Nilfisk-Advance CS7000 - Industrial Cleaning Equipment

Nilfisk-Advance CS7000 - Industrial Cleaning Equipment
CS7000™
Service Manual
Advance CS7000 Hybrid LPG, Model Number 56509000
Advance CS7000 Hybrid Diesel, Model Number 56509001
Advance CS7000 B, Model Number 56509002
Advance CS7000 Hybrid LPG EcoFlex™, Model Number 56509006
Advance CS7000 Hybrid Diesel EcoFlex™, Model Number 56509007
Advance CS7000 B EcoFlex™, Model Number 56509008
Advance CS7000 Fuel Cell EcoFlex™, Model Number 56383115
Advance CS7000 Hybrid Gasoline EcoFlex™, Model Number 56511001
Nilfisk CS7000 Hybrid LPG EU, Model Number 56509003
Nilfisk CS7000 Hybrid Diesel EU, Model Number 56509004
Nilfisk CS7000 Battery EU, Model Number 56509005
Nilfisk CS7000 Hybrid Petrol EcoFlex™, Model Number 56111002
English
05/11 Revised 02/13 Form No. 56043151
Service Manual – CS7000
Contents
Contents
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
General Machine Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Service Manual Purpose and Application . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Other Reference Manuals and Information Sources . . . . . . . . . . . . . . . . . . . . . 14
Nilfisk-Advance Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Engine Manufacturers’ Technical Manuals . . . . . . . . . . . . . . . . . . . . . . 15
Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Parts and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Cautions and Warning Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Hopper Prop Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
To Engage the Hopper Prop Rod . . . . . . . . . . . . . . . . . . . . . . . . . . 18
To Disengage the Hopper Prop Rod . . . . . . . . . . . . . . . . . . . . . . . . 18
Jacking the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Transporting the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Towing the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Diagnostic and Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Fastener Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Overall Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Recommended Service Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Daily Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Maintenance Every 15 to 20 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Monthly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Maintenance Every 150 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Maintenance Every 400 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Maintenance Every 800 to 1000 Hours . . . . . . . . . . . . . . . . . . . . . . . . . 28
Maintenance Every 1500 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Maintenance Every 1900 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Maintenance Every 2000 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
EcoFlex System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
To Purge When Changing Detergents (the scrub system must be off) . . . . . . 31
To Purge Weekly (the scrub system must be off) . . . . . . . . . . . . . . . . . 31
To Change the Detergent Mix Ratio (the scrub system must be on) . . . . . . . 32
PM Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Machine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Control Panel - General
Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Miscellaneous Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Miscellaneous Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Scrub Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Scrub Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Sweep Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Sweep Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Hopper Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
LCD Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
General Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Battery Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
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LPG Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diesel Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Broom Adjustment (Battery, LPG and Diesel) . . . . . . . . . . . . . . . . . .
Battery Charge Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault, Caution and Warning Displays . . . . . . . . . . . . . . . . . . . . . . . . .
Fault Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Caution Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warning Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Foot Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents
40
41
41
41
42
42
42
43
44
44
Chassis System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Component Locations - Battery Machine (major components) . . . . . . . . . . . . . . . 45
Component Locations - LPG and Diesel Machine (major components) . . . . . . . . . . . 46
Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
CAN Bus Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
CAN BUS message routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Main Machine Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Drive Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Steering Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Fault Code Table (Main machine controller) . . . . . . . . . . . . . . . . . . . . . . 54
Hidden Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Configuration Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Configuration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
User Options Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Service Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
To Operate: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Control Panel LEDs all stay lit - CAN Bus problems . . . . . . . . . . . . . . . . . 72
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Main Machine Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Shop Measurements – Main Machine Controller . . . . . . . . . . . . . . . . . . . 75
J2 Connector (White) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
J3 Connector (Gray) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
J7 Connector (Black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Dust Control/DustGuard™ Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Dust Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
DustGuard™ Spray System (optional) . . . . . . . . . . . . . . . . . . . . . . . 81
DustGuard™ System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 82
Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Impeller and Filter System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Dust Control Filter Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
DustGuard™ Spray System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
To Clean the Dust Control Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
To Remove the Dust Control Filter . . . . . . . . . . . . . . . . . . . . . . . . 87
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Contents
To Clean the Dust Control Filter . . . . . . . . . . . . . . . . . . . . . . . . . .
To Reinstall the Dust Control Filter . . . . . . . . . . . . . . . . . . . . . . . .
To Clean the DustGuard™ Strainer Screen . . . . . . . . . . . . . . . . . . . . . .
To Clean the DustGuard™ Spray Nozzles . . . . . . . . . . . . . . . . . . . . . . .
To Adjust the DustGuard™ Spray Nozzles . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To Remove and Reinstall the DustGuard™ Solenoid Valve Assembly . . . . . . . .
To Remove and Reinstall the DustGuard™ Pump . . . . . . . . . . . . . . . . . .
To Remove and Reinstall the Dust Control Filter Switch . . . . . . . . . . . . . . .
To Remove and Reinstall the Impeller Assembly . . . . . . . . . . . . . . . . . . .
To Disassemble and Reassemble the Impeller Assembly . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
88
88
89
90
90
91
93
93
94
95
95
96
97
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Wiring Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Current Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
42 Volt Alternator (Generator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Low Voltage Cutout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
42 Volt Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Incandescent Headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
LED Headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Electrical Panel Contactor/Relay location . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Harness to Harness Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Connector Pin-Outs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Component ID to Connector ID Look Up Table . . . . . . . . . . . . . . . . . . . 109
Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
K14 Safety Relay and K15 Auxiliary Relays . . . . . . . . . . . . . . . . . . . . . 131
Early Style K14 Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Early Style K15 Auxiliary Relay . . . . . . . . . . . . . . . . . . . . . . . . . 131
Late style K14 Safety Relay and K15 Auxiliary Relay . . . . . . . . . . . . . 132
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Charging the Battery (Battery Model) . . . . . . . . . . . . . . . . . . . . . . . . 133
Generator Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
42 volt generator is not charging . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Insufficient machine operation time (Battery Model) . . . . . . . . . . . . . . . . 133
Insufficient machine operation time with engine off (Hybrid models) . . . . . . . . 133
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
42 volt Generator Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
42 volt Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Generator Drive Belt Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Head Light bulb - Standard 12v Halogen . . . . . . . . . . . . . . . . . . . . . . . 137
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Battery (Battery Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Low Voltage Cut Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Battery Run Time (Battery powered machine) . . . . . . . . . . . . . . . . . . . . 138
Current Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Engine System, Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
157
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Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Engine starter control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Fuel pump control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Engine Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Over Temperature Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Low Oil Pressure Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Engine RPM control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Glow plug control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Diesel Engine Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . 168
Change Engine Oil and Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Change Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Replace Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Bleed Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Inspect Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Replace Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
No crank – The starter does not engage . . . . . . . . . . . . . . . . . . . . . . . 172
Cranks but does not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Cannot Achieve Either Run or Maximum Engine Speed Settings (Run 2200 RPM, Maximum
Power 2400 RPM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Compression Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Fuel Pump; . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Engine Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Engine Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Engine Oil Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Engine Oil Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Radiator Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Shop Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Engine RPM Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Engine Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Fuel System Return Fuel Flow . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Glow Plug Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Engine System - LPG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Starter Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Control Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cranking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Normal Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine RPM Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Normal Engine Shut Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step One . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
182
182
183
183
185
186
186
187
188
189
189
190
190
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Step Two . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Overheat Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lost Oil Pressure Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Change Engine Oil and Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . .
Change Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspect Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replace Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Spark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking LPG Primary Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . .
No crank - The starter does not engage . . . . . . . . . . . . . . . . . . . . . . . .
Cranks but does not start – No Spark . . . . . . . . . . . . . . . . . . . . . . . .
Cranks but does not start (has sufficient spark) . . . . . . . . . . . . . . . . . . .
Achieves one but not ALL RPM modes. . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine OIl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shop Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spark Controller Measurements: . . . . . . . . . . . . . . . . . . . . . . . . .
Governor Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Woodward L Series Actuator Measurements . . . . . . . . . . . . . . . . . .
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
191
192
193
194
198
198
199
200
200
200
201
201
201
202
203
203
204
205
205
206
206
206
206
206
206
207
207
207
208
208
209
Engine System - Petrol (Gasoline) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Kubota WG972-GL-E3-NFK-1 Petrol (Gasoline) . . . . . . . . . . . . . . . . . . .
Circuit Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Starter and Carburetor Choke Control . . . . . . . . . . . . . . . . .
Throttle Control Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cranking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Normal Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine RPM Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Normal Engine Shut Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Overheat Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lost Oil Pressure Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Right Side View (Toward front of machine) . . . . . . . . . . . . . . . . .
Engine Back Side View (Toward right of machine) . . . . . . . . . . . . . . . . .
Engine Left Side View (Toward back of machine) . . . . . . . . . . . . . . . . .
Fuel Tank Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Change Engine Oil and Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . .
Change Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspect Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
210
210
210
211
211
213
214
214
215
216
217
217
218
219
220
221
222
223
223
224
225
225
226
226
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Replace Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Spark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No crank - The starter does not engage . . . . . . . . . . . . . . . . . . . . . . . .
Cranks but does not start – No Spark . . . . . . . . . . . . . . . . . . . . . . . .
Cranks but does not start (has sufficient spark) . . . . . . . . . . . . . . . . . . .
Achieves one but not ALL RPM modes. . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shop Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spark Controller Measurements: . . . . . . . . . . . . . . . . . . . . . . . . .
Governor Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Woodward L Series Actuator Measurements . . . . . . . . . . . . . . . . . .
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents
227
228
228
228
229
229
230
231
231
232
232
232
232
232
233
233
233
234
234
235
Hopper System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Hopper System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Hopper Hydraulic System Circuit Details . . . . . . . . . . . . . . . . . . . . . . 238
Hopper at Rest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Hopper Being Raised . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Hopper Being Lowered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
The Following Conditions Must Be Met for the Hopper to be Raised and Lowered239
The Following Conditions Must Be Met for the Hopper Door Open and Close 240
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Upper and Lower Hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Hydraulic Power Pack Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
Hopper Dump Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Hopper Dump Door Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Dump Door Extend and Retract Limit Switches . . . . . . . . . . . . . . . . . . . 242
Hopper Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Hopper Prop Rod and Pull Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
To Remove and Reinstall the Hydraulic Power Pack Assembly . . . . . . . . . . . 245
LPG and Diesel Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
Battery Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
To Remove and Reinstall the Hopper Lift Cylinder . . . . . . . . . . . . . . . . . 249
To Replace the Oil in the Hydraulic System . . . . . . . . . . . . . . . . . . . . . 252
To Remove and Reinstall the Hopper Dump Door Actuator Assembly . . . . . . . 261
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Options and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
263
Recovery System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recovery System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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273
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275
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Recovery Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recovery Tank Cover and Debris Basket . . . . . . . . . . . . . . . . . . . . . . .
Vacuum Fan Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vacuum Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Float Cage and Ball Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To Clean the Vacuum Filter and Filter Screen . . . . . . . . . . . . . . . . . . . .
To Clean the Debris Basket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To Remove the Recovery Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To Reinstall the Recovery Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To Remove and Reinstall a Vacuum Motor . . . . . . . . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
276
276
277
277
277
278
278
279
280
281
281
283
284
285
285
Scrub System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scrub Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scrub System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Following Conditions Must be Met for the Scrub System To Operate . . .
Scrub Deck Actuator Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brush Current Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scrub Motor Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Right Scrub Arm Gas Spring and Lever Arm Bracket . . . . . . . . . . . . . . . .
Side Squeegee Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scrub Deck Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To Replace a Leading Deck Blade . . . . . . . . . . . . . . . . . . . . . . . . . . .
To Replace a Trailing Deck Blade . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To Remove and Reinstall a Side Squeegee Assembly . . . . . . . . . . . . . . . .
To Remove and Reinstall the Scrub Deck Actuator . . . . . . . . . . . . . . . . .
To Remove and Reinstall the Scrub Deck . . . . . . . . . . . . . . . . . . . . . . .
To Remove and Reinstall a Scrub Motor Assembly . . . . . . . . . . . . . . . . .
To Replace the Scrub Motor Carbon Brushes . . . . . . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
286
286
286
286
287
288
288
288
289
289
289
289
290
290
291
291
291
292
293
293
294
294
297
298
301
302
Solution System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solution Flow Control - Non-EcoFlex™ Machines . . . . . . . . . . . . . . . . . .
Solution Flow Control - EcoFlex™ Machines . . . . . . . . . . . . . . . . . . . . .
EcoFlex™ Detergent System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Extended Scrub System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Hot Water System (LP and Diesel EcoFlex™ Machines Only) . . . . . .
Optional Wash Hose Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional High-pressure Spray System (LP and Diesel Only) . . . . . . . . . . . .
Solution Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solution System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Following Conditions Must be Met for the Solution System to Operate . .
303
303
303
303
303
304
304
304
304
305
305
306
307
307
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The Following Conditions Must be Met for the Extended Scrub System to Operate
307
The Following Conditions Must be Met for the Low Pressure Wash Hose to Operate
308
The Following Conditions Must be Met for the EcoFlex™ System to Operate . 308
The Following Conditions Must be Met for the High-pressure Spray System to Operate
308
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
Solution Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
Drain Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
Solution Filter and Solution Shutoff Valve . . . . . . . . . . . . . . . . . . . . 309
Solution Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
Solution Pump (EcoFlex™ Models Only) . . . . . . . . . . . . . . . . . . . . . . . 310
Low Pressure (Wash Hose) Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 310
Solution Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
Solution Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
EcoFlex™ Detergent Bottles and Pumps . . . . . . . . . . . . . . . . . . . . . . . 312
High-pressure Spray System Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 312
Extended Scrub System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
To Clean the Solution Filter Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 314
To Clean the Extended Scrub System Strainer . . . . . . . . . . . . . . . . . . . 315
To Clean the High Pressure Solution Filter . . . . . . . . . . . . . . . . . . . . . 315
To Adjust the Belt Tension on the High Pressure Pump . . . . . . . . . . . . . . . 316
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
To Remove and Reinstall the Solution Tank . . . . . . . . . . . . . . . . . . . . . 320
To Remove and Reinstall the Solution Shutoff Valve . . . . . . . . . . . . . . . . 324
To Remove and Reinstall the Solution Filter Assembly . . . . . . . . . . . . . . . 324
To Remove and Reinstall the Solution Solenoid Valve . . . . . . . . . . . . . . . . 325
To Remove and Reinstall a Detergent Pump (EcoFlex™ Models Only) . . . . . . . 325
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
Squeegee System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Squeegee System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To Remove and Reinstall the Squeegee Blades . . . . . . . . . . . . . . . . . . . .
To Remove and Reinstall the Front Squeegee Blade . . . . . . . . . . . . . .
To Remove and Reinstall the Rear Squeegee Blade . . . . . . . . . . . . . . .
Squeegee End Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Squeegee Caster Wheel Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . .
To Adjust the Squeegee Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To Adjust the Squeegee Casters . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To Remove and Reinstall the Squeegee Support Assembly . . . . . . . . . . . . .
To Remove and Reinstall the Squeegee Lift Arm . . . . . . . . . . . . . . . . . .
To Remove and Reinstall the Squeegee Lift Actuator . . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
329
329
329
329
330
330
331
331
331
332
332
332
333
334
335
336
336
336
337
338
338
Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
339
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Service Manual – CS7000
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Wheel Rotation Sensor . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Travel Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Codes (DTCs) . . . . . . . . . . . . . . . . . . . . . . . . . . .
To retrieve steering system codes from the “hidden menu”: . . . . . . . . . . .
Diagnostic Trouble Code Table . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symptom Troubleshooting (No DTC stored) . . . . . . . . . . . . . . . . . . . . .
Steering Inoperative - Steering Controller Status LED is Blinking Rapidly .
Steering Inoperative - Steering Controller Status LED is Off . . . . . . . . .
Steering Inoperative - Steering Controller Status LED is On Steady . . . . .
No “Steering Feel” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Wheel Is Difficult To Turn . . . . . . . . . . . . . . . . . . . . . . .
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Wheel Rotation Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shop Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Wheel Rotation Sensor Voltage Measurements . . . . . . . . . . . .
Steering Controller Voltage Measurements . . . . . . . . . . . . . . . . . . .
J5 Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor U, V and W Terminal Pair Voltages . . . . . . . . . . . . . . . . . . . .
Motor U, V and W Terminal Pair Frequency . . . . . . . . . . . . . . . . . . .
System Current Draw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents
339
339
339
340
341
341
342
343
347
348
348
348
348
349
353
353
353
353
353
353
354
354
355
358
358
360
360
360
361
361
362
362
362
362
362
362
Sweep System, Main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
Main Sweep System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 364
Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
The Following Conditions Must be Met for the Main Sweep System To Operate365
Main Broom Actuator Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
Broom Current Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
Main Broom and Drive Components . . . . . . . . . . . . . . . . . . . . . . . . . 366
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
To Adjust the Main Broom Height . . . . . . . . . . . . . . . . . . . . . . . . . . 367
To Adjust the Main Broom Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
Inspecting/Replacing Main Broom Motor Carbon Brushes . . . . . . . . . . . . . . . . . 369
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
To Remove the Main Broom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
To Install the Main Broom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
To Remove and Reinstall the Broom Motor Assembly . . . . . . . . . . . . . . . . 375
To Remove and Reinstall the Broom Lift Actuator . . . . . . . . . . . . . . . . . . 376
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Service Manual – CS7000
Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
Sweep System, Side Broom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
Side Broom System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 380
Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
The Following Conditions Must be Met for the Side Broom Sweep System To Operate
381
Side Broom Actuator Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
Side Brooms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
Side Broom Motor Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
Side Broom Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
To Remove and Reinstall a Side Broom . . . . . . . . . . . . . . . . . . . . . . . . 383
Inspecting/Replacing Side Broom Motor Carbon Brushes . . . . . . . . . . . . . . . . . 384
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
To Remove and Reinstall a Side Broom Motor Assembly . . . . . . . . . . . . . . 387
To Remove and Reinstall a Side Broom Hub Assembly . . . . . . . . . . . . . . . 389
To Remove and Reinstall the Side Broom Actuator . . . . . . . . . . . . . . . . . 389
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
Wheel System, Non-Traction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To Adjust the Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To Remove and Reinstall a Wheel . . . . . . . . . . . . . . . . . . . . . . . . . .
To Remove and Reinstall a Brake and Spindle Assembly . . . . . . . . . . . . . .
393
393
394
394
395
395
395
396
Wheel System, Traction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Wheel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Powering up the Drive Controller . . . . . . . . . . . . . . . . . . . . . . . .
Drive Pedal Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAN Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Pedal Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Summary of LED display formats . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Pedal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Motor and Gearbox Assembly . . . . . . . . . . . . . . . . . . . . . . . . .
397
397
397
397
398
398
398
398
399
402
403
404
404
404
404
405
405
406
407
407
417
418
418
418
xi
Service Manual – CS7000
Drive Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shop Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Controller Voltage Measurements . . . . . . . . . . . . . . . . . . . . .
Low Current 35 Pin Connector (J4) . . . . . . . . . . . . . . . . . . . . . . . .
Motor U, V and W Terminal Pair Voltages . . . . . . . . . . . . . . . . . . . .
Motor U, V and W Terminal Pair Frequency . . . . . . . . . . . . . . . . . . .
System Current Draw - Driving only with no cleaning functions . . . . . . . .
Wheel Drive Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents
422
422
423
423
423
423
424
424
425
425
425
xii
Service Manual – CS7000
General Information
General Machine Description
The CS7000 machines are industrial automatic rider sweeper/scrubbers with multiple sweep/scrub singlepass coverage. Both battery (all electric) and hybrid (LPG and diesel) models are available with or without
the EcoFlex™ and DustGuard™ options. The scrub system uses three disc scrub brushes with variable scrub
pressure and solution flow rates. The sweep system has a center main broom and left- and right-hand side
brooms.
A fuel cell powered model has also been added. It is virtually a battery model that has had the large monoblock battery replaced with a fuel cell provided by Plug Power.
Service Manual Purpose and Application
This Service Manual a technical resource designed to aid service personnel in maintaining and repairing the
CS7000 Sweeper/Scrubber to ensure optimum performance and long service life. Please read it thoroughly
before servicing your machine.
Revision History
• 8/11 - Not available
• 6/12
–– General Information - Technical specifications table updated
–– Control System - Updated Configuration Display, Configuration Menu and User Options Menu
Sections. Added “Power Distribution Fault” to fault code table. Updated installation instructions fro
main machine controller.
–– Electrical System - Added information on new LED headlights. Added wiring connection diagram for
K14 Safety Relay and K15 Auxiliary Relay
–– Engine LPG - Updated Functional Description of engine RPM control. Updated Troubleshooting for
RPM Control problem.
• 2/13
–– General Information - Introduce Fuel Cell powered model
–– Engine System, Petrol (Gasoline) - Add new chapter
–– Electrical System - Updated wiring diagram
–– Wheel System, Traction - Add information on fastening electrical cables to the drive controller.
13
Service Manual – CS7000
General Information
Other Reference Manuals and Information Sources
Nilfisk-Advance Publications
Model Name
Model
Number
Advance CS7000 Hybrid LPG
56509000
Advance CS7000 Hybrid Diesel
56509001
Advance CS7000 B
56509002
Advance CS7000 Hybrid LPG EcoFlex™
56509006
Advance CS7000 Hybrid Diesel EcoFlex™
56509007
Advance CS7000 B EcoFlex™
56509008
Nilfisk-Advance CS7000 Hybrid LPG EU
56509003
Nilfisk-Advance CS7000 Hybrid Diesel EU
56509004
Nilfisk-Advance CS7000 Battery EU
56509005
Instructions for Use
Form Number
Parts List
Form
Number
56041979: English, Spanish,
French
56042540
56041980: English, Turkish,
Bulgarian, Romanian
56041981: Danish, Norwegian,
Swedish, Finnish
56041982: German, French,
Dutch, Russian
56041983:Spanish,
Portuguese,
Italian, Greek
56041984: Estonian, Latvian,
Lithuanian,
Slovenian
56041985: Slovakian, Czech,
Polish, Hungarian
These manuals can be found on the following Nilfisk-Advance’s electronic supported databases:
• Nilfisk-Advance Dealer Customer Zone
• Nilfisk-Advance website: www.Nilfisk-Advance-us.com
• EzParts service / parts CD-ROM
56042541
14
Service Manual – CS7000
General Information
Engine Manufacturers’ Technical Manuals
Engine Model
Publication Title
Diesel: D1305-E3B-KEA-1
Kubota WSM Workshop Manual, Diesel Engine,
05-E3B Series, 05-E3BG Series
LPG: WG972-GL-E3-NFK-1
Kubota WSM Workshop Manual, Gasoline, LPG
Engine, WG752-G-E3, WG752-GL-E3,
WG972-G-E3, WG972-GL-E3
Conventions
All references to right, left, front and rear in this manual are as seen from the Operator’s seat position.
Parts and Service
Repairs should be performed by an Authorized Nilfisk-Advance Service Center that employs factory-trained
service personnel and maintains an inventory of Nilfisk-Advance original replacement parts and accessories.
Call the Nilfisk-Advance Dealer named below for repair parts or service. Please specify the Model Number
(same as the Part Number) and Serial Number when discussing your machine.
(Dealer, affix service sticker here.)
*Note:On Fuel Cell models, all issues related to the fuel cell must be referred to Plug Power, not
Nilfisk-Advance.
Nameplate
The Part (Model) Number and Serial Number of your
machine are shown on the Nameplate located on the top of
the machine frame, at the left rear side of the machine
underneath the recovery tank. To access the Nameplate, tip
the recovery tank out away from the machine.
This information is needed when ordering repair parts for the
machine.
15
Service Manual – CS7000
General Information
Cautions and Warning Symbols
Nilfisk-Advance uses the symbols below to signal potentially dangerous conditions. Read this information
carefully and take the necessary steps to protect personnel and property.
Danger! Is used to warn of immediate hazards that will cause severe personal injury or death.
Warning! Is used to call attention to a situation that could cause severe personal injury.
Caution! Is used to call attention to a situation that could cause minor personal injury or
damage to the machine or other property.
General Safety Instructions
Warning! Be sure to follow these safety precautions to avoid situations that could cause
severe personal injury.
• This machine should only be used 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. Clean only while ascending (driving up) the ramp.
• Keep sparks, flame and smoking materials away from batteries. Explosive gases are vented
during normal operation.
• Charging the batteries produces highly-explosive hydrogen gas. Charge the batteries only in
well-ventilated areas away from open flame. Do not smoke while charging the batteries.
• Remove all jewelry when working near electrical components.
• Turn the Key Switch off (O) and disconnect the batteries before servicing electrical components.
• Never work underneath a machine without safety blocks or stands to support the machine.
• Do not dispense flammable cleaning agents, operate the machine on or near these agents, or
operate in areas where flammable liquids exist.
• To avoid hydraulic oil injection or injury, always wear appropriate clothing and eye protection
when working with or near any hydraulic system.
• Do not operate this machine on ramps or inclines of more than a two-percent gradient.
• Only use the brushes provided with the machine or those specified in the instruction manual.
The use of other brushes may impair safety.
Caution! Do not pressure-wash the operator control panel, fuse panel, contactor panel or
engine compartment area.
16
Service Manual – CS7000
General Information
Caution! Be sure to follow these safety precautions to avoid situations that could cause
personal injury, damage to property or equipment damage.
• This machine is not approved for use on public paths or roads.
• This machine is not suitable for picking up hazardous dust.
• Use care when using scarifier discs and grinding stones. Nilfisk-Advance will not be held
responsible for any damage to floor surfaces caused by scarifiers or grinding stones.
• When operating this machine, make sure that bystanders, 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 first turning the Key Switch off (O), removing the
key and securing the machine.
• Apply the parking brake before exiting the Operator’s seat.
• Turn the Key Switch off (O) and remove the key before changing the brushes, and before
opening any access panels.
• Take precautions to prevent hair, jewelry or loose clothing from becoming caught in moving
parts.
• Use caution when moving this machine in below-freezing temperature conditions. Any water in
the solution or recovery tanks, or in the hose lines could freeze, causing damage to valves and
fittings. Flush with windshield washer fluid.
• The batteries must be removed from the machine before the machine is scrapped. Disposal of
the batteries should be done safely and in accordance with your local environmental regulations.
• Do not use on surfaces having a gradient exceeding that marked on the machine.
• All doors and covers are to be positioned as indicated in the instruction manual before using the
machine.
• Refer to the Electrical System section in this manual for additional specific battery charger
warnings.
17
Service Manual – CS7000
General Information
Hopper Prop Rod
Warning! Never work underneath the raised hopper without the hopper prop rod engaged.
To Engage the Hopper Prop Rod
1. Press and hold the hopper raise button to raise the hopper all the way up.
2. Pull the Pull Rod to pivot the bottom of the Hopper
Prop Rod toward the Hopper Lift Cylinder until it
contacts the Hopper Lift Cylinder.
3. Press and hold the hopper lower button to lower the
hopper until the Hopper Prop Rod contacts the top of
the Hopper Lift Cylinder.
To Disengage the Hopper Prop Rod
Hopper
Prop
Rod
1. Press and hold the hopper raise button to raise the
hopper slightly so the Hopper Prop Rod lifts off of the
Hopper Lift Cylinder.
2. Push the Pull Rod to pivot the bottom of the Hopper
Prop Rod away from the Hopper Lift Cylinder.
Hopper
Lift
Cylinder
3. Press and hold the hopper lower button to lower the
hopper.
Pull
Rod
18
Service Manual – CS7000
General Information
Jacking the Machine
Warning! Never work under a machine without safety stands or blocks to support the machine.
When jacking the machine, do so at the designated Tie Down/Jacking Locations.
Transporting the Machine
Caution! Before transporting the machine on an open truck or trailer, make sure the machine
is tied down securely and all access doors and covers are secured (tape and strap as
needed).
The jacking and tie-down locations are identified with a graphic molded
into the exterior body panels.
The jacking and tie-down locations are in front of the front wheels, and at the rear of the machine below the
solution tank.
Jacking/
Tie-down
Location
Front Jacking/Tie-down Location
Rear Jacking/Tie-down Location
19
Service Manual – CS7000
General Information
Towing the Machine
Caution! If the machine must be towed, move the machine for short distances only and do not
move the machine faster than a normal walking pace (2-3 mph, 3-5 kph).
Tow the machine backward from one of the rear frame tie-down locations as shown
below. Do not push the machine due to the possibility of damage to the solution and
recovery tanks.
Do not tow the machine by the squeegee tool.
• To enter the “Push Mode”, which allows steering while towing
the machine, turn the Key Switch on while pressing and
holding both the Speed Switch and the High Pressure Wand
Switch.
Press and hold
while turning key
switch on to enter
Push Mode
• On machines not equipped with a squeegee
guard kit, tow the machine by one of the two
Tie-down Slots on the chassis (shown in green).
Tie-down
Slot (2)
• On machines equipped with a squeegee guard
kit, tow the machine by the two Tie-down Slots
on the squeegee guard (shown in red).
Tie-down
Slot (2)
20
Service Manual – CS7000
• On machines equipped with an “early” rear
corner roller kit but no squeegee guard kit,
it’s recommended that you remove the left
rear Corner Roller/Bumper Assembly in order
to access a tie-down location for the tow hook.
“Later” corner guard kits have been improved
to allow use of the left Tie-down Slot for
towing without removing the left corner roller/
bumper assembly.
General Information
Corner Roller/
Bumper
Assembly (2)
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 Nilfisk-Advance Industrial floor cleaning equipment.
• Laptop computer loaded with current version of EzParts, Adobe Reader and (preferably cellular) internet
access
• Digital volt ohmmeter (DVOM) with DC current clamp
• Hydrometer
• Battery load tester for checking 36V and 12V batteries.
• Automotive fuel pressure test gauge (used on diesel engines)
• Static control wrist strap
• Set of torque wrenches
• Hard (printed) copies of service manuals for regularly serviced machines (available at
www.advance-us.com and other Nilfisk-Advance websites).
These tools are also available from Nilfisk-Advance, Inc.:
• Vacuum water lift gauge, p/n 56205281
21
Service Manual – CS7000
General Information
Technical Specifications
General Specifications
Machine Dimensions
Length
103” [262 cm]
Width
With right side squeegee assembly pivoted under the machine – 48” [122 cm]
With squeegee – 53” [135 cm]
Height
Without
overhead guard
– 59” [150 cm]
With overhead
With overhead
With debris hopper raised – 90”
guard (US) – 82” guard (EU) – 79” [229 cm]
[208 cm]
[201 cm]
Minimum Aisle
Turnaround
Width
Right turn – 102” [259 cm]
Transport
Ground
Clearance
3” [7,6 cm] (side skirts on scrub deck)
Left turn – 104” [264 cm]
Machine Weight
Hybrid LPG
Dry Weight – 3,636 lbs
[1,649 kg]
GVW (full solution and dust control tanks) – 4,676 lbs. [2,121 kg]
Hybrid Diesel
Dry Weight – 3,511 lbs
[1,593 kg]
GVW (full solution and dust control tanks) – 4,537 lbs. [2,058 kg]
Battery
Machine
Dry Weight – 4,682 lbs
[2,124 kg]
GVW (full solution and dust control tanks) – 5,716 lbs. [2,593 kg]
Maximum Tire Loading - with full solution and dust control tanks
Hybrid LPG
146 psi [10,26 kg/cm2]
Hybrid Diesel
137 psi [9,63 kg/cm2]
Battery Machine
148 psi [10,41 kg/cm2]
Battery Configuration
Hybrid LPG and Diesel
(3) 12-volt battery pack, (1) separate 12-volt engine starting battery
Battery Machine
US Battery
(1) 36-volt battery, 770 amp-hours,
6 hour rate, 5.4 hour run time
EU Battery
(1) 36-volt battery, 800 amp-hours,
5 hour rate, 5.4 hour run time
22
Service Manual – CS7000
General Information
Solution System
Solution Tank Capacity
75 gal. [284 L]
Recovery Tank Capacity
75 gal. [284 L]
Solution Pump
Precision-flow electric pump/solenoid valve
Flow Rates
One Light
Two Lights
Three Lights
Four Lights
Five Lights
1 gpm [3,79
L/min]
1.5 gpm [5,68
L/min]
2 gpm [7,57
L/min]
2.5 gpm [9,46
L/min]
3 gpm [11,36 L/
min]
EcoFlex™ System
Refillable Cartridge Capacity
2.2 gal [8,32 L]
Available Dilution Rates
300:1, 256:1, 200:1, 150:1, 128:1, 100:1, 64:1, 50:1,
32:1, and 26:1
Low Detergent Warning
Standard
Scrub System
Scrub Brushes
Disc (3), 17” [43 cm] dia.
Scrub Path
48” [122 cm]
Brush Motors
[3] 36 VDC, 1 HP, 2750 RPM, 26 Amp
Dust Control/ DustGuard System
DustGuard Tank Capacity
29 gal. [110 L]
DustGuard Nozzle Flow Rate
Battery Machine
6.4 gph (size 100 nozzle)
LP and Diesel Machines
6.7 gph (size 100 nozzle)
Dust Control Motor
36 VDC, 7 Amps average, 8 Amps max.
Sweep System
Main Broom
12.2” [31 cm] diameter x 35.4” [90 cm] long
Sweep Path
61” [154 cm] With dual side brooms
Main Broom Motor
36 VDC, 1.14 HP, 3000 RPM, 20 Amps average
Side Broom
15” [38,1 cm] diameter
Side Broom Motor
42 VDC, 2800 RPM (no load), .25 HP
Hopper Weight Capacity
300 lbs [136 kg]
Hopper Volume Capacity
7.0 ft3 [198 L]
Vacuum System
Vacuum
Vacuum Motor
Sealed
48” H2O
With 1” dia. Orifice
25” to 30” H2O
42 VDC, 15 Amps average, 17 Amps max.
23
Service Manual – CS7000
General Information
Drive System
Steering
Rear wheel, “steer-by-wire” system. The steering controller receives input
from the steering wheel to drive the steering actuator motor. The steering
actuator motor drives a gear that meshes to a large ring gear that rotates
the drive wheel assembly.
Brakes (service and parking)
Mechanical drum brakes, one on each front wheel, mechanically actuated
Machine Performance
Machine Speeds
Transport speed – 5.5 mph [8.85 kph]
Scrubbing and sweeping speed – 3.5 mph [5.63 kph]
Gradeability (vehicle loaded to
gross vehicle weight)
Transport – 12 degrees/21% slope
Brake Holding
18 degrees/32.5% grade
Tilt Stability
Empty Tanks – 24.0 degrees/44.5% Full Tanks – 23.0 degrees/37.0%
grade
grade
Approach/Trail Angles
Approach Angle – 7.5 degrees/13%
grade)
Trail Angle – 20.9 degrees/38%
grade)
Maximum Machine Scrub Times
US Battery, 770 amp-hour, 6 hour
rate – 5.4 hours run time
EU Battery, 800 amp-hour, 5 hour
rate – 5.4 hours run time
Fuel Consumption
Hybrid LPG – 5.5 hours
Hybrid Diesel – 15 hours
(approximate)
Scrubbing/Sweeping – 10 degrees/ 17.6% slope
Noise and Vibration
Hybrid LPG
Operator Sound Levels @ 82 dBA
Operator’s Ear
Hybrid Diesel
Battery Machine
81 dBA
72 dBA
Sound Power
LwA 103
LwA 102
N/A
Hand/Arm Vibration
Levels
0.33 m/s2
0.35 m/s2
0.36 m/s2
Operator Seat Vibration
Levels
0.03 m/s2
0.03 m/s2
0.02 m/s2
24
Service Manual – CS7000
General Information
Fastener Torque Specifications
Standard Torque
Specifications (unless
otherwise specified)
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.
Overall Dimensions
4”
[10 cm]
61”
[155 cm]
48”
[122 cm]
25
Service Manual – CS7000
General Information
103”
[262 cm]
59”
150 cm]
Maintenance
Maintenance Schedule
Keep the machine in top condition by closely following the maintenance schedule. Maintenance intervals
given are for average operating conditions. Machines used in severe environments may require service more
often. In general:
• Keep the fuel tank filled (diesel). This helps to reduce condensation and moisture entering the fuel
system.
• Be aware of the yellow Attention Indicator light, the red Warning Indicator light and the LCD Display on
the Operator panel for icons and fault codes that indicate a critical or non-critical fault condition. Refer to
the LCD Display Icons section for a listing and explanation of the LCD display icons and fault codes.
• Refer to the engine service manual for recommended engine service intervals and procedures.
Recommended Service Materials
• Engine Oil (refer to your engine manual)
• Manufacturer-recommended coolant (antifreeze) 50/50 mix (LPG and diesel models only)
• Lithium-base grease
• Loctite® (or equivalent) thread sealant in the appropriate grades
• Never-Seez® (or equivalent) anti-seize compound
26
Service Manual – CS7000
General Information
Daily Maintenance
Caution! Do not pressure-wash the operator control panel, fuse panel, contactor panel or
engine compartment area.
Maintenance Item
Procedure
Perform “After Use” maintenance steps
“After use” maintenance is normally the responsibility of the
machine Operator. Refer to the Instructions for Use.
Check the engine oil level.
Check the engine coolant level in the reservoir.
Engine (LPG and diesel only)
Check for engine and coolant leaks.
Check the air cleaner service indicator and service the air filter
when the indictor is shown red.
Check that the drain hose cap is sealed.
Recovery tank
Drain and clean the inside of the tank; flush with clean water.
Clean the squeegee; check the blades for damage/wear and
deflection.
Scrub housing side skirts
Check for damage/wear.
Scrub brushes
Main and side brooms
Check for debris wrapped around the brushes/brooms and for
damage/wear.
Parking brake and foot pedal brake
Check for correct operation of brakes; adjust as needed.
Maintenance Every 15 to 20 Hours
Maintenance Item
Battery/Batteries
Procedure
Check the electrolyte level in the battery.
Check the battery cables and connections.
Solution tank filter
Inspect and clean the debris filter on the solution filter system.
EcoFlex™ detergent system
Purge the detergent delivery lines.
Rotate the main broom.
Sweep brooms
Inspect/adjust the main and side brooms.
Inspect the side broom housing skirts.
DustGuard™
Clean the DustGuard™ system spray nozzles.
Dust hopper
Clean the hopper filter; inspect the hopper seals.
27
Service Manual – CS7000
General Information
Monthly Maintenance
Maintenance Item
Procedure
Squeegee caster wheel axle and pivot
Pump a small amount of grease into each grease fitting on the
machine until grease seeps out around the bearings.
Steering gears
Apply grease to lubricate.
Squeegee tool end wheels
Engine/Battery compartment latch
Recovery tank latch
Apply light machine oil to lubricate.
Brake Pedal (parking brake) linkage
Maintenance Every 150 Hours
Maintenance Item
Procedure
Engine maintenance (LPG and diesel only)
Change the engine oil and oil filter. *Also review the engine
manufacturer’s additional maintenance requirements.
Radiator and oil cooler (LPG and diesel
only)
Inspect and clean the exterior core cooling fins.
LPG fuel system vaporizer/regulator –
LPG engines only
Inspect and drain any oil buildup from the LPG fuel vaporizer/
regulator.
Maintenance Every 400 Hours
Maintenance Item
Procedure
Air intake housing and hoses (LPG and
diesel only)
Inspect the complete air intake system for correct routing, kinks,
restrictions, sound tight connections, holes and cracks in hoses.
Battery/Batteries
Check electrolyte level; check terminals for corrosion, loose
connections.
Fuel Filter (diesel only)
Replace fuel filter cartridge (located before injector pump).
Maintenance Every 800 to 1000 Hours
Maintenance Item
Procedure
Engine maintenance (LPG only)
Change the spark plugs.
Radiator
Flush and refill radiator with 50/50 mix of water and antifreeze.
42-volt alternator drive belt
Replace the drive belt.
28
Service Manual – CS7000
General Information
Maintenance Every 1500 Hours
Maintenance Item
Procedure
Main broom motor carbon brushes
Check and replace as needed.
Side broom motor carbon brushes
Check and replace as needed.
Maintenance Every 1900 Hours
Maintenance Item
Procedure
Scrub brush motor carbon brushes
Check and replace as needed.
Maintenance Every 2000 Hours
Maintenance Item
Procedure
Engine maintenance (LPG and diesel only) * Review the engine manufacturer’s additional maintenance
requirements.
*Note:The engine maintenance schedule shown lists the recommended engine service intervals.
Refer to the Other Reference Manuals and Information Sources/Engine Manufacturers’
Technical Manuals section for list of available engine manufacturers’ service manuals. Refer
to these manuals for more complete maintenance and service information and instructions.
29
Service Manual – CS7000
General Information
Lubrication Points
Recovery
Tank Latch
(oil)
Engine/Battery
Compartment
Latch (oil)
Brake Pedal
(parking brake)
Linkage (oil)
Squeegee Tool
End Wheel (2)
(oil)
Squeegee
Caster Wheel
Axle and Pivot (2)
(grease)
Steering
Gears
(grease)
30
Service Manual – CS7000
General Information
EcoFlex System Maintenance
You will need to purge the system of the previous detergent when switching to a different detergent.
Service Note:Move the machine over a floor drain before purging because a small amount of
detergent will be dispensed in the process.
To Purge When Changing Detergents (the scrub system must be off)
1. Disconnect and remove the detergent bottles.
2. Turn the key switch on and wait a few seconds for the start-up sequence to finish.
3. Press and hold the detergent switch
for approximately two seconds.
4. Release the switch when the detergent purge icon appears on the display and the detergent indicator
starts flashing.
Note: Once activated, the purge process takes at least 10 seconds. Normally one purge cycle is
adequate to purge the system.
To Purge Weekly (the scrub system must be off)
1. Disconnect and remove the detergent bottles.
2. Install and connect bottles filled with clean hot water.
3. Turn the key switch on and wait a few seconds for the start-up sequence to finish.
4. Press and hold the detergent switch
for approximately two seconds.
5. Release the switch when the detergent purge icon appears on the display and the detergent indicator
starts flashing.
Note: Once activated, the purge process takes at least 10 seconds. Normally one purge cycle is
adequate to purge the system..
31
To Change the Detergent Mix Ratio (the scrub system must be on)
1. Press and hold the detergent switch
for two seconds.
2. Release the switch once the detergent indicator begins flashing.
3. While the light is flashing, press and release the detergent switch to select the next detergent
mixture ratio. Once the desired ratio is selected, the detergent system will return to normal operation
within three seconds.
Note: The detergent mixture will be displayed for approximately 10 seconds each time the scrub
mode changes, or each time the detergent switch is pressed. Once set, the detergent flow rate
automatically increases and decreases with the solution flow rate, but the detergent mix ratio
will remain the same. If an Operator would prefer the flexibility of setting different detergent
dilution ratios for different solution flow rates, this specific programming option can be
found in the Control System section.
Note: During scrubbing, the detergent system can be turned off at any time by pressing the
detergent switch to allow scrubbing with water only. No detergent is dispensed until the
scrub system is activated and the drive pedal is pushed forward.
Service Tip:Follow the To Purge Weekly instructions above if the machine is going to be stored for
an extended period of time, or if you plan to discontinue use of the detergent system.
Service Manual – CS7000
General Information
PM Checklist
Nilfisk-Advance CS7000
PM Checklist
Customer
A
B
C
D
L
M
W
Address
City
St
Model #
Serial #
Zip
Hours
Defect Codes
needs adjustment
binding
dirty or contaminated
damaged, bent or torn
leaks
missing
worn out
Does
Not
Work



Ref
Operational Inspection Items
OK
Defect Codes
(circle)































 
 
 

 
















 
   

 
 
 
 
   
 


 
 
   

















 







OK
Defect Codes
(circle)
Does
Not
Work

   


 


   




 
 
 






















Ref
Visual Inspection Items
Comments
 
 
 
 
 
 
Copyright 2011 Nilfisk-Advance








Page 1 of 2
5/12/2011
33
Service Manual – CS7000
Ref
General Information
Visual Inspection Items
 
 
 



































Comments
OK




















Does
Not
Work

























































  
 

   
   
 
   
 



















 
Defect Codes
(circle)























 
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 

Work Completed By:
Service Technician Signature
Copyright 2011 Nilfisk-Advance
Acknowledged By:
Date
Customer Signature
Page 2 of 2
Date
5/12/2011
34
Service Manual – CS7000
General Information
Machine Controls
Control Panel - General
Layout
Miscellaneous
Controls
The CS7000 control panel is
organized by machine function
with the scrub, sweep and
hopper functions conveniently
grouped together. Miscellaneous
controls such as the key switch,
emergency-stop switch, speed
control, light switch, highpressure wand switch, extended
scrub system switch and horn
button are located in front of the
Operator.
Scrubbing
Controls
Sweeping
Controls
Hopper
Controls
Note: The switches
with a “I” below them
are press-and-release
switches. The buttons
noted with an “T” below
them are momentary
buttons.
Miscellaneous Controls
Emergency
Stop
• Emergency Stop – maintained
palm switch; removes off all
power to the machine functions
when pressed. To reset the
Emergency Stop switch, rotate
the red knob clockwise.
Left Turn
Signal
Hazard
Flasher
Right Turn
Signal
LCD
Display
• Left and Right Turn Signal –
switch on the corresponding
turn signal.
• Hazard Flasher – (optional)
switches on the four-way
hazard flashers.
• Key Switch – main power/
ignition switch.
• LCD Display – displays the
various machine status icons
and informational displays.
• Speed Switch – functions as follows:
Key
Switch
Extended
Scrub
Switch
Speed
Switch
Headlight
Switch
High-pressure
Wand Switch
Horn
Button
–– LPG and diesel machines –
increments the engine speed
up and down through the three
speed ranges. Note that the
engine speed will increase automatically when certain machine functions are engaged.
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Service Manual – CS7000
General Information
–– Battery machines – increases the machine scrub speed to the full transport speed.
• Headlight Switch – switches on the headlights.
• Horn Button – sounds the horn when pressed.
• High-pressure Wand Switch – engages the high-pressure spray wand solution pump (LPG and diesel only).
• Extended Scrub Switch – enables the optional extended scrub (recycle) function.
Miscellaneous Indicators
• Attention Indicator – lights to
alert the Operator of a machine
condition requiring attention.
Attention
Indicator
Left Turn
Indicator
Right Turn
Indicator
Warning
Indicator
• Left and Right Turn Indicators –
indicates that the corresponding
turn signal is flashing.
• Warning Indicator – lights to
alert the Operator of a warning
or fault condition.
Extended
Scrub
Indicator
• Extended Scrub Indicator – lights
to indicate that the extended
scrub function is enabled.
• High-speed Indicator – lights
to indicate that the engine is
running at high speed.
• Headlight Indicator – lights to
indicate that the headlights are
on.
• High-pressured Wand Indicator –
lights to indicate that the wand
high-pressure pump is engaged.
High-speed
Indicator
Headlight
Indicator
High-pressure
Wand
Indicator
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Service Manual – CS7000
General Information
Scrub Controls
• Scrub Pressure Increase Button
– increases the scrub pressure
one level when pressed. Note
that the scrub pressure LED
indicators in the One Touch
Scrub Switch will light to
indicate the selected scrub
pressure.
• One Touch Scrub Switch –
enables the scrub, solution
and recovery systems, and
the EcoFlex™ system (if the
machine is so equipped). Note
that the scrub brush pressure
and solution flow will be at their
lowest levels. The scrub brushes
will run, the solution will flow
and the squeegee vacuum will
turn on when the machine
begins moving forward.
• Scrub Pressure Decrease Button
– decreases the scrub pressure
one level when pressed.
Scrub
Pressure
Increase
Button
Solution
Flow
Increase
Button
One-touch
Scrub
Switch
Solution
Switch
Scrub
Pressure
Decrease
Button
Solution
Flow
Decrease
Button
Vacuum/
Wand
Switch
Burst of
Power
Switch
(EcoFlex™
only)
Detergent
Switch
• Burst Of Power Switch –
increases both the scrub brush
pressure and solution flow one
step higher for 60 seconds.
• Solution Flow Increase Button – increases the solution flow rate one level when pressed. Note that the
solution flow LED indicators in the Solution Switch will light to indicate the selected solution flow
rate.
• Solution Switch – enables and disables the solution system.
• Solution Flow Decrease Button – decreases the solution flow rate one level when pressed.
• Vacuum/Wand Switch – enables and disables on the vacuum system.
• Detergent Switch – enables and disables the detergent system (on models so equipped).
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Service Manual – CS7000
General Information
Scrub Indicators
• Scrub Pressure Indicators –
indicate the scrub pressure
setting. One LED indicates
the lightest scrub pressure
and three LEDs indicates the
heaviest scrub pressure.
• Burst of Power Indicator – lights
during normal operation;
flashes to indicate a 60-second
burst of power.
• Solution Flow Indicators –
indicate the solution flow
setting. One LED indicates
the lowest solution flow and
five LEDs indicate the highest
solution flow.
• Vacuum/Wand Indicator –
indicates that the vacuum
system is enabled.
Solution
Flow
Indicators
Scrub
Pressure
Indicators
Vacuum/
Wand
Indicator
Burst of
Power
Indicator
(EcoFlex™
only)
Detergent
Indicator
• Detergent Indicator – indicates
that the detergent system is
enabled.
Sweep Controls
Broom
Height
Raise
Button
• Broom Height Raise/Lower
Buttons – raise and lower the
selected broom from its current
position.
• Side Broom Switch – enables and
disables the side brooms. Note
that if you switch off the side
brooms, the DustGuard™ spray
nozzles will also switch off.
• One-touch Sweep Switch –
enables the main broom, side
brooms, dust control fan and
DustGuard™ spray nozzles.
• Main Broom Float Switch –
directs the main machine
controller to drive the main
broom actuator all the way
down so the weight of the main
broom is resting on the floor.
The linkage is slotted to allow
the broom to follow the contour
of the floor.
One-touch
Sweep
Switch
Main
Broom
Float
Switch
Dust
Control
Fan
Switch
Side
Broom
Switch
Broom
Select
Switch
Broom
Height
Lower
Button
DustGuard™
Spray
Switch
Filter
Shaker
Switch
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Service Manual – CS7000
General Information
• Dust Control Fan Switch – enables and disables the dust control fan.
• Broom Select Switch – functions as follows:
–– When the one-touch sweep is enabled, the Broom Select Switch selects the broom (main broom or side
brooms) that will be raised or lowered when the Broom Height Raise Button and Broom Height Lower
Button are pressed.
–– When the one-touch sweep is not enabled, pressing the Broom Select Switch once will lower the side
brooms, switch on the side broom motors for a short time, then raise the side brooms. Pressing the
Broom Select Switch twice will lower the main broom, switch on the main broom motor for a short time,
then raise the main broom.
• DustGuard™ Spray Switch – enables and disables the DustGuard™ spray nozzles.
• Filter Shaker Switch – switches on the filter shaker. The shaker will cycle 16 times, then switch off.
Sweep Indicators
Main Broom
On Indicator
• Main Broom On Indicator –
indicates that the main broom
is enabled.
• Side Broom On Indicator –
indicates that the side brooms
are enabled.
• Main Broom Float Indicator –
indicates that the main broom
is set to the “float” mode.
• Dust Control Fan On Indicator –
indicates that the dust control
fan is enabled.
• DustGuard™ On Indicator –
indicates that the DustGuard™
system is enabled.
• Filter Shaker On Indicator –
indicates that the filter shaker
motor is running.
Side Broom
On Indicator
Main
Broom
Float
Indicator
DustGuard™
On
Indicator
Dust
Control
Fan On
Indicator
Filter
Shaker
On
Indicator
39
Service Manual – CS7000
General Information
Hopper Controls
• Hopper Raise Button – raises the
hopper.
• Hopper Lower Button – lowers
the hopper.
• Hopper Door Open Button – opens
the hopper door.
• Hopper Door Close Button –
closes the hopper door.
Hopper
Door
Open
Button
Hopper
Raise
Button
Hopper
Door
Close
Button
Hopper
Lower
Button
LCD Displays
General Displays
Battery Machine
The general LCD display on the battery machine shows
the solution level in the solution tank, the total sweep/
scrub time on the hour meter, and the state of battery
charge. If the machine is equipped with an EcoFlex™
system, the display will also show the detergent system
icon and current dilution ratio.
Dilution
Ratio
Solution
Level
Sweep/
Scrub Time
Battery
Charge
Level
LPG Machine
The general LCD display on the LPG machine shows
the solution level in the solution tank, the total engine
run time and the recycle system icon (if actuated). If
the machine is equipped with an EcoFlex™ system, the
display will also show the detergent system icon and
current dilution ratio.
Dilution
Ratio
Note: No battery charge or fuel level will be
displayed while the engine is running.
Recycle
System
Solution
Level
Engine
Run Time
40
Service Manual – CS7000
General Information
Diesel Machine
The general LCD display on the diesel machine shows the
solution level in the solution tank, the total engine run
time, the recycle system icon (if actuated) and the fuel
tank level. If the machine is equipped with an EcoFlex™
system, the display will also show the detergent system
icon and current dilution ratio.
Dilution
Ratio
Solution
Level
Engine
Run Time
Note: The fuel level will be displayed while the
engine is running.
Recycle
System
Fuel
Level
Broom Adjustment (Battery, LPG and Diesel)
The broom adjustment LCD display shows the main
broom position, the broom(s) selected for adjustment,
the broom movement, the total run time and the battery
charge/fuel level.
Broom(s) Broom
Selected Direction
Main Broom
Position
Run
Time
Battery
Charge/
Fuel Level
Battery Charge Indicator
The battery charge indicator shows the charge state of
battery and will retain the charge state when the key is
turned off. Five vertical bars indicates a fully-charged
battery after a complete charging cycle. No bars indicates
a discharged battery. Note that no bars will be shown if
the machine is in the low-voltage cutout mode.
Zero Bars:
Discharged
Five Bars:
Charged
You can choose between two different low-voltage cutout
thresholds depending on whether maintenance-free or
standard batteries are being used.
Note: The following percentages are based on useable battery capacity not total battery capacity.
Therefore, 100% discharge = 80% of total battery capacity for standard wet cell batteries, or
70% of total battery capacity for maintenance-free batteries.
41
Service Manual – CS7000
General Information
Battery Charge Indicator
Standard Battery
Alternate/Maintenance-free
Battery
Reset to 5 bars
Low Voltage Cutout Reset
Low Voltage Cutout Reset
5 bars
Never below 35.9 V
Never below 35.9 V
4 bars
Never below 35.4 V
Never below 35.4 V
3 bars
Never below 34.4 V
Never below 34.4 V
2 bars
Never below 33.9 V
Never below 33.9 V
1 bar
Never below 32.2 V
Never below 33.3 V
0 bars
Never below 30.9 V
Never below 32.8 V
Not displayed
Low Voltage Cutout active
Low Voltage Cutout active
Fault, Caution and Warning Displays
Fault Displays
The system can detect overloads and short circuits on
various hardware circuits, and detect system faults. There
is no hardware detection of open circuits.
Non-critical
Fault Number
These non-critical faults detected by the main machine
controller will be displayed on the display panel in the
hour meter section. If more than one fault exists, the
display will sequence through the fault codes at onesecond intervals. Faults are display as a mechanical
wrench icon followed by a two-digit code. Caution and
warning displays take priority over non-critical fault
displays.
Refer to the Electrical System section for a list of the noncritical fault codes.
Caution Displays
Any cautions detected by the main machine controller
will be shown on the left side of the display. Only the fuel/
battery level and hour meter indicators will remain.
Cautions icons are displayed as a non-inverse graphic.
If more than one caution and/or warning exists, the
display will sequence through the active warnings and
cautions at one-second intervals.
Refer to the table below for a list of the displayed
cautions.
Caution
Icon
42
Service Manual – CS7000
General Information
Caution
Condition causing Fault
Low-voltage Cutout
The batteries need to be charged.
Hopper Temperature
Hopper temperature has
exceeded the operational
temperature.
Solution Level Low
(Icon number 246)
Solution level has been low longer
than 10 seconds
Display Icon
Warning Displays
Any warnings detected by the main machine controller
will be shown on the left side of the display. Only the
fuel/battery level and hour meter indicators will remain.
Warnings are displayed as inverse graphics. If more
than one warning and/or caution exists, the display will
sequence through the active warnings and cautions at
one-second intervals.
Refer to the table below for a list of the displayed
warnings.
Description
Critical fault warning
Low battery warning
Low fuel warning
Parking brake warning
Recovery tank full warning
Engine temp hot
Engine fault
Engine Oil Pressure
Display Icon
Warning
Icon
43
Service Manual – CS7000
General Information
Steering Wheel
The steering system in the CS7000
is a “steer by wire” system that
uses an encoder and brushless
AC three-phase motor to transfer
steering wheel input to the drive
wheel.
Note that when the machine key
switch is off, the Steering Wheel
will “freewheel” with no turning
resistance. Once the machine is
powered-up, normal steering feel
is restored.
Steering
Wheel
Circuit
Breakers
Tilt
Lever
The standard Tilt Lever allows the
Steering Wheel to be tilted up and
down to suit the Operator.
The Circuit Breakers are mounted
on the panel adjacent to the
Operator position.
Foot Pedals
The Brake Pedal/Parking Brake
brakes the machine, and locks in
the applied position when used as
a parking brake.
The Drive Pedal moves the
machine forward and backward.
Machine direction and speed are
proportional to the Drive Pedal
position.
Brake Pedal/
Parking Brake
Drive
Pedal
44
Service Manual – CS7000
45
Chassis System
Component Locations - Battery Machine (major components)
Battery
Stop Plate
Assembly
Rear Battery
Cover
Assembly
Battery
Guide
Weldment
Front Engine
Cover
Assembly
Battery
Stop
Weldment
Right Door
Assembly
Pull Rod
Assembly
Dust
Shield
Left Cover
Assembly
Front
Battery
Guide
Chassis
Weldment
Service Manual – CS7000
Chassis System
Component Locations - LPG and Diesel Machine (major components)
Engine
Cover
Assembly
Front Engine
Cover
Assembly
Right Door
Assembly
Pull Rod
Assembly
Dust
Shield
Left Cover
Assembly
Chassis
Weldment
46
Service Manual – CS7000
Control System
Functional Description
The CS7000 has several “controllers” which operate various parts of the machine and which communicate
with one another via a CAN bus. The CAN bus is like a “phone line” between all of the controllers that allow
them to communicate with one another.
The main machine controller is responsible for operating all of the “cleaning functions” of the machine. All of
the operator requests from the control panel are communicated to the main machine controller via the CAN
bus. This greatly reduces the number of wires needed between the control panel and the main machine
controller. The main machine controller tells the control panel what indicator lights to turn on and what to
display in the LCD screen. The main machine controller monitors many circuits for overloads (shorts) and
can set many diagnostic trouble codes that simplify troubleshooting.
Main Machine Controller
The steering controller operates the steering system – See the Steering System chapter for more
information.
The drive controller operates the wheel traction drive motor. – See the Wheel System, Traction chapter for
more information.
47
Service Manual – CS7000
Control System
CAN Bus Circuit
The main machine controller and the control panel are the two major players on the CAN Bus. The main
machine controller provides a “bias voltage” on the CAN bus wires that the messages ride on. It also has a
termination resistor inside it that connects the CAN Hi and CAN Lo circuits together. The control panel also
has a termination resistor. These termination resistors are important for normal circuit operation. If one of
them fails, communication will stop. The steering controller and the drive controller are both tied into the
CAN Bus circuits but do not contain termination resistors.
Main Machine Controller
Bias volts
CAN Hi
Termination
Resistor
120 ohms
Can Lo
Steering Controller
Drive Controller
Termination
Resistor
120 ohms
Control Panel
48
Service Manual – CS7000
Control System
CAN BUS message routing
The following outline describes what messages are communicated over the CAN Bus from one controller to
another.
Control Panel
• Messages Sent
–– To Main Machine Controller
◦◦ Operator switch inputs
–– To Drive Controller
◦◦ None
–– To Steering Controller
◦◦ None
• Messages Received
–– From Main Machine Controller
◦◦ LED display instructions
◦◦ LCD display instructions
◦◦ Fault History for main controller, steering controller and drive controller
–– From Drive Controller
◦◦ None
–– From Steering Controller
◦◦ None
Main Machine Controller
• Messages Sent
–– To Control Panel
◦◦ LED display instructions
◦◦ LCD display instructions
◦◦ Fault History for main controller, steering controller and drive controller
–– To Drive Controller
◦◦ Push Mode On/Off
◦◦ Transport Mode On/Off
◦◦ Sweep System On/Off
◦◦ Scrub System On/Off
49
Service Manual – CS7000
◦◦ Machine (Power Plant) Type - Battery/Engine (Hybrid)
◦◦ Hopper Up/Down
–– To Steering Controller
◦◦ None
• Messages Received
–– From Control Panel
◦◦ Operator switch inputs
–– From Drive Controller
◦◦ Drive System Fault Codes
◦◦ Machine motion signal (Forward, Neutral, or Reverse)
–– From Steering Controller
◦◦ Steering System Fault Codes
Drive Controller
• Messages Sent
–– To Main Machine Controller
◦◦ Drive System Fault Codes
◦◦ Machine motion signal (Forward, Neutral or Reverse)
◦◦ Reverse signal
–– To Steering Controller
◦◦ None
–– To Control Panel
◦◦ None
• Messages Received
–– From Main Machine Controller
◦◦ Push Mode On/Off
◦◦ Transport Mode On/Off
◦◦ Sweep System On/Off
◦◦ Scrub System On/Off
◦◦ Power Plant Type - Battery/Engine (Hybrid)
◦◦ Hopper Up/Down
–– From Steering Controller
◦◦ None
Control System
50
Service Manual – CS7000
–– From Control Panel
◦◦ None
Steering Controller
• Messages Sent
–– To Main Machine Controller
◦◦ Steering System Faults
–– To Drive Controller
◦◦ None
–– To Control Panel
◦◦ None
• Messages Received
–– From Main Machine Controller
◦◦ None
–– From Drive Controller
◦◦ None
–– From Control Panel
◦◦ None
Control System
51
Service Manual – CS7000
Control System
Component Locations
• Main Machine Controller
• Control Panel
• Drive Controller
• Steering Controller
Main Machine
Controller
Steering
Controller
Drive
Controller
Control
Panel
Caution! Do not pressure wash the control panel, main machine controller, steering controller,
drive controller or any other electrical components.
52
Service Manual – CS7000
Control System
Troubleshooting
There are two important things you need to know about electrical diagnosis on the CS7000 machine. First,
it is capable of setting fault codes that can help narrow down the possible causes. Second, there is a special
“Service Mode” built into the machine that will help you diagnose electrical problems quickly. See the “Fault
Codes” and “Service Mode” sections below for more information.
Fault Codes
The main machine controller monitors every circuit it controls for overloads (excessive current draw). If it
sees an overload it will set and display a fault code and shut the circuit down. For instance, if the side broom
contactor coil becomes shorted and draws too much current, it will set and display a code 19 and shut down
the side broom contactor control circuit. This means the side broom motors will not work and there will be
a code 19 displayed. You should check the fault code table below to find out what “19” means. When you
see that it means “Side Broom Contactor (K8) Winding Circuit Overload “ that will help you narrow down the
possible causes that you need to diagnose. Once the problem is corrected the fault code will no longer be
displayed. However, it will remain in the fault code history.
Not all electrical problems will be accompanied by a fault code. The main machine controller does not set
faults for open circuits or “not enough current draw”. For instance, if the side broom motor contactor coil
becomes open and draws no current, there will NOT be a code set for this condition. The side brooms will
not work because of the open contactor coil but there will be no fault code. The main machine controller does
not monitor every electrical circuit. For instance, it monitors the control side of the side broom contactor
coil because it completes the circuit for the winding. It does not monitor the “contact” or “load” side of the
contactor.
Any fault codes detected by the main machine controller will be displayed on the LCD display as they occur.
Critical faults are displayed like this code 50:
If more than one critical fault exists, the display will sequence through the active warnings and cautions at
one-second intervals.
Non-critical faults are displayed like this code 19:
If more than one non-critical fault exists, the display will sequence through the fault codes and the hour
meter at one-second intervals.
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Service Manual – CS7000
Control System
Fault Code Table (Main machine controller)
Fault # Description
Setting Conditions
Consequences
None
Power Distribution Fault
If the voltage of the 36v battery
pack falls too low, the LCD will
display this message. You need
to charge the 36v battery pack.
00
Auxiliary Contactor (K9) Winding
Circuit Overload
Short circuit or > 4 Amps
01
12 Volt Alternator is not charging
Battery voltage is less than 10
volts with the engine running
02
Not used
03
Not used
04
Excessive Engine Temperature
Engine Temperature switch
closed with the engine running.
Shut down engine
05
Low Engine Oil Pressure
Loss of engine run signal (Oil
pressure switch open) with the
key switch still on.
Shut down engine
06
Glow Plug Relay Overload
07
42 Volt Alternator is not charging
< 37 volts for > 30 Seconds.
08
Throttle 1 circuit overload
Current Overload
09
Throttle 2 circuit overload
Current Overload
10
Start Command circuit overload
> 18 Amps
11
Ignition On circuit overload
> 18 Amps
12
VACC1 circuit breaker tripped
Aux Contactor energized with
no voltage at J2-13 VACC1
13
VACC2 circuit breaker tripped
Aux Contactor energized with
no voltage at J3-26 VACC2
14
VACC3 circuit breaker tripped
Aux Contactor energized with
no voltage at J3-34 VACC3a
and J3-35 VACC3b
15
VACC6 circuit breaker tripped
Key on with no voltage at J2-34
VACC6a and J2-35 VACC6b
16
Scrub Deck Actuator (M11)
Overload
> 7 Amps for 4 seconds or short Disables detergent,
circuit
solution and scrub motors.
17
Main Broom Actuator (M21)
Overload
> 6 Amps for 4 seconds or
short circuit
18
Side Broom Actuator (M13)
Overload
> 7 Amps for 4 seconds or short Disables side brooms.
circuit
19
Side Broom Contactor (K8)
Winding Circuit Overload
> 4 Amps or short circuit
Disables side brooms.
20
Dust Control Contactor (K6)
Winding Circuit Overload
> 4 Amps or short circuit
Disables dust control.
21
Left Brush Contactor (K1)
Winding Circuit Overload
> 4 Amps or short circuit
Disables detergent,
solution and scrub motors.
22
Center Brush Contactor (K2)
Winding Circuit Overload
> 4 Amps or short circuit
Disables detergent,
solution and scrub motors.
Disables sweep functions.
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Service Manual – CS7000
Control System
Fault # Description
Setting Conditions
Consequences
23
Right Brush Contactor (K3)
Winding Circuit Overload
> 4 Amps or short circuit
Disables detergent,
solution and scrub motors.
24
Broom Contactor (K4) Winding
Circuit Overload
> 4 Amps or short circuit
Disables sweep functions.
25
Hydraulic Pump1 Contactor (K4)
Winding Circuit Overload
> 4 Amps or short circuit
26
Hydraulic Pump2 Contactor (K4)
Winding Circuit Overload
> 4 Amps or short circuit
27
Dust Filter Plugged
Closed switch
Warning message only
28
Dump Door Actuator (M26)
Overload
> 7 Amps for 4 seconds
Disables sweep functions
and hopper door.
29
Hopper Over Temperature
Closed hopper temperature
switch
Turns off the Dust Control
motor, the Main Broom
system, the Side Broom
system, and closes the
hopper dump door.
30
Shaker Motor (M14) Overload
> 20 Amps or short circuit
31
Solution Pump (M19) or
Extended Scrub Pump (M25)
Overload
> 24 amps or short circuit
32
High Pressure Washer Pump
Electromagnetic Clutch Overload
> 18 Amps or short circuit
33
Low Pressure Wash Pump (M23)
Overload
> 20 Amps or short circuit
34
Dust Guard Pump (M22)
Overload
> 20 Amps or short circuit
35
Solution Solenoid Valve (L1)
Winding Overload
> 4 Amps or short circuit
Disables detergent,
solution and scrub motors.
36
Chemical (Detergent) pump M17
overload
> 2.5 Amps or short circuit
Disables detergent.
37
Chemical (Detergent) pump M18
overload
> 2.5 Amps or short circuit
Disables detergent.
38
Vacuum Contactor (K5) Winding
Circuit Overload
> 4 Amps or short circuit
Disables detergent,
solution, scrub motors and
recovery.
39
Squeegee Actuator (M12)
Overload
> 5 Amps for 4 seconds or short Disables detergent,
circuit
solution, scrub motors and
recovery.
40
Right Front Turn Signal (LT4)
Overload
> 3 Amps or short circuit
41
Left Front Turn Signal (LT7)
Overload
> 3 Amps or short circuit
42
Right Rear Stop Turn Signal
(LT11) Overload
> 6 Amps or short circuit
43
Left Rear Stop Turn Signal (LT9)
Overload
> 6 Amps or short circuit
44
Head Lamp Circuit (LT2, LT3,
LT8) Overload
Short circuit
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Control System
Fault # Description
Setting Conditions
Consequences
45
Tail Lamp Circuit (LT5, LT6)
Overload
> 3 Amps or short circuit
46
Back-up Alarm (H1) Overload
> 4 Amps or short circuit
47
Horn (H2) Overload
Short circuit
48
Not used
49
Low Voltage Cutout
< 30.8 V for Wet Acid Battery
< 32.5 V for Gel Battery
Warning message and
disable all sweep and
scrub functions except
recovery system
50
A Fault Has Been Set In The
Steering Controller (A5)
Steering controller has
communicated an emergency
error message to the main
machine controller (Retrieve
the specific steering system
code by using the hidden menu
“configuration display” fault
recall.)
Disables all sweep and
scrub functions
51
A Fault Has Been Set In The
Drive Controller (A2)
Drive controller has
communicated a fault to
the main machine controller
(Retrieve the specific drive
system code by using the
hidden menu “configuration
display” fault recall.)
Disables all sweep and
scrub functions
52
Vacuum Motor Circuit (M6, M7)
Overload
> 40 Amps for 20 seconds or
short circuit
Disables detergent,
solution, scrub motors and
recovery.
53
Scrub Brush Motor Circuit (M2,
M3, M4) Overload
> 75 Amps for 25 seconds or
short circuit
Disables detergent,
solution and scrub motors.
54
Main Broom Motor (M1) Overload > 28 Amps for 30 seconds or
short circuit
Disables sweep functions.
Note: If this code is set after
installing a new broom, adjust the
broom height.
55
Broom Motor Current Sensor
fault
Main broom motor contactor
Disables sweep functions
has been off more than 5
seconds but the broom motor
current sensor is reporting > 6 A
(2.6V).(Make sure the sensor is
reading the correct wire(s))
56
Brush Motors Current Sensor
fault
Brush motor contactors have
been off more than 5 seconds
but the brush motor current
sensor is reporting > 6 A (2.6V)
(Make sure the sensor is
reading the correct wire(s)).
Disables scrub functions
57
Vacuum Motor Current Sensor
fault
Vacuum motor contactors have
been off more than 5 seconds
but the brush motor current
sensor is reporting > 6 A (2.6V).
(Make sure the sensor is
reading the correct wire(s))
Disables scrub and
recovery functions
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Control System
Hidden Menus
The main machine controller supports a “hidden menu” which allows you to match the controller to the
machine, set some user options and perform time saving service tests. There are three main hidden menus
modes; Configuration Display, Configuration Menu and User Options Menu. A unique switch sequence is
used to enter each mode.
Configuration Display
The configuration display mode is a “read only” mode that allows you to check how the main machine
controller thinks the machine is equipped without running the risk of accidentally changing a value. It also
allows you to check historical faults for the main machine controller, steering controller and drive controller.
To enter the Configuration Display:
1. While Pressing and holding the hazard flasher switch, turn the key on.
2. Continue to hold the switch until the LCD reads “Configuration Display”, and then release the switch.
Once in the configuration display, you can scroll the “arrow cursor” through the menu using the scrub
pressure increase and decrease buttons. To enter a menu selection, press the One-touch scrub switch. To exit
and return to the configuration display mode, press the solution switch. To exit the hidden menu, turn the
key switch off.
Scroll Up
Enter
Exit
Scroll Down
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The Following is an outline of the menu:
• 1 Machine Type
• 2 Battery Type
• 3 Detergent System
• 4 EcoFlex System
• 5 Dust Guard system
• 6 Ex Scrub System
• 7 Back-Up Alarm
• 8 Signal Lights
• 9 Plugged Filter Kit
• 10 Hopper Temp Kit
• 11 Low Press Wash
• 12 High Press Wash
• 13 Scrub Motor Type
• 14 Display Screen
• 15 Light Option
• 16 Fault Recall
• 17 Haram Captor (Used to configure the machine for a special market)
Control System
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Configuration Menu
The configuration menu is a “read and write” mode that allows you to check and change the machine
configuration values in order to tell the main machine controller how the machine is equipped. This
“matches” the controller to the machine and must be done anytime a new main machine controller is
installed.
Note The configuration menu also contains time saving service tests in the Service Menu. See the
separate “Service Mode” section below for more details.
To enter the Configuration Menu:
1. While pressing and holding both of the turn signal switches, turn the key on.
2. Continue to hold the switches until the LCD reads “Configuration Menu”, and then release the switches.
Once in the configuration menu, you can scroll the “arrow cursor” through the menu using the scrub
pressure increase and decrease buttons. To enter a menu selection, press the One-touch scrub switch. The
arrow cursor points to the currently selected value. Scroll the cursor to the desired value and press the Onetouch scrub switch to save the new value and return to the configuration menu. If you want to return to the
configuration menu without saving a new value, press the solution switch. To exit the hidden menu, turn the
key switch off .
The following is an outline of the menu. Default values are bold text.
• 1 Machine Type
–– 1 Undefined (When the machine type is “undefined” the control panel will display the configuration
menu whenever the key is turned on.)
–– 2 Battery
–– 3 Diesel
–– 4 Propane
–– 5 Gas (Petrol)
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Service Manual – CS7000
• 2 Battery Type
–– 1. Undefined (When the machine type is
“undefined” the control panel will display
the configuration menu whenever the key is
turned on.)
–– 1 Wet (Lead Acid)
–– 2 Sealed (gel)
• 3 Detergent System
–– 1 Installed?
◦◦ 1 Not Installed
◦◦ 2 Installed
–– Display Format
◦◦ 1 Ratio
◦◦ 2 Percentage
• 4 EcoFlex System
–– 1 Not Installed
–– 2 Installed
• 5 Dust Guard system
–– 1 Not Installed
–– 2 Installed
• 6 Ex Scrub System
–– 1 Not Installed
–– 2 Installed
• 7 Back-Up Alarm
–– 1 Not Installed
–– 2 Installed
• 8 Signal Lights
–– 1 Not Installed
–– 2 Installed
• 9 Plugged Filter Kit
–– 1 Not Installed
–– 2 Installed
• 10 Hopper Temp Kit
–– 1 Not Installed
Control System
–– 2 Installed
• 11 Low Press Wash
–– 1 Not Installed
–– 2 Installed
• 12 High Press Wash
–– 1 Not Installed
–– 2 Installed
• 13 Scrub Motor Type
–– 1 Option 1 (Select Option 1)
–– 2 Option 2 (Do not select Option 2)
• 14 Display Screen
–– 1 US Display
–– 2 Global Display
• 15 Light Option (Head Lights)
–– 1 Standard Light
–– 2 LED Light
Caution! Selecting “LED Light” on
a machine with standard
incandescent head lights can
cause the bulbs to blow out
and shatter.
• 16 Service Menu
–– 1 Service Mode (Must turn key off to exit
service mode)
◦◦ Example:
−− Batt 36.839V
−− Pedal 2.58V
–– 2 Battery Level
◦◦ E.G.
−− 2 Sealed (gel)
−− 37.710 V
−− Level 5
–– 3 Solution Reading
◦◦ E.G.
Neutral
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Control System
−− Reading 0x67
−− Level 3
–– 4 Fault Detection
◦◦ 1 Enabled
◦◦ 2 Disabled
–– 5 About
◦◦ Example:
−− CS7000
−− 56510353_Rev_F
–– 6 Shaker Continuous
◦◦ 1 No
◦◦ 2 Yes
–– 7 Actuator Sequence (For engineering use)
• 17 Restore Defaults (Resets all Configuration Menu selections and User Options selections to default
values)
–– Are you sure? (One-touch scrub switch = “Yes”. Solution switch= “No”.
• 18 Haram Captor
–– 1 No (Use for all CS7000 models)
–– 2 Yes (Use for special market Haram Captor model to customize solution level processing and scrub
pressures)
User Options Menu
The user options menu allows you to customize certain machine functions according to machine operator
preferences.
To enter the User Options Menu:
1. While pressing and holding the One-touch scrub switch AND the solution switch, turn the key on.
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2. Continue to hold the switches until the LCD reads “User Options Menu”, and then release the switches.
Once in the user options menu, you can scroll through the menu using the scrub pressure increase and
decrease buttons. To enter a menu selection, press the One-touch scrub switch. To exit and return to the
User options menu mode, press the solution switch. To make a selection and return, press the One-touch
scrub switch. To exit the hidden menu, turn the key switch off.
Scroll Up
Enter
Exit
Scroll Down
The following is an outline of the User Options Menu Default values are bold text or noted.
• 1 Scrub System
–– 1 Scrub Mode 1st Use - The default scrub mode used the first time after power up. After first time,
mode is last used.
◦◦ 1 Light - The scrub mode will default to the Light setting when activated. (DEFAULT)
◦◦ 2 Heavy - The scrub mode will default to the Heavy setting when activated.
◦◦ 3 Extreme - The scrub mode will default to the Extreme setting when activated.
–– 2 Detergent Start Up - Determines if the detergent system will be activated when the scrub is turned
on.
◦◦ 1 Off - always disabled when the scrub system is activated.
◦◦ 2 On - always enabled when the scrub system is activated.
◦◦ 3 Last State - returned to state when the scrub system was last on.
–– 3 Maximum Mode - The maximum scrub mode that the operator can select.
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◦◦ 1 Light - The only available scrub mode will be the Light setting.
◦◦ 2 Heavy - The Light and Heavy scrub mode will be available.
◦◦ 3 Extreme - All scrub modes will be available.
–– 4 Light Scrub Mode - The light scrub pressure, solution rate and detergent rate can be programmed
depending on its application where high solution rate is needed with light scrub pressure or low
solution rate with heavy scrub pressure.
◦◦ 1 Scrub Pressure −− RANGE: 1-MIN, 2-MED, 3-MAX
−− DEFAULT: 1-MIN
◦◦ 2 Solution Flow
−− RANGE: Off,1 – 5
−− DEFAULT: 1
–– 5 Heavy Scrub Mode - The heavy scrub pressure, solution rate and detergent rate can be programmed
depending on its application where a higher solution rate is need with heavy scrub pressure or low
solution rate with heavy scrub pressure.
◦◦ 1 Scrub Pressure
−− RANGE: 1-MIN, 2-MED, 3-MAX
−− DEFAULT: 2-MED
◦◦ 2 Solution Flow
−− RANGE: 1 – 5
−− DEFAULT: 2
–– 6 Extreme Scrub Mode - The extreme scrub pressure, solution rate and detergent rate can be
programmed depending on its application where a higher solution rate is need with extreme scrub
pressure or low solution rate with extreme scrub pressure.
◦◦ 1 Scrub Pressure
−− RANGE: 1-MIN, 2-MED, 3-MAX
−− DEFAULT: 3 - MAX
◦◦ 2 Solution Flow
−− RANGE: 1 – 5
−− DEFAULT: 3
–– 7 Neutral Off Delay - This determines how long before the brushes are stopped after returning to
neutral
◦◦ RANGE: 0.5 – 5 seconds
◦◦ INCREMENT: 0.5 seconds
◦◦ DEFAULT: 0.5 seconds
–– 8 Scrub Down Time - When activated the scrub is lowered for a period of time before the control starts
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moving the deck based on the current of the brush motors.
◦◦ RANGE: 1 – 3 seconds
◦◦ INCREMENT: 0.1 seconds
◦◦ DEFAULT: 2 seconds
–– 9 Solution In Reverse - Determines whether solution will flow when the machine backs up.
◦◦ 1 Off (This is default)
◦◦ 2 On
• 2 Sweep System
–– 1 Sweep Off Timeout - This determines how long before the dust control and brooms are stopped after
returning to neutral
◦◦ RANGE: 0.5 – 5 seconds
◦◦ INCREMENT: 0.5 seconds
◦◦ DEFAULT: 0.5 seconds
–– 2 Shaker Duration - Determines how long the shaker will run once it is activated.
◦◦ RANGE: 10 – 40 seconds
◦◦ INCREMENT: 1 second
◦◦ DEFAULT: 15 seconds
• 3 Recovery System –– 1 Sqg Down Time - Sets the time to extend the squeegee when lowering it into the active position.
◦◦ RANGE: 1 – 4 seconds
◦◦ INCREMENT: 0.25 seconds
◦◦ DEFAULT: 4 seconds
–– 2 Sqg Up Time - (Lift in Reverse) Sets the time to retract the squeegee. When backing up with the
recovery system active, the control unit will automatically raise the squeegee to prevent dragging on
the floor.
◦◦ RANGE: 1 – 4 seconds
◦◦ INCREMENT: 0.25 seconds
◦◦ DEFAULT: 2 seconds
–– 3 Vacuum Off Delay - Sets the timeout for the vacuum during the recovery power down sequence.
◦◦ RANGE: 12 - 20 seconds
◦◦ INCREMENT: 1 second
◦◦ DEFAULT: 12 seconds
–– 4 Recovery Mode - Sets when the recovery system begins the power down sequence (only when the
Scrub System is being shut off). This is only affective when the system is operating when turned off.
◦◦ 1 Normal - starts immediately
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◦◦ 2 Neutral - waits for the machine to return to neutral
–– 5 Detect RTF (Recovery Tank Full) The machine is equipped with a feature that will automatically
shut off the vacuum and scrub systems and display a recovery tank full icon on the control panel
display when the recovery tank becomes full. If problems are encountered with the vacuum shutoff
feature, such as the vacuum shutting off even when the recovery tank is not full, this feature can be
turned off.
◦◦ 1 No - Do not detect recovery tank full
◦◦ 2 Yes - Detect recovery tank full
• 4 User Lockouts
–– 1 Spd Control Adjust (Battery only) - Blocks the user from increasing the speed when scrubbing or
sweeping.
◦◦ Unlocked
◦◦ Locked
–– 2 Scrub Mode Adjust - Blocks the user from changing scrub mode settings.
◦◦ 1 Unlocked
◦◦ 2 Detergent - Prevents the user from changing detergent settings.
◦◦ 3 Detergent & Sol - Prevents the user from changing detergent and solution settings.
• 5 Extended Scrub System
–– Start Up State
◦◦ Off – always disabled when the scrub system is activated.
◦◦ On – always enabled when the scrub system is activated.
◦◦ Last State – returned to state when the scrub system was last on.
• 6 Low Voltage cutout - The batteries are monitored. Once the voltage drops below the cutout level,
various systems are shut down to prevent depleting the batteries. The batteries must be charged above a
reset level before normal operation is allowed. The LVC clearing will set the batteries to full. This setting
adjusts the cutout and reset voltages. The description is on a “per cell” basis. There are 18 cells.
–– 1 1.75V, 2.15V
–– 2 1.75V, 2.09V
–– 3 1.83V, 2.09V
• 7 Reduced Speed Mode - Cougar can be programmed to automatically limit the maximum travel speed
while scrubbing only, either scrubbing or sweeping, or always.
–– When Scrub - The maximum travel speed will be reduced while scrubbing.
–– When Scrub&Sweep - The maximum travel speed will be reduced when scrubbing or sweeping.
–– Always – The maximum speed is the Scrubbing speed setting.
• 8 Engine Idle Delay - This setting adjusts how many seconds to delay before returning the engine RPM to
idle after the machine stops moving.
• idle.
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Service Manual – CS7000
–– RANGE: 10 – 250 seconds
–– INCREMENT: 1 second
–– DEFAULT: 20 seconds
• 9 Back-up Alarm
–– 1 Off - never on
–– 2 Reverse Only - Only on in reverse
–– 3 Fwd & Reverse - on when in motion
–– 4 Fwd, Rev & Hopper - on when motion or the hopper is lifted
• 10 Headlights
–– 1 Normal - User controls with key switch (DEFAULT)
–– 2 Always On - On when machine is running. Key switch allow momentary off.
• 11 Broom Lift in Rev
–– 1 No
–– 2 Yes
• 12 Maximum Speed
–– RANGE: 20% - 100%
–– INCREMENT: 20%
–– DEFAULT: 100%
Control System
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Service Mode
The service mode makes some diagnostic testing easier. Some outputs (like the scrub brush motors) are only
turned on when other conditions are met, such as when the machine is moving. It can be difficult to check
for voltage to the scrub brush motors while the machine is moving. Also, if voltage is not present, it leaves in
question what other conditions may not have been met yet. The service mode solves these problems for you
by allowing you to request that the controller ignore all other conditions and directly turn on the scrub brush
motors (or other output loads).
Enter the service mode through the “Configuration Menu”.
1. While holding down both the left and right turn signal switches, turn the key switch on.
2. Continue to hold the switches down until the “Configuration Menu” is displayed, then release the
switches.
3. Press and release the scrub pressure decrease button several times to scroll down the menu list until the
arrow cursor is aligned with the “15 Service Menu” selection.
4. Press the One-touch scrub switch to enter the service menu.
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5. With the arrow cursor aligned with “Service Mode”, press the One-touch scrub switch to enter the mode.
“Service Mode” will be displayed at the top of the LCD followed by battery voltage, drive pedal position
sensor voltage, drive mode (Reverse, Neutral or Forward) and any current main machine controller faults..
Once in the service mode, you will be able to turn various electrical loads on and off through the control
panel buttons. Some loads are toggled on and off by a single button press, while others are only on when the
button is held down. To exit the service mode: Turn the Key Switch off.
Scroll Up
Enter
Exit
Scroll Down
To Operate:
Scrub Motors
Pressing the One-touch scrub switch once will turn all of the brush motors on (energize all
contactors) and illuminate the button LEDs. The scrub pressure indicators will be on while
the brush motors are on. Pressing the switch again will turn the brush motors off (deenergize the contactors).
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Control System
Scrub Deck Actuator
Pressing the scrub pressure increase button will move the deck down. Each press and
release will extend the actuator motor a little. Holding the button down will run the motor
in the extend direction.
Pressing the scrub pressure decrease button will move the deck up. Each press will retract
the motor a little. Holding the button down will run the motor in the retract direction.
Vacuum Motor and Squeegee Actuator
Pressing the vacuum/wand switch once will move the squeegee down (extend actuator),
turn on the vacuum motors (energize relay) and illuminate the vacuum/wand indicator.
Pressing the button again will move the squeegee up (retract actuator) and turn the
vacuum motor off (de-energize relay).
Solution Valve (and pump if equipped)
Pressing the solution switch once turns on the solution valve to allow solution to flow. At
least one of the solution flow indicator lights will come on. If the model is equipped with a
solution pump, the pump will run at the flow rate indicated by the solution flow indicators.
While the solution system is “on” you can increase or decrease the solution flow rate by
pressing the solution flow increase and decrease buttons.
Detergent Pumps
Pressing the detergent switch once will cycle the detergent pumps on and off (if equipped)
and illuminate the detergent indicator. You should be able to hear and feel the pumps click.
The detergent ratio will be displayed in the LCD while the pump is running. Pressing the
detergent switch again will turn off the pump.
Side Broom Motors
Pressing the side broom switch once will turn on the side broom motors (energize relay).
The side broom button on indicator will illuminate. Pressing the button again will turn off
the side brooms (de-energize relay).
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Side Broom Actuator
Press the broom select switch (1) until the side broom on indicator (2) flashes slowly. Then press and hold
the down arrow (3) to move the side brooms down. Press and hold the up arrow (3) to move the side brooms
up.
Main Broom Motors
Pressing the One-touch sweep switch once will turn on the main broom motor (energize
relay). The main broom on indicator will illuminate. Pressing the button again will turn off
the motor (de-energize relay).
Main Broom Actuator
Press the broom adjustment selection button (1) until the main broom button indicator (2) flashes slowly.
Then press and hold the down arrow (3) to move the main broom down. Press and hold the up arrow (3)to
move the main broom up.
Shaker Motor
Pressing the filter shaker switch once will turn on the shaker motor and illuminate the
filter shaker on indicator. Pressing the button again will turn off the motor.
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Dust Guard Pump
Pressing the dust guard spray switch will turn on the dust guard pump and illuminate the
dust guard on indicator. Pressing the switch again will turn off the pump.
Dust Control Motor
Pressing the dust control fan switch will turn on the dust control motor (energize relay)
and illuminate the dust control fan on indicator. Pressing the switch again will turn off the
motor (de-energize relay).
Hopper Hydraulic Pump
Pressing and holding either the hopper raise or lower buttons will energize the relays to operate the pump.
Hopper Door Motor
Pressing and holding either the hopper door open or close buttons will move the door in the
appropriate direction until the limit is reached. This is different than normal operation where
a single press opens or closes the door completely.
Extended Scrub Pump
Pressing the extended scrub switch will turn on the extended scrub pump (and solution
pump and solution valve if equipped) and illuminate the extended scrub indicator. Pressing
the switch again will turn off the pump.
High Pressure Wash Pump
Pressing the High-pressure wand switch will turn on high pressure pump electromagnetic
clutch and illuminate the high pressure wand indicator. Pressing the button again will turn
off the pump.
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Control System
Troubleshooting
Control Panel LEDs all stay lit - CAN Bus problems
If communication on the CAN bus fails, the operator may or may not notice anything. If they notice anything
it will likely be that the control panel powers up when the key is turned on but all of the LEDs remain lit
and there is no response to pushing any switch on the control panel.
Control panel appearance with CAN Bus failure
If this happens, start by checking to see if either the steering controller or drive controller is causing the
problem by unplugging their low current connectors one at a time. If normal operation is restored after
unplugging one of the controllers, that controller is corrupting the communication on the CAN Bus and
should be replaced.
Next inspect the CAN Bus wires for shorts to ground, shorts to power or short to one another.
• Turn the key off and unplug the control panel, the main machine controller, steering controller and the
drive controller connectors.
• At the main machine controller connector, check for the presence of voltage on each of the CAN Bus wires.
If there is voltage (example 12v or 36v), the wire is shorted to a voltage source. Find and correct the short
circuit.
• Using an ohmmeter, check for continuity between each of the CAN Bus wires and battery negative. If
continuity is found, there is a short to ground (battery negative). Find and correct the short circuit.
• Using an ohmmeter, check the continuity of all of the wires from the main machine controller connector
to each of the other connectors. If any wire does not have continuity there is an open. Find and correct the
open circuit.
If the wiring is not the problem, check to see if the main machine controller is capable of providing the
“bias” voltage on the circuit.
• Make sure the key is off and then plug in only the main machine controller.
• Turn the key on and then check the voltage on each of the CAN Bus wires at the Control Panel Connector.
If there is no voltage, the main machine controller is defective because it is not providing bias voltage.
If the voltage on the CAN Hi (YEL) wire is approximately 3.3v and the voltage on the CAN Low (GRN) wire
is approximately 1.8v, the main machine controller is providing the bias voltage. This indicates that the
control panel is the source of the problem and needs to be replaced.
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Removal and Installation
Main Machine Controller
1. Turn the key switch off and disconnect the main battery connector.
2. Remove the recovery tank.
3. Remove the control panel plate to frame fasteners
4. Lay the controller and wiring down. Disconnect the 3 electrical connectors. Note, the connectors on the
harness are color coded and keyed to match the connectors on the controller.
5. Reassemble in reverse order.
Note. To avoid repeat controller failure, when replacing a controller, you should check all of the load
devices it controls to make sure none of them are shorted.
6. Turn the key on. You will automatically be taken to the Configuration Menu on the Control Panel LCD.
a. You must select the Machine Type and the Battery Type before the machine will be allowed to
operate.
b. You must also go through the remaining menu selections and inform the new main machine
controller how the machine is equipped, so that it can properly manage all of the machine’s features.
c. Adjust the Main Broom and Side Broom height.
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Control Panel
1. Empty the solution tank. (The tank must be empty upon reassembly for the solution level indicator to
work properly).
2. Disconnect the main battery connector.
3. Remove key and key switch retaining nut.
4. Remove the 6 control panel mounting screws.
5. Pull control panel forward and remove the clear hose from the white fitting on the solution tank.
Remove
HERE!
DO NOT REMOVE THE HOSE FROM THE CIRCUIT BOARD!
6. Disconnect the electrical connector.
7. Separate the key switch from the board.
8. Move the lock tab for the emergency stop switch and separate the back half of the switch from the
control panel.
Move Lock Tab
Separate
9. Before reassembly, make sure the solution tank is empty. The pressure sensor used to measure the tank
liquid level depends on the tank being empty when the hose is reconnected.
10. Reassemble in reverse order.
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Specifications
Shop Measurements – Main Machine Controller
The following tables contain some “real world” shop voltage measurements to help you recognize what
“normal” looks like. All voltage values were measured with the black (Negative) voltmeter lead connected to
the main battery negative unless otherwise specified.
J2 Connector (White)
J2 Pin
Wire
Circuit Description
Value/Condition
1
091 ORN/YEL
Left Front Turn Lamp
10.3v when off
0.02v when on
2
094 ORN/BLU
Left Rear Stop/Turn Lamp
11.1v when off
0.01v when on
3
098 YEL/RED
Right Front Turn Lamp
10.3v when off
0.02v when on
4
101 YEL/GRN
Right Rear Stop/Turn Lamp
11.1v when off
0.01v when on
5
107 TAN/BLK
Tail Lamps
5.1v when off
0.01v when on
6
064 BLK/YEL
Dust Control Motor Contactor
Grounds to energize
0.07v when energized
37v when not energized
7
119 BRN/WHT
Detergent Pump (M17)
Pulsed voltage is too fast for useful
measurement value
8
080 WHT/GRN
Squeegee Actuator Motor
37v at rest or when going down
0.04 going up
9
078 BLU/BRN
Squeegee Actuator Motor
37v at rest or when going up
0.01v going down
10
132 RED/GRN
Scrub Deck Actuator Motor
37v at rest or when going down
0.15v going up
11
135 YEL/GRA
Scrub Deck Actuator Motor
37v at rest or when going up
19v going down
12
162 BLK
Battery Negative
0.001v scrub and sweep systems running
13
057 VIO
VACC 1
Power supply from Aux
Contactor
0v Key Off
37v Key On (Aux Contactor energized)
14
051 BLK/ORN
Auxiliary Contactor
Grounds to energize
0.07v when energized
37v when not energized
15
163 BRN/BLK
Side Broom Motor Contactor
Grounds to energize
0.08v when energized
16
063 GRN/GRA
Main Broom Motor Contactor
Grounds to energize
0.08v when energized
17
045 BLU
Vacuum Motor Contactor
Grounds to energize
0.08v when energized
18
150 BLK/RED
Shaker Motor
PWM ground
10.6v shaker motor running
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Service Manual – CS7000
Control System
J2 Pin
Wire
Circuit Description
Value/Condition
19
116 WHT/YEL
Detergent Pump (M17)
Pulsed voltage is too fast for useful
measurement value
20
157 YEL/ORN
Solution Solenoid Valve
Grounds to energize
0.1v when energized
21
160 BLU/VIO
Detergent Pump (M18)
Pulsed voltage is too fast for useful
measurement value
22
167 BLK/YEL
Lamps Common
12v key on
23
169 BRN
Head Lamps and Curb Lamp
PWM ground to turn on lights
37v key on and lights off
33.7v key on headlights on
24
039 ORN/RED
Hydraulic Pump Motor
Contactor (K12)
Grounds to energize
0.08v when energized (Hopper Down)
25
047 YEL/BLU
Left Brush Motor Contactor
Grounds to energize
0.08v when energized
26
015 WHT/VIO
Center Brush Motor Contactor
Grounds to energize
0.08v when energized
27
061 GRA/RED
Right Brush Motor Contactor
Grounds to energize
0.08v when energized
28
038 BLU/ORN
Hydraulic Pump Motor
Contactor (K11)
Grounds to energize
0.08v when energized (Hopper Up)
29
---
30
---
31
---
32
221 GRA/BLIU
Detergent Pump (M18)
Pulsed voltage is too fast for useful
measurement value
33
---
34
054 BLK/WHT
VACC6a
Power supply from Aux Relay
0v Key Off
37v Key On (Aux Relay energized)
35
053 BLK/WHT
VACC6b
Power supply from Aux Relay
0v Key Off
37v Key On (Aux Relay energized)
J3 Connector (Gray)
J3 Pin
Wire
Circuit Description
Value/Condition
1
042 VIO/ORN
Extended Scrub Pump
PWM ground
Not measured
2
093 RED/YEL
Solution Control Pump
PWM ground
37v no flow
27v minimum flow rate
5.6v maximum flow rate
3
030 BRN/WHT
Main Broom Actuator
Reversing polarity driver
37v at rest or when moving down
5.4v when moving up
4
031 RED/VIO
Main Broom Actuator
Reversing polarity driver
37v at rest or when moving up
5.3v when moving down
5
106 GRA/VIO
Side Broom Actuator
Reversing polarity driver
37v at rest or when moving down
0.08v when moving up
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Service Manual – CS7000
Control System
J3 Pin
Wire
Circuit Description
Value/Condition
6
111 BRN/GRN
Dump Door Actuator
Reversing polarity driver
37v at rest or closing
0.07v opening
7
115 RED/GRA
Dump Door Actuator
Reversing polarity driver
37v at rest or opening
0.03v closing
8
118 WHT/ORN
High Pressure Pump Clutch
Coil
0.003v Off
11.9v On (Service Mode)
9
123 PINK
Ignition On Output
12v out to engine system
0v key off
12.1v key on
10
129 BLU/PINK
Start Output
12v out to starter
0v key off
10.9v cranking (12v if starter disabled)
11
131 GRA/ORN
Throttle 2 Output
0.03v or 13.8v (depending on throttle
request)
12
134 GRA/BLU
Throttle 1 Output
0.03v or 13.8v (depending on throttle
request)
13
137 BRN/RED
Dust Guard Control (Pump and
Valve)
Grounds to turn both on
0.05v when energizing valve and running
pump
14
139 VIO/BRN
Horn
Ground to turn on
0.24v when sounding horn
15
144 BLK
Battery Negative
0.006v with scrub, sweep and vacuum
motors free running
16
142 BLK
Battery Negative
0.006v with scrub, sweep and vacuum
motors free running
17
250 GRN/ORN
Side Broom Actuator
Reversing polarity driver
37v at rest or when moving up
0.05v when moving down
18
149 BLK
Battery Negative
0.006v with scrub, sweep and vacuum
motors free running
19
154 BLK
Battery Negative
0.006v with scrub, sweep and vacuum
motors free running
20
156 BLK
Battery Negative
0.006v with scrub, sweep and vacuum
motors free running
21
159 BLK
Battery Negative
0.006v with scrub, sweep and vacuum
motors free running
22
---
23
059 VOI/RED
12V supply
Power supply from starting
battery
0v key off
12.1v key on
24
171 GRN/WHT
Low Pressure Pump
37v (Not “Installed”)
0v (“Installed”)
25
---
26
058 GRA
VACC2
Power supply from Aux
Contactor
0v Key Off
37v Key On (Aux Relay energized)
27
076 GRN/BRN
Backup Alarm
Not measured
28
---
29
166 BLK
Battery Negative
0.006v with scrub, sweep and vacuum
motors free running
30
---
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Service Manual – CS7000
J3 Pin
Wire
31
---
32
049 ORN/BLK
33
---
34
35
Control System
Circuit Description
Value/Condition
Glow Plug Output
12v out to energize relay
11.6v when glow plug relay energized
0v key off or after time out period
056 GRA/BLK
VACC3a
Power supply from Aux
Contactor
0v Key Off
37v Key On (Aux Relay energized)
055 GRA/BLK
VACC3b
Power supply from Aux
Contactor
0v Key Off
37v Key On (Aux Relay energized)
J7 Connector (Black)
J7 Pin
Wire
Circuit Description
Value/Condition
1
092 GRN/BLU
Interlock Switch Input
37v when all interlock switches closed
0v otherwise
2
095 GRN
CAN Bus Low
2.448v
3
099 YEL
CAN Bus High
2.52v
4
102 GRA
Run Signal Output
14v when engine running
0v key off, on or cranking (starter disabled)
5
108 GRA/YEL
Engine Coolant Temperature
4.99v normal temp
6
112 TAN/WHT
Fuel Level Sender
3.3v open circuit
1.8v float at bottom
0.37v float at top
7
117 YEL/RED
Low LP Pressure Switch
5.0v when open
8
---
9
---
10
130 WHT/BRN
+12v
Power out to Control Panel
12.07v
11
133 BLK
B- (Ground) for Control Panel
0.002v
12
050 YEL/BRN
Suppression Diode
37v key on
13
141 ORN
Key Switch On Input
37v key on
0v key off
14
046 RED/BLK
Hopper Interlock Switch
0.0v full down position
4.8v otherwise
15
035 GRA/YEL
Extended Scrub Level Switch
4.8v (machine not equipped)
16
143 WHT/GRA
Dust Control Filter Switch
4.8v (machine not equipped)
17
145 ORN/GRA
Brake Switch
0v brake pedal at rest position
4.8v brake pedal pressed (not at rest)
18
151 YEL/VIO
19
155 VIO/GRN
Key Switch Start Input
37v key in start
0v key off or on
20
---
21
161 RED/ORN
Scrub Deck Retract Limit
Switch
0.0v full up position
4.8v otherwise
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Service Manual – CS7000
Control System
J7 Pin
Wire
Circuit Description
Value/Condition
22
168 ORN/RED
Hopper Dump Door Extend
Limit Switch
0.0v full closed position
4.8v otherwise
23
170 YEL/WHT
Hopper Dump Door Retract
Limit Switch
0.0v wide open position
4.8v otherwise
24
172 BLU/YEL
+5v
Power out to Current Sensors
4.97v
25
174 VIO/WHT
BGround for Current Sensors
0.002v
26
---
27
178 BRN
Brush Motor Current Sense
2.49v at rest (no current)
2.86v free-running at 22 amps
28
---
29
184 RED/WHT
Vacuum Motor Current Sense
2.49v at rest (no current)
3.01v Vac running, cover open at 28 amps
30
---
31
215 ORN/BLU
Broom Motor Current Sense
2.49v at rest (no current)
2.71v free-running at 12 amps
32
---
33
032 BLU/ BLK
POT High
Power supply for Main Broom
Actuator Position Sensor
3.304v (plugged in or unplugged)
34
033 GRA/GRN
Wiper
Main Broom Actuator Position
Sensor input
0.002v full up position
3.02v bottom of travel
(9.93v when open)
35
034 TAN/RED
POT Low
B- for Main Broom Actuator
Position Sensor
0.002v
79
Service Manual – CS7000
80
Dust Control/DustGuard™ Systems
Functional Description
Overview
The dust control system pulls air through the hopper and through a filter to trap the dust from the hopper.
The optional DustGuard™ system sprays a fine stream of water in front of each side broom to minimize the
dust created by the main broom.
Dust Control System
The Impeller Assembly, mounted in the Hopper Cover, pulls
air from the Upper Hopper through the Filter which traps
the dust generated by the sweep system. The Impeller
Assembly exhausts the filtered air through vents in the
Hopper Cover.
An optional dust control filter switch will shut off the
vacuum motor in the Impeller Assembly if the vacuum on
the clean side of the filter gets too high as a result of a
clogged Filter. When the switch is activated, the LCD will
display an icon to the operator.
The removable Filter Shaker Assembly vibrates the Filter
when the filter shaker switch is pressed to shake large
particles from the input side of the Filter back into the
hopper. This reduces Filter maintenance and helps
maintain adequate airflow through the Filter. The Filter
Shaker Assembly will automatically switch on when the
sweep system is turned off.
Hopper
Cover
Impeller
Assembly
Filter
Shaker
Assembly
Filter
Upper
Hopper
Service Manual – CS7000
Dust Control/DustGuard™ Systems
DustGuard™ Spray System (optional)
The DustGuard Pump pumps water from a separate
reservoir in the upper hopper to Nozzles on the
front of the machine. The Nozzles direct a fine
stream of water onto the floor in front of the side
brooms to help reduce the dust generated by the
brooms.
DustGuard
Pump (inside
Pump Guard)
The DustGuard™ Solenoid Valve opens to allow
water flow from the DustGuard Pump to the Nozzles
when the power to the DustGuard Pump switches
on. A removable Strainer is installed in the water
line upstream of the DustGuard Pump and Solenoid
Valve. Removable strainers are also located inside
of the Nozzle assemblies.
Solenoid
Valve
When installed, the DustGuard™ spray system
will turn on automatically when the main broom/
sweep system is turned on.
Strainer
DustGuard
Pump
Solenoid
Valve
Strainer
Nozzles
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Service Manual – CS7000
Dust Control/DustGuard™ Systems
DustGuard™ System Wiring Diagram
F1
RED
Battery
36V
RED
+
BLK
-
Fuse, 400 A
+
A1 Main Machine Controller
G
ORN
ORN
42V Alternator
CAN
BUS
S14
B1
VIO/GRN
3
123
YEL/BRN
B
3
J7-19 Start Input
4
K9
BLK/ORN
J2-14 Output
YEL/BRN
J7-12 Supression
Diode
Fe
K14
6
Seat Switch
GRN/YEL
4
1
Safety Switch
Relay (signal from
A5 Steer by
Wire Controller)
Contactor, Aux
K9
RED
BLU/GRN
1
2
Chassis
Ground
S13
S15
PINK
GRA/ORN
2
J1-1
J1-2
J1-3
J1-4
J7-13 Key Switch
Input
ORN
S9
WHT/BRN
BLK
YEL
GRN
Aux Contactor
Ignition Switch
ORN
1
J7-10 +12V
J7-11 BJ7-3 CAN H
J7-2 CAN L
A3 Control Panel
TAN
2
GRN/BLU
2
1
Emergency
Stop Switch
Battery
Interlock
J7-1 Interlock
Input
Fe
J7-14
Input
BLK
1
2
Hopper
Interlock Switch
VACC3
CB3
Ground
1 25 Amp
VACC2
CB2
BLU/GRN
1
L2
1
BLK
BLK
BLK
BLK
BLK
BLK
BLK
J3-15
J3-16
J3-18
J3-19
J3-20
J3-21
J3-29
GRA/BLK J3-34 Input
Vacc 3a
2
VACC1
CB1
GRA
2 25 Amp
S3
RED/BLK
J7-16 Input
S6
WHT/GRA
1
BLK
2
Dust Control
Filter Switch
2
Dust Guard
Valve
GRA
BRN/RED J3-13 Output
M
M22
Pump - Dust Guard
K6
VIO
Contactor, Dust
Control Motor
M14
VIO RED M
BLK
BLK/YEL
J2-6 Output
BLK/RED
J2-18 PWM Output
Shaker
Motor
VIO
Dust Control
Motor CB5
K6
BRN/WHT
RED
1 10 Amp
RED
FROM
F1
2
ORN/GRN
1
2
Contactor, Dust
Control Motor
A1
M5
M
BLK
A2
Dust Control
Motor
B-
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Service Manual – CS7000
Dust Control/DustGuard™ Systems
Circuit Description
The following conditions must be met for the DustGuard™ system to operate:
• The DustGuard™ system must be installed in the configuration menu.
• There must be positive voltage to the J7-1 Interlock Input. For this to happen:
–– The Seat Switch S9 must be closed.
–– The Safety Relay K14 on the Steer By Wire Controller A5 must energize the coil to close the Safety Relay
K14 contactor.
–– The Emergency Stop Switch S15 must be closed.
–– The Battery Interlock S13 must be closed (battery machines) or jumpered (Diesel and LPG machines).
• The 400-amp Fuse F1 must be closed to provide positive voltage from the Battery to the load side of Auxiliary
Contactor K9, and to the 10-amp circuit breaker CB5.
• The Ignition Switch S14 must be closed to provide positive voltage to the Auxiliary Contactor K9 coil. The
J2-14 Output on the A1 Main Machine Controller provides ground to the Auxiliary Contactor K9 coil when the
Ignition Switch S14 provides an input to the Key Switch Input J7-12.
• The Auxiliary Contactor K9 must be closed to provide positive voltage to circuit breaker VACC2/CB2.
• Circuit breaker VACC1/CB1 must closed to provide positive voltage to the Dust Control Motor Contactor K6
coil and the Shaker Motor M14.
• The J2-6 Output provides the negative ground to the Dust Control Motor Contactor K6 coil under the
following conditions:
–– If the hopper is down:
◦◦ The A1 Main Machine Controller must receive a signal from the A3 Control Panel via the CAN BUS that
the operator has pressed the DustGuard™ spray switch (blue LED on).
◦◦ The A1 Main Machine Controller must receive a signal from the A2 Drive Controller via the CAN BUS
that the machine is moving forward or backward.
–– If the hopper is up, the A1 Main Machine Controller must receive a signal from the A3 Control Panel via
the CAN BUS that the operator has pressed the DustGuard™ spray switch. Note that the seat switch
does not have to be closed.
• Circuit breaker CB5 must closed to provide positive voltage to the load side of Dust Control Motor Contactor
K6.
• Dust Control Motor Contactor K6 must be closed to provide positive voltage to the Dust Control Motor M5.
• Dust Control Motor M5 must be connected to battery ground.
• Circuit breaker VACC2/CB2 must closed to provide positive voltage to the DustGuard Valve L2 and the
DustGuard Pump M22.
• The J3-13 Output provides the negative ground to the DustGuard Valve L2 and the DustGuard Pump M22
under the following conditions:
–– The A1 Main Machine Controller must receive a signal from the A3 Control Panel via the CAN BUS that the
operator has pressed the DustGuard™ spray switch (blue LED on).
–– The A1 Main Machine Controller must receive a signal from the A2 Drive Controller via the CAN BUS that
the machine is moving forward.
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Service Manual – CS7000
Dust Control/DustGuard™ Systems
• The J2-18 Output provides the negative ground to the Shaker Motor M14 under the following conditions:
–– If the hopper is down and the DustGuard™ system is enabled, the A1 Main Machine Controller will
switch on the Shaker Motor M14 automatically for preset duration when the sweep system is switched
off.
–– If the hopper is up, the A1 Main Machine Controller must receive a signal from the A3 Operator Interface
Panel via the CAN BUS that the operator has pressed the filter shaker switch (blue LED on).
Component Locations
Impeller and Filter System
The Impeller Assembly houses the dust control
vacuum motor and is mounted in the Hopper
Cover. The Impeller Assembly pulls air from
the hopper through the filter. The filtered air
is exhausted through Vents in the front of the
Hopper Cover.
Vent
(typical)
Hopper
Cover
Impeller
Assembly
The rectangular Dust Control Filter seals
against the Upper Hopper and is held in place
by the Filter Shaker Assembly.
The electric motor in the Filter Shaker Assembly
drives two eccentric weights to vibrate or
“shake” the Dust Control Filter to dislodge dust
and allow it to drop down into the hopper. Two
Thumb Nuts secure the Filter Shaker Assembly
and Dust Control Filter to the Upper Hopper.
Upper
Hopper
Filter
Shaker
Assembly
Dust
Control
Filter
Thumb
Nut (2)
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Service Manual – CS7000
Dust Control/DustGuard™ Systems
Dust Control Filter Switch
The optional Dust Control Filter Switch is mounted above
the Filter Shaker Assembly on the Upper Hopper. The Dust
Control Filter Switch will close and generate a warning if
the hopper vacuum gets too high, indicating a plugged
Dust Control Filter. Note that the Dust Control Filter Switch
is factory-set to close at 2” of water, 0.147” Hg or 0.072
psi.
Dust Control
Filter Switch
If the dust control filter switch is not installed in the
hopper, there will be a Threaded Plug installed in the
switch hole.
Threaded
Plug
85
Service Manual – CS7000
Dust Control/DustGuard™ Systems
DustGuard™ Spray System
The DustGuard Pump is mounted on the Upper Hopper and
is protected by the Pump Guard. The Strainer screens the
incoming water upstream of the DustGuard Pump. The
Solenoid Valve, downstream of the DustGuard Pump, opens
to allow water flow to the nozzles when the power to the
DustGuard Pump is switched on.
Strainer
Solenoid
Valve
DustGuard
Pump
Pump
Guard
Upper
Hopper
The Spray Nozzles are mounted on the
front of the machine and spray an oval
pattern of water mist across the width of
each side broom.
Spray
Nozzles
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Service Manual – CS7000
Dust Control/DustGuard™ Systems
Maintenance and Adjustments
Warning! Before performing any machine maintenance or adjustments, make sure the key
switch is off, the key is removed from the machine and the parking brake is engaged.
To Clean the Dust Control Filter
To Remove the Dust Control Filter
1. Lift the hopper cover.
2. Disconnect the Shaker Motor Electrical
Connector.
3. Loosen the two Thumb Nuts, then slide
the Filter Shaker Assembly toward the
left and remove it from the machine.
Shaker Motor
Electrical
Connector
Filter
Shaker
Assembly
Thumb
Nut (2)
4. Lift the Dust Control Filter out of the
machine.
5. Inspect the top of the Dust Control
Filter for damage. A large amount
of dust on top of the Filter is usually
caused by a hole in the Filter or a
damaged filter gasket.
Dust
Control
Filter
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Service Manual – CS7000
Dust Control/DustGuard™ Systems
To Clean the Dust Control Filter
Caution: • Wear safety glasses when cleaning the filter.
• Clean the filter in a well-ventilated area.
• Be careful not to puncture the filter element.
1. Check the filter surfaces, and urethane gasket on the bottom of the filter for signs damage. If the filter
surfaces or gasket are damaged, replace the filter.
2. Clean the dust control filter using either of the two methods below:
Method 1:
a. Vacuum any loose dust from the filter.
b. Gently tap the filter against a flat surface (with the dirty side down) to remove loose dust and dirt.
Method 2:
a. Vacuum any loose dust from the filter.
b. Blow compressed air (maximum pressure 100 psi) into the clean side of the filter (in the opposite
direction of the airflow).
To Reinstall the Dust Control Filter
1. Install the Dust Control Filter into the
recess in the upper hopper.
Note: Make sure the arrow on the
“Air Flow” Indicator Decal
on the side of the filter is
pointing upward.
2. Install the Filter Shaker Assembly onto the
Dust Control Filter. Make sure the shaker
motor electrical connector is positioned
toward the rear of the machine.
3. Slide the Filter Shaker Assembly toward
the right so the Filter Clamps engage the
Thumb Nut studs on the upper hopper.
Thumb
Nut (2)
Filter
Shaker
Assembly
Filter
Clamp (2)
Dust
Control
Filter
4. Tighten the two Thumb Nuts.
5. Reconnect the Shaker Motor Electrical
Connector.
6. Close the hopper cover.
“Air Flow”
Indicator
Decal
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Service Manual – CS7000
Dust Control/DustGuard™ Systems
To Clean the DustGuard™ Strainer Screen
1. Drain the water from the upper hopper. Note that you can do this one of several ways. The most
convenient way is to remove the Strainer Cover and Screen and drain the upper hopper through the
DustGuard™ strainer.
Note: Place a suitable container underneath the upper hopper to catch the water from the hopper
reservoir.
2. Raise the hopper and engage the prop rod.
Note: Place a suitable container underneath the filter to catch any water that may leak from the
hoses.
3. Unscrew the Strainer Cover and remove the Strainer Cover and
Screen from the Strainer Base.
4. Clean any accumulated dirt or debris from the Screen.
5. Reinstall the Screen into the Strainer Base.
Strainer
Base
6. Make sure the Rubber Washer is installed correctly in the Strainer
Cover, then reinstall and hand-tighten the Strainer Cover.
Screen
Rubber
Washer
Strainer
Cover
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Service Manual – CS7000
Dust Control/DustGuard™ Systems
To Clean the DustGuard™ Spray Nozzles
1. Raise the hopper slightly if desired for easier access
to the DustGuard™ nozzles.
7/8” Wrench
Note: Place a suitable container underneath
the nozzles to catch any water that may
leak from the hoses.
Plastic
Nozzle
Adapter
2. Hold the Plastic Nozzle Adapter with a 7/8” Wrench to
keep it from rotating in the Nozzle Bracket when you
remove the Nozzle Cap. This will maintain the correct
spray pattern orientation of the Spray Nozzle.
Nozzle
Cap
3. Rotate the Nozzle Cap one-quarter turn
counterclockwise (as viewed from the front of
the machine) to remove the Nozzle Cap, Spray
Nozzle and Check Valve Strainer from the Plastic
Nozzle Adapter.
4. Rinse the Nozzle Cap, Spray Nozzle and Check
Valve Strainer in clean water to remove any
accumulated dirt or sediment. If necessary,
rinse or soak the components in vinegar or
other commercial cleaner to remove any
mineral deposits.
5. Reassemble the DustGuard™ nozzles by
following the above steps in reverse order.
Nozzle
Cap
Spray
Nozzle
Nozzle
Bracket
Check Valve
Strainer
To Adjust the DustGuard™ Spray Nozzles
The Spray Nozzles should be approximately 10
to 20 degrees from vertical as shown in order to
spray the water evenly top to bottom in front of
the side brooms. (Note that the hopper has been
raised slightly in the adjacent photo.) The spray
pattern should wet the floor across the whole
width of the side broom. If the spray pattern is
not correct:
1. Carefully rotate the Plastic Nozzle Adapter
with a 7/8” Wrench to orient the Spray Nozzle.
2. After you rotate the Plastic Nozzle Adapter,
make sure the Brass Nozzle Adapter is holding
Plastic Nozzle Adapter securely in the Nozzle
Bracket. Tighten the Brass Nozzle Adapter to
the Plastic Nozzle Adapter as necessary.
Plastic
Nozzle
Adapter
Brass
Nozzle
Adapter
Spray
Nozzle
90
Service Manual – CS7000
Dust Control/DustGuard™ Systems
Troubleshooting
Note: You can use the Service Mode to toggle the various system components on and off to check for
function. Refer to the Control System/Service Mode section for information on how to enter
and use the Service Mode.
Problem
Cause
Correction
The DustGuard™
system does not
operate.
The DustGuard™ system
is not installed in the
configuration menu.
Make sure the DustGuard™ system is installed in the
configuration menu.
Inadequate water flow
to the DustGuard™
nozzles
Inadequate water level in
upper hopper
Check the water level.
The water strainer screen is
plugged.
Clean the strainer screen.
The water hoses/nozzles are
plugged.
Check and clean the water hoses/nozzles as
necessary.
The water solenoid valve is
plugged or not functioning
correctly.
Check for voltage at the solenoid valve.
• If there is voltage at the solenoid, check the
solenoid coil resistance. It should measure 125
ohms ± 10%. If the coil resistance is not within
spec replace the solenoid valve.
• If there is no voltage at the solenoid:
1. Check the wiring and circuit breakers upstream
of the solenoid.
2. Check the J3-13 output from A1 Main Machine
Controller.
The DustGuard™ pump (M22)
is not operating correctly.
Check for voltage at the pump.
• If there is voltage at the pump, replace the pump.
• If there is no voltage at the pump:
1. Check the wiring and circuit breakers upstream
of the pump.
2. Check the J3-13 output from A1 Main Machine
Controller.
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Service Manual – CS7000
Problem
Dust Control/DustGuard™ Systems
Cause
The dust control motor The dust control filter switch is
will not run.
closed, indicating that the filter
is plugged.
There is no voltage to the dust
control motor.
Correction
1. Clean the filter.
2. Check the dust control filter switch. The switch
should be open with no vacuum in the hopper
(dust control motor off). Replace the dust control
filter switch if necessary.
1. Check the wiring and circuit breakers upstream of
the dust control motor.
2. Check the coil resistance in the K6 contactor
coil. If the coil resistance is not 118 ohms ± 10%,
replace the contactor.
3. Check the continuity through contactor K6 with the
coil energized. If the contacts are open, replace
the contactor.
4. Check the J2-6 output from A1 Main Machine
Controller.
The dust control motor is not
operating correctly.
The shaker motor will
not run.
There is no voltage to the
shaker motor.
If there is voltage to the dust control motor, replace the
motor.
1. Check the wiring and circuit breakers upstream of
the shaker motor.
2. Check the J2-18 output from A1 Main Machine
Controller.
The shaker motor is not
operating correctly.
If there is voltage to the shaker motor, replace the
motor.
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Service Manual – CS7000
Dust Control/DustGuard™ Systems
Removal and Installation
Warning! Before removing or reinstalling any machine components, make sure the key switch
is off, the key is removed from the machine and the parking brake is engaged.
To Remove and Reinstall the DustGuard™ Solenoid Valve Assembly
1. Drain the water from the upper hopper. Note that you can do this one of several ways. The most
convenient way is to remove the Strainer Cover and screen and drain the upper hopper through the
DustGuard Strainer.
Note: Place a suitable container underneath the upper hopper to catch the water from the hopper
reservoir.
2. Turn the key switch on, raise the hopper and engage the prop rod, then turn off the key switch.
Note: Place a suitable
container underneath the
Strainer
Cover
Solenoid Valve Assembly
to catch any water
that may leak from the
Hose
Solenoid Valve Assembly
and hoses.
Nyloc™
Nut (2)
3. Disconnect the Solenoid
Electrical Connector.
4. Remove the two Nyloc™ Nuts
holding the Solenoid Valve
Assembly to the Hopper Lift
Weldment.
5. Disconnect the two Hoses and
remove the Solenoid Valve
Assembly from the machine.
6. Reinstall the Solenoid Valve
Assembly by following the
above steps in reverse order.
DustGuard
Strainer
Solenoid
Electrical
Connector
Solenoid
Valve
Assembly
Hose
Hopper
Lift
Weldment
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Service Manual – CS7000
Dust Control/DustGuard™ Systems
To Remove and Reinstall the DustGuard™ Pump
1. Drain the water from the upper hopper. Note that you can do this one of several ways. The most
convenient way is to remove the strainer cover and screen and drain the upper hopper through the
DustGuard™ strainer.
Note: Place a suitable container underneath the upper hopper to catch the water from the hopper
reservoir.
2. Turn the key switch on, raise
the hopper and engage the
prop rod, then turn off the key
switch.
Note: Place a suitable
container underneath the
DustGuard Pump to catch
any water that may leak
from the DustGuard Pump
and hoses.
3. Disconnect the Pump Electrical
Connector.
4. Disconnect the two Hoses from
the DustGuard Pump.
5. Remove the four Phillips
Screws and washers holding
the Pump Guard and DustGuard
Pump to the Upper Hopper
and remove the Pump Guard
and DustGuard Pump from the
machine.
Note that you’ll need to cut
the Wire Tie holding the Pump
Electrical Connector wires to
the Pump Guard in order to
separate the Pump Guard and
DustGuard Pump.
6. Reinstall the DustGuard Pump
by following the above steps in
reverse order.
Hose
Hose
DustGuard
Pump
Phillips
Screw (4)
Pump
Electrical
Connector
Wire
Tie
Pump
Guard
Pump
Electrical
Connector
Phillips
Screw (4)
DustGuard
Pump
Isolator (4)
Pump
Guard
DustGuard
Pump
Hose
Hose
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Service Manual – CS7000
Dust Control/DustGuard™ Systems
Note: The Pump Guard base should
be positioned under the four
DustGuard Pump Isolators.
DustGuard
Pump
Pump
Guard
DustGuard
Pump
Isolator (4)
To Remove and Reinstall the Dust Control Filter Switch
1. Lift the hopper cover.
2. Disconnect the two Electrical Connectors from the Dust
Control Filter Switch.
3. Unscrew the Dust Control Filter Switch from the upper
hopper.
Dust Control
Filter Switch
Electrical
Connectors
To Remove and Reinstall the Impeller Assembly
1. Lift the Hopper Cover.
2. Remove the six Screws and washers holding the
Impeller Assembly to the Hopper Cover.
3. Carefully pull the Impeller Assembly partway off of the
Hopper Cover.
4. Disconnect the Vacuum Motor electrical connector,
then remove the Impeller Assembly from the machine.
5. Reinstall the Impeller Assembly by following the above
steps in reverse order.
Hopper
Cover
Screw (6)
Impeller
Assembly
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Service Manual – CS7000
Dust Control/DustGuard™ Systems
To Disassemble and Reassemble the Impeller Assembly
1. Remove the three Nyloc™ Nuts, Screws
and Spacers holding the Vacuum Plate
and Gasket to the Vacuum Support and
attached Vacuum Motor.
Vacuum
Support
Screw (3)
Screw (3)
Vacuum
Motor
2. Remove the three Nyloc™ Nuts holding
the Vacuum Motor to the Vacuum
Support and remove the Vacuum Motor.
Nyloc™
Nut (3)
Nyloc™
Nut (3)
Spacer (3)
Vacuum
Plate and
Gasket
Gasket
Protection
Grate
Vacuum
Support
Vacuum
Motor
Vacuum
Plate
Note: To prevent the three
Screws from spinning
when removing the
Nyloc™ Nuts to remove
the Vacuum Motor, place
a wrench on the Screw
heads under the Vacuum
Motor Tabs.
3. Reassemble the impeller assembly
following the above steps in reverse
order.
Vacuum
Support
Nyloc™
Nut (typical)
Screw
(typical)
Vacuum
Motor
Tab
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Service Manual – CS7000
Dust Control/DustGuard™ Systems
Specifications
Component
Specifications
Type - Diaphragm w/bypass
Nominal Voltage - 36 VDC
DustGuard Pump
Flow Rate - 1.1 GPM
Current - 1.0 Amp max.
Pressure - 30 psi max.
Nominal Voltage - 36 VDC, 11 Watts
DustGuard Solenoid Valve
Coil Resistance - 125 Ohms ± 10%
Media Type - synthetic with UltraWeb (cellulose optional)
Dust Control Filter
Media Quantity - 120 ft2 (approximate)
Media Configuration - PowerCore
Dust Control Vacuum Motor
Current - 7 Amps average, 8 Amps max.
Dust Control Motor Contactor
(K6)
118 Ohms ± 10%
Dust Control Filter Switch
Actuation setting ± 20%: factory set at 2” H2O/
0.147” Hg/0.072 psi
Voltage - 36 VDC
Current - 0.8 Amps average
Power - 90 Watts
Filter Shaker Motor
Ingress Protection - IP44
Insulation Class - B
Duty - intermittent (S2 10 min.)
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Service Manual – CS7000
Electrical System
The electrical system chapter contains wiring diagrams, electrical panel information and covers other
components that are not covered in other chapters. For instance, the Solution Pump is covered in the
Solution System Chapter.
Functional Description
Overview
The CS7000 uses electricity to operate almost everything. The “Battery” model has a large capacity 36 volt
storage battery for its only power source.
Power from the 36v battery supplies all machine electrical loads.
Battery Model Power Distribution
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Service Manual – CS7000
Electrical System
“Hybrid” models use a large, engine-driven 42 volt generator for their main power source with a smaller 36
volt battery pack connected in “parallel” with the generator, as a “back up”.
When the engine is running the 42 volt generator provides the electrical power to operate the 36v machine
electrical loads as well as recharge the 36v battery pack. If the machine demands more current than the 42
volt generator can provide, the 36 volt battery pack supplies the extra boost that is needed. If the engine is
not running the machine can work for a limited time on just the 36 volt battery pack The main machine uses
a 36v supply to operate some 36v electrical loads.
Hybrid Power Supply
Hybrid models also have a separate 12 volt starting battery.
The main purpose of the staring battery is to start the engine. The engine drives a separate 12 volt generator
(Alternator) to recharge the starting battery and supply power for 12v engine electrical loads. The main
machine controller is supplied a 12v power source which it uses to control some 12v engine electrical devices.
12v Power Distribution - Engine models only
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Service Manual – CS7000
Electrical System
If you combine the power distribution for both the engine electrical loads and the 36v machine electrical
loads it looks like this.
Combined Power Distribution - Engine Models
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Service Manual – CS7000
Electrical System
All models have a large connector to disconnect power from the machine. A circuit breaker panel located on
the left side of the operator foot well area provides circuit protection for multiple circuits.
The electrical system makes use of hall effect current sensors to provide amp draw information to the main
machine controller for some circuits.
Current Sensor
Wiring Harnesses
Wires are color coded and have connector information printed near each end of the wire. In the photo below,
the left end of the wire goes to connector X274 pin A and the right side of the wire goes to connector J3 pin 9.
The main harness is the same for all models. Connectors which are not used for certain models or features
have plugs covering them or may be “jumped” together as is the case for the battery interlock switch on
engine models.
There are splices in the harness that are shrink wrapped. There are also two “splice saver” connectors which
look like capped off connectors, but actually connect many wires together through a “comb” that is inserted
into the connector.
The CAN Bus wire pairs are twisted to prevent electrical interference from corrupting the messages. If any
repairs are performed on the CAN Bus wires, the wire pairs must be twisted approximately once per inch.
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Service Manual – CS7000
Electrical System
Circuit Protection
Circuit protection is accomplished with both fuses and circuit breakers. There are 2 large fuses. F1 is a 400
amp fuse that provides “complete machine” protection. F2 is a 150 amp fuse that protects the motor circuits
for the main broom, scrub motors and vacuum motors.
Switched Power
A key switch (Ignition Switch) is used to provide switched power to the main machine controller but
it carries only a small amount of current. The main machine controller in turn energizes an Auxiliary
Contactor to provide 36 volt high current capacity supply to many circuits. The main machine controller also
energizes an Auxiliary Relay which provides a 12 volt power supply to itself. The main machine controller
then uses this 12 volts to switch out to various circuits like the Ignition output to the engine system.
Current Sensors
The CS7000 utilizes 3 hall effect current sensors to report amp draw information for the vacuum motors,
scrub motors and main broom motor to the main machine controller. They work much like an inductive amp
clamp for a digital multi-meter. The motor circuit ground wires run through the “circle loop”. The sensor
“reads” the amperage and converts it to a voltage value for the main machine controller to “read”. With no
current flow, the sensors report 2.5 volts. As current increases the voltage increases. (Provided the sensors
are installed correctly. If they are installed “backwards” the voltage will drop with increased current).
“Tape Tab” must
point toward
Battery Positive
Wires pass
through circle
Current Sensor
42 Volt Alternator (Generator)
The 42 volt generator provides the electrical power needed to operate the machine and to recharge the 36
volt battery pack. It is belt driven by a pulley located at the rear of the engine (Right side of machine).
Lighting
All headlights, curb light, taillights and turn lights are controlled by the main machine controller. Head
lights are standard. The curb light and turn lights are optional See the Options and Accessories chapter for
more information on curb lights and turn lights.
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Service Manual – CS7000
Electrical System
Low Voltage Cutout
The scrub system and solution system are cut off by the main machine controller if the system voltage falls
too low (Approx 31.5v for “wet” batteries or 32.94v for gel batteries). This is done to prevent damaging the
batteries from over discharging. The operator will see the low voltage warning icon displayed when the low
voltage cut out mode is active
There are actually two levels of low voltage cut off. The first level disables the scrub and sweeping functions.
The second level will also disable the recovery function. In either case, the hopper functions are not disabled.
Once the machine has gone into the low voltage cut out mode, the batteries must be fully recharged before
normal operation is restored (Approx 38.7v) .
Circuit Descriptions
42 Volt Generator
The 36 volt battery pack positive cable runs directly to the 42 volt generator positive terminal. The battery
pack negative cable runs directly to the 42 volt generator negative terminal. The generator positive and
negative terminals also have cables that go to the main power connector. When the main power connector is
connected, this supplies power to the entire machine.
36v Battery Pack
42v
Gen.
Main Power
Connector
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Service Manual – CS7000
Electrical System
Headlights
Two types of headlights are used on the CS7000. Early machines, use incandescent 12v halogen bulbs. Later
machines use LED headlights. The machine must be properly configured to operate each type correctly using
the Configuration Menu.
Incandescent Headlight
LED Headlight
Incandescent Headlights
Battery positive power is supplied to the head lamps through, F1, CB6 (VACC6), and the K15a Auxiliary
relay contacts. The other side of the headlights are wired in parallel to the main machine controller J2-23.
To turn the headlights on, the controller switches J2-23 to ground. (It is not a complete ground. It is Pulse
Width Modulated to provide approximately 3.3 volts rather than full machine system voltage.)
LED Headlights
Battery positive power is supplied to the head lamps through, F1, CB6 (VACC6), and the K15a Auxiliary
relay contacts. The other side of the headlights are wired in parallel to the main machine controller J2-23.
To turn the headlights on, the controller switches J2-23 to ground which applies full system voltage to the
headlights.
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Service Manual – CS7000
Electrical System
Component Locations
• 36 volt Battery (Battery Model)
• 36 volt Battery Pack (Hybrid Models) - Right of engine under fuel tank.
• 42 volt Generator - Front of engine behind rubber shield. (Raise hopper for access.)
• Circuit Breaker Panel
• Starting Battery
• Electrical Panel - Left side of solution tank under metal plate. (Remove recovery tank for access.)
• Main Fuse F1 400 Amps
• F2 150 Amp Fuse
• Auxiliary Relay - See Electrical Panel
• Auxiliary Contactor - See electrical panel
• Horn
• Battery Interlock Switch (Hybrid models use a jumper in place of this switch)
• Seat Switch
Battery Interlock Switch - Under here
Main Power
Disconnect
Horn
36v Battery
36 volt Battery (Battery Model)
Switch “reads” tang
Fr
on
t
Battery Interlock
Connector with Jumper
on Hybrid Model
Engine Compartment area. Shown during assembly for clarity.
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Service Manual – CS7000
Electrical System
Battery Pack
(Under Fuel Tank)
Starting Battery
36 volt Battery Pack (Hybrid Models)
Circuit Breaker Panel
Seat Switch - bottom of seat
42 volt Generator
Electrical Panel
Fuse F1 400 Amps and F2 150 amps - Behind
metal panel. Shown with panel pulled forward
Fuse F1 400 Amps - Side view.
Shown with panel pulled forward
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Service Manual – CS7000
Electrical Panel Contactor/Relay location
Electrical Panel
Electrical System
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Service Manual – CS7000
Electrical System
Harness to Harness Connector Locations
Most connectors are plugged into a component like the squeegee actuator; find the squeegee actuator and
you can locate the squeegee actuator electrical connector. However, there are a few connectors that connect
two harness. These are pictured here.
• Main Harness X1 and X2 to Hopper Harness X262 and X263
• Main Harness X274 to Engine Interface Harness X175
• Main Harness X166 to Taillight Harness X239
Underneath
• Engine Interface Harness X265 and X266 to Engine Harness (Photo of diesel engine)
Below
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Service Manual – CS7000
Electrical System
Connector Pin-Outs
The following pages contain details about every electrical connector that contains more than one “cavity”.
The connector pin-out information is organized with a table on the left which identifies the location of wires
in the connector and images on the right which show what the connector looks like. The table on the left has
a header that describes the connector ID, the name of the component that it plugs into and the component’s
ID number. (There are a few connectors that do not plug into a component but plug into another harness
or are empty. These have the connector ID and the “name” of the connector only.) The images to the right
of each table have a “3 dimensional” view of the connector to help you recognize it on the machine and a “2
dimensional” view of the “back side” or “wire side” of the connector. This is to help you match up the wires
and pin numbers of the connector.
The connector pin-out information is organized by the connector ID in alphabetical order. If you are viewing
this document on a computer, you can search for the component ID or component name to find the pin out
chart. However, if you are viewing a paper copy, it will be easier for you to find the correct pin-out table if
you know the connector ID. To learn the connector ID, find the component ID from the wiring diagram. Then
use the “Component ID to Connector ID Look Up Table” below to find the connector ID.
Component ID to Connector ID Look Up Table
Component ID
Component Name
Connector ID
A1
Main Machine Controller
J2
A1
Main Machine Controller
J3
A1
Main Machine Controller
J7
A2
Drive controller
J4
A3
Control panel
J1
A5
Steering controller
J5
B1
Brush Motor Current Sensor
X183
B2
Broom Motor Current Sensor
X181
B3
Vacuum Motor Current Sensor
X182
E4
Steering wheel sensor
X98
H1
Back up alarm (Optional)
X178
J8
Can bus programmer connector
J8
J10
Drive Controller Programmer
J10
L1
Solution Solenoid Valve
X190
L2
Dust guard valve
X140
LT1
Trouble light
X258
LT2
Right headlight
X162
LT3
Left headlight
X161
LT5
Taillight, right
X154
LT6
Taillight, left
X153
LT8
Curb light (optional)
X165
LT9
Stop turn light, left
X180
LT10
Beacon (optional)
X257
LT11
Stop turn light, right
X184
M1
Main Broom motor
X25
M2
Motor, left brush
X19
M3
Motor, center brush
X18
M4
Motor, right brush
X17
M5
Dust control motor
X21
M6
Vacuum Motor
X23
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Service Manual – CS7000
Electrical System
Component ID
Component Name
Connector ID
M7
Vacuum Motor
X24
M8
Right side broom motor
X28
M9
Left side broom motor
X26
M10
Hydraulic Pump, Hopper Lift
X126
M11
Scrub Deck Actuator Motor
X256
M12
Squeegee Lift actuator
X22
M13
Side broom actuator
X109
M14
Shaker motor
X20
M16
Steering Actuator
X97
M19
Pump, Solution Control (Optional)
X111
M20
Fuel pump
X275
M21
Main Broom actuator
X27
M22
Dust guard pump
X122
M23
Pump, Low Pressure (Optional)
X20
M23
Low Pressure Pump (Optional)
X120
M24
Wheel Drive Motor
X99
M24
Wheel Drive Motor
X100
M25
Pump, Extended Scrub (optional)
X118
M26
Dump door actuator motor
X124
R1
Drive Pedal Position Sensor
X145
S1
Scrub Deck Retract Limit Switch
X255
S3
Hopper Interlock Switch
X204
S4
Extended Scrub Level Switch (optional)
X268
S5
Brake switch
X202
S7
Dump door extend limit switch
X236
S8
Dump door retract limit switch
X238
S13
Battery interlock switch
X187
S16
Steering Travel Limit Switch, Right
X106
S17
Steering Travel Limit Switch, Left
X105
J1 - Control Panel (A3)
Pin
Wire # Color
1
130 WHT/BRN
2
304 BLK
3
301 YEL
4
300 GRN
FRONT
SIDE
MOLEX 430250400
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Service Manual – CS7000
Electrical System
J2 - Main Machine Controller (A1)
Pin
Wire # Color
1
091 ORN/YEL
2
094 ORN/BLU
3
098 YEL/RED
4
101 YEL/GRN
5
107 TAN/BLK
6
064 BLK/YEL
7
119 BRN/WHT
8
080 WHT/GRN
9
078 BLU/BRN
10
132 RED/GRN
11
135 YEL/GRA
12
162 BLK
13
057 VIO
14
051 BLK/ORN
15
163 BRN/BLK
16
063 GRN/GRA
17
045 BLU
18
150 BLK/RED
19
116 WHT/YEL
20
157 YEL/ORN
21
160 BLU/VIO
22
167 BLK/YEL
23
169 BRN
24
039 ORN/RED
25
047 YEL/BLU
26
015 WHT/VIO
27
061 GRA/RED
28
038 BLU/ORN
29
---
30
---
31
---
32
221 GRA/BLIU
33
---
34
054 BLK/WHT
35
053 BLK/WHT
J2
AMP 776164-2
NEUTRAL
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Service Manual – CS7000
Electrical System
J3 - Main Machine Controller (A1)
Pin
Wire # Color
1
042 VIO/ORN
2
093 RED/YEL
3
030 BRN/WHT
4
031 RED/VIO
5
106 GRA/VIO
6
111 BRN/GRN
7
115 RED/GRA
8
118 WHT/ORN
9
123 PINK
10
129 BLU/PINK
11
131 GRA/ORN
12
134 GRA/BLU
13
137 BRN/RED
14
139 VIO/BRN
15
144 BLK
16
142 BLK
17
250 GRN/ORN
18
149 BLK
19
154 BLK
20
156 BLK
21
159 BLK
22
---
23
059 VIO/RED
24
171 GRN/WHT
25
---
26
058 GRA
27
076 GRN/BRN
28
---
29
166 BLK
30
---
31
---
32
049 ORN/BLK
33
---
34
056 GRA/BLK
35
055 GRA/BLK
J3
AMP 776164-4
GRAY
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Service Manual – CS7000
Electrical System
J4 - Drive Controller (A2)
Pin
Wire # Color
1
185 ORN
2
---
3
---
4
---
5
---
6
126 VIO/GRN
7
186 BLK/PINK
8
187 TAN/RED
9
188 GRN/BLU
10
---
11
---
12
---
13
127 TAN/ORN
14
---
15
189 WHT/BLK
16
190 BRN/RED
17
---
18
191 VIO/BLK
19
---
20
---
21
---
22
---
23
192 YEL
24
---
25
193 VIO/WHT
26
194 PINK/RED
27
---
28
195 WHT/ORN
29
196 BLU/GRN
30
---
31
197 PINK/WHT
32
198 PINK/BLU
33
---
34
---
35
342 GRN
AMP 776164-1
BLACK
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Service Manual – CS7000
Electrical System
J5 - Steering Controller (A5)
Pin
Wire # Color
1
083 GRA/ORN
2
199 BRN/WHT
3
200 ORN/BLK
4
201 BLK
5
202 WHT
6
203 BLU/GRA
7
---
8
204 BLK
9
---
10
308 RED/WHT
11
307 GRN/WHT
12
084 GRA/ORN
13
207 WHT/BLU
14
---
15
343 GRN
16
208 YEL/RED
17
309 BLU
18
073 VIO
19
210 ORN/RED
20
310 GRN/BLK
21
---
22
---
23
212 YEL
AMP770680-1
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Service Manual – CS7000
Electrical System
J7 - Main Machine Controller (A1)
Pin
Wire # Color
1
092 GRN/BLU
2
095 GRN
3
099 YEL
4
102 GRA
5
108 GRA/YEL
6
112 TAN/WHT
7
117 YEL/RED
8
---
9
---
10
130 WHT/BRN
11
133 BLK
12
050 YEL/BRN
13
141 ORN
14
046 RED/BLK
15
035 GRA/YEL
16
143 WHT/GRA
17
145 ORN/GRA
18
151 YEL/VIO
19
155 VIO/GRN
20
---
21
161 RED/ORN
22
168 ORN/RED
23
170 YEL/WHT
24
172 BLU/YEL
25
174 VIO/WHT
26
---
27
178 BRN
28
---
29
184 RED/WHT
30
---
31
215 ORN/BLU
32
---
33
032 BLU/ BLK
34
033 GRA/GRN
35
034 TAN/RED
AMP 776164-1
BLACK
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Service Manual – CS7000
Electrical System
J8 - CAN Bus Connector
Pin
Wire # Color
1
---
2
241 GRN
3
242 BLK
4
---
5
---
6
---
7
243 YEL
8
---
9
---
1
9
AMP 5-747905-2
J10 - Drive Controller Programmer
Pin
Wire
1
196 BLU/GRN
2
249 BLK/PINK
3
195 WHT/ORN
4
193 VIO/WHT
SIDE
TOP
MOLEX 39012041
X1 - Hopper Harness Connector (X262)
Pin
Wire
A
264 GRA
B
137 BRN/RED
C
143 WHT/GRA
D
244 BLK
E
151 YEL/VIO
F
240 BLK
G
070 ORN/GRN
H
248 BLK
J
067 VIO
K
150 BLK/RED
L
169 BRN
M
238 BLK/WHT
A
M
DELPHI 15326915
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Service Manual – CS7000
Electrical System
X2 - Hopper Harness Connector (X263)
Pin
Wire
A
---
B
091 ORN/YEL
C
284 BLK/YEL
D
098 YEL/RED
E
106 GRA/VIO
F
250 GRN/ORN
G
111 BRN/GRN
H
115 RED/GRA
J
168 ORN/RED
K
235 BLK
L
170 YEL/WHT
M
239 BLK
N
071 WHT/RED
P
233 BLK
X17- Brush Motor, Right (M4)
Pin
Wire # Color
A
251 BLK
B
152 BLU/YEL
A
P
DELPHI 15326917
A
DELPHI 12052613
X18 - Brush Motor, Center (M3)
Pin
Wire
A
109 GRA/BLK
B
254 BLK
A
DELPHI 12015792
X19 - Brush Motor, Left (M2)
Pin
Wire
A
113 WHT/ORN
B
253 BLK
A
DELPHI 12052613
X20 - Shaker Motor (M14)
Pin
Wire
A
267 VIO
B
268 BLK/RED
A
DELPHI 12052613
117
Service Manual – CS7000
X21 - Dust Control Motor (M5)
Pin
Wire
A
259 ORN/GRN
B
260 BLK
Electrical System
A
TOP
SIDE
DELPHI 15300027
X22 - Squeegee Lift Actuator (M12)
Pin
Wire
A
080 WHT/GRN
B
078 BLU/BRN
X23 - Vacuum Motor (M6)
Pin
Wire
A
017 BLU/GRA
B
018 BLK
X24 - Vacuum Motor (M7)
Pin
Wire
A
019 BLU/GRA
B
020 BLK
A
DELPHI 12052613
A
DELPHI 12052613
A
DELPHI 12052613
X25 - Main Broom Motor (M1)
Pin
Wire
A
043 BRN/VIO
B
044 BLK
A
DELPHI 12052613
X26 - Left Side Broom Motor (M9)
Pin
Wire
A
213 WHT/RED
B
214 BLK
A
DELPHI 12052613
118
Service Manual – CS7000
X27 - Main Broom Actuator (M21)
Pin
Wire
A
030 BRN/WHT
B
031 RED/VIO
C
032 BLU/ BLK
D
033 GRA/GRN
E
034 TAN/RED
F
---
Electrical System
A
F
DELPHI 12124107
X28 - Right Side Broom Motor (M8)
Pin
Wire
A
295 WHT/RED
B
297 BLK
A
DELPHI 12052613
X97 - Steering Actuator (M16)
Pin
Wire
1
299 ORN/BLK
2
202 WHT
3
203 BLU/GRA
4
208 YEL/RED
5
---
6
298 BLK
1
6
DEUTSCH DTM06-6S
119
Service Manual – CS7000
X98 - Steering Wheel Sensor (E4)
Pin
Wire
1
307 GRN/WHT
2
309 BLU
3
205 BLK
4
209 ORN/BLK
5
308 RED/WHT
6
310 GRN/BLK
7
206 BLK
8
211 ORN/BLK
9
199 BRN/WHT
10
329 GRA/ORN
11
---
12
---
Electrical System
12
1
DEUTSCH DTM04-12PA
X99 - Wheel Drive Motor (M24)
Pin
Wire
1
194 PINK/RED
2
198 PINK/BLU
3
197 PINK/WHT
4
288 BLK/PINK
AMP 282088-1
X100 - Wheel Drive Motor (M24)
Pin
Wire
1
187 TAN/RED
2
289 BLK/PINK
AMP 282080-1
X102 - Generator Harness Connector
(X107)
Pin
Wire
+
228 WELDING RED 3-0
-
235 WELDING BLK 3-0
AMP906
120
Service Manual – CS7000
Electrical System
X105 - Steering Travel Limit Switch, Left
(S17)
Pin
Wire
A
210 ORN/RED
B
270 GRA/ORN
A
DELPHI 12010973
X106 - Steering Travel Limit Switch, Right
(S16)
Pin
Wire
A
207 WHT/BLU
B
277 GRA/ORN
A
DELPHI 12010973
X109 - Side Broom Actuator (M13)
Pin
Wire
A
282 GRA/VIO
B
283 GRN/ORN
A
DELPHI 12015792
X111 - Pump, Solution Control (M19)
Pin
Wire
A
269 GRA
B
093 RED/YEL
A
DELPHI 12010973
X118 - Pump, Extended Scrub (M25)
Pin
Wire
A
041 GRA
B
042 VIO/ORN
A
DELPHI 12010973
X120 - Low Pressure Pump (M23)
Pin
Wire
A
266 GRA
B
171 GRN/WHT
A
DELPHI 12010973
121
Service Manual – CS7000
Electrical System
X122 - Dust Guard Pump (M22)
Pin
Wire
A
147 GRA
B
148 BRN/RED
A
DELPHI 12010973
X124 - Dump Door Actuator Motor (M26)
Pin
Wire
A
286 BRN/GRN
B
287 RED/GRA
A
TOP
SIDE
DELPHI 15300027
X126 - Hydraulic Pump, Hopper Lift (M10)
Pin
Wire
A
175 BLU/YEL
B
177 RED/BRN
A
DELPHI 12015792
X140 - Dust Guard Valve (L2)
Pin
Wire
A
086 GRA
B
087 BRN/RED
A
DELPHI 12015792
X145 - Drive Pedal Position Sensor (R1)
Pin
Wire
A
189 WHT/BLK
B
190 BRN/RED
C
191 VIO/BLK
A
DELPHI 12162182
122
Service Manual – CS7000
X153 - Tail Lamp, Left (LT9)
Pin
Wire
A
010 TAN/BLK
B
011 BLK/YEL
Electrical System
A
TOP
SIDE
DELPHI 12052641
X154 - Tail Lamp, Right (LT5)
Pin
Wire
A
012 TAN/BLK
B
025 BLK/YEL
A
TOP
SIDE
DELPHI 12124819
X161 - Left Head Lamp (LT3)
Pin
Wire
A
236 BRN
B
237 BLK/WHT
A
TOP
SIDE
DELPHI 12124819
X162 - Right Head Lamp (LT2)
Pin
Wire
A
274 BRN
B
276 BLK/WHT
A
TOP
SIDE
DELPHI 12124819
X165 - Curb Lamp
Pin
Wire
A
273 BRN
B
275 BLK/WHT
A
DELPHI 12015792
123
Service Manual – CS7000
Electrical System
X166 - Tail Lamp Harness Connector (X239)
Pin
Wire
A
094 ORN/BLU
B
107 TAN/BLK
C
285 BLK/YEL
D
101 YEL/GRN
A
DELPHI 12020832
X172 - Splice Saver Connector Comb
Pin
Wire
A
265 GRA
B
264 GRA
C
097 GRA
D
041 GRA
E
255 GRA
F
---
TOP
SIDE
A
DELPHI 12059573
X173 - Splice Saver Connector Comb
Pin
Wire
A
037 GRA
B
269 GRA
C
266 GRA
D
---
E
---
F
265 GRA
TOP
SIDE
A
DELPHI 12059573
X175 - Main Harness Connector
Pin
Wire
A
319 PINK
B
322 BLU/PINK
C
323 GRN/YEL
D
324 GRA
E
325 GRA/ORN
F
326 GRA/BLU
G
327 WHT/ORN
H
328 YEL/RED
J
330 TAN/WHT
K
334 BRN/ORN
L
335 ORN
M
---
A
M
DELPHI 15326915
124
Service Manual – CS7000
Electrical System
X178 - Back Up Alarm (H1)
Pin
Wire
A
037 GRA
B
076 GRN/BRN
A
DELPHI 12015792
X180 - Stop/Turn Lamp, Left (LT9)
Pin
Wire
A
023 ORN/BLU
B
009 BLK/YEL
A
DELPHI 12162000
X181 - Broom Motor Current Sensor (B2)
Pin
Wire
A
261 BLU/YEL
B
256 VIO/WHT
C
215 ORN/BLU
A
DELPHI 15326808
X182 - Vacuum Motor Current Sensor (B3)
Pin
Wire
A
262 BLU/YEL
B
257 VIO/WHT
C
184 RED/WHT
A
DELPHI 15326808
X183 - Brush Motor Current Sensor (B1)
Pin
Wire
A
263 BLU/YEL
B
258 VIO/WHT
C
178 BRN
A
DELPHI 15326808
125
Service Manual – CS7000
X184 - Stop/Turn Lamp, Right (LT11)
Pin
Wire
A
014 YEL/GEN
B
024 BLK/YEL
Electrical System
A
DELPHI 12162000
X187 - Battery Interlock Switch (S13)
Pin
Wire
A
315 TAN
B
338 GRN/BLU
A
DELPHI 12010973
X190 - Solution Solenoid Valve (L1)
Pin
Wire
A
157 YEL/ORN
B
089 VIO
A
DELPHI 12015792
X202 - Brake Switch (S5)
Pin
Wire
A
145 ORN/GRA
B
231 BLK
A
DELPHI 12010973
X204 - Hopper Interlock Switch (S3)
Pin
Wire
A
046 RED/BLK
B
230 BLK
A
DELPHI 12010973
126
Service Manual – CS7000
Electrical System
X236 - Dump Door Extend Limit Switch (S7)
Pin
Wire
A
290 ORN/RED
B
291 BLK
A
DELPHI 12010973
X238 - Dump Door Retract Limit Switch (S8)
Pin
Wire
A
292 YEL/WHT
B
293 BLK
A
DELPHI 12010973
X239 - Main Harness Connector (X166)
Pin
Wire
A
023 ORN/BLU
B
013 TAN/BLK
C
022 BLK/YEL
D
014 YEL/GRN
A
DELPHI 12020830
X255 - Scrub Deck Retract Limit Switch (S1)
Pin
Wire
A
161 RED/ORN
B
229 BLK
A
DELPHI 12010973
X256 - Scrub Deck Actuator Motor (M11)
Pin
Wire
A
132 RED/GRN
B
135 YEL/GRA
A
DELPHI 12052613
X257 - Beacon (LT10)
Pin
Wire
A
220 VIO
B
234 BLK
A
DELPHI 12015792
127
Service Manual – CS7000
X258 - Trouble Light (LT1)
Pin
Wire
A
316 YEL/BRN
B
232 BLK
Electrical System
A
DELPHI 12015792
X262 - Main Harness Connector (X1)
Pin
Wire
A
176 GRA
B
181 BRN/RED
C
223 WHT/GRA
D
224 BLK
E
225 YEL/VIO
F
226 BLK
G
259 ORN/GRN
H
260 BLK
J
267 VIO
K
268 BLK/RED
L
271 BRN
M
272 BLK/WHT
A
M
DELPHI 15326910
X263 - Main Harness Connector (X2)
Pin
Wire
A
---
B
218 ORN/YEL
C
279 BLK/YEL
D
281 YEL/RED
E
282 GRA/VIO
F
283 GRN/ORN
G
286 BRN/GRN
H
287 RED/GRA
J
290 ORN/RED
K
291 BLK
L
292 YEL/WHT
M
293 BLK
N
294 WHT/RED
P
296 BLK
A
P
DELPHI 15326922
128
Service Manual – CS7000
Electrical System
X265 - Engine Harness Connector
Pin
Wire
A
321 PINK
B
341 PINK
C
318 BLK/RED
D
317 PINK/YEL
E
---
F
322 BLU/PINK
G
323 GRN/YEL
H
---
J
---
K
---
L
---
M
---
N
---
P
---
R
---
S
---
A
TOP
SIDE
S
DELPHI 15326868
X266 - Engine Harness Connector
Pin
Wire
A
---
B
---
C
324 GRA
D
---
E
---
F
---
G
---
H
---
J
325 GRA/ORN
K
326 GRA/BLU
L
---
M
---
N
---
P
---
R
---
S
---
A
S
DELPHI 15326863
129
Service Manual – CS7000
Electrical System
X268 - Extended Scrub Level Switch (S4)
Pin
Wire
A
035 GRA/YEL
B
036 BLK
A
DELPHI 12015792
X270 - Main Harness Connector (X271)
Pin
Wire
A
017 BLU/GRA
B
018 BLK
C
019 BLU/GRA
D
020 BLK
A
B
DELPHI 12015798
X271 - Vacuum Motor Harness (X270)
Pin
Wire
A
026 BLU/GRA
B
027 BLK
C
028 BLU/GRA
D
029 BLK
A
D
DELPHI 12015024
X274 - Engine Interface Harness Connector
(X175)
Pin
Wire
A
123 PINK
B
129 BLU/PINK
C
108 GRA/YEL
D
102 GRA
E
131 GRA/ORN
F
134 GRA/BLU
G
118 WHT/ORN
H
117 YEL/RED
J
112 TAN/WHT
K
355 ORN
L
222 BRN/ORN
M
---
A
M
DELPHI 15326910
130
Service Manual – CS7000
Electrical System
X275 - Fuel Pump (M20)
Pin
Wire
A
317 PINK/YEL
B
318 BLK/RED
A
DELPHI 12010973
Wiring Connections
K14 Safety Relay and K15 Auxiliary Relays
Early Style K14 Safety Relay
6 = GRA/ORN
4 = PINK
A = VIO
B = ORN or ORN/GRY
Early Style K15 Auxiliary Relay
TAN/GRN
BLK/WHT
VIO/RED
GRA/WHT
ORN (2)
BLK X195
131
Service Manual – CS7000
Electrical System
Late style K14 Safety Relay and K15 Auxiliary Relay
GRAY/ORN
K14 Safety Relay
Pink
GRAY/ORN (2)
BLK/WHT
GRA/WHT
VIO
ORN (2)
K15 Auxiliary Relay
TAN/GRN
VIO/RED
BLK X195
K14 Safety Relay
K15 Auxiliary Relay
132
Service Manual – CS7000
Electrical System
Maintenance and Adjustments
Charging the Battery (Battery Model)
See User Manual
Generator Drive Belt
The generator drive belt tension is maintained by an auto-tensioner and does not require adjustment.
Troubleshooting
42 volt generator is not charging
Potential Causes
• Broken or slipping drive belt - Check the drive belt
• No power to voltage regulator terminal - Check for battery voltage (36v) to the voltage regulator connector
• Open or corroded cable connections - visually inspect cable connections
• Generator/Regulator assembly
Insufficient machine operation time (Battery Model)
Potential Causes
• Battery is not fully charged
• Loose or corroded cable connections
• Battery
Insufficient machine operation time with engine off (Hybrid models)
Potential Causes
• Battery is not fully charged
• Loose or corroded cable connections
• Battery
133
Service Manual – CS7000
Electrical System
Removal and Installation
42 volt Generator Drive Belt
Note: Instructions are for both diesel and LPG models. Photos are of diesel.
1. Lift hopper up, engage hopper prop rod and then lower to safety lock position.
2. Open the side cover and remove the lower panel.
Open
Remove
3. Remove the retaining pin and swing out the fuel tank.
4. Remove the 36v battery pack top cover.
5. Disconnect the main battery negative and positive cables.
6. Remove the two battery pack tray to frame attachment bolts.
7. Slide the battery pack tray outboard to the end of the tether cable.
Tether Cable
134
Service Manual – CS7000
Electrical System
8. Remove the tank guard plate.
Tank Guard
Plate
Belt Guard
Bolts
a. Remove plate to frame bolts.
b. Remove the plate to belt guard bolts.
c. Remove the “P” clamp cable and fuel line fasteners.
9. Remove the belt tension release tool from the side of the starting battery.
Remove Bolts
Tool
10. Using the bolts that had attached the tool to the battery tray, bolt one end of the tool to the tensioner
pulley and bolt the other end to the generator pulley. Pull the two tool halves together by “tightening”
the long bolt. This will compress the auto-tensioner “spring” and release the tension on the drive belt.
Turn the bolt until there is enough slack to remove the belt.
Install Bolts
Tool
11. Remove the belt.
12. Reassemble in reverse order.
Tighten Bolt
135
Service Manual – CS7000
Electrical System
42 volt Generator
1. Remove Engine and Generator as an assembly. See relevant engine chapter.
2. Remove generator drive belt.
3. Label wiring for correct reassembly and then remove.
4. Support generator with a lift.
5. Remove generator to engine mounting bolts
Rear
Mounting
Bolt
Front
Mounting
Bolts
6. Remove generator.
7. Reassemble in reverse order.
Generator Drive Belt Tensioner
1. Remove Drive Belt.
2. Retract the tensioner tool bolt to relieve the spring tension.
3. Remove the tensioner tool.
4. Raise and lock hopper in place.
5. Remove lower rubber curtain fasteners to gain access to engine area and move the curtain aside.
6. Remove the tensioner mounting bolt from the back side of the generator mounting bracket. See photo.
In Here
7. Reassemble in reverse order.
136
Service Manual – CS7000
Electrical System
Head Light bulb - Standard 12v Halogen
1. Disconnect headlight electrical connector
Caution! DO NOT install a replacement halogen bulb into the socket while the headlight is
plugged in. If the configuration menu is set for LED headlights, up to 42 volts could
be available to the headlights. Plugging the 12 volt halogen bulb into a 42 volt source
could cause the bulb to shatter in your hand.
2. Replace Bulb
3. Enter the Configuration Menu, “Light Option and select “Standard Light”.
4. Re-connect the headlight electrical connector.
137
Service Manual – CS7000
Electrical System
Specifications
Battery (Battery Model)
Capacity - 98 AH @ 20 HR
Low Voltage Cut Out
The low voltage cut out specification in use is set in the user options menu.
Menu #
Cut Out AT:
Restore Operation at:
Battery Type
1
1.75v per cell (31.5v total)
2.15v per cell (38.7v total)
Wet
2
1.83v per cell (32.9v total)
2.09v per cell (37.6v total)
Gel
3
1.75v per cell (31.5v total)
2.09v per cell (37.6v total)
(User Preference)
Battery Run Time (Battery powered machine)
Approx 5.4 hours (770 AH, 6 hr rate, and 900 AH 5 hr rate)
Auxiliary Relay
Winding Resistance: 652 Ohms
Auxiliary Contactor
Winding Resistance: 118 Ohms
138
Service Manual – CS7000
Electrical System
Current Sensors
Amperage Measured
Voltage Output
120 A
4.5v
60 A
3.5v
45 A
3.25v
30 A
3.0v
15 A
2.75v
0A
2.5v
-60 A
1.5v
-120 A
0.5v
Input/Output Table
Nominal Value
Black voltmeter lead
on:
LT7
12V OFF / 0V ON
B-(Ground)
LT9
12V OFF / 0V ON
B-(Ground)
Output
Right Front Turn Lamp LT4
12V OFF / 0V ON
B-(Ground)
Output
Right Rear Stop/Turn LT11
Lamp
Tail Lamps
LT5 and
LT6
Dust Control Motor
K6
Grounds to
Contactor
energize
12V OFF / 0V ON
B-(Ground)
12V OFF / 0V ON
B-(Ground)
36V OFF / 0V ON
B-(Ground)
0-12V
J2-19
Battery 30.5- 38V
Engine ON 37-40.5V
Battery 30.5- 38V
Engine ON 37-40.5V
Battery 30.5- 38V
Engine ON 37-40.5V
Battery 30.5- 38V
Engine ON 37-40.5V
Battery 30.5- 38V
Engine ON 37-40.5V
Battery 30.5- 38V
Engine ON 37-40.5V
J2-9
Conn. Pin Wire
Desig.
Description
ID
J2
1
Output
Left Front Turn Lamp
J2
2
Output
Left Rear Tail Lamp
J2
3
J2
4
J2
5
J2
6
J2
7
119 BRN/
WHT
Output
Detergent Pump
M17
J2
8
Output
9
J2
10
J2
11
J2
12
Squeegee Actuator
Motor
Squeegee Actuator
Motor
Scrub Deck Actuator
Motor
Scrub Deck Actuator
Motor
Battery Negative
M12
J2
080 WHT/
GRN
078 BLU/
BRN
132 RED/
GRN
135 YEL/
GRA
162 BLK
J2
13
057 VIO
Power
Supply
VACC 1
J2
14
Output
Auxiliary Contactor
K9
J2
15
051 BLK/
ORN
163 BRN/
BLK
Output
Side Broom Motor
Contactor
K8
J2
16
063 GRN/
GRA
Output
Main Broom Motor
Contactor
K4
J2
17
045 BLU
Output
Vacuum Motor
Contactor
J2
18
150 BLK/
RED
Output
J2
19
116 WHT/
YEL
Output
091 ORN/
YEL
094 ORN/
BLU
098 YEL/
RED
101 YEL/
GRN
107 TAN/
BLK
064 BLK/
YEL
Output
Output
Output
Output
Output
Ground Supply
M12
M11
M11
Signal
PWM SIGNAL
(Reversing
Polarity)
Reversing
Polarity
Reversing
Polarity
Reversing
Polarity
Reversing
Polarity
Power supply
from Aux
Contactor
Grounds to
energize
Grounds to
energize
J2-8
J2-11
J2-10
B+
B-(Ground)
36V OFF / 0V ON
B-(Ground)
36V OFF / 0V ON
B-(Ground)
Grounds to
energize
36V OFF / 0V ON
B-(Ground)
K5
Grounds to
energize
36V OFF / 0V ON
B-(Ground)
Shaker Motor
ground
M14
Detergent Pump
M17
PWM SIGNAL Battery 30.5- 38V
(half second
Engine ON 37-40.5V
cycles)
PWM SIGNAL 0-12V
(Reversing
Polarity)
B-(Ground)
J2-7
139
Service Manual – CS7000
Electrical System
Desig.
Description
ID
Signal
J2
20
157 YEL/
ORN
Output
L1
ON/OFF signal
J2
21
160 BLU/
VIO
Output
Solution Solenoid
Valve
Grounds to energize
Detergent Pump
M18
J2
22
Output
Lamps Common
J2
23
167 BLK/
YEL
169 BRN
Output
J2
24
039 ORN/
RED
Output
J2
25
047 YEL/
BLU
Output
Head Lamps and Curb LT2,
Lamp
LT3,
PWM ground to turn LT8
on lights
Hydraulic Pump Motor K12
Contactor
Grounds to energize
Left Brush Motor
K1
Contactor
PWM SIGNAL 0-12V
(Reversing
Polarity)
Regulated 12V 12
supply
PWM ground to 0
turn on lights
Grounds to
energize
36V OFF / 0V ON
B-(Ground)
J2
26
015 WHT/ Output
VIO
Center Brush Motor
Contactor
K2
Grounds to
energize
36V OFF / 0V ON
B-(Ground)
J2
27
061 GRA/
RED
Output
Right Brush Motor
Contactor
K3
Grounds to
energize
36V OFF / 0V ON
B-(Ground)
J2
28
038 BLU/
ORN
Output
Grounds to
energize
36V OFF / 0V ON
B-(Ground)
J2
J2
J2
J2
29
30
31
32
------221 GRA/
BLU
Hydraulic Pump Motor K11
Contactor (K11)
Grounds to energize
Output
Detergent Pump
J2
J2
33
34
35
J3
1
Power
Supply
Power
Supply
Output
VACC6a
J2
Extended Scrub Pump M25
Power supply 36/40.5
from Aux Relay
Power supply 36/40.5
from Aux Relay
PWM ground 0-36V
J3
2
Output
Solution Control Pump M19
PWM ground
0-36V
J3
3
--054 BLK/
WHT
053 BLK/
WHT
042 VIO/
ORN
093 RED/
YEL
030 BRN/
WHT
PWM SIGNAL 0-12V
(Reversing
Polarity)
Output
J3-4
4
031 RED/
VIO
Output
0-36V
J3-3
J3
5
106 GRA/
VIO
Output
PWM SIGNAL
(Reversing
Polarity)
PWM SIGNAL
(Reversing
Polarity)
Reversing
Polarity
0-36V
J3
Battery 30.5- 38V
Engine ON 37-40.5V
J3-17
J3
6
Output
0-36V
J3-7
J3
7
111 BRN/
GRN
115 RED/
GRA
Main Broom Actuator
Reversing polarity
driver
Main Broom Actuator
Reversing polarity
driver
Side Broom Actuator
Reversing polarity
driver
Dump Door Actuator
0-36V
J3-6
J3
8
118 WHT/
ORN
Output
12V
B-(Ground)
J3
9
123 PINK
Output
J3
10
129 BLU/
PINK
Output
Output
M18
VACC6b
Dump Door Actuator
Reversing polarity
driver
High Pressure Pump
Clutch Coil
Ignition On Output
12v out to engine
system
Start Output
12v out to starter
M21
M21
M13
M26
M26
Y1
Reversing
polarity driver
Reversing
polarity driver
High Side
Driver Engine
12V
High Side
Driver Engine
12V
High Side
Driver Engine
12V
Nominal Value
Black voltmeter lead
on:
Conn. Pin Wire
12V
12V
J2-32
B-(Ground)
B-(Ground)
J2-21
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Conn. Pin Wire
Desig.
Description
ID
J3
11
131 GRA/
ORN
Output
Throttle 2 Output
J3
12
134 GRA/
BLU
Output
Throttle 1 Output
J3
13
137 BRN/
RED
Output
Dust Guard Control
(Pump and Valve)
High Side
0V or 12V
Driver Engine
12V
High Side
0V or 12V
Driver Engine
12V
L2, M22 Grounds to turn 0V
both on
J3
14
Output
J3
J3
J3
15
16
17
139 VIO/
BRN
144 BLK
142 BLK
250 GRN/
ORN
J3
J3
J3
J3
J3
J3
18
19
20
21
22
23
149 BLK
154 BLK
156 BLK
159 BLK
--059 VIO/
RED
Ground Supply
Ground Supply
Ground Supply
Ground Supply
Horn
Ground to turn on
Battery Negative
Battery Negative
Side Broom Actuator
Reversing polarity
driver
Battery Negative
Battery Negative
Battery Negative
Battery Negative
Power Supply
12V supply
J3
24
171 GRN/
WHT
Output
Low Pressure Pump
J3
J3
25
26
--058 GRA
Power Supply
VACC2
J3
27
Output
Backup Alarm
J3
J3
J3
J3
J3
28
29
30
31
32
076 GRN/
BRN
--166 BLK
----049 ORN/
BLK
Ground Supply
Battery Negative
Output
Glow Plug Output
J3
J3
33
34
--056 GRA/
BLK
Power Supply
VACC3a
J3
35
055 GRA/
BLK
Power Supply
VACC3b
J7
1
Input
J7
2
092 GRN/
BLU
095 GRN
J7
3
099 YEL
J7
4
102 GRA
Communication
Communication
Output
J7
5
J7
6
J7
7
J7
8
108 GRA/
YEL
112 TAN/
WHT
117 YEL/
RED
---
Ground Supply
Ground Supply
Output
Input
Input
Input
Signal
Nominal Value
Black voltmeter lead
on:
B-(Ground)
H2
Grounds to
energize
0V
B-(Ground)
M13
Reversing
Polarity
Battery 30.5- 38V
Engine ON 37-40.5V
J3-5
M23
Power supply 12V
from starting
battery
Grounds to
0V
energize
Also requires
internal
pressure switch
in pump
B-(Ground)
36V
B-(Ground)
0V
B-(Ground)
High Side
Driver Engine
12V
12V
B-(Ground)
36V
B-(Ground)
36V
B-(Ground)
Interlock Switch Input
Power supply
from Aux
Contactor
Power supply
from Aux
Contactor
Logic Input
36V
B-(Ground)
CAN Bus Low
Digital Signal
0 or 5V
B-(Ground)
CAN Bus High
Digital Signal
0 or 5V
B-(Ground)
Run Signal Input
Engine Logic
Input
Logic Input
12 V Engine Running
B-(Ground)
Engine Coolant
Temperature
Fuel Level Sender
Low LP Pressure
Switch
H1
Power supply
from Aux
Contactor
Grounds to
energize
B-(Ground)
S12
Analog Signal
S11
Logic Input
5V
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Service Manual – CS7000
Conn. Pin Wire
J7
J7
9
10
J7
11
J7
12
J7
J7
13
14
J7
15
J7
16
J7
17
J7
18
J7
19
J7
J7
20
21
J7
22
J7
23
J7
24
J7
25
174 VIO/
WHT
J7
J7
26
27
--178 BRN
J7
J7
28
29
J7
J7
30
31
J7
J7
32
33
--184 RED/
WHT
--215 ORN/
BLU
--032 BLU/
BLK
J7
34
J7
35
Desig.
--130 WHT/ Output
BRN
133 BLK
Output
050 YEL/
BRN
141 ORN
046 RED/
BLK
035 GRA/
YEL
143 WHT/
GRA
145 ORN/
GRA
151 YEL/
VIO
155 VIO/
GRN
--161 RED/
ORN
168 ORN/
RED
170 YEL/
WHT
172 BLU/
YEL
Electrical System
Description
ID
Signal
Nominal Value
Black voltmeter lead
on:
12v
A3
12V
B-(Ground)
B-
A3
Power out to
Control Panel
Ground for
Control Panel
36V
B-(Ground)
B-(Ground)
B-(Ground)
Special
Suppression Diode
Power Supply
Input
Input
Key Switch On Input
Hopper Interlock
Switch
Extended Scrub Level
Switch
Dust Control Filter
Switch
Brake Switch
Input
Hopper Fire Switch
S14
S3
Power supply
Logic Input
36V
0 or 5V
S4
Logic Input
0 or 5V
S6
Logic Input
0 or 5V
S5
Logic Input
0 or 5V
B-(Ground)
S10
Logic Input
0 or 5v
B-(Ground)
Input
Key Switch Start Input S14
Logic Input
0 or 36V
B-(Ground)
Input
S1
Logic Input
0 or 5V
B-(Ground)
S7
Logic Input
0 or 5V
B-(Ground)
S8
Logic Input
0 or 5V
B-(Ground)
Output
Scrub Deck Retract
Limit Switch
Hopper Dump Door
Extend Limit Switch
Hopper Dump Door
Retract Limit Switch
+5V
5V
B-(Ground)
Output
B-
5v Power out
to Current
Sensors
Ground
for Current
Sensors
0V
B-(Ground)
Input
Brush Motor Current
Sense
B1
Analog Signal 2.5 - 4.7
B-(Ground)
Input
Vacuum Motor Current B3
Sense
Analog Signal 2.5 - 4.7
B-(Ground)
Input
Broom Motor Current B2
Sense
Analog Signal 2.5 - 4.7
B-(Ground)
Input
POT High
R4
B-(Ground)
033 GRA/
GRN
Input
Wiper
R4
034 TAN/
RED
Input
POT Low
R4
Power supply 3.3V
for Main Broom
Actuator
Position
Sensor
Main Broom
0 to 3.3V
Actuator
Position
Sensor input
B- for Main
0V
Broom Actuator
Position
Sensor
Input
Input
Input
Input
B-(Ground)
B-(Ground)
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Electrical System
Wiring Diagrams
Wiring diagrams show how electrical components are connected together and to a large degree “how things
work”. They do not show where things are located. Here are some tips when using these diagrams. Every
component has both an “ID” and a “name”
Component ID
Component Name
Typically relays (and contactors) are “split up” so that the relay winding is separated from the contacts. The
“control” side of the relay is shown in one location and the “load” side of the relay is shown in another
location. The two pieces may or may not be on the same page.
K10 Contactor
Contacts on sheet 4
K10 Contactor
coil on sheet 1
When a circuit breaks across sheets there is a “sign post” at both ends to help you quickly identify where the
circuit leaves one sheet and picks up on another. The sign post may be the wire color or a circuit description.
On Sheet 1
On Sheet 1
.
On Sheet 2
On Sheet 5
The wiring diagrams show when a circuit passes through an in-line connector and identifies the two halves
of the connector. If you need to locate one of these connectors, see the Harness to Harness Connector
Locations section. To find a connector that plugs into a component, see the Component Locations section
to locate the component then follow the wire lead (if there is one) to the connector. If you need more detailed
information about what a multi-pin connector looks like and where the wires are located in the connector,
see the Connector Pin-Outs section.
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Engine System, Diesel
This chapter covers the fuel supply system, engine RPM governor control system and glow plug starting aid.
See the Kubota D1305 Workshop Manual 9Y111-00124.pdf for information related to the mechanical engine
and high pressure fuel injection system.
Functional Description
One of the engines available in the CS7000 is a Kubota Diesel (D1305-E3B-KEA-1). It is a three cylinder,
liquid cooled, naturally aspirated engine. It has mechanical injector pump that is fitted with an actuator
which physically moves the fuel lever inside the pump.
Fuel is stored in a tank on the right side of the engine compartment. The tank swings out to provide easier
access to the engine compartment and contains a fuel level sending unit. An electric pump supplies low
pressure fuel to the diesel injector pump. There is a replaceable fuel filter cartridge between the fuel pump
and the injector pump. The injector pump has s small “return” line that runs to the closest injector. The
return circuit is carried from injector to injector where it exits the rear injector and is connected to a hose
which returns back to the fuel tank. .
The engine uses glow plugs to aid in starting a cold engine. The main machine controller operates a glow
plug relay which supplies power to the glow plugs when needed.
The engine RPM is controlled with the Woodward APECS 3000 Electronic Engine Speed Governing System
based on requests from the main machine controller. The main machine controller sends signals to the
Woodward Gov. controller to request one of three engine speeds based on operator request or cleaning mode.
Note: There is a “dead man” level on the side of the injector pump that can be used to shut the
injection pump fuel down to shut off the engine manually.
Move to shut
down engine
Dead Man Lever
Dead man lever in normal run position
Dead man lever held in shut down position
The cooling system consists of a standard radiator and belt driven fan. Note that the fan pushes air away
from the engine and out through the radiator.
Service Manual – CS7000
Engine System, Diesel
Engine starter control
To get the engine starter to engage, the key switch is held in the start position which supplies 36 volts to the
main machine controller connector J7 pin 19. This is the start input request. The main machine controller
receives a 12 V supply on connector J3 pin 23 from the engine starter battery. It uses this voltage supply to
send voltage out connector J3 pin 10 to the starter solenoid.
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Fuel pump control
The main machine controller uses the same 12 V battery supply from connector J3 pin number 23 to operate
the fuel pump. When the key is turned on, 36 volts is supplied to the main machine controller connector J7
pin number 13. In response, the controller sends voltage out connector J3 pin number 9 to the oil pressure
switch. As the engine cranks oil pressure builds up causing the oil pressure switch to close and supply
voltage to the fuel pump. The other side of the fuel pump is connected to ground. If oil pressure is lost, the oil
pressure switch will open removing power from the fuel pump.
Engine Protection
The engine will be automatically shut down by the main machine controller if the engine overheats or oil
pressure is lost.
When the engine is running, the main machine controller sends a 12 volt power supply out on connector J3
pin number 9 to power up the governor controller When the main machine controller wants to shut down the
engine, it removes this power supply to the governor controller. When the governor loses the power supply it
causes the engine to shut down.
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Engine System, Diesel
Over Temperature Shutdown
Here is how the engine over temperature shutdown works. To monitor engine temperature, the main
machine controller sends a voltage through an internal resistor out connector J7 pin number 5 on the green
wire with a yellow stripe to the engine coolant temperature switch. The switch is normally open. When the
engine overheats the switch closes. The closing of the switch connects the voltage source to ground which
drops the voltage seen by the main machine controller to nearly 0 volts. An engine temperature fault occurs
when the coolant sensor switches to ground. This fault will be displayed on the Control panel. In response to
the overheat condition, the main machine controller waits five seconds to give the operator time to park the
machine then removes the power supply going out connector J3 pin number 9 from the APECS 3000
Governor controller, which causes the engine to shut down.
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Engine System, Diesel
Low Oil Pressure Shutdown
Here is how the low oil pressure shutdown works. The main machine controller sends 12 V out connector J3
pin number 9 to the APECS governor controller and the oil pressure switch. When there is oil pressure, the
switch connects the voltage back as an “engine run signal” to the main machine controller connector J7 pin
number 4. Once the main machine controller has seen that the engine is running, it continues to monitor
that voltage. If engine oil pressure is lost, the “engine run signal” to the main machine controller will also be
“lost” (voltage drops from 12v to 0v). In response, the main machine controller sets an oil pressure fault,
displays it on the control panel and immediately removes the power supply going out connector J3 pin
number 9 from the APECS 3000 Governor controller, which causes the engine to shut down.
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Engine System, Diesel
Engine RPM control
The Woodward APECS (Advanced Proportional Engine Control System) controller manages the engine RPM
through the use of an electronic actuator. The controller monitors the actual engine RPM via a speed sensor
which reads the flywheel ring gear teeth and compares it to the desired speed setting. The controller sends
out a pulse width modulated signal to an actuator, which is connected to the engine fuel control lever inside
the injector pump. The actuator is “spring loaded” in the “no fuel” position. This means that by default,
the actuator shuts off the fuel and prevents the engine from running when there is no electrical current
available. When the governor wants to increase the engine speed, it increases the amount of current it sends
through the actuator.
The main machine controller is responsible for telling the governor controller the desired RPM based on
the operator’s request or machine operation mode. It communicates this with two circuits; Throttle 1 and
Throttle 2. To request idle speed it does not apply voltage to either circuit. To request “Run” speed, it sends
out 12 volts on throttle 2 circuit only. To request “maximum power” speed, it sends out 12 volts on throttle 1
circuit only.
Speed Mode
Engine Speed
Throttle 1
Throttle 2
Idle
1700 RPM
0
0
Run
2200 RPM
0
12v
Maximum Power
2400 RPM
12v
0
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Engine System, Diesel
There are several conditions that will override the user’s engine speed request.
• High pressure wash forces to run speed.
• If the engine is at idle speed, the engine will be forced to the run speed when sweeping only or vacuuming
only. The force idle (neutral time-out) will return the engine to idle speed.
• If the engine is at idle or run speed, the engine will be forced to maximum power speed when scrubbing
only or scrubbing and sweeping. The force idle (neutral time-out) will return the engine to idle speed.
• If the override is run speed, the user can change between maximum power speed and run speed.
• If the override condition goes away (e.g. sweep system turns off) and the user has not changed the engine
mode, the engine is returned to the mode before the forced override.
The controller is capable of identifying some fault conditions and displaying a fault code. A flashing LED
displays the fault conditions. When power is first applied to the controller, the LED will flash just once for
one second to indicate that the LED is operational. If there is more than one fault, the LED will flash them
all. If there are no faults the LED will flash once every reset and from then on indicate the detection of
engine speed. The controller will attempt to shut the engine down for all faults and will not permit starting
after reset with fault 1, 5 and 6.
Note: If any fault in the APECS governor control system causes the engine to stall, the Engine
Warning message will be displayed on the control panel. This is because once the engine
stalls, engine oil pressure is lost and the main machine controller responds as it always does
when it sees a loss of oil pressure after the engine has been running. This means the main
machine controller will display the engine warning message and remove the power supply
from the APECS controller causing it to power down and turn off its status LED light.
Flash Code
Fault
Remedy
1
APECS unit not calibrated
Calibrate APECS unit
2
Engine Speed Excessive
Check parameter setting. Overspeed criteria may be
too sensitive
Check for electrical noise entering controller.
Check wiring and connections.
Check case ground.
Make sure linkage moves freely, without backlash.
Check tip of speed sensor.
3
Engine Speed too low
Check parameter settings.
Check linkage and the actuator travel.
Check load and make sure it is not greater than the
capacity of the engine.
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Engine System, Diesel
Flash Code
Fault
Remedy
4
Engine shutdown due to engine
protection input
Check parameter settings.
Check what may have triggered the protection input.
(Loss of oil pressure, engine overheat)
5
Factory settings lost
If calibration file is available, download calibration file
and cycle power again.
If controller still does not work or if no calibration file is
available, consult factory.
6
APECS unit failed
Electrical noise may be entering the controller.
Check wiring, shielding and connections to controller.
Cycle power to engine.
If controller still does not work, consult factory.
Glow plug control
The engine is equipped with glow plugs to assist starting a cold engine. The glow plugs have an internal
resistive element that increases in resistance as it heats up. This protects the glow plug from overheating by
reducing the current flow as it gets hot.
Whenever the key is turned on, the main machine controller tells the control panel to display the “glow plugs
on” icon and sends out 12 V from connector J3 pin number 32 to the glow plug relay winding. Since the other
side of the winding is connected to ground, this energizes relay which in turn supplies power from circuit
breaker 11 to the glow plugs. After approximately 10 seconds, the main machine controller de-energizes
the glow plug relay by removing the 12 volts from the winding which also removes the power from the glow
plugs.
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Engine System, Diesel
Component Locations
• Fuel tank - Right side of engine compartment
• Fuel level sending unit - Top of fuel tank
• Fuel pump - Top of fuel tank
• Fuel filter - Front left engine compartment area. Mounted on frame between engine and hopper.
• Injector pump
• APECS Governor Controller - Front engine area mounted on engine.
• Glow plugs
• Glow plug relay - Electrical panel area
Air Cleaner
• Engine starter
• Alternator (42v)
• Engine alternator (12v)
• Oil pressure switch
• Coolant temperature switch
• Actuator
• Engine RPM sensor
• Air Cleaner
Top of engine compartment with top covers removed
Fuel Pump
Fuel Tank
Fuel Level
Sending Unit
Fuel Tank (Shown with hopper up)
Fuel Tank (Shown swung out)
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Engine System, Diesel
Actuator
APECS Governor Controller
Fuel Filter
Injector Pump
Alternator (42v)
Front Engine Area (Hopper up and rubber curtain lifted)
Engine RPM Sensor
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Engine System, Diesel
Glow Plugs
Glow Plug Relay
Electrical Panel
Alternator (12v)
Oil Pressure
Switch
Engine - Back Side
Coolant
Temperature
Switch
Starter
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Maintenance and Adjustments
Diesel Engine Maintenance Schedule
First 50 hours:
• Change engine oil and filter
Every 50 hours:
• Check fuel hoses and clamps.
• Check restricted air filter indicator. Replace air filters as needed.
Every 100 hours:
• Check fan belt tension.
• Check engine starting battery
Every 200 hours:
• Change engine oil and filter
• Check radiator hoses and clamps
• Check intake air hoses
Every 400 hours:
• Replace the fuel filter
Every 500 hours:
• Flush cooling system
• Replace fan belt
Every 800 hours:
• Check valve clearance
Every 1500 hours:
• Check injection nozzle pressure
Every 3000 hours:
• Check injection pump timing
Every 2 years
• Replace radiator hoses and clamps
• Replace fuel hoses and clamps
• Replace intake air hoses
• Replace engine starting battery
Engine System, Diesel
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Engine System, Diesel
Change Engine Oil and Oil Filter
1. Drain the recovery tank for later removal.
2. Shut off the engine and allow it to cool sufficiently to avoid burning yourself with hot engine oil.
3. Remove the left side engine cover.
4. Tip the recovery tank outward. Remove the squeegee vacuum hose and release the recovery tank tether
cable, then lower the recovery tank to the ground for better access to the engine oil filter area.
5. Remove the oil filter with an oil filter wrench.
6. Apply a light coat of engine oil to the new filter cartridge gasket.
7. Screw the new cartridge on and tighten by hand. Over tightening may damage the gasket.
8. Remove the remote oil drain hose end from the radiator bracket.
9. Remove the plug and drain the oil into a suitable container.
10. Reinstall the plug-and reattach the drain hose to the radiator bracket.
11. Refill the engine with oil.
Change Engine Coolant
1. Allow the engine to cool sufficiently to relieve cooling system pressure and avoid burns.
2. Remove the radiator cap.
3. Remove the left side engine cover.
4. Locate the remote engine coolant drain hose, remove the plug and direct the coolant into a suitable
container.
5. Reinstall the drain plug and reposition the drain hose.
6. Refill with a 50/50 mixture of engine antifreeze and water.
Replace Fuel Filter
1. Raise the hopper, engage the hopper prop rod and lower the hopper onto the safety lock.
2. Loosen the screws along the bottom edge of the rubber curtain in front of the engine compartment and
move the curtain in order to gain access to the fuel filter.
3. Unscrew the filter from the filter base.
4. Apply a light coat of fuel oil on the cartridge gasket and screw it on by hand-tightening.
5. Bleed the air out of the fuel system as directed below, reinstall the rubber curtain and lower the hopper.
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Engine System, Diesel
Bleed Fuel System
Bleeding air out of the fuel system is required if the engine ran out of fuel, the fuel filter has been replaced
or the fuel lines have been opened.
CAUTION: To avoid personal injury; Do not bleed a hot engine as this could cause fuel to spill
onto a hot exhaust manifold creating a danger of fire.
1. Loosen the air vent plug at the top of the fuel filter housing.
2. Operate the fuel pump. (Cranking engine or jump with 12v power supply).
3. Tighten the air vent plug when bubbles no longer come up.
Inspect Air Filter
Check the service indicator mounted on the air cleaner elbow. If the red disc is visible in the “window”, the
filters should be cleaned or replaced.
Clear Window = Okay
Red in Window = Restricted Filters
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Engine System, Diesel
Replace Air Filters
1. Remove left side engine cover.
2. Open right side engine cover and swing out fuel tank.
3. Remove the top engine covers by:
a. Disconnecting the gas spring from one end.
b. Remove two bolts, one on each side, under the cover and lift the cover assembly off.
Gas Spring
Remove
Remove
Remove Top Engine Cover Fasteners
4. Release the latches and remove the air filter housing cover.
5. Remove the outer filter element.
6. Blow out air cleaner housing with compressed air with inner filter element still in place to prevent dirt
from entering the engine air intake.
7. Remove the inner filter element.
8. Clean residual dust from the inside of the air cleaner housing, taking care to prevent any dirt or debris
from entering the air intake.
9. Install a new inner filter element and then the new outer filter element making sure that they seal well
at their ends.
10. Install the air cleaner housing cover. “Top” is indicated on the cover.
11. Set the top engine cover in place.
12. Install the two fasteners finger tight, then close the cover and allowing it to latch properly.
13. Now, tighten the fasteners with a wrench.
14. Open the top cover, swing the fuel tank back into position and the right engine cover.
15. Install the left engine cover.
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Engine System, Diesel
Troubleshooting
No crank – The starter does not engage
Possible causes
Check
36v Battery Pack drained
Battery pack voltage
Engine Battery
Load test battery
Starter
Check power to starter solenoid
Battery Cable
Check voltage drop from battery positive to starter battery terminal.
Engine Ground
Check voltage drop from starter case to battery negative.
No voltage to the starter solenoid
Check for tripped circuit breaker #9 (CB9)
• Auxiliary Relay
• Key Switch
• Main Machine controller
Cranks but does not start
Possible causes:
• No fuel
–– Empty Tank
–– Insufficient fuel supply
◦◦ Clogged Filter
◦◦ Clogged line
◦◦ Fuel pump
• Contaminated fuel
• APECS governor controller
• Engine RPM Sensor
• Actuator
• Incorrect injection timing
• Injection pump
• Mechanical engine
–– Insufficient compression
–– Fuel camshaft worn
• Plugged Intake
• Plugged Exhaust
Check for power to the main machine controller from the Auxiliary Relay
Check for power to the main machine controller from Key Switch
cranking circuit
Check powers, grounds, inputs and crank request output
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Engine System, Diesel
Diagnostic steps:
1. Check governor control system.
a. Does the APECS governor controller status light flash once immediately following “key on”?
If not, check power and grounds for the APECS governor controller
If so, go on to next step
b. Does the status light come on during cranking?
If not, check the Engine RPM sensor input. (Resistance and voltage output while cranking)
If so, go on to next step
c. Is there more than 4 volts available to the actuator during cranking?
If not, the governor controller may have failed.
If so, the governor controller appears to be working correctly. Check the fuel actuator
2. Check the fuel actuator
a. Check the actuator resistance. It should be around 3.0 ohms.
If it is open or shorted, replace the actuator. If it is Okay, go to the next test.
b. Substitute the function of the actuator by removing it from the injection pump and operating the
throttle control manually. (You can reach into the hole and operate it with your finger or use the
dead man lever on the side of the injector pump)
3. Check fuel system
a. Check the fuel for contamination
b. Check the fuel pressure to the injector pump during cranking
If the fuel supply system is Okay, check the mechanical engine.
4. Check mechanical engine
a. Check compression
b. Check for plugged intake or exhaust
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Engine System, Diesel
Cannot Achieve Either Run or Maximum Engine Speed Settings (Run 2200 RPM,
Maximum Power 2400 RPM).
The approach to diagnosing an engine RPM control problem is to check the inputs to the governor controller
and check the output to the actuator. If the inputs are good and the output is bad, the conclusion is that the
controller is the problem. If the output control is okay but the RPM doesn’t change, then the actuator is the
likely problem. However, don’t forget that insufficient fuel supply or a restricted exhaust could appear like
an RPM control problem if the engine cannot run well enough to achieve a higher RPM.
Possible Causes:
• Actuator
• APECS 3000 Governor Controller
• Wiring
• Main Machine Controller
Diagnostic steps:
1. Check the power and ground supplies to the controller.
a. Is there sufficient power and ground?
◦◦ If so, go on to check the speed request inputs.
◦◦ If not, repair.
2. Check the speed request inputs
a. With the engine running press the engine speed button and check for 12v to the throttle 1 and
throttle 2 wires at the governor controller.
b. Is 12v present on either of the throttle wires with the engine running at idle speed?
◦◦ If so, go on to check the actuator output
◦◦ If not, check the wiring between the main machine controller and the governor controller.
3.
Check the actuator output.
a. Does it change with the speed request?
◦◦ If so, the actuator is the likely problem.
◦◦ If not, the controller appears to be the problem.
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Service Manual – CS7000
Engine System, Diesel
Compression Test
1. Begin with a fully charged battery.
2. Remove the air cleaner assembly. Cover the air inlet opening to prevent foreign objects from falling into
the engine.
3. Remove the glow plug electrical connector nuts and connector “rail”.
Remove nuts
Remove
connector
“rail”
4. Insulate the electric terminal that feeds the rail to prevent it from shorting to ground.
Insulate
Terminal
5. Clean the area around the glow plugs to prevent any debris from falling into the engine cylinders when
they are removed. Remove the glow plugs.
6. To test the compression of one of the cylinders, screw in an appropriate adapter into the glow plug
threads in the cylinder head and attach a suitable compression gauge. Pictured are Snap-On Diesel
Compression gauge EEPD500 used with compression test adapter fitting TU-15-35 and coupler M3569.
Snap-On
TU-15-35
Snap-On
M3569
Snap-On
EEPD500
175
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