Nilfisk-Advance 7765 User manual

Engine System, Gasoline/LPG 106Service Manual – Advance 7765 / Nilsk CR1500

Engine System, Gasoline/LPG 107Service Manual – Advance 7765 / Nilsk CR1500

Engine System, Gasoline/LPG 108Service Manual – Advance 7765 / Nilsk CR1500
Specications
Engine Specications
3.0 L GM
Engine type Vertical, liquid cooled, four-cylinder, push rod actuated
overhead valve, solid-state distributor
Displacement 181 cubic inches (2966 cc)
Compression Ratio 9.2:1
Fuel Gasoline 87 or 89 octane unleaded gasoline with no more than
10% ethanol by volume
LP 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(ywheelend)
Valve Lifters Flat follower
Oil Capacity 4qts.[3.79L]withoutoillter
4.5qts.[4.26L]withoillter
Oil Filter PF-25 or equivalent
Minimum Oil
Pressure (Hot)
6 psi [0.41 bar] @ 1000 RPM
18 psi [1.24 bar] @ 2000 RPM
Cooling Capacity 4 qts. [3.79 L] without radiator
12 qts. [11.36 L] with radiator

Engine System, Gasoline/LPG 109Service Manual – Advance 7765 / Nilsk CR1500
Special Tools
Diagnostic Communication Cable and software, p/n 56305647
Cooling System Tool

110Service Manual – Advance 7765 / Nilsk CR1500
Hopper System
Functional Description
Overview
The hopper system holds the dust and debris swept up by the brooms.
There are two different hopper congurations; a manual dump (MD) hopper and a variable dump (VD)
hopper.
• The manual dump hopper is xed. A manual dump lever opens a hopper ap to empty the hopper onto the
oor below the machine. Machines with a manual dump hopper do not have a dust control system.
• The variable dump hopper has a hydraulic cylinder that raises the hopper for 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 lter, dust control motor and impeller, and lter shaker motor. Refer to the
Dust Control System section for more information on the dust control components.
Hopper – Manual Dump Machines
The Manual Dump Hopper is
xed. Moving the Hopper
Dump Handle to the OPEN
position empties the
contents of the Manual
Dump Hopper onto the oor
underneath the machine.
Note that there are no
electrical or hydraulic
components associated
with the Manual Dump
Hopper.
Manual
Dump
Hopper
Hopper
Dump
Handle

Hopper System 111Service Manual – Advance 7765 / Nilsk CR1500
Hopper – Variable Dump Machines
The Variable Dump
Hopper pivots on the Rod
supported by the frame.
The Hopper Lift Cylinder
swings the Variable Dump
Hopper up to allow it to be
emptied into 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 Cylinder
Hopper
Lift
Cylinder
Variable
Dump
Hopper

Hopper System 112Service Manual – Advance 7765 / Nilsk CR1500
The hydraulic valves that control the Hopper Lift Cylinder and Hopper Dump Cylinder are mechanically
actuated by the Hopper Lift Lever and the Hopper Dump Door 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
Hopper
Dump Door
Lever

Hopper System 113Service Manual – Advance 7765 / Nilsk CR1500
Hopper System Wiring Diagram – Variable Dump Machine
Electrical Circuit Description – Variable Dump Machine
The only electrical components associated with the hopper system are the Hopper Switch and the Hopper Door
Switch. Both of these “whisker” switches 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)
8535 46
15
1557
15
86
1
Side Broom
Switch
2
1
Main Broom
Switch
2
1
Dust Control Switch
Option
2
337
1
Shaker Motor Switch
2
Main Broom Solenoid (2)
38
Side Broom Solenoid (5)
39
15
B-
7
7
CB6
15 A
137 2C CN.O. N.O.
1
Battery 12 VDC
+-
Bat. Ignition
Switch

Hopper System 114Service Manual – Advance 7765 / Nilsk CR1500
Hopper System Hydraulic Diagrams – Variable Dump Machine
Hopper Control Valves in Neutral Position
The hydraulic oil ows from the Auxiliary Pump, through non-priority leg of the priority ow divider, then
through the Main Control Valve to the Hopper Control Valve. Note that the oil will take this path regardless of
whether the Main Broom, Dust Control and Scrub Brush Motors are on or off.
When the Hopper Dump Cylinder Valve and Hopper Lift Cylinder Valve are in the neutral position, the oil ows
through 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
CD
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
Hopper
Control
Valve
In
Oil
Cooler
Filter
9.7 GPM
Main Broom
Solenoid (2)
Normal Rotation
Brush (4)
Reverse
Rotation
Brush (3)
To Side
Broom
Valve
Hopper Lift
Cylinder Valve
Hopper Dump
Cylinder Valve
To Return
Block
2500
PSI
Relief
Valve
T1

Hopper System 115Service Manual – Advance 7765 / Nilsk CR1500
Lift Hopper
When the hopper lift lever is moved to the “raise” position, the oil ows through the check valve on the
Hopper Lift Cylinder Valve and to the bottom port on the Lift Cylinder to raise the hopper. The oil from the top
port on the Lift Cylinder goes to the return line to the Filter and Reservoir.
Lift Cylinder
A
CD
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 Rotation
Brush (4)
Reverse
Rotation
Brush (3)
Hopper Lift
Cylinder Valve
Hopper Dump
Cylinder Valve
To Side
Broom
Valve
To Return
Block
2500
PSI
Relief
Valve
T1

Hopper System 116Service Manual – Advance 7765 / Nilsk CR1500
Lower Hopper
When the hopper lift lever is moved to the “lower” position, the Hopper Lift Cylinder Valve connects both ports
on the Lift Cylinder to the return lines going to the Reservoir. This effectively creates equal pressure on both
ends of the Lift Cylinder to allow the hopper to lower under its own weight.
Lift Cylinder
A
CD
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
Brush (3)
Hopper Lift
Cylinder Valve
Hopper Dump
Cylinder Valve
To Side
Broom
Valve
1.02
CIR
Reservoir
Auxiliary
Pump
To Return
Block
2500
PSI
Relief
Valve
T1

Hopper System 117Service Manual – Advance 7765 / Nilsk CR1500
Open Hopper Dump Door
When the hopper dump door lever is moved to the “open” position, the oil ows through the check valve on
the Hopper Dump Cylinder Valve and to the bottom port on the Dump Cylinder to open the hopper dump door.
Note that the incoming oil pressure will open the Pilot on the Check Valve on the Dump Cylinder to allow oil
to ow from the top port on the Dump Cylinder. The Check Valve keeps the hopper dump door closed until oil
pressure is applied to the bottom port on the Dump Cylinder and to the Pilot on the Check Valve.
The oil from the top port on the Dump Cylinder ows back through the Hopper Dump Cylinder Valve, then to the
return line to the Oil Cooler, Filter and Reservoir.
Lift Cylinder
A
CD
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
Hopper
Control
Valve
In
Oil
Cooler
Filter
9.7 GPM
Main Broom
Solenoid (2)
Normal Rotation
Brush (4)
Reverse
Rotation
Brush (3)
To Side
Broom
Valve
Hopper Lift
Cylinder Valve
Hopper Dump
Cylinder Valve
Close
Door
Check
Valve
w/Pilot
Lift
Hopper
Hopper
Down
Open
Door
1.02
CIR
Reservoir
Auxiliary
Pump
To Return
Block
2500
PSI
Relief
Valve
T1

Hopper System 118Service Manual – Advance 7765 / Nilsk CR1500
Close Hopper Dump Door
When the hopper dump door lever is moved to the “close” position, the oil ows through the check valve on
the Hopper Dump Cylinder Valve and to the top port on the Dump Cylinder to close the hopper dump door.
The oil from the bottom port on the Dump Cylinder ows back through the Hopper Dump Cylinder Valve, then 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 Side
Broom
Valve
Hopper Lift
Cylinder Valve
Hopper Dump
Cylinder Valve
Close
Door
Lift
Hopper
Hopper
Down
Open
Door
A
CD
B
1.02
CIR
Reservoir
Auxiliary
Pump
To Return
Block
2500
PSI
Relief
Valve
T1

Hopper System 119Service Manual – Advance 7765 / Nilsk CR1500
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
The Hopper Lift 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
Hopper
Door Switch
Hopper
Dump Door
Cylinder
Hopper
Dump Door

Hopper System 120Service Manual – Advance 7765 / Nilsk CR1500
The Hopper Control Valve is mounted on the frame
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.
Lubrication Points
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
Fitting
Hopper
Lift
Cylinder
Hopper
Lift
Cylinder
Collar (2)
Pin

Hopper System 121Service Manual – Advance 7765 / Nilsk CR1500
• The Pins and Collars connecting
the Hopper 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)

Hopper System 122Service Manual – Advance 7765 / Nilsk CR1500
• The four hopper rod Grease
Fittings.
Warning! Never work under the hopper
without rst engaging the Safety
Lock Arm.
Grease
Fittings
Grease
Fittings
Safety Lock
Arm (shown in
engaged position)

Hopper System 123Service Manual – Advance 7765 / Nilsk CR1500
Troubleshooting
Problem Cause Correction
Hopper not rising
when the hopper lift
lever is moved to
the “raise” position.
The hopper lift cylinder valve
in the hopper control valve
is not operating correctly.
Check the hopper lift cylinder valve and repair/
replace as necessary.
Binding in the hopper mount
or hopper lift cylinder.
Check for any mechanical binding or damage to the
hopper pivot points, hopper lift cylinder and cylinder
mounting points, 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 door pivot points, dump door cylinder and
cylinder mounting points, and correct as necessary.
Hopper dump
door not opening
when the hopper
dump door lever is
moved to the “open”
position.
Hopper door pilot check
valve not operating correctly.
Check the hopper door pilot check valve and repair/
replace as necessary.

124Service Manual – Advance 7765 / Nilsk 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.
Electrically-controlled solenoid valves direct the hydraulic oil to the various system components to perform
the steering, scrubbing, sweeping, dust control and solution recovery functions.
The hydraulic oil circulates through the oil cooler attached to the rear of the engine radiator.
The hydraulic return oil lter is mounted on top of the oil reservoir and has a replaceable lter 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 various components:
• The Drive Pump
(1.24 CIR) is
a variable-
displacement
axial piston
pump that
powers the
drive wheel.
Note that
Drive Pumps on
machines prior
to serial number
1000034942
have a slightly
different
hose/port
conguration
than that shown
here.
To Return
Block/Manifold To Return
Block/
Manifold
To Front
Port on Rear
Wheel Motor
To Rear Port on
Rear Wheel Motor
To Squeegee
Vacuum Fan
Motor Drive
Pump

Hydraulic System 125Service Manual – Advance 7765 / Nilsk CR1500
• The Auxiliary Pump is a
multiple-gear pump. Two
separate 1.02 CIR output
ports power the other machine
systems.
Note that the gas and diesel
tting congurations are
slightly different, but the port
functions are the same.
Hydraulic Valves
• The Main Control
Valve controls
the oil ow to
the main broom
motor, dust
control motor,
scrub brush
motors and
hopper control
valve.
Note that the
functions of
ports 3and 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
To Bottom Port
on Main
Broom Motor
To Dust
Control Motor
To Hopper
Control Valve
To Scrub
Brush Motors
From Scrub
Brush Motors
Main
Control Valve