SCRUBBER
IPX4
Operating Instructions
MODELS: FLX3
FLX3T
D
980087 07/19/03
FLXSP3
FLXSP3T
Read these instructions before using the machine
MACHINE DATA LOG/OVERVIEW
2
YOUR DEALER
Address:
MODEL _______________________________________
DATE OF PURCHASE__________________________
SERIAL NUMBER______________________________
SALES REPRESENTATIVE # ___________________
DEALER NAME________________________________
OPERATIONS GUIDE NUMBER __________________
PUBLISHED___________________________________
Copyright 2003 Windsor Industries, Printed in USA
Name:__________________________________________________________________________________________________
_______________________________________________________________________________________________
Phone Number:__________________________________________________________________________________________
OVERVIEW
The Flex3™ is a revolutionary rider type scrubber with four wheel articulated design for superior
maneuverability, simple operation, and low maintenance. The machine design permits access to
areas even traditional walk behind machines cannot reach. The squeegee design, location, and
steering geometry allows the operator to make tight turns while recovering full width of the scrub
path. Controls are logically designed for easy touch button operation, strategically laid out at the
operator’s fingertips, easily reached from a comfortable seat. In addition, the four wheel stance
continues the Windsor concept for operator comfort and stability. The Flex3™ was designed from
the ground up for ease of maintenance.
FLX3 980087 04/01/03
TABLE OF CONTENTS
3
Machine Data Log/Overview..........................2
Table of Contents...........................................3
HOW TO USE THIS MANUAL
How to use this Manual..................................1-1
SAFETY
Important Safety Instructions.........................2-1
Hazard Intensity Level...................................2-2
Safety Label Location.....................................2-3
OPERATIONS
Technical Specifications................................3-1
How the Machine Works ................................3-3
Components...................................................3-4
Controls..........................................................3-5
Machine Operation.........................................3-15
Pre-Run Machine Inspection......................3-15
Starting Machine.........................................3-15
Filing Machine.............................................3-15
Scrubbing....................................................3-16
Double Scrub..............................................3-17
Emptying & Cleaning Tanks.......................3-18
MAINTENANCE
Batteries.........................................................4-2
Low-Battery Shut-Down.................................4-4
Squeegee Adjustment....................................4-5
Adjusting Squeegee Pitch...........................4-5
Adjusting Deflection....................................4-5
Replace Rear Squeegee Blades...................4-6
Replace Front Squeegee Blades...................4-6
Scrub Head-Disk. ...........................................4-7
Scrub Brushes...............................................4-7
Replacement/Installing Scrub Brushes.........4-7
Scrub Head- Cylindrical.................................4-8
Differential Drive Chain..................................4-10
Drive Wheel Chain.........................................4-10
Brakes............................................................4-11
Tires and Wheels...........................................4-11
Vacuum Motors..............................................4-12
Brush Motors..................................................4-13
Towing or Pushing.........................................4-15
Machine Jacking............................................4-16
Machine Storage............................................4-16
Service Schedule...........................................4-17
Machine Troubleshooting...............................4-18
GROUP PARTS LIST
Brake.............................................................5-1
Control Panel.................................................5-3
Decal..............................................................5-5
Differential......................................................5-7
Electrical........................................................5-9
Floor...............................................................5-11
Forward/Reverse Pedal.................................5-13
Front Bumper – Disk.....................................5-15
Front Bumper - Cylindrical............................5-17
Front Frame...................................................5-19
Front Wheel...................................................5-21
Rear Frame...................................................5-23
Rear Wheel....................................................5-25
Recovery Tank .............................................5-27
Scrub Brush/Pad Driver................................5-29
Scrub Head – Cylindrical...............................5-31
Scrub Head – Cyl. Valve & Hopper...............5-33
Scrub Head – Disk ........................................5-35
Scrub Head Lift - Cylindrical..........................5-37
Scrub Head Lift - Disk...................................5-39
Seat................................................................5-41
Solution Hoses & Fittings..............................5-43
Solution Tank ................................................5-45
Squeegee - Standard....................................5-47
Squeegee - Tight...........................................5-51
Squeegee Lift ................................................5-55
Steering .........................................................5-57
Vacuum ........................................................5-59
Wiring – Battery.............................................5-61
Wiring – Control Panel...................................5-63
Wiring – Electrical Panel...............................5-65
Wiring – Front Frame....................................5-67
Wiring – Rear Frame.....................................5-69
Wiring – Schematic .......................................5-71
Suggested Spare Parts.................................5-72
EC Declaration of Conformity .......................5-73
Notes .............................................................5-75
Warranty........................................................5-76
FLX3 980087 07/19/03
HOW TO USE THIS MANUAL
1-1
This manual contains the following sections:
- HOW TO USE THIS MANUAL
- SAFETY
- OPERATIONS
- MAINTENANCE
- PARTS LIST
The HOW TO USE THIS MANUAL section will tell
you how to find important information for ordering
correct repair parts.
Parts may be ordered from authorized dealer. When
placing an order for parts, the machine model and
machine serial number is important. Refer to the
MACHINE DATA box, which is filled out during the
installation of your machine. The MACHINE DATA
box is located on the inside of the front cover of this
manual.
MODEL
DATE OF PURCHASE
SERIAL NUMBER
SALES REPRESENTATIVE #
DEALER NAME
OPERATIONS GUIDE NUMBER
PUBLISHED
Copyright 2003 Windsor Industries, Printed in USA
The model and serial number of your machine are
located approximately where indicated.
The OPERATIONS section is to familiarize the
operator with the operation and function of the
machine.
The MAINTENANCE section contains preventive
maintenance to keep the machine and its
components in good working condition. They are
listed in this general order:
- Batteries
- Squeegee Assembly
- Scrub Head
- Differential Drive Chain
- Drive Wheel Chain
- Brakes
- Tires and Wheels
- Vacuum Motors
- Brush Motors
- Towing and Pushing Machine
- Storage
- Service Schedule
- Troubleshooting
The PARTS LIST section contains assembled parts
illustrations and corresponding parts list. The parts
lists include a number of columns of information:
- REF – column refers to the reference
number on the parts illustration.
- PART NO. – column lists the part
number for the part.
- QTY – column lists the quantity of the
part used in that area of the machine.
- DESCRIPTION – column is a brief
description of the part.
- SERIAL NO. FROM – column indicates
the first machine the part number is
applicable to. When the machine design
has changed, this column will indicate
serial number of applicable machine.
The main illustration shows the most
current design of the machine. The
boxed illustrations show older designs. If
column has an asterisk (*), call
manufacturer for serial number.
- NOTES – column for information not
noted by the other columns.
The SAFETY section contains important information
regarding hazard or unsafe practices of the
machine. Levels of hazards is identified that could
result in product or personal injury, or severe injury
resulting in death.
NOTE: If a service or option kit is installed on your
machine, be sure to keep the KIT INSTRUCTIONS
that came with the kit. It contains replacement parts
numbers needed for ordering future parts.
NOTE: The 98# on the lower left corner of the front
cover is the part number for this manual.
FLX3 980087 04/01/03
2-1
IMPORTANT SAFETY INSTRUCTIONS
!
WARNING:
When using a battery powered appliance, basic precaution
must always be followed, including the following:
READ ALL INSTRUCTIONS BEFORE USING THIS MACHINE.
To reduce the risk of fire, electric shock, or injury:
Use only indoors. Do not use outdoors or expose to rain.
Use only as described in this manual. Use only manufacturer’s recommended components and
attachments.
If the machine is not working properly , has been dropped, damaged, left outdoors, or dropped into
water, return it to an authorized service center.
Do not operate the machine with any openings blocked. Keep openings free of debris that may reduce
airflow.
This machine is not suitable for picking up hazardous dust.
Machine can cause a fire when operating near flammable vapors or materials. Do not operate this
machine near flammable fluids, dust or vapors.
This machine is suitable for commercial use, for example in hotels, schools, hospitals,
factories, shops and offices for more than normal housekeeping purposes.
Maintenance and repairs must be done by qualified personnel.
If foam or liquid comes out of machine, switch off immediately .
Disconnect battery before cleaning or servicing.
Before the machine is discarded, the batteries must be removed and properly disposed of.
Make sure all warning and caution labels are legible and properly attached to the machine.
During operation, attention shall be paid to other persons, especially children.
Before use all covers and doors shall be put in the positions specified in the instructions.
When leaving unattended , secure against unintentional movement.
The machine shall only be operated by instructed and authorized persons.
When leaving unattended , switch off or lock the main power switch to prevent unauthorized use.
Only chemicals recommended by the manufacturer shall be used.
This appliance has been designed for use with the brushes specified by the manufacturer. The fitting
of other brushes may affect its safety.
SAVE THESE INSTRUCTIONS
FLX3 980087 04/01/03
HAZARD INTENSITY LEVEL
2-2
!
WARNING
!
WARNING
!
WARNING
The following symbols are used throughout this guide as indicated in their descriptions:
HAZARD INTENSITY LEVEL
There are three levels of hazard intensity identified by signal words -WARNING and CAUTION and FOR
SAFETY. The level of hazard intensity is determined by the following definitions:
WARNING - Hazards or unsafe practices which COULD result in severe personal injury or death.
! CAUTION
CAUTION - Hazards or unsafe practices, which could result in, minor personal injury or product or property
damage.
FOR SAFETY: To Identify actions, which must be followed for safe operation of equipment.
Report machine damage or faulty operation immediately. Do not use the machine if it is not in proper
operating condition. Following is information that signals some potentially dangerous conditions to the
operator or the equipment. Read this information carefully. Know when these conditions can exist. Locate
all safety devices on the machine. Please take the necessary steps to train the machine operating
personnel.
FOR SAFETY:
DO NOT OPERATE MACHINE:
Unless Trained and Authorized.
Unless Operation Guide is Read and understood.
In Flammable or Explosive areas.
In areas with possible falling objects.
WHEN SERVICING MACHINE:
Avoid moving parts. Do not wear loose clothing; jackets, shirts, or sleeves when working on the
machine. Use Windsor approved replacement parts.
! WARNING
Batteries emit hydrogen gas. Explosion or fire can result. Keep sparks and open flame away. Keep
solution tank in raised position when charging. Keep sparks and flames away from the batteries.
Do not smoke around batteries.
Disconnect batteries before working on machine. Only qualified personnel should work inside
machine. Always wear eye protection and protective clothing when working on or near batteries.
Avoid skin contact with the acid contained in the batteries.
Never allow metal to lie across battery tops.
FLX3 980087 04/01/03
SAFETY LABEL LOCATION
2-3
SAFETY DECAL
80814
LOCATED ON FRAME
SUPPORT WARNING 82448
LOCATED ON FRAME
BATTERY CAUTION 80885
BATTERY COMPARTMENT PLATE
FOR SAFETY
NOTE: These drawings indicate the location of safety labels on the Flex3TM. If, at any time, the labels become
illegible, promptly replace them.
SAFETY DECAL 81925
500700
LOCATED ON BACK SIDE OF FRONT
NEXT TO VACUUM INLET
SAFETY DECAL 81494
SAFETY DECAL 81505
SAFETY DECAL 82447
NEXT TO 82448 DECAL
FLX3 980087 04/01/03
TECHNICAL SPECIFICATIONS
SPECIAL NOTES:
The weighted root mean square acceleration at
ITEM DIMENSION/CAPACITY
Rated Voltage 36VDC
Rated Amperage 90 Amps
Batteries 6 x 6 Volt 360 AH @ 20hr rate
Scrub Brush Motors 2 x .75 hp (0.56 kW)
Vacuum Motor 2 x .75 hp (.056 kW) @ 18,000 rpm
Propelling Motor 2 hp (.745 kW) @ 2700 rpm, 27A
Mass (GVW) 2102 lbs. (953 kg)
Weight empty without batteries 914 lbs. (415 kg)
Solution Control Gravity feed, fully variable with automatic shut-
off in neutral
Solution tank capacity 35 gal. (132l)
Recovery tank capacity 35 gal. (132l)
Scrub brush diameter for 34 in. (86 cm) disk
scrub head
Scrub brush diameter for 34 in. (86 cm)
cylindrical scrub head
Scrub brush length for 34 in. (86 cm) cylindrical
scrub head
Scrub brush pressure 0-200 lbs. (0-91 kg)
Scrub brush speed (Disk) 200 rpm
Scrub brush speed (cyl) 800 rpm
Tires 4 x 16 in (40.64 cm) foam filled black knobby
Maximum speed 6.2 mile/hour (10k/hr)
Coverage 49,300 sq. ft/hr (4,590 sq. m/hr) at 3.5 mph
Frame construction Welded cold rolled steel and steel plate with
Brakes Dual self centering mechanical 6 in (15.24 cm)
Minimum aisle u-turn width 96 in (243.8 cm)
17 in (43.0 cm)
6 in (15.2 cm)
32 in. (81.3 cm)
standard.
(5.6k/hr) with 2 in (5 cm) overlap.
epoxy powder coat finish.
disc with hand lock parking brake.
The sound pressure level at the operator’s ear
was measured to be 76 dBA. This was a
nearfield, broad-band measurement taken in a
typical industrial environment on a tile floor. This
appliance contains no possible source of impact
noise. The instantaneous sound pressure level is
below 63 dBA.
3-1
FLX3 980087 04/01/03
the operator’s arms was measured to be below
2.5m/s². this was a tri-axial, third-octave-band
measurement made during normal operation on a
composite tile floor. The measurement and
related calculations were made in accordance
with ANSI S3.34-1986.
TECHNICAL SPECIFICATIONS
3-2
SQUEEGEE
WIDTH
HEAD
ITEM DIMENSION/CAPACITY
Height 44.5 in (113 cm)
Length with disk head 95.2 in (241.8 cm)
Length with cylindrical head 95.8 in (243.3 cm)
Width with standard squeegee 48.7 in (123.7 cm)
Width with tight squeegee 43.0 in (109.2 cm)
Width w/o squeegee 42.5 in (108.0 cm)
WIDTH
HEIGHT
TOP VIEW
RIGHT SIDE VIEW
LENGTH
FLX3 980087 04/01/03
HOW THE MACHINE WORKS
3-3
The Flex3TM is a battery powered, self-propelled,
hard floor scrubber intended for commercial use.
The appliance applies a cleaning solution onto a
hard floor, scrubs the floor with brushes, and then
vacuums the soiled water back into the recovery
tank.
The machine's primary systems are the solution
system, scrub system, recovery system, and
operator control system.
The function of the solution system is to store
cleaning solution and deliver it to the scrub system.
The solution system consists of the solution tank,
strainers, valve and controls. The solution tank
stores cleaning solution (water and detergent) until it
is delivered to the scrub system. The strainers
protect the valve from debris. The valve is a
solenoid type valve, which controls the delivery of
cleaning solution to the scrub system. The valve
automatically prevents solution flow unless the scrub
brushes are turned on and the machine is being
propelled. The solution control switch controls the
amount of cleaning solution delivered to the scrub
system by controlling the amount of time the valve is
open.
The function of the scrub system is to scrub the
floor. The disk scrub systems consists of two rotary
type disk scrub brushes, motors, scrub deck skirt, lift
actuator and controls. The brushes scrub the floor
as the motors drive the brushes. The brush drive
hubs allow the scrub brushes to follow irregularities
and changes in the floor without loosing contact with
the floor. The scrub deck skirts and side squeegees
control the cleaning solution on the floor so that the
squeegee can pick it up. The one touch switch
controls the motors and lift actuator to turn the
motors on and lower the deck, or turn the motors off
and raise the deck. The brush pressure switch
controls the down pressure on the scrub deck.
The scrub plus system consists of two cylindrical
type brushes, motors, scrub deck skirts, hopper, lift
actuator, and controls. The cylindrical scrub head is
designed to eliminate debris that may be caught in
the squeegee while scrubbing. Water is applied to
the first scrubbing brush turning in a clockwise
rotation when viewed from the right or operator’s
side of machine. The first brush scrubs dirt and
debris between the brushes. The second scrubbing
brush, turning in a counter clockwise rotation, picks
up debris and throws it into a removable hopper.
The larger debris that might catch under the
squeegee is collected in the hopper. Water is
allowed to drain out the hopper into the squeegee
path where it is recovered from the floor. The scrub
deck skirts control the cleaning solution on the floor
so that the squeegee can pick it up. The one touch
switch controls the motors and lift actuator to turn
the motors on and lower the deck, or turn the motors
off and raise the deck. The brush pressure switch
controls the down pressure on the scrub deck.
The function of the recovery system is to vacuum the
soiled water back into the recovery tank. The
recovery system consists of the squeegee, vacuum
motors, filter, recovery tank and controls. The
squeegee wipes the dirty solution off the floor as the
machine moves forward. The vacuum motors
provide suction to draw the dirty solution off the floor
and into the recovery tank. The filter protects the
vacuum fan from debris and foam. The recovery
tank stores the dirty solution.
The float switch in the tank activates the recovery
tank full indicator, shuts off the scrub motors and
solution flow, raises the scrub deck then squeegee,
and shuts off vacuum motor.
The function of the operator control system is to
control the direction and speed of the machine. The
directional control system consists of the
direction/speed control pedal, steering wheel, brake
pedal, propel controller, and drive wheels. The
direction/speed pedal signals forward or reverse
direction and speed. The controller interprets signals
from the direction/speed pedal to command the drive
wheel to propel or slow the machine. The steering
wheel articulates the machine to travel in the
direction desired by the operator. The brake can be
used to hold the machine on slopes.
FLX3 980087 04/01/03
COMPONENTS
3-4
1
8
5
7
6
4
9
12
1. Control Panel
2. Front Bumper
3. Electrical Cover
13
3
2
10
11
7. Recovery Tank Cover
8. Recovery Tank Drain Hose
9. Recovery Tank Drain Cap
4. Solution Tank
5. Solution Tank
Cover
6. Recovery Tank
10. Scrub Head
11. Solution Tank Drain Hose
12. Squeegee
13. Vacuum Motors
FLX3 980087 04/01/03
CONTROLS
3-5
3
5
7
4
10
2
1
1. Key Switch
2. Emergency Stop Button
6
9
8
14
8. Recycle Switch (Optional)
9. Recycle Indicator Light (Optional)
3. One Touch Switch
4. Brush Pressure Switch
5. Solution Control Switch
6. Vacuum/Squeegee Switch
7. Display Toggle Switch
• Information Screen 1
• Information Screen 2
• Hour Meter
• Fault Codes and Special Icons
• Battery Meter
10. Headlight Switch (Optional)
11. Brake Pedal
12. Parking Brake Knob
13. Directional Control Pedal and Speed
Reduction Feature
14. Horn Button
15. Steering Wheel
16. Steering Wheel Tilt Lever
17. Squeegee Camber Adjustment Knob
18. Squeegee Deflection Adjustment Knob
FLX3 980087 04/01/03
CONTROLS
3-6
18
15
12
11
13
16
17
FLX3 980087 04/01/03
CONTROLS
3-7
1. KEY SWITCH
Controls the power for the machine functions. To turn the machine power on, rotate key clockwise.
When the key is turned on the battery symbol will flash for 12 seconds while the system runs selfdiagnostics and returns scrub deck and squeegee to raised position, if necessary. The controller will
not respond to other commands until this routine is complete. To turn the machine power off, rotate
key counterclockwise.
INFORMATION DISPLAY
2. EMERGENCY STOP BUTTON
This safety feature is designed to cut all power to the machine at any time. To shut the machine
power off, push the Emergency Stop switch. To reset the machine, rotate the switch clockwise.
INFORMATION DISPLAY
FLX3 980087 04/01/03
CONTROLS
3-8
3. ONE TOUCH SWITCH
This switch controls the scrub brushes and vacuum all in one touch. To start scrubbing, press the one touch
switch. The brush drive motors will turn on, the scrub deck will lower to the “light scrub” position, the solution will
flow at “two bars” rate, the squeegee will lower and the vacuum will turn on. The information display window will
show which functions are operating. If the direction control pedal is in the neutral position for more than two
seconds the brushes and solution flow will stop. If the one touch switch is activated without brushes installed, the
brush motors will stop, the scrub deck will rise, and the brush pressure indicator will display error code 9000. To
stop scrubbing, press the one touch switch. The brush drive motors will turn off, the scrub deck will raise the
solution flow will stop, the squeegee will raise after a 15 second delay, and the vacuum motor will turn off. This
delay is to clear the vacuum hose of recovered solution.
INFORMATION DISPLAY
4. BRUSH PRESSURE SWITCH
This switch controls the amount of brush pressure to the floor. There are 5 different pressure settings. To
decrease the amount of down pressure, press the top of the brush pressure switch (-). To increase the
amount of down pressure, press the bottom of the brush pressure switch (+). The information display screen
will show the amount of pressure.
NOTE: Press switch and hold momentarily each time to change brush pressure.
INFORMATION DISPLAY
LESS PRESSURE
MORE PRESSURE
FLX3 980087 04/01/03
CONTROLS
3-9
5. SOLUTION CONTROL SWITCH
This switch controls the amount of solution flow to the scrub deck. There are 5 different flow settings.
To increase the solution flow, press the solution control switch (+). To decrease solution flow, press
the top of the switch (-). If the brush motors are turned off or the direction control lever is in neutral,
the flow is automatically interrupted until the motors are turned on again, or the drive pedal is moved
forward or reverse. This feature prevents unintentional draining of the solution tank and allows the
operator to adjust the solution flow to the scrub deck without resetting each time the scrubbing
operation is interrupted. If recycling option is installed, this switch controls the amount of solution flow
to the scrub deck by controlling the speed of the pump.
NOTE: Press switch and hold momentarily each time to change solution flow.
INFORMATION DISPLAY
LESS SOLUTION MORE SOLUTION
6. VACUUM/SQUEEGEE SWITCH
This switch independently controls the vacuum motor and squeegee position. To start the vacuum motor
and lower the squeegee to the floor, press the bottom of the switch. To raise the squeegee and turn off
the vacuum motor, press the top of the switch. The squeegee will raise after a 15 second delay, and the
vacuum motor will turn off 15 seconds later, in order to clear vacuum hose of recovered solution.
Indicates vac motor is running
FLX3 980087 04/01/03
CONTROLS
3-10
Brush Run Time:
7. DISPLAY TOGGLE SWITCH
The display toggle switch allows you to change the information display screen. Two screens are available.
• INFORMATION DISPLAY –SCREEN 1
• INFORMATION DISPLAY –SCREEN 2
• The hour meter is viewed on screen 2 of the information display. Hours are displayed for key ON
time, brush run time, and traction motor time.
Key ON Hours:
Records the entire time that the key is on.
Records the time spent with the brushes
running and gives true brush motor time.
Traction Motor Time:
Records the time spent propelling the
machine and gives true traction motor time.
• Fault codes/icon will appear on either display screen when the controller detects a problem within
the electrical system. The codes/icons are used to assist users as well as service technicians in
identifying and correcting problems. See troubleshooting section for more information on fault
codes. The machine must be keyed off, then on again, to clear fault code after repair.
FLX3 980087 04/01/03
CONTROLS
3-11
• Icon appears if throttle is depressed when the key is turned on. To correct, lift foot off of throttle. If this
does not clear the icon, the throttle may be damaged and should be checked by a qualified service
technician.
• The float switch is located inside the recovery tank. The purpose of the float switch is to notify the user
that the recovery tank is full. When the float switch is activated, the scrub brush motors and solution flow
will stop, the scrub deck will raise, the squeegee will rise after 60 seconds, and the vacuum motor will
turn off 10 seconds later.
• The battery meter can be viewed at the left side of either information screen 1 or information screen 2.
The level of battery charge is indicated by the horizontal bars in the battery meter box. When the
batteries require charging, the icon will flash and a battery inhibit icon will appear on the right side of
either information screen. Scrub and solution functions that are running when the battery inhibit icon
appears will be automatically shut off. It is not possible to restart scrub functions while the battery inhibit
is displayed. The controller reserves enough battery charge to allow pick-up of residual water and
transport back to a charging station.
FLX3 980087 04/01/03
CONTROLS
3-12
8. RECYCLE SWITCH (OPTIONAL)
This switch controls the solution recycle pump. To start recycle pump, press the switch. A green light above
the circuit breakers will indicate that pump is on. The solution control switch will control the speed of the
pump and therefore the amount of solution flow to the scrub deck. Make sure there is an adequate amount of
water in recovery tank before starting recycle pump, and turn off recycle pump when water level reaches filter.
To stop the solution recycle pump, press the switch. The pump will stop and the green indicator light will turn
off, and the solenoid valve will resume control of solution flow to the scrub deck.
9. RECYCLE INDICATOR LIGHT (OPTIONAL)
This light will turn on when the recycle pump is on, and turn off when the recycle pump is off.
10. HEADLIGHT SWITCH (OPTIONAL)
Turns on optional headlight for improved visibility in low light areas.
FLX3 980087 04/01/03
CONTROLS
3-13
11. BRAKE PEDAL
The brake pedal is located on the floor to the left side of the steering column pedestal. The pedal
operates the disc brakes on the drive wheels. To slow or stop the vehicle, apply pressure to the
brake pedal.
12. PARKING BRAKE KNOB
The orange knob located on the left side of the steering column pedestal is used to set the parking
brake. To set the parking brake, fully depress the brake pedal and push the parking brake knob. To
release the parking brake, fully depress the brake pedal. Then release pressure on the brake pedal.
The parking brake knob will return it to its’ released position.
FOR SAFETY: Before leaving or servicing machine; stop on level surface, set parking brake,
turn off machine and remove key.
13. DIRECTIONAL CONTROL PEDAL AND SPEED REDUCTION FEATURE
This pedal controls the direction of travel and the speed of the vehicle. Slowly pressing the front of the
pedal causes the machine to travel forward. Pressing the rear of the pedal causes the vehicle to
travel in reverse. The vehicle speed can be controlled by varying the pressure on the front or rear of
the pedal.
FOR SAFETY: The vehicle can coast for a short distance after releasing the directional pedal.
Remove the foot from pedal and use brakes to slow or stop the machine.
SPEED REDUCTION FEATURE
Maximum speed of machine can be decreased to 80% of maximum by disconnecting wire 41 white
from wire 42 white, located at 20 pin connector at controller. Machine is set at 100% speed setting
at factory.
FLX3 980087 04/01/03
CONTROLS
3-14
14. HORN BUTTON
The horn button is located on the control panel at the left side of the steering wheel. The horn is activated by
pushing the button.
15. STEERING WHEEL
The steering wheel articulates the machine to turn in the direction desired by the operator.
16. STEERING TILT LEVER
The steering tilt lever is located on the right side of the steering wheel. To engage the tilt adjustment,
pull up on the lever and adjust the steering column to desired position. Release lever and allow it to lock into
desired position.
17. SQUEEGEE CAMBER ADJUSTMENT KNOB
The squeegee camber adjustment knob is located at the center of the squeegee at the rear of the machine.
(See maintenance section for adjustment).
18. SQUEEGEE DEFECTION ADJUSTMENT KNOB
The squeegee deflection knob is located at the rear of the machine, on right side of the squeegee assembly.
(See maintenance section for adjustment).
FLX3 980087 04/01/03
MACHINE OPERATION
3-15
PRE-RUN MACHINE INSPECTION
Do a pre-run inspection to find possible problems
that could cause poor performance or lost time from
breakdown. Follow the same procedure each time to
avoid missing steps.
1. Visually check for exterior damage, leaks,
damaged or worn tires.
2. Check brushes or pads and drivers for proper
installation and wear. Weekly check scrub deck
skirts for proper contact with floor. See
BRUSHES in MAINTENANCE SECTION.
3. Check debris hopper (cylindrical scrubhead) to
be sure it is empty.
4. Check squeegee for wear and proper
adjustment. See SQUEEGEE ADJUSTMENT in
MAINTENANCE SECTION.
5. Check for securely attached drain hose, plug,
and caps.
6. Check battery condition, recharge if necessary.
See BATTERIES in maintenance section.
7. Check the brakes and steering for proper
operation. See BRAKES and STEERING in
MAINTENANCE SECTION.
STARTING MACHINE
NOTE: Perform pre-run machine check before
operating machine.
FOR SAFETY: Before starting machine, make
sure that all safety devices are in place and
operating properly.
FILLING THE MACHINE
FOR SAFETY: Before leaving or servicing
machine; stop on level surface, set parking
brake, turn off machine and remove key.
1. Set squeegee and scrub deck to up position, set
parking brake, and turn off key switch.
2. Remove solution tank cover.
! WARNING
Flammable materials can cause an explosion or
fire. Do not use flammable materials in the tanks.
3. The solution tank can be filled to the bottom lip
of the fill inlet. Leave room for detergent. The
solution tank capacity is 50 gallons (189 liters).
The water must not be hotter than 140 L (60LC) to
prevent damage to the tank. Measure the
required amount of chemical into the solution
tank after filling with water. Dry chemicals
should be thoroughly mixed before being added
into solution tank. Commercially available, high
alkaline floor cleaners are suitable for use in the
solution system.
4. Inspect solution tank cover vent for obstructions.
Replace solution tank cover.
1. The operator should be in the seat with foot on
the brake pedal or with the parking brake on.
The directional pedal must be in the neutral
position to avoid unintentional movement.
NOTE: The Operator must be in position on the
seat to activate machine in desired direction.
2. Turn the key switch clockwise to the “ON”
position.
3. Release the brake, then press lightly on the
directional pedal in the desired direction and
drive to the filling area.
FLX3 980087 04/01/03
MACHINE OPERATION
3-16
SCRUBBING
Plan the scrubbing pattern in advance. The longest
track is around the perimeter of the area to be
cleaned. For efficient operation, the runs should be
the longest possible without turning, stopping, or
raising or lowering scrub deck/squeegee.
In order to achieve the best possible results, the
area that is to be cleaned should be swept before
scrubbing. Large debris, strings and wire must be
removed to prevent being caught in brushes or
squeegee.
The machine will automatically raise the squeegee
slightly when reverse travel is selected. If the
machine is allowed to stand in neutral with the scrub
deck down for more than 2 seconds, the solutions
flow stops and brush motors stop. If either forward
or reverse travel is selected, the solution flow will
continue in the same setting and the scrub brush
motors will continue in their same setting once
movement of machine begins. Overlap the brush
path and avoid transporting over previously cleaned
areas.
TO BEGIN SCRUBBING
! CAUTION
When operating the machine around people, pay
close attention for unexpected movement. Use
extra caution around children.
1. Place foot on brake pedal or check to make sure
parking brake has been set.
2. With directional pedal in neutral turn key switch
to “ON”.
3. Release brake.
4. Press the directional pedal to travel in the
desired direction and steer to the start of the
scrub pattern.
5. Press the one-touch switch (#1) on the control
panel. The brush motors will start, the scrub
deck will lower to the light scrub position, the
solution will begin to flow, the squeegee will
lower to the floor and the vacuum motors will
start.
6. Adjust the speed of the machine, solution flow
and scrub brush pressure as necessary.
NOTE: Once solution flow rate is set it is not
necessary to shut off solution when stopping
scrubbing. Solution flow is automatically shut off
when brush motors stop. When brush motors
are activated, flow automatically resumes.
! WARNING
Flammable liquids and/or reactive metals can
cause explosions or fire! Do not pick up.
FLX3 980087 04/01/03
MACHINE OPERATION
3-17
TO STOP SCRUBBING
1. Press the one-touch switch (#1) on the control
panel. The brush motors will stop and the scrub
deck will raise to the park position. After 15
seconds, the squeegee will raise, and 15
seconds later the vacuum motor will turn off.
This delay is to clear the vacuum hose of
recovered solution.
2. Allow directional pedal to return to neutral.
3. Apply brake to stop machine.
4. Turn key switch off.
5. Set parking brake.
FOR SAFETY: Before leaving or servicing
machine; stop on level surface, set parking
brake, turn off machine and remove key.
EMERGENCY STOP PROCEDURE
1. Turn key switch to off position. If an electrical
problem is suspected push in emergency stop
button.
2. Release pressure on directional pedal.
3. Apply brakes.
NOTE: Turning the key switch off during normal
running operation will stop all motors and actuators.
When the key is turned back on the system will
automatically return scrub deck and squeegee to
raised position.
DOUBLE SCRUB
Floors which are heavily soiled or have thick
accumulation of floor finish may not clean sufficiently
with one pass. In these cases it will be necessary to
double scrub.
To double scrub, make the first pass over the
surface being cleaned with the squeegee up, the
solution on, and brushes down. This allows the
solution to stay in contract with the soil while
loosening the surface accumulation with the
brushes. Allow time for the first application to stay in
contact with floor. Length of time between the first
and second pass depends on amount of
accumulation and the type of chemical being used.
A second scrubbing with the squeegee down and
again the solution and brushes on will further loosen
soil. The additional application of solution will further
assist the difficult cleaning job. Caution should be
used when double scrubbing, maintain safe driving
speed on wet floors.
FLX3 980087 04/01/03
MACHINE OPERATION
3-18
EMPTYING AND CLEANING TANKS
RECOVERY TANK
1. Touch the scrub deck switch (#1) on the console
to raise the scrub deck, stop the motors, raise
the squeegee and turn off vacuum motors and
solution.
2. Park the machine next to a floor drain. Drain
hose is on left rear corner of machine.
3. Turn off the key switch and set the machine’s
parking brake.
4. Unhook the drain hose from retainer. Unscrew
T-handle on plug enough to loosen plug and
lower hose in direction of drain. Stand behind
end of hose. Recovered solution will come out
with force. Slowly remove plug from drain hose.
5. Recovery tank should be flushed out with clean
water on a daily basis. Direct water from fill
hose into recovery drain hose. Repeat until
clean water comes out of drain hose. Do not
use water hotter than 140 L F (60L C) to clean the
tank. Damage to tank may occur.
6. Large debris or compacted dirt may be removed
by clean out cap located at rear lower center of
recovery tank. Regular flushing of recovery tank
should make this step unusual.
7. Replace plug and secure drain hose in bracket.
8. If machine is to be stored, leave recovery tank
cover open and drain hose off.
SOLUTION TANK
1. Park the machine next to a floor drain. Drain
hose is on right side at middle.
2. Turn off the key switch and set the machine’s
parking brake.
3. Unhook the small drain hose from the retainer.
Unscrew T-handle on plug enough to loosen
plug, then lower hose in direction of the drain.
Slowly remove plug from drain hose.
4. Remove the solution tank cover.
5. Flush the solution tank out with clean water and
run several gallons of clean water through
systems. Do not use water hotter than 140º F
(60º C) to clean tank. Damage may occur.
NOTE: Never allow solution to remain in tank.
Damage to tank, seals and valves could occur.
6. Replace the drain plug and secure drain hose in
bracket.
SOLUTION
TANK LID
TOP VIEW
DRAIN
HOSE
SOLUTION
TANK DRAIN
CLEAN OUT
REAR VIEW
FLX3 980087 04/01/03
MAINTENANCE
4-1
11
12
8
1
10
2
6
1. Batteries
2. Squeegee Assembly
3. Scrub Head (Disk Shown)
4
9 5
7
7. Solution Strainers
8. Float Switch
9. Vacuum Motors
3
4. Drive Chains
5. Brakes
6. Tires and Wheels
10. Brush Motors
11. Fuse
12. Circuit Breakers
FLX3 980087 04/01/03
MAINTENANCE
4-2
SPECIFIC GRAVITY
BATTERY CONDITION
1. BATTERIES
The batteries provide the power to operate the
machine. The batteries require regular maintenance
to keep them operating at peak efficiency.
To get the greatest life from the batteries charge
them when their charge level reaches 25%of a full
charge. Use a hydrometer to check the charge
level.
Do not allow the batteries to remain in a discharged
condition for any length of time. Never expose a
discharged battery to temperatures below freezing.
Discharged batteries will freeze causing cracked
case. Do not operate the machine if the batteries
are in poor condition or if they have a charge level
below 25%, specific gravity below 1.177.
Keep all metallic objects off the top of the batteries,
as they may cause a short circuit. Replace worn or
damaged cables and terminals.
Check the electrolyte level in each battery cell
before and after charging the batteries. Never add
acid to the batteries use water. Do not allow water
level to fall below the battery plates. Portions of
plates exposed to air will be destroyed. Do not
overfill. Keep plugs firmly in place at all times.
! WARNING
When servicing machine, avoid contact with
acid.
! WARNING
Batteries emit hydrogen gas. Explosion or fire
can result. Keep sparks and open flame away.
Keep covers open when charging.
! WARNING
Wear eye protection and protective clothing
when working with batteries.
4. Wipe off the top of the batteries at least once a
week.
5. Test battery condition with a hydrometer at least
once a week.
6. Ensure that all connections are tight and all
corrosion removed.
7. Every 4 to 6 months remove the batteries from
the machine and clean the battery cases and
battery compartment.
NOTE: Do not take readings immediately after
adding water. If the water and acid are not
thoroughly mixed, the reading may not be accurate.
To find the correct specific gravity reading when the
temperature of the battery electrolyte is other than
80L F (27L C).
Add (+) to the specific gravity reading
0.004 (4 points), for each 10L F (6L C) above 80 L F
(27L C) Subtract (-) from the specific gravity reading
0.004 (4 points), for each 10L F (6L C) below 80L F
(27L C).
! WARNING
Charge batteries in a well ventilated area.
BATTERY MAINTENANCE
1. When cleaning the batteries, use a solution of
baking soda and water. Do not allow the
cleaning fluid to enter the battery cells.
Electrolyte will be neutralized.
2. Maintain the proper electrolyte level in each
battery cell. If a cell should accidentally
overflow, clean immediately.
3. Do not add water until the battery is fully
charged.
1.265 100% CHARGED
1.225 75% CHARGED
1.190 50% CHARGED
1.155 25% CHARGED
1.120 DISCHARGED
FLX3 980087 04/01/03
MAINTENANCE
TO CHARGE BATTERIES
! WARNING
! WARNING
result. Keep sparks and open flame away. Keep
covers open when charging.
! WARNING
working with batteries.
! WARNING
1. Stop the machine in a clean, well ventilated area
next to the charger.
2. Turn the machine off and set parking brake.
FOR SAFETY: Before leaving or servicing
machine, stop on level surface, apply parking
brake, turn off machine and remove key.
3. Raise the tank and raise the support arm to lock
in place.
When servicing machine,
avoid contact with acid.
Batteries emit hydrogen
gas. Explosion or fire can
Wear eye protection and
protective clothing when
Charge batteries in a well
ventilated area.
FOR SAFETY: When charging, connect the
charger to the batteries before connecting the
charger to the AC wall outlet. Never connect the
charger to the AC first. Hazardous sparks may
result.
7. Use a 36 volt DC charger that will automatically
shut off when the batteries are fully charged to
charge the six battery pack.
8. Plug the charger into the battery connector. Plug
charger into power outlet. The charger gauge
should indicate that the batteries are charging.
If the charger does not automatically start up,
verify that charger is plugged into batteries.
9. When the batteries are fully charged, disconnect
the charger from the batteries.
10. Connect the batteries to the machine connector.
11. Check the electrolyte level. It should be up to
the indicator ring. If necessary add distilled
water.
12. Lower the tank.
! WARNING
Batteries emit hydrogen gas. Explosion or fire
can result. Keep sparks and open flame away.
Keep covers open when charging.
4. Check the electrolyte level in each battery cell.
Before charging, add just enough water to cover
up the plates. After recharging has completed,
add just enough water to bring up the level to
the indicator ring. If water level is too high
before charging, normal expansion of the
electrolytes may cause and overflow, resulting in
loss of battery acid balance and damage to the
machine.
5. Replace battery caps, and leave them in place
while charging.
6. Unplug the battery connector from the machine.
Unplug the battery charger from power outlet.
Charger connection
4-3
FLX3 980087 04/01/03
MAINTENANCE
4-4
LOW BATTERY SHUT-DOWN
The electronic system is equipped with battery
voltage sensors. When the batteries are exhausted
to a preset level, the scrubbing system will shut
down to protect the batteries from damage, and the
battery lockout icon will appear on the display.
TO REMOVE BATTERIES
1. Stop the machine in a clean area next to the
charger.
2. Turn off machine and set parking brake.
FOR SAFETY: Before leaving or servicing
machine, stop on level surface, apply parking
brake, turn off machine and remove key.
3. Drain recovery tank.
4. Raise the tank and raise the support arm to lock
in place.
5. Disconnect battery pack from the machine.
6. Use the proper size open end wrench to
disconnect main ground wire first and secure
cable terminal away from batteries.
7. Disconnect main positive lead and secure cable
terminal away from battery/batteries.
8. Loosen both terminals on each jumper cable
and remove one at a time.
9. Prepare a suitable battery site to place batteries.
10. Attach suitable battery lifting device and lift
batteries from the machine.
TO REPLACE BATTERIES
1. Refer to diagram. Place batteries in battery
compartment.
2. Connect all jumper cables positive to negative to
the six batteries.
3. Connect the positive cable to battery in the
position shown.
4. Connect negative cable to battery in the position
shown.
_
+
_
BLK
+
RED RED
RED RED
+
_
BLK
_
BLK RED
_
RED
_
_
+
+
BLK
+
BLK
+
BLK
! CAUTION
Batteries are a potential environmental hazard.
Consult your battery supplier for safe disposal
methods.
FLX3 980087 04/01/03
MAINTENANCE
4-5
2. SQUEEGEE ASSEMBLY
The steering geometry and the design of the
squeegee assembly allows the squeegee assembly
to follow the track of the scrub head even in hard
turns. Turns are not pushed sideways around a
pivot point but turn in an arc. This feature eliminates
the need to use side squeegees. The assembly
rides on the floor supported by two wheels that
follow changing levels in the floor. Down pressure
and squeegee flair is constant in relation to the floor.
Spring tension is applied to the squeegee to
maintain good contact with the floor
NOTE: Refer to ADJUSTING SQUEEGEE below.
Rollers are mounted on each end of the squeegee
assembly to assist in rolling by obstacles. The
squeegee assembly is easily removed from lift
mechanism for service and transport.
SQUEEGEE ADJUSTMENT
Adjusting the squeegee is a two-part process. First,
the squeegee tool must have correct pitch in order
for the squeegee blade to have the same deflection
at each tip as well as at the center. The pitch
adjustment is facilitated by the use of a spirit level
mounted on the squeegee tool. The second
adjustment is the amount of deflection or “bend” in
the rear blade. This deflection is controlled by the
height of the tool from the floor. That height is
varied by the wheel adjustment.
5. Again check the deflection of the squeegee
blades. Repeat steps 1 through 4 until the
deflection is equal across the entire rear
squeegee blade.
TO ADJUST SQUEEGEE DEFLECTION
1. Choose a smooth, level surface. Lower the
squeegee and drive forward at least 2 feet.
2. With the squeegee down, stop the machine and
set the parking brake. Do not allow the machine
to roll back.
FOR SAFETY: Before leaving or servicing
machine; stop on level surface, turn off machine
and remove key.
3. Observe the amount of squeegee deflection. It
should deflect 3/8in (9.5 mm) across the entire
width of the squeegee.
4. To adjust the squeegee defection, loosen knob
on the squeegee slide bar.
5. Sliding bar to the left increases deflection.
Sliding bar to the right decreases deflection.
6. Tighten knob on squeegee slide bar.
7. Turn on the key switch and release the parking
brake. Raise and then lower squeegee
assembly. Drive forward at least 2 feet (60 cm).
8. Repeat steps 2 through 7 until deflection of 3/8
in. (9.5 cm) is reached.
SQUEEGEE DEFLECTION
TO ADJUST SQUEEGEE PITCH
1. Choose a smooth, level surface. Turn on the key
switch, release the machine parking brake,
lower the squeegee and drive forward at least 2
feet (60 cm).
2. With the squeegee down, stop the machine and
set the parking brake. Do not allow the machine
to roll back.
FOR SAFETY: Before leaving or servicing
machine; stop on level surface, turn off machine
and remove key.
3. Determine the differences, if any, in deflection of
the squeegee blade between each end and the
middle. Proper adjustment is obtained when
deflection is equal all the way across tool. This
should correspond to the bubble being in the
middle position of the spirit level.
4. To decrease the deflection of the squeegee
blade at the ends, turn knob on squeegee
trailing arm clockwise. To increase the deflection
at the ends of the squeegee assembly, turn
knob counter clockwise.
CORRECT
NOT ENOUGH
TOO MUCH
SIDE VIEW OF SQUEEGEE BLADE
FLX3 980087 04/01/03
MAINTENANCE
4-6
TO REMOVE SQUEEGEE ASSEMBLY
1. With the squeegee in the up position, turn off the
key switch and set the parking brake.
2. To remove squeegee tool to work on bench,
raise the recovery tank and raise the support
arm to lock in place.
FOR SAFETY: Before leaving or servicing
machine; stop on level surface, turn off machine
and remove key.
3. Disconnect vacuum hose and loosen the two
squeegee retaining knobs.
4. Pull squeegee assembly rearward from the
lifting carrier.
5. With squeegee assembly on bench inspect or
repair as necessary.
6. To reinstall, align squeegee assembly to lift
carrier. Push forward until squeegee is fully
engaged.
7. Tighten knobs.
8. Attach vacuum hose.
TO REPLACE OR ROTATE REAR
SQUEEGEE BLADES
1. With the squeegee in the up position, turn off the
key switch and set the parking brake.
SQUEEGEE ASSEMBLY
SQUEEGEE
ASSEMBLY
CARRIER
REAR VIEW
TO REPLACE OR ROTATE FRONT
SQUEEGEE BLADES
1. With squeegee assembly on bench, loosen
retaining bolt and locking nut on the left side of
the retaining strap.
2. Remove front retainer strap.
3. Remove squeegee blade from locating pins on
squeegee tool and rotate to new position or
replace as required.
4. Install blade on locating pins of squeegee tool.
5. Replace front retainer strap.
6. Secure strap by tightening retaining bolt and
locking nut on retainer strap.
NOTE: Changing of squeegee blades does not
always necessitate a readjustment. Refer to section
on adjusting squeegee.
FOR SAFETY: Before leaving or servicing
machine; stop on level surface, turn off machine
and remove key.
2. Unlock and pull open latch on rear of squeegee
tool.
3. Remove blade retainer straps from squeegee
tool.
4. Remove squeegee blade from locating pins on
squeegee tool and rotate to new position or
replace as required.
5. Install blade on locating pins of squeegee tool.
6. Install squeegee retainer straps.
7. Fasten and lock latch. Latch is adjustable.
Adjust latch only tight enough to take up slack in
retaining strap.
NOTE: Changing of squeegee blades does not
always necessitate a readjustment. Refer to section
on adjusting squeegee.
FLX3 980087 04/01/03
MAINTENANCE
4-7
3. SCRUB HEAD-DISK
The scrub head consists of two rotary type scrub
brushes, drive motors, and splash skits. The
operator can select one of five different down
pressures on the touch control panel. Adjustments
are made automatically by the machine when floor
conditions change. There are no mechanical
adjustments to be made by the operator. The drive
hub allows brushes to follow irregularities and
changes in floor without losing contact with floor.
SCRUB BRUSHES
There are four different types of brushes available to
cover applications from cleaning heavily soiled floors
to polishing. A pad driver is also available to take
advantage of the many cleaning pads on the market
and further add to the flexibility of the machine.
Please refer to the following to assist in selecting the
proper brush or pad for the work at hand.
UNCOATED FLOORS
Aggressive Grit is a nylon fiber impregnated with
silicone carbide grit. It grinds away stain, soil, and
removes surface material.
Mild Grit is a less aggressive silicone carbide grit
suitable for cleaning medium soil conditions.
Advantages are faster ground speed than nylon
bristles on light solid applications.
Nylon is a general-purpose scrub brush with stiff
bristles.
FINISHED FLOORS
Nylon bristles are used in a variety of applications
on coated or uncoated surfaces.
Polypropylene bristles work on a variety of floor
surfaces. Does not soften in water
Blue Pads (Scrubbing) are used for heavy-duty
scrubbing and light stripping. The blue pads remove
less finish than brown stripping pads, yet will remove
black marks, stains and dirt.
Brown Pads (Stripping) are used for easy and
complete removal of old floor waxes/finishes. They
will quickly remove ground in dirt, black heel marks,
and spills. When used with the proper stripper, this
pad leaves the floor clean and ready for finishing.
REPLACING OR INSTALLING SCRUB
BRUSHES
The scrub brushes should be checked before each
day’s work for wire, string, wear, or damage. The
scrub brushes should be replaced if brush bristles
are missing or if shorter than 5/8 inch.
NOTE: For uniform scrubbing, scrub brushes must
be replaced as a set.
1. With the scrub deck up, turn off the machine and
set the parking brake.
2. Locate release lever on top of brush or pad
driver. With finger rotate release lever against
spring pressure counter clockwise. Brush/pad
driver will release and drop down.
3. To reinstall, center the cut out of the release
lever plate on brush/pad driver to be installed
under the brush drive hub.
4. Raise brush/pad drive up until assembly
contacts brush hub. Rotate slightly until drive
engages release lever plate.
5. While holding upward pressure, rotate brush/pad
driver assembly clockwise. When fully engaged,
release lever plate will rotate under spring
pressure to lock assembly.
NOTE: Check that release plate is completely closed
and pad/brush is securely attached. Damage to
driver or brush could occur.
White Pads (Polishing) are used for dry polishing to
achieve a high-gloss appearance, or surface
washing on highly polished or burnished floors.
Red Pads (Buffing) are used for light-duty
scrubbing. When used with a mild detergent they
will provide surface cleaning without removing the
finish.
6. Repeat the procedure for the opposite side of
the machine.
FLX3 980087 04/01/03
MAINTENANCE
4-8
SCRUB HEAD-CYLINDRICAL
The dual cylindrical scrub head is designed to
eliminate debris that may be caught in the squeegee
while scrubbing. Water is applied to the first
scrubbing brush turning in a clockwise rotation when
viewed from the right or operator’s side of machine.
The first brush scrubs dirt and debris between the
brushes. The second scrubbing brush, turning in a
counter clockwise rotation, picks up debris and
throws it into a removable hopper. The larger debris
which might catch under the squeegee is collected
in the hopper. Water is allowed to drain out the
hopper into the squeegee path where it is recovered
from the floor. The automatic operating procedure is
the same as the disc machine.
MAINTENANCE
The brushes should wear evenly side to side if
properly adjusted. Scrub brushes should be
exchanged front to back every 50 hours to ensure
even wear since the rear brush contacts the floor
with more force. It is not necessary to rotate end for
end since swapping front to back puts the brushes in
the opposite rotation, as well as balancing wear.
Scrub brushes should be replaced as a set when
bristle length wears to height of yellow
PerformAlertTM bristles.
SCRUB BRUSH REPLACEMENT
1. Observe location of drive hub lugs. It is usually
easier to position the lugs to the 12 o’clock-6
o’clock position (vertical) or 9 o’clock-3 o’clock
position (horizontal).
2. Orient brush notches to match the position of the
drive hub lugs and slide onto hub. It may be
necessary to lift the drive side of the brush.
3. Push brush until a positive stop is felt. The idler
plate cannot be installed until the brush is fully
sealed on the drive hub.
4. Allow brush to drop below scrub deck. Line up
lugs on idler plate with notched in brush and fully
insert plate onto brush.
5. Line up hook on idler door with notches on side
of scrub head.
6. Slide idler door up until lip rests on top of scrub
head.
7. Latch door into position.
SCRUB BRUSH REMOVAL
The scrub brushes are removed from the side of the
machine. The front is removed front the right side
and the rear is removed from the left side.
1. Unlatch idler side door.
2. Pull out on top of door until lip on door clears
brush head.
3. Push down on door until hooks on door are free
of scrub head side.
4. Pull out on door with a rocking motion to free
idler door from end of brush.
5. Pull brush out with a rocking motion to free
brush from drive hub.
FLX3 980087 04/01/03
MAINTENANCE
4-9
DUMPING HOPPER
The removable hopper is located behind the rear
scrub brush. If the hopper becomes full, it will not
accept any more debris. Remove the hopper by
sliding it out from the operator’s side of the machine.
The hopper can then be dumped from the top or the
left side door can be removed to dump debris from
the end. The side door is also convenient for
flushing the hopper clean with running water.
BELT REPLACEMENT
1. Remove scrub brushes.
2. Remove four bolts securing broom drive seal
and retainer.
3. Slacken belt tension by means of jack bolt under
motor.
4. The drive hub may be unscrewed from the
inside. Flats are provided on interior drive pulley
axle to facilitate removal.
5. Place belt on motor pulley then pull down into
scrub head.
6. Insert drive hub from inside of scrub head and
through lower loop of belt.
7. Screw axle into side of scrub head.
8. Re-tension belt to deflect 1/8” at center of span
when a pressure of 4 pounds is applied.
9. Install broom drive seal and retainer.
10. Install scrub brushes.
SCRUB DECK ADJUSTMENT
Scrub deck adjustment consists of two types of
adjustments. The first is to insure the individual
brushes make the same width pattern end to end.
Any tapered brush pattern should be adjusted out.
The second is to make the pattern of equal width
between front and rear brushes. Unequal patterns
are caused by the scrub deck not being parallel to
the floor. Proper adjustment is obtained when the
contact patterns of the brushed on the floor show
two 1” rectangles the width of the brushed. The
rectangles should be parallel to each other.
TESTING, ADJUSTMENT OF INDIVIDUAL
BRUSHES
1. Move the machine to an unfinished area of floor
to avoid marking finish.
2. With water valve off, lock brakes, and lower
scrub head to floor. Allow brushes to run until
automatic shut off occurs. It may be necessary
to repeat this step in the same location until a
good mark can be seen on the floor. This can be
accomplished by touching lightly the directional
pedal to restart the scrub deck without moving
the machine.
3. Raise the scrub deck and note the brush
patterns on the floor. There should be two
rectangles with parallel sides. If the pattern is
tapered, proceed as follows.
ADJUSTMENT OF INDIVIDUAL
BRUSHES
The brush pattern is adjusted front he idler side only.
The idler shaft is locked into position by means of an
allen head screw on the idler door. The shaft is
secured in an eccentric position. With the screw
loose the shaft may be rotated by means of the flats
machined on the interior side of the shaft to achieve
different heights.
1. Determine if idler is to be moved up or down to
balance the pattern.
2. Remove idler door on brush to be balanced.
3. Measure distance of axle from top of door and
record.
4. Loosen allen head screw from outside door.
5. Rotate shaft to new position. Hold shaft in
position.
6. Tighten allen head screw.
7. Install door on machine.
8. Re-start and readjust as necessary.
LEVELING THE SCRUB HEAD
Leveling the cylindrical head is accomplished by a
single bolt and lock nuts located in the adjustment
channel at rear, center of the scrub deck. To
increase pattern width on rear brush, loosen lock
nuts on socket head cap screw and adjust screw
cap down. To increase pattern width on front brush,
adjust screw up. After adjustment, be sure to tighten
lock nuts.
FLX3 980087 04/01/03
MAINTENANCE
4-10
4. DIFFERENTIAL DRIVE CHAIN
The differential drive chain transfers power from the
drive motor to the differential. Check the chain
condition every 200 hours of operation. A tight chain
causes wear on bearings, chain, and increased
power consumption. A worn chain causes wear on
the sprocket.
ADJUSTING DIFFERENTIAL DRIVE
CHAIN
FOR SAFETY: Before leaving or servicing
machine: Stop on level surface, set parking
brake, turn off machine and remove key.
1. From underneath the rear of machine loosen the
two motor mounting bolts. Do no remove bolts.
For ease of service, bolts screw into nut plates.
It is not necessary to use a backup wrench.
2. There are two nuts on the threaded rod attached
to the motor position bracket. Loosen the nuts.
3. Tighten the nut in front of frame cross member
to increase chain tension. Screw the nut to the
rear of frame away from the motor to decrease
chain tension. On the slack side, chain should
deflect between 1/2” and 3/4” measured
midway between the center lines of the
sprockets.
4. Tighten nuts against each other to fix
adjustment.
5. Tighten motor mounting bolts.
DRIVE WHEEL CHAIN
The drive wheel chains transfer power from the
differential shaft to the drive wheels. Check chain
condition and tension every 200 hours of operation.
The chain should deflect 1/2 in (13 cm) on the side
opposite the idler. Lubrication of drive chain is not
recommended. Clean dirt and grease build up from
chain to eliminate the abrasive effects.
ADJUSTING THE DRIVE WHEEL CHAINS
1. Turn off machine with key switch and set parking
brake.
FOR SAFETY: Before leaving or servicing
machine; Stop on level surface, set parking
brake, turn off machine and remove key.
2. Loosen the two bolts on the chain tension plate.
3. Slide the plate to adjust tension.
4. Tighten chain tensioner mounting bolts.
FLX3 980087 04/01/03
MAINTENANCE
4-11
float switch is activated.
5. BRAKES
The brake pedal and the parking brake operate the
two self-centering rear axle disc brakes. With the
parking brake set, the brakes should hold machine
from moving with full throttle in either forward or
reverse. This brake check should be performed in
the pre-run check before each days operation. The
disc and calipers should be inspected every 200
hours of operation for cracks and disc wear. The
disc brakes should be adjusted so that the disc pads
are as close to the disc as possible, without causing
brakes to drag.
FOR SAFETY: Before leaving or servicing
machine; Stop on level surface, set parking
brake, turn off machine and remove key.
1. Remove batteries from machine. (Refer to
section on BATTERY REMOVAL).
2. Jack up rear of machine and support on jack
stands. (Refer to section on JACKING
MACHINE).
3. Once machine is secure on jack stands, release
parking brake.
4. Locate the brake adjustment screw on each
brake caliper.
5. Loosen the lock nut and turn the adjusting screw
to adjust each brake so pad just contacts brake
disc. Repeat on opposite side. Adjust both
sides for equal contact. Arms should be in same
position relative to each other.
6. Lower machine and reinstall batteries.
7. SOLUTION STRAINERS
The solution strainers are located behind each front
wheel of the FlexCat3. The solution strainers protect
the solenoid valve from debris. If there is little or no
solution flow to the ground, check the strainers for
debris. Drain the solution tank and clean the solution
strainers. To remove the strainer, turn the bottom
part of the strainer counterclockwise until the bottom
is separated. Clean out the debris from the wire
mesh and re-assemble. Make sure the O-ring gasket
is in place when re-assembled.
8. FLOAT SWITCH
The float switch is located inside the recovery tank.
The purpose of the float switch is to notify the user
that the recovery tank is full. When the float switch is
activated, the scrub brush motors and solution flow
will stop, the scrub deck will raise, the squeegee will
rise after 60 seconds, and the vacuum motor will
turn off 10 seconds later.
Icon appears on information screen 1 when
6. TIRES AND WHEELS
Inspect tires for proper inflation, cuts and abrasions.
Tires should be inflated to 60 psi (4 bars) front and
rear (pneumatic tires only).
Check lug nuts for tightness. Lug nuts should be
tightened to 80 foot-pounds (11 kg-meters). Wheels
should be checked for cracked or bent rims.
FLX3 980087 04/01/03
MAINTENANCE
Important:
If armature
commutator is not concentric, extremely
Vac Motor Carbon Brushes Replacement
9. VACUUM MOTORS
! WARNING
Do not use a pressure washer to clean around
the vacuum motors. Use tap pressure only. Care
must be taken so that water is not directed into
vacuum motor air intakes.
CHANGING VACUUM MOTORS
1. Remove two well-nuts from vacuum cover on
each side. Slide vacuum cover off.
2. Remove three well-nuts holding vacuum motor
on each side. Remove vacuum motor.
3. Disconnect vacuum motors at quick disconnect.
Reverse steps to install.
VACUUM MOTOR CARBON BRUSH
REPLACEMENT
End Cap
Carbon Brushes
pitted, or grooved the motor will need to be replaced
or sent to a qualified service center to restore vac
performance.
Note:
Place
stop in
groove.
These brushes wear quicker as the length shortens
due to increased heat.
Spring inside brush housing will damage motor if
brushes are allowed to wear away completely.
3/8
Periodically check the length of the carbon brushes.
Replace both carbon brushes when either is less
than 3/8" long.
FLX3 980087 04/01/03
4-12
MAINTENANCE
4-13
10. BRUSH MOTORS
! WARNING
Do not use a pressure washer to clean around
the brush motors. Use tap pressure only.
CHANGING BRUSH MOTORS
1. Remove front bumper.
2. With the scrub deck in the stored position,
disconnect brush motor wiring connector from
harness.
3. Remove retaining bolt, lock washer, flat washer
and star drive from brush motor shaft.
4. Remove 4 brush motor mounting bolts located
under scrub deck.
5. Remove brush motor. If needed, lower scrub
deck for more clearance.
6. Reverse steps to install.
BRUSH MOTOR CARBON BRUSH
REPLACEMENT
1. Scribe alignment marks on motor barrel to motor
cap and motor barrel to motor frame.
2. Remove end cap from motor.
NOTE: Motors contain two wave washers in
cap. Do not lose these.
3. Release brush from spring tension. Remove
screw connecting brush wire lead to brush
holder. Clean brush holder to insure free
movement.
4. Install new brush and reinstall connecting screw
and lead.
5. When all new brushes are installed. Place all in
retracted position, held into brush holder by
spring tension.
6. Carefully place end cap onto bearing on motor
shaft.
NOTE: On motors use care to assure wave
washer alignment.
7. With end cap in partially installed position,
release all brushes to contact position with
motor commutator.
NOTE: Failure to insure all brushes are released
will result in motor failure.
8. Reset end cap and realign with scribe marks on
motor barrel.
9. Maintain alignment between motor barrel base
and cap, and between motor barrel and motor
frame. Reinstall the two attach bolts from cap
into base
FLX3 980087 04/01/03
4-14
11. FUSE
The fuse is a one-time circuit protection device
designed to stop the flow of electrical current in
the event of an electrical overload. If fuse is
blown, it must be replaced.
The fuse is located inside the electrical
compartment, under the seat.
12. CIRCUIT BREAKERS
Interrupt the flow of power in the event of an
electrical overload. When a circuit breaker is
tripped, reset it by pressing the exposed button.
If a circuit breaker continues to trip, the cause of
the electrical overload should be found and
corrected.
30 Amp
Protects the left scrub brush motor.
30 Amp
Protects the right scrub brush motor.
2 Amp. Protects the scrub deck
actuator.
MAINTENANCE
2 Amp. Protects the squeegee
lift actuator.
FLX3 980087 04/01/03
TRANSPORTING MACHINE
4-15
TOWING OR PUSHING MACHINE
The machine may be towed for short distances at
speeds not to exceed 5 m.p.h.. Be careful to avoid
damaging machine. Attach towing device at tiedown points. The machine may be pushed by hand
from the rear of recovery tank.
MACHINE TIE-DOWNS
There are four tie-down points located at the corners
of the machine. The front tie downs are 1 1/2-inch
(3.8 cm) diameter holes in the frame on each side.
The rear tie-downs are on the tank support bracket
on either side of the machine at the rear. Tie-downs
must be of proper type and strength. The combined
strength of all tie-downs must be strong enough to
lift two times the weight of the machine. Tie-downs
must be positioned to prevent the machine from
moving forward, backward, or to either side. Use all
four corners of the machine with the tie-downs
running out opposite directions. Tie-downs must be
attached to the transporting vehicle securely.
PREPARATION FOR TRANSPORTING
1. Remove squeegee tool to eliminate interference
with tie-downs.
2. Scrub head must be in the up position before
loading.
NOTE: When transporting the machine on a trailer or
in a truck, in addition to using tie-downs, be sure to
set the parking brake and block tires to prevent the
machine from rolling.
TIE DOWN
TIE DOWN
TIE DOWN
TIE DOWN
TIE DOWN
JACK POINT
TIE DOWN
JACKPOINT
FLX3 980087 04/01/03
TIE DOWN
JACKPOINT
JACKING MACHINE
4-16
MACHINE JACKING
The machine may be jacked up for service or
inspection by using the specified jack locations.
Always block the tires when jacking up the machine.
FOR SAFETY: Before leaving machine or
servicing machine; stop on a level surface, set
parking brake, turn off machine and remove key.
The rear jack points are the tank support brackets
just ahead of the rear squeegee. Remove the
squeegee tool before jacking.
NOTE: See SQUEEGEE TOOL REMOVAL in the
Maintenance Section.
TO JACK UP MACHINE
1. Empty the recovery and solution tank.
2. Turn the key switch off and set the parking
brake.
FOR SAFETY: Before leaving or servicing
machine; stop on level surface, set parking
brake, turn off machine and remove key.
3. Block the tires that are not being raised to
prevent the machine from rolling.
MACHINE STORAGE
If the machine is to be stored for extended periods of
time, the following steps must be taken to minimize
the chance of corrosion or deposits forming.
1. Drain both solution and recovery tank. Clean
soil and chemical build up from tanks. Flush with
clean water including the solution delivery
system. Leave solution tank lid and recovery
cover open.
2. Raise the rear squeegee assembly and the
scrub deck.
3. Remove brushes and rinse with clean water.
Dry thoroughly.
4. Wash squeegee blades with clean water.
5. Park the machine in a cool dry area.
6. Check the charge level on the batteries monthly.
Recharge when batteries drop below 25%
charge. If suitable space exist to store batteries,
remove from machine.
7. Perform next lubrication interval.
FOR SAFETY: When servicing machine, block
machine tires before raising machine.
4. Using a jack or adequate capacity, raise the
machine using the designated jack points.
FOR SAFETY: When serving machine, use hoist
or jack of adequate capacity, jack machine at
designated jack locations only. Block machine
with jack stands when raised.
5. When machine is raised, use jack stands at the
designated jack locations.
FOR SAFETY: Block machine at designated jack
locations with jack stands when raised
6. Slowly lower the machine onto the jack stands.
7. Be sure that the machine is secure.
8. Service or inspect the machine as required.
9. When finished working on the machine, raise the
machine off the jack stands.
10. Remove the jack stands.
11. Lower the machine to the floor. Block wheels as
they are lowered.
12. Remove wheel block after machine has been
completely lowered.
FLX3 980087 04/01/03
MAINTENANCE
4-17
SERVICE SCHEDULE
MAINTENANCE BEFORE EACH
WORK PERIOD
Check water level of batteries after charging;
add distilled water if necessary
Check that recovery tank cover seals tightly
Visually check for damaged or worn tires *
Check brushes or pads for proper installation
Check vacuum hose connections
Check that squeegee is securely attached
and properly adjusted
Check for securely attached drain hose, plug
and caps
Check brakes and steering for proper
operation
Clean out solution tank *
Run vacuum motors to dry
Clean brushes or pads and check wear *
Clean squeegee blades and check wear
Clean out recovery tank and vacuum filter *
Clean and inspect float shutoff
Clean outside of tanks, check for damage *
Store with covers off tanks
Charge batteries *
Check steering cables for wear.
Clean off top of batteries *
Check battery cells with hydrometer
Inspect scrub deck skirts *
Clean solution strainers
Check battery connections are tight *
Clean battery cases and battery
compartment
Check parking brake adjustment *
Check brakes discs and calipers for damage
or wear
Clean pivot points on squeegee and scrub
deck
Check all motors for carbon brush wear
Check motor commutators *
*
*
*
*
*
*
*
AFTER EACH
WORK PERIOD50HRS
*
*
*
*
*
*
*
100
HRS
*
200
HRS
*
*
*
NOTE: Traction drive, wheels and batteries should be serviced based on traction drive hour meter. The
scrub brush hour meter should be used for all other service schedule items.
FLX3 980087 04/01/03
MACHINE TROUBLESHOOTING
PROBLEM CAUSE
No power to machine
Little or no propel
Reverse speed only
Poor or no water pick-up
Squeegee will not go up/down
Battery disconnected Check connections of all battery
Emergency shut-off
activated
Battery cables corroded Clean connections
Main fuse blown Replace fuse
Faulty key switch Replace switch
Low battery charge Charge batteries
Machine turned on with
pedal not in neutral position
Controller overheated 7802/7801 Allow cool down period
Loose motor connection 7800 Check wires and connections
Loose throttle connections or
faulty throttle potentiometer
Loose seat switch
connection or faulty seat
switch
Faulty throttle Check throttleForward speed only
Faulty throttle Check throttle
Squeegee out of adjustment Adjust squeegee
Debris caught on squeegee Remove debris
Worn squeegee blades Rotate or replace squeegee
Vacuum hose clogged Clear obstruction from hose
Vacuum hose disconnected
from squeegee or recovery
tank
Vacuum hose damaged Replace hose
Vacuum motor inlet filter
dirty
Recovery tank not sealed Replace damaged seals
Foam filling recovery tank Empty recovery tank use less or
Circuit breaker tripped Reset breaker
Loose connection Check wires and connections
Faulty actuator Repair/replace actuator
ERROR
CODE
0814 Check wires and connections
SOLUTION
cable connections
Reset
Allow pedal to return to neutral
Restart.
from controller to motor
from throttle to LCD and
potentiometer resistance
Check connections and switch
continuity
blades
Reconnect vacuum hose
Clean or replace inlet filter
different detergent
Use defoamer
from controller to actuator
FLX3 980087 04/01/03
4-18
MACHINE TROUBLESHOOTING
PROBLEM CAUSE ERROR
CODE
Vacuum motors do not run, or
run slowly
Poor scrubbing performance Debris caught in scrub
Little or no solution flow to the
floor
Brush motors do not run, or
run slowly
Recovery tank full Drain recovery tank
Recovery tank float
switch dirty
Loose motor connection 7700 Check motor wires and
Worn vacuum motor
brushes
brushes
Worn brushes or pads Replace brushes or pads
Improper detergent,
brush or pad used
Low scrub brush down
pressure
Low battery charge Charge batteries
Solution tank empty Fill solution tank
Solution flow turned off
or set too low
Solution strainers
plugged
Solution system
plumbing obstructed
Solution solenoid valve
obstructed or stuck
Vent hole in solution
tank lid obstructed
Faulty solenoid valve
connection
Circuit breaker(s) tripped 7600 Reset circuit breaker(s)
Low battery charge Charge battery
SOLUTION
Clean float switch
connections
Replace brushes, check
commutator
Remove debris
Contact equipment or
application specialists
Increase brush pressure
Turn on or increase flow
setting
Clean solution strainers
Clear obstruction from
plumbing
Clean or replace valve
Clear obstruction from vent
hole
Check wiring to solution valve
Scrub deck will not go
down/up
Scrub deck goes down, then
raises
Error code not listed is
displayed
4-19
Loose connection 7600 Check motor wires and
connection
Worn brush motor
brushes
Actuator circuit breaker
tripped
Loose connection 9000 Check motor wires and
Faulty actuator 9000 Repair/replace actuator
No brushes or pad
drivers on machine
Controller detects
electrical problem
9000 Reset breaker
9000 Install brushes or pad drivers
Replace brushes, check
commutator
connections
Contact service technician
FLX3 980087 04/01/03
MACHINE TROUBLESHOOTING - CONTROLLER FAULT CODES
ERROR
CODE
None LCD display on, but incomplete Disconnect batteries and wait 1
0A01 Power down error Disconnect batteries and wait 1
0204 Memory corrupt Replace controller.
All 080_
codes
All 140 _
Codes
All 310_
Codes
7500 LCD module communications timeout Wiring fault on 6-way serial link
7501 LCD module settings corrupt Disconnect batteries and wait 1
All 760_
Codes
All 770_
Codes
7800 Traction motor open circuit fault Check for open circuit on propel
7801 Traction motor overcurrent error Check for short circuit on propel
7802 Traction motor in power foldback state Propel motor current has
All 790_
Codes
9000 Brush current requirement not satisfied Check that brushes or pads are
PROBLEM SOLUTION
minute before re-applying power.
minute before re-applying power.
Throttle wiring Check for short or open circuits in
throttle wiring.
Check for short circuit between
B+ and traction output.
Possible short circuit of motors, auxiliary outputs
(headlight, recycle pump, or back-up alarm),
wiring or damaged controller
Brush motor or brush circuit fault Check for short or open circuits in
Vacuum motor or vacuum circuit fault Check for short or open circuits in
Emergency stop error E-stop input active or wiring fault.
Check for short circuits. If code is
present after short circuits are
repaired, replace controller.
between controller and display.
minute before re-applying power.
brush motors or wiring.
vacuum motor(s) or wiring.
motor or wiring.
motor or wiring.
exceeded current limit for the
foldback time.
installed. Check for open circuit
in scrub lift actuator, circuit
breaker or wiring.
FLX3 980087 04/01/03
4-20
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