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Engine System - Industrial Cleaning Equipment

1. i Qi i WOODWARD funuse g L SERIES L i 34 ACTUATOR i ae DEUTSCH i Yo CONNECTOR i RUN ENABLE SIGNAL funuse RED GRN 16 i GRN 16 E E a A i RED BLK 16 id ys RED 18 RED BLK 16 __ ct d EE RED 18 CRANKREQUEST BLU PNK 16 eo E OS E ea i Gay Lb o WOODWARD 3 m FUEL LOCK OFF SOLENOID gt mo il MAGNETIC x D J al i N3 03420R o N0000000 Fa PICK UP x FUEL PUMP z i V SHIELDED WIRE fake RPM a BLK 18 Ww B i AEES RN65127 TO PINI T i FUSE amp RELAY CRANK ht HIGH COOLANT TEMP LON GIL PRESS BLOCK ASSY REQUEST y SHUTDOWN RELAY SHUTDOWN REQUEST RELAY i RELAY ie RELAY 0 047yF CONNECTOR 2 PUR 16 Oba oA uu BLK WHT 16 FN 153268 RED 14 e u oS TO NILFISK HARNESS SPEED 2 LIV OUTFIT anil A ca 3 ey OUTPUT pee ae ee ia et BATTERY 0 ped ENGINE RUN 12VINPUT GRY 16 ftom g E 3 Ja a KUBOTA igu rjo FUEL HIGH COOLANT TEMP GROUND INPUT GRN YEL 16 gt A GRY LT BLU 16 SOLENOID A RED 16 EG551 44790 Se cT00024 TEMP SWITCH BLU LT OIL SWITCH DT06 6S GREY OPENFOR GRN 16 OPEN FOR PROPANE PLUG NORMAL TEMP GRY PRESSURE gree REDIG DT04 6P I FUEL SELECT CONNECTOR s if ao a A 0 t O ed E A i Wet DWARD RO i i s AUT CHOKE b SOL NOID E A741 j rami DT06 6S BLACK GASOLI NE PLUG Engine RPM Control The Woodward L series actuato
2. Circuit Description R FROM Fl D an a BLK gt RIVE MOTOR M24 K7 RED 1 7 T RED 1 2 B B E WHEEL DRIVE pe U RED RIVE CUNTRUOLI 4 7 CURTIS 1234 SPEED CONTROLLER 5V J4 26 PINK RED cane PHASE B J4 32 gt 5 G S amp x U a Ly i PHASE A J4 31 a eS ee VIO GRN L SENSOR GROUND J4 7 OD K7 5 RIVER 1 J4 6 D z TANZ ORN TEMP SENSOR J4 8 ot As a E ee WHEEL DRIVE BLK PINK PINK WHF m BLK WHT z gt KSI COIL POWER RETURN J4 13 TAN RED x BLK WHT a DS THROTTLE POT WIPER J4 16 BRN RED BLK WHT 5V THROTTLE POT HIGH J4 15 iA ee l E Drive Pedal OTOKOM Position Sensor B POT LOW J4 18 vIO BLK INTERLOCK J4 9 KSI J4 1 a CAN H J4 23 YEL CAN CAN L J4 35 rey CT BUS 4 OY Ja 25 VIO WHT 4 TX J4 28 WHT OR 3 RX J4 29 3LU GRN 1
3. l Rod A On 2 Disconnect the Extension Springs from i R pa the Squeegee Support Assembly using 2 a CS a spring puller See the Special Tools A a p pad iw al section xX A Tas 3 Remove the 3 4 16 Screw holding the Squeegee Support Assembly to the Rod End 4 Carefully remove the Squeegee Support Assembly from the machine 5 Reinstall the Squeegee Support Assembly by following the above steps in reverse order S AAN Note Use removable Loctite Ae carbiy PAFA thread sealer when reinstalling the 3 4 16 Screw Tighten the 3 4 16 Screw to 270 ft lbs To Remove and Reinstall the Squeegee Lift Arm 1 Remove the Rear Squeegee Assembly and Squeegee Support Assembly 2 Disconnect the Extension Springs from the Squeegee Lift Arm 3 Remove the Cotter Pin washers and Clevis Pin connecting the Squeegee Lift Actuator to the Squeegee Lift Arm 4 Remove the Shoulder Screws flat washers Flange Bearings and Nyloc Nuts connecting the Front Brackets to the machine frame then remove the Squeegee Lift Arm from the machine 5 Reinstall the Squeegee Lift Arm by following the above steps in reverse order 336 Service Manual CS7000 Squeegee System 337 To Remove and Reinstall the Squeegee Lift Actuator 1 Remove the recovery tank 2 Remove the squeegee tool assembly This will reduce the weight on the Squeegee Lift Arm 3 Disconnect the lift ac
4. Steering Limit Switches Speed regulator Difference between set value and Obstructions to steering actuator gear supervision actual value for speed regulator are rotation above limit l Excessive gear backlash Loose connection in steering actuator encoder wiring Steering Actuator Induction speed The estimated speed is above limit estimation supervision Service Manual CS7000 Steering System 353 Symptom Troubleshooting No DTC stored Steering Inoperative Steering Controller Status LED is Blinking Rapidly Check for steering system codes Steering Inoperative Steering Controller Status LED is Off Check power and ground supplies to the steering controller Steering Inoperative Steering Controller Status LED is On Steady Check each input to make sure it 1s operating correctly Refer to the Specifications Section Shop measurements information e Steering wheel rotation sensor Each encoder signal should switch between approximately 5 volts and 0 volts as the steering wheel is turned very slowly Travel limit switches There should be approximately 0 volts at one or both inputs at the controller No Steering Feel Possible Causes Steering wheel rotation sensor TFD Check for open circuit in the TFD coil e Steering Controller Not controlling TFD Check the power supply into the TFD Check the ground control voltage It should be around 24 volts Check the current draw of
5. Not opening throttle Service Manual Haram Captor Il Engine System Petrol Gasoline 230 Achieves one but not ALL RPM modes The approach to diagnosing an engine RPM control problem is to check the inputs to the L series actuator If the inputs are good and the output is bad the conclusion is that the actuator is the problem However don t forget that insufficient fuel supply or a restricted exhaust could appear like an RPM control problem if the engine cannot run well enough to achieve a higher RPM Possible Causes e Failed Engine Speed Sensor e Actuator linkage e Actuator power supply e Actuator e Wiring e Main Machine Controller Diagnostic steps 1 Visually inspect the linkage between the actuator arm and the carburetor throttle lever Is the linkage okay o If not repair o If so go to next step 2 Check the power and ground supplies to the actuator Is there sufficient power and ground o If so go on to check the Engine RPM Sensor input o If not repair 3 Check the Engine RPM Sensor input Check the AC voltage while the engine is running or check resistance of sensor through wiring harness from the actuator connector Is the Engine RPM sensor input okay o If so go on to check the speed request inputs o If not repair 4 Check the speed request inputs With the engine running press the engine speed button and check for 12v to the throttle 1 wire at the actuator Is 12v present on the
6. ENGINE RUN 12V INPUT i i 12v HI GH COOLANT TEMP Signal TEMP SWITCH 3 OIL SWITCH OPEN FOR OPEN FOR NORMAL TEMP PRESSURE i2Zv BATTERY STARTER Main Machine Controller 188 Service Manual CS7000 Engine System LPG 189 Normal Running e 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 The rest of the circuit remains unchanged IGNITION POWER IGNITION REQUEST FOR IGNITER amp a ALTERNATOR WOODWARD L SERIES ACTUATOR FUEL LOCK OFF SOLENOID HIGH COOLANT PEMP SHUTDOWN RELAY LOW OIL PRESS SHUTDOWN IGNITION REQUEST RELAY Throttle 2 12V OUTPUT ENGINE RUN 12V INPUT g J OIL SWITCH OPEN FOR PRESSURE 12v HI GH COOLANT TEMP Signal TEMP SWITCH OPEN FOR NORMAL TEMP izv BATTERY STARTER Main Machine Controller Engine RPM Control The Woodward L serles actuator directly monitors the engine speed sensor input and adjusts the throttle linkage to maintain the current target engine speed If it is unable to maintain the speed within the desired window it will shut the engine down by removing the path to battery negative for the ignition request relay through the actuator Note that if the actuator loses the RPM signal while the engine
7. a P i a 5 rg ee ei Be E ip je Aai a ie le A ka Sg A a id d k Th Sweep System Main 377 Service Manual CS7000 Sweep System Main 378 Specifications RPM 3400 Main Broom Motor Voltage 36 VDC Amperage 26 Amps Dynamic Load 400 lbs maximum Static Load 1000 lbs maximum Restraining Torque Actuator is internally restrained Input Voltage 30 to 40 VDC Main Broom Actuator Amperage 4 Amps at rated dynamic load Overload Protection Ball detent clutch with load rating between 450 and 700 Ibs Thermal Protection Automatic resetting thermal breaker enclosed in motor housing Wiring Polarity e To extend actuator connect red lead to positive and yellow lead to negative e To retract actuator connect yellow lead to positive and red lead to negative Nilfisk 7 Advance Service Manual CS7000 379 Sweep System Side Broom Functional Description Overview 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 The side broom sweep system includes the Side Brooms Side Broom Motors and the Side Broom Actuator which lowers and raises the Side Brooms via linkages connected to the Side Broom LIft Weldment The Side Broom Actuator lowers the Side Brooms any time the sweep system 1s enabled The Side Broom Motors switch on when the drive pedal i
8. gt Ja a KUBOTA 5 ff w Hlo FUEL HI GH COOLANT TEMP GROUND INPUT GRN YEL 16 r r GRY ll LT BLU 16 SOLENOI D L RED 16 EG551 44790 k cT00024 TEMP SWITCH BLU LT OIL SWITCH DT06 6S GREY OPEN FOR GRN 16 OPEN FOR PROPANE PL s NORMAL TEMP GRY PRESSURE i Baie A r AADE TAR an me 0 O O Vaf a a WOODWARD AUTO CHOKE SOLENOID B SA 4741 0 v0 i ti DT06 6S BLACK GASOLI NE PLUG Service Manual Haram Captor Il Engine System Petrol Gasoline 216 Cranking e 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 This energizes the crank request relay and battery power is passed through the contacts to the starter solenoid engaging the starter to turn the engine crankshaft The starter motor power is also fed to the choke solenoid which pulls the carburetor choke closed e Once oil pressure builds up the oil pressure switch opens The loss of ground through the oil pressure switch causes the low oil pressure shutdown relay to de energize o Battery power is then passed through the closed at rest contacts to the main machine controller as the engine run signal and to the Woodward
9. 8 00 Drive Nut Cylinder Positions Extended Position 9 75 Side Broom Actuator Current Draw shop measurements Average 2 to 3 Amps Performance data for the following load conditions No load Full load Start Thrust 0 Ibs Thrust 600 Ibs Thrust 600 Ibs Speed 39 in min Speed 30 in min Amps 1 4 Max Amps 6 7 1 0 Special Tools A long needle nose pliers is recommended to remove the hair cotter pin when removing reinstalling the side broom actuator The photo shown here is a typical example Nilfisk Advance Service Manual CS7000 393 Wheel System Non Traction Functional Description The non traction wheels support the front of the machine and house the machine 4 2 20 brakes The wheel system includes the Wheels Brake and Spindle Assemblies and the various mounting hardware The wheels are mounted in the wheel wells on the front sides of the machine between the main broom cover panels and the side brooms The Wheels are held onto the Brake and Spindle Assemblies with Slotted Nuts f Brake and and Cotter Pins The Brake and Spindle KE Spindle Assemblies are fastened to the machine y lJ RB Assembly frame with 1 2 20 Hex Screws A Brake Rod from the Brake Pedal Assembly actuates the pivoting Brake Bar Weldment Brake Pedal _ The Brake Bar Weldment actuates the two R individual brake levers on the Brake and Spindle Assemblies via Clevis Yokes and Clevis
10. Service Manual CS7000 Engine System LPG 203 Cranks but does not start No Spark Possible causes e Spark Control Module not powered up Ignition request relay Woodward L Series Actuator not energizing ignition request relay Spark control module ground e Crank Position Sensor e Spark Control Module e Wiring e Ignition Coils not likely that all 3 coils would fail at once Cranks but does not start has sufficient spark Possible causes No fuel Empty Tank Fuel lock off solenoid stuck closed Fuel lock off solenoid not energized o Ignition request fuse blown o High coolant temp shut down relay Closed at rest contacts not making connection o Engine oil pressure switch not opening for pressure o Engine Insufficient oil pressure to open switch Pressure Regulator e Mechanical engine Insufficient compression Plugged Intake Plugged Exhaust e Actuator Not opening throttle Service Manual CS7000 Engine System LPG 204 Achieves one but not ALL RPM modes The approach to diagnosing an engine RPM control problem is to check the inputs to the L series actuator If the inputs are good and the output is bad the conclusion is that the actuator is the problem However don t forget that insufficient fuel supply or a restricted exhaust could appear like an RPM control problem if the engine cannot run well enough to achieve a higher RPM Possible Causes e Failed
11. e Replace the squeegee blade s 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 the 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 1 Drain the recovery tank 2 Release the Recovery Tank Latch Handle and tip the tank away from the machine 3 Remove the squeegee hose from the recovery tank _ i Recovery aa Tank Latch o p a Handle Service Manual CS7000 Recovery System 282 4 Disconnect the Recovery Tank Vacuum Motor Electrical Connector Recovery Tank Vacuum Motor Electrical Connector an extended scrub system you must disconnect the Float Switch Wiring Harness and Solution Hose before you can remove the recovery tank These are described in steps 5 and 6 Note If your machine is equipped with E Solution Hose If your machine is not equipped with an extended scrub system skip to step 7 Float Switch Wiring Harness 5 Loosen the Knurled Collar and disconnect the Float Switch Wiring Harness i Float Switch Wiring Harness a lt n E _ Service Manual CS7000 Recovery System 283 6 Pull the
12. CS7000 Hopper Being Lowered When the operator pushes the button to lower the hopper the main machine controller energizes the K12 contactor by grounding the control winding of the contactor This causes a magnetic field to pull the normally closed contacts open and at the same time closes the normally open contacts Battery voltage is now applied through the closed set of K12 contacts to one side of the pump The other side of the pump is connected to battery negative through the normally closed contacts of the K11 contactor This completes the circuit and causes the pump to run in the Down direction Circuit Description Hopper System Y lt ey switch K11 At rest Main Machine Controller Hopper Down M Hopper Hydraulic Pump Motor Control Circuit Load Circuit Energized The Following Conditions Must Be Met for the Hopper to be Raised and Lowered There must be positive voltage to the J7 1 Interlock Input For this to happen The Seat Switch S9 must be closed The Safety Relay K14 on the Steer By Wire Controller A5 must energize the coil to close the Safety Relay K14 contactor The Emergency Stop Switch S15 must be closed The Battery Interlock S13 must be closed battery machines or jumpered Diesel and LPG machines The 400 amp Fuse F1 must be closed to provide positive voltage from the Battery to the load side of Hydraulic Pum
13. If the coil resistance is not 118 ohms 10 replace the contactor Check the continuity through contactor K4 with the coil energized If the contacts are open replace the contactor There is no ground connection Check the wiring and connectors from the broom motor to the broom motor to battery ground repair as necessary 372 Service Manual CS7000 Sweep System Main 373 Problem Cause Correction The broom lift actuator No voltage to the main broom 1 Check the wiring and connectors from the A1 is not raising and actuator Main Machine Controller to the main broom lowering the main actuator motor and repair as necessary broom 2 Check the operation of the broom lift actuator motor M21 If the motor doesn t operate correctly replace the broom lift actuator 3 Check the voltage outputs from J3 3 and J2 4 on the A1 Main Machine Controller The main broom is The potentiometer R4 in the Check the voltage output from J7 34 to ground not moving to the broom lift actuator is not as the broom lift actuator raises and lowers the previous position operating correctly broom The voltage should vary from 0 full up when the sweep position to approximately 3 3 VDC full down system is enabled position If the voltages are not in the 0 to 3 3 volt range replace the broom lift actuator There is no voltage from the Check the output from J7 33 on the A1 Main Machine A1 Main Machine Controller to Controller p
14. If the engine has not already shut down the system will then shut down as if the operator had shut off the key Normal engine shut off s IGNITION CONNECTOR FUEL PUMP PNK YEL 16 FOR PLUGGINGINTO IGNITION REQUEST PNK 16 KUBOTA IGNITION HARNESS Q CONNECTOR 1 PACKARD 16 PIN MALE PNK BLU 16 P N 15326863 Y WHT 16 CO PNK BLU 16 PNK GRN 16 TO NILFISK HARNESS i g WOODWARD i A SA a4 ACTUATOR ERE x a z DEUTSCH r i as yo CONNECTOR unuseo fe e 6 BTO6 1 284 RUN ENABLE SIGNAL MOLN PNK RN a 5 J PNK BLU RED 18 TO PINA Jf macneTiC i l J pick uP Ysni ELDED WIRE Engine RPM Sensor SHUTDOWN SIGNAL CRANK REQUEST _BLU PNK 16 eee S 3 WOODWARD 4 FUEL LOCK OFF SOLENOID i N3 03420R FUEL PUMP GRY BLU_16 RED BLK 14 T BLK 18 AEES RNG65127 TO PINE i FUSE amp RELAY BLOCK ASSY 0 047 LIM HE Pii SHUTDOWN a HIGH COOLANT TEMP SHUTDOWN RELAY W PACKARD 16 PI N FEMALE oOo yy rT Jrrnass26ass je ae TO NILFISK HARNESS SPEED 2 12V OUTPUT an HS SPEED 2 12V OUTPUT RED 16 JOC GRY BLU 16 STARTER SPEED H uzv OUTPUT SPEED 3 12V OUTPUT BLACK 16 GRY O BATTERY 0 ps ENGINE RUN 12V INPUT GRY 16 k zla KUBOTA Am FUEL HIGH COOLANT TEMP GROUND INPUT GRN YEL 16 LT BLU 16 SOLENOID aft EG551 44790 A CT00024 TEMP SWITCH BLU LT OIL SWITCH DT06 6S GREY OPEN F
15. TEGE vos YEU Service Manual CS7000 Hopper System 256 16 Remove the Reservoir Guard F Reservoir 17 Loosen the four Phillips Screws holding the Reservoir to the Pump Assembly and remove the Reservoir tin Note Leaving the Phillips Screws in E a 4 aa a la ad ie Z Pump Assembly the Pump Assembly will make it easier to reinstall the Reservoir 18 Empty the oil out of the Reservoir Wipe any dirt or debris out of the Reservoir as necessary using a clean lint free rag 19 Check the O ring between the Reservoir and Pump Assembly to make sure it is not damaged Replace the O ring if necessary 20 Make sure the O ring between the reservoir and pump assembly is installed correctly then reinstall the reservoir onto the pump assembly AN Note The reservoir has threaded brass inserts that can be damaged if the Phillips screws are colt overtightened 21 Carefully tighten the four Phillips screws Do not overtighten 22 Refill the reservoir with 10w 30 oil to the MAX fill line Do not overfill Service Manual CS7000 23 Loosen the Plug on the UP Hydraulic Hose then position the end of the UP Hydraulic Hose over the drip pan 24 Jog the hopper raise button to run the pump and force the oil out of the UP Hydraulic Hose until the oil runs clear with no foaming or air evident in the oil 25 Remove the Cap from the Lower Cylinder Fitting 26 Remov
16. ee oe Terminal 2 Fe LEFT i WOR on T _ n k gt 4 bS P Ei i ia tl Service Manual CS7000 Scrub System 299 8 Carefully pry the End Casting from the Frame Be careful not to lose the wave washer between the End Casting and End the motor bearing 9 Replace the carbon brushes as follows a Observe how the springs roll when the brush is J pushed back before taking it apart Cup side of spring b Remove a brush and spring Spring unrolls on this side held open c Install a new brush and spring into the brush holder Thread the brush wire lead through the brush holder Position the back end of the brush in the cup of the spring so that the spring will unroll as the brush is pushed back once it is installed 10 Install the other three Brushes 11 12 Service Manual CS7000 Scrub System 300 d Push the Brush back against the spring and insert a stiff temporary Retaining Wire paper clip or x Remove silicone sealer from the holes The wire Push Brush A must go through the holes in the brush holder Against Spring Cf pe just in front of the Brush to hold the Brush back y lp Sey against the spring pressure S gt T pin through the access hole in the end cover ki va Retaining Wire Hole A Retaining Wire as T pin shown k rey F Retaining Wire Rei
17. right hand Side Squeegee Assembly hits an object or obstacle This provides some compliance to prevent damage to the Side Squeegee Assembly Assembly 2 To release the Gas Spring to pivot the right Arm Weldment backward for service or maintenance proposes pull the top of the Lever Arm Bracket toward you and swing the Arm Weldment backward Service Manual CS7000 Side Squeegee Assemblies The Side Squeegee Assemblies are mounted to Weldment Arms that are attached to the Deck Arm Weldments The Side Squeegee Assemblies are spring loaded to keep them firmly on the floor A Catch Plate allows you to lock the Side Squeegee Assemblies in the upper position for double scrub cleaning and maintenance An Edge Guard held in position by a Knob protects the right hand Side Squeegee Assembly and swings out to allow access to the Blade Strap and Trailing Deck Blade The Latch Assembly releases to allow you to remove the Blade Strap and Trailing Deck Blade The Leading Deck Blades are held in place by strap weldments and wing knobs Scrub Deck Actuator Scrub System Trailing Deck Blade Leading Deck Blade The Scrub Deck Actuator is pinned to the machine frame and to the pivoting Deck Lift Assembly Arm When the Scrub Deck Actuator extends or retracts it lowers or lifts the free side of the Deck Lift Assembly Arm The Deck Lift Assembly Arm pivots on flange bearings and bus
18. 5V B1 Brush J7 27 Brush Current UD Current Sense Sensor VIO WHT J7 25 B C a BLU YEL B3 Vacuum RED WHY J7 29 Vacuum Current C Current Sense Sensor SVB VIOIWHT N RED FROM F1 K5 RED BLU GRA BLK Fuse 150 A 1 2 Contactor Vacuum Motor A Vacuum Motor BLU GRA V A Vacuum B Current Sensor Service Manual CS7000 Recovery System 275 Circuit Description The following conditions must be met for the recovery system to operate The Hopper Interlock Switch S3 must be closed There must be positive voltage to the J7 1 Interlock Input For this to happen The Seat Switch S9 must be closed The Safety Relay K14 on the Steer By Wire Controller A5 must energize the coil to close the Safety Relay K14 contactor The Emergency Stop Switch S15 must be closed The Battery Interlock S13 must be closed The 400 amp Fuse F1 must be closed to provide positive voltage from the Battery to the load side of Auxiliary Contactor K9 The Ignition Switch 14 must be closed to provide positive voltage to the Auxiliary Contactor K9 coil The J2 14 Output on the A1 Main Machine Controller provides ground to the Auxiliary Contactor K9 coil when the Ignition Switch S14 provides an input to the Key Switch Input J7 13 The Auxiliary Contactor K9 must be closed to provide positive voltage to circuit breaker VACC1 CB1 Circuit breaker VACC1 CB1 must be closed to provide positive voltage to the Vacuum Motor Contactor K6 The J
19. BLK WHT 2 J10 CURTIS PROGRAMER CONNECTOR Powering up the Drive Controller When the key switch is turned on power is supplied on the orange wire to pin J4 1 When each interlock switch closes seat switch safety relay switch emergency stop switch and battery interlock switch power is supplied on the green blue wire to pin J4 9 When power is available on both J4 1 and J4 9 the drive controller supplies battery voltage out of J4 13 to the K7 wheel drive contactor The power flows through the contactor coil and back into the controller at J4 6 where it is switched to ground to energize the K7 wheel drive relay The contacts of the energized K7 contactor supply battery power to the large B bolt on 398 Service Manual CS7000 Wheel System Traction 399 terminal of the controller Ground Battery Negative 1s supplied to the large bolt on B terminal of the drive controller Drive Pedal Sensor The primary sensor input is the drive pedal sensor The drive controller supplies 5 volts out of pin J4 15 on the white black wire to the drive pedal sensor The voltage passes through the potentiometer resistive strip and returns to the drive controller on the violet black wire to pin J4 18 where it 1s grounded inside the controller The drive pedal sensor input wiper goes from the sensor on the bro
20. CS7000 Hopper System 248 Battery Models 1 Open the right battery side cover 2 Use some large hooks to grab the bumper and raise the hopper up slightly using a hoist or other suitable method chassis or other suitable supports to prevent the hopper from accidentally lowering while you re working underneath the hopper A Warning Before working underneath the raised hopper install blocks between the hopper and 3 Remove the fasteners and remove the Reservoir Guard 4 Disconnect the pump electrical Ea connector BS Guard 5 Remove the hydraulic hoses from the i F pump 6 Remove the two hydraulic pump mounting bolts and remove the Hydraulic Power Pack assembly 7 Transfer fittings to the new Hydraulic Power Pack assembly and attach the assemble to the frame but do not connect the hoses yet The system has to be filled with oil 8 Fill the reservoir with 10W 30 engine oil are Note In the remaining steps it is important that the oil level always be maintained above the vain minimum mark on the reservoir 9 Plug the up port of the pump assembly It 1s labeled on the pump 10 Momentarily run the pump to get oil out of the down port by pressing the hopper down switch 11 Transfer the plug from the up port to the down port of the pump assembly 12 Momentarily run the pump to get oil out of the up port by pressing the hopper up switch 13 Remove all remaining plugs from the pum
21. Collar on the quick disconnect fitting and disconnect the Solution Hose Collar ind a a he ee eRe tee Solution Hose 7 Disconnect the Tether Hook and carefully tip and lift the recovery tank off of the mounting pins on the machine frame AAN Service Note You may want to lay the NA recovery tank down onto a skid or other suitable platform on a pallet jack in order to more easily move the recovery tank once it s removed from the machine To Reinstall the Recovery Tank 1 Set the recovery tank onto the mounting pins on the machine frame 2 Swing the recovery tank up and reattach the Tether Hook to the recovery tank 3 Reconnect the recovery tank vacuum motor electrical connector 4 Reconnect the extended scrub wiring harness and solution hose if so equipped 5 Reinstall the squeegee hose 6 Swing the recovery tank up into position until the recovery tank latch handle engages Service Manual CS7000 Lift up the Recovery Tank Cover Remove one of the Hinge Tabs then twist and remove the Recovery Tank Cover from the Vacuum Fan Cover Assembly This will allow access to the screw underneath the Recovery Tank Cover that holds the Vacuum Fan Cover Assembly to the recovery tank Remove the five Screws and washers holding the Vacuum Fan Cover Assembly to the recovery tank Carefully lift the Vacuum Fan Cover Assembly off of the recovery tank making sure the Float Cages pass up through the cutouts
22. Dump Door Actuator Assembly 1 2 3 Note Open the hopper and engage the hopper prop rod Open the hopper dump door to relieve the tension on the hopper dump door actuator assembly Remove the Cotter Hair Pin Washers and Clevis Pin holding the Dump Door Actuator Yoke to the Dump Door slightly as you remove the Clevis Pin will make it easier to remove the Clevis Pin from the Dump Door and Dump Door Actuator Yoke the cotter hair pin washers and clevis pin holding the actuator and spring in the Dump Door Actuator Yoke Carefully swing the Door Dump Actuator Assembly down to access the Electrical Connector Disconnect the Electrical Connector Remove the cotter hair pin washers and Clevis Pin holding the Dump Door Actuator Assembly to the frame then remove the Dump Door Actuator Assembly from the machine Reinstall the hopper dump door actuator assembly by following the above steps in reverse order Note Lifting the Dump Door up You don t need to remove amp Clevis Pin Cotter Hair Pin ben Electrical Connector Dump Door Actuator Assembly al 261 Service Manual CS7000 Hopper System 262 Specifications Displacement 0 0321 in per revolution Circuit Type reversible locking Hydraulic Pump Reservoir Assembl y Reservoir Capacity 45 in 26 in usable Oil Type 10W 30 automotive oil Voltage 36 VDC Output Torque 151 ft
23. GRY BLU 16 STARTER SPEED ua OUTPUT Deere AR BATTERY KUBOTA FUEL RY thee ORYG 0 047 pF ENGINE RUN 12V INPUT GRY 16 q j i l HIGH COOLANT TEMP GROUND INPUT GRN YEL 16 LT BLU 16 SOLENOID EG551 44790 4 CT00024 TEMP SWITCH BLU LT OIL SWITCH DT06 6S GREY OPEN FOR GRN 16 OPEN FOR PROPANE PLIPG NORMAL TEMP GRY PRESSURE RED AG DT04 6P FUEL SELECT CONNECTOR mos kd 0 0 0 8 S l Q i WOO2WARD AUTO CHOKE o ol H zr lo A z DT06 6S BLACK GASOLINE PLUG Service Manual Haram Captor Il Engine System Petrol Gasoline 215 Ignition On e When the main machine controller sees the key switch input it sends 12v out on the Ignition Request circuit e 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 e Ignition power is fed to the low oil pressure shut down relay energizing the relay Since there is no oil pressure the oil pressure switch is closed causing the relay to be energized This prevents power from being passed to the engine run input into the main machine controller e 12v passes through the fuel select connector from pin 8 to 1 via the gasoline plug connector to the ignition request relay coil e 12v is provided to the actuator pin 1 which wakes it up The actuator provides a switched path from pin 9 to 5 This provides a ground for the ignition
24. L series actuator pin 8 From this point on the run enable signal to the actuator is maintained by the low oil pressure shutdown relay o The same power is also passed to the power relay coil energizing the relay Battery power is then passed through the closed when energized contacts of the power relay back into the ignition request circuit and to the control relay winding energizing the control relay IGNITION POWER FORIGNITER amp N IGNITION CONNECTOR FUEL PUMP PNK YEL 16 FOR PLUGGING I NTO IGNITIONREQUEST PNK 16 KUBOTA IGNITION HARNESS PNK BLK 16 CONNECTOR 1 RY WHT 16 AA o y PACKARD 16 PIN MALE PNK BLU 16 PNK BLU 16 4 PNK i 16 P N15326863 PNK GRN 16 R A TO NILFISK HARNESS Ley garpaann POWER i na ae RELAY i WOODWARD nusen F L SERIES 20 A 4 35 e r ACTUATOR i PEE PIE 2 gt j s DEUTSCH l MEST gg ye CONNECTOR 1 3 16 i 10A gt ENI RUN ENABLE SIGNAL MALY am b 5 funusen RED RED GRN 16 RED GRN 16 Bis GRN 16 a ee E 154 1 RED BLK 16 ooo oo CS CY RED 18 i g SHUTDOWN SIGNAL CRANKREQUEST BLU PNK 16 Eomma Pje aa eee se eee 5 7 i o T a WOODWARD 3 Til gt FUEL LOCK OFF x SOLENOID ke jf jf MAGNETIC N3 03420R C r f PICK ICK UP FUELPUMP Engi me x i Nou V SHIELDED WIRE faeces RPM a h He l i AEES RN65127 TOPIN ii 2 i i FUSEGRELAY CRANE HIGH COMLART
25. Main Machine Controller must receive a signal from the A2 Drive Controller via the CAN BUS that the machine is moving forward or reverse The 150 amp Fuse F2 must be closed to provide positive voltage from the Battery to the load side of the Broom Motor Contactor K4 The Broom Motor M1 must have connections to battery ground B Main Broom Actuator Motor The J3 3 and J2 4 PWM Outputs from the Al Main Machine Controller provide voltage to the Main Broom Actuator Motor M21 The output polarity determines whether the Main Broom Actuator Motor lowers or raises the scrub deck The resistance through the main broom actuator potentiometer R4 varies with the broom height The J7 33 POT HIGH pin sends a fixed positive voltage to R4 with J7 35 POT LOW as a ground The Al Main Machine Controller reads the voltage through R4 from J7 34 WIPER to determine the broom height Service Manual CS7000 Sweep System Main 366 Broom Current Sensor e J7 24 provides 5 volts to the Broom Current Sensor e J7 25 provides battery ground B to the Broom Current Sensor The Input from the Broom Current Sensor provides the Broom Current Sense signal to J7 31 on the Al main machine controller The Al main machine controller monitors the current value to set a fault code and shut down the motor if too much current is being used Component Locations Main Broom and Drive Components The Main Broom is supported by the Broom Arm Assembly and the Broom S
26. NILDO attached Brake Rods and Rod Ends rome le Ql Brake Bar Weldment Service Manual CS7000 Wheel System Non traction 394 Maintenance and Adjustments Warning Before performing any maintenance or adjustments make sure the key switch is off and the key is removed from the machine Chock the machine wheels to prevent the machine from moving To Adjust the Brakes 1 Remove the appropriate side panel to access the Clevis Yoke Brake Bar 2 Lift the Fork on the Clevis Yoke then pull it Kian gt a Weldment toward you to remove it from the Clevis Yoke s ry 3 Lift the Clevis Yoke out of the Brake Bar Weldment This will allow the Clevis Yoke to rotate on the Brake Rod Clevis f p4 Yoke T 4 Rotate the Clevis Yoke on the Brake Rod to effectively lengthen or shorten the Brake Rod Note that lengthening the Brake Rod will apply more pressure to the brakes with comparable brake pedal travel 5 When the brake is adjusted correctly reinstall the Fork onto the Clevis Yoke then reinstall the side panel Service Manual CS7000 Wheel System Non traction 395 6 If steps 1 through 5 don t provide adequate adjustment remove the wheel and adjust the Rod End as follows 1 4 20 a Remove the Nyloc Nut 1 4 20 Bolt and washers holding the Rod End to the Brake Lever b Loosen the Locknut c Rotate the Rod End on the Brake Rod to effectively le
27. QPEN GEAR LUBE to front 180 of ring gear teeth and all around pinion gear teeth 19 Reassemble in reverse order Drive Wheel 1 Block front wheels Loosen drive wheel lug nuts Jack the rear of the machine up to get the drive wheel off the ground Remove the drive wheel lug nuts and remove the wheel 5 Reassemble in reverse order Drive Controller 1 Disconnect the main power connector Remove the recovery tank Label the power and motor cables to aid in correct reassembly lt lt Remove the bolts securing the motor and power cables 5 Disconnect the low current connector 6 Remove controller attaching screws and remove the controller 7 Reassemble in reverse order When attaching cables use the correct hardware in the correct order to avoid damage caused from a loose connection Torque to 90 IN LBS 10 17 Nm Cable Terminal i ks l SCR HEX M6 1 X 25mm Drive Controller M Y i i 7 Da e WSH INT SHPRF 1 4 Damaged Drive Controller terminal from loose D connection Case removed for clarity Service Manual CS7000 Wheel System Traction 423 Specifications Shop Measurements Shop measurements are values that were measured on a real machine While they are not specifications they can help you recognize normal vs abnormal Drive Controller Voltage Measurements All voltages are DC unless otherwise stated and were measured with the negative black voltmeter lead on batter
28. Remove and Reinstall a Brake and Spindle Assembly Le Jack up the machine at a designated jacking point Install safety stands or blocks to support the machine while you work on it Remove the Wheel from the Brake and Spindle Assembly Remove the Nyloc nut and 1 4 20 screw holding the Rod End to the Brake Lever Remove the two 1 2 20 hex screws and remove the Brake and Spindle Assembly from the machine Reinstall the Brake and Spindle Assembly by following the above steps in reverse order Wheel System Non traction Brake and Spindle Assembly Brake and Spindle Assembly E aN ii an Nilfisk Advance 396 Service Manual CS7000 397 Wheel System Traction Functional Description A single rear wheel provides both traction drive and steering The major components of the drive wheel system are the drive pedal drive controller drive wheel motor gearbox and drive wheel The drive wheel is mounted to a gearbox which carries the vehicle load provides gear reduction and converts the plane of rotation from horizontal to vertical The gearbox is driven by a brush less three phase AC motor A drive controller directly operates the drive motor based on input requests from a drive pedal sensor potentiometer which is mounted on the side of the drive pedal If you push the pedal forward the machine will move forward If you push it farther forward the machine will increase
29. Remove and Reinstall the Broom Lift Actuator 1 Remove the recovery tank Remove the main broom from the machine Turn the key switch on and switch the machine to the Service Mode me e Extend the scrub deck downward in the Service Test Mode This will give you additional clearance for removing the hair cotter pins and clevis pins on the broom lift actuator 5 Extend the main broom downward in the Service Test Mode so the bristles rest on the floor This will minimize the weight on the broom lift actuator 6 Remove the Hair Cotter Pin washers 6 p and 50 x 2 75 Clevis Pin holding the i d bottom of the Broom Lift Actuator to the x Broom Support Weldment Broom Lift Actuator Hair Cotter Pin i Ee ae Pag os Soo DTAP Broom e Support ri Weldment DEO eN a Braas 50 x 1 75 Clevis Pin Broom Support Weldment Service Manual CS7000 7 10 Remove the Hair Cotter Pin washers and 50 x 1 75 Clevis Pin holding the top of the Broom Lift Actuator to the Spring Arm Disconnect the Broom Lift Actuator electrical connector and remove the Broom Lift Actuator from the machine Reinstall the Broom Lift Actuator by NAY following the above steps in reverse 50 x 1 75 order Clevis Pin Check the main broom height and main broom sweep pattern and adjust Lm as necessary Refer to the To Adjust s the Main Broom Height section
30. Side Broom Sweep System To Operate The Hopper Interlock Switch S3 must be closed There must be positive voltage to the J7 1 Interlock Input For this to happen The Seat Switch S9 must be closed The Safety Relay K14 on the Steer By Wire Controller A5 must energize the coil to close the Safety Relay K14 contactor The Emergency Stop Switch S15 must be closed The Battery Interlock S13 must be closed The 400 amp Fuse F1 must be closed to provide positive voltage from the Battery to the load side of Auxiliary Contactor K9 and circuit breaker CB7 The Ignition Switch 14 must be closed to provide positive voltage to the Auxiliary Contactor K9 coil The J2 14 Output on the A1 Main Machine Controller provides ground to the Auxiliary Contactor K9 coil when the Ignition Switch S14 provides an input to the Key Switch Input J7 13 The Auxiliary Contactor K9 must be closed to provide positive voltage to circuit breaker VACC1 CB1 Circuit breaker VACC1 CB1 must be closed to provide positive voltage to the Side Broom Motor Contactor K8 coll The J2 15 Output on the A1 Main Machine Controller must provide a ground to the Side Broom Motor Contactor K8 coil J2 15 provides ground to K8 under the following conditions The A1 Main Machine Controller must receive a signal from the A3 Control Panel via the CAN BUS that the operator has pressed the sweep and side broom switches The A1 Main Machine Controller must receive a signa
31. TEMP iow Gi PRLS i BLOCK ASSY SHUTDOWN RELAY SHUTDOWN CONNECTOR 2 PACKARD 16 PI N FEMALE P N 15326868 TO NILFISK HARNESS SPEED 2 12V OUTPUT RED 16 i cial ak GRY BLU 16 y SPEED 3 qzy OUTPUT SPEED 3 12V OUTPUT BLACK 16 0 047p HAD ae SPEED 2 12V OUTPUT STARTER GRY O 0 pm ENGINE RUN 12V INPUT GRY 16 Llo o Ja F KUBOTA aclu ele FUEL HIGH COOLANT TEMP GROUND INPUT _GRN YEL 16 GRY LT BLU 16 SOLENOID d RED 16 2 EG551 44790 m cT00024 TEMP SWITCH BLU LT OIL SWITCH DT06 6S GREY OPENFOR GRN 16 OPENFOR PROFANT PLUG NORMAL TEMP GRY PRESSURE f a N BERIG DT04 6P FUEL SELECT T CONNECTOR i 2 WEIDWARD KO 0 ALTO CHOKE LP NOID ee G Saad 741 j o J Cm2 DTO06 6S BLACK GASOLI NE PLUG Service Manual Haram Captor Il Engine System Petrol Gasoline 217 Normal Running e 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 The rest of the circuit remains unchanged IGNITION POWER FORIGNITER g r IGNITION CONNECTOR FUEL PUMP PNK YEL 16 FOR PLUGGINGINTO IGNITION REQUEST PNK 16 KUBOTA IGNITION HARNESS Q CONNECTOR 1 PACKARD 16 PIN MALE P N 15326863 TO NILFISK HARNESS
32. The emergency stop switch 15 on the Operator control panel is disengaged rotate clockwise e The safety relay from the steering system K14 is closed e The seat switch S9 is closed e The battery interlock proximity sensor S13 is closed Check the wiring and connectors from the A Main Machine Controller to the squeegee actuator motor and repair as necessary Check the operation of the squeegee actuator motor If the motor doesn t operate correctly replace the squeegee actuator Check the voltage outputs from J2 8 and J2 9 on the A1 Main Machine Controller Make sure the squeegee hose is installed correctly in the recovery tank and on the squeegee weldment Check the squeegee hose for damage or cracks and replace if necessary Flip the squeegee blade s around to position a new blade surface on the floor e Replace the squeegee blade s The squeegee down time is not set correctly Refer to the Control System Troubleshooting Hidden Menus User Options Menu section Adjust the squeegee tilt Refer to the Maintenance and Adjustments To Adjust the Squeegee Tilt section Service Manual CS7000 Squeegee System Removal and Installation Warning Before removing or reinstalling any machine components make sure the key switch is off the key is removed from the machine and the parking brake is engaged To Remove and Reinstall the Squeegee Support Assembly 1 Remove the Rear Squeegee Assembly
33. and solution system e The Solution Shutoff Valve allows you shut off the solution flow to the machine for solution system maintenance E Note There is a Valve Shield PAPP mounted onto the solution tank that is not shown in the above photo The Valve Shield is designed to prevent damage to the Solution Shutoff Valve Solution Shutoff Solution Filter Solution System 309 l a Service Manual CS7000 Solution Pressure Sensor The Solution Pressure Sensor on the back of the Operator Interface Panel uses the air i Operator n pressure 1n the Sensor Tube to determine interface the solution level in the tank The Sensor Panel gt Tube is connected via the Sensor Tube f Fitting to a hollow vertical tube inside the solution tank This vertical tube is open at the bottom and is filled with air The solution in the tank will exert pressure on the air in the tube proportional to the level of solution in the tank The Solution ff Solution Pressure Sensor monitors the air Me ee Pressure pressure in the Sensor Tube and converts l mA Sensor this pressure value to a solution level as 7 shown on the LCD display on the Operator Interface Panel Solution Pump EcoFlex Models Only The Solution Pump is mounted underneath the rear right hand side of the solution tank and pumps the solution to the solution solenoid valve Sa Low Pressure Wash Hose Pump The optional Low Pressure wash hos
34. check for ial and use the Service Mode Problem Cause Correction The main sweep An interlock is not closed Before you start troubleshooting a specific system system is not check to make sure operating correctly e The emergency stop switch S15 on the Operator control panel is disengaged rotate clockwise e The safety relay from the steering system K14 is closed e The seat switch S9 is closed e The battery interlock proximity sensor S13 is closed e The Ai Main Machine Controller is receiving the appropriate signal from the A3 Control Panel via the CAN BUS The main broom The 150 amp Fuse F2 is Check the Fuse F2 and replace if necessary motor will not run blown The hopper is overfilled or is Check for a fault code 54 Main Broom Motor lip loaded Overload If you see fault code 54 empty the hopper There is no voltage to the K4 Check circuit breakers CB1 and CB3 and reset if contactor coil necessary Check the K9 contactor coil resistance If the coil resistance is not 118 ohms 10 replace the contactor Check the continuity through contactor K9 with the coil energized If the contacts are open replace the contactor Check the J2 16 output from A1 Main Machine Controller There is no positive voltage to Check the wiring and connectors from the load the broom motor side of contactor K4 to the broom motor and repair as necessary Check the K4 contactor coil resistance
35. creating friction between the plates and discs that resists steering wheel movement The resistance is proportional to the current flow The Steering Controller regulates the amount of current flow to provide the right steering feel Field Coil ee gal Steering Inside CS Shaft mah Splines Clutch Housing Clutch Housing Splines to hold Fiber Discs CE Steel Plates and Fiber Discs Steering Actuator The Steering Actuator consists of a motor gear set and a position sensor The motor operates on three phase AC Alternating Current and is a brushless design It rotates a gear set that drives the output shaft The output shaft is keyed to a drive gear which no o drives a large ring gear to turn the rear drive wheel s iir N assembly There is also a sensor inside the motor me that reports position and rotation information to the Steering Controller This information provides feedback to the controller so that it can verify that the motor actually moved as it was commanded to The Steering Actuator has an internal encoder that translates motor rotation information into digital ie hg signals The end of the motor shaft has a special eo Motor Stator AE aan diametrically polarized magnet on it The line of FEAN Ry ile w ae separation between the north and south magnetic Pam OO poles rotates in close proximity to the encoder The encoder reads the movement of the magnet
36. entire length of the main broom To adjust the width of the Main Broom Sweep Pattern switch on and lower the main broom as described in step 1 While the main broom motor is running press the Broom Height Raise Button or Broom Height Lower Button to adjust the broom height Note that e Raising the main broom will narrow the a Main Main Broom Sweep Pattern E Broom Bea Sweep I Pattern e Lowering the main broom will widen the Main Broom Sweep Pattern Allow the broom motor to stop and the broom to retract upward The machine controller will remember the new main broom height and will return the broom to this position when the sweep system is enabled 367 Service Manual CS7000 Z To Adjust the Main Broom Tilt 1 Loosen the two 1 4 20 Nyloc Nuts holding the Bearing on which the Broom Support Weldment pivots on the right side Note that the 1 4 20 Nyloc Nuts and Bearing are accessed from the inside of the main broom compartment and are located behind the 1 2 13 Screw just to the rear of the Broom Arm Assembly Also note that the Bearing and mounting screws ride in slotted holes in the supporting weldment to allow for up down adjustment Move the Bearing and attached Broom Support Weldment up or down as necessary so the width of the main broom sweep pattern is consistent along the entire length of the main broom Note that e Raising the right side of the main broom will
37. from the Lower Cylinder Fitting 4 g UP Hydraulic Install a Plug into the end of the UP b a Hose Hydraulic Hose This will prevent dirt and air from being drawn into the UP Hydraulic Hose when you run the cylinder rod downward Rotate the Lower Cylinder Fitting downward to direct the oil into the drip pan Press the hopper lower button to run the pump and force the oil out of the Lower Lower Cylinder Fitting until all of the oil has been Cylinder 8 i a drained from the bottom of the cylinder Fitting Manually press the cylinder ram down as necessary to ensure all of the oil is out of the bottom of the cylinder Service Manual CS7000 Hopper System 255 12 Rotate the Lower Cylinder Fitting upward back to its original upward position and make sure the Lower Cylinder Fitting nut is tight 13 Install a Cap into the Lower Cylinder Fitting Lower Cylinder Fitting 14 Disconnect the DOWN Hydraulic Hose from the DOWN Pump Port DOWN Hydraulic Hose Ty A ee WET 1 E Byer HiNG AMD EYE ITH OR WEAR PO CA 7 HSTEMA NYECCION o DAMA DOWN Oy Ema yp eel que iy MY ORALLY roa Travai LEZ SU Pump Pao HUQUE PORTES EGEZ vOs YEU Port 15 Install a Cap on the DOWN Pump Port Been Papa i Am ESTE ey ETEMA Sa YECCION O DANA ta Daie FV ora woe tp ey An TRAVAILLEZ SUF Popa LIC E
38. function must be installed in the configuration menu The 400 amp Fuse F1 must be closed to provide positive voltage from the Battery to the load side of Auxiliary Contactor K9 The Ignition Switch S14 must be closed to provide positive voltage to the Auxiliary Contactor K9 coil The J2 14 Output on the A1 Main Machine Controller provides ground to the Auxiliary Contactor K9 coil when the Ignition Switch S14 provides voltage to the Key Switch Input J7 13 e Circuit breaker VACC2 CB2 must closed to provide positive voltage to the Low Pressure Pump M23 e The J3 24 Output must provide negative ground to the Low Pressure Pump M23 This output will be active whenever the key switch is on The internal pressure switch in the Low Pressure Pump M23 must be closed for the pump to run 5 psi when the hose nozzle is opened and shut pump off at 45 psi when the hose nozzle is ex Note The internal pressure switch in the low pressure pump is set to switch the pump on at 25 psi in closed The Following Conditions Must be Met for the EcoFlex System to Operate The J2 19 J2 7 J2 32 and J2 21 PWM Outputs provide power to the Chemical Metering Pumps M17 and M18 respectively under the following conditions The detergent system and EcoFlex system must both be installed in the configuration menu e The A1 Main Machine Controller must receive a signal from the A3 Control Panel via the CAN BUS that the operator has pressed the
39. gap to approximately 20 30 KV and clip the tester to a good ground on the engine 3 Crank the engine over and check for consistent arcing across the tester gap Checking LPG Primary Pressure 1 Turn off the propane tank valve with the engine running and allow the engine to run out of fuel Test Port Plug 2 Turn key switch off Ue EPST 3 Remove the primary chamber test port plug located on top of the vaporizer regulator 4 Install thread adapter part number 50360A into the test port 5 Install fitting from LPG pressure test kit into the thread adapter Service Manual CS7000 Engine System LPG 202 6 Using the LPG test gauge kit Part 56504450 hook up the blue pressure gauge hose to fitting 7 Open propane tank valve 8 Start engine Specification 4 3 PSI 32 7kPA 9 When finished reinstall the test port plug using a suitable pipe thread sealant E G Loctite 305384 No crank The starter does not engage Possible causes e 36v battery pack drained preventing main machine controller from powering up e Engine Battery e Starter e Battery to starter cable Engine Ground e No voltage to the starter solenoid Open circuit breaker CB9 Auxiliary Relay o Burned contacts or not energized Key Switch Main Machine Controller Woodward L Series Actuator Not supplying ground for crank request relay Crank request relay e Wiring
40. in the tank Disconnect the Vacuum Motor electrical connector Loosen the Hose Clamp and disconnect the Foam Tube Assembly from the Vacuum Motor Carefully lift the Vacuum Motor out of the recovery tank Reinstall the Vacuum Motor by following the above steps in reverse order fe Note Before you reinstall a ep vacuum motor check the Vacuum Fan Seal Assembly and the Vacuum Duct Gaskets for any wear or damage and replace if necessary Recovery System To Remove and Reinstall a Vacuum Motor on A ia oo Pi y i m ee a Tn fe e t as Recovery A Tank Cover en i Hinge a Va Tab s ae ao id Vacuum Fan Cover Assembly Vacuum Fan Cover Assembly Gasket 2 Vacuum Motor 2 Foam Tube Assembly 2 Vacuum Fan Seal Assembly 284 Service Manual CS7000 Recovery System 285 Specifications Voltage 42 VDC Vacuum Motor Insulation Class A Average 15 Am Current Draw i 9 gt Maximum 17 Ca Sealed 48 HO 48 H O Vacuum System Vacuum With 1 dia Orifice 25 to 30 H O Special Tools Vacuum water lift gauge Nilfisk Advance part number 56205281 Nilfisk Advance Service Manual CS7000 286 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 Th
41. lbs Hydraulic Pump Motor Output Speed 3669 RPM full load Current Draw 15 9 Amps full load Horsepower 0 55 HP full load Voltage 24 to 40 VDC Stroke 6 inches Dynamic Load Rating 400 Ibs Static Load Rating 1000 Ibs Dump Door Actuator Restraining Torque 100 in lbs Clutch ball detent clutch setting 600 to 900 Ibs Full Load Speed 0 55 in sec Current Rating 9 Amps Typical Current Draw 1 3 Amps Proximity Sensor Door Extend and Retract Limit Switches Hopper Interlock Switch Make 250 typical Air Gap Break 313 typical Nilfisk 7 Advance Service Manual CS7000 263 Options and Accessories Description Illustration Seat Belt Kit Recovery Tank Recovery Tank Clean Out Kit Clean Out Door 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 Up Alarm connects to the existing machine wiring to sound a warning when the machine is moving in reverse Service Manual CS7000 Options and Accessories 264 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 mount
42. machine maintenance or adjustments make sure the key switch is off the key is removed from the machine and the parking brake is engaged To Clean the Vacuum Filter and Filter Screen 1 Rotate the two Latches 90 degrees and remove the Vacuum Filter Lid Assembly Vacuum Filter Lid Latch 2 Assembly 2 Remove and clean the Filter and Filter Screen with a vacuum or by washing them in warm water 3 When the Filter and Filter Screen are clean and dry reinstall them into the recovery tank WAY Service Note The Filter and ok Filter Screen must be completely dry before reinstalling 4 Rotate the two Latches back 90 degrees to secure the Vacuum Filter Lid Assembly Service Manual CS7000 Recovery System 279 To Clean the Debris Basket 1 Unhook the Latch open the Recovery Tank Cover and lift the Debris Basket out of the recovery tank 2 Rinse any accumulated material from the Debris Basket then reinstall it in the recovery tank A Ei m i r ot i a F _ sr ee a i Ls i b Recovery Tank Cover AS 3 Close the Recovery Tank Cover and secure the Latch a Service Manual CS7000 Recovery System 280 Troubleshooting pe Note You can use the Service Mode to toggle the various system components on and off to check for reine function Refer to the Control System Service Mode section for information on how to enter and use the Service Mode Problem Cause
43. narrow the sweep pattern on the right side e Lowering the right side of the main broom will widen the sweep pattern on the right side Tighten the two 1 4 20 Nyloc Nuts Check the main broom sweep pattern Readjust the main broom tilt as necessary Sweep System Main Note If the width of the main broom sweep pattern is not consistent along the entire length of the main broom you may need to adjust the main broom tilt Refer to the To Adjust the Main Broom Tilt section below Broom Arm Assembly Weldment 1 2 13 Screw 1 2 13 Screw Arm Assembly 368 Service Manual CS7000 Sweep System Main 369 Inspecting Replacing Main Broom Motor Carbon Brushes 1 Remove the main broom motor and gearbox assembly See the Removal and Installation section 2 Create witness marks on the gearbox motor end bells covers and the motor casing for reassembly s i i i E F Note Weep Hole faces floor when installed 3 Remove the gearbox from the motor i Service Manual CS7000 Sweep System Main 370 4 Remove the electrical connection cover Remove the wires from the electrical connections Note the locations of the wires for reassembly 5 Working from the gearbox end of the motor remove the two long through bolts SI 7 4 _ gt 6 Pry off the end bell cove
44. of the old oil Never mix two different types of oil Engine oil should have properties of API classification SH or better Use the proper SAE Engine Oil according to ambient temperature Above 25 C 77 F SAE30 or SAE10W 30 0 C to 25 C 82 F to 77 F SAE20 or SAE10W 30 Below 0 C 82 F SAE1LOW or SAE10W 30 Engine Coolant Use only ethylene glycol or propylene glycol type anti freeze for this engine Always assure a 50 50 anti freeze and water mixture regardless of temperature Shop Measurements The following information provides some real world shop measurements to help you recognize what normal looks like Ignition System Ignition coil primary resistance 2 15 ohms Ignition coil secondary resistance 18 4 K ohms Spark Output 30 KV consistently Using adjustable spark tester Crank position sensor resistance 2 18 K ohms Crank position sensor output cranking 1 1 VAC average 2 0 VAC RMS Crank position sensor output running 5 5 VAC average Service Manual CS7000 Engine System LPG 207 Spark Controller Measurements Pin Letter Wire Color on Circuit Voltage with key on machine unplugged E BLU Crank Position Ov Sensor F BLK Ground And other 0 004v leg of Crank sensor fe Rea Power Supply fy m nosa O 1 Notused S S Governor Control System Woodward L Series Actuator Measurements Pin Wire Color Circuit Description Connecto
45. power up it goes into an error mode There is no power to the ignition system or carburetor fuel shut off solenoid IGNITION POWER FOR IGNITER E Aen IGNITION CONNECTOR FOR PLUGGING INTO KUBOTA IGNITION HARNESS FUEL PUMP PNK YEL 16 IGNITION REQUEST PNK 16 PNK BLK 16 Q CONNECTOR 1 PACKARD 16 PIN MALE PNK BLU 16 PNK BLU 16 P N15326863 A S PNK GRN 16 TO NI LFI SK HARNESS WOODWARD L SERIES ACTUATOR DEUTSCH CONNECTOR NTNS 12S4 RUN ENABLE SIGNAL RED BLK 16 J jo es E RED 18 i i SHUTDOWN SIGNAL CRANK REQUEST BLU PNK 16 __ JH mu j HHH 3 TO PIN A 7 i WOODWARD 7 j HTa s i FUELLOCK OFF j R P d Il fy 4 p r f SOLENOID a f macnetic P eb ae en an N3 0342 OR o l z f mcur i k l B i i a A V SHIELDED WIRE ate REM i z i La pea Lin Aa dans i A BLK 18 5 i mih i TO PINE i A 7 AEESRN65127 w E TT L OaS _ J aie FUSE amp RELAY CRANE f HIGH COOLANT TEH LOW DIL PRESS BLOCKASSY REQUIST ie SHUTDOWN RELAY SHUTDOWN i RELAY alz RELAY Uo debate eveesaavensy cere csveaveut wala cons ceca saubes vase ce coe sous iS cua cian fo vee EAT S PAETA VEENA EEE MER NENA AET R ude ER A EA see T 2 CONNECTOR 2 PACKARD 16 PIN FEMALE ll ee ne BLK WHT 16 P N15326868 rt rman s TO NILFISK HARNESS SPEED 2 12V OUTPUT ram pi SPEED 2 12V OUTPUT RED 16 J mr 16
46. relief valve operating The low pressure The low pressure wash Install the low pressure wash function in the wash hose is not function is not installed in the configuration menu operating configuration menu The low pressure pump M23 Check for voltage at the pump is not operating e f there is voltage at the pump replace the pump e If there is no voltage at the pump 1 Check the wiring and circuit breakers upstream of the pump Check the J3 24 output from A1 Main Machine Controller Service Manual CS7000 Solution System 320 Removal and Installation Warning Before removing or reinstalling any machine components make sure the key switch is off the key is removed from the machine and the parking brake is engaged To Remove and Reinstall the Solution Tank Caution The solution tank is relatively heavy It s recommended that the solution tank be removed by two or more persons using the appropriate equipment to prevent possible personal injury or damage to the solution tank 1 Disconnect the battery batteries 2 Drain and remove the recovery tank 3 Drain the solution tank 4 Disconnect the solution hoses from the solution tank 5 Disconnect the electrical connector from the Drive Pedal Brake Pedal Cover Weldment 6 Remove the Brake Pedal Cover Weldment Drive wo Pedal 7 Remove the Circuit Breaker Panel and disconnect the circuit breaker connectors ex Note Label t
47. request relay turning it on The ignition request relay passes battery power to the ignition system carburetor fuel shut off solenoid and the low oil pressure shutdown relay common contact at pin 3 IGNITION POWER d FOR IGNI TER solenold a IGNI TI ON CONNECTOR FUEL PUMP PNK YEL 16 FOR PLUGGI NG I NTO KUBOTA IGNI TI ON HARNESS IGNI TI ON REQUEST PNK 16 PNK BLK 16 CONNECTOR 1 PACKARD 16 PIN MALE PNK BLU 16 P N 15326863 TO NI LFI SK HARNESS WOODWARD unused a L SERIES i A ACTUATOR E IGN amp ST DEUTSCH a CONNECTOR i 10A RUN ENABLE SIGNAL i MALN REDL H H H Bia wo hee 2 2 O i i ner RED BLK 16 2 o ee e SHUTDOWN SIGNAL RED 18 CRANK REQUEST BLU PNK 16_ T kme ee NTEN TOPINA m gt WOODWARD i k S i FUEL LOCK OFF SOLENOID gt V Jf MAGNETIC Fil i RUEL PUMP j or eo 7 f SHIELDED WIRE Engine RPM 2 j Sensor a BLK 18 u E TOPINE te AEES RNG5127 FUSE amp RELAY J ee i CRANK z 2 HIGH COMERT TIMP LON OIL Pars BLOCK ASSY REQUESE Jg SHUTDOWN RELAY SHUTDOWN i I RELAY ale RELAY 0 047 pF CONNECTOR 2 PACKARD 16 PIN FEMALE au Jorn 15326868 i e HE ra TO NI LFI SK HARNESS SPEED 2 EE OUTPUT ream SPEED 2 12V OUTPUT RED 16 y GRY BLU SPEED metal OUTPUT el HH at _ BATTERY 0 0478 ENGI NE RUN 12V INPUT GRY 16 f T
48. solution flow rates The detergent pumps receive PWM outputs from the Al Main Machine Controller to regulate the detergent dispense rate according to the solution flow rate The detergent supply line from the detergent bottle is split into two lines one feeding each detergent pump The two lines from the pumps merge into one line which is then connected to the solution hose upstream of the solution solenoid valve Extended Scrub System Machines equipped with the extended scrub system will pump the recovered water from the recovery tank to the scrub brushes when the solution tank is empty The extended scrub system uses an additional pump M25 to pump the recovered water to the scrub brushes In order for the extended scrub system to work the extended scrub system must be enabled the solution tank low sensor must be actuated and the float valve in the recovery tank must be closed to indicate adequate water level in the recovery tank Note that when the machine is in the scrub mode The solution pump will continue to run along with the extended scrub pump The EcoFlex pumps will continue to add detergent to the recovered water Optional Hot Water System LP and Diesel EcoFlex Machines Only On EcoFlex models equipped with the optional hot water system the solution control pump pumps the solution to a heat exchanger The heat exchanger is plumbed to the engine cooling system and uses the hot engine coolant to heat the solution
49. spark across the gap of the spark plug and ignites the air fuel mixture ISNITER Spark Control Module ASSY GRN BLU gt J Yo oe a M i gt zZ Z x Q T T COIL 5 COIL 2 COIL 1 TEF L 12v from Ignition Request Relay Crank Position Sensor Service Manual CS7000 Engine System LPG 185 Engine Starter Control To get the engine starter to engage the key switch is held in the start position which supplies 36 volts to the main machine controller on the violet wire with the green stripe to connector J7 pin 19 This is the start input request The main machine controller receives a 12 V supply on connector J3 pin 23 from the engine starter battery It uses this voltage supply to send 12 volts out of connector J3 pin 10 to the crank request relay coil The other side of the relay coil is grounded through the Woodward L series actuator With power and ground across the relay winding the relay energizes and fused battery power from terminal 30 is sent to the starter solenoid Battery Ground Cranking 36v BATTERY STARTER Key Switch 36v Start Position Aux Relay Contact 12v WOODWARD L SERIES ACTUATOR Main Machine Controller Service Manual CS7000 Engine System LPG 186 Throttle Control Modes Ignition Off e 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 e B
50. speed If you push the pedal backward the machine will move in reverse The drive pedal is spring loaded in the center or neutral position Drive Pedal Drive Wheel Motor Gearbox and Drive Wheel Drive Pedal The drive pedal is spring loaded in the neutral position The drive pedal position sensor is a potentiometer mounted on the side of the pedal that tracks the pedal position The sensor is pre adjusted and comes with the pedal assembly Drive Controller The drive controller is a self contained sealed unit It controls when and how the current flows to the stator windings to rotate the motor based primarily on the drive pedal sensor input but it also monitors rotational speed sensors and a temperature sensor inside the motor Service Manual CS7000 Wheel System Traction Drive Wheel Motor The drive wheel motor is a brush less three phase AC design It is mounted on top of the gear box in the rear of the machine It provides rotational power to the gear box The wheel drive motor can change rotation direction to propel the machine both forward and backward Gear Box The gear box provides gear reduction between the drive motor and the drive wheel It converts the plane of rotation from horizontal to vertical and it supports the weight of the machine There are no serviceable parts inside the gear box The gear box incorporates a large turning plate bearing that allows the box to pivot in order to provide steering
51. sulfur fuel change the 0 50 5000 ppm engine oil at shorter intervals approximately half Low Sulfur Fuel CF CF 4 CG 4 CH 4 or Cl 4 CF or Cl 4 Sulfur Content lt 0 05 500 ppm or Ultra Low Sulfur Fuel Sulfur Content lt 0 0015 15 ppm Class CF 4 CG 4 and CH 4 engine oils cannot be used on EGR type engines CJ 4 classification oil is intended for use in engines equipped with DPF Diesel Particulate Filter and is Not Recommended for use in Kubota E3 specification engines Service Manual CS7000 Engine System Diesel 179 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 When a Non Road engine runs on high sulfur fuel it is advisable to use a CF or better classification engine oil with a high Total Base Number a minimum TBN of 10 is recommended Engine Oil Viscosity Temperature Above 25 C 77 F SAE 30 or SAE 10W 30 SAE 10W 40 0 to 25 C 32 F to 77 F SAE 20 or SAE 10W 30 SAE 10W 40 Below 0 C 32 F SAE 10W or SAE 10W 30 SAE 10W 40 Cooling System Engine Coolant A 50 50 mix of distilled water and ethylene glycol is recommended Radiator Cap 13 PSI Shop Measurements The following inf
52. switch is off the key is removed from the machine and the parking brake is engaged To Remove and Reinstall a Side Broom 1 Turn the key switch on raise the hopper to convenient height then turn the key switch off 2 Remove the key from the machine 3 Unscrew the Thumb Nut Weldment then remove the Side Broom and Side Broom Guard from the Side Broom Side Broom OQ Hub Assembly Hub Assembly 4 Reinstall the Side Broom by following the above steps Side Broom Guard in reverse order Service Manual CS7000 Sweep System Side Broom 384 Inspecting Replacing Side Broom Motor Carbon Brushes 1 Remove the side broom motor and gearbox assembly See the Removal and Installation section 2 Create witness marks on the gearbox motor end bells covers and the motor casing for reassembly 3 Loosen the wire retaining nut and remove the two through bolts Do not lose or damage the rubber washers 4 Remove the end cover Do not lose or damage the O ring seal Carbon Brushes N apr O ring Service Manual CS7000 Sweep System Side Broom 385 5 Inspect the carbon brushes and replace as necessary New brush length is approximately 13 16 20 mm 6 Reinstall the cover with O ring in place a Gently pry the carbon brushes back against their springs just far enough to slip them over the commutator b Gently slide the cover into place
53. the Steer By Wire Controller A5 must energize the coil to close the Safety Relay K14 contactor The Emergency Stop Switch S15 must be closed The Battery Interlock S13 must be closed battery machines or jumpered Diesel and LP machines The 400 amp Fuse F1 must be closed to provide positive voltage from the Battery to the load side of Auxiliary Contactor K9 The Ignition Switch 14 must be closed to provide positive voltage to the Auxiliary Contactor K9 coil The J2 14 Output on the A1 Main Machine Controller provides ground to the Auxiliary Contactor K9 coil when the Ignition Switch S14 provides an input to the Key Switch Input J7 12 The Auxiliary Contactor K9 must be closed to provide positive voltage to circuit breakers VACC1 CB1 and VACC2 CB2 Circuit breaker VACC1 CB1 must be closed to provide positive voltage to Solution Valve L1 Circuit breaker VACC2 CB2 must closed to provide positive voltage to the Solution Control Pump M19 EcoFlex machines only Note that VACC2 CB2 must closed to provide positive voltage to the Extended Scrub Pump M25 and Low Pressure Pump M23 as well The J2 20 PWM Output provides negative ground to Solenoid Valve L1 and the J3 2 PWM Output provides negative ground to the Solution Control Pump M19 under the following conditions The A1 Main Machine Controller must receive a signal from the A3 Control Panel via the CAN BUS that the operator has pressed the scrub switch The A1 Main M
54. the TFD coil o Approximately 400 mA Regular steering feel o Approximately 900 to 1000 mA steering feel at soft stop o Ifthe current draw is normal but the steering feel is not replace the steering wheel rotation sensor Steering Wheel Is Difficult To Turn Unplug the steering wheel rotation sensor If the steering wheel is still difficult to turn there is a mechanical binding in the steering wheel rotation sensor TFD Service Manual CS7000 Steering System 354 Removal and Installation Steering Wheel Assembly SH S gt Thy ANY 8 EF J a A N os gt N h AN V pe eN NA WWE Lal Zz KIN _ L Uey 1 Turn the machine off set the parking brake and disconnect the 36 V battery main power plug 2 Lift the Rear Engine Cover A to access the Main Harness Connector and Steering Clamp Plate E on the Steering Assembly B as shown 3 Unplug the Torque Feedback Device Connector C from the Main Harness 4 Remove the hardware D and Steering Clamp Plate E from the Steering Assembly B 5 Remove and save the 4 Pan Screws F and remove the Steering Assembly B See Detail 1 Service Manual CS7000 Steering System 355 Steering Wheel Rotation Sensor Caution Do not hit steering wheel shaft with a hammer to remove the steering wheel Doing so may damage the encoder inside the steering wheel sensor Remove steering wheel assembly See Stee
55. the Woodward L series actuator disables the ignition system by de energizing the Ignition Request relay In the case of the engine overheating the high coolant temperature shut down relay shuts the engine off by removing power from the fuel lock off solenoid causing the engine to run out of fuel and stall 191 Service Manual CS7000 Engine System LPG Engine Overheat Shutdown If the engine overheats the temperature switch closes This completes a path to ground for the high coolant temp shut down relay and energizes the relay This removes power from the fuel lock off solenoid This does not shut the engine down immediately but allows the engine to use up the fuel trapped in the regulator before stalling due to lack of fuel The main machine controller monitors the engine coolant temperature by sending out a 5v feed through an internal resistor to the temperature switch When the switch closes the voltage on the switch side drops from 5v to Ov In response the main machine controller sets an overheat code and alerts the operator After a 5 second delay it removes the 12v Ignition request signal If the engine has not already shut down the system will then shut down as if the operator had shut off the key Normal engine shut off IGNITION POWER IGNITION REQUEST FOR IGNITER amp E A ALTERNATOR WOODWARD L SERIES ACTUATOR LOCK OFF SOLENOID LOW OIL PRESS SHUTDOWN RELAY SPEED 2 12V OUTPU
56. the contacts are open replace the contactor Check the J2 28 and J2 24 Outputs from A1 Main Machine Controller Check the motor wiring and connections from contactors K11 and K12 to the hydraulic pump motor and the ground connections from the contactors to battery ground Repair as necessary Service Manual CS7000 Hopper System 245 Problem Cause Correction The hopper dump Something is physically door will not open or lodged between the door close and the lower hopper The Dump Door Actuator Motor M26 is not operating correctly The sensor on the Door Extend Limit Switch S7 is not functioning correctly The hopper dump door will not open The sensor on the Door Retract Limit Switch S8 is not functioning correctly The hopper dump door will not close Removal and Installation Check the door and hopper and clear or remove any debris or objects as necessary 1 Check the wiring and connectors from the A1 Control Board to the dump door actuator motor and repair as necessary Check the operation of the dump door actuator motor If the motor doesn t operate with battery voltage applied to it replace the dump door actuator Check the voltage outputs from J3 6 and J3 7 on the A1 Control Board Check the sensor switch function as follows e The switch should close when it comes within approximately 250 of a ferrous material e The switch should open when it moves approxima
57. the minimum mark on the reservoir To Replace the Oil in the Hydraulic System le Note Refer to the adjacent hydraulic system schematic ne when disassembling and reassembling the hydraulic power pack components 1 Raise the hopper 2 Engage the parking brake and remove the key from the key switch 3 Support the hopper in its raised position with an overhead hoist or other suitable support Warning The hopper must be adequately and securely supported with a hoist or other suitable support before the hopper lift cylinder is disconnected The hopper prop rod cannot be used to support the hopper when the hopper lift cylinder is disconnected or removed Hopper System 252 HOPPER LIFT 2 0X13 06X1 125 Service Manual CS7000 4 5 Remove the External Retaining Ring next to the Frame Weldment as shown Use Wire Ties or other suitable strapping to support the Hydraulic Cylinder while you work on the system External Retaining Ring remove Hopper System 253 6 10 11 Service Manual CS7000 Hopper System 254 Support the hopper lift cylinder and hopper prop rod Then remove the Cylinder Pin External Retaining Ring do not remove Cylinder Pj ak Sleeve Bearing Hopper S Prop Rod inside weldment Place a drip pan underneath the hydraulic power pack assembly and hydraulic cylinder Disconnect the UP Hydraulic Hose
58. throttle 1 wire o If so replace the actuator o If not check the wiring between the main machine controller and the governor controller o Ifthe wiring is okay check the output coming out of the main machine controller Service Manual Haram Captor Il Engine System Petrol Gasoline 231 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 The front right mount has a square hole in the chassis for a carriage bolt The other 3 are threaded holes in the frame 1 Remove engine Top cover 2 Disconnect the 36v battery pack main positive and negative cables 3 Disconnect the 12v battery negative cable 4 Disconnect the 12v battery positive cable 5 Disconnect fuel supply and return lines 6 Disconnect battery positive and negative cables at the starter 7 Disconnect the engine wiring connectors 8 Remove the 4 motor mount fasteners Note photos are of diesel engine al Ty Square Hole A w Front Right _ Engine Mount 2 KS ET Rear Right J Threaded Hole gt g P Sa Rear Left Front Right mes Mount Rear engine mounting locations Shown with hopper up and engine being installed engine being installed 9 Lift the assembly out of the chassis using a suitable hoist attached to t
59. tighten the Filter Cover Service Manual CS7000 Solution System 316 To Adjust the Belt Tension on the High Pressure Pump 1 Drain and remove the recovery tank 2 Loosen the four 3 8 16 Screws holding the High pressure Pump Assembly to the machine frame High pressure E Pump Assembly 3 Loosen the Locknuts on the Em ension two Tension Adjust Screws Adjust Screw 2 4 Adjust the Tension Adjust Screws to move the High on hos pressure Pump Assembly up or down as necessary to obtain the correct drive belt tension as follows Locknut 2 e LPG Machines For a new belt a deflection of 0 12 when a force of 2 6 to 2 8 lbs is applied and for a used belt a deflection of 0 12 when a force of 2 2 to 2 4 lbs is applied e Diesel Machines For a new belt a deflection of 0 13 when a force of 2 4 to 2 5 lbs is applied and for a used belt a deflection of 0 13 when a force of 2 1 to 2 2 lbs is applied 5 When the belt tension is correct a Hold the Tension Adjust Screws in position to keep them from turning then tighten the Locknuts b Tighten the four 3 8 16 Screws Service Manual CS7000 Solution System 317 Troubleshooting er Note You can use the Service Mode to toggle the various system components on and off to check for reine function Refer to the Control System Service Mode section for information on how to enter and use the Service Mode Problem Cause Co
60. vehicle has dead battery or severe damage Yellow LED flashing Controller 1s operating normally Yellow and red LEDs both on solid Controller is in Flash program mode Red LED on solid Watchdog failure or no software loaded Cycle KSI to restart and if necessary load software Red LED and yellow LED flashing alternately Controller has detected a fault 2 digit code flashed by yellow LED identifies the specific fault one or two flashes by red LED indicate whether first or second code digit will follow Service Manual CS7000 Wheel System Traction 407 Troubleshooting Chart The troubleshooting chart provides the following information on all the controller faults e fault code e fault name as displayed on the programmer s LCD e the effect of the fault e possible causes of the fault e fault set conditions e fault clear conditions Whenever a fault is encountered and no wiring or vehicle fault can be found shut off KSI Key Switch and turn it back on to see if the fault clears If it does not shut off KSI and remove the low current 35 pin connector from the drive controller Check the connector for corrosion or damage clean it if necessary and re insert it Note Some of the codes listed in the table are for circuits that are not utilized on the CS7000 Troubleshooting Chart Programmer LCD Possible Cause s Set Clear Conditions Display Effect Of Fault Set Phase current exceeded the current measurement lim
61. voltage is lower than the low ShutdownThrottle fault threshold can be changed Throttle pot wiper voltage too with the VCL function Setup_ Service Manual CS7000 Flash Code A3 44 4 46 AT Ol Programmer LCD Display Effect Of Fault Pot2 Wiper High FullBrake Note This circuit ts not used on the CS7000 Pot2 Wiper Low FullBrake Note This circuit ts not used on the CS7000 Pot Low Overcurrent ShutdownThrottle FullBrake EEPROM Failure ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle ShutdownInterlock ShutdownDriver1 ShutdownDriver2 ShutdownDriver3 ShutdownDriver4 ShutdownPD FullBrake ShutdownPump HPD Sequencing Fault ShutdownThrottle Troubleshooting Chart Possible Cause s See Monitor menu Inputs Pot2 Raw Pot2 wiper voltage too high 1 See Monitor menu Inputs Pot2 Raw 2 Pot2 wiper voltage too low See Monitor menu Outputs Pot Low Combined pot resistance connected to pot low is too low Failure to write to EEPROM memory This can be caused by EEPROM memory writes initiated by VCL Vehicle Control Language by the CAN Bus by adjusting parameters with the programmer or by loading new software into the controller KSI interlock direction and throttle inputs applied in incorrect sequence Faulty wiring crimps or switches at KSI interlock direction or throttle inputs See Moni
62. with the coil energized If the contacts are open replace the contactor Check the J2 15 output from A1 Main Machine Controller Check the wiring and connectors from the load side of contactor K8 to the side broom motors and repair as necessary Check the K8 contactor coil resistance If the coil resistance is not 118 ohms 10 replace the contactor Check the continuity through contactor K8 with the coil energized If the contacts are open replace the contactor There is no ground connection Check the wiring and connectors from the side broom to the side broom motors motors to battery ground repair as necessary Service Manual CS7000 Sweep System Side Broom 387 Problem Cause Correction The side broom No voltage to the side broom 1 Check the wiring and connectors from the A1 actuator is not raising actuator Main Machine Controller to the side broom and lowering the side actuator and repair as necessary brooms 2 Check the voltage outputs from J3 5 and J3 17 on the A1 Main Machine Controller The side broom actuator is not Check the operation of the side lift actuator motor working M13 If the motor doesn t operate replace the side broom actuator 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 a Side B
63. 2 Service Note You can remove and the reinstall the solution solenoid valve with the scrub deck either in or out of the machine Empty and remove the recovery tank from the machine Remove the scrub deck from the machine if desired Refer to the Scrub System section Disconnect the Electrical Connector on the Solution Solenoid Valve from the adjacent wiring harness Note that you may need to cut the wire tie holding the Solution Solenoid Valve wires to the Solution Manifold Loosen the Hose Clamp holding the Solution Solenoid Valve to the Solution Manifold Remove the two Hex Head Screws holding the Solution Solenoid Valve to the deck assembly and remove the Solution Solenoid Valve from the machine Reinstall the Solution Solenoid Valve following the above steps in reverse order Solution Solenoid i aP A Electrical f Connector 2 j Solution Manifold il To Remove and Reinstall a Detergent Pump EcoFlex Models Only 1 Lift up the Operator seat and engage the Seat Prop Rod Remove the detergent bottles Remove the two Screws holding the Cover Weldment and remove the Cover Weldment Seat Prop ha F S Screw 2 Cover d mam N Weldment Rod Service Manual CS7000 Solution System 326 4 Carefully slide the Detergent Pump out of the Pump i Pump Mount Mount Weldment 3 te Detergent Me Weldment Hoses pr 5 Disconnect t
64. 2 17 Output on the A1 Main Machine Controller must provide a ground to the Vacuum Motor Contactor K6 coil J2 17 provides ground to K6 under the following conditions The A1 Main Machine Controller must receive a signal from the A3 Control Panel via the CAN BUS that the operator has pressed the scrub switch The A1 Main Machine Controller must receive a signal from the A2 Drive Controller via the CAN BUS that the machine is moving forward The voltage to J7 29 Vacuum Current Sense on the A1 Main Machine Controller from the Vacuum Current Sensor B3 must be within the acceptable range to indicate both vacuum motors are working correctly The 150 amp Fuse F2 must be closed to provide positive voltage from the Battery to the load side of the Vacuum Motor Contactor K6 The Vacuum Motor Contactor K6 contacts must be closed The Vacuum Motors M6 and M7 must have connections to battery ground B Service Manual CS7000 Component Locations Recovery Tank Recovery System The Recovery Tank is on the left rear side of the machine The Squeegee Hose carries the scrub solution from the squeegee to the Recovery Tank The Drain Hose allows you to empty the Recovery Tank The vacuum motors are located underneath the Vacuum Fan Cover Assembly The debris basket can be accessed by opening the Recovery Tank Cover Vacuum Fan Cover Assembly Recovery Tank Cover Squeegee Hose Recovery Tank Co
65. 2 E3 Workshop Manual 9Y111 05710 for detailed information related to the complete mechanical engine Functional Description One of the engines available in the CS7000 is a LPG Kubota WG972 GL E3 NFK 1 It is a three cylinder liquid cooled naturally aspirated engine The fuel system does not utilize a control module It is mechanically controlled The ignition system is self contained That is it has no interaction with the fuel system and shares no components with it The fuel system begins with a 33 pound propane fuel tank which is horizontally mounted on the right side of the engine compartment The tank swings out to provide easier access to the engine compartment There is an in line pressure relief valve and a pressure switch between the tank and the fuel pressure vaporizer regulator The fuel pressure vaporizer regulator takes in high pressure propane liquid changes it to a vapor and reduces it to a constant low pressure gas for the engine to draw in and burn The change from liquid to gas absorbs a lot of heat and acts as an air conditioner To prevent frosting up the regulator it is heated with engine coolant The vaporizer regulator supplies gaseous fuel to the carburetor through a hose The carburetor has an additional fuel shut off solenoid that must be energized for fuel to flow through the carburetor to the engine G e B g shut off Ase J y solenoid Fuel Vaporizer D O Regulator i cm Da Kub
66. 2 V Alternator e Ignition coils Engine Left Side View Toward back of machine e 12 V alternator Engine starter e Oil pressure switch e Coolant temperature switch 7 g ti 2 Oil pressure switch A J wis a st p Service Manual Haram Captor Il Engine System Petrol Gasoline 224 Fuel Tank Area l T Vapor Canister e Fuel tank A e Fuel Pump e Fuel Filter e Fuel Sending Unit As gt J 4 i e e Vapor Canister bu D Fuel Tank Fuel Sending Unit 4 P B v yy a N Service Manual Haram Captor Il Engine System Petrol Gasoline 225 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 Check engine oil level Check and replenish coolant Check air cleaner element First 50 hours Change engine oil Replace engine oil filter Every 50 hours Clean air cleaner element Check fuel hoses and clamps Every 100 hours Clean spark plug Check fuel filter Check fan belt tension and damage Every 200 hours Change engine oil Replace engine oil filter Check radiator hoses and clamp bands Every 1 year Replace air cleaner element Replace gasoline fuel hose clamp bands and fuel filter Clean fuel tank inside Clean water jacket and radiator interior E
67. 4v and 2 6v when in the center neutral position c Ifthe voltage is not within the correct range loosen the sensor mounting screws and rotate the sensor to achieve the correct value Then tighten down the mounting screws Drive Motor and Gearbox Assembly The drive motor gearbox and drive wheel are removed as an assembly out of the bottom of the machine Once removed separate the motor from the gearbox 1 Remove the squeegee tool Remove the recovery tank and hose 2 3 Turn the key switch on and press the vacuum button to lower the squeegee support 4 Unplug the squeegee actuator electrical connector then turn off the key Remove the squeegee actuator 5 Disconnect the main power connector Service Manual CS7000 Wheel System Traction 419 6 Disconnect all of the main machine controller connectors and pull the harness aside Remove the controller mounting bracket fasteners and pull it away to gain access to the drive motor wiring Label the drive motor cables for proper reassembly then remove them from the motor I 8 Working from under the machine remove the cover plate that is under the steering drive gear There are two screws on each side paa 3 l PEF l 7 n ga t s a T T r Te x p t e A An i a Er a s a i 9 Lift the squeegee lift bar and tie it up 10 Block drive wheel with wheel chocks on both sides so that it cannot roll Serv
68. 9 Clear Voltage is supplied to the interlock circuit pin J4 9 and the drive pedal is returned to neutral Set Runtime VCL code error condition Clear Edit VCL application software to fix this error condition flash the new compiled software and matching parameter defaults cycle KSI Service Manual CS7000 Wheel System Traction 415 Troubleshooting Chart Programmer LCD Possible Cause s Display Effect Of Fault External Supply Out of External load on the 5V and 12V supplies draws either too _ much or too little current None unless a fault action is programmed in VCL Fault Checking Menu parameters Ext Supply Max and Ext Supply Min are mis tuned See Monitor menu Outputs Ext Supply Current OS General Internal controller fault ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle ShutdownInterlock ShutdownDriver1 ShutdownDriver2 ShutdownDriver3 ShutdownDriver4 ShutdownPD FullBrake ShutdownPump PDO Timeout Time between CAN PDO messages recelved exceeded ShutdownInterlock CAN the PDO Timeout Period NMT State set to Pre operational Stall Detected Stalled motor ShutdownEMBrake Motor encoder failure Control Mode changed to l 7 LOS Limited Operating Bad crimps or faulty wiring Strategy Problems with power supply for the motor encoder See Monitor menu Motor Motor RPM Fault On Other Traction Dual Drive fault s
69. CS7000 Wheel System Traction 411 Flash Code CO an Se bo we oo we u On gt ce No H Se OD Programmer LCD Display Effect Of Fault Main Open Short ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle FullBrake ShutdownPump Coil2 Driver Open Short ShutdownDriver2 Note This circuit is not used on the CS7000 EMBrake Open Short ShutdownEMBrake ShutdownThrottle FullBrake Note This circuit is not used on the CS7000 Coil3 Driver Open Short ShutdownDrivers Note This circuit is not used on the CS7000 Coil4 Driver Open Short ShutdownDriver4 Note This circuit is not used on the CS7000 PD Open Short ShutdownPD Note This circuit is not used on the CS7000 Encoder Fault ShutdownEMBrake Troubleshooting Chart Possible Cause s Open or short on driver load Dirty connector pins Bad crimps or faulty wiring Open or short on driver load Dirty connector pins Bad crimps or faulty wiring Open or short on driver load Dirty connector pins Bad crimps or faulty wiring Open or short on driver load Dirty connector pins Bad crimps or faulty wiring Open or short on driver load Dirty connector pins Bad crimps or faulty wiring Open or short on driver load Dirty connector pins Bad crimps or faulty wiring Motor encoder failure Bad crimps or faulty wiring See Monitor menu Motor Motor RPM
70. Correction Neither of the vacuum An interlock is not motors will run closed The 150 amp Fuse F2 is blown There is no voltage to the K5 contactor coil There is no voltage to the vacuum motors There is an open circuit in the vacuum motor wiring The vacuum current sensor B3 is not operating correctly generating a fault Before you start troubleshooting the recovery system check to make sure e The emergency stop switch S15 on the Operator control panel is disengaged rotate clockwise e The safety relay from the steering system K14 is closed e The seat switch S9 is closed e The battery interlock proximity sensor S13 is closed e The Ai Main Machine Controller is receiving the appropriate signal from the A3 Control Panel via the CAN BUS Check the Fuse F2 and replace if necessary Check circuit breaker CB1 reset if necessary The contactor K9 is not providing positive voltage to the K5 contactor coil Check the K9 contactor coil resistance If the coil resistance is not 118 ohms 10 replace the contactor Check the continuity through contactor K9 with the coil energized If the contacts are open replace the contactor Check the J2 14 output from A1 Main Machine Controller Check the K5 contactor coil resistance If the coil resistance is not 118 ohms 10 replace the contactor Check the continuity through contactor K5 with the coil energized If the contact
71. ET bridge enabled Clear Bring capacitor voltage above Severe Undervoltage limit Set Capacitor bank voltage exceeded the Severe Overvoltage limit with FET bridge enabled Clear Bring capacitor voltage below Severe Overvoltage limit and then cycle KSI Set Heatsink temperature exceeded 85 C 185 F Clear Bring heatsink temperature below 85 C 185 F Service Manual CS7000 Wheel System Traction 409 Programmer LCD Display Effect Of Fault Flash Code Undervoltage Cutback Reduced drive torque 24 Overvoltage Cutback Reduced brake torque 6 5V Supply Failure None unless a fault action is programmed in Vehicle Control Language 2 Digital Out 6 Overcurrent Digital Output 6 driver will not turn on Note This circuit is not used on the CS7000 Troubleshooting Chart Possible Cause s Normal operation Fault shows that the batteries need recharging Controller is performance limited at this voltage Battery parameters are misadyjusted Non controller system drain on battery Battery resistance too high Battery disconnected while driving See Monitor menu Battery Capacitor Voltage Blown B fuse or main contactor did not close Normal operation Fault shows that regen braking currents elevated the battery voltage during regen braking Controller is performance limited at this voltage Battery parameters are misadjusted Battery resistance too
72. Engine Speed Sensor e Actuator linkage e Actuator power supply e Actuator e Wiring e Main Machine Controller Diagnostic steps 1 Visually inspect the linkage between the actuator arm and the carburetor throttle lever Is the linkage okay o If not repair o If so go to next step 2 Check the power and ground supplies to the actuator Is there sufficient power and ground o If so go on to check the Engine RPM Sensor input o If not repair 3 Check the Engine RPM Sensor input Check the AC voltage while the engine is running or check resistance of sensor through wiring harness from the actuator connector Is the Engine RPM sensor input okay o If so go on to check the speed request inputs o If not repair 4 Check the speed request inputs With the engine running press the engine speed button and check for 12v to the throttle 1 wire at the actuator Is 12v present on the throttle 1 wire o If so replace the actuator o If not check the wiring between the main machine controller and the governor controller o Ifthe wiring is okay check the output coming out of the main machine controller Service Manual CS7000 Engine System LPG 205 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 The front right
73. Fast Rotation In order to determine which direction the steering wheel is rotating the controller looks at two signals Al and B1 at a time These signals are intentionally offset out of phase from one another This is physically built into the way the encoder works When A1 and B1 are both reporting low the controller will be able to tell which direction the steering wheel is rotating by which of the signals goes high first If Al switches high first then the wheel turning left If B1 switches first the wheel is turning right A2 and B2 are used as an extra redundant pair of signals When A1 and B1 are Both Low Next High Determines Direction Ee SANE Pe PP _ Pa I When Ai and B1 are Both Low Next High Determines Direction lt lt i 5 Both Low Both Low k A1 Switches High Before B1 Left l B1 Switches High Before A1 Right 1 A1 5 V 20 ms Right Turn 3 0 Ric AiAi 5 V 20 me Left Turn 4 R T i Left Turn Right Turn The steering wheel sensor also contains a TFD Torque Feedback Device The TFD is powered on the same circuit as the controller J5 1 Power is supplied to a coil winding inside the TFD on sensor pin 10 The power flows through the coil out sensor pin 9 and into controller J5 2 Inside the controller there is a switch that opens and closes rapidly to provide a controlled ground for the coil When a ground is s
74. GRA BLK J3 34 Input Contactor Aux GRAIBLK J3 35 Input VACC1 CB1 vio lt 225 Amp GRA 4 225 Amp 1 M25 GRA VIO ORN Pump Extended Scrub M23 GRN WHT Pump Low Pressure optional M19 Pump Solution Control optional WHT YEL M17 m WHT BRN Pump Chemical Metering optional WHT YEL M18 L1 m WHT BRN gt lt Pump Chemical Metering optional VIO 1 F 2 YEL ORN Solution Valve AN VIO AN RED ERON A3 Control Panel ns GRN YEL Chassis Ground Solution System 306 A1 Main Machine Controller J7 19 Start Input J2 14 Output Fe 3 J7 12 Supression J7 14 RED BLK BLK Diode 1 Hopper Interlock Switch J7 13 Key Switch Input J7 15 Input eee n i BLK Extended Scrub Level Switch closes when tank is empty Input J3 1 PWM Output J3 24 Output Ground De BLK eee ner ek O J3 19 L BLK J2 19 PWM Output A 33 20 eu J2 7 PWM Output B ek pu J3 29 BLK J2 32 PWM Output A J3 9 Output i High pressure J2 21 PWM Output B Pump Clutch J2 20 PWM Output J7 10 12V CAN J7 11 B BUS J7 3 CANH J7 2 CAN L Service Manual CS7000 Solution System 307 Circuit Description The Following Conditions Must be Met for the Solution System to Operate The Hopper Interlock Switch S3 must be closed There must be positive voltage to the J7 1 Interlock Input For this to happen The Seat Switch S9 must be closed The Safety Relay K14 on
75. 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 position Hopper Prop Rod and Pull Rod The Hopper Prop Rod is a safety mechanism that must be engaged when personnel are working underneath the hopper to prevent the hopper from being lowered The Hopper Prop Rod pivots toward the rear of the machine to engage the top of the Hopper Lift Cylinder and hold the hopper in its raised position Warning Before working underneath the raised hopper engage the Hopper Prop Rod as follows 1 Raise the hopper all the way up 2 Pull the Pull Rod to pivot the bottom of the Hopper Prop Rod toward the Hopper Lift Hopper Cylinder until it contacts the Hopper Lift Lift Cylinder gt Cylinder 3 Lower the hopper until the Hopper Prop Rod contacts the top of the Hopper Lift Cylinder To disengage the Hopper Prop Rod 1 Raise the hopper all the way up 2 Push the Pull Rod to pivot the bottom of the Hopper Prop Rod off of the Hopper Lift Cylinder 3 Lower the hopper Service Manual CS7000 Hopper System 244 Troubleshooting oe Note You can use the Service Mode to toggle the various system components on and off to check for reine function Refer to the Control System Service Mode section for information on how to enter and use the Service Mode Problem Cause Correc
76. ITCH DT06 6S GREY OPENFOR GRN 16 OPENFOR PROFANT PLUG NORMAL TEMP GRY PRESSURE wr RED 16 DT04 6P D FUEL SELECT 3 CONNECTOR G jan f Xin Oo O 0 Ai Fa _ a f A WOODWARD O 7 AUTO CHOKE DD SOLENOID e E SA 4741 r 4 j Inama DTO6 6S BLACK GASOLINE PLUG Service Manual Haram Captor Il Engine System Petrol Gasoline 220 Lost Oil Pressure Shutdown ae 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 The actuator immediately switches off the internal ground for the shut down control circuit at pin 9 causing the ignition request relay to de energize This shuts down the ignition system and the carburetor fuel shut off solenoid causing the engine to stall immediately Note that the power relay remains latched on due to ignition voltage supplied by the control relay When the low oil pressure shut down relay energizes power is also lost for the engine run signal to the main machine controller The loss of the engine run signal is interpreted as loss of oil pressure by the main machine controller It responds by immediately displaying an engine warning message to the operator and removing the 12v power going out to the ignition request circuit
77. L GRA So o BLU YEL J7 24 5V S1 B1 sven J7 21 Input RED ORN BLK Koa Input BRN J7 27 Brush Retract esis C Current Sense Limit lad 5V B Switch VIO WHT J7 25 B L AN VIO K1 M2 YN WHT ORN BLK RED 1 2 Brush Motor Left FROM FA Contactor Left Brush Motor F2 K2 M3 GRA BLK M BLK Fuse 150 A 1 2 Brush Motor Center Contactor Center Brush Motor K3 M4 a BLU YEL O BLK Brush Motor Right 1 2 Contactor Right Brush Motor z Brush Current Sensor P Service Manual CS7000 Scrub System 288 Circuit Description The Following Conditions Must be Met for the Scrub System To Operate The Hopper Interlock Switch S3 must be closed There must be positive voltage to the J7 1 Interlock Input For this to happen The Seat Switch S9 must be closed The Safety Relay K14 on the Steer By Wire Controller A5 must energize the coil to close the Safety Relay K14 contactor The Emergency Stop Switch S15 must be closed The Battery Interlock S13 must be closed The 400 amp Fuse F1 must be closed to provide positive voltage from the Battery to the load side of Auxiliary Contactor K9 The Ignition Switch 14 must be closed to provide positive voltage to the Auxiliary Contactor K9 coil The J2 14 Output on the A1 Main Machine Controller provides ground to the Auxiliary Contactor K9 coil when the Ignition Switch S14 provides an input to the Key Switch Input J7 13 The Auxiliary C
78. LIMIT LEFT LIMIT INPUT J5 19 ORN RED ol ORN lt SWITCH LEFT TRAVEL LIMIT 36 V From Key Switch KIL A SAFTY RELAY DUTPUT J5 18 vo SN ORN RELAY SAFTY CAN_H J5 23 YEL a gt gt CAN H CAN_L J5 15 GRN gt CAN L CAN_GND J5 8 v BLK J p R3 D GRA WHT OMS 4 ORN RESISATOR 10 OHM Service Manual CS7000 Steering System 343 Circuit Description The steering controller power has more than one power supply The main heavy current power sources are bolt on lugs that supply both battery positive and negative connections These connection points are clearly labeled on the controller This power is used to convert the direct current to 3 phase alternating current which drives the actuator motor There is also a switched power source that goes to J5 1 This power begins at the battery positive terminal goes through circuit breaker 4 through the ignition switch through the seat switch and then to connector J5 pin 1 This is used to wake up the controller and supply power for lower current circuits Power is also supplied to J5 pin 12 but this is not truly a power supply It is used to identify what machine the controller is attached to The steering controller sends a 5 volt power supply out of J5 3 which provides power to the steering actuator encoder at pin 1 and the steering wheel rotation sensor encoder pins 4 and 8 The steering rotation sensor encoder has 2 grounds at pins 3 and 7 These are not connected directly to battery negati
79. NESS WOODWARD L SERIES ACTUATOR DEUTSCH CONNECTOR DTAG 71264 RUN ENABLE SIGNAL RED GRN 16 RED GRN 16 Qe l RED 18 SHUTDOWN SIGNAL TOPINA ct H na e CRANKREQUEST BLU PNK 16 J ww J J wr eoh WOODWARD PACKARD 16 PI N FEMALE A BLK WHT 16 f FUELLOCK OFF 3 SOLENOID a C E N3 03420R an i P N 15326868 ph e n a A H Jf maGneTic f ICK UP Tsn ELDED WIRE Engine RPM Sensor BLK 18 TO PINE GRY BLU_16 imi RED BLK 14 s a i AEES RN65127 gt x i FUSE amp RELAY IGNITION S BLOCK ASSY REQUEST RELAY oani lt _ CONTROL 5 RELAY x Ieee LOW hl PRESS SHUTDOWN RELAY HIGH COOLAWT TEMP SHUTDOWN RELAY CONNECTOR 2 PUR 16_ FUEL PUMP TO NILFISK HARNESS SPEED 2 12V OUTPUT ap SPEED 2 12V OUTPUT RED 16 i Cr RED 16 e GRY BLU 16 STARTER Sa 3 aav OUTPUT BATTERY 0 047 ENGINE RUN 12VINPUT GRY 16 t s a KUBOTA fam FUEL HIGH COOLANT TEMP GROUND INPUT GRN YEL 16 i LT BLU 16 SOLENOID EG551 44790 CT00024 TEMP SWITCH BLU LT OIL SWITCH DT06 6S GREY OPENFOR GRN 16 OPENFOR PROPANE PLUG NORMAL TEMP GRY PRESSURE RED LG DT04 6P D FUEL SELECT i T T CONNECTOR aa 3 E WOODWARD D 6 AUTO CHOKE SOLENOID G E SA 4741 L CTH DT06 6S BLACK GASOLINE PLUG Service Manual Haram Ca
80. OR GRN 16 OPEN FOR egorant PLUG NORMAL TEMP GRY PRESSURE DT04 6P FUEL SELECT E Th ee ea p SA 4741 Q 4 wah ee Cat DTO6 6S BLACK GASOLI NE PLUG Note Ifthe engine stalls due to loss of fuel or ignition oil pressure will eventually be lost When J this happens the main machine controller will treat it as a lost oil pressure condition display a warning message to the machine operator and initiate the lost oil pressure shut down sequence a Service Manual Haram Captor II Engine System Petrol Gasoline 221 Component Locations Engine components are grouped according to the area of the engine They are photographed on an engine Engine Right el p a s vy gt j Engine Back 4 gt g 2 Engine Left AI gt g Service Manual Haram Captor Il Engine System Petrol Gasoline 222 Engine Right Side View Toward front of machine e Actuator e Choke Solenoid e Carburetor mixer Engine RPM sensor e Crank position sensor e Petrol fuel shut off solenoid e Fuel Select Connector Fuel Select Connector Choke Solenoid i j F f eres eme sr LPG shut off solenoid Crank position sensor Fe 7 Petrol fuel shut off solenoid Engine RPM sensor e A Service Manual Haram Captor Il Engine System Petrol Gasoline 223 Engine Back Side View Toward right of machine Spark Controller 4
81. Sensor Signal Phase B 2 0 V wheel spinning any speed 33 Noted a Caj S noa i CAN Bus Low 245V Motor U V and W Terminal Pair Voltages U to V 0 8 2 2 VAC with stationary motor Up to 26 VAC with wheel off ground and full forward speed V to W 0 3 2 2 VAC with stationary motor Up to 26 VAC with wheel off ground and full forward speed W to U 0 3 2 2 VAC with stationary motor Up to 26 VAC with wheel off ground and full forward speed Motor U V and W Terminal Pair Frequency U to V 21 23 KHZ with stationary motor Up to 300 KHZ with wheel off ground and full forward speed V to W 21 23 KHZ with stationary motor Up to 300 KHZ with wheel off ground and full forward speed W to U 21 23 KHZ with stationary motor Up to 300 KHZ with wheel off ground and full forward speed Service Manual CS7000 System Current Draw Driving only with no cleaning functions Measured with amp clamp around battery positive feed to drive controller e Approximately 1 4 amps when the machine begins to move Average 51 amps full speed with maximum scrub pressure e Max 100 Amps Wheel Drive Contactor Winding 194 Ohms Special Tools Curtis Programmer 1311 Part number 56409441 Wheel System Traction Nilfisk Advance 425
82. Service Manual CS7000 Engine System Diesel 176 7 Disconnect the injector pump actuator connector to prevent the engine from starting 8 Remove any cover over the air inlet but be very careful not to allow anything to get sucked in during the test 9 Crank the engine over until the compression gauge stops climbing Record the reading Specification is 541 to 597 psi 8 73 to 4 11 MPa with an allowable limit of 327 psi 2 26 MPa Difference among Cylinders 10 or less 10 Repeat for the other cylinders 11 Reassemble in reverse order Service Manual CS7000 Removal and Installation Engine Assembly Engine System Diesel 177 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 The front right mount has a square hole in the chassis for a carriage bolt The other 8 are threaded holes in Engine Mount i Rear Right J Threaded Hole Rear Left A EA hoiei k Rear dicli z mr p te Ne TN Rear engine mounting locations Shown with engine being installed the frame 1 Remove engine Top cover 2 Disconnect the 36v battery pack main positive and negative cables 3 Disconnect the 12v battery negative cable 4 Disconnect the 12v battery positive cable 5 Disconnect fuel supply and return lines 6 Disconnect batte
83. Set Clear Conditions Set Main contactor driver pin 6 1s either open or shorted Pin 6 is the K7 wheel drive contactor coil driver circuit This fault can be set only when Main Enable On Clear Correct open or short and cycle driver Set Driver 2 pin 5 is either open or shorted This fault can be set only when EM Brake Type 0 Clear Correct open or short and cycle driver Set Electromagnetic brake driver pin 5 is either open or shorted This fault can be set only when EM Brake Type gt 0 Clear Correct open or short and cycle driver Set Driver 3 pin 4 is either open or shorted Clear Correct open or short and cycle driver Set Driver 4 pin 8 is either open or shorted Clear Correct open or short and cycle driver Set Proportional driver pin 2 is either open or shorted Clear Correct open or short and cycle driver Set Motor encoder phase failure detected Clear Cycle KSI Service Manual CS7000 Wheel System Traction 412 Troubleshooting Chart Flash Programmer LCD Possible Cause s Set Clear Conditions Code Display Effect Of Fault 37 Motor Open Motor phase is open Set Motor phase U V or W detected open ShutdownMotor Bad crimps or faulty wiring ShutdownMainContactor Clear Cycle KSI ShutdownEMBrake ShutdownThrottle FullBrake ShutdownPump 38 K7 Wheel Drive K7 Wheel Drive contactor tips Set Just prior to the K7 wheel Contactor Welde
84. T ir ENGI NE RUN 12V INPUT 12v HI GH COOLANT TEMP Signal TEMP SWITCH J OIL SWITCH OPEN FOR q OPEN FOR NORMAL TEMP PRESSURE i v BATTERY STARTER Main Machine Controller 192 Service Manual CS7000 Engine System LPG 193 Lost Oil Pressure Shutdown Ifthe 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 The actuator immediately switches off the internal ground for the shut down control circuit at pin 9 causing the ignition request relay to de energize This shuts down the ignition system and the carburetor fuel shut off solenoid causing engine to stall immediately The high coolant temp shut down relay also energizes removing power through the closed at rest contacts to the fuel lock off solenoid e When the low oil pressure shut down relay energizes power is also lost for the engine run signal to the main machine controller The loss of the engine run signal is interpreted as loss of oil pressure by the main machine controller It responds by immediately displaying an engine warning message to the operator and removing the 12v power going out to the ignition request circuit If the engine has not already shut down the system will then shut down as if the operator had shut off the key Norm
85. The vacuum motors switch on automatically when the scrub system is enabled and the machine moves forward The motors will switch off after a predetermined time delay once machine motion stops The vacuum motors can also be switched on independent of the scrub system by pressing the vacuum wand switch This is used to pick up solution already on the floor or when using a wand on the squeegee hose A current sensor monitors the combined current draw of both vacuum motors and will display a fault if the vacuum motor current draw is too high Service Manual CS7000 Recovery System Wiring Diagram Vacuum Motor Recovery System 274 Battery F1 36V RED RED Fae BLK Fuse 400A A1 Main Machine Controller A3 Control Panel ORN 42V Alternator J7 10 12v WHTIERN z CAN S14 B a ve aa CAN cen B1 i23 J7 19 Start Input z B YEL BRN 3 g 4 BLK ORN J2 14 Output K9 L Aux Contactor GRN YEL YEL BRN J7 12 Supression Ignition Switch Diode ORN J7 13 Key Switch panies Fe Input TRUN s9 K14 S15 13 ORN GRA ORN PINK TAN GRNIBLU J7 1 Interlock wo 3 E i 3 1 2 Input Fe Seat Switch Safety Switch Emergency Battery 3 Relay signal from Stop Switch Interlock J7 14 RED BLK BLK A5 Steer by Input 1 2 Wire Controller Hopper Interlock Switch Contactor Aux VACC3 Ground RED BLU GRN A GRA BLK J3 34 Input a 1 2 OK 25 Amp J3 18 BLK jgtg BLK a J3 21 BLK J3 29 BLK BLU J2 17 Output Contactor Vacuum Motor BLU YEL J7 24
86. US J7 3 CAN H ai VIOIGRN J7 19 Start Input TRE CANE 7 YELIBRN 3 g 4 BLK ORN J2 14 Output K9 Aux Contactor GRN YEL YEL BRN J7 12 Supression Ignition Switch Diode ORN J7 13 Key Switch sai Fe Input COMI S9 K14 a 13 ORN GRA ORN PINK TAN GRN BLU J7 1 Interlock Fe ca E To 1 2 Input S3 Seat Switch Safety Switch Emergency Battery RED BLK BLK Relay signal from Stop Switch Interlock 1 2 AS Steer by Hopper Wire Controller Interlock Switch Contactor Aux VACC3 Ground K9 CB3 BLK RED j BLUGRN 6 GRAVBLK J3 34 Input aa 125 Amp 7 J3 16 k SaL o oak pa J3 21 BLK BLK J3 29 BLU ORN J2 28 Output Contactor Hydraulic Dump Door PUMP MOTOT Actuator Motor K12 to Red to Extend VIO ORN RED J2 24 Output Contactor M26 Hydraulic Pump Motor J3 6 Output BRN GRN__ RED M YEL J3 7 Output REDIGRA Fe S7 Door Extend Limit Switch Fe S8 N J7 23 Input YEHWHT i BLK VIO Door Retract Limit Switch Contactor Hydraulic Hydraulic Contactor Hydraulic Hydraulic Pump Motor Pump Motor Pump Motor Pump Motor CB8 K11 Assembly K12 a ORN WHT eS een 25 Amp a l2 1 2 M10 5 6 5 6 BLK N N RED ORN WHT B FROM F1 Service Manual CS7000 Hopper System Hopper Hydraulic System Circuit Details A hydraulic cylinder ram driven by a self contained hydraulic pump and motor raises and lowers the hopper The pump motor power and ground polarity are reversed to make the motor run in opp
87. a K i 4 Ir OoOo o i F r Tr T n i i TA Puf 2 a i 3 z a i la ot i i rf fs J i ie i F 4 k The bottom rear Solution Tank Mounting Screw is located underneath the machine on the right side by the solution shutoff valve and drain hose f he oP Solution Tank Mounting Screw Er 0 Service Manual CS7000 Solution System 323 The bottom center Solution Tank Mounting Screw is located underneath the machine by the right hand side squeegee assembly Solution Tank i Mounting Screw f The bottom front Solution Tank Mounting Screw is located underneath the machine by the main broom actuator and scrub deck actuator 14 Remove the solution tank from the machine 15 Reinstall the solution tank by following the above steps in reverse order Service Manual CS7000 Solution System 324 To Remove and Reinstall the Solution Shutoff Valve 1 Drain the solution tank 2 Remove the valve shield 3 Remove the nuts washers and U bolts holding the Solution Filter Assembly to Hose to Solution the mounting plate Solenoid Valve AAN Note Place a suitable container reine underneath the shutoff valve to catch any solution that may leak from the hoses or filter 4 Loosen the clamp holding the Connecting Hose to the Solution Shutoff Valve then disconnect the Connecting Hose and attached Solution Filter Assembly from the Solution Shutoff Valve Solut
88. achine Controller must receive a signal from the A2 Drive Controller via the CAN BUS that the machine is moving forward or optional in reverse The Following Conditions Must be Met for the Extended Scrub System to Operate The extended scrub system requires the same conditions to operate as does the solution system with the following additions The extended scrub function must be installed in the configuration menu The J3 1 PWM Output provides the negative ground to the Extended Scrub Pump M25 under the following conditions The A1 Main Machine Controller must receive a low solution signal via the CAN BUS from the A3 Control Panel The A1 Main Machine Controller must receive a signal from the A3 Control Panel via the CAN BUS that the operator has pressed the extended scrub switch The A1 Main Machine Controller must receive a signal from the A2 Drive Controller via the CAN BUS that the machine is moving forward or reverse Service Manual CS7000 Solution System 308 The Extended Scrub Level float Switch S4 in the recovery tank must be open to prevent the J7 15 Input from going to battery negative Note the switch opens when there is adequate water in the recovery tank and closes when the recovery tank is empty The Following Conditions Must be Met for the Low Pressure Wash Hose to Operate E Note The low pressure wash hose does not require the interlocks to be closed to operate pee The low pressure wash
89. ake was commanded to set and time has elapsed to allow the brake to fully engage vehicle movement has been sensed Clear Activate the throttle Service Manual CS7000 Wheel System Traction 417 Flash Programmer LCD Code Display Effect Of Fault 93 Encoder LOS Limited Operating Strategy Enter LOS control mode 94 Emer Rev Timeout ShutdownEMBrake ShutdownThrottle Illegal Model Number ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle Dualmotor Parameter Mismatch Note Not used on CS7000 Fault History FullBrake ShutdownPump Troubleshooting Chart Possible Cause s Limited Operating Strategy control mode has been activated a result of either an Encoder Code 86 or a Stall Detect Code 73 Motor encoder failure Bad crimps or faulty wiring Vehicle is stalled Emergency Reverse was activated and concluded because the EMR Timeout timer has expired The emergency reverse input is stuck On Model_Number variable contains illegal value not 1234 1236 1238 or 1298 Software and hardware do not match Controller defective Dual Drive fault see Dual Drive manual Set Clear Conditions Set Encoder Fault Code 86 or Stall Detect Fault Code 73 was activated and Brake or Interlock has been applied to activate LOS control mode allowing limited motor control Clear Cycle KSI or if LOS mode was activated by the Stall Fault cl
90. al engine shut off IGNITION POWER IGNITION REQUEST FOR IGNITER amp RUN ENABLE SIGNAL ALTERNATOR WOODWARD L SERIES ACTUATOR LOCK OFF SOLENOID LOW OIL PRESS SHUTDOWN SPEED 3 12V OUTPUT ie ee eee eee ENGINE RUN 12V INPUT HIGH COOLANT TEMP Signal H TEMP SWITCH q OIL SWITCH OPEN FOR OPEN FOR NORMAL TEMP PRESSURE i v BATTERY STARTER Main Machine Controller Service Manual CS7000 Engine System LPG 194 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 See next pages for photos e Engine Right Side View Toward V Z Ss ea ws engine Lott RN Engine relay box NIKKI Fuel Vaporizer Regulator Ng N T a Actuator gt Carburetor mixer Engine RPM sensor Crank position sensor Carburetor fuel shut off solenoid e Engine Back Side View Toward right of machine Spark Controller Fuel lock off solenoid 42 V Alternator Ignition coils e Engine Left Side View Toward back of machine 12 V alternator Engine starter Oil pressure switch Coolant temperature switch e Fuel Tank Area Fuel tank Pressure relief valve Low LPG pressure switch Service Manual CS7000 Engine System LPG Engine Right Side View Toward front of mach
91. and align the witness marks made earlier 7 Reinstall the through bolts and tighten the wire retaining nut Service Manual CS7000 Troubleshooting and use the Service Mode Sweep System Side Broom 386 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 Problem Cause Correction The side sweep An interlock is not closed system is not operating correctly The side broom motors will not run The 400 amp Fuse F1 is blown Before you start troubleshooting a specific system check to make sure The emergency stop switch 15 on the Operator control panel is disengaged rotate clockwise The safety relay from the steering system K14 is closed The seat switch S9 is closed The battery interlock proximity sensor S13 is closed The A1 Main Machine Controller is receiving the appropriate signal from the A3 Control Panel via the CAN BUS Check the Fuse F1 and replace if necessary Circuit breaker CB7 is open Reset circuit breaker CB7 There is no voltage to the K8 contactor coil There is no positive voltage to the side broom motors Check circuit breakers CB1 and CB3 and reset if necessary Check the K9 contactor coil resistance If the coil resistance is not 118 ohms 10 replace the contactor Check the continuity through contactor K9
92. ant hose of LPG vaporizer Check vacuum lock hose of LPG vaporizer Drain tar Check valve clearance Clean cylinder head Check valve seats Every 2 years Replace intake air line Replace LPG fuel hose and clamp bands Replace coolant hose of LPG vaporizer Replace vacuum lock hose of LPG vaporizer Check primary chamber Check air tight of secondary chamber Check vacuum lock system Replace radiator hoses and clamp bands Replace battery Change radiator coolant L L C Change Engine Oil and Oil Filter l 2 8 J 10 Reinstall the plug and reattach the drain hose to the radiator bracket Drain the recovery tank for later removal Engine System LPG Shut off the engine and allow it to cool sufficiently to avoid burning yourself with hot engine oil Remove the left side engine cover Tip the recovery tank outward Release the recovery tank tether cable and recover hose then lower the recovery tank to the ground for better access to the engine oil filter area Remove the oil filter with an oil filter wrench Apply a light coat of engine oil to the new filter cartridge gasket Screw the new cartridge on and tighten by hand Over tightening may damage the gasket Remove the remote oil drain hose end from the radiator bracket Remove the plug and drain the oil into a suitable container 11 Refill the engine with oil 199 Service Manual CS7000 Engine System LPG 200 Change Engine Coolant 1 Allow
93. as a history of the faults that have been set since the history log was last cleared The 1311 displays the faults by name To use the programmer connect it to the serial port connector located on the left side of the machine by the bank of contactors 405 Service Manual CS7000 Wheel System Traction 406 3 Accessing the configuration display mode of the hidden menu a Press and hold the hazard warning flasher button down while turning on the key Wait until the Configuration Display screen appears then release the button b Press and release the scrub pressure decrease button several times until the cursor arrow is pointing at 15 Fault Recall then press the scrub button to enter the fault recall menu c Press the scrub pressure decrease button to scroll down to 3 Speed Faults then press the scrub button d The Speed faults menu displays all of the fault codes that have ever been set by the drive controller and communicated to the main machine controller The codes are displayed in reading order separated by commas and are sorted with the most recent at the top left See the Troubleshooting Chart below to look up what the code means e To exit press the solution button Summary of LED display formats The two LEDs have four different display modes indicating the type of information they are providing Types of LED Display Display Neither LED illuminated Controller is not powered on or
94. as it circulates through the heat exchanger The hot water system increases the solution temperature approximately 50 degrees F The heated solution is then mixed with detergent and sent through the open solution solenoid valve and solution manifold to the brushes won Note If your machine is equipped with a hot water system do not add detergent to the solution colt tank as this can foul the heat exchanger Optional Wash Hose Kit The optional wash hose kit uses a separate low pressure pump M23 to pump solution from the solution tank to the hose and nozzle located behind the Operator seat The wash hose kit operates independently and does not require the Operator to actuate the seat switch A pressure switch on the low pressure pump will switch on the pump when the hose nozzle is opened and the solution pressure in the hose drops Service Manual CS7000 Solution System Optional High pressure Spray System LP and Diesel Only The optional high pressure spray system uses a separate pump driven by the engine via a clutch to pump solution at high pressure from the tank to the hose and wand The high pressure spray system operates independently and has its own separate filter strainer and supply and return ports on the solution tank es Solution Level Sensor The solution pressure sensor sends a linear signal to the Al Main Machine Controller to indicate the solution level in the tank This signal is
95. attery power is provided to the run enable input of the L Series actuator through the power relay closed at rest contacts If it doesn t have this signal present on power up it goes into an error mode There is no power to the fuel lock off solenoid There is no power to the ignition system or carburetor fuel shut off solenoid IGNITION POWER FOR IGNITER amp IGNITION REQUEST RUN ENABLE SIGNAL ALTERNATOR WOODWARD L SERIES ACTUATOR CRANK REQUEST FUEL Carb i LOCK OFF Fuel Eng RPM HIGH COOLANT TEMP LOW OIL PRESS IGNITION SOLENOID SHUTDOWN RELAY SHUTDOWN REQUEST RELAY Shut Off Sansor RELAY 3 Solenoid SPEED 2 12V OUTPUT ee ENGINE RUN 12V INPUT HI GH COOLANT TEMP Signal TEMP SWITCH OIL SWITCH OPEN FOR OPEN FOR NORMAL TEMP PRESSURE 12v BATTERY STARTER Main Machine Controller Service Manual CS7000 Engine System LPG 187 Ignition On When the main machine controller sees the key switch input it sends 12v out on the Ignition Request circult When the actutor receives 12v at pin 1 it wakes up The actuator provides a ground through itself for the shut down control circuit The ignition request relay is energized as long as there is not a shutdown condition within the L Series actuator passing battery power to the ignition system carburetor fuel shut off solenoid and the low oil press shutdown relay common contact at pin 3 Ignition power is
96. ay turned on Stop Switch Interlock 1 2 and off by AS Hopper Steering Controller Interlock Switch Ground WN J3 15 BLK ee ae rA J3 21 BLK J3 29 BLK Squeegee Actuator Motor A to RED to Extend M12 J2 8 Output WHT GRN___RED m ORN BLU BRN J2 9 Output Service Manual CS7000 Squeegee System 330 Circuit Description The following conditions must be met for the squeegee system to operate The Hopper Interlock Switch S3 must be closed e There must be positive voltage to the J7 1 Interlock Input For this to happen The Seat Switch S9 must be closed The Safety Relay K14 on the Steer By Wire Controller A5 must energize the coil to close the Safety Relay K14 contactor The Emergency Stop Switch S15 must be closed The Battery Interlock S13 must be closed The A1 Main Machine Controller must receive a signal from the A3 Control Panel via the CAN BUS that the operator has pressed the scrub switch The J2 8 and J2 9 Outputs from the A1 Main Machine Controller provide voltage to the Squeegee Actuator Motor M12 The output polarity determines whether the Squeegee Actuator Motor lowers or raises the squeegee Component Locations The Rear Squeegee Assembly is attached to the Squeegee Support Assembly with two split Squeegee Clips that clamp onto Sep Squeegee horizontal pins in the Squeegee Support Front Fo T Lift Actuator Bracket 2 Assembly The front of the Squeegee Support A
97. bel controller wiring to make correct reassembly easier then disconnect all wiring 5 Remove 4 controller mounting screws 6 Reassemble in reverse order Steering Actuator 1 Drain recovery tank 2 Turn machine off set the parking brake and disconnect the main power plug 3 Remove recovery tank a Tip tank out and let it rest on the retention cable b Disconnect the vacuum motor electrical connector If equipped with extended scrub also disconnect the additional electrical connector and hose connection c With a helper remove the retaining cable clip tip tank down and remove it 4 Disconnect wiring to main machine controller 5 Label the steering controller wiring and the drive controller wiring to make correct reassembly easier then disconnect all wiring to both controllers Service Manual CS7000 Steering System 359 6 Remove the three screws securing the controller mounting bracket to the frame then remove the assembly 7 Disconnect the steering actuator encoder connector 8 Remove the four steering actuator mounting bolts 9 Remove the steering actuator 10 Reassemble in reverse order Service Manual CS7000 Steering System 360 Specifications Shop Measurements Shop measurements are values that were measured on a real machine While they are not specifications they can help you recognize normal vs abnormal Steering Wheel Rotation Sensor Voltage Measurements All voltages are DC
98. cludes the solution tank main body of machine and solution pressure level sensor solution shutoff valve solution filter solution pump or pumps some models solution solenoid valve and the associated plumbing to distribute solution to the nozzles at the three scrub brushes A capped solution drain hose allows you to drain the solution tank The solution flows to the scrub brushes any time the scrub system is enabled the scrub deck is lowered and the drive pedal is not 1n the neutral position Programming options allow you to enable or disable solution flow when the machine moves in reverse When the scrub system is disabled no solution will flow to the brushes regardless of drive pedal or scrub deck position The operator can enable the solution system independent of the scrub system to pre wet the floor before enabling the scrub and or recovery systems Solution Flow Control Non EcoFlex Machines On the non EcoFlex machines an electrically activated solenoid valve controls the solution flow The solution is gravity fed to the solenoid valve and the solenoid valve output volume is controlled by the Main Controller through a PWM pulsed width modulated output The Al Main Machine Controller monitors the solution level via a solution pressure sensor Also refer to the Component Locations Solution Tank Solution Pressure Sensor section As the solution level drops the PWM output will increase to compensate for the loss of solution h
99. coder that translates steering wheel rotation information into four digital signals The end of the steering shaft has a special diametrically polarized magnet on it The line of separation between the north and south magnetic poles rotates in close proximity to the encoder The three images below show how a wire on a clear plastic CD case rotates as the shaft rotates Steering c ee shaft The encoder reads the movement of the magnetic a _ Rotates fields and creates a four 5v square wave signals There are two pairs of signals For each pair when the steering wheel rotates one of the signals switches before the other so that the controller can tell which direction the steering wheel is being turned The second pair of signals provides redundant information a at a ering wheel rotation sensor shaft is turned Service Manual CS7000 Steering System 340 The Steering Wheel Sensor also has an electromagnetic clutch called a Torque Feedback Device which provides steering feel to the operator The clutch consists of multiple fiber discs and steel plates which are alternately stacked The steel plates are splined to the steering shaft so they always rotate with the shaft The fiber discs are splined to the clutch housing and are held stationary When electrical current flows through the clutch field coil winding the magnetic field generated pulls the plates together
100. covery System section 2 Make sure the solution shutoff valve is closed then disconnect the solution hose to the solution solenoid valve 3 Turn on the key switch and put the machine into the Service Mode to allow you to jog the scrub deck up and down Service Manual CS7000 Scrub System 295 4 Disconnect the Electrical Connectors to the three Scrub Motors to the Proximity Sensor on the Deck Lift Arm Assembly and to the Solution Solenoid Valve Jog the Scrub Deck up or down as necessary to access the Electrical Connectors Note that you may need to cut wire ties to access the Electrical Connectors 5 Extend the scrub deck downward in the Service Test mode to minimize the weight on the M12 1 75 x 35mm Screws supporting the Deck Lift Arm Assembly and Scrub Deck 6 Remove the two M12 1 75x 35mm Screws washers Bushings and Flange Bearings holding the Deck Lift Arm Assembly and attached Scrub Deck to the machine frame 7 Remove the Bow tie Cotter Pin washers and Clevis Pin holding the Scrub Deck Actuator to the Deck Lift Arm Assembly 8 Jack the machine up as necessary to get enough clearance to remove the Scrub Deck then support the machine with jack stands 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 9 Slide the Scrub Deck and attached Deck Lift Arm Assembly out from under the machine Deck Li
101. d are welded closed drive contactor closing the capacitor bank voltage B ShutdownMotor Motor phase U or V is connection terminal was ShutdownMainContactor disconnected or open loaded orashorti meand the ShutdownEMBrake voltage did not discharge ShutdownThrottle An alternate voltage FullBrake ShutdownPump path such as an external Clear Cycle KSI precharge resistor 1s providing a current to the capacitor bank B connection terminal 39 Main Contactor Did Not Main contactor did not close Set With the main contactor Close l l commanded closed the Main contactor tips are capacitor bank voltage B ShutdownMotor oxidized burned or not connection terminal did not ShutdownMainContactor making good contact charge to B ShutdownEMBrake l ShutdownThrottle External load on capacitor Clear Cycle KSI FullBrake ShutdownPump bank B connection terminal that prevents capacitor bank from charging Blown B fuse 41 Throttle Wiper High see Monitor menu Inputs Set Throttle pot wiper pin 16 voltage is higher than the high ShutdownThrottle Throttle Pot wiper voltage fault threshold can be changed too high with the VCL function Setup_ Pot_Faults Clear Bring throttle pot wiper voltage below the fault threshold 2 low Pot_Faults Clear Bring throttle pot wiper voltage above the fault threshold 4 Throttle Wiper Low see Monitor menu Inputs Set Throttle pot wiper pin 16 Throttle Pot
102. e Pump is mounted next to the Solution Pump underneath the rear right hand side of the solution tank The Low Pressure Pump pumps solution to the optional wash hose behind the Operator seat Solution System 310 Tube Fitting Solution lt Shutoff Valve 3 shown on Low Pressure Pump Service Manual CS7000 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 to the three Hoses going to the three scrub brushes Note that the adjacent drawing is a top view looking down onto the scrub deck Note that the Solution Solenoid Valve is designed to be easy to remove and install It is possible for dirt or debris to interfere with the Solution Solenoid Valve seat and prevent the seat from sealing This can prevent the Solution Solenoid Valve from shutting off the solution flow completely and requires that the Solution Solenoid Valve be cleaned or replaced Solution Nozzles The Solution Nozzles are part of the deck weldment and direct the solution onto the brushes The right hand scrub motor has been loosened and moved slightly in order to show the Solution Nozzle s T E We or d M O Solution System 311 F gt Solution Solenoid Left hand Scrub Motor Solution NS A Nozzle g typical Service Manual CS7000 Soluti
103. e Cause s External load impedance on Digital Output 7 driver pin 20 is too low Motor temperature is at or above the programmed Temperature Hot setting and the requested current is being cut back Motor Temperature Control Menu parameters are mis tuned See Monitor menu Motor Temperature and Inputs Analog2 If the application doesn t use a motor thermistor Temp Compensation and Temp Cutback should be programmed Off Motor thermistor is not connected properly If the application doesn t use a motor thermistor Motor Temp Sensor Enable should be programmed Off See Monitor menu Motor Temperature and Inputs Analog2 Open or short on driver load Dirty connector pins Bad crimps or faulty wiring Set Clear Conditions Set Digital Output 7 pin 20 current exceeded 15 mA Clear Remedy the overcurrent cause and use the VCL function Set_DigOut to turn the driver on again Set Motor temperature is at or above the Temperature Hot parameter setting Clear Bring the motor temperature within range Set Motor thermistor input pin 8 is at the voltage rail 0 or 10V Clear Bring the motor thermistor input voltage within range Set Driver 1 pin 6 is either open or shorted Pin 6 is the K7 wheel drive contactor coil driver circuit This fault can be set only when Main Enable Off Clear Correct open or short and cycle driver Service Manual
104. e Locknut 2 Use a wrench on the flats of the Threaded Shaft to turn the Threaded Shaft to raise or lower the Squeegee Caster as necessary 3 When the Squeegee Caster is at the correct height tighten the Locknut 4 Check the squeegee tilt angle and adjust as necessary Refer to the To Adjust the Squeegee Tilt section on the preceding page Threaded Shaft k z s b Ba E we a WwW 4 oS F N Squeegee System 334 MZ Locinut Es l J v Squeegee Caster Service Manual CS7000 Troubleshooting Squeegee System 335 A Note You can use the Service Mode to toggle the various system components on and off to check for rene function Refer to the Control System Service Mode section for information on how to enter and use the Service Mode Problem Cause Correction The squeegee will not rise or lower The squeegee is not picking up the water effectively The squeegee is not picking up the water consistently along the entire length of the squeegee An interlock is not closed The squeegee actuator motor M12 is not operating There is a vacuum leak between the squeegee weldment and the recovery tank The squeegee blade s is are worn out The squeegee actuator is not lowering the squeegee far enough onto the floor The squeegee tilt need to be adjusted Before you start troubleshooting a specific system check to make sure e
105. e edge guard not shown on right hand side squeegee assembly only 2 Press the Latch Lock open the Latch and remove the Blade Strap and Trailing Deck Blade from the Blade Support Weldment 3 Reverse the existing Trailing Deck Blade to position a new blade surface on the floor or install a new Trailing Deck Blade onto the Blade Support Weldment pins as shown 4 Hook the end of the Blade Strap into the matching Tab on the Blade Support Weldment 5 Wrap the Blade Strap over the Trailing Deck Blade and close the Latch Service Manual CS7000 Scrub System 292 Troubleshooting pe Note You can use the Service Mode to toggle the various system components on and off to check for reine function Refer to the Control System Service Mode section for information on how to enter and use the Service Mode Problem Cause Correction The scrub system An interlock is not Before you start troubleshooting the scrub system check to does not operate closed make sure e The emergency stop switch S15 on the Operator control panel is disengaged rotate clockwise e The safety relay from the steering system K14 is closed e The seat switch S9 is closed e The battery interlock proximity sensor S13 is closed e The A1 Main Machine Controller is receiving the appropriate signal from the A3 Control Panel via the CAN BUS None of the scrub The 150 amp Fuse Check the Fuse F2 and replace if necessary deck motors will run F2 is b
106. e motor is stationary You can see how all 3 phases are being pulsed in unison The vertical position of each trace was adjusted to separate them for better clarity Other wise all three would blend together as a single trace Dt t a EET a ae Ne he E a a a A Ta Ea Drive Motor U 10 W 20 us P Drive Motor V 10 V 20 us B1 Dre Noto I IRIT Drive Motor U V and W Stationary Below is an oscilloscope waveform that shows the 3 phases of the motor U V and W when the motor is moving forward You can see how each phase is now unique and no longer in unison Again the vertical position of each trace was adjusted to separate them for better clarity t Drive Motor U 10 W 20 us P Drive Motor V 10 W 20 us Bi Dire Moto I 0 us Forwaral Drive Motor U V and W Moving Forward Service Manual CS7000 Wheel System Traction 401 The drive motor has an internal encoder that provides feedback to the drive controller regarding rotation direction and speed The drive controller provides a 5v power supply out of pin J4 26 to the encoder connector pin 2 The drive controller provides an internal ground for the encoder at pin J4 7 The encoder has 2 speed sensors Phase A and Phase B that monitor the rotation of the motor shaft Each sensor creates a 4v square wave pattern that increases in frequency as the motor rotation speed increases Below are oscilloscope waveforms which show the Phase B speed sensor input when the mo
107. e 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 The operator can enable the scrub system independent of the solution and recovery systems to scrub without adding or picking up solution Scrub Pressure Control The electric scrub deck actuator motor M11 moves the scrub deck up and down to control the scrub pressure The retract limit switch proximity sensor S1 stops the upward deck movement at the upper travel limit The brush current sensor B1 acts like an amp clamp around the brush motor wires to constantly measure the total current draw of all three brush motors This current reading is sent to the Al Main Machine Controller on pin J7 27 Brush Current Sense The Al Main Machine Controller interprets this current value and raises or lowers the scrub deck as follows Ifthe brush motor current drops below the preset limits for the selected scrub pressure 1 3 the scrub deck actuator will lower the scrub deck to increase the scrub pressure and current draw until the current draw is again within the correct range Ifthe brush motor current rises above the preset limit for the selected scrub pressure the scrub deck actuator will raise the scrub deck to decrease the scrub pressure and current draw until the current draw is again within the correct range The scrub brush current monitoring and scrub deck actuator a
108. e the Plug from the UP Hydraulic Hose and reconnect the UP Hydraulic Hose to the Lower Cylinder Fitting 27 Press the hopper raise button to raise the cylinder ram to the end of its stroke to purge the oil from the top of the hydraulic cylinder Check the oil level in the reservoir frequently as you do this and add oil as necessary The oil level in the reservoir should be at the MIN line with the cylinder ram fully extended upward Lower Cylinder Fitting Hopper System 257 SY P Lower Cylinder Fitting us i UP t N lt ve air into the clevis end of the cylinder If this happens you will have to restart the procedure le Note Be careful not to let the oil level in the reservoir fall below the MIN line to avoid introducing ne from step 8 Service Manual CS7000 Hopper System 258 28 Remove the cap from the DOWN Pump Port and reconnect the DOWN Hydraulic Hose to the DOWN Pump Port DOWN Hydraulic Hose SS DOWN Pump 29 Disconnect the UP Hydraulic Hose from the Lower Cylinder Fitting 30 Install a Cap onto the Lower Cylinder Fitting 31 Install a Plug into the UP Hydraulic Hose uP Hose 4 Hydraulic Service Manual CS7000 92 33 OA 30 36 Slightly loosen the DOWN Hydraulic Hose at the Upper Cylinder Fitt
109. ead pressure in order to maintain a consistent solution flow rate regardless of solution level in the tank The solution solenoid s coil circuit opens and closes pulsing on and off pulling the valve diaphragm on and off its seat This way the Al Main Machine Controller can manage the three different auto flow volumes and two different override flow rates On non EcoFlex machines the operator must manually mix the detergent with the water in the solution tank if detergent is desired in the solution Solution Valve Desired Flow per Solution Setting Solution Flow Setting Desired Flow GPM ee eS ST Solution Flow Control EcoFlex Machines EcoFlex models use a solution control pump M19 to supply the solution to the scrub brushes On EcoFlex machines the solution solenoid valve remains open when the solution control pump is running and the solution flow is controlled by the pump output This allows more precise mixing of the detergent water mix to the brushes The EcoFlex detergent delivery line is plumbed into the solution line between the solution pump and the solution solenoid valve Service Manual CS7000 Solution System 304 EcoFlex Detergent System The EcoFlex detergent system uses dual diaphragm pumps M17 and M18 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
110. ear by ensuring encoder senses proper operation Motor RPM 0 and Throttle Command 0 Set Emergency Reverse was activated and ran until the EMR Timeout timer expired Clear Turn the emergency reverse input Off Set Illegal Model_Number variable when KSI cycles a check is made to confirm a legal Model_Number and a fault is issued if one is not found Clear Download appropriate software for your controller model The 1311 programmer can be used to access the controller s fault history file The programmer will read out all the faults the controller has experienced since the last time the fault history file was cleared Faults such as contactor faults may be the result of loose wires contactor wiring should be carefully checked Faults such as over temperature may be caused by operator habits or by overloading Service Manual CS7000 Wheel System Traction 418 Removal and Installation Drive Pedal Assembly 1 Disconnect drive pedal position sensor electrical connector Remove drive pedal mounting screws Remove pedal assembly p Reassemble in reverse order 5 Validate the drive pedal sensor adjustment and adjust if necessary a Use Service Mode to view the sensor voltage in the control panel LCD See Control System Service Mode for instructions on how to enter the service mode Drive Status Drive Pedal Position Sensor Voltage b The drive pedal sensor voltage should be between 2
111. easurements Scrub Brush Motor Right Current Draw shop measurements Average 19 Amps Max 37 Amps Average 17 Amps Max 23 Amps Average 17 Amps Max 26 Amps Input Voltage 34 40 VDC Dynamic Load 500 Ibs max Static Load 1000 Ibs max Restraining Torque 100 in lbs min 9 Amps max at rated dynamic load Current Draw Deck Actuator Motor 2 5 Amps Typical End of Stroke Ball detent clutch with a load rating between 600 and 1000 los will ratchet at end of stroke Thermal Protection Automatic resetting thermal breaker enclosed in motor housing Wiring Polarity e To extend actuator connect red lead to positive and yellow lead to negative e To retract actuator connect yellow lead to positive and red lead to negative Service Manual CS7000 Scrub System 302 Air Gap Make 250 in typical Retract Limit Switch Proximity Sensor Air Gap Break 313 in typical Contact resistance initial 150 millionms max Special Tools A spring puller is recommended to remove the Extension Springs from the Weldment Arms when removing the Side Squeegee Assemblies There are several types of spring pullers a typical example is shown here Nilfisk 7 Advance Service Manual CS7000 303 Solution System Functional Description Overview The solution system delivers water or detergent and water to the floor for the scrub system The solution system in
112. ee Dual Drive manual Controller Note Not used on CS7000 75 Dual Severe Fault 1 Dual Drive fault see Dual Drive manual Note Not used on CS7000 Set Clear Conditions Set The external supply current combined current used by the 5V supply pin and 12V supply pin 25 is either greater than the upper current threshold or than the lower current threshold The thresholds are defined by the External Supply Max and External Supply Min parameter settings Clear Bring the external supply current within range Set Internal controller fault detected Clear Cycle KSI Set Time between CAN PDO messages recelved exceeded the PDO Timeout Period Clear Cycle KSI or receive CAN NMT message Set No motor encoder movement detected Clear Either cycle KSI or detect valid motor encoder signals while operating in LOS mode and return Throttle Command 0 and Motor RPM Service Manual CS7000 Wheel System Traction 416 Programmer LCD Display Effect Of Fault Flash Code Motor Type Fault ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle VCL OS Mismatch 87 91 ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle ShutdownInterlock ShutdownDriver1 ShutdownDriver2 ShutdownDriver3 ShutdownDriver4 ShutdownPD FullBrake ShutdownPump 2 9 EM Brake Failed to Set Shutdown EM Brake ShutdownThrottle FullBrake ShutdownPump Mot
113. el and LPG machines e The J3 6 and J3 7 Outputs must provide voltage to the Dump Door Actuator Motor M26 when the A1 Main Machine Controller receives a signal from the A3 Control Panel via the CAN BUS that the operator has pressed the hopper door open or hopper door close button For the hopper door to open the A1 Main Machine Controller must not receive negative voltage at the J7 22 Input from the Dump Door Extend Limit Switch 7 For the hopper door to close the A1 Main Machine Controller must not receive negative voltage at the J7 23 input from the Dump Door Retract Limit Switch S8 Component Locations Upper and Lower Hopper The Upper Hopper light gray and Lower Hopper dark gray are on the front of the machine The Hopper Cover houses the dust control impeller pump filter and filter shaker assembly The Upper and Lower Hoppers are connected and pivot up and down as a single unit Hopper Cover Upper Hopper Lower Hopper Service Manual CS7000 Hydraulic Power Pack Assembly The Hydraulic Power Pack Assembly is mounted on the front of the machine frame and can be accessed when the hopper is up The Hydraulic Power Pack Assembly extends and retracts the Hopper Lift Cylinder which raises and lowers the hopper Hydraulic Power Pack Assembly Hopper Lift Cylinder Hopper System 241 Service Manual CS7000 Hopper Dump Door The Hopper Dump Door on the bottom o
114. em will then shut down as if the operator had shut off the key Normal engine shut off aa aie IGNITION CONNECTOR FUEL PUMP PNK YEL 16 FOR PLUGGINGINTO IGNITION REQUEST PNK 16 KUBOTA IGNITION HARNESS GRY 16 PNK BLU 16 CONNECTOR 1 PACKARD 16 PI N MALE PNK BLU 16 PNK iMt 16 P N 1532 PNK GRN 16 pi R 6863 TO NILFISK HARNESS QNTROLLER a WOODWARD P L SERIES i A Ja ACTUATOR i ESAE Sz DEUTSCH a 5 CONNECTOR fee Ten i 10 RUN ENABLE SIGNAL MAL a BI i idA 14 i s SHUTDOWN SIGNAL REDIS x CRANK REQUEST BLU PNK 16 3 WOODWARD Zz FUELLOCK OFF 3 WED j a i SOLENOID x 18 V J j MAGNETIC f T N3 0342 OR o j ICK UP x FUEL PUMP p sEngi 3 D O SHIELDED WI RE Engine RPM m Sensor p z BLK BLK 18 W E Z AEES RN65127 TOPINE bs _ i FUSE amp RELAY CRANK i HIGH COOLANT The Law GL Peles i BLOCK ASSY REQUEST 2E SHUTDOWN RELAY SHUTDOWN REQUEST RELAY i RELAY zs 0 047 Concors ane sha EPE E E E T E A E PACKARD 16 PI N FEMALE YA ee Li i BLK WHT 16 P N15326868 Ci oo Oy Roas S OO O S O i CTO NILPISE HARNESS O i ee l SPEED 2 12V OUTPUT Fae A SPEED 3 12V OUTPUT 0 047pf o 3 sla a KUBOTA 5 al HIS HIGH COOLANT TEMP GROUND INPUT GRN YEL 16 GRY LT BLU 16 SOLENOID b RED 16 EG551 44790 h i cT00024 TEMP SWITCH BLU LT OIL SW
115. ep System Main 365 Circuit Description The Following Conditions Must be Met for the Main Sweep System To Operate e The Hopper Interlock Switch S3 must be closed There must be positive voltage to the J7 1 Interlock Input For this to happen The Seat Switch S9 must be closed The Safety Relay K14 on the Steer By Wire Controller A5 must energize the coil to close the Safety Relay K14 contactor The Emergency Stop Switch S15 must be closed The Battery Interlock S13 must be closed The 400 amp Fuse F1 must be closed to provide positive voltage from the Battery to the load side of Auxiliary Contactor K9 The Ignition Switch S14 must be closed to provide positive voltage to the Auxiliary Contactor K9 coil The J2 14 Output on the A1 Main Machine Controller provides ground to the Auxiliary Contactor K9 coil when the Ignition Switch S14 provides an input to the Key Switch Input J7 13 The Auxiliary Contactor K9 must be closed to provide positive voltage to circuit breaker VACC1 CB1 e Circuit breaker VACC1 CB1 must be closed to provide positive voltage to the Broom Motor Contactor K4 e The J2 16 Output on the A1 Main Machine Controller must provide a ground to the Broom Motor Contactor K4 coil J2 16 provides ground to K4 under the following conditions The A1 Main Machine Controller must receive a signal from the A3 Control Panel via the CAN BUS that the operator has pressed the sweep switch The A1
116. etaining Ring next to the Frame Weldment as shown External Retaining Ring remove 8 Support the hopper lift cylinder and hopper External Retaining prop rod Then remove the Cylinder Pin Ring do not remove ea Frame Weldment f Cylinder Pi a Sleeve Bearing Hopper SE Prop Rod inside weldment Service Manual CS7000 9 To install the hopper lift cylinder place it in position at the lower pivot point and reinstall the Hinge Pin Weldment and the 1 4 20 Screw 10 Use Wire Ties or other suitable strapping to ial 12 support the Hydraulic Cylinder while you work on the system See adjacent photo Reinstall elbow fittings and attach the hose from the lower cylinder port to the up port on the pump assembly Fill the reservoir with 10W 30 engine oil Note In the remaining steps it is ah important that the oil level 13 14 15 16 always be maintained above the minimum mark on the reservoir Operate the pump by pressing the hopper up switch on the control panel until the cylinder is fully extended Reattach the hose from the upper cylinder to the down port of the pump assembly Reattach the upper cylinder yoke along with the red safety support flange bearing cylinder pin and retaining ring Run the hopper down and then back to the full up position and make sure the oil level is Hopper System 251 Service Manual CS7000 at
117. f the hopper opens to allow the hopper to be emptied Hopper Dump Door Actuator The electric Hopper Dump Door Actuator 1s pinned to the Hopper Lift Weldment and Hopper Dump Door and opens and closes the Hopper Dump Door The Spring and Yoke on the rod end of the Hopper Dump Door Actuator allow the Hopper Dump Door to move a short distance toward the closed position when the Hopper Dump Door is open This is designed to prevent machine damage if the machine is backed away from a dumpster and the Hopper Dump Door catches on or contacts the dumpster AN Caution Hopper System 242 Da Hopper Dump Door Pg Actuator A d Hopper Y T 24 gu Lift TAD P Weldment wf Hopper Dump W Door ha Spring and Yoke ra E The Spring is pre compressed about an inch so use caution if you ever need to disassemble the Spring from the Yoke Dump Door Extend and Retract Limit Switches The Dump Door Retract and Dump Door Extend Limit Switches are proximity sensors that sense when the hopper dump door is open retracted and closed extended Note that The Dump Door Extend Limit Switch senses the Dump Door Actuator Yoke when the dump door is closed The Dump Door Retract Limit Switch senses the dump door itself when the door is open Dump Door Retract EE PAES Limit Switch a H x z t I Dump Door Extend EN Limit Switch Service Manual CS7000 Hopper System 243
118. f Valve is pre set at the factory and is not adjustable Extended Scrub System When the Extended Scrub Level float Switch inside the Recovery Tank closes to indicate adequate water level the Extended Scrub Pump switches on to pump water to the scrub brushes The water passes through the Strainer inside the Recovery Tank then through the Water Supply Line in the Bulkhead Plates and Gasket to the inlet side of the Extended Scrub Pump Note that the second piece of conduit in the Bulkhead Plates and Gasket is for the Extended Scrub Level Switch wires The Extended Scrub Pump is mounted to a bracket outside of the Recovery Tank The water from the Extended Scrub Pump is plumbed into the solution line upstream of the solution solenoid valve Solution System Solution Return High pressure Wand Relief Valve Hose sia B pressure Pump Solution Supply Solution Tank Line d i 5 y l z lt Recovery Tank l inside view l IE n P A NI i Extended Scrub Level PE float Switch Bulkhead Plates and f Gasket Service Manual CS7000 Solution System 314 Maintenance and Adjustments Warning Before performing any machine maintenance or adjustments make sure the key switch is off the key is removed from the machine and the parking brake is engaged To Clean the Solution Filter Screen 1 Close the so
119. ft Arm Assembly Flange Bearing 2 M12 1 75 x 35mm Screw 2 Scrub ao sil Motor 3 FEF Bow tie Cotter Pin 2 Electrical Connector 3 fa a a j Solution Solenoid Valve Service Manual CS7000 Scrub System 296 10 Reinstall the Scrub Deck by following the above steps in reverse order es Service Note When you reinstall the Scrub Deck eer e Make sure you reconnect the Scrub Motors to the correct Electrical Connectors in the wire harness as follows Left scrub motor White Orange wire Center scrub motor Gray Black wire Right scrub motor Blue Yellow wire e Make sure the two Flange Bearings are installed in the machine frame through holes and that the Bushings and washers are installed correctly before installing the two M12 1 75x 35mm Screws e You may find it easier to use a tapered punch or other suitable tool to align the Bushings Flange Bearings and Deck Lift Arm Assembly with the through holes in the frame before you install the M12 1 75x 35mm Screws Service Manual CS7000 To Remove and Reinstall a Scrub Motor Assembly l 2 i pA Note Make sure the Key is installed nin Remove the scrub deck from the machine Scrub System Disconnect the electrical connector from the Scrub Motor Assembly Electrical Connector Remove the Scrub Brush from the Brush Plate Assembly Remove the 5 16 18 X 1 25 Socket Head Screw from the gearbox shaft and carefull
120. gnostic Trouble Code Table DTC AC Current Excessive DC Power Supply Low Voltage DC Power Supply High Voltage DC Power Supply High Voltage DC Power Supply Insufficient The hardware detected excessive current flow in the steering actuator motor circuits The software detected that the DC power supply B and B voltage is too low The software detected that the DC power supply B and B voltage is too high The hardware detected that the DC power supply B and B voltage is too high The B and B cables did not supply enough current to charge a capacitor inside the controller within 10 seconds Actuator shorted burned stator windings Wiring U V amp W Shorted to ground or one another Steering Controller Internal Short Note Can also be caused by too low DC supply voltage on Bt Battery Positive and Negative connections at source and controller Battery Positive and Negative cables Battery Positive and Negative connections at source and controller Battery Positive and Negative cables Note If there is too much resistance between the controller and the battery during regenerative braking the voltage can climb Battery Positive and Negative connections at source and controller Battery Positive and Negative cables Note If there is too much resistance between the controller and the battery during regenerative braking the voltage can climb Batter
121. h S1 closes it connects the J7 21 Input to ground which signals the A1 Main Machine Controller that the scrub deck has reached its upper limit The A1 Main Machine Controller will switch off the J2 10 and J2 11 PWM Outputs to stop the upward scrub deck travel Service Manual CS7000 Scrub System 289 Brush Current Sensor e J7 24 provides 5 volts to the Brush Current Sensor e J7 25 provides battery ground B to the Brush Current Sensor The Input from the Brush Current Sensor provides the Brush Current Sense signal to J7 27 on the Al Controller Board The Al Controller Board uses this current value to run the Scrub Deck Actuator Motor M11 in the appropriate direction to either raise or lower the scrub deck to maintain the total scrub motor current draw within the prescribed range for the selected scrub pressure Component Locations Scrub Motor Assemblies Scrub Motor prided The left hand and center Scrub Motor Assembly 3 cist Assemblies are mounted on the Deck Weldment The right hand Scrub Motor Assembly is mounted on the Arm Weldment bolted to the Deck Weldment The Right angle Gearboxes are mounted on spacers to position them correctly on the Deck and Arm Weldments Right angle Gearbox 3 Right Scrub Arm Gas Spring and Lever Arm Bracket The Gas Spring keeps the right Arm Weldment and attached Side Squeegee Assembly extended outward during normal scrubbing but will allow the Arm Weldment to pivot backward if the
122. hat the limit of travel has been reached but the controller calculated position indicates that the mechanism should not be near the limit of travel Steering Actuator encoder feedback error Difference between set value and actual value for current regulator are above limit Difference between set value and actual value for position regulator are above limit Actuator shorted burned stator windings Wiring U V amp W Shorted to ground or one another Steering Controller Internal Short Note Can also be caused by too low DC supply voltage on B Excessive backlash in steering gears Controller Configuration Steering Limit Switches Steering Limit Switch wiring Wiring between actuator encoder and controller Actuator Encoder Signals Obstructions to steering actuator gear rotation Excessive gear backlash Loose connection in steering actuator encoder wiring Steering Actuator Obstructions to steering actuator gear rotation Excessive gear backlash Loose connection in steering actuator encoder wiring Steering Actuator 351 Service Manual CS7000 Steering System 352 Motor cable not One or more of the motor cables Wiring U V and W cables and connected U V between the steering actuator and connections or W wire open the steering controller are not connected Position This error occurs when the steering Excessive backlash in steering gears calibration err
123. hat was trapped in the vaporizer regulator When the engine stalls and loses oil pressure the oil pressure switch closes energizing the low oil pressure shut down relay This removes power from the power relay coil causing it to de energize and remove power from the ignition request relay This de energizes the ignition request relay causing the ignition system to shut down and turns off the carburetor fuel shut off solenoid stopping the flow of any remaining fuel When the power relay de energized it also removed power from the control relay coil low oil pressure shut down relay coil high coolant temp shut down relay coil and pin 1 of the Woodward L series actuator This turns off the actuator which releases the switched to ground connection through pin 9 of the actuator IGNITION POWER IGNITION REQUEST g FOR IGNI TER amp RUN ENABLE SI GNAL ALTERNATOR WOODWARD L SERIES ACTUATOR LOCK OFF SOLENOID SPEED 2 12V OUTPUT ENGI NE RUN 12V I NPUT HI GH COOLANT TEMP Signal TEMP SWITCH OIL SWITCH OPEN FOR OPEN FOR NORMAL TEMP PRESSURE 1 v BATTERY STARTER Main Machine Controller 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 In the case of lost oil pressure
124. he Detergent Hoses and Electrical Detergent jas J D Connectors then remove the Detergent Pump from the rump 2 machine 6 Reinstall the Detergent Pump by following the above steps in reverse order Electrical Connectors Specifications Component Specifications 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 EcoFlex models only Voltage 36 VDC permanent magnet Current 3 9 Amps max Flow Rate 3 3 GPM 2 75 Amps with 20 psi inlet pressure Service Manual CS7000 Component Specifications Type diaphragm self priming internal check valve Voltage 36 VDC permanent magnet Internal pressure switch e Set to switch pump on at 25 5 psi e Set to shut pump off at 45 psi Performance Specifications average Low pressure Wash Hose Pump Pressure psi GPM Amps h 3216 1 3 00 N No O on D OO M 5 Oo O M NI op a a iY no on Nh CO O Type Axial piston Max Pump Speed 1750 RPM Max Flow Rate 2 11 gpm 8 l min High Pressure Pump Max Outlet Pressure 2 200 psi 150 bar Max Inlet Pressure 116 psi 8 bar Oil Type SAE 30 10 oz capacity Shaft Rotation counterclockwise horizontal mo
125. he circuit breaker connectors as you remove them to make sure they are reconnected correctly Service Manual CS7000 Solution System 321 8 Disconnect the Steering Sensor Electrical Connector Steering Sensor Electrical Connector 9 Disconnect the additional wiring running from the solution tank to the engine ground starter engine interface etc 10 Remove the Electrical Panel Electrical Panel 11 Remove the Main Machine Controller Main Machine Controller 12 Disconnect any additional solution lines or electrical connectors from the solution tank that may be present if your machine is equipped with an extended scrub system high pressure spray system or wash hose kit Service Manual CS7000 Solution System 322 13 Remove the five mounting screws holding the solution tank to the frame The mounting screw locations are shown below The three bottom mounting screws Solution Tank are located underneath the machine Mounting Screw two on the right side and one in Locations the center of the frame The two top mounting screws are located on the vertical supports on the left side of the machine where the main machine controller is mounted The two top Solution Tank Mounting Screws are located on the vertical supports on the left side of the machine z Solution Tank Mounting Screw E r Solution Tank x b Mounting Screw
126. he scrub deck then owes remove the side squeegee assembly from the machine 2 Carefully remove the Extension Springs from the tabs on the upper Weldment Arm er Note The Bushings in the upper rine and lower Weldment Arms are different Make sure to note where the hardware items are located as you remove the squeegee assembly to ensure the mounting hardware is reinstalled correctly 4 Reinstall the side squeegee assembly by following the above steps in reverse order Service Manual CS7000 Scrub System 294 To Remove and Reinstall the Scrub Deck Actuator 1 Remove the recovery tank refer to the Recovery System section 2 Turn on the key switch and put the machine into the Service Test mode to allow you to jog the scrub deck up and down 3 Extend the scrub deck downward in the Service Test mode to minimize the Deck weight on the Scrub Deck Actuator Lift Arm Assembly 4 Disconnect the Scrub Deck Actuator electrical connector 5 Remove the Bow tie Cotter Pin washers and Clevis Pin holding the Scrub Deck Actuator to the Deck Lift Arm Assembly 6 Remove the Bow tie Cotter Pin and Clevis Pin holding the Scrub Deck Cotter Pin 2 Actuator to the machine frame then remove the Scrub Deck Actuator from the machine 7 Reinstall the Scrub Deck Actuator by following the above steps in reverse order To Remove and Reinstall the Scrub Deck 1 Remove the recovery tank refer to the Re
127. he two engine lift points 10 Reassemble in reverse order Connect the battery negative cables last Service Manual Haram Captor Il Engine System Petrol Gasoline 232 Specifications Engine Oil Engine oil capacity 3 4 L 0 90 U S gals e IMPORTANT When using an oil of different maker or viscosity from the previous one remove all of the old oil Never mix two different types of oil Engine oil should have properties of API classification SH or better Use the proper SAE Engine Oil according to ambient temperature o Above 25 C 77 F SAE30 or SAE10W 30 o 0 C to 25 C 82 F to 77 F SAE20 or SAE10W 30 o Below 0 C 82 F SAE10W or SAE10W 30 Engine Coolant Use only ethylene glycol or propylene glycol type anti freeze for this engine Always assure a 50 50 anti freeze and water mixture regardless of temperature Shop Measurements The following information provides some real world shop measurements to help you recognize what normal looks like Ignition System Ignition coil primary resistance 2 15 ohms Ignition coil secondary resistance 18 4 K ohms Spark Output 80 KV consistently Using adjustable spark tester Crank position sensor resistance 2 18 K ohms Crank position sensor output cranking 1 1 VAC average 2 0 VAC RMS Crank position sensor output running 5 5 VAC average Service Manual Haram Captor Il Engine System Petrol Gasoline 233 Spark C
128. high for given regen current Battery disconnected while regen braking See Monitor menu Battery Capacitor Voltage External load impedance on the 5V supply pin 26 is too low See Monitor menu outputs 5 Volts and Ext Supply Current External load impedance on Digital Output 6 driver pin 19 is too low Set Clear Conditions Set Capacitor bank voltage dropped below the Undervoltage limit with the FET bridge enabled Clear Bring capacitor voltage above the Undervoltage limit Set Capacitor bank voltage exceeded the Overvoltage limit with the FET bridge enabled Clear Bring capacitor voltage below the Overvoltage limit Set 5V supply pin 26 outside the 5V 10 range Clear Bring voltage within range Set Digital Output 6 pin 19 current exceeded 15 mA Clear Remedy the overcurrent cause and use the VCL function Set_DigOut to turn the driver on again Service Manual CS7000 Wheel System Traction 410 Programmer LCD Display Effect Of Fault Flash Code H Digital Out 7 Overcurrent Digital Output 7 driver will not turn on Note This circuit is not used on the CS7000 2 Motor Temp Hot Cutback Reduced drive torque f 8 9 Motor Temp Sensor Fault 31 MaxSpeed reduced LOS Limited Operating Strategy and motor temperature cutback disabled K7 Wheel Drive Contactor Coil Driver Open Short ShutdownDriverl1 Troubleshooting Chart Possibl
129. hings in the frame to raise and lower the attached scrub deck Note that the scrub deck is free to float left to right to conform to the floor surface Sensor Target Deck Lift Assembly Arm The Retract Limit Switch S1 will detect the Sensor Target Bracket when the scrub deck is fully retracted upward and stop the Scrub Deck Actuator motor 290 Service Manual CS7000 Scrub System 291 Maintenance and Adjustments Warning Before performing any machine maintenance or adjustments make sure the key switch is off the key is removed from the machine and the parking brake is engaged To Replace a Leading Deck Blade 1 Loosen the Knob and swing out the edge Strap guard not shown Deck Blade Weldment on right hand side squeegee assembly Support only Weldment 2 Remove the two Wing Knobs 3 Remove the Strap Weldment and Leading Deck Blade from inside of the Blade Support Weldment 4 Reverse the existing Trailing Deck Blade to position a new blade surface on the floor or install a new Trailing Deck Blade onto the Strap Weldment pins as shown Knob 2 5 Install the Trailing Deck Blade and Strap Weldment on the inside of the Blade Support Weldment then reinstall and tighten the two Wing Knobs 6 Swing the edge guard back into position then tighten the Knob right hand side squeegee assembly only To Replace a Trailing Deck Blade 1 Loosen the Knob and swing out th
130. ic fields and creates a two 5v square wave signals As the motor rotates one of the signals switches before the other so that the controller can tell which direction the motor is rotating Steering Actuator Service Manual CS7000 Steering System 341 Steering Travel Limit Switches The Steering Travel Limit Switches are magnetic proximity switches that are normally open They are mounted on each side of the frame There is a bracket mounted on the drive wheel steering ring gear with a tooth As the gear rotates the tooth moves with it When the tooth lines up with one of the proximity switches its internal switch closes to let the controller know it should stop moving in that direction Proximity Switch Steering Controller The steering controller is the heart of the steer by wire system It operates the steering actuator based on input requests from the steering wheel rotation sensor and the travel limit proximity switches It has robust self diagnostics to protect itself and shut down the steering system if a serious error occurs It is a sealed unit with no serviceable parts inside It is capable of storing DTCs Diagnostic Trouble Codes See the Troubleshooting section for more information There is a green LED Status Indicator built into the controller that provides important information to the service technician Note you must be looking straight at it and not from an angle for
131. ice Manual CS7000 Wheel System Traction 420 11 Remove the 2 inner gear box to frame bolts and loosen the remaining 4 4 Remove 2 Loosen 4 S 12 Lift the machine just enough to take weight off the gear box and remove the remaining 4 gear box to frame bolts 13 Attach a lifting strap around the drive motor You will use the strap to guide and lower the assembly 14 Slowly lift the machine up to allow the drive motor and gear box assembly to come out the bottom while holding the motor assembly upright using the lifting strap Y yi A gt A i d 15 Secure the machine safely on jack stands Service Manual CS7000 Wheel System Traction 421 16 Hook up a hoist to the lift strap and put a slight tension on the strap Remove the rear wheel chock and allow the assembly to roll backward and downward out of the machine controlling the movement by lowering the hoist and blocking the wheel a 18 Reassembly notes a Be sure to apply anti seize compound to the motor shaft splines and gearbox splines Apply Anti seize b If installing a new gear box be sure to fill it to the bottom of the fill plug with 80W90 oil when the assembly is installed Holds 2 2L 59 Gal Part number 56510411 RMA SF AAAAAASS j Service Manual CS7000 Wheel System Traction 422 c If installing a new gear box be sure to transfer the splash shield Splash shield d Apply 56510412
132. ile turning with stationary machine Measured at each U V and W wire e Approximately 4 5 amps while turning with stationary machine Steering Contactor Winding 118 Ohms Safety Relay Winding 813 Ohms Special Tools 3 jaw puller for steering wheel removal Nilfisk 7 Advance Steering System 362 Service Manual CS7000 363 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 The broom lift actuator lowers the main broom any time the sweep system is enabled The main broom motor switches on when the drive pedal is moved from the neutral position The operator can enable the sweep system independent of the scrub system The hopper door opens when sweeping to allow the debris to be thrown into the hopper A potentiometer in the main broom actuator sends a voltage signal to the Al Main Machine Controller that varies with the broom height The Al Main Machine Controller uses this signal to return the broom to the previous height setting whenever the sweep system 1s enabled The main sweep system has a float function in which the main machine controller drives the actuator all the way down so the weight of the main broom is resting on the floor The linkage is slotted which allows the broom
133. inder ram and prop rod to the hopper lift weldment Make sure the sleeve bearing and the two flange bearings are not damaged and are installed correctly ea m Raise the hopper and check the position of the Upper Cylinder Fitting and DOWN Hydraulic ete TE a Hose Cylinder w Fitting jr e The Upper Cylinder Fitting should be positioned vertically and with enough clearance so it doesn t contact the adjacent frame surfaces r a a a A x i e Pra A e S y gt e S S iit f Aa i 5 We p J k F r r 1 eal A w n io f k 4 k a ea r j ia ni eee E nata The DOWN Hydraulic Hose should be positioned so it has adequate clearance in the frame cutout Loosen and reposition the Upper Cylinder Fitting and DOWN Hydraulic Hose as l p TA necessary to avoid any abrasion or damage M Ki DOWN Hydraulic Hose 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 Hydraulic Loosen and reposition the UP Hydraulic Hose ose as necessary to avoid any abrasion or damage Reinstall the reservoir guard Check the oil level in the reservoir It should be at the MIN line when the cylinder is fully extended hopper is raised Service Manual CS7000 Hopper System To Remove and Reinstall the Hopper
134. ine Carburetor mixer Carburetor fuel shut of solenoid Ll Crank position sensor E r J 195 Service Manual CS7000 Engine System LPG 196 Engine Back Side View Toward right of machine Fuel lock off solenoid Spark Controller PE a 42v Alternator Engine Left Side View Toward back of machine Coolant temperature switch Ya Service Manual CS7000 Engine System LPG 197 gt F a a Service Manual CS7000 Engine System LPG 198 Maintenance and Adjustments Maintenance Checklist This check list is courtesy of the Kubota engine Workshop Manual See the workshop manual for more details on performing these operations Daily Check engine oil level Check and replenish coolant Check air cleaner element Check LPG tank setting condition Check LPG fuel connector First 50 hours Change engine oil Replace engine oil filter Every 50 hours Clean air cleaner element Check LPG fuel hose and clamp bands LPG fuel check Every 100 hours Clean spark plug Check fuel filter Check fan belt tension and damage Every 200 hours Change engine oil Replace engine oil filter Check LPG tank setting condition Check radiator hoses and clamp bands Every 1 year Replace air cleaner element Clean carburetor Clean water jacket and radiator interior Service Manual CS7000 Every 1000 hours Replace spark plug Check cool
135. ing Jog the hopper lower button to run the pump and force the oil out of the DOWN Hydraulic Hose at the Upper Cylinder Fitting until the oil runs clear with no foaming or air evident in the oil Tighten the DOWN Hydraulic Hose on the Upper Cylinder Fitting Remove the cap from the Lower Cylinder Fitting Remove the plug from the UP Hydraulic Hose and reconnect the UP Hydraulic Hose to the Lower Cylinder Fitting Cylinder Fitting Hopper System 259 Upper Cylinder Fitting DOWN Hydraulic Hose 4 i yp BE Hydraulic Hose 1 Sima 37 Run the hydraulic cylinder ram up and down several times using the hopper raise and hopper lower buttons to check for correct function Note There is a Velocity Fuse inside the lower down hydraulic cylinder port that will shut off the flow of oil through the fitting if the oil flow rate exceeds 1 5 gallons per minute This is to prevent the hopper from dropping down if the up hydraulic hose or lower cylinder fitting fails If the ram fails to retract downward it could be due to the Velocity Fuse Let the hydraulic system sit idle for a few moments to allow the Velocity Fuse to reset then try retracting the ram again Velocity Fuse inside lower cylinder fitting Service Manual CS7000 Hopper System 260 38 39 40 Al 42 Remove the wire ties and reconnect the cyl
136. ing There is no voltage Check the output from J2 10 and J2 11 from the A1 Main output from the Machine Controller A1 Main Machine Controller Service Manual CS7000 Scrub System 293 Problem Cause Correction The scrub deck The retract limit Check the switch function and replace if necessary Note that actuator will not switch S1 is the retract limit switch is a proximity switch should be closed raise the deck shorted out when close to the metal The scrub pressure The brush current Check the wiring and connections from the A1 Main is inconsistent sensor B1 is not Machine Controller to the brush current sensor and repair as operating correctly necessary Check the 5V output from J7 24 and the ground output from J7 25 to the brush current sensor B1 from the A1 Main Machine Controller Check the input to J7 27 on the A1 Main Machine Controller from the brush current sensor If the output is not between 2 5 and 4 7 volts replace the brush current sensor Removal and Installation is off the key is removed from the machine and the parking brake is engaged A Warning Before removing or reinstalling any machine components make sure the key switch To Remove and Reinstall a Side Squeegee Assembly 1 Loosen the knob and swine out the edge guard Weldment Arm upper 3 Remove the Screws washers Spring 2 Bushings Flange Bearings and Nyloc Nuts holding the side squeegee Weldment assembly to t
137. ing Pin 3 Remove the Side Broom Hub Assembly from the Gearbox Shaft 4 Reinstall the Side Broom Hub Assembly by following the above steps in reverse order A Service Note Coat the Gearbox Shaft PAFA with Never Seez or equivalent anti seize compound before installing the Side Broom Hub Assembly eee Gearbox Shaft E SideBroom Hub Assembly Motor Assembly To Remove and Reinstall the Side Broom Actuator 1 Dump the hopper 2 Make sure the parking brake is engaged 3 Turn the key switch on and switch the machine to the Service Mode 4 on or underneath the hopper 5 Raise the hopper far enough to minimize the weight of the side brooms on the actuator then support the hopper with jack stands or other suitable supports A Warning Always make sure the hopper is adequately supported before performing any work Cut the wire tie and disconnect the side broom actuator electrical connector Service Manual CS7000 Sweep System Side Broom 390 6 Remove the two 3 8 16 x 75 Screws z me holding the Actuator Bracket Weldment 3 8 16 x 75 _ Actuator to the H Lift Weldment AON Bracket o the Hopper Li eldment wW l Weldment 7 Extend the side brooms in the Service Mode to extend the side broom actuator This will give you some additional clearance for better access to the hair cotter pin holding the Side Broom Actuator to the side broom lift weldme
138. ing 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 controller switches the ground to the turn signals on and off Service Manual CS7000 Options and Accessories 265 Description Illustration Rear Corner Roller Kit Hopper Temperature Sensor Kit The Hopper Temperature Sensor Temperature Kit includes a Temperature Switch 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 to turn off the dust control motor main broom system and side broom system and close the hopper dump door Plugged Filter Switch Kit The Plugged Filter Switch Kit includes a Dust Control Filter Switch that threads into the hopper and connects to the existing wiring harness The Dust Control Filter Switch will generate a warning if the hopper vacuum gets too high indicating a plugged dust control filter Service Manual CS7000 Options and Accessories 266 Description Illustration High Pressure Pump Kit LPG and Diesel Hybrids The High Pressure Pump Kit includes a separate high pressure solution pump engine driven pump clutch and drive belt high pressure wand assembly and the associated valves and plumbing The high pressure solution pump pumps solu
139. ion Shutoff 5 Carefully unscrew the Solution Shutoff Valve from the solution tank 6 Reinstall the Solution Shutoff Valve by following the above steps in reverse order gt Hose E A i Solution Shutoff Valve threads before installing it into the solution tank Make sure the Solution Shutoff Valve is oriented correctly on the tank so the barbed fitting on the Solution Shutoff Valve aligns with Connecting Hose on the Solution Filter Assembly E Service Note Apply Loctite No More Leaks White Threaded Plastic Pipe Sealant to the pe To Remove and Reinstall the Solution Filter Assembly 1 Close the Solution Shutoff Valve 2 Remove the nuts washers and U bolts holding the Solution Filter Assembly to the mounting plate AAN Note Place a suitable container underneath the filter to catch any solution that may leak from the vie filter or hoses 3 Loosen the clamp holding the Connecting Hose to the Solution Filter Assembly then remove the Connecting Hose from the Solution Filter Assembly 4 Loosen the clamp on the Hose that runs from the Solution Filter Assembly to the Solution Solenoid Valve and remove the Hose from the Solution Filter Assembly 5 Remove the Solution Filter Assembly from the machine 6 Reinstall the Solution Filter Assembly by following the above steps in reverse order Service Manual CS7000 Solution System 325 To Remove and Reinstall the Solution Solenoid Valve l
140. is running it will shut the engine down If the actuator never sees an RPM signal it does not know that the engine is running and has not tried but failed to control the RPM Therefore it remains in a cranking mode and does not shut the engine down The main machine controller communicates the desired engine speed mode to the actuator via the Throttle 1 and Throttle 2 wires It either sends out Ov or 12v on each wire depending on the desired speed mode Speed Mode Engine Speed Throttle 1 Throttle 2 Idle 1700 RPM Oo OT Run 2500 RPN oa 2700 RPN 120 Service Manual CS7000 Engine System LPG 190 There are several conditions that will override the user s engine speed request e High pressure wash forces to run speed Ifthe engine is at idle speed the engine will be forced to the run speed when sweeping only or vacuuming only The force idle neutral timeout will return the engine to idle speed Ifthe engine is at idle or run speed the engine will be forced to maximum power speed when scrubbing only or scrubbing and sweeping The force idle neutral timeout will return the engine to idle speed Ifthe override is run speed the user can change between maximum power speed and run speed Ifthe override condition goes away e g sweep system turns off and the user has not changed the engine mode the engine is returned to the mode before the forced override Normal Engine Shut Off Step One When the key switch
141. is shut off the main machine controller stops sending 12v out the ignition request circuit This removes the power source for the fuel lock off solenoid that had been flowing through the closed at rest contacts of the high coolant temp shut down relay No more fuel will flow into the vaporizer regulator but the engine continues to run on the fuel that is trapped in the regulator You may recall that when the key was first turned on that the ignition request voltage energized the ignition request relay and provided power for the ignition system If this is true how can the engine stay running after the ignition request voltage is shut off by the main machine controller It is able to stay running because the energized power relay is providing battery power to the ignition request relay keeping it energized so that the ignition system is still powered up IGNITION POWER IGNITION REQUEST FOR IGNITER amp _ A sr ALTERNATOR WOODWARD L SERIES ACTUATOR LOCK OFF HIGH COOLANT FEMP LOW OIL PRESS SOLENOID SHUTDOWN RELAY SHUTDOWN IGNITION REQUEST RELAY SPEED 2 12V OUTPUT ENGINE RUN 12V INPUT 12v HI GH COOLANT TEMP Signal TEMP SWITCH J OIL SWITCH OPEN FOR OPEN FOR NORMAL TEMP PRESSURE izZv BATTERY STARTER Main Machine Controller Service Manual CS7000 Engine System LPG Step Two The engine continues to run until it uses up the fuel t
142. it External short of phase U V or W motor connections Controller Overcurrent ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle FullBrake ShutdownPump Current Sensor Fault Clear Cycle KSI Motor parameters are mis tuned Controller defective Leakage to vehicle frame from Set Controller current sensors phase U V or W short in have invalid offset reading Shutdown Motor motor stator ShutdownMainContactor ShutdownEMBrake ShutdownThrottle FullBrake ShutdownPump Precharge Failed Clear Cycle KSI Controller defective External load on capacitor Set Precharge failed to charge ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle FullBrake ShutdownPump Controller Severe Undertemp ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle FullBrake ShutdownPump bank B connection terminal that prevents the capacitor bank from charging See Monitor menu Battery Capacitor Voltage Temperature information is not accurate Controller is operating in an extreme environment the capacitor bank to the KSI voltage Clear Cycle Interlock input or use VCL function Precharge Set Heatsink temperature below 40 C Clear Bring heatsink temperature above 40 C and cycle interlock or KSI Service Manual CS7000 Troubleshooting Chart Wheel System Traction 408 Flash Programmer LCD C
143. it to be visible Off Blinking slowing 1HZ Blinking rapidly 10HZ f Status Indicator A Steering Controller Service Manual CS7000 Steering System Wiring Diagram RED FROM F1 JN STEER BY WIRE cB RED Tae Ce 10 BRN GRA 7 h GRA WHT CONTACTOR STEERING Steering System 342 DF B B BLK M16 STEERING ACTUATOR WIRES ON ACTUATOR U BRN N L V RED V WHT Y W Ee WHT GRN YEL BLK RED Tad STEERING CONTROLER AJ ATIY U ENCODER_IN_1 J5 5 WHT ANV ENCODER_IN_2 J5 6 BLU GRA TEMP SENSOR J5 16 PINK SENSOR_SUPPLY_GND J5 4 BLK E4 5V SENSOR_SUPPLY J5 3 ORN BLK X98 LJ LI a ENCODER_IN_3 J5 11 GRN WHT D GRN Al agigag Bl ENCODER_IN_4 J5 10 RED WHT X 1 eS LTD ye DIGITAL_IN_4 J5 17 BLU gt BLU A2 B2 DIGITAL_IN_6 J5 20 GRN BLK os 3 M CND 1 Syma VOLT 1 5V RED BI GRN BLK B2 gt X RED BLK GND 2 Syor VOLT 2 5V TFD CONTROL J5 2 BRN WHT 3 gt gt BLK F D CONTROL B _INPUT J5 1 ORN w gt WHT FD Bt POWER APPLICATION CONFIG INPUT J5 12 ORN STEERING WHEEL ROTATION SENSOR S16 RIGHT LIMIT INPUT J5 13 WHT BLU Oey ORN SWITCH RIGHT TRAVEL
144. l from the A2 Drive Controller via the CAN BUS that the machine is moving forward or reverse Circuit breaker CB7 must be closed to provide positive voltage to the load side of Side Broom Motor Contactor K8 Side Broom Motor Contactor K8 must be closed to provide positive voltage to the Side Broom Motors M8 and M9 The Side Broom Motors M8 and M9 must have connections to battery ground B Side Broom Actuator Motor The J3 5 and J3 17 Outputs from the A1 Main Machine Controller provide voltage to the Side Broom Actuator Motor M13 The output polarity determines whether the Side Broom Actuator Motor lowers or raises the side brooms Service Manual CS7000 Component Locations Side Brooms The Side Brooms are mounted on the front corners of the machine below the hopper Side Broom Motor Assemblies The side broom motor assemblies consist of the Side Broom Motors and Side Broom Gearbox The Side Broom Motor Assemblies are mounted on Side Broom Arm Assemblies connected to the side broom lift weldment Side Broom Actuator The Side Broom Actuator is on the upper hopper and lowers and raises the side broom lift weldment and attached side broom motor assemblies Sweep System Side Broom 382 Side Broom Se Motor Service Manual CS7000 Sweep System Side Broom 383 Maintenance and Adjustments Warning Before performing any maintenance or adjustments on the side sweep system make sure the key
145. lenoid engaging the starter to turn the engine crankshaft The ignition system is functional at this point but there is not any fuel yet so the engine is not able to start Once oil pressure builds up the oil pressure switch opens The loss of ground through the oil pressure switch causes the high coolant temperature shutdown relay to de energize Ignition request power is then passed through the closed at rest contacts to the fuel lock off solenoid allowing fuel to flow and the engine to start The loss of ground through the oil pressure switch also causes the low oil pressure shutdown relay to de energize o Battery power is then passed through the closed at rest contacts to the main machine controller as the engine run signal and to the Woodward L series actuator From this point on the run enable signal to the actuator is maintained by the low oil pressure shutdown relay o The same power is also passed to the power relay coil energizing the relay Battery power is then passed through the closed when energized contacts of the power relay back into the ignition request circuit and to the control relay winding energizing the control relay IGNITION POWER IGNITION REQUEST FOR IGNITER amp pi D ALTERNATOR WOODWARD L SERIES ACTUATOR HIGH COOLANT PEMP SHUTDOWN RELAY LOW OIL PRESS SHUTDOWN IGNITION REQUEST RELAY SPEED 2 12V OUTPUT
146. llow the machine to automatically compensate for a variety of floor surfaces and scrubbing conditions while maintaining constant scrubbing pressure If the scrub deck actuator is unable to maintain the combined brush motor current draw below 75 amps for 25 seconds or if there is a short circuit the Al Main Machine Controller will set an over current fault code Service Manual CS7000 Scrub System 287 Scrub System Wiring Diagram Battery F1 36V RED RED I BLK Fuse 400 A A1 Main Machine Controller A3 Control Panel ORN 42V Alternator OSETE z CAN J7 11 B L BLK S14 i gt F A ad ee TEE B1 i23 J7 19 Start Input L B YEL BRN 3 il 4 BLK ORN J2 14 Output K9 Aux Contactor GRN YEL YEL BRN J7 12 Supression Ignition Switch Diode ORN J7 13 Key Switch paca Fe Input mm s9 K14 S15 13 ORN GRA ORN PINK TAN GRN BLU J7 1 Interlock Fe T h BAF 1 2 Input S3 Seat Switch Safety Switch Emergency Battery RED BLK BLK Relay signal from Stop Switch Interlock 1 2 A5 Steer by Hopper Wire Controller Interlock Switch Contactor Aux VACC3 Ground K9 CB3 BLK RED j j BLUIGRN 5 GRAVBLK 13 34 Input ep 125 Amp 2 pee Pa BLK ne e J3 21 BLK BLK J3 29 YEL BLU J2 25 Output Contactor Left Brush Motor Scrub Deck 2o is FAAS J2 26 Output Actuator Motor Contactor Center be pee Ge Brush Motor giii E VIO GRA RED P J2 10 PWM Output RED GRN RED m YEL Contactor Right Brush Motor J2 141 PWM Outpu YE
147. lock ShutdownDriver1 ShutdownDriver2 ShutdownDriver3 ShutdownDriver4 ShutdownPD FullBrake ShutdownPump Troubleshooting Chart Possible Cause s Emergency Reverse operation has concluded but the throttle forward and reverse inputs and interlock have not been returned to neutral This is a safety fault caused by a change in certain parameter settings so that the vehicle will not operate until KSI is cycled For example if a user changes the Throttle Type this fault will appear and require cycling KSI before the vehicle can operate There is an open in the interlock circuit J4 9 Seat Switch Emergency Switch Battery Interlock Steering Safety Relay VCL code encountered a runtime VCL error See Monitor menu Controller VCL Error Module and VCL Error This error can then be compared to the runtime VCL module ID and error code definitions found in the specific OS system information file Set Clear Conditions Set At the conclusion of Emergency Reverse the fault was set because various inputs were not returned to neutral Clear If EMR_Interlock On clear the interlock throttle and direction inputs If EMR_Interlock Off clear the throttle and direction inputs Set Adjustment of a parameter setting that requires cycling of KSI Clear Cycle KSI Set The drive pedal is outside of the neutral position when there is no voltage to the interlock circuit J4
148. lown There is no voltage Check circuit breaker CB1 and reset if necessary to the K1 K2 and K3 The contactor K9 is not providing positive voltage to the K1 contactor coils K2 and K3 contactor coils 1 Check the K9 contactor coil resistance If the coil resistance is not 118 ohms 10 replace the contactor Check the continuity through contactor K9 with the coil energized If the contacts are open replace the contactor Check the J2 14 output from A1 Main Machine Controller An individual scrub There is no voltage Check the coil resistance in the K1 K2 K3 contactor coil deck motor will not to the corresponding lf the coil resistance is not 118 ohms 10 replace the run contactor coil K1 contactor K2 K3 _ Check the continuity through contactor K1 K2 K3 with the coil energized If the contacts are open replace the contactor Check the J2 25 J2 26 J2 27 output from A1 Main Machine Controller There is an open Check the motor wiring and connections from contactor K1 circuit in the scrub K2 K3 to the motor and the ground connection from the motor wiring motor to battery ground Repair as necessary The motor is not Replace the scrub deck motor operating correctly The scrub deck There is an open Check the wiring and connections from the A1 Main Machine actuator is not circuit in the deck Controller to the scrub deck actuator motor and repair as raising and lowering actuator motor necessary the deck wir
149. lug and direct the coolant into a suitable container Reinstall the drain plug and reposition the drain hose Refill with a 50 50 mixture of engine antifreeze and water Service Manual Haram Captor Il Engine System Petrol Gasoline 227 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 Red in Window Restricted Filters Clear Window Okay Replace Air Filters 1 Release the latches and remove the air filter housing cover 2 Remove the outer filter element 3 Blow out air cleaner housing with compressed air with inner filter element still in place to prevent dirt from entering the engine air intake 4 Remove the inner filter element 5 Clean residual dust from the inside of the air cleaner housing taking care to prevent any dirt or debris from entering the air intake 6 Install a new inner filter element and then the new outer filter element making sure that they seal well at their ends 7 Install the air cleaner housing cover Service Manual Haram Captor Il Engine System Petrol Gasoline 228 Troubleshooting Checking Spark 1 Remove the spark plug wire from the spark plug and insert an adjustable KV tester in the end of the wire 2 Adjust the gap to approximately 20 30 KV and clip the tester to a good ground on the engine 3 Crank the engine over and check fo
150. lution shutoff valve E Note Place a suitable container underneath the filter to catch any solution that may leak from the vine hoses 2 Unscrew the Filter Cover and remove the Filter Cover and Screen from the Filter Base Filter 3 Clean any accumulated dirt or debris from the Screen 4 Reinstall the Screen into the Filter Base _ Rubber 5 Make sure the Rubber Washer is installed correctly in the Filter Cover fe Screen then reinstall and hand tighten the Filter Cover Filter Base Service Manual CS7000 Solution System 315 To Clean the Extended Scrub System Strainer 1 Open the recovery tank cover and remove the debris basket 2 Rinse any accumulated material off of the Extended Scrub System Strainer using normal water hose pressure 3 Reinstall the debris basket and close the recovery tank cover Extended Scrub System Strainer To Clean the High Pressure Solution Filter 1 Drain and remove the recovery tank E Note Place a suitable container underneath the filter to catch any solution that may leak from the reine hoses 2 Unscrew the Filter Cover and remove the Filter Cover and screen from the Filter Base 3 Clean any accumulated dirt or debris from the screen 4 Reinstall the screen into the Filter Base 5 Make sure the rubber washer is fs a 7 3 Filter sancti installed correctly in the Filter Cover A Ty Cover then reinstall and hand
151. mount has a square hole in the chassis for a carriage bolt The other 3 are threaded holes in the frame 1 Remove engine Top cover 2 Disconnect the 36v battery pack main positive and negative cables 3 Disconnect the 12v battery negative cable 4 Disconnect the 12v battery positive cable 5 Disconnect fuel supply and return lines 6 Disconnect battery positive and negative cables at the starter 7 Disconnect the engine wiring connectors 8 Remove the 4 motor mount fasteners Note photos are of diesel engine ll i A WAS j J eA Hole Lp Front eA A LPS i y p Cla Se Engine Mount Z ET Rear Right J Threaded Hole gt g P Sa Rear Left f ri a l Threaded Hole 7 _ Front Left S Threaded Hole yt Jengine Mount S Rear Right h Front Right X A i ia i vA m Front engine mounting locations Shown with Rear engine mounting locations Shown with hopper up and engine being installed engine being installed 9 Lift the assembly out of the chassis using a suitable hoist attached to the two engine lift points 10 Reassemble in reverse order Connect the battery negative cables last Service Manual CS7000 Engine System LPG 206 Specifications Fuel System Primary Chamber Pressure 4 3 PSI 82 7 kPA Fuel Lock Off Solenoid Resistance 10 ohms Engine Oll 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
152. n controller pin J4 29 and serial port connection pin 1 The serial port pin 2 provides a ground for the programmer Service Manual CS7000 Wheel System Traction 403 Component Locations e Drive Pedal Position Sensor e Drive controller e Drive Wheel Motor Drive Wheel Motor Drive Controller e 3 Da gt b 7 A AY amp S Pictured with recovery fank removed Service Manual CS7000 Wheel System Traction 404 Maintenance and Adjustments Drive Controller There are no user serviceable parts in Curtis 1234 controller No attempt should be made to open repair or otherwise modify the controller Doing so may damage the controller and will void the warranty It is recommended that the controller and connections be kept clean and dry and that the controller s fault history file be checked and cleared periodically Drive Pedal Position Sensor The Drive Pedal Position Sensor does not require adjustment It comes with the pedal assembly and is pre adjusted If you believe it has come out of adjustment you can adjust it using a voltmeter With the key on and the sensor plugged in back probe the center wiper terminal with your red voltmeter lead Connect your black voltmeter lead to battery negative With the sensor mounting screws loose rotate the sensor body until your voltmeter reads 2 5V then tighten the mounting screws Gear Box Check the gear box oil level periodically It should be filled t
153. nce Service Manual CS7000 236 Hopper System Functional Description Overview The hopper system holds the dirt dust and debris swept up by the brooms The hydraulic lift cylinder raises the hopper to allow the accumulated dirt and debris to be dumped into a suitable receptacle then lowers the hopper back down into the normal operating position The hopper lift cylinder is powered by a separate hydraulic power pack that includes an electric motor and hydraulic pump Two double pole contactors control the lift cylinder direction by reversing the polarity to the pump motor The hopper dump door driven by an electric actuator can be opened by pressing the hopper door open button when the hopper is up to empty the hopper Proximity sensors limit the hopper dump door actuator travel Note that the hopper door opens automatically to receive the dirt and debris from the brooms when the hopper is in the operating position and the sweep system is enabled Once the sweep system is switched off the hopper door closes An interlock prevents the hopper door from being opened manually if the hopper is down The hopper interlock proximity sensor signals the Al Main Machine Controller when the hopper is closed Service Manual CS7000 Hopper System Wiring Diagram Hopper System 237 Battery F1 36V RED RED I BLK Fuse 400 A A1 Main Machine Controller A3 Control Panel ORN 40 44 42V Alternator al z CAN J7 11 B O S14 B
154. nd troubleshooting of engine starting or running problems See the Kubota WG972 E3 Workshop Manual 9Y111 05710 for detailed information related to the complete mechanical engine Functional Description Kubota WG972 GL E3 NFK 1 Petrol Gasoline The Kubota WG972 is a three cylinder liquid cooled naturally aspirated engine The fuel system does not utilize a control module It is mechanically controlled The ignition system is self contained That is it has no interaction with the fuel system and shares no components with it The fuel system begins with a petrol gasoline fuel tank which is horizontally mounted on the right side of the engine compartment The tank swings out to provide easier access to the engine compartment An electric fuel pump is mounted to the top of the tank The tank contains a fuel level sending unit The carburetor has an additional fuel shut off solenoid that must be energized for petrol to flow through the carburetor to the engine l Gasoline Petrol Fuel Tank Carburetor The engine RPM is controlled with a Woodward L Series governor speed actuator based on requests from the main machine controller The main machine controller sends signals to the Woodward L Series governor speed actuator to request one of three engine speeds based on operator request or cleaning mode The actuator has a built in microprocessor which receives the requests and in turn physically moves the carbure
155. nect orange lead to positive and red lead to negative Special Tools A spring puller is recommended to remove the Extension Springs from the Squeegee Support Assembly and Squeegee Lift Arm when removing these components There are several types of spring pullers a typical example is shown here Nilfisk Advance Service Manual CS7000 339 Steering System Functional Description Summary The steering system utilizes steer by wire technology The major electrical components are the Steering Controller Steering Wheel Rotation Sensor Steering Actuator and the Steering Travel Limit Switches The Steering Controller receives input signals from the Steering Wheel Rotation sensor that tell it which direction the steering wheel is turning and how fast it is rotating Based on these inputs the Steering Controller drives the Steering Actuator Motor with a three phase alternating current to rotate a gear The gear 1s meshed to a large ring gear that rotates the drive wheel assembly either right or left The Steering Controller also monitors two travel limit switches proximity switches that signal when the drive wheel has steered to 1s maximum desired angle in either direction 1 a oO a L A i Proximity Sensor Travel Steering Controller Steering Wheel Steering Actuator Limit Switch Rotation Sensor Steering Wheel Rotation Sensor The Steering Wheel Rotation Sensor has an internal en
156. nect the vacuum hose from the Rear Squeegee Assembly 4 Squeegee r Support 3 Loosen the two Knobs on the Squeegee a Assembly Clips and pull the Rear Squeegee Assembly away from the Squeegee Support Assembly A Note The Squeegee Blades have four usable edges and can be rotated end for end or top to bottom reine to position a new blade surface on the floor To Remove and Reinstall the Front Squeegee Blade 1 Release the Push Pull Clamp and remove the Weldment Strap Squeegee Weldment 2 Remove the Front Squeegee Blade from Front Squeegee the Squeegee Weldment Blade 3 Rotate the existing Front Squeegee Blade top to bottom or end for end to position a new blade surface on the floor or install a new Front Squeegee Blade onto the Squeegee Weldment pins 4 Reinstall the Weldment Strap then secure the Push Pull Clamp Weldment Strap Push Pull Clamp SEA Squeegee Squeegee Clip 2 Assembly 331 Service Manual CS7000 Squeegee System 332 To Remove and Reinstall the Rear Squeegee Blade 1 Release the Latch and remove the Squeegee Strap rap 2 Remove the Rear Squeegee Blade from the Squeegee s Rear Weldment B 3 Rotate the existing Rear Squeegee Blade top to bottom or end for end to position a new blade surface on the floor 5 queegee or install a new Rear Squeegee Blade onto the Squeegee Weldment pins Squeegee Weldment 4 Reinstall the Squeegee St
157. ngthen or shorten the Brake Rod Note that lengthening the Brake Rod will apply more pressure to the brakes with comparable brake pedal travel d When the brake is adjusted correctly tighten the Locknut then reinstall the Rod End onto the Brake Lever e Reinstall the wheel Troubleshooting The wheels are The wheel bearings worn Check the wheel wheel bearings and brake and making excess noise The wheel and or brake spindle assembly and replace as required and spindle assembly are damaged The brakes are not The brakes are out of Adjust the brakes working correctly adjustment The brake linings are worn Replace the brake linings out Removal and Installation Warning Before performing any maintenance or adjustments make sure the key switch is off and the key is removed from the machine Chock the machine wheels to prevent the machine from moving 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 To Remove and Reinstall a Wheel 1 Jack up the machine at a designated jacking point 2 Install safety stands or blocks to support the machine while you work on it Service Manual CS7000 Remove the Grease Cap Remove the Cotter Pin Slotted Nut and washer Remove the Wheel from the Brake and Spindle Assembly Reinstall the Wheel by following the above steps 1n reverse order To
158. nstall the Wave Washer Make sure the bottom edges of the Wave Washer contact the outside bearing P Wave race as shown m A Washer Reinstall the end casting in stages as follows a Reinstall the end casting with brushes far enough into the frame so the brushes will contact the commutator when the temporary retaining wires are removed then remove the retaining wires b Press the end casting into the frame leaving about a 1 8 gap between the frame and end casting Make sure to align the witness marks on the end casting and frame as noted in step 3 c Reinstall the threaded rods lock washers and hex nuts but don t tighten the hex nuts yet Service Manual CS7000 d Carefully install a new Gasket between the Frame and the End Casting Make sure the Gasket is seated flat on the mating surfaces e Once the Gasket is installed fully seat the End Casting onto the Frame f Tighten the hex nuts 13 Reinstall the terminals and top terminal nuts then reinstall the terminal cover and acorn nuts 14 Seal the retaining wire holes in the end cover with silicone sealant Specifications Scrub System 301 F a a SE ae d ao a 3 aa E _ i pa E ol ai j z z z i i 7 N i 2 7 N pi 5 Scrub Brush Motors all 35 VDC 1 HP 2750 RPM 26 Amp Scrub Brush Motor Current Draw shop Center measurements Scrub Brush Motor Left Current Draw shop m
159. nt Hopper Lift Boat Weldment a e Side Broom Actuator 8 Usea long needle nose pliers to remove the Hair Cotter Pin then slide Ay the Side Broom Actuator off of the pin on the side broom lift weldment and remove it from the machine Hair E Cotter y Pin 9 Reinstall the Side Broom Actuator by following the above steps in reverse order E Note Be careful not to rotate N A fa Drive are the Drive Nut Cylinder on w Nut the Side Broom Actuator d Cylinder when it s disconnected from the machine This can change the extended and retracted positions of the Side Broom Actuator and the subsequent extended and retracted positions of the side brooms Adjustment Cover Service Manual CS7000 Sweep System Side Broom 391 existing Side Broom Actuator has been rotated on the Acme threaded shaft check the Service Note If youre installing a new Side Broom Actuator or if the Drive Nut Cylinder on the wits as actuator extended and retracted dimensions and set as follows 1 Reconnect the side broom actuator electrical connector 2 Install the Drive Nut Cylinder onto the drive screw threads just a few turns 3 Hold on to the drive nut cylinder to keep it from rotating then retract the side broom actuator using the Service Mode until the motor stops 4 Check the retracted position dimension as shown in the adjacent drawing 5 Adjust the retracted posi
160. o the bottom of the fill plug with 80W90 gear oil 56510411 If you want to change the oil there is a drain plug at the bottom of the gear box _ Drain Plug nan Service Manual CS7000 Wheel System Traction Troubleshooting Fault Codes The drive controller has very robust fault code capabilities Since most problems will result in setting a fault code whenever there is a problem with the drive system the first thing you should do is check for fault codes There are three different ways to retrieve fault codes l Counting the drive controller status LED flash code Status LEDs a Use the 1311 programmer a The pair of LEDs built into the controller one red one yellow produce flash codes displaying all the currently set faults in a repeating cycle Each code consists of two digits The red LED flashes once to indicate that the first digit of the code will follow the yellow LED then flashes the appropriate number of times for the first digit The red LED flashes twice to indicate that the second digit of the code will follow the yellow LED flashes the appropriate number of times for the second digit The numerical codes used by the yellow LED are listed in the troubleshooting chart which also lists possible fault causes and describes the conditions that set and clear each fault 1311 Programmer Serial Port Connector The 1311 programmer will display all faults that are currently set as well
161. ode Display Effect Of Fault Controller Severe Overtemp ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle FullBrake ShutdownPump Severe Overvoltage ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle FullBrake ShutdownPump 17 Severe Undervoltage Reduced drive torque 22 Controller Overtemp Cutback Reduced drive and brake torque Possible Cause s Temperature information is not accurate Controller is operating in an extreme environment Excessive load on vehicle Improper mounting of controller Battery Menu parameters are misadjusted Non controller system drain on battery Battery resistance too high Battery disconnected while driving See Monitor menu Battery Capacitor Voltage Blown B fuse or main contactor did not close Battery menu parameters are misadjusted Battery resistance too high for given regen current Battery disconnected while regen braking See Monitor menu Controller Temperature Controller is performance limited at this temperature Controller is operating in an extreme environment Excessive load on vehicle Improper mounting of controller Set Clear Conditions Set Heatsink temperature above 95 C 2038 F Clear Bring heatsink temperature below 95 C 203 F and cycle interlock or KSI Set Capacitor bank voltage dropped below the Severe Undervoltage limit with F
162. on System 312 EcoFlex Detergent Bottles and Pumps The EcoFlex Detergent Bottles are located underneath the Operator seat and supply detergent to the two EcoFlex Detergent Dotercent Pumps The two EcoFlex Detergent Pumps Pump 2 run simultaneously and pump detergent through separate lines that merge into one main detergent supply line The detergent h supply line 1s plumbed into the solution EcoFlex supply upstream of the solution solenoid Detergent valve A Bottle 2 im EcoFlex High pressure Spray System Pump The High pressure Pump is driven by an Electric Clutch run by a Pulley off of the engine The Electric Clutch is engaged and drives the High pressure Pump when the Operator presses the high pressure wand switch on the control panel f x High PESES A pressure N Pump x SN EA urey coment Electric Clutch Toar am Service Manual CS7000 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 Ifthe trigger valve on the High pressure Wand is open the solution flows through the Hose Coupler and to the attached High pressure Wand Ifthe trigger valve on the High pressure Wand is closed the Relief Valve directs the solution into the Solution Return Line and back into the Solution Tank Note that the Relie
163. only This is set at 80 of the total speed potential The user can override the scrubbing mode by pressing the speed switch 3 Hopper Up This is set at 50 of the total speed potential for safety reasons The following table explains what conditions dictate the speed mode which is used Battery Model Speed Mode Hybrid Models Speed Mode Hopper Up Hopper Up E _ Up Hopper Down Not Scrubbing Transport Hopper Down Scrubbing No Scrubbing Transport Override Hopper Down Scrubbing Transport Transport Override The main machine controller also communicates a special Push Mode request to the drive controller via the CAN Bus when initiated by the user Normally the drive motor locks the drive wheel to prevent it from rotating when in the neutral position The push mode allows the drive wheel to turn without resistance while still allowing steering operation making it easier to tow the machine To request the push mode turn the key switch on while pressing and holding both the speed switch and the high pressure wand switch Press and hold while turning key switch on to enter Push Mode Hand Held Programmer The drive controller can communicate with a hand held programmer The controller provides power for the programmer by sending 12v out of pin J4 25 to the serial port connection pin 4 The transmit wire runs between controller pin J4 28 and serial port connection pin 3 The receive wire runs betwee
164. ontactor K9 must be closed to provide positive voltage to circuit breakers VACC1 CB1 and VACC2 CB2 Circuit breaker VACC1 CB1 must be closed to provide positive voltage to Solution Valve L1 Circuit breaker VACC2 CB2 must closed to provide positive voltage to the Left Brush Motor Contactor K1 the Center Brush Motor Contactor K2 and the Right Brush Motor Contactor K3 The J2 25 J2 26 and J2 27 Outputs on the A1 Main Machine Controller must provide ground to the Left Brush Motor Contactor K1 coil the Center Brush Motor Contactor K2 coil and the Right Brush Motor Contactor K3 coil respectively The J2 25 J2 26 and J2 27 Outputs provide a ground under the following conditions The A1 Main Machine Controller must receive a signal from the A3 Control Panel via the CAN BUS that the operator has pressed the scrub switch The A1 Main Machine Controller must receive a signal from the A2 Drive Controller via the CAN BUS that the machine is moving forward or reverse The 150 amp Fuse F2 must be closed to provide positive voltage from the Battery to the load side of Contactors K1 K2 and K3 The Brush Motors M2 M3 and M4 must have connections to battery ground B Scrub Deck Actuator Motor The J2 10 and J2 11 PWM Outputs from the A1 Main Machine Controller provide voltage to the Scrub Deck Actuator Motor M11 The output polarity determines whether the Scrub Deck Actuator Motor lowers or raises the scrub deck When the Retract Limit Switc
165. ontroller Measurements Pin Letter Wire Color on Circuit Voltage with key on machine unplugged E BLU Crank Position Ov Sensor F BLK Ground And other 0 004v leg of Crank sensor fe Rea Power Supply fy m nosa O 1 Notused S S Governor Control System Woodward L Series Actuator Measurements Pin Wire Color Circuit Description Connector Connector Unplugged Plugged In Noasa oo Noras Oo o NotUsea m CLR Engine RPM Sensor 2 Noted an CLR 6 8 CE 10 u 12 RPM Sensor Output measured at the actuator Pin 3 and 11 with the connector plugged in 0 68v AC when cranking 2 138v AC when running Engine RPM sensor resistance 2 07 K ohms Service Manual Haram Captor Il Engine System Petrol Gasoline 234 Fuel System Fuel Pressure 3 5 4 0 PSI 24 27 Kpa Fuel volume 0 5L in 15 seconds Carburetor Fuel Shut off Solenoid resistance 38 ohms Electric Choke Solenoid resistance 2 5 ohms Engine Engine Vacuum at idle approx 17 5 inches HG 59 Kpa When returning from low RPM to idle vacuum momentarily peaks around 21 HG Engine Compression Cyl 1 170 PSI Cyl 2 170 PSI Cyl 3 170 PSI Service Manual Haram Captor Il Engine System Petrol Gasoline 235 Special Tools Adjustable KV Spark Tester Most automotive parts suppliers sell these tools Shown is 50850 from Lisle corporation http www lislecorp com KV Scale Nilfisk Adva
166. or controller calculated actuator motor position indicates the mechanism Controller Configuration is beyond a steering travel limit switch position but the switch has not indicated that the end has been Steering Limit Switch wiring reached The steering controller believes that the physical position of the steered wheel is beyond the soft limit that should have been indicated by the steering travel limit switch closing This error also occurs when a steering travel limit switch closes indicating that the limit of travel has been reached but the controller calculated position indicates that the mechanism should not be near the limit of travel 24 Steering Limit Switches 25 Position sensor This error occurs when the steering Excessive backlash in steering gears controller calculated actuator motor position indicates the mechanism Controller Configuration is beyond a steering travel limit switch position but the switch has not indicated that the end has been Steering Limit Switch wiring reached The steering controller believes that the physical position of the steered wheel is beyond the soft limit that should have been indicated by the steering travel limit switch closing This error also occurs when a steering travel limit switch closes indicating that the limit of travel has been reached but the controller calculated position indicates that the mechanism should not be near the limit of travel
167. or Characterization Fault ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle FullBrake ShutdownPump Troubleshooting Chart Possible Cause s Motor characterization failed during characterization process See Monitor menu Controller Motor Characterization Error for cause O none 1 encoder signal seen but step size not determined set Encoder Step Size manually 2 motor temp sensor fault 3 motor temp hot cutback fault 4 controller overtemp cutback fault 5 controller undertemp cutback fault 6 undervoltage cutback fault 7 severe overvoltage fault 8 encoder signal not seen or one both channels missing 9 motor parameters out of characterization range The Motor_Type parameter value is out of range The VCL software in the controller does not match the OS software in the controller Vehicle movement sensed after the EM Brake has been commanded to set EM Brake will not hold the motor from rotating Set Clear Conditions Set Motor characterization failed during the motor characterization process Clear Correct fault cycle KSI Set Motor_Type parameter is set to an illegal value Clear Set Motor_Type to correct value and cycle KSI Set VCL and OS software do not match when KSI cycles a check is made to verify that they match and a fault is issued when they do not Clear Download the correct VCL and OS software into the controller Set After the EM Br
168. ormation provides some real world shop measurements to help you recognize what normal looks like Engine RPM Sensor Resistance 2 2K ohms Output while cranking Unplugged 3 0 5 0 VAC Output at idle Connected 10 8 VAC Actuator Resistance 3 0 Ohms Service Manual CS7000 Engine System Diesel 180 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 Starter 168 Amps cranking Glow Plug Relay Winding 46 Ohms Service Manual CS7000 Engine System Diesel 181 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 Nilfisk Advance Service Manual CS7000 182 Engine System LPG 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 See the Kubota WG97
169. osite directions Two contactors K11 and K12 are used to operate the pump Each contactor has two sets of contacts one that is closed when at rest normally closed and one that is open normally open when at rest Hopper at Rest When the hopper is at rest the normally closed contacts of each contactor connect both sides of the hopper hydraulic pump motor to Key switch a battery negative Since there is no difference in electrical pressure voltage across the pump no current flows and the pump remains Off Hopper Hydraulic Pump Motor K11 K12 At rest At rest Main Machine Controller Hopper Being Raised 7 E When the operator pushes the button to raise the hopper the main machine controller energizes the K11 contactor by grounding the lt ey switch Oe control winding of the contactor This causes a magnetic field to pull the normally closed contacts open and at the same time closes Cm the normally open contacts Battery voltage Tae is now applied through the closed set of K11 di a a eae contacts to one side of the pump The other side of the pump is connected to battery negative through the normally closed contacts K11 of the K12 contactor This completes the Selaa circuit and causes the pump to run in the Up direction Hopper UP Main Machine Controller Control Circuit Load Circuit 238 Service Manual
170. ota LPG Engine The engine RPM is controlled with a Woodward L Series governor speed actuator based on requests from the main machine controller The main machine controller sends signals to the Woodward L Series governor speed actuator to request one of three engine speeds based on operator request or cleaning mode The actuator has a built in microprocessor which receives the requests and in turn physically moves the carburetor mixer throttle blade to achieve the requested engine speed The cooling system consists of a standard radiator and belt driven fan Note that the fan pushes air away from the engine and out through the radiator Service Manual CS7000 Engine System LPG 183 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 u A Crank Position Sensor Toothed Ring and flywheel Ignition Coils The heart of the system is the spark control module It controls the current flow of each ignition coil primary circuit in order to control when spark occurs based on inputs from the crank position sensor Each coil fires twice per cylinder cycle Once to initiate the power stroke and once in exhaust stroke waste spark The crank sensor is a two wire AC pulse generator I
171. otentiometer R4 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 the Main Broom 1 Make sure the main broom is in the raised position 2 Lift up the Latch and swing open the Broom Door Service Manual CS7000 Sweep System Main 3 Move the Dust Flap out of the way and swing open the Broom Arm Assembly 4 Pull the Main Broom out of the machine To Install the Main Broom 1 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 2 Close the Broom Arm Assembly hg E i making sure the Main Broom engages DEA Arm Assembly E the Hub on the Broom Arm Assembly e t t 3 Move the Dust Flap back into position then close and latch the Broom Door 4 Check and adjust the broom Arm Stop on the Broom Door as necessary The Arm Stop should be adjusted to prevent the Broom Arm from moving outward while still allowing the door to latch easily Adjustment l Arm Stop contact area gr yt 7 ro m s f j pom ud Arm Stop po b s v i Zi 5 4 s ane y Remove and Ww relocate to adjust f Note Make sure you adjust the main broom height when installing a new broom Failure to do so will reduce the life of
172. oth of the detergent Check for voltage at the pumps pumps are not operating correctly e If there is voltage at a pump replace the pump e If there is no voltage at a pump 1 Check the wiring from J2 19 and J2 7 and J2 32 and J2 21 to the pumps 2 Check the J2 19 J2 7 J2 32 and J2 21 outputs from A1 Main Machine Controller The hot water system The solution is not circulating Check the solution hoses to and from the heat is not operating through the heat exchanger exchanger and repair replace as necessary Service Manual CS7000 Solution System 319 Problem Cause Correction The high pressure The high pressure wand Press the high pressure wand switch to engage the spray system is not switch on the control panel high pressure solution pump operating has not been pressed The high pressure wash Install the high pressure wash function in the function is not installed in the configuration menu configuration menu The solution filter screen is Clean the solution filter screen plugged The high pressure pump Check that the belt on the engine pulley is driving the clutch is not engaging clutch pulley Adjust the belt tension or replace the belt as necessary Check the connection from the clutch to battery ground and repair as necessary Check the output from J3 9 on A1 Main Machine Controller If there is voltage from J3 9 to the clutch replace the clutch The relief valve is not Replace the
173. output from A1 Main Machine Controller Service Manual CS7000 Solution System 318 Problem Cause Correction Inadequate solution The extended scrub function Install the extended scrub function in the configuration flow to the brushes in is not installed in the menu the extended scrub configuration menu mode The stainer in the recovery Remove and clean the strainer tank is dirty or plugged The extended scrub level The switch should be closed when in the lowermost float switch S4 is not position tank empty and open when in the uppermost providing a ground to J7 15 position tank full Input on A1 Main Machine Controller If the continuity through the switch in its upper and lower positions is not correct 1 Check the wiring and repair as necessary 2 Ifthe wiring is OK replace the switch The extended scrub pump Check for voltage at the pump M25 is not operating correctly e If there is voltage at the pump replace the pump e If there is no voltage at the pump 1 Check the wiring and circuit breakers upstream of the pump Check the J3 1 output from A1 Main Machine Controller No detergent flow to The detergent and EcoFlex Install both the detergent and EcoFlex functions in the solution system functions are not installed in the configuration menu the configuration menu The detergent supply lines are Check the detergent lines and clean replace as clogged necessary One or b
174. p Motor Contactor K12 The Ignition Switch 14 must be closed to provide positive voltage to the Auxiliary Contactor K9 coil The J2 14 Output on the A1 Main Machine Controller provides ground to the Auxiliary Contactor K9 coil when the Ignition Switch S14 provides an input to the Key Switch Input J7 12 e The Auxiliary Contactor K9 must be closed to provide positive voltage to circuit breaker VACC1 CB1 The Hydraulic Pump Motor circuit breaker CB8 must closed to provide positive voltage to the load side of the Hydraulic Pump Motor Contactors K11 and K12 The load side of the Hydraulic Pump Motor Contactors K11 and K12 must be connected to battery ground e The J2 28 and J2 24 Outputs must provide negative ground to the Hydraulic Pump Motor Contactor coils K11 and K12 respectively when the A1 Main Machine Controller receives a signal from the A3 Control Panel via the CAN BUS that the operator has pressed the hopper raise or hopper lower button 239 Service Manual CS7000 Hopper System 240 The Following Conditions Must Be Met for the Hopper Door Open and Close There must be positive voltage to the J7 1 Interlock Input For this to happen The Seat Switch S9 must be closed The Safety Relay K14 on the Steer By Wire Controller A5 must energize the coil to close the Safety Relay K14 contactor The Emergency Stop Switch S15 must be closed The Battery Interlock 13 must be closed battery machines or jumpered Dies
175. p and the hoses and attach the hoses to the pump assembly a Lower cylinder hose to up port on pump b Upper cylinder hose to down port on pump Service Manual CS7000 Hopper System 249 14 Run the hopper to the full up position and make sure the oil level is at the minimum mark on the reservoir To Remove and Reinstall the Hopper Lift Cylinder 1 Raise the hopper to a convenient working height 2 Support the hopper with a hoist to prevent it from falling once the hopper lift cylinder is disconnected is disconnected or removed The hopper prop rod cannot be used to support the A Warning The hopper must be adequately supported with a hoist before the hopper lift cylinder hopper when the hopper lift cylinder is disconnected or removed 3 Place a suitable container under the hopper lift cylinder to catch any hydraulic oil that may leak from the cylinder and hoses 4 Loosen and disconnect the hoses from the cylinder Plug the hoses to prevent dirt and air from entering the hoses 5 Plug the hopper lift cylinder ports to prevent oil from leaking out and to prevent dirt and air from entering the cylinder 6 Remove the 1 4 20 Screw holding the Hinge Pin Weldment then remove the Hinge Pin Weldment oH 1 4 20 Screw Service Manual CS7000 Hopper System 250 7 There are two External Retaining Rings holding the Cylinder Pin in position To remove the Cylinder Pin remove the External R
176. pply from steering controller to both encoder pairs B supply for both encoders through the steering controller Can Bus Wiring Controller termination resistor Note The steering controller does not require any CAN bus messages to operate the steering system Controller Electrical Connections Controller Controller Electrical Connections Controller Controller Electrical Connections Controller Steering Wheel Rotation Sensor Torque Feedback Device Shorted winding Short to B on TFD control circuit Service Manual CS7000 Steering System AC Current Excessive 14 Position calibration error Steering Actuator Encoder Circuits Current regulator supervision Position regulator supervision The software detected excessive current flow in the steering actuator motor circuits The Center Position has not been able to be established Not properly calibrated to right and left travel limit switches This error occurs when the steering controller calculated actuator motor position indicates the mechanism is beyond a steering travel limit switch position but the switch has not indicated that the end has been reached The steering controller believes that the physical position of the steered wheel is beyond the soft limit that should have been indicated by the steering travel limit switch closing This error also occurs when a steering travel limit switch closes indicating t
177. proportional to the solution level An icon on the LCD display indicates the solution level in the tank If the solution level has been low longer than 10 seconds the LCD display will show the solution level low caution icon The conditions under which the solution level low icon is displayed depend on the state of the extended scrub system as follows e With the extended scrub system off Ifthe clean solution is low the solution level low icon will be displayed Ifthe clean solution is not low the solution level low icon will not be displayed e With the extended scrub system on Ifthe extended scrub solution level in the recovery tank is not low the solution level low icon will not be displayed Ifthe extended scrub solution level is low but the clean solution level is not low the solution level low icon will not be displayed If both the extended scrub and clean solution levels are low the solution level low icon will be displayed 305 Service Manual CS7000 Solution System Wiring Diagram Battery F1 36V RED RED Fit BLK Fuse 400A ORN 42V Alternator a O S14 3 VIO GRN Bt h23 B YEL BRN 3 g 4 BLK ORN K9 Aux Contactor YEL BRN Ignition Switch ORN Fe S9 K14 S15 13 ORN GRA ORN PINK TAN GRN BLU J7 1 Interlock t 2 6 4 T 1 2 Seat Switch Safety Switch Emergency Battery Relay signal from Stop Switch Interlock A5 Steer by Wire Controller VACC3 K9 CB3 RED BLU GRN a 5
178. protect itself and disable the steering system if necessary When a serious error is detected the controller sets a DTC Diagnostic Trouble Code and communicates the code to the main machine controller via the CAN bus The main machine controller will set a machine level code of 50 and tell the control panel to display it to the operator Machine code 50 means that there is a DTC set in the steering system In order to get the specific steering system DTC enter the hidden menu configuration display function To retrieve steering system codes from the hidden menu 1 Press and hold the hazard warning flasher button down while turning on the key Wait until the Configuration Display screen appears then release the button 2 Press and release the scrub pressure decrease button several times until the cursor arrow is pointing at 15 Fault Recall then press the scrub button to enter the fault recall menu 3 Press the scrub pressure decrease button to scroll down to 2 Steering Faults then press the scrub button Service Manual CS7000 ge Steering System 349 The Steering faults menu displays all of the codes that have ever been set in the system The codes are displayed in reading order separated by commas and are sorted with the most recent at the top left See the Diagnostic Trouble Code Table below to look up what the code means n To exit press the solution button Dia
179. provided to the common contact at pin 3 of the high coolant temp shutdown relay and the common contact at pin 3 of the control relay Since there is no oil pressure the oil pressure switch is closed causing the Low oil pressure shutdown relay to be energized This prevents power from being passed to the engine run input into the main machine controller The high coolant temp shutdown relay coil is also grounded through the closed oil pressure switch causing it to be energized This prevents power from being passed to the fuel lock off solenoid IGNITION POWER IGNITION REQUEST FOR IGNITER amp l 1 ALTERNATOR a af RUN ENABLE SIGNAL WOODWARD L SERIES ACTUATOR HIGH CGOGLANWT EMP SHUTDOWN RELAY SHUTDOWN RELAY SPEED 2 12V OUTPUT SF ee a ee gt ENGINE RUN 12V INPUT HI GH COOLANT TEMP Signal TEMP SWITCH OIL SWITCH OPEN FOR OPEN FOR NORMAL TEMP PRESSURE izZv BATTERY STARTER Main Machine Controller Service Manual CS7000 Engine System LPG Cranking When the main machine controller sees the 36v cranking request from the key switch it sends out 12v on the crank request circuit to the crank request relay winding The other side of the winding is grounded through pin 9 of the actuator as long as there is not a shutdown condition within the L Series actuator This energizes the crank request relay and battery power is passed through the contacts to the starter so
180. ptor Il Engine System Petrol Gasoline 219 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 In the case of lost oil pressure the Woodward L series actuator disables the ignition system by de energizing the Ignition Request relay In the case of the engine overheating the high coolant temperature shut down relay shuts the engine off by removing power from the fuel pump causing the engine to run out of fuel and stall Engine Overheat Shutdown If the engine overheats the temperature switch closes This completes a path to ground for the high coolant temp shut down relay and energizes the relay This removes power from the fuel pump This does not shut the engine down immediately but allows the engine to use up the fuel in the carburetor float bowl before stalling due to lack of fuel The main machine controller monitors the engine coolant temperature by sending out a 5v feed through an internal resistor to the temperature switch When the switch closes the voltage on the switch side drops from 5v to Ov In response the main machine controller sets an overheat code and alerts the operator After a 5 second delay it removes the 12v Ignition request signal If the engine has not already shut down the syst
181. r Connector Unplugged Plugged In Noasa oo Noras Oo o NotUsea m CLR Engine RPM Sensor 2 Noted an CLR 6 8 CE 10 u 12 RPM Sensor Output measured at the actuator Pin 3 and 11 with the connector plugged in 0 68v AC when cranking 2 138v AC when running Engine RPM sensor resistance 2 07 K ohms Service Manual CS7000 Engine System LPG 208 Fuel System Carburetor LPG shut off solenoid resistance 27 3 ohms Fuel Lock Off Solenoid resistance 10 1 ohms Primary Pressure 4 6 PSI Engine Engine Vacuum at idle approx 14 5 15 HG When returning from low RPM to idle vacuum momentarily peaks around 21 HG Engine Compression Cyl 1 170 PSI Cyl 2 170 PSI Cyl 3 170 PSI Service Manual CS7000 Engine System LPG Special Tools LPG test gauge kit Part 56504450 LPG test port adapter Male 1 8 BSPT to Female 1 8 NPT Part 50360A us I 8 NPT ke Adjustable KV Spark Tester Most automotive parts suppliers sell these tools Shown is 50850 from Lisle corporation http www lislecorp com KV Scale Nilfisk Advance 209 Service Manual Haram Captor Il 210 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 a
182. r at the end opposite the gear box Take care not to loose the rubber O ring seal or the wave washer PS a New brush length is approximately 7 8 22 mm T Service Manual CS7000 Sweep System Main 371 8 Temporarily set the O ring seal aside 9 Install the wave washer Retain it with some grease if necessary 10 Reinstall the cover a Gently pry the carbon brushes back against their springs just far enough to slip them over the commutator a a b Gently slide the cover into place and align the witness marks made earlier 11 Reinstall the through bolts and tighten them until the end covers are nearly seated leaving enough room to install the O ring seal Install the O ring and then tighten the through bolts Leave room for O ring fee l G T PY L n E Prreertret reer errr i NN Apigptaptertna Install O ring 12 Reconnect the wiring and attach the wire cover 13 Reinstall the gearbox making sure to align the witness marks The weep hole must be facing the floor when the assembly is installed on the machine Note Weep Hole faces floor when installed Service Manual CS7000 Sweep System Main Troubleshooting function Refer to the Control System Service Mode section for information on how to enter pe Note You can use the Service Mode to toggle the various system components on and off to
183. r consistent arcing across the tester gap No crank The starter does not engage Possible causes e 86v battery pack drained preventing main machine controller from powering up e Engine Battery Starter e Battery to starter cable Engine Ground e No voltage to the starter solenoid Open circuit breaker CB9 Auxiliary Relay o Burned contacts or not energized Key Switch Main Machine Controller Woodward L Series Actuator Not supplying ground for crank request relay Crank request relay e Wiring Service Manual Haram Captor Il Engine System Petrol Gasoline 229 Cranks but does not start No Spark Possible causes Spark Control Module not powered up Ignition request relay Woodward L Series Actuator not energizing ignition request relay Spark control module ground e Crank Position Sensor e Spark Control Module e Wiring e Ignition Coils not likely that all 3 coils would fail at once Cranks but does not start has sufficient spark Possible causes No fuel Empty tank Fuel pump inoperative No electrical power to fuel pump o Ignition request fuse blown o High coolant temp shut down relay Closed at rest contacts not making connection o Open wire on positive or negative side of fuel pump No power to carburetor petrol fuel shut off solenoid e Mechanical engine Insufficient compression Plugged Intake Plugged Exhaust e Actuator
184. r directly monitors the engine speed sensor input and adjusts the throttle linkage to maintain the current target engine speed If it is unable to maintain the speed within the desired window it will shut the engine down by removing the path to battery negative for the ignition request relay through the actuator Note that if the actuator loses the RPM signal while the engine is running it will shut the engine down If the actuator never sees an RPM signal it does not know that the engine is running and has not tried but failed to control the RPM Therefore it remains in a cranking mode and does not shut the engine down The main machine controller communicates the desired engine speed mode to the actuator via the Throttle 1 and Throttle 2 wires It either sends out Ov or 12v on each wire depending on the desired speed mode Speed Mode Engine Speed Throttle 1 1700 RPM Oo 2500 RPN io 2700 RPN 120 Service Manual Haram Captor Il Engine System Petrol Gasoline 218 There are several conditions that will override the user s engine speed request e High pressure wash forces to run speed Ifthe engine is at idle speed the engine will be forced to the run speed when sweeping only or vacuuming only The force idle neutral time out will return the engine to idle speed Ifthe engine is at idle or run speed the engine will be forced to maximum power speed when scrubbing only or scrubbing and sweeping The force idle neu
185. rap then close the Latch Squeegee End Wheels Once a month apply light machine oil to the Squeegee End Wheels Squeegee Caster Wheel Bearings Once a month pump a small amount of grease into the Grease Fitting on both caster wheels on the squeegee support assembly until grease seeps out around the bearings Service Manual CS7000 Squeegee System 333 To Adjust the Squeegee Tilt 1 Lower the squeegee and drive the machine forward a short distance so the squeegee assumes its normal operating angle 2 Check the deflection angle of the Rear Squeegee Blade It should be approximately 45 degrees to the floor surface as shown Squeegee Blade The ends of the squeegee should deflect as shown while still making full contact with the floor 3 Ifthe Squeegee tilt angle needs to be adjusted a Lift the Crank Handle out of the i Yoke E b Rotate the Crank Handle to raise i ee 1 2 13 or lower the 1 2 13 Screw as meee D _ lt necessary so the squeegee blades are at the correct angle to the floor 4 When the squeegee tilt adjustment is correct replace the Crank Handle into the Yoke 4 Crank DPA Handle Service Manual CS7000 To Adjust the Squeegee Casters The height of the Squeegee Casters may need to be adjusted to compensate for squeegee wear and to obtain the correct squeegee tilt angle To adjust the height of a Squeegee Caster 1 Loosen th
186. re working underneath the hopper 7 Remove the two 3 8 16 Nyloc Nuts and remove the Reservoir Guard 8 Disconnect the pump electrical connector 9 Disconnect the hydraulic hoses from the pump 10 Remove the two hydraulic pump mounting bolts and remove the Hydraulic Power Pack assembly 11 Transfer fittings to the new Hydraulic ES F Ha Power Pack assembly and attach BS A mes N EA the assembly to the frame but do not x TEPA mn ie en ae connect the hoses yet The system has Reservoir Eh ae to be filled with oil n i Guard 12 Fill the reservoir with 10W 30 engine A b oil pe Note In the remaining steps it is important that the oil level always be maintained above the reine minimum mark on the reservoir 13 Plug the up port of the pump assembly It 1s labeled on the pump 14 Momentarily run the pump to get oil out of the down port by pressing the hopper down switch 15 Transfer the plug from the up port to the down port of the pump assembly 16 Momentarily run the pump to get oil out of the up port by pressing the hopper up switch 17 Remove all remaining plugs from the pump and the hoses and attach the hoses to the pump assembly a Lower cylinder port hose to up port on pump b Upper cylinder port hose to down port on pump 18 Run the hopper to the full up position and make sure the oil level is at the minimum mark on the reservoir Service Manual
187. ring Wheel Assembly section directly above 6 Remove steering wheel nut and washer 7 Remove steering wheel using a three jaw puller DO NOT hit the shaft with a hammer 8 Remove retaining nut spring and spring anchor hardware Service Manual CS7000 Steering System 356 9 Remove tilt lever pivot hardware on one side 11 Remove steering pivot nut and hardware on one side then on the other MnP p 4 Service Manual CS7000 Steering System 357 13 Remove the 4 nuts and screws securing the steering wheel rotation sensor then remove the sensor and shaft out of the weldment 15 Reassemble in the reverse order a Reassembly tip When installing the steering pivot hardware use a short bent wire hook along with an open end wrench to position and hold the nut Service Manual CS7000 Steering System 358 Steering Controller 1 Drain recovery tank 2 Turn machine off set the parking brake and disconnect the main power plug 3 Remove recovery tank a Tip tank out and let it rest on the retention cable b Disconnect the vacuum motor electrical connector If equipped with extended scrub also disconnect the additional electrical connector and hose connection c With a helper remove the retaining cable clip tip tank down and remove it 4 La
188. room Motor Assembly 1 Dump the hopper 2 Make sure the parking brake is engaged 3 Turn the key switch on and switch the machine to the Service Mode 4 Raise the hopper so the side brooms are at a convenient working height then support the hopper with jack stands or other suitable supports work on or underneath the hopper A Warning Always make sure the raised hopper is adequately supported before performing any 5 Extend the side brooms in the Service Mode to access the mounting hardware 6 Open the hopper door 7 Remove the side broom refer to the To Remove and Reinstall a Side Broom section 8 Disconnect the side broom motor electrical connector Note that you may need to cut the wire tie holding the wires to the motor 9 Remove the Phillips Screw and Nyloc Nut holding the Cable Assembly to the Arm on the Side Broom Lift Arm on Weldment Side Broom se a Cable Assembly Lift Weldment Service Manual CS7000 10 11 Note Removing the Side Broom oe Assembly is easier if one AN Broom Assembly carefully as you remove it from the 12 13 ae Service Note Use Loctite 242 vine blue on the 1 2 13 x 75 Hex Slightly loosen the 1 2 13 x 75 Hex Screw Note that this screw is threaded directly into the hopper lift weldment Remove the two 1 2 13 x 1 5 Hex Screws washers and Nyloc nuts Note that the washers and Nyloc nuts are located inside
189. rrection The solution system An interlock is not closed Before you start troubleshooting a specific system does not operate check to make sure e The emergency stop switch S15 on the Operator control panel is disengaged rotate clockwise e The safety relay from the steering system K14 is closed e The seat switch S9 is closed e The battery interlock proximity sensor S13 is closed e The Ai Main Machine Controller is receiving the appropriate signal from the A3 Control Panel via the CAN BUS Inadequate solution Inadequate solution level in Check the solution level flow to the brushes in tank the scrub mode The solution filter screen is Clean the solution filter screen plugged The solution shutoff valve is Clean or replace the solution shutoff valve plugged or inoperative The solution solenoid valve is Check the solution solenoid coil resistance It should plugged or not functioning measure 72 ohms 10 If the coil resistance is not within spec replace the solution solenoid valve The solution manifold solution Check and clean the manifold hoses solution nozzles hoses solution nozzles are as necessary plugged The solution control pump Check for voltage at the pump M19 is not operating EcoFlex machines only e If there is voltage at the pump replace the pump e If there is no voltage at the pump 1 Check the wiring and circuit breakers upstream of the pump Check the J3 2
190. ry positive and negative cables at the starter 7 Disconnect the engine wiring connectors 8 Remove the 4 motor mount fasteners Front Left Engine Mount Front engine mounting locations Shown with hopper up and engine being installed 9 Lift the assembly out of the chassis using a suitable hoist attached to the two engine lift points 10 Reassemble in reverse order Connect the battery negative cables last Service Manual CS7000 Engine System Diesel 178 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 decreases Engine Compression 541 to 597 psi 3 73 to 4 11 MPa with an allowable limit of 327 psi 2 26 MPa Difference among Cylinders 10 or less Engine Oil Capacity 1 5 US Gallons 5 7L Engine Oil Type Refer to the following table for the suitable American Petroleum Institute API classification of engine oil according to the engine type with internal EGR external EGR or non EGR and the Fuel Type Used Low Sulfur Ultra Low Sulfur or High Sulfur Fuels Fuel Type Engine oil classification API classification Engines with non EGR Engines with external EGR Engines with internal EGR High Sulfur Fuel CF 0 05 500 ppm lt If the CF 4 CG 4 CH 4 or Cl 4 engine Sulfur Content lt oil is used with a high
191. s are open replace the contactor Check the vacuum motor wiring and connections from contactor K5 to the motors and the ground connections from the motors to battery ground Repair as necessary Check the wiring and connections from the A1 Main Machine Controller to the vacuum current sensor and repair as necessary Check the 5V output from J7 24 and the ground output from J7 25 to the vacuum current sensor B3 from the A1 Main Machine Controller Check the input to J7 29 on the A1 Main Machine Controller from the vacuum current sensor If the output is not between 2 5 and 4 7 volts replace the vacuum current sensor Service Manual CS7000 Recovery System 281 Problem Cause Correction An individual vacuum No voltage to the Check the wiring and connections to the vacuum motor and motor will not run vacuum motor repair as necessary The motor is not If there is voltage to the vacuum motor replace the motor operating correctly Poor water pick up There is a vacuum e Make sure the squeegee hose is installed correctly in the leak between the recovery tank and on the squeegee weldment squeegee weldment and the recovery tank Check the squeegee hose for blockage damage or cracks and repair replace as necessary The squeegee is e Check the squeegee and clean repair as necessary plugged The squeegee e Flip the squeegee blade s around to position a new blade blade s is are worn surface on the floor out
192. s moved from the neutral position The operator can enable and disable the Side Brooms independent of the main sweep system Service Manual CS7000 Side Broom System Wiring Diagram RED F1 RED J2 15 Output Contactor Side Broom Motor VIO CB7 K8 4 X O VIO GRA 1 2 Contactor Side Broom WHT RED WHT RED RED FROM F1 J3 17 Outpu Sweep System Side Broom 380 Fuse 400 A A1 Main Machine Controller A3 Control Panel ORN 42V Alternator 37 10 12y WETS z CAN J7 11 B S14 i aa R BOS Jara CAN n orn K Bi h23 J7 19 Start Input v B YEL BRN 3 g 4 BLK ORN J2 14 Output K9 4 Aux Contactor GRN YEL YEL BRN J7 12 Supression Ignition Switch Diode ORN J7 13 Key Switch Chassis Ground Fe Input s9 K14 S15 13 S ORN GRA ORN PINK TAN GRN BLU J7 1 Interlock Fe 1 a a N 2 Input s3 Seat Switch Safety Switch Emergency Battery J7 14 RED BLK BLK Relay signal from Stop Switch Interlock Input A5 Steer by Hopper Wire Controller Interlock Switch Ground BLK Contactor Aux VACC3 e BLK K9 CB3 J3 16 BLU GRN A GRA BLK J3 34 Input Isat 125 Amp 2 Vacc 3a J3 19 pe J3 21 BLK J3 29 BLK K8 VIO 3 BRN BLK Side Broom Actuator Motor to red to extend M13 GRA VIO RED BLK J3 5 Output GRN ORN BLK Right Side Broom Motor Left Side Broom Motor Service Manual CS7000 Sweep System Side Broom 381 Circuit Description The Following Conditions Must be Met for the
193. scrub and EcoF lex switches e The A1 Main Machine Controller must receive a signal from the A2 Drive Controller via the CAN BUS that the machine is moving forward or reverse The Following Conditions Must be Met for the High pressure Spray System to Operate The high pressure wash system must be installed in the configuration menu The J3 8 Output provides positive voltage to the High Pressure Pump Clutch under the following conditions The A1 Main Machine Controller must receive a signal from the A3 Control Panel via the CAN BUS that the scrub and detergent systems are enabled The A1 Main Machine Controller must receive a signal from the A2 Drive Controller via the CAN BUS that the machine is in Neutral and NOT moving forward or reverse The feature is disables when the machine is moving The High Pressure Pump Clutch must be connected to battery negative Service Manual CS7000 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 Solution Filter and Solution Shutoff Valve The Solution Filter and Solution Shutoff Valve are mounted underneath the rear right hand side of the solution tank r Solution The Solution Filter prevents any dirt or Shutoff Valve particulates that may be in the solution Solent tank from entering the solution cosd solenoid valve
194. slowly GRA ORN Application Config J5 13 WHT BLU Right Travel Limit Switch 0 002v when not at limit 38 19v when at right limit Jsa i Notused S o J5 16 PINK Motor Temp Sensor 0 564v at room temperature 3 0v with sensor unplugged J5 17 BLU Steering Wheel Sensor Encoder A2 4 8v or 0 10v switches high and low as steering wheel is moved slowly J5 18 VIO Safety Relay Control 38 2v at initial key on 0 015v when relay is energized J5 19 ORN RED Left Travel Limit Switch 0 008v when not at limit 38 2v when at left limit J5 20 GRN BLK Steering Wheel Sensor Encoder B2 4 8v or 0 10v switches high and low as steering wheel is moved slowly Jeet Notused o o 22 newsa J523 Service Manual CS7000 Motor U V and W Terminal Pair Voltages e Uto V 1 9 VAC with stationary motor Up to 18 VAC when motor is turning quickly Vto W 1 9 VAC with stationary motor Up to 18 VAC when motor is turning quickly e W to U 1 9 VAC with stationary motor Up to 18 VAC when motor is turning quickly Motor U V and W Terminal Pair Frequency e Uto V 16 20 HZ with stationary motor Up to 250 HZ when motor is turning quickly gt Vto W 16 20 HZ with stationary motor Up to 250 HZ when motor is turning quickly e W to U 16 20 HZ with stationary motor Up to 250 HZ when motor is turning quickly System Current Draw Measured with amp clamp around battery positive feed to steering controller e Approximately 4 5 amps wh
195. ssembly is attached to the machine frame by a pivoting Rod End This allows the rear of the Squeegee Support Assembly and attached squeegee to tilt up and down and pivot side to side to conform to the floor surface The two Squeegee Casters support Squeegee Support the Squeegee Support Assembly on the floor Assembly Squeegee Lift Arm The rear of the Squeegee Support Assembly rests on and is supported by the Squeegee A Lift Arm The pivoting Front Brackets on wee Extension the Squeegee Lift Arm are attached to the i Spring 1a machine frame The Squeegee Lift Actuator raises and lowers the rear of the Squeegee Lift Arm which pivots up and down to raise and lower the Squeegee Support Assembly and the attached Rear Squeegee Assembly The Squeegee Support Assembly and Rear Squeegee Assembly swing left to right to allow the Rear Squeegee Assembly to pick up water on the inside of the corner when machine is turning The Extension Springs Squeegee re center the Squeegee Support Assembly Assembly and Rear Squeegee Assembly once the Ze machine is again moving in a straight line Service Manual CS7000 Squeegee System Maintenance and Adjustments Warning Before performing any squeegee maintenance or adjustments make sure the key switch is off the key is removed from the machine and the parking brake is engaged To Remove and Reinstall the Squeegee Blades 1 Raise the squeegee to its retracted position 2 Discon
196. stinguish the cylinders from one another This allows it to fire the right ignition coil at the right time Below is what the crank sensor wave form looks like on an oscilloscope Notice that every sixth pattern is wide Service Manual Haram Captor Il Engine System Petrol Gasoline 212 The spark control module is fed power on pin G from the Ignition Request relay Pin F is connected to eround The two wires form the crank position sensor are connected to pins E and F All three ignition coils are fed the same power from the ignition request relay The 12v power supply flows through each coil primary circuit to the spark control unit The spark control unit supplies a switched ground for each of the ignition coil primary windings When it supplies a ground current flows through the coil primary winding and builds up a magnetic field around the coil When the ground is released the current stops flowing abruptly and the magnetic field collapses The collapsing magnetic field induces a high voltage in the ignition coil secondary winding which produces a spark across the gap of the spark plug and ignites the air fuel mixture ISNITER Spark Control Module ASSY GRN BLU gt J Yo oe a M i gt zZ Z x Q T T COIL GE 2 COIL 1 12v from Ignition Request Relay Crank Position Sensor Service Manual Haram Captor Il Engine System Petrol Gasoline 213 Engine Starter and Carb
197. t has a wire coil inside of it As the toothed ring rotates the teeth pass in line with the end of the sensor tip This induces a voltage spike that the spark control module can read as cylinder position information The number of spikes per minute is translated as engine RPM One tooth on the ring is wider than the other five This creates a unique spike so that the spark control module can distinguish the cylinders from one another This allows it to fire the right ignition coil at the right time Below is what the crank sensor wave form looks like on an oscilloscope Notice that every sixth pattern is wide Service Manual CS7000 Engine System LPG 184 The spark control module is fed power on pin G from the Ignition Request relay Pin F is connected to eround The two wires form the crank position sensor are connected to pins E and F All three ignition coils are fed the same power from the ignition request relay The 12v power supply flows through each coil primary circuit to the spark control unit The spark control unit supplies a switched ground for each of the ignition coil primary windings When it supplies a ground current flows through the coil primary winding and builds up a magnetic field around the coil When the ground is released the current stops flowing abruptly and the magnetic field collapses The collapsing magnetic field induces a high voltage in the ignition coil secondary winding which produces a
198. tely 313 away from the material If the switch is not operating correctly replace the switch Check the sensor switch function as follows e The switch should close when it comes within approximately 250 of a ferrous material e The switch should open when it moves approximately 313 away from the material If the switch is not operating correctly replace the switch A Warning Before removing or reinstalling any machine components make sure the key switch is off the key is removed from the machine and the parking brake is engaged To Remove and Reinstall the Hydraulic Power Pack Assembly LPG and Diesel Models 1 Disconnect the battery 2 Open the right engine side cover and remove the right battery tray cover 3 Swing the fuel tank out Service Manual CS7000 Hopper System 246 4 Remove the two Tray Mounting Bolts holding the 36 volt battery pack tray to the frame Tray Mounting Bolt T j oe i Tray Mounting Bolt 5 Slide the tray with the batteries out to the limit of the tether cable Service Manual CS7000 Hopper System 247 6 Use some large hooks to grab the bumper and raise the hopper up slightly using a hoist or other suitable method chassis or other suitable supports to prevent the hopper from accidentally lowering A Warning Before working underneath the raised hopper install blocks between the hopper and while you
199. the Solution System section for more information Squeegee Guard Kit Super Duty Kit The Super Duty Kit includes a front bumper kit deluxe seat kit anda rear corner roller kit Service Manual CS7000 Options and Accessories 269 Description Illustration Spray Wash Hose Kit The Spray Wash Hose Kit includes a separate low pressure pump to pump solution from the solution tank to the hose and nozzle located behind the Operator seat An automatic pressure switch will switch on the pump when the hose nozzle is opened then shut the pump off when the nozzle is closed Refer to the Solution System section for more information Overhead Guard Kit 82 Work Light Kit Tir R See 36 volt Trouble Lamp The Work Light Kit includes a 12 volt Lamp 36 volt Trouble Lamp and mounting hardware The 12 volt Lamp adds additional lighting to the operator side of the machine for visibility in low lit areas The pull out 36 volt Trouble Lamp is mounted under the hood Service Manual CS7000 Options and Accessories 270 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 LED warning beacon and electrical connector and the mounting hardware to mo
200. the broom and may lead to setting a code 54 main broom overload which will shut down the main broom Ran a 374 Service Manual CS7000 To Remove and Reinstall the Broom Motor Assembly 1 2 e Remove the main broom from the machine Open the hopper and engage the prop rod 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 Remove the 1 4 20 Hex Screw and washer holding the Weldment Panel to the machine frame Note that the front edge of the Weldment Panel is pinned to the frame Disconnect the broom motor electrical connector from the wiring harness Remove the three 5 16 18 Hex Screws holding the Broom Motor Assembly to the Broom Support Weldment and remove the Broom Motor Assembly from the machine Reinstall the Broom Motor Assembly following the above steps in reverse order E Broom Drive E Hub Assembly 5 16 18 Hex Screw Sweep System Main 5 16 18 Weldment Hex Screw 3 Panel 1 4 20 Hex Screw Support Weldment Service Note Apply Never Seez or an equivalent anti seize compound on the gearbox shaft when you reinstall the Broom Drive Hub Assembly Apply Loctite 242 blue on the 5 16 18 Hex Screws when reinstalling the Broom Drive Hub Assembly and Broom Motor Assembly 375 Service Manual CS7000 Sweep System Main 376 To
201. the engine to cool sufficiently to relieve cooling system pressure and avoid burns 2 Remove the left side engine cover 3 Remove the radiator cap 4 Locate the remote engine coolant drain hose remove the plug and direct the coolant into a suitable container 5 Reinstall the drain plug and reposition the drain hose 6 Refill with a 50 50 mixture of engine antifreeze and water 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 Red in Window Restricted Filters Clear Window Okay Replace Air Filters 1 Release the latches and remove the air filter housing cover 2 Remove the outer filter element 3 Blow out air cleaner housing with compressed air with inner filter element still in place to prevent dirt from entering the engine air intake 4 Remove the inner filter element 5 Clean residual dust from the inside of the air cleaner housing taking care to prevent any dirt or debris from entering the air intake 6 Install a new inner filter element and then the new outer filter element making sure that they seal well at their ends 7 Install the air cleaner housing cover Service Manual CS7000 Engine System LPG 201 Troubleshooting Checking Spark 1 Remove the spark plug wire from the spark plug and insert an adjustable KV tester in the end of the wire 2 Adjust the
202. the hopper person holds the Side Broom Assembly in place while another person removes the 1 2 13 x 75 Hex Screw Caution Handle the Side Sweep System Side Broom Side Broom Assembly q 1 2 13 x 75 Hex Screw ha Bnd eat oR i NK 112 13 x 1 5 Hex Screw 2 ii ki y gt 4 machine The Motor Bracket Weldment and attached Motor Assembly are free to move on the Side Broom Arm Assembly and can create pinch points Remove the 1 2 13 x 75 Hex Screw and washer and carefully remove the Side Broom Assembly from the machine Reinstall the side broom motor assembly by following the above steps in reverse order Screw when you reinstall the Screw Motor Bracket Weldment Side Broom Arm Assembly Assembly to the Arm on the side broom lift weldment leave a 0 19 0 03 4 8 mm AV Service Note When you reinstall the Cable wipe 0 7 mm gap between the Phillips Screw and Arm to allow the Cable Assembly to move freely on the Phillips Screw 0 19 0 03 4 8 mm 0 7 mm Phillips Screw Cable Assembly 388 Service Manual CS7000 Sweep System Side Broom 389 To Remove and Reinstall a Side Broom Hub Assembly 1 Remove the side broom motor assembly from the machine 2 Make sure the Motor Assembly and Side Broom Hub Assembly are adequately supported then carefully drive out the Spr
203. the power supply from the drive motor controller This shuts down the drive wheel system Key Switch Seat Switch PAN 2D o oami o Interlock J 4 9 Emergency Battery Stop Interlock Switch Switch Drive Controller Steering Controller The steering controller can communicate with other devices via a CAN bus The CAN bus wires are at J5 23 J5 15 and J5 8 The steering actuator motor has 3 stator windings that are interconnected These wires are the working wires of the motor The controller supplies AC voltage and current to these winding to create a magnetic field that will act upon the rotor magnetic field and apply torque to spin the rotor The controller is capable of switching the current to the windings on and off in specific order to make the motor turn either clockwise or counterclockwise and control the speed of the motor The motor windings are wired directly to the bolt on lugs of the steering controller They are clearly marked U V and W Service Manual CS7000 Steering System 346 The Steering Motor incorporates an encoder that reports both direction and speed information to the controller The operation is similar to the steering wheel rotation sensor encoders however there is only a single pair of signals and the pattern is not square The frequency of the signal provides speed information The signals are slightly offset to indicate rotation direction The encoder recei
204. tion The hopper will not An interlock is not closed Before you start troubleshooting the hopper system rise or lower check to make sure e The emergency stop switch S15 on the Operator control panel is disengaged rotate clockwise e The safety relay from the steering system K14 is closed e The seat switch S9 is closed e The battery interlock proximity sensor 13 is closed battery machines only e The A1 Main Machine Controller is receiving the appropriate signal from the A3 Control Panel via the CAN BUS There is no voltage to the Check circuit breaker CB1 and reset if necessary K11 and K12 contactor coils The contactor K9 is not providing positive voltage to the K11 and K12 contactor coils 1 Check the K9 contactor coil resistance If the coil resistance is not 118 ohms 10 replace the contactor Check the continuity through contactor K9 with the coil energized If the contacts are open replace the contactor Check the J2 28 and J2 24 Outputs from A1 Main Machine Controller There is no voltage to the Check circuit breaker CB8 and reset if necessary Hydraulic Pump Motor The contactors K11 and K12 are not providing Assembly M10 voltage to the Hydraulic Pump Motor Assembly M10 1 Check the coil resistance on the K11 and K12 contactor If the coil resistance is not 117 ohms 10 replace the contactor Check the continuity through contactors K11 and K12 with the coil energized If
205. tion by rotating the Drive Nut Cylinder on the Drive Nut threaded shaft as necessary Cylinder 6 Hold on to the drive nut cylinder to keep it from rotating then extend the side broom actuator using the Service Mode until the motor stops 8 00 RETRACTED POSITION 9 75 EXTENDED POSITION 7 Check the extended position dimension 8 Ifthe distance is not correct remove the rubber adjuster cover from the end of the motor Then rotate the nylon nut found under the cover with a 1 2 18 mm SOCKET Not a screwdriver Turning the nut one click will change the distance approximately on tenth of an inch 2 5 mm After changing the adjustment run the motor in and out and recheck the extended position dimension Remove Adjuster Cover Rotate Nylon Nut to Adjust A Note Use a 1 2 18mm socket to turn the adjuster 9 After each adjustment hold the drive nut cylinder run the actuator IN amp OUT and recheck the dimensions Reinstall the adjuster cover Service Manual CS7000 Sweep System Side Broom 392 Specifications No load Speed 2 800 RPM Rotation Clockwise Side Broom Motors all Voltage 42 VDC Power 25 HP Continuous Duty Side Broom Motor Left eaten Daw eHoP Average 3 Amps Max 4 Amps measurements Side Broom Motor Right Suu ERT OTAN SROP Average 3 Amps Max 4 Amps measurements 36 VDC 1 6 HP Motor to drive screw ratio 21 7 1 Retracted Position
206. tion from the tank to the hose and wand when the clutch is engaged Refer to the Solution System section for more information Front Corner Roller Kit Extended Scrub Kit The Extended Scrub Kit includes an additional Solution Pump a Float Switch Strainer and associated plumbing to pump recovered water to the scrub brushes once the solution tank is empty Refer to the Solution System section for more information Service Manual CS7000 Options and Accessories 267 Description Illustration EcoFlex Chemical Injection Kit The EcoFlex Chemical Injection Kit includes the detergent pumps detergent bottles mounting hardware and associated plumbing to inject detergent into the solution flow to the scrub brushes Refer to the Solution System section for more information Overhead Guard Kit 79 Deluxe Seat Kit Service Manual CS7000 Options and Accessories 268 Description Illustration Hot Water Scrub Kit The Hot Water Scrub Kit includes a i Heat Heat Exchanger mounting hardware Exenanger and associated plumbing to route the solution through the Heat Exchanger before it is mixed with detergent and sent to the scrub brushes Routing through the Heat Exchanger will increase the solution temperature approximately 50 degrees F The Heat Exchanger is plumbed to the engine cooling system and uses the hot engine coolant to heat the solution as it circulates through the Heat Exchanger Refer to
207. to follow the contour of the floor Service Manual CS7000 Sweep System Main 364 Main Sweep System Wiring Diagram Battery F1 36V RED RED Fit BLK Fuse 400A A1 Main Machine Controller A3 Control Panel ORN 42V Alternator J7 10 12v METERS a CAN J7 11 B O S14 B TOIAN Ne fara CAN oR Bi i23 J7 19 Start Input z B YEL BRN 3 g 4 BLK ORN J2 14 Output K9 L Aux Contactor GRN YEL YEL BRN J7 12 Supression Ignition Switch Diode ORN J7 13 Key Switch ean Fe Input al s9 K14 S15 13 ORN GRA ORN PINK TAN GRN BLU J7 1 Interlock m 2 E maA 1 2 Input Fe Seat Switch Safety Switch Emergency Battery s3 Relay signal from Stop Switch Interlock J7 14 RED BLK BLK A5 Steer by Input 1 2 Wire Controller Hopper Interlock Switch Contactor Aux VACC3 Ground a p J3 15 BLK RED BLU GRN mS Tig BLK 125 Amp 2 ae aes a J3 21 BLK J3 29 BLK GRN GRA J2 16 Output Contactor Broom Motor Main Broom Actuator Motor BLU YEL J7 24 5V to red to extend Brush M21 J7 27 Brush peal Current Sense J3 3 PWM Output PE BRNAWHT RED m ORN J2 4 PWM Output REDO AN VIO B2 SLU EL J7 33 Pot High Broom ORN BLU J7 31 Broom i GRA GRN Current C Current Sense IT 3ANIpEr R4 Sensor 5V B VIO WHT J7 35 Pot Low TAN RED C BLU BLK AN Z RED FROM F1 F2 Ka M1 RED BRN VIO m BLK Fuse 150 A 1 2 Broom Motor Contactor Broom Broom IN Current Sensor IN B B Service Manual CS7000 Swe
208. tor is rotating slowly and when it is rotating fast Phase B slow rotation Phase B fast rotation The signals that the speed sensors produce are slightly offset from one another This allows the controller to verify the rotation direction of the motor When both signals are low the next signal that switches high 5v indicates the rotation direction Both Low Ais next High Bis next High B Phase B 5 Vo 400 us H Phe A 400 ug P Phas B 5 V 400 us B Phase A 400 up R Forward Motion Reverse Motion The drive motor also has an internal temperature sensor that is monitored by the drive motor controller The drive controller sends a 12v supply through an internal resistor and out pin J4 8 to the motor 2 wire connector pin 1 This is connected to the temperature sensor The other side of the sensor 1s connected to the two wire connector pin 2 This is connected to the controller pin J4 7 where it is grounded inside the controller Service Manual CS7000 Wheel System Traction 402 CAN Bus The drive controller communicates with the main machine controller via the CAN Bus The drive controller transmits error codes to the main machine controller The main machine controller sends several messages to the drive controller that regulate machine speed mode The drive controller has three speed setting modes 1 Transport This is set at 100 of the total speed potential 2 Scrubbing Speed Battery models
209. tor menu Inputs Wheel System Traction Set Clear Conditions Set Pot2 wiper pin 17 voltage is higher than the high fault threshold can be changed with the VCL function Setup_Pot_ Faults Clear Bring Pot2 wiper voltage below the fault threshold Set Pot2 wiper pin 17 voltage is lower than the low fault threshold can be changed with the VCL function Setup_Pot_ Faults Clear Bring Pot2 wiper voltage above the fault threshold Set Pot low pin 18 current exceeds 10mA Clear Clear pot low overcurrent condition and cycle KSI Set Controller operating system tried to write to EEPROM memory and failed Clear Download the correct software OS and matching parameter default settings into the controller and cycle KSI Set HPD High Pedal Disable or sequencing fault caused by incorrect sequence of KSI interlock direction and throttle inputs Clear Reapply inputs in correct sequence 413 Service Manual CS7000 Wheel System Traction 414 Flash Code 41 49 51 Programmer LCD Display Effect Of Fault Emer Rev HPD ShutdownThrottle ShutdownEM Brake Parameter Change Fault ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle FullBrake ShutdownPump High Pedal Disable ShutdownMotor VCL Vehicle Control Language Run Time Error ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle ShutdownInter
210. tor mixer throttle blade to achieve the requested engine speed The cooling system consists of a standard radiator and belt driven fan Note that the fan pushes air away from the engine and out through the radiator Service Manual Haram Captor Il Engine System Petrol Gasoline 211 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 gt Crank Position Sensor Toothed Ring and flywheel Ignition Coils The heart of the system is the spark control module It controls the current flow of each ignition coil primary circuit in order to control when spark occurs based on inputs from the crank position sensor Each coil fires twice per cylinder cycle Once to initiate the power stroke and once in exhaust stroke waste spark The crank sensor is a two wire AC pulse generator It has a wire coil inside of it As the toothed ring rotates the teeth pass in line with the end of the sensor tip This induces a voltage spike that the spark control module can read as cylinder position information The number of spikes per minute is translated as engine RPM One tooth on the ring is wider than the other five This creates a unique spike so that the spark control module can di
211. tral time out will return the engine to idle speed Ifthe override is run speed the user can change between maximum power speed and run speed Ifthe override condition goes away e g sweep system turns off and the user has not changed the engine mode the engine is returned to the mode before the forced override Normal Engine Shut Off When the key switch is shut off the main machine controller stops sending 12v out the ignition request circuit This removes the power source for the fuel pump that had been flowing through the closed at rest contacts of the high coolant temp shut down relay and from the ignition request relay which turns it off Turning off the ignition request relay causes ignition to be immediately lost and the engine to shut off It also turns off the gasoline shut off solenoid on the carburetor Several other events also take place The ignition request power is lost from pin 1 of the Woodward actuator When this happens it switches off the path to ground from pin 9 to 5 De energizing the ignition request relay also results in the loss of the engine run signal through the low oil pressure shut down relay closed at rest contacts turning off the power relay and control relay IGNITION POWER FORIGNITER i t a IGNITION CONNECTOR FOR PLUGGI NGI NTO KUBOTA IGNITION HARNESS FUEL PUMP PNK YEL 16 IGNITION REQUEST PNK 16 QO CONNECTOR 1 PACKARD 16 PI N MALE P N 15326863 TO NILFISK HAR
212. tuator electrical connector 4 Remove the Cotter Pin washers and Clevis Pin connecting the Squeegee Lift Actuator to the Squeegee Lift Arm ot goes Spacer 5 Remove the Cotter Pin 5 x 2 75 Clevis Pin and Spacer connecting the Squeegee Lift Actuator to machine frame and remove the Squeegee Lift Actuator from the machine Squeegee Lift Actuator 6 Reinstall the Squeegee Lift Actuator by following the above steps in reverse order ex Note The Squeegee Lift vain Actuator does not Le require adjustment after installation Service Manual CS7000 Squeegee System 338 Specifications Component Specifications Squeegee Blade Front Material Linatex 40 Red Gum Color Red Hardness 40 5 Shore A Durometer Squeegee Blade Rear Red Gum Tensile Strength 3000 Psi Minimum Elongation 600 Minimum Dynamic Load 200 lbs maximum Static Load 250 Ibs maximum Restraining Torque Actuator is internally restrained Amperage 3 Amps at rated dynamic load End of Stroke Actuator has internal limit switches connected to the motor to shut off power at ends of Squeegee Lift Actuator stroke Overload Protection Ball detent clutch with load rating between 250 and 500 Ibs Thermal Protection Automatic resetting thermal breaker enclosed in motor housing Wiring Polarity e To extend actuator connect red lead to positive and orange lead to negative e To retract actuator con
213. unless otherwise stated and were measured with the negative black voltmeter lead on battery negative and the key on Pin Wire Color harness Circuit Voltage Condition side 1 GRN WHT Encoder Al 4 77V Move steering wheel slowly 0 09v Voltage switches from low to high 2 BLU Encoder A2 4 77V Move steering wheel slowly 0 10v switches from low to high RED WHT Encoder B1 4 77V Move steering wheel slowly 0 09v Voltage switches from low to high GRN BLK Encoder B2 4 76v Move steering wheel slowly 0 10 ae switches from low to high o pe foo pooo e BRN WHT TFD control 23 89v No noticeable change at soft stop Service Manual CS7000 Steering System 361 Steering Controller Voltage Measurements J5 Connector r v4 8 COCOCOCT J QOOOOOO IIL COGO 16 L 23 J5 5 WHT Motor Encoder 2 6v motor stationary 3 5v motor moving J5 6 BLU GRA Motor Encoder 2 6v motor stationary 3 5v motor moving Jaf Noted 0 009v 9 Notused S G J5 10 RED WHT Steering Wheel Sensor Encoder B1 4 8v or 0 10v switches high and low as steering wheel is moved slowly J5 11 GRN WHT Steering Wheel Sensor Encoder A1 4 8v or 0 09v switches high and low as steering wheel is moved
214. unt the beacon onto the machine The beacon will flash whenever the machine key switch is on Solution Fill Shut Off Kit The Solution Fill Shut Off Kit allows you to connect a garden hose to the fitting and fill the solution tank without having to monitor the water level in the tank When the solution tank is full a float valve will automatically shut off the water flow into the tank Service Manual CS7000 Description Vacuum Wand Kit Overhead Guard Canopy Kit Front Bumper Kit The Front Bumper Kit includes the front bumper weldment a front corner roller kit and mounting hardware Illustration Options and Accessories 271 Service Manual CS7000 Options and Accessories 272 Description Illustration Accessory Socket Kit The Accessory Socket Kit includes a 12 volt automotive type adapter to power accessories or personal electronics and a circuit breaker Drain Hose Extension Arm Rest Option R H Only Nilfisk Advance Service Manual CS7000 273 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 The solution travels through the squeegee hose through a debris basket which catches any large particles then into the recovery tank
215. unting only Solution System 327 Service Manual CS7000 Solution System 328 Special Tools Loctite No More Leaks White Threaded Plastic Pipe Sealant used on solution shutoff valve threads Nilfisk Advance Service Manual CS7000 329 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 A vacuum hose attached to the support assembly lifts the water from the squeegee and directs it to the recovery tank The squeegee lift actuator raises and lowers the squeegee as appropriate for the operation being performed The squeegee mounting system is designed to allow the squeegee blades enough side to side movement to conform to the floor surface and swing sideways when turning Squeegee System Wiring Diagram Battery F1 36V RED RED i BLK Fuse 400A A1 Main Machine Controller A3 Control Panel ORN 42V Alternator J7 10 12v WHT ERN ra CAN J7 11 B S14 i gt eee e ee B1 423 J7 19 Start Input v B YEL BRN 3 a 4 BLK ORN J2 14 Output K9 _4 Aux Contactor GRN YEL YEL BRN J7 12 Supression Ignition Switch Diode ORN J7 13 Key Switch ale Fe Input s9 K14 S15 13 ORN GRA ORN PINK TAN GRN BLU J7 1 Interlock Fe 1 2 6 F ar 1 2 Input 3 0 Seat Switch Safety Switch Emergency Battery RED BLK BLK Rel
216. upplied current flows through the winding and creates a magnetic field As the percentage of ground time is increased the current flow increases causing a stronger magnetic field to be created in the TFD The magnetic field creates a clamping force on the TFD clutch pack which in turn provides steering feel to the operator There are two travel limit proximity switches Each switch receives voltage on the same circuit as J5 1 through the seat switch The switches are normally open When the cam tooth lines up with the switch the switch closes sending the voltage on to the steering controller The right travel limit switch is connected to J5 13 The left travel limit switch is connected to J5 19 344 Service Manual CS7000 Steering System 345 The steering controller controls a safety relay K14 to shut down the drive wheel system in the event that there is a serious steering system error The relay coil receives battery voltage from the key switch The same as J5 1 The voltage flows through the relay coil and on to the controller J5 18 Inside the controller there is a switch that closes to battery negative to energize the relay The relay contacts close allowing battery voltage to the drive controller interlock switch circuit J4 9 In the event of a serious steering system error the steering controller opens its internal switch to de energize the safety relay coil This causes the relay contacts to open and removes
217. upport Weldment The Broom Motor Assembly drives the Main Broom and is mounted to the Broom Support Weldment The Broom Lift Actuator raises and lowers the Broom Support Weldment which pivots on the machine frame to raise and lower the attached Main Broom Motor The Broom Door Assembly swings out Assembly WA ae oe of the way to allow access to the Broom et gt FE Assembly Arm Assembly The Broom Arm Assembly KOAN A is hinged to allow the Main Broom to be removed from the machine for maintenance or replacement The left and right Skirts direct the debris swept by the Main Broom into the hopper Service Manual CS7000 Maintenance and Adjustments A is engaged To Adjust the Main Broom Height l Sweep System Main Warning Before performing any maintenance or adjustments on the main sweep system make sure the key switch is off the key is removed from the machine and the parking brake Turn the key switch on then press the Broom Select Switch twice to select the main broom The main broom motor will start and the actuator will lower the broom to its preset height After running for a short time the broom motor will shut off and the actuator will raise the broom to its upper position Broom Height Raise Button Broom Height Lower Button Check the Main Broom Sweep Pattern on the floor The Pattern should be 2 to 3 50 75 mm wide and consistent in width along the
218. uretor 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 It uses this voltage supply to send 12 volts out of connector J3 pin 10 to the crank request relay coil The other side of the relay coil is grounded through the Woodward L series actuator With power and ground across the relay winding the relay energizes and fused battery power from terminal 30 is sent to the starter solenoid An electrically operated solenoid pulls the carburetor choke closed when the starter 1s engaged Battery Grouna Cranking 36v BATTERY STARTER 12v BATTERY Choke 7 Solenoid Key Switch 36v Start Position Aux Relay Contact 12v WOODWARD L SERI ES ACTUATOR Main Machine Controller Service Manual Haram Captor Il Engine System Petrol Gasoline 214 Throttle Control Modes Ignition Off e 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 e Battery power is provided to the run enable input of the L Series actuator through the power relay closed at rest contacts If it doesn t have this signal present on
219. ve but go to steering controller J5 4 The controller provides a clean filtered ground for the encoder circuits The encoder built into the steering actuator also has a ground at pin 6 which is grounded through the controller J5 4 The steering wheel rotation sensor encoder has 4 internal switches See image below Each switch is fed approximately 5 volts 4 7v from the steering controller on its own wire As the steering wheel rotates the switches cycle on and off to ground causing the 5v to drop to Ov and back up again This creates four separate 5 volt square wave signals which are read by the steering controller Note that the encoder circuits use twisted pair wiring to eliminate electrical noise Encoder 1 Steering Wheel Rotation Sensor Steering Controller Service Manual CS7000 Steering System As the steering wheel rotates the Al signal switches back and forth from Ov low to 5v high When viewed on a scope oscilloscope it looks like a square wave pattern When the steering wheel rotation is slow the switching frequency is slow This is seen as longer and fewer square wave patterns on the scope screen When the steering wheel rotation is faster the switching frequency is faster This is seen as more but shorter patterns on the scope screen This changing frequency is how the controller sees the steering wheel rotation speed The same is true for all 4 signals Slow Rotation
220. ver and Debris Basket The Debris Basket is located below the Recovery Tank Cover and attached Recovery Cover Gasket The recovered solution is directed through the Debris Basket before going into the recovery tank to screen out any debris or large particulates Recovery Cover Gasket 276 Service Manual CS7000 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 top of the Recovery Tank The two plastic Latches rotate to allow the Vacuum Filter Lid Assembly to be removed to access the Filter and Filter Screen Vacuum Motors The Vacuum Motors sit on the Vacuum Fan Seal Assembly in the Recovery Tank and are held in place by the Vacuum Fan Cover Assembly The air from the Vacuum Motors is exhausted through Foam Tubes no minimize noise Float Cage and Ball Assemblies The Float Cage and Ball Assemblies are attached to the Vacuum Fan Cover Assembly and prevent any recovered water from being drawn in through the Vacuum Motors Recovery System Vacuum Filter Lid Assembly Filter Screen Vacuum Fan Cover Vacuum Fan Cover Assembly Float Cage and Ball Assembly 2 Vacuum Fan Seal Assembly Recovery Tank 277 Service Manual CS7000 Recovery System 278 Maintenance and Adjustments Warning Before performing any
221. very 1000 hours Replace spark plug Check valve clearance Service Manual Haram Captor Il Engine System Petrol Gasoline 226 Clean combustion chamber if necessary 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 1 2 8 9 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 Tip the recovery tank outward Release the recovery tank tether cable and recover hose then lower the recovery tank to the ground for better access to the engine oil filter area Remove the oil filter with an oil filter wrench Apply a light coat of engine oil to the new filter cartridge gasket Screw the new cartridge on and tighten by hand Over tightening may damage the gasket Remove the remote oil drain hose end from the radiator bracket Remove the plug and drain the oil into a suitable container 10 Reinstall the plug and reattach the drain hose to the radiator bracket 11 Refill the engine with oil Change Engine Coolant i Z Allow the engine to cool sufficiently to relieve cooling system pressure and avoid burns Remove the left side engine cover Remove the radiator cap Locate the remote engine coolant drain hose remove the p
222. ves a 5v power supply at pin 1 from the steering controller pin J5 3 The encoder is grounded on pin 6 through the steering controller J5 4 The encoder sends a wave signal out of pin 2 to controller J5 5 and out of pin 8 to controller J5 6 H Motor Encoder JSG 1 V 40 ms Right ote ad 4 Right ALL e Au Left Turn Right Turn Service Manual CS7000 Component Locations e Steering Wheel Rotation Sensor Steering Wheel Rotation Sensor Connector Steering System 347 Steering Actuator Rear of machine in front of drive wheel motor e Steering Controller Left rear of machine Steering Wheel Rotation Sensor Steering Controller Steering Wheel Rotation Sensor Connector Steering Actuator 5 Photo taken without tanks Service Manual CS7000 Steering System 348 Maintenance and Adjustments Check bolt torque of wiring connections at the Steering Controller every six months Troubleshooting If a problem occurs with the steering system begin by checking the Status LED condition on the steering controller and for steering system DTCs Diagnostic Trouble Codes If the Status LED does not light check the power and ground supplies for the controller first If the Status LED is flashing and there are DTCs diagnose the cause of the DTC If there are no codes follow the symptom troubleshooting Diagnostic Trouble Codes DTCs The steering controller monitors the steering system to
223. wn red wire to pin J4 16 When the drive pedal is in the spring loaded neutral position the wiper is exactly in the middle of the resistive strip This provides an input equal to 1 2 of the voltage available across the resistive strip 2 5v When the drive pedal moves forward the wiper moves closer to the 5v supply increasing the input voltage When the drive pedal moves backward the wiper moves closer to the ground supply decreasing the input voltage Below is an oscilloscope waveform that shows the drive pedal sensor sweep starting in the neutral position moving to full reverse then to full forward i Eliza REE oe Full Forward Position 4 7v a eee ee J oie Pedal Position 1 v 1100 mes Netral Full Re 1i EWE Drive Pedal Sensor Input sweep Service Manual CS7000 Wheel System Traction 400 Drive Motor The drive controller supplies current to the drive motor stator windings on the three large U V and W wires When stationary the controller pulses a current to all the motor stator windings in unison This holds the motor in a fixed position To make the motor rotate the controller shifts the timing duration and current of each of the windings This continuously changes the location and strength of the magnetic field poles created by the stator windings which causes torque to be applied to the rotor Below is an oscilloscope waveform that shows the 3 phases of the motor U V and W when th
224. y Positive and Negative connections at source and controller Battery Positive and Negative cables Service Manual CS7000 DTC Motor Temperature High Steering Controller Temperature High Steering Wheel Rotation Sensor Circuits CAN Bus communication lost Controller Hardware Fault Internal 15V supply voltage is low Internal 5V supply voltage is low or high Torque Feedback Device Excessive Current an n bo n The Motor Temperature is above 180 C 856 F The Steering Controller Temperature is above 125 C 257 F One or more of the four digital encoder signals is missing or is not occurring in the correct sequence with its paired partner The steering controller is not receiving CAN Bus messages The internal current sensor is out of calibration The internal 15V supply voltage on the board is too low The internal 5V supply voltage on the board is either too low or too high Excessive current flow through the torque feedback device circuit Steering System 350 Restrictions to steering actuator movement Actuator temperature sensor accuracy Restrictions to steering actuator movement Actuator temperature sensor accuracy Sensor All 4 encoder signals for proper high voltage to low voltage switching as the steering wheel is turned slowly Open wiring intermittent connections Shorted wiring to one another or to ground 5v power su
225. y negative and the key switch on Low Current 35 Pin Connector J4 PFOOOOOO0000000 3000000000008 pPOOOOODOOCOCOOOD Voltage 1 ORN Key switch input Provides logic power for the controller and power for the coil drivers 2 f Nousd i BS Note e Ntsc S5 Not set VIO GRN K7 Wheel Drive Contactor Driver Momentary 38 V at first key on 5 6v when contactor is on Pa BLK PINK Input and output ground reference 0 008 V TAN RED Motor Temperature Sensor 1 22 V Room Temp 12 V open circuit o enne interock Switch input SSS a e E a e ECA a e 13 TAN RED K7 Wheel Drive Contactor Coil 38 18 V Power o Notusea D WHT BLK Throttle POT High 5 V supply 5 14 V 16 BRN RED Throttle POT wiper Pedal Position 4 79 V Full Forward Sensor Input 2 52 V Neutral 0 29 V Full Reverse Service Manual CS7000 Wheel System Traction 424 i7 Not Used VIO BLK Throttle POT Low 4 9 17 19 Notused 20 Not Used D 2 7 CAN Bus High af f Nouse o o 25 VIO WHT Unregulated low power 12 V output Power for Serial Port Connector PINK RED Regulated low power 5v output Ca O o S noise 28 WHT ORN Serial Transmit for Serial Port Connector 29 BLU GRN Serial Receive for Serial Port Connector 30 Not Used OO 31 PINK WHT Drive Motor Encoder Speed 4 06 V or 0 08 V stationary Sensor Signal Phase A 2 0 V wheel spinning any speed 32 PINK BLU Drive Motor Encoder Speed 4 06 V or 0 08 V stationary
226. y remove the Brush Plate Assembly Remove the four Hex Head Metric Screws then lift the Scrub Motor Assembly and Motor Spacer off of the Arm Weldment shown or deck weldment Reassemble the Scrub Motor Assembly following the above steps in reverse order correctly before you reinstall the Brush Plate Assembly onto the scrub motor shaft _ i IT R hI fi oe iran _ a io Motor Assembly 297 Service Manual CS7000 Scrub System 298 To Replace the Scrub Motor Carbon Brushes on Note The minimum length of the carbon brushes in the scrub motors is 0 5 18 mm If the carbon ool brushes are less than 0 5 13 mm long replace them 1 Remove the scrub motor assembly from the scrub deck 2 Remove the scrub motor from the right angle gearbox 3 Note the position of the witness marks stamped into the frame and castings on both ends of the motor 4 Remove the two Acorn Nuts and open the Terminal Cover 5 Use a backup wrench to hold the Bottom Terminal Nuts in place then remove the Top Terminal Nuts and Terminals Make sure to note the wire Bottom E polarity Terminal Nut 2 jie 6 Remove the Terminal Cover 7 Remove the Hex Nuts Lock Washers and Threaded Rods holding the two t Moe 2k aoe ee Threaded Il F G a4 reade end castings to the Frame Terminal K A MG amp SS 3 Rod 2 Nut 2 nce ee o ghd y f F aft F af Fi r

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