Nilfisk-Advance HYDRO-RETRIEVER 2052, 56459504 battery, CR 1300, 56459994 battery-Hydro-MaxTM II, 56459505 battery-Hydro-MaxTM II Service Manual

...

8/99 revised 9/05 Form Number 56043052

Hydro-Retriever™ 2052 CR 1300

SERVICE MANU AL Advance MODELS 56459504 (battery), 56459505 (battery-Hydro-Max™ II) Nilfisk MODELS 56459992 (battery), 56459994 (battery-Hydro-Max™ II)

78 - FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300

SAFETY INSTRUCTIONS....................................................................................................................................................2

GENERAL INFORMATION .............................................................................................................................................. 2-3

OTHER MANUALS............................................................................................................................................................3

PARTS & SERVICE STATEMENT....................................................................................................................................3

NAME PLATE DATA .........................................................................................................................................................3

TRANSPORTING ..............................................................................................................................................................3

TOWING ............................................................................................................................................................................3

JACKING ...........................................................................................................................................................................3

KNOW YOUR MACHINE ................................................................................................................................................. 4-5

SPECIFICATIONS AND MAINTENANCE ...................................................................................................................... 6-11

PERIODIC MAINTENANCE CHART.................................................................................................................................8

LUBRICATION .................................................................................................................................................................. 9

BATTERY SYSTEM ..................................................................................................................................................... 12-14

INSTALLATION ...............................................................................................................................................................12

MAINTENANCE .............................................................................................................................................................. 13

TESTING .........................................................................................................................................................................13

BATTERY / CHARGER SPECIFICATIONS ....................................................................................................................14

SCRUB BRUSH SYSTEM............................................................................................................................................ 15-26

FUNCTIONAL OVERVIEW .............................................................................................................................................15

BRUSH LIFT ACTUATOR MOTOR FUNCTION .............................................................................................................15

ELECTRICAL SYSTEM DIAGRAM ........................................................................................................................... 15-17

SCRUB BRUSH MOTOR FUNCTION ............................................................................................................................ 16

LOW VOLTAGE CUT-OUT FUNCTION.................................................................................................................... 16-17

TROUBLESHOOTING FLOW CHART...................................................................................................................... 18-22

MOTOR CARBON BRUSH INSPECTION & REMOVAL ................................................................................................23

SCRUB BRUSH MOTOR REMOVAL .............................................................................................................................23

BELT AND GEAR BOX COUPLER REMOVAL ..............................................................................................................24

BELT TENSION ADJUSTMENT ..................................................................................................................................... 24

LIFT ACTUATOR MOTOR REMOVAL ........................................................................................................................... 25

FRONT SKIRT ADJUSTMENT ....................................................................................................................................... 26

SWEEPING SYSTEM .................................................................................................................................................. 27-38

FUNCTIONAL OVERVIEW .............................................................................................................................................27

ELECTRICAL SYSTEM DIAGRAM .................................................................................................................................27

TROUBLESHOOTING FLOW CHART...................................................................................................................... 28-31

MAINTENANCE .............................................................................................................................................................. 32

BROOM HEIGHT ADJUSTMENT ...................................................................................................................................32

BROOM LEVEL ADJUSTMENT......................................................................................................................................33

BROOM REMOVAL/REPLACEMENT ............................................................................................................................ 33

BROOM BEARING REPLACEMENT ..............................................................................................................................34

BROOM MOTOR CARBON BRUSH INSPECTION........................................................................................................34

BROOM MOTOR REMOVAL ..........................................................................................................................................35

BROOM BELT REMOVAL/ADJUSTMENT .....................................................................................................................36

BROOM SIDE SKIRT LIFT MOTOR REMOVAL.............................................................................................................36

BROOM HOUSING SKIRTS REPLACEMENT & ADJUSTMENT............................................................................. 37-38

SOLUTION SYSTEM ................................................................................................................................................... 39-43

FUNCTIONAL OVERVIEW .............................................................................................................................................39

ELECTRICAL SYSTEM DIAGRAM .................................................................................................................................39

TROUBLESHOOTING GUIDE .................................................................................................................................. 40-41

SOLUTION TANK REMOVAL .........................................................................................................................................42

SOLUTION SOLENOID VALVE & FILTER HOUSING REPLACEMENT .......................................................................43

MAIN SOLUTION CONTROL VALVE REPLACEMENT .................................................................................................43

VACUUM/RECOVERY SYSTEM ................................................................................................................................. 44-49

FUNCTIONAL OVERVIEW .............................................................................................................................................44

ELECTRICAL SYSTEM DIAGRAM .................................................................................................................................45

SERVICE CHECKLIST....................................................................................................................................................45

TROUBLESHOOTING GUIDE .................................................................................................................................. 45-47

VACUUM MOTOR REMOVAL ........................................................................................................................................48

VACUUM FILTER...................................................................................................................................................... 48-49

RECOVERY TANK REMOVAL .......................................................................................................................................49

TABLE OF CONTENTS

FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300 - 1

TABLE OF CONTENTS

SQUEEGEE SYSTEM.................................................................................................................................................. 50-56

FUNCTIONAL OVERVIEW .............................................................................................................................................50

ELECTRICAL SYSTEM DIAGRAM .................................................................................................................................50

TROUBLESHOOTING FLOW CHART...................................................................................................................... 51-53

SQUEEGEE ADJUSTMENT BEFORE SN1321040 .......................................................................................................54

SQUEEGEE BLADE REPLACEMENT BEFORE SN1321040 ........................................................................................55

SQUEEGEE ADJUSTMENT AFTER SN1321039 .......................................................................................................... 56

SQUEEGEE BLADE REPLACEMENT AFTER SN1321039 ...........................................................................................57

SQUEEGEE ACTUATOR LIFT MOTOR REPLACEMENT .............................................................................................58

HYDRO-MAX™ II SYSTEM ......................................................................................................................................... 59-61

FUNCTIONAL OVERVIEW .............................................................................................................................................59

ELECTRICAL DIAGRAM.................................................................................................................................................59

RECOVERY TANK MAINTENANCE...............................................................................................................................61

SOLUTION DETERGENT TANK MAINTENANCE .........................................................................................................61

TROUBLESHOOTING GUIDE ........................................................................................................................................61

STEERING/BRAKE SYSTEM ...................................................................................................................................... 62-63

FUNCTIONAL OVERVIEW .............................................................................................................................................62

STEER WHEEL SPINDLE REMOVAL ............................................................................................................................62

STEERING CHAIN ADJUSTMENT .................................................................................................................................62

BRAKE ADJUSTMENT ...................................................................................................................................................63

WHEEL DRIVE SYSTEM ............................................................................................................................................. 64-74

FUNCTIONAL OVERVIEW ..........................................................................................................................................64

ELECTRICAL SYSTEM DIAGRAM ..............................................................................................................................65

TROUBLESHOOTING GUIDE ............................................................................................................................... 66-71

NO FWD OR REV DRIVE .................................................................................................................................. 66-68

NO FWD (REV ONLY) ....................................................................................................................................... 69-70

NO REV (FWD ONLY) ....................................................................................................................................... 70-71

WHEEL MOTOR REMOVAL ........................................................................................................................................71

WHEEL MOTOR CARBON BRUSH INSPECTION .....................................................................................................71

DIFFERENTIAL REMOVAL ......................................................................................................................................... 72

FORWARD & REVERSE SWITCH ADJUSTMENT & REPLACEMENT................................................................ 72-73

SPEED POTENTIOMETER REPLACEMENT ............................................................................................................. 73

SPEED POTENTIOMETER ADJUSTMENT ................................................................................................................74

ELECTRICAL SYSTEM................................................................................................................................................ 75-81

ACTUATOR DRIVE NUT ADJUSTMENT .......................................................................................................................75

ELECTRICAL COMPONENT LOCATION DIAGRAM ............................................................................................... 76-77

ELECTRICAL SCHEMATIC AND WIRING DIAGRAMS BEFORE SN 1296730 ...................................................... 78-79

ELECTRICAL SCHEMATIC AND WIRING DIAGRAMS AFTER SN 1296729 ......................................................... 80-81

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

2 - FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300

GENERAL INFORMATION

CAUTIONS AND WARNINGS SYMBOLS

Nilfisk-Advance 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

Specific 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, flame and smoking materials away from batteries. Explosive gases are vented during normal operation.

• Charging the batteries produces highly explosive hydrogen gas. Charge batteries only in well-ventilated areas, away from open

flame. Do not smoke while charging the batteries.

• Remove all jewelry when working near electrical components.

• Turn the key switch off (O) and disconnect the batteries before servicing electrical components.

• Never work under a machine without safety blocks or stands to support the machine.

• Do not dispense flammable cleaning agents, operate the machine on or near these agents, or operate in areas where flammable

liquids 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.

• Use care when using scarifier discs and grinding stones. Nilfisk-Advance will not be held responsible for any damage to floor

surfaces caused by scarifiers or grinding stones.

• 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 first turning the key switch off (O), removing the key and applying the parking

brake.

• Turn the key switch off (O) before changing the brushes, and before opening any access panels.

• Take precautions to prevent hair, jewelry, or loose clothing from becoming caught in moving parts.

• 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.

• Use good common sense, practice good safety habits and pay attention to the yellow decals on this machine.

SAVE THESE INSTRUCTIONS

revised 3/00

FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300 - 3

OTHER MANUALS AVAILABLE FOR YOUR MACHINE

The following manuals are available from the Nilfisk-Advance Literature Service Department (order according to model name and machine’s serial number):

• A Parts List and Operation Manual are available for each machine.

• Operation Manuals for the CR 1300 are multi-language: (Danish, Norwegian, Swedish, Finnish), (English, German, French, Dutch) or

(Spanish, Portuguese, Italian, Greek).

PARTS AND SERVICE

Repairs should be performed by your Authorized Nilfisk-Advance Service Center, who employs factory trained service personnel, and maintains an inventory of Nilfisk-Advance original replacement parts and accessories. Call the NILFISK-ADVANCE INDUSTRIAL DEALER named below for repairs or service. Please specify the Model and Serial Number when discussing your machine.

(Dealer, affix service sticker here.)

NAMEPLATE

The Model Number and Serial Number of your machine are shown on the Nameplate, located on the wall of the operator’s compartment. 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 __________________________________

TRANSPORTING THE MACHINE

CAUTION!

Before driving the machine up a ramp and onto a truck or trailer, remove the squeegee tool and the brushes from the machine to avoid damage.

CAUTION!

Before transporting the machine on an open truck or trailer, make sure that . . .

• The solution tank cover and the circuit breaker access cover is taped closed.

• The broom access door is latched securely.

• The scrub brushes are installed and in the down position.

• The squeegee is installed and in the down position.

• The sweeping broom lever is in the down position.

• The machine is tied down securely – see tie down locations Page 4 (21).

• The machine parking brake is set.

• All access doors and covers are secured.

TOWING

CAUTION!

If the machine must be towed or pushed, make sure the Key Switch (Main Power) (31) is in the OFF position and do not move the machine faster than 5 mph.

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.

GENERAL INFORMATION

revised 3/00

4 - FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300

KNOW YOUR MACHINE

1 Battery Compartment / Recovery Tank Cover 2 Strobe Light 3 Left Rear Access Door (Solution Tank Drain inside door) 4 Battery 5 Solution Tank Fill 6 Circuit Breaker Access Cover 7 Headlights 8 Scrub Brushes 9 Solution Flow Control Valves 10 Inline Solution Strainer (located under solution tank) 11 Outer Access Door

12 Broom 13 Debris Tray 14 Inner Access Door 15 Squeegee 16 Vacuum Filter and Housing 17 Right Rear Access Door 18 Tip-Out Seat (Access to Differential,

Vacuum Motor and Emergency Battery Disconnect) 19 Recovery Tank Drain Hose 20 Recovery Tank Cleanout Cap 21 Tie Down Locations (4)

revised 3/00

FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300 - 5

KNOW YOUR MACHINE

22 Emergency Battery Disconnect 23 Solution Lever 24 Broom Lever 25 Squeegee Switch 26 Solution Switch 27 Scrub Brushes Switch 28 Headlight Switch 29 Battery Meter

30 Hour Meter 31 Master Key Switch 32 Forward/Reverse Drive Pedal 33 Brake Pedal 34 Horn 35 Parking Brake 36 Hydro-Max™ II Recycle Pump Switch (Opt) 37 Hydro-Max™ II Detergent Tank Empty Light (Opt)

revised 3/00

6 - FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300

SPECIFICATIONS AND MAINTENANCE

General Machine Specifications English (Metric)

Machine Length 89 in. (226 cm) Machine Width w/o Squeegee 54-1/2 in. (138 cm) Machine Height 79 in. (200 cm) with Overhead Guard

56 in. (142 cm) w/o Overhead Guard Machine *Net Weight 1889 lbs. (857 kg) Machine **Gross Weight 3792 lbs. (1720 kg)

Cleaning Width (scrubbing path) 50 in. (127 cm) Coverage Rate Per Hour 84,000 sq. ft. (7,084 m2) Brush Diameter (qty of 4) 13.5 in. (34 cm) Brush Speed 180 rpm Brush Pressure 285 lbs. (129 kg) Broom Speed 575 rpm (no load) Broom Pattern (sweep position) 1 to 1-1/2 in. (25 to 38 mm) width Broom Size 11-1/2 in. Dia. X 36 in. (29 cm X 91 cm)

Solution Tank Capacity 60 gal. (227 L) Recovery Tank Capacity 60 gal. (227 L) Vacuum Water Lift 57 in. (sealed)

24 in. (1 in. orifice)

Ramp Climbing Ability (gradeability) Transport 25% grade (14°)

Cleaning 22% grade (13°) Sound Level 77.8 dB (A)/20uPa (at operator) Transport Speed 6 mph (9 km/h) forward

4 mph (6.5 km/h) reverse Minimum Aisle Turn Width 138 in. (350 cm) Rt, 143 in. (363 cm) Lt Battery Power Source 36 volt,475A PN. 56454400 Battery Weight 1,382 lbs. (1475 lbs. max) Battery Compartment Size Height 24 in. (61 cm) Width 15-3/4 in. (40 cm) Length 38-1/2 in. (98 cm) Propelling Motor (wheel drive) 36V, 4 hp, 35A*** (level floor) Brush Drive Motor 36V, 3 hp, 50-65A*** Vacuum Motor 36V, 1 hp, 23A*** Broom Motor 36V, 1 hp, 20A*** (full float position)

* Net Weight: Standard machine without options, empty solution and recovery tanks. Without removable scrub brushes and no battery installed.

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

***Average current draw under normal working loads. Specifications are subject to change without notice.

revised 3/00

FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300 - 7

KNOW YOUR MACHINE

revised 3/00

56 in. (142 cm)

Wi t h out overhead guard

79 in. (200 cm)

Wi t h overhead guard

89 in. (226 cm)

54.5 in. (138 cm)

FRONT VIEW

SIDE VIEW

8 - FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300

SPECIFICATIONS AND MAINTENANCE

MAINTENANCE SCHEDULE

Maintenance intervals given are for average operating conditions. Machines used in severe operational environments may require service more often.

MAINTENANCE ITEM DAILY 50 HRS 100 HRS 1000 HRS (YEARLY)

Perform the 7 Daily Machine After Use Maintenance Steps X

* Charge Battery & Check Water Level X X

Check & Adjust Parking Brake X X

Inspect & Adjust Brush/Broom Skirts X

Inspect & Clean Vacuum Filter X X

** Inspect Sweeping Broom/Adjust, Rotate & Check Pattern X X

Lubricate All Grease Fittings X

Check Differential Oil Level X

Check Gearbox Oil level X

Inspect Carbon Brushes All Motors X

Additional Solution System Mtce. X

Additional Recovery System Mtce. X

*** Squeegee Tool Adjustment & Blade Replacement X X

* See Battery System section for maintenance instructions. ** See Sweeping System section for maintenance instructions. *** See Squeegee System section for maintenance instructions.

WARNING!

Turn the key switch off (O), disconnect the battery, and set the parking brake before servicing the machine.

AFTER USE

1 Move the machine to a designated waste water “Disposal Site”. 2 Empty the debris tray. Open the Outer Access Door (11) and the Inner Access Door (14). Slide the Debris Tray (13) out of the machine.

Empty the tray, and flush it with water to clean out the perforations (drain holes).

3 Empty and rinse the recovery tank. Remove the Drain Hose (19) from its hanger (located on left rear of recovery tank), remove the plug

and empty the tank. Open the Recovery Tank Cover (1) and flush the tank and drain hose with clean water. Put the drain hose back on its hanger. Note: When normal draining and flushing are not adequate to remove all silt and debris from the tank bottom, remove the large center mounted clean out cap to help rinse out large debris.

4 Empty and rinse the solution tank. Open the Left Rear Access Door (3) and remove the Solution Drain Hose. Direct the hose to a

designated “DISPOSAL SITE” and remove the drain cap to empty the tank. Flush the tank and drain hose with clean water.

5Clean the squeegee tool. Remove the Squeegee (15) and rinse under running water. Inspect the blades for damage. Reverse or replace

the blades if they are nicked, torn or worn to a radius.

6Flush the vacuum hose and squeegee tool inlet. Back the machine over a floor drain, then run water down through the pick-up tube

in the recovery tank (on the left side of the tank from the rear of the machine).

7Clean the scrub brushes. Remove the four Scrub Brushes (8) and rinse them under running water. Inspect the brushes for wear and

replace if necessary. Rotate the brushes; move the inner brushes to the outside position, and the outside brushes in for more even brush wear.

PARKING BRAKE ADJUSTMENT

The Parking Brake (35) should be re-adjusted to where it firmly holds its (locked park) setting without easily being released. Normal adjustment of the parking brake can be accomplished from the operator compartment. Turn the handle knob on the end of the lever

clockwise (CW) to increase the brake tension. Note: If the knob adjustment is inadequate to firmly hold its brake setting, this indicates the need to inspect the brake shoes and cables for excessive wear and the need for service replacement.

revised 3/00

FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300 - 9

BRUSH/BROOM SKIRT INSPECTION

Every 50 hours, inspect the rubber skirts all around the machine and in the broom housing; replace if damaged or worn. Reference Sweeping section for more detailed information.

VACUUM FILTER MAINTENANCE

Every 50 hours, open the Right Rear Access Door (17) and open the small filter door. Remove the filter, rinse in clear water, wring out thoroughly, and put it back into the machine. Rotation of two filters is recommended. See Vacuum / Recovery section for illustration and further explanation.

LUBRICATION

Every 100 hours, using a grease gun pump grease into the Grease Fittings (A) as shown until grease starts to seep out around the bearing(s). Then wipe off excess grease.

Grease fitting locations are:

1 The universal joint steering shaft fitting (access by removing the front fascia panel). 2 The two steering chain sprockets fittings (access by removing recovery tank and sprocket plate). 3 The main steering spindle fitting (access by removing recovery tank and sprocket plate). 4 The rear steer wheel axle fitting (access under rear of chassis).

SPECIFICATIONS AND MAINTENANCE

revised 3/00

FIGURE 1

10 - FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300

DIFFERENTIAL OIL LEVEL

Every 100 hours, check the differential fluid level. Tip the Operator’s Seat (18) forward and remove the dipstick from the tube. Oil level should show about one inch. Add SAE 90W gear oil, if necessary. Do not over-fill! Differential oil capacity is 5 quarts (5.67 liters).

GEARBOX OIL LEVEL

Check the oil level in the brush drive gear cases once each year or when there is evidence of oil leakage.

To check the oil level . . .

1 Turn the key switch ON and put the brush switch in the ON (I) position. When the brushes are all the way down, turn the key switch OFF. 2 Remove the (2) lower corner panels from front of the machine. 3 See Figure 2. Remove the Oil Plug (B) from the top of each gear box and measure the oil level. The maximum oil level is 1-1/2 inches

(3.8 cm) from the top of the gear case. If the oil is more than 1-3/4 inches (4.5 cm) from the top of the gear case, add 140W gear lube.

SPECIFICATIONS AND MAINTENANCE

revised 3/00

FRONT

FIGURE 2

FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300 - 11

SPECIFICATIONS AND MAINTENANCE

MOTOR CARBON BRUSH INSPECTION

Check the carbon brush wear on the vacuum, scrub, broom and drive motors at least once a year or 1000 hours. If the carbon brush is worn to a length of 3/8 inch (10 mm) or less remove and replace all of the carbon brushes. Reference each separate machine system section in this manual for additional information.

Listed below are the motor part numbers and carbon brush replacement part numbers.

Motor Type Motor P.N. Carbon Brush P.N.

Vacuum 56454206 56454208 (set of 2) Scrub 56409825 56409739 (set of 4) Broom 56454457 56468382 (set of 2) Drive 56454484 56454485 (set of 8)

SOLUTION TANK MAINTENANCE

Every 50 hours, drain and clean the solution tank. Open the Left Rear Access Door (3) and pull the drain hose from the clips. Direct the hose to a designated waste water “DISPOSAL SITE” and remove the plug. When the solution has drained, put the plug back in the hose and put the hose back in the clips. Turn the Master Key Switch (31) ON, lower the brushes (27), turn the Solution Lever (23) ON, then turn the Solution Solenoid Switch (26) ON. Flush the tank with clean water to clean out the solution valves (the Drive Pedal (32) must be depressed to activate the solution solenoid valve). Shut the Solution Lever OFF when finished.

Remove and clean the Inline Solution Strainer (10). To access the filter housing for removal, work through the front scrub brush opening. No tools are needed to remove the filter, just hand tighten only. Note: The solution tank must be empty to service the filter strainer. Flush the bowl and filter and reassemble.

RECOVERY TANK MAINTENANCE

Every 50 hours, inspect the gaskets that seal against the bottom of the recovery tank and around the recovery tank cover. Replace the gaskets if they are damaged or not sealing properly.

revised 3/00

12 - FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300

BATTERY SYSTEM

BATTERY INSTALLATION

WARNING!

Use extreme caution when working with batteries. Sulfuric acid in batteries can cause severe injury if allowed to contact the skin or eyes. Explosive hydrogen gas is vented from inside the batteries through openings in the battery caps. This gas can be ignited by any arc, spark or flame.

CAUTION!

Electrical components in this machine can be severely damaged if the batteries are not installed and connected properly.

1 Make sure the machine’s key switch (main power) (31) is in the off position and the emergency quick disconnect (22) is depressed, also

apply the parking brake (35) and block the wheels.

2 Open both the L&R (3 & 17) rear access doors. Then remove the qty of (2) each hairpins, washers and curved hinge pins that retain the

battery/ recovery compartment cover (1) to the chassis.

3 Lift the battery compartment cover straight up and remove it completely from the machine. 4 Remove the right side battery compartment support to allow for the necessary clearance for lowering the battery into position. 5 Lay a piece of plywood, cardboard or non-conductive material on top of the battery to keep any lift chains or cabling from touching the cell

connectors or battery terminals. This is to prevent a possible dangerous short circuit.

6 See Figure 1. Use an overhead hoist or a forklift to lift the battery up and into the machine. The battery connector should face the right

side of the machine. Note: Always use as a spreader bar to prevent excessive pressure on the ends of the battery.

7 See Figure 2. Install the battery cables as shown (red is positive/black is negative) then connect the battery connector to the machine

connector, located inside the right rear access door. Note: Reference the battery wiring decal PN 014825 for correct battery pack cable connections for application where qty (6) 6 volt batteries are used.

revised 3/00

FIGURE 1

FIGURE 2

FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300 - 13

BATTERY SYSTEM

BATTERY MAINTENANCE

WARNING!

Use extreme caution when working with batteries. Sulfuric acid in batteries can cause severe injury if allowed to contact skin or eyes. Explosive hydrogen gas is vented from inside the battery caps. This gas can be ignited by any electrical arc, spark, or flame.

When working with batteries:

• Remove all jewelry

• Wear safety glasses, gloves and apron

• Do not smoke

• Do not allow tools to touch more than one battery terminal at a time

• Work in a well ventilated area

Proper maintenance of electric vehicle batteries can greatly extend their life. There are 3 simple rules for good battery maintenance:

• Maintain Proper Electrolyte Level - Use distilled water in batteries whenever possible. If batteries are discharged, add just enough water to cover the plates in each cell. If batteries are fully charged, fill each cell to the bottom of the filler tube. Do not over-fill the battery(s)!

Do not add acid to batteries!

• Keep the Battery(s) Charged - Batteries should be charged each time that a machine is used for more than 1 hour. Machine operators should open all battery access doors to avoid a concentrated build-up of hydrogen gas. Operators should follow the instructions provided with their specific battery charger, to determine how long the battery(s) should be charged. Even when a machine is stored, the battery(s) should be charged once a month to prevent the battery(s) from “sulfating”. Almost all battery caps are vented, so there’s no need to loosen or remove them for charging.

• Keep the Batteries Clean - Use a damp cloth to wipe dirt and liquid from the top of the battery(s). Battery terminals must be clean and tight. If the top of the battery(s) is wet after charging, the battery(s) has probably been over-filled or over-charged.

Service Tip: To neutralize any acid or corrosion build up on top of the batteries, tighten the caps and wash the tops of the batteries with a solution of backing soda and water (2 tablespoons of backing soda to 1 quart of water).

BATTERY TESTING

A battery problem is usually recognized by the machine operator, as a decrease in the machine’s running time. This condition is caused by one (or more) “dead cells” in the battery system – that is, one (or more) cell that is putting out less voltage than the other cells.

Note: Always charge batteries before testing. There are 2 ways to find a dead cell:

• Use a hydrometer to check the specific gravity (or “state of charge”) of the fluid in each cell. A dead cell is one that reads 50 points (or more) lower than the other cells.

• Use a volt meter to check the voltage of the battery(s) with the brush and vacuum systems running. The battery(s) with the dead cell will read 1 or 2 volts low.

If the battery(s) in the machine is more than 1 year old, it’s usually best to replace it (them).

revised 3/00

14 - FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300

BATTERY SYSTEM

BATTERY SPECIFICATIONS

Use a combination of multiple 2-volt cell units to construct a 36 Volt DC battery pack system. Nilfisk-Advance recommended battery pack capacity is a 475 AH @ 6 Hour Rate deep cycle battery system. Note: The battery pack

must fit the battery compartment size listed below. Battery compartment size

Height 24-3/4 inches (63 cm) Width 19-3/4 inches (50 cm) Length 37-3/4 inches (95 cm) Maximum Battery Weight 1475 lbs. (669 kg)

BATTERY CHARGER SPECIFICATIONS

Use a 36 Volt DC output charger matching the AC input line voltage supply to be used. Always when selecting a battery charger follow the recommendation of the battery supplier to match the proper charger DC output

amperage to the amp/hour rating batteries being installed. This will prevent the battery pack from being over or under charged. The recommended 475 AH battery should be matched to a 36V, 90 Amp output charger.

revised 3/00

FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300 - 15

SCRUB BRUSH SYSTEM

B+ B-

Mot or +

Mot or -

Di rec ti on - 36V Timer Out

Timer In 1 Timer In 2

S10 S11

B+ B-

Mot or -

Mot or +

Di rec ti on - 0V Timer Out

Timer In 1 Timer In 2

S10 S11

FUNCTIONAL OVERVIEW

The four rotary disc type brushes on the front of the machine are driven by two gear cases coupled together. A single 3HP-(36V) motor mounted on top of the left brush gear case drives the two gear cases. A poly v-belt connects the motor to the input shaft on the left gear case. The input shaft to the left gear case also drives the input shaft on the right case through the use of a flexible coupler. A balance spring and counter weights are used to equalize the pressure on all four of the scrub brushes.

BRUSH LIFT ACTUATOR MOTOR FUNCTION

The brush drive gear case assembly (including the side skirts) are raised and lowered by the electric actuator (lift) motor (M3). See figure 1 (Scrub Brushes Lowered). To operate the lift motor the positive portion of the system circuit voltage is routed through both the S7 brush switch and K9 low voltage relay. This positive voltage signal is the input for the E1 lift actuator module to function. This closes an internal relay that directs the output voltage (polarity) to the lift motor lowering the gear case assembly. The (S11) down limit switch opens and stops the lift motor travel. See figure 2 (Scrub Brushes Raised). Repositioning the S7 brush switch to the raise position removes the positive direction input signal to the E1 module. This causes a polarity change to the lift motor and the S10 up limit switch stops the scrub brush raise travel.

Scrub Brushes Lowered

Scrub Brushes Raised

revised 3/00

FIGURE 1

FIGURE 2

16 - FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300

SCRUB BRUSH SYSTEM

B+ B-

Mot o r+

Mot o r-

Di rec ti on

Timer Out

Timer In 1 Timer In 2

S10 S11

S19

S13

Seat Switch

SCRUB BRUSH MOTOR FUNCTION

See Figure 3. To energize the K5 brush motor solenoid the S7 brush switch must be on (brushes lowered) and the K9 relay contacts closed. This completes the positive voltage input to the solenoid. The negative input to the solenoid is supplied when the drive pedal is depressed (FWD or REV). This closes either the S3 or S1 directional switches that triggers the E1 module’s timer inputs to close the negative timer output connection. This completes the K5 solenoid circuit and the M4 brush motor will run. Note: The timer output voltage from E1 will remain closed for 3 seconds after the drive pedal is returned to neutral. Then the output circuit is open and the brushes and solution will stop. This feature eliminates the nuisance stopping and starting of both systems (brush & solution) when the machine changes direction.

S7 Brush Switch is shown in the ON position (brushes lowered) & the S3 Forward Directional Switch closed.

LOW VOLTAGE CUT-OUT FUNCTION

Special Operational Note: This machine uses a special low battery voltage cut out system to help prolong battery life. The brush motor, broom motor and solution valve will turn off automatically and cease to function when the batteries reach an 80% depth of discharge. The machine’s dash mounted battery meter (28) will double flash to notify the operator that the battery pack is at an 80% depth of discharge. All the machine systems will return to normal when the battery is recharged.

Explanation of the component functions used in the low voltage cutout system. See Figure 4A or 4B. When the battery gauge (P2) senses an 80% depth of discharge the K8 module is switched open. This will cause the yellow K8 output wire to read zero volts, which will then de-energize the K9 relay coil. The yellow wire from the K8 module is fused and its YEL/RED output wire controls the positive K6 broom motor solenoid. The K9 relay switch contacts manage the voltage inputs to the K5 brush solenoid, L1 solution solenoid valve and the E1 brush lift actuator control. Note: Under normal operating conditions the K8 module output is closed and the K9

relay is energized.

revised 3/00

FIGURE 3

FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300 - 17

SCRUB BRUSH SYSTEM

B+ B-

Mot or +

Mot or -

Di rect i on

Timer Out

Timer In 1 Timer In 2

S10 S11

Battery

YEL

YEL/RED

To K6 Broom Mot or Sol enoid

To K5 Bru sh

Mot or Solenoid

To L1 Sol uti on

Sol enoid

BLU/RED

BLU

BLK

K9 IS SHOWN IN THE DE-ENERGIZED STATE

RED

ORN

BLK

S13

BLU

WHT/ O RN

RED/B RN

B+ B-

Mot or +

Mot or -

Di rec ti on

Timer Out

Timer In 1 Timer In 2

S10 S11

Battery

YEL

YEL/RED

To K6 Broom

Mot or Solenoid

To K5 Bru sh

Mot or Solenoid

To L1 Sol uti on

Sol enoid

BLU/RED

BLU

BLK

K9 IS SHOWN IN THE DE-ENERGIZED STATE

ORN

RED

Wiring Change Note (Serial Number Break) Note: Hydro-Retriever™ 2052 machines built after S.N. 1296729 and all CR 1300 machines have the K8 low voltage cutout module input wiring

changed. The wiring change turns off the broom and brushes any time the seat switch is opened (operator is off the seat). The addition of the dotted lines shown in Figure 4B illustrates this change. Reference the electrical system section for complete ladder and schematic diagrams by serial number breaks.

Figure 4A shows wiring for Hydro-Retriever™ 2052 machines built before SN 1296730

Figure 4B shows wiring for Hydro-Retriever

™

2052 machines built after SN 1296729 & all CR 1300 machines

revised 3/00

FIGURE 4B

FIGURE 4A

LOW VOLTAGE CUT-OUT FUNCTION (CONTINUED)

18 - FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300

SCRUB BRUSH SYSTEM

Check the battery meter. Is it double

flashing

Check for 36V (pos.) at

both the Red & Org input

wires on the K8 module

Recharge battery

pack (the low voltage

cut out is functioning).

Brush / Brush Lift /

Broom / Solution

Systems; do not work (See Fig.4)

Check the function of

the S4 Key Switch

and S13 Seat Switch

repair or replace.

Check for 36V at both

the Yel & Blk output

wires on the K8 module

Replace the K8

low voltage cut

out module

Check continuity on the

F8 fuse (1.5A)*

Replace the F8

(1.5A) fuse

Check for 36V at

the A& B (K9) coil

relay terminals

Replace the K9

low voltage cut

out relay

Locate the open in

the K9 coil relay

wiring and repair

Yes

TROUBLESHOOTING GUIDE

Possible Symptoms

1 Brush / Brush Lift / Broom / Solution; do not work 2 Scrub brushes do not turn 3 Scrub brushes do not lower 4 Scrub brushes do not raise

SYMPTOM ONE

Note: Do all testing with the master key switch ON, seat switch S13 closed, brush switch S7 in the ON position and the parking brake set.

revised 3/00

*Note: Some of the early Hydro-Retriever™ 2052 machines do not use the F8 Fuse.

FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300 - 19

SCRUB BRUSH SYSTEM

SYMPTOM TWO

Note: Test with the key switch on, brushes down, parking brake set, seat switch closed and drive pedal slightly depressed (either FWD or REV).

Part A: Scrub Brush Motor Load Circuit Troubleshooting Guide

TROUBLESHOOTING GUIDE (CONTINUED)

revised 3/00

Yes

Scrub brushes

do not turn (see

Figure 3).

Check continuity on

the F1 (80A) brush

motor circuit breaker.

Reset or replace

the F1 (80A) brush

motor circuit

breaker.

Check for 36V at the

wire #70 output termi-

nal on the K5 brush

motor solenoid.

See part B scrub

brush control circuit

troubleshooting.

Check for 36V at

the M4 brush

motor.

Repair or replace the

M4 brush motor.

Check continuity on

both the #74 (neg.) &

#70 (pos.) wires to M4.

Repair or replace.

20 - FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300

SCRUB BRUSH SYSTEM

SYMPTOM TWO

Part B: Scrub Brush Motor Control Circuit Troubleshooting Guide

revised 3/00

Check for 36V at

the K5 solenoid

coil wires

Wht/Gra &

Blu/Red

Scrub brushes

do not turn (see

Figure 3).

Replace the

K5 Brush

Motor Solenoid

Yes

Check for 36V at

the Pos. K5 coil

wire Blu/Red to

a Neg. battery

standoff

Check for 36V

at the Neg. K5

coil wire

Wht/Gra to a

positive battery

standoff

Yes

Check for 36V at

the Org/Grn wire

on the S7 brush

switch

Check for 36V at

the blue wire on

the S7 brush

switch

Check for correct

wiring & repair or

replace

Replace the S7

brush switch

Yes

Check for 36V (Pos.) at the timer

input #1 on the E1 brush lift actuator

control. Note: The Fwd drive pedal

switch S3 must be closed. Repeat

this check at the timer #2 for the Rev

switch S1.

Check function of

K9 coil & con-

tacts. Repair or

replace.

Replace the E1

brush lift

actuator control

board

Yes

Check Seat Switch

and wiring repair

or replace.

TROUBLESHOOTING GUIDE (CONTINUED)

FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300 - 21

SCRUB BRUSH SYSTEM

SYMPTOM THREE

Note: Do all testing with the master key switch ON, brush switch S7 in the ON position and the parking brake set.

revised 3/00

TROUBLESHOOTING GUIDE (CONTINUED)

Yes

Scrub brushes

do not lower

(see Figure 1).

Check for 36V at

the M3 lift motor

harness connection

Replace the

M3 lift motor

Check for continuity

through the S11 down

limit switch

Replace the S11 down limit switch

Back probe at the

Blu/Red direction

input wire on the E1

controller, should

read 36V

Check for 36V at the

motor power output

GRN/BLK (pos.) &

VIO/BLK (neg.) on the

E1 controller.

Check function of K9

coil & contacts. Repair

wiring or replace.

Replace the E1

controller

Repair wiring and

connections to the

M3 lift motor

22 - FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300

SCRUB BRUSH SYSTEM

SYMPTOM FOUR

Note: Do all testing with the master key switch OFF, brush switch S7 in the ON position and the parking brake set.

revised 3/00

TROUBLESHOOTING GUIDE (CONTINUED)

Yes

Scrub brushes do not

raise (see Fig. 4)

Check for 36V at the

M3 lift motor harness

connection

Replace the

M3 lift motor

Check for continuity through the S10 UP

limit switch

Replace the S10

UP limit switch

Back probe the

blu/red direction

input wire on the E1

controller, should

read zero V

Check for 36V at the

motor power output

GRN/BLK (neg.) & VIO/BLK (pos.) on

the E1 controller

Check function of

K9 coil & contacts.

Repair wiring or

replace.

Replace the E1

controller

Repair wiring and

connections to the

M3 lift motor

FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300 - 23

SCRUB BRUSH SYSTEM

MOTOR CARBON BRUSH INSPECTION AND REMOVAL

NOTE: The carbon brushes in the scrub brush motor should be inspected once a year or 1000 hours, and any accumulated dust blown out with compressed air.

1 Put the scrub deck in the raised position and turn the key switch OFF. 2 Remove the front outer body fascia panel from the machine (2 screws). 3 Remove the brush motor spring and put the scrub deck in the lowered position and turn the key OFF. 4 Remove the headlight-mounting panel secured with (6) screws. Then pull the panel out and disconnect wiring and remove. 5 See Figure 5. Remove or loosen the carbon brush inspection cover retaining screw (A) and pull off both the pinned covers (B). Using a

flash light inspect one of the motor brushes. If the carbon brush is worn to a length of 3/8 inch (10 mm) or less remove the scrub brush motor (see scrub brush removal; section below) and replace all the carbon brushes.

SCRUB BRUSH MOTOR REMOVAL

1 Follow steps 1-4 in the carbon brush inspection section. 2 See Figure 5. Loosen the (2) hex HD. Screws (C) and back them out 3 or 4 turns. 3 Turn the (2) screws (D) (CW) to loosen tension on the brush belt. Then remove the belt from the motor pulley. 4 Disconnect the motor wiring at the motor terminals. 5 Remove the (4) (E) screws securing the motor and lift the motor out through the front of the machine. 6 Follow the steps in reverse order to reassemble. Note: When reassembling, position the motor all the way to the front (the holes in the motor

base are slotted).

7 Connect the motor wire #74 to the positive motor terminal and the #70 wire to the negative motor terminal. 8 Readjust the belt tension; follow the instructions in the belt tension adjustment section.

revised 3/00

FIGURE 5

24 - FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300

SOLUTION SYSTEM

BELT AND GEAR BOX COUPLER REMOVAL

1 Put the scrub deck in the raised position and turn the key switch OFF. 2 Remove the front outer body fascia panel from the machine (2 screws). 3 Remove the headlight-mounting panel secured with (6) screws. Then pull the panel out and disconnect wiring and remove. 4 Remove the brush motor spring and put the scrub deck in the lowered position and turn the key OFF and disconnect the battery connector. 5 See Figure 5. Loosen the (2) hex HD. Screws (C) and back them out 3 or 4 turns. 6 Turn the (2) Screws (D) (CW) to loosen tension on the brush belt. Then remove the belt from the motor pulley. 7 See Figure 6. Remove the (3) Bolts (G) and (3) Nuts (H) from the universal Casting (I). Then work the belt between the casting and the

Flexible Coupler (J) to remove the belt from the machine.

8 Belt installation: Follow the above steps in reverse order to install a new belt, then readjust the belt tension (see belt adjustment section

for instructions).

Follow the additional step below to replace the gear box flexible couplers.

9 Remove the (6) Bolts (G) and (6) Nuts (H) from both universal castings, and then work the Flexible Couplers (J) out from between the drive

castings.

BELT TENSION ADJUSTMENT

1 Follow steps 1-4 in the carbon brush inspection section. 2 See Figure 5. Loosen the (2) hex HD. Screws (C) and back them out 3 or 4 turns. 3 Turn the (2) Screws (D) clockwise to loosen the tension on the brush belt or turn counter-clockwise to increase tension on the belt. When

adjusted properly, the belt tension should be approximately 1/4 inch (6 mm) deflection at mid point between pulleys when moderate pressure is applied. Note: Check the alignment of both pulleys using a straight edge when servicing the brush belt.

4 Tighten the (2) (C) Bolts. Note: Measure the distance between Plate (F) and the top of the gear case at each of the Bolts (D) to make sure

that the motor is parallel. If the distance is not equal at both points, loosen the Bolts (C) and readjust.

revised 3/00

FIGURE 6

FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300 - 25

SCRUB BRUSH SYSTEM

LIFT ACTUATOR MOTOR REMOVAL

1 Put the scrub deck in the raised position and turn the key switch OFF. 2 Remove the front outer body fascia panel from the machine (2 screws). 3 Remove the brush motor spring and put the scrub deck in the lowered position and turn the key OFF. 4 Remove the headlight-mounting panel secured with (6) screws. Then pull the panel out and disconnect wiring and remove. 5 Remove the (4) scrub brushes. 6 Important Note: If the brush lift actuator is stuck in the up position it will be necessary to jack up the machine and block the gear case

assembly. This must be done to relieve the weight from the actuator to allow the mounting pins to be removed.

WARNING!

Never work under machine without safety stands or blocking to support the machine.

7 Remove the left side operator compartment access panel (qty 8 screws). 8 Cut the tie straps for the actuator wiring harness and disconnect the wiring from the Up & Down limit switches and the actuator motor. 9 Service Tip Option: For easier actuator servicing and inspection remove the solution tank from the machine (see solution system for

instructions).

10 See figure 7. Remove the (2) hex HD Screws (K) from Pin (L), then separate the (M) Switch Bracket from the actuator assembly. 11 On the spring mount side of Pin (L) remove the retaining ring (N), then slide the pin out of the lower actuator mount. 12 Remove the back (rear) retaining ring (O) from the upper mounting pin (P), and then slide the pin out. 13 Remove the actuator from the machine by lowering and tilting the motor head to the rear and working the rod end of the actuator out through

the front of the brush motor opening.

14 Measure the dimension X on the limit switch-mounting bracket (Q), as shown. Then loosen the retaining screw and slide it from the old

actuator. Reinstall it on the new actuator using the previously measured dimension.

15 Follow the steps in reverse order to install. Then run the actuator up & down to test the system for proper operation.

revised 3/00

FIGURE 7

FRONT

26 - FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300

SCRUB BRUSH SYSTEM

FRONT SKIRT ADJUSTMENT

The front skirts have 3 functions:

1 To keep water from splashing outside of the squeegee’s path. 2 To wipe water from the floor in front of the drive wheels. 3 To channel debris into the path of the sweeping broom.

Adjust or replace the skirts, if they don’t perform any of these functions, using the steps below.

1 Remove the left and right corner panels (with the roller bumpers) from the front of the machine. 2 With the brushes on the machine, lower the brush drive assembly to the floor and turn the engine off. 3 See Figure 8. Loosen the (4) Bolts (R) on each skirt bracket. Position the skirt bracket so that the edge of the rubber skirt (S) just touches

the floor.

4 Lower just the rear end of the skirt bracket an additional 1/4 inch (6 mm). 5 Tighten the (4) Bolts (R) on each skirt bracket. 6 Operate the machine in forward and reverse to test the wiping action of the skirts. The skirts should wipe the floor almost completely dry

in front of the drive wheels.

NOTE: If the rear portion of the skirt is adjusted too low, the skirts will not return to proper position (folded out) when the direction of travel is

changed from reverse to forward.

7 Re-install the corner panels, if no re-adjustments are needed.

revised 3/00

FRONT

FIGURE 8

FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300 - 27

SWEEPING SYSTEM

FUNCTIONAL OVERVIEW

Broom System Functional Overview

A cylindrical sweeping broom is used to keep small debris out of the squeegee tool blades, eliminating the need to sweep before scrubbing. The debris is lifted over the top of the broom and into a small hopper. The hopper is perforated so that the water, swept up along with the debris can drain back onto the floor to be picked up by the squeegee tool. The broom housing side skirts keep the water and debris confined to the broom area in helping guide the litter into the hopper and the water to the squeegee.

Main Broom Motor Function:

See Figure 1. To energize the K6 broom motor solenoid the S14 broom switch must be closed by lowering the broom raise/lower lever to the sweep position. This completes the negative voltage input for the K6 solenoid circuit.

Broom Side Skirt Actuator Motor Function:

The broom housing skirts (both left & right sides) are raised and lowered by two separate electrical (lift) actuator motors M8 & M9. To activate the side skirts (lower them to the floor) the broom lever must be lowered to close the S14 broom switch. This negative voltage signal is the input for both the E4 & E5 lift actuator modules to function. This (negative) 36V at both the direction terminals closes an internal relay that directs the output voltage (polarity) to the lift motors and the side skirts are lowered to the floor. The lift actuator motors use internal limit switches to open the circuit and stop the motors’ travel for both raising and lowering functions. Placing the broom raise/lower lever into the off raised position removes the –36V input signal to the E4 & E5 modules and will now read zero volts at the directional terminals. This then opens the internal relay and changes the polarity at the module’s output and the skirts are automatically raised.

Sweeping System Electrical Diagram

revised 3/00

B+ B-

Mot o r +

Mot o r -

Di rec ti on

Timer Out

Timer In 1 Timer In 2

B+ B-

Mot o r +

Mot o r -

Di rec ti on

Timer Out Timer In 1 Timer In 2

S14

YEL/ RED

28 - FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300

SWEEPING SYSTEM

TROUBLESHOOTING GUIDE

Possible Symptoms

1 Broom motor will not run 2 Broom side skirts will not lower 3 Broom side skirts will not raise

SYMPTOM ONE

Note: Do all testing with the master key switch ON, seat switch closed, broom lever in the ON position and the parking brake set.

Part A: Sweeping Broom Motor Load Circuit Troubleshooting Guide

revised 3/00

Broom motor does

not run (see Fig. 1).

Check continuity on the

F3 (40A) broom motor

circuit breaker

Reset or replace the

F3 (40A) broom motor

circuit breaker

At the K6 broom motor

solenoid Check for

36V at the wht/vio wire

to negative battery

standoff

Check for 36V at the

M1 broom motor

See part B sweeping broom control circuit

troubleshooting

Repair or replace the

M1 broom motor

Yes

Repair or

replace wiring.

FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300 - 29

SWEEPING SYSTEM

revised 3/00

TROUBLESHOOTING GUIDE (CONTINUED)

YEL/ RED

B+ B-

Mot o r -

Mot o r + Di rec ti on

(- 36V)

Timer Out Timer In 1 Timer In 2

B+ B-

Mot o r -

Mot o r + Di rec ti on

(- 36V)

Timer Out Timer In 1 Timer In 2

S14

BLK/ WHT BLK

BLKWHT/ VI OGRNRED

YEL/ WHT

BLK/ WHT

ORN/ RED

RED/ GRN

BLK/ WHT

GRN/ GRY

BLU/ YEL

Broom On Skirts Lowered

SYMPTOM ONE

Note: Do all testing with the master key switch ON, seat switch closed, broom lever in the ON position and the parking brake set.

Part B: Sweeping Broom Control Circuit Troubleshooting Guide

FIGURE 1

Sweeping broom motor does not run

(see Fig. 1).

Check for 36V at

the K6 solenoid

field coil wires

yel/red & blk/wht

Check for -36V at

the blk/wht wire

on the K6 sole-

noid to a positive

battery standoff.

Check continu-

ity on the S14 broom switch.

Replace the

S14 brush

switch.

Replace the

K6 broom

motor solenoid

Repair the

(+)yel/red wire

from the K8

module to the

K6 field coil

Repair the (-) blk

wire from the

S14 switch back

to the negative

standoff.

Yes

30 - FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300

SWEEPING SYSTEM

SYMPTOM TWO

Note: Do all testing with the master key switch ON, seat switch closed, broom lever in the ON position and the parking brake set.

TROUBLESHOOTING GUIDE (CONTINUED)

revised 3/00

Broom side

skirts will not

lower (see

Figure 1)

Verify sweep-

ing broom is

turning

Back probe the blk/wht

direction input wire on

the E4 or E5 controllers

to a positive battery

standoff. Should read

negative 36V

Check for 36V

at the side skirt

motors (M8 &

M9).

See symptom

1, broom motor

does not run.

Check continuity

of the side skirt

lift motor's inter-

nal limit switch-

es and diodes.

Replace the

defective side

skirt lift motor

M8 or M9

Repair or

replace switch

components as

needed.

Check for 36V at the

controllers E4 & E5

power outputs M+ & M-.

Repair or replace

the wiring from the S14 broom

switch

Check for 36V at the controllers E4 & E5 power inputs B+

& B-.

Repair control-

lers input power

wires yel/wht (+)

& blk (-).

Replace the E4

or E5 controller

card

Repair wiring to

the M8 & M9

motors

Yes

FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300 - 31

SWEEPING SYSTEM

B+ B-

Mot o r +

Mot o r -

Di rec ti on

(0V)

Timer Out

Timer In 1 Timer In 2

B+ B-

Mot o r +

Mot o r -

Di rec ti on

(0V)

Timer Out Timer In 1 Timer In 2

S14

YEL/ RED

BLK/ WHT BLK

BLKWHT/ VI OGRNRED

YEL/ WHT

BLK/ WHT

ORN/ RED

RED/ GRN

BLK/ WHT

GRN/ GRY

BLU/ YEL

Yes

Broom side

skirts will not

raise (see

Figure 2)

Check for 36V

at the side skirt

motors (M8 &

M9).

Check continuity

of the side skirt lift motors internal limit switch-

es and diodes.

Replace the

defective side

skirt lift motor

M8 or M9

Repair or

replace switch

components as

needed.

Check for 36V at the

controllers E4 & E5

power outputs M+ & M-.

Check for 36V at the

controllers E4 & E5

power inputs B+ & B-.

Repair controllers

input power wires

yel/wht (+) & blk

(-).

Replace the E4 or

E5 controller card

Repair wiring to the

M8 & M9 motors

Broom Off Skirts Raised

SYMPTOM THREE

Note: Do all testing with the master key switch ON, broom lever in the OFF position and the parking brake set.

TROUBLESHOOTING GUIDE (CONTINUED)

revised 3/00

FIGURE 2

32 - FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300

SWEEPING SYSTEM

BROOM MAINTENANCE

The sweeping broom must be serviced at regular intervals to maintain good sweeping performance. The following maintenance steps should be completed every 50 hours of operation. Note: Side skirts must be in the raised position to fully open broom access door.

1 Clean built-up dirt from the inside of the broom housing. 2 Remove any string wrapped around the broom, broom drive hub or the idler hub. 3 Clean built-up dirt from the hopper drain holes. 4 Remove the broom and rotate (turn it end for end). See Broom Removal / Replacement section.

BROOM HEIGHT ADJUSTMENT

The working height of the sweeping broom is adjusted to compensate for bristle wear. Before adjusting, always check the length of the sweeping broom bristles. Replace the broom if the bristle length is 1 3/4 inches (44 mm) or less.

To adjust the sweeping broom . . .

1 Drive the machine to an area with a level, dry floor and apply the parking brake. 2 Lower the broom lever to start and place the broom lever in the sweep position. Do not move the machine. Let the broom run for about

1 minute. This allows the broom to polish a “strip” on the floor.

3 After 1 minute, turn the broom off, release the parking brake and move the machine out of the way, so that the polished strip is visible. The

width of the strip should be 1 to 1 1/2 inches (25 to 38 mm).

4 If the strip is too narrow (or too wide), open the lower access door on the left side of the machine, loosen the lock Nut (A) and adjust

Turnbuckle (B) (see Figure 3). This turnbuckle controls the working height of the sweeping broom. Lower the broom if the strip is too narrow. Raise the broom if the strip is too wide.

revised 3/00

FIGURE 3

FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300 - 33

SWEEPING SYSTEM

BROOM LEVEL ADJUSTMENT

The sweeping broom has a level adjustment to control the height of just the right end of the broom. This allows the broom to be adjusted so that it runs parallel to the floor. The adjustment bolts are located at the right end of the broom, inside the broom access door.

Once the broom level is set at the factory, further adjustment is seldom necessary. Adjust the broom level only if the sweeping broom pattern (see Broom Height Adjustment) appears to be tapered after installing a new broom, or if the broom diameter of a used broom is larger on one end than it is on the other.

To level the sweeping broom . . .

1 minute. This allows the broom to polish a “strip” on the floor.

3 After 1 minute, release the parking brake and move the machine out of the way, so that the polished strip is visible. 4 If the strip is tapered, loosen the (2) Bolts (C) (see Figure 4). 5 Use adjustment Bolts (D) to lower the right end of the broom, if the right end of the strip is too narrow or to raise the broom if the right end

of the strip is too wide. The heads of both bolts should be tight against the broom idler arm when adjustment is completed.

6 Tighten the lock nuts on the Bolts (D) and tighten the Bolts (C). Repeat steps 1-3 to check adjustment, readjust if necessary.

BROOM REMOVAL / REPLACEMENT

The sweeping broom should be replaced when the bristles are worn to a length of 1 3/4 inches (44 mm). To remove the main broom . . .

1 Open the lower access door on the right side of the machine and the inner broom housing door. 2 Loosen the lock nut and turn the Bolt (D) (see Figure 4) clockwise (as viewed from the head) to move the head of the bolt away from the

idler arm.

3 Remove the (2) Bolts (C) and pull the idler arm assembly away from the broom. Then slide the broom out of the broom housing.

revised 3/00

FIGURE 4

34 - FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300

SWEEPING SYSTEM

FRONT

1-1 1/4"

(25-30 mm)

BLOCKS

BEARI NGS

SPACER

BROOM BEARING REPLACEMENT

There are sealed ball bearings in the idler hub (on the right end of the broom) and in the drive hub (on the left end of the broom). Whenever the broom is removed for service, these bearings should be checked. Binding, noisy operation or excessive play indicate that the bearings should be replaced.

To remove the idler arm (on the right end of the machine) . . .

1 Open the lower access door on the right side of the machine and the inner broom housing door. 2 Loosen the lock nut and turn the Bolt (D) (see Figure 4) to move it away from the idler arm. 3 Remove the (2) Bolts (C) and pull the idler arm assembly away from the broom.

To remove the drive hub assembly (on the left end of the broom) . . .

1 Remove the sweeping broom. 2 Open both access doors on the left side of the machine. 3 See Figure 5. Remove the belt tension Spring (E). 4 Remove the cotter pin that holds the broom Lift Cable

(F) onto the drive hub arm.

5 Remove the (2) (G) Bolts that hold the drive hub arm in

place.

6 Being careful not to damage the belt, slide the drive hub

assembly out of the broom housing.

To replace the bearings in either hub . . .

1 Place the hub assembly in a vise as shown in Figure 6. 2 Remove Nut (N) and pull the hub off of the arm. 3 Place the hub on two blocks as shown in Figure 7.

Using a hammer and punch, tap the bearing out of the hub.

4 Press new bearings into the hub and re-install the hub

on the arm.

5 Re-install the hub and test the machine.

BROOM MOTOR – CARBON BRUSH INSPECTION

The carbon brushes in the sweeping broom motor should be inspected once a year or 1000 hours. To Inspect the brushes . . .

1 Disconnect the battery cables and remove the battery and the battery tray from the machine. 2 Remove the brush cover from the brush motor and remove the carbon brushes. Replace the carbon brushes if thet are worn to a length of 3/8 inch (10

mm) or less.

revised 3/00

FIGURE 5

FIGURE 6

FIGURE 7

FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300 - 35

SWEEPING SYSTEM

BROOM MOTOR REMOVAL

Attention read before servicing:

Removal method A: Follow steps (1-8) to remove the broom motor when the machine’s battery can be removed. This is the preferred method and needs the proper overhead lift equipment to remove the battery.

Removal method B: Follow steps (9-19) when field servicing, when the battery can’t be removed.

Method A: To remove the broom motor . . .

1 Disconnect the battery cables and remove the battery and the battery tray from the machine. 2 See Figure 5. Open the left side access door and loosen the (2) (I) Bolts. 3 Remove the (2) (J) lock nuts and loosen the belt by turning the (2) (K) Bolts. 4 Remove the belt tension Spring (E) and remove the belt from the motor pulley. 5 Disconnect the broom motor leads. 6 Remove the (4) motor mount bolts (L) and lift the motor out of the machine.

Note: When installing the broom motor, push it up to the top of the mounting slots before tightening the mounting bolts.

7 Follow the steps above in reverse order to re-assemble. 8 Adjust the belt tension so that there is a 1-1 1/4 inch (25-30 mm) space at the idler pulley as shown in Figure 5.

Method B: To remove the broom motor . . .

9 Drain the recovery tank and then remove the tank from the machine (see vacuum system section in this manual for instructions). 10 Turn the key switch on and move the squeegee switch to the ON position to lower the squeegee tool to the floor. Turn key off and disconnect

the battery connector plug assembly.

11 See Figure 8. Remove the rear-retaining Ring (O), Pin (P) and separate the squeegee lift motor at its mounting bracket (Q). Then swing

the lift motor forward to gain access to the broom motor wiring and remove both wires. Note: The wht/vio motor wire connects to the top terminal A1 and the black wire connects to the bottom terminal A2.

12 Open the left rear access door and remove the belt guard (2 screws and 2 nuts). 13 See Figure 5. Remove the (2) (J) lock nuts and the (2) (K) belt adjustment bolts. 14 Loosen the (2) (I) motor mount bracket pivot bolts and swing the motor forward. 15 Remove the belt tension Spring (E) and remove the belt from the motor pulley. 16 Remove the (2) (I) Bolts from the mount weldment (H) and then work the motor & mount assembly out through the left side frame opening.

Note: See Figure 9 for the proper motor orientation in helping guide the motor in or out from the machine (it is a very tight fit).

17 See Figure 5. Remove the (4) (L) motor mount bolts and separate the motor from the mount bracket (M). 18 Follow the steps above in reverse order to reassemble. Note: When installing the broom motor push it up to the top of the mounting slots

before tightening the (4) (L) Bolts.

19 Adjust the belt tension and test the broom for proper operation (see the broom belt adjustment section for instructions).

revised 3/00

FRONT

FIGURE 8

FIGURE 9

FRONT

36 - FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300

SWEEPING SYSTEM

BROOM BELT REMOVAL / ADJUSTMENT

Attention: Remove the battery or the recovery tank to allow the needed access for servicing the broom motor belt easily. To remove the broom belt . . .

WARNING!

Turn the key switch off and disconnect the battery connector before servicing.

1 Lower the sweeping broom to the floor, and then open both the upper and lower left side access doors. 2 Remove the (2) bolts and nuts securing the belt guard. 3 See Figure 5. Loosen the (2) Lock Nuts (J) and the (2) Bolts (I) as shown. Next loosen the belt tension by turning both the Bolts (K)

counterclockwise.

4 Remove the belt tension Spring (E), and then work the belt off the broom drive motor pulley. 5 Mark the alignments of the (2) broom support arms then remove the (2) (G) Bolts and separate. 6 Remove the cotter pin from the Linkage (F) then disconnect the linkage from the arm and remove the belt from the machine. 7 Reassemble in reverse order and refer to the broom belt adjustment section for proper belt tensioning.

To adjust the broom belt . . .

1 Follow steps 1-3 in the broom belt removal section. 2 Turn the (2) Bolts (K) evenly clockwise so there is a 1to1-1/4 inch (25 to 30 mm) space at the idler pulley, as shown in figure 5. 3 Test the broom motor for proper operation.

BROOM SIDE SKIRT LIFT MOTOR REMOVAL

1 Turn the key switch on and put the broom raise/lower lever in the on (down) position to lower the side skirts. Then turn the key switch off

and disconnect the battery connector.

2 Remove the squeegee tool from the machine. Then locate the motor harness and disconnect. 3 See Figure 10. Remove the qty (5) Screws (R) that secure the cable mount bracket (S) and the actuator motor assembly (X), lower both

to the floor.

4 Remove the Retainer Ring (T) and separate the lift cable from the actuator Pin (U) and remove the motor assembly from the machine.

Note: All new replacement actuator motors are not supplied with the drive nut adjusted for a specific system application. Important: When installing a new broom side skirt lift motor or drive nut, follow the actuator drive nut adjustment instructions in the electrical system

manual section.

5 After setting the proper actuator drive nut adjustments for the lift motor follow steps 1-4 in reverse order to reassemble.

Lift cable removal:

• Remove both of the cable anchor nuts, cable pulley guard and the retainer ring and pin that secures the cable to the side skirt lift weldment.

revised 3/00

FRONT

FIGURE 10

FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300 - 37

SWEEPING SYSTEM

BROOM HOUSING SKIRTS

Rubber skirts are installed at the front and the sides of the broom housing to keep debris and water confined to the sweeping area of the machine. For good sweeping performance, all skirts must be in good condition and properly adjusted.

The front Skirt (Y) (see Figure 11) keeps litter from being thrown out of the broom housing, once it enters. It also acts as a ramp to guide the litter off the floor and into the hopper.

Small inner side Skirts (Z) on the left and right ends of the broom housing, keep debris and water from flowing around the ends of the sweeping broom.

The large outer Skirts (AA) help channel the wastewater to the rear pickup squeegee. NOTE: The side skirts only function when the skirts are lowered to the floor by side skirt lift motors (see sweeping system functional overview).

FRONT SKIRT REPLACEMENT / ADJUSTMENT

1 Remove the (2) Bolts (BB) (see Figure 11) from the broom housing and slide the front skirt assembly from under the machine. 2 Remove all of the Screws (CC) and remove the old skirt from the angle and strap. 3 Install all of the Screws (CC) in the new strap, skirt and angle. The top edge of the skirt should be up against the angle, as shown in Figure

11.

4 Mount the skirt assembly on the front of the broom housing and check the distance between the bottom of the skirt and the floor. If necessary,

re-position the skirt so that it is 1/8-1/4 inch (3-6 mm) off of the floor.

NOTE: The machine will not sweep properly if the front skirt drags on the floor. Trim the skirt if necessary, to obtain proper floor clearance.

INNER SKIRT REPLACEMENT / ADJUSTMENT

Adjust the inner skirts if the machine leaves a narrow trail of debris at one or both ends of the broom (with the squeegee up). Before adjusting, inspect the skirt – replace if torn.

1 See Figure 11. Loosen the Bolts (DD) to adjust the height of the inner skirts. Both skirts should just touch the floor.

NOTE: Adjust the right-inner skirt with the inner broom access door closed.

2 To replace the skirts, remove the Bolts (DD), remove the skirt assemblies from the broom housing. Then remove Screws (EE).

revised 3/00

FIGURE 11

FRONT

BROOM HOUSI NG

ANGLE

SKIRT

STRAP

38 - FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300

SWEEPING SYSTEM

OUTER SIDE SKIRT ADJUSTMENT

Adjust the outer broom housing skirts (LT and RT side) if the machine leaves water on the floor when turning. Inspect the skirts before adjusting; replace them if they are nicked, torn or if the wiping edge is worn to a large radius.

1 To adjust the fold over on the outer skirts (operating position). See Figure 12. 2 With new outer skirts installed, lower the sweeping broom housing to the floor and turn the key switch on. Note: Don’t move the machine,

the side skirts will lower and must stand straight up. Then turn the key switch off.

3 Per each side loosen the Lock Nuts (FF) and turn the (2) stop Bolts (GG) so there is 3/16 to 1/4 inch (5 to 6 mm) clearance between the

head of the bolt and the stop plate.

4 The clearance dimension shown is only a starting point. Make needed adjustments to keep an even fold over and prevent any water from

passing underneath the blades.

5 To adjust the skirting for wear, increase the distance between both the bolt heads and stop plates. This will lower the skirt to the floor and

increase the fold over.

revised 3/00

3/16-1/4 inch

(5-6 mm)

Increase For Wear

Lift Cable

Note: When installing a new lift cable, adjust the cable anchor connectors to obtain about a 1/2 i nch (13 mm) of cl earance as shown with the side skirts down.

1/2 inch (13 mm)

FIGURE 12

FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300 - 39

SOLUTION SYSTEM

B+ B-

Mot o r+

Mot o r-

Di rec ti on

Timer Out

Timer In 1 Timer In 2

S10 S11

S19

S13

Seat Switch

FUNCTIONAL OVERVIEW

Functional Overview Standard Solution System:

A 60-gallon (227 L) capacity solution tank is located to the left of the operator’s compartment. Plumbed to it is an externally mounted serviceable solution filter, to help keep dirt out of the solution valves. The tank is also fitted with a flexible drain hose to facilitate quick draining for system maintenance.

The solution system uses (4) valves to regulate the amount of solution dispensed onto the floor. See Figure 2 showing the valve layout. A lever located on the control panel operates the main (master) flow valve; its function is to control the water volume to the (2) individual scrub brush final control valves. The electrical solenoid valve (L1) and dash mounted solution switch (S19) start and stop the solution flow. The (S19) solution ON/ OFF switch when ON works in-conjunction with the drive pedal switch that controls the timer input to the E1 controller that energize the (L1) solution solenoid valve. The solution will flow to the scrub brushes any time the drive pedal is depressed (FWD/REV). Note: When the solution on/off switch (S19) is turned off, no flow can occur regardless of the other valves being on or the drive pedal position.

Explanation of the Solenoid Valve Function

See Figure 1. To energize the L1 solution solenoid the S7 brush switch must be on (brushes lowered) and the K9 relay contacts closed. This completes the positive voltage input to the solenoid. The negative voltage input to the solenoid is supplied when the drive pedal is depressed (FWD or REV). This closes either the S3 or S1 directional switches that triggers the E1 control module’s timer inputs that close the negative timer output connection. This completes the L1 solution solenoid circuit and the valve is open (ON). Note: The timer output voltage from E1 will remain closed for 3 seconds after the drive pedal is returned to neutral. Then the output circuit is open and the brushes and solution will stop. This feature eliminates the nuisance stopping and starting of both systems when the machine changes direction.

Solution System Electrical Diagram

revised 3/00

FIGURE 1

40 - FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300

SOLUTION SYSTEM

Solution On-Off

Lever

From

Solution

Tank

Mai n Solution

Control Val ve

Solution

Solenoid Valve

Flow Control

Valve

To Brushes

Solution

Filter

TROUBLESHOOTING GUIDE

Problem Possible Cause

Inadequate or no solution flow No solution in the tank

Main solution flow control valve lever is in the off position The 2 final output flow control valves are in the off position Clogged solution filter, valves and hoses Defective solution solenoid valve (L1)* Defective control panel solution switch (S19)

*See Solenoid Troubleshooting flow chart for electrical system diagnostics.

revised 3/00

FIGURE 2

FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300 - 41

SOLUTION SYSTEM

TROUBLESHOOTING GUIDE (CONTINUED)

Electrical Symptom

1 Solenoid valve will not open (energize).

SYMPTOM

NOTE: Test with the key switch on, solution switch on, brushes down, seat switch closed, drive pedal slightly depressed (Fwd or Rev) & parking brake set.

*Service Tip: Access the L1 solenoid wiring harness by tipping the seat forward.

revised 3/00

Yes

Solenoid will

not open

(energize).

See fig. 1.

Separate the wir-

ing harness connector that feeds

the L1 solenoid

(2 wires wht &

wht/gry). Test for

36V

Test the resistance of

the L1 solenoid coil. If

it reads infinity coi l is open or if it reads 75

ohms or less it is short-

ed (a good coil should

read 84 ohms).

Replace the

solenoid coil if

testing shows it

shorted or open.

Check for 36V

(neg) from the

wht/gry L1 har-

ness feed wire

to a positive

battery standoff

Check for 36V

(pos.) from the

wht L1 harness

feed wire to a

negative battery

standoff

Replace the S19

solution switch

Repair or replace

wiring from the E1

controller timer out-

put connection

located on the K5

brush motor

solenoid

Check for 36V

(pos.) at the blu/red

input wire on the

S19 solution switch

Verify scrub brushes are

turning

See Brush

system trou-

bleshooting

Symptom

1& 2.

Repair or replace

the blu/red input

wire to the S19

solution switch

42 - FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300

SOLUTION SYSTEM

FRONT

SOLUTION TANK REMOVAL

1 Drain the solution tank using the drain hose found behind the left rear access door. 2 Turn the master key switch off and disconnect the battery connector before servicing. 3 Remove the front outer body fascia panel from the machine (2 screws) and also remove the headlight panel assembly (6 screws). 4 See Figure 3. Remove the solution tank drain hose P-clamp (A) (1 screw). 5 Loosen the solution tank feed Hose Clamp (B) and remove the Hose (C) from the tank Elbow (D). Service Tip Note: The feed Hose (C)

is often difficult to the remove from the barbed elbow Fitting (D). It may be necessary to remove the lower left front corner panel (which retains the bumper roller) weldment from the machine (7 screws). Back probe the end of the hose with a screwdriver and apply a small amount of a spray lubricant at the elbow/hose fitting and pull firmly to remove.

6 See Figure 4. Remove the cover from the left electrical panel (12 screws). Then remove the top and middle (4) Screws (T) and loosen

the bottom (2). Note: This step is necessary to allow the needed clearance for removing the tank.

7 Remove the warning strobe light from the machine (2 screws) and disconnect its wiring harness. 8 See Figure 3. Remove the (3) hex HD Screws (E) that secure the tank to the frame mounts. Then lift the solution tank straight up and

off the machine.

9 Follow steps in reverse order to reassemble.

revised 3/00

FIGURE 3

FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300 - 43

SOLUTION SYSTEM

FRONT

SOLUTION SOLENOID VALVE AND FILTER HOUSING REPLACEMENT

1 To access the solenoid valve first drain the solution tank then remove the solution tank from the machine. See solution tank removal section

for instructions.

2 See figure 3. Loosen the Hose Clamp (F) and remove the outlet solution Hose (G) at the Solenoid Valve (H). Service Tip Note: The solution

hoses can be stubborn (difficult) to separate at their barbed fittings. To remove more easily quickly heat the hose and pry it off using a screwdriver.

3 Remove the Solution Strainer Cup (I) from its housing, then remove the (2) Screws (J) that secure the Housing Bracket (K) to the frame. 4 Disconnect the solenoid wiring harness and pull out the valve and filter assembly from the machine. 5 Repair or replace the needed individual system components and then reassemble following the above steps in reverse order. Note: To

clean valve, replace the solenoid coil and or replace the valve diaphragm you need only remove the solution tank. The coil is easily removed by unthreading it from the valve housing and the valve housing top cover is held together with (4) hex HD screws.

MAIN SOLUTION CONTROL VALVE REPLACEMENT

1 Drain the solution tank, then remove the scrub brushes and lower the brush drive assembly to the floor. Next turn the master key switch

off and disconnect the battery connector.

2 See Figure 3. Loosen the hose clamps and remove the (2) brush feed Hoses (L) from the outlet Tee fitting (M) at the valve (*see service

tip note). Then remove the plastic Tee from the control valve.

3 Remove the Screw (N) that holds the Valve Arm (O) to the linkage Lever (P) and separate. Note: Don’t lose the pivot bushings that are

part of the control linkage.

4 Remove the (2) Screws (Q) and Nuts (R) that fasten the valve to the mount bracket (S) and separate. 5 Loosen the hose clamp on the inlet side of the valve, and then separate the hose by pulling the valve down and out from the machine.

*Service Tip Note: The solution’s feed hoses are often difficult to remove from the barbed fittings. To help remove, back probe the end of the

hose with a screwdriver and apply a small amount of a spray lubricant at the hose fitting and pull firmly to remove.

revised 3/00

FIGURE 4

44 - FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300

VACUUM / RECOVERY SYSTEM

Squeegee

Squeegee Hose

Vacuum Filter

Vacuum Motor

Shut-off

Float

Recovery Tank

Drain Hose

Recovery Tank

Cover

FRONT

Cover Gasket

FUNCTIONAL OVERVIEW

Vacuum / Recovery System General

Dirt and water are lifted off the floor into the recovery tank by airflow, created by a 3-Stage 36V vacuum motor. The wastewater and air enter the vacuum system at the squeegee tool, through small openings (notches) located in the front squeegee blade. The small openings are the entrance points for the water and air, and help speed up the airflow producing the suction to lift the wastewater off of the floor. The air and wastewater move through the squeegee hose at high speed until it reaches the recovery tank. There the air slows down because of the increased volume (large size) of tank. With the decreased air speed the heavier water falls to the bottom of the recovery tank. Then at the same time the airflow continues through the tank, shutoff float, vacuum hose, vacuum motor filter and is exhausted out of the vacuum motor housing. No wastewater ever actually moves through the vacuum motor, just clean air.

The vacuum system uses a shutoff float to prevent the tank from being overfilled and stops any water from being sucked into the vacuum motor.

Vacuum Motor Function

See Figure 2. To energize the K7 vacuum motor solenoid under normal operations the vacuum/squeegee switch *S6 must first be turned on (squeegee lowered). With the machine’s drive pedal depressed (Fwd) the S3 switch closes and triggers the E2 module timer input to activate (close) an internal relay that controls the timer output terminal’s negative voltage signal. This completes the K7 solenoid circuit and the M6 vacuum motor will run. Note: the timer output voltage from E2 will remain closed for 10 seconds after the drive pedal is return to neutral or reverse, then the output circuit is opened and the vacuum motor will stop. Note: This 10-sec. shut off delay helps prevent water from draining back out of the squeegee tool.

*S6 Note: Listed is the three usable functions for the rocker switch S6. (1) The upper switch position lowers the squeegee tool and controls the vac motors ON/OFF function when the machine is moving. (2) The middle position is the off position for both the vac motor/squeegee lift. (3) The lower position controls the continuous run vac motor function when used with the optional vacuum accessory tools.

revised 3/00

FIGURE 1

FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300 - 45

VACUUM / RECOVERY SYSTEM

WHT/ YEL RED/WHT BLK

BLU

BLK

WHT/ BL U

WHT/ GRN

GRA/ WHT

WHT/ BR N

ORN/ WHT

WHT / RE D

RED/ BRN

YEL/ BRN

BLU

GRN/ BRN

RED

B+ B-

Mot o r+

Mot o r-

Di rec ti on

Timer Out

Timer In 1 Timer In 2

Forwar d Throttle Switch

Vacuum Motor ON / S6 & S3 Are Closed

VACUUM / RECOVERY SYSTEM SERVICE CHECKLIST

Whenever there is a vacuum problem, it’s best to check over the entire system. Use the checklist below as a guide, to thoroughly check the vacuum system.

Clean built-up dirt from the inside of the squeegee tool. Replace the squeegee blades if they are nicked or torn. Inspect the hose between the squeegee tool and the recovery tank, rinse any built-up dirt from the hose. Replace the hose if it is kinked

or damaged. Inspect and make sure the gasket(s) on the recovery tank cover and tank bottom are sealing and not damaged. Inspect and clean the vacuum motor filter. Make sure that the recovery tank drain valve seals airtight.

TROUBLESHOOTING GUIDE

If water flows around the ends of the squeegee tool, instead of being pulled into the tool, the vacuum system is not working properly. When a vacuum system performs poorly, it is usually because of one of the following problems:

Vacuum Leak(s) – Air flowing into the vacuum system past a bad gasket or leaky hose, damaged tank, or a leaky drain valve. A vacuum leak below the water line will create turbulence in the recovery tank, causing water to enter the vacuum filter and motor.

Restriction(s) – Anything that blocks the flow of air through the system. Restrictions may also be caused by built-up debris in the squeegee tool, vacuum hoses or wherever the airflow is forced to make a sharp turn.

Both leaks and restrictions decrease the quantity of air flowing through the squeegee tool. The air that does go through the squeegee tool moves slower, so it has less pick-up power.

revised 3/00

FIGURE 2

46 - FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300

VACUUM / RECOVERY SYSTEM

TROUBLESHOOTING GUIDE (CONTINUED)

Possible Symptom

1 Vacuum motor will not run

SYMPTOM ONE

Note: Do all testing with the master key switch ON, seat switch closed, S6 vac/squeegee switch ON (squeegee lowered), the drive pedal depressed in Fwd and the parking brake set.

Part A: Vacuum Motor Load Circuit Troubleshooting Guide

revised 3/00

Yes

Check continuity on

the F2 (40A) vac

motor circuit breaker

Check for 36V at the

red/wht wire (output

terminal) on the K7 vac

motor solenoid to a Neg.

battery standoff.

Vacuum motor will not

run (see Figure 2).

Reset or replace the

F2 (40A) vac motor

circuit breaker

See part B vac motor control circuit trouble-

shooting guide.

Check for 36V at the

M6 vac motor.

Repair or replace the

M6 vac motor

Repair or replace

wiring to vac motor.

FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300 - 47

VACUUM / RECOVERY SYSTEM

SYMPTOM ONE

Note: Do all testing with the master key switch ON, seat switch closed, S6 vac/squeegee switch ON (squeegee lowered), the drive pedal depressed in Fwd and the parking brake set.

Part B: Vacuum Motor Control Circuit Troubleshooting Guide

TROUBLESHOOTING GUIDE (CONTINUED)

revised 3/00

Yes

Vacuum motor

will not run (See

Figure 2).

Check for 36V at the K7 vac motor solenoid field coil

wires blue &

grn/brn

Replace the K7

vac motor solenoid

Check for 36V at

the (Pos.) K7 sole-

noid blue coil wire

to a (Neg.) battery

standoff

Check for 36v at

the (Neg.) K7 sole-

noid coil wire

grn/brn to a (Pos.)

battery standoff

Repair or

replace wiring

back to the S4

key switch

Check for 36V at

the S6 vac switch

orn/wht wire to a

(Pos.) battery

standoff

Check for 36v

(Pos.) at the timer

input #1(red/wht wire) located on

the E2 Squeegee

lift controller. Note: The forward drive pedal switch

S3 must be closed

Replace the S6

vac motor switch

Replace the E2

Squeegee lift

actuator control

board

Yes

48 - FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300

VACUUM / RECOVERY SYSTEM

VACUUM MOTOR REMOVAL

1 Turn the key switch OFF and disconnect the battery connector (behind the right rear access door). 2 Lift the operator’s seat and put the prop rod in position to hold it up. 3 Disconnect the vacuum motor wiring connector. 4 See Figure 3. Remove the (3) Screws (A) and Baffle (B), then lift the motor out of the machine.

VACUUM FILTER

The Vacuum Filter prevents light debris and dust from entering the vacuum motor. The filter should be serviced by the machine operator each time that the machine is used.

For access to the vacuum filter, open the right rear access door. The filter box is located just below the battery. To service the filter . . .

1 See Figure 4. Turn Latch (C), open Door (D) and pull the filter out of the filter box. 2 Wash the filter in warm water and let it dry completely before re-installing. Replace the filter if it is damaged or has a heavy build-up of

hardened dirt.

CAUTION!

The vacuum motor can be damaged by operating the machine without the vacuum filter in place.

revised 3/00

FIGURE 3

FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300 - 49

VACUUM / RECOVERY SYSTEM

Foam Filter

FRONT

Filter Box

RECOVERY TANK REMOVAL

Recommended Tools: To remove hardware use (1) 7/16-inch combination wrench & (1) 7/16-inch socket wrench.

1 First drain the recovery tank using the side

mounted drain hose. Then lift the battery/ recovery compartment cover and position the prop rod to support.

2 Remove the tank clean out plug and scoop

and flush all the solid sediment debris through the clean out opening. Note: Cleaning tank will reduce the weight for easier removal and installation.

3 See Figure 5. Remove the (4) hex HD

Screws (E), (2) tank Retainers (F) and (4) Nyl Loc hex Nuts (G) as shown. Note: Collect the (8) Shims (H) (4 per side) that will fall away, when the tank hardware is removed.

4 With the assistance of a helper, remove the

complete recovery tank assembly from the machine by pulling straight up and back.

5 Re-install by following the above steps in

reverse order.

revised 3/00

FIGURE 4

FIGURE 5

50 - FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300

SQUEEGEE SYSTEM

SQUEEGEE LIFT MOTOR SYSTEM GENERAL OVERVIEW

The squeegee pick up tool is raised and lowered by an electric actuator motor and cable assembly located at the back of the machine, below the battery and recovery tank. The squeegee lift circuit is controlled by the S6 vacuum/squeegee switch located on the dashboard, the reverse directional switch S2 mounted on the drive pedal linkage and the E2 actuator controller mounted in the left panel electrical box are the system components that manage the functions of the F5 squeegee lift motor.

Squeegee Lift Motor Function

See diagram below. To lower the squeegee tool to the floor place the S6 vacuum/squeegee rocker switch to the on position. With the S6 vacuum/ squeegee switch closed a negative 36V passes through the closed S2 reverse switch and is the direction-input signal for the E2 controller. The negative 36V at the direction terminal energizes the internal relay built into the module and directs the correct output voltage (polarity) to run the M5 squeegee lift motor. The lift actuator motor uses two internal limit switches to open the motor circuit and stop the motor’s travel for both raising and lowering functions. To raise the squeegee tool the drive pedal must be placed in reverse and this opens the S2 reverse switch and removes the –36V input signal to the E2 module. Note: It can also be raised by placing the S6 switch in the middle (off) position, which also removes the –36V signal to the module. The E2 direction terminal will now read zero volts and this de-energizes the internal relay and changes the polarity at the module’s output and the squeegee tool is raised automatically.

Squeegee System Electrical Diagram

Note: Squeegee Tool Is Shown Lowered

revised 3/00

WHT/ YEL RED/WHT BLK

BLU

BLK

WHT/ BL U

WHT/ GRN

GRA/ WHT

WHT/ BR N

ORN/ WHT

WHT / RE D

RED/ BRN

YEL/ BRN

BLU

GRN/ BRN

RED

B+ B-

Mot o r-

Mot o r+

Di rec ti on

Timer Out

Timer In 1 Timer In 2

Forwar d Throttle Switch

FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300 - 51

SQUEEGEE SYSTEM

Yes

Squeegee tool

will not lower.

On the E2 controller check for 36V at the M- & M+ output

terminals. The

gry/wht is (-) &

wht/brn is (+).

Check for 36V at

the M5 actuator

motor wiring con-

nector (gry/wht &

wht/brn)

Inside the M5

motor check conti-

nuity on the internal

limit switches &

diodes

Replace the defec-

tive M5 squeegee

lift motor

Repair or replace

the motor switch

componets as

needed

Repair the M5

motor wiring

connector

On the E2 controller

check for -36V at

the wht/blu direction

input terminal to a

(Pos.) battery

standoff

Replace the E2

controller module

On the S6 switch

check for 36V at

the wht/grn wire to

a (Pos.) battery

standoff

Replace the S6

vac/squeegee lift

switch

On the S2 switch

check for 36V at

the wht/blu wire to

a (Pos.) battery

standoff

Replace the S2

reverse squeegee

lift switch

Yes

TROUBLESHOOTING GUIDE

Possible Symptoms

1 Squeegee tool will not lower 2 Squeegee tool will not raise 3 Squeegee tool will not raise in reverse

SYMPTOM ONE

Note: Test with key switch ON, Vacuum/Squeegee switch S6 ON (lowered position) and the parking brake set.

revised 3/00

52 - FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300

SQUEEGEE SYSTEM

SYMPTOM TWO

Note: Test with key switch ON, Vacuum/Squeegee switch S6 OFF (raised position) and the parking brake set.

TROUBLESHOOTING GUIDE (CONTINUED)

revised 3/00

Yes

Squeegee tool

will not raise

On the E2 control-

ler check for 36V

at the M- & M+

output wires. The

gry/wht is (+) &

wht/brn is (-).

Check for 36V at

the M5 actuator

motor wiring har-

ness connector

(gry/wht & wht/brn)

Inside the M5

motor check conti-

nuity on the inter-

nal limit switches

& diodes

Replace the defective M5 squeegee lift

motor

Repair or replace

the motor switch

componets as

needed

Repair the M5

motor wiring

connector.

Check for zero

volts at the

wht/blu direc-

tion input wire

to a (Pos.) bat-

tery standoff

Replace the E2

controller module

On the S6 switch

check for 36V at the wht/grn wire

to a (Pos.) bat-

tery standoff.

Replace the S6

vac/squeegee lift

switch

Yes

FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300 - 53

SQUEEGEE SYSTEM

SYMPTOM THREE

Note: Test with key switch ON, Vacuum/Squeegee switch S6 ON, the reverse S2 switch open by slightly activating the drive in reverse and the parking brake set.

TROUBLESHOOTING GUIDE (CONTINUED)

revised 3/00

Yes

Squeegee tool will

not raise when in

reverse

Verify that the squeegee

tool will raise with the

vac/squeegee lift switch

S6 in the OFF position.

Check for the proper

operation (continuity)

of the S2 reverse lift

switch. It should be open with the drive

pedal in reverse.

See symptom 2

squeegee will not

raise when the S6

dash switch is in the

OFF position

Replace the S2

reverse squeegee lift

switch or adjust so

that it is closed with

pedal in Fwd & open

with the pedal in Rev.

54 - FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300

SQUEEGEE SYSTEM

FRONT

Squeegee Mount

SQUEEGEE ADJUSTMENT FOR MACHINES BEFORE SN1321040

Before adjusting the squeegee . . .

1 Remove the squeegee tool from the machine and inspect the squeegee blades. If the front edge of the wiping blade is worn to a radius,

nicked or torn, remove it from the squeegee and turn it around so the edge that used to face forward now faces toward the back of the machine. If both edges of the blade are worn or damaged, replace the blade (see Blade Replacement).

2 Check the squeegee casters in front of the squeegee mount. Replace the casters if they are damaged or worn out (figure 2).

To adjust the squeegee . . .

1 Turn the key switch ON and put the vacuum/

squeegee switch (location dashboard) in the ON (up) position.

2 See Figure 1. Adjust the (2) Screws (A) to

set the squeegee angle. The entire length of the wiping blade should be flat against the floor. If the blade is high in the middle, turn the screws clockwise. If the blade is high on the ends, turn the screws counterclockwise. Make small adjustments (2 turns or less) at each screw to avoid bending the squeegee mount.

3 Drive the machine forward to bend over

the squeegee blades into their “operating position” and look at the squeegee caster wheels. If they do not touch the floor, increase the squeegee pressure by loosening the thumb screw in collar (B), pulling the collar toward the back of the machine and tightening the thumb screw. Make equal adjustments on both sides of the squeegee mount.

4 If the squeegee leaves puddles of water in

low spots on the floor, lower the operating position of the squeegee by removing the Washers (C) (See Figure 2). Install the washers on top of Bracket (D) for future use.

revised 3/00

FIGURE 1

FIGURE 2

• If the wiping blade bends over too far, remove washers from the top of Bracket (D) and install them between the caster and the bottom

of the bracket.

FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300 - 55

SQUEEGEE SYSTEM

SQUEEGEE BLADE REPLACEMENT FOR MACHINES BEFORE SN1321040

There are (3) rubber blades on the squeegee. The front blade increases the velocity of the air entering the squeegee. The wiping blade wipes the floor dry. The rear blade supports the wiping blade.

The wiping blade works best when there is a sharp corner on its front edge. As the squeegee is used, the front edge wears to a radius. When this happens, the blade can be removed from the squeegee and turned around so the sharp edge that used to face the back of the machine is facing forward.

To replace the squeegee blades . . .

1 Remove the squeegee from the machine, remove the front strap and the front blade from the squeegee. 2 Remove the wing nuts at the ends of the rear straps, release the latch at the center of the straps and remove the wiping blade and the back-

up blade.

3 Clean the squeegee thoroughly and install the new blades. 4 Put the squeegee back on the machine. The flat washers on the (4) squeegee mounting studs should be positioned between the top of

the squeegee mount and the bottom of the tee nuts.

revised 3/00

FIGURE 3

FRONT

Tension Strap

Back-up Blade

Wi p i ng Blade

Front Strap

Front Blade

Tee Nuts

Wi ng Nut

Squeegee We l dme n t

Latch

56 - FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300

SQUEEGEE SYSTEM

FRONT

Squeegee Mount

FRONT

Squeegee Mount

Wi p i ng Blade

Squeegee

SQUEEGEE ADJUSTMENT FOR MACHINES AFTER SN1321039

Before adjusting the squeegee . . .

1 Remove the squeegee tool from the machine and inspect the squeegee blades. If the front edge of the wiping blade is worn to a radius,

nicked or torn, remove it from the squeegee and turn (or flip) it around so that a sharp edge now faces the front of the machine. If all four edges of the blade are worn or damaged, replace the blade (see Blade Replacement).

2 Check the squeegee casters in front of the squeegee mount. Replace the casters if they are damaged or worn out (Figure 2).

To adjust the squeegee . . .

1 Turn the key switch ON and put the

vacuum/squeegee switch (location dashboard) in the ON (up) position.

2 See Figure 1. Adjust the (2) Screws (E) to

3 Drive the machine forward to bend over

the squeegee blades into their “operating position” and look at the squeegee caster wheels. If they do not touch the floor, increase the squeegee pressure by loosening the thumb screw in collar (F), pulling the collar toward the back of the machine and tightening the thumb screw. Make equal adjustments on both sides of the squeegee mount.

4 If the squeegee leaves puddles of water in

low spots on the floor, lower the operating position of the squeegee by removing the Washers (G) (See Figure 2). Install the washers on top of Bracket (H) for future use.

revised 3/00

FIGURE 4

FIGURE 5

• If the wiping blade bends over too far, remove washers from the top of Bracket (H) and install them between the caster and the bottom

of the bracket.

FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300 - 57

SQUEEGEE SYSTEM

FRONT

Squeegee We l dme n t

Wi p i ng Blade

Back-up Blade

Tension Strap

Latch

Wi ng Nut

Front Strap

Front Blade

Tee Nuts

SQUEEGEE BLADE REPLACEMENT FOR MACHINES AFTER SN1321039

There are (3) rubber blades on the squeegee. The front blade increases the velocity of the air entering the squeegee. The wiping blade wipes the floor dry. The rear blade supports the wiping blade.

The wiping blade works best when there is a sharp corner on its front edge. As the squeegee is used, the front edge wears to a radius. When this happens, the blade can be removed from the squeegee and turned around so that a sharp edge is facing forward. The wiping blade has four usable edges.

To replace the squeegee blades . . .

up blade.

3 Clean the squeegee thoroughly and install the new blades. 4 Put the squeegee back on the machine. The flat washers on the (4) squeegee mounting studs should be positioned between the top of

the squeegee mount and the bottom of the tee nuts.

revised 3/00

FIGURE 6

58 - FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300

SQUEEGEE SYSTEM

FRONT

SQUEEGEE ACTUATOR LIFT MOTOR REPLACEMENT

1 Turn the key switch off and disconnect the battery connector (inside the right rear door). 2 Remove the recovery tank from the machine (see the recovery tank removal instructions in the Vacuum Recovery section). 3 Reach under the battery, cut wire ties and disconnect the wiring connector for the squeegee lift actuator. 4 See Figure 4. Remove the (2) Screws (E), (2) Nuts (F) and drive nut bracket (G) from the squeegee lift lever arm (H). 5 Remove one of the retaining rings from the Pin (I), then pull the pin out of the mount bracket and lift the actuator motor out of the machine.

Note: All new replacement actuator motors are not supplied with the drive nut adjusted for a specific system application. Important: When installing a new squeegee lift motor or drive nut, follow the actuator drive nut adjustment instructions in the electrical system

section of this manual.

6 After setting the proper actuator drive nut adjustments for the lift motor follow steps 1-5 in reverse order to reassemble.

revised 3/00

FIGURE 7

FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300 - 59

HYDRO-MAX™ II SYSTEM

FUNCTIONAL OVERVIEW

The optional Hydro-Max™ II system extends the solution’s useful capacity (conserves water usage) by recycling the wastewater picked up from the floor. This allows the machine to scrub continuously, saving time in emptying the recovery tank and refilling the solution tank. The wastewater entering the recovery tank passes through special baffles and filters to remove most of the dirt, then new soap is injected into the treated solution as it is pumped back into the solution tank.

The system operates electrically by closing the Hydro-Max™ II recycling ON/OFF switch (S8) located on the dash panel. Note: Reference the machine Operator Manual for exact system operation steps. With solution usage and wastewater recovery the pump is started when the two mercury switches (S17 start and S18 stop) mounted on float Arm (A) are closed (see Figure 2). The solution tank stop switch (S16) is normally closed, should the solution tank become over filled this switch will open and not allow the pump to run.

The specific functional operation of the mercury switches S17 & S18 start out both open. This is caused by the switch arm float not being activated the recovery tank is empty (dry). With the system prepared for use (see Operator Manual to operate the Hydro-Max™ II system) the recovery tank is filled with clean water when starting Hydro-Max™ II use. When scrubbing, the wastewater is picked-up and the water level and float both rise. The float switches are mounted at two different angles and the S18 (stop) switch closes first then with additional water level increase the S17 (start) switch closes and the K4 pump relay is energized and the pump motor starts. The pump will run continuously within a range set between the difference of the water level and float angle.

Notes: * H2 shown in the diagram is the low solution chemical tank indicator light. ** S15 is the detergent tank level float switch.

Hydro-Max™ II Wiring Diagram

revised 3/00

( )

In Recovery

Tank

N.C.

Dry

In Solution

Tank

( )

N.O.

Dry

S17

N.O.

Dry

RED

BLK

Pump Mot or

( )

36V

S15

BLU

S18

S16

60 - FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300

HYDRO-MAX™ II SYSTEM

FRONT

From Squeegee To Vac Motor

Pump

Drai n

S17

S18

RIGHT

(closed)

Str ainer

Scree n

revised 3/00

FRONT

Met eri ng

Barb

From Detergent Tank

Into Solution Tank

Pump

Float Switches

S17 & S18

Det ergent

Tank

S15

S16

FIGURE 1

FIGURE 2

FIGURE 3

FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300 - 61

HYDRO-MAX™ II SYSTEM

HYDRO-MAX™ II RECOVERY TANK MAINTENANCE

IMPORTANT!

The recovery tank should be cleaned after each use, in order for Hydro-Max™ II system to operate properly.

To clean the tank…

1 See Figure 3. Use the two Drain Hoses (B) to drain both the recovery tank compartments (one on each side of the tank). 2 Lift out the removable Screen Panel (C) and rinse under running water. 3 Rinse the pump pick up strainer Screen (D) thoroughly (located on the right side of the tank). 4 Remove the two clean-out Doors (E) from the back of the tank. Scoop out any built up sludge and flush the bottom of the tank. 5 Then reinstall the clean-out doors and the screen panel.

SOLUTION DETERGENT TANK MAINTENANCE

1 Remove the metering barb from the detergent hose and elbow mount then soak the barb in hot water to loosen chemical build up. For

stubborn cleanup soak the barb in a light muriatic acid solution and use a pin to clean hardened chemical from the hole. Note use caution when working with acid wear safety glasses and gloves.

2 Clean the detergent storage tank by flushing the detergent tank with clean water to remove built up debris. Service Tip: Attach a piece

of hose to the tank outlet elbow with the metering barb removed to help drain contents into container.

HYDRO-MAX™ II SYSTEM TROUBLESHOOTING

Problem Possible Cause

Water does not transfer from the Clogged pump pick up filter recovery tank to the solution tank Defective pump float switches

Defective switch in solution tank Defective solution pump

Vacuum shut off float closes prematurely Picking up water from a source other than machine

Clogged pump pick up filter

Solution chemical not injected Clogged metering barb

Stuck check valve in chemical injector Air leak in chemical hose

revised 3/00

62 - FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300

STEERING & BRAKING SYSTEM

FUNCTIONAL OVERVIEW

Steering System

A single steer wheel at the back of the machine is operated by a single chain, which connects the steer wheel spindle to the steering column in the operator’s compartment. The steering system requires little service other then routine lubrication and inspection. Note: See the general maintenance section in this manual for steering lubrication instructions.

STEER WHEEL SPINDLE REMOVAL

1 Turn the operator’s steering wheel so that the steer wheel is straight. 2 Remove the squeegee tool and recovery tank from the machine. See the Vacuum/ Recovery System section in this manual for instructions

for the recovery tank removal.

3 See Figure 1. Remove the chain guard over the steer spindle Sprocket (A). 4 Loosen the (2) Bolts (B) and locknut (C), then turn the chain adjustment Bolt (D) Counterclockwise to loosen the chain tension. This will

make the chain loose enough to remove the steering spindle sprocket.

5 Remove the Bolt (E) and its washer from the center of the spindle sprocket. Work the Sprocket (A) up and off the splined spindle. 6 Lift the lock tab off the top of the spindle; then remove the cotter pin and large spindle nut.

WARNING!

Never work under the machine without safety stands or blocking installed under the frame.

7 Jack up the rear of the machine and slide the wheel spindle assembly down and out the bottom of the spindle mount housing. Note: Remove

the (4) Bolts (F) if the spindle housing must also be replaced.

Follow the instructions in reverse order to re-assemble.

STEERING CHAIN TENSION ADJUSTMENT

1 Remove the recovery tank and chain guard. 2 See Figure 1. Loosen the 2 Bolts (B) and locknut (C), then turn the chain adjustment Bolt (D) to set the chain tension (counterclockwise

to loosen the clockwise to tighten). The chain should have a deflection of 1/4 to 3/8 inch (6 to 9 mm) with moderate pressure at the midpoint as shown.

revised 3/00

FIGURE 1

FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300 - 63

STEERING & BRAKING SYSTEM

FRONT

BRAKE ADJUSTMENT

Cables are used to connect the brake pedal and the parking brake lever to the brake mechanism on the (2) front wheels. The brake pedal should have about 1 inch (25.4 mm) of down travel before the brakes are fully engaged. If there is too much pedal travel, the brakes should be adjusted.

To adjust the brakes . . .

1 Remove the rear floor panel from the operator’s compartment (just behind the drive pedal). 2 Turn the knob on the end of the parking brake lever to release tension on the brake cables. 3 Adjust the brake cables (under the floor panel) for 1 inch (25.4 mm) of pedal travel. 4 Hold the brake pedal down and check the brake cables for equal tension. Re-adjust the cables if necessary. 5 Test drive the machine in an open area to make sure that the brakes don’t pull the machine to the right or left when applied. 6 If there is not enough adjustment left in the cables, remove the wheels and brake drums and inspect the brake shoes. If the lining on the

shoes is adequate, re-install the brake drums and wheels, loosen the cable tension and turn the star wheel adjuster (inside the brake drum) until the brakes just start to drag. Then re-adjust the brake cables.

7 Turn the knob on the parking brake lever so there is moderate resistance when the handle is lifted. 8 Release the parking brake and operate the machine to make sure that the brakes do not bind during machine operation.

revised 3/00

FIGURE 2

64 - FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300

WHEEL DRIVE SYSTEM

Differential

Drive Motor

Vent Tube

Oil Check & Fill

FUNCTIONAL OVERVIEW

Wheel Drive System

The Hydro-Retriever™ 2052B / CR 1300 is driven by a 4 horsepower permanent magnet motor, coupled to an automotive-type differential. The speed of the motor is regulated by a solid-state speed control (A1), located in the front electrical compartment. A potentiometer (R2), operated by the drive pedal, regulates the speed control.

The direction of travel is controlled by contactors (K2 & K3) mounted next to the speed control. Two directional switches (S3 & S1), also operated by the drive pedal, control the contactors. An electronic interlock (E3) is used to prevent “plugging”. When the drive pedal is quickly moved from forward to reverse, the machine coasts almost to a complete stop and then gently goes into reverse. The interlock works the same way if the pedal is moved from reverse to forward.

The main contactor (K1) brings B+ voltage to the speed control and the forward/reverse contactors. The (S13) switch under the operator’s seat controls the main contactor, so the machine will not move without pressure on the seat.

The drive motor is protected by a 200 amp fuse, located in the left electrical compartment (as viewed facing the front of the machine). The contactor coils and the interlock are protected by a 15 amp circuit breaker, located in the right electrical compartment (as viewed facing the front of the machine).

revised 3/00

FIGURE 1

FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300 - 65

WHEEL DRIVE SYSTEM

KSI

COILM+M-

FWD

REVB+B-

B- B+

S13

revised 3/00

FIGURE 2

FIGURE 3

66 - FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300

WHEEL DRIVE SYSTEM

TROUBLESHOOTING GUIDE

Follow the instructions under the “Symptom” that best describes the condition of the machine being serviced.

DANGER!

Before troubleshooting the drive system, jack up the machine so the drive wheels are off the floor and place jack stands under the frame. This will prevent injury if the drive motor starts during testing.

Possible Symptoms

1 No forward or reverse drive 2 No forward drive (reverse only) 3 No reverse drive (forward only)

Note: All references to “right” and “left” are as viewed from the operator’s seat.

SYMPTOM ONE: NO FORWARD OR REVERSE DRIVE

1 Disconnect the battery connector (behind the right-rear access door) and remove the front access panel.

• See Figure 4. Remove the 200 amp drive fuse and check it with a continuity tester or ohmmeter. Replace the fuse if necessary.

revised 3/00

FIGURE 4

FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300 - 67

WHEEL DRIVE SYSTEM

DANGER!

Do not attempt to perform the next step with the drive wheels on the floor. The drive motor may run at full speed when the drive pedal is pressed.

2 Jack up the front of the machine, so both drive wheels

are off the floor. Place jack stands under the frame.

• See Figure 5. Disconnect wire #41 from terminal (A)

(on the speed control) and connect it to terminal (B), along with the negative wire.

• Reconnect the battery, sit in the operator’s seat (to

close the seat switch), turn the key switch ON and press the drive pedal.

• If the drive motor runs at full speed in both directions,

go to step 3.

• If the drive motor doesn’t run in either direction, go to

step 4.

• Important Note: Reconnect wire #41 to the (A) termi-

nal after following all steps.

3 Turn the key switch OFF.

• See Figure 6. Disconnect the Orange/Blue and the

Green/White wires from the speed control. Connect the wires to the leads from an ohmmeter.

• Press the front of the drive pedal and watch the

ohmmeter. The meter should read 0 ohms in neutral and move smoothly up to 4500 ohms at full pedal deflection.

• If meter reads as described above, the main potenti-

ometer is O.K. - replace the speed control.

• If the meter doesn’t read as described above, see

Speed Potentiometer Replacement and Adjustment sections.

TROUBLESHOOTING GUIDE (CONTINUED)

revised 3/00

FIGURE 5

FIGURE 6

68 - FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300

WHEEL DRIVE SYSTEM

4 Turn the key switch ON and push down on the operator’s seat while watching the main contactor (see Figure 7).

• If the contacts in the main contactor move when the seat is pushed, go to step 6.

• If the contacts in the main contactor do not move when the seat is pushed, go to step 5. 5 See Figure 7. Disconnect the Red/Brown and Black wires from the coil terminals on the main contactor. Connect a DC voltmeter to the

wires (positive to Red/Brown).

• Turn the key switch ON and push down on the operator’s seat.

• If the meter reads 0 volts check the safety switch under the operator’s seat.

• If the meter reads 36 volts, replace the main contactor. 6 Turn the key switch ON, push down on the operator’s seat and press the drive pedal. The forward contactor (see Figure 7) should engage

when the pedal is pushed forward and the reverse contactor should engage when the pedal is pushed in reverse.

• If both contactors engage as described above, go to step 7.

• If the contactors do NOT engage as described above, check the forward and reverse switch mechanism (see Forward/Reverse Switch

section). If the switches work properly, replace the electronic interlock.

7 Lift the operator’s seat and disconnect wires 21 and 22 from the wheel drive motor. Use jumper cables to connect a 12 volt battery directly

to terminals on the motor.

• If the motor runs, check the contacts in the forward, reverse and the main contactor for defects.

• If the motor does not run, remove the motor from the machine, repair or replace as required.

TROUBLESHOOTING GUIDE (CONTINUED)

revised 3/00

FIGURE 7

FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300 - 69

WHEEL DRIVE SYSTEM

SYMPTOM TWO: NO FORWARD DRIVE (REVERSE ONLY)

DANGER!

Note: All references to “right” and “left” are as viewed from the operator’s seat. 1 Remove the front access panel and turn the key switch ON.

• Push down on the operator’s seat, press the front of the drive pedal and watch the forward contactor (see Figure 8).

• If the forward contactor engages when the drive pedal is pressed, check the contacts in the forward contactor, replace the forward/reverse

contactor assembly if necessary.

• If the forward contactor does NOT engage, go to step 2. 2 See Figure 8. Disconnect the diode (at the end of the Red/Green wire) and White/Red wire from the forward contactor. Connect a DC

voltmeter to the wire and the diode as shown.

• Turn the key switch ON, push down on the operator’s seat, and press the front of the drive pedal.

• If the meter reads 0 volts, go to step 3.

• If the meter reads 36 volts, replace the forward/reverse contactor assembly.

TROUBLESHOOTING GUIDE (CONTINUED)

revised 3/00

FIGURE 8

70 - FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300

WHEEL DRIVE SYSTEM

3 See Figure 9. Disconnect the diode from the Red/

Green wire and connect a DC voltmeter as shown.

• If the meter reads 36 volts, replace the diode.

• If the meter reads 0 volts, check the forward and

reverse switch mechanism (see Forward/Reverse Switch section). If the switches work properly, replace the electronic interlock.

SYMPTOM THREE: NO REVERSE DRIVE (FORWARD ONLY)

DANGER!

Note: All references to “right” and “left” are as viewed from the operator’s seat.

1 Open the front access panel and turn the key switch ON.

TROUBLESHOOTING GUIDE (CONTINUED)

• Push down on the operator’s seat,

press the back of the drive pedal and watch the reverse contactor (see Figure 10).

• If the reverse contactor engages

when the drive pedal is pressed, check the contacts in the reverse contactor, replace the forward/reverse contactor assembly if necessary.

• If the reverse contactor does NOT

engage, go to step 2.

2 See Figure 10. Disconnect the di-

ode (at the end of the Red/Green wire) and the Violet wire from the reverse contactor. Connect a DC voltmeter to the wire and the diode as shown.

• Turn the key switch ON, push down

on the operator’s seat, and press the back of the drive pedal.

• If the meter reads 0 volts, go to step

• If the meter reads 36 volts, replace

the forward/reverse contactor assembly.

revised 3/00

FIGURE 9

FIGURE 10

FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300 - 71

WHEEL DRIVE SYSTEM

3 See Figure 11. Disconnect the diode from the Red/

Green wire and connect a DC voltmeter as shown.

• If the meter reads 36 volts, replace the diode.

• If the meter reads o volts, check the forward and

reverse switch mechanism (see Forward/Reverse Switch section). If the switches work properly, replace the electronic interlock.

WHEEL MOTOR REMOVAL

1 Remove the solution tank (see Solution System for instructions). 2 See Figure 12. Move the machine so the master link on chain coupler (C) is facing toward the front of the machine. 3 Disconnect the battery connector (inside the right-rear door). 4 Remove the master link and the chain from the coupler. 5 Lift the operator’s seat and disconnect wires #21 & #22 from the motor. Note: Use a wrench to hold the inner nut on each terminal while loosening the outer nut. 6 Remove the four Bolts (D) and work the motor out of the machine.

WHEEL MOTOR – CARBON BRUSH INSPECTION

The carbon brushes in the wheel motor should be checked every 1000 hours of operation. To check the carbon brushes, tip the operator’s seat forward and carefully remove one of the brushes from the motor. If the brush is worn to a length of 3/8 inch (10 mm) or less, remove the motor from the machine and replace all the brushes.

TROUBLESHOOTING GUIDE (CONTINUED)

revised 3/00

FIGURE 11

FIGURE 12

72 - FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300

WHEEL DRIVE SYSTEM

DIFFERENTIAL REMOVAL

1 Remove the solution tank (see Solution System for instructions). 2 Remove the wheel drive motor (see Wheel Motor Removal section for instructions). 3 Loosen the lug nuts on both front wheels. Then jack up the front of the machine so the wheels are about 1-1/2 inches (38 mm) off the floor.

WARNING!

Never work under the machine without jack stands or blocks supporting the frame.

4 Place blocks or jack stands under each of the front roller bumpers to support the machine. Then remove both front wheels. 5 Loosen the hose clamp and remove the filler/vent tube from the differential. 6 Drain the gear lube or plug the filler/vent opening in the differential. 7 See Figure 13. Remove the 4 Screws (E) and the 4 Bolts (F) (2 on each side of the machine). 8 Place blocks under both brake drums. Then remove the 4 Bolts (G) (2 on each side of the machine). 9 Tilt the top of the differential forward and remove the blocks from under the brake drums. 10 Jack the front of the machine up about 12 inches (31 cm) and place jack stands under the frame. 11 Slide the differential out from under the left side of the machine.

FORWARD & REVERSE SWITCH ADJUSTMENT & REPLACEMENT

DANGER!

WARNING!

Safe operation of the machine may be affected by the forward and reverse drive switches. Use extreme care when adjusting or replacing the switches and their operating linkage.

Before replacing or adjusting the forward or reverse switch…

1 Gently move the front of the drive pedal up and down in neutral, to check the free travel in the pedal. If there is more than 1/8 inch (3 mm)

free travel at the front of the drive pedal, adjust Bracket (H) (see Figure 14) up or down to eliminate the free travel.

2 Gently move the drive pedal to the full forward and full reverse position to check for binding or rough operation. Clean and lubricate the

pedal and potentiometer linkage or replace defective parts as required.

3 Make sure that Collar (I) is centered between the levers on the forward and the reverse switches. If it is not, loosen the (2) set screws in

the collar, center the collar between the switch levers and tighten the set screws.

4 Make sure that the (2) set screws in Collar (I) face directly toward the front of the machine. The speed potentiometer linkage can bind if

the collar is turned to the right or left. If necessary, loosen the set screws in the collar, turn it to the proper position and tighten the set screws.

revised 3/00

FIGURE 13

FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300 - 73

WHEEL DRIVE SYSTEM

FRONT

Sqeegee Lift

Switch

Forward

Switch

Reverse

Switch

To replace the forward, reverse & squeegee switches…

1 See Figure 14. Remove the front access panel and remove the (2) Screws (J). 2 Pull switch bracket (K) out of the compartment as far as the attached linkage will allow and remove the switch needing replacement. 3 Install the new switch (or switches) but do not tighten the mounting screws. 4 Reinstall switch bracket (K) but do not tighten the (2) Screws (J). Adjust the switches.

To adjust the forward, reverse & squeegee switches...

1 See Figure 14. Loosen the (2) Screws (J) and the mounting screws in forward and reverse switches. 2 Put a block of wood under the front of the drive pedal. This will hold the pedal in the REVERSE position. 3 Slowly move switch bracket (K) toward collar (I) until the squeegee lift switch clicks. Then continue to move the bracket an additional 1/

16 inch (1.5 mm) toward the collar and tighten the Screws (J).

4 Slide the REVERSE switch towards the switch collar (I) until it clicks. Then move the switch an additional 1/16 inch (1.5 mm) toward the

collar and tighten the switch mounting screws.

5 Remove the block of wood from the front of the drive pedal and put it under the back of the pedal. This will hold the pedal in the FORWARD

position.

6 Slide the FORWARD switch towards the switch collar (I) until it clicks. Then move the switch an additional 1/16 inch (1.5 mm) toward the

collar and tighten the switch mounting screws.

SPEED POTENTIOMETER REPLACEMENT

WARNING!

Safe operation of the machine may be affected by the speed potentiometer. Use extreme care when adjusting or replacing the potentiometer and its operating linkage.

Check the potentiometer for proper adjustment before replacing. See Speed Potentiometer Adjustment section.

To replace the potentiometer . . .

1 Disconnect the battery connector (behind right-rear door) and remove the electrical access panel on front of the machine. 2 See Figure 14. Disconnect the (2) wires from Potentiometer (L). 3 Move Hose Clamp (M) to your left as far as possible, on Coupler (O). 4 Remove Nut (N) and pull the potentiometer out of Coupler (O). 5 Install the new potentiometer, making sure that the tab on the potentiometer engages the hole in Bracket (Q).

Follow steps in reverse order to install the new potentiometer. Then follow potentiometer adjustment instructions.

FORWARD & REVERSE SWITCH ADJUSTMENT & REPLACEMENT (CONTINUED)

revised 3/00

FIGURE 14

74 - FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300

WHEEL DRIVE SYSTEM

SPEED POTENTIOMETER ADJUSTMENT

Before adjusting the potentiometer . . .

• Gently move the front of the drive pedal up and down in neutral, to check the free travel in the pedal. If there is more than 1/8 inch (3 mm) free travel at the front of the drive pedal, adjust Bracket (H) (see Figure 14) up or down to eliminate the free travel.

• Gently move the drive pedal to the full forward and full reverse position to check for binding or rough operation. Clean and lubricate the

pedal and potentiometer linkage or replace defective parts as required.

• Make sure that Collar (I) is centered between the levers on the (2) set screws in the collar, center the collar between the switch levers and tighten the set screws.

• Make sure that the (2) set screws in Collar (I) face directly toward the front of the machine. The speed potentiometer linkage can bind if the collar is turned to the right or left. If necessary, loosen the set screws, turn the collar to the proper position and tighten the set screws.

To adjust the potentiometer . . .

1 Disconnect the battery connector (behind right-rear door) and remove the electrical access panel on the front of the machine. 2 Adjust the reverse stop bolt, located under the back of the drive pedal. The pedal should hit the stop bolt at the same time the edges of

the pedal hit the floor panel.

3 See Figure 15. Move Hose Clamp (S) to your right, as far as possible on Coupler (R). 4 Remove the (2) wires from the potentiometer terminals and connect an ohmmeter as shown. 5 Grip Coupler (R) and turn it until the meter reads 0 ohms. 6 Push the back of the drive pedal flat against the floor panel and turn Coupler (R) until the meter reads 3500 ohms. 7 Release the pedal and move Clamp (S) to the left end of Coupler (R). 8 Watch the ohmmeter while pressing down on the front of the drive pedal. The pedal should hit the forward stop bolt (under the front of the

drive pedal) when the meter reads 4500 ohms.

• If the meter reads 4500 ohms before the pedal hits the stop bolt, release the pedal and adjust the bolt upward.

• If meter reads less than 4500 ohms when the pedal hits the stop bolt, adjust the stop bolt downward.

9 Connect the wires to the potentiometer, close the front panel and test the machine for proper operation.

revised 3/00

FIGURE 15

FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300 - 75

ELECTRICAL SYSTEM

IN Position

OUT Position

Broom Side Skirt &

Squeegee Lift

Nut Orientation

ACTUATOR DRIVE NUT ADJUSTMENT

This manual section explains the steps for adjusting the drive nut settings for all three of the machine’s lift actuator motors. Reference the chart below to find the In & Out dimensional specification for the specific actuator motor needing adjustment.

Qty Part # Actuator Motor Drive Nut In Position Drive Nut Out Position

2 56391627 Broom Side Skirt 4-5/8” (117 mm) 6-1/2” (165 mm) 1 56391627 Squeegee Lift 6-3/8” (162 mm) 8-1/2” (216 mm)

1 See Figure 1. This shows the special

actuator power cord adapter (PN

56407502) that is needed to connect the machine’s battery pack and actuator motor for setting the drive nut limit settings.

2 Open the machine battery compart-

ment and disconnect the battery connector. The battery pack is needed to power the lift actuator motor to properly set the IN & OUT limit switches.

3 Connect the actuator motor to be

tested to the power cord adapter end. Then connect the alligator clips from the cord adapter (red clip to the positive and black to negative) to battery connector or battery posts. The rocker switch is used to change the motor rotation in setting the correct drive nut dimension.

4IMPORTANT: On all the new replace-

ment actuator motors it will be necessary to remove the drive nut (spin it off) the shaft and turn it end for end so that nut’s pin pocket points toward the motor as shown. This must be done before setting the drive nut dimensions.

5 See Figure 2. Hold onto the Actuator

Drive Nut (A) and press the rocker switch to run the drive motor and retract the nut towards the motor housing (it’s IN limit).

6 Measure the position of the drive nut

on the actuator shaft. Manually turn the plastic nut to the IN position as shown in the chart.

7 Hold the drive nut then press the

adapter cord rocker switch to run the drive motor to the OUT position (wait until the motor stops).

8 Measure the position of the drive nut on the shaft and compare the measurement with the OUT position shown in the chart. 9 When the measurement doesn’t match the dimension shown in the chart it is necessary to remove the Adjuster Cover (B) and adjust the

Out position.

10 To increase the travel of the drive nut, turn the adjuster clockwise. To decrease the travel of the nut, turn the adjuster counter clockwise.

NOTE: Use a 5/16” (8 mm) wrench to turn the adjuster. Each click of the adjuster will change the nut travel 1/16 inch (1.6 mm).

11 After each adjustment, hold the drive nut, run the actuator IN & OUT and check both dimensions. After checking that the drive nut limits

are set correctly then replace the adjuster cover. NOTE: Run the drive nut to the OUT (extended) position for machine installation.

revised 3/00

FIGURE 1

FIGURE 2

76 - FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052, CR 1300

ELECTRICAL SYSTEM

ELECTRICAL COMPONENTS

1 Circuit Breaker, 10 Amp (Aux. 2 / F7) 2 Circuit Breaker, 5 Amp (Drive Control Circuit / F5) 3 Circuit Breaker, 80 Amp (Brush Motor / F1) 4 Circuit Breaker, 40 Amp (Vac Motor / F2) 5 Circuit Breaker, 15 Amp (Aux. 1 / F4) 6 Circuit Breaker, 40 Amp (Broom Motor / F3) 7 Relay (Low Voltage Cut-Out / K9) 8 Dual Control Assembly

(Brush & Squeegee Lift Actuator Control / E1 & E2)

9 Dual Control Assembly

(Side Skirt Actuator Control / E4 & E5)

10 Contactor, 36V (Brush Motor / K5) 11 Solenoid, 36V (Broom Motor / K6) 12 Solenoid, 36V (Vac Motor / K7) 13 Forward / Reverse Interlock (E3) 14 Contactor SPST (Main / K1) 15 Contactor 36VDC (Forward/Reverse / K2 & K3) 16 Speed Control 17 Fuse, 200 Amp (Wheel Drive Motor / F6)

revised 3/00

FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052 / CR 1300 - 77

ELECTRICAL SYSTEM

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COMPONENT LOCATION

Item Description

1 H6 - Horn 2 L1 - Solution Solenoid 3 M1 - Broom Motor 4 M2 - Recycle Pump Motor (Hydro-Max II) 5 M3 - Brush Lift Actuator 6 M4 - Brush Motor 7 M5 - Squeegee Lift Actuator 8 M6 - Vacuum Motor

9 M7 - Wheel Drive Motor 10 M8 - Left Side Skirt Lift Actuator 11 M9 - Right Side Skirt Lift Actuator 12 R2 - Throttle Potentiometer 10K Ohm 13 S1 - Reverse Throttle Switch 14 S2 - Reverse Squeegee Lift Switch 15 S3 - Forward Throttle Switch 16 S10 - Brush Lift UP Limit Switch 17 S11 - Brush Lift DOWN Limit Switch 18 S13 - Seat Switch 19 S14 - Broom Switch 20 S15 - Detergent Tank Float Switch (Hydro-Max II) 21 S16 - Solution Tank Float Switch (Hydro-Max II) 22 S17 - Recovery Tank Start Float Switch (Hydro-Max II) 23 S18 - Recovery Tank Stop Float Switch (Hydro-Max II) 24 S20 - Battery Tray Interlock Switches (Optional)

revised 3/00

ELECTRICAL SYSTEM

78 - FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052 / CR 1300

revised 9/05

A1 Speed Controller

D1 Suppression Diode D2 Suppression Diode D3 Suppression Diode D4 Blocking Diode D5 Suppression Diode D6 Suppression Diode D7 Suppression Diode D8 Blocking Diode D9 Suppression Diode

D10 Suppression Diode

E1 Brush Lift Actuator Control Module E2 Squeegee Lift Actuator Control Module E3 Forward / Reverse Interlock E4 Left Side Skirt Lift Actuator Control Module E5 Right Side Skirt Lift Actuator Control Module

F1 Brush Motor Circuit Breaker (80A) F2 Vacuum Motor Circuit Breaker (40A) F3 Broom Motor Circuit Breaker (40A) F4 Auxilliary Circuit 1 Circuit Breaker (15A) F5 Drive Control Circuit Circuit Breaker (5A) F6 Wheel Drive Motor Fuse (200A) F7 Auxilliary Circuit 2 Circuit Breaker (10A) F8 Fuse (1.5A)

H1 Recovery Tank Full Light H2 Detergent Tank Empty Light (Hydro-Max II) H3 Strobe Light H4 Left Headlight H5 Right Headlight H6 Horn

K1 Main Contactor K2 Forward Direction Contactor K3 Reverse Direction Contactor K4 Recycle Pump Relay (Hydro-Max II) K5 Brush Motor Contactor K6 Broom Motor Contactor K7 Vacuum Motor Contactor K8 Low Voltage Cut-Out Module K9 Low Voltage Cut-Out Relay

Item Description

SCHEMATIC / WIRING DIAGRAM FOR HYDRO-RETRIEVER™ 2052 MACHINES BUILT BEFORE SN 1296730

Item Description

L1 Solution Solenoid

M1 Broom Motor M2 Recycle Pump Motor (Hydro-Max II) M3 Brush Lift Actuator M4 Brush Motor M5 Squeegee Lift Actuator M6 Vacuum Motor M7 Wheel Drive Motor M8 Left Side Skirt Lift Actuator M9 Right Side Skirt Lift Actuator

P1 Hourmeter P2 Fuel Gauge, Battery

R1 Resistor 250 Ohm, 5 Watt R2 Throttle Potentiometer 10K Ohm

S1 Reverse Throttle Switch S2 Reverse Squeegee Lift Switch S3 Forward Throttle Switch S4 Key Switch S5 Headlight Switch S6 Vacuum / Squeegee Switch S7 Brush Switch S8 Recycle Pump Switch (Hydro-Max II)

S9 Horn Switch S10 Brush Lift UP Limit Switch S11 Brush Lift DOWN Limit Switch S12 Vacuum Pressure Switch S13 Seat Switch S14 Broom Switch S15 Detergent Tank Float Switch (Hydro-Max II) S16 Solution Tank Float Switch (Hydro-Max II) S17 Recovery Tank Start Float Switch (Hydro-Max II) S18 Recovery Tank Stop Float Switch (Hydro-Max II) S19 Solution Switch

Note: Location of optional interlock switches that are used in the battery slide out kit #56459909. Reference schematic #56459316 for electrical interlock switch wiring. Slide out kit is available for Hydro-Retriever™ 2052 machines after SN 1295923, and all CR 1300 machines.

RED

BLU

RED/BLK

RED

BRN/BLK

BT1

WHT

BLK

GRN WIRE NOT USED

RED ORN YEL

YEL/RED

BLK

BLK BLK

BLK

BRN

YEL/RED

BRN/YEL

BLU

WHT/VIO

S14

BLK/WHT

YEL/RED

ORN

GRN

S12

RED

BLU

YEL/WHT

RED/GRN ORN/RED BLK/WHT

MOTOR -

MOTOR +

TIMER IN 1

DIRECTION

B+ B-

TIMER IN 2

TIMER OUT

BLK/WHT

BLU/YEL GRN/GRY

MOTOR -

MOTOR +

TIMER IN 1

DIRECTION

B+ B-

TIMER IN 2

TIMER OUT

BRN/WHT

BLK

S15

YEL/BLU

GRA

S16

ORN/BLK

YEL/BLK

BLU/WHT

YEL/BLU

BLK

S17

GRA

S18

GRA

BLK ORN/GRN

BLU

BLU/RED

1 4

3 6

GRA/RED

WHT/BLK

BLK ORN/GRN

BLU/BLK

WHT/BLK

VIO/BLK

BLU

WHT/BLK

S10 S11

GRN/BLK

WHT/GRA WHT/RED

VIO/BLK BLU/RED

BLK

BLU

MOTOR -

MOTOR +

TIMER IN 1

DIRECTION

B+ B-

TIMER IN 2

TIMER OUT

VIO

WHT/GRA

WHTBLU/RED

S19

WHT/RED

BLU

VIO

WHT/GRN

WHT/BLU

BLU

GRN/BRN

BLK

ORN/WHT

BLU

ORN/WHT

WHT/BRN

GRA/WHT

WHT/BLU

BLU

BLK

WHT/RED

NO CONNECTION

BLK

MOTOR -

MOTOR +

TIMER IN 1

DIRECTION

B+ B-

TIMER IN 2

TIMER OUT

BLK

GRA/YEL ORN/RED RED/GRN

KSI

COIL

M+

FWD

REV

B+

B-

M-

RED/WHT

WHT/ORN

RED/BRN

WHT/YEL

RED/BRN

S13

BLU

RED

YEL/BRN

VIO

WHT/RED

VIO

WHT/RED

VIO

VIO/YEL

M-

B-

B+

ORN/BLU

GRN/WHT

BLK

RED/BRN

BLK

H4 H5

YEL/WHT

BLK

FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052 / CR 1300 - 79

ELECTRICAL SYSTEM

revised 9/05

FOR HYDRO-RETRIEVER™ 2052 MACHINES BEFORE SN 1296730

ORN/BLU 36A-B

GRN/ WHT 59A-B

RED/ BRN 21C-B

GRA/ YEL 84A-B

RED/ BRN 21D-B

VIO 7B-A

VIO 7C-A

YEL/BRN 41A-B

WHT/RED 92A-B

WHT/RED 92B-B

YEL/BRN 41A-A

RED/ BRN 21C-A

RED/ BRN 21B-A

BLK 0B- A

BLK 0U-A

RED/ BRN 21D-A

RED/ BRN 21E-A

VIO 7C-B VIO 7E-B

WHT/RED 92C-B

WHT/RED 92G-B

WHT/GRN 95A-B WHT/GRN 95C-B

WHT/BLU 96A-B

WHT/BLU 96C-B

BRN/YEL 14C-A

BLK 0A B-B

WHT/BLU 96A-A

WHT/GRN 95A-A

BRN 1A-B

BLK 0AA-B

BRN 1A-A

WHT/RED 92B-A

BLU 6M-A

WHT/RED 92C-A

RED/GRN 25B-A

VIO 7A-B

VIO 7B-B

RED/GRN 25A-B

RED/GRN 25B-B

BLK 0V -A

BLU 6T- B

RED/BLK 20C-B

GRA 8 B-A

VIO/BLK 70E-A

GRN/BRN 51C-B

ORN/WHT 39C-B

WHT/GRN 95C-A

BRN/WHT 19B-A

0RN 3B-A

BLU 6A -B

GRN/BRN 51A-B

RED/BLK 20A-B

ORN 3A- B

VIO/BLK 70A-B

BRN/YEL 14A-B

BLK 0C- B

WHT/GRN 95B-B

BRN/WHT 19A-B

ORN/WHT 39A-B

GRA 8 A- B

RED/BLK 20A-A

YEL/BLK 40C-A

YEL/BLU 46B-B

BRN/WHT 19B-B

GRA 8 C-A

BLU 6A -A

BLU 6B-A

BLK 0A-A

RED/ BRN 21A-A

VIO 7A-A

WHT/RED 92A-A

ORN/RED 32A-A

GRA/ YEL 84A-A

RED/ GRN 25A-A

VIO/YEL 74A-A

ORN/RED 32A-B

BRN/YEL 14B-A

BLK 0A -B

RED/ BRN 21A-B

BLK 0B- B

RED/ BRN 21B-B

BLU 6D- A

BLU 6C-A

BLK 0E-B

BLK 0D- B

YEL/BLU 46A-B

ORN/BLK 30A-B

BLU/WHT 69A-B

BLU 6J-

BLK 0N- B

YEL/BLK 40A-B

RED 2 B-B

RED 2 C-B

RED/BLK 20B-B

RED 2 A- B

WHT/ORN 93A-B

BLU 6G-B

GRN/ BRN 51B-B BLU 6K-B

RED/ WHT 29A-

WHT/YEL 94A-A

WHT/GRA 98A-B

BLU/RED 62B-B

BLU/RED 62A-B

WHT/BLU 96C-A

VIO 7E-A

WHT/VIO 97A-A

WHT/BRN 91B-A

BLK 0A E-A

VIO/BLK 70C-A

BLK 0S-A

GRA/ WHT 89B-A

BLK 0J- A

WHT/BRN 91A-A

BLK 0T -A

WHT/VIO 97 B-A

ORN/WHT 39C-A

GRN/ BLK 50B-A

GRA/ WHT 89A-A

BLK 0W- A

WHT/RED 92G-A

WHT/RED 92D-A

GRN/ BLK 50A-A

VIO 7D-A

VIO/BLK 70B-A

WHT/BLU 96B-A

ORN/WHT 39B-A

BLU 6L- A

YEL/BLK 40B-A

YEL/BLK 40A-A

BLK 0R-A

ORN/BLK 30B-A

BLK 0A F-A

BLU/WHT 69A-A

WHT/ORN 93A-A

RED/ WHT 29B-A

BLU 6R-A

BLU/WHT 69B-A

GRN/ BRN 51C-A

YEL/BLU 46B-A

RED/ BLK 20B-A

RED/ WHT 29A-A

WHT/ORN 93B-A

RED/ BLK 20C-A

GRN/ BRN 51B-A

BRN/YEL 14D-A

BLK 0X-A

BLK 0P-A

YEL/BLU 46A-A

ORN/BLK 30A-A

BLU 6D- B

BLU 6E-B

BRN/YEL 14A-A

BLK 0G-B

ORN/WHT 39A-A

BLK 0G-A

BLK 0F- B

BLK 0H- A

BLK 0E-A

BLU 6F-B

VIO/BLK 70A-A

BLK 0F- A

GRN/BRN 51A-A

WHT/GRN 95B-A

-- -

SPLICE 0T-B, 0U-B, 0V-B

SPLICE 4 0 B-B , 40 C- B, 4 0 D-

SPLICE 70C-B, 70D-B, 70E-B

SPLICE 0W-B, 0X-B, 0Y-B,

NO CONNECTION

X14

X15

X13 X12

X10

S17

X11

SPLICE OY-A, OAA-A, OAB-A

X8 X7

7470

NO CONNECTION

BLK OC-A

BLK OD-A

RED/BLK 20B-A

BRN/BLK 10 C-B

YEL/WHT 49A-A

BRN/BLK 10 C-A

WHT/BLK 90D-B

WHT/BLK 90C-A

YEL/RED 42A-B

YEL/RED 42B-A

BLU/BLK 60C-B

ORN/GRN 35C-B

YEL/WHT 49A-B

ORN/GRN 35B-B

YEL/WHT 49B-B

12345

X16

SPLICE: BLU 6B-B, BLU 6U-B, RED, ORN.

KSI

COIL

M+

FWD

REV

B+B-M-

BLK OJ-A

BLK OP-A

BLK OR-A

BLK OS-A

BLK OL-B

BLK ON-A

BLK OAJ- B

BRN/BLK 10 B-A

NO CONNECTION

SPLICE: 6 M-B, 6R-B, 6T-

SPLICE: 14B-B, 14C-B, 14D-B

NO CONNECTION

BLU/BL K 6 0B- B

SPLICE: OZ-A, OAL -B, OAK- A, OAP- B

OZ-B

8B-B

SPLICE

8D-B

8C-B

B-

M-

B+

GRN/ WHT 59A-A

VIO/YEL 74A-B

ORN/BLU 36A-A

BRN/WHT 19A-A

BLK OI-B

ORN 3A- A

BLK OI-A

BLK OH-B

WHT 9B-A

WHT 9A-B

BLU/RED 62E-B

BLU/RED 62D-B

(B) SPLICE: 8B-B, 8C-B, 8D-B

BLU 6U-B

BLU 6C-B

ORN/GRN35D-A

GRN NO T U SED

RED

ORN

WHT

BLK

YEL/RED 42A-A

YEL

231

RED/BLK 20B-B

WHT

BLK

BLK OM-A

BLK OQ-A

SPLICE 92D-B,92E-B,92F-B

SPLICE: 90B-B, 90C-B, 90E-B

BLK OK-B

D10

GRN 5 A - A

WHT/YEL 94A-B

RED 2 D-B

BRN/BLK 10A-A

YEL/RED 42D-A

GRN 5 A - B

BLK/WHT 09B-A

WHT/VIO 97A-B

BLK/WHT 09A-A

YEL/RED 42C-A

BLK/WHT 09C-A

ORN/GRN 35A-A

BLK OAI-A

WHT/BLK 90A-A

GRA/RED 82A-A

BLK OAJ-A

BLU/BLK 60A-A

YEL/RED 42C-A

BLU/RED 62A-A

BLU/RED 62C-A

BLK OAI-B

X18

X19

TIMER OUT

MOTOR-

MOTOR+

TIMER IN 2

B-

DIRECTION

B+

TIMER IN 1

WHT/GRA 98B-B

NO CONNECTION

RED 2 D-A

RED 2 A- A

RED 2 B-A

RED 2 C-A

SPLICE: 6 G-A, 6H-A, 6I-A, 6 J-A, 6K-

YEL/WHT 49C-A

YEL/WHT 49E-A

BLU 6L- B

BLU 6H-B

BLK OL-A

GRN/ BLK 50A-B

VIO/BLK 70B-B

BLU/RED 62B-A

WHT/GRA 98A-A

WHT/RED 92F-A

VIO 7D-B

BLU 6I-B

BLK OK-A

GRA/ WHT 89A-B

WHT/BRN 91A-B

WHT/BLU 96B-B

ORN/WHT 39B-B

WHT/RED 92E-A

YEL/WHT 49E-B

BLK OM-B

RED/ GRN 25A-A

ORN/RED 32A-A

BLK/WHT 09A-B

49D-B YEL/WHT 49D-A

BLK OQ-B

BLU/YEL 64A-A

GRN/ GRA 5 8 B -A

BLK/WHT 09B-B

X17

BLU/RED 62C-

BLU/RED 62D-A

WHT/GRA 98C-A

WHT/GRA 98B-A

WHT/BLK 90B-A

ORN/GRN 35A-B

BLU/BL K 6 0A -B

GRA/ RED 82A-B

BRN/BLK 10 B-B

BRN/BLK 10 A-B

YEL/RED 42B-B YEL/RED 42C-B

BLU/BL K 6 0B-A

ORN/GRN 35B-A

GRA/ RED 82B-A

WHT/BLK 90A-B

GRN/ GRA 5 8 B -B

BLU/YEL 64B-B BLU/YEL 64A-B

ORN/RED 32B-B

ORN/RED 32A-B

BLK/WHT 09D-B

BLK/WHT 09C-B

RED/ GRN 25A-BRED/ GRN 25B-B

YEL/WHT 49B-A

YEL/WHT 49C-B

BLU 6P-B

GRA 8 A- A

BLU 6F-A

BLU/BLK 60C-A

WHT/BLK 90D-A

ORN/GRN35D-B

ORN/GRN 35C-A

BLU 6E-A

WHT 9A-A

BLU/RED 62E-A

S18

TIMER OUT

MOTOR-

MOTOR+

TIMER IN 2

B-

DIRECTION

B+

TIMER IN 1

TIMER OUT

MOTOR-

MOTOR+

TIMER IN 2

B-

DIRECTION

B+

TIMER IN 1

TIMER OUT

MOTOR-

MOTOR+

TIMER IN 2

B-

DIRECTION

B+

TIMER IN 1

ORN/BLK 30B-B

GRA 8D-A

YEL/BLK 40D-A

WHT/GRA 98C-B

WHT 9B-B

BLU 6Q-A

BLU 6P-A

ORN 3B-B

S12

BLK 0AP-A

BLU/W HT 69B-B

BLK 0AF-B

RED/WHT 29B-B

RED/BRN 21E-B

WHT/ORN 93B-B

S13

S14

BLK 0AL-A

BLK/WHT 09D-A

S19

S11

S10

S16

S15

ORN/RED 32B-A

RED/GRN 25B-A

BLU/YEL 64B-A

GRN/GRA 58B-B

RED

BLK

RED

BLK

GRA/WHT 89B-B

WHT/BRN 91B-B

WHT/VIO 97B-B

BLK 0AE-B

BLU6Q-B

BLK 0AK-B

WHT/BLK 90F-B

GRN/BLK 50B-B

VIO/BLK 70D-A

GRA/RED 82B-B

GRA/RED 82C-B

WHT/BLK 90E-A

WHT/BLK 90F-A

GRA/RED 82C-A

ELECTRICAL SYSTEM

80 - FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052 / CR 1300

revised 9/05

A1 Speed Controller

D1 Suppression Diode D2 Suppression Diode D3 Suppression Diode D4 Blocking Diode D5 Suppression Diode D6 Suppression Diode D7 Suppression Diode D8 Blocking Diode D9 Suppression Diode

D10 Suppression Diode

H2 Detergent Tank Empty Light (Hydro-Max II) H3 Strobe Light H4 Left Headlight H5 Right Headlight H6 Horn

Item Description

SCHEMATIC / WIRING DIAGRAM FOR HYDRO-RETRIEVER™ 2052 MACHINES AFTER SN 1296729 AND ALL CR 1300 MACHINES

Item Description

L1 Solution Solenoid

P1 Hourmeter

P2 Fuel Gauge, Battery

R1 Resistor 250 Ohm, 5 Watt

R2 Throttle Potentiometer 10K Ohm

S1 Reverse Throttle Switch

S2 Reverse Squeegee Lift Switch

S3 Forward Throttle Switch

S4 Key Switch

S5 Headlight Switch

S6 Vacuum / Squeegee Switch

S7 Brush Switch

S8 Recycle Pump Switch (Hydro-Max II)

S9 Horn Switch S10 Brush Lift UP Limit Switch S11 Brush Lift DOWN Limit Switch S13 Seat Switch S14 Broom Switch S15 Detergent Tank Float Switch (Hydro-Max II) S16 Solution Tank Float Switch (Hydro-Max II) S17 Recovery Tank Start Float Switch (Hydro-Max II) S18 Recovery Tank Stop Float Switch (Hydro-Max II) S19 Solution Switch

Note: Location of optional interlock switches that are used in the battery slide out kit #56459909. Reference schematic #56459316 for electrical interlock switch wiring.

RED

BLU

RED/BLK

RED

BRN/BLK

BT1

WHT

BLK

GRN WIRE NOT USED

RED

ORN

YEL

YEL/RED

BLK

BRN

YEL/RED

BRN/YEL

BLU

WHT/VIO

S14

D10

BLK/WHT

YEL/RED

GRN

RED

YEL/WHT

RED/GRN

ORN/RED

BLK/WHT

MOTOR -

MOTOR +

TIMER IN 1

DIRECTION

B+

B-

TIMER IN 2

TIMER OUT

BLK/WHT

BLU/YEL

WHT/YEL

MOTOR -

MOTOR +

TIMER IN 1

DIRECTION

B+

B-

TIMER IN 2

TIMER OUT

BLK

ORN/GRN

BLU

BLU/RED

GRA/RED

WHT/BLK

BLK

ORN/GRN

BLU/BLK

WHT/BLK

VIO/BLK

BLU

WHT/BLK

S10 S11

GRN/BLK

WHT/GRA

WHT/RED

VIO/BLK

BLU/RED

BLK

BLU

MOTOR -

MOTOR +

TIMER IN 1

DIRECTION

B+

B-

TIMER IN 2

TIMER OUT

VIO

WHT/GRA

WHTBLU/RED

S19

WHT/RED

BLU

VIO

WHT/GRN

WHT/BLU

BLU

GRN/BRN

BLK

ORN/WHT

BLU

ORN/WHT

WHT/BRN

GRA/WHT

WHT/BLU

BLU

BLK

WHT/RED

NO CONNECTION

BLK

MOTOR -

MOTOR +

TIMER IN 1

DIRECTION

B+

B-

TIMER IN 2

TIMER OUT

BLK

GRA/YEL

ORN/RED

RED/GRN

KSI

COIL

M+

FWD

REV

B+

B-

M-

RED/WHT

WHT/ORN

RED/BRN

WHT/YEL

RED/BRN

S13

BLU

RED

YEL/BRN

VIO

WHT/RED

VIO

WHT/RED

VIO

VIO/YEL

M-

B-

B+

ORN/BLU

GRN/WHT

BLK

RED/BRN

BLK

YEL/WHT

BLK

RED/BRN

GRA

S18

GRA

BLU

ORN/BLK

S17

YEL/BLK

BLU/WHT

YEL/BLU

GRA

S16

BRN/WHT

BLK

S15

D11

FORM NO. 56043052 / HYDRO-RETRIEVER™ 2052 / CR 1300 - 81

ELECTRICAL SYSTEM

revised 9/05

FOR HYDRO-RETRIEVER™ 2052 MACHINES AFTER SN 1296729 AND ALL CR 1300 MACHINES

ORN/BLU 36A-B

GRN/WHT 59A-B

RED/BRN 21C-B

GRA/ YEL 84A-B

RED/BRN 21D-B

VIO 7B-A

VIO 7C-A

YEL/BRN 41A-B

WHT/RED 92A-B

WHT/RED 92B-B

YEL/BRN 41A-A

RED/BRN 21C-A

RED/BRN 21B-A

BLK 0B-A

BLK 0U-A

RED/BRN 21D-A

RED/BRN 21E-A

VIO 7C-B VIO 7E-B

WHT/RED 92C-B

WHT/RED 92G-B

WHT/GRN 95A-B

WHT/GRN 95C-B

WHT/BLU 96A-B

WHT/BLU 96C-B

BRN/YEL 14C-A

BLK 0AB-B

WHT/BLU 96A-A

WHT/GRN 95A-A

BRN 1A-B

BLK 0AA-B

BRN 1A-A

WHT/RED 92B-A

BLU 6M-A

WHT/RED 92C-A

RED/GRN 25D-A

VIO 7A-B

VIO 7B-B

RED/GRN 25C-B

RED/GRN 25D-B

BLK 0 V-A

BLU 6T -B

RED/BLK 20C-B

GRA 8 B- A

VIO/ BLK 70E-A

GRN/BRN 51C-B

ORN/WH T 3 9 C-B

WHT/GRN 95C-A

BRN/WHT 19B-A

BLU 6A -B

GRN/BRN 51A-B

RED/BLK 20A-B

VIO/ BLK 70A-B

BRN/YEL 14A-B

BLK 0 C-B

WHT/GRN 95B-B

BRN/WHT 19A-B

ORN/WHT 39A-B

GRA 8 A - B

RED/BLK 20A-A

BLU 6A -A

BLU 6B- A

BLK 0A-A

RED/BRN 21A-A

VIO 7A-A

WHT/RED 92A-A

ORN/RED 32A-A

GRA/YEL 84A-A

RED/GRN 25C-A

VIO/YEL 74A-A

ORN/RED 32A-B

BRN/YEL 14B-A

BLK 0A -B

RED/ BRN 21A-B

BLK 0B- B

RED/ BRN 21B-B

BLU 6D- A

BLU 6C- A

BLK 0 E-B

BLK 0 D-B

YEL/BLU 46A-B

ORN/BLK 30A-B

BLU/WHT 69A-B

BLU 6J-B

BLK 0P-B

YEL/BLK 40A-B

GRN/BRN 51B-B

BLU 6K-B

RED/WHT 29A-B

WHT/YEL 94A-A

WHT/GRA 98A-B

BLU/RED 62B-A

BLU/RED 62C-A

WHT/BLU 96C-A

VIO 7E-A

WHT/VIO 97A-A

WHT/BRN 91B-A

BLK 0AE-A

VIO/BLK 70C-A

BLK 0S-A

GRA/WHT 89B-A

BLK 0J-A

WHT/BRN 91A-A

BLK 0T-A

WHT/VIO 97B-A

ORN/WHT 39C-A

GRN/BLK 50B-A

GRA/WHT 89A-A

BLK 0W-A

WHT/RED 92G-A

WHT/RED 92D-A

GRN/BLK 50A-A

VIO 7D-A

VIO/BLK 70B-A

WHT/BLU 96B-A

ORN/WHT 39B-A

BLU 6L-A

YEL/BLK 40B-A

YEL/BLK 40A-A

BLK 0R-A

ORN/BLK 30B-A

BLK 0AF-A

BLU/WHT 69A-A

WHT/ORN 93A-A

RED/WHT 29B-A

BLU 6R-A

BLU/WHT 69B-A

GRN/BRN 51C-A

YEL/BLU 46B-A

RED/BLK 20B-A

RED/WHT 29A-A

WHT/ORN 93B-A

RED/BLK 20C-A

GRN/BRN 51B-A

BRN/YEL 14D-A

BLK 0X-A

BLK 0P-A

YEL/BLU 46A-A

ORN/BLK 30A-A

BLU 6D- B

BLU 6E-B

BRN/YEL 14A-A

BLK 0 G-B

ORN/WHT 39A-A

BLK 0 G-A

BLK 0 F-B

BLK 0 H-A

BLK 0 E-A

BLU 6F- B

VIO/ BLK 70A-A

BLK 0 F-A

GRN/BRN 51A-A

WHT/GRN 95B-A

-- -

SPLICE 0T-B, 0U-B, 0V-B

SPLICE 40B-B, 40C-B, 40D-B

SPLICE 70C-B, 70D-B, 70E-B

SPLICE 0W-B, 0X-B, 0Y-B, OZ-B

NO CONNECTION

X14

X15

X13 X12

X10

S17

X11

SPLICE OY-A, OAA-A, OAB-A

X8 X7

7470

NO CONNECTION

BLK OC-A

BLK OD-A

RED/BLK 20B-A

BRN/BLK 10 C-B

YEL/ WHT 49A-A

BRN/BLK 10 C-A

WHT/BLK 90D-B

WHT/BLK 90C-A

YEL/ RED 42A-B

YEL/ RED 42B-A

BLU/ BLK 6 0C- B

ORN/GRN 35C-B

YEL/ WHT 49A-B

ORN/GRN 35B- B

YEL/ WHT 49B-B

12345

X16

KSI

COIL

M+

FWD

REV

B+B-M-

BLK OJ-A

BLK OP-A

BLK OR-A

BLK OS-A

BLK OL-A

BLK OAJ-A

BRN/BLK 10 B-A

NO CONNECTION

SPLICE: 6 M-B, 6R-B, 6T-A

SPLICE: 14B-B, 14C-B, 14D-B

NO CONNECTION

BLU/ BLK 6 0B- B

SPLICE: OZ-A, OAL -B, OAK- A, OAP- B

8B-B

SPLICE

8D-B

8C-B

B-

M-

B+

GRN/ WHT 59A-A

VIO/YEL 74A-B

ORN/BLU 36A-A

BRN/WHT 19A-A

BLK OH-B

WHT 9B-A

WHT 9A-B

BLU/ RED 62E-B

BLU/ RED 62D-B

(B) SPLICE: 8B-B, 8C-B, 8D-B

BLU 6U- B

BLU 6C- B

ORN/GRN35D-A

GRN N OT USED

RED

ORN

WHT

BLK

YEL/ RED 42A-A

YEL

231

RED/BLK 20B-B

WHT

BLK

BLK OM-A

BLK OQ-A

SPLICE 92D-B,92E-B,92F-B

SPLICE: 90B-B, 9 0C-B, 90 E-B

D10

YEL/RED 42D-B

GRN 5A-B

BLK/WHT 09B-A

WHT/VIO 97A-B

BLK/WHT 09A-A

BLK/WHT 09C-A

ORN/GRN 35A-A

BLK ON-A

WHT/BLK 90A-A

GRA/RED 82A-A

BLK OM-B

BLU/BLK 60A-A

YEL/RED 42C-A

BLU/RED 62A-B

BLU/RED 62B-B

BLK OP-A

X18

X19

TIMER OUT

MOTOR-

MOTOR+

TIMER IN 2

B-

DIRECTION

B+

TIMER IN 1

WHT/GRA 98B-B

NO CONNECTION

RED 2D-A

RED 2A-A

RED 2B-A

RED 2C-A

SPLICE: 6 G-A, 6H-A, 6I-A, 6 J-A, 6K-A

YEL/WHT 49C-A

YEL/WHT 49E-A

BLU 6H-B

BLK OJ-B

GRN/BLK 50A-B

VIO/BLK 70B-B

BLU/RED 62A-A

WHT/GRA 98A-A

WHT/RED 92F-A

VIO 7D-B

BLU 6I-B

BLK OL-B

GRA/WHT 89A-B

WHT/BRN 91A-B

WHT/BLU 96B-B

ORN/WHT 39B-B

WHT/RED 92E-A

YEL/WHT 49E-B

BLK OAJ-B

RED/GRN 25A-B

ORN/RED 32A-A

BLK/WHT 09A-B

49D-B YEL/WHT 49D-A

BLK OQ-B

BLU/YEL 64A-A

GRN/GRA 58A-B

BLK/WHT 09B-B

X17

BLU/RED 62C-BBLU/RED 62D-A

WHT/GRA 98C-A

WHT/GRA 98B-A

WHT/BLK 90B-A

ORN/GRN 35A-B

BLU/BLK 60A-B

GRA/RED 82A-B

BRN/BLK 10B-B

BRN/BLK 10A-B

YEL/RED 42B-B YEL/RED 42C-B

BLU/BLK 60B-A

ORN/GRN 35B-A

GRA/RED 82B-A

WHT/BLK 90A-B

GRN/GRA 58B-B

GRN/GRA 58A-A

BLU/YEL 64B-B BLU/YEL 64A-B

ORN/RED 32B-B

ORN/RED 32A-B

BLK/WHT 09D-B

BLK/WHT 09C-B

RED/GRN 25A-ARED/GRN 25B-B

YEL/WHT 49B-A

YEL/WHT 49C-B

BLU 6P-B

GRA 8 A - A

BLU 6F- A

BLU/ BLK 6 0C- A

WHT/BLK 90D-A

ORN/GRN35D-B

ORN/GRN 35C-A

BLU 6E-A

WHT 9A-A

BLU/ RED 62E-A

S18

TIMER OUT

MOTOR-

MOTOR+

TIMER IN 2

B-

DIRECTION

B+

TIMER IN 1

TIMER OUT

MOTOR-

MOTOR+

TIMER IN 2

B-

DIRECTION

B+

TIMER IN 1

TIMER OUT

MOTOR-

MOTOR+

TIMER IN 2

B-

DIRECTION

B+

TIMER IN 1

ORN/BLK 30B-B

GRA 8D-A

YEL/BLK 40D-A

WHT/GRA 98C-B

WHT 9B-B

BLK 0AP-A

BLU/WHT 69B-B

BLK 0AF-B

RED/WHT 29B-B

RED/BRN 21E-B

WHT/ORN 93B-B

S13

S14

BLK 0AL-A

BLK/WHT 09D-A

S19

S11

S10

S16

S15

ORN/RED 32B-A

RED/GRN 25B-A

BLU/YEL 64B-A

GRN/GRA 58B-A

RED

BLK

RED

BLK

GRA/WHT 89B-B

WHT/BRN 91B-B

WHT/VIO 97B-B

BLK 0AE-B

BLU6P-A

BLK 0AK-B

WHT/BLK 90F-B

GRN/BLK 50B-B

VIO/BLK 70D-A

GRA/RED 82B-B

GRA/RED 82C-B

WHT/BLK 90E-A

WHT/BLK 90F-A

GRA/RED 82C-A

RED/BRN 21F-B

RED/BRN 21F-A

RED/BRN 21G-A

RED/BRN 21G-B

YEL/RED 42D-A

D10

YEL/BLK 40C-A

YEL/BLU 46B-B

BRN/WHT 19B-B

GRA 8C-A

GRN 5A-A

RED 2B-B

WHT/YEL 94A-B

RED 2C-B

RED/BLK 20B-B

RED 2A-B

WHT/ORN 93A-B

BLU 6G-B

BLU 6L-B

BRN/BLK 10A-A

RED 2D-B

BT1

NO CONNECTION

D11

42E-A 42E-B

BLK ON-B

Austria (Sales Sub)

Nilﬁ sk-Advance GmbH Phone: +43 Voralberger Allee 46 1616 58 30 22 A-1230 Wien Fax: +43 info@nilﬁ sk-advance.at 1616 58 30 40 www.nilﬁ sk-advance.at

Belgium (Sales Sub)

Nilﬁ sk-Advance NV/SA Phone: +32 Doornveld Sphere Business Park (0)2467 60 50 Industrie Asse 3, No. 11 Fax: +32 B-1731 Zellik-Asse (0)2463 44 16 www.nilﬁ sk-advance.be

Czech Republic (Sales Sub)

Nilﬁ sk-Advance s.r.o. Phone: +420 Lysinská 44/1863 2 44 09 09 12 143 00 Praha - Modrany +420 Czech Republic 2 44 09 09 21 4

Fax: +420 2 44 40 23 93

Denmark

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

Denmark (Prod. Sub)

Gerni A/S Phone: +45 Myntevej 2 89 12 22 00 DK-8900 Randers Fax: +45 www.gerni.com 86 43 14 81

Denmark (Sales Sub)

Nilﬁ sk-Advance Nordic A/S Phone: +45 Sognevej 25A 43 23 40 50 Postbox 344 Fax: +45 DK-2605 Brøndby 43 23 40 60 kundeservice@nilﬁ sk-advance.dk www.nilﬁ sk-advance.dk

France (Sales Sub)

Nilﬁ sk-Advance S.A. Phone: +33 27 avenue de la Baltique 1695 98 700 Villebon sur Yvette Fax: +33 P.B. 246 1695 98 701 F-91944 Courtaboeuf Cedex info@nilﬁ sk-advance.fr www.nilﬁ sk-advance.fr

Germany (Sales Sub)

Nilﬁ sk-Advance AG Phone: +49 Siemensstrasse 25-27 4101 3990 Postfach 1361 Fax: +49 D-25462 Rellingen 4101 39 91 91 info@nilﬁ sk-advancede www.nilﬁ sk-advance.de

Greece (Sales Sub)

Nilﬁ sk-Advance A.E. Tel.: +30 8, Thoukididou Str. 210 963 3443 Argioupoli Fax: +30 Gr - 164 52 Athens 210 965 0975 Greece

Holland (Sales Sub)

Nilﬁ sk-Advance B.V. Phone: +31 Camerastraat 9 (2e verdieping) 36 546 07 00 1322 BB Almere Fax: +31 Postbus 60112 36 523 51 48 1320 AC Almere www.nilﬁ sk-advance.nl

Ireland (Sales Sub)

Nilﬁ sk-Advance Limited Phone: +35 28 Sandyford Ofﬁ ce Park 3 12 94 38 38 Sandyford, Dublin 18 Fax: +35 Ireland 3 12 94 38 45

Italy (Prod & Sales Sub)

CFM SpA Phone: +39 Nilﬁ sk-Advance Div. Guardamiglio 0377 /414021 Localita Novella III /45 1124 I-26862 Guardamiglio (Mi) Fax: +39

0377 51 443

Italy (Prod & Sales Sub)

CFM S.p.A. Phone: +39 Via Porrettana 1991 059 973 0000 I-41059 Zocca (Modena) Fax: +39 cfm@cfm.it 059 973 0099

Norway (Sales Sub)

Nilﬁ sk-Advance AS Phone: +47 Ulvenveien 89C 23 06 75 00 N-0581 Oslo Fax: +47

23 06 75 01

Poland (Sales Sub)

Nilﬁ sk-Advance Sp.Z.O.O. Phone: +48 05-800 Pruszków 22 738 37 50 ul. 3-go MAJA 8 Fax: +48 Poland 22 738 37 51

Portugal (Sales Sub)

Nilﬁ sk-Advance, Lda. Phone: +35 Sintra Business Park 121 911 2670 Zona Industrial Da Abrunheira Fax: +35 Ediﬁ cio 1, 1o A 121 911 2679 P-2710-089 Sintra

Russia (Sales Sub)

Nilﬁ sk-Advance LLC Phone: 7 Vyatskaya str. 27, bld. 7 095 783 9602 127015 Moscow Fax: +7 Russia 095 783 9603

Spain (Sales Sub)

Nilﬁ sk-Advance S.A. Phone: +34 Torre D’Ara 93 741 2400 Passeig del Rengle, 5 Pl.10 Fax: +34 E-08302 Mataró (Barcelona) 93 757 8020 nilﬁ sk@nilﬁ sk-advance.es

Sweden (Sales Sub)

Nilﬁ sk -Advance A/S Phone: +46 Sjöbjörnsvägen 5 8555 94400 Box 44045 Fax: +46 S-100 73 Stockholm 8555 94430 info@nilﬁ sk-advance.se www.nilﬁ sk-advance.se

Sweden (Prod.)

Nilﬁ sk-Advance A/S Phone: +46 Åmål Branch 5321 7500 Strömsbergsgatan Fax: +46 Box 127 5321 7595 S-662 23 Åmål

Switzerland (Sales Sub)

Nilﬁ sk-Advance AG Phone: +41 Ringsstrasse 19 71 92 38 444 Kirchberg/Industrie Stelzl Fax: +41 CH-9500 Wil 71 92 35 283 www.nilﬁ sk-advance.ch

UK (Sales Sub)

Nilﬁ sk-Advance Limited Phone: +44 Newmarket Road 1284 763163 Bury St. Edmunds Fax: +44 UK-Suffolk IP33 3SR 1284 750 562

USA (Prod.)

Nilﬁ sk-Advance Inc. Phone: +1 763 14600 21.st Avenue North 745 3500 Plymouth, MN 55447-3408 Fax: +1 763 www.mn.nilﬁ sk-advance.com 745 3718

USA (Sales Sub)

Nilﬁ sk-Advance America Inc. Phone: +1 610 300 Technology Drive 647 6420 Malvern, PA 19355 Fax: +1 610 www.pa.nilﬁ sk-advance.com 647 6427

Canada (Sales Sub)

Nilﬁ sk-Advance Canada Comp. Phone: + 1 905 396 Watline Avenue 712 3260 Mississauga, Ontario L4Z 1X2 Fax: +1 905

712 3255

Australia (Sales Sub)

Nilﬁ sk-Advance Pty. Ltd. Phone: +61(0)2 48 Egerton Street 9648 2700 Silverwater, NSW 2128 Fax: +61(0)2 Postal addresse: 9648 2711 PO Box 6046 Silverwater. NSW 1811 info@nilﬁ sk-advance.com.au www.nilﬁ sk-advance.com.au

China (Shenzhen)

Nilﬁ sk-Advance (Shenzhen) Ltd Phone: +86 755 Blok 3, Unit 130, 1001 Honghua Road 8359 7937 el. Int. Commercial & Trade Center 8359 7939-42 Fuitian Free Trade Zone Fax: +86 755 518038 Shenzhen 8359 1063 P.R. China

China (Suzhou)

Nilﬁ sk-Advance Professional Phone: +86 512 Cleaning Equipment (Suzhou) Co. Ltd. 8918 5656 306 Su Hong Zhong Road, Build. 2 Fax: +86 512 Suzhou Industrial Park 8918 5666 215021 Suzhou P.R. China

Hong Kong (Sales Sub)

Nilﬁ sk-Advance Ltd. Phone: +852 2001 HK Worsted Mills Ind’l Bldg., 2427 5951 31-39 Wo Tong Tsui St. Fax: +852 Kwai Chung, Hong Kong 2487 5828

Japan (Sales Sub)

Nilﬁ sk-Advance Inc. Phone: +8145 3-17-40-101 Chigasaki Higashi 942 7741 Tsuzuki-ku, Yokohama 224-0033 Fax: +8145 Japan 942 6545

Malaysia (Sales Sub)

Nilﬁ sk-Advance Sdn Bhd Phone: +60 3 No. 21, Jalan SS 25/41 7956 8188 Mayang Industrial Park Fax: +60 3 47301 Petaling Jaya 7966 6828 Selangor, Malaysia

New Zealand (Sales Sub)

Nilﬁ sk-Advance Limited Phone: +64(0)9 Danish House 525 0092 6 Rockridge Avenue Fax: +64(0)9 Penrose 92-829 525 6440 Auckland1135 Postal addresse: Private Bag 92 825 Auckland New Zealand

Singapore (Sales Sub)

Nilﬁ sk-Advance Pte. Ltd. Phone: + 65 22,Woodlands Industrial Park E1 6 7599100 Singapore 757740 Fax: +65 sales@nilﬁ sk-advance.com.sg 7599133

Taiwan, ROC (Sales Sub)

Nilﬁ sk-Advance Ltd. Phone: +886 Taiwan Branch (H.K.) 2 2239 8812 1F, No. 193, Sec.2 Fax: +886 Xing Long Rd., Taipei 2 2239 8832 Taiwan, R.O.C.

Thailand (Sales Sub)

Nilﬁ sk-Advance Co. Ltd. Phone: +66 2 89 Soi Chokechai-Ruammitr 275-5630 Viphavadee-Rangsit Road Fax: +66 2 Ladyao, Jatuchak, Bangkok 10900 691-4079 Thailand

Nilfisk-Advance HYDRO-RETRIEVER 2052, 56459504 battery, CR 1300, 56459994 battery-Hydro-MaxTM II, 56459505 battery-Hydro-MaxTM II Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual