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Nilfisk-Advance Adgressor BR 1050CS, Service Manual

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Nilfisk-Advance Adgressor BR 1050CS Service Manual Download Page 2

2 - FORM NO. 56043097 / Adgressor

™

 / BR 850S, 850CS, 950S, 950CS, 1050S, 1050CS

TABLE OF CONTENTS

GENERAL INFORMATION ...................................................................................................................................................2
SAFETY INSTRUCTIONS ....................................................................................................................................................3
SPECIFICATIONS & MAINTENANCE ...............................................................................................................................4-6
PM CHECKLIST ................................................................................................................................................................7-8
KNOW YOUR MACHINE .................................................................................................................................................9-15
STEERING SYSTEM .....................................................................................................................................................16-17
  STEERING COLUMN ASSEMBLY SHROUD REMOVAL ................................................................................................16
  STEERING CHAIN REMOVAL AND TENSIONING .........................................................................................................17
WHEEL DRIVE SYSTEM ...............................................................................................................................................18-27
  GENERAL FUNCTIONAL OVERVIEW .............................................................................................................................18
  DRIVE MOTOR SYSTEM CONTROLLER FUNCTION OVERVIEW ...............................................................................18
  WHEEL DRIVE TROUBLESHOOTING GUIDE ................................................................................................................21
  STEERING SPINDLE & WHEEL DRIVE MOTOR ASSEMBLY REMOVAL ......................................................................22
  DRIVE TIRE REMOVAL ....................................................................................................................................................22
  BRAKE ADJUSTMENT .....................................................................................................................................................24
  DRIVE WHEEL BRAKE STRAP REPLACEMENT ...........................................................................................................25
  WHEEL DRIVE MOTOR CARBON BRUSH INSPECTION ..............................................................................................25
  POTENTIOMETER REMOVAL & TESTING .....................................................................................................................26
  POTENTIOMETER INSTALLATION & ADJUSTMENT .....................................................................................................27
  DRIVE PEDAL NEUTRAL ADJUSTMENT ........................................................................................................................27
SCRUB BRUSH SYSTEM .............................................................................................................................................28-35
  FUNCTIONAL OVERVIEW ...............................................................................................................................................28
  SCRUB BRUSH SYSTEM TROUBLESHOOTING ...........................................................................................................29
  SCRUB BRUSH DECK REMOVAL (DISC & CYLINDRICAL) ..........................................................................................30
  SCRUB BRUSH MOTOR ASSEMBLY REMOVAL (DISC) ...............................................................................................31
  SCRUB BRUSH GEARBOX REMOVAL AND OUTPUT SHAFT REPLACEMENT (DISC) ..............................................31
  SCRUB BRUSH SIDE SKIRT REPLACEMENT (DISC) ...................................................................................................32
  SIDE SKIRT HEIGHT ADJUSTMENT (DISC) ...................................................................................................................32
  SCRUB BRUSH FRONT/REAR SKIRT REPLACEMENT (DISC) ....................................................................................32
  BRUSH DECK ACTUATOR REMOVAL (DISC & CYLINDRICAL) ....................................................................................33
  SCRUB BRUSH MOTOR REMOVAL (CYLINDRICAL) ....................................................................................................34
  SCRUB BRUSH BELT REPLACEMENT (CYLINDRICAL) ...............................................................................................34
  SCRUB BRUSH SYSTEM MAINTENANCE .....................................................................................................................34
  SCRUB BRUSH REMOVAL AND INSTALLATION (CYLINDRICAL) ................................................................................35
  SIDE SKIRT MAINTENANCE & ADJUSTMENT (CYLINDRICAL) ...................................................................................35
  CORRECT SCRUB MOTOR WIRING CONNECTIONS ..................................................................................................36
  CORRECT BRUSH ROTATION DIRECTIONS ................................................................................................................37
SOLUTION SYSTEM .....................................................................................................................................................38-41
  FUNCTIONAL OVERVIEW ...............................................................................................................................................38
  SOLUTION SOLENOID CIRCUIT OVERVIEW ................................................................................................................39
  TROUBLESHOOTING GUIDE .........................................................................................................................................40
  SOLUTION SYSTEM MAINTENANCE .............................................................................................................................40
  SOLUTION SOLENOID REMOVAL ..................................................................................................................................40
  SOLENOID VALVE DISASSEMBLY AND CLEANING .....................................................................................................41
RECOVERY SYSTEM ...................................................................................................................................................42-45
  FUNCTIONAL OVERVIEW ...............................................................................................................................................42
  VACUUM MOTOR CIRCUIT OVERVIEW ........................................................................................................................43
  TROUBLESHOOTING GUIDE .........................................................................................................................................44
  VACUUM / RECOVERY SYSTEM SERVICE MAINTENANCE CHECKLIST ...................................................................44
  MAINTENANCE OF VACUUM FILTER AND FLOAT CAGE .............................................................................................44
  RECOVERY TANK REMOVAL .........................................................................................................................................45
  VACUUM MOTOR REMOVAL ..........................................................................................................................................45
SQUEEGEE SYSTEM ...................................................................................................................................................46-48
  SQUEEGEE SYSTEM LIFT MOTOR OVERVIEW ...........................................................................................................46
  TROUBLESHOOTING ......................................................................................................................................................46
  SQUEEGEE LIFT ACTUATOR MOTOR REMOVAL .........................................................................................................47
  SQUEEGEE LIFT CABLE REPLACEMENT .....................................................................................................................47
  SQUEEGEE MAINTENANCE ...........................................................................................................................................48
  SQUEEGEE ADJUSTMENT .............................................................................................................................................48

revised 10/06

Summary of Contents for Adgressor BR 1050CS

Page 1: ...850CS 950S 950CS BR 1050S 1050CS Advance MODELS 56314661 2820D 56314662 3220D 56314663 2820C 56314664 3220C 56314826 3520D 56314827 3820D 56314828 3520C 56314829 3820C Nilfisk MODELS 56314674 850S 56314675 850CS 56314830 950S 56314831 1050S 56314832 950CS 56314833 1050CS ...

Page 2: ...NT DISC 31 SCRUB BRUSH SIDE SKIRT REPLACEMENT DISC 32 SIDE SKIRT HEIGHT ADJUSTMENT DISC 32 SCRUB BRUSH FRONT REAR SKIRT REPLACEMENT DISC 32 BRUSH DECK ACTUATOR REMOVAL DISC CYLINDRICAL 33 SCRUB BRUSH MOTOR REMOVAL CYLINDRICAL 34 SCRUB BRUSH BELT REPLACEMENT CYLINDRICAL 34 SCRUB BRUSH SYSTEM MAINTENANCE 34 SCRUB BRUSH REMOVAL AND INSTALLATION CYLINDRICAL 35 SIDE SKIRT MAINTENANCE ADJUSTMENT CYLINDR...

Page 3: ...L OVERVIEW 58 MAIN CONTROL BOARD TROUBLESHOOTING GUIDE 58 MAIN CONTROLLER ERROR CODES 58 59 MAIN CONTROLLER SERVICE TEST MODE 60 63 MAIN CONTROL BOARD SPECIAL PROGRAM OPTIONS 64 71 ELECTRICAL COMPONENT LOCATION before Serial Number chart 73 WIRING DIAGRAM before Serial Number chart 74 WIRING SCHEMATIC before Serial Number chart 75 WIRING DIAGRAM after Serial Number chart 76 WIRING SCHEMATIC after ...

Page 4: ...e machine Use the space below to note the Model Number and Serial Number of your machine for future reference MODEL NUMBER SERIAL NUMBER TRANSPORTING THE MACHINE CAUTION Before transporting the machine on an open truck or trailer make sure that The machine is tied down securely see tie down locations 25 All access doors and covers are secured tape and strap as necessary The machine parking brake i...

Page 5: ...ng electrical components Never work under a machine without safety blocks or stands to support the machine Do not dispense flammable cleaning agents operate the machine on or near these agents or operate in areas where flammable liquids exist Do not clean this machine with a pressure washer CAUTION This machine is not approved for use on public paths or roads This machine is not suitable for picki...

Page 6: ... 3 15 mph 5 1 kphm Grade Ability Transport 20 11 5 deg Grade Ability Working Scrubbing 8 4 6 deg Wheel Drive Motor 1 5 hp 1100 watt Vacuum Motor 3 stage 75 hp 560 watt Vacuum Water Lift for one motor Sealed 68 in Open Hole Adapter 1 18 in Vacuum Water Lift for two motors Sealed 78 in Open Hole Adapter 1 25 in Power Source Batteries 6 6 volt 20 hour rate Battery Weight 305 amp STD 90 lbs 198kg Batt...

Page 7: ...250 RPM 250 RPM 250 RPM 250 RPM Cylindrical 900 RPM 900 RPM 900 RPM 900 RPM Minimum Aisle Turn Width 63 in 160cm 63 in 160cm 63 in 160cm 63 in 160cm Machine Net Weight English 657 lbs 657 lbs 657 lbs 657 lbs Metric 298 kg 298kg 298 kg 298 kg Machine Gross Weight English 1553 lbs 1553lbs 1553 lbs 1553 lbs Metric 705 kg 705kg 705 kg 705 kg Cleaning Width scrubbing path English 28 in 32 in 35 in 38in...

Page 8: ...ncy as a new brush WARNING Turn the key switch off set the parking brake and disconnect the battery before servicing the machine LUBRICATING THE MACHINE Once a month pump a small amount of grease into each grease fitting on the machine until grease seeps out around the bearings Grease fitting locations are Squeegee Wheel Axle qty 2 Steering Wheel Shaft Universal joint Once a month apply light mach...

Page 9: ...ution Control On Off and flow volume Min Max A B L 11 Emergency Battery Disconnect Control Lever B D 12 Right Side broom Sweep System Accessory cylindrical only A B D 13 Tilt Steering Mechanism and Seat A B D 14 Optional Accessories headlight safety beacon etc D 15 Main Control Board Special Program Options check all applicable program settings reference SVR Manual 56043097 Example Fault Recall Mo...

Page 10: ...er torque Tread Wear W 38 Brake Band Lining Wear Adjust Free Play A B W 39 Drive Pedal Linkage neutral return Torsion Spring A B 40 Steering Chain lubricate tension 1 4 Deflection A B C 41 Steering Column knob plunger spring also Universal Joint Grease A D 42 Rear Wheels W 43 Sweep Debris Tray cylindrical only C NOTE For additional service information see service manual form number 56043097 and op...

Page 11: ...Circuit Breaker 12 Control Circuit Circuit Breaker 13 Emergency Stop Switch Battery Disconnect Lever 14 Scrub Deck 15 Rear Wheel 16 Battery Compartment under seat 17 Recovery Tank Shutoff Float KNOW YOUR MACHINE 18 Vacuum Motor Filter Housing 19 Squeegee Assembly 20 Solution Filter 21 Recovery Tank Drain Hose 22 Machine Battery Connector 23 Control Panel 24 Squeegee Tilt Adjust Knob 25 Operator Se...

Page 12: ...Scrub Pressure Increase Indicator F Scrub Pressure Increase Switch G Scrub Pressure Hourmeter Display H Wand Switch Indicator I Wand Switch J Key Switch K Battery Condition Indicator L Speed Select Switch M Speed Select Indicator N Horn Switch O Vacuum Switch P Vacuum System Indicator Q Solution System Indicator R Solution Switch CONTROL PANEL A B C D E F G H I J K L M N O P Q R ...

Page 13: ...cator will flash red Scrub Pressure Decrease Switch D If the scrub system is off pressing this switch will cause the following to occur The scrub system will be enabled with the scrub pressure set to the last used setting and the scrub deck will be lowered The vacuum system will be enabled and the squeegee will be lowered The solution system will be enabled The travel speed will be limited to the ...

Page 14: ...ed to the scrub speed setting As soon as the throttle is moved from the neutral position the scrub brushes will start turning and the vacuum will turn on If the direction is forward the solution flow will start If the direction is reverse the squeegee will raise and the solution flow will be stopped The heavy scrub pressure indicator will be green if the scrub system is on and the heavy pressure h...

Page 15: ...he scrub brushes and raising the scrub deck turning the solution flow off to the scrub deck and raising the squeegee NOTE automatic shutoff of the vacuum motor when the recovery tank is full is disabled when the wand is enabled The float in the recovery tank will still prevent water from entering the vacuum motor but the motor will not shut off Key Switch J Main power switch Speed Select Switch L ...

Page 16: ...m is enabled but the drive pedal is at neutral and the current scrub pressure is at 8 or less This indicator will be green if the scrub system has been turned on the current scrub pressure is at 8 or less and the machine is moving in either direction This indicator will be off if the scrub system has been turned OFF or the scrub pressure is set at 9 Scrub Pressure Hourmeter Display G The single ch...

Page 17: ...as been reached flashing red indicator the batteries must be FULLY recharged to reset the battery condition indicator The scrub system will not function until the indicator has been reset DESCRIPTION OF HOURMETER STATUS DISPLAY The single character display in the upper right corner of the control panel is primarily used as a display for the hourmeter function This display is also used to display t...

Page 18: ...ic Trim Cup F can now be removed 4 Remove the 4 Screws G securing the Column Shroud H and pull it off from the Column Base I Lower Column 1 Tilt the steering wheel column as far back close to the seat as possible 2 Remove the tilt column release Knob J threaded from its shaft 3 Remove the 4 Screws K securing the Lower Shroud L and next pull the shroud far enough away from the column base to clear ...

Page 19: ...back left screw 3 Remove both Master Links Q that secure the chain to the Steer Plate P then remove the chain from the chassis 4 Reassemble parts in reverse order and adjust chain tension so that there is about 3 16 1 4 4 7 6 4mm total deflection with moderate pressure applied at the Mid point R as shown Service Tip Note Use a pry bar or shims between the chassis and steer column to help secure th...

Page 20: ...ges switches the battery voltage On and Off PWM that varies the motor speed KSI Key Switch Input PWM Pulse Width Modulation also called chopping is a technique that switches battery voltage to the motor ON and OFF very quickly thereby controlling the speed of the motor DRIVE MODE SELECTION OPERATION OVERVIEW The A1 speed Controller allows operation in two distinct modes mode 1 M1 mode 2 M2 Mode 1 ...

Page 21: ...SW POT LO POT HIGH FORWARD FOR REV PIN 3 POT LO PIN 1 POT HI PIN 2 POT WIPER PIN 16 PROG2 DRIVER PIN 8 MAIN B A2 M PIN 11 MULTIMODE ACC SOLUTION VACUUM BRUSH B 1 B 2 B 3 B 4 A1 SPEED CONTROLLER INTERFACE THERMISTOR I VAC I BRUSH E1 CONTROL BOARD HORN HORN SPEED MODE CONTROL J4 8 J2 5 J3 5 J3 6 J4 12 J4 6 J4 2 J2 1 J2 2 J2 3 J2 8 J4 7 J4 1 J2 7 J2 6 J2 10 J3 1 J3 4 J3 3 J3 2 J4 11 J4 10 J4 4 J4 9 J...

Page 22: ...10 9 R1 Voltage Values 0 2 5V Reverse 2 5 5V Forward FIGURE 4 This drawing shows additional controller input circuit detail The R1 pot is shown in the neutral position Resistance is measured between pot low and pot wiper FIGURE 3 R1 5K Ohms E1 Main Control Board Partial WHT YEL YEL VIO View Non stem end Speed Limit Pot LO Pot HI J2 9 J4 9 J4 3 YEL YEL GRA HI LO WIPER A1 Speed Control Pin Connectio...

Page 23: ...s placed in Rev Pin 16 s voltage signal to E1 is lost 0 volts This lost open circuit signal is what tells the E1 controller to turn on the back up alarm H1 turn off the solution solenoid valve L1 and raise the squeegee tool changes polarity to the Lift motor M2 WHEEL DRIVE TROUBLESHOOTING GUIDE Problem Possible Cause Wheel drive motor will not run in forward and reverse Batteries need charging low...

Page 24: ...g under both front frame legs to support machine when removing the wheel spindle assembly Service Note Be careful not to damage the threads and bearing surfaces when guiding the spindle shaft down through the frame opening 7 Inspect bearings and shaft seal and replace as needed 8 To remove the steer spindle weldment K you must remove the steer plate J with splash fender held by 4 L flat head socke...

Page 25: ...FORM NO 56043097 Adgressor BR 850S 850CS 950S 950CS 1050S 1050CS 23 WHEEL DRIVE SYSTEM FIGURE 5 A FRONT D F G E L J K I H N O Q P M R ...

Page 26: ...and threading the adjustment screw T In or Out 3 To access the brake rod remove the front pedal mounting hardware items B C then swing pivot the pedal backwards out of the way 4 Use a 3 8 wrench and 1 8 hex key wrench to both loosen and tighten the rods adjustable hardware 5 Note Also check the brake bands brake lining for wear when excessive pedal travel can not be eliminated through adjustments ...

Page 27: ...fully expand the brake band enough to clear the drive wheel brake drum and remove from the machine 4 To install the brake band follow the above steps in reverse order See the Brake Adjustment section in this manual and adjust the brake pedal free play and test the brake system for proper operation CAUTION Test drive the machine and check for positive brake pedal and parking brake functions WHEEL D...

Page 28: ...e the link rod mounting hardware items AG 4 Loosen the Nut AH and Screw AI at the drive pedal Throttle Lever AJ Then pry the lever off from the end of the item AC potentiometer shaft Next remove the pot from the Mount Housing AK Testing the Potentiometer Note The pot doesn t have to be removed from the housing to test 1 Test the potentiometer using an Ohmmeter the pot specification is 5K Ohms 2 Co...

Page 29: ...lish this WARNING Disconnect the machine s battery pack connector 13 before servicing Note See Figures 8 9 Before making any adjustments inspect the Torsion Spring AL for defects and the correct positions of both spring ends repair or replace To Adjust Pedal Spring 1 Loosen the Screw AM Nut AN the screw with bushing is positioned between both Fwd Rev torsion spring ends Its placement controls the ...

Page 30: ...the needed R1 throttle output to the A1 speed controller which causes either FWD or REV motor action At the moment of R1 throttle input the A1 controller closes an internal coil driver and outputs a NEG 36V signal from pin 7 wire color Red Blk to the E1 J4 10 connection This input signal causes the controller to output a NEG 36V signal from J2 pin 1 wire Wht Red that energizes the K1 brush motor s...

Page 31: ...4 J4 9 J4 3 PIN 15 KSI STATUS J4 5 J2 9 PIN 4 SPEED LIMIT S P E E D L I M I T MOTOR BRUSH Amps 33 1 2 B BLU ORN BLU ORN YEL GRN MAIN CONTACTOR K3 PIN 7 PROG 1 DRIVER PIN 14 POWER ENABLE K3 BLK BLK BLU M M 1 0 MOTOR BRUSH RED NOTE M8 IS USED ON CYLINDERICAL AND 35 38 DISK DECKS ONLY M7 IS USED ON ALL MODELS 35 38 DISK DECK POLARITY OF M8 M 8 M BLU BLK MOTOR BRUSH NOTE M10 IS USED ON CYLINDERICAL AN...

Page 32: ...3 See Figure 2 Separate the solution system water line quick disconnect fittings located on top of the scrub deck Grip the bottom movable Sleeve A on the quick disconnect fitting assembly and pull on the top Fitting B to separate the hoses 4 Unplug the brush motor wiring harness C under left side of machine 5 Remove the lower Hitch Pin D that secures the brush deck lift actuator to the scrub deck ...

Page 33: ...e the 8 Q Screws use a 5mm hex wrench that hold in place the Dust Covers R Next remove the shaft retainer hardware items S T Then tap out the Output Shaft U using a brass shaft to help prevent any possible damage 7 Re assemble in reverse order and test for proper operation Note The proper motor installation position is where the two motor wires face the front and left side on the scrub deck platfo...

Page 34: ... Tip The skirts Retainer Knobs V can be loosened with skirts left on and the Adjuster Collars X rotated by reaching under the skirt housing 3 Turn theAdjuster Collars X Up or Down to where the blades just fold over enough when scrubbing that all the waste water is contained inside the skirting Note Make small adjustments to obtain good blade wiping Do not lower the blades too much to where they fo...

Page 35: ...ons see the electrical section for the Actuator Drive Nut Adjustment instructions 8 To disassemble the Drive Nut AE from the actuator shaft remove the 2 Screws AF and separate both Retainers AG AH from the Spring Housing AI 9 Remove the 4 spring housing retainer Screws AJ and slide the spring housing and long Compression Spring AK from the actuator shaft Next spin the drive nut off the shaft and s...

Page 36: ...disconnect lever 13 before servicing 1 See Figure 6 Remove Hairpin AM and swing open the scrub deck skirt assembly right or left side and remove the belt guard s AN 4 screws each 2 Important Service Tip The left and right side drive belts are not the same lengths they must be ordered individually P N 56407465 left side P N 56407466 right side 3 Loosen the scrub brush belt tension hardware on the B...

Page 37: ...l use the blades will wear in time The operator will notice a small amount of water leaking out underneath the side skirts The skirt height adjustment is automatic on this system using spring tension and movable linkage arms to control the blade pressure The side skirt assemblies must move up and down freely for proper operation To replace the scrub system side skirts See Figure 6 Remove the 2 Hai...

Page 38: ...36 FORM NO 56043097 Adgressor BR 850S 850CS 950S 950CS 1050S 1050CS SCRUB BRUSH SYSTEM CORRECT SCRUB MOTOR WIRING CONNECTIONS FIGURE 10 revised 10 06 ...

Page 39: ...FORM NO 56043097 Adgressor BR 850S 850CS 950S 950CS 1050S 1050CS 37 SCRUB BRUSH SYSTEM CORRECT BRUSH ROTATION DIRECTIONS FIGURE 11 revised 10 06 ...

Page 40: ...n the operator s steering column support is the solution lever tee handle The lever and connected cable move the flow control valve arm that regulates solution flow to meet a specific operator s scrub application See Figure 2 The electrical circuit that turns on energizes the solenoid coil L1 is activated through the E1 control panels switch buttons touch pad Note See the Know Your Machine section...

Page 41: ...rol board E1 terminal J4 pin 8 BLK wire This supports the operation of the boards processing logic functions Battery ground supply input for all the control boards negative output coil circuits Its E1 terminal connection is J2 pin 5 wire Blk Outputs A battery ground output from the E1 control board terminal connector J2 pin 3 wire Vio Blk This controlled output turns on and off the L1 solenoid coi...

Page 42: ...iddle front of the solution tank see molded FILTERØ callout No tools are needed to remove the filter hand tighten only Service Tip The manual solution control lever must be placed in the full OFF position This prevents loss of solution when servicing the filter strainer with a partial or full tank Solution Delivery Trough Note on the cylindrical scrub deck clean the holes in the delivery trough to...

Page 43: ...uctions 2 See Figure 3 Remove the 4 I Screws and disassemble the valve be careful not to lose any internal parts 3 Thoroughly wash dirt from block J and diaphragm K 4 After reassembling test the solenoid valve for proper operation DISC MACHINE SOLUTION PLUMBING DETAIL Top of Hose L uses a 109 diameter hole in the center This prevents unbalanced solution flow FIGURE 3 FIGURE 4 FRONT E H G Assembly ...

Page 44: ...ry tank There the air slows down because of the increased volume large size of tank With the decreased air speed the heavier water falls to the bottom of the recovery tank Then at the same time the airflow continues through the tank shutoff float vacuum motor and is exhausted out of the vacuum exhaust hose No wastewater ever actually moves through the vacuum motor just working air The vacuum syste...

Page 45: ...nput for the control board E1 terminal J4 pin 8 wire Blk This supports the operation of the board s processing logic functions with the above mentioned S1 key switch input A battery ground input for all the E1 boards negative solenoid coil output circuits Its E1 terminal connection is J2 pin 5 wire Blk Outputs A battery ground output from the E1 control board terminal connector J2 pin 2 wire Gra B...

Page 46: ...l for specific fault descriptions and service repair actions VACUUM RECOVERY SYSTEM SERVICE MAINTENANCE CHECKLIST Whenever there is a vacuum problem it s best to check over the entire system Use the checklist below as a guide to thoroughly check the vacuum system Clean built up dirt from the inside of the squeegee tool Replace the squeegee blades if they are nicked or torn Inspect the hose between...

Page 47: ...rushing of the squeegee hose Don t pull the tank immediately away from the machine the vacuum motor wiring harness located on the lower left front corner must be disconnected to complete the separation VACUUM MOTOR S REMOVAL 1 See Figure 3 Remove the vacuum duct Cover C that is secured to the recovery tank by a qty of 6 Screws B 2 Separate the wiring harness from each motor and lift motor s out fr...

Page 48: ...lf of the normal distance observed when in the machine scrub off mode Moving the drive pedal back to the neutral forward position closes the A1 throttle forward output and the E1 control board gains its signal The J3 connector output reverses the polarity and lowers the tool back onto the floor Programming Note The Squeegee raise in reverse time period is adjustable See the instruction in the Elec...

Page 49: ...e 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 6 Locate the wire tie that attaches the motor wiring to the chassis and then disconnect the motor harness 7 From underneath the machine remove the Hairpin C securing the lift motor Pin D and disassemble the motor from th...

Page 50: ... I on top of the squeegee and remove the squeegee tool from the mount 2 Remove both rear Tension Straps first 3 Remove all the wing nuts that hold the front blade in place then remove tension strap and blade 4 The squeegee blade has 4 working edges Turn the blade so a clean undamaged edge points toward the front of the machine Replace the blade if all 4 edges are nicked torn or worn to a large rad...

Page 51: ...rely damaged if the batteries are not installed and connected properly Batteries should be installed by Nilfisk Advance or by a qualified electrician 1 Remove the batteries from their shipping crate and carefully inspect them for cracks or other damage If damage is evident contact the carrier that delivered them or the battery manufacturer to file a damage claim 2 Turn the Master Key Switch J OFF ...

Page 52: ... this selection NOTE The following percentages are based on useable battery capacity not total battery capacity Therefore 100 discharge 80 of total battery capacity for standard wet cell batteries or 70 of total battery capacity for maintenance free batteries Explanation of Battery Indicator Lights and Voltage Ranges 36 volt of Battery Indicator Discharge Standard Alternate Green Full to 50 34 0 3...

Page 53: ...amp cloth to wipe dirt from the top of the batteries Battery terminals must be clean and tight If the tops of the batteries are wet after charging the batteries have probably been over filled or over charged Note If there is acid on the batteries wash the tops of the batteries with a solution of baking soda and water 2 tablespoons of baking soda to 1 quart of water BATTERY TESTING A battery proble...

Page 54: ... red clip to the positive and black to negative to battery connector or battery posts The rocker switch is used to change the motor rotation in setting the correct drive nut dimension Instructions for Squeegee Lift Actuator Drive Nut Adjustment 1 See Figure 3 Hold onto the Actuator Drive Nut A and press the rocker switch to run the drive motor and retract the nut towards the motor housing it s IN ...

Page 55: ...n pocket away from the motor 2 Follow steps 1 7 in the section labeled Instructions for Squeegee Lift Actuator Drive Nut Adjustment reference previous page 3 After adjusting the actuator drive nut dimensions follow step 10 in the Brush Deck Actuator Removal manual section to reassemble Service Tip See Figure 5 Note the correct orientation of the Spring Housing E when installing the complete motor ...

Page 56: ...tions 2 Connect the programmer put it in diagnostic mode and read the displayed fault information In this example the display shows No Faults Present indicating that the controller has not detected anything out of the norm 3 Put the programmer in test mode and observe the status of inputs and outputs in the forward direction In this example the display shows that the forward input did not activate...

Page 57: ...e 2 Broken throttle pot 3 Broken throttle mechanism 2 4 OO OOOO Speed limit pot fault 1 Speed limit pot wiper wire broken 2 Broken speed limit pot 3 3 OOO OOO Throttle fault 1 Throttle input wire open 2 Throttle input wire shorted to B or B 3 Throttle pot defective 4 Wrong throttle type selected 4 1 OOOO O Low battery voltage 1 Battery voltage 16 volts 24V models 2 Corroded or loose battery termin...

Page 58: ...emove electrical panel to access controller then observe LED status light on touch pad operator panel wand indicator light 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...

Page 59: ...just a parameter and a limit is reached the display will stop changing To see why the display has stopped changing press the MORE INFO key If the limit is related to another parameter that information will be displayed changing the value of the related parameter may allow the original parameter to be adjusted further Otherwise the display simply says Max Limit or Min Limit MAINTENANCE There are no...

Page 60: ...re and current draw of the brush motor s When either the decrease or increase scrub pressure switch is depressed this will lower the scrub deck to the operating position and by activating the foot pedal start the brush motor The controller is continuously monitoring the current to the brush motor and when it senses a current draw out of the desired range it automatically raises or lowers the brush...

Page 61: ...rcuit open 1 Check for open in brush motor wiring or defective motor 2 Brush solenoid coil resistance Check the negative supply cable at the brush motor for a wiring 120 Ohms 10 problem or improper modifications this is a special cable and must be replaced with the original OEM 3 Replace defective brush motor contactor 4 Check if brushes are installed E22 Scrub motor short Same as E06 E23 Vacuum m...

Page 62: ...Continue to hold the wand switch until the status display indicates t for test mode 5 Release the wand switch 6 The function of each switch and indicator is described in the following pages 7 To exit this mode turn the main power on off key switch to the off position CONTROL PANEL A Scrub OFF Indicator B Scrub OFF Switch C Scrub Pressure Decrease Indicator D Scrub Pressure Decrease Switch E Scrub ...

Page 63: ...nt The display will show 0 followed by a long blank period The above sequence will repeat If over current faults are present the status display will indicate the error codes Output Controls See Figure 5 The control panel switches are used to control various output functions of the main control unit Below is a list of each switch and the function it controls Following the list is a detailed descrip...

Page 64: ... These are 1 output off direction up 2 output on direction down 3 output off direction down 4 output on direction up When the output is in state 1 the actuator output is turned off The scrub pressure increase indicator should be off If the indicator is flashing green this indicates that the control is sensing current flow through the actuator shorted output driver control error If the scrub pressu...

Page 65: ...ither the scrub deck lift actuator or the squeegee lift actuator See the descriptions above for more details Fast Slow Switch L This switch is used to toggle the state of the multimode output to the speed control This is used to select which speed limit the speed control uses Pressing and releasing this switch will alternately turn the multimode output on and off The indicator M provides the follo...

Page 66: ... shut down the scrub system when the battery voltage falls to the selected threshold The cutout level is adjustable The standard setting is 31 volts 1 72 volts per cell and the alternate setting is 32 5 volts 1 81 volts per cell Select the proper cutout level based on the battery manufacturer s specifications It is important to note that some maintenance free batteries including some gelled electr...

Page 67: ...tch operating mode this switch may also be referred to as the heavy scrub pressure select switch Pressure Increase Decrease Mode with 3 Pressure Settings Factory Default 1 Turn the main power key switch to the off position 2 Press and hold the scrub pressure decrease switch 3 While holding the pressure decrease switch turn the main power key switch to the on position 4 Continue to hold the pressur...

Page 68: ... switch to the off position 2 Press and hold the scrub pressure decrease switch 3 While holding the pressure decrease switch turn the main power key switch to the on position 4 Continue to hold the pressure decrease switch until the scrub pressure decrease indicator is green 5 Release the pressure decrease switch 6 Pressing and releasing the scrub pressure decrease switch will now select between 0...

Page 69: ...atus display will now indicate E or d 6 Pressing and releasing the vacuum switch will now select between E for enabled or d for disabled Enabled means that the automatic shutoff feature is turned on disabled means that the automatic shutoff feature is turned off 7 To save the new setting turn the main power key switch to the off position 8 The new setting will be saved and will remain in effect un...

Page 70: ...nce will repeat 8 To pause the display press and hold the solution switch 9 To clear the stored codes press and release the scrub system off switch The display will now show Go to step 11 10 If it is desired to save the codes go to step 11 11 To exit the error code recall mode turn the main power key switch to the off position Turning Fault Detection On or Off FACTORY DEFAULT ON Normally the main ...

Page 71: ... FACTORY DEFAULT MODE S SCRUBBER SIZE 8 IF 28 OR 32 DISC OR ANY CYLINDRICAL DECK L IF 35 OR 38 DECK The Adgressor BR 850S and 850CS can be equipped with numerous scrub deck options This function configures the control unit current settings for each of the scrub deck types Improper setting of the motor type may result in motor damage due to overloading To select the proper scrub deck motor type 1 T...

Page 72: ...hes turn the main power key switch to the on position 4 Continue to hold both switches until the wand indicator is flashing 5 Release both switches The status display will now indicate a number from 0 to 9 depending on the current sleep delay period 6 Pressing and releasing the wand switch will now select the delay period The level will increment from 0 to 9 0 off sleep disabled 1 10 minutes 2 20 ...

Page 73: ... to the off position 8 The new setting will be saved and will remain in effect until it is changed again Forward Annunciator Volume Control FACTORY DEFAULT 0 OFF The Adgressor BR 850S and 850CS are equipped with an audible warning device which functions as a horn a back up alarm and a forward annunciator The volume of the forward annunciator can be adjusted to one of ten settings 1 is the minimum ...

Page 74: ...72 FORM NO 56043097 Adgressor BR 850S 850CS 950S 950CS 1050S 1050CS ELECTRICAL SYSTEM Drive Motor Breakdown ...

Page 75: ... H2 Headlight Optional H3 Strobe Light Optional K1 Contactor Brush Motor K2 Contactor Vacuum Motor K3 Contactor Speed Controller L1 Solenoid Valve M1 Lift Actuator Brush M2 Lift Actuator Squeegee M3 Motor Drive Wheel M4 Motor Pump Optional M5 Motor Vacuum M6 Motor Vacuum Optional M7 Motor Gearbox Assembly Disc or Motor Brush Cyl M8 Motor Brush Cylindrical only R1 Potentiometer 5K S1 Switch Key S2 ...

Page 76: ...T KEY F3 CIRCUIT BREAKER 10 AMP H1 HORN BACKUP ALARM 1 2 F4 FUSE 1 A R1 POT 5K OHM 1 2 3 S4 K2 CONTACT N O RED RED BLK RED RED BRN YELBRN YEL BRN RED WHT ORN BLK BLK YEL WHT GRN GRA VIO YEL BLK RED GRN BLU BLK RED BLK BRN BLK WHT YEL ORN RED GRN BLK WHT BRN WHT BRN VIO BLK WHT BRN WHT BRN GRA BLK BRN WHT BLK WHT BRN WHT BRN WHT BRN BLK BLK WHT RED WHT RED BLK RED WHT WHT RED BLK BRN RED RED RED YE...

Page 77: ... 18 2 BRN WHT 20 1 BRN WHT 20 1 BLU 14 1 VIO BLK 18 1 GRN YEL 16 1 GRN YEL 16 3 GRN YEL 16 1 RED GRN 8 1 RED GRN 8 1 WHT BRN 16 9 WHT BRN 16 8 BLK 18 2 YEL VIO 18 1 WHT BRN 16 8 WHT BRN 16 3 WHT BRN 16 6 WHT BRN 16 3 WHT BRN 16 6 WHT BRN 16 4 WHT BRN 16 5 WHT BRN 16 5 GRN YEL 16 2 BLU 8 1 BLK 10 4 BLU 10 1 BLK 10 4 BLK 12 2 BLK 12 3 BLK 12 4 BLK 12 1 BRN YEL 16 3 BRN YEL 16 3 BRN RED 18 1 BLK 8 1 ...

Page 78: ...5K OHM M3 MOTOR WHEEL DRIVE M M6 MOTOR VAC M S3 S6 M2 SQUEEGEE LIFT ACTUATOR M M8 MOTOR BRUSH M S1 SW SPST KEY L1 VALVE SOLENOID K2 CONTACT N O D2 ZENER TVS M11 PUMP SOLUTION M F5 FUSE 5 A F4 FUSE 1 A M9 MOTOR SIDE BROOM M H2 LAMP HEAD M5 MOTOR VAC M H3 LAMP FLASHING K3 CONTACT N O D1 ZENER TVS M8 MOTOR BRUSH M 1 2 1 2 1 2 1 2 1 2 1 2 2 1 1 2 1 2 3 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 R...

Page 79: ...GRN YEL 16 2 BLU 8 1 BLK 10 4 BLU 10 1 BLK 10 4 BLK 12 2 BLK 12 3 BLK 12 4 BLK 12 1 BRN YEL 16 3 BRN YEL 16 3 BRN RED 18 1 BLK 8 1 BLK 10 2 BLK 18 4 WHT BRN 16 9 WHT 12 2 BLK 12 2 WHT 12 1 BLK 12 1 BLK 18 1 WHT BRN 16 4 WHT 12 3 BLK 12 3 WHT 12 4 BLK 12 4 ORN 20 2 ORN 20 2 YEL VIO 18 1 YEL VIO 18 1 VIO 20 2 VIO 20 2 WHT YEL 16 1 ORN BLU 20 1 BLU BLK 20 1 BLU BLK 20 1 RED BLK 20 1 ORN BLU 20 1 ORN ...

Page 80: ...ctuator Squeegee M3 Motor Drive Wheel M4 Motor Pump Optional M5 Motor Vacuum M6 Motor Vacuum Optional M7 Motor Gearbox Assy Disc or Motor Brush Cyl M8 Motor Gearbox Assy Disc or Motor Brush Cyl M10 Motor Gearbox Assy Disc only M11 Pump Solution AXP EDS M12 Pump Chemical AXP EDS R1 Potentiometer 5K S1 Switch Key S2 Switch Seat M7 M8 M2 M5 H3 M6 S1 E1 K1 K3 A1 F2 F3 H2 M3 F1 H1 R1 M11 L1 M1 S2 K2 E2...

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Page 82: ...www nilfisk advance com 2006 ...

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