Nilfisk-Advance Advenger 2800ST Quick Start Service Manual Download

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ELECTRICAL SYSTEM

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

Connector J2

Pin

Wire

Circuit

Measured

Comment

BLK

Ground

0.06v

Vacuum On

BLK

Ground

0.06v

Vacuum On

BLK/WHT

Speed Limit

4.45v Transport

3.4v Scrub

1.1v Strip

Signal Out to Speed Controller

VIO

POT Low

0.38v

From Speed Controller. Used for Speed

Limit Signal

YEL

POT Hi

4.58v

From Speed Controller. Used for Speed

Limit Signal

BLK

Ground

0.05v

Vacuum On

BLK

Ground

0.05v

Vacuum On

BRN/RED

Vac Motor Sense

0.153v

Single Vac On. 22.6 A

YEL/RED

Brush Motor Sense 0.12v

Brush motors on. (Do not run long off the

ground)

BLK/WHT

Act. Pos 2

4.9v Act Up

0.001 v Sw closed

In Serv. Test Mode, press scrub + once.

Let it stop, then press it two more times

to drive until the switch closes to see the

change.

RED/VIO

Act. Pos 1

4.9v Act Up

0.001 v Sw closed

In Serv. Test Mode, press scrub + once. Let

it stop, then press it again to drive until

the switch closes to see the change.

Summary of Contents for Advenger 2800ST

Page 1: ...O 56043121 Quick Start Service Manual Advance MODELS 56601000 56601001 56601002 56601003 56601004 56601005 56601006 56601007 56601008 56601009 56601010 56601011 56601012 56601013 56601019 56601020 56601891 56601892 Nilfisk MODELS 56601014 56601015 56601016 English ...

Page 2: ...in Controller Error Codes Advenger BR 755 855 and ST 19 Speed Control Error Flash Codes 20 Error Code System Diagnostics Advenger BR 755 855 and ST 21 SQUEEGEE SYSTEM 24 Troubleshooting Squeegee Issues 25 Squeegee Adjustments 26 Squeegee Lift Actuator Replacement Advenger BR 755 855 27 Squeegee Lift Actuator Drive Nut Adjustment Advenger BR 755 855 28 Squeegee Lift Cable Replacement Advenger BR 75...

Page 3: ... 82 Service Test Mode ADVENGER BR 755 855 Disc and Cyl 82 Changing Control Board Program Settings 83 Changing Program Settings Advenger BR 755 855 Disc and Cyl 84 Changing Program Settings ST 85 Service Test Mode ST 86 Hidden Menus REV 87 Program Options REV 88 Service Test Mode ADVENGER BR 755 855 REV 90 MAINTENANCE SCHEDULES 92 OPERATOR PREVENTIVE MAINTENANCE MACHINE IN USE 92 OPERATOR PREVENTIV...

Page 4: ...or expanded instructions to procedures noted here Note Bold numbers in parentheses in the text indicate an illustrated item Note All references to right left front and rear in this manual are as seen from the operator s position General Machine Description The Advenger BR 755 855 and ST machines are commercial automatic floor scrubbers available with multiple deck sizes multiple corresponding sque...

Page 5: ...ry when working near electrical components Turn the key switch off O and disconnect the batteries before servicing electrical components Never work under a machine without safety blocks or stands to support the machine Do not dispense flammable cleaning agents operate the machine on or near these agents or operate in areas where flammable liquids exist Do not clean this machine with a pressure was...

Page 6: ...41 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 ...

Page 7: ...ight standard machine w o options w full solution tank empty recovery tank and heaviest batteries installed 1451 lbs 658 kg Net Weight standard machine w o options batteries or removable brushes w empty solution and recovery tanks 536 lbs 244 kg 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 Protecti...

Page 8: ...gular Scrub 38 gal min 1 44 L min or 70 minutes per solution tank 2 Heavy Scrub 62 gal min 2 35 L min or 40 minutes per solution tank 3 Extreme Scrub 92 gal min 3 48 L min or 23 minutes per solution tank Advenger BR 755 855 Solution Flow Rates Disc and Cy 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...

Page 9: ...peeds Disc Right hand Single Motor 215 260 RPM Left hand Motor 215 260 RPM REV approx 2 000 RPM Scrub Motors Cylindrical Right hand Motor 5 HP 373 watts Left hand Motor 5 HP 373 watts Scrub Head Speeds Cylindrical Right hand Motor 900 RPM Left hand Motor 900 RPM Scrub Force 28 ST 1 Regular Scrub 75 85 lbs 32 7 37 0 kg 2 Extreme Scrub factory setting 170 180 lbs 77 1 81 6 kg Scrub Force 34 ST 1 Reg...

Page 10: ...and ST 36 5 inches 93 m Cylindrical Advenger BR 755 855 32 inches 81 m Transporting The Machine CAUTION Before transporting the machine on an open truck or trailer 1 Remove the Squeegee Assembly 11 and secure 2 Tie the machine down securely at the Locations A shown in FIGURE 2 3 Tape and strap all access doors and covers as necessary 4 In temperatures below freezing remove all water from the machi...

Page 11: ...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 ...

Page 12: ...gee Assembly 11 to access these locations Use a bottle jack at these points B as shown in FIGURE 5 FIGURE 4 FIGURE 5 Emergency Stop Knob WARNING The Emergency Stop Knob 7 disconnects power from the Speed Control and Drive Wheel It does not disconnect the batteries but will continue to power the control board Do not use the Emergency Stop Knob as a substitute for disconnecting the red Anderson batt...

Page 13: ...eaker 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 o...

Page 14: ...Tank Fill Cover 26 Recovery Tank Cover 27 Vacuum Motor Filter Housing 28 Strainer Basket optional on ST models 29 Recovery Tank Shutoff Float 30 Squeegee Storage Hook 31 Recovery Tank Drain Hose 32 Squeegee Tilt Adjustment Knob 33 Seat Prop Rod 34 Machine Battery Connector 35 Rear Squeegee Blade Removal Latch 36 Hopper Cylindrical models only 37 Recovery Hose 38 Solution Solenoid Valve 39 Front Sq...

Page 15: ... 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 refres...

Page 16: ...er 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 Extr...

Page 17: ... NOTE 1 Recovery Tank FULL status is indicated by the Solution Flow Indicator LED C1 turning Off This status allows machine transport but disables all active systems and disables the control panel switches except for the Horn Switch K To reset empty the tank and cycle the key switch NOTE 2 Battery Low Low Voltage Cutout status is indicated by the red battery LED M flashing It triggers at 20 55V on...

Page 18: ...sing 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 flow rate can be changed b...

Page 19: ...3 Solution solenoid open Solution 47 31 2 4 Brush motor circuit open Scrub 31 32 NA Scrub deck lift actuator open Scrub 32 33 3 1 Vacuum motor circuit open Recovery 42 34 NA Squeegee lift actuator open Squeegee 21 35 3 2 Brush motor contactor coil open Scrub 31 36 3 3 Vacuum motor contactor coil open Recovery 42 37 NA Chemical pump open AXP EDS 47 60 3 4 Brush motor circuit contacts stuck closed S...

Page 20: ...ontactor driver failed closed 3 1 OOO O HPD fault present for 10 sec 1 Misadjusted throttle 2 Broken throttle pot or throttle mechanism 3 2 OOO OO brake On fault 1 Electromagnetic brake driver shorted 2 Electromagnetic brake coil open 3 3 OOO OOO precharge fault 1 Controller failure 2 Low battery voltage 3 4 OOO OOOO brake Off fault 1 Electromagnetic brake driver open 2 Electromagnetic brake coil ...

Page 21: ... deck lift actuator overload x 5 Brush motor overload x x x X x 6 Squeegee lift actuator overload x x 7 Vacuum motor overload x x x x 8 Solution solenoid overload x x x 9 Vacuum contactor coil overload x x x x 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...

Page 22: ...ous in reverse Foot Pedal in Neutral 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 Press Scrub Off 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 tota...

Page 23: ...queegee to prevent damage Solution Solenoid Off Brush motor circuit On Vacuum motor circuit On for 10 seconds Foot Pedal Neutral Brush motor circuit Off but enabled Vacuum motor circuit On for 10 seconds then enabled Solution Solenoid Off but enabled Lift Scrub Deck Solution Solenoid Off Brush motor circuits Off Lift Squeegee Vacuum motor circuit Off after 10 seconds Vac Mode Seated Closed Lower S...

Page 24: ...ger 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 ST ...

Page 25: ...place Squeegee is hopping Wheel isn t making contact with the floor reposition wheel in slot on squeegee tool Refer to Squeegee Adjustments section Squeegee tips are being driven into the floor Adjust squeegee using Adjustment Knob turning CW to raise tips Advenger BR 755 855 Lift motor runs in both directions but does not raise or lower the squeegee tool assembly 1 Threads in the moveable lift mo...

Page 26: ...tical 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 ...

Page 27: ...e it from the solution tank platform Guide the tank off the rear of the machine to the floor 6 See Figure 9 From the back of the machine remove the Retainer Ring A securing the lift cable Pin B and separate the pin and cable from the motor drive tube housing and chassis mounts Note Don t lose the two plastic cable spacers positioned in motor drive tube 7 Locate the wire tie that attaches the motor...

Page 28: ...rn 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 i...

Page 29: ...r 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 batte...

Page 30: ...re 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 FR...

Page 31: ...e 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 th...

Page 32: ...eel center 5 Pound the steering wheel C off from behind using a mallet observing Woodruff key as it may fly 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...

Page 33: ...ssing 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...

Page 34: ...r Finish Removal Mode When in the scrub mode pressing the Floor finish Removal Mode Switch reduces the machine transport speed and modifies the deck pressure and solution flow rates Pressing the Floor Finish Removal Mode switch again will slightly increase the transport speed Pressing it a third time will exit the Floor Finish Removal mode and return to the scrub mode ...

Page 35: ...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 ...

Page 36: ...iring problem or improper modifications this is a special cable and must be replaced with original OEM due to sense wire 3 Check K2 contacts if open circuit while scrub is on replace K2 4 Verify brushes are installed 5 Verify the brushes are touching the floor and there is no interference between the deck and the floor 35 3 2 Visible in Fault Recall Mode Brush motor K2 contactor coil open 1 Check ...

Page 37: ...A Overload Current Wire Colors M4 2 5 3 5 5A for 4 seconds Blue Orange Black Troubleshooting Scrub System Issues It is unlikely that the scrub system will malfunction without generating an error code so most issues will be found on the preceding tables A few more machine specific items are listed here Problem Possible Cause Advenger BR 755 855 Scrub deck lift actuator overload Mechanical interfere...

Page 38: ...ve the Deck Actuator 6 Using the Actuator Power Cord Adapter 56407502 from your Nilfisk Advance service tool kit set the Extend and Retract limit switch positions as shown in the Scrub Deck Lift Actuator Drive Nut Adjustment section CAUTION Failure to set the lower stop correctly may result in damage to the Spring Housing F Disc and Cylindrical Decks 7 Then reassemble in reverse order after drive ...

Page 39: ...ng Guide B in reference to the shoulder as shown in the figure below 7 Manually turn the plastic Spring Housing F assembly until the position measure matches the figure below 8 Hold the Spring Housing and press the rocker switch running the motor until it stops but no further than 4 from the shoulder as shown in the figure below or damage to the Housing may occur 9 If the measurement doesn t match...

Page 40: ...uator 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...

Page 41: ...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 ...

Page 42: ... deck turn it over so the Brush Plates are on top 3 Remove the hex socket screw A from the Motor Gimbal located at the Brush Plate center 4 Remove the Brush Plate Assembly B NOTE It may be necessary to pry the assembly off the motor shaft Do not pry on the outer edge of the Brush Plate Assembly B as this could damage the plate Pry using a flat screw driver C against the aluminum gimbal shoulder un...

Page 43: ...to lack of water 11 Reattach the motor bracket assembly to the deck making sure to use the correct holes If position is not correct brushes will either interfere with each other or with the deck sides 12 Lubricate the Motor Gimbal and apply anti seize to the socket head bolt before reassembly 13 Press the Brush Plate firmly onto the motor shaft If it is not pressed in completely the deck will not ...

Page 44: ... Motor Removal REV 1 Remove the Brush Head from the machine See Removal and Installation Brush Head 2 Flip the deck disc side up and remove the pads 3 Remove the pad holder by removing the 6 attaching screws 4 Remove the counter weight by removing the two attaching bolts Counter weight ...

Page 45: ...ck 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 se...

Page 46: ...s 4 Press the bearing out of the driver motor using an arbor press 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 ...

Page 47: ...chine 2 Remove the brush motor 3 Remove the retainers 4 Remove the motor plate by removing the 4 isolator nuts Inspect the splash shield and replace if damaged 5 Flip the scrub head upright and remove each of the isolators from the brush head by removing the attaching nuts Remove Remove 4 isolator nuts Inspect Splash Shield Isolators Remove ...

Page 48: ... 5 N m Install the 4 plastic covers over the nuts 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...

Page 49: ...00ST 3800ST BR 755 BR 855 Scrub Motor Carbon Brushes REV 1 Remove the brush head from the machine 2 Remove wire retaining nut and rubber packing 3 Mark orientation of end plates to motor housing and remove both through bolts 4 Remove end plate ...

Page 50: ...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 e Install the other three br...

Page 51: ...it far enough so that the brushes will contact the commutator when the temporary retaining wires are removed Then remove the wires b Fully seat the end cover c Install the through bolts d Seal the retaining wire holes in the end cover with silicone sealant Carbon Brush Commutator ...

Page 52: ...s 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 ...

Page 53: ...ected 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 rea...

Page 54: ... Refer to the section Understanding Control of Squeegee Scrub and Recovery Systems via Modes for details about functionality of the Recovery System due to multiple systems operating in tandem under various seat switch and button configurations For the Recovery System to function properly the systems mentioned above in addition to the Wheel Drive System must be operating properly in order for the v...

Page 55: ...RECOVERY SYSTEM 55 Service Manual Advenger 2800ST 3800ST BR 755 BR 855 ST ...

Page 56: ...em or improper modifications this is a special cable and must be replaced with original OEM due to sense wire 3 Check K1 contacts if open circuit while vac is turned on 0V at J3 12 replace K1 36 3 3 Visible in Fault Recall Mode Vacuum K1 contactor coil open 1 Check coil resistance see chart below 2 Check for tight connections at contactor and GRA BLK wire to control board Repair or replace 61 4 1 ...

Page 57: ...tomatically Vacuum motor is normally dry now it s wet and failing Vacuum leak below the water line creating turbulence in the recovery tank causing water to enter the vacuum motor The control board doesn t indicate the recovery tank is full before the ball valve shuts off the vac motor 1 Check the vacuum motor sense wire BRN RED for break or poor connection mV signal 2 Check that cage for ball flo...

Page 58: ...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 ...

Page 59: ...d 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...

Page 60: ...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...

Page 61: ... section Solution Solenoid Nominal Resistance Nominal Current Overload Current Wire Colors L1 35 ohms 650 mA 750 mA BRN VIO BLK Chemical Pump Nominal Current Overload Current Wire Colors M2 PWM 870 mA PWM n a Troubleshooting Solution AXP EDS System Issues Problem Possible Cause Inadequate or no solution flow No solution in the tank Red Solution Shutoff Valve 21 is in the Off position Clogged Solut...

Page 62: ...SOLUTION SYSTEM 62 Service Manual Advenger 2800ST 3800ST BR 755 BR 855 Solution System Diagram FIGURE 28 ...

Page 63: ... the solution solenoid thereby keeping the flow rate constant FIGURE 29 A malfunction of either the Pressure Sensor the Control Panel or an air leak in the pressure sensing system may affect the performance of either the Chemical Pump or the Solution Solenoid or both ST The pulsed 24V output of the control board that controls duty cycle of the Solution Solenoid is driven by 1 Control board program...

Page 64: ...o 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 flat blade screwdriver or 5 16 socket loosen the two hose clamps on the valve and remove the black Solution Hose A from the inlet side and the clear hose B coming from the deck manifold 5 Using a 7 16 socket remove th...

Page 65: ...ad 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 sys...

Page 66: ...l is connected 2 Refer to Speed Control Flash Codes section 3 Repair 4 Reset machine via key switch ST the Fault Indicator LED is blinking 1 1 and the Extreme Solution Flow LED flashes a code 1 Verify connector at Drive Pedal is connected 2 Refer to Speed Control Flash Codes section 3 Repair 4 Reset machine via key switch The wheel drive motor will not run in forward or reverse 1 Batteries need ch...

Page 67: ...ow 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...

Page 68: ... 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 WHITE BLACK ORANGE RED WHITE RED GREEN YELLOW BLACK ...

Page 69: ... the machine down at the rear lifting points 3 Raise the front of the machine by jacking at the center front flat surface of the solution tank 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...

Page 70: ...ub 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 ti...

Page 71: ...ght motor side up as shown CAUTION To prevent gear oil from draining from the gearbox disassemble the motor with the Drive Wheel assembly in a vertical position If some oil is lost drain completely and refill the oil as indicated at the bottom of the page 3 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...

Page 72: ...ns 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 th...

Page 73: ...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 ...

Page 74: ... 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 B 24V to M4 for 3...

Page 75: ...BLK Advenger BR 755 855 24V B Backprobe J3 Output to Contactors Solution Solenoid Horn Speed Control error status EM Brake reverse status J3 connected at control board Referenced to Measure J3 Measure Referenced to B 24V flashed speed control status error code ORN BLU 7 14 BRN Key switch 24V B B Speed control EM brake signal 24V moving on neutral off RED WHT 6 13 WHT RED 24V for 2 sec to K2 then 1...

Page 76: ...like Battery Negative used used for the black voltmeter lead and each pin location was back probed with the red voltmeter lead unless otherwise specified Connector J1 Pin Wire Circuit Measured 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...

Page 77: ...troller 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 0 001 v Sw closed In Serv Test Mode press scrub once Let it stop then press it two more times to drive until the switch closes to see the...

Page 78: ...v N 0 2v FWD or REV 7 ORN BLU Status 1 2v No Code 24 5v Unstable 24 5v for a bit then cycles when there is a code 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 0 2v on Cycles on low and medium 0 2v steady on high 12 GRA BLK Vac Contactor 25v off 0 19v on 13 WHT RED Brush Contactor 25v off 0 15v ...

Page 79: ...uity 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 prob...

Page 80: ...rward 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 fitting at the control board when the hose is removed e...

Page 81: ...el assembly using the new panel assembly 1 2 from the kit NOTE the clear hose must not be kinked otherwise the Solution System will not function properly CAUTION To prevent damage to the new control panel assembly due to static electricity ESD wear a properly grounded static control wrist strap before removing the new assembly from its protective static shielding bag and throughout the entirety of...

Page 82: ...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 G OFF DOWN OFF ...

Page 83: ...ems 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 f...

Page 84: ... 755 C 34 disc BR 855 2 CHEMICAL SELECTION AXP On US mode X XXX EDS On EU mode AXP EDS Off 3 DETERGENT MODE Off no Evergreen board default Mode 1 US Evergreen On Mode 2 EU or non Evergreen preset 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 Low Med High Low Medium ...

Page 85: ...e display to show what the current setting is Press the Solution On Off switch to save the setting then turn key switch Off to exit the hidden menu 1 SWITCHES PRESSED B D C K 2 INITIAL LED INDICATION 3 BLINKS FUNCTION LOW Solution MED Solution HIGH Solution RED YEL GRN Low Voltage Cutout Wet Gel AGM Scrub Deck Size 28 34 Single Dual Vac Motor S D Max Scrub Speed of Transport Speed 50 60 Recovery T...

Page 86: ...he 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 C ENERGIZED DE ENERGIZED Solution Med Activate brush motor contactor K2 B ENERGIZED DE ENERGIZED Solution High Activate vacuum motor contactor K1 D ...

Page 87: ...wer 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 pre...

Page 88: ... Used to lock out any solution flow rate settings Low Normal Medium Heavy High Extreme Low and Medium Low and High High and Medium During normal operation the flow rate s that are locked out will not be able to be selected Recovery Tank Full Enable Disable Used to enable or disable Recovery Tank Full automatic shutoff feature Enable means that the automatic shutoff feature is turned on disable mea...

Page 89: ...essure 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 incr...

Page 90: ... 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 Control...

Page 91: ...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 ...

Page 92: ...tem 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 Shaf...

Page 93: ...hes for wear Replace if 9 5mm 3 8 inches or shorter 300 Op Hrs Inspect brush motor carbon brushes Replace if 9 5mm 3 8 inches or shorter 500 Op Hrs While brush motor being checked also check for wear at Motor Gimbal inside Brush Plate Remove and replace if worn 500 Op Hrs Inspect drive motor carbon brushes Original carbon brush length is 19 1mm 3 4 inches Replace when shorter than 6 3 mm 1 4 inche...

Page 94: ... SM56043101 for speed control changes Noisy Sluggish 6 Scrub System Raise Lower auto scrubbing functions A B 7 Scrub Brush pressure settings Normal Heavy Extreme scrub for Advenger BR 755 855 Normal Extreme for ST A B 8 Squeegee System Raise Lower ADVENGER BR 755 855 Auto raise in reverse A B D 9a Vacuum Performance Single Motor sealed water lift 63 1 inch open hole aperture 10 C L W 9b Vacuum Per...

Page 95: ...um Float Ball Cage Assembly Clean Float C M 28 Recovery Lid Gasket C D L 29 Recovery Tank Drain Hose Cap Flush C L 30 Recovery Tank Strainer Basket Clean C D 31 Squeegee Pick Up Tool and Hose Back Flush C L 32 Squeegee Blades clean rotate A C D W 33 Squeegee Lift Actuator Motor Advenger BR 755 855 Cable A B D 34 ST Squeegee Lift Cable Plastic Bushing in Steering Column Cable too tight if Worn W 35...

Page 96: ... 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 E...

Page 97: ...9 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...

Page 98: ...FORM NO 56043121 Advenger 2800ST 3400ST BR 755 BR 855 77 ELECTRICAL SYSTEM ...

Page 99: ...RAKE 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 56601806 REV 3 1 OF 2 1 OF 2 2 DISCONNECT RED WIRE ON CB2 AND REPLACE WITH GREEN WIRE FROM CHARGER WHEN CHARGER IS USE...

Page 100: ...TA 55447 3408 DRAWN PROJ ENG NILFISK ADVANCE INC 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 PMO A B B A C B J1 8 POSITION_1_ J2 12 POSITION_2_ J2 11 A B 8 8 12 8 8 12 CK OPTIONAL 3 3...

Page 101: ...80 FORM NO 56043121 Advenger 2800ST 3400ST BR 755 BR 855 Wiring Harness Diagram REV Deck 56601807 Revision A ...

Page 102: ...Warning optional H2 Horn Backup Alarm K1 Contactor Vacuum Motor K2 Contactor Brush Motor L1 Solenoid Valve M1 Motor Drive Wheel M5 Motor Vacuum M6 Motor Vacuum Optional M7 Motor Brush M8 Motor Brush R1 Potentiometer 5K S1 Switch Key S2 Switch Seat S4 Emergency Disconnect S5 Deck Switch S6 Squeegee Switch Y1 Electromagnetic Brake COMPONENT LOCATION 2800ST 3400ST Component Location 2800ST 3400ST ...

Page 103: ... 56601183 1 Contactor 24v 100 Amp K2 56412179 1 Contactor 24v L1 56601064 1 Solenoid Valve Assy M1 56601050 1 Motor Drive Wheel M5 56601132 1 Motor Vac 24vdc M6 56601132 1 Motor Vac 24vdc optional M7 56601134 2 Motor Gearbox Assy M8 56601134 2 Motor Gearbox Assy R1 N A 1 Part of 56601052 S1 56303553 1 Key Switch 56303526 A R Replacement Key Set S2 7 82 00050 1 Squeegee Switch S4 56407130 1 Disconn...

Page 104: ...FORM NO 56043121 Advenger 2800ST 3400ST BR 755 BR 855 83 ELECTRICAL SYSTEM ...

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