Nilfisk-Advance Cr 1100 User manual

CR 1100, CR 1200
QUICK START TROUBLESHOOTING
SERVICE MANUAL
1/09 revised 9/09
FORM NO. 56043126
Printed in USA
Nilfisk 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 Nilfisk 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 Nilfisk Service Center, who employs factory trained service personnel, and
maintains an inventory of Nilfisk 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, affix 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 Nilfisk 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
Nilfisk 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
Specific 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, flame 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
flame. 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 flammable cleaning agents, operate the machine on or near these agents, or operate in areas where flammable
liquids exist.
•Do not clean this machine with a pressure washer.
CAUTION!
•This machine is not approved for use on public paths or roads.
•This machine is not suitable for 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 first 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 fittings. Flush with windshield washer fluid.
•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 Specifications 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 fill 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
Specifications 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
1Raise the squeegee, the scrub brushes, and the brooms.
2Shake the dust control filter and empty the hopper.
3Drain and flush the recovery tank.
4Tip 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.
5Remove and clean the squeegee tool.
6Remove and clean the scrub brushes. Rotate the scrub brushes.
7Wipe the machine with a damp cloth.
8Perform all required maintenance before storage.
9Move 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 Nilfisk 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 Nilfisk 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 first 350 hours of operation (break in period).
Required oil specification: API GL4, SAE 80/90 weight gear oil.
Gear case oil fill capacity is 2.8 quarts (2.7 liters). NOTE: Refer to Mechanical Repair Service Manual (56043127) for drain and fill 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 fluids 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 filter).
HOPPER DUST CONTROL FILTER
The hopper dust control filter must be cleaned regularly to maintain the efficiency of the vacuum system. Follow the recommended filter service intervals for the
longest filter life.
CAUTION!
Wear safety glasses when cleaning the filter.
Do not puncture the paper filter.
Clean the filter in a well-ventilated area.
To remove the hopper dust control filter...
1Lift the Hopper Cover (16) on top of the hopper. Make
sure that the Hopper Cover Prop Rod (9) is in place.
2Inspect the top of the Hopper Dust Control Filter (17)
for damage. A large amount of dust on top of the filter
is usually caused by a hole in the filter or a damaged
filter gasket.
3Turn 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).
4Lift the Hopper Dust Control Filter (17) out of the
machine.
5 Clean the filter using one of the methods below:
Method “A”
Vacuum loose dust from the filter. Then gently tap
the filter against a flat 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 filter. Then blow
compressed air (maximum pressure 100 psi) into the
clean side of the filter (in the opposite direction of the
airflow).
Method “C”
Vacuum loose dust from the filter. Then soak the filter
in warm water for 15 minutes, and then rinse it under
a gentle stream of water (maximum pressure 40 psi).
Let the filter dry completely before putting it back into
the machine.
6Follow the instructions in reverse order to install the
filter. If the gasket on the filter 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 filled.
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
Copyright 2004 Nilfisk-Advance. Page 1 of 2 6/11/2004
Nilfisk CR 1100/1200 B
PM Checklist Defect Codes
Customer A needs adjustment
Bbinding
Address C dirty or contaminated
Ddamaged, bent or torn
City St Zip Lleaks
Mmissing
Model Serial Hours Wworn 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