Minuteman E24, E26, E28, E33XL, E30ECO Service Manual

SERVICE MANUAL

For E Series Scrubbers

Models: E24, E26, E28,

E30, E33, E33XL

,

E30ECO, E2830, E3030,

For:

Training

E3330 and H26

Troubleshooting

Adjustments

Rev 07/07/2014

Contents

1 Warnings Page 6
2 General Information Page 7
3 Maintenance Intervals Page 8

3.1 Minuteman System Maintenance K (Customer) Page 9

3.2 Minuteman System Maintenance I (125 hours
of o

p

eration) Page 10

p)

g

3.3 Minuteman System Maintenance II (250 hours
of operation) Page 11

3.4 Minuteman System Maintenance S (500 hrs of

operation, at least yearly)

Page 12

4 Squeegee Cable and Recovery Tank Gasket Page 13

4.1 Squeegee Adjustment (First Version) Page 14

4.2 Squeegee Adjustment (new Style) Page 15

4.3 Squeegee Lift Cable, Micro Switch, Vacuum Motor

Page 16

4.4 Squeegee Wheel Adjustment Page 17

5 Brush Head (Disk Brushes) Connections Page 18

5.1 Brush Motor Information Page 19

2

Contents

6 Brush Head Transport Position Page 21

6.1 Brush Switch Page 22

6.2 B

rush Pressure

Adj

ustment on the Disk Models

P

age

23

6.3 Brush Pressure (Disk Decks) Page 24

6.4 Cylindrical Brush Head Electrical Connections Page 25

6.5 Cylindrical Brush Head Adjustment Page 26

7 Drive and Wheels - General Data Page 27

7.1 Electric Brake Page 27

7.2 Transaxle Motor Page 28

7.3 Carbon Brushes

Page 29

7.4 Drive Potentiometer Page 30

8 Water Supply Page 31

8.1 Solenoid Page 31

8.2 Solution Filter

Page 31

8.3 Solution Tank Cleanout Page 32

8.4 Solution Flow Rates Page 33

8.5 Water Pump Page 34

9 The Last E

rror

P

age

35

10 Table of Error Codes and Information Page 36

3

Contents

11 Battery Charger Page 38

11.1 Operating Instructions Page 40

11.2 Charger Error Codes Page 40

11.3 Charger Trouble Shooting

Page 44

11.4 Charger Maintenance Points Page 45

11.5 Programming The Charger Page 46

11.6 Replacing The Charger Harness Page 49

12 Batteri

es

P

age

50

12.1 Maintaining Wet Lead Acid Batteries Page 50

12.2 Load Testing Batteries Page 52

12.3 Hydrometer Testing Page 53

13 Fuse Locations Version 2 Page 56

13.1 Controller Version 3 Page 57

4

Contents

14 Controller Connections Page 58
15 Trouble Shooting Controller Page 59
16 Contactor Harness Page 60

g
17 Contactor Wiring Page 61
18

Testing the Main Power Relay Page 63

19 Wiring Diagram Models with 19 Gallon Tanks Page 68
20 Wiring Diagram Models with 24 Gallon Tanks Page

7220 Wiring Diagram Models with 24 Gallon Tanks Page 73

20 Wiring Diagram Models with 30 Gallon Tanks Page 7

8

21 Notes Page 83

5

1. Warnings

• Disconnect the A.C. Cord from the outlet and and D.C. Cord from the battery

pack before servicing the machine

.

Except for making voltage and current

measurements.

• Before replacing the main fuses, only loosen the nuts. Do not remove them

completely. Failure to do so could cause a short circuit.

• Place the new stripe fuse fully and evenly under the nuts and washers and

make sure not to twist the end tabs, they can easily be torn.

• After an

y

repair work is done, test the machine for proper operation.

yp , pp p

• When servicing the machine always observe the general safety and accident

prevention guidlines.

6

2. General Information

•The display offers a service indication. Upon turning on the key switch, a four digit

number describing the software version (e.g. 1.0.0.2) appears for about 3 seconds,

foll

owed by another 4-digit code indicating the last error recorded, then followed by

the hour meter.

•If a failure occurs, the code appears in the control panel and an acoustic signal

sounds. The current error code appears as 4

-

digit alpha

-

numerical code with

flashing dots in the service display. Only if these criteria are met, the error is a
current one!
The error codes are listed in a tables in chapter 10.

•When raising the machine with a car

g

jack use the area of the frame in front of
the caster wheels on the left or the right.

7

3. 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 b

e 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 h

ours of operation

)

To be preformed by an authorized Minuteman Service Center in accordance with the
machine-specific system maintenance.

•Minuteman System Maintenance II: (after every 250 hours of operation)

To b

e preformed by an authorized Minuteman Service Center in accordance w

ith th

e

machine-specific 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 machine­spec

ifi

c system maintenance.

8

3.1 Minuteman System Maintenance K

Tobeperformedbythe



customer/user



Interval

Daily Weekly
Fillthecleanwatertankandmixtheproperamountandtypeofcleaningsolution. O
Chargethebatteries. O

Check



thebrushhead,Cleanifneededwithadampcloth.Donotgetwaterinsidethemotor

.

O

Checkthesqueegee,cleanifneeded O
Checkthelidgasketontherecoverytank. O
Emptyandflushtherecoverytankwithcleanwater. O

Cl

eanthe

filter/floatinsideth

erecoverytank.

O

Checkthewaterlevelsofallthebatteries.Adddistilledwater,ifneeded.Donotoverfill. O
Checkthepadsandbrushesforwear.Replaceifneeded. O
Checkthesqueegeehoseforclogs,damageandwear.Replaceifneeded O

Check

thesqueegeerubbersforcutsandwear.Fliptheblade(s)overorreplace.

O

Checkthesolutionfilter.Cleanifneeded. O
Flushthecleanwatersolutiontankwithwarmwater. O
Testallthefunctionsofthemachine. O

9

3.2 Minuteman System Maintenance I

Tobeperformedbytheauthorizedservicecenter

Interval

Every125hoursof

operation

Checkthebatterycharger.Makesureitisfunctioningproperly

O

Checktherecoverylidgasket.Replaceifneeded

O

Lubricate



thebrushliftlinkageswithgrease

.

Useasmallbrush

.

O

Checkforloosehardware,tightenifneeded.

O

Checkthetirepressureonpneumaticwheelsat65PSI,ifequipped.

O

Lubricatethesqueegeelinkageswithgrease.Useasmallbrush.

O

Inspecttheentiremachinefordamage,wearandproperoperation.

O

10

3.3 Minuteman System Maintenance II

Tobeperformedbytheauthorizedservicecenter

Interval

Every250

hoursof

operation

Inspect



thecasterwheelsforwearanddamage

.

Repair,ifneeded

.

O

Inspectthecarbonbrushesforwearinthetransaxle.Replace,ifneeded. O
Inspecttherecoverydrainhoseforwearordamage.Replace,ifneeded. O

Inspect



thebrushbumperrollersforwearordamage

.

Replace,ifneeded

.

O

Inspectthecarbonbrushesforwearinthebrushmotorsforwear.
Blowoutwithcompressedair. O

Inspecttherecoveryhosefordamageorwear.Replace,ifneeded. O
Inspectthesqueegeeassemblyforproperadjustment.Repair,ifneeded. O
Testthemachineforproperoperation. O

11

3.4 Minuteman System Maintenance S

Tobeperformedbytheauthorizedservicecenter Interval

(Safety Ch

ec

k)

p y

Every500hoursof

operation

Replacethecarbonbrushesinthetransaxle. O

Replacethecarbonbrushesinthebrushmotors. O

Testthemachineforproperoperation. O

12

4. Squeegee Cable And Gasket

4. The squeegee cable is attached to the lift lever (top) via a spring (Fig. 5/5). The bottom is
attached to the eyebolt at the squeegee mechanism (Fig. 5/6). The squeegee lift cable can be
accessed after opening the electronic module cover at the rear of the machine.
The vacuum motor is connected to the A1 at A1.X34:5+6 on the controller. Current
consumption of the vacuum motor amounts to approx. 25A max.
The vacuum water lift in the closed tank is at least 65 inches (150mbar).

Recovery Lid Gasket

Insert the recovery tank cover gasket (Fig. 5/7) so that the seam is positioned at the front center
with a gap of approx. 1mm. The dirty drip water on the top sealing surface will be drawn into the
recovery water tank.

Fig. 5/5

Fig. 5/6

Fig. 5/7

13

4.1 Squeegee Adjustment

V

ersion one

4.1 Squeegee Adjustment

Correct squeegee adjustment is prerequisite for optimal suction results.
Before ad

j

ustment first check the pitch of the squeegee and re-adjust if required.

jpqg

jq

1. Place machine on level ground.

2. Loosen nut of the adjustment screw (pos. 3, Fig. 5/1) and adjust sealing strips in
parallel to the floor. Turn adjustment screw clockwise: clearance between squeegee
blade and floor broadens in the center. Turn ad

j

ustment screw counter-clockwise:

j

clearance between squeegee blade and floor narrows in the center.

3. Turn machine on, lower squeegee and check drying pattern.

1 Squeegee
2 Star-shaped knob
3 Adjustment screw

4 Suction hose

5 Toggle-type fastener

Fig. 5/1

14

4.2 Squeegee Adjustment

V

ersion Two

4.2 Squeegee Adjustment

Correct squeegee adjustment is prerequisite for optimal suction results.
Before ad

j

ustment first check the pitch of the squeegee and re-adjust if required.

jpqg

jq

1. Place machine on level ground.

2. Loosen the two bolts, located on each side (Fig 5/2A) with the squeegee attached
while holding another wrench on the location shown on Fig 5/2B. Adjust squeegee
rubbers so that the

y

are parallel to the floor, by turning the long adjustment shaft on the

yp ,y g gj

right side with an open end or adjustable wrench (Fig 5/2B). Adjust until the rear
squeegee blade folds equally accross the entire length, while moving the machine
slightly forward.

3. Ti

g

hten the two bolts on the ends while holding the center shaft with the wrench.

gg

4. Turn machine on, lower squeegee and check drying pattern.

Fig 5/2BFig 5/2A

15

4.3 Squeegee Wheel Adjustment

4.3 The clearance between the support roller and floor with squeegee unfolded

(Factory setting) is: 0.1181099 Inches

±

0.01968498 inches (3 mm

±

0.5)

.
Note: Some floor surfaces may require adjusting the caster washers for optimum performance.
See following page.

16

4.4 Squeegee Wheel Adjustment

4.4 Note: When adjusting the wheel height, there should always be 5 washers on each wheel
assembly position # 15 in order fully tighten bolts. Move washers from the top to the bottom of

Pos 1 – Hexagon screw M8x25 A2
PN 01059530

the bracket or visa versa when making adjustments

.

The caster controls the pressure on the

squeegee blade.

Pos 5 – Hexagon screw M8x16 A2
PN 01071740

Pos 6 – Washer B8,4
PN 00101550

Pos 7 – fixed Roller
PN 01077810

Pos 8 – Angle with fixed roller, complet

Fig. 5/3

PN 01079070

Pos 15 – Distance Washer
PN 01079080

g

17

4.5 Squeegee Lift Cable, Switch & Motor

4.5 Squeegee Lift Cable, Lever, Micro Switch

and Vacuum Motor

•The vacuum motor micro switch is mounted
behind the squeegee lift lever (Fig. 5/4). Adjust the

micro switch so that the vacuum motor can be

turned off by lifting the squeegee by the lever.
Loosen the screws on the switch to adjust.

•Vacuum motor is switched on upon lowering of the
squeegee.

•The micro switch is a normally open switch which
is terminated to input A1.X9:3+9 on the controller.

When the squeegee is lowered, there should be

continuaty between both contacts (with the plug
A1.X9 being disconnected).

Fig. 5/4

NOTE: The squeegee lift cable spring will need to disconnected from the silver

18

lever before the squeegee lift lever plate can be removed from the machine.
Access can be made from the controller/charger area in the rear of the machine.
See Chapter 4.

5. Brush Head (Disk) Connections

5. C

onnection of Brush Motors to Disk Brush Hea

d

Connect the brush motors of the disk brush head in accordance with the electric diagrams. Find the
assignment of connecting stud of the motors listed in the below table. Then check the correct
direction of brush motor rotation.

The left-hand motor seen in direction of travel is M3, the right-hand one is M4.

Cable

Motor connection

Connectors

M4

M3

Harness

Disk brush

at the motor -M3/4

Stud bolt above

Connection N

Stud bolt below

Connection P

19

5.1 Brush Motor Information

5.1 Brush Motors

The brush motors are switched on and off by a micro-switch located at the rear at the brush head
lift-out system. This switch is realised as NO (normally open) switch. To attain safe function of the
brush motors

,

correct adjustment of this switch is required.

,j q

Electric connection of the switch is realised at the central control at A1.X9:4 + 10.

Maximum current consumption of the brush motors (in practical use) must not exceed 30A per
motor on the 26 and 30“ disk brush decks. The maximum amperage for the 33“ disk decks is 40A.

Lower settings are recommended for longer motor life, run time and traction.

When checking the carbon brushes make sure that the scroll spring is pressing the carbon brush
against the commutator, does not contact the guide and that distance to carbon brush guide is
sufficient.

Replace the carbon brushes, if required.

20

6. Brush Head

6. Brush Head Transport Position

•The lever provided is for lifting up the brush head. It features 3 positions for adjusting

the lift linkage (Fig. 6/1). The top hole is the transporting and ramp climbing position. In

this position, the lift linkage is to be adjusted so that a 1mm gap appears between the
lever and the screw head at the chassis (Fig. 6/2).

•The m

iddle hol

e pos

iti

on is for scru

bbi

ng w

ith

pads.

•The bottom hole (Fig. 6/1) is the normal scrubing position of the brush head.

Transport Position
Scrubbing position

with pads
Scrubbing position

1 mm

Fig. 6/2

21

with brushes

Fig. 6/1

6.1 Brush Switch

6.1 Brush Switch

•The brush motors are switched on and off by a micro-switch located at the rear at the

-

brush head lift

out system Figure 6/3. This switch is a NO (normally open) switch. To

attain safe function of the brush motors, the correct adjustment of this switch is
required.

•Electric connection of the switch is connected to the central control circuit board at

A1.X9:4 + 10 connector

. In

the lifted

-

up position, the switch should open and close

when brush head is lowered.

Fig. 6/3

22

6.2 Brush Pressure Adjustment (Disk Models)

Brush Pressure Setting on Disk models.

•

The bolt on the left can be adjusted to increase or

decrease the brush pressure.

•Models with 19 gallon tanks This pressure adjustment
will affect the models in the normal scrubbing mode. (no
extra

p

ressure option

)

Adjustment
Screw

Increase
pressure

pp)

•Models with 30 gallon tanks. This pressure adjustment
will only affect the models in the heavy pressure mode
only (second foot lever activated).

2nd notch

1st notch

•

The indicator on the right should never be set past the

second notch.

•NOTE: When making changes, the current draw should
be less than 30 amps. per motor on the 26 and 30” disk

”

decks under load maximum

. 40

amps max on 33 decks

.

•Lower settings are recommended for longer motor life,
longer run time and traction.

•Verify the current with brushes under load, with a digital

Decrease
pressure

clamp-on meter.

•Only an authorized Minuteman Service Center should
make changes to the brush pressure setting.

23

Note: The factory setting
set at the second notch

6.3 Brush Pressure (Disk Models)

Heavy
Brush

Pressure

(2nd Foot

Specific

Surface Pressure

Model

Area Per

Brush

B

rush

Pressure

Pedal

Engaged)

Specific Surface

Pressure

with Heavy Brush

Pressure

E3330

1055 cm²

163.525 inch²

400 N =

90 lb 600 N = 135 lb 0.19 N/cm² = .275 lbs per inch²

0.28 N/cm² = .406 lbs per
inch²

²

=

²=

E3030

761 cm

1 17.955 inch²

320 N

72 lb 600 N = 135 lb 0.21 N/cm² = .35 lbs per inch²

0.39 N/cm

.

565 lbs per

inch²

E2830

280 cm²

43.400 inch²

240 N =

54 lb NA 0.43 N/cm² = .623 lbs per inch² NA

240 cm²

²

260 N =

²

²

E24

37.200

inch

58 lbNA0.54 N/cm = .783 lbs per inch

NA

E26

586.5 cm²

90.908 inch²

350 N =

79 lb NA 0.3 N/cm² = .435 lbs per inch² NA

24

6.4 Brush Head (Cylindrical)

6.4 Electric Connections

• Connect the brush motors of the cylindrical broom head in accordance with
the electric diagrams. Find the assignment of connecting stud of the motors
listed in the below table. Then check the correct direction of brush motor
rotation.

• The left-hand motor seen in direction of travel is M3, the right-hand one is
M4.

M3 M4

Motor connection

Cyl. brush head

Cable

Harness

Connectors

at the motor -M3/4

Stud bolt above

Stud bolt below

Connection P

Connection N

25