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Nilfisk-Advance CR 1500, Service Manual

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Nilfisk-Advance CR 1500 Service Manual Download Page 73

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Service Manual – Advance 7765 / Nilfisk CR1500

Solution System

Functional Description

The solution system directs and regulates the solution flow from the solution tank to the scrub brushes.

Overview – Standard Solution System

On machines not equipped 

with the ESP/Recycle 

option, the solution travels 

from the 

Solution Tank

 

through the 

Inlet Strainer

, 

then to the regulating 

Ball 

Valve

. The 

Ball Valve

 is 

manually controlled by the 

solution control lever and 

regulates the solution flow 

to the three 

Scrub Brushes

.

The 

Squeegee

 picks up 

the wastewater from the 

floor and directs it to the 

Recovery Tank

. 

Solution 

Tank

Ball 

Valve

Inlet 

Strainer

Recovery 

Tank

Squeegee

Scrub 

Brush (3)

Summary of Contents for CR 1500

Page 1: ...Engine System Gasoline LPG 106 Service Manual Advance 7765 Nilfisk CR1500 ...

Page 2: ...Engine System Gasoline LPG 107 Service Manual Advance 7765 Nilfisk CR1500 ...

Page 3: ... 33 lb tank size with manual shutoff Spark Plugs AC Delco R45TS gap 045 1 14 mm Spark Plug Wiring Match numbered coil position to spark plug number see the Firing Order and Plug Wire Routing subsection Engine Firing Order 1 3 4 2 Ignition Timing 0 degrees BTDC Engine Rotation CCW flywheel end Valve Lifters Flat follower Oil Capacity 4 qts 3 79 L without oil filter 4 5 qts 4 26 L with oil filter Oi...

Page 4: ...Engine System Gasoline LPG 109 Service Manual Advance 7765 Nilfisk CR1500 Special Tools Diagnostic Communication Cable and software p n 56305647 Cooling System Tool ...

Page 5: ... emptying into a dumpster or other receptacle A second hydraulic cylinder opens and closes the hopper dump door Machines equipped with a variable dump hopper are also equipped with a dust control system The dust control system includes a hopper filter dust control motor and impeller and filter shaker motor Refer to the Dust Control System section for more information on the dust control components...

Page 6: ...a dumpster or other receptacle The Hopper Dump Door Cylinder opens and closes the Hopper Dump Door The Hopper Switch called the Hopper Down Switch in the Parts List closes when the Variable Dump Hopper is fully down The Hopper Door Switch called the Dump Door Switch in the Parts List closes when the Hopper Dump Door is closed Rod Hopper Switch Hopper Door Switch Hopper Dump Door Hopper Dump Door C...

Page 7: ...or Lever respectively Links connect the Hopper Lift Lever and Hopper Dump Door Lever to the corresponding side of the Hopper Control Valve Link To Upper Port on Hopper Dump Door Cylinder To Rear Port on Hopper Lift Cylinder To Lower Port on Hopper Dump Door Cylinder To Front Port on Hopper Lift Cylinder From T Port on Main Control Valve To Rear Oil Cooler Hopper Control Valve Hopper Lift Lever Hop...

Page 8: ...es must be closed in order to get positive voltage to the Shaker Motor Switch Dust Control Switch Main Broom Switch and Side Broom Switch Hopper Switch Hopper Door Switch Held Closed by Hopper Held Closed by Door 7 B R1 Shaker Relay Dust Control Solenoid 1 85 35 46 15 15 57 15 86 1 Side Broom Switch 2 1 Main Broom Switch 2 1 Dust Control Switch Option 2 3 37 1 Shaker Motor Switch 2 Main Broom Sole...

Page 9: ...h the Hopper Control Valve then through the Oil Cooler Return Block and Filter to the Reservoir Note that the hydraulic lines from the Dump Cylinder and the bottom port on the Lift Cylinder are deadheaded in the Hopper Control Valve to hold the hopper and dump door in position Lift Cylinder A C D B Dump Cylinder To Scrub Brush Motors To Main Broom and Dust Control Motors From Main Broom and Dust C...

Page 10: ...ter and Reservoir Lift Cylinder A C D B Dump Cylinder To Scrub Brush Motors To Main Broom and Dust Control Motors From Main Broom and Dust Control Motors From Scrub Brush Motors 75 GPM Main Control Valve P P1 1 2 3 T 4 1 02 CIR Return Block Reservoir Auxiliary Pump Out Close Door Lift Hopper Hopper Down Open Door Hopper Control Valve In Oil Cooler Filter 9 7 GPM Main Broom Solenoid 2 Normal Rotati...

Page 11: ...nder its own weight Lift Cylinder A C D B Dump Cylinder To Scrub Brush Motors To Main Broom and Dust Control Motors From Main Broom and Dust Control Motors From Scrub Brush Motors 75 GPM Main Control Valve P P1 1 2 3 T 4 Return Block Out Close Door Lift Hopper Hopper Down Open Door Hopper Control Valve In Oil Cooler Filter 9 7 GPM Main Broom Solenoid 2 Normal Rotation Brush 4 Reverse Rotation Brus...

Page 12: ... Cylinder and to the Pilot on the Check Valve The oil from the top port on the Dump Cylinder flows back through the Hopper Dump Cylinder Valve then to the return line to the Oil Cooler Filter and Reservoir Lift Cylinder A C D B Dump Cylinder To Scrub Brush Motors To Main Broom and Dust Control Motors From Main Broom and Dust Control Motors From Scrub Brush Motors 75 GPM Main Control Valve P P1 1 2...

Page 13: ...to the return line going to the Oil Cooler Filter and Reservoir Lift Cylinder Dump Cylinder To Scrub Brush Motors To Main Broom and Dust Control Motors From Main Broom and Dust Control Motors From Scrub Brush Motors 75 GPM Main Control Valve P P1 1 2 3 T 4 Return Block Out Hopper Control Valve In Oil Cooler Filter 9 7 GPM Main Broom Solenoid 2 Normal Rotation Brush 4 Reverse Rotation Brush 3 To Si...

Page 14: ... Cylinder is attached to the machine frame and Hopper and raises and lowers the Hopper The Hopper Dump Door Cylinder opens and closes the Hopper Dump Door The Hopper Switch contacts the Hopper Dump Door Cylinder and closes when the Hopper is down The Hopper Door Switch contacts the Hopper Dump Door and closes when the Hopper Dump Door is closed Hopper Lift Cylinder Hopper Hopper Hopper Switch Hopp...

Page 15: ...ts Warning Before performing any machine maintenance make sure the key switch is off the key is removed from the machine and the parking brake is engaged Every 100 hours apply a high quality lithium based grease to the following areas The Grease Fitting on the top of the Hopper Lift Cylinder The Pin and Collars connecting the Hopper Lift Cylinder to the frame yoke Hopper Control Valve Links Grease...

Page 16: ...Dump Door Cylinder to the Hopper Dump Door and hopper yoke The Hopper Pivot Points Note that these are easier to access if the Support Wing Covers are removed as shown here Pin Collar 2 Hopper Dump Door Cylinder Hopper Dump Door Pin Support Wing Cover removed from Frame Hopper Pivot Point left side shown ...

Page 17: ...e Manual Advance 7765 Nilfisk CR1500 The four hopper rod Grease Fittings Warning Never work under the hopper without first engaging the Safety Lock Arm Grease Fittings Grease Fittings Safety Lock Arm shown in engaged position ...

Page 18: ...and correct as necessary Hopper dump door not opening or closing when the hopper dump door lever is moved to the open or close position The hopper dump cylinder valve in the hopper control valve is not operating correctly Check the hopper dump cylinder valve and repair replace as necessary Binding in the dump door mount or dump door cylinder Check for any mechanical binding or damage to the dump d...

Page 19: ...raulic oil circulates through the oil cooler attached to the rear of the engine radiator The hydraulic return oil filter is mounted on top of the oil reservoir and has a replaceable filter element Note The individual hydraulic motors and cylinders are described in the corresponding machine system sections Hydraulic Pumps The engine drives the two hydraulic pumps that send the hydraulic oil to the ...

Page 20: ...flow to the main broom motor dust control motor scrub brush motors and hopper control valve Note that the functions of ports 3 and 4 will be reversed when the scrub motors are run in the reverse rotation From Reservoir To Port P on Main Control Valve To Port P on Power Steering Unit To Squeegee Vacuum Motor Auxiliary Pump To Return Block Manifold From Auxiliary Pump To Port 2 on Side Broom Valve T...

Page 21: ... To Lower Port on Squeegee Deck Cylinder To Upper Port on Squeegee Deck Cylinder From Port T on Power Steering Unit To Lower Port on Scrub Deck Cylinder To Rear Case Drain Port on Reservoir To Upper Port on Scrub Deck Cylinder Cylinder Control Valve From Side Broom Valve From Front Port on Hopper Lift Cylinder From Port T1 on Main Control Valve To Charge Circuit on Drive Pump Front From Case Drain...

Page 22: ...Forward Relay Scrub Brush Switch Brush Pressure Switch Raise Lower CB7 15 A 7 18 58 7 2 30 87 1 2 1 2 3 46 46 40 40 3 43 43 87a 1 Scrub Brush Solenoid 6 Scrub Brush Solenoid 8 Normal Rotation Brush 4 14 18 Reverse Rotation Brush 3 18 Scrub Brush Lock Up Solenoid 9 18 7 7 Squeegee Lock Up 10 30 Squeegee Fan Motor Solenoid 12 40 Squeegee Cylinder Solenoid 7 B 7 Brush Rotation Switch 1 2 3 CB8 15 A 7...

Page 23: ... 0 CIR 2500 PSI 75 GPM Main Control Valve Dust Control Motor Main Broom Motor P P1 1 2 3 T 4 T1 15 4 CIR 1 02 CIR 1 02 CIR 1 24 CIR Return Block Vonberg Check Valve 120 psi 270 PSI 2200 RPM Rear Wheel Motor Reservoir Drive and Auxiliary Pumps Out Hopper Control Valve In Oil Cooler Filter 9 7 GPM 8 2 GPM 1 5 GPM Cylinder Control Valve P T Main Broom Solenoid 2 Normal Rotation Brush 4 Reverse Rotati...

Page 24: ...lve Main Broom Motor P P1 1 2 3 T 4 T1 15 4 CIR 1 02 CIR 1 02 CIR 1 24 CIR Return Block Vonberg Check Valve 120 psi 270 PSI 2200 RPM Reservoir Drive and Auxiliary Pumps Oil Cooler Filter 9 7 GPM 8 2 GPM 1 5 GPM Cylinder Control Valve P T Main Broom Solenoid 2 Squeegee Fan Motor Solenoid 12 Normal Rotation Brush 4 Reverse Rotation Brush 3 Scrub Brush Solenoid 6 Scrub Brush Solenoid 8 Squeegee Cylin...

Page 25: ...ncluded in this section Hydraulic Pumps Hydraulic Reservoir Oil Filter Oil Cooler Main Control Valve Cylinder Control Valve Return Block Manifold The Drive Pump and Auxiliary Pump are mounted on the rear of the engine toward the front of the machine and are driven by the engine crankshaft Drive Pump Auxiliary Pump ...

Page 26: ...incoming oil The Clogging Indicator is a pressure gauge on the return line that displays the oil pressure upstream of the Oil Filter When the pressure required to pass the oil through the Oil Filter becomes too high needle in the red zone the Oil Filter element must be replaced The Oil Filter has a check valve that will open to bypass the Oil Filter when the incoming oil pressure exceeds 15 psi Cl...

Page 27: ...ol Valve is mounted on the underside of the machine in front of and to the left of the scrub deck Radiator Oil Cooler Main Broom Solenoid 2 Reverse Rotation Brush 3 Normal Rotation Brush 4 Main Control Valve top view shown while machine is being assembled Main Control Valve Main Control Valve bottom view shown mounted in assembled machine ...

Page 28: ... floor of the Operator compartment The Return Block Manifold is attached to the frame behind the hopper hydraulic valves on the right side of the machine Cylinder Control Valve Scrub Brush Solenoid 6 Scrub Brush Solenoid 8 Scrub Brush Lock Up Solenoid 9 Squeegee Cylinder Solenoid 7 Squeegee Lock Up Solenoid 10 Return Block Manifold ...

Page 29: ...einstall the fill cap then swing the Operator seat back up into position Note Change and flush the oil if major contamination from a mechanical failure occurs Hydraulic Oil Filter Caution Make sure the hydraulic system is not under pressure and that the hydraulic filter and reservoir are cool to the touch before servicing the filter Make sure you are wearing the appropriate clothing and eye protec...

Page 30: ...easurements you can compare them to the specifications to analyze a problem You can use digital tachometers flow gauges meters or pressure gauges to troubleshoot the hydraulic system The pressure gauge should have a range of 0 to 3000 psi see the Special Tools section The flow meter must be rated to 3000 psi and 10 gal min The most convenient way to check for oil flow is to check the RPM of the mo...

Page 31: ... connect the pressure gauge 2 Run the engine in the high throttle position and allow the hydraulic oil to warm up The bypass pressure is the pressure reading with no motor or cylinder operating The operational pressure is the pressure range in which the motor or cylinders will operate A much lower than normal bypass pressure could indicate a gear pump problem If the bypass pressure remains the sam...

Page 32: ...ype manually variable displacement axial piston pump tow valve included Displacement 1 24 CIR Speed 3600 RPM max Continuous pressure 3000 PSI 206 8 bar max Relief Setting Main Ports 3500 psi 241 3 bar Auxiliary Pump Type multiple gear pump Displacement Front 1 02 CIR Rear 1 02 CIR Main Control Valve Solenoid Valves Initial Current Draw 1 67 amps Nominal Coil Resistance 7 2 ohms Cylinder Control Va...

Page 33: ...PM 1050 PSI 8 1 GPM 1500 PSI 7 4 GPM 400 PSI 8 1 GPM 400 PSI 7 4 GPM 7 33 02546 Scrub Motors Left Inlet 50 PSI 0 GPM 50 PSI 0 GPM 540 PSI 8 1 GPM 590 PSI 7 4 GPM 820 PSI 8 1 GPM 1100 PSI 7 4 GPM 7 33 02180 To Return Block from Port T1 on 2500 PSI Relief Valve 50 PSI 0 GPM 50 PSI 0 GPM 50 PSI 0 GPM 50 PSI 1 0 GPM 50 PSI 0 GPM 50 PSI 1 0 GPM 8 33 02201 To Hopper Valves from T Port on Main Control Va...

Page 34: ... Steering Cylinder Rod End 380 PSI 1500 PSI 7 33 02225 Power Steering Cylinder Base End 1750 PSI 390 PSI Side Broom Hydraulic Specifications GM and Mitsubishi Engines With Hopper Valves in Neutral Side Broom Only On Side Broom Off Hose Location Pressure RPM Flow Pressure Flow 7 33 02181 Side Broom Motor Inlet 216 PSI 80 RPM 7 GPM 50 PSI 0 GPM 8 33 02277 Side Broom Motor Inlet 216 PSI 10 RPM 7 GPM ...

Page 35: ... 380 PSI 8 25 GPM 7 33 02734 Main Control Valve T Port Low Dump 50 PSI 8 25 GPM 7 33 02180 Main Control Valve T1 Port 50 PSI 0 004 GPM Main Broom Hydraulic Specifications Mitsubishi Engines With Hopper Valves in Neutral Main Broom Only ON Hose Location Pressure RPM Flow 8 33 02214 Main Broom Motor Inlet from Main Control Valve 1 Port 970 PSI 420 RPM 8 25 GPM 7 33 02332 Main Broom Motor Outlet High...

Page 36: ...let 830 PSI 8 25 GPM 480 PSI 8 25 GPM 7 33 02205 Dust Control Solenoid Wet Sweep Bypass Valve Outlet 430 PSI 8 25 GPM 430 PSI 8 25 GPM Dust Control System Hydraulic Specifications Mitsubishi Engines Variable Dump Models With Hopper Valves in Neutral Dust Control On Main Broom On Dust Control Off Hose Location Pressure RPM Flow Pressure Flow 7 33 02332 Dust Control Motor Inlet No Wet Sweep Bypass o...

Page 37: ...et 280 PSI 7 2 GPM 1320 PSI 7 3 GPM 350 PSI 7 3 GPM 8 33 02192 Vacuum Fan Motor Outlet 150 PSI 7 2 GPM 135 PSI 7 3 GPM 267 PSI 7 3 GPM Squeegee System Hydraulic Specifications Mitsubishi Engines Squeegee Raised Squeegee Lowered Reverse Hose Location Pressure Flow Pressure Flow Pressure Flow 7 33 02225 Cylinder Control Valve T port 50 PSI 1 4 GPM 50 PSI 1 4 GPM 50 PSI 1 4 GPM 7 33 02190 Cylinder Co...

Page 38: ...g of 2500 psi Main Control Valve Specifications Component Component Description Hydraulic Circuit Function RV1 Poppet type relief valve 2500 psi 172 4 bar Relief Valve to T1 FR1 Plug SV1 Solenoid operated two way piloted poppet type hydraulic cartridge valve normally open screw in Main Broom Solenoid 2 SV2 Solenoid operated two way piloted poppet type hydraulic cartridge valve normally open screw ...

Page 39: ...w in hydraulic directional valve Scrub Brush Solenoid 6 S4 A solenoid operated four way two position direct acting spool type screw in hydraulic cartridge valve Squeegee Cylinder Solenoid 7 S5 A solenoid operated three way direct acting spool type screw in hydraulic directional valve Scrub Brush Solenoid 8 S6 A solenoid operated two way normally closed poppet type screw in hydraulic cartridge valv...

Page 40: ... 7765 Nilfisk CR1500 Special Tools Hydraulic test gauge w connector 3000 PSI range p n 56504516 Flow Meter rated at 3000 psi and 10 gal min typical shown Various hydraulic fittings required to connect hydraulic test gauge into hydraulic circuits ...

Page 41: ...components and operation Recovery Tank Standard Recovery System The standard Recovery Tank holds 100 gallons 379 liters of wastewater and is not plumbed to the solution tank The Drain Plug Assembly plugs the drain hole to the Drain Hose The Drain Plug Assembly uses an expanding plug that expands when the Tee handle is tightened rotated clockwise to seal the drain hole The Recovery Tank tilts out a...

Page 42: ...overy Tank with the ESP Recycle option has an additional Solution Inlet Filter and supplies filtered wastewater to the ESP Pump that pumps it back into the solution tank The ESP Pump is controlled by the Recovery High Float Switch in the Recovery Tank shown on the previous page and will switch on when the Recycling System ON OFF Switch is set to ON and the Recovery High Float Switch actuates the H...

Page 43: ...r Weldment The Vacuum Motor assembly includes the internal relief valve and the Solenoid Valve that controls the oil flow to the Vacuum Motor The Float Ball moves up and down inside of the Float Ball Strap If the water level in the recovery tank gets too high the Float Ball will rise to plug the opening in the Fan Duct to keep water out of the Vacuum Motor and fan assembly Vacuum Motor Solenoid Va...

Page 44: ...pen to allow the hydraulic oil to flow through the Squeegee Fan Motor Solenoid 12 and bypass squeegee vacuum fan motor When the Reverse Relay switches to position 87 diode D2 prevents voltage from the Reverse Relay from energizing the Squeegee Fan Motor Solenoid 12 This allows the squeegee vacuum fan motor to run when the machine is in reverse Not shown is that power from 87 is used to raise the s...

Page 45: ...ty leg on the Auxiliary Pump to the Squeegee Vacuum Motor The hydraulic oil then returns to the Drive Pump charge circuit The Case Drain allows any oil leaked into the motor case to drain into the Reservoir to prevent it from building up pressure and possibly damaging the motor seals The Check Valve relieves the pressure in the Squeegee Vacuum Motor when it is shut off and allows the high speed Sq...

Page 46: ...alls the 2200 PSI Relief Valve opens to allow the oil to flow through the 2200 PSI Relief Valve to prevent damage to the Squeegee Vacuum Motor or hydraulic system Auxiliary Pump 2200 PSI Relief Valve open Squeegee Fan Motor Solenoid 12 Squeegee Vacuum Motor 0 151 CIR 1 02 CIR 8 2 GPM Reservoir 1 02 CIR 1 24 CIR Drive Pump ...

Page 47: ...overy High Float Switch Drain Hose and Hose Holder Vacuum Motor and Fan Assembly Recovery Tank The Recovery Tank is located on the front left hand side of the machine and swings out away from the machine for access and cleaning The Recovery Tank Lid cover assembly houses the vacuum motor assembly and swings up for access to the Recovery Tank Float Ball and Float Ball Strap Recovery Tank Lid Recove...

Page 48: ...ill actuate the High Recovery Warning Light on the instrument panel approximately five minutes before the recovery tank is full and before the Float Ball shuts off the vacuum to the recovery tank The Hose Holder and Drain Hose swing out to free the Drain Hose when draining the recovery tank Drain Plug Assembly Recovery High Float Switch High Recovery Warning Light Drain Hose Hose Holder ...

Page 49: ...low access to the Float Ball and Float Ball Strap Removing the upper cover weldment allows access to the Vacuum Motor attached Solenoid Valve and Relief Valve and the Fan Assembly This also allows access to the Hydraulic Hoses and the Vacuum Hose Float Ball Strap Float Ball Recovery Tank Lid Vacuum Hose Vacuum Motor Hydraulic Hose 3 Solenoid Valve Fan Assembly Relief Valve ...

Page 50: ...stalled with an oil filter wrench Troubleshooting Problem Cause Correction Poor water pickup Vacuum leak s due to Leaky vacuum hose Bad recovery tank lid gasket Drain plug not installed correctly Damaged tank Check the squeegee vacuum hose and tighten replace as necessary Check the recovery tank lid gasket and replace as necessary Make sure drain plug is installed correctly Check the recovery tank...

Page 51: ...lenoid when the fan motor is on and 12 VDC to the solenoid when the fan motor is off Check the solenoid coil resistance If not 6 6 ohms 10 replace the solenoid Also see the Recovery System Wiring Diagram Vacuum Test 1 Remove the rear squeegee assembly from the Squeegee Support Weldment 2 Block the Squeegee Support Weldment 3 Install the Vacuum Test Gauge into the Hose 4 Start the engine and switch...

Page 52: ...gee Vacuum Fan Motor Displacement 0 000652 gal rev 0 151 CIR Max Pressure 1500 psi 103 4 bar Max Speed 4000 RPM Relief Valve 2200 psi 151 7 bar Vacuum Water Lift Sealed 30 76 cm of water Squeegee Fan Motor Solenoid 12 Nominal Coil Resistance 6 6 Ohms measured Special Tools Vacuum water lift gauge p n 56205281 ...

Page 53: ...liary pump powers the scrub deck hydraulic cylinder Scrub Deck The three Hydraulic Scrub Motors are mounted on the Scrub Deck and power the Drive Brush Assemblies The Brushes snap into the latches on the Drive Brush Assemblies The ball valve regulates the solution flow to the Water Feed Hose connected to the 90 Nipple on the Tee Fitting The three other Water Feed Hoses supply the solution to the B...

Page 54: ...ves on the Main Control Valve control the hydraulic oil to the scrub brush motors from Port 3 or Port 4 depending on the direction of the scrub brush motors The oil returns from the motors to Port 3 or Port 4 depending on the direction of the scrub brush motors Oil to and from Scrub Brush Motors Main Control Valve Reverse Rotation Brush 3 Normal Rotation Brush 4 ...

Page 55: ...s the scrub deck up when the engine is shut off The top port on the Scrub Deck Hydraulic Cylinder is connected to the C2 Port on the Cylinder Control Valve The bottom port on the Scrub Deck Hydraulic Cylinder is connected to the C1 Port on the Cylinder Control Valve To C2 Port on Cylinder Control Valve To C1 Port on Cylinder Control Valve Scrub Deck Hydraulic Cylinder To Top Port on Scrub Deck Hyd...

Page 56: ...e Brush Rotation Switch is set to the top forward position the Reverse Rotation Brush 3 solenoid is de energized to allow the scrub brush motors to run in the normal forward direction When the Brush Rotation Switch is set to the bottom reverse position the Reverse Rotation Brush 3 solenoid is energized and reverses the direction of the oil flow to the scrub brushes This runs the scrub brushes in r...

Page 57: ...sure When the Drive Pedal Forward Sensor switches the Forward Relay R4 contacts to the 87 Lower position the Scrub Brush Switch is set to the Lower position and the Brush Pressure Switch is set to the heavy scrub two bar position the Scrub Brush Lock Up Solenoid 9 and Scrub Brush Solenoid 8 are energized This connects the top port on the scrub deck cylinder to the 270 psi oil from the power steeri...

Page 58: ...4 solenoid valve If the Main Broom Switch is off the Main Broom Solenoid 2 is de energized open The oil will flow through the Main Broom Solenoid 2 valve and Normal Rotation Brush 4 solenoid valve then go to the Hopper Control Valve To Side Broom Valve Scrub Brush Motors 10 0 CIR 10 0 CIR 0 34 CIR 4 50 CIR 10 0 CIR 75 GPM Main Control Valve Dust Control Motor Main Broom Motor P P1 1 2 3 T 4 1 02 C...

Page 59: ...ontrol Valve In either of these two cases the oil will flow through the open Normal Rotation Brush 4 solenoid valve and bypass the Scrub Brush Motors To Side Broom Valve Scrub Brush Motors 10 0 CIR 10 0 CIR 0 34 CIR 4 50 CIR 10 0 CIR 75 GPM Main Control Valve Dust Control Motor Main Broom Motor P P1 1 2 3 T 4 1 02 CIR 1 24 CIR Return Block Reservoir Drive and Auxiliary Pump To Hopper Control Valve...

Page 60: ... Scrub Brush Motors If the Main Broom Motor is off Main Broom Solenoid 2 valve is open the oil will flow through the Main Broom Solenoid 2 valve to the Reverse Rotation Brush 3 solenoid valve then to the Scrub Brush Motors To Side Broom Valve Scrub Brush Motors 10 0 CIR 10 0 CIR 0 34 CIR 4 50 CIR 10 0 CIR 75 GPM Main Control Valve Dust Control Motor Main Broom Motor P P1 1 2 3 T 4 1 02 CIR 1 24 CI...

Page 61: ...hese two cases the oil from the discharge side of the Scrub Brush Motors will pass though the Reverse Rotation Brush 3 solenoid valve again then go to the Hopper Control Valve To Side Broom Valve Scrub Brush Motors 10 0 CIR 10 0 CIR 0 34 CIR 4 50 CIR 10 0 CIR 75 GPM Main Control Valve Dust Control Motor Main Broom Motor P P1 1 2 3 T 4 1 02 CIR 1 24 CIR Return Block Reservoir Drive and Auxiliary Pu...

Page 62: ...se Rotation Brush 3 solenoid which reverses the oil flow to the Scrub Brush Motors To Side Broom Valve Scrub Brush Motors 10 0 CIR 10 0 CIR 0 34 CIR 4 50 CIR 10 0 CIR 75 GPM Main Control Valve Dust Control Motor Main Broom Motor P P1 1 2 3 T 4 1 02 CIR 1 24 CIR Return Block Reservoir Drive and Auxiliary Pump To Hopper Control Valve 9 7 GPM T1 Main Broom Solenoid 2 Normal Rotation Brush 4 Reverse R...

Page 63: ... allows the scrub deck to move downward under its own weight Note that both the Scrub Brush Solenoid 6 and Scrub Brush Solenoid 8 valves are deadheaded when not energized directing the oil from the discharge side of the Power Steering Unit to the Squeegee Cylinder Solenoid 7 valve The Check Valve maintains the circuit pressure at 270 psi To and From Squeegee Hydraulic Deck Cylinder Scrub Deck Cyli...

Page 64: ...heavy scrub pressure The Check Valve maintains the circuit pressure at 270 psi The oil from the lower port on the Scrub Deck Cylinder has a open path through the energized Scrub Brush Lock Up Solenoid 9 valve and the de energized Scrub Brush Solenoid 6 valve to the return line to the Reservoir To and From Squeegee Hydraulic Deck Cylinder Scrub Deck Cylinder C3 C4 C2 C1 1 02 CIR Check Valve 270 PSI...

Page 65: ...its retracted position The Check Valve maintains the circuit pressure at 270 psi The oil from the upper port on the Scrub Deck Cylinder has a open path through the de energized Scrub Brush Solenoid 8 valve to the return line to the Reservoir To and From Squeegee Hydraulic Deck Cylinder Scrub Deck Cylinder C3 C4 C2 C1 T 1 02 CIR Check Valve 270 PSI Reservoir Auxiliary Pump 8 2 GPM 1 5 GPM Cylinder ...

Page 66: ...rts the weight of the Scrub Deck when in its retracted position to prevent it from floating down To and From Squeegee Hydraulic Deck Cylinder Scrub Deck Cylinder C3 C2 C1 1 02 CIR Check Valve 270 PSI Reservoir Auxiliary Pump 8 2 GPM 1 5 GPM Cylinder Control Valve P T To Squeegee Vacuum Motor Scrub Deck Locked Up Squeegee Lock Up 10 Scrub Brush Lock Up Solenoid 9 Scrub Brush Solenoid 6 Scrub Brush ...

Page 67: ...ve Cylinder Control Valve The Scrub Deck is suspended underneath the machine and pivots up and down on a mechanical mount The three Hydraulic Scrub Motors are mounted vertically on the Scrub Deck The Scrub Deck Hydraulic Cylinder is attached to the Scrub Deck and machine frame and lowers and raises the Scrub Deck Scrub Deck Hydraulic Scrub Motor 3 Scrub Deck Hydraulic Cylinder top Scrub Deck Hydra...

Page 68: ...mal Rotation Brush 4 solenoid is energized it closes to direct the oil flow in and out of Ports 3 and 4 on the Main Control Valve The direction of oil flow is determined by the position of the Reverse Rotation Brush 3 solenoid valve which controls the direction of brush rotation Main Control Valve bottom view shown mounted in assembled machine Port 3 Port 4 Main Control Valve Main Control Valve to...

Page 69: ...nd or switch as necessary Normal Rotation Brush 4 solenoid in the Main Control Valve not operating stuck open 1 Check the coil resistance of the Normal Rotation Brush 4 solenoid If not 7 2 ohms 10 replace the coil 2 If the coil resistance is within spec check for binding or a mechanical problem Repair or replace the valve as necessary Unable to change scrub brush rotation direction No voltage to t...

Page 70: ...he Scrub Brush Lock Up Solenoid 9 and repair as necessary Scrub Deck Lock Up Solenoid 9 in the Cylinder Control Valve not opening when energized stuck closed 1 Check the coil resistance of the Scrub Brush Lock Up Solenoid 9 If the coil resistance is not 9 8 ohms 10 replace the coil 2 If the coil resistance is within spec check for binding or a mechanical problem Repair or replace the valve as nece...

Page 71: ...op of Scrub Deck Cylinder to reservoir return when de energized stuck open 1 Check the coil resistance of the Scrub Brush Solenoid 8 If the coil resistance is not 9 8 ohms 10 replace the coil 2 If the coil resistance is within spec check for binding or a mechanical problem Repair or replace the valve as necessary Specifications Component Specifications Component Specifications Normal Rotation Brus...

Page 72: ...Scrub System 177 Service Manual Advance 7765 Nilfisk CR1500 Special Tools Hydraulic test gauge w connector 3000 psi range p n 56504516 ...

Page 73: ...not equipped with the ESP Recycle option the solution travels from the Solution Tank through the Inlet Strainer then to the regulating Ball Valve The Ball Valve is manually controlled by the solution control lever and regulates the solution flow to the three Scrub Brushes The Squeegee picks up the wastewater from the floor and directs it to the Recovery Tank Solution Tank Ball Valve Inlet Strainer...

Page 74: ...an expanding plug that expands when the Tee handle is tightened rotated clockwise to seal the drain hole The Drain Hose is supported by a hose holder which swings out away from the machine to free the Drain Hose to drain the Solution Tank When the solution level in the Solution Tank is low the Solution Low Switch will actuate the Low Solution Warning Light on the instrument panel The solution tank...

Page 75: ... flow Note that this a mechanical system and is not affected by the status of the scrub system or whether or not the machine is moving Whenever the Solution Control Lever is moved from the off position solution will flow to the scrub deck Also note that the solution flow control is the same for all machines regardless of whether or not they re equipped with the ESP Recycle option Solution From Sol...

Page 76: ...p that pumps the filtered wastewater light blue arrows back into the Solution Tank The Recovery High Switch red float switch in the Recovery Tank and Recycling System On Off switch on the instrument panel control the ESP Solution Pump The Detergent Pump pumps detergent red arrows from the Detergent Tank into the solution stream The solution detergent mixture violet arrow is then delivered to the t...

Page 77: ... is low The Solution High Switch in the Solution Tank will light the HIGH SOLUTION warning light on the instrument panel when the water level in the Solution Tank is too high Detergent Pump The Detergent Pump pumps detergent from the Detergent Tank into the solution line downstream of the ball valve The Detergent Flow knob on the instrument panel controls the detergent flow rate Front Detergent Lo...

Page 78: ...s The Solenoid Valve is controlled by the proximity sensors at the drive pedal as follows When the drive pedal is in the forward or reverse position the Solenoid Valve is energized and opens to allow solution flow to the scrub brushes When the drive pedal is in the neutral position the Solenoid Valve is de energized and closes to shut off the solution flow to the scrub brushes Solution From Soluti...

Page 79: ...bly The Solution Valve controls the solution flow through the Solution Feed Hose to the Spray Nozzle mounted on the end of the Wand Assembly The Hose Assembly connects to the squeegee vacuum hose on the machine to provide vacuum pick up to the Tool Assembly The On Off Toggle Switch that controls the Water Pump is mounted on the instrument panel Wand Assembly Solution Feed Hose Solution Valve On Of...

Page 80: ...w Switch liquid level switch that switches on the Low Solution Warning Light on the instrument panel when the solution level in the solution tank is low The Ignition Switch must be on for the Solution Low Switch and Low Solution Warning Light to function 7 B 7 CB8 15 A 7 2 1 Solution Low Switch 19 1 2 20 1 2 Low Solution Warning Light Red Battery 12 VDC Bat St Ign Acc Ignition Switch Low Solution ...

Page 81: ...tage to the Rheostat Switch The Rheostat Switch is a two terminal potentiometer that controls the voltage to the Detergent Pump to regulate the detergent pump speed detergent flow to the solution line When the detergent level in the detergent tank drops low enough to actuate close the Detergent Low Switch liquid level switch the Detergent Low Switch provides positive voltage to light the Detergent...

Page 82: ...nob Standard Solution System The Solution Tank is fixed and is located on the front right hand side of the machine The Cover Support Rod holds the Cover Weldment in the open position The Drain Plug Assembly can be removed to drain the Solution Tank through the drain hose The Inlet Strainer filters the solution before it goes to the ball valve The Solution Low Switch liquid level switch actuates th...

Page 83: ... Hose when draining the solution tank The Solution Control Lever to the left of the Operator actuates the solution control link connected to the ball valve to regulate the solution flow The solution flow rate is continuously variable from No Flow to a maximum of 3 GPM Drain Hose Hose Holder Solution Control Lever No Flow 3 GPM Solution Control Lever ...

Page 84: ...all Valve remove the Access Panel on the floor of the Operator compartment The solution Solenoid Valve is included in the Solution Off in Neutral option and is mounted on a bracket above the scrub deck The Solenoid Valve switches off the solution flow to the scrub brushes when the machine is in neutral Solution Control Link Ball Valve Access To Ball Valve Access Panel Solution Control Link Solenoi...

Page 85: ...ution from the recovery tank to the solution tank The Detergent Pump is mounted on the side of the machine chassis and supplies detergent to the solution line The LS DMP Switch is mounted in line with the solution control lever and closes when the solution control lever is moved forward off of the no flow position ESP Pump Detergent Pump LS DMP Switch ...

Page 86: ...witch liquid level switch is mounted in the top of the solution tank and switches on the High Solution light on the instrument panel when the solution level is high The ESP Recycling System On Off switch is mounted on the instrument panel and controls the power to the ESP and detergent pumps The Detergent Flow Off Max control knob regulates the voltage to the detergent pump to control the pump spe...

Page 87: ... flush the detergent system 1 Rinse the detergent tank with clean water 2 Pour clean water into the detergent tank 3 Set the DETERGENT FLOW KNOB to MAX and run the detergent and solution systems to purge the detergent pump and lines Troubleshooting Problem Cause Correction No or inadequate solution flow to the scrub brushes Low solution level in solution tank Check the solution level in the tank a...

Page 88: ...P Recycle option only Recycling System ON OFF switch is set to OFF Set the Recycling System ON OFF switch to ON Detergent Flow knob is set to OFF Turn the Detergent Flow knob clockwise from the OFF position Detergent tank is empty Check the detergent tank and refill as necessary Detergent supply lines are clogged Check the detergent lines and clean replace as necessary Detergent pump not operating...

Page 89: ...l option only Voltage 12 VDC continuous duty Power Consumption 11 Watts Coil Resistance 13 Ohms 10 25 C Water Pump Power Spray Wand option only Voltage 12 VDC Current 10 6 A 100 psi 6 9 bar Pressure 80 100 psi 5 5 6 9 bar Solution System Solution System Flow Rates Gravity fed continuously variable from zero to 3 5 GPM 13 25 LPM ESP Detergent System Detergent Tank High density Polyethylene 6 gal 22...

Page 90: ...queegee deck cylinder lowers the squeegee assembly to the floor for normal scrubbing and raises the squeegee when the machine is not scrubbing or is moving in reverse Rear Squeegee Assembly The Squeegee Clamp Strap on the rear squeegee assembly holds the Inner and Outer Squeegees and Squeegee Spacers on the Squeegee Weldment The two inner Squeegee Knobs fasten the Squeegee Inlet Duct and Squeegee ...

Page 91: ...maintain the correct angle to the floor as the squeegee moves up and down The Shafts with locking Collars connect the Squeegee Supports to the Left and Right Pivot Brackets fastened to the machine frame The Squeegee Supports pivot on the Shafts in the Left and Right Pivot Brackets to allow the squeegee to pivot side to side Squeegee Arm 4 Squeegee Support 2 Left Pivot Bracket Right Pivot Bracket R...

Page 92: ...ylinder The Squeegee Deck Lift Cylinder extends and retracts to pivot the Squeegee Lift Arm down and up The Squeegee Lift Arm raises and lowers the Squeegee Lift Chain attached to the squeegee support weldment to raise and lower the squeegee Squeegee Deck Lift Cylinder Squeegee Lift Arm Squeegee Lift Chain ...

Page 93: ...nnected to the C4 Port on the Cylinder Control Valve The Squeegee Cylinder Solenoid 7 valve controls the oil flow to the Squeegee Deck Cylinder The Squeegee Lock Up 10 solenoid valve holds the squeegee up when the engine is shut off To C3 Port on Cylinder Control Valve To C4 Port on Cylinder Control Valve Squeegee Lock Up 10 Squeegee Cylinder Solenoid 7 Cylinder Control Valve To Lower Port on Sque...

Page 94: ...queegee When the Squeegee Blade Switch on the instrument panel is set to the squeegee raise position Squeegee Blade Switch position 3 the Squeegee Cylinder Solenoid 7 is energized to direct the hydraulic oil to the bottom port on the squeegee deck cylinder to raise the squeegee When the drive pedal moves to the reverse position the Drive Pedal Reverse Sensor switches to position 2 This energizes t...

Page 95: ...k Cylinder This holds the squeegee up in the retracted position when the machine is shut off C3 C4 C2 C1 1 02 CIR Check Valve 270 PSI Reservoir Auxiliary Pump 8 2 GPM 1 5 GPM Cylinder Control Valve P T To Squeegee Vacuum Motor Scrub Brush Solenoid 6 Scrub Brush Solenoid 8 Squeegee Cylinder Solenoid 7 Squeegee Lock Up 10 Scrub Brush Lock Up Solenoid 9 Squeegee Deck Cylinder To and From Scrub Deck C...

Page 96: ...he squeegee Note that the Squeegee Cylinder Solenoid 7 will also be energized to raise the squeegee when the drive pedal is moved to reverse and actuates the reverse relay C3 C4 C2 C1 1 02 CIR Check Valve 270 PSI Reservoir Auxiliary Pump 8 2 GPM 1 5 GPM Cylinder Control Valve P T To Squeegee Vacuum Motor Scrub Brush Solenoid 6 Scrub Brush Solenoid 8 Squeegee Cylinder Solenoid 7 Squeegee Lock Up 10...

Page 97: ...his directs the hydraulic oil to the top port on the Squeegee Deck Cylinder to lower the squeegee C3 C4 C2 C1 1 02 CIR Check Valve 270 PSI Reservoir Auxiliary Pump 8 2 GPM 1 5 GPM Cylinder Control Valve P T To Squeegee Vacuum Motor Scrub Brush Solenoid 6 Scrub Brush Solenoid 8 Squeegee Cylinder Solenoid 7 Squeegee Lock Up 10 Scrub Brush Lock Up Solenoid 9 Squeegee Deck Cylinder To and From Scrub D...

Page 98: ...ssembly is mounted to the Squeegee Support Weldment on the rear of the machine The swing squeegee support connects the rear squeegee assembly to the machine frame The Squeegee Arms form parallel linkages to maintain the squeegee angle when the squeegee is raised and lowered The Squeegee Supports pivot on Shafts to allow the squeegee to move side to side Rear Squeegee Assembly Squeegee Support Weld...

Page 99: ...linder Solenoid 7 and Squeegee Lock Up 10 solenoid are part of the Cylinder Control Valve located below the access panel on the floor of the Operator compartment The hydraulic hose from Port C3 on the Cylinder Control Valve is connected to the upper port on the squeegee deck cylinder The hydraulic hose from Port C4 on the Cylinder Control Valve is connected to the lower port on the squeegee deck c...

Page 100: ...ee Cylinder Solenoid 7 in the Cylinder Control Valve 1 Check circuit breaker CB8 and reset if necessary 2 Check the continuity from CB8 through the Squeegee Blade Switch to the Squeegee Cylinder Solenoid 7 There should be 12 VDC to the Squeegee Cylinder Solenoid 7 with the Squeegee Blade Switch in the squeegee raise position The Squeegee Cylinder Solenoid 7 in the Cylinder Control Valve not switch...

Page 101: ... 206 Service Manual Advance 7765 Nilfisk CR1500 Specifications Component Specifications Squeegee Lock Up 10 Solenoid Valve Squeegee Cylinder Solenoid 7 Valve Initial Current 1 22 amps Nominal Coil Resistance 7 2 ohms ...

Page 102: ...g wheel rotates the shaft on the power steering unit which controls the oil flow to the Power Steering Cylinder The Power Steering Cylinder extends and retracts the attached Rack which then rotates the Spur Gear and attached Rear Wheel Support to turn the Rear drive Wheel Spur Gear Rack Rear Wheel Support Hydraulic Connections to Power Steering Unit Power Steering Cylinder Rear Wheel Rear Wheel Mo...

Page 103: ... of the Power Steering Unit goes to the pressure side P port on the Cylinder Control Valve The Power Steering Cylinder is connected to the R and L ports on the Power Steering Unit Power Steering Unit Steering Column Assembly Steering Weldment Housing Steering Wheel Power Steering Unit From Priority Port on the Auxiliary Pump To Power Steering Cylinder To Port P on the Cylinder Control Valve To Pow...

Page 104: ...ts current position The number of degrees that the Gerotor Metering Mechanism rotates determines the volume of oil that the Power Steering Cylinder receives from the Valve This allows the drive wheel to turn in proportion to the steering wheel rotation Steering Wheel Stationary When the engine is running the Auxiliary Pump sends oil through the priority flow divider to the P port on the Power Stee...

Page 105: ...ering Mechanism The Gerotor Metering Mechanism sends the appropriate volume of oil to the Power Steering Cylinder corresponding to the amount of steering wheel rotation Power Steering Unit 1500 PSI 3 05 CIR P T Power Steering Cylinder L R Reservoir Auxiliary Pump 1 02 CIR 1 5 GPM To Cylinder Control Valve To Squeegee Vacuum Motor Gerotor Metering Mechanism Direct Mechanical Link Drive Wheel Moves ...

Page 106: ...Mechanism The Gerotor Metering Mechanism again sends the appropriate volume of oil to the Power Steering Cylinder corresponding to the amount of steering wheel rotation Power Steering Unit 1500 PSI 3 05 CIR P T Power Steering Cylinder L R Reservoir Auxiliary Pump 1 02 CIR 1 5 GPM To Cylinder Control Valve To Squeegee Vacuum Motor Gerotor Metering Mechanism Direct Mechanical Link Drive Wheel Moves ...

Page 107: ...e the Relief Valve opens up to allow the hydraulic oil to pass through the Relief Valve and to the Cylinder Control Valve The Relief Valve will also open if something is preventing the drive wheel from rotating to steer Power Steering Unit 3 05 CIR P T Power Steering Cylinder L R Reservoir Auxiliary Pump 1 02 CIR 1 5 GPM To Cylinder Control Valve To Squeegee Vacuum Motor Steering Wheel Held at Ful...

Page 108: ... turned The Check Valve allows the oil pumped from the Gerotor Metering Mechanism to flow to and from the Power Steering Cylinder to allow the machine to be steered manually with the engine off Power Steering Unit 1500 PSI 3 05 CIR P T Power Steering Cylinder L R Reservoir Auxiliary Pump 1 02 CIR 1 5 GPM To Cylinder Control Valve To Squeegee Vacuum Motor Gerotor Metering Mechanism Direct Mechanica...

Page 109: ...e every 100 hours of operation Note that the Rear Wheel Support Lubrication Fitting is mounted on the bottom of the Rear Wheel Support There is a Cutout in the frame to allow access to the Rack Guide Lubrication Fitting Service Note To grease the Rack turn the steering wheel all the way toward the right This will extend the Rack toward the rear of the machine to allow you to grease the teeth on th...

Page 110: ...ling any machine components make sure the key switch is off the key is removed from the machine and the parking brake is engaged Note If the steering cylinder is removed mark the teeth where the rack engages the spur gear so the rack and spur gear engage at the same location when the steering cylinder is reinstalled Specifications Component Specifications Steering Rear wheel hydraulic cylinder and...

Page 111: ...m and Idler Arm The Hydraulic Broom Drive Motor mounts to the Broom Drive Arm and drives the Main Broom via the Broom Driver Hub The Broom Drive Arm and Idler Arm are attached to the Broom Chamber Shaft which is located inside of the broom chamber The Broom Chamber Shaft clamps to the Shaft and attached RH and LH Arm Assemblies The Shaft RH and LH Arm Assemblies are located outside of the broom ch...

Page 112: ...Broom Lift Control Lever forward and backward extends and retracts the Adjusting Rod which then rotates the Crank The Crank raises and lowers the Broom Lift Link which then raises and lowers the Shaft to lift or lower the main broom assembly Main Broom Lift Control Lever Broom Lift Link Shaft Crank Adjusting Rod ...

Page 113: ...2 valve in the Main Control Valve supplies hydraulic oil to the main broom and dust control motors from Port 1 The oil returns from the motors to the Main Control Valve at Port 2 Oil from Port 1 to Main Broom and Dust Control Motors Oil From Main Broom and Dust Control Motors to Port 2 Main Control Valve Main Broom Solenoid 2 ...

Page 114: ...the Ignition Switch is on and the Main Broom Switch on the instrument panel is switched on Note that the Hopper Switch and the Hopper Door Switch must both be closed for the main broom motor to operate Also refer to the Main Broom Sweep System Hydraulic Diagrams section Hopper Switch Hopper Door Switch Held Closed by Hopper Held Closed by Door 15 57 1 Main Broom Switch 2 Main Broom Solenoid 2 38 B...

Page 115: ...y leg of the priority flow divider then through the Main Broom Solenoid 2 valve The oil will then flow to the Normal Rotation Brush 4 solenoid valve bypassing both the Main Broom Motor and the Dust Control Motor 4 50 CIR 75 GPM Main Broom Motor 1 2 1 02 CIR 1 24 CIR Return Block Reservoir Auxiliary Pump Drive Pump 9 7 GPM Main Broom Solenoid 2 To Normal Rotation Brush 4 To Side Broom Valve To Retu...

Page 116: ...ain Broom Motor and Dust Control Motor The oil will then flow from the discharge side of the Dust Control Motor to port 2 on the Main Control Valve The Case Drain from the Main Broom Motor goes to the Return Block 4 50 CIR 75 GPM Main Broom Motor 1 02 CIR 1 24 CIR Return Block Reservoir Auxiliary Pump Drive Pump 9 7 GPM Main Broom Solenoid 2 To Normal Rotation Brush 4 To Side Broom Valve To Dust C...

Page 117: ...ontrol Valve The Main Broom is located inside the broom chamber The Hydraulic Broom Drive Motor is mounted on the Broom Drive Arm The upper portion of the main broom linkage consists of the Main Broom Lift Control Lever Adjusting Rod and Crank Moving the Main Broom Lift Control Lever moves the Adjusting Rod that pivots the Crank Hydraulic Broom Drive Motor Broom Drive Arm Main Broom Crank Main Bro...

Page 118: ...Manual Advance 7765 Nilfisk CR1500 The lower portion of the main broom linkage consists of the Crank and Broom Lift Link As the Crank pivots it moves the Broom Lift Link up and down to raise and lower the main broom Broom Lift Link Crank ...

Page 119: ...and to the left of the scrub deck When the Main Broom Solenoid 2 valve is energized it closes to direct the oil flow through Port 1 on the Main Control Valve The oil is directed through the main broom motor and dust control motor then returns to Port 2 on the Main Control Valve Main Control Valve bottom view shown mounted in assembled machine Main Control Valve Port 1 Port 2 Main Control Valve top...

Page 120: ...emoved from the machine and the parking brake is engaged To Adjust the Main Broom Height 1 Loosen one of the Jam Nuts holding the Adjusting Rod in position on the Broom Lever Bracket 2 Adjust the position of the Jam Nuts on the Adjusting Rod to raise or lower the main broom height as necessary 3 When the main broom height is correct tighten the two Jam Nuts Jam Nut Jam Nut Adjusting Rod Broom Leve...

Page 121: ...g from the Main Broom Switch to the Main Broom Solenoid 2 valve There should be 0 volts to the solenoid when the main broom and dust control motors are off and 12 VDC to the solenoid when the motors are on Main Broom Solenoid 2 valve not operating correctly 1 Check the solenoid coil resistance If not 7 2 ohms 10 replace the coil Also see the Main Broom Sweep System Wiring Diagram 2 If the coil res...

Page 122: ... CIR auxiliary pumps powers the Hydraulic Side Broom Motor The Side Broom Switch on the instrument panel switches the side broom on and off The Operator manually raises and lowers the Side Broom with the Lift Knob and Cable connected to the pivoting Side Broom Arm Weldment The side broom sweep system is standard on variable dump models and is available as an option on manual dump models Lift Knob ...

Page 123: ... Broom Switch on the instrument panel is switched on Note that the Hopper Switch and the Hopper Door Switch must both be closed for the side broom motor to operate Also refer to the Side Broom Sweep System Hydraulic Diagrams section To Top of Return Block To B Port on Side Broom Motor To A Port on Side Broom Motor From P1 on Main Control Valve Side Broom Valve Hopper Switch Hopper Door Switch Held...

Page 124: ...en This allows the hydraulic oil to flow from the Auxiliary Pump through priority leg of the priority flow divider then through the Side Broom Valve The oil will then flow to the Return Block and Filter then to the Reservoir Side Broom Valve A B Side Broom Motor 1 93 CIR 75 GPM P P1 1 02 CIR Return Block Reservoir Filter 9 7 GPM To Main Broom Solenoid 2 To Return Block Auxiliary Pump 2500 PSI Main...

Page 125: ...ump through priority leg of the priority flow divider then through the Side Broom Valve and Side Broom Motor The oil will then flow from the discharge side of the Side Broom Motor to the Return Block and Filter then to the Reservoir Side Broom Valve A B Side Broom Motor 1 93 CIR 1 02 CIR Return Block Reservoir Filter 9 7 GPM Auxiliary Pump 75 GPM P P1 To Main Broom Solenoid 2 To Return Block 2500 ...

Page 126: ...lve The Side Broom and Side Broom Motor are mounted on the Side Broom Arm Weldment The Side Broom Arm Weldment is attached to the machine frame and pivots up and down to raise and lower the Side Broom The Side Broom Valve is mounted below the floor of the Operator compartment and to the right of the Cylinder Control Valve Side Broom Motor Side Broom Arm Weldment Side Broom Side Broom Valve Cylinde...

Page 127: ... Adjust the Side Broom Height 1 Remove the Cotter Pin from the Pin 2 Remove the Pin holding the Clevis to the Strap 3 Loosen the Locking Nut and rotate the Clevis as necessary to raise or lower the side broom height 4 Once the side broom height is correct reinstall the Pin into the Clevis and Strap 5 Install a new Cotter Pin into the Pin 6 Make sure the Clevis and Strap move freely with no binding...

Page 128: ...e Broom Switch function and repair replace as necessary Check the wiring from the Side Broom Switch to the Side Broom Solenoid 5 There should be 0 volts to the solenoid when the Side Broom Switch is off and 12 VDC to the solenoid when the Side Broom Switch is on Side Broom Solenoid 5 is not operating 1 Check the coil resistance of the Side Broom Solenoid 5 If not 10 1 ohms 10 replace the coil 2 If...

Page 129: ... and cotter pin hold the Front Wheel Hubs and attached Molded Wheels and Brake Discs and the associated roller bearings and washers onto the Stub Axle Weldments The brake rods actuate the Brake Caliper Assembly Weldments which compress the brake pads against the Brake Discs to stop the machine Four 1 2 20 x 1 0 HHC Screws fasten the Stub Axle Weldments to the machine frame Brake Caliper Assembly W...

Page 130: ...rake caliper assembly weldments on the frame When the Brake Pedal pivots the Cross Shaft the Brake Rods actuate the brake caliper assembly weldments to apply the machine brakes When the Parking Brake Lever is lifted it pulls on the Parking Brake Cable The Parking Brake Cable pivots the Cross Shaft to hold the machine brakes in the applied position Cross Shaft Brake Pedal Brake Rod 2 Brake Pedal Cl...

Page 131: ...s to the Cross Shaft 4 Rotate the 3 8 Rod Clevis to adjust the brake tension on the corresponding wheel as necessary 5 Reinstall the 5 16 18 Screw and nut 6 Make sure the 3 8 Rod Clevis is aligned with the Cross Shaft then tighten the 3 8 16 Jam Nut 7 Close and latch the broom chamber door 8 Repeat steps 1 through 7 above for the other front wheel brake Note that the brakes on both front wheels sh...

Page 132: ...eldment are damaged Check the wheel and stub axle weldment and replace as required The brakes are not working correctly The brakes are out of adjustment Adjust the brake tension The brake linings are worn out Replace the brake linings Specifications Component Specifications Brakes service Mechanical disc brakes one on each front wheel cable actuated Wheel front load bearing Size 16 in x 3 5 in 406...

Page 133: ...oling purposes This leaked oil returns to the reservoir and requires make up oil that is supplied to the drive pump through the charge circuit Drive Pump The Drive Pump is driven by the engine and powers the hydraulic drive wheel motor Note that the Drive Pump was changed in early 2010 beginning with machine serial number 1000034942 from part number 7 60 05026 to part number 56514943 This change a...

Page 134: ...e motor receives the hydraulic oil This determines the machine direction The distance to which the swash plate is moved determines the volume of hydraulic oil to the drive motor This determines the machine speed Note that the forward reverse controls for the GM and Mitsubishi engines are different The forward reverse controls also vary depending on which model drive pump is installed part number 7...

Page 135: ...ion Arm to the neutral position when the foot pedal is released Forward Reverse Controls GM Engines After s n 1000034942 The foot pedal actuates the Forward Reverse Cable which connects to the Hydroback The Hydroback transfers the Forward Reverse Cable motion to the Pintle Arm Weldment which pivots the swash plate inside of the Drive Pump to control the machine direction and speed The Hydroback re...

Page 136: ...Assembly GM Engines The Foot Pedal pivots on the Foot Pedal Mount Brackets to move the Forward Reverse Cable forward and backward The Forward Reverse Cable actuates the forward reverse controls connected to the drive pump Foot Pedal Forward Reverse Cable Foot Pedal Mount Bracket 2 ...

Page 137: ...Plate and Transmission Arm Weldment The Transmission Arm Weldment pivots the swash plate inside of the Drive Pump to control the machine direction and speed The Centering Control returns the Foot Pedal Forward Reverse Cable Shift Arm Transmission Arm Plate and Transmission Arm Weldment to the neutral position when the Foot Pedal is released Foot Pedal Forward Reverse Cable Shift Arm Transmission A...

Page 138: ...o the Hydroback The Hydroback transfers the Forward Reverse Cable motion to the Pintle Arm Weldment which pivots the swash plate inside of the Drive Pump to control the machine direction and speed The Hydroback returns the Foot Pedal Forward Reverse Cable and Pintle Arm Weldment to the neutral position when the Foot Pedal is released Foot Pedal Forward Reverse Cable Hydroback Pintle Arm Weldment D...

Page 139: ...ar Wheel Support The standard Rear Wheel Motor is a 15 4 CIR hydraulic motor that drives the Rear Wheel The two top Hydraulic Hoses are connected to the drive pump The bottom Hydraulic Hose is the Case Drain connected to the return block When the internal tow valve in the drive pump is actuated it bypasses the hydraulic circuit from the drive pump to the Rear Wheel Motor to allow the Rear Wheel to...

Page 140: ...sor and Drive Pedal Reverse Sensor These sensors are proximity sensors that actuate the Forward Relay and Reverse Relay to enable and disable the machine functions that are related to the direction of machine travel 15 A 7 30 B 7 Battery 12 VDC Bat Ignition Switch R4 Forward Relay Drive Pedal Forward Sensor 12 56 1 2 3 46 85 86 CB5 2 1 87a 87 CB5 2 1 87a 87 R3 Reverse Relay Drive Pedal Reverse Sen...

Page 141: ... When the foot pedal is in the neutral position with the engine running the Drive Pump will not send any oil to the Rear Wheel Motor Tow bypass Valve Relief Valve Relief Valve Check Valve Check Valve 15 4 CIR 1 24 CIR Return Block Vonberg Check Valve 120 psi 2200 RPM Rear Wheel Motor Drive Pump From Main Broom Motor ...

Page 142: ...n the oil is free to flow to and from the Rear Wheel Motor through the Tow Valve when the rear wheel is rotated bypassing the Drive Pump Refer to the General Information Towing or Pushing the Machine subsection in this manual Note that while only one drive wheel direction is shown in the drawing below the Tow Valve functions the same when the drive wheel is moved in either forward or reverse Tow V...

Page 143: ...he foot pedal moves the swash plate in the Drive Pump controls the machine direction The distance to which the foot pedal moves the swash plate in the Drive Pump controls the machine speed The Check Valves control the oil flow to the Drive Pump charge circuits The case drain from the Rear Wheel Motor goes to the Return Block Tow bypass Valve Relief Valve Relief Valve Check Valve Check Valve 15 4 C...

Page 144: ...any reason rear wheel stalled etc the corresponding internal Relief Valve in the Drive Pump will open to bypass the Rear Wheel Motor to prevent damage to the hydraulic components Tow bypass Valve Relief Valve Relief Valve open Check Valve Check Valve 15 4 CIR 1 24 CIR Return Block Vonberg Check Valve 120 psi 2200 RPM Rear Wheel Motor Drive Pump From Main Broom Motor ...

Page 145: ... Adjustment 1 Jack up the rear of the machine to get the drive wheel up off the ground 2 Install safety blocks or stands to support the rear of the machine 3 Start the engine and observe the wheel rotation with the engine idling If the wheel is rotating either forward or reverse with the drive pedal in the neutral position adjust the Hydroback as follows a Loosen the two 3 8 16 Screws holding the ...

Page 146: ...or forward reverse controls are damaged or dirty Clean or replace the cable or forward reverse controls as necessary Specifications Component Specifications Component Specifications Tire rear drive steer Size 16 in x 6 in 406 mm x 152 mm Rear Drive Wheel Motor Displacement Standard Motor 15 4 CIR High torque Motor 19 8 CIR Shaft Rotation Clockwise as viewed from slot end Drive Pump Type manually v...

Page 147: ...s Description Torque Specification Steering Castle Spindle Nut Torque to 40 ft lb 54 Nm then loosen to align cotter pin 20 Lug Nut Torque to 100 ft lb 135 Nm 13 Hex Nut Torque to 100 ft lb 135 Nm 16 Slotted Hex Nut 270 ft lb 366 Nm Steering Castle Spindle Nut 1 2 20 Lug Nut 5 1 2 13 Hex Nut 4 Slotted Hex Nut ...

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