Minuteman E24 Service Manual
  1. Manuals
  2. Brands
  3. Minuteman Manuals
  4. Scrubber
  5. E24
  6. Service manual

Minuteman E24 Service Manual

E series
Hide thumbs Also See for E24:
Table of Contents

Advertisement

Quick Links

See also: User Manual
SERVICE MANUAL
Rev 07/07/2014
For E Series Scrubbers
For E Series Scrubbers
Models: E24, E26, E28,
E30, E33, E33XL,
E30 E33 E33XL
E30ECO, E2830, E3030,
E3330 and H26
E3330 and H26
For:
Training
Troubleshooting
Troubleshooting
Adjustments

Advertisement

Table of Contents
loading

Related Manuals for Minuteman E24

Summary of Contents for Minuteman E24

  • Page 1 SERVICE MANUAL For E Series Scrubbers For E Series Scrubbers Models: E24, E26, E28, E30 E33 E33XL E30, E33, E33XL, E30ECO, E2830, E3030, E3330 and H26 E3330 and H26 For: Training Troubleshooting Troubleshooting Adjustments Rev 07/07/2014...

  • Page 2: Table Of Contents

    Page 10 3.3 Minuteman System Maintenance II (250 hours of operation) Page 11 3.4 Minuteman System Maintenance S (500 hrs of operation at least yearly) operation, at least yearly) Page 12 Page 12 Squeegee Cable and Recovery Tank Gasket Page 13 4.1 Squeegee Adjustment (First Version)
  • Page 3 Contents Brush Head Transport Position Page 21 6.1 Brush Switch Page 22 6 2 B 6.2 Brush Pressure Adjustment on the Disk Models h Di k M d l Page 23 6.3 Brush Pressure (Disk Decks) Page 24 6.4 Cylindrical Brush Head Electrical Connections Page 25 6.5 Cylindrical Brush Head Adjustment Page 26...
  • Page 4 Contents Battery Charger Page 38 11.1 Operating Instructions Page 40 11.2 Charger Error Codes Page 40 11 3 Charger Trouble Shooting 11.3 Charger Trouble Shooting Page 44 Page 44 11.4 Charger Maintenance Points Page 45 11.5 Programming The Charger Page 46 11.6 Replacing The Charger Harness Page 49 B tt i...
  • Page 5 Contents Controller Connections Page 58 Trouble Shooting Controller Page 59 Contactor Harness Page 60 Contactor Wiring Page 61 Testing the Main Power Relay Page 63 Wiring Diagram Models with 19 Gallon Tanks Page 68 Wiring Diagram Models with 24 Gallon Tanks Wiring Diagram Models with 24 Gallon Tanks Page 72 Page 73...

  • Page 6: Warnings

    1. Warnings • Disconnect the A.C. Cord from the outlet and and D.C. Cord from the battery pack before servicing the machine Except for making voltage and current pack before servicing the machine. Except for making voltage and current measurements. •...

  • Page 7: General Information

    2. General Information •The display offers a service indication. Upon turning on the key switch, a four digit number describing the software version (e.g. 1.0.0.2) appears for about 3 seconds, f ll followed by another 4-digit code indicating the last error recorded, then followed by 4 di it d i di th l...

  • Page 8: Maintenance Intervals

    M i t I ( ft 125 h To be preformed by an authorized Minuteman Service Center in accordance with the machine-specific system maintenance. •Minuteman System Maintenance II: (after every 250 hours of operation) To be preformed by an authorized Minuteman Service Center in accordance with the...

  • Page 9: Minuteman System Maintenance K (Customer)

    3.1 Minuteman System Maintenance K To be performed by the customer/user To be performed by the customer/user                                                                    Interval Interval Daily Weekly Fill the clean water tank and mix the proper amount and type of cleaning solution. Charge the batteries. Check the brush head Clean if needed with a damp cloth Do not get water inside the motor Check the brush head, Clean if needed with a damp cloth. Do not get water inside the motor.  Check the squeegee, clean if needed Check the lid gasket on the recovery tank. Empty and flush the recovery tank with clean water. Clean the filter/float inside the recovery tank.

  • Page 10: Minuteman System Maintenance I (125 Hours Of Operation)

    3.2 Minuteman System Maintenance I To be performed by the authorized service center Interval Every 125 hours of  operation Check the battery charger.  Make sure it is functioning properly Check the recovery lid gasket.  Replace if needed Lubricate the brush lift linkages with grease Use a small brush Lubricate the brush lift linkages with grease.  Use a small brush. Check for loose hardware, tighten if needed. O   Check the tire pressure on pneumatic wheels at 65 PSI, if equipped.  Lubricate the squeegee linkages with grease.  Use a small brush. Inspect the entire machine for damage, wear and proper operation.

  • Page 11: Minuteman System Maintenance

    3.3 Minuteman System Maintenance II To be performed by the authorized service center Interval Every 250  hours of  operation Inspect the caster wheels for wear and damage Repair if needed Inspect the caster wheels for wear and damage.  Repair, if needed. Inspect the carbon brushes for wear in the transaxle.  Replace, if needed. Inspect the recovery drain hose for wear or damage.  Replace, if needed. Inspect the brush bumper rollers for wear or damage Replace if needed Inspect the brush bumper rollers for wear or damage.  Replace, if needed. Inspect the carbon brushes for wear in the brush motors for wear.   Blow out with compressed air. Inspect the recovery hose for damage or wear.  Replace, if needed. ...

  • Page 12: Minuteman System Maintenance S

    3.4 Minuteman System Maintenance S (S f t Ch (Safety Check) To be performed by the authorized service center Interval Every 500 hours of  operation Replace the carbon brushes in the transaxle. Replace the carbon brushes in the brush motors. Test the machine for proper operation.
  • Page 13 4. Squeegee Cable And Gasket 4. The squeegee cable is attached to the lift lever (top) via a spring (Fig. 5/5). The bottom is attached to the eyebolt at the squeegee mechanism (Fig. 5/6). The squeegee lift cable can be accessed after opening the electronic module cover at the rear of the machine.

  • Page 14: Squeegee Adjustment (First Version)

    Squeegee Adjustment Version one 4.1 Squeegee Adjustment Correct squeegee adjustment is prerequisite for optimal suction results. Before adjustment first check the pitch of the squeegee and re-adjust if required. 1. Place machine on level ground. 2. Loosen nut of the adjustment screw (pos. 3, Fig. 5/1) and adjust sealing strips in parallel to the floor.
  • Page 15 Squeegee Adjustment Version Two 4.2 Squeegee Adjustment Correct squeegee adjustment is prerequisite for optimal suction results. Before adjustment first check the pitch of the squeegee and re-adjust if required. 1. Place machine on level ground. 2. Loosen the two bolts, located on each side (Fig 5/2A) with the squeegee attached while holding another wrench on the location shown on Fig 5/2B.

  • Page 16: Squeegee Wheel Adjustment

    Squeegee Wheel Adjustment The clearance between the support roller and floor with squeegee unfolded (Factory setting) is: 0 1181099 Inches ± 0 01968498 inches (3 mm ±0 5) (Factory setting) is: 0.1181099 Inches ± 0.01968498 inches (3 mm ±0.5). Note: Some floor surfaces may require adjusting the caster washers for optimum performance. See following page...
  • Page 17 Squeegee Wheel Adjustment 4.4 Note: When adjusting the wheel height, there should always be 5 washers on each wheel assembly position # 15 in order fully tighten bolts. Move washers from the top to the bottom of the bracket or visa versa when making adjustments The caster controls the pressure on the the bracket or visa versa when making adjustments.
  • Page 18 4.5 Squeegee Lift Cable, Switch & Motor 4.5 Squeegee Lift Cable, Lever, Micro Switch and Vacuum Motor and Vacuum Motor •The vacuum motor micro switch is mounted behind the squeegee lift lever (Fig. 5/4). Adjust the micro switch so that the vacuum motor can be micro switch so that the vacuum motor can be turned off by lifting the squeegee by the lever.
  • Page 19 5. Brush Head (Disk) Connections 5. Connection of Brush Motors to Disk Brush Head h M t t Di k B Connect the brush motors of the disk brush head in accordance with the electric diagrams. Find the assignment of connecting stud of the motors listed in the below table. Then check the correct direction of brush motor rotation.

  • Page 20: Brush Motor Information

    5.1 Brush Motor Information Brush Motors Brush Motors The brush motors are switched on and off by a micro-switch located at the rear at the brush head lift-out system. This switch is realised as NO (normally open) switch. To attain safe function of the brush motors, correct adjustment of this switch is required.

  • Page 21: Brush Head Transport Position

    6. Brush Head 6. Brush Head Transport Position •The lever provided is for lifting up the brush head. It features 3 positions for adjusting the lift linkage (Fig 6/1) The top hole is the transporting and ramp climbing position In the lift linkage (Fig.

  • Page 22: Brush Switch

    6.1 Brush Switch 6.1 Brush Switch •The brush motors are switched on and off by a micro-switch located at the rear at the brush head lift-out system Figure 6/3 This switch is a NO (normally open) switch To brush head lift out system Figure 6/3. This switch is a NO (normally open) switch. To attain safe function of the brush motors, the correct adjustment of this switch is required.

  • Page 23: Brush Pressure (Disk Decks)

    •Verify the current with brushes under load, with a digital clamp-on meter. Note: The factory setting •Only an authorized Minuteman Service Center should make changes to the brush pressure setting. set at the second notch...
  • Page 24 6.3 Brush Pressure (Disk Models) Heavy Specific Brush Pressure Surface Pressure (2nd Foot Area Per Area Per Specific Surface Specific Surface with Heavy Brush with Heavy Brush Brush Pedal Model Brush Pressure Pressure Pressure Engaged) 1055 cm² 400 N = 0.28 N/cm²...
  • Page 25 6.4 Brush Head (Cylindrical) 6.4 Electric Connections • Connect the brush motors of the cylindrical broom head in accordance with the electric diagrams. Find the assignment of connecting stud of the motors listed in the below table. Then check the correct direction of brush motor rotation.
  • Page 26 6.5 Adjusting Cylindrical Deck Spacer Block on this side also Spacer Block 26 5 mm high 26.5 mm high Part number for the gauges are available by request.

  • Page 27: Electric Brake

    Drive and Wheels . General Data Torque of wheel bolts: 23 foot lbs Torque of wheel nuts: 18 foot lbs Wheel speed in max. drive potentiometer position: Forward: (3.1 mph) 110 min-1 Reverse: (1.55 mph) 55 min-1 Torque of setting for screws on caster mounting: 17 foot lbs 7.1 Electric Brake (E33 and 30 Gallon Tank Models Only) •The drive motor is equipped with a electric brake on the transaxle.

  • Page 28: Transaxle Motor

    7.2 Transaxle Motor 7.2. Transaxle Drive Motor •Drive motor, axle and differential are a single unit. •The wheel drive is nearly maintenance-free. Check the carbon brushes of the drive motor at regular intervals during maintenance Carbon brushes are worn if the during maintenance.

  • Page 29: Carbon Brushes

    7.3 Transaxle Motor Carbon Brushes 7.3 Carbon Brushes Close the cover of carbon brushes again as shown in photos 7/2, 7/3 and 7/4. Make sure that the plastic lock is placed in a motor housing recess for brushes.

  • Page 30: Drive Potentiometer

    7.4 Drive and Wheels 7.4 Drive Potentiometer Circuit •Potentiometer Resistance 5.875 k Ω +- 30% Value: •Asssignment of connecting plug (A1.X4): Pin 1: Ground Pin 2: 24Volts Pin 3: Digital signal of drive direction 1 Pin 4: Digital signal of drive direction 2 Pin 5: Potentiometer wiper Pin 6:...

  • Page 31: Water Supply

    8. Water Supply 8.1 The solenoid valve releases or stops supply of water flowing to the brushes. The solenoid valve is located at the front pane of the battery compartment. The solenoid valve is electrically connected to the central controller A1 at t d t th t ll A1 t...

  • Page 32: Solution Tank Cleanout

    8.3 Water Supply (Solution Tank Clean out) •The Models E33, E2830, E3030 and E3330 with the 30 tanks will be equipped with a clean out plug on the solution tank equipped with a clean out plug on the solution tank. •The plug may be removed to clean out debris that is inside the tank.

  • Page 33: Solution Flow Rates

    8.4 Solution Flow rates Water Setting 1.45 Gallons per min Disk Brush  30 & 33" 2 68 2.68 3 46 3.46 4 61 4.61 5 84 5.84 9 82 9.82 15 43 15.43 Pump Voltage V lt Gallons per min Cyl. Brush 24" 4.69 5.99 6.85 7.47 8.45 9.24 Pump Voltage Gallons per min Cyl. Brush 28"...

  • Page 34: Water Pump

    8.5 Water Pump 8.5 Solution Control • Models equipped with water pump • The solution flow rate is affected by the speed of the drive system. • The controller adjusts the voltage to the pump to regulate water volume. • The faster the machine is driven the more water will flow to the brushes brushes.

  • Page 35: Th L The Last Error T E P

    9. The Last Error 9. All Minuteman E24, E26, E2830, E30ECO, E30, E28, E3030, E3330, E33XL H26 H30 E33XL, H26, H30 and 19, 24 and 30 gallon models are equipped with an d 19 24 d 30 error memory which will indicate the last error that occurred in the machine.
  • Page 36 10. Table of Error Codes Error code Error source Remarks Check temperature of brush motors; check current consumption of brush motors; check 1.2.5.2. Thermal switch Brush 1/2 wiring of thermal switch (X8 and X9 plugs) of the brush motors (series connection). Input A1.X9:1 and 7 Blocking protection Brush 1/2 Electronic Brush motors smooth running? Check current...
  • Page 37 10. Table of Error Codes Error code Error source Remarks Check connecting cable between central 4.5.2.5. Control panel not recognized controller and control panel. This error occurs upon switching on only. Check connecting cable between central 4.5.3.5. No response control panel (Timeout) controller and control panel.

  • Page 38: Operating Instructions

    24V - 22A Charger 10.1 Operating Instructions...
  • Page 39 11.1 24V - 22A Charger...
  • Page 40 11.1 24V - 22A Charger...

  • Page 41: Charger Error Codes

    11.2 Charger Error Codes 10.2 Note: The following are error indicators that could occur during the battery charging process. All errors will be in the form of a blinking display picture of the battery of the battery. The display indicator figure # 1 will display a blinking doted square, if the battery malfunctions for the following reasons: The battery has less than 1.25 volts per cell.
  • Page 42 11.2 Charger Error Codes The display indicator figure # 2 will blink, when the charger timer times out. This occurs when the battery voltage on a 24 volt battery pack does not reach 22 8 22.8 volts or higher after 30 minutes. The charger will shut off. hi h ill h Fig.
  • Page 43 11.2 Charger Error Codes The display indicator figure # 4 will blink when the charger is over heating: 1. The cooling air is restricted 2. The cooling fan is not working. 3. The cooling hose is not connected or is obstructed. Fig.
  • Page 44 11.3 Trouble Shooting the Charger •Symptom - charger has no output. Check for loose or burnt connections on the side of the charger. •Use a test cord by-pass the original AC power cord •Use a test cord by-pass the original AC power cord. Note: Continuity and voltage tests may not be adequate for testing the condition of the AC cord.

  • Page 45: Charger Maintenance Points

    11.4 24V - 14A Charger •10.4 Charger Maintenance Points •Check the following, when servicing the machine: •The charger unit should be secured by rubber strap. •The wires going to and from the charger should be secured with plastic wire ties. They should be routed so that there are not any kinks, pinched or crushed wires.

  • Page 46: Programming The Charger

    11.5 Programming the Charger 10.5 The automatic scrubbers are equipped with the new on board automatic charger. The charger will be programmed from the factory for the wet lead acid batteries. Machines that were purchased with gel maintenance free batteries installed at the Machines that were purchased with gel maintenance free batteries installed at the factory will be programmed for gel.
  • Page 47 11.5 Programming the Charger Cont. 5. Push and hold the button in for 2 to 4 seconds and release. The charger will turn off. 6. Push and hold the button in again for >10 seconds and release. This puts the charger into the programming mode.
  • Page 48 11.5 Programming the Charger Cont. Mode # 0 is for the Mode # 1 is for AGM Mode # 5 is for gel type Trojan # 956752 batteries 956749 (260 batteries using chargers 260 Ah b tt i 260 Ah batteries for the Ah) &...
  • Page 49 11.5 Programming the Charger Cont. 9. To save the desired mode, press and hold the button for more than 5 seconds and release. The picture on the display will blink rapidly indicating the setting has been stored. has been stored. 10.

  • Page 50: Replacing The Charger Harness

    11.6 Replacing the Charger Harness •When replacing the charger output harness (W8) 97094346 on 19 gallon models or 011722530 on 30 gallon models with the electric brake. •Use the K-E24261668 Charger Retro fit kit in addition when either the harness or charger is being replaced. •Inspect the receptacle on the charger for burnt or damage.

  • Page 51: Maintaining Wet Lead Acid Batteries

    12. Batteries 12.1 Maintaining Wet Lead Acid Batteries 1. Always keep the water levels above the plates 2. Fill cells with distilled water only. Tap water can cause an excessive build up of minerals and reduce the chemical reaction of excessive build up of minerals and reduce the chemical reaction of the batteries.

  • Page 52: Battery Charger

    12.1 Batteries 5 Ch 5. Check water level daily. Fill, if needed. l d il Fill if 6. Keep all the battery cable connections tight. 7. Keep all the battery posts and cables clean. Clean the battery cases with a mixture of baking soda and water solution or commercial spray that neutralizes the acid.

  • Page 53: Load Testing Batteries

    12.2 Load Testing Batteries 12 2 L 12.2 Load Testing Load test battery with an automotive type load tester. This test puts an ampere load on the batteries and measures the voltage at the same time. If voltage drops too low on the meter this would indicate that the batteries are weak or discharged.

  • Page 54: Hydrometer Testing

    12.3 Hydrometer Testing Batteries 12.3 Hydrometer Testing on Lead Acid Wet Batteries • Hydrometer testing can used to measure the specific gravity of deep cycle batteries. This allows you to detect weak cells, which are causing loss of running time. It can only detect these types problems. The hydrometer should have specific gravity markings such as 1.265, 1.250, 1.225, and so •...
  • Page 55 12.3 Hydrometer Testing Batteries Cont. • To do an accurate test, the battery water level must be high enough to extract enough electrolyte to fill hydrometer enough so that the indicator floats. If the water levels are low, water should be added prior to charging in order to let the electrolyte to mix.
  • Page 56 12.3 Batteries (Wet Lead Acid) • Minuteman batteries are rated for 500 charge cycles. Every time the batteries are charged it uses one cycle. To insure getting the expected life, unnecessary charging should be avoided. • The specific gravity will reflect the percentage of charge remaining in the battery.

  • Page 57: Fuse Locations Version

    13. Fuse Locations (Version 2 Controller) All the fuses are located on the main control circuit board. Part Numbers 00059580 Fuse 125 Amp 80 Volts (Brush & Vac. Motors) 00972420 Fuse 100 Amp. 80 Volts (Brush & Vac. Motors) 00733630 F 00733630 Fuse 10 Amp.
  • Page 58 13.1 Fuse Locations (Version 3 Controller) 10 Amp Fuse 32 or 80 Volts 00733630 125 Amp Fuse 80 Volts 00059580 00059580 2 Amp Fuse 32 Volts 00972430 50 Amp Fuse 80 Volts 00902440 5 Amp Fuse 32 Volts 00906120...

  • Page 59: Controller Connections

    14. Controller Connections...

  • Page 60: Trouble Shooting Controller

    15. Trouble Shooting the Controller Note: If the 5 amp fuse on the controller blows, It could indicate: 1. A faulty contactor (not closing on the negative side). 2. Poor connection on the battery negative side of the contactor. 3. Poorly crimped terminals on the contactor connections. 4.

  • Page 61: Contactor Harness

    16. Contactor Wiring – Harness...

  • Page 62: Contactor Wiring

    17. Contactor Wiring Proper wiring of the contactor is critical Control Board To batteries and charger...

  • Page 63: Testing The Main Power Relay

    18. Testing the Main Power Relay Digital Volt Meter g ta From Battery B tt From Battery 25 Volts 25 Volts Controlled Controlled Note: Measure the voltage across the Note: Measure the voltage across the B+ and the B- coil terminals with the Controlled wires attached and the key switch turned on.
  • Page 64 18. Testing the Main Power Relay Di it l V lt M t Digital Volt Meter From Battery From Battery 25 Volts 25 Volts Controlled Controlled Note: Measure the voltage from a battery negative source to the B+ terminal of the main relay’s coil to determined of the B+ is being supplied to the coil.
  • Page 65 18. Testing the Main Power Relay Digital Volt Meter g ta From Battery From Battery 25 Volts 25 Volts Controlled Controlled Note: Measure the voltage from the battery positive source to the B- terminal of the main relay’s coil to determined of the B- is being supplied to the coil.
  • Page 66 18. Testing the Main Power Relay Note: Measure the voltage on the incoming battery side 25.5 volts 5 5 o ts across the B+ & B- th B+ & B terminals when the machine is powered up and under load. From Battery From Battery Controlled...
  • Page 67 18. Testing the Incoming Contact Voltage on the Main Power Relay Note: The The relay is voltage should 22.4 defective be exactly the volts same as the Volt Meter Note: The incoming voltage was 25.5 battery side battery side volts when the machine is under load.
  • Page 69 For Models E24, E26, H26 and E30ECO...
  • Page 71 For Models E24, E26, H26 and E30ECO...
  • Page 72 For Models E24, E26, H26 and E30ECO...
  • Page 73 For Models E28 and E30 Only...
  • Page 74 For Models E28 and E30 Only...
  • Page 75 91026567 motor connection 35mm² cable connection conical brush cylindrical marking conical brush scrub brush at motor -M3/4 -M3:1 -M3:N -M3:N binder plug topside 35mm² 6mm² -M3:2 -M3:P -M3:P connection N -M4:1 -M4:P -M4:N binder plug below P(+) -M4:2 -M4:N -M4:P connection P notice: loom of cables -W13 (97098503) and loom of...
  • Page 76 91026567 date of plot: 19.12.2007 003 / Ri. / 19.12.07 [ 004 / kupe / 19.12.07 ] ref. designation part no path ref. designation part no path controller 90541483 /1.20 battery connector 160A /1.2 control panel 90487216 /1.26 connector 2 poles /1.36 key board 90487232...
  • Page 77 91026567 machine with conical brush -S11 -X12 -X32 -M1.S1 -X102 -M3.S1 -X10 -X18 -X19 -M4.S1 -X25 -X26 -X24 -X31 machine with cylindrical brush -X12 -X101 -M3.S1 -M1.S1 -X10 -X18 -X19 top view of battery block -M4.S1 driving direction For Models E28 and E30 Only Benennung Zeichnungs-Nr.
  • Page 78 91026906 supply main -G2.X1: on-board-charger -A1.X1: -A1.X2: -G2.X4: -G2.X2: -G2.X3: controller -M3.S1 125A θ -A1.X21: -A1.X34: brush motor connection motor left LOGIC cable connection conical brush marking conical brush at motor -M3/4 -M3:1 -M3:N binder plug topside -M3:2 -M3:P connection N -M4:1 -M4:P binder plug below...
  • Page 79 91026906 date of plot: 12.12.2007 B-Stand : 001 / Ri. / 12.12.07 [ 002 / kupe / 12.12.07 ] ref. designation path ref. designation path controller E24 / E26 /1.18 control panel /1.28 key board /1.30 battery /1.2 on-board-charger /1.6 main contactor /1.10...
  • Page 80 91026898 motor connection 35mm² cable connection conical brush marking conical brush at motor -M3/4 35mm² 6mm² -M3:1 -M3:N binder plug topside -M3:2 -M3:P connection N P(+) -M4:1 -M4:P binder plug below -M4:2 -M4:N connection P -M3.S1: -A1.X9:1 -M3.S1 N(-) -A1.X1: -A1.X2: controller θ...
  • Page 81 001 / Ri. / 12.12.07 [ 002 / kupe / 12.12.07 ] ref. designation part no path ref. designation part no path controller E24 / E26 90541483 /1.20 -X102 connection virtual ground at direction switch /1.13 control panel 90487216 /1.26...
  • Page 82 91026898 -S11 -X32 -X102 -X12 -M1.S1 -M1.S2 -M1.Y1 -X25 -M3.S1 -X26 -X10 -X17 -X18 -X19 -X24 -X31 -X27 -M4.S1 -X101 top view of battery block For Models E2830, E3030, E3330 and E33XL Only driving direction Benennung Zeichnungs-Nr. 2007 Datum Name VES-Nr.

  • Page 83: Notes

    21. Notes...

This manual is also suitable for:

E26E28E33xlE30ecoE280E3030 ... Show all

Table of Contents