACUUM RED84 BLK 8 1 d BLU ORN 8 Sema K2 WHT 124 1 ak 3 WATS RED GRN 8 1 Eus p Bko 21 E xd RED 8 2 4 F1 BLU 8 1 RED81 341 1 2 241 SQUEEGEE LIFT ACTUATOR 2 FUSE 150A BRUSH LIFT ACTUATOR 2 505 1 RED 1 2 1 M SET MX 217 162 M BLK hs 8 gt ORN 16 1 E a gx 5 m PANEL BONDING x48 xu la 5 X66 C Be BLU 101 t x x Jo n FUSE 5 AMP us T Mg fe RED 1 2 E lt BLU 10 2 BLK 1 2 2064 vy x33 L BLK 1 1 TAT X14 Ap B he BLK 1 2 H1 RED 10 1 i xt E 3 A MN rll 4 8 5 B
10. SPEED LIMIT 229 WHTYEL PIN 4 SPEED LIMIT M LE ET por tow liso YEL VIO PIN 1 POT HI 3 CONTROL BOARD m GRA PIN 2 POT WIPER IL 2 262 DEN YEL PIN3 POT LO E i224 RI A LI 1 M E eps POT 5K OHM SPEED CONTROLLER AlN gt BLK Programming Note The Squeegee raise in reverse time period is adjustable See the instruction in the Electrical Special Programming manual section to change the distance the squeegee will raise in reverse TROUBLESHOOTING Squeegee Lift Motor Operation Problem Possible Cause e Lift Motor runs in both directions Threads in the moveable lift but does not raise or lower the motor assembly drive tube are squeegee tool assembly damaged stripped Lift cable damaged stretched or broken e Lift motor does not run and the e Lift Motor Electrical system failure hourmeter Status display shows an error fault code 05 19 or 20 Reference the main control board troubleshooting guide in the Electrical System of this manual for specift fault descriptions amp service repair actions 46 FORM NO 56043097 Adgressor BR 8505 850 5 9505 950CS 10505 1050 5 SQUEEGEE LIFT ACTUATOR MOTOR REMOVAL 1 UJ 5 6 7 Note New replacement lift actuator motors do not come with the lift nut pre adjusted Important After removing the actuator motor and before replacing a new motor or drive nut the IN amp OUT li
11. 2 Connect loosely together both the Link Rod AE to the Pedal AF and the Throttle Lever AJ to the potentiometer input shaft Then tighten only the Link Rod AE pedal mounting Hardware AG Note Check the movement of the Foot P edal AF it must move freely in both Fwd and Rev 3 See Figure 8 inset Attach test leads from a volt ohm meter set meter on 0x100 scale to the YEL and VIO wire connection points on the potentiometer to check it s total resistance example 4800 Ohms 4 Next connect ohmmeter test leads to the GRA and VIO potentiometer connection points Then using a small screwdriver turn the shaft end on the pot to half the total resistance previously measured Example 4800 Ohms divided by 2 2400 Ohms Then without turning the shaft tighten the Screw Al and Nut AH to secure the setting at the Throttle Lever AJ 5 Follow steps 1 2 in reverse order see Potentiometer Removal steps to fnish the installation Then test drive the machine for proper speed and FWD REV directional control DRIVE PEDAL NEUTRAL ADJ USTMENT amp PEDAL REPLACEMENT If the drive pedal has been removed or replaced the neutral position for the pedal will have to be set Follow the steps below to accomplish this A WARNING Disconnect the machine s battery pack connector 13 before servicing Note See Figures 8 amp 9 Before making any adjustments inspect the Torsion Spring AL for defects and the correct positions of both spring
12. C and install the Short compression Spring D onto the actuator lead screw shaft frst Next reinstall the plastic drive nut as shown with the nut pin pocket away rtm from the motor 2 Follow steps 1 7 in the section labeled Instructions for Squeegee Lift Actuator Drive Nut Adjustment reference previous page 3 After adjusting the actuator drive nut dimensions follow step 10 in the Brush Deck Actuator Removal manual section to reassemble Service Tip See Figure 5 Note the Correct orientation of the Spring Housing E when installing the complete motor assembly and also run the spring housing assembly to the OUT extended position for machine installation OUT 3 5 8 92mm Spring Housing Assembly FIGURE 5 FORM NO 56043097 Adgressor BR 8505 850CS 9505 950 5 10505 1050CS 53 ELECTRICAL SYSTEM CURTIS CONTROLLER DIAGNOSTICS Diagnostics Method A Uses the machine s control panel hourmeter display and wand switch indicator FUNCTION OF THE SPEED CONTROLLER STATUS LIGHT AND DISPLAY The Curtis 1237 speed control will output a fault code if there is a problem associated with the speed control and wheel drive system See Figure 6 If a speed control fault occurs the Hourmeter Status display F will indicate E 03 When the E03 is being displayed and detects a fault the Green Indicator G normally the accessory wand indicator light will fash a special erro
13. SCRUB BRUSH SYSTEM SCRUB BRUSH DECK REMOVAL DISC amp CYLINDRICAL SCRUB BRUSH MOTOR ASSEMBLY REMOVAL DISC visser SCRUB BRUSH GEARBOX REMOVALAND OUTPUT SHAFT REPLACEMENT DISC SCRUB BRUSH SIDE SKIRT REPLACEMENT DISC SIDE SKIRT HEIGHT ADJUSTMENT 015 C SCRUB BRUSH FRONT REAR SKIRT REPLACEMENT DISC BRUSH DECK ACTUATOR REMOVAL DISC amp CYLINDRICAL SCRUB BRUSH MOTOR REMOVAL CYLINDRICAL SCRUB BRUSH BELT REPLACEMENT CYLINDRICAL SCRUB BRUSH SYSTEM MAINTENANCE SCRUB BRUSH REMOVAL AND INSTALLATION CYLINDRICAL SIDE SKIRT MAINTENANCE amp ADJ USTMENT CYLINDRICAL CORRECT SCRUB MOTOR WIRING CONNECTIONS CORRECT BRUSH ROTATION DIRECTIONS SOLUTION SYSTEM FUNCTIONAL OVERVIEW eene SOLUTION SOLENOID CIRCUIT OVERVIEW TROUBLESHOOTING GUIDE SOLUTION SYSTEM SOLUTION SOLENOID REMOVAL eset SOLENOID VALVE DISASSEMBLY AND CLEANING RECOVERY 5 FUNCTIONAL VACUUM MOTOR CIRCUIT OVERVIEW TROUBLESHOOTING GUIDE VACUUM RECOVERY SYSTEM SERVICE MAINTENANCE CHECKLIST MAINTENANCE OF VACUUM FILTER AND FLOAT CAGE RECOVERY TANK REMOVAL VACUUM MOTOR REMOVAL
14. This represents the scrub pressure that the operator will be able to select using the heavy scrub pressure select switch The scrub pressure increase indicator will now be illuminated Use the pressure increase switch to set the desired pressure 11 Press the scrub system off switch to save this setting 12 The status display will now show to indicate that the procedure is done 13 The new setting will be saved and will remain in effect until itis changed again Light Heavy Scrub Mode Turn the main power key switch to the off position Press and hold the scrub pressure decrease switch While holding the pressure decrease switch turn the main power key switch to the on position Continue to hold the pressure decrease switch until the scrub pressure decrease indicator is green Release the pressure decrease switch Pressing and releasing the scrub pressure decrease switch will now select between 0 1 2 3 4 or 5 Set the mode to 2 Press the scrub system off switch to save this setting The status display will now show a number from 1 to 5 This represents the maximum scrub pressure that the operator will be able to select using the light scrub pressure select switch Use the pressure decrease switch to set the desired pressure 9 scrub system off switch to save this setting 10 The status display will now show a number from 1 the setting from step 8 to 9 This represents the maximum scrub pressure that the o
15. To save the new setting turn the main power key switch to the off position 8 The new setting will be saved and will remain in effect until it is changed again Hn CC WwW FORM NO 56043097 Adgressor BR 8505 850CS 9505 950CS 10505 1050CS 67 ELECTRICAL SYSTEM SPECIAL PROGRAM OPTIONS CONTINUED Recall Of Stored Error Codes Whenever an electrical system fault is detected by the main control unit one or more error codes are displayed and stored by the control unit If it is desired the error code if any from the previous operation of the machine can be recalled for troubleshooting purposes To recall the last stored error codes perform the following steps 1 Turn the main power key switch to the off position Press and hold the solution switch While holding the solution switch turn the main power key switch to the on position Continue to hold the solution switch until the solution indicator is green Release the solution switch If there were previously no error codes stored the display will now show Go to step 11 If error codes were stored the display will now show the stored code s and the scrub system off indicator will now be red An example of how two codes 6 and 18 would be displayed is as follows The display will show E followed by a brief blank period The display will show 0 followed by a brief blank period The display will show 6 followed by a slightly longer blank
16. WHT BRN LI WHT RED CES NOTE PRESSURE SWTCHON op CONTACTOR BRUSH PARTOF PUMPASSEMBLY OPTIONAL SAssf e K 53 M4 WHT BRN Dio 3M y Ams 3 BLK 4 NOTE SWITCHIS PARTOF 8 PUMP ACCESSORY LAMP ASSEMBLY 54 H2 WHT BRN 13 2 162 2_ Amps 1 67 BLK 5 LAMP HEAD H3 Ju WHT BRN IKA 2_Amps 2 BLK 4 LAMP FLASHING m gt K2 a 4 RED 1 2 10 AWG WHT 1 2 BLK 4 CONTACT M5 t NOTE M10 IS USED MOTOR ye ON 35 amp 38 DISK 2 DECKS ONLY MOTOR BRUSH M6 Mio OPTIONAL 5 MOTOR VAC 18 WIM7ISUSEDONALLMODELS gt ki M7 RED 1 2 8AWG BLU BLU qy _BLK CONTACT N O 35 amp 38 DISK DECK POLARITY OF M8 MOTOR BRUSH x NOTE M8 IS USED ON CYLINDERICAL i M8 m a M8 2 AND 35 amp 38 DISK DECKS ONLY a x MOTOR BRUSH BRUSH F5 55 9 BLU 1 12 RED 16AWG 27 1 gue BLK FUSE 5 AMP SW SIDE BROOM 9 OPTIONAL ON CYLINDRICAL MACHINE ONLY _ MOTORSIDEBROOM 74 FORM NO 56043097 Adgressor BR 8506 850CS 950C 950CS 10505 1050C5 revised 9 05 SCHEMATIC FOR ADGRESSOR BR 8505 850CS 9505 950CS 10505 1050CS before Serial Nurrber Chart ELE CTRICAL SYSTEM
17. brush headlight warning beacon etc A closed 51 key switch supplies input voltage to the E1 terminal 2 pin 10 wire Brn This powers up turns on the control board s processing logic functions A closed S2 operator safety seat switch enables the starting of the entire automatic machine scrubbing system functions Its E1 terminal connection is J 4 pin 11 wire Orn Outputs A control board E1 battery voltage output from the solenoid accessory terminal connection 2 pin 48 Wht Brn wire completes the positive voltage to the vacuum solenoid coil Negative battery circuit inputs and outputs Inputs A main battery ground input for the control board 61 terminal J 4 pin 8 wire Blk This supports the operation of the board s processing logic functions with the above mentioned S1 key switch input A battery ground input for all the E1 boards negative solenoid coil output circuits Its E1 terminal connection is 2 pin 5 wire Outputs battery ground output from the E1 control board terminal connector 2 pin 2 wire Gra Blk This control board output completes the K2 vacuum solenoid coil circuit Pos amp Neg and pulls in the vacuum solenoid load contact K2 making the vacuum motor s M5 amp M6 run This occurs every time the throttle is moved off its neutral setting and the vacuum switch is on Note When the throttle is returned to neutral the vacuum will remain on for 10 seconds and th
18. turn off the solution solenoid valve L1 and raise the squeegee tool changes polarity to the Lift motor M2 WHEEL DRIVE TROUBLESHOOTING GUIDE Problem forward and reverse forward or reverse 03 fault code Wheel drive motor will not run in Wheel drive in one direction only loss of either Hourmeter status display shows an error Possible Cause Batteries need charging low battery voltage recharge batteries Wheel Drive Motor Circuit Breaker F2 tripped reset 70A circuit breaker Control Circuit Circuit Breaker F3 amp F4 tripped reset circuit breaker e Parking Brake 6 set release parking brake e Emergency Stop Switch 13 tripped reconnect battery to reset e Safety Switch S2 in seat not closed check seat switch Defective Wheel Drive Motor replace motor Defective Throttle Potentiometer R1 replace Testthe Fwd amp Rev R1 wiring outputs pins 1 2 amp 3 atthe speed control for an open Repair wiring or replace the R1 pot Controller can t change electrical polarity to wheel motor replace the A1 speed control Speed controller has sensed an operation error code fault see the Status LED Fault Codes Table 1 in the Electrical System Curtis Speed Control Troubleshooting Section FORM NO 56043097 Adgressor BR 8505 850CS 9505 950CS 10505 1050CS 21 WHEEL DRIVE SYSTEM STEERING SPINDLE AND WHEEL DRIVE MOTOR AS
19. 15 STEERING SYSTEM STEERING COLUMN ASSEMBLY SHROUD REMOVAL Upper Column 1 See Figure 1 Remove the center Wheel Adapter A from the steering wheel Pry it off using a fat bladed screwdriver 2 Remove the steering shaft retainer Hex Nut B use a 3 4 socket wrench and the two Washers C amp D Next pull straight back on the steering wheel to remove it from the metal Wheel Adapter E 3 keyed metal wheel adapter from the steering shaft by using a two jaw gear puller With the wheel adapter off the loose Plastic Trim Cup F can now be removed 4 Remove the 4 Screws G securing the Column Shroud and pull it off from the Column Base I Lower Column 1 Tilt the steering wheel column as far back close to the seat as possible 2 Remove the tilt column release Knob J threaded from its shaft 3 Remove the 4 Screws securing the Lower Shroud L and next pull the shroud far enough away from the column base to clear the tilt release shaft through the shroud opening Note This will take some effort in prying the fbxible plastic shroud around the movable tilt shaft 4 Gripthe shroud and pull up to completely release it from the steering column base and the foot brake assembly FIGURE 1 gt Remove plug 7 to access grease universal joint View from back D 50 side of panel I FRONT 16 FORM NO 56043097 Adgressor BR 850
20. 56043097 Adgressor BR 8505 850CS 9506 950CS 10505 1050CS 73 revised 9 05 For Machines before Serial Nun ber Chart SERIAL NUIVBER CHART 1863250 BR 850 1863260 BR 1050 and Adgressor rrodels 1863255 BR 950 ELECTRICAL SYSTEM WIRING DIAGRAM SCHEMATIC FOR Ackgyessor BR 8505 850CS 9505 950CS 10505 1050CS before Serial Number Chart Description AL CONTROLLER BTL BATTERY 1 CONTROL PANEL ASSEMBLY F1 FUSE 150 F2 CIRCUIT BREAKER 7 WHEEL DRIVE F3 CIRCUIT BREAKER 1 CONTROL CIRCUIT F4 FUSE 1 F5 CIRCUIT BREAKER 5 SIDE BROOM OPTIONAL Hl HORN BACKUP ALARM H2 HEADLIGHT OPTIONAL H3 STROBE LIGHT OPTIONAL CONTACTOR BRUSH MOTOR K2 CONTACTOR VAC MOTOR CONTACTOR WHEEL DRIVE L1 SOLENOID VALVE 1 LIFT ACTUATOR BRUSH M2 LIFT ACTUATOR SQUEEGEE M3 MOTOR DRIVE WHEEL MA MOTOR PUMP OPTIONAL M5 MOTOR VACUUM 36VDC M6 MOTOR VACUUM 36VDC 7 MOTOR GEARBOX ASSY DISC OR MOTOR BRUSH 36VDC CYLINDRICAL MOTOR BRUSH 36VDC CYLINDRICAL MOTOR SIDE BROOM OPTIONAL M10 MOTOR GEARBOX ASSY 35 amp 38 DISC R1 POTENTIOMETER 5K S1 SWITCH KEY 52 SWITCH SEAT S3 SWITCH PUMP SA SWITCH HEADLIGHT S5 SWITCH SIDE BROOM Wiring diagram for Machines built before this Serial Number Chart 1863250 BR 850 1863255 BR 950 1863260 BR 1050 all Adgressor modes
21. MOTOR BRUSH pe ee aln Ge ge eee 1 F5 S5 BLU 102 RED 2 L1 BLK FUSE 5 A SW SIDE BROOM OPTIONAL ON CYLINDRICAL MACHINE ONLY MOTOR SIDE BROOM 56015807 REV C REFERENCE WIRING DIAGRAM 56314967 76 FORM NO 56043097 Ackressor BR 8505 850CS 9505 950CS 10505 1050CS revised 5 06 SCHEMATIC FOR ADGRESSOR BR 8505 850CS 9505 950CS 10505 1050CS after Serial Nurrber Chart ELE SYSTE CTRICAL M ORN RED 20 1 J4 51 BRN
22. Solution Filter 13 Emergency Stop Switch Battery 21 Recovery Tank Drain Hose Disconnect Lever 22 Machine Battery Connector 14 Scrub Deck 23 Control Panel 15 RearWheel 24 Squeegee Tilt Adjust Knob 16 Battery Compartment under seat 25 Operator Seat Adjustment Lever 17 Recovery Tank Shutoff Float 26 SmartSolutions ECO Solution 27 Tie Down Locations 3 FORM NO 56043097 Adgressor BR 8505 850 5 9505 950 5 10505 1050CS 9 CONTROL PANEL A Scrub OFF Indicator Key Switch B Scrub OFF Switch K Battery Condition Indicator C Scrub Pressure Decrease Indicator L Speed Select Switch D Scrub Pressure Decrease Switch M Speed Select Indicator E Scrub Pressure Increase Indicator Switch F Scrub Pressure Increase Switch 0 Vacuum Switch G Scrub Pressure Hourmeter Display P Vacuum System Indicator H Wand Switch Indicator Q Solution System Indicator Wand Switch R Solution Switch 9 Def mat iri OTTER J fS tem E 71 6 10 FORM NO 56043097 Adgressor BR 8505 850CS 9505 950CS 10505 1050 5 KNOW YOUR MACHINE FUNCTIONAL DESCRIPTION OF CONTROL BUTTONS The controls on the Adgressor BR850s and BR850CS were designed with
23. This plug is not labeled on early models but has the label M7 on later models This plug is only used for the right side motor on 35 amp 38 disk decks This connector will have a Dummie plug covering it from the factory on all cylindrical and 28 amp 32 disk models It hasa red and a black wire connected to it This plug is not labeled on early models but has the label M10 on later models Brush Rotation Brush Rotation Direction Direction 35 3 motor deck shown 36 FORM NO 56043097 Adgressor BR 8505 850 5 9505 950CS 10505 1050 5 revised 10 06 SCRUB BRUSH SYSTEM CORRECT BRUSH ROTATION DIRECTIONS ALL CYLINDRICAL DECKS Motor Rotation FIGURE 11 Motor R tation Brush Rotation 35 38 DISK DECKS Brush Brush Rotation Rotation Brush Rotation FRONT 28 32 DISK DECKS Brush Rotation Brush Rotation FRONT revised 10 06 FORM NO 56043097 Adgressor BR 8505 850CS 9505 950CS 10505 1050CS 37 SOLUTION SYSTEM FUNCTIONAL OVERVIEW See Figure 1 The plastic polyethylene molded main body structure fulfils three design functional uses They are the platform for the operator s seat mount cavity for the electrical panel and as the storage tank for the machine s scrubbing solution The solution tank fil capacity is 42 gallo
24. be saved and will remain in effect until it is changed again gt WN Squeegee Raise In Reverse Time Period Adjustment FACTORY DEFAULT 5 2 0 SECONDS When backing up with the recovery system active the control unit will automatically raise the squeegee just enough to prevent dragging on the fbor The time that the squeegee is raised is adjustable from 1 to 4 8 seconds in 2 second increments To adjustthe distance the squeegee is raised in reverse perform the following steps Turn the main power key switch to the off position Press and hold the scrub pressure decrease and the vacuum switch While holding both switches turn the main power key switch to the on position Continue to hold both switches until the vacuum indicator is fbshing yellow Release both switches The status display will now indicate a number from 0 to 19 depending on the current time period NOTE If the decimal point is not illuminated the display is indicating 0 9 If the decimal point is illuminated the display is indicating 10 19 6 Pressing and releasing the vacuum switch will now select the time period The level will increment from 0 to 19 0 2 1 second 1 2 1 2 seconds 2 1 4 seconds up to 19 24 8 seconds 7 To save the new setting tum the main power key switch to the off position 8 new setting will be saved and will remain in effect until itis changed again CC WN 70 FORM NO 56043097 Adgressor BR
25. containing additives to provide anti oxidant anti corrosion and good lubricity properties Use a total quantity of 4 9 5 6 oz 140 160g of grease to service gear case The grease to be used must have excellent mechanical stability water resistance and high load carrying capacity The MR 158 grease is particularly recommended for automotive applications including wheel bearing lubrication Available NLGI consistency 3 Average Drop Penetration ASTM Worked Grade Point C mm 10 at 25 C Base MR 158 Grease 180 220 250 Lithium 6 FORM NO 56043097 Adgressor BR 8505 850 5 9505 950 5 10505 1050 5 Advance Adgressor 2820 3220 3520 3820 D C Models Nilfisk BR 850 950 1050 S CS Models Disc and Cylindrical PM Checklist Defect Codes Customer needs adjustment B binding Address C dirty or contaminated D damaged bent or torn City St Zip L leaks M missing Model Serial Hours W worn out Does OPERATIONAL INSPECTION ITEMS Defect Codes Not circle Work Drive System Performance reference SVR Manual for Curtis drive programmer speed changes noisy sluggish Scrub System Raise Lower and auto scrubbing functions 7 Scrub Brush Pressure Settings see SVR Manual programming 3 different modes Squeegee System Raise Lower and auto lift in reverse function 13 Tilt Steering Mechanism and Seat Emergency Battery Disconnect
26. from the machine 3 Remove the Link Rod AE from the Pedal AF Note Be careful not to lose the link rod mounting hardware items AG 4 Loosen the Nut AH and Screw AI at the drive pedal Throttle Lever AJ Then pry the lever off from the end of the item AC potentiometer shaft Next remove the pot from the Mount Housing Testing the Potentiometer Note The pot doesn t have to be removed from the housing to test Test the potentiometer using an Ohmmeter the pot specifration is 5K Ohms Connect the meter leads to each of the outside connections on the potentiometer The meter should read approximately 5000 Ohms plus or minus 500 Ohms Next move one of the testleads to the middle connection and turn the stem in both directions The range of the readings should be approximately 0 5000 Ohms or 5000 0 Ohms increasing and decreasing through its full range If you do not get these readings replace the potentiometer FIGURE 8 Violet Yellow Gray 26 FORM NO 56043097 Adgressor BR 8505 850CS 9505 950CS 1050S 1050 5 WHEEL DRIVE SYSTEM POTENTIOMETER INSTALLATION AND ADJ USTMENT A WARNING The adjustment of the potentiometer is to set the drive pedal for a neutral drive motor operation If the potis not adjusted properly the machine will creep in either FWD or REV 1 Figure 8 Install the pot into the Mount Housing AK and tighten the attachment nut
27. in reverse See Figure 1 To getthe squeegee tool to lift in reverse the drive pedal must be moved off its neutral or forward position which opens the normal closed 36V pos control voltage from the A1 speed control output pin 16 This sensed loss of the pos pin 16 control voltage signal creates the required E1 board input to the 4 connector 4 wire This then activates an internal relay circuit that outputs the correct voltage polarity for the M2 squeegee lift motor to run a specifed time output from 3 connector pins 2 amp 3 This raises the squeegee off the fbor to the back up position which is half of the normal distance observed when in the machine scrub off mode Moving the drive pedal back to the neutral forward position closes the A1 throttle forward output and the E1 control board gains its signal The 3 connector output reverses the polarity and lowers the tool back onto the fbor RED 1 ES 2 RED i as BLK BATTERY 36 Vdc F3 51 52 RED 157 2 BRNYEL 159 BRN 12 2 f gt ORN SW SW SEAT SPST KEY SQUEEGEE LIFT ACTUATOR ORN z CA z amp gt S 2 a amp amp z 081413 BLUBLK 5 S 5 83 s 5 3 I 5 8 8 amp THERMISTOR 7 amp Bik a INTERFACE
28. input to pin 11 The controller is now in scrub speed mode 2 and the speed control mode select is switched ON Pressing the dash panel Speed Select S witch L its Indicator Light M turns ON This action leaves the speed control input pin 11 fbating and actively switches it Off 0 volts pulling it to B changing the output to the transport speed mode 1 Note The maximum machine drive wheel speed setting for the two drive modes 1 amp 2 can be changed by using the Curtis handheld programmer Reference the Curtis programmer instructions found in the electrical system manual section to change speed settings from their original factory specifrations 18 FORM NO 56043097 Adgressor BR 8505 850CS 9505 950CS 10505 1050 5 WHEEL DRIVE SYSTEM BLK 37 FORM NO 56043097 Adgressor BR 8505 850CS 9505 950 5 10505 1050CS 19 B A SB E OE gt Es z z c x 48 8 9 X ac gt z 2 lt NW 8 Nid i 1 Tr p moma gt 5 M90 19 5 g I9 9 Z E 8 gt 9 als H3MOd 1 Nid 5 5 5 o gt ota a o 5 9 3I 01 90 M 1 1 1 l a g ii Q 8 MBAHaqzooad etNd EEE 2 5 C _ lt o ul
29. mount bracket 3 Disconnect the brush lift motor wire harness at the motor 4 Remove the top actuator inspection Cover AB held with 3 screws Cover location operator s compartment below front of seat 5 Remove the Hairpin AC then slide the upper Mount Pin AD out from the chassis mount bracket 6 Remove the complete actuator lift motor assembly from underneath the machine Note Do not turn or reposition the drive nut on the actuator shaft mark if needed 7 Important After removing the actuator motor and before replacing a new motor or drive nut the IN amp OUT limit switches must be set or checked to their correct dimensional speciftations see the electrical section for the Actuator Drive Nut Adjustment instructions 8 To disassemble the Drive Nut AE from the actuator shaft remove the 2 Screws AF and separate both Retainers AG amp AH from the Spring Housing Al 9 Remove the 4 spring housing retainer S crews AJ and slide the spring housing and long Compression S pring AK from the actuator shaft Next spin drive nut off the shaft and save the top short Compression Spring AL Note See the Actuator Drive NutAdjustment section in this manual to properly install a new drive nut 10 After adjusting the drive nut follow steps 1 9 in reverse order to re install the scrub deck lift motor in the machine Service Tip Wrap a small amount of tape around the spring housing to prevent it from spinning out of adjustme
30. on the actuator shaft Manually turn the steel tube to the IN position as shown in the chart Hold the drive nut then press the adapter cord rocker switch to run the drive motor to the OUT position wait until the motor stops Measure the position of the drive nut on the shaft and compare the measurement with the OUT position shown in the chart When the measurement doesn t match the dimension shown in the chart it is necessary to remove the Adjuster Cover B and adjust the Out position 6 increase the travel of the drive nut turn the adjuster clockwise To decrease the travel of the nut turn the adjuster counter clockwise NOTE Use a 1 2 13 mm socket to turn the adjuster Each click of the adjuster will change the nut travel 1 16 inch 1 6 mm 7 After each adjustment hold the drive nut run the actuator IN amp OUT and check both dimensions After checking that the drive nut limits are set correctly then replace the adjuster cover Service Tip Note Use the above power cord adapter to help position the drive nut in or out for ease in actuator motor installations FIGURE 3 S 2mm 3 3 8 IN 86mm OUT 52 FORM NO 56043097 Adgressor BR 8505 850CS 9505 950CS 10505 1050CS ELECTRICAL SYSTEM Instructions for Scrub Brush Lift Actuator Drive Nut Adjustment 1 SeeFigures 4and5 new scrub lit actuator motor remove spin off FIGURE 4 the Drive Nut
31. status signal This indicator will be lit if the status signal from the speed control is active If a speed control fault exists this indicator will fash the fault code from the speed control Refer to the speed control section for details on these codes Status Display G If no over current faults are present the status display will show the battery voltage This display is accurate to within 0 15 volts Therefore the voltage displayed may not correlate precisely to a high accuracy calibrated voltmeter An example of how 36 0 volts would be displayed is as follows The display will show 3 followed by a brief blank period The display will show 6 followed by a brief blank period The display will show followed by a brief blank period serves as decimal point The display will show 0 followed by a long blank period The above sequence will repeat If over current faults are present the status display will indicate the error codes Output Controls See Figure 5 The control panel switches are used to control various output functions of the main control unit Below is a list of each switch and the function it controls Following the list is a detailed description of each function Scrub off switch B Controls brush motor s Scrub pressure decrease switch D Controls scrub deck lift actuator Scrub pressure increase switch F Controls squeegee lift actuator Vacuum switch O Controls vacuum motor s Solution
32. switch R Controls solution solenoid Horn switch N Used to jog actuators Speed select switch L Selects the various speed control speed limits Wand switch I If this switch is pressed the wand indicator will illuminate Scrub System Off Switch B This switch is used to toggle the state of the brush motor Pressing and releasing this switch will alternately turn the brush motor on and off The indicator provides the following status information Off Brush motor output is off and there is no brush motor current sensed Steady Green Brush motor output is on and there is normal brush motor current sensed Brief On Green Flash Brush motor output is off and brush motor current is being sensed abnormal condition Brief Off Green Flash Brush motor output is on and brush motor current is not being sensed abnormal condition Flashing Red Brush motor overload has occurred FORM NO 56043097 Adgressor BR 8505 850CS 9505 950CS 10505 1050CS 61 ELECTRICAL SYSTEM SERVICE TEST MODE CONTINUED Scrub ON Pressure Decrease Switch D This switch is used to control the output to the scrub deck lift actuator Pressing and releasing this switch will cycle the actuator output through 4 States These are 1 output off direction up 2 output on direction down 3 output off direction down 4 output on direction When the outputis in state 1 the actuator output is turned off The s
33. to the brush CCW Rotation housing then pull the plates down and out F from shaft end to remove Grip the scrub brush then pull Rotation Belt from shaft end wb 1 and slide it out from the housing end 4 To install the brush slide it into the housing lift slightly push and turn until it seats into the drive end assembly a i ee eee 5 Re install the idler end plate assemblies close the skirt assemblies and secure with BLUE BLK the hairpins SIDE SKIRT MAINTENANCE amp ADJ USTMENT CYLINDRICAL General Overview The side skirts function is to channel the wastewater to the rear pick up squeegee helping contain the water within the machine s cleaning path During normal use the blades will wear in time The operator will notice a small amount of water leaking out underneath the side skirts The skirt height adjustment is automatic on this system using spring tension and movable linkage arms to control the blade pressure The side skirt assemblies must move up and down freely for proper operation To replace the scrub system side skirts See Figure 6 Remove the 2 Hairpins and swing the skirt assemblies open Remove the AR Screws and nuts then remove the skirts and replace To adjust the scrub system side skirts Note The side skirt blade assemblies have two minor adjustments they are the individual front collar height and the rear blad
34. turned off and the scrub deck is not up yet or if the scrub deck is up and there is no weight on the seat the indicator will be red If there is a fault in the scrub system this indicator will fbsh red Scrub Pressure Decrease Switch D If the scrub system is off pressing this switch will cause the following to occur The scrub system will be enabled with the scrub pressure set to the last used setting and the scrub deck will be lowered The vacuum system will be enabled and the squeegee will be lowered The solution system will be enabled The travel speed will be limited to the scrub speed setting As soon as the throttle is moved from the neutral position the scrub brushes will start turning and the vacuum will turn on If the direction is forward the solution fbw will start If the direction is reverse the squeegee will raise and the solution fbw will be stopped The scrub pressure decrease indicator will be green if the scrub system is on and the pressure is set at 1 or 2 The indicator will be off if the scrub system is off or if the scrub pressure is set to maximum The indicator will be yellow if the scrub system has been enabled but the throttle is in neutral Scrub Pressure Increase Switch F If the scrub system is off pressing this switch will cause the following to occur The scrub system will be enabled with the scrub pressure set to the last used setting and the scrub deck will be lowered The vacuum system will be en
35. turning and the vacuum will turn on If the direction is forward the solution fbw will start If the direction is reverse the squeegee will raise and the solution fbw will be stopped e The light scrub pressure indicator will be green if the scrub system is and the light pressure has been selected The indicator will be off if the scrub system is off The indicator will be yellow if the scrub system has been enabled at the light pressure setting but the throttle is in neutral 12 FORM NO 56043097 Adgressor BR 8505 850CS 9505 950CS 10505 1050 5 KNOW YOUR MACHINE If the heavy scrub pressure is active pressing this switch will cause the pressure to return to the last used light scrub pressure setting If the light scrub pressure is already selected when this switch is pressed the scrub pressure will increase up to the maximum limit programmed for the light scrub pressure The pressure will then roll over to the minimum setting of 1 Heavy Scrub Pressure Select Switch If the scrub system is off pressing this switch will cause the following to occur The scrub system will be enabled with the scrub pressure set to the last used heavy pressure setting and the scrub deck will be lowered The vacuum system will be enabled and the squeegee will be lowered The solution system will be enabled travel speed will be limited to the scrub speed setting e AS soon as the throttle is moved from the n
36. 0505 1050 5 revised 6 05 Specifrations common to deck size Model designation 28 Adgressor 2820 D C 32 Adgressor 3220 D C BR 850S CS 35 Adgressor 3520 D C BR 950S CS 38 Adgressor 3820 D C BR 1050S CS 28 32 Machine Width with S queegee English 32 6 in B 36 6 in C Metric 83 6cm B 93cm Scrub Brush Size qty of 2 for 28 and 32 0V of 3 for 35 and 38 Disc Diameter 14 25 in 36cm 16 in 40 6cm Cylindrical Diameter 5 15 in 14 6cm 5 75 in 14 6cm Length 21 in 68cm 3lin 79cm Scrub Brush Motor Disc 1 1 5 HP 1100 watts 1 1 5 HP 1100 watts Cylindrical All Cylindrical Models use 2 75 HP 560 watts Scrub Brush Speed Disc 250 RPM 250 RPM Cylindrical 900 RPM 900 RPM Minimum Aisle Turn Width 63 in 160cm 63 in 160cm Machine Net Weight English 657 Ibs 657 Ibs Metric 298 kg 298kg Machine Gross Weight English 1553 Ibs 1553lbs Metric 105 kg 705kg Cleaning Width scrubbing path English 28 in 32 in Metric 71cm 81cm Coverage Rate Per Hour 4 MPH English 49 280 ft 56 320 f Metric 4578m 5232m Coverage Rate Per Hour 2 5 MPH English 30 800 ft 35 200 f Metric 2861m 3270m SPECIFICATIONS 35 42 1 in D 107cm D NA 5 75 in 14 6cm 34 in 86cm 3 6 HP 448 watts 250 RPM 900 RPM 63 in 160cm 657 105 298 kg 1553 Ibs 705 kg 35 in 89cm 61 600 ft 5722m 38 500 ft 357
37. 0505 1050CS 31 SCRUB BRUSH SYSTEM SCRUB BRUSH SIDE SKIRT REPLACEMENT DISC 1 2 3 4 See Figure 4 Loosen the 4 side skirt Retainer Knobs V 2 per side and pull the Skirt Assemblies W off from the scrub deck Remove all the hardware that holds the blade and retainer to the skirt housing Each of the 2 blades has 2 working edges Reinstall the blades to the skirt housing so a clean undamaged edge points inside towards the scrub brushes Replace the blades as a set if they are nicked torn or worn beyond their ability to be adjusted Reinstall the skirt housing assemblies onto the machine and adjust the blade for proper contact to the fbor when the brush deck is placed in the scrub position SIDE SKIRT HEIGHT ADJ USTMENT DISC 1 2 3 See Figure 4 The side skirthousing knob retainer screw studs have leveling Adjuster Collars X thatare to be raised or lowered to compensate for blade wear To adjust remove the Skirt Assemblies W from the Scrub Deck Y to access the Adjuster Collars X Adjustment Tip The skirts Retainer Knobs V can be loosened with skirts left on and the Adjuster Collars X rotated by reaching under the skirt housing Turn the Adjuster Collars X Up or Down to where the blades justfold over enough when scrubbing that all the waste water is contained inside the skirting Note Make small adjustments to obtain good blade wiping Do notlowerthe blades too much to where they fold over excessiv
38. 3 drive system fault If error 03 is shown the throttle is not set properly for the potentiometer and or drive pedal neutral position Check both again and readjust FIGURE 9 co gt UJ Right Side View Front View FORM NO 56043097 Adgressor BR 8505 850CS 9505 950CS 10505 1050CS 27 SCRUB BRUSH SYSTEM FUNCTIONAL OVERVIEW Disc Brush System Overview See Figure 2 The machines Adgressor 2820D 3220D and BR 850S use the disc type scrub system A single 1 1 1 2HP 36V DC permanent magnet motor is connected at both ends with 2 90 degree gearboxes that drive the two disc rotary brushes The 3520D 3820D models use the disc type scrub system also but with 3 6HP 36V horizontally mounted DC permanent magnet motor gearbox assemblies Cylindrical Brush System Overview See Figure 6 The machines Adgressor 2820C 3220 3520 3820 and BR 850 5 use two cylindrical brushes that counter rotate to sweep up light debris and scrub atthe same time Each scrub brush is powered on opposing ends by individual 3 4 HP permanent magnet motors attached to separate poly V belt pulley drives General Brush Overview On all models the scrub deck platform is raised amp lowered automatically by a vertically mounted electric lift actuator motor M1 The operation ofthe machine s scrub functions are activated when the operator selects presses either the scrub pressure increase or de
39. 3097 Adgressor BR 8505 850 5 9505 950 5 1050S 1050CS ELECTRICAL SYSTEM BATTERY SPECIFICATIONS Use a combination of multiple 2 volt cell units wired in series to construct a 36 Volt DC battery pack system Nilf k Advance recommended battery pack capacity is 305 or 395 AH 9 20 Hour Rate deep cycle battery system six 6V batteries Note The battery pack must fi the battery compartment size listed in Speciftations BATTERY CHARGER SPECIFICATIONS Use a 36 Volt DC output charger matching the DC battery pack voltage and the inputAC line voltage supply being used Always when selecting a battery charger follow the recommendation of the battery supplier to match the proper charger DC output amperage to the amp hour rating batteries being installed This will prevent the battery pack from being over or under charged The recommended 305 AH battery should be matched to a 36V 20 or 25 Amp charger The recommended 395 AH battery should be matched to a 36V 36 Amp charger INSTALL THE BATTERIES A WARNING Use extreme caution when working with batteries Sulfuric acid in batteries can cause severe injury if allowed to contact the skin or eyes Explosive hydrogen gas is vented from inside the batteries through openings in the battery caps This gas can be ignited by any electrical arc spark or fame When Servicing Batteries Remove all jewelry Do not smoke Wear chemical goggles rubber gloves and a protect
40. 4 Check for short circuit in brush motor or wiring 5 Inspect gearbox for failure disc Repair or replace 6 Check excessive belt tension and idler bearing cyl See the Main Control Board Special Program Options section to activate the Brush Type Selection function 58 FORM NO 56043097 Adgressor BR 8505 850CS 9505 950 5 10505 1050 5 ELECTRICAL SYSTEM MAIN CONTROLLER ERROR CODES CONTINUED Error Code Fault Description Vacuum motor overload Normal current load 17 19 Amps 1 motor Normal current load 34 38 Amps 2 motors Troubleshooting Action 1 Check for debris in vac motor 2 Worn carbon brushes 3 Defective motor bearings 4 Check for short circuit in vac motor or wiring Repair or replace Solution solenoid overload 1 Check for a wiring problem 2 Check coil resistance spec is 125 Ohms or 15 Replace solution solenoid if lower than 105 Ohms Scrub deck lift actuator circuit open 1 Check for disconnected actuator wiring open in wiring or defective actuator motor Repair or replace 2 Check controller output voltage should be 36V if 0V controller failure replace Scrub deck lift actuator short Squeegee lift actuator circuit open 1 Check for binding or frozen brush lift linkage and excessive weight on brush deck 2 Check for short circuit in brush lift motor and wiring Repair or replace 1 Check for disconnected ac
41. 5 850CS 9505 950C5 10505 1050 5 STEERING SYSTEM STEERING CHAIN REMOVAL AND TENSIONING 1 the master key switch off and separate the battery pack emergency disconnect 13 2 See Figure 2 From underneath the front of the machine loosen the 4 M Screws and push the lower steering column to the rear of the machine This is done to separate the Chain from the Steer Sprocket 0 Service Note Use a 5 8 socket with 3 extension to loosen Screws and also correctly position the large hole in the Steer Plate P in order to access the far back left screw Remove both Master Links Q that secure the chain to the Steer Plate P then remove the chain from the chassis 4 Reassemble parts in reverse order and adjust chain tension so that there is about 3 16 1 4 4 7 6 4mm total defection with moderate pressure applied at the Mid point R as shown Service Tip Note Use a pry bar or shims between the chassis and steer column to help secure the tension adjustment when tightening the 4 steering column mounting screws UJ Maintenance 1 Inspect the chain for looseness and binding re tension the chain to 3 16 1 4 4 7 6 4mm defection by following the above adjustment instructions 2 Keep all of the steer chain links oiled to prevent excessive wear and binding FIGURE 2 gt O OO O U 1 f H View from under the machine n FR
42. 541255 29125259 REDIWHT 18 1 CHEMICAL INJECTION BLUIORN 16 1 5582 2 5 9 x WHT BRN 18 4 SYSTEM OPTION 85 5 63 92 8 BLK 18 8 WHT BRN 16 1 1 8 a EB BLUIGRA 18 1 J BLK 12 1 WHT BRN 16 2 X62 Pal CONTACTOR 5 SPEED CONTROLLER 3 25 4 GRN YEL 18 1 BRUSH 0 082 8 CREE EDS WHIBRN1BS 2 BLK 18 4 K1 i ni BLU TIT E WHT BRN18 SP7 xu AJB WHT RED 18 2 18 9 BLK 164 LGRNIYEL 18 1 WHTIBRN 16 3 LC WaT 7 CONTACTOR v YEL BLK 8 1 M E de WHT 124 VACUUM RED8 1 BLK 8 1 BLK 12 3 K2 cM 2 St 128 BLUDRN ET g Note When Chemical Injection Is Used Discard Exerc 3 Buu E RED GRN 8 1 X60 And Plug X61 Into X69 BK102 71 SP4 RED 8 2 4 F1 i x61 BLU 8 1 RED 8 1 3 1 1 2 SQUEEGEE LIFT ACTUATOR 2 FUSE 150A BRUSH LIFT ACTUATOR BRN 16 1 pe 5 5 1 RED 1 2 M1 212 GRNYEL 163 X a My WHT BRN 18 2 5 GRNYEL162 9 RET ORN 16 1 3 N 2 BLK 18 6 gt B T PANEL BONDING 2 F E D C B A X48 AB BLU 10 1 31 86011 ce REDI2 s T T BLK 12 5 6 rn PETERT FUSE 5 AMP XV Mg BEKI i BLK 1 2 H1 RED 10 1 2 xsi i X0 10 E 1 B 1 Q z 22 5 922 BATTERY 36 Vdc z 1 86082 zi E er EL elsi MOTOR 16 5 g HORN BLK 16 1 zi al la
43. 6m 38 45 1 in E 115cm E NA 5 75 in 14 6cm 37 in 94cm 3 6 448 watts 250 RPM 900 RPM 63 in 160cm 657 105 298 kg 1553 Ibs 705 kg 38in 97cm 66 880 ft 6213m 41 800 ft 3883m Net Weight Standard machine without options empty solution and recovery tanks without removable scrub brushes and no batteries installed Gross Weight Standard machine without options full solution tank and empty recovery tank with removable scrub brushes and 305 AH batteries Listings for watts are maximum values FORM NO 56043097 Adgressor BR 8505 850 5 9505 950 5 10505 1050CS 5 MAINTENANCE SCHEDULE Maintenance intervals given are for average operating conditions Machines used in severe operational environments may require service more often MAINTENANCE ITEM Daily Weekly Monthly Yearly Charge Batteries Check Clean Tanks amp Hoses Check Clean R otate the Brushes P ads Check Clean Adjust the Squeegee Check Clean Vacuum Shut Off Float Check Clean the vacuum motor foam fiter s Clean Hopper on Cylindrical System Check Each Battery Cell s Water Level Inspect Scrub Housing Skirts Inspect and clean Solution F ilter Check Foot Parking Brake For Wear amp Adjustment Clean Solution Trough on Cylindrical System Lubrication Grease Fittings Check Carbon Brushes Note See the individual machine system sections for maintenance information Have Nilfsk Ad
44. 8505 850 5 9505 950CS 10505 1050 5 ELECTRICAL SYSTEM SPECIAL PROGRAM OPTIONS CONTINUED Back up Alarm Volume Control FACTORY DEFAULT 0 OFF The Adgressor BR 8505 and BR850CS are equipped with an audible warning device which functions as a horn a back up alarm and a forward annunciator The volume of the back up alarm can be adjusted to one of ten settings 1 is the minimum setting and 9 is the maximum setting 0 is off To change the back up alarm volume perform the following steps Turn the main power key switch to the off position Press and hold the horn switch While holding the horn switch turn the main power key switch to the on position Continue to hold the horn switch until the red battery status indicator is lit and the status display shows a number from 0 to 9 depending on the current volume setting Release the horn switch 6 Pressing and releasing the horn switch will now select the volume level The level will increment from 0 to 9 9 being the loudest To hear the back up alarm volume select the reverse direction by pressing lightly on the throttle 7 To save the new setting turn the main power key switch to the off position 8 new setting will be saved and will remain in effect until itis changed again WN L3 Forward Annunciator Volume Control FACTORY DEFAULT 0 OFF The Adgressor BR 8505 and 850CS are equipped with an audible warning device which functions as a horn a back up alar
45. AL NUMBER TRANSPORTING THE MACHINE A CAUTION Before transporting the machine on an open truck or trailer make sure that machine is tied down securely see tie down locations 25 Allaccess doors and covers are secured tape and strap as necessary machine parking brake is set TOWING A CAUTION If the machine must be towed or pushed make sure the Key Switch Main Power J is in the OFF position and do not move the machine faster than a normal walking pace 2 3 mph 3 5kph and for short distances only OTHER MANUALS AVAILABLE The following manuals are available from the Nilf amp k Advance Literature Service Department for your Rider Scrubber e Parts List Form Number 56042446 Operation Manual Form Number 56041568 Danish Norwegian S wedish Finnish 56041569 German French Dutch Russian 56041570 Spanish Portuguese Italian Greek 56041581 Estonian Latvian Lithuanian Slovenian 56041582 Slovakian Czech Polish Hungarian 56041583 English Spanish Curtis Programmer Manual Number 56043101 2 FORM NO 56043097 Adgressor BR 8505 850CS 9505 950 5 10505 1050 5 CAUTIONS AND WARNINGS SYMBOLS Nilf amp k Advance uses the symbols below to signal potentially dangerous conditions Always read this information carefully and take the necessary steps to protect personnel and property A DANGER Is used to warn of immediate hazards th
46. ATTERY 36 Vdc 25 ye 5 ale 3 MOTOR 5 LI HORN BLK 16 1 E x SIDE BROOM ES ORN RED 20 1 BLK 8 1 Se 2L SW SIDE BROOM C GRNIBLK 20 1 aa Note Optional On Cylindrical Machine Only 2121212 x 2 2 x xo gt k e 5568 amp 39223 2 z S wmm d Li 552522 44444 gt gt ge 5325 2 A AA e ma a amp 59 vo EP B x p wt BJA Em 2 AAA e 2 A B oi x24 x25 221411 x AT ART gm XXL VY A A d MOTOR 4 S4 H2 Cylinderical Deck Polarity Of M BRUSH M3 L1 gt M X5 23 1 as 8 7 LI ELS pol sr Co Sel CHASSIS BONDING TVS ASSY xn A POT TEROTHE SW SPST L EE MN MOTOR VALVE Li 7 GROUND A AMP HEAD BA Note M7 Is Used On All Model WHEEL DRIVE SOLENOID 0 fade Note nes Switch Is Part Of Li bl xX45 I 35 And 38 Deck Polarity Of M8 1 4 8 I M l 152 M hoa M8 M10 B QUUD AN MN M uoc M7 X53 M8 V m On Part Of Pump Assembly MOTOR BRUSH MOTOR BRUSH Tr TES V Per n 38 Disk Decks Note M10 Is Used On 35 amp 38 Disk Decks Only I An ylindrical Decks Note Terminals X53 X54 Are Used On Only MOTOR BRUSH MOTOR BRUSH Oylinderical Decks
47. Adgressor BR 8505 850C5 9505 950C5 BR 10505 1050C5 SERVICE MANUAL Advance MODELS 56314661 2820D 56314662 3220D 56314663 2820C 56314664 3220 56314826 3520D 56314827 3820D 56314828 3520 56314829 3820C Nilf amp k MODELS 56314674 8505 56314675 850C S 56314830 9505 56314831 10505 56314832 950C S 56314833 1050C 5 Nilfisk Advance setting standards 10 04 revised 10 06 FORM NO 56043097 TABLE OF CONTENTS GENERAL INFORMATION SAFETY INSTRUCTIONS SPECIFICATIONS amp MAINTENANCE _ ____ KNOW YOUR MACHINE STEERING SYS TEM ee etit autem STEERING COLUMN ASSEMBLY SHROUD REMOVAL STEERING CHAIN REMOVAL AND TENSIONING WHEEL DRIVE 5 GENERAL FUNCTIONAL OVERVIEW DRIVE MOTOR SYSTEM CONTROLLER FUNCTION OVERVIEW WHEEL DRIVE TROUBLESHOOTING GUIDE een STEERING SPINDLE amp WHEEL DRIVE MOTOR ASSEMBLY REMOVAL _______ __ _ BRAKE ADJUSTMENT tees DRIVE WHEEL BRAKE STRAP REPLACEMENT WHEEL DRIVE MOTOR CARBON BRUSH POTENTIOMETER REMOVAL amp TESTING POTENTIOMETER INSTALLATION amp DRIVE PEDAL NEUTRAL ADJ USTMENT SCRUB BRUSEH SYSTEM n ettet eo edes FUNCTIONAL gt
48. BRN BLK 1 2 CONTACT N O 25 52 F4 H BRN YEL 1922 BRN 12 2 ORN 1 2 ORN z 2 CIRCUIT BREAKER 10 SW SPST KEY Mi M2 SW SEAT FUSE 1 A BRUSH SQUEEGEE 3 LIFT ACTUATOR LIFT ACTUATOR M3 MAIN CONTACTOR BRN YEL BRN J3 4 ORN BLK J3 1 RED WHT J3 3 BLK YEL 43 2 WHT GRN co z m x gt gt B co n TTE Ti Bee E oo amp a g 22 AWG THERMISTOR EE 121 2 ORN RED oa HORN J4 1 o 22 BACKUP ALARM INTERFACE 2 GRNBLK horn d J2 9 WHTVEL SPEED LIMIT 3 a PIN 1 94 z MOTOR WHEEL DRIVE 20 2 WIPER gt E PIN 3 POT LO a 6 o POT 5K OHM SPEED CONTROLLER BRN WHT CONTROL BOARD BRN WHTJ4 OPTIONAL D2 ZENER TVS 4 8 M11 J1 3 E2 BLU YEL 1 6 2 Ji 9 CHEMICAL a SYSTEM BLK WHT 18 VALVE SOLENOID WHT BRN WHT BRN WHT BRN RED WHT PUMP SOLUTION D1 ZENER TVS BLU GRA J1 1 PUMP CHEMICAL WHT BRN WHT BRN BRN RED CONTACT N O WHT MOTOR VAC ee NOTE M10 IS USED ON 35 amp 38 DECK ONLY M10 2 I MOTOR VAC MOTOR BRUSH gt 2 BLU BLK CONTACT CYLINDRICAL DECK POLARITY OF M8 NOTE M8 IS USED ON 3 CYLINDERICAL AND 35 amp 38 zi DECK ONLY ta 2 a
49. Continue to hold the pressure increase switch until the scrub pressure increase indicator is green Release the pressure increase switch The status display will now indicate d for done The scrub switch operating mode and pressure limits have now been restored Turn the main power key switch to the off position Turning the Automatic Vacuum Shutoff Option On or Off FACTORY DEFAULT ON The Adgressor BR 8505 and 850C 5 are equipped with a feature that will automatically shut off the vacuum and scrub systems and display FULL on the status display if the recovery tank becomes filed If problems are encountered with the vacuum automatic shutoff feature such as the vacuum shutting off even if the recovery tank is not full this feature can be turned off see also vacuum auto shutoff threshold adjustment To turn this feature on or off perform the following steps 1 Turn the main power key switch to the off position Press and hold the vacuum switch While holding the vacuum switch turn the main power key switch to the on position Continue to hold the vacuum switch until the vacuum indicator is green Release the vacuum switch The status display will now indicate E or d Pressing and releasing the vacuum switch will now select between E for enabled or d for disabled Enabled means that the automatic shutoff feature is turned on disabled means that the automatic shutoff feature is turned off 7 To save th
50. Control Lever 2 Right Side broom Sweep System Accessory cylindrical only Optional Accessories headlight safety beacon etc 10 Solution Control On Off and flow volume Min Max 1 15 Main Control Board Special Program Options check all applicable program settings Program as needed reference SVR Manual 56043097 Example Fault Recall Mode Etc 6 Battery Charger Operation D O Does VISUAL INSPECTION ITEMS Defect Codes Not Ref Comments OK circle Work 7 Serab Brush Drive Bek wear ylindrical only Serab Brash Deck Actuator Moor Brash Drive Plate Retainer Cipso a Coo I 1 E al Oo iz ng m 98 ae I See E E EE a EE E L 1 i functi Vacuum Performance sealed water lift 68 and 1 inch open hole adapter 18 inches C L W E ox ete 19 20 1 1 2 N N 8 1 23 24 5 Vacuum Moor Gastes and Fies 9 Recovery Tank Cover Gasket Squeegee Pick Up Tool amp Hose Back flush es ite L NIN Copyright 2004 Nilfisk Advance Page 1 of 2 10 21 2004 FORM NO 56043097 Adgressor BR 8505 850 5 9505 950 5 10505 1050CS 7 VISUAL INSPECTION ITEMS continued Defect Codes Comments OK circle Sque
51. E There are no user serviceable parts inside the Curtis PMC 1237 controller No attempt should be made to open the controller Opening the controller may damage it and will void the warranty However itis recommended that the controller exterior be cleaned periodically and if a handheld programmer is available this periodic cleaning provides a good opportunity to check the controller s diagnostic history HANDHELD PROGRAMMER USE Optional Curtis handheld programmer allows you to program test and diagnose Curtis controllers Use of a handheld programmer is described more fully in the CURTIS PROGRAMMER MANUAL 56043101 FORM NO 56043097 Adgressor BR 8505 850CS 9505 950CS 10505 1050CS 57 ELECTRICAL SYSTEM FUNCTIONAL OVERVIEW OF MAIN CONTROL BOARD The primary function of the main control board E1 is to position the scrubbing brush s with respect to the fbor surface using a lift actuator motor to maintain the correct brush pressure and current draw of the brush motor s When either the decrease or increase scrub pressure switch is depressed this will lower the scrub deck to the operating position and by activating the foot pedal start the brush motor The controller is continuously monitoring the current to the brush motor and when it senses a current draw out of the desired range it automatically raises or lowers the brush deck by turning on the brush actuator motor This process is repeated until the brush motor is shut
52. IWHT 20 1 BRNIWET 20 1 _ 19 C 8 70202 re SW SPST KEY ORN BLU 20 1 B BRN YEL 16 1 BRN RED 18 1 BRN RED 18 1 Di 12 UE REDIBLK 20 1 REDEK 2 1 GRN YEL 16 3 IR 22 E1 V a E x CONTROL BOARD BONDING aR v2 CONTROL BOARD 7 GRAIBLK 18 1 GRAJBLK 18 1 2 7 VIO BLK 18 1 VIO BLK 18 1 3 8 X39 X41 BLK 16 2 BLK 16 2 al s By B BLK12 1 x ao BRN 18 1 l 1 2 ADT A WHT 12 1 WHUBEN TET WHTBRN 16 X lt 2 BRN YEL 16 4 BRNIYEL 16 4 BRN YEL 16 4 M 5 pa m T BRN YEL 16 3 BRNIYEL 16 3 J3 a z e BRN Y RED WHT 16 1 RED WHT 16 1 amp a WHTIGRN 16 1 E z 5 lt 0 uj 53 BIOYEL 161 BUEN a8 4 MOT R VACUUM F3 F28 gt BUCS ORN 20 1 ORNIBLK 16 1 ORN BLK 16 1 Oe BIK122 irem GT ONU A WHT 12 2 CIRCUIT CIRCUIT BREAKER ORNIBLU 20 1 Is Optional M6 BREAKER 10 AMP Y BRNIWHT 20 1 piona 70 AMP F4 YELIGRN 16 1 LAMP FLASHING T RED BLK 20 1 FUSE 1 A orn 16 1 WHTIYEL 16 1 H3 MOT R VACUUM 20 2 BLKMHT 18 2 JL Note eee YEL 20 1 BLK 18 9 M12 Xz M6 Is Optional GRA 20 1 BLU VEL 18 2 RED WHT 18 1 M 70202 WHT BRN 18 5 My VIO 20 1 NL xs CONTACTOR J ERE PUMP CHEMICAL MAIN Spt BRNBLK 8 1 Y BLUIGRA T T ak K3 GF ihe BIOS eis TORN 184 DPUVHVSVESIMESNGCUAD LIAN g2 i 5
53. M ge 2 2l zz SIDE BROOM BLK 18 2 E E ORN RED 20 1 BLK 8 1 5 S 5 855 52 SW SIDE BROOM 338 Ag zm GRNIBLK 20 1 gt gt gt zm 2mm Note Optional On Cylindrical Machine Only xe LY co st SEIS qui s 5 ege ss Sls eje gt gt gt gt gt gt gt gt M pa 5 A Zl I lod Typenr 239025 9 gam mu ae 2 3 Og MEE d Bee Ele 2 esha x CC Sa I je m X44 E X49 x50 L 4 E e Y Ys 544444 BL A XL AA d J z gt B 8 _ 01 5_ I 606464 42234 9 1 SP3 ilii SER 14008 in ki gt Ls IL B 9 x55 X24 X25 II NR M xz xr ET T TTE 3 EM MOTOR PT C ms 3 amp i D2 _ 18 Cylinderical Deck Polarity Of M8 508 1 Ed M 1 ZENER TVS R1 2 AU PUMP ACCESSORY EE 1 SENE SW SPST OPTIONAL 55 Sog fr IM SOLENOID BJA Note M7 Is Used On All Models WHEEL DRIVE Ae Note A Switch Is Part Of Lamp A bl x45 135 And 38 Deck Polarity Of M8 1 S6 M11 BIA MN M8 M10 EO 1 x AN LAN PUMP SOLUTION 7 8 M M OPTIONAL AN MOTOR BRUSH MOTOR BRUSH Nore md on a 38 Disk Decks Note M10 Is Used On 35 amp 38 Disk Decks Only
54. Mode with 3 Pressure Settings Factory Default Turn the main power key switch to the off position Press and hold the scrub pressure decrease switch While holding the pressure decrease switch turn the main power key switch to the on position Continue to hold the pressure decrease switch until the scrub pressure decrease indicator is green Release the pressure decrease switch Pressing and releasing the scrub pressure decrease switch will now select between 0 1 2 3 4 or 5 Set the mode to 3 4 or 5 depending on the range of pressure desired see above 7 Pressthe scrub system off switch to save this setting 8 status display will now show d to indicate that the procedure is done 9 new setting will be saved and will remain in effect until itis changed again gt WN IM Pressure Increase Decrease Mode with 9 Pressure Settings Advenger Mode Turn the main power key switch to the off position Press and hold the scrub pressure decrease switch While holding the pressure decrease switch turn the main power key switch to the on position Continue to hold the pressure decrease switch until the scrub pressure decrease indicator is green Release the pressure decrease switch Pressing and releasing the scrub pressure decrease switch will now select between 0 1 2 3 4 or 5 Set the mode to 1 Press the scrub system off switch to save this setting The status display will now show a number from 1 to 3
55. ONT FORM NO 56043097 Adgressor BR 8505 850CS 9505 950 5 10505 1050CS 17 WHEEL DRIVE SYSTEM GENERAL FUNCTIONAL OVERVIEW See Figures 1 amp 2 An 1100 watt 1 5 HP permanent magnet 36V motor gear transmission combination wheel M3 unit is used to propel all machines A Curtis model 1237 PMC solid state speed controller 1 regulates outputs the variable speed Fwd Rev wheel drive motor functions The controller unit is located to the left of the operator seat behind the electrical access panel The potentiometer R1 mounted to the operator s foot pedal inputs to the A1 controller the machine operator s desired speed and directional demands DRIVE MOTOR SYSTEM CONTROLLER FUNCTION OVERVIEW See Figure 2 To make the A1 speed controllers internal control circuits operational power it up the two switches S1 key and S2 seat must be closed This circuit inputs a positive 36V to the Al speed controls pin terminal 15 KSI The F2 circuit breaker 70 Amp supplies the positive high current load circuit input to the B controller terminal Blu Orn wire The black wire from the negative battery standoff supplies the battery ground input to the B terminal for both the control and load circuits See Figure 3 Depressing the foot pedal in either Fwd or Rev will move the 5K Ohm R1 potentiometer shaft off its centered balanced neutral setting of approximately 2500 Ohms With this pot shaft
56. Off Green Flash Speed control mode 2 is selected scrub speed Wand Switch I This switch does not control any output functions Pressing this switch will illuminate the wand indicator FORM NO 56043097 Adgressor BR 8505 850CS 9505 950CS 10505 1050CS 63 ELECTRICAL SYSTEM MAIN CONTROL BOARD SPECIAL PROGRAM OPTIONS Displaying the Control Unit Revision Level If itis desired to view the revision level of the control unit perform the following steps 1 Turn the main power key switch to the off position Press and hold the scrub system off switch and the speed select switch While holding both switches turn the main power key switch to the on position Continue to hold both switches until the speed select indicator is fashing Release both switches The status display will now indicate the revision level of the control unit The displayed value will be a letter from A to Z To exit this mode turn the main power key switch to the off position gt WwW Selection of Low Voltage Cutout Threshold FACTORY DEFAULT S STANDARD The Adgressor BR 8505 and BR 850 5 are equipped with a low voltage cutout feature to prevent over discharging the batteries This feature will automatically shut down the scrub system when the battery voltage falls to the selected threshold The cutout level is adjustable The standard setting is 31 volts 1 72 volts per cell and the alternate setting is 32 5 volts 1 81 vo
57. ROLLER ERROR CODES Error Code Fault Description Troubleshooting Action Drive system fault 1 Check for a tripped drive motor circuit breaker 70 amp Investigate reason for possible mechanical over load Examples Sticking brakes parking brake not released prolonged ramp climbing 2 Observe the green fbshing wand indicator light location operator panel then see Curtis drive motor controller section to further troubleshoot the drive system Table 1 Scrub deck lift actuator overload 1 Check for binding or frozen brush lift linkage and excessive normal current load 1 2 5 Amps weight on brush deck 2 Check for short circuit in brush motor max current load 6 Amps and wiring Repair or replace max current no load 1 4 Amps Squeegee lift actuator overload 1 Check for binding or frozen squeegee lift linkage and normal current load 1 1 5 Amps excessive weight on squeegee 2 Check for short circuit in max current load 6 Amps wiring or actuator motor R epair or replace max current no load 1 4 Amps Scrub motor overload 1 Check for binding in rotation of brushes or improper brush Note See Table 2 Scrub Pressure for detail lift actuator operation 2 Check the negative supply cable load current values for the different atthe brush motor for a wiring problem or improper modiftations and also the small YEL VIO current sense wire 3 Check to see that the proper brush programming type is selected disc or cyl
58. SEMBLY REMOVAL A WARNING Turn the main key switch J to the off position and disconnect the battery pack by pushing in the emergency disconnect lever 13 Next block both rear wheels so machine can t roll 1 SeeFigure 5 Remove the brake foot pedal A secured by the 2 screws D that fasten the pedal mount bracket to the chassis allowing access to the spindle retainer nut 2 Pulloutthe brake rod E and use a 1 7 16 socket to remove the large spindle nut from its shaft 3 From underneath the front of the machine remove the 4 G screws and push the lower steering column to the rear of the machine This is done to separate the chain from the steer sprocket I Service Note Use a 5 8 socket with 3 extension to remove screws and also correctly position the large hole in the steer plate J in order to access the far back left screw 4 On the right side ofthe drive motor remove the motor wiring cover and observe the 2 wires red green amp yellow black attached to the motor terminal connections for reassembling shown in Figure 4 5 Then remove the wires using a 13mm wrench 5 Remove the 1 socket head cap screw use a 3mm hex wrench that retains the motor wiring harness P clamp then pull wiring to the rear of the machine A WARNING Never work under machine without safety stands or blocking to support the machine 6 Safely jack up or lift the front of the machine to a height of approximately 16 inches 41 cm t
59. SQUEEGEE SYSTEM esercito een SQUEEGEE SYSTEM LIFT MOTOR OVERVIEW TROUBLESHOOTING tnnt SQUEEGEE LIFT ACTUATOR MOTOR REMOVAL SQUEEGEE LIFT CABLE REPLACEMENT SQUEEGEE E SQUEEGEE AD USTMENT revised 10 06 TABLE OF CONTENTS EREGTRICAESYSTEMZ 5 n eed er cervo eon eh mehr te b aded _ BATTERIES CHARGERS SPECIFICATIONS INSTAEESTHESBATTERIES porn ERN pP DRAIN DESCRIPTION OF THE BATTERY LOW VOLTAGE CUTOUT FEATURE DESCRIPTION OF THE BATTERY CONDITION INDICATOR CHARGING THE BATTERIES eene nnns BATTERY MAINTENANCE enne BATTERY TESTING m e E tn ACTUATOR DRIVE NUT ADJ USTMENT CURTIS SPEED CONTROL ca MAIN CONTROL BOARD FUNCTIONAL OVERVIEW MAIN CONTROL BOARD TROUBLESHOOTING GUIDE MAIN CONTROLLER ERROR CODES eene MAIN CONTROLLER SERVICE TEST MODE eene MAIN CONTROL BOARD SPECIAL PROGRAM 5 ELECTRICAL COMPONENT LOCATION before Serial Number chart WIRING DIAGRAM before Serial Number WIRING SCHEMATIC before Serial Number chart WIRING DIAGRAM
60. This represents the maximum scrub pressure that the operator will be able to select Use the pressure decrease switch to set the desired pressure limit 9 Press the scrub system off switch to save this setting 10 The status display will now show d to indicate that the procedure is done 11 The new setting will be saved and will remain in effect until itis changed again C Ui amp WN FORM NO 56043097 Adgressor BR 8505 850CS 9505 950CS 10505 1050 5 65 ELECTRICAL SYSTEM SPECIAL PROGRAM OPTIONS CONTINUED Fixed Pressure Mode Turn the main power key switch to the off position Press and hold the scrub pressure decrease switch While holding the pressure decrease switch turn the main power key switch to the on position Continue to hold the pressure decrease switch until the scrub pressure decrease indicator is green Release the pressure decrease switch Pressing and releasing the scrub pressure decrease switch will now select between 0 1 2 3 4 or 5 Set the mode to 0 Press the scrub system off switch to save this setting The status display will now show a number from 1 to 5 This represents the scrub pressure thatthe operator will be able to select using the light scrub pressure select switch Use the pressure decrease switch to set the desired pressure Press the scrub system off switch to save this setting The status display will now show a number from 1 the setting from step 8 to 9
61. abled and the squeegee will be lowered The solution system will be enabled The travel speed will be limited to the scrub speed setting As soon as the throttle is moved from the neutral position the scrub brushes will start turning and the vacuum will turn on If the direction is forward the solution fbw will start If the direction is reverse the squeegee will raise and the solution fbw will be stopped The scrub pressure increase indicator will be green if the scrub system is on and the pressure is set at 2 or 3 The indicator will be off if the scrub system is off or if the scrub pressure is set to minimum The indicator will be yellow if the scrub system has been enabled but the throttle is in neutral FORM NO 56043097 Adgressor BR 8505 850CS 9505 950CS 10505 1050CS 11 KNOW YOUR MACHINE Fixed Pressure Mode Scrub System Off Switch Pressing this switch when the scrub system is active will cause the following to occur The scrub brushes will turn off and the scrub deck will raise to the up position solution fbw will be stopped e The frst time that this switch is pressed the vacuum squeegee system will NOT be turned off This is so that any remaining water may be picked up without having to turn the vacuum back on If this switch is pressed a second time pressed after the scrub system has been turned off the squeegee will raise and the vacuum will shut of after a 10 second delay e travel s
62. ad the displayed fault information In this example the display shows No Faults Present indicating that the controller has not detected anything out of the norm 3 Putthe programmer in test mode and observe the status of inputs and outputs in the forward direction In this example the display shows that the forward input did not activate when forward was selected which means the problem is either in the electronic throttle or the throttle wiring 4 Checkorreplace the electronic throttle and wiring and repeatthe test If the programmer shows the forward switch closing and the vehicle now drives normally the problem has been corrected Refer to the Status Fault Codes Table 1 for suggestions covering a wide range of possible faults DIAGNOSTIC HISTORY The handheld programmer can be used to access the controller s diagnostic history fle Connectthe programmer press the MORE INFO key and then while continuing to hold the MORE INFO key press the DIAGNOSTICS key The programmer will read out all the faults thatthe controller has experienced since the last time the diagnostic history fle was cleared The faults may be intermittent faults faults caused by loose wires or faults caused by operator errors Faults such as HPD or over temperature may be caused by operator habits or by overloading After a problem has been diagnosed and corrected clearing the diagnostic history fle is advisable This allows the controller to accumulate a new fle o
63. after Serial Number chart WIRING SCHEMATIC after Serial Number ELECTRICAL COMPONENT LOCATION after Serial Number chart Note All references to right left front or rear in this manual are as seen from the operator s stand point revised 10 06 FORM NO 56043097 Adgressor BR 8505 850 5 9505 950 5 10505 1050CS 1 GENERAL INFORMATION INTRODUCTION This manual will help you get the most from your Nilfsk Advance Rider Scrubber Read it thoroughly before servicing the machine Note Bold numbers in parentheses indicate an item illustrated on pages 9 10 This product is intended for commercial use only PARTS AND SERVICE Repairs when required should be performed by your Authorized Nilf amp k Advance Service Center who employs factory trained service personnel and maintains an inventory of Nilf amp k Advance original replacement parts and accessories Call the NILFISK ADVANCE DEALER named below for repair parts or service Please specify the Model and Serial Number when discussing your machine Dealer affk service sticker here NAME PLATE The Model Number and Serial Number of your machine are shown on the Nameplate on the machine This information is needed when ordering repair parts for the machine Use the space below to note the Model Number and Serial Number of your machine for future reference MODEL NUMBER SERI
64. at will cause severe personal injury or death A WARNING Is used to call attention to a situation that could cause severe personal injury AN CAUTION Is used to call attention to a situation that could cause minor personal injury or damage to the machine or other property GENERAL SAFETY INSTRUCTIONS Specift Cautions and Warnings are included to warn you of potential danger of machine damage or bodily harm A 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 e Keep sparks fame and smoking materials away from batteries Explosive gases are vented during normal operation e 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 0 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 fammable cleaning agents operate the machine on or near these agents or operate in areas where fammable liquids exist Do notclean this machine with a pressure washer CAUTION e This machine is not approved for use on publ
65. cator E e This indicator will be yellow if the scrub system is enabled but the drive pedal is at neutral and the current scrub pressure is at 8 or less e This indicator will be green if the scrub system has been turned on the current scrub pressure is at8 or less and the machine is moving in either direction This indicator will be off if the scrub system has been turned OFF or the scrub pressure is set at 9 Scrub Pressure Hourmeter Display G The single character display on the control panel is primarily used as a display for the scrub pressure This display is also used to display the machine hours and any control system fault codes If any of the systems on the machine on or if the throttle is not neutral the display will indicate the scrub pressure setting 1 9 If the scrub system is off the display will indicate 0 Upon power up or if the machine has been idle for at least ten seconds with all systems turned off the display will indicate the machine hours The format for the display of the hours is as follows Example 123 4 hours e The display will indicate 1 followed by a short blank period e The display will indicate 2 followed by a short blank period e The display will indicate 3 followed by a short blank period e The display will indicate _ followed by a short blank period this is used as a decimal point to indicate tenths of hours The display will indicate 4 tenths followed by a long blank period T
66. crease mode panel buttons The scrub pad or brush pressure ranges light amp heavy are independently programmable allowing the operator the choice to vary the scrubbing effort pressure while operating the machine Note See the Main Control Board Special Program Options section in this manual for more detailed operation and instructions to change scrub pressure settings See Figure 1 The machine s main scrub system input and output operating functions are regulated managed by the combined membrane switch display panel and main control board E1 The major scrub system functions are Scrub Brush Motor Run Function To turn On energize the K1 brush motor solenoid either the scrub pressure increase or decrease button location E1 panel must be pressed and the foot activated drive pedal moved off its neutral position triggering an output from the R 1 directional throttle potentiometer These two operator functions deliver the required E1 control board and A1 speed control circuit inputs Detailed Explanation of the scrub motor function A closed E1 membrane panel switch input either decrease or increase enables the E1 microprocessor automatic functions for the brush lift brush solenoid solution solenoid vacuum solenoid and squeegee lift The next step is the movement of the foot pedal for the needed R1 throttle output to the Al speed controller which causes either FWD or REV motor action At the moment of R 1 throttle input the A1 contr
67. crub pressure decrease indicator should be off If the indicator is fashing green this indicates that the control is sensing current fbw through the actuator shorted output driver control error If the scrub pressure decrease switch was the last switch pressed itis possible to momentarily activate the actuator output using the horn switch This can be used to jog the actuator to allow precise positioning of the actuator NOTE the actuator can only move in this situation if itis notat its up limit When the output is in state 2 the actuator output is turned on The scrub pressure decrease indicator should be green or fBshing green The indicator will be a steady green if the control senses current fbw through the actuator It will fash green if no actuator current fbw is sensed actuator at limit open circuit open output driver The horn switch has no effect in this state When the outputis in state 3 the actuator output is turned off The scrub pressure decrease indicator should be off If the indicator is fashing green this indicates that the control is sensing current fbw through the actuator shorted output driver control error If the scrub pressure decrease switch was the last switch pressed itis possible to momentarily activate the actuator output using the horn switch This can be used to jog the actuator to allow precise positioning of the actuator NOTE the actuator can only move in this situation if itis not at its down limit When th
68. cted pressing this switch will select the light scrub pressure If the light scrub pressure is already selected pressing this switch will have no effect Heavy Scrub Pressure Select Switch If the scrub system is off pressing this switch will cause the following to occur The scrub system will be enabled with the scrub pressure set to the heavy setting and the scrub deck will be lowered The vacuum system will be enabled and the squeegee will be lowered The solution system will be enabled The travel speed will be limited to the scrub speed setting As soon as the throttle is moved from the neutral position the scrub brushes will start turning and the vacuum will turn on If the direction is forward the solution fbw will start If the direction is reverse the squeegee will raise and the solution fbw will be stopped heavy scrub pressure indicator will be green if the scrub system is on and the heavy pressure has been selected The indicator will be off if the scrub system is off The indicator will be yellow if the scrub system has been enabled at the heavy pressure setting but the throttle is in neutral If the light scrub pressure setting is selected pressing this switch will select the heavy scrub pressure If the heavy scrub pressure is already selected pressing this switch will have no effect Light Heavy Scrub Mode Scrub System Off Switch Pressing this switch when the scrub system is active will cause the following to
69. cuum and solution indicators will all be yellow indicating thatthe systems are enabled and ready to turn on when the throttle is moved to forward reverse A green indicator means that the particular system is on A flashing green indicator means that the particular system is in a delayed off condition An example of this is when a scrub mode is selected and the throttle goes from forward or reverse to neutral When this happens the vacuum indicator will fash green indicating that the vacuum is still on but that it will be turning off after the delay period Scrub Off Indicator A e This indicator will be green if the scrub system is off and ready to be activated This indicator will be red if the scrub system has been turned off and the scrub deck is not up yet or if the scrub deck is up and there is no weight on the Seat This indicator will fash red if there is a fault in the scrub system This indicator will be off if the scrub system has been activated Scrub Pressure Decrease Indicator C e This indicator will be yellow if the scrub system is enabled but the drive pedal is at neutral and the current scrub pressure is at 2 or more e This indicator will be green if the scrub system has been turned on the current scrub pressure is at 2 or more and the machine is moving in either direction This indicator will be off if the scrub system has been turned OFF or the scrub pressure is set at 1 Scrub Pressure Increase Indi
70. d into the forward position Note When the solution on off button is turned off no fbw can occur regardless of the manual fbw control being on drive pedal activated and the scrub deck down FIGURE 1 Solution Tank Electrical Solenoid Valve L1 5 Smart Solutions ec f 9 Valve 27 y SS Flow Control Valve C 38 FORM NO 56043097 Adgressor BR 8505 850CS 9505 950CS 10505 1050 5 SOLUTION SYSTEM SOLUTION SOLENOID CIRCUIT OVERVIEW Auto Mode Positive battery circuit inputs and outputs Inputs A Solenoid circuit control coil voltage input to control board E1 connector 2 pin 5 6 amp 7 wire colors Brn Yel A closed S1 key switch supplies input voltage to the E1 terminal 2 pin 10 wire Brn This powers up turns on the control board s processing logic functions Aclosed S2 operator safety seat switch enables allows the starting of the entire automatic machine scrubbing system functions Its E1 terminal connection is J 4 pin 11 wire Outputs A control board E1 battery voltage output from the solenoid accessory terminal connection 2 pin 8 Wht Brn wire Negative battery circuit inputs and outputs Inputs A main battery ground input for the control board 61 terminal 4 pin 8 BLK wire This supports the opera
71. e Figure 3 Remove the vacuum duct Cover C that is secured to the recovery tank by a qty of 6 Screws B Separate the wiring harness from each motor and lift motor s out from their mounting cavity Inspect all the vacuum recovery system Gaskets items E F G amp H also clean the vacuum motor s Foam Filters J amp Screens L and Exhaust Hoses M Inspect the carbon motor brushes if less than 3 8 10 in length replace be separated from the vacuum Duct Cover C by removing the slotted Pin by using a fbt bladed screwdriver CO C FORM NO 56043097 Adgressor BR 8505 850CS 9505 950CS 10505 1050CS 45 SQUEEGEE SYSTEM SQUEEGEE SYSTEM LIFT MOTOR OVERVIEW See Figure 2 The squeegee pickup tool is raised and lowered by a 36V actuator motor assembly mounted horizontally in the center rear of the chassis underneath the recovery tank The main control board assembly E1 regulates manages the machine s squeegee tool system input and output operating functions See the Know Your Machine section in this manual for a detailed description of vacuum squeegee operation modes OPERATIONAL OVERVIEW OF THE SQUEEGEE LIFT MOTOR REVERSE FUNCTION During normal machine scrubbing the squeegee operates in the auto mode To prevent squeegee blade damage and excessive wearthe squeegee tool is automatically lifted from the fbor any time the machine is operated
72. e indicator light will fash green RED BTI BLK Battery 36 Vdc RED z g Thermistor 5 E 2 gt m E 428 ace Control Board Speed Controller WHT BRN e o E E 1 al ET L z K2 2 WHT BRN m GRA BLK amp ea Vacuum Solenoid Coil RED 2 WHT Contact N o FORM NO 56043097 Adgressor BR 8505 850CS 9505 950 5 10505 1050 5 43 RECOVERY SYSTEM TROUBLESHOOTING GUIDE If water fbws around the ends of the squeegee tool instead of being pulled into the tool the vacuum system is not working properly When a vacuum system performs poorly itis usually because of one of the following problems Vacuum Leak s Air fbwing into the vacuum system pasta bad gasketor leaky hose damaged tank or a leaky drain valve A vacuum leak below the water line will create turbulence in the recovery tank causing water to enter the vacuum motor Restriction s Anything that blocks the fbw of air through the system Restrictions may also be caused by built up debris in the squeegee tool vacuum hoses fbat cage or wherever the airfbw is forced to make a sharp turn Both leaks and restrictions decrease the quantity of air fbwing through the squeegee tool The air that does go through the squeegee tool moves slower so ithas less pick up power Vacuum Electrical Components The vacuum systems major electrical components are monitored by the
73. e new setting turn the main power key switch to the off position 8 The new setting will be saved and will remain in effect until it is changed again Cc CC WwW Vacuum Automatic Shut off Threshold Adjustment FACTORY DEFAULT 4 The sensitivity of the automatic vacuum shut off feature can be adjusted if necessary This adjustment sets the amount of change required in the vacuum power consumption to cause the control unit to indicate a full recovery tank condition The setting is adjustable from 0 to 9 0 is the minimum sensitivity 9 is the maximum sensitivity If the unit falsely indicates a tank full condition try setting this parameter to a lower value If the control unit fails to shut the vacuum system off when the recovery tank fbat ball plugs the vacuum inlet try setting this parameter to a higher value To adjust the vacuum shutoff sensitivity perform the following steps 1 Turn the main power key switch to the off position Press and hold the scrub pressure decrease and the solution switch While holding both switches turn the main power key switch to the on position Continue to hold both switches until the solution indicator is fbshing yellow Release both switches The status display will now indicate a number from 0 to 9 depending on the threshold setting Pressing and releasing the solution switch will now select the threshold level The level will increment from 0 to 9 0 minimum sensitivity 9 maximum sensitivity
74. e output is in state 4 the actuator output is turned on The scrub pressure decrease indicator should be green or fBshing green The indicator will be a steady green if the control senses current fbw through the actuator It will fash green if no actuator current fbw is sensed actuator at limit open circuit open output driver The horn switch has no effect in this state Scrub ON Pressure Increase Switch F This switch is used to control the output to the squeegee lift actuator Pressing and releasing this switch will cycle the actuator output through 4 states These are 1 output off direction up 2 output on direction down 3 output off direction down 4 output on direction When the output is in state 1 the actuator outputis turned off The scrub pressure increase indicator should be off If the indicator is fashing green this indicates that the control is sensing current fbw through the actuator shorted output driver control error If the scrub pressure increase switch was the last switch pressed itis possible to momentarily activate the actuator output using the horn switch This can be used to jog the actuator to allow precise positioning of the actuator NOTE the actuator can only move in this situation if itis not at its up limit When the output is in state 2 the actuator output is turned on The scrub pressure increase indicator should be green or flashing green The indicator will be a steady green if
75. e pressure spring See Figure 9 The Stop Collar AS is installed on the pivot hinge bolt to help control the front skirt mount bracket s travel when the scrub deck is lowered It limits the front of the blade from folding curling under when scrubbing Thus allowing the blade to hold its shape better reduce blade damage and wear A limited amount of adjustment for general blade wear and squeegee wiping performance can be made by reinstalling the spring attachment Screw AT into a different mount hole A B or C This change will increase or decrease the spring force pressure pulling down on the rear edge of the skirt blade Position C creates maximum down pressure on the blade and position A is minimum pressure FIGURE 9 FORM NO 56043097 Adgressor BR 8505 850CS 9505 950CS 10505 1050 5 35 SCRUB BRUSH SYSTEM CORRECT SCRUB MOTOR WIRING CONNECTIONS FIGURE 10 This plug is only used for the middle motor on 35 amp 38 disk decks This connector will have a Dummie plug covering it from the factory on all cylindrical and 28 amp 32 disk models It hasa blue and a black wire connected to it This plug is not labeled on early models but has the label M8 on later models All cylindrical and 28 amp 32 disk decks have a single connector and plug into this connector t has a blue and a black wire connected to it
76. e recovery tank becomes full This feature can be disabled if desired See the programming section for details Solution Switch R This switch is used to turn the solution system on or off Pressing this switch when the scrub system has been activated will alternate between on and off The solution fbw will only turn on when the throttle is moved from the neutral position in the forward direction The solution fbw will turn off if the throttle returns to neutral or is moved to reverse Pressing this switch when the scrub system is off will momentarily turn the solution fbw on to allow pre wetting of the scrub brushes FORM NO 56043097 Adgressor BR 8505 850CS 9505 950 5 10505 1050CS 13 KNOW YOUR MACHINE DESCRIPTION OF INDICATORS ON THE CONTROL PANEL In general the following guidelines apply to the control panel indicators A steady red indicator means that the function is inhibited for some reason For example if the scrub system is off and the operator is not on the seat the scrub System indicator will be red indicating that the system cannot be turned on until the operator is on the seat fbshing red or yellow indicator means that fault has occurred in the particular system An example of this would be an over current fault A yellow indicator means thatthe particular function has been enabled butis not currently on For example if a scrub mode is selected and the throttle is in neutral the scrub system va
77. e terminal will not turn on the battery post Then tighten the nut half an additional turn Do not over tighten the terminals or they will be very difftult to remove for future service 7 Coatthe terminals and posts with spray on battery terminal coating available at most auto parts stores 8 of the black rubber boots over each of the terminals and retain with Supplied tie straps 25 9 Connect the battery pack connector to the Machine Battery Connector 22 and close the operator s seat platform 305A H 20HR RATE Note Removal of the recovery tank can make battery installation easier FORM NO 56043097 Adgressor BR 8505 850CS 9505 950CS 10505 1050CS 49 ELECTRICAL SYSTEM DESCRIPTION OF THE BATTERY LOW VOLTAGE CUTOUT FEATURE All models discussed in this manual are equipped with a low voltage cutout feature to prevent over discharging of the batteries When a machine s battery pack voltage falls below speciftally defned thresholds voltage settings the scrub system is automatically shut down The cutout level is adjustable The standard lead acid battery wet cell setting is 1 72V per cell and alternate maintenance free battery gel cell setting is 1 81V per Cell The standard setting is factory selected and should be used unless the battery manufacturer specifes the higher cutout voltage Special Service Note On all machines 36V a minimum recharge voltage of 2 09 volts per ce
78. easing the vacuum switch will now select between 1 for a single vacuum motor or 2 for dual vacuum motors To save the new setting turn the main power key switch to the off position The new setting will be saved and will remain in effect until itis changed again CO gt C I Control Unit Sleep Delay Period FACTORY DEFAULT 1 10 MINUTES Ifthe Adgressor BR 8505 and 850CS are left in an idle state for a period determined by the sleep delay setting the control unit will automatically raise the scrub deck raise the squeegee and turn off any accessories This is to conserve battery power The sleep period is adjustable from 10 to 90 minutes in 10 minute increments It can also be turned off To change the sleep delay period perform the following steps Turn the main power key switch to the off position Press and hold the scrub system off and the wand switch While holding both switches turn the main power key switch to the on position Continue to hold both switches until the wand indicator is fbshing Release both switches The status display will now indicate a number from 0 to 9 depending on the current sleep delay period Pressing and releasing the wand switch will now select the delay period The level will increment from 0 to 9 0 off sleep disabled 1 10 minutes 2 20 minutes up to 9 90 minutes 7 To save the new setting turn the main power key switch to the off position 8 The new setting will
79. ed 10 pins Not Used 6 pins 20 FORM NO 56043097 Adgressor BR 8505 850CS 9505 950 5 10505 1050 5 WHEEL DRIVE SYSTEM Low Current A1 Speed Control Pin Key Detail Pin Wire Color 15 1 2 3 4 ERA 233 gt a 8 43 A 22 PNE ONES 14 Om 16 Throttle Pot R1 pot high input Throttle Pot R1 pot wiper input Throttle Pot R1 pot low input Controller Pin Description amp Function S peed limit pot input Tied to Pot High Open not used Open not used Program 1 Auxiliary Driver Battery output to the main controller E1 to turn on activate all auto scrub functions Pin 7 will read approximately 36 volts when the foot pedal is in Fwd or Rev Main Contactor Output Open not used Open not used Mode Select 1 Drive motor scrub speed input from the E1 Open not used Open not used Status Fault Speed controller fault output to main control panel fault indicator light accessory wand KSI key switch input Battery powers up controller logic circuits Program 2 Auxiliary Driver Battery outputto the main controller E1 that controls the entire auto reverse machine functions How the program 2 functions is when the foot pedal is placed in Rev Pin 4165 voltage signal to E1 is lost 0 volts This lost open circuit signal is what tells the E1 controller to turn on the back up alarm H1
80. egee Moun Wheel icesez acw seger 1 a 35 Banery Pack Condition lean amp wate 36 Front Drive Wheel Motor Carbon Brushes CW 88 Brake Band Lining Wer AdetBePuy asw s Drive Pedal Linkage retn an Steering Column knob amp plunger spring also Universal Jom Grese ap a fraw 2222 0 47 LLL 35 Sweep Debris Tray NOTE For additional service information see service manual form number 56043097 and operators manual form numbers 56041581 56041583 amp 56041568 56041570 Defect Codes A needs adjustment C or contaminated M missing B binding D damaged bent or torn W worn out L leaks WORK COMPLETED BY ACKNOWLEDGED BY Service Technician Signature Date Customer Signature Date Copyright 2004 Nilfisk Advance Page 2 of 2 10 21 2004 8 FORM NO 56043097 Adgressor BR 8505 850 5 9505 950 5 10505 1050 5 Ul UN rm Recovery Tank Cover Solution Tank Fill Cover Operator s Seat Solution Tank Drain Hose Steering Wheel Tilt Adjust Knob Brake Pedal Parking Brake Solution Flow Control Lever Drive Pedal Directional Speed Hopper cylindrical models only KNOW YOUR MACHINE 10 Drive and Steer Wheel 18 Vacuum Motor Filter Housing 11 Wheel Drive Circuit Breaker 19 Squeegee Assembly 12 Control Circuit Circuit Breaker 20
81. ely and cause unneeded blade wear SCRUB BRUSH DECK FRONT REAR SKIRT REPLACEMENT DISC 1 2 Replace with new blades when they are nicked torn or worn beyond their ability to contain brush wastewater within the skirting See Figure 4 A quantity of 16 or 18 Panel Fasteners Z must be removed to allow the skirt material to be replaced Method A The easiest method to access the fasteners is to remove the scrub deck Method B Place the scrub deck in the Up position then remove both the left and right side skirt assemblies from the machine Cut the panel fastener heads off using a chisel or pry the heads out from the deck mounting holes using a large screwdriver or thin piece of metal Note The panel fasteners are not designed to be reused Install the new skirts with new panel fasteners tap them into the mounting holes with a soft faced hammer FIGURE 4 32 FORM NO 56043097 Adgressor BR 8505 850 5 9505 950CS 10505 1050 5 SCRUB BRUSH SYSTEM BRUSH DECK ACTUATOR REMOVAL DISC amp CYLINDRICAL 1 Lowerthe scrub deck with the scrub brushes installed Don t turn the key switch off until disconnecting the battery pack by using the emergency disconnect lever 13 This procedure is done to prevent the scrub deck from automatically raising when the key is turned off 2 See Figure 5 From underneath the machine remove the clevis Mount Pin AA that secures the lower actuator housing to the scrub deck
82. ends repair or replace To Adjust Pedal Spring 1 Loosen Screw AM amp Nut AN the screw with bushing is positioned between both Fwd amp Rev torsion spring ends Its placement controls the needed pre load pressure to eliminate excessive pedal free play and a balanced spring rate to return the pedal to a centered neutral position 2 the screw back into the pedal frame slot to increase spring tension and eliminate pedal free play Then tighten the screw amp nut being careful not to pull on the linkage connection to the pot shaft and disturb move its neutral setting To Replace Pedal or Spring Position the torsion spring ends A amp B as shown This is with the bushing and screw not installed Place the bushing inside the pedal channel pilot it into position using a scratch awl or a pin punch Then pivot press the pedal and insert the screw from the opposite side pushing the guide tool out Use a screwdriver to tap and pry the bushing back in the pedal slot to increase spring tension Work the bushing back amp forth on both sides of the pedal to obtain equal spacing Then tighten the screw and nut A correctly adjusted drive pedal will have minimal amount of free play when selecting a drive direction Reconnect the batteries and test the machine to make sure it does not creep forward or reverse when the pedal returns to neutral Service Tip Also confrm the Hourmeter S tatus Display G is free of the error code 0
83. ets L to the gearboxes and separate FIGURE 3 Remove the 8 Q Screws use a 5mm hex wrench that hold in place the Dust Covers R Next remove the shaft retainer hardware items S amp T Then tap out the Output Shaft U using a brass shaft to help prevent any possible damage Re assemble in reverse order and test for proper operation Note The proper motor installation position is where the two motor wires face the front and left side on the scrub deck platform SCRUB BRUSH GEARBOX REMOVAL AND OUTPUT SHAFT REPLACEMENT DISC 1 Follow steps 1 7 of the Scrub Brush Deck Removal Disc amp Cylindrical section and steps 2 6 ofthe Scrub Brush Motor Removal Disc section See Figure 3 Remove the hardware items N amp O that secure the Hub I to the Output Shaft U then pull the hub from the shaft and save the key Note Skip this step if shaft does not need to be replaced Remove the 4 socket head cap screws use a 5mm hex wrench securing the gearbox that needs replacement Re assemble in reverse order and test for proper operation Service Tip Apply a small amount of grease or Never Seize to the gearbox output shafts when reinstalling the drive Hub s I Note The gearbox output shafts rotate the brush holders in the opposite direction of other Nilf amp k Advance automatic scrubbers see below FRONT SCRUB BRUSH SYSTEM FORM NO 56043097 Adgressor BR 8505 850CS 9505 950 5 1
84. eutral position the scrub brushes will start turning and the vacuum will turn on If the direction is forward the solution fbw will start If the direction is reverse the squeegee will raise and the solution fbw will be stopped heavy scrub pressure indicator will be green if the scrub system is on and the heavy pressure has been selected The indicator will be off if the scrub system is off The indicator will be yellow if the scrub system has been enabled at the heavy pressure setting but the throttle is in neutral If the light scrub pressure is active pressing this switch will cause the pressure to return to the last used heavy scrub pressure setting If the heavy scrub pressure is already selected when this switch is pressed the scrub pressure will increase up to the maximum limit programmed for the heavy scrub pressure The pressure will then roll over to the minimum value programmed for the heavy scrub mode Wand Switch I This switch is used when an external scrub wand is used Pressing this switch will turn the vacuum on continuously without regard to the throttle position It will also enable the optional solution pump If the scrub system was on it will be turned off This includes turning off the scrub brushes and raising the scrub deck turning the solution fbw off to the scrub deck and raising the squeegee NOTE automatic shutoff ofthe vacuum motor when the recovery tank is full is disabled when the wand is enabled The fbat i
85. evenly at points 120 degrees apart to slowly work it from the motor bearing 4 Using a 5mm hex key wrench remove the 8 socket cap screws Q that secure the drive tire R to the motor drive hub and complete the tire removal 5 Installa new drive tire and tighten torque the 8 socket cap screws Q to 12 Ft Lbs 16 2 N M Service Tip Apply a small amount of Loctite 242 to all the cap screws to preventthe fasteners from backing out 6 Re assemble in reverse order following all the steps outlined in the steer spindle and drive motor removal section 22 FORM NO 56043097 Adgressor BR 8505 850CS 9505 950 5 1050S 1050 5 WHEEL DRIVE SYSTEM FORM NO 56043097 Adgressor BR 8505 850CS 9505 950 5 10505 1050 5 23 WHEEL DRIVE SYSTEM BRAKE ADJ USTMENT 1 gt WN See Figure 6 Adjustthe E brake rod s length to eliminate any foot pedal free play space between the pedal and rod end when the pedal is at rest not being engaged The rod length can be changed by loosening the jam nut S and threading the adjustment screw T In or Out To access the brake rod remove the front pedal mounting hardware items B amp C then swing pivot the pedal backwards out of the way Use a 3 8 wrench and 1 6 hex key wrench to both loosen and tighten the rods adjustable hardware Note Also check the brake bands brake linin
86. f faults By checking the new diagnostic history fle at a later date you can readily determine whether the problem was indeed completely fked To clearthe diagnostic history fie go to the Special Program Menu by pressing and holding the MORE INFO key and then pressing the PROGRAM key scroll through the menu until Clear Diagnostic History is the top line in the display and then press MORE INFO again The programmer will prompt you to acknowledge or cancel See the CURTIS PROGRAMMER MANUAL 56043101 for more detail on programmer operation 54 FORM NO 56043097 Adgressor BR 8505 850CS 9505 950 5 10505 1050 5 STATUS LIGHT DISPLAY ELECTRICAL SYSTEM STATUS LED FAULT CODES TABLE 1 EXPLANATION Output fault POSSIBLE CAUSE 1 Short in motor or in motor wiring 2 Controller failure Overcurrent fault 1 Short in motor or in motor wiring 2 Controller failure EEPROM fault 1 EEPROM failure or fault Main contactor fault 1 Main contactor welded ain contactor driver fault ain contactor coil fault Precharge fault Internal controller fault Low battery voltage Motor voltage fault Motor voltage does not correspond to throttle request M1 or M2 output shorted to B or B Internal motor short Controller failure HPD fault Improper sequence of KSI power enable and throttle inputs 2 Misadjusted throttle pot HPD fault p
87. f fbat just open the right rear recovery tank cover to access the fbat cage assembly back center in recovery tank The cage openings must be kept free of any debris that can restrict maximum airfbw To keep it clean wipe off with a rag regularly or remove and f sh with water The cage is a two piece design and can be snapped apart to separate Note Another method of accessing the cage fbat for servicing is to remove the 6 B Screws and remove the vacuum duct housing C from the recovery tank top opening 44 FORM NO 56043097 Adgressor BR 8505 850 5 9505 950CS 10505 1050 5 RECOVERY SYSTEM RECOVERY TANK REMOVAL 1 Drainthe recovery tank using the recovery tank FIG URE 3 drain hose 2 Disconnect the squeegee hose from the squeegee tool and remove the tool from its mount 3 SeeFigure 3 Open the hinged recovery tank VACUUM MOTOR S REMOVAL 1 4 Service Note The hinged Tank Cover D can easily Cover D and grip the top inside edge of th tank then pull straight up to separate it from the solution tank seat platform Then guid the tank off the rear of the machine to th fbor Important Service Note Support th e e e e bottom of the tank on its left corner to prevent crushing of the squeegee hose Don t pull the tank immediately away from the machine the vacuum motor wiring harness located on the lower left front corner must be disconnected to complete the separation Se
88. g brake functions WHEEL DRIVE MOTOR CARBON BRUSH INSPECTION 500 HOURS WHEEL DRIVE SYSTEM free play and test the brake system for proper operation See Figure 7 There are 6 carbon brush assemblies 4 ofthem are located equally spaced on the outside diameter of motor end bell cover Remove the inspection caps 2 by carefully twisting the cap a 1 8 of a turn counterclockwise The other 2 brushes are located behind the motor wiring terminal cover AA Remove the black cover and terminal mounting hardware Note The 4 motor commutator brushes are secured with two slotted screws A new carbon brush measures 20mm 780 inches in length Replace the brushes when worn to a length less than 9 5mm 375 inches FIGURE 7 FORM NO 56043097 Adgressor BR 8505 850CS 9505 950CS 10505 1050CS 25 1 2 3 WHEEL DRIVE SYSTEM POTENTIOMETER REMOVAL AND TESTING A WARNING Disconnect the machine s battery pack connector 13 before servicing Potentiometer Removal 1 SeeFigure 8 Remove the 5 Screws AB securing the drive pedal mount assembly to the chassis then carefully lift the pedal assembly up and lay iton its side 2 Observe the 3 wires connected to the Drive Pedal Potentiometer pot AC and also the single GRN YEL throttle ground wire AD note the proper wire colors and their terminal connections for re assembly Then disconnect wiring and remove the pedal mount assembly
89. g for wear when excessive pedal travel can not be eliminated through adjustments Service by replacing worn brake band and readjust and test for proper brake operation FIGURE 6 Pivot Em 24 FORM NO 56043097 Adgressor BR 8505 850CS 9505 950 5 10505 1050 5 DRIVE WHEEL BRAKE STRAP REPLACEMENT A WARNING Turn the key switch to the off position and then disconnect the battery pack by activating the emergency stop switch battery disconnect lever 13 1 SeeFigure 7 Remove from the brake band U the front lower outside retainer ring V external type Service Tip Use retaining pliers tip Size 038 inches 1 mm to prevent damage when removing all retainer rings Then drive outthe pin W from the brake band end 2 Remove the socket head cap screw X use a 6mm hex key wrench that fastens the left side brake lever to the support mount Y Next separate the brake lever from the mount bracket and pull it down to access the back retaining ring and remove it at this time 3 Remove the second mount pin then carefully expand the brake band enough to clear the drive wheel brake drum and remove from the machine 4 install the brake band follow the above steps in reverse order See the Brake Adjustment section in this manual and adjust the brake pedal A CAUTION Test drive the machine and check for positive brake pedal and parkin
90. he display sequence will repeat Wand Switch Indicator H e This indicator will be green if the Wand Switch has been turned ON e This indicator will be off if the Wand Switch has been turned OFF Speed Selector Indicator M e This indicator will be green if a scrub mode has been selected and the faster scrub speed has been selected This indicator will be off if the Speed Select Switch has been turned OFF Vacuum System Indicator P e This indicator will be green if the vacuum is on e This indicator will fash green if the vacuum is in the 10 second delayed off condition e This indicator will be yellow if the vacuum is enabled but the drive pedal is in neutral e This indicator will fash yellow if there is a vacuum system fault e This indicator will be off if the vacuum is disabled and turned off Solution System Indicator Q e This indicator will be green if the solution is on e This indicator will be yellow if the solution is enabled but the drive pedal is in neutral e This indicator will fbsh yellow if there is a solution system fault e This indicator will be off if the solution is disabled and turned off 14 FORM NO 56043097 Adgressor BR 8505 850CS 9505 950CS 10505 1050 5 KNOW YOUR MACHINE DESCRIPTION OF THE BATTERY CONDITION INDICATORS The battery condition indicator J consists of three lights a green G a yellow Y and a red R The voltage indication will change based o
91. ic paths or roads This machine is not suitable for picking up hazardous dust Do not use scarifer discs and grinding stones Nilf amp k Advance will not be held responsible for any damage to fbor surfaces caused by scarifers or grinding stones can also cause damage to the brush drive system e When operating this machine ensure that third parties particularly children are not endangered Before performing any service function carefully read all instructions pertaining to that function Do not leave the machine unattended without fist turning the key switch off O removing the key and applying the parking brake the key switch off 0 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 e Use caution when moving this machine in below freezing temperature conditions Any water in the solution or recovery tanks or in the hose lines could freeze causing damage to valves and fittings Flush with windshield washer flid e batteries must be removed from the machine before the machine is scrapped The disposal of the batteries should be safely done in accordance with your local environmental regulations SAVE THESE INSTRUCTIONS FORM NO 56043097 Adgressor BR 8505 850 5 9505 950 5 10505 1050CS 3 SPECIFICATIONS
92. illed water in batteries whenever possible If batteries are discharged add just enough water to cover the plates in each cell If batteries are fully charged fil each cell to the bottom of the filer tube Do not over fil the batteries Do not add acid to batteries Keep the Batteries Charged Weekly Batteries should be charged each time that a machine is used for more than 1 hour Machine operators should open the battery compartment cover for charging to avoid a concentrated build up of hydrogen gas Operators should follow the instructions provided with their specift battery charger to determine how long the batteries should be charged Even when a machine is stored the batteries should be charged once a month to prevent the batteries from sulfating Almost all battery caps are vented so there s no need to loosen or remove them for charging Keep the Batteries Clean Monthly Use a damp cloth to wipe dirt from the top of the batteries Battery terminals must be clean and tight If the tops of the batteries are wet after charging the batteries have probably been over filed or over charged Note If there is acid on the batteries wash the tops of the batteries with a solution of baking soda and water 2 tablespoons of baking soda to 1 quart of water BATTERY TESTING A battery problem is usually recognized by the machine operator as a decrease in the machine s running time This condition is usually caused by one or more dead cells
93. in the battery system that is one or more cells that is putting out less voltage than the other cells Note Always charge batteries before testing There are 2 ways to fnd a dead cell Use a hydrometer to check the specift gravity or state of charge of the flid in each cell A dead cell is one that reads 50 points or more lower than the other cells Use a volt meter to check the voltage of each battery with the scrub and drive motors running The battery with the dead cell will read 1 or 2 volts lower than the other batteries in the system If the batteries in the machine are more than 1 year old it s usually best to replace the whole set rather than replacing just one battery The chart below shows the approximate percent charged of an electric vehicle battery at various specift gravity values corrected to 80 F 26 7 C APPROXIMATE STATE OF CHARGE 1 265 Initial Charged Full Charge 100 1 265 75 1 225 50 1 190 25 1 155 Discharged 1 120 FORM NO 56043097 Adgressor BR 8505 850CS 9505 950CS 10505 1050CS 51 ELECTRICAL SYSTEM ACTUATOR DRIVE NUT ADJ USTMENT This manual section explains the steps for adjusting the drive nut housing assembly setting for the machine s two actuator motors Reference the chart below to find the IN amp OUT dimensional speciftation for the specift actuator motor needing adjustment Part Actuator Motor Drive Nut Housing Assy IN Drive Nut Housing A
94. ive apron Work in a well ventilated area Do not allow tools to touch more than one battery terminal at a time A CAUTION Electrical components in this machine can be severely damaged if the batteries are not installed and connected properly Batteries should be installed by Nilf amp k Advance or by a qualifed electrician 1 Remove the batteries from their shipping crate and carefully inspect them FIGURE 1 for cracks or other damage If damage is evident contact the carrier that delivered them or the battery manufacturer to fle a damage claim 2 Turm the Master Key Switch J OFF O and remove the key 3 Toaccessthe battery compartmenttip the operator s seatforward and setthe FRONT 36V prop rod Remove the battery cables from inside the battery compartment 4 Yourmachine comes fromthe factory with enough battery cables to install six 6 volt 305 395 Amp hour batteries Using two people and an appropriate lifting strap carefully III the batteries into the compartment tray exactly as shown on machine decal Figure 1 5 The terminals on the battery cables are marked for positive and for negative Install the battery cables as shown with the terminals marked T T the positive battery terminals and the terminals marked on the negative terminals Position the cables so the battery caps can be easily removed for battery service 6 Carefully tighten the nut in each battery terminal until th
95. ll must be reached to allow the scrub brush and solution system to reset function again The 36V battery pack must increase to a 37 6 volt minimum DESCRIPTION OF THE BATTERY CONDITION INDICATORS The Battery Condition Indicator K will give an indication of the state of charge of the batteries The battery condition indicator will retain the state of charge even if the key has been turned off The state of charge indication is reset to full charge when the batteries have been recharged It is also possible to choose between two different low voltage thresholds depending on whether maintenance free or standard batteries are being used have qualified service engineer perform this selection NOTE The following percentages are based on useable battery capacity not total battery capacity Therefore 100 discharge 80 of total battery capacity for standard wet cell batteries or 70 of total battery capacity for maintenance free batteries Explanation of Battery Indicator Lights and Voltage Ranges 36 volt of Battery Indicator Discharge Standard Alternate Green Full to 50 34 04 34 54 Green amp Yellow 5096 to 7596 33 0 34 0 34 0 34 5 Yellow 75 to 90 32 0 33 0 33 5 34 0 Yellow amp Red 90 to 95 31 5 32 0 33 0 33 5 Red 95 to 09 31 0 31 5 32 5 33 0 Flashing R ed C utoff 10096 31 0 32 5 Important Note See the Main Control Board Special Program Options manual section located in the Electrical Syste
96. lts per cell Selectthe proper cutout level based on the battery manufacturer s specifrations It is important to note that some maintenance free batteries including some gelled electrolyte cells are capable of being safely discharged down to 1 72 volts per cell To select between the two cutout levels 1 Turn the main power key switch to the off position Press and hold the scrub system off switch While holding the scrub system off switch turn the main power key switch to the on position Continue to hold the scrub system off switch until the scrub off indicator turns green Release the scrub off switch The status display will now show S or Pressing and releasing the scrub off switch will now select between the two options For the standard cutout level select S For the alternate cutout level select To save the new setting turn the main power key switch to the off position 8 new setting will be saved and will remain in effect until itis changed again Cc U CC W 64 FORM NO 56043097 Adgressor BR 8505 850 5 9505 950CS 10505 1050 5 ELECTRICAL SYSTEM SPECIAL PROGRAM OPTIONS CONTINUED Selection of Scrub Switch Operation and Scrub Pressure Limits FACTORY DEFAULT MODE 3 PRESSURE INCREASE DECREASE MODE LIMIT 23 MAXIMUM The scrub system switches on the Adgressor BR 8505 and 850CS be programmed to operate a number of different ways The operation
97. m and a forward annunciator The volume of the forward annunciator can be adjusted to one of ten settings 1 is the minimum setting and 9 is the maximum setting 0 is off To change the forward annunciator volume perform the following steps 1 Turn the main power key switch to the off position 2 Pressand hold the scrub system off and the horn switch 3 While holding both switches turn the main power key switch to the on position 4 Continue to hold both switches until the green battery status indicator is lit and the status display shows a number from 0 to 9 depending on the current volume setting Release the horn switch 6 Pressing and releasing the horn switch will now select the volume level The level will increment from 0 to 9 9 being the loudest To hear the forward annunciator volume select the forward direction by pressing lightly on the throttle 7 To save the new setting tum the main power key switch to the off position 8 The new setting will be saved and will remain in effect until it is changed again FORM NO 56043097 Adgressor BR 8505 850CS 9505 950CS 10505 1050CS 71 ELECTRICAL SYSTEM Drive Motor Breakdown KG 2 SS n 72 FORM NO 56043097 Adgressor BR 8505 850 5 9505 950CS 10505 1050 5 2 5 15 8 P Co XI mm CE SP Sza Ne NX e 2 27 FORM NO
98. m and follow the instructions for changing the low voltage cutout threshold CHARGING THE BATTERIES Charge the machine s battery pack each time the machine is used or when the Battery Condition Indicator is showing red fbshing indicator lights Note The machine also uses a special low voltage cutout that inhibits the scrub system see in this manual section the Description of the Battery Low Voltage Cutout Feature To Charge the Batteries Depress the Battery Disconnect 13 Open the Battery Compartment Cover 16 to provide proper ventilation Push the connector from the charger into the Battery Connector 22 Follow the instructions on the battery charger Check the flid level in all battery cells after charging the batteries Add distilled water if necessary to bring the flid level up to the bottom of the filer tubes A WARNING Do not fil the batteries before charging Only charge batteries in a well ventilated area Do not smoke while servicing the batteries Ru N mp 50 FORM 56043097 Adgressor BR 8505 850CS 9505 950 5 10505 1050 5 ELECTRICAL SYSTEM BATTERY MAINTENANCE Proper maintenance of electric vehicle batteries can greatly extend their life Well maintained batteries may last up to 3 years but failure after 1 year is common if maintenance has been poor There are 3 simple rules for good battery maintenance Maintain Proper Electrolyte Level Weekly Use dist
99. m the chassis mount Then pull the motor forward to remove it completely from the machine to their correct specifrations see the Electrical System for the Actuator Drive Nut Adjustment instructions After setting the correct actuator lift nut dimensions follow steps 1 7 in reverse order to re install Follow steps 1 5 in Squeegee Lift Actuator Motor Removal above Note The motor does not need to be dismounted from the frame Remove the lower squeegee cable hair pin E and mounting pin F to allow complete removal of lift cable Reassemble in reverse order and test for proper raise and lower functions FORM NO 56043097 Adgressor BR 8505 850CS 9505 950CS 10505 1050CS 47 SQUEEGEE SYSTEM SQUEEGEE MAINTENANCE If the squeegee leaves narrow streaks or water the blades may be dirty or damaged Remove the squeegee rinse it under warm water and inspect the blades Reverse or replace the blades if they are cut torn wavy or worn To Reverse or Replace the Rear Squeegee Wiping Blade 1 SeeFigure3 Raise the squeegee tool off the fbor then unsnap the Center Latch on the squeegee tool 2 Remove the Tension Straps 3 Slip the rear blade off the alignment pins 4 Thesqueegee blade has 4 working edges Turn the blade so a clean undamaged edge points toward the front of the machine Replace the blade if all 4 edges are nicked torn or worn to a large radius 5 Install the blade following
100. main controller to detect any system function failures error codes The system components covered are the vacuum motor and vacuum solenoid Detected error codes from the main controller are displayed on the hour meter LED display as they occur Note Reference the Main Control Board Troubleshooting G uide in the Electrical System of this manual for specift fault descriptions and service repair actions VACUUM RECOVERY SYSTEM SERVICE MAINTENANCE CHECKLIST Wheneverthere is a vacuum problem it s bestto check over the entire system Use the checklist below as a guide to thoroughly check the vacuum System Clean built up dirt from the inside of the squeegee tool Replace the squeegee blades if they are nicked or torn Inspect the hose between the squeegee tool and the recovery tank rinse any built up dirt from the hose Replace the hose if itis kinked or damaged Inspect and make sure the gaskets on the recovery tank covers are sealing and not damaged Inspect and clean the vacuum motor fbat cage and vacuum fiter agd LILILI Make sure thatthe recovery tank drain valve seals airtight MAINTENANCE OF VACUUM FILTER AND FLOAT CAGE See Figure 3 To inspect and clean the vacuum motor foam fiter just lift open the tethered Vac Duct Cover A Remove the fiter by pulling it out from the housing opening Clean the fiter by vacuum or washing it out in warm water Note The fiter must be completely dry before reinstalling To inspect the vacuum shut of
101. mit switches must be set or checked 8 SQUEEGEE LIFT CABLE REPLACEMENT FIGURE 2 1 SQUEEGEE SYSTEM Lower the squeegee tool to the fbor and then disconnect the battery pack by pushing in the emergency disconnect lever 13 This procedure is done to prevent the squeegee mount from automatically raising when the key is turned off Drain the recovery tank using the recovery tank drain hose Disconnect the squeegee hose from the squeegee tool and remove the tool from its mount Open the hinged recovery tank cover and grip the top inside edge of the tank then pull straight up to separate it from the solution tank seat platform Then guide the tank off the rear of the machine to fbor Important Service Note Support the bottom of the tank on its left corner to prevent crushing of the squeegee hose Don t pull the tank immediately away from the machine the vacuum motor wiring harness located on the lower left front corner must be disconnected to complete the separation See Figure 2 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 tlose 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 C securing the lift motor P in D and disassemble the motor fro
102. movement the pot s resistance value changes which generates a variable voltage signal 0 5 volts These control board voltage input signals are what energizes the Fwd amp Rev directional relays which selects the motor polarity and what also manages switches the battery voltage On and Off P WM that varies the motor speed KSI Key Switch Input 6 WM Pulse Width Modulation also called chopping is a technique that switches battery voltage to the motor ON and OFF very quickly thereby controlling the speed of the motor DRIVE MODE SELECTION OPERATION OVERVIEW The A1 speed Controller allows operation in two distinct modes mode 1 M1 amp mode 2 M2 Mode 1 M1 is the transport speed range and is automatically selected when the scrub system is OFF deck up This allows maximum variable vehicle speed operation Mode 2 M2 is the reduced slower scrub speed range and is automatically selected when the scrub mode is ON deck down The operator can over ride the reduced M2 scrub speed by pressing the dash panel Speed Select Switch L This allows the operator to scrub at the higher M1 transport speed Note the Indicator Light M will be green when the faster transport speed is selected THE SPEED SELECTOR CIRCUIT INPUT The main controller E1 will output a 30 31 volt approximately battery positive B signal from the speed limit terminal 4 2 Brn Wht wire This positive signal connection delivers the required Al speed control
103. n the cutoff level standard or alternate selected in the control unit The battery voltage ranges for the various indications are listed below Standard Alternate Green 34 004 34 504 Green amp Yellow 33 00 33 99 34 00 34 49 Yellow 32 00 32 99 33 50 33 99 Yellow amp Red 31 50 31 99 33 00 33 49 Red 31 00 31 49 32 50 32 99 Flashing Red C utoff lt 31 00 lt 32 50 NOTE Refer to service manual for selection of alternate cut off level Once the low voltage cutout level has been reached fshing red indicator the batteries must be FULLY recharged to reset the battery condition indicator The scrub system will not function until the indicator has been reset DESCRIPTION OF HOURMETER STATUS DISPLAY The single character display in the upper right corner of the control panel is primarily used as a display for the hourmeter function This display is also used to display the following information depending upon which mode the control is in Error codes Brush pressure adjustment setting for the scrub mode Display of control system default parameters Recovery tank FULL indicator NOTE Reference in the Electrical System manual section the Main Control Board Troubleshooting Guide and the Control Board Special Program Options sections These sections will explain the machine error code descriptions and scrub system controller default parameter changes FORM NO 56043097 Adgressor BR 8505 850CS 9505 950CS 10505 1050CS
104. n the recovery tank will still prevent water from entering the vacuum motor but the motor will not shut off Key Switch J Main power switch Speed Select Switch L This switch will allow the operator to selectthe transport speed limit while the scrub system is enabled thereby allowing scrubbing at a higher rate of speed This option can be disabled if desired See the programming section for details The transport and scrub speed limits can be programmed using a Curtis handheld programmer Refer to the Curtis Speed Control manual section for details Horn Switch N This switch will sound the horn as long as the switch is held The horn also functions as an automatic back up alarm when the throttle is moved to the reverse position The volume of the back up alarm is programmable It can also be programmed to provide an annunciation feature that will sound whenever the machine is in motion See the programming section for details Vacuum Switch 0 This switch is used to turn the vacuum system on or off When the vacuum is on the squeegee will lower unless the machine is in reverse and when the vacuum is off the squeegee will raise P ressing this switch will alternate between on and off The vacuum will only turn on when the throttle is moved from the neutral position It will remain on for 10 seconds after the throttle returns to neutral The vacuum also has an automatic shutoff feature that will turn the vacuum and scrub systems off if th
105. n turn observing the programmer Each input should show the correct state on the programmer 6 vehicle off the blocks and drive itin an open area It should have smooth acceleration and good top speed 56 FORM NO 56043097 Adgressor BR 8505 850CS 9505 950 5 10505 1050 5 ELECTRICAL SYSTEM PROGRAMMING VEHICLE SPEED CHANGES The maximum high speed M1 transport and maximum low speed M2 scrub can be changed electronically using the handheld programmer To change a parameter using the programmer press the PROGRAM key and scroll down the Program Menu until the desired parameter is the top line of the display Press the appropriate CHANGE VALUE key up or down until the desired number is reached The parameter is now set at the desired value All programming occurs in real time In other words the parameters can be changed while the vehicle is in operation The upper and lower limits of parameters are set at the factory Some parameters have dependencies on other parameters When the programmer is being used to adjust a parameter and a limit is reached the display will stop changing To see why the display has stopped changing press the MORE INFO key If the limit is related to another parameter that information will be displayed changing the value of the related parameter may allow the original parameter to be adjusted further Otherwise the display simply says Max Limit or Min Limit MAINTENANC
106. nections for reinstallation Then remove the 3 Screws AP and lift the motor out from the scrub deck 5 Reassemble in reverse order and adjust the belt tension to 1 2 9 16 inches 13 14 mm as shown in Figure 7 Note Install motors with wires pointing to the rear towards the plastic motor wiring standoffs Rotation from shaft end SCRUB BRUSH BELT REPLACEMENT CYLINDRICAL A WARNING Disconnect the battery pack by activating the emergency stop switch battery disconnect lever 13 before servicing 1 Figure 6 Remove Hairpin AM and swing open the scrub deck skirt assembly right or left side and remove the belt guard s AN 4 screws each 2 Service Tip The left and right side drive belts are notthe same lengths they must be ordered individually P N 56407465 left side amp P N 56407466 right side 3 Loosen the scrub brush belt tension hardware on the Belt Idler Pulley AO using a 5 8 wrench Pull the idler wheel away from the backside of the belt and roll the belt off both the motor and brush pulleys Then inspect for wear and replace as needed 4 Re nstallthe drive belt and tension the belt as shown in Figure 7 Then install the belt guard reconnect the battery pack and test the scrub system for proper operation SCRUB BRUSH SYSTEM MAINTENANCE FIGURE 7 The scrubbing system mus
107. ns 157L Plumbed into the fbw control valve hose outlet is a serviceable solution fiter to keep debris from entering the solenoid valve Also fited to the fbw control valve is a short fexible drain hose to empty the tank for system maintenance The solution system uses 2 valves to stop start and regulate the amount of solution dispensed onto the fbor Located underneath the right side of the solution tank two feet back from the front is mounted the electrical solution solenoid valve L1 Its function is to stop and start the solution fbw to the scrub brushes Located on the operator s steering column support is the solution lever tee handle The lever and connected cable move the fbw control valve arm that regulates solution fbw to meet a specift operator s scrub application See Figure 2 The electrical circuit that turns on energizes the solenoid coil L1 is activated through the E1 control panels switch buttons touch pad Note See the Know Your Machine section in this manual for a detailed explanation of the complete solution operation modes During normal machine scrubbing the solution system s Auto Mode is selected and works in conjunction with the A1 wheel drive speed controller and the foot pedal throttle This input activates the scrub system s outputs to turn on amp off the L1 solenoid valve The solution fbws to the scrub brushes any time the manual fbw control valve is open the scrub deck is lowered and the drive pedal is pushe
108. nt Service Tip Shown in the Electrical System is the actuator power cord adapter PN 56407502 and instructions for use This tool can be used to help position raise or lower the drive nut housing for ease in the actuator mounting pin installations An additional method to control the output to the pad brush lift actuator for installation and removal is to read the instructions in the Service Test Mode section for the special output control of the Scrub Pressure Increase Switch F See Electrical System for steps to enter the Service Test Mode FIGURE 5 FORM NO 56043097 Adgressor BR 8505 850CS 9505 950 5 10505 1050CS 33 SCRUB BRUSH SYSTEM SCRUB BRUSH MOTOR S REMOVAL CYLINDRICAL 1 See Figure 6 Remove the Hairpin AM from both the scrub deck skirt assemblies and swing them open 2 Nextremove the Belt Guards AN 4 screws per side With an operator in 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 removed A WARNING FIGURE 6 Disconnect the battery pack by activating the emergency stop switch battery disconnect lever 13 before servicing 3 Next loosen the scrub brush belt tension Hex screw in the center of the Belt Idler AO using a 5 8 wrench 4 Figure 8 Remove the wiring at both the Pos amp Neg brush motor terminal studs and note the correct wiring con
109. o remove the wheel motor spindle assembly Place wood blocking under both front frame legs to support machine when removing the wheel spindle assembly Service Note Be careful not to damage the threads and bearing surfaces when guiding the spindle shaft down through the frame opening 7 Inspectbearings and shaft seal and replace as needed 8 the steer spindle weldment you must remove the steer plate J with splash fender held by 4 L fathead socket screws use a 5mm hex wrench then separate the brake return spring and lay these removed parts to the side Next remove the 4 item M fbt head socket screws 55mm length then fnish removing the spindle weldment 9 See the Drive Tire Removal section for further disassembly steps 10 Re assemble in reverse order and tighten the spindle shaft nut to 20ft lbs 27 Nm to eliminate any bearing play 52 VN dd O FIGURE 4 5 Red Gm Yel BIk Wire Wire DRIVE TIRE REMOVAL 1 Follow the steps 1 8 in the Steer Spindle and Wheel Drive Motor Assembly Removal section 2 SeeFigure 5 Remove the socket head cap screw O use a 6mm hex key wrench that fastens the right side brake lever to the support mount N Then separate the brake lever from the support mount 3 Carefully separate tap off the motor end bell housing P from the main motor case Service Tip To remove the housing use a brass drift or piece of hard wood and strike the end bell edge
110. occur The scrub brushes will turn off and the scrub deck will raise to the up position solution fbw will be stopped e The fist time that this switch is pressed the vacuum squeegee system will NOT be turned off This is so that any remaining water may be picked up without having to turn the vacuum back on If this switch is pressed a second time pressed after the scrub system has been turned off the squeegee will raise and the vacuum will shut of after a 10 second delay e travel speed limit will return to the transport speed setting The scrub off indicator will be green if the scrub system is off and ready to be activated The indicator will be off if the scrub system has been activated If scrub system has been turned off and the scrub deck is not up yet or if the scrub deck is up and there is no weight on the seat the indicator will be red If there is a fault in the scrub system this indicator will fash red Light Scrub Pressure Select Switch If the scrub system is off pressing this switch will cause the following to occur The scrub system will be enabled with the scrub pressure set to the last used light pressure setting and the scrub deck will be lowered The vacuum system will be enabled and the squeegee will be lowered The solution system will be enabled The travel speed will be limited to the scrub speed setting As soon as the throttle is moved from the neutral position the scrub brushes will start
111. of the scrub mode switches is described in the user manual Following is a description of how to program the control for each mode of operation Operation mode 0 Two fied pressure settings Operation mode 1 Adjustable pressure increase decrease mode nine pressure settings Advenger mode Operation mode 2 Adjustable pressure light heavy pressure modes nine pressure settings Operation mode 3 Adjustable pressure increase decrease mode three pressure settings full pressure range Operation mode 4 Adjustable pressure increase decrease mode three pressure settings low pressure range Operation mode 5 Adjustable pressure increase decrease mode three pressure settings high pressure range See the chart below for the equivalent pressure settings for modes 3 4 and 5 pole ud ec En UaFentPressure Settings 2 1 Program Option 3 p poo E E I ee NOTE There are three control panel switches associated with the scrub system The left most switch is the scrub system off switch The center Switch is mainly referred to as the scrub pressure decrease switch Depending on the scrub switch operating mode this switch may also be referred to as the light scrub pressure select switch The right most switch is mainly referred to as the scrub pressure increase switch Depending on the scrub switch operating mode this switch may also be referred to as the heavy scrub pressure select switch Pressure Increase Decrease
112. off The controller also manages the other supportive systems such as the squeegee lift solution on off and vacuum motor Note See the Know Your Machine system in this manual for a complete explanation of the machine s operation The secondary function ofthe main control is to detect any system failures and display an error code on the hour meter display or store itin the main control board s recall memory mode The error code s are used to help the serviceperson determine the fault and to quickly guide in repairing a specift system malfunction Note See the Troubleshooting Guide for further information An additional special feature of the main control board is to change program settings for a set of specift machine functions See the Main Control Board Special Program Options section in this manual for further information TROUBLESHOOTING GUIDE Any error codes detected by main control board will be displayed on the hour meter LED display as they occur If more than one error exists the display will sequence through the error codes at one second intervals The error display will show on the hour meter as the letter E followed by a two digit code EX E03 would be a drive system fault When troubleshooting any Fault Description noted with a double asterisk follow the instructions for temporarily disabling the control boards special fault detection program See the Main Control Board Special Program Options section in this manual MAIN CONT
113. oller closes an internal coil driver and outputs a NEG 36V signal from 7 wire color Red Blk to the 61 4 10 connection This input signal causes the controller to output a NEG 36V signal from J 2 1 wire Wht Red that energizes the brush motor solenoid coil pulling in the high current contactor making the brush motor s turn on run Scrub Brush Actuator Lift Motor Function The control board outputs activate raise and lower the scrub deck for installing removing and controlling the scrub brushes selected currentload The negative brush motor wire is specially designed so that it has a known specifed resistance value As brush motor current passes through the negative wire that is in effect a low value resistor a small voltage is measured across it which is proportional to the motor current This current measurement circuit shunt is made up of two small diameter sense wires 4 12 Yel Vio amp 4 8 and are the inputs used by the control board to calculate the exact current level of the scrub brush motor s Any temperature change to the large Neg motor wire affects its resistance so the circuit temperature is sensed by a thermistor built into the control board This allows the controller to provide a level of error correction for the temperature resistance changes When the controller senses a current draw out of the desired range it automatically turns on the M1 actuator motor to raise or lower the
114. one touch operation in mind For single pass scrubbing the user can simply depress one switch and all systems on the machine will be ready to go For most single pass scrubbing operations the operator should only need to use the top three switches on the control panel These are the Scrub System Off Scrub Pressure Decrease and Scrub Pressure Increase switches The scrub system switches can be programmed to operate three different ways The frst method of operation described below is the factory default setting See the programming section for details Pressure Increase Decrease Mode Factory Default Scrub Off Switch B Pressing this switch when the unitis in a scrub mode will cause the following to occur The scrub brushes will turn off and the scrub deck will raise to the up position solution fbw will be stopped e The fist time that this switch is pressed the vacuum squeegee system will NOT be turned off This is so that any remaining water may be picked up without having to turn the vacuum back on If this switch is pressed a second time pressed after the scrub system has been turned off the squeegee will raise and the vacuum will shut of after a 10 second delay e travel speed limit will return to the transport speed setting The scrub off indicator will be green if the scrub system is off and ready to be activated The indicator will be off if the scrub system has been activated If scrub system has been
115. pages 7 Toexitthis mode turn the main power on off key switch to the off position CONTROL PANEL A Scrub OFF Indicator Battery Condition Red Indicator B Scrub OFF Switch Speed Select Switch C Scrub Pressure Decrease Indicator Speed Select Indicator D Scrub Pressure Decrease Switch Horn Switch E Scrub Pressure Increase Indicator F Scrub Pressure Increase Switch G Scrub Pressure Hourmeter Display H I Vacuum Switch Vacuum System Indicator Solution System Indicator Solution Switch Battery Condition Yellow Indicator Battery Condition Green Indicator Wand Switch Indicator Wand Switch Key Switch 2 60 FORM NO 56043097 Adgressor BR 8505 850CS 9505 950 5 10505 1050 5 ELECTRICAL SYSTEM SERVICE TEST MODE CONTINUED Input Indicators See Figure 5 for button locations Note the seat switch must be closed for any of the following three indicators to be lit Battery status red indicator K Speed control forward signal This indicator will be lit if the forward signal from the speed control is active Battery status yellow indicator S Speed control forward reverse signal This indicator will be lit if the forward reverse signal from the speed control is active Battery status green indicator T Speed control
116. panel wand indicator light If a programmer is available connect itto the programmer plug in port 2 Siton the seat and turn 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 using a programmer put it into the diagnostic mode by pressing the DIAGNOSTICS key The display should indicate No Faults Found Note Before pressing the diagnostics key wait until model screen appears if the throttle is activated prior to this screen appearing the controller will shut down If there is a problem the LED will fash a diagnostic code and the programmer will display a diagnostic message If you are conducting the checkout without a programmer look up the LED diagnostic code in the DIAGNOSTICS section of this chapter Table 1 When the problem has been corrected it may be necessary to cycle the key or seat switch to clear the fault code 4 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 referto the DIAGNOSTICS section of this chapter Table 1 5 Ifyou are using a programmer put it into the test mode by pressing the TEST key Scroll down to observe the status of the forward reverse and brake switch Cycle each switch i
117. peed limit will return to the transport speed setting The scrub off indicator will be green if the scrub system is off and ready to be activated The indicator will be off if the scrub system has been activated If scrub system has been turned off and the scrub deck is not up yet or if the scrub deck is up and there is no weight on the seat the indicator will be red If there is a fault in the scrub system this indicator will fbsh red Light Scrub Pressure Select Switch If the scrub system is off pressing this switch will cause the following to occur The scrub system will be enabled with the scrub pressure set to the light setting and the scrub deck will be lowered The vacuum system will be enabled and the squeegee will be lowered The solution system will be enabled The travel speed will be limited to the scrub speed setting As soon as the throttle is moved from the neutral position the scrub brushes will start turning and the vacuum will turn on If the direction is forward the solution fbw will start If the direction is reverse the squeegee will raise and the solution fbw will be stopped The light scrub pressure indicator will be green if the scrub system is on and the light pressure has been selected The indicator will be off if the scrub system is off The indicator will be yellow if the scrub system has been enabled at the light pressure setting but the throttle is in neutral If the heavy scrub pressure setting is sele
118. perator will be able to select using the heavy scrub pressure select switch The scrub pressure increase indicator will now be illuminated Use the pressure increase switch to set the desired pressure 11 Press the scrub system off switch to save this setting 12 The status display will now show to indicate that the procedure is done 13 The new setting will be saved and will remain in effect until itis changed again Ul gt WN o gt WN SCRUB PRESSURE PA amp CURRENT LOAD AM PS SPECIFICATIONS TABLE 2 112132214 1516 77 8 9 28200 32200 8505 Disc 1 1 2 2820C 3220C BR850CS 3520 3820 All Cyl 2 3 4 HP 3520D 3820D Disc 3 6 HP Values given are approximate 66 FORM NO 56043097 Adgressor BR 8505 850 5 9505 950C S 10505 1050 5 ELECTRICAL SYSTEM SPECIAL PROGRAM OPTIONS CONTINUED Restoring the scrub modes and pressures to factory default settings FACTORY DEFAULT MODE 23 PRESSURE INCREASE DECREASE MODE LIMIT 23 MAXIMUM If itis desired to restore the scrub switch operating mode and pressure limit to the default setting perform the following steps 1 Turn the main power key switch to the off position Press and hold the scrub pressure increase switch While holding the pressure increase switch turn the main power key switch to the on position
119. period The display will show E followed by a brief blank period The display will show 1 followed by a brief blank period The display will show 8 followed by a long blank period above sequence will repeat 8 pause the display press and hold the solution switch 9 To clear the stored codes press and release the scrub system off switch The display will now show Go to step 11 10 Ifitis desired to save the codes go to step 11 11 To exit the error code recall mode turn the main power key switch to the off position YUH US WP Turning Fault Detection On or Off FACTORY DEFAULT ON Normally the main control unit will perform checks of the electrical system during operation If a fault occurs in a particular system that system and possibly others will be shut down This can make troubleshooting the system difftult This option will allow service personnel to disable some of the fault detection checks to facilitate troubleshooting This will not disable the over current protection on any of the systems To turn the fault checking on or off 1 Turn the main power key switch to the off position Press and hold the scrub system off switch and the solution switch While holding both switches turn the main power key switch to the on position Continue to hold both switches until the solution indicator is yellow Release both switches The status display will now indicate or d Pressing and releasing the
120. r replace S hort Circuit defnition No accessory wiring 1 Loss of battery pos output to all system contactors brush solution solenoid and vacuum and system accessories headlight warning beacon solution pump 2 Check controller accessory terminal output J 2 8 Wht Brn wire voltage should be 36V if OV controller failure replace A short circuit is a parallel path of very low resistance often caused accidentally With low resistance there is an excessive amount of current The excessive current will either meltthe wires or open a fusible link FORM NO 56043097 Adgressor BR 8505 850CS 9505 950CS 10505 1050CS 59 ELECTRICAL SYSTEM SERVICE TEST MODE The purpose of the service test mode program is to assist the service repairperson with numerous quick short cut troubleshooting procedures These test instructions allow for the separate control of each individual electrical system component independent of the normal machine operator inputs To enter the service test mode perform the following steps 1 Turn the main power on off key switch to the off position 2 Press and hold the Wand Switch I 3 While holding the wand switch turn the main power on off key switch to the on position 4 Continue to hold the wand switch until the status display indicates t for test mode 5 Release the wand switch 6 Thefunction of each switch and indicator is described in the following
121. r code sequence until the fault is corrected See Table 1 for a description of the fault indications Service Note Instructions on how to read the error code status light Example OO 0 two light fBshes a short pause one light fash a long pause and the code will be repeated This indicates a fault code 2 1 FIGURE 6 OG IC AZ DN 2 Ce AIS un Ce KOJ Diagnostics Method B Uses the optional handheld Curtis programmer PROGRAMMER DIAGNOSTICS With a programmer diagnostics and troubleshooting is more direct than with the LED alone The programmer presents complete diagnostic information in plain language no codes to decipher Faults are displayed in the Diagnostic Menu and the status of the controller inputs outputs is displayed in the Test Menu The following 4 step process is generally used for diagnosing and troubleshooting an inoperative vehicle 1 visually inspect the vehicle for obvious problems 2 diagnose the problem using the programmer 3 test the circuitry with the programmer and 4 correct the problem Repeat the last three steps as necessary until the vehicle is operational Example A vehicle that does not operate in forward is brought in for repair 1 Examine the vehicle and its wiring for any obvious problems such as broken wires or loose connections 2 Connect the programmer put itin diagnostic mode and re
122. r device When working around any battery powered vehicle proper safety precautions should be taken These include but are not limited to proper training wearing eye protection avoiding loose clothing and jewelry and using insulated wrenches After installing a controller and before operating the vehicle carefully complete the following checkout procedure If you fnd a problem during the checkout refer to the DIAGNOSTICS section of this chapter for further information The installation checkout can be conducted with or without the handheld programmer The checkout procedure is easier with a programmer otherwise observe the Status LED for codes located on operator panel wand indicator light The part number of the handheld programmer is 56409441 NOTE If you have a programmer with a serial number before 2100 you will need to update your programmer A free upgrade kit is available order part number 56409822 Also a different quad 4 pin programmer cable 56409823 is needed to link the programmer to the controller plug in port A WARNING Putthe vehicle up on blocks to getthe 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 is in neutral Do not stand or allow anyone else to stand directly in front of or behind the vehicle during the tests 1 Remove electrical panel to access controller then observe LED status light on touch pad operator
123. resent for 5 sec 1 Misadjusted throttle 2 Broken throttle pot 3 Broken throttle mechanism 00 0000 Speed limit pot fault 1 Speed limit pot wiper wire broken 2 Broken speed limit pot 000 000 Throttle fault 1 Throttle input wire open 2 Throttle input wire shorted to B or B 3 Throttle pot defective 4 Wrong throttle type selected Low battery voltage 1 Battery voltage lt 16 volts 24V models 2 Corroded or loose battery terminal 3 Loose controller terminal 0000 00 Overvoltage 1 Battery voltage gt 36 volts 24V models 2 Vehicle operating with charger attached 0000 000 Over Under temp cutback 1 Temperature gt 95 C 203 F or lt 25 C 13 F 2 Excessive load on vehicle 3 Improper mounting of controller 4 Operation in extreme environments XNOTE A KSI key switch input system problem is a specift 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 FORM NO 56043097 Adgressor BR 8505 850CS 9505 950CS 10505 1050CS 55 ELECTRICAL SYSTEM INSTALLATION CHECKOUT FOR THE CURTIS SPEED CONTROLLER N SAFETY The 1237 controller is inherently a high powe
124. rub pressure increase switch will now select between the four settings Select 8 if the machine is equipped with a 28 or 32 disc type scrub deck or any size cylindrical scrub deck Select L if the deck is equipped with a 35 or 38 disc type scrub deck A CAUTION Improperly setting this parameter can result in serious damage to the machine If this is set for motors not installed on the machine the motors may be overloaded which can cause overheating and permanent damage to the motors It could also create a fre hazard C FORM NO 56043097 Adgressor BR 8505 850CS 9505 950CS 10505 1050CS 69 ELECTRICAL SYSTEM SPECIAL PROGRAM OPTIONS CONTINUED Single or Dual Vacuum Motor Selection FACTORY DEFAULT 1 SINGLE VACUUM MOTOR The Adgressor BR 8505 and 850CS comes with a standard single vacuum motor A dual vacuum motor option is available The control unit must be programmed for the number of vacuum motors installed to provide the proper overload protection To program the control for the number of vacuum motors perform the following steps Turn the main power key switch to the off position Press and hold the scrub system off and vacuum switches While holding both switches turn the main power key switch to the on position Continue to hold both switches until the vacuum indicator is yellow Release both switches The status display will now indicate 1 or 2 Pressing and rel
125. scrub deck This process is on going in maintaining the operator s selected scrub motor current load PA to sustain the desired brush working pressure Low Voltage Cut Out Function The purpose of the low voltage cutout function is to help prolong battery life The main control board E1 is programmed to monitor the machine s battery pack voltage to prevent over discharging of the batteries The brush motors brush lift actuator and solution solenoid valve will turn OFF automatically and cease to function when the batteries are discharged to the selected cutout level The cutout level is adjustable between two settings The standard battery type wet cell is 31 5 volts 1 75 volts per cell and maintenance free battery gel is 33 volts 1 83 volts per cell Note See the Electrical System for instruction in selecting setting the two different thresholds Thermistor A special semiconductor resistor whose resistance value varies with temperature Note See the Know Your Machine section in this manual for a complete explanation for all scrub system operational modes 28 FORM NO 56043097 Adgressor BR 8505 850CS 9505 950 5 10505 1050 5 On all models disc amp cylindrical the scrub sys
126. se off from its valve body barbed fiting 5 Remove the two Hex Screws G that secure the valve to the solution tank Then pull the valve body towards the rear separating it from the solution inlet Hose H completing the part removal 40 FORM NO 56043097 Adgressor BR 8505 850 5 9505 950 5 10505 1050 5 SOLUTION SYSTEM SOLENOID VALVE DISASSEMBLY AND CLEANING 1 Remove the solenoid valve See the Solenoid Valve Removal section for instructions 2 See Figure 3 Remove the 4 I Screws and disassemble the valve be careful not to lose any internal parts 3 Thoroughly wash dirt from block J and diaphragm K 4 Afterreassembling testthe solenoid valve for proper operation FIGURE 3 DISC MACHINE SOLUTION PLUMBING DETAIL Top of Hose L uses a 109 diameter hole in the center This prevents unbalanced solution fbw FIGURE 4 pe p gt e FRONT B FORM NO 56043097 Adgressor BR 8505 850CS 9505 950CS 10505 1050CS 41 RECOVERY SYSTEM FUNCTIONAL OVERVIEW Vacuum Recovery System General Dirt and water are lifted off the fbor into the recovery tank by airfbw created by a 3 Stage 36V vacuum motor The wastewater and air enter the vacuum system at the squeegee tool through small openings notches located in the front squeegee blade The small openings are the entrance points for the water and air and help speed up the airfbw producing the
127. sed Steady Green Vacuum output is on and there is normal vacuum motor current sensed Brief On Green Flash Vacuum motor output is off and vacuum motor current is being sensed abnormal condition Brief Off Green Flash Vacuum motor output is on and vacuum motor current is not being sensed abnormal condition Flashing Red Vacuum motor overload has occurred 62 FORM NO 56043097 Adgressor BR 8505 850 5 9505 950CS 10505 1050 5 ELECTRICAL SYSTEM SERVICE TEST MODE CONTINUED Solution Switch R This switch is used to toggle the state ofthe solution solenoid Pressing and releasing this switch will alternately turn the solution solenoid on and off The indicator Q provides the following status information Off Solenoid output is off Green Solenoid output is on Flashing Red Solution solenoid contactor coil overload has occurred Horn Switch N This switch is used to momentarily activate either the scrub deck lift actuator or the squeegee lift actuator See the descriptions above for more details Fast Slow Switch L This switch is used to toggle the state of the multimode outputto the speed control This is used to select which speed limitthe speed control uses Pressing and releasing this switch will alternately turn the multimode output on and off The indicator M provides the following status information Steady Green Speed control mode 1 is selected transport speed Brief
128. solution switch will now select between E for enabled or d for disabled Enabled means that the fault checking is turned on disabled means that the fault checking is turned off To save the new setting turn the main power key switch to the off position 8 The new setting will be saved and will remain in effect until it is changed again C CC WwW 68 FORM NO 56043097 Adgressor BR 8505 850 5 9505 950CS 10505 1050 5 ELECTRICAL SYSTEM SPECIAL PROGRAM OPTIONS CONTINUED Turning the High Speed Scrub Option On or Off FACTORY DEFAULT ON The control system on the Adgressor BR 850S and 850CS are programmed to limit the maximum speed while scrubbing to a value less than that allowed for driving when not scrubbing The speed select switch on the control panel will override this speed limit feature and allow scrubbing at maximum speed If itis desired to prevent scrubbing at this faster speed the speed select feature can be turned off To turn this feature on or off perform the following steps Turn the main power key switch to the off position Press and hold the speed select switch While holding the speed select switch turn the main power key switch to the on position Continue to hold the speed select switch until the speed select indicator is green Release the speed select switch The status display will now indicate E or d Pressing and releasing the speed select switch will now select bet
129. ssy OUT 56393303 Scrub Brush Lift disc amp cyl 3 8 9mm 3 5 8 92mm 56397230 Squeegee Lift 3 32 2mm 3 3 8 86mm The Drive Nut Housing Assy IN OUT Position dimensions are measured when completely assembled Reference points are the gear box step to the edge of the Steel Tube A as shown in Figure 3 or the edge of the plastic Spring Housing Assembly as shown in Figure 4 F lush even to end of step General Instructions for All Actuator Motors F IG U R E 2 1 Figure 2 This shows the special actuator power cord adapter PN 56407502 that is needed to connect the machine s battery pack and actuator motor for setting the drive nut limit settings 2 Open the machine battery compartment and disconnect the battery connector The battery pack is needed to power the lift actuator motor to properly set the IN amp OUT limit switches 3 Connect the actuator motor to be tested to the power cord adapter end Then connect the alligator clips from the cord adapter red clip to the positive and black to negative to battery connector or battery posts The rocker switch is used to change the motor rotation in setting the correct drive nut dimension Instructions for Squeegee Lift Actuator Drive Nut Adjustment 1 See Figure 3 Hold onto the Actuator Drive Nut A and press the rocker switch to run the drive motor and retract the nut towards the motor housing it s IN limit Measure the position of the drive nut
130. suction to lift the wastewater off ofthe fbor The air and wastewater move through the squeegee hose at high speed until it reaches the recovery tank There the air slows down because of the increased volume large Size oftank With the decreased air speed the heavier water falls to the bottom of the recovery tank Then atthe same time the airfbw continues through the tank shutoff fbat vacuum motor and is exhausted out of the vacuum exhaust hose No wastewater ever actually moves through the vacuum motor just working air The vacuum system uses a shutoff fbat to prevent the tank from being overfiled and stops any water from being sucked into the vacuum motor The Adgressors BR 8505 amp 8505 are equipped with a feature that will automatically shut off the vacuum and scrub systems and display FULL on the hourmeter status display if the recovery tank becomes filed FIGURE 1 Recovery Tank Cover d Cover Gasket Squeegee Hose Drain Hose 42 FORM NO 56043097 Adgressor BR 8505 850CS 9505 950 5 1050S 1050CS RECOVERY SYSTEM VACUUM MOTOR CIRCUIT OVERVIEW Auto Mode See Figure 2 Positive battery circuit inputs and outputs Inputs A Solenoid circuit control coil voltage input to control board E1 connector 2 5 6 amp 7 wire colors Brn Yel Note This input voltage supplies all the machine s accessory and solenoid coil circuits solution vacuum
131. t be serviced at regular intervals to maintain 1 2 to 9 16 12 14mm good scrubbing performance Follow the maintenance steps listed below 1 Rinse clean built up debris from the debris hopper drain holes daily 2 Clean drain holes in the solution delivery trough on top of the scrub deck weekly Oll 3 Clean built up dirt from the inside of the scrub brush housing weekly 2 ow 4 Remove any string wrapped around the scrub brush drive hub and idler O hub weekly A 5 Remove both the scrub brushes and rotate turn end for end weekly See Scrub Brush Removal and Installation Cyl section 9 O 6 Inspectthe scrub brush bristles for wear the brushes should be replaced when the bristle length is 1 inch 26 mm or less monthly 6 9 34 FORM NO 56043097 Adgressor BR 8505 850C5 9505 950C5 10505 1050 5 SCRUB BRUSH SYSTEM SCRUB BRUSH REMOVAL AND INSTALLATION CYLINDRICAL 1 Make sure the key switch is off and FIGURE 8 disconnect the battery pack before servicing 2 To access the brushes swing open both the side skirt assemblies See Figure 6 Note The skirts are held in place by Hairpins AM on each side remove the pins and swing the skirt assemblies out of Left M otor Right M otor Brush FRONT the way H 3 Loosen the black knobs one on each side that secure the removable bearing 118 idler support Plate AQ
132. tem s major electrical components are monitored by the main controller E1 to detect any system function failures error codes The system components covered are the brush motor s M7 amp M8 brush solenoid K1 and brush lift actuator motor M1 Detected error codes from the main controller are displayed on the hour meter LED display G as they occur Note Reference the Main Control Board Troubleshooting Guide in the Electrical System of this manual for specift fault descriptions and service repair actions x 2 5 4 59 e 85 8 lt 2 a 8 ui NIV 8 9 2 X ETS 8 8 g SCOWLLINW LI Nid Wid J Wid amp M90 18 a E OS 5 8 LI 5 18 IS SI SQ1ES iz YIMOd VI Nid 8 E C z ESG Z 2 909 2 Nid t n T 2 8 s 7909 9 M 2 2 2 e 5 m amp 09 mg lt l 52 XI So gt 5 B z gt 23 xix g 52 5 8 8 286 E es Be XO S 8 lz J 8 3 4 5 d d 2 8 x gt gt 2 gt BA 6 9 3 gr 09VM904 5 gbi ory Mawes tah Ms 1 36 8 amp eat 8 z _ OITA a D amp rot gg SL MANAO z 5 5 49 25 O8 2 8 zi5 IAWN 8 o 1 039 THWN36 Nua Ore Ms ADA usnug LE 9 58 gg T
133. the control senses current fbw through the actuator It will fash green if no actuator current fbw is sensed actuator at limit open circuit open output driver The horn switch has no effect in this state When the output is in state 3 the actuator output is turned off The scrub pressure increase indicator should be off If the indicator is fashing green this indicates that the control is sensing current fbw through the actuator shorted output driver control error If the scrub pressure increase switch was the last switch pressed itis possible to momentarily activate the actuator output using the horn switch This can be used to jog the actuator to allow precise positioning of the actuator NOTE the actuator can only move in this situation if it is not at its down limit When the output is in state 4 the actuator output is turned on The scrub pressure increase indicator should be green or flashing green The indicator will be a steady green if the control senses current fbw through the actuator It will fash green if no actuator current fbw is sensed actuator at limit open circuit open output driver The horn switch has no effect in this state Vacuum Switch 0 This switch is used to toggle the state of the vacuum motor Pressing and releasing this switch will alternately turn the vacuum motor on and off The indicator P provides the following status information Off Vacuum motor output is off and there is no vacuum motor current sen
134. the steps in reverse order and adjust the squeegee tilt To Reverse or Replace the Front Squeegee Blade 1 Raisethe squeegee tool off the fbor then loosen the 2 Thumb Nuts I on top of the squeegee and remove the squeegee tool from the mount 2 Remove both rear Tension Straps fist 3 Remove all the wing nuts that hold the front blade in place then remove tension strap and blade 4 squeegee blade has 4 working edges Turn the blade so a clean undamaged edge points toward the front of the machine Replace the blade if all 4 edges are nicked torn or worn to a large radius 5 Install the blade following the steps in reverse order and adjust the squeegee tilt SQUEEGEE ADJ USTMENT There is just one squeegee tool adjustment possible angle Adjusting the Squeegee Angle Adjust the squeegee angle whenever a blade is reversed or replaced or if the squeegee is not wiping the fbor dry 1 Park the machine on a fht even surface and lower the squeegee Then drive the A machine forward enough to have the squeegee blades fold over to the rear 2 Loosen the Lock Wing Nut J hand tightened This secures the squeegee mount angle from easily vibrating out of adjustment 3 Turn the Adjustment Knob to tilt the tool forward or backwards until the rear squeegee wiping blade touches the fbor evenly across its entire width 4 Re tighten by hand the Lock Wing Nut J FIGURE 3 48 FORM NO 5604
135. tion of the boards processing logic functions Battery ground supply input for all the control boards negative output coil circuits Its E1 terminal connection is 2 pin 5 wire Outputs A battery ground output from the E1 control board terminal connector 2 pin 3 wire Vio Blk This controlled output turns on and off the 11 solenoid coil that stops and starts the solution fbw through the valve body This occurs every time the throttle is moved off its neutral setting into forward FIGURE 2 RED pri BLK Battery 36 Vdc RED V BRN YEL co BRN 1422 ORN ORN Sw Spst Sw Seal Key BLU BLK Interface SPEED LIMIT 2 9 PIN 4 SPEED LIMIT Evan PIN 2 POT WIPER POT HI J4 3_ VIO 1 3 YEL PIN 3 POT LO LC R 1 POT 5K OHM FORWARD 4 4 PIN15 KSI N e a z WHT YEL WHT BRN 2 8 acc J2 3 SOLUTION E1 Control Board A1 Speed Controller WHT BRN VIO BLK Valve Solenoid BLK FORM NO 56043097 Adgressor BR 8505 850CS 9505 950 5 10505 1050CS 39 SOLUTION SYSTEM TROUBLESHOOTING GUIDE Problem Possible Cause Inadequate or no solution fbw No solution in the tank Main solution fbw control valve lever is in the off position Clogged solution fiter valves hoses amp solution delivery trough cyl Defective solution solenoid valve L1 Solution system fault in the main controller E 1
136. tuator motor is not run while it is disconnected from the deck or chassis mounts This precaution will prevent the actuator drive nut from being misadjusted moved out of its set specifration To install a scrub deck follow the above steps in reverse order FIGURE 2 CEN p Ss a Set stop bolt so that brush bi gt gt hubs are approximately 1 above the floor disc FRONT Slide deck assembly out from under right side of machine 30 FORM NO 56043097 Adgressor BR 8505 850 5 9505 950CS 10505 1050 5 SCRUB BRUSH MOTOR ASSEMBLY REMOVAL DISC Service Note The items listed shaft dust covers keys output shafts shaft mounting hardware and gear box mounting brackets must be salvaged saved and reused when replacing the complete motor and gear box assembly As shown in Figure 3 Follow steps 1 7 of the Scrub Brush Deck Removal Disc amp Cylindrical section See Figure 3 Remove the scrub brushes from the Brush Holders F Remove the 3 Screws G from each thermoid disc flexible coupler and remove the Brush Holders from both I Hubs Note Use a 1 2 3 4 13mm socket wrench to remove Screws G Remove all 8 hardware items J amp K thatsecure the gear case Mount Brackets L to the scrub deck plate Then remove the complete Motor Assembly M from the scrub deck by pulling it straight up Remove the 8 hex Screws P that secure the Mounting Brack
137. tuator wiring open in wiring or defective actuator motor Repair or replace 2 Check controller output voltage should be 36V if 0V controller failure replace Squeegee lift actuator short Check for binding or frozen squeegee lift linkage and excessive weight on squeegee 2 Check for short circuit in wiring or actuator motor Repair or replace Scrub motor circuit open Brush solenoid coil resistance 120 Ohms 10 1 Check for open in brush motor wiring or defective motor 2 Check the negative supply cable at the brush motor for a wiring problem or improper modifrations this is a special cable and must be replaced with the original OEM 3 Replace defective brush motor contactor 4 Check if brushes are installed Scrub motor short Same as E06 Vacuum motor circuit open Vac solenoid coil resistance 120 Ohms 10 1 Check for disconnected vacuum motor wiring open in wiring defective vacuum motor and vac contactor failure Repair or replace 2 Check controller output voltage should be 36V if OV controller failure replace Vacuum motor short Same as E07 Solution solenoid circuit open 1 Check for disconnected solenoid wiring plug open in wiring or defective solenoid Repair or replace 2 Check controller output voltage should be 36V if OV controller failure replace Coil solution solenoid short 1 Check for a short circuit in wiring or solenoid coil Repair o
138. vance Check vacuum motor carbon brushes Qty 2 once a year or after 300 operating hours Check brush motor carbon brushes Qty 4 once a year or after 500 operating hours Note if the vacuum or brush motor brushes are 9 5mm 3 8 inches or shorter replace them Check wheel drive motor carbon brushes every 500 operating hours The original length of each brush is 20mm 25 32 inches Replace when shorter than 9 5 mm 3 8 inches to obtain the same motor efftiency as a new brush A WARNING Tum the key switch off set the parking brake and disconnect the battery before servicing the machine LUBRICATING THE MACHINE Once a month pump a small amount of grease into each grease fiting on the machine until grease seeps out around the bearings Grease fiting locations are Squeegee Wheel Axle qty 2 Steering Wheel Shaft Universal joint Once a month apply light machine oil to lubricate the Steering Chain e General Pivot Points for the Squeegee Brush Linkage and Side Skirts Squeegee mount angle adjustment knob threads BATTERIES AND CHARGERS Attention See the electrical system manual section for battery installation and charger system requirements WHEEL DRIVE MOTOR GREASE SPECIFICATION If drive motor gear housing grease replacement is needed when repair services are performed Example inspection shows grease contamination Clean gear sets and housing and re pack Use a multi purpose high melting point Lithium based grease
139. ween E for enabled or d for disabled Enabled means that the high speed scrub feature is turned on disabled means that the high speed scrub feature is turned off 7 To save the new setting turn the main power key switch to the off position 8 new setting will be saved and will remain in effect until itis changed again amp WN IM Scrub Deck Motor Type Selection FACTORY DEFAULT MODE S SCRUBBER SIZE 8 IF 28 OR 32 DISC OR ANY CYLINDRICAL DECK L IF 35 OR 38 DECK The Adgressor BR 8505 and 850CS can be equipped with numerous scrub deck options This function confgures the control unit current settings for each of the scrub deck types Improper setting of the motor type may result in motor damage due to overloading To select the proper scrub deck motor type 1 Turn the main power key switch to the off position Press and hold the scrub system off and scrub pressure increase switches While holding both switches turn the main power key switch to the on position Continue to hold both switches until the scrub pressure increase indicator is yellow Release both switches The status display will now indicate S or E Pressing and releasing the scrub pressure increase switch will now select between S for scrubber and E for extractor Make sure that S is displayed Press the scrub system off switch to save this setting 8 status display will now display 4 6 8 or L Pressing the sc

Adgressor™ BR 850S, 850CS, 950S, 950CS BR 1050S

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Adgressor&trade; BR 850S, 850CS, 950S, 950CS BR 1050S

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Adgressor™ BR 850S, 850CS, 950S, 950CS BR 1050S