Nilfisk-Advance CS7000 Service Manual
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Nilfisk-Advance CS7000 Service Manual

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CS7000™

Service Manual

Advance
56383115(48 Fuel Cell EcoFlex)
56509000(48 LPG Hybrid),
56509001(48 Diesel Hybrid)
56509002(48 Battery)
56509006(48 LPG Hybrid EcoFlex)
56509007(48 Diesel Hybrid EcoFlex)
56509008(48 Battery EcoFlex)
56511001(48 Gasoline/Petrol Hybrid
EcoFlex)
56511540(48 LPG LEV Hybrid)
56511541(48 LPG LEV Hybrid EcoFlex)
Nilfisk
56509003(1200 LPG Hybrid)
56509004(1200 Diesel Hybrid)
56509005(1200 Battery),
56511002(1200 Gasoline/Petrol
Hybrid)
56384409(1200 LPG Hybrid),
556384410(1200 Battery)
56511564(1200 LPG LEV Hybrid)
05/11 Revised 09/15 Form No. 56043151
English

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Questions and answers

David Chavez
March 15, 2025

We have aSc7000 scrubber Ecoflex and propane we have problems with the scrubber and sweeping brooms is not function except the scugge vacuum no codes is traveling back and forward tested on maint menu everything work manually can you help me to find the problem.

0
1 comments:
Mr. Anderson
March 15, 2025

Possible issues with the Nilfisk-Advance CS7000 scrubber and sweeping brooms not functioning, despite the scrubber vacuum working and no error codes displayed, could include:

1. Main Broom Motor Overload or Short Circuit – If the broom motor has been overloaded or there is a short circuit, the sweep functions will be disabled. Checking the broom height adjustment after installing a new broom may help.

2. Broom Motor Current Sensor Fault – If the main broom motor contactor has been off for more than 5 seconds, but the broom motor current sensor is still reporting a current above 6A, the sweep functions may be disabled. Ensuring the sensor is reading the correct wires may resolve this.

3. Brush Motors Current Sensor Fault – If the brush motor contactors have been off for more than 5 seconds, but the brush motor current sensor is reporting a current above 6A, the scrub functions may be disabled. Checking the sensor connections may help.

If no error codes are displayed, manually inspecting the broom and brush motor circuits, checking for loose connections, and ensuring proper sensor operation may help identify the issue.

This answer is automatically generated

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Summary of Contents for Nilfisk-Advance CS7000

  • Page 1: Service Manual

    CS7000™ Service Manual Nilfisk Advance 56383115(48 Fuel Cell EcoFlex) 56509003(1200 LPG Hybrid) 56509000(48 LPG Hybrid), 56509004(1200 Diesel Hybrid) 56509001(48 Diesel Hybrid) 56509005(1200 Battery), 56509002(48 Battery) 56511002(1200 Gasoline/Petrol Hybrid) 56509006(48 LPG Hybrid EcoFlex) 56384409(1200 LPG Hybrid), 56509007(48 Diesel Hybrid EcoFlex) 556384410(1200 Battery)

  • Page 2: Table Of Contents

    Service Manual – CS7000 Contents Contents General Information General Machine Description Service Manual Purpose and Application Revision History Other Reference Manuals and Information Sources Nilfisk-Advance Publications Engine Manufacturers’ Technical Manuals Conventions Parts and Service Nameplate Cautions and Warning Symbols General Safety Instructions...
  • Page 3 Service Manual – CS7000 Contents 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 Chassis System Component Locations - Battery Machine (major components)
  • Page 4 Service Manual – CS7000 Contents 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...
  • Page 5 Service Manual – CS7000 Contents 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 Step Two Engine Overheat Shutdown Lost Oil Pressure Shutdown...
  • Page 6 Service Manual – CS7000 Contents Replace Air Filters Troubleshooting Engine Management System Checking Spark Checking LPG Primary Pressure Removal and Installation Engine Assembly Specifications Fuel System Engine Oil Engine Coolant Shop Measurements Ignition System Fuel System Engine Special Tools Engine System - Petrol (Gasoline)
  • Page 7 Service Manual – CS7000 Contents Spark Controller Measurements: Governor Control System Woodward L Series Actuator Measurements Fuel System Engine Special Tools Engine System, Diesel Functional Description Engine starter control Fuel pump control Engine Protection Over Temperature Shutdown Low Oil Pressure Shutdown...
  • Page 8 Service Manual – CS7000 Contents viii Hopper Hydraulic System Circuit Details Hopper at Rest Hopper Being Raised Hopper Being Lowered Circuit Description Component Locations Upper and Lower Hopper Hydraulic Power Pack Assembly Hopper Dump Door Hopper Dump Door Actuator Dump Door Extend and Retract Limit Switches...
  • Page 9 Service Manual – CS7000 Contents 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...
  • Page 10 Service Manual – CS7000 Contents To Remove and Reinstall the Solution Tank To Remove and Reinstall the Solution Shutoff Valve To Remove and Reinstall the Solution Filter Assembly To Remove and Reinstall the Solution Solenoid Valve To Remove and Reinstall a Detergent Pump (EcoFlex™ Models Only)
  • Page 11 Service Manual – CS7000 Contents 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...
  • Page 12 Service Manual – CS7000 Contents 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...

  • Page 13: General Information

    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...

  • Page 14: Other Reference Manuals And Information Sources

    56041983: Spanish, 56042541 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...

  • Page 15: Engine Manufacturers' Technical Manuals

    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.

  • Page 16: Cautions And Warning Symbols

    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.
  • Page 17 Continued operation under this condition may result in damage to the engine, catalytic converter or other machine components. • 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.

  • Page 18: Hopper Prop Rod

    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 Press and hold the hopper raise button to raise the hopper all the way up.

  • Page 19: Jacking The Machine

    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).

  • Page 20: Towing The Machine

    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.

  • Page 21: 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 •...

  • Page 22: Technical Specifications

    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 With overhead With overhead With debris hopper raised –...
  • Page 23 Service Manual – CS7000 General Information Solution System Solution Tank Capacity 75 gal. [284 L] Recovery Tank 75 gal. [284 L] Capacity Solution Pump Precision-flow electric pump/solenoid valve Flow Rates One Light Two Lights Four Lights Five Lights Three Lights 1 gpm [3,79 1.5 gpm...
  • Page 24 Service Manual – CS7000 General Information Vacuum System Vacuum Sealed 48” H2O With 1” dia. Orifice 25” to 30” H2O Vacuum Motor 42 VDC, 15 Amps average, 17 Amps max. Drive System Steering Rear wheel, “steer-by-wire” system. The steering controller receives input from the steering wheel to drive the steering actuator motor.

  • Page 25: Fastener Torque Specifications

    Service Manual – CS7000 General Information Noise and Vibration Hybrid LPG Hybrid Diesel Battery Machine Operator Sound Levels 82 dBA 81 dBA 72 dBA @ Operator’s Ear Sound Power LwA 103 LwA 102 Hand/Arm Vibration 0.33 m/s2 0.35 m/s2 0.36 m/s2...

  • Page 26: Overall Dimensions

    Service Manual – CS7000 General Information Overall Dimensions 4” [10 61” [155 48” [122 103” [262 59” 150...

  • Page 27: Maintenance

    Service Manual – CS7000 General Information 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: •...

  • Page 28: Maintenance Every 15 To 20 Hours

    Service Manual – CS7000 General Information Maintenance Every 15 to 20 Hours Maintenance Item Procedure Check the electrolyte level in the battery. Battery/Batteries Check the battery cables and connections. Solution tank filter Inspect and clean the debris filter on the solution filter system.

  • Page 29: Maintenance Every 800 To 1000 Hours

    Service Manual – CS7000 General Information 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.

  • Page 30: Lubrication Points

    Service Manual – CS7000 General Information Lubrication Points Recovery Engine/Battery Tank Latch Compartment (oil) Latch (oil) Brake Pedal (parking brake) Linkage (oil) Squeegee Tool End Wheel (2) (oil) Squeegee Caster Wheel Axle and Steering Pivot (2) (grease) Gears (grease)

  • Page 31: Ecoflex System Maintenance

    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.

  • Page 32: To Change The Detergent Mix Ratio (The Scrub System Must Be On)

    Service Manual – CS7000 General Information To Change the Detergent Mix Ratio (the scrub system must be on) Press and hold the detergent switch for two seconds. Release the switch once the detergent indicator begins flashing. While the light is flashing, press and release the detergent switch to select the next detergent mixture ratio.

  • Page 33: Pm Checklist

    Service Manual – CS7000 General Information PM Checklist Nilfisk-Advance CS7000 PM Checklist Defect Codes Customer needs adjustment binding Address dirty or contaminated damaged, bent or torn City leaks missing Model # Serial # Hours worn out Does Defect Codes Operational Inspection Items...
  • Page 34 Service Manual – CS7000 General Information Does Defect Codes Visual Inspection Items Comments (circle) Work                         ...

  • Page 35: Machine Controls

    Service Manual – CS7000 General Information Machine Controls Control Panel - General Layout Miscellaneous The CS7000 control panel is Controls organized by machine function with the scrub, sweep and hopper functions conveniently grouped together. Miscellaneous controls such as the key switch, emergency-...

  • Page 36: Miscellaneous Indicators

    Service Manual – CS7000 General Information – Battery machines – increases the machine scrub speed to the full transport speed. • – switches on the headlights. Headlight Switch • – sounds the horn when pressed. Horn Button • – engages the high-pressure spray wand solution pump (LPG and diesel only).

  • Page 37: Scrub Controls

    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 Solution will light to Pressure Scrub Switch...

  • Page 38: Scrub Indicators

    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. Solution Scrub • – lights Flow Burst of Power Indicator...

  • Page 39: Sweep Indicators

    Service Manual – CS7000 General Information • – enables and disables the dust control fan. Dust Control Fan Switch • – functions as follows: Broom Select Switch – When the one-touch sweep is enabled, the selects the broom (main broom or side...

  • Page 40: Hopper Controls

    Service Manual – CS7000 General Information Hopper Controls • – raises the Hopper Raise Button Hopper hopper. Door Open Hopper Raise Button • – lowers Hopper Lower Button Button the hopper. Hopper • – opens Hopper Door Open Button Door Hopper the hopper door.

  • Page 41: Diesel Machine

    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 Dilution Solution Engine time, the recycle system icon (if actuated) and the fuel...

  • Page 42: Fault, Caution And Warning Displays

    Service Manual – CS7000 General Information Alternate/Maintenance-free Battery Charge Indicator Standard Battery 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...

  • Page 43: Warning Displays

    Service Manual – CS7000 General Information Caution Condition causing Fault Display Icon The batteries need to be Low-voltage Cutout charged. Hopper temperature has Hopper Temperature exceeded the operational temperature. Solution Level Low Solution level has been low (Icon number 246)

  • Page 44: Steering Wheel

    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 Steering Wheel wheel.

  • Page 45: Chassis System

    Service Manual – CS7000 Chassis System Component Locations - Battery Machine (major components) Battery Rear Battery Stop Plate Cover Assembly Assembly Battery Front Engine Guide Cover Weldment Assembly Battery Stop Weldment Right Door Assembly Pull Rod Assembly Dust Shield Left Cover...

  • Page 46: Component Locations - Lpg And Diesel Machine (Major Components)

    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...

  • Page 47: Control System

    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.

  • Page 48: Can Bus Circuit

    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.

  • Page 49: Can Bus Message Routing

    Service Manual – CS7000 Control System ◦ Push Mode On/Off CAN BUS message routing ◦ Transport Mode On/Off The following outline describes what messages are communicated over the CAN Bus from one controller ◦ Sweep System On/Off to another. ◦ Scrub System On/OffMachine (Power Plant)

  • Page 50: Steering Controller

    Service Manual – CS7000 Control System ◦ Transport Mode On/Off – To Drive Controller ◦ Sweep System On/Off ◦ None ◦ Scrub System On/Off – To Control Panel ◦ Power Plant Type - Battery/Engine (Hybrid) ◦ None ◦ Hopper Up/Down •...

  • Page 51: Component Locations

    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,...

  • Page 52: Troubleshooting

    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”...

  • Page 53: Fault Code Table (Main Machine Controller)

    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.
  • Page 54 Service Manual – CS7000 Control System Fault # Description Setting Conditions Consequences VACC3 circuit breaker tripped Aux Contactor energized with no voltage at J3-34 VACC3a and J3-35 VACC3b VACC6 circuit breaker tripped Key on with no voltage at J2-34 VACC6a and J2-35 VACC6b Scrub Deck Actuator (M11) >...
  • Page 55 Service Manual – CS7000 Control System Fault # Description Setting Conditions Consequences Chemical (Detergent) pump M18 > 2.5 Amps or short circuit Disables detergent. overload Vacuum Contactor (K5) Winding > 4 Amps or short circuit Disables detergent, Circuit Overload solution, scrub motors and recovery.
  • Page 56 Service Manual – CS7000 Control System Fault # Description Setting Conditions Consequences Main Broom Motor (M1) Overload > 28 Amps for 30 seconds or Disables sweep functions. short circuit Note: If this code is set after installing a new broom, adjust the broom height.

  • Page 57: Hidden Menus

    Service Manual – CS7000 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;...
  • Page 58 Service Manual – CS7000 Control System The Following is an outline of the menu: Description (Early main controller) Description (Late main controller) Machine Type Machine Type Battery Type Battery Type Detergent System Detergent System EcoFlex System EcoFlex System Dust Guard system...

  • Page 59: Configuration Menu

    Service Manual – CS7000 Control System 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”...
  • Page 60 Service Manual – CS7000 Control System The following is an outline of the configuration • 7 Back-Up Alarm menu. Default values are bold text. – 1 Not Installed • 1 Machine Type – 2 Installed – 1 Undefined (When the machine type is •...
  • Page 61 Service Manual – CS7000 Control System • 15 or 16 Service Menu − Scrub Pressure Increase (+) switch: Turn on Medium Scrub LED2 – 1 Service Mode (Must turn key off to exit service mode) − Scrub Pressure Decrease (-) switch: Turn on Heavy Scrub LED3 ◦...
  • Page 62 • 16 or 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”. – 17 or 18 Haram Captor – 1 No (Use for all CS7000 models)

  • Page 63: User Options Menu

    Service Manual – CS7000 Control System 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: While pressing and holding the One-touch scrub switch AND the solution switch, turn the key on.
  • Page 64 Service Manual – CS7000 Control System 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.
  • Page 65 Service Manual – CS7000 Control System ◦ 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 ◦...
  • Page 66 Service Manual – CS7000 Control System – 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).
  • Page 67 Service Manual – CS7000 Control System • 7 Reduced Speed Mode - The CS7000 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.

  • Page 68: Service Mode

    Service Manual – CS7000 Control System Service Mode The service mode makes electrical troubleshooting faster and easier. It allows you to use the machine interface to “read” some controller inputs and to “directly” turn on many outputs in order to quickly determine whether the problem is on the “input side”...
  • Page 69 Service Manual – CS7000 Control System Press the One-touch scrub switch to enter the service menu. 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..
  • Page 70 Service Manual – CS7000 Control System − BRM, VAC and RUN are intended for engineers. All values are hexadecimal. − MIL (Malfunction Indicator Lamp) is the input request from the engine controller (LPG LEV engine only) to the main controller to turn on the “check engine” icon..

  • Page 71: To Operate

    Service Manual – CS7000 Control System 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.
  • Page 72 Service Manual – CS7000 Control System 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).
  • Page 73 Service Manual – CS7000 Control System 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. Dust Guard Pump Pressing the dust guard spray switch will turn on the dust guard pump and illuminate the dust guard on indicator.
  • Page 74 Service Manual – CS7000 Control System 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.

  • Page 75: Control Panel Leds All Stay Lit - Can Bus Problems

    Service Manual – CS7000 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.

  • Page 76: Removal And Installation

    Service Manual – CS7000 Control System Removal and Installation Main Machine Controller Turn the key switch off and disconnect the main battery connector. Remove the recovery tank. Remove the control panel plate to frame fasteners 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.

  • Page 77: Control Panel

    Service Manual – CS7000 Control System Control Panel Empty the solution tank. (The tank must be empty upon reassembly for the solution level indicator to work properly). Disconnect the main battery connector. Remove key and key switch retaining nut. Remove the 6 control panel mounting screws.

  • Page 78: Specifications

    Service Manual – CS7000 Control System 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.

  • Page 79: J3 Connector (Gray)

    Service Manual – CS7000 Control System J2 Pin Wire Circuit Description Value/Condition 116 WHT/YEL Detergent Pump (M17) Pulsed voltage is too fast for useful measurement value 157 YEL/ORN Solution Solenoid Valve 0.1v when energized Grounds to energize 160 BLU/VIO Detergent Pump (M18)
  • Page 80 Service Manual – CS7000 Control System J3 Pin Wire Circuit Description Value/Condition 111 BRN/GRN Dump Door Actuator Reversing 37v at rest or closing 0.07v opening polarity driver 115 RED/GRA Dump Door Actuator Reversing 37v at rest or opening 0.03v closing...

  • Page 81: J7 Connector (Black)

    Service Manual – CS7000 Control System J3 Pin Wire Circuit Description Value/Condition 049 ORN/BLK Glow Plug Output 12v out to 11.6v when glow plug relay energized 0v energize relay key off or after time out period 056 GRA/BLK VACC3a Power supply from...
  • Page 82 Service Manual – CS7000 Control System J7 Pin Wire Circuit Description Value/Condition 168 ORN/RED Hopper Dump Door Extend 0.0v full closed position 4.8v otherwise Limit Switch 170 YEL/WHT Hopper Dump Door Retract 0.0v wide open position 4.8v otherwise Limit Switch...

  • Page 83: Dust Control/Dustguard™ Systems

    Service Manual – CS7000 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 ™...

  • Page 84: Dustguard™ Spray System (Optional)

    Service Manual – CS7000 Dust Control/DustGuard Systems ™ DustGuard™ Spray System (optional) pumps water from a separate DustGuard Pump reservoir in the upper hopper to on the Nozzles front of the machine. The direct a fine Nozzles stream of water onto the floor in front of the side...

  • Page 85: Dustguard™ System Wiring Diagram

    Service Manual – CS7000 Dust Control/DustGuard Systems ™ DustGuard™ System Wiring Diagram Battery Fuse, 400 A A1 Main Machine Controller A3 Control Panel WHT/BRN J7-10 +12V J1-1 42V Alternator J7-11 B- J1-2 J7-3 CAN H J1-3 VIO/GRN J7-2 CAN L...

  • Page 86: Circuit Description

    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 .

  • Page 87: Component Locations

    Service Manual – CS7000 Dust Control/DustGuard Systems ™ – The must receive a signal from the via the that A1 Main Machine Controller A2 Drive Controller CAN BUS the machine is moving forward. • The provides the negative ground to the...

  • Page 88: Dust Control Filter Switch

    Service Manual – CS7000 Dust Control/DustGuard Systems ™ Dust Control Filter Switch The optional is mounted above Dust Control Filter Switch on the . The Filter Shaker Assembly Upper Hopper Dust will close and generate a warning if Control Filter Switch the hopper vacuum gets too high, indicating a plugged .

  • Page 89: Dustguard™ Spray System

    Service Manual – CS7000 Dust Control/DustGuard Systems ™ DustGuard™ Spray System is mounted on the DustGuard Pump Upper Hopper is protected by the . The screens the Pump Guard Strainer incoming water upstream of the . The DustGuard Pump , downstream of the...

  • Page 90: Maintenance And Adjustments

    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 Lift the hopper cover.

  • Page 91: To Clean The Dust Control Filter

    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. 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.

  • Page 92: To Clean The Dustguard™ Strainer Screen

    Service Manual – CS7000 Dust Control/DustGuard Systems ™ To Clean the DustGuard™ Strainer Screen 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 and drain the upper hopper through the...

  • Page 93: To Clean The Dustguard™ Spray Nozzles

    Service Manual – CS7000 Dust Control/DustGuard Systems ™ To Clean the DustGuard™ Spray Nozzles Raise the hopper slightly if desired for easier access to the DustGuard™ nozzles. 7/8” Wrench Note: Place a suitable container underneath the Plastic nozzles to catch any water that may leak Nozzle from the hoses.

  • Page 94: Troubleshooting

    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 section for information on how to enter Control System/Service Mode and use the Service Mode.
  • Page 95 Service Manual – CS7000 Dust Control/DustGuard Systems ™ Problem Cause Correction The dust control motor The dust control filter switch is 1. Clean the filter. will not run. closed, indicating that the filter 2. Check the dust control filter switch. The switch is plugged.

  • Page 96: Removal And Installation

    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 Drain the water from the upper hopper.

  • Page 97: To Remove And Reinstall The Dustguard™ Pump

    Service Manual – CS7000 Dust Control/DustGuard Systems ™ To Remove and Reinstall the DustGuard™ Pump 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™...

  • Page 98: To Remove And Reinstall The Dust Control Filter Switch

    Service Manual – CS7000 Dust Control/DustGuard Systems ™ Note: The base should Pump Guard 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 Lift the hopper cover.

  • Page 99: To Disassemble And Reassemble The Impeller Assembly

    Service Manual – CS7000 Dust Control/DustGuard Systems ™ To Disassemble and Reassemble the Impeller Assembly Remove the three Nyloc™ Nuts Screws holding the Vacuum Spacers Vacuum Plate Support to the Screw (3) and Gasket Vacuum Support attached Vacuum Motor Screw (3)

  • Page 100: Specifications

    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 ±...

  • Page 101: Electrical System

    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.
  • Page 102 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.
  • Page 103 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. 36V Battery Pack 36V “Machine” Electrical Loads 42V Alternator Main Machine Controller...

  • Page 104: Wiring Harnesses

    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.

  • Page 105: Circuit Protection

    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.

  • Page 106: Low Voltage Cutout

    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.

  • Page 107: Headlights

    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 Configuration Menu.

  • Page 108: Component Locations

    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.) •...
  • Page 109 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 - Side view.

  • Page 110: Electrical Panel Contactor/Relay Location

    Service Manual – CS7000 Electrical System Electrical Panel Contactor/Relay location Electrical Panel...

  • Page 111: Harness To Harness Connector Locations

    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.

  • Page 112: Connector Pin-Outs

    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.
  • Page 113 Service Manual – CS7000 Electrical System Component ID Component Name Connector ID Vacuum Motor Right side broom motor Left side broom motor Hydraulic Pump, Hopper Lift X126 Scrub Deck Actuator Motor X256 Squeegee Lift actuator Side broom actuator X109 Shaker motor...
  • Page 114 Service Manual – CS7000 Electrical System J2 - Main Machine Controller (A1) Wire # Color 091 ORN/YEL 094 ORN/BLU 098 YEL/RED 101 YEL/GRN 107 TAN/BLK 064 BLK/YEL 119 BRN/WHT 080 WHT/GRN 078 BLU/BRN 132 RED/GRN 135 YEL/GRA 162 BLK 057 VIO...
  • Page 115 Service Manual – CS7000 Electrical System J3 - Main Machine Controller (A1) Wire # Color 042 VIO/ORN 093 RED/YEL 030 BRN/WHT 031 RED/VIO 106 GRA/VIO 111 BRN/GRN 115 RED/GRA 118 WHT/ORN 123 PINK 129 BLU/PINK 131 GRA/ORN 134 GRA/BLU 137 BRN/RED...
  • Page 116 Service Manual – CS7000 Electrical System J4 - Drive Controller (A2) Wire # Color 185 ORN 126 VIO/GRN 186 BLK/PINK 187 TAN/RED 188 GRN/BLU 127 TAN/ORN 189 WHT/BLK 190 BRN/RED 191 VIO/BLK 192 YEL 193 VIO/WHT 194 PINK/RED 195 WHT/ORN...
  • Page 117 Service Manual – CS7000 Electrical System J5 - Steering Controller (A5) Wire # Color 083 GRA/ORN 199 BRN/WHT 200 ORN/BLK 201 BLK 202 WHT 203 BLU/GRA 204 BLK 308 RED/WHT 307 GRN/WHT 084 GRA/ORN 207 WHT/BLU 343 GRN 208 YEL/RED...
  • Page 118 Service Manual – CS7000 Electrical System J7 - Main Machine Controller (A1) Wire # Color 092 GRN/BLU 095 GRN 099 YEL 102 GRA 108 GRA/YEL 112 TAN/WHT 117 YEL/RED 130 WHT/BRN 133 BLK 050 YEL/BRN 141 ORN 046 RED/BLK 035 GRA/YEL...
  • Page 119 Service Manual – CS7000 Electrical System J8 - CAN Bus Connector Wire # Color 241 GRN 242 BLK 243 YEL AMP 5-747905-2 J10 - Drive Controller Programmer Wire 196 BLU/GRN 249 BLK/PINK 195 WHT/ORN SIDE 193 VIO/WHT MOLEX 39012041 X1 - Hopper Harness Connector (X262)
  • Page 120 Service Manual – CS7000 Electrical System X2 - Hopper Harness Connector (X263) Wire 091 ORN/YEL 284 BLK/YEL 098 YEL/RED 106 GRA/VIO DELPHI 15326917 250 GRN/ORN 111 BRN/GRN 115 RED/GRA 168 ORN/RED 235 BLK 170 YEL/WHT 239 BLK 071 WHT/RED 233 BLK...
  • Page 121 Service Manual – CS7000 Electrical System X21 - Dust Control Motor (M5) Wire 259 ORN/GRN 260 BLK SIDE DELPHI 15300027 X22 - Squeegee Lift Actuator (M12) Wire 080 WHT/GRN 078 BLU/BRN DELPHI 12052613 X23 - Vacuum Motor (M6) Wire 017 BLU/GRA...
  • Page 122 Service Manual – CS7000 Electrical System X27 - Main Broom Actuator (M21) Wire 030 BRN/WHT 031 RED/VIO 032 BLU/ BLK 033 GRA/GRN 034 TAN/RED DELPHI 12124107 X28 - Right Side Broom Motor (M8) Wire 295 WHT/RED 297 BLK DELPHI 12052613...
  • Page 123 Service Manual – CS7000 Electrical System X98 - Steering Wheel Sensor (E4) Wire 307 GRN/WHT 309 BLU 205 BLK 209 ORN/BLK 308 RED/WHT 310 GRN/BLK 206 BLK 211 ORN/BLK DEUTSCH DTM04-12PA 199 BRN/WHT 329 GRA/ORN X99 - Wheel Drive Motor (M24)
  • Page 124 Service Manual – CS7000 Electrical System X105 - Steering Travel Limit Switch, Left (S17) Wire 210 ORN/RED 270 GRA/ORN DELPHI 12010973 X106 - Steering Travel Limit Switch, Right (S16) Wire 207 WHT/BLU 277 GRA/ORN DELPHI 12010973 X109 - Side Broom Actuator (M13)
  • Page 125 Service Manual – CS7000 Electrical System X122 - Dust Guard Pump (M22) Wire 147 GRA 148 BRN/RED DELPHI 12010973 X124 - Dump Door Actuator Motor (M26) Wire 286 BRN/GRN 287 RED/GRA SIDE DELPHI 15300027 X126 - Hydraulic Pump, Hopper Lift (M10)
  • Page 126 Service Manual – CS7000 Electrical System X153 - Tail Lamp, Left (LT9) Wire 010 TAN/BLK 011 BLK/YEL SIDE DELPHI 12052641 X154 - Tail Lamp, Right (LT5) Wire 012 TAN/BLK 025 BLK/YEL SIDE DELPHI 12124819 X161 - Left Head Lamp (LT3)
  • Page 127 Service Manual – CS7000 Electrical System X166 - Tail Lamp Harness Connector (X239) Wire 094 ORN/BLU 107 TAN/BLK 285 BLK/YEL 101 YEL/GRN DELPHI 12020832 X172 - Splice Saver Connector Comb Wire 265 GRA 264 GRA 097 GRA 041 GRA SIDE...
  • Page 128 Service Manual – CS7000 Electrical System X178 - Back Up Alarm (H1) Wire 037 GRA 076 GRN/BRN DELPHI 12015792 X180 - Stop/Turn Lamp, Left (LT9) Wire 023 ORN/BLU 009 BLK/YEL DELPHI 12162000 X181 - Broom Motor Current Sensor (B2) Wire...
  • Page 129 Service Manual – CS7000 Electrical System X184 - Stop/Turn Lamp, Right (LT11) Wire 014 YEL/GEN 024 BLK/YEL DELPHI 12162000 X187 - Battery Interlock Switch (S13) Wire 315 TAN 338 GRN/BLU DELPHI 12010973 X190 - Solution Solenoid Valve (L1) Wire 157 YEL/ORN...
  • Page 130 Service Manual – CS7000 Electrical System X236 - Dump Door Extend Limit Switch (S7) Wire 290 ORN/RED 291 BLK DELPHI 12010973 X238 - Dump Door Retract Limit Switch (S8) Wire 292 YEL/WHT 293 BLK DELPHI 12010973 X239 - Main Harness Connector (X166)
  • Page 131 Service Manual – CS7000 Electrical System X258 - Trouble Light (LT1) Wire 316 YEL/BRN 232 BLK DELPHI 12015792 X262 - Main Harness Connector (X1) Wire 176 GRA 181 BRN/RED 223 WHT/GRA 224 BLK 225 YEL/VIO 226 BLK DELPHI 15326910 259 ORN/GRN...
  • Page 132 Service Manual – CS7000 Electrical System X265 - Engine Harness Connector Wire 321 PINK 341 PINK 318 BLK/RED 317 PINK/YEL SIDE 322 BLU/PINK DELPHI 15326868 323 GRN/YEL X266 - Engine Harness Connector Wire 324 GRA DELPHI 15326863 325 GRA/ORN 326 GRA/BLU...
  • Page 133 Service Manual – CS7000 Electrical System X268 - Extended Scrub Level Switch (S4) Wire 035 GRA/YEL 036 BLK DELPHI 12015792 X270 - Main Harness Connector (X271) Wire 017 BLU/GRA 018 BLK 019 BLU/GRA 020 BLK DELPHI 12015798 X271 - Vacuum Motor Harness (X270)

  • Page 134: Wiring Connections

    Service Manual – CS7000 Electrical System X275 - Fuel Pump (M20) Wire 317 PINK/YEL 318 BLK/RED DELPHI 12010973 Wiring Connections K14 Safety Relay and K15 Auxiliary Relays Early Style K14 Safety Relay 6 = GRA/ORN 4 = PINK A = VIO...

  • Page 135: Late Style K14 Safety Relay And K15 Auxiliary Relay

    Service Manual – CS7000 Electrical System Late style K14 Safety Relay and K15 Auxiliary Relay GRAY/ORN K14 Safety Relay Pink GRAY/ORN (2) ORN (2) BLK/WHT GRA/WHT K15 Auxiliary Relay TAN/GRN BLK X195 VIO/RED K14 Safety Relay K15 Auxiliary Relay...

  • Page 136: Maintenance And Adjustments

    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 •...

  • Page 137: Removal And Installation

    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. Lift hopper up, engage hopper prop rod and then lower to safety lock position.
  • Page 138 Service Manual – CS7000 Electrical System 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.

  • Page 139: 42 Volt Generator

    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.

  • Page 140: Head Light Bulb - Standard 12V Halogen

    Service Manual – CS7000 Electrical System Head Light bulb - Standard 12v Halogen 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.

  • Page 141: Specifications

    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:...

  • Page 142: Current Sensors

    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 2.5v -60 A 1.5v -120 A 0.5v Input/Output Table Black voltmeter lead Conn. Pin Wire Desig.
  • Page 143 Service Manual – CS7000 Electrical System Black voltmeter lead Conn. Pin Wire Desig. Description Signal Nominal Value 157 YEL/ Output Solution Solenoid ON/OFF signal Valve Grounds to energize 160 BLU/ Output Detergent Pump PWM SIGNAL 0-12V J2-32 (Reversing Polarity) 167 BLK/...
  • Page 144 Service Manual – CS7000 Electrical System Black voltmeter lead Conn. Pin Wire Desig. Description Signal Nominal Value 131 GRA/ Output Throttle 2 Output High Side 0V or 12V Driver Engine 134 GRA/ Output Throttle 1 Output High Side 0V or 12V...
  • Page 145 Service Manual – CS7000 Electrical System Black voltmeter lead Conn. Pin Wire Desig. Description Signal Nominal Value 130 WHT/ Output Power out to B-(Ground) Control Panel 133 BLK Output Ground for Control Panel 050 YEL/ Special Suppression Diode B-(Ground) 141 ORN...

  • Page 146: Wiring Diagrams

    Service Manual – CS7000 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”...
  • Page 147 Service Manual – CS7000 Electrical System 56509170 Rev L Sheet 1 of 9...
  • Page 148 Service Manual – CS7000 Electrical System 56509170 Rev L Sheet 2 of 9...
  • Page 149 Service Manual – CS7000 Electrical System 56509170 Rev L Sheet 3 of 9...
  • Page 150 Service Manual – CS7000 Electrical System 56509170 Rev L Sheet 4 of 9...
  • Page 151 Service Manual – CS7000 Electrical System 56509170 Rev L Sheet 5 of 9...
  • Page 152 Service Manual – CS7000 Electrical System 56509170 Rev L Sheet 6 of 9 (SN 1000048160 and later. Kubota Gas and LPG before LEV (E4) )
  • Page 153 Service Manual – CS7000 Electrical System 56509170 Rev L Sheet 7 of 9 (Kubota LEV (E4) only) See LEV Engine Side Wiring 56511576_REV_A_LEV_ENG sheet 1 of 1...
  • Page 154 Service Manual – CS7000 Electrical System 56509170 Rev L Sheet 8 of 9 (Before SN 1000048160. Kubota LPG before LEV (E4))
  • Page 155 Service Manual – CS7000 Electrical System 56509170 Rev L Sheet 9 of 9...

  • Page 156: Lev Engine Side Wiring 56511576_Rev_A_Lev_Eng Sheet 1 Of 1

    Service Manual – CS7000 Electrical System LEV Engine Side Wiring 56511576_REV_A_LEV_ENG sheet 1 of 1 See 56509170 Rev L Sheet 7 of 9 for mating ECU Interface Connector...

  • Page 157: Engine System - Lpg

    9Y111-05710 for detailed information related to the complete mechanical engine. Functional Description One of the engines available in the CS7000 is a LPG Kubota (WG972-GL-E3-NFK-1). It is a three cylinder, liquid cooled, naturally aspirated engine. The fuel system does not utilize a control module. It is mechanically controlled.

  • Page 158: Circuit Descriptions

    Service Manual – CS7000 Engine System - LPG Circuit Descriptions Ignition System The ignition system consists of a spark control module (aka Ignitor), three ignition coils, and a crank position sensor. The crank position sensor reads a rotating 6 toothed ring which is mounted on the flywheel between the flywheel and the engine.
  • Page 159 Service Manual – CS7000 Engine System - LPG The spark control module is fed power on pin G from the Ignition Request relay. Pin F is connected to ground. The two wires form the crank position sensor are connected to pins E and F.

  • Page 160: Engine Starter Control

    Service Manual – CS7000 Engine System - LPG 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 on the violet wire with the green stripe to connector J7 pin 19.

  • Page 161: Throttle Control Modes

    Service Manual – CS7000 Engine System - LPG Throttle Control Modes Ignition Off • Battery power is available through the main fuse to the crank request relay common contact, the ignition request relay common contact and the power relay common contact.

  • Page 162: Ignition On

    Service Manual – CS7000 Engine System - LPG Ignition On • When the main machine controller sees the key switch input, it sends 12v out on the Ignition Request circuit. • When the actutor receives 12v at pin 1, it “wakes up”.

  • Page 163: Cranking

    Service Manual – CS7000 Engine System - LPG Cranking • When the main machine controller sees the 36v cranking request from the key switch, it sends out 12v on the crank request circuit to the crank request relay winding. The other side of the winding is grounded through pin 9 of the actuator (as long as there is not a shutdown condition within the L-Series actuator).

  • Page 164: Normal Running

    Service Manual – CS7000 Engine System - LPG Normal Running • When the key is released to the “run” position, the main machine controller turns off the voltage to the crank request circuit. This de-energizes the crank request relay and removes power from the starter solenoid.

  • Page 165: Normal Engine Shut Off

    Service Manual – CS7000 Engine System - LPG 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.

  • Page 166: Step Two

    Service Manual – CS7000 Engine System - LPG Step Two The engine continues to run until it uses up the fuel that was trapped in the vaporizer/regulator. When the engine stalls, and loses oil pressure, the oil pressure switch closes, energizing the low oil pressure shut down relay.

  • Page 167: Engine Overheat Shutdown

    Service Manual – CS7000 Engine System - LPG Engine Overheat Shutdown • If the engine overheats, the temperature switch closes. This completes a path to ground for the high coolant temp shut down relay and energizes the relay. This removes power from the fuel lock off solenoid.

  • Page 168: Lost Oil Pressure Shutdown

    Service Manual – CS7000 Engine System - LPG Lost Oil Pressure Shutdown • If the engine oil pressure is lost, the oil pressure switch will close causing the low oil pressure shut down relay to energize taking power away from the “closed at rest” contact. This removes the power from the run enable signal to pin 8 of the Woodward L series actuator.

  • Page 169: Component Locations

    Service Manual – CS7000 Engine System - LPG Component Locations Engine Front Engine Right Engine components are grouped according to the area of the engine. They are photographed on an engine that is not installed in the machine for better visibility. See next pages for photos.
  • Page 170 Service Manual – CS7000 Engine System - LPG Engine Right Side View (Toward front of machine) NIKKI Fuel Vaporizer/ Engine relay box Regulator Actuator Carburetor/mixer Carburetor fuel shut off solenoid Crank position sensor Engine RPM sensor...
  • Page 171 Service Manual – CS7000 Engine System - LPG Engine Back Side View (Toward right of machine) Fuel lock off solenoid Spark Controller Ignition coils 42v Alternator Engine Left Side View (Toward back of machine) Coolant temperature switch 12v alternator Oil pressure switch...
  • Page 172 Service Manual – CS7000 Engine System - LPG Fuel Tank Area Fuel Tank Low LP Pressure Pressure relief valve Switch...

  • Page 173: Maintenance And Adjustments

    Service Manual – CS7000 Engine System - LPG Maintenance and Adjustments Maintenance Checklist This check list is courtesy of the Kubota engine Workshop Manual. See the workshop manual for more details on performing these operations. Daily: • Check engine oil level •...

  • Page 174: Change Engine Oil And Oil Filter

    Service Manual – CS7000 Engine System - LPG Every 1000 hours • Replace spark plug • Check coolant hose of LPG vaporizer • Check vacuum lock hose of LPG vaporizer • Drain tar • Check valve clearance • Clean cylinder head •...

  • Page 175: Change Engine Coolant

    Service Manual – CS7000 Engine System - LPG Change Engine Coolant Allow the engine to cool sufficiently to relieve cooling system pressure and avoid burns. Remove the left side engine cover. Remove the radiator cap. Locate the remote engine coolant drain hose, remove the plug and direct the coolant into a suitable container.

  • Page 176: Troubleshooting

    Service Manual – CS7000 Engine System - LPG Troubleshooting Checking Spark Remove the spark plug wire from the spark plug and insert an adjustable KV tester in the end of the wire. Adjust the gap to approximately 20 - 30 KV and clip the tester to a good ground on the engine.

  • Page 177: No Crank - The Starter Does Not Engage

    Service Manual – CS7000 Engine System - LPG Using the LPG test gauge kit - Part # 56504450, hook up the blue pressure gauge hose to fitting. Open propane tank valve. Start engine. (Specification - 4.3 PSI, 32.7kPA) When finished, reinstall the test port plug using a suitable pipe thread sealant.

  • Page 178: Cranks But Does Not Start - No Spark

    Service Manual – CS7000 Engine System - LPG Cranks but does not start – No Spark Possible causes: • Spark Control Module not powered up. – Ignition request relay – Woodward L Series Actuator not energizing ignition request relay – Spark control module ground •...

  • Page 179: Achieves One But Not All Rpm Modes

    Service Manual – CS7000 Engine System - LPG Achieves one but not ALL RPM modes. The approach to diagnosing an engine RPM control problem is to check the inputs to the L series actuator. If the inputs are good and the output is bad, the conclusion is that the actuator is the 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.

  • Page 180: Removal And Installation

    Service Manual – CS7000 Engine System - LPG Removal and Installation Engine RPM Sensor Installation Screw in the sensor until the end of the sensor contacts the engine starter ring gear. Back out the sensor 1/2 turn to establish an air gap between the sensor and the ring gear Tighten the jamb nut.

  • Page 181: Specifications

    Service Manual – CS7000 Engine System - LPG Specifications Fuel System Primary Chamber Pressure - 4.3 PSI (32.7 kPA) Fuel Lock Off Solenoid Resistance - 10 ohms Engine OIl Engine oil capacity - 3.4 L, 0.90 U.S.gals • IMPORTANT – When using an oil of different maker or viscosity from the previous one, remove all of the old oil.

  • Page 182: Spark Controller Measurements

    Service Manual – CS7000 Engine System - LPG Spark Controller Measurements: Pin Letter Wire Color on Circuit Voltage with key on machine unplugged Crank Position Sensor Ground (And other 0.004v leg of Crank sensor) Power Supply 11.2v Not used Not used...

  • Page 183: Fuel System

    Service Manual – CS7000 Engine System - LPG Fuel System Carburetor LPG shut off solenoid resistance – 27.3 ohms Fuel Lock Off Solenoid resistance - 10.1 ohms Primary Pressure - 4.6 PSI Engine Engine Vacuum at idle - approx 14.5 - 15” HG When returning from low RPM to idle vacuum momentarily peaks around 21”...

  • Page 184: Special Tools

    Service Manual – CS7000 Engine System - LPG Special Tools LPG test gauge kit - Part # 56504450 LPG test port adapter. (Male 1/8” BSPT to Female 1/8” NPT) Part # 50360A 1/8” BPST 1/8” NPT Adjustable KV Spark Tester.

  • Page 185: Engine System - Lpg Lev

    Service Manual – CS7000 Engine System - LPG LEV This chapter provides a brief summary of the Kubota propane “LEV” (Low Emission Vehicle) engine which was introduced around September 2015. Kubota refers to the engine model as WG972-E4. “E4” designates EPA Tier 3 / CARB Tier 4 models, depending on engine displacement and output classification.

  • Page 186: Circuit Descriptions

    Service Manual – CS7000 Engine System - LPG LEV Circuit Descriptions Engine Starter Control Holding the key switch in the start position supplies a 36 volt “input request” to the main machine controller to engage the engine starter. In turn the main machine controller sends a 12 volt output to the starter relay winding.

  • Page 187: Engine Rpm Control

    Service Manual – CS7000 Engine System - LPG LEV Engine RPM Control The ECU directly monitors the engine speed and adjusts the throttle angle to maintain the current target engine speed. The main machine controller communicates the desired engine speed mode to the ECU via the Throttle 1 and Throttle 2 wires.

  • Page 188: Component Locations

    Service Manual – CS7000 Engine System - LPG LEV Component Locations • Ignition Coils (3) Ignition • Temperature Manifold Absolute Coils (3) Pressure (TMAP) sensor • Electronic Throttle Body (ETB) Vaporizer • Vaporizer • Engine Control Unit (ECU) • Crankshaft Position Sensor (CKP) LP Mixer •...
  • Page 189 Service Manual – CS7000 Engine System - LPG LEV • Fuel Tank Area Fuel Tank Area – Fuel tank – Pressure relief valve – Low LPG pressure switch Fuel Tank Low LP Pressure Pressure relief valve Switch...

  • Page 190: Maintenance And Adjustments

    Service Manual – CS7000 Engine System - LPG LEV Maintenance and Adjustments Maintenance Checklist Refer to the Kubota “Workshop Manual – Gasoline, LPG, NG Engine WG972-E4 (EFI)” Code No.9Y111-11080 Change Engine Oil and Oil Filter Drain the recovery tank for later removal.

  • Page 191: Inspect Air Filter

    Service Manual – CS7000 Engine System - LPG LEV 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...

  • Page 192: Troubleshooting

    Service Manual – CS7000 Engine System - LPG LEV Troubleshooting Engine Management System Kubota provides software that enables you to use a laptop to interface with the engine controller like an “automotive scan tool”. It is called the Kubota Gasoline Service Tool (KGST). Although it mentions “gasoline”...

  • Page 193: Checking Lpg Primary Pressure

    Service Manual – CS7000 Engine System - LPG LEV Checking LPG Primary Pressure Turn off the propane tank valve with the engine running and allow the engine to run out of fuel. Remove Steel Turn key switch off. Plate Swing out the propane tank.

  • Page 194: Removal And Installation

    Service Manual – CS7000 Engine System - LPG LEV Removal and Installation Engine Assembly The complete engine including the exhaust, radiator and 42v alternator are removed as an assembly. There is no need to drain engine oil or coolant. The assembly is attached to the chassis at 4 rubber motor mounts.

  • Page 195: Specifications

    Service Manual – CS7000 Engine System - LPG LEV Specifications Fuel System Fuel Lock Off Solenoid Resistance - 12.65 Ω @ 20° C (60° F) Engine Oil Engine oil capacity - 3.4 L, 0.90 U.S.gals • IMPORTANT – When using an oil of different maker or viscosity from the previous one, remove all of the old oil.

  • Page 196: Fuel System

    Service Manual – CS7000 Engine System - LPG LEV Fuel System • Fuel Lock Off Solenoid resistance - 13 ohms • Primary Pressure - 3.4 PSI • Engine coolant temperature sensor - 0.875v at 142 Deg. F. Engine Engine Vacuum at idle (1700 RPM) - approx 16.5 - 17” HG When returning from Run (2500 RPM) to idle (1700 RPM) vacuum momentarily peaks around 22”...

  • Page 197: Special Tools

    Service Manual – CS7000 Engine System - LPG LEV Special Tools KGST Software. Download from EZparts Password for use with the WGG972GL-E4 (LEV) engine: LayVijZuWSOp Diagnostic Cable Adapter Part# 56511575 Used to connect ECOM cable to Kubota LEV diagnostic connector...
  • Page 198 Service Manual – CS7000 Engine System - LPG LEV Adjustable KV Spark Tester Most automotive parts suppliers sell these tools. Shown is 50850 from Lisle corporation. http://www.lislecorp.com/ KV Scale...

  • Page 199: Engine System - Petrol (Gasoline)

    Service Manual – Haram Captor II Engine System - Petrol (Gasoline) This chapter covers the things “on top” of the mechanical engine that make it run, such as the fuel system, governor control and ignition system. It also includes routine engine maintenance information and troubleshooting of engine starting or running problems.

  • Page 200: Circuit Descriptions

    Service Manual – Haram Captor II Engine System - Petrol (Gasoline) Circuit Descriptions Ignition System The ignition system consists of a spark control module (aka Ignitor), three ignition coils, and a crank position sensor. The crank position sensor reads a rotating 6 toothed ring which is mounted on the flywheel between the flywheel and the engine.
  • Page 201 Service Manual – Haram Captor II Engine System - Petrol (Gasoline) The spark control module is fed power on pin G from the Ignition Request relay. Pin F is connected to ground. The two wires form the crank position sensor are connected to pins E and F. All three ignition coils are fed the same power from the ignition request relay.

  • Page 202: Engine Starter And Carburetor Choke Control

    Service Manual – Haram Captor II Engine System - Petrol (Gasoline) Engine Starter and Carburetor Choke 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 on the violet wire with the green stripe to connector J7 pin 19.

  • Page 203: Throttle Control Modes

    Service Manual – Haram Captor II Engine System - Petrol (Gasoline) Throttle Control Modes Ignition Off • Battery power is available through the main fuse to the crank request relay common contact, the ignition request relay common contact and the power relay common contact. •...

  • Page 204: Ignition On

    Service Manual – Haram Captor II Engine System - Petrol (Gasoline) Ignition On • When the main machine controller sees the key switch input, it sends 12v out on the Ignition Request circuit. • 12v is provided to the common contact at pin 3 of the high coolant temp. shutdown relay and on through the normally closed contacts to the fuel pump.

  • Page 205: Cranking

    Service Manual – Haram Captor II Engine System - Petrol (Gasoline) Cranking • When the main machine controller sees the 36v cranking request from the key switch, it sends out 12v on the crank request circuit to the crank request relay winding. The other side of the winding is grounded through pin 9 of the actuator (as long as there is not a shutdown condition within the L-Series actuator).

  • Page 206: Normal Running

    Service Manual – Haram Captor II Engine System - Petrol (Gasoline) Normal Running • When the key is released to the “run” position, the main machine controller turns off the voltage to the crank request circuit. This de-energizes the crank request relay and removes power from the starter solenoid.

  • Page 207: Normal Engine Shut Off

    Service Manual – Haram Captor II Engine System - Petrol (Gasoline) 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.

  • Page 208: Engine Overheat Shutdown

    Service Manual – Haram Captor II Engine System - Petrol (Gasoline) Engine Protection Modes The engine will be shut off in the event that it overheats or loses oil pressure after it has been running. The main machine controller will display a warning message to the operator for either case and will also initiate an engine shut down as a back up measure.

  • Page 209: Lost Oil Pressure Shutdown

    Service Manual – Haram Captor II Engine System - Petrol (Gasoline) Lost Oil Pressure Shutdown • If the engine oil pressure is lost, the oil pressure switch will close causing the low oil pressure shut down relay to energize taking power away from the “closed at rest” contact. This removes the power from the run enable signal to pin 8 of the Woodward L series actuator.

  • Page 210: Component Locations

    Service Manual – Haram Captor II Engine System - Petrol (Gasoline) Component Locations Engine components are grouped according to the area of the engine. They are photographed on an engine that is not installed in the machine for better visibility. Engine Front Engine Right Engine Left...

  • Page 211: Engine Right Side View (Toward Front Of Machine)

    Service Manual – Haram Captor II Engine System - Petrol (Gasoline) Engine Right Side View (Toward front of machine) • Actuator • Choke Solenoid • Carburetor/mixer • Engine RPM sensor • Crank position sensor • Petrol fuel shut off solenoid •...

  • Page 212: Engine Back Side View (Toward Right Of Machine)

    Service Manual – Haram Captor II Engine System - Petrol (Gasoline) Engine Back Side View (Toward right of machine) • Spark Controller Spark Controller • 42 V Alternator • Ignition coils 42v Alternator Ignition coils Engine Left Side View (Toward back of machine) •...

  • Page 213: Fuel Tank Area

    Service Manual – Haram Captor II Engine System - Petrol (Gasoline) Fuel Tank Area • Fuel tank • Fuel Pump Vapor Canister • Fuel Filter • Fuel Sending Unit Fuel Filter • Vapor Canister Fuel Pump Fuel Tank Fuel Sending Unit...

  • Page 214: Maintenance And Adjustments

    Service Manual – Haram Captor II Engine System - Petrol (Gasoline) Maintenance and Adjustments Maintenance Checklist This check list is courtesy of the Kubota Gasoline, LPG, engine Workshop Manual. See the workshop manual for more details on performing these operations. Daily: •...

  • Page 215: Change Engine Oil And Oil Filter

    Service Manual – Haram Captor II Engine System - Petrol (Gasoline) Every 2 years • Replace intake air line • Replace breather hose • Replace radiator hoses and clamp bands • Replace battery • Replacing ignition wires • Change radiator coolant (L.L.C.) Change Engine Oil and Oil Filter Drain the recovery tank for later removal.

  • Page 216: Inspect Air Filter

    Service Manual – Haram Captor II Engine System - Petrol (Gasoline) 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 Replace Air Filters...

  • Page 217: Troubleshooting

    Service Manual – Haram Captor II Engine System - Petrol (Gasoline) Troubleshooting Checking Spark Remove the spark plug wire from the spark plug and insert an adjustable KV tester in the end of the wire. Adjust the gap to approximately 20 - 30 KV and clip the tester to a good ground on the engine.

  • Page 218: Cranks But Does Not Start - No Spark

    Service Manual – Haram Captor II Engine System - Petrol (Gasoline) Cranks but does not start – No Spark Possible causes: • Spark Control Module not powered up. – Ignition request relay – Woodward L Series Actuator not energizing ignition request relay –...

  • Page 219: Achieves One But Not All Rpm Modes

    Service Manual – Haram Captor II Engine System - Petrol (Gasoline) Achieves one but not ALL RPM modes. The approach to diagnosing an engine RPM control problem is to check the inputs to the L series actuator. If the inputs are good and the output is bad, the conclusion is that the actuator is the 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.

  • Page 220: Removal And Installation

    Service Manual – Haram Captor II Engine System - Petrol (Gasoline) Removal and Installation Engine RPM Sensor Installation Screw in the sensor until the end of the sensor contacts the engine starter ring gear. Back out the sensor 1/2 turn to establish an air gap between the sensor and the ring gear Tighten the jamb nut.

  • Page 221: Specifications

    Service Manual – Haram Captor II Engine System - Petrol (Gasoline) Specifications Engine Oil Engine oil capacity - 3.4 L, 0.90 U.S.gals • IMPORTANT – When using an oil of different maker or viscosity from the previous one, remove all of the old oil. –...

  • Page 222: Spark Controller Measurements

    Service Manual – Haram Captor II Engine System - Petrol (Gasoline) Spark Controller Measurements: Pin Letter Wire Color on Circuit Voltage with key on machine unplugged Crank Position Sensor Ground (And other 0.004v leg of Crank sensor) Power Supply 11.2v Not used Not used BLU/BLK...

  • Page 223: Fuel System

    Service Manual – Haram Captor II Engine System - Petrol (Gasoline) Fuel System Fuel Pressure - 3.5-4.0 PSI (24-27 Kpa) Fuel volume - 0.5L in 15 seconds Carburetor Fuel Shut-off Solenoid resistance - 38 ohms Electric Choke Solenoid resistance - 2.5 ohms Engine Engine Vacuum at idle - approx 17.5 inches HG (59 Kpa) When returning from low RPM to idle vacuum momentarily peaks around 21”...

  • Page 224: Special Tools

    Service Manual – Haram Captor II Engine System - Petrol (Gasoline) Special Tools Adjustable KV Spark Tester. Most automotive parts suppliers sell these tools. Shown is 50850 from Lisle corporation. http://www. lislecorp.com/ KV Scale...

  • Page 225: Engine System, Diesel

    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.

  • Page 226: Fuel Pump Control

    Service Manual – CS7000 Engine System, Diesel 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.

  • Page 227: Engine Protection

    Service Manual – CS7000 Engine System, Diesel 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.

  • Page 228: Over Temperature Shutdown

    Service Manual – CS7000 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.

  • Page 229: Low Oil Pressure Shutdown

    Service Manual – CS7000 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”...

  • Page 230: Engine Rpm Control

    Service Manual – CS7000 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.
  • Page 231 Service Manual – CS7000 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.

  • Page 232: Glow Plug Control

    Service Manual – CS7000 Engine System, Diesel Flash Code Fault Remedy Engine shutdown due to engine Check parameter settings. protection input Check what may have triggered the protection input. (Loss of oil pressure, engine overheat) Factory settings lost If calibration file is available, download calibration file and cycle power again.

  • Page 233: Component Locations

    Service Manual – CS7000 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.
  • Page 234 Service Manual – CS7000 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...
  • Page 235 Service Manual – CS7000 Engine System, Diesel Glow Plugs Glow Plug Relay Electrical Panel Coolant Temperature Switch Alternator (12v) Starter Oil Pressure Switch Engine - Back Side...

  • Page 236: Maintenance And Adjustments

    Service Manual – CS7000 Engine System, Diesel 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.

  • Page 237: Change Engine Oil And Oil Filter

    Service Manual – CS7000 Engine System, Diesel Change Engine Oil and Oil Filter Drain the recovery tank for later removal. Shut off the engine and allow it to cool sufficiently to avoid burning yourself with hot engine oil. Remove the left side engine cover.

  • Page 238: Bleed Fuel System

    Service Manual – CS7000 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.

  • Page 239: Replace Air Filters

    Service Manual – CS7000 Engine System, Diesel Replace Air Filters Remove left side engine cover. Open right side engine cover and swing out fuel tank. 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.

  • Page 240: Troubleshooting

    Service Manual – CS7000 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.
  • Page 241 Service Manual – CS7000 Engine System, Diesel Diagnostic steps: 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.

  • Page 242: Cannot Achieve Either Run Or Maximum Engine Speed Settings (Run 2200 Rpm, Maximum Power 2400 Rpm)

    Service Manual – CS7000 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.

  • Page 243: Compression Test

    Service Manual – CS7000 Engine System, Diesel Compression Test Begin with a fully charged battery. Remove the air cleaner assembly. Cover the air inlet opening to prevent foreign objects from falling into the engine. Remove the glow plug electrical connector nuts and connector “rail”.
  • Page 244 Service Manual – CS7000 Engine System, Diesel Disconnect the injector pump actuator connector to prevent the engine from starting. Disconnect Remove any cover over the air inlet but be very careful not to allow anything to get “sucked in” during the test.

  • Page 245: Removal And Installation

    Service Manual – CS7000 Engine System, Diesel Removal and Installation Engine RPM Sensor Installation Screw in the sensor until the end of the sensor contacts the engine starter ring gear. Back out the sensor 1/2 turn to establish an air gap between the sensor and the ring gear Tighten the jamb nut.

  • Page 246: Specifications

    Service Manual – CS7000 Engine System, Diesel Specifications Fuel Pump; • Fuel Pressure 2.5 - 4 PSI • Fuel Volume - 0.5 Gallons per minute Glow Plugs • Resistance - Approx. 0.9 ohms • Current Draw - Approx. 12 - 13 Amps. (As the glow plugs heat up, resistance increases and current...

  • Page 247: Engine Oil Viscosity

    Service Manual – CS7000 Engine System, Diesel • Oil used in the engine should have API classification and Proper SAE Engine Oil Viscosity according to the ambient temperatures where the engine is operated. • With strict emission control regulations now in effect, the CF-4 and CG-4 engine oils have been developed for use with low sulfur fuels, for On-Highway vehicle engines.

  • Page 248: Engine Compression

    Service Manual – CS7000 Engine System, Diesel Engine Compression #1 = 410 psi #2 = 420 psi #3 = 400 Fuel System Return Fuel Flow 4.0 oz (120 ml) with the return line removed, engine off and fuel pump running...

  • Page 249: Special Tools

    Service Manual – CS7000 Engine System, Diesel Special Tools Diesel Compression Gauge There are many brands of compression gauges available. Shown is a Snap-On EEPD500 Gauge kit Compression Gauge Fitting for Glow Plug threads. Shown is Snap-On TU-15-35 Threads - M8 X 1.0...

  • Page 250: Hopper System

    Service Manual – CS7000 Hopper System Functional Description Overview The hopper system holds the dirt, dust and debris swept up by the brooms. The hydraulic lift cylinder raises the hopper to allow the accumulated dirt and debris to be dumped into a suitable receptacle, then lowers the hopper back down into the normal operating position.

  • Page 251: Hopper System Wiring Diagram

    Service Manual – CS7000 Hopper System Hopper System Wiring Diagram Battery Fuse, 400 A A1 Main Machine Controller A3 Control Panel WHT/BRN J7-10 +12V J1-1 42V Alternator J7-11 B- J1-2 J7-3 CAN H J1-3 VIO/GRN J7-2 CAN L J1-4 J7-19 Start Input...

  • Page 252: Hopper Hydraulic System Circuit Details

    Service Manual – CS7000 Hopper System Hopper Hydraulic System Circuit Details A hydraulic cylinder (ram), driven by a self-contained hydraulic pump and motor, raises and lowers the hopper. The pump motor power and ground polarity are reversed to make the motor run in opposite directions.

  • Page 253: Hopper Being Lowered

    Service Manual – CS7000 Hopper System Hopper Being Lowered When the operator pushes the button to lower the hopper, the main machine controller energizes the contactor by grounding the Key switch control winding of the contactor. This causes a magnetic field to pull the normally-closed...

  • Page 254: Component Locations

    Service Manual – CS7000 Hopper System The Following Conditions Must Be Met for the Hopper Door Open and Close • There must be positive voltage to the . For this to happen: J7-1 Interlock Input – The must be closed.

  • Page 255: Hydraulic Power Pack Assembly

    Service Manual – CS7000 Hopper System Hydraulic Power Pack Assembly Hydraulic Power Pack Assembly mounted on the front of the machine frame and can be accessed when the hopper is up. The Hydraulic Power Pack extends and retracts the Assembly...

  • Page 256: Hopper Dump Door

    Service Manual – CS7000 Hopper System Hopper Dump Door on the bottom of Hopper Dump Door the hopper opens to allow the hopper to be emptied. Hopper Dump Door Actuator Hopper Dump Door The electric Hopper Dump Door Actuator Actuator...

  • Page 257: Hopper Interlock Switch

    Service Manual – CS7000 Hopper System Hopper Interlock Switch is a proximity sensor on the left front Hopper Interlock Switch of the machine frame that senses when the hopper is all the way down in the normal operating position. Hopper...

  • Page 258: Troubleshooting

    Service Manual – CS7000 Hopper System Troubleshooting Note: You can use the Service Mode to toggle the various system components on and off to check for function. Refer to the section for information on how to enter Control System/Service Mode and use the Service Mode.
  • Page 259 Service Manual – CS7000 Hopper System Problem Cause Correction The hopper dump Something is physically Check the door and hopper and clear or remove any door will not open or lodged between the door debris or objects as necessary. close.

  • Page 260: Removal And Installation

    Service Manual – CS7000 Hopper System 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 Hydraulic Power Pack Assembly LPG and Diesel Models Disconnect the battery.
  • Page 261 Service Manual – CS7000 Hopper System Slide the tray with the batteries out to the limit of the tether cable. Tray and Batteries Use some large hooks to grab the bumper and raise the hopper up slightly using a hoist or other suitable method.

  • Page 262: Battery Models

    Service Manual – CS7000 Hopper System 13. Plug the up port of the pump assembly.(It is labeled on the pump) 14. Momentarily run the pump to get oil out of the “down port” by pressing the hopper down switch. 15. Transfer the plug from the up port to the down port of the pump assembly 16.
  • Page 263 Service Manual – CS7000 Hopper System Fill the reservoir with 10W 30 engine oil. Note: In the remaining steps it is important that the oil level always be maintained above the minimum mark on the reservoir. Plug the up port of the pump assembly.(It is labeled on the pump)

  • Page 264: To Remove And Reinstall The Hopper Lift Cylinder

    Service Manual – CS7000 Hopper System To Remove and Reinstall the Hopper Lift Cylinder Raise the hopper to a convenient working height. Support the hopper with a hoist to prevent it from falling once the hopper lift cylinder is disconnected.
  • Page 265 Service Manual – CS7000 Hopper System There are two holding External Retaining Rings in position. To remove the Cylinder Pin , remove the Cylinder Pin External Retaining Ring next to the as shown. Frame Weldment External Retaining Ring (remove) Support the hopper lift cylinder and hopper prop rod.
  • Page 266 Service Manual – CS7000 Hopper System To install the hopper lift cylinder, place it in position at the lower pivot point and reinstall , and the Hinge Pin Weldment 1/4”-20 Screw. Hinge Pin Weldment 1/4”-20 Screw 10. Use or other suitable strapping to...

  • Page 267: To Replace The Oil In The Hydraulic System

    Service Manual – CS7000 Hopper System To Replace the Oil in the Hydraulic System Note: Refer to the adjacent hydraulic system schematic when disassembling and reassembling the hydraulic power pack components. Raise the hopper. Engage the parking brake and remove the key from the key switch.
  • Page 268 Service Manual – CS7000 Hopper System Remove the next to the External Retaining Ring as shown. Frame Weldment External Retaining Ring (remove) or other suitable strapping to Wire Ties support the while you work Hydraulic Cylinder on the system. Wire...
  • Page 269 Service Manual – CS7000 Hopper System Support the hopper lift cylinder and hopper prop rod. Then remove the Cylinder Pin External Retaining Ring (do not Flange remove) Bearing (2) Frame Weldment Cylinder Sleeve Bearing (inside weldment) Hopper Prop Rod Place a drip pan underneath the hydraulic power pack assembly and hydraulic cylinder.
  • Page 270 Service Manual – CS7000 Hopper System 12. Rotate the upward back Lower Cylinder Fitting to its original upward position and make sure nut is tight. Lower Cylinder Fitting 13. Install a into the Lower Cylinder Fitting Lower Cylinder Fitting 14. Disconnect the from “DOWN”...
  • Page 271 Service Manual – CS7000 Hopper System 16. Remove the Reservoir Guard Reservoir Guard 17. Loosen the four holding the Phillips Screws to the and remove Reservoir Pump Assembly Reservoir Note: Leaving the Pump Phillips Screws Phillips Assembly will make it...
  • Page 272 Service Manual – CS7000 Hopper System 23. Loosen the on the Plug “UP” Hydraulic Hose, then position the end of the “UP” Hydraulic “UP” over the drip pan. Hose Hydraulic Hose Plug 24. Jog the hopper raise button to run the pump and force the oil out of the “UP”...
  • Page 273 Service Manual – CS7000 Hopper System 28. Remove the cap from the “DOWN” Pump Port and reconnect the “DOWN” Hydraulic Hose “DOWN” Pump Port “DOWN” Hydraulic Hose “DOWN” Pump Port 29. Disconnect the from the “UP” Hydraulic Hose Lower Cylinder Fitting 30.
  • Page 274 Service Manual – CS7000 Hopper System 32. Slightly loosen the “DOWN” Hydraulic Hose Upper Cylinder Upper Cylinder Fitting Fitting 33. Jog the hopper lower button to run the pump and force the oil out of the “DOWN” Hydraulic at the...
  • Page 275 Service Manual – CS7000 Hopper System 38. Remove the wire ties and reconnect the cylinder ram and prop rod to the hopper lift weldment. Make sure the sleeve bearing and the two flange bearings are not damaged and are installed correctly.

  • Page 276: To Remove And Reinstall The Hopper Dump Door Actuator Assembly

    Service Manual – CS7000 Hopper System To Remove and Reinstall the Hopper Dump Door Actuator Assembly Open the hopper and engage the hopper prop rod. Open the hopper dump door to relieve the tension on the hopper dump door actuator assembly.

  • Page 277: Specifications

    Service Manual – CS7000 Hopper System Specifications Component Specifications Displacement - 0.0321 in. per revolution Circuit Type - reversible, locking Hydraulic Pump/Reservoir Assembly Reservoir Capacity - 45 in. (26 in. usable) Oil Type - 10W-30 automotive oil Voltage - 36 VDC Output Torque - 151 ft-lbs.

  • Page 278: Options And Accessories

    Service Manual – CS7000 Options and Accessories Description Illustration Seat Belt Kit Recovery Tank Clean Out Door Recovery Tank Clean Out Kit The Recovery Tank Clean Out Kit includes a removable Recovery to allow Tank Clean Out Door easier cleaning and flushing of the...
  • Page 279 Service Manual – CS7000 Options and Accessories Description Illustration Fire Extinguisher Kit LED Brake Light/Turn Signal Kit The LED Brake Light/Turn Signal Kit includes front turn signal lights, rear brake/turn signal lights, a rear corner roller kit, mounting hardware and electrical connectors. The main machine controller powers the turn signal lights and brake light.
  • Page 280 Service Manual – CS7000 Options and Accessories Description Illustration Rear Corner Roller Kit Hopper Temperature Sensor Kit The Hopper Temperature Sensor Temperature Switch Kit includes a Temperature Switch and mounting hardware. If the temperature in the hopper rises to a certain point, the...
  • Page 281 Service Manual – CS7000 Options and Accessories Description Illustration High Pressure Pump Kit - LPG and Diesel Hybrids The High Pressure Pump Kit includes a separate high-pressure solution pump, engine-driven pump clutch and drive belt, high- pressure wand assembly, and the associated valves and plumbing.
  • Page 282 Service Manual – CS7000 Options and Accessories Description Illustration EcoFlex Chemical Injection Kit ™ The EcoFlex Chemical Injection ™ Kit includes the detergent pumps, detergent bottles, mounting hardware and associated plumbing to inject detergent into the solution flow to the Solution scrub brushes.
  • Page 283 Service Manual – CS7000 Options and Accessories Description Illustration Hot Water Scrub Kit The Hot Water Scrub Kit includes a Heat Exchanger , mounting hardware Heat Exchanger and associated plumbing to route the solution through the Heat Exchanger before it is mixed with detergent and sent to the scrub brushes.
  • Page 284 Service Manual – CS7000 Options and Accessories Description Illustration Spray Wash Hose Kit The Spray Wash Hose Kit includes a separate low-pressure pump to pump solution from the solution tank to the hose and nozzle located behind the Operator seat. An...
  • Page 285 Service Manual – CS7000 Options and Accessories Description Illustration Overhead Guard Beacon Kit The Overhead Guard Beacon Kit includes an LED beacon and electrical connector, and the mounting hardware to mount the beacon onto the overhead guard. The beacon will flash whenever the machine key switch is on.
  • Page 286 Service Manual – CS7000 Options and Accessories Description Illustration Vacuum Wand Kit Overhead Guard Canopy Kit Front Bumper Kit The Front Bumper Kit includes the front bumper weldment, a front corner roller kit and mounting hardware.
  • Page 287 Service Manual – CS7000 Options and Accessories Description Illustration Accessory Socket Kit The Accessory Socket Kit includes a 12-volt “automotive” type adapter to power accessories or personal electronics, and a circuit breaker. Drain Hose Extension Arm Rest Option (R/H Only)

  • Page 288: Recovery System

    Service Manual – CS7000 Recovery System Functional Description Overview The recovery system picks up the scrubbing solution from the floor and directs it to the recovery tank. Two vacuum motors draw air from the recovery tank to create a vacuum in the tank and at the squeegee to pick up the solution.

  • Page 289: Recovery System Wiring Diagram

    Service Manual – CS7000 Recovery System Recovery System Wiring Diagram Battery Fuse, 400 A A1 Main Machine Controller A3 Control Panel WHT/BRN J7-10 +12V J1-1 42V Alternator J7-11 B- J1-2 J7-3 CAN H J1-3 VIO/GRN J7-2 CAN L J1-4 J7-19 Start Input...

  • Page 290: Circuit Description

    Service Manual – CS7000 Recovery System Circuit Description The following conditions must be met for the recovery system to operate: • The must be closed. Hopper Interlock Switch S3 • There must be positive voltage to the . For this to happen: J7-1 Interlock Input –...

  • Page 291: Component Locations

    Service Manual – CS7000 Recovery System Component Locations Recovery Tank is on the left rear side Recovery Tank of the machine. The carries Vacuum Fan Recovery Squeegee Hose Cover Assembly Tank Cover the scrub solution from the squeegee to . The...

  • Page 292: Vacuum Fan Cover Assembly

    Service Manual – CS7000 Recovery System Vacuum Fan Cover Assembly includes the Vacuum Fan Cover Assembly Vacuum Filter Vacuum Lid Assembly Filter Filter Screen Vacuum Fan Cover Filter Lid fastens to the top of the Vacuum Fan Cover Assembly Assembly .

  • Page 293: Maintenance And Adjustments

    Service Manual – CS7000 Recovery System Maintenance and Adjustments Warning! Before performing any machine maintenance or adjustments, make sure the key switch is off, the key is removed from the machine and the parking brake is engaged. To Clean the Vacuum Filter and Filter Screen...

  • Page 294: To Clean The Debris Basket

    Service Manual – CS7000 Recovery System To Clean the Debris Basket Unhook the , open the Latch Recovery and lift the Tank Cover Debris Basket out of the recovery tank. Debris Basket Rinse any accumulated material from , then reinstall it in Debris Basket the recovery tank.

  • Page 295: Troubleshooting

    Service Manual – CS7000 Recovery System Troubleshooting Note: You can use the Service Mode to toggle the various system components on and off to check for function. Refer to the section for information on how to enter Control System/Service Mode and use the Service Mode.

  • Page 296: Removal And Installation

    Service Manual – CS7000 Recovery System Problem Cause Correction An individual vacuum No voltage to the Check the wiring and connections to the vacuum motor and motor will not run. vacuum motor. repair as necessary. The motor is not If there is voltage to the vacuum motor, replace the motor.
  • Page 297 Service Manual – CS7000 Recovery System Disconnect the Recovery Tank Vacuum Motor Electrical Connector Recovery Tank Vacuum Motor Electrical Connector Note: If your machine is equipped with an extended scrub system, you Solution must disconnect the Float Switch Hose Wiring Harness...

  • Page 298: To Reinstall The Recovery Tank

    Service Manual – CS7000 Recovery System Pull the on the quick-disconnect fitting Collar and disconnect the Solution Hose Collar Solution Hose Disconnect the and carefully tip Tether Hook and lift the recovery tank off of the mounting pins on the machine frame.

  • Page 299: To Remove And Reinstall A Vacuum Motor

    Service Manual – CS7000 Recovery System To Remove and Reinstall a Vacuum Motor Lift up the Recovery Tank Cover Remove one of the , then twist and Hinge Tabs remove the from the Recovery Recovery Tank Cover Tank Cover . This will allow...

  • Page 300: Specifications

    Insulation Class - A Vacuum Motor Average - 15 Amps Current Draw Maximum - 17 Amps Sealed – 48” H Vacuum System Vacuum With 1” dia. Orifice – 25” to 30” H Special Tools Vacuum water lift gauge, Nilfisk-Advance part number 56205281...

  • Page 301: Scrub System

    Service Manual – CS7000 Scrub System Functional Description Overview The scrub system includes the scrub brushes, scrub brush motors, side squeegees, and the scrub deck actuator which lowers and raises the scrub deck. The scrub deck actuator lowers the scrub brushes any time the scrub system is enabled. The brush motors switch on when the drive pedal is moved from the neutral position.

  • Page 302: Scrub System Wiring Diagram

    Service Manual – CS7000 Scrub System Scrub System Wiring Diagram Battery Fuse, 400 A A1 Main Machine Controller A3 Control Panel WHT/BRN J7-10 +12V J1-1 42V Alternator J7-11 B- J1-2 J7-3 CAN H J1-3 VIO/GRN J7-2 CAN L J1-4 J7-19 Start Input...

  • Page 303: Circuit Description

    Service Manual – CS7000 Scrub System Circuit Description The Following Conditions Must be Met for the Scrub System To Operate • The must be closed. Hopper Interlock Switch S3 • There must be positive voltage to the . For this to happen: J7-1 Interlock Input –...

  • Page 304: Brush Current Sensor

    Service Manual – CS7000 Scrub System Brush Current Sensor • provides +5 volts to the J7-24 Brush Current Sensor • provides battery ground ( ) to the J7-25 Brush Current Sensor • The Input from the provides the signal to...

  • Page 305: Side Squeegee Assemblies

    Service Manual – CS7000 Scrub System Side Squeegee Assemblies Side Squeegee Assemblies are mounted to Weldment Arms Latch Weldment that are attached to the Deck/Arm Assembly . The Weldments Side Squeegee Catch are spring-loaded to Assemblies Knob Plate keep them firmly on the floor. A...

  • Page 306: Maintenance And Adjustments

    Service Manual – CS7000 Scrub System Maintenance and Adjustments Warning! Before performing any machine maintenance or adjustments, make sure the key switch is off, the key is removed from the machine and the parking brake is engaged. To Replace a Leading Deck Blade...

  • Page 307: Troubleshooting

    Service Manual – CS7000 Scrub System Troubleshooting Note: You can use the Service Mode to toggle the various system components on and off to check for function. Refer to the section for information on how to enter Control System/Service Mode and use the Service Mode.

  • Page 308: Removal And Installation

    Service Manual – CS7000 Scrub System Problem Cause Correction The scrub deck The retract limit Check the switch function and replace if necessary. Note that actuator will not switch ( ) is the retract limit switch is a proximity switch should be closed raise the deck.

  • Page 309: To Remove And Reinstall The Scrub Deck Actuator

    Service Manual – CS7000 Scrub System To Remove and Reinstall the Scrub Deck Actuator Remove the recovery tank (refer to the section). Recovery System Turn on the key switch and put the machine into the Service Test mode to allow you to jog the scrub deck up and down.
  • Page 310 Service Manual – CS7000 Scrub System Disconnect the to the three , to the on the Electrical Connectors Scrub Motors Proximity Sensor Deck Lift Arm and to the . Jog the up or down as necessary to access the Assembly...
  • Page 311 Service Manual – CS7000 Scrub System 11. Reinstall the by following the above steps in reverse order. Scrub Deck Service Note: When you reinstall the Scrub Deck • Make sure you reconnect the to the correct in the wire harness as...

  • Page 312: To Remove And Reinstall A Scrub Motor Assembly

    Service Manual – CS7000 Scrub System To Remove and Reinstall a Scrub Motor Assembly Remove the scrub deck from the machine. Disconnect the electrical connector from the Scrub Motor Assembly Electrical Connector Remove the from the Scrub Scrub Brush Brush Plate...

  • Page 313: To Replace The Scrub Motor Carbon Brushes

    Service Manual – CS7000 Scrub System To Replace the Scrub Motor Carbon Brushes Note: The minimum length of the carbon brushes in the scrub motors is 0.5” [13 mm]. If the carbon brushes are less than 0.5” [13 mm] long, replace them.
  • Page 314 Service Manual – CS7000 Scrub System Carefully pry the from the End Casting . Be careful not to lose the wave Frame washer between the End Casting the motor bearing. Casting Frame Replace the carbon brushes as follows: a. Observe how the springs roll when the brush is pushed back before taking it apart.
  • Page 315 Service Manual – CS7000 Scrub System d. Push the back against the spring and insert Brush a stiff temporary (paper clip or Retaining Wire ) through the access hole in the end cover. T-pin (Remove silicone sealer from the holes.) The wire...

  • Page 316: Specifications

    Service Manual – CS7000 Scrub System d. Carefully install a new between the Gasket Frame and the . Make sure the End Casting Gasket seated flat on the mating surfaces. Casting e. Once the is installed, fully seat the Gasket...

  • Page 317: Special Tools

    Service Manual – CS7000 Scrub System Component Specifications Air Gap @ Make - .250 in. (typical) Retract Limit Switch Air Gap @ Break - .313 in. (typical) (Proximity Sensor) Contact resistance (initial) - 150 milliohms max. Special Tools A spring puller is recommended to remove the Extension Springs from the Weldment Arms when removing the Side Squeegee Assemblies.

  • Page 318: Solution System

    Service Manual – CS7000 Solution System Functional Description Overview The solution system delivers water, or detergent and water, to the floor for the scrub system. The solution system includes the solution tank (main body of machine) and solution pressure (level) sensor, solution shutoff valve, solution filter, solution pump or pumps (some models), solution solenoid valve, and the associated plumbing to distribute solution to the nozzles at the three scrub brushes.

  • Page 319: Ecoflex™ Detergent System

    Service Manual – CS7000 Solution System EcoFlex™ Detergent System The EcoFlex™ detergent system uses dual diaphragm pumps ( ) to pump detergent into the solution flow upstream of the solution solenoid valve. Two detergent pumps are used when necessary to ensure adequate detergent supply at the higher detergent and solution flow rates.

  • Page 320: Optional High-Pressure Spray System (Lp And Diesel Only)

    Service Manual – CS7000 Solution System Optional High-pressure Spray System (LP and Diesel Only) The optional high-pressure spray system uses a separate pump, driven by the engine via a clutch, to pump solution at high pressure from the tank to the hose and wand.

  • Page 321: Solution System Wiring Diagram

    Service Manual – CS7000 Solution System Solution System Wiring Diagram Battery Fuse, 400 A 42V Alternator A1 Main Machine Controller VIO/GRN J7-19 Start Input YEL/BRN BLK/ORN J2-14 Output Aux Contactor J7-14 J7-12 Supression YEL/BRN RED/BLK Input Diode Ignition Switch Hopper...

  • Page 322: Circuit Description

    Service Manual – CS7000 Solution System Circuit Description The Following Conditions Must be Met for the Solution System to Operate • The must be closed. Hopper Interlock Switch S3 • There must be positive voltage to the . For this to happen: J7-1 Interlock Input –...

  • Page 323: The Following Conditions Must Be Met For The Ecoflex™ System To Operate

    Service Manual – CS7000 Solution System – The (float) in the recovery tank must be open to prevent the Extended Scrub Level Switch S4 J7-15 Input from going to battery negative. Note the switch opens when there is adequate water in the recovery tank, and closes when the recovery tank is empty.

  • Page 324: Component Locations

    Service Manual – CS7000 Solution System Component Locations Solution Tank Drain Hose underneath the rear right-hand side of the Drain Hose solution tank allows you to drain the solution tank. To Pipe drain the tank, remove the Pipe Cap Drain...

  • Page 325: Solution Pressure Sensor

    Service Manual – CS7000 Solution System Solution Pressure Sensor on the back Solution Pressure Sensor of the uses the air Operator Interface Panel Sensor Operator pressure in the to determine Sensor Tube Tube Interface the solution level in the tank. The...

  • Page 326: Solution Solenoid Valve

    Service Manual – CS7000 Solution System Solution Solenoid Valve is located Solution Solenoid Valve on the top center of the scrub deck and supplies the solution to the Solution . The connects to Manifold Solution Manifold Solution the three going to the three scrub...

  • Page 327: Ecoflex™ Detergent Bottles And Pumps

    Service Manual – CS7000 Solution System EcoFlex™ Detergent Bottles and Pumps are located EcoFlex™ Detergent Bottles underneath the Operator seat and supply EcoFlex™ detergent to the two EcoFlex™ Detergent Detergent . The two Pumps EcoFlex™ Detergent Pumps Pump (2) run simultaneously and pump detergent through separate lines that merge into one main detergent supply line.

  • Page 328: Extended Scrub System

    Service Manual – CS7000 Solution System supplies solution Solution Supply Line from the to the Solution Tank High-pressure . The pumps the Pump High-pressure Pump solution to the which functions Relief Valve as follows: Solution • If the trigger valve on the...

  • Page 329: Maintenance And Adjustments

    Service Manual – CS7000 Solution System Maintenance and Adjustments Warning! Before performing any machine maintenance or adjustments, make sure the key switch is off, the key is removed from the machine and the parking brake is engaged. To Clean the Solution Filter Screen Close the solution shutoff valve.

  • Page 330: To Clean The Extended Scrub System Strainer

    Service Manual – CS7000 Solution System To Clean the Extended Scrub System Strainer Open the recovery tank cover and remove the debris basket. Rinse any accumulated material off of the Extended Scrub System Strainer using normal water hose pressure. Reinstall the debris basket and close the recovery tank cover.

  • Page 331: To Adjust The Belt Tension On The High Pressure Pump

    Service Manual – CS7000 Solution System To Adjust the Belt Tension on the High Pressure Pump Drain and remove the recovery tank. Loosen the four 3/8”-16 Screws holding the High-pressure to the machine Pump Assembly frame. High-pressure Pump Assembly Loosen the...

  • Page 332: Troubleshooting

    Service Manual – CS7000 Solution System Troubleshooting Note: You can use the Service Mode to toggle the various system components on and off to check for function. Refer to the section for information on how to enter Control System/Service Mode and use the Service Mode.
  • Page 333 Service Manual – CS7000 Solution System Problem Cause Correction Inadequate solution The extended scrub function Install the extended scrub function in the configuration flow to the brushes in is not installed in the menu. the extended scrub configuration menu. mode The stainer in the recovery Remove and clean the strainer.
  • Page 334 Service Manual – CS7000 Solution System Problem Cause Correction The high-pressure The high-pressure wand Press the high-pressure wand switch to engage the spray system is not switch on the control panel high-pressure solution pump. operating. has not been pressed. The high pressure wash...

  • Page 335: Removal And Installation

    Service Manual – CS7000 Solution System 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 Solution Tank Caution: The solution tank is relatively heavy.
  • Page 336 Service Manual – CS7000 Solution System Disconnect the Steering Sensor Electrical Connector Steering Sensor Electrical Connector Disconnect the additional wiring running from the solution tank to the engine (ground, starter, engine interface, etc.). 10. Remove the Electrical Panel Electrical Main Machine...
  • Page 337 Service Manual – CS7000 Solution System 13. Remove the five mounting screws holding the solution tank to the frame. The mounting screw locations are shown below. The three bottom mounting screws Solution Tank are located underneath the machine Mounting Screw...
  • Page 338 Service Manual – CS7000 Solution System The bottom center Solution Tank Mounting is located underneath the machine by Screw the right-hand side squeegee assembly. Solution Tank Mounting Screw The bottom front Solution Tank Mounting Screw is located underneath the machine by the Solution Tank main broom actuator and scrub deck actuator.

  • Page 339: To Remove And Reinstall The Solution Shutoff Valve

    Service Manual – CS7000 Solution System To Remove and Reinstall the Solution Shutoff Valve Drain the solution tank. Remove the valve shield. Remove the nuts, washers and U-bolts holding the Solution Filter Assembly Hose to Solution the mounting plate. Solenoid Valve...

  • Page 340: To Remove And Reinstall The Solution Solenoid Valve

    Service Manual – CS7000 Solution System To Remove and Reinstall the Solution Solenoid Valve Service Note: You can remove and the reinstall the solution solenoid valve with the scrub deck either in or out of the machine. Empty and remove the recovery tank from the machine.

  • Page 341: Specifications

    Service Manual – CS7000 Solution System Carefully slide the out of the Detergent Pump Pump Pump Mount Mount Weldment Detergent Weldment Hoses Disconnect the Detergent Hoses Electrical Detergent , then remove the from the Pump (2) Connectors Detergent Pump machine.
  • Page 342 Service Manual – CS7000 Solution System Component Specifications Type - diaphragm, self-priming, internal check valve Voltage - 36 VDC, permanent magnet Internal pressure switch: • Set to switch pump on at 25 ± 5 psi • Set to shut pump off at 45 psi...

  • Page 343: Special Tools

    Service Manual – CS7000 Solution System Special Tools Loctite® “No More Leaks” White Threaded Plastic Pipe Sealant (used on solution shutoff valve threads)

  • Page 344: Squeegee System

    Service Manual – CS7000 Squeegee System Functional Description Overview The squeegee assembly is mounted at the bottom rear of the machine and picks up the water from the floor. Two squeegee blades (front and rear) pick up the water and direct it into the squeegee support assembly.

  • Page 345: Circuit Description

    Service Manual – CS7000 Squeegee System Circuit Description The following conditions must be met for the squeegee system to operate: • The must be closed. Hopper Interlock Switch S3 • There must be positive voltage to the . For this to happen: J7-1 Interlock Input –...

  • Page 346: Maintenance And Adjustments

    Service Manual – CS7000 Squeegee System Maintenance and Adjustments Warning! Before performing any squeegee maintenance or adjustments, 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 Squeegee Blades Raise the squeegee to its retracted position.

  • Page 347: To Remove And Reinstall The Rear Squeegee Blade

    Service Manual – CS7000 Squeegee System To Remove and Reinstall the Rear Squeegee Blade Release the and remove Latch Squeegee Squeegee Strap Strap Remove the Rear Squeegee from the Rear Blade Squeegee Squeegee Weldment Blade Rotate the existing Rear top-to-bottom...

  • Page 348: To Adjust The Squeegee Tilt

    Service Manual – CS7000 Squeegee System To Adjust the Squeegee Tilt Lower the squeegee and drive the machine forward a short distance so the squeegee assumes its normal operating angle. Check the deflection angle of the . It Rear Squeegee Blade should be approximately 45 degrees to the floor surface as shown.

  • Page 349: To Adjust The Squeegee Casters

    Service Manual – CS7000 Squeegee System To Adjust the Squeegee Casters The height of the may need to be adjusted to Squeegee Casters compensate for squeegee wear and to obtain the correct squeegee tilt angle. To adjust the height of a...

  • Page 350: Troubleshooting

    Service Manual – CS7000 Squeegee System Troubleshooting Note: You can use the Service Mode to toggle the various system components on and off to check for function. Refer to the section for information on how to enter Control System/Service Mode and use the Service Mode.

  • Page 351: Removal And Installation

    Service Manual – CS7000 Squeegee System 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 Squeegee Support Assembly...

  • Page 352: To Remove And Reinstall The Squeegee Lift Actuator

    Service Manual – CS7000 Squeegee System To Remove and Reinstall the Squeegee Lift Actuator Remove the recovery tank. Remove the squeegee tool assembly. (This will reduce the weight on the Squeegee Lift Arm Disconnect the lift actuator electrical connector. Remove the...

  • Page 353: Specifications

    Service Manual – CS7000 Squeegee System Specifications Component Specifications Squeegee Tool Assembly Squeegee Blade, Front, Material - Linatex 40 Red Gum Color - Red Hardness - 40 ±5 Shore A Durometer Squeegee Blade, Rear, Red Tensile Strength - 3000 Psi Minimum Elongation - 600% Minimum Dynamic Load - 200 lbs.

  • Page 354: Steering System

    Service Manual – CS7000 Steering System Functional Description Summary The steering system utilizes steer by wire technology. The major electrical components are the Steering Controller, Steering Wheel Rotation Sensor, Steering Actuator and the Steering Travel Limit Switches. The Steering Controller receives input signals from the Steering Wheel Rotation sensor that tell it which direction the steering wheel is turning and how fast it is rotating.

  • Page 355: Steering Actuator

    Service Manual – CS7000 Steering System The Steering Wheel Sensor also has an electromagnetic clutch called a “Torque Feedback Device” which provides steering feel to the operator. The clutch consists of multiple fiber discs and steel plates which are alternately stacked. The steel plates are splined to the steering shaft so they always rotate with the shaft.

  • Page 356: Steering Travel Limit Switches

    Service Manual – CS7000 Steering System Steering Travel Limit Switches The Steering Travel Limit Switches are magnetic “proximity” switches that are normally open. They are mounted on each side of the frame. There is a bracket mounted on the drive wheel steering ring gear with a “tooth”.

  • Page 357: Steering System Wiring Diagram

    Service Manual – CS7000 Steering System Steering System Wiring Diagram 36 V From Key Switch...

  • Page 358: Circuit Description

    Service Manual – CS7000 Steering System Circuit Description The steering controller power has more than one power supply. The main heavy current power sources are bolt on lugs that supply both battery positive and negative connections. These connection points are clearly labeled on the controller.
  • Page 359 WaveStar : NotesSheet(1) Page: 1 Service Manual – CS7000 Steering System WaveStar : NotesSheet(2) Page: 1 As the steering wheel rotates, the A1 signal switches back and forth from 0v (low) to 5v (high). When viewed on a scope (oscilloscope) it looks like a “square wave” pattern. When the steering wheel rotation is slow, the switching frequency is slow.
  • Page 360 Service Manual – CS7000 Steering System The steering controller controls a safety relay (K14) to shut down the drive wheel system in the event that there is a serious steering system error. The relay coil receives battery voltage from the key switch (The same as J5-1).
  • Page 361 Service Manual – CS7000 Steering System The Steering Motor incorporates an encoder that reports both direction and speed information to the controller. The operation is similar to the steering wheel rotation sensor encoders however; there is only a single “pair” of signals and the pattern is not square. The frequency of the signal provides speed information.

  • Page 362: Component Locations

    Service Manual – CS7000 Steering System Component Locations • Steering Wheel Rotation Sensor • Steering Wheel Rotation Sensor Connector • Steering Actuator - Rear of machine in front of drive wheel motor. • Steering Controller - Left rear of machine...

  • Page 363: Maintenance And Adjustments

    Service Manual – CS7000 Steering System Maintenance and Adjustments Check bolt torque of wiring connections at the Steering Controller every six months. Troubleshooting If a problem occurs with the steering system, begin by checking the Status LED condition on the steering controller and for steering system DTCs (Diagnostic Trouble Codes).

  • Page 364: Diagnostic Trouble Code Table

    Service Manual – CS7000 Steering System The Steering faults menu displays all of the codes that have ever been set in the system. The codes are displayed in “reading order”, separated by commas and are sorted with the most recent at the top left.
  • Page 365 Service Manual – CS7000 Steering System Error Source Description Check Motor The Motor Temperature is above 180 Restrictions to steering actuator Temperature °C (356 °F) movement. High Actuator - temperature sensor accuracy Steering The Steering Controller Temperature Restrictions to steering actuator Controller is above 125 °C (257 °F)
  • Page 366 Service Manual – CS7000 Steering System Error Source Description Check AC Current – The software detected excessive Actuator - shorted/burned stator Excessive current flow in the steering actuator windings. motor circuits. Wiring (U, V & W) - Shorted to ground or one another.
  • Page 367 Service Manual – CS7000 Steering System Error Source Description Check Motor cable not One or more of the motor cables Wiring - U, V and W cables and connected (U,V between the steering actuator and connections. or W wire open)

  • Page 368: Symptom Troubleshooting (No Dtc Stored)

    Service Manual – CS7000 Steering System Symptom Troubleshooting (No DTC stored) Steering Inoperative - Steering Controller Status LED is Blinking Rapidly Check for steering system codes. Steering Inoperative - Steering Controller Status LED is Off Check power and ground supplies to the steering controller.

  • Page 369: Removal And Installation

    Service Manual – CS7000 Steering System Removal and Installation Steering Wheel Assembly Turn the machine off, set the parking brake and disconnect the 36 V battery main power plug. Lift the Rear Engine Cover (A) to access the Main Harness Connector and Steering Clamp Plate (E) on the Steering Assembly (B) as shown.

  • Page 370: Steering Wheel Rotation Sensor

    Service Manual – CS7000 Steering System Steering Wheel Rotation Sensor Caution! Do not hit steering wheel shaft with a hammer to remove the steering wheel. Doing so may damage the encoder inside the steering wheel sensor. Remove steering wheel assembly (See section directly above).
  • Page 371 Service Manual – CS7000 Steering System Remove tilt lever pivot hardware on one side. 10. Remove tilt lever pivot nut on other side. Remove tilt lever, then remove pivot hardware 11. Remove steering pivot nut and hardware on one side, then on the other.
  • Page 372 Service Manual – CS7000 Steering System 13. Remove the 4 nuts and screws securing the steering wheel rotation sensor, then remove the sensor and shaft out of the weldment. 14. Remove the nut and bolt that attaches the universal joint to the sensor shaft.

  • Page 373: Steering Controller

    Service Manual – CS7000 Steering System Steering Controller Drain recovery tank. Turn machine off, set the parking brake and disconnect the main power plug. Remove recovery tank a. Tip tank out and let it rest on the retention cable. b. Disconnect the vacuum motor electrical connector. (If equipped with extended scrub, also disconnect the additional electrical connector and hose connection.)
  • Page 374 Service Manual – CS7000 Steering System Remove the three screws securing the controller mounting bracket to the frame, then remove the assembly. Disconnect the steering actuator encoder connector. Remove the four steering actuator mounting bolts. Remove the steering actuator. 10. Reassemble in reverse order.

  • Page 375: Specifications

    Service Manual – CS7000 Steering System Specifications Shop Measurements Shop measurements are values that were measured on a real machine. While they are not “specifications”, they can help you recognize normal vs. abnormal. Steering Wheel Rotation Sensor Voltage Measurements All voltages are DC unless otherwise stated and were measured with the negative (black) voltmeter lead on battery negative and the key on.

  • Page 376: Steering Controller Voltage Measurements

    Service Manual – CS7000 Steering System Steering Controller Voltage Measurements J5 Connector Wire Color Circuit Voltage J5-1 GRA/ORN Key Switch Power 38.5 J5-2 BRN/WHT TFD Control 23.9v J5-3 ORN/BLK 5v supply - out 5.03 J5-4 Ground (Internal) 0.002v J5-5 Motor Encoder 2.6v (motor stationary) 3.5v (motor...

  • Page 377: Motor U, V And W Terminal Pair Voltages

    Service Manual – CS7000 Steering System Motor U, V and W Terminal Pair Voltages • U to V - 1.9 VAC with stationary motor. Up to 18 VAC when motor is turning quickly. • V to W - 1.9 VAC with stationary motor. Up to 18 VAC when motor is turning quickly.

  • Page 378: Sweep System, Main

    Service Manual – CS7000 Sweep System, Main Functional Description Overview The main sweep system picks up debris from the floor and throws it into the hopper for later disposal. The main sweep system includes the main broom, broom motor, and the broom lift actuator which lowers and raises the main broom.

  • Page 379: Main Sweep System Wiring Diagram

    Service Manual – CS7000 Sweep System, Main Main Sweep System Wiring Diagram Battery Fuse, 400 A A1 Main Machine Controller A3 Control Panel WHT/BRN J7-10 +12V J1-1 42V Alternator J7-11 B- J1-2 J7-3 CAN H J1-3 VIO/GRN J7-2 CAN L...

  • Page 380: Circuit Description

    Service Manual – CS7000 Sweep System, Main Circuit Description The Following Conditions Must be Met for the Main Sweep System To Operate • The must be closed. Hopper Interlock Switch S3 • There must be positive voltage to the . For this to happen: J7-1 Interlock Input –...

  • Page 381: Broom Current Sensor

    Service Manual – CS7000 Sweep System, Main Broom Current Sensor • provides +5 volts to the J7-24 Broom Current Sensor • provides battery ground ( ) to the J7-25 Broom Current Sensor • The Input from the provides the signal to...

  • Page 382: Maintenance And Adjustments

    Service Manual – CS7000 Sweep System, Main Maintenance and Adjustments Warning! Before performing any maintenance or adjustments on the main sweep system, make sure the key switch is off, the key is removed from the machine and the parking brake is engaged.

  • Page 383: To Adjust The Main Broom Tilt

    Service Manual – CS7000 Sweep System, Main Note: If the width of the main broom sweep pattern is not consistent along the entire length of the main broom, you may need to adjust the main broom tilt. Refer to the To Adjust the Main section below.

  • Page 384: Inspecting/Replacing Main Broom Motor Carbon Brushes

    Service Manual – CS7000 Sweep System, Main Inspecting/Replacing Main Broom Motor Carbon Brushes Remove the main broom motor and gearbox assembly. See the section. Removal and Installation Create witness marks on the gearbox, motor end bells (covers) and the motor casing for reassembly.
  • Page 385 Service Manual – CS7000 Sweep System, Main Remove the electrical connection cover. Remove the wires from the electrical connections. Note the locations of the wires for reassembly. Working from the gearbox end of the motor, remove the two long through bolts.
  • Page 386 Service Manual – CS7000 Sweep System, Main Temporarily set the O-ring seal aside. Install the wave washer. (Retain it with some grease if necessary) 10. Reinstall the cover. a. Gently pry the carbon brushes back against their springs just far enough to slip them over the commutator.

  • Page 387: Troubleshooting

    Service Manual – CS7000 Sweep System, Main Troubleshooting Note: You can use the Service Mode to toggle the various system components on and off to check for function. Refer to the section for information on how to enter Control System/Service Mode and use the Service Mode.

  • Page 388: Removal And Installation

    Service Manual – CS7000 Sweep System, Main Problem Cause Correction The broom lift actuator No voltage to the main broom 1. Check the wiring and connectors from the A1 is not raising and actuator. Main Machine Controller to the main broom lowering the main actuator motor and repair as necessary.

  • Page 389: To Install The Main Broom

    Service Manual – CS7000 Sweep System, Main Move the out of the way and Dust Flap swing open the Dust Broom Arm Assembly Flap Pull the out of the Main Broom machine. Main Broom To Install the Main Broom Install the...

  • Page 390: To Remove And Reinstall The Broom Motor Assembly

    Service Manual – CS7000 Sweep System, Main To Remove and Reinstall the Broom Motor Assembly Remove the main broom from the machine. Open the hopper and engage the prop rod. Remove the holding 5/16”-18 Hex Screw onto the Broom Drive Hub Assembly...

  • Page 391: To Remove And Reinstall The Broom Lift Actuator

    Service Manual – CS7000 Sweep System, Main To Remove and Reinstall the Broom Lift Actuator Remove the recovery tank. Remove the main broom from the machine. Turn the key switch on and switch the machine to the Service Mode. Extend the scrub deck downward in the Service Test Mode. This will give you additional clearance for removing the hair cotter pins and clevis pins on the broom lift actuator.
  • Page 392 Service Manual – CS7000 Sweep System, Main Remove the , washers Hair Cotter Pin holding the .50” x 1.75” Clevis Pin top of the to the Broom Lift Actuator Hair Cotter Spring Arm Spring Arm Disconnect the Broom Lift Actuator electrical connector and remove the from the machine.

  • Page 393: Specifications

    Service Manual – CS7000 Sweep System, Main Specifications Component Specifications RPM - 3400 Main Broom Motor Voltage - 36 VDC Amperage - 26 Amps Dynamic Load - 400 lbs. maximum Static Load - 1000 lbs. maximum Restraining Torque - Actuator is internally restrained...

  • Page 394: Sweep System, Side Broom

    Service Manual – CS7000 Sweep System, Side Broom Functional Description Side Broom Side Broom Side Broom Actuator Overview Motor (2) Lift Weldment run in opposite directions Side Brooms to direct debris from the sides of the machine toward the center where the main broom can direct it into the hopper.

  • Page 395: Side Broom System Wiring Diagram

    Service Manual – CS7000 Sweep System, Side Broom Side Broom System Wiring Diagram Battery Fuse, 400 A A1 Main Machine Controller A3 Control Panel WHT/BRN J7-10 +12V J1-1 42V Alternator J7-11 B- J1-2 J7-3 CAN H J1-3 VIO/GRN J7-2 CAN L...

  • Page 396: Circuit Description

    Service Manual – CS7000 Sweep System, Side Broom Circuit Description The Following Conditions Must be Met for the Side Broom Sweep System To Operate • The must be closed. Hopper Interlock Switch S3 • There must be positive voltage to the .

  • Page 397: Component Locations

    Service Manual – CS7000 Sweep System, Side Broom Component Locations Side Brooms are mounted on the front corners of the Side Brooms machine, below the hopper. Side Broom Side Broom Side Broom Motor Assemblies The side broom motor assemblies consist of the...

  • Page 398: Maintenance And Adjustments

    Service Manual – CS7000 Sweep System, Side Broom Maintenance and Adjustments Warning! Before performing any maintenance or adjustments on the side sweep system, make sure the key switch is off, the key is removed from the machine and the parking brake is engaged.

  • Page 399: Inspecting/Replacing Side Broom Motor Carbon Brushes

    Service Manual – CS7000 Sweep System, Side Broom Inspecting/Replacing Side Broom Motor Carbon Brushes Remove the side broom motor and gearbox assembly. See the section. Removal and Installation Create witness marks on the gearbox, motor end bells (covers) and the motor casing for reassembly.
  • Page 400 Service Manual – CS7000 Sweep System, Side Broom Inspect the carbon brushes and replace as necessary. New brush length is approximately 13/16” (20 Reinstall the cover with O-ring in place. a. Gently pry the carbon brushes back against their springs just far enough to slip them over the commutator.

  • Page 401: Troubleshooting

    Service Manual – CS7000 Sweep System, Side Broom Troubleshooting Note: You can use the Service Mode to toggle the various system components on and off to check for function. Refer to the section for information on how to enter Control System/Service Mode and use the Service Mode.

  • Page 402: Removal And Installation

    Service Manual – CS7000 Sweep System, Side Broom Problem Cause Correction The side broom No voltage to the side broom 1. Check the wiring and connectors from the A1 actuator is not raising actuator. Main Machine Controller to the side broom and lowering the side actuator and repair as necessary.
  • Page 403 Service Manual – CS7000 Sweep System, Side Broom 10. Slightly loosen the 1/2”-13 x .75” . Note that this screw is Hex Screw threaded directly into the hopper lift weldment. 11. Remove the two 1/2”-13 x 1.5” Hex , washers and Nyloc nuts.

  • Page 404: To Remove And Reinstall A Side Broom Hub Assembly

    Service Manual – CS7000 Sweep System, Side Broom To Remove and Reinstall a Side Broom Hub Assembly Remove the side broom motor assembly from the machine. Make sure the Motor Assembly Side Broom are adequately supported, then Hub Assembly carefully drive out the...
  • Page 405 Service Manual – CS7000 Sweep System, Side Broom Remove the two 3/8”-16 x .75” Screws 3/8”-16 x .75” holding the Actuator Actuator Bracket Weldment Screw (2) Bracket to the Hopper Lift Weldment Weldment Extend the side brooms in the Service Mode to extend the side broom actuator.
  • Page 406 Service Manual – CS7000 Sweep System, Side Broom Service Note: If you’re installing a new Side Broom Actuator, or if the on the Drive Nut Cylinder existing Side Broom Actuator has been rotated on the Acme threaded shaft, check the actuator extended and retracted dimensions and set as follows: Reconnect the side broom actuator electrical connector.

  • Page 407: Specifications

    Service Manual – CS7000 Sweep System, Side Broom Specifications Component Specifications No-load Speed - 2,800 RPM Rotation - Clockwise Side Broom Motors (all) Voltage - 42 VDC Power - .25 HP, Continuous Duty Current Draw (shop Side Broom Motor - Left Average - 3 Amps Max.

  • Page 408: Wheel System, Traction

    Service Manual – CS7000 Wheel System, Traction Functional Description A single rear wheel provides both traction drive and steering. The major components of the drive wheel system are the drive pedal, drive controller, drive wheel motor, gearbox and drive wheel. The drive wheel is mounted to a gearbox which carries the vehicle load, provides gear reduction and converts the plane of rotation from horizontal to vertical.

  • Page 409: Drive Wheel Motor

    Service Manual – CS7000 Wheel System, Traction Drive Wheel Motor The drive wheel motor is a brush-less three phase AC design. It is mounted on top of the gear box in the rear of the machine. It provides rotational power to the gear box. The wheel drive motor can change rotation direction to propel the machine both forward and backward.

  • Page 410: Powering Up The Drive Controller

    Service Manual – CS7000 Wheel System, Traction Powering up the Drive Controller When the key switch is turned on, power is supplied on the orange wire to pin J4-1. When each interlock switch closes (seat switch, safety relay switch, emergency stop switch and battery interlock switch ), power is supplied on the green/blue wire to pin J4-9.
  • Page 411 Service Manual – CS7000 Wheel System, Traction Drive Motor The drive controller supplies current to the drive motor stator windings on the three large U, V and W wires. When stationary, the controller pulses a current to all the motor stator windings in “unison”. This holds the motor in a fixed position.
  • Page 412 Service Manual – CS7000 Wheel System, Traction WaveStar : NotesSheet(2) Page: 1 The drive motor has an internal “encoder” that provides feedback to the drive controller regarding rotation direction and speed. The drive controller provides a 5v power supply out of pin J4-26 to the encoder connector pin 2.

  • Page 413: Can Bus

    Service Manual – CS7000 Wheel System, Traction CAN Bus The drive controller communicates with the main machine controller via the CAN Bus. The drive controller transmits error codes to the main machine controller. The main machine controller sends several messages to the drive controller that regulate machine speed mode.

  • Page 414: Component Locations

    Service Manual – CS7000 Wheel System, Traction Component Locations • Drive Pedal Position Sensor • Drive controller • Drive Wheel Motor Drive Pedal Position Sensor Drive Wheel Motor Drive Controller Pictured with recovery tank removed...

  • Page 415: Maintenance And Adjustments

    Service Manual – CS7000 Wheel System, Traction Maintenance and Adjustments Drive Controller There are no user serviceable parts in Curtis 1234 controller. No attempt should be made to open, repair, or otherwise modify the controller. Doing so may damage the controller and will void the warranty. It is recommended that the controller and connections be kept clean and dry and that the controller’s fault...

  • Page 416: Troubleshooting

    Service Manual – CS7000 Wheel System, Traction Troubleshooting Fault Codes The drive controller has very robust fault code capabilities. Since most problems will result in setting a fault code, whenever there is a problem with the drive system, the first thing you should do is check for fault codes.

  • Page 417: Summary Of Led Display Formats

    Service Manual – CS7000 Wheel System, Traction Accessing the “configuration display” mode of the hidden menu a. Press and hold the hazard warning flasher button down while turning on the key. Wait until the “Configuration Display” screen appears, then release the button.

  • Page 418: Troubleshooting Chart

    Check the connector for corrosion or damage, clean it if necessary, and re-insert it. Note: Some of the codes listed in the table are for circuits that are not utilized on the CS7000. Troubleshooting Chart...
  • Page 419 Service Manual – CS7000 Wheel System, Traction Troubleshooting Chart Flash Possible Cause(s) Set/Clear Conditions Programmer LCD Code Display/ Effect Of Fault Temperature information is Set: Heatsink temperature Controller Severe not accurate. above +95°C (+203°F) Overtemp ShutdownMotor; Controller is operating in an Clear: Bring heatsink ShutdownMainContactor;...
  • Page 420 Service Manual – CS7000 Wheel System, Traction Troubleshooting Chart Flash Possible Cause(s) Set/Clear Conditions Programmer LCD Code Display/ Effect Of Fault Normal operation. Fault Set: Capacitor bank Undervoltage Cutback shows that the batteries need voltage dropped below the Reduced drive torque.
  • Page 421 Service Manual – CS7000 Wheel System, Traction Troubleshooting Chart Flash Possible Cause(s) Set/Clear Conditions Programmer LCD Code Display/ Effect Of Fault External load impedance on Set: Digital Output 7 (pin 20) Digital Out 7 Overcurrent Digital Output 7 driver (pin current exceeded 15 mA.
  • Page 422 Service Manual – CS7000 Wheel System, Traction Troubleshooting Chart Flash Possible Cause(s) Set/Clear Conditions Programmer LCD Code Display/ Effect Of Fault Open or short on driver load. Set: Main contactor driver (pin Main Open/Short 6) is either open or shorted.
  • Page 423 Service Manual – CS7000 Wheel System, Traction Troubleshooting Chart Flash Possible Cause(s) Set/Clear Conditions Programmer LCD Code Display/ Effect Of Fault Motor phase is open. Set: Motor phase U, V, or W Motor Open detected open. ShutdownMotor; Bad crimps or faulty wiring.
  • Page 424 Service Manual – CS7000 Wheel System, Traction Troubleshooting Chart Flash Possible Cause(s) Set/Clear Conditions Programmer LCD Code Display/ Effect Of Fault See Monitor menu » Inputs: Set: Pot2 wiper (pin 17) voltage Pot2 Wiper High Pot2 Raw. is higher than the high fault FullBrake.
  • Page 425 Service Manual – CS7000 Wheel System, Traction Troubleshooting Chart Flash Possible Cause(s) Set/Clear Conditions Programmer LCD Code Display/ Effect Of Fault Emergency Reverse operation Set: At the conclusion of Emer Rev HPD has concluded, but the Emergency Reverse, the fault ShutdownThrottle;...
  • Page 426 = 0. See Monitor menu » Motor: Motor RPM. Dual Drive fault: see Dual Fault On Other Traction Drive manual. Controller Note: Not used on CS7000 Dual Drive fault: see Dual Dual Severe Fault Drive manual. Note: Not used on CS7000...
  • Page 427 Service Manual – CS7000 Wheel System, Traction Troubleshooting Chart Flash Possible Cause(s) Set/Clear Conditions Programmer LCD Code Display/ Effect Of Fault Motor characterization failed Set: Motor characterization Motor Characterization during characterization failed during the motor Fault process. See Monitor characterization process.

  • Page 428: Fault History

    Dualmotor Parameter Drive manual. Mismatch Note: Not used on CS7000 Fault History The 1311 programmer can be used to access the controller’s fault history file. The programmer will read out all the faults the controller has experienced since the last time the fault history file was cleared. Faults such as contactor faults may be the result of loose wires;...

  • Page 429: Removal And Installation

    Service Manual – CS7000 Wheel System, Traction Removal and Installation Drive Pedal Assembly Disconnect drive pedal position sensor electrical connector. Remove drive pedal mounting screws. Remove pedal assembly. Reassemble in reverse order. Validate the drive pedal sensor adjustment and adjust if necessary.
  • Page 430 Service Manual – CS7000 Wheel System, Traction Disconnect all of the main machine controller connectors and pull the harness aside. Remove the controller mounting bracket fasteners and pull it away to gain access to the drive motor wiring. Label the drive motor cables for proper reassembly, then remove them from the motor.
  • Page 431 Service Manual – CS7000 Wheel System, Traction 11. Remove the 2 inner gear box to frame bolts and loosen the remaining 4. Remove 2 Loosen 4 12. Lift the machine just enough to take weight off the gear box and remove the remaining 4 gear box to frame bolts.
  • Page 432 Service Manual – CS7000 Wheel System, Traction 16. Hook up a hoist to the lift strap and put a slight tension on the strap. Remove the rear wheel chock and allow the assembly to roll backward and downward out of the machine controlling the movement by lowering the hoist and blocking the wheel.

  • Page 433: Drive Wheel

    Service Manual – CS7000 Wheel System, Traction c. If installing a new gear box, be sure to transfer the splash shield. Splash shield d. Apply 56510412 (OPEN GEAR LUBE) to front 180° of ring gear teeth and all around pinion gear teeth.

  • Page 434: Specifications

    Service Manual – CS7000 Wheel System, Traction Specifications Shop Measurements Shop measurements are values that were measured on a real machine. While they are not “specifications”, they can help you recognize normal vs abnormal. Drive Controller Voltage Measurements All voltages are DC unless otherwise stated and were measured with the negative (black) voltmeter lead on battery negative and the key switch on.

  • Page 435: Motor U, V And W Terminal Pair Voltages

    Service Manual – CS7000 Wheel System, Traction Wire Color Circuit Voltage VIO/BLK Throttle POT Low 0.21 V Not Used Not Used Not Used Not Used CAN Bus High 2.53 V Not Used VIO/WHT Unregulated low power +12 V 12.91 V output.

  • Page 436: System Current Draw - Driving Only With No Cleaning Functions

    Service Manual – CS7000 Wheel System, Traction System Current Draw - Driving only with no cleaning functions Measured with amp clamp around battery positive feed to drive controller. • Approximately 1-4 amps when the machine begins to move • Average 51 amps full speed with maximum scrub pressure •...

  • Page 437: Wheel System, Non-Traction

    Service Manual – CS7000 Wheel System, Non-Traction Functional Description The non-traction wheels support the front of the machine and house the machine 1/2”-20 Hex brakes. The wheel system includes the Wheel Screw Wheels Brake and Spindle Assemblies the various mounting hardware. The...

  • Page 438: Maintenance And Adjustments

    Service Manual – CS7000 Wheel System, Non-traction Maintenance and Adjustments Warning! Before performing any maintenance or adjustments, make sure the key switch is off and the key is removed from the machine. Chock the machine wheels to prevent the machine from moving.

  • Page 439: Troubleshooting

    Service Manual – CS7000 Wheel System, Non-traction If steps 1 through 5 don’t provide adequate adjustment, remove the wheel and adjust the as follows: Rod End 1/4”-20 Brake a. Remove the Bolt Nyloc 1/4”-20 Bolt ™ washers holding the to the...

  • Page 440: To Remove And Reinstall A Brake And Spindle Assembly

    Service Manual – CS7000 Wheel System, Non-traction Remove the Grease Cap Brake Remove the Cotter Pin Slotted Nut Lever washer. 1/2”-20 Hex Remove the from the Wheel Wheel Brake and Screw Spindle Assembly Reinstall the by following the Wheel above steps in reverse order.

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