Tornado FK 3000 Operation And Illustrated Parts Manual
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Tornado FK 3000 Operation And Illustrated Parts Manual

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TORNADO
INDUSTRIES
7401 W. LAWRENCE AVENUE
CHICAGO, IL 60706
(708) 867-5100 FAX (708) 867-6968
www.tornadovac.com
Tornado
Operation and Illustrated Parts Manual
For Commercial Use Only
FK 3000 Automatic Scrubber
Catalog No.
99430
â
ã2003 Tornado
Form No. L9430C
7/03
Industries All rights reserved.

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  • Page 1 7401 W. LAWRENCE AVENUE CHICAGO, IL 60706 (708) 867-5100 FAX (708) 867-6968 www.tornadovac.com Tornado Operation and Illustrated Parts Manual For Commercial Use Only FK 3000 Automatic Scrubber Catalog No. 99430 â ã2003 Tornado Form No. L9430C 7/03 Industries All rights reserved.
  • Page 2 NOTES...
  • Page 3 S t a n d a r d W a r r a n t y P r o g r a m * 10 Years: All plastic tanks and rotationally-molded bodies Warranties do not cover 2 Years: components subject Parts on all Tornado and Tornado/Karcher cleaning normal wear or abuse and misuse, and have other 1) 2) equipment limitations specified here.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS INTRODUCTION SAFETY INSTRUCTIONS GROUNDING INSTRUCTIONS UNIT CONTROLS AND INDICATORS INSTALLATION SQUEEGEE BRUSHES PRE START-UP FILLING SOLUTION TANK PREVENTATIVE MAINTENANCE PROGRAM BATTERY CARE BATTERY REMOVAL BATTERY CHARGING BATTERY SAFETY PRECAUTIONS SQUEEGEE BLADES SQUEEGEE ADJUSTMENT SOLUTION PUMP INTAKE FILTER RECOVERY TANK SOLUTION TANK VACUUM MOTOR...

  • Page 5: Introduction

    INTRODUCTION Congratulations on the purchase of your new Tornado FK 3000! The FK 3000 combines many advanced features to maximize reliability, performance, and ease of use. The most notable addition is the incorporation of the industry’s first fully functional digital control and display system on an automatic floor scrubber.

  • Page 6: Safety Instructions

    Do not unplug charger by pulling on cord. To unplug, grasp plug, not cord. Any repairs performed on this machine should be done by Tornado Authorized Service Personnel. Do not operate the unit when fatigued or under the influence of alcohol or drugs.

  • Page 7: Grounding Instructions

    Keep this manual on file and handy. If additional information is needed, please contact your local distributor or contact us at: TORNADO INDUSTRIES Phone: (708) 867-5100 7401 W. LAWRENCE AVE.

  • Page 8: Unit Controls And Indicators

    Unit Controls and Indicators Control Panel 1. Variable Drive Speed Control Knob 2. 3-Position Vacuum Motor Switch: Automatic – Controlled by transaxle Off – for double-scrubbing floors On – for stationary hand tool recovery 3. LCD Display See page 9 for display capabilities 4.
  • Page 9 Unit Controls and Indicators Display Screens Use the Display Mode Button (to the right of the display) to toggle between three unique screens. Each screen displays a different set of icons and numerical readouts to give you useful information about your machine’s operating status. For particulars on diagnostic fault code information, see page 26.

  • Page 11: Installation Squeegee

    INSTALLATION Squeegee 1. Make sure the Squeegee Control Lever is lifted to the UP position. The Rocker (squeegee mount) is already installed on the Bracket. Loosen the two Squeegee Locking Knobs enough to allow it to slide onto the Rocker. 2.

  • Page 12: Brushes

    INSTALLATION Brushes 1. Raise the Brush Housing using the switch on the control panel. (Emergency Switch pulled out, and Keyswitch turned on.) Once the Housing is fully up, turn off the Keyswitch. 2. Place Brushes or Pad Holders under the cover.

  • Page 13: Pre Start-Up

    4. Replace the Filler Plug and tighten its wing nut. Please Note: Before you begin using your new FK 3000, notice that the charging connector is underneath the Cover / Recovery Tank. This is a safety feature to ensure that the Cover is open to freely vent battery gases during charging.

  • Page 14: Preventative Maintenance Program

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

  • Page 15: Battery Removal

    MAINTENANCE 3. After filling batteries, replace the battery caps. Using baking soda or ammonia and water solution, saturate a cloth and wring until drip dry. Use this cloth to wipe the battery tops. 4. The battery terminals and should be coated with a protective lubricant to prevent cor- rosion.

  • Page 16: Battery Charging

    B. Amber light: All cells are OK but the total battery capacity is reduced. This usually indi- cates that the batteries are aging. C. Red light: The battery capacity is low and the entire charger/battery system needs to be inspected by a qualified Tornado serviceman.
  • Page 17 A. Someone should be within range of your voice and close enough to come to your aid when you work on battery operated machinery, such as your FK 3000. B. Have plenty of fresh running water, soap, or baking soda nearby in case battery acid contacts skin, eyes, or clothing.

  • Page 18: Squeegee Blades

    MAINTENANCE Squeegee Blades 1. If a squeegee blade is worn or ripped, raise the Squeegee and remove the entire aluminum Squeegee Assembly from the Rocker. Disconnect the vacuum hose, loosen both Squeegee Locking Knobs and slide the Squeegee out. 2. Unscrew both Star Knobs at either end of the Squeegee, and remove the Rollers.
  • Page 19 MAINTENANCE Squeegee Blades 4. Pull out each Blade from one end. Both front and rear Blades have two working edges. Flip each blade for a new edge when worn. Replace Blades once both edges are worn. 4. Clean squeegee blades with a damp cloth.

  • Page 20: Squeegee Adjustment

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

  • Page 21: Solution Pump Intake Filter

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

  • Page 22: Solution Tank

    For more extensive cleaning of the tank, remove the Top Cover Lid and flush out the tank with clean water as necessary. MAINTENANCE Draining Solution Tank: 1. Locate drain hose at rear of unit and position over floor drain or container. 2.

  • Page 23: Lubricating Your Machine

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

  • Page 24: Troubleshooting Instructions

    TORNADO FK 3000 TROUBLESHOOTING INSTRUCTIONS This section is designed to instruct your personnel in methods of troubleshooting on the Tornado FK 3000. Common maintenance-related issues are noted below, followed by a full Troubleshooting Chart. Vacuum System - Poor Suction During machine operation, if the vacuum...
  • Page 25 TROUBLESHOOTING Poor Solution Flow If an inadequate supply of solution is reaching the floor, check the solution hoses for kinks. These hoses are connected to the brush drive assembly. If there are no kinks in the solution hoses, pull the hoses from the brush cover fittings and check the entire line for blockage. Electrical Problems If Brush Motors do not run, check the following: 1.
  • Page 26 • Keep battery tops clean and dry. • Keep water level 1/4” above cell plates. • Keep excessive heat and metal items away from batteries. • Use a TORNADO charger with correct voltage and current rating. TROUBLESHOOTING CHART PROBLEMS POSSIBLE CAUSE AND CORRECTIVE ACTION Unit completely inoperative •...
  • Page 27 • Circuit breakers tripped due to overload. Wait several minutes, then reset circuit breaker. • Faulty components motor or circuitry. Consult authorized Tornado Service Center. Vacuum motor operates, but • Recovery tank cover is loose or missing. there is little or no suction at Tighten or replace.
  • Page 28 Error codes displayed in the LCD Display indicate that the Electronic Control System may be detecting problems with electrical connections, worn parts, power system controls, or batteries. Be sure to write down the error code before calling your Authorized Tornado Distributor, Service Center, or the Tornado Technical Service Department.
  • Page 29 Emergency stop/BB codes Emergency stop error 7900 Belly button switch activated 7901 900x Customer specific codes 9000 NOTE: Most of these codes are internal errors and cannot be rectified externally. Contact your Authorized Tornado Distributor, Service Center, or the Tornado Technical Service Department.

  • Page 30: Preventative Maintenance Checklist

    • Tighten all loose linkages, screws and nuts on entire machine. CLEANING THE FK 3000 Although the FK 3000 has an exceptionally tough and chemical-resistant body, it houses sophisticated electronics and wiring systems. To avoid the chance of shorting or corroding electrical components or connectors, clean the body with a damp sponge or brush only.
  • Page 31 SOLUTION TANK – EXPLODED VIEW “A” (Ref. Drawing #31504)
  • Page 32 SOLUTION TANK – EXPLODED VIEW “B” (Ref. Drawing #31504)
  • Page 33 SCREW, FLANGED HEX HEAD 3/8-16 X ½ 31357 STOPPER PLUG, 3.0” 31358 ATTACHMENT PIECE (RETAINER STRAP) 31393 ELBOW FITTING, 90DEG, ½” 31394 SIGHT TUBE 31551 COVER, SOLUTION TANK CAVITY 30818 DECAL, TORNADO W/LOGO 3.5 X 15.5 * = NOT SHOWN...

  • Page 34: Recovery Tank

    RECOVERY TANK – EXPLODED VIEW (Ref. Drawing #31503)
  • Page 35 VACUUM MOTOR 19973 ASSEMBLY, VAC INTAKE 30503 ASSEMBLY, RECOVERY INLET 30623 SCREW, FLANGED HEX HEAD ¼-20 X ½ 31237 HOSE, RECOVERY DRAIN 31354 COVER GASKET 31355 ASSEMBLY, TOP COVER 31337 DECAL, TORNADO SWIRL LOGO, 5.0” DIA.* * = NOT SHOWN...
  • Page 36 SQUEEGEE ASSEMBLY – EXPLODED VIEW (Ref drawing #K47770560)
  • Page 37 SQUEEGEE ASSEMBLY – PARTS LIST ITEM PART NUMBER DESCRIPTION K50072170 PLATE K50171360 BRACKET, SQUEEGEE TAILPIECE K50294690 SPACER, STEEL 1.44” LONG K50314640 CHANNEL K50314650 TAILPIECE K50314820 TAILPIECE K50443040 CASTER WHEEL FRAME K51053200 SPACER K53080570 HEX STUD, DOUBLE-SIDED THREAD K54012440 INSERT (PLATE) K54012500 INSERT (PLATE) K55150960...
  • Page 38 SQUEEGEE MOUNT ASSEMBLY – EXPLODED VIEW (Ref. Drawing #32031)

  • Page 39: Squeegee Assembly

    SQUEEGEE MOUNT ASSEMBLY PARTS LIST (Ref. Drawing #32031) ITEM QTY PART # DESCRIPTION 00851 WASHER, PLAIN ¼” 01497 HEX NUT, FINISHED, ¼-20 01574 LOCK WASHER ¼” 01589 HEX NUT, FINISHED, 5/16-18 02568 WASHER, PLAIN 5/16 02581 HEX NUT, FINISHED, 3/8-16 03320 SCREW, HEX HEAD CAP, 3/8-16 X 1.0 03321...

  • Page 40: Brush Drive Assembly

    BRUSH DRIVE ASSEMBLY – EXPLODED VIEW (Ref. Drawing #31501)
  • Page 41 BRUSH DRIVE ASSEMBLY – PARTS LIST (Ref. Drawing #31501)

  • Page 42: Transaxle Assembly

    TRANSAXLE ASSEMBLY – EXPLODED VIEW (Ref. Drawing #19686)
  • Page 43 TRANSAXLE ASSEMBLY – PARTS LIST (Ref. Drawing #19686)

  • Page 44: Control Box & Solution Pump Module

    CONTROL BOX & SOLUTION PUMP MODULE – EXPLODED VIEW (Ref. Drawing #31469)
  • Page 45 CONTROL BOX & SOLUTION PUMP MODULE – PARTS LIST (Ref. Drawing #31469)

  • Page 46: Actuator Assembly

    ACTUATOR ASSEMBLY – EXPLODED VIEW & PARTS LIST (Ref. Drawing #31386)
  • Page 47 CONTROL PANEL – EXPLODED VIEW (Ref. Drawing #31474)
  • Page 48 CONTROL PANEL – PARTS LIST (Ref. Drawing #31474)

  • Page 49: Trigger Assembly

    TRIGGER ASSEMBLY – EXPLODED VIEW (Ref. Drawing #31500)
  • Page 50 TRIGGER ASSEMBLY - PARTS LIST (Ref. Drawing #31500)
  • Page 51 MAIN ASSEMBLY – EXPLODED VIEW “A” (Ref. Drawing #99430)
  • Page 52 MAIN ASSEMBLY – EXPLODED VIEW “B” (Ref. Drawing #99430)
  • Page 53 MAIN ASSEMBLY – EXPLODED VIEW “C” (Ref. Drawing #99430)
  • Page 54 MAIN ASSEMBLY – EXPLODED VIEW “D” (Ref. Drawing #99430)
  • Page 55 MAIN ASSEMBLY – PARTS LIST (Ref. Drawing #99430)
  • Page 56 WIRING DIAGRAM Sheet 1 of 2 (Ref. Drawing 31417)
  • Page 57 WIRING DIAGRAM Sheet 2 of 2 (Ref. Drawing 31417)

  • Page 58: Wiring Harness

    WIRING HARNESS CONTROL FUNCTION Sheet 1 of 2 (Ref. Drawing 31418)
  • Page 59 WIRING HARNESS CONTROL FUNCTION Sheet 2 of 2 (Ref. Drawing 31418)
  • Page 60 WIRING HARNESS POWER FUNCTION Sheet 1 of 2 (Ref. Drawing 31419)
  • Page 61 WIRING HARNESS POWER FUNCTION Sheet 2 of 2 (Ref. Drawing 31419)

  • Page 62: Replacement Items & Accessories

    REPLACEMENT ITEMS AND ACCESSORIES FK 3000 Floorkeeper Automatic Scrubber Catalog # Description Shipping Weight Replacement Items 99154 16” Pad Holder 30543 Oil-Resistant Linatex Front Squeegee Blade 30544 Oil-Resistant Linatex Rear Squeegee Blade Optional Items 99172 16” Firm Poly Scrub Brush (2 required) 99173 16”...

This manual is also suitable for:

99430Floorkeeper lr 3099440

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