Tornado Floorkeeper 99328 User manual

Tornado
Operation and Illustrated Parts Manual
For Commercial Use Only
Long-Range Floorkeeper Automatic Scrubber
Catalog No.
99328 & 99332
Form No. L9332AA 2/01 ã2001 TornadoâIndustries All rights reserved.
TORNADO
®
INDUSTRIES
7401 W. LAWRENCE AVENUE
CHICAGO, IL 60706
[phone] FAX [phone]
www.tornadovac.com

2
NOTES

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This illustrated parts book covers:
MODEL 99328 99332
SIZE 28" 32”
VOLTS (CHARGER) 36V 36V
AMPS 20 20
CAPACITY 20 GAL. (79l) 20 GAL (79l)
SERIES A A
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, 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
UNIT CONTROLS AND INDICATORS 6
INSTALLATION
BATTERY 8
SQUEEGEE 9
RECOVERY TANK DRAIN 10
BRUSHES 10
PRE START-UP
FILLING SOLUTION TANK 11
PREVENTATIVE MAINTENANCE PROGRAM
INTRODUCTION 12
BATTERY CARE 12
BATTERY CHARGING 14
SQUEEGEE BLADES 15
SQUEEGEE ADJUSTMENT 16
VACUUM AND WATER RECOVERY SYSTEM 17
SOLUTION AND RECOVERY (Vacuum) TANKS 17
VACUUM MOTOR 18
WHEELS 18
LUBRICATING YOUR MACHINE 19
MOTOR BRUSH REPLACEMENT 19
TROUBLESHOOTING INSTRUCTIONS
VACUUM SYSTEM (POOR SUCTION) 20
POOR SOLUTION FLOW 21
ELECTRICAL PROBLEMS 22
BATTERIES NOT HOLDING CHARGE 22
TROUBLESHOOTING SYMPTOMS CHART 23
LCD DISPLAY DIAGNOSTIC ERROR CODES 24
PREVENTATIVE MAINTENANCE CHECKLIST 25
ILLUSTRATED PARTS LISTS
28” SQUEEGEE - EXPLODED VIEW & PARTS LIST 26
32” SQUEEGEE - EXPLODED VIEW & PARTS LIST 27
SQUEEGEE PIVOT FRAME ASSEMBLY - EXPLODED VIEW 28
SQUEEGEE PIVOT FRAME ASSEMBLY - PARTS LIST 29
SOLUTION CONTROL ASSEMBLY - EXPLODED VIEW & PARTS LIST 30
DRAIN & SOLUTION VALVES - EXPLODED VIEW & PARTS LIST 31
28” BRUSH MOTOR ASSEMBLY - EXPLODED VIEW 32
28” BRUSH MOTOR ASSEMBLY - PARTS LIST 33
32” BRUSH MOTOR ASSEMBLY - EXPLODED VIEW 34
32” BRUSH MOTOR ASSEMBLY - PARTS LIST 35
RECOVERY (VACUUM) TANK ASSEMBLY - PARTS LIST 36
RECOVERY (VACUUM) TANK ASSEMBLY – EXPLODED VIEW 1 37
RECOVERY (VACUUM) TANK ASSEMBLY – EXPLODED VIEW 2 38
SOLUTION TANK ASSEMBLY - EXPLODED VIEW & PARTS LIST 39
BATTERY ASSEMBLY - EXPLODED VIEW & PARTS LIST 40
CONTROL PANEL ASSEMBLY - EXPLODED VIEW & PARTS LIST 41
TRIGGER ASSEMBLY - EXPLODED VIEW & PARTS LIST 42
MAIN VIEW “A” – MAJOR SUBASSEMBLIES EXPLODED VIEW 43
MAIN VIEW “B” – EXPLODED VIEW 44
MAIN VIEW “B” – PARTS LIST 45
MAIN VIEW “C” – EXPLODED VIEW 46
MAIN VIEW “C” – PARTS LIST 47
COVER ASSEMBLY - EXPLODED VIEW & PARTS LIST 48
WIRING DIAGRAM 49
WIRING HARNESS CONTROL FUNCTIONS 50
WIRING HARNESS POWER FUNCTIONS 51

5
INTRODUCTION
Congratulations on the purchase of your new
Tornado Floorkeeper! The Floorkeeper
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.
This new Floorkeeper’s simplified wiring
harness uses quick-disconnects, and combined
with the digital controller, it makes servicing and
troubleshooting easy. A tough new rotomolded
housing extends over an advanced one-piece
steel weldment, making this new Long-Range
both more rugged and much lighter than
previous Long-Range models.
Additional features include removable 20-gallon solution and vacuum tanks, a reliable 18:1 gear
ratio transaxle, non-marking 11” tires, easy-access batteries, and error code generation on its
LCD display. The new Long-Range Floorkeeper 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 Floorkeeper. 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
TO AVOID DANGER:
•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 main-
tenance. 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.

6
Unit Controls and Indicators
Control Panel
1. Vacuum Motor
Switch
2. Variable Speed
Control Knob
3. LCD Display
4. Display Mode
Button
5. Brush Pressure Switch
Rear Controls
6. Adjustable
Solution
Control
7. Dual Drive
Levers
8. Dual Reverse
Buttons
9. Emergency
Stop Switch
10.Key Lock
11.Circuit Breaker
12.Squeegee Control Lever
13.Recovery Tank Drain Hose

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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 Long-Range’s operating status. For particulars on diagnostic fault code
information, see page 24.

8
INSTALLATION
Batteries
Raise top cover using handle, and pivot forward until
retainer cords are taut.
CAUTION
Batteries are heavy. To avoid injury, use two people
to lift into position.
Place batteries in metal tray liner. Orient each battery
exactly as shown in bottom photo, or refer to chart
located under the hood. Ensure that positive and
negative terminals are positioned and connected
correctly.
CAUTION
Observe polarity.
Place battery terminal protectors over posts.
WARNING
Battery acid can cause severe burns. Make sure
battery caps are tight to avoid spills or splashing of
acid.
Close cover.

9
INSTALLATION
Squeegee
1. Make sure squeegee adjustment
lever is locked in UP position.
Install two adjustment knob
assemblies on squeegee
assembly. Do not thread in all
the way.
2. Slide squeegee assembly on
pivot frame and tighten
adjustment knobs.
3. Insert hose end into squeegee
assembly nozzle throat. Press
down tightly.
Squeegee can be locked in UP position by
raising lever and moving it to the left.
Squeegee can be locked in DOWN position
by pushing lever down and moving it to left.
NOTE: For even floors, squeegee can be set
to float by setting lever halfway between UP
and DOWN positions. Lock in DOWN position
for uneven floors.
NOTE: Never store machine with squeegee
in down position.
NOTE: Always raise squeegee while
backing up.

10
INSTALLATION
Recovery Tank Drain
Install drain door on mounting hardware. Make sure thumb screws
are tight. Place top of hose on hose bracket.
Brushes
1. Raise brush heads using switch on control panel.
2. Place brushes or pad holders under cover. Locate
brush coupler. Pull up to lock in place.
3. Check to see that two solution feed hoses are
connected to fittings on top of brush cover.

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PRE START-UP
Turn key and power switch on and lower brushes to
test. Brush motors will automatically turn on when
brushes are lowered.
Filling Solution Tank
1. Raise top cover.
2. Always empty recovery tank before filling solution
tank. This will eliminate overfilling of recovery
tank.
Lift solution tank cover and fill.
3. Close top covers by pushing covers down.
You are now ready to operate your machine.
Follow maintenance schedule on page 23 to ensure proper operation of your machine.

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TORNADO FLOORKEEPER
PREVENTIVE MAINTENANCE PROGRAM
Introduction
This section is designed to instruct your personnel in methods of maintenance on the Tornado
Floorkeeper. 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 covers and lock in place.
2. Remove battery caps and fill.
NOTE: Fill batteries with distilled water only. This
will increase battery life substantially.

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MAINTENANCE
CAUTION
Do not overfill the battery cells. Do not use a hose
or pail. If batteries are accidentally overfilled,
remove excess water with the hydrometer provided
with the machine. Dispose of excess in accordance
with local, state and federal regulations.
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 connections need
to be coated with a protective lubricant to
prevent corrosion.
WARNING
Avoid accidental contact with battery terminals and
possible electrical shock. Replace protective
plastic terminal covers after battery maintenance.

14
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 covers 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 Andersenä
connector 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 indicates 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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MAINTENANCE
Squeegee Blades
1. If a squeegee blade is worn or ripped, raise the squeegee
assembly and remove the entire squeegee assembly.
Disconnect vacuum hose, loosen two thumb screws and
slide pivot frame out. Remove the wing nuts on the rear of
the squeegee housing. Then remove the metal support
strap.
2. Squeegee blades can be repositioned to provide a new edge. See Figure 1
The front blade has two working edges (ref. #1, 2).
Flip blade for new edge when worn.
The rear blade has four working edges (see ref. #3 through 6).
When edge is worn, turn blade so new edge is on bottom,
facing front of squeegee.
NOTE: Edges of front and rear blades must be parallel to
each other.
3. Place the metal support strap back into position. Replace
the wing nuts on rear of the squeegee housing. Do not over-
tighten wing nuts as this will wrinkle the squeegee blade and
cause streaking during recovery.
Always keep the squeegee blade edge straight for best
results.
Clean squeegee blades with a damp cloth.

16
MAINTENANCE
Squeegee Adjustment
1. Height and flatness adjustments are made by
loosening the four screws (A & B) and lifting or lowering
the entire squeegee mechanism as desired.
2. Turn machine on and move machine forward slightly.
3. Look down at the contact being made between the
squeegee blades and the floor. Make adjustments
as required.
4. Correct adjustment is made when squeegee blades rest
evenly on the floor. Tighten four screws (A & B).
Blade pressure is adjusted by lengthening or shortening
the length of the squeegee link.
There are three holes at each end of link which are used
for adjustments.
For Smooth Floors:
Use the soft (3/1 6”) rear squeegee blade. (Standard)
Release the squeegee lever above and allow the
squeegee to rest on the floor.
For Rough Floors:
Use the firm (1/4” thick) rear squeegee blade.
Lock the handle in the down position so that squeegee is
forced down to floor.

17
MAINTENANCE
Vacuum and Water Recovery System
NOTE: A dirty or clogged filter will greatly reduce
suction and ability of machine to recover water.
Inspect vacuum filter after each use as follows:
1. Disconnect hose.
2. Turn the two cam-shaped thumb locks.
3. Remove filler assembly.
4. Remove foam filter and rinse with clean water.
5. Drain and flush tanks with clean water.
6. Leave filter assembly out of tank to allow
system to dry when not in use.
A liquid shutoff is built into the filter system to prevent overfilling
tank.
Solution and Recovery (Vacuum) Tanks
Draining Recovery (Vacuum) Tank:
1. Lift drain hose and remove from hook.
2. Insert end of hose into large pail or drain area.
3. Push ball to the side and drain. (Do not remove ball from
hose.)
4. For more extensive cleaning of tank, loosen two thumb nuts
and remove cover. Flush out tank with clean water as necessary.

18
MAINTENANCE
Draining Solution Tank:
1. Locate drain hose at front of unit and position over
acceptable floor drain or container.
2.Turn valve handle to open drain valve.
3.Return valve handle to closed position. Tuck drain
hose back on machine.
Flush and clean tanks after each use and allow to air
dry to eliminate odors and corrosion of vacuum motor.
Vacuum Motor
To service vacuum motor which is located above re-
covery tank:
1. Disconnect vacuum hose clamp.
2. Remove four screws.
3. Disconnect wires and remove cover.
4. Remove vacuum motor to service.
Wheels
Machines are equipped with either ‘foam-filled” or hard
urethane tires. No service is required.

19
MAINTENANCE
Lubricating Your Machine
WARNING
Unit must be switched “OFF” before greasing wheel
fittings. Wipe off excess.
Once a week grease swivel casters with grease gun
provided. Each caster has two fittings: one at the axle
(A) and one on the swivel part of caster (B).
Motor Brush Replacement
Use the appropriate hour meter on the LCD Display to monitor runtimes for each motor.
Tornado recommends changing motor brushes at the intervals specified below in order to avoid
potential damage to the commutators. Replacement brushes need to be inspected and
changed more often due to commutator wear. Always permanently record any brush
inspections and replacements you make.
Don’t attempt to use the Motor Fault Error feature of the LCD Display as a signal that motor
brushes need changing. A Motor Fault that occurs directly from brush wear would indicate a
high risk of motor damage.
Motor Recommended Motor Brush Change Interval
Transaxle 1800 hours initially, 900-1400 hours for replacements
Brush 2600 hours initially, 1300-2000 hours for replacements
Vacuum 600-650 hours initially, 400-500 hours for replacements

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TORNADO FLOORKEEPER®
TROUBLESHOOTING INSTRUCTIONS
This section is designed to instruct your personnel in methods of troubleshooting on the
Tornado Floorkeeper.
Vacuum System (Poor Suction)
During machine operation, if the vacuum motor is running but the solution is not being picked
up, do the following:
Check for:
1. Full recovery tank. When tank is full, liquid shutoff closes to prevent water from entering
vacuum motor.
2. Loose hose on float/filter, creating an air leak.
3. Clogged filter.
4. Clogged stand pipe near filter. Remove cap to inspect and clean with hose.
5. A. Check to see that ball closure is in place on end of drain hose.
B. Check to see that thumb nuts on recovery tank drain cover are tight.
C. Check to see if liquid shutoff unit is properly seated on top of recovery tank, the filter
gasket is not damaged, and cam lock nuts are tight.