Advance Advenger 2800ST 3400ST BR755 BR855 Operators Manual

Advance Advenger 2800ST 3400ST BR755 BR855 Operators Manual
Advenger™
2800ST, 3400ST
BR 755, BR 855
Quick Start Service Manual
Advance MODELS:
56601000, 56601001, 56601002,
56601003,56601004, 56601005, 56601006,
56601007, 56601008, 56601009, 56601010,
56601011, 56601012, 56601013, 56601019,
56601020, 56601891, 56601892
Nilfisk MODELS: 56601014, 56601015,
56601016
English
9/09 Revised 11/13 FORM NO. 56043121
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
Contents
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Quick Start Service Manual Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General Machine Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Parts and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cautions and Warnings Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Related Reference Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Diagnostic and Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Transporting The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Towing the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Jacking Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Emergency Stop Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Know Your Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Machine Front RH View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Machine Rear LH View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CONTROL PANEL (Advenger / BR 755, 855 Disc and Cylindrical models) . . . . . . . . . . . . . . . 15
CONTROL PANEL (REV models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CONTROL PANEL (ST Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Basic Machine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Main Controller Error Codes – Advenger / BR 755, 855 and ST . . . . . . . . . . . . . . . . . . . . . 19
Speed Control Error Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Error Code System Diagnostics – Advenger / BR 755, 855 and ST . . . . . . . . . . . . . . . . . . . 21
SQUEEGEE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Troubleshooting Squeegee Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Squeegee Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Squeegee Lift Actuator Replacement - Advenger / BR 755, 855 . . . . . . . . . . . . . . . . . . . 27
Squeegee Lift Actuator Drive Nut Adjustment - Advenger / BR 755, 855 . . . . . . . . . . . . . . . 28
Squeegee Lift Cable Replacement - Advenger / BR 755, 855 . . . . . . . . . . . . . . . . . . . . . . 29
Squeegee Lift Cable Replacement - ST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Squeegee Lift Cable Adjustment - ST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Steering Column Assembly Shroud Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
SCRUB SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Troubleshooting Scrub System Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Scrub Deck Lift Actuator Replacement - Advenger / BR 755, 855 . . . . . . . . . . . . . . . . . . . 38
Scrub Deck Lift Actuator Drive Nut Adjustment - . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Scrub DECK REMOVAL - Disc and REV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Scrub Brush Motor Removal - DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Scrub Brush Motor Removal - DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Motor Plate and isolators (REV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Scrub DECK REMOVAL - Cylindrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Scrub Brush Motor Removal - Cylindrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
ii
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
Contents
RECOVERY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Troubleshooting Recovery System Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Replacing a Vacuum Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
SOLUTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Troubleshooting Solution & AXP/EDS System Issues . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Solution System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Solution System Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Replacing the Solution Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
WHEEL DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Troubleshooting Drive Wheel Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Replacing the Drive Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Replacing the Drive Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Inspecting/Replacing the Drive Wheel Assembly Carbon Brushes . . . . . . . . . . . . . . . . . . . 71
Replacing the Rear Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Control board j1, j2, and j3 pin outs and test points . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Curtis Speed Control Installation Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 79
Replacing the Operator Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Programming Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Service Test Mode - ADVENGER / BR 755, 855 (Disc and Cyl.) . . . . . . . . . . . . . . . . . . . . . 82
Changing Control Board Program Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Changing Program Settings - Advenger / BR 755, 855 (Disc and Cyl.) . . . . . . . . . . . . . . . . . 84
Changing Program Settings - ST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Service Test Mode - ST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Hidden Menus (REV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Program Options (REV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Service Test Mode - ADVENGER / BR 755, 855 (REV) . . . . . . . . . . . . . . . . . . . . . . . . . . 90
MAINTENANCE SCHEDULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
OPERATOR PREVENTIVE MAINTENANCE – MACHINE IN USE . . . . . . . . . . . . . . . . . . . . . . 92
OPERATOR PREVENTIVE MAINTENANCE – MACHINE IN STORAGE . . . . . . . . . . . . . . . . . . . 93
SERVICE TECHNICIAN SUGGESTED MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
RECOMMENDED MAINTENANCE MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
PM Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Expanded Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Component Location (Advenger/BR 755, 855) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
WIRING DIAGRAM / SCHEMATIC (Advenger / BR 755, 855 Disc and Cylindrical Decks) . . . . . . . 76
Wiring Diagram (REV Deck) - 56601806 Revision A Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . 78
Wiring Diagram (REV Deck) - 56601806 Revision A Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . 79
Wiring Harness Diagram (REV Deck) - 56601807 Revision A . . . . . . . . . . . . . . . . . . . . . . 80
Component Location (2800ST, 3400ST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
WIRING DIAGRAM / SCHEMATIC (2800ST, 3400ST) . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
iii
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
Introduction
Introduction
Quick Start Service Manual Purpose
This manual is a technical resource that Nilfisk-Advance expects to be utilized while an Advenger / BR 755, 855 or ST is being serviced.
It contains information deemed necessary to provide basic troubleshooting, maintenance, and repairs within a timeframe of 2-3 hours
maximum. If your repair involves multiple visits to repair the same problem or the repair cannot be completed within 3 hours, a call to
Nilfisk-Advance Technical Support is needed, whether to alert the factory to potential issues or to provide the customer with an acceptable
level of service. Refer to the website www.advance-us.com for additional information not contained here-in, as well as updates or
expanded instructions to procedures noted here.
Note: Bold numbers in parentheses in the text indicate an illustrated item.
Note: All references to right, left, front and rear in this manual are as seen from the operator’s position.
General Machine Description
The Advenger / BR 755, 855 and ST machines are commercial automatic floor scrubbers available with multiple deck sizes, multiple
corresponding squeegee blade sizes and materials, and variable scrub pressure and solution flow rates..
Parts and Service
Repairs should be performed by an Authorized Nilfisk-Advance Service Center that employs factory-trained service personnel and
maintains an inventory of Nilfisk-Advance original replacement parts and accessories.
Nameplate
The Model Number and Serial Number of the machine are shown on the Nameplate located on the chassis under the left rear corner as
shown.
This information is required when ordering repair parts for the machine or contacting Nilfisk-Advance Technical Support.
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Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
Introduction
Cautions and Warnings Symbols
Advance uses the symbols below to signal potentially dangerous conditions. Always read this information carefully and take the
necessary steps to protect personnel and property.
DANGER!
Is used to warn of immediate hazards that will cause severe personal injury or death.
WARNING!
Is used to call attention to a situation that could cause severe personal injury.
CAUTION!
Is used to call attention to a situation that could cause minor personal injury or damage to the machine or other property.
Read all instructions before using.
General Safety Instructions
Specific Cautions and Warnings are included to warn you of potential danger of machine damage or bodily harm.
This machine is for commercial use, for example in hotels, schools, hospitals, factories, shops and offices other than normal
residential housekeeping purposes.
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WARNING!
This machine shall be used only by properly trained and authorized persons.
This machine is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack
of experience and knowledge.
While on ramps or inclines, avoid sudden stops. Avoid abrupt sharp turns. Use low speed down ramps.
Keep sparks, flame and smoking materials away from batteries. Explosive gases are vented during normal operation.
Charging the batteries produces highly explosive hydrogen gas. Charge batteries only in well-ventilated areas, away from open
flame. Do not smoke while charging the batteries.
Remove all jewelry when working near electrical components.
Turn the key switch off (O) and disconnect the batteries before servicing electrical components.
Never work under a machine without safety blocks or stands to support the machine.
Do not dispense flammable cleaning agents, operate the machine on or near these agents, or operate in areas where flammable
liquids exist.
Do not clean this machine with a pressure washer.
Only use the brushes provided with the appliance or those specified in the instruction manual. The use of other brushes may
impair safety.
Observe the Gross Vehicle Weight, GVW, of the machine when loading, driving, lifting or supporting the machine.
CAUTION!
This machine is not approved for use on public paths or roads.
This machine is not suitable for picking up hazardous dust.
Do not use scarifier discs and grinding stones. Advance will not be held responsible for any damage to floor surfaces caused by
scarifiers or grinding stones (can also cause damage to the brush drive system).
When operating this machine, ensure that third parties, particularly children, are not endangered.
Before performing any service function, carefully read all instructions pertaining to that function.
Do not leave the machine unattended without first turning the key switch off (O), removing the key and applying the parking
brake.
Turn the key switch off (O) and remove the key, before changing the brushes, and before opening any access panels.
Take precautions to prevent hair, jewelry, or loose clothing from becoming caught in moving parts.
Use caution when moving this machine in below freezing temperature conditions. Any water in the solution, recovery or
detergent tanks or in the hose lines could freeze, causing damage to valves and fittings. Flush with windshield washer fluid.
5
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
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Introduction
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The batteries must be removed from the machine before the machine is scrapped. The disposal of the batteries should be
safely done in accordance with your local environmental regulations.
Do not use on surfaces having a gradient exceeding that marked on the machine.
All doors and covers are to be positioned as indicated in the instruction manual before using the machine.
This machine should only be used and stored indoors..
SAVE THESE INSTRUCTIONS
Related Reference Sources
Nilfisk-Advance provides Operator Manuals, Sales literature, Parts Lists, Technical Service Bulletins, and Instruction Sheets on our website www.
advance-us.com for 24/7 availability of information to order parts, operate, troubleshoot, or repair all current production and most pruned machine
models.
For the Advenger and ST please refer to the following documents for additional information:
Parts List - Form Number 56042495
Operation Manual - Form Number 56041735 (English, Spanish)
For the BR 755, 855 please refer to the following documents for additional information:
Parts List - Form Number 56042496
Operation Manual - Form Number 56041738 (Danish, Norwegian, Swedish, Finnish)
Operation Manual - Form Number 56041739 (German, French, Nederlands, Russian)
Operation Manual - Form Number 56041740 (Spanish, Portuguese, Italian, Greek)
Operation Manual - Form Number 56041741 (Estonian, Latvian, Lithuanian, Slovenian)
Operation Manual - Form Number 56041742 (Slovakian, Czech, Polish, Hungarian)
Operation Manual - Form Number 56041743 (English, Turkish)
Curtis Programmer Manual 56043101
TSB US2008-984 Batteries and Chargers
TSB US2008-979 QuiQ Delta-Q Battery Charger Reprogramming Kit 56315732 Instructions
Diagnostic and Service Tools
In addition to a full set of metric and standard tools, the following items are required in order to successfully and quickly perform troubleshooting
and repair of Nilfisk-Advance commercial floor cleaning equipment.
1 Laptop computer loaded with current version of EZParts, Adobe Reader, and (preferably cellular) internet access
2 Digital voltmeter (DVM) with DC current clamp
3 Hydrometer
4 Battery load tester for checking 6V batteries
5 Bearing puller
6 Static control wrist strap
7 Set of torque wrenches
8 Hard (printed) copies of service manuals for all regularly serviced machines (available at www.advance-us.com and other Nilfisk-Advance
websites)
9 6” section of 1 1/2” PVC pipe with a 1” hole drilled into one side to check vacuum system against 1” lift spec
10 1 1/2” and 2 3/8” drill bit or hole cutter if a Dual Vac Kit is to be installed
Also these tools available from Nilfisk-Advance, Inc.:
56407502
56205281
56206921
56409441
56409823
56315732
56422174
Actuator Power Cord Adapter
Water Lift Gauge
Timer Bypass Kit (used to bypass timing function when troubleshooting shelf chargers)
Curtis Handheld Programmer
Curtis Adapter Cable (Quad Plug)
Delta-Q QuiQ Onboard Charger Interface Module
Tire Puller Kit for Drive Wheel Assembly
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
Introduction
Technical Specifications
GENERAL
Machine Voltage
24 VDC
Length (W/squeegee): 60 in (152.4 cm)
Dimensions (without Squeegee and
Scrub Deck)
Scrub Deck and
Squeegee Widths
Tank Capacities
Width (body): 27.5 in (70 cm)
Height (Recovery tank): 51.7 in (131.3cm)
Scrub Deck Width:
Squeegee Width:
30.3 in (77 cm) 28 disc, REV
32.6 in (82.8 cm)
36.3 in (92.2 cm) 34 disc
41.4 in (105.2 cm)
31.6 in (80.3 cm) 28 cyl
32.6 in (82.8 cm)
Solution Tank: 28 gal (106 l)
Recovery Tank: dynamic: 25 gal (95 l); static: 28 gal (106 l)
Gross Weight (standard machine w/o options; w/full solution tank, empty recovery tank and
1451 lbs (658 kg)
heaviest batteries installed)
Net Weight (standard machine w/o options, batteries or removable brushes; w/empty solution and
536 lbs (244 kg)
recovery tanks)
Static Wheel Loading
Front: 615 lbs (279 kg)
Rear: 836 lbs (379 kg)
Static Wheel Pressure
Front: 174.7 psi (12.3 kg/cm )
Ingress Protection Code
IPX3
Sound Pressure Level
(IEC 60704-1)
63.7 dB(A)
Rear: 124.7 psi (8.8 kg/cm2)
2
Vibrations at the Hand Controls (ISO 5349-1)
.26 m/s2
Vibrations at the Seat (EN 1032)
.05 m/s2
Gradeability
Transport: 16 % / 9 degrees
Cleaning: 9 % / 5 degrees
Battery Compartment Dimensions
Maximum Battery Compartment
25” L X 15.5” W X 21” H
Without the Box:
26.25” X 16” X 21”
Advance Models
FIGURE 1
Nilfisk Models
7
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
Introduction
Technical Specifications
Electrical Specifications
Number of Batteries 4 / Battery Voltage 6V 310 Ah wet
Number of Batteries 4 / Battery Voltage 6V 420 Ah wet
Number of Batteries 4 / Battery Voltage 6V 312 Ah AGM
Batteries
Standard Battery Capacity: 305 amp-hours @ 20-hour rate
Onboard Battery Charger
DRIVE SYSTEM
24-volt
Output 25A
Manufacturer: Delta Q
Gel Compatible: Yes
Model: 912-2400-N1
Drive Wheel
Diameter: 9.84 in (25 cm) / Width: 3.15 in (80 cm)
Type/Material: Blue Urethane
Drive Motor
1.05 HP (780 watts)
Max. Transport Speed
SOLUTION SYSTEM
Solution Control
Advenger
BR 755, 855
Solution
Flow Rates
Disc and Cyl
Rev: 2.61 mph (4.20 km/h)
Pulse-control Solenoid Valve
(1) Regular Scrub
.38 gal/min (1.44 L/min) or 70 minutes per solution tank
(2) Heavy Scrub
.62 gal/min (2.35 L/min) or 40 minutes per solution tank
(3) Extreme Scrub
.92 gal/min (3.48 L/min) or 23 minutes per solution tank
Advenger
(1) Regular
BR 755, 855
Solution
(2) Heavy
Flow Rates Disc
(3) Extreme
and Cy
ST Solution
Flow Rates
(Average)
Fwd: 3.91 mph (6.30 km/h)
Scrub Mode 0.2 gal/min (0.7 L/min) Floor Finish Removal Mode 0.1 gal/min (0.4 L/min)
Scrub Mode 0.4 gal/min (1.5 L/min) Floor Finish Removal Mode 0.2 gal/min (0.7 L/min)
Scrub Mode 0.2 gal/min (3.0 L/min) Floor Finish Removal Mode 0.4 gal/min (1.5 L/min)
(1) Regular Scrub
.30 gal/min (1.13 L/min) or 60 minutes per solution tank
(2) Heavy Scrub
.48 gal/min (1.82 L/min) or 45 minutes per solution tank
(3) Extreme Scrub
.88 gal/min (3.33 L/min) or 30 minutes per solution tank
AXP™ / EDS™ System Available
Advenger / BR 755, 855 only
Detergent Ratios Available
400:1 = .25%
300:1 = .3%
256:1 = .4%
Recycle System Available
No
200:1 = .5%
150:1 = .66%
128:1 = .8%
100:1 = 1%
64:1 = 1.5%
50:1 = 2%
32:1 = 3%
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Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
RECOVERY SYSTEM
Vacuum Motor(s)
Vacuum Water
Lift (measured at
recovery hose)
One Motor
Two Motors
.75 HP (560-watt) 3-stage
Sealed: 63.0 in of Water (15.7 kPa)
1” Open-hole Aperture: 10.3 in of Water (2.6 kPa)
Sealed: 65.0 in of Water (16.2 kPa)
1” Open-hole Aperture: 18.5 in of Water (4.6 kPa)
TECHNICAL SPECIFICATIONS
SCRUB SYSTEM
Scrub Deck Types
Disc, Cylindrical and REV
REV and Disc: (2) 14 in (35.6 cm) Scrub Path: 28 in (71.1 cm)
Scrub Brush/Pad Sizes
and Types
Disc: (2) 17 in (43.2 cm) Scrub Path: 34 in (86.4 cm)
Cylindrical: (2) 27 in (68.6 cm) Scrub Path: 28 in (71.1 cm)
Scrub Motors - Disc
Number of Motors 2
Right-hand/Single Motor: .64 HP (480 watts)
Left-hand Motor: .64 HP (480 watts)
Scrub Head Speeds - Disc
Right-hand/Single Motor: 215-260 RPM
Left-hand Motor: 215-260 RPM
REV approx 2,000 RPM
Scrub Motors – Cylindrical
Right-hand Motor: .5 HP (373 watts)
Left-hand Motor: .5 HP (373 watts)
Scrub Head Speeds – Cylindrical
Right-hand Motor: 900 RPM / Left-hand Motor: 900 RPM
Scrub Force 28” ST
Scrub Force 34” ST
(1) Regular Scrub: 75-85 lbs (32.7-37.0 kg)
(2) Extreme Scrub (factory setting): 170-180 lbs (77.1-81.6 kg)
(1) Regular Scrub: 95-105 lbs (41.4-45.7 kg)
(2) Extreme Scrub (factory setting): 195-205 lbs (88.5-93.0kg)
(1) Regular Scrub: 70-90 lbs ( 31.8-39.2kg)
Scrub Force Advenger / BR 755, 855 - Disc
(2) Heavy Scrub: 120-150 lbs (52.3-65.3kg)
(3) Extreme Scrub: 180-220 lbs (78.4-95.8 kg)
(1) Regular Scrub: 45-60 lbs (20.4-27.2 kg)
Scrub Force Advenger / BR 755, 855 Cylindrical
(2) Heavy Scrub: 70-80 lbs (31.8–36.3 kg)
(3) Extreme Scrub: 90-100 lbs (40.8-45.4 kg)
(1) Regular Scrub: 80 lbs (36kg)
Scrub Force Advenger / BR 755, 855 Cylindrical
(2) Heavy Scrub: 125 lbs (57kg)
(3) Extreme Scrub: 175lbs (80 kg)
Introduction
9
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
Introduction
MINIMUM AISLE TURN AROUND RADIUS (TURNING LEFT)
28” deck Advenger / BR 755, 855
and ST
34” deck Advenger / BR 755, 855
and ST
Cylindrical Advenger / BR 755, 855
63 inches (1.63 m)
67.5 inches (1.71 m)
63 inches (1.63 m)
MINIMUM DOOR PASS-THRU WIDTH (SIDE SKIRTS ON, SQUEEGEE OFF)
28” deck Advenger / BR 755, 855
and ST
34” deck Advenger / BR 755, 855
and ST
Cylindrical Advenger / BR 755, 855
31 inches (.79 m)
36.5 inches (.93 m)
32 inches (.81 m)
Transporting The Machine
CAUTION!
Before transporting the machine on an open truck or trailer:
1 Remove the Squeegee Assembly (11) and secure.
2 Tie the machine down securely at the Locations (A) shown in FIGURE 2.
3 Tape and strap all access doors and covers as necessary.
4 In temperatures below freezing, remove all water from the machine and flush with windshield washer fluid to prevent damage to
valves and fittings.
5 Do not drive machine onto a ramp grade exceeding 16% (9 degrees) or damage to the machine may occur.
Tie-Down Points
FIGURE 2
10
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
Introduction
Towing the Machine
CAUTION!
The Drive Wheel (4) has a built in electromagnetic brake that is engaged whenever the Key Switch is Off or the Drive Pedal (3) is in the Neutral
position, i.e. there is no power to the Speed Control. This brake can be manually over ridden if necessary by inserting a medium to large
screwdriver behind the Yoke (A) as shown in FIGURE 3. (A rubber door stop can also be used). This should only be done in the event you need
to push or pull the machine.
Tow the machine for short distances only.
FIGURE 3
11
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
Jacking Points
Introduction
FIGURE 4
Front - When facing the front of the machine and underneath looking
up, place the jack to the left of the chain on the frame member (A) as
shown in FIGURE 4.
FIGURE 5
Rear – Remove Squeegee Assembly (11) to access these locations.
Use a bottle jack at these points (B) as shown in FIGURE 5.
Emergency Stop Knob
WARNING!
The Emergency Stop Knob (7) disconnects power from the Speed Control and Drive Wheel.
It does not disconnect the batteries, but will continue to power the control board . Do not use the Emergency Stop Knob as a substitute
for disconnecting the red Anderson battery connector inside the battery compartment.
FIGURE 6
12
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
Know Your Machine
Machine Front RH View
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Operator’s Seat
Solution Tank Drain Hose
Drive Pedal, Directional/Speed
Drive Wheel
Drive Wheel Circuit Breaker (70 Amp)
Control Circuit Circuit Breaker (10 Amp)
Emergency Stop
Scrub Deck
Rear Wheel
Battery Compartment (under seat)
Squeegee Assembly
Detergent Cartridge Access Cover (AXP/EDS or EcoFlex models only)
Detergent Cartridge (AXP/EDS or EcoFlex models only)
Scrub Deck Raise/Lower Lever (ST models only)
Deck Skirt Removal Knobs
Battery Charger Access Door
Battery Charger (optional)
Seat Adjustment Knob (optional on ST models)
Deck Skirt Height Adjustment Knob
Front Roller Bumper
Know Your Machine
13
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
KNOW YOUR MACHINE
Machine Rear LH View
21
22
23
24
25
26
27
28
29
30
31
32
Solution Shutoff Valve
Squeegee Raise/Lower Lever (ST models only)
Steering Wheel Tilt Adjust Knob
Control Panel
Solution Tank Fill Cover
Recovery Tank Cover
Vacuum Motor Filter Housing
Strainer Basket (optional on ST models)
Recovery Tank Shutoff Float
Squeegee Storage Hook
Recovery Tank Drain Hose
Squeegee Tilt Adjustment Knob
Know Your Machine
33
34
35
36
37
38
39
40
Seat Prop-Rod
Machine Battery Connector
Rear Squeegee Blade Removal Latch
Hopper (Cylindrical models only)
Recovery Hose
Solution Solenoid Valve
Front Squeegee Blade Removal Thumb Nut
Solution Filter
14
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
Know Your Machine
15
KNOW YOUR MACHINE
CONTROL PANEL (Advenger / BR 755, 855 Disc and Cylindrical models)
A Key Switch
B Solution Increase Switch
C Solution ON/OFF Switch
C1 Solution Flow Indicators (Normal, Heavy & Extreme)
D Solution Decrease Switch
E AXP/EDS (EcoFlex) ON/OFF Switch
FDisplay
F1 Hour Meter
F2 Solution Tank Level Indicator
F3 Fault Codes
F4 AXP/EDS or EcoFlex Indicator (if so equipped)
F5 Detergent Ratio Indicator
F6 Battery Indicator
F7 Recovery Tank FULL Indicator
F8 Battery Low Indicator
G
H
I
J
K
L
Scrub Pressure Increase Switch
Scrub ON/OFF Switch
H1 Scrub Pressure Indicators (Normal, Heavy and Extreme)
Scrub Pressure Decrease Switch
EverGreen (Burst of Power) Switch
Horn Switch
Vacuum/Wand Switch
NOTE 1: The display will go into Sleep Mode to save power if the
machine is turned on, in Neutral pedal, and idle for more than 10
minutes. Closing the seat switch, moving the drive pedal, or pressing
a control panel button will refresh the LCD display and LEDs.
F1
F
B
F2
F3
G
F4
C
F5
F6
H
C1
F
H1
D
I
J
K
E
L
A
F7
!
F8
!
NOTE 2: Recovery Tank FULL (F7) status allows machine
transport but disables all active systems and disables the control
panel switches except for the Horn Switch (K). To reset, empty the
tank and cycle the key switch.
NOTE 3: Battery Low (Low Voltage Cutout) Indicator (F8) triggers
at 20.55V on the wet setting and at 21.75V on the gel setting.
Refer to “Changing Program Settings - Advenger / BR 755, 855” to
change battery type programming.
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
Know Your Machine
16
CONTROL PANEL (REV models)
F9 Floor Finish Removal Speed Indicator (low, high)
F10 Detergent Indicator Bar Graph (off, weak, strong)
G Scrub Pressure Increase Switch
H Scrub ON/OFF Switch
H1 Scrub Pressure Indicators (Normal, Heavy and
Extreme)
I Scrub Pressure Decrease Switch
J Burst of Power Switch
K Horn Switch
L Vacuum/Wand Switch
O Floor Finish Removal Mode Switch
A Key Switch
B Solution ON / Increase Switch
C1 Solution Flow Indicators (Normal, Heavy & Extreme)
D Solution Decrease / OFF Switch
E Detergent ON/OFF Switch
FDisplay
F1 Hour Meter
F2 Solution Tank Level Indicator
F3 Fault Codes
F4 Detergent Indicator (if so equipped)
F5 Detergent Ratio Indicator
F6 Battery Indicator
F7 Recovery Tank FULL Indicator
F8 Battery Low Indicator
F1
F
B
F2
F9
G
F5
F4
H
C1
H1
D
I
J
O
K
F7
F8
E
L
A
F10
F6
F3
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
Know Your Machine
KNOW YOUR MACHINE
CONTROL PANEL (ST Models)
A Key Switch
B Solution Increase Switch
C Solution ON/OFF Switch
C1 Solution Flow Indicators (Normal, Heavy & Extreme)
D Solution Decrease Switch
KHorn
M Battery Indicator
N Fault Indicator
NOTE 1: Recovery Tank FULL status is indicated by the Solution Flow
Indicator LED (C1) turning Off. This status allows machine transport but
disables all active systems and disables the control panel switches except
for the Horn Switch (K). To reset, empty the tank and cycle the key switch.
NOTE 2: Battery Low (Low Voltage Cutout) status is indicated by the
red battery LED (M) flashing. It triggers at 20.55V on the wet setting and
21.75V on the gel setting. Refer to “Changing Program Settings - ST” to
change battery type programming.
N
B
C
K
C1
D
M
A
17
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
Know Your Machine
KNOW YOUR MACHINE
As you read this manual, you will occasionally run across a bold number in parentheses – example: (2). A bold number refers to an item
shown on the Know Your Machine pages unless otherwise noted (bold letters refer to items on the same page). Refer back to the Know
Your Machine pages whenever necessary to pinpoint the location of an item mentioned in the text.
Basic Machine Operation
(refer to Operator Manuals such as 56041735 / 56041743 (English) for detailed information regarding how to operate the machine):
1
2
3
4
5
6
7
Turn on the key to turn on the graphical display showing battery condition, hour meter, solution tank level and AXP/EDS dilution ratio if
so equipped.
ADVENGER / BR 755, 855: Pressing the red SCRUB ON / OFF button once will enable regular scrub mode. The deck and rear
squeegee will be lowered to the floor.
ST: Manually lower the scrub deck and squeegee using levers (14) and (22).
Depress the foot pedal forward to begin scrubbing. The brushes, water and vacuum will turn on.
When the machine stops the brushes and water will stop. The vacuum will continue to run for 10 seconds and then stop.
At any time the scrub mode can be changed to regular, heavy or extreme scrub by using the SCRUB + or SCRUB - button.
At any time the solution flow rate can be changed by using the SOLUTION + or SOLUTION - button.
If the scrub mode and solution flow rate are at different positions they can be reset or aligned using two methods.
A Use the SOLUTION + or SOLUTION - buttons to change the solution flow rate to match the scrub mode setting.
B Change the scrub mode using the SCRUB + or SCRUB - buttons. The scrub pressure and solution flow will automatically be
aligned for optimized results.
To stop all scrubbing functions and transport the machine, (ADVENGER / BR 755, 855) press the red SCRUB ON / OFF button or
[(ST) return the scrub deck and squeegee control levers to the up position]. The solution and brushes will stop, [(ADVENGER / BR
755, 855) the deck and squeegee will raise], and the vacuum will shut off after a 10 second delay.
18
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
Know Your Machine
Main Controller Error Codes – Advenger / BR 755, 855 and ST
Advenger /
BR 755, 855
Display Error
Code
ST Service
LED Blink
Code *
Fault Description
System
Affected
Refer to page:
3
1,1
Speed control fault
Wheel Drive
52
4
NA
Scrub deck lift actuator overload
Scrub
32
5
1, 2
Brush motor overload
Scrub
31
6
NA
Squeegee lift actuator overload
Squeegee
21
7
1, 3
Vacuum motor overload
Recovery
42
8
1, 4
Solution solenoid overload
Solution
47
9
2, 1
Vacuum contactor coil overload
Recovery
42
10
2, 2
Brush motor contactor coil overload
Scrub
31
11
NA
Chemical pump overload
AXP/EDS
47
30
2, 3*
Solution solenoid open
Solution
47
31
2, 4
Brush motor circuit open
Scrub
31
32
NA
Scrub deck lift actuator open
Scrub
32
33
3, 1
Vacuum motor circuit open
Recovery
42
34
NA
Squeegee lift actuator open
Squeegee
21
35
3, 2
Brush motor contactor coil open
Scrub
31
36
3, 3
Vacuum motor contactor coil open
Recovery
42
37
NA
Chemical pump open
AXP/EDS
47
60
3, 4
Brush motor circuit contacts stuck closed
Scrub
31
61
4, 1
Vacuum motor circuit contacts stuck closed
Recovery
42
62
4, 2
Solution solenoid control fault
Probable board failure
63
4, 3
Brush contactor coil control fault
Probable board failure
64
4, 4
Vacuum contactor coil control fault
Probable board failure
* ST open circuit errors are only visible in Fault Recall Mode, accessible via the Hidden Menu. Refer to “Changing Program Settings - ST”
section. Then verify fault by entering Service Test Mode.
19
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
Know Your Machine
Speed Control Error Flash Codes
STATUS LED FAULT CODES (TABLE 1)
LED CODE
STATUS LIGHT
DISPLAY
EXPLANATION
POSSIBLE CAUSE
1,1
O O
over-/under-temperature cutback
1. Temperature >97°C (206°F) or < -25°C (-13°F).
2. Excessive load on vehicle.
3. Operation in extreme environments.
4. Electromagnetic, foot or parking brake not
releasing properly.
1,2
O OO
throttle fault
1. Throttle input wire open or shorted.
2. Throttle pot defective.
3. Wrong throttle type selected.
1,3
O OOO
speed limit pot fault
1. Speed limit pot wire(s) broken or shorted.
2. Broken speed limit pot.
1,4
O OOOO
battery voltage too low
1. Battery voltage <17 volts.
2. Bad connection at battery or controller.
1,5
O OOOOO
battery voltage too high
1. Battery voltage >36 volts.
2. Vehicle operating with charger attached.
3. Intermittent battery connection.
2,1
OO O
main contactor driver Off fault
1. Main contactor driver failed open.
2,3
OO OOO
main contactor fault
1. Main contactor welded or stuck open.
2. Main contactor driver fault.
3. Brake coil resistance too high.
2,4
OO OOOO
main contactor driver On fault
1. Main contactor driver failed closed.
3,1
OOO O
HPD fault present for >10 sec.
1. Misadjusted throttle.
2. Broken throttle pot or throttle mechanism.
3,2
OOO OO
brake On fault
1. Electromagnetic brake driver shorted.
2. Electromagnetic brake coil open.
3,3
OOO OOO
precharge fault
1. Controller failure.
2. Low battery voltage.
3,4
OOO OOOO
brake Off fault
1. Electromagnetic brake driver open.
2. Electromagnetic brake coil shorted.
3,5
OOO OOOOO
HPD (High Pedal Disable) fault
1. Improper sequence of throttle and KSI*,
push, or inhibit inputs.
2. Misadjusted throttle pot
4,1
OOOO O
current sense fault
1. Short in motor or in motor wiring.
2. Controller failure.
4,2
OOOO OO
motor voltage fault (hardware
failsafe)
1. Motor voltage does not correspond to
throttle request.
2. Short in motor or in motor wiring.
3. Controller failure.
4,3
OOOO OOO
EEPROM fault
1. EEPROM failure or fault.
4,4
OOOO OOOO
power section fault
1. EEPROM failure or fault.
2. Short in motor or in motor wiring.
3. Controller failure.
*NOTE: A KSI (key switch input) system problem is a specific HPD (high pedal disable) type operational fault, caused by the operator
activating the Fwd/Rev drive pedal before turning on the main key switch or activating the throttle before sitting on the seat. This can be
cleared by returning the operator’s drive pedal to neutral and cycling the key switch OFF and ON.
20
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
Know Your Machine
21
Error Code System Diagnostics – Advenger / BR 755, 855 and ST
The following table describes the systems that are disabled for each error code to assist you in understanding machine response to error code status.
Disable System
Flash Indicator
Brush motor overload
x
x
6
Squeegee lift actuator overload
x
x
7
Vacuum motor overload
x
x
8
Solution solenoid overload
x
x
9
Vacuum contactor coil overload
x
x
10
Brush contactor coil overload
x
x
11
Chemical Pump overload
x
30
Solution solenoid open
x
x
31
Brush motor open
x
x
32
Brush deck lift actuator open
33
Vacuum motor open
x
x
34
Squeegee lift actuator open
x
x
35
Brush contactor coil open
x
x
36
Vacuum contactor coil open
x
x
37
Chemical pump open
x
60
Brush motor circuit contacts stuck closed
61
Vacuum motor circuit contacts stuck closed
62
Solution solenoid coil control fault
63
Brush contactor coil control fault
64
Vacuum contactor coil control fault
Vacuum Indicator
5
Brush Motor Indicator
Brush deck lift actuator overload
Solution Indicator
4
Chemical Indicator
Disable Brush Motors
x
Brush Deck Lift Disable
Disable Solution
x
Speed control fault
Disable Recovery
Disable Chemical
Fault Description
Display Code
x
3
x
x
X
x
x
x
x
x
x
x
X
x
x
x
x
x
x
x
x
x
x
x
x
x
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
Know Your Machine
UNDERSTANDING CONTROL OF SQUEEGEE, SCRUB, AND RECOVERY SYSTEMS VIA MODES
Due to the unique One-Touch functions of the new Advenger / BR 755, 855 and ST, multiple systems are engaged via one action defined by the Mode that is chosen - Scrub
Mode, Vacuum Mode, Floor Finish Removal or Wand Mode. The following tables outline the various components of the systems that are controlled in tandem by pressing
a particular button or engaging the Drive Pedal in Forward, Neutral, or Reverse under normal machine operation. To bypass these systems, refer to the “Service Test
Mode” section.
Advenger / BR 755, 855
Mode
Operator
Position
Seat Switch
Status
Action
Scrub Mode
Seated
Closed
Press Scrub On
Press Foot Pedal
Forward
Press Foot Pedal
Reverse
Foot Pedal in Neutral
Press Scrub Off
Press Scrub Off Foot Pedal in
Neutral >10 sec.
Vac Mode
Seated
Closed
Press Vac/Wand On
Standing
Open
Squeegee lowers (24V to M3 for 4 seconds - adjustable.)
Scrub deck lowers (24V to M4 for 3 sec., then pulsed signal)
Vacuum motor circuit On
Scrub motor circuit On
Solution Solenoid On
Chemical Pump On if equipped
Solution Solenoid Off
Chemical Pump Off if equipped
Squeegee raises (reverse 24V to M3 for 4 seconds)
Pulsed voltage to M4 deck actuator maintaining down position
Brush motor circuit On
Vacuum motor circuit off after 10 seconds continuous in reverse
Brush motor circuit Off but Enabled
Vacuum motor circuit Off after 10 sec. but Enabled
Pulsed voltage to M4 deck actuator maintaining down position
Squeegee in down position
Brush motor circuit Off
Scrub deck raises (reverse 24V to M4 for 3 sec.)
Squeegee raises after 10 sec. (reverse 24V to M3 for 4 seconds)
Vacuum motor circuit On for 20 seconds total
Solution Solenoid Off
Chemical Pump Off if equipped
Brush motor circuit Off
Scrub deck raises (reverse 24V to M4 for 3 sec.)
Squeegee raises (reverse 24V to M3 for 4 seconds)
Vacuum motor circuit Off
Solution Solenoid Off
Chemical Pump Off if equipped
Squeegee lowers (24V to M3 for 4 seconds)
Press Foot Pedal
Forward
Vacuum motor circuit On
Press Foot Pedal
Reverse
Squeegee raises until Foot Pedal in Neutral or Forward again (reverse
24V to M3 for 4 sec.)
Vacuum motor circuit On for 10 seconds
Press Vac/Wand Off
Squeegee raises after 10 sec (reverse 24V to M3 for 4 seconds) *
Vacuum motor circuit On for 20 seconds total *
* If drive pedal in Neutral >10 sec, squeegee will raise and vac motor
circuit will be Off immediately with no delay.
Press Vac/Wand Off Twice
Wand Mode*
Result
Press Vac/Wand On
Squeegee raises immediately (reverse 24V to M3 for 4 seconds)
Vacuum motor circuit Off immediately
Squeegee lowers (24V to M3 for 4 seconds)
Vacuum motor circuit On
22
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
* Recovery Tank Full is disabled in Wand Mode
Press Vac/Wand Off
Know Your Machine
Squeegee raises (reverse 24V to M3 for 4 sec.)
Vacuum motor circuit Off
UNDERSTANDING CONTROL OF SQUEEGEE, SCRUB, AND RECOVERY SYSTEMS VIA MODES
ST
Mode
Operator
Position
Seat Switch
Status
Action
Scrub Mode
Seated
Closed
Lower Scrub Deck
Brush motor circuit enabled
Lower Squeegee
Vacuum motor circuit enabled
Press Foot Pedal
Forward
Vacuum motor circuit On
Brush motor circuit On
Solution Solenoid On
Press Foot Pedal
Reverse
(Lift Squeegee to prevent
damage)
Foot Pedal Neutral
Lift Scrub Deck
Lift
Squeegee
Vac Mode
Seated
Closed
Solution Solenoid Off
Brush motor circuit On
Vacuum motor circuit On for 10 seconds
Brush motor circuit Off but enabled
Vacuum motor circuit On for 10 seconds, then enabled
Solution Solenoid Off but enabled
Solution Solenoid Off
Brush motor circuits Off
Vacuum motor circuit Off after 10 seconds
Lower Squeegee
Vacuum motor circuit enabled
Press Foot Pedal
Forward
Vacuum motor circuit On
Press Foot Pedal
Reverse
(Lift Squeegee to prevent
damage)
Vacuum motor circuit Off after 10 seconds
Foot Pedal Neutral
Wand Mode
Result
Standing
Open
Vacuum motor circuit On for 10 seconds, then enabled
Lower Squeegee
Vacuum motor circuit On
Raise Squeegee
Vacuum motor circuit Off after 10 seconds
23
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
SQUEEGEE SYSTEM
SQUEEGEE SYSTEM
Refer to the section “Understanding Control of Squeegee, Scrub, and Recovery Systems via Modes” for explanation of control due to
functionality of multiple systems in tandem.
Advenger / BR 755, 855
ST
24
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
SQUEEGEE SYSTEM
SQUEEGEE LIFT ACTUATOR CIRCUIT ERROR CODES AND MEASUREMENTS - ADVENGER / BR
755, 855
Advenger /
BR 755, 855
Display
Error Code
6
ST Service
LED
Blink Code
NA
34
NA
Fault Description
Troubleshooting Action
Squeegee lift actuator overload
1. 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.
Squeegee lift actuator open
1. Check for disconnected actuator wiring, open in wiring or
defective actuator motor. Repair or replace.
2. Check controller output voltage at BLK/YEL wire.
Actuator
Nominal Current (A)
Overload Current
Wire Colors
M3
2.5 - 3.5
5A for > 4 seconds
BLK/YEL & WHT/GRN
Troubleshooting Squeegee Issues
Problem
Possible Cause
Not enough adjustment of squeegee tool by turning adjustment Squeegee Mount Weldment Bracket is bent. Replace
knob
Squeegee is “hopping”
Wheel isn’t making contact with the floor - reposition wheel in slot on squeegee
tool. Refer to “Squeegee Adjustments” section.
Squeegee tips are being driven into the floor
Adjust squeegee using Adjustment Knob turning CW to raise tips.
Advenger / BR 755, 855
Lift motor runs in both directions but does not raise or lower
the squeegee tool assembly
1. Threads in the moveable lift motor assembly drive tube are damaged
(stripped).
2. Lift cable damaged (stretched or broken).
Lift motor does not run and the display shows an error fault
code
Lift motor electrical system failure - refer to chart in “Main Controller Error
Codes” for service actions.
ST
Squeegee lift Linkage Arm at steering column keeps bending
or breaking
Squeegee Lift Cable is too tight - follow instruction in “Squeegee Lift Cable
Adjustment - ST” section.
Squeegee lift Linkage Arm / Knob doesn’t raise or lower
squeegee
Cable Bushing under Eyelet of Squeegee Cable in Steering Column is worn or
Weldment Linkage is bent/sheared because Squeegee Lift Cable is too tight.
Follow instruction in “Squeegee Lift Cable Adjustment - ST” section.
25
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
SQUEEGEE SYSTEM
Squeegee Adjustments
Correct squeegee alignment is critical to water pickup performance and life of squeegee blades. If the squeegee is not angled correctly or
hops, use the following settings as nominal and adjust as necessary to achieve the required performance.
Tilt – FIGURE 7
Factory setting is 0.625” nominal
Wheel Height – FIGURE 8
Factory setting is 0.87” nominal
FIGURE 7
FIGURE 8
26
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
SQUEEGEE SYSTEM
Squeegee Lift Actuator Replacement - Advenger / BR 755, 855
CAUTION!
The Recovery Tank is heavy and care should be taken in removing it. Two people recommended, or battery roll-out unit.
1 Lower the squeegee tool to the floor and then disconnect the battery pack at the red Anderson connector in the battery compartment.
2 Drain the recovery tank using the Recovery Tank Drain Hose (31).
3 Disconnect the squeegee hose from the squeegee tool and remove the tool from its mount.
4 Lift up the seat and unplug vacuum motor (and warning beacon if equipped) connectors located in battery compartment.
5 Open the hinged recovery tank cover and grip the top inside edge of the tank, then pull straight up to free it from the solution tank
platform. Guide the tank off the rear of the machine to the floor.
6 See Figure 9. From the back of the machine, remove the Retainer Ring (A) securing the lift cable Pin (B) and separate the pin and
cable from the motor drive tube housing and chassis mounts. Note: Don’t lose the two plastic cable spacers positioned in motor drive
tube.
7 Locate the wire tie that attaches the motor wiring to the chassis and then disconnect the motor harness
8 From underneath the machine remove the Hairpin (C) securing the lift motor Pin (D) and disassemble the motor from the chassis
mount. Then pull the motor towards the machine front to remove it completely.
NOTE: New replacement lift actuator motors do not come with the lift nut pre-adjusted.
Follow the “Squeegee Lift Actuator Drive Nut Adjustment” procedure using 56407502 Actuator Power Cord Adapter to set the new lift
actuator to the correct settings:
9 When finished, reassemble in reverse order.
FIGURE 9
27
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
SQUEEGEE SYSTEM
Squeegee Lift Actuator Drive Nut Adjustment - Advenger / BR 755, 855
1
WARNING!
FIGURE 10
Open the battery compartment and disengage the red
Anderson battery connectors.
2 Connect the Scrub Deck Lift Actuator (completely
assembled) to the Actuator Power Cord Adapter
56407502 (Figure 10) (see “Diagnostic and Service
Tools”).
3 Connect the red alligator clip to the positive battery
terminal.
4 Connect the black alligator clip to the negative battery
terminal.
5 See Figure 11. Hold onto the metal nut (A) and press
the rocker switch to run the motor and retract the nut
towards the motor housing (the IN or Retract Limit).
6 With the motor laying on a flat surface, place a 3/8”
pin or bolt through the top mounting holes (C) and the
bottom (nut) mounting holes (D) because you will be measuring the distance between them..
7 Manually turn the metal nut (A) until the distance between the outer edge of one pin and the inner edge of the other pin*
matches the Retracted setting shown below.
8 Hold the metal nut and press the rocker switch, running the motor until it stops. If the measurement doesn’t match 13.25” (33.65cm)
as shown below, pry off the black cover (B) to access the Cam Adjuster.
9 Using a 1/2” socket, gently turn the adjuster CW to increase travel, CCW to decrease travel of the Drive Nut. Each click of the adjuster
will change the nut travel by 0.09” (2.29mm) or just under 3/32”.
10 After each adjustment, re-check the travel by holding the metal nut and running the actuator IN and OUT, checking against the values
below.
11 Repeat until it is set correctly and replace the Cam Adjuster cover (B).
12 DO NOT TURN THE NUT before mounting - mark the position on the shaft if helpful.
Actuator Setting – mounting hole center to center:
Retracted: 9.00” +/- .06
Extended: 13.25” +/- .06
* It’s not practical to measure center to center of the holes, so an outer edge to inner edge of the pins measurement is suggested.
FIGURE 11
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Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
SQUEEGEE SYSTEM
Squeegee Lift Cable Replacement - Advenger / BR 755, 855
1
2
3
4
Follow steps 1-6 of “Squeegee Lift Actuator Replacement - Advenger / BR 755, 855” to disengage front end of lift cable under
machine.
NOTE: the motor does not need to be disconnected for this procedure.
See Figure 12. Using 7/16” wrenches, remove the hex head bolt and associated hardware (A) to free other end of lift cable.
Reassemble in reverse order and test for proper raise and lower functions.
When lifting the recovery tank back onto the machine, pay attention to the location of the foam tubes. Route them into the battery
tray, otherwise they will crush.
FIGURE 12
29
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
SQUEEGEE SYSTEM
Squeegee Lift Cable Replacement - ST
CAUTION!
The Recovery Tank is heavy and care should be taken in removing it. Two people recommended, or battery roll-out unit.
REAR:
1 Lower the Squeegee Tool to the floor and then disconnect the battery pack at the red Anderson connector in the battery compartment.
2 Drain the recovery tank using the Recovery Tank Drain Hose (31).
3 Disconnect the Squeegee Hose from the Squeegee Tool and remove the tool from its mount via the two thumbscrews.
4 Lift up the seat and unplug the vacuum motor (and warning beacon if equipped) connectors located in the battery compartment.
5 Open the hinged recovery tank cover and grip the top inside edge of the tank, then pull straight up to free it from the solution tank platform.
Guide the tank off the rear of the machine to the floor.
6 See Figure 13. Using 7/16” wrenches, remove the hex head bolt and associated hardware (A) from the Squeegee Pivot Bracket
Weldment to free this end of the lift cable.
7 Loosen the Adjustment Nut (B) to free the cable from the slotted Cable Bracket.
8 Remove the Cotter and Clevis pins (C) at the white plastic roller to permit cable eyelet clearance as the cable is later pulled through from
the front of the machine.
FRONT:
1 Follow the steps outlined in “Steering Column Assembly Shroud Removal” to allow access to Squeegee Lift Cable in the Steering Column.
2 Use a 1/2” wrench to loosen the cable nuts from the Linkage Arm to free the cable. Note condition of plastic bushing in eyelet and replace
if worn.
3 Loosen Adjustment Nut to free cable from slotted Cable Bracket.
4 Using a 3/8” socket, remove charger and charger bracket underneath, exposing cavity though which cable passes.
5 Pull the cable through the machine from the front.
To reinstall the cable, reverse this procedure.
Follow instructions found in “Squeegee Lift Cable Adjustment – ST” to correctly set the Squeegee Lift Cable tightness.
FIGURE 13
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Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
SQUEEGEE SYSTEM
Squeegee Lift Cable Adjustment - ST
REAR – Figure 14
Factory setting is 0.25”
Follow steps 1 – 6 of Squeegee Lift Actuator Replacement - Advenger / BR 755, 855
• If the cable is too long and the squeegee doesn’t lift off the ground, move the nut closest to the squeegee away from the machine, decreasing
the distance from the nut to the reference end (Figure 14).
• If the cable is too short (squeegee doesn’t reach the ground), back the nut towards the machine, increasing the distance from the nut to the
reference end (Figure 14).
To check the adjustment, lift up on the Squeegee Lift Lever. It should not require excessive force. Too much force needed to move the handle means
that the cable is too tight (short) and the nut should be adjusted accordingly.
FIGURE 14
FRONT – Figure 15
Factory setting is 0.50”
Follow the steps outlined in “Steering Column Assembly Shroud Removal”
• If the cable is too long and the squeegee doesn’t lift off the ground,
move the upper nut away from the machine, decreasing the distance
from the nut to the reference end (Figure 15).
• If the cable is too short (squeegee doesn’t reach the ground), back the
nut towards the machine, increasing the distance from the nut to the
reference end (Figure 15).
FIGURE 15
31
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
SQUEEGEE SYSTEM
Steering Column Assembly Shroud Removal
1
2
3
4
5
6
7
8
See Figure 16. Remove the 4 screws fastening the Lower Column Shroud (A) to the Lower Column Weldment.
(ST) Using a 7/16” socket, remove Squeegee Lift Knob and Linkage Arm (B).
Using a flat bladed screwdriver, pry off the steering wheel plastic center cap.
Using a ¾” socket, remove the hex nut from the steering wheel center.
Pound the steering wheel (C) off from behind using a mallet, observing Woodruff key as it may fly off in the process.
Pull off accordion Steering Boot (D) from the upper steering column.
Lift the battery charger cover.
Pry the plastic Lower Column Shroud off of the weldment by starting on the left side (away from knob) so shroud can clear the
Weldment Linkage bump on the right side (ST - you may want to tap the linkage in a bit to permit clearance).
Reassemble in reverse order, applying a light coating of Silicone Spray or water to the inside of the Steering Boot to permit free travel over
the shaft.
FIGURE 16
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Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
SCRUB SYSTEM
SCRUB SYSTEM
Advenger / BR 755, 855 Disc and Cylindrical - pressing the Scrub On button with the seat switch closed causes the scrub deck and squeegee
to drop. The control board provides 24V to the deck lift actuator M4; this signal is DVM measureable for 3 seconds and then becomes a pulsed
signal while the deck is down. Pressing the drive pedal forward causes the brush and vacuum contactors K2 and K1 to energize. The 24V brush
and vacuum motors M7, M8, M5, (M6) turn on; the pulsed solution solenoid L1 and chemical pump M2 turn on. Combined brush motor current is
monitored via the YEL/VIO sense wire. Reversing the drive pedal turns off the solution solenoid and chemical pump, but the deck remains down
and the brush motors stay on (for double scrub). Because multiple systems are engaged via one button, a further summary is provided in the
section “Understanding Control of Squeegee, Scrub, and Recovery Systems via Modes.”
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Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
SCRUB SYSTEM
Advenger / BR 755, 855 REV Scrub Mode The scrub mode operates like the Disc and cylindrical models
Floor Finish Removal Mode
When in the scrub mode, pressing the Floor finish Removal Mode Switch reduces the machine transport speed and modifies the deck
pressure and solution flow rates. Pressing the Floor Finish Removal Mode switch again will slightly increase the transport speed. Pressing it a
third time will exit the Floor Finish Removal mode and return to the scrub mode.
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Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
SCRUB SYSTEM
ST - with the seat switch closed, lowering the squeegee and brush deck and pressing the drive pedal forward causes the brush and
vacuum contactors to energize. The 24V brush and vacuum motors turn on; the pulsed solution solenoid turns on. Combined brush motor
current is monitored via the YEL/VIO sense wire. Reversing the drive pedal turns off the solution solenoid, but the brush motors stay on
(for double scrub).
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Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
SCRUB SYSTEM
BRUSH MOTOR CONTROL AND LOAD CIRCUIT ERROR CODES AND MEASUREMENTS
Advenger /
BR 755, 855
Display
Error Code
ST Service
LED
Blink Code
5
1, 2
Brush motor circuit overload
10
2, 2
Brush motor K2 contactor coil overload
Fault Description
2, 4
31
Visible
in Fault
Recall Mode
35
3, 2
Visible
in Fault
Recall Mode
60
3, 4
63
4, 3
Brush motor circuit open
Brush motor K2 contactor coil open
Brush motor circuit contacts stuck closed
Brush motor K2 contactor coil control fault
Troubleshooting Action
1. Check for binding in rotation of brushes or improper brush
lift actuator operation.
2. Check for mechanical interference of the brushes with the
side skirts.
3. Check the negative supply cable at the brush motor for a
wiring problem, improper modifications, or poor connections
at the YEL/VIO sense wire.
4. Check that the deck is set correctly in the control board
programming.
Check for short circuit in wiring or K2 contactor coil. Repair
or replace.
1. Check for motor wiring open or defective motor
2. Check the negative supply cable at the brush motor for a
wiring problem or improper modifications (this is a special
cable and must be replaced with original OEM due to sense
wire).
3. Check K2 contacts – if open circuit while scrub is on*,
replace K2.
4. Verify brushes are installed.
5. Verify the brushes are touching the floor and there is no
interference between the deck and the floor.
1. Check coil resistance (see chart below)
2. Check for tight connections at contactor and WHT/RED
wire to control board.
Repair or replace.
With no power to circuit, if contacts measure 0 ohms they’re
stuck. Replace K2.
1. If J3-13 is 24V referenced to B+ when Scrub switch is Off,
replace control board.
2. If J3-13 is 0V referenced to B+ when Scrub switch is Off,
disable fault via Hidden Menu. Refer to “Control Board J1,
J2, and J3 Pin Outs and Test Points” section.
* with Scrub On, the control board at the contactor coils should measure -24V for 2 seconds, then drop to -18V when referenced to B+. The
solution solenoid when On should measure -24V or 0V referenced to B+.
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Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
Brush
Motor Type
SCRUB SYSTEM
Scrub
Pressure
Nominal Current (A)
+/- 3A
Low
Medium
High
27
32
40
Low
Medium
High
23
30
35
Low
Medium
High
Does not use Target Amps for
Scrub Pressure
60
Red
&
Black
Brush
Contactor Coil
Nominal
Resistance
Nominal Current
Overload Current
Wire Colors
K2
120 ohms
200 mA +/- 100 mA
750 mA
Brown
&
White/Red
Disc
Cylindrical
REV
Overload Current (A)
Wire Colors
Red
&
Black
60
Red
&
Black
48
SCRUB DECK LIFT ACTUATOR ERROR CODES AND MEASUREMENTS - ADVENGER / BR 755,
855
Advenger /
BR 755, 855
Display
Error Code
ST
Service LED
Blink Code
4
NA
Scrub deck lift actuator overload
32
NA
Scrub deck lift actuator open
Fault Description
Troubleshooting Action
1. Check for improper actuator adjustment – refer to Actuator Drive
Nut Adjustment section.
2. Check for binding or frozen brush deck lift linkage and excessive
weight on brush deck.
3. Check for short circuit in brush motor and wiring. Repair or
replace.
1. Check for disconnected actuator wiring, open in wiring, defective
actuator motor, or drift in motor current draw to less than 100mA
(call factory for instructions). Repair or replace.
Lift Actuator
Nominal Current (A)
Overload Current
Wire Colors
M4
2.5 – 3.5
5A for > 4 seconds
Blue & Orange/Black
Troubleshooting Scrub System Issues
It is unlikely that the scrub system will malfunction without generating an error code, so most issues will be found on the preceding tables. A few
more machine-specific items are listed here:
Problem
Possible Cause
Advenger / BR 755, 855
Scrub deck lift actuator overload
Mechanical interference between the deck and the ground.
Badly worn internal components of actuator.
ST
Brush motor overload
Pin/spring location is too aggressive on the deck linkage for the floor/brush
combination.
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Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
SCRUB SYSTEM
Scrub Deck Lift Actuator Replacement - Advenger / BR 755, 855
1
2
3
4
5
6
Lower the scrub deck per the instructions found in “Service Test Mode.”
Quickly disconnect the batteries at the red Anderson battery connector inside the battery compartment. This is done not only for safety
but to keep the deck from rising.
Unplug the Deck Lift Actuator connector. (Two connectors for REV deck)
Remove the Cotter Hairpins from the both ends of the actuator.
Remove the Deck Actuator.
Using the Actuator Power Cord Adapter 56407502 from your Nilfisk-Advance service tool kit, set the Extend and Retract limit switch
positions as shown in the “Scrub Deck Lift Actuator Drive Nut Adjustment” section.
CAUTION!
Failure to set the lower stop correctly may result in damage to the Spring Housing (F). (Disc and Cylindrical Decks)
7
Then reassemble in reverse order after drive nut position has been set.
NOTE: to replace a portion of this assembly (items A - G), follow these instructions as they apply, noting component position in the
diagram at right, and set limit switch end stops in accordance with the instructions found in “Scrub Deck Lift Actuator Drive Nut Adjustment”
section.
FIGURE 17
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Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
SCRUB SYSTEM
Scrub Deck Lift Actuator Drive Nut Adjustment Advenger / BR 755, 855 Disc and Cylindrical
1
WARNING!
FIGURE 18
Open the battery compartment and disengage the red
Anderson battery connectors.
2 Connect the Scrub Deck Lift Actuator (completely
assembled) to the Actuator Power Cord Adapter 56407502
(see “Diagnostic and Service Tools”).
3 Connect the red alligator clip to the positive battery terminal.
4 Connect the black alligator clip to the negative battery
terminal.
5 Hold onto the plastic Spring Housing (F) /Drive Nut
assembly and press the rocker switch to run the motor and
retract the nut towards the motor housing (the IN or Retract
Limit).
6 Measure the position of the Spring Housing Guide (B) in
reference to the shoulder as shown in the figure below.
7 Manually turn the plastic Spring Housing (F) assembly until the position measure matches the figure below.
8 Hold the Spring Housing and press the rocker switch, running the motor until it stops but no further than 4” from the shoulder as
shown in the figure below or damage to the Housing may occur.
9 If the measurement doesn’t match 3.94” (100.08mm) as shown below, pry off the black cover (H) to access the Cam Adjuster.
Using a 1/2” socket, gently turn the adjuster CW to increase travel, CCW to decrease travel of the Drive Nut. Each click of the adjuster will
change the nut travel by 0.09” (2.29mm) or just under 3/32”.
10 After each adjustment, re-check the travel by holding the Spring Housing/Drive Nut assembly and running the actuator IN and OUT,
checking against the values below.
11 Repeat until it is set correctly and replace the Cam Adjuster cover (H).
FIGURE 19
39
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
SCRUB SYSTEM
Advenger / BR 755, 855 REV
The total travel of the actuator is not adjustable, however, the position of the spring housing must be
“timed” to the fully extended motor position as follows:
1
2
3
4
5
6
WARNING!
Open the battery compartment and disengage the red Anderson battery connectors.
Connect the Scrub Deck Lift Actuator two wire motor connector (completely assembled) to the Actuator Power Cord Adapter
56407502 (see “Diagnostic and Service Tools”).
Connect the red alligator clip to the positive battery terminal.
Connect the black alligator clip to the negative battery terminal.
Hold onto the plastic Spring Housing (F) /Drive Nut assembly and press the rocker switch to run the motor to the fully extended
position.
Manually turn the plastic Spring Housing (F) assembly until the position measure matches the figure below in the extened position.
3 1/4” Extended (No Load)
0” Retracted (No Load)
40
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
SCRUB SYSTEM
41
Scrub DECK REMOVAL - Disc and REV
WARNING!
DISCONNECT BATTERIES BEFORE SERVICING.
Scrub Deck Removal / Re-installation
1
2
3
4
5
6
7
Remove both deck side skirt assemblies.
Lower the scrub deck with brushes (pads) installed. STD / AXP / EDS SERVICE NOTE: Don’t turn the key switch off until after disconnecting
the battery. This procedure is done to prevent the scrub deck from automatically raising when the key is turned off.
See Figure 20. Disconnect the solution system water line located on top of the scrub deck.
Disconnect brush motor wiring harness connectors (A) (under right side of machine) and actuator connector(s).
Remove the two (B) Hitch Pins that attach the scrub deck to the machine chassis linkage arm weldment.
From the right side of the machine pull the deck out from under the machine to complete the removal.
To install a scrub deck and roller bumper (if applicable), follow the previous steps in reverse order.
FIGURE 20
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
SCRUB SYSTEM
Scrub Brush Motor Removal - DISC
(also needed for Carbon Brush check)
1 See SCRUB DECK REMOVAL-DISK to remove the scrub deck assembly.
2 See Figure 21. After removing the deck turn it over so the Brush Plates are on top.
3 Remove the hex socket screw (A) from the Motor Gimbal located at the Brush Plate center.
4 Remove the Brush Plate Assembly (B). NOTE: It may be necessary to pry the assembly off the motor shaft. Do not pry on the outer
edge of the Brush Plate Assembly (B) as this could damage the plate. Pry using a flat screw driver (C) against the aluminum gimbal
shoulder underneath the Brush Plate.
FIGURE 21
42
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
Scrub Brush Motor Removal - DISC
See Figure 22. Mark the bolt locations (A) before removing them
because one deck is used for all deck sizes and there are multiple
configurations.
6 See Figure 23. Extract the solution hose (B) from the motor
bracket (C).
7 Remove the bolts and nuts (D) and remove the motor assembly (E)
from the deck.
8 Disassemble the existing scrub brush motor from the bracket.
9 Apply Loctite #242 to the motor bolts before fastening the new
motor to the bracket.
10 Feed the hose back into the bracket making sure that the hose is
pointed towards the shaft.
5
SCRUB SYSTEM
FIGURE 22
CAUTION!
If the hose is not positioned correctly, the scrub brush will be
damaged (melted) due to lack of water.
11 Reattach the motor/bracket assembly to the deck making sure to
use the correct holes. (If position is not correct, brushes will either
interfere with each other or with the deck sides.)
12 Lubricate the Motor Gimbal and apply anti-seize to the socket head
bolt before reassembly.
13 Press the Brush Plate firmly onto the motor shaft. If it is not pressed
in completely, the deck will not be level, causing one motor to
prematurely burn out. (see Caution).
CAUTION!
ST - the control board monitors total current drawn by both motors
combined. It cannot differentiate if one is bound and pulling high
current, or if one is forced into the floor while the other is barely
making contact. To verify proper operation of each motor, monitor
them individually with a current clamp while the machine is
scrubbing.
14 Firmly tighten the socket head screw without
over-torquing as damage to Motor Gimbal may
occur.
FIGURE 23
43
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
Scrub Brush Deck Motor Removal - REV
1. Remove the Brush Head from the machine. (See Removal and Installation, Brush Head.)
2. Flip the deck disc side up and remove the pads.
3. Remove the pad holder by removing the 6 attaching screws.
4. Remove the counter weight by removing the two attaching bolts
Counter weight
SCRUB SYSTEM
44
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
SCRUB SYSTEM
5. Lift the driver motor with the eccentric from the brush motor shaft being careful not to lose the squarecut key.
Driver Motor
Key
Eccentric
6. Note the orientation of the brush motor electrical leads relative to the deck to make sure you install the
motor in the same position. You may want to mark the orientation of the brush motor to the motor plate.
Then separate the brush motor from the motor plate by removing the 4 attaching screws and remove the
motor.
7. Reassemble in reverse order noting the following:
8. Use a small amount of Loctite Threadlocker blue 243 or equivalent on all fasteners.
9. Apply Loctite Anti-seize (90101A) to the bore of the eccentric before installing eccentric on brush motor
shaft.
45
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
SCRUB SYSTEM
Drive Motor, Bearing and Eccentric (REV)
Removal
1. Remove the brush head and brush motor according to the previous
sections.
2. Press the eccentric out of the bearing inner race using an arbor
press.
3. Remove the bearing retainer by removing the three fasteners.
4. Press the bearing out of the driver motor using an arbor press.
Eccentric
Bearing
Bearing
Retainer
Driver
Motor
Gasket
Installation
1. Apply Loctite 609 retaining compound to the bearing bore in the driver motor and to the surface of the inner bearing race.
2.
3.
4.
5.
6.
Press the bearing into the driver motor.
Install the bearing retainer.
Press the eccentric into the bearing.
Install a new gasket on the driver motor with the adhesive side toward the driver motor.
Apply Loctite Anti-seize (90101A) to the bore of the eccentric.
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Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
SCRUB SYSTEM
Motor Plate and isolators (REV)
Removal
1. Remove the brush head from the machine.
2. Remove the brush motor.
3. Remove the retainers.
Remove
4. Remove the motor plate by removing the 4 isolator nuts. Inspect the splash shield and replace if damaged..
Inspect
Splash Shield
Remove
4 isolator
nuts
5. Flip the scrub head upright and remove each of the isolators from the brush head by removing the attaching nuts.
Isolators
Remove
47
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
SCRUB SYSTEM
Installation
1. Apply Loctite blue 243 threadlocker or equivalent to the threads of each isolator.
2. Install the isolators in the brush head. Position each one so that the color stripe it will be visible when the motor plate is installed.
Torque each nut to 8-10 ft. lbs. (10.8- 13.5 N m). Install the 4 plastic covers over the nuts.
Color
Stripe
3. Apply Loctite blue 243 threadlocker or equivalent to the threads of each isolator. Install the motor plate and 4 isolator nuts.
Torque each nut to 8-10 ft. lbs. (10.8- 13.5 N m). Ensure that the isolator rubber does not twist when you tighten the nuts.
Visually inspect the color stripe to make sure that it is straight line and not twisted. If it is twisted, loosen the nut and repeat the
procedure. It may be necessary to hold the isolator in position with your hand while tighten the nut.
48
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
Scrub Motor Carbon Brushes (REV)
1. Remove the brush head from the machine.
2. Remove wire retaining nut and rubber packing.
3. Mark orientation of end plates to motor housing and remove both through bolts.
4. Remove end plate.
SCRUB SYSTEM
49
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
SCRUB SYSTEM
5. Replace the carbon brushes.
a. Observe how the springs roll when the brush is pushed back before taking it apart.
b. Remove a brush and spring.
c. Install a new brush and spring into the brush holder. Thread the brush wire lead through the brush holder. Position the
back end of the brush in the “cup” of the spring so that the spring will unroll as the brush is pushed back once it is
installed.
Cup Side
d. Push brush back against the spring and insert a stiff temporary retaining wire (Paper clip) through the access hole in
the end cover. (Remove silicone sealer from the holes) The wire must go through the holes in the brush holder just in
front of the brush to hold the brush back against the spring pressure.
Paper Clip
e. Install the other three brushes.
6. Install the spring washer so that the “fingers” will press against the outside bearing race.
Fingers
against
Outer Race
7. Install the end cover in stages.
Paper Clip
50
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
SCRUB SYSTEM
a. Install it far enough so that the brushes will contact the commutator when the temporary retaining wires are removed.
Then remove the wires.
Carbon
Brush
Commutator
b. Fully seat the end cover.
c. Install the through bolts.
d. Seal the retaining wire holes in the end cover with silicone sealant.
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Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
SCRUB SYSTEM
Scrub DECK REMOVAL - Cylindrical
WARNING!
DISCONNECT BATTERIES BEFORE SERVICING.
Scrub Deck Removal / Re-installation
1
2
3
4
5
6
7
Remove both deck side skirt assemblies and the debris tray.
Lower the scrub deck with brushes installed. STD / AXP / EDS SERVICE NOTE: Don’t turn the key switch off until after disconnecting
the battery pack. This procedure is done to prevent the scrub deck from automatically raising when the key is turned off.
See Figure 24. Disconnect the solution system water line located on top of the scrub deck.
Disconnect both brush motor wiring harness connectors (A) (under right side of machine).
Remove the two (B) Hitch Pins that attach the scrub deck to the machine chassis linkage arm weldment.
From the right side of the machine pull the deck out from under the machine to complete the removal.
To install a scrub deck and roller bumper (if applicable), follow the previous steps in reverse order.
FIGURE 24
52
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
SCRUB SYSTEM
53
Scrub Brush Motor Removal - Cylindrical
1
2
See SCRUB DECK REMOVAL-CYLINDRICAL to remove the scrub deck assembly.
See Figure 25. Remove the Belt Cover (A) on each 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 replaced. Remove the
Belt (B).
3 Remove the wiring at both the Pos. & Neg. brush motor terminal studs and note the correct wiring connections (for reinstallation). Then
remove the (3) Screws (C) and lift the motor (D) out from the scrub deck.
4 Reassemble in reverse order, installing motors with wires pointing to the rear towards the hopper.
5 Apply anti-seize to the motor shafts.
* Rotation from shaft end.
NOTE: the belts are self-tensioning.
FIGURE 25
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
RECOVERY SYSTEM
RECOVERY SYSTEM
The recovery system is controlled via the control board output to contactor K1 coil, turning on one or both (if equipped) vac motors M5
(M6), with control board feedback provided via the BRN/RED vac motor current-monitoring sense wire.
Refer to the section “Understanding Control of Squeegee, Scrub, and Recovery Systems via Modes” for details about functionality of the
Recovery System due to multiple systems operating in tandem under various seat switch and button configurations.
For the Recovery System to function properly, the systems mentioned above in addition to the Wheel Drive System must be operating
properly in order for the vac motors to turn on unless by-passed by entering Service Test Mode for troubleshooting purposes.
ADVENGER / BR 755, 855
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Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
ST
RECOVERY SYSTEM
55
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
RECOVERY SYSTEM
RECOVERY SYSTEM ERROR CODES AND MEASUREMENTS
Advenger
/ BR 755,
855 Display
Error Code
ST
Service LED
Blink Code
7
1, 3
Vacuum motor circuit overload
9
2, 1
Vacuum K1 contactor coil overload
Fault Description
Troubleshooting Action
1. Check for motor wiring open or defective motor,
2. Check the negative supply cable at the vac motor for a wiring
problem or improper modifications (this is a special cable and must
be replaced with original OEM due to sense wire).
3. Check K1 contacts - if open circuit while vac is turned on (0V at
J3-12), replace K1.
3, 1
33
Visible
in Fault
Recall Mode
36
3, 3
Visible
in Fault
Recall Mode
61
4, 1
64
4, 4
1. Check for debris in vac motor
2. Check for worn carbon brushes
3. Check for defective/corroded motor bearings
4. Check for short circuit in vac motor or wiring.
5. Check the negative supply cable at the vac motor for a wiring
problem, improper modifications, or poor connections at the BRN/
RED sense wire.
Repair or replace.
Check for short circuit in wiring or K1 contactor coil.
Repair or replace
Vacuum motor circuit open
Vacuum K1 contactor coil open
1. Check coil resistance (see chart below).
2. Check for tight connections at contactor and GRA/BLK wire to
control board. Repair or replace.
Vacuum K1 contactor contacts stuck
closed
With no power to circuit, if contacts measure 0 ohms they’re stuck.
Replace K1.
Vacuum contactor coil control fault
1. If J3-12 is 24V referenced to B+ when Vacuum switch is Off,
replace control board.
2. If J3-12 is 0V referenced to B+ when Vacuum switch is Off,
disable fault via Hidden Menu. Refer to “Control Board J1, J2, and
J3 Pin Outs and Test Points” section.
Vacuum
Motor
Single/Dual
Nominal Current (A)
+/- 3A
Overload Current (A)
Wire Colors
M5
Single
20
30
White & Black
M5 + M6
Dual
40
60
White & Black
Vacuum
Contactor Coil
Nominal
Resistance
Nominal Current
Overload Current
Wire Colors
K1
100 ohms
240 mA +/- 50 mA
750 mA
Brown
&
Gray/Black
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Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
RECOVERY SYSTEM
57
Troubleshooting Recovery System Issues
Problem
Possible Cause
Advenger / BR 755, 855 and ST
Poor water pickup from squeegee tool
Vacuum motor keeps corroding and failing.
Vacuum motor is normally dry, now it’s wet and
failing.
1. Misadjusted squeegee tool - refer to “Squeegee Alignments” section
2. Worn or damaged blades - refer to Operating Manual for instructions
3. Leak in vacuum system - check for bad gasket, leaky hose, damaged tank, leaky drain
valve.
4. Restriction in vacuum system - check for debris in squeegee tool, vacuum hoses, float
cage, or wherever air is forced to make a sharp turn.
Liquid is being pulled into vac motor due to excessive foam in recovery tank. Recommend
defoamer and don’t fill until shuts off automatically.
Vacuum leak below the water line creating turbulence in the recovery tank, causing water
to enter the vacuum motor.
The control board doesn’t indicate the recovery
tank is full before the ball valve shuts off the vac
motor.
1. Check the vacuum motor sense wire (BRN/RED) for break or poor connection (mV
signal).
2. Check that cage for ball float is clean.
Display shows the recovery tank is full but it’s not.
Disable Recovery Tank Full automatic shut-off via Hidden Menu.
ST
Vacuum motor doesn’t turn on
1. Go into Fault Recall mode and check for error code 3,1 for vac motor circuit problem.
2. Check limit switch S6 in steering column. Moving the handle to the down position
should move squeegee cable down and close switch S6 turning on the vac motor circuit if
operating properly.
Vacuum motor contactor doesn’t energize
Go into Fault Recall mode and check for error 3,3
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
RECOVERY SYSTEM
Replacing a Vacuum Motor
WARNING!
DISCONNECT BATTERIES BEFORE SERVICING.
RECOVERY TANK REMOVAL
1
2
3
4
See Figure 26. Drain the Recovery Tank (A) using the Drain Hose(B).
Disconnect the Recovery Hose (C) from the squeegee.
Disconnect the vacuum motor wiring from the main harness. NOTE: Also disconnect optional Beacon wiring if installed.
Remove the Recovery Tank (A) from the machine.
FIGURE 26
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Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
RECOVERY SYSTEM
REPLACING A VACUUM MOTOR
VACUUM MOTOR ASSEMBLY REMOVAL
5
6
7
See Figure 27. Lay the Recovery Tank (A) on it’s back.
Remove the (6) Screws (B) and remove the Vacuum Motor Cover (C) from the tank.
Remove Plate and Gaskets (D) and Vacuum Motor (E).
NOTE: The wires should be protruding up through the hole and not from around the edge of the plate. If they are coming from under the
plate, examine for damage and repair if cut.
VACUUM MOTOR ASSEMBLY INSTALLATION
8
9
Attach gaskets (F) and (G) to the new vac motor; attach gasket (H) to the Vac Motor Cover, and insert motor into base.
Reassemble in reverse order, paying attention to route wires up through hole and out towards the back in the groove of Vac Motor
Cover (C).
FIGURE 27
59
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
SOLUTION SYSTEM
SOLUTION SYSTEM
The Solution System is controlled via a pulsed 24V signal from the control board at J3-11 to the Solution Solenoid valve. On Advenger /
BR 755, 855 machines, the solution flow rate is also controlled via feedback provided by a pressure sensor on the control board. For more
details, refer to the “Solution System Control” section in this chapter.
To avoid clogging and malfunction of solution system components, it is recommended to avoid using chemicals that are known in the
industry to cause performance degradation in commercial auto scrubbers. These chemicals include d-limonene (frequently found in
“orange” type cleaners and not listed on the MSDS), and in hard-water areas, carbonates, silicates, and phosphates, which are listed on
the MSDS.
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Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
SOLUTION SYSTEM
SOLUTION & AXP/EDS SYSTEM ERROR CODES AND MEASUREMENTS - ADVENGER / BR 755,
855 AND ST
Advenger /
BR 755, 855
Display
Error Code
ST Service
LED
Blink Code
Fault Description
Troubleshooting Action
8
1, 4
Solution solenoid overload
11
NA
Chemical pump overload
2, 3
30
1. Check for a wiring problem.
2. Check coil resistance (see below).
3. Replace solenoid if coil is shorted.
1. Check for a wiring problem.
2. Replace pump.
1. Check for disconnected solenoid wiring plug, open in
wiring, or open in solenoid (see below).
2. Repair or replace.
Voltage at control board should be -24V referenced to B+.
Visible in
Fault Recall
Mode
Solution solenoid open
37
NA
Chemical pump open
62
4, 2
Solution solenoid control fault
Solution
Solenoid
Nominal
Resistance
Nominal Current
Overload Current
Wire Colors
L1
35 ohms
650 mA
750 mA
BRN & VIO/BLK
Chemical Pump
Nominal Current
Overload Current
Wire Colors
M2
PWM
870 mA PWM
n/a
1. Check for disconnected plug or open in wiring.
2. Repair or replace
When the pump is On, it makes a clicking noise.
If the board output is correct it should appear as a pulsed
signal to a DVM.
1. If J3-11 is 24V referenced to B+ when Solution switch is
Off, replace control board.
2. If J3-11 is 0V referenced to B+ when Solution switch is Off,
disable fault via Hidden Menu. Refer to “Control Board J1,
J2, and J3 Pin Outs and Test Points” section.
Troubleshooting Solution & AXP/EDS System Issues
Problem
Possible Cause
Inadequate or no solution flow
No solution in the tank.
Red Solution Shutoff Valve (21) is in the Off position .
Clogged Solution Filter (20), valve L1, or hoses.
L1 Solution Solenoid Valve defect.
Main controller fault.
Advenger / BR 755, 855
Solution tank level indicator shows empty even
though the tank is full
Solution flow and/or chemical rate don’t appear to
follow programming
Solution level indicator doesn’t work after new
control board installed
Chemical rate doesn’t match manufacturer
specifications
Small clear hose at pressure sensor on control board is kinked - refer to “Replacing the
Operator Control Panel“ for instructions.
1. Air leak at hose connection to pressure sensor.
2. Air leak at Pressure Sensing Tube fitting.
3. Small clear hose at pressure sensor on Interface Control Panel is kinked.
1. Solution tank wasn’t completely drained before installation of new Interface Control
Panel. Completely drain the solution tank and the pressure differential should work
properly again.
2. Check for air leaks at re-connected hose fittings.
Check that pump is wired correctly and that the polarity isn’t reversed.
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Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
Solution System Diagram
FIGURE 28
SOLUTION SYSTEM
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Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
SOLUTION SYSTEM
Solution System Control
Advenger / BR 755, 855
The control board output of pulsed voltage signals driving the Solution System is controlled by the following three parameters:
1 The deck size and type (factory set but selectable via Hidden Menu).
2 The Solution Flow Rate chosen by the operator through the user interface.
3 The Liquid Level Sensor.
The liquid level in the Solution Tank is measured by the Pressure Sensor through the Pressure Sensing Tube. As the liquid level decreases,
the pulsed feedback of the Pressure Sensor drives the control board to compensate for this drop in maximum output by adjusting the duty
cycle of the solution solenoid, thereby keeping the flow rate constant.
FIGURE 29
A malfunction of either the Pressure Sensor, the Control Panel, or an air leak in the pressure sensing system may affect the performance of
either the Chemical Pump or the Solution Solenoid, or both.
ST
The pulsed 24V output of the control board that controls duty cycle of the Solution Solenoid is driven by:
1 Control board programming of deck size and type (factory set but selectable via the Hidden Menu).
2 The Solution Flow Rate chosen by the operator through the user interface.
ST machines don’t have a Pressure Sensor that monitors liquid level in the Solution Tank. Since the maximum output of the Solution Solenoid
varies with liquid level, as the level drops in the tank, the output of the Solution Solenoid will also drop. As the tank empties, this results in a
decrease in solution output to the brushes from the “full” rate.
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Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
SOLUTION SYSTEM
Replacing the Solution Solenoid Valve
1
2
3
4
5
6
7
Advenger / BR 755, 855 - follow instructions found in “Service Test Mode” to lower the scrub deck.
ST - manually lower the scrub deck.
WARNING!
Quickly disconnect the batteries at the red Anderson connectors in the battery compartment (done for safety and to keep the deck from
rising back up).
Reach under the front left side of the machine and manually close the red Solution Shutoff Valve (21) adjacent to the Solution Filter (20).
Using a flat blade screwdriver or 5/16” socket, loosen the two hose clamps on the valve and remove the black Solution Hose (A) from
the inlet side and the clear hose (B) coming from the deck manifold.
Using a 7/16” socket, remove the bolt fastening the Solution Solenoid to the machine.
Unplug the valve body at the connector (C).
Replace the valve and reassemble in reverse order.
FIGURE 30
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Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
WHEEL DRIVE SYSTEM
65
WHEEL DRIVE SYSTEM
The drive wheel assembly is directly connected to the Curtis 1228 speed control, which not only provides an output signal of 24V to the drive wheel
for forward and reverse movement, but also monitors current and temperature, and controls the electromagnetic brake. It is the same for both the
Advenger / BR 755, 855 and ST models. The speed control is programmable through, and can be monitored via, the Curtis Handheld Programmer
56409441 and Curtis Adapter Cable with Quad Plug 56409823, listed in the recommended “Diagnostic and Service Tools” section of this manual.
For information on how to use the Curtis programmer, please refer to the Curtis Programmer Manual 56043101.
The 5k Ohm throttle pot R1 in the foot pedal controls drive speed and forward/reverse movement. The throttle pot input to the main control board
also determines whether or not the scrub and vacuum systems will engage, and is therefore critical to machine performance. If the control board
senses a Neutral position of the foot pedal, it will not engage these other systems unless placed in Service Test Mode or one of the vacuuming-only
modes.
The Electromagnetic Brake is engaged whenever the foot pedal is in Neutral, and released for forward or reverse motion.
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
WHEEL DRIVE SYSTEM
WHEEL DRIVE CIRCUIT ERROR CODES AND MEASUREMENTS
Advenger /
BR 755, 855
Display
Error Code
3
ST Service
LED
Blink Code
1, 1
Fault Description
Troubleshooting Action
Speed control fault
(will disable all systems unless fault
detection is disabled in the Hidden
Menu)
1. Verify connector at Drive Pedal is connected
2. Refer to “Speed Control Flash Codes” section
3. Repair
4. Reset machine via key switch.
Wheel Drive
Motor
Typical Current (A)
Transport, Full Throttle
Typical Current (A)
Scrub Mode, Level Floor
Wire Colors
M1
15 - 20
15 - 50
Red/Green and Yellow/Black
(2 wires combined - required to prevent
overheating if rotor locks)
Troubleshooting Drive Wheel Issues
Problem
Advenger / BR 755, 855 - the LCD indicates E03 and
the chemical LED flashes a code
ST - the Fault Indicator LED is blinking 1, 1 and the
Extreme Solution Flow LED flashes a code
The wheel drive motor will not run in forward or reverse.
The wheel drive motor will only run in either
forward or reverse.
Possible Cause
1. Verify connector at Drive Pedal is connected.
2. Refer to “Speed Control Flash Codes” section.
3. Repair
4. Reset machine via key switch.
1. Verify connector at Drive Pedal is connected.
2. Refer to “Speed Control Flash Codes” section.
3. Repair
4. Reset machine via key switch.
1. Batteries need charging (low battery voltage, recharge batteries)
2. Wheel Drive Motor Circuit Breaker (CB1) tripped (reset 70A circuit breaker)
3. Control Board Circuit Breaker (CB2) tripped (reset circuit breaker)
4. Emergency Stop Knob (7) tripped (pull out and twist)
5. Safety Switch (S2) in seat not closed (check seat switch)
6. Defective Wheel Drive Motor (replace motor)
7. Defective Throttle Potentiometer (R1) (replace)
1. Test the Fwd & Rev (R1) wiring outputs (pins 3, 4 & 13) at the
speed control for an open. Repair wiring or replace the R1 pot.
2. Controller can’t change electrical polarity to wheel motor replace the (A2) speed control.
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Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
WHEEL DRIVE SYSTEM
Replacing the Drive Wheel Assembly
WARNING!
Park the machine on a dry flat surface, turn the main key switch (J) to the Off position and disconnect the battery pack at the red Anderson
connectors inside the battery compartment.
1 Block the rear wheels.
2 Jack up the front of the machine as shown in “Jacking Points” section or use a hoist to lift up the front end of the machine.
3 See Figure 31. Using a 17mm socket, loosen but don’t remove the four bolts (A) at the steering sprocket to allow the chain to release
some.
4 Using a 3/8” magnetic socket, remove the four bolts holding the charger in place, and move the charger over to the side.
5 See Figure 32. Using a 1 7/16” socket, remove the hex nut (B) at the top of the Spindle Weldment.
6 See Figure 33. Turn the Drive Wheel to the right and remove the motor wiring cover (C).
7 Using a 13mm and a 7mm socket, remove the nuts and wires from the drive motor.
8 See Figure 34. Turn the motor towards the left. Using a 7/16” socket and wrench, remove the P-clamp (D).
9 Jack up the front end of the machine enough to allow the wheel to slip free from the machine.
10 See Figure 31. Using a 17mm socket, remove the four bolts (A) at the top to free the motor from the Steering Plate.
FIGURE 32
FIGURE 31
FIGURE 33
FIGURE 34
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Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
WHEEL DRIVE SYSTEM
REPLACING THE DRIVE WHEEL ASSEMBLY (CONTINUED)
11 Reassemble the drive wheel in reverse order, attaching the motor wires as shown.
CAUTION!
Use a Torque Wrench set at 20 ft-lb to retighten the 1 1/2” hex nut at the top of the steering spindle.
NOTE:
Orient the wires in such a way as to minimize bending at the crimps for optimum motor performance.
There are (2) each YEL/BLK and RED/GRN going to each post.
FIGURE 35
YELLOW/BLACK
WHITE
RED/WHITE
BLACK
RED/GREEN
ORANGE
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Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
WHEEL DRIVE SYSTEM
Replacing the Drive Tire
Replacing the drive tire (metal wheel with urethane tire) requires the tire pulling kit (56422174). The drive
tire may be replaced without removing the drive assembly from the machine, but you may find it easier to
remove the drive wheel assembly.
1. To reduce the weight of the machine, drain both the recovery and solution tanks. To lower the center of
gravity of the machine, you may even choose to remove the recovery tank from the machine.
2. Block both sides of the machine at the rear lifting points (15) to keep the machine stable and prevent
it from rolling. To prevent tipping, it is also a good idea to
chain the machine down at the rear lifting points.
3. Raise the front of the machine by jacking at the center front
flat surface of the solution tank.
38
4. Using a 5mm hex key, remove the four screws (38) that
secure the drive hub (40) to the internal gearbox.
5. Using a 5mm hex key, remove the six screws (39) that
secure the drive hub to the tire (wheel).
40
6. Insert the four wheel puller bolts (41) through the drive
housing, and hand tighten them until they equally touch the
metal wheel portion of the tire assembly.
39
7. Using a 5mm hex key, gradually tighten each bolt at about
1/2 to 1 turn at a time. Work in a crisscross pattern so each
bolt pushes the wheel off the main bearing (42) equally. (The
wheel hub (40) will come free after just a few turns.)
For reference, the wheel/tire presses over the main bearing (42). The drive hub (40) is lightly pressed onto
the tapered disk (43) of the gearbox.
Motor removed
for clarity.
42
43
41
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Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
WHEEL DRIVE SYSTEM
Replacement Notes
1. Install the drive hub (40) to the new
wheel/tire using the six socket head cap
screws (39).
43
44
38
40
2. Remove the tire pulling bolts (41) from
the drive housing.
3. Lightly install the two alignment pins
(44) into two of the threaded holes of the
gearbox output disk (43).
4. Slide the drive hub (with the new wheel/
tire) over the alignment pins.
39
5. Gently tap on the upper portion of the
drive hub (40) to get the wheel started
over the main bearing (42) until the
mounting screws (38) can be started in
their threads.
6. Remove the alignment pins (44), and replace them with the two remaining mounting screws (38).
7. In small increments, simultaneously tighten all four mounting screws to pull the drive hub tight to the
gearbox output disk (43).
8. Finish reassembling the machine by reversing the disassembly steps.
The Drive Wheel is assembled as shown:
FIGURE 36
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Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
WHEEL DRIVE SYSTEM
Inspecting/Replacing the Drive Wheel Assembly Carbon Brushes
IMPORTANT!
To remove/replace/inspect the Carbon Brushes, observe the following:
1
2
The motor must come off of the machine.
The motor assembly must be kept vertical while being disassembled to prevent loss of gear oil.
WARNING!
Park the machine on a dry flat surface, turn the main key
switch (J) to the Off position and disconnect the battery
pack at the red Anderson connectors inside the battery
compartment.
1
2
Follow the instructions in “Replacing the Drive Wheel
Assembly”.
Place the motor assembly upright, motor side up, as shown.
CAUTION!
To prevent gear oil from draining from the gearbox,
disassemble the motor with the Drive Wheel assembly in a
vertical position. If some oil is lost, drain completely and refill
the oil as indicated at the bottom of the page.
3
4
5
6
7
8
See Figure 37. Remove the four metric socket head cap
screws (A) securing the electric motor to the casting.
Use a hard piece of wood or a brass drift punch to tap the
motor mounting flange (3 notched locations (B)) to loosen.
Grip the motor/brake end bell and pull the motor (C) up and out
of its housing.
Inspect the 4 carbon brushes and springs. A new carbon brush
measures 3/4”. If less than 1/4”, replace.
Clean the foam filters, and blow out the motor.
If gear oil has been lost, drain and replace with 4.5856 oz (130
g) of Mobilgear 600 XP 150 or AGIP BLASIA 150 gear oil.
FIGURE 37
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Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
WHEEL DRIVE SYSTEM
Replacing the Rear Wheels
WARNING!
Park the machine on a dry flat surface, turn the main key switch Off and disconnect the battery pack at the red Anderson connectors
in the battery compartment.
1
2
3
4
5
6
7
Block the front Drive Wheel (4).
Jack the Rear Wheel (9) to be replaced per the instructions at the front of this manual in “Jacking Points” section.
To prevent injury, if the rear wheel bearing has frozen, replace the bottle jack with blocks or a jack stand before pounding the wheel.
See Figure 38. Use a 17mm socket to remove bolt (A), washer (B) and wheel (C).
If the bearing has seized, pound off the wheel and use a bearing puller to remove the inner race from the axle.
Apply anti-seize to the inner bearing surface of the new wheel; then replace wheel on axle.
Apply anti-seize to the bolt threads before refastening bolt, washer and wheel.
FIGURE 38
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Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
ELECTRICAL SYSTEM
73
FIGURE 39
ELECTRICAL SYSTEM
ACCESS TO PANEL: CHEMICAL PUMP, CHARGER INTERLOCK, FUSES,
CONTACTORS, SPEED CONTROL
1
2
3
•
•
•
•
WARNING!
Open the battery compartment and disengage the red Anderson
battery connectors.
Remove the 3 (AXP/EDS - 4) screws fastening the electrical panel
to the front of the machine.
See Figure 39. Inside are found the following:
Curtis speed control (A) with Drive Wheel motor and logic
connections
K1 and K2 contactors (B)
Fuses (C) - as shown with onboard charger green interlock wire
connected. If no charger, red wire shown would be connected
there instead.
Chemical pump (D) (below fuses)
THROTTLE POTENTIOMETER WIPER
MEASUREMENT (NEUTRAL POSITION)
Use a DVM and extended insulated probe tips (shown)
to measure the throttle potentiometer Neutral voltage
the wiper (pin 4, the GRA wire) referenced to the Bstandoff (green wires).
at
WARNING!
Open the Electrical Access Panel carefully per step 2
above.
Batteries must be connected to perform this measurement
so extreme caution should be observed.
CAUTION!
Use only insulated test probes designed to
backprobe. SPEED CONTROL IS POWERED
during these tests.
Referenced to the negative battery standoff, the wiper voltage should read:
Neutral: 2 - 3V
Reverse: < 2V (engage pedal in reverse to measure)
Forward: > 3V (engage pedal forward to measure)
Pin
3
4
5
6
9
13
14
16
18
Function
5kOhm Pot High
5kOhm Pot Wiper
Seat Switch
Brake Error Status
5kOhm Pot Low
Brake +
Reverse Alarm
Speed Limit
Wire Color
YEL
GRA
GRA/BLK
RED/WHT
ORN/BLU
VIO
ORN
BLU/BLK
BLK/WHT
FIGURE 40
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
ELECTRICAL SYSTEM
Control board j1, j2, and j3 pin outs and test points
CAUTION!
Always take measurements at the end connectors for troubleshooting purposes. If readings taken there do not indicate the problem, check the
control board as a last resort as damage to the board may occur (see Caution statements in “Replacing Operator Control Panel” section).
Use a DVM and extended insulated probe tips (shown) to take the following measurements.
CAUTION!
Use only insulated test probes designed to backprobe. CONTROL BOARD IS POWERED during these tests.
Perform steps 2 and 3 of “Replacing Operator Control Panel” section, observing noted Caution statements.
J1 - Advenger / BR 755, 855 only - Brush deck lift actuator, squeegee lift actuator, chemical pump
To backprobe J1 for voltages, leave J1 connected to the control board.
Disc and Cylindrical
The followoing tables show the connector in the center, highlighted in gray with related informatin for the pin
off to either side.
Referenced to
Measure
B+
+24V to M4 for 3 sec. deck
downward travel
0V to M4 for 3 sec.
deck upward travel
B+
0V to M4 for 3 sec. deck
downward travel
+24V to M4 for 3 sec.
deck upward travel
BLU
4
B+
Not measurable using DVM
BLU/GRY
B-
Not measurable using DVM
J1
ORN/BLK
RED/YEL
Measure
Referenced to
WHT/GRN
0V to M3 for 3 sec.
squeegee down travel
24V to M3 for 3 sec.
squeegee up travel
B+
9
BLK/YEL
24V to M3 for 3 sec.
squeegee down travel
0V to M3 for 3 sec.
squeegee up travel
B+
3
8
BLK
B-
2
7
1
6
5
10
Range of 24V measurements is 20 – 26 V
74
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
ELECTRICAL SYSTEM
Backprobe J2 - Speed Control outputs, ST deck and squeegee lever position, and sense wires, J2 connected at control board:
Referenced to
Measure
B-
n/a
YEL
6
12
B-
n/a
VIO
5
11
B-
n/a
J2
BLK/WHT
4
9
Referenced to
BLK/YEL
ST squeegee lever switch S6
Closed sq down 0V
Open sq up 5V
B-
ORN/RED
ST deck lever switch S5
Closed deck up 0V
Open deck down 5V
B-
M7 & M8 sense
monitor brush heights for deck
actuator feedback
0-200 mV
B-
M5 & M6 sense
monitor vac motors to determine
when tank is full
1-200 mV
B-
YEL/VIO
10
3
Measure
BRN/RED
B+
Advenger / BR 755,
855 B- (ground) input
to board
+24V
Advenger /
BR 755, 855
BLK
2
8
BLK
+24V
B+
B+
B- (ground)
Input to board
+24V
BLK
1
7
BLK
Advenger / BR 755, 855 +24V
B+
Backprobe J3 - Output to Contactors, Solution Solenoid, Horn; Speed Control error status, EM Brake, reverse status, J3 connected at
control board :
Referenced to
Measure
J3
Measure
Referenced to
B-
+24V flashed speed control status
error code
ORN/BLU
7
14
BRN
Key switch +24V
B-
B-
Speed control EM brake signal
+24V
(moving on / neutral off)
RED/WHT
6
13
WHT/RED
*
+24V for 2 sec to K2
then 18V pulsed voltage
B+
B-
Speed control reverse
direction +24V
(reverse off / forward on)
BLU/BLK
5
12
GRA/BLK
**
+24V for 2 sec to K1
then 18V pulsed voltage
B+
B-
Seat switch +24V
GRA/BLK
4
11
VIO/BLK
***
Pulsed +24V
B+
3
10
ORN/RED
-Output to horn +15V
B-
+Output to horn +15V
B-
B+
Advenger / BR 755, 855 Ground
+24V
BLK
2
9
GRN/BLK
B-
Advenger / BR 755, 855 Power
+24V
BRN/YEL
1
8
BRN/YEL
* test point for brush motor contactor coil control error 63
** test point for vacuum contactor coil control error 64
*** test point for solution solenoid control error 62
75
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
ELECTRICAL SYSTEM
Rev Measurements
The information in the following tables was taken from measuring a single machine with a REV deck. These
values will vary from machine to machine based on battery charge level etcc., however, they will still give
you a picture of what normal should look like. Battery Negative used used for the black voltmeter lead and
each pin location was back-probed with the red voltmeter lead unless otherwise specified.
Connector J1
Pin
Wire
Circuit
Measured
1
RED/YEL
Detergent Pump
2.05v Key on
2
-
3
BLU/GRY
Detergent Pump
2.08v Key on
4
BLU
Deck Actuator
1.9v rest
Comment
24v Down
0.3v Up
5
ORN/BLK
Deck Actuator
2.0v rest
24v Up
0.3v Down
6
-
7
-
8
YEL/BLK
B- for Act. Pos.
Switches
0.06v
9
BLK/YEL
Squeegee Actuator
2.1v Rest
0.3v down
24.1 Up
10
WHT/GRN
Squeegee Actuator
2.1v Rest
0.3v down
24.1 Up
Vacuum On
76
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
ELECTRICAL SYSTEM
Connector J2
Pin
Wire
Circuit
Measured
Comment
1
BLK
Ground
0.06v
Vacuum On
2
BLK
Ground
0.06v
Vacuum On
3
-
4
BLK/WHT
Speed Limit
4.45v Transport
Signal Out to Speed Controller
3.4v Scrub
1.1v Strip
5
VIO
POT Low
0.38v
From Speed Controller. Used for Speed
Limit Signal
6
YEL
POT Hi
4.58v
From Speed Controller. Used for Speed
Limit Signal
7
BLK
Ground
0.05v
Vacuum On
8
BLK
Ground
0.05v
Vacuum On
9
BRN/RED
Vac Motor Sense
0.153v
Single Vac On. 22.6 A
10
YEL/RED
Brush Motor Sense
0.12v
Brush motors on. (Do not run long off the
ground)
11
BLK/WHT
Act. Pos 2
4.9v Act Up
In Serv. Test Mode, press scrub + once.
Let it stop, then press it two more times
to drive until the switch closes to see the
change.
0.001 v Sw closed
12
RED/VIO
Act. Pos 1
4.9v Act Up
0.001 v Sw closed
In Serv. Test Mode, press scrub + once. Let
it stop, then press it again to drive until
the switch closes to see the change.
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Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
ELECTRICAL SYSTEM
Connector J3
Pin
Wire
Circuit
Measured
Comment
1
BRN/GRN
B+
25.5v
Key Off or On
2
BLK
Ground
0.05v
Vacuum On
3
-
4
BLK/GRY
Seat Switch
25.2v
Weight on Seat
5
BLU/BLK
REV
24.5v N or FWD
1.5v REV
6
RED/WHT
FOR/REV (Motion)
25.3v N
0.2v FWD or REV
7
ORN/BLU
Status
1.2v No Code
24.5v - Unstable
8
BRN/GRN
B+
25.1v
9
GRN/BLK
Horn -
13.2v Horn Off
24.5v for a bit, then cycles when there is a
code
Key Off or On
0.01v Horn On
10
ORN/RED
Horn +
15.0v
Horn on or off
11
VIO/BLK
Solution Solenoid
25v off
Cycles on low and medium. 0.2v steady on
high
0.2v on
12
GRA/BLK
Vac Contactor
25v off
0.19v on
13
WHT/RED
Brush Contactor
25v off
Stronger pull in. Limit current for hold in.
0.15v initial on
5v on
14
BLU/ORN
Key Switch
25.1v
Key on
78
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
ELECTRICAL SYSTEM
Curtis Speed Control Installation Checkout Procedure
After installing a controller and before operating the vehicle, carefully complete the following checkout procedure. If you find a problem during
checkout, refer to the Curtis programmer manual for more information.
The installation checkout can be conducted with or without the handheld programmer. The checkout procedure is easier with a programmer
otherwise observe the Status LED for codes (located on operator panel wand indicator light).
WARNING!
Put the vehicle up on blocks to get the drive wheel off the ground before beginning these tests.
Turn the key switch off and make sure that the seat switch is open, and the throttle (pedal) is in neutral.
Do not stand, or allow anyone else to stand, directly in front of or behind the vehicle during the tests.
Remove the electrical panel to access the controller.
1 Observe the error status fault indicator on the operator control panel. If a programmer is available, connect it to the programmer plug-in
port
2 Sit on the seat and 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 are using a programmer, put it into diagnostic mode by pressing the DIAGNOSTICS key.
• If there is no error detected, the display should indicate “No Faults Found”. Note: Before pressing the diagnostics key, wait until
model # screen appears, if the throttle is activated prior to this screen appearing the controller will shut down.
• If there is a problem, the control panel will flash a diagnostic code and the programmer will display a diagnostic message. If you are
conducting the checkout without a programmer, refer to the Status LED Fault Codes table in “Speed Control Error Flash Codes” to
diagnose the cause.
4 When the problem has been corrected, it may be necessary to cycle the key or seat switch to clear the fault code.
5 While sitting on the seat, operate the throttle. The motor should begin to turn in the selected direction. If it does not, verify the wiring to
the controller, and the motor. The motor should run proportionally faster with increasing throttle. If not, refer to the Curtis manual.
6 Put the programmer into test mode by pressing the TEST key. Scroll down to observe the status of the forward, reverse and brake switch.
Cycle each switch in turn, observing the programmer. Each input should show the correct state on the programmer.
7 Take the vehicle off the blocks and drive it in an open area. It should have smooth acceleration and good top speed.
79
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
ELECTRICAL SYSTEM
Replacing the Operator Control Panel
WARNING!
DISCONNECT BATTERIES BEFORE SERVICING.
CAUTION!
To prevent damage to the new control panel assembly due to static electricity (ESD), wear a properly grounded static control wrist strap before
removing the new assembly from its protective static shielding bag and throughout the entirety of the installation process until the four screws
attaching the assembly to the machine have been re-fastened.
CONTROL PANEL REMOVAL
1
2
See Figure 41. Flip the seat forward and prop. Remove the (4) Screws (A) from the Control Panel Assembly (B) then lift and tilt the Control
Panel Assembly (B) to access the underside.
Take note of the wiring connections for reassembly and then disconnect all wiring and the small clear hose. Advenger / BR 755, 855 Completely drain the solution tank to prevent:
• water squirting out of the fitting at the control board when the hose is removed
• erroneous pressure reading due to a loss of pressure differential in Pressure Sensing Tube after the new control board is installed.
CAUTION!
DO NOT disconnect the small clear hose from the circuit board because this is connected to the pressure sensor and may damage the
sensor and board. It should only be disconnected from the fitting on the top of the tank.
FIGURE 41
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Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
ELECTRICAL SYSTEM
REPLACING THE OPERATOR CONTROL PANEL
CONTROL PANEL DISASSEMBLY, ASSEMBLY AND INSTALLATION
1
2
3
See Figure 42. Remove the Key Switch (A) from the panel assembly.
Remove the (5) Screws (B), the Circuit Board (C) and the Tab (D) from the panel assembly. NOTE: Save Items (A-D) and discard the
panel assembly.
Follow all previous steps in reverse order to reassemble and install the control panel assembly using the new panel assembly (1 & 2) from
the kit.
NOTE: the clear hose must not be kinked otherwise the Solution System will not function properly.
CAUTION!
To prevent damage to the new control panel assembly due to static electricity (ESD), wear a properly grounded static control wrist strap
before removing the new assembly from its protective static shielding bag and throughout the entirety of the installation process until
the four screws attaching the assembly to the machine have been re-fastened.
The ribbon cable(s) and membrane switch grounding film are fragile - do not scratch or crease during assembly or they may be damaged.
FIGURE 42
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Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
Programming Functions
82
Programming Functions
Service Test Mode - ADVENGER / BR 755, 855 (Disc and Cyl.)
The purpose of Service Test Mode is to by-pass the lock-out function of the normal control system of components that are in an error state and
allow those components to be manually turned on and off for troubleshooting purposes. (Components in an overload error state will still be locked
out for safety reasons.)
Advenger / BR 755, 855 - Service Test Mode is accessed via the Hidden Menus. To enter, turn the key switch Off, then press and hold the Scrub
and Vacuum switches together. Turn key switch back On and hold the switches for 2 seconds until the Solution and Scrub indicators both turn on.
Release both switches - the display will now read “Programming Options.” Scroll through the menus using the Solution + or - switches and enter
program 16 for Service Test Mode.
Advenger / BR 755, 855 Desired Action
Press
Switch
G
K
C
L
E
H
Raise/lower scrub deck lift actuator M4
Raise/lower squeegee lift actuator M3
Activate solution solenoid L1
Activate vacuum motor contactor K1
Activate AXP/EDS pump M2
Activate brush motor contactor K2
Toggles
LCD Display Indication *
ON/OFF
OFF...DOWN...OFF...UP
DECK
OFF...DOWN...OFF...UP
SQG
ENERGIZED...DE-ENERGIZED
SOL
ENERGIZED…DE-ENERGIZED
VAC
ON...OFF
CPUMP
ENERGIZED...DE-ENERGIZED
BRUSH
* LCD also displays SPD speed control ON/OFF, actual battery voltage measured, and any error codes.
F1
F
B
F2
F3
G
F4
C
F5
F6
H
C1
F
H1
D
I
J
K
E
L
A
F7
!
F8
!
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
Programming Functions
Changing Control Board Program Settings
Although the Advenger / BR 755, 855 and ST are delivered with a standard factory preset configuration, there will be times, such as when a control
board is replaced, when battery type is changed, or a different size scrub deck is installed, when some parameters in the control system software
will need to be changed. Most programmable functions are outlined below. For more details, call the Technical Service Department at NilfiskAdvance.
IMPORTANT
For field control board replacements, critical settings are highlighted below in bold letters.
Advenger / BR 755, 855 and ST settings that can be changed per the following tables are:
1. Low Voltage Cutout (Depth of Discharge) - 20.55V wet battery or 21.75V gel/AGM battery
2. Scrub Deck size - 28” or 34”
3. Number of Vacuum Motors installed (single or dual configuration - to prevent over current detection malfunction)
4. Maximum speed while scrubbing as a percentage of travel speed (50% - 90%)
5. Recovery Tank Full automatic shut-off disable/enable.
6. Restore factory defaults
7. Fault Recall of previous error codes to aid in troubleshooting.
8. Fault Detection over-ride - disable Fault Detection so systems aren’t shut down while in error state (exception is overload).
9. Solution Flow Rate lock-out
Advenger / BR 755, 855 models allow these additional programming changes to be made via the Hidden Menu:
NOTE: Replacement control boards come with Evergreen (EcoFlex) OFF and AXP/EDS (EcoFlex) disabled.
10. Chemical (Detergent)Selection - Turn AXP/EDS (EcoFlex) Off or On with display indicating US or European (ratio or %) format.
11. Detergent Mode - . Turn on Mode 1 (machine factory preset for US market) to enable standard Evergreen (EcoFlex) mode in which
pressing the Evergreen (EcoFlex) button enables preset ratio for 60 seconds. Turn on Mode 2 (factory preset for the EU market) to run at a
preset ratio. In this mode, pressing the Evergreen (Ecoflex) button increments the ratio (solution concentration) to the next stronger level for
60 seconds.
NOTE: To run the machine in a constant user-defined ratio, turn the Detergent Mode to Off and set the chemical ratio by pressing and holding the
AXP/EDS (Chemical) On/Off switch (E).
12. Brush Pressure lock-out - during normal operation, the pressure settings that are locked out will not be selectable.
13. Chemical rate bias - AXP/EDS (EcoFlex) control set to 10% more or less chemical than the user programmed ratio
14. Deck down time - time for which the control system applies 24V to the deck actuator to raise or lower the scrub deck after the Scrub On
switch is pressed (adjustable from 1 to 5 seconds).
15. Backup Alarm volume
16. Horn volume
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Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
Programming Functions
Changing Program Settings - Advenger / BR 755, 855 (Disc and Cyl.)
1
2
3
4
5
6
To enter this Hidden Menu, turn the key switch Off, then press and hold the Scrub and Vacuum switches together.
Turn key switch back On and hold the switches for 2 seconds until the Solution and Scrub indicators both turn on.
Release both switches - the display will now read “Programming Options.” Scroll through the menus using the Solution + or - switches and
enter the program number corresponding to the needed function.
To enter a submenu, press the Solution switch.
To save and go back to the main menu, press the Scrub switch.
To exit the hidden menu, turn the key switch off.
Prog.
Function
Option 1
Option 2
Option 3
Option 4, etc.
1
DECK TYPE
28” disc /
BR 755
28” Cyl /
BR 755 C
34” disc /
BR 855
--
2
CHEMICAL SELECTION
AXP On
US mode: X:XXX
EDS On
EU mode: %
AXP/EDS Off
3
DETERGENT MODE
Mode 1
US Evergreen On
4
VACUUM SELECTION
Off
no Evergreen
(board default)
1 (single)
2 (dual)
Mode 2
EU or non-Evergreen
preset
--
5
LOW VOLTAGE CUTOUT
Wet battery 80%
Gel/AGM Battery 70%
--
6
MAXIMUM SCRUB SPEED
100%
90%
80%
50%
7
LOCK OUT BRUSH PRES
(displayed pressure is locked out)
Low
Med
High
Low & Medium, Low &
High, High & Medium
8
LOCK OUT SOLUTION
(displayed rate is locked out)
Low
Med
High
Low & Medium, Low &
High, High & Medium
9
RECOVERY TANK FULL
(automatic shutoff turned on)
ENABLED
DISABLED
--
--
10
CHEMICAL RATE BIAS
NONE (equal)
+10% MORE CHEM
-10% LESS CHEM
--
11
DECK DOWN TIME
12
RESTORE FACTORY DEFAULTS
14
FAULT RECALL
15
FAULT DETECTION
17
Incremental from 1 to 5 seconds in 0.1 second intervals
NO
YES
--
--
No faults
occurred - display
is “-”
ENABLED
Error codes
BACKUP ALARM VOL
Off
Low
Med
High
18
FWR ALARM VOL
Off
Low
Med
High
19
HORN VOL
Off
Low
Med
High
To erase history, press the Solution switch while
in this mode.
DISABLED
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Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
Programming Functions
Changing Program Settings - ST
1
2
3
To enter this Hidden Menu, turn key switch Off, then press and hold the buttons shown in the table below simultaneously.
Turn key switch back On and hold for 2 seconds until the indicated LEDs for the desired function turn On, then release the switches.
Use the Solution + or - switches to change the setting. The fault code LED will blink at the same rate as the fault code display to show
what the current setting is.
Press the Solution On/Off switch to save the setting, then turn key switch Off to exit the hidden menu.
(1)
SWITCHES PRESSED
B
D
C
LOW
Solution
FUNCTION
Low Voltage Cutout
●
●
Single/Dual Vac Motor
●
Max Scrub Speed % of
Transport Speed
●
●
Restore Factory
Defaults
●
Fault Detection
●
Solution Flow Rate
Lockout
●
●
HIGH
Solution
(3)
BLINKS
RED
YEL
GRN
●
●
●
●
●
●
●
●
●
Fault Recall
MED
Solution
●
Scrub Deck Size
Recovery Tank Full
Shutoff
(2)
INITIAL LED INDICATION
K
●
●
●
●
●
●
●

Wet
Gel/AGM
28”
34”
S
D
50%
60% *
Enabled
Disabled
No
Yes
Enabled
Disabled
None
Low **
●
●
●

●
●
●
●
●
* 70% - 100% are 3 to 6 blinks respectively.
** Medium, High, Low & Medium, Low & High, Medium & High are 3 to 7 blinks respectively.
N
B
C
K
C1
D
M
A
85
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
Programming Functions
Service Test Mode - ST
The purpose of Service Test Mode is to by-pass the lock-out function of the normal control system of components that are in an error state and
allow those components to be manually turned on and off for troubleshooting purposes. (Components in an overload error state will still be locked
out for safety reasons.)
ST - To enter Service Test Mode, turn key switch Off, then press and hold the three buttons shown below simultaneously. Turn key switch back On
and hold for 2 seconds until the red, yellow, and green LEDs turn On, then release the switches.
ST Desired Action
Press
Switch
C
B
D
Activate solution solenoid L1
Activate brush motor contactor K2
Activate vacuum motor contactor K1
Other Status Indicators
Toggles
LED Indication
ON/OFF
ENERGIZED...DE-ENERGIZED
Solution Med
ENERGIZED...DE-ENERGIZED
Solution High
ENERGIZED...DE-ENERGIZED
Solution Low
LED
Main control board
Indication
ST Service LED Blink Code
Speed Control
Speed Control Error Flash Code
Battery RED - Blinking
Drive pedal
Forward
Reverse
Fault Indicator
Battery YELLOW - ON
Battery GREEN - ON
N
B
C
K
C1
D
M
A
86
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
Programming Functions
Hidden Menus (REV)
Hidden menus are used to configure the main controller to match the machine that it is installed on
(Programming Options) and to perform time-saving diagnostic tests (Service Test Mode). The service test
mode is found as a menu item under programming options.
Enter Hidden Menus
1. Turn the main power switch to the off position.
2. Press and hold the scrub ON/OFF switch and vacuum/wand switch.
3. While holding both switches, turn the main power key switch to the on position.
4. Continue to hold both switches for approximately 2 seconds until the display shows “Program Options”.
a. To scroll through the menu use the solution on/increase switch or solution decrease/off switches
b. To enter a sub menu press the Floor Finish Removal Mode Switch (Rev).
c. To save and return to the main menu press the scrub ON/OFF switch.
Save and
Return
Scroll
Enter
Hold while
turning on key
to enter Hidden
Menu
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Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
Programming Functions
Program Options (REV)
Program options must be set whenever the Main Controller has been replaced.
• Scrub Deck Type - This function configures the control unit current settings and flow rate settings for
each of the scrub deck types. Note: After replacing the controller the machine will not operate until a deck
type has been selected.
• Chemical Selection - Used to let the controller know whether the onboard detergent dispensing system
has been installed and which market area the machine is in. The market area determines whether to
show the detergent dilution rate as a ratio (US-style) or percentage (EU/Global-style) .
• Vacuum motor quantity selection - The main controller must be programmed for the number of
vacuum motors installed so that the current overload protection and recovery tank full will function
properly.
• Low Voltage Cutout Selection - The purpose of the special low battery voltage cutout function is to
help prolong battery life. The scrub deck will be raised and the brush motors and solution solenoid valve
will turn OFF automatically and cease to function when the batteries discharge to the selected cutout
level. The cutout level is adjustable between two settings. The standard setting (wet cell/lead acid) is
20.55 volts and alternate setting (gel/maintenance free) is 21.75 volts.
• Maximum Scrub Speed - The control system is programmed to limit the maximum speed while
scrubbing to a value less than that allowed for driving when not scrubbing (100%, 90%, 80%, 70%, and
60%).
• Lock Out Brush Pressure - Used to lock out any brush pressure settings Low, Medium, High, Low and
Medium, Low and High, High and Medium. During normal operation, the pressure setting(s) that are
locked out will not be able to be selected. Default is “None”
• Lock Out Solution Flow Rate - Used to lock out any solution flow rate settings: Low (Normal), Medium
(Heavy), High (Extreme), Low and Medium, Low and High, High and Medium. During normal operation,
the flow rate(s) that are locked out will not be able to be selected.
• Recovery Tank Full Enable/Disable - Used to enable or disable Recovery Tank Full automatic shutoff
feature. Enable means that the automatic shutoff feature is turned on; disable means that the automatic
shutoff feature is turned off.
• Chemical Ratio Bias - Used to increase or decrease the chemical mix rate by 10% to achieve a more or
less concentrated mix than that determined by user programmed ratio
• Deck Down Time Period Adjustment - When the scrub on/off switch is pressed, the control unit
will automatically lower the deck for a specified amount of time. The time that the deck is lowered is
adjustable from 1 second to 5 seconds in 0.1 second increments.
• Restore Factory Default - This submenu should reset all parameters stored in the EEPROM except
Brush on Time. Note: after restoring factory defaults, all of the program options must be reviewed and set
appropriately. The machine will not work until at least the deck type is selected.
• Display Revision Level - The LCD display will show the revision level of the software in the control
board.
• Fault Recall - Whenever the control unit detects an electrical system fault, one or more error codes are
displayed and stored in the EEPROM. If it is desired, the error code (if any) from the previous operation
for the machine can be recalled for troubleshooting purposes. If no fault code is present, the display will
show a “-“
• Fault Detection - Normally, the main control unit will perform checks of the electrical system during
operation. If a fault occurs in a particular system, that system (and possibly others) will be shut down.
This can make troubleshooting the system difficult. This option will allow service personnel to disable
some of the fault detection checks to facilitate troubleshooting. This will not disable the over-current
protection on any of the systems.
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Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
Programming Functions
• 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 operator inputs. Exit by
pressing the scrub on/off switch six times.
• Backup Alarm Vol - Used to adjust the volume of the back up alarm or turn it off.
• FORWARD ALARM VOLUME - Used to adjust the volume of the forward annunciation alarm or turn it
off.
• Horn Volume - Used to adjust the horn volume or turn it off.
• Save last scrub setting - provides two choices of what happens when the key is turned off; 1)
Remember last scrub settings. Solution flow, scrub pressure or 2) Factory default scrub settings (chemical
remembered, low water, low pressure)
• Burst Of Power - This selection screen only applies when the machine does not have the chemical
option installed. In that case, the Burst of Power button on the control panel can be set to perform in
one of two ways: when disabled it is a non-functioning button, and when enabled it will attempt to make
a temporary increase in the solution flow rate, brush pressure, and vacuum level when pressed. When
the chemical option is installed, the Burst of Power button is always functional regardless of the value
selected in this menu. When pressed, the Burst of Power button will attempt to make a temporary
increase in the solution flow rate, brush pressure, vacuum level and chemical flow rate.
• Panel Test - This is a special mode that allows you to test each control panel switch. The display will
indicate which switch was last pressed and then provide a count for each subsequent press.Exit by
pressing the scrub on/off switch six times.
89
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
Programming Functions
Service Test Mode - ADVENGER / BR 755, 855 (REV)
The service test mode provides time-saving diagnostic tests. You can request that the main controller turn various outputs on and off without
the normally required prerequisite inputs in order to quickly prove whether the output is working or not. The service test mode can also be
used to verify some input signals.
The Service Test Mode is accessed via the Hidden Menus. Enter the program options and then scroll to the Service Test Mode.
Output Tests
Once in service test mode use the control panel switches to request that various outputs are turned on/off.
The LCD provides feedback to let you know that the controller saw your request and is attempting to carry it
out.
Controls
Scrub Deck
Actuator
Controls
Solution
Solenoid
Controls
Scrub Motor
Contactor
Controls
Squeegee Lift
Actuator
Controls
Detergent
Pump
Service Test Mode Switch Operation
Controls
Vacuum
Contactor
90
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
Programming Functions
Input Tests
Once in service test mode the LCD displays output test fedback. It also displays current speed control
direction, battery voltage to the main controller and any current error codes.
Current
Error Codes
Battery
Voltage
Current
Speed
Control
Direction
Output Test
Feedback
91
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
MAINTENANCE SCHEDULES
MAINTENANCE SCHEDULES
OPERATOR PREVENTIVE MAINTENANCE – MACHINE IN USE
MAINTENANCE ITEM
Daily
Charge Batteries
●
Check/Clean Tanks & Hoses
●
Check/Clean/Adjust Squeegee
●
Check/Clean/Rotate Brushes/Pads
●
Empty/Clean Strainer Basket in Recovery Tank
●
Check/Clean Vacuum Shut-Off Float
●
Check/Clean vacuum motor foam filter(s)
●
Clean Hopper on Cylindrical System
●
Weekly
Charge Batteries – full charge cycle 12-15 hrs
●
Check Each Battery Cell’s Water Level (wet batteries)
●
Check/Clean/Adjust Scrub Deck Side Skirts
●
Check/Clean Solution Filter
●
Clean Solution Trough on Cylindrical System
●
Purge Detergent System (If equipped)
●
Monthly
Lubricate Steering Chain
●
Lubricate Pivot Points for Squeegee & Scrub Deck Linkage
●
Lubricate Side Skirt Adjustment Knobs (19)
●
Lubricate Steering Wheel Shaft Universal Joint (A)
●
Lubricate Front Roller Bumper (20)
●
Lubricate Squeegee Tilt Adjustment Knob (32)
●
(ST) Check for Squeegee Cable Bushing wear inside Steering Column.
Wear indicates need for replacement and cable adjustment (too tight)
●
FIGURE 43
92
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
MAINTENANCE SCHEDULES
MAINTENANCE SCHEDULES
OPERATOR PREVENTIVE MAINTENANCE – MACHINE IN STORAGE
MAINTENANCE ITEM
Daily
Weekly
Monthly
Check Each Battery Cell’s Water Level (wet)
●
Charge Batteries – full charge cycle 12-15 hrs
●
Yearly
SERVICE TECHNICIAN SUGGESTED MAINTENANCE
MAINTENANCE ITEM
Quarterly
Clean battery tops and posts with baking soda solution
●
Inspect battery connections for tight, corrosion-free fit
●
Perform hydrometer battery check (wet batteries) to identify bad cells
●
Perform voltmeter check of individual batteries (gel/AGM) to identify bad cells
●
Perform battery load test to identify degraded batteries resulting in poor run time
●
Yearly
Inspect vacuum motor carbon brushes for wear
(Replace if 9.5mm (3/8 inches) or shorter)
Inspect brush motor carbon brushes
(Replace if 9.5mm (3/8 inches) or shorter)
300 Op Hrs
While brush motor being checked, also check for wear at Motor Gimbal inside Brush Plate.
Remove and replace if worn.
Inspect drive motor carbon brushes
(Original carbon brush length is 19.1mm (3/4 inches). Replace when shorter than 6.3 mm (1/4
inches) to obtain the same motor efficiency as a new brush.)
500 Op Hrs
RECOMMENDED MAINTENANCE MATERIALS
Typical adhesives and lubricants used on Advenger / BR 755, 855
include Loctite(R) Silver Grade Anti-Seize, Loctite
formulas 242, 680, 414, 409, and No More Leaks(TM)
80724 sealant; Uniroyal M6325 Adhesive, CRC White
Lithium Grease, Sprayon S00206 All-Purpose Silicone
Lube, light machine oil such as 10W-30 motor oil,
Mobil SHC 634 lube and Mobilgear 600 XP 150
(EU: AGIP BLASIA 150) gear case oil.
To clean wet batteries, baking soda will also be needed.
500 Op Hrs
500 Op Hrs
93
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
MAINTENANCE SCHEDULES
PM Checklist
Advance Advenger 2805, 2905, 3405
Advance 2800ST, 3400ST
Nilfisk BR 755, 855
Disc and Cylindrical
PM Checklist
Defect Codes
A
needs adjustment
B binding
Address C
dirty or contaminated
D damaged, bent or torn
City St Zip Lleaks
Mmissing
Model Serial Hours W worn out
Customer Ref
OPERATIONAL INSPECTION ITEMS
OK or
N/A
Defect Codes
(circle)
1
Steering
A B
Does
Not
Work
2
Drive Pedal Operational (check for Fwd/Rev Drive & any neutral creep)
A B D
3
Seat Switch
D
4
Electrical Parking Brake (Brake releases when the key is turned on and the drive pedal is
engaged. Brake engages when machine is at rest.)
A B W
5
Drive System Performance (refer to Curtis Programmer Manual SM56043101 for speed
control changes)
Noisy
Sluggish
6
Scrub System (Raise, Lower, auto scrubbing functions)
A B
7
Scrub Brush (pressure settings Normal/Heavy/Extreme scrub for Advenger / BR 755, 855;
Normal/Extreme for ST)
A B
8
Squeegee System (Raise, Lower, ADVENGER / BR 755, 855 - Auto-raise in reverse)
A B D
9a
Vacuum Performance Single Motor
(sealed water lift 63”, 1-inch open hole aperture 10”)
C L W
9b
Vacuum Performance Dual Motor (sealed water lift) (sealed water lift 65”, 1-inch open hole
aperture 18”)
C L W
10
Solution Control (On/Off, Increase & Decrease for Normal/Heavy/Extreme)
A B L
11
Emergency Stop Knob
B D
12
Tilt Steering Mechanism and Seat
A B D
13
Optional Accessories
D
14
Main Control Board Special Program Options and Fault Recall Mode– check all applicable
program settings per Changing Program Settings section and examine stored fault codes.
15
Battery Charger Programmed Correctly for Battery
A
16
Battery Charger Operation
D
94
Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855
MAINTENANCE SCHEDULES
Ref
VISUAL INSPECTION ITEMS
Comments
17
Scrub Brushes (check for wear and rotate)
18
Scrub Brush Motor Carbon Brushes
Wear Limit 3/8”
B L W
19
Scrub Brush Motor Gimbals
In Brush Plates
W
20
Auto Tension Belt – Wear and Tension (cylindrical)
A D W
21
Spring Retainers
On Brush Plates
D
22
Scrub Deck Skirt Position
Slight Flare
A B W
23
Solution Solenoid Valve
C L
24
Solution Tank, Delivery Hoses & Filter
Clean Filter Screen
C L
25
Vacuum Motor Carbon Brushes
Wear Limit 3/8”
W
26
Vacuum Motor Gaskets & Filters
L W
27
Vacuum Float Ball & Cage Assembly
Clean Float
C M
28
Recovery Lid Gasket
C D L
29
Recovery Tank Drain Hose & Cap
Flush
C L
30
Recovery Tank Strainer Basket
Clean
C D
31
Squeegee Pick-Up Tool and Hose
Back Flush
C L
32
Squeegee Blades (clean & rotate)
A C D W
33
Squeegee Lift Actuator Motor (Advenger / BR 755, 855) & Cable
A B D
34
(ST) Squeegee Lift Cable Plastic Bushing in Steering Column
Cable too tight if Worn
W
35
Battery Condition (clean & water)
Load Test
C W
36
Front Drive Wheel Motor Carbon Brushes
Wear Limit 1/4”
C W
37
Drive Pedal Linkage Neutral Return
A C
38
Steering Chain Lube & Tension
1/4” Deflection
A B C
39
Steering Column Universal Joint
A D
40
Rear Wheels
C
41
Sweep Hopper
C
WORK COMPLETED BY:
__________________________________
Service Technician Signature
_________
Date
OK or
N/A
D e f e c t
Codes
(circle)
D o e s
N o t
Work
A B D W
ACKNOWLDEGED BY:
________________________________ ________
Customer Signature
Date
95
___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
ELECTRICAL SYSTEM
Expanded Electrical System
___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
Component Location (Advenger/BR 755, 855)
COMPONENT LOCATION (Advenger / BR 755, 855)
Item
Description
A1
A2
F1
CB1
CB2
H1
H2
K1
K2
L1
M1
M2
M3
M4
M5
M6
M7
M8
R1
S1
S2
S4
Y1
Control PCB Assy
Controller, Speed
Fuse 150 Amp
Circuit Breaker, 70 Amp
Circuit Breaker, 10 Amp
Beacon, Warning (optional)
Horn/Backup Alarm
Contactor, Vacuum Motor
Contactor, Brush Motor
Solenoid Valve
Motor / Drive Wheel
Pump, Chemical (AXP/EDS only)
Squeegee Lift Actuator
Brush Lift Actuator
Motor, Vacuum
Motor, Vacuum (Optional)
Motor, Brush
Motor, Brush
Potentiometer, 5K
Switch, Key
Switch, Seat
Emergency Disconnect
Electromagnetic Brake
FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855- 75
WIRING DIAGRAM / SCHEMATIC (Advenger / BR 755, 855 Disc and Cylindrical Decks)
Item
Ref. No. Qty Description
A1
A2
56601565
56601061
1
1
Control PCB Assy
Controller, Speed
BATN/A
Battery
F1
56412089
1
Fuse, 150 Amp
CB1
CB2
56454429
56507644
1
1
Circuit Breaker, 70 Amp
Circuit Breaker, 10 Amp
H1
H2
56307166
56412177
1
1
Beacon, Warning (optional)
Horn/Backup Alarm
K1
K2
56601183
56412179
1
1
Contactor 24v, 100 Amp
Contactor 24v
L1
56601064
1
Solenoid Valve Assy
M1
M2
M3
M4
M5
M6
M7
M8
56601050
56315241
56601147
56601432
56601132
56601132
56315061
56601134
56315061
56601134
1
1
1
1
1
1
1
2
1
2
Motor / Drive Wheel
Pump, Chemical
Actuator, Motor 24v
Lift Actuator Assembly
Motor, Vac 24vdc
Motor, Vac 24vdc (optional)
Motor, 24 Vdc, .5 Hp, 1800 Rpm (cylindrical)
Motor Gearbox Assy (disk)
Motor, 24 Vdc, .5 Hp, 1800 Rpm (cylindrical)
Motor Gearbox Assy (disk)
R1
N/A
1
Part of 56601052
S1
*
S2
S4
56303553
56303526
7-82-00050
56407130
1
A/R
1
1
Key Switch
Replacement Key Set
Switch, Seat
Disconnect, Emergency
Y1
56601507
1
Brake, Electromagnetic
56315124
1
Charger, On-Board 24v TSBUS2008-984
76 - FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855
ELECTRICAL SYSTEM
FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855- 77
CONFIDENTIAL
Wiring Diagram (REV Deck) - 56601806 Revision A Sheet 1 of 2
THIS DRAWING AND THE DESIGN REPRESENTED HEREON IS THE PROPERTY OF NILFISK-ADVANCE, INC.,
PLYMOUTH, MINNESOTA AND IT HAS BEEN ISSUED WITH THE UNDERSTANDING THAT IT WILL NOT BE REPRODUCED NOR COPIED NOR USED FOR ANY PURPOSE OTHER THAN FOR WHICH IT WAS ISSUED AND RECIPIENT
AGREES TO RETURN IT UPON REQUEST.
DWG. NO.
SHEET
56601806
1 OF 2
REV
1
RED
CB1
RED
2
F1
2
RED
A
BATTERY PACK, 24 Vdc
BT1
+
-
ECO
A-08516
REVISIONS
DATE
9-27-12
RELEASE
DFTM
PMO
APPD
WGL
BLK
FUSE, 150A.
1
BRN/BLK
RED
CIRCUIT BREAKER, 70A.
BLK
E2
CHARGER DELTA Q
GND
LP1
1
WHT/BRN
2
BLK/ORN
BLU/ORN
BRN/GRN
1
SEAT SWITCH
SW1
2 BLK/GRA
WHT/BRN 1
2 WHT/BRN
BRN/GRN J3-1 B+
BRN/GRN J3-8 B+
BLU/ORN J3-14 KEY SWITCH
SEAT
SWITCH J3-4
BLK/GRA
BLK/GRA
E3
MAIN MACHINE CONTROLLER
K1
MOTION J3-6
BLU/ORN
4
GRY/BLK
J3-12 VACUUM
CONTACTOR
Y1
ELECTRIC BRAKE
E1
WHEEL DRIVE
CONTROLLER
RED/WHT
STATUS J3-7
REV. ALARM J3-5
CONTACTOR VACUUM
ORN
PIN 6 - BRAKE -
ORN/BLU
PIN 9 - STATUS
BLU/BLK
PIN 16 - REV. ALARM
BLK
B-
PIN 8 - MODE
K2
BLU/ORN
3
4
WHT/RED
BLK/WHT
SPEED LIMIT J2-4
J3-13 BRUSH
CONTACTOR
VIO
POT. HIGH J2-6
YEL
POT. LOW J2-5
VIO C
M- RED/GRN
-
PIN 13 - POT. LOW
GRY
CONTACTOR BRUSH
PIN 18 - SPEED LIMIT
PIN 4 - POT. WIPER
M1
B
L1
1
2
VIO/BLK
J3-11 SOLUTION SOLENOID
A
M
+
M+ YEL/BLK
YEL
PIN 3 - HIGH
DRIVE PEDAL SENSOR
SW4
MOTOR, WHEEL DRIVE
RED
3
BLK
1
FLASHING WARNING BEACON
OPTIONAL
EMERGENCY SWITCH
SW3
B+
1 BRN/GRN
BLK
2
2
2
RED/WHT 1
RED
KEY SWITCH
SW2
BLU/ORN
2
CIRCUIT BREAKER, 10 AMP
CB2
2
PIN 5 - KSI
~
B-
PIN 14 - BRAKE +
B+
SOLUTION SOLENOID VALVE
B+
B-
NOTES:
1. REFERENCE WIRING DIAGRAM 56601807
2. DISCONNECT RED WIRE ON CB2 AND REPLACE WITH
GREEN WIRE FROM CHARGER WHEN CHARGER IS USED.
3. WHEN VIEWING FROM THE TOP RIGHT BOOST MOTOR TURNS
COUNTER CLOCKWISE, LEFT BOOST MOTOR
TURNS COLCKWISE
78 - FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855
FORMS.DSN - C SIZE FORM 1/12/99
NOTES UNLESS OTHERWISE
SPECIFIED
1. ALL DIMENSIONS IN INCHES.
2. DO NOT SCALE DRAWING.
3. ALL DIMENSIONS APPLY AFTER
PLATING AND HEAT TREATING,
BUT BEFORE PAINTING.
4. REMOVE ALL BURRS AND SHARP
EDGES.
DIM. IN [ ] ARE MM.
UNITS IN [ ] ARE ISO METRIC
AS NOTED.
DRAWN
8-8-12
PMO
8-8-12
CK
NILFISK-ADVANCE, INC.
CHECKED
PROJ ENG
APPROVED
PLYMOUTH, MINNESOTA 55447-3408
TITLE
DIAGRAM-LADDER
APPROVED
APPROVED
SIZE
ORCAD
3
FIRST USED ON REV
DWG. NO.
REV.
C
SCALE
56601806
ASSY.
56601E53
A
SHEET
1 OF 2
Wiring Diagram (REV Deck) - 56601806 Revision A Sheet 2 of 2
CONFIDENTIAL
THIS DRAWING AND THE DESIGN REPRESENTED HEREON IS THE PROPERTY OF NILFISK-ADVANCE, INC.,
PLYMOUTH, MINNESOTA AND IT HAS BEEN ISSUED WITH THE UNDERSTANDING THAT IT WILL NOT BE REPRODUCED NOR COPIED NOR USED FOR ANY PURPOSE OTHER THAN FOR WHICH IT WAS ISSUED AND RECIPIENT
AGREES TO RETURN IT UPON REQUEST.
DWG. NO.
B+
B
BLK/YEL
MOTOR,SQUEEGEE LIFT ACTUACTOR
M2
SQUEEGEE ACT(-) J1-9
A
WHT/GRN
+
RED
SQUEEGEE ACT(+) J1-10
H1
-
+
ORN/RED
E3
MAIN MACHINE CONTROLLER
B- J1-8
J3-10 HORN +
HORN
H1
POSITION_1_ J2-12
B
56601806
SHEET
2 OF 2
REV
B-
A
ECO
REVISIONS
DATE
DFTM
SEE SHEET ONE
APPD
-
M
YEL/BLK
SW
A
2
RED/VIO
1
SW
POSITION_2_ J2-11
DECK ACT (-) J1-5
C
2
BLK/WHT
1
B ORN/BLK
M3
GRN/BLK
J3-9 HORN -
DECK ACT (+) J1-4
A
+
BLU
M
-
MOTOR,DECK LIFT ACTUACTOR
-
M10
+
M
RED/YEL
DETERGENT PUMP
BLU/GRY
J1-1 + DETERGENT
PUMP
J1-3 - DETERGENT
PUMP
BLK
BLK
BLK
BLK
BLK
B- J2-8
B- J2-7
B- J2-1
B- J2-2
B- J3-2
BOOST MOTOR SENSE J2-10
VACUUM MOTOR SENSE J2-9
YEL/VIO
BRN/RED
K1
RED
1
2
BLK
OPTIONAL
1
WHT
CONTACTOR, VACUUM
2
M8
M
MOTOR, VAC
1
WHT
2
BLK
M9
M
OPTIONAL
RED
1
M4
3
K2
2
RED
+
RED
MOTOR, VAC
M
-
BLK
BLK
CONTACTOR, BRUSH
RIGHT MOTOR BOOST
M5
3
RED
-
M
+
BLK
LEFT MOTOR BOOST
NOTES UNLESS OTHERWISE
SPECIFIED
1. ALL DIMENSIONS IN INCHES.
2. DO NOT SCALE DRAWING.
3. ALL DIMENSIONS APPLY AFTER
PLATING AND HEAT TREATING,
BUT BEFORE PAINTING.
4. REMOVE ALL BURRS AND SHARP
EDGES.
DRAWN
8-8-12
CHECKED
PROJ ENG
APPROVED
APPROVED
8-8-12
PMO
NILFISK-ADVANCE, INC.
FORM
/ 2800ST, 3400ST
/ BR 755,
BR 855- 79
CKNO. 56043121 - Advenger
PLYMOUTH,
MINNESOTA
55447-3408
TITLE
Wiring Harness Diagram (REV Deck) - 56601807 Revision A
80 - FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855
Component Location (2800ST, 3400ST)
COMPONENT LOCATION (2800ST, 3400ST)
Item
Description
A1
A2
F1
CB1
CB2
H1
H2
K1
K2
L1
M1
M5
M6
M7
M8
R1
S1
S2
S4
S5
S6
Y1
Control PCB Assy
Controller, Speed
Fuse 150 Amp
Circuit Breaker, 70 Amp
Circuit Breaker, 10 Amp
Beacon, Warning (optional)
Horn/Backup Alarm
Contactor, Vacuum Motor
Contactor, Brush Motor
Solenoid Valve
Motor / Drive Wheel
Motor, Vacuum
Motor, Vacuum (Optional)
Motor, Brush
Motor, Brush
Potentiometer, 5K
Switch, Key
Switch, Seat
Emergency Disconnect
Deck Switch
Squeegee Switch
Electromagnetic Brake
FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855- 81
WIRING DIAGRAM / SCHEMATIC (2800ST, 3400ST)
ELECTRICAL SYSTEM
BAT
WIRING DIAGRAM / SCHEMATIC (2800ST, 3400ST)
Item
Ref. No. Qty Description
A1
A2
56601566
56601061
1
1
Control PCB Assy
Speed Control
BATN/A
Battery
F1
56412089
1
Fuse, 150 Amp
CB1
CB2
56454429
56507644
1
1
Circuit Breaker, 70 Amp
Circuit Breaker, 10 Amp
H1
H2
56307166
56412177
1
1
Beacon, Warning (optional)
Horn/Backup Alarm
K1
K2
56601183
56412179
1
1
Contactor 24v, 100 Amp
Contactor 24v
L1
56601064
1
Solenoid Valve Assy
56601050
56601132
56601132
56601134
56601134
1
1
1
2
2
Motor / Drive Wheel
Motor, Vac 24vdc
Motor, Vac 24vdc (optional)
Motor Gearbox Assy
Motor Gearbox Assy
N/A
1
Part of 56601052
S1
*
S2
S4
S5
S6
56303553
56303526
7-82-00050
56407130
56305053
56601160
1
A/R
1
1
1
1
Key Switch
Replacement Key Set
Squeegee Switch
Disconnect, Emergency
Deck Switch
Squeegee Switch
Y1
56601507
1
Brake, Electromagnetic
56315124
1
Charger, On-Board 24v TSBUS2008-984
M1
M5
M6
M7
M8
R1
82 - FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855
ELECTRICAL SYSTEM
FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855- 83
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