Nilfisk-Advance Hydro-Retriever 2052 Page 80 Service Manual Download

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ELECTRICAL SYSTEM

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

revised 9/05

Speed Controller

Suppression Diode

Blocking Diode

Suppression Diode

Blocking Diode

Suppression Diode

D10

Suppression Diode

Brush Lift Actuator Control Module

Squeegee Lift Actuator Control Module

Forward / Reverse Interlock

Left Side Skirt Lift Actuator Control Module

Right Side Skirt Lift Actuator Control Module

Brush Motor Circuit Breaker (80A)

Vacuum Motor Circuit Breaker (40A)

Broom Motor Circuit Breaker (40A)

Auxilliary Circuit 1 Circuit Breaker (15A)

Drive Control Circuit Circuit Breaker (5A)

Wheel Drive Motor Fuse (200A)

Auxilliary Circuit 2 Circuit Breaker (10A)

Fuse (1.5A)

Recovery Tank Full Light

Detergent Tank Empty Light (Hydro-Max II)

Strobe Light

Left Headlight

Right Headlight

Horn

Main Contactor

Forward Direction Contactor

Reverse Direction Contactor

Recycle Pump Relay (Hydro-Max II)

Brush Motor Contactor

Broom Motor Contactor

Vacuum Motor Contactor

Low Voltage Cut-Out Module

Low Voltage Cut-Out Relay

Item

Description

SCHEMATIC / WIRING DIAGRAM FOR HYDRO-RETRIEVER

™

2052

MACHINES BUILT BEFORE SN 1296730

Item

Description

Solution Solenoid

Broom Motor

Recycle Pump Motor (Hydro-Max II)

Brush Lift Actuator

Brush Motor

Squeegee Lift Actuator

Vacuum Motor

Wheel Drive Motor

Left Side Skirt Lift Actuator

Right Side Skirt Lift Actuator

Hourmeter

Fuel Gauge, Battery

Resistor 250 Ohm, 5 Watt

Throttle Potentiometer 10K Ohm

Reverse Throttle Switch

Reverse Squeegee Lift Switch

Forward Throttle Switch

Key Switch

Headlight Switch

Vacuum / Squeegee Switch

Brush Switch

Recycle Pump Switch (Hydro-Max II)

Horn Switch

S10

Brush Lift UP Limit Switch

S11

Brush Lift DOWN Limit Switch

S12

Vacuum Pressure Switch

S13

Seat Switch

S14

Broom Switch

S15

Detergent Tank Float Switch (Hydro-Max II)

S16

Solution Tank Float Switch (Hydro-Max II)

S17

Recovery Tank Start Float Switch (Hydro-Max II)

S18

Recovery Tank Stop Float Switch (Hydro-Max II)

S19

Solution Switch

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

™

2052 machines

after SN 1295923, and all CR 1300 machines.

RED

BLU

RED/BLK

RED

BRN/BLK

BT1

WHT

BLK

GRN WIRE NOT USED

RED
ORN

YEL

YEL/RED

BLK

BLK
BLK

BLK

BRN

YEL/RED

BRN/YEL

BLU

WHT/VIO

S14

BLK/WHT

YEL/RED

ORN

GRN

S12

RED

BLU

YEL/WHT

RED/GRN

ORN/RED

BLK/WHT

MOTOR -

MOTOR +

TIMER IN 1

DIRECTION

B+
B-

TIMER IN 2

TIMER OUT

BLK/WHT

BLU/YEL

GRN/GRY

MOTOR -

MOTOR +

TIMER IN 1

DIRECTION

B+
B-

TIMER IN 2

TIMER OUT

BRN/WHT

BLK

S15

YEL/BLU

GRA

S16

ORN/BLK

YEL/BLK

BLU/WHT

YEL/BLU

BLK

S17

GRA

S18

GRA

BLK

ORN/GRN

BLU

BLU/RED

1
4

3
6

GRA/RED

WHT/BLK

BLK
ORN/GRN

BLU/BLK

WHT/BLK

VIO/BLK

BLU

WHT/BLK

S10

S11

GRN/BLK

WHT/GRA

WHT/RED

VIO/BLK

BLU/RED

BLK

BLU

MOTOR -

MOTOR +

TIMER IN 1

DIRECTION

B+

B-

TIMER IN 2

TIMER OUT

VIO

WHT/GRA

WHT

BLU/RED

S19

WHT/RED

BLU

VIO

WHT/GRN

WHT/BLU

BLU

GRN/BRN

BLK

ORN/WHT

BLU

ORN/WHT

WHT/BRN

GRA/WHT

WHT/BLU

BLU

BLK

WHT/RED

NO CONNECTION

BLK

MOTOR -

MOTOR +

TIMER IN 1

DIRECTION

B+

B-

TIMER IN 2

TIMER OUT

BLK

GRA/YEL

ORN/RED

RED/GRN

KSI COIL M+

FWD REV B+ B-

M-

RED/WHT

WHT/ORN

RED/BRN

WHT/YEL

RED/BRN

S13

BLU

RED

YEL/BRN

VIO

WHT/RED

VIO

WHT/RED

VIO

VIO/YEL

M-

B-

B+

ORN/BLU

GRN/WHT

BLK

RED/BRN

BLK

YEL/WHT

BLK

Summary of Contents for Hydro-Retriever 2052

Page 1: ...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 ...

Page 2: ...JUSTMENT 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 BRO...

Page 3: ... 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 SPE...

Page 4: ... 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 Donotdispenseflammablecleaningagents operatethemachineonorneartheseagents oroperateinareaswhereflammable liquids exist Do not clean this machine with a pressure washer CAUTION This machine is not appro...

Page 5: ...epair 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 Beforedrivingthemachineuparampandontoatruckortrailer removethesqueegeetoolandthebrushesfromthemachinetoavoid damage CAUTION Before transportin...

Page 6: ...rushes 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 revise...

Page 7: ...e 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 ...

Page 8: ...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 ...

Page 9: ...FORM NO 56043052 HYDRO RETRIEVER 2052 CR 1300 7 KNOW YOUR MACHINE revised 3 00 56in 142cm Without overheadguard 79in 200cm Withoverheadguard 89in 226cm 54 5in 138cm FRONTVIEW SIDEVIEW ...

Page 10: ...e 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...

Page 11: ...ded 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 ...

Page 12: ...ses 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...

Page 13: ...e 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 ac...

Page 14: ...s 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 ...

Page 15: ... 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...

Page 16: ...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 batte...

Page 17: ...the scrub brushes BRUSH LIFT ACTUATOR MOTOR FUNCTION Thebrushdrivegearcaseassembly includingthesideskirts areraisedandloweredbytheelectricactuator lift motor M3 Seefigure1 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 act...

Page 18: ... 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 motorandsolutionvalvewillturnoffautomaticallyandceasetofunctionwhenthebatteriesreachan80 depthofdischarge Themachine sdash mounted ba...

Page 19: ...RED BLU BLK 1 1 K9ISSHOWNINTHEDE ENERGIZEDSTATE 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 ...

Page 20: ...ltage 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 ...

Page 21: ...OTING 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 ...

Page 22: ... 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 t...

Page 23: ...wer 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 wir...

Page 24: ... 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 ...

Page 25: ...ct 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...

Page 26: ...der 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 ...

Page 27: ...e 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...

Page 28: ...sembly to the floor and turn the engine off 3 See Figure 8 Loosen the 4 Bolts R on each skirt bracket Position the skirt bracket so that the edge of the rubber skirt S just touches the floor 4 Lower just the rear end of the skirt bracket an additional 1 4 inch 6 mm 5 Tighten the 4 Bolts R on each skirt bracket 6 Operate the machine in forward and reverse to test the wiping action of the skirts The...

Page 29: ... right sides are raised and lowered by two separate electrical lift actuator motors M8 M9 To activate the side skirts lower them to the floor the broom lever must be lowered to close the S14 broom switch This negative voltage signal is the input for both the E4 E5 lift actuator modules to function This negative 36V at both the direction terminals closes an internal relay that directs the output vo...

Page 30: ... the parking brake set Part A Sweeping Broom Motor Load Circuit Troubleshooting Guide revised 3 00 Broom motor does not run see Fig 1 Check continuity on the F3 40A broom motor circuit breaker Reset or replace the F3 40A broom motor circuit breaker At the K6 broom motor solenoid Check for 36V at the wht vio wire to negative battery standoff Check for 36V at the M1 broom motor See part B sweeping b...

Page 31: ...h the master key switch ON seat switch closed broom lever in the ON position and the parking brake set Part B Sweeping Broom Control Circuit Troubleshooting Guide FIGURE 1 Sweeping broom motor does not run see Fig 1 Check for 36V at the K6 solenoid field coil wires yel red blk wht Check for 36V at the blk wht wire on the K6 sole noid to a positive battery standoff Check continu ity on the S14 broo...

Page 32: ...doff Should read negative 36V Check for 36V at the side skirt motors M8 M9 See symptom 1 broom motor does not run Check continuity of the side skirt lift motor s inter nal limit switch es and diodes Replace the defective side skirt lift motor M8 or M9 Repair or replace switch components as needed Check for 36V at the controllers E4 E5 power outputs M M Repair or replace the wiring from the S14 bro...

Page 33: ...motors M8 M9 Check continuity of the side skirt lift motors inter nal limit switch es and diodes Replace the defective side skirt lift motor M8 or M9 Repair or replace switch components as needed Check for 36V at the controllers E4 E5 power outputs M M Check for 36V at the controllers E4 E5 power inputs B B Repair controllers input power wires yel wht blk Replace the E4 or E5 controller card Repai...

Page 34: ...ays check the length of the sweeping broom bristles Replace the broom if the bristle length is 1 3 4 inches 44 mm or less To adjust the sweeping broom 1 Drive the machine to an area with a level dry floor and apply the parking brake 2 Lower the broom lever to start and place the broom lever in the sweep position Do not move the machine Let the broom run for about 1 minute This allows the broom to ...

Page 35: ...room to polish a strip on the floor 3 After 1 minute release the parking brake and move the machine out of the way so that the polished strip is visible 4 If the strip is tapered loosen the 2 Bolts C see Figure 4 5 Use adjustment Bolts D to lower the right end of the broom if the right end of the strip is too narrow or to raise the broom if the right end of the strip is too wide The heads of both ...

Page 36: ...eofthemachine 3 See Figure 5 Remove the belt tension Spring E 4 Remove the cotter pin that holds the broom Lift Cable F onto the drive hub arm 5 Remove the 2 G Bolts that hold the drive hub arm in place 6 Beingcarefulnottodamagethebelt slidethedrivehub assembly out of the broom housing To replace the bearings in either hub 1 Place the hub assembly in a vise as shown in Figure 6 2 Remove Nut N and ...

Page 37: ...uctions 10 TurnthekeyswitchonandmovethesqueegeeswitchtotheONpositiontolowerthesqueegeetooltothefloor Turnkeyoffanddisconnect the battery connector plug assembly 11 See Figure 8 Remove the rear retaining Ring O Pin P and separate the squeegee lift motor at its mounting bracket Q Then swing the lift motor forward to gain access to the broom motor wiring and remove both wires Note The wht vio motor w...

Page 38: ... Bolts K evenly clockwise so there is a 1to1 1 4 inch 25 to 30 mm space at the idler pulley as shown in figure 5 3 Test the broom motor for proper operation BROOM SIDE SKIRT LIFT MOTOR REMOVAL 1 Turn the key switch on and put the broom raise lower lever in the on down position to lower the side skirts Then turn the key switch off and disconnect the battery connector 2 Remove the squeegee tool from...

Page 39: ...embly from under the machine 2 Remove all of the Screws CC and remove the old skirt from the angle and strap 3 Install all of the Screws CC in the new strap skirt and angle The top edge of the skirt should be up against the angle as shown in Figure 11 4 Mounttheskirtassemblyonthefrontofthebroomhousingandcheckthedistancebetweenthebottomoftheskirtandthefloor Ifnecessary re position the skirt so that...

Page 40: ...st stand straight up Then turn the key switch off 3 Per each side loosen the Lock Nuts FF and turn the 2 stop Bolts GG so there is 3 16 to 1 4 inch 5 to 6 mm clearance between the head of the bolt and the stop plate 4 The clearance dimension shown is only a starting point Make needed adjustments to keep an even fold over and prevent any water from passing underneath the blades 5 To adjust the skir...

Page 41: ...njunctionwiththedrivepedalswitchthatcontrolsthetimerinputtotheE1controllerthatenergizethe L1 solution solenoidvalve Thesolutionwillflowtothescrubbrushesanytimethedrivepedalisdepressed FWD REV Note Whenthesolutionon offswitch S19 is turned off no flow can occur regardless of the other valves being on or the drive pedal position Explanation of the Solenoid Valve Function See Figure 1 To energize the...

Page 42: ...DE Problem Possible Cause Inadequate or no solution flow No solution in the tank Main solution flow control valve lever is in the off position The 2 final output flow control valves are in the off position Clogged solution filter valves and hoses Defective solution solenoid valve L1 Defective control panel solution switch S19 See Solenoid Troubleshooting flow chart for electrical system diagnostic...

Page 43: ...t gry Test for 36V Test theresistanceof theL1solenoidcoil If it readsinfinitycoil is openor if it reads75 ohmsor lessit isshort ed agoodcoil should read84ohms Replace the solenoid coil if testing shows it shorted or open Check for 36V neg from the wht gry L1 har ness feed wire to a positive battery standoff Check for 36V pos from the wht L1 harness feed wire to a negative battery standoff Replace ...

Page 44: ...he remove from the barbed elbow Fitting D It may be necessary to remove the lower left front corner panel which retains the bumper roller weldment from the machine 7 screws Back probe the end of the hose with a screwdriver and apply a small amount of a spray lubricant at the elbow hose fitting and pull firmly to remove 6 See Figure 4 Remove the cover from the left electrical panel 12 screws Then r...

Page 45: ...liseasilyremoved by unthreading it from the valve housing and the valve housing top cover is held together with 4 hex HD screws MAIN SOLUTION CONTROL VALVE REPLACEMENT 1 Drain the solution tank then remove the scrub brushes and lower the brush drive assembly to the floor Next turn the master key switch off and disconnect the battery connector 2 See Figure 3 Loosen the hose clamps and remove the 2 ...

Page 46: ...hrough the vacuum motor just clean air The vacuum system uses a shutoff float to prevent the tank from being overfilled and stops any water from being sucked into the vacuum motor Vacuum Motor Function See Figure 2 To energize the K7 vacuum motor solenoid under normal operations the vacuum squeegee switch S6 must first be turned on squeegee lowered With the machine s drive pedal depressed Fwd the ...

Page 47: ...tank bottom are sealing and not damaged Inspect and clean the vacuum motor filter Make sure that the recovery tank drain valve seals airtight TROUBLESHOOTING GUIDE Ifwaterflowsaroundtheendsofthesqueegeetool insteadofbeingpulledintothetool thevacuumsystemisnotworkingproperly Whenavacuum system performs poorly it is usually because of one of the following problems Vacuum Leak s Air flowing into the ...

Page 48: ...et Part A Vacuum Motor Load Circuit Troubleshooting Guide revised 3 00 No No Yes Yes Yes Check continuity on the F2 40A vac motor circuit breaker Check for 36V at the red wht wire output terminal on the K7 vac motor solenoid to a Neg battery standoff Vacuum motor will not run see Figure 2 Reset or replace the F2 40A vac motor circuit breaker See part B vac motor control circuit trouble shooting gu...

Page 49: ...e K7 vac motor solenoid field coil wires blue grn brn Replace the K7 vac motor solenoid Check for 36V at the Pos K7 sole noid blue coil wire to a Neg battery standoff Check for 36v at the Neg K7 sole noid coil wire grn brn to a Pos battery standoff Repair or replace wiring back to the S4 key switch Check for 36V at the S6 vac switch orn wht wire to a Pos battery standoff Check for 36v Pos at the t...

Page 50: ...ts light debris and dust from entering the vacuum motor The filter should be serviced by the machine operator each time that the machine is used For access to the vacuum filter open the right rear access door The filter box is located just below the battery To service the filter 1 See Figure 4 Turn Latch C open Door D and pull the filter out of the filter box 2 Wash the filter in warm water and le...

Page 51: ...emove the tank clean out plug and scoop andflushallthesolidsedimentdebristhrough the clean out opening Note Cleaning tank will reduce the weight for easier removal and installation 3 See Figure 5 Remove the 4 hex HD Screws E 2 tank Retainers F and 4 Nyl Loc hex Nuts G as shown Note Collectthe 8 Shims H 4perside thatwill fall away when the tank hardware is re moved 4 With the assistance of a helper...

Page 52: ...r The negative 36V at the direction terminal energizes the internal relay built into the module and directs the correct output voltage polarity to run the M5 squeegee lift motor The lift actuator motor uses two internal limit switches to open the motor circuit and stop the motor s travel for both raising and lowering functions To raise the squeegee tool the drive pedal must be placed in reverse an...

Page 53: ...or wiring connector On the E2 controller check for 36V at the wht blu direction input terminal to a Pos battery standoff Replace the E2 controller module On the S6 switch check for 36V at the wht grn wire to a Pos battery standoff Replace the S6 vac squeegee lift switch On the S2 switch check for 36V at the wht blu wire to a Pos battery standoff Replace the S2 reverse squeegee lift switch Yes No Y...

Page 54: ... is Check for 36V at the M5 actuator motor wiring har ness connector gry wht wht brn Inside the M5 motor check conti nuity on the inter nal limit switches diodes Replace the defective M5 squeegee lift motor Repair or replace the motor switch componets as needed Repair the M5 motor wiring connector Check for zero volts at the wht blu direc tion input wire to a Pos bat tery standoff Replace the E2 c...

Page 55: ... No Yes Squeegee tool will not raise when in reverse Verify that the squeegee tool will raise with the vac squeegee lift switch S6 in the OFF position Check for the proper operation continuity of the S2 reverse lift switch It should be open with the drive pedal in reverse See symptom 2 squeegee will not raise when the S6 dash switch is in the OFF position Replace the S2 reverse squeegee lift switc...

Page 56: ... entire length of the wiping blade should be flat against the floor If the blade is high in the middle turn the screws clockwise If the blade is high on the ends turn the screws counter clockwise Make small adjustments 2 turns or less at each screw to avoid bend ing the squeegee mount 3 Drive the machine forward to bend over the squeegee blades into their operating position and look at the squeege...

Page 57: ...so the sharp edge that used to face the back of the machine is facing forward To replace the squeegee blades 1 Remove the squeegee from the machine remove the front strap and the front blade from the squeegee 2 Remove the wing nuts at the ends of the rear straps release the latch at the center of the straps and remove the wiping blade and the back up blade 3 Clean the squeegee thoroughly and insta...

Page 58: ...rews E to setthesqueegeeangle Theentirelength of the wiping blade should be flat against thefloor Ifthebladeishighinthemiddle turn the screws clockwise If the blade is highontheends turnthescrewscounter clockwise Make small adjustments 2 turns or less at each screw to avoid bending the squeegee mount 3 Drive the machine forward to bend over the squeegee blades into their operating position and loo...

Page 59: ...front edge wears to a radius When this happens the blade can be removed from the squeegee and turned around so that a sharp edge is facing forward The wiping blade has four usable edges To replace the squeegee blades 1 Remove the squeegee from the machine remove the front strap and the front blade from the squeegee 2 Remove the wing nuts at the ends of the rear straps release the latch at the cent...

Page 60: ...e the 2 Screws E 2 Nuts F and drive nut bracket G from the squeegee lift lever arm H 5 Remove one of the retaining rings from the Pin I then pull the pin out of the mount bracket and lift the actuator motor out of the machine Note All new replacement actuator motors are not supplied with the drive nut adjusted for a specific system application Important When installing a new squeegee lift motor or...

Page 61: ...p switch S16 is normally closed should the solution tank become over filled this switch will open and not allow the pump to run ThespecificfunctionaloperationofthemercuryswitchesS17 S18startoutbothopen Thisiscausedbytheswitcharmfloatnotbeingactivated the recovery tank is empty dry With the system prepared for use see Operator Manual to operate the Hydro Max II system the recovery tank is filled wi...

Page 62: ... SYSTEM D FRONT C E B B FromSqueegee ToVacMotor To Pump Drain Drain S17 S18 A RIGHT closed closed Strainer Screen revised 3 00 FRONT Metering Barb FromDetergent Tank IntoSolutionTank Pump M2 Float Switches S17 S18 Detergent Tank S15 S16 FIGURE 1 FIGURE 2 FIGURE 3 ...

Page 63: ...ow mount then soak the barb in hot water to loosen chemical build up For stubborn cleanup soak the barb in a light muriatic acid solution and use a pin to clean hardened chemical from the hole Note use caution when working with acid wear safety glasses and gloves 2 Clean the detergent storage tank by flushing the detergent tank with clean water to remove built up debris Service Tip Attach a piece ...

Page 64: ...olt D Counterclockwise to loosen the chain tension This will make the chain loose enough to remove the steering spindle sprocket 5 Remove the Bolt E and its washer from the center of the spindle sprocket Work the Sprocket A up and off the splined spindle 6 Lift the lock tab off the top of the spindle then remove the cotter pin and large spindle nut WARNING Never work under the machine without safe...

Page 65: ...25 4 mm of pedal travel 4 Hold the brake pedal down and check the brake cables for equal tension Re adjust the cables if necessary 5 Test drive the machine in an open area to make sure that the brakes don t pull the machine to the right or left when applied 6 If there is not enough adjustment left in the cables remove the wheels and brake drums and inspect the brake shoes If the lining on the shoe...

Page 66: ...y the drive pedal control the contactors An electronic interlock E3 is used to prevent plugging When the drive pedal is quickly moved from forwardtoreverse themachinecoastsalmosttoacompletestopandthengentlygoesintoreverse Theinterlockworksthesamewayifthepedal is moved from reverse to forward The main contactor K1 brings B voltage to the speed control and the forward reverse contactors The S13 swit...

Page 67: ...FORM NO 56043052 HYDRO RETRIEVER 2052 CR 1300 65 WHEEL DRIVE SYSTEM M _ E3 KSI COIL M M FWD REV B B K2 D2 K3 D3 D4 D8 K2 K3 S3 S1 K1 D1 R1 B B R2 S13 F5 M7 A1 revised 3 00 FIGURE 2 FIGURE 3 ...

Page 68: ...his will prevent injury if the drive motor starts during testing Possible Symptoms 1 No forward or reverse drive 2 No forward drive reverse only 3 No reverse drive forward only Note All references to right and left are as viewed from the operator s seat SYMPTOM ONE NO FORWARD OR REVERSE DRIVE 1 Disconnect the battery connector behind the right rear access door and remove the front access panel See...

Page 69: ...the drive motor runs at full speed in both directions go to step 3 If the drive motor doesn t run in either direction go to step 4 ImportantNote Reconnectwire 41tothe A termi nal after following all steps 3 Turn the key switch OFF See Figure 6 Disconnect the Orange Blue and the Green White wires from the speed control Connect the wires to the leads from an ohmmeter Press the front of the drive ped...

Page 70: ...Turn the key switch ON push down on the operator s seat and press the drive pedal The forward contactor see Figure 7 should engage when the pedal is pushed forward and the reverse contactor should engage when the pedal is pushed in reverse If both contactors engage as described above go to step 7 If the contactors do NOT engage as described above check the forward and reverse switch mechanism see ...

Page 71: ...ive pedal and watch the forward contactor see Figure 8 If the forward contactor engages when the drive pedal is pressed check the contacts in the forward contactor replace the forward reverse contactor assembly if necessary If the forward contactor does NOT engage go to step 2 2 See Figure 8 Disconnect the diode at the end of the Red Green wire and White Red wire from the forward contactor Connect...

Page 72: ...as viewed from the operator s seat 1 Open the front access panel and turn the key switch ON TROUBLESHOOTING GUIDE CONTINUED Push down on the operator s seat press the back of the drive pedal and watch the reverse contactor see Figure 10 If the reverse contactor engages when the drive pedal is pressed check the contacts in the reverse contactor replace the forward re verse contactor assembly if nec...

Page 73: ...he machine 3 Disconnect the battery connector inside the right rear door 4 Remove the master link and the chain from the coupler 5 Lift the operator s seat and disconnect wires 21 22 from the motor Note Use a wrench to hold the inner nut on each terminal while loosening the outer nut 6 Remove the four Bolts D and work the motor out of the machine WHEEL MOTOR CARBON BRUSH INSPECTION The carbon brus...

Page 74: ...DANGER Before troubleshooting the drive system jack up the machine so the drive wheels are off the floor and place jack stands under the frame This will prevent injury if the drive motor starts during testing WARNING Safe operation of the machine may be affected by the forward and reverse drive switches Use extreme care when adjusting or replacing the switches and their operating linkage Before re...

Page 75: ...rd the collar and tighten the switch mounting screws 5 Remove the block of wood from the front of the drive pedal and put it under the back of the pedal This will hold the pedal in the FORWARD position 6 Slide the FORWARD switch towards the switch collar I until it clicks Then move the switch an additional 1 16 inch 1 5 mm toward the collar and tighten the switch mounting screws SPEED POTENTIOMETE...

Page 76: ...just the potentiometer 1 Disconnect the battery connector behind right rear door and remove the electrical access panel on the front of the machine 2 Adjust the reverse stop bolt located under the back of the drive pedal The pedal should hit the stop bolt at the same time the edges of the pedal hit the floor panel 3 See Figure 15 Move Hose Clamp S to your right as far as possible on Coupler R 4 Re...

Page 77: ...ewreplace mentactuatormotorsitwillbeneces sary to remove the drive nut spin it off theshaftandturnitendforendso that nut s pin pocket points toward the motor as shown This must be done before setting the drive nut di mensions 5 See Figure 2 Hold onto the Actuator Drive Nut A and press the rocker switch to run the drive motor and retractthenuttowardsthemotorhous ing it s IN limit 6 Measure the posi...

Page 78: ...15 Amp Aux 1 F4 6 Circuit Breaker 40 Amp Broom Motor F3 7 Relay Low Voltage Cut Out K9 8 Dual Control Assembly Brush Squeegee Lift Actuator Control E1 E2 9 Dual Control Assembly Side Skirt Actuator Control E4 E5 10 Contactor 36V Brush Motor K5 11 Solenoid 36V Broom Motor K6 12 Solenoid 36V Vac Motor K7 13 Forward Reverse Interlock E3 14 Contactor SPST Main K1 15 Contactor 36VDC Forward Reverse K2 ...

Page 79: ...11 M9 Right Side Skirt Lift Actuator 12 R2 Throttle Potentiometer 10K Ohm 13 S1 Reverse Throttle Switch 14 S2 Reverse Squeegee Lift Switch 15 S3 Forward Throttle Switch 16 S10 Brush Lift UP Limit Switch 17 S11 Brush Lift DOWN Limit Switch 18 S13 Seat Switch 19 S14 Broom Switch 20 S15 Detergent Tank Float Switch Hydro Max II 21 S16 Solution Tank Float Switch Hydro Max II 22 S17 Recovery Tank Start ...

Page 80: ...ecycle Pump Switch Hydro Max II S9 Horn Switch S10 Brush Lift UP Limit Switch S11 Brush Lift DOWN Limit Switch S12 Vacuum Pressure Switch S13 Seat Switch S14 Broom Switch S15 Detergent Tank Float Switch Hydro Max II S16 Solution Tank Float Switch Hydro Max II S17 Recovery Tank Start Float Switch Hydro Max II S18 Recovery Tank Stop Float Switch Hydro Max II S19 Solution Switch Note Location of opti...

Page 81: ... A NO CONNECTION NO CONNECTION NO CONNECTION SPLICE 6M B 6R B 6T A SPLICE 14B B 14C B 14D B NO CONNECTION BLU BLK 6 0 B B SPLICE OZ A OAL B OAK A OAP B OZ B 32 8B B SPLICE 8D B 8C B 31 31 33 32 B M B 41 GRN WHT 59A A VIO YEL 74A B ORN BLU 36A A BRN WHT 1 9 A A BLK OI B ORN 3 A A BLK OI A BLK OH B WHT 9 B A WHT 9 A B BLU RED 6 2 E B BLU RED 6 2 D B A B B SPLICE 8B B 8C B 8D B BLU 6 U B BLU 6 C B 2 ...

Page 82: ...ch S6 Vacuum Squeegee Switch S7 Brush Switch S8 Recycle Pump Switch Hydro Max II S9 Horn Switch S10 Brush Lift UP Limit Switch S11 Brush Lift DOWN Limit Switch S13 Seat Switch S14 Broom Switch S15 Detergent Tank Float Switch Hydro Max II S16 Solution Tank Float Switch Hydro Max II S17 Recovery Tank Start Float Switch Hydro Max II S18 Recovery Tank Stop Float Switch Hydro Max II S19 Solution Switch...

Page 83: ...B 41 GRN WHT 59A A VIO YEL 74A B ORN BLU 36A A BRN WHT 1 9 A A BLK OH B WHT 9 B A WHT 9 A B BLU RED 6 2 E B BLU RED 6 2 D B A B B SPLICE 8B B 8C B 8D B BLU 6 U B BLU 6 C B 2 3 4 1 ORN GRN3 5 D A GRN NOT USED RED ORN WHT BLK YEL RED 4 2 A A YEL 2 3 1 4 RED BLK 2 0 B B WHT BLK A A B B A B 74 B LK O M A B LK O Q A SPLICE 92D B 92E B 92F B SPLICE 90B B 90C B 90E B 6 A B 4 7 D10 K4 9 YEL RED 42D B GRN ...

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Page 86: ...Advance A E Tel 30 8 Thoukididou Str 210 963 3443 Argioupoli Fax 30 Gr 164 52 Athens 210 965 0975 Greece Holland Sales Sub Nilfisk Advance B V Phone 31 Camerastraat 9 2e verdieping 36 546 07 00 1322 BB Almere Fax 31 Postbus 60112 36 523 51 48 1320 AC Almere www nilfisk advance nl Ireland Sales Sub Nilfisk Advance Limited Phone 35 28 Sandyford Office Park 3 12 94 38 38 Sandyford Dublin 18 Fax 35 Ir...

Page 87: ...42 Fuitian Free Trade Zone Fax 86 755 518038 Shenzhen 8359 1063 P R China China Suzhou Nilfisk Advance Professional Phone 86 512 Cleaning Equipment Suzhou Co Ltd 8918 5656 306 Su Hong Zhong Road Build 2 Fax 86 512 Suzhou Industrial Park 8918 5666 215021 Suzhou P R China Hong Kong Sales Sub Nilfisk Advance Ltd Phone 852 2001 HK Worsted Mills Ind l Bldg 2427 5951 31 39 Wo Tong Tsui St Fax 852 Kwai C...

Page 88: ...www nilﬁsk advance com 2005 ...

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