Nilfisk-Advance 7765 Service Manual
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Nilfisk-Advance 7765 Service Manual

Nilfisk-Advance 7765 Service Manual

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Service Manual – Advance 7765 / Nilfisk CR1500
Engine System, Gasoline/LPG
106

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Summary of Contents for Nilfisk-Advance 7765

  • Page 1 Service Manual – Advance 7765 / Nilfisk CR1500 Engine System, Gasoline/LPG...
  • Page 2 Service Manual – Advance 7765 / Nilfisk CR1500 Engine System, Gasoline/LPG...

  • Page 3: Specifications

    Service Manual – Advance 7765 / Nilfisk CR1500 Engine System, Gasoline/LPG Specifications Engine Specifications 3.0 L GM Vertical, liquid cooled, four-cylinder, push rod actuated Engine type overhead valve, solid-state distributor Displacement 181 cubic inches (2966 cc) Compression Ratio 9.2:1 87 or 89 octane unleaded gasoline with no more than...

  • Page 4: Special Tools

    Service Manual – Advance 7765 / Nilfisk CR1500 Engine System, Gasoline/LPG Special Tools Diagnostic Communication Cable and software, p/n 56305647 Cooling System Tool...

  • Page 5: Hopper System

    Service Manual – Advance 7765 / Nilfisk CR1500 Hopper System Functional Description Overview The hopper system holds the dust and debris swept up by the brooms. There are two different hopper configurations; a manual dump (MD) hopper and a variable dump (VD) hopper.
  • Page 6 Service Manual – Advance 7765 / Nilfisk CR1500 Hopper System Hopper – Variable Dump Machines Variable Dump pivots on the Hopper supported by the frame. Hopper Lift Cylinder swings the Variable Dump up to allow it to be Variable Hopper...
  • Page 7 Service Manual – Advance 7765 / Nilfisk CR1500 Hopper System The hydraulic valves that control the are mechanically Hopper Lift Cylinder Hopper Dump Cylinder actuated by the and the respectively. connect the Hopper Lift Lever Hopper Dump Door Lever Links...
  • Page 8 Service Manual – Advance 7765 / Nilfisk CR1500 Hopper System Hopper System Wiring Diagram – Variable Dump Machine Battery 12 VDC Ignition Bat. Switch Shaker Motor Switch Shaker Relay Hopper Switch Hopper Door Switch Option N.O. N.O. 15 A (Held Closed by Hopper)
  • Page 9 Service Manual – Advance 7765 / Nilfisk CR1500 Hopper System Hopper System Hydraulic Diagrams – Variable Dump Machine Hopper Control Valves in Neutral Position Hopper Control Valve Hopper Dump Cylinder Valve Hopper Lift Lift Cylinder Cylinder Valve Cooler Dump Cylinder...
  • Page 10 Service Manual – Advance 7765 / Nilfisk CR1500 Hopper System Lift Hopper Hopper Control Valve Hopper Hopper Dump Down Lift Cylinder Valve Hopper Hopper Lift Lift Cylinder Cylinder Valve Close Door Open Door Cooler Dump Cylinder From Scrub Brush Motors...

  • Page 11: Lower Hopper

    Service Manual – Advance 7765 / Nilfisk CR1500 Hopper System Lower Hopper Hopper Control Valve Hopper Hopper Dump Down Lift Cylinder Valve Hopper Hopper Lift Lift Cylinder Cylinder Valve Close Door Open Door Cooler Dump Cylinder From Scrub Brush Motors...
  • Page 12 Service Manual – Advance 7765 / Nilfisk CR1500 Hopper System Open Hopper Dump Door Hopper Control Valve Hopper Hopper Dump Down Lift Cylinder Valve Hopper Hopper Lift Lift Cylinder Cylinder Valve Close Door Open Check Door Valve w/Pilot Cooler Dump Cylinder...
  • Page 13 Service Manual – Advance 7765 / Nilfisk CR1500 Hopper System Close Hopper Dump Door Hopper Control Valve Hopper Hopper Dump Down Lift Cylinder Valve Hopper Hopper Lift Lift Cylinder Cylinder Valve Close Door Open Door Cooler Dump Cylinder From Scrub...

  • Page 14: Component Locations

    Service Manual – Advance 7765 / Nilfisk CR1500 Hopper System Component Locations The following components are included in this section: • Hopper Lift Cylinder • Hopper Dump Door Cylinder • Hopper Switch and Hopper Door Switch • Hopper Control Valve...
  • Page 15 Service Manual – Advance 7765 / Nilfisk CR1500 Hopper System is mounted on the frame Hopper Control Valve to the right of the hydraulic pumps. The Links connect to the two individual valves to the hopper lift lever and hopper dump door lever.
  • Page 16 Service Manual – Advance 7765 / Nilfisk CR1500 Hopper System • The connecting Pins Collars Hopper Dump Door Cylinder to the Hopper Dump Door hopper yoke. Collar (2) Hopper Hopper Dump Dump Door Door Cylinder • The . Note Hopper Pivot Points...
  • Page 17 Service Manual – Advance 7765 / Nilfisk CR1500 Hopper System • The four hopper rod Grease Fittings Grease Grease Fittings Fittings Warning! Never work under the hopper without first engaging the Safety Lock Arm. Safety Lock Arm (shown in engaged position)

  • Page 18: Troubleshooting

    Service Manual – Advance 7765 / Nilfisk CR1500 Hopper System Troubleshooting Problem Cause Correction Hopper not rising The hopper lift cylinder valve Check the hopper lift cylinder valve and repair/ when the hopper lift in the hopper control valve replace as necessary.

  • Page 19: Hydraulic System

    Service Manual – Advance 7765 / Nilfisk CR1500 Hydraulic System Functional Description Overview The hydraulic system powers the drive wheel motor, scrub brushes, vacuum fan, main broom, and side broom (if the machine is so equipped). The hydraulic system also actuates the scrub deck and squeegee deck cylinders, hopper lift and hopper door cylinders (VD machines only), and the power steering unit and power steering cylinder.
  • Page 20 Service Manual – Advance 7765 / Nilfisk CR1500 Hydraulic System • The is a Auxiliary Pump multiple-gear pump. Two separate 1.02 CIR output ports power the other machine From Reservoir systems. Note that the gas and diesel fitting configurations are...
  • Page 21 Service Manual – Advance 7765 / Nilfisk CR1500 Hydraulic System • The Cylinder Control controls the Valve oil flow to the scrub deck cylinder and squeegee deck cylinder. Cylinder Control Valve To Lower Port on Squeegee Deck Cylinder To Upper Port on Scrub...

  • Page 22: Electrical Schematic

    Service Manual – Advance 7765 / Nilfisk CR1500 Hydraulic System Electrical Schematic Battery 12 VDC Ignition Bat. Switch Acc. Hopper Switch Hopper Door Switch Option N.O. N.O. 15 A (Held Closed by Hopper) (Held Closed by Door) Dust Control Switch...
  • Page 23 Service Manual – Advance Condor™ XL, Nilfisk ER 1300/1600 Hydraulic System Hydraulic Schematics Squeegee Deck Side Cylinder Variable Dump Machine Broom Cylinder Valve Control Squeegee Valve Lock Up (10) 1.93 Hopper Squeegee Control Cylinder Side Broom Hopper Dump Valve Solenoid (7) Cylinder Valve Motor Scrub...
  • Page 24 Service Manual – Advance Condor™ XL, Nilfisk ER 1300/1600 Hydraulic System Manual Dump Machine Squeegee Deck Side Cylinder Broom Cylinder Valve Control Squeegee Valve Lock Up (10) 1.93 Squeegee Cylinder Side Broom Solenoid (7) Motor (optional) Scrub Deck Cylinder Scrub Brush Solenoid (6) 2200 Squeegee...
  • Page 25 Service Manual – Advance 7765 / Nilfisk CR1500 Hydraulic System Component Locations The following components are included in this section: • Hydraulic Pumps • Hydraulic Reservoir • Oil Filter • Oil Cooler • Main Control Valve • Cylinder Control Valve •...
  • Page 26 Service Manual – Advance 7765 / Nilfisk CR1500 Hydraulic System is located to the right Hydraulic Oil Reservoir of and below the Operator seat. A Fluid Level shows the oil level in the Sight Gauge Hydraulic Oil Clogging Indicator Reservoir...
  • Page 27 Service Manual – Advance 7765 / Nilfisk CR1500 Hydraulic System is mounted to the rear of the engine Oil Cooler Radiator Radiator Cooler is mounted on the underside of the machine, in front of and to the left of the scrub Main Control Valve deck.
  • Page 28 Service Manual – Advance 7765 / Nilfisk CR1500 Hydraulic System Cylinder Control Valve located below the access panel on the floor of the Operator Scrub Brush Scrub Brush Solenoid (6) Solenoid (8) compartment. Squeegee Lock Up Solenoid (10) Cylinder Control Valve...

  • Page 29: Maintenance And Adjustments

    Service Manual – Advance 7765 / Nilfisk CR1500 Hydraulic System Maintenance and Adjustments Warning! Before performing any machine maintenance or adjustments, make sure the key switch is off, the key is removed from the machine and the parking brake is engaged.

  • Page 30: General Troubleshooting

    Service Manual – Advance 7765 / Nilfisk CR1500 Hydraulic System Troubleshooting General Troubleshooting Problem Cause Correction General poor Low oil hydraulic level. Check the oil level in the reservoir hydraulic and add oil as necessary. performance. Hydraulic oil temperature too high.
  • Page 31 Service Manual – Advance 7765 / Nilfisk CR1500 Hydraulic System Checking Nominal Pressure Readings Note: There are two #8 Flat Face O-ring Fittings on the that can be used to Auxiliary Auxiliary Pump Pump check the pressure from both sides of the . Checking the hydraulic Auxiliary Pump...

  • Page 32: General Specifications

    Service Manual – Advance 7765 / Nilfisk CR1500 Hydraulic System Specifications General Specifications Component Specifications System Capacity – 16.5 gal. [62.46 L] Capacities Reservoir Capacity – 6 gal. [22.7 L] Fluid Type Mobil Multi Purpose ATF or equivalent Dexron III fluid Type – manually-variable displacement, axial piston pump, tow valve included Displacement –...
  • Page 33 Service Manual – Advance Condor™ XL, Nilfisk ER 1300/1600 Hydraulic System Scrub Deck Hydraulic Specifications In Neutral Forward or Reverse Forward Scrub Brush Rotation Reverse Scrub Brush Rotation Scrub Deck Raised Scrub Deck Raised Scrub Deck Normal Down Scrub Deck Heavy Down Scrub Deck Normal Down Scrub Deck Heavy Down Hose...
  • Page 34 Service Manual – Advance Condor™ XL, Nilfisk ER 1300/1600 Hydraulic System Steering Circuit Hydraulic Specifications Steering Only: Stationary Locked Full Locked Full Clockwise Neutral/Center Counterclockwise Hose Location Pressure Flow Pressure Flow Pressure Flow 7-33-02191 Power Steering Unit “T” Port 400 PSI 1.4 GPM 380 PSI 1.4 GPM...
  • Page 35 Service Manual – Advance Condor™ XL, Nilfisk ER 1300/1600 Hydraulic System Main Broom Hydraulic Specifications – GM Engines With Hopper Valves in “Neutral” Main Broom Only ON Hose Location Pressure Flow 8-33-02214 Main Broom Motor Inlet from Main Control Valve “1” Port 970 PSI 420 RPM 8.25 GPM...
  • Page 36 Service Manual – Advance Condor™ XL, Nilfisk ER 1300/1600 Hydraulic System Dust Control System Hydraulic Specifications – GM Engines (Variable Dump Models) With Hopper Valves in “Neutral” Main Broom On Dust Control On Dust Control Off Hose Location Pressure Flow Pressure Flow Dust Control Motor Inlet...
  • Page 37 Service Manual – Advance Condor™ XL, Nilfisk ER 1300/1600 Hydraulic System Squeegee System Hydraulic Specifications – GM 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 <...
  • Page 38 Service Manual – Advance 7765 / Nilfisk CR1500 Hydraulic System Note: The cylinder Pressures and Flow rates on the preceding pages are with the hopper stabilized and at rest. Peak relief pressure is 2500 psi. The pressure while raising the hopper will depend on the weight of the hopper. If the hopper dump door cylinder or hopper lift cylinder is fully-extended or retracted (dump door only) and the lever is not returned to the neutral position, the pressure will go to the relief setting of 2500 psi. Main Control Valve Specifications Main Control Valve Component Component Description Hydraulic Circuit Function 2500 psi [172.4 bar] Relief Valve...
  • Page 39 Service Manual – Advance 7765 / Nilfisk CR1500 Hydraulic System Cylinder Control Valve Specifications Cylinder Control Valve Component Component Description Hydraulic Circuit Function A solenoid-operated, two-way, normally closed, Scrub Brush Lock Up Solenoid (9) poppet-type, screw-in hydraulic cartridge valve A solenoid-operated, three-way, direct-acting, spool-...
  • Page 40 Service Manual – Advance 7765 / Nilfisk CR1500 Hydraulic System 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: Recovery System

    Service Manual – Advance 7765 / Nilfisk CR1500 Recovery System Functional Description Overview The recovery system picks up the scrubbing solution from the floor and directs it into the recovery tank. The squeegee vacuum fan, driven by a hydraulic motor powered by the auxiliary pump, draws air from the recovery tank to create a vacuum in the tank and at the squeegee to pick up the solution.
  • Page 42 Service Manual – Advance 7765 / Nilfisk CR1500 Recovery System will actuate the Recovery High (Float) Switch High Recovery Warning Light approximately five minutes before the recovery tank is full to allow time to complete the scrubbing cycle before the float ball shuts off the vacuum to the recovery tank.
  • Page 43 Service Manual – Advance 7765 / Nilfisk CR1500 Recovery System Vacuum Motor/Fan Assembly The hydraulic drives Vacuum Motor that spins in the Impeller Fan Duct to create the vacuum in the recovery Solenoid tank. Valve Vacuum Motor and fan assembly...
  • Page 44 Service Manual – Advance 7765 / Nilfisk CR1500 Recovery System Recovery System Wiring Diagram – Standard Recovery System Battery 12 VDC Ign. Ignition Bat. Switch Acc. Squeegee Blade Switch 15 A Squeegee Fan Motor Solenoid (12) Reverse Relay High Recovery...
  • Page 45 Service Manual – Advance 7765 / Nilfisk CR1500 Recovery System Recovery System Hydraulic Diagrams Squeegee Vacuum Fan Off When the Squeegee is off, Vacuum Motor Squeegee Fan Motor 2200 Squeegee Squeegee is energized. Vacuum Fan Motor Solenoid (12) 0.151 Relief...
  • Page 46 Service Manual – Advance 7765 / Nilfisk CR1500 Recovery System Squeegee Vacuum Fan Stalled If the Squeegee Vacuum stalls, the Motor 2200 PSI opens to allow Relief Valve 2200 Squeegee Squeegee the oil to flow through Vacuum Fan Motor 0.151...

  • Page 47: Recovery Tank

    Service Manual – Advance 7765 / Nilfisk CR1500 Recovery System Component Locations The following components are included in this section: Also refer to the section. Solution System • Recovery Tank • Recovery Tank Lid • Drain Plug Assembly • Recovery High (Float) Switch •...
  • Page 48 Service Manual – Advance 7765 / Nilfisk CR1500 Recovery System can be removed to Drain Plug Assembly drain the through the Recovery Tank Drain Hose The red will Recovery High (Float) Switch actuate the High Recovery Warning Light Drain Plug...
  • Page 49 Service Manual – Advance 7765 / Nilfisk CR1500 Recovery System are mounted Vacuum Motor Fan Assembly on the . The Recovery Tank Lid Recovery Tank Lid Float Ball Float Ball swings open to allow access to the Strap Float Ball...

  • Page 50: Daily Maintenance

    Service Manual – Advance 7765 / Nilfisk CR1500 Recovery System Maintenance 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. Daily Maintenance • Check the gasket on the recovery tank cover for damage/wear.
  • Page 51 Service Manual – Advance 7765 / Nilfisk CR1500 Recovery System Problem Cause Correction Squeegee vacuum Circuit breaker CB8 is Reset the circuit breaker. fan motor not tripped. running. Squeegee fan motor • Check the wiring from the Squeegee Blade Switch solenoid valve not operating to the fan motor solenoid valve.
  • Page 52 Service Manual – Advance 7765 / Nilfisk CR1500 Recovery System Specifications Component Specifications Displacement – 0.000652 gal/rev; 0.151 CIR Max. Pressure – 1500 psi [103.4 bar] Squeegee Vacuum Fan Motor Max. Speed – 4000 RPM Relief Valve – 2200 psi [151.7 bar] Vacuum Water Lift (Sealed) 30”...

  • Page 53: Scrub System

    Service Manual – Advance 7765 / Nilfisk CR1500 Scrub System Functional Description Overview The scrub system includes the scrub deck, the three hydraulic scrub brush motors, the scrub deck hydraulic cylinder that lowers and raises the deck, and the associated hydraulic solenoid valves. One of the 1.02 CIR auxiliary pumps powers the scrub brush motors.
  • Page 54 Service Manual – Advance 7765 / Nilfisk CR1500 Scrub System Scrub Brush Motor Control Valves Normal Rotation Brush Reverse Normal Rotation Rotation Brush (3) Reverse Brush (4) solenoid valves on Rotation Brush (3) Main Control control the Valve hydraulic oil to...
  • Page 55 Service Manual – Advance 7765 / Nilfisk CR1500 Scrub System Scrub Deck Hydraulic Cylinder and Control Valves lowers and Scrub Deck Hydraulic Cylinder raises the scrub deck. Scrub Brush Solenoid (6) in the Scrub Brush Solenoid (8) Cylinder Control raise and lower the scrub deck and control Valve the two scrub pressures.

  • Page 56: Circuit Descriptions

    Service Manual – Advance 7765 / Nilfisk CR1500 Scrub System Scrub System Wiring Diagram Battery 12 VDC Ignition Bat. Switch 15 A Forward Relay Drive Pedal Forward Sensor Scrub Brush Solenoid (6) Raise Brush Pressure Switch Scrub Brush Solenoid (8)
  • Page 57 Service Manual – Advance 7765 / Nilfisk CR1500 Scrub System Scrub Deck Cylinder in the cylinder Scrub Brush Solenoid (6) Scrub Brush Solenoid (8) Scrub Brush Lock Up Solenoid (9) control valve control the scrub deck hydraulic cylinder to lower and raise the scrub deck, and determine which of the two scrub pressures is used.
  • Page 58 Service Manual – Advance 7765 / Nilfisk CR1500 Scrub System Scrub System Hydraulic Diagrams Scrub Brush Motors Off To Hopper Control Valve 10.0 10.0 10.0 Scrub Brush Motors Return Block Reverse Rotation Brush (3) Dust 0.34 Control Motor Normal Rotation...
  • Page 59 Service Manual – Advance 7765 / Nilfisk CR1500 Scrub System To Hopper Control Valve 10.0 10.0 10.0 Scrub Brush Motors Return Block Reverse Rotation Brush (3) Dust 0.34 Control Motor Normal Rotation Brush (4) Main 4.50 Broom Motor To Side...
  • Page 60 Service Manual – Advance 7765 / Nilfisk CR1500 Scrub System Scrub Brush Motors On To Hopper Control Valve 10.0 10.0 10.0 Scrub Brush Motors Return Block Reverse Rotation Brush (3) Dust 0.34 Control Motor Normal Rotation Brush (4) Main 4.50...
  • Page 61 Service Manual – Advance 7765 / Nilfisk CR1500 Scrub System To Hopper Control Valve 10.0 10.0 10.0 Scrub Brush Motors Return Block Reverse Rotation Brush (3) Dust 0.34 Control Motor Normal Rotation Brush (4) 4.50 Main Broom To Side Motor...
  • Page 62 Service Manual – Advance 7765 / Nilfisk CR1500 Scrub System Scrub Brush Motors Running in Reverse To Hopper Control Valve 10.0 10.0 10.0 Scrub Brush Motors Return Block Reverse Rotation Brush (3) Dust 0.34 Control Motor Normal Rotation Brush (4) 4.50...
  • Page 63 Service Manual – Advance 7765 / Nilfisk CR1500 Scrub System Scrub Deck Down at Normal Scrub Pressure To and From Squeegee Hydraulic Deck Cylinder Power Steering Cylinder Squeegee Cylinder Lock Up (10) Control Valve Power Steering Squeegee Check Valve Unit...
  • Page 64 Service Manual – Advance 7765 / Nilfisk CR1500 Scrub System Scrub Deck Down at High Scrub Pressure To and From Squeegee Hydraulic Power Steering Deck Cylinder Cylinder Squeegee Cylinder Lock Up (10) Control Valve Power Steering Squeegee Check Valve Unit...
  • Page 65 Service Manual – Advance 7765 / Nilfisk CR1500 Scrub System Scrub Deck Up To and From Squeegee Hydraulic Power Steering Deck Cylinder Cylinder Squeegee Cylinder Lock Up (10) Control Valve Power Steering Squeegee Check Valve Unit Scrub 270 PSI Cylinder...
  • Page 66 Service Manual – Advance 7765 / Nilfisk CR1500 Scrub System Scrub Deck Up with Engine Shut Off To and From Squeegee Hydraulic Power Steering Deck Cylinder Cylinder Squeegee Cylinder Lock Up (10) Control Valve Power Steering Squeegee Check Valve Unit...
  • Page 67 Service Manual – Advance 7765 / Nilfisk CR1500 Scrub System Component Locations The following components are included in this section: • Scrub Deck and Hydraulic Scrub Motors • Scrub Deck Hydraulic Cylinder • Main Control Valve • Cylinder Control Valve...
  • Page 68 Service Manual – Advance 7765 / Nilfisk CR1500 Scrub System Normal Rotation Brush (4) solenoid Reverse Rotation Brush (3) valves are part of the Main Control . The Valve Main Control Valve mounted on the underside of the Port 3 machine, in front of and to the left of the scrub deck.
  • Page 69 Service Manual – Advance 7765 / Nilfisk CR1500 Scrub System Scrub Brush Solenoid (6) Scrub Brush Solenoid (8) Scrub Brush are part of the Scrub Brush Scrub Brush Lock Up Solenoid (9) Solenoid (6) Solenoid (8) located below Cylinder Control Valve the access panel on the floor of the Operator compartment.
  • Page 70 Service Manual – Advance 7765 / Nilfisk CR1500 Scrub System Problem Cause Correction Scrub deck will not No voltage to the Scrub 1. Check circuit breaker CB7 and reset if necessary. extend downward Brush Lock Up Solenoid 2. Check the wiring from CB7 to the Scrub Brush...
  • Page 71 Service Manual – Advance 7765 / Nilfisk CR1500 Scrub System Problem Cause Correction Scrub deck not Scrub Brush Solenoid (6) 1. Check the coil resistance of the Scrub Brush being raised to the not opening when energized Solenoid (6). If the coil resistance is not 9.8 ohms retracted position.
  • Page 72 Service Manual – Advance 7765 / Nilfisk CR1500 Scrub System Special Tools Hydraulic test gauge w/connector, 3000 psi range, p/n 56504516...

  • Page 73: Solution System

    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...
  • Page 74 Service Manual – Advance 7765 / Nilfisk CR1500 Solution System Solution Tank The standard Solution Tank holds 100 gallons [379 liters] of solution which is gravity-fed through the ball valve to the scrub Tee-handle brushes. Solution Tank filters the Inlet Strainer...
  • Page 75 Service Manual – Advance 7765 / Nilfisk CR1500 Solution System Solution Flow Control , located to the left Solution Control Lever of the Operator, pivots to move the Solution up and down. The Control Link Solution Control rotates the lever arm on the...
  • Page 76 Service Manual – Advance 7765 / Nilfisk CR1500 Solution System Overview – ESP/Recycle Option On machines equipped with the ESP/Recycle Solution Recovery Solution option, wastewater Pump Tank Tank is pumped from Detergent Recovery Tank Tank to the Solution Tank to be recycled to...
  • Page 77 Service Manual – Advance 7765 / Nilfisk CR1500 Solution System Detergent and Solution Tanks is mounted Detergent Tank in the and supplies Solution Tank detergent to the Detergent Pump in the Detergent Low Switch will light the Detergent Tank warning light on the...
  • Page 78 Service Manual – Advance 7765 / Nilfisk CR1500 Solution System Solution Off in Neutral Option The Solution Off in Neutral Option includes a Solenoid 90° Nipple on between the Valve Tee Fitting Solution Water Feed from the Hose solution tank and 90°...
  • Page 79 Service Manual – Advance 7765 / Nilfisk CR1500 Solution System Power Spray Wand (optional) The optional Power Spray Wand uses a separate 12-volt to pump solution through the solution Water Pump hose on the to the mounted on the . The...
  • Page 80 Service Manual – Advance 7765 / Nilfisk CR1500 Solution System Standard Solution System Wiring Diagram Battery 12 VDC Ign. Ignition Bat. Switch Acc. 15 A Low Solution Warning Light Solution Low Switch Circuit Description The only electrical circuit on the standard Solution System is the wiring and...
  • Page 81 Service Manual – Advance 7765 / Nilfisk CR1500 Solution System ESP/Recycle Option Wiring Diagram ESP On/Off ESP Pump Switch LS-DMP Switch Detergent Pump 9B 1 Rheostat Detergent Switch Detergent Low Light Low Switch Solution Solution High Light High Switch Circuit Description •...
  • Page 82 Service Manual – Advance 7765 / Nilfisk CR1500 Solution System Component Locations The following components are included in this section: • Solution Tank • Solution Low Switch • Drain Hose and Hose Holder • Solution Control Lever • Ball Valve •...
  • Page 83 Service Manual – Advance 7765 / Nilfisk CR1500 Solution System swing out Hose Holder Drain Hose from the side of the machine to free the when draining the solution Drain Hose tank. Drain Hose Hose Holder , to the left of the Operator, actuates the...
  • Page 84 Service Manual – Advance 7765 / Nilfisk CR1500 Solution System is located above the scrub Ball Valve deck and is actuated by Solution Control Ball connected to the solution control Valve Link lever. To access the , remove the Ball Valve...
  • Page 85 Service Manual – Advance 7765 / Nilfisk CR1500 Solution System ESP/Recycle Option is mounted on the machine chassis and pumps ESP Pump filtered solution from the recovery tank to the solution tank. ESP Pump is mounted on the side of the machine chassis Detergent Pump and supplies detergent to the solution line.
  • Page 86 Service Manual – Advance 7765 / Nilfisk CR1500 Solution System (liquid level Detergent Low Switch switch) is mounted inside the detergent tank and switches on the Low Detergent light on the instrument panel when the detergent level is low. Detergent...

  • Page 87: Solution Tank

    Service Manual – Advance 7765 / Nilfisk CR1500 Solution System Maintenance 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. Solution Tank To clean the solution tank: Lift the solution tank lid (cover).
  • Page 88 Service Manual – Advance 7765 / Nilfisk CR1500 Solution System Problem Cause Correction No solution being Recycling System ON/OFF Set the Recycling System ON/OFF switch to ON. transferred from the switch is set to OFF. recovery tank to the Solution inlet filter dirty or Clean or replace the filter.
  • Page 89 Service Manual – Advance 7765 / Nilfisk CR1500 Solution System Specifications Component Specifications Component Specifications Solution Tank 100 gal. [379.L] capacity Voltage – 12 VDC, continuous duty Solution Solenoid Valve (Solution Power Consumption – 11 Watts Off in Neutral option only) Coil Resistance –...

  • Page 90: Squeegee System

    Service Manual – Advance 7765 / Nilfisk CR1500 Squeegee System Functional Description Overview The squeegee system includes the rear squeegee assembly, swing squeegee support, squeegee lift assembly, squeegee deck cylinder and the associated solenoid valves. The rear squeegee assembly is mounted at the bottom rear of the machine and picks up the water from the floor.

  • Page 91: Swing Squeegee Support

    Service Manual – Advance 7765 / Nilfisk CR1500 Squeegee System Swing Squeegee Support on the Squeegee Arms swing squeegee support form parallel linkages that connect the Rear Pin on the Weldments Squeegee Support Weldment Squeegee Supports Vacuum Right These linkages allow the...
  • Page 92 Service Manual – Advance 7765 / Nilfisk CR1500 Squeegee System Squeegee Lift Assembly And Squeegee Deck Cylinder extends Squeegee Deck (Lift) Cylinder and retracts to pivot the Squeegee Lift Arm down and up. raises and lowers Squeegee Lift Arm attached to the...
  • Page 93 Service Manual – Advance 7765 / Nilfisk CR1500 Squeegee System Squeegee Deck Cylinder and Control Valves The top port on the Squeegee Deck Cylinder connected to the on the C3 Port Cylinder Control To C3 Port . The bottom port on the...
  • Page 94 Service Manual – Advance 7765 / Nilfisk CR1500 Squeegee System Squeegee System Wiring Diagram Battery 12 VDC Ignition Bat. Switch 15 A Squeegee Lock Up (10) 15 A Raise (Traverse) Squeegee Squeegee Fan Motor Solenoid (12) Blade Switch 15 A...
  • Page 95 Service Manual – Advance 7765 / Nilfisk CR1500 Squeegee System Squeegee System Hydraulic Diagrams Squeegee Up, Key Switch Off Squeegee Deck Power Steering Cylinder Cylinder Squeegee Cylinder Lock Up (10) Control Valve Power Steering Unit Check Valve Squeegee Squeegee 270 PSI...
  • Page 96 Service Manual – Advance 7765 / Nilfisk CR1500 Squeegee System Squeegee Up, Engine Running Squeegee Deck Power Steering Cylinder Cylinder Squeegee Cylinder Lock Up (10) Control Valve Power Steering Unit Squeegee Check Valve Squeegee Cylinder 270 PSI Solenoid (7) Scrub Brush...
  • Page 97 Service Manual – Advance 7765 / Nilfisk CR1500 Squeegee System Squeegee Down, Engine Running Squeegee Deck Power Steering Cylinder Cylinder Squeegee Cylinder Lock Up (10) Control Valve Power Steering Unit Squeegee Check Valve Squeegee Down Cylinder 270 PSI Solenoid (7)
  • Page 98 Service Manual – Advance 7765 / Nilfisk CR1500 Squeegee System Component Locations The following components are included in this section: • Rear Squeegee Assembly • Swing Squeegee Support • Squeegee Lift • Cylinder Control Valve is mounted to Rear Squeegee Assembly...
  • Page 99 Service Manual – Advance 7765 / Nilfisk CR1500 Squeegee System The squeegee lift includes the Squeegee Deck (Lift) . The Cylinder Squeegee Lift Arm Squeegee Deck is attached to the machine frame on (Lift) Cylinder the upper right rear of the machine, behind the battery.
  • Page 100 Service Manual – Advance 7765 / Nilfisk CR1500 Squeegee System Troubleshooting General Troubleshooting Problem Cause Correction Poor Water Pick-up. The squeegee blades are Check and replace the blades as necessary. torn or worn. The squeegee assembly is Readjust the squeegee. (Refer to the Instructions for out of adjustment.
  • Page 101 Service Manual – Advance 7765 / Nilfisk CR1500 Squeegee System Specifications Component Specifications Squeegee Lock Up (10) Initial Current – 1.22 amps Solenoid Valve Squeegee Cylinder Nominal Coil Resistance – 7.2 ohms Solenoid (7) Valve...

  • Page 102: Steering System

    Service Manual – Advance 7765 / Nilfisk CR1500 Steering System Functional Description Overview The steering system includes the power steering unit, Power Power Steering Cylinder Rack Steering Spur Gear Cylinder The steering wheel rotates the shaft on the power steering unit which...
  • Page 103 Service Manual – Advance 7765 / Nilfisk CR1500 Steering System is mounted to the Power Steering Unit Steering Weldment Housing Steering and is driven by the Column Assembly Steering Steering Wheel Wheel Power Steering Unit Steering Column Assembly Steering Weldment...

  • Page 104: Hydraulic Diagrams

    Service Manual – Advance 7765 / Nilfisk CR1500 Steering System Hydraulic Diagrams Power Steering Unit Description uses the Power Steering Unit input from the steering wheel to turn the drive wheel in the appropriate Power Steering direction to steer the machine. When...
  • Page 105 Service Manual – Advance 7765 / Nilfisk CR1500 Steering System Steering Wheel Turned Toward the Right When the Operator turns the steering wheel to the right, the directs Valve the hydraulic oil to the corresponding Power Steering side of the...
  • Page 106 Service Manual – Advance 7765 / Nilfisk CR1500 Steering System Steering Wheel Turned Toward the Left When the Operator turns the steering wheel to the left, the directs the hydraulic oil to Valve Power Steering the opposite side of the...
  • Page 107 Service Manual – Advance 7765 / Nilfisk CR1500 Steering System Steering Wheel Held in Full Right or Left Position When the steering wheel is held to the stop in its full-right or full-left turn position (full-right is shown here), opens up to allow the...
  • Page 108 Service Manual – Advance 7765 / Nilfisk CR1500 Steering System Turning the Steering Wheel with the Engine Off When the engine is off and no hydraulic oil is being pumped to , the Power Steering Unit Gerotor Power Steering acts like a...
  • Page 109 Service Manual – Advance 7765 / Nilfisk CR1500 Steering System Maintenance Warning! Make sure the steering system and surrounding components are cool to the touch before attempting to grease the steering system lubrication fittings. Failure to observe this safety precaution can result in severe burns.

  • Page 110: Removal And Installation

    Service Manual – Advance 7765 / Nilfisk CR1500 Steering System Troubleshooting Problem Cause Correction The steering Backlash in the spur gear Adjust the rack so it’s closer to the spur gear. “wanders”. and rack The steering is hard Not enough oil to the Check the pump output and correct as necessary.
  • Page 111 Service Manual – Advance 7765 / Nilfisk CR1500 Sweep System, Main Broom Functional Description Overview The main broom sweep system includes the main broom and lift linkage, hydraulic broom drive motor and the main broom solenoid valve. One of the 1.02 CIR auxiliary pumps powers the broom drive motor.

  • Page 112: Main Broom Lift Linkage

    Service Manual – Advance 7765 / Nilfisk CR1500 Sweep System, Main Broom Main Broom Lift Linkage Moving the Main Broom Lift Control forward and backward Lever extends and retracts the Adjusting , which then rotates the Crank raises and lowers the...
  • Page 113 Service Manual – Advance 7765 / Nilfisk CR1500 Sweep System, Main Broom Main Broom Motor Control Valve valve Main Broom Solenoid (2) in the supplies Main Control Valve hydraulic oil to the main broom and dust control motors from Port .
  • Page 114 Service Manual – Advance 7765 / Nilfisk CR1500 Sweep System, Main Broom Main Broom Sweep System Wiring Diagram Battery 12 VDC Ignition Bat. Switch Hopper Switch Hopper Door Switch N.O. N.O. 15 A Main Broom (Held Closed by Hopper) (Held Closed by Door)
  • Page 115 Service Manual – Advance 7765 / Nilfisk CR1500 Sweep System, Main Broom Main Broom Sweep System Hydraulic Diagrams Main Broom Motor Off To Normal Rotation Brush (4) From Dust Control Motor Return Block To Dust Control Motor Main 4.50 Main Broom...
  • Page 116 Service Manual – Advance 7765 / Nilfisk CR1500 Sweep System, Main Broom Main Broom Motor On To Normal Rotation Brush (4) From Dust Control Motor Return Block To Dust Control Motor Main 4.50 Main Broom Broom Solenoid (2) Motor 9.7 GPM...
  • Page 117 Service Manual – Advance 7765 / Nilfisk CR1500 Sweep System, Main Broom Component Locations The following components are included in this section: • Main Broom, Broom Drive Arm and Hydraulic Broom Drive Motor. • Main Broom Lift Linkage • Main Control Valve...
  • Page 118 Service Manual – Advance 7765 / Nilfisk CR1500 Sweep System, Main Broom The lower portion of the main broom linkage consists of the . As the Crank Broom Lift Link pivots, it moves the Crank Broom Crank up and down to raise and Lift Link lower the main broom.
  • Page 119 Service Manual – Advance 7765 / Nilfisk CR1500 Sweep System, Main Broom valve Main Broom Solenoid (2) is part of the Main Control Valve Main and controls the oil flow to the Control Valve main broom motor. The Main is mounted on the...
  • Page 120 Service Manual – Advance 7765 / Nilfisk CR1500 Sweep System, Main Broom Maintenance and Adjustments Warning! Before performing any machine maintenance or adjustments, make sure the key switch is off, the key is removed from the machine and the parking brake is engaged.
  • Page 121 Service Manual – Advance 7765 / Nilfisk CR1500 Sweep System, Main Broom Troubleshooting Problem Cause Correction Main broom motor Circuit breaker CB6 is Reset the circuit breaker. not running. tripped. No voltage to the Main • Check for continuity through the hopper and Broom Solenoid (2) valve.
  • Page 122 Service Manual – Advance 7765 / Nilfisk CR1500 Sweep System, Side Broom Functional Description Overview The side broom sweep system includes the Side Broom Cable Hydraulic Side Broom Motor Lift Side Broom Arm Weldment Knob , and the side broom Cable solenoid valve.
  • Page 123 Service Manual – Advance 7765 / Nilfisk CR1500 Sweep System, Side Broom controls the oil flow to Side Broom Valve the hydraulic side broom motor. Side Broom Valve From P1 on Main Control Valve To “A” Port on Side Broom Motor...
  • Page 124 Service Manual – Advance 7765 / Nilfisk CR1500 Sweep System, Side Broom Side Broom Sweep System Hydraulic Diagrams Side Broom Motor Off When the is off, the solenoid is de-energized (open). This allows the Side Broom Motor Side Broom Valve...
  • Page 125 Service Manual – Advance 7765 / Nilfisk CR1500 Sweep System, Side Broom Side Broom Motor On When the is on, the solenoid is energized. This forces the hydraulic oil to Side Broom Motor Side Broom Valve flow from the through priority leg of the priority flow divider, then through the...
  • Page 126 Service Manual – Advance 7765 / Nilfisk CR1500 Sweep System, Side Broom Component Locations The following components are included in this section: • Side Broom, Side Broom Motor and Side Broom Arm Weldment • Side Broom Valve are mounted Side Broom...
  • Page 127 Service Manual – Advance 7765 / Nilfisk CR1500 Sweep System, Side Broom Maintenance and Adjustments Warning! Before performing any machine maintenance or adjustments, make sure the key switch is off, the key is removed from the machine and the parking brake is engaged.
  • Page 128 Service Manual – Advance 7765 / Nilfisk CR1500 Sweep System, Side Broom Troubleshooting General Troubleshooting Problem Cause Correction Side Broom motor Circuit breaker CB6 is Reset the circuit breaker. not running. tripped. No voltage to the Side • Check for continuity through the hopper and Broom Solenoid (5).
  • Page 129 Service Manual – Advance 7765 / Nilfisk CR1500 Wheel System, Non-traction Functional Description The non-traction wheel system supports the front of the machine and includes the braking system. Five 1/2”-20 x 1.56 Studs fasten 1/2”-20 Lug Nuts to the Molded Wheels Brake Caliper .
  • Page 130 Service Manual – Advance 7765 / Nilfisk CR1500 Wheel System, Non-traction When the Brake Pedal depressed it pivots the which pulls Brake Pedal Cross Shaft Clevis (2) the two toward Brake Rods the rear. The Brake Pedal on the Clevises...
  • Page 131 Service Manual – Advance 7765 / Nilfisk CR1500 Wheel System, Non-traction Maintenance and Adjustments Warning! Before performing any machine maintenance or adjustments, make sure the key switch is off and the key is removed from the machine. Service Brake Adjustment...
  • Page 132 Service Manual – Advance 7765 / Nilfisk CR1500 Wheel System, Non-traction Troubleshooting Problem Cause Correction The wheels are The wheel bearings are Check the wheel bearings and replace as required. making excessive worn. noise. The wheel and/or stub axle Check the wheel and stub axle weldment and weldment are damaged.
  • Page 133 Service Manual – Advance 7765 / Nilfisk CR1500 Wheel System, Traction Functional Description Overview The traction wheel system includes the hydraulic drive wheel motor and drive pump, and the foot pedal and associated components that control the direction and speed of the drive wheel motor.
  • Page 134 Service Manual – Advance 7765 / Nilfisk CR1500 Wheel System, Traction Drive Pump After Machine Serial Number 1000034942 Drive Pump on machines after serial number 1000034942 is part From Squeegee Vacuum Fan number 56514943. New Location Motor of Case Drain...
  • Page 135 Service Manual – Advance 7765 / Nilfisk CR1500 Wheel System, Traction Forward/Reverse Controls – GM Engines Before s/n 1000034942 The foot pedal actuates the Forward/Reverse which rotates Cable Hydrostat . The Arm Plate Hydrostat Arm Plate Centering is fastened to the...
  • Page 136 Service Manual – Advance 7765 / Nilfisk CR1500 Wheel System, Traction Foot Pedal Assembly – GM Engines pivots on the Foot Pedal Foot to move the Pedal Mount Brackets forward and Forward/Reverse Cable backward. The Forward/Reverse actuates the forward/reverse Cable...
  • Page 137 Service Manual – Advance 7765 / Nilfisk CR1500 Wheel System, Traction Forward/Reverse Controls – Mitsubishi Diesel Engines Before s/n 1000034942 actuates Foot Pedal Forward/Reverse Cable which rotates the Shift Arm and attached Transmission Arm Plate Transmission Foot . The Arm Weldment...
  • Page 138 Service Manual – Advance 7765 / Nilfisk CR1500 Wheel System, Traction Forward/Reverse Controls – Mitsubishi Diesel Engines After s/n 1000034942 actuates Foot Pedal Forward/Reverse Cable which connects to the . The Hydroback Hydroback transfers the Forward/ motion to the Reverse Cable...
  • Page 139 Service Manual – Advance 7765 / Nilfisk CR1500 Wheel System, Traction Rear Wheel and Rear Wheel Motor Rear Wheel (tire and outer rim) Rear Wheel is bolted to the Cotter Support Drive Wheel Hub The assembled Slotted Rear Wheel Drive Wheel Hub...
  • Page 140 Service Manual – Advance 7765 / Nilfisk CR1500 Wheel System, Traction Electrical Schematic Battery 12 VDC Ignition Bat. Switch 15 A Forward Relay Drive Pedal Forward Sensor Drive Pedal Reverse Sensor Reverse Relay Electrical Circuit Description The only electrical components associated with the traction wheel system are the Drive Pedal Forward Sensor .
  • Page 141 Service Manual – Advance 7765 / Nilfisk CR1500 Wheel System, Traction Hydraulic Diagrams Rear Wheel Motor in Neutral When the foot pedal is in the neutral position with the engine running, the will not send any oil Drive Pump to the...
  • Page 142 Service Manual – Advance 7765 / Nilfisk CR1500 Wheel System, Traction Tow Valve in Bypass Position When the engine is off, the acts like a hydraulic pump and makes it difficult to rotate the Rear Wheel Motor rear wheel. The machine is equipped with a to eliminate this problem when towing or pushing the Tow Valve machine.
  • Page 143 Service Manual – Advance 7765 / Nilfisk CR1500 Wheel System, Traction Rear Wheel Motor in Forward or Reverse When the engine is running and the foot pedal is moved to either the forward or reverse position, the Drive sends oil to the to drive the machine in the corresponding direction.
  • Page 144 Service Manual – Advance 7765 / Nilfisk CR1500 Wheel System, Traction Rear Wheel Motor Stalling Out If the is unable to run in forward or reverse for any reason (rear wheel stalled, etc.), the Rear Wheel Motor corresponding internal in the...
  • Page 145 Service Manual – Advance 7765 / Nilfisk CR1500 Wheel System, Traction Maintenance and Adjustments Warning! Before performing any machine maintenance or adjustments (other than the Hydroback adjustment), make sure the key switch is off, the key is removed from the machine and the parking brake is engaged.
  • Page 146 Service Manual – Advance 7765 / Nilfisk CR1500 Wheel System, Traction Troubleshooting Problem Cause Correction The machine The forward/reverse controls Adjust the forward/reverse controls and/or linkage so “creeps” forward or are out of adjustment. the machine is stationary when the foot pedal is in backward when the the neutral position.
  • Page 147 Service Manual – Advance 7765 / Nilfisk CR1500 Wheel System, Traction Wheel Drive System Torque Specifications Description Torque Specification Steering Torque to 40 ft.- Steering Castle Castle lb. [54 Nm], then (Spindle) Nut (Spindle) Nut loosen to align cotter pin.

This manual is also suitable for:

Cr 1500

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