Nilfisk-Advance CR 1100 Quick Start Troubleshooting Manual

CR 1100, CR 1200

QUICK START TROUBLESHOOTING

SERVICE MANUAL

1/09 revised 9/09

FORM NO. 56043126

Printed in USA

Nilﬁ sk MODELS: 56303004 (CR 1200), 56303005 (CR 1100 / OBS)

2 - FORM NO. 56043126 - CR 1100, CR 1200

TABLE OF CONTENTS

GENERAL INFORMATION ................................................................................................................................................1-2

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

SPECIFICATIONS .............................................................................................................................................................4-5

MAINTENANCE .................................................................................................................................................................6-7

PM CHECKLIST ................................................................................................................................................................8-9

KNOW YOUR MACHINE ...............................................................................................................................................10-21

MAIN CONTROLLER SELF-DIAGNOSTIC TEST MODE ................................................................................................ 18

MAIN CONTROLLER ERROR CODES .......................................................................................................................19-21

GENERAL MACHINE TROUBLESHOOTING GUIDE TABLE OF CONTENTS ................................................................. 22

WHEEL DRIVE SYSTEM ...............................................................................................................................................23-28

FLOWCHART ................................................................................................................................................................... 23

TROUBLESHOOTING GUIDE..........................................................................................................................................25

DRIVE AND ACCESSORY FUNCTIONS ....................................................................................................................27-28

STEERING SYSTEM ..........................................................................................................................................................29

POWER STEERING ......................................................................................................................................................... 29

SWEEPING SYSTEM ....................................................................................................................................................30-35

MAIN BROOM .............................................................................................................................................................30-31

SIDE BROOMS ............................................................................................................................................................32-33

SIDE BROOM LIFT ACTUATOR .................................................................................................................................34-35

HYDRAULIC SYSTEM ..................................................................................................................................................36-37

HYDRAULIC PUMP MOTOR .......................................................................................................................................36-37

HOPPER SYSTEM ........................................................................................................................................................38-45

HOPPER DUMP DOOR...............................................................................................................................................38-40

HOPPER ......................................................................................................................................................................42-45

SQUEEGEE SYSTEM ........................................................................................................................................................ 46

SQUEEGEE ......................................................................................................................................................................46

VACUUM SYSTEM ........................................................................................................................................................47-48

VACUUM MOTOR .......................................................................................................................................................47-48

DUST CONTROL SYSTEM ...........................................................................................................................................49-51

IMPELLER MOTOR .....................................................................................................................................................49-50

SHAKER MOTOR .............................................................................................................................................................51

SCRUB SYSTEM ...........................................................................................................................................................52-56

SCRUB DECK LIFT .....................................................................................................................................................52-54

SCRUB MOTORS ........................................................................................................................................................55-56

SOLUTION SYSTEM ..........................................................................................................................................................57

SOLUTION SOLENOID VALVE ........................................................................................................................................57

PROGRAMMABLE CONTROL OPTIONS .....................................................................................................................58-66

ELECTRICAL SYSTEM .................................................................................................................................................67-81

CURTIS CONTROLLER DIAGNOSTICS .........................................................................................................................67

STATUS LED FAULT CODES (TABLE 1) ....................................................................................................................... 68

INSTALLATION CHECKOUT FOR THE CURTIS SPEED CONTROLLER ....................................................................69

ELECTRICAL COMPONENT LOCATION......................................................................................................................... 71

WIRING LADDER DIAGRAM (BEFORE SN 1767238) .................................................................................................... 72

WIRING SCHEMATIC (BEFORE SN 1767238)................................................................................................................73

WIRING LADDER DIAGRAM (AFTER SN 1767237) ....................................................................................................... 74

WIRING SCHEMATIC (AFTER SN 1767237 BUT BEFORE SN 1808249) ......................................................................75

WIRING DIAGRAM (AFTER SN 1808248) ..................................................................................................................76-77

WIRING SCHEMATIC (AFTER SN 1808248)..............................................................................................................78-79

HYDRAULIC SYSTEM .......................................................................................................................................................80

HYDRAULIC COMPONENT LOCATION .......................................................................................................................... 80

HYDRAULIC SCHEMATIC ............................................................................................................................................... 80

Note: All references to right, left, front, or rear in this manual are as seen from the operator’s stand-point.

FORM NO. 56043126 - CR 1100, CR 1200 - 1

INTRODUCTION

This manual will help you get the most from your Nilﬁ sk rider Scrubber-Sweeper. Read it thoroughly before servicing the machine.

Note: Bold numbers and letters in parentheses and underlined indicate an item illustrated on pages 10-13 i.e. (B).

This product is intended for commercial use only.

PARTS AND SERVICE

Repairs, when required, should be performed by your Authorized Nilﬁ sk Service Center, who employs factory trained service personnel, and

maintains an inventory of Nilﬁ sk original replacement parts and accessories.

Call the NILFISK DEALER named below for repair parts or service. Please specify the Model and Serial Number when discussing your machine.

(Dealer, afﬁ x service sticker here.)

NAME PLATE

The Model Number and Serial Number of your machine are shown on the Nameplate on the machine. This information is needed when ordering

repair parts for the machine. Use the space below to note the Model Number and Serial Number of your machine for future reference.

MODEL NUMBER ________________________________________

SERIAL NUMBER ________________________________________

GENERAL INFORMATION

2 - FORM NO. 56043126 - CR 1100, CR 1200

A

HOPPER SAFETY SUPPORT

WARNING!

Make sure the Hopper Safety Support (A) is in place whenever attempting to do any maintenance work under or near the raised

hopper. The Hopper Safety Support (A) holds the hopper in the raised position to allow work to be performed under the hopper.

NEVER rely on the machine’s hydraulic components to safely support the hopper.

JACKING THE MACHINE

CAUTION!

Never work under a machine without safety stands or blocks to support the machine.

• When jacking the machine, do so at designated locations (Do Not jack on the hopper) – see jacking locations (11).

TRANSPORTING THE MACHINE

CAUTION!

Before transporting the machine on an open truck or trailer, make sure that . . .

• All access doors are latched securely.

• The machine is tied down securely - see tie-down locations (4).

• The machine parking brake is set.

GENERAL INFORMATION

OTHER MANUALS AVAILABLE

The following manuals are available from the Nilﬁ sk Literature Service Department, for your Rider Scrubber/Sweeper:

• Parts List - Form Numbers 56042507

• Operation Manual - Form Numbers 56041565 (Danish, Norwegian, Swedish, Finnish)

56041566 (German, French, Dutch, Russian)

56041567 (Spanish, Portuguese, Italian, Greek)

56041575 (Estonian, Latvian, Lithuanian, Slovenian)

56041576 (Slovakian, Czech, Polish, Hungarian)

56041776 (English)

• Mechanical Repair Service Manual 56043127

FORM NO. 56043126 - CR 1100, CR 1200 - 3

CAUTIONS AND WARNINGS

SYMBOLS

Nilﬁ sk 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.

GENERAL SAFETY INSTRUCTIONS

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

WARNING!

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

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

while ascending (driving up) the ramp.

• Keep sparks, ﬂ ame and smoking materials away from the battery.

• Charging the batteries produces highly explosive hydrogen gas. Charge batteries only in well-ventilated areas, away from open

ﬂ ame. Do not smoke while charging the batteries.

• Remove all jewelry when working near electrical components.

• Take precautions to prevent hair, jewelry, or loose clothing from becoming caught in moving parts.

• Turn the key switch off (O), disconnect the battery, and set the parking brake before servicing the machine.

• Never work under a machine without safety blocks or stands to support the machine.

• Do not dispense ﬂ ammable cleaning agents, operate the machine on or near these agents, or operate in areas where ﬂ ammable

liquids exist.

• Do not clean this machine with a pressure washer.

CAUTION!

• This machine is not approved for use on public paths or roads.

• This machine is not suitable for picking up hazardous dust.

• When operating this machine, ensure that third parties, particularly children, are not endangered.

• Before performing any service function carefully read all instructions pertaining to that function.

• Do not leave the machine unattended without ﬁ rst turning the key switch off (O), removing the key and applying the parking

brake.

• Turn the key switch off (O) before changing the brooms and brushes, and before opening any access panels.

• Use caution when moving this machine in below freezing temperature conditions. Any water in the solution or recovery tanks or

in the hose lines could freeze, causing damage to valves and ﬁ ttings. Flush with windshield washer ﬂ uid.

• The battery must be removed from the machine before the machine is scrapped. The disposal of the battery should be safely done

in accordance with your local environmental regulations.

SAVE THESE INSTRUCTIONS

4 - FORM NO. 56043126 - CR 1100, CR 1200

General Speciﬁ cations common to All Models English (Metric)

Dimensions

Length 105 inches (267cm)

Height 59 inches (150cm)

Height w/overhead guard 79 inches (200cm)

Ground clearance 3 inches (7.6cm)

Minimum ceiling height dumping clearance 92 inches (233.6cm)

Weights CR 1100 CR 1200

Net weight* 3197 lbs. (1450kg) 3200 lbs. (1451kg)

Gross weight** 5535 lbs. (2510kg) 5702 lbs. (2586kg)

Speed and Gradeability

Maximum travel speed / Maximum reverse speed 6 mph (9.6km/h) / 4 mph (6.4km/h)

Maximum grade angle scrubbing 7.5 deg.

Maximum grade angle non-scrubbing 12 deg.

Sound Level

At operators ear 77.2 dBA

Sweep System

Sweeping path w/out side broom(s) 40 inches (102cm)

Main broom diameter 14 inches (35.5cm)

Side broom diameter 20 inches (50.8cm)

Side broom bristle length 7 inches (17.7cm)

Main broom speed 380 RPM

Side broom speed 100 RPM

Hopper System

Capacity 9.2 Cu. Ft. (261l)

Lifting capacity 550 lbs. (250kg)

Dump height (variable) Max. 60 inches (152cm)

Dump height with door open 56-1/2 inches (143.5cm)

Dust Control System

Filter type: Pleated paper panel

Filter dimension 3-3/16” x 20” x 27” (8cm x 50.8cm x 68.5cm)

Filter media area 78 ft2 (7.25m2)

Steering System

Type: Power assisted chain drive

Turns lock to lock right: 2-1/2

Turns lock to lock left: 2-1/2

Minimum aisle turn width 118 in. (300cm) left and right

Hydraulic System

Oil type: SAE 10W-30

System ﬁ ll capacity 1.7 qts. (1.6l)

Recovery System

Vacuum water lift (sealed) minimum 72 inches

Vacuum water lift (open hole adapter 1”) minimum 6.3 inches

Electrical System

Battery compartment size

Width 18.25” (46.35cm)

Height 23.75” (60.32cm)

Length 38.75” (98.42cm)

Battery Weight and Dimensions

Maximum weight: 770 Amp/Hr @ 6 hrs 1875 lbs. (850.5kg) / 38.69” (98.3cm) L x 18” (45.7cm) W x 22.81” (57.9cm) H

Minimum weight: 510 Amp/Hr @ 6 hrs 1480 lbs. (635kg) / 38.05” (96.6cm) L x 15.54” (39.5cm) W x 22.81” (57.9cm) H

*Net Weight: Standard machine without options, empty solution and recovery tanks, without removable scrub brushes and battery removed.

**Gross Weight: Standard machine without options, full solution tank and empty recovery tank, with removable scrub brushes and maximum sized

battery (770AH).

SPECIFICATIONS

FORM NO. 56043126 - CR 1100, CR 1200 - 5

Height

Length

Width

FRONT VIEW

SIDE VIEW

Speciﬁ cations common to Deck Size English (Metric)

CR 1100 CR 1200

Width w/out squeegee & deck 50 inches (127cm) 50 inches (127cm)

Solution Tank Capacity 60 gal. (227) 80 gal. (303)

Recovery Tank Capacity 60 gal. (227) 80 gal. (303)

Scrubbing Rate per hour 75,700 ft2 (7,630m2) 84,500 ft2 (7,850m2)

Sweeping path w/side brooms (2) X 62 in. (158cm)

Sweeping path w/side broom (1) 51” (130cm) X

Sweeping rate per hour 134, 600 ft2 (12,500m2) 163,700 ft2 (15,210m2)

Scrub Brush quantity 3 3

Scrub Brush diameter 15” (38cm) 17” (43cm)

Scrub Brush Motor Speed 225 RPM 225 RPM

Squeegee Tool Width 51.25” (130cm) 57” (145cm)

SPECIFICATIONS

6 - FORM NO. 56043126 - CR 1100, CR 1200

MAINTENANCE

AFTER USE

1 Raise the squeegee, the scrub brushes, and the brooms.

2 Shake the dust control ﬁ lter and empty the hopper.

3 Drain and ﬂ ush the recovery tank.

4 Tip the recovery tank out and check the squeegee hose elbow below the tank for debris. DO NOT run water down the recovery tank vacuum tubes, this may

cause damage to the vacuum motors.

5 Remove and clean the squeegee tool.

6 Remove and clean the scrub brushes. Rotate the scrub brushes.

7 Wipe the machine with a damp cloth.

8 Perform all required maintenance before storage.

9 Move the machine to a clean, dry storage area.

10 Store the machine with the brooms, the squeegee and the scrub brushes in the UP position, and the tank covers open so that the tanks can air out.

REPORT ANY DEFECT OR MALFUNCTION NOTED DURING OPERATION TO AUTHORIZED SERVICE OR MAINTENANCE PERSONNEL.

MAINTENANCE SCHEDULE

Keep the machine in top condition by following the maintenance schedule closely. Maintenance intervals given are for average operating conditions.

Machines used in severe environments may require service more often.

25 150 300 Yearly

MAINTENANCE ITEM Daily Hours Hours Hours (1,000hrs)

Charge Battery X

Drain / Check / Clean Tanks & Hoses X

Check / Clean / Rotate Scrub Brushes & Pads X

Check / Clean / Adjust Squeegee X

*Check / Clean Vacuum Motor Inlet Screen Cap X

Clean Solution Filter (32) X

Check Battery Cell Water Level(s) X

Check Foot/ Parking Brake For Wear & Adjustment X

Inspect Broom Housing Skirts X

Check Hydraulic Fluid Level X

Check / Clean Hopper Dust Control Filter Using Method “A” X

Inspect Scrub Deck Skirts X

Main Broom Maintenance X

Side Broom Maintenance X

Lubrication X

Inspect Main Broom Upper & Lower Belts X

Check / Clean Hopper Dust Control Filter Using Method “B” X

Check / Clean Hopper Dust Control Filter Using Method “C” X

Replace Hydraulic Oil & Filter X

** Check Carbon Brushes X X

Have Nilﬁ sk service center inspect the wheel drive gearbox X

* DO NOT run water down the vacuum tube in the recovery tank this will damage the vacuum motors. Vacuum tube is on left side of tank with screen cap.

** Have your Nilﬁ sk Dealer check the vacuum motors carbon motor brushes once a year or after 300 operating hours, all other motors yearly or 1000 hours.

DRIVE WHEEL GEAR CASE OIL

Change the gear lube in the drive wheel gear case after the ﬁ rst 350 hours of operation (break in period).

Required oil speciﬁ cation: API GL4, SAE 80/90 weight gear oil.

Gear case oil ﬁ ll capacity is 2.8 quarts (2.7 liters). NOTE: Refer to Mechanical Repair Service Manual (56043127) for drain and ﬁ ll instructions.

LUBRICATING THE MACHINE

Every 150 hours apply light machine oil to maintain free movement of all general pivot points. Example the seat, and broom door hinges etc. Broom, squeegee

and hopper pivots use composite bearings materials and there lubrication is not required.

Grease Fitting locations:

* 1 on each steering sprocket, 6 total

* 2 on drive wheel gear case spindle

* 1 on each squeegee caster, 2 total

Lube Oil locations:

* steering chain

FORM NO. 56043126 - CR 1100, CR 1200 - 7

WARNING

For the protection of the environment; when servicing any of the machine’s lubrication ﬂ uids they must be disposed of safely in accordance with your

local environmental regulations (recycling). Examples of machine lubrication products: (Hydraulic system oil, Hydraulic system oil ﬁ lter).

HOPPER DUST CONTROL FILTER

The hopper dust control ﬁ lter must be cleaned regularly to maintain the efﬁ ciency of the vacuum system. Follow the recommended ﬁ lter service intervals for the

longest ﬁ lter life.

CAUTION!

Wear safety glasses when cleaning the ﬁ lter.

Do not puncture the paper ﬁ lter.

Clean the ﬁ lter in a well-ventilated area.

To remove the hopper dust control ﬁ lter...

1 Lift the Hopper Cover (16) on top of the hopper. Make

sure that the Hopper Cover Prop Rod (9) is in place.

2 Inspect the top of the Hopper Dust Control Filter (17)

for damage. A large amount of dust on top of the ﬁ lter

is usually caused by a hole in the ﬁ lter or a damaged

ﬁ lter gasket.

3 Turn the two hold-downs to the side (one on each

side at the front of the frame) to release the shaker

frame, then swing the Dust Filter Shaker Assembly

(18) up and latch in place with the Shaker Assembly

Latch (19).

4 Lift the Hopper Dust Control Filter (17) out of the

machine.

5 Clean the ﬁ lter using one of the methods below:

Method “A”

Vacuum loose dust from the ﬁ lter. Then gently tap

the ﬁ lter against a ﬂ at surface (with the dirty side

down) to remove loose dust and dirt. NOTE: Take

care not to damage the metal lip which extends past

the gasket.

Method “B”

Vacuum loose dust from the ﬁ lter. Then blow

compressed air (maximum pressure 100 psi) into the

clean side of the ﬁ lter (in the opposite direction of the

airﬂ ow).

Method “C”

Vacuum loose dust from the ﬁ lter. Then soak the ﬁ lter

in warm water for 15 minutes, and then rinse it under

a gentle stream of water (maximum pressure 40 psi).

Let the ﬁ lter dry completely before putting it back into

the machine.

6 Follow the instructions in reverse order to install the

ﬁ lter. If the gasket on the ﬁ lter is torn or missing, it

must be replaced.

HYDRAULIC OIL

Raise and prop (HH) the hopper. See Figure 1. The oil level should be approximately 1 inch (2.54cm) below the bottom of the Elbow (A) on the front of the reservoir

when the hopper is up (when the hopper is fully down the oil level should be up to the bottom of the elbow). If it is below this level, add 10W30 motor oil. Change

the oil if major contamination from a mechanical failure occurs. SERVICE NOTE: The Cap (B) on Elbow (A) on the side of the reservoir is for adding oil. SERVICE

NOTE: Remove Vent Plug (D) to allow oil to be ﬁ lled.

IMPORTANT!

This machine is equipped with an Indicator Light (F) which lights if the Hydraulic Oil Filter (C / Figure 1) requires changing. The

Hydraulic Filter (C / Figure 1) is found on the side of the Hydraulic Power Unit (27) as shown.

MAINTENANCE

FIGURE 1

8 - FORM NO. 56043126 - CR 1100, CR 1200

Nilfisk CR 1100/1200 B

PM Checklist Defect Codes

Customer A needs adjustment

Bbinding

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 Defect Codes

(circle)

Does

Not

Work

1 Check Neutral Sense Switch Operation. To test, sit on seat and depress the drive pedal

then turn the key switch on. The machine should not move, it should set a drive

system code.

A B C

2 Drive pedal operation, check for FWD & REV drive and any neutral return creep A

3 Seat safety switch (machine will not drive without an operator on seat) A rough

4 Drive System Performance (Reference SVR manual for Curtis drive programmer speed

changes). A low power

5 Battery compartment interlock safety switch (machine will not run with bar removed) A C

6 Steering Noisy sluggish

7 Brakes (check both service & parking) A B W

8 Hopper Up/Down (also check operation of the safety hopper support) A B

9 Hopper Dump Door Open/Close A B

10 Main Broom Raise /Lower A B

11 Side Broom Raise /Lower A B C

12 Main Broom On/Off and sweeping performance A B C

13 Side Broom On/Off and sweeping performance <----->

14 Scrub System (Raise/Lower and auto scrubbing functions and performance) <----->

15 Squeegee System (Raise/Lower, Auto Lift in Reverse and water pickup performance) A B

16 Vacuum Performance (Sealed water lift 72" and 1- inch open hole adapter 6-7 inches) C L W

17 Solution Control (On/Off and Flow Volume Min/Max) C L

18 Perform the machine self-diagnostic test. (see manual PN 56043126) <----->

19 Headlights, Gauges and (optional) accessories rotating beacon, backup alarm <----->

20 Dust control filter shaker & impeller <----->

21 Battery charger (auto turn On & Off)

22 Battery emergency disconnect knob, tilt steering mechanism and seat adjustment lever A B

Ref VISUAL INSPECTION ITEMS Comments OK Defect Codes

(circle)

Does

Not

Work

23 Side Broom Height (min bristle wear 3 inches) A B D W

24 Side Broom Motor(s) B

25 Hopper Cover Gasket D W

26 Hopper Dust Filter & Gasket C D W

27 Impeller Motor (remove cover to access motor & fan) C W

28 Hopper Dump Door Cylinder B L

29 Hopper Skirting & Seals (raise hopper to inspect) D M W

30 Hopper Dump Door & Seal (raise hopper to inspect) B D W

31 Brake Cable, Brake Shoes & Drum Wear A B W

32 Hopper Lift Cylinder & Hopper Magnetic Switch A B L

33 Main Broom Pattern Adjustment (min bristle wear 2-1/2"

6.4cm length) & Magnetic on/off broom switch 2-3" (5-7.5cm) wide

pattern A B D W

34 Main Broom Motor (open left side access door to inspect

belts) ABW

FORM NO. 56043126 - CR 1100, CR 1200 - 9

Ref VISUAL INSPECTION ITEMS (continued) Comments OK Defect Codes

(circle)

Does

Not

Work

35 Broom Housing & Door Skirts D M W

36 Battery (Load Test) Clean & Water C W

37 Circuit Breaker panel (inspect electrical connections) C D

38 Hydraulic System Hoses & fittings L

39 Hydraulic Oil Reservoir Level (10W-30 engine oil only)

Hydraulic Oil Filter (change yearly or 1,000 hrs.) Fill level (bottom of

elbow with hopper

closed)

L Add Oil

40 Steer Spindle & Drive Wheel motor (remove recovery tank)* D L

41 Rear Tire (check lug nut torque 100 FT LB, 135Nm) W

42 Drive Wheel gear case (see service manual)* Gear oil level L

43 Front & Rear Tires Tread wear W

44 Steering chain & sprockets Oil chain / grease

sprockets

45 Steering chain tension Adjust*

46 Gear case/spindle grease fittings Grease

47 Scrub Brushes, check for wear and rotate D M W

48 Scrub Deck Skirts D M W

49 Solution Solenoid Valve C

50 Solution Flow Control Valve and Linkage A B D W

51 Solution Tank, Delivery Hoses & Filter Clean filter screen C L

52 Vacuum Motor Gasket & Metal Elbow Gasket C D L

53 Vacuum Stand Pipe Deflector Clean C D M

54 Recovery Tank Cover Gasket L M W

55 Recovery Tank Drain Hose & Cap C D L

56 Squeegee Pick-Up Hose & Metal Elbow Back flush C D L

57 Squeegee Tool & Blades Clean & Rotate A D W

58 Squeegee Casters (lubricate) A D W

*See service manual 56043127.

*NOTE: For additional service information see service manuals form numbers 56043126 &

56043127.

Defect Codes A needs adjustment C dirty or contaminated M missing

B binding D damaged, bent or torn W worn out

L leaks

WORK COMPLETED BY: ACKNOWLEDGED BY:

Service Technician Signature Date Customer Signature Date

10 - FORM NO. 56043126 - CR 1100, CR 1200

1 Operator’s Seat

2 Strobe Light (optional / standard on Nilﬁ sk Models)

3 Solution Tank Fill

4 Tie Down Locations

5 Recovery Tank Drain Hose

6 Recovery Tank Latch

7 Left Battery Compartment Access Panel

8 Main Broom Left Access Door (belt/motor access)

9 Hopper Cover Prop Rod

10 Front Wheel

11 Jacking Location

12 Left Side Broom

13 Hopper Cover Latch

14 Headlights

15 Right Side Broom

16 Hopper Cover

17 Dust Control Filter

18 Dust Control Shaker Assembly

19 Shaker Assembly Latch

20 Battery

21 Battery Compartment Door

22 Steering Wheel

KNOW YOUR MACHINE

1

2

3

4

5

7

8

4

10

12

13

14

15

16

17

18

19

9

21

22

11

6

20

FORM NO. 56043126 - CR 1100, CR 1200 - 11

23 Electrical Compartment Door

24 Water Level Gauge

25 Recovery Tank Lid

26 Recovery Tank “Tip-Out” Grip

27 Hydraulic Power Unit (Reservoir & Filter)

28 Right Battery Compartment Access Panel

29 Main Broom Right Access Door (broom removal)

30 Access Door Latch

31 Skirt Assembly

32 Inline Solution Filter

33 Solution Tank Drain Hose

34 Rear Roller Bumper

35 Squeegee Tool Handle

36 Squeegee Tool Assembly

37 Tail Light

KNOW YOUR MACHINE

36 35

37

25

26

27

4

28

29

30

31

32

33

4

34

11

24

23

12 - FORM NO. 56043126 - CR 1100, CR 1200

A Low Battery Indicator

B Horn

* Horn ON Indicator

C Parking Brake Indicator (not used)

D Headlights

* Headlight ON Indicator

E Speed Controller Fault Code Status Light

F Hydraulic Filter Plugged Indicator

G Speed Switch

* Speed Switch Indicator

H Scrub Pressure Decrease Switch

* Scrub Pressure Decrease Indicator

I Scrub Pressure Increase Switch

* Scrub Pressure Increase Indicator

J Scrub Pressure Display

K Solution Switch

* Solution ON Indicator

L Solution Tank Empty Indicator

M Recovery Tank Full Indicator

N Vacuum System Switch

* Vacuum System ON Indicator

O Scrub System OFF Switch

* Scrub System Indicator

P Side Broom ON

* Side Broom ON Indicator

Q Main Broom ON Indicator

R Light Sensor

S Shaker Switch

* Shaker ON Indicator (left)

* Dust Filter Plugged Indicator (right / optional)

T Dust Control Switch

* Dust Control ON Indicator

U Side Broom UP/OFF Switch

* Side Broom OFF Indicator

V Open Dump Door Switch

* Open Dump Door Indicator

W Hopper Open Indicator

X Hopper Over-temp Indicator

Y Close Dump Door Switch

* Close Dump Door Indicator

Z Lower Hopper Switch

* Lower Hopper Indicator

AA Raise Hopper Switch

* Raise Hopper Indicator

BB Hour Meter Display

CC Main Power Switch

DD Battery Condition Indicator

CONTROL PANEL

AB

C

D

E

FG

BB

CC

DD

I

J

H

K

L

M

P

Q

R

S

V

W

X

Y

Z

AA

T

U

N

O

FORM NO. 56043126 - CR 1100, CR 1200 - 13

EE Solution Flow Control Lever

FF Main Broom Raise/Lower (ON/OFF) Lever

GG Main Broom Adjust Knob (height pattern)

HH Hopper Safety Support Lever

II Control Panel

JJ Main Broom Overload Indicator Light

KK Emergency Battery Disconnect

LL Steering Wheel Tilt Lever

MM Drive Pedal

NN Brake Pedal

OO Parking Brake Latch

PP Operator Seat Adjustment Lever

OPERATOR’S COMPARTMENT

MM

NN

FF

GG

HH II

EE

KK

LL

JJ

OO

PP

14 - FORM NO. 56043126 - CR 1100, CR 1200

1 Operator’s Seat – Operator sits here. Seat is adjustable forward and back.

2 Strobe Light (optional / standard on Nilﬁ sk models) – This light starts ﬂ ashing when the ignition switch is turned ON.

3 Solution Tank Fill – Open to ﬁ ll the solution tank, use non-foaming chemicals only. 75 gallon (284 liter) maximum capacity.

4 Tie down Locations – Safe point to tie down machine while transporting.

5 Recovery Tank Drain Hose – Used to empty the recovery tank (hold the end of the hose above the water level in the tank to avoid sudden,

uncontrolled ﬂ ow of waste water).

6 Recovery Tank Latch – Push down on latch lever to release recovery tank for “Tip-Out” feature.

7 Left Battery Compartment Access Panel – Panel lifts straight up after opening Battery Compartment Door (21) to provide access to the

battery compartment from the left side of the machine. SERVICE NOTE: Battery can only be removed from this side.

8 Main Broom Left Access Door – Open to access main broom for servicing.

9 Hopper Cover Prop Rod – Used to support the hopper cover while raised.

10 Front Wheel – Machine front wheel.

11 Jacking Location – Safe points for jacking machine up. DO NOT jack the machine on the hopper.

12 Left Side Broom – Used for sweeping along walls or curbs.

13 Hopper Cover Latch – Holds Hopper Cover (16) in place.

14 Headlights – Use when sweeping in hard to see areas.

15 Right Side Broom – Used for sweeping along walls or curbs.

16 Hopper Cover – Open to access the hopper dust control ﬁ lter.

17 Dust Control Filter – Filters dust from the air.

18 Dust Control Shaker Assembly – Vibrates the Dust Control Filter (17) to shake dust out of it.

19 Shaker Assembly Latch – Used to hold the Shaker Assembly (18) UP while servicing the ﬁ lter.

20 Battery – Provides electrical power for operating the machine.

21 Battery Compartment Door – Unlatch and open to access battery compartment.

22 Steering Wheel – Used to steer machine left or right.

23 Electrical Compartment Door – Open this door to access the main controller and solenoids. DO NOT open this door unless the Emergency

Battery Disconnect (KK) has been pushed IN.

24 Water Level Gauge – When ﬁ lling the solution tank do not exceed the maximum level.

25 Recovery Tank Lid – Open to rinse and clean inside of recovery tank.

26 Recovery Tank “Tip-Out” Grip – Grab and pull here after unlatching to tip the recovery tank out to the side for cleaning.

27 Hydraulic Power Unit (Reservoir / Filter) – Holds the hydraulic system oil, 1.7 quart (1.6 liter) capacity. SERVICE NOTE: Open and prop

the hopper to add oil. Hydraulic return oil ﬁ lter on side of the unit ﬁ lters oil after ﬂ owing through system and prior to returning to reservoir.

28 Right Battery Compartment Access Panel – Panel lifts straight up after opening Battery Compartment Door (21) to provide access to the

battery compartment from the Right side of the machine.

29 Main Broom Right Access Door – Open to access main broom for servicing.

30 Access Door Latch – Push UP on lever to unlatch (Recovery Tank utilizes same latch for “Tip-Out” feature).

31 Skirt Assembly – Scrub system has left and right skirt assemblies to channel solution on ﬂ oor into the path of the squeegee assembly.

32 Inline Solution Filter – Filters solution prior to dispensing on ﬂ oor.

33 Solution Tank Drain Hose – Used to empty the solution tank.

34 Rear Roller Bumper – Protects both machine and other objects in the event the machine brushes up against anything.

35 Squeegee Handle – Loosen these two handles to remove the squeegee assembly from the machine.

36 Squeegee Assembly – Picks up solution after scrubbing.

37 Tail Light – Turns ON with headlights.

KNOW YOUR MACHINE DESCRIPTIONS

FORM NO. 56043126 - CR 1100, CR 1200 - 15

A Low Battery Indicator – This indicator will ﬂ ash when the battery requires charging.

B Horn Switch – This switch will sound the horn as long as the switch is held.

* Horn Indicator: Lights up when the horn switch is pressed.

C Parking Brake Indicator – This indicator is currently not used.

D Headlight Switch – Turns the headlights and taillights ON or OFF.

* Headlight ON Indicator: Lights up when the lights are ON. It is OFF when the lights are OFF.

E Speed Controller Fault Code Status Light – This light will ﬂ ash on and off identifying a speed controller fault. Note: Refer to troubleshooting chart in this manual for

explanation.

F Hydraulic Filter Plugged Indicator – Indicates when the hydraulic oil ﬁ lter should be serviced. Have your Nilﬁ sk Service Center check the machine. SERVICE NOTE:

This light may give a FALSE indication when the hydraulic oil is cold.

G Speed Select Switch – This switch will allow the operator to select the transport speed limit while the scrub system is enabled thereby allowing scrubbing at a higher

rate of speed. This option can be disabled if desired. See the programming section for details.

The transport and scrub speed limits can be programmed using a Curtis handheld programmer. Refer to the electrical section in this manual for details.

* Speed Select Switch Indicator: This indicator will be green if a scrub mode has been selected and the faster scrub speed has been selected. This indicator will be off

if the Speed Select Switch has been turned OFF.

SCRUB SYSTEM

H Scrub Pressure Decrease Switch – 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 lightest 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

• As soon as the drive pedal 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 ﬂ ow

will start. If the direction is reverse, the squeegee will raise and the solution ﬂ ow will be stopped. The scrub brushes will turn off after an adjustable delay once the drive

pedal returns to neutral. See the programming section for details.

If the scrub system is already enabled when this switch is pressed and the scrub pressure is at 2 or 3, the scrub pressure will decrease. If the switch is held, the pressure

will decrement until the minimum setting of 1 is reached.

* Scrub Pressure Decrease Indicator: The scrub pressure decrease indicator will be lit if the scrub system is enabled and the pressure is set at 1 or 2. The indicator

will be off if the scrub system is off or if the scrub pressure is set to 3.

I Scrub Pressure Increase Switch – 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 lightest 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

• 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 ﬂ ow will

start. If the direction is reverse, the squeegee will raise and the solution ﬂ ow will be stopped. The scrub brushes will turn off after an adjustable delay once the drive

pedal returns to neutral. See the programming section for details.

If the scrub system is already enabled when this switch is pressed and the scrub pressure is at 1 or 2, the scrub pressure will increase. If the switch is held, the pressure

will increment until the maximum setting of 3 is reached.

* Scrub Pressure Increase Indicator: The scrub pressure increase indicator will be lit if the scrub system is on and the pressure is set at 2 or 3. The indicator will be off

if the scrub system is off or if the scrub pressure is set to 1.

J Scrub Pressure Display:

The single character display on the control panel is used as a display for the scrub pressure. If the scrub system is ON, the display will indicate the relative pressure

setting of 1, 2 or 3 otherwise it is blank. Note: This display is also used to show error codes see the main controller A1 self diagnostic test mode found in this manual

for a complete explanation.

K Solution Switch - This switch is used to turn the solution system on or off. Pressing this switch when the scrub system has been activated will alternate between on and

off. The solution ﬂ ow will only turn on when the drive pedal is moved from the neutral position in the forward direction. The solution ﬂ ow will turn off if the drive pedal

returns to neutral or is moved to reverse. Pressing this switch when the scrub system is off will momentarily turn the solution ﬂ ow on to allow pre-wetting of the scrub

brushes.

* Solution System Indicator: The solution indicator will be lit if the solution is enabled. If the solution is off, this indicator will be OFF.

L Solution Tank Empty Indicator – This indicator will illuminate when the solution tank is low.

M Recovery Tank FULL Indicator – This indicator will ﬂ ash when the recovery tank is FULL. The vacuum system is shut OFF at this point. Draining the recovery tank

will reset this indicator.

N Vacuum System Switch – This switch is used to turn the vacuum system on or off. When the vacuum is on the squeegee will lower (unless the machine is in reverse)

and when the vacuum is off the squeegee will rise. Pressing this switch will alternate between on and off. The vacuum will only turn on when the drive pedal is moved

from the neutral position. It will remain on for 10 seconds after the drive pedal returns to neutral.

The vacuum also has an automatic shutoff feature that will turn the vacuum and scrub systems off if the recovery tank becomes full. If this occurs, the recovery tank full

indicator (M) will ﬂ ash. The vacuum shutoff delay is adjustable. See the programming section for details.

* Vacuum System Indicator: The vacuum indicator will be lit if the vacuum is enabled. It will ﬂ ash if the vacuum is in the delayed-off condition. If the vacuum is off, this

indicator will be off.

O Scrub System OFF Switch - Pressing this switch when the unit is in a scrub mode will cause the following to occur:

• The scrub brushes will turn off

• The scrub deck will raise to the UP position

• The solution ﬂ ow will be stopped

• The ﬁ rst time that this button is pressed, the vacuum/squeegee system will NOT be turned off. This is so that any remaining water may be picked up without having to

turn the vacuum back on. If this button is pressed a second time (pressed after the scrub mode has been turned off) the squeegee will raise and the vacuum will shut

off after a 10 second delay.

* Scrub System OFF Indicator: This indicator will be lit if the scrub system is OFF. This indicator will be OFF if the scrub system is enabled or running.

CONTROL PANEL DESCRIPTIONS

16 - FORM NO. 56043126 - CR 1100, CR 1200

SWEEP SYSTEM

P Side Broom DOWN/ON Switch – This switch is used to lower and/or turn the side broom(s) on. The side broom(s) will lower whenever this

switch is pressed until the bottom limit is reached. The side broom(s) will turn on when the drive pedal is moved from the neutral position. They

will remain on for approximately 5 seconds after the drive pedal returns to neutral. This shutoff period is adjustable. See the service manual for

details.

* Side Broom ON Indicator:

• This indicator will be lit if the side broom(s) are turned ON.

Q Main Broom ON Indicator: This indicator will be lit if the main broom is down, otherwise it is OFF.

R Light Sensor – Not currently used.

S Shaker Switch – This switch controls the hopper dust control ﬁ lter shaker. Pressing this button will cause the dust control to turn off and the

shaker to turn on. The shaker will run for approximately 20 seconds. This period is adjustable. See the service manual for details. Pressing

the switch while the shaker is operating will cancel the timer and turn the shaker off. If the dust control was previously on, it will turn back on.

* Shaker Indicator (left): This indicator will be lit if the shaker is turned ON, otherwise it is OFF.

* Dust Filter Plugged Indicator (right / optional): This indicator will be lit if the dust ﬁ lter requires cleaning, otherwise it is OFF. NOTE:

Requires optional Hopper Filter Switch Kit.

T Dust Control Switch – This switch controls the hopper dust control. Pressing this switch alternates between on and off. The dust control will

run when the drive pedal is moved from the neutral position. The dust control will remain on for approximately 5 seconds after the drive pedal

returns to neutral. This shutoff period is adjustable. See the service manual for details.

* Dust Control Indicator: This indicator will be green if the dust control system is ON, otherwise it is OFF.

U Side Broom UP/OFF Switch – This switch is used to raise and/or turn the side broom(s) off. The side broom(s) will rise whenever this switch

is pressed until the upper limit is reached. When the upper limit is reached, the side broom(s) will turn off.

* Side Broom OFF Indicator: This indicator will be lit if the side broom(s) are turned OFF.

HOPPER SYSTEM

V Open Dump Door Switch – This switch is used to open the hopper dump door. This switch will only function when the main broom is down or

when the hopper is raised. NOTE: The dump door will automatically open when the hopper is fully down and the main broom is lowered.

* Open Dump Door Indicator: This indicator will be lit while the dump door is in the process of opening, otherwise it is OFF.

W Hopper Open Indicator: This indicator ﬂ ashes if the hopper is open, otherwise it is OFF.

X Hopper Overtemp Indicator – This indicator will ﬂ ash when the hopper temperature exceeds 140 degrees Fahrenheit. NOTE: the hopper

temperature switch is optional.

Y Close Dump Door Switch – This switch is used to close the hopper dump door. This switch will only function when the main broom is up or

when the hopper is raised. NOTE: The dump door will automatically close when the main broom is raised or when the hopper is raised.

* Close Dump Door Indicator: This indicator will be lit while the dump door is in the process of closing, otherwise it is OFF.

Z Lower Hopper Switch – This switch is used to lower the hopper. The hopper will drop as long as this switch is held. Once the hopper is in the

full-down position, the Hopper Open Indicator (W) will turn off. If any of the sweep or scrub functions were on when the hopper was raised, they

will be reactivated. The dump door will automatically open or close depending on whether the main broom is down or up. The switch indicator

will be lit as long as the switch is held.

* Lower Hopper Indicator: This indicator will be lit while the hopper is in the process of lowering, otherwise it is OFF.

AA Raise Hopper Switch – This switch is used to raise the hopper. Pressing this switch will cause the following to occur:

• The switch indicator will illuminate

• If the dump door is open (main broom down) the door will close

• The main broom, side brooms, scrub system, solution, and vacuum will all turn off

• If the dust control was on, it will remain on unless programmed otherwise

• Once the dump door is closed, the hopper will begin to raise

• The hopper will continue to raise as long as this switch is held

Once the hopper is no longer in the full-down position, the Hopper Open Indicator (W) will ﬂ ash. The dump door open and close switches will

now be functional

* Raise Hopper Indicator: This indicator will be lit while the hopper is in the process of raising, otherwise it is OFF.

BB Hour meter / Error Code Display – Upon power up or if the machine has been idle for at least ten seconds with all systems turned off, the

hour meter will display the hours for each major electric motor system for 3 seconds and continue to cycle through each system as long as the

drive pedal is in neutral and all systems are OFF. Once the drive pedal is pressed or any system activated it will indicate the drive system hours

(default). If an overload fault occurs, the display will indicate the associated error code immediately.

CONTROL PANEL DESCRIPTIONS

FORM NO. 56043126 - CR 1100, CR 1200 - 17

CC Main Power / Key Switch – Main Power Switch.

DD Battery Condition Indicator - The battery condition indicator consists of three lights, a green (G), a yellow (Y), and a red (R). The voltage

indication will change based on the cutoff level (standard or alternate) selected in the control unit. The battery voltage ranges for the various

indications are listed below:

Standard

Green 34.00

Green & Yellow 33.00-33.99

Yellow 32.00-32.99

Yellow & Red 31.50-31.99

Red 31.00-31.49

Flashing Red/Cutoff <31.00

NOTE: Refer to service manual for selection of alternate cut-off level. Once the low voltage cutout level has been reached (ﬂ ashing red indicator)

the battery must be FULLY recharged to reset the battery condition indicator. The scrub system will not function until the indicator has been reset.

COCKPIT

EE Solution Flow Control Lever – Move this lever FORWARD to increase solution ﬂ ow to the ﬂ oor. Move BACKWARD to decrease the amount of

solution ﬂ ow to the ﬂ oor. When the Drive Pedal (OO) is released from either forward or reverse travel, the solution ﬂ ow will stop automatically,

and resume when the drive is engaged. Solution ﬂ ows in forward only, stops in reverse.

FF Main Broom Raise/Lower (ON/OFF) Lever – This lever primarily controls the main broom. It can also control the side brooms and dust control

if desired. Lowering this lever will cause the following to occur:

• The main broom indicator will illuminate

• The main broom will be lowered to the operating position

• The side brooms will be lowered to the operating position

• The dust control will be enabled

• The hopper dump door will open

As soon as the drive pedal is moved from the neutral position the main broom and side brooms will start turning and the dust control will turn

on. The brooms and dust control will remain on for approximately 5 seconds after the drive pedal returns to neutral. This shutoff period is

adjustable. See the service manual for details.

Raising the main broom lever will cause the following to occur:

• The main broom indicator will turn off

• The main broom will be raised to the off position

• The side brooms will be raised and will turn off

• The dust control will turn off

• The hopper dump door will close

The side brooms and dust control can be programmed not to automatically come on with the main broom. See the service manual for details

GG Main Broom Adjust Knob – Used to compensate for main broom wear in order to maintain a 3 inch (7.62cm) wide broom pattern.

HH Hopper Safety Support Lever – NEVER work under a raised hopper without the safety support engaged. To engage; raise the hopper all the

way UP, pull back on lever and then lower hopper until it seats.

II Control Panel – See items A through DD.

JJ Main Broom Overload Indicator Light – This indicator will be lit if the main broom pressure is too high. The main broom will shut off if

overloaded for an extended period of time.

KK Emergency Battery Disconnect – Push in on knob to disconnect battery.

LL Steering Wheel Tilt Lever – Pull lever out to release steering column for adjusting up or down.

MM Drive Pedal – Controls the machine’s travel speed and direction:

Push down on the Back of the pedal to move the machine Backward.

Push down on the Front of the pedal to move the machine Forward.

The SPEED of the machine will increase as the pedal is pushed closer to the ﬂ oor. Maximum forward speed is faster than maximum reverse

speed.

NN Brake Pedal – Operates the mechanical brakes on the front wheels.

OO Parking Brake Latch – Used to “lock” the brake pedal in place after engaging the brakes. NEVER leave machine unattended without setting

Parking Brake. Press on this latch with your foot instead of the brake pedal to activate.

PP Operator Seat Adjustment Lever - Use this lever to slide the operator’s seat forward or backward.

CONTROL PANEL DESCRIPTIONS

18 - FORM NO. 56043126 - CR 1100, CR 1200

IMPORTANT SERVICE TIP

Before any troubleshooting is done perform this troubleshooting special control system procedure.

MAIN CONTROLLER (A1) SELF-DIAGNOSTIC TEST MODE

If problems with the main electronic control system are suspected, this self-diagnostic mode may help isolate the problem. When this mode is

activated, the control unit will activate each one of the outputs in sequence and test for short circuits, open circuits, or overload conditions. This

mode will also provide an easy test for the touch panel switches and indicators.

If an abnormal condition is encountered with one of the outputs, an error code will be displayed on the Scrub Pressure Display (J) see Figure 2.

1 During this test, the horn will sound brieﬂ y and the scrub deck and squeegee will move if they are in the up position. If the hopper is not in the

down position it will also move slightly.

CAUTION!

Make sure that all persons are away from these parts of the machine to prevent injury.

2 Turn the main power key switch to the off position.

3 Press and hold the side broom down/on switch.

4 While holding the side broom down/on switch, turn the main power key switch to the on position.

5 Continue to hold the side broom down/on switch until all indicators except the side broom down/on indicator turn off (approximately two

seconds).

6 Release the side broom down/on switch.

7 The control will now activate each output in sequence and perform the tests mentioned above.

8 If no abnormal conditions are detected, the display will now show “-”. Go to step 10.

9 If abnormal output conditions were detected, the display will now show the error code(s), see “Main Control Error Code Display Descriptions

Table”. An example of how two codes, 6 and 18, would be displayed is as follows:

• The display will show “E” followed by a brief blank period

• The display will show “0” followed by a brief blank period

• The display will show “6” followed by a slightly longer blank period

• The display will show “E” followed by a brief blank period

• The display will show “1” followed by a brief blank period

• The display will show “8” followed by a long blank period

• The above sequence will repeat

10 To test any of the control panel switches, press the desired switch. The indicator for that switch should illuminate. If not, consult the general

machine troubleshooting section of this manual which will show machine system ﬂ ow charts.

11 The hopper limit, main broom, recovery tank full, and solution tank empty switches may also be tested in this mode. The corresponding

indicators will indicate the state of each of the inputs.

12 To exit this mode, turn the main power key switch to the off position.

NOTE: If the machine is not equipped with an optional back-up alarm, an error code 59 will be indicated.

KNOW YOUR MACHINE

FIGURE 2

J

Page is loading ...

Nilfisk-Advance CR 1100 Quick Start Troubleshooting Manual

Nilfisk-Advance CR 1100 Quick Start Troubleshooting Manual

Related papers

Other documents