Minuteman ERIDE 30 Service Manual
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Minuteman ERIDE 30 Service Manual

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Service Manual
For the
ERIDE 30
ERIDE 30
For models starting with serial
GERIDE3000001 and following
Training
Troubleshooting g
Adjustments

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Summary of Contents for Minuteman ERIDE 30

  • Page 1 Service Manual For the ERIDE 30 ERIDE 30 For models starting with serial GERIDE3000001 and following Training Troubleshooting g Adjustments...

  • Page 2: Table Of Contents

    Contents Information General Information 2.1 Settings 2.2 Short Description 2.2.1 Deactivating Vacuuming / Dirty Water Tank Full 2.2.2 Home Position of the Machine 2.2.3 Seat Contact Switch 2.2.4 Introduction to Programming 2.2.5 Reset Last Error Which Occurred in the Start Screen Technical Data h i l D t Maintenance Intervals...
  • Page 3 Contents Machine Settings 6.1 Basic Settings 6.1.1 Machine Type 6.1.2 Cleaning Units 6.1.3 Battery Setting 6 2 S tti 6.2 Settings On Customer Request (PPV) t (PPV) Mechanical Components 7.1 Squeegee 7.2 Forward and Reverse Switch 7 3 B 7.3 Brush Head Lifting Unit d Lifti U it 7.4 Potentiometer in the Brush Head Lifting Unit...
  • Page 4 Contents Drive Control Unit ATECH / ZAPI 9 1 Automatic Monitoring of Components 9.1 Automatic Monitoring of Components 9.2 Diagnosis LED for Drive Module (ZAPI) 9.3 Explanations of Error Messages Error Reference Chart with Information on Service Display Adjustment of Disk Brake Adjustment of Disk Brake Real-Time Clock (RTC) Notes...

  • Page 5: Information

    1. Information Attention: All work on the vehicle may only be completed after disconnection of the power supply (disconnect the battery plug) with the exception of the current and voltage measurements. When changing high current fuses, only loosen the screws. Never unscrew the screws completely, otherwise there is a risk of short circuit.

  • Page 6: General Information

    2. General Information •The ERIDE30 is equipped with a service indicator in the operating hour counter display. After switching the key switch on, a four-character code appears for approx. 3 seconds in the display which indicates the software version (e.g. 1.001), possibly another four-character code which indicates the last fault which has occurred followed b th by the operating hour counter.

  • Page 7: Settings

    2.1 Settings •The relevant settings can be defined in the machine's Configuration menu. The The relevant settings can be defined in the machine s Configuration menu. The diagnostics connector with order number PN 03006790 is required in order to define these settings.

  • Page 8: Short Description

    2.2 Short Description •The vehicle is controlled by means of the following electronics: • Central electronics system (A1) Central electronics system (A1) • Operating and indicator panel (A2) • Drive control (A4) •The control electronics (A1) assumes all the control and monitoring tasks in the vehicle except for the driving functions.

  • Page 9: Deactivating Vacuuming / Dirty Water Tank Full

    2.2.1 Deactivating Vacuuming / Dirty Water Tank Full •Vacuuming is switched off manually by the operator using the corresponding button or automatically when the “Dirty water tank full” signal is received in order to protect the “ f ” suction turbines. •Deactivation by the operator: •...

  • Page 10: Home Position Of The Machine

    2.2.2 Home Position of the Machine •After switching the machine on, all the components are set to their "home position" when the seat contact switch is actuated (closed). •The lifting elements are raised as long as they have not been switched off by the The lifting elements are raised as long as they have not been switched off by the micros witch monitoring the top end position integrated in the lifting element.

  • Page 11: Seat Contact Switch

    2.2.3 Seat Contact Switch •The seat contact switch is connected to the control electronics A1 at A1:X9.8+18. it h i t d t th t l l A1 t A1 X9 8+18 •The control electronics (A1) reacts to the opening of the seat contact switch with a 2- second delay.
  • Page 12 2.2.3 Seat Contact Switch •The drive control is provided with its own diagnosis and self-test. •Therefore, the function of the drive control is inhibited when the machine is switched on if the drive potentiometer is not in its neutral position or is not detected as being in on if the drive potentiometer is not in its neutral position or is not detected as being in neutral.

  • Page 13: Introduction To Programming

    2.2.4 Introduction to Programming A1.X3 •The ERIDE30 can be configured by means of the software and adapted to various options. software and adapted to various options. •The software is also used to adapt the machine to the various hardware (machine type, batteries - TSG). •The modification of parameters not described in this manual could lead to machine malfunction.
  • Page 14 2.2.4 Introduction to Programming •Press and hold Buttons 1 and 2 simultaneously (Fig. 2.3) and switch on the key switch. The following display Button 3 Dashboard appears in the operating hour counter after approx. 3 seconds: Button 2 Fig. 2.1 •The start screen of the Configuration Button 1 menu is now open.
  • Page 15 2.2.4 Introduction to Programming •You can navigate through the Configuration menu using the three 3 buttons indicated on the operating panel. Button 3 Dashboard Button 1 is the "Water on/off " button; Button 2 the "Water +-" button; Button 3 the "Silent Mode"...
  • Page 16 2.2.4 Introduction to Programming •Press Button 1 to change the active level: Configuration • Chapter -> Configuration -> Content -> Chapter Chapter Chapter Content Content •Press Button 2 to increase the value in the active level. •After reaching the highest value, pressing again calls in the lowest value the lowest value.

  • Page 17: Reset Last Error Which Occurred In The Start Screen

    2.2.5 Reset Last Error in the Start Screen •Access the programming level as described in Chapter 2.2.4. Fig. 2.1 appears. The diagnostics connector must be connected to A1.X3. •Press Button 2 six times, the last error which occurred is indicated in the display. e.g. •Press and hold Button 3 for approx.

  • Page 18: Technical Data H I L D T

    Technical Data Technical Data: Working width Inches 29.5 Effective suction width Inches 37.4 Area performance up to sq ft per hr 51,700 Working speed up to Voltage Protection class (VDE 0700) Air volume, Vacuum Pressure, vacuum Water Lift Drive motor Watts Watts Brush motor watts Watts Vacuum motor watts Watts Number of brushes Number of brushes Brush diameter Inches Brush RPMs Brush pressure (Maximum) Solution tank capacity Gallons 30.6 Recovery tank capacity Recovery tank capacity Gallons Gallons 30 6 30.6...
  • Page 19 Technical Data...

  • Page 20: Maintenance Intervals

    Maintenance Intervals In a modular structure, the System Maintenance determines the specific technical works to be executed and equally fixes the period between two maintenance cycles. For each of the maintenances, the replaceable parts are determined as well. Find further details described in the specific chapters. System Maintenance K: To be performed by the customer in accordance with the maintenance and care instructions To be performed by the customer in accordance with the maintenance and care instructions...

  • Page 21: System Maintenance (Customer)

    4.1 System Maintenance K The daily and weekly maintenance intervals must be performed by the customer/operator.

  • Page 22: System Maintenance I

    4.2 System Maintenance I •The following maintenance work must be performed by an authorized Service Center.

  • Page 23: System Maintenance

    4.3 System Maintenance II The following maintenance work must be performed by an authorized Service Center.

  • Page 24: System Maintenance S

    4.4 System Maintenance S (Safety Check) The following maintenance work must be performed by an authorized Service Center.

  • Page 25: Cleaning Programs

    Cleaning Programs (FPV) The cleaning programs define the behavior of the water supply to the brushes, the brush motors in respect of the position of the drive direction switch, the drive potentiometer (forwards, neutral, reverse) and the squeegee. The drive direction switch S07 and drive potentiometer switch S08 provide a 24 V signal for forward drive at input A01.X10:4 and for reversing at input A01.X10:5.
  • Page 26 5. Cleaning Programs (FPV) Contents Function Function Brush off when drive control is in neutral Brush off when drive control is in reverse Lift brush when drive control is in neutral Lift brush when drive control is in reverse Water off when drive control is in neutral Water off when drive control is in reverse...
  • Page 27 5. Cleaning Programs (FPV) Description Description FPV Set Refer to FPV table Refer to FPV table Refer to FPV table Refer to FPV table Refer to FPV table Refer to FPV table Refer to FPV table Refer to FPV table t FPV t bl Refer to FPV table Refer to FPV table...

  • Page 28: Machine Settings

    6. Machine Settings 6.1 Basic Settings 6 1 1 Machine Type 6.1.1 Machine Type There are various model types, equipment installed and working widths regarding the machines in the ERIDE30 series. These types can be set in the Configuration menu. To check and change the machine type setting, access programming level as described in Chapter 2 2 4 The parameters setting possible are stipulated in Table described in Chapter 2.2.4.

  • Page 29: Cleaning Units

    6.1.2 Machine Settings 6.1.2 Cleaning Units (Brush Deck) Description Cleaning Units (Brush Deck Type) Disk brush 750 mm (30") Chart 6.2...

  • Page 30: Battery Setting

    6.1.3 Machine Settings 6.1.3 Battery Setting (TSG - total discharge signal transducer) In order to achieve the optimum operating time for the machine with the batteries installed and optimum service life of the batteries, it is essential to set the battery monitor, referred to as TSG, to the correct discharge curve.
  • Page 31 6.1.3 Machine Settings 6.1.3 Battery Setting (TSG - total discharge signal transducer) Battery Types Battery Types •GiS and GiV are flat plate batteries, •PzS and PzV are tube plate batteries •PzS and PzV are tube plate batteries •GiV and PzV are sealed, absolutely •maintenance-free gel batteries •GiS and PzS are sealed, low-maintenance batteries with liquid electrolyte.
  • Page 32 6.1.3 Machine Settings 6.1.3 Battery Setting (TSG - total discharge signal transducer) Batte ry Se tting (Lonest battery life - shorter run) Crown without offset (Default setting - Longest Run Time) Crown with offset Crown with offset GIS, = "USA" Flat Plate Wet Lead Acid GIS = "Foreign"...
  • Page 33 6.1.4 Machine Settings 6.1.4 TSG •This adjustment is necessary so that the TSG can operate correctly. •To check and change the machine type setting, access programming level as described in Chapter 2.2.4. The parameters setting possible are stipulated in Table 6.4.

  • Page 34: Settings On Customer Request (Ppv) O C T R T (Ppv)

    Machine Settings 6.2 Settings On Customer Request •The programmable program versions can be used to complete various settings on the machines. •E.g. it is possible to program whether the last error which occurred on the machine should be displayed or not when the machine is switched on again.
  • Page 35 Machine Settings 6.2 Settings On Customer Request Description "Last error" indicator after switching on the machine Deactivate Activate Water level when switching on scrubbing g Last setting Preset level (4) Chart 6.5/1...
  • Page 36 Machine Settings 6.2 Settings On Customer Request Description Water level when switching on scrubbing and vacuuming Last setting Preset level Chart 6.5/2...
  • Page 37 Machine Settings 6.2 Settings On Customer Request Description Water Setting Water Setting From last level to first level (in circuit) Change direction on reaching max./min. level (ping-pong) Chart 6.5/3...

  • Page 38: Mechanical Components

    Mechanical Components 7.1 Squeegee Fig. 7.1...
  • Page 39 Mechanical Components 7.1 Squeegee Adjustment of the squeegee assembly. The angle/pitch adjustment is the decisive factor in ensuring the assembly squeegee blades lie evenly on the floor. 1. Park the machine on a level surface and lower the squeegee. 2. Loosen the counter nut on the screw (Fig. 7.1/3) and use the counter nut to adjust the squeegee so that the ends of the sealing strips just make contact with the floor.
  • Page 40 Mechanical Components 7.1 Squeegee Abb 30 Abb. 30 Fig. 7.3 Fig 7 2 Fig. 7.2...
  • Page 41 Mechanical Components 7.1 Squeegee Height adjustment Th h i ht dj The height adjustment is set to 3 mm at the factory. If, despite an optimum angle t t 3 t th f If d adjustment, streaks are produced, the distance between the rollers and floor must be adjusted by altering the number of washers (Fig.
  • Page 42 Mechanical Components 7.1 Squeegee Squeegee connection The drawing (Fig 7.4) specifies the dimensions for adjusting of the suspension springs (60 mm) 2.36” and ) 2 36” the threaded rods for adjusting the parallel alignment (151 mm) 5.94” of the squeegee connection. Fig 7 4 Fig.

  • Page 43: Forward And Reverse Switch

    Mechanical Components 7.2 Forward and Reverse Switch Function The pictures below show the mechanical function of the switch Rear View Front View Front View Rear View Rear View Front View The front view of the switch is shown in the picture. The are 4 terminals on each side.
  • Page 44 7.2 Forward and Reverse Switch The pictures below show the wiring of the switch...

  • Page 45: Brush Head Lifting Unit H H D Lifti U It

    Mechanical Components 7.3 Brush Head Lifting Unit...
  • Page 46 Mechanical Components 7.3 Brush Head Lifting Unit...

  • Page 47: Potentiometer In The Brush Head Lifting Unit

    Mechanical Components 7 4 Potentiometer in the Brush Head Lifting Unit 7.4 Potentiometer in the Brush Head Lifting Unit The potentiometer of the lifting element is powered by a 2.5 V reference voltage at A1.X19:1. Reference point for this voltage is A1.X19:3. Depending on the position of the potentiometer, the voltage at A1.X19:2 is between 0 and 2.5V.

  • Page 48: Water Pump

    8. Water Pump •To control the function of the water pump, the voltage for the individual levels can be To control the function of the water pump, the voltage for the individual levels can be disconnected at the central electronics unit (A1.X11:4+11). The following results are achieved when measuring with a True RMS measuring instrument and water in the tank but with the suction turbines switched off: •...

  • Page 49: Water Quantities

    Water Quantities •Measuring the water quantities provides a good, reliable method with which to check the function of the water pump. Let the pump run and measure the volume of water the function of the water pump. Let the pump run and measure the volume of water fed per minute (l/min.).

  • Page 50: Water Pump Standstill Recognition

    8.2 Water Pump Standstill Recognition If the pump does not supply water to the brushes due to clogging of the hoses or lack of water, the standstill recognition is activated. or lack of water, the standstill recognition is activated. Automatic standstill recognition for water pump: The electronic module allows protection of the water pump if the pump does not deliver correctly This means if the pump takes in water from the tank and cannot deliver correctly.

  • Page 51: Drive Control Unit Atech / Zapi

    Drive Control Unit ATECH / ZAPI The ZAPI drive control unit is equipped with a diagnosis connector The ZAPI drive control unit is equipped with a diagnosis connector. Any changes of the factory presetting values and parameters is forbidden. Position of connectors A = Connector for relay control and control inputs B = Connector for diagnosis device and alarm LED...
  • Page 52 Drive Control Unit ATECH / ZAPI Connectors, Description of ZAPI Drive Control Speed reduction no 1 input; normally close contact toward battery positive: Speed reduction no 1 input; normally close contact toward battery positive: active when pin is free. Europe quick inversion input; normally open contact; active when pin is connected to battery positive.

  • Page 53: 1 Automatic Monitoring Of Components

    Drive Control Unit ATECH / ZAPI •9 1 Automatic Monitoring of Components 9.1 Automatic Monitoring of Components •The micro-processor executes evaluation of basic controller functions. •This evaluation concerns the following 4 states: •Check upon switching on by key switch: •Watchdog, current sensor, power MOS FETs, contactor drive (contactor driver), direction switch, potentiometer connections, EEPROM •Check during standstill: •Watchdog, current, power MOS FETs, contactor drive (contactor driver), potentiometer...

  • Page 54: Diagnosis Led For Drive Module (Zapi)

    Drive Control Unit ATECH / ZAPI 9.2 Diagnosis LED for Drive Module (ZAPI) Flash-Code Message Status* Remark WATCH-DOG Faulty electronic 2/3/4/5) EEPROM Faulty electronic (EEprom) INCORRECT START Direction selected when switching on (or incorrect IR connection) VMN LOW MOSFET short-circuited VMN HIGH Diodes short-circuited or direction contactor stuck VACC NOT OK...

  • Page 55: Explanations Of Error Messages

    Drive Control Unit ATECH / ZAPI 9.3 Explanations of Error Messages •1) WATCH-DOG •Test in rest position as well as during riding; internal auto-test function of hard- and software; replace controller in case of error alarm! •2) EEPROM PAR. KO •Error in the memory area containing the adjustment parameters.
  • Page 56 Drive Control Unit ATECH / ZAPI •4) EEPROM DATA KO •Data in the memory area which controls the hour meter are faulty. •If alarm disappears, after switching key switch off and on, mind the fact that the hour meter is reset to zero meter is reset to zero.
  • Page 57 Drive Control Unit ATECH / ZAPI •6) INCORRECT START 6) INCORRECT START •Incorrect sequence of start conditions. Depending on SAFETY SWITCH programming, system starts if the following sequence is respected: • - key switch – handle micro-switch – direction switch (HANDLE) •...
  • Page 58 Drive Control Unit ATECH / ZAPI •7) VMN LOW 7) VMN LOW •Test in rest state and during ride until VMN is pulsed out to up to 80%; •If contactors are open, voltage at VMN connection normally amounts to 50% VBatt. If this voltage value is insufficient (<...
  • Page 59 Drive Control Unit ATECH / ZAPI •8) VMN HIGH 8) VMN HIGH •Test in rest state; •If contactors are open, voltage at VMN connection normally amounts to 50% VBatt. If this voltage value is exceeded (> 70% VBatt), an alarm is output. Possible causes: a) A direction contactor is permanently closed since mechanically blocked ) A di ll bl...
  • Page 60 Drive Control Unit ATECH / ZAPI •9) VACC NOT OK •Test in rest state; •Test in rest state; •Alarm is displayed if, referred to the saved minimum value, potentiometer voltage is higher than 1V. •Possible causes: • • a) Wire broken at potentiometer or inductive sensor a) Wire broken at potentiometer or inductive sensor.
  • Page 61 Drive Control Unit ATECH / ZAPI •11) HIGH CURRENT 11) HIGH CURRENT •Test in rest state – contactor open; •If measured current is >50A, alarm is output and the system switches off. The current sensor is defective (replace controller!) •12) PEDAL WIRE KO •If no voltage is measured at pin NPOT (A12), to which the negative wire of the potentiometers is connected, an alarm is output.
  • Page 62 Drive Control Unit ATECH / ZAPI •13) TEMPERATURE 13) TEMPERATURE •This message signals that controller temperature has exceeded 76°C. •Maximum current is reduced step by step to zero at a temperature of 86°C. Possible causes: a) If the alarm is output immediately after system ON with cold controller a) If the alarm is output immediately after system ON with cold controller, temperature monitoring is faulty (replace controller!) b) If the alarm is output after relatively short period of operation, heat is...
  • Page 63 Drive Control Unit ATECH / ZAPI •15) DRIVER 1 KO 15) DRIVER 1 KO •If voltage at connection NT1 (A11) does not correspond to determined value, an alarm is output and the system switches off. •Possible causes: a) Wire broken at connection NT1 (A11) or coil of reverse direction contactor •...
  • Page 64 Drive Control Unit ATECH / ZAPI •17) DRIVER 2 KO 17) DRIVER 2 KO •If voltage at connection NT2 (A4) does not correspond to determined value, an alarm is output and the system switches off. •Possible causes: • a) Wire broken at connection NT2 (A4) or coil of forward direction contactor is defective.
  • Page 65 Drive Control Unit ATECH / ZAPI •19) DRIVER SHORTED (only H0 STANDARD TRACT ) 19) DRIVER SHORTED (only H0 STANDARD TRACT.) •If voltage at connection NT1 (A11) does not correspond to determined value, an alarm is output and the system switches off. •Possible causes: •...
  • Page 66 Drive Control Unit ATECH / ZAPI When does • First test Result Second test Result Error error occur? --> --> Forward direction In forward contactor closes for 0 3 contactor closes for 0.3 direction only At the forward direction contactor, a sec.
  • Page 67 Drive Control Unit ATECH / ZAPI The make contact of the forward direction contactor (TA) or the break The make contact of the forward direction contactor (TA) or the break contact of the reverse direction contactor (TI) is soiled or blocked. Clean contacts or, if required, replace contactor group.
  • Page 68 Drive Control Unit ATECH / ZAPI The break contact of the forward direction contactor (TA) or the make The break contact of the forward direction contactor (TA) or the make contact of the reverse direction contactor (TI) is soiled or blocked. Clean contacts or, if required, replace contactor group.
  • Page 69 Drive Control Unit ATECH / ZAPI No connection to motor: No connection to motor: - Carbon brushes without contact to collector (Fig. 1) - Connection cable of carbon brushes interrupted (Fig. 2) - Motor winding defective or motor cable interrupted - Incorrect connection of motor Incorrect connection of motor...
  • Page 70 Drive Control Unit ATECH / ZAPI B1 The forward direction contactor is correctly driven but does not close. - Contactor coil is defective; use ohmmeter to measure resistance Contactor coil is defective; use ohmmeter to measure resistance - Contact is mechanically blocked - Nominal voltage of contactor coil higher than battery voltage B2 The reverse direction contactor is correctly driven but does not close.
  • Page 71 Drive Control Unit ATECH / ZAPI 21) POSITION HANDLE If upon switching on, the handle micro-switch has already been actuated, error is signalled (only if SAFETY SWITCH is programmed to HANDLE). Possible causes: a) Handle micro-switch stuck b) Incorrect operation 22) INVERSION 22) INVERSION If upon switching on, the emergency reverse (dead man) button is depressed, an alarm...

  • Page 72: Error Reference Chart With Information On Service Display

    Error Reference Chart with Information on Service Display Error number / Error source Comment Message number Check temperature of brush motors; check power consumption of brush motors; check cabling of thermostatic switch (connector X3 and X4) of 1.2.5.2. Thermostatic switch, brush 1/2 brush motors (series circuit).
  • Page 73 Error Reference Chart with Information on Service Display Error number / Error source Comment Message number 3 1 6 E 3.1.6.E. Power fuses (group signal) Group signal, fuses -F02; -A01.F2 F02 A01 F2 Message appears after the "Last error" display 3.2.6.5.
  • Page 74 Error Reference Chart with Information on Service Display Error number / Error source Comment Message number Overload of small consumers (solenoid valve, 3.3.6.2. Group signal, low power outputs buzzer) 3.4.1.1. Drive rheostat Check drive direction switch and cabling Check thermostatic switch and cabling of drive 3.4.5.1.
  • Page 75 Error Reference Chart with Information on Service Display Error number / Error source Comment Message number Check connection cable for control unit (-A01) - 4.5.2.5. Operating panel not detected operating panel (-A02). This error only occurs when switching the machine on Check connection cable for control unit (-A01) - Operating panel response 4.5.3.5.

  • Page 76: Adjustment Of Disk Brake

    11. Adjustment of Disk Brake •...

  • Page 77: Real-Time Clock (Rtc)

    12. Real-Time Clock (RTC) •The ERIDE30 is equipped with a real- time clock which is integrated in the vehicle's control system. When the Dashboard vehicle is switched off the clock is vehicle is switched off, the clock is supplied with power from a backup Button 5 battery on the control electronics.
  • Page 78 12. Real-Time Clock (RTC) •In order to access the Setup menu, press and hold Button 1 and Button 2 simultaneously while the key switch is switched on switched on. •After approx. 3 seconds, the year setting appears in the operating hour counter. (In the example, 11 for 2011).
  • Page 79 12. Real-Time Clock (RTC) •The value in the respective display can be increased by pressing Button 3 once or reduced by pressing Button 4 once. If the respective button is pressed and held for longer than one second, the value changes automatically at a constant speed. •If a value is modified, the point at the bottom right behind the number disappears.

  • Page 80: Notes

    12.2 Notes...

  • Page 81: Wiring Diagrams

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