Page 1 SERVICE MANUAL Version 1.0 Operator and Parts Manual R.P.S. Corporation Phone: 1-800-634-4060 R.P.S. Corporation Phone: 1-800-450-9824 P.O. Box 241 Fax: 1-866-632-6961 P.O. Box 241 Fax: 1-866-632-6961 Racine, Wisconsin Racine, Wisconsin 53401 www.tomcatequip.com...
Page 2 CAUTION! To reduce the chance of personal injury and/or property damage, the following instructions must be careful observed: Proper service and repair are important to the safety of the service technician and the safe reliable operation of all cleaning equipment. If part replacement is necessary, the part must be replaced with one of the same part number or with an equivalent part.
Page 3 Mid-Central Corporation. This includes all text, illustrations, tables and charts. ©2006 R.P.S. Corporation Printed in U.S.A. As our policy is one of constant improvement, all speciﬁcations are subject to change without notice.
Page 4 SAFETY SAFETY MESSAGE Your safety and the safety of others is very important and operating this unit safely is an important responsibility. To help you make informed decisions about safety, we have provided opera- tion procedures and other safety information in this manual. This information informs you of potential hazards that could hurt you or others.
Page 5: Safety Precautions
SAFETY SAFETY PRECAUTIONS • Hazardous voltage. Shock, Burns or electrocution can result. ALWAYS disconnect the batteries before servicing machine. • Batteries emit hydrogen gases, explosion or ﬁre can result. Keep sparks and open ﬂame away! • Charge unit in a well ventilated area and keep battery compartment open when charging or explosion or ﬁre could result.
Page 7: Table Of Contents
TABLE OF CONTENTS CONTENTS MAINTENANCE MAINTENANCE SCHEDULE ............1-1 LUBRICATION ..................1-1 MACHINE PARTS CONTROL DESCRIPTION ............2-3 SQUEEGEE SYSTEM SQUEEGEE SYSTEM COMPONENTS ..........3-1 SQUEEGEE SUSPENSION BREAKDOWN ........3-2 TRIANGLE PLATE & TOW BAR ..........3-3 UP/DOWN MOVEMENT ...............3-3 SIDEWAYS MOVEMENT .............3-3 SQUEEGEE BLADES ..............3-3 REPLACING BLADES ..............3-4 ORDERING BLADES ..............3-4...
Page 8 TABLE OF CONTENTS SOLUTION SYSTEM DISPENSING SOLUTION ............. 6-1 ADJUSTING SOLUTION FLOW ............6-2 DRAINING SOLUTION TANK ..............6-2 CLEANING SOLUTION FILTER ............6-2 SOLUTION SYSTEM ELECTRICAL CIRCUIT ......6-2 SOLUTION SYSTEM DIAGNOSIS FLOW CHART 1 OF 2 ..6-3 SOLUTION SYSTEM DIAGNOSIS FLOW CHART 2 OF 2 ..6-4 BRUSH DRIVE SYSTEM DISC ......................
Page 9 TABLE OF CONTENTS BATTERY SAFETY 11-1 DANGER OF EXPLODING BATTERIES ........... 11-1 SAFE CHARGING ................11-1 HANDLING BATTERY ACID .............. 11-2 WATER ....................11-2 BATTERY TERMINAL TYPES ............11-2 TAPERED TOP TERMINAL (S.A.E. POST) ....... 11-2 STUD TERMINAL ............... 11-3 COMBINATION TERMINAL ............
Page 10 TABLE OF CONTENTS COMPUTER CONTROL SYSTEM 13-1 CONTROLLER OVERVIEW ............13-1 INPUTS ....................13-1 OUTPUTS ................... 13-1 PULSE WIDTH MODULATION ........... 13-1 CONTINUITY TESTING .............. 13-1 SOFT START ................13-2 CONNECTIONS ..................13-2 MOLEX MINI FIT JR..............13-2 AMP TERMINALS ...............13-2 BINDING POST TERMINALS ............13-2 TIMED CIRCUITS ................13-2 BATTERY METER ................13-2 DOWN PRESSURE CONTROL ............13-2...
Page 11 SPECIFICATIONS Machine Length 58 3/4 in. (149cm) Machine Height 40 1/4 in. (102cm) Machine Chassis Width 24.1/2 in. (62 cm) Machine Current Consumption (Average) 55 Amps Brush Motor: Up to 70 Amps Vacuum Motor: Up to 30 Amps Transport Drive: Up to 70 Amps Solution Tank Capacity 30 Gallons (114 liters)
Page 12 SPECIFICATIONS Magnum-26C Magnum-26D Magnum-30C Magnum-30D Magnum-34C Magnum-34D Machine Width with Squeegee 32 3/4 in. 32 3/4 in. 36 3/4 in. 36 3/4 in. 43 3/4 in. 43 3/4 in. 83 cm 83 cm 93 cm 93 cm 111 cm 111 cm Scrub Brush Size (qty.
Page 13: Maintenance
MAINTENANCE MAINTENANCE MAINTENANCE SCHEDULE �� ATTENTION! Make sure machine is turned off and the batteries are disconnected before performing any repairs or service on the machine! Your machine is equipped with four brush-type motors that require periodic inspection to assess wear.
Page 14 MAINTENANCE �� ...
Page 15 MAINTENANCE �� ...
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Page 17: Machine Parts
MACHINE INTRODUCTION MACHINE PARTS M AC H I NE C O NT R O LS A N D F EAT U R ES 1. MAIN POWER SWITCH 2. FORWARD/REVERSE SWITCH (RED) 3. SPEED CONTROL KNOB 4. LCD SCREEN 5. MENU CONTROL T R O LS A N D F EAT U R ES 6.
Page 18 FIGURE 2. MACHINE INTRODUCTION FIGURE 3. M AC H I NE C O NT R O LS A N D F EAT U R ES 20. TRACTION DRIVE 21. SOLUTION FLOW VALVE 22. SOLUTION FILTER 23. DRIVE BUTTON 24. “DRAIN SAVER” STRAINER 25.
Page 19: Control Description
MACHINE INTRODUCTION CONTROL DESCRIPTION 1. MAIN POWER SWITCH: Turns the machine on and off. 2. FORWARD/REVERSE SWITCH (RED): Makes the machine move backwards when depressed. 3. SPEED CONTROL KNOB: Controls the speed of the Traction Drive. 4. LCD SCREEN: Lists status, functions and settings of the machine. 5.
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Page 21: Squeegee System
SQUEEGEE SYSTEM SQUEEGEE SYSTEM The Magnum’s squeegee system is designed to work with the recovery system to pick up water and dirt from the ﬂoor using air ﬂow created by the vacuum motor. The front blade of the squeegee tool is designed with notches that allow the air ,water and dirt to pass through it while metering the air, increasing its speed through the tool and recovery system.
Page 22: Squeegee Suspension Breakdown
SQUEEGEE SYSTEM A pitch adjustment that allows the operator to adjust the squeegee for different ﬂoor surfaces. This is used for creating more of a leak under the front blade for smooth ﬂoors or less of one for rough ﬂoors. SQUEEGEE SUSPENSION BREAKDOWN �...
Page 23: Triangle Plate & Tow Bar
SQUEEGEE SYSTEM TRIANGLE PLATE & TOW BAR These parts cannot be bent at all. They must be completely straight and ﬂat. If either is bent replace it. If you replace the triangle plate, adjust the clearance between the bottom of the plate and the top of the tow bar so clearance is 7/8”...
Page 24: Replacing Blades
SQUEEGEE SYSTEM The front blade wears very well when properly adjusted, but it can get torn. It can be installed one of two ways: “3 notches down” for normal ﬂoors, and “5 notches down” for extremely smooth ﬂoors. REPLACING BLADES We stock individual blades or blade kits that include a blade set and new set of squeegee wheels.
Page 25: Squeegee Adjustment
SQUEEGEE SYSTEM SQUEEGEE ADJUSTMENT A squeegee needs to be adjusted to the type of surface that it is operating on. This means the adjustments that pick up well on rough concrete will probably not work well on glass- smooth vinyl tile or ceramic tile. The reverse would hold true also, a squeegee set up for a smooth surface will not work well on rough surfaces.
Page 26: Squeegee Adjustment Examples
SQUEEGEE SYSTEM SQUEEGEE ADJUSTMENT EXAMPLES �� FRONT BLADE FRONT BLADE � � � � �� ...
Page 27: Squeegee Wheel Adjustment
SQUEEGEE SYSTEM The squeegee assemble has adjustable squeegee wheels. The adjustment for this is a 5/16 ﬁne thread bolt and lock nut. It was designed this way to keep non-service person- nel from adjusting it. The squeegee wheels wear with use and periodic adjustment of their height is required.
Page 28 SQUEEGEE SYSTEM �� ...
Page 29 SQUEEGEE SYSTEM MAGNUM SQUEEGEE DIAGNOSTIC FLOW CHART 1 of 2 Operate the Verify operation with the Is there a Squeegee does machine and verify customer and educate the problem with the not pick up water the customers customer on the way their machine? complaint machine works...
Page 30 SQUEEGEE SYSTEM MAGNUM SQUEEGEE DIAGNOSTIC FLOW CHART 2 of 2 From Previous Page Check to make sure the spacers, washers and springs are all there and in working order. Are there Replace parts and missing parts? adjust squeegee Verify the measurement where the front of the Operate the triangle plate bolts to the...
Page 31: Squeegee Lift System
SQUEEGEE LIFT SYSTEM SQUEEGEE LIFT SYSTEM The squeegee lift system on the Magnum was designed with simplicity in mind. It has very straight forward operation and minimal parts to assure consistent and highly reliable opera- tion. TO OPERATE Move the squeegee lift lever from right to left. The squeegee will drop and the vacuum motor will then run.
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Page 33: Recovery System
RECOVERY SYSTEM RECOVERY SYSTEM The recovery system of the Magnum series is powered by a 24 volt 550 watt vacuum motor. The recovery tank is designed with a large lid to facilitate 100% access for complete clean- ing out the recovery tank when use of the machine is ﬁnished. The vacuum motor draws air in through the squeegee tool, through the squeegee hose and into recovery tank.
Page 34: Vacuum Float
RECOVERY SYSTEM VACUUM FLOAT The vacuum ﬂoat assembly is located inside the RETAINING recovery tank and is accessed by opening the re- CLAMP covery tank lid. The ﬂoat assembly stops the ﬂow of air in the event that the recovery tank is ﬁlled to capacity.
Page 35: Vacuum Motor
RECOVERY SYSTEM VACUUM MOTOR The vacuum motor used on the Magnum series scrubbers is a high efﬁciency, shunt would motor. The motor runs a approximately 12, 000 RPM. The motor is rated at 550 watts and has 72” of water lift. Although the motor has service parts available it is advised to replace the entire motor as all the motor parts have about the same life and repairs are usually cost prohibitive.
Page 36 RECOVERY SYSTEM MAGNUM RECOVERY SYSTEM DIAGNOSTIC FLOW CHART 1 of 3 Instruct customer on Machine is not Verify customer Is there a how to operate their picking up water. complaint problem? machine Retest the machine Is the recovery Empty tank and tank empty and the clean ”Drain “Drain Saver”...
Page 37 RECOVERY SYSTEM MAGNUM RECOVERY SYSTEM DIAGNOSTIC FLOW CHART 2 of 3 FROM PAGE 1 Bill customer Adjust squeegee Instruct customer on and retest proper machine Is the squeegee machine Did this remedy maintenance adjusted properly? (See squeegee the problem? section for assistance) Install squeege Did this remedy...
Page 38 RECOVERY SYSTEM MAGNUM RECOVERY SYSTEM DIAGNOSTIC FLOW CHART 3 of 3 FROM PAGE 2 Bill the customer Check inside the hose for obstructions Clean out Were any Did this remedy the obstructions or obstructions or problem? clogs and clogs found? retest machine.
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Page 40: Solution System
SOLUTION SYSTEM SOLUTION SYSTEM The solution system on the Magnum series consists of main body of the machine which is also the solution tank, the ﬁll opening, sight gauge/drain, ﬁlter, potentiometer, controller, and solution solenoid valve. The solution is turned on automatically when the brush deck is turned on and turns off automatically when the brush deck tuns off.
Page 41: Adjusting Solution Flow
SOLUTION SYSTEM SOLUTION SYSTEM ELECTRICAL CIRCUIT The electrical circuit of the Magnum series is divided into two parts. The input circuit and the output circuit. The input circuit consists of the controller, the scrub switch and the solution potentiometer. The controller produces a high (5 volt) and a low (0 volt) signal that is sent to the potentiometer the potentiometer outputs a varied voltage from 0 to 5 volts.
Page 42: Solution System Diagnosis Flow Chart 1 Of 2
SOLUTION SYSTEM SOLUTION SYSTEM DIAGNOSIS FLOW CHART 1 of 2 Advise Customer on Test Machine / Does the machine proper machine NO Solution flow Verify Complaint dispense water? operation Is the scrub switch Turn on the water turned on? switch Turn the solution Is the solution potentiometer to...
Page 43: Solution System Diagnosis Flow Chart 2 Of 2
SOLUTION SYSTEM SOLUTION SYSTEM DIAGNOSIS FLOW CHART 2 of 2 From Previous Page Does the scrub deck turn on See Section 13 “Brush when a green handlebar Switch”page 13-12 button is depressed? Use a voltmeter to test for voltage across the Deltrol valve terminals when the green handle bar button is depressed.
Page 44: Brush Drive System
BRUSH DRIVE SYSTEM BRUSH DRIVE SYSTEM The brush drive system on the Magnum Series comes in two versions. The disc type and the cylindrical type. Each one has its own merits although they do the same thing which is turn the scrub brush or scrub pad.
Page 45: Setting Brush Pressure
BRUSH DRIVE SYSTEM SETTING BRUSH PRESSURE The scrub deck pressure is adjusted continuously while scrubbing. Using the brush pres- sure switch on the control panel you set the desired scrubbing pressure. The desired brush pressure is shown on a bar graph on the LCD display. There are 5 different settings to choose from.
Page 46: Installing & Removing Brushes
BRUSH DRIVE SYSTEM INSTALLING & REMOVING BRUSHES DISC MACHINES With the machine turned on, turn off the brush deck switch. Turn machine power off. Open the two latches on the jaws and swing them aside. Rotate each brush until both tabs of the spring clip are accessible.
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Page 48: Brush Lift System
BRUSH LIFT SYSTEM BRUSH LIFT SYSTEM The active brush lift system on the Magnum series consists of an actuator, down pres- sure springs, scrub switch and the controller. The brush deck is raised and lowered by the brush deck actuator which is driven by the controller. The actuator circuit is internally protected from electrical overload by the controller.
Page 49: Down Pressure
BRUSH LIFT SYSTEM ing the parameters of the controller. When the throttle button is depressed the controller monitors the amp draw of the brush motor and adjusts the scrub deck height to obtain the target amp draw on the scrub motors. The target amp draw of the motors is set using the brush pressure switch on the control panel.
Page 50: Actuator Adjustment
BRUSH LIFT SYSTEM ACTUATOR ADJUSTMENT To access the limit switch in the actuator remove the black rubber strip on the face of it. Loosen the set screw just enough for the switch to slide. To increase the travel of the deck slide the limit switch down toward the ﬂoor.
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Page 52: Traction Drive System
TRACTION DRIVE SYSTEM TRACTION DRIVE SYSTEM The Magnum series of scrubbers is powered by and electric transaxle system. The trans- axle is self contained and bolts to the bottom of the frame. The trans-axle is equipped with a 1/2 horsepower motor that transfers power through a shear key into the differential as- sembly.
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Page 54: Chassis System
CHASSIS SYSTEM CHASSIS SYSTEM The chassis system on the Magnum series is built on a heavy duty 7 gauge powder coated full frame. The frame gives the machine great strength and durability. Everything is fas- tened to the frame using stainless steel hardware allowing for easy servicing should a repair be needed.
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Page 56: Battery Safety
BATTERY SYSTEM BATTERY SAFETY DANGER OF EXPLODING BATTERIES Batteries contain sulfuric acid and produce explosive mixtures of hydrogen and oxygen. Because self-discharge action generates hydrogen gas even when the battery is not in op- eration. Make sure batteries are stored and worked on in a well ventilated area. ALWAYS wear ANSI Z87.1 (U.S.
Page 57: Handling Battery Acid
BATTERY SYSTEM HANDLING BATTERY ACID Battery acid, or electrolyte, is a solution of sulfuric acid and water that can destroy clothing and burn the skin. Use extreme caution when handling electrolyte and keep an acid neu- tralizing solution - such as baking soda or house hold ammonia mixed with water - readily available.
Page 58: Stud Terminal
BATTERY SYSTEM STUD TERMINAL The stud terminal is typically used on heavy duty batter- ies. The terminals have a stainless steel threaded stud embedded in them that the connections are made to. COMBINATION TERMINAL The combination terminals come in a few different conﬁgurations.
Page 59: Battery System
BATTERY SYSTEM BATTERY SYSTEM The battery system for the Magnum series consists of either 2 - 12 volt or 4 -6 volt deep cycle batteries. They are offered in 3 different sizes of lead acid and 2 sizes of mainte- nance free gel battery for each machine.
Page 60: Battery Cables & Terminals
BATTERY SYSTEM BATTERY CABLES & TERMINALS The battery cable connections must remain tight and corrosion free. In the event that the battery cables or terminals become corroded follow accepted battery safety precautions, disassemble and clean the terminals with a baking soda and water solution and a wire brush, making sure not to get any INSIDE the battery.
Page 61 BATTERY SYSTEM The state-of-charge of a lead acid battery can be determined by the speciﬁc gravity of the electrolyte (its weight compared to water). The speciﬁc gravity can be measured directly with a hydrometer or determined by the stabilizing voltage. A hydrometer is a bulb-type syringe which will extract electrolyte from a cell.
Page 62 BATTERY SYSTEM When testing with a load tester you are looking for a difference between cells of the batter- ies. All the battery cells should have similar readings. Any battery that contains a cell that has a value lower than .050 of the rest of the cells indicates you have a bad battery. Load test with a load tester: Make sure batteries are fully charged.
Page 63: Battery Replacement
BATTERY CHARGERS There are 2 different chargers available for the Magnum series machines. We offer an off- board charger standard with the machine and an on-board charger is available as an op- tion.
Page 64: On-Board Charger
BATTERY SYSTEM ON-BOARD CHARGER An on-board charger is offered as an option on the Magnum series of machines. The charger is a waterproof charger that is mounted right to the chassis of the scrubber. It is operated by simply plugging the power cord into the wall. The charger then will run through its charge cycle and automatically shut off.
Page 65: On Board Charger Trouble Shooting
BATTERY SYSTEM � � � � ON BOARD CHARGER TROUBLE SHOOTING � � �� ...
Page 66: Fault Codes
BATTERY SYSTEM FAULT CODES FLASHING RED LED: Corrupt program memory in micro controller detected, charger mi- croprocessor has become corrupted. Charger must be returned to the factory. FLASHING YELLOW LED: Timer has expired. The 253-2441 uses a timer to independent- ly monitor each mode of the charge cycle: bulk, absorption and ﬁnish.
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Page 68: Electrical System
RELAYS The Magnum series uses only one relay. This relay is used to power the buss bars and iso- late them from the controller. There are relays internally mounted in the controller but these are not serviceable.
Page 69: Vacuum Motor
ELECTRICAL SYSTEM VACUUM MOTOR The vacuum motor is a very high speed motor that develops vacuum for the recovery sys- tem. The motors are designed to give a service life of 500 hours. See the “Recovery Sys- tem” chapter 5 for more information. ACTUATORS The Magnum uses only one actuator.
Page 70: Controller High Amp Output Terminals
ELECTRICAL SYSTEM REMOVAL TOOL MOLEX MINI-FIT JR. CRIMPING TOOL CONTROLLER HIGH AMP OUTPUT TERMINALS (Brush, Vacuum, Traction) The controller high amp output connectors are crimped with a special crimping tool at the factory. The tool is not practical to use in the ﬁeld so in the event that a new terminal is needed a wire end kit is available that is ﬁeld installable.
Page 71 ELECTRICAL SYSTEM YELLOW #201 RED #182 RED #202 RED #27 RED #183 BLACK #233 BLACK #233 BLACK #233 RED/WHT #220 SWITCH, VACUUM GREEN #221 BLACK #260 WHITE #261 BLACK #233 GREEN #232 BLACK #233 WHITE #234 GREEN #232 BLACK #233 WHITE #234 YELLOW #201 RED #202...
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Page 79: Computer Control System
COMPUTER CONTROL SYSTEM COMPUTER CONTROL SYSTEM The Magnum series of machines is equipped with the Central Command II control system. Central Command II is designed around a very powerful controller that is has a industrial computer integrated into it. The controller is linked to a Liquid Crystal Display (LCD) to relay information to the operator or the service technician.
Page 80: Soft Start
COMPUTER CONTROL SYSTEM SOFT START Three of the outputs; traction, brush & vacuum, have a soft start function on them. This function provides the ability to start and stop a motor gradually over a measured period of time, 0-10 seconds. This aids in the longevity of the motors and anything driven by them as it greatly decreases the shock load on them.
Page 81 COMPUTER CONTROL SYSTEM LCD DISPLAY The LCD display is a multi function display that conveys machine information to the opera- tor about the operation state of the machine and diagnostic information in the event of a malfunction. The LCD display communicates to the controller on a serial data connection that is made via the 6 wire connector running from the display to the controller.
Page 82: Screen 3
COMPUTER CONTROL SYSTEM SCREEN 3 To access this from screen 1 press the green page button twice. 9: BATTERY METER - This meter shows the charge level of the batteries in the machine. This gauge is designed to read properly while the machine is in use and therefore will vary during usage of the machine.
Page 83: On Board Diagnostics
COMPUTER CONTROL SYSTEM ON BOARD DIAGNOSTICS The Central Command II control system utilizes a Diagnostic Code system that displays diagnostic codes on the LCD display should a malfunction of the machine occur. The diag- nostic code can be looked up in the diagnostic code chart and it will assist you in determin- ing the cause of malfunction.
Page 84: Tri-State Logic
COMPUTER CONTROL SYSTEM decide what device there is a request for and how it should operate the device. TRI-STATE LOGIC The Central Command II system uses very low voltage throughout it’s control system. This voltage is less than battery voltage and the controller will be destroyed if battery volt- age is induced into the control circuits.
Page 85: Programming
COMPUTER CONTROL SYSTEM PROGRAMMING We use the same controllers on nearly all of our machines. The controller’s embedded computer needs a set of instructions to operate the machine. The instructions are the program the computer runs and we can modify this program by changing it’s “parameters”. This is what makes it possible to use the same controller in most of our machines but have each one of them react differently.
Page 86 COMPUTER CONTROL SYSTEM MAGNUM BATTERY DIAGNOSTIC FLOW CHART 1 of 1 Operate machine BATTERIES are not Instruct owner on and verify the Do the batteries working properly / proper machine customers work properly? Diminished run time. operation complaint. Is the Are the Fill batteries following The batteries are...
Page 87 COMPUTER CONTROL SYSTEM MAGNUM BRUSH DECK ACTUATOR DIAGNOSTIC FLOW CHART 1 of 1 Operate machine BRUSH DECK Instruct owner on and verify the Does the actuator ACTUATOR does not proper machine customers work properly? operate properly. operation complaint. Turn on the scrub deck switch and then drive the machine.
Page 88 COMPUTER CONTROL SYSTEM MAGNUM BRUSH PRESSURE SWITCH DIAGNOSTIC FLOW CHART 1 of 2 Operate machine Instruct owner on “BRUSH PRESSURE” and verify the Does the switch proper machine switch does not work. customers work properly? operation complaint. At the 20 pin Molex connector Using voltmeter set the meter to DC at the controller, back probe volts.
Page 89 COMPUTER CONTROL SYSTEM MAGNUM BRUSH PRESSURE SWITCH DIAGNOSTIC FLOW CHART 2 of 2 FROM PAGE 1 “A” Place the ( + ) probe back on the center terminal of the switch. (yellow wire) Move the switch down and note your reading. Was the voltage between 0 and 0.3 Call the factory...
Page 90 COMPUTER CONTROL SYSTEM MAGNUM BRUSH SWITCH DIAGNOSTIC FLOW CHART 1 of 2 Operate machine Instruct owner on “BRUSH SWITCH” and verify the Does the switch proper machine does not work. customers work properly? operation complaint. Turn on the scrub deck switch and then At the 20 pin Molex connector drive the machine.
Page 91 COMPUTER CONTROL SYSTEM MAGNUM BRUSH SWITCH DIAGNOSTIC FLOW CHART 2 of 2 FROM FROM PAGE 1 PAGE 1 “A” “B” With a voltmeter set to the DC volt scale measure Did the voltage of the Is the voltage Replace the brush from the negative terminal raise to between 4.8 between 4.8 and 5.2...
Page 92 COMPUTER CONTROL SYSTEM MAGNUM BUSS RELAY DIAGNOSTIC FLOW CHART 1 of 2 Operate machine Is the (+) Instruct owner on “( + ) BUSS BAR” does and verify the buss bar receiving proper machine not power up. customers battery voltage? operation complaint.
Page 93 COMPUTER CONTROL SYSTEM MAGNUM BUSS RELAY DIAGNOSTIC FLOW CHART 2 of 2 From From Page 1- Page 2 Is there Repair break in the wiring battery voltage between terminal #86 (black wire) across these and the negative buss bar terminals? Is there Repair connection battery voltage...
Page 94 COMPUTER CONTROL SYSTEM MAGNUM DRIVE MOTOR DIAGNOSTIC FLOW CHART 1 of 1 Operate machine Does the Instruct owner on “DRIVE MOTOR” does and verify the drive motor work proper machine not work. customers properly? operation complaint. Does Address machine anything else not turning on first.
Page 95 COMPUTER CONTROL SYSTEM MAGNUM EMERGENCY STOP DIAGNOSTIC FLOW CHART 1 of 1 Operate machine Does the Instruct owner on “EMERGENCY STOP and verify the EMERGENCY proper machine SWITCH” does not work. customers STOP work operation complaint. properly? Replace the Can you EMERGENCY STOP depress the E- SWITCH ASSEMBLY...
Page 96 COMPUTER CONTROL SYSTEM MAGNUM KEY SWITCH DIAGNOSTIC FLOW CHART 1 of 1 Operate machine Instruct owner on “KEY SWITCH” does not and verify the Does the switch proper machine work. customers work properly? operation complaint. Using a voltmeter set to DC volts. Connect the ( -) probe of the meter to the ( - ) buss bar.
Page 97 COMPUTER CONTROL SYSTEM MAGNUM LCD WINDOW DIAGNOSTIC FLOW CHART 1 of 1 Operate machine Is there Instruct owner on LCD Window does not and verify the something wrong proper machine operate properly. customers with the display? operation complaint. Replace the display and 6 wire harness with a known Call tech support good or a new display and...
Page 98 COMPUTER CONTROL SYSTEM MAGNUM ONBOARD CHARGER DIAGNOSTIC FLOW CHART 1 of 1 Operate machine Does Instruct owner on ONBOARD CHARGER and verify the the charger work proper machine does not work customers properly? operation complaint. Measure the voltage of the batteries and record it Ask CUSTOMER...
Page 99 COMPUTER CONTROL SYSTEM MAGNUM ONBOARD CHARGER DIAGNOSTIC FLOW CHART 1 of 1 Operate machine Does Instruct owner on ONBOARD CHARGER and verify the the charger work proper machine does not work customers properly? operation complaint. Measure the voltage of the batteries and record it Ask CUSTOMER...
Page 100 COMPUTER CONTROL SYSTEM MAGNUM ONBOARD CHARGER DIAGNOSTIC FLOW CHART 1 of 2 FROM PAGE 1 With a voltmeter set to the DC scale measure the Does the green voltage of the light turn on when the battery pack in the charger is plugged into machine while the the wall?
Page 101 COMPUTER CONTROL SYSTEM MAGNUM PAGE SWITCH DIAGNOSTIC FLOW CHART 1 of 1 Operate machine Instruct owner on “PAGE” switch is and verify the Does the switch proper machine in operative. customers work properly? operation complaint. Unplug the 20 pin connector from the back of the LCD display Using and Ohm meter measure...
Page 102 COMPUTER CONTROL SYSTEM MAGNUM SQUEEGEE ACTUATOR DIAGNOSTIC FLOW CHART 1 of 1 Operate machine Instruct owner on SQUEEGEE ACTUATOR and verify the Does the actuator proper machine does not operate properly. customers work properly? operation complaint. Turn each switch that can operate the vacuum on one at a time;...
Page 103 COMPUTER CONTROL SYSTEM MAGNUM VACUUM MOTOR DIAGNOSTIC FLOW CHART 1 of 1 Operate machine Instruct owner on “VACUUM MOTOR” does and verify the Does the motor proper machine not run. customers work properly? operation complaint. Turn on the vac motor switch and depress foot pedal.
Page 104 COMPUTER CONTROL SYSTEM MAGNUM WATER POTENTIOMETER DIAGNOSTIC FLOW CHART 1 of 3 Operate machine WATER Can you change Instruct owner on and verify the POTENTIOMETER does water volume with the proper machine customers not change water delivery. Potentiometer? operation complaint. FROM PAGE 3 “C”...
Page 105 COMPUTER CONTROL SYSTEM MAGNUM WATER POTENTIOMETER DIAGNOSTIC FLOW CHART 2 of 3 FROM PAGE 1 “A” While it’s disconnected, Was there a measure the voltage at the smooth sweeping orange wire that was voltage from 0 to 5 connected to the center volts? terminal of the potentiometer.
Page 106 COMPUTER CONTROL SYSTEM MAGNUM WATER POTENTIOMETER DIAGNOSTIC FLOW CHART 3 of 3 FROM PAGE 1 “B” Unscrew the solution screen and make sure Was there a good that water flows solid flow of water out freely out of the of the hose? filter when the bowl and filter are off.
Page 107 COMPUTER CONTROL SYSTEM MAGNUM SPRAY JET DIAGNOSTIC FLOW CHART 1 of 2 Operate machine Is there Instruct owner on Spray Jet does not work and verify the something wrong proper machine properly customers with the Spray operation complaint. Jet? Turn on the Does the Is there Fill solution tank...
Page 108 COMPUTER CONTROL SYSTEM MAGNUM SPRAY JET DIAGNOSTIC FLOW CHART 2 of 2 FROM PAGE 1 Call the factory “A” With a voltmeter set to the Was there Was there DC scale measure from battery battery the negative lead to the voltage? voltage? positive battery terminal.
Page 109 REPAIR INSTRUCTIONS 253-01 VACUUM MOTOR R&R 2/23/2006 Page 1 of 5 TIME REQUIRED: 30 MINUTES NUMBER OF TECHS: 1 PERSON REQUIRED PARTS � 290-250 Vacuum motor � Qty(1) 4’’ wire tie � Qty(2) 10-12 butt connectors REQUIRED TOOLS � 7\16 12 Point deep well socket �...
Page 110 REPAIR INSTRUCTIONS 253-01 VACUUM MOTOR R&R 2/23/2006 Page 2 of 5 2. Release the latch on the front of the jaws and open them. (see figure below) NEED PITCHER WHEN NEW PARTS ARE HERE 3. Carefully tip tank back. (see figure below) DISCONNECTING BATTERIES 1.
Page 111 REPAIR INSTRUCTIONS 253-01 VACUUM MOTOR R&R 2/23/2006 Page 3 of 5 3. Pull the red cable off and secure away from post .( See figure below) VACUUM MOTOR IS LOCATED ON THE BOTTOM SIDE OF RECOVERY AND SOLTION TANK (see figure below) REMOVING VACUUM MOTOR 1.
Page 112 REPAIR INSTRUCTIONS 253-01 VACUUM MOTOR R&R 2/23/2006 Page 4 of 5 1. Using a side cutters remove the yellow 10-12 AWG butt connectors. (see figure below) 2. Using 7\16”12 point deep well socket remove the (Qty: 3) 1\4 -20 nylock nuts that mount vacuum motor to tank. 3.
Page 113 REPAIR INSTRUCTIONS 253-01 VACUUM MOTOR R&R 2/23/2006 Page 5 of 5 2. Locate red and black wires from machine and the two black wires from new vacuum motor strip 5\16”off each end. (See figure below) 3. Using a crimper with insolated 10 &12 setting connect the 10-12 butt connecters to the wires from the machine to the vacuum motor.
Page 114 REPAIR INSTRUCTIONS 253-02 DRAINING TANKS 2/23/2006 Page 1 of 1 NUMBER OF TECHS: 1 PERSON COMPLETELY DRAINING RECOVERY AND SOLUTION TANKS. 1. Make sure machine is on level ground and by a floor drain. 2. Pull down on solution drain hose and set on floor drain to completely drain solution tank.
Page 115 REPAIR INSTRUCTIONS 253-03 HANDLE BAR BUTTON SWITCH R&R 2/23/2006 Page 1 of 2 TIME REQUIRED: 30 MINUTES Per: SWITCH NUMBER OF TECHS: 1 PERSON REQUIRED PARTS � Qty(2) 1/2’’ long 16 awg shrink tubing � Qty(2) 7-229 Push button switch REQUIRED TOOLS �...
Page 116 REPAIR INSTRUCTIONS 253-03 HANDLE BAR BUTTON SWITCH R&R 2/23/2006 Page 2 of 2 REMOVING OLD PUSH BUTTON SWITCH PLATE 1. Using a 3” #2 Phillips head screw driver remove the two 8\32x1\2” screws that hold the switch plate on handle bars. 2.
Page 117 REPAIR INSTRUCTIONS 253-04 DISCONNECTING BATTERIS 2/23/2006 Page 1 of 1 NUMBER OF TECHS: 1 PERSON REQUIRED PARTS � NONE REQUIRED TOOLS � 9\16 12- point box wrench PLACE MACHINE ON LEVEL GROUND AND CHOCK WHEELS. DISCONNECTING BATTERIES 1. Pull back the terminal cover, on the right batteries positive (+) terminal. 2.
Page 118 REPAIR INSTRUCTIONS 253-05 TRANSAXLE R&R 2/23/2006 Page 1 of 4 TIME REQUIRED: 45 MINUTES NUMBER OF TECHS: 1 PERSON REQUIRED PARTS � 32- 3000 Transaxle � Qty(1) 8” wire tie � Qty(2) 10-12 butt connectors REQUIRED TOOLS � 9\16” 12 Point socket �...
Page 119 REPAIR INSTRUCTIONS 253-05 TRANSAXLE R&R 2/23/2006 Page 2 of 4 REMOVING TRANSAXLE 1. Using a 1/2” socket remove the (Qty 4) 5/16 nuts that hold each tire on axle.(Remove tiers) 2. Cut the wire tie that is around the wires harness located in the right rear tier compartment.
Page 120 REPAIR INSTRUCTIONS 253-05 TRANSAXLE R&R 2/23/2006 Page 3 of 4 4. Mark transaxle mounts and frame on both sides of machine before removing. (see figure below) 5. Using a 1\2” socket remove the (Qty 2) 5\16-18 nuts that hold the each (Qty2) axle mount to frame.
Page 121 REPAIR INSTRUCTIONS 253-05 TRANSAXLE R&R 2/23/2006 Page 4 of 4 REINSTALLING TRANSAXLE 1. Strip red and black transaxle wires 5\16”. 2. Strip red and black harness wires 5\16”. 3. Crimp butt connectors on to transaxle wires. 4. Carefully put new transaxle into position. 5.
Page 122 REPAIR INSTRUCTIONS 253-06 JACKING UP DISK MACHINE 2/23/2006 Page 1 of 1 NUMBER OF TECHS: 1 PERSON REQUIRED TOOLS � 3 Ton jack � (QTY:2) Wheel chocks COMPLETELY DRAIN RECOVERY AND SOLUTION TANKS. (SEE REPAIR INSTRUCTION # 253-04) MAKE SURE MACHINE IS ON LEVEL GROUND. JACKING UP MACHINE 1.
Page 123 REPAIR INSTRUCTIONS 253-07 JACKING UP CYLINDRICAL MACHINE 2/23/2006 Page 1 of 1 NUMBER OF TECHS: 1 PERSON REQUIRED TOOLS � 3 Ton jack � (QTY:2) Wheel chocks COMPLETELY DRAIN RECOVERY AND SOLUTION TANKS. (SEE REPAIR INSTRUCTOIN # 253-04) MAKE SURE MACHINE IS ON LEVEL GROUND. JACKING UP MACHINE 1.
Page 124 REPAIR INSTRUCTIONS 253-09 CYLINDRICAL BELT R&R 2/23/2006 Page 1 of 3 TIME REQUIRED: 15 MINUTES NUMBER OF TECHS: 1 PERSON REQUIRED PARTS � (QTY: 1) 353-8230 CYLINDRICAL BELT REQUIRED TOOLS � 9/16’’ CROWS FOOT 3/8’’ DRIVE � 9/16’’ OPEN END WRENCH PLACE MACHINE ON LEVEL GROUND AND CHOCK WHEELS.
Page 125 REPAIR INSTRUCTIONS 253-09 CYLINDRICAL BELT R&R 2/23/2006 Page 2 of 3 2. Using a 9/16’’ open end wrench loosen the (QTY: 1) 3/8-24 locking nut and (QTY: 1) 3/8-24x1’’ belt tension bolt. (see figure below) BELT TENTION BOLT LOCKING NUT 3.
Page 126 REPAIR INSTRUCTIONS 253-09 CYLINDRICAL BELT R&R 2/23/2006 Page 3 of 3 INSTALLING NEW CYLINDICAL BELT 1. Install belt on top sprocket then slip it onto bottom sprocket. 2. Using a 9/16’’ open end wrench slowly tighten the 3/8’’-24x1’’ belt tension bolt. (NOTE: BELT TENTION SHOULD BE NO LESS THEN ¼’’...
Page 127 REPAIR INSTRUCTIONS RI-19 Magnum Service Manual V1.0...
Page 128 REPAIR INSTRUCTIONS RI-20 Magnum Service Manual V1.0...
Page 129 INDEX INDEX Index SQUEEGEE SYSTEM 3-1 LIFT SYSTEM 3-1 SQUEEGEE TOOL 3-1 Magnum Service Manual V1.0...
Page 130 INDEX INDEX Magnum Service Manual V1.0...
Page 131 INDEX INDEX Magnum Service Manual V1.0...
Page 132 SAFETY SAFETY MESSAGE Your safety and the safety of others is very important and operating this unit safely is an important responsibility. To help you make informed decisions about safety, we have provided operation procedures and other safety information in this manual. This information informs you of potential hazards that could hurt you or others.
Page 133 SAFETY SAFETY PRECAUTIONS • Hazardous voltage. Shock, Burns or electrocution can result. ALWAYS disconnect the batteries before servicing machine. • Batteries emit hydrogen gases, explosion or ﬁre can result. Keep sparks and open ﬂame away.! • Charge unit in a well ventilated area and keep battery compartment open when charging or explosion or ﬁre could result.
Page 134 INDEX INDEX Magnum Service Manual V1.0...

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Magnum-26c Magnum-26d Magnum-30c Magnum-30d Magnum-34c Magnum-34d

R.P.S. Corporation Magnum Series Service Manual

Maintenance

Machine Parts

Squeegee System

Squeegee Adjustment Examples

Squeegee Lift System

To Operate

Squeegee Lift Adjustments

Squeegee Lift Electrical Circuit

Recovery System

Solution System

Solution System Electrical Circuit

Brush Drive System

Installing & Removing Brushes

Brush Lift System

Brush Lift Electrical Circuit

Traction Drive System

Chassis System

Chassis Replacement

Battery Safety

Battery System

Battery Maintenance & Care

Battery Chargers

Electrical System

Switches

Relays

Motors

Actuators

Wiring

Computer Control System

Controller Overview

Diagnosing the Control System

Programming

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Summary of Contents for R.P.S. Corporation Magnum Series

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