Related Manuals for Nilfisk-Advance 56303004
Summary of Contents for Nilfisk-Advance 56303004
- Page 1 CR 1100, CR 1200 MECHANICAL REPAIR SERVICE MANUAL Nilfisk MODELS: 56303004 (CR 1200), 56303005 (CR 1100 / OBS) 1/09 Revised 6/12 FORM NO. 56043127 Printed in USA...
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Page 2: Table Of Contents
TABLE OF CONTENTS GENERAL INFORMATION ..............................1-2 SAFETY INSTRUCTIONS ..............................3 KNOW YOUR MACHINE ..............................4-7 STEERING SYSTEM .................................8-9 STEERING WHEEL REMOVAL ............................8 POWER STEERING UNIT REMOVAL..........................8 STEERING CHAIN ADJUSTMENT............................. 9 STEERING CHAIN REMOVAL ............................9 WHEEL DRIVE SYSTEM ...............................10-13 DRIVE TIRE REMOVAL .............................. -
Page 3: General Information
GENERAL INFORMATION ELECTRICAL SYSTEM ..............................40-45 ACTUATOR DRIVE NUT ADJUSTMENT.......................... 40 ELECTRICAL COMPONENT LOCATION......................... 41 WIRING LADDER DIAGRAM (BEFORE SN 1767238) ....................42 WIRING SCHEMATIC (BEFORE SN 1767238)........................ 43 WIRING LADDER DIAGRAM (AFTER SN 1767237) ....................... 44 WIRING SCHEMATIC (AFTER SN 1767237)........................45 Note: All references to right, left, front, or rear in this manual are as seen from the operator’s stand-point. - Page 4 GENERAL INFORMATION 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.
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Page 5: Safety Instructions
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. -
Page 6: Know Your Machine
KNOW YOUR MACHINE Operator’s Seat 12 Left Side Broom Strobe Light 13 Hopper Cover Latch Solution Tank Fill 14 Headlights Tie Down Locations 15 Right Side Broom Recovery Tank Drain Hose 16 Hopper Cover Recovery Tank Latch 17 Dust Control Filter Left Battery Compartment Access Panel 18 Dust Control Shaker Assembly Main Broom Left Access Door (belt/motor access) - Page 7 KNOW YOUR MACHINE 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...
- Page 8 CONTROL PANEL Low Battery Indicator Side Broom ON Horn Side Broom ON Indicator Horn ON Indicator Main Broom ON Indicator Parking Brake Indicator (not used) Light Sensor Headlights Shaker Switch Headlight ON Indicator Shaker ON Indicator (left) Speed Controller Fault Code Status Light Dust Filter Plugged Indicator (right / optional) Hydraulic Filter Plugged Indicator Dust Control Switch...
- Page 9 OPERATOR’S COMPARTMENT 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 Control Panel Main Broom Overload Indicator Light KK Emergency Battery Disconnect LL Steering Wheel Tilt Lever MM Drive Pedal NN Brake Pedal OO Parking Brake Latch...
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Page 10: Steering System
STEERING SYSTEM STEERING WHEEL REMOVAL See Figure 1.1. Pry up steering wheel Cap (A). Remove center hex Nut (B). Note: This is a metric nut, you will need a 24mm socket. Use a steering wheel puller to remove steering wheel from splined shaft. Note: It may be necessary to enlarge holes in steering wheel, also be sure to support the metal splined bushing in the center of the steering wheel (see Figure 1.2) when pulling the wheel. -
Page 11: Steering Chain Adjustment
STEERING SYSTEM FIGURE 1.3 Mid-point chain tension STEERING CHAIN ADJUSTMENT Turn the Key Switch (Main Power) (CC) to the OFF position, set the Parking Brake (OO) and disconnect the batteries. See Figure 1.3. Remove the (4) steering shaft cover screws and (6) (J) Floor Plate (Chain Cover) screws then remove both covers together. Loosen the 4 (K) Bolts that secure the chain idler sprockets assembly to the floor. -
Page 12: Wheel Drive System
WHEEL DRIVE SYSTEM FIGURE 2.1 DRIVE TIRE REMOVAL WARNING! Never work under a machine without safety block or stands to support machine. Disconnect battery before servicing. Turn steering wheel to the right full lock position and also remove the squeegee tool. Disconnect the battery pack, set parking brake and block front wheels. -
Page 13: Gearbox Removal
WHEEL DRIVE SYSTEM GEARBOX REMOVAL Follow the steps of the Wheel Drive Motor Removal section. Drain the gearbox oil see Gearbox Drain and Fill instructions. See Figure 1.3. Remove the (4) steering shaft cover screws and (6) (J) Floor Plate (Chain Cover) screws then remove both covers together. Loosen the 4 (K) Bolts that secure the chain idler sprockets assembly to the floor. -
Page 14: Rotary Sensor (Directional Pot Setting)
WHEEL DRIVE SYSTEM ROTARY SENSOR (DIRECTIONAL POT SETTING) Open the rear electrical control panel door to access the Curtis Speed Control. Disconnect the 24 pin plug from the controller. With a Volt / Ohmmeter check the resistance of the rotary sensor at the plug wires WHT/BLK pin14 and VIO/BLK pin 13. Divide the measured resistance in half to find the neutral setting (dead-band). -
Page 15: Drive Pedal Pivot Neutral Adjustment
WHEEL DRIVE SYSTEM DRIVE PEDAL PIVOT NEUTRAL ADJUSTMENT If the drive pedal pivot has been removed or replaced, the neutral position for the pedal will have to be set. Follow the steps below to accomplish this. WARNING! Disconnect the machine’s battery pack connector (13) before servicing. Note: See Figures 2.3 &... -
Page 16: Front Wheel System
FRONT WHEEL SYSTEM FRONT WHEEL REMOVAL AND BRAKE INSPECTION Raise hopper and engage safety support. Open broom-housing door (LH or RT) and remove the top gasket seal (so not to damage). Place jack towards front of housing and jack on machine frame to where the front wheel clears the floor. - Page 17 FRONT WHEEL SYSTEM FIGURE 3.1 FRONT 5/8 - 3/4" (15-19 mm) FORM NO. 56043127 - CR 1100, CR 1200 - 15...
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Page 18: Hydraulic System
HYDRAULIC SYSTEM HYDRAULIC PUMP MOTOR REMOVAL CAUTION! FIGURE 4.1 Disconnect the battery before servicing. Remove right side battery panel. See Figure 4.2. Remove the top right side Cosmetic Cover (A) and pump assembly Rubber Cover (B). See Figure 4.1. Remove the two hex head Screws (C) fastening the Pump Solenoid (D) to the motor frame. -
Page 19: Hydraulic Pump Removal
HYDRAULIC SYSTEM HYDRAULIC PUMP REMOVAL (WHEN HOPPER CAN BE RAISED WITH THE PUMP OR EXTERNAL MEANS) Note: If raising the hopper without the pump operating you must have the key on and hopper up switch activated while raising the hopper. This will allow movement of the hopper cylinder by returning the oil back to the reservoir. - Page 20 HYDRAULIC SYSTEM FIGURE 4.3 Hopper Lift Dump Door 18 - FORM NO. 56043127 - CR 1100, CR 1200...
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Page 21: Sweeping System
SWEEPING SYSTEM MAIN BROOM MAINTENANCE Since the Main Broom Motor always turns in the same direction, the bristles on the broom eventually become curved, reducing sweeping performance. Sweeping performance can be improved by removing the broom and turning it around (end-for-end). This procedure, known as “rotating” the main broom, should be done once every 30 hours of operation. -
Page 22: Broom Lever Switch S8 Replacement And Adjustment
SWEEPING SYSTEM BROOM LEVER SWITCH S8 REPLACEMENT AND ADJUSTMENT Drain, unlatch and swing open the recovery tank to locate the switch access panel. Remove the (4) screws from the access panel near the location of the broom lever. Remove the two wire connectors from the broom switch (S8) and then remove the screw and nut that fasten it to the chassis. Install new switch but leave the mounting screws loose. -
Page 23: Main Sweeping Broom Motor Removal
SWEEPING SYSTEM MAIN SWEEPING BROOM MOTOR REMOVAL WARNING! Disconnect the battery Pack using the emergency disconnect knob (KK) before servicing. Drain and remove the recovery tank then remove the top broom motor frame access cover fastened with two screws. Follow the instructions in this manual section for the removal of the main broom belt. It must be removed first to access the inner broom motor belts. -
Page 24: Main Broom Motor Belt Removal
SWEEPING SYSTEM MAIN BROOM MOTOR BELT REMOVAL Remove the left side scrub brush skirt assembly and then lower the scrub deck. Drain the Vacuum recovery tank and remove the tank from the machine. Then disconnect the battery. Follow the Main Broom Drive Belt Replacement instructions in this manual section. They must be removed first to access the inner broom motor belts. -
Page 25: Side Broom Motor Removal
SWEEPING SYSTEM SIDE BROOM MOTOR REMOVAL Lower the side broom(s). Note: The main broom must be first lowered to allow the side brooms to be lowered. Raise hopper to a comfortable work position (eye level). Then remove the side broom and disconnect the motor connector to the motor that needs to be serviced. -
Page 26: Side Broom Lift Actuator Motor Replacement
SWEEPING SYSTEM SIDE BROOM LIFT ACTUATOR MOTOR REPLACEMENT Removal Place the side brooms in the lowered position if possible or blocking underneath the brooms to remove weight from the lift linkage. Open hopper cover, set cover prop rod, remove hopper filter, and latch filter rack. Then remove the hopper access panel held in-place by (11) Philips head screws. -
Page 27: Main Broom Lift Cable Replacement
SWEEPING SYSTEM MAIN BROOM LIFT CABLE REPLACEMENT Drain the recovery tank then remove the tank completely from the machine by disconnecting its support strap and wiring connector. This is done to access the broom cable and solution cable inspection cover. Remove the inspection cover held in place by (4) screws. -
Page 28: Hopper System
HOPPER SYSTEM SEALS AND SKIRTS IDENTIFICATION AND REPLACEMENT To access: Hopper should be empty. Raise and support the hopper, open the dump door. WARNING! Do not have engine running when working under hopper. Description Blade Hopper Boot Dust Shield Blade Dump Door Wiper Seal Horizontal Hopper Door Blade... -
Page 29: Dump Door Cylinder Removal
HOPPER SYSTEM FIGURE 6.2 FRONT DUMP DOOR CYLINDER REMOVAL To access: Raise Hopper Cover and engage hopper cover prop rod. See Figure 6.2. Raise and support Shaker Assembly (H). Remove filter assembly. Remove (11) Bolts (I) and remove Access Panel (J). To remove cylinder: Remove the two hoses from Door Cylinder (K). -
Page 30: Hopper Lift Cylinder Removal
HOPPER SYSTEM HOPPER LIFT CYLINDER REMOVAL Note: To remove the cylinder it is necessary for the hopper to be in the raised position. If the cylinder will not raise under its own power it will be necessary to press and hold the hopper raise switch with the key switch on and raise the hopper with an overhead hoist or some other alternate method. -
Page 31: Impeller Motor Removal
HOPPER SYSTEM FIGURE 6.4 IMPELLER MOTOR REMOVAL WARNING! Remove key and disconnect battery before servicing impeller. Raise and support hopper cover. See Figure 6.4. Raise and support shaker assembly and remove Filter (Q). Remove 11 bolts from access cover and remove cover. Disconnect the 2 wires at the Impeller Motor. -
Page 32: Solution System
SOLUTION SYSTEM SOLUTION TANK REMOVAL Drain both the solution and recovery tanks using the tanks’ drain hoses, then lower the scrub deck then disconnect the battery pack. See Figure 7.1. Remove the Fuse Access Panel (A) and disconnect the solution float wire harness connector. Remove the Operator’s seat by removing the 6 (B) Screws and 2 (C) Nuts from the Seat Mount Plate and disconnect the Seat Switch Wires. - Page 33 SOLUTION SYSTEM FIGURE 7.1 FRONT FORM NO. 56043127 - CR 1100, CR 1200 - 31...
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Page 34: Scrub System
SCRUB SYSTEM SCRUB DECK ASSEMBLY REMOVAL Remove both scrub deck side skirts and Squeegee assembly. Then lower the scrub deck and leave the scrub brushes on so that the deck can slide easily to remove. See Figure 8.2. Remove the scrub deck lift cylinder Clevis Pin (A) and Hair Pin (B) from its deck mount. Service Note: Then raise the scrub deck to retract (shorten) deck cylinder to allow needed clearance so the cylinder rod clears the deck-mounting pocket. - Page 35 SCRUB SYSTEM FIGURE 8.2 Orientation of actuator for 43" deck to Center Brush to Left Brush FRONT to Right Brush Rotation Rotation Rotation FORM NO. 56043127 - CR 1100, CR 1200 - 33...
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Page 36: Recovery System
RECOVERY SYSTEM TROUBLESHOOTING GUIDE If water flows around the ends of the squeegee tool, instead of being pulled into the tool, the vacuum system is not working properly. When a vacuum system performs poorly, it is usually because of one of the following problems: Vacuum Leak(s) –... -
Page 37: Vacuum Motor Replacement
RECOVERY SYSTEM VACUUM MOTOR REPLACEMENT Remove recovery tank; following the steps in Recovery Tank Removal section. See Figure 9.2. Remove the (3) item (A) Hex Screws. Disconnect the vacuum motor plug. Remove the vacuum motor(s) (B). Reassemble the vacuum motor(s) in reverse order following the steps above and check for proper fan operation. NOTE: Vacuum motors will not operate if the recovery tank sense switch (NC) is not connected to the main harness. -
Page 38: Squeegee System
SQUEEGEE SYSTEM SQUEEGEE MAINTENANCE After each use, clean the squeegee tool and check the blades for damage. If the squeegee leaves water in the middle of its path or at both ends of its path, it probably needs to be adjusted. Reverse or replace the blades if they are cut, torn, wavy or worn. To adjust the squeegee: Park the machine on a level floor, lower the squeegee and drive forward a short distance. - Page 39 SQUEEGEE SYSTEM FIGURE 10.1 7.5" (19cm) 7.5" (19cm) FRONT FORM NO. 56043127 - CR 1100, CR 1200 - 37...
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Page 40: Removal Of Squeegee Mount Assembly
SQUEEGEE SYSTEM REMOVAL OF SQUEEGEE MOUNT ASSEMBLY Lower the squeegee mount. See Figure 10.2. Disconnect the lower lift Motor pin (I). Remove the squeegee tool from its mount to allow the needed clearance in removing the mount assembly. Remove the (4) Parallel Arms (J) (two per side) from the squeegee mount Towers (K) as shown. Then remove the Mount Assembly (L) from underneath the machine. - Page 41 SQUEEGEE SYSTEM FIGURE 10.2 FORM NO. 56043127 - CR 1100, CR 1200 - 39...
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Page 42: Electrical System
ELECTRICAL SYSTEM ACTUATOR DRIVE NUT ADJUSTMENT This manual section explains the steps for adjusting the drive nut (housing assembly) setting for the machine’s two adjustable actuator motors. Reference the chart below to find the IN & OUT dimensional specification for the specific actuator motor needing adjustment. Part # Actuator Motor Drive Nut IN position... -
Page 43: Electrical Component Location
ELECTRICAL SYSTEM COMPONENT LOCATION Item Description Control Box Assembly Switch/Display Panel Assembly Curtis 1244 Speed Controller Capacitor, 180 MFD Circuit Breaker, 25 Amp (Auxiliary Circuit 1) Circuit Breaker, 5 Amp (Auxiliary Circuit 2) Circuit Breaker, 20 Amp (Auxiliary Circuit 3) Circuit Breaker, 15 Amp (Dust Control) Circuit Breaker, 20 Amp (Side Brooms) Circuit Breaker, 70 Amp (Hydraulic Pump)) -
Page 44: Wiring Ladder Diagram (Before Sn 1767238)
WIRING DIAGRAM (before SN 1767238) ELECTRICAL SYSTEM Item Description Battery, 36 Vdc CONTROL BOX ASSEMBLY SWITCH/DISPLAY PANEL ASSEMBLY CURTIS 1244 SPEED CONTROLLER CURTIS 1244 SPEED CONTROLLER Fuse, 400 A. BATTERY 36VDC YEL/BRN BRN/RED Lamp, Trouble CAPACITOR, 180 MFD YEL/BRN WHT/BLK Reverse Forward J1-22... -
Page 45: Wiring Schematic (Before Sn 1767238)
WIRING SCHEMATIC (before SN 1767238) ELECTRICAL SYSTEM SP23 SP24 FUSES BLK 18-12 F10: MAIN VIO 16-17 F11: BRUSH MOTORS SWITCH, KEY LAMP, FLASHING SWITCH, MAIN BROOM X49 X50 YEL/BRN 18-4 LAMP, BROOM OVERLOAD FUSE, 400 A. RED 6-1 RED 3/0-1 RED 1-1 ORN 18-1 SP18... -
Page 46: Wiring Ladder Diagram (After Sn 1767237)
WIRING DIAGRAM (after SN 1767237) ELECTRICAL SYSTEM Item Description Battery, 36 Vdc CONTROL BOX ASSEMBLY SWITCH/DISPLAY PANEL ASSEMBLY CURTIS 1244 SPEED CONTROLLER Fuse, 400 A. BATTERY 36VDC EL/BRN CURTIS 1244 SPEED CONTROLLER Lamp, Trouble CAPACITOR, 180 MFD BLK/WHT 2-1 2 LAMP GROUND BLK/WHT CIRCUIT BREAKER, 25 AMP (AUXILIARY CIRCUIT 1) -
Page 47: Wiring Schematic (After Sn 1767237)
WIRING SCHEMATIC (after SN 1767237) ELECTRICAL SYSTEM SP23 SP24 FUSES BLK 18-12 F10: MAIN VIO 16-17 F11: BRUSH MOTORS LAMP, FLASHING SWITCH, MAIN BROOM X4 X50 YEL/BRN 18-4 LAMP, BROOM OVERLOAD SWITCH, KEY FUSE, 400 A. RED 6-1 RED 1-1 RED 3/0-1 ORN 18-1 SP18... - Page 48 ELECTRICAL SYSTEM WIRING DIAGRAM sheet 1 of 3 (after SN 1808248) Item Description BATTERY, 36 Vdc 56303540 Rev. F Sheet 1 of 3 Control Box Assembly Switch/Display Panel Assembly Battery 36Vdc FUSE, 400 A. YEL/BRN Circuit Breaker, 25 Amp (Auxiliary Circuit 1) CIRCUIT BREAKER, 5 AMP LAMP, TROUBLE Circuit Breaker, 5 Amp (Auxiliary Circuit 2)
- Page 49 WIRING DIAGRAM sheets 2 & 3 of 3 (after SN 1808248) 56303540 Rev. F Sheet 2 of 3 56303540 Rev. F Sheet 3 of 3 BRN/GRA GRN/WHT CONTACT N.O. CIRCUIT BREAKER, 40 AMP CURTIS 1244 SPEED CONTROLLER BRN/RED REVERSE FORWARD WHT/BLK STEERING ACTUATOR BLK/YEL...
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