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Nilfisk-Advance Cr 1100, Quick Start Troubleshooting Manual

Get the most out of your Nilfisk-Advance CR 1100 with our comprehensive Instructions For Use Manual. This manual is available to download for free from manualshive.com, providing you with all the essential information you need to operate and maintain your CR 1100 effectively.

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FORM NO. 56043126 - CR 1100, CR 1200 - 

69

ELECTRICAL SYSTEM

INSTALLATION CHECKOUT FOR THE CURTIS SPEED CONTROLLER

 SAFETY!

The 1244 controller is inherently a high power device.  When working around any battery powered vehicle, proper safety precautions 
should be taken.  These include, but are not limited to: proper training, wearing eye protection, avoiding loose clothing and jewelry, and 
using insulated wrenches.

After installing a controller and before operating the vehicle, carefully complete the following checkout procedure.  If you 

fi

 nd a problem during the 

checkout, refer to the 

DIAGNOSTICS

 section of this chapter for further information.

The installation checkout can be conducted with or without the handheld programmer.  The checkout procedure is easier with a programmer 
otherwise observe the Status LED for codes.  The part number of the handheld programmer is 

56409441

.  

NOTE:

  The CR 1100/1200 has a 

newer revision controller if you have a programmer with a serial number before 2100 you will need to update your programmer.  A free upgrade kit 
is available, order part number 

56409822

.  Also a different quad 4 pin programmer cable (PN 

56409823

) is needed to link the programmer to the 

controller plug-in port.

 WARNING!

Put the vehicle up on blocks to get the drive wheel off the ground before beginning these tests.
Turn the key switch off and make sure that the seat switch is open, and the throttle is in neutral.
Do not stand, or allow anyone else to stand, directly in front of or behind the vehicle during the tests.

1

  Remove electrical panel to access controller then observe LED status light on controlller.  If a programmer is available, connect it to the 

programmer connector.

2

 

Turn the key switch on.  The programmer should “power up” with an initial display, and the controller’s Status LED should begin steadily blinking 
a single 

fl

 ash (once every 5 seconds).  If neither happens, check for continuity in the key switch circuit and controller ground.

3

  If you are using a programmer, put it into the diagnostic mode by pressing the DIAGNOSTICS key.  The display should indicate “No Faults 

Found”.  Note: Before pressing the diagnostics key, wait until model # screen appears, if the throttle is activated prior to this screen appearing 
the controller will shut down.

• 

Close the seat switch (sit in the seat).  The LED should continue blinking a single 

fl

 ash (every 5 seconds) and the programmer should continue 

to indicate no faults.  If there is a problem, the LED will 

fl

 ash a diagnostic code and the programmer will display a diagnostic message.  If you 

are conducting the checkout without a programmer, look up the LED diagnostic code in the 

DIAGNOSTICS

 section of this chapter 

(Table 1)

.

• 

When the problem has been corrected, it may be necessary to cycle the key or seat switch to clear the fault code.

4

  While sitting on the seat, operate the throttle.  The motor should begin to turn in the selected direction.  If it does not, verify the wiring to the 

main contactor, and the motor.  The motor should run proportionally faster with increasing throttle.  If not, refer to the 

DIAGNOSTICS

 section of 

this chapter 

(Table 1)

.

5

  If you are using a programmer, put it into the test mode by pressing the TEST key.  Scroll down to observe the status of the forward, reverse 

and brake switch (brake switch is actually the seat switch on the CR 1100/1200).  Cycle each switch in turn, observing the programmer.  Each 
input should show the correct state on the programmer.

6

  Take the vehicle off the blocks and drive it in an open area.  It should have smooth acceleration and good top speed.

PROGRAMMING VEHICLE SPEED CHANGES

The maximum high-speed (transport) and maximum low speed (scrub) can be changed electronically, using the handheld programmer.  To change 
a parameter using the programmer, press the PROGRAM key, and scroll down the Program Menu until the desired parameter is the top line of the 
display.  Press the appropriate CHANGE VALUE key (“up” or “down”) until the desired number is reached.  The parameter is now set at the desired 
value.  All programming occurs in real time.  In other words, the parameters can be changed while the vehicle is in operation.
The upper and lower limits of parameters are set at the factory.  Some parameters have dependencies on other parameters.  When the programmer 
is being used to adjust a parameter and a limit is reached, the display will stop changing.  To see why the display has stopped changing, press the 
MORE INFO key.  If the limit is related to another parameter, that information will be displayed; changing the value of the related parameter may 
allow the original parameter to be adjusted further.  Otherwise, the display simply says “Max Limit” or “Min Limit.”
Use of the programmer is described more fully in the 

PROGRAMMER OPERATION  

section of this chapter.

MAINTENANCE

There are no user-serviceable parts inside the Curtis PMC 1244 controller.  No attempt should be made to open the controller.  Opening the 
controller may damage it and will void the warranty.
However, it is recommended that the controller exterior be cleaned periodically, and if a handheld programmer is available, this periodic cleaning 
provides a good opportunity to check the controller’s diagnostic history 

fi

 le.

Summary of Contents for Cr 1100

Page 1: ...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 ...

Page 2: ...E 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 ELEC...

Page 3: ...rvice 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 wh...

Page 4: ...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 Departm...

Page 5: ...s 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 exi...

Page 6: ...eight 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 capaci...

Page 7: ...l 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...

Page 8: ...el 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 Usi...

Page 9: ...m 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 dus...

Page 10: ...e 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 ...

Page 11: ...ain 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 Clea...

Page 12: ...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 ...

Page 13: ... 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 ...

Page 14: ...tem 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 Indicat...

Page 15: ... 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 ...

Page 16: ...g the filter 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 ...

Page 17: ...ub 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 scr...

Page 18: ...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 flashes if the hopper is open otherwise it is OFF X Hopper Overtemp Indicator This indicator will flash when the hopper temperature exceeds 140 degrees Fahrenheit NOTE the hopper temperature switch is optional Y Close Dump ...

Page 19: ... 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 clo...

Page 20: ...n 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 ...

Page 21: ...t short Check for wiring problems at the K1 coil Check K1 coil resistance if below 116 ohms Replace 16 Left scrub motor M2 contactor coil current too high Same as Error 15 Replace coil Shorted Coil 17 Left scrub motor M2 contactor coil circuit open Check for open in coil wiring Check for 36V at the K1 coil wire colors VIO YEL BLU 18 Shaker circuit short See shaker will not run troubleshooting flow...

Page 22: ... for 36V at the K7 coil wire colors VIO BLU 39 Door close solenoid coil circuit short Check for wiring problems at the L5 coil Check L5 coil resistance if below 66 ohms Replace 40 Door close solenoid coil current too high Same as Error 39 Replace coil Shorted Coil 41 Door close solenoid coil circuit open Check for open in coil wiring Check for 36V at the L5 coil wire colors VIO BLU RED 42 Side bro...

Page 23: ...or coil circuit open Check for open in coil wiring Check for 36V at the K11 coil wire colors VIO BLU WHT 57 Back up alarm circuit short Check alarm and wiring 58 Back up alarm current too high Check alarm and wiring 59 Back up alarm circuit open Check alarm and wiring 60 Side broom actuator circuit short Check for short in wires or motor 61 Side broom actuator circuit current too high Check for bi...

Page 24: ...t run 49 50 Shaker motor does not operate 51 Scrub deck will not raise 52 Scrub deck will not lower 53 54 Scrub deck motors will not operate 55 56 Solution solenoid valve s do not operate 57 Note To aid in machine system troubleshooting see the electrical and hydraulic manual sections for additional drawing of part component locations and diagrams to support wiring and hydraulic circuits SCRUB 3 A...

Page 25: ...l pin 1 ORN and pin 9 ORN See Table 1 Curtis troubleshooting Status LED Fault Codes See No drive no machine accessory functions in this manual Do the A2 display panel lights come on Repair or replace the ORN wire s Check for 36V at A3 speed control pin 2 GRN Check for 36V through the seat switch and battery interlock switch Repair or replace wiring or switches Motor still does not operate Check th...

Page 26: ...el Speed Controller Fault Code Status Light Wrench 6 Not Used 7 Not Used 8 Not Used 9 ORN Battery Pos Coil Return input connects internal suppression diode to K5 coil 10 Not Used 11 Not Used 12 Not Used 13 VIO BLK Throttle input Wire pot high 14 WHT BLK Throttle input Wire pot Low 15 BRN RED Throttle input Wire pot wiper 16 Not Used 17 BLK YEL Main Contactor Driver Battery 36V output to main conta...

Page 27: ...operational power it up the main power Key Switch S11 must be closed Next the seat switch S9 and battery interlock S13 must be closed for the main contactor K5 to be energized Depressing the foot pedal in either Fwd or Rev will move the throttle pot R1 out of its neutral position and provide the needed directional and throttle inputs for controller outputs Depressing the foot pedal in either Fwd o...

Page 28: ...T GRA BRN RED WHT BLK VIO BLK X51 ORN RED ORN ORN BLU BLK GRN F1 F2 B M B BLK RED 1 1 RED 1 2 A1 A2 F1 F2 WHT YEL RED 1 A2 BLK 1 A1 Motor Wheel Drive RED BLU Contact N O Contactor Wheel Drive Pot 5k Ohm A B C R1 A3 CURTIS 1244 SPEED CONTROLLER M15 K5 K5 2 1 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 M ...

Page 29: ...re voltage at the coil Replace the A1 control board Check coil resistance at K10 120 ohms or 10 Replace K10 contactor Are the red and grn acc lights on Check for 36V at the K10 load output BLU GRN wire to bat ground Check for 36V at K10 load input RED wire to bat ground At the A1 board is the red key switch light on At the A1 board are the grn and red acc lights on Repair or replace wiring Replace...

Page 30: ...ght E flashing at the A2 display board See Curtis troubleshooting section Check for an open circuit from the A3 Curtis Speed controller pin 20 GRA wire to A1 main board J2 26 GRA wire Repair or replace GRA wire Replace the A1 Main Board Machine auto reverse function does not work With the seat switch closed drive wheel jacked properly place the pedal in reverse position At the A3 Curtis Speed cont...

Page 31: ... yes yes yes no At the K9 solenoid load wire BRN GRA battery input check for 36V to battery ground Is the F9 40 amp CB open Check for a short in the steering motor or load wires Reset the F9 40 amp CB Does the power steering operate Replace Power Steering Unit Repair or replace defective wire Does the power steering operate At the K9 solenoid load wire GRA WHT output to steering motor check for 36...

Page 32: ...om will not turn On the A1 board is the main broom indicator light on Check the adjustment and operation of the S8 main broom switch Is the switch open when main broom lever is lowered Check for 36V at the K4 solenoid coil wire colors GRN GRA VIO Check both wire s for continuity Repair or replace defective wire s Does the broom run Clean adjust or replace the broom switch S8 Does the broom run Che...

Page 33: ...age broom lug inserts and debris wrapped around motor or broom At the K4 solenoid load wire RED 6 1 battery input check for 36V to battery ground Remove debris and make any repairs or replace damage parts Does the broom run Repair or replace defective wire s Does the broom run Repair or replace the M1 main broom motor Replace K4 solenoid Does the broom run At the K4 solenoid load wire RED 6 2 outp...

Page 34: ...pedal activated Place in forward or Reverse Side broom s will not turn On the A1 board is the side broom grn indicator light on Check for 36V at the K8 solenoid coil wire colors BRN BLK VIO Check both wire s for continuity Repair or replace defective wire s Does the side broom s run Check the K8 coil resistance 120 ohms or 10 Replace the A1 main controller Does the side broom s run Replace K8 sole...

Page 35: ...t or replace CB Do the side broom s run At the K8 solenoid load wire VIO GRA battery input check for 36V to battery ground Repair or replace defective wire Do the side broom s run Repair or replace the M8 M9 side broom motors Replace K8 solenoid Do the side broom s run At the K8 solenoid load wire WHT RED output to side broom motor s check for 36V to battery ground Check for 36V at side broom moto...

Page 36: ...programmed to lower automatically Check for a 36V at the motor harness plug Repair or replace wiring to motor Does the motor operate Replace lift motor Side broom s will not lower On the A1 board does the green side broom lift indicator light stay on while motor is extending Replace the A1 main controller Does the side broom s run At the A2 display panel is the side broom increase light on Substit...

Page 37: ...ly Repair the wiring to motor Does the motor retract On the A1 board does the side broom lift indicator red light stay on momentarily while the motor is retracting Check for open circuit in lift motor wiring to the A1 board J1 35 GRA VIO J1 23 GRN ORN Side broom s will not raise Check for an open in lift motor At the A2 display panel is the side broom decrease light on Substitute an A2 display pan...

Page 38: ... no no yes yes yes Separate the motor from the pump is the coupler sheared See pump removal in the Mechanical Repair Service Manual Hydraulic pump will not operate Replace Pump Assembly Replace damaged coupler yes no TROUBLESHOOTING GUIDE Possible Symptom 1 Hydraulic pump motor will run but all hydraulic functions do not operate Note Do all testing with the key switch on and hopper raise button pr...

Page 39: ...wire ORN WHT battery input check for 36V to battery ground Repair or replace defective wire Does the pump operate Repair or replace pump motor Replace K11 solenoid Does the pump operate At the K11 solenoid load wire output to pump motor check for 36V to battery ground Check for 36V at pump motor negative input from battery ground Repair or replace defective wire from battery ground Does the pump o...

Page 40: ... door open switch is its green indicator light on Substitute a new A2 display panel Does dump door operate Press and hold dump door open button At the A1 board is the door open green indicator light on Replace A1 control board Does dump door operate Check for 36V at L4 dump door coil Wire color VIO BRN GRN Repair or replace L4 coil wiring Does dump door operate Check for coil resistance at L4 66 o...

Page 41: ...or close switch is its green indicator light on Substitute a new A2 display panel Does dump door operate Press and hold dump door close switch At the A1 board is the door close green indicator light on Replace A1 control board Does dump door operate Check for 36V at L5 dump door coil Wire color VIO BLU RED Repair or replace L5 coil wiring Does dump door operate Check for coil resistance at L5 66 o...

Page 42: ...Plumb in a pressure gauge at the pump port D See Figure 1 Test the relief valve setting 1500psi by activating the door close switch Adjust clean or replace relief valve Does dump door operate Remove and disassemble L4 door open L5 door closed Spool valve cartridge inspect clean and reinstall Does the door operate Replace defective spool valve L4 door open L5 door closed Does the door operate Repla...

Page 43: ...FORM NO 56043126 CR 1100 CR 1200 41 HOPPER SYSTEM Gauge 3 000 PSI 207 bar Hose 2 61 cm 6 000 PSI 414 bar Fitting Parker Diagnostics PD222 B D FIGURE 1 ...

Page 44: ...oes the hopper raise Replace A1 control board Does the hopper raise Check for 36V at L6 hopper up coil Wire color VIO RED GRA Repair or replace L6 coil wiring Does the hopper raise Check for coil resistance at L6 66 ohm Replace L6 coil Does the hopper raise See hydraulic hopper will not raise troubleshooting section part B Press and hold Hopper up switch At the A1 board is the hopper up green indi...

Page 45: ...ts weight 550 lbs capacity Empty the hopper Does the hopper raise Plumb in a pressure gauge at the pump port B See Figure 1 Test the relief valve setting 1500psi by activating the hopper up switch Adjust clean or replace relief valve Does the hopper raise Remove and disassemble L6 hopper raise spool valve cartridge inspect clean and reinstall Does the hopper raise Replace defective spool valve L6 ...

Page 46: ...ght on Substitute a new A2 display panel Does the hopper lower Replace A1 control board Does the hopper lower Check for 36V at L6A hopper down coil Wire colors VIO YEL RED Repair or replace L6A coil wiring Does the hopper lower Check for coil resistance at L6A 66 ohms Replace L6A coil Does the hopper lower See hydraulic hopper Lower troubleshooting section part B Press and hold Hopper lower switch...

Page 47: ... stand underneath a hopper that is not supported with the use of a safety support Hopper will not lower Inspect for possible mechanical binding of Hopper linkage Hopper cylinder Repair or replace damaged parts Does the hopper lower Remove and disassemble L6A hopper lower spool valve cartridge inspect clean and reinstall Does the hopper lower Replace defective spool valve L6A hopper lower no no no ...

Page 48: ...e switch is its green indicator light on Substitute a new A2 display panel Does squeegee operate While pressing the squeegee switch does the squeegee lift light stay on at the A1 board for 5 10 sec Down RED Up GREEN Replace A1 control board Does squeegee motor operate Repair or replace wiring or motor Are the squeegee lift lights on momentarily while the squeegee switch is pressed 1 sec or less Ch...

Page 49: ...tch must be closed is the green vacuum light on at the A1 main board Replace A1 control board Does the vacuum motor operate On the A2 board is the recovery tank full light on Inspect clean or replace tank indicator switch and wires Switch is closed when tank is empty Locate the indicator switch plug and jump out the machine harness wires GRA YEL and BLK Does the light go off Check for 36V input at...

Page 50: ...g debris in and around motor Reset or replace CB At the K7 solenoid load wire GRN RED battery input check for 36V to battery ground Repair or replace defective wire Do the motor s run Repair or replace the M6 M7 vacuum motors Replace K7 solenoid Do the motor s run At the K7 solenoid load wire BLU GRA output to motor s check for 36V to battery ground Check for 36V at each motor wires BLU GRA BLK Re...

Page 51: ...on the A2 display panel is its green indicator light on Substitute a new A2 display panel Does impeller operate On the A1 board is the dust control light on Replace A1 control board Does the impeller motor operate Check for 36V at K6 impeller motor coil Wire colors VIO BRN YEL Repair or replace K6 coil wiring Does impeller motor operate Check K6 coil resistance 120 ohms or 10 Repair or replace K6 ...

Page 52: ...hanical binding debris in and around motor Reset or replace CB At the K6 solenoid load wire BRN WHT battery input check for 36V to battery ground Repair or replace defective wire Does the motor run Repair or replace the M5 dust impeller motor Replace K6 solenoid Does the motor run At the K6 solenoid load wire ORN GRN output to motor check for 36V to battery ground Check for 36V at motor wires ORN ...

Page 53: ...switch on the A2 display board Does its green indicator light come on Substitute an A2 display panel Does the shaker operate On the A1 board is the shaker green indicator light on Replace the A1 control board Does the shaker operate Check for 36V at the shaker motor M14 Wire colors BLK RED VIO Check wires for continuity Repair or replace wires Does the shaker operate Repair or replace motor yes ye...

Page 54: ... BLK wire to battery ground At the lift motor separate the plug and check for continuity between the RED and ORN wires retract limit switch at the motor plug On the A1 Board is the retract limit yellow light on Note the yellow limit light is one of 14 grouped together Replace lift motor Check for continuity in the lift motor wire colors RED YEL Repair or replace wiring plug or motor Separate motor...

Page 55: ...d and the BLK wire to battery ground At the lift motor separate the plug and check for continuity between the RED and BLK wires extend limit switch at the motor plug On the A1 board is the extend limit yellow light on Note the yellow limit light is one of the 14 grouped together Replace lift motor See Motor Load section On the A2 board is the recovery tank full light on Inspect clean or replace ta...

Page 56: ...ase switch does the scrub deck lift light turn on at the A1 board Down RED Up GREEN Check for continuity in the lift motor wire colors RED YEL Repair or replace wiring plug or motor Separate motor plug and then jump lift motor to battery wires RED YEL Does the motor run Check for continuity at the motor harness plug wires RED GRN to pin J1 12 and YEL GRA J1 11 at the A1 board Repair or replace wir...

Page 57: ...Brush motor load section Do other auto drive functions work See machine drive auto function do not work section Press the scrub increase switch along with moving the foot pedal Are the numbers 1 2 and 3 green scrub lights on at the A1 board Left brush does not run Check for 36V at K1 brush motor coil Wires VIO YEL BLU Repair or replace coil wiring Does the motor run Check coil resistance 120 ohms ...

Page 58: ...oid load wires K1 WHT ORN K2 GRA BLK K3 BLU YEL output to motor check for 36V to battery ground Check for 36V at brush motors wires M2 M3 M4 Is the F11 250 amp Fuse open Inspect individual motor gearbox assy for possible mechanical problems Repair motor gearbox Left brush motor does not run Check for 36V at K1 brush motor load wire RED VIO battery input to battery ground Right brush does not run C...

Page 59: ...ight on at the A2 Display Panel Substitute a new A2 Display Panel Do the solution valve s work On the A1 control board is the solution indicator light on Replace the A1 control board Do the solution valve s work Check for 36V at the solution valve s Repair or replace wiring to solution valve s Do the solution valve s work Check the resistance of the solution valve s 70 ohms Replace the solution va...

Page 60: ... the on position 4 Continue to hold the vacuum squeegee switch until all indicators except the vacuum squeegee indicator turn off approximately two seconds 5 Release the vacuum squeegee switch 6 The status display will now show a number from 1 to 9 Pressing and releasing the vacuum squeegee switch will increase the displayed value until 9 is reached The next press will return to 1 Each increment r...

Page 61: ...ition 4 Continue to hold the shaker switch until all indicators except the shaker indicator turn off approximately two seconds 5 Release the shaker switch 6 The status display will now show a number from 1 to 9 Pressing and releasing the shaker switch will increase the displayed value until 9 is reached The next press will return to 1 Each increment represents two seconds with 1 equal to twelve se...

Page 62: ...proximately two seconds 5 The status display will now show a number from 1 to 3 Pressing and releasing the scrub pressure increase switch will increase the displayed value until 3 is reached The next press will return to 1 If 1 is selected the only available scrub pressure will be the minimum setting If 2 is selected the minimum and medium scrub pressures will be available If 3 is selected all scr...

Page 63: ...indicators except the side broom up off and scrub off indicators turn off approximately two seconds 5 Release both switches 6 The status display will now show a number from 0 to 2 Pressing and releasing the side broom up off switch will increase the displayed value until 2 is reached The next press will return to 0 If 0 is selected the side brooms will not come on with the main broom They will be ...

Page 64: ... automatically To select the operating mode 1 Turn the main power key switch to the off position 2 Press and hold the shaker and scrub system off switches 3 While holding both switches turn the main power key switch to the on position 4 Continue to hold both switches until all indicators except the shaker and scrub off indicators turn off approximately two seconds 5 Release both switches 6 The sta...

Page 65: ...off position 2 Press and hold the fast slow switch 3 While holding the fast slow switch turn the main power key switch to the on position 4 Continue to hold the fast slow switch until all indicators except the fast slow indicator turn off approximately two seconds 5 Release the fast slow switch 6 The status display will now show a 0 or a 1 Pressing and releasing the fast slow switch will alternate...

Page 66: ...bnormal output conditions were detected the display will now show the error code s 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 displ...

Page 67: ... a long blank period The above sequence will repeat 8 To clear the stored codes press and release the solution switch The display will now show Go to step 10 9 If it is desired to save the codes go to step 10 10 To exit the error code recall mode turn the main power key switch to the off position Reset of All Programmable Parameters to Factory Default Settings To reset all of the above parameters ...

Page 68: ... change the sleep delay period perform the following steps 1 Turn the main power key switch to the off position 2 Press and hold the scrub system off and the hopper up switches 3 While holding both switches turn the main power key switch to the on position 4 Continue to hold both switches until all indicators except the scrub system off and the hopper up indicators turn off approximately 2 seconds...

Page 69: ...fer to the Status Fault Codes Table 1 for suggestions covering a wide range of possible faults DIAGNOSTIC HISTORY The handheld programmer can be used to access the controller s diagnostic history file Connect the programmer press the MORE INFO key and then while continuing to hold the MORE INFO key press the DIAGNOSTICS key The programmer will read out all the faults that the controller has experi...

Page 70: ...y too short 2 3 OO OOO High Pedal Disable HPD fault 1 Improper sequence of direction and throttle inputs 2 Wrong HPD type selected 3 Misadjusted throttle pot 4 Sequencing delay too short 2 4 OO OOOO Emergency reverse circuit check fault 1 Emergency reverse wire open 2 Emergency reverse check wire open 3 1 OOO O Contactor driver overcurrent 1 Contactor coil shorted 3 2 OOO OO Welded Main Contactor ...

Page 71: ...rogrammer will display a diagnostic message If you are conducting the checkout without a programmer look up the LED diagnostic code in the DIAGNOSTICS section of this chapter Table 1 When the problem has been corrected it may be necessary to cycle the key or seat switch to clear the fault code 4 While sitting on the seat operate the throttle The motor should begin to turn in the selected direction...

Page 72: ......

Page 73: ...ctor Dust Control Motor K7 Contactor Vacuum Motor K8 Contactor Side Broom K9 Contactor Steering K10 Contactor Auxiliary K11 Contactor Hydraulic Pump Motor L1 Valve Solution L4 Valve Dump Door Open L5 Valve Dump Door Close L6 Valve Hopper Raise L6A Valve Hopper Lower M1 Motor Broom 2 0 HP M2 Motor Left Brush M3 Motor Center Brush M4 Motor Right Brush M5 Motor Dust Control M6 Motor Vacuum M7 Motor V...

Page 74: ...rcuit Breaker 15 Amp K9 Contact N O F11 Fuse 250 Amp K8 Contact N O F5 Circuit Breaker 20 Amp K5 Contactor Wheel Drive A3 CURTIS 1244 SPEED CONTROLLER M5 Motor Dust Control M M9 Motor Left Side Broom M M16 Motor Steering M M10 Motor Asm Hyd Pump M K11 Contact N O K4 Contact N O M8 Motor Right Side Broom M K3 Contact N O K6 Contact N O K5 Contact N O R1 Pot 5k Ohm M15 Motor Wheel Drive M1 Motor Bro...

Page 75: ...N VALVE SOLUTION REVERSE FORWARD POT 5K OHM MOTOR BROOM MOTOR CENTER BRUSH MOTOR RIGHT BRUSH MOTOR LEFT BRUSH CIR BREAKERS F1 AUXILIARY CIRCUIT 1 F2 AUXILIARY CIRCUIT 2 F3 AUXILIARY CIRCUIT 3 F4 DUST CONTROL MOTOR F5 SIDE BROOM MOTORS F6 NONE F7 HYDRAULIC PUMP F8 VACUUM MOTORS F9 POWER STEERING K6 K1 K7 K2 K3 K8 K9 K4 K5 K10 L1 L2 M4 M3 M2 M1 S12 L5 L4 L6 L6A S7 M10 K11 H8 M14 M8 H4 H3 M9 S3 M16 C...

Page 76: ...t S8 Switch Main Broom K4 Contactor Broom Motor K6 Contactor Dust Control Motor H1 Backup Alarm optional K3 Contactor Right Brush Motor K9 Contactor Steering L5 Valve Dump Door Close L2 Valve Solution B GRA ORN RED BRN BLU BLK ORN BLU RED WHT B GRN ORN A B 1 2 1 2 1 2 RED BLK 1 2 2 1 1 2 A B 1 2 1 2 1 2 1 2 1 2 WHT GRN 1 2 1 2 ORN RED GRA RED WHT BRN BLU BLK BLK ORN BLU VIO VIO RED RED VIO VIO GRN...

Page 77: ...RAULIC PUMP F8 VACUUM MOTORS F9 POWER STEERING K6 K1 K7 K2 K3 K8 K9 K4 K5 K10 L1 L2 M4 M3 M2 M1 S12 L5 L4 L6 L6A S7 M10 K11 H8 M14 M8 H4 H3 M9 S3 M16 C1 BT1 H9 A2 S11 F1 F2 F3 F4 F5 F7 F8 F9 S4 M5 M13 S6 S10 S13 M7 M6 S12 S9 F11 F10 H10 S8 H7 GRA WHT 18 2 BLK 18 8 VIO 16 10 VIO 16 11 VIO 16 12 VIO 16 13 VIO 16 14 VIO 16 22 WHT BLK 18 2 BRN RED 18 2 VIO BLK 18 2 BRN 18 2 BLK 1 1 BLK 8 1 BLK 8 2 WHT...

Page 78: ...CK SWITCH HOPPER INTERLOCK 1 2 CONTACTOR LEFT BRUSH MOTOR CONTACTOR LEFT BRUSH MOTOR A A SWITCH MAIN BROOM SWITCH MAIN BROOM 1 2 VALVE DUMP DOOR OPEN VALVE DUMP DOOR OPEN 1 2 SWITCH SEAT SWITCH SEAT 2 1 VALVE DUMP DOOR CLOSE VALVE DUMP DOOR CLOSE 1 2 MOTOR BRUSH ACTUATOR MOTOR BRUSH ACTUATOR YEL RED CONTACTOR RIGHT BRUSH MOTOR CONTACTOR RIGHT BRUSH MOTOR M PUMP AXP SOLUTION M PUMP AXP SOLUTION LAM...

Page 79: ... 2 J5 11 J5 10 J5 17 J5 20 J5 1 J5 18 FROM SEAT SWITCH J5 13 J5 19 J5 23 J5 15 J5 8 CAN M 3 STEERING ACTUATOR M 3 STEERING ACTUATOR U V W CIRCUIT BREAKER 40 AMP 1 2 X72 X72 7 2 3 RELAY SAFETY A B CONTACT N O 1 2 SWITCH LEFT TRAVEL LIMIT 1 2 RESISTOR 10 OHM 1 2 STEERING WHEEL SENSOR A1 GRN A2 BLU B1 RED B2 GRN BLK TORQUE 1 BLK TORQUE 2 WHT GND 1 ORN VOLT 1 5V WHT BLK GRD 2 RED BLK VOLT 2 5V ORN BLK...

Page 80: ...4 1 VIO 16 2 BLU GRA 12 2 BLU GRA 12 1 GRN RED 8 1 BLU 18 1 VIO 16 2 VIO 16 3 ORN GRN 14 2 BRN WHT 14 1 BRN YEL 18 1 BLK YEL 18 1 RED 1 1 RED 1 2 ORN 18 4 ORN 18 3 GRN GRA 18 1 RED 6 1 RED 6 2 VIO 16 3 VIO 16 5 GRA RED 18 1 RED VIO 8 3 BLU YEL 8 1 VIO 16 5 VIO 16 6 WHT VIO 18 1 RED VIO 8 2 GRA BLK 8 1 VIO 16 6 VIO 16 7 YEL BLU 18 1 RED VIO 8 1 WHT ORN 8 1 VIO 16 7 RED 1 2 WHT YEL 10 1 F1 F2 A2 A1 ...

Page 81: ...N B L K 2 0 2 G R N B L K 2 0 1 BLK WHT 20 1 G R A O R N 2 0 7 B L K W H T 2 0 1 G R A O R N 2 0 1 GRA ORN 20 1 O R N R E D 2 0 1 G R N 2 0 1 Y E L 2 0 1 B L K 2 0 3 YEL 20 1 GRN 20 1 BLK 20 3 BLK 10 1 GRN WHT 10 1 FROM SHEET 1 A 1 A 2 G N D 1 V O LT 1 5V B 1 B 2 G N D 2 V O LT 2 5V T O R Q U E 1 T O R Q U E 2 MOTOR LEADS ROUTE AWAY FROM LOW CURRENT WIRING CONNECT TO X170 ON SHEET 1 CONNECT TO X16...

Page 82: ...lacement Hydraulic Filter Element 3 Contactor K11 4 Solenoid Valve Dump Door Open 5 Solenoid Valve Dump Door Close 6 Solenoid Valve Hopper Raise 6A Solenoid Valve Hopper Lower 7 Motor Assembly M10 8 Cylinder Hydraulic 9 Cylinder Hopper Lift COMPONENT LOCATION HYDRAULIC SCHEMATIC 9 8 5 2 6 6A 4 7 3 ...

Page 83: ...Nilfisk Advance A S Sognevej 25 DK 2605 Brøndby Denmark Tel 45 43 23 81 00 Fax 45 43 43 77 00 www nilfisk advance com ...

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