Nilfisk-Advance 56459994 battery-Hydro-MaxTM II User manual

8/99 revised 9/05 Form Number 56043052

Hydro-Retriever™ 2052

CR 1300

SERVICE MANUAL

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

1Battery Compartment / Recovery Tank Cover

2Strobe Light

3Left Rear Access Door (Solution Tank Drain inside door)

4Battery

5Solution Tank Fill

6Circuit Breaker Access Cover

7Headlights

8Scrub Brushes

9Solution 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

123

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 hout 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

1Move the machine to a designated waste water “Disposal Site”.

2Empty 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).

3Empty 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.

4Empty 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:

1The universal joint steering shaft fitting (access by removing the front fascia panel).

2The two steering chain sprockets fittings (access by removing recovery tank and sprocket plate).

3The main steering spindle fitting (access by removing recovery tank and sprocket plate).

4The 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 . . .

1Turn 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.

2Remove the (2) lower corner panels from front of the machine.

3See 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

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.

1Make 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.

2Open 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.

3Lift the battery compartment cover straight up and remove it completely from the machine.

4Remove the right side battery compartment support to allow for the necessary clearance for lowering the battery into position.

5Lay 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.

6See 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.

7See 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 -

Direction - 36V

Timer Out

Timer In 1

Timer In 2

S4

K9 S7 E1

S10 S11 M3

_

+

M

B+

B-

Mot or -

Mot or +

Direction - 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 or+

Mot or-

Direction

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-

Motor+

Motor-

Direction

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

Motor Sol enoid

+

To K5 Brush

Motor Solenoid

To L1 Solution

Solenoid

BLU/RED

BLU

BLK

1

1K9 IS SHOWN IN THE DE-ENERGIZED STATE

P2

RED

ORN

BLK

F5 S13

BLU WHT/ ORN

RED/BRN

+

V

M

B+

B-

Motor+

Motor-

Direction

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

Motor Solenoid

+

To K5 Brush

Motor Solenoid

To L1 Solution

Solenoid

BLU/RED

BLU

BLK

1

1K9 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

No

Yes

No

Yes

No

Yes

TROUBLESHOOTING GUIDE

Possible Symptoms

1Brush / Brush Lift / Broom / Solution; do not work

2Scrub brushes do not turn

3Scrub brushes do not lower

4Scrub 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.

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