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Crescent CS7010 User Manual

Crescent CS7010
329 pages
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CS7010
www.crescentindustrial.co.uk
Service
Manual

Table of Contents

Other manuals for Crescent CS7010

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Crescent CS7010 Specifications

General IconGeneral
ModelCS7010
CategoryScrubber
Power SourceElectric
TypeWalk-behind
Brush Deck Size710 mm
Frequency60 Hz
Brush Width710 mm

Summary

General Information

General Machine Description

Overview of the CS7010 sweeper/scrubber, its capabilities, and model variants.

Service Manual Purpose and Application

Defines the manual's role as a resource for service personnel.

Revision History

Records changes and updates made to the service manual.

Other Reference Manuals and Information Sources

Lists related manuals and information sources for Nilfisk-Advance equipment.

Conventions

Explains terms and references used in the manual for clarity.

Parts and Service

Details requirements for performing repairs and obtaining parts.

Nameplate

Locates and describes the machine's identification nameplate.

Safety

Symbols

Explains hazard symbols used in the manual for safety recognition.

General Safety Instructions

Provides essential safety warnings and precautions for operating the machine.

Property Damage Messages

Lists important guidelines to prevent damage to the machine and property.

Hopper Prop Rod

Details the procedure for engaging and disengaging the hopper prop rod.

Lifting the Machine

Provides safety precautions and guidelines for lifting the machine.

Transporting the Machine

Outlines procedures and safety measures for transporting the machine.

Towing the Machine

Explains the correct procedures and precautions for towing the machine.

Diagnostic and Service Tools

Lists essential tools required for troubleshooting and repair.

Technical Specifications

General Specifications

Lists key technical specifications for various CS7010 models.

Overall Dimensions

Provides dimensional data for the machine.

Fastener Torque Specifications

Details torque specifications for fasteners used in machine assembly.

Maintenance

Maintenance Schedule

Outlines recommended maintenance intervals for optimal machine performance.

Recommended Service Materials

Lists specific lubricants, fluids, and materials for servicing the machine.

Routine Maintenance

Details regular maintenance tasks to be performed on the machine.

Lubrication Points

Identifies key lubrication points on the machine for proper upkeep.

EcoFlex System Maintenance

Provides procedures for maintaining the EcoFlex detergent system.

PM Checklist

A checklist for periodic maintenance inspections and defect tracking.

Machine Controls

Control Panel - General Layout

Overview of the CS7010 control panel layout and component grouping.

Miscellaneous Controls

Details the function of various miscellaneous controls on the panel.

Scrub Controls

Explains the operation and functions of the scrub system controls.

Sweep Controls

Describes the operation and functions of the sweep system controls.

Hopper Controls

Details the operation and functions of the hopper control buttons.

OLED Display

Explains the indicators and icons displayed on the OLED screen.

Steering Wheel

Describes the steer-by-wire system and steering wheel operation.

Foot Pedals

Explains the function of the drive and brake pedals.

Control System

Functional Description

Overview of the CS7010's distributed controller network.

Functional Diagram

Illustrates the interconnections of the machine's control system components.

Power Modules

Details the function and role of the system's power modules.

CAN Bus Communication

Explains the CAN Bus communication protocol used in the machine.

Component Locations

Identifies the physical locations of key control system components.

Main Machine Controller Programming

Describes how to program the Main Machine Controller for machine functions.

Service Mode Access

Procedure for entering Service Mode to access advanced configurations.

Menu Navigation

Explains how to navigate through the machine's menu system.

Programming Menu Outline

Provides an overview of the available programming menu options.

Hours Menu

Displays machine operating time for various functions.

Faults Menu

Lists active and past machine faults for troubleshooting.

Service Menu

Provides access to diagnostic tools for machine troubleshooting.

Output Test

Allows manual control of system functions for testing purposes.

Panel Test

Verifies the functionality of control panel switches, LEDs, and display pixels.

Options Menu

Allows adjustment of machine settings for specific uses and needs.

Configuration Menu

Enables configuration of machine options based on installed equipment.

System Menu

Displays firmware revision and control board serial number.

Firmware Update

Procedure for updating the machine's firmware via USB.

Troubleshooting

Fault Codes

Lists and explains error codes reported by controllers for diagnostics.

A1 Main Controller

Details fault codes and conditions specific to the A1 Main Controller.

A2 Power Module #1

Lists fault codes and conditions for the A2 Power Module.

A3 Power Module #2

Lists fault codes and conditions for the A3 Power Module.

A4 Drive Controller

Lists fault codes and conditions for the A4 Drive Controller.

A5 Steering Controller

Lists fault codes and conditions for the A5 Steering Controller.

Device Output Dependencies

Details operating conditions required for various device outputs.

Removal and Installation

Main Machine Controller

Procedure for removing and installing the Main Machine Controller.

J1 Connector

Provides pinout specifications and shop measurements for the J1 connector.

J2 Connector

Provides pinout specifications and shop measurements for the J2 connector.

A2 Power Module 1

Specifies pinout and voltage/condition data for A2 Power Module 1.

A3 Power Module 2

Specifies pinout and voltage/condition data for A3 Power Module 2.

Chassis System

Functional Description

Describes the chassis as the primary structural backbone of the machine.

Wheel System, Non-Traction

Functional Description

Details the non-traction wheel system and its brake components.

Adjust the Brakes

Provides instructions for adjusting the machine's brake system.

Troubleshooting

Lists common problems and solutions related to wheels and brakes.

Removal and Installation

Outlines procedures for removing and installing wheels and bearings.

Wheel

Procedure for removing and installing the machine's wheel.

Wheel Bearing

Details the removal and installation of wheel bearings.

Brake and Spindle Assembly

Procedure for removing and installing the brake and spindle assembly.

Wheel System, Traction

Functional Description

Overview of the traction drive system components.

Drive Motor

Describes the 3-phase AC induction motor used for traction drive.

Drive Pedal Potentiometer

Explains the function and setup of the drive pedal potentiometer.

Drive Controller

Details the InMotion AC Superdrive controller for the drive motor.

Circuit Description

Explains the circuit operation of the drive controller.

Powering up the Drive Controller

Describes the sequence for powering up the drive controller.

CAN Bus

Explains the communication between the drive controller and main controller.

Component Locations

Identifies the physical locations of drive system components.

Maintenance and Adjustments

Covers maintenance and adjustment procedures for the drive system.

Gear Box Oil

Procedure for checking and changing the gearbox oil.

Drive Pedal Neutral Position

Procedure for adjusting the drive pedal neutral position.

Troubleshooting

Lists common problems and solutions for the drive system.

Fault Codes

References fault codes for the A4 Drive Controller.

Removal and Installation

Provides steps for removing and installing the drive motor and gearbox.

Drive Motor and Gearbox Assembly

Procedure for removing and installing the drive motor and gearbox.

Drive Wheel

Procedure for removing and installing the drive wheel.

Drive Controller

Procedure for removing and installing the drive controller.

Specifications

Lists specifications for drive system components.

Shop Measurements

Provides shop measurements for the drive controller.

Steering System

Functional Description

Overview of the steer-by-wire system and its components.

Steering Limit Switches

Describes the function and location of steering limit switches.

Steering Motor

Details the 3-phase AC permanent magnet remotely commutated steering motor.

Commutator Resolver

Explains the commutation process using a resolver for steering motor feedback.

Steering Position Sensor & TFD

Describes the steering wheel position sensor and Torque Feedback Device.

Steering Controller

Details the operation and function of the steering controller.

Functional Diagram

Illustrates the steering system's wiring and component connections.

Component Locations

Identifies the physical locations of steering system components.

Troubleshooting

Lists common steering system problems and their solutions.

Fault Codes

References fault codes for the A5 Steering Controller.

Symptom Troubleshooting

Guides troubleshooting based on observed steering system symptoms.

Loss of Steering Resistance

Troubleshooting steps for issues related to steering resistance.

Excessive Steering Resistance and/or Drive Wheel Position Errors

Diagnosing steering issues related to resistance and drive wheel position.

Limit Switch Testing

Procedure for testing the steering system's limit switches.

Removal and Installation

Provides steps for removing and installing steering components.

Steering Wheel Sensor and TFD

Procedure for removing and installing the steering wheel sensor and TFD.

Steering Controller

Procedure for removing and installing the steering controller.

Steering Actuator Motor

Procedure for removing and installing the steering actuator motor.

Specifications

Lists specifications for steering system components.

Shop Measurements

Provides shop measurements for the steering controller.

Steering Controller Measurements

Details pinouts and voltage measurements for the steering controller.

Electrical System

Overview

Describes the CS7010's electrical system and power configurations.

Circuit Protection

Details the layers of circuit protection within the machine's electrical system.

Un-Switched Power

Explains power supply that remains active when the machine is off.

Switched Power

Describes power that is activated by the ignition switch.

Prime Power Alternator (Generator)

Details the function of the alternator in providing power and charging.

Lighting

Information on standard and optional lighting systems.

Low Voltage Cutout

Explains the system's protection against low battery voltage.

Component Locations

Identifies the physical locations of electrical system components.

Battery Interlock or Interlock Jumper

Describes the battery interlock switch and bypass jumper.

Hybrid Machine Batteries

Details the battery setup for hybrid machine models.

Circuit Protection and Control

Overview of circuit protection elements and system control.

Electrical Panel Layout

Illustrates the layout and components within the electrical panel.

Harness to Harness Connector Locations

Shows locations of key harness connectors for system integration.

J1 Main Machine Controller

Provides pinout and wire color details for the J1 connector.

J2 Main Machine Controller

Provides pinout and wire color details for the J2 connector.

J3 Power Module #1

Provides pinout and wire color details for the J3 connector.

J4 Power Module #2

Provides pinout and wire color details for the J4 connector.

J5 Drive Controller

Provides pinout and wire color details for the J5 connector.

J6 Steering Controller

Provides pinout and wire color details for the J6 connector.

X113 Hopper Harness 2

Details the pinout for the X113 Hopper Harness 2.

X112 Hopper Harness 1

Details the pinout for the X112 Hopper Harness 1.

X45 Engine Interface

Provides pinout information for the X45 Engine Interface connector.

X98 Steering Motor

Provides pinout information for the X98 Steering Motor connector.

X91/92 Wheel Drive Motor

Provides pinout information for the X91/92 Wheel Drive Motor connectors.

X56 Steering Wheel Position Sensor

Details the pinout for the X56 Steering Wheel Position Sensor.

X82 Main Broom Actuator

Details the pinout for the X82 Main Broom Actuator connector.

X130 Dump Door Actuator

Details the pinout for the X130 Dump Door Actuator connector.

X85 Vacuum Motor Harness

Details the pinout for the X85 Vacuum Motor Harness.

X99 Tail Light Harness

Details the pinout for the X99 Tail Light Harness.

X47 Foot Pedal

Details the pinout for the X47 Foot Pedal connector.

X124 Shaker Motor

Details the pinout for the X124 Shaker Motor connector.

X107 Main Broom

Details the pinout for the X107 Main Broom connector.

X104 Right Brush

Details the pinout for the X104 Right Brush connector.

X106 Center Brush

Details the pinout for the X106 Center Brush connector.

X105 Left Brush

Details the pinout for the X105 Left Brush connector.

X48 Foot Brake

Details the pinout for the X48 Foot Brake connector.

X57 Beacon

Details the pinout for the X57 Beacon connector.

X84 Extended Scrub Level

Details the pinout for the X84 Extended Scrub Level connector.

X86 Backup Alarm

Details the pinout for the X86 Backup Alarm connector.

X87 Squeegee Actuator

Details the pinout for the X87 Squeegee Actuator connector.

X93 Left Limit Switch

Details the pinout for the X93 Left Limit Switch connector.

X94 Right Limit Switch

Details the pinout for the X94 Right Limit Switch connector.

X100 Deck Actuator

Details the pinout for the X100 Deck Actuator connector.

X101 Extended Scrub Pump

Details the pinout for the X101 Extended Scrub Pump connector.

X102 Soultion Control Pump

Details the pinout for the X102 Solution Control Pump connector.

X103 Low Pressure Pump

Details the pinout for the X103 Low Pressure Pump connector.

X114 Dust Guard Valve

Details the pinout for the X114 Dust Guard Valve connector.

X115 Dust Guard Pump

Details the pinout for the X115 Dust Guard Pump connector.

X123 Dust Fan

Details the pinout for the X123 Dust Fan connector.

X125 Left Side Broom

Details the pinout for the X125 Left Side Broom connector.

X127 Left Headlight

Details the pinout for the X127 Left Headlight connector.

X132 Side Broom Actuator

Details the pinout for the X132 Side Broom Actuator connector.

X133 Right Side Broom

Details the pinout for the X133 Right Side Broom connector.

X135 Dump Door Closed Switch

Details the pinout for the X135 Dump Door Closed Switch connector.

X136 Right Headlight

Details the pinout for the X136 Right Headlight connector.

K1 and K5 Relays

Describes the function and operation of K1 and K5 relays.

Maintenance and Adjustments

Covers maintenance tasks for the electrical system.

Charging the Battery (Battery Model)

Instructions for charging the battery on battery-powered models.

Generator Drive Belt

Information on the generator drive belt tension and adjustment.

Troubleshooting

Diagnoses common electrical system issues.

Alternator-generator is not charging

Troubleshooting steps for a non-charging alternator/generator.

Insufficient machine operation time (Battery Model)

Troubleshooting battery life issues on battery models.

Insufficient machine operation time with engine off (Hybrid models)

Troubleshooting battery life issues on hybrid models with engine off.

Removal and Installation

Procedure for removing and installing the alternator-generator drive belt.

Alternator-Generator Drive Belt

Steps for removing and installing the alternator-generator drive belt.

Alternator-Generator

Procedure for removing the alternator-generator assembly.

Wiring Diagrams

Introduction to understanding wiring diagrams and schematics.

Working with Schematics and Diagrams

Explains how to interpret and navigate wiring schematics.

Navigation

Describes how to use tags and coordinates for referencing drawings.

Common Schematic Symbols

Explains common symbols used in electrical schematics.

Control Board Inputs and Outputs

Details specific symbols for control board inputs and outputs.

Identification

Explains how components are identified within schematics.

Switches

Describes different types of switches and their schematic representation.

Relays

Explains how relays are represented and function in schematics.

Electrical Schematic (Ladder Diagram)

Presents the electrical schematic of the main controller.

Sheet 1, Main Controller Part 1

Part 1 of the main controller's electrical schematic.

Sheet 2, Main Controller Part 2

Part 2 of the main controller's electrical schematic.

Sheet 3, A2 Power Module #1

Electrical schematic for the A2 Power Module #1.

Sheet 4, A3 Power Module #2

Electrical schematic for the A3 Power Module #2.

Sheet 5, A4 Drive Controller

Electrical schematic for the A4 Drive Controller.

Sheet 6, A5 Steering Controller

Electrical schematic for the A5 Steering Controller.

Sheet 7, Kubota Diesel Engine System

Electrical schematic for the Kubota Diesel Engine System.

Sheet 8, Kubota Gasoline Engine System

Electrical schematic for the Kubota Gasoline Engine System.

Sheet 9, Kubota LEV Engine System Part 1

Part 1 of the Kubota LEV Engine System electrical schematic.

Sheet 10, Kubota LEV Engine System Part 2

Part 2 of the Kubota LEV Engine System electrical schematic.

Sheet 11, Trackclean Connections

Electrical schematic detailing Trackclean system connections.

Wiring Harness Diagram

Diagrams illustrating the routing of main wiring harnesses.

Sheet 1: Main Harness 1

Wiring diagram for the main harness, section 1.

Sheet 2: Main Harness 2

Wiring diagram for the main harness, section 2.

Sheet 3: Main Harness 3

Wiring diagram for the main harness, section 3.

Sheet 4: Hopper Harness

Wiring diagram for the hopper harness.

Sheet 5: LEV Engine Interface

Wiring diagram for the LEV engine interface harness.

Sheet 6: Glow Plug, Vacuum, Tail Light

Wiring diagram for glow plug, vacuum, and tail light systems.

Sheet 7: Engine Battery, Generator Harness

Wiring diagram for engine battery and generator harnesses.

Sheet 8: Trackclean Harness

Wiring diagram for the Trackclean harness.

Engine System - LPG LEV

Functional Description

Overview of the Kubota propane LEV engine and its systems.

Circuit Descriptions

Explains the operation of key engine circuits.

Engine Starter Control

Describes the control circuit for the engine starter.

Engine RPM Control

Explains how the engine RPM is managed by the ECU and controller.

Normal Engine Shut Off

Procedure for normal engine shutdown via the key switch.

Engine Protection Modes

Details engine shutdown modes for overheating or low oil pressure.

Component Locations

Identifies key components of the LPG LEV engine.

Maintenance and Adjustments

Covers maintenance tasks for the LPG LEV engine.

Maintenance Checklist

Provides a checklist for routine LPG LEV engine maintenance.

Change Engine Oil and Oil Filter

Procedure for changing engine oil and oil filter.

Change Engine Coolant

Procedure for changing engine coolant.

Inspect Air Filter

Guidance on inspecting the air filter using the service indicator.

Replace Air Filters

Procedure for replacing the engine's air filter elements.

Troubleshooting

Diagnoses common issues with the LPG LEV engine management system.

Engine Management System

Details troubleshooting the engine management system using KGST software.

Checking Spark

Procedure for checking the engine's spark system.

Checking LPG Primary Pressure

Procedure for checking the LPG primary pressure.

Removal and Installation

Procedure for removing and installing the engine assembly.

Engine Assembly

Steps for removing and reinstalling the complete engine assembly.

Specifications

Lists technical specifications for the LPG LEV engine.

Special Tools

Lists special tools required for engine system diagnostics and maintenance.

Engine System, Diesel

Functional Description

Overview of the Kubota Diesel engine and its systems.

Engine starter control

Describes the control circuit for the engine starter.

Fuel pump control

Explains the control circuit for the fuel pump.

Engine Protection

Details engine shutdown modes for overheating or low oil pressure.

Over Temperature Shutdown

Explains the automatic shutdown mechanism for engine overheating.

Low Oil Pressure Shutdown

Explains the automatic shutdown mechanism for low oil pressure.

Engine RPM control

Describes how the engine RPM is controlled via the Woodward governor.

Troubleshooting

Diagnoses common issues with the diesel engine management system.

Flash Code

Lists and explains fault codes for the APECS governor control system.

Glow plug control

Explains the operation of the glow plug system for cold starting.

Component Locations

Identifies key components of the diesel engine.

Maintenance and Adjustments

Provides a maintenance schedule for the diesel engine.

Diesel Engine Maintenance Schedule

Outlines recommended maintenance intervals for the diesel engine.

Change Engine Oil and Oil Filter

Procedure for changing engine oil and oil filter.

Change Engine Coolant

Procedure for changing engine coolant.

Replace Fuel Filter

Procedure for replacing the diesel engine's fuel filter.

Bleed Fuel System

Procedure for bleeding air from the diesel fuel system.

Inspect Air Filter

Guidance on inspecting the air filter using the service indicator.

Replace Air Filters

Procedure for replacing the diesel engine's air filter elements.

Troubleshooting

Diagnoses common diesel engine starting problems.

No crank – The starter does not engage

Troubleshooting steps when the starter does not engage.

Cranks but does not start

Troubleshooting steps when the engine cranks but does not start.

Check governor control system.

Diagnostic step to check the governor control system status.

Check the fuel actuator

Diagnostic step to check the fuel actuator's resistance and function.

Check fuel system

Diagnostic step to check the fuel system for contamination and pressure.

Check mechanical engine

Diagnostic step to check the mechanical engine for issues.

Cannot Achieve Either Run or Maximum Engine Speed

Troubleshooting engine speed control issues.

Compression Test

Procedure for testing engine cylinder compression.

Removal and Installation

Procedure for removing and installing the engine assembly.

Engine RPM Sensor Installation

Procedure for installing the engine RPM sensor.

Engine Assembly

Steps for removing and reinstalling the complete engine assembly.

Specifications

Lists technical specifications for the diesel engine.

Fuel Pump;

Specifications for the diesel engine's fuel pump.

Glow Plugs

Specifications for the diesel engine's glow plugs.

Engine Compression

Specifies engine compression values for diesel models.

Engine Oil Capacity

Specifies the engine oil capacity for diesel models.

Engine Oil Type

Recommends API classifications and SAE viscosity for engine oil.

Engine Oil Viscosity

Provides engine oil viscosity recommendations based on temperature.

Cooling System

Recommends coolant mixture for the engine's cooling system.

Engine Coolant

Specifies the recommended coolant mixture for the engine.

Radiator Cap

Specifies the pressure rating for the radiator cap.

Shop Measurements

Provides shop measurements for engine RPM sensor and actuator.

Engine RPM Sensor

Lists resistance and output measurements for the engine RPM sensor.

Actuator

Lists resistance measurement for the engine actuator.

Special Tools

Diesel Compression Gauge

Details the diesel compression gauge and its components.

Compression Gauge Fitting for Glow Plug threads

Specifies the fitting for glow plug threads used with compression testing.

Gauge Coupler

Describes the coupler required for connecting the compression test components.

Engine System - Petrol (Gasoline)

Functional Description

Overview of the Kubota gasoline engine and its systems.

Circuit Descriptions

Explains the operation of key engine circuits.

Ignition System

Details the components and operation of the ignition system.

Engine Starter and Carburetor Choke Control

Describes the control circuit for the engine starter and choke.

Throttle Control Modes

Explains different modes for engine throttle control.

Ignition Off

Describes the machine state when the ignition is off.

Ignition On

Describes the machine state when the ignition is on.

Cranking

Explains the engine cranking sequence and related circuits.

Normal Running

Describes the engine operation during normal running conditions.

Engine RPM Control

Explains how engine RPM is controlled via the Woodward actuator.

Engine Protection Modes

Details engine shutdown modes for overheating or low oil pressure.

Engine Overheat Shutdown

Explains the automatic shutdown mechanism for engine overheating.

Lost Oil Pressure Shutdown

Explains the automatic shutdown mechanism for low oil pressure.

Component Locations

Identifies key components of the gasoline engine.

Engine Front

Identifies components located at the front of the engine.

Engine Right

Identifies components located at the right side of the engine.

Engine Left

Identifies components located at the left side of the engine.

Engine Back

Identifies components located at the back of the engine.

Engine Right Side View (Toward front of machine)

View showing components on the right side of the engine.

Engine Back Side View (Toward right of machine)

View showing components on the back side of the engine.

Engine Left Side View (Toward back of machine)

View showing components on the left side of the engine.

Fuel Tank Area

Shows the location and components of the fuel tank system.

Maintenance and Adjustments

Provides a maintenance checklist for the gasoline engine.

Maintenance Checklist

Outlines daily, periodic, and annual maintenance tasks for the engine.

Change Engine Oil and Oil Filter

Procedure for changing engine oil and oil filter.

Change Engine Coolant

Procedure for changing engine coolant.

Inspect Air Filter

Guidance on inspecting the air filter using the service indicator.

Replace Air Filters

Procedure for replacing the engine's air filter elements.

Troubleshooting

Diagnoses common engine starting and running problems.

Checking Spark

Procedure for checking the engine's spark system.

No crank - The starter does not engage

Troubleshooting steps when the starter does not engage.

Cranks but does not start – No Spark

Troubleshooting steps when the engine cranks but has no spark.

Cranks but does not start (has sufficient spark)

Troubleshooting steps when the engine cranks but does not start with spark.

Achieves one but not ALL RPM modes.

Troubleshooting engine RPM control issues.

Removal and Installation

Procedure for removing and installing the engine assembly.

Engine RPM Sensor Installation

Procedure for installing the engine RPM sensor.

Engine Assembly

Steps for removing and reinstalling the complete engine assembly.

Specifications

Lists technical specifications for the gasoline engine.

Engine Oil

Specifies engine oil capacity, type, and viscosity recommendations.

Engine Coolant

Specifies the recommended coolant mixture for the engine.

Shop Measurements

Provides shop measurements for ignition system components.

Ignition System

Lists specifications for the ignition system components.

Solution System

Functional Description

Overview of the solution system and its components.

Overview

Describes the function of the solution system in delivering water/detergent.

Solution Flow Control - Non-EcoFlex™ Machines

Explains solution flow control for non-EcoFlex machines.

Solution Flow Control - EcoFlex™ Machines

Explains solution flow control for EcoFlex machines.

EcoFlex™ Detergent System

Details the EcoFlex detergent injection system.

Extended Scrub System

Describes the operation of the extended scrub system.

Optional Hot Water System (LP and Diesel EcoFlex™ Machines Only)

Details the optional hot water system for EcoFlex models.

Optional Wash Hose Kit

Describes the optional wash hose kit and its operation.

Optional High-pressure Spray System (LP and Diesel Only)

Details the optional high-pressure spray system for LP and Diesel models.

Solution Level Sensor

Explains the function and display of the solution level sensor.

Solution System Wiring Diagram

Illustrates the wiring for the solution system components.

Circuit Description

Explains the operation of the solution system circuits.

Extended Scrub System

Details the operation and requirements of the extended scrub system.

EcoFlex Option

Explains the EcoFlex detergent injection system using solenoid pumps.

Component Locations

Identifies the physical locations of solution system components.

Solution Tank

Locates the solution tank and its drain hose.

Solution Filter and Solution Shutoff Valve

Locates the solution filter and shutoff valve and their functions.

Solution Pressure Sensor

Explains the solution level detection via pressure sensor.

Solution Pump (EcoFlex™ Models Only)

Locates the solution pump for EcoFlex models.

Low Pressure (Wash Hose) Pump

Locates the optional low pressure wash hose pump.

Solution Solenoid Valve

Describes the solution solenoid valve and its maintenance.

Solution Nozzles

Locates the solution nozzles on the scrub deck.

EcoFlex™ Detergent Bottles and Pumps

Describes the location and function of EcoFlex detergent bottles and pumps.

High-pressure Spray System Pump

Details the high-pressure spray system pump driven by an electric clutch.

Maintenance and Adjustments

Covers maintenance and adjustment procedures for the solution system.

To Clean the Solution Filter Screen

Procedure for cleaning the solution filter screen.

To Clean the Extended Scrub System Strainer

Procedure for cleaning the extended scrub system strainer.

To Clean the High Pressure Solution Filter

Procedure for cleaning the high pressure solution filter.

To Adjust the Belt Tension on the High Pressure Pump

Procedure for adjusting belt tension on the high-pressure pump.

Troubleshooting

Diagnoses common problems with the solution system.

Inadequate solution flow to the brushes in the scrub mode

Troubleshooting steps for inadequate solution flow during scrubbing.

No detergent flow to the solution system

Troubleshooting steps for lack of detergent flow.

The hot water system is not operating.

Troubleshooting issues with the optional hot water system.

The high-pressure spray system is not operating.

Troubleshooting steps when the high-pressure spray system is inactive.

The low-pressure wash hose is not operating.

Troubleshooting issues with the low-pressure wash hose.

Removal and Installation

Procedure for removing and installing the solution tank.

Solution Tank

Steps for removing and installing the solution tank.

Solution Shutoff Valve

Procedure for removing and installing the solution shutoff valve.

Solution Filter Assembly

Procedure for removing and installing the solution filter assembly.

Solution Solenoid Valve

Procedure for removing and installing the solution solenoid valve.

Detergent Pump (EcoFlex™ Models Only)

Procedure for removing and installing the EcoFlex detergent pump.

Specifications

Lists technical specifications for solution system components.

Scrub System

Functional Description

Overview of the scrub system components and operation.

Overview

Describes the function of the scrub system.

Scrub System Wiring Diagram

Illustrates the wiring for the main and side broom scrub systems.

Circuit Description

Explains the operation of the scrub system circuits.

Scrub Deck Actuator Motor

Details the operation of the scrub deck actuator motor.

Component Locations

Identifies the physical locations of scrub system components.

Scrub Motor Assemblies

Locates the scrub motor assemblies and their gearboxes.

Right Swingarm

Describes the right swingarm, gas spring, and service access.

Side Squeegee Assemblies

Describes the side squeegee assemblies and their components.

Scrub Deck Actuator

Details the scrub deck actuator and its mounting.

Maintenance and Adjustments

Covers maintenance and adjustment procedures for the scrub system.

Replace a Leading Deck Blade

Procedure for replacing the leading deck blade.

Replace a Trailing Deck Blade

Procedure for replacing the trailing deck blade.

Removal and Installation

Procedure for removing and installing the side squeegee assembly.

Side Squeegee Assembly

Steps for removing and reinstalling the side squeegee assembly.

Scrub Deck Actuator

Procedure for removing and installing the scrub deck actuator.

Actuator Adjustment

Procedure for adjusting the scrub deck actuator's retracted position.

Scrub Motor

Procedure for removing and reinstalling the scrub motor.

Scrub Motor Carbon Brushes

Procedure for inspecting and replacing scrub motor carbon brushes.

Specifications

Lists technical specifications for scrub system components.

Squeegee System

Functional Description

Overview of the squeegee system and its function.

Overview

Describes how the squeegee picks up and directs solution.

Squeegee and Recovery Wiring Diagram

Illustrates the wiring for the squeegee and recovery systems.

Component Locations

Identifies the physical locations of squeegee system components.

Side Brooms

Locates the side brooms on the machine.

Side Broom Motors

Locates the side broom motor assemblies and gearboxes.

Side Broom Actuator

Locates the side broom actuator and describes its function.

Maintenance and Adjustments

Covers maintenance and adjustment procedures for the squeegee system.

Changing Squeegee Blades

Procedure for changing the front and rear squeegee blades.

Front Squeegee Blade

Procedure for replacing the front squeegee blade.

Rear Squeegee Blade

Procedure for replacing the rear squeegee blade.

Squeegee End Wheels

Maintenance task for lubricating squeegee end wheels.

Squeegee Caster Wheel Bearings

Maintenance task for greasing squeegee caster wheel bearings.

Squeegee Tilt Adjustment

Procedure for adjusting the squeegee's tilt angle.

Squeegee Casters Adjustment

Procedure for adjusting the height of squeegee casters.

Troubleshooting

Diagnoses common problems with the squeegee system.

The squeegee is not picking up the water effectively.

Troubleshooting steps for poor water pick-up by the squeegee.

Removal and Installation

Procedure for removing and installing the squeegee lift actuator.

Squeegee Lift Actuator

Steps for removing and installing the squeegee lift actuator.

Actuator Adjustment

Procedure for adjusting the squeegee lift actuator's retracted position.

Squeegee Support Assembly

Procedure for removing and installing the squeegee support assembly.

Squeegee Lift Arm

Procedure for removing and installing the squeegee lift arm.

Specifications

Lists technical specifications for squeegee system components.

Squeegee Tool Assembly

Lists material and hardness specifications for squeegee blades.

Squeegee Lift Actuator

Lists specifications for the squeegee lift actuator.

Special Tools

Recommends a spring puller for squeegee assembly removal.

Recovery System

Functional Description

Overview of the recovery system and its function.

Overview

Describes how the recovery system picks up solution and directs it to the tank.

Recovery and Squeegee Wiring Diagram

Illustrates the wiring for the recovery and squeegee systems.

Component Locations

Identifies the physical locations of recovery system components.

Recovery Tank

Locates the recovery tank and its drain hose.

Recovery Tank Cover and Debris Basket

Locates the recovery tank cover and debris basket.

Vacuum Fan Cover Assembly

Describes the vacuum fan cover assembly and its components.

Vacuum Motors

Locates the vacuum motors within the fan cover assembly.

Float Cage and Ball Assemblies

Describes the float cage and ball assemblies for preventing water intake.

Maintenance and Adjustments

Covers maintenance procedures for the recovery system.

Clean the Vacuum Filter and Filter Screen

Procedure for cleaning the vacuum filter and filter screen.

Clean the Debris Basket

Procedure for cleaning the debris basket.

Troubleshooting

Diagnoses common problems with the recovery system.

An individual vacuum motor will not run.

Troubleshooting steps when a vacuum motor fails to run.

Poor water pick-up.

Troubleshooting steps for poor water pick-up performance.

Removal and Installation

Procedure for removing and installing the recovery tank.

Recovery Tank

Steps for removing and reinstalling the recovery tank.

Vacuum Motor

Procedure for removing and installing the vacuum motor.

Specifications

Lists technical specifications for vacuum system components.

Special Tools

Lists a special tool for vacuum system measurements.

Sweep System, Main

Functional Description

Overview of the main sweep system components and operation.

Overview

Describes the function of the main sweep system.

Sweep System Wiring Diagram

Illustrates the wiring for the main broom and side broom circuitry.

Circuit Description

Explains the operation of the main broom actuator and motor circuits.

Main Broom Actuator

Details the function and control of the main broom actuator.

Main Broom Motor

Describes the operation of the main broom motor.

Component Locations

Identifies the physical locations of main broom components.

Main Broom and Drive Components

Locates the main broom, motor, and lift actuator assembly.

Maintenance and Adjustments

Covers maintenance and adjustment procedures for the main sweep system.

Adjust the Main Broom Height

Procedure for adjusting the main broom's operating height.

Adjust the Main Broom Tilt

Procedure for adjusting the main broom's tilt angle for sweep pattern.

Removal and Installation

Procedure for removing and installing the main broom.

Main Broom

Steps for removing and reinstalling the main broom.

Replacement

Procedure for replacing the main broom.

Broom Motor

Procedure for removing and reinstalling the broom motor.

Main Broom Motor Carbon Brushes

Procedure for inspecting and replacing main broom motor carbon brushes.

Specifications

Lists technical specifications for main broom motor and actuator.

Sweep System, Side Broom

Functional Description

Overview of the side broom system and its function.

Overview

Describes how side brooms direct debris and their operation.

Side Broom and Main Broom Wiring Diagram

Illustrates the wiring for side broom and main broom systems.

Component Locations

Identifies the physical locations of side broom components.

Side Brooms

Locates the side brooms on the machine.

Side Broom Motors

Locates the side broom motor assemblies and gearboxes.

Side Broom Actuator

Locates the side broom actuator and describes its function.

Maintenance and Adjustments

Covers maintenance procedures for the side broom system.

Replacing a Side Broom

Procedure for replacing the side broom.

Side Broom Motor Carbon Brushes

Procedure for inspecting and replacing side broom motor carbon brushes.

Removal and Installation

Procedure for removing and installing the side broom motor.

Side Broom Motor

Steps for removing and reinstalling the side broom motor.

Side Broom Hub

Procedure for removing and reinstalling the side broom hub assembly.

Side Broom Actuator

Procedure for removing and installing the side broom actuator.

Specifications

Lists technical specifications for side broom system components.

Dust Control/DustGuard™ Systems

Functional Description

Overview of the dust control system and its function.

Overview

Describes how the dust control system filters dust and sprays water.

Dust Control System

Details the impeller and filter assembly for dust control.

DustGuard Spray System (optional)

Describes the optional DustGuard spray system for dust suppression.

Dust Control and Hopper Wiring Diagram

Illustrates the wiring for the dust control and hopper systems.

Component Locations

Identifies the physical locations of dust control system components.

Impeller and Filter System

Locates the impeller and filter system components.

Dust Control Filter Switch

Describes the function and location of the dust control filter switch.

DustGuard Spray System

Describes the DustGuard pump, solenoid valve, and spray nozzles.

Maintenance and Adjustments

Covers maintenance procedures for the dust control system.

Clean the Dust Control Filter

Procedure for cleaning the dust control filter.

Clean the DustGuard Strainer Screen

Procedure for cleaning the DustGuard strainer screen.

Clean the DustGuard Spray Nozzles

Procedure for cleaning the DustGuard spray nozzles.

Adjust the DustGuard Spray Nozzles

Procedure for adjusting the spray angle of the DustGuard nozzles.

Troubleshooting

Diagnoses common problems with the dust control system.

The DustGuard system does not operate.

Troubleshooting steps when the DustGuard system is inactive.

Inadequate water flow to the DustGuard nozzles

Troubleshooting steps for inadequate water flow to DustGuard nozzles.

Removal and Installation

Procedure for removing and installing dust control system components.

DustGuard Solenoid Valve

Procedure for removing and installing the DustGuard solenoid valve.

Dust Control Filter Switch

Procedure for removing and installing the dust control filter switch.

DustGuard Pump

Procedure for removing and installing the DustGuard pump.

Impeller Assembly

Procedure for removing and installing the impeller assembly.

Specifications

Lists technical specifications for dust control system components.

Hopper System

Functional Description

Overview of the hopper system and its functions.

Overview

Describes the hopper's role in collecting debris and its lift mechanism.

Upper and Lower Hopper

Describes the upper and lower hopper components and their connection.

Hydraulic Power Pack Assembly

Locates and describes the hydraulic power pack assembly.

Hopper and Dust Control Wiring Diagram

Illustrates the wiring for the hopper and dust control systems.

Component Locations

Identifies the physical locations of hopper system components.

Upper and Lower Hopper

Locates the upper and lower hopper assemblies.

Hydraulic Power Pack Assembly

Locates the hydraulic power pack assembly and its function.

Hopper Dump Door

Describes the hopper dump door and its purpose.

Hopper Dump Door Actuator

Details the electric actuator for the hopper dump door.

Dump Door Limit Switch

Describes the proximity sensor that detects the closed dump door.

Hopper Interlock Switch

Describes the hopper interlock switch and its function.

Hopper Prop Rod and Pull Rod

Explains the safety mechanism for working under the raised hopper.

Maintenance and Adjustment

Covers maintenance and adjustment procedures for the hopper system.

Hydraulic Oil Change/Flush

Procedure for changing and flushing the hydraulic oil.

Dump Door Actuator Adjustment

Procedure for adjusting the dump door actuator's potentiometer and position.

Dump Door Open Position

Procedure for adjusting the dump door's open position.

Removal and Installation

Procedure for removing and installing the hydraulic power pack assembly.

Hydraulic Power Pack Assembly

Steps for removing and installing the hydraulic power pack assembly.

Hopper Lift Cylinder

Procedure for removing and installing the hopper lift cylinder.

Hopper Interlock Switch

Procedure for removing and installing the hopper interlock switch.

Hopper Dump Door Actuator

Procedure for removing and installing the hopper dump door actuator.

Specifications

Lists technical specifications for hopper system components.

Options and Accessories

Seat Belt Kit

Describes the seat belt kit option.

Recovery Tank Clean Out Kit

Describes the recovery tank clean out kit option.

Back-Up Alarm Kit

Describes the back-up alarm kit option.

Fire Extinguisher Kit

Describes the fire extinguisher kit option.

LED Brake Light/Turn Signal Kit

Describes the LED brake and turn signal kit option.

Rear Corner Roller Kit

Describes the rear corner roller kit option.

Hopper Temperature Sensor Kit

Describes the hopper temperature sensor kit option.

Plugged Filter Switch Kit

Describes the plugged filter switch kit option.

High Pressure Pump Kit - Engine Powered Hybrids

Describes the high-pressure pump kit for engine-powered hybrids.

Front Corner Roller Kit

Describes the front corner roller kit option.

Extended Scrub Kit

Describes the extended scrub kit option.

EcoFlex™ Chemical Injection Kit

Describes the EcoFlex chemical injection kit.

Overhead Guard Kit - 82” Standard Clearance

Describes the overhead guard kit with standard clearance.

Overhead Guard Kit - 79” Low Clearance

Describes the overhead guard kit with low clearance.

Overhead Guard Canopy Kit

Describes the overhead guard canopy kit.

Deluxe Seat Kit

Describes the deluxe seat kit with seat belt and arm rest.

Hot Water Scrub Kit

Describes the hot water scrub kit with heat exchanger.

Front Bumper Kit

Describes the front bumper kit and its components.

Super Duty Kit

Describes the super duty kit components.

Spray Wash Hose Kit

Describes the spray wash hose kit and its operation.

Overhead Guard Beacon Kit

Describes the overhead guard beacon kit.

Warning Beacon Kit

Describes the warning beacon kit.

Solution Fill Shut-Off Kit

Describes the solution fill shut-off kit for tank filling.

Vacuum Wand Kit

Describes the vacuum wand kit accessory.

Accessory Socket Kit

Describes the accessory socket kit for powering electronics.

Drain Hose Extension

Describes the drain hose extension accessory.

Arm Rest Option

Describes the arm rest option for the seat.