Nilfisk-Advance SR 1100 P/B Service Manual Download Page 65

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SERVICE MANUAL

TROUBLESHOOTING

S30N1100(1)2002-01

127

TROUBLESHOOTING

ELECTRICAL PART

See the

Eco Troubleshooting Pocket Book

See the User’s Manual for the Honda petrol version engine (explosion engine version).

MECHANICAL PART

SWEEPING SYSTEM

The main brush does not rotate.

Possible cause:
1.

Drive belt from the electric motor broken (replace the belt).

The main/side brushes does not lift/lower.

Possible cause:
1.

Side brush lifting cable not adjusted or broken (adjust or replace it).

FLAP

The machine does not suck correctly

Possible cause:
1.

The flaps are not correctly adjusted (adjust the flaps).

The flaps are not integral (replace them).

The liftable front flap does not turn back to the correct closing position (correct the problem).

DUST AND DEBRIS COLLECTION SYSTEM

The suction system (fan) does not suck debris and dust sufficiently.

Possible cause:
1.

Foreign materials obstruct the fan (remove them).

The fan blades are not integral (replace the fan).

The panel filter is obstructed or wet (clean it).

The hopper is full (empty it).

The filter shaker does not operate correctly (check and correct the problem).

The machine lifts the dust

Possible cause:
1.

The panel filter is obstructed/broken (replace it).

The hopper is full (empty it).

The side brush rotation speed is excessive (decrease it).

STEERING AND BRAKING SYSTEM

The steering system is hard/does not operate regularly.

Possible cause:
1.

The steering chain is dirt (clean the chain).

The steering chain has been (wrongly) lubricated and fetched dirt and debris that prevent it from moving
normally (clean the chain).

The steering chain is deformed (replace the chain).

Summary of Contents for SR 1100 P/B

Page 1: ...SR 1100 P B SR 5110 P B S30N1100 1 2002 01 MANUALE DI ASSISTENZA SERVICE MANUAL ...

Page 2: ...Nilﬁsk Advance Italia S p A Località Novella Terza 26862 Guardamiglio Lodi Italia www nilﬁsk advance com Phone 39 0377 451124 Fax 39 0377 51443 Printed in Italy ...

Page 3: ...ITCH ADJUSTMENT 84 MAIN BRUSH MOTOR ELECTRICAL INPUT CHECK 85 MAIN BRUSH MOTOR REPLACEMENT 86 MAIN BRUSH MOTOR BRUSHES OR CARBON BRUSHES CHECK AND REPLACEMENT 87 SIDE BRUSH MOTOR ELECTRICAL INPUT CHECK 88 SIDE BRUSH MOTOR REPLACEMENT 89 SIDE BRUSH MOTOR BRUSHES OR CARBON BRUSHES CHECK AND REPLACEMENT 90 MAIN BRUSH ACTUATOR REMOVAL 91 FLAP 92 FLAP HEIGHT AND OPERATION CHECK AND ADJUSTMENT 92 SIDE F...

Page 4: ...CHECK 113 ELECTRICAL SYSTEM 114 BATTERY REMOVAL INSTALLATION MAINTENANCE AND CHARGING 114 FUSE REPLACEMENT 114 POWER ELECTRONIC BOARD REPLACEMENT 115 COMPONENT LAYOUTI 116 WIRING DIAGRAM 118 PETROL VERSION ENGINE 120 ENGINE MANUAL START EMERGENCY CONDITION WITH THE BATTERY COMPLETELY DISCHARGED 120 ENGINE AIR FILTER CLEANING 121 ENGINE OIL REPLACEMENT 122 CHECK AND TENSION OF THE BELT FROM THE ENG...

Page 5: ...ubleshooting Pocket Book User s Manual for Honda petrol version engine NOTICE Ensure that the support rod safety device 36 is inserted whenever you work under the open hood 21 WARNING Do not work under the lifted machine if it is not securely fixed WARNING Before transporting the machine ensure that All doors and carters are closed The ignition key is not inserted The machine is fastened to the me...

Page 6: ...ery far from sparks flames and smoke During the normal operation explosive gases are delivered Do not wear jewels when working near electrical components Do not work under the lifted machine if it is not securely fixed Do not operate the machine near inflammable liquids or vapors Make sure the hood support rod is securely fixed when working under the open hood Instructions for petrol version engin...

Page 7: ...ine weight without batteries 240 kg Batteries Batteries standard no 4 batteries 6 Volt 240 Ah Battery voltage 24 V Battery housing dimensions Height 13 5 in 350 mm Width 28 5 in 725 mm Length 18 in 465 mm CAUTION Carefully read all maintenance repair instructions before carrying out any maintenance repair procedure Take all necessary precautions to prevent hair jewels and loose dresses from being ...

Page 8: ...r 90 W 6000 RPM Panel paper filter standard 2 95 m2 from 15 to 20 µm Vacuum in main brush compartment 10 12 mm H2O Specific characteristics for the petrol version engine Engine model Honda G150K1 144 cc Power at 3 600 RPM 3 8 Hp 2 8 kW Regulation at 3 200 RPM 3 HP 2 2 KW Starter Electric Fuel tank 2 5 liters Engine oil 0 7 liters Batteries standard no 2 batteries 6 Volt 240 Ah Battery housing widt...

Page 9: ...onic board 305 The machine functions stop High temperature in the electronic control circuits 95 C If the ambient temperature is high wait for 20 minutes to allow the machine to get cool If the problem persists call the Service personnel to have the electric motors checked 306 All functions and the traction are disenabled High temperature in the electronic control circuits 105 C Perform the same p...

Page 10: ...ing paragraphs See GENERAL INFORMATION and SAFETY ACCIDENT PREVENTION Operation On delivery Every 25 hours Every 50 hours Every100 hours Every200 hours Every400 hours Battery liquid level and voltage Volt or two weeks Visual inspection of the belt from the engine to the main brush Flap height and operation check Side brush height adjustment Panel filter cleaning and integrity check Filter shaker o...

Page 11: ... time after 20 hours or after 1 month Operation On delivery Twice a week Every 20 hours Every100 hours Every100 hours or every 8 months Every400 hours Engine oil level check Engine air filter cleaning Engine oil replacement Spark plug check cleaning Belt tension check from the engine to the dynamotor Replacement of the belt from the engine to the dynamotor Engine speed check and adjustment ...

Page 12: ...ing pedal 15 Servo brake pedal 16 Accelerator 17 Parking brake lever 18 Left side brush control lever optional 19 Right side brush control lever 20 Operator s seat 21 Hood to reach the internal components 22 Side flap 23 Front flap 24 Rear wheel 25 Main brush 26 Right side brush 27 Left side brush optional 28 Front wheel 29 Bumper optional 30 Front headlight 31 Electrical component case cover 32 C...

Page 13: ...SERVICEMANUAL GENERAL INFORMATION GB S30N1100 1 2002 01 75 MACHINE NOMENCLATURE CONTINUE S300075 ...

Page 14: ...ON ENGINE 11 Petrol version engine start and stop button 37 Batteries 41 Right side cover of the engine compartment 42 Cover screws 53 Petrol version engine 54 Ignition spark plug 55 Fuel fillercap 56 Fuel tank 57 Air filter 58 Electric generator 59 Separator panel between batteries and engine S300076 ...

Page 15: ...g the following procedure 5 Carry out step 1 and 2 in the reverse order Figure 1 S300077 BELT REPLACEMENT 1 Turn the ignition key 10 to OFF position and activate the parking brake 17 2 Remove the screw 51 and open the left side door 40 3 To ease off the belt tension loosen the screws A and move the engine B in the direction indicated by the arrow 4 Remove the belt C from the pulleys 5 Install the ...

Page 16: ...correctly fits on the related entrainer hub E Check also that the entrainer hub is free from dirt or foreign materials cords clothes etc accidentally rolled up 7 Carry out steps from 1 to 4 in the reverse order Remark This machine is equipped with an automatic adjustment of the pressure and of the position of the main brush so no adjustment is needed If the 800 code appears on the screen it means ...

Page 17: ...ecessary to adjust the brush height proceeding as described in step 2 2 Turn the ignition key 10 to OFF position and activate the parking brake 17 3 Open the hood 21 and fix it with the support rod 36 4 Unscrew the related knob A and by means of the lever 18 and or 19 change the adjustment disk position by one hole Reinstall the knob A 5 Perform step 1 again to check the proper adjustment of the s...

Page 18: ...isengaging it from the four pins C 3 Install the new brush on the machine engaging it on the pins C and on the tabs A 4 Carry out the side brush height adjustment as described on the previous page Figure 9 S300085 Remark 1 Brushes with harder or softer bristles are available This procedure is applicable to each type of brushes Remark 2 This procedure refers to the right brush the procedure for the...

Page 19: ... electrical connection M 7 Remove the screws E and the lever F 8 Remove the screws G and the lever H at the cabinet bench 9 Remove the screw I and separate the lever H in the two parts of which it is composed 10 Remove the cable L from the lever H housing 11 Reinstall in the reverse order of removal tighten the terminals A and B on the cable C under the following conditions Lever 19 in lifted posi...

Page 20: ... fairlead D and install the terminals E and F without tightening them 7 Install the brush L see related paragraph 8 Slide the terminals E and F on the cable C and tighten them under the following conditions Lever 18 in lifted position Side brush 27 lifted 2 cm from the ground 9 Connect the micro switch I wiring harness G electrical cables to the machine preset connector H according to the followin...

Page 21: ...SERVICEMANUAL SWEEPING SYSTEM GB S30N1100 1 2002 01 83 Figure 12 S300160 ...

Page 22: ...ch adjustment according to following step 2 Turn the ignition key 10 to OFF position and activate the parking brake 17 3 Open the hood 21 and fix it with the support rod 36 4 Disconnect the battery electrical connector 38 5 Remove the screws E and move the lever F 6 Loosen the screws C and adjust the micro switch D position 7 Install in the reverse order of removal 8 Perform step 1 again Figure 13...

Page 23: ...he underlying diagram inserting the 10 A fuse H for safety s sake 11 With an ammeter I check that the main brush motor input is approx 3 A at 24V 12 If the input is greater perform the motor brushes check see the procedure on the following pages If necessary disassemble the motor see the procedure on the following page clean it and check its moving parts 13 If the above mentioned procedures do not...

Page 24: ...and open the left side door 40 6 Disconnect the motor electrical cables A from the connection B 7 Remove the screws C and the motor D disengaging it from its pulley E and from the belt F Disassembly at the cabinet bench 8 Remove the screw N 9 Remove the engine from the pulley H and recover the key I and the spacer L 10 Install in the reverse order of removal Remark When reinstalling before tighten...

Page 25: ...clamp C 4 For each of the four brushes lift the retaining spring D and remove the brushes E 5 Check if the four brushes are worn out The brushes are worn when there is not sufficient contact with the motor armature because of their use of the contact surface which is not integral or because the thrust spring is broken etc 6 If necessary remove the brushes to replace them by unscrewing the nuts F a...

Page 26: ... check that the side brush motor input is less than 1 5 A at 24V 9 If the input is greater perform the motor brushes check see the procedure on the following pages If necessary disassemble the motor see the procedure on the following page clean it and check its moving parts 10 If the above mentioned procedures do not lead to a correct motor input it is necessary to replace the motor see the proced...

Page 27: ...from the fairlead G 8 Remove the fixing nut H of the motor assembly rotation pin 9 Remove the motor assembly I Disassembly at the cabinet bench 10 Remove the flange L and recover the key M 11 Remove the screw and the lever N 12 Remove the screws O and the side brush motor P 13 Reinstall in the reverse order of removal tighten the terminals D and E on the cable F under the following conditions Leve...

Page 28: ... Remove dust and dirt from the motor exterior part then disengage and remove the covers E 9 Remove the retaining spring F and pull out the brushes G 10 Check if the two brushes are worn out The brushes are worn when there is not sufficient contact with the motor armature because of their use of the contact surface which is not integral or because the thrust spring is broken etc 11 If necessary rem...

Page 29: ...ve the screw 51 and open the left side door 40 5 Cut the clamp A and disconnect the actuator electrical connection B 6 Unscrew the nuts C and D and remove the actuator E 7 Install in the reverse order of removal Figure 25 S300100 Remark if the spare actuator E has an electrical connection B that is not connected to the related cable connect it according to the instructions inside the spare actuato...

Page 30: ...ont E and rear F flap integrity Replace the flaps see figure 2 when they have cuts B larger than 20 mm or cracks C larger than 10 mm see the Flap replacement paragraph 8 Check that the front E and rear F flaps rub lightly on the floor but are not completely lifted from the ground see figure 4 After loosening the screws D if necessary adjust the flap position Then tighten the screws D 9 Press the f...

Page 31: ...just the side flap height as described on the previous page 7 Carry out steps from 1 to 3 in the reverse order Figure 7 S300107 REAR FLAP REPLACEMENT 1 Drive the machine on a level ground 2 Turn the ignition key 10 to OFF position and activate the parking brake 17 3 Remove the main brush as described in the related paragraph 4 Remove the screws A the straps B and the rear flap C 5 Reinstall the ne...

Page 32: ...ble end C from the support D 6 Remove the nut E 7 Operating on the right front side of the front flap remove the nut F and then remove the flap from its support G 8 At the cabinet bench remove the screws H the strap I and the front flap L Install the new front flap L with the strap I and the nuts H 9 Carry out steps from 4 to 7 in the reverse order 10 Adjust the height and check the operation of t...

Page 33: ...clamp D from the cable 7 Disconnect the clip and detach the cable end E from the flap lifting pedal lever F 8 Remove the front flap control cable G 9 Carry out steps from 4 to 8 in the reverse order 10 Adjust the height and check the operation of the front flap as described on the following pages Press the front 14 flap lifting pedal completely and check that the front flap lifts 5 cm approximatel...

Page 34: ... compressed air H of max 6 bars blowing only from the side protected by the wire gauze I According to the filter type take care of the following cautions Paper filter standard antistatic and micro fiber glass filter optional do not use water or detergents to clean it the filter can be damaged Polyester filter optional see the specifications supplied by the Manufacturer s using inadequate detergent...

Page 35: ...attery electrical connector 38 4 Remove the cover 52 from the panel filter compartment it is resting 5 Remove the screws 45 and the baffle plate 44 A type electric fan 6 Remove the electric fan A after disconnecting the related electrical connection B type electric fan 7 Remove the screws B and remove the electric fan C after disconnecting the related electrical connection 8 Install in the reverse...

Page 36: ...Turn the ignition key 10 to OFF position and activate the parking brake 17 2 Open the hood 21 and fix it with the support rod 36 3 Disconnect the battery electrical connector 38 4 Remove the cover 52 from the panel filter compartment it is resting 5 Disconnect the filter shaker motor B electrical connection A 6 Loosen without removing them the screws B from both sides 7 Pull out the bezel C by dis...

Page 37: ...he cleaning 5 Carry out steps from 1 to 3 in the reverse order Figure 1 S300121 SERVO BRAKE AND PARKING BRAKE ADJUSTMENT 1 Drive the machine on a level ground 2 Turn the ignition key 10 to OFF position 3 Operating at the side of the front wheel loosen the lock nut A turn the register B as necessary and then tighten the lock nut A 4 Check the brake proper operation by means of the servo brake pedal...

Page 38: ...e ground Then securely fix it in this position 4 Remove the nut A and the front wheel B 5 Disengage the brake lever D lead in wire C if necessary loosen the register G 6 Remove the four screws E and the brake assembly F 7 Disassemble the brake lever D then install it on the new brake assembly F in the same position as the old brake assembly 8 Install in the reverse order of removal 9 Carry out the...

Page 39: ...5 Disengage the brake lever D lead in wire C if necessary loosen the register E 6 Remove the screw F and the pulley G 7 Loosen the registers E and H and remove them from their fixing supports 8 Remove the screw E 9 Cut the clamp L 10 Remove the cable M and recover the pulley G 11 Install in the reverse order of removal with the following change Before the M cable installation screw down the regist...

Page 40: ...tion and remove it 12 After cutting the related clamps disconnect the electrical cables fixed on the column L 13 On a level ground and taking all necessary precautions hook the machine at the front anchorages 33 by means of a proper lifting system and lift it 30 cm from the ground Then securely fix it in this position 14 Unscrew the nut M and remove the front wheel N 15 Disengage the lead in wire ...

Page 41: ...SERVICEMANUAL STEERING AND BRAKING SYSTEM GB S30N1100 1 2002 01 103 Figure 5 S300125 G S B A C E D I L Q T N U P O M R H H H H F F F F V U Z AA ...

Page 42: ...he rear wheels 24 to rotate freely without touching the ground in the following tests 8 Connect the traction motor to the machine battery as described in the underlying diagram inserting the 10 A fuse H for safety s sake 9 With an ammeter F check that the traction motor input is less than 8 A at 24V If the input is greater carry out the motor brush check see the procedure on the following pages If...

Page 43: ...3 connection D and from the connection E on the electronic board Remove the cables B and C from the retainers along its run up to the traction motor 10 By means of a proper lifting system hook the machine at the rear anchorages 34 and lift it 20 cm from the ground Then securely fix it in this position 11 Remove the screws F on both sides of the machine and lower the rear axle assembly G Disassembl...

Page 44: ...SERVICE MANUAL TRACTION SYSTEM GB 106 S30N1100 1 2002 01 Figure 5 S300130 Figure 6 S300131 O O O S S S N N P P P P S M O I H R L L Q T T T T ...

Page 45: ...clamp C 4 For each of the four brushes lift the retaining spring D and remove the brushes E 5 Check if the four brushes are worn out The brushes are worn when there is not sufficient contact with the motor armature because of their use of the contact surface which is not integral or because the thrust spring is broken etc 6 If necessary remove the brushes to replace them by unscrewing the nuts F a...

Page 46: ...r 38 5 Remove the screws A move the accelerator pedal B forward and then lift it 6 Remove the screws C and the guard D 7 Loosen the screws E and adjust the micro switch F position against the lever G when it is activated a click must be heard tighten the screws E Press lightly the accelerator pedal and check that the micro switch F is activated a click must be heard 8 Carry out steps from 1 to 6 i...

Page 47: ...n lift it 6 Remove the screws C and the guard D 7 Loosen the screw E and adjust the accelerator potentiometer F operating on the register G according to the procedures described in the Eco Troubleshooting Pocket Book Tighten the screw E 8 Carry out steps from 1 to 6 in the reverse order 9 Carry out accelerator pedal B operation tests WARNING To adjust the accelerator potentiometer it is necessary ...

Page 48: ...e of the hood 21 disconnect the machine running consent micro switch electrical connector 47 5 Disconnect the electrical cables 48 from the clamps 49 6 Remove the nuts A and the seat stuffing B 7 Remove the adhesive C and pull out the electrical cables D from the hood 8 Removing the machine running consent micro switch E by detaching the adhesive F 9 Install in the reverse order of removal 10 Chec...

Page 49: ...and F to the cables G and H and then connect the connectors between them 9 Insert the cables H in the rod L from the upper side and make them come out from the hole M 10 Fix the flashing light O on the rod L by means of the screws N 11 Insert the rod L in its support C until it fits and then fix it in its position by means of the screw P 12 Insert the cables H in the hole B then connect them to th...

Page 50: ...C or Nilfisk model D bumper 4 Unscrew the eyebolt E and the screw F and remove the wheel G and the spacer on machine both side reassemble the spacer but not the wheel with the screw and the eyebolt 5 If necessary install the bumper roller I on the Advance model bumper frame L 6 Install the bumper L on the machine with the screws M and the flare washers N reuse the screws A and the flare washers B ...

Page 51: ...d nut tightening other fixing element proper position other component and item visible faults 7 Disengage the support rod safety device 34 and close the hood 19 8 On a level ground and taking all necessary precautions hook the machine at the front anchorages 33 by means of a proper lifting system and lift it 30 cm from the ground Then securely fix it in this position 9 Under the chassis check the ...

Page 52: ...attery electrical connector 38 5 Remove the screws 32 and the cover 44 8 A fuse replacement Ignition key fuse 6 Separate the two elements of the fuse carrier A bayonet joint 7 Remove the 8 A fuse B 100 A fuse replacement Electronic board fuse 8 Unscrew the nuts C and disconnect the related electrical cable terminals 9 Remove the 100 A fuse D 3 A fuse replacement Main brush jack fuse 10 Remove the ...

Page 53: ...the wiring diagram 6 Disconnect the electrical connectors E F G H I L M N refer also to the wiring diagram 7 Recover the fuse O 8 Disconnect the electronic board P from the retainers Q and then remove it 9 Install in the reverse order of removal 10 Carry out the machine electronic programming according to the procedures indicated in the Eco Troubleshooting Pocket Book Figure 3 S300144 WARNING When...

Page 54: ...1 16 Ignition key C1 17 Under seat micro switch C2 18 Running consent micro switch C3 19 Jack lower micro switch C5 20 Jack upper micro switch C6 21 Traction deactivation key C7 22 Combined switch C8 23 Horn combined switch C9 24 Emergency stop button C10 25 Battery connection C11 26 100 A main fuse F1 27 8 A light fuse F2 28 Accelerator potentiometer P1 29 Side brush potentiometer P2 30 Input ele...

Page 55: ...SERVICEMANUAL ELECTRICAL SYSTEM GB S30N1100 1 2002 01 117 Figure 4 S300146 ...

Page 56: ...charging diode F1 100 A fuse F2 8 A light fuse F2 L1 Lights M1 Suction motor M2 Left side brush motor M3 Right side brush motor M4 Main brush motor M5 Traction motor M6 Actuator motor M7 Filter shaker motor M8 Dynamotor M9 Cooling fan MA Forward gear MI Reverse gear P1 Accelerator potentiometer P2 Side brush potentiometer R1 Braking resistance RL1 Braking resistance relay RL2 Display exchange rela...

Page 57: ...SERVICEMANUAL ELECTRICAL SYSTEM GB S30N1100 1 2002 01 119 Figure 5 S300146 ...

Page 58: ...tivate the Starter 6 Pull slowly the engine pull starter cord C until a certain resistance is achieved then pull strongly and start the engine 7 Release the lever B to disengage the starter 8 To turn the engine off connect the engine electric circuit connector A 9 To proceed using the machine Turn the ignition key 10 to ON position Press the start button 11 Connect the engine electric circuit conn...

Page 59: ...t side cover 44 4 Remove the retainer A and open the engine air filter cover B 5 Remove and clean the pre filter C with warm water and soap then wring and dry it Check the pre filter integrity if necessary replace it 6 Remove and clean the filter D with compressed air max 6 bars If the cleaning is unsatisfactory replace the filter 7 Reinstall the filters B and C 8 Carry out steps from 1 to 3 in th...

Page 60: ... By means of a funnel insert new oil refer to the Engine User s Manual to choose the correct type of oil through the hole E until it reaches the hole lower edge F 7 Carry out steps from 1 to 4 in the reverse order Remark It is advisable to drain the oil when the engine is hot CAUTION Collect and dispose of the materials according to the law in force Remark While filling up with new oil keep the dr...

Page 61: ...en the belt bending value E is not higher than 1 mm with a pressure D of 20 Kg If necessary adjust the belt tension according to the following steps from 6 to 11 6 Loosen the four screws F 7 Insert a lever G in the hole H push it in the direction indicated by the arrow until the belt I is correctly tensioned and then tighten the screws F 8 Lower the hood 21 9 Start the engine and let it run for fe...

Page 62: ...tion and activate the parking brake 17 3 Open the hood 21 and fix it with the support rod 36 4 Remove the screws A and the dynamotor safety guard B 5 Loosen the four screws C and move the dynamotor D to loosen the belt 6 Remove the belt E 7 Install in the reverse order of removal After the installation adjust the belt E tension correctly see the previous pages Figure 9 S300152 Figure 10 S300155 ...

Page 63: ... A and the dynamotor connector B 6 Remove the four fastening screws C of the petrol version engine 7 Remove the petrol version engine D 8 Remove the dynamotor screws E and guard F at the cabinet bench 9 Loosen the screws G and remove the belt H from the pulley I 10 Remove the screw L and the pulley I and recover the related key 11 Remove the screws G and the dynamotor M 12 Install in the reverse o...

Page 64: ...t the retaining spring B and remove the brushes C 4 Check if the four brushes are worn out The brushes are worn when there is not sufficient contact with the motor armature because of their use of the contact surface which is not integral or because the thrust spring is broken etc 5 If necessary remove the brushes to replace them by unscrewing the nuts D and disengaging the lead in wires E It is a...

Page 65: ...position correct the problem DUST AND DEBRIS COLLECTION SYSTEM The suction system fan does not suck debris and dust sufficiently Possible cause 1 Foreign materials obstruct the fan remove them 2 The fan blades are not integral replace the fan 3 The panel filter is obstructed or wet clean it 4 The hopper is full empty it 5 The filter shaker does not operate correctly check and correct the problem T...

Page 66: ... seat is incorrect seat correctly to activate the running consent under seat micro switch 3 The seat stuffing is damaged and the micro switch does not activate replace the seat 4 The brake is activated deactivate it 5 The slope is higher than the maximum allowed change direction PETROL VERSION ENGINE See the User s Manual for the Honda petrol version engine and The petrol version engine does not s...

Page 67: ...ose of this pocket book is to enable you to properly service the range of ECO sweepers This is not a complete service manual but helps to identify and solve the more common problems which may occur on this range of sweepers ...

Page 68: ...ng paragraphs the components in bold letters for example dynamotor M M M M8 8 8 8 or micro switch C C C C5 5 5 5 are referring to the electric wiring diagram of the machine which shows all electric connections or to the topographic drawing of the machine which shows the location of all electric components N N N NO O O OT T T TE E E E 2 2 2 2 all necessary checks are listed according to such a sequ...

Page 69: ......

Page 70: ...appear on the display either during normal sweeping or when the machine is turned On by key switch This section follows the list of the advice safety error codes along with the type of problem related to each one and the inspections to be carried out W W W WA A A AR R R RN N N NII I IN N N NG G G G TURN MACHINE OFF AND DISCONNECT BATTERY BEFORE SERVICING N N N NO O O OT T T TE E E E MAKE A RESET S...

Page 71: ...ry recharge eventually check the good health of the battery N N N No o o ot t t te e e e 1 1 1 1 in a fully charged battery the electrolyte density must not be lower than 1 28 Kg Lt N N N No o o ot t t te e e e 2 2 2 2 starting from microprocessor version 3 3 the End Of Discharge Voltage can be PROGRAMMED in the following way W W W WE E E ET T T T B B B BA A A AT T T TT T T TE E E ER R R RII I IE ...

Page 72: ...drive motor case with a pink chemical compound starting from the machine serial number 003708168 the sensor is fixed with a metal support and a screw a a a a If the temperature sensor C C C C4 4 4 4 is NOT mounted on the traction motor M M M M5 5 5 5 check wire connection of pin 5 of connector C C C CN N N N1 1 1 1 of main electronic board S S S SK K K K3 3 3 3 it must be connected to the negative...

Page 73: ... 6 will appear on the display II I IN N N NS S S SP P P PE E E EC C C CT T T TII I IO O O ON N N NS S S S A A A AN N N ND D D D T T T TR R R RO O O OU U U UB B B BL L L LE E E E S S S SH H H HO O O OO O O OT T T TII I IN N N NG G G G a a a a the appearance of code 3 3 3 30 0 0 05 5 5 5 could be normal in the following cases The environment temperature is higher than 40 C 104 F The machine worked f...

Page 74: ...t least 40 minutes before starting to work again in this way code 3 3 3 30 0 0 06 6 6 6 may disappear if it doesn t proceed with the following inspections b b b b Check that the parking brake is not activated c c c c Check both parking and service brake adjustment and functioning d d d d Check the efficiency of the cooling fan M M M M9 9 9 9 in the main electronic board compartment e e e e Check t...

Page 75: ...e working pressure are in order check the following items lower limit microswitch for main broom control C C C C5 5 5 5 in electric wiring diagram it could be faulty electric motor of actuator for main broom up down control M M M M6 6 6 6 in El Diagram it could be jammed or burnt out According to the version of the machine the micro switch can be internal more recent machines or external to the ja...

Page 76: ...nical Program is set at a value not lower than P69 Section 5 paragraph 5 4 2 e e e e If none of above problems occurred make the following checks verify that the actuator M M M M6 6 6 6 for main broom up down control and relevant limit switch C C C C5 5 5 5 are properly working see also trouble shooting actions specified for M M M M6 6 6 6 and C C C C5 5 5 5 in previous section dedicated to advice...

Page 77: ...g the normal job safety code 3 3 3 30 0 0 07 7 7 7 appears and all machine functions are blocked II I IN N N NS S S SP P P PE E E EC C C CT T T TII I IO O O ON N N NS S S S A A A AN N N ND D D D T T T TR R R RO O O OU U U UB B B BL L L LE E E E S S S SH H H HO O O OO O O OT T T TII I IN N N NG G G G a a a a Release the accelerator pedal if safety code 3 3 3 30 0 0 07 7 7 7 does not disappear proce...

Page 78: ...by turning the machine off wait 5 seconds and then turn the machine on again If code 3 3 3 30 0 0 02 2 2 2 does NOT disappear check 100 A fuse F F F F1 1 1 1 on the main electronic board S S S SK K K K3 3 3 3 Check coil and coil wiring of solenoid contactor T T T TL L L L1 1 1 1 cold coil resistance is about 70 Ohm the resistance value can increase by 10 15 Ohm when the coil is warm b b b b If fus...

Page 79: ...off all machine functions are blocked II I IN N N NS S S SP P P PE E E EC C C CT T T TII I IO O O ON N N NS S S S A A A AN N N ND D D D T T T TR R R RO O O OU U U UB B B BL L L LE E E E S S S SH H H HO O O OO O O OT T T TII I IN N N NG G G G a a a a Check the connecting wires and the functioning of the potentiometer P P P P1 1 1 1 b b b b If necessary replace the potentiometer P P P P1 1 1 1 once ...

Page 80: ...ry mode leaving the dynamotor M M M M8 8 8 8 cable disconnected W W W WA A A AR R R RN N N NII I IN N N NG G G G when working in battery mode a battery charger is required for proper battery recharge c c c c Check that there is no interruption in the wire connections of the drive motor M M M M5 5 5 5 on models SR 1100 and SR 5110 the interruption could occur near the coils EMC filters placed in se...

Page 81: ...for example on the red wire of the flashing beacon cable in this case it is also necessary to replace the fuse F F F F2 2 2 2 with an 8 Amp one instead of 5 Amp the broken electronic board S S S SK K K K3 3 3 3 will have to be replaced as soon as possible f f f f3 3 3 3 if the operation described at point g1 didn t make code 3 3 3 33 3 3 33 3 3 3 disappear re connect the suction motor M M M M1 1 1...

Page 82: ...G 2 2 2 2 1 1 1 10 0 0 0 THE MACHINE IS ONLY MOVING IN FORWARD GEAR OR REVERSE GEAR 2 2 2 2 1 1 1 11 1 1 1 THE MACHINE IS MOVING SLOWLY BOTH IN FORWARD AND REVERSE GEAR SEE PROBLEM 22 ALSO 2 2 2 2 1 1 1 12 2 2 2 LIGHTS AND OR HORN ARE NOT WORKING 2 2 2 2 1 1 1 13 3 3 3 THE HOPPER IS NOT GOING UP ONLY MODEL SR 1300 2 2 2 2 1 1 1 14 4 4 4 THE HOPPER DOOR DOES NOT OPEN ONLY MODEL SR 1300 2 2 2 2 1 1 ...

Page 83: ... the function and electric connections of microswitches M M M MA A A A and M M M MII I I lodged inside the multifunction lever see table 5 5 1 in Section 5 d d d d Check the adjustment of the acceleration potentiometer P P P P1 1 1 1 see the acceleration potentiometer P P P P1 1 1 1 setting values and its reset procedure in paragraphs 5 2 and 5 3 in Section 5 e e e e If all previous inspections di...

Page 84: ...the engine stop wire disconnected This means that the engine stop wire will have to be re connected to stop the engine at the end of the working session C C C Ca a a as s s se e e e N N N N 2 2 2 2 the dynamotor M M M M8 8 8 8 doesn t turn T T T Tr r r ro o o ou u u ub b b blll le e e e s s s sh h h ho o o oo o o ot t t tiii in n n ng g g g a a a a Check the charge level and the efficiency of the ...

Page 85: ...ed on the display when the engine switches off if the voltage is around 29 Volt 30 Volt we can say that the machine behaviour is normal the engine switching off is due to the intervention of the automatic cutoff avoiding the battery being overcharged d d d d In any case check the battery efficiency and its actual charge level In fact the behaviour described at previous point c is correct only in t...

Page 86: ...es up down T T T Tr r r ro o o ou u u ub b b blll le e e e s s s sh h h ho o o oo o o ot t t tiii in n n ng g g g a a a a If the main broom electric motor M M M M4 4 4 4 is turning correctly check the efficiency of the pulleys and of the transmission belt b b b b If the motor is not turning check the motor M M M M4 4 4 4 electric connection wires c c c c Check the efficiency of the motor M M M M4 ...

Page 87: ...ment of the main electronic board S S S SK K K K3 3 3 3 2 7 SIDE BROOMS ARE NOT TURNING Additional observation all functions are responding to the controls T T T Tr r r ro o o ou u u ub b b blll le e e e s s s sh h h ho o o oo o o ot t t tiii in n n ng g g g a a a a Check whether the knob potentiometer P P P P2 2 2 2 on the dash board is in the zero speed position b b b b Check the electric connec...

Page 88: ...e 5 1 1 in Section 5 b b b b If the electric fan M M M M1 1 1 1 and its electric connections are in order replace the main electronic board S S S SK K K K3 3 3 3 2 9 THE FILTER SHAKER MOTOR M7 IS NOT WORKING Additional observation all other machine functions are responding to the controls when P1 or P2 has been pressed T T T Tr r r ro o o ou u u ub b b blll le e e e s s s sh h h ho o o oo o o ot t...

Page 89: ...M M MA A A A and M M M MII I I placed inside the multifunction lever see the table 5 5 1 in Section 5 2 11 THE MACHINE IS MOVING SLOWLY BOTH IN FORWARD AND REVERSE GEAR SEE ALSO PROBLEM 22 C C C Ca a a as s s se e e e N N N N 1 1 1 1 the problem occurs only when working program P1 is On or when P2 is On T T T Tr r r ro o o ou u u ub b b blll le e e e s s s sh h h ho o o oo o o ot t t tiii in n n n...

Page 90: ...lectric connections and functioning of the key C C C C1 1 1 1 of the front light L L L L1 1 1 1 and of the horn C C C CL L L L b b b b Check the functioning of the switches C C C C8 8 8 8 and C C C C9 9 9 9 lodged in the multifunction lever see the table 5 5 1 in Section 5 2 13 THE HOPPER IS NOT GOING UP ONLY MODEL SR 1300 C C C Ca a a as s s se e e e N N N N 1 1 1 1 you cannot hear the hydraulic ...

Page 91: ...rrect connection of the two hydraulic hoses see Draw 2 UP and DN connections of the hydraulic hoses c c c c Check the hydraulic system hoses and lifting cylinder the hydraulic oil tank and the hydraulic pump to verify that there is no break or oil dripping N N N NO O O OT T T TE E E E the hydraulic pump is equipped with two safety valves which open in case of too high pressure of the oil in the hy...

Page 92: ... microswitches if the jack motor is not equipped with a 3 Amp fuse look for a suitable fuse holder and mount it in series with one of the two motor M M M M1 1 1 11 1 1 1 electric wires see also TSB IT 2000 012 in Section 5 f f f f If the jack motor operates replace the electronic board S S S SK K K K4 4 4 4 2 15 THE HOPPER IS NOT GOING DOWN ONLY MODEL SR 1300 C C C Ca a a as s s se e e e N N N N 1...

Page 93: ...he above specified inspections didn t remove the problem replace the complete hydraulic pump 2 16 THOUGH THE EMERGENCY BUTTON C10 HAS BEEN PRESSED THE MACHINE IS NOT SLOWING DOWN ENOUGH Trouble shooting a a a a Check the electric connections and the efficiency of resistor R R R R1 1 1 1 resistance value of 0 56 Ohm b b b b Check the electric connections and the operation of relay R R R RL L L L1 1...

Page 94: ...o o o ou u u ub b b blll le e e e s s s sh h h ho o o oo o o ot t t tiii in n n ng g g g a a a a Check that the battery is charged enough and working b b b b Check that the parking brake is not engaged and that the service brakes are in order efficient and correctly adjusted c c c c Check the drive motor M M M M5 5 5 5 efficiency see Draw 1 and Table 5 1 1 electric motors current draw specificatio...

Page 95: ...ity of the electrolyte must not be lower than 1 28 Kg litre N N N NO O O OT T T TE E E E 2 2 2 2 starting from the micro processor version 3 3 the end of discharge voltage of the battery can be programmed in the following way W W W WE E E ET T T T B B B BA A A AT T T TT T T TE E E ER R R RII I IE E E ES S S S automatic stop of the functions except traction at 20 5 Volt G G G GE E E EL L L L B B B ...

Page 96: ... voltage value enter the Technical Program of the machine and properly set raw No 11 which shows reading PA0 or PA1 in the Technical Program itself Section 5 c c c c Check the connections and the functioning of the recharging diode D D D D1 1 1 1 the diode D D D D1 1 1 1 is installed starting from 2ND GENERATION machine serial number 90800355 d d d d Check the operation of the solenoid contactor T...

Page 97: ...t at P91 with the 3 digit display For more detailed information about the replacement of spare parts on machines equipped with a 4 digit display see TSB IT 2000 023 in Section 5 Discharged or broken battery The flat cable which connects the electronic board S S S SK K K K3 3 3 3 to the electronic card S S S SK K K K2 2 2 2 is partially disconnected or defective The display card S S S SK K K K2 2 2...

Page 98: ...cted The battery is discharged or defective The key fuse F F F F2 2 2 2 has blown try to understand what could have caused the the fuse blowing by looking at the machine electric wiring diagram The key C C C C1 1 1 1 electric wires are disconnected check that the battery 24 Volt voltage reaches pin 4 of main electronic board S S S SK K K K3 3 3 3 connector C C C CN N N N3 3 3 3 The key switch C C ...

Page 99: ...200 1300 5 5 5 5 4 4 4 4 1 1 1 1 USER PROGRAM 5 5 5 5 4 4 4 4 2 2 2 2 TECHNICAL PROGRAM 5 5 5 5 5 5 5 5 HARNESS COLOUR CODES TABLES 5 5 5 5 6 6 6 6 INTERNAL COMBUSTION ENGINES RPM 5 5 5 5 7 7 7 7 STATUS OF THE SWITCHES FOR ELECTRIC POWER CONTROL IN THE DIFFERENT WORKING CONDITION 5 5 5 5 8 8 8 8 TECHNICAL SERVICE BULLETINS TSB IT 2000 012 2000 023 2001 004 5 5 5 5 9 9 9 9 ELECTRIC WIRING DIAGRAMS ...

Page 100: ...orresponds to speed zero stopped motor 24 V corresponds to maximum speed that s to say when the full battery voltage is applied across the motor terminals T T T TA A A AB B B BE E E EL L L LL L L LA A A A 5 5 5 5 1 1 1 1 1 1 1 1 E E E EL L L LE E E EC C C CT T T TR R R RII I IC C C C M M M MO O O OT T T TO O O OR R R RS S S S C C C CU U U UR R R RR R R RE E E EN N N NT T T T D D D DR R R RA A A AW...

Page 101: ...gher than 1100 Ohm with the pedal in maximum speed position with the potentiometer disconnected from the electronic board with the traction rear wheels lifted from the floor and the pedal in the maximum speed position the voltage across the drive motor M M M M5 5 5 5 must be equal to the battery voltage around minus 0 3 Volt P P P P2 2 2 2 p p p po o o ot t t te e e en n n nt t t tiii io o o om m ...

Page 102: ...lue with a Ohmmeter f f f f Connect the potentiometer connector paying attention that the shaft doesn t rotate re connect the battery and switch the machine on again only with the key g g g g Enter the Technical Program of the machine and reach row N 12 or in any case the last row i e when all lighting zeros appear on the display h h h h Temporarily press the suction motor control button on the da...

Page 103: ... increase the potentiometer P P P P1 1 1 1 value set in the previous point m e g adjust at 250 Ohm instead of 200 Ohm eventually repeat the same operation until the voltage at the traction motor terminals has reached the desired value ...

Page 104: ...ion there are other options which are described in the following tables To enter the USER Program proceed in the following way turn the key switch On keeping the display button pressed in about three seconds the first row of the program will appear on the display instead of the usual battery voltage release the button now To change decrease increase the values shown on the display use P1 and P2 bu...

Page 105: ...1 1 12 2 2 20 0 0 00 0 0 0 5 5 5 51 1 1 12 2 2 20 0 0 0 S S S ST T T TD D D D S S S SE E E ET T T TT T T TII I IN N N NG G G G 1 1 1 13 3 3 30 0 0 00 0 0 0 1 10x Main brush pressure Program P1 from 1 to 9 X 1 for min brush pressure X 9 for max brush pressure 102 102 102 2 11x Max working speed Program P1 from 0 to 9 X 0 for min speed range X 9 for max speed range 119 119 119 3 20x Main brush press...

Page 106: ...seconds the first row of the program instead of the usual battery voltage will appear on the display release the buttons now To change decrease increase the values shown on the display use P1 and P2 buttons respectively To pass to the next row of the program push temporarily the display button To set the new values in the microprocessor memory and exit the programming sequence press the display bu...

Page 107: ...min speed 9 max speed 2 P1X Drive motor acceleration ramp from 0 to 9 it is better to have smooth acceleration in order to reduce the drive motor stress P15 for 1100 5110 P13 for 1200 5120 P13 for 1300 0 quick accel 9 smooth accel 3 P2X Machine braking ramp from 0 to 9 P22 for 1100 5110 P20 for 1200 5120 P20 for 1300 0 quick braking 9 smooth break 4 P3X displaying the temperature of the electronic...

Page 108: ... place only through the diode D D D D1 1 1 1 see the electric wiring diagram For what concerns the battery discharge this can t take place if T T T TL L L L1 1 1 1 remains open in this way the dynamo M M M M8 8 8 8 alone provides for the feeding of the electric system If the electric power coming from the dynamo M M M M8 8 8 8 is not enough e g if the machine starts to climb a very steep slope a t...

Page 109: ...y i e around 24 V After a P8X time see the previous list the solenoid T T T TL L L L1 1 1 1 will automatically return to the rest condition open contact not energised coil and after that If in the meanwhile the overload condition has ended up T T T TL L L L1 1 1 1 will stay open at rest coil not energised If the overload condition is going on a further re closing of T T T TL L L L1 1 1 1 will take...

Page 110: ... M MA A A A 2 Green black Pink thin o 35mmq Contact M M M MII I I 3 Black Grey Common M M M MA A A A M M M MII I I 4 Yellow Orange double electric wire Light L L L L1 1 1 1 and d d d diii is s s sp p p plll la a a ay y y y light 5 Orange Pink 1 mmq Horn C C C CL L L L 6 Brown light blue Red 24 Volt 7 White Not used 8 Dark blue Not used T T T Ta a a ab b b b 5 5 5 5 5 5 5 5 2 2 2 2 C C C CO O O ON ...

Page 111: ...n the table below M M M MO O O OD D D DE E E EL L L L A A A AN N N ND D D D V V V VE E E ER R R RS S S SII I IO O O ON N N N R R R RP P P PM M M M N N N NO O O OM M M MII I IN N N NA A A AL L L L V V V VA A A AL L L LU U U UE E E E II I IN N N N T T T TH H H HE E E E A A A AB B B BO O O OV V V VE E E E S S S SP P P PE E E EC C C CII I IF F F FII I IE E E ED D D D C C C CO O O ON N N ND D D DII I I...

Page 112: ...GII I IN N N NE E E E S S S ST T T TA A A AR R R RT T T T P P P PH H H HA A A AS S S SE E E E E E E EN N N NG G G GII I IN N N NE E E E T T T TU U U UR R R RN N N NE E E ED D D D O O O ON N N N E E E EN N N NG G G GII I IN N N NE E E E T T T TU U U UR R R RN N N NE E E ED D D D O O O ON N N N SWITCH IDENTIFICATION AS PER MACHINE ELECTR DIAGRAM BATTERY MODE FUEL MODE NORMAL LOAD FUEL MODE OVERLOAD ...

Page 113: ...wound around a main broom hub shaft blocked the main broom up down movement the mentioned internal limit switches could work not properly So doing a damage either of the actuator electric motor or of the machine electronic circuit board could occur In order to prevent this critical condition the use of A 2 5 Amp rating protection fuse is RECOMMENDED the fuse holder must be inserted in series with ...

Page 114: ... with internal microswitches is in production it does include a more reliable microswitch hitting device It is possible to recognise the new style actuator because the moving piston can NOT be turned by hand it was possible only with the old style actuator with internal microswitches N N N NO O O OT T T TE E E E the use of the 2 5 Amp rating protection fuse is also suggested with previous electric...

Page 115: ...t be done according to Fig 12 02 for machines starting from serial number 94504714 the connections must be done according to Fig 12 01 4 4 4 4 control open close of the hopper door on model SR 1300 in this case the connections must be done according to Tab 12 01 Fig 12 01 Jack motor actuator 145 5573 000 view from the pin insertion side connector pin function applicable for main brush up down cont...

Page 116: ... N N NT T T TR R R RO O O OL L L L C C C CO O O OL L L LO O O OU U U UR R R R O O O OF F F F W W W WII I IR R R RE E E E O O O ON N N N E E E EL L L LE E E EC C C CT T T TR R R RO O O ON N N NII I IC C C C B B B BO O O OA A A AR R R RD D D D S S S SK K K K4 4 4 4 S S S SII I ID D D DE E E E C C C CO O O OL L L LO O O OU U U UR R R R A A A AN N N ND D D D F F F FU U U UN N N NC C C CT T T TII I IO ...

Page 117: ... IS S S SP P P PL L L LA A A AY Y Y Y D D D DII I IS S S SP P P PL L L LA A A AY Y Y Y R R R RE E E EA A A AD D D DII I IN N N NG G G G 1 1 1 1 V V V Vo o o olll lt t t tm m m me e e et t t te e e er r r r the battery voltage is normally shown on the display A block function will be activated in case of battery undervoltage when battery voltage will be around 20V all machine functions will stop ex...

Page 118: ...d 3 pages document T T T TA A A AB B B BL L L LE E E E 2 2 2 2 0 0 0 0 D D D DII I IS S S SP P P PL L L LA A A AY Y Y Y V V V VE E E ER R R RS S S SII I IO O O ON N N N T T T Th h h hr r r re e e ee e e e d d d diii ig g g giii it t t ts s s s d d d diii is s s sp p p plll la a a ay y y y F F F Fo o o ou u u ur r r r d d d diii ig g g giii it t t ts s s s d d d diii is s s sp p p plll la a a ay y ...

Page 119: ...MODELS Nilfisk SR 1100 5110 1200 5120 1300 Advance SR 1100 1300 When replacing the main PCB S S S SK K K K3 3 3 3 on the machine electric wiring diagram a proper setting of the machine Technical Program must be done according to the attached flow chart see next page A sticker identical to Fig 1 is now glued on the PCB compartment door on all the ECO machines and on the PCB carton box when PCB is s...

Page 120: ...rt at low battery voltage 22 Volt W W W WA A A AR R R RN N N NII I IN N N NG G G G the use of 3_1 setting inside the Machine User Program is forbidden when the machine is equipped with diode D D D D1 1 1 1 Set the Technical Program according to Fig 1 i e P70 if machine is battery version P71 if machine is ECO petrol or diesel version PA0 if machine is equipped with Wet batteries PA1 if machine is ...

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Nilfisk-Advance SR 1100 P/B, Service Manual

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