cyclone 4500eu2 copy · 4 - form no. 56043125 / cyclone 4500 2ws, 4ws general safety instructions...

Cyclone™ 4500

12/08 FORM NO. 56043125

SERVICE MANUAL

Cyclone 45005638062556380835Nilfisk Cyclone 450056380676

2 - FORM NO. 56043125 / Cyclone 4500 2ws, 4ws

TABLE OF CONTENTS

table of contents ............................................................................................................... 2GENERAL SAFETY INSTRUCTIONS ............................................................................. 5Safety recommendations ................................................................................................ 11BEFORE OPERATING EQUIPMENT: ............................................................................ 11Equipment & Clothing ..................................................................................................... 11Standard Practice & Procedures .................................................................................... 12BATTERY SAFE HANDLING GUIDELINES ......................................................................FIGURE 1 ....................................................................................................................... 13INTRODUCTION ............................................................................................................ 14KNOW YOUR MACHINE ............................................................................................... 15KNOW YOUR MACHINE ............................................................................................... 16KNOW YOUR MACHINE ............................................................................................... 17KNOW YOUR MACHINE ............................................................................................... 18Jacking the machine ....................................................................................................... 19Towing or pushing the machine ...................................................................................... 20Filling Water/Reclaim Tanks ........................................................................................... 21Filling Water/Reclaim Tanks WITH REMOTE FILL ......................................................... 21PREPARING THE MACHINE FOR USE ........................................................................ 22Filling Water/Reclaim Tanks (CONTINUED) .................................................................. 22Prep For Transit .............................................................................................................. 23Prep For Transit .............................................................................................................. 24Prep For Transit .............................................................................................................. 25Prep For Transit .............................................................................................................. 26OTHER MANUALS AVAILABLE ..................................................................................... 27DIAGNOSTIC AND SERVICE TOOLS .......................................................................... 28DIAGNOSTIC AND SERVICE TOOLS .......................................................................... 28Troubleshooting Best Practices ...................................................................................... 30Technical specifi cations .................................................................................................. 37Engine Specifi cations .................................................................................................... 39Engine Specifi cations ..................................................................................................... 40BRAKING SYSTEM ....................................................................................................... 44BRAKING SYSTEM ....................................................................................................... 45 ....................................................................................................................................... 47Temperature Controller ................................................................................................... 48CYCLONE WATER FLOW ............................................................................................. 49MAINTENANCE ............................................................................................................. 62Maintenance ................................................................................................................... 63MAINTENANCE ............................................................................................................. 64MAINTENANCE ............................................................................................................. 65Maintenance ................................................................................................................... 66Changing Spray Tips ...................................................................................................... 66Maintenance ................................................................................................................... 67Hydraulic Filter Pop-Out indicator .................................................................................. 67ENGINE MAINTENANCE .............................................................................................. 70ENGINE Oil – dIESEL .................................................................................................... 70Bio diesel fuel ................................................................................................................. 72ENGINE COOLANT ....................................................................................................... 73Engine air fi lter maintenance-Kubota ............................................................................. 79Engine air fi lter-John deere ............................................................................................ 80MAINTENANCE ............................................................................................................. 81hydraulic system Troubleshooting .................................................................................. 83general hydraulic specifi cations table ............................................................................. 84hydraulic system ............................................................................................................. 89hydraulic System ............................................................................................................ 90Appendix ........................................................................................................................ 91Wiring

FORM NO. 56043125 / Cyclone 4500 2ws, 4ws - 3


GENERAL SAFETY INSTRUCTIONSSpecifi c Cautions and Warnings are included to warn you of potential danger of machine damage or bodily harm.

READ ALL INSTRUCTIONS BEFORE SERVICINGCAUTION AND WARNING SYMBOLSAdvance uses the symbols below to signal potentially dangerous conditions. Always read this information carefully and take the necessary steps to protect personnel and property.

DANGER!THIS SYMBOL IS USED TO WARN OF IMMEDIATE HAZARDS THAT WILL CAUSE SEVERE PERSONAL INJURY OR DEATH.* This machine emits exhaust gases (carbon monoxide) that can cause serious injury or death; always provide adequate ventilation when

using machine.

WARNING!THIS SYMBOL IS USED TO CALL ATTENTION TO A SITUATION THAT COULD CAUSE SEVERE PERSONAL INJURY.* This machine shall be used only by properly trained and authorized persons.* While on ramps or inclines, avoid sudden stops when loaded. Avoid abrupt sharp turns. Use low speed down hills. High speed operation is designed only for use on level surfaces.* To avoid hydraulic oil injection or injury always wear appropriate clothing and eye protection when working with or near hydraulic system.* Turn the key switch off (O) and disconnect the batteries before servicing electrical components.* Never work under a machine without safety blocks or stands to support the machine.* Do not dispense fl ammable cleaning agents, operate the machine on or near these agents, or operate in areas where fl ammable liquids

exist.* Ear plugs or other hearing protection devices are mandatory. The engines, pumps, and Cyclone Cleaning Head all produce decibel levels

high enough to cause hearing loss.


CAUTION!THIS SYMBOL IS USED TO CALL ATTENTION TO A SITUTION THAT COULD CAUSE MINOR PERSONAL INJURY OR DAMAGE TO THE

MACHINE OR OTHER PROPERTY.* This machine is only approved for hard surface use.* This machine is not suitable for picking up hazardous dust.* When operating this machine, ensure that third parties (particularly children) are not endangered.* Before performing any service function, carefully read all instructions pertaining to that function.* Do not leave the machine unattended without fi rst turning the key switch off (O), removing the key and applying the parking brake.* Turn the key switch off (O) and remove the key before opening any access panels.* Take precautions to prevent hair, jewelry, or loose clothing from becoming caught in moving parts.* Before use, all doors and hoods should be properly latched.* Do not use on surfaces having a gradient exceeding that marked on the machine.

NOTES:Pay attention to the yellow decals on this machine. If you have any questions, contact your supervisor or your local Advance Industrial Dealer. Should your machine malfunction, do not attempt to correct the problem. Only a trained company mechanic or an authorized Advance Dealer Service person shall make repairs to this equipment. The maximum rated incline during operation in 24”. Reference the separately supplied engine manufacturer’s maintenance and operator manuals for more detailed engine specifi cation and service data

SAVE THESE INSTRUCTIONS


LISEZ TOUTES LES INSTRUCTIONS AVANT UTILISATIONSYMBOLES ATTENTION ET AVERTISSEMENTAdvance utilise les symboles ci-dessous pour signaler des conditions potentiellement dangereuses. Lisez toujours ces informations attentivement et prenez les mesures qui s’imposent pour protéger le personnel et les biens.

INSTRUCTIONS GENERALES DE SECURITEDes signaux de prudence et d’avertissement sont inclus pour vous indiquer un danger potentiel de dommages de la machine ou de blessure corporelle.

DANGER!CE SYMBOLE EST UTILISE POUR AVERTIR DE DANGERS IMMEDIATS QUI ENTRAINERONT DES BLESSURES PERSONNELLES GRAVES OU MORTELLES.* Cette machine émet des gaz d’échappement (monoxide de carbone) qui peuvent entraîner des blessures graves ou mortelles : assurez

toujours une ventilation correcte lors de l’utilisation de cette machine.

ATTENTION!CE SYMBOLE EST UTILISE POUR ATTIRER L’ATTENTION SUR UNE SITUATION QUI POURRAIT ENTRAINER DES BLESSURES PERSONNELLES GRAVES.* Cette machine doit être utilisée uniquement par des personnes autorisées et correctement formées.* Sur les rampes ou les plans inclinés, évitez les arrêts brutaux lorsque la machine est chargée. Evitez les virages serrés. Roulez doucement

dans les pentes. * Pour éviter la projection d’huile hydraulique ou des blessures, portez-toujours un vêtement de protection approprié et des lunettes de

protection lorsque vous travaillez avec ou à proximité d’un système hydraulique.* Tournez la clé pour couper le contact (O) et débranchez les batteries avant de procéder à la maintenance des composants électriques.* Ne travaillez jamais sous une machine sans que celle-ci soit mise sur cales ou sur chandelles.* N’utilisez pas de produits détergents infl ammables, n’utilisez pas la machine à proximité de ces produits, et n’utilisez pas la machine dans

des zones contenant des produits infl ammables.* Des bouchons d’oreille et tout autre équipement de protections obligatoires. Les moteurs, les pompes et la tête de nettoyage Cyclone

génèrent tous des niveaux de décibels assez élevés pour entraîner une perte d’audition.


PRUDENCE!CE SYMBOLE EST UTILISE POUR ATTIRER L’ATTENTION SUR UNE SITUATION QUI POURRAIT ENTRAINER DES BLESSURES LEGERES OU ENDOMMAGER LA MACHINE OU D’AUTRES BIENS.* Cette machine n’est pas homologuée pour être utilisée sur la voie publique.* Cette machine est homologuée pour être utilisée uniquement sur des surfaces dures.* Cette machine n’est pas conçue pour aspirer des poussières dangereuses.* Lors de l’utilisation de cette machine, assurez-vous qu’aucune personne (et notamment des enfants) ne se trouvent en danger.* Avant de procéder à toute procédure de maintenance, lisez attentivement les instructions relatives à cette procédure de maintenance.* Ne laissez pas la machine sans surveillance sans préalablement couper le contact (O), retirer la clé et appliquer le frein de stationnement.* Coupez le contact (O) et retirez la clé avant d’ouvrir les trappes d’accès.* Prenez les précautions d’usage pour éviter que vos cheveux, bijoux, ou vêtements vagues ne se prennent dans les parties mobiles.* Avant toute utilisation, toutes les trappes et capots doivent être correctement fi xés.* N’utilisez pas cette machine sur des surfaces dont la déclivité est supérieure à celle indiquée sur la machine.

REMARQUES:Lisez bien les autocollants jaunes apposés sur la machine. Pour toute question, contactez votre superviseur ou votre revendeur local Advance Industrial. En cas de défaillance de votre machine, n’essayez pas de la réparer vous-même. Seul un technicien formé par l’entreprise ou un technicien de maintenance d’un revendeur Advance Dealer autorisé peut réparer cet équipement.L’inclinaison nominale maximale en cours de fonctionnement est de 24”. Consultez les manuels de l’opérateur et de maintenance fournis par le fabricant du moteur pour obtenir des spécifi cations et des données d’entretien du moteur plus détaillées

CONSERVEZ CES INSTRUCTIONS


LEA TODAS LAS INSTRUCCIONES ANTES DE UTILIZARSÍMBOLOS DE PRECAUCIÓN Y ADVERTENCIAAdvance utiliza los símbolos que se indican más abajo para señalar situaciones potencialmente peligrosas. Lea siempre con atención esta información y tome las medidas necesarias para la protección de las personas y la propiedad.

INSTRUCCIONES GENERALES DE SEGURIDADSe incluyen precauciones y advertencias específi cas que advierten de los peligros potenciales de daños a la máquina o lesiones personales.

¡PELIGRO!ESTE SÍMBOLO SE UTILIZA PARA ADVERTIR SOBRE RIESGOS INMEDIATOS QUE CAUSARÁN LESIONES PERSONALES GRAVES O LA MUERTE.* Esta máquina emite gases de escape (monóxido de carbono) que pueden producir lesiones graves e incluso fatales; facilite siempre la

ventilación adecuada cuando utilice la máquina.

¡ADVERTENCIA!ESTE SÍMBOLO SE UTILIZA PARA LLAMAR LA ATENCIÓN SOBRE UNA SITUACIÓN QUE PODRÍA CAUSAR LESIONES PERSONALES GRAVES.* Esta máquina únicamente deben utilizarla personas autorizadas y con la debida formación.* Al circular sobre rampas o pendientes, evite las paradas bruscas si lleva carga. Evite las curvas muy cerradas. Circule lentamente al bajar

pendientes. * Para evitar la introducción de aceite hidráulico o lesiones provocadas por aceite hidráulico, utilice siempre las ropas y la protección ocular

apropiados cuando trabaje con el sistema hidráulico o cerca de él.* Apague el interruptor de contacto (O) y desconecte las baterías antes de realizar mantenimiento o reparaciones en los componentes

eléctricos.* Nunca trabaje debajo de una máquina sin colocar antes bloques o soportes de seguridad que sostengan la misma.* No aplique sustancias limpiadoras infl amables ni utilice la máquina sobre estas sustancias o cerca de ellas, ni tampoco en zonas en las que

haya líquidos infl amables.* Tapones para los oídos o dispositivos de protección auditiva son obligatorios. Los motores, las bombas y el Cabezal de Limpieza Ciclónica

producen niveles de decibeles lo sufi cientemente altos como para causar pérdida auditiva (sordera).


¡PRECAUCIÓN!ESTE SÍMBOLO SE UTILIZAR PARA LLAMAR LA ATENCIÓN SOBRE UNA SITUACIÓN QUE PODRÍA CAUSAR LESIONES PERSONALES MENORES O DAÑO A LA MÁQUINA U OTROS BIENES.* Esta máquina no ha sido aprobada para su uso en vías públicas.* Esta máquina está aprobada sólo para uso sobre superfi cie dura.* Esta máquina no es apta para la recogida de sustancias peligrosas en polvo.* Cuando utilice la máquina, asegúrese de que no existe peligro para terceras personas, especialmente niños.* Antes de realizar cualquier función de mantenimiento o reparación, lea con atención todas las instrucciones relativas a la misma.* No abandone la máquina sin antes apagar el interruptor de llave (O), retirar la llave y aplicar el freno de estacionamiento.* Apague el interruptor de llave (O) y retire la llave antes de abrir cualquiera de los paneles de acceso.* Tome las debidas precauciones para evitar que pelo, joyas o prendas amplias queden atrapados entre elementos en movimiento.* Antes de utilizar la máquina, todas las puertas y cubiertas deberían asegurarse adecuadamente.* No utilice la máquina en superfi cies con pendientes superiores a las indicadas en la máquina.

NOTAS:Preste atención a las pegatinas amarillas colocadas en la máquina. Si tiene alguna duda, consulte con su supervisor o con el distribuidor industrial de Advance de su zona. Si su máquina presenta funcionamiento incorrecto, no intente corregir el problema. Solo un mecánico de la compañía con la formación adecuada o una persona de mantenimiento del distribuidor de Advance podrán realizar las reparaciones a este equipo.La inclinación máxima durante la operación es 24”. : Si desea datos más detallados sobre especifi caciones y servicio del motor, consulte el manual de utilización y mantenimiento del motor elaborado por el fabricante y entregado por separado.

GUARDE ESTAS INSTRUCCIONES


Safety recommendationsBefore Operating EquipmentEquipment and ClothingStandard Practice & ProceduresThis information was prepared to aid in the identifi cation of potentially unsafe conditions when using high-pressure water blast equipment. These practices describe how to use high-pressure water jets for cleaning hard surfaces. These practices do NOT replace the training necessary to operate and maintain high-pressure water jet systems. It should be noted that other potential hazards might exist which have not been mentioned in this manual.BEFORE OPERATING EQUIPMENT:Before operation of this equipment, it is important that you read the Owner’s Manual for each of the component parts installed in your machine. It is especially important to read and understand all of the safety information included in the manuals. Failure to do so could result in damage to the equipment, serious injury or death to the operator and may void any and all warranties associated with this equipment.

WARNING!This equipment has:MOVING PARTS at HIGH RATES OF SPEEDVERY HOT WATERHIGH PRESSURE WATERDIESEL FUELIn all cases, Advance products are sold with the understanding that the purchaser agrees to THOROUGHLY TRAIN ALL OPERATING AND MAINTENANCE PERSONNEL IN THE CORRECT AND SAFE OPERATION AND MAINTENANCE OF THE CYCLONE SYSTEM.

WARNING!Do NOT attempt to change Original Equipment Manufacturer (OEM) parts or equipment. Use of non-OEM parts could result in damage to the equipment, serious injury or death to the operator and may void any and all warranties associated with this equipment.EQUIPMENT & CLOTHING1 Ear plugs or other hearing protection devices are mandatory. The engines, pumps, and Cyclone Cleaning Head all produce decibel levels

high enough to cause hearing loss.2 Leather gloves should be worn at all times. The Cyclone SYSTEM uses 160°F water. High-pressure and return hoses and couplings get hot

enough to burn you.3 Safety glasses are recommended when operating the Cyclone System.4 Long pants are recommended when operating the Cyclone System.


Standard Practice & Procedures1 After the CYCLONE 4500 has come to a complete stop, turn off the engine and apply parking brake. Never leave the CYCLONE 4500

engine running unattended.2 A strong vacuum is formed from the rotation of the Cyclone cleaning head. Therefore, all surface plates such as manhole covers, utility

access covers and large debris must be secured, removed or avoided during the cleaning process.3 All surfaces should be swept prior to operating the cyclone 4500, hard surface cleaner.4 The cyclone 4500 is not designed to pick up particulate matter such as sand.

WARNING!These items could cause extensive and costly damage to the blades and spray bars and serious injury or death to the operator.1 Always turn off the engine before fueling.2 Never point the hand-held spray gun at yourself or another person. Water coming out of the gun is at a high enough pressure to cause injury

or death.3 This equipment should not be used without consulting all applicable standards, guidelines, or recommendations of the United States

Occupational Safety and Health Administration (OSHA), the American Society of Testing Materials (ATSM), the National Standards Institute (ANSI), and the instructions, recommendations and standards of Advance. Advance does not guarantee that the practices described and the recommendations contained in this manual will prevent harm or injury, even when such equipment is properly used in conformity with the recommended practices. In the event of bodily injury, nothing in this manual should substitute for proper medical care.


BATTERY SAFE HANDLING GUIDELINES FIGURE 1

Always wear proper eye, face and hand protection when working with battery• Never lean over battery while boosting, testing, or charging• Exercise caution when working with metallic tools or conductors to prevent short circuits and arcing• Keep terminals protected to prevent accidental shorting• Replace any battery that has signs of damage to the terminals, case, or cover• Install battery in a ventilated area for operation and during charging• DO NOT ADD WATER TO THE OPTIMA BATTERY•

Battery MaintenanceThe OPTIMA battery is truly maintenance free. When charged properly you will not have to worry about leaking, corrosion, or gassing. Periodically inspect your battery terminal connections to ensure they are clean, snug, and protected from the elements. Open circuit voltage (OCV) and storage:OCV: 34 >12.8 volts (for a fully charged battery)D34 >13.0 volts (for a fully charged battery)Battery Storage Because of the high purity lead grid in the OPTIMA battery, it has a self-discharge rate much lower than conventional fl at-plate batteries. This means the OPTIMA can sit for longer periods retaining enough charge to start your vehicle. Depending on storage temperature, the OPTIMA can usually sit for 8 to 12 months and start most vehicles. When possible, store your battery in a cool, dry location. Check the battery voltage every 6 months and charge if it falls below 12.6 volts.Remember, newer vehicles with on-board electronics such as computers, LCD screens, game systems, GPS units, clocks, etc., require battery power to retain system memory while the vehicle is parked. If the vehicle is to be stored for long periods you should use a maintenance charger to compensate for this drain. This charger should be voltage regulated between 13.2 - 13.8 volts, 1 amp maximum. On older vehicles, without electronics, disconnect the battery cables when the vehicle is not being used for extended periods.


INTRODUCTIONService Manual PurposeThis manual is a technical resource that Nilfi sk-Advance expects to be utilized when servicing a Cyclone 4500. It contains information deemed necessary to provide basic troubleshooting, maintenance and repairs within a reasonable timeframe (example - 2-3 hours). If your repair involves multiple visits to repair the same problem, or the repair cannot be completed within 3-4 hours, a call to Nilfi sk-Advance Technical Support is needed to alert the factory to potential issues and/or provide the customer with an acceptable level of service. Refer to the website www.advance-us.com for additional information not contained herein as well updates or expanded instructions to procedures noted here.

Note: Bold numbers in parentheses in text indicate an illustrated item.

Note: All references to right, left, front and rear in this manual are as seen from the operator’s position (seat).

General Machine DescriptionThe Cyclone 4500 is an industrial rider hard surface cleaning machine with single pass coverage. All models use a single high-pressure cyclone cleaning head with dual spray tips and multi-stage water recycling. All models are equipped with a right-hand high-pressure curb cleaner and off aisle high-pressure cleaning wand.

Parts and ServiceRepair should be performed by an Authorized Nilfi sk-Advance Service Center that employs factory-trained service personnel and maintains an inventory of Nilfi sk-Advance original replacement parts and accessories.

NameplateSee Figure 1. The Model Number and Serial Number of the machine are shown on the nameplate (A) located to the left of the steering column support.

MODEL NUMBER ________________________________________________

SERIAL NUMBER ________________________________________________

This information is required when ordering repair parts for the machine or contacting Nilfi sk-Advance Technical Support.

FIGURE 1


KNOW YOUR MACHINEAs you read this manual, you will occasionally run across a bold number or letter in parentheses, i.e., (2). These numbers refer to an item shown on these pages unless otherwise noted. Refer back to these pages whenever necessary to pinpoint the location of an item mentioned in the text. NOTE: Refer to the service manual for detailed explanations of each item illustrated on these pages.1 Engine Air Filter2 Radiator Cap3 Hydraulic Level Gauge4 Hydraulic Filter Pop-Out5 Hydraulic Breather Filter6 Water Filter Pressure Gauges7 Bleed Valves8 Water Filters9 Reclaim #1 Drain10 Reclaim #2 Drain11 Reclaim #3 Drain12 Filter Drain13 Fresh Water Drain

1

2

3

45

6

8

7

910

11

1213


KNOW YOUR MACHINE14 Operator Seat15 Fuel Access Door16 Seat Belt17 Cyclone Cleaning Head18 Burner Exhaust19 Hot Water Coil, Burner, Fuel Filter Access Door20 Remote Water Fill Connection


KNOW YOUR MACHINE21 Cyclone Breather Tubes22 Cleaning Wand23 Parking Brake24 Wand Control Lever25 Curb Cleaner Lever26 Recovery Tank / Debris Tray27 Fresh Water Tank #128 Reclaim Tank #129 Reclaim Tank #230 Reclaim Tank #331 Fresh Water Tank #232 Fresh Water Tank #333 Cyclone Pressure Control Lever


KNOW YOUR MACHINEA Engine Coolant Temp GaugeB Engine Oil Pressure GaugeC Electrical System Volt MeterD Hour MeterE Fuel GaugeF 20 Amp Fuse (throttle)G 20 Amp Fuse (cyclone)H 20 Amp Fuse (pump)I 20 Amp Fuse (burner)J 20 Amp FuseK 8 Amp FuseL 2 Amp FuseM Ignition SwitchN Water Temperature ControllerO Throttle SwitchP Cyclone SwitchQ Pump SwitchR Burner SwitchS 20 Amp FuseT Deck Raise/Lower SwitchU Hi/Lo Water Level Indicator LightV 2 Wheel / 4 Wheel Steer SwitchW Directional Control LeverX Brake PedalZ high/low speed switch

AB C D E

F G H I J

K

L

MN

O P Q RS T U

V

W

X Z


Jacking the machine CAUTION!

Never work under a machine without safety stands or blocks to support the machine.• When jacking the machine, do so at three designated locations: The front cross-member between the two front tires, and at each side of the

rear of the chassis.• When positioning the jack, take care to avoid hitting the hydraulic cylinders or sense switch!

FIGURE 2

A

B


Towing or pushing the machine CAUTION!

IF THE TOW VALVES ARE NOT PROPERLY ADJUSTED, DAMAGE TO THE HYDRAULIC SYSTEM WILL RESULT.DO NOT TOW THE MACHINE FASTER THAN A WALKING PACE.TOW OPTIONS ARE MEANT TO BE USED FOR A SHORT TIME ONLY. DO NOT USE FOR AN EXTENDED PERIOD OF TIME.

Tools Required13 MM box end wrench4 mm Allen Wrench

TOW VALVE SETTING1) To actuate the tow valves, loosen the two lock nuts (A).2) Turn the two Allen screws (B & C) six turns clockwise. Be accurate, as the secondary function of these valves is the high pressure regulation.3) To disengage, turn the screws counter-clockwise until the exact position of the screws are reset. Torque the locknut to 5ft.lb. (7 Nm)4) Recheck the high pressure relief settings after tow valves have been repositioned!

A - 13MM Lock NutB - 4mm Allen Tow Valve / High Pressure Relief AC - 4mm Allen Tow Valve / High Pressure Relief B

FIGURE 3

A

B C


Filling Water/Reclaim Tanks1 See Figure 4. Put the water hose in Reclaim Tank #2 (D) and fi ll Reclaim Tanks #1, #2 & #3 (B) to 1” from the top. NOTE: Once tank #2

fi lls water will automatically fl ow into Reclaim #1 (C) and Reclaim #3 (E).2 Start the engine and set Throttle Switch (O) to the ON position.3 Open the valves on top of each fi lter housing. After the water begins to fl ow close the valves.4 Keep the Throttle Switch (O) ON until the fi lter pump turns OFF or until water stops fl owing into the clean water tanks (A).5 Fill the Clean Water Tanks to 6” from the top.

FILLING WATER/RECLAIM TANKS WITH REMOTE FILL1 See Figure 4. Connect garden hose to Remote Fill Connection (F) and rotate Remote Water Fill Valve (G) to the UP position for reclaim

tanks.2 Turn on garden hose and fi ll reclaim tanks to 1” from the top then turn hose off. Start the engine and set Throttle Switch (O) to the ON

position.3 Open the valves on top of each fi lter housing. After the water begins to fl ow close the valves.4 Keep the Throttle Switch (O) ON until the fi lter pump turns OFF or until water stops fl owing into the clean water tanks (A).5 Rotate Remote Water Fill Valve (G) to the DOWN position, turn garden hose ON and fi ll the Clean Water Tanks to 6” from the top. Turn

garden hose OFF.

FIGURE 4

A AB

C D E

F

G


PREPARING THE MACHINE FOR USE

FILLING WATER/RECLAIM TANKS (CONTINUED)6 See fi gure 5. The high-pressure pump (A) is located to the rear and below the engine bell housing. 7 Once water fl ows through this valve with no air, the pump supply is primed.

FIGURE 5

WARNING!!CAUTION: DO NOT OVERFILL RECLAIM TANKS. WATER CAN SPILL ONTO THE GROUND, which defeats the total recovery principal of this machine.


Prep For Transit CAUTION!

NEVER USE CHAINS OR LOAD BINDERS TO SECURE THIS MACHINE. When tying down this machine, only cloth ratchet straps with a minimum capacity of 10,000 lbs are recommended (see picture at right). Be sure to note the proper load rating and tensile strength of the straps to be used. The Cyclone 4500 weighs around 4000lbs. dry, and approximately 6000lbs. full of water. All four corners of the machine shall be secured. The cyclone 4500 needs to be winterized before transporting into cold weather climates.1 Carefully load the machine into the desired position on the trailer.2 Lower the cleaning head (A) (fi gure 4), and apply the parking brake (B) (fi gure 6).

FIGURE 6


PREP FOR TRANSIT3 Locate the tie down rings (A) at the rear of the machine. Use tie down straps hooked into these rings and then hooked to a secure position

on the trailer to the rear of the machine and tighten the straps.

FIGURE 7

WARNING!!DO NOT allow ANY strap to make contact with the body or doors of the machine!!


PREP FOR TRANSIT4 At the right front corner of the machine, locate the tie down ring (A) (fi gure 8).

FIGURE 85 Hook a tie down strap into the ring. Hook the strap to a tie down point on the trailer forward of the machine, and tighten the strap.



PREP FOR TRANSIT6 At the left front corner of the machine, locate the tie down ring (B) (fi gure 9).

FIGURE 97 Hook a tie down strap into the ring. Hook the strap to a tie down point on the trailer forward of the machine, and tighten the strap.



OTHER MANUALS AVAILABLEThe manuals listed below can be found via Nilfi sk-Advance’s two electronic supported databases. They are:Nilfi sk-Advance website (www.advance.us.com) and EzParts service/parts CD-ROM.

Parts List• - (all systems w/optional kits and accessories)………………………………………………...

Instructions for Use• - ........................................... ……………………………………………………….

Engine Manuals• Kubota Diesel Engine Operator Manual − (English, French, German, Italian, Spanish)− ................................................................................ 16622-8916-3Kubota Diesel Engine Service Manual (English, French, German)− ............................................. 97897-01640Kubota Diesel Engine Service Manual (English)− ......................................................................... 97897-02432John Deere Diesel Engine Service Manual (English)………………………………………………….− Burner Controller……………………………………………………………………………………………− High Pressure Pump……………………………………………………………………………………...− Trombetta Governor……………………………………………………………………………………….− Drive Pump Assembly…………………………………………………………………………………….−


DIAGNOSTIC AND SERVICE TOOLS In addition to a full set of metric and standard tools, the following items are required in order to successfully and quickly perform troubleshooting and repair of Nilfi sk-Advance Industrial fl oor cleaning equipment.

Tools:Laptop computer loaded with current version of Ez Parts, Adobe Reader and (preferably cellular) internet access•

Digital voltmeter (DVM) with DC & AC current clamps•

Hydrometer•

Coolant / Anti-freeze temperature tester•


DIAGNOSTIC AND SERVICE TOOLS In addition to a full set of metric and standard tools, the following items are required in order to successfully and quickly perform • troubleshooting and repair of Nilfi sk-Advance Industrial fl oor cleaning equipment.

Battery load tester for checking 6V and 12V batteries •

Automotive fuel pressure test gauge (for use on diesel engines)•

Static control wrist strap•

Diesel engine compression gauge•

Set of torque wrenches• Hard (printed) copies of service manuals for regularly serviced machines (available at • www.advance-us.com and other Nilfi sk-Advance websites)

Hydraulic test gauge w/connector 3000 psi range• ………………………………………………………. 56504516


Troubleshooting Best Practices

The purpose of this section is to assist in descriptions of the best practices for the purpose of electrical and hydraulic troubleshooting.

The four step troubleshooting process:1st) Confi rm the operator complaint:

If you do not understand the nature of the operator complaint you will not be prepared to solve the customer’s complaint when you arrive at the machine Do not begin system or component testing or replacement until after you’ve validated the customer complaint.The majority of the time, the specifi c details within the customer complaint will lead you to the precise location needed complete the repair accurately!

2nd) Review the manual for specifi cations, fl uid fl ow or electrical diagrams:

Become familiar with the specifi cations or diagrams relating to the issue that the operator is complaining of prior to attempting repairs or tests.Having understanding of the way the machine operates, fl uid fl ows or electricity travels with in the system that you’re attempting to repair will allow you to communicate better with the customer.When dealing with hydraulic or electrical issues, confi rm that shared circuits can not create a negative effect the area you’re trying to repair.

3rd) Isolate the problem through testing

Keeping this process of testing organized is the key to effi cient troubleshooting.Write down the tests you plan to complete and a column for your results.When you fi nd yourself sharing details with others from your troubleshooting process this written information will become indispensable.

4th) Make repairs ad validate against the customer complaint.

Always use Nilfi sk-advance parts to ensure reliability in your repair.The most important part of making a repair is validating that you have repaired exactly what the original operator complaint stated.


The Voltage Drop test:

Use a digital voltmeter for power and ground testing with voltage drops.

FIGURE

Switches, wire connections and contactors should conduct current with the minimum loss of voltage. A voltage drop of more than .10 volts on high current circuits and .01 volts low current circuits is ideal.A loss of voltage or drop of more than the voltages shown above indicates a problem. Check the circuit for loose dirty beds corroded, pitted or poor connections.

1) Place a digital volt ohm meter in a voltage range equal to or slightly less than maximum circuit voltage.2) Connect the positive lead to the end of the wire connector or switch closes the battery.3) Connect the negative lead to the other end of the wire or switch or connection to be tested very4) Turn on the components the circuit the circuit must have current fl owing through to do a voltage drop test.5) The digital voltmeter will show the difference in voltage between the two points where your leads are connected.


Switch test:Use a digital volt meter for testing relays and switches under load.

FIGURE


Battery test:

Load To 50% of the CCA rating of the battery:

FIGURE


Starter test/ alternator test:

FIGURE

Test a short to ground with a test light in place of the fuse.

Testing for continuity with an ohm meter may yield different results with different meters.

Flow meters are plumed inline with the water or hydraulic circuit to be fl ow tested.Hydraulic pressure gauges are to be teed into the circuit to be tested.

Hydraulic test Reccomendations:

1. Confi rm that the suction strainer located either in the line between the hydraulic reservoir and pump or inside the reservoir, is clean. Restrictions in the pump’s suction line will cause pump cavitations, a loss of high pressure and can cause excessive pump noise.2. Verify that the suction line within the reservoir is covered with at least 3” of oil. Failure to maintain a fl ooded suction line can also lead to the conditions stated above.


Technical specifi cations

General Machine Dimensions and Capacities

Model Cyclone 4500Model No. 56380625, 56380676

Length 135 in (342.9 cm)

Height 77 in (195.58 cm)

Width/frame 60 in (152.4 cm)

Cleaning path width (cyclone deck only) 33 in. ( 83.32 cm ) @ 50.6 nozzle passes per second

Floor to spray tip 1.38”(3.505cm)

Generator 3kw 110 volt

Filter transfer pump 160 psi (11.03 bar)

Coverage 67.8 sq ft / min (20.66 m2)

Water temp max 160°F (71.11°C)

Burner 130 psi (8.96 bar) / 12v

Burner BTU 250,000 BTU / 73.26 Kilowatt-hours

Curb cleaner 8” at 12“ (20.32@ 30.48 cm) distance to curb

Fresh water tank capacity 100 gal. (378L)

Recycled water tank 100 gal. (378L)

Cyclone RPM 1520 RPM @ 2000 engine RPM, 147 mph (236.57 kilometers per hour) Tip Velocity est.

Cyclone water recovery 5.4 GPM (20.44 Liters)

Recovery tank volume capacity 4.5 gallons (17L)

Weight empty 4000 lbs / 1814.36 kilograms

Weight GVWR 6000 lbs / 2721.55 kilograms

Min. Aisle Turn 19’ (5.79 meters) 4ws, 27’ 2ws (8.22 meters)

Transport ground clearance 4.25 inches (10.79 cm) deck raised

Operator sound level @ operator ear 91.6 dBA @ 2200 RPM

Certifi cation ETL

Fuel tank capacity 15.7 gallons (59.43 liters)

Steering 2ws/4ws 1.6 / 3.2 turns lock to lock


Wheel base 102 inches (259.08 cm)

Wheel Track 45.5” (115.57 cm) rear / 46.8” (118.872 cm) front

Hydraulic Capacity 8 gal (30.3 L) reservoir 10 gal (37.8 L) total system

Sound Pressure Level (IEC 60335-2-72: 2002 Amend. 1:2005, ISO 11201)

91.6 dB (A)


Vibrations at the Hand Controls (EN 13059 and ISO 5349-1)

0.70 m/s2

Vibrations at the Seat (EN 13059 and EN 1032)

0.01 m/s2

Maximum Wheel Floor Loading (right front) psi / N/mm2 36 / 0.25

Maximum Wheel Floor Loading (left front) psi / N/mm2 35 / 0.24

Maximum Wheel Floor Loading (right rear) psi / N/mm2 67 / 0.46

Maximum Wheel Floor Loading (left rear) psi / N/mm2 58 / 0.40

High Pressure Pump 4500 psi. (310 bar)


Engine Specifi cations John Deere

Engine typeVertical, liquid cooled, 4 cylinder, 66HP 4-cycle turbo diesel engine

Displacement 2.4 liter

Fuel #2 diesel

Oil Capacity 3.5 qts. (3.3 L) with fi lter

Oil Pressure 14 PSI (minimum with engine hot at idle)

Cooling System 8 qts. (7.5 L) total (fi fty/fi fty mix)

Fuel Capacity 12 gal. (45.4 L) Gasoline tank

The 66 hp turbocharged 2.4 Liter John Deere industrial engine. The engine is designed in this application to run at 1000 RPM’s low speed. 2200 RPM’s in high speed. The specifi c RPM setting of the engine in high speed must be adjusted to suit the needs of the output frequency of the 110 V AC generator attach the engine. Failure to run this engine in the proper RPM ranges will result in damage to the high-pressure pump or the generator.


Engine Specifi cations Kubota

Engine Model TypeKubota V2403-M-T-E3B Vertical, liquid cooled, 4 cylinder, 59 hp (43.99KW) / 4-cycle turbo diesel engine

Emission Regulation Interim Tier4/Stage lllA

Displacement 2.4 liter

Fuel Diesel fuel No. 2-D (ASTM D975), JP8 provisional usage

Combustion system IDI

Starter Capacity 12V 2 KW

Alternator Capacity 12V 40 A Regulated @ 13.5-14.1 volts

Oil Capacity 2.51 gal (9.5L)

Cooling Capacity 1.77 gallons (6.7 L)

Horsepower 59 Horsepower 44kW

Idle Speed Low idle 1100 RPM

Operational Speed 2000 RPM

Fuel consumption 1.5 gallons (5.678118 liters) per hour + 1.5 GPH ( 5.67 liters) Burner appx.

*Specifi cation is subject to change without notice.*Output: Gross Intermittent SAE J1995\


Power System Performance

Transport speed forward Low speed 6.5 mph (10.5 km/h)High speed 12 mph (19.31213 km/h)

Transport speed reverse 4 mph (6.5 km/h) reverseGrade ability – Cleaning & Transporting 16% 22% low transport speed

Steering Brakes and Tires

Steering Front wheel or 4 Wheel hydraulic cylinder and rotary valve controlled

Service Brakes Single piston Caliper disk brakes, one at each front wheel, hydraulic actuated

Tire (front 2) Front 185/80/13 load range D, 25.4” OD (64.51 cm)Tire (rear 2) Rear 185/80/13 load range D , 25.4” OD (64.51 cm)

Parking brake Cable operated mechanical caliper, single disc

Water System Delivery Rates & Cleaning Speed

water pressure and fl ow rates2000 PSI (137.89 bar) low-pressure selection 4000 PSI (275.79 bar) high-pressure selection at 6GPM (22.71 liters per minute)

Water fi lters 4.25”x34”

Two stainless steel pleated 30 μ1500 in.² (9677.4 sq cm) each fi lterTwo stainless steel pleated 75 μ1500 in.² (9677.4 sq cm) each fi lter

Cleaning area per hour 30000-40000 sq ft (2787.09-3716.12 meters squared) @ 2 to 2.5 mph (3.21 to 4.023 KPH)

Curb Cleaner and Wand

water pressure and fl ow

Curb cleaner 40° 3000 PSI (206.84 bar) at 8 gallons (30.28 liters) per minuteWand cleaner 15° 3000 PSI (206.84 bar) at 7 gallons (26.49 liters) per minute


Fastener Torque Specifi cations

Standard Torque Specifi cations (unless otherwise specifi ed)

Size Plated Steel Stainless Steel#10 42 in.-lb. 28 in.-lb.1/4“ 100 in.-lb. 67 in.-lb.5/16” 17 ft.-lb. 11 ft.-lb.3/8” 31 ft.-lb. 20 ft.-lb.1/2” 75 ft.-lb. 50 ft.-lb.3/4” 270 ft.-lb. 180 ft.-lb.M5 61 in.-lb. 36 in.-lb.M6 9 ft.-lb. 62 in.-lb.M8 22 ft.-lb. 13 ft.-lb.

M10 44 ft.-lb. 25 ft.-lb.M12 70 ft.-lb. 40 ft.-lb.

Machine specifi c Torque Specifi cations

Item No. Description Torque

Specifi cation

1 Front disc brake Castle (Spindle) Nut

Torque to 40 ft.-lb., then loosen to align

cotter pin.2 Front brake caliper

attaching bolts Torque to 37 ft.-lb.

3 Spray tipsUse 2 to 3 turns of Tefl on tape, torque

to 67 pounds4 Tie rod ends Torque to 35 ft.-lb.

5 Drive Wheel Motor Spindle Nut

Torque to 375 ft.-lb. (lubed) or 475 ft.-lb. (dry), then tighten to

align cross hole.6 Wheel lug nuts Torque to 75 ft.-lb.


BRAKING SYSTEMThe machine’s brake system employs a combined hydraulic disc braking system operated by a foot pedal and a hand set parking brake operated by a lever / cable system. The brake pedal should have about 1 to 1-1/4 in. (25 to 32 mm) of free play. If the pedal action is spongy and shows excessive free play, inspect the brake system components listed below and make proper service repairs.

• Check brake pad lining thickness (fi gure 12)

• Check master brake cylinder fl uid level (Figure 13)• Check brake calipers and brake lines for system leaks or hose abrasion (Figure 14)

CAUTION!After service or adjustment of either the hydraulic components or parking lever always test-drive the machine for safe operation. The service brakes are hydraulic single piston caliper front disk brakes.The master cylinder is a single cylinder with a remote reservoir.The reservoir is located under the hood to the right side of the rear of the dash. Flushing the fl uid annually is recommended to reduce the water content within the system but not required.

CAUTION: this braking system is designed for use with DOT 3 fl uid only!

Bleeding procedure

To bleed the system after servicing the pads apply pressure on the pedal then have someone open and close the caliper farthest from the master cylinder fi rst (left side) then allow the pedal to rise and press again repeating the process for the right side. Continue this until the brake fl uid fl ows freely from the bleed screws on the top of the calipers. (Figure 15)


BRAKING SYSTEMParking brake

The parking brake is made of lever actuated caliper, pads and disk. These items are mounted in front of the rear differential and affi xed to the front of the differentialThere is a cable attaching the hand brake lever to the caliper.

To adjust the parking brake, turn the Handle Knob on the end of the lever clockwise (CW) to increase the brake locking force.

NOTE: If the knob adjustment is inadequate to fi rmly hold its brake setting, this indicates the requirement to inspect the brake pads for excessive wear and the need for service replacement. (Figure 16)

When adjusting the brake be sure the caliper is pinching the disc from both sides before adjusting the cable.After wear on the brake pads occur back shimming the caliper will likely assure the distance to the disc is correct on the drive motor side. (Figure 17)


BURNER:

The burner assembly is comprised of a few main components: 1) burner 2) fuel control solenoid valve3) Igniter4) 12v Motor5) blower 6) heat exchanger coil7) diesel fuel supply fi lter. 8) high-pressure relief valve9) Cad Cell “eye” (Inside the burner Gun Assembly)

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High Pressure ReliefFuel FilterFuel Control Valve

Thermocouple

Burner Assembly Heat Exchanger Housing

Burner GunFuel Filter Location


BURNER continued:

F1 10amp fuse (Under Burner cover)F2 30 amp fuse (Under Burner cover)Figure 19

The fuel solenoid valve opens with temp controller demand.The burner injects the fuel through a nozzleA blower atomizes the diesel fuel / air mixture is factory adjusted.The Igniter initiates the combustion processThe cad cell confi rms combustion and keeps the oil valve open and the motor runningThe heat exchanger converts the hot air to hot water.The controller turns the circuit off when the desired temperature is met.The pressure relief protects the system from over pressure conditions.The pressure relief opens at 5000 PSIThe cad” may be cleaned with a soft cotton cloth during burner maintenance.The burner tip size should only be replaced with the same size tip.

The airfl ow adjustment must not be tampered with to keep this combustion process burn clean.Fuel must be supplied in a clean uninterrupted manor through the fuel fi lter to the burner for complete combustion.

WarningLeaks in the water circuit may be caused by freezing of this system.If the burner will not stay fi red the cad eye may be contaminated.

BurnerSwitch

12V


Temperature ControllerNo maintenance is typically required other than verifi cation of the temperature.The temperature setting has been preset to 160 degrees Fahrenheit. The burner will heat the water to this temperature before the fuel supply is shut off.

TEMPERATURE SETTING ON THE WATER TEMPERATURE CONTROLLER1. The temperature setting has been preset to 160 degrees Fahrenheit. The Burner will heat the water to this temperature before the fuel

supply is shut off. The water is then able to cool to 159 degrees before the burner is activated again. Changing the HI-temperature setting on the Controller is possible with a few simple steps.

2. There are four buttons on the keypad: E, M, >, ̂ . You want to access the “S-HI” parameter that is the “set high temperature” mark. Perform the following:

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A. Press E and while holding it in, press M.B. You will see “COND” lit up.C. Press > until the display reads “COM”.D. Press M to access “S-HI”E. Press M again and 170 should be on the display.F. Press > to move between digits.G. Press ^ to increase each digit’s value. (It will go to 0 after 9)H. Once the display reads the high temperature you selected, press E and then M to return to the standard display. (It will also return if you don’t do anything for 15 seconds.)


CYCLONE WATER FLOWAfter the initial fi lling and bleeding process and raising the engine to high-speed water fl ow is initiated.The fi lter pump fl ow position will turn on a switch to energize the fi lter pump. The fi lter pump draws water from the reclaim tanks, forcing the water through the stainless steel pleated 75 μ fi lters that into the 30 μ stainless steel pleated fi lters. Water then enters the clean water tanks. Next the water leaves the clean water tanks Continues through the charge pump and continues to the anti-weep solenoid.When the water pressurizes the pressure switch, and the high-pressure pump switches on water then fl ows through the high pressure pump. The water fl ow continues through the pressure relief and burner heating coilNow the water will fl ow to the water selector valves, and continue to the wand the curb cleaner or the cyclone head and out to the spray tips. (Figure 20 with Kubota)

DrainValve

ReclaimPump

High PressureLow Pressure

The cyclone blades create lower pressures, drawing water off the cleaned surface forcing the water into the cyclone chamber outlets discharging the water to the recovery tank mounted to the side of the cyclone deck. The water fl ows out of the bottom of the recovery tank to the deck lift pump to the reclaim tanks. Then the water fl ows from reclaim 1 to 2 to 3 dropping heavy sediment as fl ow continues from tank to tank.Then the water raises the fl oat causing the fi lter pump to engage and force the water through the 75 micron and 30 micron stainless fi lters and back into the clean water tanks. Then the water fl ow process continues over again. (Fugure with John Deere & 110v System)

DrainValve

ReclaimPump

High PressureLow Pressure


CYCLONE DECK:

Cyclone Rotation:

With the engine running in high speed, and the cyclone switch engaged, a series of events occurs. An electrical signal from the cyclone switch opens the solenoid controlled hydraulics valve allowing hydraulic fl uid fl ow to the cyclone deck motor. The cyclone deck motor rotates a belt connected to the cyclone shaft allowing rotational motion of the cyclone blade and bars. (Figure 21)

CYCLONE DECK:

Recovery pump: (Figure 22)

With the engine running in high speed, and cyclone switch engaged electrical signal from the cyclone switch opens the solenoid controlled hydraulic valves, allowing hydraulic fl uid fl ow to the cyclone motor. The cyclone motor rotates a belt connected to the recovery pump shaft.


CYCLONE DECK:

Recovery tank: (Figure 23)

The recovery tanks primary function is to separate the large size debris recovered from the cleaning process. Recovery tank is feed by two large inlet tubes mounted on the ends. The recovery tank has a removable lid with air/water separation hoses affi x to the top. Inside the recovery tank, you will fi nd a stainless steel mesh tray. When properly placed. This tray prevents large chunks of debris rocks, cigarette butts or any other large material from entering the recovery tank drain.

CYCLONE DECK:

High pressure union: (Figure 24)

The purpose of the high-pressure swivel is to allow water to fl ow into the rotating portion of the cycle assembly. The high-pressure swivel assembly contains two ceramic discs that seal the high-pressure water fl ow. The ceramic discs are lubricated by the water fl owing through the high-pressure swivel assembly. Although you can use the cyclone four recovery water from the ground is preferred to keep the swivel lubricated with the high-pressure water touring cycle operation. The accelerated wear may occur if the ceramic discs are run dry for extended periods of time.


CYCLONE DECK:

Deck lift and lower cylinders: (Figure 25)

To raise or lower the deck to hydraulic cylinders of attached to the frame in front of the water tanks are hydraulically controlled to raise or lower the deck. Electrical signal comes from the lift/lower switch. The signal controls, a solenoid operated hydraulic valve that allows fl uid power into either the rod and or and of the hydraulic cylinders creating a situation where the cylinders extend or retract the lift or lower the cyclone deck.

IgnitionFeed B+


SKIRT INSPECTION (Figure 26)

The skirting on the cyclone deck is to provide a more effi cient dealing area and higher velocity of the cyclonic action within the area of the cyclone. As well this skirting protects people or objects within the general area to be cleaned from water spray or debris spray that may result from the cyclone cleaning process.

When installing or replacing skirting use silicone sealant on the bolts affi xing the skirting and the upper skirting seal.


CYCLONE DECK:

Cyclone protective disc: (Figure 27)

A

The protective disc is covering the blades and bars on the bottom of the cyclone head. The protective disc has openings for the spray nozzles. Observe the maintenance schedule for inspecting the inner and outer protective disc mounting bolts as contact with foreign debris may wear the heads of these bolts off prematurely. When checking the mounting bolts it is advisable to verify the integrity of the protective disc for stress cracks or impact damage.


DRIVE SYSTEM

The drive system consists of a hydraulic power system and electrical control system. The hydrostatically controlled transmission pump assembly (Figure 28)

is belt driven off of the rear of the engine. Power to the pump comes to the pump via a belt drive attached to an over-hung load adapter mounted in-line with the pump assembly.

The transmission propulsion pump is a variable displacement piston style pump with two pulse width modulated frequency valves controlling forward and reverse fl uid fl ow to the drop hydraulic drive motor. When the operator depresses the fl oor mounted safety switch, then lifts up on the drive control directional lever and moves the lever into the forward or reverse position. An electrical signal for the forward or reverse motion is sent from the drive control directional lever into the drive controller card.

The drive controller card that applies a pulse width modulated voltage, which to either the forward or reverse solenoid operated frequency control valves on the main transmission pump. The frequency control valves of the pump are opened proportionally to that of the drive control levers input.

Then fl uid will fl ow from the main transmission pump to the drive motor creating forward or reverse rotation of the drive motor.

14.5

Engine

Drive Circuit


FRONT END AND TIRES

Functional Overview The front suspension is a parallel link coil spring suspension.

The steering Angle reffered to as toe is determined by the inner and outer tie rod end distance to the centerline of the machine.Saw tooth pattern (front or rear steering tires)A saw toothed wear pattern with the sharp edges felt when dragging your hand across the tire from inside to the outer edge would indicate excessive toe in.

A saw toothed pattern with the sharp edges felt when dragging your hand across the tire from outside to the inner edge would indicate

excessive toe out.

Wear on both the inside and the outside edges would indicate operation of the machine with lower than normal tire pressure.


HIGH PRESSURE PUMP (Figure A)

A

The high-pressure pump is a piston style belt driven pump. The high-pressure pump is controlled by electric clutch. The pressure pump is designed to fl ow 5.5 gallons per minute at 5000 PSI. One electrical pump request signal has been requested by the operator by turning on. The pump switch on the dashboard electrical signal fl ows from the switch through the low-pressure cutout and then engages the high-pressure pump. The control signal from the switch engages relay number two to create current path to the electric clutch.


LIGHTS, TURN SIGNALS AND BACKUP ALARMThe headlights and tail light circuit on the cyclone are directly controlled by the ignition switch. When the ignition switch is switched on the headlights and tail lights will always be activated for safety. Relay number four, controls the reverse lights, as well as the back up alarm. Whenever an output signal from the joystick controller card indicates reverse the reverse lights in the backup alarm will be energized. Whenever a signal to the fuel control solenoid on the engine is present from the positive bus-bar the warning beacon on the top of the machine will be energized.

Terminal XOn the joystickConnector

Buss BarIGN B+


STEERINGSteering system on the cyclone 4500 is a hydraulic steering system available in either two wheel steering or four wheel steering models. The steering system consists of a solid or switch for two wheel steer/4 wheel steer a rear steer valve rear steer cylinder, four wheel steer selector above, as well as a Main control box mounted logic circuit(Figure 40)When the four wheel two wheel selector switch is in the two wheel steer mode. Hydraulic fl uid fl ow is only available to the front steering cylinder. When the four wheel to wheel selector switch is the four wheel steering mode and electrical signal is sent to the logic circuit for steering to request 4WS steering. When the front steer cylinder is centered a position switch on the front steer cylinder will energize the logic circuit in the Main control box. When this circuit is energize a selector valve(Figure 40)will open and allow proportional fl uid fl ow from the steering gear attached to the steering column to move the front and rear steer cylinders in opposing directions to create a tighter turning radius. When the two wheel steer selector switch is switched from four to start two wheel steering A request is sent to the rear steer cylinder. Fluid will fl ow to the rear steer cylinder until the right and left position switches mounted in the rear steer cylinder are back to center.

IGN B+


110V SYSTEM (US Model Only)

Generator and meter

The generator system consists of a 110 V generator, which runs at 60 Hz. The frequency is controlled, based solely on engine rpm. The generator is only to be considered functional when the engine is at the higher RPM setting. Mounted to the rear of the hydraulic tank you will fi nd a voltage and frequency meter. The default measurement that you will see on the face of the meter is AC volts on the top of this meter to fi nd a button one to press this button will indicate frequency on the gauge.

The fi lter pump is 110 V alternating current water pump. The fi lter pump plugs into an outlet beneath the AC voltage and frequency gauge. The fi lter pump was trolled by a fl oat switch mounted in the number three reclaim tank. When water reaches within 6 inches of the top of tank the fi lter pump is energize. The only time the fi lter pump will operate is when the engine is at high speed and water has reached the top of the tank.


MAINTENANCE

Keep the machine in top condition by following the maintenance schedule closely. Maintenance intervals given are for average operating conditions. Machines used in severe environments may require service more often. In general:

• Keep the fuel tank fi lled (gasoline or diesel). This helps to reduce condensation and moisture entering the fuel system.• Be aware of the red service indicator light.• Reference the engine service manual for recommended engine service intervals and procedures. Recommended Service Materials• Engine Oil (15 W. 40)• Hydraulic Oil • Manufacturer-recommended Coolant (antifreeze) 50/50 mix• Lithium-base Grease• Tefl on tape type thread sealant in the appropriate grades• Never-Seez® (or equivalent) anti-seize compound


MAINTENANCEDaily Weekly Monthly Annually

Cyclone SystemCyclone Belt Tension and Condition XGrease Bottom Spindle Bearing XGrease Top Spindle Bearing XGrease Return Pump Bearing XGrease Return Pump Idler Bearing XCyclone Brush Skirting condition @ 40hrs XCheck Cyclone High Pressure Tips & Bolts @ 15hrs XCheck Cyclone Deck Cables for Wear or Abrasion XCheck Cyclone Deck Casters and Blade/Bars XEngine SystemCheck Engine Oil XCheck Fuel Filter XCheck Air Filter & Inlet Tube Service @ 500hrs X XCheck Indicator Lamps XChange Engine Oil & Filter @ 250 Hours XReplace Fuel Filter XClean Crankcase Vent Tube XCheck Engine RPM XCheck Belt Tensioner And Belt Wear XCheck Engine Ground Connection XCheck Engine Mounts XService Battery Connections XCheck Cooling System XPressure Test Cooling System XFlush Cooling System @ 1000 hrs or Annually XTest Thermostat XReplace Belt XClean Radiator Fins X



Low Pressure Water SystemCheck For Leaks & Verify Service Light Operation XClean 30 and 75 Micron Filters XClean Debris Tray and Screen XRinse Out Tanks & Check Seals XRecovery Hose from Tank to Pump Cyclone Deck XHigh Pressure Water SystemCheck Oil Level in High Pressure Pump XCheck For Oil / Water Leaks XVerify Pressure XOil Change High Pressure Pump @ 500 hrs XClutch Condition & Pressure Switch XWand and Curb Sprayer Condition XDrive SystemCheck for Leaks XCheck Tire Condition and Pressure XSteering SystemCheck for Loose Components XCheck Tire Wear for Alignment Issues XVerify Rear Steering Operation XWheels And Axles Grease @ 40hrs XFuel SystemDrain Water from Fuel Separator XChange Fuel Filter for Burner XBurner SystemCheck For Leaks XCheck Flame Adjustment XCheck Temperature Adjustment XFilter pumpCheck clutch operation XCheck Belt Tension X



Braking SystemCheck For Leaks XVerify Fluid Level XCheck For Brake Wear and Condition XHydraulic SystemCheck For Leaks XVerify Pressures XVerify Lift Lower Switch Operation XVerify Cyclone Pump Operation XVerify Steering Select Valve Operation 4ws XClean Hydraulic Cooler XLubricate Overhung Load Adaptor @ 40hrs XReplace Return Filter @ 500 hrs XReplace Hydraulic Breather @ 500hrs XHydraulic Fluid Sample Test @ 1000 hrs XSafety Items Verify Seat Belt Latch Operation XWarning System Lights, Backup, Alarm XService Brake Operation / Parking Brake X


MAINTENANCECHANGING SPRAY TIPS1 Spray tips should be changed every 8 - 16 hours depending on the severity of the cleaning being done. This can be determined if the machine is

losing pressure due to the tips opening up from excessive wear.2 Use a 9/16” or 14 mm socket to remove the spray tips from the spray bars. This can be done without removing the protective shield.3 Wrap the threads of the new tips with a minimum of 5 wraps of Tefl on tape and replace into the spray bars. The slot in the tip must be aligned in

the direction of the spray bar for the system to operate correctly.

WARNING!Always support the Cyclone head prior to working beneath the deck. When installing new spray tips, they must have a MINIMUM of 5 wraps of Tefl on tape to make sure the stainless steel threads on the tip DO NOT CONTACT the threads of the stainless steel spray bar. Contact between the two can cause the tip to seize inside the spray bar, and the spray bar will have to be replaced.

FIGURE 44


MAINTENANCEHYDRAULIC FILTER POP-OUT INDICATORHydraulic breather should be replaced every 250 hours.See Figure 45. Indicator (A) will indicate when the hydraulic fi lter needs to be replaced.Hydraulic fi lter pop-out should be checked daily. Never operate the Cyclone 4500 with a dirty hydraulic fi lter. Doing so will cause severe system damage and will VOID MANUFACTURER’S WARRANTY.

FIGURE 45

A


LUBRICATIONPOINTS


GROUNDLOCATIONS

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ENGINE MAINTENANCE

ENGINE OIL – DIESELSee corresponding engine manual for engine oil viscosity recommendations.Check the engine oil level when the machine is parked on a level surface and the engine is cool. Change the engine oil after the fi rst 35 hours of operation and every 150 hours after that.

* Diesel Lubricating Oil Note:With the emission control now in effect, the CF-4 and CG-4 lubricating oils have been developed for use with a low-sulfur fuel used in on-road vehicle engines. When an off-road vehicle engine runs on a high-sulfur fuel, it is advisable to employ the CF, CD or CE lubricating oil with a high total base number. If the CF-4 or CG-4 lubricating oil is used with a high-sulfur fuel, change the lubricating oil at shorter intervals.

ENGINE OIL

Check the engine oil level when the machine is parked on a level surface and the engine is cool. Change the engine oil after the fi rst 35 hours of operation and every 150 hours after that.

Oils meeting one of the following specifi cations are recommended:

� ACEA Oil Sequence E4� ACEA Oil Sequence E5� ACEA Oil Sequence E6� ACEA Oil Sequence E7

Oil must meet any of the following:

� John Deere TORQ-GARD SUPREME� API Service Category CJ-4� API Service Category CI-4� API Service Category CI-4 Plus� API Service Category CH-4� ACEA Oil Sequence E3

Multi-viscosity diesel engine oils are preferred.


Replace the oil fi lter with every oil change. Recommended lubricating oil when low-sulfur or high-sulfur fuel is employed

FuelLubricatingOil class

Low sulfur(0.5 % ≥) High sulfur Remarks

CF O O TBN ≥ 10CF-4 O XCG-4 O X

O : Recommended X : Not recommended


BIO DIESEL FUEL

CAUTION!The use of bio diesel fuel is not recommended.The fuel is not only utilized to operate the engine, but the burner as well.In order to keep the burner exhaust emissions to a minimum, number two diesel fuel is the only recommendation for fueling the Cyclone 4500.

ENGINE COOLANT

CAUTION!Do not remove the radiator cap when the engine is hot.The turbo may stay hot longer than the cooling system.

Check the engine coolant level before operation. Open the rear engine compartment door and allow the engine to cool completely. Slowly remove the Radiator Fill Cap (Figure 47)If coolant is not visible at the bottom of the fi ller neck, add a mixture of half water and half engine manufacturer approved anti-freeze approximately ½ inch from the top of the tank (see engine manual for antifreeze recommendations).If the level is low, add a 50/50 mix of water and the recommended type antifreeze. Clean the radiator and oil cooler exteriors by washing with low-pressure water or using compressed air every 150 hours.

Caution: Do not use cooling system sealing additives or antifreeze that contains sealing additives.

Caution: Do not mix ethylene glycol and propylene glycol base coolants. Avoid automotive-type coolants automotive-type coolants (such as those meeting ASTM D3306). These coolants do not contain the correct additives to protect heavy-duty diesel engines. They often contain a high concentration of silicates and may damage the engine or cooling system.


BRAKE OPERATION

This machine is equipped with hydraulic front disc service brakes. If the machine sees little brake usage greasing the caliper sliders may be needed annually. This should be performed with Sil-glide or equivalent brake slider lubricant, never use high pressure grease.

The front service brakes are self adjusting, loss of fl uid can either mean that of signifi cant brake pad wear of a leak.


HYDRAULIC OIL

WARNING!To avoid hydraulic oil injection or injury, always wear appropriate clothing and eye protection when working with or near hydraulic system.

IMPORTANT!Change the Hydraulic Oil Filter after the fi rst 35 hours of operation. After that, change the fi lter when the Hydraulic Filter indicator (Figure 49) indicates service is necessary.

A

The hydraulic reservoir is located in the Engine Compartment (Figure 50) Check the hydraulic oil in the reservoir after running the machine, while the hydraulic oil is still warm. See sight gauge mounted on the side of the reservoir, located behind the right rear access door (Figure 51). The oil level should be in the center of the sight gauge (Figure 52). Add hydraulic oil to obtain the proper reservoir level between the high and low marks.

Note: All cylinders should be retracted prior to checking this level.(Cyclone Deck In the Up Position)


RECOVERY TANK MAINTENANCE

After every use, inspect the gasket that seals the recovery tank top around the recovery tank cover. Replace the gasket if it is damaged or not sealing properly. Clean out the recovery tank sediment and tray clear hose to pump. The tray only goes in one way. Make sure there is no restriction to the outlet (to pump) or inlet tubes (from cyclone) Make sure the air tubes are clear of debris and fi rmly reattached prior to use. Any blockage in the outlet hose fi tting or hose to the pump inlet as this will lead to the tank over fl owing.


ENGINE AIR FILTER MAINTENANCE-KUBOTACheck the Engine Air Filter Service Indicator (5) before each use of the machine.

CAUTION!When servicing the engine air fi lter elements, use extreme care to prevent loose dust from entering the engine. Dust can severely damage the engine.The engine air fi lter contains a Primary (outer) and a Safety (inner) fi lter element. The Primary Element can be cleaned twice before being replaced. The Safety Element should be replaced every third time that the Primary Filter Element is replaced. Never attempt to clean the Inner Safety Element.To clean the Primary Filter Element, unsnap the two clips at the end of the air fi lter and remove the end housing. Pull the primary element out. Clean the element with compressed air (maximum pressure 100 psi)


ENGINE AIR FILTER-JOHN DEEREProper maintenance of the engine air fi lter is extremely important. Service the air fi lter every 50 hours, - more frequently in dirty conditions. Always tighten the clamp securely. Cleaning/Servicing K & N Air Filters

Tools required:K & N Air Filter Cleaner - normally 1 liter bottle.K & N Air Filter Oil - 200ml aerosol is best.Shallow Tray Cleaning the Air Filter:Tap the element to dislodge any large embedded dirt, and then gently brush it with a soft bristle brush. Add cleaning solution to the shallow tray, 3/4 the depth of the pleats. Roll the fi lter in the tray, trying to prevent dirty solution run inside the fi lter. Wait for up to 5 minutes, rinse fi lter from inside with water from the tap. Do not use high pressure. Shake of excess water and allow to dry naturally overnight.

CAUTION!Use only Nilfi sk Brand air fi lter cleaner!Do Not use petrol, thinners paraffi n etc.Do Not use detergents.Do Not steam clean!Do Not use compressed air.Do Not use hot air guns for drying. The use of any of the above can cause harm to the fi lter media, or shrink and harden the rubber end caps.Excess heat will shrink the fi lter media. Compressed air will blow holes in the element.

After air fi lter is completely dry, always re-oil before using. If using K&N aerosol - hold the can 3ins away & spray oil down into each pleat with one pass per pleat. Do Not go “round & around” WAIT 20 minutes for oil to spread. The white gauze should appear red, have no “white spots” and be drip less.

If using K&N squeeze bottle - squeeze K&N air fi lter oil down into the bottom and along each pleat - only one pass per pleat. Let oil wick into cotton for 20 minutes. Re-oil any white spots still showing. Caution: Never use any oil other than RED K&N AIR FILTER OIL.Never use a K&N air fi lter without oil. (The fi lter will not stop the dirt without the oil.)K&N air fi lter oil is a compound of mineral and animal oil blended with special polymers to form a very effi cient tack barrier. Red dye is added to show just where you have applied the oil. Eventually the red color will fade but the oil will remain and will fi lter the air.


MAINTENANCE

Red service Indicator Light The service indicator light will light up only when there is not enough water supply for the required demand.

ENGINE SPEED GOVERNING SYSTEM

Ignition Feed


HYDRAULIC SYSTEM TROUBLESHOOTINGAccurate measurements are the key to troubleshooting a hydraulic system. Once measurements are obtained, they can be compared with specifi cations to analyze a problem.When troubleshooting hydraulic systems are three typical methods used tachometers, fl ow gauges or pressure gauges.

The most convenient method is to check motor RPM with a digital tachometer. The diagram below should be used to check for proper motor RPM, hydraulic oil fl ow or pressure differential. The readings are nominal fi gures and there will be variations due to manufacture’s tolerances and system oil temperature. If any reading varies greater then 20%, there will be a noticeable loss of performance and should be corrected.


GENERAL HYDRAULIC SPECIFICATIONS TABLECyclone Deck Rotation Circuits Displacement

Cu. In. / cc GPM/L RPM IN PSI/bar Relief

PSICyclone Pump, engine @ 2000 RPM no systems running (test port P1)

1.95 (31.95477) 17 (64.35) 2111 1200 (82.73)-

1600 (110.31)2000

(137.89)

Cyclone Motor 1.5 (24.5806) 16.8 (63.59) 3810 800 (55.15) 2000 (137.89)

IgnitionFeed B+


Steering Circuits DisplacementCu. In. / cc GPM/L RPM IN PSI/bar

Steering unit (driving and turning) load reactive 9.73 (159.44) 5(18.92) 120 500/34.47Steering cylinder front (2.375” OD Rod Diameter 1” OD)Steering cylinder Rear

IGN B+


Charge and Deck Lift Pump DisplacementCu. In./CC GPM RPM

IN PSI/bar ReliefPSI

transmission charge pump and lift lower test port, engine @ 2000 RPM no systems running (test port 3b) 1.10/18cc 3.0(11.35) 2000 290/

19.99 325/22.4

transmission main propulsion, engine @ 2000 RPM (test port 3a) 1.1/18cc 9.75(36.9) 2000

325-1800/22.4-124.1

3000/206.84

Cyclone Lift Cylinders2” bore 1” rod 9.5” stroke7 second raise time cold

325/22.4


Propulsion Pump Circuits DisplacementCu. In. GPM/L RPM

ININ A PSI/

barRelief

PSI/barTransmission pump charge pressure 325/22.4

Transmission main propulsion, engine @ 2000 1.1/18cc 9.75(36) 2000 325-1800/ (22.40-124.10) 3000/206.84

Propulsion Motor 14.5/237.61cc

14.5

Engine

Drive Circuit


Hydraulic Reservoir CapacityHydraulic reservoir capacity: 18.5 gallons 70.030 Liters


HYDRAULIC SYSTEM

HYDRAULIC TRUTH TABLEElectrical Solenoid’s Energized Status – Component to Operate

Solenoid Functions Cyclone motor

Cyclone lift B

Cyclone lift A 4ws 2nd

Speed Forward ReverseCyclone Fan XDeck Down XDeck UP X4ws ON X2ws OnHigh speed Drive XLow Speed DriveForward drive X / 0 XRear drive X / 0 X

NOTE: Drive signals are PWM not charging voltage


HYDRAULIC SYSTEM


APPENDIXWIRING DIAGRAM


APPENDIXHYDRAULIC DIAGRAM


APPENDIX_____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

PM CHECK LIST

Customer Address 1Address 2 City St Zip Model Serial NumberHour MeterEngine Serial Number

Defect Codes

A: needs adjustment B: binding C: dirty or contaminated D: damaged, bent or tornL: leaks or low M: missing W: worn out

RefVISUAL INSPECTION ITEMS

Comments OKDefect Codes

D o e s N o t Work

1 Check engine oil level – change every 500 hours along with the fi lter

2 Check engine air fi lter3 Check engine coolant level4 Check radiator fi ns5 Check fan belt6 Check high pressure pump belt7 Check generator belt8 Check cyclone reclaim pump belt 9 Cyclone Belt 10 Recovery tank cover seal condition 11 Cyclone deck lift cylinder seals and cables inspect for leaks,

wear, and abrasion

12 Cyclone deck position parallel to chassis, check for bent or broken linkage.

13 Cyclone protective disk and retaining bolts14 Cyclone spray tip condition 15 Cyclone deck skirt condition16 Cyclone blade / bar condition17 Recovery hose from cyclone basket tank to reclaim pump 18 Cyclone Deck caster wheels adjust / inspect19 Cyclone deck damage from impact20 Hydraulic Oil Level / Sample test @ 1000 hours21 Recovery hose from cyclone basket tank to reclaim pump

clear of debris 22 Seal Between Recovery Tank and Tank Cover23 Fresh water and reclaim tanks– no leaks, clear of debris24 Generator voltage and frequency25 Check for Hydraulic oil leaks26 Front Tires – Condition /Pressure

Rear Tire –Condition / Pressure27 Machine and/or engine dirty28 110v pump operation when fl oat rises to top


Ref Normal Maintenance Cyclone Maintenance Interval Performed Not required yet1 Change engine oil 250 hours2 Engine oil fi lter changed 250 hours3 Engine air fi lter cleaned and oiled 500 hours4 Engine fuel fi lter changed 500 hours 5 Cooling Fan blade condition As required6 Tire rotation Every PM7 String, wire, twine, and banding material removed from

hydraulic motor shafts and pump shafts near pulleysAs required

8 Cyclone disk bolts As required9 Tie Rod end condition As required10 Ball Joint Condition As required11 Control arm shaft condition As required12 Hydraulic oil change As required13 Hydraulic oil fi lters change As required14 Recycling fi lter acid washed As required15 Machine lubrication – drive wheel, front wheels, and

steering guideEvery PM

16 Grease suspension and u- joints Every PM


RefOPERATIONAL INSPECTION ITEMS

OKDefect Codes

D o e s N o t Work

1 Steering 2ws and 4ws centering during 2ws operation2 Drive Operation (check for Fwd/Rev drive & released stop)3 Squeegee raises when in Reverse4 Brakes (service & parking) Confi rm service & parking brake is functional stops with

service brake and parking brake holds.5 Water System Performance high pressure application and recovery operational.6 Boiler temperature rise and control7 Cyclone Lift System (Raise/Lower Head)8 Wand and cyclone water pressure 9 Belt and hose conditions no loose belts or crimped hoses10 Filter pressures 75 and 30 micron11 Water leaks during operation 12 Hydraulic leaks 13 Filter check lamp and hydraulic fi lter indicator14 Seat belt latch 15 Headlight, Turn Signals, and Flashing Light16 Engine Speed Control17 Deck casters rotate check deck up18 Fluid levels

WORK COMPLETED BY: ACKNOWLEDGED BY:

Service Technician Signature Date Customer Signature Date

cyclone 4500eu2 copy · 4 - form no. 56043125 / cyclone 4500 2ws, 4ws general safety instructions...

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