Tornado FK 3000, 99430, Floorkeeper LR 30, 99440 Operation And Illustrated Parts Manual

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Tornado

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Operation and Illustrated Parts Manual

For Commercial Use Only

TORNADO® INDUSTRIES

7401 W. LAWRENCE AVENUE

CHICAGO, IL 60706

(708) 867-5100 FAX (708) 867-6968

www.tornadovac.com

FK 3000 Automatic Scrubber

Catalog No.

99430

NOTES

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This illustrated parts book covers:

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MODEL 99430 SERIES C SIZE 30" VOLTS (CHARGER) 36V AMPS (CHARGER) 20 CAPACITY 30 GAL. (114L)

All specifications are subject to change without notice.

Tornado® Standard Warranty Program*

10 Years:

All plastic tanks and rotationally-molded bodies

Warranties do not cover components subject to normal wear or abuse and misuse, and have other limitations not specified here. For full details , contact your Authorized Tornado Distributor, Service Center, or the Tornado Technical Service Department.

Parts on all Tornado and Tornado/Karcher cleaning

Labor on all Tornado and Tornado/Karcher cleaning

2 Years:

equipment

1 Year:

equipment

1) 2)

1 Year:

Warranty on batteries, one full year, not pro-rated.

* Effective January 1st, 2001. Terms subject to change without notice.

1) Windshear™ Blower-Dryer, Insulation Blowers, CW 50, CW 100, PAC Vac are warranted for 1 (one) year for parts and labor.

2) Warranties on the ICC1, KMR 1200, KMR 1250, and KMR 1700 are 24 months parts/6 months labor OR 1000 hours of operation, whichever comes first. Warranties on the BR and BD 1000 are 24 months parts/12 months labor OR 1000 hours of operation, whichever comes first.

, and Duo-Upright Carpetkeepers™

TABLE OF CONTENTS

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INTRODUCTION 5

SAFETY INSTRUCTIONS 6

GROUNDING INSTRUCTIONS 7

UNIT CONTROLS AND INDICATORS 8

INSTALLATION

SQUEEGEE 10 BRUSHES 11

PRE START-UP

FILLING SOLUTION TANK 12

PREVENTATIVE MAINTENANCE PROGRAM

BATTERY CARE 13 BATTERY REMOVAL 14 BATTERY CHARGING 15 BATTERY SAFETY PRECAUTIONS 16 SQUEEGEE BLADES 17 SQUEEGEE ADJUSTMENT 18 SOLUTION PUMP INTAKE FILTER 19 RECOVERY TANK 19 SOLUTION TANK 20 VACUUM MOTOR 20 LUBRICATING YOUR MACHINE 21 MOTOR BRUSH REPLACEMENT 21

TROUBLESHOOTING INSTRUCTIONS

COMMON ISSUES 22 TROUBLESHOOTING CHART 24 LCD DISPLAY DIAGNOSTIC ERROR CODES 26

PREVENTATIVE MAINTENANCE CHECKLIST 28

ILLUSTRATED PARTS LISTS

SOLUTION TANK 29 RECOVERY TANK 32 SQUEEGEE ASSEMBLY 34 SQUEEGEE TOW ARM 36 BRUSH DRIVE ASSEMBLY 38 TRANSAXLE ASSEMBLY 40 CONTROL BOX & SOLUTION PUMP MODULE 42 ACTUATOR ASSEMBLY 44 CONTROL PANEL ASSEMBLY 45 TRIGGER ASSEMBLY 47 MAIN VIEW “A” 49 MAIN VIEW “B” 50 MAIN VIEW “C” 51 MAIN VIEW “D” 52 MAIN VIEW – PARTS LIST 53 WIRING HARNESS 54 CONTROL HARNESS 56 POWER HARNESS 58 REPLACEMENT ITEMS & ACCESSORIES 60

INTRODUCTION

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Congratulations on the purchase of your new Tornado FK 3000! The FK 3000 combines many advanced features to maximize reliability, performance, and ease of use.

The most notable addition is the incorporation of the industry’s first fully functional digital control and display system on an automatic floor scrubber. With it, you’ll be able to easily and accurately monitor an assortment of system settings and conditions. Tornado’s new digital controller has a unique soft-start feature that increases both efficiency and powertrain lifespan.

Its patented, tough rotomolded structural housing serves as a multi-function one-piece frame, making this new model Floorkeeper both more rugged and much lighter than conventional metalframe models.

This new FK 3000’s simplified wiring harness uses quick-disconnects, and combined with the digital controller and error code generation on its LCD display, makes servicing and troubleshooting easy.

Additional features include integral 30-gallon solution and recovery tanks, a sealed, maintenance-free ¾ hp transaxle, and easy-access batteries. Solution flow is precisely controlled by an adjustable flow rate pump, unlike gravity-feed systems that change flow based on tank fill level. Vacuum power can be set for hands-free automatic operation, off to conserve battery power when double-scrubbing, and constant-on for use with the optional hand tool accessory set. The new FK 3000 automatic scrubber was designed and built to exceed your needs for durability and serviceability in demanding commercial environments.

This manual is designed to instruct your personnel in the operation, maintenance and methods of troubleshooting on your Tornado FK 3000. Please read through this manual and keep it handy to ensure that you get maximum satisfaction and value from this new advance in floor care.

OBSERVE THESE PRECAUTIONS FOR SAFE USE OF THIS MACHINE

• Back the machine down inclines or ramps. Do not store machine on inclines.

• Make certain that the power switch is OFF before removing or installing brushes.

• Use care when working on electrical terminals —short circuits can cause burns and

throw sparks.

• Disconnect both positive and negative battery terminals before attempting any

adjustment or maintenance. Brush or traction drive motors and drive components could cause injury if started while being worked on.

• Charge batteries in a ventilated room where gases cannot accumulate. Gases given off

during charging could ignite in a confined space. Make certain that the top covers are open when charging so gases cannot accumulate.

• Battery acid can cause injury to the eyes or burn the skin.

Safety Instructions

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When using this machine, basic precautions should always be followed. Read all instructions before using this machine.

WARNING: To reduce the risk of fire, electric shock, or injury:

Turn off all controls, unplug from power source and allow unit to cool down before attempting any maintenance or adjustment. Turn off and disconnect battery clip when not in use.

Do not expose to rain or submerge in water. Store indoors. Do not use pressurized water to clean machine. Do not use machine on stairs.

Do not allow to be used as a toy. This machine is to be used by adults only.

Use only as described in this manual.

If machine does not appear to be working properly or has been dropped, left outdoors, submerged, or damaged in any way, refer to the troubleshooting steps detailed in this manual.

Keep hair, loose clothing, fingers, and all parts of body away from openings and moving parts.

Do not put any object into openings. Do not use with any opening blocked. Keep openings free of dust, lint, hair, and anything that may reduce air flow.

Do not pick up anything with this machine that is burning or smoking, such as cigarettes, matches, or hot ashes.

Do not pick up flammable or combustible liquids, such as gasoline or petroleum solvents, or use machine where they may be present.

When using the charger supplied with this machine, do not handle cord or plug with wet hands.

Unroll the charger AC power cord before plugging it into a grounded outlet. Do not pull or carry by cord, use cord as handle, close a door on cord, or pull cord around sharp edges or corners. Do not run machine over cord. Keep cord away from heated surfaces.

Check power cord for signs of crushing, cutting or heat damage. If replacement of plug or cord is needed, use only identical replacement parts.

Keep all connections dry and off the ground. Do not allow electrical cords to contact water. Do not use extension cords with this product. Do not unplug charger by pulling on cord. To unplug, grasp plug, not cord.

Any repairs performed on this machine should be done by Tornado Authorized Service Personnel.

Do not operate the unit when fatigued or under the influence of alcohol or drugs.

The manufacturer cannot be held responsible for any damage/injury caused to persons or property because of improper procedures used which are not specified in this manual.

SAVE THESE INSTRUCTIONS

WARNING: Failure to adhere to any of the instructions provided in this

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manual could result in serious bodily injury or property damage!

BEFORE OPERATING MACHINE:

Read this manual completely before attempting to operate machine. This manual has important information for the use and safe operation of the machine. Keep this manual on file and handy. If additional information is needed, please contact your local distributor or contact us at:

TORNADO INDUSTRIES Phone: (708) 867-5100 7401 W. LAWRENCE AVE. Fax: (708) 867-6968 CHICAGO, IL 60706 Internet Address: http://www.tornadovac.com

GROUNDING INSTRUCTIONS

The charger supplied with this machine must be grounded. If it should malfunction or break down, grounding provides a path of least resistance for electrical current to reduce the risk of electric shock. This appliance is equipped with a cord having an equipment-grounding conductor and grounding plug. The plug must be plugged into an appropriate outlet that is properly installed and grounded in accordance with all local codes and ordinances.

WARNING: Improper connection of the equipment-grounding conductor can result in electric shock. Check with a qualified electrician or service person if you are in doubt as to whether the outlet is properly grounded. Do not modify the plug provided with the appliance; if it will not fit the outlet, have a proper outlet installed by a qualified electrician. This appliance is for use on a nominal 120-volt circuit, and has a grounding plug that looks like the plug illustrated in sketch A. A temporary adapter that looks like the adapter illustrated in sketches B and C may be used to connect this plug to a 2-pole receptacle as shown in sketch B if a properly grounded outlet is not available. The temporary adapter should be used only until a properly grounded outlet (sketch A) can be installed by a qualified electrician. The green-colored rigid ear, lug or the like, extending from the adapter must be connected to a permanent ground such as a properly grounded outlet box cover. Whenever the adapter is used, it must be held in place by a metal screw.

Unit Controls and Indicators

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Control Panel

1. Variable Drive Speed Control Knob

2. 3-Position Vacuum Motor Switch:

Automatic – Controlled by transaxle

Off – for double-scrubbing floors

On – for stationary hand tool recovery

3. LCD Display

See page 9 for display capabilities

4. Brush Position Switch

5. Solution Flow Rate Knob

6. Display Mode Button

Rear Controls

7. Solution Filler Plug

8. Solution Level Sight Tube

9. Squeegee Control Lever

10. Solution Tank Drain Hose

11. Dual Reverse Buttons

12. Emergency Stop Switch

13. Locking Keyswitch

14. Dual Drive Levers

Unit Controls and Indicators

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Display Screens

Use the Display Mode Button (to the right of the display) to toggle between three unique screens. Each screen displays a different set of icons and numerical readouts to give you useful information about your machine’s operating status. For particulars on diagnostic fault code information, see page 26.

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INSTALLATION

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Squeegee

1. Make sure the Squeegee Control Lever is

lifted to the UP position.

The Rocker (squeegee mount) is already installed on the Bracket. Loosen the two Squeegee Locking Knobs enough to allow it to slide onto the Rocker.

2. Insert the Squeegee Assembly fully, bent

ends forward, onto the Rocker. Tighten the two Squeegee Locking Knobs securely.

Notice that the Squeegee Assembly should be free to rotate slightly from side

to side, allowing the Squeegee to follow floor contours.

3. Insert the hose end into the squeegee

assembly nozzle throat. Press down tightly.

4. To ensure that both the ends and

the center of the Squeegee Blades are

evenly loaded, loosen the Rocker Adjustment Knobs. Lower the Squeegee Assembly to the floor by pulling the Squeegee Control Lever down, then rotate the Squeegee Assembly until the entire length of the rear Blade is in even contact with the floor. Tighten the Rocker Knobs.

IMPORTANT: Never store the machine with the Squeegee in the down position. This can damage the Squeegee Blades and affect water pick-up.

The Squeegee is not designed to pick up water while backing up. When backing the machine, raise the squeegee to avoid the risk of damaging the rubber edges or upsetting the Rocker tilt adjustment.

INSTALLATION

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Brushes

1. Raise the Brush Housing using the switch on the control panel. (Emergency Switch pulled out, and Keyswitch turned on.) Once the Housing is fully up, turn off the Keyswitch.

2. Place Brushes or Pad Holders under the cover. Locate the Brush Coupler. Pull up the Brushes to lock them in place.

Brush Housing Skirt Adjustment

3. When properly adjusted, the Brush Housing Skirt prevents the rotating brushes from flinging solution off to the sides, where the Squeegee may not be able to reach.

Power the Brush Housing down so that the Brushes or Pads contact the floor. Locate and unscrew the two Skirt Locking Knobs, and slide the Skirt evenly down to just clear the floor. Retighten both knobs.

As Pads or Brushes wear, or whenever the Pads or Brushes are removed or replaced, recheck for proper Skirt clearance.

PRE START-UP

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Make sure the Emergency Stop Switch is pulled out. Turn the Keyswitch on. The LCD Display should light and show the battery charge level.

Lower the brushes to test for rotation. The Brush motors will automatically turn on when Brushes are lowered. Raise the Brushes.

Shut the Keyswitch off and connect the battery charger to the Charging System Connector. Batteries should be fully charged prior to first use.

Filling the Solution Tank

1. Always empty the Recovery Tank before filling the Solution Tank. This will eliminate overfilling of the Recovery Tank.

2. Remove the Solution Tank Filler Plug by unscrewing its wing nut just far enough to loosen its fit in the hole.

3. Fill the Solution Tank no higher than the top of the clear Sight Tube.

4. Replace the Filler Plug and tighten its wing nut.

Please Note:

Before you begin using your new FK 3000, notice that the charging connector is underneath the Cover / Recovery Tank. This is a safety feature to ensure that the Cover is open to freely vent battery gases during charging. As the Recovery Tank fills, it will become increasingly difficult to raise it in order to perform battery or component service. Do not attempt to lift the Cover / Recovery Tank whenever it contains more than a few gallons of liquid. Empty the Recovery Tank first.

What to do when the batteries become fully discharged while in use:

Under low battery charge conditions, provision has been made to retain drive power even after the vacuum motor system has automatically shut down. When the vacuum motor shuts off, set its switch to off. Raise the Brush Housing fully up to shut off the Brush motors and Solution Pump, conserving energy. Drive the unit to a floor drain at once and empty the Recovery Tank. Return the unit to your battery charging station and recharge the batteries.

TORNADO FK 3000

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PREVENTATIVE MAINTENANCE PROGRAM

Introduction

This section is designed to instruct your personnel in methods of maintenance on the Tornado FK 3000. By following these procedures, repair costs and down time will be greatly reduced. These procedures are for simple repairs that can easily be done by your own personnel.

WARNING

Battery acid is toxic and corrosive; avoid bodily contact.

First Aid:

EYES: Wash with liberal quantities of running

water for 15 minutes.

SKIN: Flush area with plentiful amounts of

running water.

INGESTION: Give milk to drink, DO NOT induce

vomiting, call a physician.

SPILLS: Wash with water or neutralize with

sodium carbonate or bicarbonate (baking soda).

Battery Care

Batteries must be checked daily. The water level must be maintained at least 1/4” above top of cell plates in each battery.

1. Raise top cover and lock in place.

2. If you use a hydrometer to check charge level in each cell, check this before adding water.

3. Remove battery caps and fill each cell 1/4”1/2” above the tops of the lead plates.

NOTE: Fill batteries with distilled water only. This will increase battery life substantially.

CAUTION

Do not overfill the battery cells. Do not use a hose or pail. If batteries are accidentally overfilled, remove excess water with a hydrometer or similar device. Dispose of excess in accordance with local, state and federal regulations.

MAINTENANCE

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3. After filling batteries, replace the battery caps. Using baking soda or ammonia and water solution, saturate a cloth and wring until drip dry. Use this cloth to wipe the battery tops.

4. The battery terminals and should be coated with a protective lubricant to prevent corrosion.

WARNING

Avoid accidental contact with battery terminals and possible electrical shock. Replace any protective plastic terminal covers after battery maintenance.

Battery Removal

Should batteries need to be removed for any reason, use two people to perform these tasks!

1. Completely drain the Recovery Tank.

2. Disconnect the vacuum motor connector,

gas spring bracket, float switch connectors,

and recovery hose. Ensure that no

connections remain.

3. Remove the three cotter and clevis pins at

the side of the cover, and remove the cover.

4. Note battery positions and all wiring connections before disconnecting wires!

MAINTENANCE

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Battery Charging

The charger is fully automatic:

1. It turns on when plugged in.

2. It switches to equalizing charge.

3. It shuts off when it reaches full charge or when batteries are defective.

NOTE: It is recommended that new batteries be fully discharged at least once (more in some cases) to enable batteries to hold a full charge.

The batteries must be charged after each use of 3 or more hours. Failure to do so will result in shortened running time.

To charge the batteries, raise top cover and lock in position.

WARNING

To avoid explosion keep covers open during charge to insure proper ventilation of gases.

1. Connect charger cable by plugging it into Andersenä connector located under rear top cover.

2. Plug AC cord into proper electrical receptacle. The red “CHARGER ON” light will automatically come on along with the “INCOMPLETE” light, meaning batteries are being charged.

3. The charger will automatically turn off when the batteries are charged to their maximum capacity. The “CHARGER ON” light will go out when the charge cycle is complete.

4. To stop the charge cycle push the “INTERRUPT” button. (Do not unplug A.C. cord while the charger is on.)

5. Check the lights on the battery charger after charger shuts off (“CHARGER ON” light should not be lit):

A. Green light: Batteries are fully charged and are in good condition.

B. Amber light: All cells are OK but the total battery capacity is reduced. This usually indi-

cates that the batteries are aging.

C. Red light: The battery capacity is low and the entire charger/battery system needs to be

inspected by a qualified Tornado serviceman.

Always observe the following personal safety precautions when working with lead

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acid batteries.

A. Someone should be within range of your voice and close enough to come to your aid

when you work on battery operated machinery, such as your FK 3000.

B. Have plenty of fresh running water, soap, or baking soda nearby in case battery acid

contacts skin, eyes, or clothing.

C. Wear complete eye protection and clothing protection.

D. If battery acid contacts skin or clothing, wash immediately with soap and water or baking

soda and water. If acid contacts eyes, immediately flood eyes with cold running water for at least ten minutes and get professional medical attention as soon as possible.

E. Never smoke or allow sparks or flame in the vicinity of batteries. Batteries give off hydrogen

gas while charging. To prevent an explosive condition, always charge batteries in a wellventilated area.

F. Use caution when using metal tools around batteries. Only use tools with an insulating

coating in good condition to prevent short circuits.

G. Remove personal effects such as rings, watches, bracelets, etc. when working on battery

operated machinery. Rings or watches can cause a short circuit, which will throw sparks to cause an explosion hazard and produce enough heat to cause a severe burn.

H. Never charge a frozen battery. Charging a frozen battery may result in explosion.

I. Always disconnect the AC supply cord from its outlet and the DC connector from the battery

before attempting any maintenance or cleaning of the batteries or battery-operated equipment.

THE FOLLOWING CAUTIONS AND PROCEDURES MUST BE OBSERVED

TO MAXIMIZE BATTERY LIFE:

• New batteries should be given a full charge before they are first used because it is difficult to determine how long the batteries have been stored.

• Limit the use of new batteries to two hours for the first five charge/discharge cycles. New batteries are not capable of their rated output until approximately thirty charge/discharge cycles.

• Do not excessively discharge batteries. Observe the battery charge gage and discontinue operation when gage reads low. Excessive discharge can cause polarity reversal of individual cells, resulting in complete battery failure shortly thereafter.

• Check the level of electrolyte in batteries weekly. Maintain the proper electrolyte level by adding distilled water as necessary. Add water to cover the tops of the lead plates ¼" to ½".

• Do not overfill batteries.

• Clean tops of batteries with a clean cloth wetted with ammoniated window cleaner

(Windex ® or equivalent). Dry batteries with a fresh cloth.

• Old batteries will require more frequent additions of water than newer batteries.

MAINTENANCE

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Squeegee Blades

1. If a squeegee blade is worn or ripped, raise

the Squeegee and remove the entire aluminum Squeegee Assembly from the Rocker. Disconnect the vacuum hose, loosen both Squeegee Locking Knobs and slide the Squeegee out.

2. Unscrew both Star Knobs at either end of

the Squeegee, and remove the Rollers.

3. Pull off the plastic End Caps at both ends of

the Squeegee.

MAINTENANCE

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Squeegee Blades

4. Pull out each Blade from one end. Both

front and rear Blades have two working edges. Flip each blade for a new edge when worn. Replace Blades once both edges are worn.

4. Clean squeegee blades with a damp

cloth. And slide them into place. The rear Blade is longer than the front, and overlaps it evenly on each end.

5. Replace the plastic end components,

and remount the Squeegee Assembly onto the Rocker. Connect the vacuum hose to the Squeegee Assembly.

MAINTENANCE

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Squeegee Adjustment

Removal of the Squeegee Assembly for cleaning or Blade servicing will not normally require Squeegee tilt readjustment. However, after remounting the Squeegee, Blade contact should be visually checked for evenness by first driving or pushing the machine forward a few inches with the Squeegee down.

Look at the rear Blade to ensure that both the ends and the center are evenly loaded. The front blade should also be contacting evenly across its length. If readjustment is needed, loosen the Rocker Adjustment Knobs. Rotate the Squeegee Assembly. Correct adjustment is made when both Squeegee Blades rest evenly on the floor. Tighten the Rocker Knobs and raise the Squeegee Assembly to its storage position.

IMPORTANT: Never store the machine with the Squeegee in the down position. This can damage the Squeegee Blades and affect water pick-up.

For Smooth Floors:

Use the standard rear squeegee blade K62732060.

For Rough Floors:

Use rear squeegee blade K62732150.

MAINTENANCE

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Solution Pump Intake Filter

NOTE: A dirty or clogged filter will greatly reduce cleaning solution flow, and decrease the ability of the machine to clean floors properly! Do not remove or modify this filter element, as it protects the Solution Pump from potential damage.

Inspect the Solution Filter periodically as follows:

1. Grip the main body and turn the front-

facing wings counterclockwise. The two components will separate to expose the mesh filter element inside.

2. Carefully clean the filter element, or

replace it.

3. Reassemble the two halves.

Solution and Recovery (Vacuum) Tanks

The Recovery Tank System Features:

The Recovery Tank is depressurized by the Vacuum Motor, and pulls spent solution and debris from the Squeegee into its interior. A stand pipe prevents water intake into the Vac Motor, and a Float Sensor prevents Vac Motor operation once the Recovery Tank is full.

Draining the Recovery Tank:

1. Position the machine at a floor drain or

other drain area.

2. Remove the drain hose from its clamp on the Brush Housing, and lift it high.

3. Unscrew the wing nut at the hose end until the plug becomes loose and can be pulled

out. Be careful to remove only the plug, not the metal tube surrounding it.

4. Lower the hose and insert the end into the waste receptacle.

5. Once the flow stops, replace the plug and stow the hose back into position.

For more extensive cleaning of the tank,

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remove the Top Cover Lid and flush out the tank with clean water as necessary.

MAINTENANCE

Draining Solution Tank:

1. Locate drain hose at rear of unit and

position over floor drain or container.

2. Pull the corded ball out of position to

expose the hole.

3. Lower the hose and position it over a

drain. Once flow has stopped, replace the ball to close the tube. Tuck drain hose back onto its hook.

NOTE:

Flush and clean both tanks after each use, and allow to air dry to eliminate odors and corrosion of vacuum motor.

Vacuum Motor

To service vacuum motor (which is mounted to the underside of the Cover/Recovery Tank):

1. Drain the Recovery Tank and raise it to the open position.

2. Disconnect wires to the Vacuum Motor, noting connections for later reattachment.

3. Remove three motor mounting screws.

4. Remove motor and inspect the mounting gasket carefully before reinstallation. Replace the gasket if necessary.

MAINTENANCE

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Lubricating Your Machine

Once a month grease swivel casters with a grease gun. Each caster has one fitting on the swivel area. Wipe off excess grease.

Motor Brush Replacement

Use the appropriate hour meter on the LCD Display to monitor runtimes for each motor. Tornado recommends changing motor brushes at the intervals specified below in order to avoid potential damage to the commutator. Replacement brushes need to be inspected and changed more often due to commutator wear. Always permanently record any brush inspections and replacements you make.

Don’t attempt to use the Motor Fault Error feature of the LCD Display as a signal that motor brushes need changing. A Motor Fault that occurs directly from brush wear would also indicate a high risk of motor damage.

Motor Recommended Motor Brush Change Interval

Transaxle 1800 hours initially, 900-1400 hours for replacements Brush 2600 hours initially, 1300-2000 hours for replacements Vacuum 600-650 hours initially, 400-500 hours for replacements

TORNADO FK 3000

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TROUBLESHOOTING INSTRUCTIONS

This section is designed to instruct your personnel in methods of troubleshooting on the Tornado FK 3000. Common maintenance-related issues are noted below, followed by a full Troubleshooting Chart.

Vacuum System - Poor Suction

During machine operation, if the vacuum motor is running but the solution is not being picked up, do the following:

1. With the vacuum motor on, place your

hand over the vacuum hose intake. If suction is strong, a blockage is in the squeegee throat.

Clear this blockage by pushing a screwdriver, or any similar tool, downward through the top of the squeegee throat.

2. Check for a loose intake hose

connection, creating an air leak.

3. Check for a clogged mesh intake screen on the standpipe inside the Recovery Tank.

4. Check to see that the ball closure is in place on the end of the Recovery Tank drain

hose.

5. Check to see that the Recovery Tank Cover disk is seated properly on its gasket.

6. Check to see that the liquid shutoff unit is properly seated at rear of recovery tank.

Since the entire Recovery Tank is placed under vacuum by the Vacuum Motor, each fitting and other entry point should be examined for potential air leakage or blockage.

NOTE: Performing these maintenance procedures will avoid problems with the recovery system requiring outside repair service. Always be very sure the vacuum system is clear of any blockage before calling for service.

Vacuum System - Vacuum Motor Inoperative

1. The Recovery Tank is full. When the Recovery Tank is full, the Liquid Shutoff closes and

stops the Vacuum Motor to prevent water from entering it.

2. If the Recovery Tank is not full, use the Troubleshooting Chart to diagnose problems with

the shutoff switch, motor, connectors, etc.

TROUBLESHOOTING

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Poor Solution Flow

If an inadequate supply of solution is reaching the floor, check the solution hoses for kinks. These hoses are connected to the brush drive assembly. If there are no kinks in the solution hoses, pull the hoses from the brush cover fittings and check the entire line for blockage.

Electrical Problems

If Brush Motors do not run, check the following:

1. Emergency Stop is pulled out.

2. Key Switch is in ON position.

3. Brushes are in down position.

4. Check the circuit breaker button located on the bottom of the main Controller Box.

Batteries Not Holding Charge

Check that the batteries have been given enough charging time to reach their full charge. This will vary according to condition of the batteries.

Check the lights on the battery charger after charger shuts off:

A. Green light — Batteries are fully charged and are in good condition.

B. Amber light — All cells are OK but the total battery capacity is reduced. This usually

indicates that the batteries are aging.

C. Red light — The battery capacity is low and the entire charger-battery system needs to be

inspected by a qualified serviceman.

The automatic charger is designed to keep batteries at optimum operating charge levels.

NOTE: If red light comes on, inspect battery connections and water level.

Check each cell with a hydrometer before and after charging to determine it batteries are weak. Do not charge or use batteries when the liquid in any one or more cells measures less than

1.150 specific gravity. A fully charged battery should read 1.270 or better after cooling 1/2 hour.

Batteries that have been properly charged yet still do not reach a full charge should be replaced. One defective battery can weaken the other batteries. Replace the defective battery if the battery pack is less than two years old. If over two years, replace the entire battery pack.

TROUBLESHOOTING

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Daily Battery Maintenance Precautions

• Add distilled water only.

• Never add acid.

• Keep vent caps tight when operating.

• Keep battery tops clean and dry.

• Keep water level 1/4” above cell plates.

• Keep excessive heat and metal items away from batteries.

• Use a TORNADO charger with correct voltage and current rating.

TROUBLESHOOTING CHART

PROBLEMS POSSIBLE CAUSE AND CORRECTIVE ACTION

Unit completely inoperative

Unit moves forward but not reverse

Unit does not move forward or reverse

Unit pulls to one side

• Wiring harness disconnected from batteries. Connect as detailed in wiring diagram.

• Batteries discharged. Charge and service the batteries as detailed this manual.

• Circuit breakers tripped due to overload. Wait several minutes, then reset circuit breakers.

• Emergency Stop button pushed. Pull button out to run.

• Keyswitch set to “OFF”. Turn key to “ON”.

• Faulty components or circuitry. Consult authorized Tornado Service Center.

• Faulty component or circuitry. Consult authorized Tornado Service Center.

• Batteries discharged. Charge and service the batteries as detailed this manual.

• Circuit breakers tripped due to overload. Wait several minutes, then reset circuit breakers.

• Faulty components or circuitry. Consult authorized Tornado Service Center.

• One (not both) brush motor inoperative. Faulty brush motor or circuitry. Consult authorized Tornado Service Center.

Vacuum motor does not operate

• Circuit breaker tripped due to overload. Wait several minutes, then reset circuit breaker.

• Vacuum switch in ”OFF” position. Move switch to “MAIN” or “AUTO” position.

• Recovery tank full. Drain recovery tank as detailed in this manual.

• Faulty vacuum motor or circuitry. Consult authorized Tornado Service Center.

TROUBLESHOOTING CHART – continued

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PROBLEMS POSSIBLE CAUSE AND CORRECTIVE ACTION

Inoperative vacuum, brush motors, and solution pump

Vacuum motor operates, but there is little or no suction at squeegee

Brush motors do not operate

• Brushes in “up” position. Lower brushes.

• Circuit breakers tripped due to overload. Wait several minutes, then reset circuit breaker.

• Faulty components motor or circuitry. Consult authorized Tornado Service Center.

• Recovery tank cover is loose or missing. Tighten or replace.

• Recovery hose is loose or disconnected. Connect or tighten.

• Blockage in recovery hose. Clear blockage by backflushing with garden hose.

• Blockage in squeegee throat. Clear blockage with screwdriver or similar instrument.

• Blockage on vacuum motor intake screen. Clear blockage with wet cloth.

• Circuit breaker tripped due to overload. Reduce brush motor load by adjusting brush pressure, increasing solution, or changing to a less aggressive pad. Wait several minutes, reset circuit breaker then resume operation.

• Brushes in “up” position. Lower brushes.

• Faulty brush motor or circuitry. Consult authorized Tornado Service Center.

Inadequate run time

Inadequate solution flow at brushes

• Excessive brush pressure. Reduce brush pressure as detailed this manual.

• Improper charging and/or battery maintenance. Charge/service batteries as instructed in this manual.

• Old batteries. Batteries have a finite useful life. Test regularly, and replace batteries periodically.

• Faulty charger. Consult authorized Tornado Service Center.

• Solution tank empty. Fill solution tank.

• Circuit breaker tripped due to overload. Wait several minutes, then resume operation.

• Solution hoses blocked or kinked. Inspect and correct problem.

• Solution knob turned off. Turn solution knob fully clockwise.

• Faulty pump or circuitry. Consult authorized Tornado Service Center.

TROUBLESHOOTING

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Diagnostic Fault Codes

Error codes displayed in the LCD Display indicate that the Electronic Control System may be detecting problems with electrical connections, worn parts, power system controls, or batteries. Be sure to write down the error code before calling your Authorized Tornado Distributor, Service Center, or the Tornado Technical Service Department.

NOTE: Most of these codes are internal errors and cannot be rectified externally. They are provided for diagnostic reference only.

Error Codes Available in the LCD Display

Code

Code Type Code Description Code

Family

00xx,01xx,02xx Internal EEPROM Codes EEPROM program checksum error 2 - Contact Tornado 0003

Running rom check error 0100

EEPROM program checksum error 1 - Contact Tornado 0204

07xx Switch Reference Codes 2.5V reference error 0705

High switch reference error 0706

08xx Throttle Codes Throttle - High reference error 0810

Throttle - Maximum wiper difference error 0811

Throttle - Maximum pull-down difference error 0812

Throttle - Maximum pull-safe difference error 0813

Throttle - Reference error 0814

Throttle - Low reference error 0815

Throttle - High reference error (ISO error) 0816

Throttle - Low reference error (ISO error) 0817

Throttle - Both LCD module and TRIO unit have throttles 0818

0A01 Power Down Code Power down error 0A01

0B0B Internal EEPROM Code EEPROM - Queue has overflowed 0B0B

1310 Supply Over Current Excessive current trip 1310

150x Solenoid Brake Codes Brake Fault 1 - Solenoid brake circuit is open. 1500

Brake Fault 2 - Solenoid brake circuit is open. 1501

Brake over current error 1507

1600 High Battery Voltage High battery voltage 1600

170x Internal Relay Codes Relay monitor fault 1704

Relay Fault 1 - Relay stuck closed 1705

Relay Fault 2 - Relay fault on Brush/Vacuum bridge circuit 1706

180x Watchdog Codes Watchdog tripped 1800

Watchdog voltage reference error - Watchdog reading high 1802

1B20 Internal Code Current Measuring Error 1B20

1D02 Throttle Spec Modified Front end reconfiguration change trip 1D02

1E0x Inhibit Codes Inhibit active 1E03

Secondary inhibit active 1E04

210x Internal Codes Internal counter error 2102

Internal counter error 2 2103

2C0x Low Battery Codes Low battery voltage 2C00

Low battery error - 2 2C01

Battery lockout trip 2C02

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2D01 Internal Code No output drive 2D01

2F01 Throttle displaced code Throttle Input displaced 2F01

310x Bridge supply Codes Low bridge voltage - possible short circuit at outputs 3100

Traction bridge fault 3101

Brush/Vac bridge fault 3102

Waiting for bridge to charge 3103

32xx, 36xx Internal processor codes Stack overflow 3201

No internal timers 3210

Internal timer out of range 3211

A to D conversion not completed before next start of conversion. 3212

Unknown A/D MUX channel 3213

ADC module is not ready 3214

Trip sense not active (Test trip latch 1 error) 3601

Micro trip output active (Test trip latch 2 error) 3602

Fault left sense not active (Test trip latch 3 error) 3603

Failed to trip when overvoltage trip forced (Test trip latch 8 error) 3608

Failed to reset when overvoltage trip reset (Test trip latch 9 error) 3609

Failed to trip when micro trip output forced (Test trip latch 10 error) 360A

Failed to reset when micro trip output reset (Test trip latch 11 error) 360B

Failed to trip when watchdog not pumped (Test trip latch 12 error) 360C

Test trip latch 13 360D

Test trip latch 14 360E

700x Freewheel Codes Startup with freewheel activated 7000

Freewheel activated in drive mode 7001

750x LCD Comms codes LCD Module communications timeout 7500

LCD Module settings corrupt 7501

760x Brush Motor codes Brush motor disconnected 7600

Brush current foldback - brushes running at current limit for 20 seconds 7601

Brush current foldback - 2 - brush current exceeds 150A 7602

Brush current foldback - 3 - hardware trip, possible short circuit on brush output 7603

Brush inhibit active 7604

770x Vacuum Motor Codes Vacuum motor disconnected 7700

Vacuum current foldback 7701

Vacuum current foldback - 2 7702

Vacuum current foldback - 3 7703

780x Traction Motor Codes Traction Motor Open Circuit Fault 7800

Traction overcurrent error 7801

Traction motor in foldback state 7802

7901 Emergency stop/BB codes Emergency stop error 7900

Belly button switch activated 7901

900x Customer specific codes 9000

NOTE: Most of these codes are internal errors and cannot be rectified externally. Contact your

Authorized Tornado Distributor, Service Center, or the Tornado Technical Service Department.

MODEL 99430C

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PREVENTIVE MAINTENANCE CHECKLIST

DAILY MAINTENANCE

START OF OPERATION

• Unplug charger from system circuitry.

• Close all plugs and covers to both liquid tanks to seal. Fill the Solution Tank as needed, and

ensure that the Recovery Tank is empty.

• Give the machine a general visual inspection.

END OF OPERATION

• Clean and wipe squeegee blades. Lift and lock them clear of the floor.

• For safety, make sure both Keyswitch and Emergency Switch are off.

• Drain and flush both tanks and leave fillers and drains open to air dry. This will help eliminate

odors and minimize Vacuum Motor corrosion.

• Add distilled water to battery cells if required.

• Charge the batteries.

WEEKLY MAINTENANCE

Check the specific gravity of fully-charged battery cells: allow a 30 minute cool-down after charging (specific gravity should be 1.270 to 1.280). Use a hydrometer to check.

MONTHLY MAINTENANCE

• Lubricate lift mechanisms (both brush and squeegee) with a light oil.

• Adjust the brush pressure (mercury switch) if needed.

• Check for wear or damage of brushes, pads and squeegee blades, replace if necessary.

• Clean all battery terminals with baking soda and water.

• Check batteries for damage, acid spills, cracks.

• Lubricate lever pivots and mechanisms, and check for looseness.

• Check the drain gaskets for wear and damage, replace if necessary.

• Make sure all electrical connections are tight.

• Clean and lubricate the caster wheels.

SEMI-ANNUAL MAINTENANCE

• Check all motors, especially check for carbon brush wear. Replace if necessary.

• Grease all bearings.

ANNUAL MAINTENANCE

• Tighten all loose linkages, screws and nuts on entire machine.

CLEANING THE FK 3000

Although the FK 3000 has an exceptionally tough and chemical-resistant body, it houses sophisticated electronics and wiring systems. To avoid the chance of shorting or corroding electrical components or connectors, clean the body with a damp sponge or brush only. Do not expose the unit to rain, hose or power spray, runoff, or poured water rinsing.

SOLUTION TANK – EXPLODED VIEW “A”

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(Ref. Drawing #31504)

SOLUTION TANK – EXPLODED VIEW “B”

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(Ref. Drawing #31504)

SOLUTION TANK – PARTS LIST

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(Ref. Drawing #31504)

ITEM QTY PART # DESCRIPTION

1 1 02568 WASHER, PLAIN 5/16 2 2 07626 HOSE CLAMP SCREW-TYPE 5/16”-7/8” 3 1 11219 WASHER, PLAIN #10 4 1 15073 SCREW, TFT PAN HEAD #10-16 X 1” 5 1 16089 STOPPER, RETAINED PLUG 6 1 16091 HOSE CLAMP 7 1 16136 SET SCREW, SOCKET HEAD #10-24 X ½” 8 1 18563 NOZZLE, DRAIN HOSE

9 2 18773 SWIVEL CASTER 10 1 19270 FITTING ,RECOVERY HOSE 11 2 19513 NUT, HEX LOCK (NYLON INSERT) 5/16-18 12 1 19544 SOLUTION TANK 13 1 19596 BRACKET, GAS SPRING MOUNTING 14 1 19724 GAS SPRING 15 1 19948 HANGER, DRAIN HOSE 16 1 30533 HOSE W/BELLOWS 17 2 30623 SCREW, FLANGED HEX HEAD ¼-20 X ½ 18 8 30647 SCREW, FLANGED HEX HEAD 3/8-16 X ½ 19 1 31357 STOPPER PLUG, 3.0” 20 1 31358 ATTACHMENT PIECE (RETAINER STRAP) 21 2 31393 ELBOW FITTING, 90DEG, ½” 22 1 31394 SIGHT TUBE 23 1 31551 COVER, SOLUTION TANK CAVITY

24* 2 30818 DECAL, TORNADO W/LOGO 3.5 X 15.5

* = NOT SHOWN

RECOVERY TANK – EXPLODED VIEW

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(Ref. Drawing #31503)

RECOVERY TANK – PARTS LIST

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(Ref. Drawing #32503)

ITEM QTY PART # DESCRIPTION

1 3 03218 WASHER, PLAIN 1/4

2 2 14142 WASHER, PLAIN .265

3 1 16091 HOSE CLAMP

4 3 17644 SCREW, HEX HEADCAP ¼-20 X 4.0

5 3 17889 SPACER, MOTOR ENCLOSURE

6 1 18226 PLUG

7 1 18357 SLEEVE, ALUMINUM

8 1 18358 RUBBER ATTACHMENT

9 1 19119 GASKET, VACUUM MOTOR 10 1 19270 FITTING ,RECOVERY HOSE 11 1 19543 RECOVERY TANK 12 1 19596 BRACKET, GAS SPRING MOUNTING 13 1 19708 FLOAT SWITCH 14 1 19930 VACUUM MOTOR 15 1 19973 ASSEMBLY, VAC INTAKE 16 1 30503 ASSEMBLY, RECOVERY INLET 17 2 30623 SCREW, FLANGED HEX HEAD ¼-20 X ½ 18 1 31237 HOSE, RECOVERY DRAIN 19 1 31354 COVER GASKET 20 1 31355 ASSEMBLY, TOP COVER

21* 1 31337 DECAL, TORNADO SWIRL LOGO, 5.0” DIA.*

* = NOT SHOWN

SQUEEGEE ASSEMBLY – EXPLODED VIEW

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(Ref drawing #K47770560)

SQUEEGEE ASSEMBLY – PARTS LIST

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ITEM QTY PART NUMBER DESCRIPTION

1 1 K50072170 PLATE 2 2 K50171360 BRACKET, SQUEEGEE TAILPIECE 3 2 K50294690 SPACER, STEEL 1.44” LONG 4 1 K50314640 CHANNEL 5 1 K50314650 TAILPIECE 6 1 K50314820 TAILPIECE 7 2 K50443040 CASTER WHEEL FRAME 8 2 K51053200 SPACER

9 2 K53080570 HEX STUD, DOUBLE-SIDED THREAD 10 2 K54012440 INSERT (PLATE) 11 2 K54012500 INSERT (PLATE) 12 2 K55150960 WHEEL, 4” DIA. BLACK 13 1 K62732150 SQUEEGEE BLADE SET 14 2 K63211330 STAR HANDLE 15 2 K63211470 CONTROL KNOB 16 2 K64354010 WHEEL 17 4 K73030370 SCREW 18 2 K73061990 SCREW 19 2 K73114220 NUT 20 2 K73120040 WASHER .33” DIA. 21 4 K73120260 WASHER 22 4 K73120580 WASHER 23 2 K73120800 SPACER 24 2 K73122770 WASHER

(Ref. Drawing #K47770560)

SQUEEGEE MOUNT ASSEMBLY – EXPLODED VIEW

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(Ref. Drawing #32031)

SQUEEGEE MOUNT ASSEMBLY PARTS LIST

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(Ref. Drawing #32031)

ITEM QTY PART # DESCRIPTION

1 4 00851 WASHER, PLAIN ¼” 2 4 01497 HEX NUT, FINISHED, ¼-20 3 2 01574 LOCK WASHER ¼” 4 2 01589 HEX NUT, FINISHED, 5/16-18 5 2 02568 WASHER, PLAIN 5/16 6 2 02581 HEX NUT, FINISHED, 3/8-16 7 2 03320 SCREW, HEX HEAD CAP, 3/8-16 X 1.0 8 8 03321 WASHER, PLAIN .391

9 7 03536 WASHER, LOCK 3/8 10 4 03931 WASHER, PLAIN 5/8 11 4 05025 HEX NUT, JAM 12 2 14142 WASHER, PLAIN .265 13 2 15677 SCREW, SOCKET HEAD, SHOULDER 3/8D X 3/8 14 1 16907 SCREW, HEX HEAD CAP 3/8-16 X 7/8 15 2 18695 BOLT, SQUEEGEE LIFT CABLE 16 2 18873 SCREW, HEX HEAD FLANGED, 3/8-16 X 1-1/4 17 1 19191 WASHER, PLAIN .328 18 1 19544 SOLUTION TANK 19 1 19599 HANDLE, SQUEEGEE LIFT 20 1 19600 MOUNTING BRACKET, LIFT HANDLE 21 4 30647 SCREW, HEX HEAD FLANGED, 3/8-16 X 1/2 22 1 31938 PIVOT LIFT 23 1 31947 U-BOLT, 3/8-16 24 1 32016 MAIN SUPPORT BRACKET 25 1 32017 PIVOT ROD 26 1 32018 SQUEEGEE STOP 27 1 32019 BRACKET 28 1 32024 LIFTING CABLE 29 1 32025 SPRING, 9/16” O.D. 30 1 32026 SCREW, SOCKET HEAD CAP, ¼-20 X 5/8 31 1 32027 SPACER, SQUEEGEE PIVOT 32 1 10721-7 GRIP, HANDLE 33 1 K47770560 SQUEEGEE ASSEMBLY 34 1 K50482340 ROCKER 35 1 K51072020 BAR 36 1 K51108680 BUSHING, SQUEEGEE MOUNTING BRACKET 37 1 K53322060 HELICAL SPRING 38 2 K63101290 KNOB, TWO-EARED 39 2 K63431320 LOCK WASHER 40 2 K73031390 SCREW 41 1 K73061510 SCREW 42 1 K73114270 NUT 43 2 K73120030 WASHER 44 2 K73120040 WASHER .33 DIA. 45 1 K73120260 WASHER

BRUSH DRIVE ASSEMBLY – EXPLODED VIEW

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(Ref. Drawing #31501)

BRUSH DRIVE ASSEMBLY – PARTS LIST

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(Ref. Drawing #31501)

TRANSAXLE ASSEMBLY – EXPLODED VIEW

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(Ref. Drawing #19686)

TRANSAXLE ASSEMBLY – PARTS LIST

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(Ref. Drawing #19686)

CONTROL BOX & SOLUTION PUMP MODULE – EXPLODED VIEW

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(Ref. Drawing #31469)

CONTROL BOX & SOLUTION PUMP MODULE – PARTS LIST

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(Ref. Drawing #31469)

ACTUATOR ASSEMBLY – EXPLODED VIEW & PARTS LIST

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(Ref. Drawing #31386)

CONTROL PANEL – EXPLODED VIEW

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(Ref. Drawing #31474)

CONTROL PANEL – PARTS LIST

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(Ref. Drawing #31474)

TRIGGER ASSEMBLY – EXPLODED VIEW

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(Ref. Drawing #31500)

TRIGGER ASSEMBLY - PARTS LIST

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(Ref. Drawing #31500)

MAIN ASSEMBLY – EXPLODED VIEW “A”

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(Ref. Drawing #99430)

MAIN ASSEMBLY – EXPLODED VIEW “B”

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(Ref. Drawing #99430)

MAIN ASSEMBLY – EXPLODED VIEW “C”

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(Ref. Drawing #99430)

MAIN ASSEMBLY – EXPLODED VIEW “D”

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(Ref. Drawing #99430)

MAIN ASSEMBLY – PARTS LIST

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(Ref. Drawing #99430)

WIRING DIAGRAM

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Sheet 1 of 2

(Ref. Drawing 31417)

WIRING DIAGRAM

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Sheet 2 of 2

(Ref. Drawing 31417)

WIRING HARNESS

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CONTROL FUNCTION

Sheet 1 of 2

(Ref. Drawing 31418)

WIRING HARNESS

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CONTROL FUNCTION

Sheet 2 of 2

(Ref. Drawing 31418)

WIRING HARNESS

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POWER FUNCTION

Sheet 1 of 2

(Ref. Drawing 31419)

WIRING HARNESS

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POWER FUNCTION

Sheet 2 of 2

(Ref. Drawing 31419)

REPLACEMENT ITEMS AND ACCESSORIES

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FK 3000 Floorkeeper Automatic Scrubber

Catalog # Description Shipping

Replacement Items

99154 16” Pad Holder 10# 30543 Oil-Resistant Linatex Front Squeegee Blade 2# 30544 Oil-Resistant Linatex Rear Squeegee Blade 2#

Optional Items

99172 16” Firm Poly Scrub Brush (2 required) 8# 99173 16” Grit Brush (2 required) 8# 90676 Wet Pick-Up Attachment Set 9#

Weight

Tornado FK 3000, 99430, Floorkeeper LR 30, 99440 Operation And Illustrated Parts Manual

Specifications and Main Features

Frequently Asked Questions

User Manual