Minuteman E24 User manual

SERVICE MANUAL
For E Series Scrubbers
For
E
Series
Scrubbers
Models: E24, E26, E28,
E30 E33 E33XL
E30
,
E33
,
E33XL
,
E30ECO, E2830, E3030,
E3330 and H26
For:
Training
Troubleshooting
E3330
and
H26
Troubleshooting
Adjustments
Rev 07/07/2014

Contents
1 Warnings Page 6
2 General Information Page 7
3 Maintenance Intervals Page 8
3.1 Minuteman System Maintenance K (Customer) Page 9
3.2 Minuteman System Maintenance I (125 hours
of o
p
eration
)
Pa
g
e 10
p)
g
3.3 Minuteman System Maintenance II (250 hours
of operation) Page 11
3.4 Minuteman System Maintenance S (500 hrs of
operation at least yearly)
Page 12
operation
,
at
least
yearly)
Page
12
4 Squeegee Cable and Recovery Tank Gasket Page 13
4.1 Squeegee Adjustment (First Version) Page 14
4.2 Squeegee Adjustment (new Style) Page 15
4 3 Squeegee Lift Cable Micro Switch Vacuum Motor
Page 16
4
.
3
Squeegee
Lift
Cable
,
Micro
Switch
,
Vacuum
Motor
Page
16
4.4 Squeegee Wheel Adjustment Page 17
5 Brush Head (Disk Brushes) Connections Page 18
5.1 Brush Motor Information Page 19
2

Contents
6 Brush Head Transport Position Page 21
6.1 Brush Switch Page 22
62B hP Adj h Di kM d l
P23
6
.
2
B
rus
h
P
ressure
Adj
ustment on t
h
e
Di
s
k
M
o
d
e
l
s
P
age
23
6.3 Brush Pressure (Disk Decks) Page 24
6.4 Cylindrical Brush Head Electrical Connections Page 25
6.5 Cylindrical Brush Head Adjustment Page 26
7 Drive and Wheels - General Data Page 27
7.1 Electric Brake Page 27
7.2 Transaxle Motor Page 28
7.3 Carbon Brushes
Page 29
7.3
Carbon
Brushes
Page
29
7.4 Drive Potentiometer Page 30
8 Water Supply Page 31
8.1 Solenoid Page 31
8 2 Solution Filter
Page 31
8
.
2
Solution
Filter
Page
31
8.3 Solution Tank Cleanout Page 32
8.4 Solution Flow Rates Page 33
8.5 Water Pump Page 34
9
Th L t E
P35
9
Th
e
L
as
t
E
rror
P
age
35
10 Table of Error Codes and Information Page 36
3

Contents
11 Battery Charger Page 38
11.1 Operating Instructions Page 40
11.2 Charger Error Codes Page 40
11 3 Charger Trouble Shooting
Page 44
11
.
3
Charger
Trouble
Shooting
Page
44
11.4 Charger Maintenance Points Page 45
11.5 Programming The Charger Page 46
11.6 Replacing The Charger Harness Page 49
12
Btt i
P50
12
B
a
tt
er
i
es
P
age
50
12.1 Maintaining Wet Lead Acid Batteries Page 50
12.2 Load Testing Batteries Page 52
12.3 Hydrometer Testing Page 53
13 Fuse Locations Version 2 Page 56
13.1 Controller Version 3 Page 57
4

Contents
14 Controller Connections Page 58
15 Trouble Shooting Controller Page 59
16 Contactor Harness Page 60
g
17 Contactor Wiring Page 61
18 Testing the Main Power Relay Page 63
19 Wiring Diagram Models with 19 Gallon Tanks Page 68
20 Wiring Diagram Models with 24 Gallon Tanks Page 7220 Wiring Diagram Models with 24 Gallon Tanks Page 73
20 Wiring Diagram Models with 30 Gallon Tanks Page 78
21 Notes Page 83
5

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
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 an
y
re
p
air work is done
,
test the machine for
p
ro
p
er o
p
eration.
yp , pp p
•When servicing the machine always observe the general safety and accident
prevention guidlines.
6

2. General Information
•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,
fll db th 4
di it d i di ti th l t d d th f ll d b
f
o
ll
owe
d
b
y ano
th
er
4
-
di
g
it
co
d
e
i
n
di
ca
ti
ng
th
e
l
as
t
error recor
d
e
d
,
th
en
f
o
ll
owe
d
b
y
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
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.
•When raisin
g
the machine with a car
g
jack use the area of the frame in front of
the caster wheels on the left or the right.
7

3. Maintenance Intervals
In a modular structure, the Minuteman System Maintenance determines the specific
technical proceedures to be preformed and sets the time interval between the two
it l
ma
i
n
t
enance cyc
l
es.
For each of the maintenance cycle, the replaceable parts are determined as well.
Further details described in the specific chapters.
•Minuteman System Maintenance K:
Tb f dbth t (idil klit l) di tth it
T
o
b
e per
f
orme
d
b
y
th
e cus
t
omer
(i
n
d
a
il
y or wee
kl
y
i
n
t
erva
l
s
)
accor
di
ng
t
o
th
e ma
i
n
t
enance
and care instructions as specified in the operating instructions.
The operator must be professionally instructed after delivery of the machine by selling
dealer.
Mi t S t M i t I
( ft 125 h f ti )
•
Mi
nu
t
eman
S
ys
t
em
M
a
i
n
t
enance
I
:
(
a
ft
er every
125
h
ours o
f
opera
ti
on
)
To be preformed by an authorized Minuteman Service Center in accordance with the
machine-specific system maintenance.
•Minuteman System Maintenance II: (after every 250 hours of operation)
Tb f db thi dMi t S i C t i d ithth
T
o
b
e pre
f
orme
d
b
y an au
th
or
i
ze
d
Mi
nu
t
eman
S
erv
i
ce
C
en
t
er
i
n accor
d
ance w
ith
th
e
machine-specific system maintenance.
•Minuteman System Maintenance S: (after every 500 hours of operation, safety check) To
be performed by an authorized Minuteman Service Center in accordance with the machine-
ifi t i t
spec
ifi
c sys
t
em ma
i
n
t
enance.
8

3.1 Minuteman System Maintenance K
To be performed by the
customer/user Interval
To

be

performed

by

the

customer/user

Interval
Daily Weekly
Fillthecleanwatertankandmixtheproperamountandtypeofcleaningsolution. O
Chargethebatteries. O
Check
the brush head Clean if needed with adamp cloth Do not get water inside the motor
O
Check

the

brush

head
,
Clean

if

needed

with

a

damp

cloth
.
Do

not

get

water

inside

the

motor
.
O
Checkthesqueegee,cleanifneeded O
Checkthelidgasketontherecoverytank. O
Emptyandflushtherecoverytankwithcleanwater. O
Cl
th filt /fl t iidth tk
O
Cl
ean
th
e
filt
er
/fl
oa
t

i
ns
id
e
th
erecovery
t
an
k
.
O
Checkthewaterlevelsofallthebatteries.Adddistilledwater,ifneeded.Donotoverfill. O
Checkthepadsandbrushesforwear.Replaceifneeded. O
Checkthesqueegeehoseforclogs,damageandwear.Replaceifneeded O
Ch k
hbb f d li hbl d ( ) l
O
Ch
ec
k
t
h
esqueegeeru
bb
ers
f
orcutsan
d
wear.F
li
pt
h
e
bl
a
d
e
(
s
)
overorrep
l
ace.
O
Checkthesolutionfilter.Cleanifneeded. O
Flushthecleanwatersolutiontankwithwarmwater. O
Testallthefunctionsofthemachine. O
9

3.2 Minuteman System Maintenance I
Tobeperformedbytheauthorizedservicecenter Interval
Every125hoursof
operation
Checkthebatterycharger.Makesureitisfunctioningproperly O
Checktherecoverylidgasket.Replaceifneeded O
Lubricate
the brush lift linkages with grease Use asmall brush
O
Lubricate

the

brush

lift

linkages

with

grease
.
Use

a

small

brush
.
O
Checkforloosehardware,tightenifneeded. O
Checkthetirepressureonpneumaticwheelsat65PSI,ifequipped.O
Lubricatethesqueegeelinkageswithgrease.Useasmallbrush. O
Inspecttheentiremachinefordamage,wearandproperoperation. O
10

3.3 Minuteman System Maintenance II
Tobeperformedbytheauthorizedservicecenter Interval
Every250
hoursof
operation
Inspect
the caster wheels for wear and damage Repair if needed
O
Inspect

the

caster

wheels

for

wear

and

damage
.
Repair
,
if

needed
.
O
Inspectthecarbonbrushesforwearinthetransaxle.Replace,ifneeded. O
Inspecttherecoverydrainhoseforwearordamage.Replace,ifneeded. O
Inspect
the brush bumper rollers for wear or damage Replace if needed
O
Inspect

the

brush

bumper

rollers

for

wear

or

damage
.
Replace
,
if

needed
.
O
Inspectthecarbonbrushesforwearinthebrushmotorsforwear.
Blowoutwithcompressedair. O
Inspecttherecoveryhosefordamageorwear.Replace,ifneeded.O
Inspectthesqueegeeassemblyforproperadjustment.Repair,ifneeded.O
Testthemachineforproperoperation. O
11

3.4 Minuteman System Maintenance S
(S f t Ch k)
Tobe
p
erformedb
y
theauthorizedservicecenter Interval
(S
a
f
e
t
y
Ch
ec
k)
p y
Every500hoursof
operation
Replacethecarbonbrushesinthetransaxle. O
l
h b bhi h bh
Rep
l
acet
h
ecar
b
on
b
rus
h
es
i
nt
h
e
b
rus
h
motors. O
Testthemachineforproperoperation. O
12

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
d ft i th l t i d l t th f th hi
accesse
d
a
ft
er open
i
ng
th
e e
l
ec
t
ron
i
c mo
d
u
l
e cover a
t
th
e rear o
f
th
e mac
hi
ne.
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
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 13

4.1 Squeegee Adjustment
V
ersion one
4.1 Squeegee Adjustment
Correct squeegee adjustment is prerequisite for optimal suction results.
Before ad
j
ustment first check the
p
itch of the s
q
uee
g
ee and re-ad
j
ust if re
q
uired.
jpqg
jq
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 ad
j
ustment screw counte
r
-clockwise:
j
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
4
Suction
hose
5 Toggle-type fastener
Fig. 5/1
14

4.2 Squeegee Adjustment
V
ersion Two
4.2 Squeegee Adjustment
Correct squeegee adjustment is prerequisite for optimal suction results.
Before ad
j
ustment first check the
p
itch of the s
q
uee
g
ee and re-ad
j
ust if re
q
uired.
jpqg
jq
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 the
y
are
p
arallel to the floor
,
b
y
turnin
g
the lon
g
ad
j
ustment shaft on the
yp ,y g gj
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. Ti
g
hten the two bolts on the ends while holdin
g
the center shaft with the wrench.
gg
4. Turn machine on, lower squeegee and check drying pattern.
Fig 5/2BFig 5/2A
15

4.3 Squeegee Wheel Adjustment
4.3 The clearance between the support roller and floor with squeegee unfolded
(Factory setting) is: 0 1181099 Inches
±
0 01968498 inches (3 mm
±
05)
(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.
See following page.
16

4.4 Squeegee Wheel Adjustment
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
Pos 1 – Hexagon screw M8x25A2
PN 01059530
the
bracket
or
visa
versa
when
making
adjustments
.
The
caster
controls
the
pressure
on
the
squeegee blade.
Pos 5 – Hexagon screw M8x16A2
PN 01071740
Pos 6 – Washer B8,4
PN 00101550
Pos 7 – fixed Roller
PN 01077810
Pos 8 – Angle with fixed roller, complet
PN 01079070
Fi
g
. 5/3
PN
01079070
Pos 15 – Distance Washer
PN 01079080
g
17

4.5 Squeegee Lift Cable, Switch & Motor
4.5 Squeegee Lift Cable, Lever, Micro Switch
and Vacuum Motor
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
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
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
18
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
5 C ti fB hM t t Di kB hH d
5
.
C
onnec
ti
on o
f
B
rus
h
M
o
t
ors
t
o
Di
s
k
B
rus
h
H
ea
d
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
Cable Motor connection Connectors
M4
M3
Harness Disk brush at the motor -M3/4
Stud bolt above
Connection N
Stud bolt below
Connection P
19

5.1 Brush Motor Information
51
Brush Motors
5
.
1
Brush
Motors
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 ad
j
ustment of this switch is re
q
uired.
,j q
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 26 and 30“ disk brush decks. The maximum amperage for the 33“ disk decks is 40A.
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.
20