Nilfisk-Advance CR 1100, CR 1200 Quick Start Troubleshooting Manual

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CR 1100, CR 1200

QUICK START TROUBLESHOOTING

SERVICE MANUAL

Nilﬁ sk MODELS: 56303004 (CR 1200), 56303005 (CR 1100 / OBS)

1/09 revised 9/09 FORM NO. 56043126

Printed in USA

TABLE OF CONTENTS

GENERAL INFORMATION ................................................................................................................................................1-2

SAFETY INSTRUCTIONS ....................................................................................................................................................3

SPECIFICATIONS .............................................................................................................................................................4-5

MAINTENANCE .................................................................................................................................................................6-7

PM CHECKLIST ................................................................................................................................................................8-9

KNOW YOUR MACHINE ...............................................................................................................................................10-21

MAIN CONTROLLER SELF-DIAGNOSTIC TEST MODE ................................................................................................18

MAIN CONTROLLER ERROR CODES .......................................................................................................................19-21

GENERAL MACHINE TROUBLESHOOTING GUIDE TABLE OF CONTENTS ................................................................. 22

WHEEL DRIVE SYSTEM ...............................................................................................................................................23-28

FLOWCHART ...................................................................................................................................................................23

TROUBLESHOOTING GUIDE..........................................................................................................................................25

DRIVE AND ACCESSORY FUNCTIONS ....................................................................................................................27-28

STEERING SYSTEM .......................................................................................................................................................... 29

POWER STEERING .........................................................................................................................................................29

SWEEPING SYSTEM ....................................................................................................................................................30-35

MAIN BROOM .............................................................................................................................................................30-31

SIDE BROOMS ............................................................................................................................................................32-33

SIDE BROOM LIFT ACTUATOR .................................................................................................................................34-35

HYDRAULIC SYSTEM ..................................................................................................................................................36-37

HYDRAULIC PUMP MOTOR .......................................................................................................................................36-37

HOPPER SYSTEM ........................................................................................................................................................38-45

HOPPER DUMP DOOR...............................................................................................................................................38-40

HOPPER ......................................................................................................................................................................42-45

SQUEEGEE SYSTEM ........................................................................................................................................................46

SQUEEGEE ...................................................................................................................................................................... 46

VACUUM SYSTEM ........................................................................................................................................................47-48

VACUUM MOTOR .......................................................................................................................................................47-48

DUST CONTROL SYSTEM ...........................................................................................................................................49-51

IMPELLER MOTOR .....................................................................................................................................................49-50

SHAKER MOTOR ............................................................................................................................................................. 51

SCRUB SYSTEM ...........................................................................................................................................................52-56

SCRUB DECK LIFT .....................................................................................................................................................52-54

SCRUB MOTORS ........................................................................................................................................................55-56

SOLUTION SYSTEM .......................................................................................................................................................... 57

SOLUTION SOLENOID VALVE ........................................................................................................................................ 57

PROGRAMMABLE CONTROL OPTIONS .....................................................................................................................58-66

ELECTRICAL SYSTEM .................................................................................................................................................67-81

CURTIS CONTROLLER DIAGNOSTICS .........................................................................................................................67

STATUS LED FAULT CODES (TABLE 1) ....................................................................................................................... 68

INSTALLATION CHECKOUT FOR THE CURTIS SPEED CONTROLLER .................................................................... 69

ELECTRICAL COMPONENT LOCATION.........................................................................................................................71

WIRING LADDER DIAGRAM (BEFORE SN 1767238) ....................................................................................................72

WIRING SCHEMATIC (BEFORE SN 1767238)................................................................................................................73

WIRING LADDER DIAGRAM (AFTER SN 1767237) .......................................................................................................74

WIRING SCHEMATIC (AFTER SN 1767237 BUT BEFORE SN 1808249) ......................................................................75

WIRING DIAGRAM (AFTER SN 1808248) ..................................................................................................................76-77

WIRING SCHEMATIC (AFTER SN 1808248)..............................................................................................................78-79

HYDRAULIC SYSTEM .......................................................................................................................................................80

HYDRAULIC COMPONENT LOCATION .......................................................................................................................... 80

HYDRAULIC SCHEMATIC ...............................................................................................................................................80

Note: All references to right, left, front, or rear in this manual are as seen from the operator’s stand-point.

2 - FORM NO. 56043126 - CR 1100, CR 1200

GENERAL INFORMATION

INTRODUCTION

This manual will help you get the most from your Nilﬁ 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 10-13 i.e. (B).

This product is intended for commercial use only.

PARTS AND SERVICE

Repairs, when required, should be performed by your Authorized Nilﬁ sk Service Center, who employs factory trained service personnel, and maintains an inventory of Nilﬁ 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, afﬁ 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 ________________________________________

FORM NO. 56043126 - CR 1100, CR 1200 - 1

GENERAL INFORMATION

HOPPER SAFETY SUPPORT

WARNING!

Make sure the Hopper Safety Support (A) is in place whenever attempting to do any maintenance work under or near the raised hopper. The Hopper Safety Support (A) holds the hopper in the raised position to allow work to be performed under the hopper. NEVER rely on the machine’s hydraulic components to safely support the hopper.

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.

OTHER MANUALS AVAILABLE

The following manuals are available from the Nilﬁ 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)

• Mechanical Repair Service Manual 56043127

2 - FORM NO. 56043126 - CR 1100, CR 1200

CAUTIONS AND WARNINGS SYMBOLS

Nilﬁ 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

Speciﬁ 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, ﬂ 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

ﬂ 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 ﬂ ammable cleaning agents, operate the machine on or near these agents, or operate in areas where ﬂ 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 ﬁ 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 ﬁ ttings. Flush with windshield washer ﬂ 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

FORM NO. 56043126 - CR 1100, CR 1200 - 3

SPECIFICATIONS

General Speciﬁ cations common to All Models English (Metric)

Dimensions

Length 105 inches (267cm) Height 59 inches (150cm) Height w/overhead guard 79 inches (200cm) Ground clearance 3 inches (7.6cm) Minimum ceiling height dumping clearance 92 inches (233.6cm)

Weights CR 1100 CR 1200

Net weight* 3197 lbs. (1450kg) 3200 lbs. (1451kg) Gross weight** 5535 lbs. (2510kg) 5702 lbs. (2586kg)

Speed and Gradeability

Maximum travel speed / Maximum reverse speed 6 mph (9.6km/h) / 4 mph (6.4km/h) Maximum grade angle scrubbing 7.5 deg. Maximum grade angle non-scrubbing 12 deg.

Sound Level

At operators ear 77.2 dBA

Sweep System

Sweeping path w/out side broom(s) 40 inches (102cm) Main broom diameter 14 inches (35.5cm) Side broom diameter 20 inches (50.8cm) Side broom bristle length 7 inches (17.7cm) Main broom speed 380 RPM Side broom speed 100 RPM

Hopper System

Capacity 9.2 Cu. Ft. (261l) Lifting capacity 550 lbs. (250kg) Dump height (variable) Max. 60 inches (152cm) Dump height with door open 56-1/2 inches (143.5cm)

Dust Control System

Filter type: Pleated paper panel Filter dimension 3-3/16” x 20” x 27” (8cm x 50.8cm x 68.5cm) Filter media area 78 ft

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 ﬁ ll capacity 1.7 qts. (1.6l)

Recovery System

Vacuum water lift (sealed) minimum 72 inches Vacuum water lift (open hole adapter 1”) minimum 6.3 inches

Electrical System

Battery compartment size Width 18.25” (46.35cm) Height 23.75” (60.32cm) Length 38.75” (98.42cm) Battery Weight and Dimensions Maximum weight: 770 Amp/Hr @ 6 hrs 1875 lbs. (850.5kg) / 38.69” (98.3cm) L x 18” (45.7cm) W x 22.81” (57.9cm) H Minimum weight: 510 Amp/Hr @ 6 hrs 1480 lbs. (635kg) / 38.05” (96.6cm) L x 15.54” (39.5cm) W x 22.81” (57.9cm) H

(7.25m2)

*Net Weight: Standard machine without options, empty solution and recovery tanks, without removable scrub brushes and battery removed. **Gross Weight: Standard machine without options, full solution tank and empty recovery tank, with removable scrub brushes and maximum sized

battery (770AH).

4 - FORM NO. 56043126 - CR 1100, CR 1200

SPECIFICATIONS

Speciﬁ cations common to Deck Size English (Metric)

CR 1100 CR 1200

Width w/out squeegee & deck 50 inches (127cm) 50 inches (127cm) Solution Tank Capacity 60 gal. (227) 80 gal. (303) Recovery Tank Capacity 60 gal. (227) 80 gal. (303) Scrubbing Rate per hour 75,700 ft2 (7,630m2) 84,500 ft2 (7,850m2) Sweeping path w/side brooms (2) X 62 in. (158cm) Sweeping path w/side broom (1) 51” (130cm) X Sweeping rate per hour 134, 600 ft2 (12,500m2) 163,700 ft2 (15,210m2) Scrub Brush quantity 3 3 Scrub Brush diameter 15” (38cm) 17” (43cm) Scrub Brush Motor Speed 225 RPM 225 RPM Squeegee Tool Width 51.25” (130cm) 57” (145cm)

FRONT VIEW

Width

Height

SIDE VIEW

Length

FORM NO. 56043126 - CR 1100, CR 1200 - 5

MAINTENANCE

AFTER USE

1 Raise the squeegee, the scrub brushes, and the brooms. 2 Shake the dust control ﬁ lter and empty the hopper. 3 Drain and ﬂ ush the recovery tank. 4 Tip the recovery tank out and check the squeegee hose elbow below the tank for debris. DO NOT run water down the recovery tank vacuum tubes, this may

cause damage to the vacuum motors.

5 Remove and clean the squeegee tool. 6 Remove and clean the scrub brushes. Rotate the scrub brushes. 7 Wipe the machine with a damp cloth. 8 Perform all required maintenance before storage. 9 Move the machine to a clean, dry storage area. 10 Store the machine with the brooms, the squeegee and the scrub brushes in the UP position, and the tank covers open so that the tanks can air out.

REPORT ANY DEFECT OR MALFUNCTION NOTED DURING OPERATION TO AUTHORIZED SERVICE OR MAINTENANCE PERSONNEL.

MAINTENANCE SCHEDULE

Keep the machine in top condition by following the maintenance schedule closely. Maintenance intervals given are for average operating conditions.

Machines used in severe environments may require service more often.

25 150 300 Yearly MAINTENANCE ITEM Daily Hours Hours Hours (1,000hrs)

Charge Battery X Drain / Check / Clean Tanks & Hoses X Check / Clean / Rotate Scrub Brushes & Pads X Check / Clean / Adjust Squeegee X *Check / Clean Vacuum Motor Inlet Screen Cap X Clean Solution Filter (32) X Check Battery Cell Water Level(s) X Check Foot/ Parking Brake For Wear & Adjustment X Inspect Broom Housing Skirts X Check Hydraulic Fluid Level X Check / Clean Hopper Dust Control Filter Using Method “A” X Inspect Scrub Deck Skirts X Main Broom Maintenance X Side Broom Maintenance X Lubrication X Inspect Main Broom Upper & Lower Belts X Check / Clean Hopper Dust Control Filter Using Method “B” X Check / Clean Hopper Dust Control Filter Using Method “C” X Replace Hydraulic Oil & Filter X ** Check Carbon Brushes X X Have Nilﬁ sk service center inspect the wheel drive gearbox X

* DO NOT run water down the vacuum tube in the recovery tank this will damage the vacuum motors. Vacuum tube is on left side of tank with screen cap. ** Have your Nilﬁ sk Dealer check the vacuum motors carbon motor brushes once a year or after 300 operating hours, all other motors yearly or 1000 hours.

DRIVE WHEEL GEAR CASE OIL

Change the gear lube in the drive wheel gear case after the ﬁ rst 350 hours of operation (break in period). Required oil speciﬁ cation: API GL4, SAE 80/90 weight gear oil. Gear case oil ﬁ ll capacity is 2.8 quarts (2.7 liters). NOTE: Refer to Mechanical Repair Service Manual (56043127) for drain and ﬁ ll instructions.

LUBRICATING THE MACHINE

Every 150 hours apply light machine oil to maintain free movement of all general pivot points. Example the seat, and broom door hinges etc. Broom, squeegee and hopper pivots use composite bearings materials and there lubrication is not required.

Grease Fitting locations:

* 1 on each steering sprocket, 6 total * 2 on drive wheel gear case spindle * 1 on each squeegee caster, 2 total

Lube Oil locations:

* steering chain

6 - FORM NO. 56043126 - CR 1100, CR 1200

MAINTENANCE

WARNING

For the protection of the environment; when servicing any of the machine’s lubrication ﬂ uids they must be disposed of safely in accordance with your local environmental regulations (recycling). Examples of machine lubrication products: (Hydraulic system oil, Hydraulic system oil ﬁ lter).

HOPPER DUST CONTROL FILTER

The hopper dust control ﬁ lter must be cleaned regularly to maintain the efﬁ ciency of the vacuum system. Follow the recommended ﬁ lter service intervals for the longest ﬁ lter life.

CAUTION!

Wear safety glasses when cleaning the ﬁ lter. Do not puncture the paper ﬁ lter. Clean the ﬁ lter in a well-ventilated area.

To remove the hopper dust control ﬁ lter...

1 Lift the Hopper Cover (16) on top of the hopper. Make

sure that the Hopper Cover Prop Rod (9) is in place.

2 Inspect the top of the Hopper Dust Control Filter (17)

for damage. A large amount of dust on top of the ﬁ lter is usually caused by a hole in the ﬁ lter or a damaged ﬁ lter gasket.

3 Turn the two hold-downs to the side (one on each

side at the front of the frame) to release the shaker frame, then swing the Dust Filter Shaker Assembly (18) up and latch in place with the Shaker Assembly Latch (19).

4 Lift the Hopper Dust Control Filter (17) out of the

machine.

5 Clean the ﬁ lter using one of the methods below: Method “A”

Vacuum loose dust from the ﬁ lter. Then gently tap

the ﬁ lter against a ﬂ at 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 ﬁ lter. Then blow

compressed air (maximum pressure 100 psi) into the clean side of the ﬁ lter (in the opposite direction of the airﬂ ow).

Method “C”

Vacuum loose dust from the ﬁ lter. Then soak the ﬁ lter

in warm water for 15 minutes, and then rinse it under a gentle stream of water (maximum pressure 40 psi). Let the ﬁ lter dry completely before putting it back into the machine.

6 Follow the instructions in reverse order to install the

ﬁ lter. If the gasket on the ﬁ lter is torn or missing, it must be replaced.

FIGURE 1

HYDRAULIC OIL

Raise and prop (HH) the hopper. See Figure 1. The oil level should be approximately 1 inch (2.54cm) below the bottom of the Elbow (A) on the front of the reservoir when the hopper is up (when the hopper is fully down the oil level should be up to the bottom of the elbow). If it is below this level, add 10W30 motor oil. Change the oil if major contamination from a mechanical failure occurs. SERVICE NOTE: The Cap (B) on Elbow (A) on the side of the reservoir is for adding oil. SERVICE

NOTE: Remove Vent Plug (D) to allow oil to be ﬁ lled.

IMPORTANT!

This machine is equipped with an Indicator Light (F) which lights if the Hydraulic Oil Filter (C / Figure 1) requires changing. The Hydraulic Filter (C / Figure 1) is found on the side of the Hydraulic Power Unit (27) as shown.

FORM NO. 56043126 - CR 1100, CR 1200 - 7

Nilfisk CR 1100/1200 B

PM Checklist

Defect Codes

Customer A needsadjustment Address C dirty or contaminated City St Zip L leaks Model Serial Hours W worn out

B binding

D damaged, bent or torn

M missing

Ref

1 Check Neutral Sense Switch Operation. To test, sit on seat and depress the drive pedal

then turn the key switch on. The machine should not move, it should set a drive

system code. 2 Drive pedal operation, check for FWD & REV drive and any neutral return creep A 3 Seat safety switch (machine will not drive without an operator on seat) A rough 4 Drive System Performance (Reference SVR manual for Curtis drive programmer speed

changes). 5 Battery compartment interlock safety switch (machine will not run with bar removed) A C 6 Steering Noisy sluggish 7 Brakes (check both service & parking) 8 Hopper Up/Down (also check operation of the safety hopper support) A B 9 Hopper Dump Door Open/Close A B

10 Main Broom Raise /Lower A B 11 Side Broom Raise /Lower 12 Main Broom On/Off and sweeping performance 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) 17 Solution Control (On/Off and Flow Volume Min/Max) C L 18 Perform the machine self-diagnostic test. (see manual PN 56043126) <-----> 19 Headlights, Gauges and (optional) accessories rotating beacon, backup alarm <-----> 20 Dust control filter shaker & impeller <-----> 21 Battery charger (auto turn On & Off) 22 Battery emergency disconnect knob, tilt steering mechanism and seat adjustment lever A B

OPERATIONAL INSPECTION ITEMS

Defect Codes

(circle)

A B C

A low power

A B W

A B C A B C

C L W

Does

Not

Work

Ref

VISUAL INSPECTION ITEMS

23 Side Broom Height (min bristle wear 3 inches) A B D W 24 Side Broom Motor(s) B 25 Hopper Cover Gasket D W 26 Hopper Dust Filter & Gasket C D W 27 Impeller Motor (remove cover to access motor & fan) 28 Hopper Dump Door Cylinder 29 Hopper Skirting & Seals (raise hopper to inspect) 30 Hopper Dump Door & Seal (raise hopper to inspect) B D W 31 Brake Cable, Brake Shoes & Drum Wear 32 Hopper Lift Cylinder & Hopper Magnetic Switch 33 Main Broom Pattern Adjustment (min bristle wear 2-1/2"

6.4cm length) & Magnetic on/off broom switch

34 Main Broom Motor (open left side access door to inspect

belts)

8 - FORM NO. 56043126 - CR 1100, CR 1200

Comments

2-3" (5-7.5cm) wide

pattern

Defect Codes

(circle)

C W

B L

D M W

A B W A B L

A B D W

ABW

Does

Not

Work

Ref

35 Broom Housing & Door Skirts 36 Battery (Load Test) Clean & Water C W 37 Circuit Breaker panel (inspect electrical connections) C D 38 Hydraulic System Hoses & fittings L 39 Hydraulic Oil Reservoir Level (10W-30 engine oil only)

Hydraulic Oil Filter (change yearly or 1,000 hrs.)

40 Steer Spindle & Drive Wheel motor (remove recovery tank)* D L 41 Rear Tire (check lug nut torque 100 FT LB, 135Nm) 42 Drive Wheel gear case (see service manual)* Gear oil level L 43 Front & Rear Tires Tread wear W 44 Steering chain & sprockets Oil chain / grease

45 Steering chain tension Adjust* 46 Gear case/spindle grease fittings Grease 47 Scrub Brushes, check for wear and rotate 48 Scrub Deck Skirts 49 Solution Solenoid Valve 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 53 Vacuum Stand Pipe Deflector Clean 54 Recovery Tank Cover Gasket 55 Recovery Tank Drain Hose & Cap 56 Squeegee Pick-Up Hose & Metal Elbow Back flush 57 Squeegee Tool & Blades Clean & Rotate 58 Squeegee Casters (lubricate)

*See service manual 56043127.

Comments

Fill level (bottom of

elbow with hopper

closed)

sprockets

VISUAL INSPECTION ITEMS (continued)

Defect Codes

(circle)

D M W

L Add Oil

D M W D M W C

C D L C D M L M W C D L C D L A D W A D W

Does

Not

Work

*NOTE: For additional service information see service manuals form numbers 56043126 &

56043127.

Defect Codes A needs adjustment C dirty or contaminated M missing B binding D damaged, bent or torn W worn out L leaks

WORK COMPLETED BY: ACKNOWLEDGED BY:

Service Technician Signature Date Customer Signature Date

FORM NO. 56043126 - CR 1100, CR 1200 - 9

KNOW YOUR MACHINE

1 Operator’s Seat 2 Strobe Light (optional / standard on Nilﬁ sk Models) 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

10 - FORM NO. 56043126 - CR 1100, CR 1200

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

FORM NO. 56043126 - CR 1100, CR 1200 - 11

CONTROL PANEL

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 Over-temp 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

12 - FORM NO. 56043126 - CR 1100, CR 1200

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

FORM NO. 56043126 - CR 1100, CR 1200 - 13

KNOW YOUR MACHINE DESCRIPTIONS

1 Operator’s Seat – Operator sits here. Seat is adjustable forward and back. 2 Strobe Light (optional / standard on Nilﬁ sk models) – This light starts ﬂ ashing when the ignition switch is turned ON. 3 Solution Tank Fill – Open to ﬁ ll the solution tank, use non-foaming chemicals only. 75 gallon (284 liter) maximum capacity. 4 Tie down Locations – Safe point to tie down machine while transporting. 5 Recovery Tank Drain Hose – Used to empty the recovery tank (hold the end of the hose above the water level in the tank to avoid sudden,

uncontrolled ﬂ ow of waste water).

6 Recovery Tank Latch – Push down on latch lever to release recovery tank for “Tip-Out” feature. 7 Left Battery Compartment Access Panel – Panel lifts straight up after opening Battery Compartment Door (21) to provide access to the

battery compartment from the left side of the machine. SERVICE NOTE: Battery can only be removed from this side. 8 Main Broom Left Access Door – Open to access main broom for servicing. 9 Hopper Cover Prop Rod – Used to support the hopper cover while raised. 10 Front Wheel – Machine front wheel. 11 Jacking Location – Safe points for jacking machine up. DO NOT jack the machine on the hopper. 12 Left Side Broom – Used for sweeping along walls or curbs. 13 Hopper Cover Latch – Holds Hopper Cover (16) in place. 14 Headlights – Use when sweeping in hard to see areas. 15 Right Side Broom – Used for sweeping along walls or curbs. 16 Hopper Cover – Open to access the hopper dust control ﬁ lter. 17 Dust Control Filter – Filters dust from the air. 18 Dust Control Shaker Assembly – Vibrates the Dust Control Filter (17) to shake dust out of it. 19 Shaker Assembly Latch – Used to hold the Shaker Assembly (18) UP while servicing the ﬁ lter. 20 Battery 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

24 Water Level Gauge – When ﬁ lling the solution tank do not exceed the maximum level. 25 Recovery Tank Lid – Open to rinse and clean inside of recovery tank. 26 Recovery Tank “Tip-Out” Grip – Grab and pull here after unlatching to tip the recovery tank out to the side for cleaning. 27 Hydraulic Power Unit (Reservoir / Filter) – Holds the hydraulic system oil, 1.7 quart (1.6 liter) capacity. SERVICE NOTE: Open and prop

28 Right Battery Compartment Access Panel – Panel lifts straight up after opening Battery Compartment Door (21) to provide access to the

29 Main Broom Right Access Door – Open to access main broom for servicing. 30 Access Door Latch – Push UP on lever to unlatch (Recovery Tank utilizes same latch for “Tip-Out” feature). 31 Skirt Assembly – Scrub system has left and right skirt assemblies to channel solution on ﬂ oor into the path of the squeegee assembly. 32 Inline Solution Filter – Filters solution prior to dispensing on ﬂ oor. 33 Solution Tank Drain Hose – Used to empty the solution tank. 34 Rear Roller Bumper – Protects both machine and other objects in the event the machine brushes up against anything. 35 Squeegee Handle – Loosen these two handles to remove the squeegee assembly from the machine. 36 Squeegee Assembly – Picks up solution after scrubbing. 37 Tail Light – Turns ON with headlights.

– Provides electrical power for operating the machine.

Battery Disconnect (KK) has been pushed IN.

the hopper to add oil. Hydraulic return oil ﬁ lter on side of the unit ﬁ lters oil after ﬂ owing through system and prior to returning to reservoir.

battery compartment from the Right side of the machine.

14 - FORM NO. 56043126 - CR 1100, CR 1200

CONTROL PANEL DESCRIPTIONS

A Low Battery Indicator – This indicator will ﬂ ash when the battery requires charging. B Horn Switch – This switch will sound the horn as long as the switch is held. * Horn Indicator: Lights up when the horn switch is pressed. C Parking Brake Indicator – This indicator is currently not used. D Headlight Switch – Turns the headlights and taillights ON or OFF. * Headlight ON Indicator: Lights up when the lights are ON. It is OFF when the lights are OFF. E Speed Controller Fault Code Status Light – This light will ﬂ ash on and off identifying a speed controller fault. Note: Refer to troubleshooting chart in this manual for

explanation.

F Hydraulic Filter Plugged Indicator – Indicates when the hydraulic oil ﬁ lter should be serviced. Have your Nilﬁ sk Service Center check the machine. SERVICE NOTE:

This light may give a FALSE indication when the hydraulic oil is cold.

G Speed Select Switch – This switch will allow the operator to select the transport speed limit while the scrub system is enabled thereby allowing scrubbing at a higher

rate of speed. This option can be disabled if desired. See the programming section for details.

The transport and scrub speed limits can be programmed using a Curtis handheld programmer. Refer to the electrical section in this manual for details. * Speed Select Switch Indicator: This indicator will be green if a scrub mode has been selected and the faster scrub speed has been selected. This indicator will be off

if the Speed Select Switch has been turned OFF.

SCRUB SYSTEM

H Scrub Pressure Decrease Switch – If the scrub system is off, pressing this switch will cause the following to occur:

• The scrub system will be enabled with the scrub pressure set to the lightest setting and the scrub deck will be lowered

• The vacuum system will be enabled and the squeegee will be lowered

• The solution system will be enabled

• As soon as the drive pedal is moved from the neutral position the scrub brushes will start turning and the vacuum will turn on. If the direction is forward the solution ﬂ ow will start. If the direction is reverse, the squeegee will raise and the solution ﬂ ow will be stopped. The scrub 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 2 or 3, the scrub pressure will decrease. If the switch is held, the pressure

will decrement until the minimum setting of 1 is reached.

* Scrub Pressure Decrease Indicator: The scrub pressure decrease indicator will be lit if the scrub system is enabled and the pressure is set at 1 or 2. The indicator

will be off if the scrub system is off or if the scrub pressure is set to 3.

I Scrub Pressure Increase Switch – If the scrub system is off, pressing this switch will cause the following to occur:

• The scrub system will be enabled with the scrub pressure set to the lightest setting and the scrub deck will be lowered

• The vacuum system will be enabled and the squeegee will be lowered

• The solution system will be enabled

• As soon as the throttle is moved from the neutral position the scrub brushes will start turning and the vacuum will turn on. If the direction is forward the solution ﬂ ow will start. If the direction is reverse, the squeegee will raise and the solution ﬂ ow will be stopped. The scrub 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 scrub pressure increase indicator will be lit if the scrub system is on and the pressure is set at 2 or 3. The indicator will be off

if the scrub system is off or if the scrub pressure is set to 1.

J Scrub Pressure Display:

The single character display on the control panel is used as a display for the scrub pressure. If the scrub system is ON, the display will indicate the relative pressure setting of 1, 2 or 3 otherwise it is blank. Note: This display is also used to show error codes see the main controller A1 self diagnostic test mode found in this manual for a complete explanation.

K Solution Switch - This switch is used to turn the solution system on or off. Pressing this switch when the scrub system has been activated will alternate between on and

off. The solution ﬂ ow will only turn on when the drive pedal is moved from the neutral position in the forward direction. The solution ﬂ ow will turn off if the drive pedal returns to neutral or is moved to reverse. Pressing this switch when the scrub system is off will momentarily turn the solution ﬂ ow on to allow pre-wetting of the scrub brushes.

* Solution System Indicator: The solution indicator will be lit if the solution is enabled. If the solution is off, this indicator will be OFF. L Solution Tank Empty Indicator – This indicator will illuminate when the solution tank is low. M Recovery Tank FULL Indicator – This indicator will ﬂ ash when the recovery tank is FULL. The vacuum system is shut OFF at this point. Draining the recovery tank

will reset this indicator.

N Vacuum System Switch – This switch is used to turn the vacuum system on or off. When the vacuum is on the squeegee will lower (unless the machine is in reverse)

and when the vacuum is off the squeegee will rise. Pressing this switch will alternate between on and off. The vacuum will only turn on when the drive pedal is moved from the neutral position. It will remain on for 10 seconds after the drive pedal returns to neutral.

The vacuum also has an automatic shutoff feature that will turn the vacuum and scrub systems off if the recovery tank becomes full. If this occurs, the recovery tank full

indicator (M) will ﬂ ash. The vacuum shutoff delay is adjustable. See the programming section for details.

* Vacuum System Indicator: The vacuum indicator will be lit if the vacuum is enabled. It will ﬂ ash if the vacuum is in the delayed-off condition. If the vacuum is off, this

indicator will be off.

O Scrub System OFF Switch - Pressing this switch when the unit is in a scrub mode will cause the following to occur:

• The scrub brushes will turn off

• The scrub deck will raise to the UP position

• The solution ﬂ ow will be stopped

• The ﬁ rst time that this button is pressed, the vacuum/squeegee system will NOT be turned off. This is so that any remaining water may be picked up without having to turn the vacuum back on. If this button is pressed a second time (pressed after the scrub mode has been turned off) the squeegee will raise and the vacuum will shut off after a 10 second delay.

* Scrub System OFF Indicator: This indicator will be lit if the scrub system is OFF. This indicator will be OFF if the scrub system is enabled or running.

FORM NO. 56043126 - CR 1100, CR 1200 - 15

CONTROL PANEL DESCRIPTIONS

SWEEP SYSTEM P Side Broom DOWN/ON Switch – This switch is used to lower and/or turn the side broom(s) on. The side broom(s) will lower whenever this

switch is pressed until the bottom limit is reached. The side broom(s) will turn on when the drive pedal is moved from the neutral position. They will remain on for approximately 5 seconds after the drive pedal returns to neutral. This shutoff period is adjustable. See the service manual for details.

* Side Broom ON Indicator:

• This indicator will be lit if the side broom(s) are turned ON.

Q Main Broom ON Indicator: This indicator will be lit if the main broom is down, otherwise it is OFF. R Light Sensor – Not currently used. S Shaker Switch – This switch controls the hopper dust control ﬁ lter shaker. Pressing this button will cause the dust control to turn off and the

shaker to turn on. The shaker will run for approximately 20 seconds. This period is adjustable. See the service manual for details. Pressing the switch while the shaker is operating will cancel the timer and turn the shaker off. If the dust control was previously on, it will turn back on.

* Shaker Indicator (left): This indicator will be lit if the shaker is turned ON, otherwise it is OFF. * Dust Filter Plugged Indicator (right / optional): This indicator will be lit if the dust ﬁ lter requires cleaning, otherwise it is OFF. NOTE:

Requires optional Hopper Filter Switch Kit.

T Dust Control Switch – This switch controls the hopper dust control. Pressing this switch alternates between on and off. The dust control will

run when the drive pedal is moved from the neutral position. The dust control will remain on for approximately 5 seconds after the drive pedal returns to neutral. This shutoff period is adjustable. See the service manual for details.

* Dust Control Indicator: This indicator will be green if the dust control system is ON, otherwise it is OFF. U Side Broom UP/OFF Switch – This switch is used to raise and/or turn the side broom(s) off. The side broom(s) will rise whenever this switch

is pressed until the upper limit is reached. When the upper limit is reached, the side broom(s) will turn off.

* Side Broom OFF Indicator: This indicator will be lit if the side broom(s) are turned OFF.

HOPPER SYSTEM V Open Dump Door Switch – This switch is used to open the hopper dump door. This switch will only function when the main broom is down or

when the hopper is raised. NOTE: The dump door will automatically open when the hopper is fully down and the main 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 ﬂ ashes if the hopper is open, otherwise it is OFF. X Hopper Overtemp Indicator – This indicator will ﬂ ash when the hopper temperature exceeds 140 degrees Fahrenheit. NOTE: the hopper

temperature switch is optional.

Y Close Dump Door Switch – This switch is used to close the hopper dump door. This switch will only function when the main broom is up or

when the hopper is raised. NOTE: The dump door will automatically close when the main broom is raised or when the hopper is raised.

* Close Dump Door Indicator: This indicator will be lit while the dump door is in the process of closing, otherwise it is OFF.

Lower Hopper Switch – This switch is used to lower the hopper. The hopper will drop as long as this switch is held. Once the hopper is in the

full-down position, the Hopper Open Indicator (W) will turn off. If any of the sweep or scrub functions were on when the hopper was raised, they will be reactivated. The dump door will automatically open or close depending on whether the main broom is down or up. The switch indicator will be lit as long as the switch is held.

* Lower Hopper Indicator: This indicator will be lit while the hopper is in the process of lowering, otherwise it is OFF. AA Raise Hopper Switch – This switch is used to raise the hopper. Pressing this switch will cause the following to occur:

• The switch indicator will illuminate

• If the dump door is open (main broom down) the door will close

• The main broom, side brooms, scrub system, solution, and vacuum will all turn off

• If the dust control was on, it will remain on unless programmed otherwise

• Once the dump door is closed, the hopper will begin to raise

• The hopper will continue to raise as long as this switch is held Once the hopper is no longer in the full-down position, the Hopper Open Indicator (W) will ﬂ ash. The dump door open and close switches will

now be functional

* Raise Hopper Indicator: This indicator will be lit while the hopper is in the process of raising, otherwise it is OFF.

BB Hour meter / Error Code Display – Upon power up or if the machine has been idle for at least ten seconds with all systems turned off, the

hour meter will display the hours for each major electric motor system for 3 seconds and continue to cycle through each system as long as the drive pedal is in neutral and all systems are OFF. Once the drive pedal is pressed or any system activated it will indicate the drive system hours (default). If an overload fault occurs, the display will indicate the associated error code immediately.

16 - FORM NO. 56043126 - CR 1100, CR 1200

CONTROL PANEL DESCRIPTIONS

CC Main Power / Key Switch – Main Power Switch. DD Battery Condition Indicator - The battery condition indicator consists of three lights, a green (G), a yellow (Y), and a red (R). The voltage

indication will change based on the cutoff level (standard or alternate) selected in the control unit. The battery voltage ranges for the various indications are listed below:

Standard

Green 34.00 Green & Yellow 33.00-33.99 Yellow 32.00-32.99 Yellow & Red 31.50-31.99 Red 31.00-31.49 Flashing Red/Cutoff <31.00

NOTE: Refer to service manual for selection of alternate cut-off level. Once the low voltage cutout level has been reached (ﬂ ashing red indicator) the battery must be FULLY recharged to reset the battery condition indicator. The scrub system will not function until the indicator has been reset.

COCKPIT EE Solution Flow Control Lever – Move this lever FORWARD to increase solution ﬂ ow to the ﬂ oor. Move BACKWARD to decrease the amount of

solution ﬂ ow to the ﬂ oor. When the Drive Pedal (OO) is released from either forward or reverse travel, the solution ﬂ ow will stop automatically, and resume when the drive is engaged. Solution ﬂ ows in forward only, stops in reverse.

FF Main Broom Raise/Lower (ON/OFF) Lever – This lever primarily controls the main broom. It can also control the side brooms and dust control

if desired. Lowering this lever will cause the following to occur:

• The main broom indicator will illuminate

• The main broom will be lowered to the operating position

• The side brooms will be lowered to the operating position

• The dust control will be enabled

• The hopper dump door will open

As soon as the drive pedal is moved from the neutral position the main broom and side brooms will start turning and the dust control will turn

on. The brooms and dust control will remain on 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 close

The side brooms and dust control can be programmed not to automatically come on with the main broom. See the service manual for details

GG Main Broom Adjust Knob – Used to compensate for main broom wear in order to maintain a 3 inch (7.62cm) wide broom pattern. HH Hopper Safety Support Lever – NEVER work under a raised hopper without the safety support engaged. To engage; raise the hopper all the

way UP, pull back on lever and then lower hopper until it seats.

II Control Panel – See items A through DD. JJ Main Broom Overload Indicator Light – This indicator will be lit if the main broom pressure is too high. The main broom will shut off if

overloaded for an extended period of time.

KK Emergency Battery Disconnect – Push in on knob to disconnect battery. LL Steering Wheel Tilt Lever – Pull lever out to release steering column for adjusting up or down. MM Drive Pedal – Controls the machine’s travel speed and direction:

Push down on the Back of the pedal to move the machine Backward. Push down on the Front of the pedal to move the machine Forward. The SPEED of the machine will increase as the pedal is pushed closer to the ﬂ oor. Maximum forward speed is faster than maximum reverse

speed.

NN Brake Pedal – Operates the mechanical brakes on the front wheels. OO Parking Brake Latch – Used to “lock” the brake pedal in place after engaging the brakes. NEVER leave machine unattended without setting

Parking Brake. Press on this latch with your foot instead of the brake pedal to activate.

PP Operator Seat Adjustment Lever - Use this lever to slide the operator’s seat forward or backward.

FORM NO. 56043126 - CR 1100, CR 1200 - 17

KNOW YOUR MACHINE

IMPORTANT SERVICE TIP

Before any troubleshooting is done perform this troubleshooting special control system procedure.

MAIN CONTROLLER (A1) SELF-DIAGNOSTIC TEST MODE

If problems with the main electronic control system are suspected, this self-diagnostic mode may help isolate the problem. When this mode is activated, the control unit will activate each one of the outputs in sequence and test for short circuits, open circuits, or overload conditions. This mode will also provide an easy test for the touch panel switches and indicators. If an abnormal condition is encountered with one of the outputs, an error code will be displayed on the Scrub Pressure Display (J) see Figure 2.

1 During this test, the horn will sound brieﬂ y and the scrub deck and squeegee will move if they are in the up position. If the hopper is not in the

down position it will also move slightly.

CAUTION!

Make sure that all persons are away from these parts of the machine to prevent injury.

2 Turn the main power key switch to the off position. 3 Press and hold the side broom down/on switch. 4 While holding the side broom down/on switch, turn the main power key switch to the on position. 5 Continue to hold the side broom down/on switch until all indicators except the side broom down/on 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

Table”. 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 display will show “1” followed by a brief blank period

• The display will show “8” followed by a long blank period

• The above sequence will repeat

10 To test any of the control panel switches, press the desired switch. The indicator for that switch should illuminate. If not, consult the general

machine troubleshooting section of this manual which will show machine system ﬂ ow charts.

11 The hopper limit, main broom, recovery tank full, and solution tank empty switches may also be tested in this mode. The corresponding

indicators will indicate the state of each of the inputs.

12 To exit this mode, turn the main power key switch to the off position.

NOTE: If the machine is not equipped with an optional back-up alarm, an error code 59 will be indicated.

FIGURE 2

18 - FORM NO. 56043126 - CR 1100, CR 1200

Display

Code Error Description

Side broom actuator overload

Output bank 1 overload (horn & shaker)

Output bank 2 overload (contactors)

Light circuit overload Check for short circuit in bulb and wiring.

Scrub deck actuator overload

Squeegee actuator overload

Scrub motor overload

Main broom overload

Accessory contactor coil circuit short

Accessory contactor coil circuit current too high Same as Error 9 Replace coil. (Shorted Coil)

Accessory contactor coil circuit open

Horn circuit short Check for wiring or horn shorted.

Horn circuit current too high

Horn circuit open

Left scrub motor M2 contactor coil circuit short Left scrub motor M2 contactor coil current too high

Left scrub motor M2 contactor coil circuit open

Shaker circuit short

Shaker circuit current too high

Shaker circuit open

Main broom contactor coil circuit short

Main broom contactor coil current too high

Main broom contactor coil circuit open Center scrub motor M3 contactor coil circuit short Center scrub motor M3 contactor coil current too high

Center scrub motor M3 contactor coil circuit open

Door open solenoid coil circuit short

Door open solenoid coil current too high

Control Error Codes for Battery Powered Captor

Troubleshooting Actions

Check for binding or frozen side broom linkage & actuator motor. Check for short circuit in lift motor or wiring.

Run self-diagnostic for specific cause

See scrub motor troubleshooting part B.

See main broom motor troubleshooting part B. Check for wiring problems at the K10 coil. Check K10 coil resistance if below 116 ohms Replace.

Check for open in coil & wiring. Check for 36V at the K10 coil wire colors YEL/BRN (+), BLU/ORN (-).

Same as Error 12 Replace Wiring or horn. Check for open in wiring. Check for 36V at the Horn wire colors VIO (+), VIO/BRN (-). Replace or repair. Check for wiring problems at the K1 coil. Check K1 coil resistance if below 116 ohms Replace.

Same as Error 15 Replace coil. (Shorted Coil) Check for open in coil & wiring. Check for 36V at the K1 coil wire colors VIO (+), YEL/BLU (-).

See shaker will not run troubleshooting flow chart.

See shaker will not run troubleshooting flow chart. Check for wiring problems at the K4 coil. Check K4 coil resistance if below 194 ohms Replace.

Same as Error 21 Replace coil. (Shorted Coil) Check for open in coil & wiring. Check for 36V at the K4 coil wire colors VIO (+), GRN/GRA (-). Check for wiring problems at the K2 coil. Check K2 coil resistance if below 116 ohms Replace.

Same as Error 24 Replace coil. (Shorted Coil) Check for open in coil & wiring. Check for 36V at the K2 coil wire colors VIO (+), WHT/VIO (-). Check for wiring problems at the L4 coil. Check L4 coil resistance if below 66 ohms Replace.

Same as Error 27 Replace coil. (Shorted Coil)

FORM NO. 56043126 - CR 1100, CR 1200 - 19

Display

Code Error Description

Door open solenoid coil circuit open

Right scrub motor M4 contactor coil circuit short. Right scrub motor M4 contactor coil current too high

Right scrub motor M4 contactor coil circuit open

Dust control contactor coil circuit short

Dust control contactor coil current too high

Dust control contactor coil circuit open

Vacuum contactor coil circuit short

Vacuum contactor coil circuit current too high

Vacuum contactor coil circuit open

Door close solenoid coil circuit short

Door close solenoid coil current too high

Door close solenoid coil circuit open

Side broom contactor coil circuit short

Side broom contactor coil current too high

Side broom contactor coil circuit open

Hopper down solenoid coil circuit short Hopper down solenoid coil circuit current too high

Hopper down solenoid coil circuit open

Hopper up solenoid coil circuit short

Troubleshooting Actions Check for open in coil & wiring. Check for 36V at the L4 coil wire colors VIO (+), BRN/GRN (-). Check for wiring problems at the K3 coil. Check K3 coil resistance if below 116 ohms Replace.

Same as Error 24 Replace coil. (Shorted Coil) Check for open in coil & wiring. Check for 36V at the K3 coil wire colors VIO (+), GRA/RED (-). Check for wiring problems at the K6 coil. Check K6 coil resistance if below 116 ohms Replace.

Same as Error 33 Replace coil. (Shorted Coil) Check for open in coil & wiring. Check for 36V at the K6 coil wire colors VIO (+), BRN/YEL (-). Check for wiring problems at the K7 coil. Check K7 coil resistance if below 116 ohms Replace.

Same as Error 36 Replace coil. (Shorted Coil) Check for open in coil & wiring. Check for 36V at the K7 coil wire colors VIO(+), BLU (-). Check for wiring problems at the L5 coil. Check L5 coil resistance if below 66 ohms Replace.

Same as Error 39 Replace coil. (Shorted Coil) Check for open in coil & wiring. Check for 36V at the L5 coil wire colors VIO (+), BLU/RED (-). Check for wiring problems at the K8 coil. Check K8 coil resistance if below 116 ohms Replace.

Same as Error 42 Replace coil. (Shorted Coil) Check for open in coil & wiring. Check for 36V at the K8 coil wire colors VIO(+), BRN/BLK (-). Check for wiring problems at the L6A coil. Check L6A coil resistance if below 66 ohms Replace.

Same as Error 45 Replace coil. (Shorted Coil) Check for open in coil & wiring. Check for 36V at the L6A coil wire colors VIO (+), YEL/RED (-). Check for wiring problems at the L6 coil. Check L6 coil resistance if below 66 ohms, replace.

Hopper up solenoid coil circuit current too high

Hopper up solenoid coil circuit open

20 - FORM NO. 56043126 - CR 1100, CR 1200

Same as Error 48 replace coil. (Shorted Coil) Check for open in coil & wiring. Check for 36V at the L6 coil wire colors VIO (+), RED/GRA (-).

Display

Code Error Description Troubleshooting Actions

Check for wiring problems at the L1 and L2 coils. Check L1 and L2 coils resistance if below 70 ohms,

Solution solenoid coil circuit short

Solution solenoid coil current too high

Solution solenoid coil circuit open

Hydraulic pump contactor coil circuit short

Hydraulic pump contactor coil current too high

Hydraulic pump contactor coil circuit open

Back-up alarm circuit short

Back-up alarm current too high

Back-up alarm circuit open

Side broom actuator circuit short

Side broom actuator circuit current too high

Side broom actuator circuit open

Scrub deck actuator circuit short

Scrub deck actuator circuit current too high

Scrub deck actuator circuit open

Squeegee actuator circuit short

Squeegee actuator circuit current too high

Squeegee actuator circuit open

replace.

Same as Error 51 Replace coil. (Shorted Coil) Check for open in coil(s) & wiring. Check for 36V at the L1 and L2 solution valve coil wire colors VIO(+), YEL/GRN (-). Check for wiring problems at the K11 coil. Check K11 coil resistance if below 149 ohms Replace.

Same as Error 54 Replace coil. (Shorted Coil) Check for open in coil & wiring. Check for 36V at the K11 coil wire colors VIO (+), BLU/WHT (-).

Check alarm and wiring

Check for short in wires or motor.

Check for binding of linkage.

See service manual section flowcharts.

Check for short in wires or motor.

Check for binding of linkage.

See service manual section flowcharts.

Check for short in wires or motor.

Check for binding of linkage.

See service manual section flowcharts.

FORM NO. 56043126 - CR 1100, CR 1200 - 21

GENERAL MACHINE SYMPTOM TROUBLESHOOTING GUIDE TABLE OF CONTENTS

No Wheel Drive ................................................................................................................................................................... 23

No Wheel Drive and no machine accessory functions ........................................................................................................27

Forward/Reverse auto accessory functions do not work ....................................................................................................28

No power assist steering .....................................................................................................................................................29

Main broom will not turn .................................................................................................................................................30-31

Side brooms will not turn ................................................................................................................................................32-33

Side broom lift actuator will not lower .................................................................................................................................34

Side broom lift actuator will not raise ..................................................................................................................................35

Hydraulic pump will not operate .....................................................................................................................................36-37

Hopper dump door will not open in the dump mode .....................................................................................................38, 40

Hopper dump door will not close in the dump mode ......................................................................................................39-40

Hopper will not raise ......................................................................................................................................................42-43

Hopper will not lower ......................................................................................................................................................44-45

Squeegee will not raise or lower .........................................................................................................................................46

Vacuum motor will not activate ......................................................................................................................................47-48

Dust control impeller will not 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.

MAIN BROOM

DUST CONTROL

DOOR CLOSE

HOPPER DOWN

FWD/REV

STATUS

HOPPER

ACC

SCRUB 3

DOOR OPEN

SOLUTION

HOPPER TEMP

DUST FILTER

RECOVERY

NOT FULL

RETRACT

HORN

SHAKER

SCRUB 2

SCRUB 1

VACUUM

SIDE

BROOM

HOPPER UP

KEY SW

ACC

HYDRAULIC

BACK-UP ALARM

SCRUB

DECK

LIFT

SQUEEGEE





LIFT

SIDE

BROOM

LIFT

LIGHTS

A1 Control Board Indicator Lights

REVERSE

SEAT SWITCH

WAND

EXTEND LIMIT

MAIN BROOM OFF

HYDRAULIC FILTER

SOLUTION EMPTY

22 - FORM NO. 56043126 - CR 1100, CR 1200

WHEEL DRIVE SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

1 No Wheel Drive

Note 1: Do all testing with key switch on, seat switch closed and battery hold down interlock switch closed.

Do the A2 display panel lights come on?

yes

Is the Speed Controller Fault Code Status Light (E the A2 display board flashing when attempting to drive the machine?

See “Table 1” Curtis

troubleshooting

Status LED Fault

Codes

) on at

yes yes

See “No drive & no machine accessory functions” in this manual

Individually check for (+)

no no

36V at the A3 speed control pin 1 (ORN) and pin 9 (ORN)

Check for (+) 36V at A3 speed control pin 2 (GRN)

yes

Check the drive motor carbon brushes for wear if worn replace. Motor still does not run

yes

Repair or replace the ORN wire(s).

Check for (+) 36V

no no

through the seat switch and battery interlock switch

yes yes

Repair or replace wiring or switches. Motor still does not operate

Replace drive motor Does the motor run?

Replace A3 speed controller

FORM NO. 56043126 - CR 1100, CR 1200 - 23

WHEEL DRIVE SYSTEM

Low Current controller A3 Pin Key Detail

Pin # Wire Color Controller Pin Description & Function

1 ORN Key switch input (KSI): Battery (+) 36V powers up controller logic circuits.

2 GRN

3 BLU/BLK

4 Not Used

5 ORN/RED

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

18 Not Used 19 RED/WHT Reverse signal driver output: Signals the A1 Main Control Board when machine is in reverse.

20 GRA

21 Not Used 22 Not Used 23 Not Used 24 Not Used

Interlock: Seat switch (S9) and Battery interlock Switch (S13) input battery (+) 36V to pin 2 to allow an output to the Pin 17 (-) 36V BLK/YEL wire to K5 contactor coil.

Mode 1: Drive motor scrub speed battery (+) input from main controller (A1). When pin 3 sees (+)36V the machine will drive in the slow scrub speed

Fault 1 output: Speed controller (A3) fault code output to the operator display panel Speed Controller Fault Code Status Light (Wrench).

Main Contactor Driver: Battery (-) 36V output to main contactor K5 Coil. Activated by Key switch input from Pin 1.

Electromagnetic brake drive: Battery (-) output to main controller (A1) to turn on (activate) all auto functions.

Detail of A3 24-pin connector:

24 23 22 21 20 19 18 17 16 15 14 13

121110987654321

24 - FORM NO. 56043126 - CR 1100, CR 1200

Used Not Used

WHEEL DRIVE TROUBLESHOOTING GUIDE

Problem Possible Cause

WHEEL DRIVE SYSTEM

• Wheel drive motor will not run in forward and

reverse

• Wheel drive in one direction only, loss of either forward and reverse

• Speed Controller Fault Code Status Light (E) ﬂ ashes a fault code.

* = See Curtis Speed Control Troubleshooting Section.

• Batteries need charging (low battery voltage, recharge batteries)

• Control Circuit, (F2) Circuit Breaker tripped (reset circuit breaker)

• Parking Brake (OO) set (release parking brake)

• Emergency Stop Switch (KK) tripped (plug in battery connector)

• Seat switch (S9) and Battery Interlock switch (S13) not closed. Repair or Replace defective switch.

• Defective Wheel Drive Motor (replace motor) *

• Defective or miss adjusted throttle pot. (R1) (replace or adjust throttle pot) *

• Defective Main Contactor (K5) (replace main contactor) *

• Test the Fwd & Rev (R1) Throttle Pot. Throttle’s wiring inputs at the speed control for an open. Forward 2.5-4.5V(pins 13 & 14) Reverse .5-2.5V(pins 15 & 14) Repair wiring or replace the throttle pot (R1).

• Controller can’t change electrical polarity to wheel motor replace the (A3) speed control. *

• Speed controller has sensed an operation error code fault. (see the Status LED Fault Codes (Table 1) in the Electrical System)

GENERAL FUNCTIONAL OVERVIEW

A 4 HP separately excited (ﬁ eld & armature) 36V DC motor/gear/wheel unit (M15) is used to propel the machine. A Curtis model 1244 PMC solid state speed controller (A3) regulates (outputs) the variable speed Fwd/Rev wheel drive motor functions. The controller unit is located in the left rear electrical access panel. The (R1) throttle pot mounted to the operator foot pedal inputs to the (A3) controller. The (A3) Controller operator’s speciﬁ c speed and direction demands.

DRIVE MOTOR SYSTEM CONTROLLER FUNCTION OVERVIEW

To make the A3 speed controller’s internal circuits 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 or Rev will move the 5K Ohm (R1) potentiometer shaft off its centered balanced (neutral) setting of approximately 2500 Ohms. With this pot shaft movement the pot’s resistance value changes which generates a variable voltage signal (0-5 volts). These control board voltage input signals are what energizes the Fwd & Rev internal directional relays, which selects the motor polarity and what also manages switches the battery voltage On and Off (*PWM) that varies the motor speed.

MOTOR OPERATION

The motor has (4) terminal connections, (2) armature A1, A2 and (2) ﬁ eld F1, F2. The separate motor armature circuit receives from the controller a chopped on time off time *PWM voltage output that varies the motor speed. The separate ﬁ eld circuit sees the current direction polarity change that effects the rotation of the motor CW for FWD and CCW for REV.

DRIVE WHEEL SYSTEM SPEEDS

The speed controller is programmed for two maximum speed setting modes, M1-max and M2-max. The M1-max is the transport speed mode and is set at 100% of the total system’s speed potential. The M2-max is the scrubbing speed mode and is set at 80% of the total system’s speed potential. Note: Both of the speed settings (M1 & M2) can be changed (increased or decreased) from the original factory speciﬁ cations only by using the hand held programmer PN 56409441. See in the electrical system section of this manual, instructions for using the programmer for speed setting changes and troubleshooting diagnostics. *PWM; pulse width modulation, also called “chopping” is a technique that switches the battery voltage ON and OFF to the motor very quickly, thereby controlling the speed of the motor.

FORM NO. 56043126 - CR 1100, CR 1200 - 25

WHEEL DRIVE SYSTEM

B+

ORN

Contactor,

Wheel Drive

BLK/YEL

BLU/BLK

GRN

ORN/RED

RED/WHT

GRA

ORN/RED

CURTIS 1244 SPEED CONTROLLER

BRN/RED

WHT/BLK

VIO/BLK

ORN

X51

RED/WHT

GRA

BLK/YEL

2423222120191817161514

987654321

121110

ORN

BLU/BLK

GRN

Pot. 5k Ohm

B-

RED 1-1 RED 1-2

Contact N.O.

F1 F2

B-

M-

B+

M15

RED/BLU

Motor, Wheel Drive

BLK 1-A1

RED 1-A2

BLK

WHT/YEL

26 - FORM NO. 56043126 - CR 1100, CR 1200

WHEEL DRIVE SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

1 No drive and no machine accessory functions

Note 1: Do all testing with key switch on seat switch closed and battery hold down interlock switch closed.

Check for open in: F10 (400 A) Fuse F2 (5A) Circuit Breaker

yes

Reset C.B. Replace Fuse. Does the machine function?

At the A1 board are the grn and red acc. lights on?

At the A1 board is the red key switch

light on?

yes

Check coil resistance at K10 120 ohms (+ or - 10%)

yes

At the K10 Aux.

coil is there 36V

YEL/BRN(+) BLK/ORN(-)

yes

1.Check for 36V(+) at the A1 board ORN wire J2-11 to battery ground

2.Check 36V(-) at the Binputs BLK wires to bat pos.

Repair or replace wiring. Is

there voltage at the coil?

yes

Replace K10

contactor. Are the red and grn acc lights on?

Repair or replace key switch or wiring

Replace the A1 control board

Check for 36V(+) at K10 load input RED wire to bat ground.

yes

Check for 36V(+) at the K10 load output BLU/GRN wire to bat. ground.

yes

Check for 36V(+) at the A1 board J1/J23 GRN/BLK wires to bat. ground.

yes

Check for 36V(+) at the F1 25 amp CB VIO wire to bat. ground.

yes

Replace the A1 control board

Repair or replace

Repair or replace CB F3 20 amp or wiring. Does the machine function?

Repair or replace CB F1 25 amp or wiring. Does the machine function?

wiring.

Replace K10

contactor

FORM NO. 56043126 - CR 1100, CR 1200 - 27

WHEEL DRIVE SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

1 Forward/ reverse auto accessory functions do not work, examples; main broom, side brooms, scrub motors, vacuum motor and dust control

motor.

Note: Do all testing with key switch on and drive pedal activated (forward/reverse)

Machine drive auto accessory functions

do not work

With the seat switch closed, drive wheel

Is the MIL light (E) flashing at the A2 display board?

jacked properly, place the pedal in forward or

reverse position. At the A3 Curtis Speed

control back probe pin 20 GRA wire check for

36V to battery positive

Replace the A3

Curtis Controller

yes

See Curtis

troubleshooting section

Machine auto reverse

function does not work

Is the MIL light (E)

flashing at the A2 display

board?

yes

Check for an open circuit from the A3 Curtis

Speed controller pin 20 GRA wire to A1 main

board J2-26 GRA wire.

yes

Repair or replace

GRA wire

With the seat switch closed, drive wheel

jacked properly, place the pedal in reverse

position. At the A3 Curtis Speed control back

probe pin 19 RED/WHT wire check for 36V

to battery positive

Replace the A1

Main Board

Replace the A3

Curtis Controller

yes yes

See Curtis

troubleshooting section

28 - FORM NO. 56043126 - CR 1100, CR 1200

Check for an open circuit from the A3 Curtis

Speed controller pin 19 RED/WHT wire to A1

main board J2-25 RED/WHT wire.

yes

Repair or replace

RED/WHT wire

Replace the A1

Main Board

TROUBLESHOOTING GUIDE

Possible Symptom

1 No power assist steering

Part A: Electrical Control Circuit

Note: Do all testing with key switch on.

STEERING SYSTEM

Do any other accessory functions work?

yes

Check for 36V at the K9 solenoid coil:

wires: BLK(-) & VIO(+)

yes

Check the K9 coil resistance

120 ohms (+ or - 10%)

Part B: Load Circuit

Note: Do all testing with key switch on.

Is the F9 40 amp

CB open?

Check both wire(s) for continuity.

yes

At the K9 solenoid load wire

BRN/GRA (battery input +) check

for 36V to battery ground.

Repair or replace defective wire(s).

Does the power steering operate?

See no accessory function

Replace K9 solenoid.

See Part B Load Circuit

Repair or replace

defective wire. Does the

power steering operate?

yes

Check for a short in

the steering motor

or load wires. Reset

the F9

40 amp CB. Does

the power steering

operate?

yes

At the K9 solenoid load wire

GRA/WHT (+ output to steering

motor) check for 36V to battery

ground.

yes

Check for 36V at power steering

motor wires GRN/WHT(+) &

BLK(-) Does the power steering

operate?

yes

Replace Power Steering Unit

Replace K9 solenoid.

Does the power steering

operate?

Repair or replace

defective wire(s) or

connectors. Does the

power steering operate?

FORM NO. 56043126 - CR 1100, CR 1200 - 29

SWEEPING SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

1 Main Broom will not turn.

Part A: Electrical Control Circuit

Note 1: Do all testing with the key switch on, broom lever lowered, hopper open indicator light off and drive pedal activated (Place in forward or Reverse). Note 2: If the main broom overload indicator light is on see part B

Main broom will not turn

On the A1 board is the main broom indicator light on?

yes

Check for 36V at the K4 solenoid coil: wire colors: GRN/GRA(-) & VIO(+)

yes

Check the K4 coil resistance 120 ohms (+ or - 10%)

yes

Check the adjustment and operation of the S8 main broom switch. Is the switch open when main broom lever is lowered.

yes

Replace the A1 main controller. Does the broom run?

Check both wire(s) for

continuity. Repair or replace defective wire(s). Does the broom run?

Replace K4 solenoid. Does the broom run?

Clean, adjust or replace the broom switch S8. Does the broom run?

30 - FORM NO. 56043126 - CR 1100, CR 1200

See Part B

SWEEPING SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

1 Main Broom will not turn.

Part B: Electrical Load Circuit

Note 1: Do all testing with the key switch on, broom lever lowered, hopper open indicator light off and drive pedal activated (Place in forward or

reverse).

Main broom will not turn

Inspect main broom for possible mechanical binding, damage broom lug inserts and debris wrapped around motor or broom.

yes

Remove debris and make any repairs or replace damage parts. Does the broom run?

At the K4 solenoid load wire

RED 6-1 (battery input +) check for 36V to battery ground.

yes

At the K4 solenoid load wire RED 6-2 (output to broom motor +) check for 36V to battery ground.

yes

Check for 36V at main broom motor.

yes

Repair or replace the M1 main broom motor

Repair or replace defective wire(s). Does the broom run?

Replace K4 solenoid. Does the broom run?

Repair or replace defective wire(s) + or -. Does the broom run?

FORM NO. 56043126 - CR 1100, CR 1200 - 31

SWEEPING SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

1 Side Broom(s) will not turn.

Part A: Electrical Control Circuit

Note 1: Check the F5 20A side broom(s) Circuit breaker if tripped reset. If breaker continues to trip see part B. Note 2: Do all testing with the key switch on, side brooms lowered, main broom lever lowered, hopper open indicator light off and drive pedal activated (Place in forward or Reverse).

Side broom(s) will not turn

At the A2 display panel is the side broom increase light on?

yes

On the A1 board is the side broom grn indicator light on?

yes

Check for 36V at the K8 solenoid coil: wire colors: BRN/BLK(-) & VIO(+)

yes

Check the K8 coil resistance 120 ohms (+ or - 10%)

yes

Substitute an A2 display panel. Does the side broom(s) run?

Replace the A1 main controller. Does the side broom(s) run?

Check both wire(s) for continuity. Repair or replace defective wire(s). Does the side broom(s) run?

Replace K8 solenoid. Does the side broom(s) run?

32 - FORM NO. 56043126 - CR 1100, CR 1200

See Part B

SWEEPING SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

1 Side Broom(s) will not turn.

Part B: Electrical Load Circuit

Note 1: Do all testing with the key switch on, side brooms lowered, broom lever lowered, hopper open indicator light off and drive pedal activated (Place in forward or reverse).

Side broom(s) will not turn

Is the F5 20 amp CB open

yes

Inspect side broom(s) for possible mechanical binding, (clean debris

wrapped around motor or brooms).

Reset 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

yes

At the K8 solenoid load wire

WHT/RED (+ output to side broom

motor(s) ) check for 36V to battery

ground.

yes

Check for 36V at side broom

motor(s) wires

WHT/RED(+) & BLK(-)

yes

Repair or replace

no no

Repair or replace defective wire(s)

or connectors. Note: there are 2

splices located in the hopper dust

control compartment for the motor

wires. Do the side broom(s) run?

defective wire. Do the

side broom(s) run?

Replace K8 solenoid. Do the side broom(s)

run?

Repair or replace the M8/M9

side broom motors

FORM NO. 56043126 - CR 1100, CR 1200 - 33

SWEEPING SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

1 Side broom lift actuator will not lower.

Note: Do all testing with key switch on, main broom lever lowered (press the side broom lower button on the A2 display panel if side brooms are not programmed to lower automatically).

Side broom(s) will not lower

At the A2 display panel is the side broom increase light on?

yes

On the A1 board does the green side broom lift indicator light stay on while motor is extending

yes

Check for a 36V at the motor harness plug.

yes

Replace lift motor

Substitute an A2 display panel. Does the side broom(s) work?

Replace the A1 main controller. Does the side broom(s) run?

Repair or replace wiring to motor. Does the motor operate?

34 - FORM NO. 56043126 - CR 1100, CR 1200

SWEEPING SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

1 Side broom lift actuator will not raise.

Note: Do all testing with key switch on, main broom lever raised (press the side broom raise button on the A2 display panel if side brooms are not programmed to raise automatically).

Side broom(s) will not raise

At the A2 display panel is the side broom decrease light on?

yes

On the A1 board does the side broom lift indicator red light stay on momentarily while the motor is retracting?

yes

Check for open circuit in lift motor wiring to the A1 board. J1-35 GRA/VIO J1-23 GRN/ORN

yes

Repair the wiring to motor. Does the motor retract?

Substitute an A2 display panel. Does the side broom(s) raise?

Replace the A1 control board

Check for an open in lift motor.

yes

Replace lift motor

FORM NO. 56043126 - CR 1100, CR 1200 - 35

HYDRAULIC SYSTEM

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 pressed at A2 Display panel.

Hydraulic pump will not operate

Separate the motor from the pump is the

coupler sheared? See pump removal in the Mechanical Repair Service Manual.

Form No. 56043127

Replace damaged coupler.

TROUBLESHOOTING GUIDE

Possible Symptom

1 Hydraulic pump motor will not operate.

yes

Replace Pump Assembly

Part A: Coil Circuit

Note: Do all testing with the key switch on and hopper raise button pressed at A2 Display panel.

Hydraulic pump motor

will not operate

At the A1 board is the

Hydraulic Pump green

indicator light on?

yes

Check for 36V at the K11 coil wire colors VIO(+) & BLU/WHT(-)

yes

Check for coil

resistance at K11

(149 ohms + or - 10%)

yes

Replace the A1 Board.

Does the pump operate?

Repair or replace K11

coil wiring.

Does the pump operate?

Replace K11 Contactor

Does the pump operate?

See Part B Load Circuit

36 - FORM NO. 56043126 - CR 1100, CR 1200

TROUBLESHOOTING GUIDE

Possible Symptom

1 Hydraulic pump motor will not operate.

Part B: Load Circuit

Note: Do all testing with the key switch on and hopper raise button pressed at A2 Display panel.

Hydraulic pump motor will not

operate

HYDRAULIC SYSTEM

At the K11 solenoid load wire

ORN/WHT (+ battery input)

check for 36V to battery ground.

yes

At the K11 solenoid load wire

(+) output to pump motor check

for 36V to battery ground.

yes

Check for 36V at pump motor

negative input from battery

ground.

yes

Repair or replace pump motor

Repair or replace defective

wire. Does the pump operate?

Replace K11 solenoid.

Does the pump operate?

Repair or replace defective

wire from battery ground.

Does the pump operate?

FORM NO. 56043126 - CR 1100, CR 1200 - 37

HOPPER SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

1 Hopper dump door will not open in the dump mode.

Part A:

To test: Key switch must be on, hopper must be raised.

Dump door will not open

Check if the hopper raise indicator

light is flashing on A2 panel

yes

On A2 Press and hold hopper door open switch, is its green indicator light on?

yes

Press and hold dump door

open button. At the A1

board is the door open green

indicator light on?

yes

At the A1 board is the

Hydraulic Pump green

indicator light on?

Check continuity and adjustment of hopper interlock switch(S3).

Note: switch will check

open when hopper is

raised

yes

Substitute a new A2 display panel.

Does dump door operate?

Replace A1 control board.

Does dump door operate?

See Hydraulic pump will not operate

Repair or replace

(S3) switch

yes

Check for 36V at L4 dump

door coil. Wire color

(+)VIO & (-)BRN/GRN

yes

Check for coil resistance at

L4 (66 ohm)

yes

See hydraulic dump door troubleshooting section part B

38 - FORM NO. 56043126 - CR 1100, CR 1200

Repair or replace L4 coil wiring

Does dump door operate?

Replace L4 coil.

Does dump door operate?

TROUBLESHOOTING GUIDE

Possible Symptom

1 Hopper dump door will not close in the dump mode.

Part A:

To test: Key switch must be on, hopper must be raised.

HOPPER SYSTEM

Dump door will not close

Check if the hopper raise indicator

light is flashing on A2 panel

yes

Press and hold hopper door

close switch, is its green

indicator light on?

yes

Press and hold dump door

close switch. At the A1

board is the door close

green indicator light on?

yes

At the A1 board is the

Hydraulic Pump green

indicator light on?

Check continuity and adjustment of hopper

interlock switch(S3).

Note: switch will check

open when hopper is

raised

yes

Substitute a new A2 display

panel. Does dump door operate?

Replace A1 control board.

Does dump door operate?

See Hydraulic pump will not

operate

Repair or replace

(S3) switch

yes

Check for 36V at L5 dump

door coil. Wire color

(+)VIO & (-)BLU/RED

yes

Check for coil resistance at

L5 (66 ohm)

yes

See hydraulic dump door troubleshooting

section part B

Repair or replace

L5 coil wiring.

Does dump door operate?

Replace L5 coil.

Does dump door operate?

FORM NO. 56043126 - CR 1100, CR 1200 - 39

HOPPER SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

1 Dump door will not open or close when in dump mode

Part B:

Door will not operate

Do any hydraulic

functions operate?

yes

Inspect for possible mechanical binding of:

•Dump door

•Dump door linkage

•Dump door cylinder

yes

Repair or replace

damaged parts. Does

dump door operate?

See pump motor runs but no

hydraulic functions

Is broom door cylinder in relief?

yes

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.

yes

Remove and disassemble

•L4 door open

•L5 door closed Spool valve (cartridge)

inspect clean and reinstall

Does the door operate?

Adjust, clean or

replace relief valve.

Does dump door

operate?

Replace defective

spool valve

L4 door open

L5 door closed

Does the door operate

40 - FORM NO. 56043126 - CR 1100, CR 1200

Replace defective dump

door cylinder

Gauge 3,000 PSI (207 bar)

Hose 2' (61 cm) 6,000 PSI (414 bar)

Fitting Parker Diagnostics PD222

HOPPER SYSTEM

FIGURE 1

FORM NO. 56043126 - CR 1100, CR 1200 - 41

HOPPER SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

1 Hopper will not raise.

Part A:

Note: Do all testing with the key switch on, hopper raise switch pressed on the display panel.

Hopper will not raise

Does the Hydraulic pump

motor run?

yes

Press and hold hopper raise

switch, is its green indicator light on?

yes

Press and hold Hopper up

switch. At the A1 board is

the hopper up green

indicator light on?

yes

Check for 36V at L6

hopper up coil.

Wire color (+)VIO

See Hydraulic pump motor will

not operate

Substitute a new A2 display panel.

Does the hopper raise?

Replace A1 control board.

Does the hopper raise?

Repair or replace L6 coil wiring.

Does the hopper raise?

& (-)RED/GRA

yes

Check for coil resistance at

L6 (66 ohm)

yes

See hydraulic hopper will not raise troubleshooting section part B

42 - FORM NO. 56043126 - CR 1100, CR 1200

Replace L6 coil.

Does the hopper raise?

TROUBLESHOOTING GUIDE

Possible Symptom

1 Hydraulic Hopper will not raise.

Part B:

Note: Key switch must be turned on

Hopper will not raise

HOPPER SYSTEM

Do any other hydraulic functions

operate?

yes

Does the pump motor run?

yes

Is the hopper over its weight

550 lbs. capacity?

yes

Empty the hopper.

Does the hopper raise?

Inspect for possible mechanical

binding of:

•Hopper linkage

•Hopper cylinder

yes

See Pump motor runs but no hydraulic function.

no no

Is hopper cylinder in relief?

yes

Plumb in a pressure gauge at the

pump port (B) See Figure 1.

Test the relief valve setting

(1500psi) by activating the

Adjust, clean or

replace relief valve.

Does the hopper raise?

hopper up switch.

Repair or replace damaged parts

does the hopper raise?

yes

Remove and disassemble

•L6 hopper raise spool valve (cartridge) inspect clean and reinstall.

•Does the hopper raise?

Replace hydraulic hopper cylinder

FORM NO. 56043126 - CR 1100, CR 1200 - 43

Replace defective

spool valve L6 hopper

raise.

Does the hopper raise?

HOPPER SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

1 Hopper will not lower.

Part A:

Note: Do all testing with the key switch on, hopper lower switch pressed on the display panel.

Hopper will not lower

Press and hold hopper

lower switch, is its green

indicator light on?

yes

Press and hold Hopper

lower switch. At the A1

board is the hopper down

green indicator light on?

yes

Check for 36V at L6A hopper

down coil. Wire colors

(+)VIO & (-)YEL/RED

yes

Substitute a new A2 display panel.

Does the hopper lower?

Replace A1 control board.

Does the hopper lower?

Repair or replace L6A coil

wiring. Does the hopper lower?

Check for coil resistance at

L6A (66 ohms)

See hydraulic hopper Lower

troubleshooting section part B

44 - FORM NO. 56043126 - CR 1100, CR 1200

Replace L6A coil.

Does the hopper lower?

TROUBLESHOOTING GUIDE

Possible Symptom

1 Hopper will not lower.

Part B:

Note: To test key switch must be on and hopper lower switch pressed.

WARNING!

Do not 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

HOPPER SYSTEM

yes

Repair or replace damaged parts.

Does the hopper lower?

•L6A hopper lower spool valve (cartridge) inspect clean and reinstall.

Remove and disassemble

Does the hopper lower?

Replace defective spool

valve

•L6A hopper lower

FORM NO. 56043126 - CR 1100, CR 1200 - 45

SQUEEGEE SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

1 Squeegee will not raise or lower.

Note: Do all testing with the key switch on, empty recovery tank and the hopper closed. Squeegee switch must be activated on the display panel.

Press the squeegee switch, is its green

indicator light on?

yes

While pressing the squeegee switch,

does the squeegee lift light stay on at

the A1 board for 5-10 sec?

Down: RED Up: GREEN

yes

Replace motor

Substitute a new A2 display panel.

Does squeegee operate?

Are the squeegee lift lights on momentarily while the squeegee switch is pressed? (1 sec or less)

yes

Check for open circuit in wiring or

motor

yes

Repair or replace wiring or motor

Replace A1 control

board. Does

squeegee motor

operate?

46 - FORM NO. 56043126 - CR 1100, CR 1200

VACUUM SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

1 Vacuum motor will not activate

Part A:

Note: Do all testing with the key switch on, empty recovery tank, hopper closed, squeegee lowered, seat switch and the foot pedal activated.

On the A2 board is the recovery

tank full light on?

yes

Locate the indicator switch plug and

jump out the machine harness wires

GRA/YEL and BLK.

Does the light go off?

yes

Inspect, clean or replace tank

indicator switch and wires.

(Switch is closed when tank is empty)

Press the squeegee

switch, is its green

indicator light on at the

A2 display panel

yes

Lower the squeegee then

activate the foot pedal.

Note seat switch must be

closed, is the green vacuum

light on at the A1 main

board?

yes

Check for 36V input at

the K7 coil wires colors

(+)VIO & (-)BLU

yes

Substitute a new A2

display panel.

Does vacuum operate?

Replace A1 control

board. Does the

vacuum motor

operate?

Repair or replace

wiring to coils. Does

vacuum motor

operate?

Check for K7 coil

resistance 120 ohms

(+ or - 10%)

yes

See Part B Load Circuit

FORM NO. 56043126 - CR 1100, CR 1200 - 47

Replace defective

contactor. Does

squeegee operate?

VACUUM SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

1 Vacuum motor will not activate

Part B:

Note: Do all testing with the key switch on, empty recovery tank, hopper closed, squeegee lowered, seat switch and the foot pedal activated.

Vacuum motor(s) will not run

Is the F8 40amp CB open

yes

Inspect motor(s) for possible

mechanical binding, (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.

yes

At the K7 solenoid load wire

BLU/GRA (+) output to motor(s)

check for 36V to battery ground.

yes

Check for 36V at each

motor wires

BLU/GRA(+) & BLK(-)

yes

Repair or replace

wires or connectors at motor(s).

defective wire. Do the

motor(s) run?

Replace K7 solenoid.

Do the motor(s) run?

Repair or replace defective

Do the motor(s) run?

48 - FORM NO. 56043126 - CR 1100, CR 1200

Repair or replace the

M6/M7 vacuum motors

DUST CONTROL SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

1 Dust control impeller motor will not run

Part A:

Note: Do all testing with the key switch on, hopper closed, dust control switch on, seat switch and foot pedal activated.

Press the dust control

switch, (located on the A2

display panel) is its green

indicator light on?

yes

On the A1 board is the dust

control light on?

yes

Check for 36V at K6 impeller

motor coil. Wire colors

(+)VIO & (-)BRN/YEL

yes

Substitute a new

A2 display panel.

Does impeller operate?

Replace A1 control board.

Does the impeller motor

operate?

Repair or replace K6 coil

wiring. Does impeller motor

operate?

Check K6 coil resistance

(120 ohms) + or - 10%

yes

Repair or replace K6

contactor. Does impeller

motor operate?

See Part B Load Circuit

FORM NO. 56043126 - CR 1100, CR 1200 - 49

DUST CONTROL SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

1 Dust control impeller motor will not run

Part B: Load Circuit

Note: Do all testing with the key switch on, hopper closed, dust control switch on, seat switch and foot pedal activated.

Dust control impeller motor

will not run

Is the F4 15 amp CB open?

yes

Inspect motor for possible

mechanical binding, (debris in

and around motor).

Reset or replace CB.

At the K6 solenoid load wire

no no

BRN/WHT (+ battery input) check

for 36V to battery ground.

yes

At the K6 solenoid load wire

ORN/GRN (+ output to motor)

check for 36V to battery ground.

yes

Check for 36V at motor wires

ORN/GRN(+) & BLK(-)

yes

Repair or replace

defective wire.

Does the motor run?

Replace K6 solenoid.

Does the motor run?

Repair or replace

defective wires or

connectors at motor

Does the motor run?

50 - FORM NO. 56043126 - CR 1100, CR 1200

Repair or replace the M5 dust

impeller motor

TROUBLESHOOTING GUIDE

Possible Symptom

1 Shaker motor does not operate

Note: Do all testing with the key switch on and shaker button pressed.

DUST CONTROL SYSTEM

Press and hold the shaker switch on the

A2 display board. Does its green

indicator light come on?

yes

On the A1 board is the shaker green

indicator light on?

yes

Check for 36V at the

shaker motor M14. Wire colors

BLK/RED(-) & VIO(+)

yes

Substitute an A2 display panel.

Does the shaker operate?

Replace the A1 control board.

Does the shaker operate?

Check wires for continuity.

Repair or replace wires.

Does the shaker operate?

Repair or replace motor.

FORM NO. 56043126 - CR 1100, CR 1200 - 51

SCRUB SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

1 Scrub deck will not raise

Note: Do all testing with the key switch on, the hopper closed.

Press the scrub off switch, is its green

indicator light on?

yes

On the A1 Board is the

retract limit yellow light

on? Note: the yellow

limit light is one of 14

grouped together.

yes

Substitute a new A2 display panel.

Does the scrub deck raise?

At the lift motor separate the plug and

check for continuity between the

RED and ORN wires (retract limit

switch) at the motor plug.

yes

Check for continuity in the harness

wires RED/ORN to pin J2-3 at the A1

board. BLK wire to battery ground.

yes

See Motor Load section

Motor Load section

Replace lift motor.

Repair or replace

wiring or plug.

Does the motor

run?

While Pressing the scrub off

switch, does the scrub deck lift

light turn on at the A1 board?

Down: RED

Up: GREEN

yes

Separate motor plug and then

jump lift motor to battery

(wires RED & YEL)

Does the motor run?

yes

Check for continuity at the motor

harness plug wires RED/GRN to

pin J1-12 and YEL/GRA J1-11 at

the A1 board.

Replace A1 control

board.

Check for

no no

continuity in the lift

motor, wire colors

RED & YEL

Repair or replace

wiring or plug.

Repair or replace

wiring, plug or motor

52 - FORM NO. 56043126 - CR 1100, CR 1200

TROUBLESHOOTING GUIDE

Possible Symptom

1 Scrub deck will not lower

Part A:

Note: Do all testing with the key switch on, recovery tank empty and the hopper closed.

On the A2 board is the recovery tank full light on?

yes

SCRUB SYSTEM

Locate the indicator switch plug and jump out

the machine harness wires GRA/YEL and

BLK. Does the light go off?

Inspect, clean or replace tank indicator switch

(Switch is closed when tank is empty)

Press the scrub pressure

increase/decrease switch, is its green

indicator light on?

yes

On the A1 board is the

extend limit yellow light

on? Note: the yellow

limit light is one of the

14 grouped together.

yes

and wires.

Substitute a new

At the lift motor

separate the plug and

check for continuity

between the RED and

BLK wires (extend

limit switch) at the

motor plug.

A2 display panel.

Does the scrub deck raise?

Open in harness wires

repair or replace wires

to A1 board

nono

Replace lift motor.

yes

Check for continuity in

the harness wires

GRN/VIO to pin J2-15

at the A1 board and the

BLK wire to battery

ground.

yes

See Motor Load section

Repair or replace

wiring or plug. Does the motor

run?

FORM NO. 56043126 - CR 1100, CR 1200 - 53

SCRUB SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

1 Scrub deck will not lower

Part B: Load

Note: Do all testing with the key switch on, recovery tank empty and the hopper closed.

While pressing the scrub

decrease or increase switch,

does the scrub deck lift light

turn on at the A1 board?

Down: RED

Up: GREEN

yes

Replace A1 control

board.

Separate motor plug and then

jump lift motor to battery

(wires RED & YEL).

Does the motor run?

yes

Check for continuity at the

motor harness plug wires

RED/GRN to pin J1-12 and

YEL/GRA J1-11 at the A1

board.

Check for

continuity in the lift

motor, wire colors

RED & YEL

Repair or replace

wiring or plug.

Repair or replace

wiring, plug or

motor

54 - FORM NO. 56043126 - CR 1100, CR 1200

SCRUB SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

1 Scrub deck motors will not operate.

Part A:

Note: Do all testing with the key switch on, seat switch closed, scrub deck pressure set on (1) foot pedal activated and solution shut off.

Scrub deck motors will not operate

Do other auto drive functions work?

yes

Press scrub decrease switch(-) On the

display, is its green indicator light on?

yes

Press the scrub increase switch along with

moving the foot pedal. Are the numbers 1, 2

See machine drive auto

function do not work section

Substitute a new A2 display panel.

Do the motors operate?

Replace A1 control board.

Do the motors operate?

and 3 green scrub lights on at the A1 board?

yes

Do any of the brush motors run? See Brush motor load section

yes

Left brush does not run.

Check for 36V at K1 brush motor

coil. Wires (+)VIO & (-)YEL/BLU

yes

Center brush does not run.

Check for 36V at K2 brush motor

coil. Wires (+)VIO & (-)WHT/VIO

yes

Right brush does not run.

Check for 36V at K3 brush motor

coil. Wires (+)VIO & (-)GRA/RED

yes

Repair or replace coil

wiring.

Does the motor run?

yes

Check coil resistance

(120 ohms) + or -

10%

yes

See Part B Load Circuit

FORM NO. 56043126 - CR 1100, CR 1200 - 55

Repair or replace

contactor. Does

scrub motor

operate?

SCRUB SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

1 Scrub deck motors will not operate.

Part B: Load Circuit

Note: Do all testing with the key switch on, seat switch closed, scrub deck pressure set on (1) foot pedal activated and solution shut off.

All the scrub brush motors will not turn

yes

Is the F11 250 amp Fuse open

yes

Inspect motor gearbox assy for

possible mechanical problems, (debris

in and around motors). Replace fuse.

Left brush motor does not run.

Check for 36V at K1 brush motor load wire

RED/VIO (+ battery input) to battery ground.

yes

Center brush does not run.

Check for 36V at K2 brush motor load wire

RED/VIO (+ battery input) to battery ground.

Inspect individual motor gearbox assy for

possible mechanical problems.

Repair motor gearbox.

Repair or replace

defective wire. Does

the motor run?

yes

Right brush does not run.

Check for 36V at K3 brush motor load wire

RED/VIO (+ battery input) to battery ground.

yes

At the solenoid load wires K1 WHT/ORN, K2 GRA/BLK, K3 BLU/YEL (+ output to

motor) check for 36V to battery ground.

yes

Check for 36V at brush

motors wires M2, M3 & M4

Repair or replace defective

yes

motor.

Replace defective

solenoid. Does the

motor run?

Repair or replace

defective wire. Does

the motor run?

56 - FORM NO. 56043126 - CR 1100, CR 1200

SOLUTION SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptom

1 Solution solenoid valve(s) do not operate.

Note: Do all testing with the key switch on, solution switch pressed, seat switch closed, scrub deck lowered and drive pedal activated in forward.

Is the solution green indicator light on at

the A2 Display Panel?

yes

On the A1 control board is the solution

indicator light on?

yes

Check for 36V at the solution valve(s). Repair or replace wiring to

yes

Check the resistance of the solution

valve(s). 70 ohms.

Substitute a new A2 Display Panel.

Do the solution valve(s) work?

Replace the A1 control board.

Do the solution valve(s) work?

solution valve(s).

Do the solution valve(s) work?

yes

Clean and repair solution valve(s).

Does the solution valve(s) work?

Replace the solution valve(s)

FORM NO. 56043126 - CR 1100, CR 1200 - 57

PROGRAMMABLE CONTROL OPTIONS

Scrub Motor Turn-Off Delay Adjustment:

FACTORY DEFAULT: 1 (0.5 second) RANGE: 1 - 9 (0.5 – 4.5 seconds)

The amount of time that the scrub brushes continue to run after the foot pedal returns to neutral is adjustable. To select the desired delay:

1 Turn the main power key switch to the off position. 2 Press and hold the scrub system off switch. 3 While holding the scrub system off switch turn the main power key switch to the on position. 4 Continue to hold the scrub system off switch until all indicators except the scrub off indicator turn off (approximately two seconds). 5 Release the scrub off switch. 6 The status display will now show a number from 1 to 9. Pressing and releasing the scrub off switch will increase the displayed value until 9 is

reached. The next press will return to 1. Each increment represents 0.5 second with 1 equal to 0.5 second.

7 To save the new setting, turn the main power key switch to the off position. 8 The new setting will be saved and will remain in effect until it is changed again.

Vacuum Turn-Off Delay Adjustment:

FACTORY DEFAULT: 1 (12 seconds) RANGE: 1 - 9 (12 – 20 seconds)

The amount of time that the vacuum continues to run after the foot pedal returns to neutral is adjustable. To select the desired delay:

1 Turn the main power key switch to the off position. 2 Press and hold the vacuum/squeegee switch. 3 While holding the vacuum/squeegee switch turn the main power key switch to 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 represents one second with 1 equal to twelve seconds.

7 To save the new setting, turn the main power key switch to the off position. 8 The new setting will be saved and will remain in effect until it is changed again.

Main and Side Broom Turn-Off Delay Adjustment:

FACTORY DEFAULT: 3 (5 seconds) RANGE: 1 - 9 (3 – 11 seconds)

The amount of time that the main broom and side brooms continue to run after the foot pedal returns to neutral is adjustable. To select the desired delay:

1 Turn the main power key switch to the off position. 2 Press and hold the side broom up/off switch. 3 While holding the side broom up/off switch turn the main power key switch to the on position.

Continue to hold the side broom up/off switch until all indicators except the side broom up/off indicator turn off (approximately two seconds).

4 5 Release the side broom up/off switch. 6 The status display will now show a number from 1 to 9. Pressing and releasing the side broom up/off switch will increase the displayed value

until 9 is reached. The next press will return to 1. Each increment represents one second with 1 equal to three seconds.

7 To save the new setting, turn the main power key switch to the off position. 8 The new setting will be saved and will remain in effect until it is changed again.

58 - FORM NO. 56043126 - CR 1100, CR 1200

PROGRAMMABLE CONTROL OPTIONS

Dust Control Turn-Off Delay Adjustment:

FACTORY DEFAULT: 3 (5 seconds) RANGE: 1 - 9 (3 – 11 seconds)

The amount of time that the dust control continues to run after the foot pedal returns to neutral is adjustable. To select the desired delay:

1 Turn the main power key switch to the off position. 2 Press and hold the dust control switch. 3 While holding the dust control switch turn the main power key switch to the on position. 4 Continue to hold the dust control switch until all indicators except the dust control indicator turn off (approximately two seconds). 5 Release the dust control switch. 6 The status display will now show a number from 1 to 9. Pressing and releasing the dust control switch will increase the displayed value until

9 is reached. The next press will return to 1. Each increment represents one second with 1 equal to three seconds.

7 To save the new setting, turn the main power key switch to the off position. 8 The new setting will be saved and will remain in effect until it is changed again.

Shaker Duration Adjustment:

FACTORY DEFAULT: 5 (20 seconds) RANGE: 1 - 9 (12 – 28 seconds)

The amount of time that the shaker runs once it has been activated is adjustable. To select the desired duration:

1 Turn the main power key switch to the off position. 2 Press and hold the shaker switch. 3 While holding the shaker switch turn the main power key switch to the on position. 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 seconds.

7 To save the new setting, turn the main power key switch to the off position. 8 The new setting will be saved and will remain in effect until it is changed again.

Hopper Door Open/Close Duration Adjustment:

FACTORY DEFAULT: 1 (2.0 seconds) RANGE: 1 - 9 (2.0 – 4.0 seconds)

The amount of time the valves that open or close the hopper door remain on when automatically opening or closing the door is adjustable. To select the desired duration:

1 Turn the main power key switch to the off position. 2 Press and hold the hopper door open switch. 3 While holding the hopper door open switch turn the main power key switch to the on position. 4 Continue to hold the hopper door open switch until all indicators except the hopper door open indicator turn off (approximately two seconds).

Release the hopper door open switch.

5 6 The status display will now show a number from 1 to 9. Pressing and releasing the hopper door open switch will increase the displayed value

until 9 is reached. The next press will return to 1. Each increment represents 0.25 second with 1 equal to two seconds.

7 To save the new setting, turn the main power key switch to the off position. 8 The new setting will be saved and will remain in effect until it is changed again.

FORM NO. 56043126 - CR 1100, CR 1200 - 59

PROGRAMMABLE CONTROL OPTIONS

Scrub Pressure Default Adjustment:

FACTORY DEFAULT: 1 (minimum pressure) RANGE: 0 - 3

The default scrub pressure that is selected each time the scrub system is activated can be adjusted. To select the desired default value:

1 Turn the main power key switch to the off position. 2 Press and hold the scrub pressure decrease switch. 3 While holding the pressure decrease switch turn the main power key switch to the on position. 4 Continue to hold the pressure decrease switch until all indicators except the scrub pressure decrease indicator turn off (approximately two

seconds).

5 The status display will now show a number from 0 to 3. Pressing and releasing the scrub pressure decrease switch will increase the displayed

value until 3 is reached. The next press will return to 0. If 0 is selected, the scrub pressure will return to the last used setting when the scrub system is activated. If 1 is selected, the scrub pressure will default to the minimum setting when activated. If 2 is selected, the scrub pressure will default to the medium setting when activated. If 3 is selected, the scrub pressure will default to the maximum setting when activated.

6 To save the new setting, turn the main power key switch to the off position. 7 The new setting will be saved and will remain in effect until it is changed again.

Scrub Pressure Limit Adjustment:

FACTORY DEFAULT: 3 (maximum pressure) RANGE: 1 - 3

The maximum scrub pressure that the operator can select can be adjusted. To select the desired limit value:

1 Turn the main power key switch to the off position. 2 Press and hold the scrub pressure increase switch. 3 While holding the pressure increase switch turn the main power key switch to the on position. 4 Continue to hold the pressure increase switch until all indicators except the scrub pressure increase indicator turn off (approximately 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 scrub pressures will be available.

6 To save the new setting, turn the main power key switch to the off position. 7 The new setting will be saved and will remain in effect until it is changed again.

Scrub Pressure Range Selection:

FACTORY DEFAULT: 1 (FULL RANGE)

The CR 1100/1200 has three scrub pressure settings. The default pressure settings range from the minimum pressure required for adequate cleaning to the maximum pressure that the scrub motors can safely handle with one setting halfway in between. It is possible to bias these settings either to a low range or a high range. If biased to the low range, the minimum setting will be the same as the default however, the middle and maximum pressures will be lower than the defaults. If the high range bias is selected, the minimum and middle pressures will be greater than the defaults but the maximum pressure will be the same. To select the pressure range:

1 Turn the main power key switch to the off position. 2 Press and hold the scrub system off and the 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 scrub pressure decrease indicator turn off (approximately 2

seconds).

5 Release both switches. The status display will now indicate a number from 1 to 3 depending on the current range. 6 Pressing and releasing the scrub pressure decrease switch will now select the pressure range. 1 = full range, 2 = low bias, 3 = high bias. 7 To save the new setting, turn the main power key switch to the off position. 8 The new setting will be saved and will remain in effect until it is changed again.

scrub pressure decrease switches.

60 - FORM NO. 56043126 - CR 1100, CR 1200

PROGRAMMABLE CONTROL OPTIONS

Back-up Alarm Mode Control:

FACTORY DEFAULT: 1 (reverse only) RANGE: 0 - 4

The CR 1100/1200 may be equipped with an optional back-up alarm. This alarm can be programmed to operate at times other than backing up or it may be turned off. To select the operating mode:

1 Turn the main power key switch to the off position. 2 Press and hold the horn switch. 3 While holding the horn switch turn the main power key switch to the on position. 4 Continue to hold the horn switch until all indicators except the horn indicator turn off (approximately two seconds). 5 Release the horn switch. 6 The status display will now show a number from 0 to 4. Pressing and releasing the horn switch will increase the displayed value until 4 is

reached. The next press will return to 0. If 0 is selected, the back-up alarm will be disabled and will not sound at any time. If 1 is selected, the alarm will sound only when backing up. If 2 is selected, the alarm will sound when driving forward or in reverse. It will be off in neutral. If 3 is selected, The alarm will sound when backing up or if the hopper is being raised or lowered. If 4 is selected, The alarm will sound when driving forward or in reverse or if the hopper is being raised or lowered.

7 To save the new setting, turn the main power key switch to the off position. 8 The new setting will be saved and will remain in effect until it is changed again.

Side Broom Mode Control:

FACTORY DEFAULT: 1 (always turns on with main broom) RANGE: 0 - 2

The side brooms on the CR 1100/1200 are programmed to always come on when the main broom is ﬁ rst activated. If this is not desired, the operating mode of the side booms can be changed. To select the operating mode:

1 Turn the main power key switch to the off position. 2 Press and hold the side broom up/off and the 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 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 manual control only. If 1 is selected, the side brooms will always come on when the main broom is initially turned on. If 2 is selected, the side brooms will come on if they were used the last time the main broom was on otherwise they will not automatically come on.

7 To save the new setting, turn the main power key switch to the off position. 8 The new setting will be saved and will remain in effect until it is changed again.

Dust Control Mode Control:

FACTORY DEFAULT: 1 (always turns on with main broom) RANGE: 0 - 2

The dust control on the CR 1100/1200 is programmed to always come on when the main broom is ﬁ rst activated. If this is not desired, the operating mode of the dust control can be changed. To select the operating mode:

1 Turn the main power key switch to the 2 Press and hold the dust control and the 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 dust control 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 dust control switch will increase the displayed value until 2

is reached. The next press will return to 0. If 0 is selected, the dust control will not come on with the main broom. It will be manual control only. If 1 is selected, the dust control will always come on when the main broom is initially turned on. If 2 is selected, the dust control will come on if it was used the last time the main broom was on otherwise it will not automatically come on.

7 To save the new setting, turn the main power key switch to the off position. 8 The new setting will be saved and will remain in effect until it is changed again.

off position.

FORM NO. 56043126 - CR 1100, CR 1200 - 61

PROGRAMMABLE CONTROL OPTIONS

Dust Control Mode Control with Hopper Up:

FACTORY DEFAULT: 2 (no change) RANGE: 0 - 2

The dust control on the CR 1100/1200 can be programmed to turn on or off or stay in its current state when the hopper is raised for dumping. To select the operating mode:

1 Turn the main power key switch to the off position. 2 Press and hold the dust control and the scrub pressure decrease 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 dust control and scrub pressure decrease 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 dust control switch will increase the displayed value until

2 is reached. The next press will return to 0. If 0 is selected, the dust control will turn off when the hopper is raised. If 1 is selected, the dust control will turn on when the hopper is raised. If 2 is selected, the dust control will remain in the same state that it was in prior to raising the hopper (no change).

7 To save the new setting, turn the main power key switch to the off position. 8 The new setting will be saved and will remain in effect until it is changed again.

Shaker Mode Control:

FACTORY DEFAULT: 1 (timed – manual control) RANGE: 0 - 3

The dust control ﬁ lter shaker on the CR 1100/1200 is programmed to run for an adjustable period of time when the operator depresses the shaker switch on the control panel. The shaker can be programmed to operate in a momentary fashion or 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 status display will now show a number from 0 to 3. Pressing and releasing the shaker switch will increase the displayed value until 3 is

reached. The next press will return to 0. If 0 is selected, the shaker will turn on only when the control panel switch is held (momentary). If 1 is selected, the shaker will run for an adjustable period of time (see above to adjust time period). If 2 is selected, the shaker will automatically run for an adjustable period of time when the main broom is turned off. If 3 is selected, the shaker will automatically run for an adjustable period of time when the hopper is lowered all the way down after being in the up position.

7 To save the new setting, turn the main power key switch to the off position. 8 The new setting will be saved and will remain in effect until it is changed again.

Control Assembly Revision Display:

To display the revision of the control assembly, perform the following steps:

1 Turn the main power key switch to the off position.

Press and hold the hopper up switch.

2 3 While holding the hopper up switch turn the main power key switch to the on position. 4 Continue to hold the hopper up switch until all indicators except the hopper up indicator turn off (approximately two seconds). 5 Release the hopper up switch. 6 The status display will now show a letter representing the revision of the display assembly. 7 To exit this mode, turn the main power key switch to the off position.

62 - FORM NO. 56043126 - CR 1100, CR 1200

PROGRAMMABLE CONTROL OPTIONS

Solution Flow in Reverse Enable/Disable:

FACTORY DEFAULT: 0 (solution ﬂ ow off in reverse) RANGE: 0 - 1

The solution ﬂ ow is programmed to stop when backing up to prevent excessive cleaning solution from being dispensed. If it is desired to allow solution ﬂ ow in reverse, perform the following steps:

1 Turn the main power key switch to the off position. 2 Press and hold the solution and the 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 solution and scrub off indicators turn off (approximately two seconds). 5 Release both switches. 6 The status display will now show a 0 or a 1. Pressing and releasing the solution switch will alternate between the two. If 0 is selected, solution

ﬂ ow will stop when backing up. If 1 is selected, solution ﬂ ow will stay on when backing up.

7 To save the new setting, turn the main power key switch to the off position. 8 The new setting will be saved and will remain in effect until it is changed again.

High Speed Scrub/Sweep (Fast/Slow Switch) Enable/Disable:

FACTORY DEFAULT: 1 RANGE: 0 - 1

Normally, the maximum travel speed is reduced during scrubbing and/or sweeping operations. The fast/slow switch on the control panel allows the operator to override this speed reduction which allows scrubbing and/or sweeping at maximum speed. If this is not desirable, this feature can be disabled. This will prevent traveling at maximum speed while scrubbing and/or sweeping. Note: see programming of reduced speed mode to select speed reduction while scrubbing and/or sweeping. To enable or disable this feature, perform the following steps:

1 Turn the main power key switch to the 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 between the two. If 0 is selected, high

speed scrubbing/sweeping will not be allowed. If 1 is selected, high speed scrubbing/sweeping will be allowed.

7 To save the new setting, turn the main power key switch to the off position. 8 The new setting will be saved and will remain in effect until it is changed again.

Reduced Speed Mode:

FACTORY DEFAULT: 1 (reduced speed while scrubbing) RANGE: 1 - 3

The CR 1100/1200 can be programmed to automatically limit the maximum travel speed while scrubbing only, sweeping only, or either scrubbing or sweeping. To select which operation will cause the automatic speed reduction, perform the following steps:

1 Turn the 2 Press and hold the fast/slow and the 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 fast/slow and scrub off indicators turn off (approximately two seconds). 5 Release both switches. 6 The status display will now show a number from 1 to 3. Pressing and releasing the fast/slow switch will increase the displayed value until

3 is reached. The next press will return to 1. If 1 is selected, the maximum travel speed will be reduced while scrubbing. If 2 is selected, the maximum travel speed will be reduced when scrubbing or sweeping. If 3 is selected, the maximum travel speed will be reduced when sweeping only.

7 To save the new setting, turn the main power key switch to the off position. 8 The new setting will be saved and will remain in effect until it is changed again.

main power key switch to the off position.

FORM NO. 56043126 - CR 1100, CR 1200 - 63

PROGRAMMABLE CONTROL OPTIONS

Control System Self-Diagnostic Mode:

If problems with the electronic control system are suspected, this self-diagnostic mode may help isolate the problem. When this mode is activated, the control unit will activate each one of the outputs in sequence and test for short circuits, open circuits, or overload conditions. This mode will also provide an easy test for the touch panel switches and indicators. If an abnormal condition is encountered with one of the outputs, an error code will be displayed. A listing of error codes is provided at the end of this section.

1 CAUTION! During this test, the horn will sound brieﬂ y and the various motors will turn on momentarily. Make sure that all persons

are away from ALL moving parts of the machine to prevent injury.

2 Turn the main power key switch to the off position. 3 Press and hold the side broom down/on switch switch. 4 While holding the side broom down/on switch, turn the main power key switch to the on position. 5 Continue to hold the side broom down/on switch until all indicators except the side broom down/on indicator turn off (approximately two

seconds).

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 display will show “1” followed by a brief blank period

• The display will show “8” followed by a long blank period

• The above sequence will repeat

10 To test any of the control panel switches, press the desired switch. The indicator for that switch should illuminate. If not, consult the service

manual trouble-shooting section.

11 The hopper limit, main broom, recovery tank full, solution tank empty, hydraulic ﬁ lter, hopper temperature, and dust control ﬁ lter switches may

also be tested in this mode. The corresponding indicators will indicate the state of each of the inputs. The speed controller fault code status light will indicate the state of the speed control fault output (a periodic ﬂ ash is normal). The Battery status indicators will indicate the following: red indicator = state of seat switch, yellow indicator = state of forward/reverse signal from speed control, green indicator = state of reverse signal from speed control. The hourmeter display will indicate the battery voltage.

12 To exit this mode, turn the main power key switch to the off position.

NOTE: If the machine is not equipped with an optional back-up alarm, an error code 59 will be indicated. Also, this test does not include the light circuit.

64 - FORM NO. 56043126 - CR 1100, CR 1200

PROGRAMMABLE CONTROL OPTIONS

Recall Of Stored Error Codes:

Whenever an electrical system fault is detected by the main control unit, one or more error codes are displayed and stored by the control unit. If it is desired, the error code (if any) from the previous operation of the machine can be recalled for troubleshooting purposes. To recall the last stored error codes perform the following steps:

1 Turn the main power key switch to the off position. 2 Press and hold the solution switch. 3 While holding the solution switch, turn the main power key switch to the on position. 4 Continue to hold the solution switch until all indicators except the solution indicator turn off (approximately two seconds). 5 Release the solution switch. 6 If there were previously no error codes stored, the display will now show “-”. Go to step 10. 7 If error codes were stored, the display will now show the stored 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 display will show “1” followed by a brief blank period

• The display will show “8” followed by 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 to the factory defaults, perform the following steps:

1 Turn the main power key switch to the off position. 2 Press and hold the all three scrub system switches (scrub off, pressure increase, & pressure decrease). 3 While holding all three switches turn the main power key switch to the on position. 4 Continue to hold all three switches until all indicators turn off and the status display shows “d” (approximately two seconds). 5 Release all switches. 6 The programmable parameters are now restored to the default values. 7 To exit this mode, turn the main power key switch to the off position.

Reset of Hourmeters to Zero:

To reset all hourmeters to zero:

1 Turn the main power key switch to the off position. 2 Press and hold the scrub pressure increase, scrub pressure decrease, and solution switches. 3 While holding all three switches turn the main power key switch to the on position. 4 Continue to hold all three switches until all indicators turn off and the status display shows “d” (approximately two seconds). 5 Release all switches. 6 The hourmeters are now reset to zero. 7 To exit this mode, turn the main power key switch

to the off position.

FORM NO. 56043126 - CR 1100, CR 1200 - 65

PROGRAMMABLE CONTROL OPTIONS

Low Voltage Cutout Level:

FACTORY DEFAULT: 1 (1.75VPC cutoff; 2.15VPC reset, VPC = Volts Per Cell) RANGE: 1-3

The low voltage cutoff feature will disable scrub and sweep functions when the battery becomes discharged. The cutoff and reset thresholds are selectable from three options. These are Option 1 – 1.75VPC cutoff, 2.15VPC reset; Option 2 – 1.75VPC cutoff, 2.09VPC reset; Option 3 – 1.83VPC cutoff, 2.09VPC reset. To select the desired cutoff level perform the following steps:

1 Turn the main power key switch to the off position. 2 Press and hold the side broom down/on and the 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 side broom down/on and scrub off indicators turn off (approximately two

seconds).

5 Release both switches. 6 The status display will now show a number from 1 to 3. Pressing and releasing the side broom down/on switch will increase the displayed

value until 3 is reached. The next press will return to 1. If 1 is selected, the cutoff level will be 1.75VPC & the reset level will be 2.15VPC. If 2 is selected, the cutoff level will be 1.75VPC & the reset level will be 2.09VPC. If 3 is selected, the cutoff level will be 1.83VPC & the reset level will be 2.09VPC.

7 To save the new setting, turn the main power key switch to the off position. 8 The new setting will be saved and will remain in effect until it is changed again.

Control Unit Sleep Delay Period:

FACTORY DEFAULT: 1 (10 minutes) RANGE: 0 - 9

If the CR 1100/1200 is left in an idle state for a period determined by the sleep delay setting the control unit will automatically turn off any accessories. This is to conserve battery power. The sleep period is adjustable from 10 to 90 minutes in 10 minute increments. It can also be turned off. To 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).

5 Release both switches. The status display will now indicate a number from 0 to 9 depending on the current sleep delay period. 6 Pressing and releasing the hopper up switch will now select the delay period. The level will increment from 0 to 9. 0 = off (sleep disabled), 1

= 10 minutes, 2 = 20 minutes, ... up to 9 = 90 minutes.

7 To save the new setting, turn the main power key switch to the off position. 8 The new setting will be saved and will remain in effect until it is changed again.

Squeegee Raise-In-Reverse Time Period Adjustment:

FACTORY DEFAULT: 3 (2.5 seconds) RANGE: 1 - 9

When backing up with the recovery system active, the control unit will automatically raise the squeegee just enough to prevent dragging on the ﬂ oor. The time that the squeegee is raised is adjustable from 2 to 4 seconds in .25 second increments. To adjust the distance the squeegee is raised in reverse, 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 vacuum 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 vacuum indicator turn off (approximately 2 seconds). 5 Release both switches. The status display will now indicate a number from 1 to 9 depending on the current time period. 6 Pressing and releasing the vacuum switch will now select the time period. The level will increment from 1 to 9. 1 = 2 second, 2 = 2.25 seconds,

3 = 2.5 seconds, ... up to 9 = 4.0 seconds.

7 To save the new setting, turn the main power key switch to the off position. 8 The new setting will be saved and will remain in effect until it is changed again.

66 - FORM NO. 56043126 - CR 1100, CR 1200

ELECTRICAL SYSTEM

CURTIS CONTROLLER (A3) DIAGNOSTICS

Diagnostics Method A: Uses the machine’s control panel LED status display.

FUNCTION OF THE SPEED CONTROLLER STATUS LIGHT AND DISPLAY

The Curtis 1244 speed control will output a fault code if there is a problem associated with the speed control and wheel drive system. See Figure 1. If a speed control or drive motor fault occurs, the Wrench Symbol (E) located in the top center on the (A2) operator panel will ﬂ ash a special error code sequence until the fault is corrected. See “Table 1” for a description of the fault indications. Service Note: Instructions on how to read the error code status light. Example, OO O = two light ﬂ ashes, a short pause, one ﬂ ash, a long pause and the code will be repeated.

FIGURE 1

Diagnostics Method B: Uses the optional hand held programmer.

PROGRAMMER DIAGNOSTICS

With a programmer, diagnostics and troubleshooting is more direct than with the LED alone. The programmer presents complete diagnostic information in plain language, no codes to decipher. Faults are displayed in the Diagnostic Menu, and the status of the controller inputs/outputs is displayed in the Test Menu.

The following 4-step process is generally used for diagnosing and troubleshooting an inoperative vehicle: (1) visually inspect the vehicle for obvious problems; (2) diagnose the problem, using the programmer; (3) test the circuitry with the programmer: and (4) correct the problem. Repeat the last three steps as necessary until the vehicle is operational.

Example: A vehicle that does not operate in “forward” is brought in for repair.

1 Examine the vehicle and its wiring for any obvious problems, such as broken wires or loose connections. 2 Connect the programmer, put it in diagnostic mode, and read the displayed fault information. In this example, the display shows “No Faults

Present”, indicating that the controller has not detected anything out of the norm.

3 Put the programmer in test mode, and observe the status of inputs and outputs in the forward direction. In this example, the display shows

that the forward input did not activate when “forward” was selected, which means the problem is either in the electronic throttle or the throttle wiring.

4 Check or replace the electronic throttle and wiring and repeat the test. If the programmer shows the forward switch closing and the vehicle now

drives normally, the problem has been corrected.

Refer 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 ﬁ le. 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 experienced since the last time the diagnostic history ﬁ le was cleared. The faults may be intermittent faults, faults caused by loose wires, or faults caused by operator errors. Faults such as contactor faults may be the result of loose wires; contactor wiring should be carefully checked out. Faults such as HPD or over temperature may be caused by operator habits or by overloading.

After a problem has been diagnosed and corrected, clearing the diagnostic history ﬁ le is advisable. This allows the controller to accumulate a new

ﬁ le of faults. By checking the new diagnostic history ﬁ le at a later date, you can readily determine whether the problem was indeed completely ﬁ xed.

To clear the diagnostic history ﬁ le, go to the Special Program Menu (by pressing and holding the MORE INFO key, and then pressing the PROGRAM key), scroll through the menu until “Clear Diagnostic History” is the top line in the display, and then press MORE INFO again. The programmer will prompt you to acknowledge or cancel.

See Curtis Programmer Manual 56043101 for more detail on programmer operation.

FORM NO. 56043126 - CR 1100, CR 1200 - 67

ELECTRICAL SYSTEM

STATUS LED FAULT CODES (TABLE 1)

LED

CODE

Off

Solid On

0,1 1,2

1,3

2,1

2,2

2,3

2,4

3,1

3,2

3,3

3,4

4,1

4,2

4,3

4,4

STATUS LIGHT

DISPLAY

– O Controller operational; no faults O OO Hardware failsafe error 1. Controller defective.

O OOO M-, current sensor, or motor fault

OO O Throttle fault

OO OO Static return to off (SRO) fault

OO OOO High Pedal Disable (HPD) fault

OO OOOO Emergency reverse circuit check fault

OOO O Contactor driver overcurrent 1. Contactor coil shorted.

OOO OO Welded Main Contactor

OOO OOO Precharge fault

OOO OOOO

OOOO O Low battery voltage

OOOO OO Overvoltage

OOOO OOO

OOOO OOOO Anti-tiedown fault

EXPLANATION

No power or defective controller Controller or microprocessor fault

Missing contactor, or main cont. did not close

Thermal cutback, due to over/undertemp

POSSIBLE CAUSE

1. Controller defective.

2. Motor ﬁ eld wiring loose.

3. Motor ﬁ eld winding open.

1. Throttle input wire open.

2. Throttle input wire shorted to B+ or B-.

3. Throttle pot defective.

4. Wrong throttle type selected

1. Improper sequence of KSI*, interlock, and direction inputs.

2. Wrong HPD type selected.

3. Interlock or direction switch circuit open.

4. Sequencing delay too short.

1. Improper sequence of direction and throttle inputs.

2. Wrong HPD type selected.

3. Misadjusted throttle pot.

4. Sequencing delay too short.

1. Emergency reverse wire open.

2. Emergency reverse check wire open.

1. Main contactor stuck closed.

2. Main contactor driver shorted.

1. Controller defective.

2. External short, or leakage path to B- on external B+ connection.

1. Any contactor coil open or not connected.

2. Main contactor missing or wire to coil open.

1. Battery voltage <undervoltage cutback limit.

2. Corroded battery terminal.

3. Loose battery or controller terminal.

1. Battery voltage >overvoltage shutdown limit.

2. Vehicle operating with charger attached.

3. Battery disconnected during regen braking.

1. Temperature >85°C (185°F) or<-25°C (-13°F).

2. Excessive load on vehicle.

3. Improper mounting of controller.

4. Operation in extreme environments.

1. Mode switches shorted to B+

2. Mode switches “tied down” to select Mode 2 or Mode 4 permanently.

*NOTE: A KSI (key switch input) system problem is a speciﬁ c HPD (high pedal disable) type operational fault, caused by the operator activating

the Fwd/Rev drive pedal before turning on the main key switch or activating the throttle before sitting on the seat. This can be cleared by returning the operator’s drive pedal to neutral and cycling the key switch OFF and ON.

68 - FORM NO. 56043126 - CR 1100, CR 1200

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.

FORM NO. 56043126 - CR 1100, CR 1200 - 69

FORM NO. 56043126 - CR 1100, CR 1200 - 71

COMPONENT LOCATION

ELECTRICAL SYSTEM

Item Description

A1 Control Box Assembly A2 Switch/Display Panel Assembly A3 Curtis 1244 Speed Controller C1 Capacitor, 180 MFD F1 Circuit Breaker, 25 Amp (Auxiliary Circuit 1) F2 Circuit Breaker, 5 Amp (Auxiliary Circuit 2) F3 Circuit Breaker, 20 Amp (Auxiliary Circuit 3) F4 Circuit Breaker, 15 Amp (Dust Control) F5 Circuit Breaker, 20 Amp (Side Brooms) F7 Circuit Breaker, 70 Amp (Hydraulic Pump) F8 Circuit Breaker, 40 Amp (Vacuum Motors) F9 Circuit Breaker, 40 Amp (Power Steering) F10 Fuse, 400 Amp (Main) F11 Fuse, 250 Amp (Brush Motors) H2 Horn H3 Headlight, Right H4 Headlight, Left H5 Lamp, Tail H6 Lamp, Tail H10 Lamp, Broom Overload K1 Contactor, Left Brush Motor K2 Contactor, Center Brush Motor K3 Contactor, Right Brush Motor K4 Contactor, Broom Motor K5 Contactor, Drive Wheel K6 Contactor, 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, Vacuum M8 Motor, Right Side Broom M9 Motor, Left Side Broom M10 Motor, Assembly, Hydraulic Pump M11 Motor, Brush Actuator M12 Motor, Squeegee Actuator M13 Motor, Side Broom Actuator M14 Motor, Shaker M15 Motor, Wheel Drive M16 Motor, Steering R1 Potentiometer, 5K Ohm S3 Switch, Hopper Interlock S4 Switch, Recovery Full S5 Switch, Solution Empty S7 Switch, Hydraulic Filter S8 Switch, Main Broom S11 Switch, Key S13 Switch, Battery Interlock

K10

M13

S13

M15

M12

M11

H10

M16

L6A

M10

K11

M14

F10

F11

S11

Contactors

Fuses

72 - FORM NO. 56043126 - CR 1100, CR 1200

ELECTRICAL SYSTEM

Lamp, Tail

Head Light, Right

K11

Contactor, Hyd. Pump Motor

K10

Contactor, Aux.

M13

Motor, Side Broom Actuator

Switch, Recovery Full

Circuit Breaker, 20 A

M11

Motor, Brush Actuator

Lamp, Curb

Head Light, Left

Contactor, Side Broom

Circuit Breaker, 25 A.

M12

Motor, Squeegee Actuator

Switch, Extend Limit

Lamp, Trouble

Switch, Seat

H10

Lamp, Broom Overload

M14

Motor, Shaker

Switch, Dust Control Filter (optional)

Lamp, Tail

K10

Contactor, Aux.

Circuit Breaker, 5 AMP

S12

Switch, Wand (optional)

Contactor, Center Brush Motor

Valve, Dump Door Open

F10

Fuse, 400 A.

Lamp, Flashing

Contactor, Left Brush Motor

BT1

Battery, 36 Vdc

S10

Switch, Hopper Fire (optional)

Switch, Hopper Interlock

Horn

S11

Switch, Key

L6A

Valve, Hopper Lower

Valve, Solution

S13

Switch, Battery Interlock

Contactor, Vacuum Motor

Switch, Solution Empty

Switch, Hydraulic Filter

Valve, Hopper Raise

Switch, Retract Limit

Switch, Main Broom

Contactor, Broom Motor

Contactor, Dust Control Motor

Backup Alarm (optional)

Contactor, Right Brush Motor

Contactor, Steering

Valve, Dump Door Close

Valve, Solution

B-

GRA

ORN/RED

BRN

BLU/BLK

ORN/BLU

RED/WHT

B+

GRN

ORN

RED

BLK

WHT

GRN

ORN/RED

GRA

RED/WHT

BRN

BLU/BLK

BLK

ORN/BLU

VIO

RED

VIO

GRN/BRN

VIO/BRN

BRN/YEL

BLU

BRN/BLK

GRA/RED

BLU/WHT

VIO

YEL/BLU

WHT/VIO

VIO

GRN/BLK

VIO YEL/GRN

RED/GRA

BLU/RED

YEL/RED

BRN/GRN

VIO

RED

VIO

YEL/BLK

BLK/REDVIO

GRN/GRAVIO

VIO

ORNYEL/BRNRED

GRN

BLK/ORN

YEL/BRN

GRA/ORN

YEL/BLK

BLK

GRN/BLU

BRN/BLU

BLK

WHT/BRN

RED/ORN

GRN/VIO

RED/GRN

BLU/BRN

GRN/ORN

YEL/GRA

WHT/GRN

GRA/VIO

BLK

GRA/WHT

YEL/VIO

BLK

RED/BLK

GRA/YEL

BLK

WHT/GRA

BLKVIO/YEL

YEL/WHT

ORN/BLK

BLK

ORN/BRN

BLU/ORN

BLK/GRA

VIO

GRN/BLK

YEL/BRN

RED

ORN

BLU/GRN

YEL/BRN

B- INPUT

CONTROL

BOX

ASSEMBLY

MODE 1

FAULT 1

BRAKE DRIVER

REVERSE SIGNAL

BRUSH CURRENT SENSE

-12 VDC

BROOM CURRENT SENSE

To Speed Controller

140 DEG. F

(+ to RED to Extend)

Switch/Display

Panel Assembly

(+ to RED to Extend)

J3-1 (+12V)

J3-3 (PIEZO)

J3-5 (SCL)

J3-6 SDA

J3-7 (B+)

J3-8 (B-)

J2-1

J2-9

J2-7

J2-19

J2-10

J2-33

J1-21

J2-11

J2-24

J1-1

J2-23

J1-4

J1-15

J1-18

J1-16

J1-14

J1-20

J1-8

J1-7

J1-19

J1-17

J1-6

J1-5

J1-3

J1-9

J2-34

J2-35

J1-10

J1-2

J2-20

J1-34

J1-32

J1-30

J1-28

J1-26

J2-31

J1-11

J1-12

J2-15

J2-3

J1-24

J1-13

J1-35

J1-23

J2-2

J2-6

J2-17

J2-5

J2-16

J2-13

J2-4

J4-14

J2-8

J2-1

J2-26

J2-25

J2-21

J2-22

To Speed Controller

J1-22

2121

RED YEL

BLK

WHT

BLK

WHT

BLK

RED

Motor, Vacuum

Contact N.O.

Circuit Breaker, 40 Amp

Circuit Breaker, 70 Amp

Motor, Left Brush

Circuit Breaker, 15 Amp

Contact N.O.

F11

Fuse, 250 Amp

Contact N.O.

Circuit Breaker, 20 Amp

Contactor, Wheel Drive

CURTIS 1244 SPEED CONTROLLER

Motor, Dust Control

Motor, Left Side Broom

M16

Motor, Steering

M10

Motor Asm., Hyd. Pump

K11

Contact N.O.

Motor, Right Side Broom

Contact N.O.

Pot. 5k Ohm

M15

Motor, Wheel Drive

Motor, Broom

Contact N.O.

Capacitor, 180 MFD

Circuit Breaker, 40 Amp

Motor, Right Brush

X51

Contact N.O.

Motor, Center Brush

B +

ORN

B-

ORN/BLU

GRA

ORN/RED

BLU/BLK

BRN

GRN

RED/WHT

CURRENT SENSE

Forward

Reverse

RED 6-2

GRA/BLK

WHT/ORN

BLU/YEL

ORN/GRN BLK

BLK

BLKBLU/GRA

BLU/GRA

BLK

WHT/RED

BLKBLK

BLK

BLK 1-A1

WHT/YEL

RED/BLU

BLK

RED 1-2

ORN

RED/WHT

BLK

RED 6-1

BRN/WHTRED

GRN/REDRED

VIO/GRARED

ORN/WHTRED

RED

RED/VIO

RED 1-1

ORN

RED 1-A2

GRN

ORN/RED

GRN/WHTBRN/GRARED

ORN BLK/YEL

BLK/YEL

RED/VIO

GRA

BLU/BLK

BRN/RED

WHT/BLK

VIO/BLK

BLK

123456789

101112

1314151617181920212223

B+

M-

F1 F2

B-

F1 F2

A2A1

Item Description

A1 CONTROL BOX ASSEMBLY A2 SWITCH/DISPLAY PANEL ASSEMBLY A3 CURTIS 1244 SPEED CONTROLLER BT1 BATTERY 36VDC C1 CAPACITOR, 180 MFD F1 CIRCUIT BREAKER, 25 AMP (AUXILIARY CIRCUIT 1) F2 CIRCUIT BREAKER, 5 AMP (AUXILIARY CIRCUIT 2) F3 CIRCUIT BREAKER, 20 AMP (AUXILIARY CIRCUIT 3) F4 CIRCUIT BREAKER, 15 AMP (DUST CONTROL) F5 CIRCUIT BREAKER, 20 AMP (SIDE BROOMS) F7 CIRCUIT BREAKER, 70 AMP (HYDRAULIC PUMP)) F8 CIRCUIT BREAKER, 40 AMP (VACUUM MOTORS) F9 CIRCUIT BREAKER, 40 AMP (POWER STEERING) F10 FUSE, 400 AMP (MAIN) F11 FUSE, 250 AMP (BRUSH MOTORS) H1 BACKUP ALARM (OPTIONAL) H2 HORN H3 HEADLIGHT, RIGHT H4 HEADLIGHT, LEFT H5 LAMP, TAIL H6 LAMP, TAIL H7 LAMP, FLASHING (OPTIONAL) H8 LAMP, CURB (OPTIONAL) H9 LAMP, TROUBLE (OPTIONAL) H10 LAMP, BROOM OVERLOAD K1 CONTACTOR, LEFT BRUSH MOTOR K2 CONTACTOR, CENTER BRUSH MOTOR K3 CONTACTOR, RIGHT BRUSH MOTOR K4 CONTACTOR, BROOM MOTOR K5 CONTACTOR, DRIVE WHEEL K6 CONTACTOR, 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 L2 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, VACUUM M8 MOTOR, RIGHT SIDE BROOM M9 MOTOR, LEFT SIDE BROOM M10 MOTOR, ASSEMBLY, HYDRAULIC PUMP M11 MOTOR, BRUSH ACTUATOR M12 MOTOR, SQUEEGEE ACTUATOR M13 MOTOR, SIDE BROOM ACTUATOR M14 MOTOR, SHAKER M15 MOTOR, WHEEL DRIVE M16 MOTOR, STEERING R1 POTENTIOMETER, 5K OHM S1 SWITCH, EXTEND LIMIT S2 SWITCH, HOPPER INTERLOCK S4 SWITCH, RECOVERY FULL S5 SWITCH, SOLUTION EMPTY S6 SWITCH, DUST CONTROL FILTER (OPTIONAL) S7 SWITCH, HYDRAULIC FILTER S8 SWITCH, MAIN BROOM S9 SWITCH, SEAT S10 SWITCH, HOPPER FIRE (OPTIONAL) S11 SWITCH, KEY S12 SWITCH, WAND (OPTIONAL) S13 SWITCH, BATTERY INTERLOCK

WIRING DIAGRAM (before SN 1767238)

FORM NO. 56043126 - CR 1100, CR 1200 - 73

WIRING SCHEMATIC (before SN 1767238)

ELECTRICAL SYSTEM

GRN/BLK 16-1

GRN/BLK 16-2

GRN/BLK 12-1

ORN 18-4

ORN 18-5

ORN 18-6

ORN 18-7

GRN 18-2

GRN 18-3

GRN 18-1

YEL/BLK 16-12

YEL/BLK 16-1

YEL/BLK 16-2

YEL/BLK 16-3

YEL/BLK 16-5

VIO 16-21

YEL/BLK 16-4

VIO 16-20

YEL/BLK 16-5

YEL/BLK 16-4

YEL/BLK 16-2

VIO 16-19

VIO 16-20

VIO 16-21

WHT/GRN 18-1

BLU/BRN 18-1

VIO 16-18

GRN/BRN 18-1

YEL

RED

GRN

WHT

RED

BLK

VIO 16-17

BLK 18-12

RED 6-1

RED 1-1

LAMP, TAIL

MOTOR, SQUEEGEE

ACTUATOR

BACKUP ALARM (OPTIONAL)

M12

SW., EXTEND LIMIT

M11

SW., RETRACT LIMIT

MOTOR, BRUSH ACTUATOR

GRA/ORN 18-1

ORN 18-2

BLK 18-18

VIO/YEL 18-1

BLK 16-1

BLK 18-11

BLK 16-2

BLK 12-8

BLU/GRA 12-1

BLK 12-9

BLU/GRA 12-2

BLK 16-2

GRA/YEL 18-1

BLK 18-24

GRA/YEL 18-2

BLK 18-3

BLK 12-4

BLK 18-4

ORN/GRN 14-1

WHT BLK

GRN/ORN 18-3

GRA/VIO 18-3

ORN/GRN 14-2

VIO 14-4

RED/BLK 18-3

WHT/RED 12-4

BLK 12-5

BLK 12-6

BLK/RED 18-2

YEL/VIO 18-3

WHT/GRA 18-3

YEL/BLK 16-10

BLK/RED 18-3

YEL/VIO 18-2

WHT/GRA 18-2

YEL/BLK 16-7

GRA/VIO 18-2

ORN/GRN 14-1

VIO 14-6

RED/BLK 18-2

WHT/RED 12-3

BLK 12-3

BLK 12-4

GRN/ORN 18-2

SWITCH, SOLUTION EMPTY

SWITCH, SEAT

SWITCH, RECOVERY FULL

MOTOR, DUST CONTROL

MOTOR, SIDE BROOM ACTUATOR

MOTORS, VACUUM

SWITCH, BATTERY INTERLOCK

HORN

SWITCH, WAND (OPTIONAL)

VALVE, DUMP

DOOR CLOSE

VALVE, DUMP

DOOR OPEN

VALVE, HOPPER RAISE

VALVE, HOPPER LOWER

SWITCH, HYD. FILTER

MOTOR ASM., HYD PUMP

LAMP, CURB

MOTOR, SHAKER

SWITCH, HOPPER FIRE

SWITCH, DUST CONTROL FILTER

MOTOR, RIGHT SIDE BROOM

HEAD LIGHT, RIGHT

HEAD LIGHT, LEFT

MOTOR, LIFT SIDE BROOM

SWITCH, HOPPER INTERLOCK

MOTOR, STEERING

CAPACITOR, 180 MFD

BATTERY, 36Vdc

LAMP, TROUBLE

SWITCH/DISPLAY

PANEL ASSEMBLY

SWITCH, KEY

CIR. BREAKER, 15 A.

CIR. BREAKER, 25 A.

CIR. BREAKER, 5 A.

CIR. BREAKER, 20 A.

CIR. BREAKER, 70 A.

CIR. BREAKER, 40 AMP

LEFT BRUSH

DUST CONTROL

CENTER BRUSH

VACUUM

RIGHT BRUSH

SIDE BROOMS

MAIN BROOM

STEERING

DRIVE

AUXILIARY

LAMP, FLASHING

SWITCH, MAIN BROOM

LAMP, BROOM OVERLOAD

FUSE, 400 A.

FUSE, 250 A.

FUSES

F10: MAIN

F11: BRUSH MOTORS

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

K10

S12

L6A

M10

K11

M14

M16

BT1

S11

M13

S10

S13

S12

F11

F10

H10

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/ORN 8-1

YEL/GRN 18-4

YEL/GRN 18-2

YEL/GRN 18-3

YEL/BRN 18-5

YEL/BRN 18-2

BLU/GRN 10-1

RED 10-1

BLK/ORN 18-1

VIO 16-1

GRN/WHT 10-1

BRN/GRA 10-1

BLK 18-10

VIO 16-1

VIO 12-3

VIO 12-5

WHT/RED 12-4

VIO/GRA 12-1

BRN/BLK 18-1

VIO 12-5

VIO 14-1

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 10-1F1

F1 F2

RED/BLU 10-1

BLK 1-A1

RED 1-A2

BLK 1-2

B-

M-

B+

RED 3/0-1

BLK 18-4

BLK 18-5

BLK 18-6

WHT/GRA 18-2

BLK 18-5

YEL/VIO 18-2

BLK 18-6

VIO 18-3

BLK/RED 18-3

RED

BLK

RED BLK

BLK 12-1

WHT/RED 12-1

VIO 14-7

YEL/BLK 16-8

YEL/BLK 16-7

YEL/BLK 16-8

YEL/BLK 16-9

VIO 14-8

YEL/BLK 16-9

BLK 12-2

WHT/RED 12-2

BLK 18-3

RED/BLK 18-2

RED 8-3

BRN/GRA 10-1

RED 8-1

GRN/RED 8-1

RED 8-2

ORN/WHT 8-1

BLK 10-1

GRN/WHT 10-1

RED 3/0-1

BLK 3/0-1

BLK 18-19

YEL/BRN 18-3

ORN/BRN 18-1

BLU/ORN 18-1

GRN/BLU 18-1

BRN/BLU 18-1

WHT/BRN 18-1

BLK 18-1

ORN 18-1

YEL/BRN 18-4

RED BLK

X34

X31

X33

X32

X53

X52

X35

X23

X27

X24

X28

X26

X30

X25

X29

X63

X62

X19 X20

X6 X5

X7 X8

X12

X11

X16

X15

X64

X65

X72

SP23

SP5

SP24

X49

X50

SP18

X71

X70

X18

X17

X54

X55

X47 X48

SP8

SP14

X38

X37

X10

SP3SP2

SP1

SP4

SP17

SP12

SP9

B-

X61

B-

X60

X51

SP21

SP6

SP13

SP22

MOTOR, DRIVE

M15

X68

X69

X58

X59

X21

X22

SP10

X67

X66

X42 X39

X41 X40

X14 X13

SP16

X43 X44

X45 X46

SP20

X57

X56

SP11

SP15

74 - FORM NO. 56043126 - CR 1100, CR 1200

Item Description

WIRING DIAGRAM (after SN 1767237)

ELECTRICAL SYSTEM

Lamp, Tail

Head Light, Right

K11

Contactor, Hyd. Pump Motor

K10

Conta ct or , Au x.

M13

Motor, Side Broom Actuator

Switch, Recovery Full

Circuit Breaker, 20 A

M11

Motor, Brush Actuator

Lamp, Curb

Head Light, Left

Contactor, Side Broom

Circuit Breaker, 25 A.

M12

Motor, Squeegee Actuator

Switch, Extend Limit

Lamp, Trouble

Switch, Seat

H10

Lamp, Broom Overload

M14

Motor, Shaker

Switch, Dust Control Filter (optional)

Lamp, Tail

K10

Contactor, Aux.

Circuit Breaker, 5 AMP

S12

Switch, Wand (optional)

Contactor, Center Brush Motor

Valve, Dump Door Open

F10

Fuse, 400 A.

Lamp, Flashing

Contactor, Left Brush Motor

BT1

Battery, 36 Vdc

S10

Switch, Hopper Fire (optional)

Switch, Hopper Interlock

Horn

S11

Switc h, K ey

L6A

Valve, Hopper Lower

Valve, Solution

S13

Switch, Battery Interlock

Contactor, Vacuum Motor

Switch, Solution Empty

Switch, Hydraulic Filter

Valve, Hopper Raise

Switch, Retract Limit

Switch, Main Broom

Contactor, Broom Motor

Contactor, Dust Control Motor

Backup Alarm (optional)

Contactor, Right Brush Motor

Contactor, Steering

Valve, Dump Door Close

Valve, Solution

B-

GRA

ORN/RED

BRN

BLU/BLK

ORN/BLU

RED/WHT

B+

GRN

ORN

RED

BLK

WHT

GRN

ORN/RED GRA RED/WHT BRN

BLU/BLK

BLK

ORN/BLU

VIO

RED

VIO

GRN/BRN

VIO/BRN

BRN/YEL

BLU

BRN/BLK

GRA/RED

BLU/WHT

VIO

YEL/BLU

WHT/VIO

VIO

GRN/BLK

VIO YEL/GRN

RED/GRA

BLU/RED

YEL/RED

BRN/GRN

VIO

RED

VIO

YEL/BLK

BLK/REDVIO

GRN/GRAVIO

VIO

ORNYEL/BRNRED

GRN

BLK/ORN

YEL/BRN

GRA/ORN

YEL/BLK

BLK

BLK BLK BLK BLK

BLK

GRN/BLU BRN/BLU

BLK

WHT/BRN

RED/ORN

GRN/VIO

RED/GRN

BLU/BRN

GRN/ORN

YEL/GRA

WHT/GRN

GRA/VIO

BLK

GRA/WHT

YEL/VIO

BLK

RED/BLK

GRA/YEL

BLK

WHT/GRA

BLKVIO/YEL

YEL/WHT

ORN/BLK

BLK

BLK/WHT

BLK

ORN/BRN

BLU/ORN

BLK/GRA

VIO

GRN/BLK

YEL/BRN

RED

ORN

BLU/GRN

B- INPUT

CONTROL BOX ASSEMBLY

MODE 1

FAULT 1

BRAKE DRIVER

REVERSE SIGNAL

BRUSH CURRENT SENSE

-12 VDC

BROOM CURRENT SENSE

To Speed Controller

140 DEG. F

(+ to RED to Extend)

Switch/Display Panel Assembly

(+ to RED to Extend)

J3-2 (SCL-H) J3-3 (SCL-L)

J3-4 (SDA-H) J3-5 (SDA-L)

J3-6 (B+) J3-1 (B-)

J2-7

J2-18

J2-8

J2-19

J2-10 J2-31

J1-21

J2-11

J2-24

J1-1

J2-35

J1-4

J1-15

J1-18

J1-16

J1-14

J1-20

J1-8

J1-7

J1-19

J1-17

J1-6

J1-5

J1-3

J1-9

J2-34 J2-33

J1-10

J1-2

J2-20

J1-34 J1-32 J1-30 J1-28 J1-26

J1-11

J1-12

J2-15

J2-3

J1-24

J1-13

J1-35

J1-23

J2-2

J2-6

J2-17

J2-5

J2-16

J2-13

J2-4

J4-14

J2-8

J2-1 J2-26 J2-25 J2-21 J2-22

To Speed Controller

2121

RED YEL

BLK

WHT

BLK

WHT

BLK

RED

GRN/BLU BRN/BLU

BLK

WHT/BRN

ORN/BRN

BLU/ORN

BLK/WHT

J2-12 J2-23

LAMP GROUND

Motor, Vacuum

Contact N.O.

Circuit Breaker, 40 Amp

Circuit Breaker, 70 Amp

Motor, Left Brush

Circuit Breaker, 15 Amp

Contact N.O.

F11

Fuse, 250 Amp

Contact N.O.

Circuit Breaker, 20 Amp

Contactor, Wheel Drive

CURTIS 1244 SPEED CONTROLLER

Motor, Dust Control

Motor, Left Side Broom

M16

Motor, Steering

M10

Motor Asm., Hyd. Pump

K11

Contact N.O.

Motor, Right Side Broom

Contact N.O.

Pot. 5k Ohm

M15

Motor, Wheel Drive

Motor, Broom

Contact N.O.

Capacitor, 180 MFD

Circuit Breaker, 40 Amp

Motor, Right Brush

X51

Contact N.O.

Motor, Center Brush

B +

ORN

B-

ORN/BLU

GRA

ORN/RED

BLU/BLK

BRN

GRN

RED/WHT

CURRENT SENSE

Forward

Reverse

RED 6-2

GRA/BLK

WHT/ORN

BLU/YEL

ORN/GRN BLK

BLK

BLKBLU/GRA

BLU/GRA

BLK

WHT/RED

BLKBLK

BLK

BLK 1-A1

WHT/YEL

RED/BLU

BLK

RED 1-2

ORN

RED/WHT

BLK

RED 6-1

BRN/WHTRED

GRN/REDRED

VIO/GRARED

ORN/WHTRED

RED

RED/VIO

RED 1-1

ORN

RED 1-A2

GRN

ORN/RED

GRN/WHTBRN/GRARED

ORN BLK/YEL

BLK/YEL

RED/VIO

GRA

BLU/BLK

BRN/RED

WHT/BLK

VIO/BLK

BLK

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B+

M-

F1 F2

B-

F1 F2

A2A1

FORM NO. 56043126 - CR 1100, CR 1200 - 75

WIRING SCHEMATIC (after SN 1767237 but before SN 1808249)

ELECTRICAL SYSTEM

GRN/BLK 16-1 GRN/BLK 16-2 GRN/BLK 12-1

ORN 18-4

ORN 18-5

ORN 18-6

ORN 18-7

GRN 18-2 GRN 18-3 GRN 18-1

YEL/BLK 16-12 YEL/BLK 16-1 YEL/BLK 16-2

YEL/BLK 16-3

YEL/BLK 16-5

VIO 16-21

YEL/BLK 16-4

VIO 16-20

YEL/BLK 16-5

YEL/BLK 16-4

YEL/BLK 16-2

VIO 16-19 VIO 16-20 VIO 16-21

WHT/GRN 18-1

BLU/BRN 18-1

VIO 16-18

GRN/BRN 18-1

YEL

RED

GRN

WHT

RED

BLK

VIO 16-17

BLK 18-12

RED 6-1 RED 1-1

LAMP, TAIL

MOTOR, SQUEEGEE ACTUATOR

BACKUP ALARM (OPTIONAL)

M12

SW., EXTEND LIMIT

M11

SW., RETRACT LIMIT

MOTOR, BRUSH ACTUATOR

GRA/ORN 18-1

ORN 18-2

BLK 18-18

VIO/YEL 18-1

BLK 16-1

BLK 18-11 BLK 16-2

BLK 12-8

BLU/GRA 12-1

BLK 12-9

BLU/GRA 12-2

BLK 16-2

GRA/YEL 18-1

BLK 18-24

GRA/YEL 18-2

BLK 18-3 BLK 12-4 BLK 18-4

ORN/GRN 14-1

WHT BLK

GRN/ORN 18-3

GRA/VIO 18-3

ORN/GRN 14-2

VIO 14-4

RED/BLK 18-3

WHT/RED 12-4

BLK 12-5

BLK 12-6

BLK/RED 18-2

YEL/VIO 18-3

WHT/GRA 18-3

YEL/BLK 16-10

BLK/RED 18-3

YEL/VIO 18-2

WHT/GRA 18-2

YEL/BLK 16-7

GRA/VIO 18-2

ORN/GRN 14-1

VIO 14-6

RED/BLK 18-2

WHT/RED 12-3

BLK 12-3

BLK 12-4

GRN/ORN 18-2

SWITCH, SOLUTION EMPTY

SWITCH, SEAT

SWITCH, RECOVERY FULL

MOTOR, DUST CONTROL

MOTOR, SIDE BROOM ACTUATOR

MOTORS, VACUUM

SWITCH, BATTERY INTERLOCK

HORN

SWITCH, WAND (OPTIONAL)

VALVE, DUMP DOOR CLOSE

VALVE, DUMP

DOOR OPEN

VALVE, HOPPER RAISE

VALVE, HOPPER LOWER

SWITCH, HYD. FILTER

MOTOR ASM., HYD PUMP

LAMP, CURB

MOTOR, SHAKER

SWITCH, HOPPER FIRE

SWITCH, DUST CONTROL FILTER

MOTOR, RIGHT SIDE BROOM

HEAD LIGHT, RIGHT

HEAD LIGHT, LEFT

MOTOR, LIFT SIDE BROOM

SWITCH, HOPPER INTERLOCK

MOTOR, STEERING

CAPACITOR, 180 MFD

BATTERY, 36Vdc

LAMP, TROUBLE

SWITCH/DISPLAY

PANEL ASSEMBLY

SWITCH, KEY

CIR. BREAKER, 15 A.

CIR. BREAKER, 25 A.

CIR. BREAKER, 5 A.

CIR. BREAKER, 20 A.

CIR. BREAKER, 70 A.

CIR. BREAKER, 40 AMP

LEFT BRUSH

DUST CONTROL

CENTER BRUSH

VACUUM

RIGHT BRUSH

SIDE BROOMS

MAIN BROOM

STEERING

DRIVE

AUXILIARY

LAMP, FLASHING

SWITCH, MAIN BROOM

LAMP, BROOM OVERLOAD

FUSE, 400 A.

FUSE, 250 A.

FUSES F10: MAIN F11: BRUSH MOTORS

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

K10

S12

L6A

M10

K11

M14

M16

BT1

S11

M13

S10

S13

S12

F11

F10

H10

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/ORN 8-1

YEL/GRN 18-4 YEL/GRN 18-2 YEL/GRN 18-3

YEL/BRN 18-2

BLU/GRN 10-1

RED 10-1

BLK/ORN 18-1

VIO 16-1

GRN/WHT 10-1

BRN/GRA 10-1

BLK 18-10

VIO 16-1

VIO 12-3

VIO 12-5

WHT/RED 12-4

VIO/GRA 12-1

BRN/BLK 18-1

VIO 12-5

VIO 14-1

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 10-1F1

F1 F2

RED/BLU 10-1

BLK 1-A1

RED 1-A2

BLK 1-2

B-

M-

B+

RED 3/0-1

BLK 18-4

BLK 18-5 BLK 18-6

WHT/GRA 18-2

BLK 18-5

YEL/VIO 18-2

BLK 18-6

VIO 18-3

BLK/RED 18-3

RED

BLK

RED BLK

BLK 12-1

WHT/RED 12-1

VIO 14-7

YEL/BLK 16-8

YEL/BLK 16-7

YEL/BLK 16-8

YEL/BLK 16-9

VIO 14-8

YEL/BLK 16-9

BLK 12-2

WHT/RED 12-2

BLK 18-3

RED/BLK 18-2

RED 8-3

BRN/GRA 10-1

RED 8-1

GRN/RED 8-1

RED 8-2

ORN/WHT 8-1

BLK 10-1

GRN/WHT 10-1

RED 3/0-1

BLK 3/0-1

BLK 18-19

YEL/BRN 18-3

ORN/BRN 18-1

BLU/ORN 18-1

GRN/BLU 18-1

BRN/BLU 18-1

WHT/BRN 18-1

BLK 18-1

ORN 18-1

YEL/BRN 18-4

RED BLK

X34

X31

X33

X32

X53

X52

X35

X23

X27

X24

X28

X26

X30

X25

X29

X63

X62

X19 X20

X6 X5

X7 X8

X12

X11

X16

X15

X64

X65

SP23

SP5

SP24

X49

X50

SP18

X71

X70

X18

X17

X54

X55

X47 X48

SP8

SP14

X38

X37

X10

SP3SP2

SP1

SP4

SP17

SP12

SP9

BX61

BX60

X51

SP21

SP6

SP13

SP22

MOTOR, DRIVE

M15

X68

X69

X58

X59

X21

X22

SP10

X67

X66

X42 X39

X41 X40

X14 X13

SP16

X43 X44

X45 X46

SP20

X57

X56

SP11

SP15

BLK/WHT 16-1

BLK/WHT 16-2

BLK 16-7

BLK 16-6

BLK 16-5

BLK 16-4

BLK 16-3

BLK 3/0-1

BLK 1-2

BLK 18-10

BLK 12-8

BLK 12-9

BLK 10-1

BLK 16-1

BLK 3/0-2

GRAY

GRN/BLK 16-2

YEL/BLK 16-12

YEL/BLK 16-1

BLK 18-1

BLU/BLK 18-1

BLK/WHT 16-1

ORN/BRN 18-1

BLK/WHT 16-2

BLU/ORN 18-1

GRA 18-1

RED/WHT 18-1

GRN 18-2

ORN/BLU 18-1

BRN 18-1

BLK/GRA 18-1

BRN/BLU 18-1

VIO/YEL 18-1

YEL/WHT 18-1

GRN/VIO 18-1

GRA/WHT 18-1

ORN/BLK 18-1

ORN 18-7

WHT/BRN 18-1

GRN/BLU 18-1

GRA/YEL 18-1

WHT/GRA 18-1

YEL/VIO 18-1

RED/ORN 18-1

RED/BLK 18-1

ORN/RED 18-1

76 - FORM NO. 56043126 - CR 1100, CR 1200

ELECTRICAL SYSTEM

WIRING DIAGRAM sheet 1 of 3 (after SN 1808248)

K11

K10

M13

M11

K12

M12

S15

H10

M14

K10

F10

Fuse,400 A.

BT1

Battery,36 Vdc

S14

S11

L6A

S13

S10

RED BLK

RED

CONTROL BOX ASSEMBLY

M17

ORN/RED

GRA

RED/WHT

BRN

BLU/BLK

BLK

ORN/BLU

VIO

RED

VIO

GRN/BRN

VIO/BRN

BRN/YEL

BLU

BRN/BLK

GRA/RED

BLU/WHT

VIO

YEL/BLU

WHT/VIOVIO

VIO

GRN/BLK

VIO

RED/GRA

BLU/RED

YEL/RED

BRN/GRN

VIO

RED

VIO

YEL/BLK

BLK/REDVIO

GRN/GRAVIO

VIO

ORN

RED

GRN

BLK/ORNYEL/BRN

YEL/BLK

YEL/GRN

BLK

BLK BLK BLK BLK

BLK

GRN/BLU BRN/BLU

BLK

WHT/BRN

RED/ORN

GRN/VIO

RED/GRN

BLU/BRN

GRN/ORN

YEL/GRA

WHT/GRN

GRA/VIO

BLKGRA/WHT

YEL/VIO BLK

RED/BLK

GRA/YEL

BLK

WHT/GRA

YEL/WHT

ORN/BLK BLK

BLK

BLK/WHT

BLK

ORN/BRN

BLU/ORN

BLK/GRAVIO

GRN/BLK

YEL/BRN

RED

ORN

BLU/GRN

BLK/WHT

GRN/BLU BRN/BLU

WHT/BRN BLK

BLU/ORN ORN/BRN

BLU/GRN GRA/BRN

GRA/BRN BLK/GRA

GRA/BRN

BLK

BLU/ORN

BLU/GRN

BLK

YEL/GRN

BLKVIO/YEL

VIO/YEL

ORN PINK GRA/ORN

ORN

TANGRA/ORN

B-

GRA

ORN/RED

BRN

BLU/BLK

ORN/BLU

RED/WHT

B+

GRN

ORN

GRA/ORN

B-INPUT

MODE1

FAULT1

BRAKEDRIVER

REVERSESIGNAL

BRUSHCURRENT SENSE

-12VDC

BROOMCURRENT SENSE

(OPTIONAL)

TOSPEED CONTROLLER

(OPTIONAL)

140DEG. F

(+TO REDTO EXTEND)

SWITCH/DISPLAY PANEL ASSEMBLY

(+TO REDTO EXTEND)

J3-2(SCL-H) J3-3(SCL-L)

J3-4(SDA-H) J3-5(SDA-L)

J3-6(B+) J3-1(B-)

J2-7

J2-18

J2-8

J2-19

J2-10 J2-31

J1-21

J2-11

J2-24

J1-1

J2-35

J1-4

J1-15

J1-18

J1-16

J1-14

J1-20

J1-8

J1-7

J1-19

J1-17

J1-6

J1-5

J1-3

J1-9

J2-34 J2-33

J1-10

J1-2

J2-20

J1-34

J1-32

J1-30 J1-28 J1-26

J1-11

J1-12

J2-15

J2-3

J1-24

J1-13

J1-35

J1-23

J2-2

J2-6

J2-5

J2-16

J2-13

J2-4

J4-14

J2-29

J2-1

J2-26

J2-25

J2-21

J2-22

TOSPEED CONTROLLER

J2-12 J2-23

LAMPGROUND

AXPSYSTEM

J2-17

TOSTEERING SYSTEM

CONTACTOR,SIDE BROOMCONTACTOR,SIDEBROOM

VALVE,HOPPER LOWERVALVE,HOPPER LOWER

1 2

SWITCH,WAND

(OPTIONAL)

SWITCH,WAND

(OPTIONAL)

MOTOR,SHAKERMOTOR,SHAKER

BLKRED

LAMP,TAILLAMP, TAIL

A B

HEADLIGHT, LEFTHEADLIGHT,LEFT

1 2

+ -

CONTACTOR,AUX.CONTACTOR,AUX.

FLOWPOSITION SENSORFLOWPOSITION SENSOR

123

CONTACTOR,STEERINGCONTACTOR, STEERING

LAMP,BROOM OVERLOADLAMP,BROOM OVERLOAD

1 2

SWITCH,SOLUTION EMPTYSWITCH, SOLUTIONEMPTY

1 2

SWITCH,BATTERY INTERLOCKSWITCH,BATTERY INTERLOCK

1 2

CONTACTOR,DUST CONTROLMOTORCONTACTOR,DUST CONTROLMOTOR

CIRCUITBREAKER, 5AMPCIRCUITBREAKER, 5AMP

1 2

SWITCH,RETRACT LIMITSWITCH,RETRACT LIMIT

WHT

GRN

CIRCUITBREAKER, 25A.CIRCUIT BREAKER,25 A.

1 2

SWITCH,HOPPER INTERLOCKSWITCH, HOPPERINTERLOCK

1 2

CONTACTOR,LEFT BRUSHMOTORCONTACTOR,LEFT BRUSHMOTOR

SWITCH,MAIN BROOMSWITCH,MAIN BROOM

1 2

VALVE,DUMP DOOROPENVALVE, DUMPDOOR OPEN

1 2

SWITCH,SEATSWITCH, SEAT

VALVE,DUMP DOORCLOSEV ALVE,DUMP DOORCLOSE

1 2

MOTOR,BRUSH ACTUATORMOTOR, BRUSHACTUATOR

YELRED

CONTACTOR,RIGHT BRUSHMOTORCONTACTOR,RIGHT BRUSHMOTOR

PUMP,AXP SOLUTIONMPUMP,AXP SOLUTION

LAMP,FLASHINGLAMP,FLASHING

1 2

RELAY,SAFETYRELAY, SAFETY

1 2

MOTOR,SIDE BROOMACTUATORMOTOR,SIDE BROOMACTUATOR

BLKWHT

VALVE,HOPPER RAISEVALVE,HOPPERRAISE

1 2

LAMP,TROUBLELAMP, TROUBLE

+ -

CONTACTOR,VACUUM MOTORCONTACTOR,VACUUM MOTOR

CONTACTOR,AUX.CONTACTOR,AUX.

1 2

SWITCH,HUYDRAULIC FILTERSWITCH,HUYDRAULIC FILTER

1 2

SWITCH,KEYSWITCH,KEY

B13

SWITCH,DUST CONTROLFILTERSWITCH,DUST CONTROLFILTER

1 2

BACKUPALARMBACKUP ALARM

+ -

HORNHORN

1 2

SWITCH,EMERGENCY STOPSWITCH,EMERGENCY STOP

1 2

MOTOR,SQUEEGEE ACTUATORMOTOR,SQUEEGEE ACTUATOR

BLKWHT

LAMP,CURBLAMP,CURB

1 2

CIRCUITBREAKER, 10A.CIRCUIT BREAKER,10 A.

1 2

SWITCH,HOPPER FIRE.

123

LAMP,TAILLAMP, TAIL

A B

CONTACTOR,BROOM MOTORCONTACTOR,BROOM MOTOR

+ -

SWITCH,EXTEND LIMITSWITCH,EXTENDLIMIT

RED

BLK

CIRCUITBREAKER, 20ACIRCUITBREAKER,20 A

1 2

CONTACTOR,HYD. PUMPMOTORCONTACTOR,HYD. PUMPMOTOR

VALVE,SOLUTIONVALVE,SOLUTION

1 2

CONTACTOR,CENTER BRUSHMOTORCONTACTOR,CENTER BRUSHMOTOR

SWITCH,RECOVERY FULLSWITCH, RECOVERYFULL

1 2

HEADLIGHT, RIGHTHEAD LIGHT, RIGHT

1 2

Item Description

A1 Control Box Assembly A2 Switch/Display Panel Assembly

BT1 Battery 36Vdc

F1 Circuit Breaker, 25 Amp (Auxiliary Circuit 1) F2 Circuit Breaker, 5 Amp (Auxiliary Circuit 2) F3 Circuit Breaker, 20 Amp (Auxiliary Circuit 3) F6

Circuit Breaker, 10A (AXP)

F10 Fuse, 400 Amp (Main)

H1 Backup Alarm (optional) H2 Horn H3 Headlight, Right H4 Headlight, Left H5 Lamp, Tail H6 Lamp, Tail H7 Lamp, Flashing (optional) H8 Lamp, Curb (optional) H9 Lamp, Trouble (optional) H10 Lamp, Broom Overload

K1 Contactor, Left Brush Motor K2 Contactor, Center Brush Motor K3 Contactor, Right Brush Motor K4 Contactor, Broom Motor K6 Contactor, 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 L2 Valve, Solution L4 Valve, Dump Door Open L5 Valve, Dump Door Close L6 Valve, Hopper Raise L6A Valve, Hopper Lower

M11 Motor, Brush Actuator M12 Motor, Squeegee Actuator M13 Motor, Side Broom Actuator M14 Motor, Shaker M17 Pump, 36VDC (AXP)

R2 Flow Position Sensor (AXP)

S1 Switch, Extend Limit S2 Switch, Retract Limit S3 Switch, Hopper Interlock S4 Switch, Recovery Full S5 Switch, Solution Empty S6 Switch, Dust Control Filter (optional) S7 Switch, Hydraulic Filter S8 Switch, Main Broom S9

Switch, Seat

S10 Switch, Hopper Fire (optional) S11 Switch, Key S12 Switch, Wand (optional) S13 Switch, Battery Interlock

revised 9/09

FORM NO. 56043126 - CR 1100, CR 1200 - 77

Motor,Vacuum

ContactN.O.

CircuitBreaker, 40 Amp

CircuitBreaker, 70 Amp

Motor,Left Brush

CircuitBreaker, 15 Amp

F11

Fuse,250 Amp

ContactN.O.

CircuitBreaker, 20 Amp

Contactor,Wheel Drive

A3 CURTIS 1244SPEED CONTROLLER

Motor,Dust Control

Motor,Left Side Broom

M10

MotorAsm., Hyd. Pump

K11

ContactN.O.

Motor,Right Side Broom

ContactN.O.

Pot.5k Ohm

M15

Motor,Wheel Drive

Motor,Broom

ContactN.O.

Motor,Right Brush

X51

ContactN.O.

Motor,Center Brush

B+

ORN

B-

ORN/BLU

GRA

ORN/RED

BLU/BLK

BRN

GRN

RED/WHT

CURRENTSENSE

Forward

Reverse

RED6-2

GRA/BLK

WHT/ORN

BLU/YEL

ORN/GRN BLK

BLK

BLKBLU/GRA

BLU/GRA

BLK

WHT/RED

BLKBLK

BLK

BLK1-A1

WHT/YEL

RED/BLU

BLK

RED1-2

ORN

RED/WHT

BLK

RED6-1

BRN/WHTRED

GRN/REDRED

VIO/GRARED

ORN/WHTRED

RED

RED/VIO

RED1-1

ORN

RED1-A2

GRN

ORN/RED

ORN BLK/YEL

BLK/YEL

RED/VIO

GRA

BLU/BLK

BRN/RED

WHT/BLK

VIO/BLK

1234567891011

1314151617181920212223

B+

M-

F1 F2

B-

F1 F2

A2A1

B+ B-

BLKBRN/GRA

RED

WHT RED BRN

WHT GRN YEL BLK RED

GRN/WHT

BLU

RED/WHT

GRN/BLK

BLK/WHT

BLK

GRN/WHT

GRA/ORN

GRN/WHT

VIO GRA/ORN

GRA/ORN

WHT/BLU

ORN/RED

GRA/ORN

YEL

GRN

BLK

GRA/ORN

B-B+

234

J5-5 J5-6

J5-16

J5-4 J5-3

J5-2

J5-11

J5-10

J5-17

J5-20

J5-1

J5-18

FROMSEAT SWITCH

J5-13

J5-19

J5-23

J5-15

J5-8

CAN

STEERINGACTUATOR

U V W

CIRCUITBREAKER, 40 AMP

1 2

X72X72

RELAY,SAFETY

A B

CONTACTN.O.

1 2

SWITCH,LEFT TRAVEL LIMIT

1 2

RESISTOR, 10OHM

1 2

STEERINGWHEEL SENSOR

GRN

BLU

RED

GRN/BLK

TORQUE1

BLK

TORQUE2

WHT

GND1

ORN

VOLT1 (+5V)

WHT/BLK

GRD2

RED/BLK

VOLT2 (+5V)

ORN/BLK

SWITCH,RIGHT TRAVEL LIMIT

1 2

K12

S17

S16

B+

B-

AC DRIVE

M16

WIRING DIAGRAM sheets 2 & 3 of 3 (after SN 1808248)

Item Description

A3 Curtis 1244 Speed Controller C1 Capacitor, 180 MFD F4 Circuit Breaker, 15 Amp (Dust Control) F5 Circuit Breaker, 20 Amp (Side Brooms) F7 Circuit Breaker, 70 Amp (Hydraulic Pump)) F8 Circuit Breaker, 40 Amp (Vacuum Motors) F11 Fuse, 250 Amp (Brush Motors) K1 Contact N.O. (Left Brush) K2 Contact N.O. (Center Brush) K3 Contact N.O. (Right Brush) K4 Contact N.O. (Main Broom) K5 Contact N.O. (Drive Wheel) K6 Contact N.O. (Dust Control) K7 Contact N.O. (Vacuum) K8 Contact N.O. (Side Brooms) K11 Contact N.O. (Hydraulic Pump Motor) 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, Vacuum M8 Gearmotor Assy (right) M9 Gearmotor Assy (left) M10 Motor, Assembly, Hydraulic Pump M15 Motor, Wheel Drive R1 Potentiometer, 5K Ohm

Item Description

A4 AC Drive NOTE 2 D1 Diode NOTE 2 E1 Torque Feedback Device NOTE 2 F9 Circuit Breaker, 40 Amp (Power Steering) K9 Contactor, Steering K12 Relay, SPST NOTE 2 M16 Gearmotor, 36VDC, Steer NOTE 2 R3 Resistor, 10 Ohm NOTE 2 S16 Switch, Right Travel Limit NOTE 2 S17 Switch, Left Travel Limit NOTE 2

NOTE 2: Only used after SN1000016403.

revised 9/09

78 - FORM NO. 56043126 - CR 1100, CR 1200

ELECTRICAL SYSTEM

WIRING SCHEMATIC (after SN 1808248)

GRN/BLK16-1 GRN/BLK16-2 GRN/BLK12-1

ORN18-4

ORN18-5

ORN18-6

ORN18-7

GRN18-2 GRN18-3 GRN18-1

YEL/BLK16-12 YEL/BLK16-1 YEL/BLK16-2

YEL/BLK16-3

YEL/BLK16-5

VIO16-21

YEL/BLK16-4

VIO16-20

YEL/BLK16-5

YEL/BLK16-4

YEL/BLK16-2

VIO16-19 VIO16-20 VIO16-21

WHT/GRN18-1

BLU/BRN18-1

VIO16-18

GRN/BRN18-1

YEL

RED

GRN

WHT

RED

BLK

VIO16-17

BLK18-12

RED6-1 RED1-1

LAMP,TAIL

MOTOR,SQUEEGEE ACTUATOR

BACKUPALARM (OPTIONAL)

M12

SW.,EXTEND LIMIT

M11

SW.,RETRACT LIMIT

MOTOR,BRUSH ACTUATOR

GRA/ORN18-1

ORN18-2

BLK18-18

VIO/YEL18-1

BLK16-1

BLK18-11 BLK16-2

BLK12-8

BLU/GRA12-1

BLK12-9

BLU/GRA12-2

BLK16-2

GRA/YEL18-1

BLK18-3 BLK12-4 BLK18-4

ORN/GRN14-1

WHT BLK

GRN/ORN18-3

GRA/VIO18-3

ORN/GRN14-2

VIO14-4

RED/BLK18-3

WHT/RED12-4

BLK12-5

BLK12-6

BLK/RED18-2

YEL/VIO18-3

WHT/GRA18-3

YEL/BLK16-10

BLK/RED18-3

YEL/VIO18-2

WHT/GRA18-2

YEL/BLK16-7

GRA/VIO18-2

ORN/GRN14-1

VIO14-6

RED/BLK18-2

WHT/RED12-3

BLK12-3

BLK12-4

GRN/ORN18-2

SWITCH,SOLUTION EMPTY

SWITCH,SEAT

SWITCH,RECOVERY FULL

MOTOR,DUST CONTROL

MOTOR,SIDE BROOM ACTUATOR

MOTORS,VACUUM

SWITCH,BATTERY INTERLOCK

HORN

SWITCH,WAND (OPTIONAL)

VALVE, DU MP DOORCLOSE

VALVE,DUMP

DOOROPEN

VALVE,HOPPER RAISE

VALVE,HOPPER LOWER

SWITCH,HYD. FILTER

MOTORASM., HYD PUMP

LAMP,CURB

MOTOR,SHAKER

SWITCH,HOPPER FIRE

SWITCH,DUST CONTROL FILTER

MOTOR,RIGHT SIDE BROOM

HEADLIGHT, RIGHT

HEADLIGHT, LEFT

MOTOR,LIFT SIDE BROOM

SWITCH,HOPPER INTERLOCK

BATTERY,36Vdc

LAMP,TROUBLE

SWITCH/DISPLAY

PANEL ASSE MBLY

SWITCH,KEY

CIR.BREAKER, 15 A.

CIR.BREAKER, 25 A.

CIR.BREAKER, 5 A.

CIR.BREAKER, 10 A.

CIR.BREAKER, 20 A.

CIR.BREAKER, 70 A.

CIR.BREAKER, 40 AMP

LEFTBRUSH

DUSTCONTROL

CENTERBRUSH

VACUUM

RIGHTBRUSH

SIDEBROOMS

MAINBROOM

STEERING

DRIVE

AUXILIARY

LAMP,FLASHING

SWITCH,MAIN BROOM

LAMP,BROOM OVERLOAD

FUSE,400 A.

FUSE,250 A.

FUSES F10:MAIN F11:BRUSH MOTORS

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:AXP OPTION F7:HYDRAULIC PUMP F8:VACUUM MOTORS F9:POWER STEERING

K10

S14

L6A

M10

K11

M14

BT1

S11

M13

S10

S13

S12

F11

F10

H10

GRA/WHT18-2 BLK18-8

VIO16-10

VIO16-11

VIO16-12

VIO16-13

VIO16-14

VIO16-22

WHT/BLK18-2

BRN/RED18-2

VIO/BLK18-2

BRN18-2 BLK1-1 BLK8-1 BLK8-2

WHT/ORN8-1

YEL/GRN18-4 YEL/GRN18-2 YEL/GRN18-3

YEL/BRN18-2

RED10-1

BLK/ORN18-1

VIO16-1

VIO12-3

VIO12-5

WHT/RED12-4

VIO/GRA12-1

BRN/BLK18-1

VIO12-5

VIO14-1

VIO16-2

BLU/GRA12-2

BLU/GRA12-1

GRN/RED8-1

BLU18-1

VIO16-2

VIO16-3

ORN/GRN14-2

BRN/WHT14-1

BRN/YEL18-1

BLK/YEL18-1

RED1-1

RED1-2

ORN18-4

ORN18-3

GRN/GRA18-1

RED6-1

RED6-2

VIO16-3

VIO16-5

GRA/RED18-1

RED/VIO8-3

BLU/YEL8-1

VIO16-5

VIO16-6

WHT/VIO18-1

RED/VIO8-2

GRA/BLK8-1

VIO16-6

VIO16-7

YEL/BLU18-1

RED/VIO8-1

WHT/ORN8-1

VIO16-7

RED1-2

WHT/YEL10-1F1

F1 F2

RED/BLU10-1

BLK1-A1

RED1-A2

BLK1-2

B-

M-

B+

RED3/0-1

BLK18-4

BLK18-5 BLK18-6

WHT/GRA18-2

BLK18-5

YEL/VIO18-2

BLK18-6

VIO18-3

BLK/RED18-3

RED

BLK

RED BLK

BLK12-1

WHT/RED12-1

VIO14-7

YEL/BLK16-8

YEL/BLK16-7

YEL/BLK16-8

YEL/BLK16-9

VIO14-8

YEL/BLK16-9

BLK12-2

WHT/RED12-2

BLK18-3

RED/BLK18-2

RED8-3

BRN/GRA10-1

RED8-1

GRN/RED8-1

RED8-2

ORN/WHT8-1

RED3/0-1

BLK3/0-1

BLK18-19

YEL/BRN18-3

ORN/BRN18-1

BLU/ORN18-1

GRN/BLU18-1

BRN/BLU18-1

WHT/BRN18-1

BLK18-1

ORN18-1

YEL/BRN18-4

RED BLK

X34

X31

X53

X52

X35

X23

X27

X24

X28

X26

X30

X25

X29

X63

X62

X19 X20

X6 X5

X7 X8

X12

X11

X16

X15

X64

X65

SP23

SP5

SP24

X49

X50

SP18

X71

X70

X18

X17

X54

X55

X47 X48

SP8

SP14

X38

X37

X10

SP3SP2

SP1

SP4

SP17

SP12

SP25

BX61

BX60

X51

SP21

SP6

SP13

SP22

MOTOR,DRIVE

M15

X68

X69

X58

X59

X21

X22

SP10

X67

X66

X42 X39

X41 X40

X14 X13

SP16

X43

X46

SP20

X57

X56

SP11

SP15

BLK/WHT16-1

BLK/WHT16-2

BLK16-7

BLK16-6

BLK16-5

BLK16-4

BLK16-3

BLK3/0-1

BLK1-2

BLK18-10

BLK12-8

BLK12-9

BLK10-1

BLK16-1

BLK3/0-2

GRAY

GRN/BLK16-2

YEL/BLK16-12

YEL/BLK16-1

BLK18-1

BLU/BLK18-1

BLK/WHT16-1

ORN/BRN18-1

BLK/WHT16-2

BLU/ORN18-1

GRA18-1

RED/WHT18-1

GRN18-2

ORN/BLU18-1

BRN18-1

BLK/GRA18-1

BRN/BLU18-1

VIO/YEL18-1

YEL/WHT18-1

GRN/VIO18-1

GRA/WHT18-1

ORN/BLK18-1

ORN18-7

WHT/BRN18-1

GRN/BLU18-1

GRA/YEL18-1

WHT/GRA18-1

YEL/VIO18-1

RED/ORN18-1

RED/BLK18-1

ORN/RED18-1

X33

YEL/GRN18-3

VIO16-9

FLOWPOSITION SENSOR (AXPOPTION)

GRA/BRN18-2

BLU/ORN 18-2

BLK18-21

ABC

CBA

X45

M17

PUMP,AXP SOLUTION (AXPOPTION)

BLK/GRA18-2

GRA/BRN18-3

X81X81

GRA/BRN18-4

BLK18-20

YEL/GRN18-5

BLU/ORN18-2

BLK/GRA18-2

VIO/YEL18-2

X167X167

X168X168

AXP SYSTEM

BLK18-20

BLK18-21 BLK18-22

SP9

SP26

VIO14-2

VIO16-8

VIO16-9

VIO14-1

GRA/BRN18-1

GRA/BRN18-3

GRA/BRN18-4

GRA/BRN18-2

212

BLU/GRN10-1

BLU/GRN18-1

(AXPOPTION)

BRN/GRA10-1

VIO16-1

GRN/WHT10-1

BLK18-10

BLK18-22

(AXPOPTION)

VIO/YEL18-1

VIO/YEL18-2

NOTE:FOR AXP SYSTEM, VIO/YEL 18-2WIRE IS SPLICED TO VIO/YEL 18-1WIRE FROMJ2

SP27SP27

YEL/GRN18-5

YEL/GRN18-1

NOTE:FOR AXP SYSTEM,YEL/GRN 18-4WIRE IS SPLICEDTO YEL/GRN 18-1WIRE FROMJ1

SP28SP28

GRA/ORN18-1

GRA/ORN 18-3

X170X169

CONNECTTO X171ON SHEET 2

CONNECTTO X172ON SHEET 2

BLU/GRN 18-1

GRA/BRN18-1

1 2

CIR.BREAKER, 10 A.

(AXPOPTION)

GRN/WHT10-1

BLK10-1

TOSTEERING SYSTEM ONSHEET 2

revised 9/09

FORM NO. 56043126 - CR 1100, CR 1200 - 79

ELECTRICAL SYSTEM

WIRING SCHEMATIC - Page 2 (after SN 1808248)

RED

BLK

YEL

GRN

WHT

RED20-1

RED20-2

WHT20-1

GRN20-1

YEL20-1

BLK20-1

BLK 20-2

BRN.

WHT.

RED.

BRN.

RED. WHT.

ORN/RED20-1

GRA/ORN20-6

GRA/ORN20-5

WHT/BLU 20-1

GRN/WHT20-1

GRA/ORN20-4

VIO20-1

GRA/ORN20-2

GRA/ORN20-3

GRA/ORN20-4

PINK20-1

GRA/ORN20-5

GRA/ORN20-6

TAN20-1

GRN..

BLU..

ORN..

WHT/BLK..

RED..

GRN/BLK..

RED/BLK..

ORN/BLK..

BLK..

WHT..

GRN/WHT20-1

BLU20-1

BLU 20-1

ORN 20-1

RED/BLK20-1

RED/BLK20-2

ORN20-1

WHT/BLK20-1

WHT/BLK 20-2

ORN/BLK20-1

RED/WHT20-1

RED/WHT20 -1

GRN/BLK20-2

GRN/BLK20-1

BLK/WHT20-1

GRA/ORN20-7

BLK/WHT20-1

GRA/ORN20-1

ORN/RED20-1

GRN 20-1

YEL 20-1

BLK 20-3

YEL20-1

GRN20-1

BLK20-3

BLK 10-1

GRN/WHT 10-1

FROM SHEET 1

A1A2GND 1

VOLT 1 (+5V)

B1B2GND 2

VOLT 2 (+5V)

TORQUE 1

TORQUE 2

MOTOR LEADS ROUTE AWAY FROM LOW CURRENT WIRING

CONNECT TO X170 ON SHEET 1

CONNECT TO X169 ON SHEET 1

X172X172

SP2SP2

SP3

122

A4 AC DRIVE

B-

B+

SP4

122

RESISTOR, 10 OHM

1 2

X15X15

1 2 3 4 5 6 7 8 9 10 11 12

X171X171

SP6

X14X14

BLACKJ5BLACK

S17

SWITCH, LEFT TRAVEL LIMIT

1 2

M16

SWITCH, EMERGENCY

S15

1 2

X13X13

RELAY, SAFETY

K12

SP5

X16X16

1 2 3 4 5 6 7 8 9 10 11 12

S16

SWITCH, RIGHT TRAVEL LIMIT

1 2

TORQUE FEEDBACK DEVICE

X173

revised 9/09

80 - FORM NO. 56043126 - CR 1100, CR 1200

Hopper Lift Dump Door

HYDRAULIC SYSTEM

Item Description

2 Replacement 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

Nilﬁ sk-Advance A/S Sognevej 25 DK-2605 Brøndby Denmark Tel: +45 43 23 81 00 Fax: +45 43 43 77 00 www.nilﬁ sk-advance.com

Nilfisk-Advance CR 1100, CR 1200 Quick Start Troubleshooting Manual

Specifications and Main Features

Frequently Asked Questions

User Manual