Tornado Floorkeeper 99328 User manual

Tornado
Operation and Maintenance Manual
For Commercial Use Only
Long-Range FloorkeeperAutomatic Scrubber
Catalog No.
99328 & 99332
For Parts List see L9332EDP
Effective 11/7/2005
Form No. L9332ED Revised 11/05 2006 TornadoIndustries 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 instruction book covers:
MODEL 99328 99332
SIZE 28" 32”
VOLTS (CHARGER) 36V 36V
AMPS 20 20
CAPACITY 20 GAL. (79l) 20 GAL (79l)
SERIES D D
All specifications are subject to change without notice.
TABLE OF CONTENTS
WARRANTY 4
INTRODUCTION 5
UNIT CONTROLS AND INDICATORS 6
INSTALLATION
BATTERY 8
SQUEEGEE 9
RECOVERY TANK DRAIN 11
BRUSHES 11
PRE START-UP
FILLING SOLUTION TANK 12
PREVENTATIVE MAINTENANCE PROGRAM
INTRODUCTION 13
BATTERY CARE 13
BATTERY CHARGING 15
SQUEEGEE BLADES 16
SQUEEGEE ADJUSTMENT 17
VACUUM AND WATER RECOVERY SYSTEM 18
SOLUTION AND RECOVERY (Vacuum) TANKS 18
VACUUM MOTOR 19
WHEELS 19
LUBRICATING YOUR MACHINE 20
MOTOR BRUSH REPLACEMENT INTERVALS 20
TROUBLESHOOTING INSTRUCTIONS
VACUUM SYSTEM (POOR SUCTION) 21
POOR SOLUTION FLOW 22
ELECTRICAL PROBLEMS 23
BATTERIES NOT HOLDING CHARGE 23
TROUBLESHOOTING PERFORMANCE SYMPTOMS CHART 24
LCD DISPLAY DIAGNOSTIC ERROR CODES 25
PREVENTATIVE MAINTENANCE CHECKLIST 28
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Thank you for choosing Tornado products. We are proud to offer the most
complete line of commercial and industrial cleaning equipment in the industry.
Our reputation for quality, innovation and durability is unsurpassed.
* Effective January 1st, 2005. Terms subject to change without notice.
1) Windshear™ Blower-Dryer, Insulation Blowers, T191, T201, T12/1, CV 30, CV 38, CW 50, CW
100, Pro PAC Vacs, Duo-Upright Carpetkeepers™, Gas & Electric Pressure Washers, and all
chargers are warranted for 1 (one) year for both parts and labor.
2) Warranties on all riding sweepers including the ICC1, KM 100/100 R, KMR 1250, and KMR
1700 are 24 months parts/6 months labor OR 1000 hours of operation, whichever comes
first. Warranties on the 75/140 & 90/140 are 24 months parts/12 months’ labor OR 1,000
hours of operation whichever comes first.
3) All non-wear item parts purchased after warranty expiration are warranted for 90 days.
4) Warranty starts from the date of sale to the consumer or, at Tornado’s discretion, 6 months
after dealer purchased the unit from Tornado, whichever comes first.
Note: Tornado, The Latest Dirt, Floorkeeper, Carpetkeeper, Carpetrinser, Carpetrinser/Dryer,
Headmaster, Taskforce, PAC-VAC, T-Lite, Glazer, Windshear, Max-Vac, CV 30, CV 38, and
Trot-Mop are trademarks of Tornado Industries.
1-800-VACUUMS
Chicago area: [phone]
Fax: [phone]
7401 W. Lawrence Avenue
Chicago, IL 60706
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INTRODUCTION
Congratulations on the purchase of your new
Tornado Long-Range Floorkeeper! The Long-
Range 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.
The Long-Range Floorkeeper’s simplified
wiring harness uses quick-disconnects, and
combined with the digital controller, it makes
servicing and troubleshooting easy. A tough
rotomolded housing extends over an advanced
one-piece steel weldment, making this new
Long-Range Floorkeeper 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 Long-Range 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.
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Unit Controls and Indicators
Control Panel
1. Vacuum Motor Switch
2. Variable Speed
Control Knob
3. LCD Display
4. Display Mode
Button
5. Brush Position
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 Floorkeeper’s operating status. For particulars on
diagnostic fault code information, see page 24.
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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.
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INSTALLATION
Squeegee
Make sure squeegee adjustment lever is locked in UP
position. Squeegee can be locked in UP position by
raising lever and moving it to the left.
Loosen the two starwheel knobs on the
squeegee assembly. Make sure the black
metal bracket on the squeegee assembly is
aimed forward, toward the concave side of the
squeegee. Lift the squeegee bracket and
washers (if present), and slide the squeegee
assembly onto the rocker plate.
The bracket and washers should rest on top of
the rocker plate, as shown.
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INSTALLATION
Squeegee
Push the squeegee as far forward as it can go.
Tighten the starwheels to secure the
squeegee in place.
Insert the hose end over the squeegee
assembly nozzle throat. Press down tightly.
Refer to the Maintenance section to properly
adjust the squeegee position for best wiping
performance.
•Never store machine with squeegee in down
position. This can damage the flexible
blades.
•Always raise squeegee while backing up, to
prevent potential damage to the squeegee
and its mounting mechanism.
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INSTALLATION
Recovery Tank Drain
Install the drain door on its mounting hardware. Make sure the
starwheels are tight. Hang the top of the hose on the hose
bracket.
Brushes
1. Raise the brush heads using the switch on
the control panel.
2. Place the brushes or pad holders under
the brush cover. Center the brushes on the
brush couplers. Pull up to lock in place.
3. Check to see that the two solution feed
hoses are connected to their fittings on top
of the 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 28 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
Long-Range 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 a hydrometer or similar
device. 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.
1. 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.
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MAINTENANCE
The battery charger requires minimal maintenance.
It should be kept clean and all connections are to
be tightly secured. In the event of intermittent
operation, examine and tighten, if necessary, all
connections. BE SURE THE CHASSIS IS
SECURELY GROUNDED. If problems cannot be
resolved consult a qualified service center.
OPERATING INSTRUCTIONS
1. Open the machine cover. Keep the cover open
during the charging process.
2. Disconnect the Andersenconnector on the
machine.
3. Connect the battery charger to the battery side
of the Andersenconnector on the machine.
This is done by grasping the plug body and
pushing it straight back into the receptacle until
it is fully engaged. The black wire must be
connected to battery negative (-), and the red
or white wire to battery positive (+). Make sure
all connections are clean and tight.
4. Connect AC supply cord to a properly
grounded 120 volt, 60 hertz, single-phase
outlet.
5. The ammeter will start after a short delay as
indicated by the transformer hum and the
ammeter movement.
WARNING: LEAD ACID BATTERIES GENERATE GASSES WHICH
CAN BE EXPLOSIVE. CHARGE ONLY IN WELL-VENTILATED
AREAS. DO NOT DISCONNECT CHARGER DC OUTPUT
TERMINALS FROM BATTERY WHEN CHARGER IS ON. THE
RESULTING ARCING AND BURNING COULD CAUSE THE
BATTERY TO EXPLODE. KEEP SPARKS, FLAME, AND SMOKING
MATERIALS AWAY FROM BATTERY.
If the charger must be stopped, always disconnect the AC supply cord from its outlet before disconnecting the DC
output terminals from the battery.
6. Monitor the ammeter for correct charge current. The initial charge current should be approximately 20 amps. If
the batteries have not been discharged, or the AC supply voltage is lower than 120 volts, the initial charge rate
may be less. If the batteries have been excessively discharged, or AC supply voltage is higher than 120 volts,
the initial charge rate may be more than 20 amps.
7. Charge current will gradually taper to approximately 6 amps depending on the age and condition of the
batteries. Charger turns off automatically when battery is fully charged. Charge time varies with battery size
and depth of discharge. Allow 10-11 hours for normal charging. Severely discharged batteries may require
more time to be properly charged and equalized.
8. After the charger has been turned off, disconnect the DC outlet plug from the battery and the AC supply cord
from the outlet.
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MAINTENANCE
Squeegee Blades
Whenever the squeegee leaves streaks or
water trails, debris at the blade edges is the
primary cause. Clean the blade edges with a
damp cloth.
If a squeegee blade is worn or nicked, raise
the squeegee assembly and remove the
entire assembly: disconnect the vacuum
hose, loosen both star handles, and slide the
squeegee assembly out.
Remove both guide wheels and end caps.
Pull each blade out from one end, and slide
its replacement into place.
Replace the end caps and guide wheels.
Slide the squeegee assembly back onto its
mount, and tighten both star handles.
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MAINTENANCE
Squeegee Adjustment
Before resuming operation, check the
squeegee blades for proper engagement to
the floor.
First, lower the squeegee and push or drive
the machine forward several inches, then
look at the consistency of the rear blade flex
all along its length as it rests on the floor. If
the rear blade does not appear evenly
loaded, readjust the squeegee assembly
using the directions below.
Loosen the two rocker thumbscrews. Hold
the squeegee and rotate it forward or
rearward until the squeegee blades contact
the floor evenly. Tighten the rocker
thumbscrews.
Push the machine forward slightly and
recheck for even blade contact.
Replacement Blade Part Numbers:
Standard K62732150
Oil Resistant K62732090
Non-Marking Oil-Resistant K62732060
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MAINTENANCE
Vacuum and Water Recovery System
NOTE: A dirty or clogged filter will greatly reduce
suction and the ability of the machine to recover
water.
Inspect the vacuum filter after each use as follows:
1. Disconnect hose.
2. Turn the two cam-shaped thumb locks.
3. Remove filter assembly.
4. Rinse the filter screen with clean water.
5. Drain and flush tank 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. Do not disassemble or modify the white plastic float, or
vacuum motor damage may result.
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.
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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 pneumatic or
optional foam-filled tires. Be sure to keep pneumatic
tires at 48-50 psi to ensure proper machine
performance. No service is required for foam-filled
tires.
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MAINTENANCE
Lubricating Your Machine
WARNING
Unit must be switched “OFF” before greasing wheel
fittings. Wipe off excess.
Once a week grease swivel casters with a grease
gun. 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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