Nilfisk-Advance 56303004 User manual

CR 1100, CR 1200
MECHANICAL REPAIR
SERVICE MANUAL
1/09 Revised 6/12
FORM NO. 56043127
Printed in USA
Nilfisk MODELS: 56303004 (CR 1200), 56303005 (CR 1100 / OBS)

2- FORM NO. 56043127 - CR 1100, CR 1200
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.................................................................................................................................................... 10
WHEEL DRIVE MOTOR REMOVAL................................................................................................................................. 10
GEARBOX REMOVAL...................................................................................................................................................... 11
GEARBOX DRAIN AND FILL............................................................................................................................................ 11
ROTARY SENSOR (DIRECTIONAL POT SETTING)....................................................................................................... 12
DRIVE PEDAL PIVOT NEUTRAL ADJUSTMENT............................................................................................................13
FRONT WHEEL SYSTEM .............................................................................................................................................14-15
FRONT WHEEL REMOVAL AND BRAKE INSPECTION ................................................................................................. 14
FRONT BRAKE SHOE ADJUSTMENT ............................................................................................................................ 14
BRAKE CABLE REPLACEMENT..................................................................................................................................... 14
HYDRAULIC SYSTEM ..................................................................................................................................................16-18
HYDRAULIC PUMP MOTOR REMOVAL ......................................................................................................................... 16
HYDRAULIC PUMP MOTOR INSTALLATION.................................................................................................................. 16
HYDRAULIC PUMP REMOVAL........................................................................................................................................ 17
SWEEPING SYSTEM....................................................................................................................................................19-25
MAIN BROOM MAINTENANCE ....................................................................................................................................... 19
BROOM LEVER SWITCH S8 REPLACEMENT AND ADJUSTMENT..............................................................................20
MAIN SWEEPING BROOM MOTOR REMOVAL..............................................................................................................21
MAIN BROOM DRIVE BELT REPLACEMENT................................................................................................................. 21
MAIN BROOM DRIVE BELT INSTALLATION AND TENSIONING ADJUSTMENT.......................................................... 21
MAIN BROOM MOTOR BELT REMOVAL ........................................................................................................................ 22
MAIN BROOM MOTOR BELT INSTALLATION AND TENSIONING ADJUSTMENT........................................................ 22
SIDE BROOM MAINTENANCE........................................................................................................................................ 22
SIDE BROOM MOTOR REMOVAL................................................................................................................................... 23
SIDE BROOM LIFT ACTUATOR MOTOR REPLACEMENT............................................................................................ 24
MAIN BROOM LIFT CABLE REPLACEMENT ................................................................................................................. 25
HOPPER SYSTEM........................................................................................................................................................26-29
SEALS AND SKIRTS IDENTIFICATION AND REPLACEMENT ......................................................................................26
DUMP DOOR CYLINDER REMOVAL .............................................................................................................................. 27
HOPPER LIFT CYLINDER REMOVAL............................................................................................................................. 28
IMPELLER MOTOR REMOVAL........................................................................................................................................ 29
HOPPER INTERLOCK SWITCH REPLACEMENT .......................................................................................................... 29
SOLUTION SYSTEM.....................................................................................................................................................30-31
SOLUTION TANK REMOVAL ........................................................................................................................................... 30
SOLUTION VALVE CONTROL CABLE REPLACEMENT ................................................................................................ 30
TROUBLESHOOTING GUIDE.......................................................................................................................................... 30
SOLUTION SYSTEM MAINTENANCE............................................................................................................................. 30
SCRUB SYSTEM...........................................................................................................................................................32-33
SCRUB DECK ASSEMBLY REMOVAL ............................................................................................................................ 32
SCRUB DECK ASSEMBLY INSTALLATION..................................................................................................................... 32
SCRUB DECK LIFT ACTUATOR MOTOR REMOVAL ..................................................................................................... 32
SCRUB BRUSH MOTOR REMOVAL ............................................................................................................................... 32
RECOVERY SYSTEM ...................................................................................................................................................34-35
TROUBLESHOOTING GUIDE.......................................................................................................................................... 34
VACUUM / RECOVERY SYSTEM SERVICE MAINTENANCE CHECKLIST................................................................... 34
RECOVERY TANK REMOVAL ......................................................................................................................................... 34
VACUUM MOTOR REPLACEMENT ................................................................................................................................ 35
SQUEEGEE SYSTEM...................................................................................................................................................36-39
SQUEEGEE MAINTENANCE........................................................................................................................................... 36
REMOVAL OF SQUEEGEE MOUNT ASSEMBLY............................................................................................................ 38
REINSTALLATION STEPS ............................................................................................................................................... 38
SQUEEGEE LIFT MOTOR REMOVAL.............................................................................................................................38

FORM NO. 56043127 - CR 1100, CR 1200 - 1
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.
INTRODUCTION
This manual will help you get the most from your Nilsk rider Scrubber-Sweeper. Read it thoroughly before servicing the machine.
Note: Bold numbers and letters in parentheses and underlined indicate an item illustrated on pages 4-7 i.e. (B).
This product is intended for commercial use only.
PARTS AND SERVICE
Repairs, when required, should be performed by your Authorized Nilsk Service Center, who employs factory trained service personnel, and
maintains an inventory of Nilsk original replacement parts and accessories.
Call the NILFISK DEALER named below for repair parts or service. Please specify the Model and Serial Number when discussing your machine.
(Dealer, afx service sticker here.)
NAME PLATE
The Model Number and Serial Number of your machine are shown on the Nameplate on the machine. This information is needed when ordering
repair parts for the machine. Use the space below to note the Model Number and Serial Number of your machine for future reference.
MODEL NUMBER ________________________________________
SERIAL NUMBER ________________________________________
GENERAL INFORMATION

2- FORM NO. 56043127 - CR 1100, CR 1200
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HOPPER SAFETY SUPPORT
WARNING!
Make sure the Hopper Safety Support (A) is in place whenever attempting to do any maintenance work under or near the raised
hopper. The Hopper Safety Support (A) holds the hopper in the raised position to allow work to be performed under the hopper.
NEVER rely on the machine’s hydraulic components to safely support the hopper.
JACKING THE MACHINE
CAUTION!
Never work under a machine without safety stands or blocks to support the machine.
• When jacking the machine, do so at designated locations (Do Not jack on the hopper) – see jacking locations (11).
TRANSPORTING THE MACHINE
CAUTION!
Before transporting the machine on an open truck or trailer, make sure that . . .
•All access doors are latched securely.
• The machine is tied down securely - see tie-down locations (4).
• The machine parking brake is set.
GENERAL INFORMATION
OTHER MANUALS AVAILABLE
The following manuals are available from the Nilsk Literature Service Department, for your Rider Scrubber/Sweeper:
• Parts List - Form Numbers 56042507
• Operation Manual - Form Numbers 56041565 (Danish, Norwegian, Swedish, Finnish)
56041566 (German, French, Dutch, Russian)
56041567 (Spanish, Portuguese, Italian, Greek)
56041575 (Estonian, Latvian, Lithuanian, Slovenian)
56041576 (Slovakian, Czech, Polish, Hungarian)
56041776 (English)
• Quick Start Troubleshooting Service Manual 56043126

FORM NO. 56043127 - CR 1100, CR 1200 - 3
CAUTIONS AND WARNINGS
SYMBOLS
Nilsk uses the symbols below to signal potentially dangerous conditions. Always read this information carefully and take the necessary
steps to protect personnel and property.
DANGER!
Is used to warn of immediate hazards that will cause severe personal injury or death.
WARNING!
Is used to call attention to a situation that could cause severe personal injury.
CAUTION!
Is used to call attention to a situation that could cause minor personal injury or damage to the machine or other property.
GENERAL SAFETY INSTRUCTIONS
Specic Cautions and Warnings are included to warn you of potential danger of machine damage or bodily harm.
WARNING!
• This machine shall be used only by properly trained and authorized persons.
• While on ramps or inclines, avoid sudden stops when loaded. Avoid abrupt sharp turns. Use low speed down hills. Clean only
while ascending (driving up) the ramp.
• Keep sparks, ame and smoking materials away from the battery.
• Charging the batteries produces highly explosive hydrogen gas. Charge batteries only in well-ventilated areas, away from open
ame. Do not smoke while charging the batteries.
• Remove all jewelry when working near electrical components.
• Take precautions to prevent hair, jewelry, or loose clothing from becoming caught in moving parts.
• Turn the key switch off (O), disconnect the battery, and set the parking brake before servicing the machine.
• Never work under a machine without safety blocks or stands to support the machine.
• Do not dispense ammable cleaning agents, operate the machine on or near these agents, or operate in areas where ammable
liquids exist.
•Do not clean this machine with a pressure washer.
CAUTION!
• This machine is not approved for use on public paths or roads.
• This machine is not suitable for picking up hazardous dust.
•When operating this machine, ensure that third parties, particularly children, are not endangered.
• Before performing any service function carefully read all instructions pertaining to that function.
• Do not leave the machine unattended without rst turning the key switch off (O), removing the key and applying the parking
brake.
• Turn the key switch off (O) before changing the brooms and brushes, and before opening any access panels.
• Use caution when moving this machine in below freezing temperature conditions. Any water in the solution or recovery tanks or
in the hose lines could freeze, causing damage to valves and ttings. Flush with windshield washer uid.
• The battery must be removed from the machine before the machine is scrapped. The disposal of the battery should be safely done
in accordance with your local environmental regulations.
SAVE THESE INSTRUCTIONS

4- FORM NO. 56043127 - CR 1100, CR 1200
1 Operator’s Seat
2 Strobe Light
3 Solution Tank Fill
4 Tie Down Locations
5 Recovery Tank Drain Hose
6 Recovery Tank Latch
7 Left Battery Compartment Access Panel
8 Main Broom Left Access Door (belt/motor access)
9 Hopper Cover Prop Rod
10 Front Wheel
11 Jacking Location
12 Left Side Broom
13 Hopper Cover Latch
14 Headlights
15 Right Side Broom
16 Hopper Cover
17 Dust Control Filter
18 Dust Control Shaker Assembly
19 Shaker Assembly Latch
20 Battery
21 Battery Compartment Door
22 Steering Wheel
KNOW YOUR MACHINE
1
2
3
4
5
7
8
4
10
12
13
14
15
16
17
18
19
9
21
22
11
6
20

FORM NO. 56043127 - CR 1100, CR 1200 - 5
23 Electrical Compartment Door
24 Water Level Gauge
25 Recovery Tank Lid
26 Recovery Tank “Tip-Out” Grip
27 Hydraulic Power Unit (Reservoir & Filter)
28 Right Battery Compartment Access Panel
29 Main Broom Right Access Door (broom removal)
30 Access Door Latch
31 Skirt Assembly
32 Inline Solution Filter
33 Solution Tank Drain Hose
34 Rear Roller Bumper
35 Squeegee Tool Handle
36 Squeegee Tool Assembly
37 Tail Light
KNOW YOUR MACHINE
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6- FORM NO. 56043127 - CR 1100, CR 1200
A Low Battery Indicator
B Horn
* Horn ON Indicator
C Parking Brake Indicator (not used)
D Headlights
* Headlight ON Indicator
E Speed Controller Fault Code Status Light
F Hydraulic Filter Plugged Indicator
G Speed Switch
* Speed Switch Indicator
H Scrub Pressure Decrease Switch
* Scrub Pressure Decrease Indicator
I Scrub Pressure Increase Switch
* Scrub Pressure Increase Indicator
J Scrub Pressure Display
K Solution Switch
* Solution ON Indicator
L Solution Tank Empty Indicator
M Recovery Tank Full Indicator
N Vacuum System Switch
* Vacuum System ON Indicator
O Scrub System OFF Switch
* Scrub System Indicator
P Side Broom ON
* Side Broom ON Indicator
Q Main Broom ON Indicator
R Light Sensor
S Shaker Switch
* Shaker ON Indicator (left)
* Dust Filter Plugged Indicator (right / optional)
T Dust Control Switch
* Dust Control ON Indicator
U Side Broom UP/OFF Switch
* Side Broom OFF Indicator
V Open Dump Door Switch
* Open Dump Door Indicator
W Hopper Open Indicator
X Hopper Overtemp Indicator
Y Close Dump Door Switch
* Close Dump Door Indicator
Z Lower Hopper Switch
* Lower Hopper Indicator
AA Raise Hopper Switch
* Raise Hopper Indicator
BB Hour Meter Display
CC Main Power Switch
DD Battery Condition Indicator
CONTROL PANEL
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FORM NO. 56043127 - CR 1100, CR 1200 - 7
EE Solution Flow Control Lever
FF Main Broom Raise/Lower (ON/OFF) Lever
GG Main Broom Adjust Knob (height pattern)
HH Hopper Safety Support Lever
II Control Panel
JJ Main Broom Overload Indicator Light
KK Emergency Battery Disconnect
LL Steering Wheel Tilt Lever
MM Drive Pedal
NN Brake Pedal
OO Parking Brake Latch
PP Operator Seat Adjustment Lever
OPERATOR’S COMPARTMENT
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8- FORM NO. 56043127 - CR 1100, CR 1200
STEERING SYSTEM
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STEERING WHEEL REMOVAL
1See Figure 1.1. Pry up steering wheel Cap (A).
2 Remove center hex Nut (B). Note: This is a metric nut, you will need a 24mm socket.
3 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.
POWER STEERING UNIT REMOVAL
1 Disconnect the battery by using the Emergency Disconnect Knob (KK).
2 Remove the 4 screws that fasten the steering unit cover to the chassis.
3 Open the Battery Cover (21) to access the Universal Joint (C) and loosen
its lower Setscrew (D).
4 Remove the wires to the Motor (E) and Capacitor (F), note location of
wires for reinstallation (salvage capacitor).
5 Remove Setscrew (G) from lower Coupler (H) and pry up on coupler with
a at screwdriver to separate.
6Loosen the 2 (I) Hose Clamps and remove motor.
7 Follow above steps in reverse order to reassemble.
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FIGURE 1.2
FIGURE 1.1

FORM NO. 56043127 - CR 1100, CR 1200 - 9
STEERING SYSTEM
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STEERING CHAIN ADJUSTMENT
1Turn the Key Switch (Main Power) (CC) to the OFF position, set the Parking Brake (OO) and disconnect the batteries.
2 See Figure 1.3. Remove the (4) steering shaft cover screws and (6) (J) Floor Plate (Chain Cover) screws then remove both covers together.
3Loosen the 4 (K) Bolts that secure the chain idler sprockets assembly to the oor. Turn the Lock Nut (L) on the idler tension adjustment bolt to
set the tension. The chain should have a deection of 11/16 inch (17.48mm) with 25 lbs of pull (force) applied at its midpoint.
4 Follow steps 2-3 in reverse order to re-assemble then test steering for proper operation.
STEERING CHAIN REMOVAL
1Follow the Solution Tank Removal instructions in this manual.
2 Turn the Key Switch to the OFF position, set the Parking Brake and disconnect the batteries.
3 See Figure 1.3. Remove the (4) steering shaft cover screws and (6) (J) Floor Plate (Chain Cover) screws then remove both covers together.
4Loosen the 4 (K) Bolts that secure the chain idler sprockets assembly to the oor. Loosen the Lock Nut (L) on the idler tension adjustment bolt
which then will release the chain tension.
5 Remove the 4 (M) Bolts that fasten the Chain Cover Plate to the Gearbox to gain accesses to Steering Chain Links.
6 Remove both master links securing the steering chain at the Steering Plate (N) then remove the chain.
7 Follow above steps in reverse order to re-assemble.
8See Steering Chain Adjustment in this manual to complete installation.
FIGURE 1.3

10 - FORM NO. 56043127 - CR 1100, CR 1200
WHEEL DRIVE SYSTEM
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DRIVE TIRE REMOVAL
WARNING!
Never work under a machine without safety block or stands to
support machine.
Disconnect battery before servicing.
1 Turn steering wheel to the right full lock position and also remove the
squeegee tool.
2 Disconnect the battery pack, set parking brake and block front
wheels.
3See Figure 2.1. Loosen the (5) (A) Wheel Lug Nuts (use a 20mm
socket) while the wheel is on the ground.
4 Jack up machine until wheel clears the oor and place jack stands
under machine.
5 Remove the (5) (A) Wheel Lug Nuts and guide wheel out from under
machine.
6 Follow steps in reverse order to install new wheel. Torque spec 100
ft/lbs (135 N-m).
WHEEL DRIVE MOTOR REMOVAL
1 Follow the Solution Tank Removal Instructions in this manual.
2 Turn the Key Switch to the OFF position, set the Parking Brake
and disconnect the batteries.
3 See Figure 2.1. Mark and remove all (4) motor wiring cables.
4 NOTE: Mark the position of both the drive motor and gearbox
for proper re-assembly.
5 Remove (1) Screw (B) and loosen the (2) Screws (C) holding
the drive motor together with the Gear Box (D). Note: All three
screws are metric, use a 13-mm wrench.
6Separate the Motor (E) from the Gearbox (D).
7 NOTE: Cover the gearbox opening with some suitable cover to
prevent contamination of the gearbox oil.
8 Re-assemble in reverse order. NOTE: The (2) Screws (C) and
the Screw (B) should be torqued to 17 ft/lbs.
FIGURE 2.1

FORM NO. 56043127 - CR 1100, CR 1200 - 11
WHEEL DRIVE SYSTEM
GEARBOX REMOVAL
1 Follow the steps of the Wheel Drive Motor Removal section.
2 Drain the gearbox oil see Gearbox Drain and Fill instructions.
3 See Figure 1.3. Remove the (4) steering shaft cover screws and (6) (J) Floor Plate (Chain Cover) screws then remove both covers together.
4 Loosen the 4 (K) Bolts that secure the chain idler sprockets assembly to the oor. Loosen the Lock Nut (L) on the idler tension adjustment bolt
which then will release the chain tension.
5 See Figure 2.1. Remove the 4 (M) Bolts that fasten the Chain Cover Plate and Steering Plate to the Gearbox. Remove the Chain Cover Plate
by rotating the Plate to slide over the motor bolt heads to access the Steering Chain Links.
6 Remove both master links securing the steering chain at the Steering Plate (N) then remove the chain.
7 Remove the (4) (G) Steering Clamps from the Steering Plate (N), then remove the Steering Plate by aligning the internal notches to clear the
motor.
8 Rotate the drive/steer tire so that it is 90 degrees (perpendicular to the frame) then block the front wheels.
9 Remove the (6) (H) Gearbox Mounting Bolts. Note: Use an 18-mm socket.
10 Safely jack up or lift the rear of the machine to remove the motor/gearbox assembly by carefully guiding it down through the bottom of the frame
opening.
WARNING!
Never work under a machine without safety stands or blocks to support the machine.
11 Rest the tire on the oor and tilt the top of the motor away from the wheel and roll out the opposite side. NOTE: The motor is heavy, block or
strap motor to assist when removing.
Installation
1 NOTE: Refer to the Gearbox Drain and Fill section.
2 Raise the rear of the frame high enough to clear the Gearbox. Then position the gearbox assembly with the drive tire installed underneath the
machine.
3 Tilt and support the gearbox assembly into position at the chassis opening and slowly lower the machine to align the (6) threaded gearbox
mounting holes with the (6) holes in the chassis.
4 Fill Gearbox with oil see Gearbox Drain and Fill instructions.
5 Apply loctite 242 (blue) to the threads of the (6) (H) Gear Box Mounting Bolts, then install and torque to 59 ft/lbs.
GEARBOX DRAIN AND FILL
Gearbox (transmission) oil specication
Type: SAE 80-90, API GL4 OR MIL L2105
Qty: 2.8 qts. (2.7 L)
1 See Figure 2.2. Remove the Oil Filler Plug (O) using a
6mm Allen wrench.
2 Remove the Oil Drain Plug (P) with the same Allen
wrench.
3 Collect the oil in a drain pan, this will take approximately
5 minutes.
4Clean the magnet in the Drain Plug (P) and re-install the
plug, torque to 16 ft/lbs.
5 Re-ll the gearbox with the proper gear lube.
6 NOTE: If the gearbox is in the machine, the wheel drive
motor will have to be removed to re-ll the gearbox
(refer to the Wheel Drive Motor Removal section). If the
gearbox is outside the machine you can re-ll through
the Oil Filler Plug hole (O) using a funnel and hose 1/2”
(13 mm) in diameter. Fill until the lube just begins to
come out through the ller hole.
7Re-install the Oil Filler Plug (O) and torque to 16 ft/lbs.
FIGURE 2.2

12 - FORM NO. 56043127 - CR 1100, CR 1200
WHEEL DRIVE SYSTEM
ROTARY SENSOR (DIRECTIONAL POT SETTING)
1Open the rear electrical control panel door to access the Curtis Speed Control.
2Disconnect the 24 pin plug from the controller.
3 With a Volt / Ohmmeter check the resistance of the rotary sensor at the plug wires WHT/BLK pin14 and VIO/BLK pin 13.
4 Divide the measured resistance in half to nd the neutral setting (dead-band).
5 Move one meter lead to wire BRN/RED pin 15.
6 Position the meter on top of the tanks so it can read easily from the foot pedal.
7At the foot pedal loosen the 2 (Q) Philip Screws and rotate the rotary sensor until you have reached the neutral dead-band then tighten the
Screws (Q) and retest the pot.
FIGURE 2.3
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FORM NO. 56043127 - CR 1100, CR 1200 - 13
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 & 2.4. Before making any adjustments, inspect the Torsion Spring (R) for defects and the correct positions of both spring
ends (repair or replace).
To Adjust Pedal Spring
1 Remove the top portion of the foot pedal see Figure 2.3.
2 Loosen the Screw (S) & Nut (T), the screw with Bushing (U) is positioned between both Fwd & Rev torsion spring ends. Its placement controls
the needed pre-load pressure to eliminate excessive pedal free-play and a balanced spring rate to return the pedal to a centered (neutral)
position.
3 Push the screw back into the pedal frame slot to increase spring tension and eliminate pedal free play. Then tighten the screw & nut being
careful not to pull on the linkage connection to the pot shaft and disturb (move) its neutral setting.
To Replace Pedal or Spring
4 Position the torsion spring ends (V& W) as shown. This is with the bushing and screw not installed.
5 Place the bushing inside the pedal channel pilot it into position using a scratch awl or a pin punch.
6 Then pivot (press) the pedal and insert the screw from the opposite side pushing the guide tool out.
7 Use a screwdriver to tap and pry the bushing back in the pedal slot to increase spring tension.
8 Work the bushing back & forth on both sides of the pedal to obtain equal spacing. Then tighten the screw and nut.
9 A correctly adjusted drive pedal will have minimal amount of free-play when selecting a drive direction.
10 Reconnect the batteries and test the machine to make sure it does not “creep” forward or reverse when the pedal returns to neutral.
11 Service Tip: Also conrm the (E) MIL (wrench) is not ashing an error code (drive system fault). If an error is shown the throttle is not set
properly for the Rotary Sensor’s neutral position. See above instructions for proper adjustment.
Operator pedal height and angle adjustments
1 Pull both pins out and reinstall in a new position to obtain a different angle to relieve operator foot fatigue.
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FIGURE 2.4

14 - FORM NO. 56043127 - CR 1100, CR 1200
FRONT WHEEL SYSTEM
FRONT WHEEL REMOVAL AND BRAKE INSPECTION
1Raise hopper and engage safety support.
2 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 oor.
3 Place safety blocking under the front frame member to support.
4 See Figure 3.1. Remove the Wheel Screw (A) then work the tire(s) off of wheel spindle. Note: the parking brake must be released to allow
wheel to be removed. Also tap on the backside of wheel with wood blocking to help loosen a stubborn stuck wheel.
5 Inspect the spindle; wheel bearings and brake shoe linings for abnormal wear and replace all worn parts. A new brake shoe lining thickness
will measure 11/64 (.172) inches or 4.4mm.
6 Check for approximately one inch (25mm) of operator brake pedal free-play (see instructions below to adjust) and test drive machine for proper
operation.
FRONT BRAKE SHOE ADJUSTMENT
1 See Figure 3.1 detail of Brake Cable mounting nuts. Note both cables need to be adjusted equally. From underneath the machine shorten or
lengthen the number of cable threads extending out of the cable casing by adjusting the cable anchor nuts to obtain the proper Brake Pedal
free play, approximately one inch (25mm). NOTE: Fewer threads will equal a tighter Brake Pedal.
BRAKE CABLE REPLACEMENT
1See Front Wheel Removal and Brake Inspection instructions to access the Brake Cable clevis and anchor nuts.
2 See Figure 3.1. Remove the brake cable from the brake arm by removing Screw and Nut (B & C) and then loosen the cable Anchor Nuts (D)
and pull brake cable casing from its mount. Repeat procedure for other wheel.
3 Loosen the cable anchor nuts (location middle of machine under operator oor plate) slide Cable anchor nuts out of their mounts.
4 Remove Screw (E) Nut (F) from the brake pedal cable guide pulley and remove pulley from the cable.
5 From underneath the machine guide the cable though the chassis to complete the removal of the cable assembly.
6 Install the new cable see Figure 3.1 for proper dimensions.
7 Tighten the cable anchor nuts at the front wheel then turn the ball joint on the new cable end until it lines up with the brake arm then reattach
the Screw and Nut (B & C). Repeat procedure for other wheel.
8 Mount both wheels back on the machine.
9From underneath the machine hand tighten Anchor Nuts (D) to the proper dimension.
10 Press the Brake Pedal a few times to take up any cable slack then check for proper free play approximately one inch (25mm) in the Brake Pedal
if too loose or tight see Front Brake Shoe Adjustment.
11 When Brake Pedal is adjusted properly, tighten the (D) Anchor Nuts.

FORM NO. 56043127 - CR 1100, CR 1200 - 15
FRONT WHEEL SYSTEM
FIGURE 3.1
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









16 - FORM NO. 56043127 - CR 1100, CR 1200
HYDRAULIC SYSTEM







HYDRAULIC PUMP MOTOR REMOVAL
CAUTION! FIGURE 4.1
Disconnect the battery before servicing.
1 Remove right side battery panel.
2 See Figure 4.2. Remove the top right side Cosmetic
Cover (A) and pump assembly Rubber Cover (B).
3 See Figure 4.1. Remove the two hex head Screws (C)
fastening the Pump Solenoid (D) to the motor frame.
4Disconnect the 2 wires from the pump motor terminals
noting location for reconnecting.
5 Remove the 2 (E) Bolts from the top of the motor.
6Carefully separate the motor Frame (F) off the motor
armature.
7 Remove the Armature (G) from the pump coupler input
noting not to lose the Coupling (H).
HYDRAULIC PUMP MOTOR INSTALLATION
1Separate the new motor armature from the motor
frame.
2Install the Coupler (H) onto the pump armature shaft then
carefully place armature into the pump assembly. Note
armature bearing must be ush with the pump housing.
3Carefully place the motor Frame (F) and end bell over
the armature.
4 Seat the carbon brushes by compressing 2 springs at a
time.
5Insert the 2 motor Bolts (E) and tighten.
6Reconnect the motor wires then raise the hopper to
reinstall the solenoid to the motor frame.
7 Install all remaining panels and covers then test for
proper operation of the hopper system.

FORM NO. 56043127 - CR 1100, CR 1200 - 17
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.
HYDRAULIC PUMP REMOVAL
(WHEN HOPPER CANNOT BE RAISED WITH THE PUMP OR EXTERNAL MEANS)
1 Disconnect the battery by using the Emergency Disconnect Knob (KK).
2 Remove right side battery panel.
3 See Figure 4.2. Remove the top right side Cosmetic Cover (A) and pump assembly Rubber Cover (B).
4 Disconnect the battery cover assembly Gas Cylinder (J) from the chassis.
5 Remove the 2 Screws (K) and nuts that fasten the Battery Cover (L) to the chassis and then remove the cover.
6 Remove all motor wiring and save for reinstallation on the new pump assembly.
7 Remove the 4 hydraulic hoses at the pump assemble. Note mark, cap and plug hoses.
8 Remove the 2 Screws (I) that fasten the pump assemble to the chassis and lift the pump out over the battery.
9 Reverse the above instructions for installation of new pump assembly.
WARNING!
Use common sense safety practices
when performing this repair.
WARNING!
When removing the pump assembly
do not rely solely on prop rod to
support hopper. Support the hopper
with some additional means such as
overhead hoist, stands etc.
1 Disconnect the battery by using the
Emergency Disconnect Knob (KK).
2See Figure 4.2. Once the hopper is
safely raised and supported remove
the rubber pump assembly Cover
(B).
3 Remove all motor wiring and save
for reinstallation on the new pump
assembly.
4 Remove the 4 hydraulic hoses at
the pump assemble. Note mark,
cap and plug hoses.
5 Remove the 2 Screws (K) that
fasten the pump assembly to the
chassis to complete its removal.
6 Reverse the above instructions for
installation of new pump assembly.
FIGURE 4.2
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






18 - FORM NO. 56043127 - CR 1100, CR 1200
HYDRAULIC SYSTEM



FIGURE 4.3