KENT razor blade 26D, razor blade 28D, 908 7101 020, razor blade 28C, 908 7099 020 Service Manual

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Page 1

Simple. Clean.

Razor Blade 26D/28D/28C

SERVICE MANUAL Kent models:

908 7099 020 - 908 7100 020 - 908 7101 020

909 6510 000(3) 2007-12

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SERVICE MANUAL

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Razor Blade 26D / 28D / 28C 909 6510 000(3)2007-12

TABLE OF CONTENTS

GENERAL INFORMATION .............................................................................................................................................. 3

CONVENTIONS .............................................................................................................................................................................. 3

MACHINE LIFTING ......................................................................................................................................................................... 3

MACHINE TRANSPORTATION ....................................................................................................................................................... 3

OTHER AVAILABLE MANUALS ...................................................................................................................................................... 3

SAFETY ........................................................................................................................................................................................... 4

SYMBOLS ....................................................................................................................................................................................... 4

GENERAL SAFETY PRECAUTIONS .............................................................................................................................................. 4

TECHNICAL DATA ........................................................................................................................................................................... 6

MAINTENANCE ............................................................................................................................................................... 8

SCHEDULED MAINTENANCE ....................................................................................................................................................... 8

SCHEDULED MAINTENANCE TABLE ........................................................................................................................................... 8

MACHINE NOMENCLATURE ......................................................................................................................................................... 9

DETERGENT SUPPLY SYSTEM................................................................................................................................... 13

SOLUTION/WASHING WATER SYSTEM AND TANK CLEANING ............................................................................................... 13

SOLUTION/WASHING WATER FILTER CLEANING .................................................................................................................... 13

SOLUTION/WASHING WATER SYSTEM SOLENOID VALVE/TAP/FILTER DISASSEMBLY/ASSEMBLY .................................. 14

TROUBLESHOOTING ................................................................................................................................................................... 16

BRUSHING SYSTEM ..................................................................................................................................................... 17

BRUSH/CYLINDRICAL BRUSH CLEANING ................................................................................................................................. 17

SIDE SKIRT CHECK (AND REPLACEMENT) .............................................................................................................................. 17

BRUSH/PAD-HOLDER DECK OR CYLINDRICAL BRUSH DECK DISASSEMBLY/ASSEMBLY ................................................. 18

BRUSH MOTOR ELECTRICAL INPUT CHECK ............................................................................................................................ 18

BRUSH MOTOR CARBON BRUSH CHECK AND REPLACEMENT ............................................................................................ 20

BRUSH/PAD-HOLDER MOTOR DISASSEMBLY/ASSEMBLY ..................................................................................................... 21

CHECK/REPLACEMENT/ADJUSTMENT OF DRIVING BELTS BETWEEN MOTORS AND CYLINDRICAL BRUSHES ............ 24

BRUSH DECK LIFTING/LOWERING ACTUATOR DISASSEMBLY/ASSEMBLY ......................................................................... 26

TROUBLESHOOTING ................................................................................................................................................................... 28

RECOVERY WATER SYSTEM ...................................................................................................................................... 29

RECOVERY WATER TANK AND VACUUM GRID AUTOMATIC SHUT-OFF FLOAT CLEANING ................................................ 29

VACUUM SYSTEM MOTOR ELECTRICAL INPUT CHECK ......................................................................................................... 30

VACUUM SYSTEM MOTOR CARBON BRUSH CHECK AND REPLACEMENT .........................................................................31

VACUUM SYSTEM MOTOR DISASSEMBLY/ASSEMBLY ........................................................................................................... 32

SQUEEGEE CLEANING/CHECK AND BLADE REPLACEMENT.................................................................................................33

SQUEEGEE LIFTING CABLE SLIDING SHOE LUBRICATION....................................................................................................34

SQUEEGEE LIFTING ACTUATOR DISASSEMBLY/ASSEMBLY ................................................................................................. 35

SQUEEGEE LIFTING CABLE DISASSEMBLY/ASSEMBLY ......................................................................................................... 36

TROUBLESHOOTING ................................................................................................................................................................... 37

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SERVICE MANUAL

909 6510 000(3)2007-12 Razor Blade 26D / 28D / 28C

TABLE OF CONTENTS

PARKING BRAKE SYSTEM .......................................................................................................................................... 38

PARKING BRAKE CHECK ............................................................................................................................................................ 38

ELECTROMAGNETIC BRAKE DISASSEMBLY/ASSEMBLY (Machines up to January 2007) ..................................................... 39

ELECTROMAGNETIC BRAKE AND DISC WITH BRAKING MASSES DISASSEMBLY/ASSEMBLY

(Machines after January 2007) ...................................................................................................................................................... 41

TROUBLESHOOTING ................................................................................................................................................................... 43

DRIVE SYSTEM ............................................................................................................................................................. 44

DRIVING WHEEL COVER DISASSEMBLY/ASSEMBLY (Machines up to January 2007) ............................................................ 44

DRIVING WHEEL COVER DISASSEMBLY/ASSEMBLY (Machines after January 2007) ............................................................ 45

DRIVE SYSTEM MOTOR ELECTRICAL INPUT CHECK (Machines up to January 2007) ........................................................... 47

DRIVE SYSTEM MOTOR ELECTRICAL INPUT CHECK (Machines after January 2007)............................................................48

DRIVE SYSTEM MOTOR CARBON BRUSH CHECK AND REPLACEMENT (Machines up to January 2007) ........................... 49

DRIVE SYSTEM MOTOR CARBON BRUSH CHECK AND REPLACEMENT (Machines after January 2007) ............................ 50

DRIVE SYSTEM MOTOR SLIDING CONTACT CHECK AND REPLACEMENT (Machines after January 2007)......................... 51

DRIVE SYSTEM MOTOR DISASSEMBLY/ASSEMBLY (Machines up to January 2007) ............................................................. 53

DRIVE SYSTEM MOTOR, BEARING AND GASKET DISASSEMBLY/ASSEMBLY (Machines after January 2007) .................... 54

FORWARD/REVERSE GEAR PEDAL DISASSEMBLY/ASSEMBLY ............................................................................................ 57

FORWARD/REVERSE GEAR PEDAL POTENTIOMETER CHECK AND ADJUSTMENT ........................................................... 58

SPEED REDUCTION SENSOR CHECK/ADJUSTMENT ............................................................................................................. 59

SPEED REDUCTION SENSOR REPLACEMENT ........................................................................................................................ 60

DRIVER'S SEAT SAFETY MICROSWITCH OPERATION CHECK .............................................................................................. 62

DRIVER'S SEAT SAFETY MICROSWITCH REPLACEMENT ...................................................................................................... 62

TROUBLESHOOTING ................................................................................................................................................................... 63

OTHER SYSTEMS ......................................................................................................................................................... 65

SCREW AND NUT TIGHTENING CHECK .................................................................................................................................... 65

FRONT FAIRING DISASSEMBLY/ASSEMBLY ............................................................................................................................. 66

ELECTRICAL SYSTEM ................................................................................................................................................. 68

MACHINE WORKING HOUR CHECK .......................................................................................................................................... 68

HOUR COUNTER RESET PROCEDURE ..................................................................................................................................... 68

BATTERY MAINTENANCE AND RECHARGING .......................................................................................................................... 68

BATTERY DISASSEMBLY/ASSEMBLY ........................................................................................................................................ 68

FUSE CHECK/REPLACEMENT .................................................................................................................................................... 69

DRIVE SYSTEM ELECTRONIC BOARD REPLACEMENT .......................................................................................................... 70

FUNCTION ELECTRONIC BOARD REPLACEMENT .................................................................................................................. 71

DASHBOARD ELECTRONIC BOARD REPLACEMENT .............................................................................................................. 72

TROUBLESHOOTING ................................................................................................................................................................... 73

FUNCTION ELECTRONIC BOARD ERROR CODES .................................................................................................................. 73

COMPONENT LAYOUT ................................................................................................................................................................ 78

WIRING DIAGRAM ........................................................................................................................................................................ 81

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Razor Blade 26D / 28D / 28C 909 6510 000(3)2007-12

GENERAL INFORMATION

CONVENTIONS

Forward, backward, front, rear, left or right are intended with reference to the operator’s position, that is to say in driving position.

MACHINE LIFTING

WARNING!

Do not work under the lifted machine without supporting it with safety stands.

MACHINE TRANSPORTATION

WARNING!

Before transporting the machine, make sure that:

All doors and cases are closed. The ignition key is removed. The machine is securely fastened to the means of transport.

– – –

OTHER AVAILABLE MANUALS

The following manuals are available at Kent Literature Service Department:

RAZOR BLADE Instructions for Use Manual 26D-28D-28C – 909 6457 000 RAZOR BLADE Spare Parts List 26D-28D-28C – 909 6458 000

– –

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SERVICE MANUAL

909 6510 000(3)2007-12 Razor Blade 26D / 28D / 28C

GENERAL INFORMATION

SAFETY

The following symbols indicate potentially dangerous situations. Always read this information carefully and take all necessary precautions to safeguard people and property.

SYMBOLS

DANGER!

It indicates a dangerous situation with risk of death for the operator.

WARNING!

It indicates a potential risk of injury for people or damage to objects.

CAUTION!

It indicates a caution or a remark related to important or useful functions. Pay careful attention to the paragraphs marked by this symbol.

NOTE

It indicates a remark related to important or useful functions.

CONSULTATION

It indicates the necessity to refer to the User Manual before performing any procedure.

GENERAL SAFETY PRECAUTIONS

Specic warnings and cautions to inform about potential damages to people and machine are shown below.

DANGER!

Before performing any maintenance/repair procedure drive the machine on a level ground, remove the ignition key and disconnect the battery. This machine must be used by properly trained and authorized personnel only.

Keep the battery away from sparks, ames and incandescent material. During the normal operation,

explosive gases are released. Do not wear jewelry when working near electrical components. Do not work under the lifted machine without supporting it with safety stands.

Do not operate the machine near toxic, dangerous, ammable and/or explosive powders, liquids or vapors.

Battery charging produces highly explosive hydrogen gas. Keep the tanks open during battery charging

and perform this procedure in well-ventilated areas and away from naked ames.

–

– –

– – – –

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Razor Blade 26D / 28D / 28C 909 6510 000(3)2007-12

GENERAL INFORMATION

GENERAL SAFETY PRECAUTIONS (Continues)

WARNING!

Carefully read all the instructions before carrying out any maintenance/repair procedure.

Before using the battery charger, ensure that frequency and voltage values, indicated on the machine serial

number plate, match the electrical mains voltage.

To reduce the risk of re, electric shock, or injury, do not leave the machine unattended when it is plugged

in. Unplug the machine from the electrical mains when not in use and before performing maintenance procedures. To avoid electric shock, do not expose to rain. Store the machine indoors. Do not allow to be used as a toy. Close attention is necessary when used near children. Use only as described in this Manual. Use only Kent’s recommended accessories. Do not use with damaged power supply cable or plug. If the machine is not working as it should, has been damaged, left outdoors or dropped into water, return it to the Service Center. Do not pull or carry the machine by the supply cable; never use the power supply cable as a handle. Do not close a door on the supply cable, or pull the supply cable around sharp edges or corners. Do not run the machine on the supply cable. Keep the power supply cable away from heated surfaces. Take all necessary precautions to prevent hair, jewelry and loose clothes from being caught by the machine moving parts. Do not smoke while charging the batteries. Do not leave the machine unattended with the ignition key inserted and without being sure that it cannot move independently.

Do not use the machine on slopes with a gradient exceeding the specications.

Do not wash the machine with direct or pressurised water jets, or with corrosive substances. Do not use the machine in particularly dusty areas. While using this machine, take care not to cause damage to people or objects. The machine storage temperature must be between +32°F and +104°F (0°C and +40°C). The machine operating temperature must be between +32°F and +104°F (0°C and +40°C). The humidity must be between 30% and 95%. Always protect the machine against the sun, rain and bad weather, both under operation and inactivity condition. Do not use the machine as a means of transport.

Do not use the machine on slopes with a gradient exceeding the specications. Do not allow the brushes to operate while the machine is stationary to avoid damaging the oor. In case of re, use a powder re extinguisher, not a water one.

Do not bump into shelves or scaffoldings, particularly where there is a risk of falling objects.

Do not remove or modify the plates afxed to the machine. If parts must be replaced, require ORIGINAL spare parts from a Dealer or Authorised Retailer.

The machine must be disposed of properly, because of the presence of toxic-harmful materials (batteries,

etc.), which are subject to standards that require disposal in special centers (see Scrapping chapter in the

User Manual). Do not allow any object to enter into the openings. Do not use the machine if the openings are clogged. Always keep the openings free from dust, hairs and any other foreign material which could reduce the air

ow.

This machine cannot be used on roads or public streets. Pay attention during machine transport when temperature is below freezing point. The water in the recovery tank or in the hoses could freeze and seriously damage the machine.

Use brushes and pads supplied with the machine and those specied in the User Manual. Using other

brushes or pads could reduce safety.

– –

–

– – – –

–

– –

– – – – – – – –

–

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SERVICE MANUAL

909 6510 000(3)2007-12 Razor Blade 26D / 28D / 28C

GENERAL INFORMATION

TECHNICAL DATA

GENERAL TECHNICAL DATA

Description 26D 28D - 28C

Cleaning width 26.0 in (660 mm) 29.1 in (740 mm)

Squeegee width 32.7 in (830 mm) 33.9 in (860 mm)

Solution tank capacity 20 gal (75 liters)

Recovery water tank capacity 20 gal (75 liters)

Min/max solution ow 0,29 - 0,9 gal/min (1,1 - 3,4 litres/min)

Solution/clean water autonomy 0,29 gal/min (1,1 litres/min): ~ 68 min Media/Average

Rear wheel diameter (on xed axle) 11.8 in (300 mm)

Wheel specic pressure on the oor (*) front116 psi (0.8 N/mm2) - rear 145 psi (1.0 N/mm2)

Front steering, driving and braking wheel diameter 9.8 in (250 mm)

Minimum turning radius 40,5 in (1030 mm)

Vacuum system motor power 0.68 hp (500 W)

Drive system motor power 0.80 hp (600 W)

Drive speed (variable) 0 to 3.7 mph (0 to 6 km/h)

Max gradeability 16% (7,2°)

Working gradeability 2% (1°)

Sound pressure level at the operator’s position (ISO 11201, ISO 4871) (LpA)

60,8 dB(A) ± 3dB(A)

Sound pressure level to the machine (ISO 3744, ISO 4871) (LwA)

82,4 dB(A)

Vibration level at the operator’s arms (ISO 5349-1) (**) 9.05 - 295.27 in/s2 (0.23 – 7.5 m/s2)

Vibration level at the operator’s body (ISO 2631-1) (**) < 47.24 in/s2 (1.2 m/s2)

Batteries

24 V battery box, 240 Ah/5 h (WET) 240 Ah C5

24 V battery box, 240 Ah/5 h (GEL) (optional) 240 Ah C5

4 6 V batteries, 180 Ah/5 h (WET) 180 Ah C5

4 6 V batteries, 180 Ah/5 h (GEL) (optional) 180 Ah C5

Standard batteries autonomy ~ 3 h

Maximum battery compartment size

24 V battery box: 14.0 x 23.9 x 14.6 in (355 x 606 x 370 mm)

4 6 V batteries, with case: 20.8 x 15.0 x 11.8 in (530 x 380 x 300 mm)

Total consumption in work condition 62 A

Vacuum system capacity 1,76 MPa (1,800 mm H2O)

Machine height 49.2 in (1,250 mm)

Machine maximum length 57.0 in (1,450 mm)

Machine width without squeegee 26.8 in (681.5 mm) 30.0 in (758 mm)

(*) Machine test have been performed under the following conditions:

with operator [165.3 lb (75 kg)] if ride-on Battery maximum size Brush and squeegee maximum size Full solution tank Optional equipment installed Wheel weight checked Each wheel print checked on cement Result expressed as maximum value for both front and rear wheels

(**) Under normal working conditions, on a level asphalt surface.

•

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Razor Blade 26D / 28D / 28C 909 6510 000(3)2007-12

GENERAL INFORMATION

TECHNICAL DATA (Continues)

TECHNICAL DATA FOR MACHINES WITH BRUSH/PAD-HOLDER DECK

Description 26D 28D

Brush diameter 13.0 in (330 mm) 14.5 in (370 mm)

Deck right/left offset 3,4/1,8 in (87,8/46,8 mm) 4,6/3 in (117,4/76,7 mm)

Brush distance from the ground (when lifted) 3,7 in (95,5 mm)

Weight without batteries and with empty tanks 308 lb (140 kg)

Maximum weight with batteries and full tanks

With 4 6 V batteries: 849 lb (385 kg)

With 24 V battery box: 1,036 lb (470 kg)

Brush/pad-holder motor power 0.54 hp (400 W)

Brush/pad-holder rotation speed 190 rpm

Brush/pad-holder pressure with extra-pressure deactivated 66 lb (30 kg)

Brush/pad-holder pressure with extra-pressure activated 110 lb (50 kg)

TECHNICAL DATA FOR MACHINES WITH CYLINDRICAL BRUSH DECK

Description 28C

Cylindrical brush size (diameter x length) 5.7 x 27.1 in (145 x 690 mm)

Deck right/left offset 5,5/3,6 in (138,7/92,2 mm)

Brush distance from the ground (when lifted) 1,8 in (45,5 mm)

Weight without batteries and with empty tanks

308 lb (140 kg)

Maximum weight with batteries and full tanks

With 4 6 V batteries: 849 lb (385 kg)

With 24 V battery box: 1,036 lb (470 kg)

Cylindrical brush motor power 0.81 hp (600 W)

Cylindrical brush rotation speed 748 rpm

Cylindrical brush pressure 73.48 lb (33.4 kg)

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SERVICE MANUAL

909 6510 000(3)2007-12 Razor Blade 26D / 28D / 28C

GENERAL INFORMATION

DIMENSIONS RAZOR BLADE 26D

681.5 mm (26.8 in)

830 mm (32.6 in)1450 mm (57.0 in)

1250 mm (49.2 in)

DIMENSIONS RAZOR BLADE 28D

758 mm (30 in)

1450 mm (57.0 in)

1250 mm (49.2 in)

860 mm (33.9 in)

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Razor Blade 26D / 28D / 28C 909 6510 000(3)2007-12

GENERAL INFORMATION

DIMENSIONS RAZOR BLADE 28C

758 mm (30 in)

1450 mm (57.0 in)

1250 mm (49.2 in)

860 mm (33.9 in)

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SERVICE MANUAL

909 6510 000(3)2007-12 Razor Blade 26D / 28D / 28C

MAINTENANCE

SCHEDULED MAINTENANCE

The lifespan of the machine and its maximum operating safety are ensured by correct and regular maintenance.

WARNING!

See the GENERAL INFORMATION and SAFETY paragraphs.

The following table provides the scheduled maintenance. The intervals shown may vary according to particular working conditions,

which are to be dened by the person in charge of the maintenance.

For instructions on maintenance procedures, see the following paragraphs.

SCHEDULED MAINTENANCE TABLE

Procedure

Daily, after

machine use

Weekly

Every six

months

Yearly

Squeegee cleaning

Brush cleaning

Tank and vacuum grid with oat cleaning

Battery charging

Squeegee blade check and replacement

Side skirt check

Solution lter cleaning

WET battery uid level check

Screw and nut tightening check (1)

Check and adjustment of driving belts between motors and cylindrical brushes

Squeegee cable sliding shoe lubrication

Electromagnetic parking brake efciency check

Brush/pad-holder motor carbon brush check or replacement

Vacuum system motor carbon brush check or replacement

Drive system motor carbon brush check or replacement

(1) And after the rst 8 working hours.

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Razor Blade 26D / 28D / 28C 909 6510 000(3)2007-12

MAINTENANCE

Control panel Emergency push-button Horn Brush/pad-holder deck and cylindrical brush deck lifting/ lowering switch Brush/pad-holder extra-pressure switch. With the cylindrical brush deck installed, this switch is disabled. Squeegee lifting/lowering and vacuum system on/off switch

Battery charge indicator 7a. Charged battery warning light (green) 7b. Semi-discharged battery warning light (yellow) 7c. Discharged battery warning light (red)

Hour counter and solution level display:

When the machine is started, it displays for a few seconds the number of working hours which have been performed. While using the machine, it displays the solution level in the tank (measured in percentage terms, compared with the full tank). When the level is below 20%, the display starts blinking. The display could indicate “000 %” even if the tank is not completely empty, thus allowing to complete the cleaning cycle; in any case,

it is recommended to check the actual solution ow

supplied to the brushes.

Solution ow control switches

10a. Flow increase switch 10b. Flow decrease switch

Maximum speed adjuster (enabled only when the brushes

are operating)

Ignition key

Steering wheel tilting control lever

Steering wheel

Forward/reverse gear pedal

Brush/pad-holder deck

Cylindrical brush deck

Side skirts

Battery charger cable housing

Battery charger cable

Solution lter

Recovery water drain hose

Squeegee vacuum hose

Squeegee

Bumper wheels

Squeegee support wheels

Squeegee mounting handwheels

Squeegee balance adjusting handwheel

Front squeegee blade

Rear squeegee blade

Squeegee rear blade fastening hook

Solution tank

Recovery water tank

Recovery water tank cover

Flashing light (optional)

Solution tap

Seat

Battery charger

Electromagnetic parking brake

Front steering, driving and braking wheel

41a. Electromagnetic brake unlock handwheel (*) 41b. Electromagnetic brake unlock handwheel (**)

Serial number plate/technical data

Rear wheels

•

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

35.

36.

37.

38.

39.

40.

42.

43.

Side skirt height adjustment knobs Recovery water tank cover (open) Recovery water tank cover gasket Recovery water vacuum duct

Vacuum grid with automatic shut-off oat

Float Grid fasteners

Solution tank ller neck

Solution tank cover Cover support rod Recovery water tank Solution tank Tank assembly (open) Batteries Battery case Battery connector Battery caps Battery connection diagrams Brush/pad-holder deck Brush/pad-holder motors Brush/pad-holder deck or cylindrical brush deck connector Solution hose Deck mounting knob Deck fastening cotter pins Deck support Brush Pad-holder Pad Cylindrical brush deck connector Connector protection cover Brush/pad-holder deck side skirt Cylindrical brush deck Cylindrical brush motors Cylindrical brush deck side skirt Skirt upper mounting knob Skirt lower mounting knob Cylindrical brush Cylindrical brush lids Lid mounting knobs Cylindrical brush debris container Debris container handle Electrical component cover Cover mounting nuts Battery charger Battery type selector (“WET” or “GEL”) Drive system electronic board protection fuse (F2) (60 A) Low power circuit protection fuse (F3) (5 A) Function electronic board protection fuse (F1) (100 A) Warning LED Electrical component panel Red LED (upper) Green LED Red LED (lower)

(*) Machines up to January 2007 (**) Machines after January 2007

44.

45.

46.

47.

48.

49.

50.

51.

56.

57.

58.

59.

60.

61.

62.

63.

64.

65.

69.

70.

71.

72.

73.

74.

75.

76.

77.

78.

79.

80.

81.

82.

83.

84.

85.

86.

87.

88.

89.

90.

91.

92.

93.

94.

95.

96.

97.

98.

99.

100.

101.

102.

103.

MACHINE NOMENCLATURE

Throughout this Manual you will nd numbers in brackets – for example: (2). These numbers refer to the components shown in the

nomenclature pages. Refer to these pages whenever it is required to identify a component mentioned in the text.

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SERVICE MANUAL

909 6510 000(3)2007-12 Razor Blade 26D / 28D / 28C

MAINTENANCE

MACHINE NOMENCLATURE (Continues)

18 36

10a

10b

41a

41b

S301315

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Razor Blade 26D / 28D / 28C 909 6510 000(3)2007-12

MAINTENANCE

MACHINE NOMENCLATURE (Continues)

S301396

S301397

S301318

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SERVICE MANUAL

909 6510 000(3)2007-12 Razor Blade 26D / 28D / 28C

MAINTENANCE

MACHINE NOMENCLATURE (Continues)

S301619

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Razor Blade 26D / 28D / 28C 909 6510 000(3)2007-12

DETERGENT SUPPLY SYSTEM

SOLUTION TANK CLEANING

Drive the machine to the appointed disposal and washing area.

Turn the ignition key (12) to "0".

Empty the solution tank (59) with the tap (36).

Start the machine (as shown in the User Manual) and keep it running until the solution tank is completely empty.

Open the cover (56) and install the support rod (57).

Clean and wash with clean water the cover (56), the tank (59) and the ller (51).

Drain the water in the tank with the tap (36).

Start the machine (as shown in the User Manual) and keep it running until the solution tank is completely empty.

Remove the support rod (57) and close the cover (56).

Clean the solution lter (see the following procedure).

SOLUTION FILTER CLEANING

Drive the machine on a level oor.

Turn the ignition key (12) to "0".

Close the solution tap (A) under the machine, behind the right rear wheel. The tap (A) is closed when it is in the position (B)

and it is open when it is in the position (C).

Remove the transparent cover (D), then remove the lter strainer (E) under the machine, in front of the right rear wheel. Clean

and install them on the support (F).

NOTE

The lter strainer (E) must be correctly positioned on the housing (G) of the support (F).

Open the tap (A).

S301320

10.

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SERVICE MANUAL

909 6510 000(3)2007-12 Razor Blade 26D / 28D / 28C

DETERGENT SUPPLY SYSTEM

SOLUTION SYSTEM SOLENOID VALVE/TAP/FILTER DISASSEMBLY/ASSEMBLY

Disassembly

Drive the machine to the appointed disposal area, and empty the recovery water tank (58) with the hose (22). Empty the solution tank (59) with the tap (36).

Place the machine on a hoisting system (if available), then lift it. Otherwise, drive the machine on a level oor.

Turn the ignition key (12) to "0". Place a suitable jack (A) under the machine right side bracket (B). Lift the machine for 0.78 in (2 cm) with the jack. Remove the screw (C) and recover the washer (D). Remove the right wheel (E). Remove the screws (F). Move the support (G) forward, by disengaging the fastener (H) from the screw (I).

Disconnect the hoses (J) and (K) from their ttings (L).

Disconnect the hose (M) from the pressure switch (N) by pulling it. Disconnect the connectors (O) of the solenoid valve (P) and of the pressure switch.

Recover the whole assembly (G) and, at the workbench, remove the solenoid valve (R), or the lter assembly (S), or the tap

(T), by disconnecting/unscrewing the connecting/fastening components.

Assembly

Assemble the components in the reverse order of disassembly, and note the following:

Before screwing the threaded ttings (U) clean them, then apply Teon tape, according to the screwing direction;

when assembling the solenoid valve (R), the stamped arrow must be tuned in the direction of the solution ow.

10.

11.

12.

13.

14.

15.

•

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Razor Blade 26D / 28D / 28C 909 6510 000(3)2007-12

DETERGENT SUPPLY SYSTEM

SOLUTION SYSTEM SOLENOID VALVE/TAP/FILTER DISASSEMBLY/ASSEMBLY (Continues)

S301321

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SERVICE MANUAL

909 6510 000(3)2007-12 Razor Blade 26D / 28D / 28C

DETERGENT SUPPLY SYSTEM

TROUBLESHOOTING

SMALL AMOUNT OF SOLUTION OR NO SOLUTION REACHES THE BRUSH

Possible causes:

The solution lter is clogged/dirty (clean).

The solution tap is closed/semi-closed (replace). The solenoid valve is broken or there is an open in the electrical connection (replace the solenoid valve/repair the electrical connection). There is debris in the solution tank clogging the output hole (clean the tank).

There are debris in the solution hoses clogging the ow (clean the hoses).

THE SOLUTION REACHES THE BRUSH ALSO WHEN THE MACHINE IS OFF

Possible causes:

There is dirt or calcium deposit on the solenoid valve gasket (clean). The solenoid valve is broken (replace).

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BRUSHING SYSTEM

BRUSH/CYLINDRICAL BRUSH CLEANING

CAUTION!

It is advisable to wear protective gloves when cleaning the brushes because there may be sharp debris.

Remove the brushes from the machine, as shown in the User Manual.

Clean and wash the brushes with water and detergent.

Check the brush bristles for integrity and wear; if necessary, replace the brushes.

SIDE SKIRT CHECK (AND REPLACEMENT)

Check

Drive the machine on a level oor.

Turn the ignition key (12) to "0".

On both sides of the machine, unscrew the knobs (A) and remove the side skirt assembly (B).

Wash and clean the side skirts.

Check that the side skirt lower edge (C):

lays down on the same level, along all its length; is integral and free from cuts and lacerations; has the inner corner (D) that is not worn;

Otherwise overturn or replace the skirts according to the following procedure.

Overturning or replacement

Remove the wing nuts (E), then remove the retaining strip (F).

Remove the skirt blade (G) and, if possible, overturn the blade to replace the lower inner corner (D) with an integral one. If the

other three corners are worn too, replace the blade.

Assembly and height adjustment

Assemble the blades (G) and skirt (B) in the reverse order of disassembly.

Start the machine (according to the procedure shown in the User Manual) and lower the deck (H), then check that the side

skirt blades (G):

slightly touch the oor;

the side blades (G) collect the solution; otherwise stop the machine and adjust the skirt height with the knobs (A) and (I). After adjusting, tighten the knobs (A) and (I).

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BRUSHING SYSTEM

BRUSH/PAD-HOLDER DECK OR CYLINDRICAL BRUSH DECK DISASSEMBLY/ASSEMBLY

NOTE

The machine can be equipped with either the brush/pad-holder deck (69) or the cylindrical brush deck (82), according to

the following procedure. To assemble/disassemble the deck it is not necessary to remove the brushes/pad-holders.

Disassembly

Drive the machine on a level oor.

Lower the deck (69) or (82) by pressing the switch (4). Turn the ignition key (12) to "0". (For brush/pad-holder deck) Disconnect the connector (71). (For cylindrical brush deck) Disconnect the connectors (71) and (79), then install the protection cover (80) on the connector (79). Disconnect the solution hose (72).

Remove the two split pins (74) and the split pin for the left lever xing.

Unscrew the knob (73) and remove the brush/pad-holder deck (69), or the cylindrical brush deck (82).

Assembly

Assemble the components in the reverse order of disassembly.

BRUSH MOTOR ELECTRICAL INPUT CHECK

WARNING!

This procedure must be performed by qualied personnel only.

Drive the machine on a level oor.

Remove the brush (76) or (87), or the pad-holder (77) as shown in the User Manual. Place two wooden shims (A) under the brush/pad-holder deck sides (B), or the cylindrical brush deck (C), as shown in the

gure. The wooden shim height must be 1.5 in (40 mm).

WARNING!

Keep the wooden shims (A) at a proper distance from the brush hubs (D).

Apply the amperometric pliers (E) on one cable (F) of the right motor (G), or on one cable (H) of the left motor (I). Turn the ignition key (12) to "I". Press the switch (4) to lower the deck (B) or (C) on the wooden shims (A). When lowering the deck, the brush motors (G) and (I) start running, then check that the electrical input of the right (G) or left motor (I) is as follows:

3 to 5 A at 24 V, for the brush/pad-holder deck motors; 5 to 6 A, at 24 V, for the cylindrical brush deck motors.

Lift the deck (B) or (C) by pressing the switch (4). Turn the ignition key (12) to "0" and remove the amperometric pliers (E). If the electrical input is higher, perform the following procedures to detect and correct the abnormal input:

Check if there is dust or dirt (ropes, cables, etc.) on the brush/pad-holder hubs. Check the motor carbon brushes (see the procedure in the relevant paragraph). If necessary, disassemble the motor (see the procedure in the relevant paragraph), and check the condition of all its components.

If the above-mentioned procedures do not lead to a correct electrical input, the motor must be replaced (see the procedure in the relevant paragraph). Perform steps 2 and 3 in the reverse order.

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BRUSHING SYSTEM

BRUSH MOTOR ELECTRICAL INPUT CHECK (Continues)

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BRUSHING SYSTEM

DISC BRUSH MOTOR CARBON BRUSH CHECK AND REPLACEMENT

Remove the brush/pad-holder deck (see the procedure in the relevant paragraph). (For cylindrical brush deck only) Remove the brush motor (see the procedure in the relevant paragraph). Remove dust and dirt from the motor carbon brush support area (A). Disengage the fasteners (B) and (C), then remove the four carbon brush supports (A). If necessary, disconnect the electrical connections (D).

Check the carbon brushes (E) for wear. Replace the carbon brushes when: the contact with the motor armature is insufcient,

the carbon brushes are worn, the carbon brush contact surface is not integral, the thrust spring is broken, etc. The minimum length of the carbon brushes (E) is 0.59 in (15 mm). When this length is reached, the carbon brushes must replaced. If necessary, disconnect the connections (F) and remove the carbon brushes with their supports (A) and replace them. Replace the carbon brushes as an assembly. Assemble the components in the reverse order of disassembly, and note the following:

When connecting the terminals (F), take care of their insulation from the surrounding parts of the frame.

S301327

CYLINDRICAL BRUSH MOTOR CARBON BRUSH CHECK AND REPLACEMENT

Remove the brush motor (see the procedure in the relevant paragraph). At the workbench, remove dust and debris from the motor, especially in the area of the protection clamp (A). Remove the protection clamp (A). For each carbon brush, move the protection (B) and remove the screws (C). Remove the carbon brushes (D). Check if the carbon brushes (D) are worn. Replace the carbon brushes when: the contact with the motor armature is

insufcient, the carbon brushes are worn, the carbon brush contact surface is not integral, the thrust spring is broken, etc.

Replace the carbon brushes as an assembly. Assemble the components in the reverse order of disassembly.

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BRUSHING SYSTEM

BRUSH/PAD-HOLDER MOTOR DISASSEMBLY/ASSEMBLY

Disassembly

Remove the brushes/pad-holders, as shown in the User Manual. Remove the brush/pad-holder deck (see the procedure in the relevant paragraph). At the workbench, disconnect the motor electrical connections (A). Cut the motor clamp (B). Remove the motor screw (C), then remove the relevant hub assembly (D). Recover the key (E). Remove the four motor screws (F). Remove the reduction unit (G).

Assembly

Assemble the components in the reverse order of disassembly, and note the following:

Place the reduction units (G) as shown in the gure.

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BRUSHING SYSTEM

CYLINDRICAL BRUSH MOTOR DISASSEMBLY/ASSEMBLY

Disassembly

Remove the deck (see the procedure in the relevant paragraph). Unscrew the knobs (A) and remove the side skirt assembly (B) on the side of the machine where the motor must be removed. Remove the screw (C), then remove the cover (D). Loosen the nuts (E) and remove the cover (F). Loosen the nut (I) and move the pulley (J) to loosen the belt (K). Remove the belt (K) from the brush motor pulley (L). Disconnect the brush motor electrical connections (M). Remove the screws (G), then remove the motor (H).

Assembly

Assemble the components in the reverse order of disassembly, and note the following:

The electrical connections (M) of the motor must be turned upwards; Install the belt (K) and tension it properly (see the procedure in the relevant paragraph).

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BRUSHING SYSTEM

CYLINDRICAL BRUSH MOTOR DISASSEMBLY/ASSEMBLY (Continues)

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BRUSHING SYSTEM

CHECK/REPLACEMENT/ADJUSTMENT OF DRIVING BELTS BETWEEN MOTORS AND CYLINDRICAL BRUSHES

Check

Drive the machine on a level oor.

Turn the ignition key (12) to "0". On both sides of the machine, unscrew the knobs (A) and remove the side skirt assembly (B). Remove the screw (C), then remove the covers (D). Loosen the nuts (E) and remove the covers (F). Visually inspect the belt (G) for integrity, cuts, tears or cracks and, if necessary, replace it according to the following procedure. Check the belt tension (G) according to the following procedure.

Replacement

If the belt (G) must be replaced, loosen the nut (J) and move the pulley (K) to loosen the belt. Tension the belt (G) according to the following procedure.

Belt tensioning

Check the tension of the belt (G) between motor and brush. The tension is correct:

when pressing the belt in its centre with a force of 22 lb (10 kg) (H), the belt bends for 0.35 in (9 mm).

If necessary, tension the belt according to the following procedure: Loosen the nut (J) and adjust the position of the pulley (K). When tensioning procedure has been performed, tighten the nut (J). Repeat step 10.

Reset

Perform steps 3 to 5 in the reverse order.

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11.

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BRUSHING SYSTEM

CHECK/REPLACEMENT/ADJUSTMENT OF DRIVING BELTS BETWEEN MOTORS AND CYLINDRICAL BRUSHES (Continues)

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BRUSHING SYSTEM

BRUSH DECK LIFTING/LOWERING ACTUATOR DISASSEMBLY/ASSEMBLY

Disassembly

Drive the machine to the appointed disposal area, and empty the recovery water tank (58) with the hose (22). Empty the solution tank (59) with the tap (36).

Drive the machine on a level oor.

Turn the ignition key (12) to "0". Carefully lift the tank assembly (60) to reach the batteries. Disconnect the battery connector (63). Remove the deck (see the procedure in the relevant paragraph). Remove the nuts (A), then carefully remove the cover (B). Carefully move the electrical component panel (C) and disconnect the deck lifting/lowering actuator connector (D). Remove the lower mounting screw (E) of the actuator (F). Remove the screw (G). Remove the actuator (F).

Assembly

Assemble the components in the reverse order of disassembly.

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BRUSHING SYSTEM

BRUSH DECK LIFTING/LOWERING ACTUATOR DISASSEMBLY/ASSEMBLY (Continues)

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BRUSHING SYSTEM

TROUBLESHOOTING

OPEN CIRCUIT

The fuse (F1) causes an open in the function electronic board supply circuit. This system prevents the circuits from being damaged in case of failure. If there is an open in the fuse, the possible causes are:

The function electronic board wiring harness is damaged or shorted (check the power cables on the function electronic board and the relevant connections). The function electronic board is damaged (replace).

ALL BRUSHES DO NOT TURN

Possible causes (see also the Electrical System chapter, function electronic board diagnosis):

The function electronic board wiring harness or the brush motors are damaged (repair). The function electronic board is damaged (replace). The brush motor is shorted (replace).

ONE BRUSH DO NOT TURN

Possible causes:

The motor carbon brushes are worn (replace).

There are bulky debris or cords around the brushes or between the brushes and their anges (remove the brushes and the

debris). The motor is faulty (repair or replace). The wiring harness is damaged (repair).

THE BRUSHES CANNOT BE LIFTED/LOWERED OR THE EXTRA PRESSURE FUNCTION CANNOT BE TURNED ON

Possible causes (see also the Electrical System chapter, function electronic board diagnosis):

The deck lifting/lowering actuator end-of-strokes are not properly adjusted (adjust). The deck lifting/lowering actuator end-of-stroke microswitches are broken (replace the actuator). The deck lifting/lowering actuator is broken (replace). There is an open in the actuator wiring harness (check the connections according to the procedures shown in the Electrical System chapter, Troubleshooting paragraph).

THE MACHINE DOES NOT COLLECT THE SOLUTION COMPLETELY

Possible causes:

The side skirts are not properly adjusted (adjust/replace).

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RECOVERY WATER SYSTEM

RECOVERY WATER TANK AND VACUUM GRID AUTOMATIC SHUT-OFF FLOAT CLEANING

Drive the machine to the appointed disposal area. Turn the ignition key (12) to "0". Lift the cover (45).

Wash with clean water the cover (45), the tank (58) and the vacuum grid (48) with automatic shut-off oat. Drain the water in

the tank through the hose (22).

If necessary, release the fasteners (A) and open the grid (B), recover the oat (C), clean all components and then reinstall

them. Check the tank cover gasket (D) for integrity.

NOTE

The gasket (D) creates vacuum in the tank that is necessary for vacuuming the recovery water.

If necessary replace the gasket (D) by removing it from its housing (E). When assembling the new gasket, install the joint (F) in

the rear central area, as shown in the gure.

Check the bearing surface (D) of the gasket (G) for integrity and sealing capabilities. Close the cover (H).

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RECOVERY WATER SYSTEM

VACUUM SYSTEM MOTOR ELECTRICAL INPUT CHECK (before S/N ..........)

WARNING!

This procedure must be performed by qualied personnel only.

Drive the machine to the appointed disposal area, and empty the recovery water tank (58) with the hose (22). Empty the solution tank (59) with the tap (36).

Drive the machine on a level oor.

Turn the ignition key (12) to "0". Carefully lift the tank assembly (60). Apply the amperometric pliers (A) on one cable (B) of the vacuum system motor (C). Turn the ignition key (12) to "I". Turn on the vacuum system motor by pressing the switch (6) and check that the motor electrical input is 18 - 22 A at 24 V. Turn off the vacuum system motor by pressing the switch (6). Turn the ignition key (12) to "0" and remove the amperometric

pliers (A). If the electrical input exceeds the specications, check the motor carbon brushes (see the procedure in the relevant

paragraph). If necessary, disassemble the vacuum system motor (see the procedure in the relevant paragraph), and check the condition of its moving parts. If the above-mentioned procedures do not lead to a correct electrical input, the motor must be replaced (see the procedure in the relevant paragraph). Carefully lower the tank assembly (60).

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RECOVERY WATER SYSTEM

VACUUM SYSTEM MOTOR FILTER CLEANING (starting from S/N ..........)

Disassembly and cleaning

Drive the machine to the appointed disposal area, and empty the recovery water tank (58) with the hose (22). Empty the solution tank (59) with the tap (36).

Drive the machine on a level oor.

Turn the ignition key (12) to "0". Disconnect the vacuum hose (23) from the squeegee (24). Carefully lift the tank assembly (60).

Remove the vacuum system motor lter (D) and clean it with water and compressed air. Install the lter (D).

Carefully lower the tank assembly (60).

VACUUM SYSTEM MOTOR ELECTRICAL INPUT CHECK (starting from S/N ..........)

WARNING!

This procedure must be performed by qualied personnel only.

Drive the machine to the appointed disposal area, and empty the recovery water tank (58) with the hose (22). Empty the solution tank (59) with the tap (36).

Drive the machine on a level oor.

Turn the ignition key (12) to "0". Carefully lift the tank assembly (60). Apply the amperometric pliers (A) on one cable (B) of the vacuum system motor (C). Turn the ignition key (12) to "I". Turn on the vacuum system motor by pressing the switch (6) and check that the motor electrical input is 16 - 19 A at 24 V. Turn off the vacuum system motor by pressing the switch (6). Turn the ignition key (12) to "0" and remove the amperometric

pliers (A). If the electrical input exceeds the specications, check the motor carbon brushes (see the procedure in the relevant

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RECOVERY WATER SYSTEM

VACUUM SYSTEM MOTOR CARBON BRUSH CHECK AND REPLACEMENT (before S/N ..........)

Drive the machine to the appointed disposal area, and empty the recovery water tank (58) with the hose (22). Empty the solution tank (59) with the tap (36).

Drive the machine on a level oor.

Turn the ignition key (12) to "0". Carefully lift the tank assembly (60) to reach the batteries. Disconnect the battery connector (63). Remove the cover (A) from the vacuum system motor (B). Remove the screws (C). Disconnect the electrical connections (D). Remove the carbon brushes (E).

Check the carbon brushes for wear. Replace the carbon brushes when: the contact with the motor armature is insufcient, the

carbon brushes are worn, the carbon brush contact surface is not integral, the thrust spring is broken, etc. If necessary, replace the carbon brushes. Replace the carbon brushes as an assembly. Assemble the components in the reverse order of disassembly.

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RECOVERY WATER SYSTEM

VACUUM SYSTEM MOTOR CARBON BRUSH CHECK AND REPLACEMENT (starting from S/N ..........)

Drive the machine to the appointed disposal area, and empty the recovery water tank (58) with the hose (22). Empty the solution tank (59) with the tap (36).

Drive the machine on a level oor.

Check the carbon brushes for wear. Replace the carbon brushes when: the contact with the motor armature is insufcient, the

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RECOVERY WATER SYSTEM

VACUUM SYSTEM MOTOR DISASSEMBLY/ASSEMBLY (before S/N ..........)

Disassembly

Drive the machine to the appointed disposal area, and empty the recovery water tank (58) with the hose (22). Empty the solution tank (59) with the tap (36).

Drive the machine on a level oor.

Turn the ignition key (12) to "0". Disconnect the vacuum hose (23) from the squeegee (24). Carefully lift the tank assembly (60). Disconnect the battery connector (63). Disconnect the connector (D) from the vacuum system motor. Remove the screws (A), then remove the recovery water tank (B) with the vacuum hose (C). Remove the screws (E). Remove the vacuum system motor (F). Recover the gasket (G).

Assembly

Assemble the components in the reverse order of disassembly, and note the following:

Check the gasket (G) for integrity and efciency, otherwise replace it.

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RECOVERY WATER SYSTEM

VACUUM SYSTEM MOTOR DISASSEMBLY/ASSEMBLY (starting from S/N ..........)

Disassembly

Drive the machine to the appointed disposal area, and empty the recovery water tank (58) with the hose (22). Empty the solution tank (59) with the tap (36).

Drive the machine on a level oor.

Turn the ignition key (12) to "0". Disconnect the vacuum hose (23) from the squeegee (24). Carefully lift the tank assembly (60). Disconnect the battery connector (63). Disconnect the connector (D) from the vacuum system motor. Remove the screws (A), then remove the recovery water tank (B) with the vacuum hose (C). Remove the screws (E) and recover the washer. Remove the vacuum motor cover(F). Recover the Filter (G) and the gasket (H). Remove the vacuum system motor (I), the acoustic insulation pipe (J) and the acoustic insulation panel (K)

Check the gasket efcency (L) if necessary, replace them.

Assembly

Assemble the components in the reverse order of disassembly, and note the following:

If necessary, clean the lter (G) before assembling it (see the procedure in the relevant paragraph).

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RECOVERY WATER SYSTEM

SQUEEGEE CLEANING/CHECK AND BLADE REPLACEMENT

CAUTION!

It is advisable to wear protective gloves when cleaning the brushes because there may be sharp debris.

Disassembly and cleaning

Drive the machine on a level oor.

Turn the ignition key (12) to "I". Lower the squeegee (24) by pressing the switch (6). Turn the ignition key (12) to "0". Disconnect the vacuum hose (23) from the squeegee. Loosen the handwheels (27) and remove the squeegee (24). Wash and clean the squeegee. In particular, clean the compartments (A) and the vacuum hole (B) from dirt and debris. Check the front blade (C) and rear blade (D) for integrity, cuts and tears; if necessary replace them as shown below. Assemble the components in the reverse order of disassembly.

Check and replacement

Clean the squeegee as shown in the previous paragraph. Check that the edges (E) of the front blade and the edges (F) of the rear blade lay down on the same level, along their length; otherwise adjust their height according to the following procedure:

Disengage the fastener (G) and loosen the wing nuts (H) to adjust the rear blade (D); then tighten the wing nuts and engage the fastener. Loosen the wing nuts (I) to adjust the front blade (C); then tighten the wing nuts.

Check the front blade (C) and rear blade (D) for integrity, cuts and tears; if necessary replace them as shown below. Check that the front corner (J) of the rear blade is not worn; otherwise, overturn the blade to replace the worn corner with an integral one. If the other corners are worn too, replace the blade according to the following procedure:

Disengage the fastener (G), remove the wing nuts (H) and the retaining strip (K), then replace (or overturn) the rear blade (D). Install the blade in the reverse order of removal. Remove the wing nuts (I) and the retaining strip (L), then replace the front blade (C). Install the blade in the reverse order of removal.

After the blade replacement (or overturning), adjust the height as shown in the previous step.

Assembly

Install the squeegee (24) and screw down the handwheels (27). Connect the vacuum hose (23) to the squeegee (24). If necessary, adjust the squeegee balance adjusting handwheel (28). Lift the squeegee (24) by pressing the switch (6).

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RECOVERY WATER SYSTEM

SQUEEGEE LIFTING CABLE SLIDING SHOE LUBRICATION

Lower the squeegee (24), according to the procedure shown in the User Manual. Remove the batteries and the battery case (see the procedure in the Electrical System chapter). Clean and lubricate the sliding shoe (A) of the squeegee lifting cable (B) with graphite grease. Install the batteries and the battery case (see the procedure in the Electrical System chapter). Lift the squeegee (24).

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RECOVERY WATER SYSTEM

SQUEEGEE LIFTING ACTUATOR DISASSEMBLY/ASSEMBLY

Disassembly

Lift the squeegee (24), according to the procedure shown in the User Manual. Remove the batteries and the battery case (see the procedure in the Electrical System chapter). Remove the retaining rings (A) and the pin (B), thus disconnecting the terminal (C) of the squeegee lifting cable (D). Remove the screw (E). Disconnect the connector (F) of the actuator (I). Disconnect the actuator connector (G) from the clamps (H). Remove the squeegee lifting actuator (I).

Assembly

Assemble the components in the reverse order of disassembly.

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RECOVERY WATER SYSTEM

SQUEEGEE LIFTING CABLE DISASSEMBLY/ASSEMBLY

Disassembly

Lift the squeegee (24), according to the procedure shown in the User Manual. Remove the batteries and the battery case (see the procedure in the Electrical System chapter). Remove the retaining rings (A) and the pin (B), thus disconnecting the terminal (C) of the squeegee lifting cable (D). Remove the screw (E) and recover the washer (F). Remove the guide (G). Carefully lower the tank assembly (59). Remove the nut and the locknut (H), then remove the lifting cable (I) from the squeegee assembly (J).

Assembly

Assemble the components in the reverse order of disassembly, and note the following:

Before assembling the lifting cable (I), lubricate the squeegee lifting cable sliding shoe (K) with graphite grease.

After installing the squeegee lifting cable, adjust the nut and the locknut (I) so that, when the squeegee is completely lifted,

the distance from the oor is 0.78 in (20 mm).

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RECOVERY WATER SYSTEM

TROUBLESHOOTING

THE VACUUM SYSTEM MOTOR DOES NOT TURN ON

The function electronic board supplies current to the vacuum system motor directly; if the motor does not work, possible causes are the following (see also the Electrical System chapter, function electronic board diagnosis):

The vacuum system motor carbon brushes are worn (replace). The vacuum system motor is faulty (check the electrical input). The function electronic board is damaged (replace).

DIRTY WATER VACUUMING IS INSUFFICIENT OR THERE IS NO VACUUMING

Possible causes:

The vacuum grid with automatic shut-off oat is activated because the recovery water tank is full (empty the recovery water

tank). The grid is dirty (clean). The tank cover is not correctly positioned (adjust).

The tank cover gasket is not efcient (replace).

The squeegee or the vacuum hose is clogged or damaged (clean or repair/replace). The vacuum gaskets are damaged or do not match perfectly (repair or replace).

THE SQUEEGEE LEAVES LINING ON THE FLOOR OR DOES NOT COLLECT WATER

Possible causes:

There is debris under the blade (remove). The squeegee blade edges are torn or worn (replace). The squeegee is not balanced (adjust it with the relevant handwheel). The recovery water drain hose plug is open (close).

THE SQUEEGEE DOES NOT LIFT/LOWER

Possible causes (see also the Electrical System chapter, function electronic board diagnosis):

The actuator is faulty (repair/replace).

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PARKING BRAKE SYSTEM

PARKING BRAKE CHECK

Lift the brushes and the squeegee, then drive the machine on a dry oor that offers a good grip.

Turn the ignition key (12) to "0". Get off of the machine and push it manually in the direction shown by the arrow (A), then check that the front wheel (B) is locked. If necessary, replace the electromagnetic brake (see the procedure in the relevant paragraph).

B (*)

B (**)

S301640

(*) Machines up to January 2007 (**) Machines after January 2007

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PARKING BRAKE SYSTEM

ELECTROMAGNETIC BRAKE DISASSEMBLY/ASSEMBLY (Machines up to January 2007)

Disassembly

Drive the machine to the appointed disposal area, and empty the recovery water tank (58) with the hose (22). Empty the solution tank (59) with the tap (36).

Place the machine on a hoisting system (if available). Otherwise, drive the machine on a level oor.

Turn the ignition key (12) to "0". Carefully lift the tank assembly (60). Disconnect the battery connector (63). Apply proper wedges to right and left rear wheels (43), so that the machine cannot move when the electromagnetic brake (39) is disassembled. Disconnect the electromagnetic brake connector (A). Disconnect the wiring harness (B) from the clamps (C). Remove the self-locking nut (D) and the unlocking handwheel (E). Remove the screws (F), then remove the cover (G). Remove the electromagnetic brake mounting screws (H). Remove the electromagnetic brake (I). Remove the brake pad (J).

Assembly

Assemble the components in the reverse order of disassembly, and note the following:

Before assembling the cover (G), check the gasket (L) for dirt, integrity and correct positioning.

To activate the electromagnetic brake, the self-locking nut (D) must be ush with the threaded tie rod (K), while the unlocking handwheel (E) must be unscrewed until it contacts the nut (D) (as shown in the gure).

WARNING!

When the unlocking handwheel (E) is unscrewed, the electromagnetic brake is activated; when the unlocking handwheel (E) is screwed, the electromagnetic brake is deactivated.

Check the parking brake (see the procedure in the relevant paragraph).

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PARKING BRAKE SYSTEM

ELECTROMAGNETIC BRAKE DISASSEMBLY/ASSEMBLY (Machines up to January 2007) (Continues)

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PARKING BRAKE SYSTEM

ELECTROMAGNETIC BRAKE AND DISC WITH BRAKING MASSES DISASSEMBLY/ASSEMBLY (Machines after January 2007)

Disassembly

Drive the machine to the appointed disposal area, and empty the recovery water tank (58) with the hose (22). Empty the solution tank (59) with the tap (36). Place the machine on a hoisting system (if available).

Otherwise, drive the machine on a level oor.

Turn the ignition key (12) to "0". Carefully lift the tank assembly (60). Disconnect the battery connector (63). Apply proper wedges to right and left rear wheels (43), so that the machine cannot move when the electromagnetic brake (39) is disassembled. Cut the fastening clamps (A). Disconnect the electromagnetic brake connector (B). Remove the screws (C), then remove the case (D) by disengaging the wiring harness grommet (E). Remove the screws (F), then remove the electromagnetic brake (G). Remove the disc with braking masses (H). Check the thickness (J) of the braking masses (K) and, if it is lower than 0.039 in (1 mm), the disc (H) must be replaced.

If necessary, remove the ange (I).

Assembly

Assemble the components in the reverse order of disassembly, and note the following:

Before assembling the electromagnetic brake (G), clean it with compressed air; then install the threaded dowels (N) so that

they are ush with the surface (O).

After assembling the electromagnetic brake (G), check that the air gap (L) is 0.007 to 0.012 in (0.19 to 0.31 mm); if necessary adjust the air gap (L) by using the adjusting spacers (M).

Check the parking brake (see the procedure in the relevant paragraph).

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PARKING BRAKE SYSTEM

ELECTROMAGNETIC BRAKE AND DISC WITH BRAKING MASSES DISASSEMBLY/ASSEMBLY (Machines after January 2007) (Continues)

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PARKING BRAKE SYSTEM

TROUBLESHOOTING

THE BRAKE DOES NOT OPERATE

Possible causes:

The electromagnetic brake unlocking handwheel (41) is screwed (unscrew and remove).

The braking masses are not efcient (replace the electromagnetic brake).

(Machines after January 2007) The electromagnetic brake air gap is not properly adjusted (adjust).

THE BRAKE DOES NOT DEACTIVATE WHEN PRESSING THE FORWARD/REVERSE GEAR PEDAL

Possible causes:

There is an open in the wiring harness between the drive system electronic board and the electromagnetic brake (check/repair the wiring harness/electrical connections). The electromagnetic brake is faulty (replace). The drive system electronic board is faulty (replace).

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DRIVE SYSTEM

DRIVING WHEEL COVER DISASSEMBLY/ASSEMBLY (Machines up to January 2007)

Disassembly

Drive the machine to the appointed disposal area, and empty the recovery water tank (58) with the hose (22). Empty the solution tank (59) with the tap (36).

Place the machine on a hoisting system (if available). Otherwise, drive the machine on a level oor.

Turn the ignition key (12) to "0". Remove the brush/pad-holder deck (16) or the cylindrical brush deck (17) (see the procedure in the relevant paragraph). Turn the front wheel (A) completely to the left. Apply proper wedges to right and left rear wheels (43), so that the machine cannot move when the front wheel (A) is lifted. With the help of an assistant, slightly lift the front part of the machine and apply to the frame brackets (B) two proper wooden

shims (C) high enough to keep the front wheel (A) lifted for about 1.18 in (3 cm) from the oor.

Lift the tank assembly (60) and disconnect the battery connector (63). Disconnect the electrical connections (D) from the drive system motor. Remove the screws (E), then remove the driving wheel cover (F).

Assembly

Assemble the components in the reverse order of disassembly.

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DRIVE SYSTEM

DRIVING WHEEL COVER DISASSEMBLY/ASSEMBLY (Machines after January 2007)

Disassembly

Otherwise, drive the machine on a level oor.

Turn the ignition key (12) to "0". Remove the brush/pad-holder deck (16) or the cylindrical brush deck (17) (see the procedure in the relevant paragraph). Turn the front wheel (R) completely to the left. Apply proper wedges to right and left rear wheels (43), so that the machine cannot move when the front wheel (R) is lifted. With the help of an assistant, slightly lift the front part of the machine and apply to the frame brackets (S) two proper wooden

shims (T) high enough to keep the front wheel (R) lifted for about 1.18 in (3 cm) from the oor.

Lift the tank assembly (60) and disconnect the battery connector (63). Remove the wiring harness fastening clamp (A). Cut the fastening clamps (B) of the connector (C). Disconnect the electromagnetic brake connector (C). Remove the screws (D), then remove the cover (E). Disconnect the electrical connections (F). Remove the screws (G), then remove the driving wheel assembly (H). At the workbench, remove the electromagnetic brake (see the procedure in the relevant paragraph). Remove the screws (I), then remove the plate (J). With a puller (K) remove the brush side bracket (L). Remove the mounting screws (M) of the driving wheel cover (N). Recover the nuts (P) and washers (O). Remove the cover (N) from the reduction unit (Q).

Assembly

Assemble the components in the reverse order of disassembly, and note the following:

If necessary, use a rubber mallet to install the cover (N). Tighten the screws (M) at 141.61 lbf·in (16 N·m; 1.63 kgf·m). Tighten the screws (I) at 194.71 lbf·in (22 N·m; 2.24 kgf·m).

S301643

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DRIVE SYSTEM

DRIVING WHEEL COVER DISASSEMBLY/ASSEMBLY (Machines after January 2007) (Continues)

S T R T

P O

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DRIVE SYSTEM

DRIVE SYSTEM MOTOR ELECTRICAL INPUT CHECK (Machines up to January 2007)

WARNING!

This procedure must be performed by qualied personnel only.

Drive the machine on a level oor.

shims (C) high enough to keep the front wheel (A) lifted for about 1.18 in (3 cm) from the oor.

WARNING!

When performing the following procedure, pay attention to the rotation of the driving wheel (A).

Apply the amperometric pliers (D) on the positive cables (red) (E). The amperometric pliers must not touch the wheel. Seat on the machine driver's seat (37). Turn the ignition key (12) to "I". Drive the machine at the maximum forward speed by pressing the pedal (15) and check that the electrical input is 10 - 15 A at 24 V. Release the pedal (15). Turn the ignition key (12) to "0" and remove the amperometric pliers (D). If the electrical input is higher, perform the following procedures to detect and correct the abnormal input:

Check if there is dust or debris preventing the wheel rotation. Check if the electromagnetic brake slows down the wheel when the drive system motor is operating (remove the electromagnetic brake and repeat the electrical input check (see the procedure in the relevant paragraph)). Check the motor carbon brushes (see the procedure in the relevant paragraph). If necessary, disassemble the motor (see the procedure in the relevant paragraph), and check the condition of all its components.

If the above-mentioned procedures do not lead to a correct electrical input, the motor must be replaced (see the procedure in the relevant paragraph). Perform steps 3 to 6 in the reverse order.

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DRIVE SYSTEM

DRIVE SYSTEM MOTOR ELECTRICAL INPUT CHECK (Machines after January 2007)

WARNING!

This procedure must be performed by qualied personnel only.

Drive the machine on a level oor.

shims (C) high enough to keep the front wheel (A) lifted for about 1.18 in (3 cm) from the oor.

WARNING!

When performing the following procedure, pay attention to the rotation of the driving wheel (A).

Check if there is dust or debris preventing the wheel rotation.

Check if the electromagnetic brake slows down the wheel when the drive system motor is operating (remove the

electromagnetic brake and repeat the electrical input check (see the procedure in the relevant paragraph)).

Check the motor carbon brushes (see the procedure in the relevant paragraph).

If necessary, disassemble the motor (see the procedure in the relevant paragraph), and check the condition of all its

components. If the above-mentioned procedures do not lead to a correct electrical input, the motor must be replaced (see the procedure in the relevant paragraph). Perform steps 3 to 6 in the reverse order.

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DRIVE SYSTEM

DRIVE SYSTEM MOTOR CARBON BRUSH CHECK AND REPLACEMENT (Machines up to January

2007)

Check

Drive the machine to the appointed disposal area, and empty the recovery water tank (58) with the hose (22). Empty the solution tank (59) with the tap (36).

Place the machine on a hoisting system (if available). Otherwise, drive the machine on a level oor.

Turn the ignition key (12) to "0". Carefully lift the tank assembly (60). Disconnect the battery connector (63). Remove dust and debris from the drive system motor outer part (F), then disengage and remove the clamp (A) from the motor. Lift the retaining springs (B) and remove the four carbon brushes (C).

Check the carbon brushes for wear. Replace the carbon brushes when: the contact with the motor armature is insufcient, the

carbon brushes are worn, the carbon brush contact surface is not integral, the thrust spring is broken, etc.

Replacement

If necessary, remove the nuts (D) and disengage the lead-in wires (E), then remove the carbon brushes.

Reset

Assemble the components in the reverse order of disassembly.

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DRIVE SYSTEM

DRIVE SYSTEM MOTOR CARBON BRUSH CHECK AND REPLACEMENT (Machines after January

2007)

Check and replacement

Otherwise, drive the machine on a level oor.

Turn the ignition key (12) to "0". Carefully lift the tank assembly (60). Disconnect the battery connector (63). Remove the drive system motor carbon brush covers (A) (bayonet joint).

Remove the gasket (B) and check them for integrity and efciency; if necessary, replace them.

Remove the screws (C), then remove the four carbon brushes (D).

Check the carbon brushes (D) for wear. Replace the carbon brushes when: the contact with the motor armature is insufcient,

the carbon brushes are worn, the carbon brush contact surface is not integral, the thrust spring is broken, etc. If necessary, replace the carbon brushes.

Reset

Assemble the components in the reverse order of disassembly.

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DRIVE SYSTEM

DRIVE SYSTEM MOTOR SLIDING CONTACT CHECK AND REPLACEMENT (Machines after January

2007)

Check and replacement

Otherwise, drive the machine on a level oor.

Turn the ignition key (12) to "0". Carefully lift the tank assembly (60). Disconnect the battery connector (63). Remove the screws (A), then remove the sliding contact cover (B). Disconnect the sliding contact connections (C). Remove the sliding contact mounting screws (D) and nuts (E). Recover the washer (E). Remove both sliding contacts (G).

Check the sliding contacts (D) for wear. Replace the sliding contacts when: the contact with the sliding ring is insufcient, the

sliding contacts are worn, the contact surface is not integral, the thrust spring is broken, etc. If necessary, replace the sliding contacts.

Reset

Assemble the components in the reverse order of disassembly, and note the following:

The sliding contact surface (H) must be turned downwards, as shown in the gure.

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DRIVE SYSTEM

DRIVE SYSTEM MOTOR SLIDING CONTACT CHECK AND REPLACEMENT (Machines after January

2007) (Continues)

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DRIVE SYSTEM

DRIVE SYSTEM MOTOR DISASSEMBLY/ASSEMBLY (Machines up to January 2007)

Disassembly

Remove the electromagnetic brake (see the procedure in the relevant paragraph). Remove the connectors (A) from the drive system motor (B). Remove the retaining ring (C) on the electromagnetic brake side. Remove the ring gear (D) and recover the key (E).

Mark the position (G) of the ange (H) on the wheel support (I), for proper reassembly. Remove the screws (F), then remove the ange (H).

Remove the screws (J). If necessary, to remove the drive system motor (K), hit the shaft (L) with a plastic mallet.

Assembly

Assemble the components in the reverse order of disassembly, and note the following:

The connectors (A) of the drive system motor (K) must be turned upwards. If the bearing (M) comes out of its seat, reinsert it by pushing it on the outer ring by using a bush with appropriate diameter.

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DRIVE SYSTEM

DRIVE SYSTEM MOTOR, BEARING AND GASKET DISASSEMBLY/ASSEMBLY (Machines after January 2007)

Disassembly

Otherwise, drive the machine on a level oor.

Turn the ignition key (12) to "0". Remove the brush/pad-holder deck (16) or the cylindrical brush deck (17) (see the procedure in the relevant paragraph). Turn the front wheel (AG) completely to the left. Apply proper wedges to right and left rear wheels (43), so that the machine cannot move when the front wheel (AG) is lifted. With the help of an assistant, slightly lift the front part of the machine and apply to the frame brackets (AH) two proper wooden

shims (AI) high enough to keep the front wheel (AG) lifted for about 1.18 in (3 cm) from the oor.

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DRIVE SYSTEM

DRIVE SYSTEM MOTOR, BEARING AND GASKET DISASSEMBLY/ASSEMBLY (Machines after January 2007) (Continues)

Remove the screws (G), then remove the driving wheel assembly (H). At the workbench, remove the electromagnetic brake (see the procedure in the relevant paragraph). Remove the screws (I), then remove the plate (J). With a puller (K) remove the brush side bracket (L). Remove the mounting screws (M) of the driving wheel cover (N). Recover the nuts (P) and washers (O). Remove the cover (N) from the reduction unit (Q). If necessary, remove the screws (S) and the fasteners (T), then remove the bearing (R); if necessary, use a puller. Remove the four screws (U), then remove the carbon brushes holder assembly (V). If necessary, remove the bearing (W). With a puller (K) remove the brush side bracket (X). If necessary, remove the screws (Z) and the fasteners (AA), then remove the bearing (Y); if necessary, use a puller. Remove the motor (AB) from the reduction unit (AC). Do not let the oil coming out of the hole (AF). Do not let dust and dirt enter the reduction unit through the hole (AF). If necessary, remove the bearing (AD). If necessary, remove the oil seal (AE).

Assembly

Assemble the components in the reverse order of disassembly, and note the following:

the reduction unit spare part (AC) is already lled with oil (AGIP BLASIA 150; quantity 21 cl).

If necessary, use a rubber mallet to install the cover (N). Tighten the screws (M) at 141.61 lbf·in (16 N·m; 1.63 kgf·m). Tighten the screws (I) at 194.71 lbf·in (22 N·m; 2.24 kgf·m).

AH AI AG AI

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DRIVE SYSTEM

DRIVE SYSTEM MOTOR, BEARING AND GASKET DISASSEMBLY/ASSEMBLY (Machines after January 2007) (Continues)

P O

U R

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DRIVE SYSTEM

FORWARD/REVERSE GEAR PEDAL DISASSEMBLY/ASSEMBLY

Disassembly

Drive the machine on a level oor.

Engage the parking brake. Remove the pedal mounting screws (A). Slightly lift the pedal (B) and disconnect the connector (C).

Assembly

Assemble the components in the reverse order of disassembly.

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DRIVE SYSTEM

FORWARD/REVERSE GEAR PEDAL POTENTIOMETER CHECK AND ADJUSTMENT

Remove the forward/reverse gear pedal (see the procedure in the relevant paragraph). At the workbench, remove the screws (A), then remove the protection (B).

Apply a tester on the connector centre contact (C) and on the side contact (D), then check that the resistance is 2,500 ± 500 Ω

(Ohm) when the pedal is released. If necessary, reset the resistance correct value by loosening the screw (F) and operating on the potentiometer screw (E). Then tighten the screw (F). Install the protection (B) and tighten the screws (A). Install the forward/reverse gear pedal (see the procedure in the relevant paragraph).

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DRIVE SYSTEM

SPEED REDUCTION SENSOR CHECK/ADJUSTMENT

Check

According to the procedure shown in the User Manual, lift the brush/pad-holder deck and the squeegee, then start the machine, drive it at high speed, make turns both on the right and on the left, and check the following:

When the steering wheel (14) is turned for more than 1/4 turn (approximately), both on the right and on the left, the machine speed automatically decreases consistently.

The machine is equipped with an anti-tilting safety system that reduces the speed when turning, irrespectively of the pressure on the pedal. The reduction of speed when turning is not a malfunction but a characteristic that improves the machine stability in every condition. If necessary, adjust the speed reduction sensor according to the following procedure.

Adjustment

Place the machine on a hoisting system (if available). Otherwise, drive the machine on a level oor.

Turn the ignition key (12) to "0".

Clean the ange (A) in the area where the speed reduction sensor (B) operates.

Turn the steering wheel until the sensor (B) moves out of the deactivation area (C). Temporarily turn the ignition key (12) to “I” with care, and check the area (D) to see if the sensor is active. Turn the ignition key (12) to "0".

Turn the steering wheel to the right and to the left and check that the maximum distance between the sensor (B) and the ange (A) is 0.059 in (1.5 mm). Check that the sensor (B) never comes into contact with the ange (A).

If necessary, loosen the nuts (E) and adjust the position of the sensor (B). After adjusting, tighten the nuts (E). Remove the machine from the hoisting system and check again (steps 1 and 2).

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DRIVE SYSTEM

SPEED REDUCTION SENSOR REPLACEMENT

Disassembly

Remove the front fairing (see the procedure in the relevant paragraph). Remove the nuts (93), then remove the cover (92). Slightly move the electrical component panel (100). Disconnect the speed reduction sensor connector (A). Remove two mounting screws (H) of the foot board (I). Lift the foot board (J) and remove the sensor cable (K) through the passage (L). Remove the nuts (M), then remove the speed reduction sensor (N) with the cable.

Assembly

Assemble the components in the reverse order of disassembly, and note the following:

Insert the speed reduction sensor wiring harness (O) with the connector (P) disconnected; then connect the wiring harness

to the connector (P), paying attention to the cable colours.

Adjust the speed reduction sensor (see the procedure in the relevant paragraph).

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DRIVE SYSTEM

SPEED REDUCTION SENSOR REPLACEMENT (Continues)

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DRIVE SYSTEM

DRIVER'S SEAT SAFETY MICROSWITCH OPERATION CHECK

Check for proper machine operation in forward and reverse gear, as shown in the User Manual. Check that the ignition key (12) is turned to “I” and that the battery green warning light (7a) is on. Slightly lift from the seat (37) and try to start the machine with the hands on the steering wheel and by gradually pressing the pedal (15), both in forward and in reverse gear: Check that the machine can move neither forward nor backward. Otherwise, check the proper operation of the safety system that prevents the machine movement if the operator is not seating on the driver's seat, according to the following procedure:

Check for driver's seat microswitch proper operation, otherwise replace it according to the following procedure.

If necessary, check the driver's seat microswitch wiring harness.

DRIVER'S SEAT SAFETY MICROSWITCH REPLACEMENT

Disassembly

Drive the machine on a level oor.

Turn the ignition key (12) to "0". Open the cover (56) and install the support rod (57). Remove the cover (A) and disconnect the microswitch connector (B). Remove the screws (C). Remove the support rod (57) and close the cover (56). Slightly move the seat (D). Remove the wiring harness (E) from the hole (F). Remove the driver's seat microswitch (G) by detaching the adhesive (H).

Assembly

Assemble the components in the reverse order of disassembly. Check that the machine cannot move if the operator is not on the driver's seat (37) (see the above-mentioned procedure).

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DRIVE SYSTEM

TROUBLESHOOTING

OPEN CIRCUIT

The fuse (F2) causes an open in the circuit. This system allows to prevent the drive system motor and its circuits from being damaged under overload conditions. If there is an open in the circuit, the possible causes are:

There are bulky debris or cords under the machine or around the driving wheels (remove the debris). The motor is damaged (check the motor electrical input).

The oor gradient is excessive (do not use the drive system on slopes with a gradient exceeding the specications).

There is a short circuit in the drive system electronic board wiring harness (repair). The drive system electronic board is faulty (replace). The parking brake is faulty (see the Parking Brake chapter).

THE MACHINE DOES NOT MOVE

Possible causes:

The battery voltage is too low (charge the battery). The forward/reverse gear pedal potentiometer is misadjusted or broken (adjust or replace). The speed adjuster is broken (replace). The drive system electronic board is faulty (replace). The wiring harness is damaged (check all connections inside the electrical component compartment, included those of the function electronic board). The drive system motor carbon brushes are worn (replace). The drive system motor is faulty (replace). The microswitch of the safety system that prevents the machine movement if the operator is not seating on the driver's seat, is broken (repair/replace). The parking brake cannot be disengaged (see the Parking Brake chapter). There is an open in the drive system electronic board fuse F2 (replace). The function electronic board is faulty (see the Electrical System chapter).

DRIVE SYSTEM ELECTRONIC BOARD ERROR CODES

The warning LED (99) stays on, when the drive system operates properly and the machine is in the following condition:

Ignition key (12) turned to "I".

If the warning LED (99) is off or ashing, it indicates an error. Check the error code according to the following table.

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DRIVE SYSTEM

TROUBLESHOOTING (Continues)

DRIVE SYSTEM ELECTRONIC BOARD ERROR CODE TABLE

LED CODES

DESCRIPTION (REMEDY)

Note Reference

LED ashing

pattern

LED off

Broken drive system electronic board, or burned drive system fuse (FT), or disconnected cable (check the drive system electronic board wiring harness).

LED on Control system operating; no failure reported.

1.1 ¤ ¤

Activated thermal protection (wait few minutes to allow the electronic board to cool down. If the problem persists, check the drive system motor electrical input).

1.2 ¤ ¤¤ Faulty forward/reverse gear pedal (check).

1.3 ¤ ¤¤¤ Wrong programming of drive system electronic board (replace).

1.4 ¤ ¤¤¤¤ Voltage too low (check the batteries).

1.5 ¤ ¤¤¤¤¤ Voltage too high (check the batteries).

2.1 ¤¤ ¤ Faulty main contact OFF function (replace the electronic board).

2.3 ¤¤ ¤¤¤ Faulty main contact (replace the electronic board).

2.4 ¤¤ ¤¤¤¤ Faulty main contact ON function (replace the electronic board).

* 3.1 ¤¤¤ ¤ Forward/reverse gear pedal pressed when starting the machine (check).

3.2 ¤¤¤ ¤¤ Wrong programming of drive system electronic board (replace).

3.3 ¤¤¤ ¤¤¤ Forward/reverse gear pedal pressed when starting the machine (check).

3.4 ¤¤¤ ¤¤¤¤ Wrong programming of drive system electronic board (replace).

3.5 ¤¤¤ ¤¤¤¤¤ Forward/reverse gear pedal pressed when starting the machine (check).

* 4.1 ¤¤¤¤ ¤ Drive system motor short circuit (check the motor and the relevant wiring harness).

* 4.2 ¤¤¤¤ ¤¤ Drive system motor short circuit (check the motor and the relevant wiring harness).

* 4.3 ¤¤¤¤ ¤¤¤ The electronic board is faulty (replace).

* 4.4 ¤¤¤¤ ¤¤¤¤

Faulty electronic board (replace), or drive system motor short circuit (check the motor and the relevant wiring harness).

* = Reset the system by turning the ignition key to “0” and then to “I”.

NOTE: the LED signals only one error code at a time; other errors are not queued.

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909 6510 000(3)2007-12 Razor Blade 26D / 28D / 28C

OTHER SYSTEMS

SCREW AND NUT TIGHTENING CHECK

Drive the machine to the appointed disposal area, and empty the recovery water tank (58) with the hose (22). Empty the solution tank (59) with the tap (36).

Drive the machine on a level oor.

Turn the ignition key (12) to "0". Carefully lift the tank assembly (60). Check:

Tightening of mounting screws and nuts; Correct position of fasteners; Visible faults in the components;

Leaks of uids.

Carefully lower the tank assembly (60).

•

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Razor Blade 26D / 28D / 28C 909 6510 000(3)2007-12

OTHER SYSTEMS

FRONT FAIRING DISASSEMBLY/ASSEMBLY

Disassembly

Drive the machine to the appointed disposal area, and empty the recovery water tank (58) with the hose (22). Empty the solution tank (59) with the tap (36).

Drive the machine on a level oor.

Turn the ignition key (12) to "0". Carefully lift the tank assembly (60). Disconnect the battery connector (63).

Remove the cover (A) (the cover is press-tted).

Remove the steering wheel nut (B) and recover the washer (C). Remove the steering wheel (D). Remove the clamp (E). Remove the screws (F) and slightly lift the control panel (G) with care. Disconnect the connectors (H) and recover the control panel. Remove the steering wheel tilting control lever support screws (I). Slightly pull the lever (J) upwards, and remove the support (K). Disconnect the lever (M) from the cable terminal (N). Remove the screws (O). Lift and remove the fairing (P).

Assembly

Assemble the components in the reverse order of disassembly.

S301355

10.

11.

12.

13.

14.

15.

16.

17.

18.

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SERVICE MANUAL

909 6510 000(3)2007-12 Razor Blade 26D / 28D / 28C

OTHER SYSTEMS

FRONT FAIRING DISASSEMBLY/ASSEMBLY (Continues)

S301356

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Razor Blade 26D / 28D / 28C 909 6510 000(3)2007-12

ELECTRICAL SYSTEM

MACHINE WORKING HOUR CHECK

Turn the ignition key (12) to "I".

In the rst 5 seconds of machine operation, the display (8) shows the total number of working hours (scrubbing/drying)

performed by the machine. Turn the ignition key (12) to "0".

HOUR COUNTER RESET PROCEDURE

NOTE

Perform this procedure only in case this cannot compromise warranties or scheduled maintenance intervals.

Turn the ignition key (12) to "0". Press and hold the switch (9) and turn the ignition key (12) to “I”. Press and hold the switch (9) until the working hours are shown on the display (8) (after 15 seconds approximately). Press and release the switch (9) 5 times, within 5 seconds. The hour counter is reset.

BATTERY MAINTENANCE AND RECHARGING

See the User Manual.

BATTERY DISASSEMBLY/ASSEMBLY

Disassembly

Drive the machine to the appointed disposal area, and empty the recovery water tank (58) with the hose (22). Empty the solution tank (59) with the tap (36).

Drive the machine on a level oor.

Turn the ignition key (12) to "0". Carefully lift the tank assembly (60) to reach the batteries. Disconnect the battery connector (63). Disconnect the battery terminals (61). Remove the batteries (61). If necessary, remove the battery case (62).

Assembly

Assemble the components in the reverse order of disassembly, and note the following:

If a battery box is installed, place it on the left side of the machine, to allow the tank assembly (60) to be closed correctly.

10.

•

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SERVICE MANUAL

909 6510 000(3)2007-12 Razor Blade 26D / 28D / 28C

ELECTRICAL SYSTEM

FUSE CHECK/REPLACEMENT

Turn the ignition key (12) to "0". Remove the nuts (93), then remove the cover (92). Check/replace the following fuse:

Drive system electronic board protection fuse (F2) (60 A) (96)

Carefully move the electronic component panel (100) and check/replace the following fuses:

Low power circuit protection fuse (F3) (5 A) (A) Function electronic board protection fuse (F1) (100 A) (B)

Install the electrical component panel (100) and the cover (92), then tighten the nuts (93).

S301400

•

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Razor Blade 26D / 28D / 28C 909 6510 000(3)2007-12

ELECTRICAL SYSTEM

DRIVE SYSTEM ELECTRONIC BOARD REPLACEMENT

Disassembly

Drive the machine to the appointed disposal area, and empty the recovery water tank (58) with the hose (22). Empty the solution tank (59) with the tap (36).

Drive the machine on a level oor.

Turn the ignition key (12) to "0". Carefully lift the tank assembly (60). Disconnect the battery connector (63). Remove the nuts (93), then remove the cover (92). Slightly move the electrical component panel (100). Disconnect the connectors (A) from the drive system electronic board (B). Remove the screws (C). Remove the drive system electronic board (B).

Assembly

Assemble the components in the reverse order of disassembly.

S301358

10.

11.

12.

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SERVICE MANUAL

909 6510 000(3)2007-12 Razor Blade 26D / 28D / 28C

ELECTRICAL SYSTEM

FUNCTION ELECTRONIC BOARD REPLACEMENT

Disassembly

Drive the machine to the appointed disposal area, and empty the recovery water tank (58) with the hose (22). Empty the solution tank (59) with the tap (36).

Drive the machine on a level oor.

Turn the ignition key (12) to "0". Carefully lift the tank assembly (60). Disconnect the battery connector (63). Remove the nuts (93), then remove the cover (92). Slightly move the electrical component panel (A). Disconnect the connectors (B) of the function electronic board (C). Disconnect the lead-in wires (D). Remove the screws (E). Remove the function electronic board (C).

Assembly

Assemble the components in the reverse order of disassembly.

S301359

10.

11.

12.

13.

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Razor Blade 26D / 28D / 28C 909 6510 000(3)2007-12

ELECTRICAL SYSTEM

DASHBOARD ELECTRONIC BOARD REPLACEMENT

Disassembly

Drive the machine to the appointed disposal area, and empty the recovery water tank (58) with the hose (22). Empty the solution tank (59) with the tap (36).

Drive the machine on a level oor.

Turn the ignition key (12) to "0". Carefully lift the tank assembly (60). Disconnect the battery connector (63). Remove the mounting screws, then slightly lift the control panel (1). Disconnect the connectors (A) of the dashboard electronic board (B). Remove the dashboard electronic board (B) by disengaging the fasteners (E).

Assembly

Assemble the components in the reverse order of disassembly.

S301360

10.

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SERVICE MANUAL

909 6510 000(3)2007-12 Razor Blade 26D / 28D / 28C

ELECTRICAL SYSTEM

TROUBLESHOOTING

See the previous chapters related to the use of the electrical system. Other possible causes:

The batteries are discharged or the connections are not efcient (charge the batteries or clean the connections).

The batteries are broken (check the battery no-load voltage).

NOTE

In the machines equipped with on-board battery charger, a fault in the battery charger and relevant connections can

affect the machine operation.

The battery charger is broken (replace) (only for machine equipped with on-board battery charger). There is an open in the fuses (replace). The wiring harness is cut or pressed (repair).

FUNCTION ELECTRONIC BOARD ERROR CODES

On the function electronic board there are the following warning LEDs:

Red LED (upper) (101) Green LED (102)

Red LED (lower) (103) Under normal conditions (ignition key turned to “I” and batteries connected), only the green LED (102) must be on. If the green LED (102) is off, the possible causes are:

The batteries are disconnected (connect/check the wiring harness).

The batteries are broken (replace).

The ignition key circuit is faulty (check the emergency push-button, the ignition switch, the battery charger).

There is an open in the fuse (97) (replace).

There is an open in the fuse (98) (replace).

If the green warning LED (102) is on, but the red LED (101) or (103) is ashing, it indicates an error. Check the error code according

to the following table.

– – –

– – – – –

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ELECTRICAL SYSTEM

TROUBLESHOOTING (Continues)

FUNCTION ELECTRONIC BOARD ERROR CODE TABLE

Electronic board

LEDs

Flashing pattern Meaning Possible causes Lock Reset

Green LED (102) Always on

Power supplied electronic board

- - -

Red LED (upper)

(101)

Slow ashing

Deck actuator timeout

Mechanical obstacle to the deck actuator movement, or faulty deck actuator, or open in the deck actuator cable (check the connections), or broken deck actuator microswitch (replace the actuator).

None

By switch (4)

Fast ashing

Abnormal reading of deck actuator position

Open in the deck actuator cable (check the connections), or broken deck actuator microswitch (replace the actuator).

Deck actuator

By ignition key

Red LED (lower)

(103) and

dashboard yellow

LED

1 ash CC MOS at start-up

Short circuit in function electronic board wiring harness (check power cables on function electronic board), or faulty function electronic board (replace).

All except

Out *

By ignition key

2 ashes

Deck actuator CC1 (lowering overcurrent)

Short circuit in deck actuator cable (check), or faulty deck actuator (replace), or faulty function electronic board (replace).

Deck actuator

By switch (4)

3 ashes

Deck actuator CC2 (lifting overcurrent)

Deck actuator

By switch (4)

4 ashes Overvoltage

Wrong battery voltage (check battery voltage and battery series/parallel connection).

General relay

By ignition key

5 ashes

Brush motor CC (overcurrent)

Short circuit in brush motor wiring harness (check), or faulty brush motors (replace), or faulty function electronic board (replace).

Brush motor output

By ignition key

6 ashes

Vacuum system motor CC (overcurrent)

Short circuit in vacuum system motor wiring harness (check), or faulty vacuum system motor (replace), or faulty function electronic board (replace).

Vacuum system motor output

By ignition key

7 ashes

IMAX_SPAZZ. (>5s at 100 A)

Mechanical obstacle to brush motor rotation (check), or faulty brush motor (replace).

Brush motor output

By ignition key

8 ashes

IMAX_ASP. (>5s at 50 A)

Mechanical obstacle to vacuum system motor rotation, or faulty vacuum system motor (replace).

Vacuum system motor output

By ignition key

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SERVICE MANUAL

909 6510 000(3)2007-12 Razor Blade 26D / 28D / 28C

ELECTRICAL SYSTEM

TROUBLESHOOTING (Continues)

FUNCTION ELECTRONIC BOARD ERROR CODE TABLE

Electronic board

LEDs

Flashing pattern Meaning Possible causes Lock Reset

Red LED (lower) (103) and dashboard yellow LED

9 ashes

Probe 1 overtemperature

Faulty cooling fan (check M9), or too heavy working conditions (let the machine cool down), or faulty function electronic board (replace).

All except

Out *

By ignition key

10 ashes

Probe 2 overtemperature

All except

Out *

By ignition key

11 ashes

Ignition key turned to "0"

False contact from ignition key circuit (check connections of dashboard, function electronic board, ignition switch, emergency push-button and battery charger).

All except

Out *

By ignition key

12 ashes

EEPROM (software failure)

Faulty function electronic board (replace).

All except

Out *

By ignition key

13 ashes

Squeegee actuator CC (lowering overcurrent)

Short circuit in function electronic board or squeegee actuator (check), or faulty squeegee actuator (replace), or stuck squeegee actuator (check), or faulty function electronic board (replace).

Squeegee actuator

By switch (6)

14 ashes

Squeegee actuator CC (lifting overcurrent)

Squeegee actuator

By switch (6)

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Razor Blade 26D / 28D / 28C 909 6510 000(3)2007-12

ELECTRICAL SYSTEM

TROUBLESHOOTING (Continues)

FUNCTION ELECTRONIC BOARD CONNECTION REFERENCE

Connectors

Key:

J1 Dashboard inputs/outputs

J2 Auxiliary inputs/outputs 1

J3 Auxiliary inputs/outputs 2

J4 Brush deck actuator

J5 Fan

PIN Description Reference voltage

Electronic board

in/out

1 Logical power from key (+) 24 V In

2 Dashboard power supply (-) 0 V Out(**)

3 Return from brush deck lifting/lowering switch Indef (0 V) In

4 Return from extra pressure switch Indef (0 V) In

5 Return from vacuum system on/off switch Indef (0 V) In

6 Brush deck lifting/lowering switch LED power supply (LED1) Indef (0 V) Out

7 Extra pressure function switch LED power supply Indef (0 V) Out

8 Vacuum system on/off switch LED power supply Indef (0 V) Out

9 Battery GREEN LED power supply Indef (0 V) Out

10 Battery YELLOW LED power supply Indef (0 V) Out(**)

11 Battery RED LED power supply Indef (0 V) Out

12 Pressure switch output 0 - 5 V Out(**)

13 Solenoid valve adjustment input 1 Indef (0 V) In

14 Solenoid valve adjustment input 2 Indef (0 V) In

15 Horn input Indef (0 V) In

16 Solenoid valve output (repetition of J2.2) Indef (0 V) Out

PIN Description Reference voltage

Electronic board

in/out

1 Solenoid valve power supply 24 V Out

2 Solenoid valve power supply Indef (0 V) Out

3 Squeegee actuator power supply 24 V Out

4 Squeegee actuator power supply Indef (0 V) Out

5 Return from driver's seat microswitch Indef (0 V) In

6 Pressure switch input 0 - 5 V In

7 Auxiliary power supply (+) +24 V Out(**)

8 Auxiliary power supply (-) 0 V Out(**)

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909 6510 000(3)2007-12 Razor Blade 26D / 28D / 28C

ELECTRICAL SYSTEM

Connectors (Continues)

PIN Description Reference voltage

Electronic board

in/out

1 Auxiliary power supply (+) 24 V Out(**)

2 Auxiliary power supply (+) 24 V Out(**)

3 Auxiliary power supply (-) 0 V Out(**)

4 Input from machine moving signal Indef (0 V) In

5 Input from reverse gear signal Indef (0 V)(*) In

6 Cylindrical brush deck enabling input Indef (0 V) In

7 Drive system inhibition output Indef (0 V) Out(**)

8 Horn output Indef (0 V) Out(**)

PIN Description Reference voltage

Electronic board

in/out

1 Deck jack power supply Indef Out

2 Deck jack power supply Indef Out

3 Jack return microswitch m0 Indef (0 V) In

4 Jack return microswitch m1 Indef (0 V) In

5 Jack return microswitch m2 Indef (0 V) In

6 Jack microswitch common power supply 0 V Out

PIN Description Reference voltage

Electronic board

in/out

1 Fan power supply 24 V Out

2 Fan power supply Indef (0 V) Out

(*) Pull-up at 24 V (**) Outputs allowed also in case of ALARM, see the error code table

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Razor Blade 26D / 28D / 28C 909 6510 000(3)2007-12

ELECTRICAL SYSTEM

COMPONENT LAYOUT

Key

BAT 24 V battery

BE Flashing light

BRX Electromagnetic brake

BZ1 Reverse gear warning buzzer/horn

C1 Battery connector C2 Battery charger auxiliary connector C3 Battery charger external fan auxiliary connector

CH Battery charger (optional)

CS Brush deck connector

CSC Cylindrical brush deck secondary connector

EB1 Function electronic board EB2 Drive system electronic board EB3 Electronic board under the control panel

EB3/2 Electronic board under control panel (optional)

EV1 Water solenoid valve

F1 Function electronic board fuse F2 Drive system electronic board fuse F3 Low power circuit fuse F4 Pump fuse (optional) K1 Ignition switch

LD1

Drive system electronic board diagnostic warning

light M1 Left brush motor M2 Right brush motor M3 Vacuum system motor M4 Brush deck actuator M5 Drive system motor M6 Squeegee actuator M7 Water pump (optional) M8 Detergent pump (optional) M9 Cooling fan

PR1 Water level sensor RV1 Working speed potentiometer

RV2 Speed potentiometer (pedal) SW0 Emergency push-button SW1 Actuator position 0 microswitch SW2 Actuator position 1 microswitch SW3 Actuator position 2 microswitch SW4 Steering sensor SW5 Driver's seat microswitch SW6 Reverse gear switch (if equipped)

Colour codes

BK Black BU Blue

BN Brown GN Green GY Grey OG Orange

PK Pink RD Red

VT Violet

WH White

YE Yellow

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SERVICE MANUAL

909 6510 000(3)2007-12 Razor Blade 26D / 28D / 28C

ELECTRICAL SYSTEM

COMPONENT LAYOUT (Continues)

RV1

SW0

EB3

RV2

SW5

SW4

BRX (*)

BRX (**)

S301651

(*) Machines up to January 2007 (**) Machines after January 2007

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Razor Blade 26D / 28D / 28C 909 6510 000(3)2007-12

ELECTRICAL SYSTEM

COMPONENT LAYOUT (Continues)

S301403

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SERVICE MANUAL

909 6510 000(3)2007-12 Razor Blade 26D / 28D / 28C

ELECTRICAL SYSTEM

WIRING DIAGRAM

Key

BAT 24 V battery

BE Flashing light

BRK Electromagnetic brake

BZ1 Reverse gear warning buzzer/horn

C1 Battery connector C2 Battery charger auxiliary connector C3 Battery charger external fan auxiliary connector

CH Battery charger (optional)

CS Brush deck connector

CSC Cylindrical brush deck secondary connector

EB1 Function electronic board EB2 Drive system electronic board EB3 Electronic board under the control panel

EB3/2 Electronic board under control panel (optional)

EV1 Water solenoid valve

F1 Function electronic board fuse F2 Drive system electronic board fuse F3 Low power circuit fuse F4 Pump fuse (optional) K1 Ignition switch

LD1

Drive system electronic board diagnostic warning

PR1 Water level sensor

RV1 Working speed potentiometer

Colour codes

BK Black BU Blue

BN Brown GN Green GY Grey OG Orange

PK Pink RD Red

VT Violet

WH White

YE Yellow

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Razor Blade 26D / 28D / 28C 909 6510 000(3)2007-12

ELECTRICAL SYSTEM

WIRING DIAGRAM (Continues)

BAT

(*) If the machine have not the

optional charger (CH)

installed, C2 connectors are

connected togheter.

EB1

B-

B+

EV1

SW2 SW1

SW3

BZ1

EB2

YEGN

LD1

SW4

BRK

SW5

EB3 (EB3/2)

SW0

CSC

J2.3

J2.2

J2.1

RV1

BNBUBK

PR1

C2(*)

M9(*)

J1.19

J1.1

B+

J3.1

J3.2 J3.3

J3.4

J1.5

J1.4

J1.3

J4.1

J4.2

J4.3

J4.4 J4.5 J4.6

J2.1

J2.2

OUT+

BR-

VA-

OUT+

J3.3

J3.6

J2.3

J2.4

J5.1

J5.2

B+

J1.5

J2.7

J2.5

J2.6J2.8

J1.9

J1.8

J1.14

J1.6

J3.4

J1.16

J3.8J3.1

J3.5

J3.7

J1.12

B-

J1.2

J1.17

J1.3J1.4 J1.13J1.18

SW6

J1.4

J1.5

J1.6

J3.2

RV2

YEBKOG

RD BK WH BU

GNBK

OGBK

RDBK

BUBK

J1.7

GNBK

J1.8

J1.7

J1.6

J1.11

J1.10

J1.9

J1.14

J1.13

J1.12

J1.2

J1.16

J1.15

J1.1

J1.2

J1.3

J1.8

J1.9

J1.10

J1.11

J1.12

J1.13

J1.14

J1.15

J1.16

J1.17

J1.18

J1.20

GN-1

BU-3

RD-3

RD-2

GN-2

OG-3

WH-3

WH-2

BU-2

OG-2

WH-1

RD-1

BU-1

OG-1

(*) If the machine have the

optional charger (CH)

installed, the M9 fan is

connected as the side box

shows.

M9 WIRINGS WHEN THE CHARGER

IS INSTALLED ON BOARD

EB1.J5.2

EB1.J5.1

S301652

Page 90

KENT razor blade 26D, razor blade 28D, 908 7101 020, razor blade 28C, 908 7099 020 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual