Minuteman E20S Service Manual
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Minuteman E20S Service Manual

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Service Manual
All E17BD, E17TD, E20S, E20BD, E20TD,
E20C, H20BD, H20TD E26ECOS and
E26ECO Automatic Scrubbers
For:
Training
Troubleshooting
Adjustments
Revised 02/10/2019

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Summary of Contents for Minuteman E20S

  • Page 1: Charge Indicator Version

    Service Manual All E17BD, E17TD, E20S, E20BD, E20TD, E20C, H20BD, H20TD E26ECOS and E26ECO Automatic Scrubbers For: Training Troubleshooting Adjustments Revised 02/10/2019...

  • Page 2: Table Of Contents

    Contents Safety Page 5 Technical Specifications Page 6 2.1 Dimensions E17BD & E20BD Page 7 2.2 Dimensions E17TD & E20TD Page 8 Maintenance Intervals Page 9 3.1 Customer Maintenance Page 10 3.2 Maintenance I after every 125 hours of operation Page 11 3.3 Maintenance II after every 250 hours of operation Page 12...
  • Page 3 Contents 8.7 Prime Chargers Page 29 8.8 Prime Charging Status Indicator Page 30 8.9 Prime Charger Fault Codes Page 31 Battery and Error Code Indicator Page 32 9.1 E17TD and E20TD Error Codes Page 33 Trouble Brush Motor Controller (Sport only) Page 38 Squeegee Adjustment (Curved) Page 39...
  • Page 4 Contents Trouble Shooting the Drive Circuit Page 59 19.1 Trouble Shooting The Traction Drive Switch Page 60 19.2 Trouble Shooting – Vacuum Motor Circuit Page 61 19.3 Trouble Shooting – Vacuum Relay Page 62 19.4 Testing the Drive System Potentiometer Page 63 Notes Page 64...

  • Page 5: Safety

    4. Do not clean machine with a pressure washer. 5. Only authorized personnel should perform repairs and maintenance. 6. Use only Minuteman genuine replacement parts. 8. Do not use machine around flammable substances. 9. The batteries should be charged only in well ventilated areas.

  • Page 6: Technical Specifications

    2. Technical Specifications E17BD, E20 Page 6...

  • Page 7: Dimensions E17Bd & E20Bd

    2.1 Dimensions E17BD & E20 BD With a Straight Squeegee Page 7...

  • Page 8: Dimensions E17Td & E20Td

    2.2 Dimensions (E17 & E20) With Curved Squeegee Page 8...

  • Page 9: Maintenance Intervals

    The operator must be professionally instructed after delivery of the machine by selling dealer. •Minuteman System Maintenance I: (after every 125 hours of operation) To be preformed 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 an authorized Minuteman Service Center in accordance with the machine- specific system maintenance.

  • Page 10: Customer Maintenance

    3.1 Minuteman System Maintenance K To be performed by the customer/user Interval Daily Weekly Fill the clean water tank and mix the proper amount and type of cleaning solution. Charger the batteries. Check the brush head, Clean if needed with a damp cloth. Do not get water inside the motor.
  • Page 11 3.2 Minuteman System Maintenance I Page 11...
  • Page 12 3.3 Minuteman System Maintenance II Page 12...

  • Page 13: Maintenance S After Every 500 Hours Of Operation

    3.4 Minuteman System Maintenance S Page 13...

  • Page 14: Batteries And Wiring

    4. Batteries & Wiring •Battery Compartment •The battery compartment is located under the recovery tank. The battery compartment can be accessed for servicing and maintenance by tilting the recovery tank. Make sure the recovery tank is has been drained before tilting. •The battery compartment contains two 12 volt batteries connected in series.

  • Page 15: Recovery Float And Gasket

    5. Recovery Float •The Recovery Float and Filter is located inside of the tank, •The filter should be checked after each use and cleaned if needed. •Remove the three screws and the cover, to access screen float for more extensive cleaning. •Failure to do so will reduce the vacuum performance of the machine.

  • Page 16: Lubrication

    6. Lubrication Regularly scheduled lubrication of certain machine parts should be performed to insure trouble-free operation of the machine. Apply a generous amount of grease into the fittings on the machine until grease seeps out around the bearings. Wipe excessive grease off with a towel.
  • Page 17 7. Charging Indicator (Version 1) •The indicator will light during the charging process. •The red light indicates, the batteries need a full charge. •The yellow light indicates, the batteries have received 80% of their charge. •The green light indicates, the batteries are fully charged.

  • Page 18: On Board Chargers (957760 And 957761) (Ver. 1 & 2)

    8. On Board Chargers (Version 1 and 2) •The Minuteman on board chargers are capable of being programmed to charge lead acid wet or gel type maintenance free batteries. •The on board charger has a variety of other programming settings.

  • Page 19: Programming The 957745 Charger

    8.1 Programming the 957745 Charger 1. Remove the large rear metal cover on rear the machine. 2. Locate the battery charger. 3. To access the Dip Switches, carefully peal the decal back on the front of the charger. Start at the bottom left side and peal up. (Removing the plastic charger cover is not necessary.) Use caution not to damage the decal.

  • Page 20: Charger Settings (957745)

    8.2 Charger Settings (957745) The dip Switches 5,6 and 7 are for selecting the amperage output of the charger. Use the 12 amp. setting only. * Note: The dip switch # 7 does not have any function at this time. Current (Amperage Output) Switch 5 Switch 6...

  • Page 21: Battery Charger Trouble Shooting

    8.3 Battery Charger Trouble Shooting Version 1 and 2 Chargers Trouble Shooting 1. Does the battery charger turn on when plugged into the A.C. outlet? 2. Can you hear the cooling fan turn on? If not, check the A.C. outlet for power.
  • Page 22 8.3 Battery Charger Trouble Shooting The Charger Turns On (957745 Charger) If the charger appears to turn on, remove the rear metal cover on the rear of the machine. The charger’s display should be lighted, when plugged in the A.C. outlet. If not, replace the charger.
  • Page 23 8.3 Battery Charger Trouble Shooting How the smart chargers work The charger is programmable for wet, gel and AGM battery types. Phase one: The charger is designed to put full output of 10 to 12 amps until the battery voltage reaches 28.8 volts for the first phase (red LED), otherwise it will time out.
  • Page 24 8.3 Charger Trouble Shooting (Excessive Gassing or Water Consumption in Batteries) If the charger appears to be charging and excessive gassing or water consumption had been or is occurring in the batteries. Check the following: A. Have the batteries been maintained on a consistent basis? Failure to maintain batteries will shorten their life and reduce their performance.

  • Page 25: Battery Charger Error Codes 957745 (Ver. 1)

    8.4 Battery Charger Error Codes 957745 Chargers Only Codes that could be displayed on the charger are as follows: “Bat” = The batteries are not detected. Voltage is below 2 volts, The polarity could be reversed or batteries disconnected. “Acd” = the charger programming set for wet lead acid batteries. (not an error) “Gel”...

  • Page 26: Programming The 957760 & 957761 Charger (Ver. 2)

    GEL/AGM (NON OEM) 135 amp hr GEL/AGM (NON OEM) 95 to 100 AH and Trojan AGM 102 (AH) hr. Minuteman Part # 956157 Note: These are the only settings available. For non OEM batteries, please contact supplier for the charging requirements.

  • Page 27: Charger Error Codes 957760 & 957761

    8.6 Battery Charger Error Codes 957760 & 957761 Chargers Only Faults are displayed red LED on the battery charge indicator. RED LED BLINKS ONCE AND REPEATS: OUTPUT CONNECTION ERROR. 1. Check for loose or corroded connections between the charger and the batteries. 2.
  • Page 28 8.6 Battery Charger Fault Codes Cont. 957760 & 957761 Chargers Only Faults are displayed red LED on the battery charge indicator cont. All Three lights blink at the same time 1. Charger is restarting 2. Charger is unable to put full output to the batteries 3.

  • Page 29: Prime Chargers

    8.7 Prime Chargers • Machines built after serial number 18060266 will be equipped the Prime Chargers • Prime chargers are pre-programmed at the factory for specific battery types and are not reprogrammable in the field. • The maximum D.C. output is 12 amps. •...

  • Page 30: Prime Charging Status Indicator

    8.8 Prime Charge Status Indicator • The charger includes one (1) local LED that can display three (3) colors to indicate charger status and fault information (see Figure 5-1). The functionality of the LED is outlined below. If an optional remote LED is being used, it will provide the same functionality.

  • Page 31: Prime Charger Fault Codes

    8.9 Prime Charger Indicator (Fault Codes) Removing AC power from the charger always clears a fault. If the charger was factory- configured for off-board use, disconnecting the charger from the battery pack also clears a fault. If a fault cannot be cleared after taking appropriate corrective action, contact your dealer for troubleshooting and/or service.

  • Page 32: Battery And Error Code Indicator

    9. Battery and Error Code Indicator Traction Drive Models only •The indicator will display the charge status during machines operation. The indicator uses ten LEDS. 1 to 10 LEDS may be illuminated at any given time. 10 being a fully charged battery pack. 1 LED would be a discharged battery pack.

  • Page 33: E17Td And E20Td Error Codes

    9.1 E17TD & E20TD Error Codes 1 Bar = Low Battery Voltage The battery needs charging or there is a bad connection to the battery. Check the connections to the battery. If the connections are good, try charging the battery. 2 Bars = Traction Motor Disconnected There is a bad connection to the Traction motor.
  • Page 34 9.1 E17TD & E20TD Error Codes 4 Bars = Battery Lockout The traction drive controller has shut down because of low battery voltage. Charge the batteries. If problem still exists: Test batteries and check all battery connections. 5 Bars = Not Used 6 Bars = Not Used Page 34...
  • Page 35 9.1 E17TD & E20TD Error Codes 7 Bars = Throttle Trip A throttle trip is indicated. The potentiometer is not detected in circuit or incorrect resistance value seen by I-drive controller. Test the 5K potentiometer circuit. 8 Bars = Control System Trip A control system trip is indicated.
  • Page 36 9.1 E17TD & E20TD Error Codes 10 Bars = High Battery Voltage An excessive voltage has been applied to the control system. connections. This is usually caused by a poor battery connection. Check the battery connections. No Bars = Control System in Sleep Mode The control system has entered sleep mode.
  • Page 37 9.1 E17TD & E20TD Error Codes Start UP This is an initialization message. Repeats until system is verified to be functional. Occurs during the initial startup of the machine, if it hasn’t been powered up for a period of time. Note: This is not a fault or error. Ripple = Throttle Displaced Looks similar to the start up above.

  • Page 38: Trouble Brush Motor Controller (Sport Only)

    10. Trouble Shooting Brush Motor Controller (Sport Models only) The I-drive brush motor controller works similar to the traction drive I-Drive controllers, except for is rated for 180 amps. The sport key switch changes the speed of the brush motor speed from 200 rpms to 400 rpms. The potentiometer for the brush controller is mounted inside the electrical box and is always set to the full clockwise position.

  • Page 39: Squeegee Adjustment (Curved)

    11. Squeegee (Curved) Page 39...

  • Page 40: Squeegee Adjustment

    11. Squeegee (Curved) 11.1 Page 40...

  • Page 41: Squeegee Caster Adjustment

    11. Squeegee Caster Adjustment (Curved) 11.2 Clearance between support roller and floor with unfolded sealing strip (Factory presetting): 3 mm ±0.5 (Fig. 5/2). Place additional 1mm spacers (pos. 15, Fig. 5/3) between the angle and the fixed roller housing (pos. 7, Fig. 5/3) to increase clearance or remove existing 1mm spacer from between the angle and the fixed roller housing in order to reduce the clearance.

  • Page 42: Squeegee Caster Adjustment

    11. Squeegee Caster Adjustment (Curved) 11.3 Curved Squeegees Only Washers may be rearranged to change the height of the squeegee caster. Note: When adjusting the wheel height, there should always be 5 washers on each wheel assembly in order fully tighten bolts. Move washers from the top to the bottom of the bracket or visa versa when making adjustments.

  • Page 43: Squeegee Caster Adjustment

    11. Squeegee Caster Adjustment (Curved) 11.4 Curved Squeegees Only •Possible squeegee caster washer combinations. Page 43...

  • Page 44: Maintaining Deep Cycle Wet Batteries

    12. Maintaining Wet Batteries 1. Always keep the water levels above the plates 2. Fill the batteries with distilled water only. Tap water can cause an excessive build up of minerals and reduce the chemical reaction of the batteries. This will shortening the life and performance of the batteries.
  • Page 45 12. Maintaining Wet Batteries 5. Check water level daily. Fill, if needed. 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 46: Load Testing The Batteries

    13. Load Testing The Batteries • 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 47: Hydrometer Testing

    14. Hydrometer Testing 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 this type problem. The hydrometer should have specific gravity markings such as 1.265, 1.250, 1.225, and so on.
  • Page 48 14. Hydrometer Testing The Batteries •Hydrometer Testing • To do an accurate test, the battery water level must be high enough to extract enough electrolyte to fill hydrometer so that the float floats. Water should be added prior to charging in order for let the electrolyte to mix.
  • Page 49 14. Hydrometer Testing The Batteries • Minuteman batteries are rated for about 500 charge cycles. The life of the battery will be greatly dependent by the maintenance they receive. • Every time the batteries are charged it uses one cycle.

  • Page 50: Transporting The Machine

    15. Transporting The Machine When transporting the machines on a trailer or truck always: • Tie down the machine securely. • Lower the brush head assembly completely to the floor. • Turn the machine off. • Failure to do the above may result in damage to the machine. Page 50...

  • Page 51: Key Switch

    16. Key Switch •The key switch has 8 terminals. Below shows the three different switch functions. The black bars indicate the internal connection made by the switch in each position. Switch Off Switch On Switch Unload Page 51...

  • Page 52: Solution Filter (New And Old)

    17.1 Solution Filter (Version 1) 17.1 Page 52...
  • Page 53 17.2 Solution Filter (Version 2) 1. The solution filter is located under the machine. 2. The filter can be cleaned by unscrewing cap. 3. Drain solution tank before cleaning filter. Filter Location New Style Solution Filter Page 53...

  • Page 54: Testing The Main Power Relay

    18. Testing the Main Power Relay on the E17, E20 and E26ECO Digital Volt Meter From Battery From Battery 25 Volts Controlled Note: Measure the voltage across the B+ and the B- coil terminals with the wires Controlled attached and the key switch turned on. It should be about 24 volts.
  • Page 55 18. Testing the Main Power Relay on the E17, E20 and E26ECO Digital Volt Meter From Battery From Battery 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 56 18. Testing the Main Power Relay on the E17, E20 and E26ECO Digital Volt Meter From Battery From Battery 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 57 18. Testing the Main Power Relay on the E17, E20 and E26ECO Note: Measure the 25.5 volts voltage across the battery side across the Digital Volt B+ & B- terminals when Meter the machine is under load. From Battery From Battery Controlled Controlled Page 57...
  • Page 58 18. Testing the Main Power Relay on the E17, E20 and E26ECO Note: The voltage should be exactly the The relay is defective 22.4 same as incoming volts battery side when the machine turned Volt Meter on and is under load (motors are running).

  • Page 59: Trouble Shooting The Drive Circuit

    19. Trouble Shooting the Drive Circuit Testing the Potentiometer and Drive Switch circuit. The potentiometer, drive switch and forward switch circuit can be tested all together from the 14 pin harness connector at the I-Drive controller (traction drive models only). •.Remove the rear panel of the machine.

  • Page 60: Trouble Shooting The Traction Drive Switch

    19.1 Trouble Shooting - Traction Drive Switch Testing the Drive Switch. •Remove the access plate on the right side of the drive handle. Test the switch that is connected to the red and white wires coming from the main harness. The blue and black connection should test open until the switch is activated.

  • Page 61: Trouble Shooting - Vacuum Motor Circuit

    19.2 Trouble Shooting –Vacuum Motor The vacuum motor will not turn on Traction Drive models only. 1. Verify the vacuum switch is functioning correctly. The machine should not move in reverse with the squeegee (vacuum on) in the down position. When squeegee is raised, the machine should back up.

  • Page 62: Trouble Shooting - Vacuum Relay

    19.3 Trouble Shooting – Vacuum Relay Retest for voltage across the vacuum coil (small) terminals with the squeegee switch and drive activated. If the voltage is below the 18 volts, replace the I-drive controller. If Coil Terminals voltage is above, continue testing the vacuum relay in step 7.

  • Page 63: Testing The Drive System Potentiometer

    19.4 Testing the Drive System Potentiometer 1. Disconnect the potentiometer from circuit 2. Use ohm meter (preferably an analog type) to measure the resistance across the two outside terminals (Fig. 1). It should measure 5K (5,000 ohms +/- 20%) 3. Measure the resistance from the center terminal to each outside terminal. Fig.

  • Page 64: Notes

    20. Notes Page 64...

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