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GTX

Operator Manual



HOW TO USE THIS MANUAL:

This manual contains the following sections:

- HOW TO USE THIS MANUAL

- MACHINE INFORMATION

- SAFETY

- OPERATIONS

- MAINTENANCE

- PARTS LIST

 

The HOW TO USE THIS MANUAL section will tell you how to find important information for ordering correct repair parts.

 

Parts may be ordered from authorized FACTORY CAT dealers. When placing an order for parts, the machine model and machine serial number is important. Refer to the MACHINE INFORMATION page which is filled out during the installation of your machine. The MACHINE INFORMATION is located on page one of this manual.

 

The serial number of your machine is located on the lower steering pedestal of the steering column of the machine.

 

The SAFETY section contains important information regarding hazard or unsafe practices of the machine. Levels of hazards are identified that could result in product or personal injury, or severe injury resulting in death.

 

The OPERATIONS section is to familiarize the operator with the operation and function of the machine.

 

The MAINTENANCE section contains preventative maintenance to keep the machine and its components in good working condition. They are listed in this general order:

- Batteries

- Scrub Brushes

- Adjusting Squeegee

- Service Schedule

- Machine Trouble shooting

 

The PARTS LIST section contains assembled parts illustrations and corresponding parts list. The parts lists include a number of columns of information:

- ITEM - column refers to the reference number on the parts illustration.

- PART NO. - Column lists the part number for the part.

- QTY - column lists the quantity of the part used in that area of the machine.

- DESCRIPTION - column is a brief description of the part.

- COMMENTS - column for information not noted by the other columns.

 

NOTE: If a service or option kit is installed on your machine, be sure to keep the KIT INSTRUCTIONS which came with the kit. It contains replacement part numbers needed for ordering future parts.

 

 

 

 

 

CONTENT ORDER OF OPERATOR’S MANUAL:

Machine Information

            Standard Warranty Policy

Machine Warranty Registration Form

Machine Specifications

Common wear parts/scrub brushes

Safety

Safety messages

Safety precautions

Controls

Machine controls and features

LCD screen menu displays

Machine Setup

          Uncrating Machine and Connecting Batteries

Attaching squeegee

Adjusting squeegee

Leveling disk deck

Leveling cylindrical deck

Attaching brushes

Adjusting shrouds

Adjusting cylindrical side wipers

Solution system

Vacuum system

Machine Operation

            Double Scrubbing

          Vac Only Scrubbing

          Operating Hints

Draining recovery & solution tanks

Override Parking Brake

Rec. Float shut off

Drain saver

Standard battery charging

Optional battery charging

On-Board charger operator manual

Changing batteries

Side broom system

Machine Options

Overhead guard

HD Side doors

On-board Soap

Spray hose

Vac wand

Diffuser exhaust bar

Stainless steel recovery tank

Stainless steel solution tank

Industrial battery

Removable battery box

On-Board soap

Spray hose

Vac wand

Maintenance

Maintenance & storing machine

Preventative maintenance records

Troubleshooting

Troubleshooting central command II

Troubleshooting

 

 

 

 

 

 

MACHINE INFORMATION:

 

Standard Warranty Policy (RPS Corporation):

 

RPS Corporation warrants its machines, parts and accessories to be free of manufacturer’s defects for the periods specified below. Warranty will be granted at the sole discretion of RPS Corporation and is subject to final claim and parts review by R.P.S. Corporation and its vendors. This policy is effective January 1, 2010 and is subject to change on production units at a future date.

 

COVERAGE, EXCLUSIONS AND LIMITATIONS:

Coverage:    All Models sold (Sweepers, Scrubbers, Burnishers)

Parts:          36 months / 1,500 hours on “Power On” hour meter

Labor:          12 months

Travel:         3 months (150 mile maximum)

Poly Tanks:   7 Years

OEM Parts:   3 months

Validity:       Fully completed Machine Delivery Form (online or fax) is on record at RPS.

Limitation:    Warranty will begin on date of machine installation to end-user or 6 months

after shipment from RPS Corp to the distributor if unsold at that time.

 

 

This warranty includes all parts on the machine except normal wear parts. Some of these exceptions are:

1. Any Brooms, Brushes, Pads or Pad Drivers including Center Clip Retainers

2. Floor Seals, Wipers, Splash Curtains, Squeegees or Gaskets.

3. Filters, Dust Collection Bags or Screens

4. The safety pins design to fail in shear, which are a fail-safe device

5. Belts, Hoses or Tubing.

6. Caster Wheels, Tires or internal tire tubes.

7. Vacuum motors with evidence of water/foam passage or more than 450

hours

8. Lights (Strobe, Headlights or bulbs).

9. The Batteries (see below).

NOT COVERED: Routine maintenance, adjustments or parts damaged from abuse, neglect, improper use of the machine, or lack of scheduled “daily, weekly, monthly” maintenance in accordance with our published PM Sheets.

 

POLY TANKS: 7 Years Coverage against leakage due to manufacturer’s defect in materials or workmanship.

NOTE: Freight coverage for 3-Years under the parts section of warranty.

 

BATTERIES: Warranted through battery manufacturer for One (1) Year (prorated) from the date of delivery. The battery manufacturer approves or denies the warranty coverage after analysis. We rely on solely on their review. NOTE NOT COVERED: Damage from lack of water, failure to use OEM charger, or non-distilled water.

 

 

 

Registration Form:

 

Please take a moment to go to the site below and register your new GTX:

http://www.factorycat.com/company/machine_delivery.html

 

 

 

 

Specifications:

 

 

DISK

CYLINDRICAL

BODY CONSTRUCTION

 

 

Tank Material:

(3/8”) Roto-Poly

(3/8”) Roto-Poly

Frame Construction:

3/16” Coated Steel

3/16” Coated Steel

Front Wheel:

10” x 3”

10” x 3”

Rear Wheel:

(2) 12” x 5”

(2) 12” x 5”

Body Dimensions (L x W x H):

54” x 26” x 55”

54” x 26” x 55”

Width (squeegee):

32” or 35”

32” or 35”

Weight (w/out batteries):

780 pounds

780 pounds

Weight (w/ standard batteries):

1,222 pounds

1,222 pounds

 

 

 

BRUSH/PAD SYSTEM

 

 

Brush/Pad Diameter:

GTX-26D - (2) 13 inches

GTX-30D - (2) 15 inches

GTX-34D - (2) 17 inches

GTX-24C - (2) 22” x 5.5”

GTX-27C - (2) 25” x 5.5”

GTX-30C - (2) 28” x 5.5”

GTX-34C - (2) 32” x 5.5”

Motor Power (standard):

(2) 0.75 hp / 300 rpm

(2) 0.75 hp / 300 rpm (24” & 27”)

Motor Power (HD Option):

(2) 1.0 hp / 350 rpm

(2) 1.0 hp / 350 rpm (30” & 34”)

Brush Pressure:

0-250 pounds

0-250 pounds

Brush Pressure Settings:

(1-5) automatic

(1-5) automatic

Actuator Rating:

500 lbs.

500 lbs.

 

 

 

BATTERY SYSTEM

 

 

System Voltage:

36 volts

36 volts

Battery AH Rating (Standard):

245 AH

245 AH

Battery AH Ration (Optional):

Up to 325 AH

Up to 325 AH

Battery Run Time:

Up to 7 hours

Up to 7 hours

Charger (110v/60Hz/auto):

36-v / 25-amp

36-v / 25-amp

 

 

 

SOLUTION SYSTEM

 

 

Solution Tank Capacity:

35-gallons

35-gallons

Solution Flow Rate:

0 – 1.5 gal/min

0 – 1.5 gal/min

Solution Filter:

Stainless Inline

Stainless Inline

 

 

 

RECOVER SYSTEM

 

 

Recovery Tank Capacity:

35 gallons

35 gallons

Vacuum Horsepower:

1.0 hp or 2.0 hp

1.0 hp or 2.0 hp

Drain Hose:

2.0” Diameter

2.0” Diameter

Vacuum (Water Lift/ Cubic ft/min):

68” / 70 cfm

68” / 70 cfm

Demisting Chamber:

3 Gallons

3 Gallons

Drain Saver:

30 cubic inches

30 cubic inches

 

 

 

DRIVE SYSTEM

 

 

Standard Drive:

1 hp, Front Motor Wheel

1 hp, Front Motor Wheel

Speed Control:

Variable 0-320 ft.

Variable 0-320 ft.

Forward Speed:

0 – 320 ft/min

0 – 320 ft/min

Reverse Speed:

0 – 200 ft/min

0 – 200 ft/min

Minimum Aisle U-Turn:

56”

56”

Sound Level:

68 dBA

68 dBA

 

 

 

PRODUCTIVITY

 

 

Cleaning Width & Rate/Hour:

24” / 26,400 sq.feet / hour

30” / 33,000 sq.feet / hour

34” / 37,400 sq.feet / hour

24” / 26,400 sq.feet / hour

27” / 29,700 sq.feet / hour

30” / 33,000 sq.feet / hour

34” / 37,400 sq.feet / hour

 

 

 

 

Common Wear Parts:

 

Table 1 - Brushes

    Brush repair kit: 40-423 Replacement locating clip for all brushes

 

 

Table 2 - Pads

    NOTE: # In Disk Column Denotes Pad Size: 13, 15, 17

                    Extra pad driver retaining clip: 40-433

 

Table 3 - New Style Cylindrical Brushes For Machine Serial Numbers #50000 or Greater

 

 

Table 4- Old Style Cylindrical Brushes For Machines Prior to Serial #50000

 

 

  Table 5 - Squeegee blade kits & Complete Squeegee Assemblies

 

 

 

NOTE: Squeegee blade kits include (1) Rear Blade, (1) Front Blade, and (2) Backup Wheels with hardware.

NOTE: Squeegee Assemblies (complete) listed above all come with Linatex blades.

NOTE: Size is stamped into the top of the painted steel squeegee body on all squeegees.

NOTE: The 32" squeegee is designed for narrow aisles and may not have the same water control around tight turns as the larger squeegees.

 

 

 

 

Safety

 

Safety Messages:

 

Your safety, and the safety of others, is very important, and operating this unit safely is an important responsibility.

 

To help you make informed decisions about safety, we have provided operating procedures and other safety information in the manual. This information informs you of potential hazards that could hurt you or others.

 

It is not practical or possible to warn you of all the hazards associated with operating this unit. You must use your own good judgment.

 

This is intended for commercial use. It is designed to be used on hard floors in an indoor environment, with the recommended pads or brushes.

 

1. Do not operate unit:

Unless trained and authorized.

Unless operator manual is read and understood.

If unit is not in proper operating condition.

Outdoors or exposed to rain.

For picking up hazardous materials/dust.

On surfaces having a gradient exceeding 2% unless the optional

Parking brake is functioning on the machine.

2. When operating unit:

Remove loose objects from the floor that may be projected from the revolving brushes.

Keep hands and feet away from revolving brushes.

Do not operate machine where flammable liquids are present.

Use extreme caution when maneuvering.

3. Before leaving:

Make sure machine is turned off.

Stop on level surfaces.

Disconnect batteries.

4. Before servicing:

Stop on level surface, and secure machine.

Disconnect batteries.

5. Before discarding machine:

The batteries must be removed and properly disposed of.

 

 

 

 

!!Safety Precautions!!

 

 

Warning: Hazardous voltage. Shock, burns or electrocution can result. Always disconnect the batteries before servicing machine.

 

Warning: Batteries emit hydrogen gases, explosion or fire can result. Keep sparks and open flames away.

 

Warning: Charge unit in a well ventilated area, and keep battery compartment open when charging. Explosion or fire could result.

 

Warning: Battery acid can cause burns. Wear protective eye wear and gloves when servicing batteries.

 

Warning: Do not store outdoors or pressure wash. Prevent from getting electronic components wet.

 

Warning: The use of parts and solutions other than recommended by the manufacturer may cause damage or endanger people.

 

Warning: Dress safely. Do not wear rings or metal wrist watches while working on this machine. They can cause an electrical short, which can cause serious burns. Do not work on this machine while wearing a tie, scarf or other loose, dangling neckwear or clothing. These loose items can tangle in the rotating parts and cause serious injury or even death.

 

Warning: Do not use the machine as a step ladder or chair.

 

Warning: Only operate this machine from the operator's seat. It was not designed to carry passengers.

 

Warning: Do not operate this machine on ramps or uneven surfaces. When climbing a ramp, always drive the machine in forward straight up or down the ramp. Never drive across the incline. Do not back down or turn on ramps!

 

Warning: Do not attempt to push or pull the machine without first manually overriding the parking brake and disconnecting both leads to the traction motor.

 

Warning: Always use the charger provided by the manufacturer to charge the machine. It is an automatic charger, specifically designed to charge at the appropriate rate. If you must use a different charger, disconnect the batteries before charging. This will prevent damage to the electronic speed controller.

 

Warning: Understand the dynamic braking system before you operate the machine on ramps. Machine does not coast. Releasing the foot pedal will automatically apply braking force, and stop the machine.

 

Warning: Do not park the machine on ramps or slopes. The machine has a parking brake, but it is recommended that it is always parked on level ground.

 

Warning: Do not operate the machine if any parts have been removed or damaged.

 

Warning: Do not remove, paint over, or destroy warning decals. If warning decals become damaged, they must be replaced.

 

Warning: Do not operate machine in unsafe condition. If the machine is in need of repair or is in any way unsafe to operate, the matter should be reported immediately to the shift supervisor. Do not operate the machine until it is returned to proper operating condition.

 

Warning: This machine must only be operated by trained operator. As part of his or her training, they must read this manual thoroughly. If extra copies are needed, contact your local dealer.

 

Warning: Always turn off the machine, before leaving it unattended.

 

Warning: Do not operate over electrical floor outlets, may result in serious injury.

 

 

 

 

CONTROLS

 

Machine Controls and Features:

 

 

1. Recovery tank lid: latch must be secured for recovery tank to seal properly.

2. Steering wheel: steers the machine.

3. Headlight: helps you see in low light areas and to warn oncoming traffic.

4. Polyurethane rollers: helps prevent damage to machine and objects you may drive close to.

5. Front drive tire: (black standard), (grey optional) drives and steers machine.

6. Adjustable seat with arm rests: your machine is equipped with an adjustable seat with arm rests.

7. Seat adjustment: permits the seat to be adjusted forward and backward for operator comfort

8. On board charger plug (optional): plugs into any three pronged outlet to charge machine

9. Side wipers: controls water on turns by directing it to the squeegee.

 

 

 

 

 

10. Horn button: sounds the horn for warning oncoming traffic.

11. Adjustable steering: four settings for operator comfort and ease of entry.

12. Machine hour meter: keeps track of total hours of use on the machine.

13. Battery hour meter: keeps track of total hours of use on the batteries.

14. Water control lockout: locks out the solution flow control so it cannot be changed.

15. Down pressure lockout: locks out the scrub deck down pressure so it cannot be changed.

16. Serial # plate: machines have individual serial number stamped on it.

17. Foot pedal: controls the acceleration and deceleration of the machine.

 

 

 

 

18. Recovery drain hose: allows for controlled draining of recovery tank dirty water.

19. Spray hose: (optional) permits cleaning in remote areas.

20. Squeegee/vac hose: vacuums squeegee. Note: keep free and clear of blockage.

21. Rear bumper: offers squeegee system protection from damage.

22. Squeegee blade: squeegees water to be recovered by the vacuum hose.

 

 

 

23. Tank latch: permits access to recovery tank.

24. Tie down points: location for tie down straps during transport.

25. Squeegee rollers: help protect the squeegee.

 

 

 

 

 

26. Recovery access door: used for flushing out recovery tank with fresh water.

27. Recovery tank: holds approximately 35- gallons of dirty "recovery" water.

28. Vacuum screen box: houses the dual stainless vac screen & shutoff balls.

29. Foam protection screen: used to protect vacuum motor from debris.

30. Drain saver: prevents debris from clogging drain.

31. Solution tank: holds approximately 35-gallons of clean water.

32. Solution tank vent: prevents vacuum from forming in the tank during operation.

 

 

 

33. LCD screen: lists functions and setting of the machine. (see page 9)

34. High water recovery light (red): indicates when the recovery tank is nearly full.

35. Menu control: scrolls through different options on the LCD display.

36. Scrub deck down pressure switch: controls the pressure put on the scrub deck.

37. Scrub deck switch: raises and lowers the scrub deck.

38. Squeegee switch: raises and lowers the squeegee.

39. Solution flow control switch: push down to reduce & up to increase flow.

40. "uni-touch" button: activates brushes, squeegee, and solution flow simultaneously.

41. Forward/reverse switch (red): controls the direction of the traction motor.

 

 

 

42. Spray jet (blue): (optional) activates spray pump for remote spray wand.

43. Vacuum switch (white): for use with remote vacuum wand.

44. Econ switch:

45. Key switch: turns the main power on and off.

46. Circuit breaker: (15 amp) positive bus bar.

47. Circuit breaker: (15 amp) negative bus bar.

48. Circuit breaker: (10 amp) side broom motors.

49. Circuit breaker: (2 amp) side broom lift actuator.

50. Side broom (yellow): lifts and lowers side brooms which turn on automatically.

51. Suds switch:

52. Emergency stop: shuts machine down in a emergency

 

 

 

 

LCD Screen Menu Displays:

 

 

                             Figure 1 - Operator Screen

 

                          Figure 2 - Maintenance Screen

 

Figure 3 - Error Screen

 

***Use green menu selection button on control panel to change screens***

 

1. Battery level indicator Indicates the energy level remaining in the batteries. (Shown on all menu displays)

2. Scrub deck down pressure gauge Sets the down pressure on the brushes.

3. Vacuum on Indicates the vacuum is "on".

4. Scrub motors on - Indicates the brush motors are "running".

5. Key switch hour meter Tells you the total hours the machine has been on.

6. Scrub brush hour meter Tells you the total hours the brush motors have been used.

7. Transport hour meter Tells you the total hours the drive system has been used.

8. Error warning symbol Indicates when there has been a diagnostic code error.

9. Diagnostic code When the machine has detected an error it will display the warning symbol and a diagnostic code which tells you what's wrong.

10. Water on Indicates the solution flow is "on"

11. Solution level Indicates the gallons per minute (G.P.M) 0 1.0.

 

 

 

 

MACHINE SETUP

 

Uncrating Machine and Connecting Batteries:

 

1. Carefully check the crate for any signs of damage. Batteries are in the unit.

 

2. To uncrate the machine, remove banding from around the crate. Take off the top and sides and dispose of properly.

 

 

3. Remove banding from machine. Remove the chocks around the drive wheels.

 

4. Turn all switches to the off position and remove key.

 

5. Tip back tank to expose the battery compartment and check to see that the battery cables are connected.

 

 

A standard machine is equipped with (6) 6-volt, deep cycle, 245 ah batteries, which form a 36 volt system. Maximum battery dimensions are 7-1/8"W x 12-1/4"L x 13-1/4"H.

 

6. Verify that all of the battery cables are connected to the batteries tightly. Locate any loose ones and connect to the open terminal. Tighten with 1/2" wrench. (DO NOT OVER TIGHTEN!) Batteries are heavy but easily damaged. Put covers in place. (See picture below)

 

7. Turn on main power switch and check the battery condition meter to ensure correct installation.

 

8. Fold down ramp, and drive machine off of the base.

 

Notify the carrier immediately if concealed damage is discovered.

 

 

 

Attaching Squeegee:

 

1. Lower the squeegee mounting plate by depressing the squeegee switch (A) to the down position. (See picture below)

 

 

2. Loosen the two knobs (B) on the squeegee and slide them into the slots in the squeegee mounting plate. (See picture below)

 

3. Tighten the two knobs (B) and connect vacuum hose (C) from the machine to the squeegee. (See picture below)

 

4. You may have to adjust the squeegee pitch by turning the pitch adjustment knob (D). (See picture below)

 

 

5. Note vac exhaust, dual vac out *assists in drying (See picture above)

 

 

 

 

Removing Squeegee:

 

1. With the squeegee in the down position, turn the key switch off & remove key.

 

2. Disconnect vacuum hose from squeegee and loosen the (2) knobs.

 

3. Pull squeegee assembly rearward from the lifting carrier.

 

4. Inspect or repair as necessary and reinstall.

 

 

 

Replacing or Rotating Squeegee Blades:

 

For safety: before leaving or servicing the machine, stop on a level surface, turn off machine, and remove key.

 

1. Remove the squeegee assembly from the machine. Remove blade retainer strap and remove squeegee blade

 

2. Rotate the squeegee to new edge position or replace as required.

 

3. Install blade on the locating pins of squeegee assembly.

 

4. Install squeegee retainer strap.

 

5. Fasten and lock knobs.

 

 

 

Adjusting Squeegee:

 

1. Turning adjustment knob clock-wise (tightening) will raise tips & lower the center of the squeegee. (SEE PICTURE BELOW)

 

 

2. This squeegee is adjusted too far back and will not pick up on the outer tips of the squeegee.

Note: the tips of the squeegee are off the floor. (SEE PICTURE BELOW)

 

 

3. This squeegee is adjusted too far forward and will not pick up in the center.

Note: center of the rear blade is spaced off the floor. (SEE PICTURE BELOW)

 

 

4. This squeegee is adjusted just right with good deflection across the entire rear blade. (SEE PICTURE BELOW)

 

 

 

 

 

Leveling Disk Decks:

 

1. Drive machine to a flat level surface and turn machine off.

 

2. Deck should be raised off the floor.

 

3. With the shrouds off, measure from the ground to a parallel surface on all four corners of the scrub deck. (See picture below)

 

 

3. If the measurements are not the same the deck is not level and needs to be adjusted.

 

4. Loosen the (2) locking nuts (4) and adjust the hexagonal arm (5). (See picture below)

 

5. Extending the adjustable arms raises the front and lowers the rear of the scrub deck. Measure & Retighten.

 

 

 

 

Leveling Cylindrical Decks:

 

1. Drive machine to a flat level surface and turn machine off.

 

2. Raise the deck off the floor.

 

3. Measure from the ground to a parallel edge on all four corners of the scrub deck. (See picture below)

 

 

4. If the measurements are not the same the deck is not level and needs to be adjusted.

 

5. Loosen the locking nut (4) and turn the hexagonal arm (5) on each side of the scrub deck to level it. (See picture below)

 

 

6. Extending the adjustable arm raises the front and lowers the rear of the scrub deck. Measure & Retighten.

 

 

 

 

 

Attaching Disk Brushes/Pads:

 

1. Turn "on" machine power.

2. Raise the scrub deck by depressing the brush switch (A) to the ("0") position and turn machine power "off". Disconnect batteries. (See picture below)

 

 

3. Loosen knobs (B) and remove shrouds to access scrub deck (See picture below)

 

 

4. Attach pads to pad drivers before connecting pad drivers to motor hub.

 

5. Attach brushes or pads to motor hubs. Squeeze the scissor locking device (C) and lift brush up on to the motor drive hub. Make sure the scissors close and lock once the brushes are on. (See picture below)

 

 

6. When brushes are attached put shrouds back on machine and tighten knobs.

 

 

 

 

Adjusting Shrouds (Disk Decks):

 

1. The shroud must be adjusted correctly in order to have proper water control during turns. The front of the shroud should be slightly higher than the rear.

 

2. To adjust shrouds loosen knobs (A) and remove shroud. (See picture below)

 

 

3. Spin the RED shroud support (B) up or down to get adjustments. (See picture below)

 

 

4. Once adjusted to the proper height; put the shroud back on top of adjustment supports and tighten knobs back down.

 

 

 

 

Adjusting Cylindrical Side Wipers:

 

1. The cylindrical deck comes equipped with side wipers for increased water control when turning.

 

2. To adjust the side wipers, first loosen the locking nut (A), then turn the adjusting screw (B) in to raise or out to lower the height of the side wiper blade. The spring (C) provides tension during adjustment. (See picture below)

 

 

3. A properly adjusted side wiper will have slight blade deflection on the floor when turning. (See picture below)

 

 

 

 

 

Solution System:

 

1. To access the items listed below, completely drain solution and recovery tanks. Carefully tip the tank back until it is supported by the strap (See picture below).

I. Gate Valve

II. Stainless steel inline filter

III. Solution Flow Valve

 

NOTE: Do Not Lie Under the Tank!!

 

 

 

2. To clean filter (A) close gate valve (B). (See pictures below)

 

Figure 4 - Gate Valve in Closed Position

 

3. Unscrew clear lid (C), remove stainless steel screen (D), rinse screen. (See picture below)

 

 

4. Reinstall stainless filter screen & tighten cap.

 

5. Open gate valve (E) (See pictures below)

 

Figure 5 - Gate Valve in Open Position

 

 

Vac System:

1. The "high recovery" light (A) (red) will illuminate and the horn will sound when the recovery tank is full. Stop immediately and drain the recovery tank. (See picture below)

 

 

2. If the red light is ignored the vac motor will overheat.

 

3. If the vac motor is pulling excessive current circuit breaker (B) (50 amps) may blow to prevent damage. If this occurs contact your service agent.

 

4. Vac switch (C) is set to engage at 45-50" of lift.

 

5. If foam or water gets past the recovery tank "vac screen/ball system" (D) the "unloader valve" (E) will drain it from the vac box. (See pictures below)

 

6. "Unloader valve" (E) is located on the bottom of the vacuum box in front of the vac motor.

 

 

 

 

MACHINE OPERATION

 

Double Scrubbing:

Steps: See picture below

 

 

1. Turn machine on with the key switch.

 

2. Lower scrub head to the floor, use the top half of the brush switch.

 

3. Adjust the solution to the desired setting. (Set half way)

 

4. Begin scrubbing by depressing the foot pedal slowly and then to the speed required. (Not shown)

 

5. Start scrubbing with the brush pressure at 1 or 2 marks, do not use the 4 or 5 marks without management's approval.

 

6. To operate machine in reverse, simply switch the reverse switch to the reverse position, back up alarm may sound and your reverse speed is set to roughly 70% of forward.

 

7. To stop the machine, let off of the foot pedal, and the machine will stop automatically. (Not shown)

 

 

 

Vac Only Scrubbing:

Steps: See picture below

 

 

1. Turn machine on with the key switch.

 

2. Lower squeegee by pressing the switch.

 

3. Begin vacuuming by depressing the foot pedal slowly and then to the speed required. (Not shown)

 

4. To operate machine in reverse, simply switch the reverse switch to the reverse position, back up alarm may sound and your reverse speed is set to roughly 70% of forward.

 

5. To stop the machine, let off of the foot pedal, and the machine will stop automatically. (Not shown)

 

 

 

Operating Hints:

 

1. Observe the amount of solution the machine is dispensing on the floor and adjust to the desired flow. To increase the solution flow rate, push solution switch (A) +, to decrease push solution switch (A) -. (See picture below)

 

2. Keep an eye on the "red" recovery full light (B) to make sure there is not foamy buildup in the recovery tank. If excess foam begins to develop, pour a recommended foam control solution into the recovery tank. (See picture below)

 

 

3. Always operate at lower speeds when scrubbing around walls and objects. You should reduce the speed, to maintain control when turning.

 

4. If squeegee starts to streak, raise and wipe the blades with a clean cloth. If the problem continues, check the blades for wear or damage, and rotate if needed.

 

5. Change or turn over pads when dirty. Rotate the scrub brushes every week.

 

6. Stay clear of objects protruding from the floor, such as sockets, grates, for they will damage the pads and squeegee blades.

 

7. During brief stops you should turn everything off, the brushes and solution will automatically stop when the foot pedal is released.

 

8. Always keep an eye on your gauges. They let you know the status of a particular system at a glance. If your battery gauge is reading low, you must stop immediately, and recharge. Running the batteries dead, will result in damage to the batteries.

 

9. When you run out of solution, raise the brushes, and continue to vacuum the remaining water until it is consumed. The "yellow" low solution light (C) will light up when the solution is low and the sight tube on the back of the tank tells you how much solution is left in the tank, (See picture above)

 

10. When you are ready to stop, pick up the brushes, turn off the solution switch, pick up the squeegee, and drive the machine back to the charging area.

 

 

 

Drain Solution Tank:

 

To drain left over cleaning solution from the solution tank, perform the following steps.

 

1. Pull the clear sight tube/drain hose (A) off barbed fitting. (See picture below)

 

2. Rinse out tank and solution flow system with clean water.

 

 

 

 

Drain Recovery Tank:

 

Always empty recovery tank when refilling the solution tank. To drain the recovery tank, perform the following steps.

 

1. Remove drain hose "B" and unscrew cap. Open the top "recovery access lid" and flush out with fresh water to keep tank clean. (See picture below)

 

2. Remove cap and begin draining, squeeze "C" to control flow. (See picture below)

 

It is the customer’s responsibility to verify that discarded water is in compliance with local, state, and federal laws. DO NOT DRAIN INTO "STORM DRAINS”!

 

 

 

3. Open the top "recovery tank lid" and flush out with fresh water to keep tank clean. Rinse the recovery tank after every use. This will prevent heavy build up on the bottom of the tank, foul odors and clogging of the drain hose. Empty "Drain Saver".

 

 

4. Once tank is empty, put the cap back on and place hose back on hook.

 

 

 

Override Parking Brake:

 

The parking brake must be released "prior" to attempting to "push/pull" the machine manually. Perform the following steps in any order.

 

1. Disconnect both positive and negative leads (1 & 2) from the traction motor. (See picture below)

 

2. Turn wing nut (3) clockwise to release the parking brake. (See picture below)

 

 

 

Recovery Tank Float Shut-Off:

 

When water is no longer being vacuumed from the floor and the vacuum fan is operating, the ball float has engaged the red high recovery light (1) will come on. (See picture below)

 

The vacuum motor will not vacuum water with recovery tank full. The recovery tank must be drained

 

1. The float shut-off (2) screen can be cleaned in or out of the machine.

 

 

2. To clean the float shut-off while it is inside the machine wipe material off screen then rinse. Check that the ball is also clean and moves freely.

 

3. To remove the float shut-off, remove the white clamp (3) grasp the screen with one hand and pull down to remove.

 

4. Screens, gaskets, and shutoff balls must be in place.

 

 

 

Recovery Tank Drain Saver:

 

The recovery tank drain saver will help prevent the drain from becoming clogged with debris.

 

1. The drain saver screen should be emptied and cleaned after you drain the tank.

 

2. To clean, pull hose (4) out of drain saver and remove screen. Empty screen into trash, wipe material off screen and then rinse the screen.

 

 

3. When finished place screen back into the recovery tank and re-insert hose into screen (5).

 

4. The screen saver must always be in place when the machine is in use to prevent clogging of drain.

 

 

 

Standard Battery Charging:

 

Charger Specifications:

DC Output voltage of 36 volts. (Standard)

Output current of 25 amps max. (Standard)

Output current of 36 amps max. (Optional W/325 ah battery upgrade)

AC Input voltage of 110 volts/60 Hz. (Standard)

Automatic shut off circuit.

Made for deep cycle batteries.

 

Danger: always charge batteries in a well ventilated area. Batteries emit hydrogen gas. Explosion or fire can result. Keep sparks and flame away. Shield eyes when servicing batteries and avoid contact with battery acid. Leave access panel open when charging!

 

 

 

Standard Charger

 

Caution: the following instructions are intended for the 36v charger supplied with the machine. Do not use any non OEM charger with this machine.

 

1. Transport machine to a well ventilated area for charging.

 

2. Turn the machine off.

 

3. Hinge opens the tank to expose the batteries. (See picture below)

Caution: (always wear eye protection when batteries are exposed)

 

4. Check the water level in each battery. Do not charge the machine unless the water is slightly higher than the plates. If needed, add enough distilled water to 1/2” above the plates. Do not over fill. Batteries can overflow during charging. Replace caps before charging.

 

5. With the grey (50) charger plug disconnected from the machine, plug the charger power cord into a grounded 110 volt standard wall outlet.

 

6. Connect the grey charger plug into the battery charging port (A) located on the seat pedestal.

 

7. The charger will automatically begin charging, and automatically shut off when fully charged (Check gauge)

 

8. After the charger has turned off, unplug the grey charger plug from the machine and disconnect the charger from the wall outlet.

 

9. Recheck the cell level after charging. If needed, add distilled water up to the correct level. Be certain to replace the caps securely and to wipe off the top of the batteries.

 

 

 

 

Optional Battery Charging:

 

Charger Specifications

Output voltage of 36 volts. (optional)

Output current of 25 amps max.

Input voltage of 110 volts/60 Hz.

Automatic shut off circuit.

Made for deep cycle batteries, wet or sealed.

 

Danger: always charge batteries in a well ventilated area. Batteries emit hydrogen gas. Explosion or fire can result. Keep sparks and flame away. Shield eyes when servicing batteries and avoid contact with battery acid. Leave access panel open when charging!

 

 

On-Board Charger

 

Caution: the following instructions are intended for the 36v "optional" on-board charger.

 

1. Transport machine to a well ventilated area for charging.

 

2. Turn the machine off.

 

3. Hinge open the tank to expose the batteries. Caution: (always wear eye protection when batteries are exposed)

 

4. Check the water level in each battery. Do not charge the machine unless the water is slightly higher than the plates. If needed, add enough distilled water to 1/2” above the plates. Do not over fill. Batteries can overflow during charging. Replace caps before charging.

 

5. Plug the extension cord into a grounded 110 volt/60 Hz standard wall outlet & flip switch.

NOTE: MUST HAVE 20 AMP SERVICE.

 

6. The charger will automatically begin charging, and automatically shut off when fully charged (Check gauge)

 

7. After the charger has turned off, unplug the extension cord from the machine and disconnect from the wall outlet.

 

8. Recheck the cell level after charging. If needed, add distilled water up to the correct level. Be certain to replace the caps securely and to wipe off the top of the batteries.

 

 

Onboard Charger Operator Manual:

 

GENERAL INFORMATION AND WARNING

• Electronic automatic battery charger with microprocessor suitable for any battery type.

• Fully automatic charging cycle with electronic setting; protected against overload, shortcircuit at clamps and reversed polarity.

• Never disconnect the battery while charging: this could cause sparks.

• Never use the equipment in the rain, in areas used for washing and in damp areas.

• Before starting to charge, make sure the voltage of the equipment suits the voltage of the battery and that the selected charging curve (for leadacid free batteries and airtight gel batteries) is correct for the type of battery to be charged. In addition, make sure the rated input voltage of the charger suits the available supply voltage and the system is equipped with grounding.

• If necessary, replace the fuse with another of the same type and value as indicated on the rating plate.

• Pay attention to any remarks of the battery manufacturer.

 

For leadacid batteries with liquid electrolyte:

• Control the water level after each charging process.

• Refill with distilled water only.

• Caution! The gases generated during charging are explosive. Do not smoke in the vicinity of the batteries. When working with cables and electrical equipment, avoid open flame and sparks.

• Attention: Use protective glasses and gloves during battery maintenance. Battery acid causes injuries. In case of contact with battery acid, wash the affected parts with a lot of fresh water and consult a doctor if necessary.

 

CONTROLS (see figure behind the cover)

1. Threedigit display + symbol (1), to view A =the charging current, U = the battery voltage, h = the charging time, C = the charging amperehours [AH], E = the energy used [KWh].

2. Button for the Selection of the display mode (2): A, U, h, C, E. After about 10 seconds the display returns to the visualization of the charging current.

3. Red control indicator (3): when it is on, the charging cycle has started.

4. Yellow control indicator (4): when it is on, the final phase of the charging cycle has started.

5. Green control indicator (5): when it is on, the charging cycle has finished.

 

OPERATION

• Plug the cord into the socket.

• Connect the battery, checking the polarity.

• Now, the battery charger’s display will show a sequence of details on the charger’s internal programming: after the name “SPE”, it will show the software release installed in the equipment, then, in sequence, the following parameters: battery voltage, charging current, charging curve number, and finally the words “GEL” or “Acd” depending on the set up charging curve being suitable for airtight gel batteries or leadacid batteries. Make sure the type of batteries to be charged (gel or leadacid batteries) matches the displayed details (“GEL” or “Acd”, respectively). If it doesn’t, contact our dealer. Now, a test is run on the battery voltage to decide if the charging process should be started or not. If the battery is not connected to the battery charger, the display will show the word “bat”. The word will stay on, even if the test is failed (for instance, reversed polarities or incorrect battery connection). If the test is passed, the display will show the battery voltage for approximately 5 seconds and the battery will begin to charge.

 

 

 

Power Cat 36 Volt 25 Amp Sealed Battery Charger:

 

The Power Cat 3625S is a sealed high frequency electronic battery charger with an on board microprocessor that can be programmed for different types of batteries. The charger features a fully automatic charging cycle and has built in protection against short circuits and reverse polarity.

 

THE CHARGER UNIT

The charger is equipped with a remote “EZlamp” 3 LED charge state indicator, located on the side of the central command, to show charge cycle information as well as diagnostic codes.

 

                                                                                                                                           Charger Status LEDs (EZLamp)

 

 

OPERATION

The 3625S is initially switched on by plugging the unit into the wall. The “EZlamp” charge state indicator then displays whether the unit is set for flooded lead or AGM type batteries by flashing the corresponding LEDs. For flooded lead batteries the “EZlamp” will display ONLY the RED LED flashing for about 5 seconds. For AGM batteries the “EZlamp” will display a flashing GREEN & RED LED for about 5 seconds.

 

EZlamp Code

Charger Phase

Flashing RED

Internal charger check – “Flooded Lead Settings”

Flashing RED & GREEN

Internal charger check – “AGM Settings”

Steady RED

Indicates first and second phase of charge

Steady YELLOW

Indicates finish charge in progress

Steady GREEN

Indicates charge cycle is complete

 

 

TROUBLE SHOOTING

In the event that there is a problem with charger here is a simple trouble shooting guide. If the unit does not power on , assure that the plug for the charger is placed firmly in the wall receptacle and that that the circuit breaker for that receptacle is not blown. Watch the “EZlamp” indicator to see if any LEDs illuminate when it is plugged in. If no LEDs light try a different power cord. If this does not fix the problem the charger needs to be replaced.

 

 

EZlamp Fault Codes

Problem

Solution

Continuous Flashing Red

-No connection to battery

-Battery connected in reverse

-Check connections to battery

Flashing Red and Yellow

-Poor Connection

-Check all connections

-Verify battery was not disconnected during charge

-Problem with battery

-Check battery

-Verify battery electrolyte levels (lead acid only)

 

 

 

 

Changing Batteries:

 

Stop machine in a clean area next to the charger. Turn off machine.

For safety: Before leaving or servicing the machine; stop on level surface, turn off machine and remove key. Use eye protection.

 

1. Tip back tank to expose batteries.

 

2. Disconnect main battery cables from machine.

 

3. Use the proper size wrench to disconnect main ground wire first and secure cable terminal away from batteries.

 

4. Disconnect main positive lead and secure cable and remove one at a time.

 

5. Loosen both terminals on each jumper cable and remove one at a time, and place away from machine.

 

6. Prepare a suitable site to place the batteries, store on a wood pallet, not on concrete.

 

7. Attach suitable battery lifting device and lift batteries from the machine

 

Warning!

Batteries are a possible environmental hazard & extremely heavy. Consult your battery supplier for safe removal & disposal methods. Use a hoist; batteries are heavy use caution!

Note: orientation of the positive and negative posts is critical for cables to reach.

Do not lift from battery posts, which cannot support the weight. (See below)

 

Figure 6 - Front of Machine to the Right

 

 

Side Broom System:

 

1. Flip side broom switch (A) up to lower and engage broom. (See picture below)

 

2. To adjust side broom height, loosen locking nut located behind screw head (B) of screw that is in front of scrub deck just inside the side wall of frame on each side of the machine. Use 1/2" wrench to loosen locking nut. (See picture below)

 

3. Turn adjustment screw (B) counter-clockwise (loosens) to lower side brooms. Turn screw clock-wise (tightens) to raise side brooms.

 

4. Retighten locking nut.

 

5. Side broom adjustment slot (C). (See picture below)

 

6. Picture below shows brooms to high.

 

7. Picture below shows brooms to low.

 

8. Picture below shows brooms just right.

 

 

 

 

 

MACHINE OPTIONS

 

Overhead Guard:

 

1. Your machine may be equipped with an "optional" "Overhead Guard" (A) that helps protect the operator from falling objects that are above the operators head. (See picture below)

 

 

 

HD Side Doors:

 

1. Your machine may be equipped with "optional" "Heavy Duty Side Doors" (C) that helps protect the machine's scrub deck from collision damage. (See picture below)

 

 

Non-Marking Tires:

 

1. Your machine may be equipped with non marking (D) tires, which may have reduced traction on some floors (See picture above)

 

 

 

 

On-Board Charger:

 

1. Your machine may be equipped with "optional" On-board charger (E) that will charge your machine. (See picture below)

 

 

 

Water Control Lock-Out:

 

Your machine may be equipped with an "optional" water control lock out switch (A), which prevents people from changing the water levels on the machine. (See picture below)

 

 

 

 

Down Pressure Lock-Out:

 

Your machine may be equipped with a "optional" down pressure lock out switch (B), which prevents people from changing the down pressure on the machine. (See picture above)

 

 

 

 

 

 

Figure 7 - Control Box

 

 

On-Board Soap:

 

1. Switch toggle switch up once for normal soap distribution and up twice for heavy duty soap distribution. (See “A” in Figure 7)

 

 

Spray Hose:

 

1. Turn on spray jet pump using the toggle switch on the central command. (See Figure 7 Item "B")

 

2. Detach spray hose from back of machine and squeeze handle.

 

 

Vac Wand:

 

1. Detach vac hose from squeegee and attach it to the vac wand. (See picture below)

 

2. Turn on vac motors using the toggle switch on the central command.  (See Figure 7 Item "C")

 

 

 

 

 

MAINTENANCE

 

Daily Maintenance:

 

1. Remove and clean pads or brushes. Never use soiled pads when cleaning. Replace pads when they become packed with residue.

 

2. Remove and clean debris from the float shut‐off screen and drain saver located inside the recovery tank.

 

3. Drain and rinse tanks thoroughly

 

4. Inspect vacuum hose for any objects obstructing the air flow.

 

5. Raise squeegee and wipe blades with a clean cloth. Store squeegee in the raised position to prevent damage or setting of the blades.

 

6. Wipe down machine if needed. Use a nonabrasive, non solvent cleaner, or a clean damp cloth.

 

7. Recharge the batteries if needed.

 

 

Weekly Maintenance:

 

1. Check battery water level in each cell of the batteries, and fill as needed. Always use distilled water to refill batteries. Batteries should be filled approximately 3/4" to 1" above the plates. Overfilling will cause the batteries to leak during charging. The charging process creates gas bubbles inside the battery, which effectively increases the volume of the electrolyte.

 

2. Clean battery tops to prevent corrosion.

 

3. Rotate brushes. Rotate the left to the right and right to left. For cylindrical models rotate from front to back, or end to end if using different materials.

 

4. Drain and rinse tanks thoroughly. To thoroughly flush out any solution chemicals in solution line and valves, refill solution tank with a few gallons of warm clean water and run machine until tank is empty.

 

 

Monthly Maintenance:

 

1. Check scrub head and squeegee lifting cables for wear and spring tension.

 

2. Check machine for water leaks and loose nuts and bolts.

 

3. Check to see if battery cables are tightened (Tighten if needed)

 

4. Check parking brake

 

 

Yearly Maintenance:

 

1. Call your local dealer for yearly maintenance

 

 

Storing Machine:

 

1. Make sure to flush the tanks out completely. To thoroughly flush out any solution chemicals in solution line and valves, refill solution tank with a few gallons of warm clean water and run machine until tank is empty.

 

2. Open the recovery tank lid to promote air circulation.

 

3. Raise brushes and squeegee.

 

 

Checking Battery Specific Gravity:

 

Use a hydrometer to check the battery specific gravity.

 

Checking Gravity

A. Hydrometer

B. Battery

 

Note: Do not take readings immediately after adding distilled water, if water and acid are not thoroughly mixed, the reading may not be accurate.

 

Check the hydrometer against this chart:

 

Specific Gravity @ 80° F (27°C)

Battery Condition

1.265

100% CHARGED

1.225

75% CHARGED

1.190

50% CHARGED

1.155

25% CHARGED

1.120

DISCHARGED

 

 

Note: if the readings are taken when the battery electrolyte is any temperature other than 80vF (27vC), the reading must be temperature corrected.

 

To find the corrected specific gravity reading when the temperature of the battery electrolyte is other than 80vF (27vC): add (+) to the specific gravity reading 0.004 (4 points), for each 10vF (6vC) above 80v (27vC). Subtract () from the specific reading 0.004 (4 points), for each 10vF (6vC) below 80vF (27vC).

 

 

 

Preventative Maintenance Records:

 

CUSTOMER INFORMATION

CUSTOMER

ADDRESS

CITY

STATE

ZIP CODE

 

MACHINE INFORMATION

MODEL #

SERIAL #

WORK ORDER#

HOUR METER:

 

BATTERY CONDITION                                                                    

Cell #1

Cell #2

Cell #3

Cell #4

Cell #5

Cell #6

Battery # 1 Hydrometer

 

 

 

 

 

 

 

Battery # 1 Water Condition

 

 

 

 

 

 

Battery # 2 Hydrometer

 

 

 

 

 

 

Battery # 2 Water condition

 

 

 

 

 

 

Battery # 3 Hydrometer

 

 

 

 

 

 

 

Battery # 3 Water Condition

 

 

 

 

 

 

Battery # 4 Hydrometer

 

 

 

 

 

 

Battery # 4 Water condition

 

 

 

 

 

 

 

Clean Battery tops. Check Battery Cable and Terminal Condition

NOTES:

 

BRUSH CONDITION

Scrub Brush Fiber Length

 

Rota ted Brushes

Brush Drive Sockets

Good                    Worn                    Needs Replacement

Drive Hubs

Good                    Worn                    Needs Replacement

Side Broom Condition

Good                    Worn                    Needs Replacement             Rotated Side to Side

 

CHECK OPERATION AND CONDITION OF:                       

IN SPEC

REPAIR

PROBLEM

Steering wheel Tilt Mechanism

 

 

 

Key Switch

 

 

 

Horn

 

 

 

Head Light

 

 

 

LCD Display

 

 

 

Page Button

 

 

 

Brush Pressure Button

 

 

 

Brush Pressure Managers Lock Out

 

 

 

Foot Pedal

 

 

 

Reverse Switch

 

 

 

Back Up Alarm

 

 

 

One Touch Switch

 

 

 

Brush Switch

 

 

 

Solution Potentiometer

 

 

 

Solution Solenoid

 

 

 

Solution Drain Valve

 

 

 

Low Solution Light

 

 

 

Brush Deck Lift System

 

 

 

Brush Motors & Motor Brushes

 

 

 

Vacuum Switch

 

 

 

Vacuum Motor performance

 

 

 

Off-Board Vac Switch

 

 

 

Squeegee Lift System

 

 

 

Squeegee Adjustment

 

 

 

Squeegee Blades

 

 

 

High Recovery Light

 

 

 

High Recovery Alarm

 

 

 

Drain Hose and Plug

 

 

 

Side Broom Operation

 

 

 

Spray Jet Switch

 

 

 

Spray Jet Pump, Hose & Nozzle

 

 

 

Strobe Light

 

 

 

Battery Charger Connectors

 

 

 

Battery Charger

 

 

 

 

CLEAN AND/OR LUBRICATE

IN SPEC

REPAIR

PROBLEM

Solution Filter

 

 

 

Squeegee Pivot Points & Knobs

 

 

 

Scrub Deck Linkage

 

 

 

Squeegee Knob Threads

 

 

 

Squeegee Pivot Points

 

 

 

Brush Head Pivot Points

 

 

 

 

VISUALLY INSPECT                                                                         

IN SPEC

REPAIR

PROBLEM

Solution Tank Condition

 

 

 

Recovery Tank & Lid Condition

 

 

 

Drain Saver

 

 

 

Vacuum Float

 

 

 

Vacuum Motor Brushes

 

 

 

Vacuum Hoses

 

 

 

Vacuum Filter

 

 

 

Solution Hoses

 

 

 

Squeegee Tool and Throat

 

 

 

Squeegee Blades

 

 

 

Blade retainers & Hardware

 

 

 

Squeegee Wheels

 

 

 

Brush Skirts

 

 

 

Brush Motor Brushes

 

 

 

Brush or Pa d Driver Condition

 

 

 

Drive Wheel Condition

 

 

 

Caster Condition

 

 

 

 

Technician's Name:            ___________________________ 

 

Technician's Signature: ___________________________                         Date:_______________

 

Customer's Name:             ___________________________

 

Customer's Signature:  ___________________________                         Date:_______________

©2006 R.P.S. Corporation

 

 

 

TROUBLESHOOTING

 

Troubleshooting Central Command:

 

1. 7601 and 7602 Error. Scrub deck current over load. This can occur when driving over a bump in the floor. To restart, turn off the key and turn it on again. To avoid this error, either slow down on bumpy parts of the floor, or reduce down pressure on the pads.

 

 

2. 1500 Error. There is an open in the parking brake circuit. Check the parking brake wiring and the parking brake coil to find the open circuit.

 

 

3. 7700, 7701, 7702, and 7703 Error. The vacuum motor has exceeded their authorized power limits. Turn off key and turn on again to clear.

 

 

4. BOOST ON Allows front wheel drive to draw more power when needed to climb ramps for 30 seconds.

 

 

5. Throttle error. You pressed the foot pedal before turning on the key. Turn off the key and try again, leaving foot off of the pedal.

 

 

6. 2C00 and 2C01 error. Low voltage warning. Voltage has dropped down below the minimum required to operate the machine. If you wait a few minutes, the batteries may come up in voltage, allowing you to drive very slowly to the recharge station. If not, you will have to release the parking brake (on the front wheel, pull lever toward the front of the machine to release) and push the machine to recharging station. You must disconnect the traction motor! (+ cable first)

 

 

7. 7802 error. The traction motor pulled excessive current perhaps running a ramp for more than the 60 seconds allowing for this. Turn off the key, turn on again, and continue. You should not use this machine to climb ramps so steep and so long that this code comes up repeatedly, or you could overheat the traction motor.

 

 

9. All other error codes. Turn off the key, and disconnect the positive battery cable from the batteries for more than one minute (the time is needed to drain the controller on-board capacitor). Reconnect cables, being sure that it is tight. Too loose and you will burn battery. If you over tighten the cables you can damage the battery lead terminal. Try again.

 

10. If the problems cannot be solved by any of this solution, call your local dealer service department.

 

 

 

Troubleshooting Central Command II V4

 

Code

Fault Description

Course of Correction

0700

Bias Voltage Error High reference signal is grounded

Bias Voltage Error High reference signal is grounded

0701

Mid Rail Voltage High

 

0702

Mid Rail Bias Voltage High

 

0704

12V supply failure

 

0705

2.5V reference error

 

0706

High reference ground fault

5 Volt reference is Contacting 0 Volt Reference

0810

Throttle High reference error

For all Throttle Diagnostic Codes

0811

Throttle Max Wiper Difference Error

Check throttle wiring for shorts or opens. Repair or replace as necessary

0812

Throttle Max Pull Down Difference Error

If diagnostic code is not cleared, then replace the throttle potentiometer

0813

Throttle Max Pull Safe Difference Error

 

0814

Throttle Reference Error

 

0815

Throttle Lo Reference Error

 

0816

Throttle Hi Reference ISO Error

 

0817

Throttle Lo Reference ISO Error

 

0818

Throttle Error: Both have Readings

 

0A01

Power down error

Check the wiring to the main power switch. This code indicates rapid power cycling

1310

Excessive Current Trip

Current Draw on Control exceeds maximum limit of 250 amps

Resistance in the machine’s Main Breaker and/or battery cable to control

Gives a false reading to the controller.

1311

Brush head actuator, excessive current

Device connected to the brush head actuator has exceeded maximum limit of 21 amps surge value and 7 amps continuous.

Check that the arms are not too tight (torque = 25 inch lbs, almost finger loose). Check that actuator system is not binding

1312

Squeegee actuator, excessive current

Device connected to squeegee actuator (on riders) has exceeded max limit of 21 amps surge value and 7 amps continuous load.

Check that the arms are not too tight (torque = 25 inch lbs, almost finger loose). Check that actuator system is not binding.

1313

Solution valve circuit, excessive current

Current exceeded seven amps max. Check valve operation. Coil may

be corroded, or short in wires.

1314

Soft Aux 4 Over current Occurred

Aux 4 is not used by us at this time.

1318

Soft Brake light Over current Occurred

Brake light circuit not used by us at this time.

131C

Backup Alarm Over current occurred

Backup alarm drew more than 2 amps max allowed. Check inline resistor

on some models. If resistor is bad, remove it, and put piece of duct tape

over speaker of alarm. (Reverse EMF from the echo is causing the problem)

1321

Aux 1 (Brush Actuator) Over current 2 Occurred

Brush actuator exceeded 12 amps for less than 0.1 sec.

See notes for 1311

1322

Aux 2 (Squeegee Actuator) Over current 2 Occurred

Squeegee actuator exceeded 12 amps for less than 0.1 sec.

See notes for 1312

1400

Bridge Fault 1 - Brush or traction motor not in correct

voltage range.

Possible short between B+ and the high amperage outputs

1401

Bridge Fault 2 - Voltage difference on traction bridge

too great

 

1402

Brush Bridge Fault - Battery/Brush bridge voltage

difference too great

 

1411

Brush actuator positive wire is shorting

Find appropriate wire and remove short.

1412

Brush actuator negative wire is shorting

Find appropriate wire and remove short.

1413

Squeegee actuator positive wire is shorting

Find appropriate wire and remove short.

1414

Squeegee actuator negative wire is shorting

Find appropriate wire and remove short.

1500

Brake Fault - Solenoid brake circuit is open

Parking Brake is disconnected or coil of brake is open.

1501

Brake Fault - Solenoid brake circuit is shorted

Parking Brake coil or wiring is shorted.

1502

Brake Fault - Brake Over Current Error

Parking brake coil is shorted internally or wiring too it is shorted

1503

Solenoid brake driver fault

 

1504

Solenoid brake interlock fault

 

1507

Brake Over current

Parking Brake is drawing too much power. Check wiring and brake.

1600

High Battery Error

Battery voltage is too high. Batteries hooked up wrong, or still on charger.

1D02

Spec Change Trip

This is normal--comes up when you reprogram the control. Turn key off and

on to reset the program.

1E03

Inhibit activated

Inhibit is power signal intended to turn off control. We don't use it.

1E04

Inhibit Activated 2

Inhibit is power signal intended to turn off control. We don't use it.

1E06

Inhibit Input Out of Range

Inhibit circuit voltage is too low or high to work. We don't use Inhibit.

2C00

Low Battery Error

Voltage in battery is too low (18 volts min on 24V system; 28V on 36V system)

2C01

Low Battery Error--2

Recharge the battery in either case. check voltage under load to see if bad

2C02

Battery lockout occurred

cell is pulling down voltage.

2C03

Battery Lockout occurred--2

 

2F01

Throttle Displaced Error

Pedal was pushed before key turned on. Not a problem. Restart machine.

3A00

Bad Program Settings

You reprogrammed the control with settings that are not authorized.

3100

Low bridge voltage

Probable short circuit of output device or wiring

3101

Traction bridge fault

 

3102

Brush/Vac bridge fault

 

3103

Waiting for bridge to charge

 

7000

Startup With Push Selected

Freewheel input signal selected at startup. Disconnect freewheel switch.

7001

Push Activated in Drive Mode

Freewheel input signal activated while driving. Disconnect freewheel switch.

NOTE: As of this reading, we do not use Freewheel. This permits pushing

machine more easily by disconnecting traction motor from control.

7500

Throttle Comms Time Out

Problem with LCD dash module or with wiring to it. Check and replace as necessary.

7501

LCD Module settings corrupt

Disconnect batteries and wait 2 minutes to reconnect

7600

Brush motor not connected

Check for open circuit

7601

Soft Brush Current Fold back

Too much load on brush motor. May be from hitting a bump or wire tangled in

brush drive mechanism. Possible wiring or brush motor short.

7602

Soft Brush Current Foldback--2

Same as above.

7603

Soft Brush Current Foldback--3

Same as above.

7604

Brush Inhibit is on

We do not use Brush Inhibit at this time.

7605

Brush startup over current detection

You may have started brushes on carpet or rubber or other high resistance material.

This may have stalled motor before actuator could react to lift brush head up.

If chronic problem, call Factory to discuss reprogramming machine for application.

7700

Soft Vacuum Motor Disconnected Error

Check wiring to vac motor. On 390, check wiring to Hella relay for vac motor

7701

Vac Motor Current Fold back

Too much amp load on vac circuit. Check wiring. May come from picking up large column of water.

7702

Soft Vacuum Current Foldback--2

Same as above

7703

Soft Vacuum Current Foldback--3

Same as above

7800

Traction Motor Fault No. 1

Check traction motor wiring and connectors. Include connector at steering pivot under floor cover!

7801

Traction Motor Over current Error

Too much current due to bad motor or wiring to motor

7802

Soft Traction Motor in Fold back State

Traction motor being overloaded, or ramp climbing that took longer than 60 seconds. (Fold back means normal low amp setting to motor. There is one minute ramp climbing surge that may be 4 times as high as the fold back rate).

7803

Motor Line Voltages Instability Timeout

May be loose wire at motor or at control. Possible motor problem

7880

Traction Speed Input Out of Range

Throttle setting wrong for motor speed. Check throttle pot and wiring.

7900

Emergency Stop Error

Emergency Stop Button is Actuated when you try to move. Optional button.

7901

Soft Belly Button Actuated

Belly Button Switch activated. We don’t use this.

8000

Service Mode

Service Timer Limits have been reached. We don’t normally use them; they are a dealer option

9000

Brushes not fitted

Check brush deck to make sure brushes are on and on securely

0003

Possible terminal short in system

For all of these diagnostic codes:

0100

 

1. Turn off key switch and disconnect battery for two minutes, using your watch to measure time.

0204

 

2. When you reconnect the battery, you must see a spark. This shows the control’s on-board capacitor has been discharged and has been refilled.

0A01

 

3. Restore the battery connection. Make sure the battery cable is on tight before trying machine or you could burn battery posts and cable

0B02

 

4. Turn on machine. If diagnostic code still shows, then replace the control

1704

 

 

1705

 

 

1706

 

 

 

 

 

 

 

 

Troubleshooting:

 

Problem

Cause

Solution

No power, nothing operates

Faulty power switch

Batteries need charging

Faulty battery

Loose battery cable

Main circuit breaker tripped

 

Contact local servicing dealer

See charging batteries

Replace battery

Tighten loose cable

Wait 5 minutes for auto reset

Determine cause and correct

 

Brush motor(s) do not operate

Brush deck is not down

Foot pedal is not depressed

Brush circuit breaker tripped

 

Carbon brushes worn

Faulty brush motor or wires

Put brush deck down

Engage foot pedal

Wait 5 minutes for auto reset

Determine cause and correct

Contact local servicing dealer

Contact local servicing dealer

 

Drive motor does not operate

Recharge switch misadjusted

Faulty speed controller or wires

Faulty drive motor

Faulty wiring

Carbon brushes worn

Contact local servicing dealer

Contact local servicing dealer

Contact local servicing dealer

Contact local servicing dealer

Contact local servicing dealer

 

Vacuum motor does not operate

Squeegee is in the up position

Faulty vacuum switch

Vacuum circuit breaker tripped

 

Faulty vacuum motor

Rotate squeegee lift lever down

Try operating "white” toggle

Wait 5 minutes for auto reset

Determine cause and correct

Contact local servicing dealer

 

Drive motor runs incorrectly

Faulty speed controller or wires

Faulty potentiometer

Loose wires

 

Contact local servicing dealer

Contact local servicing dealer

Contact local servicing dealer

Insufficient solution flow

Solution tank low

Flow knob turned down

Solution filter clogged

Solution line clogged

Solution valve clogged

 

Refill solution tank, drain recovery tank

Move lever to on

Remove cover and clean

Remove and blow out with compressed air

Remove cover and clean

No solution flow

No solution in tank

Solution valve off

Solution switch off

Solution screen clogged

Faulty solution solenoid

Faulty solution switch

 

Fill solution tank

Rotate lever to on

Turn solution switch on

Remove and clean screen

Contact local servicing dealer

Contact local servicing dealer

Poor water recovery

Recovery tank is full

Ball/screen in recovery

Tank is clogged

Vacuum hose is clogged

Squeegee is clogged

Squeegee blade is worn

Faulty vacuum hose

Vacuum motor gasket torn

Tank gasket faulty

Drain plug loose

Vac motor faulty

Battery charge low

 

Empty recovery tank

Remove screen and clean

 

Remove debris

Remove debris

Rotate or replace blades

Contact local servicing dealer

Contact local servicing dealer

Contact local servicing dealer

Tighten lid

Contact local servicing dealer

Charge batteries overnight

Poor water recovery on turns

Wipers worn

Wipers chatter

Squeegee swing is binding

Incorrect squeegee size

 

Replace wiper material

Tighten pivot points

Contact local servicing dealer

Contact local servicing dealer

Tires noisy

Bearing dry

Faulty hubs

 

Grease bearings

Contact local servicing dealer

 

Poor traction

Excessive brush pressure

Worn drive tire

Heavy soap concentration

 

Reduce pressure with switch

Replace tires

Contact local servicing dealer

Short run time

Batteries run down

Batteries still down

Batteries low on water

Batteries over cycled

 

Charge batteries twice

Contact local servicing dealer

Fill with distilled water to ¾” above the lead plates

Contact local servicing dealer

 

 

 

Battery Maintenance Guide

 

 

SAFETY:

Always wear protective clothing, gloves and goggles when handling batteries

If acid contacts your skin or eyes, flush with water immediately

Keep flames, sparks and metal objects away from batteries

Charge batteries in a well-ventilated area

To avoid short circuits do not lay objects on top of battery

Check that all cable connections to the terminal are properly tightened; connections that are too tight or too loose could result in post breakage, meltdown or fire

 

INSPECTION & CLEANING:

Keep batteries clean and dry from residue

Check that all vent caps are tight

Use a solution of baking soda and water to clean if there is acid residue on batteries or corrosion on the terminals

Protective spray or petroleum jelly should be applied to terminals to reduce corrosion

 

STORAGE:

Batteries should be fully charged prior to and during storage

Never store discharged batteries

Store batteries in a cool, dry place

Recharge batteries before putting them back into service

 

WATERING:

ADD WATER, NEVER ACID, TO CELLS (distilled water recommended)

DO NOT OVERWATER

Before charging the batteries, only add water if the plates are exposed. Add just enough water to cover the plates, and then charge the batteries. Once fully charged, add water to the proper level as indicated below

For fully charged standard deep cycle batteries, add water to level of 1/8" (3 mm) below bottom of vent well (see diagram A)

For fully charged Plus Series batteries, add water to the maximum water level indicator (see diagram B)

After watering, secure vent caps back on batteries

 

          Diagram A

 

                        Diagram B

 

Maximum Battery Size for Replacement

Standard 245AH Batteries

 

Upgraded 325AH Batteries

Dimensions Inches (mm)

 

Dimensions Inches (mm)

Length

Width

Height

 

Length

Width

Height

10 3/8”

(264)

7 1/8”

(181)

10 7/8”

(276)

 

12 1/4”

(311)

7”

(178)

14 3/8”

(365)