Nilfisk-Advance CS7000 Fuel Cell EcoFlex User manual

CS7000™
05/11 Revised 02/13 Form No. 56043151
Service Manual
Advance CS7000 Hybrid LPG, Model Number 56509000
Advance CS7000 Hybrid Diesel, Model Number 56509001
Advance CS7000 B, Model Number 56509002
Advance CS7000 Hybrid LPG EcoFlex™, Model Number 56509006
Advance CS7000 Hybrid Diesel EcoFlex™, Model Number 56509007
Advance CS7000 B EcoFlex™, Model Number 56509008
Advance CS7000 Fuel Cell EcoFlex™, Model Number 56383115
Advance CS7000 Hybrid Gasoline EcoFlex™, Model Number 56511001
Nilfisk CS7000 Hybrid LPG EU, Model Number 56509003
Nilfisk CS7000 Hybrid Diesel EU, Model Number 56509004
Nilfisk CS7000 Battery EU, Model Number 56509005
Nilfisk CS7000 Hybrid Petrol EcoFlex™, Model Number 56111002
English

Contents iiService Manual – CS7000
Contents
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
General Machine Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Service Manual Purpose and Application . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Other Reference Manuals and Information Sources . . . . . . . . . . . . . . . . . . . . . 14
Nilsk-Advance Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Engine Manufacturers’ Technical Manuals. . . . . . . . . . . . . . . . . . . . . . .15
Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Parts and Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Cautions and Warning Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Hopper Prop Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
To Engage the Hopper Prop Rod . . . . . . . . . . . . . . . . . . . . . . . . . . 18
To Disengage the Hopper Prop Rod. . . . . . . . . . . . . . . . . . . . . . . . .18
Jacking the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Transporting the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Towing the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Diagnostic and Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Technical Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
General Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Fastener Torque Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Overall Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Recommended Service Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Daily Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Maintenance Every 15 to 20 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Monthly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Maintenance Every 150 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Maintenance Every 400 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Maintenance Every 800 to 1000 Hours . . . . . . . . . . . . . . . . . . . . . . . . . 28
Maintenance Every 1500 Hours. . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Maintenance Every 1900 Hours. . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Maintenance Every 2000 Hours. . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
EcoFlex System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
To Purge When Changing Detergents (the scrub system must be off) . . . . . . 31
To Purge Weekly (the scrub system must be off). . . . . . . . . . . . . . . . . .31
To Change the Detergent Mix Ratio (the scrub system must be on) . . . . . . . 32
PM Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Machine Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Control Panel - General
Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Miscellaneous Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Miscellaneous Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Scrub Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Scrub Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Sweep Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Sweep Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Hopper Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
LCD Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
General Displays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Battery Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Contents iiiService Manual – CS7000
LPG Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Diesel Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Broom Adjustment (Battery, LPG and Diesel) . . . . . . . . . . . . . . . . . . .41
Battery Charge Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Fault, Caution and Warning Displays . . . . . . . . . . . . . . . . . . . . . . . . . 42
Fault Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Caution Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Warning Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Foot Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Chassis System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Component Locations - Battery Machine (major components) . . . . . . . . . . . . . . . .45
Component Locations - LPG and Diesel Machine (major components) . . . . . . . . . . . 46
Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
CAN Bus Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
CAN BUS message routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Main Machine Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Drive Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Steering Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Fault Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Fault Code Table (Main machine controller) . . . . . . . . . . . . . . . . . . . . . . 54
Hidden Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Conguration Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Conguration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
User Options Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Service Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
To Operate:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Control Panel LEDs all stay lit - CAN Bus problems . . . . . . . . . . . . . . . . .72
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Main Machine Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Shop Measurements – Main Machine Controller . . . . . . . . . . . . . . . . . . . 75
J2 Connector (White) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
J3 Connector (Gray) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
J7 Connector (Black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Dust Control/DustGuard™ Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Dust Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
DustGuard™ Spray System (optional) . . . . . . . . . . . . . . . . . . . . . . . 81
DustGuard™ System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 82
Circuit Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Impeller and Filter System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Dust Control Filter Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
DustGuard™ Spray System. . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
To Clean the Dust Control Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
To Remove the Dust Control Filter . . . . . . . . . . . . . . . . . . . . . . . . .87

Contents ivService Manual – CS7000
To Clean the Dust Control Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 88
To Reinstall the Dust Control Filter . . . . . . . . . . . . . . . . . . . . . . . . 88
To Clean the DustGuard™ Strainer Screen . . . . . . . . . . . . . . . . . . . . . . 89
To Clean the DustGuard™ Spray Nozzles . . . . . . . . . . . . . . . . . . . . . . . 90
To Adjust the DustGuard™ Spray Nozzles . . . . . . . . . . . . . . . . . . . . . . .90
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
To Remove and Reinstall the DustGuard™ Solenoid Valve Assembly . . . . . . . . 93
To Remove and Reinstall the DustGuard™ Pump . . . . . . . . . . . . . . . . . . .94
To Remove and Reinstall the Dust Control Filter Switch . . . . . . . . . . . . . . . 95
To Remove and Reinstall the Impeller Assembly . . . . . . . . . . . . . . . . . . . 95
To Disassemble and Reassemble the Impeller Assembly . . . . . . . . . . . . . . .96
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Wiring Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Current Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
42 Volt Alternator (Generator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Low Voltage Cutout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
42 Volt Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Incandescent Headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
LED Headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Electrical Panel Contactor/Relay location. . . . . . . . . . . . . . . . . . . . . . . . . . 107
Harness to Harness Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Connector Pin-Outs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Component ID to Connector ID Look Up Table . . . . . . . . . . . . . . . . . . . 109
Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
K14 Safety Relay and K15 Auxiliary Relays . . . . . . . . . . . . . . . . . . . . . 131
Early Style K14 Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Early Style K15 Auxiliary Relay . . . . . . . . . . . . . . . . . . . . . . . . . 131
Late style K14 Safety Relay and K15 Auxiliary Relay . . . . . . . . . . . . . 132
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Charging the Battery (Battery Model) . . . . . . . . . . . . . . . . . . . . . . . . 133
Generator Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
42 volt generator is not charging . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Insufcient machine operation time (Battery Model) . . . . . . . . . . . . . . . . 133
Insufcient machine operation time with engine off (Hybrid models). . . . . . . . 133
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
42 volt Generator Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
42 volt Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Generator Drive Belt Tensioner. . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Head Light bulb - Standard 12v Halogen. . . . . . . . . . . . . . . . . . . . . . . 137
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Battery (Battery Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Low Voltage Cut Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Battery Run Time (Battery powered machine) . . . . . . . . . . . . . . . . . . . . 138
Current Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Engine System, Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157

Contents vService Manual – CS7000
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Engine starter control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Fuel pump control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Engine Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Over Temperature Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Low Oil Pressure Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Engine RPM control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Glow plug control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Diesel Engine Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . 168
Change Engine Oil and Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Change Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Replace Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Bleed Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Inspect Air Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Replace Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
No crank – The starter does not engage . . . . . . . . . . . . . . . . . . . . . . . 172
Cranks but does not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Cannot Achieve Either Run or Maximum Engine Speed Settings (Run 2200 RPM, Maximum
Power 2400 RPM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Compression Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Engine Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Fuel Pump; . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Engine Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Engine Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Engine Oil Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Engine Oil Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Radiator Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Shop Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Engine RPM Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Engine Compression. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Fuel System Return Fuel Flow . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Glow Plug Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Engine System - LPG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Circuit Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Engine Starter Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Throttle Control Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Ignition Off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Ignition On. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Cranking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Normal Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Engine RPM Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Normal Engine Shut Off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Step One . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

Contents viService Manual – CS7000
Step Two . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Engine Overheat Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Lost Oil Pressure Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Change Engine Oil and Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Change Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Inspect Air Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Replace Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Checking Spark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Checking LPG Primary Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
No crank - The starter does not engage. . . . . . . . . . . . . . . . . . . . . . . . 202
Cranks but does not start – No Spark . . . . . . . . . . . . . . . . . . . . . . . . 203
Cranks but does not start (has sufcient spark) . . . . . . . . . . . . . . . . . . . 203
Achieves one but not ALL RPM modes.. . . . . . . . . . . . . . . . . . . . . . . . 204
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Engine Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Engine OIl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Engine Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Shop Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Spark Controller Measurements: . . . . . . . . . . . . . . . . . . . . . . . . . 207
Governor Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Woodward L Series Actuator Measurements . . . . . . . . . . . . . . . . . . 207
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Engine System - Petrol (Gasoline) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Kubota WG972-GL-E3-NFK-1 Petrol (Gasoline) . . . . . . . . . . . . . . . . . . . 210
Circuit Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Engine Starter and Carburetor Choke Control . . . . . . . . . . . . . . . . . 213
Throttle Control Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Ignition Off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Ignition On. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Cranking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Normal Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Engine RPM Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Normal Engine Shut Off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Engine Overheat Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Lost Oil Pressure Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Engine Right Side View (Toward front of machine) . . . . . . . . . . . . . . . . . 222
Engine Back Side View (Toward right of machine) . . . . . . . . . . . . . . . . . 223
Engine Left Side View (Toward back of machine) . . . . . . . . . . . . . . . . . 223
Fuel Tank Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Change Engine Oil and Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Change Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Inspect Air Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

Contents viiService Manual – CS7000
Replace Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Checking Spark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
No crank - The starter does not engage. . . . . . . . . . . . . . . . . . . . . . . . 228
Cranks but does not start – No Spark . . . . . . . . . . . . . . . . . . . . . . . . 229
Cranks but does not start (has sufcient spark) . . . . . . . . . . . . . . . . . . . 229
Achieves one but not ALL RPM modes.. . . . . . . . . . . . . . . . . . . . . . . . 230
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Engine Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Engine Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Shop Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Spark Controller Measurements: . . . . . . . . . . . . . . . . . . . . . . . . . 233
Governor Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Woodward L Series Actuator Measurements . . . . . . . . . . . . . . . . . . 233
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Hopper System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Hopper System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Hopper Hydraulic System Circuit Details . . . . . . . . . . . . . . . . . . . . . . 238
Hopper at Rest. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Hopper Being Raised . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Hopper Being Lowered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Circuit Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
The Following Conditions Must Be Met for the Hopper to be Raised and Lowered239
The Following Conditions Must Be Met for the Hopper Door Open and Close 240
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Upper and Lower Hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Hydraulic Power Pack Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
Hopper Dump Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Hopper Dump Door Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Dump Door Extend and Retract Limit Switches . . . . . . . . . . . . . . . . . . . 242
Hopper Interlock Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Hopper Prop Rod and Pull Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
To Remove and Reinstall the Hydraulic Power Pack Assembly . . . . . . . . . . . 245
LPG and Diesel Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
Battery Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
To Remove and Reinstall the Hopper Lift Cylinder . . . . . . . . . . . . . . . . . 249
To Replace the Oil in the Hydraulic System . . . . . . . . . . . . . . . . . . . . . 252
To Remove and Reinstall the Hopper Dump Door Actuator Assembly . . . . . . . 261
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Options and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263
Recovery System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
Recovery System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 274
Circuit Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276

Contents viiiService Manual – CS7000
Recovery Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Recovery Tank Cover and Debris Basket . . . . . . . . . . . . . . . . . . . . . . . 276
Vacuum Fan Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Vacuum Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Float Cage and Ball Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
To Clean the Vacuum Filter and Filter Screen . . . . . . . . . . . . . . . . . . . . 278
To Clean the Debris Basket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
To Remove the Recovery Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
To Reinstall the Recovery Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
To Remove and Reinstall a Vacuum Motor . . . . . . . . . . . . . . . . . . . . . . 284
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
Scrub System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
Scrub Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
Scrub System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
Circuit Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
The Following Conditions Must be Met for the Scrub System To Operate . . . 288
Scrub Deck Actuator Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
Brush Current Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
Scrub Motor Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
Right Scrub Arm Gas Spring and Lever Arm Bracket . . . . . . . . . . . . . . . . 289
Side Squeegee Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
Scrub Deck Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
To Replace a Leading Deck Blade. . . . . . . . . . . . . . . . . . . . . . . . . . . 291
To Replace a Trailing Deck Blade. . . . . . . . . . . . . . . . . . . . . . . . . . . 291
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
To Remove and Reinstall a Side Squeegee Assembly . . . . . . . . . . . . . . . . 293
To Remove and Reinstall the Scrub Deck Actuator . . . . . . . . . . . . . . . . . 294
To Remove and Reinstall the Scrub Deck. . . . . . . . . . . . . . . . . . . . . . . 294
To Remove and Reinstall a Scrub Motor Assembly . . . . . . . . . . . . . . . . . 297
To Replace the Scrub Motor Carbon Brushes . . . . . . . . . . . . . . . . . . . . 298
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
Solution System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .303
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Solution Flow Control - Non-EcoFlex™ Machines . . . . . . . . . . . . . . . . . . 303
Solution Flow Control - EcoFlex™ Machines . . . . . . . . . . . . . . . . . . . . .303
EcoFlex™ Detergent System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
Extended Scrub System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
Optional Hot Water System (LP and Diesel EcoFlex™ Machines Only) . . . . . . 304
Optional Wash Hose Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
Optional High-pressure Spray System (LP and Diesel Only) . . . . . . . . . . . . 305
Solution Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
Solution System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
Circuit Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
The Following Conditions Must be Met for the Solution System to Operate . . 307

Contents ixService Manual – CS7000
The Following Conditions Must be Met for the Extended Scrub System to Operate
307
The Following Conditions Must be Met for the Low Pressure Wash Hose to Operate
308
The Following Conditions Must be Met for the EcoFlex™ System to Operate . 308
The Following Conditions Must be Met for the High-pressure Spray System to Operate
308
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
Solution Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
Drain Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
Solution Filter and Solution Shutoff Valve. . . . . . . . . . . . . . . . . . . . 309
Solution Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
Solution Pump (EcoFlex™ Models Only) . . . . . . . . . . . . . . . . . . . . . . . 310
Low Pressure (Wash Hose) Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 310
Solution Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
Solution Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
EcoFlex™ Detergent Bottles and Pumps . . . . . . . . . . . . . . . . . . . . . . . 312
High-pressure Spray System Pump. . . . . . . . . . . . . . . . . . . . . . . . . . 312
Extended Scrub System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
To Clean the Solution Filter Screen. . . . . . . . . . . . . . . . . . . . . . . . . . 314
To Clean the Extended Scrub System Strainer . . . . . . . . . . . . . . . . . . . 315
To Clean the High Pressure Solution Filter . . . . . . . . . . . . . . . . . . . . . 315
To Adjust the Belt Tension on the High Pressure Pump. . . . . . . . . . . . . . . 316
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
To Remove and Reinstall the Solution Tank . . . . . . . . . . . . . . . . . . . . . 320
To Remove and Reinstall the Solution Shutoff Valve . . . . . . . . . . . . . . . . 324
To Remove and Reinstall the Solution Filter Assembly . . . . . . . . . . . . . . . 324
To Remove and Reinstall the Solution Solenoid Valve. . . . . . . . . . . . . . . . 325
To Remove and Reinstall a Detergent Pump (EcoFlex™ Models Only) . . . . . . . 325
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
Squeegee System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
Squeegee System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 329
Circuit Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
To Remove and Reinstall the Squeegee Blades. . . . . . . . . . . . . . . . . . . . 331
To Remove and Reinstall the Front Squeegee Blade . . . . . . . . . . . . . . 331
To Remove and Reinstall the Rear Squeegee Blade . . . . . . . . . . . . . . . 332
Squeegee End Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
Squeegee Caster Wheel Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
To Adjust the Squeegee Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
To Adjust the Squeegee Casters. . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
To Remove and Reinstall the Squeegee Support Assembly . . . . . . . . . . . . . 336
To Remove and Reinstall the Squeegee Lift Arm . . . . . . . . . . . . . . . . . . 336
To Remove and Reinstall the Squeegee Lift Actuator . . . . . . . . . . . . . . . . 337
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .339

Contents xService Manual – CS7000
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
Steering Wheel Rotation Sensor . . . . . . . . . . . . . . . . . . . . . . . . . 339
Steering Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
Steering Travel Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . 341
Steering Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
Steering System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
Circuit Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
Diagnostic Trouble Codes (DTCs) . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
To retrieve steering system codes from the “hidden menu”:. . . . . . . . . . . 348
Diagnostic Trouble Code Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
Symptom Troubleshooting (No DTC stored) . . . . . . . . . . . . . . . . . . . . . 353
Steering Inoperative - Steering Controller Status LED is Blinking Rapidly . 353
Steering Inoperative - Steering Controller Status LED is Off . . . . . . . . . 353
Steering Inoperative - Steering Controller Status LED is On Steady . . . . . 353
No “Steering Feel” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
Steering Wheel Is Difcult To Turn . . . . . . . . . . . . . . . . . . . . . . . 353
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
Steering Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
Steering Wheel Rotation Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
Steering Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
Steering Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
Shop Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
Steering Wheel Rotation Sensor Voltage Measurements . . . . . . . . . . . . 360
Steering Controller Voltage Measurements . . . . . . . . . . . . . . . . . . . 361
J5 Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
Motor U, V and W Terminal Pair Voltages. . . . . . . . . . . . . . . . . . . . 362
Motor U, V and W Terminal Pair Frequency. . . . . . . . . . . . . . . . . . . 362
System Current Draw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
Steering Contactor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
Sweep System, Main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
Main Sweep System Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . 364
Circuit Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
The Following Conditions Must be Met for the Main Sweep System To Operate365
Main Broom Actuator Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
Broom Current Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
Main Broom and Drive Components . . . . . . . . . . . . . . . . . . . . . . . . . 366
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
To Adjust the Main Broom Height . . . . . . . . . . . . . . . . . . . . . . . . . . 367
To Adjust the Main Broom Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
Inspecting/Replacing Main Broom Motor Carbon Brushes. . . . . . . . . . . . . . . . . 369
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
To Remove the Main Broom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
To Install the Main Broom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
To Remove and Reinstall the Broom Motor Assembly . . . . . . . . . . . . . . . . 375
To Remove and Reinstall the Broom Lift Actuator. . . . . . . . . . . . . . . . . . 376

Contents xiService Manual – CS7000
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
Sweep System, Side Broom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
Side Broom System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 380
Circuit Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
The Following Conditions Must be Met for the Side Broom Sweep System To Operate
381
Side Broom Actuator Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
Side Brooms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
Side Broom Motor Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
Side Broom Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
To Remove and Reinstall a Side Broom. . . . . . . . . . . . . . . . . . . . . . . . 383
Inspecting/Replacing Side Broom Motor Carbon Brushes . . . . . . . . . . . . . . . . . 384
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
To Remove and Reinstall a Side Broom Motor Assembly . . . . . . . . . . . . . . 387
To Remove and Reinstall a Side Broom Hub Assembly . . . . . . . . . . . . . . . 389
To Remove and Reinstall the Side Broom Actuator . . . . . . . . . . . . . . . . . 389
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
Wheel System, Non-Traction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
To Adjust the Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
To Remove and Reinstall a Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . 395
To Remove and Reinstall a Brake and Spindle Assembly . . . . . . . . . . . . . . 396
Wheel System, Traction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
Drive Pedal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
Drive Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
Drive Wheel Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
Gear Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
Circuit Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
Powering up the Drive Controller . . . . . . . . . . . . . . . . . . . . . . . . 398
Drive Pedal Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
CAN Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Drive Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Drive Pedal Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Gear Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
Fault Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
Summary of LED display formats. . . . . . . . . . . . . . . . . . . . . . . . . . . 406
Troubleshooting Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
Troubleshooting Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
Fault History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
Drive Pedal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
Drive Motor and Gearbox Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 418

Contents xiiService Manual – CS7000
Drive Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
Drive Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
Shop Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
Drive Controller Voltage Measurements . . . . . . . . . . . . . . . . . . . . . 423
Low Current 35 Pin Connector (J4). . . . . . . . . . . . . . . . . . . . . . . . 423
Motor U, V and W Terminal Pair Voltages. . . . . . . . . . . . . . . . . . . . 424
Motor U, V and W Terminal Pair Frequency. . . . . . . . . . . . . . . . . . . 424
System Current Draw - Driving only with no cleaning functions . . . . . . . . 425
Wheel Drive Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425

13Service Manual – CS7000 13
General Information
General Machine Description
The CS7000 machines are industrial automatic rider sweeper/scrubbers with multiple sweep/scrub single-
pass coverage. Both battery (all electric) and hybrid (LPG and diesel) models are available with or without
the EcoFlex™and DustGuard™options. The scrub system uses three disc scrub brushes with variable scrub
pressure and solution ow rates. The sweep system has a center main broom and left- and right-hand side
brooms.
A fuel cell powered model has also been added. It is virtually a battery model that has had the large mono-
block battery replaced with a fuel cell provided by Plug Power.
Service Manual Purpose and Application
This Service Manual a technical resource designed to aid service personnel in maintaining and repairing the
CS7000 Sweeper/Scrubber to ensure optimum performance and long service life. Please read it thoroughly
before servicing your machine.
Revision History
• 8/11 - Not available
• 6/12
– General Information - Technical specications table updated
– Control System - Updated Conguration Display, Conguration Menu and User Options Menu
Sections. Added “Power Distribution Fault” to fault code table. Updated installation instructions fro
main machine controller.
– Electrical System - Added information on new LED headlights. Added wiring connection diagram for
K14 Safety Relay and K15 Auxiliary Relay
– Engine LPG - Updated Functional Description of engine RPM control. Updated Troubleshooting for
RPM Control problem.
• 2/13
– General Information - Introduce Fuel Cell powered model
– Engine System, Petrol (Gasoline) - Add new chapter
– Electrical System - Updated wiring diagram
– Wheel System, Traction - Add information on fastening electrical cables to the drive controller.

General Information 14Service Manual – CS7000
Other Reference Manuals and Information Sources
Nilfisk-Advance Publications
Model Name Model
Number
Instructions for Use
Form Number
Parts List
Form
Number
Advance CS7000 Hybrid LPG 56509000
56041979: English, Spanish,
French 56042540
Advance CS7000 Hybrid Diesel 56509001
Advance CS7000 B 56509002
Advance CS7000 Hybrid LPG EcoFlex™ 56509006
Advance CS7000 Hybrid Diesel EcoFlex™ 56509007
Advance CS7000 B EcoFlex™ 56509008
Nilsk-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, Latvian,
Lithuanian,
Slovenian
56041985: Slovakian, Czech,
Polish, Hungarian
56042541
Nilsk-Advance CS7000 Hybrid Diesel EU 56509004
Nilsk-Advance CS7000 Battery EU 56509005
These manuals can be found on the following Nilsk-Advance’s electronic supported databases:
• Nilsk-Advance Dealer Customer Zone
• Nilsk-Advance website: www.Nilsk-Advance-us.com
• EzParts service / parts CD-ROM

General Information 15Service Manual – CS7000
Engine Manufacturers’ Technical Manuals
Engine Model Publication Title
Diesel: D1305-E3B-KEA-1 Kubota WSM Workshop Manual, Diesel Engine,
05-E3B Series, 05-E3BG Series
LPG: WG972-GL-E3-NFK-1 Kubota WSM Workshop Manual, Gasoline, LPG
Engine, WG752-G-E3, WG752-GL-E3,
WG972-G-E3, WG972-GL-E3
Conventions
All references to right, left, front and rear in this manual are as seen from the Operator’s seat position.
Parts and Service
Repairs should be performed by an Authorized Nilsk-Advance Service Center that employs factory-trained
service personnel and maintains an inventory of Nilsk-Advance original replacement parts and accessories.
Call the Nilsk-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, afx service sticker here.)
*Note: On Fuel Cell models, all issues related to the fuel cell must be referred to Plug Power, not
Nilsk-Advance.
Nameplate
The Part (Model) Number and Serial Number of your
machine are shown on the Nameplate located on the top of
the machine frame, at the left rear side of the machine
underneath the recovery tank. To access the Nameplate, tip
the recovery tank out away from the machine.
This information is needed when ordering repair parts for the
machine.

General Information 16Service Manual – CS7000
Cautions and Warning Symbols
Nilsk-Advance uses the symbols below to signal potentially dangerous conditions. Read this information
carefully and take the necessary steps to protect personnel and property.
Danger! Is used to warn of immediate hazards that will cause severe personal injury or death.
Warning! Is used to call attention to a situation that could cause severe personal injury.
Caution! Is used to call attention to a situation that could cause minor personal injury or
damage to the machine or other property.
General Safety Instructions
Warning! Be sure to follow these safety precautions to avoid situations that could cause
severe personal injury.
• This machine should only be used by properly-trained and authorized persons.
• While on ramps or inclines, avoid sudden stops when loaded. Avoid abrupt sharp turns. Use low
speed down hills. Clean only while ascending (driving up) the ramp.
• Keep sparks, ame 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 ame. Do not smoke while charging the batteries.
• Remove all jewelry when working near electrical components.
• Turn the Key Switch off (O) and disconnect the batteries before servicing electrical components.
• Never work underneath a machine without safety blocks or stands to support the machine.
• Do not dispense ammable cleaning agents, operate the machine on or near these agents, or
operate in areas where ammable liquids exist.
• To avoid hydraulic oil injection or injury, always wear appropriate clothing and eye protection
when working with or near any hydraulic system.
• Do not operate this machine on ramps or inclines of more than a two-percent gradient.
• Only use the brushes provided with the machine or those specied in the instruction manual.
The use of other brushes may impair safety.
Caution! Do not pressure-wash the operator control panel, fuse panel, contactor panel or
engine compartment area.

General Information 17Service Manual – CS7000
Caution! Be sure to follow these safety precautions to avoid situations that could cause
personal injury, damage to property or equipment damage.
• This machine is not approved for use on public paths or roads.
• This machine is not suitable for picking up hazardous dust.
• Use care when using scarier discs and grinding stones. Nilsk-Advance will not be held
responsible for any damage to oor surfaces caused by scariers or grinding stones.
• When operating this machine, make sure that bystanders, particularly children, are not
endangered.
• Before performing any service function, carefully read all instructions pertaining to that
function.
• Do not leave the machine unattended without rst turning the Key Switch off (O), removing the
key and securing the machine.
• Apply the parking brake before exiting the Operator’s seat.
• Turn the Key Switch off (O) and remove the key before changing the brushes, and before
opening any access panels.
• Take precautions to prevent hair, jewelry or loose clothing from becoming caught in moving
parts.
• Use caution when moving this machine in below-freezing temperature conditions. Any water in
the solution or recovery tanks, or in the hose lines could freeze, causing damage to valves and
ttings. Flush with windshield washer uid.
• The batteries must be removed from the machine before the machine is scrapped. Disposal of
the batteries should be done safely and in accordance with your local environmental regulations.
• Do not use on surfaces having a gradient exceeding that marked on the machine.
• All doors and covers are to be positioned as indicated in the instruction manual before using the
machine.
• Refer to the Electrical System section in this manual for additional specic battery charger
warnings.

General Information 18Service Manual – CS7000
Hopper Prop Rod
Warning! Never work underneath the raised hopper without the hopper prop rod engaged.
To Engage the Hopper Prop Rod
1. Press and hold the hopper raise button to 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. 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 Rod away from the Hopper Lift Cylinder.
3. Press and hold the hopper lower button to lower the
hopper.
Hopper
Prop
Rod
Hopper
Lift
Cylinder
Pull
Rod

General Information 19Service Manual – CS7000
Jacking the Machine
Warning! Never work under a machine without safety stands or blocks to support the machine.
When jacking the machine, do so at the designated Tie Down/Jacking Locations.
Transporting the Machine
Caution! Before transporting the machine on an open truck or trailer, make sure the machine
is tied down securely and all access doors and covers are secured (tape and strap as
needed).
The jacking and tie-down locations are identied 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/Tie-down LocationFront Jacking/Tie-down Location
Jacking/
Tie-down
Location

General Information 20Service Manual – CS7000
Towing the Machine
Caution! If the machine must be towed, move the machine for short distances only and do not
move the machine faster than a normal walking pace (2-3 mph, 3-5 kph).
Tow the machine backward from one of the rear frame tie-down locations as shown
below. Do not push the machine due to the possibility of damage to the solution and
recovery tanks.
Do not tow the machine by the squeegee tool.
• To enter the “Push Mode”, which allows steering while towing
the machine, turn the Key Switch on while pressing and
holding both the Speed Switch and the High Pressure Wand
Switch.
• On machines not equipped with a squeegee
guard kit, tow the machine by one of the two
Tie-down Slots on the chassis (shown in green).
• On machines equipped with a squeegee guard
kit, tow the machine by the two Tie-down Slots
on the squeegee guard (shown in red).
Press and hold
while turning key
switch on to enter
Push Mode
Tie-down
Slot (2)
Tie-down
Slot (2)