WORKSHOP HANDBOOK MXR

Transcription

1 WORKSHOP HANDBOOK MXR Version: AA Date: January 15, 2014 Document Number: /ATE

2 Contents I Product Introduction 4 1 Serial Number and Technical Support The Serial Tag Serial Tag location Main Technical Features 6 II Anomalies Resolution Guide 8 3 Trouble-shooting for the most common anomalies Electrical system: what to do if Mechanical scrubbing system: what to do if Drying system: what to do if Frame and traction system: what to do if Solution delivery system: what to do if Disassembling Procedures Electrical Installation Mechanical Friction System Drying System Frame and Traction System Solution Delivery System III Machine Description 30 5 Electrical System Structure Description Location of Electrical components Adjustments Maintenance and Checks Alarm Table Menu tables Technical Features Recommended Spare Parts

3 6 Mechanical Rubbing System Structure Description: Adjustments Maintenance and checks Technical Features Consumable Spare Parts Recommended Spare parts Drying System Structure Description Adjustments Maintenance and Checks Technical Features Consumable Spare Parts Recommended Spare Parts Machine Frame and Traction System Structure Description Adjustments Maintenance and Checks Technical Features Consumable spare parts Suggested spare parts Cleaning Solution Supply System Structure Description: Maintenance and Checks Technical Features Recommended Spare parts IV Accessories and Add-On Accessories Accessories List Blinking Kit Onboard Charger Kit Splashguard Kit Cleaning Accessories Kit Consumable Spare Parts

4 Part I Product Introduction 4

5 1-5 Chapter 1 Serial Number and Technical Support 1.1 The Serial Tag 1.2 Serial Tag location To have access to the Serial Tag is necessary to open the glove box on the steering column. The Serial Number is an extremely important information which has to be provided each time a Technical Support is required or is necessary to buy spare parts or accessories. The serial number is the only way to identify the machine by model, production date type equipments in general. 5

6 2-6 Chapter 2 Main Technical Features Technical Data TECHNICAL DESCRIPTION U/M Mxr Maximum Ramp Gradient % 8 Steering Diameter mm 3680 Machine Length mm 1265 Machine length with optional storage compartment mm 1400 Machine Height mm 1030 Machine height with optional blinking kit mm 1070 Machine Width (without squeegee) mm 600 Machine Width (without squeegee) with optional toolbox kit mm 620 Wheel Base mm 730 Wheel Track mm 520 Footrest height from the ground mm 230 Seat height from the footrest mm 466 Handlebar distance from the back seat mm 530 6

7 Weigths and Pressures 1 TECHNICAL DESCRIPTION U/M Mxr Machine Weight (empty and without batteries) kg Gross Weight of the machine in work conditions (machine + batteries + water + operator) kg Weight front wheel kg Front wheel touching surface cm kg Front wheel pressure cm 2 Weight rear right wheel kg Rear right wheel touching surface cm kg Rear right wheel pressure cm 2 Weight rear left wheel kg Rear left wheel touching surface cm Rear left wheel pressure kg cm Weight and Pressures depends on how much water there is in the tanks and on what type of battery the machine fits.

8 2-8 Part II Anomalies Resolution Guide 8

9 3-9 Chapter 3 Trouble-shooting for the most common anomalies 3.1 Electrical system: what to do if... The machine doesn t switch on 1 The emergency button is pressed Release the emergency button. 2 The key is in position 0 Rotate the key in position I. 3 The key switch is not properly connected Restore the proper connections. 4 The key switch doesn t work Replace the key switch (see section at page 18). 9

10 3-10 The batteries don t work properly 1 The batteries are not properly connected Restore the proper battery connections. 2 The batteries are discharged Perform a complete charge cycle. 3 Battery terminal are oxidized Disconnect the batteries, clean the batteries terminals and reconnect properly the batteries. 4 With the machine in working conditions one battery has a voltage lower (difference higher than 2 V) than the other ones 5 The fuse on the loop wire is damaged Replace the battery with lower voltage. Check for possible short circuits, If not present replace the loop wire. 6 The power wires are damaged Replace the damaged wires. 7 The battery charger is not properly adjusted Adjust properly the battery charger. 8 The battery charger doesn t work Check the proper section (see section 3.1 at page 10). The battery charger doesn t work 1 The battery charger is not connected to the power supply 2 The battery charger is not connected to the batteries 3 The battery charger has one or more lights (or LEDs) blinking continuously 4 The battery charger is properly connected but it doesn t switch on Connect the charger to a supplied electric socket. Connect the charger to the batteries. The battery charger is in error conditions, verify the alarm tables and solve the issue by following the related instructions (see section at page 40). Replace the battery charger.

11 The display shows an alarm message 1 The display shows an alarm message Check what alarm message is shown and solve the related issue by following the proper instructions (see section at page 44) The machine has a very limited working autonomy 1 The batteries connections are oxidized 2 When the machine is working a battery voltage is lower and lower than the other batteries (The difference is bigger than 2V) 3 The battery charger is not properly adjusted 4 The BDI (Battery Discharge Indicator) is not properly adjusted 5 Batteries have been working for several cycles Unplug the connection wires, wash the wire connections with water and reconnect them protecting them with grease. Replace the battery with the lower voltage. Verify the type of battery in use and adjust the battery charger properly following the instructions (see section at page 41). Verify the type of battery used on the machine and adjust properly the BDI. Replace the batteries.

12 3.2 Mechanical scrubbing system: what to do if The machine doesn t clean well 1 The machine is switched off Switch on the machine. 2 The machine doesn t switch on Refer to the proper section (see section 3.1 at page 9). 3 The machine is not in working condition 4 The display shows an alarm message Switch on the machine. Lower the scrubbing base. Press the traction pedal. Check what alarm message is shown and solve the related issue by following the proper instructions (see section at page 44). 5 The brush rotates in opposite way Check the motor connections. 6 The brush deck motor is not supplied 7 The microswitch of the scrubbing base lifting lever doesn t work 8 The microswitch of the traction pedal doesn t work Verify the motor connections. Replace the microswitch (see section at page 19). Replace the microswitch (see section at page 19). 9 The brush is not properly engaged Release and engage properly the brush. 10) The solution flow rate is not correct or not enough Refer to the proper section. The brush deck doesn t move 1 The brush deck Lever doesn t move Check that there are no mechanical obstacles to the movement of the lever. 2 The lever moves but the brush deck doesn t move 3 The brush deck is lowered but it doesn t touch the ground Check that the lifting cable runs in its sheath and the chain is free to move. Check that the brush deck lifting arms are free to move. Check the settings of the lifting cable.

13 3.3 Drying system: what to do if... The machine doesn t dry well 1 The machine is switched off Switch on the machine The machine doesn t switch on Refer to the proper section (see section 3.1 at page 9). 3 The squeegee is lifted up from the floor 4 The squeegee rubber blades are worn out or broken Lower down the squeegee. Rotate or replace the squeegee rubber blades. 5 The recovery tank is full Empty the recovery tank following the proper procedure. 6 The squeegee is not properly adjusted 7 The squeegee vacuum chamber is stuck or dirty 8 The squeegee adapter is stuck or dirty 9 The vacuum hose is stuck or broken 10 The vacuum hose is not properly fitted in Adjust the squeegee properly following the proper procedure (see section at page 58). Clean the squeegee vacuum chamber. Clean the squeegee adapter. Clean or replace the vacuum hose. Connect the vacuum hose properly. 11 The vacuum filter is dirty or stuck Disassemble and clean the vacuum filter. 12 The vacuum cover is not well positioned or is missing 13 The vacuum cover gasket doesn t adhere properly Position properly the vacuum cover. Replace the vacuum cover gasket.

14 3-14 The vacuum motor doesn t work properly 1 The vacuum motor is switched off Switch on the vacuum motor. 2 The vacuum motor is not powered properly 3 The microswitch on the squeegee lifting lever doesn t work 4 The display shows an alarm message 5 The vacuum motor carbon brushes are worn out 6 The vacuum motor is supplied but it doesn t work Check the power connections on the vacuum motor. Replace the microswitch. Check what alarm message is shown and solve the related issue by following the proper instructions (see section at page 44). Replace the vacuum motor carbon brushes. Replace the vacuum motor. The squeegee doesn t move 1 The squeegee Lever doesn t move Check that there are no mechanical obstacles to the movement of the lever. 2 The lever moves but the squeegee doesn t move 3 The squeegee is lowered but it doesn t touch the ground Check that the lifting cable runs in its sheath and the chain and the rear lever is free to move. Check the settings of the lifting cable.

15 3.4 Frame and traction system: what to do if... The traction motor doesn t work properly 1 The machine is switched off Switch on the machine The machine doesn t switch on Check the proper section (see section 3.1 at page 9). 3 The batteries are discharged Connect the battery charger and perform a complete charge cycle. 4 The operator is not sitting on the seat The operator must sit on the seat. 5 The operator is sitting on the seat Check and / or replace the deadman seat microswitch. 6 The pedal is not pressed Press the pedal depending on the required speed. 7 The pedal is pressed Check and / or replace the potentiometer or the microswitch inside the pedal. 8 The display shows an alarm message 9 The brush deck motor is not supplied Check what alarm message is shown and solve the related issue by following the proper instructions (see section at page 44). Verify the motor connections. 10 The electrobrake doesn t disengage Check the connections of the electrobrake.

16 3.5 Solution delivery system: what to do if The delivered solution is not correct or not enough 1 The machine is switched off Switch on the machine. 2 The machine doesn t switch on Refer to the proper section (see section 3.1 at page 9). 3 The solution tank is empty Fill up the solution tank. 4 The proportional valve for the solution flow adjustment is completely closed 5 The hose that connects the solution tank to the filter is stuck Open the proportional valve to the desired position. Clean the hose. 6 The solution filter is stuck Clean the solution filter. 7 The brush deck is not in working conditions Lower the brush deck to the floor Press the traction pedal to start the washing. 8 The solenoid valve doesn t work Check the solenoid valve connections and, if necessary, replace it (see section at page 28). 9 The display shows an alarm message 10 The detergent doesn t fit the type of dirt Check what alarm message is shown and solve the related issue by following the proper instructions (see section at page 44). Replace the detergent with a proper one.

17 Chapter Disassembling Procedures WARNING: BEFORE TO PERFORM ANY OPERATION DESCRIBED BELOW VERIFY THAT THE MACHINE TANKS ARE COMPLETELY EMPTY, THE MACHINE HAS TO BE TURNED OFF. DISCONNECT THE BATTERIES AND REMOVE THEM FROM THE MACHINE. AT LAST, VERIFY THAT THE PARKING BRAKE IS ENGAGED AND THE MACHINE IS IN A TOTALLY SAFE CONDITION. 17

18 4.1 Electrical Installation Key Switch Put the machine in safe conditions. Unscrew the screws on the control card from the top part and remove the card (see fig ) Remove the screws that secure the front carter to the steering column (see fig ) (see fig ). Disconnect the wires connected to the key switch. Unscrew the ring nut that secures the key switch to the steering column (see fig ) Remove the key switch Main Card Put the machine in safe conditions Remove the screws to remove the footrest. Remove the screws to remove the electrical system cover (see fig ) Control Card Put the machine in safe conditions. Remove the screws that secure the upper and lower part of the steering wheel (see fig ). Separate the top part from the bottom part. Disconnect the communication cable between the Control card and the Main card. Disconnect the electrical wiring of the emergency button and of the Main card. Remove the screws that secure the card to the support bracket. Remove the card.

19 To remove the microswitch, unscrew the two screws and remove the device Traction Pedal Put the machine in safe conditions. Remove the screws to remove the footrest. Release the footswitch connector and unscrew the two screws holding the pre-assembly pedal. Remove the pedal Dead Man Switch (Seat microswitch) Put the machine in safe conditions. Unscrew the screws to remove the electrical system cover (see fig ). Unscrew the lower screws that fix the seat (see fig ). Unscrew the rear screws that fix the seat (see fig ). Remove the seat from the machine (see fig ). Remove the switch connecting joints. Remove the dead man Switch Microswitch Put the machine in safe conditions. Remove the screws that secure the front carter to the steering column. Disconnect the wires connected to the microswitch.

20 Brush Coupling Flange Put the machine in safe conditions. Disassemble the Brush Deck from the machine (see section at page 20). Unscrew the Coupling Flange rotating it in the same direction as the brush in standard working conditions. Proceed at reverse to refit the part. Note: Before to refit the part lubricate the thread in order to prevent blockings because of dirt or oxide. 4.2 Mechanical Friction System Brush Deck Assembly Release the brush from the Brush Deck. Put the machine in safe conditions. Make sure that the electrobrake is enabled. Lower the brush deck to the floor. Remove the lift arms from the frame. Disconnect the electrical connector of the brush motor and the electric connector of the solenoid valve. Disconnect the solution supply hose. Disconnect the lift chain from the brush plate. Lift the front wheel in order to lift the front part of the machine of about 20cm. Pull off the brush deck sideways to the machine Brush Motor Put the machine in safe conditions. Disassemble the Brush Deck from the machine (see section at page 20). Unscrew the Coupling Flange from the motor shaft (see section at page 20). Disconnect the electrical connector of the motor. Disconnect the water hose from the motor (see fig ). Unscrew the 4 fixing screws and remove the motor (see fig ). Proceed at reverse to refit the part. Note: Use the thread lock liquid on the screw during the assembling.

21 Bumper Wheel Release the Brush from the Brush deck. Put the machine in safe conditions. Make sure that the brush deck is in lifted position. Unscrew the top bushing of the wheel. Remove the wheel. Proceed at reverse to refit the part. Note: Use the thread lock liquid on the screw during the assembling Brush deck lifting arms Put the machine in safe conditions. Disassemble the Brush Deck from the machine (see section at page 20). Replace worn out bushings with new ones. Proceed at reverse to refit the part. Before fixing the lift arms, proceed to lubricate the bushings with grease Fixing and adjustment plate Put the machine in safe conditions. Disassemble the Brush Deck from the machine (see section at page 20). Disassemble the brush deck lifting arms. Remove the screw that secures the fixing and adjustment plate to the brush deck. Proceed at reverse to refit the part. Unscrew the screws that hold the lift arms from the brush deck (see fig ) (see fig ). Proceed at reverse to refit the part Brass Bushings Put the machine in safe conditions. Disassemble the brush deck lifting arms

22 Drying System Squeegee Put the machine in safe conditions. Unplug the Vacuum Hose (see fig ). Loose the knobs that block the Squeegee to the Squeegee Support (see fig ). Move the squeegee sideways to release it from the squeegee support (see fig ). Proceed at reverse to refit the part. Check the adjustment of the squeegee support. Loosen the screw that secures the squeegee coupling from the lower side of the squeegee support fulcrum and remove it (see fig ). Loosen the screw that secures the gas spring from squeegee coupling and remove it (see fig ). Loosen the screw that secures the chain to the squeegee rear lifting lever (see fig ). Remove the squeegee support. Proceed at reverse to refit the part Squeegee Support Squeegee Coupling Put the machine in safe conditions. Disassemble the Squeegee from the Machine. Squeegee Support Fulcrum Put the machine in safe conditions. Disassemble the squeegee coupling. Remove the batteries from the machine. Make sure that both tanks are completely empty. Remove the battery support from the machine (see fig ) Loosen the upper fixing screw of the squeegee support hub fulcrum (see fig ). Lay the machine on the left side.

23 Remove the screws that secure the reinforcing plate of the squeegee support fulcrum and remove it. together with, it will be also removed the squeegee support fulcrum hub (see fig ). Remove the squeegee support fulcrum rotating it properly (see fig ) Recovery Tank Make sure that the recovery tank is completely empty. Put the machine in safe conditions Vacuum Hose Put the machine in safe conditions. Unplug the Vacuum Hose from the Squeegee (see fig ). Uncouple the squeegee from the plastic clip (see fig ). Uncouple the Vacuum Hose from the Recovery tank Inlet (see fig ). Slip off the hose from its housing (see fig ). Proceed at reverse to refit the part. Remove the recovery tank lid. Remove the vacuum hose (see fig ). Unplug the charger cable - vacuum motor - blinking light. Cut the clamps that secure the cables to the solution tank. Loosen the screw that fix the safety cord of the tank (see fig ). Unscrew the screws holding the opening hinges to the recovery tank (see fig ). Proceed at reverse to refit the part.

24 Vacuum Motor Put the machine in safe conditions. Open the Recovery Tank. Disconnect the power cords of the Vacuum Motor. Cut the plastic clamp that secures the condensate drain hose to the recovery tank (see fig ). Loosen the screws and remove the vacuum motor cover (see fig ) Unscrew the nuts that secure the vacuum motor to the recovery tank (see fig ) Floater and Vacuum Filter Put the machine in safe conditions. Remove the Recovery Tank Lid. Unscrew the floating filter body. Remove the cap from the floating filter body. Remove the sponge suction filter. Proceed at reverse to refit the part. Pull out the vacuum motor and remove the sound absorbing sponges (see fig ). Loosen the screws to remove the motor fixing plate. Proceed at reverse to refit the part

25 4.3.7 Drain Hose Put the machine in safe conditions. Loosen the clamp that secures the drain hose to the recovery tank (see fig ). Unhook the hose from the plastic clip (see fig ). Remove the hose from its housing (see fig ). Proceed at reverse to refit the part. 4.4 Frame and Traction System Front Wheel Put the machine in safe conditions. Lift up the front wheel from the ground. Unscrew one of the fixing screws of the wheel shaft to the support. Remove the wheel securing shaft to the support. Proceed at reverse to refit the part Fase Fase Fase Rear Wheel Put the machine in safe conditions. Lift up the related rear wheel from the ground. Remove the hub cap by levering with a small flat screwdriver. Loosen the fixing bolt of the wheel to the axle shaft. Proceed at reverse to refit the wheel (Use the thread lock liquid on the screw during the assembling).

26 Loosen the screws that secure the lower support of the steering shaft (see fig ). Loosen the grains (see fig ) Regolazione sterzo Steering shaft Remove the chain joint (see fig ). Remove the chain from the sprocket. Proceed at reverse to refit the part. Put the machine in safe conditions. Remove the front carter from the steering column by loosening the screws. Loosen the upper grains from the universal joint Remove the steering wheel from the machine. Loosen the lower grains from the universal joint. Loosen the chain draw grains Remove the chain joint. Remove the chain from the steering column. Remove the column support by loosening the screws Remove the chain tensioner bracket. Pull out the steering column from the lower support. Proceed at reverse to refit the part Steering Chain Put the machine in safe conditions. Remove the front carter from the steering column by loosening the screws (see fig ) Crown of the wheel support bearings cam Put the machine in safe conditions. Remove the steering chain (see section at page 26). Lift the front wheel off the ground. Remove the screws securing the front wheel to the frame (see fig ).

27 Remove the sprocket fixing screws (see fig ). Remove the sprocket. Remove the screws that secure the cam to the sprocket and remove the cam. Remove the Front Wheel (see fig ). Remove the bearings pin. Remove the bearings (see fig ). Proceed at reverse to refit the part. ATTENTION: WHEN ASSEMBLING, PAY EXTREME ATTENTION AT THE CORRECT POSITIONING OF THE SPACER , BECAUSE IT IS FUNDAMENTAL FOR THE PROPER FUNCTIONING OF THE PAR T. 4.5 Solution Delivery System Solution Tank Put the machine in safe conditions. Remove the recovery tank (see section at page 23) (see fig ). Remove the battery tray (see fig ). Remove the steering column carter.(see fig ). Remove the footrest. Remove the electrical installation carter (see fig ). Remove the support bracket of the Main card. Remove the traction pedal assembly. Remove the seat and the deadman microswitch (see fig ) Fixing screws of the wheel to the frame Wheel support pin Fixing screws of the steering sprocket Bearings in the wheel fork Disconnect the water hose from the brush deck (see fig ). Disconnect the control rod from the water valve (see fig ). Remove the screws that secure the solution tank to the machine frame. Remove the tank, pulling it out from the steering column, taking care not to damage the steering wheel. Turn the tank and remove the solution delivery system (see fig ). Proceed at reverse to refit the part Bearings on the steering sprocket Hoses Put the machine in safe conditions. Loosen the clamps that hold the hose to the fitting.

28 Water Valve/Solution Filter Put the machine in safe conditions. Disconnect the control rod from the water valve (see fig ). Disconnect the hose from the fitting, attached to the water valve (see fig ). Disconnect the hose from the fitting attached to the solution filter (see fig ). Loosen the screws that hold the support plate to the solution tank (see fig ). Remove the group including the water valve and the solution filter (see fig ). Unscrew the elbow fitting attached to the water valve (see fig ). Unscrew the water valve from the nipple fitting and remove it (see fig ). Unscrew the nipple fitting from the solution filter and unscrew the straight fitting from the solution filter (see fig ). Remove the solution filter (see fig ) Cut any eventual clamps that secure the hose to the machine body. Remove the hose from the fitting Solenoid Valve Put the machine in safe conditions. Remove the hoses connected to the solenoid valve. Loosen the screw that secures the solenoid connector and disconnect the connector from the solenoid coil. Unscrew the plastic nut that secures the solenoid valve to its support.

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30 4-30 Part III Machine Description 30

31 Chapter 5 Electrical System 5.2 Description Structure 1. Main Card A main card runs all the functions of the machine, traction, brush base, vacuum and water. The main card receive as input, all the information from the control card, the safety micro and all the electronic devices of the machine. These signals are translated from the main card to run correctly the scrubber dryer and to prevent any safety problem to the operator. The dash board can be used also as a programmer console to modify the parameter of all the machine s functions (traction, vacuum and washing) and, also, to check the consumption of all the motors and batteries. 2. Dash board 3. Control Card 4. Microswitches: brush motor, vacuum motor, inhibition of reverse, curve speed reduction and deadman switch 5. Electrobrake 6. Emergency button 7. Traction pedal 8. Batteries and battery charger 31

32 Location of Electrical components

33 List of Components CB Battery charger 1 CBR Charger safety contact CD Control Card EL Solenoid Valve FE Emergency button J Main Card 5-33 LAMP Safety blinking light M1 Traction Motor M1E Traction Motor electrobrake M2 Brush Motor M3 Vacuum Motor ML Control microswitches MS Seat microswitch MULTIM Curve sensor microswitch PM Potentiometer and pedal microswitch 1 Optional

34 5.3.1 Main Card The Main Card is the heart of the machine and, depending of the input information, decides how to use the devices of the machine during normal work. On the table here below, is possible to identify the input/output signals of the card Dashboard and Control card Functions of Dashboard: Manage and set up the main functions and command of the machine during the normal work Check the alarm code in order to detect a possible malfunction. Enter in three different menu: Input & Output Signals F1 Key general fuse (3A). J1 Vacuum motor and Brush motor. J2 Traction motor. J3 Solenoid valve, electrobrake, blinking light. J6 Dashboard control buttons. J7 Limit switch: squeegee, brush deck, curve speed reduction, inhibition of reverse, deadman switch, traction control, battery charger, potentiometer. The user menu to check the status of the batteries and the hourmeter of the machine (depending of the set up into user menu ). If a defect is detected on the machine, this menu show a short message concerning the alarm. The operator menu containing the basic adjustment, accessible by the user of the machine. The advanced menu where is possible to modify the set up of the machine by expert technicians. ATTENTION: THE OPERATOR MENU IS ACCESSIBLE WITHOUT ANY RESTRIC- TION, WHEREAS TO ENTER INTO THE AD- VANCED MENU A PASSWORD IS NEEDED.

35 Functions and Commands Entry into Operator Menu and Advanced Menu The dashboard could be used like a programming console. If you press a determinate combination of buttons you can enter into two menu: Operator Menu. Advanced Menu The structure of the menu can be shown in the section (see section at page 45): During the normal working, the display shows the hourmeter and the battery control card (in percentage). When the charge of the batteries goes down to a fixed value, the battery control card disable the brush motor and, after that, the vacuum motor; in particular, the battery control card disable the brush motor (vacuum motor and traction motor still work) when the remaining charge of the batteries are 20% and disable also the vacuum motor when the remains charge of the batteries are 10% Function of the buttons 1 Not Used 2 ENTER (Confirm) 3 SCROLL UP/PLUS (Scroll up and Increase) 4 SCROLL DOWN/MINUS (Scroll down and Decrease)

36 Operator Menu For example, from EN to IT to modify the language 5-36 To enter to the Operator menu go ahead as follow: With the machine off, press in the same time button 2, 3 and 4 Turn on the key, with the three buttons pressed. Waiting the upload of the working menu Release the buttons To move inside of the menu, press the button 3 and the button 4. To modify a parameter or confirm a changed value, press the button 2. Change a Parameter (in the Operator Menu) To change a parameter proceed as follows: Run the menu with the button 3 or 4 and select the parameter to change. Select the submenu to be changed pressing the button 2 Utilize the button 3 and 4, to shift all the available values for the parameter necessary to modify. To confirm the new value press the button 2 To save the change is necessary to return to the user menu; to exit from working menu select the menu exit Turn OFF the machine Press in the same time, the buttons 2, 3 and 4 Until the buttons are pressed, turn ON the key and wait the upload of the working menu Use the buttons 3 or 4 to select the submenu language To modify the parameters of this menu, press the button 2. To confirm the possibility to change parameters, the first line on the display will blink Utilize buttons 3 or 4 to shift all the values on this menu and select the value IT Confirm the new value by pressing the button 2 To save this modification, select the submenu exit and confirm by pressing button 2.

37 Advanced Menu The Advanced Menu can be reached from the operator menu by accessing the password parameter and setting the value 60. Change a Parameter (in the Advanced Menu) To change the value of a parameter, proceed as follows: Scroll through the submenus with the buttons 3 and 4. Select the submenu that contains the parameters to be changed using the button 2. Scroll through the parameters with the buttons 3 and 4 to find the parameter to be edited. Select the parameter with the button 2. Use the buttons 3 and 4 to scroll through the list of available values of the parameter. Confirm the new value of the parameter using the button 2. To enable the changes, it is necessary to return to the menu work ; to exit the parameters and return to the Advanced Menu press simultaneously the buttons 3 and 4, then find the sub-menu Exit and confirm with button 2. Check/Monitor Function It is possible to view all the values of the Check/monitor function during the normal work of the machine. To view the values, following the instruction: Turn OFF the machine Press in the same time, the buttons 2, 3 and 4 Until the buttons are pressed, turn ON the key and wait the upload of the working menu Use the buttons 3 or 4 to select the submenu password Confirm pressing button 2 Press button 3 or 4 until to select the password 60 Confirm the password by pressing the button 2 to enter into the advanced menu Press the button 3 or 4 to select the menu Check/Monitor Confirm by pressing the button 2 Press the button 3 or 4 to select the parameter you want to check during normal work. Press the button 2 to confirm After confirmed, the display will return to normal view, but instead of the battery control card it will be displayed the values of the selected parameters. By pressing the button 2 it is possible to check the parameters of the Check/Monitor submenu To exit form the Check/Monitor view, turn OFF and ON the machine. 5-37

38 Control Card The Control Card is located inside of the steering wheel and transfers all the information and settings to the Main Card. The Control Card is linked to the Main Card by a connecting cable (item J6) Microswitches The machine is provided with a series of microswitches that send signals to the main card. In particular: Brush motor Microswitch (1). With lowered brush deck lifting lever and closed micro the deck goes down to the floor and the brush motor starts running (as long as the gear pedal is pressed). The cleaning function is active. Vacuum motor Microswitch (2). With lowered squeegee lifting lever and closed micro the squeegee goes down to the floor and the vacuum motor starts running. The cleaning function is active. Reverse function Microswitch (3). With lowered squeegee lifting lever and activated drying function (closed microswitch) the reverse function is inhibited.

39 Curve speed reduction Microswitch. it is positioned below the platform, tangent to a cam. After a predetermined angle of rotation of the steering, the microswitch opens and the curve speed reduction function is activated. The percentage of the speed reduction is an adjustable parameter. switched off and the electrobrake is disengaged, the electrobrake blocks however, in case of exceeding a certain speed (when pushing the machine or if the machine is on an inclined floor). If the machine is switched on, the drive is inhibited if the electrobrake is disengaged Deadman Microswitch. The micro switch is located below the seat. With the operator on board, the traction and the brush deck can be activated Emergency button The machine is equipped with an emergency button, aimed at the protection of the operator in case of sudden critical conditions. A press of the button switches off the power to the Main card and the machine stops immediately Electrobrake The machine is equipped with electrobrake. The electro-brake is engageable through an appropriate control lever positioned on the electro-brake itself, close to the traction motor. looking at a global security condition, even if the machine is Traction Pedal The traction pedal have an internal microswitch that closes when the pedal is

40 pressed and a potentiometer to adjust the intensity of the traction speed. 5.4 Adjustments Traction Pedal The microswitch and the potentiometer inside the traction pedal are properly adjusted during assembly of the pedal Batteries and battery charger The machine is available with the optional battery charger. To get access to the battery charger and the battery compartment is enough to actuate the recovery tank release hook, positioned behind the seat. On the batteries there is a loop wire with 80 Ampere general protection fuse. If it is necessary to calibrate the potentiometer remove the platform, release the control connector and pull the pedal out by unscrewing the two screws Procedure: Remove the plastic cap and loosen the adjustment dowel. Rotate the pedal lateral spindle clockwise, until it is in the zero position.

41 Using the tester to measure the resistance (Ω) place the tester terminals corresponding to the green and yellow wires and check the resistance value to be approximately zero Ω. Turn the potentiometer shaft counterclockwise until the tester gives 0,5 Ω (± 0,1). Lock the dowel and replace the plastic cap. Reinstall the pedal and the footrest Microswitch Check functionality and conditions of the brush motor microswitch, the vacuum motor microswitch, of reverse inhibition microswitch, the curve speed reduction microswitch. Check that with microswitch pressed, remain about 0.5 mm clearance between the lever and the body of the device. Make sure the lever of the micro is working properly. Otherwise, proceed as follows: Move the DIP switches using the loop adjustment. Fix the screws to lock the microswitches taking care not to over tighten in order not to ruin the devices. When the setting is finished, verify the correct functionality of the microswitches Battery Charger (CB) The battery charger is positioned behind the operator s seat and is easily accessible by pressing the release button on the recovery tank. When connected to the power supply, a red led will blink once, the yellow led blink once and the green led blink depending of the type of battery for which the charger is set A Proper Charging cycle follows the below phases order Phase LED Description A Red Blinking, check of battery status B Red First charging phase C YellowSecond charging phase D Green Charged battery Unscrew the fixing screws. Check if the charger is properly set according to the installed batteries.

42 Charging curve SetUp ECO Function 5-42 To set up the charger, follow the instructions: Use a screwdriver to remove the small black plastic cap Set-up the internal dipswitches according to the following table The dipswitches are divided in two couple. The higher couple are the dipswitches 1 and 2, the couple down are the dipswitches 3 and 4. The following table shows how to setup the dipswitches 1 and 2. Set-up of Charging Curve DP1 DP2 Set Up Flash OFF OFF Wet cell batteries 1 ON ON Gel TROJAN 2 OFF ON Generic GEL or 3 AGM batteries ON OFF Gel EXIDE SON- 4 NENSCHEIN DP3: OFF (not used) DP4: OFF (not used) Restore the the small black plastic cap. Once activated the ECO function (with the proper button), lower the brushdeck and let the brush motor and the vacuum motor work. With the ECO mode activated, check if the noise of the vacuum motor and the brush motor is reduced. Connect an Amperometric to the positive cable of the batteries and check if the current consumption in ECO mode is less than normal function (without ECO mode). ATTENTION. We don t give the amperometric reference values because they can change depending of the working conditions of the machine. Error Codes of Charger The charger have an alarm system. The alarm code is shown by blinks of the yellow led. Flash Description Error code 1 Wrong battery, Inverted polarity, short circuit to the exit 2 Timeout alarm, Defect of the battery 3 Defect of the Charger 4 Overtemperature alarm

43 5.5 Maintenance and Checks Electrical System Check (to perform every 150h) Check the functions and the proper connections of the switches, microswitches, motors, solenoid valve, contactors, power fuses, thermal fuses, battery loop wires and emergency button. Check periodically, the wiring connections status. To get access to the electrical system, remove the carter sited near the emergency button Batteries Check (to perform every 150h) Check the proper connection of the Loop wire with 80 Ampere general fuse Emergency Button Check (to perform every 150h) Check the correct functionality of the emergency button. Once pressed, the machine must stop immediately Electrobrake Check (to perform every 150h) Check the functionality of the electrobrake. With control lever rotated downward (electrobrake ON), and switched on machine, if the emergency button is pressed, the machine must stop immediately. With control lever rotates upward (electrobrake OFF), and switched on machine, the traction must be disabled.

44 5.6 Alarm Table Alarms Alarms of Overcurrent and Temperature 5-44 Id Alarm Meaning Solution AL 1: Function Amp. Brush AL 2: Function Amp. Vacuum AL 3: Function Power Broken AL 4: Function Overcurrent AL 5: Function Overtemperature Brush Amperometric Protection Vacuum Amperometric Protection Damage of Power Output overcurrent on brush or vacuum Thermal protection on brush/vacuum Check consumption of the brush motor. Detected high current on brush motor. Check consumption of the vacuum motor. Detected high current on vacuum motor. Damage power of brush or vacuum: replace the main card. This alarm could be shown also during the trailing of the machine. Detect a shortcircuit on output brush motor or vacuum motor: Check connections and motors. Overtemperature of brush/vacuum motor: check consumption of motors. Traction Alarms Id Alarm Meaning Solution AL 14: Traction Lever pressed AL 15: Traction Overtemperature AL 16: Traction Power damage AL 17: Traction Overcurrent AL 18: Traction Amp. Traction AL 19: Traction Electrobrake Safety lever pressed before starting Thermal protection on traction Power of traction damage Traction Overcurrent Traction Amperometric protection Electrobrake not inserted Detected safety microswitch pressed before starting : release the safety lever. Overtemperature on traction : check consumption of traction motor (IMx BT). Replace the main card. This alarm could be shown also during the trailing of the machine. (IMx BT) Detected a shortcircuit on the traction motor output: Check connections and traction motor (IMx BT). Check how the traction function is used. Detected too high working current on traction motor (IMx BT). Check the condition of the electrobrake and its related microswitch. General Alarms Id Alarm Meaning Solution AL 20: General EEprom malfunction AL 21: General Key AL 22: General General Relay AL 23: General Overvoltage AL 24: Traction Battery connections AL 25: General Control Card connection Error reading internal memory Error key sequence Damage of general relay Overvoltage Battery not connected to the main card No communication between control card and main card Replace the main card. Error on key signal: Check the key connection. Check, also, the batteries connections and main card Check the traction motor connections. If the connection are OK, the general relay on the main card is damaged: replace the main card. The same alarm is present also if power fuse is damaged Detected a overvoltage on the main card. Check the batteries connections. Check the traction motor, Detected high voltage on traction motor (IMx BT) Check the connections between control card and main card.

45 5.7 Menu tables Menu scheme Make sure the machine is turned off. Press simultaneously the buttons 2,3,4. Turn on the machine while holding down the buttons. Wait the loading of the Operator Menu For the submenus of the Advanced Menu, refer to the specific tables.

46 5.7.2 Working Menu 5-46 MENU DEFAULT CHOICES DESCRIPTION General Setup: Language: ## General Setup: Mod: ####### General Setup: Battery: ### General Setup: Reset Cnt: # General Setup: Display Cnt: ### General Setup: Exit General Setup: Key h: #### h:## m General Setup: Tr h: #### h:## m General Setup: Br h: #### h:## m General Setup: Vac h: #### h:## m General Setup: password: ### IT IT-EN-FR-SP- DE Setup language MXR... Setup type of machine GEL N GEL-WET- AGM-GE1- WE1 Setup kind of battery Reset partial hourmeter. Key KEY-TR Select the kind of hourmeter: key connect to the key - tr. connect to the traction motor N Exit from the menu. Total hourmeter connect to the key. Total hourmeter connect to the traction. Total hourmeter connect to the brush motor. Total hourmeter connect to the vacuum motor. 60 This password is necessary to enter into the Advanced menu, utilized by expert technicians only Advanced Menu MENU Options menu: General sets. Options menu: Brushes sets. Options menu: Pumps sets. Options menu: Vacuum sets. Options menu: Traction sets. Options menu: Check/Monitor. Options menu: Engineer pars. Options menu: Exit..... DESCRIPTION Enter to the general parameters (language, battery... ). Enter to the parameters for the brush base. Enter to the parameters of water and chemical pumps (if present). Enter to the parameters of vacuum motor. Enter to the parameters of traction motors. Enter to view the list of working parameters. Protected parameters (calibrations and factory settings) Exit and return to the main menu.

47 General Sets MENU DEFAULT VALUES DESCRIPTION General Sets: Language: ## General Sets: Mod: ### General Sets: Battery: ## General Sets: Rst.Cnthr: ## General Sets: Rst.Main Cnthr: ## IT IT-EN-FR-SP- DE Setup the language of the display. Mxr... Setup of the machine model (Normal version or with dosing system). GEL N N GEL-WET- AGM-GE1- WE1 Setup of the battery type. Reset partial hourmeter (like on working menu ). Reset total hourmeter (key, brush, vacuum, traction) Brushes Sets Parameter Default Min Max Description Brushes Sets: I Max: ## [Amp] Brushes Sets: I Nom: ## [Amp] Brushes Sets: T Nom: ## [s] Brushes Sets: T Off: #.# [s] Brushes Sets: T Reset: ## [s] Brushes Sets: T On: #.# [s] Brushes Sets: Eco Speed: ## [V] Brushes Sets: Lev.1: ### [A] Brushes Sets: Lev.2: ### [A] Brushes Sets: Lev.3: ### [A] Maximum current from the main card to the brush motor Rated current; with T Nom manages the amperometric protection (alarm + stop brush motor) Rated timer; with I Nom manages the amperometric protection (alarm + stop brush motor) Delay of switching off of the brush motor when the safety lever is released Timing of reset amperometric protection (overcurrent) Delay to switching on of the brush motor when the safety lever is pressed Value of Voltage reduction of brush motor, during ECO mode Parameter not managed Parameter not managed Parameter not managed. Pumps Sets Parameter not managed

48 Vacuum Sets Parameter Default Min Max Description 5-48 Vacuum Sets: I Max: ## [Amp] Vacuum Sets: I Nom: ## [Amp] Vacuum Sets: T Nom: ## [s] Vacuum Sets: T Off: ## [s] Vacuum Sets: T reset: ## [s] Vacuum Sets: Eco Speed: ## [V] Vacuum Sets: Rit Up: ## [s] Vacuum Sets: optional3: ## Vacuum Sets: optional2: ## Vacuum Sets: optional1: ## Maximum current from the main card to the vacuum motor Rated current; with T Nom manages the amperometric protection (alarm + stop vacuum motor) Rated timer; with I Nom manage the amperometric protection (alarm + stop vacuum motor) Delay of switching on of the vacuum motor when the switch is pressed Timing of reset amperometric protection (overcurrent) Value of Voltage reduction of vacuum motor, during ECO mode Parameter not managed. 0 0 Parameter not managed. 0 0 Parameter not managed. 0 0 Parameter not managed.

49 Traction Sets Parameter Default Min Max Description Traction Sets: Acc Ramp: #.# [s] Traction Sets: Dec Ramp: #.# [s] Traction Sets: Rev Ramp: #.# [s] Traction Sets: FW Speed: ### [%] Traction Sets: BW Speed: ### [%] Traction Sets: Min Speed: ### [%] Traction Sets: Ref 0: #.# [V] Traction Sets: Ref FW: #.# [V] Traction Sets: Ref BW: ## [V] Traction Sets: Ref DB: 0.### [V] Traction Sets: Brake Del: ### [S] Traction Sets: Mode1 V: ## [%] Traction Sets: Mode1 I: ## [A] Traction Sets: Runaway: ### [Volt] Traction Sets: optional3: ## Traction Sets: optional2: ## Traction Sets: optional1: ## Traction Sets: I Max: ## [Amp] Traction Sets: I Nom: ## [Amp] Traction Sets: T Nom: ## [s] Acceleration ramp. The time necessary to arrive at the maximum speed Deceleration ramp. The time necessary to stop the machine when the safety lever is released The time necessary to invert the way Maximum speed in forward way (expressed in %) Maximum speed in reverse way (expressed in % respect the maximum speed in forward way) Minimum speed when the safety lever is pressed Minimum voltage of the potentiometer when released Maximum voltage of the potentiometer in forward speed when safety lever is pressed Maximum voltage of the potentiometer in backward speed when safety lever is pressed Potentiometer dead band Engaging time of electronic brake when the machine is stopped Voltage setting for the curve speed reduction microswitch Current intensity setting for the curve speed reduction microswitch Parameter not managed. 0 0 Parameter not managed. 0 0 Parameter not managed. 0 0 Parameter not managed Maximum output from the main card to the traction motor Rated Current; with T Nom detect the amperometric protection threshold. (Alarm + stop traction motor) Rated Timer; with I Nom detect the amperometric protection threshold. (Alarm + stop traction motor). 5-49

50 Check / Monitor 5-50 Check / Monitor: I Tr: ### [Amp] Check / Monitor: I Br: ## [Amp] Check / Monitor: I Vac: ## [Amp] Check / Monitor: V Tr: #### [V] Check / Monitor: V Batt: #### [V] Check / Monitor: Vref: ### [V] Check / Monitor: Wtr Pump: ### [%] Check / Monitor: Det Pump: ### [%] Check / Monitor: BR Temp: ## [C] Check / Monitor: TR Temp: ## [C] Check / Monitor: TR Ovrld: ### [%] Show current of traction motor. Show current of brush motor. Show current of vacuum motor. Show voltage of traction motor. Show battery voltage. Show the voltage reference of the traction pedal. Show % speed of water pump. Show % speed of chemical pump. Show temperature inside of main card, related to brush/vacuum. Show temperature inside of main card, related to traction. Show the percentage value of the amperometric protection of traction motor (when 100% the amperometric protection cuts the current).

51 5.8 Technical Features TECHNICAL DESCRIPTION U/M Mxr Dimension of Battery compartment (l x L x h) mm 362x354x290 Batteries Rated Voltage Maximum batteries weight kg 2x41 V Ah 2x(12/105) 5.9 Recommended Spare Parts 5-51 PN Description MAIN CARD 7CFCP CONTROL CARD SERIAL CABLE FOR CONTROL CARD TRACTION PEDAL ASSEMBLY COMPLETE KEY SWITCH MICROSWITCH 3X22 L.C.FLAT SEAT MICROSWITCH COMPLETE SEALED MICROSWITCH EMERGENCY BUTTON BATTERY CHARGER KIT

52 Chapter 6 Mechanical Rubbing System 6.2 Description: Structure 1. Motor 2. Bumping Wheel 3. Brush Base 4. Brush coupling Flange 5. Lifting mechanism 6. Brush deck lifting arms 7. Brass bushings 8. Fixing and adjustment plate The washing function of the machine is obtained by the interaction of the cleaning solution with the dirt present on the floor. To facilitate and enhance this interaction, is used a system of mechanical rubbing which consists in a device which rubs on the floor. This device can be of various nature (pad or brush), in each case, its function is to mechanically remove the dirt from the ground and facilitate the reaction between the dirt and cleaning solution. A direct current electric motor connected to a case of gear reduction provides the rotational movement of the brush coupling flange. To the flange is coupled the brush (or the pad holder provided with pad) that rotates together with the flange. After lowering the base to the ground, the brush touches and rubs on the floor providing the desired mechanical rubbing. 52

53 6.3 Adjustments Fixing and adjustment plate The brush deck must be free to move pivoted to its support so that the brush acts parallel to the floor. This allows the brush to evenly lean to the ground and perform its function properly. Requirements: Mounted brush, switched off machine. Procedure: Hook the brush to the base. Loosen the adjustment nuts. Lower the brush deck to the ground so that the brush lies uniformly and parallel to the floor. Tighten the adjustment nuts Loosen the nuts brush deck to the ground Tighten the nuts the brush has a chance to pass under the base in an easy manner. In any case, the lowest part of the deck, must have a height from the ground of at least 7 cm. 6.4 Maintenance and checks Motor Check (to perform every 150h) The motor should rotate evenly and smoothly. It s important that the reduction case is not noisy and that the motor current consumption is not higher than the declared on the plate, regardless of the load which it is subjected. It is necessary that the motor carbon brushes are always in good condition and show no signs of abnormal wear. Maintenance (to perform every 600h) Motor carbon brushes replacement: Procedure: Put the machine in safe conditions. Remove the brush deck from the machine. Loosen the screws that secure the collar brush guard. Disconnect the Carbon brushes from the input power line to the motor. Replace the carbon brushes being careful not to ruin them during assembly. Proceed to the reverse operations to reassemble it all Brush deck lifting cable Adjust the lifting cable using the appropriate register on the sheath so that when the base is in the raised position Brass bushings Check (to perform every 150h) The brass bushings allow a fluid and little tiring rotational movement of the

54 base. To prevent the base is locked in a position without the possibility of movement, is important that the brass bushings are in good condition and clean. In case of excessive wear it is necessary to proceed with the replacement. Maintenance (to perform every 900h) Brass bushings replacement: Procedure: Bumping Wheel Check (to perform every 150h) The bumping wheel (see fig.??) must be free to rotate and its diameter must not be too small due to wear. A bumping wheel in poor condition can lead to cracking of the brush base when working skimming some obstacles (walls, shelving, etc). If necessary, replace it. Put the machine in safe conditions Lower the brush deck to the ground Loosen the screws that fix the arms to the brush deck Remove the bushings and replace them with new bushings. Proceed to the reverse operations to reassemble it all, sprinkle the new bushings with lubricating grease before mounting. Adjust to the base once finished Ruota Paracolpi Brushes Base Check (to perform every 150h) The basement must be kept clean and intact. A ruined basement may be dangerous to the machine and the operator that uses it. If necessary, replace it Rimozione viti Lifting mechanism Boccole Check (to perform every 150h) The lifting mechanism should be clean and lubricated. The lubrication of the cables must be done with silicone spray, it should not be used any grease or oil to prevent that the dirt paste itself to the classics lubricants, and lock the mechanism. The lubrication of chains must be done with lubricant grease.

55 6.4.6 Brush coupling flange Check (to perform every 150h) The brush coupling flange is of plastic material and is not subject to particular wear. Like the other components its cleanliness is essential to allow the brush to engage and disengage smoothly. It is also essential that the brush locking spring has full functionality in order to keep the brush in the correct position. If necessary, replace it Flangia Fixing and adjustment plate Check (to perform every 150h) The fixing plate must be in good condition, must not show signs of corrosion or deformation. An incorrect fixing and adjustment plate does not allow the entire Mechanical Rubbing group to work properly Plate

56 6.5 Technical Features 6-56 TECHNICAL DESCRIPTION U/M Mxr Working width mm 560 Working capacity, up to m2/h 2632 Number of brushes Nr 1 Maximum diameter of the active part of the brush φ mm 560 Brush turns rpm 180 Brush motor voltage V 24 Brush motor power W 450 Max weight on brush kg Consumable Spare Parts PN Description φ (mm) Bristle φ Bristle (mm) Colour BRUSH PPL 0,3 560 PPL 0,3 Blue BRUSH PPL 0,6 560 PPL 0,6 White BRUSH PPL 0,9 560 PPL 0,9 Black BRUSH TYNEX 560 ABRASIVE 0,9 Gray PAD HOLDER Carbon Brushes BR.MOT.CARBON BR Recommended Spare parts PN Description GEAR MOTOR 24V 400W 140RPM H2O W/MOLEX BASE BUMPER WHEEL D=100 H= BRUSH FLANGE

57 Chapter 7 Drying System 7.2 Description The machine dries the floor using an integrated Drying System. After the washing, the solution used with the mechanical action of the brush to remove the dirt, is collected by a system which vacuum it out from the floor. The system is basically made by a vacuum motor which produces an underpressure in the system. This underpressure causes an air flow which flows in the whole vacuum circuit. The air that flows in the squeegee (when it is lowered on the floor) allows it to collect the water on the floor mixing it with the water and, via the vacuum system, is brought to the recovery tank. In the recovery tank the water mixed with the dirt stops and the air keep flowing throughout the circuit reaching the vacuum motor and being discharged in the environment via the exhaust manifold Structure 1. Squeegee 2. Squeegee Support 3. Vacuum Hose 4. Recovery Tank 5. Filter and Floating 6. Vacuum Motor 7. Drain Hose 57

58 7.3 Adjustments Squeegee Support The Squeegee Support has to be adjusted with the Squeegee fitted on, lowered on the floor and vacuum system on. The goal of the adjustment is to let the squeegee blade be angled 45 degrees to the floor for its whole length. Lower the squeegee on the floor keeping the squeegee rubbers perfectly vertical. Fix the wheels of the squeegee support by tightening the nuts loosened earlier Turn the screw (2) to adjust the B movement (Figure 1) until the correct setting is obtained. Verify with a functional test the obtained adjustment To obtain the proper squeegee adjustment act on the wheels of the squeegee support (1) to move the squeegee in the A direction and on the inclination screw (2) to adjust the B movement Wheel locking nuts Squeegee lifting cable Adjust the squeegee lifting cable using the adjuster on the sheath so that when the squeegee is lowered to the floor, it can move laterally in all its possible excursion Movements Adjustments Procedure Put the machine in safe conditions. Loosen the nuts holding the wheels of the squeegee support interpose between the squeegee wheels and the floor a thickness of approximately 1.5 mm (±0,1mm)

59 7.4 Maintenance and Checks Squeegee Check (to perform every 4h) To have a good performance of the squeegee the blades have to be in a good conditions. The squeegee chamber and the squeegee adapter have to be clean and completely free from debris. Blades have to adhere perfectly to the squeegee body and have to be kept in that position by the plastic blade holder which are kept by the plastic wing nuts Rear Rubber Front Rubber Maintenance (to perform every 45h) 7-59 Put the machine in safe conditions. Remove the squeegee from the machine. Rotate the wing nut that block the blade holders. Remove the blade holder. Remove the front blade and replace it with a new one. Repeat the same operations for the rear blade. The rear blade can be used 4 times (one for each edge) before being replaced. Proceed at reverse to reinstall properly the blade holders Squeegee Support Check (to perform every 150h) The squeegee support has to be completely free to move to lie perfectly on the floor. It is important that it can rotate freely around the fixing central axle and it is properly pressed on the floor by the gas spring Maintenance (to perform every 600h) Put the machine in safe conditions. Remove the squeegee from the squeegee support. Completely unscrew the nuts holding the squeegee support wheels. Remove and replace the squeegee support wheels. Proceed at reverse to reinstall the parts. At the end of the assemblying perform the proper squeegee adjustment (see section at page 58).

60 Check that the recovery tank is completely empty. Remove the recovery tank cover. Unscrew the filter and the floater. Remove the Gasket Replace the Gasket. Open the cap of the filter body. Remove and clean (replace if necessary) the filter. Proceed at reverse to restore the parts Vacuum Hose Check (to perform every 4h) The vacuum hose has to be clean and intact. It is mandatory that the hose has no crack to not decrease the underpressure. The suction hose is particularly sensitive in the coupling areas between the pipe and couplings and in tight curves Filtro e Galleggiante Check (to perform every 4h) The filter has to be clean and it is important that nothing blocks or reduces the floater mobility. The filter has to be clean to avoid that water or dirt goes inside the vacuum motor, the floater has to be free to move and has to block completely the air flow when it is in blocking position (UP). Maintenance (to perform every 4h) Put the machine in safe conditions.

61 7.4.5 Recovery Tank Check (to perform every 150h) The recovery tank has to be clean and has not to have cracks or, in general, any kind of damage. The Lid housing has to be even and flat to allow the gasket to adhere perfectly to the tank to avoid any air infiltration. The hose fittings have to be in optimum condition in order to avoid any dirty water leakage or any pressure drop during the job Vacuum Motor Check (to perform every 150h) The vacuum motor with the inlet completely open has to absorb between 10 and 18A. The motor carbon brushes have to be in good conditions and their length has to be no lower than 6-8mm. The motor contacts have to be clean, they have not to be oxidized or have any kind of damage. The motor wires insulation has to be flexible and intact to avoid any possible short circuit. The magnetic circuit of the motor has to be in good conditions and clean. Maintenance (to perform every 450h) 7-61 Put the machine in safe conditions Disassemble the motor from the machine (see section at page 24). Remove the cooler fan plastic cover from the motor. Slip off the motor carbon brushes Replace the worn out carbon brushes with new ones Proceed at reverse to restore the parts.

62 7.4.7 Drain Hose Check (to perform every 4h) The Drain Hose has to be perfectly fitted in the recovery tank fittings in order to avoid any dirty water leakage. The Drain Cap has to seal perfectly the hose to avoid any pressure drop or dirty water leakage. The Drain Manifold has to be flexible and has to have no cracks to avoid any break down during the bending to drain the machine Fase 1

63 7.5 Technical Features TECHNICAL DESCRIPTION U/M Mxr Squeegee width mm 705 Optional Squeegee width mm 800 Vacuum Motor Stages Nr 2 Squeegee adapter type Vertical Vacuum Motor Power W 310 Vacuum Motor Voltage V 24 Vacuum Motor Depression mmh 2 O 970 Recovery Tank l Consumable Spare Parts 7-63 PN Description Squeegee 705mm RUBBER KIT 33 SHORE RUBBER KIT 40 SHORE PU LATEX RUBBER KIT WHEEL D=80 L=23 SUPERLAN GRAY Squeegee 800mm RUBBER KIT 33 SHORE SP= RUBBER KIT 40 SHORE PU SP= RUBBER KIT LATEX SP= WHEEL D=80 L=23 SUPERLAN GRAY Carbon Brushes VACUUM MOTOR CARBON BRUSHES 7.7 Recommended Spare Parts PN Description VACUUM MOTOR 24V 310W H950 2ST VACUUM HOSE D38x DRAIN HOSE D.38x1474 D.50 W/CAP STRAIGHT ADAPTER D=40 TERGI BUMPER WHEEL D=100 H= GAS SPRING 16-1 L=146 L=40 F=150 N FLOATER PROTECTION D=62 d=47 S= FILTER D.103x25 AU PPI 10

64 Chapter 8 Machine Frame and Traction System 8.2 Description Structure Squeegee and Brushdeck Levers Steering column Front Wheel Frame Rear Wheels Traction Motor The frame is a unique structure in painted steel. On it are coupled the steering system including the levers for the activation of the drying system and mechanical friction system, and the traction system. The steering system is composed by a steering column connected to a steering wheel, which acts directly on the front wheel. The steering is ensured by a pinion and a crown, connected by a chain. The pinion is welded directly onto the steering, while the crown is installed on the assembly front wheel. On top of the steering column, there are the levers for the activation of the squeegee and the mechanical friction system. To ensure the proper functioning of the two systems, in the steering column are installed some microswitches that act directly on the affected systems. The traction of the machine is guaranteed by an electric motor installed in combination with a gear, whose output shafts act directly on the rear wheels of the machine, ensuring traction. The gear motor is equipped with an electrobrake which ensures the immobility of the machine when it is not moving. Both the front wheel the rear wheels are non-marking and antiskid. 64

65 8.3 Adjustments Scrubdeck Lever and Squeegee Lever The levers have to be adjusted so as to ensure the smooth lifting and lowering of the brush deck and squeegee. At the same time, they must activate properly the microswitches of the vacuum motor and of the brush motor. Procedure Put the machine in safe conditions. Movements adjustment: Remove the steering wheel cover. Act on the sheaths adjusting nuts to increase or decrease the length. Check that with the raised levers the squeegee and the brushdeck rise and lowered properly without interfering with the frame. Restore the steering wheel cover. Microswitch Actuation: Remove the steering wheel cover. Make sure that the microswitches are correctly pressed when the lifting/lowering levers of the squeegee and the brush deck are moved. Adjust the microswitches by the screws so that they are properly pressed when operating the levers. Restore the steering wheel cover Movements adjustment Procedure Microswitch activation Put the machine in safe conditions. Remove the steering wheel cover. Loosen the nuts securing the bottom support plate of the steering shaft. Release the grains locking nuts, set the optimum tension of the chain by acting on the grains, lock the adjustment by tightening the locking nuts. Once found the optimum tension retighten the fixing nuts to lock the bottom supporting plate of the steering shaft. Restore the steering wheel cover Steering wheel The steering wheel should be adjusted when there is too much clearance between the chain that acts on the pinion connected to the steering bar of the steering wheel and the crown mounted on the front wheel Steering adjustment

66 8.4 Maintenance and Checks Levers Check (to perform every 150h) The operating levers of the squeegee and the brush deck, must always be operated with ease and without excessive effort from the operator. Maintenance (to perform every 600h) Replacement of the brass laminated bushings: Steering Check (to perform every 150h) The steering must always be precise and free to rotate smoothly. Check that the ring and the pinion coupling chain has no excessive clearance and is not noisy. Maintenance (to perform every 600h) Periodically grease the ring and pinion coupling chain. If the chain is too loose, adjust the chain tension as described in the Settings paragraph Put the machine in safe conditions. Remove the steering wheel cover. Lower the squeegee and the brush deck to the floor. Unscrew the screws that hold the levers to the steering column and remove the internal levers. Proceed with the removal of the bushings and replace them with new bushings. Restore the steering wheel cover Steering adjustment Front Wheel Check (to perform every 150h) The wheel must be free to rotate smoothly without friction. The wheel surface, must always be in good condition Steering adjustment Maintenance (to perform every 600h) Periodically check the wheel bearings status. Periodically grease the wheel bearings Traction motor Check (to perform every 150h) During normal running, the current consumption must be between 5 and 7 Amps. ATTENTION At the start the absorption current of the motor is much higher.

67 The carbon brushes of the traction motor drive must be at least 6-8 mm long. The isolation of the power cables of the motor and the electrobrake, must be complete in all their parts and do not show signs of cracks. The cables must demonstrate flexibility. The activation lever of the electrobrake should activate only if a certain push is applied. With electrobrake engaged and the machine not powered, the machine itself should not move. With electrobrake engaged and the machine powered but not moving, the machine itself should not move. With electrobrake engaged, when acting the traction, the machine itself have to move. Lifting the machine to make the rear wheels neutral, by spinning a wheel (in any sense) the other should turn in the opposite direction Maintenance (to perform every 600h) Motor carbon brushes replacement: Put the machine in safe conditions. Remove the protection plastic covers. disconnect the carbon brushes from the electrical connection to the motor. Replace the carbon brushes being careful not to ruin them during assembly. Proceed to reverse operations for reassembly Rear Wheels Check (to perform every 150h) The wheel surface, must always be in good condition.

68 8.5 Technical Features TECHNICAL DESCRIPTION U/M Mxr Traction motor Voltage V 24 Traction motor Power W 300 Traction wheel (num/diam/width) Nr/φmm/mm 1/175/60 Rear wheels (num/diam/width) Nr/φmm/mm 2/225/64 Wheels material Thermoplastic Polyurethane Wheel hardness Sh 85 Maximum forward speed km/h 5.6 Maximum reverse speed km/h Consumable spare parts 8-68 PN Description FRONT WHEEL D=175 d=20 S=60 WITH BEARINGS REAR WHEEL D=225 L=69 Carbon Brushes TR. MOTOR CARBON BRUSHES 8.7 Suggested spare parts PN Description TRACTION MOTOR 24V 300W 115G 18A EL.BR.+MOLEX

69 Chapter 9 Cleaning Solution Supply System 9.2 Description: 9.1 Structure 1. Solution Tank 2. Hoses 3. Water Valve 4. Solution Filter 5. Solenoid Valve 6. Distributor The Cleaning Solution Supply System is made by a tank commonly called solution tank or clean water tank. In this tank the clean water is mixed with the detergent to create the cleaning solution that the machine will use to clean. The solution is then canalized to the filter and the water valve. The filter is used to stop debris that could stuck the hose system and compromise the proper functioning of the system, the water valve is used to adjust the solution that will fall on the floor in order to have the correct amount of solution required for washing. The water valve is placed upstream of the filter to allow the filter cleaning even with fully or partially full solution tank. Once passed through the water valve the solution arrive to the solenoid valve that blocks the delivery when the brush is not working and allow the flow while brush works. The end of the solution path is the distributor that canalizes the flow in the middle of the brush. The solution tank is also equipped with a drain hose to empty it in case of need

70 9.3 Maintenance and Checks Solution Tank Check (to perform every 50h) The solution tank has to be clean and intact. It has not to have cracks or any other kind of damage. Verify, when the tank is completely filled up, that there are not leakage. If necessary replace the Solution Tank Clean Water Filter Check (to perform every 4h) The filter has to be periodically cleaned. When it is fitted on the machine no leakage has to be present. The filter cartridge has to be intact and has not to present any anomaly Hoses Check (to perform every 50h) Every single hose has to be intact and has not to be worn out. It is extremely important that the hoses kept the original flexibility and they haven t suffered any chemical reaction with the detergent used with the machine. If necessary proceed with the replacement of the damaged hoses Solenoid Valve Check (to perform every 50h) The solenoid valve has to block completely the solution flow when the brush deck is not working. Viceversa it has to grant the full flow rate when the brush deck is working Water Valve Check (to perform every 50h) It is extremely important that when adjusted at minimum the valve blocks completely the water flow and that the adjustment lever is mechanically free to move for its while stroke.

71 9.3.6 Distributor Check (to perform every 150h) The distributor has to be intact and has to grant the proper solution flow without any leakage in the gearbox. 9-71

72 9.4 Technical Features TECHNICAL DESCRIPTION U/M Mxr Solution Tank l 65 Clean Water Filter Steel cartridge Water Valve Steel ball valve 9.5 Recommended Spare parts Codice Descrizione COMPLETE SOLENOID 24V 1/2 ACL CLEAN WATER FILTER 1/2 F/F COMPL GASKET OR 2X38 MM 9-72

73 Part IV Accessories and Add-On

74 Chapter 10 Accessories 10.1 Accessories List Blinking Kit Onboard Charger Kit Splashguard Kit Using a Phillips screwdriver to tighten the 3 screws supplied with the kit, taking care to use the silicone paste (red paste) previously applied on the screws. Cleaning Accessories Kit Blinking Kit Description The kit consists of a alarmflashing yellow light. Although this light is not considered mandatory by law, if the user requires it for their particular needs is possible to equip the machine with this accessory Installing instructions Unplug the power cable of the batteries. Place the rubber circular base provided with the kit at the predisposition on the rear side of the recovery tank near the entrance of the suction hose. Make sure the slot in the rubber base is fixed at the trimmer guard on the recovery tank. Place the blinker on the rubber base so as shown in the figure so as to match between rubber base and body of the blinker the three holes for the fixing screws crosswise Remove the two screws of the brush rear support and remove the support. Accompanying the supply cable of the blinker so that it is placed laterally to the suction hose. Accompany the supply cable of the blinker inside the battery compartment through the slot on the rear of the solution tank. The entry point is the same for which the suction hose passes.

75 Connect the power cable connector of the blinker to the of the connector of the wiring inside the battery compartment. Tighten the brush rear support. Reconnect the battery cables and proceed to a functional check of the machine

76 10.3 Onboard Charger Kit Secure the cables to the clips with plastic ties Description The machine is available in CB version which is the version with the built in charger. Anyway, in a standard machine, the battery charger can be fitted acting as follows Machine Preparation Before to start the kit installation is mandatory to put the machine in safe condition. Release the brush, switch off the machine and unplug the batteries Installing instructions Fit the charger into the housing and fasten it with the 4 supplied screws, taking care to add the two washers on the slots. Reconnect the battery cables and proceed to a functional check of the machine Mount the base on the housing, tightening the screw in the insert. Connect the battery charger cables 1 : Connect the charger power cable to the cables XCB of the machine harness. Connect the safety contact cables to the cables XCBR of the machine harness. 1 Refer also to the Electric Scheme

77 10.4 Splashguard Kit Description Even if the solution output is in the middle of the brush, on particular not absorbing kind of floors could be necessary a Splashguard in order to avoid the dispersing of the solution outside of the scrubbing path. The Functioning of this kit is absolutely equal to the other ones similar to it Installing instructions Release the brush, switch off the machine and unplug the batteries. the grooves in the front of the deck. The height of the hole from the bottom side of the base should be 13 mm. Fix the blades using the M4 screws provided with the kit. Tighten the nut and locknut. Determine the position of the remaining fixing holes Ø4 starting from the grooves on the rear side of the deck. Consider the drive position as a reference. Keep the hole 13 mm height from the bottom side of the deck. Lower the brush deck. Mount the splashguard blades supplied with the kit. The spring should be attached to the side without slot (traditional hole). The side with the loop has to be fastened to the deck first Fix the splashguard blades to the deck. Drill two holes φ 4 matching Make the left side hole 8 cm from the corresponding rear groove. Make the right side hole 10 cm from the corresponding rear groove. Once drilled the fixing holes, attach the blades and the splashguard rubbers by pulling the spring and using the M4 screws provided with the kit. Attach nuts and locknuts.

78 Reconnect the battery cables and proceed to a functional check of the machine with a brush attached to the base. Place the front support bracket as shown in the image (upwards slot of the bracket). Secure the bracket with the four M5 provided screws. Tighten the screws with the washers and locking nuts included in the kit. Restore the front carter of the machine Cleaning Accessories Kit Description The set of the cleaning accessories allows to equip the machine with a coupling system for many accessories for manual cleaning. These can significantly reduce downtime while increasing the productivity of the machine and make it much more comfortable the working shift of the operator Installing instructions Unplug the power cable of the batteries. Remove the front carter of the machine by removing the six support screws. Drill four holes Ø5 at predispositions on the back of the front carter.

79 The accessories group is grafted in pressure. The side bracket must be inserted in predisposition located below the recovery tank. The side bracket is provided with a slot and a fixing hole. Install the bracket as shown in the figure and secure the bracket with the two M5 screws supplied with the kit Reconnect the battery cables and proceed to a functional check of the machine.

80 10.6 Consumable Spare Parts PN Description SPLASHGUARD RUBBER L=

81 10-81 Fimap S.p.A. Workshop Handbook MXR Fimap S.p.A. Via Invalidi del Lavoro, S.Maria di Zevio Verona - ITALY Tel Fax Edizione: January 15, 2014