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Minuteman KS32R Service Manual

32” rider sweeper
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12/03/2013
Service Manual
KS32R
KS32R
32" Rider Sweeper
Trouble Shooting
Adjustments
Adj
For the
For
Training
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t
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Summary of Contents for Minuteman KS32R

  • Page 1 Service Manual For the KS32R KS32R 32” Rider Sweeper Training Trouble Shooting Adjustments CLICK TO ORDER PARTS shop.monsterjanitorial.com 12/03/2013...

  • Page 2: Table Of Contents

    Contents 1.0 General Description Page 3 2.0 Technical Data Page 4 3.0 Design and Mechanics Page 8 3.1 Operation Page 8 3.2 Cylindrical Broom and Side Broom Page 9 3 3 D 3.3 Dust Hopper und Dust filter t filt Page 12 3.4 Steering Page 13...

  • Page 3: General Description

    1.0 General Description Note: Machine is shown with optional left side broom installed...

  • Page 4: Technical Data

    2.0 Technical Data KS32R Dimensions and weights Length with Side Broom 1282 Width without Side Broom Width with 1 Side Broom (Standard) Width with 2 Side Brooms (Optional) Width with 2 Side Brooms (Optional) Hight bove Steering Column 1237 Turning Radius 1580 Basic Weight (incl.
  • Page 5 2.0 Technical Data Filter area m² Plate Filter Stk. Flow Rate m³/h Low Pressure Cylindrical Broom Length / Diameter 670 / 250 Wear Limit Diameter Rotation Speed 1/min Sweeping Mark 45 +/-10 Number of Bristle Array (2 Half-Shell) Stk. each 10 Standart Bristles K901 left / right / rear...
  • Page 6 2.0 Technical Data Diameter Bristle Length Wear Limit / Length of Bristlle Rotation Speed 1/min Standart Bristles Polyethersulfone) Hopper Volume 2 x 25 Front Wheel (Drive) Amer Adiprene red Rear Wheels Rubber Blend Spec. Wheel Pressure Front / Rear l. / Rear r. N/mm²...
  • Page 7 2.0 Technical Data Battery V / Ah 2 x 12 Volt 105 AH Gel Total Power Power Drive Motor 600 (60min) Current Consumption Driving Plane Area / 16% Climbing 7 / 60 Power Sweeping Drive Current Consumption Sweeper and Dust Extraction Current Consumption Sweeper + Side Br..

  • Page 8: Design And Mechanics

    3.0 Design and Mechanics 3.1 Operation Double push button switch sweeping ON-OFF Forward/reverse switch The travel pedal is right of the steering column. The brake pedal, and the park brake lock, is left. Also the pedal for the oversize material flap is on the left side, close to the seat console.

  • Page 9: Cylindrical Broom And Side Broom

    3.2 Cylindrical and Side Broom...
  • Page 10 3.2 Cylindrical Note: The main broom does not lower for the operation: the broom is always in the down position contacting the floor. (also in transport). The brush material is K901. To change the brush you have to remove both To change the brush you have to remove both dust hoppers.

  • Page 11: Side Broom

    3.2 Side Broom The material is PES. The changing is much easier as you only have to loose a hexagonal nut. On the underside of the broom block there are hexagonal nuts and washers for mounting the side broom.

  • Page 12: Dust Hopper Und Dust Filter T H D D T Filt P

    3.3 Dust Hopper and Dust Filter To reach the fan and panel filter, you will have to open the seat cover and then remove the cap.

  • Page 13: Steering

    3.4 Steering The steering link operates directly The steering link operates directly to the carrier plate where the electric drive is mounted. To adjust the tapered roller bearings follow this instructions: Tighten nut to 60Nm Than loose nut after it –Turning steering wheel about 90°to the left and right and right.

  • Page 14: Brake

    3.5 Brake...
  • Page 15 3.5 Brake • The following steps are required to assemble the bowden cable and to adjust the brake: • -The cable coating of the bowden cable remains in the machine • -Contrive the cable into the cable coating on one side and fix it to the clamping nut (overlap for approx.

  • Page 16: Electric Drive

    3.6 Electric Drive The travel drive assembly is complete. It includes the wheel.
  • Page 17 3.6 Front Wheel Drive – Changing Wheel Steps to be executed for changing the front drive wheel Remove holder between Dismount drive unit at the the plate and the brush separation point between the flange wheel support plates Remove the lateral Loosen fixing screws of plate Loosen fixing screws of plate sealing plug...
  • Page 18 3.6 Front Wheel Drive – Changing Wheel Loosen the  Pull brush flange off 8 wheel bolts the motor axle Remove brush flange h fl Pull off the tire...
  • Page 19 3.6 Front Wheel Drive – Changing Wheel Tighten wheel bolts Check condition and crosswise with 16Nm cleanliness of slip rings Check carbon brushes Check carbon brushes for wearing and smooth Insert new tyre and tighten running in the brush wheel bolts crosswise and holder hand-tight...
  • Page 20 3.6 Front Wheel Drive – Changing Wheel Insert sealing plug Place brush flange and into borehole drive in straight onto the motor shaft motor shaft Screw fastening plate Then maintenance is  completed completed. Drive unit may be  mounted to the machine.

  • Page 21: Electric

    4.0 Electric 4.1 The electrical circuit of the KS32R has some logical operations that are controlled by the LDS board the drive controller and relays Here is a brief description of the logic the LDS board, the drive controller and relays. Here is a brief description of the logic...

  • Page 22: Electrical Description

    4.1 Electric LDS function If at the LDS A2 X1/PIN1 voltage is applied, the output X1/PIN8 is energized. This activates the K2 relay. The K2 relay switches power on the contacts PIN4 to PIN2. Through this, the current path to the input X1/PIN4 at the LDS will be closed. This feedback is evaluated by the LDS A2.
  • Page 23 4.1 Electric Sweeping function The double push button S3 is used to switch ON/OFF the sweeping (main broom motor M2) (main broom motor M2). It is supplied, with power on the path A2 X1/PIN10 (when LDS is active) => temperature switch M2 YE1 to YE2 =>...
  • Page 24 4.1 Electric The drive controller A1 also monitors the seat contact switch. Driving If the drive controller A1 X1/PIN15 has correct power supply it is active. Additionally, if the plug X1/PIN11 (temperature switch drive motor o.k.) is supplied and the main power supply BP1 is energized works the output X1/PIN14 and the potentiometer output X1/PIN1.
  • Page 25 4.1 Electric Monitoring of seat contact switch If seat contact switch S5 is interrupted during operation there is no signal anymore to X1/PIN5 of Controller A1 This leads to an operation there is no signal anymore to X1/PIN5 of Controller A1. This leads to an internal program procedure that will change, after approx.

  • Page 26: Electric Box

    The Electric box is located behind a bolted panel above the hopper. Here are all important components of the electrical system, with the exception of the control switch and the drive potentiometer. The KS32R is equipped with an onboard charger. It is also mounted in the electric box. q pp The attached power cord is in a open chamber, on the right hand side of the machine.
  • Page 27 4.2 Electric Box A1 Drive Controller F3 Fuse K3A, K3B and K2 Relays Onboard Charger G2 F1 and F2 Fuse Main Relay...

  • Page 28: Drive Controller

    4.3 Drive Controller The drive controller is not programmable. The seat switch is wired in the drive controller circuit. The seat switch is wired in the drive controller circuit. This prevents accidental operation, when not sitting in the seat. The error code LED indicator is located here...
  • Page 29 4.3 Drive Controller The drive potentiometer R1 receives from drive controller A1 a 12V reference voltage supply. It has internally a fixed resistor of 1.7 k Ohm and is connected in series with a variable resistor 0-4 k Ohm. A voltage between 0V and 12V is given back to the control (between X1/PIN2 and X1/PIN3) This leads voltage between 0V and 12V is given back to the control (between X1/PIN2 and X1/PIN3).
  • Page 30 4.3 Drive Controller Error Codes Error/Alarm Code Code Description Trouble Shooting Alarm A1 / 1 FORWARD At key-on travel direction Attend starting sequence / check wires switch ON switch S2 is closed to X1/PIN12 and plugs Alarm A2 / 2 REVERS switch At key-on travel direction Attend starting sequence / check wires and switch S2 is closed to X1/PIN13...
  • Page 31 4.3 Drive Controller Error Codes Error/Alarm Code Code Description Trouble Shooting Alarm A10 / 10 High voltage High voltage Battery voltage is above 45V; Check the batteries Alarm A11 / 11 Overload Protection against overload; Check motor current current current Current >70A Current 70A Alarm A12 / 12 Locking device...

  • Page 32: Lds

    4.4 LDS (Low Discharge Signal) The LDS is mounted underneath the dash board. The DIP switches allows the battery type to be changed. This changes the voltage that the machine shuts down at, when the batteries are discharged. NOTE: Setting the dip switches incorrectly may damage batteries.
  • Page 33 4.4 LDS Settings •If all Dip switches are ON then the wired detection is used •If all Dip-switches are ON, then the wired detection is used. •The LDS could show via the LED´s (LDS; bottom row) the following error messages: Error 1) All LED´s flashing (Red and 3 x Green) means that PIN 4 of LDS has no return signal =>...

  • Page 34: Battery Types

    4.4 Battery Types Battery types defined •GiS and GiV are flat 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 AGM batteries with liquid electrolyte. AGM batteries are wrapping electrodes with fiberglass separators.

  • Page 35: Charger

    4.5 Charger The KS32R comes standard with a built in charger. The charger is integrated into the sweepers electrical system and can not be removed. The charger is delivered with the characteristic curve for the standard battery (currently the only version). It is possible to modify these characteristics. For this, the charger must be released from the holder, because the programming button is located on the bottom side.

  • Page 36: Charger Settings

    4.5 Charger Settings Default setting for factory supplied gel batteries Default setting for factory supplied gel batteries = Indicates LED is on. =Indicates LED is off.
  • Page 37 4.5 Charger Status Indicator Displayed via the top LED row on the LDS display Note: If there is a error, the LEDs flash once per second Description Of Errors Battery missing; Connected reverse poled; Cell voltage < 1,25V Cell voltage > 2,4V Longer than 30min.

  • Page 38: Recommended Maintenance

    5.0 Recommended Maintenance Weekly Maintenance Interval Interval Activity daily weekly Check battery charge; charge battery, if necessary Clean broom space of cylindrical broom Clean panel air filter using shaking device Clean panel air filter using shaking device Empty the dirt hopper Check side broom for signs of wear and damage;...
  • Page 39 5.0 Recommended Maintenance Every 125 Hours Interval Activity Activity every 125 operating hours Check battery and charger Check side broom for signs of wear and damage; change, if necessary Check cylindrical broom for signs of wear and damage; change, if li d i necessary Check sweeping pattern of side broom;...
  • Page 40 5.0 Recommended Maintenance Every 250 Hours Interval Activity Activity every 250 operating hours All maintenance work in accordance with Hako system maintenance I Check fan belt; adjust belt tension or change fan belt, if necessary Check the visual appearance of the vehicle Test drive and function test of all safety-related components Test drive and function test of all safety related components...
  • Page 41 5.0 Recommended Maintenance Every 500 Hours Interval Activity every 500 operating hours every 500 operating hours All maintenance work in accordance with Hako system Check electrical systems (operating panel, on-board charger, battery poles, cables, seat contact switch, lighting, fuses, relays and control lamps) control lamps) Check the carbon brushes of the drive motor and central motor for...

  • Page 42: Notes

    6.0 Notes...

  • Page 43: Wiring Diagrams

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