Service manual

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SERVICE MANUAL

R.P.S. Corporation Phone: 1-800-634-4060

P.O. Box 241 Fax: 1-866-632-6961

Racine, Wisconsin

Version 1.0

2023 SERIES

Summary of content (98 pages)

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SERVICE MANUAL 2023 SERIES Version 1.0 R.P.S. Corporation P.O.
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CAUTION! To reduce the chance of personal injury and/or property damage, the following instructions must be careful observed: Proper service and repair are important to the safety of the service technician and the safe reliable operation of all cleaning equipment. If part replacement is necessary, the part must be replaced with one of the same part number or with an equivalent part.
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FOREWORD R.P.S. Corporation service manuals are intended for use by professional, qualiﬁed technicians. Attempting repairs or service without the appropriate training, tools, and equipment could cause injury to you or others and damage to your piece of equipment that may cause it not to operate properly This manual should be kept in a convenient place for easy reference. When properly used, it will meet the needs of technicians and equipment owners.
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SAFETY SAFETY MESSAGE Your safety and the safety of others is very important and operating this unit safely is an important responsibility. To help you make informed decisions about safety, we have provided operation procedures and other safety information in this manual. This information informs you of potential hazards that could hurt you or others. It is not practical or possible to warn you of all the hazards associated with operating this unit. You must use your own good judgement.
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SAFETY SAFETY PRECAUTIONS • Hazardous voltage. Shock, Burns or electrocution can result. ALWAYS disconnect the batteries before servicing machine. • Batteries emit hydrogen gases, explosion or ﬁre can result. Keep sparks and open ﬂame away.! • Charge unit in a well ventilated area and keep battery compartment open when charging or explosion or ﬁre could result. • Battery acid can cause burns. Wear protective face-shield and gloves when servicing batteries. • Do not store outdoors or pressure wash.
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TABLE OF CONTENTS TOC CONTENTS MAINTENANCE 1-1 MAINTENANCE SCHEDULE ............................................................... 1-1 LUBRICATION ...................................................................................... 1-1 BLANK .........................................................................................1-4 THIS PAGE WAS INTENTIONALLY LEFT BLANK .....................1-4 MACHINE PARTS 2-1 MAIN COMPONENTS .....................................................................
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TOC TABLE OF CONTENTS SOLUTION SYSTEM 6-1 DISPENSING SOLUTION ............................................................. 6-1 ADJUSTING SOLUTION FLOW ...................................................6-2 DRAINING SOLUTION TANK ......................................................6-2 CLEANING SOLUTION FILTER ...................................................6-2 SOLUTION SOLENOID VALVE ...................................................6-2 BRUSH DRIVE SYSTEM 7-1 BRUSH ASSIST ......................
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TABLE OF CONTENTS TOC BATTERY SYSTEM ..................................................................... 11-4 BATTERY MAINTENANCE & CARE ................................................ 11-4 LEAD ACID BATTERIES (TRADITIONAL) ................................ 11-4 LEAD ACID BATTERIES (MAINTENANCE FREE) ................... 11-4 GEL CELL BATTERIES .............................................................. 11-4 BATTERY CABLES & TERMINALS........................................... 11-5 BATTERY TESTING ...
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TOC TABLE OF CONTENTS BLANK THIS PAGE WAS INTENTIONALLY LEFT BLANK toc - 4 2023 Service Manual V1.
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SPECIFICATIONS Machine Length Machine Height Machine Chassis Width 51 3/4 in. 42 7/8 in. 18.00 in. (132cm) (109cm) (46 cm) Machine Current Consumption (Average) 47 Amps Brush Motor: Up to 30 Amps Vacuum Motor: Up to 30 Amps Solution Tank Capacity Recovery Tank Capacity 19 Gallons 19 Gallons (72 liters) (72 liters) Solution Flow Rate Operating Noise Level (at operator) 0 - 2 GPM 70 dB(A) (0 - 7.56 liters/min) Forward Scrub Speed 0 - 300 ft.
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SPECIFICATIONS 2023-20 2023-20HD 2023-23 Machine Width with Squeegee 32 3/4 in. 83 cm 32 3/4 in. 83 cm 32 3/4 in. 83 cm Scrub Brush Size (qty. 1) 20 in. 51 cm 20 in. 51 cm 23 in. 59 cm Scrub Brush Motor (qty. 1) .75 hp 1.0 hp 1.0 hp Scub Brush Speed 200 rpm 200 rpm 200 rpm Machine Net Weight * 334 lbs. 148 kg. 334 lbs. 148 kg. 352 lbs. 160 kg. Machine Gross Weight ** 458 lbs. 208 kg. 458 lbs. 208 kg. 484 lbs. 220 kg. Cleaning Width 20 in. 51 cm 20 in. 51 cm 23in.
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MAINTENANCE MAINTENANCE MAINTENANCE SCHEDULE ��
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1 MAINTENANCE ��
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MAINTENANCE ��
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1 MAINTENANCE BLANK THIS PAGE WAS INTENTIONALLY LEFT BLANK 1-4 2023 Service Manual V1.
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MACHINE INTRODUCTION 2 MACHINE PARTS 2 1. HANDLE BARS 2. RECOVERY LID 3. CONTROL PANEL 4. CIRCUIT BREAKERS 5. SOLUTION GAUGE/DRAIN 6. SQUEEGEE ASSEMBLY 7. FRONT WHEELS 8. REAR CASTERS 9. SOLUTION FILTER 10. SQUEEGEE LIFT 11. CHARGER PORT 12. RECOVERY DRAIN HOSE 1 3 12 4 11 5 10 7 9 6 8 13. SOLUTION TANK 14. BODY LOCK DOWN SCREW 15. BODY ALLEN WRENCH 16. DRAIN SAVER SCREEN 17. VACUUM FLOAT AND SCREEN 18. SOLUTION VALVE 19. SOLUTION FILL 20.
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2 MACHINE INTRODUCTION MAIN COMPONENTS Handle Bars (1) - The handle bars are located at the back of the machine and have a green button on the right side handle. When the green button is depressed it turns on the brush motor and solution ﬂow if the control panel switches are turned on. Recovery Tank Lid (2) - The recovery tank lid is equipped with a clear dome to allow you to see the condition of the recovery tank while in use.
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MACHINE INTRODUCTION CONTROL PANEL � � � � � � � � � � � � � �� P � � � � � � �� A. Main Power Switch B. Vacuum Switch C. Solution Switch D. Brush Motor Switch E. Handle Switch F. Battery Gauge G. Brush Pressure Gauge H. Emergency Stop (Optional) I . Key Switch (Optional) J. Vacuum Motor Circuit Breaker K. Brush Motor Circuit Breaker L. Brush Actuator Circuit Breaker M. Water Jet Switch (Optional) N. Hour Meter O.
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2 MACHINE INTRODUCTION CONTROL SWITCHES Main Power Switch (A)- Turn power on and off to the entire machine Vacuum Switch (B) - Turns the vacuum motor on and off Solution Switch (C) - When in the on position the solution ﬂows when the brushes run. Brush Motor Switch (D) - When in the on position the brushes will run when the handle bar button is depressed. Handle Bar Button (E) - Activates the brush motor and water if selected when it is depressed.
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SQUEEGEE SYSTEM SQUEEGEE SYSTEM A scrubber’s squeegee system is designed to work with the recovery system to pick up water and dirt from the ﬂoor using air ﬂow created by the recovery system. The front blade of the squeegee tool is designed with notches in it that allow the air, water and dirt to pass through it while metering the air, increasing it’s speed through the tool and recovery system. The optimal performance of a squeegee is very dependent on proper adjustment and maintenance.
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3 SQUEEGEE SYSTEM A pitch adjustment that allows the operator to adjust the squeegee for different ﬂoor surfaces. This is used for creating more of a leak under the front blade for smooth ﬂoors or less of one for rough ﬂoors. SQUEEGEE SUSPENSION BREAKDOWN � � � � � � � � � � � A. SQUEEGEE SWING PLATE – The swing plate is vulnerable to bending if the machine is driven over a curb or large bump. Always check this for straightness. If it is bent at all it must be replaced.
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SQUEEGEE SYSTEM TRIANGLE PLATE & TOW BAR These parts cannot be bent at all. They must be completely straight and ﬂat. If either is bent replace it. If you replace triangle plate, adjust the clearance between the bottom of the plate and the top of the tow bar underneath so clearance is 7/8” (22 mm). Squeegee will not work if this adjustment is off! PIVOT BOLTS PIVOT POINT UP/DOWN MOVEMENT The squeegee must be able to travel up and down freely so it can glide over bumps and uneven surfaces.
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3 SQUEEGEE SYSTEM The front blade wears very well when properly adjusted, but it can get torn. It can be installed one of two ways: “3 notches down” for normal ﬂoors, and “5 notches down” for extremely smooth ﬂoors. REPLACING BLADES We stock individual blades or blade kits that include a blade set and new set of squeegee trailing wheels. We recommend changing the trailing wheels when you change blades as they are wear items and they are critical to the proper operation of the squeegee.
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SQUEEGEE SYSTEM SQUEEGEE ADJUSTMENT A squeegee needs to be adjusted to the type of surface that it is operating on. This means the adjustments that pick up well on rough concrete will probably not work well on glasssmooth vinyl tile or ceramic tile. The reverse would hold true also, a squeegee set up for a smooth surface will not work well on rough surfaces.
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3 SQUEEGEE SYSTEM SQUEEGEE ADJUSTMENT EXAMPLES �� 3-6 � ��
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SQUEEGEE SYSTEM The squeegee has trailing wheels that MUST touch the ﬂoor and roll as the machine is traveling forward. They MUST both be adjusted to the same height. You can check their adjustment by removing the squeegee from the machine, making sure the squeegee has good blades on it and setting the squeegee on a ﬂat surface. The wheels will wear down under normal use and their diameter will change. To maintain the system properly, the customer receives new trailing wheels with the squeegee blade kit.
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3 SQUEEGEE SYSTEM ��
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SQUEEGEE SYSTEM SQUEEGEE SYSTEM DIAGNOSIS FLOW CHART 1 of 2 Squeegee does not pick up water Operate the machine and verify the customers complaint Is there a problem with the machine? Is the squeegee adjusted properly? A vacuum gauge is necessary to accurately test the suction of the vacuum motor. Verify operation with the customer and educate the customer on the way their machine works. NO Adjust squeegee as best as possible. NO YES Check for good suction and air flow at the squeegee hose.
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3 SQUEEGEE SYSTEM SQUEEGEE SYSTEM DIAGNOSIS FLOW CHART 1 of 2 From Previous Page Check to make sure the spacers, washers and springs are all there and in working order. Are there missing parts? Replace parts NO Verify the measurement where the front of the triangle plate bolts to the tow bar. There should be EXACTLY 7/8" clearance on all machines except the 390/420 series.
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SQUEEGEE LIFT SYSTEM SQUEEGEE LIFT SYSTEM The squeegee lift system on the 2023 system was designed with simplicity in mind. It has very straight forward operation and minimal parts to assure consistent and highly reliable operation. TO OPERATE To lower the squeegee place your foot under the yellow lever located at the right rear of the machine below the control panel. To lift the squeegee press down on the yellow colored lever with your foot.
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RECOVERY SYSTEM RECOVERY SYSTEM The recovery system of the 2023 series is powered by a 24 volt 550 watt vacuum motor. The recovery tank is designed with a large lid to facilitate the ability to completely clean out the recovery tank when use of the machine is ﬁnished. The vacuum motor draws air in through the squeegee tool, through the squeegee hose and into recovery tank. The water travels with the air ﬂowing through the system and falls out of the air when it reaches the recovery tank.
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5 RECOVERY SYSTEM VACUUM FLOAT The vacuum ﬂoat assembly is located inside the recovery tank and is accessed by opening the recovery tank lid. The ﬂoat stops the ﬂow of air in the event that the recovery tank is ﬁlled to capacity. To clean: Remove the white retaining clamp from the screen. Pull the vac screen / ﬂoat ball assembly off the vac box. Rinse with hot water. Scrub with a brush if necessary Dry thoroughly. Replace vac screen / ﬂoat ball assembly onto vac box. Replace and tighten clamp.
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RECOVERY SYSTEM MODEL 2023 RECOVERY SYSTEM DIAGNOSTIC FLOW CHART 1 of 3 Machine is not picking up water. Verify customer complaint Is there a problem? Retest the machine YES Empty tank and clean ”Drain Saver” and float ball cage.
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5 RECOVERY SYSTEM MODEL 2023 RECOVERY SYSTEM DIAGNOSTIC FLOW CHART 2 of 3 FROM PAGE 1 Bill customer Instruct customer on proper machine maintenance Is the squeegee adjusted properly? YES Did this remedy the problem? Did this remedy the problem? YES Install squeege back on the machine and test operation. Clean the squeegee. Inspect the blades and wheels. Replace parts as necessary.
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RECOVERY SYSTEM MODEL 2023 RECOVERY SYSTEM DIAGNOSTIC FLOW CHART 2 of 3 FROM PAGE 2 Bill the customer Check inside the hose for obstructions YES Clean out obstructions or clogs and retest machine. Did this remedy the problem? YES Were any obstructions or clogs found? NO Remove the float cage and measure the vacuum at the float screen bracket NO Call the factory Replace vacuum motor and retest machine Do you have good vacuum? YES NO NO Unbolt the vacuum motor from the tank.
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SOLUTION SYSTEM SOLUTION SYSTEM The solution system on the 2023 series consists of main body of the machine which is also the solution tank, the ﬁll opening, sight gauge/drain, ﬁlter, ball valve (not on early production machines), Solution solenoid valve and solution control panel switch. The solution is turned on with the toggle switch on the control panel of the machine and lets solution ﬂow out of the machine only when the brush is running.
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6 SOLUTION SYSTEM ADJUSTING SOLUTION FLOW To adjust the solution ﬂow use the ball valve mounted on the right side of the brush deck. (Note: Early production models did not have a ball valve. On these models the solution solenoid valve is adjusted to control the amount of solution ﬂow.) SOLUTION SOLENOID VALVE DRAINING SOLUTION TANK Detach the solution drain / sight gauge hose from the upper barb and lower into a suitable drain or receptacle.
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SOLUTION SYSTEM SOLUTION SYSTEM DIAGNOSIS FLOW CHART 1 of 2 Does the machine dispense water? Test Machine / Verify Complaint NO Solution flow YES Advise customer on proper machine operation NO Fill solution tank with water NO Turn on the water switch NO Is the water switch turned on? YES Open the ball valve Is the ball valve at the brush deck open? NO YES Remove the solution filter screen Does water flow out of tank? YES Is there water in the tank NO Solution tank outlet is clogged.
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6 SOLUTION SYSTEM SOLUTION SYSTEM DIAGNOSIS FLOW CHART 2 of 2 From Previous Page Back out all the way and install lock nut.
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BRUSH DRIVE SYSTEM BRUSH DRIVE SYSTEM The brush drive system on the 2023 series is also a machine drive assist system. This means that the force created by the pad on the ﬂoor is also used to help propel the machine forward when scrubbing. The system consists of the brush drive motor, brush driver hub, scrub brush or pad holder, the idler wheel and the adjustment knob. The drive hub is a “gimbaled” design that helps compensate for irregularities of the ﬂoor.
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7 BRUSH DRIVE SYSTEM SETTING BRUSH PRESSURE Lower the scrub deck to the ﬂoor. Turn on the solution switch and turn on the brush by using the green handlebar button. Observe the brush pressure gauge on the control panel and make sure it does not enter the red zone while scrubbing. If the machine is operated in the red zone, the motor is being over-worked, and it will blow the brush circuit breaker. If this breaker blows, wait until it cools and reset it. Reduce brush pressure and resume scrubbing.
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BRUSH DRIVE SYSTEM BRUSH DECK DIAGNOSIS FLOW CHART 1 of 2 Scrub brush motor not operating properly Is the brush motor operating properly? Test Machine / Verify Complaint Advise customer on proper machine operation. YES NO Is the main power switch on? NO Turn on the main power switch. Check condition of the batteries. YES Is the power indicator lit on the control panel? NO Check for power into the main control panel Is there power in? YES Charge Batteries.
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7 BRUSH DRIVE SYSTEM BRUSH DECK DIAGNOSIS FLOW CHART 2 of 2 FROM PAGE 1 “A” FROM PAGE 1 “B” Check for ( + ) battery voltage at the green wire going to the coil circuit on the brush relay when the green handle bar button is depressed. Is there ( + ) battery voltage? YES Check for ( + ) battery voltage on the other load terminal of the relay when it clicks. NO Repair the wiring from the ( + ) buss to the brush motor relay.
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BRUSH LIFT SYSTEM BRUSH LIFT SYSTEM The brush lift system on the 2023 series consists of an actuator, a rocker switch, circuit breaker, lifting linkage and down pressure springs. The brush deck and motor are raised and lowered by the brush deck actuator. The actuator is controlled by a switch on the control panel. The actuator circuit is protected by a 2 amp, push-to-reset, circuit breaker on the back of the control panel.
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8 BRUSH LIFT SYSTEM DOWN PRESSURE Down pressure is controlled manually by the operator raising or lowering the deck. The amount of down pressure is monitored using the brush pressure gauge located on the lower right corner of the control panel. This gauge should always be in the green when operating. If the gauge goes into the red there is too much brush pressure being applied. STANDARD MODEL HD MODEL BRUSH LIFT SYSTEM ADJUSTMENTS The brush lift system has two adjustments that can be made to it.
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BRUSH LIFT SYSTEM ACTUATOR ADJUSTMENT To access the limit switch in the actuator remove the black rubber strip on the face of it. Loosen the set screw just enough for the switch to slide. To increase the travel of the deck slide the limit switch down toward the ﬂoor. To increase the travel slide the limit switch up towards the top of the machine. When the switch is repositioned gently tighten the set screw and replace the black rubber strip.
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8 BRUSH LIFT SYSTEM BRUSH DECK LIFT DIAGNOSIS FLOW CHART 1 of 2 Brush deck does not raise or lower. Does the brush deck raise or lower? Test machine / Verify the complaint. YES Advise customer on proper machine operation. NO Turn on main power switch NO Is the main power switch on? Check condition of the batteries. NO YES Is the power indicator lit on the control panel? Charge batteries.
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BRUSH LIFT SYSTEM BRUSH DECK LIFT DIAGNOSIS FLOW CHART 2 of 2 Find and repair break in wiring. FROM PAGE 1 NO Disconnect the wires at the actuator. Attach one of your meter leads to each connector on the wire harness side of the machine. These will be pink and white wires. Do they both have good continuity? YES Rock the switch forward and backward and observe you meter readings. Check continuity from the pink and white wires at the actuator to the actuator switch. NO Replace the brush deck switch.
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TRACTION DRIVE SYSTEM TRACTION DRIVE SYSTEM The 2023 model is not currently offered with a drive option. 2023 Service Manual V1.
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CHASSIS SYSTEM CHASSIS SYSTEM The chassis system in built on a heavy duty 7 gauge powder coated full frame. The frame gives the machine great strength and durability. Everything is fastened to the frame using stainless steel hardware allowing for easy servicing should a repair be needed. The machine rolls on two 8” rubber tires and two 4” poly casters providing solid stable operation.
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BATTERY SYSTEM BATTERIES BATTERY SAFETY DANGER OF EXPLODING BATTERIES Batteries contain sulfuric acid and produce explosive mixtures of hydrogen and oxygen. Because self-discharge action generates hydrogen gas even when the battery is not in operation. Make sure batteries are stored and worked on in a well ventilated area. ALWAYS wear ANSI Z87.1 (U.S. Standard) approved safety glasses and face shield or splash proof goggles when working on or near batteries.
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11 BATTERY SYSTEM HANDLING BATTERY ACID Battery acid, or electrolyte, is a solution of sulfuric acid and water that can destroy clothing and burn the skin. Use extreme caution when handling electrolyte and keep an acid neutralizing solution - such as baking soda or house hold ammonia mixed with water - readily available. When handling batteries: Always wear proper eye, face and hand protection.
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BATTERY SYSTEM Stud Terminal The stud terminal is typically used on heavy duty batteries. The terminals have a stainless steel threaded stud embedded in them that the connections are made to. Combination Terminal The combination terminals come in a few different conﬁgurations. The two most common conﬁgurations are the “side by side” and the stacked. In the side by side there is a tapered top terminal with a stud terminal right next to it.
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11 BATTERY SYSTEM BATTERY SYSTEM The battery system for the 2023 models consists of 2 deep cycle batteries. They are offered in 2 different sizes of lead acid and one size of maintenance free gel battery for each machine. The batteries are the power source for all of the working parts of the machine and must be maintained properly to realize optimal run time as well as longevity. Deep cycle batteries provide large storage capacity of the electricity that powers the scrubber.
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BATTERY SYSTEM BATTERY CABLES & TERMINALS The battery cable connections must remain tight and corrosion free. In the event that the battery cables or terminals become corroded follow accepted battery safety precautions, disassemble and clean the terminals with a baking soda and water solution and a wire brush, making sure not to get any INSIDE the battery. Once the terminals and cables are clean and dry, inspect them thoroughly for any damage or signs of arcing or over-heating.
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11 BATTERY SYSTEM The state-of-charge of a lead acid battery can be determined by the speciﬁc gravity of the electrolyte (its weight compared to water). The speciﬁc gravity can be measured directly with a hydrometer or determined by the stabilizing voltage. A hydrometer is a bulb-type syringe which will extract electrolyte from a cell. A glass ﬂoat or a plastic disk in the hydrometer body is calibrated to read in terms of speciﬁc gravity. A common range of speciﬁc gravity used on these ﬂoats is 1.
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BATTERY SYSTEM When testing with a load tester you are looking for a difference between cells of the batteries. All the battery cells should have similar readings. Any battery that contains a cell that has a value lower than .050 of the rest of the cells indicates you have a bad battery. LOAD TESTING Load test with a load tester: Make sure batteries are fully charged. Disconnect batteries from the machine and each other so each battery can be tested individually.
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11 BATTERY SYSTEM BATTERY REPLACEMENT When replacing batteries in a machine it is important to replace them with quality batteries that are designed for high-output deep-cycle applications, such as the ones furnished by the factory when the machine was new. All batteries are NOT created equal. In the event you are considering other manufactures batteries make sure to compare their 75 AMP RESERVE CAPACITY. That is the ONLY speciﬁcation that corresponds to the usage the batteries will be seeing.
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ELECTRICAL SYSTEM ELECTRICAL SYSTEM The electrical system on the 2023 was designed with simplicity being a core quality. In designing the system this way it is not complicated by a computer and is very basic to repair. All the circuits are controlled by either switches, relays or a combination of the two. The circuits are protected by push to reset circuit breakers located on the rear of the control panel.
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ELECTRICAL SYSTEM 12 + WHITE #61 4 BLACK #2 2 1 CIRCUIT BREAKER, MAIN RED #59 4 - 3 BATTERY 12 VOLT BLACK 10 GAUGE RED 10 GAUGE WHITE #61 2 BLACK #2 1 2 CIRCUIT BREAKER 1 2 CIRCUIT BREAKER 1 CIRCUIT BREAKER YELLOW #48 2 RED #58 Document Number 000-000 2 A GREEN #110 LAMP METER AMP V RED #3 METER, VOLT H METER, HOUR 1 2 Sheet RED #57 M3 PINK #62 BLACK #17 5 + + PINK #63 2023 Main Schematic RED #26 Wednesday, October 05, 2005 1 CONNECTOR, CHARGER 1 1 PINK #63
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ELECTRICAL SYSTEM BLANK THIS PAGE WAS INTENTIONALLY LEFT BLANK 2023 Service Manual V1.
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REPAIR INSTRUCTIONS 2/16/2006 2023-01 SHROUD CURTAIN ADJUSTMENT Page 1 of 1 TIME REQUIRED: 10 MINUTES NUMBER OF TECHS: 1 PERSON REQUIRED PARTS none REQUIRED TOOLS none 1. Make sure machine is on level floor. 2. Release the black latch on left side of the shroud. (see figure below) NOTE: On the right and left side of shroud there are Qty: (2) 10/32 x1/2 screws one on each side, they are left slightly loose so band and curtain can slide up and down. 3.
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RI REPAIR INSTRUCTIONS 2/16/2006 2023-02 SCRUB DECK ACTUATOR R&R Page 1 of 6 TIME REQUIRED: 20 MINUTES NUMBER OF TECHS: 1 PERSON REQUIRED PARTS � Qty: (1) 190-2210 ACTUATOR REQUIRED TOOLS � 7/16’’ 12- point box wrench � 9/16’’ 12- point socket � needle nose pliers � Qty: (2) 2’’ x 4’’x24’’ wood boards COMPLETELY DRAIN SOLUTION & RECOVERY TANKS MAKE SURE MACHINE IS ON LEVEL GROUND AND WHEELS ARE CHOCKED AND SCUB DECK IS IN UP POSITION. OPENING TANK 1.
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REPAIR INSTRUCTIONS 2/16/2006 2023-02 SCRUB DECK ACTUATOR R&R Page 2 of 6 3. Carefully lean tank back to expose battery compartment. DISCONNECT BATTERIES 1. Locate the positive terminal that is in front left of battery pack. 2. Using a 9/16’’ 12- point socket loosen and remove the 5\16’’ nut. 3. Remove the red cable and secure away from terminal .( See figure below) REMOVING SCRUB DECK ACTUATOR 1. Locate the wiring harness that is behind the actuator. 2.
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RI REPAIR INSTRUCTIONS 2/16/2006 2023-02 SCRUB DECK ACTUATOR R&R Page 3 of 6 (Red and orange wires not Shown) 3. Using a 7/16 12-point box wrench loosen and remove the (Qty 2) ¼-20 jam nylock nuts that holds the down pressure springs to the actuator anchor and the actuator arm.(see figure below) 4. ¼ -20 jam nylock nuts 5. Remove the down pressure springs from the top stud. (see figure below) Down pressure Spring RI-4 2023 Service Manual V1.
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REPAIR INSTRUCTIONS 2/16/2006 2023-02 SCRUB DECK ACTUATOR R&R Page 4 of 6 6. Using Qty :( 2) 2’’x 4’’x24’’ wood boards stack them up and put them under the center of the scrub deck. (see figure below) NOTE: You may have to lift on scrub deck slightly to install 2’’x4’’x24’’wood boards. NOTE: MAKE SURE THE BOARDS ARE SUPPORTING THE FULL WEIGTH OF THE SCRUBDECK. 7. Using a needle nose pliers remove the1/2’’ Rue Ring Cotter pin that is located at the top of the actuator.(see figure below) 8.
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RI REPAIR INSTRUCTIONS 2/16/2006 2023-02 SCRUB DECK ACTUATOR R&R Page 5 of 6 9. Using a needle nose pliers remove the 3/8’’ Rue ring cotter.(see figure below) 10. Remove the 3/8’’x2 ½’’ clevis pin. (see figure below)NOTE: There is a ½’’x3/8’’x1’’ oil light bushing in this hole, make sure to misplace it.(see figure below) ½’’x3/8’’x1’’ oil light bushing 11. Remove actuator. (see figure below) RI-6 2023 Service Manual V1.
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REPAIR INSTRUCTIONS 2/16/2006 2023-02 SCRUB DECK ACTUATOR R&R Page 6 of 6 INSTALLING NEW ACTUATOR 1. Hold new actuator with movable shaft in up position. 2. Install the ½’’x 2’’ clevis pin on the top of actuator to the machine. 3. Install the ½’’ Rue ring cotter. 4. Install the ½’’x 3/8’’x1’’ oil light bushing in bottom hole of actuator. 5. Install the 3/8’’x 2 ½’’ clevis pin on bottom of actuator. 6. Install the 3/8’’ Rue ring cotter. 7. Reinstall the Qty :( 2) down pressure springs. 8.
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RI REPAIR INSTRUCTIONS 2/16/2006 2023-03 SOLUTION FLOW VALVE R&R Page 1 of 5 TIME REQUIRED: 15 MINUTES NUMBER OF TECHS: 1 PERSON REQUIRED PARTS � Qty: (1) 190-4500 solution flow valve � Qty: (1) 8’’ wire tie REQUIRED TOOLS � 7/16’’ 12- point box wrench � 7/16’’ 12 - point socket � 3/16’’ flat head screw driver � 13/16’’ open end wrench � side cutters � 9/16’’ 12- point socket COMPLETELY DRAIN SOLUTION & RECOVERY TANKS MAKE SURE MACHINE IS ON LEVEL GROUND, WHEELS ARE CHOCKED AND SCUB DECK IS IN UP POSIT
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REPAIR INSTRUCTIONS 2/16/2006 2023-03 SOLUTION FLOW VALVE R&R Page 2 of 5 NOTE: IF MACHINE HAS KEY SWITCH, REMOVE KEYS BEFORE NEXT STEP. 3. Carefully lean tank back to expose battery compartment. DISCONNECTING BATTERIES 1. Locate the positive terminal that is in front left of battery pack. 2. Using a 9/16’’ 12- point socket loosen and remove the 5\16’’ nut. 3. Remove the red cable and secure away from terminal .( See figure below) REMOVING SOLUTOIN FLOW VALVE 1.
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RI REPAIR INSTRUCTIONS 2/16/2006 2023-03 SOLUTION FLOW VALVE R&R Page 3 of 5 2. Using a side cutters, cut the wire tie that holds the orange and black wires to valve. (see figure below ) 3. Using a needle nose pliers, carefully remove the orange and black wire from valve. (see figure below) 4. Remove the ½’’ reinforced hose from the ball valve. (see figure below) 5. Using a 13/16’’ open end wrench carefully loosen and remove the ball valve from the solution flow valve.
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REPAIR INSTRUCTIONS 2/16/2006 2023-03 SOLUTION FLOW VALVE R&R Page 4 of 5 6. Using a 7/16’’ 12-point socket and a 7/16’’ 12 point box wrench loosen and remove the ¼’’- 20x1/2’’ bolt and jam nut. (see figure below ) 7. Remove the solution flow valve. NOTE: Before installing new solution flow valve check adjustment. ADJUSTING NEW SOLUTION VALVE 1. Using a 7/16’’ 12-point box wrench loosen the ¼’’ – 20 nut. 2. Using a 3/16’’ flat head screw driver, back adjustment screw all the way out.
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RI REPAIR INSTRUCTIONS 2/16/2006 2023-03 SOLUTION FLOW VALVE R&R Page 5 of 5 REINSTALLING SOLUTION FLOW VALVE 1. Hold new solution flow valve in position and install the ¼’’20x1/2’’ bolt and ¼’’20 nut and tighten. 2. Reinstall the ball valve onto solution flow valve and tighten using a 13/16’’ open wrench. NOTE DON’T OVER TIGHTEN. 3. Reinstall ½’’ hose and clamp on to ball valve and tighten the ½’’ hose clamp using a 3/16’’ flat head screw driver. 4.
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REPAIR INSTRUCTIONS 2/16/2006 2023-04 RESETTABLE CIRCUIT BREAKER R&R Page 1 of 5 TIME REQUIRED: 30 MINUTES NUMBER OF TECHS: 1 PERSON REQUIRED PARTS: SELECT THE APPROPRIATE CIRCUIT BREAKER � Qty: (1) actuator 2 amp resettable circuit breaker 7-837 � Qty: (1) brush motor 30 amp re-settable circuit breaker 290-9609 � Qty: (1) HD brush motor 40 amp re-settable circuit breaker 190-9609 � Qty: (1) vacuum motor 25 amp re-settable circuit breaker 190-8370 REQUIRED TOOLS � # 2 Phillips screw driver � Pliers � Nee
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RI REPAIR INSTRUCTIONS 2/16/2006 2023-04 RESETTABLE CIRCUIT BREAKER R&R Page 2 of 5 3. Carefully lean tank back to expose battery compartment.(see figure below) DISCONNECT BATTERIES 1. Locate the positive terminal that is in front left of battery pack. 2. Using a 9/16’’ 12- point socket loosen and remove the 5\16’’ nut. 3. Remove the red wire and secure away from terminal.( See figure below) REMOVING CONTROL PANEL 1.
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REPAIR INSTRUCTIONS 2/16/2006 2023-04 RESETTABLE CIRCUIT BREAKER R&R Page 3 of 5 3. Remove the two # 14x2 ½’’ sheet metal screws. NOTE: MARKED AS # 26 BELOW. 4. Carefully remove control panel. RI-15 2023 Service Manual V1.
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RI REPAIR INSTRUCTIONS 2/16/2006 2023-04 RESETTABLE CIRCUIT BREAKER R&R Page 4 of 5 REMOVING THE 2 AMP RESETTABLE CIRCUIT BREAKER 1. Using a needle nose pliers carefully disconnect the two pink wires from the back of circuit breaker. NOTE: MAKE SURE TO GRAB CONNECTORS NOT WIRES. (see figure below) REMOVING THE 25, 30, OR 40 amp RESETTABLE CIRCUIT BREAKER 1. Using # 2 Phillips screw driver carefully remove the Qty:(2) 8/32’’ screws that hold the # 10 ring connectors to the circuit breaker.
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REPAIR INSTRUCTIONS 2/16/2006 2023-04 RESETTABLE CIRCUIT BREAKER R&R Page 5 of 5 4. Reinstall control panel. 5. Reconnect batteries. 6. Close tank and reinstall the 5/16’’ – 18 x3’’ bolt in relief ports and tighten using the 3/16’’ Allen wrench. 7. Reinstall 3/16’’ Allen wrench back in location. INSTALLING THE 25, 30.AND 40 AMP CIRCUIT BREAKER 1. Install resettable circuit breaker and knurled nut. 2. Using a pliers carefully tighten the knurled nut snug. 3.
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RI REPAIR INSTRUCTIONS 2/16/2006 2023-05 BATTERY R&R Page 1 of 4 TIME REQUIRED: 15 MINUTES NUMBER OF TECHS: 1 PERSON REQUIRED PARTS � Qty: (2) 190-2110 battery,12 volt 140 amp AH, REQUIRED TOOLS � 9/16’’ 12-point deep well socket � ½’’ 12-point socket � volt meter � battery terminal protector COMPLETELY DRAIN SOLUTION & RECOVERY TANKS MAKE SURE MACHINE IS ON LEVEL GROUND AND WHEELS ARE CHOCKED AND SCUB DECK IS IN UP POSITION. OPENING TANK 1.
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REPAIR INSTRUCTIONS 2/16/2006 2023-05 BATTERY R&R Page 2 of 4 NOTE: IF MACHINE HAS KEY SWITCH, REMOVE KEYS BEFORE NEXT STEP. 3. Carefully lean tank back to expose battery compartment.(see figure below) DISCONNECTING BATTERIES 1. Locate the positive terminal that is in front left of battery pack. 2. Using a 9/16’’ 12- point socket loosen and remove the 5\16’’ nut. 3. Remove the red wire and secure away from terminal .( See figure below) 4. Remove remaining cables and set aside.
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RI REPAIR INSTRUCTIONS 2/16/2006 2023-05 BATTERY R&R Page 3 of 4 INSTALLING NEW BATTERIERS 1. When installing new batteries make sure that the terminals are on the outside of the machine. 2. Reconnect the jumper wire. NOTE: MAKE SURE NOT TO OVER TIGHTEN CONNECTTION.(see figure below) 3. Using a voltage meter check voltage between the negative and positive terminal. Voltage should be 24 volts or slightly higher. (see figure below) RI-20 2023 Service Manual V1.
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REPAIR INSTRUCTIONS 2/16/2006 2023-05 BATTERY R&R Page 4 of 4 4. Reconnect the red wire on the front left positive terminal of the battery pack. NOTE: MAKE SURE NOT TO OVER TIGHTEN CONNECTION 5. Reconnect the black wire on the front right negative terminal of battery pack. NOTE: MAKE SURE NOT TO OVER TIGHTEN CONNECTION. 6. Spray terminals with battery terminal protector. 7. Replace battery terminal covers. 8.
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RI REPAIR INSTRUCTIONS 2/16/2006 2023-06 Cleaning Solution Filter Page 1 of 2 TIME REQUIRED: 15 MINUTES NUMBER OF TECHS: 1 PERSON REQUIRED PARTS None REQUIRED TOOLS � One pair of rubber gloves COMPLETELY DRAIN SOLUTION TANK PLACE MACHINE ON LEVEL GROUND AND CHOCK WHEELS. REMOVING FILTER 1. Filter is located at the rear bottom side of the machine, 2. Access to filter is in front of squeegee swing plate. (see figure below) Inline filter 3. Unscrew cover counter- clockwise, and remove the filter screen.
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REPAIR INSTRUCTIONS 2/16/2006 2023-06 Cleaning Solution Filter Page 2 of 2 CLEANING FILTER SCREEN 1. Rinse filter screen and clear cover until clear of debris. (see figures below) Note: Check threads on cover and filter screen housing for debris. INSTALLING CLEAN FILTER SCREEN 1. Place filter screen in center of clear filter screen cover. Install filter screen and clear filter screen cover on to housing and tighten. (see figures below) 2. Fill solution tank with water.
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RI REPAIR INSTRUCTIONS 2/16/2006 2023-07 SQUEEGEE TOOL R&R Page 1 of 5 TIME REQUIRED: 15 MINUTES NUMBER OF TECHS: 1 PERSON REQUIRED PARTS � SEE PARTS MANUAL FOR SQUEEGEE KIT PART # REQUIRED TOOLS � 7/16’’ 12- point box wrench � 7/16’’ 12- point deep well socket � # 2 Philips screw driver NOTE: THE REAR SQUEEGEE BLADE IS DESIGNEDTO BE FLIPPED OVER SO ALL FOUR EGDES CAN BE USED. REMOVING SQUEEGEE TOOL BLADES 1. Using a # 2 Philips screw driver hold the # 10-32 screws and remove wing nuts.
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REPAIR INSTRUCTIONS 2/16/2006 2023-07 SQUEEGEE TOOL R&R Page 2 of 5 3. Remove rear squeegee blade.(see figure below) 4. Remove the Qty: (8) # 10-32’’ screws and front squeegee tool band. (see figure below) NOTE: SET SCREWS DOWN IN THE ORDER YOU TAKE THEM OUT. THEY VARY IN LENGTH. 5. Remove the front squeegee tool blade. (see figure below) 2023 Service Manual V1.
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RI REPAIR INSTRUCTIONS 2/16/2006 2023-07 SQUEEGEE TOOL R&R Page 3 of 5 REMOVING SQEEGEE TOOL TRAIL WHEELS 1. Using a 7/16’’ 12-point box wrench and a 7/16’’ 12-point socket loosen and remove the ¼’’ -20 x 1 5/8’’ bolt and ¼’’ 20 jam nylock nut and Qty: (2) ¼’’ nylon flat washers. (see figure below) REMOVING TRAIL WHEEL MOUNT 1. Using a 7/16’’ 12-point deep well socket loosen and remove the Qty: (2) ¼ -20 x 1’’ bolts that hold down the trail wheel mount to the squeegee tool.
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REPAIR INSTRUCTIONS 2/16/2006 2023-07 SQUEEGEE TOOL R&R Page 4 of 5 INSTALLING NEW SQUEEGEE TOOL TRAIL WHEEL 1. Hold trail wheel into position and install ¼’’ – 20 x 1’’5/8’’ bolt and ¼’’ nylon flat washers and ¼’’-20 nylock nut and tighten so wheel spins freely. REINSTALLING SQUEEGEE TOOL BLADES & BANDS 1. Install the Qty: (2) center screws into the squeegee tool band and the squeegee tool front blade and install onto the squeegee tool.(see figure below) 2.
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RI REPAIR INSTRUCTIONS 2023-07 SQUEEGEE TOOL R&R 2/16/2006 Page 5 of 5 4. Install the wing nuts on loosely. 5. Then starting from the center two screws hand tighten in the order shown below. 8 6 4 1 2 3 5 7 6. Set squeegee on level flat surface and check to make sure the trail wheels are the same distance from the surface. Most are adjusted ¼’’ to ½’’ from surface. If this is not an even amount squeegee will not perform correctly.
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INDEX INDEX A E ACTUATOR ...................................................................... 12-1 EMERGENCY STOP ........................................................ 2-3 BRUSH DECK ........................................................................ 8-2, RI-2 CIRCUIT BREAKER .................................................................... RI-13 B F FILTER BATTERY CHARGING ........................................................................ 11-1, 11-8 GAUGE .......................
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INDEX INDEX S SAFETY MESSAGE .................................................................................................. PRECAUTIONS ........................................................................................ SERIAL NUMBER ............................................................. 2-3 SKIRTS ADJUSTMENTS ............................................................................. RI-1 SOLUTION DISPENSING .............................................................................