SPRG 2022a

SPRG Service Partner Reference Guide 2022a

What’s Inside: • • • •

About USA-CLEAN Business Guidelines ARMORTM Battery and Charger Guide • Propane Buffer Guide • Brush Selection Guide • USAfix™ Overview

• Procedures • Robots • Docs & QR Codes • Testing Forms • Standard Stocking Items

Prices subject to change Pricing discount already applied NO INFORMATION MAY BE REPRODUCED WITHOUT AUTHORIZATON BY USA-CLEAN, INC.

Table of Contents

Service Partner Reference Guide 2022a

Insurance Information........................ 19-20

Business Guidelines

National Service Program........................7-9 USA-CLEAN Mobile App....................... 10-11 Service Channel.................................... 12-14 USA-CLEAN Programs......................... 15-16 How We Win............................................... 17 National Performance Rating................... 18

Batteries

SNSR Batteries............................................ 21 ARMOR™............................................... 25-36 Safety Guidelines................................. 37-38 Battery Characteristics........................ 39-41 AGM Battery Testing.................................. 42 Wet Battery Failure.................................... 43

Wet Battery Tips......................................... 44 Battery Factoids......................................... 47 Battery MFG Date Codes..................... 48-49 Runtime Issues........................................... 50 Removal and Installation.......................... 51 Selcet a Battery Chargers.......................... 52

Battery Charger States.............................. 53 Top Selling Battery Chargers.................... 54 Lester SCR Chargers............................ 55-57 Lestronic II Chargers............................ 58-59 SPE CBSW1-S Chargers........................ 60-61 Lithium Battery/Chargers................... 22-23

Propanes

Emissions Testing.................................63,88 High Emissions..................................... 64-65 Preventative Maintenance........................ 66 Standard Repair Times.............................. 67 Dust Bonnet Comparisons................. 68-69 Safety Guildelines...................................... 70

“Do These 6 Things Daily”......................... 71 Carbon Monoxide Saftety................... 72-73 Propane Buffer Overview................... 74-75 Troubleshooting Guide........................76,79 Repair Guide......................................... 77-78 Kawasaki FH500/FH541V.................... 80-85

Kawasaki FS481V.................................. 86-87 Propane Regulations................................. 89

USAfix™

SP Home Screen......................................... 94 Work Order Management......................... 95 Parts Lookup........................................ 96-97 Troubleshooting/Dispatch.................. 98-99 TASKI Warranty................................ 100-101 Tech. Education and Training.................102

Robotics and Procedures

T7AMR Procedures.......................... 104-106 Roboscrub 20 Procedures.............. 107-111 Roboscrub 20 Controls.................... 112-114 RS26 Procedures.............................. 115-120 Electrical Components............................121 RS26 Additional Procedures........... 122-124

R26 Controls..................................... 125-129 RS26 Operation................................ 130-131 Autonomous Mode.......................... 132-135 Error Codes....................................... 136-145 T7AMR Repair Guides...................... 146-158 Roboscrub 20 Repair Guides.......... 159-168

RS26 Gen 2 Repair Guides.............. 169-201

Return Policy.............................................208

Forms and Appendx

Battery Testing Form...............................202 Tax Exemption Form...............................203 Site Evaluation Form................................204 Complete Equipment Analysis...............205 Bill of Lading Information Request........206 Standard Stocking Items.........................207

Brusshes

About USA-CLEAN

USA-CLEAN History...................................... 1 Distributor Program.................................... 2 MFG Discounts............................................. 3 How to Order................................................ 4 About USA-CLEAN........................................ 5 USAfix™ Overview........................................ 6

ii.

Clutch Plates............................................... 90 Lugs and Pad Holders............................... 91 Brush Selection Guide............................... 92

Log into USAfix™ at www.usaclean.com

1-800-USA-CLEAN (800-872-2532)

About USA-CLEAN

Letter from Bruce Bushert Dear Service Partners,

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!

About USA-CLEAN

History

Service Partner Reference Guide 2022a

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

1-800-USA-CLEAN (800-872-2532)

Log into USAfix™ at www.usaclean.com

1

About USA-CLEAN

Distributor Program

Service Partner Reference Guide 2022a

About USA-CLEAN

Introducing the USA-CLEAN equipment distributor program!

EQ276517 Retails for: $3,595.00 Qty

Your Price

Discount

Profit

1

$3,055.75

15.00%

$539.25 ea

5

$2,696.25

25.00%

$898.75 ea

10

$2,516.50

30.00%

$1,078.50 ea

EQ255854 Retails for: $4,295.00

2

341-1021 Retails for: $5,625.00

Qty

Your Price

Discount

Profit

Qty

Your Price

Discount

Profit

1

$3,650.75

15.00%

$644.25 ea

1

$4,781.25

15.00%

$843.75 ea

5

$3,221.25

25.00%

$1,073.75 ea

5

$4,218.75

25.00%

$1,406.25 ea

10

$3,006.50

30.00%

$1,288.50 ea

10

$3,937.50

30.00%

$1,687.50 ea

Log into USAfix™ at www.usaclean.com

1-800-USA-CLEAN (800-872-2532)

About USA-CLEAN

MFG Discounts

Service Partner Reference Guide 2022a

About USA-CLEAN

40% off

20% off

Plus hundreds more!

Economy Shipping

Ground

$10.95

2nd Day

$29.95

NDA

$49.95

* economy shipping; oversized, HAZMAT, and other exceptions apply

1-800-USA-CLEAN (800-872-2532)

Log into USAfix™ at www.usaclean.com

3

About USA-CLEAN

How to Order

Service Partner Reference Guide 2022a

About USA-CLEAN

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

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

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

“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.”

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)

Example of complete order info

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.

General Contact Info Parts Orders

parts@usaclean.com

1-800-872-2532 ext. 1

Parts Lookup

parts@usaclean.com

1-800-872-2532 ext. 2

Tech Support & Dispatch

dispatch@usaclean.com

1-800-872-2532 ext. 3

Service Execution

se@usaclean.com

1-800-872-2532 ext. 6

Federal Employers Identification #

37-1319273

Tax Exempt Reseller #

(see page 203 for form)

IVR Repair Updates #

217-329-0298

Fax #

217-877-4086

Mailing Address

Website

4

2503-3972

2803 N. 22nd Street Decatur, IL 62526 www.usaclean.com

Log into USAfix™ at www.usaclean.com

1-800-USA-CLEAN (800-872-2532)

About USA-CLEAN

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

About USA-CLEAN

About USA-CLEAN

Service Partner Reference Guide 2022a

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

1-800-USA-CLEAN (800-872-2532)

Log into USAfix™ at www.usaclean.com

5

About USA-CLEAN

USAfix™ Overview About USA-CLEAN 6

Service Partner Reference Guide 2022a

USAfix™

•

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.

Log into USAfix™ at www.usaclean.com

1-800-USA-CLEAN (800-872-2532)

Business Guidelines

National Service Program

Service Partner Reference Guide 2022a

It’s Easy to do Business with USA-CLEAN* 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!

Business Guidelines

Following these 5 simple requirements:

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.

1-800-USA-CLEAN (800-872-2532)

Log into USAfix™ at www.usaclean.com

7

Business Guidelines

National Service Program

Service Partner Reference Guide 2022a

Best Practices

Business Guidelines

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

8

Log into USAfix™ at www.usaclean.com

1-800-USA-CLEAN (800-872-2532)

Business Guidelines

National Service Program

Service Partner Reference Guide 2022a

•

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.

Business Guidelines

Onsite

Quoting •

Repairs exceeding NTE must be quoted.

•

Quote Fundamentals: - Make and model verified

- Total labor and travel for both 1st and 2nd trips

- Serial number

- 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).

1-800-USA-CLEAN (800-872-2532)

Log into USAfix™ at www.usaclean.com

9

Business Guidelines

USA-CLEAN Mobile App

Service Partner Reference Guide 2022a

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!

Business Guidelines

Step by Step Guide to the USAfix™ Mobile App STEP 1

STEP 2

1.

Your login is your email

1.

Refresh to see an updated list of tickets assigned to you

2.

Your USAfix™ password

2.

Click here to log out in order to switch users.

3.

If you have forgotten, click forgot password.

3.

You will see age of repairs and if ESDs are due

STEP 3 1.

10

Log into USAfix™ at www.usaclean.com

Clicking on one of the repairs will take you to that ticket

1-800-USA-CLEAN (800-872-2532)

Business Guidelines

STEP 4

STEP 5

1.

Click the cog icon to see the PDF of the work order

1.

2.

You will see the name of the onsite contact and have the ability to text or call them.

Type in details on what was found (troubleshooting, etc.)

2.

3.

You will have the same Status options at the IVR or USAfix™

Add photos; critical for abuse/neglect, freight damage, identifying parts needed, etc.

4.

Any notes that have been added to the ticket

3.

Click “Update Ticket” to be taken to the signature screen.

Business Guidelines

USA-CLEAN Mobile App

Service Partner Reference Guide 2022a

hi

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.

1-800-USA-CLEAN (800-872-2532)

Log into USAfix™ at www.usaclean.com

11

Business Guidelines

Service Channel

Service Partner Reference Guide 2022a

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:

Business Guidelines

•

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.

12

Log into USAfix™ at www.usaclean.com

1-800-USA-CLEAN (800-872-2532)

Business Guidelines

Service Channel

Service Partner Reference Guide 2022a

App is as easy as 1-2-3!

Open the Service Channel Application and select PIN code. Enter Pin # listed in your ticket.

Business Guidelines

Step 1:

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.

1-800-USA-CLEAN (800-872-2532)

Log into USAfix™ at www.usaclean.com

13

Business Guidelines

Service Channel

Service Partner Reference Guide 2022a

Step 3: Business Guidelines 14

“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!

Log into USAfix™ at www.usaclean.com

1-800-USA-CLEAN (800-872-2532)

Business Guidelines

USA-CLEAN Programs

Service Partner Reference Guide 2022a

Programs Offered by USA-CLEAN to Grow Your Business Planned Maintenance Program

•

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

Business Guidelines

Advantages:

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

•

Over mileage still applies

Turnaround

•

Complete within 30 days of receiving work order

Parts

•

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

•

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

Quote Needed

PM Checklist

Please sign and date below if you are in agreement with the rates stated above Print Name ______________________________________________________ Signature ________________________________________________________

1-800-USA-CLEAN (800-872-2532)

Date __________________________________

Log into USAfix™ at www.usaclean.com

15

Business Guidelines

USA-CLEAN Programs

Service Partner Reference Guide 2022a

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 Business Guidelines

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.

16

Log into USAfix™ at www.usaclean.com

1-800-USA-CLEAN (800-872-2532)

Business Guidelines

How We Win

Service Partner Reference Guide 2022a

How We Win (In Managed Services Programs) Schedule Route Work Arrange to visit sites on a weekly or biweekly basis. Perform work is performed. Route work starts slowly, but develops into regular repairs.

Consider offering incentives to begin route work such as a

Business Guidelines

1

repair work when needed. Don’t charge the customer if no

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

2

technicians. Educate your clients that PM programs can save money and increase their equipment uptime.

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.

3

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.

Establish a Connection with the General Managers General managers (GM), sometimes ops managers (OM), have the ultimate authority on equipment repair decisions.

4

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.

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17

Business Guidelines

National Performance Rating (NPR)

Service Partner Reference Guide 2022a

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%.

Business Guidelines

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%

USAfix™ Mobile App

• 18

usaclean.com Web

IVR Phone System

usaclean.com

(217) 329-0298

Please note that the number of work orders and turn rates are used to determine tie-breakers.

Log into USAfix™ at www.usaclean.com

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Business Guidelines

Service Partner Reference Guide 2022a

Insurance Information

Insurance Information 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.

Business Guidelines

INDEMNIFICATION

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.

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19

Business Guidelines

Insurance Information

Service Partner Reference Guide 2022a

Business Guidelines 20

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Batteries

Service Partner Reference Guide 2022a

Standard National Service Rate

SNSR Batteries Please invoice at list price (shown below). Log into USAfix™ to see SP price.

Gel Batteries

6V Economy 225 Ah

12V Economy 102 Ah

6V Improved Runtime 305 Ah

6V Improved Runtime 189 Ah

$132.86 162-0003

$329.58 162-6022

$243.03 162-0005

Batteries

Wet Cell Batteries

$343.62 162-6021

6V Rider Scrubbers 390 Ah $296.22 162-0019

12V Economy 105 Ah $137.73 162-0011

AGM Battery 12V Economy 33Ah $147.32 162-6025

12V Improved Runtime 150 Ah $278.77 162-0057

12V Improved Runtime 195 Ah $379.12 162-0002

1-800-USA-CLEAN (800-872-2532)

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21

Batteries

Lithium

Service Partner Reference Guide 2022a

Lasts 10+ years - 10x longer than lead-acid

Over 3,500 cycles

Maintenance-free

Quick-charge

Batteries

1 Lithium Battery Can Replace 10 Packs of Batteries Over its Lifespan!

5 Batteries Power 97% of Scrubbers and Buffers

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

777-9109 36V 105amp (medium) T600 32” class

777-9105 36V 160amp (large) B5/B7 Buffer class

*Kit part numbers listed here include battery, charger and plug. *Co-branded sales materials available.

22

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Batteries

Lithium

Service Partner Reference Guide 2022a

What’s Included Regular Price

SP Price

Profit

Replaces Trojan

777-9102

$1,875.90

$1,126.64

$448.36

J-185 (qty2)

777-9103

$2,541.90

$1526.63

$582.37

T-125 (qty4)

777-9104

$2,763.90

$1,659.96

$671.04

J305 (qty4)

777-9109

$3,108.00

$1,866.62

$466.70

T-105 (qty6)

777-9105

$3,885.00

$2,333.28

$583.38

-

Voltage Meter

Battery

Charger Plug

Lithium Ion (LiFePO4) Battery (25.6V 160Ah)

Lead-acid Battery (24V 330Ah)

Cycle Life

>3500 times

<500 times

Design Life

Up to 15 years

1 year

Maintenance

No need

Regular water filling and checks

Self-discharge

2-3% per year

5% per month

Shelf Life

7-10 years

6 months

Charging Time

Quick Charge - up to 2.5 hours Standard Charge - 4.5 hours

12 hours

Charging Frequency

No memory, cahrge anytime

Charge every day after use

Charging at Low Voltage

will start < 1 volt

Must be over 80% or 19.2 volts*

Run Time

3+ hours on single charge

3+ hours on single charge

Weight

81.6 lbs

348 lbs

Safety

Multiple built-in protections

Gas inside may cause explosion

Eco-friendly

No pollution

Harmful lead

Cost Effective

More benefits, less man-hour costs

Less benefits, more man-hour costs

Number of Batteries

One battery (no individual jumpers to corrode or arc)

Multiple batteries

Batteries

Charger

Part Number

*Pandemics cause battery loss and service calls.

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23

Batteries

National Battery Specifications

Service Partner Reference Guide 2022a

Part #

Volts

Amp Hrs

Type

Length

Width

Height

Weight

Notes

162-0003

6

235

WET

10.25 in

7.06 in

11.12 in

62.00 lbs

T-105/225amp

162-0004

6

250

WET

11.75 in

7.19 in

11.63 in

74.00 lbs

162-0005

6

330

WET

12.19 in

7.19 in

15.00 in

87.00 lbs

162-0012

6

350

WET

12.19 in

7.19 in

15.00 in

96.00 lbs

162-0019

6

430

WET

12.38 in

7.19 in

17.00 in

111.00 lbs

162-0044

6

250

AGM

10.31 in

7.13 in

11.14 in

76.10 lbs

*

162-6021

6

189

GEL

10.25 in

7.08 in

10.82 in

68.00 lbs

*

162-0011

12

105

WET

12.63 in

6.75 in

9.38 in

53.00 lbs

27TM/105amp

162-0018

12

130

WET

13.00 in

6.75 in

9.38 in

55.00 lbs

Group 31

*

162-0057

12

150

WET

12.96 in

7.13 in

11.13 in

85.00 lbs

*

162-0002

12

195

WET

15.50 in

7.00 in

14.50 in

108.00 lbs

162-0021

12

215

WET

15.50 in

7.00 in

14.50 in

130.00 lbs

162-0007

12

12

AGM

5.91 in

3.43 in

5.71 in

10.00 lbs

Propane

162-0050

12

14

AGM

5.31 in

3.50 in

6.56 in

11.60 lbs

Propane

162-0006

12

18

AGM

7.13 in

3.00 in

6.59 in

12.60 lbs

Propane

162-6025

12

33

AGM

7.78 in

5.20 in

6.75 in

27.00 lbs

162-0001

12

35

AGM

7.76 in

5.15 in

6.61 in

21.83 lbs

162-0039

12

44

AGM

7.75 in

6.50 in

6.72 in

30.90 lbs

162-0052

12

65

AGM

10.18 in

6.62 in

7.81 in

43.00 lbs

162-0055

12

68

AGM

10.85 in

7.00 in

7.80 in

50.00 lbs

162-0041

12

85

AGM

10.24 in

6.65 in

9.29 in

55.34 lbs

Group 24

162-0042

12

115

AGM

12.91 in

6.77 in

9.49 in

72.10 lbs

Group 31

162-0045

12

140

AGM

13.43 in

6.77 in

11.38 in

94.82 lbs

162-6022

12

102

GEL

12.94 in

6.82 in

9.64 in

70.00 lbs

*

*

*

Batteries

*

*

J305G/285amp

L16G/360amp

J185P/195amp

Propane

swingo 455

*SNSR (measurements may vary by manufacturer)

24

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1-800-USA-CLEAN (800-872-2532)

Batteries

ARMOR™

Batteries

Service Partner Reference Guide 2022a

1-800-USA-CLEAN (800-872-2532)

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25

Batteries

ARMOR™

Service Partner Reference Guide 2022a

Batteries 26

Log into USAfix™ at www.usaclean.com

1-800-USA-CLEAN (800-872-2532)

Batteries

ARMOR™ 2

Batteries

Service Partner Reference Guide 2022a

1-800-USA-CLEAN (800-872-2532)

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27

Batteries

ARMOR™ 2

Service Partner Reference Guide 2022a

Batteries 28

Log into USAfix™ at www.usaclean.com

1-800-USA-CLEAN (800-872-2532)

Batteries

ARMOR™ 2

Batteries

Service Partner Reference Guide 2022a

1-800-USA-CLEAN (800-872-2532)

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29

Batteries

ARMOR™ FAQ

Service Partner Reference Guide 2022a

ARMOR™ telematics device Frequently Asked Questions

1.

What is ARMOR? 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?

Batteries

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.

2018.01.25 Rev 1 30

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Batteries

ARMOR™ FAQ

Service Partner Reference Guide 2022a

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.

What happens if I don't have a cell phone signal?

Batteries

6.

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.

2018.01.25 Rev 1 1-800-USA-CLEAN (800-872-2532)

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31

Batteries

ARMOR™ FAQ

Service Partner Reference Guide 2022a

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.?

Batteries

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. II. III. IV.

12vdc – 36vdc battery powered floor equipment - https://youtu.be/cJm2AkBYbeE Forklifts – coming soon Generators – coming soon 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)

2018.01.25 Rev 1 32

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Batteries

ARMOR™ FAQ

Service Partner Reference Guide 2022a

ARMOR™ telematics device Frequently Asked Questions

24.

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.

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?

Batteries

23.

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.

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33

Batteries

ARMOR™ FAQ

Service Partner Reference Guide 2022a

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?

Batteries

         33.

What activates the audible beep?     

34.

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

Can I turn off the audible beep? 

35.

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” button is pressed and held It flashes five times when the “New Batteries Installed” button is pressed and held

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.

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.

2018.01.25 Rev 1 34

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Batteries

ARMOR™ FAQ

Service Partner Reference Guide 2022a

Batteries

ARMOR™ telematics device Frequently Asked Questions

<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).  Battery Completed Charge Time  Maintenance Due  High Impact Event  Geo Fence Status b. Rolling 7 Day Page  Runtime report for the last 7 days  Equipment Filters i. Mfg ii. Model iii. Nickname c. Calendar Page (Monthly View) 2018.01.25 Rev 1 1-800-USA-CLEAN (800-872-2532)

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Batteries

ARMOR™ FAQ

Service Partner Reference Guide 2022a

ARMOR™ telematics device Frequently Asked Questions

Filters for i. Activity/Events 1. Equipment Utilized 2. Equipment Charged 3. Equipment Maintenance Past Due 4. Equipment Outside of Geo-Fence 5. Major Impact Detected ii. Equipment 1. Manufacturer 2. Model 3. Equipment Nickname iii. Location 1. State 2. City 3. Site Name 4. And Site Lookup/Search 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. 

Batteries 36

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Batteries

Safety Guidelines

Service Partner Reference Guide 2022a

Personal Protective Equipment (PPE) Required for possible hazards for the following safety and training steps.

Apron

Gloves

Boots

Goggles

1.

!

!

Make sure all connections are very tight or you run the risk of melting the posts or causing an explosion.

Batteries

Remove all jewelry before servicing batteries.

5.

2.

!

6.

!

Always turn all machine switches off when installing batteries.

Remove caps to check water level in every cell.

3.

7.

!

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.

!

Always reattach caps to batteries. Do not charge with caps loose or removed.

!

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.

* These are general maintenance and safety guidelines. Please consult manufacturer instructions before performing any repairs or maintenance.

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Batteries

Safety Guidelines

Service Partner Reference Guide 2022a

9.

!

13.

Batteries

If contact with battery acid occurs IMMEDIATELY rinse contact location with water for 15 minutes.

If battery acid is present, sprinkle baking soda on battery acid to neutralize it.

10.

14.

!

Charge batteries in a well-ventilated area.

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.

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!

Always use two people to install the batteries.

NOTE: While batteries are charging they emit highly explosive hydrogen gas.

38

!

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Batteries

Battery Characteristics

Service Partner Reference Guide 2022a

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.

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

Batteries

Deep Cycle Batteries or Traction 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)

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Batteries

Battery Characteristics

Service Partner Reference Guide 2022a

AGM and Wet Batteries

Advantages

AGM

Batteries

Disadvantages

Wet

•

Maintenance free

•

Lower cost

•

Air transportable (non HAZMAT)

•

Longer deep cycle life

•

Spill proof/Leak proof

•

Maintained by adding distilled water

•

Minimal corrosion

•

High discharge rate capability

•

Installs upright or on side

•

Better availability worldwide

•

Low to no gases released

•

Long, proven history of use

•

Periodic maintenance is required

•

Only can be used in upright position

•

More expensive

•

Produces gas while charging

•

Sensitive to overcharging

•

Spillable

•

Voltage regulated chargers must be used

•

May emit acid spray if overcharged

•

Requires ventilation

•

Cannot be shipped by air (HAZMAT shipping)

What are Amp-Hours?

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.

40

•

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.

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Batteries

Battery Characteristics

Service Partner Reference Guide 2022a

Battery Chemistry Lead-Acid Batteries - 155 year old technology - Utilizes an Oxidation/Reduction Reaction (Redux) between sulfuric acid solution and lead/lead oxide plates.

- 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.

Batteries

Sulfuric acid is converted into water during discharge.

- 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 Series Connect

Parallel Connect

Series/Parallel Connect

To increase voltage, connect batteries in a series. This will not increase the system capacity.

To increase capacity, connect batteries in parallel. This will not increase the system voltage.

To increase both voltage and capacity, connect additional batteries in a series and parallel.

Example Above Two 6V batteries at 225Ah connected in a series

Example Above Two 6V batteries at 225Ah connected in parallel

Example Above Four 6V batteries at 225Ah connected in series/parallel

System Voltage 6V + 6V = 12V system capacity = 225Ah

System Voltage 6V system capacity = 225Ah + 225Ah = 450Ah

System Voltage 6V + 6V = 12V system capacity = 225Ah + 225Ah = 450Ah

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Batteries

AGM Battery Testing

Service Partner Reference Guide 2022a

AGM and Wet Batteries 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.** Batteries

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.

•

42

Healthy batteries will decline in a linear, predictable rate.

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Batteries

Wet Battery Failure

Service Partner Reference Guide 2022a

1. Battery case is swollen

2. Batteries were dry or low on water

3. Corroded terminals

Batteries

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

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Batteries

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

Batteries

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

Service Partner Reference Guide 2022a

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.

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

Hydrometer 162-0100 $10.74

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.

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.

44

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Batteries

Wet Battery Testing

Service Partner Reference Guide 2022a

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. 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.

State of Charge

6 Volt

12 Volt

100%

6.36

12.70

90%

6.24

12.50

80%

6.21

70% 60%

Volts

Depth of Discharge

24 Volt

36 Volt

2.12

25.40

38.10

0

2.08

25.00

37.50

10

12.42

2.07

24.85

37.25

20

6.15

12.32

2.05

24.65

37.00

30

6.10

12.20

2.03

24.40

36.60

40

50%

6.03

12.06

2.01

24.10

36.20

50

40%

5.95

11.90

1.98

23.80

35.70

60

30%

5.88

11.75

1.96

23.50

35.25

70

20%

5.79

11.58

1.93

23.20

34.75

80

10%

5.67

11.31

1.89

22.60

33.95

90

0%

5.25

10.50

1.75

21.00

31.50

100

(SOC)

per Cell

Batteries

State of Charge (SOC) (%) – An expression of the present battery capacity as a percentage of

(DOD)

* 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.

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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?

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45

Batteries

Wet Battery Testing

Service Partner Reference Guide 2022a

Specific Gravity Test 1.

2.

3.

4.

5.

6.

7.

Batteries

8.

9.

• • • • • •

Do not add water at this time.

Fill and drain the hydrometer 2 to 4 times before pulling out a sample.

There should be enough sample electrolyte in the hydrometer to completely support the float.

Take a reading, record it, and return the electrolyte to the cell.

Repeat the steps 2-4 to test the other battery cells.

Replace the vent caps and wipe off any electrolyte that might have spilled.

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 Compare the readings.

Check the state of charge by using the below table.

State of Charge Level

Specific Gravity

100%

1.265 or Greater

75%

1.225 - 1.230

50%

1.185 - 1.190

25%

1.140 - 1.175

Discharged

1.125 or Less

Hydrometer 162-0100 $10.74

Hydrometers:

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.

•

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.

The .84 Method •

This allows you to verify battery voltage without a voltmeter.

•

Take the specific gravity per cell. Add .84 to the number and you should end up with the same as the voltage reading.

1.200

Example:

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.

46

•

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.

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Batteries

Battery Factoids

Service Partner Reference Guide 2022a

•

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.

Batteries

Battery Factoids

Example:

24V = 21.00V at 100% DOD

36V = 31.50V at 100% DOD

24V = 23.20V at 80% DOD

36V = 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.

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Batteries

Battery Manufacturer Date Codes

Service Partner Reference Guide 2022a

Crown Battery Two ways to identify the age of the battery:

Month

Year

A - January

G - July

10 - 2010

15 - 2015

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.

B - February

H - August

11 - 2011

16 - 2016

C - March

I - September

12 - 2012

17 - 2017

D - April

J - October

13 - 2013

18 - 2018

Example A17 = January 2017 Example L15 = December 2015

E - May

K - November

14 - 2014

19 - 2019

F - June

L - December

Batteries

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

Month

Year

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

FullRiver Battery For the example, reference the date • code photo on the right.

48

•

“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.

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If there are any other additional characters (in this example the “02”), then these are strictly factory and operator codes.

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Batteries

Service Partner Reference Guide 2022a

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.

Year

G - July

0 - 2010

5 - 2015

B - February

H - August

1 - 2011

6 - 2016

C - March

I - September

2 - 2012

7 - 2017

D - April

J - October

3 - 2013

8 - 2018

E - May

K - November

4 - 2014

9 - 2019

F - June

L - December

Batteries

Example B2 = February 2012

Month A - January

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

Month

Year

A - January

G - July

0 - 2010

5 - 2015

B - February

H - August

1 - 2011

6 - 2016

C - March

I - September

2 - 2012

7 - 2017

D - April

J - October

3 - 2013

8 - 2018

E - May

K - November

4 - 2014

9 - 2019

F - June

L - December

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

Month

Year

A - January

G - July

0 - 2010

5 - 2015

B - February

H - August

1 - 2011

6 - 2016

C - March

I - September

2 - 2012

7 - 2017

D - April

J - October

3 - 2013

8 - 2018

E - May

K - November

4 - 2014

9 - 2019

F - June

L - December MFG Location X - Corona Y - Augusta Z - Evans

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49

Batteries

Runtime Issues

Service Partner Reference Guide 2022a

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.

Vac Motor Runtime at 25amp Draw (hrs)

Scrubbing Runtime at 50amp Draw (hrs)

Stripping Runtime at 75amp Draw (hrs)

Amp Hour

12

195

6.25

2.68

1.66

6

225

7.45

3.14

1.82

6

250

9.00

4.00

2.50

6

275

10.00

4.47

2.80

6

305

11.25

4.75

2.92

6

335

12.45

5.48

3.38

6

412

14.44

6.31

3.93

Batteries

Volts*

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.

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Batteries

Removal and Installation

Service Partner Reference Guide 2022a

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.

Apron

Gloves

Boots

Goggles

4.

Disconnect batteries from machine.

Remove batteries one at a time using a battery strap.

2.

5.

Remove nut and washer from jumper cables.

Install new batteries using a battery strap.

Note the battery connection pattern for new battery installation.

Use manufacturer connection pattern or install exactly as removed.

3.

6.

Remove all cables.

Replace the old battery cables with new cables.

Batteries

1.

Tightly fasten nuts to complete installation.

Battery Lifting Strap 162-5055 $5.60

Battery Cable 998-0010 $3.87

Filler Jug

Post Cleaner

162-1000

993-1163

$17.37

$4.06

* These are general maintenance and safety guidelines. Please consult manufacturer instructions before performing any repairs or maintenance.

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51

Batteries

How to Select a Battery Charger

Service Partner Reference Guide 2022a

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

Batteries

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.

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Batteries

Battery Charger States

Service Partner Reference Guide 2022a

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.

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.

Batteries

2.

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.

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

Battery Charging Tips: 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.

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53

Batteries

Top Selling Battery Chargers

Service Partner Reference Guide 2022a

24 Volt Off Board

12amp Charger

20amp Charger

for batteries under 130Ah

for batteries between 130Ah and 305Ah

Batteries

162-5059

162-5061

162-5060

$271.73 with small (SB50) red plug

$304.00 with large (SB175) red plug

$304.00 with small (SB50) red plug

*To change profiles from wet to AGM, use switch located in front of charger.

*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

162-5062

$336.00 with large (SB175) gray plug

$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

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Dual Pro transformer charger conversion kit For use with all battery sizes (wet and AGM batteries)

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Batteries

Changing Profiles in Lester SCR Chargers

Service Partner Reference Guide 2022a

*Before changing profiles unplug your charger and wait to ensure there is no active electricity!

Old Style

•

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).

New Style

B. Locate the Circuit Board Old Style

Batteries

A. Charger Styles

New Style 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.

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.

2. Remove rubber cap in front of charger with a flathead screwdriver.

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.

3. The profile board will now be exposed.

C. Change the Jumper Profile Old Style

New Style 4. Notice the black jumper. It is shown in the Profile 1 setting (top two prongs).

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 one pin exposed at the top. Be sure to push the jumper all the way on.

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.

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.

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55

Batteries

4 Things Fix 98% of All Lester SCR Chargers

A

PROBLEM: Charger plug is cracked, melted, or damaged.

SOLUTION: Replace charger plug and install new plug correctly.

Charger Plugs 50amp small 1 1/2 x 1 7/8 inch

175amp large Batteries

2 1/8 x 3 1/8 inch

B

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 24V & 36V - E series 162-5079 $68.08 36V - X series 162-5080 $58.10 24V & 36V Fuse assembly 162-5001 $25.42

C

Cord Sets 24V & 36V 25amp - AC Cord Set

Service Partner Reference Guide 2022a

D

without pins Gray 991-2104 $4.48 Red 991-2102 $2.01 with pins Gray 991-2105 $3.55 Red 991-2103 $4.22 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 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 control board assembly.

Control Board Assembly 24V & 36V - E series 162-5081 $102.21 36V - X series 162-5082 $122.40

QUESTIONS? Not sure if your current charger supports a switch to AGM batteries?

E and X series 25amp 162-5087 $54.17 36V 30amp - AC Cord Set E series 30amp 162-5088 $34.43

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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.

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Batteries

Lester SCR Battery Charger

Service Partner Reference Guide 2022a

*This charger is suitable for AGM and Wet batteries.

A

D

How to Change Profiles in SCR Chargers

4 Things That Fix 98% of all SCR Chargers:

C

Batteries

See page 55

A) Charger plug B) SCR kit and fuse C) Cord D) Control board

B

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.

Ref

Part #

Description

Price

Req

1

162-5001

24V & 36V fuse assembly

25.42

1

2a

162-5076

Relay board assembly (24V 25amp - E series)

42.00

1

2b

162-5077

Relay board assembly (36V 25amp - E series)

40.75

1

2c

162-5078

Relay board assembly (36V 30amp - X series)

44.02

1

3a

162-5079

SCR assembly kit (E series)

68.08

1

3b

162-5080

SCR assembly kit (X series)

58.10

1

4a

162-5081

Control board assembly (E series)

102.21

1

4b

162-5082

Control board assembly (X series)

122.40

1

5a

162-5083

AC circuit breaker (24V 25amp - E series)

31.21

1

5b

162-5084

AC circuit breaker(OBSOLETE) (36V 25amp - E series and 36V 30amp - X series)

31.20

1

6a

162-5085

Ammeter (E series)

44.40

1

6b

162-5056

Ammeter (X series)

29.97

1

7

162-5086

Switch kit (X series)

18.76

1

8a

162-5087

AC cord set kit (24V 25amp - E series and 36V 30amp - X series)

54.17

1

8b

162-5088

AC cord set kit (36V 25amp - E series)

34.43

1

8c

162-5011

AC cord set with molded plug (E series model 25940)

47.29

1

N/S

162-5089

Wiring kit (LEDs, control cables and wires) (E series)

47.34

1

N/S

162-5090

Wiring kit (LEDs, control cables and wires)(X series)

55.28

1

N/S

162-5091

Transformer (36V 25amp E series charger)

1

N/S

162-5092

Transformer (24V 25amp E series charger) (OBSOLETE)

1

N/S

162-5093

Transformer (36V 30amp X series charger) (OBSOLETE)

1

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57

Batteries

5 Things Fix 98% of All Lestronic II Chargers

A

PROBLEM: Charger plug is cracked, melted, or damaged.

SOLUTION: Replace charger plug and install new plug correctly.

Service Partner Reference Guide 2022a

Charger Plugs without pins Gray 991-2104 $4.48 Red 991-2102 $2.01 with pins Gray 991-2105 $3.55 Red 991-2103 $4.22

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 Gray 162-5003 $33.30 Red 162-5013 $33.30

175amp large Batteries

2 1/8 x 3 1/8 inch

B

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

D

SOLUTION: You need to replace the timer.

Heat Sink/Diode Assembly with 2 diodes. Fits both 24V/36V chargers.

162-5006

PROBLEM: Charger does not click?

Charger does not shut-off?

Charge Timer with Relay

$33.30

Fuse Assembly Fits most 24V/36V chargers.

24V

162-5037

$155.84

36V

162-5036

$173.16

162-5001 $25.42

C

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.

Capacitor 24 and 36V capacitor If low DC amp replace capacitor.

E

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

162-5008

$32.97

78 inch long with a molded plug for the 24V and the 36V chargers 162-5018 $45.95

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Batteries

Lestronic II Battery Charger

Service Partner Reference Guide 2022a

*This charger is NOT suitable for AGM batteries.

C

5 Things That Fix 98% of all Lestronic II Chargers:

A

B

See previous page for more details.

Ref

Part #

Description

Price

Req

001

162-5065

Charger case assembly

103.10

1

002a

162-5066

36V transformer assembly

198.00

1

002b

162-5067

24V transformer assembly

287.46

1

003a

162-5039

24V 2-wire electronic timer

133.87

1

003b

162-5037

24V 3 wire timer assembly

155.84

003c

162-5051

Electronic timer-new style 24V

123.11

162-5036

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 inches)

003d

003e

003f

173.16

162-5095

36V electronic timer assembly (OBSOLETE) (slide out removable style)

162-5054

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.)

155.84

115.20

Batteries

D E

A) Charger plug B) Fuse and heat sink C) Capacitor D) Timer E) Cord

Ref

Part #

Description

Price

Req

006a

162-5068

Ammeter (36V) (before week 12 year 90)

44.40

1

006b

162-5009

Ammeter (corner mount) (36V) (after week 12 year 90)

33.30

1

1

006c

162-5068

Ammeter (24V)

44.40

1

1

007a

162-5001

24V & 36V fuse assembly

25.42

1

007b

162-5024

24V & 36V fuse holder assembly (cap not sold separately)

19.98

1

008

170-1284

Strain relief

6.46

2

010a

162-5033

36V DC cord set with 175amp large SB175 gray plug (36V)

87.91

1

010b

162-5005

36V DC cord set with 50amp small SB50 gray plug (36V)

87.91

1

010c

162-5019

24V DC cord set with 175amp large SB175 red plug (24V)

67.93

1

010d

162-5034

24V DC cord set with 50amp small SB50 red plug (24V)

67.93

1

1

1

1

004

162-5008

24V & 36V capacitor

32.97

1

011

162-5018

14/3 AC cord set with molded plug

45.95

1

005a

162-5006

Heat sink/diode assembly (includes 2 diodes)

33.30

1

012a

162-5003

175amp charger plug with pins and brackets (gray) SB175 (36V)

33.30

1

005b

162-5114

Heatsink assembly with 2 diodes (model 09513)

39.20

1

012b

162-5013

175amp charger plug with pins and brackets (red) SB175 (24V)

33.30

1

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59

Batteries

SPE CBSW1-S Charger Breakdown

Service Partner Reference Guide 2022a

External Components Part #

Description

Price

Req

001

162-0102

6.3amp fuse

2.85

1

002

162-0103

Fuse holder

5.34

1

003

162-5116

Charger switch

9.64

1

004

162-0108

Power cord with plug

12.46

1

Ref

Part #

Description

Price

Req

001

162-0106

Control card and microcontroller

87.25

1

002

N/A

Not available (24V transformer)

003

162-0107

Power module

004

162-1006

005

162-0104

Batteries

Ref

Internal Components

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1 144.14

1

Control board fuse

3.07

1

15amp fuse

7.72

1

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Batteries

Esprit Series CBSW1-SCharger 24/12 Troubleshooting SPE-CBSW1-S

Service Partner Reference Guide 2022a

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

Batteries

   

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

E-Mail

Ph: 905.636.9865 Fax: 905.636.9879 info@bti-chargers.com Web: www.bti-chargers.com

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61

Notes

Batteries 62

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Propane Buffers

Service Partner Reference Guide 2022a

Emissions Testing

Propane Emissions Testing Instructions 1.

Locate machine, verify and record machine specific data such as make, model and serial number.

2.

3.

Check oil and add oil if necessary.

4.

Check the compression on cylinder 1 & 2. (see page 82 - page 87)

If Compression Test Failed Set the valves. (see page 82 - page 87)

Propanes

Check frame for cracks and that motor is mounted securely.

After Valves Are Set Check compression on cylinder 1 and 2.

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

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.

Report test results, make, model and serial number to coordinator promptly.

Onsite updates are best.

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Propane Buffers

High Emissions

Service Partner Reference Guide 2022a

Possible Causes of High Emissions 1

2

3

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.

Propanes

- 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.

4

Idle and/or brass output on fuel regulator needs adjusted/fuel regulator needs replaced 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.

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Propane Buffers

High Emissions

Service Partner Reference Guide 2022a

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.

6

Propanes

5

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.

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65

Propane Buffers

Preventative Maintenance Steps

Service Partner Reference Guide 2022a

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

Propanes

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™ 66

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Propane Buffers

Standard Repair Times (SRTs) Difficulty

5 minutes

Check muffler for carbon monoxide

Procedure

Low

•

*Check fuel lines

Low

•

*Check spark plug wires

Low

•

*Fill oil to proper level

Low

•

Test fuel regulator

Low

•

Check air filters

Low

•

*Check oxygen sensor

Low

•

*Replace air filters

Low

•

Tighten fuel connector

Low

•

*Check spark plugs

Low

•

Test oil pressure switch

Low

•

*Replace spark plugs

Low

•

Test ignition module for spark with tester

Low

•

Check compression

Medium

•

Replace fuel lines

Medium

•

*Change oil and oil filter

Low

•

Test the fuel lock-off

Low

•

Medium

•

Replace oxygen sensor

Low

•

Replace the fuel lock-off

Medium

•

Replace fuel regulator

Medium

•

Replace oil pressure switch

15 minutes

30 minutes

45 minutes

75 minutes

120 minutes

Propanes

Service Partner Reference Guide 2022a

Replace muffler

High

•

Set valves and recheck compression

High

•

Replace ignition module

High

•

Test kill switch wiring harness

High

•

Replace kill switch wiring harness

Medium

•

*Preventative maintenance program

Medium

•

Pull cylinder head and check valve seats

Medium

•

Replace 1 cylinder head

High

•

Replace 2 cylinder heads

High

•

*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.

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67

Propane Buffers

OEM Dust Bonnet and Cage Comparison

Service Partner Reference Guide 2022a

Kawasaki 18HP (FS481V) 14

24

15

201-0098 16

154-0244

201-0099 26

17

204-0162 Propanes

18

19

20

160-0123

21

27

22

160-0112

154-3442

30

154-2368

23

170-3218

154-3508

28

29

252-1548

154-0245

154-3574

189-8539

991-9014

25

NON-OEM Option

170-3219 991-9014 $14.83

68

154-2359

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160-0123 $49.78

Propane Buffers

Service Partner Reference Guide 2022a

OEM Dust Bonnet and Cage Comparison

Kawasaki 18HP (FS481V) MFG/Model

Ref

Bonnet

SP Price

Ref

Cage

SP Price

Answer

14

201-0098

35.92

15

201-0099

22.99

Lowrider

14

201-0098

35.92

15

201-0099

22.99

Reliant

14

201-0098

35.92

15

201-0099

22.99

Sidewinder

14

201-0098

35.92

15

201-0099

22.99

Foreman

16

204-0162

28.95

17

189-8539

36.32

Optima

16

204-0162

28.95

17

189-8539

36.32

PB

16

204-0162

28.95

17

189-8539

36.32

Contractor

18

991-9014

14.83

19 20

160-0123 (metal) 160-0112 (plastic)

49.78 26.24

Dust Control

18

991-9014

14.83

19 20

160-0123 (metal) 160-0112 (plastic)

49.78 26.24

Talon

18

991-9014

14.83

19 20

160-0123 (metal) 160-0112 (plastic)

49.78 26.24

18

991-9014

14.83

19 20

160-0123 (metal) 160-0112 (plastic)

49.78 26.24

PBU

22

170-3218

35.53

23

170-3219

68.91

Whirlamatic

18

991-9014

14.83

19 20

160-0123 (metal) 160-0112 (plastic)

49.79 26.24

18

991-9014

14.83

19 20

160-0123 (metal) 160-0112 (plastic)

49.79 26.24

Blue Sky

21

252-1548

22.46

19

160-0123

49.79

Diamond

21

252-1548

22.46

19

160-0123

49.79

PE400BU (before SN 77459)

24

154-0244

35.10

27

154-3508

31.44

PE400BU (after SN 77458)

26

154-3574

35.10

27

154-3508

31.44

PE420BU

28

154-3442

35.10

27

154-3508

31.44

PE440BU

29

154-2368

18.01

30

154-2359

48.70

Superbuffer

24

154-0244

35.10

25

154-0245

39.95

Lightning (1 handle style)

18

991-9014

14.83

19 20

160-0123 (metal) 160-0112 (plastic)

49.78 26.24

Lightning (2 handle style)

21

252-1548

22.46

19 20

160-0123 (metal) 160-0112 (plastic)

49.78 26.24

Aztec

Betco

Propanes

Eagle Solutions (Stonekor)

Eagle Power (IPC Eagle) EaglePro Nilfisk-Advance

NSS Commander Onyx

Pioneer

Windsor

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69

Propane Buffers

Safety Guidelines

Service Partner Reference Guide 2022a

1.

!

5.

Always keep face, fingers or any other body part or loose clothing away from any machine opening or moving part.

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.

2.

6.

!

To stop your machine turn off propane tank then turn the key off.

!

Never service machine near fire or flame.

Propanes

Always turn the propane tank and key switch off before servicing.

3.

!

Always store propane tanks outside.

4.

7.

!

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.

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!

Always allow the engine time to cool before performing any maintenance as hot parts can cause severe burns.

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.

70

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Propane Buffers

Service Partner Reference Guide 2022a

“Do These 6 Things Daily”

5.

Check oil level.

Check hoses for wear.

2.

6.

Check/clean air filter.

Store propane tanks outside.

Propanes

1.

3.

Clean dust hood.

4.

Check/replace pad.

*These are general maintenance and safety guidelines. Please consult manufacturer instructions before performing any repairs or maintenance.

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Propane Buffers

Carbon Monoxide and Safety Standards

Service Partner Reference Guide 2022a

The following message from OSHA is found at http://www.osha.gov/OshDoc/data_General_Facts/carbonmonoxide-factsheet.pdf

What is Carbon Monoxide?

A MESSAGE FROM USA-CLEAN

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?

Propanes

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.

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

Who is At Risk?

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.

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Propane Buffers

Service Partner Reference Guide 2022a

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.)

• 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.

Propanes

• Use respirators with appropriate canisters for short periods under certain circumstances where CO levels are not exceedingly high.

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.

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73

Propane Buffers

Propane Buffer System Overview

Service Partner Reference Guide 2022a

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 Propanes

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 74

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Propane Buffers

Propane Buffer System Overview

Propanes

Service Partner Reference Guide 2022a

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.

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Propane Buffers

Troubleshooting Guide

Service Partner Reference Guide 2022a

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

Propanes

- 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.

76

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Propane Buffers

Repair Guide

Service Partner Reference Guide 2022a

Tools Needed

3.

A. Volt Meter

Close up of red lead on volt meter connected to positive battery post.

1.

4.

Check that the battery connection and terminals are tight. Loose connectors will cause emissions device faults and starter to engage erratically.

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.

2.

5.

Using a volt meter, connect red lead to positive post and black lead to negative post, engine or frame.

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.

If voltage is 12.5-12.7V, perform load test. (see below)

Tools

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.

Propanes

Engine Won’t Turn Over

Part #

Description

SP Price

991-1810

Compression tester

$39.95

991-6009

Battery load tester

$79.68

993-0794

Battery tester

$117.00

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 safety guidelines. Please consult manufacturer instructions before performing any repairs or maintenance.

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77

Propane Buffers

Repair Guide

Service Partner Reference Guide 2022a

Engine Turns Over but Won’t Start 1.

4.

Check that propane tank is full.

Check plug wires that connect to the spark plug.

Change tank.

If necessary, tighten.

NOTE: Empty, low or faulty propane tanks are #1 problem.

If damaged, replace.

2.

5.

Check hose connections.

Remove the air filter cover.

If loose, tighten.

Propanes

3.

6.

Check engine oil level.

Check the air filter for debris or obstruction.

If necessary, clean or replace.

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.

Change the air filter every 100 hours of use.

*These are general maintenance and safety guidelines. Please consult manufacturer instructions before performing any repairs or maintenance.

78

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Propane Buffers

Troubleshooting Guide

Service Partner Reference Guide 2022a

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.

1.

Move to Safe Location - If you detect a leak, move propane buffer and propane tank outside immediately.

- Leaking propane is very dangerous.

2.

Propanes

What to Do if There is A Propane Leak

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.

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79

Propane Buffers

Kawasaki FH500/FH541V Repair Guide

Service Partner Reference Guide 2022a

Replacing the Solenoid Tools Needed

5.

A. 1/2 inch ratchet-socket

Pull red and white wires from post.

B. 7/16 inch wrench

6.

Disconnect the Anderson plug or power from the battery.

Using a 7/16 inch wrench, remove nut on right post to disconnect red wire.

2.

7.

Locate the starter solenoid.

Pull red wire from post.

3.

8.

Disconnect the white wire by pulling off the connector.

Remove the bolt that secures the solenoid to the engine.

4.

9.

Using a 7/16 inch wrench, remove nut on left post to disconnect red and white wires.

Using a 1/2 inch ratchet and deep socket, remove solenoid from machine and replace with a new solenoid.

Propanes

1.

Reverse steps 1-8 to reassemble machine.

*These are general maintenance and safety guidelines. Please consult manufacturer instructions before performing any repairs or maintenance.

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Propane Buffers

Service Partner Reference Guide 2022a

Kawasaki FH500/FH541V Repair Guide

Replacing the Starter Tools Needed

3.

A. 12mm socket

Once the 2 bolts have been removed, remove the old starter by pulling it down and out away from the engine.

1.

4.

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.

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.

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.

Propanes

B. 7/16 inch wrench

*These are general maintenance and safety guidelines. Please consult manufacturer instructions before performing any repairs or maintenance.

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Propane Buffers

Kawasaki FH500V/FH541V Repair Guide

Service Partner Reference Guide 2022a

How to Set the Valves and Check Compression Tools Needed

4.

A. Compression tester

Locate the spark plug wire.

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

5.

Pull to disconnect the spark plug wire.

H. Allen wrench (3mm) Propanes

I. Wrench (14mm)

1.

6.

Pull the dust bonnet off the filter support.

Locate the spark plug.

2.

7.

Using a 10mm socket remove the 4 acorn nuts.

Using a 3/4 inch socket, remove the spark plug.

3.

8.

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.

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Propane Buffers

Service Partner Reference Guide 2022a

Kawasaki FH500V/FH541V Repair Guide

9.

14.

Do not start the buffer, just turn the engine over.

If tester shows below 110 PSI, set the valves.

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.

10.

15.

Compression test both sides and write down the results and set aside.

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.

11.

16.

Locate the valve cover.

Insert a 0.006 inch feeler gauge between the rocker arm and the spring. Check gap on top and bottom rocker arms.

12.

17.

Using a 10mm socket, remove 2 bolts from valve cover.

If the gap is too tight or too big, use a 14mm socket to loosen the nut on top and bottom rocker arms.

13.

18.

Pull to remove the valve cover (rocker arms are now visible).

Hold the nut and use a 3mm Allen wrench to loosen the set screw on top and bottom rocker arms.

Propanes

How to Set the Valves and Check Compression

*These are general maintenance and safety guidelines. Please consult manufacturer instructions before performing any repairs or maintenance.

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83

Propane Buffers

Kawasaki FH500/FH541V Repair Guide

Service Partner Reference Guide 2022a

How to Set the Valves and Check Compression

Propanes

19.

21.

Insert a 0.006 inch feeler gauge between the rocker arm and the spring, hold and tighten nut on top and bottom rocker arms.

Repeat steps 6-20 on the other cylinder head.

20.

22.

Hold bolt with 3mm Allen wrench and use the 14mm socket to tighten set screw and bolt at the same time.

Repeat steps 8-10 on both cylinder heads to retest compression for comparison. Compare 1st and 2nd results.

Compression should have increased.

Recheck gap at top and bottom rocker arms.

Complete the valves on each side before starting the other side.

Reassemble machine.

*These are general maintenance and safety guidelines. Please consult manufacturer instructions before performing any repairs or maintenance.

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Propane Buffers

Service Partner Reference Guide 2022a

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)

Propanes

Spark Plug Ignition Module with Boot 178-0024 166-0004 $48.01 $3.90

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.

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Propane Buffers

Kawasaki FS481V

Service Partner Reference Guide 2022a

How to Set the Valves and Check Compression Tools Needed

4.

A. Compression tester

Using a 13/16 inch deep socket, remove both spark plugs.

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)

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.

Propanes

G. Phillips screwdriver

Place a rag under the valve cover to catch the oil. The cover gasket may break so have 2 new gaskets ready.

1.

6.

Pull the bonnet off the top of the engine.

Place the 11/16 inch socket on the top nut with a long extension and turn the engine clockwise.

2.

7.

Using a Phillips screwdriver, remove the 3 screws holding the cage.

Turn the engine so that the exhaust (bottom) valve goes in and out.

Continue turning until the intake (top) valve goes in and out.

Remove the cage to access the bolt on top of the flywheel.

3.

Pull the spark plug boots off the spark plugs.

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.

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Propane Buffers

Service Partner Reference Guide 2022a

Kawasaki FS481V

How to Set the Valves and Check Compression 8.

11.

Insert a .006 inch feeler gauge between the top of the spring and the rocker arm on one of the valves.

Re-install the valve cover with a new gasket if needed. Hand tighten the valve cover bolts.

If the feeler gauge goes in and out freely, then the valve clearance is okay and you can move onto the other valve.

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.

Propanes

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.

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.

Spark Plug 166-0008 $3.59

14.

Reinstall the spark plugs by hand to get them started, then tighten with ratchet socket.

Reverse steps 1-3 to reassemble the machine.

*These are general maintenance and safety guidelines. Please consult manufacturer instructions before performing any repairs or maintenance.

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87

Propane Buffers

Emissions Testing

Service Partner Reference Guide 2022a

How to Perform an Emissions Test 1.

4.

Inspect the emissions tester device for damage and/or kinks in tubing.

Insert the metal probe into the muffler tailpipe.

Replace if necessary.

2.

5.

Start the machine and run at high throttle in a well ventilated area.

Monitor emissions until ppm readout stabilizes.

1-2 minutes should be enough time.

Propanes

Let machine run for 2-3 minutes before testing.

3.

6.

Turn on the emissions tester.

Set machine at low throttle and measure emissions ppm when stabilized.

Re-zero device if capable.

Emissions Tester 991-1832

$480.90

*These are general maintenance and safety guidelines. Please consult manufacturer instructions before performing any repairs or maintenance.

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Propane Buffers

Service Partner Reference Guide 2022a

USA-CLEAN Propane Regulations

Best Practices When Working with Propane Buffers a

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.

b

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.

c

Federal and State law prohibits tampering with Emission Control Systems on any propane powered equipment.

Propanes

***Never bypass Emission Control Systems***

d

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.

e

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.

f

Equipment must be tested every 6 months at a minimum.

g

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.

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Brushes and Clutch Plates

Clutch Plates

NP9200

991-2208 SP Price $10.58

G-400S

996-0077 SP Price $29.98

Service Partner Reference Guide 2022a

4148PMB

G200MM

G100

G-400X

996-0338 SP Price $12.88

996-0340 SP Price $67.70

996-0336 SP Price $36.64

996-0086 SP Price $29.98

NP-500

4112MB

4110MB

4104MB

996-6014 SP Price $18.46

996-1557 SP Price $71.79

996-6017 SP Price $26.77

996-6015 SP Price $30.86

Brusshes

4103MB

996-1616 SP Price $239.87

90

G-200PB

996-6016 SP Price $57.10

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ANP-16

996-6019 SP Price $14.70

NP-46

996-6018 SP Price $10.58

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Brushes and Clutch Plates

Lugs and Pad Holders

Service Partner Reference Guide 2022a

Lugs

L-801 (small)

996-0339 SP Price $11.12

L-800P (standard)

996-0341 SP Price $14.66

L-800T (tall)

996-1535 SP Price $14.66

Center-Lok II

991-2201

Big Mouth

Big Mouth

(left hand thread)

(right hand thread)

(complete)

(Male portion only)

Big Mouth

Pad Grab III

Split Retainer

(reverse thread)

(pad holder & ring)

(pad holder ring)

991-2214 SP Price $18.35

Center-Lok 3 991-2206 SP Price $22.21

991-2201 SP Price $13.76

996-0372 SP Price $20.00

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991-2202 SP Price $20.00

991-2210 SP Price $26.44

Brusshes

Pad Holders

991-2203 SP Price $17.20

991-2209 SP Price $10.03

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91

Brushes and Clutch Plates

Brush Selection Guide

Service Partner Reference Guide 2022a

Daily Cleaning Brush • •

Use for daily scrubbing Saves money compared to pads

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

Lite Grit Scrubbing Brush • • •

Replaces red pads Use for daily grit scrubbing Saves money compared to pads

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

Medium Grit Scrubbing Brush • • •

Replaces blue and green pads Use for scrubbing grouted tile Use for deep scrubbing of wax

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

Brusshes

Heavy Grit Scrubbing Brush • • •

Replaces black pads Use for scrubbing warehouse concrete, grocery non-slip and even sidewalks Use for stripping wax

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

• •

Use for holding on pad Use for driving a carpet bonnet

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

Carpet Brush

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Brusshes

Notes

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93

USAfix™

Service Partner Home Screen

Service Partner Reference Guide 2022a

1

5

2

3

17

4

6

7

8

9

10

12

11

13

14 15

See next page for work order management

16

USAfix™ Home Screen USAfix™

1. Shopping cart & checkout - Displays current number of items in cart. Click to begin checkout.

10. Parts - See page 96 and page 97 for Parts Lookup.

2. Change Password - Click to change your USAfix™ password.

11. TEC - Click to view required tests and certifications.

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.

13. Inventory - Work orders needing site inventory.

5. Work Orders and Sites - Click to view active work orders or total sites serviced.

14. Shop Recon - Click to view our reconditioned equipment on our website.

6. Home Button - Click to go to or refresh work order list.

15. Support Team - Displays members of our service and warranty team.

7. Site Selection Dropdown - Allows switching between locations.

16. National Performance Rating - Shows how you are rated in different areas based on service provided.

8. My Info - Click to view personal information as well as rates, payments and warranty options.

17. Shop As-Is Equipment - Click to be directed to our list of As-Is equipment for sale.

9.

94

12. Warranty - Check warranty status or create a warranty request. See page 100 and page 101 for how to file TASKI warranty.

Documents - Access service partner reference materials.

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USAfix™

Work Order Management

Service Partner Reference Guide 2022a

USAfix™ Work Order Management 10

1 2

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.

6

7

8

9

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.

3

11

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.

4

USAfix™

11. Invoice - Click to create an invoice.

5

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USAfix™

Parts Lookup

Service Partner Reference Guide 2022a

2 1

4

From the homepage, on the equipment list, find the machine you need parts for and click “parts & diagrams”.

3 5

6

How to get to this screen

If you want to find parts for equipment that isn’t in your list, click PARTS > Search on the menubar and search for equipment.

8

7

9 11

10 12 13

14

15

16

USAfix™ Parts Lookup USAfix™

1. Equipment Photo - Displays photo of currently selected equipment.

9. Stocking Status - Displays “In Stock” if part is in stock for same day shipping.

2. Equipment Details - Displays equipment make, model and equipment type.

10. Part number - Displays USA-CLEAN part number.

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.

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.

8. Part Description - Displays part description.

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USAfix™

Parts Lookup

Service Partner Reference Guide 2022a

1 5

2

3

4

7

8 9 10

6 11

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.

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.

USAfix™

USAfix™ Diagram Viewer

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.

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.

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USAfix™

Troubleshooting & Dispatch

Service Partner Reference Guide 2022a

1

3 2

4

7

5

6

8

9

11

10 12 USAfix™

13

18

14

98

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15

16 17

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USAfix™

Service Partner Reference Guide 2022a

Troubleshooting & Dispatch

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.

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.

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.

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.

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”.

USAfix™

9. Select Problem - To begin troubleshooting, first select a problem category and specific problem, then click “Forward” at the bottom right.

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.

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99

USAfix™

TASKI Warranty

Service Partner Reference Guide 2022a

1

2 3 4

5

USAfix™

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.

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USAfix™

TASKI Warranty

Service Partner Reference Guide 2022a

1

2 3 4

6

TASKI Warranty Report

USAfix™

5

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.

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USAfix™

Technical Education & Training

Service Partner Reference Guide 2022a

5

1

2 3

6 4

7

How to get to this screen

Click TEC on the menubar to get to the TEC training screen.

USAfix™ Technical Education & Certification (TEC) USAfix™

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: 1. Fleet Management 2. Daily Operations 3. Preventative Maintenance 4. 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.

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Notes

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T7AMR Components and Procedures

Service Partner Reference Guide 2022a

Robotics and Procedures 104

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T7AMR Components and Procedures

Robotics and Procedures

Service Partner Reference Guide 2022a

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T7AMR Components and Procedures

Service Partner Reference Guide 2022a

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Roboscrub 20 Components and Procedures

Robotics and Procedures

Service Partner Reference Guide 2022a

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Roboscrub 20 Components and Procedures

Service Partner Reference Guide 2022a

Robotics and Procedures 108

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Roboscrub 20 Components and Procedures

Components Overview

Lower Lidar Removal

Manual Operation

Lidar Protection Cage

Troubleshooting

Replacing BCM

Brake Release

Testing/Troublshooting Drive System

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Robotics and Procedures

Service Partner Reference Guide 2022a

109

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Roboscrub 20Components and Procedures

Robotics and Procedures 110

Service Partner Reference Guide 2022a

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

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Robotics - Brain OS Powered

Service Partner Reference Guide 2022a

Roboscrub 20 Components and Procedures

Kinetec Error Codes

Diagnostic App Errors

Robotics and Procedures

Brain Error Codes

Wiring Diagrams

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Roboscrub 20 Controls Overview

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Robotics and Procedures 112

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Roboscrub 20 Controls Overview

Robotics and Procedures

Service Partner Reference Guide 2022a

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Roboscrub 20 Controls Overview

Service Partner Reference Guide 2022a

Robotics and Procedures 114

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1. Clean Water Tank 2. Hose fill Clean Water Port & Cap 3. Squeegee assembly Squeegees - Adjustment

RS26 Components and Procedures

4. Wheels, 10-inch 5. Scrub head assembly 6. Side squeegee assembly

Robotics and Procedures

Service Partner Reference Guide 2022a

Squeegees - Adjustment

*see next page for references 7-13

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RS26 Components and Procedures 7. Brake pedal 8. Accelerator pedal 9. Front drive wheel

Service Partner Reference Guide 2022a

Steering - Encoder Replacement

Drive Wheel Replacement

Steering - Motor Replacement Traction Brake and Encoder - Installation and Maintenance

Steering - Troubleshooting Guide Traction Encoder - Troubleshoot or Replace

Traction Wheel Replacement

12. Adjusting handle, seat 13. On-board battery charger receptacle Delta Q Charger - Charging Port Retrofit

Robotics and Procedures

10. Operator seat 11. Steering wheel Steering - Angle Troubleshooting

Delta Q Charger - Check Charging Profile

*see next page for references 13 (continued)-18 116

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RS26 Components and Procedures

Service Partner Reference Guide 2022a

Delta Q Charger - Data Retrieval

Camera Replacement - Front 2D Camera

Delta Q Charger - Data Retrieval

Camera Replacement - Side 2D Camera

14. Detergent level watching window

Connection Interface

Sensors/Cameras 15. Sensors - Planar Lidar 16. Sensors - Lower Lidar 17. Sensors - Front 3D Camera 18. Sensors - Side 3D Camera Sensors/Cameras Links

Field Calibration Procedure

Camera Locations

How to Take Photos

Robotics and Procedures

Cameras - Cleaning Sensors and Cameras

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RS26 Components and Procedures

Service Partner Reference Guide 2022a

Planar LIDAR Sample Photo (B) Sensors/Cameras Links continued.

JAWS Installation

Slanted LIDAR - Installation & Calibration

LIDAR - IFM Diagnostics

Slanted LIDAR - Installation Video

Planar LIDAR Part Photo

Slanted LIDAR - Reflector Target Installation

Planar LIDAR Replacement

Robotics and Procedures

19. Front Bumper Skirt

Planar LIDAR Sample Photo (A)

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Front Bumper - Removal and Replacing Gen 2 Support Bracket

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RS26 Components and Procedures

Robotics and Procedures

Service Partner Reference Guide 2022a

*see next page for references 20-42

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RS26 Components and Procedures

20. Warning light

Warning Light Replacement

Service Partner Reference Guide 2022a

VIB Dashboard 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

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

VIB Dashboard - Replacement

Touchscreen 31. User Interface LCD screen 32. General alert indicator 33. Battery indicator Touchscreen Link Robotics and Procedures 120

Touchscreen - Replacement

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Electrical Components

Service Partner Reference Guide 2022a

Description

Part #

Description

288.0095

110 2D Camera Module

288-0066

Harness, Down Trunk

288-0099

60mm Fan Assembly

288-0065

Harness, Power Trunk

278-0526

Ametk Vacuum Motor, 3 Stage, Kit

288-0055

Harness, Up Trunk

288-0046

Antenna, 4G Sentinel

288-0042

Horizontal 5 LIDAR

288-0054

Assembly, Start-Pause Button

278-0561

Horn, 24VDC, Kit

288-0053

Assy, Control Panel Replacement Service (w/ VIB)

288-0094

IFM O3D with Heatsinks

288-0104

Barrier Block

288-0069

Key Switch Assembly

288-0119

Battery Connect Cable 4AWG (410mm), Red, RS26

288-0078

Left O3X 3D Sensor

288-0121

Battery Connect Cable 4AWG (505mm), Red, RS26

278-0588

Linear Actuator, Kit

288-0120

Battery Connect Cable 4AWG (584mm), Black, RS26

288-0072

M3x25mm M-F Standoff

288-0122

Battery Connect Cable 4AWG, Black, ICE RS26

288-0126

Main Controller

288-0033

Battery. Full River DC335. 6 Volt. 335AH

288-0128

Master Contactor, Double

288-0087

Blinker, Turn Signal

278-0410

Micro Switch

288-0112

Brain Control Module

288-0013

Motor Amplifier Module

278-0589

Brush Motor, 24VDC 450W, Kit

288-0029

Off Board Charger Cable

288-0123

Bus Bar

278-0558

Peristaltic Pump, Kit

278-0402

Button, Emergency Stop

288-0088

Right O3X 3D Sensor

288-0075

Cable, Toggle Switch

278-0570

Sensor, Solution Level

278-0643

Caution Light, Kit

278-0570

Sensor, Solution Level, Kit

288-0007

Circuit Breaker, 20A Panel

288-0067

Service Port Ethernet

278-0988

Circuit Breaker, 2A

288-0052

Communications Module,

288-0124

Diode with Cable

288-0113

288-0059

Drive Wheel with Encoder

"Slanted 7 LIDAR * * Slanted 7 LIDAR (TiM 571), 800-00241-01, installation requires authorization from Brain Engineering"

288-0062

Electrically Released Brake

288-0001

Solenoid Valve, 24VDC

288-0063

Eltra Traction Encoder

288-0134

Steering Column Motor Assy

288-0073

Enclosure, VIB

288-0076

Toggle Switch

288-0137

Encoder with Gearbox, Steering

278-1901

Traction Encoder

278-0404

Fuse, 150A

288-0070

Vehicle Interface Board

Robotics and Procedures

Part #

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RS26 Additional Procedures

Service Partner Reference Guide 2022a

BCM - Replacement

Batteries - Lithium Battery Instructions

Breakers - Gen1 Unit Support

Batteries - Torque Rework

Breakers - How to Check

Batteries - Unit Runtime - Expectation over Time

Clean Float Switch - Inspection

BCM - Moving Gyro Test

Clean Float Switch - Replacement

BCM - Power Testing (USAC)

Connectivity - Pairing with Mobile

Robotics and Procedures

Batteries - Lithium Batteries Conversion

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Service Partner Reference Guide 2022a

RS26 Additional Procedures Scrub Brush - Tension Adjustment

Modem - Replace the Y Cable

Solenoid - Check Connections

Modem and LTE Antenna - Replacement

Solenoid - Installing Retrofit Harness

Modem and LTE Antenna - Upgrading

Solenoid - Installing

Motor Amplifier - Replacement

Solenoid - Wiring and Continuity

RS26 - Crating Instructions

Test Route Marker - Home marker 10

Robotics and Procedures

Microswitch - Replacement

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RS26 Additional Procedures

Service Partner Reference Guide 2022a

U-Joint - Replacement

Wiring - Checking for Voltage and Power Loss

Unit Installations - Uncrating Form 2.2

Wiring - Downtrunk - Replacement

Vacuum Motor - Replacement

Wiring - P4 on Kinetek to J6 Connector on VIB

Water Flow - Inspections Checklist

Wiring - Uptrunk - Replacement

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RS26 Controls Overview

Service Partner Reference Guide 2022a

Robotics and Procedures

MANUAL FUNCTIONS - (RIGHT SIDE CONTROL PANEL)

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RS26 Controls Overview

Service Partner Reference Guide 2022a

DOUBLE SCRUBBING (MANUAL MODE ONLY)

Initiate double scrubbing by using the one­ touch 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-enabled 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.

WARNING •

Double scrubbing is functional in manual mode only and sh ould only be used in a controlled envir onment, where there is no potential for slippi ng and falling.

HORN Robotics and Procedures

Use this button to activate horn

BRAIN CORPORATION

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RS26 Controls Overview

Robotics and Procedures

Service Partner Reference Guide 2022a

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RS26 Controls Overview

Service Partner Reference Guide 2022a

Setting Cleaning Function

Robotics and Procedures 128

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Service Partner Reference Guide 2022a

RS26 Controls Overview

Robotics and Procedures

AUTONOMOUS FUNCTIONS - (LEFT SIDE USER INTERFACE)

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RS26 Operating the Machine

Service Partner Reference Guide 2022a

ADDITIONAL OPERATING COMPONENTS AND VEHICLE FEATURES

Robotics and Procedures 130

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RS26 Operating the Machine

BLUE AUTONOMY BUTTON

Robotics and Procedures

WARNING

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Autonomous Mode

Service Partner Reference Guide 2022a

HOME LOCATION CODES

Robotics and Procedures 132

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Autonomous Mode

Service Partner Reference Guide 2022a

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.

LOST 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 manually operated when in an elevator or around automatic doors.

TEACHING AND SAVING ROUTES

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

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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.

Robotics and Procedures

7. Initiate power on the Brain-enabled scrubber using the momentary key/ignition

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.

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Autonomous Mode

Service Partner Reference Guide 2022a

Robotics and Procedures 134

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Service Partner Reference Guide 2022a

Autonomous Mode

ROC INDICATOR - Pairing Phone with Brain-enabled Scrubber

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Robotics and Procedures

TO ACCESS THE ALERTS SCREEN:

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Error Codes

Service Partner Reference Guide 2022a

Robotics and Procedures 136

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Error Codes

Robotics and Procedures

Service Partner Reference Guide 2022a

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Error Codes

Service Partner Reference Guide 2022a

Robotics and Procedures 138

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Error Codes

Robotics and Procedures

Service Partner Reference Guide 2022a

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Error Codes

Service Partner Reference Guide 2022a

Robotics and Procedures 140

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Error Codes

Robotics and Procedures

Service Partner Reference Guide 2022a

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Error Codes

Service Partner Reference Guide 2022a

Robotics and Procedures 142

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Error Codes

Robotics and Procedures

Service Partner Reference Guide 2022a

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Error Codes

Service Partner Reference Guide 2022a

Robotics and Procedures 144

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Error Codes

Robotics and Procedures

Service Partner Reference Guide 2022a

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Maintenance Schedule

Service Partner Reference Guide 2022a

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

Charge the batteries

X

Drain/clean tanks and hoses

X

Clean/clear brushes/pad

X

Weekly

Clean/clear squeegee

X

Clean/clear vacuum shut-off float

X

Check/replace squeegee blades

X

Check/clean solution filter

X

Check/fill battery water levels (wet batteries only)

X

Yearly

Check/replace motor carbon brushes

X

Robotics and Procedures

Serial Number Location 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

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Know Your Machine

Robotics and Procedures

Service Partner Reference Guide 2022a

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Simplified Recovery System

Service Partner Reference Guide 2022a

Robotics and Procedures 148

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Simplified Recovery System

Robotics and Procedures

Service Partner Reference Guide 2022a

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No Solution Flow

Service Partner Reference Guide 2022a

These are general maintenance guidelines.

Please consult your owner’s manual prior to performing any repairs or maintenance on this machine.

Difficulty

Tools

Low

No

Low Low Low Low

No No No No

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.

Low

Yes

Low

Yes

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

Robotics and Procedures 150

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Service Partner Reference Guide 2022a

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.

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4. Remove filter. Check for damage and clogs.

If filter is damaged replace.

2.. Drain solution tank.

5. Rinse Filter

3. Locate Filter inside of Solution Tank. unscrew filter.

6. Screw Filter in place.

Robotics and Procedures

1. Open solution tank.

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Poor or No Pickup

Service Partner Reference Guide 2022a

These are general maintenance guidelines.

Please consult your owner’s manual prior to performing any repairs or maintenance on this machine.

Robotics and Procedures 152

Difficulty

Tools

Low

No

Low

No

Low

No

Low

No

Low

No

Low

No

Low Low Low

No No No

High

Yes

High

Yes

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.

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Service Partner Reference Guide 2022a

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.

4 Inspect hose for damage and cracks.

Remove any clogs. Replace hose if necessary.

Reverse steps to reinstall.

2.Disconnect hose from back of machne.

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Robotics and Procedures

3.Disconnect hose from Squeegee Weldment.

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Cleaning and Replacing Drain Hose

Service Partner Reference Guide 2022a

These are general maintenance guidelines.

Please consult your owner’s manual prior to performing any repairs or maintenance on this machine.

Tools Needed:

4.Use a flat head screw drive to loosen hose clamp.

A: Flat Head Screwdriver

4.Pull to remove hose.

2.Locate Drain hose on back of machine.

4.Check Recovery Tank for clogs.

3. Tilt back Recovery tank.

Drain hose is connected underneath.

5. Inspect Hose for damage and clogs. Replace Hose if needed.

Robotics and Procedures

1. Drain Recovery Tank.

Reverse the steps to install new hose.

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Replacing the Vacuum Motor

Service Partner Reference Guide 2022a

These are general maintenance guidelines.

Please consult your owner’s manual prior to performing any repairs or maintenance on this machine.

Tools Needed:

5. Unscrew the 3 nuts.

A: 14 mm Socket

Note: 1 nut on motor will need a wrench to be taken off.

A: 10 mm Socket

Tool: 10mm socket

B: Flat Head Screwdriver 1. Locate vacuum on motor on top of machine.

4. Loosen Hose Clamp and Disconnect hose.

2. Check seal for damage and wear

Tool:Flat Head Screw Driver.

3. Unscrew nuts.

6. Disconnect wiring

Robotics and Procedures

Note: Lid is on hinges and will fall back if not braced.

3.Vac Motor is now exposed

7.Vac motor is now disconnected.

Reverse process to install a new vac motor

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Replacing the Squeegee Blades

Service Partner Reference Guide 2022a

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.

4. Unscrew all four 4-sided knobs on top of assembly.

Pull to remove the hose.

2. Loosen both 4-sided knobs on top of the assembly.

Once knobs are loose. Pull back assembly off the brackets.

3. Open latch

Robotics and Procedures

4. Remove Strap.

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5. Remove Squeegee Retainer (1) from Squeegee Housing (2).

2

1 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.

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Replacing the Side Skirts

Service Partner Reference Guide 2022a

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.

5. Slide squeegee off retainer.

Inspect for wear and damage.

Note: Left and Right skirts have the same removal steps.

Reverse steps to reinstall

2. Locate pin on the front of the Skirt. Pull Pin.

6. To remove the skirt retainer from deck. Follow steps 1-4 then remove the pin on the back side of the retainer.

3. Open latch on the front of the deck.

7. Remove Retainer from deck.

Robotics and Procedures

Reverse steps to reinstall.

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.

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Replacing Front Skirt

Service Partner Reference Guide 2022a

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.

Robotics and Procedures

3. Inspect Squeegee and Skirt clamp for damage and wear.

Reverse steps to reinstall.

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Maintenance Schedule

Service Partner Reference Guide 2022a

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

Charge the batteries

X

Drain/clean tanks and hoses

X

Clean/clear brushes/pad

X

Weekly

Clean/clear squeegee

X

Clean/clear vacuum shut-off float

X

Check/replace squeegee blades

X

Check/clean solution filter

X

Check/fill battery water levels (wet batteries only)

X X

Serial Number Location

Robotics and Procedures

Check/replace motor carbon brushes

Yearly

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159

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

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Know Your Machine

Service Partner Reference Guide 2022a

Robotics and Procedures 160

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Simplified Recovery System

Robotics and Procedures

Service Partner Reference Guide 2022a

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Simplified Solution System

Service Partner Reference Guide 2022a

Robotics and Procedures 162

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No Solution Flow

Service Partner Reference Guide 2022a

These are general maintenance guidelines.

Please consult your owner’s manual prior to performing any repairs or maintenance on this machine.

Tools

Low

No

Low Low Low Low

No No No No

Low

Yes

Low

Yes

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

Robotics and Procedures

Difficulty

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Cleaning and Replacing Solution Filter

Service Partner Reference Guide 2022a

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.

4.Remove any debris.

2. Remove Solution Cap and Filterby turning clockwise.

Excess liquid in filter bowl will drain out.

5. Rinse Screen

3. Remove metal screen from bowl.

6. Once clean, reverse steps to reinstall.

Robotics and Procedures 164

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Poor or No Pickup

Service Partner Reference Guide 2022a

These are general maintenance guidelines.

Please consult your owner’s manual prior to performing any repairs or maintenance on this machine.

Tools

Low

No

Low

No

Low

No

Low

No

Low

Yes

Low

Yes

Low

No

Low

No

Low Low Low

No No No

High

Yes

High

Yes

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.

Robotics and Procedures

Difficulty

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.

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Cleaning and Replacing Vacuum Hose

Service Partner Reference Guide 2022a

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

4.Inspect hose for damage and cracks.

Remove any clogs.

Replace hose if necessary.

2. Pull hose to disconnect from weldment

Robotics and Procedures 166

3. Disconnect hose from back of tank.

Located next to drain hose

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Cleaning and Replacing Drain Hose

Service Partner Reference Guide 2022a

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. Drain hose is now removed.

Clean or replace the hose.

Tools Needed:

A: Flat Head Screwdriver

1. Drain Recovery Tank.

5. Clean any debris and clogs in the recovery tank hose.

Reverse steps to reinstall.

Robotics and Procedures

2. Drain hose located behind batteries.

3.Use flat head screwdrive to loosen hose clamp.

Note: Hose clamp can be at a difficult angle will need to use different lengths of screwdrive to loosen or spin the hose clamp.

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Replacing Squeegee Blades

Service Partner Reference Guide 2022a

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

4. Remove front and rear squeegee straps.

Disconnect the hose.

5. Remove Front and Rear Squeegee blades.

3. Unlock latch

5. Inspect Squeegee blades for wear and damage.

Clean assembly of debris.

Robotics and Procedures

2. Loosen both 3-sided knobs on top of the assembly.

Once knobs are off. Slide assembly out from under machine.

Flip or replace Squeegee Blades.

Reverse steps to reinstall.

3. Unscrew thumb screw.

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*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.

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Maintenance Schedule

Service Partner Reference Guide 2022a

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

Charge the batteries

X

Drain/clean tanks and hoses

X

Clean/clear brushes/pad

X

Weekly

Clean/clear squeegee

X

Clean/clear vacuum shut-off float

X

Check/replace squeegee blades

X

Check/clean solution filter

X

Check/fill battery water levels (wet batteries only)

X X

Serial Number Location

Robotics and Procedures

Check/replace motor carbon brushes

Yearly

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169

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

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Know Your Machine

Service Partner Reference Guide 2022a

Robotics and Procedures 170

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Simplified Recovery System

Robotics and Procedures

Service Partner Reference Guide 2022a

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171

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Simplified Solution System

Service Partner Reference Guide 2022a

Robotics and Procedures 172

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No Solution Flow

Service Partner Reference Guide 2022a

These are general maintenance guidelines.

Please consult your owner’s manual prior to performing any repairs or maintenance on this machine.

Tools

Low

No

Low

No

Low Low

No No

Low Low Low

No No No

Low Low High

Yes Yes Yes

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.

Robotics and Procedures

Difficulty

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Cleaning and Replacing Solution Filter

Service Partner Reference Guide 2022a

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.

5. Rinse filter.

2. Open solution tank.

6. Reverse process to install a new filter.

3. Locate filter inside of solution tank.

Unscrew filter.

Robotics and Procedures

4 Remove filter. Check for damage and clogs.

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Checking Solenoid Valve Connections

Service Partner Reference Guide 2022a

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.

Robotics and Procedures

3. For easy access lay on the right side of the scrubber to locate solenoid.

4. Locate Solenoid underneath scrubber.

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Installing/Replacing Solenoid

Service Partner Reference Guide 2022a

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

4. Empty clean water tanks. Remove zip ties, loosen hose clamp and disconnect hoses.

C. Right angled screwdriver

5. Remove screws holding solenoid to scrubber.

1. Follow steps 1-3 on page 175.

Reverse process to install new solenoid.

2. Locate solenoid cable bundle.

Robotics and Procedures

3 Unplug the spade connectors to the solenoid valve.

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Replacing the Solution Float Switch

Service Partner Reference Guide 2022a

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. Cut zip ties and unplug the float switch plug.

Tools Needed A. Wire cutters

1. Remove squeegee assembly.

5. Unscrew the nut under the machine.

2. Press vacuum button on panel to lower squeegee actuator.

6. Loosen pins in the plug.

3. Locate float switch plug under the back of the machine.

7. Remove blue clamp on bottom of the plug.

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Note: You can use wire cutters to cut male end plug off if you are unable to remove pins and skip to step 9.

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Robotics and Procedures

B. Pliers

177

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Replacing the Solution Float Switch

Service Partner Reference Guide 2022a

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.

Robotics and Procedures

11. Switch is removed from tank.

Reverse process to install a new switch.

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Poor or No Pickup

Service Partner Reference Guide 2022a

These are general maintenance guidelines.

Please consult your owner’s manual prior to performing any repairs or maintenance on this machine.

Tools

Low

No

Low

No

Low

No

Low

No

Low

No

Low

No

Low Low Low

No No No

High

Yes

High

Yes

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.

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Robotics and Procedures

Difficulty

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Cleaning and Replacing Vacuum Hose

Service Partner Reference Guide 2022a

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. Reverse process to install new vacuum hose.

Tools Needed

A. Phillips head screwdriver

1. Locate vacuum hose on back of machine.

5. Unscrew trap inside of the recovery tank.

2. Pull hose from back of tank.

6. Remove any debris, rinse trap.

Robotics and Procedures

Reverse process to install new trap.

3. Pull hose from squeegee weldment.

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Cleaning and Replacing Drain Hose

Service Partner Reference Guide 2022a

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. Pull drain hose to remove.

Tools Needed

A. Flat head screwdriver

1. Locate drain hose on the back of the machine.

5. Reverse process to instal new hose.

Robotics and Procedures

2. Drain recovery tank.

3. Loosen hose clamp.

Note: Tilt back recovery tank.

Drain hose is connected underneath.

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Replacing the Vacuum Motor

Service Partner Reference Guide 2022a

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. Unscrew the 3 nuts holding the motor to the bracket.

Tools Needed A. 14mm socket wrench B. 10mm socket wrench C. Flat head screwdriver

1. Open recovery tank lid and locate the 4 bolts.

5. Loosen hose clamp and disconnect hose.

2. Remove bolts.

6. Disconnect the vacuum motor plug.

Note: Lid is on hinges and will fall back if not braced.

Robotics and Procedures

3 Vacuum motor is now exposed

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7. Reverse process to install a new vacuum motor.

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Replacing Squeegee Blades

Service Partner Reference Guide 2022a

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.

5. Unscrew all four 4-sided knobs on top of the assembly.

2. Loosen both 4-sided knobs on top of the assembly.

Once knobs are loose. Pull assembly off the bracket.

6. Remove squeegee retainer (1) from squeegee housing (2).

2

1

3. Open latch.

7. Remove squeegee blades.

Reverse process to install new blades.

Robotics and Procedures

Flip or replace the blades.

4. Remove strap.

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Replacing Side Skirts and Bristles

Service Partner Reference Guide 2022a

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.

5. Locate the two knobs under the machine behind the brush deck and unscrew.

Slide side bristle out from under the machine.

2. Unscrew 5 knobs and washers on the back side of the bracket.

6. Unscrew the 3 knobs on the back if the side bristle.

3. Remove skirt strap.

7. Remove strap and brush from bracket.

Robotics and Procedures

Reverse process to install new bristle.

4. Remove squeegee blade from bracket.

Flip or replace blade.

Reverse process to install a new blade.

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Replacing Front Skirt

Service Partner Reference Guide 2022a

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:

4. Remove all Screws from the Skirt and slide Clamp and Squeegee off the Scrub head.

A: Two 13mm wrench

B: 10mm wrench

1. 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.

Robotics and Procedures

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.

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Replacing and Adjusting Squeegee Casters

Service Partner Reference Guide 2022a

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. Loosen nut.

Tools Needed

A. Crescent wrench.

1. Remove squeegee assembly.

5. Loosen or tighten nut depending on where you want your squeegee assembly to sit.

2. Use a block to lift squeegee bracket.

6. Remove nut completely from caster and remove caster from bracket.

Robotics and Procedures

Reverse process to install a new caster.

3. Locate caster on squeegee bracket.

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Replacing the Recovery Float Switch

Service Partner Reference Guide 2022a

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. Remove plate.

Tools Needed A. 13mm socket wrench B. Phillips screwdriver C. Pliers

5. Locate plug under plate and disconnect.

2. Tilt recovery tank.

6. Remove clip holding the switch cord to the recovery tank.

3. Remove the 4 bolts on plate.

7. Using pliers loosen nut.

Robotics and Procedures

1. Lift seat.

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187

Robotics - Brain OS Powered

Replacing the Recovery Float Switch

Service Partner Reference Guide 2022a

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.

12. Open recovery tank lid

Note: You can use wire cutters to cut male end plug off if you are unable to remove pins and skip to step 11.

13. Locate switch in recovery tank.

10. Remove plug to expose pins.

14. Pull switch from recovery tank.

11. Remove nut.

15. Switch is removed from tank.

Robotics and Procedures

9. Remove blue clamp on bottom of the plug.

Reverse process to install a new switch.

188

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Robotics - Brain OS Powered

Replacing the Actuator

Service Partner Reference Guide 2022a

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

4. Pull pin.

A. Wire cutters B. Right angled needle nose pliers C. 13mm socket wrench

5. Remove the 2 bolts holding on the cover and remove cover.

2. Use a ratchet strap under the brush deck and ratchet up the deck slightly to relieve pressure to make removing pins easier.

6. Locate actuator plug and cut zip ties.

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.

7. Unplug the actuator plug.

Robotics and Procedures

1. Key the machine on and drop the brush deck (green button).

Turn machine off.

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189

Robotics - Brain OS Powered

Replacing the Actuator

Service Partner Reference Guide 2022a

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.

13. Key machine on and hold actuator and press the green button.

Actuator should be in the down position.

10. Actuator is now free. Pull actuator from machine.

14. Align the holes on the arms with the holes on the actuator and reinsert pin and cotter pin.

Robotics and Procedures

Raise and lower brush deck to test actuator.

11. Insert new actuator.

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Robotics - Brain OS Powered

Removing Brush Deck

Service Partner Reference Guide 2022a

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.

3. Place ratchet strap under brush deck. Leave enough room to be able to hook both hooks together on the seat.

Tools Needed A. Flat head screwdriver

B. Right angled needle nose pliers C. Ratchet Strap

4. Key the machine on and drop the brush deck (green button).

Turn machine off.

D. Jack

5.Locate hose connected to elbow and loosen hose clamp.

1. Remove left and right side brush and skirt.

Robotics and Procedures

Note: See Replacing side skirts and bristles. See page 41.

2. Remove both brushes under the deck.

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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.

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191

Robotics - Brain OS Powered

Removing Brush Deck

Service Partner Reference Guide 2022a

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.

11. Remove bottom cotter pins on both left and right arms.

8. Disconnect the solenoid.

12. Pull bottom pins from both left and right arms.

9. Unplug both brush motors.

13. Locate both actuator pins.

10. Use a ratchet strap under the brush deck and ratchet up the deck slightly to relieve pressure to make removing pins easier.

14. Remove cotter pins and pull actuator pins from bracket.

Robotics and Procedures

7. Pull smaller hose and disconnect from elbow.

192

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Robotics - Brain OS Powered

Removing Brush Deck

Service Partner Reference Guide 2022a

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.

19. Reverse process to install new brush deck.

16. Remove both left and right arms from underneath the machine.

20. When reinstall deck and attaching to actuator, make sure all holes are aligned correctly.

Note : See Replacing the Actuator page 190.

Robotics and Procedures

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.

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193

Robotics - Brain OS Powered

Replacing the Brush Motors

Service Partner Reference Guide 2022a

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.

3. Loosen bolt.

Tools Needed A. 11mm socket Hydraulic gear puller

B. 13mm socket wrench C. 14mm socket wrench

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.

4. Remove bolt and washer.

D. Impact Ratchet (optional)

E. Flat head or phillps head screwdriver (optional) 5. Use a gear puller to remove hub.

1. Follow steps 1-18 on page 191 - page 193 to remove the brush deck Robotics and Procedures

2. Flip deck over and expose the hubs.

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6. Remove left and right hub

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Robotics - Brain OS Powered

Replacing the Brush Motors

Service Partner Reference Guide 2022a

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.

Robotics and Procedures

Reverse process to install new brush motors.

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195

Robotics - Brain OS Powered

Break Release

Service Partner Reference Guide 2022a

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. Locate the brake release.

Tools Needed A. Brake release wedge.

B. Flat head screw driver. (optional)

1. Lift seat

5. Wedge tool between the brake release and brake.

2. Locate tool under seat.

6. Check that tool is secure.

Machine can move easily around.

Remove wedge once machine is in its location.

Robotics and Procedures

Note: If tool is unavailable a flat head screw driver will work following the same steps.

Note: Make sure all emergency stop buttons are disengaged.

3. Locate brake under the machine.

196

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Robotics - Brain OS Powered

Replacing the Micro Switch

Service Partner Reference Guide 2022a

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

4. Tilt recovery tank.

A. 13mm socket wrench B. Phillips screwdriver C. 6mm socket wrench D. Needle nose pliers.

5. Locate battery box cover.

2. Disconnect seat switch plug.

6. Remove the 2 bolts from cover.

3. Remove the seat.

7. List battery box cover from frame.

Robotics and Procedures

1. Lift seat.

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197

Robotics - Brain OS Powered

Replacing the Micro Switch

Service Partner Reference Guide 2022a

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.

Robotics and Procedures

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.

198

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Robotics - Brain OS Powered

Testing Voltage on the Micro Switch

Service Partner Reference Guide 2022a

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.

Note: Press button down to close circuit.

If this is not pressed down voltmeter will not be able to read continuity.

Tools Needed

A. Voltmeter

1. Follow steps 1-10 on page 197 - page 198.

Robotics and Procedures

2. Set voltmeter to continuity.

3. Test microswitch.

If there is continuity the voltmeter will beep.

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199

Robotics - Brain OS Powered

Testing and Removing Circuit Breaker

Service Partner Reference Guide 2022a

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. Set voltmeter to continuity.

Tools Needed A. Voltmeter

B. 9/16th wrench C. Needle nose pliers

1. Follow steps 1-3 on page 199.

2. Locate circuit breaker.

4. Test circuit breaker.

If there is continuity the volt meter will beep.

5. To replace circuit breaker, Loosen nut on back of circuit breaker.

Robotics and Procedures

3. Disconnect the circuit breaker.

5. Remove nut and washer.

Reverse process to install a new circuit breaker.

200

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Robotics - Brain OS Powered

Replacing the Key Switch

Service Partner Reference Guide 2022a

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. Underneath the panel locate the key switch and the plug.

Tools Needed A. Flat head screwdriver B. Needle nose pliers

C. 3/32 inch allen wrench

1. Locate key on control panel and turn machine off. Remove key from key switch.

5. Unplug the key switch plug.

2. Using an allen wrench remove all 5 screws on control panel.

5. Using needle nose pliers, loosen and remove the nut around the key switch.

3. Using a flat head screwdriver to lift panel from console.

6. Pull key switch from panel.

Robotics and Procedures

Note : Press down on the tab and pull apart to disconnect the plug.

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Reverse process to install a new key switch.

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201

Forms

Battery Testing

Service Partner Reference Guide 2022a

Access this form under the documents tab when you log into USAfix™

USA-CLEAN Battery Testing & Warranty Form **MUST BE COMPLETE FOR BATTERIES LESS THAN 1 YEAR OLD**

Work Order: Battery Specs - Required Date Code:

Voltage:

6V

12V

MFG:

Chemistry:

WET

AGM

GEL

Model: Physical Inspection

1

3

2

4

5

6

Water Level (1 = Good; 2 = Low; 3 = Plates Exposed) : 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

1

2

3

4

5

6

Forms and Appendx

Cell 1: Cell 2: Cell 3:

202

(12V battery)

Cell 4:

(12V battery)

Cell 5:

(12V battery)

Cell 6:

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Forms

Service Partner Reference Guide 2022a

Tax Exemption Form

Forms and Appendx

hi

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203

Forms

Site Evaluation Form

Service Partner Reference Guide 2022a

Forms and Appendx 204

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Forms

Complete Equipment Analysis Form

Forms and Appendx

Service Partner Reference Guide 2022a

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205

Forms

Bill of Lading Information Request Form

Service Partner Reference Guide 2022a

Forms and Appendx 206

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Standard Stocking Items

Service Partner Reference Guide 2022a

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

•

Keyswitch

•

Squeegee Wheels

•

Brushes (customer required)

•

Pad Driver

•

Tank Gaskets

•

Casters

•

Potentiometer

•

Tank Lids

•

Center-Lok

•

Solenoid Valve

•

Toggle Switch

•

Clutch Plates

•

Spare Keys

•

Vacuum Hose

•

Drain Hose

•

Squeegee Blades and Straps

•

Vacuum Floats

•

Hoses (customer required)

•

Squeegee Knobs

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Forms and Appendx

•

207

Return Policy

Service Partner Reference Guide 2022a

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 208

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Forms and Appendx

Notes

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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) 2. Include any notes pertinent to the repair 3. Check ONE of the machine status boxes provided 4. Tie tag onto a visible area of the machine Repair Status Tags # 100-1034

USA-CLEAN, Inc. 2803 N. 22nd St. Decatur, IL 62526 1-800-872-2532 www.usaclean.com Part # 100-1166

©2021 USA-CLEAN, Inc.

NO INFORMATION MAY BE REPRODUCED WITHOUT AUTHORIZATON BY USA-CLEAN, INC.