To diagnose the 4-001 trouble code on the Crescent CS7010:

- Code 4-001 indicates a Drive Controller Timeout.
- This is a critical fault meaning the main controller is not receiving heartbeat messages from the drive controller.
- Check the communication wiring and connectors between the main controller and the drive controller.
- Inspect for loose or damaged cables.
- If wiring is intact, the drive controller or main controller may be faulty.

This answer is automatically generated

Ron Lewis

July 30, 2025

Main scrub deck does not go down shows codes 2-024and 2-025

Summary of Contents for Crescent CS7010

Page 1 CS7010 Service Manual www.crescentindustrial.co.uk...
Page 2: Table Of Contents
Service Manual – CS7010™ Contents Contents 03 - 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 Safety Symbols General Safety Instructions...
Page 3 Service Manual – CS7010™ Contents Hours Menu Faults Menu Service Menu A1 Main Controller A2 and A3 Power Modules A4 Drive Controller Engine Menu Output Test Panel Test Options Menu Configuration Menu System Menu Maintenance and Adjustment Firmware Update Troubleshooting...
Page 4 Service Manual – CS7010™ Contents Drive Pedal Neutral Position Troubleshooting Fault Codes Removal and Installation Drive Motor and Gearbox Assembly Drive Wheel Drive Controller Specifications Shop Measurements Wheel Drive K4 Contactor Drive Controller 22 - Steering System Functional Description Steering Limit Switches...
Page 5 Service Manual – CS7010™ Contents Alternator-Generator Drive Belt Alternator-Generator Wiring Diagrams Working with Schematics and Diagrams Navigation Common Schematic Symbols Electrical Schematic (Ladder Diagram) Sheet 1, Main Controller Part 1 Sheet 2, Main Controller Part 2 Sheet 3, A2 Power Module #1...
Page 6 Service Manual – CS7010™ Contents 28 - Engine System, Diesel Functional Description Engine starter control Fuel pump control Engine Protection Over Temperature Shutdown Low Oil Pressure Shutdown Engine RPM control Glow plug control Component Locations Maintenance and Adjustments Diesel Engine Maintenance Schedule...
Page 7 Service Manual – CS7010™ Contents Normal Engine Shut Off Engine Overheat Shutdown Lost Oil Pressure Shutdown Component Locations Engine Right Side View (Toward front of machine) Engine Back Side View (Toward right of machine) Engine Left Side View (Toward back of machine)
Page 8 Service Manual – CS7010™ Contents viii High-pressure Spray System Pump Extended Scrub System Maintenance and Adjustments To Clean the Solution Filter Screen To Clean the Extended Scrub System Strainer To Clean the High Pressure Solution Filter To Adjust the Belt Tension on the High Pressure Pump...
Page 9 Service Manual – CS7010™ Contents Squeegee Support Assembly Squeegee Lift Arm Specifications Special Tools 40 - Recovery System Functional Description Overview Recovery and Squeegee Wiring Diagram Component Locations Recovery Tank Recovery Tank Cover and Debris Basket Vacuum Fan Cover Assembly...
Page 10 Service Manual – CS7010™ Contents Side Broom Motor Side Broom Hub Side Broom Actuator Specifications Special Tools 50 - Dust Control/DustGuard™ Systems Functional Description Overview Dust Control System DustGuard Spray System (optional) Dust Control and Hopper Wiring Diagram Component Locations...
Page 11: 03 - General Information
Service Manual Purpose and Application This Service Manual a technical resource designed to aid service personnel in maintaining and repairing the CS7010 Sweeper/Scrubber to ensure optimum performance and long service life. Please read it thoroughly before servicing your machine. Revision History...
Page 12: Other Reference Manuals And Information Sources
Service Manual – CS7010™ 03 - General Information Other Reference Manuals and Information Sources Nilfisk-Advance Publications Model Name Instructions for Use Form Number Parts List Advance CS7010 56091206: English, Spanish, French 56042665 Nilfisk CS7010 56042666 These manuals can be found on the following Nilfisk-Advance’s electronic supported databases: •...
Page 13: Safety
Service Manual – CS7010™ 03 - General Information Safety Symbols It is important for you to read and understand this manual The information it contains relates to protecting your safety and preventing problems. The symbols below are used to help you recognize this information.
Page 14 Service Manual – CS7010™ 03 - General Information respective manufacturer. − Battery charging may produce highly explosive hydrogen gas. Charge the batteries only in well-ventilated areas and away from ignition sources or open flames. − Safe operation of this machine requires the operator to ensure others within close proximity are not endangered or the machine is not left operational and unattended allowing unauthorized use.
Page 15: Hopper Prop Rod
Service Manual – CS7010™ 03 - General Information Hopper Prop Rod CAUTION: 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...
Page 16: Lifting The Machine
Service Manual – CS7010™ 03 - General Information Lifting the Machine CAUTION: Never work under a machine without safety stands or blocks to support the machine. When lifting the machine, do so at the designated Tie Down/Support Locations. Transporting the Machine...
Page 17: Towing The Machine
Service Manual – CS7010™ 03 - 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).
Page 18: Diagnostic And Service Tools
Service Manual – CS7010™ 03 - General Information 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 Industrial floor cleaning equipment.
Page 19: Technical Specifications
Service Manual – CS7010™ 03 - General Information Technical Specifications General Specifications Model CS7010 48G CS7010 48LP CS7010 48LP CS7010 48D CS7010 48B Battery Part Numbers 56511001 56509000 56511540 56509001 56511713 56509006 56511541 56509007 56511811 Main Battery 36V, 770 Ah,...
Page 20: Overall Dimensions
Service Manual – CS7010™ 03 - General Information Overall Dimensions 4” [10 61” [155 48” [122 103” [262 59” 150...
Page 21: Fastener Torque Specifications
Service Manual – CS7010™ 03 - General Information Fastener Torque Specifications Size Plated Steel Stainless Steel 42 in.-lb. 28 in.-lb. 1/4“ 100 in.-lb. 67 in.-lb. 5/16” 17 ft.-lb. 11 ft.-lb. 3/8” 31 ft.-lb. 20 ft.-lb. Standard Torque 1/2” 75 ft.-lb.
Page 22: Maintenance
Service Manual – CS7010™ 03 - 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 23 Service Manual – CS7010™ 03 - General Information Interval Maintenance Item Day Wk Mo 15-20 1000 1500 2000 Lubricate squeegee caster wheels and pivot Lubricate steering gears Lubricate squeegee side wheels Lubricate engine/battery bay latch Lubricate recovery tank latch Lubricate brake linkage...
Page 24: Lubrication Points
Service Manual – CS7010™ 03 - 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...
Page 25: Ecoflex System Maintenance
Service Manual – CS7010™ 03 - General Information EcoFlex System Maintenance You will need to purge the system of the previous detergent when switching to a different detergent Note: Move the machine over a floor drain before purging because a small amount of detergent will be dispensed in the process.
Page 26: Pm Checklist
Service Manual – CS7010™ 03 - General Information PM Checklist Nilfisk-Advance CS7010 Defect Codes → Customer Needs adjustment → Binding → Contaminated, dirty Address → Damaged, bent, or torn → Leaks → City Missing → Worn out Model # Serial #...
Page 27 Service Manual – CS7010™ 03 - General Information Defect Codes Ref Visual Inspection Items (circle) Scrub deck housing and door skirts Solution system pumps and solenoid valves as many as six pumps Solution tank, delivery hoses and filter clean filter screen...
Page 28: Machine Controls
Service Manual – CS7010™ 03 - General Information Machine Controls Control Panel - General Layout The CS7010 control panel is organized by machine function with the scrub, sweep and hopper functions conveniently grouped together Miscellaneous controls such as the key switch, emergency-stop...
Page 29: Scrub Controls
Service Manual – CS7010™ 03 - General Information Scrub Controls • Scrub Pressure Increase Button – increases the scrub pressure one level Pressure Flow when pressed Increase Increase • One Touch Scrub Button – enables the scrub, solution, and recovery systems,...
Page 30: Sweep Controls
Service Manual – CS7010™ 03 - General Information Sweep Controls Broom Height Side • One-touch Sweep Button – enables the Raise Broom main broom, side brooms, dust control fan and DustGuard™ spray nozzles. Broom Select • Broom Select Button –...
Page 31: Oled Display
Service Manual – CS7010™ 03 - General Information OLED Display Scrub Pressure Indicator Solution Flow Indicator Detergent Indicator D Detergent Ratio Indicator Detergent Indicator Bar Graph Speedometer G Solution Tank Level Indicator H Battery Indicator Active Fault Codes Hour Meter...
Page 32: Steering Wheel
Service Manual – CS7010™ 03 - General Information Steering Wheel The steering system in the CS7010 is a “steer Steering by wire” system that uses an encoder and Wheel brushless AC three-phase motor to transfer steering wheel input to the drive wheel Note that when the machine key switch is off, the steering wheel will “freewheel”...
Page 33: 04 - Control System
Functional Description The CS7010 is a distributed network of various controllers that interact to control all of the machine functions. The top level controller is the Main Machine Controller (MMC), which provides commands to the other controllers directing them to complete their associated tasks. (Refer to the “Functional Diagram”...
Page 34: Functional Diagram
Service Manual – CS7010™ 04 - Control System Functional Diagram Detergent Pump 1 Engine Control Main Machine Detergent Pump 2 Controller Ext Scrub Pump Dust Guard Pump/Valve Solution Pump Start Horn Backup Alarm Solution Valve VACC Hyd Clutch CAN-0 Headlights...
Page 35: Power Modules
Service Manual – CS7010™ 04 - Control System Power Modules As the name suggests, the power modules handle the high-power output functions for the machine. They receive commands from the main machine controller via the CAN Bus network. The power modules provide...
Page 36: Can Bus Communication
Service Manual – CS7010™ 04 - Control System CAN Bus Communication CAN Bus communication was originally created for the automotive industry to allow distributed modules (Nodes) throughout the vehicle to communicate with each other over a single serial channel without any single Node being the Master of the communication channel.
Page 37: Component Locations
Service Manual – CS7010™ 04 - Control System Component Locations Drive Steering Controller Controller Main Machine Controller & Operator Interface K4 Relay K1 Relay K5 Relay Main Fuse K3 Relay K2 Relay A2 Power Module #1 A3 Power Module #2...
Page 38: Main Machine Controller Programming
Service Manual – CS7010™ 04 - Control System Main Machine Controller Programming The Main Machine Controller is programmable for machine specific functions and configurations through a text menu system. Various parts of the menu system are hidden, and available only to the technician. The Technician-level (Service Mode) permits access to the whole menu system.
Page 39: Programming Menu Outline
Service Manual – CS7010™ 04 - Control System Programming Menu Outline Hours A1 Main Controller On Time J1-1 Throttle 1 A2 Power Module 1 Drive Time J1-2 Throttle 2 Scrub Time A2 Mod: B+, Deg C A3 Power Module 2...
Page 40: Hours Menu
Service Manual – CS7010™ 04 - Control System Hours Menu (1/5) Hours The hours menu displays the amount of time the machine has been active in each of the listed categories The On Time represents On Time 0126.5 the total time that the machine has been powered up, regardless Drive Time 0009.2...
Page 41: A2 And A3 Power Modules
Service Manual – CS7010™ 04 - Control System A2 and A3 Power Modules A2 Power Module (1/16) The two Power Module menus provide information regarding all of the motors which are driven by the power modules. It lists the PWM...
Page 42: Output Test
Service Manual – CS7010™ 04 - Control System Output Test The Output Test menu provides manual control of various system functions for troubleshooting purposes. This permits devices to be operated even when prerequisite conditions are not met, such as permitting the scrub brushes to turn on with the hopper up and the machine stationary.
Page 43 Service Manual – CS7010™ 04 - Control System Neutral Delay (s): This sets how long the brushes remain active Options (8/16) (in seconds) when the machine is stationary. The minimum is 1/2 second, the maximum is 5 seconds, and the increment is every 1/2...
Page 44: Configuration Menu
Service Manual – CS7010™ 04 - Control System Configuration Menu The configuration menu provides access to configure the machine based on which options are installed. If you install an option to a customer’s machine, you will need to configure the controller to specify that the option is installed, or the option may not function Additional information is contained in the instruction sheets that accompany the option kits.
Page 45: Maintenance And Adjustment
Service Manual – CS7010™ 04 - Control System Maintenance and Adjustment Firmware Update Copy the firmware file to the root directory of a USB flash drive. The file needs to be located in the root directory or the Controller won’t know where to find it.
Page 46: Troubleshooting
04 - Control System Troubleshooting When troubleshooting the machine, the CS7010 main controller should be one of the first steps for most troubleshooting scenarios. All of the distributed controllers throughout the system report their status back to the main controller, including error codes So when any of the controllers, including the MMC itself, experience any sort of fault, the operator’s interface will display that/those fault(s).The tables in the next...
Page 47 Service Manual – CS7010™ 04 - Control System A1 Main Controller Fault Description Level Condition Code 1-101 L2 Sol Valve Short Non-Critical The controller has detected more than 5 amps at the Solution Solenoid. • The most likely cause is a damaged solenoid with an internal short. • Check the coil resistance of the solenoid. If it is significantly below the normal coil resistance of 108 Ω, then replace the...
Page 48 Service Manual – CS7010™ 04 - Control System A1 Main Controller Fault Description Level Condition Code 1-106 M19 Det Pump 1 Short Non-Critical The controller has detected more than 2 amps at one of the optional detergent pumps under the operator’s seat.
Page 49 Service Manual – CS7010™ 04 - Control System A1 Main Controller Fault Description Level Condition Code 1-322 Eng Throttle 1 Short Non-Critical The output current is above 5 amps. 1-323 Eng Throttle 2 Short Non-Critical Eng Glow Plug Short Output current is above 5 amps (diesel machines only) 1-324 Non-Critical Engine 12V alternator fault - voltage was below 10V for more...
Page 50 Service Manual – CS7010™ 04 - Control System A2 Power Module #1 Fault Description Level Condition Code M1 Main Broom Open The power module has detected an open circuit (amperage 2-021 Non-Critical below 0.5A) to the respective motor. This could be the result M2 Dust Fan Open 2-022 Non-Critical of a disconnected wire at the motor or module, or it could be M3 Side Brooms Open 2-023 Non-Critical that the motor’s brushes have worn beyond service. M4 Vac 1 Open 2-024 Non-Critical M5 Vac 2 Open 2-025 Non-Critical M6 MB Act Open 2-026 Non-Critical M7 Dump Door Open...
Page 51 Service Manual – CS7010™ 04 - Control System A2 Power Module #1 Fault Description Level Condition Code The power module has detected that the output switching 2-051 M1 Main Broom Mosfet Critical transistor for the respective motor is not switching off when Short expected. If the condition persists, the likely cause is that the 2-052 M2 Dust Fan Mosfet Critical power module has failed and needs replacement. Short • Disconnect the associated output and then cycle the...
Page 52 Service Manual – CS7010™ 04 - Control System A2 Power Module #1 Fault Description Level Condition Code UnderTemp Cutback Internal temperature is below -25C - output current will be 2-087 Non-Critical reduced K2 Coil Open 2-088 Critical The module has detected an open circuit at the K2 relay coil. The power module’s output is not working properly and all 2-091 M1 Main Broom HW...
Page 53 Service Manual – CS7010™ 04 - Control System A3 Power Module #2 Fault Description Level Condition Code The DC capacitor bank voltage dropped below under-voltage 3-018 UnderVolt Cutoff Critical cutoff limit. Check for low battery or loose power terminal connections. M11 Hopper Open The power module has detected an open circuit (amperage 3-021 Non-Critical below 0.5A) to the respective motor. This could be the result M11 Hopper Open 3-022 Non-Critical of a disconnected wire at the motor or module, or it could be M13 Ctr Brush Open 3-023 Non-Critical that the motor’s brushes have worn beyond service. M14 Lt Brush Open 3-024 Non-Critical...
Page 54 Service Manual – CS7010™ 04 - Control System A3 Power Module #2 Fault Description Level Condition Code The power module has detected that the output switching 3-051 M11 Hopper Mosfet Critical transistor for the respective motor is not switching off when Short expected. If the condition persists, the likely cause is that the 3-052 M11 Hopper Mosfet Critical power module has failed and needs replacement. Short • Disconnect the associated output and then cycle the...
Page 55: A4 Drive Controller
Service Manual – CS7010™ 04 - Control System A3 Power Module #2 Fault Description Level Condition Code Internal CAN Bus counter exceeded 128 3-083 CAN Bus Critical Internal master did not receive slave controller message in 3-084 Actuator Timeout Critical timeout period OverTemp Cutback Internal temperature exceeded cutback temperature - output 3-086 Non-Critical current will be reduced UnderTemp Cutback Internal temperature is below -25C - output current will be 3-087 Non-Critical reduced K3 Coil Open...
Page 56 Service Manual – CS7010™ 04 - Control System A4 Drive Controller Fault Description Level Condition Code Motor OverTemp Motor temperature is above 180 °C. Check motor or 4-105 Critical temperature feedback circuit. Ctrl OverTemp Controller power stage temperature is above 110 °C 4-106 Critical 4-108 CAN Fault Critical CAN bus communication error, typically a timeout 4-109 Current Sensor Critical Current sensor offset is too high.
Page 57: A5 Steering Controller
Service Manual – CS7010™ 04 - Control System A4 Drive Controller Fault Description Level Condition Code 4-224 Throttle Signal Critical Throttle pot value is out-of-range. Possible short of J5-20 to either V+ or V-. Drive Enable Open 4-227 Critical Drive enable signal from steering controller is open...
Page 58 Service Manual – CS7010™ 04 - Control System A5 Steering Controller Fault Description Level Condition Code Software detected failure of the K5 coil circuit. 5-112 K5 Contactor Critical • Coil amperage greater than 2.1A-Peak or 1.1A for 10 sec. • Coil amperage greater than 200 ma when coil not commanded to operate. • Possible internal current senor fault within the controller. Motor OverCurrent 5-113 Critical Motor rms current is too high 5-114...
Page 59: Device Output Dependencies
Service Manual – CS7010™ 04 - Control System Device Output Dependencies When troubleshooting machine devices, it is helpful to know under what conditions that device is normally permitted to operate. The table below lists these dependencies for each device in the machine.
Page 60 Service Manual – CS7010™ 04 - Control System Output Dependencies Output Dependencies Comments • Not in Panel Test Horn H2 • Not in Output Test • No horn output fault Backup Alarm H1 • Enabled in options menu The dependencies will vary • Opt: Applicable throttle % from Drive Controller based on which option is set for • Opt: Hopper interlock switch SW6 open forward/reverse/hopper alarms.
Page 61 Service Manual – CS7010™ 04 - Control System Output Dependencies Output Dependencies Comments • Hopper down Vacuum Motor 1 or 2 - • E-Stop closed Wand Mode • Battery Interlock closed • No critical faults • No recovery system faults • Recovery tank not full • Not in Low Voltage Cut-out • Hopper down...
Page 62 Service Manual – CS7010™ 04 - Control System Output Dependencies Output Dependencies Comments • Hopper down If solution in reverse is Solution Pump • Positive throttle % from Drive Controller configured, any non-neutral • Seat switch closed throttle input will set. • E-Stop closed • Battery Interlock closed • No critical faults • No scrub, recovery or solution system faults • Recovery tank not full...
Page 63 Service Manual – CS7010™ 04 - Control System Output Dependencies Output Dependencies Comments • Hopper down Side Broom Motors • Seat switch closed • E-Stop closed • Battery Interlock closed • No critical faults • Hopper temp switch open (If configured) • Positive throttle % from Drive Controller • No main broom or side broom system faults • Not in Low Voltage Cut-out...
Page 64 Service Manual – CS7010™ 04 - Control System Output Dependencies Output Dependencies Comments • Hopper down Adjustment set point properly Side Broom Actuator - Down • Seat switch closed set to lower broom to floor • E-Stop closed • Battery Interlock closed • No critical faults • Hopper temp switch open (If configured) • No main broom or side broom system faults • Not in Low Voltage Cut-out...
Page 65: Removal And Installation
Service Manual – CS7010™ 04 - Control System Removal and Installation Main Machine Controller Disconnect the main battery connector. Begin draining the solution tank. The tank must be empty when reconnecting the pressure sensor tubing during reassembly. You can continue disassembly while the tanks drains.
Page 66: Specifications-Shop Measurements
Service Manual – CS7010™ 04 - Control System Specifications—Shop Measurements 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 67 Service Manual – CS7010™ 04 - Control System Wire Circuit Description Value/Condition Comments Run Signal input 4.5 V Key on Signal from engine controller. The run signal is active low for the LEV engine but 0.018 Engine Running all the other engines the run signal is high (+12V).
Page 68: J2 Connector
Service Manual – CS7010™ 04 - Control System J2 Connector Wire Circuit Description Value/Condition Comments YEL-BRN CAN 0 High 2.79 V CAN 0 Low 2.30 V Battery Negative Power 0.001 V BLU-BLK Sensor Ground 0.001 V Battery Negative Power 0.001 V GRY-GRN 3.3V sensor supply 2.89 V...
Page 69: Power Modules
Service Manual – CS7010™ 04 - Control System Power Modules A2 Power Module 1 For clarity, some outputs listed in the table are out of sequence so that related functions can be grouped together for those motors using 2-pin outputs.
Page 70: A3 Power Module 2
Service Manual – CS7010™ 04 - Control System A3 Power Module 2 For clarity, some outputs listed in the table are out of sequence so that related functions can be grouped together for those motors using 2-pin outputs. Wire Circuit Description...
Page 71: 10 - Chassis System
Service Manual – CS7010™ 10 - Chassis System Functional Description The chassis is the primary backbone of the machine that all other systems attach. Engine Solution Tank Recovery Chassis Tank Hopper Squeegee Scrub Deck Main Broom...
Page 72: 14 - Wheel System, Non-Traction
Service Manual – CS7010™ 14 - Wheel System, Non-Traction Functional Description The non-traction wheels support the front of the machine and house the machine brakes. The wheel system includes the Spindle Wheel Wheels, Brake and Spindle Assemblies and the various mounting hardware The...
Page 73: Maintenance And Adjustments
Service Manual – CS7010™ 14 - Wheel System, Non-Traction Maintenance and Adjustments Adjust the Brakes As the brake shoe lining wears, it requires greater travel from the shoes to press firmly against the drums in the wheels. When properly adjusted, the brakes should be fully released when the brake pedal is in the...
Page 74: Troubleshooting
Service Manual – CS7010™ 14 - Wheel System, Non-Traction Troubleshooting Problem Cause Correction The wheels are The wheel bearings worn. Check the wheel, wheel bearings, and brake and making excess noise. spindle assembly and replace as required. The wheel and/or brake and spindle assembly are damaged. The brakes are not The brakes are out of adjustment Adjust the brakes. working correctly. The brake linings are worn out. Replace the brake linings. Removal and Installation Wheel Wheel Bearing Regardless whether the procedure is being completed to replace a wheel versus a bearing, both right and left sides should be completed together.
Page 75: Brake And Spindle Assembly
Service Manual – CS7010™ 14 - Wheel System, Non-Traction Brake and Spindle Assembly 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.
Page 76: 20 - Wheel System, Traction
Service Manual – CS7010™ 20 - 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...
Page 77: Drive Pedal Potentiometer
Service Manual – CS7010™ 20 - Wheel System, Traction Drive Pedal Potentiometer The drive pedal potentiometer is a variable resistor connected to the Pin J5--20 input of the drive controller, with pins J5--31 and J5--32 as reference voltages. As the resistance changes, the drive controller increases or decreases drive motor speed The drive pedal is set up in what’s called a wig-wag configuration, where drive direction is controlled by...
Page 78: Circuit Description
Service Manual – CS7010™ 20 - Wheel System, Traction Circuit Description (C) TO 4B4 WHEEL DRIVE DRIVE MOTOR DRIVE CONTROLLER +11V VIO-GRN B+ (HS_OUT) J5-29 TAN-ORN B- (OD_1) J5-4 WHEEL DRIVE PNK-RED +11V J5-5 TAN-BLK ENCODER IN 2 +11V J5-7...
Page 79: Can Bus
Service Manual – CS7010™ 20 - 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...
Page 80: Maintenance And Adjustments
Service Manual – CS7010™ 20 - Wheel System, Traction Maintenance and Adjustments Gear Box Oil CAUTION: Disconnect the main battery connector before servicing the drive system. If the machine is unexpectedly powered on, the steering initialization routine can cause serious injury.
Page 81: Troubleshooting
Service Manual – CS7010™ 20 - 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 All fault codes for all system modules are displayed by the Main Machine Controller.
Page 82 Service Manual – CS7010™ 20 - Wheel System, Traction Working from under the machine, remove the cover plate that is under the steering drive gear. There are two screws on each side 10 Lift the squeegee lift bar and tie it up.
Page 83 Service Manual – CS7010™ 20 - Wheel System, Traction 16 Secure the machine safely on jack stands. 17 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 84: Drive Wheel
Service Manual – CS7010™ 20 - Wheel System, Traction Drive Wheel Chock front wheels and disconnect the main battery connector. While the weight of the machine is still on the drive wheel, slightly loosen the drive wheel lug nuts Jack the rear of the machine up to get the drive wheel off the...
Page 85: Specifications
Service Manual – CS7010™ 20 - 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. 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 86: 22 - Steering System
Service Manual – CS7010™ 22 - Steering System Functional Description The steering system utilizes steer-by-wire technology, which means there is no mechanical connection between the operator’s steering wheel and the drive wheel steering mechanism The steering mechanism at the drive wheel uses a large ring gear to rotate the entire drive wheel and motor assembly.
Page 87: Steering Motor
Service Manual – CS7010™ 22 - Steering System Steering Motor 0˚ 360˚ The steering motor is a 3-phase AC, permanent magnet, remotely commutated motor with internal resolver commutation feedback. The first part of this description is fairly common, and is electrically the same as brushless...
Page 88: Commutator Resolver
Service Manual – CS7010™ 22 - Steering System Commutator Resolver Commutation is the process of switching power in the motor windings to coincide with the position of the magnetic field of the rotor. A brushed motor achieves this with mechanical commutation (the brushes).
Page 89: Steering Position Sensor & Tfd
Service Manual – CS7010™ 22 - Steering System Steering Position Sensor & TFD The operator’s steering wheel is connected to a rotary position Channel x Channel y sensor with an integral Torque Feedback Device (TFD). Even though this is a single device, the two functions are distinct and semi-unrelated.
Page 90: Functional Diagram
Service Manual – CS7010™ 22 - Steering System Functional Diagram Main Machine Controller VACC CAN-0 Steering Sensor Position PWM Torque Feedback 2Ø Resolver Steering Module CAN-0 VACC 3Ø Power Temperature Enable Drv Wheel Drive Module Travel Limit Switches...
Page 91: Component Locations
Service Manual – CS7010™ 22 - 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 92: Troubleshooting
Service Manual – CS7010™ 22 - Steering System Troubleshooting Fault Codes The steering controller has very robust fault code capabilities. Since most problems will result in setting a fault code, whenever there is a problem with the steering system, the first thing you should do is check for fault codes All fault codes for all system modules are displayed by the Main Machine Controller.
Page 93: Removal And Installation
Service Manual – CS7010™ 22 - Steering System Removal and Installation Steering Wheel Sensor and TFD This procedure requires removal of the steering wheel and also the steering assembly from the machine in order to properly access the sensor/TFD. Even though it would appear that some of these steps could be skipped during disassembly, the reassembly process would be very difficult.
Page 94 Service Manual – CS7010™ 22 - Steering System Disconnect the 2 wires from the E-stop switch. Disconnect the 3 wires from the ignition Orange switch. Make note of the wire positions for later replacement 10 Finish removing the steering assembly from the...
Page 95: Steering Controller
Service Manual – CS7010™ 22 - Steering System Steering Controller Support Drain recovery tank. Recovery Cable Tank Turn machine off, set the parking brake and disconnect the main power plug Tip the recovery tank out and let it rest on the support cable.
Page 96: Specifications
Service Manual – CS7010™ 22 - 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. All voltages are DC unless otherwise stated and were measured with the negative (black) voltmeter lead on battery negative and the key on.
Page 97: 24 - Electrical System
Solution System Chapter Functional Description Overview The CS7010 is an electrically driven system, but with various prime-power configurations. All configurations utilize a 36-volt battery system, but the hybrid models incorporate engine-alternator power generation to constantly charge the batteries. When the engine is running the alternator provides the electrical power to operate the machine electrical loads as well as recharge the battery pack.
Page 98: Circuit Protection
Service Manual – CS7010™ 24 - Electrical System Circuit Protection There are several layers of circuit protection. The top level protection is the 400-amp fuse from the main battery pack. The second level protection is the circuit breakers in the operator’s platform. This includes the 5-amp circuit breaker to the main controller, the 25-amp breaker to loads on the main controller, and a 25- amp breaker to the steering system.
Page 99: Component Locations
Service Manual – CS7010™ 24 - Electrical System Component Locations Battery Interlock or Interlock Jumper Battery powered machines have an interlock switch (proximity sensor), to detect if the battery retaining bar is not lowered into position. If the sensor is open, machine function is disabled to prevent the batteries from shifting in the machine during travel.
Page 100: Circuit Protection And Control
Service Manual – CS7010™ 24 - Electrical System Circuit Protection and Control Circuit Breaker Panel Electrical Panel 400 Amp Fuse Seat Switch - bottom of seat Alternator Generator...
Page 101: Electrical Panel Layout
Service Manual – CS7010™ 24 - Electrical System Electrical Panel Layout K4 Relay Drive Controller K5 Relay Steering Controller K1 Relay Main Machine Main Fuse Controller 400 Amp K2 Relay K3 Relay Power Module #1 Power Module #2 Battery Neg.
Page 102: Harness To Harness Connector Locations
Service Manual – CS7010™ 24 - 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...
Page 103 Service Manual – CS7010™ 24 - Electrical System Main Harness X45 to Engine Interface Harness X137 Engine Interface Harness X137 to Engine Harness (Photo of diesel engine) Behind Battery Telematics Jumper Vacuum Motor Harness Vacuum Harness...
Page 104: Connector Pin-Outs
Service Manual – CS7010™ 24 - Electrical System Connector Pin-Outs The following pages contain details about every electrical connector that contains more than one “cavity”. This is to help you match up the wires and pin numbers of the connector.
Page 105 Service Manual – CS7010™ 24 - Electrical System J2 Main Machine Controller Color Name YEL-BRN Throttle 1 Throttle 2 Hyd. Clutch BLU-BLK Headlights VACC1 Ignition output GRY-GRN WHT-GRN L2 Solution Valve ORN-GRY Start output GRY-YEL E-Stop input Battery Interlock input GRN-WHT Seat Switch input YEL/WHT...
Page 106 Service Manual – CS7010™ 24 - Electrical System J4 Power Module #2 Color Name GRN-VIO M17 Deck Actuator Motor BRN-GRN K3Coill GRN-WHT CAN 1 Low YEL-WHT CAN 1 High PNK-YEL Curtis Programmer RED-GRY M17 Deck Actuator Motor PNK-VIO Curtis Programmer PNK-WHT Curtis Programmer RED-BRN M18 Side Broom Actuator...
Page 107 Service Manual – CS7010™ 24 - Electrical System J5 Drive Controller Color Name KSI (Control Power) Input TAN-ORN K4 Coil Control: PWM Bat- PNK-RED 11V out commutator BLK-PNK Sensor ground out TAN-BLK Commutator 1 input PNK-BLU Commutator 2 input Seat Switch input ORN-GRN Steering Ready...
Page 108 Service Manual – CS7010™ 24 - Electrical System J6 Steering Controller Color Name VIO-WHT TFD coil (positive) KSI (Key Switch Input) ORN-GRN ORN-GRN Enable Drive output 12V power to resolver RED-BLU Internal sensor ground VIO-GRY Encoder 1A input WHT-GRY Encoder 1B input Batt- Control Power Batt- to steering wheel sensor K5 Relay Coil YEL-BLK...
Page 109 Service Manual – CS7010™ 24 - Electrical System X113 Hopper Harness 2 Color Name VIO-WHT TFD coil (positive) KSI (Key Switch Input) ORN-GRN ORN-GRN Enable Drive output 12V power to resolver RED-BLU Internal sensor ground VIO-GRY Encoder 1A input WHT-GRY Encoder 1B input Batt- Control Power Batt- to steering wheel sensor K5 Relay Coil...
Page 110 Service Manual – CS7010™ 24 - Electrical System X45 Engine Interface Color Name PINK Ignition BLU-PNK Start GRN-YEL Coolant temp Run signal GRY-ORN Throttle 2 GRY-BLU Throttle 1 WHT-ORG Hydraulic clutch YEL-RED Oil Pressure TAN-WHT Fuel level TAN-RED Check Engine X98 Steering Motor...
Page 111 Service Manual – CS7010™ 24 - Electrical System Common 6-Pole Connectors X56 Steering Wheel Position Sensor Color Name RED-GRN GRN-GRY Encoder 1 GRN-BLK Encoder 2 VIO-WHT Batt+ BRN-GRN TFD control X82 Main Broom Actuator Color Name BLK-GRY PWM A TAN-VIO...
Page 112 Service Manual – CS7010™ 24 - Electrical System X47 Foot Pedal Color Name WHT-BLK BRN-RED Wiper VIO-BLK X124 Shaker Motor Color Name BLU-GRY Control A ORN-RED Control B GRN-YEL Chassis Ground 2-Pole High Power Connectors X107 Main Broom Color Name...
Page 113 Service Manual – CS7010™ 24 - Electrical System Common 2-Pole Connectors X48 Foot Brake X100 Deck Actuator Color Name Color Name ORN-GRY RED-GRY Signal Control A GRN-VIO Control B X57 Beacon X101 Extended Scrub Pump Color Name Color Name VIO-ORN...
Page 114 Service Manual – CS7010™ 24 - Electrical System Common 2-Pole Connectors (continued) X125 Left Side Broom X133 Right Side Broom Color Name Color Name GRN-GRY GRN-GRY K2 B+ K B+ WHT-BRN BLK-WHT Control Control X127 Left Headlight X135 Dump Door Closed Switch...
Page 115: Maintenance And Adjustments
Service Manual – CS7010™ 24 - 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 Alternator-generator is not charging Potential Causes •...
Page 116: Removal And Installation
Service Manual – CS7010™ 24 - Electrical System Removal and Installation Alternator-Generator Drive Belt Side Cover WARNING: Severe arc-flash hazard. Use caution when working with the main battery terminals to avoid shorting across the battery. Note: Instructions are for both diesel and LPG...
Page 117 Service Manual – CS7010™ 24 - Electrical System Slide the battery tray out until it reaches the end of the tether cable. Tank Guard Screws (5) Remove the two screws that secure the belt P-Clamp guard to the back of the tank guard plate.
Page 118: Alternator-Generator
Service Manual – CS7010™ 24 - Electrical System Alternator-Generator WARNING: Severe arc-flash hazard. Use caution when working with the main battery terminals to avoid shorting across the battery. Remove the Alternator-Generator Drive Belt described on page 116. In conjunction with that procedure, also remove the belt guard when removing the tank guard.
Page 119: Wiring Diagrams
Service Manual – CS7010™ 24 - Electrical System Wiring Diagrams Working with Schematics and Diagrams Wiring diagrams show how electrical components are connected together and to a large degree “how things work”. However, they do not specifically show where things are located on the machine. The most common diagram is the schematic.
Page 120: Common Schematic Symbols
Service Manual – CS7010™ 24 - Electrical System Common Schematic Symbols Control Board Inputs and Outputs: Not all control board inputs or outputs are given special symbolic meaning, but to the left are a couple of commons symbols. The right-hand side shows an input MAIN CONTROL BOARD with a pull-up resistor.
Page 121: Electrical Schematic (Ladder Diagram)
Service Manual – CS7010™ 24 - Electrical System Electrical Schematic (Ladder Diagram) 56511580, Rev B Sheet 1, Main Controller Part 1 CONFIDENTIAL THIS DRAWING AND THE DESIGN REPRESENTED HEREON IS THE PROPERTY OF NILFISK, INC., BROOKLYN PARK, MINNESOTA AND IT HAS BEEN ISSUED WITH THE UNDERSTANDING THAT IT WILL NOT BE REPRO- DUCED NOR COPIED NOR USED FOR ANY PURPOSE OTHER THAN FOR WHICH IT WAS ISSUED AND RECIPIENT AGREES TO RETURN IT UPON REQUEST.
Page 122: Sheet 2, Main Controller Part 2
Service Manual – CS7010™ 24 - Electrical System Sheet 2, Main Controller Part 2 CONFIDENTIAL (PP) TO 1F5 THIS DRAWING AND THE DESIGN REPRESENTED HEREON IS THE PROPERTY OF NILFISK, INC., BROOKLYN PARK, MINNESOTA AND IT HAS BEEN ISSUED WITH THE UNDERSTANDING THAT IT WILL NOT BE REPRO- DUCED NOR COPIED NOR USED FOR ANY PURPOSE OTHER THAN FOR WHICH IT WAS ISSUED AND RECIPIENT AGREES TO RETURN IT UPON REQUEST.
Page 123: Sheet 3, A2 Power Module #1
Service Manual – CS7010™ 24 - Electrical System Sheet 3, A2 Power Module #1 CONFIDENTIAL THIS DRAWING AND THE DESIGN REPRESENTED HEREON IS THE PROPERTY OF NILFISK, INC., BROOKLYN PARK, MINNESOTA AND IT HAS BEEN ISSUED WITH THE UNDERSTANDING THAT IT WILL NOT BE REPRO- DUCED NOR COPIED NOR USED FOR ANY PURPOSE OTHER THAN FOR WHICH IT WAS ISSUED AND RECIPIENT AGREES TO RETURN IT UPON REQUEST.
Page 124: Sheet 4, A3 Power Module #2
Service Manual – CS7010™ 24 - Electrical System Sheet 4, A3 Power Module #2 CONFIDENTIAL THIS DRAWING AND THE DESIGN REPRESENTED HEREON IS THE PROPERTY OF NILFISK, INC., BROOKLYN PARK, MINNESOTA AND IT HAS BEEN ISSUED WITH THE UNDERSTANDING THAT IT WILL NOT BE REPRO- DUCED NOR COPIED NOR USED FOR ANY PURPOSE OTHER THAN FOR WHICH IT WAS ISSUED AND RECIPIENT AGREES TO RETURN IT UPON REQUEST.
Page 125: Sheet 5, A4 Drive Controller
Service Manual – CS7010™ 24 - Electrical System Sheet 5, A4 Drive Controller CONFIDENTIAL THIS DRAWING AND THE DESIGN REPRESENTED HEREON IS THE PROPERTY OF NILFISK, INC., BROOKLYN PARK, MINNESOTA AND IT HAS BEEN ISSUED WITH THE UNDERSTANDING THAT IT WILL NOT BE REPRO- DUCED NOR COPIED NOR USED FOR ANY PURPOSE OTHER THAN FOR WHICH IT WAS ISSUED AND RECIPIENT AGREES TO RETURN IT UPON REQUEST.
Page 126: Sheet 6, A5 Steering Controller
Service Manual – CS7010™ 24 - Electrical System Sheet 6, A5 Steering Controller CONFIDENTIAL THIS DRAWING AND THE DESIGN REPRESENTED HEREON IS THE PROPERTY OF NILFISK, INC., BROOKLYN PARK, MINNESOTA AND IT HAS BEEN ISSUED WITH THE UNDERSTANDING THAT IT WILL NOT BE REPRO- DUCED NOR COPIED NOR USED FOR ANY PURPOSE OTHER THAN FOR WHICH IT WAS ISSUED AND RECIPIENT AGREES TO RETURN IT UPON REQUEST.
Page 127: Sheet 7, Kubota Diesel Engine System
Service Manual – CS7010™ 24 - Electrical System Sheet 7, Kubota Diesel Engine System CONFIDENTIAL THIS DRAWING AND THE DESIGN REPRESENTED HEREON IS THE PROPERTY OF NILFISK, INC., BROOKLYN PARK, MINNESOTA AND IT HAS BEEN ISSUED WITH THE UNDERSTANDING THAT IT WILL NOT BE REPRO- DUCED NOR COPIED NOR USED FOR ANY PURPOSE OTHER THAN FOR WHICH IT WAS ISSUED AND RECIPIENT AGREES TO RETURN IT UPON REQUEST.
Page 128: Sheet 8, Kubota Gasoline Engine System
Service Manual – CS7010™ 24 - Electrical System Sheet 8, Kubota Gasoline Engine System CONFIDENTIAL THIS DRAWING AND THE DESIGN REPRESENTED HEREON IS THE PROPERTY OF NILFISK INC., BROOKLYN PARK, MINNESOTA AND IT HAS BEEN ISSUED WITH THE UNDERSTANDING THAT IT WILL NOT BE REPRO-...
Page 129: Sheet 9, Kubota Lev Engine System Part 1
Service Manual – CS7010™ 24 - Electrical System Sheet 9, Kubota LEV Engine System Part 1 CONFIDENTIAL THIS DRAWING AND THE DESIGN REPRESENTED HEREON IS THE PROPERTY OF NILFISK, INC., BROOKLYN PARK, MINNESOTA AND IT HAS BEEN ISSUED WITH THE UNDERSTANDING THAT IT WILL NOT BE REPRO-...
Page 130: Sheet 10, Kubota Lev Engine System Part 2
Service Manual – CS7010™ 24 - Electrical System Sheet 10, Kubota LEV Engine System Part 2 CONFIDENTIAL THIS DRAWING AND THE DESIGN REPRESENTED HEREON IS THE PROPERTY OF NILFISK, INC., BROOKLYN PARK, MINNESOTA AND IT HAS BEEN ISSUED WITH THE UNDERSTANDING THAT IT WILL NOT BE REPRO- DUCED NOR COPIED NOR USED FOR ANY PURPOSE OTHER THAN FOR WHICH IT WAS ISSUED AND RECIPIENT AGREES TO RETURN IT UPON REQUEST.
Page 131: Sheet 11, Trackclean Connections
Service Manual – CS7010™ 24 - Electrical System Sheet 11, Trackclean Connections CONFIDENTIAL THIS DRAWING AND THE DESIGN REPRESENTED HEREON IS THE PROPERTY OF NILFISK, INC., BROOKLYN PARK, MINNESOTA AND IT HAS BEEN ISSUED WITH THE UNDERSTANDING THAT IT WILL NOT BE REPRO- DUCED NOR COPIED NOR USED FOR ANY PURPOSE OTHER THAN FOR WHICH IT WAS ISSUED AND RECIPIENT AGREES TO RETURN IT UPON REQUEST.
Page 132: Wiring Harness Diagram
Service Manual – CS7010™ 24 - Electrical System Wiring Harness Diagram 56511581, Rev A, 9-01-2017 Sheet 1: Main Harness 1 CONFIDENTIAL THIS DRAWING AND THE DESIGN REPRESENTED HERON IS THE PROPERTY OF NILFISK INC., BROOKLYN PARK, MINNESOTA AND IT HAS BEEN ISSUED WITH THE UNDERSTANDING THAT IT WILL NOT BE REPRO- DUCED NOR COPIED NOR USED FOR ANY PURPOSE OTHER THAN FOR WHICH IT WAS ISSUED AND RECIPIENT AGREES TO RETURN IT UPON REQUEST.
Page 133: Sheet 2: Main Harness 2
Service Manual – CS7010™ 24 - Electrical System Sheet 2: Main Harness 2 CONFIDENTIAL THIS DRAWING AND THE DESIGN REPRESENTED HERON IS THE PROPERTY OF NILFISK INC., BROOKLYN PARK, MINNESOTA AND IT HAS BEEN ISSUED WITH THE UNDERSTANDING THAT IT WILL NOT BE REPRO- DUCED NOR COPIED NOR USED FOR ANY PURPOSE OTHER THAN FOR WHICH IT WAS ISSUED AND RECIPIENT AGREES TO RETURN IT UPON REQUEST.
Page 134: Sheet 3: Main Harness 3
Service Manual – CS7010™ 24 - Electrical System Sheet 3: Main Harness 3 CONFIDENTIAL THIS DRAWING AND THE DESIGN REPRESENTED HERON IS THE PROPERTY OF NILFISK INC., BROOKLYN PARK, MINNESOTA AND IT HAS BEEN ISSUED WITH THE UNDERSTANDING THAT IT WILL NOT BE REPRO- DUCED NOR COPIED NOR USED FOR ANY PURPOSE OTHER THAN FOR WHICH IT WAS ISSUED AND RECIPIENT AGREES TO RETURN IT UPON REQUEST.
Page 135: Sheet 4: Hopper Harness
Service Manual – CS7010™ 24 - Electrical System Sheet 4: Hopper Harness CONFIDENTIAL THIS DRAWING AND THE DESIGN REPRESENTED HERON IS THE PROPERTY OF NILFISK INC., BROOKLYN PARK, MINNESOTA AND IT HAS BEEN ISSUED WITH THE UNDERSTANDING THAT IT WILL NOT BE REPRO- DUCED NOR COPIED NOR USED FOR ANY PURPOSE OTHER THAN FOR WHICH IT WAS ISSUED AND RECIPIENT AGREES TO RETURN IT UPON REQUEST.
Page 136: Sheet 5: Lev Engine Interface
Service Manual – CS7010™ 24 - Electrical System Sheet 5: LEV Engine Interface CONFIDENTIAL THIS DRAWING AND THE DESIGN REPRESENTED HERON IS THE PROPERTY OF NILFISK INC., BROOKLYN PARK, MINNESOTA AND IT HAS BEEN ISSUED WITH THE UNDERSTANDING THAT IT WILL NOT BE REPRO- DUCED NOR COPIED NOR USED FOR ANY PURPOSE OTHER THAN FOR WHICH IT WAS ISSUED AND RECIPIENT AGREES TO RETURN IT UPON REQUEST.
Page 137: Sheet 6: Glow Plug, Vacuum, Tail Light
Service Manual – CS7010™ 24 - Electrical System Sheet 6: Glow Plug, Vacuum, Tail Light CONFIDENTIAL THIS DRAWING AND THE DESIGN REPRESENTED HERON IS THE PROPERTY OF NILFISK INC., BROOKLYN PARK, MINNESOTA AND IT HAS BEEN ISSUED WITH THE UNDERSTANDING THAT IT WILL NOT BE REPRO- DUCED NOR COPIED NOR USED FOR ANY PURPOSE OTHER THAN FOR WHICH IT WAS ISSUED AND RECIPIENT AGREES TO RETURN IT UPON REQUEST.
Page 138: Sheet 7: Engine Battery, Generator Harness
Service Manual – CS7010™ 24 - Electrical System Sheet 7: Engine Battery, Generator Harness CONFIDENTIAL THIS DRAWING AND THE DESIGN REPRESENTED HERON IS THE PROPERTY OF NILFISK INC., BROOKLYN PARK, MINNESOTA AND IT HAS BEEN ISSUED WITH THE UNDERSTANDING THAT IT WILL NOT BE REPRO- DUCED NOR COPIED NOR USED FOR ANY PURPOSE OTHER THAN FOR WHICH IT WAS ISSUED AND RECIPIENT AGREES TO RETURN IT UPON REQUEST.
Page 139: Sheet 8: Trackclean Harness
Service Manual – CS7010™ 24 - Electrical System Sheet 8: Trackclean Harness CONFIDENTIAL THIS DRAWING AND THE DESIGN REPRESENTED HERON IS THE PROPERTY OF NILFISK INC., BROOKLYN PARK, MINNESOTA AND IT HAS BEEN ISSUED WITH THE UNDERSTANDING THAT IT WILL NOT BE REPRO- DUCED NOR COPIED NOR USED FOR ANY PURPOSE OTHER THAN FOR WHICH IT WAS ISSUED AND RECIPIENT AGREES TO RETURN IT UPON REQUEST.
Page 140: 28 - Engine System - Lpg Lev
Service Manual – CS7010™ 28 - 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 141: Circuit Descriptions
Service Manual – CS7010™ 28 - 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 142: Engine Rpm Control
Service Manual – CS7010™ 28 - 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...
Page 143: Component Locations
Service Manual – CS7010™ 28 - Engine System - LPG LEV Component Locations • Ignition • Ignition Coils (3) Coils (3) • Temperature Manifold Absolute Pressure (TMAP) sensor Vaporizer • Electronic Throttle Body (ETB) • Vaporizer • Engine Control Unit (ECU) LP Mixer •...
Page 144 Service Manual – CS7010™ 28 - 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 145: Maintenance And Adjustments
Service Manual – CS7010™ 28 - 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 146: Inspect Air Filter
Service Manual – CS7010™ 28 - 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.
Page 147: Troubleshooting
Service Manual – CS7010™ 28 - 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 148: Checking Lpg Primary Pressure
Service Manual – CS7010™ 28 - 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 Turn key switch off. Remove Steel Plate Swing out the propane tank.
Page 149: Removal And Installation
Service Manual – CS7010™ 28 - 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 150: Specifications
Service Manual – CS7010™ 28 - 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 151: Fuel System
Service Manual – CS7010™ 28 - 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”...
Page 152: Special Tools
Service Manual – CS7010™ 28 - Engine System - LPG LEV Special Tools KGST Software Download from EZparts Password for use with the WGG972GL-E4 (LEV) engine: YyiVhVpVjPvV Note: Kubota renews the password annually. Contact Technical Support if the password is no longer valid. Diagnostic Cable Adapter Part# 56511575...
Page 153 Service Manual – CS7010™ 28 - 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 154: 28 - Engine System, Diesel
Functional Description One of the engines available in the CS7010 is a Kubota Diesel (D1305-E3B-KEA-1). It is a three cylinder, liquid cooled, naturally aspirated engine. It has mechanical injector pump that is fitted with an actuator which physically moves the fuel lever inside the pump Fuel is stored in a tank on the right side of the engine compartment.
Page 155: Engine Starter Control
Service Manual – CS7010™ 28 - Engine System, Diesel Engine starter control The Main Machine Controller controls the starter solenoid on the engine, based on the input from the keys witch To get the engine starter to engage, the key switch is held in the start position which supplies 36 volts to the main machine controller connector J1 pin 21 This is the start input request The main machine controller receives a 12 V supply on connector J1 pin 13 from the engine starter battery.
Page 156: Engine Protection
Service Manual – CS7010™ 28 - 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...
Page 157: Low Oil Pressure Shutdown
Service Manual – CS7010™ 28 - 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 158: Engine Rpm Control
Service Manual – CS7010™ 28 - 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 159 Service Manual – CS7010™ 28 - 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 160: Glow Plug Control
Service Manual – CS7010™ 28 - Engine System, Diesel Flash Code Fault Remedy APECS unit failed Electrical noise may be entering the controller. Check wiring, shielding and connections to controller. Cycle power to engine. If controller still does not work, consult factory. Glow plug control The engine is equipped with glow plugs to assist starting a cold engine The glow plugs have an internal resistive element that increases in resistance as it heats up.
Page 161: Component Locations
Service Manual – CS7010™ 28 - 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 162 Service Manual – CS7010™ 28 - 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 163 Service Manual – CS7010™ 28 - Engine System, Diesel Glow Plugs Glow Plug Relay Electrical Panel Coolant Temperature Switch Alternator (12v) Starter Oil Pressure Switch Engine - Back Side...
Page 164: Maintenance And Adjustments
Service Manual – CS7010™ 28 - 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 165: Change Engine Oil And Oil Filter
Service Manual – CS7010™ 28 - 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.
Page 166: Bleed Fuel System
Service Manual – CS7010™ 28 - 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.
Page 167: Replace Air Filters
Service Manual – CS7010™ 28 - 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.
Page 168: Troubleshooting
Service Manual – CS7010™ 28 - 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 Check power to starter solenoid Starter Check voltage drop from battery positive to starter battery terminal. Battery Cable Check voltage drop from starter case to battery negative. Engine Ground Check for tripped circuit breaker #9 (CB9) No voltage to the starter solenoid Check for power to the main machine controller from the Auxiliary Relay •...
Page 169 Service Manual – CS7010™ 28 - 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 •...
Page 170: Cannot Achieve Either Run Or Maximum Engine Speed
Service Manual – CS7010™ 28 - Engine System, Diesel Cannot Achieve Either Run or Maximum Engine Speed The approach to diagnosing an engine RPM control problem is to check the inputs to the governor controller and check the output to the actuator. If the inputs are good and the output is bad, the conclusion is that the controller is the problem.
Page 171: Compression Test
Service Manual – CS7010™ 28 - 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 172 Service Manual – CS7010™ 28 - 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 Crank the engine over until the compression gauge stops climbing.
Page 173: Removal And Installation
Service Manual – CS7010™ 28 - 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 174: Specifications
Service Manual – CS7010™ 28 - 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 175: Engine Oil Viscosity
Service Manual – CS7010™ 28 - 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 176: Engine Compression
Service Manual – CS7010™ 28 - 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 177: Special Tools
Service Manual – CS7010™ 28 - 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 Gauge Coupler If using the Snap-On diesel compression EEPD500 Gauge kit and Snap-On TU-15-35 glow plug thread fitting, a coupler must be used to join the fitting to the gauge hose. Shown are Snap-On couplers M3569 and M3570...
Page 178: Engine System - Petrol (Gasoline)
Service Manual – CS7010™ 28 - 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 179: Circuit Descriptions
Service Manual – CS7010™ 28 - 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 180 Service Manual – CS7010™ 28 - 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.
Page 181: Engine Starter And Carburetor Choke Control
Service Manual – CS7010™ 28 - 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 This is the start input request The main machine controller receives a 12 V supply on connector J3 pin 23 from the engine starter battery.
Page 182: Throttle Control Modes
Service Manual – CS7010™ 28 - 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 183: Ignition On
Service Manual – CS7010™ 28 - 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 184: Cranking
Service Manual – CS7010™ 28 - 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 185: Normal Running
Service Manual – CS7010™ 28 - 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 186: Normal Engine Shut Off
Service Manual – CS7010™ 28 - 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 187: Engine Overheat Shutdown
Service Manual – CS7010™ 28 - 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 188: Lost Oil Pressure Shutdown
Service Manual – CS7010™ 28 - 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 189: Component Locations
Service Manual – CS7010™ 28 - 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.
Page 190: Engine Right Side View (Toward Front Of Machine)
Service Manual – CS7010™ 28 - 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 191: Engine Back Side View (Toward Right Of Machine)
Service Manual – CS7010™ 28 - 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 192: Fuel Tank Area
Service Manual – CS7010™ 28 - Engine System - Petrol (Gasoline) Fuel Tank Area • Fuel tank Vapor Canister • Fuel Pump • Fuel Filter • Fuel Sending Unit Fuel Filter • Vapor Canister Fuel Pump Fuel Tank Fuel Sending Unit...
Page 193: Maintenance And Adjustments
Service Manual – CS7010™ 28 - 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 194: Change Engine Oil And Oil Filter
Service Manual – CS7010™ 28 - 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 195: Inspect Air Filter
Service Manual – CS7010™ 28 - 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.
Page 196: Troubleshooting
Service Manual – CS7010™ 28 - 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...
Page 197: Cranks But Does Not Start - No Spark
Service Manual – CS7010™ 28 - 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 198: Achieves One But Not All Rpm Modes
Service Manual – CS7010™ 28 - 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...
Page 199: Removal And Installation
Service Manual – CS7010™ 28 - 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 200: Specifications
Service Manual – CS7010™ 28 - 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 201: Spark Controller Measurements
Service Manual – CS7010™ 28 - 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 Coil 3 Driver 11.2v...
Page 202: Fuel System
Service Manual – CS7010™ 28 - 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)
Page 203: 30 - Solution System
Service Manual – CS7010™ 30 - 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 level (pressure) 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 204: Ecoflex™ Detergent System
Service Manual – CS7010™ 30 - 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 205: Optional High-Pressure Spray System (Lp And Diesel Only)
Service Manual – CS7010™ 30 - 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 206: Solution System Wiring Diagram
Service Manual – CS7010™ 30 - Solution System Solution System Wiring Diagram X166 X169 FUSE, 400 A. BATTERY, 36VDC IGNITION SW 5 AMP MAIN RELAY MAIN MACHINE YEL-BRN BLK-ORN CONTROLLER TO 1A3, 1D2 J1-19 YEL-BRN VACC1 J1-6 MAIN RELAY VACC2...
Page 207 In many other machines, the solenoid is actively driven in only one direction (usually intake), but passively returned via the return spring (usually exhaust). For higher flow rates, the CS7010 machine uses AC- Driven, Active-Return solenoid pumps. So even though the return spring already wants to “Passively” drive the plunger outward, the Main Machine Controller “Actively”...
Page 208: Component Locations
Service Manual – CS7010™ 30 - Solution System Component Locations Solution Tank Drain Hose The Drain Hose underneath the rear right-hand side of the solution tank allows you to drain the solution tank. To drain the tank, remove the Pipe Cap.
Page 209: Solution Pressure Sensor
Service Manual – CS7010™ 30 - Solution System Solution Pressure Sensor The level in the solution tank is detected with a remote-read pressure transducer located on the Main Machine Control board. The weight of the water column in the solution tank produces a pressure...
Page 210: Solution Solenoid Valve
Service Manual – CS7010™ 30 - Solution System Solution Solenoid Valve The solution solenoid valve is located on the top center of the scrub deck and supplies the solution to the solution manifold The solution manifold connects Solution to the three hoses going to the three scrub...
Page 211: Ecoflex™ Detergent Bottles And Pumps
Service Manual – CS7010™ 30 - Solution System EcoFlex™ Detergent Bottles and Pumps The EcoFlex™ Detergent Bottles are located underneath the Operator seat and supply detergent to the two EcoFlex™ EcoFlex™ Detergent Pumps. The two EcoFlex™ Detergent Pump (2) Detergent Pumps run simultaneously and...
Page 212: Extended Scrub System
Service Manual – CS7010™ 30 - Solution System The solution supply line supplies solution from the solution tank to the high-pressure pump. The high-pressure pump pumps the solution to the relief valve which functions as follows: • If the trigger valve on the high-pressure...
Page 213: Maintenance And Adjustments
Service Manual – CS7010™ 30 - Solution System Maintenance and Adjustments CAUTION: 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...
Page 214: To Clean The Extended Scrub System Strainer
Service Manual – CS7010™ 30 - 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 215: To Adjust The Belt Tension On The High Pressure Pump
Service Manual – CS7010™ 30 - 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 pump assembly to the machine frame. High-pressure Pump Assembly...
Page 216: Troubleshooting
Service Manual – CS7010™ 30 - 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 Control System/Service Mode section for information on how to enter and use the Service Mode.
Page 217 Service Manual – CS7010™ 30 - Solution System Problem Cause Correction No detergent flow to Install both the detergent and EcoFlex™ functions in The detergent and EcoFlex™ the configuration menu. the solution system functions are not installed in the configuration menu. Check the detergent lines and clean/replace as The detergent supply lines are clogged. necessary. One or both of the detergent Check for voltage at the pumps. pumps are not operating • If there is voltage at a pump, replace the pump.
Page 218: Removal And Installation
Service Manual – CS7010™ 30 - Solution System Removal and Installation CAUTION: 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. Solution Tank CAUTION: The solution tank is relatively heavy.
Page 219 Service Manual – CS7010™ 30 - 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...
Page 220 Service Manual – CS7010™ 30 - Solution System 12 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 Mounting Screw are located underneath the machine...
Page 221 Service Manual – CS7010™ 30 - Solution System The bottom center Solution Tank Mounting Screw is located underneath the machine by the right-hand side squeegee assembly. Solution Tank Mounting Screw The bottom front Solution Tank Mounting Screw Solution Tank is located underneath the machine by the main Mounting Screw broom actuator and scrub deck actuator.
Page 222: Solution Shutoff Valve
Service Manual – CS7010™ 30 - Solution System Solution Shutoff Valve Drain the solution tank. Remove the valve shield Remove the nuts, washers and U-bolts Hose to Solution holding the Solution Filter Assembly to Solenoid Valve the mounting plate Note: Place a suitable container...
Page 223: Solution Solenoid Valve
Service Manual – CS7010™ 30 - Solution System Solution Solenoid Valve 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 224: Detergent Pump (Ecoflex™ Models Only)
Service Manual – CS7010™ 30 - Solution System Detergent Pump (EcoFlex™ Models Only) Lift up the Operator seat and engage the Seat Prop Rod Remove the detergent bottles. Seat Prop Remove the two screws holding the cover weldment and remove the cover...
Page 225: Specifications
Service Manual – CS7010™ 30 - Solution System Specifications Specifications Component Solution Solenoid Valve 36V, Coil Resistance - 72 ohms ± 10% Type - diaphragm dosing pump with stroke adjustment Voltage - 12 VDC EcoFlex™ Detergent Pump Flow Calibration - 87 ml/min ± 3 ml/min Water Lift - 3.5 in Type - diaphragm, self-priming, internal check valve Solution Control Pump Voltage - 36 VDC, permanent magnet (EcoFlex™...
Page 226: 34 - Scrub System
Service Manual – CS7010™ 34 - 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 227: Circuit Description
34 - Scrub System Service Manual – CS7010™ Circuit Description Scrub functions are driven by the Main Machine Controller via Power Module #2 using CAN Bus commands. The Power Module receives its control power (turn-on power) via the KSI (Keyswitch) input. The power module controls its own main power by energizing the K3 relay.
Page 228: Side Squeegee Assemblies
34 - Scrub System Service Manual – CS7010™ Side Squeegee Assemblies The side squeegee assemblies are mounted to arms that are attached to the main deck and swingarm. Latch Weldment Assembly The side squeegee assemblies are spring-loaded to keep them firmly on...
Page 229: Maintenance And Adjustments
34 - Scrub System Service Manual – CS7010™ Maintenance and Adjustments CAUTION: Before working near the scrub deck, disconnect the main battery connector to prevent the deck from moving unexpectedly if the machine were to initialize. Replace a Leading Deck Blade...
Page 230: Removal And Installation
34 - Scrub System Service Manual – CS7010™ Removal and Installation CAUTION: Before working near the scrub deck, disconnect the main battery connector to prevent the deck from moving unexpectedly if the machine were to initialize. Side Squeegee Assembly Loosen the knob and swing out the edge Nyloc ®...
Page 231: Scrub Deck Actuator
34 - Scrub System Service Manual – CS7010™ Scrub Deck Actuator Remove the Recovery Tank described on page 254 Deck Turn on the key switch and put the Clevis Lift Arm Pin (2) machine into the Service Test mode to...
Page 232: Scrub Deck
34 - Scrub System Service Manual – CS7010™ Scrub Deck Remove the Recovery Tank described on page 254. Make sure the solution shutoff valve is closed, then disconnect the solution hose to the solution solenoid valve Turn on the key switch and put the machine into the Service Mode to allow you to jog the scrub deck up...
Page 233 34 - Scrub System Service Manual – CS7010™ supporting the deck lift arm assembly and scrub deck, and remove the two screws, washers, bushings, and flange bearings holding the deck lift arm assembly and attached scrub deck to the machine frame.
Page 234: Scrub Motor
34 - Scrub System Service Manual – CS7010™ Scrub Motor Remove the Scrub Deck described on page Electrical Connector Disconnect the electrical connector from the Scrub Scrub Motor Assembly. Motor Assembly Remove the Scrub Brush from the Brush Plate Assembly.
Page 235: Scrub Motor Carbon Brushes
34 - Scrub System Service Manual – CS7010™ 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 236 34 - Scrub System Service Manual – CS7010™ Carefully pry the End Casting from the Frame. Be careful not to lose the wave washer between the End Casting and the motor bearing. Note the following: • The rotor’s bearing is a light press into...
Page 237 34 - Scrub System Service Manual – CS7010™ 12 While holding the brush (F) and coil spring (G) together, feed the brush wire through the brush holder. 13 Insert the brush and coil spring into the brush holder. The brush wire should be toward the top, away from the brush cap.
Page 238 34 - Scrub System Service Manual – CS7010™ Note: The wave washer (J) fits between the rotor bearing and the end cap. When placing it in the end cap before assembly, note that the fingers (K) face toward the bearing.
Page 239: Specifications
34 - Scrub System Service Manual – CS7010™ Specifications Specifications Component Scrub Brush Motors (all) 35 VDC, 1 HP, 2750 RPM, 26 Amp Current Draw (shop Scrub Brush Motor - Center Average - 19 Amps Max. - 37 Amps measurements) Current Draw (shop Scrub Brush Motor - Left Average - 17 Amps Max.
Page 240: 38 - Squeegee System
Service Manual – CS7010™ 38 - 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 241: Component Locations
Service Manual – CS7010™ 38 - Squeegee System Component Locations The rear squeegee assembly is attached to the squeegee support assembly with two split squeegee clips that clamp onto Squeegee Lift horizontal pins in the squeegee support Front Actuator assembly.
Page 242: Maintenance And Adjustments
Service Manual – CS7010™ 38 - Squeegee System Maintenance and Adjustments CAUTION: Disconnect the main battery connector before working near the drive wheel. If the machine is unexpectedly powered on, the steering initialization routine can cause serious injury. Changing Squeegee Blades...
Page 243: Squeegee End Wheels
Service Manual – CS7010™ 38 - Squeegee System Rear Squeegee Blade Release the latch and remove the Squeegee Strap squeegee strap Remove the rear squeegee blade Rear Squeegee from the squeegee weldment Blade Rotate the existing rear squeegee blade top-to-bottom or end-for-end...
Page 244: Squeegee Tilt Adjustment
Service Manual – CS7010™ 38 - Squeegee System Squeegee Tilt Adjustment 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 Rear Squeegee Blade. It should be approximately 45 degrees to the floor surface as shown.
Page 245: Squeegee Casters Adjustment
Service Manual – CS7010™ 38 - Squeegee System Squeegee Casters Adjustment The height of the squeegee casters may need to be adjusted to compensate for squeegee wear and to obtain the correct squeegee tilt Threaded angle To adjust the height of a squeegee caster:...
Page 246: Removal And Installation
Service Manual – CS7010™ 38 - Squeegee System Removal and Installation CAUTION: 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. Squeegee Lift Actuator Tilt the recovery tank down.
Page 247: Squeegee Support Assembly
Service Manual – CS7010™ 38 - Squeegee System Squeegee Support Assembly CAUTION: Disconnect the main battery connector before working near the drive wheel. If the machine is unexpectedly powered on, the steering initialization routine can cause serious injury. Remove the Rear Squeegee Assembly.
Page 248: Specifications
Service Manual – CS7010™ 38 - Squeegee System Specifications Specifications Component Squeegee Tool Assembly Squeegee Blade, Front, Red Material - Linatex 40 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 249: 40 - Recovery System
Service Manual – CS7010™ 40 - 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 250: Component Locations
Service Manual – CS7010™ 40 - Recovery System Component Locations Recovery Tank The recovery tank is on the left rear side of the machine The squeegee hose carries Vacuum Fan Recovery the scrub solution from the squeegee to Cover Tank Cover the recovery tank.
Page 251: Vacuum Fan Cover Assembly
Service Manual – CS7010™ 40 - Recovery System Vacuum Fan Cover Assembly The vacuum fan cover assembly includes the vacuum filter lid assembly, filter, filter screen and vacuum fan cover. The vacuum fan cover assembly fastens to the Vacuum Filter Lid top of the recovery tank.
Page 252: Maintenance And Adjustments
Service Manual – CS7010™ 40 - Recovery System Maintenance and Adjustments CAUTION: 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. Clean the Vacuum Filter and Filter Screen...
Page 253: Clean The Debris Basket
Service Manual – CS7010™ 40 - Recovery System Clean the Debris Basket Unhook the latch, open the recovery tank cover and lift the debris basket out Debris of the recovery tank. Basket Rinse any accumulated material from the debris basket, then reinstall it in the recovery tank.
Page 254: Removal And Installation
Service Manual – CS7010™ 40 - Recovery System Removal and Installation Recovery Tank CAUTION: The recovery tank is relatively heavy. It’s recommended that the recovery tank be removed by two or more persons to prevent possible personal injury or damage to the recovery tank.
Page 255 Service Manual – CS7010™ 40 - Recovery System Loosen the knurled collar and disconnect the float switch wiring harness. Float Switch Wiring Harness Knurled Collar Pull the collar on the quick-disconnect fitting and disconnect the solution hose Collar Solution Hose...
Page 256: Vacuum Motor
Service Manual – CS7010™ 40 - Recovery System Vacuum Motor Lift up the recovery tank cover. Remove one of the hinge tabs, then twist and remove the recovery tank cover from the vacuum Recovery fan cover assembly. This will allow access to...
Page 257: Specifications
Service Manual – CS7010™ 40 - Recovery System Specifications Specifications Component Voltage - 42 VDC 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 258: 42 - Sweep System, Main
Service Manual – CS7010™ 42 - 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 259: Sweep System Wiring Diagram
Service Manual – CS7010™ 42 - Sweep System, Main Sweep System Wiring Diagram The diagram below contains both main broom and side broom circuitry. X166 X169 FUSE, 400 A. BATTERY, 36VDC IGNITION SW 5 AMP MAIN RELAY MAIN MACHINE YEL-BRN...
Page 260: Circuit Description
Service Manual – CS7010™ 42 - Sweep System, Main Circuit Description Main Broom Actuator The main broom actuator raises and lowers the main broom. Instead of the typical end limit switches, this actuator provides analog position feedback to the Main Machine Controller. A potentiometer in the head of the actuator returns a variable voltage between 0 and 3.3 volts back to the main controller.
Page 261: Maintenance And Adjustments
Service Manual – CS7010™ 42 - Sweep System, Main Maintenance and Adjustments CAUTION: 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 262: Adjust The Main Broom Tilt
Service Manual – CS7010™ 42 - Sweep System, Main Adjust the Main Broom Tilt Loosen the two 1/4”-20 Nyloc® Broom Arm nuts holding the bearing on Assembly which the broom support Main weldment pivots on the right Broom side. Note that the 1/4”-20 nyloc®...
Page 263: Removal And Installation
Service Manual – CS7010™ 42 - Sweep System, Main Removal and Installation CAUTION: 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.
Page 264 Service Manual – CS7010™ 42 - Sweep System, Main Replacement Install the Main Broom into the machine. Rotate the Main Broom as necessary to make sure the broom lugs on the far side engage the drive hub on the broom motor.
Page 265: Broom Motor
Service Manual – CS7010™ 42 - Sweep System, Main Broom Motor Remove the Main Broom described on page 263 Broom Drive Open the hopper and engage the prop Hub Assembly Remove the 5/16”-18 Hex Screw holding the Broom Drive Hub Assembly onto the gearbox shaft, then remove the Broom Drive Hub Assembly,washer and key.
Page 266: Main Broom Motor Carbon Brushes
Service Manual – CS7010™ 42 - Sweep System, Main Main Broom Motor Carbon Brushes You have the option of completing this procedure with the motor mounted to the machine, or removing the motor and completing this on a bench. The procedure is the same, and it is just a matter of which method is...
Page 267 Service Manual – CS7010™ 42 - Sweep System, Main Remove the two nuts, washers, and grommets from the long studs that secure the outboard end bell. While taking care to not loosen the motor casing from the bottom end bell, remove the top end bell from the motor •...
Page 268 Service Manual – CS7010™ 42 - Sweep System, Main 16 Retract each of the 4 brushes away from the Retracted center, and until the brush spring presses Brush against the side of the brush, as shown. • This will hold the brushes retracted for...
Page 269: Broom Lift Actuator
Service Manual – CS7010™ 42 - Sweep System, Main Broom Lift Actuator Remove the Recovery Tank described on page 254 Remove the Main Broom described on Broom Lift page 263 Actuator Turn the key switch on and switch the machine to the Service Mode...
Page 270: Specifications
Service Manual – CS7010™ 42 - Sweep System, Main Specifications Specifications Component 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 271: 48 - Sweep System, Side Broom
Service Manual – CS7010™ 48 - Sweep System, Side Broom Functional Description Side Broom Side Broom Side Broom Actuator Overview Motor (2) Lift Weldment The Side Brooms run in opposite directions to direct debris from the sides of the machine toward the center where the main broom can direct it into the hopper.
Page 272: Side Broom And Main Broom Wiring Diagram
Service Manual – CS7010™ 48 - Sweep System, Side Broom Side Broom and Main Broom Wiring Diagram X166 X169 FUSE, 400 A. BATTERY, 36VDC IGNITION SW 5 AMP MAIN RELAY MAIN MACHINE YEL-BRN BLK-ORN CONTROLLER TO 1A3, 1D2 J1-19 YEL-BRN...
Page 273: Component Locations
Service Manual – CS7010™ 48 - Sweep System, Side Broom Component Locations Side Brooms The Side Brooms are mounted on the front corners of the machine, below the hopper. Side Broom Side Broom Side Broom Motors The side broom motor assemblies consist of the Side Broom Motors and Side Broom Gearbox.
Page 274: Maintenance And Adjustments
Service Manual – CS7010™ 48 - Sweep System, Side Broom Maintenance and Adjustments CAUTION: 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 275: Side Broom Motor Carbon Brushes
Service Manual – CS7010™ 48 - Sweep System, Side Broom Side Broom Motor Carbon Brushes Remove the Side Broom Motor described on page 277. Create witness marks on the gearbox, motor end bells (covers) and the motor casing for reassembly.
Page 276 Service Manual – CS7010™ 48 - Sweep System, Side Broom Inspect the carbon brushes and replace as necessary. New brush length is approximately 13/16” (20 mm) Reinstall the cover with O-ring in place. Gently pry the carbon brushes back against their springs just far enough to...
Page 277: Removal And Installation
Service Manual – CS7010™ 48 - Sweep System, Side Broom Removal and Installation CAUTION: 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.
Page 278: Side Broom Hub
Service Manual – CS7010™ 48 - Sweep System, Side Broom 12 Remove the 1/2”-13 x .75” Hex Screw and washer and carefully remove the Side Broom Assembly from the machine. Motor Assembly 13 Reinstall the side broom motor assembly by following the above steps in reverse...
Page 279: Side Broom Actuator
Service Manual – CS7010™ 48 - Sweep System, Side Broom Side Broom Actuator Empty the hopper and make sure the parking brake is engaged. Turn the key switch on and switch the machine to the Service Mode Raise the hopper far enough to minimize...
Page 280 Service Manual – CS7010™ 48 - Sweep System, Side Broom Note: If you’re installing a new Side Broom Actuator, or if the Drive Nut Cylinder on the existing Side Broom Actuator has been rotated on the Acme threaded shaft, check the actuator...
Page 281: Specifications
Service Manual – CS7010™ 48 - Sweep System, Side Broom Specifications Specifications Component 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. - 4 Amps...
Page 282: 50 - Dust Control/Dustguard™ Systems
Service Manual – CS7010™ 50 - Dust Control/DustGuard™ Systems Functional Description Overview The dust control system pulls air through the hopper and through a filter to trap the dust from the hopper. The optional DustGuard system sprays a fine stream of water in front of each side broom to minimize the dust created by the main broom.
Page 283: Dustguard Spray System (Optional)
50 - Dust Control/DustGuard™ Systems Service Manual – CS7010™ DustGuard Spray System (optional) The DustGuard Pump pumps water from a separate reservoir in the upper hopper to Nozzles on the front of the machine The Nozzles direct a fine stream of water onto the floor in front of the...
Page 284: Dust Control And Hopper Wiring Diagram
50 - Dust Control/DustGuard™ Systems Service Manual – CS7010™ Dust Control and Hopper Wiring Diagram X166 X169 FUSE, 400 A. BATTERY, 36VDC IGNITION SW 5 AMP MAIN RELAY MAIN MACHINE YEL-BRN BLK-ORN CONTROLLER TO 1A3, 1D2 J1-19 YEL-BRN GRY-VIO VACC1...
Page 285: Component Locations
50 - Dust Control/DustGuard™ Systems Service Manual – CS7010™ Component Locations Impeller and Filter System The Impeller Assembly houses the dust control vacuum motor and is mounted in the Hopper Cover. The Impeller Assembly pulls Vent air from the hopper through the filter. The...
Page 286: Dust Control Filter Switch
50 - Dust Control/DustGuard™ Systems Service Manual – CS7010™ Dust Control Filter Switch The optional Dust Control Filter Switch is mounted above the Filter Shaker Assembly on the Upper Hopper. The Dust Control Filter Switch will close and generate a...
Page 287: Dustguard Spray System
50 - Dust Control/DustGuard™ Systems Service Manual – CS7010™ DustGuard Spray System The DustGuard Pump is mounted on the Upper Hopper and is protected by the Pump Guard. The Strainer screens the incoming water upstream of the DustGuard Pump The Solenoid Valve, downstream of the DustGuard Pump,...
Page 288: Maintenance And Adjustments
50 - Dust Control/DustGuard™ Systems Service Manual – CS7010™ Maintenance and Adjustments CAUTION: Before performing any machine maintenance or adjustments, make sure the key switch is off, the key is removed from the machine and the parking brake is engaged.
Page 289: Clean The Dustguard Strainer Screen
50 - Dust Control/DustGuard™ Systems Service Manual – CS7010™ 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 Strainer Cover and Screen and drain the upper hopper through the...
Page 290: Adjust The Dustguard Spray Nozzles
50 - Dust Control/DustGuard™ Systems Service Manual – CS7010™ Adjust the DustGuard Spray Nozzles The Spray Nozzles should be approximately 10 to Spray 20 degrees from vertical as shown in order to spray Nozzle the water evenly top to bottom in front of the side brooms.
Page 291: Removal And Installation
50 - Dust Control/DustGuard™ Systems Service Manual – CS7010™ Removal and Installation CAUTION: 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.
Page 292: Dustguard Pump
50 - Dust Control/DustGuard™ Systems Service Manual – CS7010™ DustGuard Pump Drain the water from the upper hopper Note that you can do this one of several ways The Hose most convenient way is to remove the strainer Hose cover and screen and drain the upper hopper...
Page 293: Impeller Assembly
50 - Dust Control/DustGuard™ Systems Service Manual – CS7010™ Impeller Assembly Lift the Hopper Cover Remove the six Screws and washers holding the Hopper Cover Impeller Assembly to the Hopper Cover. Carefully pull the Impeller Assembly partway off of the...
Page 294: Specifications
50 - Dust Control/DustGuard™ Systems Service Manual – CS7010™ Specifications Specifications Component Type - Diaphragm w/bypass Nominal Voltage - 36 VDC Flow Rate - 1.1 GPM DustGuard Pump Current - 1.0 Amp max. Pressure - 30 psi max. Nominal Voltage - 36 VDC, 11 Watts DustGuard Solenoid Valve Coil Resistance - 125 Ohms ± 10%...
Page 295: 52 - Hopper System
Service Manual – CS7010™ 52 - 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,...
Page 296: Hopper And Dust Control Wiring Diagram
Service Manual – CS7010™ 52 - Hopper System Hopper and Dust Control Wiring Diagram X166 X169 FUSE, 400 A. BATTERY, 36VDC IGNITION SW 5 AMP MAIN RELAY MAIN MACHINE YEL-BRN BLK-ORN CONTROLLER TO 1A3, 1D2 J1-19 YEL-BRN GRY-VIO VACC1 J1-6...
Page 297: Component Locations
Service Manual – CS7010™ 52 - Hopper System Component Locations Upper and Lower Hopper The Upper Hopper (light gray) and Lower Hopper (dark Hopper gray) are on the front of the machine, The Hopper Cover Cover houses the dust control impeller pump, filter and filter shaker assembly.
Page 298: Hopper Dump Door
Service Manual – CS7010™ 52 - Hopper System Hopper Dump Door The Hopper Dump Door on the bottom of the hopper opens to allow the hopper to be emptied Hopper Dump Door Actuator Hopper Dump Door The electric Hopper Dump Door Actuator...
Page 299: Hopper Interlock Switch
Service Manual – CS7010™ 52 - Hopper System Hopper Interlock Switch The Hopper Interlock Switch is a proximity sensor on the left front of the machine frame that senses when the hopper is all the way down in the normal operating...
Page 300: Maintenance And Adjustment
Service Manual – CS7010™ 52 - Hopper System Maintenance and Adjustment Hydraulic Oil Change/Flush Raise the hopper Engage the parking brake and remove the key from the key switch. Support the hopper in its raised position with an overhead hoist or other suitable support.
Page 301 Service Manual – CS7010™ 52 - 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 302 Service Manual – CS7010™ 52 - Hopper System Rotate the Lower Cylinder Fitting upward back to its original upward position and make sure the Lower Cylinder Fitting nut is tight Install a Cap into the Lower Cylinder Fitting Lower Cylinder Fitting Disconnect the “DOWN”...
Page 303 Service Manual – CS7010™ 52 - Hopper System 10 Remove the Reservoir Guard Reservoir Guard 11 Loosen the four Phillips Screws holding the Reservoir to the Pump Assembly and remove the Reservoir Pump Phillips Assembly Screw (4) Note: Leaving the Phillips Screws in the Pump Assembly will make it easier to reinstall the Reservoir.
Page 304 Service Manual – CS7010™ 52 - Hopper System 17 Loosen the Plug on the “UP” Hydraulic Hose, then position the end of the “UP” Hydraulic Hose “UP” over the drip pan Hydraulic Hose Plug 18 Jog the hopper raise button to run the pump and force the oil out of the “UP”...
Page 305 Service Manual – CS7010™ 52 - Hopper System 22 Remove the cap from the “DOWN” Pump Port and reconnect the “DOWN” Hydraulic Hose to the “DOWN” Pump Port. “DOWN” Hydraulic Hose “DOWN” Pump Port 23 Disconnect the “UP” Hydraulic Hose from the...
Page 306 Service Manual – CS7010™ 52 - Hopper System 29 Remove the cap from the Lower Cylinder Fitting 30 Remove the plug from the “UP” Hydraulic Hose and reconnect the “UP” Hydraulic Hose to the Lower Cylinder Fitting “UP” Hydraulic Hose...
Page 307 Service Manual – CS7010™ 52 - Hopper System 34 Raise the hopper and check the position of the “UP” Hydraulic Hose. The “UP” Hydraulic Hose should be positioned as shown so it doesn’t contact the hopper when the hopper is down “UP”...
Page 308: Dump Door Actuator Adjustment
Service Manual – CS7010™ 52 - Hopper System Dump Door Actuator Adjustment There are two stages for adjusting the dump door actuator. The first is to ensure that the internal potentiometer is synchronized to the actuator lead screw The second is to adjust door open position...
Page 309 Service Manual – CS7010™ 52 - Hopper System Dump Door Open Position If the hopper is not still raised from the first part of Dump Door Open this procedure, raise it and engage the prop rod To ensure the dump door is first closed, press the dump door close button on the control panel.
Page 310: Removal And Installation
Service Manual – CS7010™ 52 - Hopper System Removal and Installation CAUTION: 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. Hydraulic Power Pack Assembly LPG and Diesel Models Disconnect the battery.
Page 311 Service Manual – CS7010™ 52 - 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 312: Battery Models
Service Manual – CS7010™ 52 - 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.
Page 313 Service Manual – CS7010™ 52 - 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) 10 Momentarily run the pump to get oil out of the “down port”...
Page 314: Hopper Lift Cylinder
Service Manual – CS7010™ 52 - Hopper System 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 WARNING: The hopper must be adequately...
Page 315 Service Manual – CS7010™ 52 - 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...
Page 316 Service Manual – CS7010™ 52 - Hopper System 10 Use Wire Ties or other suitable strapping to support the Hydraulic Cylinder while you work on the system. (See adjacent photo.) 11 Reinstall elbow fittings and attach the hose from the lower cylinder port to the up port on the pump assembly.
Page 317: Hopper Interlock Switch
Service Manual – CS7010™ 52 - Hopper System Hopper Interlock Switch The hopper interlock switch detects when the hopper frame is in the fully down position. Symptoms of failure or misadjustment are that certain machine functions will be disabled as though the hopper was raised.
Page 318: Hopper Dump Door Actuator
Service Manual – CS7010™ 52 - Hopper System Hopper Dump Door Actuator Open the hopper and engage the hopper Clevis prop rod If possible, open the hopper dump door to Washer (2) relieve the tension on the hopper dump door actuator...
Page 319: Specifications
Service Manual – CS7010™ 52 - Hopper System Specifications Specifications Component 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. Output Speed - 3669 RPM (full load) Hydraulic Pump Motor Current Draw - 15.9 Amps (full load) Horsepower - 0.55 HP (full load)
Page 320: 90 - Options And Accessories
Service Manual – CS7010™ 90 - 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 Tank Clean Out Door to allow easier cleaning and flushing of the Recovery Tank. Recovery Tank Back-Up Alarm Kit The Back-Up Alarm Kit includes the Back-Up Alarm, electrical connector and mounting hardware. The Back-...
Page 321 Service Manual – CS7010™ 90 - 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. The turn signals don’t use a conventional flasher unit. The main machine...
Page 322 Service Manual – CS7010™ 90 - Options and Accessories Description Illustration Rear Corner Roller Kit Hopper Temperature Sensor Kit Temperature Switch The Hopper Temperature Sensor Kit includes a Temperature Switch and mounting hardware. If the temperature in the hopper rises to a certain point, the Temperature Switch will generate a caution and signal the main machine controller...
Page 323 Service Manual – CS7010™ 90 - Options and Accessories Description Illustration High Pressure Pump Kit - Engine Powered 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 324 Service Manual – CS7010™ 90 - Options and Accessories Description Illustration EcoFlex ™ Chemical Injection Kit Chemical Injection The EcoFlex ™ Kit includes the detergent pumps, detergent bottles, mounting hardware and associated plumbing to inject detergent into the solution flow to the scrub brushes. Refer to the Solution System section for more information. Overhead Guard Kit - 82”...
Page 325 Service Manual – CS7010™ 90 - Options and Accessories Description Illustration Deluxe Seat Kit with seat belt and arm rest Heat Exchanger Hot Water Scrub Kit The Hot Water Scrub Kit includes a Heat Exchanger, mounting hardware and associated plumbing to route the solution through the Heat Exchanger before it is mixed with detergent and sent to the scrub brushes.
Page 326 Service Manual – CS7010™ 90 - Options and Accessories Description Illustration Front Bumper Kit The Front Bumper Kit includes the front bumper weldment, a front corner roller kit and mounting hardware. Super Duty Kit The Super Duty Kit includes a front bumper kit, deluxe seat kit and a rear corner roller kit. Spray Wash Hose Kit The Spray Wash Hose Kit includes...
Page 327 Service Manual – CS7010™ 90 - 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. Warning Beacon Kit The Warning Beacon Kit includes an...
Page 328 Service Manual – CS7010™ 90 - Options and Accessories Description Illustration Vacuum Wand Kit 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...
Page 329 We supply a full range of cleaning equipment for rental or purchase. For more information, or a cleaning solution to suit your business, please get in touch – For a more comprehensive product range, please visit our website. Address Contact Berrington House, t: 0845 33 77 695 Berrington Road,...

Crescent CS7010 Service Manual

03 - General Information

04 - Control System

10 - Chassis System

14 - Wheel System, Non-Traction

20 - Wheel System, Traction

22 - Steering System

24 - Electrical System

28 - Engine System - LPG LEV

28 - Engine System, Diesel

Engine System - Petrol (Gasoline)

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Summary of Contents for Crescent CS7010