This 2022a Service Partner Reference Guide (SPRG) is an exciting new publication. We have added a very expanded Robotics Section as a highlight of this publication. We have added lithium and provided updates to USAfix™ desktop and mobile app, ServiceChannel tips, our ARMOR™ telematics device specifications, NPR (National Performance Rating) and much more!
3rd party service is central to our success. We have increased importance in the marketplace utilizing our combined skills. We constantly grow and learn based upon what we see. We are a market needs driven company. This means our success is to listen to and serve the ever changing needs. This new SPRG will help us be more in synch. Use this book as a tool to learn, teach and guide you and your service teams. We will teach more and more on robotics, telemetry and Lithium as we go forward. We will empower you beyond the mechanical part of our jobs to become technology experts.
Technology is central to our vision and future so we talk about it all the time. More updates are included in this addition with Lithium, USAfix™, ARMOR™ and our mobile app. ARMOR is a great tool for managing runtime and charge time intervals for operations, service and capital planning. We are shipping, installing and using technology every single day and appreciate your help our growth.
Welcome to our new 2022a SPRG! Get ready to learn, change and continue to growth in 2023!
Bruce Bushert, President, CEO
How to Order Parts
Order Online at www.usaclean.com
• First time users call 1-800-USA-CLEAN for login info
• Log in at www.usaclean.com
• Browse thousands of parts photos and full equipment diagrams
Call 1-800-USA-CLEAN
• Call 800-872-2532
• Available for orders or tech support Monday-Friday 7:00AM-5:00PM CST, or leave a voicemail after hours
• Be sure to include your complete order info (see right)
• 90% of orders ship the same day
Fax or email to USA-CLEAN
• Fax to 217-877-4086
• Email parts@usaclean.com
• Be sure to include your complete order info (see right)
General Contact Info
Parts Orders parts@usaclean.com
Parts Lookup parts@usaclean.com
Complete Parts Order Info
• Your info: name, title, company and phone #/email
• Location info: site name/number, city and state
• Order info: part #, part description, part quantity
Example of complete order info
“My name is John Smith, Acme Corp. Ops Manager at Memorial Hospital in Chicago, Illinois. You can reach me at 312-555-5555. I’d like 2 pad drivers, part # 172-2175.”
Parts shipped fast
We stock all commonly ordered parts for same day shipping on orders placed before 5:00PM CST. Our inventory grows and adjusts to keep the items you need in stock.
Tech Support & Dispatch dispatch@usaclean.com
Service Execution se@usaclean.com
Federal Employers Identification # 37-1319273
Tax Exempt Reseller # 2503-3972 (see page 203 for form)
IVR Repair Updates # 217-329-0298
Fax # 217-877-4086
Mailing Address
2803 N. 22nd Street Decatur, IL 62526
Website www.usaclean.com
1-800-872-2532 ext. 1
1-800-872-2532 ext. 2
1-800-872-2532 ext. 3
1-800-872-2532 ext. 6
USA-CLEAN Overview
USA-CLEAN, Inc. is a C corporation with over 30 years of experience located in Decatur, IL. We provide repair parts, service, equipment, technical support and asset management to large building service contractors, national retail chains, healthcare and education facilities.
Our focused obsession is to help thousands of floor cleaning equipment owners across America with quality service at competitive rates. Our program is dynamic, flexible, unbiased and comes with an unmatched suite of web enabled tools through USAfix™.
Benefits USA-CLEAN and Service Partners Provide National Accounts
National Accounts choose USA-CLEAN exclusively because we offer:
• One phone call and one bill
• Technician availability in all 50 states, Canada and Puerto Rico
• Service to over 90% of the population on a single trip charge
• Asset tracking and capital forecasts.
Technical Support
• Complete parts lookup online. Check machine models, parts and diagrams of all machines whenever you need them.
• Technical Support Services provides troubleshooting tips and techniques.
• USAfix™ provides brush and propane master guides for better comprehension of trouble machine types and parts.
Easy to Order Parts and Supplies at a Great Discount for Service Partners
• Thousands of parts in stock for easy order
• Orders received by 5:00PM CST ship same day
• Easy to order via phone, fax, email or online within USAfix™
• Our central location allows us to send parts to most of the country in three days or less vis UPS Ground service
• Drop shipments direct from the manufacturer are available
• Our strategic relationships with Minuteman, Pacific, Graco and TASKI give many benefits when ordering from USA-CLEAN
• USAfix™ is a USA-CLEAN creation. It is our proprietary software developed by in-house programmers.
• Access the most dynamic fleet management software available for the floor cleaning equipment industry.
• Manage dispatch, work orders and invoicing online for faster repair times.
• Streamlined warranty claims allow you and the customer to save time and money.
• Monitor machine repairs by site, region or equipment type.
• Track all equipment repairs for the lifetime of the machines.
• Purchase parts and reconditioned equipment.
• Download or view support documents and manuals for most models.
• Technical Education Certifications (TEC) are available to train technicians on unfamiliar equipment.
It’s Easy to do Business with USA-CLEAN*
Following these 5 simple requirements:
1. Bill at our mutually agreed upon rates for labor and travel
2. Charge no greater than manufacturer list price on parts, minus 10%
3. Invoice within 10 days of job completion
4. Comply with workers compensation and general liability insurance requirements
5. Communicate, Communicate, Communicate!
Benefits USA-CLEAN Gives Service Partners
• Discount on parts
We make it easy to order parts and supplies at a great discount for service partners. You will receive a 20% off or higher on parts. We have thousands of parts that are in stock and most orders ship same day for quick repair times.
• Partner with the best nationwide service program and grow as we continue to grow We have focused more than 10 years on equipment repair service.
• Grow your service with our customers
Increase your service department with our local retail and non-retail accounts. For other programs we offer to grow your business please see page 15 and page 16.
• USAfix™ - Online Service Partner Website
USAfix™ is the dynamic fleet management software available for the floor cleaning equipment industry. USAfix™is a USA-CLEAN creation developed by our in-house programmers that makes communication simple and more efficient. USAfix™ offers quick look up for parts, invoicing and much more! Total site repair management makes it easy to track all equipment repairs for the lifetime of the machine.
• Other Exclusive Offerings
- 15% off repaired and fully reconditioned equipment
- Distribution for ARMOR telematics device
- Managed Service Program
• Exclusive Distributor Programs
- floorcare.biz equipment distributor program
- Lithium distributor program Program Terms
• Relationship - It is understood by the parties that you are an independent contractor with respect to USA-CLEAN, Inc. and not an employee of USA-CLEAN, Inc.
• Confidentiality - You will not at any time or in any manner, either directly or indirectly, use for the personal benefit of your company, or divulge, disclose or communicate in any manner any information that is proprietary to USA-CLEAN, Inc. Your company will protect such information and treat it as strictly confidential. This provision will continue to be effective if ever there is a termination of this agreement.
• Termination - USA-CLEAN, Inc. and/or subcontractor may terminate the agreement by providing 10 days prior written notice.
National Service Program
Best Practices
USA-CLEAN specializes in National Accounts and we understand the problems associated with working with the headquarters, regional managers and the field. We have assembled a quick list of Best Practices to follow when working with National Accounts. Please review the list with your Service Manager, Coordinators and Technicians. Over the years we have found that these best practices create and maintain happy customers. We trust our network to understand the customers’ needs and to make the best decisions for those customers.
Communication
Communication is key when it comes to happy customers! You can never over communicate when it comes to National Account business. There are 4 critical points of communication:
1. When you receive a work order from USAC, let us know what day the technician will first be onsite.
2. The USA-CLEAN USAfix™Mobile App will allow you to call the customer when the technician is in route to the site. If the mobile app is not being utilized, the work order will contain the necessary contact information.
3. While the technician is onsite they have 3 options for updating the operational status of the machine:
a) USA-CLEAN Mobile App
b) IVR Repair Hotline
c) Log into USAfix™
4. Expected date when a technician will return to site with the necessary parts.
5. Utilize the mobile app to checkout with the customer onsite. This is the “Signed Work Order” reqirement.
Before Going Onsite
• Customer expectations when it comes to repair turns:
- Onsite the first time to evaluate the machine; within 36 hours of receiving the work order
- Provide repair estimates if over the NTE; within 24 hours of being onsite
- Back onsite once parts arrive; within 24 hours of parts arriving
Nail these expectations and the customers will be thrilled with the service!
• Make sure the technician reads the work order notes before leaving for repair. Certain parts may be required or the site may request that a specific person be contacted before arriving onsite.
• Stock common wear parts on your service trucks (especially common aftermarket vacuum motors). See page 207 for a list of these items. Our work order notes are very good at helping identify which parts may be required for the repair. Our network average completes the repair over 85% of the time on the 1st trip.
• NTE = Not to Exceed: Every work order has an NTE. If parts, labor and travel exceed the NTE, please quote the repair before proceeding further.
• ESD = Estimated Service Date: A more accurate description is the date the tech will next be onsite. Very important that we keep this information up-to-date.
• Technical support documents are available online.
• Warranty - review the work order to see if the machine is under warranty. Make sure you save all replaced parts if the machine is under warranty just in case the OEM requests those parts back.
• When repairing propane buffers, always bring your own propane tank.
1) Tanks onsite are locked up
2) These tanks are frequently overfilled and are often the source of the problem
Onsite
• See the managed Services section for specific advice (page 16 and page 17).
• Call ahead to contact while on the way to site.
• Confirm make/model and serial number. Record serial number if work order doesn’t have one listed. Record hour meter reading.
• Communicate with designated contact if they are present onsite.
• Hang Repair Status tag (see back cover)
• Either update work order status via our mobile app or online, or call IVR Repair Hotline; every time.
• Fill out the battery testing form (see page 202) and list criteria.
• Repairs under NTE requiring 2nd trip do not need to be quoted.
• Never remove a machine from site without talking to USA-CLEAN and receiving permission. Contacts onsite are rarely authorized to make these decisions for our corporate clients. With this in mind, our clients almost always prefer that all repair work is completed onsite. Exceptions are possible but please get permission first.
• Work orders need to be signed every time you are onsite or use 5 star app.
Quoting
• Repairs exceeding NTE must be quoted.
• Quote Fundamentals:
- Make and model verified
- Serial number
- Total labor and travel for both 1st and 2nd trips
- Details
- Part numbers, descriptions, price and quantities
• Quotes need to be submitted within 24 hours of initial visit.
• Back onsite within 24 hours of parts arriving
• Battery pricing to match SNSR (see page 21)
Invoicing and Warranty
• Save warranty parts a minimum of 30 days.
• Invoice within 10 days. Invoices submitted after 10 days may be rejected or penalized.
• File warranty with OEM or request from USAC.
• Clear and accurate repair notes. Use single agreed upon hourly rate and bill only for the time you were onsite and in quarter-hour increments.
• Use agreed upon travel rate that covers 120 round trip miles traveled for each trip to the site.
• Over mileage applies if you have traveled further than 120 round trip miles. You will be paid at your negotiated per mile over 120 miles.
• You may not charge higher than manufacturer’s list price on all parts.
• Abuse or neglect should be noted during service. If abuse or neglect is determined it must be stated on invoice and/or work order.
• No sales tax (see page 203).
USA-CLEAN Mobile App
Mobile App Guide
Communication is key to our success! We have developed the Service Partner Mobile App for a simple way to keep us updated on your open repairs.
Download it now!
Step by Step Guide to the USAfix™ Mobile App
STEP 1
1. Your login is your email
2. Your USAfix™ password
3. If you have forgotten, click forgot password.
STEP 2
1. Refresh to see an updated list of tickets assigned to you
2. Click here to log out in order to switch users.
3. You will see age of repairs and if ESDs are due
1. Clicking on one of the repairs will take you to that ticket
STEP 3
USA-CLEAN Mobile
STEP 4
1. Click the cog icon to see the PDF of the work order
2. You will see the name of the onsite contact and have the ability to text or call them.
3. You will have the same Status options at the IVR or USAfix™
4. Any notes that have been added to the ticket
STEP 6
The signature screen is where the onsite contact who is checking the tech out will “sign off” on the repair. This replaces the need for physical signed paperwork. ALWAYS check out with someone onsite. Ask them to leave a rating and sign you out.
- This is required each time you complete a repair. This protects you against claims of recalls or unsatisfactory work and ensures we are meeting customer expectations on repairs. Even if they choose not to leave a rating, they will need to type their name and sign.
1. Contact will rate their satisfaction with the repair (1-5 stars)
2. Contact will type their name
3. Contact will sign their name on the screen
4. Once the “Submit” button is clicked the corporate customer and USA-CLEAN will be notified or repair status and of who checked the tech out.
STEP 5
1. Type in details on what was found (troubleshooting, etc.)
2. Add photos; critical for abuse/neglect, freight damage, identifying parts needed, etc.
3. Click “Update Ticket” to be taken to the signature screen.
Service Channel Service
Channel
Service Channel is used to track open work orders, monitor completion of work orders and provide updates to several customers. What does that mean? Let’s break it down:
• GPS Compliance is required. This means the tech only has two options to check-in/out of repairs on location.
- The tech can either use the Service Channel GPS application (https://servicechannel.com/gps-check-in-app-for-contractor-partners/)
- If the application is not working or the tech doesn’t have a mobile device/signal, the tech can use a phone at the facility and call 516-500-7776 (backup 516-200-3363) to check-in upon arrival and check-out upon completion of your visit.
• New Service Channel work orders are created for separate issues for tracking by the customer.
- Sometimes this results in multiple Service Channel work orders being assigned to one open ticket on your side. Make sure you review the notes on the ticket carefully before going to location.
- The PIN will always vary by customer, it will be noted in the ticket.
• Both a check-in and a check-out are needed each time you go onsite.
- The “check-in” step basically affirms the customer’s issue and starts the clock for the time spent on location.
- When performing “check-out” ensure you’re choosing the proper code. If parts are needed, do NOT select “complete”. This will result in premature closure of the ticket without resolution and will negatively affect our customer’s scores.
• What if I can’t check-in or out?
- If you’re using the phone application, go ahead and restart your phone. This resolves the majority of problems with errors in the application.
- If the mobile app is unresponsive, go ahead and utilize the option to check-in/out with the site’s phone. You can ask a member of management for access.
- If neither of these are working, the tech MUST call our USA-CLEAN Service Execution team at 800-872-2532, option 5.
• What if I forget to check-in/out?
- It’s understood that accidents happen and sometimes and sometimes a check-in/out is missed. If that occurs, you will have 48 hours after your initial visit to return to the location to complete the required step.
- USA-CLEAN is not responsible for payment of this extra trip.
• What else affects vendor scores since Service Channel is so important?
- Missed ETAs. ESDs are given to these customers daily. When we miss an ESD, that triggers a compliance failure with Service Channel. Compliance failures result in lower scores for vendors. Repeated issues affect a vendor’s ability to work with certain client’s facilities.
- Improperly closing a work order when work is not complete or when parts are needed. This is also viewed as a compliance failure.
- Duration of open tickets. The faster we’re able to resolve an issue, the better the client scores.
App is as easy as 1-2-3!
Step 1:
Open the Service Channel Application and select PIN code. Enter Pin # listed in your ticket.
Step 2:
Tap “work orders” to view all open tickets. You don’t need an account or password to use the application when inputting a PIN.
Step 3:
“Search” and input the work order number you’re wanting to check-in/out on. Once you pick the work order, the button in the center will let you either check-in or out. You can also add notes and photos regarding your repair. These notes go directly to our customers!
Programs Offered by USA-CLEAN to Grow Your Business
Planned Maintenance Program
Advantages:
• Greater customer satisfaction
• Aids in financial forecasting
• Improves profitability and technician utilization
• More opportunities for add-on sales (i.e. parts)
• Growing demand from our customer base
Program Components:
PM Rates
• Riding Equipment = $85.00
• Walk Behind Battery Equipment & Propane Buffers = $50.40
• Small/Plug-In Equipment = $16.20
• A single trip charge = $45.00
• Your work order NTE will reflect these rates
• Parts required for a PM are not included in rates
• These are NOT hourly rates, these are rates by service on the equipment type
Mileage
Turnaround
Parts
Quote Needed
• Over mileage still applies
• Complete within 30 days of receiving work order
• Standard wear parts that need to be brought along are listed in USAfix™and can be added to your shopping cart prior to the trip
• Propane Buffers require the following parts replaced: oil, oil filter, air filter, pre-filter and spark plugs
• It is your responsibility to have these parts available while onsite performing PM
• If you find repairs are required, do not complete PM or install PM parts. Contact your coordinator and provide a repair estimate.
• Once approved, a new work order will then be created
PM Checklist
• The checklist needs to be filled out entirely
• Checklists can be found once logged into USAfix™ under “Documents”
• A customer signature is required
• The checklist must be sent in along with the invoice payment
Please sign and date below if you are in agreement with the rates stated above
USA-CLEAN Programs
Managed Services Overview
An exclusive benefit of being part of the USA-CLEAN network is the potential of tapping into the multi-million dollar Managed Services industry. USA-CLEAN has exclusive contracts with the largest Managed Services companies in the world. Our Managed Services clients focus on non-retail environmental control services in healthcare facilities, nursing homes, universities, school districts, entertainment & sporting venues, government facilities, etc.
The expectations and available service programs for managed services facilities are different than those of a BSC at a retail location. Each managed service facility typically owns their own P&L which puts the equipment purchasing and service decisions in the hands of the site’s general manager. A strong and trusted relationship with the key decision makers is absolutely critical. USA-CLEAN can open the door for the opportunity but owning and maintaining this relationship is your responsibility. The stronger the relationship, the more profitable the account will be over the long term. Please review the “How We Win” section on the next page for some helpful tips.
Managed Services Program
Break/Fix & Planned Maintenance – Having a PM contract with a client significantly increases the probability that future repair business beyond the PM will be performed by your company.
Site Evaluations – USA-CLEAN has developed a site evaluation process to acquire and document the key assets at each facility. These assets will be loaded into USAfix™ and will serve as the core for our comprehensive asset management solution.
Safety Inspections - USA-CLEAN has developed a program to provide annual equipment safety audits. The goals of the program:
• Evaluate our client’s fleet of equipment and assess the functionality of each machine
• “Tag-out” equipment that is not safe to operate
• Affix a unique asset tag to each machine
• Provide a written safety assessment for each machine
Future repairs may be generated from these evaluations but the goal of the audit is not to provide repair estimates. Specific details regarding the Safety Inspection process can be downloaded from the “Documents” tab in USAfix™.
Contact USA-CLEAN Service Network Development if your company would be interested in managed services repair business in your region. Our Development expert will guide you through the process and review the criteria based on the available business.
There are two types of site evaluations, the Basic and the Complete. (see forms section page 204)
Both ask you to provide the make, model, and the serial number of each machine, the operational condition and details on any issues found on the evaluation forms you will find in the “Documents” section on you USAfix™ Homepage.
The Complete asks for you to submit full quotes on each unit and tickets will be made for billing eval time and labor for each machine. In both instances the initial dispatch is where a basic travel and labor is charged for the initial eval trip.
The forms must be filled out correctly and submitted promptly for this process to work smoothly.
Please reach out to your coordinator if you are not clear on the steps needed.
How We Win (In Managed Services Programs)
Schedule Route Work
1
Arrange to visit sites on a weekly or biweekly basis. Perform repair work when needed. Don’t charge the customer if no work is performed. Route work starts slowly, but develops into regular repairs.
Consider offering incentives to begin route work such as a waived trip charge, vac swap program, or bench work. The predictable work and steady income will be a great asset to you.
Arrange a PM Program
Planned maintenance programs are beneficial to clients and technicians. Educate your clients that PM programs can save money and increase their equipment uptime.
2
3
Need help introducing a PM program? We can help you with checklist templates, pricing guidelines and techniques for getting started.
Own the Relationship
A well managed facility can be very profitable. Start a conversation about your client’s equipment needs. Understand their fleet. Provide useful recommendations about repair and replace decisions. Trust is gained when you help them save money.
You have the power to make yourself an invaluable resource that the client cannot afford to lose.
4
Establish a Connection with the General Managers General managers (GM), sometimes ops managers (OM), have the ultimate authority on equipment repair decisions. Although your day-to-day business may be with someone on the staff, you should establish a relationship with the GM/OM to ensure your long term security.
Meet at least once a month with the GM/OM to report equipment status and maintain your relationship.
National Performance Rating (NPR)
National Performance Guidelines
The National Performance Rating (NPR) is calculated monthly and is designed to highlight our top performing service providers. At the end of each month, we assess network performance to our top national accounts and recognize the top 5 low and high volume (based on work order count in the month) providers. Your monthly NPR score is the average of the five category scores listed below. Each category score is a range of 0-100%.
Turn Times
• Each dispatch has an expected turn time based on customer, machine and program.
- Robots: 7 days
- Standard machines in retail: 3 days
- Standard machines in non-retail: 7 days
• Turn Times measures the % of work order completed within the turn expectation.
Communication
• Each customer gets the daily status of all work orders.
• Communication measures the % of work orders adequately statused.
• Was the work order accepted/rejected the same business day as dispatched?
• Was an ESD (estimated service date) set promptly?
- Same day as dispatch for most repairs, same business day as quote approval if not waiting on parts, same business day as parts arrive.
• Was the ticket updated from site before tech left?
- USAfix, Mobile App, Email or Phone
• Was quote (with full details) submitted within 24 hours of being onsite?
- Part numbers, part quantity, part price, labor hours, trip charges and details on troubleshooting/diagnosis.
• Were all required tasks listed on work order completed?
- Service channel updates, photos submitted, testing/troubleshooting completed, forms completed and submitted.
• Was any request for further information responded to?
Invoicing
• We have a deadline to submit our invoice to the customer to avoid non-payment.
• We ask that all providers have their invoice to us by 10 days after service is completed to allow us time to process the customer.
• Pass/Fail
• Invoicing measures the % if invoices not recieved by the 10 day deadline.
Compliance
• Does the Service Provider have a Certificate on file for an active General Liability policy?
• Does the Service Provider have a Certificate on file for an active Workers Comp policy or waiver?
• Does the Service Provider’s rate meet the average rate for the area?
• Was the work order found to be a True Recall (meaning previous dispatch was not completed due to proper satisfaction)?
• Compliance measures the % of work orders found meeting all requirements.
Customer Review/Mobile App Checkout
• When checking out with the customer via the USAfix Mobile App, the customer will be given the option of leaving a score on a 1-5 scale.
• Goal for reviews is a 5.0.
• Goal for Mobile App Checkout is 90%
• Please note that the number of work orders and turn rates are used to determine tie-breakers.
Insurance Information
INDEMNIFICATION
The Work performed by the Subcontractor shall be at the risk of the Subcontractor exclusively. To the fullest extent permitted by law, Subcontractor shall indemnify, defend (at Subcontractor’s sole expense) and hold harmless Contractor, the Owner (if different from Contractor), affiliated companies of Contractor, their partners, joint ventures, representatives, members, designees, officers, directors, shareholders, employees, agents, successors, and assigns (“Indemnified Parties”), from and against any and all claims for bodily injury, death or damage to property, demands, damages, actions, causes of action, suits, losses, judgments, obligations and any liabilities, costs and expenses (including but not limited to investigative and repair costs, attorneys’ fees and costs, and consultants’ fees and costs) (“Claims”) which arise or are in any way connected with the Work performed, Materials furnished, or Services provided under this Agreement by Subcontractor or its agents. These indemnity and defense obligations shall apply to any acts or omissions, negligent or willful misconduct of Subcontractor, its employees or agents, whether active or passive. Said indemnity and defense obligations shall further apply, whether or not said claims arise out of the concurrent act, omission, or negligence of the Indemnified Parties, whether active or passive. Subcontractor shall not be obligated to indemnify and defend Contractor or Owner for claims found to be due to the sole negligence or willful misconduct of Indemnified Parties.
Subcontractor’s indemnification and defense obligations hereunder shall extend to Claims occurring after this Agreement is terminated as well as while it is in force, and shall continue until it is finally adjudicated that any and all actions against the Indemnified Parties for such matters which are indemnified hereunder are fully and finally barred by applicable Laws.
INSURANCE
Upon execution of this Agreement, and prior to the Subcontractor’s commencing any work or services with regard to the Project, the Subcontractor shall carry commercial general liability insurance on ISO form CG 00 01 10 01 (or a substitute form providing equivalent coverage) and the Subcontractor shall provide the contractor with a Certificate of Insurance and Additional Insured Endorsement on ISO form CG 20 10 11 85 (or a substitute form providing equivalent coverage) or on the combination of ISO forms CG 20 10 10 01 and CG 20 37 10 01 (or substitute forms providing equivalent coverage) naming the Contractor and the Owner as Additional Insureds thereunder. Additional insured coverage shall apply as primary insurance with respect to any other insurance afforded to Owner and Contractor. The coverage available to the Contractor and Owner, as Additional Insureds, shall not be less than $I million dollars Each Occurrence, $2 million General Aggregate (subject to a per project general aggregate provision applicable to the project), $2 million Products/Completed Operations Aggregate and $1 million Personal and Advertising Injury limits. Such insurance shall cover liability arising from premises, operations, independent contractors, products-completed operations, personal and advertising injury, and liability assumed under an insured contract (including the tort liability of another assumed in a business contract). There shall be no endorsement or modification of the Commercial General Liability form arising from pollution, explosion, collapse, underground property damage or work performed by subcontractors All Subcontractor insurance carriers must maintain an A.M. Best rating of “A-” or better. Coverage shall be afforded to the Additional Insureds whether or not a claim is in litigation.
The insurance coverage required shall be of sufficient type, scope, and duration to ensure coverage for the Contractor or Owner for liability related to any manifestation date within the applicable statutes of limitation and/or repose which pertain to any work performed by or on behalf of the Contractor or Owner in relation to the Project. • Subcontractor agrees to maintain the above insurance for the benefit of Contractor and Owner for a period of two years following completion of work performed for Contractor.
Each Certificate of Insurance shall provide that the insurer must give the Contractor at least 30 days’ prior written notice of cancellation and termination of the Contractor’s coverage thereunder. Not less than two weeks prior to the expiration, cancellation or termination of any such policy, the Subcontractor shall supply the Contractor with a new and replacement Certificate of Insurance and Additional Insured endorsement as proof of renewal of said original policy. Said new and replacement endorsements shall be similarly endorsed in favor of Contractor and Owner as set forth above.
Additionally, and prior to commencement of the Work, the Subcontractor shall provide the Contractor with a Certificate of Insurance showing liability insurance coverage for the Subcontractor and any employees, agents, or Sub-Subcontractors of the Subcontractor for any Workers’ Compensation, Employer’s Liability and Automobile Liability. In the event any of these policies are terminated, Certificates of Insurance showing replacement coverage shall be provided to Contractor. Coverages shall be no less than the following:
Workers’ Compensation and Employers’ Liability Insurance: As required by law and affording thirty (30) days written notice to Contractor prior to cancellation or non-renewal, providing coverage of not less than $500,000 for bodily injury caused by accident and $500,000 for bodily injury by disease.
Business Auto Liability Insurance: Written in the amount of not less than $ 1,000,000 each accident. Waiver of Subrogation: Subcontractor shall obtain from each of its insurers a waiver of subrogation on Commercial General Liability in favor of Contractor and Owner with respect to Losses arising out of or in connection with the Work.
SNSR Batteries
Please invoice at list price (shown below). Log into USAfix™ to see SP price.
Wet Cell Batteries
6V Economy
225 Ah
$132.86 162-0003
6V Improved Runtime
305 Ah
$243.03 162-0005
6V Rider Scrubbers
390 Ah $296.22 162-0019
12V Economy
105 Ah
$137.73 162-0011
12V Improved Runtime
150 Ah $278.77 162-0057
12V Improved Runtime
195 Ah $379.12 162-0002
Gel Batteries
12V Economy 102 Ah
$329.58 162-6022
6V Improved Runtime 189 Ah
$343.62 162-6021
AGM Battery
12V Economy 33Ah
$147.32 162-6025
Batteries
Lasts 10+ years - 10x longer than lead-acid Over 3,500 cycles
777-9102 24V 80amp (small) T3 20” class
777-9103 24V 105amp (medium) TF 26-32” class
777-9104 24V 160amp (large) T7 Rider class
*Kit part numbers listed here include battery, charger and plug.
*Co-branded sales materials available.
777-9109 36V 105amp (medium) T600 32” class
777-9105 36V 160amp (large) B5/B7 Buffer class
5 Batteries Power 97% of Scrubbers and Buffers
1 Lithium Battery Can Replace 10 Packs of Batteries Over its Lifespan!
National Battery Specifications
1. What is ARMOR?
ARMOR™ telematics device Frequently
Asked Questions
ARMOR™ is a patented telematics device collects equipment data on daily run times, charge times, charge cycles, maintenance needs, if the machine has experienced an impact (subject to the specific functionality of the equipment)
2. How does ARMOR work?
A circuit board installed in the machine records information when the machine is being used or being charged and then sends the information via the cell phone network to a central database.
3. About Event Records for 12vdc-36vdc Battery Powered Floor Equipment
Event records are individual records sent by ARMOR to our servers in response to certain events that have occurred with the machine that ARMOR is integrated into.
a. Device Checked In – is a daily record sent by ARMOR to indicate that it is communicating with our servers (if other records have reported in for the day, this record may not be present. This record will show up between 7:00 am and 8:00 local time each day.
b. Charge Started – indicates that the batteries are on a charger, but the charge cycle is not completed. This record is sent after 5 minutes of charging has been detected.
c. Charged – indicates that the charge cycle is complete and the duration of the charge. This record will be sent after 5 minutes of no charging is recognized.
d. Ran – indicates the machine has been operated and the duration of use. This record will be sent after 30 minutes of no run time has been measured or 5 minutes after the batteries have been connected to a charger (whichever one comes first)
e. Maintenance Performed – a manually created record (by the person maintaining the batteries). This record will be sent immediately.
f. New Batteries Installed – a manually created record (by the person installing the new batteries). This record will be sent immediately
g. Service requested – A service request can be initiated at the machine by pressing buttons 1 and 3). This will send an alert to USA-CLEAN Inc. who will respond to the designated contact that was set up during ARMOR activation. Appropriate action will be coordinated by the two parties. This record will be sent immediately.
4. Why is there a delay in my data showing up?
When provisioned devices experience connectivity issues to end servers or to the Verizon network, applications will automatically retry network access using Data Retry Guidelines back-off intervals: two immediate connection attempts; one attempt after 1 minute; one attempt after 2 minutes; one attempt after 8 minutes; one attempt after each of the next four 15 minute intervals; finally 1 connection attempt every 90 minutes*
*Application retry intervals are separate from any modem retries that may be occurring as per guidelines in the LIE Data Retry Guidelines document. These back-off intervals also assume that no application driven resets or reboots occur on the device.
ARMOR™ telematics device
Frequently Asked Questions
5. Can I use ARMOR in an area where I don't ever get cell phone service?
No. There needs to be a cell phone service. Verizon’s network has great coverage and we are experiencing a tremendously high coverage rate. Our data is pushed from basements and inside metal buildings where making a phone call may be difficult. Pushing a text or data is easier than making a voice call.
6.What happens if I don't have a cell phone signal?
ARMOR will store the information collected and then send it the next time it has a cellular signal.
7.What information does it record?
Data on daily run times, charge times, charge cycles, maintenance needs, location, and if the machine has experienced an impact.
8.How will the activation process work? How does new equipment get added to the system?
Activation will take place within two business days. Visit www.armordata.com and click on “Registration” to fill out the form. Your ARMOR will become active on the Verizon network and your armordata.com account will be set up. You will receive an email notification from support@armordata.com with your password.
9.How do I pay for the cell phone data service?
When you purchase ARMOR, the device includes one year of data. Once your contract time is up, additional years of service can be purchased online at www.armordata.com
10.What if I purchase ARMOR and then decide I don't want it anymore? What is the cancellation/refund policy?
The first year of service is non-refundable. The remaining yearly service plans are prorated for a refund and may include a termination fee.
11.How do I check on my machines?
There may be a login page where you purchased your machine that is equipped with ARMOR You may also visit www.armordata.com From there, you will be able to access your machine records and reports.
12.How does the request for service feature work? Who gets notified when this happens? Is there an automated process to contact people?
When the request for service is pressed, an email will be sent to the customer's designated email address. This is set at the time of registration or in the user settings inside of your www.armordata.com login.
13.How much does ARMOR cost?
ARMOR is competitively priced. Please check with your authorized ARMOR manufacturer or distributor for pricing. The ARMOR device and one year of data is the basic plan. You may then renew your data plans and even transfer your ARMOR device to new units that you own.
ARMOR™ telematics device Frequently
Asked Questions
14 What is the rated useful life of ARMOR?
7 to 10 years in a dry and controlled environment, dependent upon Verizon support.
15 Are there additional costs such as: installation; monitoring/report; setup/activation costs; any other special fees/costs monthly/annually etc.?
Your original purchase of ARMOR and your data plan covers everything except installation.
16 How difficult is it to install an aftermarket ARMOR device?
a. ARMOR installation is very simple and can be done less than 15 minutes. View the following simple YouTube videos for your type of equipment, which guides you through the installation and activation process.
I. 12vdc – 36vdc battery powered floor equipment - https://youtu.be/cJm2AkBYbeE
II. Forklifts – coming soon
III. Generators – coming soon
IV.Propane Engines – coming soon
b. Activate your device at www.armordata.com and then click “Registration.”
17.Is ARMOR available everywhere?
No. ARMOR is currently available in the United States where Verizon is available.
18.When is ARMOR going to be available?
ARMOR is available today.
19 Does ARMOR work on corded machines (to record run time, impact to machine)?
The current version of ARMOR does not support corded machines, but this functionality is under development.
20. Does ARMOR work on machines with gel batteries (to record run time, impact to machine)?
Yes, ARMOR works on any battery driven machine. Gel battery maintenance would consist of checking cables and connections but not adding water, as they are sealed.
21 How is ARMOR supported and by whom?
ARMOR is supported by the certified seller of the device or your chosen ARMOR certified service provider.
22. How is ARMOR installed?
ARMOR is installed in three ways:
1. At the factory where the machine is produced
2. By a certified service technician
3. By the machine user or owner (using the YouTube video installation guides, taking less than 15 minutes)
23. If the equipment to which the ARMOR device is attached is decommissioned, can the device be transferred to another piece of equipment?
Yes, ARMOR can be transferred to any ARMOR compatible equipment.
24. How is that change identified within whatever system used to monitor the ARMOR devices in use?
To move ARMOR to another device, you can contact customer service at USA-CLEAN. Your ARMOR device has to be physically moved and also reassigned to the new equipment.
25. How do you change ARMOR/Equipment locations?
A similar process is used to move ARMOR to another location, but easier if not moved to another machine. For example, to move the machine to a new location, ARMOR remains on the machine and the machine data is simply moved in our database.
26 What is the manufacturing capacity and time frame?
ARMOR’s American manufacturer can produce 10,000 per month, depending on component availability (like the cellular modem in the device). Larger quantities than scheduled in regular production runs may be purchased with approximately eight weeks lead time.
27 Will it be possible to get a large quantity of ARMOR units?
Yes. Available inventory can be shipped to your chosen ARMOR certified Manufacturer, certified Service Provider or shipped directly to the site for self-installation and activation.
28.What certifications and testing has ARMOR undergone?
ARMOR devices utilize FCC approved components, are tested by independent laboratories, and certified by Verizon.
29. How will ARMOR affect battery life?
The current draw on the batteries by the ARMOR device is so small that it will not noticeably impact battery performance. ARMOR draws about 45ma when idle and about 70ma when transmitting (if cell towers are far away, transmitting amp draw can be higher).
30.What is the ARMOR warranty?
ARMOR is covered for material and workmanship defects for one year (physical damage from misuse or abuse/neglect is not covered). If a defect is found, a replacement unit will be shipped to you (a call tag will be included for returning the old unit). When the old unit is tested and found defective, a refund will be issued.
31.What are the maintenance alerts? How are they set up? Can maintenance alerts be customized? Do alerts show on the dashboard?
Maintenance alerts are currently designed around two events:
1. “Request Service” buttons are pressed and an email is sent to the customer’s chosen service provider
2. The machine reaches 90 days or 100 hours of use. At this time, the ARMOR device will beep and the light will flash to alert the user that service is due.
ARMOR™ telematics device Frequently Asked
Questions
Alerts show on the dashboard at armordata.com. These alerts can be built around many factors such as: impact, number of days not charged, number of days not utilized, and daily utilization thresholds. The list is endless with our custom programming services.
32.What activates the Red LED on the membrane switch?
It flashes when power is connected, for example when new batteries or cables are installed
It flashes at the end of each step of the activation/button pressing process (3) steps
It flashes after 90 calendar days since the last device reset (maintenance or battery replacement)
It stays on solid after 99 calendar days since the last device reset (maintenance or battery replacement)
It flashes after 100 hours of run time since the last device reset (maintenance or battery replacement)
It stays on solid after 110 hours of run time since the last device reset (maintenance or battery replacement)
It flashes twice when “Request Service Help” is initiated
It flashes five times when the “Maintenance Performed” b utton is pressed and held
It flashes five times when the “New Batteries Installed” button is pressed and held
33.What activates the audible beep?
It beeps when power is connected, for example when new batteries or cables are installed
It beeps twice when “Request Service Help” is initiated
o It beeps twice more when the request for service help message is received by our servers
It beeps five times every five minutes once maintenance becomes due
It beeps five times when the “Maintenance Performed” button is pressed and held
It beeps five times when the “New Batteries Installed” button is pressed and held
34.Can I turn off the audible beep?
Yes, there are two ways to do this:
1. Press the “Silence Alarm” button, this will silence the alarm for 24 hours.
2. Request a permanent silence of the alarm, this is only recommended for areas such as hospitals or where a beeping sound can be a cause for concern in a healthcare or safety environment. You can request this by emailing a request to support@armordata.com.
35 How does the “impact” feature work?
The ARMOR device has an integrated accelerometer. The accelerometer can measure an impact between 0 and 8g’s (1 g = the force of gravity). Impact or g -force is displayed for 3 axis (X, Y, and Z). To understand the 3 axis, see image below. Imagine the “block” as the ARMOR device sitting on a flat surface. Z impact would be an up or down force, X and Y would be forces from front to back or left to right depending on the orientation.
<1.25g – Stationary - The equipment has not moved much, if at all. Generally this means a maximum of less than 1.25g of acceleration during the reporting period.
1.25g - 2.00g - Normal use - The equipment has moved, but not violently. Generally this means a maximum of less than 2g of acceleration during the reporting period.
2.00g – 4.00g - Possible impact - The equipment has been jostled, but there might not be a problem. Generally this means a maximum of less than 4g of acceleration during the reporting period.
>4G - Probable impact - The equipment has been impacted significantly, damage is likely. Generally this means a maximum of more than 4g of acceleration during the reporting period.
36. About ARMORdata.com
ARMORdata.com is a software application that provides you with an in-depth view of the operational history/status for your ARMOR installed equipment. It consists of (5) main pages.
a. Dashboard page – Displays data for the current calendar day for the following
Run Time Page
Battery Charging (lets you know if the battery(s) are currently being charged).
d. Equipment Detail Page (accessed by clicking on any equipment line)
Equipment Overview, Serial Numbers, ARMOR info, etc
Daily reported event information – runtime, charge time, impact, service requests, and equipment outside the Geo-Fence
e. Reports Page
Average Utilization Comparison
i. Lists all equipment and displays average daily run time and total run time both for the last 30 days and for the entire equipment history.
Equipment Utilized Today
i. Lists all equipment with run time today.
Equipment Not Utilized Recently
i. Lists all equipment with zero run time in the last 30 days or more.
Past Due on Maintenance
i. Lists all equipment currently past due on maintenance.
Fleet List
i. Lists all equipment and sites, with details including manufacturer, model, serial number, and ARMOR MEID.
Raw Data Report
i. Lists all times that an ARMOR device reported run, charge or impact data. This report contains the raw data used to create all other reporting on ARMORdata.com.
Personal Protective Equipment (PPE)
Required for possible hazards for the following safety and training steps.
Apron Boots Gloves Goggles
1. !
Remove all jewelry before servicing batteries.
5. !
Make sure all connections are very tight or you run the risk of melting the posts or causing an explosion.
2. !
Always turn all machine switches off when installing batteries.
3. !
Keep sparks, flame and smoking materials away from batteries.
Explosive gases are created while charging batteries.
4. !
Always wear protective safety gear while servicing batteries.
6. !
Remove caps to check water level in every cell. Always reattach caps to batteries. Do not charge with caps loose or removed.
7. !
The water level should be visible and touching the bottom of the opening (illustrated here with the screwdriver).
8. !
Using a funnel, fill every low cell with distilled water.
Safety Guidelines
9. !
If contact with battery acid occurs IMMEDIATELY rinse contact location with water for 15 minutes.
13.
!
If battery acid is present, sprinkle baking soda on battery acid to neutralize it.
10.
Charge batteries in a well-ventilated area.
!
NOTE: While batteries are charging they emit highly explosive hydrogen gas.
14.
!
Always use two people to install the batteries.
11. !
Never lay anything on top of batteries as arcing may occur.
12. !
Always connect batteries as shown on the machine installation decal or manufacturer service manual to avoid shorting out the batteries.
* These are general maintenance and safety guidelines. Please consult manufacturer instructions before performing any repairs or maintenance.
3 Main Battery Application Types
Starting or SLI (Starting, Lighting, and Ignition) Batteries
These batteries are most commonly used to start and run engines since engine starters require a large starting current for a short amount of time. The plates of these batteries are very thin in order to cover a large surface area. The plates are composed of a lead “sponge”, which are similar in appearance to a very fine foam sponge. Not appropriate for use with battery powered floor equipment. Use for starting propane and gas engine equipment.
Deep Cycle Batteries or Traction Batteries
These batteries are composed of thick solid lead plates which allows them to be discharged down as much as 80% of battery capacity. The thick plates decrease the surface area giving the batteries less “instant” power that starting batteries need. These batteries are ideal for battery powered floor equipment.
Marine and Pseudo Cycle Batteries
Marine batteries are usually a “hybrid” and fall between the starting and deep-cycle batteries. The plates are composed of lead sponge but are heavier and coarser than starting batteries. While there are exceptions, marine batteries should not be used in scrubber application.
Avoid utilizing any “deep cycle” batteries that list CCA (cold cranking amps) or CA (cranking amps) in the product specifications. These batteries are not true deep cycle batteries designed for the depth-of-discharge required for floor equipment. Double check the specifications for the all AGM Group 24/31 batteries since these are utilized in the trucking industry and are commonly misrepresented as “deep cycle”.
3 Main Battery Construction Types
Flooded or Wet Cell
These are the most commonly used batteries as they provide the lowest cost per amp-hour. The plates are submerged in an acid “bath” and require adequate water levels at all times.
Absorbed Glass Mat (AGM)
These are a class of valve-regulated lead acid batteries (VRLA) in which the electrolyte is held in glass mats as opposed to freely flooding the plates. The acid is contained within sponges in between the plates. Because of their sandwich construction and low internal resistance, they can charge and discharge at a much faster rate than the other types. AGM and gel batteries are the only “sealed” options.
Gel
A silica gelling agent is added to the battery’s acid solution which creates a semi-stiff paste in between the plates. This greatly reduces gas and volatility of the cells.
Batteries are composed of multiple 2V cells. The number of cells in a battery determines the total voltage of a battery.
Example: Three 2V cells = One 6V battery
(Note: Actual voltage is 2.12V x 3 = 6.36V)
Battery Characteristics
AGM and Wet Batteries
AGM
• Maintenance free
Advantages
• Air transportable (non HAZMAT)
• Spill proof/Leak proof
• Minimal corrosion
• Installs upright or on side
• Low to no gases released
Wet
• Lower cost
• Longer deep cycle life
• Maintained by adding distilled water
• High discharge rate capability
• Better availability worldwide
• Long, proven history of use
Disadvantages
• More expensive
• Sensitive to overcharging
• Voltage regulated chargers must be used
What are Amp-Hours?
• Periodic maintenance is required
• Only can be used in upright position
• Produces gas while charging
• Spillable
• May emit acid spray if overcharged
• Requires ventilation
• Cannot be shipped by air (HAZMAT shipping)
All deep cycle batteries are rated in amp-hours (AH). An amp-hour is one amp for one hour (amps x hours), or 10 amps for 1/10 of an hour.
• For instance, if you have something that pulls 20 amps and you use it for 20 minutes (or 1/3 of an hour), then the total amp-hours used would be 6.67 AH (20 amps x 1/3 hours).
The generally accepted AH rate for nearly all deep cycle batteries is a 20 hour rate. This means that the 12V batteries are discharged down to 10.5 volts over a 20 hour period while the total actual amp-hours they supply are measured. Sometimes ratings at a 6- and 100-hour rate are given for comparison and different applications.
• The 6-hour rate is often used for industrial batteries, as that is a typical daily duty cycle.
• Sometimes the 100-hour rate is given simply to make the battery look better than it actually is. It is also useful for figuring battery capacity for long-term backup amp-hour requirements.
Battery Chemistry
Lead-Acid Batteries
- 155 year old technology
- Utilizes an Oxidation/Reduction Reaction (Redux) between sulfuric acid solution and lead/lead oxide plates.
Sulfuric acid is converted into water during discharge.
- Specific gravity can be used to determine acid concentration, and therefore the state of charge.
- Discharged batteries can freeze at a higher temperature than a fully charged battery.
- Overcharging will cause electrolysis of the water, releasing free Hydrogen and Oxygen which is an explosion hazard.
- This water will need to be replaced over the life of the battery.
Battery Configurations
Before deciding how to connect your batteries, you first must determine:
• which batteries will be used (based on your system voltage)
• and how many batteries will be used (space is usually the primary limiting factor)
You may connect a series of six 6V batteries or three 12V batteries in order to meet the requirements for a 36V system. However, the size of your battery compartment , your performance requirements, and your price range may all limit your options.
Connecting batteries in series does not increase the capacity of the batteries. It simply increases the overall voltage to meet your system requirements. Once your voltage requirements are met, and if space allows, you can double the batteries in parallel connection which doubles your battery capacity.
Most Common in Floor Care
To increase voltage, connect batteries in a series. This will not increase the system capacity.
Example Above
Two 6V batteries at 225Ah connected in a series
System Voltage
6V + 6V = 12V system capacity = 225Ah
To increase capacity, connect batteries in parallel. This will not increase the system voltage.
Example Above
Two 6V batteries at 225Ah connected in parallel
System Voltage
6V system capacity = 225Ah + 225Ah = 450Ah
To increase both voltage and capacity, connect additional batteries in a series and parallel.
Example Above
Four 6V batteries at 225Ah connected in series/parallel
AGM testing is different than wet testing because specific gravity cannot be tested.
1. Make sure the batteries are fully charged.*
2. Obtain the voltage readings from each battery.
3. Load test the batteries and record the results.
4. If applicable, disconnect the onboard charger.
5. Attach a volt meter and run the machine for 20 minutes under a full load.**
6. After 20 minutes, document the voltage while under load.
7. Continue to operate the equipment for an additional 5 minutes while watching the voltage.
8. Document your findings on a form like the one on page -.
* The battery industry’s standard level for AGM batteries is a maximum on-charge voltage measurement of 2.38 volts per cell (28.56V for a 24V system). Refer to “Open-Circuit Voltage Test” on page 45, Open-Circuit Voltage Test, for further state of charge details.
** Test procedures require a 20 minute runtime because the typical battery load tester does not apply a load long enough to notice quality errors in the manufacturing of new AGM batteries.
• Suspect batteries will often give a normal voltage reading while at rest. However, the voltage will decline rapidly or will be erratic while under load. This may take 15-30 minutes before the symptoms are exhibited. AGM batteries that are failing can give the impression of good performance for an extended period of time before exhibiting a rapid voltage decline while under load.
• The resting voltage (no load) will immediately rebound so testing the battery without a load will yield “healthy” results making it appear that batteries are fine. Once a load is reapplied and the battery pack voltage is monitored, the voltage will quickly fall and yield the packs actual voltage capacity.
• Healthy batteries will decline in a linear, predictable rate.
Wet Battery Failure
Signs Batteries Might Be Failing
Most Common Causes of Wet Battery Failure
Top 2 Causes:
1. Allowing batteries to remain in a discharged state
2. Overcharging
Other Causes:
• Loss of electrolyte due to heat or overcharging
• Undercharging with voltages less than 2.3V/cell
• Vibration
• Using tap water Please See page 42 for Wet Battery Tips
Other Signs or Causes of Wet Batteries Going Bad
• Fumes coming from cells - sulfur smell (rotten egg)
• Batteries have sat unused for several months
• Batteries over 12 months old
• Electrical components do not perform as well
• Batteries not holding a charge/Low runtime - the only conclusive proof
1. Battery case is swollen 2. Batteries were dry or low on water
Corroded terminals
Wet Battery Tips
• #1 tip is to keep batteries fully charged
• Distilled water kept at proper levels is the best way to maintain your battery life. Tap water has minerals that will short the plates and shorten your battery life.
• Water below the plates KILLS that portion of the plates. If your batteries run low on water and cover only 75% of the plates, you have lost 25% of your battery life.
• Fill low batteries to just above the plates, charge, then top off to 1/2 inch from the top. DO NOT overfill.
• Battery efficiency decreases with falling temperatures.
• Bad bearings on drive or brush motors put a heavy amp draw on your batteries.
• A fast charge cannot fully recharge a battery; follow up with a slow charge for 3 to 4 hours.
• A hot battery charges (and overcharges) faster than a cold one.
• Battery swelling is usually caused by overcharging.
• All batteries have a normal discharge rate that increases with the temperature.
• Store batteries in a cool location to minimize self discharging.
• An old battery myth - a battery on a concrete floor discharges very rapidly. NOT TRUE: it will run down just as fast on any other surface.
• A fully charged battery freezes at -85°F (50% charge at -15°F and 25% charge at +5°F).
• A battery left in a discharged state will “sulfate” and lose capacity. Keep your battery fully charged - do not leave it in a discharged state. Lead-acid batteries do not have a memory.
• Today’s smart chargers do not over charge. Plug your machine in to the charger after each use.
Gravity Test Your Batteries:
Fully charge your batteries and test them with a hydrometer. If one cell is bad, then the battery is bad. One bad battery will put an excessive load on remaining batteries. If you just added water (distilled only), then you will need to run your batteries through a couple of charges to get an accurate reading.
Hydrometer 162-0100 $10.74
Visual inspection alone is not sufficient enough to determine the overall health of a battery. Open-circuit voltage and specific gravity readings can give a good indication of a battery’s charge level, age, and health. Routine checks will also help to reveal signs of improper care, such as undercharging and over-watering, and possibly even locate a bad or weak battery.
Wet Battery Testing
Open-Circuit Voltage Test
For accurate voltage readings fully charge the batteries, then do not charge or discharge the batteries for at least 6 hours but preferable 24 hours prior to testing.
1. Disconnect all loads from the batteries.
2. Use a voltmeter to measure the voltage.
3. Check the state of charge with the table below.
If the battery registers below the given table values, then the battery should be replaced. State of Charge (SOC) (%) – An expression of the present battery capacity as a percentage of maximum capacity. SOC is generally calculated using current integration to determine the change in battery capacity over time. Depth of Discharge (DOD) (%) – The percentage of battery capacity that has been discharged expressed as a percentage of maximum capacity. A discharge to at least 80 % DOD is referred to as a deep discharge.
* Healthy wet cell batteries will reach a maximum on-charge voltage of 2.5 to 2.6 volts per cell. Resting voltage of 2.12 per cell. * Wet cell batteries should never be discharged below 1.75 volts per cell in normal operations.
Load Test
Load test shows how the baseline voltage reacts to demand. This can be tested in the following ways:
1. Hand Held Load Tester
- This portable device puts on a high amp load for 10 seconds.
- Load testers are designed to test starter batteries for a short duration and do not apply a load long enough to conclusively determine if a deep cycle battery is completely functional.
- The readout shows if the batteries Pass or Fail based on the voltage drop.
- If the battery fails then it needs to be replaced. If it passes, the battery is not necessarily healthy and further evaluation is required if the end user is experiencing low runtime.
2. Component Loading
- This method uses the machine components to drain the battery pack over several minutes.
- For example, run the vacuum motor and monitor battery voltage.
- 15 minutes or more may be needed.
- Does the voltage drop make sense? Is each battery consistent?
Wet Battery Testing
Specific Gravity Test
1. Do not add water at this time.
2. Fill and drain the hydrometer 2 to 4 times before pulling out a sample.
3. There should be enough sample electrolyte in the hydrometer to completely support the float.
4. Take a reading, record it, and return the electrolyte to the cell.
5. Repeat the steps 2-4 to test the other battery cells.
6. Replace the vent caps and wipe off any electrolyte that might have spilled.
7. Correct the readings to 80°F:
- Add .0004 to readings for every 10°F above 80°F
- Subtract .0004 for every 10°F below 80°F
8. Compare the readings.
9. Check the state of charge by using the below table.
• Hydrometer reading of all cells should be at least 1.225 and show less than .05 points difference between high and low.
• More than .05 points difference: replace the battery.
• Less than .05 points, but some cells read less than 1.225: recharge the battery.
• Replace the vent caps during recharge.
• Charge the battery using a properly matched automatic charger until all cells measure a specific gravity of 1.265 to 1.275.
• If charging won’t bring up specific gravity, replace the battery.
The .84 Method
• This allows you to verify battery voltage without a voltmeter.
Hydrometer 162-0100 $10.74
Hydrometers:
• Hydrometers using a float with a graduated scale are best. Avoid types with floating colored balls or inaccurate dials.
• Hydrometer readings should not vary more than .05 between cells. If you see a larger difference, this could indicate a bad cell.
• Take the specific gravity per cell. Add .84 to the number and you should end up with the same as the voltage reading.
Example: 1.200 specific gravity + .84 method
2.04 voltage for that cell
Low Voltage Shutdown
• Approximately 25.40V is a full charge for 24V systems and 38.10V for 36V systems
• Some battery models are equipped with low voltage shutdown.
• Battery scrubbers go into low voltage shutdown mode when they reach the following approximate voltages*
(for TASKI models, check the battery type setting using TASKI service software).
- 23.5V for AGM batteries
- 20 to 22V for Wet batteries
* These are approximate voltages. Please check with manufacturers for specific voltages.
• Transportation mode is activated until the machine can reach its location to be charged.
• Batteries need to be fully charged and fully cycled each use.
Battery Factoids
• Nearly all batteries will not reach full capacity until cycled 10-30 times. A brand new battery will have a capacity of about 5-10% less than the rated capacity.
• Lead-Acid batteries DO NOT have a memory, and the rumor that they should be fully discharged to avoid this “memory” is totally false and will lead to early battery failure.
• At around 10.5 volts, the specific gravity of the acid in the battery gets so low that there is very little left that it can do.
• Batteries in storage should be above 2.07 volts per cell. They will begin the process of internal sulfation at 2.07 volts. Batteries that drop below 2.0 volts per cell while in storage will suffer significant and irreversible damage.
• False Capacity - a battery can meet the voltage tests for being at full charge, yet be much lower than its original capacity. If plates are damaged, sulfated or partially gone from long use, the battery may give the appearance of being fully charged, but in reality acts like a battery of a much smaller size. This same thing can occur in AGM cells if they are overcharged and gaps or bubbles occur. What is left of the plates may be fully functional, but with only 20% of the plates left. Batteries usually go bad for other reasons before reaching this point, but it is something to be aware of if your batteries seem to test okay but lack capacity and go dead very quickly under load.
• Voltage readings will NOT tell you how good the battery condition is - only a sustained load test can do that.
• Battery life is directly related to how deep the battery is cycled each time. Most golf cart batteries are rated for about 550 cycles at 80% depth of discharge.
Example: 24V = 21.00V at 100% DOD
= 31.50V at 100% DOD
= 23.20V at 80% DOD
= 34.75V at 80% DOD
Refer to page <?>, Open-Circuit Voltage Test, for further state of charge details.
• Water should be added after fully charging the battery pack unless the water is too low and the plates are exposed.
• Plate thickness (of the positive plate) matters because of a factor called “positive grid corrosion”. This ranks among the top 3 reasons for battery failure. The positive (+) plate is what gets eaten away gradually over time, so eventually there is nothing left. It all falls to the bottom as sediment. Thicker plates are directly related to longer life, so other things being equal, the battery with the thickest plates will last the longest. The negative plate in the batteries expands somewhat during discharge, which is why nearly all batteries have separators, such as a glass mat or paper, which can be compressed.
• Wet batteries discharge 5-10% a month while AGM batteries discharge 2-3% a month.
• Older batteries self-discharge faster than new batteries. Older wet batteries may discharge as much as 7% a week. Older AGM may discharge 2% a week.
• Automotive batteries typically have plate about .040” thick, while forklift batteries may have plates more than .025” thick. This is almost 7 times as thick as auto batteries. The typical golf cart will have plates that are around .07 to .11” thick. US Battery and Trojan L-16 types are .090”. The Crown L-16HC size has .22” thick plates.
Sulfation
During use, small sulfate crystals form, but these are normal and not harmful to the batteries. During prolonged charge deprivation, the amorphous lead sulfate converts to a stable crystalline that deposit on the negative plates. This leads to the development of large crystals which reduce the battery’s active material and negatively impact capacity.
Battery Manufacturer Date Codes
Crown Battery
Two ways to identify the age of the battery:
1. Date sticker on top of the battery. The letter on the code stands for the month. The second and third number represent the year.
Example A17 = January 2017
Example L15 = December 2015
2. The battery has a plate number on the front of the battery that is engraved with the MFG date, shift, year, etc.
Deka Battery
The letter on the code stands for the month and the number stands for the year. “I” is skipped in the months to eliminate confusion with the number “1”.
Example L2 = November 2012
FullRiver Battery
For the example, reference the date code photo on the right.
• “K” (1st Character) means year 2000.
• “14” (2nd & 3rd Character) means the specific year made. In this example, the battery was made in the year 2014.
• “04” The 4th and 5th character represent the week number of that year. In this example, the battery was made in the fourth week of 2014, or the last week of January.
A - January G - July 10 - 2010 15 - 2015
B - February H - August 11 - 2011 16 - 2016
C - March I - September 12 - 2012 17 - 2017
D - April J - October 13 - 2013 18 - 2018
E - May K - November 14 - 2014 19 - 2019
F - June L - December
A - January G - July 0 - 2010 5 - 2015
B - February H - August 1 - 2011 6 - 2016
C - March J - September 2 - 2012 7 - 2017
D - April K - October 3 - 2013 8 - 2018
E - May L - November 4 - 2014 9 - 2019
F - June M - December
• If there are any other additional characters (in this example the “02”), then these are strictly factory and operator codes.
Battery Manufacturer Date Codes
Interstate Battery
There is a 4 to 5-digit code engraved into the cover. The first 2 digits on the far left will tell you the month and date of the battery.
Example B2 = February 2012
Trojan Battery
The letter on the code stands for the month and the number stands for the year.
Example B5 = February 2015
Example C4 = March 2014
U.S. Battery
For flooded lead acid batteries the date code is stamped and the first letter refers to the month, the number refers to the year and the last letter refers to the manufacturer location.
Example K4X = November 2014 Corona
Example D6Z = April 2016 Evans
For AGM batteries the date is etched into the case of the battery. The date is written in a DDMMYY format.
Example 150914 = September 15, 2014
MFG Location
- Corona
- Augusta Z - Evans
How Long Should A Battery Auto Scrubber Run
Numbers below represent optimal runtime. Batteries may be bad if they achieve less than 60% of listed time.
Important Note: Scrubbing amp draw figures were measured in our service department measuring between 47amps and 49amps with around 18amps being the vacuum motor. Vacuum motors run at higher amps freewheeling and run at the lowest amps under the heaviest load. Batteries hooked in a series (plus to minus on the cables) multiplies the volts not the amps and this does not change the runtime. If all batteries were hooked in parallel the amps would be multiplied and the volts would stay the same giving more runtime. DO NOT TRY HOOKING YOUR BATTERY PACK IN PARALLEL because your scrubber will not run on 6 volts or 12 volts.
*Volts are irrelevant. Amp hours provide runtime.
How Long Had Machine Decreased Runtime
• Days since runtime decreased, check your charger
- Check that machine is charging for entire amount of time.
- The charger has an auto-shut off
- Check the fuse in the charger. If bad, replace.
• Parts: Fuse
- Check connection and/or plug for damage. Replace
• Parts: Charger plug
• Months since runtime decreased
- Have the batteries decreased to an unsatisfactory runtime gradually?
- If yes, replace the batteries.
• Parts: Batteries
* These are general maintenance and safety guidelines. Please consult manufacturer instructions before performing any repairs or maintenance.
CAUTION - Before handling batteries please read the Battery Safety Section on page <?> and page <?>.
Personal Protective Equipment (PPE) Required for possible hazards for the following safety and training steps.
1.
Disconnect batteries from machine.
4.
Remove batteries one at a time using a battery strap.
2.
Remove nut and washer from jumper cables.
Note the battery connection pattern for new battery installation.
5.
Install new batteries using a battery strap. Use manufacturer connection pattern or install exactly as removed.
3.
Remove all cables.
6.
Replace the old battery cables with new cables. Tightly fasten nuts to complete installation.
* These are general maintenance and safety guidelines. Please consult manufacturer instructions before performing any repairs or maintenance.
How to Select a Battery Charger
5 Things to Consider When Selecting A Battery Charger
1. Battery System Voltage
Battery chargers are voltage specific and must match the battery system. A battery system will be overcharged and damaged if a charger is used that is rated for more than the battery system voltage. A battery system will never be fully charged if a charger that is rated less than the battery system voltage is used.
2. Battery Type
The type of battery must be known to avoid damage. The charge algorithm is completely different between wet and AGM batteries. The most common mistake is when a customer changes from wet to AGM batteries then tries to use the same charger used before. If a charger does not have the capability to switch between wet and AGM settings, then a new one would be required. Wet chargers will stop at 2.6 volts per cell and allows “gassing” stage. AGM chargers will stop at 2.3 to 2.35 volts per cell before the critical “gassing” stage.
3. Battery Size
The size of a battery is measured by its amp hour (Ah) capacity. This is a very important factor when choosing a battery charger. The general rule is to have the start current of the charger be approximately 10% of the size of battery. For a 100Ah battery, the charger would then provide 10 amps of DC current (.10 x 100 = 10). This will produce the ideal output to achieve the desired 8-hour charge cycle for a normally discharged battery.
4. Charger Start Current and Time
If you want to charge batteries faster, simply increase the current output of the charger. Charging causes the battery temperature to increase. At some point the charger output will exceed the battery’s ability to endure this heat which is otherwise known as the thermal limit of the battery. It is important to be observant of the 10% rule to avoid this limit. The temperature should not rise about 115°F with a starting electrolyte temperature of 85°F. OEM battery manufacturers state that batteries should not be charged when the ambient temperature exceeds 120°F.
5. Onboard or Off Board Style
Decide whether the charger is going to be mounted on the machine or will it be stationary on a shelf.
SCR Battery Chargers
Silicon Control Rectifier (SCR) is a solid state current controlling device which blocks reverse current polarity. A small amount of current is applied to the SCR to open the gate and allow the one-way flow of current through the SCR. The advantages of a SCR switch:
• High speed switch requiring very little current to open the gate
• Small in size with high efficiency (less heat) and great reliability
SCR battery chargers use SCRs along with conventional transformers to regulate the charger output. Since the SCR switching action is controlled, SCRs provide more precise control of output voltage and can be easily interfaced with a microprocessor to implement various charging profiles required for sealed batteries. SCR chargers are smaller than old style ferroresonant charger, less expensive to manufacturer and allow for a controlled charging profile.
High Frequency Switchmode Chargers
A Switchmode battery charger incorporates a front end AC-DC rectifier (vs. a conventional transformer) and a switchmode power converter that switches the current to high frequency. A smaller and more efficient high frequency transformer is utilized and the DC output voltage and current are controlled by adjusting the pulse width (Pulse Width Modulation).
High frequency chargers are much more efficient, light and smaller than conventional transformer based chargers. Eliminating the heat generated by the HF charger components is critical and most of these chargers require forced air from a cooling fan. In general, the components of the HF charger are not as durable as other chargers and the circuit board are fairly complex and not serviceable.
Battery Charger States
3 Stages of A Battery Charger
1.
Bulk Charge
In this first stage, the highest voltage and amperage is uses. The level of charge that can be applied without overheating the battery is known as the battery’s natural absorption rate. For a typical 12V AGM battery, the charging voltage will reach 14.6 to 14.8V while flooded battery can be even higher. For a gel battery, the voltage should be no more than 14.2 to 14.3V. This stage will recharge batteries that are severely drained. There is no risk of overcharging because the battery hasn’t even reached full charge yet.
2.
Absorption Charge
The charger enters this stage once the batteries reach about 80% state of charge. At this point, the charger will maintain a steady voltage while the amperage declines. The lower current going into the battery safely brings up the charge on the battery without overheating it. The last 20% of charge takes much longer compared to the first 20% during the bulk stage as the current continuously declines until the battery almost reaches full capacity.
3. Float Charge
Some chargers enter this stage as early at 85% state of charge but other begin closer to 95%. The voltage will taper down and maintain a steady 13.2 to 13.4V which is the maximum voltage a 12V battery can hold. There is a charge going to the battery at all times, but only at a safe rate to ensure a full state of charge and nothing more. This is critically important to bring up weaker cells to a full and equal voltage to the rest of the pack.
Battery Charging Tips:
NOTE
Two factors determine when the typical charger shuts off to prevent overcharging:
1. Maximum charger voltage
- 2.6V per cell for wet batteries
- 2.3V per cell for AGM batteries
2. Rate of voltage increase
- Batteries are considered to be fully charged when the rate of voltage increase has decreased to less than .012V over 30 minutes
1. Before charging, refer to the instructions provided by the charger’s manufacturer.
2. Batteries should be charged after each use.
3. Lead-acid batteries do not develop a memory and do not need to be fully discharged before recharging. For example, how often does your car battery charge? All the time it is kept full.
4. Charge only in well-ventilated areas. Keep sparks or flames away from a charging (wet) battery.
5. Verify that the charger voltage settings are correct.
6. Check water levels of wet batteries.
7. Tighten all vent caps before charging. (wet)
8. Do not overcharge or undercharge batteries. Both can lead to premature battery failure.
9. Do not charge a frozen battery.
10. Avoid charging at temperatures above 120°F.
Top Selling Battery Chargers
24 Volt Off Board
12amp Charger for batteries under 130Ah
162-5059
$271.73 with small (SB50) red plug
*To change profiles from wet to AGM, use switch located in front of charger.
20amp Charger for batteries between 130Ah and 305Ah
162-5061
$304.00 with large (SB175) red plug
162-5060
$304.00 with small (SB50) red plug
*To change profiles from wet to AGM, use switch located in front of charger.
36 Volt Off Board
20amp Charger for batteries between 130Ah and 305Ah
162-5063
$336.00 with large (SB175) gray plug
162-5062
$336.00 with small (SB50) gray plug
*To change profiles from wet to AGM, use switch located in front of charger.
30amp Charger for batteries between 225Ah and 395Ah
Wet battery configured
162-5064
$758.35 with large gray plug
AGM battery configured 162-5074
$758.35 with large gray plug
36 Volt Onboard - Transformer Based
162-9027
$476.76
Dual Pro transformer charger conversion kit
For use with all battery sizes (wet and AGM batteries)
Changing Profiles in Lester SCR Chargers
*Before changing profiles unplug your charger and wait to ensure there is no active electricity!
A. Charger Styles
• Before changing the profile in your SCR charger, check if you have the old or new style charger (pictured to the left).
• Then follow the directions below based on which style you have.
• NOTE: Profile 1 and Profile 2 do not have a consistent specified wet or AGM setting. Please see our charger selection on previous page to purchase the charger configuration that fits your battery needs the most. Before changing profiles, please note what the original profile your charger is on and what battery setting it is tied to (wet or AGM).
B. Locate the Circuit Board
1. Locate the sticker on your charger that will be marked with what configuration your charger is set on. This setting will be tied to either Profile 1 or Profile 2 once you open the charger.
2. Use a Phillips head screwdriver to remove the 12 screws from the charger cover. Remove the cover from the charger.
3. Locate the charger control board. The pin and jumper for changing the setting is on the circuit board at the rear of the charger housing.
C. Change the Jumper Profile
4. Notice the black jumper. It is shown in the Profile 1 setting (top two prongs).
1. Locate the sticker on your charger that will be marked with what configuration your charger is set on. This setting will be tied to either Profile 1 or Profile 2 once you open the charger.
2. Remove rubber cap in front of charger with a flathead screwdriver.
5. To change to the Profile 2 setting, use needle-nose pliers to pull off the jumper and move it to the position as shown in the picture leaving one pin exposed at the top. Be sure to push the jumper all the way on.
6. Re-assemble the cover onto the charger and label the back of the charger to show what the current configuration is for future reference.
3. The profile board will now be exposed.
4. The red jumper shown is Profile 1 where the right pin is exposed.
5. To change to the Profile 2 setting. Use needle-nose pliers to pull off the jumper and move it to the position as shown in the picture, leaving the left pin exposed. Be sure to push the jumper all the way on.
6. Re-assemble the cover onto the charger and label the back of the charger to show what the current configuration is for future reference.
Old Style New Style
Old Style New Style
Old Style
New Style
4 Things Fix 98% of All Lester SCR Chargers
AB
PROBLEM:
Charger plug is cracked, melted, or damaged.
SOLUTION:
Replace charger plug and install new plug correctly.
PROBLEM:
Charger won’t turn on.
SOLUTION:
You will most likely need to replace the SCR (silicon controlled rectifier) and fuse assembly
SCR (Silicon Controlled Rectifier) and Fuse
CCharger Plugs
175amp large
2 1/8 x 3 1/8 inch
50amp small 1 1/2 x 1 7/8 inch without pins Gray 162-5031 $4.79 Red 162-5032 $6.59 with pins Gray 991-2112 $10.39 Red 162-5045 $7.86 with pins & brackets
DPROBLEM: Charger does not click? Charger does not shut-off?
SOLUTION:
You need to replace the control board assembly.
Cord Sets
Control Board Assembly
QUESTIONS?
Not sure if your current charger supports a switch to AGM batteries?
Are you experiencing charging issues with your charger?
Please contact one of our technical support representatives at 1-800-872-2532 with your charger information and our experts will determine its charging capability or the parts needed to correct the charging issues.
*This charger is suitable for AGM and Wet batteries.
B ADCHow to Change Profiles in SCR Chargers
See page 55
4 Things That Fix 98% of all SCR Chargers:
A) Charger plug
B) SCR kit and fuse
C) Cord
D) Control board
See previous page for more details.
*Please note the parts depicted are for SCR E and X series chargers only. For information about parts for the 24V 12amp dual mode charger, 162-5059, please contact USA-CLEAN at 1-800-872-2532.
5 Things Fix 98% of All Lestronic II Chargers
BAPROBLEM:
Charger plug is cracked, melted, or damaged.
SOLUTION:
Replace charger plug and install new plug correctly.
PROBLEM:
Charger won’t turn on.
SOLUTION:
Check for a blown fuse. If a fuse is blown, then you will most likely need to replace both the fuse assembly and the heat sink/diode assembly
CHeat Sink/Diode Assembly with 2 diodes. Fits both 24V/36V chargers.
162-5006 $33.30
Fuse Assembly Fits most 24V/36V chargers.
PROBLEM:
Charger hums? Meter doesn’t move? Charger doesn’t charge?
SOLUTION:
If you are running into all of these issues, then you need to replace the capacitor.
50amp small
1 1/2 x 1 7/8 inch without pins
175amp large
2 1/8 x 3 1/8 inch
$4.22
Gray 162-5031 $4.79
Red 162-5032 $6.59 with pins
Gray 991-2112 $10.39 Red 162-5045 $7.86 with pins & brackets
Gray 162-5003 $33.30 Red 162-5013 $33.30
PROBLEM: Charger does not click? Charger does not shut-off?
SOLUTION: You need to replace the timer.
ECapacitor
24 and 36V capacitor If low DC amp replace capacitor.
162-5008 $32.97
Cord Sets
50amp Small Plug DC Cord Set
Gray 162-5005 $87.91
Red 162-5034 $67.93
175amp Large Plug DC Cord Set
Gray 162-5033 $87.91
Red 162-5019 $67.93
AC Cord Set
78 inch long with a molded plug for the 24V and the 36V chargers 162-5018 $45.95
*This charger is NOT suitable for AGM batteries.
Lestronic II Battery Charger
003d
36V 3-wire electronic timer (old style) (This is the old style timer. It has 3 levels. The green control board is sandwiched between 2 metal plates. The control board is approx. 3 3/4 in by 2 1/2
36V 2-wire electronic timer (new style)(This is the new style timer. It has 2 levels. The green control board attached to a white control board. The control board is approx. 2 in by 2 inches.)
5 Things That Fix 98% of all Lestronic II Chargers: A) Charger plug
B) Fuse and heat sink
C) Capacitor
D) Timer
E) Cord
Charger Breakdown
Troubleshooting Guide
SWITCH NOT LIT - NO DISPLAY- NO OUTPUT
Check wall outlet for power
Check 6.3a input fuse on rear of unit
Check power cord and plug
Check main switch
“BAT” FAULT IS DISPLAYED
Check ALL battery connections
Check for correct polarity
Check battery pack voltage
Check the 15a output fuse on the power module card
SWITCH IS LIT - NO DISPLAY- NO OUTPUT
Check 1.6a control card fuse located on main power card
NO CURRENT OUTPUT – DISPLAY READS “00.00”
Check AC input to power card at the “+” and “--“ terminals
Check bridge rectifier output
Check mosfets and repair or replace power module assembly
CURRENT OUTPUT IS ERRATIC
Check main capacitors on power module
Repair or replace complete power module assembly
DISPLAY PANEL VISUALS ARE ERRATIC
Check cable connections to display card
Replace display card
Propane Emissions Testing Instructions
1.
Locate machine, verify and record machine specific data such as make, model and serial number.
2.
Check frame for cracks and that motor is mounted securely.
3.
Check oil and add oil if necessary.
4.
Check the compression on cylinder 1 & 2. (see page 82 - page 87)
5.
Warm up unit, then perform emissions testing on both high and low throttle settings inside tailpipe. (check high throttle first) Emissions testing steps on page 88.
6.
If emissions passed and PM is requested, move onto Preventative Maintenance Steps on page 66.
Passed All Tests
Report test results, make, model and serial number to coordinator promptly. Onsite updates are best.
If Compression Test Failed
Set the valves. (see page 82 - page 87)
After Valves Are Set
Check compression on cylinder 1 and 2.
Failed Any Test
Report test results, make, model and serial number, along with repair estimate to coordinator promptly. Onsite updates are best.
See page 64 and page 65 for possible causes of high emissions.
Propanes
High Emissions
Possible Causes of High Emissions
Machine may require a 100-hour service/tune up
Change the oil, clean/replace the dust bonnet and replace the following parts: oil filter, air filter(s), pre-filter(s) and spark plugs (gap correctly).
Valve clearances may need to be set
If the engine has been run for more than 200 hours since last valve setting, reset the calces to the proper clearances and do a compression test. The compression on each cylinder should be at least 100 PSI. If lower than 100 PSI after setting the valves, the cylinder head(s) will need to be replaced.
Engine may be running on one cylinder
This can be caused by a spark plug boot coming off the spark plug, and ignition module failure on one side or a problem with a cylinder head valve being stuck open preventing compression. Do the following:
- Check to make sure that both spark plug boots are securely attached to the end of the spark plug.
- Check the spark on both ignition modules by using a spark tester.
- Perform a compression test on both cylinders. If one shows zero, open up that valve cover and inspect for valve or push rod damage. If damage is found, then replace the necessary parts or the cylinder head.
Step 1 - Idle adjustment WITHOUT a brass output fuel adjustment
This step is for propane buffers that feature the idle screw adjustment only, without an additional brass output fuel adjustment. On the fuel regulator, just above or below (depending on how the regulator is mounted on the frame) where is says “IDLE”, there is a small, round, metal cap approximately 1/4” wide covering the idle adjustment screw. Remove this cap by drilling a small hole in the cap and then pry it off with a small screwdriver. Once the cap has been removed, the idle screw adjustment will now be visible. Using a small, standard screwdriver or a 3/32” Allen wrench (depending on model), turn the screw counterclockwise until the top of the screw is near the top of the cap lip. This will lean up the fuel mixture and should reduce the emissions on idle. Start the engine. If the engine does not start, turn the idle screw on the test regulator clockwise a few turns until the engine starts and runs good. After setting the idle screw, recheck the emissions with a CO tester with the engine on idle and high. If the emissions are within the acceptable range on both idle and high, then the engine has passed the CO test. If the CO level is still too high during the test, proceed to Step 2.
Step 2 - Fuel regulator bypass without the fuel lockoff
This step is necessary if the engine has failed the CO test from Step 1. Have a new fuel regulator with the high pressure fuel line complete with brass fittings ready for this step. Pull off the fuel & vac hoses from the old regulator and attach them to the test regulator. Then attach the high pressure line on the test regulator to the propane tank. This will bypass the old regulator and the test regulator is used to determine if the old regulator is bad. Make sure the test regulator is secure on the machine before starting. Start and run the engine again to repeat the emissions test with the CO tester. If the engine does not start, turn the idle screw, recheck the emissions with a CO tester with the engine on idle and high. If the emissions are within the acceptable range on both idle and high, then the test regulator has determined that the old regulator is bad and will need to be replaced.
Idle adjustment WITH brass output fuel adjustment
Some propane buffers feature an additional brass output fuel adjustment on the fuel regulator. This brass adjustment is located on the regulator with the fuel hose attached. Perform Step 1 above and if the CO level is still too high after performing that step, then locate the silver cap on top of the brass adjustment. Drill a small hole in the cap and then pry it off with a small screwdriver. Once the cap has been removed, the diamond shaped adjustment screw will now be visible. Use a 3/32” Allen wrench and loosen the set screw on the side of the adjustment. Start the engine and rev up to high. Use a 7mm nut driver and turn the adjustment clockwise to lean up the fuel mixture. Turn clockwise until the engine begins to bog down and then turn the screw counterclockwise until the engine runs smoothly again. The fuel has now been adjusted as lean as possible. Tighten the set screw on the side of the adjustment. Recheck the emissions with a CO tester with the engine on idle and high. If the emissions are within the acceptable range on both idle and high, then the engine has passed the CO test. If the CO level is still too high during the test, replace the fuel regulator.
The catalytic muffler may be bad
Over time with use and extreme heat, the catalytic material inside the muffler will go bad or break apart, causing the catalyst to become ineffective and cause the CO level to go up. If this occurs, replace the muffler. A catalytic muffler will remove up to 1,500 ppm of CO.
The oxygen (O2) sensor or emissions module may be bad
A faulty oxygen sensor will not cause high emissions, but can send a false reading to the emissions module, causing what seems to be a high emissions shutdown. If the emissions warning light comes on, check the CO level. If the CO level measures normal, replace the oxygen sensor and/or the emissions module.
Propanes
Preventative Maintenance Steps
Procedures
1. Change oil and oil filter
2. Check, clean and replace
a. Dust bonnet (clean)
b. Pre-filter (replace)
c. Air filter (replace)
3. Check tire/caster condition and replace if needed and approved
a. Free and smooth movement
b. Surface condition of the wheel
c. Lubricate
4. Check belt and replace if needed and approved
a. Damage (cracks, missing teeth, excessive wear)
b. Proper belt tension
5. Check pad system and replace components if needed and approved
a. Pad holder
b. Pad driver
c. Pad
d. Lubricate pad drive bearings if applicable
6. Torque motor mounting bolts
7. Torque muffler mounting bolts
8. Check all wiring
a. Signs of over heating on insulation
b. Cracks in insulation
c. Good connections
9. Check key switch
a. Overall operation
10. Check battery system
a. Cable condition and tight connection
b. Battery voltage
i. with machine off
ii. with machine on and charging
c. Replace battery if needed and approved
11. Check spark plugs and replace if necessary
a. No excessive fouling
b. Correctly gapped
12. Check fuel system
a. Check fuel supply hose for cracks or wear
b. Check vacuum hose(s) for cracks or wear
c. Check connections
13. Start machine
14. Check that hour meter is working
15. Check throttle cable linkage condition
16. Check dust control system if applicable
a. Skirt condition
b. Hose condition
c. Bag condition
Please follow these steps to ensure thorough and accurate preventative maintenance. For all preventative maintenance checklists please visit www.usaclean.com and log into USAfix™
Standard Repair Times (SRTs)
Check muffler for carbon monoxide
*Check fuel lines
*Check spark plug wires
*Fill oil to proper level
*Check
*Replace air filters
*Check spark plugs
*Replace spark plugs
Test ignition module for spark with tester
*Change oil and oil filter
Replace 2 cylinder heads
*part of PM program
These times are typical for Kawasaki engines. These times may increase or decrease depending on what engine and frame is being repaired.
Accumulation of tasks will share SRT. Please use these times as a guideline for quoting and billing customers. For even more propane troubleshooting tips please login to USAfix™.
*These are general maintenance and safety guidelines. Please consult manufacturer instructions before performing any repairs or maintenance.
Propanes
OEM Dust Bonnet and Cage Comparison
Kawasaki 18HP (FS481V)
OEM Dust Bonnet and Cage Comparison
Kawasaki 18HP (FS481V)
Safety Guidelines
1. !
Always keep face, fingers or any other body part or loose clothing away from any machine opening or moving part.
2. !
To stop your machine turn off propane tank then turn the key off. Always turn the propane tank and key switch off before servicing.
3. !
Always store propane tanks outside.
5. !
If machine was tipped and laying on air filter side, place the machine outdoors and run until the machine is no longer smoking. DO NOT RUN INDOORS.
6. !
Never service machine near fire or flame.
7. !
Always allow the engine time to cool before performing any maintenance as hot parts can cause severe burns.
4. !
Never lay the machine on the air filter side. Engine oil can enter the air cleaner and cause the engine to smoke, run rich, and shut down.
8. !
Always disconnect the propane tank after each use.
*These are general maintenance and safety guidelines. Please consult manufacturer instructions before performing any repairs or maintenance.
“Do
Check/clean air filter.
Check hoses for wear.
Check/replace pad.
*These are general maintenance and safety guidelines. Please consult manufacturer instructions before performing any repairs or maintenance.
Propanes
Check oil level.
Clean dust hood.
Carbon Monoxide and Safety Standards
The following message from OSHA is found at http://www.osha.gov/OshDoc/data_General_Facts/carbonmonoxide-factsheet.pdf
What is Carbon Monoxide?
Carbon monoxide (CO) is a poisonous, colorless, odorless, and tasteless gas. Although it has no detectable odor, CO is often mixed with other gases that do have an odor. Therefore, you can inhale CO right along with gases that you can smell and not even know that CO is present. CO is a common industrial hazard resulting from the incomplete burning of natural gas and any other material containing carbon such as gasoline, kerosene, oil, propane, coal, and wood. Forges, blast furnaces and coke ovens produce CO, but one of the most common sources of exposure in the workplace is the internal combustion engine.
How Does Carbon Monoxide Harm You?
Carbon monoxide is harmful when breathed because it displaces oxygen in the blood and deprives the heart, brain, and other vital organs of oxygen. Large amounts of CO can overcome you in minutes without warning, causing you to lose consciousness and suffocate. Besides tightness across the chest, initial symptoms of CO poisoning may include headache, fatigue, dizziness, drowsiness, or nausea. Sudden chest pain may occur in people with angina. During prolonged or high exposures, symptoms may worsen and include vomiting, muscle weakness, confusion, and collapse in addition to loss of consciousness. Symptoms vary widely from person to person. CO poisoning may occur sooner in those most susceptible: young children, elderly people, people with lung or heart disease, people at high altitudes, or those who already have elevated CO blood levels, such as smokers. Also, CO poisoning poses a special risk to fetuses. CO poisoning can be reversed if caught in time. But even after recovery, acute poisoning may result in permanent damage to the parts of your body that require a lot of oxygen such as the heart and brain. Significant reproductive risk is also linked to CO.
Who is At Risk?
A MESSAGE FROM USA-CLEAN
There is a lot of confusion concerning what is safe with carbon monoxide levels expelled from propane buffers. The EPA sets emission standards for outdoors, but we have found no standards set by them for indoor use.
OSHA sets indoor safe air standards but nowhere did we find limits for tailpipe emissions. Most safe buffers we test measure from 0 ppm (0 parts carbon monoxide per one million parts of air) to 150 ppm at the tailpipe. Unsafe buffers measure 500 ppm and above. If at six month intervals the buffer measures 250 ppm or higher please monitor emissions closely. Carbon monoxide above 500 ppm is unsafe and must be removed from service immediately. Also, each community has its’ local codes that are enforced by its’ local Fire Marshals. Most importantly, work in a well ventilated area with an engine that is emitting safe levels of carbon monoxide. To assist in your safety, use our CO safety patches described below.
Not sure if your buffer is safe? Our CO safety patches can be attached to the handle of your buffer and will tell you if your buffer is emitting unsafe levels of carbon monoxide. Each patch is effective for 3 months.
Order part # 154-0269
You may be exposed to harmful levels of CO in boiler rooms, breweries, warehouses, petroleum refineries, pulp and paper production, and steel production; around docks, blast furnaces, or coke ovens; or in one of the following occupations:
• Welder
• Garage mechanic
• Firefighter
• Carbon-black maker
• Organic chemical synthesizer
• Metal oxide reducer
• Longshore worker
• Diesel engine operator
• Forklift operator
• Marine terminal worker
• Toll booth or tunnel attendant
• Customs inspector
• Police officer
• Taxi driver
What Can You Do If You Suspect Someone Has Been Poisoned?
When you suspect CO poisoning, promptly taking the following actions can save lives:
• Move the victim immediately to fresh air in an open area.
• Call 911 or another local emergency number for medical attention or assistance.
• Administer 100% oxygen using a tight-fitting mask if the victim is breathing.
• Administer cardiopulmonary resuscitation if the victim has stopped breathing.
Warning: You may be exposed to fatal levels of CO poisoning in a rescue attempt. Rescuers should be skilled at performing recovery operations and using recovery equipment. Employers should make sure that rescuers are not exposed to dangerous CO levels when performing rescue operations.
Carbon Monoxide and Safety Standards
The following message from OSHA is found at http://www.osha.gov/OshDoc/data_General_Facts/carbonmonoxide-factsheet.pdf
How Can Employers Help Prevent CO Poisoning
To reduce the chances of CO poisoning in your workplace, you should take the following actions:
• Install an effective ventilation system that will remove CO from work areas.
• Maintain equipment and appliances (e.g., water heaters, space heaters, cooking ranges) that can produce CO in good working order to promote their safe operation and to reduce CO formation.
• Consider switching from gasoline or propane powered equipment to equipment powered by electricity, batteries, or compressed air if it can be used safely.
• Prohibit the use of gasoline or propane powered engines or tools in poorly ventilated areas.
• Provide personal CO monitors with audible alarms if potential exposure to CO exists.
• Test air regularly in areas where CO may be present, including confined spaces. See Title 29 of the Code of Federal Regulations (CFR) 1910.146.
• Use a full-face piece pressure-demand self-contained breathing apparatus (SCBA) certified by the National Institute for Occupational Safety and Health (NIOSH), or a combination full-face piece pressure demand supplied-air respirator with auxiliary self-contained air supply in areas with high CO concentrations, i.e., those immediately dangerous to life and health atmospheres. (See 29 CFR 1910.134.)
• Use respirators with appropriate canisters for short periods under certain circumstances where CO levels are not exceedingly high.
• Educate workers about the sources and conditions that may result in CO poisoning as well as the symptoms and control of CO exposure. In addition, if your employees are working in confined spaces where the presence of CO is suspected, you must ensure that workers test for oxygen sufficiency before entering.
What Can Employees Do to Prevent CO Poisoning?
Employees should do the following to reduce the chances of CO poisoning in the workplace:
• Report any situation to your employer that might cause CO to accumulate.
• Be alert to ventilation problems, especially in enclosed areas where gases of burning fuels may be released.
• Promptly report complaints of dizziness, drowsiness, or nausea.
• Avoid overexertion if you suspect CO poisoning and leave the contaminated area.
• Tell your doctor that you may have been exposed to CO if you get sick.
• Avoid the use of gas or propane powered engines, such as those in powered washers as well as heaters and forklifts, while working in enclosed spaces.
What Are the OSHA Standards for CO Exposure?
• The OSHA PEL is 50 parts per million (ppm). OSHA standards prohibit worker exposure to more than 50 parts of the gas per million parts of air averaged during an 8-hour time period.
• The 8-hour PEL for CO in maritime operations is also 50 ppm. Maritime workers, however, must be removed from exposure if the CO concentration in the atmosphere exceeds 100 ppm. The peak CO level for employees engaged in Ro-Ro operations (roll-on roll-off operations during cargo loading and unloading) is 200 ppm.
How Can You Get More Information on Safety and Health?
OSHA has various publications, standards, technical assistance, and compliance tools to help you, and offers extensive assistance through workplace consultation, voluntary protection programs, grants, strategic partnerships, state plans, training, and education. OSHA’s Safety and Health Program Management Guidelines (Federal Register 54:3904-3916, January 26, 1989) detail elements critical to the development of a successful safety and health management system. This and other information are available on OSHA’s website.
• For one free copy of OSHA publications, send a self-addressed mailing label to OSHA Publications Office, P.O. Box 37535, Washington, DC 20013-7535; or send a request to our fax at (202) 693-2498, or call us at (202) 693-1888.
• To order OSHA publications online at www.osha.gov, go to Publications and follow the instructions for ordering.
• To file a complaint by phone, report an emergency, or get OSHA advice, assistance, or products, contact your nearest OSHA office under the “U.S. Department of Labor” listing in your phone book, or call toll-free at (800) 321-OSHA (6742). The teletypewriter (TTY) number is (877) 889-5627.
• To file a complaint online or obtain more information on OSHA federal and state programs, visit OSHA’s website.
Propane Buffer System Overview
Electrical System
E1. Key switch
- Turn key switch to “start” position to turn over engine
- Once engine starts release key to “on” position
E2. Battery
- Gives power to solenoid (E3) to start
E3. Starter Solenoid (engaged by key switch)
- Tells starter (E4) to start turning
E4. Starter
- Turns flywheel (M2) to turn over engine
Fuel System
F1. Propane Tank
- 200 PSI vapor propane
F2. Propane Regulator
- Reduces vapor to 5 PSI
F3. Carburetor
- Combines fuel and air to enter combustion chamber
Spark System
S1. Spark Plug
- Creates spark to explode fuel
- Explosion pushes piston (M1) down
S2. Ignition Module
- Magnets on flywheel (M2) spin past ignition modules and cause spark
Mechanical System
M1. Piston
- Turns crankshaft (M3)
M2. Flywheel
- Spins crankshaft (M3) with starter engaged
- While running it provides air flow to cool engine
M3. Crankshaft (driven by pistons)
- Turns clutch/pulley (M4)
M4. Clutch/Pulley
- Turns belt (M6) - which turns pad driver pulley (M5)
M5. Pad Driver Pulley
M6. Belt
- Drives pad driver pulley (M5)
- Rotates pulley (M5) and clutch/pulley (M4)
M7. Pad Driver
- Attach pad to and buff
Propane Buffer System Overview
Starting
Key switch - sends power to starter solenoid to open
Battery - sends power to starter solenoid
Starter Solenoid - sends power to starter
Starter - engages (gear pops up) and turns flywheel
Flywheel - turns magnets past ignition modules
Charging
Flywheel - turns
Stator (located under flywheel) - creates AC (as the flywheel turns) which is sent to the voltage regulator
Voltage Regulator - converts AC to DC - sends DC power to starter solenoid
Starter Solenoid - sends DC to the battery
Battery - charges from the DC power being sent to it.
Propanes
Troubleshooting Guide
What to Do if Engine Will Not Turn Over
1. Battery Connections
- Check battery connections. If loose, tighten. Connections must be very tight. If damaged, replace.
2. Test Battery
- Using a volt meter, check battery voltage. See step 2 on next page for battery voltage testing instructions.
- Voltage should be 12.5V - 12.7V. If lower, charge battery.
- If battery does not reach 12.2V after charging, replace battery.
- If battery tests between 12.5V and 12.7V, load test. See step 2 on next page for load testing instructions.
3. Check Wiring
- Make sure wiring harness is plugged into the bottom of the key switch. Check that connection is secure.
4. Test Starter
- Using a volt meter, check voltage at starter. See step 4 on next page for starter voltage testing instructions.
- If voltage starter is 12V, turn key to start engine. If engine will not turn over, starter is bad. Replace starter.
- If voltage at starter is less than 12V, recheck battery connections. If still less than 12V, check solenoid.
5. Test Solenoid
- Using a volt meter, check voltage at solenoid. See step 5 on next page for solenoid testing instructions.
- If voltage is 12V, turn key to start engine. If engine will not turn over, solenoid is bad. Replace solenoid.
- If voltage is less than 12V, recheck battery connections. If still less than 12V, key switch is bad. Replace key switch.
What to Do if Engine Will Turn Over, But Will Not Start
1. Check Fuel Supply
- Check that propane tank is full and that the valve on the tank is open completely.
- If necessary, change tanks. Empty, low or faulty propane tanks are the #1 propane problem.
- Check fuel hose connections. If loose, tighten.
2. Check Oil
- Check engine oil level. If low, add oil up to the fill line on the dipstick. The oil pressure switch will stop the spark and the fuel flow if the oil is low.
3. Check Spark Plug
- Check wires that connect spark plug. If necessary, tighten. If damaged, replace.
4. Check Air Flow
- Check air filter for debris or obstruction. If necessary, clean or replace.
- Change air filter every 100 hours of use.
5. Check Spark Arrestor
- Check arrestor for debris. If necessary, clean or replace.
If the machine shakes badly when in use the buffing pad is either off-center or damaged. Shut machine off, remove pad holder and pad, re-install and check machine.
*These are general maintenance and safety guidelines. Please consult manufacturer instructions before performing any repairs or maintenance.
Engine Won’t Turn Over
3.
Close up of red lead on volt meter connected to positive battery post.
Using a volt meter, connect the red lead to the starter and the black lead to ground. Turn the key to the start position. If meter reads 12V but engine will not turn over, replace the starter. If that doesn’t work see next step. Tools Needed
2.
Check that the battery connection and terminals are tight. Loose connectors will cause emissions device faults and starter to engage erratically.
4.
Using a volt meter, connect red lead to positive post and black lead to negative post, engine or frame.
If voltage is 12.5-12.7V, perform load test. (see below) 1.
Performing a Load Test with Load Tester
You will need a hand held load tester. Connect the load tester to the battery posts. Press the load switch and then monitor the battery voltage to make sure it stays in the good (green) range. If the battery voltage drops into the weak (yellow) or the low/replace (red) range, then replace the battery.
Performing a Load Test with Volt Meter
You will need a volt meter. Connect the red lead from the volt meter to the positive, red post of the battery. Then connect the black lead from the volt meter to the negative, black post of the battery, the engine, or the frame to display the battery voltage. Then turn the engine to the start position for a few seconds to check for proper battery voltage. If the engine turns over slowly and/or the battery voltage drops off quickly, then replace the battery.
*These are general maintenance and
5.
Connect red lead to the solenoid and black lead to ground. Turn key to start. If 12V but engine will not turn over, replace solenoid. If no voltage is found, replace the key switch.
Propanes
Repair Guide
Engine Turns Over but Won’t Start
1.
Check that propane tank is full.
Change tank.
NOTE: Empty, low or faulty propane tanks are #1 problem.
4.
Check plug wires that connect to the spark plug. If necessary, tighten. If damaged, replace.
Check hose connections. If loose, tighten.
Check engine oil level. If low, add oil up to the full line on the dipstick. The oil pressure switch will stop the spark and fuel flow if the oil level is low. 2.
5.
Remove the air filter cover.
6.
*These are general maintenance and safety guidelines. Please consult manufacturer instructions before performing any repairs or maintenance. 3.
Check the air filter for debris or obstruction. If necessary, clean or replace.
Change the air filter every 100 hours of use.
What to Do if Engine Shuts Down During Use
1. Check Fuel Supply
- Check that propane tank is full.
- Check tanks. Empty low of faulty propane tanks are the #1 propane problem.
2. Check Oil
- Check the engine oil level. If low, add oil up to the fuel line on the dipstick. The oil pressure switch will stop the spark and the fuel flow if the oil level is low.
3. Check Spark Plug Connection
- Check plug wires that connect to the spark plug. If necessary, tighten. If damaged, replace.
4. Check Air Flow
- Check the air filter for debris or obstruction. If necessary, clean or replace.
- Change the air filter every 100 hours of use.
- Check the muffler for blockage at tailpipe. Remove blockage.
What to Do if There is A Propane Leak
1. Move to Safe Location
- If you detect a leak, move propane buffer and propane tank outside immediately.
- Leaking propane is very dangerous.
2. Check Quick Connect
- Check that quick connect is secure.
- If loose, reconnect. If damaged, replace.
3. Check O-Ring
- Check that o-ring is properly installed.
- If necessary, re-seat o-ring. If damaged or worn, replace.
Machine Gives Off Bad Odor or Red Emissions Light Comes on During Use
1. Check Oil Level
- Add oil if low.
2. Check Dust Bonnet and Air Filter
- Clean or replace dust bonnet on top of machine.
- Clean or replace air filter.
3. Check Spark Plug Wires
- Check to make sure both spark plug wires are securely attached to the end of the spark plug.
- Check to make sure that one of the spark plugs is not broken.
- A spark plug that is not firing correctly will allow fuel to pass through to the muffler which will negatively affect emissions
4. Change Propane Tank
- An overfilled propane tank will cause the regulator to freeze.
Engine Starts but With Limited Power/Running on One Cylinder
1. Check Spark Plug Wires
- Check to make sure both spark plug wires are securely attached to the end of the spark plug.
- Check to make sure that one of the spark plugs is not broken.
2. Check Dust Bonnet and Air Filter
- Clean or replace dust bonnet on top of machine.
- Clean or replace air filter.
Kawasaki FH500/FH541V Repair Guide
Replacing the Solenoid
Tools Needed
A. 1/2 inch ratchet-socket
B. 7/16 inch wrench
Locate the starter solenoid. 1.
Pull red and white wires from post.
3.
Disconnect the Anderson plug or power from the battery. 4.
Using a 7/16 inch wrench, remove nut on right post to disconnect red wire. 5.
*These are general maintenance and safety guidelines. Please consult manufacturer instructions before performing any repairs or maintenance. 2.
Pull red wire from post.
Using a 7/16 inch wrench, remove nut on left post to disconnect red and white wires.
8.
Disconnect the white wire by pulling off the connector. 7.
Remove the bolt that secures the solenoid to the engine. 9.
Using a 1/2 inch ratchet and deep socket, remove solenoid from machine and replace with a new solenoid.
Reverse steps 1-8 to reassemble machine.
Kawasaki FH500/FH541V Repair Guide
Replacing the Starter
Tools Needed
3.
Once the 2 bolts have been removed, remove the old starter by pulling it down and out away from the engine.
1.
Pull back the red, rubber cover on the starter cable. Loosen & remove the nut underneath with a 7/16” wrench. Remove the cable from the starter.
2.
Using a 12mm socket, long extension, and ratchet, loosen & remove the two bolts holding the starter to the engine, one on either side of the starter gear.
4.
Install the new starter by pushing it up into proper position and reinstall & tighten the (2) 12mm bolts through the back of the starter to the engine. Also, reinstall the red starter cable to the starter and tighten the nut to secure the cable. Pull the red, rubber cover back over the nut. Turn over the engine with the key to test for proper operation.
*These are general maintenance and safety guidelines. Please consult manufacturer instructions before performing any repairs or maintenance.
Propanes
Kawasaki FH500V/FH541V Repair Guide
How to Set the Valves and Check Compression
Tools Needed
A. Compression tester
B. Feeler gauge (.006”)
C. Ratchet socket (10mm)
D. Ratchet socket (14mm)
E. Ratchet socket (11/16”)
F. Ratchet socket (3/4”)
G. Flat tip screwdriver
H. Allen wrench (3mm)
I. Wrench (14mm)
Locate the spark plug wire.
Pull to disconnect the spark plug wire.
Pull the dust bonnet off the filter support.
Locate the spark plug.
Using a 10mm socket remove the 4 acorn nuts.
Using a 3/4 inch socket, remove the spark plug.
Lift the filter support off the engine.
Using a compression tester, twist the tester into spark plug hole on engine.
*These are general maintenance and safety guidelines. Please consult manufacturer instructions before performing any repairs or maintenance.
Kawasaki FH500V/FH541V Repair Guide
How to Set the Valves and Check Compression
Do not start the buffer, just turn the engine over. If tester shows below 110 PSI, set the valves.
10.
Compression test both sides and write down the results and set aside.
11.
Locate the valve cover.
12.
Using a 10mm socket, remove 2 bolts from valve cover.
13.
Pull to remove the valve cover (rocker arms are now visible).
*These are general maintenance and safety guidelines. Please consult manufacturer instructions before performing
14.
Using a 11/16 inch socket, turn the flywheel clockwise until each rocker arm goes in and out and stops. They will not be at the same time.
15.
Insert a flat tip screwdriver in the spark plug hole and turn flywheel until it pushes the screwdriver out and stops. This is top dead center.
16.
Insert a 0.006 inch feeler gauge between the rocker arm and the spring. Check gap on top and bottom rocker arms.
17.
If the gap is too tight or too big, use a 14mm socket to loosen the nut on top and bottom rocker arms.
18.
Hold the nut and use a 3mm Allen wrench to loosen the set screw on top and bottom rocker arms.
Propanes
Kawasaki FH500/FH541V Repair Guide
How to Set the Valves and Check Compression
19.
Insert a 0.006 inch feeler gauge between the rocker arm and the spring, hold and tighten nut on top and bottom rocker arms.
21.
Repeat steps 6-20 on the other cylinder head. Complete the valves on each side before starting the other side.
20.
Hold bolt with 3mm Allen wrench and use the 14mm socket to tighten set screw and bolt at the same time.
Recheck gap at top and bottom rocker arms.
22.
Repeat steps 8-10 on both cylinder heads to retest compression for comparison. Compare 1st and 2nd results. Compression should have increased.
Reassemble machine.
*These are general maintenance and safety guidelines. Please consult manufacturer instructions before performing any repairs or maintenance.
Kawasaki FH500/FH541V Repair Guide
How to Install an Ignition Module
1.
• Remove spark plugs. Remove 4 acorn nuts. Remove filter support. Remove bolts from plastic top shroud. Remove top shroud. Ignition modules will be exposed.
•Use a 10mm wrench to remove the bolts from each ignition module. Remove the kill wire connector from module.
•Install new modules. (Do not tighten)
2.
Spin the flywheel clockwise until the magnet on the flywheel is in front of the module.
3.
•Insert feeler gauge and gap module .016 inch away from the magnet.
•Tighten the 2 module bolts. Repeat on opposite side. There should be a .016 inch gap between the module and the magnet on the flywheel.
•Reinstall the shroud and filter.
*These are general maintenance and safety guidelines. Please consult manufacturer instructions before performing any repairs or maintenance.
Propanes
How to Set the Valves and Check Compression
Tools Needed
A. Compression tester
B. Feeler gauge (.006” & .025”)
C. Ratchet socket (10mm) (deep & std)
D. Ratchet socket (11/16”)
E. Ratchet deep socket (13/16”)
F. Wrench (10mm) (2)
G. Phillips screwdriver
1.
Pull the bonnet off the top of the engine.
2.
Using a Phillips screwdriver, remove the 3 screws holding the cage.
Remove the cage to access the bolt on top of the flywheel.
3.
Pull the spark plug boots off the spark plugs.
4.
Using a 13/16 inch deep socket, remove both spark plugs.
5.
Using a 10mm standard socket, remove the valve cover by removing the 5 bolts. This exposes the top of the cylinder head and both valves.
Place a rag under the valve cover to catch the oil. The cover gasket may break so have 2 new gaskets ready.
6.
Place the 11/16 inch socket on the top nut with a long extension and turn the engine clockwise.
7.
Turn the engine so that the exhaust (bottom) valve goes in and out. Continue turning until the intake (top) valve goes in and out.
Insert a long Phillips screwdriver into the spark plug hole until you feel it stop on the top piston. Turn the engine again slowly until the screwdriver stops moving outward. Stop turning the engine.
*These are general maintenance and safety guidelines. Please consult manufacturer instructions before performing any repairs or maintenance.
How to Set the Valves and Check Compression
8.
Insert a .006 inch feeler gauge between the top of the spring and the rocker arm on one of the valves.
If the feeler gauge goes in and out freely, then the valve clearance is okay and you can move onto the other valve. If the gauge is tight or you have to force it in, then you need to adjust the valve clearance. See steps 9-12 to adjust this.
11.
Re-install the valve cover with a new gasket if needed. Hand tighten the valve cover bolts.
Repeat steps 5-12 to set the other cylinder valves.
9.
Locate the bolt and nut on the rocker arm. Using (2) 10mm wrenches, one on the head of the bolt and the other on the nut. Hold the head of the bolt while slightly loosening the nut.
10.
Once the nut is loosened, use the 10mm wrench to turn the head of the bolt clockwise while at the same time inserting the feeler gauge between the top of the spring and the rocker arm.
When the feeler gauge goes in and out freely, stop moving the bolt head. Hold bolt head in place while tightening the nut. Recheck valve clearance with gauge and repeat process if not correct.
12.
Using a compression tester, perform a compression test on both cylinders after both sets of valves have been set.
Compression should be close to or at 120 PSI. If the compression is 90 PSI or below after setting the valves there may be a problem with the cylinder head.
13.
Gap the spark plugs with a .025 inch feeler gauge and lubricate the threads on the plug before installation.
Install new resistor type spark plugs if the engine is in need of service.
14.
Reinstall the spark plugs by hand to get them started, then tighten with ratchet socket.
Reverse steps 1-3 to reassemble the machine.
Propanes
How to Perform an Emissions Test
1.
Inspect the emissions tester device for damage and/or kinks in tubing. Replace if necessary.
4.
Insert the metal probe into the muffler tailpipe.
2.
Start the machine and run at high throttle in a well ventilated area.
Let machine run for 2-3 minutes before testing.
5.
Monitor emissions until ppm readout stabilizes. 1-2 minutes should be enough time.
3.
Turn on the emissions tester.
Re-zero device if capable.
6.
Set machine at low throttle and measure emissions ppm when stabilized.
*These are general maintenance and safety guidelines. Please consult manufacturer instructions before performing any repairs or maintenance.
USA-CLEAN Propane Regulations
Best Practices When Working with Propane Buffers
Tanks must be stored off-site or in an upright position in a locked, tamper-proof, steel mesh storage cabinet on the building exterior.
The cabinet must have at least five feet of space between the cabinet and the nearest building opening (door or window), unless otherwise specified by City, State or Federal ordinances.
All propane buffers should be equipped with catalytic converters that are in good working order. The catalytic element inside the muffler will degrade over time. It is very important to replace the muffler at the recommended intervals. Catalytic mufflers will decrease carbon monoxide (CO) emissions by up to 1,500 ppm.
Federal and State law prohibits tampering with Emission Control Systems on any propane powered equipment.
***Never bypass Emission Control Systems***
Operators and technicians should be certified with the proper handling and operating procedures of propane powered equipment. USA-CLEAN offers an online certification process for technicians. A comprehensive document related to all aspects of propane storage and safety is available in NFPA Standard #58.
The MAXIMUM amount of carbon monoxide (CO) emissions allowed in the USA-CLEAN Emissions Program, measured in the tailpipe and under load, is 500 ppm. Buffers emitting more than 500 ppm should be immediately removed from service or flagged as unsafe.
Equipment must be tested every 6 months at a minimum.
Never test or operate propane buffers in a small confined space. Testing and operation of the buffer should occur in “open” areas with proper ventilation.
*These are general maintenance and safety guidelines. Please consult manufacturer instructions before performing any repairs or maintenance.
Propanes
Lugs and Pad Holders
Lugs
L-801 (small)
996-0339
SP Price $11.12
Pad Holders
Center-Lok II (left hand thread)
991-2214
SP Price $18.35
Center-Lok 3
991-2206
SP Price $22.21
L-800P (standard)
996-0341
SP Price $14.66
L-800T (tall) 996-1535
SP Price $14.66
991-2201 (right hand thread)
991-2201
SP Price $13.76
Big Mouth (reverse thread)
996-0372
SP Price $20.00
Big Mouth (complete) 991-2202
SP Price $20.00
Pad Grab III (pad holder & ring)
991-2210
SP Price $26.44
Big Mouth (Male portion only)
991-2203
SP Price $17.20
Split Retainer (pad holder ring)
991-2209
SP Price $10.03
Brusshes Brushes
Brush Selection Guide
Daily Cleaning Brush
• Use for daily scrubbing
• Saves money compared to pads
Lite Grit Scrubbing Brush
• Replaces red pads
• Use for daily grit scrubbing
• Saves money compared to pads
Medium Grit Scrubbing Brush
• Replaces blue and green pads
• Use for scrubbing grouted tile
• Use for deep scrubbing of wax
Heavy Grit Scrubbing Brush
Carpet Brush
• Replaces black pads
• Use for scrubbing warehouse concrete, grocery non-slip and even sidewalks
• Use for stripping wax
Technical Specifications
• Specifically designed for daily cleaning of high gloss floor surfaces while maintaining floor shine
• Irregular bristle length to assure cleaning on uneven surfaces
Technical Specifications
• Nylon bristles impregnated with silicone carbide
• A lite scrub
• For use on VCT and all hard and resilient floors including quarry tile, brick, stone and concrete
• Use for holding on pad
• Use for driving a carpet bonnet
Technical Specifications
• Nylon bristles impregnated with silicone carbide
• A medium/aggressive general scrub
• For use on VCT and all sealed hard floors including tile, vinyl, marble, terrazzo, concrete and non-slip floors
Technical Specifications
• Nylon bristles impregnated with silicone carbide
• A medium/aggressive general scrub
• For use on VCT and all sealed hard floors including tile, vinyl, marble, terrazzo, concrete and non-slip floors
Technical Specifications
• Heavy polypropylene bristle
• Bristles short and uneven for pad penetration
• Complete with riser for proper pad size needs
• Red bristles indicate not for use as a scrubbing brush without pads
• Use for deep cleaning of carpet
• Use when pre-spraying/ scrubbing, then extracting
Technical Specifications
• Supported by an adjusting gliding plate so the bristles can be set to the correct cleaning depth
• Reduced machine drag, operator fatigue, and cleans more efficiently
• Designed for periodic, deep cleaning
Pad Driver
Brusshes
USAfix™ Home Screen
1. Shopping cart & checkout - Displays current number of items in cart. Click to begin checkout.
2. Change Password - Click to change your USAfix™ password.
3. Log Out - Click to log out of USAfix™.
4. Ask Us Online - Ask any floor equipment question and get answers from our Customer Care team.
5. Work Orders and Sites - Click to view active work orders or total sites serviced.
6. Home Button - Click to go to or refresh work order list.
7. Site Selection Dropdown - Allows switching between locations.
8. My Info - Click to view personal information as well as rates, payments and warranty options.
9. Documents - Access service partner reference materials.
10. Parts - See page 96 and page 97 for Parts Lookup.
11. TEC - Click to view required tests and certifications.
12. Warranty - Check warranty status or create a warranty request. See page 100 and page 101 for how to file TASKI warranty.
13. Inventory - Work orders needing site inventory.
14. Shop Recon - Click to view our reconditioned equipment on our website.
15. Support Team - Displays members of our service and warranty team.
16. National Performance Rating - Shows how you are rated in different areas based on service provided.
17. Shop As-Is Equipment - Click to be directed to our list of As-Is equipment for sale.
USAfix™ Work Order Management
1. Pre-Serivce - Accept/reject work orders and/or customer approved repair. Click to open.
2. Ready to Service - Shows current open work orders. Click to open.
3. Post-Service- Shows how may work orders are ready to be invoiced. Click to open.
4. Waiting on Customer - Work orders waiting on USA-CLEAN for direction. Click to open.
5. Stored Equipment - List of customer equipment being stored in the tech’s shop. Click to open.
6. Parts & Diagrams - Click to view parts and diagrams for selected equipment.
7. Tech Support - Click for troubleshooting.
8. Documents - Click to view technical documents for selected equipment.
9. Machine History - Click to view detailed repair history.
10. Update - Click to update the work order.
11. Invoice - Click to create an invoice.
USAfix™ Parts Lookup
1. Equipment Photo - Displays photo of currently selected equipment.
2. Equipment Details - Displays equipment make, model and equipment type.
3. Diagrams - Click to view equipment diagrams and parts lists. See details on next page.
4. Let Us Help - If you don’t see the part you’re looking for, click to create a Parts Request. We’ll do some research and get back to you ASAP.
5. Search Part Description - Search “motor”, “filter” or “wheel” to find parts for selected equipment.
6. Top Parts - Displays the top selling parts for this equipment. Click part lines to get more details.
7. Part Photos - Displays part photo. USA-CLEAN has thousands of parts photos available to make part lookup easier.
8. Part Description - Displays part description.
From the homepage, on the equipment list, find the machine you need parts for and click “parts & diagrams”.
If you want to find parts for equipment that isn’t in your list, click PARTS > Search on the menubar and search for equipment.
9. Stocking Status - Displays “In Stock” if part is in stock for same day shipping.
10. Part number - Displays USA-CLEAN part number.
11. Price - Displays part price with any discounts applied.
12. Shipping From - Displays location of part (Illinois or New Jersey) to help coordinate shipping times.
13. OEM or Certified Replacement Part - Identifies parts as genuine OEM or USA-CLEAN Certified Replacement Part.
14. Quantity - To select quantity, change this number before hitting “Add to order”.
15. Add to Order - Click to add this part to your cart.
16. Alternative items - Some parts have cheaper or closer replacement part numbers available. Look for these to save money.
USAfix™ Diagram Viewer
1. Diagram Selector - Click and select from dropdown to switch between diagrams for selected equipment.
2. Equipment Make/Model - Displays equipment make and model.
3. Print Diagram - Click to view printable version of selected diagram and parts list.
4. Print All - Click to view printable version of all diagrams and parts lists for selected equipment.
5. Equipment Photo - Displays photo of selected equipment.
6. Reference Numbers - Lists all reference number flagged on diagram. Click to view part details.
7. Part Details - Displays part description, quantity required, price, part number, stocking status, and photo.
8. Add to Order - Click to add selected part to your cart.
9. More Info - Click to display detailed part description and show any alternative items.
10. Diagram - Displayed across a large area of the screen for easy reading.
11. Let Us Help - If you don’t see the part you’re looking for, click to create a Parts Request. We’ll do some research and get back to you ASAP.
USAfix™ Troubleshooting & Dispatch
1. Tech button - To begin troubleshooting or dispatch, click the from the homepage equipment list.
2. Equipment Information - Displays equipment photo, and machine-specific information.
3. Warranty Status - Displays status of warranty coverage for this equipment.
4. Docs - Click to view technical documents for your equipment.
5. Parts - Click to find parts for this equipment. See page 97.
6. Troubleshooting Required - Some users are required by their corporate office to complete some troubleshooting steps before dispatch. This area displays which troubleshooting level is required.
7. Quick Dispatch - Click to skip troubleshooting and dispatch a technician ASAP. Skipping troubleshooting is not recommended for anyone looking to cut costs.
8. Ask Our Experts - Submit a request for technical help from our in house technicians.
9. Select Problem - To begin troubleshooting, first select a problem category and specific problem, then click “Forward” at the bottom right.
10. Troubleshooting Issue - During troubleshooting, the equipment issue is displayed above the troubleshooting steps.
11. Print Troubleshooting - Click to print troubleshooting steps. This is useful if you need to take the instructions to the machine location.
12. Blue Troubleshooting Steps - Troubleshooting steps highlighted in blue are considered to be the top three fixes to try first. Quite often, they’ll solve your issue on the spot.
13. Troubleshooting Details - Troubleshooting steps with a to them have additional details. Click the to show detailed instructions.
14. Found Problem? - As you work through the troubleshooting steps, check the boxes to indicate which troubleshooting steps you have tried, and which one worked. If you need to dispatch a technician, the results of these steps will be sent in the work order, which may help them get your machine fixed faster.
Troubleshooting & Dispatch
15. Troubleshooting Difficulty - Indicates the technical expertise recommended to attempt the troubleshooting described.
16. Resources - Diagrams, technical bulletins and other helpful resources are listed here. Refer to the Resources column to help work your way through the troubleshooting step.
17. Repair Guide Difficulty - Indicates the technical expertise recommended to attempt the fixes required.
18. Solved Free, Parts Required, Need Tech - Once the troubleshooting steps are complete, click to indicate whether the problem has been solved, whether parts are needed, or whether a technician should be dispatched.
How to get to this screen
From the homepage, on the equipment list, find the machine you need troubleshooting or dispatch for and click “tech support”.
TASKI Warranty Form
TASKI warranty is only available for TASKI distributors.
1. Warranty Form - Select “TASKI Warranty Form for Service Partner” under the “Warranty” tab. This is the warranty request form that will need to be filled out. Fill in all the information needed for each category. Your warranty request may be rejected due to lack of information provided.
2. Machine Information - Enter all machine information here; Model, Install Date, Machine Hours, Repair Date and Serial Number
3. Customer Information - Enter customer information; Customer, Customer Address, City, State and Zip.
4. Parts Information - Enter Labor and Travel times, along with the parts replaced.
5. Notes - Add notes describing the repair. When finished, click “Submit”.
Please note that your warranty may be rejected if there are no notes describing what repair was done on your machine.
Solution: Refile and add notes.
TASKI Warranty Report
TASKI warranty is only available for TASKI distributors.
1. Warranty Filed - Select “Warranty Filed” under the “Warranty” tab. This will show you a list of warranties filed. On this page you can view the status of each warranty
2. Approved - Warranty is approved, but not yet credited.
3. Rejected - Warranty has not been approved.
4. Credit - Warranty has been approved and credited. Check within each warranty filed for details on credits
5. Warranty Form Link - Clicking on these numbers will open the warranty form showing the details of the warranty filed. All of the information submitted with the TASKI warranty form will be shown.
6. Approved Amount - Here you can view the approved amount on the warranty filed.
Technical Education & Training
How to get to this screen
Click TEC on the menubar to get to the TEC training screen.
USAfix TEC is the place to go to learn about and get certified in proper floor equipment care techniques.
1. Certification Types - Certifications are divided between Required and Optional types. Click either to view training materials and tests. The following tests are required:
Fleet Management
Daily Operations
Preventative Maintenance
Break/Fix
2. Certification List - Within Required and Optional are listed certifications. Both training materials and a test exists within each certification.
3. Training Materials - All certifications include training materials to be studied before taking the test. Materials include text, pictures and even YouTube videos.
4. Tests - In the Testing section, you will find at least one test for each certification.
5. Test - All TEC tests are multiple choice and let you know how you scored instantly. To pass, you must score at least 90%. If you fail to pass the test on your first two attempts, you will be notified which answers are incorrect so you can review the training material.
6. Certificate of Achievement - Upon completing a certification, you are awarded this printable record of your success.
7. Test Expiration Date - Certifications expire after one year. To stay certified, simply retake the test.
Roboscrub 20 Components and Procedures
Roboscrub 20 Components and Procedures
Components Overview
Roboscrub 20 Components and Procedures
Lower Lidar Removal
Manual Operation
Lidar Protection Cage
Troubleshooting
Replacing BCM
Brake Release
Testing/Troublshooting Drive System
20Components and Procedures
Replacing the Drive Wiring Plate
Removing the Cowling, Wheel, E-Stop, Key Switch, UI Screen and Control Console
Steering Troubleshooting
Modem Troubleshooting
2D Camera Troubleshooting
Failure to Install Ferrite
3D Camera Troubleshooting
How to Read Kinetek Error Codes
Kinetec Error Codes
Roboscrub 20 Components and Procedures
Diagnostic App Errors
Brain Error Codes
Wiring Diagrams
20 Controls Overview
Squeegees - Adjustment
*see next page for references 7-13
1. Clean Water Tank
2. Hose fill Clean Water Port & Cap
3. Squeegee assembly
Squeegees - Adjustment
4. Wheels, 10-inch
5. Scrub head assembly
6. Side squeegee assembly
9. Front
Drive Wheel Replacement
Traction Brake and Encoder - Installation and Maintenance
Steering - Encoder Replacement
Traction Encoder - Troubleshoot or Replace
Steering - Motor Replacement
Wheel Replacement
Steering - Angle Troubleshooting
Steering - Troubleshooting Guide
*see next page for references 13 (continued)-18
7. Brake pedal
8. Accelerator pedal
drive wheel
Traction
12. Adjusting handle, seat
13. On-board battery charger receptacle
10. Operator seat 11. Steering wheel
Delta Q Charger - Charging Port Retrofit
Delta Q Charger - Check Charging Profile
Delta Q Charger - Data Retrieval
RS26 Components and Procedures
Camera Replacement - Front 2D Camera
Delta Q Charger - Data Retrieval
Camera Replacement - Side 2D Camera
14. Detergent level watching window
Sensors/Cameras
15. Sensors - Planar Lidar
16. Sensors - Lower Lidar
17. Sensors - Front 3D Camera
18. Sensors - Side 3D Camera
Sensors/Cameras Links
Cameras - Cleaning Sensors and Cameras
Connection Interface
Field Calibration Procedure
*see next page for reference 19
Camera Locations
How to Take Photos
Planar LIDAR Sample Photo (B)
Sensors/Cameras Links continued.
JAWS Installation
Slanted LIDAR - Installation & Calibration
LIDAR - IFM Diagnostics
Slanted LIDAR - Installation Video
Slanted LIDAR - Reflector Target Installation
Front Bumper - Removal and Replacing Gen 2 Support Bracket
Planar LIDAR Part Photo
Planar LIDAR Replacement
Planar LIDAR Sample Photo (A)
19. Front Bumper Skirt
*see next page for references 20-42
RS26 Components and Procedures
20. Warning light
Warning Light Replacement
21. Recovery tank cover
22. Recovery tank
23. Cup holder
24. Cap
25. Detergent bottle
26. Battery box
27. Drain hose, recovery tank
28. Drain hose, solution tank
29. Vacuum hose
30. Blue autonomy button
Touchscreen
31. User Interface LCD screen
32. General alert indicator
33. Battery indicator
Touchscreen Link
Touchscreen - Replacement
34. Momentary key/ignition
35. Emergency stop
36. Detergent level indicator and control
37. Water level indicator and control
38. Scrubber depth indicator
39. Horn
40. One-touch button
41. Vacuum pump button
42. Directional switch
VIB Dashboard Link
Dashboard - Replacement
VIB
VIB Dashboard
Part # Description
288.0095 110 2D Camera Module
288-0099 60mm Fan Assembly
278-0526 Ametk Vacuum Motor, 3 Stage, Kit
288-0046 Antenna, 4G Sentinel
288-0054 Assembly, Start-Pause Button
288-0053 Assy, Control Panel Replacement Service (w/ VIB)
Initiate double scrubbing by using the onetouch button to turn on the machine.
1 ext, press the vacuum bLJtton to turn o f the vacLJLJm
Doing this raises the squeegee off the floor. Double scrubbfng is a mode of operation in which the Brain-enabl ed scrubber cleans the floor wi hout simultaneously removing the fluid fro the floor's surface. Only the scrub deck is engaged while double scrubbing. The squeegee is not in operation, allowing solution to remain on the floor for increased cleaning solution dwell time.
Double scrubbing is functional in manual mode only and sh ould only be used in a • controlled envir onment, where there is no po tential for slippi ng and falling.
Use this button to activate horn
HORN
Setting Cleaning Function
HOME LOCATION CODES
SELECTING LOCATIONS FOR THE HOME LOCATION CODE
Home location codes should be placed near commonly cleaned areas, on an open wall or column, where there's easy viewing access from the right side of the machine. It should be in an area that does not change from day to day. It is recommended that the home location code area be the most consistent place on the route.
SCANNING HOME LOCATION CODES
In order to scan a home location code, position the right side of the Brain-enabled scrubber a minimum of 24-inches from the code. The camera used to scan the code is located on the right side of the machine's steering column.
LOS T OR DAMAGED HOME LOCATION CODES
If a home location code is lost or damaged, contact your service representative.
TEACHING A NEW CLEANING ROUTE
The machine can store up to six routes in memory per home location.
WARN I NG
Routes should not include driving into an elevator. The machine should always be manual ly operated when in an elevator or around automatic doors.
TEACHING AND SAVING ROUTES
7. Initiate power on the Brain-ena bled scrubber using the momentary key/ignition
2. Using the touchscreen move the blinking cursor to highligh "teach route."
3. The user interface will 111struct operator to drive to the home location code.
4 If the macl1ine is not positioned properly in r,ont of home location code, an error code will appear on the user interface LCD touchscreen stating ·Error1 Home Location Not Found" or "Machine is too clos : I too close, you will see a red highlight around the home location code
5 If the home location code is visible within the live video camera view and the Brain-enabled scrubber is within the appropriate distance fror the code, the machine will begin scanning and state ·scanning Home Location." You will see a green highlight around the image of the code on the UL
6 Once the Brain-enabled scrubber completes scanning the home location code. a ·success· message appears.
7. Using the touchscreen, move the blinking cursor and select an available slot to assign to the new cleaning route In some cases, the cursor will au omatically move the next available route
8. The Brain-enabled scrubber will indicate it's now ready to learn a route by staling "Ready I will learn as you drive." The LCD screen will shift to "Learning Mode."
Drive the machine through the entire desired cleaning route. This allows the machine to map and store the new route in memory
Note: The machine will not recall the component settings (water level, solution level and scrub deck pressure). This is to allow the end user to choose the appropriate settings based on need for the day or cleaning area. Tt1e robot operator should decide on waler, solution and scrub dee level and adjust before each route is selected.
10. The robot completes its map by running a loop. It is important to finish the desired cleaning route at the home location wher the route was start cl. A route cannot be saved in memory without completing his step. Always start and stop in the exact same location.
71 Selec ·save· by pressing the save button.
12. The user interface will ask "Are you sure you want to save this route?"
13 Press the button again to indicate ·ves •
7'1 I he Brain OS software will automatically save the route and will then appear on tt1e "Run Route· menu option hen selected.
ROC INDICATOR - Pairing Phone with Brain-enabled Scrubber
TO ACCESS THE ALERTS SCREEN:
Robotics
Maintenance Schedule
Tennant T7AMR
These are general maintenance guidelines. Please consult your owner’s manual prior to performing any repairs or maintenance on this machine.
Maintenance Task Daily Weekly Yearly
Charge the batteries X
Drain/clean tanks and hoses X
Clean/clear brushes/pad X
Clean/clear squeegee
Clean/clear vacuum shut-off float
Check/replace squeegee blades
Check/clean solution filter
Check/fill battery water levels (wet batteries only)
Check/replace motor carbon brushes
Lubrication Tips: Once a month, pump a small amount of grease into each grease fitting on the machine until grease seeps out around the bearings.
Grease fitting locations are:
• Rear caster wheel axle and swivel (2) per assembly
• If chain drive (2) pillow block bearings
Apply light machine oil to lubricate the:
• Drive chain (if no transaxle)
• Squeegee tool adjustment knob, wheels, and rollers
• Pivot points for the squeegee and scrub brush linkage
Serial Number Location
No Solution Flow
These are general maintenance guidelines.
Please consult your owner’s manual prior to performing any repairs or maintenance on this machine.
Difficulty
Check the tank
• If the solution tank is empty, fill the solution tank.
Test for solution flow
• If no flow, you may have a clog in the tank or lines.
• Pull hose from filter to check for water flowing through the filter.
• Pull hose from solenoid valve to check for water flowing into the solenoid valve.
• Pull hose from the other side of the solenoid valve. Turn the valve to the open position and check for water flowing through the solenoid valve.
Note: See Cleaning and Replacing Solution Filter on page 151
Note: Engage the solenoid valve (by turning the brushes on), seat switch, and pedal. Make sure the solenoid valve is open and the machine is on.
If the solenoid valve will not open
• Put a volt meter on 2 wires on the solenoid valve. Turn the solution switch on.
Note: Engage the solenoid valve (by turning the brushes on), seat switch, and pedal. Make sure the solenoid valve is open and the machine is on.
• If you get voltage but no water flow past the solenoid, the solenoid is bad. Replace the valve.
- Parts: Solenoid Valve
Cleaning and Replacing Solution Filter
These are general maintenance guidelines. Please consult your owner’s manual prior to performing any repairs or maintenance on this machine. **Before you begin: Turn the machine off.
4.
for damage and clogs. If filter is damaged replace.
1. Open solution tank.
2.. Drain solution tank.
3. Locate Filter inside of Solution Tank. unscrew filter.
Remove filter. Check
5. Rinse Filter
6. Screw Filter in place.
Poor or No Pickup
These are general maintenance guidelines. Please consult your owner’s manual prior to performing any repairs or maintenance on this machine.
Difficulty
Check the tank
• If recovery tank is full, empty the recovery tank.
Check the recovery lid and gasket
• Check lid is on correctly and not damaged. If damaged, replace the lid.
- Parts: Recovery Tank Lid
• Check gasket for tight seal or damage. If damaged, replace the gasket.
- Parts: Gasket
Check the drain hose
• Check hose for cracks or damage. If damaged, replace the drain hose.
- Parts: Drain Hose with Plug
Check the vacuum hose
• Detach squeegee hose from squeegee assembly. Turn the vacuum motor on and place hand over hose to check for suction. If low suction, check for clog. Remove any clogs.
• Check hose for cracks or damage. If damaged, replace the hose.
- Parts: Hose
Check the squeegee blades
• Remove the squeegee and flip over.
• Check the squeegee for debris, remove debris.
• Check if blades are worn or damaged. If blades are worn or damaged, replace the blades.
- Parts: Squeegee Blades
Note: See Replacing Squeegee Blades on page 156
Check the vacuum motor
• Check carbon brushes. If worn, replace brushes.
- Parts: Carbon Brushes
• If no clog and still low or no suction, replace the vacuum motor.
- Parts: Vacuum Motor
Note: See Replacing the Vacuum Motor on page 155.
Cleaning and Replacing the Vacuum Hose
These are general maintenance guidelines. Please consult your owner’s manual prior to performing any repairs or maintenance on this machine. **Before you begin: Turn the machine off.
1.Locate Vacuum hose on back of machine.
2.Disconnect hose from back of machne.
3.Disconnect hose from Squeegee Weldment.
4 Inspect hose for damage and cracks. Remove any clogs. Replace hose if necessary. Reverse steps to reinstall.
Cleaning and Replacing Drain Hose
These are general maintenance guidelines. Please consult your owner’s manual prior to performing any repairs or maintenance on this machine.
Tools Needed:
A: Flat Head Screwdriver
4.Use a flat head screw drive to loosen hose clamp.
4.Pull to remove hose.
4.Check Recovery Tank for clogs.
5. Inspect Hose for damage and clogs. Replace Hose if needed. Reverse the steps to install new hose.
2.Locate Drain hose on back of machine.
1. Drain Recovery Tank.
3. Tilt back Recovery tank. Drain hose is connected underneath.
Replacing the Vacuum Motor
These are general maintenance guidelines. Please consult your owner’s manual prior to performing any repairs or maintenance on this machine.
Tools Needed:
A: 14 mm
Socket
A: 10 mm
Socket
B: Flat Head
Screwdriver
1. Locate vacuum on motor on top of machine.
2. Check seal for damage and wear
3. Unscrew nuts.
Note: Lid is on hinges and will fall back if not braced.
3.Vac Motor is now exposed
5. Unscrew the 3 nuts.
Note: 1 nut on motor will need a wrench to be taken off.
Tool: 10mm socket
4. Loosen Hose Clamp and Disconnect hose.
Tool:Flat Head Screw Driver.
6. Disconnect wiring
7.Vac motor is now disconnected.
Reverse process to install a new vac motor
Replacing the Squeegee Blades
These are general maintenance guidelines. Please consult your owner’s manual prior to performing any repairs or maintenance on this machine. **Before you begin: Turn the machine off.
1. Locate vac hose attached to squeegee weldment on the back of machine. Pull to remove the hose.
4. Unscrew all four 4-sided knobs on top of assembly.
2. Loosen both 4-sided knobs on top of the assembly. Once knobs are loose. Pull back assembly off the brackets.
5. Remove Squeegee Retainer (1) from Squeegee Housing (2).
6. Remove Squeegee blades. Clean any clog and debris from housing. Check Squeegee blades for wear or damage. Flip or Replace Squeegee bkades. Reverse steps to reinstall.
3. Open latch
4. Remove Strap.
Replacing the Side Skirts
These are general maintenance guidelines. Please consult your owner’s manual prior to performing any repairs or maintenance on this machine. **Before you begin: Turn the machine off.
1. Locate skirt on brush deck under machine.
Note: Left and Right skirts have the same removal steps.
5. Slide squeegee off retainer. Inspect for wear and damage.
Reverse steps to reinstall
2. Locate pin on the front of the Skirt. Pull Pin.
3. Open latch on the front of the deck.
4. Slide the front side of the retainer off the deck.
Note: Retainer will still be attached by a pin on the back side. It does not have to be removed to remove the squeegee.
6. To remove the skirt retainer from deck. Follow steps 1-4 then remove the pin on the back side of the retainer.
7. Remove Retainer from deck.
Reverse steps to reinstall.
Replacing Front Skirt
These are general maintenance guidelines. Please consult your owner’s manual prior to performing any repairs or maintenance on this machine. **Before you begin: Turn the machine off.
Tools Needed:
A: 14mm wrench
1. Locate Front Skirt on the front of the deck.
2.Remove all screws and nuts from the Clamp.
3. Inspect Squeegee and Skirt clamp for damage and wear.
Reverse steps to reinstall.
Minuteman Roboscrub 20
These are general maintenance guidelines. Please consult your owner’s manual prior to performing any repairs or maintenance on this machine.
Maintenance Task Daily Weekly Yearly
Charge the batteries X
Drain/clean tanks and hoses X
Clean/clear brushes/pad X
Clean/clear squeegee X
Clean/clear vacuum shut-off float
Check/replace squeegee blades
Check/clean solution filter X
Check/fill battery water levels (wet batteries only) X
Check/replace motor carbon brushes X
Lubrication Tips: Once a month, pump a small amount of grease into each grease fitting on the machine until grease seeps out around the bearings.
Grease fitting locations are:
• Rear caster wheel axle and swivel (2) per assembly
• If chain drive (2) pillow block bearings
Apply light machine oil to lubricate the:
• Drive chain (if no transaxle)
• Squeegee tool adjustment knob, wheels, and rollers
• Pivot points for the squeegee and scrub brush linkage
Serial Number Location
Simplified Solution System
These are general maintenance guidelines.
Please consult your owner’s manual prior to performing any repairs or maintenance on this machine. Difficulty
Check the tank
• If the solution tank is empty, fill the solution tank.
Test for solution flow
• If no flow, you may have a clog in the tank or lines.
• Pull hose from filter to check for water flowing through the filter.
• Pull hose from solenoid valve to check for water flowing into the solenoid valve.
• Pull hose from the other side of the solenoid valve. Turn the valve to the open position and check for water flowing through the solenoid valve.
Note: See Cleaning and Replacing Solution Filter on page 164
Note: Engage the solenoid valve (by turning the brushes on), seat switch, and pedal. Make sure the solenoid valve is open and the machine is on.
If the solenoid valve will not open
• Put a volt meter on 2 wires on the solenoid valve. Turn the solution switch on.
Note: Engage the solenoid valve (by turning the brushes on), seat switch, and pedal. Make sure the solenoid valve is open and the machine is on.
• If you get voltage but no water flow past the solenoid, the solenoid is bad. Replace the valve.
- Parts: Solenoid Valve
Cleaning and Replacing Solution Filter
These are general maintenance guidelines. Please consult your owner’s manual prior to performing any repairs or maintenance on this machine. **Before you begin: Turn the machine off.
1. Drain Solution Tank. Locate Solution filter under the machine.
2. Remove Solution Cap and Filterby turning clockwise. Excess liquid in filter bowl will drain out.
3. Remove metal screen from bowl.
4.Remove any debris.
6. Once clean, reverse steps to reinstall.
5. Rinse Screen
These are general maintenance guidelines. Please consult your owner’s manual prior to performing any repairs or maintenance on this machine.
Difficulty
Check the tank
• If recovery tank is full, empty the recovery tank.
Check the recovery lid and gasket
• Check lid is on correctly and not damaged. If damaged, replace the lid.
- Parts: Recovery Tank Lid
• Check gasket for tight seal or damage. If damages, replace the gasket.
- Parts: Gasket
Check the float switch
• Check if float is damaged. If damaged, replace the float switch.
- Parts: Float Switch
Check the drain hose
• Check the drain plug for a tight seal or damage. If damaged, replace the drain plug.
- Parts: Drain Plug
• Check hose for cracks or damage. If damaged, replace the drain hose.
- Parts: Drain Hose with Plug
Check for clog in vacuum hose
• Detach squeegee hose from squeegee assembly. Turn the vacuum motor on and place hand over hose to check for suction. If low suction, check for clog. Remove any clogs.
• Check hose for cracks or damage. If damaged, replace the hose.
- Parts: Hose
Check the squeegee blades
• Remove the squeegee and flip over.
• Check the squeegee for debris, remove debris.
• Check if blades are worn or damaged. If blades are worn or damaged, replace the blades.
- Parts: Squeegee Blades
Note: See Replacing Squeegee Blades on page 168
Check the vacuum motor
• Check carbon brushes. If worn, replace brushes.
- Parts: Carbon Brushes
• If no clog and still low or no suction, replace the vacuum motor.
- Parts: Vacuum Motor
Note: See Replacing the Vacuum Motor
Cleaning and Replacing Vacuum Hose
These are general maintenance guidelines. Please consult your owner’s manual prior to performing any repairs or maintenance on this machine. **Before you begin: Turn the machine off.
1. Locate vac hose attached to squeegee weldment under machine
2. Pull hose to disconnect from weldment
3. Disconnect hose from back of tank. Located next to drain hose
4.Inspect hose for damage and cracks. Remove any clogs.
Replace hose if necessary.
Cleaning and Replacing Drain Hose
These are general maintenance guidelines. Please consult your owner’s manual prior to performing any repairs or maintenance on this machine. **Before you begin: Turn the machine off.
Tools Needed:
A: Flat Head Screwdriver
4.
is
removed. Clean or replace the hose.
3.Use flat head screwdrive to
Note: Hose clamp can be at a difficult angle will need to use different lengths of screwdrive to loosen or spin the hose clamp.
Reverse steps to reinstall.
2. Drain hose located behind batteries.
loosen hose clamp.
Drain hose
now
5. Clean any debris and clogs in the recovery tank hose.
1. Drain Recovery Tank.
Replacing Squeegee Blades
These are general maintenance guidelines. Please consult your owner’s manual prior to performing any repairs or maintenance on this machine. **Before you begin: Turn the machine off.
1. Locate vac hose attached to squeegee weldment under machine
Disconnect the hose.
2. Loosen both 3-sided knobs on top of the assembly. Once knobs are off. Slide assembly out from under machine.
5. Inspect Squeegee blades for wear and damage. Clean assembly of debris. Flip or replace Squeegee Blades. Reverse steps to reinstall.
*Minuteman has upgraded to this new style of Squeegee assembly. Replacing the hardware for the bands to just a thumb screw and has suggested that old style assemblies be replaced with the current style.
3. Unlock latch
4. Remove front and rear squeegee straps.
5. Remove Front and Rear Squeegee blades.
3. Unscrew thumb screw.
ICE RS26 GEN 2
These are general maintenance guidelines. Please consult your owner’s manual prior to performing any repairs or maintenance on this machine.
Maintenance Task Daily Weekly Yearly
Charge the batteries X
Drain/clean tanks and hoses X
Clean/clear brushes/pad X
Clean/clear squeegee
Clean/clear vacuum shut-off float
Check/replace squeegee blades
Check/clean solution filter
Check/fill battery water levels (wet batteries only)
Check/replace motor carbon brushes X
Lubrication Tips: Once a month, pump a small amount of grease into each grease fitting on the machine until grease seeps out around the bearings.
Grease fitting locations are:
• Rear caster wheel axle and swivel (2) per assembly
• If chain drive (2) pillow block bearings
Apply light machine oil to lubricate the:
• Drive chain (if no transaxle)
• Squeegee tool adjustment knob, wheels, and rollers
• Pivot points for the squeegee and scrub brush linkage
Serial Number Location
Simplified Solution System
These are general maintenance guidelines.
Please consult your owner’s manual prior to performing any repairs or maintenance on this machine. Difficulty
Check the tank
• If the solution tank is empty, fill the solution tank.
Solution control knob is set too low
• Check that the solution control knob is set to release solution.
Check the solution filter and hoses
• Check for clogs. Remove any clogs.
• Check for wear/cracks in the filter and solution hoses. If damaged, replace.
- Parts: Solution Filter Solution hoses
Note: See Cleaning and Replacing the Solution Filter on page 174
Test for solution flow
• Pull hose from filter to check for water flowing through the filter.
• Pull hose from solenoid valve to check for water flowing into the solenoid valve.
• Pull hose from the other side of the solenoid valve. Turn the valve to the open position and check for water flowing through the solenoid valve.
Note: See Cleaning and Replacing Solution filter on page 174.
Note: Engage the solenoid valve (by turning the brushes on), seat switch, and pedal. Make sure the solenoid valve is open and the machine is on.
Test solenoid valve
• Put volt meter on 2 wires to the solenoid valve (red to red; black to black).
• Engage solenoid valve (by turning brushes on).
• If you get voltage, but no water flow past the solenoid valve, the solenoid is bad. Replace valve.
- Parts: Solenoid valve
Note: See Cleaning and Replacing the Solenoid on page 176
Cleaning and Replacing Solution Filter
These are general maintenance guidelines. Please consult your owner’s manual prior to performing any repairs or maintenance on this machine. **Before you begin: Turn the machine off.
2. Open solution tank.
4 Remove filter. Check for damage and clogs.
3. Locate filter inside of solution tank. Unscrew filter.
6. Reverse process to install a new filter.
5. Rinse filter.
1. Drain solution tank.
Checking Solenoid Valve Connections
These are general maintenance guidelines. Please consult your owner’s manual prior to performing any repairs or maintenance on this machine. **Before you begin: Turn the machine off.
1. Lower scrub deck (1) and turn off the vacuum (2) and power off machine.
5. Check for frayed, loose, worn or disconnected wires.
Note: Give wires a gentle tug with wires meet strain relief to check if wires are loose or worn.
2. Remove right side brush and squeegee.
3. For easy access lay on the right side of the scrubber to locate solenoid.
4. Locate Solenoid underneath scrubber.
These are general maintenance guidelines.
Please consult your owner’s manual prior to performing any repairs or maintenance on this machine.
**Before you begin: Turn the machine off.
Tools Needed
A. Flat head screwdriver
B. Needle nose pliers
C. Right angled screwdriver
4. Empty clean water tanks. Remove zip ties, loosen hose clamp and disconnect hoses.
1. Follow steps 1-3 on page 175
5. Remove screws holding solenoid to scrubber. Reverse process to install new solenoid.
2. Locate solenoid cable bundle.
3 Unplug the spade connectors to the solenoid valve.
Replacing the Solution Float Switch
These are general maintenance guidelines. Please consult your owner’s manual prior to performing any repairs or maintenance on this machine. **Before you begin: Turn the machine off.
Tools Needed
2. Press vacuum button on panel to lower squeegee actuator.
3. Locate float switch plug under the back of the machine.
4. Cut zip ties and unplug the float switch plug.
5. Unscrew the nut under the machine.
6. Loosen pins in the plug.
Note: You can use wire cutters to cut male end plug off if you are unable to remove pins and skip to step 9.
7. Remove blue clamp on bottom of the plug.
1. Remove squeegee assembly.
A. Wire cutters
B. Pliers
Replacing the Solution Float Switch
These are general maintenance guidelines. Please consult your owner’s manual prior to performing any repairs or maintenance on this machine. **Before you begin: Turn the machine off.
8. Remove plug to expose pins.
9. Remove nut.
10. Pull switch from solution tank.
11. Switch is removed from tank.
Reverse process to install a new switch.
These are general maintenance guidelines. Please consult your owner’s manual prior to performing any repairs or maintenance on this machine.
Check the tank
• If recovery tank is full, empty the recovery tank.
Check the recovery lid and gasket
• Check lid is on correctly and not damaged. If damaged, replace the lid.
- Parts: Recovery Tank Lid
• Check gasket for tight seal or damage. If damaged, replace the gasket.
- Parts: Gasket
Check the drain hose
• Check hose for cracks or damage. If damaged, replace the drain hose.
- Parts: Drain Hose with Plug
Check the vacuum hose
• Detach squeegee hose from squeegee assembly. Turn the vacuum motor on and place hand over hose to check for suction. If low suction, check for clog. Remove any clogs.
• Check hose for cracks or damage. If damaged, replace the hose.
- Parts: Hose
Check the squeegee blades
• Remove the squeegee and flip over.
• Check the squeegee for debris, remove debris.
• Check if blades are worn or damaged. If blades are worn or damaged, replace the blades.
- Parts: Squeegee Blades
Note: See Replacing Squeegee Blades on page 183
Check the vacuum motor
• Check carbon brushes. If worn, replace brushes.
- Parts: Carbon Brushes
• If no clog and still low or no suction, replace the vacuum motor.
- Parts: Vacuum Motor
Note: See Replacing the Vacuum Motor on page 182.
Cleaning and Replacing Vacuum Hose
These are general maintenance guidelines. Please consult your owner’s manual prior to performing any repairs or maintenance on this machine. **Before you begin: Turn the machine off.
Tools Needed
A. Phillips head screwdriver
2. Pull hose from back of tank.
4. Reverse process to install new vacuum hose.
3. Pull hose from squeegee weldment.
1. Locate vacuum hose on back of machine.
5. Unscrew trap inside of the recovery tank.
6. Remove any debris, rinse trap. Reverse process to install new trap.
These are general maintenance guidelines.
Cleaning and Replacing Drain Hose
Please consult your owner’s manual prior to performing any repairs or maintenance on this machine.
**Before you begin: Turn the machine off.
Tools Needed
1. Locate drain hose on the back of the machine.
5. Reverse process to instal new hose.
Note: Tilt back recovery tank. Drain hose is connected underneath.
A. Flat head screwdriver
2. Drain recovery tank.
4. Pull drain hose to remove.
3. Loosen hose clamp.
Replacing the Vacuum Motor
These are general maintenance guidelines. Please consult your owner’s manual prior to performing any repairs or maintenance on this machine. **Before you begin: Turn the machine off.
Tools Needed
A. 14mm
socket wrench
B. 10mm socket wrench
C. Flat head screwdriver
1. Open recovery tank lid and locate the 4 bolts.
2. Remove bolts.
Note: Lid is on hinges and will fall back if not braced.
3 Vacuum motor is now exposed
4. Unscrew the 3 nuts holding the motor to the bracket.
5. Loosen hose clamp and disconnect hose.
6.
7. Reverse process to install a new vacuum motor.
Disconnect the vacuum motor plug.
Replacing Squeegee Blades
These are general maintenance guidelines. Please consult your owner’s manual prior to performing any repairs or maintenance on this machine. **Before you begin: Turn the machine off.
1. Locate vacuum hose attached to the squeegee weldment on the back of the machine. Pull hose.
2. Loosen both 4-sided knobs on top of the assembly. Once knobs are loose. Pull assembly off the bracket.
5. Unscrew all four 4-sided
3. Open latch.
4. Remove strap.
6. Remove squeegee retainer (1) from squeegee housing (2).
7. Remove squeegee blades.
Flip or replace the blades.
Reverse process to install new blades.
knobs on top of the assembly.
Replacing Side Skirts and Bristles
These are general maintenance guidelines. Please consult your owner’s manual prior to performing any repairs or maintenance on this machine. **Before you begin: Turn the machine off.
1. Locate the side skirt on the brush deck. Turn knobs to loosen.
2. Unscrew 5 knobs and washers on the back side of the bracket.
3. Remove skirt strap.
4. Remove squeegee blade from bracket.
Flip or replace blade. Reverse process to install a new blade.
5. Locate the two knobs under the machine behind the brush deck and unscrew. Slide side bristle out from under the machine.
6. Unscrew the 3 knobs on the back if the side bristle.
7. Remove strap and brush from bracket. Reverse process to install new bristle.
These are general maintenance guidelines. Please consult your owner’s manual prior to performing any repairs or maintenance on this machine. **Before you begin: Turn the machine off.
Tools Needed:
A: Two 13mm wrench
B: 10mm wrench
4. Remove all Screws from the Skirt and slide Clamp and Squeegee off the Scrub head.
Locate Front Skirt under machine attached to the Scrub head.
5. Inspect Squeegee and Skirt clamp for damage and wear. Flip or Replace blades. Reverse steps to reinstall.
2. On right hand side remove Protective Wheel bracket.
Note: You may need to take wheel off to remove bracket.
3. Loosen the Bolt on the Right hand bracket.
Note: This step will help remove the Skirt clamp.
1.
Replacing and Adjusting Squeegee Casters
These are general maintenance guidelines. Please consult your owner’s manual prior to performing any repairs or maintenance on this machine. **Before you begin: Turn the machine off.
Tools Needed
2.
5. Loosen or tighten nut depending on where you want your squeegee assembly to sit.
6. Remove nut completely from caster and remove caster from bracket. Reverse process to install a new caster.
1. Remove squeegee assembly.
Use a block to lift squeegee bracket.
3. Locate caster on squeegee bracket.
4. Loosen nut.
A. Crescent wrench.
Replacing the Recovery Float Switch
These are general maintenance guidelines. Please consult your owner’s manual prior to performing any repairs or maintenance on this machine. **Before you begin: Turn the machine off.
Tools Needed
6.
clip holding the switch cord to the recovery tank.
1. Lift seat.
5. Locate plug under plate and disconnect.
2. Tilt recovery tank.
3. Remove the 4 bolts on plate.
Remove
7. Using pliers loosen nut.
4. Remove plate.
A. 13mm socket wrench
B. Phillips screwdriver
C. Pliers
Replacing the Recovery Float Switch
These are general maintenance guidelines. Please consult your owner’s manual prior to performing any repairs or maintenance on this machine. **Before you begin: Turn the machine off.
8. Loosen pins in the plug.
Note: You can use wire cutters to cut male end plug off if you are unable to remove pins and skip to step 11.
9. Remove blue clamp on bottom of the plug.
plug to expose pins.
10. Remove
11. Remove nut.
13. Locate switch in recovery tank.
14. Pull switch from recovery tank.
15. Switch is removed from tank.
Reverse process to install a new switch.
12. Open recovery tank lid
These are general maintenance guidelines. Please consult your owner’s manual prior to performing any repairs or maintenance on this machine. **Before you begin: Turn the machine off.
Needed
A. Wire cutters
B. Right angled needle nose pliers
C. 13mm socket wrench
1. Key the machine on and drop the brush deck (green button). Turn machine off.
2. Use a ratchet strap under the brush deck and ratchet up the deck slightly to relieve pressure to make removing pins easier.
3. Locate actuator pin and cotter pin. Remove cotter pin and washer. Push the pin to allow enough of the pin to be able to be pulled from the other side.
5. Remove the 2 bolts holding on the cover and remove cover.
plug and cut zip ties.
6. Locate actuator
7. Unplug the actuator plug.
4. Pull pin. Tools
Replacing the Actuator
These are general maintenance guidelines. Please consult your owner’s manual prior to performing any repairs or maintenance on this machine. **Before you begin: Turn the machine off.
8. Locate cotter pin and pull to remove.
12. Plug in actuator
9. Locate pin and remove.
10. Actuator is now free. Pull actuator from machine.
13. Key machine on and hold actuator and press the green button. Actuator should be in the down position.
14. Align the holes on the arms with the holes on the actuator and reinsert pin and cotter pin. Raise and lower brush deck to test actuator.
11. Insert new actuator.
Removing Brush Deck
These are general maintenance guidelines. Please consult your owner’s manual prior to performing any repairs or maintenance on this machine. **Before you begin: Turn the machine off.
Tools Needed
1. Remove left and right side brush and skirt.
Note: See Replacing side skirts and bristles. See page 41.
2. Remove both brushes under the deck.
3. Place ratchet strap under brush deck. Leave enough room to be able to hook both hooks together on the seat.
4. Key the machine on and drop the brush deck (green button). Turn machine off.
5.Locate hose connected to elbow and loosen hose clamp.
6. Pull to remove hose.
Note: Hose may be snug and need pulled off using pliers. There will be water in the line drain into towels.
A. Flat head screwdriver
B. Right angled needle nose pliers
C. Ratchet Strap D. Jack
Removing Brush Deck
These are general maintenance guidelines. Please consult your owner’s manual prior to performing any repairs or maintenance on this machine. **Before you begin: Turn the machine off.
7. Pull smaller hose and disconnect from elbow.
8. Disconnect the solenoid.
9. Unplug both brush motors.
10. Use a ratchet strap under the brush deck and ratchet up the deck slightly to relieve pressure to make removing pins easier.
11. Remove bottom cotter pins on both left and right arms.
12. Pull bottom pins from both left and right arms.
13. Locate both actuator pins.
14. Remove cotter pins and pull actuator pins from bracket.
Removing Brush Deck
These are general maintenance guidelines. Please consult your owner’s manual prior to performing any repairs or maintenance on this machine. **Before you begin: Turn the machine off.
15. Remove top cotter pin from left and right arm.
16. Remove both left and right arms from underneath the machine.
17. Slowly release ratchet strap. Deck will be disconnected from machine and sit on the floor.
18. Deck can be removed from either the left or right side. Slightly jack machine up enough to slide deck out from underneath machine. Move actuator to the side while moving deck.
19. Reverse process to install new brush deck.
20. When reinstall deck and attaching to actuator, make sure all holes are aligned correctly.
Note : See Replacing the Actuator page 190
Replacing the Brush Motors
These are general maintenance guidelines. Please consult your owner’s manual prior to performing any repairs or maintenance on this machine. **Before you begin: Turn the machine off.
Tools Needed
A. 11mm socket Hydraulic gear puller
B. 13mm socket wrench
C. 14mm socket wrench
D. Impact Ratchet (optional)
E. Flat head or phillps head screwdriver (optional)
1. Follow steps 1-18 on page 191 - page 193 to remove the brush deck
2. Flip deck over and expose the hubs.
3. Loosen bolt.
Note: You will need to brace the hub when loosening the bolt. Place a long screwdriver through a hole on the hub and loosen bolt or you can use an impact ratchet.
5. Use a gear puller to remove hub.
6. Remove left and right hub
4. Remove bolt and washer.
Replacing the Brush Motors
These are general maintenance guidelines. Please consult your owner’s manual prior to performing any repairs or maintenance on this machine. **Before you begin: Turn the machine off.
7. Remove the 3 bolts under left and right side hubs.
8. Slide both left and right side motor from under the deck. Reverse process to install new brush motors.
Break Release
These are general maintenance guidelines. Please consult your owner’s manual prior to performing any repairs or maintenance on this machine. **Before you begin: Turn the machine off.
Tools Needed
2. Locate tool under seat.
Note: If tool is unavailable a flat head screw driver will work following the same steps.
4. Locate the brake release.
5. Wedge tool between the brake release and brake.
6. Check that tool is secure. Machine can move easily around. Remove wedge once machine is in its location.
Note: Make sure all emergency stop buttons are disengaged.
3. Locate brake under the machine.
1. Lift seat
A. Brake release wedge.
B. Flat head screw driver. (optional)
These are general maintenance guidelines. Please consult your owner’s manual prior to performing any repairs or maintenance on this machine. **Before you begin: Turn the machine off.
Tools Needed
1. Lift seat.
2. Disconnect seat switch plug.
3. Remove the seat.
4. Tilt recovery tank.
A. 13mm socket wrench
B. Phillips screwdriver
C. 6mm socket wrench
D. Needle nose pliers.
5. Locate battery box cover.
6. Remove the 2 bolts from cover.
7. List battery box cover from frame.
Replacing the Micro Switch
These are general maintenance guidelines. Please consult your owner’s manual prior to performing any repairs or maintenance on this machine. **Before you begin: Turn the machine off.
8. Locate switch on weldment.
9. Remove 2 nuts and 2 screws on the switch
10. Disconnect switch.
Note: Take a note or picture of the terminal connection for replacement.
11. Reverse process to install a new micro switch.
Note: When reinstalling switch make sure switch as at the right angel. Line up holes.
Testing Voltage on the Micro Switch
These are general maintenance guidelines. Please consult your owner’s manual prior to performing any repairs or maintenance on this machine. **Before you begin: Turn the machine off.
Tools Needed
Note: Press button down to close circuit. If this is not pressed down voltmeter will not be able to read continuity.
1. Follow steps 1-10 on page 197 - page 198
2. Set voltmeter to continuity.
3. Test microswitch. If there is continuity the voltmeter will beep.
Robotics
A. Voltmeter
Testing and Removing Circuit Breaker
These are general maintenance guidelines. Please consult your owner’s manual prior to performing any repairs or maintenance on this machine. **Before you begin: Turn the machine off.
Tools Needed
A. Voltmeter
B. 9/16th wrench
C. Needle nose pliers
1. Follow steps 1-3 on page 199
4. Set voltmeter to continuity.
4. Test circuit breaker. If there is continuity the volt meter will beep.
3.
5. To replace circuit breaker, Loosen nut on back of circuit breaker.
5. Remove nut and washer.
Reverse process to install a new circuit breaker.
Disconnect the circuit breaker.
2. Locate circuit breaker.
Replacing the Key Switch
These are general maintenance guidelines. Please consult your owner’s manual prior to performing any repairs or maintenance on this machine. **Before you begin: Turn the machine off.
Tools Needed
1. Locate key on control panel and turn machine off. Remove key from key switch.
2. Using an allen wrench remove all 5 screws on control panel.
3. Using a flat head screwdriver to lift panel from console.
4. Underneath the panel locate the key switch and the plug.
5. Unplug the key switch plug. Note : Press down on the tab and pull apart to disconnect the plug.
5. Using needle nose pliers, loosen and remove the nut around the key switch.
6. Pull key switch from panel. Reverse process to install a new key switch.
A. Flat head screwdriver
B. Needle nose pliers
C. 3/32 inch allen wrench
Battery Testing
Work Order:
USA-CLEAN Battery Testing & Warranty Form
**MUST BE COMPLETE FOR BATTERIES LESS THAN 1 YEAR OLD**
Bulging or Physical Defect (Check if applicable) :
**Disconnect Battery Cables for next two tests**
Load Test (P= Pass; F= Failed) :
Resting Voltage (each battery) :
**Reconnect existing battery cables or Replace with new if required**
Starting Voltage of the battery pack:
Run the machine and capture battery pack voltage while under load after 20 minutes ❶ :
Battery pack voltage after 5 minutes on the battery charger:
❶ AGM Equipped Units Only - If reported runtime is less than 45 minutes:
Operate the machine until shutdown or a max of 45 min. Record under load voltage and note runtime
**Hydrometer Readings Are Required if Wet Batteries are less than 1 year old**
Specific Gravity Readings
Cell 1:
Cell 2:
Cell 3:
(12V battery) Cell 4:
(12V battery) Cell 5:
(12V battery) Cell 6:
Bill of Lading Information Request Form
Standard Stocking Items
Standard Auto Scrubber Stocking Items
Very Important: If these parts are not stocked and are needed, there will be no payment for a return trip. It is essential that you stock common parts for our customers in your areas. Login to USAfix™ and find your population list to determine the exact parts that you need to stock
• Vacuum Motors - 3 most common
- 36V 3 stage tangential - part# 991-1202
• Common Models
Clarke-Alto Encore S28, S33, S38
Minuteman 320 and 380
Nilfisk-Advance Warrior 32D, 34RST
NSS Champ 2929RB and 3329RB
NSS Wrangler 27F/B, 33F/B, 2730 and 3330
Tennant 5680
Tomcat 250, GTX34, XR
- 24V 2 stage tangential - part# 991-1210
• Common Models
Clarke-Alto Encore S20, L20
Minuteman 260, 265
Nobles SpeedScrub 2701, 3301
Nobles SS5
NSS Wrangler 26F/B, 2625
Tennant 1610 (tank)
Tennant 5400
Tennant T5
- 24V 3 stage tangential with snout - part# 991-1230
• Common Models
Nilfisk-Advance ConvertaMax 20, 26
Tennant 1610 (vac shoe)
Tomcat 350
Windsor Saber Compact 20
Windsor Saber Cutter 26, 32
• Other Common Parts
• Battery Cables
• Brushes (customer required)
• Casters
• Center-Lok
• Clutch Plates
• Drain Hose
• Hoses (customer required)
• Keyswitch
• Pad Driver
• Potentiometer
• Solenoid Valve
• Spare Keys
• Squeegee Blades and Straps
• Squeegee Knobs
• Squeegee Wheels
• Tank Gaskets
• Tank Lids
• Toggle Switch
• Vacuum Hose
• Vacuum Floats
Parts Return Policy
Please request a return authorization number from our customer service department before returning any parts. Clearly mark the return authorization number on the outside of any package you return.
USA-CLEAN will provide credit, less a 20% restocking fee on all returned items not showing signs of damage or use.
Please speak to customer service about your return authorization number within 30 days of accepting your shipment. Return the parts within 45 days of gaining your return authorization number and do not forget to mark the return authorization number on the outside of your return package.
USA-CLEAN will only pay return freight charges when the parts returned are a result of a USA-CLEAN error.
USA-CLEAN understands extenuating circumstances. If for any reason at all you are not satisfied with your order, please call and discuss these issues with our customer service manager and we will strive to remedy the situation.
Forms and Appendx
Update Work Orders 24/7
Call 217-329-0298 to Update Work Orders
You will need to provide the following information:
• Work Order #, city and state ready to confirm
• One of the following options:
1. Machine is operational and repair is complete
2. Machine is functional but further repair is needed
3. Machine is not operational
• You may also provide a short update concerning what was done and the work order will be updated
Update With The USA-CLEAN Mobile App
Download the USA-CLEAN USAfix mobile app to your smart phone
• Update your work orders right from your phone at any time
• The USA-CLEAN Mobile App also allows you to call or send an alert to the customer when the technician is in route to the site.
Repair Status Tags
Repair status tags are designed to communicate the repair status of equipment to our customers. Contact your service coordinator to receive your tags now!
4 simple steps will cover the most essential information:
1. Fill out required details (Work Order # (formally DEC#), Date, Make/Model)
