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

Advenger™

2800ST, 3400ST

BR 755, BR 855

Quick Start Service Manual

Advance MODELS: 56601000, 56601001, 56601002, 56601003,56601004, 56601005, 56601006, 56601007, 56601008, 56601009, 56601010, 56601011, 56601012, 56601013, 56601019, 56601020, 56601891, 56601892

Nilsk MODELS: 56601014, 56601015,

56601016

English

9/09 Revised 11/13 FORM NO. 56043121

Contents iiService Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

Contents

Introducon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Quick Start Service Manual Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

General Machine Descripon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Parts and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Cauons and Warnings Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

General Safety Instrucons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Related Reference Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Diagnosc and Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Technical Specicaons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Technical Specicaons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Electrical Specicaons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Transporng The Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Towing the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Jacking Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Emergency Stop Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Know Your Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Machine Front RH View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Machine Rear LH View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

CONTROL PANEL (Advenger / BR 755, 855 Disc and Cylindrical models) . . . . . . . . . . . . . . . 15

CONTROL PANEL (REV models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

CONTROL PANEL (ST Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Basic Machine Operaon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Main Controller Error Codes – Advenger / BR 755, 855 and ST. . . . . . . . . . . . . . . . . . . . . 19

Speed Control Error Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Error Code System Diagnoscs – Advenger / BR 755, 855 and ST . . . . . . . . . . . . . . . . . . . 21

SQUEEGEE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Troubleshoong Squeegee Issues. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Squeegee Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Squeegee Li Actuator Replacement - Advenger / BR 755, 855 . . . . . . . . . . . . . . . . . . . 27

Squeegee Li Actuator Drive Nut Adjustment - Advenger / BR 755, 855 . . . . . . . . . . . . . . . 28

Squeegee Li Cable Replacement - Advenger / BR 755, 855 . . . . . . . . . . . . . . . . . . . . . . 29

Squeegee Li Cable Replacement - ST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Squeegee Li Cable Adjustment - ST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Steering Column Assembly Shroud Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

SCRUB SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Troubleshoong Scrub System Issues. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Scrub Deck Li Actuator Replacement - Advenger / BR 755, 855 . . . . . . . . . . . . . . . . . . . 38

Scrub Deck Li Actuator Drive Nut Adjustment - . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Scrub DECK REMOVAL - Disc and REV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Scrub Brush Motor Removal - DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Scrub Brush Motor Removal - DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Motor Plate and isolators (REV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Scrub DECK REMOVAL - Cylindrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Scrub Brush Motor Removal - Cylindrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

Contents iiiService Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

RECOVERY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Troubleshoong Recovery System Issues. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Replacing a Vacuum Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

SOLUTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Troubleshoong Soluon & AXP/EDS System Issues . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Soluon System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Soluon System Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Replacing the Soluon Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

WHEEL DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Troubleshoong Drive Wheel Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Replacing the Drive Wheel Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Replacing the Drive Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Inspecng/Replacing the Drive Wheel Assembly Carbon Brushes . . . . . . . . . . . . . . . . . . . 71

Replacing the Rear Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Control board j1, j2, and j3 pin outs and test points. . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Curs Speed Control Installaon Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 79

Replacing the Operator Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Programming Funcons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Service Test Mode - ADVENGER / BR 755, 855 (Disc and Cyl.) . . . . . . . . . . . . . . . . . . . . . 82

Changing Control Board Program Sengs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Changing Program Sengs - Advenger / BR 755, 855 (Disc and Cyl.) . . . . . . . . . . . . . . . . . 84

Changing Program Sengs - ST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Service Test Mode - ST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86

Hidden Menus (REV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Program Opons (REV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

Service Test Mode - ADVENGER / BR 755, 855 (REV) . . . . . . . . . . . . . . . . . . . . . . . . . . 90

MAINTENANCE SCHEDULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

OPERATOR PREVENTIVE MAINTENANCE – MACHINE IN USE . . . . . . . . . . . . . . . . . . . . . . 92

OPERATOR PREVENTIVE MAINTENANCE – MACHINE IN STORAGE. . . . . . . . . . . . . . . . . . . 93

SERVICE TECHNICIAN SUGGESTED MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

RECOMMENDED MAINTENANCE MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

PM Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Expanded Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Component Locaon (Advenger/BR 755, 855). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

WIRING DIAGRAM / SCHEMATIC (Advenger / BR 755, 855 Disc and Cylindrical Decks) . . . . . . . 76

Wiring Diagram (REV Deck) - 56601806 Revision A Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . 78

Wiring Diagram (REV Deck) - 56601806 Revision A Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . 79

Wiring Harness Diagram (REV Deck) - 56601807 Revision A . . . . . . . . . . . . . . . . . . . . . . 80

Component Locaon (2800ST, 3400ST). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

WIRING DIAGRAM / SCHEMATIC (2800ST, 3400ST) . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Introduction 4Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

Introduction

Quick Start Service Manual Purpose

This manual is a technical resource that Nil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 Nil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 oor scrubbers available with multiple deck sizes, multiple corresponding squeegee blade sizes and materials, and variable scrub pressure and solution ow rates..

Parts and Service

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

Introduction 5Service Manual – Advenger, 2800ST, 3800ST, 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

Specic Cautions and Warnings are included to warn you of potential danger of machine damage or bodily harm. This machine is for commercial use, for example in hotels, schools, hospitals, factories, shops and ofces other than normal residential housekeeping purposes.

WARNING!

* This machine shall be used only by properly trained and authorized persons. * This machine is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack

of experience and knowledge. * While on ramps or inclines, avoid sudden stops. Avoid abrupt sharp turns. Use low speed down ramps. * Keep sparks, 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

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 ammable cleaning agents, operate the machine on or near these agents, or operate in areas where ammable

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

impair safety. * Observe the Gross Vehicle Weight, GVW, of the machine when loading, driving, lifting or supporting the machine.

CAUTION!

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

scari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 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 ttings. Flush with windshield washer uid.

Introduction 6Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

* The batteries must be removed from the machine before the machine is scrapped. The disposal of the batteries should be

safely done in accordance with your local environmental regulations. * Do not use on surfaces having a gradient exceeding that marked on the machine. * All doors and covers are to be positioned as indicated in the instruction manual before using the machine. * This machine should only be used and stored indoors..

SAVE THESE INSTRUCTIONS

Related Reference Sources

Nil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 Nilsk-Advance commercial 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 Nil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 Nil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

Technical Specications

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:

Introduction 7Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

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, REV 32.6 in (82.8 cm)

36.3 in (92.2 cm) 34 disc 41.4 in (105.2 cm)

31.6 in (80.3 cm) 28 cyl 32.6 in (82.8 cm)

Solution Tank: 28 gal (106 l)

Recovery Tank: dynamic: 25 gal (95 l); static: 28 gal (106 l)

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 Nilsk Models

FIGURE 1

Technical Specications

Electrical Specications

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

Introduction 8Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

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 Disc and Cyl

Advenger BR 755, 855 Solution Flow Rates Disc and Cy

(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 Mode 0.2 gal/min (0.7 L/min) Floor Finish Removal Mode 0.1 gal/min (0.4 L/min)

(2) Heavy Scrub Mode 0.4 gal/min (1.5 L/min) Floor Finish Removal Mode 0.2 gal/min (0.7 L/min)

(3) Extreme Scrub Mode 0.2 gal/min (3.0 L/min) Floor Finish Removal Mode 0.4 gal/min (1.5 L/min)

Pulse-control Solenoid Valve

(1) Regular Scrub .30 gal/min (1.13 L/min) or 60 minutes per solution tank

ST Solution Flow Rates (Average)

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

Detergent Ratios Available

Recycle System Available No

(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

400:1 = .25% 200:1 = .5% 100:1 = 1% 32:1 = 3% 300:1 = .3% 150:1 = .66% 64:1 = 1.5% 256:1 = .4% 128:1 = .8% 50:1 = 2%

RECOVERY SYSTEM

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

Vacuum Water Lift (measured at recovery hose)

One Motor

Two Motors

Sealed: 63.0 in of Water (15.7 kPa) 1” Open-hole Aperture: 10.3 in of Water (2.6 kPa)

Sealed: 65.0 in of Water (16.2 kPa) 1” Open-hole Aperture: 18.5 in of Water (4.6 kPa)

TECHNICAL SPECIFICATIONS

SCRUB SYSTEM

Scrub Deck Types Disc, Cylindrical and REV

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

Introduction 9Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

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 REV approx 2,000 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)

(1) Regular Scrub: 80 lbs (36kg)

(2) Heavy Scrub: 125 lbs (57kg)

(3) Extreme Scrub: 175lbs (80 kg)

MINIMUM AISLE TURN AROUND RADIUS (TURNING LEFT)

Introduction 10Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

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)

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 ush with windshield washer uid to prevent damage to

valves and ttings.

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

Tie-Down Points

FIGURE 2

Introduction 11Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

Towing the Machine

CAUTION!

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

Tow the machine for short distances only.

FIGURE 3

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.

Introduction 12Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

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

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 or EcoFlex models only) 13 Detergent Cartridge (AXP/EDS or EcoFlex 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

Know Your Machine 13Service Manual – Advenger, 2800ST, 3800ST, 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

Know Your Machine 14Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

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

Know Your Machine 15Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

KNOW YOUR MACHINE

CONTROL PANEL (Advenger / BR 755, 855 Disc and Cylindrical models)

A Key Switch B Solution Increase Switch C Solution ON/OFF Switch C1 Solution Flow Indicators (Normal, Heavy & Extreme) D Solution Decrease Switch E AXP/EDS (EcoFlex) ON/OFF Switch F Display F1 Hour Meter F2 Solution Tank Level Indicator F3 Fault Codes F4 AXP/EDS or EcoFlex Indicator (if so equipped) F5 Detergent Ratio Indicator F6 Battery Indicator F7 Recovery Tank FULL Indicator F8 Battery Low Indicator

G Scrub Pressure Increase Switch H Scrub ON/OFF Switch H1 Scrub Pressure Indicators (Normal, Heavy and Extreme) I Scrub Pressure Decrease Switch J EverGreen (Burst of Power) 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

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.

CONTROL PANEL (REV models)

Know Your Machine 16Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

A Key Switch B Solution ON / Increase Switch C1 Solution Flow Indicators (Normal, Heavy & Extreme) D Solution Decrease / OFF Switch E Detergent ON/OFF Switch F Display F1 Hour Meter F2 Solution Tank Level Indicator F3 Fault Codes F4 Detergent Indicator (if so equipped) F5 Detergent Ratio Indicator F6 Battery Indicator F7 Recovery Tank FULL Indicator F8 Battery Low Indicator

F9 Floor Finish Removal Speed Indicator (low, high) F10 Detergent Indicator Bar Graph (off, weak, strong) G Scrub Pressure Increase Switch H Scrub ON/OFF Switch H1 Scrub Pressure Indicators (Normal, Heavy and Extreme) I Scrub Pressure Decrease Switch J Burst of Power Switch K Horn Switch L Vacuum/Wand Switch O Floor Finish Removal Mode Switch

F10

KNOW YOUR MACHINE

CONTROL PANEL (ST Models)

Know Your Machine 17Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

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) 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.

Know Your Machine 18Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

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 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 ow rate can be changed by using the SOLUTION + or SOLUTION - button. 6 If the scrub mode and solution 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 ow rate to match the scrub mode setting.

B Change the scrub mode using the SCRUB + or SCRUB - buttons. The scrub pressure and solution 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.

Main Controller Error Codes – Advenger / BR 755, 855 and ST

Know Your Machine 19Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

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.

Speed Control Error Flash Codes

STATUS LED FAULT CODES (TABLE 1)

Know Your Machine 20Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

LED CODE STATUS LIGHT

DISPLAY

1,1

1,2

1,3

1,4

1,5

2,1

2,3

2,4

3,1

3,2

3,3

3,4

3,5

4,1

4,2

4,3

4,4

O O over-/under-temperature cutback 1. Temperature >97°C (206°F) or < -25°C (-13°F).

O OO throttle fault 1. Throttle input wire open or shorted.

O OOO speed limit pot fault 1. Speed limit pot wire(s) broken or shorted.

O OOOO battery voltage too low 1. Battery voltage <17 volts.

O OOOOO battery voltage too high 1. Battery voltage >36 volts.

OO O main contactor driver Off fault 1. Main contactor driver failed open.

OO OOO main contactor fault 1. Main contactor welded or stuck open.

OO OOOO main contactor driver On fault 1. Main contactor driver failed closed.

OOO O HPD fault present for >10 sec. 1. Misadjusted throttle.

OOO OO brake On fault 1. Electromagnetic brake driver shorted.

OOO OOO precharge fault 1. Controller failure.

OOO OOOO brake Off fault 1. Electromagnetic brake driver open.

OOO OOOOO HPD (High Pedal Disable) fault

OOOO O current sense fault 1. Short in motor or in motor wiring.

OOOO OO motor voltage fault (hardware

OOOO OOO EEPROM fault 1. EEPROM failure or fault.

OOOO OOOO power section fault 1. EEPROM failure or fault.

EXPLANATION POSSIBLE CAUSE

2. Excessive load on vehicle.

3. Operation in extreme environments.

4. Electromagnetic, foot or parking brake not releasing properly.

2. Throttle pot defective.

3. Wrong throttle type selected.

2. Broken speed limit pot.

2. Bad connection at battery or controller.

2. Vehicle operating with charger attached.

3. Intermittent battery connection.

2. Main contactor driver fault.

3. Brake coil resistance too high.

2. Broken throttle pot or throttle mechanism.

2. Electromagnetic brake coil open.

2. Low battery voltage.

2. Electromagnetic brake coil shorted.

1. Improper sequence of throttle and KSI*, push, or inhibit inputs.

2. Misadjusted throttle pot

2. Controller failure.

1. Motor voltage does not correspond to

failsafe)

throttle request.

2. Short in motor or in motor wiring.

3. Controller failure.

2. Short in motor or in motor wiring.

3. Controller failure.

*NOTE: A KSI (key switch input) system problem is a speci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.

Know Your Machine 21Service Manual – Advenger, 2800ST, 3800ST, 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

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

7 Vacuum motor overload x x x x

8 Solution solenoid overload x x x

9 Vacuum contactor coil overload x x x x

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

Know Your Machine 22Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

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 dened by the Mode that is chosen - Scrub

Mode, Vacuum Mode, Floor Finish Removal or Wand Mode. The following tables outline the various components of the systems that are controlled in tandem by pressing a particular button or engaging the Drive Pedal in Forward, Neutral, or Reverse under normal machine operation. To bypass these systems, refer to the “Service Test

Mode” section.

Advenger / BR 755, 855

Mode

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

Vac Mode Seated Closed

Wand Mode* Standing Open

Brush motor circuit Off

Press Scrub Off Foot Pedal in

Neutral >10 sec.

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

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

Know Your Machine 23Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

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

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

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

Mode

Scrub 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

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

Vac Mode Seated Closed

Wand Mode Standing Open

Lift

Squeegee

Lower Squeegee Vacuum motor circuit enabled

Press Foot Pedal

Forward

Press Foot Pedal

Reverse

(Lift Squeegee to prevent

damage)

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

Vacuum motor circuit Off after 10 seconds

Vacuum motor circuit On

Vacuum motor circuit Off after 10 seconds

SQUEEGEE SYSTEM 24Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

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

SQUEEGEE SYSTEM 25Service Manual – Advenger, 2800ST, 3800ST, 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 oor - reposition wheel in slot on squeegee

tool. Refer to “Squeegee Adjustments” section.

Squeegee tips are being driven into the 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.

SQUEEGEE SYSTEM 26Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

Squeegee Adjustments

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

Tilt – FIGURE 7

Factory setting is 0.625” nominal

Wheel Height – FIGURE 8

Factory setting is 0.87” nominal

FIGURE 7

FIGURE 8

SQUEEGEE SYSTEM 27Service Manual – Advenger, 2800ST, 3800ST, 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 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 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 nished, reassemble in reverse order.

FIGURE 9

SQUEEGEE SYSTEM 28Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

Squeegee 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 (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 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.

FIGURE 10

Actuator Setting – mounting hole center to center:

Retracted: 9.00” +/- .06 Extended: 13.25” +/- .06

* It’s not practical to measure center to center of the holes, so an outer edge to inner edge of the pins measurement is suggested.

FIGURE 11

SQUEEGEE SYSTEM 29Service Manual – Advenger, 2800ST, 3800ST, 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

SQUEEGEE SYSTEM 30Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

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 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 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

SQUEEGEE SYSTEM 31Service Manual – Advenger, 2800ST, 3800ST, 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

SQUEEGEE SYSTEM 32Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

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 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 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

SCRUB SYSTEM 33Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

SCRUB SYSTEM

Advenger / BR 755, 855 Disc and Cylindrical - pressing the Scrub On button with the seat switch closed causes the scrub deck and squeegee to drop. The control board provides 24V to the deck lift actuator M4; this signal is DVM measureable for 3 seconds and then becomes a pulsed signal while the deck is down. Pressing the drive pedal forward causes the brush and vacuum contactors K2 and K1 to energize. The 24V brush and vacuum motors M7, M8, M5, (M6) turn on; the pulsed solution solenoid L1 and chemical pump M2 turn on. Combined brush motor current is monitored via the YEL/VIO sense wire. Reversing the drive pedal turns off the solution solenoid and chemical pump, but the deck remains down and the brush motors stay on (for double scrub). Because multiple systems are engaged via one button, a further summary is provided in the section “Understanding Control of Squeegee, Scrub, and Recovery Systems via Modes.”

SCRUB SYSTEM 34Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

Advenger / BR 755, 855 REV -

Scrub Mode The scrub mode operates like the Disc and cylindrical models

Floor Finish Removal Mode

When in the scrub mode, pressing the Floor nish Removal Mode Switch reduces the machine transport speed and modies the deck pressure and solution ow rates. Pressing the Floor Finish Removal Mode switch again will slightly increase the transport speed. Pressing it a

third time will exit the Floor Finish Removal mode and return to the scrub mode.

SCRUB SYSTEM 35Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

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).

SCRUB SYSTEM 36Service Manual – Advenger, 2800ST, 3800ST, 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 modi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 modi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 oor and there is no interference between the deck and the 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+.

Visible

in Fault

Recall Mode

Brush motor K2 contactor coil open

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

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.

SCRUB SYSTEM 37Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

Brush

Motor Type

Disc

Cylindrical

REV

Brush

Contactor Coil

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

Scrub

Pressure

Low

Medium

High

Low

Medium

High

Low

Medium

High

Nominal

Resistance

Nominal Current (A)

+/- 3A

27 32 40

23 30 35

Does not use Target Amps for

Scrub Pressure

Nominal Current Overload Current Wire Colors

Overload Current (A) Wire Colors

Red

Black

Red

Black

Red

Black

Brown

White/Red

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

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.

Lift Actuator Nominal Current (A) Overload Current Wire Colors

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

Troubleshooting Scrub System Issues

It is unlikely that the scrub system will malfunction without generating an error code, so most issues will be found on the preceding tables. A few

more machine-speci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.

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

Badly worn internal components of actuator.

combination.

SCRUB SYSTEM 38Service Manual – Advenger, 2800ST, 3800ST, 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. (Two connectors for REV deck) 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 Nil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). (Disc and Cylindrical Decks)

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

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

FIGURE 17

SCRUB SYSTEM 39Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

Scrub Deck Lift Actuator Drive Nut Adjustment -

Advenger / BR 755, 855 Disc and Cylindrical

FIGURE 18

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 gure below.

7 Manually turn the plastic Spring Housing (F) assembly until the position measure matches the 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 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 19

SCRUB SYSTEM 40Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

Advenger / BR 755, 855 REV

The total travel of the actuator is not adjustable, however, the position of the spring housing must be “timed” to the fully extended motor position as follows:

WARNING!

1 Open the battery compartment and disengage the red Anderson battery connectors. 2 Connect the Scrub Deck Lift Actuator two wire motor connector (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 to the fully extended

position. 6 Manually turn the plastic Spring Housing (F) assembly until the position measure matches the gure below in the extened position.

3 1/4” Extended (No Load)

0” Retracted (No Load)

SCRUB SYSTEM 41Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

Scrub DECK REMOVAL - Disc and REV

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 brush motor wiring harness connectors (A) (under right side of machine) and actuator connector(s). 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

SCRUB SYSTEM 42Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

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 at screw driver (C) against the aluminum gimbal

shoulder underneath the Brush Plate.

FIGURE 21

Scrub Brush Motor Removal - DISC

SCRUB SYSTEM 43Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

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

con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 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 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

over-torquing as damage to Motor Gimbal may

occur.

FIGURE 23

Scrub Brush Deck Motor Removal - REV

1. Remove the Brush Head from the machine. (See Removal and Installation, Brush Head.)

2. Flip the deck disc side up and remove the pads.

3. Remove the pad holder by removing the 6 attaching screws.

SCRUB SYSTEM 44Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

4. Remove the counter weight by removing the two attaching bolts

Counter weight

SCRUB SYSTEM 45Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

5. Lift the driver motor with the eccentric from the brush motor shaft being careful not to lose the squarecut key.

Driver Motor

Key

Eccentric

6. Note the orientation of the brush motor electrical leads relative to the deck to make sure you install the motor in the same position. You may want to mark the orientation of the brush motor to the motor plate. Then separate the brush motor from the motor plate by removing the 4 attaching screws and remove the motor.

7. Reassemble in reverse order noting the following:

8. Use a small amount of Loctite Threadlocker blue 243 or equivalent on all fasteners.

9. Apply Loctite Anti-seize (90101A) to the bore of the eccentric before installing eccentric on brush motor shaft.

Drive Motor, Bearing and Eccentric (REV)

SCRUB SYSTEM 46Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

Removal

1. Remove the brush head and brush motor according to the previous sections.

2. Press the eccentric out of the bearing inner race using an arbor press.

3. Remove the bearing retainer by removing the three fasteners.

4. Press the bearing out of the driver motor using an arbor press.

Eccentric

Bearing

Driver

Motor

Bearing

Retainer

Gasket

Installation

1. Apply Loctite 609 retaining compound to the bearing bore in the driver motor and to the surface of the inner bearing race.

2. Press the bearing into the driver motor.

3. Install the bearing retainer.

4. Press the eccentric into the bearing.

5. Install a new gasket on the driver motor with the adhesive side toward the driver motor.

6. Apply Loctite Anti-seize (90101A) to the bore of the eccentric.

Motor Plate and isolators (REV)

Removal

1. Remove the brush head from the machine.

2. Remove the brush motor.

3. Remove the retainers.

Remove

4. Remove the motor plate by removing the 4 isolator nuts. Inspect the splash shield and replace if damaged..

SCRUB SYSTEM 47Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

Inspect

Splash Shield

Remove

4 isolator

nuts

5. Flip the scrub head upright and remove each of the isolators from the brush head by removing the attaching nuts.

Isolators

Remove

SCRUB SYSTEM 48Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

Installation

1. Apply Loctite blue 243 threadlocker or equivalent to the threads of each isolator.

2. Install the isolators in the brush head. Position each one so that the color stripe it will be visible when the motor plate is installed.

Torque each nut to 8-10 ft. lbs. (10.8- 13.5 N m). Install the 4 plastic covers over the nuts.

Color

Stripe

3. Apply Loctite blue 243 threadlocker or equivalent to the threads of each isolator. Install the motor plate and 4 isolator nuts.

Torque each nut to 8-10 ft. lbs. (10.8- 13.5 N m). Ensure that the isolator rubber does not twist when you tighten the nuts. Visually inspect the color stripe to make sure that it is straight line and not twisted. If it is twisted, loosen the nut and repeat the procedure. It may be necessary to hold the isolator in position with your hand while tighten the nut.

Scrub Motor Carbon Brushes (REV)

1. Remove the brush head from the machine.

2. Remove wire retaining nut and rubber packing.

3. Mark orientation of end plates to motor housing and remove both through bolts.

SCRUB SYSTEM 49Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

4. Remove end plate.

5. Replace the carbon brushes.

a. Observe how the springs roll when the brush is pushed back before taking it apart. b. Remove a brush and spring. c. Install a new brush and spring into the brush holder. Thread the brush wire lead through the brush holder. Position the

back end of the brush in the “cup” of the spring so that the spring will unroll as the brush is pushed back once it is installed.

d. Push brush back against the spring and insert a stiff temporary retaining wire (Paper clip) through the access hole in

the end cover. (Remove silicone sealer from the holes) The wire must go through the holes in the brush holder just in front of the brush to hold the brush back against the spring pressure.

SCRUB SYSTEM 50Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

Cup Side

e. Install the other three brushes.

6. Install the spring washer so that the “ngers” will press against the outside bearing race.

Fingers against

Outer Race

7. Install the end cover in stages.

Paper ClipPaper Clip

SCRUB SYSTEM 51Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

a. Install it far enough so that the brushes will contact the commutator when the temporary retaining wires are removed.

Then remove the wires.

Carbon

Brush

Commutator

b. Fully seat the end cover. c. Install the through bolts. d. Seal the retaining wire holes in the end cover with silicone sealant.

SCRUB SYSTEM 52Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

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

SCRUB SYSTEM 53Service Manual – Advenger, 2800ST, 3800ST, 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

RECOVERY SYSTEM 54Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

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 con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

RECOVERY SYSTEM 55Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

RECOVERY SYSTEM ERROR CODES AND MEASUREMENTS

RECOVERY SYSTEM 56Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

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 modi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 modi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

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, 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 ll until shuts off automatically.

RECOVERY SYSTEM 57Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

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 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.

RECOVERY SYSTEM 58Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

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

RECOVERY SYSTEM 59Service Manual – Advenger, 2800ST, 3800ST, 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

SOLUTION SYSTEM 60Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

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 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.

SOLUTION SYSTEM 61Service Manual – Advenger, 2800ST, 3800ST, 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 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 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 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 speci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 ttings. Check that pump is wired correctly and that the polarity isn’t reversed.

Solution System Diagram

FIGURE 28

SOLUTION SYSTEM 62Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

SOLUTION SYSTEM 63Service Manual – Advenger, 2800ST, 3800ST, 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 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.

SOLUTION SYSTEM 64Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

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 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

WHEEL DRIVE SYSTEM 65Service Manual – Advenger, 2800ST, 3800ST, 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 vacuuming-only modes. The Electromagnetic Brake is engaged whenever the foot pedal is in Neutral, and released for forward or reverse motion.

WHEEL DRIVE CIRCUIT ERROR CODES AND MEASUREMENTS

WHEEL DRIVE SYSTEM 66Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

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 ashes a code

ST - the Fault Indicator LED is blinking 1, 1 and the

Extreme Solution Flow LED 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.

WHEEL DRIVE SYSTEM 67Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

Replacing the Drive Wheel Assembly

WARNING!

Park the machine on a dry 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

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

WHEEL DRIVE SYSTEM 68Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

YELLOW/BLACK

WHITE

RED/WHITE

BLACK

ORANGE

RED/GREEN

WHEEL DRIVE SYSTEM 69Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

Replacing the Drive Tire

Replacing the drive tire (metal wheel with urethane tire) requires the tire pulling kit (56422174). The drive

tire may be replaced without removing the drive assembly from the machine, but you may nd it easier to

remove the drive wheel assembly.

1. To reduce the weight of the machine, drain both the recovery and solution tanks. To lower the center of gravity of the machine, you may even choose to remove the recovery tank from the machine.

2. Block both sides of the machine at the rear lifting points (15) to keep the machine stable and prevent it from rolling. To prevent tipping, it is also a good idea to chain the machine down at the rear lifting points.

3. Raise the front of the machine by jacking at the center front

at surface of the solution tank.

4. Using a 5mm hex key, remove the four screws (38) that secure the drive hub (40) to the internal gearbox.

5. Using a 5mm hex key, remove the six screws (39) that secure the drive hub to the tire (wheel).

6. Insert the four wheel puller bolts (41) through the drive housing, and hand tighten them until they equally touch the metal wheel portion of the tire assembly.

7. Using a 5mm hex key, gradually tighten each bolt at about 1/2 to 1 turn at a time. Work in a crisscross pattern so each bolt pushes the wheel off the main bearing (42) equally. (The wheel hub (40) will come free after just a few turns.)

For reference, the wheel/tire presses over the main bearing (42). The drive hub (40) is lightly pressed onto the tapered disk (43) of the gearbox.

Motor removed

for clarity.

Replacement Notes

WHEEL DRIVE SYSTEM 70Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

1. Install the drive hub (40) to the new wheel/tire using the six socket head cap screws (39).

2. Remove the tire pulling bolts (41) from the drive housing.

3. Lightly install the two alignment pins (44) into two of the threaded holes of the gearbox output disk (43).

4. Slide the drive hub (with the new wheel/ tire) over the alignment pins.

5. Gently tap on the upper portion of the drive hub (40) to get the wheel started over the main bearing (42) until the mounting screws (38) can be started in their threads.

6. Remove the alignment pins (44), and replace them with the two remaining mounting screws (38).

7. In small increments, simultaneously tighten all four mounting screws to pull the drive hub tight to the gearbox output disk (43).

8. Finish reassembling the machine by reversing the disassembly steps.

The Drive Wheel is assembled as shown:

FIGURE 36

WHEEL DRIVE SYSTEM 71Service Manual – Advenger, 2800ST, 3800ST, 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 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 re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 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 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.

WHEEL DRIVE SYSTEM 72Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

Replacing the Rear Wheels

WARNING!

Park the machine on a dry 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

ELECTRICAL SYSTEM 73Service Manual – Advenger, 2800ST, 3800ST, 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

ELECTRICAL SYSTEM 74Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

Control board j1, j2, and j3 pin outs and test points

CAUTION!

Always take measurements at the end connectors for troubleshooting purposes. If readings taken there do not indicate the problem, check the control board as a last resort as damage to the board may occur (see Caution statements in “Replacing Operator Control Panel” section).

Use a DVM and extended insulated probe tips (shown) to take the following measurements.

CAUTION!

Use only insulated test probes designed to backprobe. CONTROL BOARD IS POWERED during these tests.

Perform steps 2 and 3 of “Replacing Operator Control Panel” section, observing noted Caution statements.

J1 - Advenger / BR 755, 855 only - Brush deck lift actuator, squeegee lift actuator, chemical pump

To backprobe J1 for voltages, leave J1 connected to the control board.

Disc and Cylindrical

The followoing tables show the connector in the center, highlighted in gray with related informatin for the pin off to either side.

Referenced to Measure 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

2 7

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+

ELECTRICAL SYSTEM 75Service Manual – Advenger, 2800ST, 3800ST, 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

3 9

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 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

ELECTRICAL SYSTEM 76Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

Rev Measurements

The information in the following tables was taken from measuring a single machine with a REV deck. These values will vary from machine to machine based on battery charge level etcc., however, they will still give you a picture of what normal should look like. Battery Negative used used for the black voltmeter lead and

each pin location was back-probed with the red voltmeter lead unless otherwise specied.

Connector J1

Pin Wire Circuit Measured Comment

1 RED/YEL Detergent Pump 2.05v Key on

2 -

3 BLU/GRY Detergent Pump 2.08v Key on

4 BLU Deck Actuator 1.9v rest

24v Down

0.3v Up

5 ORN/BLK Deck Actuator 2.0v rest

24v Up

0.3v Down

6 -

7 -

8 YEL/BLK B- for Act. Pos.

0.06v Vacuum On

Switches

9 BLK/YEL Squeegee Actuator 2.1v Rest

0.3v down

24.1 Up

10 WHT/GRN Squeegee Actuator 2.1v Rest

0.3v down

24.1 Up

ELECTRICAL SYSTEM 77Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

Connector J2

Pin Wire Circuit Measured Comment

1 BLK Ground 0.06v Vacuum On

2 BLK Ground 0.06v Vacuum On

3 -

4 BLK/WHT Speed Limit 4.45v Transport

Signal Out to Speed Controller

3.4v Scrub

1.1v Strip

5 VIO POT Low 0.38v From Speed Controller. Used for Speed

Limit Signal

6 YEL POT Hi 4.58v From Speed Controller. Used for Speed

Limit Signal

7 BLK Ground 0.05v Vacuum On

8 BLK Ground 0.05v Vacuum On

9 BRN/RED Vac Motor Sense 0.153v Single Vac On. 22.6 A

10 YEL/RED Brush Motor Sense 0.12v Brush motors on. (Do not run long off the

ground)

11 BLK/WHT Act. Pos 2 4.9v Act Up

In Serv. Test Mode, press scrub + once. Let it stop, then press it two more times

0.001 v Sw closed

to drive until the switch closes to see the change.

12 RED/VIO Act. Pos 1 4.9v Act Up

In Serv. Test Mode, press scrub + once. Let it stop, then press it again to drive until

0.001 v Sw closed

the switch closes to see the change.

Connector J3

Pin Wire Circuit Measured Comment

1 BRN/GRN B+ 25.5v Key Off or On

2 BLK Ground 0.05v Vacuum On

3 -

4 BLK/GRY Seat Switch 25.2v Weight on Seat

5 BLU/BLK REV 24.5v N or FWD

1.5v REV

6 RED/WHT FOR/REV (Motion) 25.3v N

0.2v FWD or REV

7 ORN/BLU Status 1.2v No Code

24.5v for a bit, then cycles when there is a code

24.5v - Unstable

8 BRN/GRN B+ 25.1v Key Off or On

9 GRN/BLK Horn - 13.2v Horn Off

0.01v Horn On

10 ORN/RED Horn + 15.0v Horn on or off

11 VIO/BLK Solution Solenoid 25v off

Cycles on low and medium. 0.2v steady on high

0.2v on

12 GRA/BLK Vac Contactor 25v off

ELECTRICAL SYSTEM 78Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

0.19v on

13 WHT/RED Brush Contactor 25v off

Stronger pull in. Limit current for hold in.

0.15v initial on

5v on

14 BLU/ORN Key Switch 25.1v Key on

ELECTRICAL SYSTEM 79Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

Curtis Speed Control Installation Checkout Procedure

After installing a controller and before operating the vehicle, carefully complete the following checkout procedure. If you 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 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.

ELECTRICAL SYSTEM 80Service Manual – Advenger, 2800ST, 3800ST, 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 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 tting on the top of the tank.

FIGURE 41

ELECTRICAL SYSTEM 81Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

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!

The ribbon cable(s) and membrane switch grounding lm are fragile - do not scratch or crease during assembly or they may be damaged.

FIGURE 42

Programming Functions 82Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

F2 F3

F4 F5 F6

Programming Functions

Service Test Mode - ADVENGER / BR 755, 855 (Disc and Cyl.)

The purpose of Service Test Mode is to by-pass the lock-out function of the normal control system of components that are in an error state and allow those components to be manually turned on and off for troubleshooting purposes. (Components in an overload error state will still be locked out for safety reasons.) Advenger / BR 755, 855 - Service Test Mode is accessed via the Hidden Menus. To enter, turn the key switch Off, then press and hold the Scrub and Vacuum switches together. Turn key switch back On and hold the switches for 2 seconds until the Solution and Scrub indicators both turn on. Release both switches - the display will now read “Programming Options.” Scroll through the menus using the Solution + or - switches and enter program 16 for Service Test Mode.

Advenger / BR 755, 855 Desired Action Press

Switch

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.

G 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

Programming Functions 83Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

Changing Control Board Program Settings

Although the Advenger / BR 755, 855 and ST are delivered with a standard factory preset con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 Nilsk-

Advance.

IMPORTANT

For 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 con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 (EcoFlex) OFF and AXP/EDS (EcoFlex) disabled.

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

11. Detergent Mode - . Turn on Mode 1 (machine factory preset for US market) to enable standard Evergreen (EcoFlex) mode in which pressing the Evergreen (EcoFlex) button enables preset ratio for 60 seconds. Turn on Mode 2 (factory preset for the EU market) to run at a

preset ratio. In this mode, pressing the Evergreen (Ecoex) button increments the ratio (solution concentration) to the next stronger level for

60 seconds.

NOTE: To run the machine in a constant user-dened ratio, turn the Detergent Mode to Off and set the chemical ratio by pressing and holding the

AXP/EDS (Chemical) On/Off switch (E).

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

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

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

15. Backup Alarm volume

16. Horn volume

Programming Functions 84Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

Changing Program Settings - Advenger / BR 755, 855 (Disc and Cyl.)

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

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

occurred - display

is “-”

Error codes To erase history, press the Solution switch while

in this mode.

Programming Functions 85Service Manual – Advenger, 2800ST, 3800ST, 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

B D C K

LOW

Solution

INITIAL LED INDICATION

MED

Solution

(2)

HIGH

Solution

RED YEL GRN

● ● ●

● ● ● ●

● ● ●

● ● ● ●

(3)

BLINKS

 

Wet Gel/AGM

28” 34”

S D

50% 60% *

Enabled Disabled

No Yes

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 **

Programming Functions 86Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

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

Programming Functions 87Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

Hidden Menus (REV)

Hidden menus are used to congure the main controller to match the machine that it is installed on (Programming Options) and to perform time-saving diagnostic tests (Service Test Mode). The service test

mode is found as a menu item under programming options.

Enter Hidden Menus

1. Turn the main power switch to the off position.

2. Press and hold the scrub ON/OFF switch and vacuum/wand switch.

3. While holding both switches, turn the main power key switch to the on position.

4. Continue to hold both switches for approximately 2 seconds until the display shows “Program Options”.

a. To scroll through the menu use the solution on/increase switch or solution decrease/off switches

b. To enter a sub menu press the Floor Finish Removal Mode Switch (Rev).

c. To save and return to the main menu press the scrub ON/OFF switch.

Scroll

Enter

Save and

Return

Hold while

turning on key

to enter Hidden

Programming Functions 88Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

Program Options (REV)

Program options must be set whenever the Main Controller has been replaced.

• ScrubDeckType - This function congures the control unit current settings and ow rate settings for each of the scrub deck types. Note: After replacing the controller the machine will not operate until a deck type has been selected.

• ChemicalSelection - Used to let the controller know whether the onboard detergent dispensing system has been installed and which market area the machine is in. The market area determines whether to show the detergent dilution rate as a ratio (US-style) or percentage (EU/Global-style) .

• Vacuummotorquantityselection - The main controller must be programmed for the number of vacuum motors installed so that the current overload protection and recovery tank full will function properly.

• LowVoltageCutoutSelection- The purpose of the special low battery voltage cutout function is to help prolong battery life. The scrub deck will be raised and the brush motors and solution solenoid valve will turn OFF automatically and cease to function when the batteries discharge to the selected cutout level. The cutout level is adjustable between two settings. The standard setting (wet cell/lead acid) is

20.55 volts and alternate setting (gel/maintenance free) is 21.75 volts.

• MaximumScrubSpeed - The control system is programmed to limit the maximum speed while scrubbing to a value less than that allowed for driving when not scrubbing (100%, 90%, 80%, 70%, and 60%).

• LockOutBrushPressure - Used to lock out any brush pressure settings Low, Medium, High, Low and Medium, Low and High, High and Medium. During normal operation, the pressure setting(s) that are locked out will not be able to be selected. Default is “None”

• LockOutSolutionFlowRate - Used to lock out any solution ow rate settings: Low (Normal), Medium (Heavy), High (Extreme), Low and Medium, Low and High, High and Medium. During normal operation, the ow rate(s) that are locked out will not be able to be selected.

• RecoveryTankFullEnable/Disable - Used to enable or disable Recovery Tank Full automatic shutoff feature. Enable means that the automatic shutoff feature is turned on; disable means that the automatic shutoff feature is turned off.

• ChemicalRatioBias - Used to increase or decrease the chemical mix rate by 10% to achieve a more or less concentrated mix than that determined by user programmed ratio

• DeckDownTimePeriodAdjustment - When the scrub on/off switch is pressed, the control unit will automatically lower the deck for a specied amount of time. The time that the deck is lowered is adjustable from 1 second to 5 seconds in 0.1 second increments.

• RestoreFactoryDefault - This submenu should reset all parameters stored in the EEPROM except Brush on Time. Note: after restoring factory defaults, all of the program options must be reviewed and set appropriately. The machine will not work until at least the deck type is selected.

• DisplayRevisionLevel - The LCD display will show the revision level of the software in the control board.

• FaultRecall - Whenever the control unit detects an electrical system fault, one or more error codes are displayed and stored in the EEPROM. If it is desired, the error code (if any) from the previous operation for the machine can be recalled for troubleshooting purposes. If no fault code is present, the display will show a “-“

• FaultDetection - Normally, the main control unit will perform checks of the electrical system during operation. If a fault occurs in a particular system, that system (and possibly others) will be shut down. This can make troubleshooting the system difcult. This option will allow service personnel to disable some of the fault detection checks to facilitate troubleshooting. This will not disable the over-current protection on any of the systems.

Programming Functions 89Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

• ServiceTestMode - The purpose of the service test mode program is to assist the service repairperson with numerous quick short-cut troubleshooting procedures. These test instructions allow for the separate control of each individual electrical system component independent of the normal operator inputs. Exit by pressing the scrub on/off switch six times.

• BackupAlarmVol - Used to adjust the volume of the back up alarm or turn it off.

• FORWARDALARMVOLUME - Used to adjust the volume of the forward annunciation alarm or turn it

off.

• HornVolume - Used to adjust the horn volume or turn it off.

• Savelastscrubsetting - provides two choices of what happens when the key is turned off; 1)

Remember last scrub settings. Solution ow, scrub pressure or 2) Factory default scrub settings (chemical remembered, low water, low pressure)

• BurstOfPower - This selection screen only applies when the machine does not have the chemical option installed. In that case, the Burst of Power button on the control panel can be set to perform in one of two ways: when disabled it is a non-functioning button, and when enabled it will attempt to make a temporary increase in the solution ow rate, brush pressure, and vacuum level when pressed. When the chemical option is installed, the Burst of Power button is always functional regardless of the value selected in this menu. When pressed, the Burst of Power button will attempt to make a temporary increase in the solution ow rate, brush pressure, vacuum level and chemical ow rate.

• PanelTest - This is a special mode that allows you to test each control panel switch. The display will indicate which switch was last pressed and then provide a count for each subsequent press.Exit by pressing the scrub on/off switch six times.

Programming Functions 90Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

Service Test Mode - ADVENGER / BR 755, 855 (REV)

The service test mode provides time-saving diagnostic tests. You can request that the main controller turn various outputs on and off without the normally required prerequisite inputs in order to quickly prove whether the output is working or not. The service test mode can also be used to verify some input signals.

The Service Test Mode is accessed via the Hidden Menus. Enter the program options and then scroll to the Service Test Mode.

Output Tests

Once in service test mode use the control panel switches to request that various outputs are turned on/off. The LCD provides feedback to let you know that the controller saw your request and is attempting to carry it out.

Controls Solution Solenoid

Controls

Detergent

Pump

Controls

Scrub Deck

Actuator

Controls

Scrub Motor

Contactor

Controls

Squeegee Lift

Actuator

Controls

Vacuum

Contactor

Service Test Mode Switch Operation

Programming Functions 91Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

Input Tests

Once in service test mode the LCD displays output test fedback. It also displays current speed control direction, battery voltage to the main controller and any current error codes.

Current

Error Codes

Battery Voltage

Current

Speed

Control

Direction

Output Test

Feedback

MAINTENANCE SCHEDULES 92Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

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 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 (If equipped) ●

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

●

MAINTENANCE SCHEDULES 93Service Manual – Advenger, 2800ST, 3800ST, 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 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 ef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

MAINTENANCE SCHEDULES 94Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

PM Checklist

Advance Advenger 2805, 2905, 3405

Advance 2800ST, 3400ST

Nil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

1 Steering A B

Defect Codes

(circle)

Does

Not Work

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

3 Seat Switch D

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

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

MAINTENANCE SCHEDULES 95Service Manual – Advenger, 2800ST, 3800ST, BR 755, BR 855

Ref VISUAL INSPECTION ITEMS Comments OK or

N/A

Defect

Codes

(circle)

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

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 W

35 Battery Condition (clean & water) Load Test C W

36 Front Drive Wheel Motor Carbon Brushes Wear Limit 1/4” C W

37 Drive Pedal Linkage Neutral Return A C

38 Steering Chain Lube & Tension 1/4” De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- 75

COMPONENT LOCATION (Advenger / BR 755, 855)

___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

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

Expanded Electrical System

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

WIRING DIAGRAM / SCHEMATIC (Advenger / BR 755, 855 Disc and Cylindrical Decks)

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

Wiring Diagram (REV Deck) - 56601806 Revision A Sheet 1 of 2

REVISIONS

REV ECO DATE DFTM APP D

RELEASE

DWG. NO. SHEET

AGREES TO RETURN IT UPON REQUEST.

PLYMOUTH, MINNESOTA AND IT HAS BEEN ISSUED WITH THE UNDERSTANDING THAT IT WILL NOT BE REPRO- DUCED NOR COPIED NOR USED FOR ANY PURPOSE OTHER THAN FOR WHICH IT WAS ISSUED AND RECIPIENT

THIS DRAWING AND THE DESIGN REPRESENTED HEREON IS THE PROPERTY OF NILFISK-ADVANCE, INC.,

CONFIDENTIAL

AS NOTED.

UNITS IN [ ] ARE ISO METRIC

DIM. IN [ ] ARE MM.

NOTES UNLESS OTHERWISE

SPECIFIED

1. ALL DIMENSIONS IN INCHES.

2. DO NOT SCALE DRAWING.

3. ALL DIMENSIONS APPLY AFTER PLATING AND HEAT TREATING, BUT BEFORE PAINTING.

4. REMOVE ALL BURRS AND SHARP EDGES.

APPROVED

CHECKED

SIZE REV.DWG. NO.

TITLE

PLYMOUTH, MINNESOTA 55447-3408

DRAWN

PROJ ENG

NILFISK-ADVANCE, INC.

E3 MAIN MACHINE CONTROLLER

PIN 6 - BRAKE -

PIN 9 - STATUS

PIN 16 - REV. ALARM

PIN 8 - MODE

PIN 18 - SPEED LIMIT

PIN 13 - POT. LOW

PIN 4 - POT. WIPER

PIN 3 - HIGH

PIN 14 - BRAKE +

PIN 5 - KSI

B+

B-

M-

M+

E1 WHEEL DRIVE CONTROLLER

J3-1 B+ J3-8 B+ J3-14 KEY SWITCH

J3-12 VACUUM CONTACTOR

J3-13 BRUSH CONTACTOR

J3-11 SOLUTION SOLENOID

SEAT SWITCH J3-4

MOTION J3-6

STATUS J3-7

REV. ALARM J3-5

SPEED LIMIT J2-4

POT. HIGH J2-6

POT. LOW J2-5

OPTIONAL

DIAGRAM-LADDER

56601806

1 OF 2

2. DISCONNECT RED WIRE ON CB2 AND REPLACE WITH GREEN WIRE FROM CHARGER WHEN CHARGER IS USED.

PMO WGL

1. REFERENCE WIRING DIAGRAM 56601807

PMO8-8-12

8-8-12 CK

9-27-12A-08516

3. WHEN VIEWING FROM THE TOP RIGHT BOOST MOTOR TURNS COUNTER CLOCKWISE, LEFT BOOST MOTOR TURNS COLCKWISE

NOTES:

BLK

WHT/BRN

REDRED

RED

BRN/GRN

GRY/BLK

VIO/BLK

WHT/BRN

GRY

VIO

YEL

BLK/WHT

RED/GRN

BLK

BLU/BLK

ORN/BLU

RED/WHT

ORN

BRN/GRN

VIO

YEL/BLK

BRN/BLK

RED

BLK/GRA

BLU/ORN BLU/ORN

BLK/GRABRN/GRN WHT/BRN BLK/GRA

BLU/ORN

WHT/RED

BLK

RED

BLU/ORN

BLK/ORN

B+

B-

SW2

KEY SWITCH

1 2

CB2

CIRCUIT BREAKER, 10 AMP

SW4

DRIVE PEDAL SENSOR

CBA

CB1

CIRCUIT BREAKER, 70A.

CONTACTOR BRUSH

LP1

FLASHING WARNING BEACON

1 2

FUSE, 150A.

1 2

SW3

EMERGENCY SWITCH

1 2

BT1

BATTERY PACK, 24 Vdc

+ -

CONTACTOR VACUUM

MOTOR, WHEEL DRIVE

Y1 ELECTRIC BRAKE

1 2

SOLUTION SOLENOID VALVE

1 2

SW1

SEAT SWITCH

B+ B-

GND

CHARGER DELTA Q

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

REVISIONS

REV ECO DATE DFTM APPD

SEE SHEET ONE

DWG. NO. SHEET

AGREES TO RETURN IT UPON REQUEST.

PLYMOUTH, MINNESOTA AND IT HAS BEEN ISSUED WITH THE UNDERSTANDING THAT IT WILL NOT BE REPRO- DUCED NOR COPIED NOR USED FOR ANY PURPOSE OTHER THAN FOR WHICH IT WAS ISSUED AND RECIPIENT

THIS DRAWING AND THE DESIGN REPRESENTED HEREON IS THE PROPERTY OF NILFISK-ADVANCE, INC.,

CONFIDENTIAL

E3 MAIN MACHINE CONTROLLER

SQUEEGEE ACT(-) J1-9

SQUEEGEE ACT(+) J1-10

DECK ACT (+) J1-4

DECK ACT (-) J1-5

BOOST MOTOR SENSE J2-10

VACUUM MOTOR SENSE J2-9

2 OF 2

56601806

J3-10 HORN +

J3-9 HORN -

J1-1 + DETERGENT PUMP

J1-3 - DETERGENT PUMP

OPTIONAL

B- J2-8 B- J2-7 B- J2-1 B- J2-2 B- J3-2

B- J1-8

POSITION_1_ J2-12

POSITION_2_ J2-11

OPTIONAL

WHT

RED

BLK

WHT/GRN

BLK/YEL

BLU

ORN/BLK

YEL/VIO

BLK

BRN/RED

RED

BLK

RED

RED BLK

BLK

ORN/RED

GRN/BLK

RED/YEL

BLU/GRY

BLK BLK

BLK

BLK/WHT

RED/VIO

YEL/BLK

BLK BLK

B+

B-

MOTOR, VAC

1 2

RIGHT MOTOR BOOST

HORN

- +

CONTACTOR, VACUUM

1 2

CONTACTOR, BRUSH

1 2

LEFT MOTOR BOOST

MOTOR,SQUEEGEE LIFT ACTUACTOR

M10

DETERGENT PUMP

MOTOR, VAC

1 2

MOTOR,DECK LIFT ACTUACTOR

Wiring Diagram (REV Deck) - 56601806 Revision A Sheet 2 of 2

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

Specifications and Main Features

Frequently Asked Questions

User Manual