Minuteman E17TD, E17BD, H20TD, E20C, H20BD Service Manual

Service Manual

All E17BD, E17TD, E20BD, E20TD, E20C,

H20BD, H20TD and E26ECO Automatic

Scrubbers

For:

Training

Troubleshooting

Adjustments

Revised 09-11-2012

Contents

1 Safety Page 4
2 Technical Specifications Page 5

2.1 Dimensions E17BD & E20BD Page 6

2.2 Dimensions E17TD & E20TD Page 7

3 Maintenance Intervals Page 8

3.1 Customer Maintenance Page 9

3.2 Maintenance I after every 125 hours of operation Page 10

1 Safety Page 4
2 Technical Specifications Page 5

2.1 Dimensions E17BD & E20BD Page 6

2.2 Dimensions E17TD & E20TD Page 7

3 Maintenance Intervals Page 8

3.1 Customer Maintenance Page 9

3.2 Maintenance I after every 125 hours of operation Page 10

3.3 Maintenance II after every 250 hours of operation Page 11

3.4 Maintenance S after every 500 hours of operation Page 12
4 Batteries and Wiring Page 13
5 Recovery Float and Gasket Page 14
6 Lubrication Page 15
7 Charge Indicator Page 16
8 On Board Chargers Page 17

8.1 Programming the 957745 Charger Page 18

8.2 Charger Settings (957745) Page 19

8.3 Battery Charger Trouble Shooting Page 20

8.4 Battery Charger Display Codes Page 24

Contents

9 Battery and Error Code Indicator Page 27

9.1 E17TD and E20TD Error Codes Page 28

10 Squeegee Adjustment (Curved) Page 33

10.1 Squeegee Adjustment Page 34

10.2 Squeegee Caster Adjustment Page 35

10.3 Squeegee Caster Adjustment Page 36

10.4 Squeegee Caster Adjustment Page 37

9 Battery and Error Code Indicator Page 27

9.1 E17TD and E20TD Error Codes Page 28

10 Squeegee Adjustment (Curved) Page 33

10.1 Squeegee Adjustment Page 34

10.2 Squeegee Caster Adjustment Page 35

10.3 Squeegee Caster Adjustment Page 36

10.4 Squeegee Caster Adjustment Page 37
11 Maintaining Deep Cycle Batteries Page 38
12 Load Testing The Batteries Page 40
13 Hydrometer Testing Page 41
14 Transporting the Machine Page 44
15 Key Switch Page 45
16 Solution Filter Page 46
17 Notes Page 47
18 Service Bulletins and Additional Information Page 48

1. Stop the machine only on level surfaces.

2. Avoid moving parts. Do not wear loose jackets, shirts, or
sleeves when working on machine.

3. Avoid contact with battery acid. Battery acid can cause
burns. When working on or around batteries, wear protective
clothing and safety glasses. Remove metal jewelry. Do not

1. Safety

1. Stop the machine only on level surfaces.

2. Avoid moving parts. Do not wear loose jackets, shirts, or
sleeves when working on machine.

3. Avoid contact with battery acid. Battery acid can cause
burns. When working on or around batteries, wear protective
clothing and safety glasses. Remove metal jewelry. Do not
lay tools or metal objects on top of the batteries.

4. Do not clean machine with a pressure washer.

5. Only authorized personnel should perform repairs and
maintenance.

6. Use only Minuteman genuine replacement parts.

8. Do not use machine around flammable substances.

9. The batteries should be charged only in well ventilated areas.

10.Always disconnect the battery pack from the machine and the
A.C cord the from outlet, when servicing the machine.

Page 4

2. Technical Specifications

E17BD, E20

Page 5

2.1 Dimensions E17BD & E20 BD

With a Straight Squeegee

Page 6

2.2 Dimensions E17TD, E20TD, E17 and E20BD

With Curved Squeegee

Page 7

3. Maintenance Intervals

•Maintenance Intervals:
In a modular structure, the Minuteman System Maintenance determines the specific
technical proceedures to be preformed and sets the time interval between the two
maintenance cycles.
For each of the maintenance cycle, the replaceable parts are determined as well.
Further details described in the specific chapters.

•Minuteman System Maintenance K:
To be performed by the customer (in daily or weekly intervals) according to the maintenance

•Maintenance Intervals:
In a modular structure, the Minuteman System Maintenance determines the specific
technical proceedures to be preformed and sets the time interval between the two
maintenance cycles.
For each of the maintenance cycle, the replaceable parts are determined as well.
Further details described in the specific chapters.

•Minuteman System Maintenance K:
To be performed by the customer (in daily or weekly intervals) according to the maintenance
and care instructions as specified in the operating instructions.
The operator must be professionally instructed after delivery of the machine by selling
dealer.

•Minuteman System Maintenance I: (after every 125 hours of operation)
To be preformed an authorized Minuteman Service Center in accordance with the machine­specific system maintenance.

•Minuteman System Maintenance II: (after every 250 hours of operation)
To be preformed an authorized Minuteman Service Center in accordance with the machine­specific system maintenance.

•Minuteman System Maintenance S: (after every 500 hours of operation, safety check) To
be performed by an authorized Minuteman Service Center in accordance with the machine­specific system maintenance.

Page 8

3.1 Minuteman System Maintenance K

Page 9

3.2 Minuteman System Maintenance I

Page 10

3.3 Minuteman System Maintenance II

Page 11

3.4 Minuteman System Maintenance S

Page 12

4. Batteries & Wiring

•Battery Compartment

•The battery compartment is located under the

recovery tank. The battery compartment can be
accessed for servicing and maintenance by tilting the
recovery tank. Make sure the recovery tank is has
been drained before tilting.

•The battery compartment contains two 12 volt

batteries connected in series.

•Battery Compartment

•The battery compartment is located under the

recovery tank. The battery compartment can be
accessed for servicing and maintenance by tilting the
recovery tank. Make sure the recovery tank is has
been drained before tilting.

•The battery compartment contains two 12 volt

batteries connected in series.

•Connect the batteries according the battery wiring

diagram to the right.

•The recommended batteries are two 12 volt, 105 Ah

deep cycle battery part number 956712 for the Wet
Lead Acid type or 12 volt 100Ah Gel Maintenance
Free is part number 956100. Do not use Automotive
or Marine type batteries.

•When changing the type of battery (going to Gel from

Wet Lead Acid or visa versa) the battery charger will
need to be programmed accordingly. See Section 8.1
on Programming the Charger.

Page 13

5. Recovery Float

•The Recovery Float and Filter is located inside of the tank,

•The filter should be checked after each use and cleaned if needed.

•Remove the three screws and the cover, to access screen float for more extensive cleaning.

•Failure to do so will reduce the vacuum performance of the machine.

•Using the machine without it in place or picking up dry material will damage the vacuum
motor.

•The Recovery Float and Filter is located inside of the tank,

•The filter should be checked after each use and cleaned if needed.

•Remove the three screws and the cover, to access screen float for more extensive cleaning.

•Failure to do so will reduce the vacuum performance of the machine.

•Using the machine without it in place or picking up dry material will damage the vacuum
motor.

3 screws

cover

screen/float

Page 14

Regularly scheduled lubrication of certain machine
parts should be performed to insure trouble-free
operation of the machine. Apply a generous amount

of grease into the fittings on the machine until grease
seeps out around the bearings. Wipe excessive

6. Lubrication

Regularly scheduled lubrication of certain machine
parts should be performed to insure trouble-free
operation of the machine. Apply a generous amount

of grease into the fittings on the machine until grease
seeps out around the bearings. Wipe excessive
grease off with a towel.

The grease points are listed below:

1. Rear squeegee caster wheel axle (2)

2. Rear squeegee caster swivel (2)

Apply lubricant to:

1. The rear squeegee pivot points

2. The scrub deck linkages.

Page 15

7. Charging Indicator

•The indicator will light during

the charging process.

•The red light indicates, the

batteries need a full charge.

•The yellow light indicates, the

Charge Indicator

•The indicator will light during

the charging process.

•The red light indicates, the

batteries need a full charge.

•The yellow light indicates, the

batteries have received 80% of
their charge.

•The green light indicates, the

batteries are fully charged.

•The red light is flashing,

indicates the charger has
detected a fault in the batteries.
(See Section 8.6) Applies to the
957745 chargers.

Page 16

8. On Board Chargers

•The Minuteman on board chargers are capable of being programmed to charge lead acid
wet or gel type maintenance free batteries.

•The on board charger does has a variety of other programming settings.

•Use caution when making changes. Incorrect settings may cause the charger to
malfunction and or damage the batteries.

•The 957745 charger (on left) has a series of dip switches located under the front decal that
can be used to change the settings.

•The Minuteman on board chargers are capable of being programmed to charge lead acid
wet or gel type maintenance free batteries.

•The on board charger does has a variety of other programming settings.

•Use caution when making changes. Incorrect settings may cause the charger to
malfunction and or damage the batteries.

•The 957745 charger (on left) has a series of dip switches located under the front decal that
can be used to change the settings.

•The 957761 charger (on right) has a accessible rotary switch at the bottom of the charger.

957745 Charger 957761 Charger

Page 17

8.1 Programming the 957745 Charger

1. Remove the large rear metal cover on rear the machine.

2. Locate the battery charger.

3. To access the Dip Switches, carefully peal the decal back on the front of the
charger. Start at the bottom left side and peal up. (Removing the plastic charger
cover is not necessary.) Use caution not to damage the decal.

1. Remove the large rear metal cover on rear the machine.

2. Locate the battery charger.

3. To access the Dip Switches, carefully peal the decal back on the front of the
charger. Start at the bottom left side and peal up. (Removing the plastic charger
cover is not necessary.) Use caution not to damage the decal.

4. There is a series of eight Dip Switches located under the decal.

5. Each switch is numbered 1 through 8.

Dip Switches 1 to 4 are for setting the type of battery.

Type of Battery Switch 1 Switch 2 Switch 3 Switch 4

Lead Acid Wet Batteries ON ON OFF ON

AGM ON OFF OFF ON

Gel and Maintenance Free ON OFF OFF ON

Page 18

Current (Amperage Output) Switch 5 Switch 6 Switch 7

4 AMPS ON ON NA

The dip Switches 5,6 and 7 are for selecting the amperage output of the
charger. Use the 12 amp. setting only. * Note: The dip switch # 7 does not
have any function at this time.

8.2 Charger Settings (957745)

8 AMPS OFF ON NA
10 AMPS ON OFF NA
12 AMPS OFF OFF ON

Dip Switch 8 is to select the output voltage, either 12 or 24 volt. Use the
24 volt setting only.

Voltage Output Switch 8

12 Volts ON
24 Volts OFF

Page 19

8.3 Battery Charger Trouble Shooting

(957745 Charger Only)

1. Does the battery charger turn on when plugged into the A.C. outlet?

2. Can you hear the cooling fan turn on? If not, check the A.C. outlet for power.

3. Try a different outlet, if needed.

4. If it still doesn’t turn on, inspect the A.C. cord. Repair if needed.

Trouble Shooting

1. Does the battery charger turn on when plugged into the A.C. outlet?

2. Can you hear the cooling fan turn on? If not, check the A.C. outlet for power.

3. Try a different outlet, if needed.

4. If it still doesn’t turn on, inspect the A.C. cord. Repair if needed.

5. If the A.C. cord is Ok, check to see if the battery connector has been plugged in to
the machine’s connector.

6. Inspect the battery cables. Make sure they are clean and tight.

7. Test the voltage of the batteries; it must be above two volts minimum, before the charger

will turn on.

8. If everything above checks OK, and the charger still doesn’t turn on or doesn’t have any

output, replace the battery charger.

Page 20

8.3 Battery Charger Trouble Shooting

The Charger Turns On

1. If the charger appears to turn on, remove the rear metal cover on the rear of
the machine.

2. The charger’s display should be lighted, when plugged in the A.C. outlet. If
not, replace the charger.

(957745 Charger Only)

The Charger Turns On

1. If the charger appears to turn on, remove the rear metal cover on the rear of
the machine.

2. The charger’s display should be lighted, when plugged in the A.C. outlet. If
not, replace the charger.

3. Check for errors on the chargers display.

4. Press the number 5 on the charger decal.

5. This will display different pieces of information about the charging process
such as errors

6. (see error list), battery voltage, output amperage, hours of charging and
estimated amp hour of battery and wattage.

7. The voltage and amperage output should start to climb after a few minutes of
starting the charger, unless batteries are still hot from charging. If not, replace
the charger.

Page 21

Excessive Gassing or Water Consumption in

Batteries

1. If the charger appears to be charging and excessive gassing or water
consumption had been or is occurring in the batteries.

8.3 Battery Charger Trouble Shooting

Excessive Gassing or Water Consumption in

Batteries

1. If the charger appears to be charging and excessive gassing or water
consumption had been or is occurring in the batteries.

2. Check the following:

A. Have the batteries been maintained on a consistent basis?

Failure to maintain batteries will shorten their life and reduce their
performance.

B. Test the batteries with a hydrometer. The batteries should be fully
charged and cooled for 2 hours after charging, before testing.
top the batteries off with distilled water prior to charging, if needed.
Do not over fill.

C. Compare the cell readings of all the cells in each battery

Page 22

•The greater the variation between cells in any one battery, the greater loss of running time.

•A battery with variations of .040 or greater should be replaced.

•The variation of .020 is considered normal.

•Specific Gravity Readings are as follows:

8.3 Charger Trouble Shooting

Excessive Gassing or Water Consumption in Batteries Continued

•The greater the variation between cells in any one battery, the greater loss of running time.

•A battery with variations of .040 or greater should be replaced.

•The variation of .020 is considered normal.

•Specific Gravity Readings are as follows:

1.280 and above 100% charged cell

1.235 to 1.240 = 75% charged cell

1.190 to 1.195 = 50% charged cell

1.150 to 1.175 = 25% charged cell

1.250 and less = 0% charged cell

•Load test the batteries with a battery load tester.

•The voltage difference should be less that 1 volt, when testing under load.

•Any battery that has 1 or more volt(s) less than the other should be replaced.

Page 23

Codes that could be displayed on the charger are as follows:

“Bat” = The batteries are not detected. Voltage is below 2 volts,

The polarity could be reversed or batteries disconnected.

“Acd” = the charger programming set for wet lead acid batteries. (not an error)
“Gel” = charger programming set for gel batteries (not an error)

8.4 Battery Charger Display Codes

957745 Chargers

Codes that could be displayed on the charger are as follows:

“Bat” = The batteries are not detected. Voltage is below 2 volts,

The polarity could be reversed or batteries disconnected.

“Acd” = the charger programming set for wet lead acid batteries. (not an error)
“Gel” = charger programming set for gel batteries (not an error)
“E01” = maximum battery voltage has been reached.
“E02” = charger is overheating, faulty cooling fan or the cooling air to charger is obstructed.
“E03” = the batteries have exceeded the normal charge time. Possible battery sulfation has

occurred. Cycle the batteries several times (charge and discharge).

“SCt” = safety timer operation. This normally occurs after any allotted phase time period has

expired.

“Srt” = internal short circuit in charger. Replace the charger.

Page 24

8.5 Programming the 957761 Battery Charger

1. Remove the rear metal panel on the machine.

2. Remove the 957761 charger completely from the machine.

3. Locate the rubber plug on the bottom right side of the charger.

4. Remove the rubber plug.

5. Locate the selector switch.

6. Use a small flat tip screw driver to turn the red indicator to the desired
setting. See the chart below.

7. Replace the rubber plug and install charger into the machine.

Switch Position

Battery Type

Instructions

1

Flooded Lead Acid Part # 956712 (115 AH)

1

Minuteman AGM (95AH) Part # 956100 (Note: Replaces the gel battery) Used after 5/11/2011

2

Flooded Lead Acid Part # 956140 (140 AH)

3

Gel Maintenance Free Part # 956135 (135AH)

4

Gel Maintenance Free Part #956100 (95 AH) Used before 5/11/2011

Note: These are the only settings available. For non OEM batteries, select from the list

above. The remaining settings do not have any additional functions.

Bottom view with plug Bottom with plug removed Selector Switch close up

Page 25

Faults are displayed red LED on the battery charge indicator.

RED LED BLINKS ONCE AND REPEATS: OUTPUT CONNECTION ERROR.

1. Check for loose or corroded connections between the charger and the batteries.

2. The output may be shorted due to improper connection to the batteries or pinched wires.

3. The output may be connected in reverse polarity to the batteries.

4. The battery voltage may be too high (higher than a 24V battery pack).
This condition can also occur, if the charger is restarted immediately after charging.
Allow batteries to cool down before restarting the charger.

8.6 Battery Charger Fault Codes

957761 Charger Only

Faults are displayed red LED on the battery charge indicator.

RED LED BLINKS ONCE AND REPEATS: OUTPUT CONNECTION ERROR.

1. Check for loose or corroded connections between the charger and the batteries.

2. The output may be shorted due to improper connection to the batteries or pinched wires.

3. The output may be connected in reverse polarity to the batteries.

4. The battery voltage may be too high (higher than a 24V battery pack).
This condition can also occur, if the charger is restarted immediately after charging.
Allow batteries to cool down before restarting the charger.

Note: The charger is not damaged by any of these problems except when connected to
Batteries totaling 48 volts or more.

RED LED BLINKS TWICE: CHARGER HAS TIMED-OUT

The charging progress timer has elapsed before charging was complete and charger has
stopped charging. Possible causes:

1. The batteries are extremely discharged – Unplug the AC cord connection for 30 seconds

minimum. Let batteries cool down if hot. Reconnect the AC cord to start a new charge cycle.

2. The electrolyte is low in one or more cells – Correct by adding distilled water.

3. Batteries are weak, old, or have one or more bad cells. Batteries will still charge but capacity

will be reduced. Replace the batteries, if needed.

4. If batteries are new, the batteries may need to be conditioned by charging and discharging them.

Some batteries may need to be cycled several times in order to condition them to their full potential.

Page 26

Faults are displayed red LED on the battery charge indicator cont.

All Three lights blink at the same time

1. Charger is restarting

2. Charger is unable to put full output to the batteries

3. Possible loose or poor connections. Check all connections.

8.6 Battery Charger Fault Codes Cont.

Page 26A

Faults are displayed red LED on the battery charge indicator cont.

All Three lights blink at the same time

1. Charger is restarting

2. Charger is unable to put full output to the batteries

3. Possible loose or poor connections. Check all connections.

4. Batteries may need to be conditioned by charging and discharging them.
Some batteries may need to be cycled several times in order to condition
them to their full potential.

9. Battery and Error Code Indicator

Traction Drive Models only

•The indicator will display the charge status during machines operation. The
indicator uses ten LEDS. 1 to 10 LEDS may be illuminated at any given time.
10 being a fully charged battery pack. 1 LED would be a discharged battery
pack.

•The indicator will also will display errors by rapidly flashing 1 to 10 LEDS.
See the following references for the type of error that it has detected.

Page 27

The battery needs charging or there is a bad connection to the battery.
Check the connections to the battery. If the connections are good, try
charging the battery.

1 Bar = Low Battery Voltage

9.1 E17TD And E20TD Error Codes

2 Bars = Traction Motor Disconnected

There is a bad connection to the Traction motor. Check all
connections between the motor and the control system.

3 Bars = Traction Drive Motor Shorted

There is a short in the Traction Drive circuit. Possible short in the drive
motor or harness.

Page 28

4 Bars = Battery Lockout

The traction drive controller has shut down because of low battery
voltage. Charge the batteries. If problem still exists: Test batteries and
check all battery connections.

9.1 E17TD And E20TD Error Codes

5 Bars = Not Used

6 Bars = Drive Inhibit

The drive circuit is inhibited when charger is plugged into a A.C
outlet. Turn the key switch off while charging.

Page 29

7 Bars = Throttle Trip

A throttle trip is indicated. Make sure that the throttle is in the rest or neutral
position before turning on the scrubber. Test the potentiometer circuit.

9.1 E17TD And E20TD Error Codes

8 Bars = Control System Trip

A control system trip is indicated. Make sure that all connections are secure.

9 Bars = Not Used

Page 30

9.1 E17TD And E20TD Error Codes

10 Bars = High Battery Voltage

An excessive voltage has been applied to the control system. connections. This
is usually caused by a poor battery connection. Check the battery connections.

No Bars = Control System in Sleep Mode

The control system has entered sleep mode. Switch the control system off
and then on again.

Page 31

Bridge Charge Step

This is an initialization message. It should only appear if a control system is
connected to a battery and turned on within 10 seconds.

9.1 E17TD And E20TD Error Codes

Ripple = Throttle Displaced

The drive switch has been activated while turning on the machine. Place
the throttle in the neutral position and turn the control system on and off
again. Possibly the drive switch is stuck on.

Page 32

10. Squeegee (Curved)

10.

Page 33

10. Squeegee (Curved)

10.1

Page 34

10. Squeegee (Curved)

10.2 Clearance between support roller and floor with unfolded sealing strip (Factory
presetting): 3 mm ±0.5 (Fig. 5/2).
Place additional 1mm spacers (pos. 15, Fig. 5/3) between the angle and the fixed roller
housing (pos. 7, Fig. 5/3) to increase clearance or remove existing 1mm spacer from
between the angle and the fixed roller housing in order to reduce the clearance. Re-insert
the spacers removed from between the angle and the fixed roller housing again above
the fixed roller housing to allow complete tightening of the screws.

3mm ± 0.5

0.118 in ± .02

Page 35

Washers may be
rearranged to change the
height of the squeegee
caster.

10.3 Curved Squeegees Only

10. Squeegee (Curved)

Washers may be
rearranged to change the
height of the squeegee
caster.

Note: When adjusting the wheel height, there should always be 5

washers on each wheel assembly in order fully tighten bolts. Move

washers from the top to the bottom of the bracket or visa versa when

making adjustments. See following page.

Page 36

10.4 Curved Squeegees Only

•Possible squeegee caster
washer combinations.

10. Squeegee (Curved)

Page 37

1. Always keep the water levels above the plates

2. Fill the batteries with distilled water only. Tap water can cause an
excessive build up of minerals and reduce the chemical reaction of
the batteries. This will shortening the life and performance of the
batteries.

11. Maintaining Deep Cycle Batteries

1. Always keep the water levels above the plates

2. Fill the batteries with distilled water only. Tap water can cause an
excessive build up of minerals and reduce the chemical reaction of
the batteries. This will shortening the life and performance of the
batteries.

3. Use appropriate filling devices when filling the batteries. Do not
use a garden hose or metal containers. Flooding the batteries can
flush the electrolyte out of the battery and shorten its life.

4. Fill cells 3/8 to 1/2 of an inch above the separators. Do not fill
above the fill marker of the batteries. Over filling can cause the
electrolyte to percolate out onto the case while charging.

Page 38

5. Check water level daily. Fill, if needed.

6. Keep all the battery cable connections tight.

7. Keep all the battery posts and cables clean. Clean the battery cases
with a mixture of baking soda and water solution or commercial spray
that neutralizes the acid. Spray the cases with a water displacement

11. Maintaining Deep Cycle Batteries

5. Check water level daily. Fill, if needed.

6. Keep all the battery cable connections tight.

7. Keep all the battery posts and cables clean. Clean the battery cases
with a mixture of baking soda and water solution or commercial spray
that neutralizes the acid. Spray the cases with a water displacement
chemical or a silicone. This will help break the flow of current across
the case and increases the life of the battery.

Note: The electrolyte on the surface of the case can cause:
A. The batteries to discharge faster even while sitting and have a shorter

run time.

B. The battery charger to stay on for extended periods. Thus causing an

over charge condition and shortening the life of the batteries.

Page 39

12. Load Testing The Batteries

• Load test battery with an automotive type load tester. This test puts

an ampere load on the batteries and measures the voltage at the same
time.

• If voltage drops too low on the meter, this would indicate that the

batteries are weak or discharged.

• A fully charged good battery should test in the good or green range of

• Load test battery with an automotive type load tester. This test puts

an ampere load on the batteries and measures the voltage at the same
time.

• If voltage drops too low on the meter, this would indicate that the

batteries are weak or discharged.

• A fully charged good battery should test in the good or green range of

the meter. Load testing can identify dead cells, broken or
disconnected plates, weak cells and charge status.

• This is good test, however it can only detect these types of failures.

• Most load testers require putting a load on the batteries for 10

seconds.

• Load testing may not detect all short run time issues.

Page 40

13. Hydrometer Testing The Batteries

•Hydrometer testing can used to measure the specific gravity of deep cycle

batteries. This allows you to detect weak cells, which are causing loss of running
time. It can only detect this type problem. The hydrometer should have specific
gravity markings such as 1.265, 1.250, 1.225, and so on.

•Hydrometers with the four balls are not accurate enough for this test are not
recommended.

•Hydrometer testing can used to measure the specific gravity of deep cycle
batteries. This allows you to detect weak cells, which are causing loss of running
time. It can only detect this type problem. The hydrometer should have specific
gravity markings such as 1.265, 1.250, 1.225, and so on.

•Hydrometers with the four balls are not accurate enough for this test are not
recommended.

•Fully charged batteries should read 1.265 and will decrease as batteries are
discharged until they reach 1.120. This test should be done when batteries are
charged and cooled. Allow one hour or more to cool. It can also be done after
batteries are partially discharged, if they are allowed to cool. However, you will
not be able to detect the full capacity of the battery.

•Note: Maintenance Free batteries can not be tested with a hydrometer.
Do not attempt to remove caps or covers. This will destroy the battery.

Page 41

13. Hydrometer Testing The Batteries

• To do an accurate test, the battery water level must be high enough to

extract enough electrolyte to fill hydrometer so that the float floats.
Water should be added prior to charging in order for let the electrolyte
to mix.

•Hydrometer Testing

• To do an accurate test, the battery water level must be high enough to

extract enough electrolyte to fill hydrometer so that the float floats.
Water should be added prior to charging in order for let the electrolyte
to mix.

• The greater the variation between cells readings, the greater the loss

of run time. For example, if the readings are 1.265, 1.265 and 1.225 in
one 6 volt battery. The low cell would be considered weak and greatly
reduce the performance of the battery or shorter run time. This
battery would have a point 40 variation. Batteries that have weakened
cells in most cases it can still be used as long they continue provide
adequate run time. A battery with a point 40 variation or more should
be determined defective.

Page 42

13. Hydrometer Testing The Batteries

• Minuteman batteries are rated for about 500 charge cycles. The life of

the battery will be greatly dependent by the maintenance they receive.

• Every time the batteries are charged it uses one cycle.

• The specific gravity will reflect the percentage of charge remaining in

the battery.

• Minuteman batteries are rated for about 500 charge cycles. The life of

the battery will be greatly dependent by the maintenance they receive.

• Every time the batteries are charged it uses one cycle.

• The specific gravity will reflect the percentage of charge remaining in

the battery.

• 100% charge = 1.265 Specific Gravity

• 75 % charge = 1.225 Specific Gravity

• 50 % charge = 1.190 Specific Gravity

• 25 % charge = 1.120 Specific Gravity

• Note : Gel maintenance free batteries can not be tested with the

hydrometer. Do not attempt to open cell covers or caps. Doing so will
destroy the battery.

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14. Transporting The Machine

When transporting the machines on a trailer or truck always:

• Tie down the machine securely.

• Lower the brush head assembly completely to the floor.

• Turn the machine off.

When transporting the machines on a trailer or truck always:

• Tie down the machine securely.

• Lower the brush head assembly completely to the floor.

• Turn the machine off.

• Failure to do the above may result in damage to the machine.

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15. Key Switch

Switch Off

Switch On

Switch Unload

•The key switch has 8 terminals. Below shows the three different switch

functions. The black bars indicate the internal connection made by the

switch in each position.

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16. Solution Filter

16.

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17. Notes

Revised 2-1-2010

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