Nilfisk-Advance CS7000 Service Manual

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Table of Contents

Quick Links

Troubleshooting

Summary of Contents for Nilfisk-Advance CS7000

Page 1 Advance CS7000 Hybrid LPG, Model Number 56509000 Advance CS7000 Hybrid Diesel, Model Number 56509001 Advance CS7000 B, Model Number 56509002 Advance CS7000 Hybrid LPG EcoFlex™, Model Number 56509006 Advance CS7000 Hybrid Diesel EcoFlex™, Model Number 56509007 Advance CS7000 B EcoFlex™, Model Number 56509008 Advance CS7000 Fuel Cell EcoFlex™, Model Number 56383115...
Page 2: Table Of Contents
Service Manual – CS7000 Contents Contents General Information General Machine Description Service Manual Purpose and Application Revision History Other Reference Manuals and Information Sources Nilfisk-Advance Publications Engine Manufacturers’ Technical Manuals Conventions Parts and Service Nameplate Cautions and Warning Symbols General Safety Instructions...
Page 3 Service Manual – CS7000 Contents LPG Machine Diesel Machine Broom Adjustment (Battery, LPG and Diesel) Battery Charge Indicator Fault, Caution and Warning Displays Fault Displays Caution Displays Warning Displays Steering Wheel Foot Pedals Chassis System Component Locations - Battery Machine (major components)
Page 4 Service Manual – CS7000 Contents To Clean the Dust Control Filter To Reinstall the Dust Control Filter To Clean the DustGuard™ Strainer Screen To Clean the DustGuard™ Spray Nozzles To Adjust the DustGuard™ Spray Nozzles Troubleshooting Removal and Installation To Remove and Reinstall the DustGuard™ Solenoid Valve Assembly To Remove and Reinstall the DustGuard™...
Page 5 Service Manual – CS7000 Contents 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 Change Engine Oil and Oil Filter...
Page 6 Service Manual – CS7000 Contents Step Two Engine Overheat Shutdown Lost Oil Pressure Shutdown Component Locations Maintenance and Adjustments Maintenance Checklist Change Engine Oil and Oil Filter Change Engine Coolant Inspect Air Filter Replace Air Filters Troubleshooting Checking Spark Checking LPG Primary Pressure No crank - The starter does not engage Cranks but does not start –...
Page 7 Service Manual – CS7000 Contents Replace Air Filters Troubleshooting Checking Spark No crank - The starter does not engage Cranks but does not start – No Spark Cranks but does not start (has sufficient spark) Achieves one but not ALL RPM modes.
Page 8 Service Manual – CS7000 Contents viii Recovery Tank Recovery Tank Cover and Debris Basket Vacuum Fan Cover Assembly Vacuum Motors Float Cage and Ball Assemblies Maintenance and Adjustments To Clean the Vacuum Filter and Filter Screen To Clean the Debris Basket...
Page 9 Service Manual – CS7000 Contents The Following Conditions Must be Met for the Extended Scrub System to Operate The Following Conditions Must be Met for the Low Pressure Wash Hose to Operate The Following Conditions Must be Met for the EcoFlex™ System to Operate 308...
Page 10 Service Manual – CS7000 Contents Functional Description Summary Steering Wheel Rotation Sensor Steering Actuator Steering Travel Limit Switches Steering Controller Steering System Wiring Diagram Circuit Description Component Locations Maintenance and Adjustments Troubleshooting Diagnostic Trouble Codes (DTCs) To retrieve steering system codes from the “hidden menu”:...
Page 11 Service Manual – CS7000 Contents Specifications Sweep System, Side Broom Functional Description Overview Side Broom System Wiring Diagram Circuit Description The Following Conditions Must be Met for the Side Broom Sweep System To Operate Side Broom Actuator Motor Component Locations...
Page 12 Service Manual – CS7000 Contents Drive Wheel Drive Controller Specifications Shop Measurements Drive Controller Voltage Measurements Low Current 35 Pin Connector (J4) Motor U, V and W Terminal Pair Voltages Motor U, V and W Terminal Pair Frequency System Current Draw - Driving only with no cleaning functions...
Page 13: General Information
Service Manual Purpose and Application This Service Manual a technical resource designed to aid service personnel in maintaining and repairing the CS7000 Sweeper/Scrubber to ensure optimum performance and long service life. Please read it thoroughly before servicing your machine. Revision History •...
Page 14: Other Reference Manuals And Information Sources
Portuguese, Italian, Greek 56041984: Estonian, Latvian, Lithuanian, Slovenian 56041985: Slovakian, Czech, Polish, Hungarian These manuals can be found on the following Nilfisk-Advance’s electronic supported databases: • Nilfisk-Advance Dealer Customer Zone • Nilfisk-Advance website: www.Nilfisk-Advance-us.com • EzParts service / parts CD-ROM...
Page 15: Engine Manufacturers' Technical Manuals
Nilfisk-Advance original replacement parts and accessories. Call the Nilfisk-Advance Dealer named below for repair parts or service. Please specify the Model Number (same as the Part Number) and Serial Number when discussing your machine.
Page 16: Cautions And Warning Symbols
General Information Cautions and Warning Symbols Nilfisk-Advance uses the symbols below to signal potentially dangerous conditions. Read this information carefully and take the necessary steps to protect personnel and property. Danger! Is used to warn of immediate hazards that will cause severe personal injury or death.
Page 17 • This machine is not approved for use on public paths or roads. • This machine is not suitable for picking up hazardous dust. • Use care when using scarifier discs and grinding stones. Nilfisk-Advance will not be held responsible for any damage to floor surfaces caused by scarifiers or grinding stones.
Page 18: Hopper Prop Rod
Service Manual – CS7000 General Information Hopper Prop Rod Warning! Never work underneath the raised hopper without the hopper prop rod engaged. To Engage the Hopper Prop Rod Press and hold the hopper raise button to raise the hopper all the way up.
Page 19: Jacking The Machine
Service Manual – CS7000 General Information Jacking the Machine Warning! Never work under a machine without safety stands or blocks to support the machine. When jacking the machine, do so at the designated Tie Down/Jacking Locations. Transporting the Machine Caution! Before transporting the machine on an open truck or trailer, make sure the machine is tied down securely and all access doors and covers are secured (tape and strap as needed).
Page 20: Towing The Machine
Service Manual – CS7000 General Information Towing the Machine Caution! If the machine must be towed, move the machine for short distances only and do not move the machine faster than a normal walking pace (2-3 mph, 3-5 kph). Tow the machine backward from one of the rear frame tie-down locations as shown below.
Page 21: Diagnostic And Service Tools
In addition to a full set of metric and standard tools, the following items are required in order to successfully and quickly perform troubleshooting and repair of Nilfisk-Advance Industrial floor cleaning equipment. • Laptop computer loaded with current version of EzParts, Adobe Reader and (preferably cellular) internet access •...
Page 22: Technical Specifications
Service Manual – CS7000 General Information Technical Specifications General Specifications Machine Dimensions Length 103” [262 cm] Width With right side squeegee assembly pivoted under the machine – 48” [122 cm] With squeegee – 53” [135 cm] Without With overhead With overhead With debris hopper raised –...
Page 23 Service Manual – CS7000 General Information Solution System Solution Tank Capacity 75 gal. [284 L] Recovery Tank Capacity 75 gal. [284 L] Precision-flow electric pump/solenoid valve Solution Pump Flow Rates One Light Two Lights Three Lights Four Lights Five Lights 1.5 gpm [5,68...
Page 24 Service Manual – CS7000 General Information Drive System Rear wheel, “steer-by-wire” system. The steering controller receives input Steering from the steering wheel to drive the steering actuator motor. The steering actuator motor drives a gear that meshes to a large ring gear that rotates the drive wheel assembly.
Page 25: Fastener Torque Specifications
Service Manual – CS7000 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. 50 ft.-lb.
Page 26: Maintenance
Service Manual – CS7000 General Information 103” [262 cm] 59” 150 cm] Maintenance Maintenance Schedule Keep the machine in top condition by closely following the maintenance schedule. Maintenance intervals given are for average operating conditions. Machines used in severe environments may require service more often.
Page 27: Daily Maintenance
Service Manual – CS7000 General Information Daily Maintenance Caution! Do not pressure-wash the operator control panel, fuse panel, contactor panel or engine compartment area. Maintenance Item Procedure “After use” maintenance is normally the responsibility of the Perform “After Use” maintenance steps machine Operator.
Page 28: Monthly Maintenance
Service Manual – CS7000 General Information Monthly Maintenance Maintenance Item Procedure Pump a small amount of grease into each grease fitting on the Squeegee caster wheel axle and pivot machine until grease seeps out around the bearings. Apply grease to lubricate.
Page 29: Maintenance Every 1500 Hours
Service Manual – CS7000 General Information Maintenance Every 1500 Hours Maintenance Item Procedure Main broom motor carbon brushes Check and replace as needed. Check and replace as needed. Side broom motor carbon brushes Maintenance Every 1900 Hours Maintenance Item Procedure Check and replace as needed.
Page 30: Lubrication Points
Service Manual – CS7000 General Information Lubrication Points Recovery Engine/Battery Tank Latch Compartment (oil) Latch (oil) Brake Pedal (parking brake) Linkage (oil) Squeegee Tool End Wheel (2) (oil) Squeegee Caster Wheel Steering Axle and Pivot (2) Gears (grease) (grease)
Page 31: Ecoflex System Maintenance
Service Manual – CS7000 General Information EcoFlex System Maintenance You will need to purge the system of the previous detergent when switching to a different detergent. Service Note: Move the machine over a floor drain before purging because a small amount of detergent will be dispensed in the process.
Page 32: To Change The Detergent Mix Ratio (The Scrub System Must Be On)
To Change the Detergent Mix Ratio (the scrub system must be on) Press and hold the detergent switch for two seconds. Release the switch once the detergent indicator begins flashing. While the light is flashing, press and release the detergent switch to select the next detergent mixture ratio.
Page 33: Pm Checklist
Service Manual – CS7000 General Information PM Checklist Nilfisk-Advance CS7000 PM Checklist Defect Codes Customer needs adjustment binding Address dirty or contaminated damaged, bent or torn City leaks missing Model # Serial # Hours worn out Does Defect Codes Operational Inspection Items...
Page 34 Service Manual – CS7000 General Information Does Defect Codes Visual Inspection Items Comments (circle) Work                         ...
Page 35: Machine Controls
Service Manual – CS7000 General Information Machine Controls Control Panel - General Layout Miscellaneous Controls The CS7000 control panel is organized by machine function with the scrub, sweep and hopper functions conveniently grouped together. Miscellaneous Scrubbing controls such as the key switch,...
Page 36: Miscellaneous Indicators
Service Manual – CS7000 General Information – Battery machines – increases the machine scrub speed to the full transport speed. • – switches on the headlights. Headlight Switch • – sounds the horn when pressed. Horn Button • – engages the high-pressure spray wand solution pump (LPG and diesel only).
Page 37: Scrub Controls
Service Manual – CS7000 General Information Scrub Controls • Scrub Pressure Increase Button – increases the scrub pressure one level when pressed. Note that the scrub pressure LED indicators in the One Touch Scrub Solution will light to Pressure Scrub Switch...
Page 38: Scrub Indicators
Service Manual – CS7000 General Information Scrub Indicators • – Scrub Pressure Indicators indicate the scrub pressure setting. One LED indicates the lightest scrub pressure and three LEDs indicates the heaviest scrub pressure. Solution Scrub • – lights Flow Burst of Power Indicator...
Page 39: Sweep Indicators
Service Manual – CS7000 General Information • – enables and disables the dust control fan. Dust Control Fan Switch • – functions as follows: Broom Select Switch – When the one-touch sweep is enabled, the selects the broom (main broom or side...
Page 40: Hopper Controls
Service Manual – CS7000 General Information Hopper Controls • – raises the Hopper Raise Button Hopper hopper. Door Hopper Open Raise • – lowers Button Hopper Lower Button Button the hopper. Hopper • – opens Hopper Door Open Button Hopper Door the hopper door.
Page 41: Diesel Machine
Service Manual – CS7000 General Information Diesel Machine The general LCD display on the diesel machine shows the solution level in the solution tank, the total engine run Dilution Solution Engine time, the recycle system icon (if actuated) and the fuel...
Page 42: Fault, Caution And Warning Displays
Service Manual – CS7000 General Information Alternate/Maintenance-free Battery Charge Indicator Standard Battery Battery Reset to 5 bars Low Voltage Cutout Reset Low Voltage Cutout Reset Never below 35.9 V Never below 35.9 V 5 bars Never below 35.4 V Never below 35.4 V 4 bars Never below 34.4 V...
Page 43: Warning Displays
Service Manual – CS7000 General Information Caution Condition causing Fault Display Icon Low-voltage Cutout The batteries need to be charged. Hopper temperature has Hopper Temperature exceeded the operational temperature. Solution Level Low Solution level has been low longer (Icon number 246)
Page 44: Steering Wheel
Service Manual – CS7000 General Information Steering Wheel The steering system in the CS7000 is a “steer by wire” system that uses an encoder and brushless AC three-phase motor to transfer steering wheel input to the drive Steering Wheel wheel.
Page 45: Chassis System
Service Manual – CS7000 Chassis System Component Locations - Battery Machine (major components) Battery Rear Battery Stop Plate Cover Assembly Assembly Battery Front Engine Guide Cover Weldment Assembly Battery Stop Weldment Right Door Assembly Pull Rod Assembly Dust Shield Left Cover...
Page 46: Component Locations - Lpg And Diesel Machine (Major Components)
Service Manual – CS7000 Chassis System Component Locations - LPG and Diesel Machine (major components) Engine Cover Assembly Front Engine Cover Assembly Right Door Assembly Pull Rod Assembly Dust Shield Left Cover Assembly Chassis Weldment...
Page 47: Control System
Control System Functional Description The CS7000 has several “controllers” which operate various parts of the machine and which communicate with one another via a CAN bus. The CAN bus is like a “phone line” between all of the controllers that allow them to communicate with one another.
Page 48: Can Bus Circuit
Service Manual – CS7000 Control System CAN Bus Circuit The main machine controller and the control panel are the two major players on the CAN Bus. The main machine controller provides a “bias voltage” on the CAN bus wires that the messages ride on. It also has a termination resistor inside it that connects the CAN Hi and CAN Lo circuits together.
Page 49: Can Bus Message Routing
Service Manual – CS7000 Control System CAN BUS message routing The following outline describes what messages are communicated over the CAN Bus from one controller to another. Control Panel • Messages Sent – To Main Machine Controller ◦ Operator switch inputs –...
Page 50: Drive Controller
Service Manual – CS7000 Control System ◦ Machine (Power Plant) Type - Battery/Engine (Hybrid) ◦ Hopper Up/Down – To Steering Controller ◦ None • Messages Received – From Control Panel ◦ Operator switch inputs – From Drive Controller ◦ Drive System Fault Codes ◦...
Page 51: Steering Controller
Service Manual – CS7000 Control System – From Control Panel ◦ None Steering Controller • Messages Sent – To Main Machine Controller ◦ Steering System Faults – To Drive Controller ◦ None – To Control Panel ◦ None • Messages Received –...
Page 52: Component Locations
Service Manual – CS7000 Control System Component Locations • Main Machine Controller • Control Panel • Drive Controller • Steering Controller Main Machine Controller Steering Controller Drive Controller Control Panel Caution! Do not pressure wash the control panel, main machine controller, steering controller,...
Page 53: Troubleshooting
Control System Troubleshooting There are two important things you need to know about electrical diagnosis on the CS7000 machine. First, it is capable of setting fault codes that can help narrow down the possible causes. Second, there is a special “Service Mode”...
Page 54: Fault Code Table (Main Machine Controller)
Service Manual – CS7000 Control System Fault Code Table (Main machine controller) Fault # Description Setting Conditions Consequences None Power Distribution Fault If the voltage of the 36v battery pack falls too low, the LCD will display this message. You need to charge the 36v battery pack.
Page 55 Service Manual – CS7000 Control System Fault # Description Setting Conditions Consequences Right Brush Contactor (K3) > 4 Amps or short circuit Disables detergent, Winding Circuit Overload solution and scrub motors. Broom Contactor (K4) Winding > 4 Amps or short circuit Disables sweep functions.
Page 56 Service Manual – CS7000 Control System Fault # Description Setting Conditions Consequences Tail Lamp Circuit (LT5, LT6) > 3 Amps or short circuit Overload Back-up Alarm (H1) Overload > 4 Amps or short circuit Horn (H2) Overload Short circuit Not used Low Voltage Cutout <...
Page 57: Hidden Menus
Service Manual – CS7000 Control System Hidden Menus The main machine controller supports a “hidden menu” which allows you to match the controller to the machine, set some user options and perform time saving service tests. There are three main hidden menus modes; Configuration Display, Configuration Menu and User Options Menu. A unique switch sequence is...
Page 58 Service Manual – CS7000 Control System The Following is an outline of the menu: • 1 Machine Type • 2 Battery Type • 3 Detergent System • 4 EcoFlex System • 5 Dust Guard system • 6 Ex Scrub System • 7 Back-Up Alarm...
Page 59: Configuration Menu
Service Manual – CS7000 Control System Configuration Menu The configuration menu is a “read and write” mode that allows you to check and change the machine configuration values in order to tell the main machine controller how the machine is equipped. This “matches” the controller to the machine and must be done anytime a new main machine controller is installed. Note The configuration menu also contains time saving service tests in the Service Menu. See the separate “Service Mode”...
Page 60 Service Manual – CS7000 Control System • 2 Battery Type – 2 Installed – 1. Undefined (When the machine type is • 11 Low Press Wash “undefined” the control panel will display – 1 Not Installed the configuration menu whenever the key is turned on.) – 2 Installed – 1 Wet (Lead Acid) • 12 High Press Wash – 2 Sealed (gel) – 1 Not Installed • 3 Detergent System...
Page 61: User Options Menu
– 7 Actuator Sequence (For engineering use) • 17 Restore Defaults (Resets all Configuration Menu selections and User Options selections to default values) – Are you sure? (One-touch scrub switch = “Yes”. Solution switch= “No”. • 18 Haram Captor – 1 No (Use for all CS7000 models) – 2 Yes (Use for special market Haram Captor model to customize solution level processing and scrub pressures) User Options Menu The user options menu allows you to customize certain machine functions according to machine operator preferences.
Page 62 Service Manual – CS7000 Control System Continue to hold the switches until the LCD reads “User Options Menu”, and then release the switches. Once in the user options menu, you can scroll through the menu using the scrub pressure increase and decrease buttons.
Page 63 Service Manual – CS7000 Control System ◦ 1 Light - The only available scrub mode will be the Light setting. ◦ 2 Heavy - The Light and Heavy scrub mode will be available. ◦ 3 Extreme - All scrub modes will be available.
Page 64 Service Manual – CS7000 Control System moving the deck based on the current of the brush motors. ◦ RANGE: 1 – 3 seconds ◦ INCREMENT: 0.1 seconds ◦ DEFAULT: 2 seconds – 9 Solution In Reverse - Determines whether solution will flow when the machine backs up. ◦ 1 Off (This is default) ◦ 2 On • 2 Sweep System...
Page 65 Service Manual – CS7000 Control System ◦ 2 Neutral - waits for the machine to return to neutral – 5 Detect RTF (Recovery Tank Full) The machine is equipped with a feature that will automatically shut off the vacuum and scrub systems and display a recovery tank full icon on the control panel display when the recovery tank becomes full.
Page 66 Service Manual – CS7000 Control System – RANGE: 10 – 250 seconds – INCREMENT: 1 second – DEFAULT: 20 seconds • 9 Back-up Alarm – 1 Off - never on – 2 Reverse Only - Only on in reverse – 3 Fwd & Reverse - on when in motion –...
Page 67: Service Mode
Service Manual – CS7000 Control System Service Mode The service mode makes some diagnostic testing easier. Some outputs (like the scrub brush motors) are only turned on when other conditions are met, such as when the machine is moving. It can be difficult to check for voltage to the scrub brush motors while the machine is moving. Also, if voltage is not present, it leaves in question what other conditions may not have been met yet.
Page 68: To Operate
Service Manual – CS7000 Control System With the arrow cursor aligned with “Service Mode”, press the One-touch scrub switch to enter the mode. “Service Mode” will be displayed at the top of the LCD followed by battery voltage, drive pedal position sensor voltage, drive mode (Reverse, Neutral or Forward) and any current main machine controller faults..
Page 69 Service Manual – CS7000 Control System Scrub Deck Actuator Pressing the scrub pressure increase button will move the deck down. Each press and release will extend the actuator motor a little. Holding the button down will run the motor in the extend direction.
Page 70 Service Manual – CS7000 Control System Side Broom Actuator Press the broom select switch (1) until the side broom on indicator (2) flashes slowly. Then press and hold the down arrow (3) to move the side brooms down. Press and hold the up arrow (3) to move the side brooms Main Broom Motors Pressing the One-touch sweep switch once will turn on the main broom motor (energize relay). The main broom on indicator will illuminate. Pressing the button again will turn off the motor (de-energize relay).
Page 71 Service Manual – CS7000 Control System Dust Guard Pump Pressing the dust guard spray switch will turn on the dust guard pump and illuminate the dust guard on indicator. Pressing the switch again will turn off the pump. Dust Control Motor Pressing the dust control fan switch will turn on the dust control motor (energize relay) and illuminate the dust control fan on indicator.
Page 72: Troubleshooting
Service Manual – CS7000 Control System Troubleshooting Control Panel LEDs all stay lit - CAN Bus problems If communication on the CAN bus fails, the operator may or may not notice anything. If they notice anything it will likely be that the control panel powers up when the key is turned on but all of the LEDs remain lit and there is no response to pushing any switch on the control panel.
Page 73: Removal And Installation
Service Manual – CS7000 Control System Removal and Installation Main Machine Controller Turn the key switch off and disconnect the main battery connector. Remove the recovery tank. Remove the control panel plate to frame fasteners Lay the controller and wiring down. Disconnect the 3 electrical connectors. Note, the connectors on the harness are color coded and keyed to match the connectors on the controller.
Page 74: Control Panel
Service Manual – CS7000 Control System Control Panel Empty the solution tank. (The tank must be empty upon reassembly for the solution level indicator to work properly). Disconnect the main battery connector. Remove key and key switch retaining nut. Remove the 6 control panel mounting screws.
Page 75: Specifications
Service Manual – CS7000 Control System Specifications Shop Measurements – Main Machine Controller The following tables contain some “real world” shop voltage measurements to help you recognize what “normal” looks like. All voltage values were measured with the black (Negative) voltmeter lead connected to the main battery negative unless otherwise specified. J2 Connector (White) J2 Pin Wire Circuit Description Value/Condition...
Page 76: J3 Connector (Gray)
Service Manual – CS7000 Control System J2 Pin Wire Circuit Description Value/Condition 116 WHT/YEL Detergent Pump (M17) Pulsed voltage is too fast for useful measurement value 157 YEL/ORN Solution Solenoid Valve 0.1v when energized Grounds to energize 160 BLU/VIO Detergent Pump (M18)
Page 77 Service Manual – CS7000 Control System J3 Pin Wire Circuit Description Value/Condition 111 BRN/GRN Dump Door Actuator 37v at rest or closing Reversing polarity driver 0.07v opening 115 RED/GRA Dump Door Actuator 37v at rest or opening Reversing polarity driver 0.03v closing...
Page 78: J7 Connector (Black)
Service Manual – CS7000 Control System J3 Pin Wire Circuit Description Value/Condition 049 ORN/BLK Glow Plug Output 11.6v when glow plug relay energized 12v out to energize relay 0v key off or after time out period 056 GRA/BLK VACC3a 0v Key Off...
Page 79 Service Manual – CS7000 Control System J7 Pin Wire Circuit Description Value/Condition 168 ORN/RED Hopper Dump Door Extend 0.0v full closed position Limit Switch 4.8v otherwise 170 YEL/WHT Hopper Dump Door Retract 0.0v wide open position Limit Switch 4.8v otherwise 172 BLU/YEL 4.97v...
Page 80: Dust Control/Dustguard™ Systems
Service Manual – CS7000 Dust Control/DustGuard™ Systems Functional Description Overview The dust control system pulls air through the hopper and through a filter to trap the dust from the hopper. The optional DustGuard system sprays a fine stream of water in front of each side broom to minimize the ™...
Page 81: Dustguard™ Spray System (Optional)
Service Manual – CS7000 Dust Control/DustGuard Systems ™ DustGuard™ Spray System (optional) pumps water from a separate DustGuard Pump reservoir in the upper hopper to on the Nozzles front of the machine. The direct a fine Nozzles stream of water onto the floor in front of the side...
Page 82: Dustguard™ System Wiring Diagram
Service Manual – CS7000 Dust Control/DustGuard Systems ™ DustGuard™ System Wiring Diagram Battery Fuse, 400 A A1 Main Machine Controller A3 Control Panel WHT/BRN J7-10 +12V J1-1 42V Alternator J7-11 B- J1-2 J7-3 CAN H J1-3 VIO/GRN J7-2 CAN L...
Page 83: Circuit Description
Service Manual – CS7000 Dust Control/DustGuard Systems ™ Circuit Description The following conditions must be met for the DustGuard™ system to operate: • The DustGuard™ system must be installed in the configuration menu. • There must be positive voltage to the .
Page 84: Component Locations
Service Manual – CS7000 Dust Control/DustGuard Systems ™ • The provides the negative ground to the under the following conditions: J2-18 Output Shaker Motor M14 – If the hopper is down and the DustGuard™ system is enabled, the will A1 Main Machine Controller...
Page 85: Dust Control Filter Switch
Service Manual – CS7000 Dust Control/DustGuard Systems ™ Dust Control Filter Switch The optional is mounted above Dust Control Filter Switch on the . The Filter Shaker Assembly Upper Hopper Dust will close and generate a warning if Control Filter Switch the hopper vacuum gets too high, indicating a plugged .
Page 86: Dustguard™ Spray System
Service Manual – CS7000 Dust Control/DustGuard Systems ™ DustGuard™ Spray System is mounted on the DustGuard Pump Upper Hopper is protected by the . The screens the Pump Guard Strainer incoming water upstream of the . The DustGuard Pump , downstream of the...
Page 87: Maintenance And Adjustments
Service Manual – CS7000 Dust Control/DustGuard Systems ™ Maintenance and Adjustments Warning! Before performing any machine maintenance or adjustments, make sure the key switch is off, the key is removed from the machine and the parking brake is engaged. To Clean the Dust Control Filter To Remove the Dust Control Filter Lift the hopper cover.
Page 88: To Clean The Dust Control Filter
Service Manual – CS7000 Dust Control/DustGuard Systems ™ To Clean the Dust Control Filter Caution: • Wear safety glasses when cleaning the filter. • Clean the filter in a well-ventilated area. • Be careful not to puncture the filter element.
Page 89: To Clean The Dustguard™ Strainer Screen
Service Manual – CS7000 Dust Control/DustGuard Systems ™ To Clean the DustGuard™ Strainer Screen Drain the water from the upper hopper. Note that you can do this one of several ways. The most convenient way is to remove the and drain the upper hopper through the...
Page 90: To Clean The Dustguard™ Spray Nozzles
Service Manual – CS7000 Dust Control/DustGuard Systems ™ To Clean the DustGuard™ Spray Nozzles Raise the hopper slightly if desired for easier access to the DustGuard™ nozzles. 7/8” Wrench Note: Place a suitable container underneath the nozzles to catch any water that may...
Page 91: Troubleshooting
Service Manual – CS7000 Dust Control/DustGuard Systems ™ Troubleshooting Note: You can use the Service Mode to toggle the various system components on and off to check for function. Refer to the section for information on how to enter Control System/Service Mode and use the Service Mode.
Page 92 Service Manual – CS7000 Dust Control/DustGuard Systems ™ Problem Cause Correction The dust control motor The dust control filter switch is 1. Clean the filter. will not run. closed, indicating that the filter 2. Check the dust control filter switch. The switch is plugged.
Page 93: Removal And Installation
Service Manual – CS7000 Dust Control/DustGuard Systems ™ Removal and Installation Warning! Before removing or reinstalling any machine components, make sure the key switch is off, the key is removed from the machine and the parking brake is engaged. To Remove and Reinstall the DustGuard™ Solenoid Valve Assembly Drain the water from the upper hopper.
Page 94: To Remove And Reinstall The Dustguard™ Pump
Service Manual – CS7000 Dust Control/DustGuard Systems ™ To Remove and Reinstall the DustGuard™ Pump Drain the water from the upper hopper. Note that you can do this one of several ways. The most convenient way is to remove the strainer cover and screen and drain the upper hopper through the DustGuard™...
Page 95: To Remove And Reinstall The Dust Control Filter Switch
Service Manual – CS7000 Dust Control/DustGuard Systems ™ Note: The base should Pump Guard be positioned under the four DustGuard Pump Isolators DustGuard Pump Pump Guard DustGuard Pump Isolator (4) To Remove and Reinstall the Dust Control Filter Switch Lift the hopper cover.
Page 96: To Disassemble And Reassemble The Impeller Assembly
Service Manual – CS7000 Dust Control/DustGuard Systems ™ To Disassemble and Reassemble the Impeller Assembly Remove the three Nyloc™ Nuts Screws holding the Vacuum Spacers Vacuum Plate Support to the Screw (3) and Gasket Vacuum Support attached Vacuum Motor Screw (3)
Page 97: Specifications
Service Manual – CS7000 Dust Control/DustGuard Systems ™ Specifications Component Specifications Type - Diaphragm w/bypass Nominal Voltage - 36 VDC DustGuard Pump Flow Rate - 1.1 GPM Current - 1.0 Amp max. Pressure - 30 psi max. Nominal Voltage - 36 VDC, 11 Watts DustGuard Solenoid Valve Coil Resistance - 125 Ohms ±...
Page 98: Electrical System
Solution System Chapter. Functional Description Overview The CS7000 uses electricity to operate almost everything. The “Battery” model has a large capacity 36 volt storage battery for its only power source. Power from the 36v battery supplies all machine electrical loads.
Page 99 Service Manual – CS7000 Electrical System “Hybrid” models use a large, engine-driven 42 volt generator for their main power source with a smaller 36 volt battery pack connected in “parallel” with the generator, as a “back up”. When the engine is running the 42 volt generator provides the electrical power to operate the 36v machine electrical loads as well as recharge the 36v battery pack.
Page 100 Service Manual – CS7000 Electrical System If you combine the power distribution for both the engine electrical loads and the 36v machine electrical loads it looks like this. Combined Power Distribution - Engine Models...
Page 101: Wiring Harnesses
Service Manual – CS7000 Electrical System All models have a large connector to disconnect power from the machine. A circuit breaker panel located on the left side of the operator foot well area provides circuit protection for multiple circuits. The electrical system makes use of hall effect current sensors to provide amp draw information to the main machine controller for some circuits.
Page 102: Circuit Protection
12 volts to switch out to various circuits like the Ignition output to the engine system. Current Sensors The CS7000 utilizes 3 hall effect current sensors to report amp draw information for the vacuum motors, scrub motors and main broom motor to the main machine controller. They work much like an inductive amp clamp for a digital multi-meter.
Page 103: Low Voltage Cutout
Service Manual – CS7000 Electrical System Low Voltage Cutout The scrub system and solution system are cut off by the main machine controller if the system voltage falls too low (Approx 31.5v for “wet” batteries or 32.94v for gel batteries). This is done to prevent damaging the batteries from over discharging.
Page 104: Headlights
Service Manual – CS7000 Electrical System Headlights Two types of headlights are used on the CS7000. Early machines, use incandescent 12v halogen bulbs. Later machines use LED headlights. The machine must be properly configured to operate each type correctly using Configuration Menu.
Page 105: Component Locations
Service Manual – CS7000 Electrical System Component Locations • 36 volt Battery (Battery Model) • 36 volt Battery Pack (Hybrid Models) - Right of engine under fuel tank. • 42 volt Generator - Front of engine behind rubber shield. (Raise hopper for access.) •...
Page 106 Service Manual – CS7000 Electrical System Battery Pack (Under Fuel Tank) Starting Battery 36 volt Battery Pack (Hybrid Models) Circuit Breaker Panel Seat Switch - bottom of seat 42 volt Generator Electrical Panel Fuse F1 400 Amps - Side view.
Page 107: Electrical Panel Contactor/Relay Location
Service Manual – CS7000 Electrical System Electrical Panel Contactor/Relay location Electrical Panel...
Page 108: Harness To Harness Connector Locations
Service Manual – CS7000 Electrical System Harness to Harness Connector Locations Most connectors are plugged into a component like the squeegee actuator; find the squeegee actuator and you can locate the squeegee actuator electrical connector. However, there are a few connectors that connect two harness.
Page 109: Connector Pin-Outs
Service Manual – CS7000 Electrical System Connector Pin-Outs The following pages contain details about every electrical connector that contains more than one “cavity”. The connector pin-out information is organized with a table on the left which identifies the location of wires in the connector and images on the right which show what the connector looks like.
Page 110 Service Manual – CS7000 Electrical System Component ID Component Name Connector ID Vacuum Motor Right side broom motor Left side broom motor Hydraulic Pump, Hopper Lift X126 Scrub Deck Actuator Motor X256 Squeegee Lift actuator Side broom actuator X109 Shaker motor...
Page 111 Service Manual – CS7000 Electrical System J2 - Main Machine Controller (A1) Wire # Color 091 ORN/YEL 094 ORN/BLU 098 YEL/RED 101 YEL/GRN 107 TAN/BLK 064 BLK/YEL 119 BRN/WHT 080 WHT/GRN 078 BLU/BRN 132 RED/GRN 135 YEL/GRA 162 BLK 057 VIO...
Page 112 Service Manual – CS7000 Electrical System J3 - Main Machine Controller (A1) Wire # Color 042 VIO/ORN 093 RED/YEL 030 BRN/WHT 031 RED/VIO 106 GRA/VIO 111 BRN/GRN 115 RED/GRA 118 WHT/ORN 123 PINK 129 BLU/PINK 131 GRA/ORN 134 GRA/BLU 137 BRN/RED...
Page 113 Service Manual – CS7000 Electrical System J4 - Drive Controller (A2) Wire # Color 185 ORN 126 VIO/GRN 186 BLK/PINK 187 TAN/RED 188 GRN/BLU 127 TAN/ORN 189 WHT/BLK 190 BRN/RED 191 VIO/BLK 192 YEL 193 VIO/WHT 194 PINK/RED 195 WHT/ORN...
Page 114 Service Manual – CS7000 Electrical System J5 - Steering Controller (A5) Wire # Color 083 GRA/ORN 199 BRN/WHT 200 ORN/BLK 201 BLK 202 WHT 203 BLU/GRA 204 BLK 308 RED/WHT 307 GRN/WHT 084 GRA/ORN 207 WHT/BLU 343 GRN 208 YEL/RED...
Page 115 Service Manual – CS7000 Electrical System J7 - Main Machine Controller (A1) Wire # Color 092 GRN/BLU 095 GRN 099 YEL 102 GRA 108 GRA/YEL 112 TAN/WHT 117 YEL/RED 130 WHT/BRN 133 BLK 050 YEL/BRN 141 ORN 046 RED/BLK 035 GRA/YEL...
Page 116 Service Manual – CS7000 Electrical System J8 - CAN Bus Connector Wire # Color 241 GRN 242 BLK 243 YEL AMP 5-747905-2 J10 - Drive Controller Programmer Wire 196 BLU/GRN 249 BLK/PINK 195 WHT/ORN SIDE 193 VIO/WHT MOLEX 39012041 X1 - Hopper Harness Connector (X262)
Page 117 Service Manual – CS7000 Electrical System X2 - Hopper Harness Connector (X263) Wire 091 ORN/YEL 284 BLK/YEL 098 YEL/RED 106 GRA/VIO DELPHI 15326917 250 GRN/ORN 111 BRN/GRN 115 RED/GRA 168 ORN/RED 235 BLK 170 YEL/WHT 239 BLK 071 WHT/RED 233 BLK...
Page 118 Service Manual – CS7000 Electrical System X21 - Dust Control Motor (M5) Wire 259 ORN/GRN 260 BLK SIDE DELPHI 15300027 X22 - Squeegee Lift Actuator (M12) Wire 080 WHT/GRN 078 BLU/BRN DELPHI 12052613 X23 - Vacuum Motor (M6) Wire 017 BLU/GRA...
Page 119 Service Manual – CS7000 Electrical System X27 - Main Broom Actuator (M21) Wire 030 BRN/WHT 031 RED/VIO 032 BLU/ BLK 033 GRA/GRN 034 TAN/RED DELPHI 12124107 X28 - Right Side Broom Motor (M8) Wire 295 WHT/RED 297 BLK DELPHI 12052613...
Page 120 Service Manual – CS7000 Electrical System X98 - Steering Wheel Sensor (E4) Wire 307 GRN/WHT 309 BLU 205 BLK 209 ORN/BLK 308 RED/WHT 310 GRN/BLK 206 BLK 211 ORN/BLK DEUTSCH DTM04-12PA 199 BRN/WHT 329 GRA/ORN X99 - Wheel Drive Motor (M24)
Page 121 Service Manual – CS7000 Electrical System X105 - Steering Travel Limit Switch, Left (S17) Wire 210 ORN/RED 270 GRA/ORN DELPHI 12010973 X106 - Steering Travel Limit Switch, Right (S16) Wire 207 WHT/BLU 277 GRA/ORN DELPHI 12010973 X109 - Side Broom Actuator (M13)
Page 122 Service Manual – CS7000 Electrical System X122 - Dust Guard Pump (M22) Wire 147 GRA 148 BRN/RED DELPHI 12010973 X124 - Dump Door Actuator Motor (M26) Wire 286 BRN/GRN 287 RED/GRA SIDE DELPHI 15300027 X126 - Hydraulic Pump, Hopper Lift (M10)
Page 123 Service Manual – CS7000 Electrical System X153 - Tail Lamp, Left (LT9) Wire 010 TAN/BLK 011 BLK/YEL SIDE DELPHI 12052641 X154 - Tail Lamp, Right (LT5) Wire 012 TAN/BLK 025 BLK/YEL SIDE DELPHI 12124819 X161 - Left Head Lamp (LT3)
Page 124 Service Manual – CS7000 Electrical System X166 - Tail Lamp Harness Connector (X239) Wire 094 ORN/BLU 107 TAN/BLK 285 BLK/YEL 101 YEL/GRN DELPHI 12020832 X172 - Splice Saver Connector Comb Wire 265 GRA 264 GRA 097 GRA 041 GRA SIDE...
Page 125 Service Manual – CS7000 Electrical System X178 - Back Up Alarm (H1) Wire 037 GRA 076 GRN/BRN DELPHI 12015792 X180 - Stop/Turn Lamp, Left (LT9) Wire 023 ORN/BLU 009 BLK/YEL DELPHI 12162000 X181 - Broom Motor Current Sensor (B2) Wire...
Page 126 Service Manual – CS7000 Electrical System X184 - Stop/Turn Lamp, Right (LT11) Wire 014 YEL/GEN 024 BLK/YEL DELPHI 12162000 X187 - Battery Interlock Switch (S13) Wire 315 TAN 338 GRN/BLU DELPHI 12010973 X190 - Solution Solenoid Valve (L1) Wire 157 YEL/ORN...
Page 127 Service Manual – CS7000 Electrical System X236 - Dump Door Extend Limit Switch (S7) Wire 290 ORN/RED 291 BLK DELPHI 12010973 X238 - Dump Door Retract Limit Switch (S8) Wire 292 YEL/WHT 293 BLK DELPHI 12010973 X239 - Main Harness Connector (X166)
Page 128 Service Manual – CS7000 Electrical System X258 - Trouble Light (LT1) Wire 316 YEL/BRN 232 BLK DELPHI 12015792 X262 - Main Harness Connector (X1) Wire 176 GRA 181 BRN/RED 223 WHT/GRA 224 BLK 225 YEL/VIO 226 BLK DELPHI 15326910 259 ORN/GRN...
Page 129 Service Manual – CS7000 Electrical System X265 - Engine Harness Connector Wire 321 PINK 341 PINK 318 BLK/RED 317 PINK/YEL SIDE 322 BLU/PINK DELPHI 15326868 323 GRN/YEL X266 - Engine Harness Connector Wire 324 GRA DELPHI 15326863 325 GRA/ORN 326 GRA/BLU...
Page 130 Service Manual – CS7000 Electrical System X268 - Extended Scrub Level Switch (S4) Wire 035 GRA/YEL 036 BLK DELPHI 12015792 X270 - Main Harness Connector (X271) Wire 017 BLU/GRA 018 BLK 019 BLU/GRA 020 BLK DELPHI 12015798 X271 - Vacuum Motor Harness (X270)
Page 131: Wiring Connections
Service Manual – CS7000 Electrical System X275 - Fuel Pump (M20) Wire 317 PINK/YEL 318 BLK/RED DELPHI 12010973 Wiring Connections K14 Safety Relay and K15 Auxiliary Relays Early Style K14 Safety Relay 6 = GRA/ORN 4 = PINK A = VIO...
Page 132: Late Style K14 Safety Relay And K15 Auxiliary Relay
Service Manual – CS7000 Electrical System Late style K14 Safety Relay and K15 Auxiliary Relay GRAY/ORN K14 Safety Relay Pink GRAY/ORN (2) ORN (2) BLK/WHT GRA/WHT K15 Auxiliary Relay TAN/GRN BLK X195 VIO/RED K14 Safety Relay K15 Auxiliary Relay...
Page 133: Maintenance And Adjustments
Service Manual – CS7000 Electrical System Maintenance and Adjustments Charging the Battery (Battery Model) See User Manual Generator Drive Belt The generator drive belt tension is maintained by an auto-tensioner and does not require adjustment. Troubleshooting 42 volt generator is not charging Potential Causes •...
Page 134: Removal And Installation
Service Manual – CS7000 Electrical System Removal and Installation 42 volt Generator Drive Belt Note: Instructions are for both diesel and LPG models. Photos are of diesel. Lift hopper up, engage hopper prop rod and then lower to safety lock position.
Page 135 Service Manual – CS7000 Electrical System Remove the tank guard plate. Tank Guard Plate Belt Guard Bolts a. Remove plate to frame bolts. b. Remove the plate to belt guard bolts. c. Remove the “P” clamp cable and fuel line fasteners.
Page 136: 42 Volt Generator
Service Manual – CS7000 Electrical System 42 volt Generator 1. Remove Engine and Generator as an assembly. See relevant engine chapter. 2. Remove generator drive belt. 3. Label wiring for correct reassembly and then remove. 4. Support generator with a lift.
Page 137: Head Light Bulb - Standard 12V Halogen
Service Manual – CS7000 Electrical System Head Light bulb - Standard 12v Halogen Disconnect headlight electrical connector Caution! DO NOT install a replacement halogen bulb into the socket while the headlight is plugged in. If the configuration menu is set for LED headlights, up to 42 volts could be available to the headlights.
Page 138: Specifications
Service Manual – CS7000 Electrical System Specifications Battery (Battery Model) Capacity - 98 AH @ 20 HR Low Voltage Cut Out The low voltage cut out specification in use is set in the user options menu. Menu # Cut Out AT:...
Page 139: Current Sensors
Service Manual – CS7000 Electrical System Current Sensors Amperage Measured Voltage Output 120 A 4.5v 60 A 3.5v 45 A 3.25v 30 A 3.0v 15 A 2.75v 2.5v -60 A 1.5v -120 A 0.5v Input/Output Table Black voltmeter lead Conn. Pin Wire Desig.
Page 140 Service Manual – CS7000 Electrical System Black voltmeter lead Conn. Pin Wire Desig. Description Signal Nominal Value 157 YEL/ Output Solution Solenoid ON/OFF signal Valve Grounds to energize 160 BLU/ Output Detergent Pump PWM SIGNAL 0-12V J2-32 (Reversing Polarity) 167 BLK/...
Page 141 Service Manual – CS7000 Electrical System Black voltmeter lead Conn. Pin Wire Desig. Description Signal Nominal Value 131 GRA/ Output Throttle 2 Output High Side 0V or 12V Driver Engine 134 GRA/ Output Throttle 1 Output High Side 0V or 12V...
Page 142 Service Manual – CS7000 Electrical System Black voltmeter lead Conn. Pin Wire Desig. Description Signal Nominal Value 130 WHT/ Output Power out to B-(Ground) Control Panel 133 BLK Output Ground for Control Panel 050 YEL/ Special Suppression Diode B-(Ground) 141 ORN...
Page 143: Wiring Diagrams
Service Manual – CS7000 Electrical System Wiring Diagrams Wiring diagrams show how electrical components are connected together and to a large degree “how things work”. They do not show where things are located. Here are some tips when using these diagrams. Every component has both an “ID”...
Page 144 Service Manual – CS7000 Electrical System 56509170 Rev G (Before SN 1000048160) Sheet 1 of 6...
Page 145 Service Manual – CS7000 Electrical System 56509170 Rev G (Before SN 1000048160) Sheet 2 of 6...
Page 146 Service Manual – CS7000 Electrical System 56509170 Rev G (Before SN 1000048160) Sheet 3 of 6...
Page 147 Service Manual – CS7000 Electrical System 56509170 Rev G (Before SN 1000048160) Sheet 4 of 6...
Page 148 Service Manual – CS7000 Electrical System 56509170 Rev G (Before SN 1000048160) Sheet 5 of 6...
Page 149 Service Manual – CS7000 Electrical System 56509170 Rev G (Before SN 1000048160) Sheet 6 of 6...
Page 150 Service Manual – CS7000 Electrical System 56509170 Rev H (SN 1000048160 and later) Sheet 1 of 7...
Page 151 Service Manual – CS7000 Electrical System 56509170 Rev H (SN 1000048160 and later) Sheet 2 of 7...
Page 152 Service Manual – CS7000 Electrical System 56509170 Rev H (SN 1000048160 and later) Sheet 3 of 7...
Page 153 Service Manual – CS7000 Electrical System 56509170 Rev H (SN 1000048160 and later) Sheet 4 of 7...
Page 154 Service Manual – CS7000 Electrical System 56509170 Rev H (SN 1000048160 and later) Sheet 5 of 7...
Page 155 Service Manual – CS7000 Electrical System 56509170 Rev H (SN 1000048160 and later) Sheet 6 of 7...
Page 156 Service Manual – CS7000 Electrical System 56509170 Rev H (SN 1000048160 and later) Sheet 7 of 7 (Sheet 6 of 7 Re-drawn in “ladder style”)
Page 157: Engine System, Diesel
Functional Description One of the engines available in the CS7000 is a Kubota Diesel (D1305-E3B-KEA-1). It is a three cylinder, liquid cooled, naturally aspirated engine. It has mechanical injector pump that is fitted with an actuator which physically moves the fuel lever inside the pump.
Page 158: Engine Starter Control
Service Manual – CS7000 Engine System, Diesel Engine starter control To get the engine starter to engage, the key switch is held in the start position which supplies 36 volts to the main machine controller connector J7 pin 19. This is the start input request. The main machine controller receives a 12 V supply on connector J3 pin 23 from the engine starter battery.
Page 159: Fuel Pump Control
Service Manual – CS7000 Engine System, Diesel Fuel pump control The main machine controller uses the same 12 V battery supply from connector J3 pin number 23 to operate the fuel pump. When the key is turned on, 36 volts is supplied to the main machine controller connector J7 pin number 13.
Page 160 Service Manual – CS7000 Engine System, Diesel Over Temperature Shutdown Here is how the engine over temperature shutdown works. To monitor engine temperature, the main machine controller sends a voltage through an internal resistor out connector J7 pin number 5 on the green wire with a yellow stripe to the engine coolant temperature switch.
Page 161 Service Manual – CS7000 Engine System, Diesel Low Oil Pressure Shutdown Here is how the low oil pressure shutdown works. The main machine controller sends 12 V out connector J3 pin number 9 to the APECS governor controller and the oil pressure switch. When there is oil pressure, the switch connects the voltage back as an “engine run signal”...
Page 162: Engine Rpm Control
Service Manual – CS7000 Engine System, Diesel Engine RPM control The Woodward APECS (Advanced Proportional Engine Control System) controller manages the engine RPM through the use of an electronic actuator. The controller monitors the actual engine RPM via a speed sensor which reads the flywheel ring gear teeth and compares it to the desired speed setting.
Page 163 Service Manual – CS7000 Engine System, Diesel There are several conditions that will override the user’s engine speed request. • High pressure wash forces to run speed. • If the engine is at idle speed, the engine will be forced to the run speed when sweeping only or vacuuming only.
Page 164: Glow Plug Control
Service Manual – CS7000 Engine System, Diesel Flash Code Fault Remedy Engine shutdown due to engine Check parameter settings. protection input Check what may have triggered the protection input. (Loss of oil pressure, engine overheat) Factory settings lost If calibration file is available, download calibration file and cycle power again.
Page 165 Service Manual – CS7000 Engine System, Diesel Component Locations • Fuel tank - Right side of engine compartment • Fuel level sending unit - Top of fuel tank • Fuel pump - Top of fuel tank • Fuel filter - Front left engine compartment area. Mounted on frame between engine and hopper.
Page 166 Service Manual – CS7000 Engine System, Diesel Actuator APECS Governor Controller Fuel Filter Injector Pump Alternator (42v) Front Engine Area (Hopper up and rubber curtain lifted) Engine RPM Sensor...
Page 167 Service Manual – CS7000 Engine System, Diesel Glow Plugs Glow Plug Relay Electrical Panel Coolant Temperature Switch Alternator (12v) Starter Oil Pressure Switch Engine - Back Side...
Page 168: Diesel Engine Maintenance Schedule
Service Manual – CS7000 Engine System, Diesel Maintenance and Adjustments Diesel Engine Maintenance Schedule First 50 hours: • Change engine oil and filter Every 50 hours: • Check fuel hoses and clamps. • Check restricted air filter indicator. Replace air filters as needed.
Page 169: Change Engine Oil And Oil Filter
Service Manual – CS7000 Engine System, Diesel Change Engine Oil and Oil Filter Drain the recovery tank for later removal. Shut off the engine and allow it to cool sufficiently to avoid burning yourself with hot engine oil. Remove the left side engine cover.
Page 170: Bleed Fuel System
Service Manual – CS7000 Engine System, Diesel Bleed Fuel System Bleeding air out of the fuel system is required if the engine ran out of fuel, the fuel filter has been replaced or the fuel lines have been opened. CAUTION: To avoid personal injury; Do not bleed a hot engine as this could cause fuel to spill onto a hot exhaust manifold creating a danger of fire.
Page 171: Replace Air Filters
Service Manual – CS7000 Engine System, Diesel Replace Air Filters Remove left side engine cover. Open right side engine cover and swing out fuel tank. Remove the top engine covers by: a. Disconnecting the gas spring from one end. b. Remove two bolts, one on each side, under the cover and lift the cover assembly off.
Page 172: Cranks But Does Not Start
Service Manual – CS7000 Engine System, Diesel Troubleshooting No crank – The starter does not engage Possible causes Check 36v Battery Pack drained Battery pack voltage Engine Battery Load test battery Starter Check power to starter solenoid Battery Cable Check voltage drop from battery positive to starter battery terminal.
Page 173 Service Manual – CS7000 Engine System, Diesel Diagnostic steps: Check governor control system. a. Does the APECS governor controller status light flash once immediately following “key on”? If not, check power and grounds for the APECS governor controller If so, go on to next step b.
Page 174 Service Manual – CS7000 Engine System, Diesel Cannot Achieve Either Run or Maximum Engine Speed Settings (Run 2200 RPM, Maximum Power 2400 RPM). The approach to diagnosing an engine RPM control problem is to check the inputs to the governor controller and check the output to the actuator.
Page 175: Compression Test
Service Manual – CS7000 Engine System, Diesel Compression Test Begin with a fully charged battery. Remove the air cleaner assembly. Cover the air inlet opening to prevent foreign objects from falling into the engine. Remove the glow plug electrical connector nuts and connector “rail”.

Nilfisk-Advance CS7000 Service Manual

General Information

Chassis System

Control System

Dust Control/Dustguard™ Systems

Electrical System

Engine System - LPG

Engine System, Diesel

Quick Links

Troubleshooting

Related Manuals for Nilfisk-Advance CS7000

Summary of Contents for Nilfisk-Advance CS7000

Table of Contents