Nilfisk-Advance CS7000 Fuel Cell EcoFlex Service Manual Download Page 6

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Contents

Service Manual – CS7000

Replace Air Filters 191

Troubleshooting

192

Engine Management System 192

Checking Spark

192

Checking LPG Primary Pressure

193

Removal and Installation 194

Shop Measurements 195

Engine System - Petrol (Gasoline) 199

Functional Description 199

Kubota WG972-GL-E3-NFK-1 Petrol (Gasoline)

199

Circuit Descriptions 200

Ignition System 200

Engine Starter and Carburetor Choke Control

202

Throttle Control Modes 203

Engine RPM Control 206

Normal Engine Shut Off 207

Engine Overheat Shutdown 208

Lost Oil Pressure Shutdown 209

Component Locations 210

Engine Right Side View (Toward front of machine)

211

Engine Back Side View (Toward right of machine)

212

Engine Left

Side View (Toward back of machine)

212

Fuel Tank Area

213

Maintenance and Adjustments 214

Maintenance Checklist

214

Change Engine Oil and Oil Filter 215

Change Engine Coolant 215

Inspect Air Filter 216

Replace Air Filters 216

No crank - The starter does not engage

217

Cranks but does not start – No Spark

218

Cranks but does not start (has sufficient spark)

218

Achieves one but not ALL RPM modes.

219

Removal and Installation 220

Engine RPM Sensor Installation 220

Shop Measurements 221

Ignition System 221

Summary of Contents for CS7000 Fuel Cell EcoFlex

Page 1: ...ybrid EcoFlex 56509007 48 Diesel Hybrid EcoFlex 56509008 48 Battery EcoFlex 56511001 48 Gasoline Petrol Hybrid EcoFlex 56511540 48 LPG LEV Hybrid 56511541 48 LPG LEV Hybrid EcoFlex English Nilfisk 56509003 1200 LPG Hybrid 56509004 1200 Diesel Hybrid 56509005 1200 Battery 56511002 1200 Gasoline Petrol Hybrid 56384409 1200 LPG Hybrid 556384410 1200 Battery 56511564 1200 LPG LEV Hybrid ...

Page 2: ...ll Dimensions 26 Maintenance 27 Maintenance Schedule 27 Recommended Service Materials 27 Daily Maintenance 27 Maintenance Every 15 to 20 Hours 28 Monthly Maintenance 28 Maintenance Every 150 Hours 28 Maintenance Every 400 Hours 28 Maintenance Every 800 to 1000 Hours 29 Maintenance Every 1500 Hours 29 Maintenance Every 1900 Hours 29 Maintenance Every 2000 Hours 29 Lubrication Points 30 EcoFlex Syst...

Page 3: ...controller 53 Hidden Menus 57 Configuration Display 57 Configuration Menu 59 User Options Menu 63 Service Mode 68 To Operate 71 Control Panel LEDs all stay lit CAN Bus problems 75 Removal and Installation 76 Main Machine Controller 76 Control Panel 77 Specifications 78 Shop Measurements Main Machine Controller 78 J2 Connector White 78 J3 Connector Gray 79 J7 Connector Black 81 Dust Control DustGua...

Page 4: ...elay location 110 Harness to Harness Connector Locations 111 Connector Pin Outs 112 Component ID to Connector ID Look Up Table 112 Wiring Connections 134 K14 Safety Relay and K15 Auxiliary Relays 134 Early Style K14 Safety Relay 134 Early Style K15 Auxiliary Relay 134 Late style K14 Safety Relay and K15 Auxiliary Relay 135 Maintenance and Adjustments 136 Charging the Battery Battery Model 136 Gene...

Page 5: ...age 177 Cranks but does not start No Spark 178 Cranks but does not start has sufficient spark 178 Achieves one but not ALL RPM modes 179 Removal and Installation 180 Engine RPM Sensor Installation 180 Engine Assembly 180 Specifications 181 Fuel System 181 Engine OIl 181 Engine Coolant 181 Shop Measurements 181 Ignition System 181 Spark Controller Measurements 182 Governor Control System 182 Woodwa...

Page 6: ...Engine RPM Control 206 Normal Engine Shut Off 207 Engine Overheat Shutdown 208 Lost Oil Pressure Shutdown 209 Component Locations 210 Engine Right Side View Toward front of machine 211 Engine Back Side View Toward right of machine 212 Engine Left Side View Toward back of machine 212 Fuel Tank Area 213 Maintenance and Adjustments 214 Maintenance Checklist 214 Change Engine Oil and Oil Filter 215 Ch...

Page 7: ...uel System 238 Inspect Air Filter 238 Replace Air Filters 239 Troubleshooting 240 No crank The starter does not engage 240 Cranks but does not start 240 Cannot Achieve Either Run or Maximum Engine Speed Settings Run 2200 RPM Maximum Power 2400 RPM 242 Compression Test 243 Removal and Installation 245 Engine RPM Sensor Installation 245 Engine Assembly 245 Specifications 246 Fuel Pump 246 Glow Plugs...

Page 8: ...k Switch Replacement 276 Specifications 277 Options and Accessories 278 Recovery System 288 Functional Description 288 Overview 288 Recovery System Wiring Diagram 289 Circuit Description 290 Component Locations 291 Recovery Tank 291 Recovery Tank Cover and Debris Basket 291 Vacuum Fan Cover Assembly 292 Vacuum Motors 292 Float Cage and Ball Assemblies 292 Maintenance and Adjustments 293 To Clean t...

Page 9: ... LP and Diesel Only 320 Solution Level Sensor 320 Solution System Wiring Diagram 321 Circuit Description 322 The Following Conditions Must be Met for the Solution System to Operate 322 The Following Conditions Must be Met for the Extended Scrub System to Operate 322 The Following Conditions Must be Met for the Low Pressure Wash Hose to Operate 323 The Following Conditions Must be Met for the EcoFl...

Page 10: ...he Squeegee Support Assembly 351 To Remove and Reinstall the Squeegee Lift Arm 351 To Remove and Reinstall the Squeegee Lift Actuator 352 Specifications 353 Special Tools 353 Steering System 354 Functional Description 354 Summary 354 Steering Wheel Rotation Sensor 354 Steering Actuator 355 Steering Travel Limit Switches 356 Steering Controller 356 Steering System Wiring Diagram 357 Circuit Descrip...

Page 11: ...shes 384 Troubleshooting 387 Removal and Installation 388 To Remove the Main Broom 388 To Install the Main Broom 389 To Remove and Reinstall the Broom Motor Assembly 390 To Remove and Reinstall the Broom Lift Actuator 391 Specifications 393 Sweep System Side Broom 394 Functional Description 394 Overview 394 Side Broom System Wiring Diagram 395 Circuit Description 396 The Following Conditions Must ...

Page 12: ...tallation 429 Drive Pedal Assembly 429 Drive Motor and Gearbox Assembly 429 Drive Wheel 433 Drive Controller 433 Specifications 434 Shop Measurements 434 Drive Controller Voltage Measurements 434 Low Current 35 Pin Connector J4 434 Motor U V and W Terminal Pair Voltages 435 Motor U V and W Terminal Pair Frequency 435 System Current Draw Driving only with no cleaning functions 436 Wheel Drive Conta...

Page 13: ...ry of Changes 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 K...

Page 14: ...ybrid Diesel 56509001 Advance CS7000 B 56509002 Advance CS7000 Hybrid LPG EcoFlex 56509006 Advance CS7000 Hybrid Diesel EcoFlex 56509007 Advance CS7000 B EcoFlex 56509008 Nilfisk Advance CS7000 Hybrid LPG EU 56509003 56041980 English Turkish Bulgarian Romanian 56041981 Danish Norwegian Swedish Finnish 56041982 German French Dutch Russian 56041983 Spanish Portuguese Italian Greek 56041984 Estonian ...

Page 15: ...thorized 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 Dealer affix service sticker here Note On Fuel Ce...

Page 16: ...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 in 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...

Page 17: ...hat 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 U...

Page 18: ...r 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 1 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 Prop ...

Page 19: ...nsporting the machine on an open truck or trailer make sure the machine is tied down securely and all access doors and covers are secured tape and strap as needed 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 Rear Jacking...

Page 20: ...d 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 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 squee...

Page 21: ...red 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 di...

Page 22: ...ry Weight 3 636 lbs 1 649 kg GVW full solution and dust control tanks 4 676 lbs 2 121 kg Hybrid Diesel Dry Weight 3 511 lbs 1 593 kg GVW full solution and dust control tanks 4 537 lbs 2 058 kg Battery Machine Dry Weight 4 682 lbs 2 124 kg GVW full solution and dust control tanks 5 716 lbs 2 593 kg Maximum Tire Loading with full solution and dust control tanks Hybrid LPG 146 psi 10 26 kg cm2 Hybrid...

Page 23: ...6 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 gal 110 L DustGuard Nozzle Flow Rate Battery Machine 6 4 gph size 100 nozzle LP and Diesel Machines 6 7 gph size 100 nozzle Dust Control Motor 36 VDC 7 Amps average 8 Amps max Sweep System Main Bro...

Page 24: ...ont wheel mechanically actuated Machine Performance Machine Speeds Transport speed 5 5 mph 8 85 kph Scrubbing and sweeping speed 3 5 mph 5 63 kph Gradeability vehicle loaded to gross vehicle weight Transport 12 degrees 21 slope Scrubbing Sweeping 10 degrees 17 6 slope Brake Holding 18 degrees 32 5 grade Tilt Stability Empty Tanks 24 0 degrees 44 5 grade Full Tanks 23 0 degrees 37 0 grade Approach ...

Page 25: ...m s2 0 36 m s2 Operator Seat Vibration Levels 0 03 m s2 0 03 m s2 0 02 m s2 Fastener Torque Specifications Standard Torque Specifications unless otherwise specified Size Plated Steel Stainless Steel 10 42 in lb 28 in lb 1 4 100 in lb 67 in lb 5 16 17 ft lb 11 ft lb 3 8 31 ft lb 20 ft lb 1 2 75 ft lb 50 ft lb 3 4 270 ft lb 180 ft lb M5 61 in lb 36 in lb M6 9 ft lb 62 in lb M8 22 ft lb 13 ft lb M10 ...

Page 26: ...General Information 26 Service Manual CS7000 Overall Dimensions 61 155 cm 48 122 cm 4 10 cm 59 150 cm 103 262 cm ...

Page 27: ...50 50 mix LPG and diesel models only Lithium base grease Loctite or equivalent thread sealant in the appropriate grades Never Seez or equivalent anti seize compound Daily Maintenance Caution Do not pressure wash the operator control panel fuse panel contactor panel or engine compartment area Maintenance Item Procedure Perform After Use maintenance steps After use maintenance is normally the respon...

Page 28: ... grease to lubricate Squeegee tool end wheels Apply light machine oil to lubricate Engine Battery compartment latch Recovery tank latch Brake Pedal parking brake linkage Maintenance Every 150 Hours Maintenance Item Procedure Engine maintenance LPG and diesel only Change the engine oil and oil filter Also review the engine manufacturer s additional maintenance requirements Radiator and oil cooler L...

Page 29: ...place 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 Note The engine maintenance schedule shown lists the recommended engine service intervals Refer to the ...

Page 30: ...e Manual CS7000 Lubrication Points Engine Battery Compartment Latch oil Recovery Tank Latch oil Squeegee Tool End Wheel 2 oil Squeegee Caster Wheel Axle and Pivot 2 grease Brake Pedal parking brake Linkage oil Steering Gears grease ...

Page 31: ...ease the switch when the detergent purge icon appears on the display and the detergent indicator starts flashing Note Once activated the purge process takes at least 10 seconds Normally one 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 sw...

Page 32: ...ch 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 Note During scrubbing the detergent s...

Page 33: ...cklist 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 Ref Operational Inspection Items OK Defect Codes circle Does Not Work Ref Visual Inspection Items Comments OK Defect Codes circle Does Not Work PM Checklist ...

Page 34: ...Manual CS7000 Copyright 2011 Nilfisk Advance Page 2 of 2 5 12 2011 Ref Visual Inspection Items Comments OK Defect Codes circle Does Not Work Work Completed By Acknowledged By Service Technician Signature Date Customer Signature Date ...

Page 35: ...llaneous 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 switches on the four way hazard flashers Key Switch main power ignition switch LCD Display displays the various machine status i...

Page 36: ...iring attention Left and Right Turn Indicators indicates that the corresponding turn signal is 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 ...

Page 37: ...re one level when pressed Burst Of Power Switch increases both the scrub brush pressure and solution flow one step higher for 60 seconds Solution Flow Increase Button increases the solution flow rate one level when pressed Note that the solution flow LED indicators in the Solution Switch will light to indicate the selected solution flow rate Solution Switch enables and disables the solution system...

Page 38: ... the selected broom from its current position Side Broom Switch enables and disables the side brooms Note that if 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 wa...

Page 39: ...oom 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 is enabled Side Broom On Indicator indicates that the side brooms are enabled Main Broom Float Indicator i...

Page 40: ...lex 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 Note No batt...

Page 41: ...ndicator shows the charge state of battery and will retain the charge state when the key is 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 is in the low voltage cutout mode You can choose between two different low voltage cutout thresholds depending on whether main...

Page 42: ...n critical faults detected by the main machine controller will be displayed on the display panel in 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 Electric...

Page 43: ...ne controller will be shown on the left side of the display Only the fuel battery level and hour meter indicators will remain 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 Critic...

Page 44: ...s powered up normal steering feel is 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...

Page 45: ...ttery Machine major components Right Door Assembly Left Cover Assembly Rear Battery Cover Assembly Front Engine Cover Assembly Dust Shield Front Battery Guide Chassis Weldment Battery Stop Plate Assembly Battery Guide Weldment Battery Stop Weldment Pull Rod Assembly ...

Page 46: ... Service Manual CS7000 Component Locations LPG and Diesel Machine major components Right Door Assembly Left Cover Assembly Engine Cover Assembly Front Engine Cover Assembly Chassis Weldment Pull Rod Assembly Dust Shield ...

Page 47: ...and can set many diagnostic trouble codes that simplify troubleshooting 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 Note An updated main machine controller Software ID 56111560 was introduced around August 2015 beginni...

Page 48: ...nects the CAN Hi and CAN 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 and the drive controller are both tied into the CAN Bus circuits but do not contain termination resistors Main Machine Controller Drive Controller Steering Controll...

Page 49: ...anel 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 Sweep System On Off Scrub System On OffMachine Power Plant Type Battery Engine Hybrid Hopper Up Down To Steering Controller None Messages Received From Control Panel Operator switch inputs From Drive Controller ...

Page 50: ...attery Engine Hybrid Hopper Up Down From Steering Controller NoneFrom Control Panel None Steering Controller Messages Sent To Main Machine Controller Steering System Faults To Drive Controller None To Control Panel None Messages Received From Main Machine Controller None From Drive Controller None From Control Panel None ...

Page 51: ...ntroller Control Panel Drive Controller Steering Controller Caution Do not pressure wash the control panel main machine controller steering controller drive controller or any other electrical components Main Machine Controller Steering Controller Drive Controller Control Panel ...

Page 52: ...ssible 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 open and draws no cur...

Page 53: ...perature switch closed with the engine running Shut down engine 05 Low Engine Oil Pressure Loss of engine run signal Oil pressure switch open with the key switch still on Shut down engine 06 Glow Plug Relay Overload 07 42 Volt Alternator is not charging 37 volts for 30 Seconds 08 Throttle 1 circuit overload Current Overload 09 Throttle 2 circuit overload Current Overload Fault Description Setting ...

Page 54: ...Right Brush Contactor K3 Winding Circuit Overload 4 Amps or short circuit Disables detergent solution and scrub motors 24 Broom Contactor K4 Winding Circuit Overload 4 Amps or short circuit Disables sweep functions 25 Hydraulic Pump1 Contactor K4 Winding Circuit Overload 4 Amps or short circuit 26 Hydraulic Pump2 Contactor K4 Winding Circuit Overload 4 Amps or short circuit 27 Dust Filter Plugged ...

Page 55: ...Amps or short circuit 47 Horn H2 Overload Short circuit 48 Not used 49 Low Voltage Cutout 30 8 V for Wet Acid Battery 32 5 V for Gel Battery Warning message and disable all sweep and scrub functions except recovery system 50 A Fault Has Been Set In The Steering Controller A5 Steering controller has communicated an emergency error message to the main machine controller Retrieve the specific steerin...

Page 56: ...he brush motor current sensor is reporting 6 A 2 6V Make sure the sensor is reading the correct wire s Disables scrub functions 57 Vacuum Motor Current Sensor fault Vacuum motor contactors have 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 Disables scrub and recovery functions 58 Engine MIL Key switch is on ...

Page 57: ...ithout 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 config...

Page 58: ...larm Back Up Alarm 8 Signal Lights Signal Lights 9 Plugged Filter Kit Plugged Filter Kit 10 Hopper Temp Kit Hopper Temp Kit 11 Low Press Wash Low Press Wash 12 High Press Wash High Press Wash 13 Scrub Motor Type Broom Motor Type 14 Display Screen Display Screen 15 Light Option Fault Recall 16 Fault Recall Haram Captor Used to configure the machine for a special market 17 Haram Captor Used to confi...

Page 59: ... 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 in the configuration menu 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 The arrow cursor points to t...

Page 60: ...6 Ex Scrub System 1 Not Installed 2 Installed 7 Back Up Alarm 1 Not Installed 2 Installed 8 Signal Lights 1 Not Installed 2 Installed 9 Plugged Filter Kit 1 Not Installed 2 Installed 10 Hopper Temp Kit 1 Not Installed 2 Installed 11 Low Press Wash 1 Not Installed 2 Installed 12 High Press Wash 1 Not Installed 2 Installed 13 Scrub Motor Type OR Broom Motor Type 1 Option 1 Select Option 1 for either...

Page 61: ...rn on Medium Scrub LED2 Scrub Pressure Decrease switch Turn on Heavy Scrub LED3 Vacuum Wand switch Turn On Vacuum LED Solution ON OFF switch Turn on Light Solution LED1 Solution Flow Increase switch Turn on Medium Solution LED2 Solution Flow Decrease switch Turn on Heavy Solution LED3 Sweep Functions Side Broom ON OFF switch Turn on Side Broom LED Main Broom ON OFF switch Turn on Main Broom LED Br...

Page 62: ...ch No 17 or 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 18 UI Part Number Used for the control panel to display properly when the hopper is not seated Late control panels PN 56511559 have a hopper up icon to be used with an updated main machine controller software ID 56111560 56511559 Late...

Page 63: ...on 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 t...

Page 64: ...ill 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 is needed with light scrub pressure or low solution rate with heavy scrub pressure 1 Scrub Pressure RANGE 1 MIN 2 MED 3 MAX D...

Page 65: ...n 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 is activated RANGE 10 40 seconds INCREMENT 1 second DEFAULT 15 seconds 3 Recovery System 1 Sqg Down Time Sets the time to extend the squ...

Page 66: ... 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 1 Unlocked 2 Detergent Prevents the user from changing detergent settings 3 Detergent Sol Prevents the user from changing detergent and ...

Page 67: ...T 20 seconds 9 Back up Alarm 1 Off never on 2 Reverse Only Only on in reverse 3 Fwd Reverse on when in motion 4 Fwd Rev Hopper on when motion or the hopper is lifted 10 Headlights 1 Normal User controls with key switch DEFAULT 2 Always On On when machine is running Key switch allow momentary off 11 Broom Lift in Rev 1 No 2 Yes 12 Maximum Speed RANGE 20 100 INCREMENT 20 DEFAULT 100 13 Fuel Tank Opt...

Page 68: ... 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 Note Beginning around August 2015 an updated main machine controller software ID 56111560 expands the capability of service test mode by allowing you to monitor several new data parameters including...

Page 69: ...ral or Forward and any current main machine controller faults With the introduction of a new main machine controller 56111560 4 more screens are available in the service test mode To cycle through the screens press the burst of power button Screen 1 Shows the battery voltage seen by the main controller the drive pedal position sensor voltage and the transport status from the drive controller Scree...

Page 70: ...r to inform that the engine has been shut down due to either high temperature or low oil pressure Screen 4 This is the main broom actuator potentiometer R4 voltage as seen by the main controller Screen 5 This screen shows the amperage reported to the main machine controller by each of the three current sensors Once in the service mode you will be able to turn various electrical loads on and off th...

Page 71: ...l 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 in...

Page 72: ...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 butto...

Page 73: ...the dust control fan on indicator Pressing the switch again will turn 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 Hopper Door Motor Pressing and holding either the hopper door open or close buttons will move the door in the appropriate direction until the limit is reached This is di...

Page 74: ...Manual CS7000 High Pressure Wash Pump Pressing the High pressure wand switch will turn on high pressure pump electromagnetic clutch and illuminate the high pressure wand indicator Pressing the button again will turn off the pump ...

Page 75: ...voltage on each of the CAN Bus wires If there is voltage example 12v or 36v the wire is 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 ...

Page 76: ...ssemble in reverse order 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 al...

Page 77: ...he 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 control panel 9 Before reassembly make sure the solution tank is empty The pressure sensor used to measure the tank l...

Page 78: ...d 37v when not energized 7 119 BRN WHT Detergent Pump M17 Pulsed voltage is too fast for useful measurement value 8 080 WHT GRN Squeegee Actuator Motor 37v at rest or when going down 0 04 going up 9 078 BLU BRN Squeegee Actuator Motor 37v at rest or when going up 0 01v going down 10 132 RED GRN Scrub Deck Actuator Motor 37v at rest or when going down 0 15v going up 11 135 YEL GRA Scrub Deck Actuat...

Page 79: ...r Contactor Grounds to energize 0 08v when energized 28 038 BLU ORN Hydraulic Pump Motor Contactor K11 Grounds to energize 0 08v when energized Hopper Up 29 30 31 32 221 GRA BLIU Detergent Pump M18 Pulsed voltage is too fast for useful measurement value 33 34 054 BLK WHT VACC6a Power supply from Aux Relay 0v Key Off 37v Key On Aux Relay energized 35 053 BLK WHT VACC6b Power supply from Aux Relay 0...

Page 80: ...Ground to turn on 0 24v when sounding horn 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 17 250 GRN ORN Side Broom Actuator Reversing polarity driver 37v at rest or when moving up 0 05v when moving down 18 149 BLK Battery Negative 0 006v with scrub sweep and vacuum motors free ru...

Page 81: ...ing starter disabled 5 108 GRA YEL Engine Coolant Temperature 4 99v normal temp 6 112 TAN WHT Fuel Level Sender 3 3v open circuit 1 8v float at bottom 0 37v float at top 7 117 YEL RED Low LP Pressure Switch 5 0v when open 8 9 10 130 WHT BRN 12v Power out to Control Panel 12 07v 11 133 BLK B Ground for Control Panel 0 002v 12 050 YEL BRN Suppression Diode 37v key on 13 141 ORN Key Switch On Input 3...

Page 82: ...sh Motor Current Sense 2 49v at rest no current 2 86v free running at 22 amps 28 29 184 RED WHT Vacuum Motor Current Sense 2 49v at rest no current 3 01v Vac running cover open at 28 amps 30 31 215 ORN BLU Broom Motor Current Sense 2 49v at rest no current 2 71v free running at 12 amps 32 33 032 BLU BLK POT High Power supply for Main Broom Actuator Position Sensor 3 304v plugged in or unplugged 34...

Page 83: ...filtered air through vents in the Hopper Cover An optional dust control filter switch will shut off the vacuum motor in 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 is activated the LCD will display an icon to the operator The removable Filter Shaker Assembly vibrates the Filter when the filter shaker switch is pr...

Page 84: ...ms 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 A 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 ...

Page 85: ...J2 14 Output J7 12 Supression Diode VIO GRN K9 Aux Contactor YEL BRN BLK ORN ORN ORN YEL BRN G J7 13 Key Switch Input J7 1 Interlock Input ORN GRA ORN ORN Safety Switch Relay signal from A5 Steer by Wire Controller 6 2 1 2 2 1 1 4 PINK TAN GRN BLU K14 Seat Switch S9 Emergency Stop Switch S15 Fe S13 Battery Interlock RED FROM F1 A3 Control Panel CAN BUS GRN YEL BLK WHT BRN GRN YEL Chassis Ground J7...

Page 86: ... 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 If the hopper is down 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 blue LED on The A1 Main Machine Controller must receive ...

Page 87: ...s pressed the filter shaker switch blue LED on Component Locations Impeller and Filter System The Impeller Assembly houses the dust control vacuum motor and is mounted in the Hopper Cover The Impeller Assembly pulls air from the hopper through the filter The filtered air is exhausted through Vents in the front of the Hopper Cover The rectangular Dust Control Filter seals against the Upper Hopper a...

Page 88: ...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 is 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 in the switch hole Dust Control Filter Switch Threaded Plug ...

Page 89: ...ing 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 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 Upper Hopper Pump Guard Strainer Solenoid Valve DustGuard Pump Spray Nozzles ...

Page 90: ...trol Filter 1 Lift the hopper cover 2 Disconnect the Shaker Motor Electrical Connector 3 Loosen the two Thumb Nuts then slide the Filter Shaker Assembly toward the left and remove it from the machine 4 Lift the Dust Control Filter out of the machine 5 Inspect the top of the Dust Control Filter for damage A large amount of dust on top of the Filter is usually caused by a hole in the Filter or a dam...

Page 91: ...oose 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 in the upper hopper Note Make sure the arrow on the Air Flow Indicator Decal on the side of the filter is pointing upward 2 Install the Filter Shaker Assembly onto t...

Page 92: ...per to catch the water from the hopper reservoir 2 Raise the hopper and engage the prop rod 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 ...

Page 93: ...k the components in vinegar or other commercial cleaner to remove any mineral deposits 5 Reassemble the DustGuard nozzles by following the above steps in reverse order 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 raise...

Page 94: ...ean the strainer screen The water hoses nozzles are plugged Check and clean the water hoses nozzles as necessary The water solenoid valve is plugged or not functioning correctly Check for voltage at the solenoid valve If there is voltage at the solenoid check the solenoid coil resistance It should measure 125 ohms 10 If the coil resistance is not within spec replace the solenoid valve If there is ...

Page 95: ...tor 2 Check the coil resistance in the K6 contactor coil If the coil resistance is not 118 ohms 10 replace the contactor 3 Check the continuity through contactor K6 with the coil energized If the contacts are open replace the contactor 4 Check the J2 6 output from A1 Main Machine Controller The dust control motor is not operating correctly If there is voltage to the dust control motor replace the ...

Page 96: ...nderneath the upper hopper to catch the water from the hopper 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 container underneath the Solenoid Valve Assembly to catch any water that may leak from the Solenoid Valve Assembly and hoses 3 Disconnect the Solenoid Electrical Connector 4 Remove the two Nyloc Nuts holding the...

Page 97: ...d Pump to catch any water that may leak from the DustGuard Pump and hoses 3 Disconnect the Pump Electrical Connector 4 Disconnect the two Hoses from the DustGuard Pump 5 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 Ele...

Page 98: ... hopper To Remove and Reinstall the Impeller Assembly 1 Lift the Hopper Cover 2 Remove the six Screws and washers holding the Impeller Assembly to the Hopper Cover 3 Carefully pull the Impeller Assembly partway off of the Hopper Cover 4 Disconnect the Vacuum Motor electrical connector then remove the Impeller Assembly from the machine 5 Reinstall the Impeller Assembly by following the above steps ...

Page 99: ...m 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 a wrench on the Screw heads under the Vacuum Motor Tabs 3 Reassemble the impeller assembly following the above steps in reverse order Vacuum Plate and Gasket Vacuum Support Screw 3 Nyloc Nut 3 Spacer 3 Vacuum Motor Screw 3 Nyloc Nut 3 Vacuum Support Vac...

Page 100: ... 125 Ohms 10 Dust Control Filter Media Type synthetic with UltraWeb cellulose optional Media Quantity 120 ft2 approximate Media Configuration PowerCore Dust Control Vacuum Motor Current 7 Amps average 8 Amps max Dust Control Motor Contactor K6 118 Ohms 10 Dust Control Filter Switch Actuation setting 20 factory set at 2 H2 O 0 147 Hg 0 072 psi Filter Shaker Motor Voltage 36 VDC Current 0 8 Amps ave...

Page 101: ...ers For instance the Solution Pump is 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 Battery Model Power Distribution 36V Battery Machine 36V Electrical Loads ...

Page 102: ...he machine 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 Hybrid models also have a separate 12 volt starting battery The main purpose of the staring battery is 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...

Page 103: ...n for both the engine electrical loads and the 36v machine electrical loads it looks like this Combined Power Distribution Engine Models 36V Battery Pack 42V Alternator Main Machine Controller 36V Machine Electrical Loads 12V Starting Battery Engine Electrical Loads 12V Alternator ...

Page 104: ...nector X274 pin A and the right side of the wire goes to connector J3 pin 9 The main harness is 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 whi...

Page 105: ...aw 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 incr...

Page 106: ...ctions 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 ...

Page 107: ...he 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 is Pulse Width Modulated to provide approximately 3 3 volts rather than full machine system voltage LED Headlights Battery positive power is supplied to the head lamps through F1 CB6 VACC6 and the K15a Auxiliary relay contacts The...

Page 108: ...lution 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 Battery Interlock Switch Under here Switch reads tang 36 volt Battery Battery Model Main Power Disconnect Horn 36v Battery Engine...

Page 109: ...ps and F2 150 amps Behind metal panel Shown with panel pulled forward Fuse F1 400 Amps Side view Shown with panel pulled forward Circuit Breaker Panel 42 volt Generator Seat Switch bottom of seat Starting Battery 36 volt Battery Pack Hybrid Models Battery Pack Under Fuel Tank ...

Page 110: ...Electrical System 110 Service Manual CS7000 Electrical Panel Contactor Relay location Electrical Panel ...

Page 111: ...you can locate the squeegee actuator electrical connector However there are a few connectors that connect two harness These are pictured here Main Harness X1 and X2 to Hopper Harness X262 and X263 Main Harness X274 to Engine Interface Harness X175 Main Harness X166 to Taillight Harness X239 Underneath Engine Interface Harness X265 and X266 to Engine Harness Photo of diesel engine Below ...

Page 112: ...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 Tab...

Page 113: ...Low Pressure Optional X20 M23 Low Pressure Pump Optional X120 M24 Wheel Drive Motor X99 M24 Wheel Drive Motor X100 M25 Pump Extended Scrub optional X118 M26 Dump door actuator motor X124 R1 Drive Pedal Position Sensor X145 S1 Scrub Deck Retract Limit Switch X255 S3 Hopper Interlock Switch X204 S4 Extended Scrub Level Switch optional X268 S5 Brake switch X202 S7 Dump door extend limit switch X236 S...

Page 114: ... WHT 8 080 WHT GRN 9 078 BLU BRN 10 132 RED GRN 11 135 YEL GRA 12 162 BLK 13 057 VIO 14 051 BLK ORN 15 163 BRN BLK 16 063 GRN GRA 17 045 BLU 18 150 BLK RED 19 116 WHT YEL 20 157 YEL ORN 21 160 BLU VIO 22 167 BLK YEL 23 169 BRN 24 039 ORN RED 25 047 YEL BLU 26 015 WHT VIO 27 061 GRA RED 28 038 BLU ORN 29 30 31 32 221 GRA BLIU 33 34 054 BLK WHT 35 053 BLK WHT AMP 776164 2 NEUTRAL J2 ...

Page 115: ...6 111 BRN GRN 7 115 RED GRA 8 118 WHT ORN 9 123 PINK 10 129 BLU PINK 11 131 GRA ORN 12 134 GRA BLU 13 137 BRN RED 14 139 VIO BRN 15 144 BLK 16 142 BLK 17 250 GRN ORN 18 149 BLK 19 154 BLK 20 156 BLK 21 159 BLK 22 23 059 VIO RED 24 171 GRN WHT 25 26 058 GRA 27 076 GRN BRN 28 29 166 BLK 30 31 32 049 ORN BLK 33 34 056 GRA BLK 35 055 GRA BLK AMP 776164 4 GRAY J3 ...

Page 116: ... 4 5 6 126 VIO GRN 7 186 BLK PINK 8 187 TAN RED 9 188 GRN BLU 10 11 12 13 127 TAN ORN 14 15 189 WHT BLK 16 190 BRN RED 17 18 191 VIO BLK 19 20 21 22 23 192 YEL 24 25 193 VIO WHT 26 194 PINK RED 27 28 195 WHT ORN 29 196 BLU GRN 30 31 197 PINK WHT 32 198 PINK BLU 33 34 35 342 GRN AMP 776164 1 BLACK ...

Page 117: ...in Wire Color 1 083 GRA ORN 2 199 BRN WHT 3 200 ORN BLK 4 201 BLK 5 202 WHT 6 203 BLU GRA 7 8 204 BLK 9 10 308 RED WHT 11 307 GRN WHT 12 084 GRA ORN 13 207 WHT BLU 14 15 343 GRN 16 208 YEL RED 17 309 BLU 18 073 VIO 19 210 ORN RED 20 310 GRN BLK 21 22 23 212 YEL AMP770680 1 ...

Page 118: ...WHT 7 117 YEL RED 8 9 10 130 WHT BRN 11 133 BLK 12 050 YEL BRN 13 141 ORN 14 046 RED BLK 15 035 GRA YEL 16 143 WHT GRA 17 145 ORN GRA 18 151 YEL VIO 19 155 VIO GRN 20 21 161 RED ORN 22 168 ORN RED 23 170 YEL WHT 24 172 BLU YEL 25 174 VIO WHT 26 27 178 BRN 28 29 184 RED WHT 30 31 215 ORN BLU 32 33 032 BLU BLK 34 033 GRA GRN 35 034 TAN RED AMP 776164 1 BLACK ...

Page 119: ...ontroller Programmer Pin Wire 1 196 BLU GRN 2 249 BLK PINK 3 195 WHT ORN 4 193 VIO WHT X1 Hopper Harness Connector X262 Pin Wire A 264 GRA B 137 BRN RED C 143 WHT GRA D 244 BLK E 151 YEL VIO F 240 BLK G 070 ORN GRN H 248 BLK J 067 VIO K 150 BLK RED L 169 BRN M 238 BLK WHT AMP 5 747905 2 1 9 SIDE TOP MOLEX 39012041 DELPHI 15326915 A M ...

Page 120: ... ORN RED K 235 BLK L 170 YEL WHT M 239 BLK N 071 WHT RED P 233 BLK X17 Brush Motor Right M4 Pin Wire Color A 251 BLK B 152 BLU YEL X18 Brush Motor Center M3 Pin Wire A 109 GRA BLK B 254 BLK X19 Brush Motor Left M2 Pin Wire A 113 WHT ORN B 253 BLK X20 Shaker Motor M14 Pin Wire A 267 VIO B 268 BLK RED DELPHI 15326917 A P DELPHI 12052613 A DELPHI 12015792 A DELPHI 12052613 A DELPHI 12052613 A ...

Page 121: ...N B 078 BLU BRN X23 Vacuum Motor M6 Pin Wire A 017 BLU GRA B 018 BLK X24 Vacuum Motor M7 Pin Wire A 019 BLU GRA B 020 BLK X25 Main Broom Motor M1 Pin Wire A 043 BRN VIO B 044 BLK X26 Left Side Broom Motor M9 Pin Wire A 213 WHT RED B 214 BLK SIDE TOP DELPHI 15300027 A DELPHI 12052613 A DELPHI 12052613 A DELPHI 12052613 A DELPHI 12052613 A DELPHI 12052613 A ...

Page 122: ... BRN WHT B 031 RED VIO C 032 BLU BLK D 033 GRA GRN E 034 TAN RED F X28 Right Side Broom Motor M8 Pin Wire A 295 WHT RED B 297 BLK X97 Steering Actuator M16 Pin Wire 1 299 ORN BLK 2 202 WHT 3 203 BLU GRA 4 208 YEL RED 5 6 298 BLK DELPHI 12124107 A F DELPHI 12052613 A DEUTSCH DTM06 6S 1 6 ...

Page 123: ... 206 BLK 8 211 ORN BLK 9 199 BRN WHT 10 329 GRA ORN 11 12 X99 Wheel Drive Motor M24 Pin Wire 1 194 PINK RED 2 198 PINK BLU 3 197 PINK WHT 4 288 BLK PINK X100 Wheel Drive Motor M24 Pin Wire 1 187 TAN RED 2 289 BLK PINK X102 Generator Harness Connector X107 Pin Wire 228 WELDING RED 3 0 235 WELDING BLK 3 0 DEUTSCH DTM04 12PA 1 12 AMP 282088 1 AMP 282080 1 AMP906 ...

Page 124: ...7 WHT BLU B 277 GRA ORN X109 Side Broom Actuator M13 Pin Wire A 282 GRA VIO B 283 GRN ORN X111 Pump Solution Control M19 Pin Wire A 269 GRA B 093 RED YEL X118 Pump Extended Scrub M25 Pin Wire A 041 GRA B 042 VIO ORN X120 Low Pressure Pump M23 Pin Wire A 266 GRA B 171 GRN WHT DELPHI 12010973 A DELPHI 12010973 A DELPHI 12015792 A DELPHI 12010973 A DELPHI 12010973 A DELPHI 12010973 A ...

Page 125: ... A 286 BRN GRN B 287 RED GRA X126 Hydraulic Pump Hopper Lift M10 Pin Wire A 175 BLU YEL B 177 RED BRN X140 Dust Guard Valve L2 Pin Wire A 086 GRA B 087 BRN RED X145 Drive Pedal Position Sensor R1 Pin Wire A 189 WHT BLK B 190 BRN RED C 191 VIO BLK DELPHI 12010973 A SIDE TOP DELPHI 15300027 A DELPHI 12015792 A DELPHI 12015792 A DELPHI 12162182 A ...

Page 126: ...T5 Pin Wire A 012 TAN BLK B 025 BLK YEL X161 Left Head Lamp LT3 Pin Wire A 236 BRN B 237 BLK WHT X162 Right Head Lamp LT2 Pin Wire A 274 BRN B 276 BLK WHT X165 Curb Lamp Pin Wire A 273 BRN B 275 BLK WHT SIDE TOP DELPHI 12052641 A SIDE TOP DELPHI 12124819 A SIDE TOP DELPHI 12124819 A SIDE TOP DELPHI 12124819 A DELPHI 12015792 A ...

Page 127: ... 264 GRA C 097 GRA D 041 GRA E 255 GRA F X173 Splice Saver Connector Comb Pin Wire A 037 GRA B 269 GRA C 266 GRA D E F 265 GRA X175 Main Harness Connector Pin Wire A 319 PINK B 322 BLU PINK C 323 GRN YEL D 324 GRA E 325 GRA ORN F 326 GRA BLU G 327 WHT ORN H 328 YEL RED J 330 TAN WHT K 334 BRN ORN L 335 ORN M DELPHI 12020832 A SIDE TOP DELPHI 12059573 A SIDE TOP DELPHI 12059573 A DELPHI 15326915 A ...

Page 128: ...09 BLK YEL X181 Broom Motor Current Sensor B2 Pin Wire A 261 BLU YEL B 256 VIO WHT C 215 ORN BLU X182 Vacuum Motor Current Sensor B3 Pin Wire A 262 BLU YEL B 257 VIO WHT C 184 RED WHT X183 Brush Motor Current Sensor B1 Pin Wire A 263 BLU YEL B 258 VIO WHT C 178 BRN DELPHI 12015792 A DELPHI 12162000 A DELPHI 15326808 A DELPHI 15326808 A DELPHI 15326808 A ...

Page 129: ...Interlock Switch S13 Pin Wire A 315 TAN B 338 GRN BLU X190 Solution Solenoid Valve L1 Pin Wire A 157 YEL ORN B 089 VIO X202 Brake Switch S5 Pin Wire A 145 ORN GRA B 231 BLK X204 Hopper Interlock Switch S3 Pin Wire A 046 RED BLK B 230 BLK DELPHI 12162000 A DELPHI 12010973 A DELPHI 12015792 A DELPHI 12010973 A DELPHI 12010973 A ...

Page 130: ... Main Harness Connector X166 Pin Wire A 023 ORN BLU B 013 TAN BLK C 022 BLK YEL D 014 YEL GRN X255 Scrub Deck Retract Limit Switch S1 Pin Wire A 161 RED ORN B 229 BLK X256 Scrub Deck Actuator Motor M11 Pin Wire A 132 RED GRN B 135 YEL GRA X257 Beacon LT10 Pin Wire A 220 VIO B 234 BLK DELPHI 12010973 A DELPHI 12010973 A DELPHI 12020830 A DELPHI 12010973 A DELPHI 12052613 A DELPHI 12015792 A ...

Page 131: ...A D 224 BLK E 225 YEL VIO F 226 BLK G 259 ORN GRN H 260 BLK J 267 VIO K 268 BLK RED L 271 BRN M 272 BLK WHT X263 Main Harness Connector X2 Pin Wire A B 218 ORN YEL C 279 BLK YEL D 281 YEL RED E 282 GRA VIO F 283 GRN ORN G 286 BRN GRN H 287 RED GRA J 290 ORN RED K 291 BLK L 292 YEL WHT M 293 BLK N 294 WHT RED P 296 BLK DELPHI 12015792 A DELPHI 15326910 A M DELPHI 15326922 A P ...

Page 132: ...nnector Pin Wire A 321 PINK B 341 PINK C 318 BLK RED D 317 PINK YEL E F 322 BLU PINK G 323 GRN YEL H J K L M N P R S X266 Engine Harness Connector Pin Wire A B C 324 GRA D E F G H J 325 GRA ORN K 326 GRA BLU L M N P R S SIDE TOP DELPHI 15326868 A S DELPHI15326863 A S ...

Page 133: ...9 BLU GRA D 020 BLK X271 Vacuum Motor Harness X270 Pin Wire A 026 BLU GRA B 027 BLK C 028 BLU GRA D 029 BLK X274 Engine Interface Harness Connector X175 Pin Wire A 123 PINK B 129 BLU PINK C 108 GRA YEL D 102 GRA E 131 GRA ORN F 134 GRA BLU G 118 WHT ORN H 117 YEL RED J 112 TAN WHT K 355 ORN L 222 BRN ORN M DELPHI 12015792 A DELPHI 12015798 A B DELPHI 12015024 A D DELPHI 15326910 A M ...

Page 134: ...Pin Wire A 317 PINK YEL B 318 BLK RED DELPHI 12010973 A Wiring Connections K14 Safety Relay and K15 Auxiliary Relays Early Style K14 Safety Relay 6 GRA ORN 4 PINK A VIO B ORN or ORN GRY Early Style K15 Auxiliary Relay ORN 2 BLK X195 VIO RED TAN GRN GRA WHT BLK WHT ...

Page 135: ...Service Manual CS7000 Late style K14 Safety Relay and K15 Auxiliary Relay GRAY ORN Pink GRAY ORN 2 VIO ORN 2 GRA WHT BLK WHT TAN GRN VIO RED BLK X195 K14 Safety Relay K15 Auxiliary Relay K14 Safety Relay K15 Auxiliary Relay ...

Page 136: ... 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 is not fully charged Loose or corroded cable connections Battery Insufficient machine ope...

Page 137: ...rop rod and then lower to safety lock position 2 Open the side cover and remove the lower panel 3 Remove the retaining pin and swing out the fuel tank 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 7 Slide the battery pack tray outboard to the end of the tether cable Tether Cable Open R...

Page 138: ...l 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 is enough slack to remove the belt Install Bolts Tool Tighten...

Page 139: ...ear Mounting Bolt Front Mounting Bolts 6 Remove generator 7 Reassemble in reverse order Generator Drive Belt Tensioner 1 Remove Drive Belt 2 Retract the tensioner tool bolt to relieve the spring tension 3 Remove the tensioner tool 4 Raise and lock hopper in place 5 Remove lower rubber curtain fasteners to gain access to engine area and move the curtain aside 6 Remove the tensioner mounting bolt fr...

Page 140: ...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 ...

Page 141: ...T Restore Operation at Battery Type 1 1 75v per cell 31 5v total 2 15v per cell 38 7v total Wet 2 1 83v per cell 32 9v total 2 09v per cell 37 6v total Gel 3 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 Resi...

Page 142: ...V J2 9 J2 9 078 BLU BRN Output Squeegee Actuator Motor M12 Reversing Polarity Battery 30 5 38V Engine ON 37 40 5V J2 8 J2 10 132 RED GRN Output Scrub Deck Actuator Motor M11 Reversing Polarity Battery 30 5 38V Engine ON 37 40 5V J2 11 J2 11 135 YEL GRA Output Scrub Deck Actuator Motor M11 Reversing Polarity Battery 30 5 38V Engine ON 37 40 5V J2 10 J2 12 162 BLK Ground Supply Battery Negative Batt...

Page 143: ... J2 32 221 GRA BLU Output Detergent Pump M18 PWM SIGNAL Reversing Polarity 0 12V J2 21 J2 33 J2 34 054 BLK WHT Power Supply VACC6a Power supply from Aux Relay 36 40 5 J2 35 053 BLK WHT Power Supply VACC6b Power supply from Aux Relay 36 40 5 J3 1 042 VIO ORN Output Extended Scrub Pump M25 PWM ground 0 36V J3 2 093 RED YEL Output Solution Control Pump M19 PWM ground 0 36V J3 3 030 BRN WHT Output Mai...

Page 144: ...upply from starting battery 12V B Ground J3 24 171 GRN WHT Output Low Pressure Pump M23 Grounds to energize Also requires internal pressure switch in pump 0V B Ground J3 25 J3 26 058 GRA Power Supply VACC2 Power supply from Aux Contactor 36V B Ground J3 27 076 GRN BRN Output Backup Alarm H1 Grounds to energize 0V B Ground J3 28 J3 29 166 BLK Ground Supply Battery Negative J3 30 J3 31 J3 32 049 ORN...

Page 145: ...14 Logic Input 0 or 36V B Ground J7 20 J7 21 161 RED ORN Input Scrub Deck Retract Limit Switch S1 Logic Input 0 or 5V B Ground J7 22 168 ORN RED Input Hopper Dump Door Extend Limit Switch S7 Logic Input 0 or 5V B Ground J7 23 170 YEL WHT Input Hopper Dump Door Retract Limit Switch S8 Logic Input 0 or 5V B Ground J7 24 172 BLU YEL Output 5V 5v Power out to Current Sensors 5V B Ground J7 25 174 VIO ...

Page 146: ...ontacts on sheet 4 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 On Sheet 1 On Sheet 2 On Sheet 1 On Sheet 5 The wiring diagrams show when a circuit passes through an in line connector and identifies the two halves of the conne...

Page 147: ...Electrical System 147 Service Manual CS7000 56509170 Rev L Sheet 1 of 9 ...

Page 148: ...Electrical System 148 Service Manual CS7000 56509170 Rev L Sheet 2 of 9 ...

Page 149: ...Electrical System 149 Service Manual CS7000 56509170 Rev L Sheet 3 of 9 ...

Page 150: ...Electrical System 150 Service Manual CS7000 56509170 Rev L Sheet 4 of 9 ...

Page 151: ...Service Manual CS7000 151 Electrical System 56509170 Rev L Sheet 5 of 9 ...

Page 152: ...Service Manual CS7000 152 Electrical System 56509170 Rev L Sheet 6 of 9 SN 1000048160 and later Kubota Gas and LPG before LEV E4 ...

Page 153: ...Service Manual CS7000 153 Electrical System 56509170 Rev L Sheet 7 of 9 Kubota LEV E4 only See LEV Engine Side Wiring 56511576_REV_A_LEV_ENG sheet 1 of 1 ...

Page 154: ...Service Manual CS7000 154 Electrical System 56509170 Rev L Sheet 8 of 9 Before SN 1000048160 Kubota LPG before LEV E4 ...

Page 155: ...Electrical System 155 Service Manual CS7000 56509170 Rev L Sheet 9 of 9 ...

Page 156: ...Service Manual CS7000 156 Electrical System LEV Engine Side Wiring 56511576_REV_A_LEV_ENG sheet 1 of 1 See 56509170 Rev L Sheet 7 of 9 for mating ECU Interface Connector ...

Page 157: ... regulator The fuel pressure vaporizer regulator takes in high pressure propane liquid changes it to a vapor and reduces it to a constant low pressure gas for the engine to draw in and burn The change from liquid to gas absorbs a lot of heat and acts as an air conditioner To prevent frosting up the regulator it is heated with engine coolant The vaporizer regulator supplies gaseous fuel to the carb...

Page 158: ... exhaust stroke waste spark The crank sensor is a two wire AC pulse generator It has a wire coil inside of it As the toothed ring rotates the teeth pass in line with the end of the sensor tip This induces a voltage spike that the spark control module can read as cylinder position information The number of spikes per minute is translated as engine RPM One tooth on the ring is wider than the other f...

Page 159: ... control unit The spark control unit supplies a switched ground for each of the ignition coil primary windings When it supplies a ground current flows through the coil primary winding and builds up a magnetic field around the coil When the ground is released the current stops flowing abruptly and the magnetic field collapses The collapsing magnetic field induces a high voltage in the ignition coil...

Page 160: ...tor J3 pin 23 from the engine starter battery It uses this voltage supply to send 12 volts out of connector J3 pin 10 to the crank request relay coil The other side of the relay coil is grounded through the Woodward L series actuator With power and ground across the relay winding the relay energizes and fused battery power from terminal 30 is sent to the starter solenoid 15A 12v BATTERY STARTER CR...

Page 161: ...s no power to the ignition system or carburetor fuel shut off solenoid IGN REQUEST MAIN CONTROLLER FUEL LOCK OFF SOLENOID OIL SWITCH OPEN FOR PRESSURE TEMP SWITCH OPEN FOR NORMAL TEMP RUN ENABLE SIGNAL SHUTDOWN Control CRANK REQUEST IGNITION REQUEST ENGINE RUN 12V INPUT HIGH COOLANT TEMP Signal SPEED 2 12V OUTPUT SPEED 3 12V OUTPUT Eng RPM Sensor STARTER 12v BATTERY ALTERNATOR IGNITION POWER FOR I...

Page 162: ...ng the Low oil pressure shutdown relay to be energized This prevents power from being passed to the engine run input into the main machine controller The high coolant temp shutdown relay coil is also grounded through the closed oil pressure switch causing it to be energized This prevents power from being passed to the fuel lock off solenoid 2 1 3 5 4 IGN REQUEST MAIN CONTROLLER FUEL LOCK OFF SOLEN...

Page 163: ...ow oil pressure shutdown relay to de energize Battery power is then passed through the closed at rest contacts to the main machine controller as the engine run signal and to the Woodward L series actuator From this point on the run enable signal to the actuator is maintained by the low oil pressure shutdown relay The same power is also passed to the power relay coil energizing the relay Battery po...

Page 164: ... but failed to control the RPM Therefore it remains in a cranking mode and does not shut the engine down The main machine controller communicates the desired engine speed mode to the actuator via the Throttle 1 and Throttle 2 wires It either sends out 0v or 12v on each wire depending on the desired speed mode Speed Mode Engine Speed Throttle 1 Throttle 2 Idle 1700 RPM 0 0 Run 2500 RPM 0 12v Maximu...

Page 165: ...lant temp shut down relay No more fuel will flow into the vaporizer regulator but the engine continues to run on the fuel that is trapped in the regulator You may recall that when the key was first turned on that the ignition request voltage energized the ignition request relay and provided power for the ignition system If this is true how can the engine stay running after the ignition request vol...

Page 166: ...EMP SWITCH OPEN FOR NORMAL TEMP RUN ENABLE SIGNAL SHUTDOWN Control CRANK REQUEST IGNITION REQUEST ENGINE RUN 12V INPUT HIGH COOLANT TEMP Signal SPEED 2 12V OUTPUT SPEED 3 12V OUTPUT Eng RPM Sensor STARTER 12v BATTERY ALTERNATOR IGNITION POWER FOR IGNITER HIGH COOLANT TEMP SHUTDOWN RELAY 1 5 4 3 2 CONTROL RELAY 1 5 4 3 2 IGNITION REQUEST RELAY POWER RELAY 1 5 4 3 2 LOW OIL PRESS SHUTDOWN RELAY 1 5 ...

Page 167: ...n overheat code and alerts the operator After a 5 second delay it removes the 12v Ignition request signal If the engine has not already shut down the system will then shut down as if the operator had shut off the key Normal engine shut off 2 1 3 5 4 IGN REQUEST MAIN CONTROLLER FUEL LOCK OFF SOLENOID OIL SWITCH OPEN FOR PRESSURE TEMP SWITCH OPEN FOR NORMAL TEMP RUN ENABLE SIGNAL SHUTDOWN Control CR...

Page 168: ...achine controller The loss of the engine run signal is interpreted as loss of oil pressure by the main machine controller It responds by immediately displaying an engine warning message to the operator and removing the 12v power going out to the ignition request circuit If the engine has not already shut down the system will then shut down as if the operator had shut off the key Normal engine shut...

Page 169: ...e relay box NIKKI Fuel Vaporizer Regulator Actuator Carburetor mixer Engine RPM sensor Crank position sensor Carburetor fuel shut off solenoid Engine Back Side View Toward right of machine Spark Controller Fuel lock off solenoid 42 V Alternator Ignition coils Engine Left Side View Toward back of machine 12 V alternator Engine starter Oil pressure switch Coolant temperature switch Fuel Tank Area Fu...

Page 170: ...170 Service Manual CS7000 NIKKI Fuel Vaporizer Regulator Actuator Carburetor mixer Engine relay box Engine RPM sensor Carburetor fuel shut off solenoid Crank position sensor Engine Right Side View Toward front of machine ...

Page 171: ...000 Spark Controller Ignition coils Fuel lock off solenoid 42v Alternator Engine Back Side View Toward right of machine Engine Left Side View Toward back of machine Coolant temperature switch 12v alternator Oil pressure switch Engine starter ...

Page 172: ...Engine System LPG 172 Service Manual CS7000 Low LP Pressure Switch Fuel Tank Pressure relief valve Fuel Tank Area ...

Page 173: ...ck LPG tank setting condition Check LPG fuel connector First 50 hours Change engine oil Replace engine oil filter Every 50 hours Clean air cleaner element Check LPG fuel hose and clamp bands LPG fuel check Every 100 hours Clean spark plug Check fuel filter Check fan belt tension and damage Every 200 hours Change engine oil Replace engine oil filter Check LPG tank setting condition Check radiator h...

Page 174: ...n the recovery tank for later removal 2 Shut off the engine and allow it to cool sufficiently to avoid burning yourself with hot engine oil 3 Remove the left side engine cover 4 Tip the recovery tank outward Release the recovery tank tether cable and recover hose then lower the recovery tank to the ground for better access to the engine oil filter area 5 Remove the oil filter with an oil filter wr...

Page 175: ...ow If the red disc is visible in the window the filters should be cleaned or replaced Replace Air Filters 1 Release the latches and remove the air filter housing cover 2 Remove the outer filter element 3 Blow out air cleaner housing with compressed air with inner filter element still in place to prevent dirt from entering the engine air intake 4 Remove the inner filter element 5 Clean residual dus...

Page 176: ...ine 3 Crank the engine over and check for consistent arcing across the tester gap Checking LPG Primary Pressure 1 Turn off the propane tank valve with the engine running and allow the engine to run out of fuel 2 Turn key switch off 3 Remove the primary chamber test port plug located on top of the vaporizer regulator 4 Install thread adapter part number 50360A into the test port 5 Install fitting f...

Page 177: ...pipe thread sealant E G Loctite 30534 No crank The starter does not engage Possible causes 36v battery pack drained preventing main machine controller from powering up Engine Battery Starter Battery to starter cable Engine Ground No voltage to the starter solenoid Open circuit breaker CB9 Auxiliary Relay Burned contacts or not energized Key Switch Main Machine Controller Woodward L Series Actuator...

Page 178: ...y that all 3 coils would fail at once Cranks but does not start has sufficient spark Possible causes No fuel Empty Tank Fuel lock off solenoid stuck closed Fuel lock off solenoid not energized Ignition request fuse blown High coolant temp shut down relay Closed at rest contacts not making connection Engine oil pressure switch not opening for pressure Engine Insufficient oil pressure to open switch...

Page 179: ...tor throttle lever Is the linkage okay If not repair If so go to next step 2 Check the power and ground supplies to the actuator Is there sufficient power and ground If so go on to check the Engine RPM Sensor input If not repair 3 Check the Engine RPM Sensor input Check the AC voltage while the engine is running or check resistance of sensor through wiring harness from the actuator connector Is th...

Page 180: ...e frame 5 Remove engine Top cover 6 Disconnect the 36v battery pack main positive and negative cables 7 Disconnect the 12v battery negative cable 8 Disconnect the 12v battery positive cable 9 Disconnect fuel supply and return lines 10 Disconnect battery positive and negative cables at the starter 11 Disconnect the engine wiring connectors 12 Remove the 4 motor mount fasteners Note photos are of di...

Page 181: ...30 0 C to 25 C 32 F to 77 F SAE20 or SAE10W 30 Below 0 C 32 F SAE10W or SAE10W 30 Engine Coolant Use only ethylene glycol or propylene glycol type anti freeze for this engine Always assure a 50 50 anti freeze and water mixture regardless of temperature Shop Measurements The following information provides some real world shop measurements to help you recognize what normal looks like Ignition System...

Page 182: ...Series Actuator Measurements Pin Wire Color Circuit Description Connector Unplugged Key On Connector Plugged In Key On 1 PNK BLK Ignition Request 11 69v 11 4v 2 Not used 3 BLK Engine RPM Sensor 4 GRA BLU Throttle 1 7 79v 0 007v 5 BLK Ground 0 007v 0 007v 6 GRA ORN Throttle 2 7 78v 0 007v 7 Not used 8 GRA WHT Run Enable Signal 11 9v 11 0v 9 BLK WHT Shut Down Signal 11 6v 0 028v 10 Not Used 11 CLR E...

Page 183: ... solenoid resistance 27 3 ohms Fuel Lock Off Solenoid resistance 10 1 ohms Primary Pressure 4 6 PSI Engine Engine Vacuum at idle approx 14 5 15 HG When returning from low RPM to idle vacuum momentarily peaks around 21 HG Engine Compression Cyl 1 170 PSI Cyl 2 170 PSI Cyl 3 170 PSI ...

Page 184: ...PG test gauge kit Part 56504450 LPG test port adapter Male 1 8 BSPT to Female 1 8 NPT Part 50360A Adjustable KV Spark Tester Most automotive parts suppliers sell these tools Shown is 50850 from Lisle corporation http www lislecorp com 1 8 BPST 1 8 NPT KV Scale ...

Page 185: ...anagement system Functional Description The WG972 E4 engine is a three cylinder liquid cooled naturally aspirated engine An Engine Control Unit ECU is mounted to the side of the engine block The ECU manages the engine speed the ignition system and the fuel system The ECU and main machine controller convey several pieces of information through dedicated wires such as requested engine speed and whet...

Page 186: ...controller sends a 12 volt output to the starter relay winding The other side of the winding connects to the ECU The ECU must connect the circuit to battery negative to energize the starter relay If the engine is already running the ECU will prevent the starter relay from operating Battery Ground Crank 36v Battery 12v Battery Main Machine Controller Engine Control Unit Key Switch Crank Position 36...

Page 187: ...bbing and sweeping The force idle neutral time out will return the engine to idle speed If the override is run speed the user can change between maximum power speed and run speed If the override condition goes away e g sweep system turns off and the user has not changed the engine mode the engine is returned to the mode before the forced override Normal Engine Shut Off Shutting off the key switch ...

Page 188: ... Pressure TMAP sensor Electronic Throttle Body ETB Vaporizer Engine Control Unit ECU Crankshaft Position Sensor CKP Engine Coolant Temperature ECT Camshaft Position Sensor CMP Engine relay box Ignition Coils 3 Vaporizer ETB ECU TMAP sensor CKP LP Mixer ECT LP Mixer CMP 12V Alternator Engine Relay Box 42V Alternator ...

Page 189: ...Engine System LPG LEV 189 Service Manual CS7000 Fuel Tank Area Fuel tank Pressure relief valve Low LPG pressure switch Low LP Pressure Switch Fuel Tank Pressure relief valve Fuel Tank Area ...

Page 190: ... an oil filter wrench 6 Apply a light coat of engine oil to the new filter cartridge gasket 7 Screw the new cartridge on and tighten by hand Over tightening may damage the gasket 8 Remove the remote oil drain hose end from the radiator bracket 9 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...

Page 191: ...t 3 Blow out air cleaner housing with compressed air with inner filter element still in place to prevent dirt from entering the engine air intake 4 Remove the inner filter element 5 Clean residual dust from the inside of the air cleaner housing taking care to prevent any dirt or debris from entering the air intake 6 Install a new inner filter element and then the new outer filter element making su...

Page 192: ...called the Kubota Gasoline Service Tool KGST Although it mentions gasoline petrol in the name it is also for use with the propane fueled engine The KGST is essential for troubleshooting engine management system issues The KGST software and Kubota KGST User Guide are available through EZparts You will need Laptop with USB port KGST Software Found in EZParts ECOM Cable for connecting the laptop to t...

Page 193: ...the primary chamber test port plug located on top of the vaporizer regulator and install the test fitting 6 Install fitting from LPG pressure test kit into the thread adapter 7 Using the LPG test gauge kit Part 56504450 hook up the blue pressure gauge hose to the fitting 8 Open propane tank valve 9 Start engine Specification 4 3 PSI 32 7kPA 10 When finished reinstall the test port plug using a sui...

Page 194: ...negative cable 4 Disconnect the 12v battery positive cable 5 Disconnect fuel supply and return lines 6 Disconnect battery positive and negative cables at the starter 7 Disconnect the engine wiring connectors 8 Remove the 4 motor mount fasteners Note photos are of diesel engine 9 Lift the assembly out of the chassis using a suitable hoist attached to the two engine lift points 10 Reassemble in reve...

Page 195: ...AE30 or SAE10W 30 0 C to 25 C 32 F to 77 F SAE20 or SAE10W 30 Below 0 C 32 F SAE10W or SAE10W 30 Engine Coolant Use only ethylene glycol or propylene glycol type anti freeze for this engine Always assure a 50 50 anti freeze and water mixture regardless of temperature Shop Measurements The following information provides some real world shop measurements to help you recognize what normal looks like ...

Page 196: ...e 13 ohms Primary Pressure 3 4 PSI Engine coolant temperature sensor 0 875v at 142 Deg F Engine Engine Vacuum at idle 1700 RPM approx 16 5 17 HG When returning from Run 2500 RPM to idle 1700 RPM vacuum momentarily peaks around 22 HG Engine Compression Cyl 1 190 PSI Cyl 2 185 PSI Cyl 3 175 PSI ...

Page 197: ...h the WGG972GL E4 LEV engine LayVijZuWSOp Diagnostic Cable Adapter Part 56511575 Used to connect ECOM cable to Kubota LEV diagnostic connector ECOM Cable Diagnostic Communication Cable and software p n 56305647 Note The Ecom cable is used but the software on the CD is for the GM engines LPG test gauge kit Part 56504450 ...

Page 198: ...Engine System LPG LEV 198 Service Manual CS7000 Adjustable KV Spark Tester Most automotive parts suppliers sell these tools Shown is 50850 from Lisle corporation http www lislecorp com KV Scale ...

Page 199: ...the right side of the engine compartment The tank swings out to provide easier access to the engine compartment An electric fuel pump is mounted to the top of the tank The tank contains a fuel level sending unit The carburetor has an additional fuel shut off solenoid that must be energized for petrol to flow through the carburetor to the engine The engine RPM is controlled with a Woodward L Series...

Page 200: ...nd once in exhaust stroke waste spark The crank sensor is a two wire AC pulse generator It has a wire coil inside of it As the toothed ring rotates the teeth pass in line with the end of the sensor tip This induces a voltage spike that the spark control module can read as cylinder position information The number of spikes per minute is translated as engine RPM One tooth on the ring is wider than t...

Page 201: ... the spark control unit The spark control unit supplies a switched ground for each of the ignition coil primary windings When it supplies a ground current flows through the coil primary winding and builds up a magnetic field around the coil When the ground is released the current stops flowing abruptly and the magnetic field collapses The collapsing magnetic field induces a high voltage in the ign...

Page 202: ...ter battery It uses this voltage supply to send 12 volts out of connector J3 pin 10 to the crank request relay coil The other side of the relay coil is grounded through the Woodward L series actuator With power and ground across the relay winding the relay energizes and fused battery power from terminal 30 is sent to the starter solenoid An electrically operated solenoid pulls the carburetor choke...

Page 203: ...ING INTO KUBOTA IGNITION HARNESS KUBOTA FUEL SOLENOID EG551 44790 SPEED 2 12V OUTPUT GRY BLU 16 SPEED 3 12V OUTPUT GRY ORG 16 SHIELDED WIRE WOODWARD AUTO CHOKE SOLENOID SA 4741 BLU LT GRN 16 HIGH COOLANT TEMP SHUTDOWN RELAY 1 5 4 3 2 BLK 16 CONTROL RELAY 1 5 4 3 2 BLK 16 IGNITION REQUEST RELAY 1 5 4 3 2 RED 18 POWER RELAY 1 5 4 3 2 RED 14 LOW OIL PRESS SHUTDOWN RELAY 1 5 4 3 2 AEES RN65127 FUSE RE...

Page 204: ...REQUEST BLU PNK 16 IGNITION REQUEST PNK 16 ENGINE RUN 12V INPUT GRY 16 HIGH COOLANT TEMP GROUND INPUT GRN YEL 16 SPEED 2 12V OUTPUT RED 16 SPEED 3 12V OUTPUT BLACK 16 MAGNETIC PICK UP Engine RPM Sensor STARTER BATTERY ALTERNATOR IGNITION POWER FOR IGNITER IGNITION CONNECTOR FOR PLUGGING INTO KUBOTA IGNITION HARNESS KUBOTA FUEL SOLENOID EG551 44790 SPEED 2 12V OUTPUT GRY BLU 16 SPEED 3 12V OUTPUT G...

Page 205: ...N3 0342 OR FUEL PUMP OIL SWITCH OPENFOR PRESSURE TEMP SWITCH OPENFOR NORMAL TEMP SHIELDED WIRE RUN ENABLE SIGNAL SHUTDOWNSIGNAL CRANK REQUEST BLU PNK 16 IGNITION REQUEST PNK 16 ENGINE RUN 12V INPUT GRY 16 HIGH COOLANT TEMP GROUND INPUT GRN YEL 16 SPEED 2 12V OUTPUT RED 16 SPEED 3 12V OUTPUT BLACK 16 MAGNETIC PICK UP Engine RPM Sensor STARTER BATTERY ALTERNATOR IGNITION POWER FOR IGNITER IGNITIONCO...

Page 206: ... PUMP OIL SWITCH OPENFOR PRESSURE TEMP SWITCH OPENFOR NORMAL TEMP SHIELDED WIRE RUN ENABLE SIGNAL SHUTDOWNSIGNAL CRANK REQUEST BLU PNK 16 IGNITION REQUEST PNK 16 ENGINE RUN 12V INPUT GRY 16 HIGH COOLANT TEMP GROUND INPUT GRN YEL 16 SPEED 2 12V OUTPUT RED 16 SPEED 3 12V OUTPUT BLACK 16 MAGNETIC PICK UP Engine RPM Sensor STARTER BATTERY ALTERNATOR IGNITION POWER FOR IGNITER IGNITIONCONNECTOR FOR PLU...

Page 207: ...losed at rest contacts turning off the power relay and control relay 10A IGN REQUEST 15A MAIN 5A CONTROLLER UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED WOODWARD FUEL LOCK OFF SOLENOID N3 0342 OR FUEL PUMP OIL SWITCH OPENFOR PRESSURE TEMP SWITCH OPENFOR NORMAL TEMP SHIELDED WIRE RUN ENABLE SIGNAL SHUTDOWNSIGNAL CRANK REQUEST BLU PNK 16 IGNITION REQUEST PNK 16 ENGINE RUN 12V INPUT GRY 16 HIGH COOLANT ...

Page 208: ...MAIN 5A CONTROLLER UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED WOODWARD FUEL LOCK OFF SOLENOID N3 0342 OR FUEL PUMP OIL SWITCH OPEN FOR PRESSURE TEMP SWITCH OPEN FOR NORMAL TEMP SHIELDED WIRE RUN ENABLE SIGNAL SHUTDOWN SIGNAL CRANK REQUEST BLU PNK 16 IGNITION REQUEST PNK 16 ENGINE RUN 12V INPUT GRY 16 HIGH COOLANT TEMP GROUND INPUT GRN YEL 16 SPEED 2 12V OUTPUT RED 16 SPEED 3 12V OUTPUT BLACK 16 MAG...

Page 209: ...IN 5A CONTROLLER UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED WOODWARD FUEL LOCK OFF SOLENOID N3 0342 OR FUEL PUMP OIL SWITCH OPENFOR PRESSURE TEMP SWITCH OPENFOR NORMAL TEMP SHIELDED WIRE RUN ENABLE SIGNAL SHUTDOWNSIGNAL CRANK REQUEST BLU PNK 16 IGNITION REQUEST PNK 16 ENGINE RUN 12V INPUT GRY 16 HIGH COOLANT TEMP GROUND INPUT GRN YEL 16 SPEED 2 12V OUTPUT RED 16 SPEED 3 12V OUTPUT BLACK 16 MAGNETIC...

Page 210: ...aptor II Component Locations Engine components are grouped according to the area of the engine They are photographed on an engine that is not installed in the machine for better visibility Engine Right Engine Left Engine Front Engine Back LPG Engine Pictured ...

Page 211: ...t of machine Actuator Choke Solenoid Carburetor mixer Engine RPM sensor Crank position sensor Petrol fuel shut off solenoid Fuel Select Connector Actuator Choke Solenoid Carburetor mixer Engine RPM sensor LPG shut off solenoid Crank position sensor Petrol fuel shut off solenoid Fuel Select Connector ...

Page 212: ... machine Spark Controller 42 V Alternator Ignition coils Engine Left Side View Toward back of machine 12 V alternator Engine starter Oil pressure switch Coolant temperature switch Spark Controller 42v Alternator Ignition coils 12v alternator Oil pressure switch Engine starter Coolant temperature switch ...

Page 213: ...ne System Petrol Gasoline 213 Service Manual Haram Captor II Fuel Tank Area Fuel tank Fuel Pump Fuel Filter Fuel Sending Unit Vapor Canister Fuel Tank Fuel Sending Unit Fuel Pump Fuel Filter Vapor Canister ...

Page 214: ... hours Change engine oil Replace engine oil filter Every 50 hours Clean air cleaner element Check fuel hoses and clamps Every 100 hours Clean spark plug Check fuel filter Check fan belt tension and damage Every 200 hours Change engine oil Replace engine oil filter Check radiator hoses and clamp bands Every 1 year Replace air cleaner element Replace gasoline fuel hose clamp bands and fuel filter Cl...

Page 215: ...ove the oil filter with an oil filter wrench 6 Apply a light coat of engine oil to the new filter cartridge gasket 7 Screw the new cartridge on and tighten by hand Over tightening may damage the gasket 8 Remove the remote oil drain hose end from the radiator bracket 9 Remove the plug and drain the oil into a suitable container 10 Reinstall the plug and reattach the drain hose to the radiator brack...

Page 216: ...r element 3 Blow out air cleaner housing with compressed air with inner filter element still in place to prevent dirt from entering the engine air intake 4 Remove the inner filter element 5 Clean residual dust from the inside of the air cleaner housing taking care to prevent any dirt or debris from entering the air intake 6 Install a new inner filter element and then the new outer filter element m...

Page 217: ... the engine over and check for consistent arcing across the tester gap No crank The starter does not engage Possible causes 36v battery pack drained preventing main machine controller from powering up Engine Battery Starter Battery to starter cable Engine Ground No voltage to the starter solenoid Open circuit breaker CB9 Auxiliary Relay Burned contacts or not energized Key Switch Main Machine Cont...

Page 218: ...g Ignition Coils not likely that all 3 coils would fail at once Cranks but does not start has sufficient spark Possible causes No fuel Empty tank Fuel pump inoperative No electrical power to fuel pump Ignition request fuse blown High coolant temp shut down relay Closed at rest contacts not making connection Open wire on positive or negative side of fuel pump No power to carburetor petrol fuel shut...

Page 219: ...the carburetor throttle lever Is the linkage okay If not repair If so go to next step 2 Check the power and ground supplies to the actuator Is there sufficient power and ground If so go on to check the Engine RPM Sensor input If not repair 3 Check the Engine RPM Sensor input Check the AC voltage while the engine is running or check resistance of sensor through wiring harness from the actuator conn...

Page 220: ... holes in the frame 1 Remove engine Top cover 2 Disconnect the 36v battery pack main positive and negative cables 3 Disconnect the 12v battery negative cable 4 Disconnect the 12v battery positive cable 5 Disconnect fuel supply and return lines 6 Disconnect battery positive and negative cables at the starter 7 Disconnect the engine wiring connectors 8 Remove the 4 motor mount fasteners Note photos ...

Page 221: ...SAE10W 30 Below 0 C 32 F SAE10W or SAE10W 30 Engine Coolant Use only ethylene glycol or propylene glycol type anti freeze for this engine Always assure a 50 50 anti freeze and water mixture regardless of temperature Shop Measurements The following information provides some real world shop measurements to help you recognize what normal looks like Ignition System Ignition coil primary resistance 2 1...

Page 222: ...oodward L Series Actuator Measurements Pin Wire Color Circuit Description Connector Unplugged Key On Connector Plugged In Key On 1 PNK BLK Ignition Request 11 69v 11 4v 2 Not used 3 BLK Engine RPM Sensor 4 GRA BLU Throttle 1 7 79v 0 007v 5 BLK Ground 0 007v 0 007v 6 GRA ORN Throttle 2 7 78v 0 007v 7 Not used 8 GRA WHT Run Enable Signal 11 9v 11 0v 9 BLK WHT Shut Down Signal 11 6v 0 028v 10 Not Use...

Page 223: ...l volume 0 5L in 15 seconds Carburetor Fuel Shut off Solenoid resistance 38 ohms Electric Choke Solenoid resistance 2 5 ohms Engine Engine Vacuum at idle approx 17 5 inches HG 59 Kpa When returning from low RPM to idle vacuum momentarily peaks around 21 HG Engine Compression Cyl 1 170 PSI Cyl 2 170 PSI Cyl 3 170 PSI ...

Page 224: ...em Petrol Gasoline 224 Service Manual Haram Captor II Special Tools Adjustable KV Spark Tester Most automotive parts suppliers sell these tools Shown is 50850 from Lisle corporation http www lislecorp com KV Scale ...

Page 225: ...s 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 Go...

Page 226: ...lied 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 is connected to ground If oil pressure is lost the oil pressure switch will open remov...

Page 227: ...oil pressure is lost When the engine is running the main machine controller sends a 12 volt power supply out on connector J3 pin number 9 to power up the governor controller When the main machine controller wants to shut down the engine it removes this power supply to the governor controller When the governor loses the power supply it causes the engine to shut down ...

Page 228: ... engine overheats the switch closes The closing of the switch connects the voltage source to ground which drops the voltage seen by the main machine controller to nearly 0 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 t...

Page 229: ...the main machine controller connector J7 pin number 4 Once the main machine controller has seen that the engine is 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 0v In response the main machine controller sets an oil pressure fault displays it on the control panel and immed...

Page 230: ...ult the actuator shuts off the fuel and prevents the engine from running when there is 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 is responsible for telling the governor controller the desired RPM based on the operator s request or machine operation mode It communi...

Page 231: ...ault 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 Note If any fault in the APECS governor control system causes the engine to stall the Engine Warning message will be displa...

Page 232: ... 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 it gets hot Whenever the key is turned on the main machine controller tells the control panel to display the glow plugs on icon an...

Page 233: ...een engine and hopper Injector pump APECS Governor Controller Front engine area mounted on engine Glow plugs Glow plug relay Electrical panel area Engine starter Alternator 42v Engine alternator 12v Oil pressure switch Coolant temperature switch Actuator Engine RPM sensor Air Cleaner Top of engine compartment with top covers removed Air Cleaner Fuel Tank Shown with hopper up Fuel Tank Shown swung ...

Page 234: ...Engine System Diesel 234 Service Manual CS7000 Fuel Filter Injector Pump Alternator 42v APECS Governor Controller Actuator Engine RPM Sensor Front Engine Area Hopper up and rubber curtain lifted ...

Page 235: ...Engine System Diesel 235 Service Manual CS7000 Electrical Panel Glow Plug Relay Glow Plugs Alternator 12v Coolant Temperature Switch Oil Pressure Switch Starter Engine Back Side ...

Page 236: ...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...

Page 237: ... 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 cap 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 ...

Page 238: ...ld cause fuel to spill onto a hot exhaust manifold creating a danger of fire 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 in the window the filt...

Page 239: ...e 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 is indicated on the cover 11 Set the top eng...

Page 240: ...id Auxiliary Relay Key Switch Main Machine controller Check for tripped circuit breaker 9 CB9 Check for power to the main machine controller from the Auxiliary Relay Check for power to the main machine controller from Key Switch cranking circuit Check powers grounds inputs and crank request output Cranks but does not start Possible causes No fuel Empty Tank Insufficient fuel supply Clogged Filter ...

Page 241: ...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 b Substitute the function of the actuator by removing it from the injection pump and operating the throttle control manually You can reach into the ho...

Page 242: ...ugh 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 on 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...

Page 243: ...om shorting to ground 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 in 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 ...

Page 244: ...et but be very careful not to allow anything to get sucked in during the test 9 Crank the engine over until the compression gauge stops climbing Record the reading Specification is 541 to 597 psi 3 73 to 4 11 MPa with an allowable limit of 327 psi 2 26 MPa Difference among Cylinders 10 or less 10 Repeat for the other cylinders 11 Reassemble in reverse order Disconnect ...

Page 245: ...threaded holes in the frame 1 Remove engine Top cover 2 Disconnect the 36v battery pack main positive and negative cables 3 Disconnect the 12v battery negative cable 4 Disconnect the 12v battery positive cable 5 Disconnect fuel supply and return lines 6 Disconnect battery positive and negative cables at the starter 7 Disconnect the engine wiring connectors 8 Remove the 4 motor mount fasteners Fron...

Page 246: ...ternal EGR external EGR or non EGR and the Fuel Type Used Low Sulfur Ultra Low Sulfur or High Sulfur Fuels Fuel Type Engine oil classification API classification Engines with non EGR Engines with internal EGR Engines with external EGR High Sulfur Fuel 0 05 500 ppm Sulfur Content 0 50 5000 ppm CF If the CF 4 CG 4 CH 4 or CI 4 engine oil is used with a high sulfur fuel change the engine oil at short...

Page 247: ...ion engine oil with a high Total Base Number a minimum TBN of 10 is recommended Engine Oil Viscosity Temperature Viscosity Above 25 C 77 F SAE 30 or SAE 10W 30 SAE 10W 40 0 C to 25 C 32 F to 77 F SAE 20 or SAE 10W 30 SAE 10W 40 Below 0 C 32 F SAE 10W or SAE 10W 30 SAE 10W 40 Cooling System Engine Coolant A 50 50 mix of distilled water and ethylene glycol is recommended Radiator Cap 13 PSI Shop Mea...

Page 248: ...ervice Manual CS7000 Engine Compression 1 410 psi 2 420 psi 3 400 Fuel System Return Fuel Flow 4 0 oz 120 ml with the return line removed engine off and fuel pump running Starter 168 Amps cranking Glow Plug Relay Winding 46 Ohms ...

Page 249: ...n is a Snap On EEPD500 Gauge kit Compression Gauge Fitting for Glow Plug threads Shown is Snap On TU 15 35 Threads M8 X 1 0 Gauge Coupler If using the Snap On diesel compression EEPD500 Gauge kit and Snap On TU 15 35 glow plug thread fitting a coupler must be used to join the fitting to the gauge hose Shown are Snap On couplers M3569 and M3570 ...

Page 250: ...tor The hopper dump door driven by an electric actuator can be opened by pressing the hopper door open button when the hopper is up to empty the hopper Proximity sensors limit the hopper dump door actuator travel by signaling to the main machine controller that the end of travel has been reached The controller then turns off the actuator motor Note that the hopper door opens automatically to recei...

Page 251: ...nition Switch 1 3 B1 B 3 2 J7 19 Start Input 42V Alternator J2 14 Output J7 12 Supression Diode VIO GRN K9 Aux Contactor YEL BRN BLK ORN ORN ORN YEL BRN G J7 13 Key Switch Input J7 1 Interlock Input ORN GRA ORN ORN Safety Switch Relay signal from A5 Steer by Wire Controller 6 2 1 2 2 1 1 4 PINK TAN GRN BLU K14 Seat Switch S9 Emergency Stop Switch S15 Fe S13 Battery Interlock RED FROM F1 A3 Control...

Page 252: ... pressure voltage across the pump no current flows and the pump remains Off Hopper Being Raised When the operator pushes the button to raise the hopper the main machine controller energizes the K11 contactor by grounding the control winding of the contactor This causes a magnetic field to pull the normally closed contacts open and at the same time closes the normally open contacts Battery voltage ...

Page 253: ...osed battery machines or jumpered Diesel and LPG machines The 400 amp Fuse F1 must be closed to provide positive voltage from the Battery to the load side of Hydraulic Pump Motor Contactor K12 The Ignition Switch S14 must be closed to provide positive voltage to the Auxiliary Contactor K9 coil The J2 14 Output on the A1 Main Machine Controller provides ground to the Auxiliary Contactor K9 coil whe...

Page 254: ...troller receives a signal from the A3 Control Panel via the CAN BUS that the operator has pressed the hopper door open or hopper door close button For the hopper door to open the A1 Main Machine Controller must not receive negative voltage at the J7 22 Input from the Dump Door Extend Limit Switch S7 For the hopper door to close the A1 Main Machine Controller must not receive negative voltage at th...

Page 255: ...raulic Power Pack Assembly is mounted on the front of the machine frame and can be accessed when the hopper is up The Hydraulic Power Pack Assembly extends and retracts the Hopper Lift Cylinder which raises and lowers the hopper Hopper Lift Cylinder Hydraulic Power Pack Assembly ...

Page 256: ... away from a dumpster and the Hopper Dump Door catches on or contacts the dumpster Caution The Spring is pre compressed about an inch so use caution if you ever need to disassemble the Spring from the Yoke Dump Door Extend and Retract Limit Switches The Dump Door Retract and Dump Door Extend Limit Switches are proximity sensors that sense when the hopper dump door is open retracted and closed exte...

Page 257: ...e the top of the Hopper Lift Cylinder and hold the hopper in its raised position Warning Before working underneath the raised hopper engage the Hopper Prop Rod as follows 1 Raise the hopper all the way up 2 Pull the Pull Rod to pivot the bottom of the Hopper Prop Rod toward the Hopper Lift Cylinder until it contacts the Hopper Lift Cylinder 3 Lower the hopper until the Hopper Prop Rod contacts the...

Page 258: ...necessary The contactor K9 is not providing positive voltage to the K11 and K12 contactor coils 1 Check the K9 contactor coil resistance If the coil resistance is not 118 ohms 10 replace the contactor 1 Check the continuity through contactor K9 with the coil energized If the contacts are open replace the contactor 1 Check the J2 28 and J2 24 Outputs from A1 Main Machine Controller There is no volt...

Page 259: ...outputs from J3 6 and J3 7 on the A1 Control Board The hopper dump door will not open The sensor on the Door Extend Limit Switch S7 is not functioning correctly Check the sensor switch function as follows The switch should close when it comes within approximately 250 of a ferrous material The switch should open when it moves approximately 313 away from the material If the switch is not operating c...

Page 260: ...from the machine and the parking brake is engaged To Remove and Reinstall the Hydraulic Power Pack Assembly LPG and Diesel Models 1 Disconnect the battery 2 Open the right engine side cover and remove the right battery tray cover 3 Swing the fuel tank out 4 Remove the two Tray Mounting Bolts holding the 36 volt battery pack tray to the frame Tray Mounting Bolt Tray Mounting Bolt ...

Page 261: ...er 7 Remove the two 3 8 16 Nyloc Nuts and remove the Reservoir Guard 8 Disconnect the pump electrical connector 9 Disconnect the hydraulic hoses from the pump 10 Remove the two hydraulic pump mounting bolts and remove the Hydraulic Power Pack assembly 11 Transfer fittings to the new Hydraulic Power Pack assembly and attach the assembly to the frame but do not connect the hoses yet The system has t...

Page 262: ...is at the minimum mark on the reservoir Battery Models 1 Open the right battery side cover 2 Use some large hooks to grab the bumper and raise the hopper up slightly using a hoist or other suitable method Warning Before working underneath the raised hopper install blocks between the hopper and chassis or other suitable supports to prevent the hopper from accidentally lowering while you re working ...

Page 263: ...t of the down port by pressing the hopper down switch 11 Transfer the plug from the up port to the down port of the pump assembly 12 Momentarily run the pump to get oil out of the up port by pressing the hopper up switch 13 Remove all remaining plugs from the pump and the hoses and attach the hoses to the pump assembly 14 Lower cylinder hose to up port on pump 15 Upper cylinder hose to down port o...

Page 264: ... cannot be used to support the hopper when the hopper lift cylinder is disconnected or removed 3 Place a suitable container under the hopper lift cylinder to catch any hydraulic oil that may leak from the cylinder and hoses 4 Loosen and disconnect the hoses from the cylinder Plug the hoses to prevent dirt and air from entering the hoses 5 Plug the hopper lift cylinder ports to prevent oil from lea...

Page 265: ...ylinder Pin remove the External Retaining Ring next to the Frame Weldment as shown 8 Support the hopper lift cylinder and hopper prop rod Then remove the Cylinder Pin External Retaining Ring remove External Retaining Ring do not remove Flange Bearing 2 Frame Weldment Cylinder Pin Remove Sleeve Bearing inside weldment Hopper Prop Rod ...

Page 266: ...ith 10W 30 engine oil Note In the remaining steps it is important that the oil level always be maintained above the minimum mark on the reservoir 13 Operate the pump by pressing the hopper up switch on the control panel until the cylinder is fully extended 14 Reattach the hose from the upper cylinder to the down port of the pump assembly 15 Reattach the upper cylinder yoke along with the red safet...

Page 267: ...pper 2 Engage the parking brake and remove the key from the key switch 3 Support the hopper in its raised position with an overhead hoist or other suitable support Warning The hopper must be adequately and securely supported with a hoist or other suitable support before the hopper lift cylinder is disconnected The hopper prop rod cannot be used to support the hopper when the hopper lift cylinder i...

Page 268: ... 4 Remove the External Retaining Ring next to the Frame Weldment as shown 5 Use Wire Ties or other suitable strapping to support the Hydraulic Cylinder while you work on the system External Retaining Ring remove Wire Ties Hydraulic Cylinder ...

Page 269: ...raulic Hose when you run the cylinder rod downward 10 Rotate the Lower Cylinder Fitting downward to direct the oil into the drip pan 11 Press the hopper lower button to run the pump and force the oil out of the Lower Cylinder Fitting until all of the oil has been drained from the bottom of the cylinder Manually press the cylinder ram down as necessary to ensure all of the oil is out of the bottom ...

Page 270: ...al upward position and make sure the Lower Cylinder Fitting nut is tight 13 Install a Cap into the Lower Cylinder Fitting 14 Disconnect the DOWN Hydraulic Hose from the DOWN Pump Port 15 Install a Cap on the DOWN Pump Port Cap Lower Cylinder Fitting DOWN Hydraulic Hose DOWN Pump Port Cap DOWN Pump Port ...

Page 271: ...n lint free rag 19 Check the O ring between the Reservoir and Pump Assembly to make sure it is not damaged Replace the O ring if necessary 20 Make sure the O ring between the reservoir and pump assembly is installed correctly then reinstall the reservoir onto the pump assembly Note The reservoir has threaded brass inserts that can be damaged if the Phillips screws are overtightened 21 Carefully ti...

Page 272: ...ower Cylinder Fitting 27 Press the hopper raise button to raise the cylinder ram to the end of its stroke to purge the oil from the top of the hydraulic cylinder Check the oil level in the reservoir frequently as you do this and add oil as necessary The oil level in the reservoir should be at the MIN line with the cylinder ram fully extended upward Note Be careful not to let the oil level in the r...

Page 273: ...ct the DOWN Hydraulic Hose to the DOWN Pump Port 29 Disconnect the UP Hydraulic Hose from the Lower Cylinder Fitting 30 Install a Cap onto the Lower Cylinder Fitting 31 Install a Plug into the UP Hydraulic Hose DOWN Hydraulic Hose DOWN Pump Port Cap Lower Cylinder Fitting Plug UP Hydraulic Hose ...

Page 274: ...he hydraulic cylinder ram up and down several times using the hopper raise and hopper lower buttons to check for correct function Note There is a Velocity Fuse inside the lower down hydraulic cylinder port that will shut off the flow of oil through the fitting if the oil flow rate exceeds 1 5 gallons per minute This is to prevent the hopper from dropping down if the up hydraulic hose or lower cyli...

Page 275: ...draulic Hose should be positioned so it has adequate clearance in the frame cutout Loosen and reposition the Upper Cylinder Fitting and DOWN Hydraulic Hose as necessary to avoid any abrasion or damage 40 Raise the hopper and check the position of the UP Hydraulic Hose The UP Hydraulic Hose should be positioned as shown so it doesn t contact the hopper when the hopper is down Loosen and reposition ...

Page 276: ...the actuator and spring in the Dump Door Actuator Yoke 4 Carefully swing the Door Dump Actuator Assembly down to access the Electrical Connector 5 Disconnect the Electrical Connector 6 Remove the cotter hair pin washers and Clevis Pin holding the Dump Door Actuator Assembly to the frame then remove the Dump Door Actuator Assembly from the machine 7 Reinstall the hopper dump door actuator assembly ...

Page 277: ...orque 151 ft lbs Output Speed 3669 RPM full load Current Draw 15 9 Amps full load Horsepower 0 55 HP full load Dump Door Actuator Voltage 24 to 40 VDC Stroke 6 inches Dynamic Load Rating 400 lbs Static Load Rating 1000 lbs Restraining Torque 100 in lbs Clutch ball detent clutch setting 600 to 900 lbs Full Load Speed 0 55 in sec Current Rating 9 Amps Typical Current Draw 1 3 Amps Proximity Sensor D...

Page 278: ...removable Recovery Tank Clean Out Door to allow easier cleaning and flushing of the Recovery Tank Back Up Alarm Kit The Back Up Alarm Kit includes the Back Up Alarm electrical connector and mounting hardware The Back Up Alarm connects to the existing machine wiring to sound a warning when the machine is moving in reverse Recovery Tank Clean Out Door Recovery Tank ...

Page 279: ...n Signal Kit includes front turn signal lights rear brake turn signal lights a rear corner roller kit mounting hardware and electrical connectors The main machine controller powers the turn signal lights and brake light The turn signals don t use a conventional flasher unit The main machine controller switches the ground to the turn signals on and off ...

Page 280: ...erate a caution and signal the main machine controller to turn off the dust control motor main broom system and side broom system and close the hopper dump door Plugged Filter Switch Kit The Plugged Filter Switch Kit includes a Dust Control Filter Switch that threads into the hopper and connects to the existing wiring harness The Dust Control Filter Switch will generate a warning if the hopper vac...

Page 281: ...plumbing The high pressure solution pump pumps solution from the tank to the hose and wand when the clutch is engaged Refer to the Solution System section for more information Front Corner Roller Kit Extended Scrub Kit The Extended Scrub Kit includes an additional Solution Pump a Float Switch Strainer and associated plumbing to pump recovered water to the scrub brushes once the solution tank is em...

Page 282: ...jection Kit The EcoFlex Chemical Injection Kit includes the detergent pumps detergent bottles mounting hardware and associated plumbing to inject detergent into the solution flow to the scrub brushes Refer to the Solution System section for more information Overhead Guard Kit 79 Deluxe Seat Kit ...

Page 283: ...t to the scrub brushes Routing through the Heat Exchanger will increase the solution temperature approximately 50 degrees F The Heat Exchanger is plumbed to the engine cooling system and uses the hot engine coolant to heat the solution as it circulates through the Heat Exchanger Refer to the Solution System section for more information Squeegee Guard Kit Super Duty Kit The Super Duty Kit includes ...

Page 284: ...ll switch on the pump when the hose nozzle is opened then shut the pump off when the nozzle is closed Refer to the Solution System section for more information Overhead Guard Kit 82 Work Light Kit The Work Light Kit includes a 12 volt Lamp 36 volt Trouble Lamp and mounting hardware The 12 volt Lamp adds additional lighting to the operator side of the machine for visibility in low lit areas The pul...

Page 285: ...arning Beacon Kit The Warning Beacon Kit includes an LED warning beacon and electrical connector and the mounting hardware to mount the beacon onto the machine The beacon will flash whenever the machine key switch is on Solution Fill Shut Off Kit The Solution Fill Shut Off Kit allows you to connect a garden hose to the fitting and fill the solution tank without having to monitor the water level in...

Page 286: ...ories 286 Service Manual CS7000 Description Illustration Vacuum Wand Kit Overhead Guard Canopy Kit Front Bumper Kit The Front Bumper Kit includes the front bumper weldment a front corner roller kit and mounting hardware ...

Page 287: ...anual CS7000 Description Illustration Accessory Socket Kit The Accessory Socket Kit includes a 12 volt automotive type adapter to power accessories or personal electronics and a circuit breaker Drain Hose Extension Arm Rest Option R H Only ...

Page 288: ... any large particles then into the recovery tank The vacuum motors switch on automatically when the scrub system is enabled and the machine moves forward The motors will switch off after a predetermined time delay once machine motion stops The vacuum motors can also be switched on independent of the scrub system by pressing the vacuum wand switch This is used to pick up solution already on the flo...

Page 289: ... 27 Brush Current Sense J7 25 B Contactor Aux VACC3 CB3 25 Amp 1 1 2 2 J3 34 Input Vacc 3a BLU GRN RED GRA BLK VIO 3 4 K9 VACC1 CB1 S14 Ignition Switch 1 3 B1 B 3 2 J7 19 Start Input 42V Alternator J2 14 Output J7 12 Supression Diode VIO GRN K9 Aux Contactor YEL BRN BLK ORN ORN ORN YEL BRN G J7 13 Key Switch Input J7 1 Interlock Input ORN GRA ORN ORN Safety Switch Relay signal from A5 Steer by Wir...

Page 290: ...3 The Auxiliary Contactor K9 must be closed to provide positive voltage to circuit breaker VACC1 CB1 Circuit breaker VACC1 CB1 must be closed to provide positive voltage to the Vacuum Motor Contactor K6 The J2 17 Output on the A1 Main Machine Controller must provide a ground to the Vacuum Motor Contactor K6 coil J2 17 provides ground to K6 under the following conditions The A1 Main Machine Control...

Page 291: ...he Vacuum Fan Cover Assembly The debris basket can be accessed by opening the Recovery Tank Cover Recovery Tank Cover and Debris Basket The Debris Basket is located below the Recovery Tank Cover and attached Recovery Cover Gasket The recovered solution is directed through the Debris Basket before going into the recovery tank to screen out any debris or large particulates Vacuum Fan Cover Assembly ...

Page 292: ... Vacuum Motors sit on the Vacuum Fan Seal Assembly in the Recovery Tank and are held in place by the Vacuum Fan Cover Assembly The air from the Vacuum Motors is exhausted through Foam Tubes no minimize noise Float Cage and Ball Assemblies The Float Cage and Ball Assemblies are attached to the Vacuum Fan Cover Assembly and prevent any recovered water from being drawn in through the Vacuum Motors Va...

Page 293: ...Rotate the two Latches 90 degrees and remove the Vacuum Filter Lid Assembly 2 Remove and clean the Filter and Filter Screen with a vacuum or by washing them in warm water 3 When the Filter and Filter Screen are clean and dry reinstall them into the recovery tank Service Note The Filter and Filter Screen must be completely dry before reinstalling 4 Rotate the two Latches back 90 degrees to secure t...

Page 294: ... the Latch open the Recovery Tank Cover and lift the Debris Basket out of the recovery tank 2 Rinse any accumulated material from the Debris Basket then reinstall it in the recovery tank 3 Close the Recovery Tank Cover and secure the Latch Recovery Tank Cover Debris Basket Latch ...

Page 295: ...actor coil resistance If the coil resistance is not 118 ohms 10 replace the contactor 2 Check the continuity through contactor K9 with the coil energized If the contacts are open replace the contactor 3 Check the J2 14 output from A1 Main Machine Controller There is no voltage to the vacuum motors 1 Check the K5 contactor coil resistance If the coil resistance is not 118 ohms 10 replace the contac...

Page 296: ...queegee is plugged Check the squeegee and clean repair as necessary The squeegee blade s is are worn out Flip the squeegee blade s around to position a new blade surface on the floor Replace the squeegee blade s Removal and Installation Warning Before removing or reinstalling any machine components make sure the key switch is off the key is removed from the machine and the parking brake is engaged...

Page 297: ...Switch Wiring Harness and Solution Hose before you can remove the recovery tank These are described in steps 5 and 6 If your machine is not equipped with an extended scrub system skip to step 7 5 Loosen the Knurled Collar and disconnect the Float Switch Wiring Harness Recovery Tank Vacuum Motor Electrical Connector Solution Hose Float Switch Wiring Harness Knurled Collar Float Switch Wiring Harnes...

Page 298: ...ck in order to more easily move the recovery tank once it s removed from the machine To Reinstall the Recovery Tank 1 Set the recovery tank onto the mounting pins on the machine frame 2 Swing the recovery tank up and reattach the Tether Hook to the recovery tank 3 Reconnect the recovery tank vacuum motor electrical connector 4 Reconnect the extended scrub wiring harness and solution hose if so equ...

Page 299: ... of the recovery tank making sure the Float Cages pass up through the cutouts in the tank 5 Disconnect the Vacuum Motor electrical connector 6 Loosen the Hose Clamp and disconnect the Foam Tube Assembly from the Vacuum Motor 7 Carefully lift the Vacuum Motor out of the recovery tank 8 Reinstall the Vacuum Motor by following the above steps in reverse order Note Before you reinstall a vacuum motor ...

Page 300: ...omponent Specifications Vacuum Motor Voltage 42 VDC Insulation Class A Current Draw Average 15 Amps Maximum 17 Amps Vacuum System Vacuum Sealed 48 H2 O With 1 dia Orifice 25 to 30 H2 O Special Tools Vacuum water lift gauge Nilfisk Advance part number 56205281 ...

Page 301: ...s current reading is sent to the A1 Main Machine Controller on pin J7 27 Brush Current Sense The A1 Main Machine Controller interprets this current value and raises or lowers the scrub deck as follows If the brush motor current drops below the preset limits for the selected scrub pressure 1 3 the scrub deck actuator will lower the scrub deck to increase the scrub pressure and current draw until th...

Page 302: ...rush Motor 1 2 K3 Contactor Center Brush Motor 1 2 K2 Contactor Left Brush Motor 1 2 K1 Fuse 150 A F2 Scrub Deck Actuator Motor Retract Limit Switch M11 J2 11 PWM Output J7 21 Input M Contactor Aux VACC3 CB3 25 Amp 1 1 2 2 J3 34 Input Vacc 3a BLU GRN RED GRA BLK VIO K9 VACC1 CB1 S14 Ignition Switch 1 3 B1 B 3 2 J7 19 Start Input 42V Alternator J2 14 Output J7 12 Supression Diode VIO GRN K9 Aux Con...

Page 303: ... the Center Brush Motor Contactor K2 and the Right Brush Motor Contactor K3 The J2 25 J2 26 and J2 27 Outputs on the A1 Main Machine Controller must provide ground to the Left Brush Motor Contactor K1 coil the Center Brush Motor Contactor K2 coil and the Right Brush Motor Contactor K3 coil respectively The J2 25 J2 26 and J2 27 Outputs provide a ground under the following conditions The A1 Main Ma...

Page 304: ...ght hand Scrub Motor Assembly is mounted on the Arm Weldment bolted to the Deck Weldment The Right angle Gearboxes are mounted on spacers to position them correctly on the Deck and Arm Weldments Right Scrub Arm Gas Spring and Lever Arm Bracket The Gas Spring keeps the right Arm Weldment and attached Side Squeegee Assembly extended outward during normal scrubbing but will allow the Arm Weldment to ...

Page 305: ... Blades are held in place by strap weldments and wing knobs Scrub Deck Actuator The Scrub Deck Actuator is pinned to the machine frame and to the pivoting Deck Lift Assembly Arm When the Scrub Deck Actuator extends or retracts it lowers or lifts the free side of the Deck Lift Assembly Arm The Deck Lift Assembly Arm pivots on flange bearings and bushings in the frame to raise and lower the attached...

Page 306: ... on the inside of the Blade Support Weldment then reinstall and tighten the two Wing Knobs 6 Swing the edge guard back into position then tighten the Knob right hand side squeegee assembly only To Replace a Trailing Deck Blade 1 Loosen the Knob and swing out the edge guard not shown on right hand side squeegee assembly only 2 Press the Latch Lock open the Latch and remove the Blade Strap and Trail...

Page 307: ...the coil resistance is not 118 ohms 10 replace the contactor 2 Check the continuity through contactor K9 with the coil energized If the contacts are open replace the contactor 3 Check the J2 14 output from A1 Main Machine Controller An individual scrub deck motor will not run There is no voltage to the corresponding contactor coil K1 K2 K3 1 Check the coil resistance in the K1 K2 K3 contactor coil...

Page 308: ... replace the brush current sensor Removal and Installation Warning Before removing or reinstalling any machine components make sure the key switch is off the key is removed from the machine and the parking brake is engaged To Remove and Reinstall a Side Squeegee Assembly 1 Loosen the knob and swing out the edge guard 2 Carefully remove the Extension Springs from the tabs on the upper Weldment Arm ...

Page 309: ...g the Scrub Deck Actuator to the Deck Lift Arm Assembly 6 Remove the Bow tie Cotter Pin and Clevis Pin holding the Scrub Deck Actuator to the machine frame then remove the Scrub Deck Actuator from the machine 7 Reinstall the Scrub Deck Actuator by following the above steps in reverse order To Remove and Reinstall the Scrub Deck 1 Remove the recovery tank refer to the Recovery System section 2 Make...

Page 310: ...e Deck Lift Arm Assembly and attached Scrub Deck to the machine frame 8 Remove the Bow tie Cotter Pin washers and Clevis Pin holding the Scrub Deck Actuator to the Deck Lift Arm Assembly 9 Jack the machine up as necessary to get enough clearance to remove the Scrub Deck then support the machine with jack stands Warning Never work under a machine without safety stands or blocks to support the machi...

Page 311: ...ite Orange wire Center scrub motor Gray Black wire Right scrub motor Blue Yellow wire Make sure the two Flange Bearings are installed in the machine frame through holes and that the Bushings and washers are installed correctly before installing the two M12 1 75x 35mm Screws You may find it easier to use a tapered punch or other suitable tool to align the Bushings Flange Bearings and Deck Lift Arm ...

Page 312: ... remove the Brush Plate Assembly 5 Remove the four Hex Head Metric Screws then lift the Scrub Motor Assembly and Motor Spacer off of the Arm Weldment shown or deck weldment 6 Reassemble the Scrub Motor Assembly following the above steps in reverse order Note Make sure the Key is installed correctly before you reinstall the Brush Plate Assembly onto the scrub motor shaft Scrub Brush 5 16 18 X 1 25 ...

Page 313: ...ition of the witness marks stamped into the frame and castings on both ends of the motor 4 Remove the two Acorn Nuts and open the Terminal Cover 5 Use a backup wrench to hold the Bottom Terminal Nuts in place then remove the Top Terminal Nuts and Terminals Make sure to note the wire polarity 6 Remove the Terminal Cover 7 Remove the Hex Nuts Lock Washers and Threaded Rods holding the two end castin...

Page 314: ...how the springs roll when the brush is pushed back before taking it apart b Remove a brush and spring c Install a new brush and spring into the brush holder Thread the brush wire lead through the brush holder Position the back end of the brush in the cup of the spring so that the spring will unroll as the brush is pushed back once it is installed End Casting Frame Cup side of spring Spring unrolls...

Page 315: ...Washer contact the outside bearing race as shown 12 Reinstall the end casting in stages as follows a Reinstall the end casting with brushes far enough into the frame so the brushes will contact the commutator when the temporary retaining wires are removed then remove the retaining wires b Press the end casting into the frame leaving about a 1 8 gap between the frame and end casting Make sure to al...

Page 316: ...urements Average 19 Amps Max 37 Amps Scrub Brush Motor Left Current Draw shop measurements Average 17 Amps Max 23 Amps Scrub Brush Motor Right Current Draw shop measurements Average 17 Amps Max 26 Amps Deck Actuator Motor Input Voltage 34 40 VDC Dynamic Load 500 lbs max Static Load 1000 lbs max Restraining Torque 100 in lbs min Current Draw 9 Amps max at rated dynamic load 2 5 Amps Typical End of ...

Page 317: ... Make 250 in typical Air Gap Break 313 in typical Contact resistance initial 150 milliohms max Special Tools A spring puller is recommended to remove the Extension Springs from the Weldment Arms when removing the Side Squeegee Assemblies There are several types of spring pullers a typical example is shown here ...

Page 318: ...t volume is controlled by the Main Controller through a PWM pulsed width modulated output The A1 Main Machine Controller monitors the solution level via a solution pressure sensor Also refer to the Component Locations Solution Tank Solution Pressure Sensor section As the solution level drops the PWM output will increase to compensate for the loss of solution head pressure in order to maintain a co...

Page 319: ...nk must be closed to indicate adequate water level in the recovery tank Note that when the machine is in the scrub mode The solution pump will continue to run along with the extended scrub pump The EcoFlex pumps will continue to add detergent to the recovered water Optional Hot Water System LP and Diesel EcoFlex Machines Only On EcoFlex models equipped with the optional hot water system the soluti...

Page 320: ...n level in the tank If the solution level has been low longer than 10 seconds the LCD display will show the solution level low caution icon The conditions under which the solution level low icon is displayed depend on the state of the extended scrub system as follows With the extended scrub system off If the clean solution is low the solution level low icon will be displayed If the clean solution ...

Page 321: ...olution Control optional M19 M J2 7 PWM Output B WHT BRN WHT YEL J2 19 PWM Output A Pump Chemical Metering optional M17 M J2 20 PWM Output VIO YEL ORN Solution Valve L1 J7 14 Input BLK J3 16 BLK J3 18 BLK J3 19 BLK J3 20 BLK J3 21 BLK WHT ORN J3 29 J3 9 Output High pressure Pump Clutch J7 10 12V J7 11 B J7 3 CAN H J7 2 CAN L VACC2 CB2 K9 25 Amp 2 1 1 2 YEL BRN J7 13 Key Switch Input VIO VACC1 CB1 ...

Page 322: ...ution Control Pump M19 EcoFlex machines only Note that VACC2 CB2 must closed to provide positive voltage to the Extended Scrub Pump M25 and Low Pressure Pump M23 as well The J2 20 PWM Output provides negative ground to Solenoid Valve L1 and the J3 2 PWM Output provides negative ground to the Solution Control Pump M19 under the following conditions The A1 Main Machine Controller must receive a sign...

Page 323: ...al pressure switch in the low pressure pump is set to switch the pump on at 25 psi 5 psi when the hose nozzle is opened and shut pump off at 45 psi when the hose nozzle is closed The Following Conditions Must be Met for the EcoFlex System to Operate The J2 19 J2 7 J2 32 and J2 21 PWM Outputs provide power to the Chemical Metering Pumps M17 and M18 respectively under the following conditions The de...

Page 324: ... side of the solution tank The Solution Filter prevents any dirt or particulates that may be in the solution tank from entering the solution solenoid valve and solution system The Solution Shutoff Valve allows you shut off the solution flow to the machine for solution system maintenance Note There is a Valve Shield mounted onto the solution tank that is not shown in the above photo The Valve Shiel...

Page 325: ... monitors the air pressure in the Sensor Tube and converts this pressure value to a solution level as shown on the LCD display on the Operator Interface Panel Solution Pump EcoFlex Models Only The Solution Pump is mounted underneath the rear right hand side of the solution tank and pumps the solution to the solution solenoid valve Low Pressure Wash Hose Pump The optional Low Pressure wash hose Pum...

Page 326: ...y to remove and install It is possible for dirt or debris to interfere with the Solution Solenoid Valve seat and prevent the seat from sealing This can prevent the Solution Solenoid Valve from shutting off the solution flow completely and requires that the Solution Solenoid Valve be cleaned or replaced Solution Nozzles The Solution Nozzles are part of the deck weldment and direct the solution onto...

Page 327: ...t merge into one main detergent supply line The detergent supply line is plumbed into the solution supply upstream of the solution solenoid valve High pressure Spray System Pump The High pressure Pump is driven by an Electric Clutch run by a Pulley off of the engine The Electric Clutch is engaged and drives the High pressure Pump when the Operator presses the high pressure wand switch on the contr...

Page 328: ...the Recovery Tank closes to indicate adequate water level the Extended Scrub Pump switches on to pump water to the scrub brushes The water passes through the Strainer inside the Recovery Tank then through the Water Supply Line in the Bulkhead Plates and Gasket to the inlet side of the Extended Scrub Pump Note that the second piece of conduit in the Bulkhead Plates and Gasket is for the Extended Sc...

Page 329: ...e solution shutoff valve Note Place a suitable container underneath the filter to catch any solution that may leak from the hoses 2 Unscrew the Filter Cover and remove the Filter Cover and Screen from the Filter Base 3 Clean any accumulated dirt or debris from the Screen 4 Reinstall the Screen into the Filter Base 5 Make sure the Rubber Washer is installed correctly in the Filter Cover then reinst...

Page 330: ...igh Pressure Solution Filter 1 Drain and remove the recovery tank Note Place a suitable container underneath the filter to catch any solution that may leak from the hoses 2 Unscrew the Filter Cover and remove the Filter Cover and screen from the Filter Base 3 Clean any accumulated dirt or debris from the screen 4 Reinstall the screen into the Filter Base 5 Make sure the rubber washer is installed ...

Page 331: ...t tension as follows LPG Machines For a new belt a deflection of 0 12 when a force of 2 6 to 2 8 lbs is applied and for a used belt a deflection of 0 12 when a force of 2 2 to 2 4 lbs is applied Diesel Machines For a new belt a deflection of 0 13 when a force of 2 4 to 2 5 lbs is applied and for a used belt a deflection of 0 13 when a force of 2 1 to 2 2 lbs is applied 5 When the belt tension is c...

Page 332: ... Panel via the CAN BUS Inadequate solution flow to the brushes in the scrub mode Inadequate solution level in tank Check the solution level The solution filter screen is plugged Clean the solution filter screen The solution shutoff valve is plugged or inoperative Clean or replace the solution shutoff valve The solution solenoid valve is plugged or not functioning Check the solution solenoid coil r...

Page 333: ...ltage at the pump If there is voltage at the pump replace the pump If there is no voltage at the pump 1 Check the wiring and circuit breakers upstream of the pump 2 Check the J3 1 output from A1 Main Machine Controller No detergent flow to the solution system The detergent and EcoFlex functions are not installed in the configuration menu Install both the detergent and EcoFlex functions in the conf...

Page 334: ...tch pulley Adjust the belt tension or replace the belt as necessary Check the connection from the clutch to battery ground and repair as necessary Check the output from J3 9 on A1 Main Machine Controller If there is voltage from J3 9 to the clutch replace the clutch The relief valve is not operating Replace the relief valve The low pressure wash hose is not operating The low pressure wash function...

Page 335: ...sing the appropriate equipment to prevent possible personal injury or damage to the solution tank 1 Disconnect the battery batteries 2 Drain and remove the recovery tank 3 Drain the solution tank 4 Disconnect the solution hoses from the solution tank 5 Disconnect the electrical connector from the Drive Pedal 6 Remove the Brake Pedal Cover Weldment 7 Remove the Circuit Breaker Panel and disconnect ...

Page 336: ...arter engine interface etc 10 Remove the Electrical Panel 11 Remove the Main Machine Controller 12 Disconnect any additional solution lines or electrical connectors from the solution tank that may be present if your machine is equipped with an extended scrub system high pressure spray system or wash hose kit Steering Sensor Electrical Connector Electrical Panel Main Machine Controller ...

Page 337: ...ting screws are located on the vertical supports on the left side of the machine where the main machine controller is mounted The two top Solution Tank Mounting Screws are located on the vertical supports on the left side of the machine The bottom rear Solution Tank Mounting Screw is located underneath the machine on the right side by the solution shutoff valve and drain hose Solution Tank Mountin...

Page 338: ...hand side squeegee assembly The bottom front Solution Tank Mounting Screw is located underneath the machine by the main broom actuator and scrub deck actuator 14 Remove the solution tank from the machine 15 Reinstall the solution tank by following the above steps in reverse order Solution Tank Mounting Screw Solution Tank Mounting Screw ...

Page 339: ...lution tank Make sure the Solution Shutoff Valve is oriented correctly on the tank so the barbed fitting on the Solution Shutoff Valve aligns with Connecting Hose on the Solution Filter Assembly To Remove and Reinstall the Solution Filter Assembly 1 Close the Solution Shutoff Valve 2 Remove the nuts washers and U bolts holding the Solution Filter Assembly to the mounting plate Note Place a suitabl...

Page 340: ...tion Solenoid Valve wires to the Solution Manifold 4 Loosen the Hose Clamp holding the Solution Solenoid Valve to the Solution Manifold 5 Remove the two Hex Head Screws holding the Solution Solenoid Valve to the deck assembly and remove the Solution Solenoid Valve from the machine 6 Reinstall the Solution Solenoid Valve following the above steps in reverse order To Remove and Reinstall a Detergent...

Page 341: ...mponent Specifications Solution Solenoid Valve 36V Coil Resistance 72 ohms 10 EcoFlex Detergent Pump Type diaphragm dosing pump with stroke adjustment Voltage 12 VDC Flow Calibration 87 ml min 3 ml min Water Lift 3 5 in Solution Control Pump EcoFlex models only Extended Scrub Pump Type diaphragm self priming internal check valve Voltage 36 VDC permanent magnet Current 3 9 Amps max Flow Rate 3 3 GP...

Page 342: ...ump on at 25 5 psi Set to shut pump off at 45 psi Performance Specifications average Pressure psi GPM Amps 10 3 16 2 1 20 3 00 2 6 30 2 76 2 9 40 2 62 3 2 50 2 26 3 5 High Pressure Pump Type Axial piston Max Pump Speed 1750 RPM Max Flow Rate 2 11 gpm 8 l min Max Outlet Pressure 2 200 psi 150 bar Max Inlet Pressure 116 psi 8 bar Oil Type SAE 30 10 oz capacity Shaft Rotation counterclockwise horizon...

Page 343: ...Solution System 343 Service Manual CS7000 Special Tools Loctite No More Leaks White Threaded Plastic Pipe Sealant used on solution shutoff valve threads ...

Page 344: ...when turning Squeegee System Wiring Diagram Fuse 400 A A1 Main Machine Controller RED RED BLK BLK J3 15 Ground F1 Battery 36V B BLK J3 16 BLK J3 18 BLK J3 19 BLK J3 20 BLK J3 21 BLK J3 29 WHT GRN RED ORN BLU BRN J2 8 Output Squeegee Actuator Motor to RED to Extend M12 J2 9 Output M S14 Ignition Switch 1 3 B1 B 3 2 J7 19 Start Input 42V Alternator J2 14 Output J7 12 Supression Diode VIO GRN K9 Aux ...

Page 345: ...queegee Support Assembly The front of the Squeegee Support Assembly is attached to the machine frame by a pivoting Rod End This allows the rear of the Squeegee Support Assembly and attached squeegee to tilt up and down and pivot side to side to conform to the floor surface The two Squeegee Casters support the Squeegee Support Assembly on the floor The rear of the Squeegee Support Assembly rests on...

Page 346: ...e The Squeegee Blades have four usable edges and can be rotated end for end or top to bottom to position a new blade surface on the floor To Remove and Reinstall the Front Squeegee Blade 1 Release the Push Pull Clamp and remove the Weldment Strap 2 Remove the Front Squeegee Blade from the Squeegee Weldment 3 Rotate the existing Front Squeegee Blade top to bottom or end for end to position a new bl...

Page 347: ... the floor or install a new Rear Squeegee Blade onto the Squeegee Weldment pins 4 Reinstall the Squeegee Strap then close the Latch Squeegee End Wheels Once a month apply light machine oil to the Squeegee End Wheels Squeegee Caster Wheel Bearings Once a month pump a small amount of grease into the Grease Fitting on both caster wheels on the squeegee support assembly until grease seeps out around t...

Page 348: ...the floor surface as shown The ends of the squeegee should deflect as shown while still making full contact with the floor 3 If the Squeegee tilt angle needs to be adjusted a Lift the Crank Handle out of the Yoke b Rotate the Crank Handle to raise or lower the 1 2 13 Screw as necessary so the squeegee blades are at the correct angle to the floor 4 When the squeegee tilt adjustment is correct repla...

Page 349: ...t the height of a Squeegee Caster 1 Loosen the Locknut 2 Use a wrench on the flats of the Threaded Shaft to turn the Threaded Shaft to raise or lower the Squeegee Caster as necessary 3 When the Squeegee Caster is at the correct height tighten the Locknut 4 Check the squeegee tilt angle and adjust as necessary Refer to the To Adjust the Squeegee Tilt section on the preceding page Threaded Shaft Loc...

Page 350: ...the squeegee actuator motor If the motor doesn t operate correctly replace the squeegee actuator 3 Check the voltage outputs from J2 8 and J2 9 on the A1 Main Machine Controller The squeegee is not picking up the water effectively There is a vacuum leak between the squeegee weldment and the recovery tank Make sure the squeegee hose is installed correctly in the recovery tank and on the squeegee we...

Page 351: ...se order Note Use removable Loctite thread sealer when reinstalling the 3 4 16 Screw Tighten the 3 4 16 Screw to 270 ft lbs To Remove and Reinstall the Squeegee Lift Arm 1 Remove the Rear Squeegee Assembly and Squeegee Support Assembly 2 Disconnect the Extension Springs from the Squeegee Lift Arm 3 Remove the Cotter Pin washers and Clevis Pin connecting the Squeegee Lift Actuator to the Squeegee L...

Page 352: ...evis Pin connecting the Squeegee Lift Actuator to the Squeegee Lift Arm 5 Remove the Cotter Pin 5 x 2 75 Clevis Pin and Spacer connecting the Squeegee Lift Actuator to machine frame and remove the Squeegee Lift Actuator from the machine 6 Reinstall the Squeegee Lift Actuator by following the above steps in reverse order Note The Squeegee Lift Actuator does not require adjustment after installation...

Page 353: ...e Actuator has internal limit switches connected to the motor to shut off power at ends of stroke Overload Protection Ball detent clutch with load rating between 250 and 500 lbs Thermal Protection Automatic resetting thermal breaker enclosed in motor housing Wiring Polarity To extend actuator connect red lead to positive and orange lead to negative To retract actuator connect orange lead to positi...

Page 354: ...ection Steering Wheel Rotation Sensor The Steering Wheel Rotation Sensor has an internal encoder that translates steering wheel rotation information into four digital signals The end of the steering shaft has a special diametrically polarized magnet on it The line of separation between the north and south magnetic poles rotates in close proximity to the encoder The three images below show how a wi...

Page 355: ...ating Current and is a brushless design It rotates a gear set that drives the output shaft The output shaft is keyed to a drive gear which drives a large ring gear to turn the rear drive wheel assembly There is also a sensor inside the motor that reports position and rotation information to the Steering Controller This information provides feedback to the controller so that it can verify that the ...

Page 356: ...steering wheel rotation sensor and the travel limit proximity switches It has robust self diagnostics to protect itself and shut down the steering system if a serious error occurs It is a sealed unit with no serviceable parts inside It is capable of storing DTCs Diagnostic Trouble Codes See the Troubleshooting section for more information There is a green LED Status Indicator built into the contro...

Page 357: ...Steering System 357 Service Manual CS7000 Steering System Wiring Diagram 36 V From Key Switch ...

Page 358: ...er supply out of J5 3 which provides power to the steering actuator encoder at pin 1 and the steering wheel rotation sensor encoder pins 4 and 8 The steering rotation sensor encoder has 2 grounds at pins 3 and 7 These are not connected directly to battery negative but go to steering controller J5 4 The controller provides a clean filtered ground for the encoder circuits The encoder built into the ...

Page 359: ...es high first If A1 switches high first then the wheel turning left If B1 switches first the wheel is turning right A2 and B2 are used as an extra redundant pair of signals Right Turn Left Turn The steering wheel sensor also contains a TFD Torque Feedback Device The TFD is powered on the same circuit as the controller J5 1 Power is supplied to a coil winding inside the TFD on sensor pin 10 The pow...

Page 360: ...he drive motor controller This shuts down the drive wheel system The steering controller can communicate with other devices via a CAN bus The CAN bus wires are at J5 23 J5 15 and J5 8 The steering actuator motor has 3 stator windings that are interconnected These wires are the working wires of the motor The controller supplies AC voltage and current to these winding to create a magnetic field that...

Page 361: ...a single pair of signals and the pattern is not square The frequency of the signal provides speed information The signals are slightly offset to indicate rotation direction The encoder receives a 5v power supply at pin 1 from the steering controller pin J5 3 The encoder is grounded on pin 6 through the steering controller J5 4 The encoder sends a wave signal out of pin 2 to controller J5 5 and out...

Page 362: ...Sensor Steering Wheel Rotation Sensor Connector Steering Actuator Rear of machine in front of drive wheel motor Steering Controller Left rear of machine Steering Wheel Rotation Sensor Steering Wheel Rotation Sensor Connector Photo taken without tanks Steering Actuator Steering Controller ...

Page 363: ...rror is detected the controller sets a DTC Diagnostic Trouble Code and communicates the code to the main machine controller via the CAN bus The main machine controller will set a machine level code of 50 and tell the control panel to display it to the operator Machine code 50 means that there is a DTC set in the steering system In order to get the specific steering system DTC enter the hidden menu...

Page 364: ...tery Positive and Negative connections at source and controller Battery Positive and Negative cables 2 DC Power Supply High Voltage The software detected that the DC power supply B and B voltage is too high Battery Positive and Negative connections at source and controller Battery Positive and Negative cables Note If there is too much resistance between the controller and the battery during regene...

Page 365: ...ply from steering controller to both encoder pairs B supply for both encoders through the steering controller 8 CAN Bus communication lost The steering controller is not receiving CAN Bus messages Can Bus Wiring Controller termination resistor Note The steering controller does not require any CAN bus messages to operate the steering system 9 Controller Hardware Fault The internal current sensor is...

Page 366: ...dicated by the steering travel limit switch closing This error also occurs when a steering travel limit switch closes indicating that the limit of travel has been reached but the controller calculated position indicates that the mechanism should not be near the limit of travel Excessive backlash in steering gears Controller Configuration Steering Limit Switches Steering Limit Switch wiring 15 Stee...

Page 367: ...ontroller Configuration Steering Limit Switches Steering Limit Switch wiring 25 Position sensor This error occurs when the steering controller calculated actuator motor position indicates the mechanism is beyond a steering travel limit switch position but the switch has not indicated that the end has been reached The steering controller believes that the physical position of the steered wheel is b...

Page 368: ... wheel is turned very slowly Travel limit switches There should be approximately 0 volts at one or both inputs at the controller No Steering Feel Possible Causes Steering wheel rotation sensor TFD Check for open circuit in the TFD coil Steering Controller Not controlling TFD Check the power supply into the TFD Check the ground control voltage It should be around 24 volts Check the current draw of ...

Page 369: ...ower plug 2 Lift the Rear Engine Cover A to access the Main Harness Connector and Steering Clamp Plate E on the Steering Assembly B as shown 3 Unplug the Torque Feedback Device Connector C from the Main Harness 4 Remove the hardware D and Steering Clamp Plate E from the Steering Assembly B 5 Remove and save the 4 Pan Screws F and remove the Steering Assembly B See Detail 1 ...

Page 370: ... steering wheel Doing so may damage the encoder inside the steering wheel sensor Remove steering wheel assembly See Steering Wheel Assembly section directly above 6 Remove steering wheel nut and washer 7 Remove steering wheel using a three jaw puller DO NOT hit the shaft with a hammer 8 Remove retaining nut spring and spring anchor hardware ...

Page 371: ...t lever pivot hardware on one side 10 Remove tilt lever pivot nut on other side Remove tilt lever then remove pivot hardware 11 Remove steering pivot nut and hardware on one side then on the other 12 Lift tilt steering column out of the steering mount box ...

Page 372: ...r then remove the sensor and shaft out of the weldment 14 Remove the nut and bolt that attaches the universal joint to the sensor shaft 15 Reassemble in the reverse order a Reassembly tip When installing the steering pivot hardware use a short bent wire hook along with an open end wrench to position and hold the nut ...

Page 373: ...n disconnect all wiring 5 Remove 4 controller mounting screws 6 Reassemble in reverse order Steering Actuator 1 Drain recovery tank 2 Turn machine off set the parking brake and disconnect the main power plug 3 Remove recovery tank a Tip tank out and let it rest on the retention cable b Disconnect the vacuum motor electrical connector If equipped with extended scrub also disconnect the additional e...

Page 374: ...three screws securing the controller mounting bracket to the frame then remove the assembly 7 Disconnect the steering actuator encoder connector 8 Remove the four steering actuator mounting bolts 9 Remove the steering actuator 10 Reassemble in reverse order ...

Page 375: ...on Pin Wire Color harness side Circuit Voltage Condition 1 GRN WHT Encoder A1 4 77v 0 09v Move steering wheel slowly Voltage switches from low to high 2 BLU Encoder A2 4 77v 0 10v Move steering wheel slowly Voltage switches from low to high 3 BLK Ground 003v 4 ORN BLK 5v supply 5 02v 5 RED WHT Encoder B1 4 77v 0 09v Move steering wheel slowly Voltage switches from low to high 6 GRN BLK Encoder B2 ...

Page 376: ...der A1 4 8v or 0 09v switches high and low as steering wheel is moved slowly J5 12 GRA ORN Application Config 38 34v J5 13 WHT BLU Right Travel Limit Switch 0 002v when not at limit 38 19v when at right limit J5 14 Not used J5 15 GRN Can Lo 2 45v J5 16 PINK Motor Temp Sensor 0 564v at room temperature 3 0v with sensor unplugged J5 17 BLU Steering Wheel Sensor Encoder A2 4 8v or 0 10v switches high...

Page 377: ...ionary motor Up to 250 HZ when motor is turning quickly V to W 16 20 HZ with stationary motor Up to 250 HZ when motor is turning quickly W to U 16 20 HZ with stationary motor Up to 250 HZ when motor is turning quickly System Current Draw Measured with amp clamp around battery positive feed to steering controller Approximately 4 5 amps while turning with stationary machine Measured at each U V and ...

Page 378: ...e operator can enable the sweep system independent of the scrub system The hopper door opens when sweeping to allow the debris to be thrown into the hopper A potentiometer in the main broom actuator sends a voltage signal to the A1 Main Machine Controller that varies with the broom height The A1 Main Machine Controller uses this signal to return the broom to the previous height setting whenever th...

Page 379: ...YEL VIO WHT BRN J7 24 5V J7 27 Brush Current Sense J7 25 B Contactor Aux VACC3 CB3 25 Amp 1 1 2 2 J3 34 Input Vacc 3a BLU GRN RED GRA BLK VIO 3 4 K9 VACC1 CB1 S14 Ignition Switch 1 3 B1 B 3 2 J7 19 Start Input 42V Alternator J2 14 Output J7 12 Supression Diode VIO GRN K9 Aux Contactor YEL BRN BLK ORN ORN ORN YEL BRN G J7 13 Key Switch Input J7 1 Interlock Input ORN GRA ORN ORN Safety Switch Relay ...

Page 380: ...ed to provide positive voltage to the Broom Motor Contactor K4 The J2 16 Output on the A1 Main Machine Controller must provide a ground to the Broom Motor Contactor K4 coil J2 16 provides ground to K4 under the following conditions The A1 Main Machine Controller must receive a signal from the A3 Control Panel via the CAN BUS that the operator has pressed the sweep switch The A1 Main Machine Contro...

Page 381: ...ed by the Broom Arm Assembly and the Broom Support Weldment The Broom Motor Assembly drives the Main Broom and is mounted to the Broom Support Weldment The Broom Lift Actuator raises and lowers the Broom Support Weldment which pivots on the machine frame to raise and lower the attached Main Broom The Broom Door Assembly swings out of the way to allow access to the Broom Arm Assembly The Broom Arm ...

Page 382: ...Sweep Pattern on the floor The Pattern should be 2 to 3 50 75 mm wide and consistent in width along the entire length of the main broom 3 To adjust the width of the Main Broom Sweep Pattern switch on and lower the main broom as described in step 1 While the main broom motor is running press the Broom Height Raise Button or Broom Height Lower Button to adjust the broom height Note that Raising the ...

Page 383: ...f the Broom Arm Assembly Also note that the Bearing and mounting screws ride in slotted holes in the supporting weldment to allow for up down adjustment 2 Move the Bearing and attached Broom Support Weldment up or down as necessary so the width of the main broom sweep pattern is consistent along the entire length of the main broom Note that Raising the right side of the main broom will narrow the ...

Page 384: ... Carbon Brushes 1 Remove the main broom motor and gearbox assembly See the Removal and Installation section 2 Create witness marks on the gearbox motor end bells covers and the motor casing for reassembly 3 Remove the gearbox from the motor Note Weep Hole faces floor when installed ...

Page 385: ...ns of the wires for reassembly 5 Working from the gearbox end of the motor remove the two long through bolts 6 Pry off the end bell cover at the end opposite the gear box Take care not to loose the rubber O ring seal or the wave washer 7 Inspect the carbon brushes and replace as necessary New brush length is approximately 7 8 22 mm O ring Wave Washer ...

Page 386: ...place and align the witness marks made earlier 11 Reinstall the through bolts and tighten them until the end covers are nearly seated leaving enough room to install the O ring seal Install the O ring and then tighten the through bolts 12 Reconnect the wiring and attach the wire cover 13 Reinstall the gearbox making sure to align the witness marks The weep hole must be facing the floor when the ass...

Page 387: ... and replace if necessary The hopper is overfilled or is lip loaded Check for a fault code 54 Main Broom Motor Overload If you see fault code 54 empty the hopper There is no voltage to the K4 contactor coil 1 Check circuit breakers CB1 and CB3 and reset if necessary 2 Check the K9 contactor coil resistance If the coil resistance is not 118 ohms 10 replace the contactor 3 Check the continuity throu...

Page 388: ...eter R4 in the broom lift actuator is not operating correctly 1 Check the voltage output from J7 34 to ground as the broom lift actuator raises and lowers the broom The voltage should vary from 0 full up position to approximately 3 3 VDC full down position 2 If the voltages are not in the 0 to 3 3 volt range replace the broom lift actuator There is no voltage from the A1 Main Machine Controller to...

Page 389: ... Assembly 3 Move the Dust Flap back into position then close and latch the Broom Door 4 Check and adjust the broom Arm Stop on the Broom Door as necessary The Arm Stop should be adjusted to prevent the Broom Arm from moving outward while still allowing the door to latch easily Note Make sure you adjust the main broom height when installing a new broom Failure to do so will reduce the life of the b...

Page 390: ... motor electrical connector from the wiring harness 6 Remove the three 5 16 18 Hex Screws holding the Broom Motor Assembly to the Broom Support Weldment and remove the Broom Motor Assembly from the machine 7 Reinstall the Broom Motor Assembly following the above steps in reverse order Service Note Apply Never Seez or an equivalent anti seize compound on the gearbox shaft when you reinstall the Bro...

Page 391: ...ce Test Mode This will give you additional clearance for removing the hair cotter pins and clevis pins on the broom lift actuator 5 Extend the main broom downward in the Service Test Mode so the bristles rest on the floor This will minimize the weight on the broom lift actuator 6 Remove the Hair Cotter Pin washers and 50 x 2 75 Clevis Pin holding the bottom of the Broom Lift Actuator to the Broom ...

Page 392: ...sconnect the Broom Lift Actuator electrical connector and remove the Broom Lift Actuator from the machine 9 Reinstall the Broom Lift Actuator by following the above steps in reverse order 10 Check the main broom height and main broom sweep pattern and adjust as necessary Refer to the To Adjust the Main Broom Height section Hair Cotter Pin Spring Arm 50 x 1 75 Clevis Pin ...

Page 393: ...orque Actuator is internally restrained Input Voltage 30 to 40 VDC Amperage 4 Amps at rated dynamic load Overload Protection Ball detent clutch with load rating between 450 and 700 lbs Thermal Protection Automatic resetting thermal breaker enclosed in motor housing Wiring Polarity To extend actuator connect red lead to positive and yellow lead to negative To retract actuator connect yellow lead to...

Page 394: ...e Brooms Side Broom Motors and the Side Broom Actuator which lowers and raises the Side Brooms via linkages connected to the Side Broom LIft Weldment The Side Broom Actuator lowers the Side Brooms any time the sweep system is enabled The Side Broom Motors switch on when the drive pedal is moved from the neutral position The operator can enable and disable the Side Brooms independent of the main sw...

Page 395: ...3 2 J7 19 Start Input 42V Alternator J2 14 Output J7 12 Supression Diode VIO GRN K9 Aux Contactor YEL BRN BLK ORN ORN ORN YEL BRN G J7 13 Key Switch Input J7 1 Interlock Input ORN GRA ORN ORN Safety Switch Relay signal from A5 Steer by Wire Controller 6 2 1 2 2 1 1 4 PINK TAN GRN BLU K14 Seat Switch S9 Emergency Stop Switch S15 Fe S13 Battery Interlock RED FROM F1 A3 Control Panel CAN BUS GRN YEL ...

Page 396: ... to provide positive voltage to circuit breaker VACC1 CB1 Circuit breaker VACC1 CB1 must be closed to provide positive voltage to the Side Broom Motor Contactor K8 coil The J2 15 Output on the A1 Main Machine Controller must provide a ground to the Side Broom Motor Contactor K8 coil J2 15 provides ground to K8 under the following conditions The A1 Main Machine Controller must receive a signal from...

Page 397: ...sist of the Side Broom Motors and Side Broom Gearbox The Side Broom Motor Assemblies are mounted on Side Broom Arm Assemblies connected to the side broom lift weldment Side Broom Actuator The Side Broom Actuator is on the upper hopper and lowers and raises the side broom lift weldment and attached side broom motor assemblies Side Broom Side Broom Side Broom Motor Side Broom Gearbox Side Broom Arm ...

Page 398: ... is engaged To Remove and Reinstall a Side Broom 1 Turn the key switch on raise the hopper to convenient height then turn the key switch off 2 Remove the key from the machine 3 Unscrew the Thumb Nut Weldment then remove the Side Broom and Side Broom Guard from the Side Broom Hub Assembly 4 Reinstall the Side Broom by following the above steps in reverse order Side Broom Guard Side Broom Hub Assemb...

Page 399: ...arbox assembly See the Removal and Installation section 2 Create witness marks on the gearbox motor end bells covers and the motor casing for reassembly 3 Loosen the wire retaining nut and remove the two through bolts Do not lose or damage the rubber washers 4 Remove the end cover Do not lose or damage the O ring seal O ring Carbon Brushes ...

Page 400: ... is approximately 13 16 20 mm 6 Reinstall the cover with O ring in place a Gently pry the carbon brushes back against their springs just far enough to slip them over the commutator b Gently slide the cover into place and align the witness marks made earlier 7 Reinstall the through bolts and tighten the wire retaining nut ...

Page 401: ...use F1 is blown Check the Fuse F1 and replace if necessary Circuit breaker CB7 is open Reset circuit breaker CB7 There is no voltage to the K8 contactor coil 1 Check circuit breakers CB1 and CB3 and reset if necessary 2 Check the K9 contactor coil resistance If the coil resistance is not 118 ohms 10 replace the contactor 3 Check the continuity through contactor K9 with the coil energized If the co...

Page 402: ...e and Reinstall a Side Broom Motor Assembly 1 Dump the hopper 2 Make sure the parking brake is engaged 3 Turn the key switch on and switch the machine to the Service Mode 4 Raise the hopper so the side brooms are at a convenient working height then support the hopper with jack stands or other suitable supports Warning Always make sure the raised hopper is adequately supported before performing any...

Page 403: ...the Side Broom Arm Assembly and can create pinch points 12 Remove the 1 2 13 x 75 Hex Screw and washer and carefully remove the Side Broom Assembly from the machine 13 Reinstall the side broom motor assembly by following the above steps in reverse order Service Note Use Loctite 242 blue on the 1 2 13 x 75 Hex Screw when you reinstall the Screw Service Note When you reinstall the Cable Assembly to ...

Page 404: ... Seez or equivalent anti seize compound before installing the Side Broom Hub Assembly To Remove and Reinstall the Side Broom Actuator 1 Dump the hopper 2 Make sure the parking brake is engaged 3 Turn the key switch on and switch the machine to the Service Mode 4 Raise the hopper far enough to minimize the weight of the side brooms on the actuator then support the hopper with jack stands or other s...

Page 405: ...otter Pin then slide the Side Broom Actuator off of the pin on the side broom lift weldment and remove it from the machine 9 Reinstall the Side Broom Actuator by following the above steps in reverse order Note Be careful not to rotate the Drive Nut Cylinder on the Side Broom Actuator when it s disconnected from the machine This can change the extended and retracted positions of the Side Broom Actu...

Page 406: ...on by rotating the Drive Nut Cylinder on the threaded shaft as necessary 6 Hold on to the drive nut cylinder to keep it from rotating then extend the side broom actuator using the Service Mode until the motor stops 7 Check the extended position dimension 8 If the distance is not correct remove the rubber adjuster cover from the end of the motor Then rotate the nylon nut found under the cover with ...

Page 407: ...Amps Side Broom Actuator 36 VDC 1 6 HP Motor to drive screw ratio 21 7 1 Drive Nut Cylinder Positions Retracted Position 8 00 Extended Position 9 75 Current Draw shop measurements Average 2 to 3 Amps Performance data for the following load conditions No load Full load Start Thrust 0 lbs Thrust 600 lbs Thrust 600 lbs Speed 39 in min Speed 30 in min Amps 1 4 Max Amps 6 7 1 0 Special Tools A long nee...

Page 408: ...sh the pedal forward the machine will move forward If you push it farther forward the machine will increase speed If you push the pedal backward the machine will move in reverse The drive pedal is spring loaded in the center or neutral position Drive Pedal Drive Controller Drive Wheel Motor Gearbox and Drive Wheel Drive Pedal The drive pedal is spring loaded in the neutral position The drive pedal...

Page 409: ...tation direction to propel the machine both forward and backward Gear Box The gear box provides gear reduction between the drive motor and the drive wheel It converts the plane of rotation from horizontal to vertical and it supports the weight of the machine There are no serviceable parts inside the gear box The gear box incorporates a large turning plate bearing that allows the box to pivot in or...

Page 410: ...pplies 5 volts out of pin J4 15 on the white black wire to the drive pedal sensor The voltage passes through the potentiometer resistive strip and returns to the drive controller on the violet black wire to pin J4 18 where it is grounded inside the controller The drive pedal sensor input wiper goes from the sensor on the brown red wire to pin J4 16 When the drive pedal is in the spring loaded neut...

Page 411: ...o be applied to the rotor Below is an oscilloscope waveform that shows the 3 phases of the motor U V and W when the motor is stationary You can see how all 3 phases are being pulsed in unison The vertical position of each trace was adjusted to separate them for better clarity Other wise all three would blend together as a single trace Below is an oscilloscope waveform that shows the 3 phases of th...

Page 412: ...ensors produce are slightly offset from one another This allows the controller to verify the rotation direction of the motor When both signals are low the next signal that switches high 5v indicates the rotation direction The drive motor also has an internal temperature sensor that is monitored by the drive motor controller The drive controller sends a 12v supply through an internal resistor and o...

Page 413: ...rubbing No Override Scrubbing Transport Hopper Down Scrubbing Override Transport Transport The main machine controller also communicates a special Push Mode request to the drive controller via the CAN Bus when initiated by the user Normally the drive motor locks the drive wheel to prevent it from rotating when in the neutral position The push mode allows the drive wheel to turn without resistance ...

Page 414: ...raction 414 Service Manual CS7000 Component Locations Drive Pedal Position Sensor Drive controller Drive Wheel Motor Pictured with recovery tank removed Drive Pedal Position Sensor Drive Controller Drive Wheel Motor ...

Page 415: ...sition Sensor does not require adjustment It comes with the pedal assembly and is pre adjusted If you believe it has come out of adjustment you can adjust it using a voltmeter With the key on and the sensor plugged in back probe the center wiper terminal with your red voltmeter lead Connect your black voltmeter lead to battery negative With the sensor mounting screws loose rotate the sensor body u...

Page 416: ... the code will follow the yellow LED then flashes the appropriate number of times for the first digit The red LED flashes twice to indicate that the second digit of the code will follow the yellow LED flashes the appropriate number of times for the second digit b The numerical codes used by the yellow LED are listed in the troubleshooting chart which also lists possible fault causes and describes ...

Page 417: ...splayed in reading order separated by commas and are sorted with the most recent at the top left See the Troubleshooting Chart below to look up what the code means e To exit press the solution button Summary of LED display formats The two LEDs have four different display modes indicating the type of information they are providing Types of LED Display Display Status Neither LED illuminated Controll...

Page 418: ...xternal short of phase U V or W motor connections 2 Motor parameters are mis tuned 3 Controller defective Set Phase current exceeded the current measurement limit Clear Cycle KSI 13 Current Sensor Fault ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle FullBrake ShutdownPump 1 Leakage to vehicle frame from phase U V or W short in motor stator 2 Controller defective Set Controlle...

Page 419: ... 6 Blown B fuse or main contactor did not close Set Capacitor bank voltage dropped below the Severe Undervoltage limit with FET bridge enabled Clear Bring capacitor voltage above Severe Undervoltage limit 18 Severe Overvoltage ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle FullBrake ShutdownPump 1 Battery menu parameters are misadjusted 2 Battery resistance too high for given...

Page 420: ...tery voltage during regen braking Controller is performance limited at this voltage 2 Battery parameters are misadjusted 3 Battery resistance too high for given regen current 4 Battery disconnected while regen braking 5 See Monitor menu Battery Capacitor Voltage Set Capacitor bank voltage exceeded the Overvoltage limit with the FET bridge enabled Clear Bring capacitor voltage below the Overvoltage...

Page 421: ...sn t use a motor thermistor Temp Compensation and Temp Cutback should be programmed Off Set Motor temperature is at or above the Temperature Hot parameter setting Clear Bring the motor temperature within range 29 Motor Temp Sensor Fault MaxSpeed reduced LOS Limited Operating Strategy and motor temperature cutback disabled 1 Motor thermistor is not connected properly 2 If the application doesn t us...

Page 422: ... short on driver load 2 Dirty connector pins 3 Bad crimps or faulty wiring Set Electromagnetic brake driver pin 5 is either open or shorted This fault can be set only when EM Brake Type 0 Clear Correct open or short and cycle driver 33 Coil3 Driver Open Short ShutdownDriver3 Note This circuit is not used on the CS7000 1 Open or short on driver load 2 Dirty connector pins 3 Bad crimps or faulty wir...

Page 423: ...lear Cycle KSI 39 Main Contactor Did Not Close ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle FullBrake ShutdownPump 1 Main contactor did not close 2 Main contactor tips are oxidized burned or not making good contact 3 External load on capacitor bank B connection terminal that prevents capacitor bank from charging 4 Blown B fuse Set With the main contactor commanded closed th...

Page 424: ...o pot low is too low Set Pot low pin 18 current exceeds 10mA Clear Clear pot low overcurrent condition and cycle KSI 46 EEPROM Failure ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle ShutdownInterlock ShutdownDriver1 ShutdownDriver2 ShutdownDriver3 ShutdownDriver4 ShutdownPD FullBrake ShutdownPump 1 Failure to write to EEPROM memory This can be caused by EEPROM memory writes i...

Page 425: ... KSI before the vehicle can operate Set Adjustment of a parameter setting that requires cycling of KSI Clear Cycle KSI 51 High Pedal Disable ShutdownMotor 1 There is an open in the interlock circuit J4 9 Seat Switch Emergency Switch Battery Interlock Steering Safety Relay Set The drive pedal is outside of the neutral position when there is no voltage to the interlock circuit J4 9 Clear Voltage is ...

Page 426: ...e ShutdownInterlock ShutdownDriver1 ShutdownDriver2 ShutdownDriver3 ShutdownDriver4 ShutdownPD FullBrake ShutdownPump 1 Internal controller fault Set Internal controller fault detected Clear Cycle KSI 72 PDO Timeout ShutdownInterlock CAN NMT State set to Pre operational 1 Time between CAN PDO messages received exceeded the PDO Timeout Period Set Time between CAN PDO messages received exceeded the ...

Page 427: ...I 89 Motor Type Fault ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle FullBrake ShutdownPump 1 The Motor_Type parameter value is out of range Set Motor_Type parameter is set to an illegal value Clear Set Motor_Type to correct value and cycle KSI 91 VCL OS Mismatch ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle ShutdownInterlock ShutdownDriver1 ShutdownDri...

Page 428: ...se input is stuck On Set Emergency Reverse was activated and ran until the EMR Timeout timer expired Clear Turn the emergency reverse input Off 98 Illegal Model Number ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle FullBrake ShutdownPump 1 Model_Number variable contains illegal value not 1234 1236 1238 or 1298 2 Software and hardware do not match 3 Controller defective Set Il...

Page 429: ...2 6v when in the center neutral position c If the voltage is not within the correct range loosen the sensor mounting screws and rotate the sensor to achieve the correct value Then tighten down the mounting screws Drive Motor and Gearbox Assembly The drive motor gearbox and drive wheel are removed as an assembly out of the bottom of the machine Once removed separate the motor from the gearbox 1 Rem...

Page 430: ...iring Label the drive motor cables for proper reassembly then remove them from the motor 7 Swing the controller bracket assembly out of the way reposition the steering motor wiring as needed 8 Working from under the machine remove the cover plate that is under the steering drive gear There are two screws on each side 9 Lift the squeegee lift bar and tie it up 10 Block drive wheel with wheel chocks...

Page 431: ...ox and remove the remaining 4 gear box to frame bolts 13 Attach a lifting strap around the drive motor You will use the strap to guide and lower the assembly 14 Slowly lift the machine up to allow the drive motor and gear box assembly to come out the bottom while holding the motor assembly upright using the lifting strap 15 Secure the machine safely on jack stands Remove 2 Loosen 4 ...

Page 432: ...e movement by lowering the hoist and blocking the wheel 17 To separate the motor from the gear box remove the attaching screws and pry apart 18 Reassembly notes a Be sure to apply anti seize compound to the motor shaft splines and gearbox splines b If installing a new gear box be sure to fill it to the bottom of the fill plug with 80W90 oil when the assembly is installed Holds 2 2L 59 Gal Part num...

Page 433: ...er 1 Disconnect the main power connector 2 Remove the recovery tank 3 Label the power and motor cables to aid in correct reassembly 4 Remove the bolts securing the motor and power cables 5 Disconnect the low current connector 6 Remove controller attaching screws and remove the controller 7 Reassemble in reverse order When attaching cables use the correct hardware in the correct order to avoid dama...

Page 434: ...N Key switch input Provides logic power for the controller and power for the coil drivers 38 12 V 2 Not Used 3 Not Used 4 Not Used 5 Not Used 6 VIO GRN K7 Wheel Drive Contactor Driver Momentary 38 V at first key on 5 6v when contactor is on 7 BLK PINK Input and output ground reference 0 008 V 8 TAN RED Motor Temperature Sensor 1 22 V Room Temp 12 V open circuit 9 GRN BLU Interlock Switch Input 38 ...

Page 435: ...tor Encoder Speed Sensor Signal Phase B 4 06 V or 0 08 V stationary 2 0 V wheel spinning any speed 33 Not Used 34 Not Used 35 GRN CAN Bus Low 2 45 V Motor U V and W Terminal Pair Voltages U to V 0 3 2 2 VAC with stationary motor Up to 26 VAC with wheel off ground and full forward speed V to W 0 3 2 2 VAC with stationary motor Up to 26 VAC with wheel off ground and full forward speed W to U 0 3 2 2...

Page 436: ...unctions Measured with amp clamp around battery positive feed to drive controller Approximately 1 4 amps when the machine begins to move Average 51 amps full speed with maximum scrub pressure Max 100 Amps Wheel Drive Contactor Winding 194 Ohms Special Tools Curtis Programmer 1311 Part number 56409441 ...

Page 437: ...ms The Wheels are held onto the Brake and Spindle Assemblies with Slotted Nuts and Cotter Pins The Brake and Spindle Assemblies are fastened to the machine frame with 1 2 20 Hex Screws A Brake Rod from the Brake Pedal Assembly actuates the pivoting Brake Bar Weldment The Brake Bar Weldment actuates the two individual brake levers on the Brake and Spindle Assemblies via Clevis Yokes and attached Br...

Page 438: ...k on the Clevis Yoke then pull it toward you to remove it from the Clevis Yoke 3 Lift the Clevis Yoke out of the Brake Bar Weldment This will allow the Clevis Yoke to rotate on the Brake Rod 4 Rotate the Clevis Yoke on the Brake Rod to effectively lengthen or shorten the Brake Rod Note that lengthening the Brake Rod will apply more pressure to the brakes with comparable brake pedal travel 5 When t...

Page 439: ... Check the wheel wheel bearings and brake and spindle assembly and replace as required The wheel and or brake and spindle assembly are damaged The brakes are not working correctly The brakes are out of adjustment Adjust the brakes The brake linings are worn out Replace the brake linings Removal and Installation Warning Before performing any maintenance or adjustments make sure the key switch is of...

Page 440: ...g point 2 Install safety stands or blocks to support the machine while you work on it 3 Remove the Wheel from the Brake and Spindle Assembly 4 Remove the Nyloc nut and 1 4 20 screw holding the Rod End to the Brake Lever 5 Remove the two 1 2 20 hex screws and remove the Brake and Spindle Assembly from the machine 6 Reinstall the Brake and Spindle Assembly by following the above steps in reverse ord...

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Nilfisk-Advance CS7000 Fuel Cell EcoFlex, Service Manual

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Summary of Contents for CS7000 Fuel Cell EcoFlex

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