Tornado FK 3000 Setup guide

Tornado
Operation and Illustrated Parts Manual
For Commercial Use Only
FK 3000 Automatic Scrubber
Catalog No.
99430
Form No. L9430C 7/03 ã2003 TornadoâIndustries All rights reserved.
TORNADO
®
INDUSTRIES
7401 W. LAWRENCE AVENUE
CHICAGO, IL 60706
[phone] FAX [phone]
www.tornadovac.com
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NOTES
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This illustrated parts book covers:
MODEL 99430
SERIES C
SIZE 30"
VOLTS (CHARGER) 36V
AMPS (CHARGER) 20
CAPACITY 30 GAL. (114L)
All specifications are subject to change without notice.
Tornado®Standard Warranty Program*
10 Years:
All plastic tanks and rotationally-molded bodies
2 Years:
Parts on all Tornado and Tornado/Karcher cleaning
equipment 1) 2)
1 Year:
Labor on all Tornado and Tornado/Karcher cleaning
equipment 1) 2)
Warranties do not cover
components subject to
normal wear or abuse and
misuse, and have other
limitations not specified
here. For full details ,
contact your Authorized
Tornado Distributor,
Service Center, or the
Tornado Technical Service
Department.
1 Year:
Warranty on batteries, one full year, not pro-rated.
* Effective January 1st, 2001. Terms subject to change without notice.
1) Windshear™ Blower-Dryer, Insulation Blowers, CW 50, CW 100, PAC Vacâ, and Duo-Upright Carpetkeepers™
are warranted for 1 (one) year for parts and labor.
2) Warranties on the ICC1, KMR 1200, KMR 1250, and KMR 1700 are 24 months parts/6 months labor OR
1000 hours of operation, whichever comes first. Warranties on the BR and BD 1000 are 24 months
parts/12 months labor OR 1000 hours of operation, whichever comes first.
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TABLE OF CONTENTS
INTRODUCTION 5
SAFETY INSTRUCTIONS 6
GROUNDING INSTRUCTIONS 7
UNIT CONTROLS AND INDICATORS 8
INSTALLATION
SQUEEGEE 10
BRUSHES 11
PRE START-UP
FILLING SOLUTION TANK 12
PREVENTATIVE MAINTENANCE PROGRAM
BATTERY CARE 13
BATTERY REMOVAL 14
BATTERY CHARGING 15
BATTERY SAFETY PRECAUTIONS 16
SQUEEGEE BLADES 17
SQUEEGEE ADJUSTMENT 18
SOLUTION PUMP INTAKE FILTER 19
RECOVERY TANK 19
SOLUTION TANK 20
VACUUM MOTOR 20
LUBRICATING YOUR MACHINE 21
MOTOR BRUSH REPLACEMENT 21
TROUBLESHOOTING INSTRUCTIONS
COMMON ISSUES 22
TROUBLESHOOTING CHART 24
LCD DISPLAY DIAGNOSTIC ERROR CODES 26
PREVENTATIVE MAINTENANCE CHECKLIST 28
ILLUSTRATED PARTS LISTS
SOLUTION TANK 29
RECOVERY TANK 32
SQUEEGEE ASSEMBLY 34
SQUEEGEE TOW ARM 36
BRUSH DRIVE ASSEMBLY 38
TRANSAXLE ASSEMBLY 40
CONTROL BOX & SOLUTION PUMP MODULE 42
ACTUATOR ASSEMBLY 44
CONTROL PANEL ASSEMBLY 45
TRIGGER ASSEMBLY 47
MAIN VIEW “A” 49
MAIN VIEW “B” 50
MAIN VIEW “C” 51
MAIN VIEW “D” 52
MAIN VIEW – PARTS LIST 53
WIRING HARNESS 54
CONTROL HARNESS 56
POWER HARNESS 58
REPLACEMENT ITEMS & ACCESSORIES 60
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INTRODUCTION
Congratulations on the purchase of your new Tornado FK 3000! The FK 3000 combines many
advanced features to maximize reliability, performance, and ease of use.
The most notable addition is the incorporation of
the industry’s first fully functional digital control and
display system on an automatic floor scrubber.
With it, you’ll be able to easily and accurately
monitor an assortment of system settings and
conditions. Tornado’s new digital controller has a
unique soft-start feature that increases both
efficiency and powertrain lifespan.
Its patented, tough rotomolded structural housing
serves as a multi-function one-piece frame,
making this new model Floorkeeper both more
rugged and much lighter than conventional metal-
frame models.
This new FK 3000’s simplified wiring harness uses
quick-disconnects, and combined with the digital controller and error code generation on its
LCD display, makes servicing and troubleshooting easy.
Additional features include integral 30-gallon solution and recovery tanks, a sealed,
maintenance-free ¾ hp transaxle, and easy-access batteries. Solution flow is precisely
controlled by an adjustable flow rate pump, unlike gravity-feed systems that change flow based
on tank fill level. Vacuum power can be set for hands-free automatic operation, off to conserve
battery power when double-scrubbing, and constant-on for use with the optional hand tool
accessory set. The new FK 3000 automatic scrubber was designed and built to exceed your
needs for durability and serviceability in demanding commercial environments.
This manual is designed to instruct your personnel in the operation, maintenance and methods
of troubleshooting on your Tornado FK 3000. Please read through this manual and keep it
handy to ensure that you get maximum satisfaction and value from this new advance in floor
care.
OBSERVE THESE PRECAUTIONS FOR SAFE USE OF THIS MACHINE
•Back the machine down inclines or ramps. Do not store machine on inclines.
•Make certain that the power switch is OFF before removing or installing brushes.
•Use care when working on electrical terminals —short circuits can cause burns and
throw sparks.
•Disconnect both positive and negative battery terminals before attempting any
adjustment or maintenance. Brush or traction drive motors and drive components could
cause injury if started while being worked on.
•Charge batteries in a ventilated room where gases cannot accumulate. Gases given off
during charging could ignite in a confined space. Make certain that the top covers are
open when charging so gases cannot accumulate.
•Battery acid can cause injury to the eyes or burn the skin.
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Safety Instructions
When using this machine, basic precautions should always be followed. Read all instructions
before using this machine.
WARNING: To reduce the risk of fire, electric shock, or injury:
Turn off all controls, unplug from power source and allow unit to cool down before attempting
any maintenance or adjustment. Turn off and disconnect battery clip when not in use.
Do not expose to rain or submerge in water. Store indoors. Do not use pressurized water to
clean machine. Do not use machine on stairs.
Do not allow to be used as a toy. This machine is to be used by adults only.
Use only as described in this manual.
If machine does not appear to be working properly or has been dropped, left outdoors,
submerged, or damaged in any way, refer to the troubleshooting steps detailed in this manual.
Keep hair, loose clothing, fingers, and all parts of body away from openings and moving parts.
Do not put any object into openings. Do not use with any opening blocked. Keep openings free
of dust, lint, hair, and anything that may reduce air flow.
Do not pick up anything with this machine that is burning or smoking, such as cigarettes,
matches, or hot ashes.
Do not pick up flammable or combustible liquids, such as gasoline or petroleum solvents, or use
machine where they may be present.
When using the charger supplied with this machine, do not handle cord or plug with wet hands.
Unroll the charger AC power cord before plugging it into a grounded outlet. Do not pull or carry
by cord, use cord as handle, close a door on cord, or pull cord around sharp edges or corners.
Do not run machine over cord. Keep cord away from heated surfaces.
Check power cord for signs of crushing, cutting or heat damage. If replacement of plug or cord
is needed, use only identical replacement parts.
Keep all connections dry and off the ground. Do not allow electrical cords to contact water. Do
not use extension cords with this product. Do not unplug charger by pulling on cord. To unplug,
grasp plug, not cord.
Any repairs performed on this machine should be done by Tornado Authorized Service
Personnel.
Do not operate the unit when fatigued or under the influence of alcohol or drugs.
The manufacturer cannot be held responsible for any damage/injury caused to persons or
property because of improper procedures used which are not specified in this manual.
SAVE THESE INSTRUCTIONS
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WARNING: Failure to adhere to any of the instructions provided in this
manual could result in serious bodily injury or property damage!
BEFORE OPERATING MACHINE:
Read this manual completely before attempting to operate machine. This manual has important
information for the use and safe operation of the machine. Keep this manual on file and handy.
If additional information is needed, please contact your local distributor or contact us at:
TORNADO INDUSTRIES Phone: [phone]
7401 W. LAWRENCE AVE. Fax: [phone]
CHICAGO, IL 60706 Internet Address: http://www.tornadovac.com
GROUNDING INSTRUCTIONS
The charger supplied with this machine must be grounded. If it should malfunction or break
down, grounding provides a path of least resistance for electrical current to reduce the risk of
electric shock. This appliance is equipped with a cord having an equipment-grounding
conductor and grounding plug. The plug must be plugged into an appropriate outlet that is
properly installed and grounded in accordance with all local codes and ordinances.
WARNING: Improper connection of the equipment-grounding conductor can result in electric
shock. Check with a qualified electrician or service person if you are in doubt as to whether the
outlet is properly grounded. Do not modify the plug provided with the appliance; if it will not fit
the outlet, have a proper outlet installed by a qualified electrician. This appliance is for use on a
nominal 120-volt circuit, and has a grounding plug that looks like the plug illustrated in sketch A.
A temporary adapter that looks like the adapter illustrated in sketches B and C may be used to
connect this plug to a 2-pole receptacle as shown in sketch B if a properly grounded outlet is
not available. The temporary adapter should be used only until a properly grounded outlet
(sketch A) can be installed by a qualified electrician. The green-colored rigid ear, lug or the like,
extending from the adapter must be connected to a permanent ground such as a properly
grounded outlet box cover. Whenever the adapter is used, it must be held in place by a metal
screw.
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Unit Controls and Indicators
Control Panel
1. Variable Drive Speed Control Knob
2. 3-Position Vacuum Motor Switch:
Automatic – Controlled by transaxle
Off – for double-scrubbing floors
On – for stationary hand tool recovery
3. LCD Display
See page 9 for display capabilities
4. Brush Position Switch
5. Solution Flow Rate Knob
6. Display Mode Button
Rear Controls
7. Solution Filler Plug
8. Solution Level Sight Tube
9. Squeegee Control Lever
10. Solution Tank Drain Hose
11. Dual Reverse Buttons
12. Emergency Stop Switch
13. Locking Keyswitch
14. Dual Drive Levers
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Unit Controls and Indicators
Display Screens
Use the Display Mode Button (to the right of the display) to toggle between three unique
screens. Each screen displays a different set of icons and numerical readouts to give you useful
information about your machine’s operating status. For particulars on diagnostic fault code
information, see page 26.
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INSTALLATION
Squeegee
1. Make sure the Squeegee Control Lever is
lifted to the UP position.
The Rocker (squeegee mount) is already
installed on the Bracket. Loosen the two
Squeegee Locking Knobs enough to allow
it to slide onto the Rocker.
2. Insert the Squeegee Assembly fully, bent
ends forward, onto the Rocker. Tighten the
two Squeegee Locking Knobs securely.
Notice that the Squeegee Assembly
should be free to rotate slightly from side
to side, allowing the Squeegee to follow
floor contours.
3. Insert the hose end into the squeegee
assembly nozzle throat. Press down
tightly.
4. To ensure that both the ends and
the center of the Squeegee Blades are
evenly loaded, loosen the Rocker
Adjustment Knobs. Lower the Squeegee
Assembly to the floor by pulling the Squeegee Control Lever down, then rotate the
Squeegee Assembly until the entire
length of the rear Blade is in even contact
with the floor. Tighten the Rocker Knobs.
IMPORTANT: Never store the machine with
the Squeegee in the down position. This can
damage the Squeegee Blades and affect
water pick-up.
The Squeegee is not designed to pick up
water while backing up. When backing the
machine, raise the squeegee to avoid the risk
of damaging the rubber edges or upsetting the
Rocker tilt adjustment.
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INSTALLATION
Brushes
1. Raise the Brush Housing using the switch
on the control panel. (Emergency Switch
pulled out, and Keyswitch turned on.) Once
the Housing is fully up, turn off the
Keyswitch.
2. Place Brushes or Pad Holders under the
cover. Locate the Brush Coupler. Pull up the
Brushes to lock them in place.
Brush Housing Skirt Adjustment
3. When properly adjusted, the Brush Housing
Skirt prevents the rotating brushes from
flinging solution off to the sides, where the
Squeegee may not be able to reach.
Power the Brush Housing down so that the
Brushes or Pads contact the floor. Locate
and unscrew the two Skirt Locking Knobs,
and slide the Skirt evenly down to just clear
the floor. Retighten both knobs.
As Pads or Brushes wear, or whenever the Pads or Brushes are removed or replaced,
recheck for proper Skirt clearance.
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PRE START-UP
Make sure the Emergency Stop Switch is
pulled out. Turn the Keyswitch on. The LCD
Display should light and show the battery
charge level.
Lower the brushes to test for rotation. The
Brush motors will automatically turn on when
Brushes are lowered. Raise the Brushes.
Shut the Keyswitch off and connect the battery
charger to the Charging System Connector.
Batteries should be fully charged prior to first
use.
Filling the Solution Tank
1. Always empty the Recovery Tank before
filling the Solution Tank. This will eliminate
overfilling of the Recovery Tank.
2. Remove the Solution Tank Filler Plug by
unscrewing its wing nut just far enough to
loosen its fit in the hole.
3. Fill the Solution Tank no higher than the
top of the clear Sight Tube.
4. Replace the Filler Plug and tighten its wing
nut.
Please Note:
Before you begin using your new FK 3000,
notice that the charging connector is
underneath the Cover / Recovery Tank. This is
a safety feature to ensure that the Cover is
open to freely vent battery gases during
charging. As the Recovery Tank fills, it will
become increasingly difficult to raise it in order
to perform battery or component service. Do
not attempt to lift the Cover / Recovery Tank
whenever it contains more than a few gallons
of liquid. Empty the Recovery Tank first.
What to do when the batteries become fully
discharged while in use:
Under low battery charge conditions, provision
has been made to retain drive power even
after the vacuum motor system has automatically shut down. When the vacuum motor shuts off,
set its switch to off. Raise the Brush Housing fully up to shut off the Brush motors and Solution
Pump, conserving energy. Drive the unit to a floor drain at once and empty the Recovery Tank.
Return the unit to your battery charging station and recharge the batteries.
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TORNADO FK 3000
PREVENTATIVE MAINTENANCE PROGRAM
Introduction
This section is designed to instruct your personnel in methods of maintenance on the Tornado
FK 3000. By following these procedures, repair costs and down time will be greatly reduced.
These procedures are for simple repairs that can easily be done by your own personnel.
WARNING
Battery acid is toxic and corrosive; avoid bodily
contact.
First Aid:
EYES: Wash with liberal quantities of running
water for 15 minutes.
SKIN: Flush area with plentiful amounts of
running water.
INGESTION: Give milk to drink, DO NOT induce
vomiting, call a physician.
SPILLS: Wash with water or neutralize with
sodium carbonate or bicarbonate
(baking soda).
Battery Care
Batteries must be checked daily. The water level
must be maintained at least 1/4” above top of cell
plates in each battery.
1. Raise top cover and lock in place.
2. If you use a hydrometer to check charge
level in each cell, check this before adding
water.
3. Remove battery caps and fill each cell 1/4”-
1/2” above the tops of the lead plates.
NOTE: Fill batteries with distilled water only. This
will increase battery life substantially.
CAUTION
Do not overfill the battery cells. Do not use a hose
or pail. If batteries are accidentally overfilled,
remove excess water with a hydrometer or similar
device. Dispose of excess in accordance with local,
state and federal regulations.
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MAINTENANCE
3. After filling batteries, replace the battery
caps. Using baking soda or ammonia and
water solution, saturate a cloth and wring until
drip dry. Use this cloth to wipe the battery tops.
4.The battery terminals and should be coated
with a protective lubricant to prevent cor-
rosion.
WARNING
Avoid accidental contact with battery terminals and
possible electrical shock. Replace any protective
plastic terminal covers after battery maintenance.
Battery Removal
Should batteries need to be removed for any
reason, use two people to perform these tasks!
1. Completely drain the Recovery Tank.
2. Disconnect the vacuum motor connector,
gas spring bracket, float switch connectors,
and recovery hose. Ensure that no
connections remain.
3. Remove the three cotter and clevis pins at
the side of the cover, and remove the cover.
4. Note battery positions and all wiring connections before disconnecting wires!
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MAINTENANCE
Battery Charging
The charger is fully automatic:
1. It turns on when plugged in.
2. It switches to equalizing charge.
3. It shuts off when it reaches full charge or when batteries are defective.
NOTE: It is recommended that new batteries be fully discharged at least once (more in some
cases) to enable batteries to hold a full charge.
The batteries must be charged after each use of 3 or more hours. Failure to do so will result in
shortened running time.
To charge the batteries, raise top cover and lock in position.
WARNING
To avoid explosion keep covers open
during charge to insure proper ventilation
of gases.
1. Connect charger cable by plugging it into
Andersenäconnector located under rear top
cover.
2. Plug AC cord into proper electrical
receptacle. The red “CHARGER ON” light will
automatically come on along with the
“INCOMPLETE” light, meaning batteries are
being charged.
3. The charger will automatically turn off when
the batteries are charged to their maximum
capacity. The “CHARGER ON” light will go out when the charge cycle is complete.
4. To stop the charge cycle push the “INTERRUPT” button. (Do not unplug A.C. cord while the
charger is on.)
5. Check the lights on the battery charger after charger shuts off (“CHARGER ON” light should
not be lit):
A. Green light: Batteries are fully charged and are in good condition.
B. Amber light: All cells are OK but the total battery capacity is reduced. This usually indi-
cates that the batteries are aging.
C. Red light: The battery capacity is low and the entire charger/battery system needs to be
inspected by a qualified Tornado serviceman.
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Always observe the following personal safety precautions when working with lead
acid batteries.
A. Someone should be within range of your voice and close enough to come to your aid
when you work on battery operated machinery, such as your FK 3000.
B. Have plenty of fresh running water, soap, or baking soda nearby in case battery acid
contacts skin, eyes, or clothing.
C. Wear complete eye protection and clothing protection.
D. If battery acid contacts skin or clothing, wash immediately with soap and water or baking
soda and water. If acid contacts eyes, immediately flood eyes with cold running water for at
least ten minutes and get professional medical attention as soon as possible.
E. Never smoke or allow sparks or flame in the vicinity of batteries. Batteries give off hydrogen
gas while charging. To prevent an explosive condition, always charge batteries in a well-
ventilated area.
F. Use caution when using metal tools around batteries. Only use tools with an insulating
coating in good condition to prevent short circuits.
G. Remove personal effects such as rings, watches, bracelets, etc. when working on battery
operated machinery. Rings or watches can cause a short circuit, which will throw sparks to
cause an explosion hazard and produce enough heat to cause a severe burn.
H. Never charge a frozen battery. Charging a frozen battery may result in explosion.
I. Always disconnect the AC supply cord from its outlet and the DC connector from the battery
before attempting any maintenance or cleaning of the batteries or battery-operated
equipment.
THE FOLLOWING CAUTIONS AND PROCEDURES MUST BE OBSERVED
TO MAXIMIZE BATTERY LIFE:
•New batteries should be given a full charge before they are first used because it is difficult to
determine how long the batteries have been stored.
•Limit the use of new batteries to two hours for the first five charge/discharge cycles. New
batteries are not capable of their rated output until approximately thirty charge/discharge
cycles.
•Do not excessively discharge batteries. Observe the battery charge gage and discontinue
operation when gage reads low. Excessive discharge can cause polarity reversal of
individual cells, resulting in complete battery failure shortly thereafter.
•Check the level of electrolyte in batteries weekly. Maintain the proper electrolyte level by
adding distilled water as necessary. Add water to cover the tops of the lead plates ¼" to ½".
•Do not overfill batteries.
•Clean tops of batteries with a clean cloth wetted with ammoniated window cleaner
(Windex ® or equivalent). Dry batteries with a fresh cloth.
•Old batteries will require more frequent additions of water than newer batteries.
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MAINTENANCE
Squeegee Blades
1. If a squeegee blade is worn or ripped, raise
the Squeegee and remove the entire
aluminum Squeegee Assembly from the
Rocker. Disconnect the vacuum hose, loosen
both Squeegee Locking Knobs and slide the
Squeegee out.
2. Unscrew both Star Knobs at either end of
the Squeegee, and remove the Rollers.
3. Pull off the plastic End Caps at both ends of
the Squeegee.
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MAINTENANCE
Squeegee Blades
4. Pull out each Blade from one end. Both
front and rear Blades have two working
edges.
Flip each blade for a new edge when worn.
Replace Blades once both edges are worn.
4. Clean squeegee blades with a damp
cloth. And slide them into place. The
rear Blade is longer than the front, and
overlaps it evenly on each end.
5. Replace the plastic end components,
and remount the Squeegee Assembly
onto the Rocker. Connect the vacuum
hose to the Squeegee Assembly.
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MAINTENANCE
Squeegee Adjustment
Removal of the Squeegee Assembly for
cleaning or Blade servicing will not normally
require Squeegee tilt readjustment. However,
after remounting the Squeegee, Blade contact
should be visually checked for evenness by
first driving or pushing the machine forward a
few inches with the Squeegee down.
Look at the rear Blade to ensure that both the
ends and the center are evenly loaded. The
front blade should also be contacting evenly
across its length. If readjustment is needed,
loosen the Rocker Adjustment Knobs. Rotate
the Squeegee Assembly. Correct adjustment
is made when both Squeegee Blades rest
evenly on the floor. Tighten the Rocker Knobs
and raise the Squeegee Assembly to its
storage position.
IMPORTANT: Never store the machine with
the Squeegee in the down position. This can
damage the Squeegee Blades and affect
water pick-up.
For Smooth Floors:
Use the standard rear squeegee blade
K62732060.
For Rough Floors:
Use rear squeegee blade K62732150.
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