Hammerhead 650RS User manual
2
Table of Contents
1 Page 3
2 Page 3
3 Page 4
Page 4
Page 5
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Page 6
4 Page 6
Page 7
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Page 9
Page 8
5 Page 9
Page 10
6 Page 10
Page 11
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Page 12
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Page 13
7 Page 13
Page 13
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8 Page 15
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9 Page 16
10 Page 17
11 Page 18
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14 Page 27
15 Page 27
16 Page 28
17
Warnings
General Information
Maintenance Intervals
3.1 System Maintenance K (Customer)
3.2 System Maintenance I (125 hours of operation) 3.3
System Maintenance II (250 hours of operation) 3.4
Hammerhead System Maintenance S
(500 hrs of operation, at least yearly)
Squeegee Cable and Recovery Tank Gasket
4.1 Squeegee Adjustment (First Version)
4.2 Squeegee Adjustment (new Style)
4.3 Squeegee Lift Cable, Micro Switch, Vacuum Motor
4.4 Squeegee Wheel Adjustment
Brush Head (Disk Brushes) Connections
5.1 Brush Motor Information
Brush Head Transport Position
6.1 Brush Switch
6.2 Brush Pressure Adjustment on the Disk Models
6.3 Brush Pressure (Disk Decks)
6.4 Cylindrical Brush Head Electrical Connections
6.5 Cylindrical Brush Head Adjustment
Drive and Wheels - General Data
7.1 Electric Brake
7.2 Transaxle Motor
7.3 Carbon Brushes
7.4 Drive Potentiometer
Water Supply
8.1 Solenoid
8.2 Solution Filter
8.4 Solution Flow Rates
8.5 Water Pump
The Last Error
Table of Error Codes and Information
Battery Charger
11.1 Operating Instructions
11.2 Charger Error Codes
11.3 Charger Trouble Shooting
11.4 Charger Maintenance Points
11.5 Programming The Charger
11.6 Replacing The Charger Harness
Batteries
12.1 Maintaining Wet Lead Acid Batteries
12.2 Load Testing Batteries
12.3 Hydrometer Testing
Fuse Locations Version 2
13.1 Controller Version 3
Controller Connections
Trouble Shooting Controller
Contactor Harness
Contactor Wiring Page 29
Page 6
HAMMERHEAD
3
1. Warnings
Disconnect the A.C. Cord from the outlet and and D.C. Cord from the battery
pack before servicing the machine. Except for making voltage and current
measurements.
Before replacing the main fuses, only loosen the nuts. Do not remove them
completely. Failure to do so could cause a short circuit.
Place the new stripe fuse fully and evenly under the nuts and washers and
make sure not to twist the end tabs, they can easily be torn.
After any repair work is done, test the machine for proper operation.
When servicing the machine always observe the general safety and accident
prevention guidlines.
The display offers a service indication. Upon turning on the key switch, a four digit
number describing the software version (e.g. 1.0.0.2) appears for about 3 seconds,
followed by another 4-digit code indicating the last error recorded, then followed by
the hour meter.
If a failure occurs, the code appears in the control panel and an acoustic signal
sounds. The current error code appears as 4-digit alpha-numerical code with
flashing dots in the service display. Only if these criteria are met, the error is a
current one!
The error codes are listed in a tables in chapter 10.
2. General Information
When raising the machine with a car
jack,use the area of the frame in front of
the caster wheels on the left or the right.
4
3. Maintenance Intervals
In a modular structure, the System Maintenance determines the specific technical
proceedures to be preformed and sets the time interval between the two maintenance
cycles.For each of the maintenance cycle, the replaceable parts are determined as well.
Further details described in the specific chapters.
System Maintenance K:
To be performed by the customer (in daily or weekly intervals) according to the maintenance
and care instructions as specified in the operating instructions.
The operator must be professionally instructed after delivery of the machine by selling
dealer.
System Maintenance I: (after every 125 hours of operation)
To be preformed by an authorized Service Center in accordance with the machine-specific
system maintenance.
System Maintenance II: (after every 250 hours of operation)
To be preformed by an authorized Service Center in accordance with the machine-specific
system maintenance.
System Maintenance S: (after every 500 hours of operation, safety check) To be
performed by an authorized Service Center in accordance with the machine-specific system
maintenance.
3.1 System Maintenance K
5
3.2 System Maintenance I
3.3 System Maintenance II
6
3.4 System Maintenance S
(Safety Check)
4. Squeegee Cable And Gasket
4. The squeegee cable is attached to the lift lever (top) via a spring (Fig. 5/5). The bottom is
attached to the eyebolt at the squeegee mechanism (Fig. 5/6). The squeegee lift cable can be
accessed after opening the electronic module cover at the rear of the machine.
The vacuum motor is connected to the A1 at A1.X34:5+6 on the controller. Current
consumption of the vacuum motor amounts to approx. 25A max.
The vacuum water lift in the closed tank is at least 65 inches (150mbar).
Recovery Lid Gasket
Insert the recovery tank cover gasket (Fig. 5/7) so that the seam is positioned at the front center
with a gap of approx. 1mm. The dirty drip water on the top sealing surface will be drawn into the
recovery water tank.
Fig. 5/5 Fig. 5/6 Fig. 5/7
7
4.1 Squeegee Adjustment
Correct squeegee adjustment is prerequisite for optimal suction results.
Before adjustment first check the pitch of the squeegee and re-adjust if required.
1. Place machine on level ground.
2. Loosen nut of the adjustment screw (pos. 3, Fig. 5/1) and adjust sealing strips in
parallel to the floor. Turn adjustment screw clockwise: clearance between squeegee
blade and floor broadens in the center. Turn adjustment screw counter-clockwise:
clearance between squeegee blade and floor narrows in the center.
3. Turn machine on, lower squeegee and check drying pattern.
1 Squeegee
2 Star-shaped knob
3 Adjustment screw
4 Suction hose
5 Toggle-type fastener
Fig. 5/1
-----Version one
4.2 Squeegee Adjustment-----Version Two
Correct squeegee adjustment is prerequisite for optimal suction results.
Before adjustment first check the pitch of the squeegee and re-adjust if required.
1. Place machine on level ground.
2. Loosen the two bolts, located on each side (Fig 5/2A) with the squeegee attached
while holding another wrench on the location shown on Fig 5/2B. Adjust squeegee
rubbers so that they are parallel to the floor, by turning the long adjustment shaft on the
right side with an open end or adjustable wrench (Fig 5/2B). Adjust until the rear
squeegee blade folds equally accross the entire length, while moving the machine
slightly forward.
3. Tighten the two bolts on the ends while holding the center shaft with the wrench.
4. Turn machine on, lower squeegee and check drying pattern.
Fig 5/2BFig 5/2A
8
4.3 The clearance between the support roller and floor with squeegee unfolded
(Factory setting) is: 0.1181099 Inches ± 0.01968498 inches (3 mm ±0.5).
Note: Some floor surfaces may require adjusting the caster washers for optimum performance.
4.3 Squeegee Wheel Adjustment
Fig. 5/3
PN 01059530
PN 01071740
PN 00101550
PN 01077810
PN 01079070
PN 01079080
4.4 Note: When adjusting the wheel height, there should always be 5 washers on each wheel
assembly position # 15 in order fully tighten bolts. Move washers from the top to the bottom of
the bracket or visa versa when making adjustments. The caster controls the pressure on the
squeegee blade.
4.4 Squeegee Wheel Adjustment
9
4.5 Squeegee Lift Cable, Switch & Motor
Squeegee Lift Cable, Lever, Micro Switch
and Vacuum Motor
The vacuum motor micro switch is mounted
behind the squeegee lift lever (Fig. 5/4). Adjust the
micro switch so that the vacuum motor can be
turned off by lifting the squeegee by the lever.
Loosen the screws on the switch to adjust.
Vacuum motor is switched on upon lowering of the
squeegee.
The micro switch is a normally open switch which
is terminated to input A1.X9:3+9 on the controller.
When the squeegee is lowered, there should be
continuaty between both contacts (with the plug
A1.X9 being disconnected).
Fig. 5/4
NOTE: The squeegee lift cable spring will need to disconnected from the silver
lever before the squeegee lift lever plate can be removed from the machine.
Access can be made from the controller/charger area in the rear of the machine.
See Chapter 4.
5. Brush Head (Disk) Connections
Connection of Brush Motors to Disk Brush Head
Connect the brush motors of the disk brush head in accordance with the electric diagrams. Find
the assignment of connecting stud of the motors listed in the below table. Then check the correct
direction of brush motor rotation.
The left-hand motor seen in direction of travel is M3, the right-hand one is M4.
M4 M3
elbaC
Harness
Motor connection
Disk brush
Connectors
at the motor -M3/4
Stud bolt above
Connection N
Stud bolt below
Connection P
10
The brush motors are switched on and off by a micro-switch located at the rear at the brush head
lift-out system. This switch is realised as NO (normally open) switch. To attain safe function of the
brush motors, correct adjustment of this switch is required.
Electric connection of the switch is realised at the central control at A1.X9:4 + 10.
Maximum current consumption of the brush motors (in practical use) must not exceed 30A per
motor on the disk brush decks.
Lower settings are recommended for longer motor life, run time and traction.
When checking the carbon brushes make sure that the scroll spring is pressing the carbon brush
against the commutator, does not contact the guide and that distance to carbon brush guide is
sufficient.
Replace the carbon brushes, if required.
5.1 Brush Motor Information
The lever provided is for lifting up the brush head. It features 3 positions for adjusting
the lift linkage (Fig. 6/1). The top hole is the transporting and ramp climbing position. In
this position, the lift linkage is to be adjusted so that a 1mm gap appears between the
lever and the screw head at the chassis (Fig. 6/2).
The middle hole position is for scrubbing with pads.
The bottom hole (Fig. 6/1) is the normal scrubing position of the brush head.
6. Brush Head Transport Position
1 mm Fig. 6/2
Transport Position
Scrubbing position
with pads
Scrubbing position
with brushes
Fig. 6/1
6.2 Brush Pressure Adjustment (Disk Models)
11
The brush motors are switched on and off by a micro-switch located at the rear at the
brush head lift-out system Figure 6/3. This switch is a NO (normally open) switch. To
attain safe function of the brush motors, the correct adjustment of this switch is
required.
Electric connection of the switch is connected to the central control circuit board at
A1.X9:4 + 10 connector. In the lifted-up position, the switch should open and close
when brush head is lowered.
6.1 Brush Switch
Fig. 6/3
The bolt on the left can be adjusted to increase or
decrease the brush pressure.
Models with 19 gallon tanks This pressure adjustment
will affect the models in the normal scrubbing mode. (no
extra pressure option)
The indicator on the right should never be set past the
second notch.
NOTE: When making changes, the current draw should
decks under load maximum.
Lower settings are recommended for longer motor life,
longer run time and traction.
Verify the current with brushes under load, with a digital
clamp-on meter.
Only an authorized Service Center should make changes
to the brush pressure setting.
2nd notch
1st notch
Adjustment
Screw
Note: The factory setting
set at the second notch
Increase
pressure
Decrease
pressure
12
6.3 Brush Pressure
Model Area Per
Brush Brush
Pressure
Heavy
Brush
Pressure
(2nd Foot
Pedal
Engaged) Specific Surface
Pressure
Specific
Surface Pressure
with Heavy Brush
Pressure
24 240 cm²
37.200 inch² 260 N =
58 lb NA 0.54 N/cm² = .783 lbs per inch² NA
26 586.5 cm²
90.908 inch² 350 N =
79 lb NA 0.3 N/cm² = .435 lbs per inch² NA
6.4 Brush Head (Cylindrical)
Electric Connections
Connect the brush motors of the cylindrical broom head in accordance with
the electric diagrams. Find the assignment of connecting stud of the motors
listed in the below table. Then check the correct direction of brush motor
rotation.
The left-hand motor seen in direction of travel is M3, the right-hand one is
M4.
M3 M4
Motor connection
Cyl. brush head
elbaC
Harness
Stud bolt below
Connection P
Connectors
at the motor -M3/4
Stud bolt above
Connection N
13
Part number for the gauges are available by request.
Spacer Block
26.5 mm high
Spacer Block on this side also
7. Drive and Wheels
General Data-
Torque of wheel bolts: 23 foot lbs
Torque of wheel nuts: 18 foot lbs
Wheel speed in max. drive potentiometer position:
Forward: (3.1 mph) 110 min-1 Reverse: (1.55 mph) 55 min-1
Torque of setting for screws on caster mounting: 17 foot lbs
Drive motor, axle and differential are a single unit.
The wheel drive is nearly maintenance-free. Check the
carbon brushes of the drive motor at regular intervals
during maintenance. Carbon brushes are worn if the
scroll spring applying the carbon brushes to the
armature, is approx. 1mm away from the guide. Contact of
the spring and the guide must be avoided since otherwise
the armature can be damaged. Before the check, remove
battery and battery tray from the machine.
The thermal switch of the drive motor is integrated in the motor and cannot be
replaced. Such switches are NC (normally closed) switches which interrupt the
circuit, if the motor temperature exceeds the limit. The thermal switch is
connected to the control board at A1.X9:2+8.
7.2 Transaxle Motor
14
7.3 Carbon Brushes
Close the cover of carbon brushes again as shown in photos 7/2, 7/3
and 7/4. Make sure that the plastic lock is placed in a motor housing
recess for brushes.
Fig. 7/2 Fig. 7/3 Fig. 7/4
Potentiometer Resistance
Value: 5.875 k
Asssignment of connecting plug (A1.X4):
Ω+- 30%
Pin 1: Ground
Pin 2: 24Volts
Pin 3: Digital signal of drive direction 1
Pin 4: Digital signal of drive direction 2
Pin 5: Potentiometer wiper
Pin 6: Potentiometer +
Pin 7: Potentiometer -
Pin 8: not assigned
7.4 Drive Potentiometer Circuit
Potentiometer
15
Coil resistance of solenoid: approx. 47
Current consumption of solenoid:
Water amount is regulated by ball valve on all
the 19 gallon and models.
8.1 The solenoid valve releases or stops supply of water flowing to the brushes.
The solenoid valve is located at the front pane of the battery compartment. The
solenoid valve is electrically connected to the central controller A1 at
A1.X11:1+2. See Fig. 8/1
Ω
approx. 0.5 A
8. Water Supply
8.2 Solution Filter
The clear water supply line to the
brushes is equipped with a filter
screen. In case of problems with the
supplied water amount, check the
screen and the hoses from clear water
tank and to the brushes. See Fig.8/2 Fig. 8/2
Fig. 8/1
8.4 Solution Flow rates
16
8.5 Water Pump
Models equipped with water pump
The solution flow rate is affected by the speed of the drive
system.
The controller adjusts the voltage to the pump to regulate water
volume.
The faster the machine is driven the more water will flow to the
brushes.
The controller uses stand still recognition circuitry. The pump
will be shut off, if the water supplied to the pump is to low or
inefficient, when the voltage supplied to the pump is above the 5
volt level. This feature is disabled if voltage is below 5 volts.
Solution Control
9. The Last Error
Allmodels are equipped with an error memory which will indicate
the last error that occurred in the machine. This last error is displayed
upon turning on the machine by key switch. The first numbers that
appear will be the software version. The second will be the last error
(if one had occured). The third will be the hour meter.
Iffour digit error code is displayed continuously with blinking dots
and the alarm is sounding, the controller has detected a problem in the
system. The machine will be inoperable. See error codes for details.
17
10. Table of Error Codes
18
11. 24V - 22A Charger
10.1 Operating Instructions
11.1 24V - 22A Charger
19
11.1 24V - 22A Charger
11.2 Charger Error Codes
Note: The following are error indicators that could occur during the battery
charging process. All errors will be in the form of a blinking display picture
of the battery.
The display indicator figure # 1 will display a blinking doted square, if the
battery malfunctions for the following reasons:
1. The battery has less than 1.25 volts per cell.
2. The battery has less than 15 volts after 30 minutes
3. The batteries are wired incorrectly (reversed polarity).
4. The batteries are missing.
5. The wrong battery type is installed.
6. The selected programming of the charger is incorrect for the
batteries that are installed.
Fig.1
Fig. 2
The display indicator figure # 2 will blink, when the charger timer times out.
This occurs when the battery voltage on a 24 volt battery pack does not reach
22.8 volts or higher after 30 minutes. The charger will shut off.
Fig. 3
The display indicator figure # 3 indicates that there is an error in the charger.
1.The charger needs repair or replacing.
20
11.2 Charger Error Codes
Fig. 4
Fig. 5
The display indicator figure # 4 will blink when the charger is over heating:
1. The cooling air is restricted
2. The cooling fan is not working.
3. The cooling hose is not connected or is obstructed.
Programming button depressed while starting the charging operation.
Symptom - charger has no output.
Check for loose or burnt connections on the side of the
charger.
Use a test cord by-pass the original AC power cord.
Note: Continuity and voltage tests may not be adequate for
testing the condition of the AC cord.
Power cords from a desk top computer will make a good test
cord.
11.3 Trouble Shooting the Charger
Charger Maintenance Points
Check the following, when servicing the machine:
The charger unit should be secured by rubber strap.
The wires going to and from the charger should be secured with plastic
wire ties. They should be routed so that there are not any kinks, pinched
or crushed wires.
The charger housing must be insulated from all metallic machine parts.
Use a multi-meter to measure the resistance between charger housing and
the frame on the machine. There should not be continuity.
Repeat the test by checking the resistance between the A.C. Cord ground
pin of the charger and frame of the machine. There should not be
continuity.
The ground pin of the A.C. cord must conduct without resistance to the
screws on the charger case.
The charger ventalation hose must in place and without obstruction.
11.4 24V - 14A Charger
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