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
19
20
1
2
3
4
5
6
7
21
9
8
9
10
11
12
13
14
15
16
21
17
18
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
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
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
A
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
B
B
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
+
M
B+
B-
Mot or +
Mot or -
Di rec ti on - 36V
Timer Out
Timer In 1
Timer In 2
S4
K9
S7
E1
S10 S11
M3
_
+
M
B+
B-
Mot or -
Mot or +
Di rec ti on - 0V
Timer Out
Timer In 1
Timer In 2
S4
K9
S7
E1
S10 S11
M3
_
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
+
M
B+
B-
Mot o r+
Mot o r-
Di rec ti on
Timer Out
Timer In 1
Timer In 2
S4
K9
S7
E1
S10 S11
M3
_
L1
K5
+
S3
S1
S19
D5
M
M4
S13
Seat Switch
To
K8
36
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
+
V
M
B+
B-
Mot or +
Mot or -
Di rect i on
Timer Out
Timer In 1
Timer In 2
12
34
S4
K8
D9
K9
BA
K9
S7
E1
S10 S11
M3
F8
F4
_
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
1
1
K9 IS SHOWN IN THE DE-ENERGIZED STATE
P2
RED
ORN
BLK
BLK
F5
S13
BLU
WHT/ O RN
RED/B RN
RED/B RN
+
V
M
B+
B-
Mot or +
Mot or -
Di rec ti on
Timer Out
Timer In 1
Timer In 2
12
34
S4
K8
D9
K9
BA
K9
S7
E1
S10 S11
M3
F8
F4
_
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
1
1
K9 IS SHOWN IN THE DE-ENERGIZED STATE
P2
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
No
Yes
Yes
No
No
Yes
No
Yes
No
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
No
Yes
No
Yes
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.
No
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
No
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
No
Replace the S7
brush switch
Yes
No
No
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
No
Yes
Check Seat Switch
and wiring repair
or replace.
No
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
No
Yes
No
No
Yes
No
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)
No
Yes
Yes
No
No
Yes
No
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
I
G
H
J
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
K
N
L
K
M
O
P
FRONT
X
Q
Q
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