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Nilfisk-Advance CS7000 - Industrial Cleaning Equipment

1. RELAY GOLW PLUG AN KUBL NGINE SYSTEM GLOW PLUGS CB11 RED WHT u X793 RED X266 X113 lt lt BLU PINK eve 30 50 LAK STARTER B 9 f RED gt BAT 2 G2 RED X265 X115 BI K gt nk PINK B PINK 12 ALTERNATOR N N APECS 3000 GUVERNUR BLK am X265 X113 Dex M15 PU ag RED PINK lt RED BC ACTUATOR WHT BLK ACTUATOR ACTUATOR M THO S GRA ORN lt SPEED SELECT 2 MAGNETIC PICKUP GR S19 S MAGNETIC PICKUP GRA YE D2 SPEED SELECT 1 SERVICE TOOL Tx N PED D R MAGNETIC SERVICE PICK UP 05 A b GRA 4 THROTTLE 2 gt UTPUT X266 X140 THROTTLE 1 gt GRA BLU K lt lt GRA UTPUT M20 X266 X140 X113 X265 X265 X113 RUN SIGNAL gt GRA C lt c 6RA BRN DS gt L PINK YEL BLK RED C c BLK 4 INPUT PUMP FUEL X265 X113 F ss COOLANT TEMP gt GRN YEL 5 GRA YEL Lots BLK 4 SWITCH COOLANT TEMP BI K GLUW PLUGS K13 GRA ORN RELAY GLOW PLUG K13 149 Electrical System Service Manual CS7000 56509170 Rev G Before SN 1000048160 Sheet 6 of 6 gt gt
2. DELPHI 15326915 Electrical System 116 Service Manual CS7000 a mee sonno w o O P X17 Brush Motor Right M4 Wire Color oa 152 BLU YEL Pm we s mm Pm Wire 5 X20 Shaker Motor M14 Pin Wire B j 268BKRED Electrical System 117 DELPHI 15326917 S DELPHI 12052613 2 lt DELPHI 1201579 S DELPHI 12052613 2 3 DELPHI 12052613 Service Manual CS7000 Pm we s _ Pm Wire s emun X23 Vacuum Motor M6 Wire 017 BLU GRA 018 BLK we 5 Pm Wire s Pm we _ e faa Electrical System SL DELPHI 15300027
3. DELPHI 12059573 DELPHI 15326915 Service Manual CS7000 Electrical System 125 X178 Back Up Alarm H1 Ph we O _ 076 GRN BRN X180 Stop Turn Lamp Left LT9 SN A B jop Vets __ X181 Broom Motor Current Sensor B2 Pe Wire 5 ase viownt Pe we _ 5 wie DELPHI 15326808 Service Manual CS7000 Electrical System 126 X184 Stop Turn Lamp Ri
4. DEUTSCH DTM04 12PA 282080 1 Electrical System 120 Service Manual CS7000 X105 Steering Travel Limit Switch Left S17 Pm Wie e monon X106 Steering Travel Limit Switch Right S16 Wie s emo Pm wie s eno Pm we s Pm Wire voon Pm we _ DELPHI 12010973 Electrical System 121 Service Manual CS7000 X122 Dust Guard Pump M22 Pm Wwe o p mesna X124 Dump Door Actuator Motor M26 Pm we B 126 Hydraulic Pump Hopper Lift M10 Pm we _ 175 BLU YEL 177 RED BRN Pm wire e nn Pe wie 5 osana 191 VIO BLK
5. RED B A BLK DRIVE MOTOR M24 K7 RED 7 7 dk RED 1 2 B WHEEL DRIVE I RED RED RED CONTROLLER CURTIS 1234 SPEED CONTROLLER 45V 44 26 L DPINK RED a PHASE J4 32 ED ES e e mr PHASE J4 31 VIO GRN TEMP SENSOR GROUND J4 7 gt DRIVER 1 J4 6 D N ANZORN SENSUR J4 8 esq cepe I I WHEEL DRIVE BLK PINK WHT BLK WHT gt KSI COIL POWER RETURN J4 13 TAN RED amp BLK WHT R1 THROTTLE POT WIPER J4 16 BRN RED y 5V THROTTLE POT HIGH J4 15 WHTZBLK POT 5K OHM B POT LOW J4 18 ES INTERLOCK J4 9 KST CAN H J4 23 YEL lt gt 04 35 GRN BUS 12V J4 25 VIO WHT 4 TX J4 28 WHT OR 3 RX J4 29 BLU GRN 1 BLK WHT 2 J10 CURTIS PROGRAMER CONNECTOR I A di DUST CONTROL MOTOR 1 9 cps EA P Ep TO DOO BRN WHT dk ORN GRN gt gt mm BLK lt CONTACTOR DUST CONTROL MOTOR rr aol a zm SIDE BROOM MOTORS 1 CB7 K8 x E ME E a RED T5 au WHT REB lt lt z BLK gt CONTAS TOR ASILE MOTOR RIGHT SIDE BROOM 9 HT REB gt BLK MOTOR LEFT SIDE BROOM HYDRAULIC
6. GLOW PLUGS 11 RED WHT So Prog RED X265 X113 lt lt B U PINK E lt NS 30 50 SIARTER I PU I 4 N T RED gt 2 BLK G2 RED 265 X113 Et BLK PINK Ag B PINK 4 AI 12 ALTERNATOR APECS 3000 GOUVER R BLK ans N BC M15 X265 X113 A RED PINK RED BC ACTUATORG E WHT BLK ACTUATOR gt X266 X140 VI B BA RA ORN x SPEED SELECT 2 MAGNETIC PICKUPC GR S19 MAGNETIC PICKUPC ee D2 SPEED SELECT 1 SERVICE TOOL T 2 RED D R MAGNETIC SERVICE gt PICK UP OS D3 I d Di GRA 4 2 gt UTPUT X266 X140 ROTTLE 1 gt GRA BLU K lt lt GRA UTPUT X266 X140 X113 X265 X265 X113 C i D C C RUN SIGNAL gt GRA lt GRA BRN D BLK RED lt BLK INPUT F X265 X113 Eas COOLANT TEMP gt GRN YEL Gv lt GRA YEL m INPUT SWITCH COOLANT TEMP BLK 2 w LUG K13 GRA ORN RELAY GLOW PLUG 155 Electrical System 56509170 Rev H SN 1000048160 and later Sheet 6 of 7 Service Manual CS7000 IGNITER ASSY j K L l HF KU amp LPG ENGINE SYSTEM GRN BLU BLK WHT REI BLK BLU BLK RED ORN ORN ORN BLK
7. IGNITION CONNECTOR FOR PLUGGING INTO KUBOTA IGINTION HARNESS ALTERNATOR WOODWARD L SERIES ACTUATOR DEUTSCH CONNECTOR 0106 12 16 GRA BLU STARTER C RUN ENABLE SIGNAL SHUTDOWN SIGNAL HUINI SHIELDED WIRE CLR 18 TO 5 PICK UP BLK 18 TO PIN B BATTERY 12VDC Service Manual CS 7000 Electrical System 150 56509170 Rev H SN 1000048160 and later Sheet 1 of 7 X102 X107 X107 102 F1 RED 4004 gt BLK 61 RED BLk BLK ORN lt lt 42V ALTERNATOR 9 RELAY AUX ORN 4 K10 ORN 1 BLK IGNITION SW LAMP TROUBLE LT mim Lot YEL BRN BLK gt 12V S14 POWER lt EN 1 7T T 9X7 BL 3 VIO GRN J7 19 START INPUT OPTION 15A BAT2 Lies K9 POWER OUTLET OPTIONAL RED BLK V YEL BRN 3 4 BLK ORN J2 14 OUTPUT CB12 m CONTACTOR AUX YEL BRN J7 12 SUPRESSION S NGINE SYSTEM SWITCH IGNITION DIODE x SEE SHEETS K15b ENGINE SYSTEM 5 OR 6 RELAY AUX
8. NEN OO o O CO CO 049 ORN BLK 056 GRA BLK 055 GRA BLK N LO NINI NJN J3 Main 776164 4 GRAY System 113 Electrica Service Manual CS7000 776164 1 BLACK Service Manual CS7000 Electrical System 114 J5 Steering Controller A5 NN Pin Wire Color D 083 GRA ORN lj L 199 BRN WHT EN CEN 4 LI _____ 1000000004 1100000000511 cU 201 BLK 202 WHT 203 BLU GRA 204 BLK 343 GRN 14 eon 212 YEL Service Manual CS7000 Electrical System 115 J7 Main Machine Controller A1 oew j gt p 20 2 m E Z 32 776164 1 BLACK Service Manual CS7000 Pm Wire Color 04 2 mem 5 Bo NY Je 7 Pm Wire Pm We 5 ie r _ ooo fowo n 5 747905 2 dipE TOP gt MOLEX 39012041
9. 2 396 To Remove and Reinstall the Squeegee Support Assembly 396 To Remove and Reinstall the Squeegee Lift Arm 396 To Remove Reinstall the Squeegee Lift Actuator 6 398 Special Tools s s e uw dead 2 EEE w W Q ear 0 du dd 398 Steering 399 Service Manual CS7000 Contents x Functional Description o3 x xo 99 4n 0o ws Ue 3 e e ope 399 s 24 wo 5 45 Q h 2 S b wa Q db UC dp dec deo Rob QU 399 Steering Wheel Rotation Sensor 339 Steering Actuator 340 Steering Travel Limit 341 Steering Controller 341 Steering System Wiring Diagram 342 Circuit 343 Component Locations 347 Maintenance and Adjustments 348 348 Diagnostic Trouble Codes 348 To retrieve steering system codes from the hidden menu 348 Diagnostic Trouble Code Table 349 Symptom Troubleshooting No DTC 353 Steering Inoperative Steering Controller Status LED is Blinkin
10. o m F n 32 servo sese 272 BLK WHT we _ a s p my E seno eno g sene ssrnepon 3 IN p eek ww 2 Electrical System 128 DELPHI 15326910 DELPHI 15326922 Service Manual CS7000 Pm we _ farn 5 r seen C o j N IN ER j s X266 Engine Harness Connector Pn Wire _ 2 2 e E C e J 2 e S INNEN C __ C No C Je DELPHI 15326868 DELPHI 15326863 Electrical System 129 Service Manual CS7000 Pm wire
11. 364 Circuit Dasepipti6n s oe deck X s 365 The Following Conditions Must be Met for the Main Sweep System To Operate365 Main Broom Actuator Motor 365 Broom Current Sensor 866 Component Locations 366 Main Broom and Drive 366 Maintenance and Adjustments 367 To Adjust the Main Broom Height 367 To Adjust the Main Broom Tilt 368 Inspecting Replacing Main Broom Motor Carbon Brushes 369 Troubleshooting s sso o o lt 2 K k s dE EO Ge Q w M Q Q dn E ok k 2 Removal and Installation 373 To Remove the Main 919 To Install the Main Broom 314 To Remove and Reinstall the Broom Motor Assembly 375 To Remove and Reinstall the Broom Lift Actuator 376 Service Manual CS7000 Contents xi gt DAS won S Q ow Ro cw wu 4 3 We e en 378 Sweep System SideBroom 879 Functional Description 379 OVeryieW s uU SURE ORE 979 Side Broom System Wiring Diagram 380 Circuit Description a asoa s s e e 881
12. wd 208 209 Engine System Petrol Gasoline 210 Functional Description W amp Q 210 Kubota WG972 GL E3 NFK 1 Petrol Gasoline 210 Circuit 211 6 es s 2 X v 9 3 2 2 0 Q X Xo x e NO 02 h N 0 2 N q Q 211 Engine Starter and Carburetor Choke Control 213 Throttle Control Modes 214 lenon O x xw w k X X k x amp S x lt Q S w Q S 214 gt 2 S S 3 eee 3 33 215 216 Normal R nni e x s s lt v lt x 80m eee eae eee WX x eee Q W bow W 217 Engine RPM Control 217 Normal Engine Shut Off 218 Engine Overheat 5 219 Lost Oil Pressure Shutdown 220 Component Locations 221 Engine Right Side View Toward front of machine 222 Engine Back Side View Toward right of machine 229 Engine Left Side View Toward back of machine 229 Fuel Tank 224 Maintenance and Adjustments 225 Maintenance Checklist 225 Change Engine Oil an
13. 418 Service Manual CS7000 Contents Xii Drive Whe l e s sss s lt lt w lt 422 Drive 422 S Mu T d RR RUE p x Z s 429 Shop 423 Drive Controller Voltage Measurements 423 Low Current 35 Pin Connector J4 423 Motor U V and W Terminal Pair Voltages 424 Motor U V and W Terminal Pair Frequency 424 System Current Draw Driving only with no cleaning functions 425 Wheel Drive 425 o ux uc ERN 425 Service Manual CS7000 13 General Information General Machine Description The CS7000 machines are industrial automatic rider sweeper scrubbers with multiple sweep scrub single pass coverage Both battery all electric and hybrid LPG and diesel models are available with or without the EcoFlex and DustGuard options The scrub system uses three disc scrub brushes with variable scrub pressure and solution flow rates The sweep system has a center main broom and left and right hand side brooms A fuel cell powered model has also been added It 1s virtually a battery model that has had the large mono block battery replaced with a fuel cell provided by Plug Power Service Manual Purpose and Applicatio
14. DELPHI 12162182 Electrical System 122 Service Manual CS7000 X153 Tail Lamp Left LT9 Pm we e onene X154 Tail Lamp Right LT5 wie s X161 Left Head Lamp LT3 Pm we _ B ew X162 Right Head Lamp LT2 Pm we B menw fwe _ e sewn w DELPHI 1201579 Electrical System 123 Service Manual CS7000 Pe we _ wrmwmk Do 285 BLK YEL 101 YEL GRN Pm wie e feasa _ 5 famea Pin Wire B Jaen LEE HE 2 je ___ we son p fea 3 RN lt T Electrical System 124 DELPHI 12020832 2 SIDE DELPHI 12059573
15. 30 5 38V B Ground B cycles J2 19 1116 WHT Detergent Pump M17 PWM SIGNAL 0 12 J2 7 YEL Reversing Polarity 139 Service Manual CS7000 Electrical System 140 J2 21 1160 BLU Output Detergent Pump M18 PWM SIGNAL 0 12V J2 32 VIO Reversing Polarity J2 23 169 BRN Output Head Lamps and Curb LT2 PWM ground to B Ground Lamp turn on lights PWM ground to turn 8 on lights J2 25 047 YEL Output Left Brush Motor K1 Grounds to 36V OFF ON B Ground BLU Contactor energize J2 27 061 GRA Output Right Brush Motor Grounds to 36V OFF ON B Ground RED Contactor energize 2 T 4233 J2 35 053 VACC6b Power supply 136 40 5 WHT Suppl from Aux Rela 093 RED Output Solution Control Pump UD id ground 0 36V YEL J3 4 031 RED Output Main Broom Actuator M21 PWM SIGNAL 0 36V J3 3 VIO Reversing polarity Reversing driver Polarit J3 111 Output Dump Door Actuator 26 Reversing 0 36V J3 7 GRN polarity driver J3 118 WHT Output High Pressure Pump 1 High Side 12V B Ground ORN Clutch Coil Driver Engine 12V J3 10 129 BLU Output Start Output High Side 12V PINK 12v out to starter Driver Engine 12V Service Manual CS7000 Electrical System J3 11 131 GRA Output Throttle 2 Output High Side OV or 12V 12V J3 12 134 GRA Throttle 1 Output High Side OV or 12V BLU Driver En
16. 4 395 To Remove and Reinstall a Wheel 395 To Remove and Reinstall a Brake Spindle Assembly 396 Wheel System Traction 397 Functional Description e m xo x 9 3 x 293 3 edo Xx x 9 897 Drive Pedal 2254553 34 35 43 4 9 397 Drive 25 s 2 W Q Q 397 Drive Wheel 398 398 Circuit Description a oe eh ae 398 Powering up the Drive Controller 398 Drive Pedal Sensor 399 CAN DS na eee s 402 Component Locations uod i x4 aX ade cook 4c cox ECKE dE ee Oe 4 ee 403 Maintenance and Adjustments 404 Drive Controlle s s s re sa errare bps 404 Drive Pedal Position 404 Gear Box ees dead lt 4 4 8155 eee eee 404 405 405 Summary of LED display formats uo oo oe oom Roe OLOR RO 9o 406 Troubleshooting 407 Troubleshooting 407 eee eee ROM EORR 417 Removal and Installation gt 418 Drive PedalAssembly _ _ _ _ 418 Drive Motor and Gearbox Assembly
17. NEL LONG IGNITER ASSY 12V J K L HF 5 E Y x GRN BLU S Q lt 5 2 COL j COIL 2 COIL 1 IGNITION REQUEST PINK 16 4 V J X265 A PINK BLK 16 PINK BLU 16 i TROLLER i UNUSED 1 ice i 5 o GN REQUEST UNUSED amp UNUSED i UNUSED vi a i MAIN E O CRANK REQUEST BLU PINK 16 5 J X265 F H r i FUEL LOCK OFF 86 87 87 a7 8 SOLENOID I x i q P 5 85 30 1 ORANK CONTROL SHUTDOWN RELAY 85 AES RNE5127 mE RELAY FUES amp RELAY ce MP RORIS cc REN eM PRIORE ES Ao RED 16 THROTTLE 2 12V OUTPUT GRA BLU 16 X266 ge itv LENT 1 X266 J 2 RUN SIGNAL 12V INPUT 175 16 Bl X266 C 2 c iB COOLENT TEMP GROUND INPUT GRN YEL 16 gt 5 4 lt 6 gt D SOLENOID Mag lt RED 16 m 6551 44790 Q gt Q OIL SWITCH TEMP SWITCH OPEN FOR OPEN FOR CRN 16 y NORMAL TEMP GRA PRESSURE RED 16
18. DELPHI 12052613 DELPHI 12052613 p ey DELPHI 12052613 p ey DELPHI 12052613 SY DELPHI 12052613 118 Service Manual CS7000 Electrical System 119 X27 Main Broom Actuator M21 w _ 5 5 es grain X28 Right Side Broom Motor M8 295 WHT RED DELPHI 12052613 X97 Steering Actuator M16 1 Pin S O 299 ORN BLK 202 WHT 203 BLU GRA 208 YEL RED 2 4 5 DEUTSCH DTM06 6S Service Manual CS7000 s mome enr Pin 6 197 PINK WHT 288 BLK PINK Pm Wire X102 Generator Harness Connector X107 Pin CHEM 235 WELDING BLK 3 0 12
19. 40 Diesel Machine 41 Broom Adjustment Battery LPG and Diesel 41 Battery Charge Indicator 41 Fault Caution and Warning Displays 42 Fault Displays s se e araso eais s Q ws de ce de WE 42 Displays EG xx 42 Warning 48 Steering Wheel nua nw scm Boh ORE OH m wd ow x X DERE 4 44 Foot Pedals xs amp h s Ww b OQ Q W s a s KORR Um E ee hee ee 6 4 Q 44 Chassis System a carros ww N XO Ue TOE Q Ue AO WO eae eee Q Q Q DP 45 Component Locations Battery Machine major 45 Component Locations LPG and Diesel Machine major components 46 Control Systemi ua woe owe 1 41 Functional Description 47 CAN BUS 48 BUS message routing 49 Contool EEG 5 5 49 Main Machine Controller 49 Drive 50 Steering Controller 51 Component w E box Q Q 0 0 02 Troubleshooting 44644 244 ok oon domom RO E mox x m X Ox XO oO wo Y DE wD Oe 53
20. Dust Control Fan Switch Filter Shaker Switch 38 Service Manual CS7000 General Information Dust Control Fan Switch enables and disables the dust control fan Broom Select Switch functions as follows When the one touch sweep is enabled the Broom Select Switch selects the broom main broom or side brooms that will be raised or lowered when the Broom Height Raise Button and Broom Height Lower Button are pressed When the one touch sweep is not enabled pressing the Broom Select Switch once will lower the side brooms switch on the side broom motors for a short time then raise the side brooms Pressing the Broom Select Switch twice will lower the main broom switch on the main broom motor for a short time then raise the main broom DustGuard Spray Switch enables and disables the DustGuard spray nozzles Filter Shaker Switch switches on the filter shaker The shaker will cycle 16 times then switch off Sweep Indicators Main Broom On Indicator indicates that the main broom 1s enabled Side Broom On Indicator indicates that the side brooms are enabled Main Broom Float Indicator indicates that the main broom is set to the float mode Dust Control Fan On Indicator indicates that the dust control fan 1s enabled DustGuard On Indicator indicates that the DustGuard system 16 enabled Filter Shaker On Indicator indica
21. Vacuum Motor Current Sensor Vacuum motor contactors have Disables scrub and fault been off more than 5 seconds recovery functions but the brush motor current sensor is reporting 6 A 2 6V Make sure the sensor is reading the correct wire s Service Manual CS7000 Control System 57 Hidden Menus The main machine controller supports a hidden menu which allows you to match the controller to the machine set some user options and perform time saving service tests There are three main hidden menus modes Configuration Display Configuration Menu and User Options Menu unique switch sequence is used to enter each mode Configuration Display The configuration display mode is a read only mode that allows you to check how the main machine controller thinks the machine 1s equipped without running the risk of accidentally changing a value It also allows you to check historical faults for the main machine controller steering controller and drive controller To enter the Configuration Display 1 While Pressing and holding the hazard flasher switch turn the key on 2 Continue to hold the switch until the LCD reads Configuration Display and then release the switch Once in the configuration display you can scroll the arrow cursor through the menu using the scrub pressure increase and decrease buttons To enter a menu selection press the One touch scrub switch To exit and return to the configuration dis
22. X Ro Xx wow 98 RU NO qe 4 98 Wiring 101 Circuit oum lt coe omo wm o dote Woe ROWOR N 3 Wo cR Q 4 NW 102 Current 102 42 Volt Alternator Generator 102 102 bow e uus e wow d woe ou S W 2 103 42 Volt 103 iun 104 Incandescent Headlights 104 LED HeadHElfs 2 u s ow baw eu 0 Q Q ae eee 42 Q x 104 Component Locations 105 Electrical Panel Contactor Relay location 107 Harness to Harness Connector Locations 108 Connector 109 Component ID to Connector ID Look Up Table 109 Wiring 131 K14 Safety Relay and K15 Auxiliary Relays 131 Early Style K14 Safety 131 Early Style K15 Auxiliary Relay 181 Late style K14 Safety Relay K15 Auxiliary 132 Maintenance and Adjustments 133 Charging the Battery Battery 133 Generator Drive Belt 133 Troubleshooting ce Rech
23. Service Manual CS7000 On machines equipped with an early rear corner roller kit but no squeegee guard kit it s recommended that you remove the left rear Corner Roller Bumper Assembly in order to access a tie down location for the tow hook Later corner guard kits have been improved to allow use of the left Tie dow n Slot for towing without removing the left corner roller bumper assembly Diagnostic and Service Tools General Information 21 Corner Roller Bumper Assembly 2 P ax 4 T r In addition to a full set of metric and standard tools the following items are required in order to successfully and quickly perform troubleshooting and repair of Nilfisk Advance Industrial floor cleaning equipment Laptop computer loaded with current version of EzParts Adobe Reader and preferably cellular internet access Digital volt ohmmeter DVOM with DC current clamp Hydrometer Battery load tester for checking 36V and 12V batteries Automotive fuel pressure test gauge used on diesel engines Static control wrist strap Set of torque wrenches Hard printed copies of service manuals for regularly serviced machines available at www advance us com and other Nilfisk Advance websites These tools are also available from Nilfisk Advance Inc Vacuum water lift gauge p n 56205281 Service Manual CS7000 General Information 22 Technical Specifications
24. CodeS Eom 53 Fault Code Table machine 54 Hidden Men s s a 9 4 eee See SPR Q SU 30 Q R amp Q 9 Q eO e XX 57 Configuration 57 Configuration 59 User Options 61 Service Mode Luo rues EE GE GA ee 67 To 68 Troubleshooting Q 12 Control Panel LEDs stay ht CAN Bus problems 2 Removal and Installation 2 e e e ox E Row eos fis Main Machine 49 Control Panel 74 Shop Measurements Main Machine Controller 75 15 J3 Connector Gray uro o ane de w amp w e amp 8 S 16 Jy Connector Black 78 Dust Control DustGuard Systems 80 Functional Description kb s 9 3 anes Cee x e Ae 4 5 8 OES Ow d 80 a ATUM 80 Dust Control System gt 80 DustGuard Spray System 81 DustGuard System Wiring Diagram 82 Circu
25. Solenoid Electrical Connector Weldment Hopper Lift 5 Disconnect the two Hoses and Weldment remove the Solenoid Valve Assembly from the machine 6 Reinstall the Solenoid Valve Assembly by following the above steps 1n reverse order Service Manual CS7000 Dust Control DustGuard Systems To Remove and Reinstall the DustGuard Pump 2 Drain the water from the upper hopper Note that you can do this one of several ways The most convenient way 18 to remove the strainer cover and screen and drain the upper hopper through the DustGuard strainer reservoir Turn the key switch on raise the hopper and engage the prop rod then turn off the key switch Note Place a suitable VA container underneath the DustGuard Pump to catch any water that may leak from the DustGuard Pump and hoses Disconnect the Pump Electrical Connector Disconnect the two Hoses from the DustGuard Pump Remove the four Phillips Screws and washers holding the Pump Guard and DustGuard Pump to the Upper Hopper and remove the Pump Guard and DustGuard Pump from the machine Note that you ll need to cut the Wire Tie holding the Pump Electrical Connector wires to the Pump Guard in order to separate the Pump Guard and DustGuard Pump Reinstall the DustGuard Pump by following the above steps in reverse order Note Place a suitable container underneath the upper hopper to catch the water fr
26. 1 Carefully rotate the Plastic Nozzle Adapter with a 7 8 Wrench to orient the Spray Nozzle 2 After you rotate the Plastic Nozzle Adapter make sure the Brass Nozzle Adapter is holding Plastic Nozzle Adapter securely in the Nozzle Bracket Tighten the Brass Nozzle Adapter to the Plastic Nozzle Adapter as necessary Service Manual CS7000 Dust Control DustGuard Systems Troubleshooting EN 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 use the Service Mode Problem Cause Correction The DustGuard The DustGuard system Make sure the DustGuard system is installed in the system does not is not installed in the configuration menu operate configuration menu Inadequate water flow Inadequate water level in Check the water level to the DustGuard upper hopper nozzles The water strainer screen is Clean the strainer screen plugged The water hoses nozzles are Check and clean the water hoses nozzles as plugged necessary The water solenoid valve is Check for voltage at the solenoid valve plugged or not functioning correctly If there is voltage at the solenoid check the solenoid coil resistance It should measure 125 ohms x 10 If the coil resistance is not within spec replace the solenoid valve e f there is no voltage at the solen
27. 15 Service Menu selection 4 Press the One touch scrub switch to enter the service menu Service Manual CS7000 Control System 68 5 With the arrow cursor aligned with Service Mode press the One touch scrub switch to enter the mode Service Mode will be displayed at the top of the LCD followed by battery voltage drive pedal position sensor voltage drive mode Reverse Neutral or Forward and any current main machine controller faults Once in the service mode you will be able to turn various electrical loads on and off through the control panel buttons Some loads are toggled on and off by a single button press while others are only on when the button 1s held down To exit the service mode Turn the Key Switch off 3 ams E Scroll Down To Operate Scrub Motors Pressing the One touch scrub switch once will turn all of the brush motors on energize all contactors and illuminate the button LEDs The scrub pressure indicators will be on while the brush motors are on Pressing the switch again will turn the brush motors off de energize the contactors Service Manual CS7000 Control System 69 Scrub Deck Actuator Pressing the scrub pressure increase button will move the deck down Each press and release will extend the actuator motor a little Holding the button down will run the motor in the extend direction Pressing the scrub pressure decrease button will move the deck up
28. 4 7 BLU oense J7 Se Een IT Y I 7 7 032 BLU Input POT High H4 Power supply 3 3V B Ground BLK for Main Broom Actuator Position Sensor J7 34 033 GRA Input Wiper R4 Main Broom Oto 3 3V B Ground GRN Actuator Position Sensor input J7 35 034 TAN Input POT Low R4 B for Main B Ground RED Broom nl Position Sensor 142 Service Manual CS7000 Electrical System 143 Wiring Diagrams Wiring diagrams show how electrical components are connected together and to a large degree how things work They do not show where things are located Here are some tips when using these diagrams Every component has both an ID and a Component ID Component Typically relays and contactors are split up so that the relay winding is separated from the contacts control side of the relay is shown in one location and the load side of the relay is shown in another location The two pieces may or may not be on the same page K10 Contactor Contacts on sheet 4 Mu E Sapu STEERING K10 Contactor coil on sheet 1 When a circuit breaks across sheets there is a sign post at both ends to help you quickly identify where the circuit leaves one sheet and picks up on another The sign post may be the wire color or a circuit description AN BLK WHT gt THROTTLE 1 OUTPUT BLK WHT On Shee
29. The Following Conditions Must be Met for the Side Broom Sweep System To Operate 381 Side Broom Actuator 381 Component Locations 382 882 Side Broom Motor 382 Side Broom 382 Maintenance and Adjustments 383 To Remove and Reinstall a Side 383 Inspecting Replacing Side Broom Motor Carbon 384 Troubleshootino 2 s s L kz a 9 bu mE x ES 386 Removal and Installation ow oho ok RR dE Wow de Wd de Xo GLO ow Ue ee Go 3 887 To Remove and Reinstall a Side Broom Motor Assembly 987 To Remove and Reinstall a Side Broom Hub Assembly 389 To Remove and Reinstall the Side Broom 389 e 2 x e k Q Q ST TESTS ST T T TT TT SZ 392 Special Toole v c UR EO UR h s je x w 6 S w Q w Q S Q Q 2 Q 392 Wheel System Non Traction 393 Functional Description 393 Maintenance and Adjustments 394 To Adjust the Brakes 394 Troubleshooting a 5 4 xk 395 Removal and Installation x ec onu eae 54 e
30. 283 To Remove and Reinstall a Vacuum Motor 284 Specifications s i s sew D OUR wep ae e a ka bea hehehe de eom ews 285 PPC 285 System ssa lt 2 x CUAL 286 Functional Description aee e Ro 9 eee c ee dr E bac 286 A m uw ate 2 amp 2 Wexuw ewmwueus xu ae 286 Scrub Pressure 1 286 Scrub System Wiring Diagram amp 299 om ce 287 Z L 288 The Following Conditions Must be Met for the Scrub System Operate 288 Scrub Deck Actuator 288 Brush Current 289 Component Locations 24 4 no oe dw 289 Scrub Motor 289 Right Scrub Arm Gas Spring and Lever Arm Bracket 289 Side Squeegee Assemblies 290 berub de ei am EE edo mob Ar owe EEE SER 4 4 290 Maintenance and Adjustments 291 To Replace Leading Deck Blade 291 To Replace a Trailing Deck Blade 291 292 Removal and Installation aooaa 293 To Remove and Reinstall a Side Squeegee Assembly
31. Engine Coolant 179 EE x eee hee E ux 179 Shop 179 Engine RPM Sensor 179 179 Engine 1 180 Fuel System Return Fuel Flow 180 CIT 180 Glow Plug Relay 180 oO zu RO ORC UA 181 Engine System LPG 182 Functional Description i s sa s mi s mas koa Rode Rode Ro ecd cue o ero 182 Circuit 2 x 9 2o X 6 Q Q N 183 Ignition System 183 Engine Starter Control 185 Throttle Control Modes 186 oni 6 l2 mu S m 2 4 WE 2 4 Q 2 WOROE ORO HO Q J e Q Q X Q W 186 linus 24s ex eee Reh ee Ree GEER Q S eee Q w W lt ee 187 su 2 s sua ZS pus s 2 z 2 E 2 Z 2 Z 188 6 sa ee lt ee eee ee doe ea eee edu Eu S b 50 189 Engine RPM Control 189 Normal Engine Shut Off 190 DIBD ONCE c2 u 2 2 3 2 30 190 Service Manual CS7000 Contents vi DICH LU dus 191 Engine Overheat 5 192 Lost Pressure Shutdown 193 Component Locatio
32. Excessive Engine Temperature Engine Temperature switch Shut down engine closed with the engine running Low Engine Oil Pressure Loss of engine run signal Shut down engine pressure switch open with the key switch still on Glow PugRelay Overoad ______ VACC1 circuit breaker tripped Aux Contactor energized with no voltage at J2 13 VACC1 02 03 04 05 07 10 1 2 13 VACC2 circuit breaker tripped Aux Contactor energized with no voltage at J3 26 VACC2 circuit breaker tripped Aux Contactor energized with no voltage at J3 34 VACC3a and J3 35 VACC3b circuit breaker tripped Key on with no voltage at J2 34 VACC6a and J2 35 VACC6b 15 6 1 Scrub Deck Actuator M11 gt 7 Amps for 4 seconds or short Disables detergent Overload circuit solution and scrub motors Main Broom Actuator M21 gt 6 Amps for 4 seconds or Disables sweep functions Overload short circuit 18 Side Broom Actuator M13 gt 7 Amps for 4 seconds or short Disables side brooms Overload circuit 19 Side Broom Contactor K8 gt 4 Amps or short circuit Disables side brooms Winding Circuit Overload 2 Dust Control Contactor K6 gt 4 Amps or short circuit Disables dust control Winding Circuit Overload 21 Left Brush Contactor K1 4 Amps or short circuit Disables detergent Winding Circuit Overload solution and scrub motors 22 Center Brush Contactor K2
33. General Specifications Machine Dimensions Length 103 262 Width With right side squeegee assembly pivoted under the machine 48 122 cm With squeegee 53 135 Height Without With overhead With overhead With debris hopper raised 90 overhead guard guard US 82 guard EU 79 229 59 150 cm 208 cm 201 cm Minimum Aisle Right turn 102 259 Turnaround Left turn 104 264 cm Width Transport 3 7 6 cm side skirts on scrub deck Ground Clearance Machine Weight Hybrid LPG Dry Weight 3 636 Ibs GVW full solution and dust control tanks 4 676 Ibs 2 121 kg 1 649 kg Hybrid Diesel Dry Weight 3 511 Ibs GVW full solution and dust control tanks 4 537 Ibs 2 058 kg 1 593 kg Battery Dry Weight 4 682 Ibs GVW full solution and dust control tanks 5 716 Ibs 2 593 kg Machine 2 124 kg Maximum Tire Loading with full solution and dust control tanks Hybrid LPG 146 psi 10 26 kg cm2 Hybrid Diesel 137 psi 9 63 kg cm2 Battery Machine 148 psi 10 41 kg cm2 Battery Configuration Hybrid LPG and Diesel 3 12 volt battery pack 1 separate 12 volt engine starting battery Battery Machine US Battery 1 36 volt battery 770 amp hours 6 hour rate 5 4 hour run time EU Battery 1 36 volt battery 800 amp hours 5 hour rate 5 4 hour run time Service Manual CS7000 General Information 23 Solution System 1 gpm 3
34. RED 2 1 COIL 3 COIL 2 1 2 1 I IGNITION CONNECTOR FOR PLUGGING INTO KUBOTA IGINTION HARNESS FUEL PUMP X265 A IGNITION REQUEST X265 1 C 18 CRANK REQUEST X265 1 F TOPIN B 6 THROTTLE 1 12V OUTPUT x266 lt 2 K SPEED 2 12V OUTPUT RED 16 _ _________ _____ IN THROTTLE 2 12V OUTOUD X266 jp 2 1 scan sis enon MAE eae SHIELDED WIRE RUN SIGNAL 12V INPUT x266 C ait C ENGINE RUN 12V IN GRY 16 o X265 Gy 1 COOLANT GROUND INPUT 16 COOLENT TEMP GROUND INPUT 156 Electrical System Service Manual CS7000 56509170 Rev H SN 1000048160 and later Sheet 7 of 7 Sheet 6 of 7 Re drawn in ladder style RU SIGNAL GNITION REQUEST COOLANT TEMP CRAN REQUEST KU Pu NG SUS HROTTLE HROTTLE 2 ALTERNA
35. Wrench ne ie Note Place a suitable container underneath Wap CM C e AL ue Plastic im 1 L ING the nozzles to catch any water that may Nozzle leak from the hoses Adapter 2 Hold the Plastic Nozzle Adapter with a 7 8 Wrench to keep it from rotating the Nozzle Bracket when you remove the Nozzle Cap This will maintain the correct spray pattern orientation of the Spray Nozzle 9 Rotate the Nozzle Cap one quarter turn counterclockwise as viewed from the front of the machine to remove the Nozzle Cap Spray Nozzle and Check Valve Strainer from the Plastic Nozzle Adapter Plastic 4 Rinse the Nozzle Cap Spray Nozzle and Check Nozzle Valve Strainer in clean water to remove any accumulated dirt or sediment If necessary rinse or soak the components in vinegar or other commercial cleaner to remove any mineral deposits 5 Reassemble the DustGuard nozzles by heck Val following the above steps in reverse order Check valve Strainer To Adjust the DustGuard Spray Nozzles The Spray Nozzles should be approximately 10 to 20 degrees from vertical as shown in order to spray the water evenly top to bottom in front of the side brooms Note that the hopper has been raised slightly in the adjacent photo The spray pattern should wet the floor across the whole width of the side broom If the spray pattern is not correct Nozzle EL
36. ia M2 RED d WHT ORN gt BLK CONTACTOR LEFT BRUSH uH K2 MS 150 RED H GRA BLK WO 77 BLK CONTACTOR CENTER BRUSH MOTOR VOOR CNTA EE M4 K3 RED H BLU YEL C2 BLK CONTACTOR RIGHT BRUSH MOTOR HUBS VAC CURRENT SENSOR K5 RED dt BLU GRA 1002 BLK CONTACTOR VAC MOTOR M6 MOTOR VACUUM BLU GRA BLK 7 MOTOR VACUUM Service Manual CS7000 Electrical System 153 56509170 Rev H SN 1000048160 and later Sheet 4 of 7 1 RUM F1 STEER BY WIRE CB10 RED CRAM x 3 BLK CONTACTOR STEERING M16 STEERING ACTUACTOR WIRES ON ACTUACTOR U BRN y RED WHT W 25 WHT GRN YEL BLK RED 0 34 STEERING CUNTRULER AD ENCODER IN 1 5 5 WHT ENCIIDER IN 2 J5 6 BLU GRA TEMP SENSOR J5 16 PINK SENSUR_SUPPLY_GND 5 4 BLK 7 5V SENSUR SUPPLY J5 3 ORN BLK X98 AL IN 3 5 1 GRN WHT ow Al BL ENCODER_IN_4 J5 10 RED WHT 1 A2 A2 DIGITAL 4 J5 17 BLU 52 BLU B2 DIGITAL IN 6 J5 20 GRN BLK B ow GND 1 VOLT 1
37. measurement value 20 157 YEL ORN Solution Solenoid Valve 0 1v when energized Grounds to energize 21 160 BLU VIO Detergent Pump M18 Pulsed voltage is too fast for useful measurement value ze reu 12v key 169 BRN Head Lamps and Curb Lamp 37v key and lights off PWM ground to turn on lights 33 7v key on headlights on 039 ORN RED Hydraulic Pump Motor 0 08v when energized Hopper Down Contactor K12 Grounds to energize 047 YEL BLU Left Brush Motor Contactor 0 08v when energized Grounds to energize 26 015 WHT VIO Center Brush Motor Contactor 0 08v when energized Grounds to energize 061 GRA RED Right Brush Motor Contactor 0 08v when energized Grounds to energize 038 BLU ORN Hydraulic Pump Motor 0 08v when energized Hopper Up Contactor K11 Grounds to energize Pump M18 Pulsed UR is too fast for useful _ value 054 Power supply from Aux Relay 37v Key On Aux Relay energized 053 BLK WHT VACC6b Ov Key Off Power supply from Aux Relay 37v Key On Aux Relay energized J3 Connector Gray Circuit Description Value Condition 1 042 VIO ORN Extended Scrub Pump Not measured PWM ground 2 093 RED YEL Solution Control Pump 37v no flow PWM ground 27 minimum flow rate 5 6v maximum flow rate 3 030 BRN WHT Main Broom Actuator 37v at rest or when moving down Reversing polarity driver 5 4v when moving up 4 031 RED VIO Main Broom Actuator 37v at rest or when moving up Reversin
38. s X270 Main Harness Connector X271 Pm Wire p D 019 BLU GRA 020 BLK s _ 5 _ X274 Engine Interface Harness Connector 175 m we e feson p w DELPHI 12015798 DELPHI 15326910 Electrical System 130 Service Manual CS7000 X275 Fuel Pump M20 LN 5 EC Wiring Connections K14 Safety Relay and K15 Auxiliary Relays Early Style K14 Safety Relay 6 GRA ORN 4 PINK A VIO ORN or ORN GRY Early Style K15 Auxiliary Relay XBX DPDT DELPHI 12010973 Electrical System 131 Service Manual CS7000 Electrical System 132 Late style K14 Safety Relay and K15 Auxiliary Relay GRAY ORN K14 Safety Relay GRAY ORN 2 K15 Auxiliary Relay 15 Auxiliary Rela Service Manual CS7000 Electrical System 133 Maintenance and Adjustments Charging the Battery Battery Model See User Manual Generator Drive Belt The generator drive belt tension 1s maintained by an auto tensioner and does
39. sounds the horn when pressed High pressure Wand Switch engages the high pressure spray wand solution pump LPG and diesel only Extended Scrub Switch enables the optional extended scrub recycle function Miscellaneous Indicators Attention Indicator lights to alert the Operator of a machine condition requiring attention Left and Right Turn Indicators indicates that the corresponding turn signal 1s flashing Warning Indicator lights to alert the Operator of a warning or fault condition Extended Scrub Indicator lights to indicate that the extended scrub function is enabled High speed Indicator lights to indicate that the engine is running at high speed Headlight Indicator lights to indicate that the headlights are on High pressured Wand Indicator lights to indicate that the wand high pressure pump is engaged Attention Left Turn Right Turn Indicator Indicator Indicator Warning Indicator Extended Scrub 4 Indicator High pressure Wand Indicator Service Manual CS7000 Scrub Controls Scrub Pressure Increase Button increases the scrub pressure one level when pressed Note that the scrub pressure LED indicators 1n the One Touch Scrub Switch will light to indicate the selected scrub pressure One Touch Scrub Switch enables the scrub solution and recovery systems and the EcoFlex system if the machine 1 so equipp
40. 2 133 42 volt generator is charging 133 Insufficient machine operation time Battery Model 133 Insufficient machine operation time with engine off Hybrid models 133 Removal and Installation 184 42 volt Generator Drive Belt 134 42 volt Generato 222 mox Ux 3 N RO XO We Q owe N 186 Generator Drive Belt Tensioner 136 Head Light bulb Standard 12v Halogen 187 Q Q Q Q Q wea 0 Q 44 138 Battery Battery 138 Low Voltage Cut Out 138 Battery Run Time Battery powered machine 138 CUrrent SIDE REC 139 gan eee lt lt 9 143 Engine System Diesel 157 Service Manual CS7000 Contents Functional Description 522 622 x39 o9 x 9 wd ow xs DEO ES E e e ope d 157 Engine starter control 4e ee 158 Ene ZEE UQ 159 Engine Protection 159 Over Temperature Shutdown 160 Low Oil Pressure Shutdown 161 Engine RPM control NE ss sws 162 Glow plug 164 Com
41. 293 To Remove and Reinstall the Scrub Deck Actuator 294 To Remove and Reinstall the Scrub 294 To Remove and Reinstall a Scrub Motor Assembly 297 To Replace the Scrub Motor Carbon Brushes 298 301 Special Tools ba ux s ws 2 eae eee ee S 302 Solution System sesse sesso s s s s s s s s s s s s s s e s so s s e e s ex 303 Functional 303 303 Solution Flow Control Non EcoFlex 303 Solution Flow Control EcoFlex 303 EcoFlex Detergent System 304 Extended Scrub System 304 Optional Hot Water System LP and Diesel EcoFlex Machines Only 304 Optional Wash Hose Kit lt wox Reo God o9 b Ee e o XR w Wb B ow d 304 Optional High pressure Spray System LP and Diesel Only 305 Solution Level Sensor 305 Solution System Wiring Diagram 306 Circuit Description lt a 307 The Following Conditions Must be Met for the Solution System to Operate 307 Service Manual CS7000 Contents ix The Following Conditions Must be Met for the Extended Scrub System to Operate 307 The Following Condition
42. 45V m B gt GRN BLK B2 1 RED BLK 4 GND 2 VOLT 2 45V TFD CONTROL J5 2 BRN WHT gt BLK FD TORQUE CONTROL 8 INPUT 25 1 ORN WHT FD B POWER APPLICATION CONFIG INPUT J5 12 ORN STFFRING WHEEL ROTATION SENSOR S16 RIGHT LIMIT INPUT J5 13 WHT BLU D ORN SWITCH RIGHT TRAVEL LIMIT LEFT LIMIT INPUT J5 19 ORN RED EH ORN SWITCH LEFT TRAVEL LIMIT FROM SEAT SWITCH SAFTY RELAY OUTPUT J5 18 VO ATI ORN J5 23 YEL r3 CAN H J5 15 GRN CAN L B CAN GND 5 8 7 BK 7 L55 _ RS GRA WHT 710809 ORN RESISTOR 10 OHM 154 Electrical System Service Manual CS7000 56509170 Rev H SN 1000048160 and later Sheet 5 of 7 KI NGINE SYSILM gt gt
43. 9 ORN gt gt TO SPEED CONTROLLER ORN J3 23 1e v VO RED 7 H TAN GRN C BRN ORN RED STARTER INPUT 7 13 INPUT KEY SWITCH T 59 K14 15 sg e A 93 6RA ORN PINK 115 N GRN BLU J7 1 INPUT EOD SWITCH SEAT RELAY SAFTY SWITCH EMERGENCY STOP SWITCH BATTERY INTERLOCK INTERLOCK E x RUN SIGNAL J7 4 RUN GRA GRA 26 ase DRN lt SIGNAL INPUT i i TD STEERING SYSTEM SPEED CONTROLLER GRN BLU gt gt gt COOLANT TEMPERATURE J7 5 COOLANT TEMPERATURE GRN YEL GRN YEL gt OUTPUT K15a INPUT P RED GRA WH p Fee BLK WHT 22 34 INPUT RELAY 5 BLK WHT BLK WHT 35 INPUT VACC 6b L u WG i 7 5 RED uh BLU GRN Toys 7 CRA BLK 3 34 INPUT E x CONTACTOR AUX VACC J3 12 THROTTLE 1 GRA BLU hon BK OUTPUT uu 13 35 INPUT R gy p VIO VACC 3b E x n 03 11 THROTTLE 2 GRA ORN lt RED gt y 2 OUTPUT CB2 OUTPUT n n GRA P o ay BLU GRN RON N START vio Je 13 VACC 1 J3 10 START BLU PINK lt BLU PINK gt gt DUTPUT lt lt t GRA J3 26 INPUT N 2 x x 00 IGNITION GROUND M25 17 IGNITION PINK lt OUTPUT J3 1 PWM DUTPUT DUTPUT SEE NOTE 2 GRA VIO ORN PUMP EXTENDED SCRUB 13 32 GLOW PLUG ORN BLK gt OUTPUT 4
44. Cylinder 249 To Replace the Oil in the Hydraulic System 202 To Remove and Reinstall the Hopper Dump Door Actuator Assembly 261 lt s o Q 2 p a 2 Ro W S Q 3 3 262 Options and 263 Recovery System 273 Functional Description 219 uuo x eave av US 219 Recovery System Wiring Diagram 274 Circuit Description 215 Component Locations o3 3 5x 53x 030x 33 4 303 2 9 23 905 94 e 3 9 276 Service Manual CS7000 Contents viii Recovery Tank x kon s o S094 m 3 44 5 WO G G SO 552 ee ewe ee 276 Recovery Tank Cover and Debris Basket 216 Vacuum Fan Cover Assembly RR E EL 211 Vacuum Motors owen eee ee ee ox Oo 277 Float Cage and Ball Assemblies 2 Maintenance and Adjustments 278 To Clean the Vacuum Filter and Filter Screen 278 Clean the Debris Basket 279 280 Removal and Installation 281 To Remove the Recovery Tank 281 To Reinstall the Recovery
45. DRIVE CUNTRULLER W CURTIS 1234 SPEED CONTROLLER 1 5V J4 86 PINK RED c 3 E PHASE J4 38 2 S amp x PHASE A J4 31 VIO GRN TEMP SENSOR GROUND J4 7 523 DRIVER 1 J4 6 AN FAN ORM TEMP SENSOR J4 8 TN WHEEL DRIVE PINK BLU PINK WHT BLK PINK zz KSI COIL POWER RETURN J4 13 TAN RED c x BLK PINK 2 HROTTLE POT WIPER J4 16 I x PINK 5V THROTTLE POT HIGH 44 15 WH BLK x 5 5 B POT LOW 24 18 vIO BLK INTERLOCK 24 9 KSI 24 1 CAN H J4 23 YEL CAN CAN L J4 35 GRN BUS 12V J4 25 VIO WHT 4 TX 44 28 WHT OR 5 24 29 BLU GR 1 BLK PINK 2 J10 CURTIS PROGRAMER CONNECTOR 3E gt ev I DUST CONTROL MOTOR B o Gg 0 L CB5 x gt x RED TS au X79 3 BRN WHT dk ORN GRN gt m BLK lt CONTACTOR DUST CONTROL MOTOR MOTOR DUST CONTROL b a a SIDE BROOM MOTORS 7 K8 gt 2 8 q RED oR dk WHT RED lt lt M BLK gt NTACTOR SIDE BR MOTOR RIGHT SIDE BROOM M9 HT REB M BLK MOTOR LEFT SIDE BROOM HYDRAULIC PUMP MOTOR nie CONTACTOR HYD M10 CONTACTOR HYD RED TAa O RN WHT BLU YEL gt RED BRN MOTOR ASM HYD PUMP sN 55 BLK BLK ORN WHF BROOM CURRENT SENSOR M1 K4 RED BRN VIO u BLK CONTACTOR BROOM Mr BRUSH CURRENT SENSOR
46. Dealer affix service sticker here Z Note On Fuel Cell models all issues related to the fuel cell must be referred to Plug Power not gt Nilfisk Advance Nameplate The Part Model Number and Serial Number of your machine are shown on the Nameplate located on the top of the machine frame at the left rear side of the machine underneath the recovery tank To access the Nameplate tip the recovery tank out away from the machine This information 16 needed when ordering repair parts for the machine 1 Q Advance Service Manual CS7000 General Information 16 Cautions and Warning Symbols Nilfisk Advance uses the symbols below to signal potentially dangerous conditions Read this 1nformation carefully and take the necessary steps to protect personnel and property Danger Is used to warn of immediate hazards that will cause severe personal injury or death Warning Is used to call attention to a situation that could cause severe personal injury Caution 1 used to call attention to a situation that could cause minor personal injury damage to the machine or other property General Safety Instructions Warning Be sure to follow these safety precautions to avoid situations that could cause severe personal injury This machine should only be used by properly trained and authorized persons While on ramps or inclines avoid sudden stops when loaded Avoid abrupt sharp turns Use low speed dow
47. Each press will retract the motor a little Holding the button down will run the motor the retract direction Vacuum Motor and Squeegee Actuator Pressing the vacuum wand switch once will move the squeegee down extend actuator turn on the vacuum motors energize relay and illuminate the vacuum wand indicator Pressing the button again will move the squeegee up retract actuator and turn the vacuum motor off de energize relay Solution Valve and pump if equipped Pressing the solution switch once turns on the solution valve to allow solution to flow At least one of the solution flow indicator lights will come on If the model is equipped with a solution pump the pump will run at the flow rate indicated by the solution flow indicators While the solution system 16 you can increase or decrease the solution flow rate by pressing the solution flow increase and decrease buttons Detergent Pumps Pressing the detergent switch once will cycle the detergent pumps on and off 1f equipped and illuminate the detergent indicator You should be able to hear and feel the pumps click The detergent ratio will be displayed the LCD while the pump 1s running Pressing the detergent switch again will turn off the pump Side Broom Motors g Pressing the side broom switch once will turn on the side broom motors energize relay The side broom button on indicator will illuminate Pressing the button again will turn off
48. Extended Scrub System Start Up State Off always disabled when the scrub system is activated On always enabled when the scrub system 13 activated Last State returned to state when the scrub system was last on 6 Low Voltage cutout The batteries are monitored Once the voltage drops below the cutout level various systems are shut down to prevent depleting the batteries The batteries must be charged above a reset level before normal operation 1s allowed The LVC clearing will set the batteries to full This setting adjusts the cutout and reset voltages The description 1s on a cell basis There are 18 cells 11 75V 2 15V 21 75V 2 09V 8 1 83V 2 09V 7 Reduced Speed Mode Cougar can be programmed to automatically limit the maximum travel speed while scrubbing only either scrubbing or sweeping or always When Scrub The maximum travel speed will be reduced while scrubbing When Scrub amp Sweep The maximum travel speed will be reduced when scrubbing or sweeping Always The maximum speed is the Scrubbing speed setting 8 Engine Idle Delay This setting adjusts how many seconds to delay before returning the engine RPM to idle after the machine stops moving idle Service Manual CS7000 Control System 66 RANGE 10 250 seconds INCREMENT 1 second DEFAULT 20 seconds 9 Back up Alarm 1 Off never on 2 Reverse Only Only on
49. N T START Vo 2 18 1 J3 10 START BLU PINK lt BLU PINK gt OUTPUT lt lt SHE GRA J3 26 INPUT 2 x 90 IGNITIO GROUND M25 J3 9 IGNITION PINK PINK OUTPUT UN 4 a J3 1 PWM OUTPUT OUTPUT SE C NO C 2 GRA VIO ORN PUMP EXTENDED SCRUB J3 32 GLOW PLUG ORN BLK OUTPUT OUTPUT M23 GRA OF GRN WHT J3 e4 DUTPUT PUMP LOW PRESSURE OPTIONAL M L2 uM MAIN MACHINE m L a 4 VALVE DUST GUARD 1 CUNTRULLER i n N L 25 M22 lt b oD 512 x 1 2 gt GRA lt BRN RED 13 13 DUTPUT 5 FUEL LEVE TAN WHT lt Z BLK PUMP DUST GUARD FUEL LEVEL SENDER T T M19 PUMP SOLUTION CONTROL SOM ii A _ OPTIONAL X X t GRA RED YEL 23 2 PWM J7 7LOW FUELL YEL RED lt lt epe BLK DUTPUT INPUT o o 18 WHT YEL J2 19 DUTPUT A SWITCH LOW LP PRESSURE ots Y1 M17 PUMP CHEMICAL METERING TS g OPTIONAL J3 8 DUTPUT WHT ORN lt t o CLUTCH HIGH PRESSURE PUMP GRA BLU Je 38 PWM QUTPUT M18 PUMP CHEMICAL METERING _ OPTIONAL J3 15 BLK BLU VIO 2 21 DUTPUT J9 16 BLK 13 18 BLK 4 m Bo INPUT 13 16 BIK 03 20 BLK 4 HORN 03 29 BLK 1 H1 t ERA h SRN BRN 03 27 DUTPUT J7 10 12V WHT BRN Jil BACKUP ALARM GRN YEL lt J7 M BH BLK Je Eo 5 TE j CAN BUS J123 X J7 3 CAN X 265 1 4 z J7 8 L GRN D CHASSI
50. PUMP MOTOR oe CONTACTOR HYD M10 CONTACTOR HYD RED Spay ORN WHE sks BLU YEL gt RED BRN Sik MOTOR ASM HYD PUMP zT 5 shes BLK BLK ORN WHF BROOM CURRENT SENSOR M1 K4 RED BRN VIO gt BLK CONTACTOR BROOM BRUSH CURRENT SENSOR ve M2 PA RED d H WHT ORN BLK FROM Fl MOTOR LEFT BRUSH F2 K2 A 150A RED db GRA BLK gt BLK CONTACTOR CENTER BRUSH MOTOR T 4 K3 RED dk BLU YEL BLK CONTACTOR RIGHT BRUSH MOTOR wx oe eae VAC CURRENT SENSOR K5 RED dk BLU GRA 1002 BLK CONTACTOR VAC MOTOR M6 MOTOR VACUUM LU AGRA 41 2 BLK PAN MOTOR VACUUM Service Manual CS7000 56509170 Rev G Before SN 1000048160 Sheet 4 of 6 RED FRDM F1 STEER BY WIRE 810 RED Tu 2777 BRN GRA CONTACTOR STEERING Electrical System T B 3 BLK M16 STEERING ACTUACTOR WIRES ON ACTUACTOR BRN P U RED WHT J W E WHT GRN YEL BLK RED 2246 STEERING CUNTRULER 5 ENCODER IN J5 5 WHT ENCUDER IN 2 J5 6 BLU GRA TEMP SENSOR J5 16 PINK SENSOR_SUPPLY_GND J5 4 BLK 5V SENSUR S
51. YEL RED Right Front Turn Lamp 10 3v when off 0 02v when on 4 101 YEL GRN Right Rear Stop Turn Lamp 11 1v when off 0 01v when on 5 107 TAN BLK Tail Lamps 5 1v when off 0 01v when on 064 BLK YEL Dust Control Motor Contactor 0 07v when energized Grounds to energize 37v when not energized 7 119 BRN WHT Detergent Pump M17 Pulsed voltage is too fast for useful measurement value 080 WHT GRN Squeegee Actuator Motor 37v at rest or when going down 0 04 going up 078 BLU BRN Squeegee Actuator Motor 37v at rest or when going up 0 01v going down 10 132 RED GRN Scrub Deck Actuator Motor 3 v at rest or when going down 0 15v going up 11 135 YEL GRA Scrub Deck Actuator Motor 3 v at rest or when going up 19v going down 162 BLK Battery Negative 0 001v scrub and sweep systems running 19 057 VIO 1 Ov Key Off Power supply from Aux 37v Key On Aux Contactor energized Contactor 14 051 BLK ORN Auxiliary Contactor 0 07v when energized Grounds to energize 3 v when not energized 15 163 BRN BLK oide Broom Motor Contactor 0 08v when energized Grounds to energize 16 063 GRN GRA Main Broom Motor Contactor 0 08v when energized Grounds to energize 17 045 BLU Vacuum Motor Contactor 0 08v when energized Grounds to energize 18 150 BLK RED Shaker Motor 10 6v shaker motor running PWM ground Service Manual CS7000 Control System 76 Circuit Description Value Condition 19 116 WHT YEL Detergent Pump M17 Pulsed voltage is too fast for useful
52. a VAN BLK WHT BRN 112 X239 C HEAD LIGHT LEFT 42 4 12V OUTPUT lt x YEL GRN RP BLK YEL m m LAMP RIGHT REAR S T 18 e o OPTIONAL BLK WHT fs BRN 171s LAMP CURB 5 12V OUTPUT e TAN BLK v R BLK YEL OPTIONAL LAMP RIGHT REAR TAIL LIS OPTIONAL lt BLK YEL a LAMP LEFT REAR TAIL 52 N LI9 OPTIONAL Je 8 12V OUTPUT lt ORN BLU X RY BLK YEL LAMP LEFT REAR S T LT10 OPTIONAL 1 1 2 VIO 69 BLK LAMP FLASHING Service Manual CS7000 Electrical System 152 56509170 Rev H SN 1000048160 and later Sheet 3 of 7 Be RED FROM F1 ON BLK DRIVE MOTOR M24 K7 RED 1 4 H RED 1 2 B WHEEL DRIVE RED RED RED W M
53. and vacuum motors Switched Power A key switch Ignition Switch 1s used to provide switched power to the main machine controller but it carries only a small amount of current The main machine controller in turn energizes an Auxiliary Contactor to provide 36 volt high current capacity supply to many circuits The main machine controller also energizes an Auxiliary Relay which provides a 12 volt power supply to itself The main machine controller then uses this 12 volts to switch out to various circuits like the Ignition output to the engine system Current Sensors The 57000 utilizes hall effect current sensors to report amp draw information for the vacuum motors scrub motors and main broom motor to the main machine controller They work much like an inductive amp clamp for a digital multi meter The motor circuit ground wires run through the circle loop The sensor reads the amperage and converts it to a voltage value for the main machine controller to read With no current flow the sensors report 2 5 volts As current increases the voltage increases Provided the sensors are installed correctly If they are installed backwards the voltage will drop with increased current Tab must point toward Battery Positive Wires pass through circle Current Sensor 42 Volt Alternator Generator The 42 volt generator provides the electrical power needed to operate the machine and to recharge the 36 volt batte
54. fuel pump When the key is turned on 36 volts 1s supplied to the main machine controller connector J7 pin number 13 In response the controller sends voltage out connector J3 pin number 9 to the oil pressure switch As the engine cranks oil pressure builds up causing the oil pressure switch to close and supply voltage to the fuel pump The other side of the fuel pump 1s connected to ground If oil pressure 16 lost the oil pressure switch will open removing power from the fuel pump Engine Protection The engine will be automatically shut down by the main machine controller if the engine overheats or oil pressure is lost When the engine 1s running the main machine controller sends a 12 volt power supply out on connector J3 pin number 9 to power up the governor controller When the main machine controller wants to shut down the engine it removes this power supply to the governor controller When the governor loses the power supply 1t causes the engine to shut down Service Manual CS7000 Engine System Diesel 160 Over Temperature Shutdown Here 1s how the engine over temperature shutdown works To monitor engine temperature the main machine controller sends a voltage through an internal resistor out connector 7 pin number 5 on the green wire with a yellow stripe to the engine coolant temperature switch The switch 1s normally open When the engine overheats the switch closes The closing of the switch connects the voltage source to ground
55. in reverse 8 Fwd amp Reverse on when in motion 4 Fwd Rev amp Hopper on when motion or the hopper is lifted 10 Headlights Normal User controls with key switch DEFAULT 2 Always On On when machine 1s running Key switch allow momentary off 11 Broom Lift in Rev 1No 2 Yes 12 Maximum Speed RANGE 20 100 INCREMENT 2096 DEFAULT 10096 Service Manual CS7000 Control System 67 Service Mode The service mode makes some diagnostic testing easier Some outputs like the scrub brush motors are only turned on when other conditions are met such as when the machine 1s moving It can be difficult to check for voltage to the scrub brush motors while the machine is moving Also if voltage is not present it leaves in question what other conditions may not have been met yet The service mode solves these problems for you by allowing you to request that the controller ignore all other conditions and directly turn on the scrub brush motors or other output loads Enter the service mode through the Configuration Menu 1 While holding down both the left and right turn signal switches turn the key switch on Amm 2 Continue to hold the switches down until the Configuration Menu is displayed then release the switches 3 Press and release the scrub pressure decrease button several times to scroll down the menu list until the arrow cursor is aligned with the
56. ol E ei gt 2 t ELK WHT 0 BRN 4 lt lt 2 23 PWM J2 22 18v OUTPUT BLK YEL HEAD LIGHT RIGHT HEAD LIGHTS CURB LITE eos BLK WHT BRN r BLK JOE 4 xm T1 X239 C 7 HEAD LIGHT LEFT sc RM SORTE MI lt BLK YEL m LAMP RIGHT REAR S T L8 2 o OPTIONAL A Y BLK WHT f BRN a 115 LAMP CURB Je 5 12V OUTPUT lt TAN BLK e R BLK YEL e OPTIONAL LAMP RIGHT REAR TAIL OPTIONAL lt lt e BLK YEL o LAMP LEFT REAR TAIL M 419 OPTIONAL J2 2 12V OUTPUT c ORN BLU X R 2 BLK YEL 4 LAMP LEFT REAR S T LT10 OPTIONAL JL VIO LR BLK LAMP FLASHING VI gt Service Manual CS7000 Electrical System 146 56509170 Rev G Before SN 1000048160 Sheet 3 of 6
57. open and draws no current there will NOT be a code set for this condition The side brooms will not work because of the open contactor coil but there will be no fault code The main machine controller does not monitor every electrical circuit For instance it monitors the control side of the side broom contactor coil because it completes the circuit for the winding It does not monitor the contact or load side of the contactor Any fault codes detected by the main machine controller will be displayed on the LCD display as they occur Critical faults are displayed like this code 50 If more than one critical fault exists the display will sequence through the active warnings and cautions at one second intervals Non critical faults are displayed like this code 19 If more than one non critical fault exists the display will sequence through the fault codes and the hour meter at one second intervals Service Manual CS7000 Control System 54 Fault Code Table Main machine controller Fault Description _________ Setting Conditions None Power Distribution Fault If the voltage of the 36v battery pack falls too low the LCD will display this message You need Sa to charge the 36v battery pack Auxiliary Contactor K9 Winding Short circuit or gt 4 Amps Circuit Overload 01 12 Volt Alternator is not charging Battery voltage is less than 10 volts with the engine running Not used Oo ___ o
58. pin numbers of the connector The connector pin out information 1s organized by the connector ID in alphabetical order If you are viewing this document on a computer you can search for the component ID or component name to find the pin out chart However if you are viewing a paper copy it will be easier for you to find the correct pin out table if you know the connector ID To learn the connector ID find the component ID from the wiring diagram Then use the Component ID to Connector ID Look Up Table below to find the connector ID Component ID to Connector ID Look Up Table Service Manual CS7000 Electrical System 110 Pump Low Pressure Optional Pump Extended Scrub optional Extended Scrub Level Switch optional J1 Control Panel A3 Wire Color 130 WHT BRN 304 301 YEL 300 GRN FRONT JC MOLEX 430250400 Service Manual CS7000 J2 Main Machine Controller A1 Pin Wire Color gt fwon meYvEUeRN s omme e osve ______ e OBP O 31 Sn AMP 776164 2 NEUTRAL Electrical System 111 Electrical System 112 Service Manual CS7000 _ ol oj L ME l co cO oo O O
59. seconds INCREMENT 0 25 seconds DEFAULT 2 seconds 3 Vacuum Off Delay Sets the timeout for the vacuum during the recovery power down sequence RANGE 12 20 seconds INCREMENT 1 second DEFAULT 12 seconds 4 Recovery Mode Sets when the recovery system begins the power down sequence only when the Scrub System is being shut off This is only affective when the system is operating when turned off 1 Normal starts immediately Service Manual CS7000 Control System 65 o 2 Neutral waits for the machine to return to neutral 5 Detect RTF Recovery Tank Full The machine is equipped with a feature that will automatically shut off the vacuum and scrub systems and display a recovery tank full icon on the control panel display when the recovery tank becomes full If problems are encountered with the vacuum shutoff feature such as the vacuum shutting off even when the recovery tank 1s not full this feature can be turned off No Do not detect recovery tank full 2 Yes Detect recovery tank full 4 User Lockouts 1 Spd Control Adjust Battery only Blocks the user from increasing the speed when scrubbing or sweeping Unlocked Locked 2 Scrub Mode Adjust Blocks the user from changing scrub mode settings Unlocked 2 Detergent Prevents the user from changing detergent settings 8 Detergent amp Sol Prevents the user from changing detergent and solution settings 5
60. the side of the injector pump that can be used to shut the lt lt Move to shut down engine E Dead Man Lever 8 normal run position Dead man lever held in shut down position Dead man lever in 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 starter control 12 12 36v Battery 12v Battery J3 23 Kev Switch 17 19 13 10 Start 12v gt Main Machine Controller Engine System Diesel 158 Starter Solenoid To get the engine starter to engage the key switch 1s held in the start position which supplies 36 volts to the main machine controller connector J7 pin 19 This 1s the start input request The main machine controller receives a 12 V supply on connector J3 pin 23 from the engine starter battery It uses this voltage supply to send voltage out connector J3 pin 10 to the starter solenoid Service Manual CS7000 Engine System Diesel 159 Fuel pump control z 36v Battery 12v 12v Battery 13 23 36v J7 13 Oil Pressure ee 23 9 Switch Key Switch 12v Run Main Machine we l Controller Fuel Pump The main machine controller uses the same 12 V battery supply from connector J3 pin number 23 to operate the
61. total battery capacity for maintenance free batteries 41 Service Manual CS7000 General Information 42 Alternate Maintenance free Battery Reset to 5 bars Low Voltage Cutout Reset Low Voltage Cutout Reset 5 bars Never below 35 9 V Never below 35 9 V 4 bars Never below 35 4 V Never below 35 4 V Battery Charge Indicator Standard Battery 3 bars 2 bars T bars Not displayed Fault Caution and Warning Displays Fault Displays The system can detect overloads and short circuits on various hardware circuits and detect system faults There is no hardware detection of open circuits Fault Number These non critical faults detected by the main machine controller will be displayed on the display panel 1n the hour meter section If more than one fault exists the display will sequence through the fault codes at one second intervals Faults are display as a mechanical wrench icon followed by a two digit code Caution and warning displays take priority over non critical fault displays Refer to the Electrical System section for a list of the non critical fault codes Caution Displays Any cautions detected by the main machine controller will be shown on the left side of the display Only the fuel Icon battery level and hour meter indicators will remain Cautions icons are displayed as a non inverse graphic If more than one caution and or warning exists the display will sequence through t
62. 1 GRA GRN WHT _ 3 24 DUTPUT PUMP LOW PRESSURE OPTIONAL Al L2 VITE MAIN MACHINE m L E T VALVE DUST GUARD ei m M m fi N L 9 M22 S 512 ES il J7 6 FUEL LEVEL rar 1 A t GRA C BRN RED 3 13 DUTPUT 2 I TAN WHT lt BLK PUMP DUST GUARD OPTIONAL FUEL LEVEL SENDER T T E M19 PUMP SOLUTION CONTROL F _ OPTIONAL 1 GRA RED YEL 53 2 J7 7LOW FUEL yer RED lt eS BLK 4 OUTPUT INPUT o 18 WHT YEL J2 19 PWM HUTPUT A 5 SWITCH LOW LP N M17 PUMP CHEMICAL METERING gt _ OPTIONAL a 13 8 WHT ORN lt t o te ee TE CLUTCH HIGH PRESSURE PUMP GRA BLU J2 32 PWM DUTPUT A M18 PUMP CHEMICAL METERING u OPTIONAL vam BLK BLU VIO OUTPUT J3 16 BLK J3 18 BLK B 13 19 BLK 4 03 20 BLK VIO BRN J3 14 DUTPUT J3 el BLK HORN 13 29 BLK 1 HI M 1 1 6RN BRN J3 27 OUTPUT J7 10 WHT BRN BACKUP ALARM GRN YEL E ES J7 11 Be BLK PER 3 Ti F CAN BUS 0 xE 7 3 CAN H X L 4 F J7 2 CAN L CHASSIS GROUND BLK WHT B RED vio FROM Fi Service Manual CS7000 Electric
63. 2 Solution Flow RANGE 1 5 DEFAULT 8 7 Neutral Off Delay This determines how long before the brushes are stopped after returning to neutral RANGE 0 5 5 seconds INCREMENT 0 5 seconds DEFAULT 0 5 seconds 8 Scrub Down Time When activated the scrub is lowered for a period of time before the control starts Service Manual CS7000 Control System 64 moving the deck based on the current of the brush motors RANGE 1 3 seconds NCREMENT 0 1 seconds DEFAULT 2 seconds 9 Solution In Reverse Determines whether solution will flow when the machine backs up 1 Off This is default 2 2 Sweep System 1 Sweep Off Timeout This determines how long before the dust control and brooms are stopped after returning to neutral RANGE 0 5 5 seconds INCREMENT 0 5 seconds DEFAULT 0 5 seconds 2 Shaker Duration Determines how long the shaker will run once it 1s activated RANGE 10 40 seconds INCREMENT 1 second DEFAULT 15 seconds 9 Recovery System 1 Sqg Down Time Sets the time to extend the squeegee when lowering it into the active position RANGE 1 4 seconds INCREMENT 0 25 seconds DEFAULT 4 seconds 2 Sqg Up Time Lift 1n Reverse Sets the time to retract the squeegee When backing up with the recovery system active the control unit will automatically raise the squeegee to prevent dragging on the floor RANGE 1 4
64. 26 P 5 4 N ms e M14 52 E gt gt m BLK RED Jede id J3 7 DUTPU lt RED GRA MOTOR SHAKER UTPUT gt 77 N MS Fe 57 Si gt J7 ee INPUT c ORN REB 1 2 gt SWITCH DOOR EXTENT LIMIT E T CLOSES WHEN DOOR IS CLOSED I N Fe CURRENT SENSOR ad 804 BRUSH B1 J7 23 INPUT lt lt lt YEL WHT 7 2 K gt gt i BLU YEL SWITCH DUMP DOGR RETRACT LIMIT 47 24 5V CLOSES WHEN DOOR IS OPEN 5 M12 INPUT E e BRN du er PRUH Je 8 OUTPUT WHT ORN reo M Jos B MOTOR SQUEEGEE ACTUATOR 5 RED EXTEND VIO WHT 5 B Je 9 UTPUT BLU BRN SENSOR wo E M13 BROOM 32 D uh BLU YEL J3 5 OUTPUT C 6RA VIO mro BK LL MOTOR SIDE BROOM ACTUATOR INPUT J7 31 BR M nS TO RED TO EXTEND E c ORNZBEU CURRENT SENSE J3 17 nurTPUT Q PLE 5v B x s 4 CURRENT SENSOR J2 12 B INPUT BLK B3 N BLU YEL EN 174 22 3 12V lt lt lt YEL RED A BLK YEL gt lt INPUT gelu J7 29 m LAMP RIGHT FRONT TURN 8 ae CURRENT SENSE m nc OPTIONAL E N ae J2 1 12V OUTPUT lt lt ORN YEL Az BLK YEL VIO WHT LAMP LEFT FRONT TURN OPTIONAL X263 C 4 oN T e S 172 S x X2 C BLK WHT s BRN lt lt 2 23 PWM J2 22 1 OUTPUT BLK YEL HEAD LIGHT RIGHT HEAD LIGHTS CURB LITE 5 GE
65. 4 Amps or short circuit Disables detergent Winding Circuit Overload solution and scrub motors Service Manual CS7000 Control System 55 Fault Description 7 Conditions 23 Right Brush Contactor K3 4 Amps or short circuit Disables detergent Winding Circuit Overload solution and scrub motors 24 Broom Contactor K4 Winding gt 4 Amps or short circuit Disables sweep functions Circuit Overload 25 Hydraulic Pump1 Contactor gt 4 Amps or short circuit Winding Circuit Overload 26 Hydraulic Pump2 Contactor K4 4 Amps or short circuit Winding Circuit Overload Dust Filter Plugged Closed switch Warning message only 28 Dump Door Actuator M26 gt Amps for 4 seconds Disables sweep functions Overload and hopper door 29 Hopper Over Temperature Closed hopper temperature Turns off the Dust Control switch motor the Main Broom system the Side Broom system and closes the hopper dump door Shaker Motor M14 Overload 20 Amps or short circuit NENNEN 31 Solution Pump M19 or gt 24 amps or short circuit Extended Scrub Pump M25 Overload 32 High Pressure Washer Pump gt 18 Amps or short circuit Electromagnetic Clutch Overload 33 Low Pressure Wash Pump M23 20 Amps or short circuit Overload Dust Guard Pump M22 gt 20 Amps or short circuit Overload 34 35 Solution Solenoid Valve L1 gt 4 Amps or short circuit Disables detergent Winding Overload solution and scrub motor
66. 5 42955594 u5 15 Cautions and Warning Symbols e 9o i8468 be des Ane DR wees CDG EH Ss 16 General Safety Instructions es 16 Hopper Prop ROQ ass bc Row Oe x e RR Oe S Q S amp Q S amp Q RO Q owe 18 To Engage the Hopper Prop 18 To Disengage the Hopper Prop Rod 18 Jacking the 19 Transporting the 19 Towing the Machine 20 Diagnostic and Service Tools hod e 584 EH 21 Technical Specifications s sssr rsss kadiou Q Q 22 General Specifications 22 Fastener Torque Specifications 25 Overall 25 Maintenance seare v S 26 Maintenance 5 26 Recommended Service Materials 26 Daily 24 Maintenance Every 15 20 Hours 21 Monthly 28 Maintenance Every 150 Hours 28 Maintenance Every 400 Hours 28 Maintenance Every 800 to 1000 Hours 28 Maintenanc
67. 6 BLK Battery Negative 0 006v with scrub sweep and vacuum motors free running 159 BLK Battery Negative 0 006v with scrub sweep and vacuum motors free D 059 VOI RED 12V supply Ov off Power supply from starting 12 1v key on battery 24 171 GRN WHT Low Pressure Pump 37v Not Installed Ov Installed 25 Je C 26 058 GRA Key Power supply from Aux 37v Key On Aux Relay energized Contactor 076 GRN BRN Backup Alarm 2 8 29 166 BLK Battery Negative 0 006v with scrub sweep and vacuum motors free running Service Manual CS7000 Control System 78 AUN Plug Output 11 6v when plug relay energized a out to relay 0v off or after time out period 0v Key lt Power supply from Aux 37v Key On Aux Relay energized Contactor 055 GRA BLK VACC3b Ov Key Off Power supply from Aux 37v Key On Aux Relay energized Contactor J7 Connector Black Circuit Description Value Condition 1 092 GRN BLU Interlock Switch Input 37v when all interlock switches closed Ov otherwise 095 GRN CAN Bus Low 2 448v 099 YEL CAN Bus High 4 102 GRA Run Signal Output 14v when engine running Ov key off on or cranking starter disabled 108 GRA YEL Engine Coolant Temperature 4 99v normal temp 112 TAN WHT Fuel Level Sender 3 3v open circuit 1 8v float at bottom 0 37v float at top 117 YEL RED Low LP Pressure Switch 5 0v when open 10 130 WH
68. 7000 Hybrid Diesel EU 56509004 Bulgarian Romanian Nilfisk Advance CS7000 Battery EU 56509005 56041981 Danish Norwegian Swedish Finnish 56041982 German French Dutch Russian 56041983 Spanish 56042541 Portuguese Italian Greek 56041984 Estonian Latvian Lithuanian Slovenian 56041985 Slovakian Czech Polish Hungarian These manuals can be found on the following Nilfisk Advance s electronic supported databases Nilfisk Advance Dealer Customer Zone Nilfisk Advance website www Nilfisk Advance us com EzParts service parts CD ROM Service Manual CS7000 General Information 15 Engine Manufacturers Technical Manuals Engine Model Publication Title Diesel D1305 E3B KEA 1 Kubota WSM Workshop Manual Diesel Engine 05 E3B Series 05 E3BG Series LPG WG972 GL E3 NFK 1 Kubota WSM Workshop Manual Gasoline LPG Engine WG752 G E3 WG752 GL E3 WG972 G E3 WG972 GL E3 Conventions All references to right left front and rear in this manual are as seen from the Operator s seat position Parts and Service Repairs should be performed by an Authorized Nilfisk Advance Service Center that employs factory trained service personnel and maintains an inventory of Nilfisk Advance original replacement parts and accessories Call the Nilfisk Advance Dealer named below for repair parts or service Please specify the Model Number same as the Part Number and Serial Number when discussing your machine
69. 79 1 5 gpm 5 68 2 gpm 7 57 2 5 9 46 3 gpm 11 36 L L min L min L min L min min EcoFlex System Refillable Cartridge Capacity 2 2 gal 8 32 L Available Dilution Rates 300 1 256 1 200 1 150 1 128 1 100 1 64 1 50 1 32 1 and 26 1 Low Detergent Warning Standard Scrub System Scrub Brushes Disc 3 17 43 cm dia Scrub Path 48 122 cm Brush Motors 3 36 VDC 1 HP 2750 RPM 26 Amp Dust Control DustGuard System DustGuard Tank Capacity 29 Mou U _ DustGuard Nozzle Flow Rate Sweep System 12 2 31 cm diameter x 35 4 90 cm long 15 38 1 cm diameter 42 VDC 2800 RPM no load 25 HP Vacuum System Vacuum 48 H2O With 1 dia Orifice 25 to 30 H2O 42 VDC 15 Amps average 17 Amps max Service Manual CS7000 General Information 24 Drive System Steering Rear wheel steer by wire system The steering controller receives input from the steering wheel to drive the steering actuator motor The steering actuator motor drives a gear that meshes to a large ring gear that rotates the drive wheel assembly Brakes service and parking Mechanical drum brakes one on each front wheel mechanically actuated Machine Performance Machine Speeds O Gradeability vehicle loaded to 18 degrees 32 5 grade Tilt Stability Empty Tanks 24 0 degrees 44 5 Full Tanks 23 0 degrees 37 0 grade grade Approach Trail Angles Approach Angle 7 5 deg
70. B4 LI TP RO Do 31 YEL BRN x lt BLK gt amp 12 i PDWER 4 pu BLK 1 T OUTLET 1 2 ME VIO GRN J7 19 START INPUT OPTION 15 2 In POWER OUTLET OPTIONAL H RED 4 BLK 8S v YEL BRN 1J H BLK ORN Je 14 DUTPUT 5 CONTACTOR AUX F NI YEL BRN 7 SUPRESSION NGINE SYSTEM SWITCH IGNITION DIODE Pin SEE SHEETS K15b ENGINE SYSTEM 5 OR 6 RELAY AUX CB9 9 7 ORN gt gt TU SPEED CONTROLLER 3 23 1g V VO RED 51 F TAN GRN Toga z 8RN ORN 1 RED STARTER B ORN INPUT J7 13 INPUT fe KEY SWITCH o S9 K14 S 513 L 1 oe 2 N 6 zh PINK alo TAN GRN BLU J7 1 INPUT SWITCH SEAT RELAY SAFTY SWITCH EMERGENCY STOP SWITCH BATTERY INTERLOCK INTERLOCK Eua UN SIGNAL J7 4 RUN GRA lt GRA gt gt 1 lt SIGNAL INPUT TO STEERING SYSTEM TO SPEED CONTROLLER GRN BLU gt COOLANT TEMPERATURE VACCE J7 5 COOLANT TEMPERATURE GRN YEL lt GRN YEL gt OUTPUT CB6 15 ere INPUT RED ORAT ul RELAY AUX 5 BLK WHT BLK WHT 46 39 UT VACC 6b TNI VACC3 CBS x R ida d BLU GRN T9 13 34 INPUT X x J3 12 THROTTLE 1 GRA BLU lt lt GRA BLU THROTLE 1 m OUTPUT VACCI OUTPUT vio meer 6 3b P x 7 T x J3 11 THROTTLE 2 GRA ORN lt GRA ORN T CB2 OUTPUT AE ERA 7 04 PT BLU GRN e
71. CS7000 Service Manual Advance CS7000 Hybrid LPG Model Number 56509000 Advance CS7000 Hybrid Diesel Model Number 56509001 Advance CS7000 B Model Number 56509002 Advance CS7000 Hybrid LPG EcoFlex Model Number 56509006 Advance CS7000 Hybrid Diesel EcoFlex Model Number 56509007 Advance CS7000 B EcoFlex Model Number 56509008 Advance CS7000 Fuel Cell EcoFlex Model Number 56383115 Advance CS7000 Hybrid Gasoline EcoFlex Model Number 56511001 Nilfisk CS7000 Hybrid LPG EU Model Number 56509003 Nilfisk CS7000 Hybrid Diesel EU Model Number 56509004 Nilfisk CS7000 Battery EU Model Number 56509005 Nilfisk CS7000 Hybrid Petrol EcoFlex Model Number 56111002 ONilfisk Advance English trusted since 1906 05 11 Revised 02 13 Form No 56043151 Service Manual CS7000 Contents ii Contents General 18 General Machine Description 13 Service Manual Purpose and 13 Fevision History s s 13 Other Reference Manuals and Information Sources 14 Nilfisk Advance Publications 14 Engine Manufacturers Technical Manuals 15 5 e eens Ba ee 15 P apta and REUS NR UE S 15 Nameplate ue och Q mod EGSXRSmDmee444 95424 5
72. Check the wiring and circuit breakers upstream of not run shaker motor the shaker motor 2 Check the J2 18 output from A1 Main Machine Controller The shaker motor is not If there is voltage to the shaker motor replace the operating correctly motor 92 Service Manual CS7000 Dust Control DustGuard Systems 93 Removal and Installation Warning Before removing or reinstalling any machine components make sure the key switch is off the key is removed from the machine and the parking brake is engaged To Remove and Reinstall the DustGuard Solenoid Valve Assembly 1 Drain the water from the upper hopper Note that you can do this one of several ways The most convenient way 1s to remove the Strainer Cover and screen and drain the upper hopper through the DustGuard Strainer 2 Note Place a suitable container underneath the upper hopper to catch the water from the hopper c reservoir 2 Turn the key switch on raise the hopper and engage the prop rod then turn off the key switch Note Place a suitable gt container underneath the Solenoid Valve Assembly to catch any water Cover 4 that may leak from the Solenoid Valve Assembly hoses x r G H 3 Disconnect the Solenoid Electrical Connector Solenoid Valve Assembly 4 Remove the two Nyloc Nuts holding the Solenoid Valve Assembly to the Hopper Lift
73. Filter Switch 0 147 Hg 0 072 psi Voltage 36 VDC Current 0 8 Amps average Power 90 Watts Filter Shaker Motor Ingress Protection IP44 Insulation Class B Duty intermittent 52 10 min Nilfisk s Advance Service Manual CS7000 98 Electrical System The electrical system chapter contains wiring diagrams electrical panel 1nformation and covers other components that are not covered other chapters For instance the Solution Pump 1s covered in the Solution System Chapter Functional Description Overview The CS7000 uses electricity to operate almost everything The Battery model has a large capacity 36 volt storage battery for its only power source Power from the 36v battery supplies all machine electrical loads Machine 36 v Electrical Loads 36v Battery Battery Model Power Distribution Service Manual CS7000 Electrical System 99 Hybrid models use a large engine driven 42 volt generator for their main power source with a smaller 36 volt battery pack connected in parallel with the generator as a back When the engine 1s running the 42 volt generator provides the electrical power to operate the 36v machine electrical loads as well as recharge the 36v battery pack If the machine demands more current than the 42 volt generator can provide the 36 volt battery pack supplies the extra boost that 1s needed If the engine 1s not running the machine
74. Ground from Aux Contactor GRN Switch Input Logic Input _ 36V B Ground BLU S GRN 22 Bus Low Digital Signal 0 or 5V B Ground cation 99 YEL NR oan Bus High Digital Signal o or 5V B Ground cation 02 Output Run Signal Input Engine Logic 12 V Engine Running B Ground Input 5 108 GRA Input Engine Coolant Logic Input 5V YEL Temperature 112 TAN Input Fuel Level Sender S12 Analog Signal WHT a YEL Input Low LP Pressure S11 Logic Input RED Switch e c c c c C IC c C mnm 141 Service Manual CS7000 Electrical System lip C Erg c op N J7 13 141 ORN Key Switch On Input J7 14 046 RED m Hopper Interlock Input 5 or 5V B around BLK Switch J7 15 035 GRA Input Extended Scrub Level 54 Logic Input 0 or 5V YEL Switch J7 16 143 WHT Input Dust Control Filter 56 Logic Input 0 or 5V GRA Switch GRA VIO VIO ss Switch Start Input pem Input 0 or 36V a I RP ORN Limit Switch LEM mmy pee pmo Pee RED Extend Limit Switch WHT Retract Limit Switch Jy 24 172 BLU Output 5V Power out 5V B Ground Sensors 25 1174 Output Ground B Ground m HEEL 2 gt BRN fou sh Not rer Motor Current s Pate Sra Signal 2 5 4 7 B Ground Sense 184 RED Input Vacuum Motor Current B3 Analog Signal 2 5 4 7 Ground WHT 215 ORN Motor Current LAIT Signal
75. Made Portugal 2 Electrical Panel Coolant Temperature Switch Oil Pressure Switch Engine Back Side 167 Service Manual CS7000 Maintenance and Adjustments Diesel Engine Maintenance Schedule First 50 hours Change engine oil and filter Every 50 hours Check fuel hoses and clamps Check restricted air filter indicator Replace air filters as needed Every 100 hours Check fan belt tension Check engine starting battery Every 200 hours Change engine oil and filter Check radiator hoses and clamps Check intake air hoses Every 400 hours Replace the fuel filter Every 500 hours Flush cooling system Replace fan belt Every 800 hours Check valve clearance Every 1500 hours Check injection nozzle pressure Every 3000 hours Check injection pump timing Every 2 years Replace radiator hoses and clamps Replace fuel hoses and clamps Replace intake air hoses Replace engine starting battery Engine System Diesel 168 Service Manual CS7000 Engine System Diesel 169 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 Remove the squeegee vacuum hose and release the recovery tank tether cable then lower the recovery tank to the ground for better access to the
76. Mechanical engine Insufficient compression Fuel camshaft worn Plugged Intake Plugged Exhaust 172 Service Manual CS7000 Engine System Diesel 173 Diagnostic steps 1 Check governor control system Does the APECS governor controller status light flash once 1mmediately following on If not check power and grounds for the APECS governor controller If so go on to next step Does the status light come on during cranking If not check the Engine RPM sensor input Resistance and voltage output while cranking If so go on to next step Is there more than 4 volts available to the actuator during cranking If not the governor controller may have failed If so the governor controller appears to be working correctly Check the fuel actuator 2 Check the fuel actuator a Check the actuator resistance It should be around 3 0 ohms If it is open or shorted replace the actuator If it is Okay go to the next test Substitute the function of the actuator by removing it from the injection pump and operating the throttle control manually You can reach into the hole and operate 1t with your finger or use the dead man lever on the side of the injector pump 3 Check fuel system a Check the fuel for contamination b Check the fuel pressure to the injector pump during cranking If the fuel supply system 1s Okay check the mechanical engine 4 Check mechanical engine a Check compress
77. Note The detergent mixture will be displayed for approximately 10 seconds each time the scrub va e Note During scrubbing the detergent system can be turned off at any time by pressing the detergent switch to allow scrubbing with water only No detergent is dispensed until the scrub system is activated and the drive pedal is pushed forward ees Service Tip Follow the To Purge Weekly instructions above if the machine is going to be stored for an extended period of time or if you plan to discontinue use of the detergent system Service Manual CS7000 General Information PM Checklist Nilfisk Advance CS7000 PM Checklist Defect Codes Customer A needs adjustment B binding Address C dirty or contaminated D damaged bent or torn City St Zip L leaks M missing Model Serial Hours W worn out Operational Inspection Items OK Engine idle speed LP 1700 RPM diesel 1700 RPM Engine run speed LP 2500 RPM diesel 2200 RPM Engine maximum power speed LP 2700 RPM diesel 2400 RPM Drive pedal operation check for forward reverse drive and any neutral creep Drive system performance max forward transport speed 5 5 mph 6 Brakes check both service and parking Steering Main broom raise lower 9 Main broom on off Side sweep brooms raise lower Side sweep brooms on off 12 DustGuard water nozzles on off 13 Dust control filter Scrub system raise lower and auto scrubbing func
78. S GROUND NNN N BLK WHTB ppp FRIIM F1 Service Manual CS7000 Electrical System 145 56509170 Rev G Before SN 1000048160 Sheet 2 of 6 RE FR F1 V B LN ZN Z ZN Fe 53 T E RED BLK 2 BI K A1 Str SWITCH HOPPER INTERLOCK b CLOSES WHEN HOPPER IS DOWN MAIN MACHINE S4 NT ROLLER 57 15 INPU1T GRA YEL 72 507 BLK o S
79. T BRN 12v 12 07v Power out to Control Panel 133 BLK B Ground for Control Panel 0 002v 050 YEL BRN Suppression Diode 37v key on 13 141 ORN Key Switch On Input 37v key on Ov key off 14 046 RED BLK Hopper Interlock Switch 0 0 full down position 4 8v otherwise 035 GRA YEL Extended Scrub Level Switch 4 8v machine not equipped 143 WHT GRA Dust Control Filter Switch 4 8v machine not equipped 17 145 ORN GRA Brake Switch Ov brake pedal at rest position 8v brake pressed not at rest 151 YEL VIO 19 155 VIO GRN Key WIR Start Input 37V lt lt in start w off or on Wa AV Deck Retract Limit 0 0v amaa up position Switch 4 8v otherwise Service Manual CS7000 Control System Circuit Description Value Condition 168 ORN RED Hopper Dump Door Extend 0 0 full closed position Limit Switch 4 8v otherwise 170 YEL WHT Hopper Dump Door Retract 0 0v wide open position Limit Switch 4 8v otherwise 172 BLU YEL 5V 4 97v Power out to Current Sensors 174 VIO WHT B 0 002v Ground for Current Sensors 178 BRN Brush Motor Current Sense 2 49v at rest no current 2 86v free running at 22 amps 2 29 184 RED WHT Vacuum Motor Current Sense 2 49v at rest no current 3 01v Vac running cover open at 28 amps S e 215 ORN BLU Broom Motor Current Sense 2 49v at rest no current 2 1v free running at 12 amps 3 032 BLU BLK POT High 3 304v plugged in or unplugged Powe
80. TACTOR HYD PUMP MOTOR TD 2 K12 gt vio ORN RED 2 24 QUTPUT 23 6 DUTPU lt lt BRI GRW T CONTACTOR HYD PUMP MOTOR 1 x T T M26 gt N e co e c N M14 gt gt VIO RES Sx BLK RED lt 2 18 PWM 43 7 DUTPU lt lt lt RED GRA MOTOR SHAKER UTPUT x N Fe S S LR J7 ee INPUT lt lt ORN REB 17 2 gt 4 SWITCH DOOR EXTENT LIMIT T T CLOSES WHEN DOOR IS CLOSED N Fe r2 BRUSH B1 J7 23 INPUT lt lt YEL WHF K gt BLU YEL SWITCH DUMP DOOR RETRACT LIMIT 47 24 5V CLOSES WHEN DOOR IS OPEN SV A M12 lt INPUT J7 27 BRUSH tc BRN CUBE ENSE J2 8 OUTPUT WHT GRN RED ORN B MOTOR SQUEEGEE ACTUATOR SV TO RED TO EXTEND _ VIO WHT J7 85 B 212 9 UTPUT BLU BRN CURRENT SENSOR M13 BROOM B2 es BLU YEL 13 5 DUTPUT lt 2 GRA VIO BK LL MOTOR SIDE BROOM ACTUATOR 5 joan mee TO RED TO EXTEND E iz C ORN BLU CURRENT SENSE 23 17 DUTPUT S c lt gt 6RN ORM 9 CURRENT SENSOR 12 B INPUT BLK 5 m m BS CN v BLU YEL d 174 a 12 gt lt NY 22 3 12V OUTPUT lt YEL RED BLK YEL gt 4 INPUT RED WHT J7 29 VAC mi LAMP RIGHT FRONT TURN c C 4 CURRENT SENSE a g OPTIONAL n sv B J2 1 12V lt lt ORN YEL BLK YEL VIO WHT LAMP LEFT FRONT TURN OPTIONAL E X263 C B I T B
81. TOR 5 N be 5124 w IGNITION CONNECTOR C EN FOR KUBOTA HARNESS K17 FUEL LOCK OFF y 87a B _ YS 30 aen 87 lt HIGH COOLANT TEMP K18 x S D RELAY 19 LOW OIL PRESSURE 87a D7 S D RELAY 30 LA z 4 ay i 87 20 1 10A D6 CONTROL RELAY K21 IGN REQUEST j 04 2 POWER RELAY uds i D9 POWER RELAY IGN REQ RELAY KUBOTA FUEL SOLENOID D10 K19 LA 87a 87a FUEL SELECT gt S 30 30 CONNECTOR 3 K Er 87 t 87 l CONTROL RELAY 5 e 8 RUN ENABLE N K16 SIARTER m D5 87a 87 M CRANK REQ NM UN RELAY BAT3 je WOODWARD AUTO CHOKE SOLENOID 1 5A CONTROLLER K20 FUEL SELECT A 9 SHUTDOWN SIGNAL IGN REQ RELAY K18 N V BAKA LOW OIL PRESSURE MAGNETIC 1 j S D RELAY K16 PICK UP A CIR RELAY K17 HIGH COOLANT TEMP S D RELAY D11 N I 7 D12 5 TEMP SWITCH coe OPEN FOR FUEL SELECT FUEL SELECT OIL PRESSURE SWITCH NORMAL TEMP CONNECTOR 5 CONNECTOR 4 d OPEN FOR PRESSURE gt ee 2 5 10K A T l I x 10K 2 6 047uF N 1 x 5 Service Manual CS7000 157 Engine System Diesel This chapter covers the fuel supply system engine RPM governor control system and glow plug starting aid See the Kubota D1305 Workshop Manual 9Y111 00124 pdf for 1nformation related to the mechanical engine and high pressure fuel injection syste
82. UPPLY J5 3 ORN BLK X98 Al ENCUDER IN 3 J5 1l GRN WHT o 5 GRN ENCODER_IN_4 55 10 RED WHT 2 A2 DIGITAL IN 4 5 17 BLU gt B2 DIGITAL IN 6 J5 20 GRN BLK S j 1 VOLT 1 5V gt RED B1 gt GRN BLK B2 5 RED BLK GND 2 VOLT 2 45V TFD CONTROL J5 2 BRN WHT 5 BIK FD TORQUE CON ROL J5 1 Hs WHT FD B POWER APPLICATION CONFIG INPUT 25 12 ORN STEERING WHEEL ROTATION SENSOR 910 RIGHT LIMIT INPUT J5 13 WHT BLU ORN SWITCH RIGHT TRAVEL LIMIT LEFT LIMIT INPUT J5 19 ORN RED 3l ORN SWITCH LEFT TRAVEL LIMIT FROM SEAT SWITCH SAFTY RELAY DUTPUT J5 18 ORN RELAY SAFTY CAN_H J5 23 YEL N gt CAN H J5 15 gt gt L CAN_GND 5 8 7 gt gt B R3 D GRA WHT OHMS K ORN RES SATOR 10 OHM 147 148 Electrical System Service Manual CS7000 56509170 Rev G Before SN 1000048160 Sheet 5 of 6
83. WITCH DUST CONTROL FILTER OPTIONAL NORMALLY OPEN CLOSES WHEN FILTER IS DIRTY 55 J7 17 INPUT 1 2 ORN GRA SWITCH BRAKE 5 7 5 n CLOSES WHEN BRAKE PEDEL IS AT REST 7 YEL ORN J2 20 PWM DUTPUT hi D VALVE SOLUTION x e 10 te 52 1 2 27 18 INPUT gt YEL VIO BLK lt K1 SWITCH HOPPER FIRE OPTIONAL j YEL BLU NORMALLY CLOSES 140 DEG CONTACTOR LEFT BRUSH MOTOR M21 J3 3 DUTPU BRN WHT RED ORN VIO WHT VIO J2 26 OUTPUT MOTOR MAIN BROOM ACTUATOR TO RED TO EXTEND CENTER BRUSH MOTOR AUTBU RED VIO VIO 3 GRA REB je 27 OUTPUT J7 33 PUT HIGH BLU BLK CONTACTOR RIGHT BRUSH MOTOR K4 27 34 WIPERL GRA GRNH VIO 3 ERN GRA Je 16 CONTAGTOR BROOM MOTOR ee TAN RED KS BLU J2 17 OUTPUT VIE CONTACTOR VAC MOTOR J2 10 PWM OUTPUT RED GRN K6 MOTOR SCRUB DECK ACTUACTOR VIO 3 BLK YEL J2 6 DUTPUT TO RED TO EXTEND 11 PWM YEL GRA CONTACTOR DUST CONTROL MOTOR Fe 5152 1 2 VIO 3 BRN BLK J2 15 OUTPUT 17 21 INPUT RED ORN D CONTACTOR SIDE BROOM CLOSES WHEN DECK IS UP BLU ORN J2 28 OUTPUT CONTACTOR HYD PUMP MOTOR m MOTOR DUMP DOOR ACTUATOR N M TO RED TO EXTEND K12 x a ORN RED l Je e4 J3 6 DUTPU lt lt BRN GRN gg YEL NC 6 CONTACTOR HYD PUMP MOTOR d x m T M
84. WITCH EXTENDED SCRUB LEVEL OPTIONAL CLOSES WHEN TANK IS EMPTY di x P S6 g x J7 16 INPUT 9 5 BLK lt lt SWITCH DUST CONTROL FILTER OPTIONAL NORMALLY OPEN CLOSES WHEN FILTER IS DIRTY 55 57 J7 17 INPUT L1 ORN GRA SWITCH BRAKE of Dn CLOSES WHEN BRAKE PEDEL IS AT REST m YEL ORN Je e0 OUTPUT Hi A I VALVE SOLUTION sit x J7 18 INPUT gt YEL VIO BLK lt K1 SWITCH HOPPER FIRE OPTIONAL 5 VIO 3 4 YEL BLU Je es UTPUT NORMALLY OPEN CLOSES AT 140 DEG F CONTACTOR LEFT BRUSH MOTOR M21 i J3 3 PWM UUTPUT BRN WHT O RN VIO 3 WHT VIO J2 26 OUTPUT MOTOR MAIN BROOM ACTUATOR TO RED TO EXTEND CONTACTOR CENTER BRUSH MOTOR J3 4 PWM DUTPU RED VIO AY VIO GRA RED J2 27 DUTPUT J7 33 PUT HIGH BLU BLK CONTACTOR RIGHT BRUSH MOTOR J7 34 WIPER GRA GRN gt R4 4 VIO 3 GRN GRA J2 16 OUTPUT CONTACTOR BROOM MOTOR Pr JAN RED K5 t EY qp BLU J8 17 DUTPUT M17 CONTACTOR VAC MOTOR J2 10 PWM OUTPUT RED GRN K6 MOTOR SCRUB DECK ACTUACTOR 3 BLK YEL je 6 DUTPUT RED TO EXTEND 11 PWM YEL GRA CONTACTOR DUST CONTROL MOTOR Fe K8 51 AL 1 VIO 3 BRN BLK Je 15 OUTPUT J7 81 INPUT RED ORN SWITCH RETRACT LIMIT PE T CONTACTOR SIDE BROOM CLOSES WHEN DECK IS UP K11 BLU ORN j2 28 OUTPUT CON
85. a Remove plate to frame bolts b Remove the plate to belt guard bolts c Remove the clamp cable and fuel line fasteners 9 Remove the belt tension release tool from the side of the starting battery 4 Remove Bolts kuwa T rj 2 10 Using the bolts that had attached the tool to the battery tray bolt one end of the tool to the tensioner pulley and bolt the other end to the generator pulley Pull the two tool halves together by tightening the long bolt This will compress the auto tensioner spring and release the tension on the drive belt Turn the bolt until there 1s enough slack to remove the belt 11 Remove the belt 12 Reassemble reverse order Service Manual CS7000 Electrical System 136 42 volt Generator PC E 2 Remove Engine and Generator as an assembly See relevant engine chapter Remove generator drive belt Label wiring for correct reassembly and then remove Support generator with a lift Remove generator to engine mounting bolts Remove generator Reassemble 1n reverse order Generator Drive Belt Tensioner Remove Drive Belt Retract the tensioner tool bolt to relieve the spring tension Remove the tensioner tool Raise and lock hopper in place Remove lower rubber curtain fasteners to gain access to engine area and move the curtain aside Remove the tensioner mounting bolt from the back side of the generator m
86. aker Assembly toward yos the right so the Filter Clamps engage the Thumb Nut studs on the upper hopper 4 Tighten the two Thumb Nuts Air Flow Indicator Decal 5 Reconnect the Shaker Motor Electrical Connector 6 Close the hopper cover Service Manual CS7000 Dust Control DustGuard Systems 89 To Clean the DustGuard Strainer Screen 1 Drain the water from the upper hopper Note that you do this one of several ways The most convenient way is to remove the Strainer Cover and Screen and drain the upper hopper through the DustGuard strainer N Note Place a suitable container underneath the upper hopper to catch the water from the hopper gt reservoir 2 Raise the hopper and engage the prop rod 2 Note Place a suitable container underneath the filter to catch any water that may leak from the hoses 3 Unscrew the Strainer Cover and remove the Strainer Cover and Screen from the Strainer Base 4 Clean any accumulated dirt or debris from the Screen 5 Reinstall the Screen into the Strainer Base 6 Make sure the Rubber Washer is installed correctly in the Strainer Cover then reinstall and hand tighten the Strainer Cover Rubber Washer Strainer Cover Service Manual CS7000 Dust Control DustGuard Systems 90 To Clean the DustGuard Spray Nozzles 1 Raise the hopper slightly if desired for easier access to the DustGuard nozzles 7 8
87. al System 151 56509170 Rev H SN 1000048160 and later Sheet 2 of 7 RE FROM BLK wut F1 V B AN Z ZN e Z S3 2 RED BLK 7 2 BLK 4 A1 gee INPUT SWITCH HOPPER INTERLOCK E CLOSES WHEN HOPPER IS DOWN MAIN MACHINE 54 CONTROLLER 57 15 GRA YEL pog BLK 1 SWITCH EXTENDED SCRUB LEVEL OPTIONAL m d CLOSES WHEN TANK IS EMPTY co N e x S6 97 16 INPUT BLK lt 5 S
88. all the Solution Tank 320 To Remove and Reinstall the Solution Shutoff Valve 324 To Remove and Reinstall the Solution Filter Assembly 924 To Remove and Reinstall the Solution Solenoid Valve 925 To Remove and Reinstall a Detergent Pump EcoFlex Models Only 325 d 326 SPCC ux v a Gus S Q S amp 328 Squeegee 329 Functional Description 329 QVORVIGW lt s 2 2 4 Q m Q NO w RUN xd 329 Squeegee System Wiring Diagram 329 Circ it Description s mom lt x amp w Row siekia 4 Q lt eee Q N 330 Component Locations 330 Maintenance and Adjustments 331 To Remove and Reinstall the Squeegee Blades 391 To Remove and Reinstall the Front Squeegee Blade 331 To Remove and Reinstall the Rear Squeegee Blade Squeegee End Wheels 332 Squeegee Caster Wheel Bearings 332 To Adjust the Squeegee 333 To Adjust the Squeegee 334 Troubleshooting ane eae Geo Geo OG ee k K k oe Moe Mw ce M wx cR 5 390 Removal and Installation
89. and the drive controller are both tied into the CAN Bus circuits but do not contain termination resistors Main Machine Controller Termination Resistor 120 ohms Drivs Controller Steering Controller Termination Resistor 120 ohms Control Panel Service Manual CS7000 Control System 49 CAN BUS message routing The following outline describes what messages are communicated over the CAN Bus from one controller to another Control Panel e Messages Sent Main Machine Controller o Operator switch inputs Drive Controller None To Steering Controller None Messages Received From Main Machine Controller LED display instructions LCD display instructions Fault History for main controller steering controller and drive controller From Drive Controller None From Steering Controller o None Main Machine Controller e Messages Sent Control Panel LED display instructions LCD display instructions Fault History for main controller steering controller and drive controller To Drive Controller Push Mode On Off Transport Mode On Off o Sweep System On Off Scrub System On Off Service Manual CS7000 Control System 50 o Machine Power Plant Type Battery Engine Hybrid Hopper Up Down To Steering Controller None Messages Received From Control Panel Operator switch inputs From Drive Controller Drive System Faul
90. can work for a limited time on just the 36 volt battery pack The main machine uses a 36v supply to operate some 36v electrical loads 36v Battery Pack 36v Machine Electrical Loads 42 Alternator Main Machine Controller Hybrid Power Supply Hybrid models also have a separate 12 volt starting battery The main purpose of the staring battery 1s to start the engine The engine drives a separate 12 volt generator Alternator to recharge the starting battery and supply power for 12v engine electrical loads The main machine controller 1s supplied a 12v power source which it uses to control some 12v engine electrical devices 12 Starting Battery Engine Electrical 12v Alternator Main Machine Controller 12v Power Distribution Engine models only Service Manual CS7000 Electrical System 100 If you combine the power distribution for both the engine electrical loads and the 36v machine electrical loads 1t looks like this 36v Battery Pack 36v Machine Electrical Loads 42v Alternator Main Machine Controller 12v Starting Battery 12v Engine Electrical Loads 12v Alternator p Combined Power Distribution Engine Models Service Manual CS7000 Electrical System 101 models have a large connector to disconnect power from the machine circuit breaker panel located on the left side of the operator foot well area provides circui
91. ce 118 Ohms 138 Service Manual CS7000 Electrical System Current Sensors Input Output Table 091 ORN Front Lamp OFF 0V ON B Ground YEL 094 ORN Output Left Rear Tail Lamp ceu 12V OFF ON B Ground BLU 098 YEL Right Front Turn Lamp 12V OFF B Ground RED J2 4 101 YEL Output Right Rear Stop Turn LT11 12V OFF ON B Ground GRN Lamp J2 5 107 Tail Lamps LT5 and 12V OFF ON B Ground BLK LT6 J2 064 BLK Output Dust Control Motor K6 Grounds to 36V OFF ON B Ground YEL Contactor energize J2 7 19 Output Detergent Pump M17 PWM SIGNAL 0 12 J2 19 WHT Reversing Polarit Pepe ee U Ex 5000 GRN Motor Polarit Engine ON 37 40 5V NE EN VE dll UN NNNM BHN Motor Polarit Engine ON 37 40 5V GRN Motor Polarit Engine ON 37 40 5V GRA Motor Polarit Engine ON 37 40 5V MEI Engine ON 37 40 5V 13 057 VIO Power 1 Power supply 30 5 38V B Ground Supply from Aux Engine ON 37 40 5V Contactor iM EMEN NEUE NM ORN energize J2 15 163 BRN Output Side Broom Motor Grounds to 36V OFF ON NET BLK Contactor energize J2 16 063 GRN Output Main Broom Motor K4 Grounds to 36V OFF ON B Ground GRA Contactor energize J2 17 045 BLU Output Vacuum Motor K5 Grounds to 36V OFF OV ON B Ground Contactor energize J2 18 150 BLK Output Shaker Motor M14 PWM SIGNAL
92. ce to prevent dirt from entering the engine air intake 7 Remove the inner filter element 8 Clean residual dust from the inside of the air cleaner housing taking care to prevent any dirt or debris from entering the air intake 9 Install a new inner filter element and then the new outer filter element making sure that they seal well at their ends 10 Install the air cleaner housing cover Top 1s indicated on the cover 11 Set the top engine cover in place 12 Install the two fasteners finger tight then close the cover and allowing 1t to latch properly 13 Now tighten the fasteners with a wrench 14 Open the top cover swing the fuel tank back into position and the right engine cover 15 Install the left engine cover Service Manual CS7000 Engine System Diesel Troubleshooting No crank The starter does not engage No voltage to the starter solenoid Check for tripped circuit breaker 49 CB9 Check for power to the main machine controller from the Auxiliary Relay Auxiliary Relay Check for power to the main machine controller from Key Switch cranking circuit Key Switch i Check powers grounds inputs and crank request output Main Machine controller Cranks but does not start Possible causes No fuel Empty Tank Insufficient fuel supply Clogged Filter o Clogged line Fuel pump Contaminated fuel APECS governor controller Engine RPM Sensor Actuator Incorrect injection timing Injection pump
93. ch Emergency Battery Relay signal from Stop Switch Interlock A5 Steer by Wire Controller Contactor Aux VACC3 Ground K9 pr J3 15 RED BLU GRN GRA BLK J3 34 Input 7 1 2 125 2 3 16 VACC1 J3 18 CB1 J3 19 5 J3 20 VACC2 CB2 _7 BLU GRN 2 25 Dust Guard Valve GRA BRN RED 5 13 Output M22 Pump Dust Guard K6 VIO E BLK YEL J2 6 Output Contactor Dust _ Control Motor M14 VIO RED M BLK BLK RED J2 18 PWM Output Shaker Motor AN VIO Dust Control K6 BRN WHT 2 1 2 Motor CB5 ORN GRN 140A Contactor Dust Control Motor RED FROM F1 Dust Control DustGuard Systems 82 A3 Control Panel GRN YEL Chassis Ground Fe S3 RED BLK BLK 1 2 Hopper Interlock Switch BLK BLK BLK BLK WHT GRA S6 BLK 1 927 Dust Control Filter Switch M5 M BLK A1 A2 Dust Control Motor Service Manual CS7000 Dust Control DustGuard Systems 83 Circuit Description The following conditions must be met for the DustGuard system to operate The DustGuard system must be installed in the configuration menu There must be positive voltage to the J7 1 Interlock Input For this to happen The Seat Switch S9 must be closed The Safety Relay K14 on the Steer By Wire Controller A5 must energize the coil to close the Safety Relay K14 contactor The Emergency Stop Switch S15 must be closed The Battery Interlock S13 must be
94. ch hole Dust Control DustGuard Systems Dust Control Filter Switch 85 Service Manual CS7000 Dust Control DustGuard Systems 86 DustGuard Spray System The DustGuard Pump is mounted on the Upper Hopper and 16 protected by the Pump Guard The Strainer screens the incoming water upstream of the DustGuard Pump The Solenoid Valve downstream of the DustGuard Pump opens to allow water flow to the nozzles when the power to the DustGuard Pump is switched on Solenoid Valve 1 DustGuard Pump Upper Hopper The Spray Nozzles are mounted on the front of the machine and spray an oval pattern of water mist across the width of each side broom Spray Nozzles Service Manual CS7000 Dust Control DustGuard Systems 87 Maintenance and Adjustments Warning Before performing any machine maintenance or adjustments make sure the key switch is off the key is removed from the machine and the parking brake is engaged To Clean the Dust Control Filter To Remove the Dust Control Filter 1 Lift the hopper cover 2 Disconnect the Shaker Motor Electrical Connector Shaker Motor 3 the two Thumb Nuts then slide Connector the Filter Shaker Assembly toward the left and remove it from the machine Filter Shaker Assembly Nut 2 4 Lift the Dust Control Filter out of the machine 5 Inspect the top of the Dust Control Filte
95. change with the speed request so the actuator is the likely problem If not the controller appears to be the problem Service Manual CS7000 Engine System Diesel 175 Compression Test 1 Begin with a fully charged battery 2 Remove the air cleaner assembly Cover the air inlet opening to prevent foreign objects from falling into the engine 3 Remove the glow plug electrical connector nuts and connector rail Remove nuts Remove connector N d Insulate Terminal 5 Clean the area around the glow plugs to prevent any debris from falling into the engine cylinders when they are removed Remove the glow plugs 6 To test the compression of one of the cylinders screw an appropriate adapter into the glow plug threads in the cylinder head and attach a suitable compression gauge Pictured are Snap On Diesel Compression gauge EEPD500 used with test __ _ fitting TU 15 35 and coupler M3569 TU 15 35 uli c 4 Li 4 4 E m i 4 va i p i Snap On Snap On in wi Mz a Xj EEPD500 R
96. ck load and make sure it is not greater than the capacity of the engine Service Manual CS7000 Engine System Diesel 164 Flash Code Faut Remedy Engine shutdown due to engine Check parameter settings protection input Check what may have triggered the protection input Loss of oil pressure engine overheat Factory settings lost If calibration file is available download calibration file and cycle power again If controller still does not work or if no calibration file is available consult factory APECS unit failed Electrical noise may be entering the controller Check wiring shielding and connections to controller Cycle power to engine If controller still does not work consult factory Glow plug control The engine is equipped with glow plugs to assist starting a cold engine The glow plugs have an internal resistive element that increases in resistance as it heats up This protects the glow plug from overheating by reducing the current flow as 1t gets hot Whenever the key is turned on the main machine controller tells the control panel to display the glow plugs on 1con and sends out 12 V from connector J3 pin number 32 to the glow plug relay winding Since the other side of the winding 1s connected to ground this energizes relay which in turn supplies power from circuit breaker 11 to the glow plugs After approximately 10 seconds the main machine controller de energizes the g
97. closed battery machines or jumpered Diesel and LPG machines The 400 amp Fuse F1 must be closed to provide positive voltage from the Battery to the load side of Auxiliary Contactor K9 and to the 10 amp circuit breaker CB5 The Ignition Switch S14 must be closed to provide positive voltage to the Auxiliary Contactor K9 coil T he J2 14 Output on the A1 Main Machine Controller provides ground to the Auxiliary Contactor K9 coil when the Ignition Switch S14 provides an input to the Key Switch Input J7 12 The Auxiliary Contactor K9 must be closed to provide positive voltage to circuit breaker VACC2 CB2 Circuit breaker VACC1 CB1 must closed to provide positive voltage to the Dust Control Motor Contactor K6 coil and the Shaker Motor M14 The J2 6 Output provides the negative ground to the Dust Control Motor Contactor K6 coil under the following conditions Ifthe hopper is down 1 Main Machine Controller must receive a signal from the Control Panel via the CAN BUS that the operator has pressed the DustGuard spray switch blue LED on The A1 Main Machine Controller must receive a signal from the A2 Drive Controller via the CAN BUS that the machine is moving forward or backward Ifthe hopper is up the A1 Main Machine Controller must receive a signal from the A3 Control Panel via the CAN BUS that the operator has pressed the DustGuard spray switch Note that the seat switch does not have to be closed Circ
98. d Oil Filter 226 Change Engine 226 Inspect Air 221 Service Manual CS7000 Contents vii Replace Air 227 Troubleshooting i 2142464 a xod ox 4 ex RE 4 ko oho 228 ws 25 94 3 4 4 228 No crank The starter does 228 Cranks but does not start Spark 229 Cranks but does not start has sufficient spark 229 Achieves one but not ALL RPM modes 230 Removal and Installation 281 Engine Assembly EA 281 s s s sa s amp p 4 22 ea eode 292 isi OIL ue eee eee 48 4 A 9 39 4 4 M RI d RE S LU 292 Engine Coolant 204 Shop Measurements 292 System 202 Spark Controller Measurements 209 Governor Control 288 Woodward L Series Actuator Measurements 298 Fuel KE Oe RO d RC 284 284 Special Tools 235 236 Functional Description 2 236 Bag RC 236 Hopper System W
99. e Every 1500 29 Maintenance Every 1900 29 Maintenance Every 2000 29 Gubrication Pontes s s k 2 2 mead K 2 dec om ouo 30 EcoFlex System 31 To Purge When Changing Detergents the scrub system must be off 3l To Purge Weekly the scrub system must ol To Change the Detergent Mix Ratio the scrub system must 2 PM Checklist x4 Q Q Q o amp HORAE RE Q 33 Machine 35 Control Panel General a 35 Miscellaneous 35 Miscellaneous Indicators 36 Scrub Controla 37 Srub Indicators 38 Sweep 38 Sweep 39 Hopper Controls A baad v v x s 40 2 5 4 2 2 2 2 2 kU Re eee es eS 2 40 General DisplayS ocean kao RO REE Re RHEE 9 Q Q w Q OHSS 40 Battery Machine 40 Service Manual CS7000 Contents iii os 2 u S lt s lt Z d deus Ui
100. e power supply going out connector J3 pin number 9 from the APECS 3000 Governor controller which causes the engine to shut down 12v 12v Battery 12 23 Power Supply 12v Removes 12v to shut down APECS 3000 Governor Controller 12 volts Normal Pressure 0 volts Lost Oil Pressure lt Oil Pressure Switch amp 4 12v from oil pressure switch MJ Main Machine Fuel Pump Controller Service Manual CS7000 Engine System Diesel Engine RPM control The Woodward APECS Advanced Proportional Engine Control System controller manages the engine RPM through the use of an electronic actuator The controller monitors the actual engine RPM via a speed sensor which reads the flywheel ring gear teeth and compares 1t to the desired speed setting The controller sends out a pulse width modulated signal to an actuator which 16 connected to the engine fuel control lever inside the injector pump The actuator is spring loaded in the no fuel position This means that by default the actuator shuts off the fuel and prevents the engine from running when there 1s no electrical current available When the governor wants to increase the engine speed it increases the amount of current it sends through the actuator The main machine controller 1s responsible for telling the governor controller the desired RPM based on the operator s request or machine operation mode It communicates this with two circuits Thr
101. e scrub system is activated 8 Last State returned to state when the scrub system was last on Maximum Mode The maximum scrub mode that the operator can select Service Manual CS7000 Control System 63 1 Light The only available scrub mode will be the Light setting 2 Heavy The Light and Heavy scrub mode will be available 3 Extreme All scrub modes will be available 4 Light Scrub Mode The light scrub pressure solution rate and detergent rate can be programmed depending on its application where high solution rate 1s needed with light scrub pressure or low solution rate with heavy scrub pressure 1 Scrub Pressure RANGE 1 MIN 2 MED 3 MAX DEFAULT 1 MIN 2 Solution Flow RANGE Off 1 5 DEFAULT 1 5 Heavy Scrub Mode The heavy scrub pressure solution rate and detergent rate can be programmed depending on its application where a higher solution rate 15 need with heavy scrub pressure or low solution rate with heavy scrub pressure 1 Scrub Pressure RANGE 1 MIN 2 MED 3 MAX DEFAULT 2 MED 2 Solution Flow RANGE 1 5 DEFAULT 2 6 Extreme Scrub Mode The extreme scrub pressure solution rate and detergent rate can be programmed depending on its application where a higher solution rate 1s need with extreme scrub pressure or low solution rate with extreme scrub pressure 1 Scrub Pressure RANGE 1 MIN 2 MED 3 MAX DEFAULT 3 MAX
102. ed Note that the scrub brush pressure and solution flow will be at their lowest levels The scrub brushes will run the solution will flow and the squeegee vacuum will turn on when the machine begins moving forward Scrub Pressure Decrease Button decreases the scrub pressure one level when pressed Burst Of Power Switch increases both the scrub brush pressure and solution flow one step higher for 60 seconds General Information Solution Flow Increase Button Button Scrub Switch Scrub Pressure Decrease Button Solution Flow Decrease Button Vacuum Wand Switch Burst of Power Solution Flow Increase Button increases the solution flow rate one level when pressed Note that the solution flow LED indicators the Solution Switch will light to indicate the selected solution flow rate Solution Switch enables and disables the solution system Solution Flow Decrease Button decreases the solution flow rate one level when pressed Vacuum Wand Switch enables and disables on the vacuum system Detergent Switch enables and disables the detergent system on models so equipped 37 Service Manual CS7000 Scrub Indicators Scrub Pressure Indicators indicate the scrub pressure setting One LED indicates the lightest scrub pressure and three LEDs indicates the heaviest scrub pressure Burst of Power Indicato
103. eering feel _ 18 restored The standard Tilt Lever allows the Steering Wheel to be tilted up and down to suit the Operator The Circuit Breakers are mounted on the panel adjacent to the Operator position Foot Pedals The Brake Pedal Parking Brake brakes the machine and locks in the applied position when used as a parking brake The Drive Pedal moves the machine forward and backward Machine direction and speed are proportional to the Drive Pedal position Brake Pedal Parking Brake General Information Nilfisk Advance 44 Service Manual CS7000 Chassis System Component Locations Battery Machine major components Rear Battery Battery Cover Stop Plate Assembly Assembly L ME Battery Front Engine E N Guide Cover h c Weldment Assembly gt dua k Battery Stop Weldment Chassis Weldment 45 Service Manual CS7000 Chassis System 46 Component Locations LPG and Diesel Machine major components Engine Cover Assembly Front Engine Cover Assembly Left Cover Assembly SW Nilfisk Advance Service Manual CS7000 47 Control System Functional Description The CS7000 has several controllers which operate various parts of the machine and which communicate with one another via a CAN bus The CAN bus is like a phone line between all of the controllers that al
104. el Machine The general LCD display on the diesel machine shows the solution level in the solution tank the total engine run time the recycle system 1con if actuated and the fuel tank level If the machine is equipped with an EcoFlex system the display will also show the detergent system icon and current dilution ratio AY Note The fuel level will be displayed while the engine is running Broom Adjustment Battery LPG and Diesel The broom adjustment LCD display shows the main broom position the broom s selected for adjustment the broom movement the total run time and the battery charge fuel level Battery Charge Indicator The battery charge indicator shows the charge state of battery and will retain the charge state when the key 1s turned off Five vertical bars indicates a fully charged battery after a complete charging cycle No bars indicates a discharged battery Note that no bars will be shown if the machine 1s in the low voltage cutout mode You can choose between two different low voltage cutout thresholds depending on whether maintenance free or standard batteries are being used General Information Recycle Fuel System Level Charge Fuel Level Therefore 100 discharge 80 of total battery capacity for standard wet cell batteries or 2 Note The following percentages are based on useable battery capacity not total battery capacity T 70 of
105. em by unplugging their low current connectors one at a time If normal operation 1 restored after unplugging one of the controllers that controller is corrupting the communication on the CAN Bus and should be replaced Next inspect the CAN Bus wires for shorts to ground shorts to power or short to one another Turn the key off and unplug the control panel the main machine controller steering controller and the drive controller connectors Atthe main machine controller connector check for the presence of voltage on each of the CAN Bus wires If there is voltage example 12v or 36v the wire 1s shorted to a voltage source Find and correct the short circuit Using an ohmmeter check for continuity between each of the CAN Bus wires and battery negative If continuity is found there is a short to ground battery negative Find and correct the short circuit Using an ohmmeter check the continuity of all of the wires from the main machine controller connector to each of the other connectors If any wire does not have continuity there 18 an open Find and correct the open circuit If the wiring is not the problem check to see if the main machine controller is capable of providing the bias voltage on the circuit Make sure the key 1s off and then plug in only the main machine controller Turn the key on and then check the voltage on each of the CAN Bus wires at the Control Panel Connector If there 1s no voltage the main mac
106. 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 1 Allow the engine to cool sufficiently to relieve cooling system pressure and avoid burns 2 Remove the radiator 3 Remove the left side engine cover 4 Locate the remote engine coolant drain hose remove the plug and direct the coolant into a suitable container 5 Reinstall the drain plug and reposition the drain hose 6 Refill with a 50 50 mixture of engine antifreeze and water Replace Fuel Filter 1 Raise the hopper engage the hopper prop rod and lower the hopper onto the safety lock 2 the screws along the bottom edge of the rubber curtain front of the engine compartment and move the curtain in order to gain access to the fuel filter 3 Unscrew the filter from the filter base 4 Apply a light coat of fuel oil on the cartridge gasket and screw it on by hand tightening 5 Bleed the air out of the fuel system as directed below reinstall the rubber curtain and lower the hopper Service Manual CS7000 Engine Sys
107. er Assembly will automatically switch on when the sweep system 1s turned off 80 Service Manual CS7000 DustGuard Spray System optional The DustGuard Pump pumps water from a separate reservoir in the upper hopper to Nozzles on the front of the machine The Nozzles direct a fine stream of water onto the floor in front of the side brooms to help reduce the dust generated by the brooms The DustGuard Solenoid Valve opens to allow water flow from the DustGuard Pump to the Nozzles when the power to the DustGuard Pump switches on removable Strainer is installed in the water line upstream of the DustGuard Pump and Solenoid Valve Removable strainers are also located inside of the Nozzle assemblies When installed the DustGuard spray system will turn on automatically when the main broom sweep system is turned on Dust Control DustGuard Systems DustGuard Pump inside Pump Guard Solenoid Valve Service Manual CS7000 DustGuard System Wiring Diagram Battery F1 36V RED RED BLK Fuse 400A 4 A1 Main Machine Controller ORN 42V Alt t 2 ernator CAN 514 BUS we J7 19 Start Input J7 2 CAN L B YEL BRN 3 4 BLK ORN J2 14 Output K9 Contactor YEL BRN J7 12 Supression Ignition Switch Diode ORN J7 13 Key Switch Fe S9 K14 S15 13 ORN GRA ORN PINK TAN GRN BLU J7 1 Interlock 1 95 amp TY 1 2 Input Seat Switch Safety Swit
108. g LED displays the fault conditions When power 1s first applied to the controller the LED will flash just once for one second to indicate that the LED 1s operational If there 1s more than one fault the LED will flash them all If there are no faults the LED will flash once every reset and from then on indicate the detection of engine speed The controller will attempt to shut the engine down for all faults and will not permit starting after reset with fault 1 5 and 6 Warning message will be displayed on the control panel This is because once the engine stalls engine oil pressure is lost and the main machine controller responds as it always does when it sees a loss of oil pressure after the engine has been running means the main machine controller will display the engine warning message and remove the power supply from the APECS controller causing it to power down and turn off its status LED light 2 Note If any fault in the APECS governor control system causes the engine to stall the Engine n Flash Code Faut 1 1 jRemedy APECS unit not calibrated Calibrate APECS unit 2 Engine Speed Excessive Check parameter setting Overspeed criteria may be too sensitive Check for electrical noise entering controller Check wiring and connections Check case ground Make sure linkage moves freely without backlash Check tip of speed sensor 3 Engine Speed too low Check parameter settings Check linkage and the actuator travel Che
109. g Rapidly 353 Steering Inoperative Steering Controller Status LED is 353 Steering Inoperative Steering Controller Status LED is On Steady 393 No Steering Feel avout oud 3x9 4x 353 Steering Wheel Is Difficult To Turn DOO Removal and Installation 354 Steering Wheel Assembly 354 Steering Wheel Rotation Sensor 355 Steering Controller 358 Steering AGLUBEPOP s domo s uro o EERE GORE OLOR UE Up OE 358 s ss saoi b Q 4 mos 860 Shop Measurements 360 Steering Wheel Rotation Sensor Voltage Measurements 360 Steering Controller Voltage Measurements 361 J5 Connector 361 Motor U V and W Terminal Pair Voltages 362 Motor U V and W Terminal Pair Frequency 362 System Current Draw 362 Steering 362 362 Special Tools 362 Sweep System 363 Functional Description s e o4 9 4 x09 o4 x 30 Xo dime X 363 s s X 2 k g n k Q Ne R 8 KOR w O S w e N x amp S w Q S Q Q h Q Q 2 Q e Q Q S Q 363 Main Sweep System Wiring Diagram
110. g polarity driver 5 3v when moving down 5 106 GRA VIO Side Broom Actuator 37v at rest or when moving down Reversing polarity driver 0 08v when moving up Service Manual CS7000 Control System 77 Wire Circuit Description Value Condition 111 BRN GRN Dump Door Actuator 37v at rest or closing Reversing polarity driver 0 07v opening 7 115 RED GRA Dump Door Actuator 3 v at rest or opening Reversing polarity driver 0 03v closing 118 WHT ORN High Pressure Pump Clutch 0 003v Off Coil 11 9v On Service Mode 123 PINK Ignition On Output Ov key off 12v out to engine system 12 1v key on 10 129 BLU PINK Start Output Ov key off 12v out to starter 10 9v cranking 12v if starter disabled 131 GRA ORN Throttle 2 Output 0 03v or 13 8v depending on throttle request 134 GRA BLU Throttle 1 Output 0 03v or 13 8v depending on throttle request 137 BRN RED Dust Guard Control Pump and 0 05v when energizing valve and running Valve Grounds to turn both on 139 VIO BRN Horn 0 24v when sounding horn Ground to turn on 15 144 BLK Battery Negative 0 006v with scrub sweep and vacuum motors free running 16 142 BLK Battery Negative 0 006v with scrub sweep and vacuum motors free running 250 GRN ORN Side Broom Actuator 3 v at rest or when moving up Reversing polarity driver 0 05v when moving down 149 BLK Battery Negative 0 006v with scrub sweep and vacuum motors free running 154 BLK Battery Negative 0 006v with scrub sweep and vacuum motors free running 15
111. ght LT11 X190 Solution Solenoid Valve L1 X202 Brake Switch S5 Wire 145 ORN GRA 231 BLK DELPHI 12010973 X204 Hopper Interlock Switch S3 tim Wire 046 RED BLK A 230 BLK DELPHI 12010973 Service Manual CS7000 Electrical System 127 Pm We _ mm X238 Dump Door Retract Limit Switch S8 we i Bs es X239 Main Harness Connector X166 We _ B ome n oveen _ X255 Scrub Deck Retract Limit Switch S1 Pin wire 161 RED ORN 229 BLK DELPHI 12010973 X256 Scrub Deck Actuator Motor M11 Wire 132 RED GRN 135 YEL GRA X257 Beacon LT10 A Wire Pin 220 VIO B 234 BLK DELPHI 1201579 Service Manual CS7000 X258 Trouble Light LT1 Pim B Pe wire 5
112. gine 12V J3 13 137 Output Dust Guard Control 2 M22 Grounds to turnjOV B Ground RED Pump and Valve both on J3 14 139 VIO Output Horn H2 Grounds to OV B Ground BRN Ground to turn on energize J3 __ 16 42BLK Ground Supply _ Battery Negative 1 Battery 30 5 38V Engine ON 37 40 5V ________ J3 17 250 GRN Output Side Broom Actuator 13 Reversing J3 5 ORN Reversing polarity Polarity driver S LS l 227 J3 19 M54BLK Ground Supply Battery Negative J3 __ 20 156BLK GroundSupply __ J3 M59BLK Ground Supply j2 Ad NENNEN J3 23 059 VIO Power Supply 12V supply Power supply 12V B Ground uu HED starting J3 24 71 GRN Output Low Pressure Pump 23 Grounds to WHT energize Also requires internal pressure switch in pum Po batter 2 J DERE 27 076 GRN Output Backup Alarm H1 Grounds to 0V B Ground BRN energize _____ E Battery Negative S0 __ o o oo EE E ORN EEG Plug Output BLK a m EE 34 056 GRA Power Supply VACC3a Power supply 36V B Ground BLK from Aux B Ground e 58 GRA Supply VACC2 Power supply 36V B Ground from Aux Contactor High Side 12V B Ground Driver Engine 12V Contactor p GRA Power Supply VACC3b BLK Power supply 36V B
113. have cables that go to the main power connector When the main power connector 1s connected this supplies power to the entire machine 36v Battery Pack Main Power Connector Service Manual CS7000 Electrical System 104 Headlights Two types of headlights are used on the CS7000 Early machines use incandescent 12v halogen bulbs Later machines use LED headlights The machine must be properly configured to operate each type correctly using the Configuration Menu Incandescent Headlight LED Headlight Incandescent Headlights Battery positive power 18 supplied to the head lamps through F1 CB6 VACCO and the K15a Auxiliary relay contacts The other side of the headlights are wired in parallel to the main machine controller J2 23 To turn the headlights on the controller switches J2 23 to ground It is not a complete ground It 1s Pulse Width Modulated to provide approximately 3 3 volts rather than full machine system voltage LED Headlights Battery positive power 18 supplied to the head lamps through F1 CB6 VACCO and the K15a Auxiliary relay contacts The other side of the headlights are wired in parallel to the main machine controller J2 23 To turn the headlights on the controller switches J2 23 to ground which applies full system voltage to the headlights Service Manual CS7000 Electrical System 105 Component Locations 36 volt Battery Battery Model 36 volt Battery Pack Hybrid Models R
114. he Vacuum Support and attached Vacuum Motor Remove the three Nyloc Nuts holding the Vacuum Motor to the Vacuum Support and remove the Vacuum Motor Note To prevent the three Screws from spinning when removing the Nyloc Nuts to remove the Vacuum Motor place wrench on the Screw heads under the Vacuum Motor Tabs 22 Reassemble the impeller assembly following the above steps reverse order 22 27 Y 4 _ Vacuum Screw v 3 x 4 XN Vacuum 3 L Nyloc QUARE Nut 3 1 Spacer 3 Vacuum Plate and Gasket Nyloc Nut typical typical 96 Service Manual CS7000 Dust Control DustGuard Systems 97 Specifications Component Specifications Type Diaphragm w bypass Nominal Voltage 36 VDC DustGuard Pump Flow Rate 1 1 GPM Current 1 0 Amp max Pressure 30 psi max Nominal Voltage 36 VDC 11 Watts DustGuard Solenoid Valve Coil Resistance 125 Ohms 10 Media Type synthetic with UltraWeb cellulose optional Dust Control Filter Media Quantity 120 ft approximate Media Configuration PowerCore Dust Control Vacuum Motor Current 7 Amps average 8 Amps max Dust Control Motor Contactor 118 Ohms 10 Actuation setting 20 factory set at 2 H O Dust Control
115. he active warnings and cautions at one second intervals Refer to the table below for a list of the displayed cautions Service Manual CS7000 General Information 43 Caution Condition Display Icon Low voltage Cutout The batteries need to be charged Hopper temperature has L Hopper Temperature exceeded the operational i temperature Solution Level Low Solution level has been low longer Icon number 246 than 10 seconds Warning Displays Any warnings detected by the main machine controller will be shown on the left side of the display Only the fuel battery level and hour meter indicators will remain lo Warnings are displayed as inverse graphics If more than one warning and or caution exists the display will sequence through the active warnings and cautions at one second intervals Refer to the table below for a list of the displayed warnings Description Display Icon Critical fault warning Low battery warning Low fuel warning 3 1 Parking brake warning Service Manual CS7000 Steering Wheel The steering system the 57000 18 a steer by wire system that uses an encoder and brushless AC three phase motor to transfer steering wheel input to the drive wheel Note that when the machine key switch 1s off the Steering Wheel will freewheel with no turning resistance Once the machine is Circuit Breakers powered up normal st
116. hine controller 1s defective because it 1s not providing bias voltage If the voltage on the CAN Hi YEL wire is approximately 3 3v and the voltage on the CAN Low GRN wire 18 approximately 1 8v the main machine controller is providing the bias voltage This indicates that the control panel 1s the source of the problem and needs to be replaced Service Manual CS7000 Control System 73 Removal and Installation Main Machine Controller 1 Turnthe key switch off and disconnect the main battery connector 2 Remove the recovery tank 3 Remove the control panel plate to frame fasteners 4 Lay the controller and wiring down Disconnect the 3 electrical connectors Note the connectors on the harness are color coded and keyed to match the connectors on the controller 5 Reassemble in reverse order MAN Note To avoid repeat controller failure when replacing a controller you should check all of the load devices it controls to make sure none of them are shorted 6 Turn the key on You will automatically be taken to the Configuration Menu on the Control Panel LCD a You must select the Machine Type and the Battery Type before the machine will be allowed to operate b You must also go through the remaining menu selections and inform the new main machine controller how the machine is equipped so that it can properly manage all of the machine s features c Adjust the Main Broom and Side Broom height Service Manual CS7000 Co
117. ight of engine under fuel tank 42 volt Generator Front of engine behind rubber shield Raise hopper for access Circuit Breaker Panel Starting Battery Electrical Panel Left side of solution tank under metal plate Remove recovery tank for access Main Fuse F1 400 Amps F2 150 Amp Fuse Auxiliary Relay See Electrical Panel Auxiliary Contactor See electrical panel Horn Battery Interlock Switch Hybrid models use a jumper in place of this switch Seat Switch zT au N f 36v Battery Pu Ne volt Battery Battery Model Battery Interlock Connector with Jumper on Hybrid Model lt Engine Compartment area Shown during assembly for clarity Service Manual CS7000 Battery Pack Under Fuel Tank 4 WW wa 36 volt Battery Pac Hybrid Models volt Generator essna ATNI oa rani Fuse F1 400 Amps Side view Shown with panel pulled forward metal panel Shown with panel pulled forward Electrical System 106 Service Manual CS7000 Electrical System 107 Electrical Panel Contactor Relay location BRUSH CURRENT SENSOR BROOM CURRENT CURRENT SENSOR SENSOR Electrical System 108 Service Manual CS7000 Harness to Harness Connector Loca
118. ion b Check for plugged intake or exhaust Service Manual CS7000 Engine System Diesel 174 Cannot Achieve Either Run or Maximum Engine Speed Settings Run 2200 RPM Maximum Power 2400 RPM The approach to diagnosing an engine RPM control problem 1 to check the inputs to the governor controller and check the output to the actuator If the inputs are good and the output is bad the conclusion is that the controller 1s the problem If the output control 1s okay but the RPM doesn t change then the actuator 1s the likely problem However don t forget that insufficient fuel supply or a restricted exhaust could appear like an RPM control problem if the engine cannot run well enough to achieve a higher RPM Possible Causes Actuator APECS 3000 Governor Controller Wiring Main Machine Controller Diagnostic steps 1 Check the power and ground supplies to the controller a Is there sufficient power and ground If so go to check the speed request inputs If not repair 2 Check the speed request inputs a With the engine running press the engine speed button and check for 12v to the throttle 1 and throttle 2 wires at the governor controller b Is 12v present on either of the throttle wires with the engine running at idle speed If so go on to check the actuator output If not check the wiring between the main machine controller and the governor controller 3 Check the actuator output a Does it
119. iring Diagram 207 Hopper Hydraulic System Circuit 1 238 Hopperdt 4o lt Eom 3 3 X Q Q Row X o ox WO 4 Q X W 238 Hopper Being 238 Hopper Being Lowered 239 Cret Descriptio ux owe X Get Bebe Qel 239 The Following Conditions Must Be Met for the Hopper to be Raised and Lowered239 The Following Conditions Must Be Met for the Hopper Door Open and Close 240 Component Locations 240 Upper and Lower Hopper 240 Hydraulic Power Pack Assembly 241 Hopper Dump Door 242 Hopper Dump Door 242 Dump Door Extend and Retract Limit 242 Hopper Interlock Switch o ow o4 XR e X Eck X a X Xo Xo eve we 248 Hopper Prop Rod Pull Rod 243 Troubleshooting 4444542424465 942 Ee BARD OE w 9 0E w 924 244 Removal and Installation ERG RUE om 245 To Remove and Reinstall the Hydraulic Power Pack Assembly 245 LPG Diesel Models ens 245 Battery Models 248 To Remove and Reinstall the Hopper Lift
120. it Description ss e s gt ess o w EE ce Sw k 83 Component Locations 84 Impeller and Filter 84 Dust Control Filter Switch 85 DustGuard Spray 86 Maintenance and Adjustments 87 To Clean the Dust Control Filter 87 Remove the Dust Control Filter 97 Service Manual CS7000 Contents iv To Clean the Dust Control Filter 88 To Reinstall the Dust Control 88 To Clean the DustGuard Strainer Screen 89 To Clean the DustGuard Spray Nozzles 90 To Adjust the DustGuard Spray Nozzles 90 Troubleshooting 91 Removal and Installation ee 93 To Remove and Reinstall the DustGuard Solenoid Valve Assembly 93 To Remove and Reinstall the DustGuard 94 To Remove and Reinstall the Dust Control Filter Switch 95 To Remove and Reinstall the Impeller Assembly 95 To Disassemble and Reassemble the Impeller Assembly 96 97 Electrical Systems e wwe AR s lt k s s e X RO o E oseke 98 Functional Description amp 4 ko 9 ow bee eK x Rods OX E
121. itical fault condition Refer to the LCD Display Icons section for a listing and explanation of the LCD display 1cons and fault codes Refer to the engine service manual for recommended engine service intervals and procedures Recommended Service Materials Engine Oil refer to your engine manual Manufacturer recommended coolant antifreeze 50 50 mix LPG and diesel models only Lithium base grease Loctite amp or equivalent thread sealant the appropriate grades Never Seez or equivalent anti seize compound Service Manual CS7000 General Information 27 Daily Maintenance Caution Do not pressure wash the operator control panel fuse panel contactor panel or engine compartment area Maintenance Item Procedure After use maintenance is normally the responsibility of the machine Operator Refer to the Instructions for Use Perform After Use maintenance steps Check the engine oil level Check the engine coolant level in the reservoir Engine LPG and diesel only Check for engine and coolant leaks Check the air cleaner service indicator and service the air filter when the indictor is shown red Check that the drain hose cap is sealed Drain and clean the inside of the tank flush with clean water Recovery tank Clean the squeegee check the blades for damage wear and deflection Scrub housing side skirts Check for damage wear Scrub brushes Check for debris wrapped around the brushe
122. ize certain machine functions according to machine operator preferences To enter the User Options Menu 1 While pressing and holding the One touch scrub switch AND the solution switch turn the key on 61 Service Manual CS7000 Control System 62 2 Continue to hold the switches until the LCD reads User Options Menu and then release the switches Once in the user options menu you can scroll through the menu using the scrub pressure increase and decrease buttons To enter a menu selection press the One touch scrub switch To exit and return to the User options menu mode press the solution switch To make a selection and return press the One touch scrub switch To exit the hidden menu turn the key switch off mmm d y o The following 1 an outline of the User Options Menu Default values are bold text or noted 1 Scrub System 1 Scrub Mode 1st Use The default scrub mode used the first time after power up After first time mode 1s last used 1 Light The scrub mode will default to the Light setting when activated DEFAULT 2 Heavy The scrub mode will default to the Heavy setting when activated 8 Extreme The scrub mode will default to the Extreme setting when activated 2 Detergent Start Up Determines if the detergent system will be activated when the scrub is turned on 1 Off always disabled when the scrub system is activated 20n always enabled when th
123. led Control System 60 2 Installed 11 Low Press Wash 1 Not Installed 2 Installed 12 High Press Wash 1 Not Installed 2 Installed 13 Scrub Motor 1 Option 1 Select Option 1 2 Option 2 Do not select Option 2 14 Display Screen 105 Display 2 Global Display 15 Light Option Head Lights 1 Standard Light 2LED Light Caution Selecting LED Light on a machine with standard incandescent head lights can cause the bulbs to blow out and shatter 16 Service Menu 1 Mode Must turn key off to exit service mode Example Batt 36 839V Pedal 2 58V Neutral 2 Battery Level o 2 Sealed gel 837 710 V Level 5 Solution Reading E G Service Manual CS7000 Control System Reading 0x67 Level 3 4 Fault Detection Enabled 2 Disabled b About Example CS7000 56510353 Rev 6 Shaker Continuous 1 2 Yes 7 Actuator Sequence For engineering use 17 Restore Defaults Resets all Configuration Menu selections and User Options selections to default values Are you sure One touch scrub switch Yes Solution switch No 18 Haram Captor 1 No Use for all CS7000 models 2 Yes Use for special market Haram Captor model to customize solution level processing and scrub pressures User Options Menu The user options menu allows you to custom
124. ling fins LPG fuel system vaporizer regulator Inspect and drain any oil buildup from the LPG fuel vaporizer LPG engines only regulator Maintenance Every 400 Hours Engine maintenance LPG and diesel only Maintenance Item Procedure Air intake housing and hoses LPG and Inspect the complete air intake system for correct routing kinks diesel only restrictions sound tight connections holes and cracks in hoses i Check electrolyte level check terminals for corrosion loose Battery Batteries U connections Fuel Filter diesel only Replace fuel filter cartridge located before injector pump Maintenance Every 800 to 1000 Hours Maintenance Item Procedure Engine maintenance LPG only Change the spark plugs Flush and refill radiator with 50 50 mix of water and antifreeze 42 volt alternator drive belt Replace the drive belt 28 Service Manual CS7000 General Information 29 Maintenance Every 1500 Hours Maintenance Item Procedure Main broom motor carbon brushes Check and replace as needed Side broom motor carbon brushes Check and replace as needed Maintenance Every 1900 Hours Maintenance Item Procedure Scrub brush motor carbon brushes Check and replace as needed Maintenance Every 2000 Hours Maintenance Item Procedure Engine maintenance LPG and diesel only Review the engine manufacturer s additional maintenance requirements Refer to the Other Reference Manuals and Info
125. low them to communicate with one another The main machine controller is responsible for operating all of the cleaning functions of the machine of the operator requests from the control panel are communicated to the main machine controller via the CAN bus This greatly reduces the number of wires needed between the control panel and the main machine controller The main machine controller tells the control panel what indicator lights to turn on and what to display the LCD screen The main machine controller monitors many circuits for overloads shorts and can set many diagnostic trouble codes that simplify troubleshooting Main Machine Controller The steering controller operates the steering system See the Steering System chapter for more information The drive controller operates the wheel traction drive motor See the Wheel System Traction chapter for more information Service Manual CS7000 Control System 48 CAN Bus Circuit The main machine controller and the control panel are the two major players on the CAN Bus The main machine controller provides a voltage on the CAN bus wires that the messages ride on It also has a termination resistor inside it that connects the CAN Hi and Lo circuits together The control panel also has a termination resistor These termination resistors are important for normal circuit operation If one of them fails communication will stop The steering controller
126. low plug relay by removing the 12 volts from the winding which also removes the power from the glow plugs Service Manual CS7000 Engine System Diesel 165 Component Locations Fuel tank Right side of engine compartment Fuellevel sending unit Top of fuel tank Fuel pump Top of fuel tank Fuel filter Front left engine compartment area Mounted on frame between engine and hopper njector pump APECS Governor Controller Front engine area mounted on engine Glow plugs Glow plug relay Electrical panel area Engine starter Alternator 42 Engine alternator 12v pressure switch Coolant temperature switch Actuator Engine RPM sensor i y E F E si i E Ax Top of engine compartment with top covers removed Air Cleaner Fuel Pump Fuel Level Sending Unit E K gt as s 4 gt w Fuel Tank Shown with hopper up Fuel Tank Shown swung out Service Manual CS7000 Engine System Diesel 166 Actuator ie x D Fuel Filter T AM 4 48 A j a LI w ED r Injector Pump py Alternator 42v Front Engine Area Hopper and rubber curtain lifted ls Engine RPM Sensor Service Manual CS7000 Engine System Diesel Glow Plugs 160 12V 75 Pd
127. m Functional Description One of the engines available in the CS7000 is a Kubota Diesel D1305 E3B KEA 1 It is a three cylinder liquid cooled naturally aspirated engine It has mechanical injector pump that is fitted with an actuator which physically moves the fuel lever inside the pump Fuel is stored in a tank on the right side of the engine compartment The tank swings out to provide easier access to the engine compartment and contains a fuel level sending unit An electric pump supplies low pressure fuel to the diesel injector pump There is a replaceable fuel filter cartridge between the fuel pump and the injector pump The injector pump has s small return line that runs to the closest injector The return circuit is carried from injector to injector where it exits the rear injector and is connected to a hose which returns back to the fuel tank The engine uses glow plugs to aid in starting a cold engine The main machine controller operates a glow plug relay which supplies power to the glow plugs when needed The engine RPM is controlled with the Woodward APECS 3000 Electronic Engine Speed Governing System based on requests from the main machine controller The main machine controller sends signals to the Woodward Gov controller to request one of three engine speeds based on operator request or cleaning mode gt injection pump fuel down to shut off the engine manually A Note There is a dead man level on
128. m 53 Troubleshooting There are two important things you need to know about electrical diagnosis on the CS7000 machine First it is capable of setting fault codes that can help narrow down the possible causes Second there is a special Service Mode built into the machine that will help you diagnose electrical problems quickly See the Fault Codes and Service Mode sections below for more information Fault Codes The main machine controller monitors every circuit it controls for overloads excessive current draw If it sees an overload it will set and display a fault code and shut the circuit down For instance if the side broom contactor coil becomes shorted and draws too much current 14 will set and display a code 19 and shut down the side broom contactor control circuit This means the side broom motors will not work and there will be a code 19 displayed You should check the fault code table below to find out what 19 means When you see that it means Side Broom Contactor K8 Winding Circuit Overload that will help you narrow down the possible causes that you need to diagnose Once the problem is corrected the fault code will no longer be displayed However it will remain in the fault code history Not all electrical problems will be accompanied by a fault code The main machine controller does not set faults for open circuits or not enough current draw For instance if the side broom motor contactor coil becomes
129. n This Service Manual a technical resource designed to aid service personnel in maintaining and repairing the CS7000 Sweeper Scrubber to ensure optimum performance and long service life Please read it thoroughly before servicing your machine Revision History 8 11 Not available 6 12 General Information Technical specifications table updated Control System Updated Configuration Display Configuration Menu and User Options Menu Sections Added Power Distribution Fault to fault code table Updated installation instructions fro main machine controller Electrical System Added information on new LED headlights Added wiring connection diagram for K14 Safety Relay and K15 Auxiliary Relay Engine LPG Updated Functional Description of engine RPM control Updated Troubleshooting for RPM Control problem 2 13 General Information Introduce Fuel Cell powered model Engine System Petrol Gasoline Add new chapter Electrical System Updated wiring diagram Wheel System Traction Add information on fastening electrical cables to the drive controller Service Manual CS7000 General Information 14 Other Reference Manuals and Information Sources Nilfisk Advance Publications 5 Parts List Model Instructions for Use Model Name Form Number Form Number Number 56041979 English Spanish 55042540 Penei Nilfisk Advance CS7000 Hybrid LPG EU 56509003 56041980 English Turkish Nilfisk Advance CS
130. n hills Clean only while ascending driving up the ramp Keep sparks flame and smoking materials away from batteries Explosive gases are vented during normal operation Charging the batteries produces highly explosive hydrogen gas Charge the batteries only well ventilated areas away from open flame Do not smoke while charging the batteries Remove all jewelry when working near electrical components Turn the Key Switch off O and disconnect the batteries before servicing electrical components Never work underneath a machine without safety blocks or stands to support the machine Do not dispense flammable cleaning agents operate the machine on or near these agents or operate in areas where flammable liquids exist To avoid hydraulic oil injection or injury always wear appropriate clothing and eye protection when working with or near any hydraulic system Do not operate this machine on ramps or inclines of more than a two percent gradient Only use the brushes provided with the machine or those specified 1n the instruction manual The use of other brushes may impair safety Caution Do not pressure wash the operator control panel fuse panel contactor panel or engine compartment area Service Manual CS7000 General Information 17 personal injury damage to property or equipment damage 1 Caution sure to follow these safety precautions to avoid situations that could cause This machine 15
131. n manual before using the machine Refer to the Electrical System section this manual for additional specific battery charger warnings Service Manual CS7000 General Information 18 Hopper Prop Rod Warning Never work underneath the raised hopper without the hopper prop rod engaged To Engage the Hopper Prop Rod Press and hold the hopper raise button to raise the hopper all the way up 2 Pullthe Pull Rod to pivot the bottom of the Hopper Prop Rod toward the Hopper Lift Cylinder until it contacts the Hopper Lift Cylinder 3 Press and hold the hopper lower button to lower the hopper until the Hopper Prop Rod contacts the top of the Hopper Lift Cylinder To Disengage the Hopper Prop Rod Press and hold the hopper raise button to raise the hopper slightly so the Hopper Prop Rod lifts off of the Hopper Lift Cylinder 2 Push the Pull Rod to pivot the bottom of the Hopper Wi Prop Rod away from the Hopper Lift Cylinder j Cylinder 3 Press and hold the hopper lower button to lower the hopper Service Manual CS7000 General Information 19 Jacking the Machine When jacking the machine do so at the designated Tie Down Jacking Locations Warning Never work under a machine without safety stands or blocks to support the machine Transporting the Machine Caution Before transporting the machine on an open truck or trailer make sure the machine is tied down securely and all access d
132. not approved for use on public paths or roads This machine 1s not suitable for picking up hazardous dust Use care when using scarifier discs and grinding stones Nilfisk Advance will not be held responsible for any damage to floor surfaces caused by scarifiers or grinding stones When operating this machine make sure that bystanders particularly children are not endangered Before performing any service function carefully read all instructions pertaining to that function Do not leave the machine unattended without first turning the Key Switch off O removing the key and securing the machine Apply the parking brake before exiting the Operator s seat Turn the Key Switch off O and remove the key before changing the brushes and before Opening any access panels Take precautions to prevent hair jewelry or loose clothing from becoming caught in moving parts Use caution when moving this machine in below freezing temperature conditions water in the solution or recovery tanks or in the hose lines could freeze causing damage to valves and fittings Flush with windshield washer fluid The batteries must be removed from the machine before the machine 1s scrapped Disposal of the batteries should be done safely and in accordance with your local environmental regulations Do not use on surfaces having a gradient exceeding that marked on the machine doors and covers are to be positioned as indicated in the instructio
133. not require adjustment Troubleshooting 42 volt generator is not charging Potential Causes Broken or slipping drive belt Check the drive belt No power to voltage regulator terminal Check for battery voltage 36v to the voltage regulator connector Open or corroded cable connections visually inspect cable connections Generator Regulator assembly Insufficient machine operation time Battery Model Potential Causes Battery 1s not fully charged Loose or corroded cable connections Battery Insufficient machine operation time with engine off Hybrid models Potential Causes Battery 1s not fully charged Loose or corroded cable connections Battery Service Manual CS7000 Electrical System 134 Removal and Installation 42 volt Generator Drive Belt Note Instructions are for both diesel and LPG models Photos are of diesel 1 Lift hopper up engage hopper prop rod and then lower to safety lock position 2 Open the side cover and remove the lower panel 4 Remove the 36v battery pack top cover 5 Disconnect the main battery negative and positive cables 6 Remove the two battery pack tray to frame attachment bolts hc Ter Slide the battery pack tray outboard to the end of the tether cable P Tether Cable Service Manual CS7000 Electrical System 135 8 Remove the tank guard plate 1 e
134. ns 194 Maintenance and Adjustments 198 Maintenance Checklist 198 Change Engine Oil and Oil Filter 42 4 244 44444 4 d4 REG ead x 199 Change Engine Coolant 4 200 Inspect Air Filter s lt w 6 5 SQ G SDE YO Oe HE de QR S 200 Replace Air Filters 200 201 Checking Spark 201 Checking LPG Primary 201 No crank The starter does 202 Cranks but does not start Spark 203 Cranks but does not start has sufficient 203 Achieves one but not ALL RPM modes 204 Removal and Installation 205 Engine s v 205 S x X Uo Ho On deas ethos bandon UE 206 Fuel veter dod G Q Q de 206 Engine 206 Engme Coolants 206 Shop 206 eni ion Systeni v s s V 2 lt 206 Spark Controller 207 Governor Control Systems uoce o esha ee Ea eR ERS 207 Woodward L Series Actuator Measurements 207 208
135. ntrol System 74 Control Panel 1 Empty the solution tank The tank must be empty upon reassembly for the solution level indicator to work properly 2 Disconnect the main battery connector 9 Remove key and key switch retaining nut 4 Remove 6 control panel mounting screws 5 Pullcontrol panel forward and remove the clear hose from the white fitting on the solution tank DO NOT REMOVE THE HOSE FROM THE CIRCUIT BOARD 6 Disconnect the electrical connector 7 Separate the key switch from the board 8 Move the lock tab for the emergency stop switch and separate the back half of the switch from the Move Lock Tab control panel 9 Before reassembly make sure the solution tank is empty The pressure sensor used to measure the tank liquid level depends on the tank being empty when the hose is reconnected 10 Reassemble reverse order Service Manual CS7000 Control System 75 Specifications Shop Measurements Main Machine Controller The following tables contain some real world shop voltage measurements to help you recognize what normal looks like All voltage values were measured with the black Negative voltmeter lead connected to the main battery negative unless otherwise specified J2 Connector White Circuit Description Value Condition 1 091 ORN YEL Left Front Turn Lamp 10 3v when off 0 02v when on 2 094 ORN BLU Left Rear Stop Turn Lamp 11 1v when off 0 01v when on 3 098
136. oid 1 Check the wiring and circuit breakers upstream of the solenoid Check the J3 13 output from A1 Main Machine Controller The DustGuard pump M22 Check for voltage at the pump is not operating correctly e f there is voltage at the pump replace the pump e f there is no voltage at the pump 1 Check the wiring and circuit breakers upstream of the pump Check the J3 13 output from A1 Main Machine Controller 91 Service Manual CS7000 Dust Control DustGuard Systems Problem Cause Correction The dust control motor The dust control filter switch is 1 Clean the filter will not run closed indicating that the filter is plugged 2 Check the dust control filter switch The switch should be open with no vacuum in the hopper dust control motor off Replace the dust control filter switch if necessary There is no voltage to the dust Check the wiring and circuit breakers upstream of control motor the dust control motor Check the coil resistance in the K6 contactor coil If the coil resistance is not 118 ohms x 10 replace the contactor Check the continuity through contactor K6 with the coil energized If the contacts are open replace the contactor Check the J2 6 output from A1 Main Machine Controller The dust control motor is not If there is voltage to the dust control motor replace the operating correctly motor The shaker motor will There is no voltage to the 1
137. ol system impeller motor _35 Recovery tank cover gasket Jooo 36 Recovery tank drain hose and cap J __ 41 Engine oil level hoses and belts LP and diesel only 42 Engine air cleaner inner and outer elements check service LP and diesel only indicator Engine coolant level LP and diesel only fill at reservoir 4 Radiator and oil cooler core blockage LP and clean diesel only 1 45 Fuel tank filter and lines diesel only LP tank hoses and fittings LP only DE y LP fuel filter service life 1500 hrs 48 LP fuel regulator lock off valve and hoses __ 51 Brake linkage and parkingbrakepedal 52 Circuit breaker panel 53 Front tires check lug nut torque 100 ft lbs 135 Nm Rear drive wheel motor steering system gear DustGuard spray nozzles and strainers Note For additional service information see the 57000 Service Manual form number 56043151 and the Instructions For Use for your machine model Work Completed By Acknowledged By Service Technician Signature Date Customer Signature Date Copyright 2011 Nilfisk Advance Page 2 of 2 5 12 2011 Service Manual CS7000 General Information Machine Controls Control Panel General Layout Miscellaneous Controls The 57000 control panel 1s organized by machine function with the scrub sweep and 4l hopper functions conveniently grouped together Miscellaneous controls such as the key switch eme
138. om the hopper Pump Electrical Connector Phillips Screw 4 Pump Electrical Connector DustGuard Pump Isolator 4 Pump Guard 94 Service Manual CS7000 Dust Control DustGuard Systems Note The Pump Guard base should 2 positioned under the four DustGuard Pump Isolators DustGuard Pump DustGuard Pump Isolator 4 To Remove and Reinstall the Dust Control Filter Switch Lift the hopper cover Disconnect the two Electrical Connectors from the Dust Control Filter Switch Unscrew the Dust Control Filter Switch from the upper hopper To Remove and Reinstall the Impeller Assembly 2 Lift the Hopper Cover p Remove the six Screws washers holding the Impeller Assembly to the Hopper Cover Carefully pull the Impeller Assembly partway off of the E Hopper Cover E 4 0 Disconnect the Vacuum Motor electrical connector cwm impeller then remove the Impeller Assembly from the machine lt Assembly 4 j jJ j j N Reinstall the Impeller Assembly by following the above V steps 1n reverse order 2 95 Service Manual CS7000 Dust Control DustGuard Systems To Disassemble and Reassemble the Impeller Assembly Remove the three Nyloc Nuts Screws and Spacers holding the Vacuum Plate and Gasket to t
139. oors and covers are secured tape and strap as needed The jacking and tie down locations are identified with a graphic molded into the exterior body panels The jacking and tie down locations are in front of the front wheels and at the rear of the machine below the solution tank k 1 Tie down Jacking Location P Front Jacking Tie down Location Rear Jacking Tie down Location Service Manual CS7000 General Information 20 Towing the Machine Caution Ifthe machine must be towed move the machine for short distances only and do not move the machine faster than a normal walking pace 2 3 mph 3 5 kph Tow the machine backward from one of the rear frame tie down locations as shown below Do not push the machine due to the possibility of damage to the solution and recovery tanks Do not tow the machine by the squeegee tool To enter the Push Mode which allows steering while towing the machine turn the Key Switch on while pressing and holding both the Speed Switch and the High Pressure Wand Switch Press and hold while turning key switch on to enter Push Mode On machines not equipped with a squeegee guard kit tow the machine by one of the two Tie down Slots on the chassis shown in green On machines equipped with a squeegee guard kit tow the machine by the two Tie down Slots on the squeegee guard shown in red Z Slot 2
140. ottle 1 and Throttle 2 To request idle speed 1t does not apply voltage to either circuit To request Run speed 1t sends out 12 volts on throttle 2 circuit only To request maximum power speed it sends out 12 volts on throttle 1 circuit only 12v Power Supply Throttle 1 Throttle 2 Actuator APECS 3000 Governor Controller Main Machine Engine RPM Controller Sensor Speed Mode Engine Speed Throttle 1 Throttle 2 Idle 1700 RPM Run 2200 RPV fa 2400 RPM EY p 162 Service Manual CS7000 Engine System Diesel 163 There are several conditions that will override the user s engine speed request 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 neutral 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 fthe override condition goes away e g sweep system turns off and the user has not changed the engine mode the engine 1s returned to the mode before the forced override The controller 1s capable of 1dentifying some fault conditions and displaying a fault code A flashin
141. ounting bracket See photo w j Reassemble in reverse order Service Manual CS7000 Electrical System 137 Head Light bulb Standard 12v Halogen 1 Disconnect headlight electrical connector Caution DO NOT install a replacement halogen bulb into the socket while the headlight is plugged in If the configuration menu is set for LED headlights up to 42 volts could be available to the headlights Plugging the 12 volt halogen bulb into a 42 volt source could cause the bulb to shatter in your hand 2 Replace Bulb 3 Enter the Configuration Menu Light Option and select Standard Light 4 Re connect the headlight electrical connector Service Manual CS7000 Electrical System D 785 224 211 811 MN 145 _ Specifications Battery Battery Model Capacity 98 AH 20 HR 213 30 81 12 934 328 521 Low Voltage Cut Out The low voltage cut out specification in use is set in the user options menu Cut Out AT Restore Operation at Battery Type 1 75v per cell 31 5v total 2 15v per cell 38 7v total 1 83v per cell 32 9v total 2 09v per cell 37 6v total 1 75v per cell 31 5v total 2 09v per cell 37 6v total User Preference Battery Run Time Battery powered machine Approx 5 4 hours 770 AH 6 hr rate and 900 AH 5 hr rate Auxiliary Relay Winding Resistance 652 Ohms Auxiliary Contactor Winding Resistan
142. play mode press the solution switch To exit the hidden menu turn the key switch off Service Manual CS7000 The Following 18 an outline of the menu 1 Machine Type 2 Battery Type 9 Detergent System 4 EcoFlex System 5 Dust Guard system 6 Ex Scrub System 7 Back Up Alarm 8 Signal Lights 9 Plugged Filter Kit 10 Hopper Temp Kit 11 Low Press Wash 12 High Press Wash 13 Scrub Motor 14 Display Screen 15 Light Option 16 Fault Recall 17 Haram Captor Used to configure the machine for a special market Control System 58 Service Manual CS7000 Control System 59 Configuration Menu The configuration menu is a read and write mode that allows you to check and change the machine configuration values in order to tell the main machine controller how the machine is equipped This matches the controller to the machine and must be done anytime a new main machine controller 16 installed MAN Note The configuration menu also contains time saving service tests in the Service Menu See the separate Service Mode section below for more details To enter the Configuration Menu 1 While pressing and holding both of the turn signal switches turn the key on 2 Continue to hold the switches until the LCD reads Configuration Menu and then release the switches Once the configuration menu you can scroll the arrow cursor through the men
143. ponent Locations 165 Maintenance and Adjustments 168 Diesel Engine Maintenance 5 168 Change Engine and Oil Filter 169 Change Engine 169 Replace Fuel Filter 169 Bleed Fuel System oa eh o 170 Inspect Air 170 Replace Air Filters 171 Troubleshooting 90d 28 172 No crank The starter does not engage 172 Cranks but does not 172 Cannot Achieve Either Run or Maximum Engine Speed Settings Run 2200 RPM Maximum Power 2400 174 wee 4 9 wk s 175 Removal and Installation 141 Engine 177 8 4 4 178 ean 178 s uu x BOHR w x S 0 w 2 Q 178 Engine 1 178 Engine Oil 178 Tye 178 Engine Viscosity 179 Cooling 179
144. purge cycle is adequate to purge the system To Purge Weekly the scrub system must be off 1 Disconnect and remove the detergent bottles 2 Install and connect bottles filled with clean hot water 3 Turn the key switch on and wait a few seconds for the start up sequence to finish T for approximately two seconds 4 Press and hold the detergent switch 5 Release the switch when the detergent purge icon appears on the display and the detergent indicator starts flashing AY Note Once activated the purge process takes at least 10 seconds Normally one purge cycle is adequate to purge the system To Change the Detergent Mix Ratio the scrub system must be on 1 Press and hold the detergent switch for two seconds 2 Release the switch once the detergent indicator begins flashing 3 While the light is flashing press and release the detergent switch to select the next detergent mixture ratio Once the desired ratio is selected the detergent system will return to normal operation within three seconds mode changes or each time the detergent switch is pressed Once set the detergent flow rate automatically increases and decreases with the solution flow rate but the detergent mix ratio will remain the same If an Operator would prefer the flexibility of setting different detergent dilution ratios for different solution flow rates this specific programming option can be found in the Control System section e
145. r lights during normal operation flashes to indicate a 60 second burst of power Solution Flow Indicators indicate the solution flow setting One LED indicates the lowest solution flow and five LEDs indicate the highest solution flow Vacuum Wand Indicator indicates that the vacuum system 1s enabled Detergent Indicator indicates that the detergent system 16 enabled Sweep Controls Broom Height Raise Lower Buttons raise and lower the selected broom from 1ts current position Side Broom Switch enables and disables the side brooms Note that 1f you switch off the side brooms the DustGuard spray nozzles will also switch off One touch Sweep Switch enables the main broom side brooms dust control fan and DustGuard spray nozzles Main Broom Float Switch directs the main machine controller to drive the main broom actuator all the way down so the weight of the main broom 16 resting on the floor The linkage 1s slotted to allow the broom to follow the contour of the floor General Information Solution Flow Indicators Scrub Pressure Indicators Vacuum Wand Indicator Burst of Power Indicator EcoFlex Indicator only Broom Height Raise Button One touch Sweep Switch Broom Height Lower Button Main Broom Float Switch Dust Guard Spray Switch
146. r for damage A large amount Dust of dust on top of the Filter is usually Control caused by a hole in the Filter or a Filter damaged filter gasket Service Manual CS7000 Dust Control DustGuard Systems 88 To Clean the Dust Control Filter A Caution Wear safety glasses when cleaning the filter Clean the filter in a well ventilated area Becareful not to puncture the filter element 1 Check the filter surfaces and urethane gasket on the bottom of the filter for signs damage If the filter surfaces or gasket are damaged replace the filter 2 Clean the dust control filter using either of the two methods below Method 1 a Vacuum any loose dust from the filter b Gently tap the filter against a flat surface with the dirty side down to remove loose dust and dirt Method 2 a Vacuum any loose dust from the filter b Blow compressed air maximum pressure 100 psi into the clean side of the filter in the opposite direction of the airflow To Reinstall the Dust Control Filter 1 Install the Dust Control Filter into the recess the upper hopper Nut 2 Note Make sure the arrow on the gt ut 2 Air Flow Indicator Decal sd on the side of the filter is Shaker pointing upward Assembly 2 Install the Filter Shaker Assembly onto the Dust Control Filter Make sure the shaker motor electrical connector 15 positioned toward the rear of the machine 3 Slide the Filter Sh
147. r supply for Main Broom Actuator Position Sensor 34 033 GRA GRN Wiper 0 002v full up position Main Broom Actuator Position 3 02v bottom of travel Sensor input 9 93v when open 35 034 TAN RED POT Low B for Main Broom Actuator Position Sensor Nilfisk 4 Advance 79 Service Manual CS7000 Dust Control DustGuard Systems Functional Description Overview The dust control system pulls air through the hopper and through a filter to trap the dust from the hopper The optional DustGuard system sprays a fine stream of water in front of each side broom to minimize the dust created by the main broom Dust Control System The Impeller Assembly mounted in the Hopper Cover pulls air from the Upper Hopper through the Filter which traps the dust generated by the sweep system The Impeller Assembly exhausts the filtered air through vents the Hopper Cover An optional dust control filter switch will shut off the vacuum motor 1n the Impeller Assembly if the vacuum on the clean side of the filter gets too high as a result of a clogged Filter When the switch 1s activated the LCD will Filter display an icon to the operator Shaker Assembly The removable Filter Shaker Assembly vibrates the Filter when the filter shaker switch 1s pressed to shake large particles from the input side of the Filter back into the hopper This reduces Filter maintenance and helps maintain adequate airflow through the Filter The Filter Shak
148. rees 13 Trail Angle 20 9 degrees 38 grade grade Maximum Machine Scrub Times US Battery 770 amp hour 6 hour EU Battery 800 amp hour 5 hour rate 5 4 hours run time rate 5 4 hours run time Fuel Consumption Hybrid LPG 5 5 hours Hybrid Diesel 15 hours approximate Noise Vibration Operator Sound Levels 82 dBA 81 dBA 72 dBA Operator s Ear Sound Power LWA 103 LwA 102 Hand Arm Vibration 0 33 m s2 0 35 m s2 0 36 m s2 Levels Operator Seat Vibration 0 03 m s2 0 03 m s2 0 02 m s2 Levels Hybrid LPG Hybrid Diesel Battery Machine Service Manual CS7000 General Information 25 Fastener Torque Specifications Size Plated Steel Stainless Steel Standard Torque Overall Dimensions Mob w ii I aW 000 A W AA Service Manual CS7000 General Information 26 E Maintenance Maintenance Schedule Keep the machine in top condition by closely following the maintenance schedule Maintenance intervals given are for average operating conditions Machines used in severe environments may require service more often In general Keep the fuel tank filled diesel This helps to reduce condensation and moisture entering the fuel system Be aware of the yellow Attention Indicator light the red Warning Indicator light and the LCD Display on the Operator panel for icons and fault codes that indicate a critical or non cr
149. rgency stop switch speed control light switch high pressure wand switch extended scrub system switch and horn button are located front of the Operator Scrubbing Controls Sweeping Controls Hopper Controls Note The switches with a below them s are press and release switches The buttons noted with an below them are momentary buttons Miscellaneous Controls Emergency Stop maintained palm switch removes off all power to the machine functions when pressed To reset the Emergency Stop switch rotate the red knob clockwise Left and Right Turn Signal switch on the corresponding turn signal Hazard Flasher optional Key switches on the four way Switch hazard flashers Key Switch main power ignition switch Switch Speed Switch LCD Display displays the various machine status icons and informational displays Speed Switch functions as follows LPG and diesel machines increments the engine speed up and down through the three speed ranges Note that the Switch Horn Button High pressure Wand Switch engine speed will increase automatically when certain machine functions are engaged Service Manual CS7000 General Information Battery machines increases the machine scrub speed to the full transport speed Headlight Switch switches on the headlights Horn Button
150. rmation Sources Engine Manufacturers Technical Manuals section for list of available engine manufacturers service manuals Refer to these manuals for more complete maintenance and service information and instructions 24 Note The engine maintenance schedule shown lists the recommended engine service intervals M Service Manual CS7000 Lubrication Points Recovery Tank Latch oil Squeegee Tool End Wheel 2 oil Squeegee Caster Wheel Axle and Pivot 2 grease Engine Battery Compartment Latch oil General Information Brake Pedal parking brake Linkage oil Steering Gears grease Service Manual CS7000 General Information 31 EcoFlex System Maintenance You will need to purge the system of the previous detergent when switching to a different detergent Service Note Move the machine over a floor drain before purging because small amount of TP detergent will be dispensed in the process To Purge When Changing Detergents the scrub system must be off 1 Disconnect and remove the detergent bottles 2 Turn the key switch on and wait a few seconds for the start up sequence to finish pe 3 Press and hold the detergent switch Gy for approximately two seconds 4 Release the switch when the detergent purge icon appears on the display and the detergent indicator starts flashing a Note Once activated the purge process takes at least 10 seconds Normally one
151. rn off the motor de energize relay Hopper Hydraulic Pump Pressing and holding either the hopper raise or lower buttons will energize the relays to operate the pump Pressing and holding either the hopper door open or close buttons will move the door in the appropriate direction until the limit 15 reached This 1s different than normal operation where a single press opens or closes the door completely Extended Scrub Pump Pressing the extended scrub switch will turn on the extended scrub pump and solution pump and solution valve if equipped and illuminate the extended scrub indicator Pressing the switch again will turn off the pump High Pressure Wash Pump Pressing the High pressure wand switch will turn on high pressure pump electromagnetic clutch and illuminate the high pressure wand indicator Pressing the button again will turn off the pump Service Manual CS7000 Control System 72 Troubleshooting Control Panel LEDs all stay lit CAN Bus problems If communication on the CAN bus fails the operator may or may not notice anything If they notice anything it will likely be that the control panel powers up when the key 15 turned on but all of the LEDs remain lit and there 1s no response to pushing any switch on the control panel Control panel appearance with CAN Bus failure If this happens start by checking to see 1f either the steering controller or drive controller 1s causing the probl
152. ry pack It 1s belt driven by a pulley located at the rear of the engine Right side of machine Lighting headlights curb light taillights and turn lights are controlled by the main machine controller Head lights are standard The curb light and turn lights are optional See the Options and Accessories chapter for more information on curb lights and turn lights Service Manual CS7000 Electrical System 103 Low Voltage Cutout The scrub system and solution system are cut off by the main machine controller if the system voltage falls too low Approx 31 5v for wet batteries or 32 94v for gel batteries This is done to prevent damaging the batteries from over discharging The operator will see the low voltage warning icon displayed when the low voltage cut out mode 16 active N There are actually two levels of low voltage cut off The first level disables the scrub and sweeping functions The second level will also disable the recovery function In either case the hopper functions are not disabled Once the machine has gone into the low voltage cut out mode the batteries must be fully recharged before normal operation is restored Approx 38 7v Circuit Descriptions 42 Volt Generator The 36 volt battery pack positive cable runs directly to the 42 volt generator positive terminal The battery pack negative cable runs directly to the 42 volt generator negative terminal The generator positive and negative terminals also
153. s 36 Chemical Detergent pump M17 gt 2 5 Amps or short circuit Disables detergent overload 27 Chemical Detergent pump M18 gt 2 5 Amps or short circuit Disables detergent overload Vacuum Contactor K5 Winding gt 4 Amps or short circuit Disables detergent Circuit Overload solution scrub motors and recovery Squeegee Actuator M12 gt 5 Amps for 4 seconds or short Disables detergent Overload circult solution scrub motors and recovery 0 Right Front Turn Signal LT4 Overload Left Front Turn Signal LT7 gt 3 Amps or short circuit gt 3 Amps or short circuit 4 Overload 2 Right Rear Stop Turn Signal 6 Amps or short circuit LT11 Overload I CO CO 3 Left Rear Stop Turn Signal LT9 6 Amps or short circuit Overload Head Lamp Circuit 172 LT3 Short circuit LT8 Overload Service Manual CS7000 Control System 56 Fault Description _________ Setting Conditions 45 Tail Lamp Circuit LT5 LT6 gt 3 Amps or short circuit Overload Back up Alarm H1 Overload 4 Amps or short circuit 5 ae Horn H2 Overload Short circuit MEE eres Low Voltage Cutout 30 8 V for Wet Acid Battery Warning message and 32 5 V for Gel Battery disable all sweep and scrub functions except recovery system A Fault Has Been Set In The Steering controller has Disables all sweep and Steering Controller A5 communicated an emergency scrub f
154. s Must be Met for the Low Pressure Wash Hose to Operate 308 The Following Conditions Must be Met for the EcoFlex System to Operate 308 The Following Conditions Must be Met for the High pressure Spray System to Operate 308 Component Locations 309 309 Drain 309 Solution Filter and Solution Shutoff Valve 309 Solution Pressure Sensor 310 Solution Pump EcoFlex Models Only 310 Low Pressure Wash Hose Pump 310 Solution Solenoid Valve uos uxo ee ee OS EO ERU e C 311 Solution Nozzles w eee 94 3 3 311 EcoFlex Detergent Bottles and Pumps O17 High pressure Spray System 012 Extended Scrub 313 Maintenance and Adjustments 314 To Clean the Solution Filter 314 To Clean the Extended Scrub System Strainer 315 To Clean the High Pressure Solution 815 To Adjust the Belt Tension on the High 316 Troubleshooting E 4 EUR ud Go wow w UR EU e es 317 Removal and Installation 320 Remove and Reinst
155. s brooms and for Main and side brooms damage wear Parking brake and foot pedal brake Check for correct operation of brakes adjust as needed Maintenance Every 15 to 20 Hours Maintenance Item Procedure Check the electrolyte level in the battery Battery Batteries Check the battery cables and connections Solution tank filter Inspect and clean the debris filter on the solution filter system EcoFlex detergent system Purge the detergent delivery lines Rotate the main broom Sweep brooms Inspect adjust the main and side brooms Inspect the side broom housing skirts DustGuard Clean the DustGuard system spray nozzles Dust hopper Clean the hopper filter inspect the hopper seals Service Manual CS7000 General Information Monthly Maintenance Maintenance Item Procedure Pump a small amount of grease into each grease fitting on the Squeegee caster wheel axle and pivot I machine until grease seeps out around the bearings Steering gears Apply grease to lubricate Squeegee tool end wheels Engine Battery compartment latch Apply light machine oil to lubricate Recovery tank latch Brake Pedal parking brake linkage Maintenance Every 150 Hours Maintenance Item Procedure Change the engine oil and oil filter Also review the engine manufacturer s additional maintenance requirements Radiator and oil cooler LPG and diesel h lina fi only nspect and clean the exterior core coo
156. t 1 The wiring diagrams show when a circuit passes through an in line connector and identifies the two halves of the connector If you need to locate one of these connectors see the Harness to Harness Connector Locations section To find a connector that plugs into a component see the Component Locations section to locate the component then follow the wire lead if there 1s one to the connector If you need more detailed information about what a multi pin connector looks like and where the wires are located the connector see the Connector Pin Outs section Service Manual CS7000 Electrical System 144 56509170 Rev G Before SN 1000048160 Sheet 1 of 6 X102 X107 X107 102 F1 RED 400K lt BLK 61 1 1 t RED BLK BLK 9 x Lob GRN ORN C SHEL K15 42V ALTERNATOR ORN 3 A BLK K1 ORN 1 BI K IGNITION SW CONTACTOR STEERING LAMP TROUBLE C
157. t Codes Machine motion signal Forward Neutral or Reverse From Steering Controller o Steering System Fault Codes Drive Controller Messages Sent To Main Machine Controller Drive System Fault Codes Machine motion signal Forward Neutral or Reverse Reverse signal To Steering Controller None Control Panel None Messages Received From Main Machine Controller Push Mode On Off Transport Mode On Off o Sweep System On Off Scrub System On Off Power Plant Type Battery Engine Hybrid Hopper Up Down From Steering Controller o None Service Manual CS7000 Control System 51 From Control Panel o None Steering Controller e Messages Sent To Main Machine Controller o Steering System Faults To Drive Controller None Control Panel None e Messages Received From Main Machine Controller None From Drive Controller None From Control Panel o None Service Manual CS7000 Control System 52 Component Locations Main Machine Controller Control Panel Drive Controller Steering Controller Main Machine Controller y Steering LL Controller y LI Drive Controller Caution Do not pressure wash the control panel main machine controller steering controller drive controller or any other electrical components Service Manual CS7000 Control Syste
158. t protection for multiple circuits The electrical system makes use of hall effect current sensors to provide amp draw information to the main machine controller for some circuits Current Sensor Wiring Harnesses Wires are color coded and have connector information printed near each end of the wire In the photo below the left end of the wire goes to connector X274 pin and the right side of the wire goes to connector J3 pin 9 AE 4 The main harness 1s the same for all models Connectors which are not used for certain models or features have plugs covering them or may be jumped together as is the case for the battery interlock switch on engine models There are splices in the harness that are shrink wrapped There are also two splice saver connectors which look like capped off connectors but actually connect many wires together through a comb that is inserted into the connector The CAN Bus wire pairs are twisted to prevent electrical interference from corrupting the messages If any repairs are performed on the CAN Bus wires the wire pairs must be twisted approximately once per inch Service Manual CS7000 Electrical System 102 Circuit Protection Circuit protection is accomplished with both fuses and circuit breakers There are 2 large fuses F1 is 400 amp fuse that provides complete machine protection F2 is a 150 amp fuse that protects the motor circuits for the main broom scrub motors
159. tem The Impeller Assembly houses the dust control vacuum motor and is mounted in the Hopper Cover The Impeller Assembly pulls air from Vent the hopper through the filter The filtered air typical 7 is exhausted through Vents the front of the Hopper Cover 20 Hopper gt gt Cover E 1 d y le Impeller _ Assembly a The rectangular Dust Control Filter seals against the Upper Hopper and is held in place Upper p Filter 5 Shaker FF Dust by the Filter Shaker Assembly Assembly Control Filter Y The electric motor in the Filter Shaker Assembly drives two eccentric weights to vibrate or shake the Dust Control Filter to dislodge dust and allow 1t to drop down into the hopper Two Thumb Nuts secure the Filter Shaker Assembly and Dust Control Filter to the Upper Hopper Service Manual CS7000 Dust Control Filter Switch The optional Dust Control Filter Switch is mounted above the Filter Shaker Assembly on the Upper Hopper The Dust Control Filter Switch will close and generate a warning if the hopper vacuum gets too high indicating a plugged Dust Control Filter Note that the Dust Control Filter Switch 1s factory set to close at 2 of water 0 147 Hg or 0 072 psi If the dust control filter switch is not installed in the hopper there will be a Threaded Plug installed the swit
160. tem Diesel 170 Bleed Fuel System Bleeding air out of the fuel system 1s required if the engine ran out of fuel the fuel filter has been replaced or the fuel lines have been opened onto a hot exhaust manifold creating a danger of fire i CAUTION To avoid personal injury Do not bleed a hot engine as this could cause fuel to spill 1 Loosen the air vent plug at the top of the fuel filter housing 2 Operate the fuel pump Cranking engine or jump with 12v power supply 3 Tighten the air vent plug when bubbles no longer come up Inspect Air Filter Check the service indicator mounted on the air cleaner elbow If the red disc is visible the window the filters should be cleaned or replaced Ca WSR Red in Window Restricted Filters Clear Window Okay Service Manual CS7000 Engine System Diesel 171 Replace Air Filters 1 Remove left side engine cover 2 Open right side engine cover and swing out fuel tank 3 Remove the top engine covers by a Disconnecting the gas spring from one end b Remove two bolts one on each side under the cover and lift the cover assembly off F Li 3 i XN Gas Spring Remove 4 Remove Top Engine Cover Fasteners 4 Release the latches and remove the air filter housing cover 5 Remove the outer filter element 6 Blow out air cleaner housing with compressed air with inner filter element still in pla
161. tes that the filter shaker motor 18 running Main Broom Side Broom On Indicator On Indicator Dust Control Fan On Indicator f W 39 Service Manual CS7000 General Information 40 Hopper Controls Hopper Raise Button raises the hopper Hopper Raise Hopper Lower Button lowers Button the hopper Hopper Door Open Button opens Hopper the hopper door Lower Button Hopper Door Close Button closes the hopper door Hopper Door Open Button Hopper Door Close Button LCD Displays General Displays Battery Machine The general LCD display on the battery machine shows the solution level 1n the solution tank the total sweep scrub time on the hour meter and the state of battery charge If the machine is equipped with an EcoFlex system the display will also show the detergent system icon and current dilution ratio LPG Machine The general LCD display on the LPG machine shows the solution level in the solution tank the total engine run time and the recycle system icon if actuated If the machine is equipped with an EcoFlex system the display will also show the detergent system icon and current dilution ratio AY Note No battery charge or fuel level will be displayed while the engine is running Dilution Ratio Sweep Scrub Time Recycle System Service Manual CS7000 Dies
162. the side brooms de energize relay Service Manual CS7000 Control System 70 Side Broom Actuator Press the broom select switch 1 until the side broom on indicator 2 flashes slowly Then press and hold the down arrow 3 to move the side brooms down Press and hold the up arrow 3 to move the side brooms up Main Broom Motors Pressing the One touch sweep switch once will turn on the main broom motor energize relay The main broom on indicator will illuminate Pressing the button again will turn off the motor de energize relay Main Broom Actuator Press the broom adjustment selection button 1 until the main broom button indicator 2 flashes slowly Then press and hold the down arrow 3 to move the main broom down Press and hold the up arrow 3 to move the main broom up Shaker Motor Pressing the filter shaker switch once will turn on the shaker motor and illuminate the filter shaker on indicator Pressing the button again will turn off the motor Fe Service Manual CS7000 Control System 71 Dust Guard Pump Pressing the dust guard spray switch will turn on the dust guard pump and illuminate the dust guard on indicator Pressing the switch again will turn off the pump Dust Control Motor Pressing the dust control fan switch will turn on the dust control motor energize relay and illuminate the dust control fan on indicator Pressing the switch again will tu
163. tions Scrub brushes on off will drift Scrub brush pressure settings 1 2 and3 Solution control on off and five flow settings Test and purge the EcoFlex detergent system if so equipped 19 Squeegee system raise lower and auto lift in reverse Vacuum performance 48 of H20 sealed 25 to 30 of H20 with 1 diameter orifice backup alarm Visual Inspection Items 23 Main broom bristles 24 Main broom motor 25 Side sweep broom bristles 26 Side broom motors 27 Scrub brush motors 28 Main scrub brushes check for wear and rotate Headlights gauges and optional accessories rotating beacon Tilt steering mechanism and seat adjustment lever Does Not Work Defect Codes circle A rough A low power low power gt gt noisy sluggish A W not functioning w gt gt Co J gt J hende C L used Does Not Work Defect Codes Comments min bristle length 2 5 em gt min bristle length 3 7 63 em gt 33 Service Manual CS7000 General Information 34 Defect Codes Does Ref Visual Inspection Items Comments Not Scrub deck housing and door skirts www 30 Solution system pumps and solenoid valves pumps Solution tank delivery hoses and filter clean filter screen _32 Dust contr
164. tions Most connectors are plugged into a component like the squeegee actuator find the squeegee actuator and you can locate the squeegee actuator electrical connector However there are a few connectors that connect two harness These are pictured here Interface Harness X175 Main Harness X274 to Engine 7 lt A 17 c LL P e s 79 p Xo N r m Tu a Service Manual CS7000 Electrical System 109 Connector Pin Outs The following pages contain details about every electrical connector that contains more than one cavity The connector pin out information is organized with a table on the left which identifies the location of wires in the connector and images on the right which show what the connector looks like The table on the left has a header that describes the connector ID the name of the component that it plugs into and the component s ID number There are few connectors that do not plug into a component but plug into another harness are empty These have the connector ID and the of the connector only The images to the right of each table have 3 dimensional view of the connector to help you recognize 16 on the machine and a 2 dimensional view of the back side or wire side of the connector This is to help you match up the wires and
165. u using the scrub pressure increase and decrease buttons To enter a menu selection press the One touch scrub switch The arrow cursor points to the currently selected value Scroll the cursor to the desired value and press the One touch scrub switch to save the new value and return to the configuration menu If you want to return to the configuration menu without saving a new value press the solution switch To exit the hidden menu turn the key switch off The following is an outline of the menu Default values are bold text 1 Machine Type Undefined When the machine type 1s undefined the control panel will display the configuration menu whenever the key 16 turned on 2 Battery 3 Diesel 4 Propane 5 Gas Petrol Service Manual CS7000 2 Battery Type 1 Undefined When the machine type is undefined the control panel will display the configuration menu whenever the key 1s turned on 1 Wet Lead Acid 2 Sealed gel 3 Detergent System 1 Installed 1 Not Installed 2 Installed Display Format Ratio o 2 Percentage 4 EcoFlex System Not Installed 2 Installed 5 Dust Guard system 1 Not Installed 2 Installed 6 Ex Scrub System Not Installed 2 Installed 7 Back Up Alarm 1 Not Installed 2 Installed 8 Signal Lights Not Installed 2 Installed 9 Plugged Filter Kit 1 Not Installed 2 Installed 10 Hopper Temp Kit Not Instal
166. uit breaker CB5 must closed to provide positive voltage to the load side of Dust Control Motor Contactor K6 Dust Control Motor Contactor K6 must be closed to provide positive voltage to the Dust Control Motor M5 Dust Control Motor M5 must be connected to battery ground Circuit breaker VACC2 CB2 must closed to provide positive voltage to the DustGuard Valve L2 and the DustGuard Pump M22 The J3 13 Output provides the negative ground to the DustGuard Valve L2 and the DustGuard Pump M22 under the following conditions A1 Main Machine Controller must receive a signal from the Control Panel via the CAN BUS that the operator has pressed the DustGuard spray switch blue LED on A1 Main Machine Controller must receive a signal from the A2 Drive Controller via the CAN BUS that the machine 1s moving forward Service Manual CS7000 Dust Control DustGuard Systems The J2 18 Output provides the negative ground to the Shaker Motor M14 under the following conditions Ifthe hopper is down and the DustGuard system is enabled the A1 Main Machine Controller will switch on the Shaker Motor M14 automatically for preset duration when the sweep system 1s switched off Ifthe hopper is up the A1 Main Machine Controller must receive a signal from the Operator Interface Panel via the CAN BUS that the operator has pressed the filter shaker switch blue LED on Component Locations Impeller and Filter Sys
167. unctions error message to the main machine controller Retrieve the specific steering system code by using the hidden menu configuration display fault recall A Fault Has Been Set In The Drive controller has Disables all sweep and Drive Controller A2 communicated a fault to scrub functions the main machine controller Retrieve the specific drive system code by using the hidden menu configuration display fault recall Vacuum Motor Circuit M6 M7 gt 40 Amps for 20 seconds or Disables detergent Overload short circuit solution scrub motors and recovery Scrub Brush Motor Circuit M2 gt 75 Amps for 25 seconds or Disables detergent M3 M4 Overload short circuit solution and scrub motors Main Broom Motor M1 Overload gt 28 Amps for 30 seconds or Disables sweep functions short circuit CO Note If this code is set after installing a new broom adjust the broom height Broom Motor Current Sensor Main broom motor contactor Disables sweep functions fault has been off more than 5 seconds but the broom motor current sensor is reporting 6 A 2 6V Make sure the sensor is reading the correct wire s Brush Motors Current Sensor Brush motor contactors have Disables scrub functions fault been off more than 5 seconds but the brush motor current sensor is reporting 6 A 2 6V Make sure the sensor is reading the correct wire s N
168. which drops the voltage seen by the main machine controller to nearly volts An engine temperature fault occurs when the coolant sensor switches to ground This fault will be displayed on the Control panel In response to the overheat condition the main machine controller waits five seconds to give the operator time to park the machine then removes the power supply going out connector J3 pin number 9 from the APECS 3000 Governor controller which causes the engine to shut down Power Supply Remaves 12v to shut down APECS 3000 5 Normal Temp Governor 0 volts Qverneat Controller SSS Coolant Temperature Switch Main Machine Controller Service Manual CS7000 Engine System Diesel 161 Low Oil Pressure Shutdown Here 1s how the low oil pressure shutdown works The main machine controller sends 12 V out connector J3 pin number 9 to the APECS governor controller and the oil pressure switch When there 1s oil pressure the switch connects the voltage back as an engine run signal to the main machine controller connector J7 pin number 4 Once the main machine controller has seen that the engine 1s running it continues to monitor that voltage If engine oil pressure is lost the engine run signal to the main machine controller will also be lost voltage drops from 12v to Ov In response the main machine controller sets an oil pressure fault displays it on the control panel and immediately removes th

Nilfisk-Advance CS7000 - Industrial Cleaning Equipment

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