Nilfisk-Advance Advenger 2800ST, Advenger 3400ST, AdvengerBR 755, Advenger BR 855, Advenger Service Manual

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Advenger 2800ST, 3400ST

BR 755, BR 855

QUICKSTART SERVICE MANUAL

Advance MODELS: 56601000, 56601001, 56601002, 56601003, 56601004 56601005, 56601006, 56601007, 56601008, 56601009, 56601010, 56601011 56601012, 56601013, 56601019, 56601020 Nilﬁ sk MODELS: 56601014, 56601015, 56601016

9/09 FORM NO. 56043121

TABLE OF CONTENTS

INTRODUCTION .......................................................................................................................................................................................... 2

QUICK START SERVICE MANUAL PURPOSE ........................................................................................................................................... 2

GENERAL MACHINE DESCRIPTION .......................................................................................................................................................... 2

PARTS AND SERVICE ................................................................................................................................................................................. 2

NAMEPLATE ................................................................................................................................................................................................ 2

CAUTION AND WARNING SYMBOLS ......................................................................................................................................................... 3

GENERAL SAFETY INSTRUCTIONS .......................................................................................................................................................... 3

RELATED REFERENCE SOURCES............................................................................................................................................................ 4

DIAGNOSTIC AND SERVICE TOOLS ......................................................................................................................................................... 4

TECHNICAL SPECIFICATIONS ................................................................................................................................................................... 5

TRANSPORTING THE MACHINE ................................................................................................................................................................ 8

TIE-DOWN POINTS ..................................................................................................................................................................................... 8

TOWING THE MACHINE ............................................................................................................................................................................. 8

JACKING POINTS ........................................................................................................................................................................................ 9

EMERGENCY STOP KNOB ......................................................................................................................................................................... 9

KNOW YOUR MACHINE ........................................................................................................................................................................... 10

MACHINE FRONT RH VIEW...................................................................................................................................................................... 10

MACHINE REAR LH VIEW .........................................................................................................................................................................11

CONTROL PANEL – ADVENGER / BR 755, 855 ....................................................................................................................................... 12

CONTROL PANEL – ST ............................................................................................................................................................................. 13

BASIC MACHINE OPERATION.................................................................................................................................................................. 14

MAIN CONTROLLER ERROR CODES - ADVENGER / BR 755, 855 AND ST ......................................................................................... 15

SPEED CONTROL ERROR FLASH CODES ............................................................................................................................................. 16

ERROR CODE SYSTEM DIAGNOSTICS - ADVENGER / BR 755, 855 AND ST ...................................................................................... 17

UNDERSTANDING CONTROL OF SQUEEGEE, SCRUB, AND RECOVERY SYSTEMS VIA MODES ................................................... 19

SQUEEGEE SYSTEM ................................................................................................................................................................................ 20

SQUEEGEE LIFT ACTUATOR CIRCUIT ERROR CODES AND MEASUREMENTS – ADVENGER / BR 755, 855 ................................. 21

TROUBLESHOOTING SQUEEGEE ISSUES ............................................................................................................................................ 21

SQUEEGEE ADJUSTMENTS .................................................................................................................................................................... 22

SQUEEGEE LIFT ACTUATOR REPLACEMENT – ADVENGER / BR 755, 855 ........................................................................................ 23

SQUEEGEE LIFT ACTUATOR DRIVE NUT ADJUSTMENT – ADVENGER / BR 755, 855 ....................................................................... 24

SQUEEGEE LIFT CABLE REPLACEMENT – ADVENGER / BR 755, 855 ................................................................................................ 25

SQUEEGEE LIFT CABLE REPLACEMENT – ST ...................................................................................................................................... 26

SQUEEGEE LIFT CABLE ADJUSTMENT – ST ......................................................................................................................................... 27

STEERING COLUMN ASSEMBLY SHROUD REMOVAL .......................................................................................................................... 28

SCRUB SYSTEM ....................................................................................................................................................................................... 29

BRUSH MOTOR CONTROL AND LOAD CIRCUIT ERROR CODES AND MEASUREMENTS ................................................................31

SCRUB DECK LIFT ACTUATOR ERROR CODES AND MEASUREMENTS – ADVENGER / BR 755, 855 ............................................. 32

TROUBLESHOOTING SCRUB SYSTEM ISSUES ................................................................................................................................... 32

SCRUB DECK LIFT ACTUATOR REPLACEMENT – ADVENGER / BR 755, 855 ..................................................................................... 33

SCRUB DECK LIFT ACTUATOR DRIVE NUT ADJUSTMENT – ADVENGER / BR 755, 855 ................................................................... 34

SCRUB DECK REMOVAL-DISC ................................................................................................................................................................ 35

SCRUB BRUSH MOTOR REMOVAL-DISC ............................................................................................................................................... 36

SCRUB DECK REMOVAL-CYLINDRICAL ................................................................................................................................................. 38

SCRUB BRUSH MOTOR REMOVAL-CYLINDRICAL ................................................................................................................................ 39

RECOVERY SYSTEM ................................................................................................................................................................................ 40

RECOVERY SYSTEM ERROR CODES AND MEASUREMENTS ............................................................................................................ 42

TROUBLESHOOTING RECOVERY SYSTEM ISSUES ............................................................................................................................. 43

REPLACING A VACUUM MOTOR ............................................................................................................................................................. 44

2 - FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855

TABLE OF CONTENTS

SOLUTION SYSTEM ................................................................................................................................................................................. 46

SOLUTION & AXP/EDS SYSTEM ERROR CODES AND MEASUREMENTS - ADVENGER / BR 755, 855 AND ST .............................. 47

TROUBLESHOOTING SOLUTION & AXP/EDS SYSTEM ISSUES........................................................................................................... 47

SOLUTION SYSTEM DIAGRAM ................................................................................................................................................................ 48

SOLUTION SYSTEM CONTROL ............................................................................................................................................................... 49

REPLACING THE SOLUTION SOLENOID VALVE .................................................................................................................................... 50

WHEEL DRIVE SYSTEM ........................................................................................................................................................................... 51

WHEEL DRIVE CIRCUIT ERROR CODES AND MEASUREMENTS ........................................................................................................ 52

TROUBLESHOOTING DRIVE WHEEL ISSUES ........................................................................................................................................ 52

REPLACING THE DRIVE WHEEL ASSEMBLY ......................................................................................................................................... 53

REPLACING THE DRIVE TIRE .................................................................................................................................................................. 54

INSPECTING/REPLACING THE DRIVE WHEEL ASSEMBLY CARBON BRUSHES ................................................................................ 55

REPLACING THE REAR WHEELS ............................................................................................................................................................ 56

ELECTRICAL SYSTEM ............................................................................................................................................................................. 57

ACCESS TO PANEL: CHEMICAL PUMP, CHARGER INTERLOCK, FUSES, CONTACTORS, SPEED CONTROL ............................... 57

THROTTLE POTENTIOMETER WIPER MEASUREMENT (NEUTRAL POSITION) ................................................................................. 57

CONTROL BOARD J1, J2, AND J3 PIN OUTS AND TEST POINTS ......................................................................................................... 58

CURTIS SPEED CONTROL INSTALLATION CHECKOUT PROCEDURE ................................................................................................ 60

REPLACING THE OPERATOR CONTROL PANEL ................................................................................................................................... 61

PROGRAMMING FUNCTIONS .................................................................................................................................................................. 63

SERVICE TEST MODE ..............................................................................................................................................................................63

CHANGING CONTROL BOARD PROGRAM SETTINGS .......................................................................................................................... 65

CHANGING PROGRAM SETTINGS – ADVENGER / BR 755, 855 ........................................................................................................... 66

CHANGING PROGRAM SETTINGS – ST ................................................................................................................................................. 67

MAINTENANCE SCHEDULES .................................................................................................................................................................. 68

OPERATOR PREVENTIVE MAINTENANCE - MACHINE IN USE ............................................................................................................ 68

OPERATOR PREVENTIVE MAINTENANCE - MACHINE IN STORAGE .................................................................................................. 69

SERVICE TECHNICIAN SUGGESTED MAINTENANCE .......................................................................................................................... 69

RECOMMENDED SERVICE MATERIALS ................................................................................................................................................. 69

PM CHECKLIST ......................................................................................................................................................................................... 70

EXPANDED ELECTRICAL SYSTEM ..................................................................................................................................................73 - 78

COMPONENT LOCATION - ADVENGER / BR 755, 855 ........................................................................................................................... 73

WIRING DIAGRAM – ADVENGER / BR 755, 855 ...................................................................................................................................... 74

ELECTRICAL SCHEMATIC – ADVENGER / BR 755, 855 ......................................................................................................................... 75

COMPONENT LOCATION - ST .................................................................................................................................................................. 76

WIRING DIAGRAM – ST ............................................................................................................................................................................ 77

ELECTRICAL SCHEMATIC – ST ............................................................................................................................................................... 78

FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855 - 1

INTRODUCTION - QUICK START SERVICE MANUAL PURPOSE

This manual is a technical resource that Nilﬁ sk-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 Nilﬁ sk-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 ﬂ oor scrubbers available with multiple deck sizes, multiple corresponding squeegee blade sizes and materials, and variable scrub pressure and solution ﬂ ow rates. Models equipped with AXP™ / EDS™ detergent systems default into the EverGreen™ cleaning mode (1:400 detergent ratio), a patented new Green cleaning technology designed to reduce chemical use, environmental impact, and the cost of cleaning.

PARTS AND SERVICE

Repairs should be performed by an Authorized Nilﬁ sk-Advance Service Center that employs factory-trained service personnel and maintains an inventory of Nilﬁ sk-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 Nilﬁ sk-Advance Technical Support.

2 - FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855

CAUTIONS AND WARNINGS SYMBOLS

Advance uses the symbols below to signal potentially dangerous conditions. Always read this information carefully and take the necessary steps to protect personnel and 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

Speciﬁ c Cautions and Warnings are included to warn you of potential danger of machine damage or bodily harm.

WARNING!

* This machine shall be used only by properly trained and authorized persons.

* While on ramps or inclines, avoid sudden stops when loaded. Avoid abrupt sharp turns. Use low speed down hills. Clean only

while ascending (driving up) the ramp.

* Keep sparks, ﬂ ame 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

ﬂ ame. 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 ﬂ ammable cleaning agents, operate the machine on or near these agents, or operate in areas where ﬂ ammable

liquids exist.

* Do not clean this machine with a pressure washer. * Only use the brushes provided with the appliance or those speciﬁ ed in the instruction manual. The use of other brushes may

impair safety.

CAUTION!

* This machine is not approved for use on public paths or roads. * This machine is not suitable for picking up hazardous dust. * Do not use scariﬁ er discs and grinding stones. Advance will not be held responsible for any damage to ﬂ oor surfaces caused by

scariﬁ ers 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 ﬁ rst 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 ﬁ ttings. Flush with windshield washer ﬂ uid.

* 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.

SAVE THESE INSTRUCTIONS

FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855 - 3

RELATED REFERENCE SOURCES

Nilﬁ sk-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 Nilﬁ sk-Advance commercial ﬂ oor 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 Nilﬁ sk-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 Nilﬁ sk-Advance, Inc.:

56407502 Actuator Power Cord Adapter 56205281 Water Lift Gauge 56206921 Timer Bypass Kit (used to bypass timing function when troubleshooting shelf chargers) 56409441 Curtis Handheld Programmer 56409823 Curtis Adapter Cable (Quad Plug) 56315732 Delta-Q QuiQ Onboard Charger Interface Module 56422174 Tire Puller Kit for Drive Wheel Assembly

4 - FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855

TECHNICAL SPECIFICATIONS

GENERAL

Machine Voltage 24 VDC

Length (W/squeegee): 60 in (152.4 cm)

Dimensions (without Squeegee and Scrub Deck)

Width (body): 27.5 in (70 cm)

Height (Recovery tank): 51.7 in (131.3cm)

Scrub Deck Width: Squeegee Width:

Scrub Deck and Squeegee Widths

Tank Capacities

Gross Weight (standard machine w/o options; w/full solution tank, empty recovery tank and heaviest batteries installed)

Net Weight (standard machine w/o options, batteries or removable brushes; w/empty solution and recovery tanks)

Static Wheel Loading Front: 615 lbs (279 kg) Rear: 836 lbs (379 kg)

Static Wheel Pressure Front: 174.7 psi (12.3 kg/cm2) Rear: 124.7 psi (8.8 kg/cm2)

Ingress Protection Code IPX3

Sound Pressure Level (IEC 60704-1)

Vibrations at the Hand Controls (ISO 5349-1) .26 m/s

Vibrations at the Seat (EN 1032) .05 m/s

Gradeability

30.3 in (77 cm) 28 disc 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)

1451 lbs (658 kg)

536 lbs (244 kg)

63.7 dB(A)

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 Nilﬁ sk Models

FIGURE 1

FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855 - 5

TECHNICAL SPECIFICATIONS

ELECTRICAL SPECIFICATIONS

Number of Batteries 4 / Battery Voltage 6V 310 Ah wet

Batteries

Number of Batteries 4 / Battery Voltage 6V 420 Ah wet Number of Batteries 4 / Battery Voltage 6V 312 Ah AGM

Standard Battery Capacity: 305 amp-hours @ 20-hour rate

Onboard Battery Charger

24-volt Manufacturer: Delta Q Model: 912-2400-N1 Output 25A Gel Compatible: Yes

DRIVE SYSTEM

Drive Wheel

Drive Motor 1.05 HP (780 watts)

Max. Transport Speed

Diameter: 9.84 in (25 cm) / Width: 3.15 in (80 cm) Type/Material: Blue Urethane

Fwd: 3.91 mph (6.30 km/h)

Rev: 2.61 mph (4.20 km/h)

SOLUTION SYSTEM

Solution Control

Advenger BR 755, 855 Solution Flow Rates

ST Solution Flow Rates (Average)

(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

(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

Pulse-control Solenoid Valve

AXP™ / EDS™ System Available Advenger / BR 755, 855 only

400:1 = .25% 200:1 = .5% 100:1 = 1% 32:1 = 3%

Detergent Ratios Available

Recycle System Available No

300:1 = .3% 150:1 = .66% 64:1 = 1.5% 256:1 = .4% 128:1 = .8% 50:1 = 2%

RECOVERY SYSTEM

Vacuum Motor(s) .75 HP (560-watt) 3-stage

Vacuum Water Lift (measured at recovery hose)

One Motor

Two Motors

6 - FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855

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 and Cylindrical

Disc: (2) 14 in (35.6 cm) Scrub Path: 28 in (71.1 cm)

Scrub Brush/Pad Sizes and Types

Scrub Motors - Disc

Scrub Head Speeds - Disc

Scrub Motors – Cylindrical

Scrub Head Speeds – Cylindrical Right-hand Motor: 900 RPM / Left-hand Motor: 900 RPM

Scrub Force 28” ST

Scrub Force 34” ST

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)

Number of Motors 2 Right-hand/Single Motor: .64 HP (480 watts) Left-hand Motor: .64 HP (480 watts)

Right-hand/Single Motor: 215-260 RPM Left-hand Motor: 215-260 RPM

Right-hand Motor: .5 HP (373 watts) Left-hand Motor: .5 HP (373 watts)

(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

Scrub Force Advenger / BR 755, 855 Cylindrical

(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)

(2) Heavy Scrub: 70-80 lbs (31.8–36.3 kg)

(3) Extreme Scrub: 90-100 lbs (40.8-45.4 kg)

MINIMUM AISLE TURN AROUND RADIUS (TURNING LEFT)

28” deck Advenger / BR 755, 855 and ST

34” deck Advenger / BR 755, 855 and ST

Cylindrical Advenger / BR 755, 855 63 inches (1.63 m)

63 inches (1.63 m)

67.5 inches (1.71 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 32 inches (.81 m)

31 inches (.79 m)

36.5 inches (.93 m)

FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855 - 7

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 ﬂ ush with windshield washer ﬂ uid to prevent damage to valves and

ﬁ ttings. 5 Do not drive machine onto a ramp grade exceeding 16% (9 degrees) or damage to the machine may occur.

TIE-DOWN POINTS

TOWING THE MACHINE

FIGURE 2

CAUTION!

The Drive Wheel (4) has a built in electromagnetic brake that is engaged whenever the Key Switch is Off or the Drive Pedal (3) is in the Neutral position, i.e. there is no power to the Speed Control. This brake can be manually over ridden if necessary by inserting a medium to large screwdriver behind the Yoke (A) as shown in FIGURE 3. (A rubber door stop can also be used). This should only be done in the event you need to push or pull the machine.

FIGURE 3

Tow the machine for short distances only.

8 - FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855

JACKING POINTS

Front - When facing the front of the machine and underneath looking

up, place the jack to the left of the chain on the frame member (A) as shown in FIGURE 4.

Rear – Remove Squeegee Assembly (11) to access these locations. Use a bottle jack at these points (B) as shown in FIGURE 5.

FIGURE 4

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

FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855 - 9

KNOW YOUR MACHINE MACHINE FRONT RH VIEW

1 Operator’s Seat 2 Solution Tank Drain Hose 3 Drive Pedal, Directional/Speed 4 Drive Wheel 5 Drive Wheel Circuit Breaker (70 Amp) 6 Control Circuit Circuit Breaker (10 Amp) 7 Emergency Stop 8 Scrub Deck 9 Rear Wheel 10 Battery Compartment (under seat) 11 Squeegee Assembly 12 Detergent Cartridge Access Cover (AXP/EDS models only) 13 Detergent Cartridge (AXP/EDS models only) 14 Scrub Deck Raise/Lower Lever (ST models only) 15 Deck Skirt Removal Knobs 16 Battery Charger Access Door 17 Battery Charger (optional) 18 Seat Adjustment Knob (optional on ST models) 19 Deck Skirt Height Adjustment Knob 20 Front Roller Bumper

10 - FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855

KNOW YOUR MACHINE MACHINE REAR LH VIEW

21 Solution Shutoff Valve 22 Squeegee Raise/Lower Lever (ST models only) 23 Steering Wheel Tilt Adjust Knob 24 Control Panel 25 Solution Tank Fill Cover 26 Recovery Tank Cover 27 Vacuum Motor Filter Housing 28 Strainer Basket (optional on ST models) 29 Recovery Tank Shutoff Float 30 Squeegee Storage Hook 31 Recovery Tank Drain Hose 32 Squeegee Tilt Adjustment Knob

33 Seat Prop-Rod 34 Machine Battery Connector 35 Rear Squeegee Blade Removal Latch 36 Hopper (Cylindrical models only) 37 Recovery Hose 38 Solution Solenoid Valve 39 Front Squeegee Blade Removal Thumb Nut 40 Solution Filter

FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855 - 11

KNOW YOUR MACHINE CONTROL PANEL (ADVENGER / BR 755, 855 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 ON/OFF Switch F Display F1 Hour Meter F2 Solution Tank Level Indicator F3 Fault Codes F4 AXP/EDS Indicator (if so equipped) F5 Detergent Ratio Indicator F6 Battery Indicator F7 Recovery Tank FULL Indicator F8 Battery Low Indicator

G Scrub Pressure Increase Switch H Scrub ON/OFF Switch H1 Scrub Pressure Indicators (Normal, Heavy and Extreme) I Scrub Pressure Decrease Switch J EverGreen Switch K Horn Switch L 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.

F2 F3

F4 F5 F6

12 - FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855

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.

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 K Horn 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) ﬂ ashing. 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.

FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855 - 13

KNOW YOUR MACHINE

As you read this manual, you will occasionally run across a bold number in parentheses – example: (2). A bold number refers to an item shown on the Know Your Machine pages unless otherwise noted (bold letters refer to items on the same page). Refer back to the Know Your Machine pages whenever necessary to pinpoint the location of an item mentioned in the text.

BASIC MACHINE OPERATION

(refer to Operator Manuals such as 56041735 / 56041743 (English) for detailed information regarding how to operate the machine):

1 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 ﬂ oor.

ST: Manually lower the scrub deck and squeegee using levers (14) and (22). 2 Depress the foot pedal forward to begin scrubbing. The brushes, water and vacuum will turn on. 3 When the machine stops the brushes and water will stop. The vacuum will continue to run for 10 seconds and then stop. 4 At any time the scrub mode can be changed to regular, heavy or extreme scrub by using the SCRUB + or SCRUB - button. 5 At any time the solution ﬂ ow rate can be changed by using the SOLUTION + or SOLUTION - button. 6 If the scrub mode and solution ﬂ ow 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 ﬂ ow rate to match the scrub mode setting.

B Change the scrub mode using the SCRUB + or SCRUB - buttons. The scrub pressure and solution ﬂ ow will automatically be aligned for

optimized results.

7 To stop all scrubbing functions and transport the machine, (ADVENGER / BR 755, 855) press the red SCRUB ON / OFF button or [(ST)

return the scrub deck and squeegee control levers to the up position]. The solution and brushes will stop, [(ADVENGER / BR 755, 855) the

deck and squeegee will raise], and the vacuum will shut off after a 10 second delay.

14 - FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855

MAIN CONTROLLER ERROR CODES – ADVENGER / BR 755, 855 AND ST

Advenger / BR 755, 855 Display Error Code

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

ST Service LED Blink Code *

Fault Description

System Affected

Refer to page:

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.

FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855 - 15

SPEED CONTROL ERROR FLASH CODES

STATUS LED FAULT CODES (TABLE 1)

LED STATUS LIGHT EXPLANATION POSSIBLE CAUSE CODE DISPLAY

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 1. Motor voltage does not correspond to failsafe) 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 speciﬁ c HPD (high pedal disable) type operational fault, caused by the operator activating

the Fwd/Rev drive pedal before turning on the main key switch or activating the throttle before sitting on the seat. This can be cleared by returning the operator’s drive pedal to neutral and cycling the key switch OFF and ON.

16 - FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855

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.

Display Code

3 Speed control fault x x x

4 Brush deck lift actuator overload x

5 Brush motor overload x x x X x

6 Squeegee lift actuator overload x x

7 Vacuum motor overload x x x x

8 Solution solenoid overload x x x

9 Vacuum contactor coil overload x x x x

Fault Description

Disable System Flash Indicator

Disable Chemical

Disable Solution

Disable Brush Motors

Disable Recovery

Brush Deck Lift Disable

Chemical Indicator

Solution Indicator

Brush Motor Indicator

Vacuum Indicator

10 Brush contactor coil overload x x x X x

11 Chemical Pump overload x x

30 Solution solenoid open x x x

31 Brush motor open x x x x

32 Brush deck lift actuator open x

33 Vacuum motor open x x x x

34 Squeegee lift actuator open x x

35 Brush contactor coil open x x x x

36 Vacuum contactor coil open x x x x

37 Chemical pump open x 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

FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855 - 17

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 deﬁ ned by the Mode that is chosen - Scrub Mode, Vacuum Mode, or Wand Mode. The following tables outline the various components of the systems that are controlled in tandem by pressing a particular button or engaging the Drive Pedal in Forward, Neutral, or Reverse under normal machine operation. To bypass these systems, refer to the “Service Test Mode” section.

Advenger / BR 755, 855

Mode

Scrub Mode Seated Closed

Operator

Position

Seat Switch

Status

Action Result

Squeegee lowers (24V to M3 for 4 seconds - adjustable.)

Press Scrub On

Press Foot Pedal

Forward

Press Foot Pedal

Reverse

Foot Pedal in Neutral

Press Scrub Off

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

Press Scrub Off Foot Pedal in

Neutral >10 sec.

Vac Mode Seated Closed

Wand Mode* Standing Open

* Recovery Tank Full is disabled in Wand Mode Press Vac/Wand Off

Press Vac/Wand On Squeegee lowers (24V to M3 for 4 seconds)

Press Foot Pedal

Forward

Press Foot Pedal

Reverse

Press Vac/Wand Off

Press Vac/Wand Off Twice

Press Vac/Wand On

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

Vacuum motor circuit On

Squeegee raises until Foot Pedal in Neutral or Forward again (reverse 24V to M3 for 4 sec.) Vacuum motor circuit On for 10 seconds

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.

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

Squeegee raises (reverse 24V to M3 for 4 sec.) Vacuum motor circuit Off

18 - FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855

UNDERSTANDING CONTROL OF SQUEEGEE, SCRUB, AND RECOVERY SYSTEMS VIA MODES

Mode

Scrub Mode Seated Closed

Vac Mode Seated Closed

Operator

Position

Seat Switch

Status

Action Result

Lower Scrub Deck Brush motor circuit enabled

Lower Squeegee Vacuum motor circuit enabled

Vacuum motor circuit On

Press Foot Pedal

Forward

Press Foot Pedal

Reverse

(Lift Squeegee to prevent

damage)

Foot Pedal Neutral

Lift Scrub Deck

Lift

Squeegee

Lower Squeegee Vacuum motor circuit enabled

Press Foot Pedal

Forward

Press Foot Pedal

Reverse

(Lift Squeegee to prevent

damage)

Brush motor circuit On Solution Solenoid On

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

Vacuum motor circuit On

Vacuum motor circuit Off after 10 seconds

Wand Mode Standing Open

Foot Pedal Neutral Vacuum motor circuit On for 10 seconds, then enabled

Lower Squeegee Vacuum motor circuit On

Raise Squeegee Vacuum motor circuit Off after 10 seconds

FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855 - 19

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

20 - FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855

SQUEEGEE LIFT ACTUATOR CIRCUIT ERROR CODES AND MEASUREMENTS - ADVENGER / BR 755, 855

Advenger /

BR 755, 855

Display

Error Code

6 NA Squeegee lift actuator overload

34 NA Squeegee lift actuator open

Actuator Nominal Current (A) Overload Current Wire Colors

ST Service

LED

Blink Code

M3 2.5 - 3.5 5A for > 4 seconds BLK/YEL & WHT/GRN

Fault Description Troubleshooting Action

TROUBLESHOOTING SQUEEGEE ISSUES

Problem Possible Cause

Not enough adjustment of squeegee tool by turning adjustment knob

Squeegee Mount Weldment Bracket is bent. Replace

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.

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.

Squeegee is “hopping” Wheel isn’t making contact with the ﬂ oor - reposition wheel in slot on squeegee

tool. Refer to “Squeegee Adjustments” section.

Squeegee tips are being driven into the ﬂ oor 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

Lift motor does not run and the display shows an error fault code

Squeegee lift Linkage Arm at steering column keeps bending or breaking

Squeegee lift Linkage Arm / Knob doesn’t raise or lower squeegee

1. Threads in the moveable lift motor assembly drive tube are damaged (stripped).

2. Lift cable damaged (stretched or broken).

Lift motor electrical system failure - refer to chart in “Main Controller Error Codes” for service actions.

Squeegee Lift Cable is too tight - follow instruction in “Squeegee Lift Cable Adjustment - ST” section.

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.

FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855 - 21

SQUEEGEE ADJUSTMENTS

Correct squeegee alignment is critical to water pickup performance and life of squeegee blades. If the squeegee is not angled correctly or hops, use the following settings as nominal and adjust as necessary to achieve the required performance.

Tilt – FIGURE 7

Factory setting is 0.625” nominal

FIGURE 7

Wheel Height – FIGURE 8

Factory setting is 0.87” nominal

FIGURE 8

22 - FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855

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 ﬂ oor 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 ﬂ oor.

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 ﬁ nished, reassemble in reverse order.

FIGURE 9

FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855 - 23

SQUEEGEE LIFT ACTUATOR DRIVE NUT ADJUSTMENT - ADVENGER / BR 755, 855

FIGURE 10

WARNING!

1 Open the battery compartment and disengage the red

Anderson battery connectors.

2 Connect the Scrub Deck Lift Actuator (completely assembled)

to the Actuator Power Cord Adapter 56407502 (Figure 10) (see

“Diagnostic and Service Tools”). 3 Connect the red alligator clip to the positive battery terminal. 4 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 ﬂ at 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

24 - FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855

SQUEEGEE LIFT CABLE REPLACEMENT - ADVENGER / BR 755, 855

1 Follow steps 1-6 of “Squeegee Lift Actuator Replacement - Advenger / BR 755, 855” to disengage front end of lift cable under machine.

NOTE: the motor does not need to be disconnected for this procedure. 2 See Figure 12. Using 7/16” wrenches, remove the hex head bolt and associated hardware (A) to free other end of lift cable. 3 Reassemble in reverse order and test for proper raise and lower functions. 4 When lifting the recovery tank back onto the machine, pay attention to the location of the foam tubes. Route them into the battery tray,

otherwise they will crush.

FIGURE 12

FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855 - 25

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 ﬂ oor 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 ﬂ oor.

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

26 - FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855

SQUEEGEE LIFT CABLE ADJUSTMENT - ST

REAR – Figure 14

Factory setting is 0.25” Follow steps 1 – 6 of Squeegee Lift Actuator Replacement - Advenger / BR 755, 855

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

FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855 - 27

STEERING COLUMN ASSEMBLY SHROUD REMOVAL

1 See Figure 16. Remove the 4 screws fastening the Lower Column Shroud (A) to the Lower Column Weldment. 2 (ST) Using a 7/16” socket, remove Squeegee Lift Knob and Linkage Arm (B). 3 Using a ﬂ at bladed screwdriver, pry off the steering wheel plastic center cap. 4 Using a ¾” socket, remove the hex nut from the steering wheel center. 5 Pound the steering wheel (C) off from behind using a mallet, observing Woodruff key as it may ﬂ y off in the process. 6 Pull off accordion Steering Boot (D) from the upper steering column. 7 Lift the battery charger cover. 8 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

28 - FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855

SCRUB SYSTEM

Advenger / BR 755, 855 - pressing the Scrub On button with the seat switch closed causes the scrub deck and squeegee to drop. The control

board provides 24V to the deck lift actuator M4; this signal is DVM measureable for 3 seconds and then becomes a pulsed signal while the deck is down. Pressing the drive pedal forward causes the brush and vacuum contactors K2 and K1 to energize. The 24V brush and vacuum motors 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.”

FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855 - 29

SCRUB SYSTEM

ST - with the seat switch closed, lowering the squeegee and brush deck and pressing the drive pedal forward causes the brush and vacuum

contactors to energize. The 24V brush and vacuum motors turn on; the pulsed solution solenoid turns on. Combined brush motor current is monitored via the YEL/VIO sense wire. Reversing the drive pedal turns off the solution solenoid, but the brush motors stay on (for double scrub).

30 - FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855

BRUSH MOTOR CONTROL AND LOAD CIRCUIT ERROR CODES AND MEASUREMENTS

Advenger /

BR 755, 855

Display

Error Code

5 1, 2 Brush motor circuit overload

10 2, 2 Brush motor K2 contactor coil overload

ST Service

LED

Blink Code

2, 4

Visible

in Fault

Recall Mode

Fault Description Troubleshooting Action

Brush motor circuit open

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 modiﬁ cations, 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 modiﬁ cations (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 ﬂ oor and there is no interference between the deck and the ﬂ oor.

3, 2

60 3, 4

63 4, 3 Brush motor K2 contactor coil control fault

* 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+.

Brush

Motor Type

Disc

Cylindrical

Brush

Contactor Coil

K2 120 ohms 200 mA +/- 100 mA 750 mA

Visible

in Fault

Recall Mode

Resistance

Brush motor K2 contactor coil open

Brush motor circuit contacts stuck closed With no power to circuit, if contacts measure 0 ohms they’re

Scrub

Pressure

Low

Medium

High

Low

Medium

High

Nominal

Nominal Current (A)

+/- 3A

27 32 40

23 30 35

Nominal Current Overload Current Wire Colors

1. Check coil resistance (see chart below)

2. Check for tight connections at contactor and WHT/RED wire to control board. Repair or replace.

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.

Overload Current (A) Wire Colors

Red

Black

Red

Black

Brown

White/Red

FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855 - 31

SCRUB DECK LIFT ACTUATOR ERROR CODES AND MEASUREMENTS - ADVENGER / BR 755, 855

Advenger /

BR 755, 855

Display

Error Code

4 NA Scrub deck lift actuator overload

32 NA Scrub deck lift actuator open

Lift Actuator Nominal Current (A) Overload Current Wire Colors

M4 2.5 – 3.5 5A for > 4 seconds Blue & Orange/Black

Service LED

Blink Code

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.

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-speciﬁ c 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.

Brush motor overload Pin/spring location is too aggressive on the deck linkage for the ﬂ oor/brush

combination.

32 - FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855

SCRUB DECK LIFT ACTUATOR REPLACEMENT - ADVENGER / BR 755, 855

1 Lower the scrub deck per the instructions found in “Service Test Mode.” 2 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. 3 Unplug the Deck Lift Actuator connector. 4 Remove the Cotter Hairpins from the both ends of the actuator. 5 Remove the Deck Actuator. 6 Using the Actuator Power Cord Adapter 56407502 from your Nilﬁ sk-Advance service tool kit, set the Extend and Retract limit switch positions

as shown in the “Scrub Deck Lift Actuator Drive Nut Adjustment” section.

CAUTION!

Failure to set the lower stop correctly may result in damage to the Spring Housing (F).

7 Then reassemble in reverse order after drive nut position has been set.

NOTE: to replace a portion of this assembly (items A - G), follow these instructions as they apply, noting component position in the diagram at right, and set limit switch end stops in accordance with the instructions found in “Scrub Deck Lift Actuator Drive Nut Adjustment” section.

FIGURE 17

FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855 - 33

SCRUB DECK LIFT ACTUATOR DRIVE NUT ADJUSTMENT - ADVENGER / BR 755, 855

WARNING!

1 Open the battery compartment and disengage the red

Anderson battery connectors.

2 Connect the Scrub Deck Lift Actuator (completely assembled)

to the Actuator Power Cord Adapter 56407502 (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 ﬁ gure below. 7 Manually turn the plastic Spring Housing (F) assembly until the

position measure matches the ﬁ gure 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 ﬁ gure 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 18

FIGURE 19

34 - FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855

SCRUB DECK REMOVAL - DISC

WARNING!

DISCONNECT BATTERIES BEFORE SERVICING.

Scrub Deck Removal / Re-installation

1 Remove both deck side skirt assemblies. 2 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.

3 See Figure 20. Disconnect the solution system water line located on top of the scrub deck. 4 Disconnect both brush motor wiring harness connectors (A) (under right side of machine). 5 Remove the two (B) Hitch Pins that attach the scrub deck to the machine chassis linkage arm weldment. 6 From the right side of the machine pull the deck out from under the machine to complete the removal. 7 To install a scrub deck and roller bumper (if applicable), follow the previous steps in reverse order.

FIGURE 20

FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855 - 35

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 ﬂ at screw driver (C) against the aluminum gimbal shoulder

underneath the Brush Plate.

FIGURE 21

36 - FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855

SCRUB BRUSH MOTOR REMOVAL - DISC

5 See Figure 22. Mark the bolt locations (A) before removing

them because one deck is used for all deck sizes and there are multiple conﬁ gurations.

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.

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 ﬁ rmly 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).

FIGURE 22

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 ﬂ oor 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 overtorquing as damage to Motor Gimbal may occur.

FIGURE 23

FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855 - 37

SCRUB DECK REMOVAL - CYLINDRICAL

WARNING!

DISCONNECT BATTERIES BEFORE SERVICING.

Scrub Deck Removal / Re-installation

1 Remove both deck side skirt assemblies and the debris tray. 2 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.

3 See Figure 24. Disconnect the solution system water line located on top of the scrub deck. 4 Disconnect both brush motor wiring harness connectors (A) (under right side of machine). 5 Remove the two (B) Hitch Pins that attach the scrub deck to the machine chassis linkage arm weldment. 6 From the right side of the machine pull the deck out from under the machine to complete the removal. 7 To install a scrub deck and roller bumper (if applicable), follow the previous steps in reverse order.

FIGURE 24

38 - FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855

SCRUB BRUSH MOTOR REMOVAL - CYLINDRICAL

1 See SCRUB DECK REMOVAL-CYLINDRICAL to remove the scrub deck assembly. 2 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

FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855 - 39

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 conﬁ gurations.

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

40 - FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855

BAT

FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855 - 41

RECOVERY SYSTEM ERROR CODES AND MEASUREMENTS

Advenger

/ BR 755,

855 Display

Error Code

7 1, 3 Vacuum motor circuit overload

9 2, 1 Vacuum K1 contactor coil overload

Service LED

Blink Code

3, 1

Visible

in Fault

Recall Mode

3, 3

Visible

in Fault

Recall Mode

Fault Description Troubleshooting Action

Vacuum motor circuit open

Vacuum K1 contactor coil open

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 modiﬁ cations, 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

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 modiﬁ cations (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.

1. Check coil resistance (see chart below).

2. Check for tight connections at contactor and GRA/BLK wire to control board. Repair or replace.

61 4, 1

64 4, 4 Vacuum contactor coil control fault

Vacuum

Motor

M5 Single 20 30 White & Black

M5 + M6 Dual 40 60 White & Black

Vacuum

Contactor Coil

K1 100 ohms 240 mA +/- 50 mA 750 mA

Vacuum K1 contactor contacts stuck closed

Single/Dual

Nominal

Resistance

Nominal Current (A)

Nominal Current Overload Current Wire Colors

+/- 3A

With no power to circuit, if contacts measure 0 ohms they’re stuck. Replace K1.

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.

Overload Current (A) Wire Colors

Brown

Gray/Black

42 - FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855

TROUBLESHOOTING RECOVERY SYSTEM ISSUES

Problem Possible Cause

Advenger / BR 755, 855 and ST

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

Poor water pickup from squeegee tool

Vacuum motor keeps corroding and failing.

valve.

4. Restriction in vacuum system - check for debris in squeegee tool, vacuum hoses, ﬂ oat 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 ﬁ ll until shuts off automatically.

Vacuum motor is normally dry, now it’s wet and failing.

The control board doesn’t indicate the recovery tank is full before the ball valve shuts off the vac motor.

Display shows the recovery tank is full but it’s not. Disable Recovery Tank Full automatic shut-off via Hidden Menu.

Vacuum motor doesn’t turn on

Vacuum motor contactor doesn’t energize Go into Fault Recall mode and check for error 3,3

Vacuum leak below the water line creating turbulence in the recovery tank, causing water to enter the vacuum motor.

1. Check the vacuum motor sense wire (BRN/RED) for break or poor connection (mV signal).

2. Check that cage for ball ﬂ oat is clean.

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.

FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855 - 43

REPLACING A VACUUM MOTOR

WARNING!

DISCONNECT BATTERIES BEFORE SERVICING.

RECOVERY TANK REMOVAL

1 See Figure 26. Drain the Recovery Tank (A) using the Drain Hose(B). 2 Disconnect the Recovery Hose (C) from the squeegee. 3 Disconnect the vacuum motor wiring from the main harness. NOTE: Also disconnect optional Beacon wiring if installed. 4 Remove the Recovery Tank (A) from the machine.

FIGURE 26

44 - FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855

REPLACING A VACUUM MOTOR

VACUUM MOTOR ASSEMBLY REMOVAL

5 See Figure 27. Lay the Recovery Tank (A) on it's back. 6 Remove the (6) Screws (B) and remove the Vacuum Motor Cover (C) from the tank. 7 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 Attach gaskets (F) and (G) to the new vac motor; attach gasket (H) to the Vac Motor Cover, and insert motor into base. 9 Reassemble in reverse order, paying attention to route wires up through hole and out towards the back in the groove of Vac Motor Cover (C).

FIGURE 27

FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855 - 45

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 ﬂ ow 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.

46 - FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855

SOLUTION & AXP/EDS SYSTEM ERROR CODES AND MEASUREMENTS - ADVENGER / BR 755, 855 AND ST

Advenger /

BR 755, 855

Display

Error Code

8 1, 4 Solution solenoid overload

11 NA Chemical pump overload

37 NA Chemical pump open

62 4, 2 Solution solenoid control fault

ST Service

LED

Blink Code

2, 3

Visible in

Fault Recall

Mode

Fault Description Troubleshooting Action

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).

Solution solenoid open

2. Repair or replace. Voltage at control board should be -24V referenced to B+.

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.

Solution

Solenoid

L1 35 ohms 650 mA 750 mA BRN & VIO/BLK

Chemical Pump Nominal Current Overload Current Wire Colors

Nominal

Resistance

M2 PWM 870 mA PWM n/a

Nominal Current Overload Current Wire Colors

TROUBLESHOOTING SOLUTION & AXP/EDS SYSTEM ISSUES

Problem Possible Cause

Inadequate or no solution ﬂ ow 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 ﬂ ow and/or chemical rate don’t appear to follow programming

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 ﬁ tting.

3. Small clear hose at pressure sensor on Interface Control Panel is kinked.

Solution level indicator doesn’t work after new control board installed

Chemical rate doesn’t match manufacturer speciﬁ cations

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 ﬁ ttings. Check that pump is wired correctly and that the polarity isn’t reversed.

FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855 - 47

SOLUTION SYSTEM DIAGRAM

FIGURE 28

48 - FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855

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 ﬂ ow 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.

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.

FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855 - 49

REPLACING THE SOLUTION SOLENOID VALVE

1 Advenger / BR 755, 855 - follow instructions found in “Service Test Mode” to lower the scrub deck.

ST - manually lower the scrub deck.

WARNING!

2 Quickly disconnect the batteries at the red Anderson connectors in the battery compartment (done for safety and to keep the deck from rising

back up). 3 Reach under the front left side of the machine and manually close the red Solution Shutoff Valve (21) adjacent to the Solution Filter (20). 4 Using a ﬂ at blade screwdriver or 5/16” socket, loosen the two hose clamps on the valve and remove the black Solution Hose (A) from the

inlet side and the clear hose (B) coming from the deck manifold. 5 Using a 7/16” socket, remove the bolt fastening the Solution Solenoid to the machine. 6 Unplug the valve body at the connector (C). 7 Replace the valve and reassemble in reverse order.

FIGURE 30

50 - FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855

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 vacuumingonly modes. The Electromagnetic Brake is engaged whenever the foot pedal is in Neutral, and released for forward or reverse motion.

FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855 - 51

WHEEL DRIVE CIRCUIT ERROR CODES AND MEASUREMENTS

Advenger / BR 755, 855 Display Error Code

3 1, 1

Wheel Drive Motor

M1 15 - 20 15 - 50

ST Service LED Blink Code

Typical Current (A) Transport, Full Throttle

Fault Description Troubleshooting Action

Speed control fault (will disable all systems unless fault detection is disabled in the Hidden Menu)

Typical Current (A) Scrub Mode, Level Floor

TROUBLESHOOTING DRIVE WHEEL ISSUES

Problem 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.

Wire Colors

Red/Green and Yellow/Black (2 wires combined - required to prevent overheating if rotor locks)

Advenger / BR 755, 855 - the LCD indicates E03 and the chemical LED ﬂ ashes a code

ST - the Fault Indicator LED is blinking 1, 1 and the Extreme Solution Flow LED ﬂ ashes 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.

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.

52 - FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855

REPLACING THE DRIVE WHEEL ASSEMBLY

WARNING!

Park the machine on a dry ﬂ at 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

FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855 - 53

REPLACING THE DRIVE WHEEL ASSEMBLY (CONTINUED)

11 Reassemble the drive wheel in reverse order, attaching the motor wires as shown.

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

REPLACING THE DRIVE TIRE

The Drive Wheel is assembled as shown:

FIGURE 36

YELLOW/BLACK

WHITE

RED/WHITE

BLACK

ORANGE

RED/GREEN

In addition to carbon brushes, parts available for replacement are:

tire with hub 56601472  (A)

tire 56601471  (B)

motor 56601473  (C)

parking brake 56601507  (D)

motor cover 56601506  (E). 1 To replace the tire, follow steps 1-3 of “Replacing the Drive Wheel Assembly.” 2 Remove the six metric socket head screws. 3 Use Tire Puller Kit 56422174 to replace the tire. 4 Reassemble in reverse order.

54 - FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855

INSPECTING/REPLACING THE DRIVE WHEEL ASSEMBLY CARBON BRUSHES

IMPORTANT!

To remove/replace/inspect the Carbon Brushes, observe the following:

1 The motor must come off of the machine. 2 The motor assembly must be kept vertical while being

disassembled to prevent loss of gear oil.

WARNING!

Park the machine on a dry ﬂ at surface, turn the main key switch (J) to the Off position and disconnect the battery pack at the red Anderson connectors inside the battery compartment.

1 Follow the instructions in “Replacing the Drive Wheel

Assembly”.

2 Place the motor assembly upright, motor side up, as shown.

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 reﬁ ll the oil as indicated at the bottom of the page.

FIGURE 37

3 See Figure 37. Remove the four metric socket head cap

screws (A) securing the electric motor to the casting.

4 Use a hard piece of wood or a brass drift punch to tap the motor

mounting ﬂ ange (3 notched locations (B)) to loosen.

5 Grip the motor/brake end bell and pull the motor (C) up and out

of its housing.

6 Inspect the 4 carbon brushes and springs. A new carbon brush

measures 3/4”. If less than 1/4”, replace. 7 Clean the foam ﬁ lters, and blow out the motor. 8 If gear oil has been lost, drain and replace with 4.5856 oz (130

g) of Mobilgear 600 XP 150 or AGIP BLASIA 150 gear oil.

FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855 - 55

REPLACING THE REAR WHEELS

WARNING!

Park the machine on a dry ﬂ at surface, turn the main key switch Off and disconnect the battery pack at the red Anderson connectors in the battery compartment.

1 Block the front Drive Wheel (4). 2 Jack the Rear Wheel (9) to be replaced per the instructions at the front of this manual in “Jacking Points” section. 3 To prevent injury, if the rear wheel bearing has frozen, replace the bottle jack with blocks or a jack stand before pounding the wheel. 4 See Figure 38. Use a 17mm socket to remove bolt (A), washer (B) and wheel (C). 5 If the bearing has seized, pound off the wheel and use a bearing puller to remove the inner race from the axle. 6 Apply anti-seize to the inner bearing surface of the new wheel; then replace wheel on axle. 7 Apply anti-seize to the bolt threads before refastening bolt, washer and wheel.

FIGURE 38

56 - FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855

ELECTRICAL SYSTEM

FIGURE 39

ACCESS TO PANEL: CHEMICAL PUMP, CHARGER INTERLOCK, FUSES, CONTACTORS, SPEED CONTROL

WARNING!

1 Open the battery compartment and disengage the red Anderson battery

connectors. 2 Remove the 3 (AXP/EDS - 4) screws fastening the electrical panel to

the front of the machine. 3 See Figure 39. Inside are found the following:

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 at the wiper (pin 4, the GRA wire) referenced to the B- standoff

(green wires).

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 Function Wire Color

3 5kOhm Pot High YEL 4 5kOhm Pot Wiper GRA 5 Seat Switch GRA/BLK 6 Brake - RED/WHT 9 Error Status ORN/BLU 13 5kOhm Pot Low VIO 14 Brake + ORN 16 Reverse Alarm BLU/BLK 18 Speed Limit BLK/WHT

FIGURE 40

FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855 - 57

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.

Referenced to Measure J1 Measure Referenced to

+24V to M4 for 3 sec. deck

B+

B+ Not measurable using DVM BLU/GRY 3 8 BLK B-

B- Not measurable using DVM RED/YEL 1 6

downward travel 0V to M4 for 3 sec. deck upward travel

0V to M4 for 3 sec. deck

downward travel

+24V to M4 for 3 sec.

deck upward travel

ORN/BLK 5 10 WHT/GRN

BLU 4 9 BLK/YEL

Range of 24V measurements is 20 – 26 V

0V to M3 for 3 sec.

squeegee down travel

24V to M3 for 3 sec.

squeegee up travel

24V to M3 for 3 sec.

squeegee down travel

0V to M3 for 3 sec. squeegee up travel

B+

58 - FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855

Backprobe J2 - Speed Control outputs, ST deck and squeegee lever position, and sense wires, J2 connected at control board:

Referenced to Measure J2 Measure Referenced to

ST squeegee lever switch S6

B- n/a YEL 6 12 BLK/YEL

B- n/a VIO 5 11 ORN/RED

B- n/a BLK/WHT 4 10

YEL/VIO

BRN/RED

Closed sq down 0V

Open sq up 5V

ST deck lever switch S5

Closed deck up 0V

Open deck down 5V

M7 & M8 sense

monitor brush heights for deck

actuator feedback

0-200 mV

M5 & M6 sense

monitor vac motors to determine

when tank is full

1-200 mV

B-

B+

Advenger / BR 755,

855 B- (ground) input

to board

+24V

B- (ground)

Input to board

+24V

Advenger /

BR 755, 855

BLK

BLK 1 7 BLK Advenger / BR 755, 855 +24V B+

2 8 BLK +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-

B- Seat switch +24V GRA/BLK 4 11

+24V ﬂ ashed speed control status

error code

Speed control EM brake signal

+24V

(moving on / neutral off)

Speed control reverse

direction +24V

(reverse off / forward on)

ORN/BLU 7 14 BRN Key switch +24V B-

RED/WHT 6 13

BLU/BLK 5 12

WHT/RED

GRA/BLK

VIO/BLK

***

+24V for 2 sec to K2

then 18V pulsed voltage

+24V for 2 sec to K1

then 18V pulsed voltage

Pulsed +24V B+

B+

B-

Advenger / BR 755, 855 Ground

+24V

Advenger / BR 755, 855 Power

+24V

* test point for brush motor contactor coil control error 63 ** test point for vacuum contactor coil control error 64 *** test point for solution solenoid control error 62

3 10 ORN/RED -Output to horn +15V B-

BLK 2 9 GRN/BLK +Output to horn +15V B-

BRN/YEL 1 8 BRN/YEL

FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855 - 59

CURTIS SPEED CONTROL INSTALLATION CHECKOUT PROCEDURE

After installing a controller and before operating the vehicle, carefully complete the following checkout procedure. If you ﬁ nd 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 ﬂ ash 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.

60 - FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855

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 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.

2 Take note of the wiring connections for reassembly and then disconnect all wiring and the small clear hose. Advenger / BR 755, 855 -

Completely drain the solution tank to prevent:

water squirting out of the ﬁ tting 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 ﬁ tting on the top of the tank.

FIGURE 41

FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855 - 61

REPLACING THE OPERATOR CONTROL PANEL

CONTROL PANEL DISASSEMBLY, ASSEMBLY AND INSTALLATION

1 See Figure 42. Remove the Key Switch (A) from the panel assembly. 2 Remove the (5) Screws (B), the Circuit Board (C) and the Tab (D) from the panel assembly. NOTE: Save Items (A-D) and discard the panel

assembly.

3 Follow all previous steps in reverse order to reassemble and install the control panel assembly using the new panel assembly (1 & 2) from

the kit.

NOTE: the clear hose must not be kinked otherwise the Solution System will not function properly.

CAUTION!

FIGURE 42

62 - FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855

PROGRAMMING FUNCTIONS SERVICE TEST MODE - ADVENGER / BR 755, 855

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

Toggles LCD Display Indication *

ON/OFF

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

* LCD also displays SPD speed control ON/OFF, actual battery voltage measured, and any error codes.

K C L E H

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

FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855 - 63

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

Toggles LED Indication

ON/OFF

Activate solution solenoid L1

Activate brush motor contactor K2

Activate vacuum motor contactor K1

Other Status Indicators Indication LED

Main control board

Speed Control

Drive pedal

C B D

ST Service LED Blink Code

Speed Control Error Flash Code

Forward Reverse

ENERGIZED...DE-ENERGIZED Solution Med

ENERGIZED...DE-ENERGIZED Solution High

ENERGIZED...DE-ENERGIZED Solution Low

Fault Indicator

Battery RED - Blinking

Battery YELLOW - ON Battery GREEN - ON

64 - FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855

CHANGING CONTROL BOARD PROGRAM SETTINGS

Although the Advenger / BR 755, 855 and ST are delivered with a standard factory preset conﬁ guration, 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 Nilﬁ sk-Advance.

IMPORTANT

For ﬁ eld 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 conﬁ guration - 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 OFF and AXP/EDS disabled.

10. Chemical Selection - Turn AXP/EDS Off or On with display indicating US or European (ratio or %) format.

11. Detergent Mode - . Turn on Mode 1 (machine factory preset for US market) to enable standard Evergreen mode in which pressing the Evergreen button enables preset ratio for 60 seconds. Turn on Mode 2 (factory preset for the EU market) to run at a preset ratio. In this mode, pressing the Evergreen button increments the ratio (solution concentration) to the next stronger level for 60 seconds.

NOTE: To run the machine in a constant user-deﬁ ned ratio, turn the Detergent Mode to Off and set the chemical ratio by pressing and holding the AXP/EDS On/Off switch (E).

12. Brush Pressure lock-out - during normal operation, the pressure settings that are locked out will not be selectable.

13. Chemical rate bias - AXP/EDS control set to 10% more or less chemical than the user programmed ratio

14. Deck down time - time for which the control system applies 24V to the deck actuator to raise or lower the scrub deck after the Scrub On switch is pressed (adjustable from 1 to 5 seconds).

15. Backup Alarm volume

16. Horn volume

FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855 - 65

CHANGING PROGRAM SETTINGS - ADVENGER / BR 755, 855

1 To enter this Hidden Menu, turn the key switch Off, then press and hold the Scrub and Vacuum switches together. 2 Turn key switch back On and hold the switches for 2 seconds until the Solution and Scrub indicators both turn on. 3 Release both switches - the display will now read “Programming Options.” Scroll through the menus using the Solution + or - switches and

enter the program number corresponding to the needed function. 4 To enter a submenu, press the Solution switch. 5 To save and go back to the main menu, press the Scrub switch. 6 To exit the hidden menu, turn the key switch off.

Prog. Function Option 1 Option 2 Option 3 Option 4, etc.

1 DECK TYPE 28” disc /

BR 755

2 CHEMICAL SELECTION AXP On

US mode: X:XXX

3 DETERGENT MODE Off

no Evergreen

(board default)

4 VACUUM SELECTION 1 (single) 2 (dual) --

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)

8 LOCK OUT SOLUTION

(displayed rate is locked out)

9 RECOVERY TANK FULL

(automatic shutoff turned on)

10 CHEMICAL RATE BIAS NONE (equal) +10% MORE CHEM -10% LESS CHEM --

11 DECK DOWN TIME Incremental from 1 to 5 seconds in 0.1 second intervals

Low Med High Low & Medium, Low &

ENABLED DISABLED -- --

28” Cyl /

BR 755 C

EDS On

EU mode: %

Mode 1

US Evergreen On

34” disc /

BR 855

AXP/EDS Off

Mode 2

EU or non-Evergreen

preset

High, High & Medium

12 RESTORE FACTORY DEFAULTS NO YES -- --

14 FAULT RECALL No faults

occurred - display

is “-”

15 FAULT DETECTION ENABLED DISABLED

17 BACKUP ALARM VOL Off Low Med High

18 FWR ALARM VOL Off Low Med High

19 HORN VOL Off Low Med High

Error codes To erase history, press the Solution switch while

in this mode.

66 - FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855

CHANGING PROGRAM SETTINGS - ST

1 To enter this Hidden Menu, turn key switch Off, then press and hold the buttons shown in the table below simultaneously. 2 Turn key switch back On and hold for 2 seconds until the indicated LEDs for the desired function turn On, then release the switches. 3 Use the Solution + or - switches to change the setting. The fault code LED will blink at the same rate as the fault code display to show what

the current setting is.

Press the Solution On/Off switch to save the setting, then turn key switch Off to exit the hidden menu.

(1)

SWITCHES PRESSED

FUNCTION

Low Voltage Cutout

Scrub Deck Size

Single/Dual Vac Motor

Max Scrub Speed % of

Transport Speed

Recovery Tank Full

Shutoff

Restore Factory

Defaults

Fault Recall

BDCK

LOW

Solution

INITIAL LED INDICATION

MED

Solution

●● ●

●● ● ●

●● ●

●●● ●

(2)

HIGH

Solution

RED YEL GRN

BLINKS



Wet Gel/AGM

28” 34”

50% 60% *

Enabled Disabled

No Yes

●●● ●

(3)

Fault Detection

Solution Flow Rate

Lockout

* 70% - 100% are 3 to 6 blinks respectively. ** Medium, High, Low & Medium, Low & High, Medium & High are 3 to 7 blinks respectively.

●● ● ●●

● ● ●●●

Enabled Disabled

None Low **

FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855 - 67

MAINTENANCE SCHEDULES

OPERATOR PREVENTIVE MAINTENANCE – MACHINE IN USE

MAINTENANCE ITEM Daily Weekly Monthly

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 ﬁ lter(s) ●

Clean Hopper on Cylindrical System ●

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 (AXP/EDS Only) ●

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

●

68 - FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855

MAINTENANCE SCHEDULES

OPERATOR PREVENTIVE MAINTENANCE – MACHINE IN STORAGE

MAINTENANCE ITEM Daily Weekly Monthly Yearly

Check Each Battery Cell’s Water Level (wet) ●

Charge Batteries – full charge cycle 12-15 hrs ●

SERVICE TECHNICIAN SUGGESTED MAINTENANCE

MAINTENANCE ITEM Quarterly Yearly

Clean battery tops and posts with baking soda solution ●

Inspect battery connections for tight, corrosion-free ﬁ t ●

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 ●

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)

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 efﬁ ciency as a new brush.)

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.

300 Op Hrs

500 Op Hrs

FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855 - 69

Advance Advenger 2805, 2905, 3405

Advance 2800ST, 3400ST

Nilﬁ sk BR 755, 855

Disc and Cylindrical

PM Checklist

Defect Codes

Customer A needs adjustment

B binding

Address C dirty or contaminated

D damaged, bent or torn

City St Zip L leaks

M missing

Model Serial Hours W worn out

Ref OPERATIONAL INSPECTION ITEMS OK or

N/A

Defect Codes (circle)

1 Steering A B

2 Drive Pedal Operational (check for Fwd/Rev Drive & any neutral creep) A B D

3 Seat Switch D

Does Not Work

4 Electrical Parking Brake (Brake releases when the key is turned on and the drive pedal is

A B W

engaged. Brake engages when machine is at rest.)

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;

A B

Normal/Extreme for ST)

8 Squeegee System (Raise, Lower, ADVENGER / BR 755, 855 - Auto-raise in reverse) A B D

9a Vacuum Performance Single Motor

C L W

(sealed water lift 63”, 1-inch open hole aperture 10”)

9b Vacuum Performance Dual Motor (sealed water lift) (sealed water lift 65”, 1-inch open hole

C L W

aperture 18”)

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

70 - FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855

Ref VISUAL INSPECTION ITEMS Comments OK or

N/A

17 Scrub Brushes (check for wear and rotate) A B D W

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

Defect Codes (circle)

Does Not Work

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

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” Deﬂ ection A B C

39 Steering Column Universal Joint A D

40 Rear Wheels C

41 Sweep Hopper C

WORK COMPLETED BY: ACKNOWLDEGED BY:

__________________________________ _________ ________________________________ ________ Service Technician Signature Date Customer Signature Date

FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855 - 71

FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855- 75

COMPONENT LOCATION (Advenger / BR 755, 855)

ELECTRICAL SYSTEM

Item Description

A1 Control PCB Assy A2 Controller, Speed F1 Fuse 150 Amp CB1 Circuit Breaker, 70 Amp CB2 Circuit Breaker, 10 Amp H1 Beacon, Warning (optional) H2 Horn/Backup Alarm K1 Contactor, Vacuum Motor K2 Contactor, Brush Motor L1 Solenoid Valve M1 Motor / Drive Wheel M2 Pump, Chemical (AXP/EDS only) M3 Squeegee Lift Actuator M4 Brush Lift Actuator M5 Motor, Vacuum M6 Motor, Vacuum (Optional) M7 Motor, Brush M8 Motor, Brush R1 Potentiometer, 5K S1 Switch, Key S2 Switch, Seat S4 Emergency Disconnect Y1 Electromagnetic Brake

76 - FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855

ELECTRICAL SYSTEM

WIRING DIAGRAM / SCHEMATIC (Advenger / BR 755, 855)

Item Ref. No. Qty Description

A1 56601565 1 Control PCB Assy A2 56601061 1 Controller, Speed

BAT N/A Battery

F1 56412089 1 Fuse, 150 Amp

CB1 56454429 1 Circuit Breaker, 70 Amp CB2 56507644 1 Circuit Breaker, 10 Amp

H1 56307166 1 Beacon, Warning (optional) H2 56412177 1 Horn/Backup Alarm

K1 56601183 1 Contactor 24v, 100 Amp K2 56412179 1 Contactor 24v

L1 56601064 1 Solenoid Valve Assy

M1 56601050 1 Motor / Drive Wheel M2 56315241 1 Pump, Chemical M3 56601147 1 Actuator, Motor 24v M4 56601432 1 Lift Actuator Assembly M5 56601132 1 Motor, Vac 24vdc M6 56601132 1 Motor, Vac 24vdc (optional) M7 56315061 1 Motor, 24 Vdc, .5 Hp, 1800 Rpm (cylindrical) 56601134 2 Motor Gearbox Assy (disk) M8 56315061 1 Motor, 24 Vdc, .5 Hp, 1800 Rpm (cylindrical) 56601134 2 Motor Gearbox Assy (disk)

R1 N/A 1 Part of 56601052

S1 56303553 1 Key Switch * 56303526 A/R Replacement Key Set S2 7-82-00050 1 Switch, Seat S4 56407130 1 Disconnect, Emergency

Y1 56601507 1 Brake, Electromagnetic

56315124 1 Charger, On-Board 24v TSBUS2008-984

FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855- 77

ELECTRICAL SYSTEM

78 - FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855

Item Description

A1 Control PCB Assy A2 Controller, Speed F1 Fuse 150 Amp CB1 Circuit Breaker, 70 Amp CB2 Circuit Breaker, 10 Amp H1 Beacon, Warning (optional) H2 Horn/Backup Alarm K1 Contactor, Vacuum Motor K2 Contactor, Brush Motor L1 Solenoid Valve M1 Motor / Drive Wheel M5 Motor, Vacuum M6 Motor, Vacuum (Optional) M7 Motor, Brush M8 Motor, Brush R1 Potentiometer, 5K S1 Switch, Key S2 Switch, Seat S4 Emergency Disconnect S5 Deck Switch S6 Squeegee Switch Y1 Electromagnetic Brake

COMPONENT LOCATION (2800ST, 3400ST)

ELECTRICAL SYSTEM

FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855- 79

ELECTRICAL SYSTEM

WIRING DIAGRAM / SCHEMATIC (2800ST, 3400ST)

Item Ref. No. Qty Description

A1 56601566 1 Control PCB Assy A2 56601061 1 Speed Control

BAT N/A Battery

F1 56412089 1 Fuse, 150 Amp

CB1 56454429 1 Circuit Breaker, 70 Amp CB2 56507644 1 Circuit Breaker, 10 Amp

H1 56307166 1 Beacon, Warning (optional) H2 56412177 1 Horn/Backup Alarm

K1 56601183 1 Contactor 24v, 100 Amp K2 56412179 1 Contactor 24v

L1 56601064 1 Solenoid Valve Assy

M1 56601050 1 Motor / Drive Wheel M5 56601132 1 Motor, Vac 24vdc M6 56601132 1 Motor, Vac 24vdc (optional) M7 56601134 2 Motor Gearbox Assy M8 56601134 2 Motor Gearbox Assy

R1 N/A 1 Part of 56601052

S1 56303553 1 Key Switch * 56303526 A/R Replacement Key Set S2 7-82-00050 1 Squeegee Switch S4 56407130 1 Disconnect, Emergency S5 56305053 1 Deck Switch S6 56601160 1 Squeegee Switch

Y1 56601507 1 Brake, Electromagnetic

56315124 1 Charger, On-Board 24v TSBUS2008-984

BAT

80 - FORM NO. 56043121 - Advenger / 2800ST, 3400ST / BR 755, BR 855

ELECTRICAL SYSTEM

Nilfisk-Advance Advenger 2800ST, Advenger 3400ST, AdvengerBR 755, Advenger BR 855, Advenger Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual