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1. 5 5 Aaaa 12 2 CONTROLLER HIGH AMP OUTPUT TERMINALS 12 3 ANDERSON BATTERY 12 3 Magnum Service Manual V1 0 toc Ill TQ C TABLE OF CONTENTS COMPUTER CONTROL SYSTEM 13 1 CONTROLLER OVERVIEW 1 13 1 INPUTS 13 1 OUTPUTS i oe 13 1 PULSE WIDTH 1 13 1 CONTINUITY TESTING eine 13 1 SOFT START issib ft ia 13 2 CONNEGTIONS l 13 2 MOLEX 13 2 AMP TERMINALES corti eror Eo opo E 13 2 BINDING POST TERMINALS 1 13 2 HMED CIRCUITS tr 13 2 METER ii e 13 2 DOWN PRESSURE CONTROL iii d 13 2 ON BOARD DIAGNOSTICS issir 13 5 LGD DISPCAY i e eTa EEEa 13 3 SCREEN a 13 3 SCREENA 2 ta 13 3 SCREEN 13 4 SCREEN A 13 4 DIAGNOSING THE CONTROL SYSTEM 13 5 METERS mem 13 5 MEASUREMENTS hectares 13 5 ECDs DIS PEAY emn 13 5 INPUT S 13 5 TRI STATE olt orm
2. Molex connector on the controller N Is 36 Volts present at this terminal Turn the key switch to the ON position and measure the voltage at either of the terminals with red wires on them Is 36 Volts Repair break in the wiring between the 8 terminal and the key switch The controller has failed Replace the controller Is 36 Volts present at this terminal NO v Measure the voltage across the main batterv terminals on the controller Is 36 Volts present across these terminals2 NO y YES present at this terminal Using a voltmeter set to DC volts Connect the probe of the meter to the buss bar With your positive probe back probe the 18 terminal on the 20 pin Molex connector on the controller Is 36 Volts present at this terminal NO YES y NO Replace the key switch There is a break in the wiring from the key switch to the controller Find and repair the break in the wiring 77277 13 18 There is a battery or battery cable problem Check the battery system Repco conto Magnum Service Manual V1 0 COMPUTER CONTROL system 3 MAGNUM LCD WINDOW DIAGNOSTIC FLOW CHART LCD Window does 1 of 1 operate ax cal tech spe A NO Did this fix Operate machi
3. 13 6 INPUTS VARIABLE 13 6 OUTPUT Bo Dunt 13 6 PROGRAMMING a a e 13 7 toc IV Magnum Service Manual V1 0 Machine Length Machine Height Machine Chassis Width Machine Current Consumption Average Solution Tank Capacitv Recoverv Tank Capacitv Solution Flow Rate Operating Noise Level at operator Forward Scrub Speed Vacuum Motor 3 Stage Water lift Airflow Power Source Batteries Standard Weight Each Mid Capacity Weight Each High Capacity Weight Each Battery Compartment Size Height Width Length Estimated Battery Run Time Battery Charger SPECIFICATIONS 58 3 4 in 149cm 40 1 4 in 102cm 24 1 2 in 62 cm 55 Amps Brush Motor Up to 70 Amps Vacuum Motor Up to 30 Amps Transport Drive Up to 70 Amps 30 Gallons 114 liters 30 Gallons 114 liters 0 2 GPM 0 7 56 liters min 70 dB A 0 300 ft min 4 1 2 mph 0 92 meters min 7 5 kph 15 hp 660 2 12 Volt 185 amp hour capacity 66 Ibs 30 kg 4 6 Volt 245 amp hour capacity 122 Ibs 56kg 4 6 Volt 325 amp hour capacity 122 Ibs 56kg 13in 33 cm 14 in 35 5 cm 17 in 43 cm Up to 5 hours 24 Volt 18 amp oPEC 1 SPECIFICATIONS Machine Width with Squeegee Scrub Brush Size qty 2 Scrub Brush Motor qty 2 standard Scrub Brush Speed
4. 4 Raise jack 5 Secure with jackstands Magnum Service Manual V1 0 RI 15 R l REPAIR INSTRUCTIONS 2 23 2006 253 09 CYLINDRICAL BELT R amp R Page 1 of 3 TIME REQUIRED 15 MINUTES NUMBER OF TECHS 1 PERSON REQUIRED PARTS e QTY 1 353 8230 CYLINDRICAL BELT REQUIRED TOOLS 9 16 CROWS FOOT 3 8 DRIVE e 9 16 OPEN END WRENCH PLACE MACHINE ON LEVEL GROUND AND CHOCK WHEELS MAKE SURE MACHINE POWER SWITCH IS IN OFF POISTION DISCONNECT BATTERIES SEE REPAIR INSTRUCTION 7253 04 REMOVING CYLINDRICAL BELT 1 Remove oylindrical belt and brush accesses door see figure below RI 16 Magnum Service Manual V1 0 REPAIR INSTRUCTIONS R l 2 23 2006 253 09 CYLINDRICAL BELT R amp R Page 2 of 3 2 Using 9 16 open end wrench loosen the QTY 1 3 8 24 locking r and QTY 1 3 8 24x1 belt tension bolt see figure below BELT TENTION BOLT LOCKING NUI 3 Using a 9 16 crows foot loosen the QTY 4 3 8 24 1 bolts that 2 located behind belt sprocket see figure below 4 Remove belt by slipping it off lower sprocket then the top sprocket s figure below Magnum Service Manual V1 0 RI 17 n REPAIR INSTRUCTIONS 2 23 2006 253 09 CYLINDRICAL BELT R amp R Page 3 of 3 INSTALLING NEW CYLINDICAL BELT 1 Install belt on top sprocket then slip it onto bottom sprocket 2 Using 9 16 open end wrench slowly tighten the 3 8 24x1 belt tension bolt NOTE BELT TENTION SHOULD
5. Did the icon turn on Go to the brush NO switch section YES Attach a voltmeter set to the DC volt scale to the pink and white wires going to the actuator Cycle the key switch off and then on and observe the voltage Does the actuator move at all N Adjust the limit switch on the actuator to make it extend more Was there battery voltage for Replace the the off board vac switch and watch the meter Was there battery voltage about 4 seconds when he machine powered C actuator NO v With a voltmeter set to the DC scale back probe terminals 4 811 on the 14 pin Molex connector on the controller Observe the meter reading when the machine is turned on Back of 14 pin Male Connector 14 13 1211 10 9 8 765 43 2 1 Was there battery voltage for NO Replace the the meter b VES Y Replace the actuator C about 4 seconds when the machine owered up controller m YES y Repair wiring to the controller Magnum Service Manual V1 0 Did this remedy the problem YES y the cst 13 9 13 COMPUTER CONTROL SYSTEM MAGNUM BRUSH PRESSURE SWITCH DIAGNOSTIC FLOW CHART 1 of 2 Operate machine and verify the customers complaint Instruct owner on YES proper machin
6. COMPUTER CONTROL system 3 MAGNUM BRUSH PRESSURE SWITCH DIAGNOSTIC FLOW CHART 2 of 2 Place the probe back on the center terminal of the switch yellow wire Move the switch down and note your reading Was the voltage between 0 and 0 3 volts NO Y Place the probe back on the bottom terminal of the switch red wire Place the probe on the top terminal black wire Was the voltage between 4 8 and 5 2 YES volts NO Y With a voltmeter set to the DC setting measure at the 14 pin Molex connector at the controller from terminal 5 to terminal 12 Back of 14 pin Male Connector 14 131211109098 61514 31 21 Was the voltage Replace the NO controller between 4 8 and 5 2 VES y pressure switch volts YES Repair the wiring from terminal 5 to the brush Magnum Service Manual V1 0 13 11 7777 13 COMPUTER CONTROL SYSTEM MAGNUM BRUSH SWITCH DIAGNOSTIC FLOW CHART BRUSH CEN Operate machine and verify the does not work 4 At the 20 pin Molex connector at the controller back probe pin 11 with the positive probe of the meter Is there between 4 8 and 5 2 volts NO Replace the controller A NO Is there between 0 8 and 2 8 volts YES Y Repai
7. 13 COMPUTER CONTROL SYSTEM MAGNUM WATER POTENTIOMETER DIAGNOSTIC FLOW CHART 3 of 3 FROM PAGE 1 B v Unscrew the solution screen and make sure NO that water flows freely out of the filter when the bowl and filter are Was there a good solid flow of water out of the hose v off Check to make sure that the stop screw on the back of the Deltrol valve is backed out all the way and there is a lock nut on the screw Was there a good solid flow of water out of the filter bowl The solution tank or the NO feed line to the filter bowl is clogged Remove the clog and re test the machine Was the screw backed out all the way and a jamb nut there Back out screw all the way NO and install a new jamb nut Re Test machine YES Y Connect a voltmeter set to the DC scale to the two wires that go to the Deltrol valve Turn the machine on and start scrubbing Watch the voltage on the meter and see if you see battery voltage either continuously or pulsed Did you see battery voltage the ve 13 28 Magnum Service Manual V1 0 COMPUTER CONTROL system 3 MAGNUM SPRAY JET DIAGNOSTIC FLOW CHART 1 of 2 and verifv the Sprav Jet does not work properly customers complaint s the mac
8. Do not park the machine on ramps or slopes Do not operate the machine if any parts have been removed or damaged Do not remove paint over or destroy warning decals If warning decals become damaged they must be replaced Do not operate machine in an unsafe condition If the machine is need of repair or is in anyway unsafe to operate the matter should be reported immediately to the shift supervisor Do not operate the machine until it is returned to proper operating condition e This machine must be operated only by a trained operator As part of their training they must read the operators manual thoroughly If extra copies are needed contact your local dealer e Always park machine on a level surface and turn the power off before leaving it unattended Do not operate over electrical floor outlets This may result in serious injury or death to the operator and others e Do not work under machine without it properly supported on suitable safety stands Do not try and lift this machine unaided it is very heavy e Do not use handle bars or steering mechanism as a lifting point CONTENTS MAINTENANCE MAINTENANCE SCHEDULE LUBRICATION iii iii ii ii ei pi MACHINE PARTS CONTROL DESCRIPTION SQUEEGEE SVSTEM SQUEEGEE SYSTEM COMPONENTS SQUEEGEE SUSPENSION BREAKDOWN TRIANGLE PLATE amp TOW BAR UP DOWN MOVEMENT SIDEWAYS MOVEMENT SQUEEGEE BLADES REPLACING BLADES ORDERING BLADES SQUEEGEE ADJUSTMENT PITCH ADJUSTMENT KNOB S
9. Do not work on this machine while wearing a tie scarf hat or any other loose or dangling neck wear or clothing Loose clothing can tangle or catch on rotating parts causing serious injury or death Do not use this machine as a ladder or a chair Operate this machine only from the operators position This machine was not designed to carry passengers or transport cargo Do not operate this machine on steep ramps or uneven surfaces When climbing a ramp always drive the machine forward straight up or down the ramp Never drive across the incline e Do not back down or turn on ramps Always use the charger provided by the manufacturer to charge the machine It is an automatic charger specifically designed to charge at the appropriate rate If you must use a different charger disconnect the batteries from the machine as this will protect the on board electronics Understand the dynamic breaking system before you operate the machine on ramps or slopes Do not park the machine on ramps or slopes Do not operate the machine if any parts have been removed or damaged Do not remove paint over or destroy warning decals If warning decals become damaged they must be replaced Do not operate machine in an unsafe condition If the machine is need of repair or is in anyway unsafe to operate the matter should be reported immediately to the shift supervisor Do not operate the machine until it is returned to proper operating conditio
10. N3SH3QNV VSZ 12 5 777 Magnum Service Manual V1 0 12 ELECTRICAL SYSTEM ermina Wire Number orPin Battery Cables Main cable to the battery pack 1 Cable from 1st to 2nd battery Cable from 2nd to 3rd battery Cable from 3rd to 4th battery Cable from 4th to 5th battery Cable from 5th to 6th battery Main cable to the battery pack 1 Main cable to the battery pack 2 Main cable to the battery pack 2 Rapid Charge 1 Rapid Charge 2 Rapid Charge 3 Rapid Charge 4 20 39 Main Power Buss General 16 Gauge ground General 16 Gauge Positive Pos Battery Power to Key or Master switch Power from main or key switch to main relay Battery to hella relay Pin 30 battery to buss breaker in Pin 87 on hella relay to buss breaker in Pin Z85 to breaker out Buss breaker out Buss breaker out 40 59 Drive System Drive motor 1 Drive motor 1 Drive Motor 4 2 Drive Motor 2 Parking brake Parking brake MDIATZIDODP FEN FA NY 12 6 Magnum Service Manual V1 0 ELECTRICAL SYSTEM 12 60 79 Solution System Low solution output from switch Low solution power to switch Solution Pump Power Controlled 390 420 430 Solution Pump Negative 390 420 430 Supply voltage to switch Non electronic controller machines only Deltrol valve power Deltrol valve switched power 80 119 Vacuum System 8 88 89 90 91
11. eene 11 3 THE L TERMINAL eerie uestem 11 3 BATTERY SYSTEM 11 4 BATTERY MAINTENANCE amp CARE 11 4 LEAD ACID BATTERIES 11 4 LEAD ACID BATTERIES MAINTENANCE FREE 11 4 BATTERIES e 11 4 BATTERY CABLES amp TERMINALS 11 5 BATTERY TESTING iii iii toot arae o Eoo a eE nee 11 5 HYDROMETERS a l 11 5 FEOAT TYPE 11 5 et 11 5 BATTERY REPLACEMENT ee 11 8 BATTERY CHARGERS 11 8 OFF BOARD CHARGER too bres obedece a dades 11 8 ON BOARD CHARGER nnn nnn nns 11 9 ON BOARD CHARGER TROUBLE SHOOTING 11 10 FAULT CODES 5 11 11 11 11 ELECTRICAL SVSTEM 12 1 SWITCHE S ersan 12 1 Qj Vcn 12 1 MOTORS cesta atc ec Ba a 12 1 BRUSH DECK MOTORS 12 1 VACUUM MOTOR eere ne 12 2 12 2 WIRING EET 12 2 STANDARD CRIMP 12 2
12. 1 800 634 4060 1 866 632 6961 SERVICE MANUAL NE O x QO LL D p C 9 O O XE e 04 C Og Qc a c Version 1 0 NANDVIN 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 Do not use replacement parts of lesser quality The service procedures recommended and described in this service manual are effective methods of performing service and repair Some of these procedures require the use of tools specifically designed for the purpose Accordingly anyone who intends to use a replacement part service procedure or tool which is not recommended by the equipment manufacturer must determine that neither his safety nor the safe operation of the equipment will be jeopardized by the replacement part service procedure or tool selected It is important to note that this manual contains various cautions and notices that must be carefully observed in order to reduce the risk of personal injury during service or repair or the possibility that improper service or repair may damage the piece of equipment or render it unsafe It is also important to note that these
13. 0 volt signal that is sent to the potentiometer the potentiometer outputs a varied voltage from O to 5 volts The control ler also sends a 5 volt signal to the scrub switch When the scrub switch is turned on this 5 volt signal is sent to the scrub input on the controller and the controller then looks at the in put from the solution potentiometer When either handle bar button is pushed the controller then starts the scrub brushes and sends pulses of electricity to the valve The more water requested ADJUSTING SOLUTION FLOW To adjust the solution flow use the solution potentiometer located on the control panel To increase the amount of solution turn it counter clock wise To decrease the amount of solution being dispensed turn it clockwise Changing the amount of solution dispensed is done by changing the amount of time the solution sole SOLUTION noid valve is open for every second KNOB DRAINING SOLUTION TANK Detach the solution drain sight gauge hose from the upper barb and lower into a suitable drain or receptacle When the solution has emptied reattach the hose to the upper barb 17 SOLUTION DRAIN SIGHT GAUGE CLEANING SOLUTION FILTER Drain solution tank with the drain hose Reach under the machine and unscrew and remove the clear part of the plastic filter housing Remove screen and clean Replace screen and clear part of filter housing SOLUTION FILTER 6 2 Magnum Serv
14. 92 93 94 95 96 97 98 99 U Schematics Wire Numbering protocol pdf Magnum Service Manual V1 0 Vac Motor 1 Vac motor 1 Vac motor 2 Vac motor 2 USED ON ONLY 390 420 and 430 Vac Motor Relay all except 390 420 430 High recovery light High recovery light Squeegee actuator Squeegee actuator Vacuum on signal to relay For Non Solid State controlled machines Vacuum power to circuit breaker Vac Switch Input Air Logic Vac Switch Output 2 of 5 2 17 2006 B 9 29 12 7 12 ELECTRICAL SYSTEM 120 139 Brush Drive Main Broom System Brush drive motor Brush Motor to meter Brush motor meter to circuit breaker Brush motor solenoid to circuit breaker Brush drive motor Deck Actuator Deck Actuator Deck actuator power to the circuit breaker Worn Motor Brush Indicator Worn Motor Brush Indicator 140 159 Side Broom System Side Broom Motor Right Side Broom Motor Right Side Broom Motor Left Side Broom Motor Side broom Switch Side broom Diode Side broom switch input Side broom switch output Side broom diode input side broom diode output L1 Schamatice Wire Niimherina nratacal ndf a 2 17 2006 m 12 8 Magnum Service Manual V1 0 ELECTRICAL SYSTEM 12 160 199 AUX options Back up alarm B Power Back up alarm Strobe Strobe Horn Horn Switch B Horn Switch output Headlight Headlight Filter Shaker Swit
15. Cautions and Notices are not exhaustive because it is impossible to warn of all the possible hazardous consequences that might result from failure to follow these instructions Factory Cat Tomcat service manuals are intended for use by professional qualified technicians Attempting repairs or service without the appropriate training tools and equip ment 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 No part of this publication may be reproduced stored in any retrieval system or transmit ted on any form or by any means including but not limited to electronic mechanical pho tocopying recording or otherwise with out the prior written permission of the Mid Central Corporation This includes all text illustrations tables and charts 2006 R P S Corporation Printed in U S A As our policy is one of constant improvement all specifications are subject to change without notice SAFETY SAFETY MESSAGE Your safety and the safety of others is very important and operating this unit safely is an important responsibility To help you make informed decisions about safety we have provided opera tion procedures and other safety information in this manual This information informs you of potential
16. Check to make sure the solution tank is at least 1 3 of the way full TOO MUCH TOO LITTLE Fill at least 1 3 full and re test machine as the tank a NO least 1 3 full v Disconnect the supply hose going to the Deltrol valve Disconnect the center terminal of the solution potentiometer With a voltmeter set to the DC scale measure the the voltage from the negative battery terminal to the center terminal of the potentiometer Turn the petitioner from minimum flow to maximum flow slowly and watch your meter The voltage should sweep smoothly from O volts to 5 volts 13 26 Magnum Service Manual V1 0 COMPUTER CONTROL system 3 MAGNUM WATER POTENTIOMETER DIAGNOSTIC FLOW CHART 2 of 3 While it s disconnected measure the voltage at the orange wire that was YES connected to the center terminal of the potentiometer Was there a smooth sweeping voltage from 0 to 5 volts NO Y With a voltmeter set to the DC scale measure from the negative battery cable to the red wire going to the potentiometer Was there between 0 8 and 2 7 volts With a voltmeter set to the DC scale measure from the YES black wire to the potentiometer amp the red wire going to the potentiometer YES With a voltmeter set to the DC scale back probe terminal 7 on th
17. Squeegee Pivot Points amp Knobs 00000 Deck Linkage 0 0 0 Caster grease fittings 00000 0 00 0 Squeegee Knob Threads oo ooo Bo Squeegee Pivot Pois o Brush Head Pivot Points TE VISUALLY INSPECT IN SPEC REPAIR PROBLEM Solution Tank Condition 0 0 2 Recovery Tank amp Lid Condition ff Drain Saver Vacuum Motor Brushes o ff NacuumHoses o o o o Vacuum Filter ooo o S T Solution Hoses o f Squeegee Tool and Throat 000000024 Squeegee Blades _ S o Blade retainers amp Hardware o SqueegeeWheels Brush Skits 00 o Brush Motor Brushes o 00000000002 Brush or Pad Driver Condition 0 0 Drive Wheel Condition 00 0 Caster Condition o o COMMENTS Technician s Name Technician s Signature Date Customer s Name Customer s Signature Date 2006 R P S Corporation 2of2 Magnum Service Manual V1 0 1 3 1 MAINTENANCE BLANK THIS PAGE WAS INTENTIONALLV LEFT BLANK l 4 Magnum Service Manual V1 0 MACHINE PARTS MADE IN U S A 377 1 800 457 8824 Magnum Service Manual V1 0 MACHINE INTRODUCTION 2 1 MAIN POWER SWITCH 2 FORWARD REVERSE SWITCH RED 3 SPEED CONTROL KNOB 4 LCD SCREEN 5 MENU CONTROL 6 SCRUB DECK DOWN PRESSURE SWITCH 7 SCRUB DECK SWITCH 8 SOLUTION FLOW CONTROL KNOB 9 SQUEEGEE LIFT LEVER 10 11 12 13 14 15 16 17 18 19
18. Machine Net Weight Machine Gross Weight Cleaning Width Cleaning Rate Per Hour HD Magnum 26C 32 3 4 in 83 cm 22 x 5 5 in 56 x 14 15 hp n a 750 rpm 489 Ibs 222 kg 967 Ibs 438 kg 24 in 61 cm 26 000 sq ft hr 2415 Sq meters hr 2415 sq meters hr Magnum 26D 32 3 4 in 83 cm 13 in 56 cm 5 hp 1 0 hp 270 rpm 489 Ibs 222 kg 967 Ibs 438 kg 26 in 66 cm 26 000 sq ft hr Magnum 30C 36 3 4 in 93 cm 28 x 5 5 in 59 x 14 cm 5 hp n a 750 rpm 491 Ibs 223 kg 971 Ibs 440 kg 27 in 69 cm 30 000 sa ft hr Magnum 30D 36 3 4 in 93 cm 15 in 59cm 175 hp 1 0 hp 270 rpm 491 Ibs 223 kg 971 Ibs 440 kg 30 in 76cm 30 000 sq ft hr Magnum 34C 43 3 4 in 111 cm 32 in x 5 5 in 81 x14 cm 75 hp n a 750 rpm 494 Ibs 224 kg 974 Ibs 442 kg 30 in T cm 34 000 sq ft hr Magnum 34D 43 3 A in 111 cm 17 in 81 cm 75 hp 1 0 hp 270 rpm 494 Ibs 224 kg 974 Ibs 442 kg 34in 87 34 000 sq ft hr 2787 sq meters hr 2787 sq meters hr 3159 sq meters hr 3159 sq meters hr NET WEIGHT Standard equipped machine with no options installed Empty recovery and solution tanks and no batter ies pad holder or scrub brush GROSS WEIGHT Standard equipped machine with no options installed Full solution and empty recovery tank Stan dard
19. Solder wires on to switch then slide shrink tubing down on to soldered area and use a heat gun to shrink tubing 5 Reinstall switch plate 6 Reconnect batteries RI 8 Magnum Service Manual V1 0 REPAIR INSTRUCTIONS R l 2 23 2006 253 04 DISCONNECTING BATTERIS Page 1 of 1 NUMBER OF TECHS 1 PERSON REQUIRED PARTS e NONE REQUIRED TOOLS e 9 16 12 point box wrench PLACE MACHINE ON LEVEL GROUND AND CHOCK WHEELS DISCONNECTING BATTERIES 1 Pull back the terminal cover on the right batteries positive terminal 2 Use 9 16 socket to loosen and remove the 5 16 nut amp Lock Washer 3 Pull the red cable off and secure away from post See figure below Magnum Service Manual V1 0 RI 9 R l REPAIR INSTRUCTIONS 2 23 2006 253 05 TRANSAXLE R amp R Page 1 of 4 TIME REQUIRED 45 MINUTES NUMBER OF TECHS 1 PERSON REQUIRED PARTS 32 3000 Transaxle e Qty 1 8 wire tie Qty 2 10 12 butt connectors REQUIRED TOOLS 9 16 12 Point socket 1 2 socket 6 3 8 extension Wire striper Wire cutter Wire crimper 10 amp 12 awg insulated setting Qty 2 jack stands 3 Ton jack QTY 2 2 X4 X12 BOARDS COMPLETELY DRAIN RECOVERY AND SOLUTION TANKS SEE REPAIR INSTRUCTION 253 02 MAKE SURE MACHINE IS ON LEVEL GROUND DISCONNECT BATTERIES SEE REPAIR INSTRUCTION 253 04 JACK UP MACHINE SEE REPAIR INSTRUCTION 253 06 FOR DISK MACHINE SEE REPAIR INSTRUCTION 253 07 FOR CYLINDRICA
20. and remove the QTY 1 wire tie that holds the vacuum motor wires to the 6 mounting stud see figure below Magnum Service Manual V1 0 RI 3 R l REPAIR INSTRUCTIONS 2 23 2006 253 01 VACUUM MOTOR R amp R Page 4 of 5 1 Using a side cutters remove the yellow 10 12 AWG butt connectors see figure below 2 Using 7116712 point deep well socket remove the Qty 3 1 4 20 nylock nuts that mount vacuum motor to tank 3 Remove vacuum motor see figure below REINSTLLING NEW VACUUM MOTOR 1 Reinstall new vacuum motor on tank Do not over tighten the Qty 3 1 4 20 nuts or you could damage the vacuum motor RI 4 Magnum Service Manual V1 0 REPAIR INSTRUCTIONS R l 2 23 2006 253 01 VACUUM MOTOR R amp R Page 5 of 5 2 Locate red and black wires from machine and the two black wires from new vacuum motor strip 5 16 off each end See figure below 3 Using a crimper with insolated 10 amp 12 setting connect the 10 12 butt connecters to the wires from the machine to the vacuum motor see figure below NOTE VACUUM MOTOR IS NOT POLARITY SENSITIVE 4 Using a QTY 1 4 wire tie reconnect vacuum wires to the 4 stud 5 Reconnect batteries Magnum Service Manual V1 0 RI 5 R l REPAIR INSTRUCTIONS 2 23 2006 253 02 DRAINING TANKS Page 1 of 1 NUMBER OF TECHS 1 PERSON COMPLETELY DRAINING RECOVERY AND SOLUTION TANKS 1 Make sure machine is on level ground and by a floor drain 2 Pull down on
21. any charger s DC plug from the machine while the charger is running This can cause an electrical arc that can ignite any flammable gasses that are in the area from either the batteries being charged or other environmental sources There is also the possibility of damaging the charger should it be unplugged from the DC current side while charging Magnum Service Manual V1 0 11 11 11 BATTERY SYSTEM BLANK THIS PAGE INTENTIONALLY LEFT BLANK 11 12 Magnum Service Manual V1 0 ELECTRICAL SYSTEM 12 ELECTRICAL SYSTEM The electrical system on the Magnum series is a 24 volt system This is not a chassis ground system for safety reasons SWITCHES The switches we use all have a similar face but are configured differently internally Major ity of them interface directly with the machine controller and carry low voltage signals It is important to not that when diagnosing theses machines NEVER jump battery power to the switches to test them as the controller can be instantaneously destroyed RELAYS The Magnum series uses only one relay This relay is used to power the buss bars and iso late them from the controller There are relays internally mounted in the controller but these are not serviceable The relay we use is a 24V 15A Hella relay This relay is energized by the key switch and is used to power the buss bars COIL SECTION 85 COIL LEAD 86 COIL LEAD SWITCH SECTION 30 COMMON 87 NORMALLY OPEN 87a NORMALLY C
22. gt ue p g fal lt a Q a m sp oc z c a z _ E 5 B MOLEX 6 PIN 182 EH o WHITE 261 GREEN 221 ORANGE 242 YELLOW RED WHT 220 BLACK 260 YELLOW O 29 O CON2 CON2 SWITCH PRUSH PRESSURE LOCK OUT Q MOLEX 4 PIN PINK 293 YELLOW 254 YELLOW 28 YELLOW 28 BLACK 29 29 WHITE 131 li TO BATTERIES c TO BATTERIES dda RPS CORPORATION RACINE WI 53401 ORANGE 71 BLACK 72 PINK 130 YELLOW 254 RED 183 WHITE 131 BLACK 184 BLACK 31 CIRCUIT BREAKER YELLOW 28 ji itle MAGNUM Central Command II Wiring Document Number 000 000 Magnum Service Manual V1 0 ELECTRICAL SYSTEM 12 G00Z 6Z Aepsen 000 000 JequinN jusuunsoq Apog 1100 INGQNOVIW LOvES IM 3NIOVH cl MON IA NOILVHOdMNOO SdH 8l Gay 8l Q3 MOV 1d v8l MOVIA O L MNid 1af AVHdS HOLOW 814 Q3 v8l MOV Ig Let SLIHM Le AHILLva AH3llvg 1 1 ANWA 1081140 JONVHO 4 AYALLVE cl MOV IA H3TIOHLNOO im NISHIQNV vos SETIDSHNQU GL DNId H39OHVHO H3TIOHLNOO OL OL H3TIOHLNOO OL Let 3LIHM HOLOW HShH8 HOLOW HOLVNLOV HOAC HOLOW H3TIOHLNOO OL H3TIOHLNOO OL HOLOW N3SH3QNV VSZ
23. 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 This machine is intended for commercial use It is designed to be used on hard floors only and in an indoor environment with the recommended pads and brushes with approved cleaning solutions DO NOT OPERATE THE UNIT UNLESS TRAINED AND AUTHORIZED UNLESS OPERATOR MANUAL IS READ AND UNDERSTOOD IF UNIT IS NOT IN PROPER OPERATING CONDITION WHEN OPERATING UNIT WEAR PROPER PROTECTIVE EQUIPMENT REMOVE LOOSE OBJECTS FROM THE FLOOR THAT MAY BE PROJECTED FROM THE REVOLVING BRUSHES DO NOT OPERATE THE MACHINE WHERE FLAMMABLE LIQUIDS OR GASES ARE PRESENT USE EXTREME CAUTION WHEN MANEUVERING MAKE SURE ALL PERSONS ARE A SAFE DISTANCE FROM THE MACHINE WHILE IN OPERATION BEFORE LEAVING THE UNIT PARK MACHINE ONALEVEL SURFACE MAKE SURE MACHINE IS TURNED OFF DISCONNECT BATTERIES BEFORE SERVICING SIOP ONALEVEL SURFACE AND SECURE MACHINE DISCONNECT BATTERIES 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 cau
24. itis depressed it is on Place the probe back on the center terminal of the switch blue wire Turn the switch on and measure the voltage Magnum Service Manual V1 0 COMPUTER CONTROL system 3 MAGNUM BRUSH SWITCH DIAGNOSTIC FLOW CHART 2of2 FROM FROM PAGE 1 PAGE 1 PA 33 VES With a voltmeter set to the DC volt scale measure from the negative buss bar to the rear terminal of the brush pressure switch v Replace the brush YES pressure switch Did the voltage of the terminal raise to between 4 8 and 5 2 volts when the switch was moved up Is the voltage between 4 8 and 5 2 volts 4 VES Y v With a voltmeter set to the DC scale c the ay measure from the 12 terminal on the 14 pin Molex connector on the controller to the negative buss bar Back of 14 pin Male Connector 14131211109 8 7 161514131211 Is the voltage between 4 8 and 5 2 volts Replace the 6 controller eno YES v Repaiur connection between terminal 12 of the 14 pin molex connector and the rear terminal on the brush deck switch Magnum Service Manual V1 0 13 13 13 COMPUTER CONTROL SYSTEM MAGNUM BUSS RELAY DIAGNOSTIC FLOW CHART BUSS BAR does not power up Operate machine and verify the 1 of 2 Is the YES Instruct own
25. pad holder or scrub brush and standard batteries SPEC 2 MAINTENANCE 1 MAINTENANCE MAINTENANCE SCHEDULE MAINTENANCE SCHEDULE Charge the batteries Inspect pad or brush condition Drain and clean out tanks and hoses Clean float screen amp drain saver in recovery tank Remove and clean squeegee tool Inspect for wear or damage Wipe down outside of machine Check batterv electrolvte level in all cells Check all skirts and wipers on machine Check batteries and terminals for irregularities Lubricate machine Check carbon brushes on motors Blow out dust from motors _ ATTENTIONI Make sure machine is turned off and the batteries are disconnected before performing anv repairs or service on the machinel Vour machine is equipped with four brush tvpe motors that require periodic inspection to assess wear Failure to inspect on regular intervals can result in motor damage that is not covered under warrantv LUBRICATION The machine requires periodic lubrication on each grease fitting on the machine and oiling of some pivot points and threads Once a month is generallv acceptable unless the ma chine is used in a severe dutv application The grease fittings are located on Rear casters The following points to be oiled lightly are Squeegee knob threads Squeegee adjustment threads Squeegee pivot points Brush head pivot points Magnum Service Manual V1 0 1 1 1 MAINTENANCE MAGNUM Serie
26. stop using the machine and recharge it The tops of the batteries must be kept clean and dry or they will induce a current leak across the top of the battery LEAD ACID BATTERIES MAINTENANCE FREE Some of our machines are equipped with Maintenance free lead acid batteries The ma jor difference between these and the traditional type of lead acid battery is that you can not check or fill the water in them GEL CELL BATTERIES Gel Cell batteries are a maintenance free battery design that has no liquid to spill out in the event that a machine would be tipped over or some other disaster were to occur The batteries perform well but not as well as a traditional flooded wet cell With gel cell bat teries there is no water level to check so there is less maintenance involved With gel bat teries the machine should be charged anytime it is used for any significant length of time Gel cell batteries should never be discharged below 60 of their capacity 21 volts on this machine or it will cause rapid failure of the battery 11 4 Magnum Service Manual V1 0 BATTERY SYSTEM 11 BATTERV CABLES TERMINALS The batterv cable connections must remain tight and corrosion free In the event that the batterv cables or terminals become corroded follow accepted batterv safetv precautions disassemble and clean the terminals with a baking soda and water solution and a wire brush making sure not to get anv INSIDE the batterv Once the termi
27. the charger will time out and present a fault indicator see section 5 When both the yellow and the red LED s are it is charging at the absorption rate Stage 2 During this second charging stage the charger holds the battery voltage at approximately 29 VDC and gradually reduces the amount of current delivered to the battery If an excessive amount of time is taken to complete this stage the charger will time out and present a fault indicator see section 5 When all three charge status LEDs are on the model 2820 24 03 is charging at a Finish rate of 5 Amps Stage 3 The Finish stage will charge the battery up to approximately 30 5 32 VDC If an excessive amount of time is taken to complete this stage the charger will time out and present a fault indicator see section 5 When the green 1 LED is on and red and yellow are off the charge cycle is completed and the battery is ready for use At least 100 of charge has been returned to the battery If the battery voltage falls below approximately 24 VDC the charger will automatically restart the charge process Magnum Service Manual V1 0 11 9 11 BATTERY SYSTEM ON BOARD CHARGER TROUBLE SHOOTING Red LED stays on for One or more defective or damaged cells Load test the batteries and replace if more than 18 Hrs Charger has reduced its output voltage below the normal necessary level due to a DC overload or a DC short Remove the source of
28. the controller With an ohm meter measure the resistance between the two terminals on the back of the e stop switch that the wires are connected to With the button popped up you should have 0 2 ohms or less of resistance NO Do you have 0 2 ohms or Magnum Service Manual V1 0 less of resistance Leave the 6 wire connector for the LCD display unplugged and turn the machine off and then back on again Observe the machine s operation the factory ja Does the machine Replace the LCD YES work properly Display now 13 17 13 COMPUTER CONTROL SYSTEM KEY SWITCH does not work Operate machine and verify the customers complaint Does the switch MAGNUM KEY SWITCH DIAGNOSTIC FLOW CHART 1 of 1 Instruct owner on YES proper machine work properly NO 7 operation Using a voltmeter set to DC volts Connect the probe of the meter to the buss bar With the positive meter lead measure at the terminal on the kev switch that has a yellow wire 64 attached to it This wire runs from the controller to the key switch Using a voltmeter set the meter to DC volts Connect the probe of the meter to the buss bar With your positive meter probe back probe the 8 terminal on the 20 pin Back of 20 pin Male Connector 20 1911817 116 15 14 13 12 T1 109 54 3421
29. the speed of the motor This is a much more efficient way of running an electrical device at less than 100 operation CONTINUITY TESTING Four of the outputs traction drive parking brake brush amp vacuum have a continuity check ing feature that monitors the device and the wiring to it from the controller for an open circuit This monitoring can be turned on and off for each circuit independently through the programming of the controller Magnum Service Manual V1 0 13 1 13 COMPUTER CONTROL SYSTEM SOFT START Three of the outputs traction brush amp vacuum have a soft start function on them This function provides the ability to start and stop a motor gradually over a measured period of time 0 10 seconds This aids in the longevity of the motors and anything driven by them as it greatly decreases the shock load on them The soft start settings are changed through the controller programming CONNECTIONS There are 3 different types of connections that are used on the controller MOLEX MINI FIT JR The Molex Mini Fit Jr connectors are used for all of the inputs and the low amperage out puts They require special tools to service and replace them See the Electrical System section 12 for serving information AMP TERMINALS The AMP terminals are specially designed terminals capable of handling high amperage connections These are used on the high amp outputs on the V 3 controls See the Elec trical System Sec
30. to the amp value of the current brush pressure setting If the motors are not drawing enough amps the controller lowers the brush deck to increase the brush pressure on the ground and therefor raise the amp draw of the motors If the amp draw of the motors is higher than the target amp value the controller raises the brush deck to relieve down pressure from the brush deck therefor reducing the amp draw of the brush motors because they can then turn more easily Macnum MADE IN U S A 1 800 634 4060 BAR GRAPH dee BRUSH PRESSURE SWITCH 7 2 Magnum Service Manual V1 0 BRUSH DRIVE SYSTEM 1 INSTALLING amp REMOVING BRUSHES DISC MACHINES With the machine turned on turn off the brush deck switch Turn machine power off Open the two latches on the jaws and swing them aside Rotate each brush until both tabs of the spring clip are accessible Squeeze the two tabs together and the brush will drop off If the brush deck does not raise high enough to remove the brushes Turn the machine power on for 10 seconds and then off again Then try removing the brushes again If the brushes still can not be removed due to lack of space the actuator or linkage must be adjusted To install a brush reverse the procedure CYLINDRICAL DECK With the brush deck raised remove the side access door from the scrub deck Grasp the scrub brush and pull and it will slide off the brush driver and out from under the scrub deck To in
31. tool and recovery system The optimal performance of a squeegee is very dependent on proper adjustment and main tenance The machines recovery system also must be operating properly for the squeegee to perform well A vacuum gauge is a handy tool for checking recovery system operation You should be able to achieve 65 of water lift on most models Put the vacuum gauge in the end of the squeegee hose to check If you have questions on this tool setup call the factory at 800 634 4060 SQUEEGEE SYSTEM COMPONENTS The squeegee tool with replaceable rollers amp blades A suspension that mounts the squeegee to the machine and allows the squeegee to move up and down with variations in the floor and pivot in turns A lift system that allows the operator to raise the squeegee off the floor The machine has a manual lift lever standard but an electric lift op tion is available Magnum Service Manual V1 0 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 N 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 re placed Make sure the plate moves up and down eas
32. 20 21 22 SPRAV JET BLUE OPTIONAL ELECTRIC SQUEEGEE LIFT GREY OPTIONAL RECYCLING SWITCH GREEN OPTIONAL ON BOARD SOAP SYSTEM WHITE OPTIONAL EMERGENCY STOP OPTIONAL CHARGER PORT KEY SWITCH OPTIONAL SERIAL NUMBER PLATE Machine identification WARNING PLATE WARNING PLATE TRACTION DRIVE SOLUTION FLOW VALVE SOLUTION FILTER 20 TRACTION DRIVE 21 SOLUTION FLOW VALVE 22 SOLUTION FILTER 2 MACHINE INTRODUCTION 33 34 35 SOLUTION LEVEL INDICATOR amp DRAIN 3 38 VACUUM HOSE AO 20 TRACTION DRIVE 21 SOLUTION FLOW VALVE 22 SOLUTION FILTER 23 DRIVE BUTTON 24 DRAIN SAVER STRAINER 25 VAC SCREEN 26 CASTER 2 MAIN TIRES 28 JAWS 29 POLYURETHANE ROLLERS 30 TANK IN TANK 31 SOLUTION FILL LID 32 RECOVERY LID CLEAR COVER CONTROL PANEL RECOVERY DRAIN HOSE ON BOARD BATTERY CHARGER SQUEEGEE BLADE SQUEEGEE PITCH ADJUSTMENT 2 2 Magnum Service Manual V1 0 MACHINE INTRODUCTION 2 CONTROL DESCRIPTION 1 MAIN POWER SWITCH Turns the machine on and off 2 FORWARD REVERSE SWITCH RED Makes the machine move backwards when depressed 3 SPEED CONTROL KNOB Controls the speed of the Traction Drive 4 LCD SCREEN Lists status functions and settings of the machine 5 MENU CONTROL Scrolls through different options on the LCD Display 6 SCRUB DECK DOWN PRESSURE SWITCH Controls the pressure put on the Scrub deck 7 SCRUB DECK SWITCH Raises
33. BE NO LESS THEN DEFLECTOIN AND NO MORE THEN 77 DEFLECTION 3 Using a 9 16 open end wrench retighten the locking nut 4 Using a 9 16 CROWS FOOT retighten the QTY 4 3 8 24 1 bolts that are behind sprocket 5 Reinstall cylindrical belt and brush accesses door 6 Reconnect batteries RI 18 Magnum Service Manual V1 0 REPAIR INSTRUCTIONS R Magnum Service Manual V1 0 RI 19 R l REPAIR INSTRUCTIONS RI 20 Magnum Service Manual V1 0 Index S SQUEEGEE SVSTEM 3 1 LIFT SVSTEM 3 1 SQUEEGEETOOL 3 1 Magnum Service Manual V1 0 l Magnum Service Manual V1 0 Magnum Service Manual V1 0 lil 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 oper ating this unit You must use your own good judgement This is intended for commercial use It is designed to be used on hard floors only and in an indoor environment with the recommended pads and brushes with ap proved cleaning solutions DO NOT OPERATE THE UNIT UNLESS TRAINED AND AUTHORIZED UNLESS OPERATOR MANUAL IS READ AND UNDERSTOOD IF UNIT IS NOT IN P
34. Clean and dry the machine after neutralization and removal of any acid The batteries should be installed in a clean and dry machine When installing batteries a terminal protectant should be used to help inhibit battery termi nal corrosion It is important to use a product specifically designed for this and not things like grease silicone or paint Read and follow the directions on the can of protectant ex actly to prevent terminal or cable failure BATTERY CHARGERS There are 2 different chargers available for the Magnum series machines We offer an off board charger standard with the machine and an on board charger is available as an op tion OFF BOARD CHARGER The standard charger supplied with the Magnum is a fully automatic charger To operate the charger all that needs to be done is plug it into the machines charger port and then plug it into the wall Once the charger is plugged into both the charger port on the machine and a wall outlet it will run until the batteries are fully charged and then shut off It is important to let the charger finish its charge cycle before disconnecting it as the last few hours of a charge cycle are very important The charger has an amp meter on the face of it to show how much electricity is being put into the batteries and it gives some idea of where the charger is in its cycle Typically on a good set of batteries when you plug in the charger and it turns on the meter will move rapidly to the high
35. ERS Helps protect machine when scrubbing near walls 30 TANK IN TANK Solution Recovery Tank 30 gallon capacity each 31 SOLUTION FILL LID Fill port for filling Solution Tank 32 RECOVERY LID Allows unfettered access to the Recovery Tank allowing it to be completely cleaned with fresh water 33 CLEAR COVER For observing Recovery Tank status while operating machine 34 CONTROL PANEL Houses machine controls 35 RECOVERY DRAIN HOSE Allows for controlled draining of Recovery Tank 36 SOLUTION LEVEL INDICATOR amp DRAIN TUBE Shows precise level of cleaning solution in Tank amp serves as a Drain Port 37 ON BOARD BATTERY CHARGER Recharges batteries 38 SQUEEGEE BLADE Recovers dirty water from the floor to be recovered by the Vacuum Hose 39 VACUUM HOSE Squeegee NOTE Keep free and clear of blockage 40 SQUEEGEE PITCH ADJUSTMENT Adjusts pitch of Squeegee Deflection should be even across the entire blade Magnum Service Manual V1 0 2 3 2 MACHINE INTRODUCTION BLANK THIS PAGE WAS INTENTIONALLV LEFT BLANK 2 4 Magnum Service Manual V1 0 SQUEEGEE SVSTEM SQUEEGEE SVSTEM 4 Magnum s squeegee system is designed to work with the recovery system to pick up water and dirt from the floor using air flow created by the vacuum motor The front blade of the squeegee tool is designed with notches that allow the air water and dirt to pass through it while metering the air increasing its speed through the
36. IFT SYSTEM 8 1 BRUSH LIFT ELECTRICAL CIRCUIT ccnn 8 1 DOWN PRESSURE 8 2 BRUSH LIFT SYSTEM ADJUSTMENTS 8 2 BRUSH LIFT ACTUATOR 8 2 ACTUATOR ADJUSTMENT 8 3 LINKAGE 95 8 3 ADJUSTMENT SCREW WITH JAMB 8 3 TRACTION DRIVE SYSTEM 9 1 TRACTION DRIVE ELECTRICAL CIRCUIT 9 1 AALE erc T Hm 9 1 DRIVE MOTOR 5525600 bes cbvec eae 0v E P da 9 1 TIRES amp WHEELS a a ia Ba b 9 1 CHASSIS SYSTEM 10 1 CHASSIS REPLACEMENT cccssccsesssscssscsssccssccssecssesssccssccsscessses 10 1 TIRES A 10 1 CASTERS iii i VsELD ia 10 1 toc il Magnum Service Manual V1 0 TABLE OF CONTENTS TQ C BATTERV SAFETY 11 1 DANGER OF EXPLODING BATTERIES 11 1 SAFE CHARGING 3 al 11 1 HANDLING BATTERY 11 2 WATER area grea e esate ct earn eet M 11 2 BATTERY TERMINAL TVPES nn rnnnnn nn nanna 11 2 TAPERED TOP TERMINAL S A E POST 11 2 STUD TERMINAL tren eroi ERE 11 3 COMBINATION TERMINAL
37. IR INSTRUCTIONS R l 2 23 2006 253 01 VACUUM MOTOR R amp R Page 1 of 5 TIME REQUIRED 30 MINUTES NUMBER OF TECHS 1 PERSON REQUIRED PARTS e 290 250 Vacuum motor e Qty 1 4 wire tie Qty 2 10 12 butt connectors REQUIRED TOOLS e 16 12 Point deep well socket 9 16 12 Point socket 6 318 extension Wire striper Wire cutter Wire crimper 10 amp 12 awg insulated setting COMPLETELY DRAIN RECOVERY TANK AND SOLTION TANK PLACE MACHINE ON LEVEL GROUND AND CHOCK WHEELS MAKE SURE MACHINE POWER SWITCH IS IN OFF POISTION TIPPING BACK TANK TO SERVICE VACUUM MOTOR 1 Release latch on the right and left of machine see figure below Magnum Service Manual V1 0 RI 1 R l REPAIR INSTRUCTIONS 2 23 2006 253 01 VACUUM MOTOR R amp R Page 2 of 5 2 Release the latch on the front of the jaws and open them see figure below NEED PITCHER WHEN NEW PARTS ARE HERE 3 Carefully tip tank back see figure below DISCONNECTING BATTERIES 1 Pull back the terminal cover on the right batteries positive terminal 2 Use 9 16 socket to loosen and remove the 5 16 nut amp Lock Washer RI 2 Magnum Service Manual V1 0 REPAIR INSTRUCTIONS R l 2 23 2006 253 01 VACUUM MOTOR R amp R Page 3 of 5 3 Pull the red cable off and secure away from post See figure below VACUUM MOTOR IS LOCATED ON THE BOTTOM SIDE OF RECOVERY AND SOLTION TANK see figure below REMOVING VACUUM MOTOR 1 Using a side cutters cut
38. L MACHINE RI 10 Magnum Service Manual V1 0 REPAIR INSTRUCTIONS R l 2 23 2006 253 05 TRANSAXLE R amp R Page 2 of 4 REMOVING TRANSAXLE 1 Using a 1 2 socket remove the Qty 4 5 16 nuts that hold each tire on axle Remove tiers 2 Cut the wire tie that is around the wires harness located in the right rear tier compartment Wires should drop down Locate the two 10 12 butt connecters Cut butt connecters off The wires that lead from transaxle to wire harness See figures below Install the QTY 2 27 47 12 boards on top of each other under the transaxle motor housing see figure below RI 11 Magnum Service Manual V1 0 R l REPAIR INSTRUCTIONS 2 23 2006 253 05 TRANSAXLE R amp R Page 3 of 4 4 Mark transaxle mounts and frame on both sides of machine before removing see figure below 5 Using a 112 socket remove the Qty 2 5116 18 nuts that hold the each Qty2 axle mount to frame 6 Remove transaxle mounts See figure below 7 Remove 2 x4 x12 boards while supporting axle 8 Remove transaxle slowly See figure below RI 12 Magnum Service Manual V1 0 REPAIR INSTRUCTIONS R l 2 23 2006 253 05 TRANSAXLE R amp R Page 4 of 4 REINSTALLING TRANSAXLE 1 Strip red and black transaxle wires 5 16 Strip red and black harness wires 5 16 Crimp butt connectors on to transaxle wires Carefully put new transaxle into position Carefully put 2 x4 x12 boards under new
39. LOSED MOTORS The motors that are used through out the machine are designed to be very durable and give long service life BRUSH DECK MOTORS The brush deck motors are DC permanent magnet gear reduction type they output large amounts of power for scrubbing The motor brushes are replaceable and are rated to give 2000 hours of service life See the Brush Drive System chapter 7 for more information Magnum Service Manual V1 0 12 1 12 ELECTRICAL SYSTEM VACUUM MOTOR The vacuum motor is a very high speed motor that develops vacuum for the recovery sys tem The motors are designed to give a service life of 500 hours See the Recovery Sys tem chapter 5 for more information ACTUATORS The Magnum uses only one actuator This actuator is for lifting the brush deck This is a heavy duty 500 Ib actuator that has internal limit switches See the Brush Lift Section Chapter 8 for more information WIRING The wiring on the machine is numbered for easy circuit determination and to be easy to trace We over size our wiring to eliminate failures and for safety reasons We use a number of different wire terminals on our machines and some require special tools to properly service or replace them STANDARD CRIMP ON TERMINALS The standard crimp on terminals we use on our equipment should be crimped with a posi tive stop ratchet type crimpers The correct color coded terminal must be installed for the machine to operate prope
40. NT A squeegee needs to be adjusted to the tvpe of surface that it is operating on This means the adjustments that pick up well on rough concrete will probablv not work well on glass smooth vinyl tile or ceramic The reverse would hold true also squeegee set up for a smooth surface will not work well on rough surfaces As a squeegee wears the dynamics or condition of the blades change sometimes requiring small adjustments or sometimes requiring a blade turning or change Our squeegee system has only one operator serviceable adjustment That adjustment is the thumb wheel directly in front of the squeegee blade By turning this knob you pivot the squeegee back and forth increasing or decreasing the amount of air allowed into the squeegee under the bottom of the front blade The basic adjustment you are trying to achieve is to have the squeegee PERFECTLY parallel with the floor From that point rock ing the squeegee forward about one half degree of pitch will reduce air leak Rocking the squeegee backwards about one half degree will increase the air leak PITCH ADJUSTMENT KNOB The triangular shaped plate that the squeegee bolts to is adjustable for a slight amount of up down pitch As you turn the knob the pitch of the squeegee changes Turning the knob clockwise lowers the front blade of the squeegee thereby closing off the air holes against the floor This increases suction on the floor If you adjust it too far for ward you can cau
41. QUEEGEE ADJUSTMENT EXAMPLES SQUEEGEE WHEEL ADJUSTMENT SQUEEGEE LIFT SYSTEM TO OPERATE iiv SQUEEGEE LIFT ADJUSTMENTS SQUEEGEE LIFT ELECTRICAL CIRCUIT RECOVERY SYSTEM RECOVERY LIB iiia DRAIN SAVER eret a VACUUM FLOAT erret BAFFLE ASSEMBLY DRAIN HOSE iieri tee VACUUM MOTOR VACUUM SAVER Magnum Service Manual V1 0 TABLE OF CONTENTS TO C toc i TQ C TABLE OF CONTENTS SOLUTION SYSTEM 6 1 DISPENSING 219 6 1 ADJUSTING SOLUTION 6 2 DRAINING SOLUTION TANK 6 2 CLEANING SOLUTION 6 2 SOLUTION SYSTEM ELECTRICAL 6 2 SOLUTION SYSTEM DIAGNOSIS FLOW CHART 1 OF 2 6 3 SOLUTION SYSTEM DIAGNOSIS FLOW CHART 2 OF 2 6 4 BRUSH DRIVE SYSTEM 7 1 G 7 1 7 1 BRUSH DRIVE ELECTRICAL CIRCUIT 7 1 SETTING BRUSH PRESSURE 7 2 INSTALLING amp REMOVING BRUSHES e 7 3 DISC MACHINE S corate a Ea 7 3 CYLINDRICAL DEGCNK i A it 7 3 BRUSH L
42. ROPER OPERATING CONDITION WHEN OPERATING UNIT WEAR PROPER PROTECTIVE EQUIPMENT REMOVE LOOSE OBJECTS FROM THE FLOOR THAT MAY BE PROJECTED FROM THE REVOLVING BRUSHES DO NOT OPERATE THE MACHINE WHERE FLAMMABLE LIQUIDS OR GASES ARE PRESENT USE EXTREME CAUTION WHEN MANEUVERING MAKE SURE ALL PERSONS ARE A SAFE DISTANCE FROM THE MACHINE WHILE IN OPERATION BEFORE LEAVING THE UNIT MAKE SURE MACHINE IS TURNED OFF PARK MACHINE ONALEVEL SURFACE DISCONNECT BATTERIES BEFORE SERVICING SIOP ONALEVEL SURFACE AND SECURE MACHINE DISCONNECT BATTERIES SAFETY SAFETY PRECAUTIONS Hazardous voltage Shock Burns or electrocution can result ALWAYS disconnect the batteries before servicing machine e Batteries emit hydrogen gases explosion or fire can result Keep sparks and open flame 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 Prevent from getting electrical components wet The use of parts and solutions other than recommended by the manufacturer may cause property damage bodily injury or death to yourself or others Dress safely Do not wear rings watches or other jewelry while working on this machine They can cause an electrical short which can cause serious burns other injury or death
43. SAE standards so that all SAE style clamps will fit any bat tery with these posts The negative terminal is made slightly smaller than the positive to reduce the possibil ity of hooking up a battery in reverse 11 2 Magnum Service Manual V1 0 BATTERY SYSTEM 11 STUD TERMINAL The stud terminal is tvpicallv used on heavv dutv batter ies The terminals have a stainless steel threaded stud embedded in them that the connections are made to COMBINATION TERMINAL The combination terminals come in a few different configurations The two most common configurations are the side bv side and the stacked In the side bv side there is a tapered top terminal with a stud terminal right next to it In the stacked configuration the stain less steel stud is embedded into the taper top terminal The combination terminals make it possible to use the batterv with a varietv of equipment without having to change the cables on it CAUTION The stacked tvpe combination battery terminals are very tall in compari son to all other configurations Make sure to check all clearances before trying to close a cover or a tank on top of these types of batteries THE L TERMINAL The L type terminal is used on many special applica tion batteries Magnum Service Manual V1 0 11 3 11 BATTERY SYSTEM BATTERY SYSTEM The battery system for the Magnum series consists of either 2 12 volt or 4 6 volt deep cycle batteries They a
44. The Magnum is equipped with a vacuum save demising chamber that allows the moisture that gets through the recovery tank The vacuum saver is a chamber that allows moist air to condense and has an automatic drain valve to empty the chamber each time the vacuum motor is turned off Magnum Service Manual V1 0 5 3 RECOVERY SYSTEM MAGNUM RECOVERY SYSTEM DIAGNOSTIC FLOW CHART Machine is not picking up water Instruct customer on how to operate their machine A Did this remedy the problem Verify customer 1 of 3 Is there a Instruct customer on NO how to operate their machine Repair or replace y parts as needed Retest machine Did this remedy complaint problem Retest the YES machine Emoty tank and Is the recovery d pr tank empty and the clean Drain ti E NO Drain Saver Saver and float and float ball ball cage cage clean YES Are the gaskets the clear recovery lid and the stainless recovery NO tank door in good condition YES Turn on vacuum NO Is the vacuum switch NO switch turned on Does the vacuum GO to vacuum motor diagnosis motor run section A VES VES v Verify Machine operation NO Does the vacuum motor run NO YES GOTO PAGE 2 Magnum Service Ma
45. This creates squeegee chatter Refer to squeegee adjustment section pg 3 5 Triangle plate is bent where the squeegee attaches Replace Squeegee Leaves Water Squeegee is actually working properly but the operator has unreal expectations Educate the operator Squeegee pitch out of adjustment Adjust Floor is extremely rough Use a solid front blade to control air better Back blade is worn out Rotate or replace blade Squeegee tool is bent amp leaking Replace tool Squeegee suspension is bent Replace bent components Operator sees water left on very hard turns Educate the operator on making more gradual turns or to shut off the water before entering a turn Squeegee howls or trumpets Squeegee is creating too much a suction on the floor Adjust squeegee to allow more air to enter from the front blade Counter clockwise adjustment Squeegee is creating too much a suction on the floor Reverse front blade so five notches face downward to allow more air flow Squeegee needs too much adjustment Customer has a varied floor surface Some of the floor is smooth other parts are very rough Frequent adjustment is normal and will be required Adjustment knob spring is missing incorrect or damaged Replace Blades wear out very quickly Floor is very rough Switch to Linatex rubber red blades which is very resistant to abrasion Floor is oily or a harsh cleaning chemical has made the blade deform Change to polyur
46. ace change The amp draw has a target value and the controller works to keep the motors at the selected amp draw by increasing or decreasing brush pressure The target pressure is represented on the LCD display and changed using the brush pressure switch on the control panel 13 2 Magnum Service Manual V1 0 COMPUTER CONTROL SYSTEM 3 LCD DISPLAY The LCD display is a multi function display that conveys machine information to the opera tor about the operation state of the machine and diagnostic information in the event of a malfunction The LCD display communicates to the controller on a serial data connection that is made via the 6 wire connector running from the display to the controller The LCD display has 4 different screens with different information presented on each SCREEN 1 Screen 1 is the default screen that appears after the machine has powered up 1 BATTERY METER This meter shows the charge level of the batteries in the machine This gauge is designed to read properly while the machine is in use and therefore will vary during usage of the machine 2 BRUSHES RUNNING This icon shows when the controller 1 BATTERY METER 2 BRUSHES RUNNING receives an input to run the scrub brushes A ROEN 4 BRUSH PRESSURE GAUGE 3 SOLUTION DISPENSING This icon indicates that the con 5 VACUUM MOTOR OPERATING troller is receiving an input to dispense water The icon flashes HIGH THROTTLE in relationship to the amo
47. akes the machine operate a certain way All inputs at the controller with the exception of the throttle input are at a voltage of 0 8 to 2 6 volts when they are ata neutral or un switched state When a signal is sent to an input via a switch it is either a LOW or HIGH reference signal The computer monitors the input terminal many times a second and when the voltage of it changes the computer reacts accordingly to the pro gram in it changing the outputs of the controller INPUTS VARIABLE VOLTAGE It addition to the standard tri state logic inputs the controller also used varied voltage inputs Examples of these inputs would be the throttle and the solution circuit On these inputs the a high and low signal are fed to a 5K potentiometer on each of the outside terminals The voltage is summed by the potentiometer and the summed voltage is sent out the center terminal of the potentiometer to the input terminal on the controller As the potentiometer is rotated the center wiper contact inside increases or decreases it s distance from the high reference signal creating a sweeping voltage from about 0 0 volts to 5 1 volts This sweeping voltage is interpreted by the controller and the outputs are then controlled according to the program OUTPUTS The outputs of the controller are controlled by the embedded computer and it s program It iterprets the inputs and energizes the out puts accordingly The outputs on the control ler are driven b
48. all models but the 390 the 390 mea surement is 1 3 8 lf this dimension is incorrect you will never get the squeegee blade adjusted properly If you believe you are having problems with this adjustment please call the factory 800 634 4060 SQUEEGEE BLADES oqueegee blades are wear items The back blade wears fastest on the edge that contacts the floor lower front edge This blade can ideally be turned four times It is important to have a sharp squeegee edge on the floor otherwise the squeegee does not scrape the water off the floor but instead glides right over it Magnum Service Manual V1 0 3 3 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 wheels We recommend changing wheels when you change blades as they are wear items and they are critical to the proper operation of the squeegee When installing blades they must be put on without bumps or ripples The squeegee should have a smooth edge that rides on the floor When adjusting the blades you need to achieve a uniform fanning of the blade from one tip to the other If the blade does not do this it is installed incorrectly or misadjusted When changing or turning squeegee blades it is very imp
49. and lowers the Scrub deck 8 SOLUTION FLOW CONTROL KNOB Turn clockwise to reduce amp outer clockwise to increase flow 9 SQUEEGEE LIFT LEVER Raises and lowers Squeegee 10 SPRAY JET BLUE OPTIONAL Activates Spray Pump for remote Spray Wand 11 ELECTRIC SQUEEGEE LIFT GREY OPTIONAL Electronically raises and lowers Squeegee 12 RECYCLING SWITCH GREEN OPTIONAL Turns on the Recycling Pump 13 ON BOARD SOAP SYSTEM WHITE OPTIONAL Dispenses soap into Solution Tank 14 EMERGENCY STOP OPTIONAL Shuts off power to the machine 15 CHARGER PORT Port for plugging an external charger into the machine Use only the charger supplied with the machine 16 KEY SWITCH OPTIONAL Turns power on to the machine Prevents unauthorized operation 17 SERIAL NUMBER PLATE Machine identification 18 WARNING PLATE Detergent Water warning 19 WARNING PLATE Explosion warning 20 TRACTION DRIVE Propels machine forward backward 21 SOLUTION FLOW VALVE Controls solution flow rate when solution switch is on 22 SOLUTION FILTER Filters water solution prior to scrubbing 23 DRIVE BUTTON Depress to drive forward release to stop starts amp stops the scrub motor 24 DRAIN SAVER STRAINER Helps prevent clogging of drain hose 25 VAC SCREEN Protects Vac Motor from debris 26 CASTER Twin casters for stability 27 MAIN TIRES Non Marking tires 28 JAWS Protects Scrub deck from collision damage 29 POLYURETHANE ROLL
50. and raise the drive wheels off the floor Using a voltmeter set the meter to DC volts Connect the probe of the meter to the drive motor terminal and the probe of the meter to the drive motor terminal Depress the throttle pedal fully and read the voltage Is the YES motor receiving wheels forward by Hand at the same 9 the motor Repair connection between at least 10 volts NO Y Using a voltmeter set the meter to DC volts On the controller back probe the and traction motor wires Depress the throttle pedal fully and read the voltage Is there at least 10 the controller output and the drive motor 13 16 MES volts at the terminals NO y oni conor Magnum Service Manual V1 0 COMPUTER CONTROL system 3 MAGNUM EMERGENCY STOP DIAGNOSTIC FLOW CHART Operate machine 1of1 Does the Instruct owner on EMERGENCY STOP and verify the EMERGENCY YES SWITCH does not work customers STOP work operation complaint properly Replace the Can you EMERGENCY STOP NO depress the E SWITCH ASSEMBLY top button A YES oes the button pop back when turn the knob to the right YES Disconnect the 6 wire connector going to the LCD display from
51. and repair To diagnose the system a clamp type DC amp meter and high impedance DC Volt meter are required The machine s LCD display will also be utilized It is important never to use jumper wires connected to battery power or ground for testing as this can instantly destroy the controller The controller is not field serviceable in any way and needs to be replaced in the event of failure METERS It is important to use a high quality meter when diagnosing the control systems on our equipment as a low quality meter can ruin a controller just by taking a measurement A good rule of thumb is if you didn t pay at least 50 for your meter don t use it on our equip ment NEVER use analog meters for diagnosing the controller systems on our machines as they WILL damage the machine A DC amp clamp is imperative for diagnosis of the control systems most DC amp clamps have a built in DC volt meter too In addition to your meter s you should have a quality set of test leads that have alligator clamps on the ends MEASUREMENTS When measuring for voltage in the control system unless otherwise specified you will al ways set your meter to the DC volts scale and connect your negative test lead to the negative battery cable or buss bar When measuring for amp draw you will always measure around ONLY 1 wire OR going to the device in question Place the meter clamp on the wire with power off to the device Zero out the meter and then pow
52. assure a good solid connection ANDERSON ANDERSON MANUAL CONNECTOR CONTACT STAKING TOOL Magnum Service Manual V1 0 12 3 1 ELECTRICAL SYSTEM 5 4 3 2 1 O 0 MOLEX 3 PIN MOLEX 6 PIN 9 WITCH HANDLEBAR is SWITCH HANDLEBAR POT SPEED olo SWITCH PAGE SES SWITCH MAIN POWER WHITE 234 RED WHT 294 gt RED WHT 241 o o SIS BLACK 233 GREEN 295 lt lt GREEN 232 d D mja SWITCH BRUSH PRESSURE Q E MOLEX 16 PIN b e S S SWITCH SCRUB Me BLACK WHT 243 O l o O RED WHT 250 LLI O gt 5 x SIE MOLEX6PIN MOLEX 14 PIN LIT x O x fix ju E N IG lt SWITCH REVERSE m id LI e 233 S Ie 2 L a BLACK 260 E ra RED 27 RED 27 1 YELLOW YELLOW ID ILI YELLOW E 0 25 QUICK CONNECT RED 202 ra YELLOW 201 511 PINK 293 p BLUEZ251 RED 182 L1 jJ c zi 4 WHITE 234 bid 233 MAIN BUSS RELAY im gt GREEN 232 ra a a y 2 LU LU 2 a r2 ol RED WHT 253 m 5 1 5 BIS 5 SWITCH SPRAV JET 9 Sit 5 TIT m ale ale o MINI us RED 30 8 Rake Re es 22 N 3c S CY IN N FEE mja Z se Lu o N c N I
53. cell in the battery pack to check it s specific gravity HYDROMETERS There are 3 types of hydrometers typically available We do not recommend the floating ball type as they are not very accurate and give minimal information regarding the batteries condition The traditional float type hydrometer and the EZ Red or dial type hydrometer give a numeric reading of each battery cell s state of charge FLOAT TYPE DIAL TYPE Magnum Service Manual V1 0 11 5 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 hvdrometer 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 1 160 to 1 325 Do not assume a battery will not take a charge because you have been charging it for a while and the float will not rise The battery may have been fully discharged and will require considerable charging time before reaching the minimum specific gravity on the float The lower the float sinks in the electrolyte the lower its specific gravity The proper way to read a hydrometer is to dray electrolyte into the body of the hydrometer while holding it ver tically so the
54. ch Input B Filter Shaker Switch Output Filter shaker motor Spray Jet Switch B Spray Jet Switch Output Spray Jet B to recycling switch Recycling Switch output Recycling B B to side broom water switch Output from side broom water switch Side broom water B LIS chematicsWire Niimherina nratacal ndf 2 a 2 17 2006 m Magnum Service Manual V1 0 12 9 12 ELECTRICAL SYSTEM 200 299 Central Command System 201 C3 8 202 18 210 5V Ref 211 220 5V Ref 221 C3 11 222 C2 5 223 C3 11 230 231 232 5V Ref 233 234 OV Ref 240 241 5V Ref 242 C2 7 243 OV Ref 250 5V Ref 251 253 5V Ref 254 C3 2 255 OV Ref 260 OV Ref 261 C3 13 2 0 C3 14 2 1 5V Ref 280 C1 1 281 C1 2 282 C1 3 283 C1 4 284 C1 5 285 C1 6 290 291 292 293 294 5V Ref 295 296 OV Ref 297 Il XSchematiraw Wire Niimherina nratacal ndf 12 10 Battery Power from the Penny amp Giles to the main key switch Power from the main or key switch back to the P amp G controller One Touch switch power in One Touch switch output Vac Squeegee Switch Ref Vac Squeegee Switch Output Vac Wand Switch Ref Vac Wand Switch Output Handle bar buttons in From center tap of speed pot Handle bar buttons out Speed Pot High Speed Pot Center Speed Pot Low Solution Switch Solution Pot High Solution Pot Center Solution Pot Low Brush Switch input Brush Switch Output Momentarv Brush Pressure switch Terminal 1 Momentarv Brush Pressure switch Te
55. controls the height of the squee gee wheels 3 2 Magnum Service Manual V1 0 SQUEEGEE SVSTEM 3 TRIANGLE PLATE amp TOW BAR These parts cannot be bent at all They must be completely straight and flat If either is bent replace it If you replace the triangle plate adjust the clearance between the bottom of the plate and the top of the tow bar so clearance is 7 8 22 mm Squeegee will not work properly if this adjustment is off UP DOWN MOVEMENT The squeegee must be able to travel up and down freely so it can glide over bumps and uneven floors Itis hinged at the front as shown If the squeegee suspension does not move up and down properly check the bolts and the Oilite bushings at the pivot point If the bolts are too tight may have been tightened by customer by mistake or the bushings are dried out or worn the squeegee will not be able to float properly SIDEWAYS MOVEMENT The squeegee must be allowed to move from side to side so that if it hits an obstacle it can move out of the way If squeegee does not move freely from side to side check the bolt tension on the two pivot bolts Check that the white plastic washers between the pivot plate and the trailing arm to make sure they are not damaged In order for the squeegee system to operate properly the parts have to be assembled properly The space between the bottom of the Squeegee triangle plate E and the squeegee trail arm C must be exactly 7 8 on
56. covery tank is filled to capacity BAFFLE ASSEMBLY The baffle assembly is also located inside the recovery tank and accessed by opening the re covery tank lid The baffle adds rigidity to the tank walls and lessens the sloshing of the water inside the recovery tank To clean the vacuum float RETAINING CLAMP t gt B HE H SCREEN 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 DRAIN HOSE To drain the recovery system we have a poly hose with an integrated flow control feature By squeez ing the hose you can control the flow of the recov ery tank as it is being emptied The hose cap is attached to the hose with a tether to help prevent loosing it 5 2 Magnum Service Manual V1 0 RECOVERY SYSTEM 4 VACUUM MOTOR The vacuum motor used on the Magnum series scrubbers is a high efficiency shunt would motor The motor runs a approximately 12 000 RPM The motor is rated at 550 watts and has 72 of water lift Although the motor has service parts available it is advised to replace the entire motor as all the motor parts have about the same life and repairs are usually cost prohibitive VACUUM MOTOR VACUUM SAVER VACUUM SAVER
57. d retest machine gt measure the vacuum at the float screen bracket Is there good Unbolt the vacuum motor from the NO vacuum NO Is there good v tank Test the vacuum directy at the vacuum motor vacuum YES Vv Check the motor saver for cracks make sure all the gaskets are in good condition and check the duck bill Is everything is good order the 5 Repair as necessarv and then retest machine Did this remedv the problem YES z NO cal the acto 5 Magnum Service Manual V1 0 RECOVERY SYSTEM 4 DLANK THIS PAGE WAS INTENTIONALLY LEFT BLANK Magnum Service Manual V1 0 5 SOLUTION SYSTEM 6 SOLUTION SVSTEM The solution svstem on the Magnum series consists of main bodv of the machine which is also the solution tank the fill opening sight gauge drain filter potentiometer controller and solution solenoid valve The solution is turned on automaticallv when the brush deck is turned on and turns off automatically when the brush deck tuns off The volume of solution is controlled by the solution potentiometer located on the control panel The potentiometer sends a varied voltage signal to the controller and the controller interprets this signal and sends power pulses down to the solution solenoid valve The more solution that is called for the longer t
58. drical brush drive svstem consists of the controller 2 brush drive motors 2 drive belts 2 brush idlers 2 circuit breakers and two scrub brushes Each scrub motor has It s own circuit breaker to protect it individually against overload in the event of individual brush motor overload BRUSH DRIVE ELECTRICAL CIRCUIT The brush drive circuit is very simple A positive and negative wire run from the control ler to the scrub deck On cylindrical machines there is a protection circuit breaker wired in line to each of the motor brushes The controller watches the amperage draw on the scrub motors and regulates the brush deck pressure to keep the motors operating at a consistent amp draw thus maintaining a consistent deck pressure The cylindrical decks have inde pendent motor protection on them because the motor demand can vary so greatly from one brush to the other and the controller views them as one motor Magnum Service Manual V1 0 T 1 1 BRUSH DRIVE SYSTEM SETTING BRUSH PRESSURE The scrub deck pressure is adjusted continuously while scrubbing Using the brush pres sure switch on the control panel you set the desired scrubbing pressure The desired brush pressure is shown on a bar graph on the LCD display There are 5 different settings to choose from The controller is programmed with an amp value for each of 5 brush pres sure settings When the scrub deck starts the controller calculates the amp draw of the motors and compares it
59. e operation Does the switch work properly BRUSH switch does not 7 At the 20 pin Molex connector at the controller back probe pin 16 with the positive probe of the meter NO Using voltmeter set the meter to DC volts Connect the probe of the meter to the buss bar with a clip on gt Back af 20 pin Mala Connecter vour meter probe Measure at the center tab of the brush pressure switch 20 19 18 17 16 15 14 13 12 11 vellow wire 1098765432 1 C Repair open circuit between 4 8 and YES ika 5 2 volts Was there between 0 8 and Replace the 2 8 volts controller A NO NO At the 20 pin Molex YES le ware connector at the between 0 8 and Sacra 2 v 2 8 volts d Place the probe the positive probe YES back on the center of the meter terminal of the switch YES yellow wire Move the y switch up and measure 13 10 Repair open circuit between the controller and the switch Place your meters probe on the lower NO the voltage Did the voltage of the terminal raise to between 4 8 terminal of the switch 4 red wires Measure the voltage Was the voltage between 4 8 and 5 2 volts and 5 2 volts when the switch was moved up Magnum Service Manual V1 0
60. e 14 pin Molex on the controller with the positive probe and place the negative probe on the negative buss bar amp with the machine turned on Was there between 4 7 amp 5 2 volts Back of 14 pin Male Connector 14 131211 10 9 8 NO 7654321 With a voltmeter set to the DC scale back probe between terminal 12 on Y the 14 pin Molex connector at the 4 Replace the Was controller and the negative buss bar potentiometer c Jeno there between with the machine turned on CONTROLLER 0 8 and 2 6 A volts Back of 14 pin Male Connector Wasthere 14 13 12 11 10 9 8 between 4 7 amp 7 6 5 41 51211 5 2 volts Repair the break in the wiring between this terminal and the center With a voltmeter set to the scale ismina OMM S POENE MELEN back probe between terminal 13 on NO the 20 pin Molex connector at the controller and the negative buss bar with the machine turned on Back of 20 pin Male Connector 20 19 18 17 16 15 14 13 12 11 10191817 615 41312 1 Was there between 4 7 and 5 2 volts REPLACE THE CONTROLLER Repair the wiring between the Repair the wiring between the as there controller and the red wire going controller and the black wire between 4 7 amp to the potentiometer going to the potentiometer 5 2 volts Magnum Service Manual V1 0 13 2
61. econds Do you have either a pulsing or steady 24 Volts YES Is it steady or Check the screw on the back of the deltrol valve and make sure itis backed out all the way and the jamb nut is tight Was the screw backed out all the way and secured with a locknut NO Back out all the wav and install lock nut Retest machine See Section 13 Water does it pulse Use vour ohm VES meter to check for Pot page 13 26 Call the factorv RESISTANCE Was there continuitv on the deltrol valve coil resistance oran open circuit OPEN CIRCUIT v Replace the deltrol valve Magnum Service Manual V1 0 BRUSH DRIVE SYSTEM 1 BRUSH DRIVE SVSTEM The brush drive svstem on the Magnum Series comes in two versions The disc tvpe and the cvlindrical tvpe Each one has its own merits although thev do the same thing which is turn the scrub brush or scrub pad DISC The disc brush drive svstem consists of the con troller 2 brush drive motors 2 brush driver hubs and 2 scrub brushes or 2 pad holders The drive hub is a gimbaled design that helps compen sate for irregularities of the floor Only original factorv equipment brushes should be used on this machine or premature scrub motor failure mav occur Will Fit brushes are usuallv not concentric and promote bearing failure CVLINDRICAL The cvlin
62. ed back To do this you must first drain the solution and recovery tanks completely Then release the 2 soft latches directly above the scrub deck on either side of the machine Now use the handle bars to tip the body of the machine backwards carefully until the strap stops it After the adjustments have been made tip up the body secure the two soft latches and test the machine BRUSH LIFT ACTUATOR The actuator must be able to extend enough to lower the brush head down so that it can reach slight dips in the floor If the head can not do this the actuator may not be extending enough The distance the actuator extends is controlled by a limit switch that is housed internally in the actuator 8 2 Magnum Service Manual V1 0 BRUSH LIFT SYSTEM 8 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 Remove this black rubber strip to gain access to the limit switch LINKAGE ADJUSTMENT If the brush deck is out of adjustment and it can not be remedied with the limit switch ad justment there is a provision for adjusting the linkage At the top of the brush deck l
63. end of the amp scale As the charge cycle progresses the meter will fall towards zero The charger shuts off automatically when the cycle is complete this is evi dent by it not humming anymore 11 8 Magnum Service Manual V1 0 BATTERY SYSTEM 11 ON BOARD CHARGER An on board charger is offered as an option on the Magnum series of machines The charger is a waterproof charger that is mounted right to the chassis of the scrubber It is operated by simply plugging the power cord into the wall The charger then will run through its charge cycle and automatically shut off The automatic charger has 4 status lights on it AUTOMATIC BATTERY CHARGER The LED Function Chart below describes the charging process NOTE The LEDs discussed below in the table are the Charge Status LEDs NOTE The AC present LED green 2 is lit at all times when AC is con nected and off when AC is not connected Display Operating condition Red on Yellow off Green 1 off Red on Yellow on Green 1 off Red on Yellow on Green 1 on Red off Yellow off Green 1 on When the red LED is on it indicates that your battery is discharged and the model 2820 24 03 is recharging the battery at the Bulk rate stage 1 This charging rate is approximately 20 Amps While the red LED is on the voltage measured with the charger on will be approximately 23 to 28 Volts If an excessive amount of time is taken to complete this stage
64. er on customers complaint Go to the KEY SWITCH diagnosis section COIL SECTION 85 COIL LEAD 86 COIL LEAD SWITCH SECTION 30 COMMON 87 NORMALLY OPEN 87a NORMALLY CLOSED Repair break in wiring between Terminal 85 and the key switch buss bar receiving battery voltage NO Does the NO machine turn on YES Y Using a voltmeter set the meter to DC volts Connect the probe of the meter to the buss bar with a clip on your meter probe With the positive lead of your meter measure the voltage at terminal 85 red wire on the buss relay with the key on Is there battery voltage at this terminal YES Using voltmeter set the meter to DC volts Measure the voltage between terminals 85 red wire and 86 black wire on the buss relay with the key on proper machine operation Using a voltmeter set the meter to DC volts Measure the voltage between terminals 85 red wire and the negative buss bar with the key on 7 77 13 14 GO TO Page 2 DA Is there battery voltage across these terminals Using a voltmeter set the meter to DC volts Connect the probe of the meter to the buss bar with a clip on your meter probe With the positive lead of your meter measure the voltage at terminal 87 red wire ff on the buss relay with the ke
65. er up the device and take your readings LCD DISPLAY The LCD is a critical component and can cause the machine to operate improperly or not operate at all There is a computer data link that is established between the LCD and the computer when the machine is powered on and all the computer information is routed in a loop through the LCD display For this reason if an LCD fails it can cause a variety of results from making the machine not turn on to making it not turn off INPUTS The switches in the Central Command System receive reference voltages from the con troller and then send signals in the form of low or high voltage to the controller The con troller interprets these signals and then the computer and it s program inside the controller Magnum Service Manual V1 0 13 5 13 COMPUTER CONTROL SYSTEM 13 6 decide what device there is a request for and how it should operate the device TRI STATE LOGIC The Central Command Il system uses very low voltage throughout it s control system This voltage is less than battery voltage and the controller will be destroyed if battery volt age is induced into the control circuits The tri state logic uses 3 voltages as follows LOW 0 0 0 3 volts MID 0 8 2 7 volts HIGH 4 8 5 2 volts The low and high voltages are reference voltages created by the controller These volt ages are sent to the various controller inputs via the control panel switches The con troller then m
66. ervice person nel from adjusting it The squeegee wheels wear with use and periodic adjustment of their height is required SQUEEGEE WHEEL ADJUSTMENT First level the squeegee so the blade has an even roll to it on the back of the squeegee tool Then adjust the wheels so the rear squeegee blade just rolls over when travelling forward Magnum Service Manual V1 0 SQUEEGEE SVSTEM SQUEEGEE TROUBLESHOOTING SQUEEGEE PROBLEM Ero Not picking up water Is the squeegee or vac system clogged Are the blades worn out Is the machine straight from side to side No pitch or lean to either side because of tire problems Does machine have a slight pitch lean backwards The unit should have about a 1 2 degree pitch lean to the rear Is the squeegee or suspension bent or missing parts Leaving streaks Dirt on blades Wipe off with rags Chip or tear in rear squeegee blade Turn blade or replace One or both wheels not touching floor Replace wheels and or their brackets shim as necessary Front or rear bolt missing or loose in triangle plate Tighten or replace Clearance between triangle and tow bar is 7 8 Falls off frequently Plastic knobs are loose Tighten Operator hand strength is too low to tighten squeegee knobs adequately causing squeegee to fall off regularly Add a bevel washer lt preferred gt or a flat washer between each knob and the squeegee Squeegee is creating too much suction on the floor
67. es working properly YES proper machine ee customers work properly Diminished run time operation complaint Is the electrolyte clear or dirty The batteries are damaged Replace DIRTY the batteries Are the batteries filled to the proper level Fill batteries following NO appropriate procedures and then charge for 2 full cycles Re test the machine YES Are the plates inside the battery straight or warped The batteries are damaged Replace the WARPED batteries STRAIGHT Y With a graduated float type hydrometer measure the specific gravity of each cell of each battery and record your results difference between any 2 cells greater Replace the YES batteries NO Verifv correct charger operation 13 8 Magnum Service Manual V1 0 COMPUTER CONTROL system 3 MAGNUM BRUSH DECK ACTUATOR DIAGNOSTIC FLOW CHART BRUSH DECK ACTUATOR does n operate properly 4 ot 1 of 1 Operate machine and verify the Does the actuator SE With the meter still connected to the machine turn on YES customers complaint work properly Instruct owner on proper machine operation Turn on the scrub deck switch and then drive the machine Observe the LCD display and see if the brush icon appears Repeat this with the one touch switch
68. ethane blades clear blades they resist chemical best 3 8 Magnum Service Manual V1 0 SQUEEGEE SVSTEM 3 MAGNUM SQUEEGEE DIAGNOSTIC FLOW CHART 1 of 2 Verify operation with the customer and educate the NO i customer on the way their machine works Is there a problem with the machine Operate the Squeegee does machine and verify not pick up water the customers complaint T H Adjust squeegee queeg NO be as best as djusted properly ibl A vacuum gauge is necessary to accuratelv test the suction of the vacuum motor VES Vv Check for good suction and air NO Is machine VES flow at the squeegee hose fixed Go to recovery Is there good l NO svstem diagnosis suction and flow VES Y Operate the machine and Replace BOTH squeegee wheels check squeegee operation Replace brackets if worn or bent YES Check to make Do BOTH wheels sure the wheels Are the rotate smoothly as NO spin freely when wheels worn stuck Inspect the smile plate the towbar and the triangle plate YES Install new parts 4 the machine moves forward YES 7 Inspect squeegee tool and linkage to the squeegee is lifted and check for wear NO or turn pooriv2 the machine for anv bent parts Are
69. float is not rubbing on the side of it Draw an amount of acid into the body so the that with the bulb fully expended the float will be lifted free not touching either side the top or the bottom Your eye should be level with the surface of the liquid in the hydrometer body Disregard the curvature of the liquid where the surface rises against the float stem and the barrel due to surface tension Keep your hydrometer and it s float clean Check them frequently for cracks The following table illustrates typical specific gravity values for a cell in various stages of charge with corresponding voltage readings OPEN CIRCUIT STATE OF HYDROMETER VOLTS CHARGE READING 12 65 100 1 260 or more 12 45 75 1 225 1 260 12 24 50 1 190 1 225 12 06 25 1 120 1 190 11 89 Totally Discharged 1 120 or less 11 6 Magnum Service Manual V1 0 BATTERY SYSTEM 11 When testing with a load tester vou are looking for a difference between cells of the batter ies All the battery cells should have similar readings Any battery that contains a cell that has a value lower than 050 of the rest of the cells indicates you have a bad battery Load test with a load tester Make sure batteries are fully charged Disconnect batteries from the machine and each other so each battery can be tested individually Using a battery load tester test each battery at either the fixed load of the tester or a 120 amp of load on a variable tester The batteries should be able to
70. he length of the power pulse When the potentiometer is turned to the MAX solution setting the valve receives constant power when the scrub deck is running When the potentiometer is set to the MIN position the solution solenoid valve receives no power even when the brushes are running The solution runs through an in line filter with a screen and a bowl attached to capture particles or debris that moves thought the solution system The screen and bowl need to be cleaned on a regular basis THE SOLUTION TANK IS MADE OF HIGH DENSITY PLASTIC THIS PLASTIC STARTS TO DEFORM AND LOOSE ITS SHAPE AT 180 DEGREES FAHRENHEIT NEVER USE WATER HOTTER THAN 135 DEGREES FAHRENHEIT DISPENSING SOLUTION Make sure the recovery tank is at least 1 2 full with desired scrubbing solution Adjust solution control knob near the center of travel Turn on the brush deck switch Activate the machine by pressing either of the green handlebar buttons The solution will start to flow when the brushes start and stop flowing when the brushes stop Turn the solution control potentiometer while scrubbing to adjust solution volume Magnum Service Manual V1 0 6 1 6 SOLUTION SYSTEM SOLUTION SYSTEM ELECTRICAL CIRCUIT The electrical circuit of the Magnum series is divided into two parts The input circuit and the output circuit The input circuit consists of the controller the scrub switch and the solution potentiometer The controller produces a high 5 volt and a low
71. hine machine re 4 NO NO turned VES Disconnect both connectors to the Sprav Jet motor and measure for voltage across the two terminals on the harness The Sprav Jet pump motor is bad Replace the pump Is there batterv voltage there VES NO With a voltmeter set to the DC scale measure from the positive lead to the negative batterv terminal Magnum Service Manual V1 0 Is there something wrong with the Spray Jet Does the Spray Jet pump run Instruct owner on proper machine operation Fill solution tank and re test the machine Is there solution in the tank YES NO gt YES Disconnect the line from the solution tank to the Sprav Jet pump at the pump Place end of line down to the floor Turn the sprav jet pump off and remove the nozzle from the end of the hose Turn the sprav jet on again Do you have good solution flow NO y There is an obstruction in the solution system Clear obstruction and re test the spray jet Does the water flow well with good pressure Replace the Spray NO Jet pump YES Y Replace the nozzle 13 29 13 COMPUTER CONTROL SYSTEM MAGNUM SPRAY JET DIAGNOSTIC FLOW CHART 2 of 2 the YES Wi
72. ice Manual V1 0 SOLUTION SYSTEM DIAGNOSIS FLOW CHART 1 of 2 E SOLUTION SYSTEM 6 wo Solution row j Does water flow out v Test Machine Verify Complaint Turn on the water switch Turn the solution potentiometer to MAX 4 NO of the filter2 VES NO Remove the solution filter screen Is the solution screen VES Solution tank outlet is clogged Clean out tank and remove foreign material from water outlet Does the machine dispense water NO Is the scrub switch turned on YES Is the solution potentiometer turned to MAX YES Is there water in the tank YES Advise Customer on proper machine operation NO Fill solution tank with water A clogged NO See Next Page Magnum Service Manual V1 0 y Clean solution screen and flush out the solution tank 6 3 SOLUTION SYSTEM SOLUTION SYSTEM DIAGNOSIS FLOW CHART 2 of 2 STEADY From Previous Page Does the scrub deck turn on when a green handlebar button is depressed YES Y See Section 13 Brush Switch page 13 12 Use a voltmeter to test for voltage across the Deltrol valve terminals when the green handle bar button is depressed Make sure to measure for at least 10 s
73. ift linkage there is a bolt that is secured with a jamb nut This bolt is used to increase or de crease the raised height of the deck If too much adjustment is made to this screw to lift the brush deck the deck may not have enough travel to reach and put pressure on the ground Adjustment screw with jamb nut If the brush head lifts too high when it is in the full raised position it may not have enough travel to extend low enough to reach into recesses in the floor If the machine exhibits this condition lower the overall brush height by backing out the screw on the upper suspension arm Magnum Service Manual V1 0 8 3 f BRUSH LIFT SYSTEM BLANK THIS PAGE WAS INTENTIONALLY LEFT BLANK 8 4 Magnum Service Manual V1 0 TRACTION DRIVE SYSTEM 0 TRACTION DRIVE SVSTEM The Magnum series of scrubbers is powered by and electric transaxle system The trans axle is self contained and bolts to the bottom of the frame The trans axle is equipped with a 1 2 horsepower motor that transfers power through a shear key into the differential as sembly The power is then transferred out to the wheels via the axle shafts The transaxle with the differential powers the machine while allowing the machine to turn easily TRACTION DRIVE ELECTRICAL CIRCUIT The traction drive electrical circuit consists of the traction drive motor controller handle bar buttons potentiometer and the reverse switch When you engage the handlebar button it
74. ily at it s pivot points B PIVOT BOLTS These are the bolts that the squeegee pivots on If they are too tight it will bind C SQUEEGEE TRAIL ARM This arm is made of 72 plate steel but is still possible to bend If it is bent at all it must be replaced D GROMMETS These grommets maintain the proper spacing between the triangle plate and the Trail Arm E SQUEEGEE TRIANGLE PLATE The squeegee is mounted to the triangle plate and ties it to the trail arm F SPRING Supplies pressure between the triangle plate and the trail arm Helps hold the adjust ment The squeegee will not operate without this spring G PITCH ADJUSTMENT KNOB The knob used to pitch the squeegee frontward or backwards The squeegee should be adjusted to be flat to the floor H SQUEEGEE HOLD DOWN KNOB These knobs anchor the squeegee to the triangle plate DO NOT OVER TIGHTEN SQUEEGEE BODY SHOWN HERE WITHOUT BLADES The squeegee body is laser cut from Y2 steel and must be perfectly straight and flat J SQUEEGEE WHEEL MOUNT The squeegee wheel mounts attach the wheels to the squeegee suspension They can be adjusted by adjusting the bolt that controls their height K SQUEEGEE WHEELS The squeegee wheels should both touch the floor during operation and roll freely They should both be adjusted to the same height These wheels are wear items and should be replaced when squeegee blades are replaced L SQUEEGEE WHEEL HEIGHT ADJUSTMENT SCREW This bolt
75. ine This gauge is designed to read properly while the machine is in use and therefore will vary during usage of the machine 10 SCRUB HOURS The hour total listed here indicates the total number of hours the brush deck has been operated on the machine 11 TRACTION HOURS The hour total listed here indicates the total number of hours the traction drive has been oper ated on the machine 12 KEY SWITCH HOUR METER This hour meter rep resents the total number of hours the machine has been powered on This does not mean however that the machine has been used this long just that it has had the power on for the time indicated SCREEN 4 This screen will appear automatically in the event of a fault being present in the machine Machine operation will be suspended until the cause of the code is remedied 7777 13 4 9 GAUGE 10 SCRUB HOURS 11 TRACTION HOURS 12 KEY SWITCH HOURS 13 DIAGNOSTIC CODE Magnum Service Manual V1 0 COMPUTER CONTROL SYSTEM 3 ON BOARD DIAGNOSTICS The Central Command II control system utilizes a Diagnostic Code system that displays diagnostic codes on the LCD display should a malfunction of the machine occur The diag nostic code can be looked up in the diagnostic code chart and it will assist you in determin ing the cause of malfunction DIAGNOSING THE CONTROL SYSTEM The Central Command ll system with all its robust capabilities is also very easy to diagnose
76. ing the leads to the battery to avoid dan gerous sparks Never try to charge a visibly damaged or frozen battery Connect the charger leads to the battery red positive lead to the positive terminal and black negative lead to the negative terminal If the charger is equipped with a quick disconnect plug use that to connect it to the machine Make sure that the machine and all its accessories are turned off Make sure that the charger leads to the battery are not broken frayed or loose Set the timer turn the charger on and slowly increase the charging rate until the desired charging rate is reached If the battery becomes hot or if violent gassing or spewing of electrolyte occurs reduce the charging rate or turn off the charger temporarily Always turn the charger OFF or unplug it from the AC power before removing the char ger leads from the battery or disconnecting the quick disconnect plug to avoid dangerous sparks Magnum Service Manual V1 0 11 1 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 neu tralizing 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 If the electrolyte is splashed into an eye immediately force the eye
77. lay with the key on Replace the bu relay Saves Replace the negative buss bar circuit breaker Repair the connection between the main breaker and the 30 terminal on the buss bar relay Repair the connection from the controller negative battery terminal to the negative circuit breaker PUT THE TOOLS DOWN AND Magnum Service Manual V1 0 Is there battery voltage across these terminals NO Y Using a voltmeter set the meter to DC volts Connect the probe of the meter to the buss bar with a clip on your meter probe With the positive lead of your meter measure the voltage at the main positive circuit breaker with the key on Is there VES batterv voltage across these terminals CALL THE DAMN FACTORY 13 15 77 13 COMPUTER CONTROL SYSTEM MAGNUM DRIVE MOTOR DIAGNOSTIC FLOW CHART Operate machine and verify the customers complaint DRIVE MOTOR TA not work 4 v 1 of 1 Does the Instruct owner on drive motor work YE proper machine operation properly ex EE not turning on first Replace the drive assembly A Can you Remove the drive rotate the drive motor from the wheel bv drive assembl hand 4 you rotate both drive v Block the rear wheels of the machine
78. maintain a voltage of 10 8 volts or greater for 15 seconds on 12 volt batteries and 4 9 volts or greater for 15 seconds on a 6 volt battery If they can not maintain their voltage while under load they are bad Load test using machine systems as a load Using a volt meter measure the voltage of each battery while the machine is under full load all systems operating If any battery shows a voltage of less than 80 of the battery with the highest voltage that battery is bad Magnum Service Manual V1 0 11 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 When a battery fails in the first 12 months of operation replacing a single battery may be acceptable if the failure was caused do to manufacturing defect If the battery pack is older than 12 months or the battery has failed due to neglect the entire battery pack should be replaced as the batteries operate as a system When replacing batteries it is important to neutralize any battery acid that is in or on the machine after battery removal
79. n e This machine must be operated only by a trained operator As part of their training they must read the operators manual thoroughly If extra copies are needed contact your local dealer e Always park machine on a level surface and turn the power off before leaving it unattended Do not operate over electrical floor outlets This may result in serious injury or death to the operator and others e Do not work under machine without it properly supported on suitable safety stands Do not try and lift this machine unaided it is very heavy e Do not use handle bars or steering mechanism as a lifting point vi Magnum Service Manual V1 0
80. nals and cables are clean and drv inspect them thoroughiv for anv damage or signs of arcing or over heating Replace and damaged cables terminals or batteries Reassemble the cables and batteries and coat terminals and connections with a battery terminal protectant IMPORTANT NOTE Make sure to apply the protectant AFTER the batteries and cables are reassembled and tightened Putting protectant on before assembly and tightening can lead to a fire BATTERY TESTING As a battery pack ages the batteries will slowly loose their ability to accept and hold a charge This will usually be noticed by a decrease in run time of the machine Neglected batteries will wear out much faster than well maintained batteries but give you similar symptoms when they do fail The proper way to check a battery pack s condition is with a battery discharge unit To use the discharge unit make sure the batteries are maintained properly and fully charged Attach the discharge unit to the machines battery pack and turn the machine on Record your results and compare them to your battery s rated capacity This will let you know how much capacity your battery pack has left If you find through the battery discharge meter that you have reduced capacity you can test each individual bat tery to find out if you have one bad battery or multiple bad batteries To test each battery you have 2 options a hydrometer test or a load test Hydrometer test Use a hydrometer on each
81. ne and verify the Is there something wrong customers E complaint with the display y Instruct owner on proper machine operation Replace the display and 6 wire harness with a known good or a new display and harness and retest the machine the problem YES y Repar is compta Magnum Service Manual V1 0 Replace the controller and retest the machine Did this solve the problem NO A YES v Replace the LCD and harness 13 19 13 COMPUTER CONTROL SYSTEM MAGNUM ONBOARD CHARGER DIAGNOSTIC FLOW CHART 1 of 1 y ONBOARD Operate machine and verifv the does not work customers complaint Tell customer to replace or eliminate the extension cord Is their extension cord cceptable Observe the extension cord Note the length and gauge of the cord The cord should ne no longer than 15 feet and be a Number 12 gauge or heavier the charger work Does properly NO 7 i4 VES Measure the voltage of the batteries and record it Ask CUSTOMER to plug the machine in to Instruct owner on VES proper machine operation charge as they 4 normally would Observe them plugging it in Were thev using an exten
82. ng the parameters we can make brush deck of a machine drop to the floor when the machine starts scrubbing and then pick itself up when the machine stops If we adjusted another parameter we could make the brushes raise up when the machine went in reverse without having the operator manipulate a switch In order to change the parameters in a controller a T 194 programing kit is necessary With a laptop computer and the programming kit access can be gained to the parameters of the machine and they can be modified to make the machine react differ ently The controller has 135 parameters that can be modified through programming To program the controller a programming kit and special software are necessary The kit for this is Central Command II Programmer CD Controller computer interface cable USB serial port adapter Controller protected power cable Jumper key Latest version of the Electrical Service Guide 1 194 programming guide Aluminum briefcase INSERT T 194 KIT PICTURE HERE This kit is required to changes the program for the computer Magnum Service Manual V1 0 13 13 COMPUTER CONTROL SYSTEM MAGNUM BATTERY DIAGNOSTIC FLOW CHART 1 of 1 Operate machine BATTERIES are not Instruct owner and verifv the Do the batteri
83. nual V1 0 the problem YES v customer RECOVERY SYSTEM MAGNUM RECOVERY SYSTEM DIAGNOSTIC FLOW CHART Instruct customer on proper machine maintenance YES Did this remedy the problem NO Install squeege back on the machine and test operation Clean the squeegee Inspect the blades and wheels Replace parts as necessary 4 VES 2 of 3 FROM PAGE 1 Is the squeegee adjusted properly YES Y Remove squeegee Adjust squeegee and retest machine See squeegee section for assistance NO Did this remedv the problem and see ifitis 4 clogged Is squeegee clogged NO Check vacuum lift atthe end of the the VES Magnum Service Manual V1 0 squeegee hose Do you have good vacuum at the squeegee hose NO See Next Page RECOVERY SYSTEM MAGNUM RECOVERY SYSTEM DIAGNOSTIC FLOW CHART a the cst YES Did this remedy the problem NO 3 of 3 FROM PAGE 2 Check inside the hose for obstructions Clean out obstructions or clogs and retest machine Were any obstructions or clogs found NO Remove the float and the ey Ja ES vacuum motor an
84. open and flood it with clean cool water for at least 15 minutes Get prompt medical attention If electrolyte is taken internally drink large quantities of water or milk DO NOT induce vomiting GET IMMEDIATE MEDICAL ATTENTION Neutralize with baking soda any electrolyte that spills on a machine or in a work area After neutralizing rinse contaminated area clean with water WATER When servicing batteries the recommended water to use is distilled water when adding it to the electrolyte However any water that is safe to drink with the exception of mineral or flavored waters is safe to use in a battery Do not use water with a high mineral content Avoid using metal containers to store acid or water The metal impurities in the water will diminish the performance of the battery Liquids besides water such as vinegar anti freeze salt water and alcohol or harmful acids such as nitric hydrochloric or acetic will cause se vere grid damage and completely ruin a battery BATTERY TERMINAL TYPES Batteries are made with an assortment of different battery terminal configurations The most common in the industry are listed here It is best to replace batteries with the exact type of battery that was in the machine including the battery terminal type If you change battery terminal types the battery cables must be changed to match the new style termi nals TAPERED TOP TERMINAL S A E POST The tapered top design uses terminal posts built to
85. ortant to note the orientation of the stainless steel retaining band for re installation The holes are offset to make a wide side and narrow side The wide side always goes UP If the band is installed incorrectly the squeegee will not function properly TOP BOTTOM ORDERING BLADES 1 Find the squeegee size Check the stamped number on the top of the squeegee body and order blades the corresponding blade size 32 35 38 or 45 inches 2 Choose the appropriate material Gum rubber These blades are tan in color and best for most applications including irregular floors They wear out quickly on rough floors however and do not tolerate oil other petroleum products or heavy citrus cleaners The kit number suffix for gum rubber is Example 28 770 G Linatex These blades are red in color and designed to be very durable while at the same time giving optimum performance They are very abrasion resistant and perform acceptably on irregular floors They tolerate oil petroleum products and heavy citrus cleaners better than gum rubber The kit number suffix for Linatex is L Polyurethane These blades are nearly clear and are recommended for oil petroleum or heavy citrus cleaner applications where Gum or Linatex would fail It rarely works as efficiently as Gum or Linatex but is somewhat abrasion resistant The kit number suffix for polyurethane is U 3 4 Magnum Service Manual V1 0 SQUEEGEE SVSTEM 4 SQUEEGEE ADJUSTME
86. ow blinking continuously excessive amount of time The red LED is blinking 1 Corrupt Microprocessor memory See fault codes below continuously Return charger to the factory 11 10 Magnum Service Manual V1 0 BATTERY SYSTEM 11 FAULT CODES FLASHING RED LED Corrupt program memorv in micro controller detected charger mi croprocessor has become corrupted Charger must be returned to the factorv FLASHING VELLOW LED Timer has expired The 253 2441 uses a timer to independent ly monitor each mode of the charge cycle bulk absorption and finish If the timer expires during any of these modes of the charge cycle there could be a problem with the battery set The timer may expire if there is a damaged battery cell in the battery set an abnor mally high ambient temperature at the charger or some other external fault which prevents completion of charge cycle These problems need to be addressed by user intervention Charger must be AC powered down and disconnected from the battery in order to reset fault condition Before resetting the charger investigate potential problems with battery or other external faults Once external problem is resolved reconnect charger output cable and reconnect AC power MAINTENANCE Periodically clean both battery terminals with baking soda and tighten all connections No other maintenance on the charger is required see the following chart as to what the light mean IMPORTANT NOTE DO NOT unplug
87. protection for both current overload as well as thermal protection A large circuit breaker is used on the power feed to the controller for extra safety against overload In the event of a malfunction the Central Command II will display a diagnostic trouble code to aid in the repairing the machine CONTROLLER OVERVIEW INPUTS The controllers input section uses a technology called tri state logic to interpret the input from the switches The tri state logic is comprised of low medium and high voltages The inputs have the mid voltage present at them until they are either drawn low or high by a switch OUTPUTS The controller has a number of outputs and each one of them is electronically protected from overload In the event of an overload the machine is shut down by the controller and a diagnostic trouble code is displayed on the LCD screen On some of the outputs the current limit can be adjusted via software to control the amount of current available to the circuit PULSE WIDTH MODULATION The controller uses a technology called pulse width modulation to control some of the output circuits Motors and accessories can be run using this technology in more than one way We can change the speed of a motor as well as control the amount of time a valve is open over one second such as in our solution system Pulse width modulation works by sending pulses of full battery voltage to the device 14 000 times a second The length of the pulses determines
88. r Power is applied to the actuator with the polarity in one direction to raise the brush deck and the opposite direction to lower the brush deck The actuator has internal limit switches that prevent it from moving too far in either direction While the circuit itself is very simple the control of this circuit is very complicated The con troller operates the output of this circuit by monitoring a number of variables Is important to know this circuit energizes the brush deck actuator to raise the brush deck for 4 seconds each time the controller is powered up For this reason it is important to make sure all body parts are clear from under the scrub deck when the machine is powered on When the scrub switch is turned on the controller runs the scrub brushes down toward the floor for a predetermined amount of time This is known as dock time and can be modified by chang Magnum Service Manual V1 0 8 1 fi BRUSH LIFT SYSTEM ing the parameters of the controller When the throttle button is depressed the controller monitors the amp draw of the brush motor and adjusts the scrub deck height to obtain the target amp draw on the scrub motors The target amp draw of the motors is set using the brush pressure switch on the control panel The brush pressure setting is shown on the LCD display in the form of a bar graph The target amps for each of the brush pressure set tings are defined by the parameters that are programed into the controller When the
89. r open circuit between pin 11 on the controller and center terminal of the brush pressure the switch Is the voltage between 4 8 and 5 2 volts 7777 13 12 ves Repair open circuit v customers complaint 1 of 2 Does the switch to switch v Instruct owner on work properly NO Y YES prepe machine operation WATER Turn on the scrub deck switch and then drive the machine Observe the LCD display and see if the brush icon appears Repeat this with the one touch switch Turn off the one touch switch At the 20 pin Molex connector at the controller back probe pin 11 with the positive probe ofthe meter Back of 20 pin Male Connector 20 19 18 17 16 15114 13 12111 10 9 8 7 6 5 4 3 21 Did the icon turn on Is the One Touch Switch Off Using a voltmeter set the meter to DC volts Connect the probe of the meter to the buss bar with a clip on your meter probe Measure at the center tab of the squeegee switch green wire Is there between Place your meters probe on the lower terminal of the switch red wires Measure the voltage 0 8 and 2 8 volts YES m to the BRUSH VES MOTOR 2 The One Touch switch is the large green button right below the water knob When
90. re offered in 3 different sizes of lead acid and 2 sizes of mainte nance 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 scrub ber There are two types of batteries that we use in our scrubber and each one has differ ent needs to keep it performing optimally BATTERY MAINTENANCE amp CARE LEAD ACID BATTERIES TRADITIONAL Lead Acid Batteries are the most common battery installed in our machines They are filled with water and battery acid and require periodic care The most important item to attend to is the battery water level This must be checked on a weekly basis because if the batteries run low on water they will be ruined Batteries should be checked before you charge them to make sure they have enough water to cover the plates inside them In the event that the water is below the tops of the plates water should be added to bring the level just above the top of the plates When adding water ALWAYS use distilled water Tap water contains things like minerals and chlorine that is detrimental to a battery Bat teries should be charged each time the machine is used for any significant time Batteries should never be discharged more than 80 of their capacity The battery gauge is to alert you when it is time to
91. rly with it s original integrity It is important to use the Ratchet style crimpers to assure the connector is installed properly The ratchet style crimpers regulates the crimp so it is not too tight or too loose Using standard pliers style crimping tools does not assure a consistent connection MOLEX CONNECTORS Molex Mini Fit Jr wire terminals are used where the wiring harness plugs into the control ler and the LCD display These terminals require a special removal tool If an attempt to remove them is made without the removal tool it is very likely that the terminal and perhaps the connector will be damaged and need to be replaced To replace a Molex Mini Fit Jr terminal a special set of Molex brand crimpers is required to achieve an acceptable crimp 12 2 Magnum Service Manual V1 0 ELECTRICAL SYSTEM 12 REMOVAL TOOL MOLEX MINI FIT JR CRIMPING TOOL CONTROLLER HIGH AMP OUTPUT TERMINALS Brush Vacuum Traction The controller high amp output connectors are crimped with a special crimping tool at the factory The tool is not practical to use in the field so in the event that a new terminal is needed a wire end kit is available that is field installable This kit is available through the parts department ANDERSON BATTERY CONNECTORS Anderson connectors are crimped by a hydraulic crimping machine at the factory This is not practical in the field We recommend using a manual staking tool and then soldering the terminal to
92. rminal 2 Momentarv Brush Pressure switch Terminal 3 Reverse switch input Reverse switch output Inhibit Switch Input Inhibit Switch output LCD Wire 1 LCD Wire 2 LCD Wire 3 LCD Wire 4 LCD Wire 5 LCD Wire 6 E Stop Input E Stop Output Traction Mode Switch 1 pole of the brush switch Input Traction Mode Switch 1 pole of the brush switch Output LCD Mode Input page switch LCD Mode Output page switch Vac Switch Air Logic Vac Switch Return 2 17 2006 m 9 29 Magnum Service Manual V1 0 ELECTRICAL SYSTEM 12 BLANK THIS PAGE WAS INTENTIONALLY LEFT BLANK Magnum Service Manual V1 0 12 11 COMPUTER CONTROL SYSTEM 3 COMPUTER CONTROL SYSTEM The Magnum series of machines is equipped with the Central Command II control system Central Command ll is designed around a very powerful controller that is has a industrial computer integrated into it The controller is linked to a Liquid Crystal Display LCD to relay information to the operator or the service technician The same controller is used in majority of our equipment both 24 and 36 volt but runs a different program for each machine The controller utilizes unitized construction eliminating many excess components from the control panel The switches on the dash board send input signals to the controller The controller then interprets the inputs via the program and operates the machine accord ingly The controller has internal
93. s PREVENTIVE MAINTENANCE WORKSHEET CUSTOMER INFORMATION CUSTOMER ADDRESS CITY STATE ZIP CODE MACHINE INFORMATION MODEL H SERIAL WORK ORDER HOUR METER BATTERY CONDITION Cell 1 Cell 2 Cell 3 Cell 4 Cell 5 Cell 6 Battery t Hydrometer Ji J po o Battery fi 1 Water Condition S e Battery 2 Hydrometer Battery 2 Water condition 0 Battery 3 Hydrometer e Battery 3 Water Condition o 4 Hydrometer e Battery 4 Water condition 2 Clean Batterv Tops Check Batterv Cable and Terminal Condition NOTES BRUSH CONDITION Scrub Brush Fiber Length 64221 Rotated Brushes Brush Drive Sockets Good Worn Needs Replacement Good Worn Needs Replacement CHECK OPERATION AND CONDITION OF IN SPEC REPAIR PROBLEM Main Power Switch or Key Swteh LLL 1 21 22 SpeedPoenmeer Cd SC 0 E 12 21 21 LL ff 1 of 2 1 2 Magnum Service Manual V1 0 MAINTENANCE MAGNUM Series PREVENTIVE MAINTENANCE WORKSHEET CHECK OPERATION AND CONDITION OF INSPEC REPAIR PROBLEM Spray Jet Switoh o ff Spray Jet Pump Hose 8 Nozze TT Battery Charger Connectors TE Battery Charger 2 02 CLEAN AND OR LUBRICATE IN SPEC REPAIR PROBLEM Solution Fiter 00
94. se burns Wear protective face shield and gloves when servicing batteries Do not store outdoors or pressure wash Prevent from getting electrical components wet The use of parts and solutions other than recommended by the manufacturer may cause property damage bodily injury or death to yourself or others Dress safely Do not wear rings watches or other jewelry while working on this machine They can cause an electrical short which can cause serious burns other injury or death Do not work on this machine while wearing a tie scarf hat or any other loose or dangling neck wear or clothing Loose clothing can tangle or catch on rotating parts causing serious injury or death Do not use this machine as a ladder or a chair Operate this machine only from the operators position This machine was not designed to carry passengers or transport cargo Do not operate this machine on steep ramps or uneven surfaces When climbing a ramp always drive the machine forward straight up or down the ramp Never drive across the incline e Do not back down or turn on ramps Always use the charger provided by the manufacturer to charge the machine It is an automatic charger specifically designed to charge at the appropriate rate If you must use a different charger disconnect the batteries from the machine as this will protect the on board electronics Understand the dynamic breaking system before you operate the machine on ramps or slopes
95. se chattering problems or excessive front squeegee blade wear If too much suction is created the squeegee will chatter and may come off the machine If this happens the suction must be reduced by turning the knob counterclockwise 1 to 2 turns to create more of an air leak at the front blade You can over adjust in either direction The squeegee will not work if the back blade is not evenly deflected across rear and if wheels do not touch the floor Magnum Service Manual V1 0 3 5 3 SQUEEGEE SYSTEM SQUEEGEE ADJUSTMENT EXAMPLES FIGURE 1 5 FRONT BLADE A B Worn Blade Squeeegee wiping edge has worn so the square edge is gone The squeegee now runs over the water instead of scraping it off the floor FIGURE 3 5 FRONT BLADE A B Too Much forward pitch on this squeegee The Rear blade is barely making contact with the floor The rear wheel are not touching the floor FIGURE 2 FRONT BLADE A B Properly Adjusted Squeegee Front blade just contacts the floor rear blade is slightly flared outward FIGURE 4 FRONT BLADE A Too Much backward pitch on this squeegee The rear blade is laying over and the front blade is not touching the floor Magnum Service Manual V1 0 SQUEEGEE SVSTEM 4 squeegee assemble has adjustable squeegee wheels adjustment for this is 5 16 fine thread bolt and lock nut It was designed this wav to keep non s
96. sends a signal to the controller and the controller then energizes the traction motor propel ling the machine forward When the reverse switch is engaged it sends 2 signals to the controller One signal instructing the machine to move backwards and one signal instruct ing itto move The controller then energizes the drive motor to propel the machine in reverse Both the forward and reverse speeds are regulated by the potentiometer located on the control panel The controller has internal protection for the drive motor It will slow the machine down if the traction motor draws too many amps for more than 60 seconds If the overload continues the controller will shut off the motor and show a diagnostic code on the LCD display The motor can be damaged if repeatedly overloaded in a short time The average amp draw for transport is 7 9 amps at full speed with all other functions off AXLE The trans axel we use on the magnum scrubber has a 1 2 HP motor mated to a differential assembly The axel has only 4 serviceable parts on it The motor the shear key the wheel mounts and the tires DRIVE MOTOR The drive motor is a separately serviced part and is easily replaced TIRES amp WHEELS The tires are available in 2 styles The standard equipment is a pneumatic tire that provides very good traction in most applications but is subject to puncture from sharp objects The optional tire is a solid rubber tire with a steel hub This tire offers superior trac
97. sion cord With a voltmeter set to the AC scale measure the voltage at the outlet v YES that they are using to charge the machine Is the voltage between 110 and 125 volts AC Find an outlet with acceptable voltage or have the customer call out an electrician to repair their outlet y NO 7777 13 20 Magnum Service Manual V1 0 COMPUTER CONTROL system 3 MAGNUM ONBOARD CHARGER DIAGNOSTIC FLOW CHART 1 of 1 Instruct owner on YES proper machine operation Does the charger work properly Operate machine ONBOARD and verifv the does not work 4 customers complaint y NO 7 Measure the voltage of the batteries and record it Ask CUSTOMER to plug the machine in to Tell customer to replace or no charge as they 4 eliminate the extension cord normally would Observe them plugging it in Were thev using an extension cord Observe the extension cord Note the length and gauge of the cord The cord should ne no longer than 15 feet and be a Number 12 gauge or heavier i4 VES Is their extension cord cceptable With a voltmeter set to the AC scale measure the YES voltage at the outlet that they are using to charge the machine v Find an ou
98. solution drain hose and set on floor drain to completely drain solution tank 3 Lift recovery tank drain hose off J hook Unscrew cap and set on floor drain to empty tank Solution drain hose Recovery dump hose RI 6 Magnum Service Manual V1 0 REPAIR INSTRUCTIONS R l 2 23 2006 253 03 HANDLE BAR BUTTON SWITCH RaRPage 1 of 2 TIME REQUIRED 30 MINUTES Per SWITCH NUMBER OF TECHS 1 PERSON REQUIRED PARTS e Qty 2 1 2 long 16 awg shrink tubing e Qty 2 7 229 Push button switch REQUIRED TOOLS e 3 long Z2 Phillips short screw driver Wire striper Wire cutter Solder gun Flux core solder Heat gun 9 16 12 point box wrench PLACE MACHINE ON LEVEL GROUND AND CHOCK WHEELS DISCONNECTING BATTERIES 1 Pull back the terminal cover on the right batterie s positive terminal 2 Use 9 16 socket to loosen and remove the 5 16 nut amp Lock Washer 3 Pull the red cable off and secure away from post See figure below Magnum Service Manual V1 0 R l REPAIR INSTRUCTIONS 2 23 2006 253 03 HANDLE BAR BUTTON SWITCH Ri RPage 2 of 2 REMOVING OLD PUSH BUTTON SWITCH PLATE 1 Using a 2 Phillips head screw driver remove the two 8 32 1 2 screws that hold the switch plate on handle bars 2 Cut wires as close to switch as possible See figure below 1 Remove old switch from switch plate and reinstall new switch onto switch plate 3 Strip wires 1 4 and slide shrink tubing on to wires 4
99. ssed and you should have less than one ohm when you press in the switch id you have the v Rear is cmt Magnum Service Manual V1 0 button and reset 44 NO correct readings the machine YES v WES Ie Replace the display with a know good display or a problem NO new one and retest the repaired machine Did this repair the machine NO the ctr YES 7 Replace the LCD displav 13 23 13 COMPUTER CONTROL SYSTEM MAGNUM SQUEEGEE ACTUATOR DIAGNOSTIC FLOW CHART 1 of 1 Operate machine and verify the customers complaint Instruct owner on proper machine operation SQUEEGEE EN does not operate i Does the actuator work properly MES v Turn each switch that can operate the vacuum on one at a time vacuum switch of board vac switch amp one touch switch Watch for the vacuum icon on the Icd display Allow about 10 seconds for it to show See Squeegee NO switch section Does the icon show on the LCD2 VES Attach a voltmeter set to the DC volt scale to the orange and green wires going to the actuator Cvcle the kev switch off and then on and observe the voltage Adjust the limit switch on the actuator o make it extend more Does the actuator move at all 4 With the me
100. stall brushes align brush with the brush drive and push until the brush slides down onto the driver Install the access door back onto the brushes If the access door does not fit up to the brush deck completely the brushes are not situated on the drivers properly Realign the brushes until they slip onto the drivers completely and the access door sits tightly against the brush deck and latch will close easily Magnum Service Manual V1 0 1 BRUSH DRIVE SYSTEM BLANK THIS PAGE INTENTIONALLY LEFT BLANK 7 4 Magnum Service Manual V1 0 BRUSH LIFT SYSTEM 6 BRUSH LIFT SYSTEM The active brush lift system on the Magnum series consists of an actuator down pres sure springs scrub switch and the controller The brush deck is raised and lowered by the brush deck actuator which is driven by the controller The actuator circuit is internally protected from electrical overload by the controller The active bush lift system is used to lower the brush deck when scrubbing is started and raise it when stopped The controller continually monitors the amperage draw of the scrub brushes and raises and lowers the scrub deck accordingly to keep the motors drawing a consistent amount of amperage thus keeping the scrub pressure uniform LIFTING LINKAGE amp DOWN PRESSURE SPRINGS BRUSH LIFT ELECTRICAL CIRCUIT The brush lift electrical circuit itself is a very simple circuit It consists of two wires that run from the controller to the actuato
101. ter still connected to the machine turn on the off board vac switch and watch the meter Was there batterv voltage for about 4 seconds when he machine powere Did this remedy the problem Replace the YES actuator C NO Y YES With a voltmeter set to the DC scale back probe terminals 3 amp 10 on the 14 pin Molex connector on the controller Observe the meter reading when the machine is turned on v Repar is comite Back of 14 pin Male Connectoa 1413121110 9 8 7654 31211 Was there batterv voltage for about 4 seconds when the machine powered up2 as there batterv voltage on the meter Replace the controller Noo b YES YES Replace the Repair wiring to actuator the controller 77 77 13 24 Magnum Service Manual V1 0 COMPUTER CONTROL system 3 MAGNUM VACUUM MOTOR DIAGNOSTIC FLOW CHART 1of1 Instruct owner on Does the motor Operate machine VACUUM MOTOR A and verifv the not run customers complaint See the VACUUM NO Does the icon SWITCH section turn on VES v YES proper machine 7 work properly operation NO Y Turn on the vac motor switch and depress foot pedal Observe the LCD display to see if the vacuum icon turns on With a voltmeter set on the DC se
102. th a voltmeter set to the DC scale measure from the negative lead to the positive battery terminal as there battery voltage as there battery voltage NO NO y in e EEE Sar TO US With a voltmeter set to the DC DC scale measure the E scale measure from both the voltage from the positive to leads at the spray jet switch to Meta the negative battery terminal the Machine turned on 9 ry v With a a voltmeter set to the DC scale measure Was there Was there battery voltage NO See the BUSS BAR power at either of NO the voltage from the across the buss POWER section the leads on the positive to the negative bars switch buss bar with the Machine turned on YES Was there battery voltage Repair wiring between the switch and the spray YES Was there power at both across the buss P YES jet pump qf the leads ae A NO YES Y No Flip the sprav jet switch the Repair wiring to between other direction and retest at the sprav jet switch and Repair the wiring between both of the leads to it the positive buss bar the negative lead and the negative buss bar VES y See BUSS RELAY section as there power at both Qf the leads NO Y Replace the Spray Jet Switch 13 30 Magnum Service Manual V1 0 REPA
103. the overload or short On board DC systems are drawing more current than the Disconnect the charger s black NEGATIVE charger can replace ring terminal from the battery Reapply AC Excessive ambient temperature has forced the charger to power and the green LED only should now cutback output current in order to self protect light Turn off all DC equipment while charging Determine the cause of the excessive ambient temperature and correct The red and yellow On board DC systems are drawing in excess of 10 amps Turn off all DC equipment while charging LED s stay on for more One or more defective or damaged cells Load test the batteries and replace if than 10 Hrs Extremely low AC voltage at the battery charger necessary Apply a higher AC voltage source or reduce the length of the extension cord Green 1 LED stays on Open DC output fuse Replace DC output fuse with a 30 Amp when the battery is known Bussmann MDA 30 to be low Faulty or contaminated terminal connections Clean and tighten or repair all terminal One or more defective or damaged cells connections Load test the batteries and replace if necessary The AC Present Green 2 No AC power available at the charger Connect AC power or reset the AC breaker on LED does not turn on Component failure the main panel when AC power is Return charger to the factory applied The yellow LED is 1 Charge cycle has timed out charging process took an 1 See fault codes bel
104. there bent Magnum Service Manual V1 0 parts NO See Next Page 3 10 SQUEEGEE SYSTEM MAGNUM SQUEEGEE DIAGNOSTIC FLOW CHART 2 of 2 From Previous Page Are there Replace parts and missing parts adjust squeegee Check to make sure the spacers washers and springs are all there and in working order NO Verify the measurement where the front of the Operate the triangle plate bolts to the von Does the towbar There should be machine work VES Bill the customer EXACTLY 7 8 clearance d properly operation on all machines except the 390 420 series It there proper Adjust the NO gt clearance there clearance YES YES Check cable NO clearance amp slack Operate the Is there proper NO Adjust clearance machine and verify Does the machine clearance and slack and or slack squeegee operate properly operation YES cov J NO Magnum Service Manual V1 0 SQUEEGEE LIFT SYSTEM A SQUEEGEE LIFT SVSTEM The squeegee lift svstem on the Magnum was designed with simplicitv in mind It has verv straight forward operation and minimal parts to assure consistent and highly reliable opera tion TO OPERATE Move the squeegee lift lever from right to left The sq
105. throttle of the machine is released the scrub brushes raise up off the floor for 2 seconds This is called raise time The purpose of this is so the scrub brushes start up under reduced load which leads to much longer motor life Raise time can be modified and is set through pro graming If scrubbing begins again the brushes drop back down to the floor and the control ler again starts analyzing the brush motor amp draw and adjusting the scrub deck pressure accordingly When the scrub deck switch is turned off the scrub head raises for four seconds to it s fully raised position DOWN PRESSURE Down pressure is regulated by the controller on the machine as The desired brush pres sure is selected by using the brush pressure switch on the control panel The brush pres sure selection is read out on the LCD display in the form of a bar graph The bar graph is segmented in to 5 levels the lowest being 1 bar and the highest being 5 bars The pres sure relative to each of the settings is programed into the controller and are fully adjustable BRUSH LIFT SYSTEM ADJUSTMENTS The brush lift system has two adjustments that can be made The first adjustment is the length of travel of the actuator ram This controls how far down it will allow the brush deck to go The second adjustment is the upper linkage adjustment that controls how high the brush deck will lift off the floor To access the actuator and its linkage the body of the machine must be tipp
106. tion 12 for serving information BINDING POST TERMINALS Binding post terminals offer the best connection available and are used for the main battery terminals on both the V 3 amp V 4 controllers On the V 4 controllers the high output connec tions have been changed to the binding post type TIMED CIRCUITS The controller has the capability to control a circuit with a certain amount of logic We can customize the operation of a component beyond the simple on off operation Timers are used for our vacuum motors and our squeegee actuators to make the machine operation more user friendly The timer settings are changed through the controller programming BATTERY METER The battery meter is integrated into the controller and the status of the battery is displayed on the LCD screen The battery condition is monitored very differently from a traditional battery meter The battery condition is calculated by measuring the internal resistance of the battery pack The battery meter is designed to read properly when the battery is under load It is not uncommon for the battery gauge to climb when the machine is under load DOWN PRESSURE CONTROL The down pressure of the scrub deck is monitored and maintained by the controller It is adjusted many times a second to deliver consistent brush pressure with changing floor conditions The controller monitors the amp draw of the scrub motors which increases and decreases with brush deck pressure and floor surf
107. tion and it will not go flat Magnum Service Manual V1 0 9 1 0 TRACTION DRIVE SYSTEM BLANK THIS PAGE INTENTIONALLY LEFT BLANK 9 2 Magnum Service Manual V1 0 CHASSIS SYSTEM ff 0 CHASSIS SVSTEM The chassis svstem on the Magnum series is built on a heavv dutv gauge powder coated full frame The frame gives the machine great strength and durabilitv Evervthing is fas tened to the frame using stainless steel hardware allowing for easv servicing should a repair be needed CHASSIS REPLACEMENT In the unlikelv even that the chassis must be replaced due to collision or damage it can easily be done We recommend transferring the components piece by piece from the old chassis to the new chassis and installing the tank last on the new chassis TIRES There are 5 different tire options for the Magnum series of scrubbers We offer pneumatic tires as a standard tire grey tires for non marking applications Both the black and grey tires are available foam filled but come with a 90 day warranty There is also a HD tire op tion which is a solid tire CASTERS There are 2 different tvpes of casters available on the Magnum series There are the red polvurethane casters which provide verv good resistance to oil and grease and roll verv well making the machine easier to steer There are also grev rubber tires which are a softer tire making the machine roll a bit smoother but thev do not hold up well in solvents or harsh environmen
108. tlet with acceptable voltage or have the customer call out an electrician to repair their outlet Is the voltage between 110 and 125 volts AC y NO 13 21 Magnum Service Manual V1 0 13 COMPUTER CONTROL SYSTEM With a voltmeter set to the DC scale measure the voltage of the battery pack in the machine while the charger is turned on Was the voltage at least 36 volts NO YES is gt MAGNUM ONBOARD CHARGER DIAGNOSTIC FLOW CHART FROM PAGE 1 Does the green light turn on when the charger is plugged into the wall NO With voltmeter set to the DC scale measure the voltage of the batterv pack in the machine 13 22 Is the voltage above 4 0 volts YES v Replace the charger Magnum Service Manual V1 0 COMPUTER CONTROL system 3 MAGNUM PAGE SWITCH DIAGNOSTIC FLOW CHART Operate machine and verify the customers complaint PAGE switch is in operative 4 Replace the page 1 of 1 Instruct owner on proper machine operation Does the switch work properly Unplug the 20 pin connector from the back of the LCD display Using and Ohm meter measure across the 2 green wires pins 12 and 16 You should have OL or infinite resistance when the switch is not depre
109. tranaxle Reinstall transaxle mounts Making sure to use alignment marks and install 5116 nuts and lock washers and tighten See figure below B 7 Crimp butt connectors from transaxle wires back to harness and put 8 Wire tie on the transaxle wires to the frame 8 Reinstall the tires 9 Remove jack stands Magnum Service Manual V1 0 RI 13 R l REPAIR INSTRUCTIONS 2 23 2006 253 06 JACKING UP DISK MACHINE Page 1 of 1 NUMBER OF TECHS 1 PERSON REQUIRED TOOLS e 3 Ton jack e QTY 2 Wheel chocks COMPLETELY DRAIN RECOVERY AND SOLUTION TANKS SEE REPAIR INSTRUCTION 253 04 MAKE SURE MACHINE IS ON LEVEL GROUND JACKING UP MACHINE 1 Make sure casters are in reverse position 2 Put wheel chocks firmly behind caster wheels see figure below aid a OT ak RED MEE uL 3 Open jaws and remove brushes 4 Center jack under scrubdeck see figure below 5 Raise jack 6 Secure machine with jackstands RI 14 Magnum Service Manual V1 0 REPAIR INSTRUCTIONS R l 2 23 2006 253 07 JACKING CYLINDRICAL MACHINE Page 1 of 1 NUMBER OF TECHS 1 PERSON REQUIRED TOOLS e 3 Ton jack e QTY 2 Wheel chocks COMPLETELY DRAIN RECOVERY AND SOLUTION TANKS SEE REPAIR INSTRUCTOIN 253 04 MAKE SURE MACHINE IS ON LEVEL GROUND JACKING UP MACHINE 1 Make sure casters are in reverse position 2 Put wheel chocks firmly behind caster wheels see figure below
110. ts Magnum Service Manual V1 0 10 1 10 CHASSIS SYSTEM BLANK THIS PAGE WAS INTENTIONALLY LEFT BLANK 10 2 Magnum Service Manual V1 0 BATTERY SYSTEM 11 BATTERV SAFETV DANGER OF EXPLODING BATTERIES Batteries contain sulfuric acid and produce explosive mixtures of hvdrogen and oxvgen Because self discharge action generates hvdrogen gas even when the batterv is not in op eration Make sure batteries are stored and worked on in a well ventilated area ALWAYS wear ANSI 287 1 U S Standard approved safety glasses and face shield or splash proof goggles when working on or near batteries Always wear proper face eye and hand protection Keep all sparks flames and forms of combustion away from the battery Never try to open a battery with non removeable vents Keep removable vents tight and level except when servicing electrolyte Make sure work area is well ventilated Never lean over battery while boosting testing or charging Exercise caution when working with metallic tools or conductors to prevent short circuits and sparks SAFE CHARGING Never attempt to charge a battery without first reviewing the instructions for the charger be ing used In addition to the manufacturer s instructions these general precautions should be followed Always wear proper eye face and hand protection Always charge batteries in a well ventilated area Keep vents tight and level Turn the charger and timer OFF before connect
111. tting measure the voltage at the vacuum motor while the machine is running and the vacuum icon is on as there 34 volts or more at the vacuum motor 6 2 VES vacuum motor NO Y Using a voltmeter set to the DC scale back probe the two lead in the vacuum plug at the controller while the machine is running and the vacuum icon is on Was there 34 volts or more t the controlle Replace the NO controller Repair connection between the vacuum motor and the controller Magnum Service Manual V1 0 13 25 13 COMPUTER CONTROL SYSTEM MAGNUM WATER POTENTIOMETER DIAGNOSTIC FLOW CHART WATER POTENTIOMETER d Operate machine and verify the ot change water delivery customers complaint 1 of 3 Instruct owner on Can you change WATER ICON While scrubbing turn the potentiometer very slowly and Observe the icon water icon on the LCD display kapa the ve Javes Does the length of time the icon stays on increase or decrease at all NO v Turn the solution potentiometer to the Maximum flow position Does the water icon on the LCD display stay on continuously water volume with the YES Potentiometer proper machine operation Does the machine dispense too much or too little water
112. ueegee will drop and the vacuum motor will then run To turn off the vacuum motor move the squeegee lift lever from left to right The squeegee will be raised and the vacuum motor will turn off after a time delay SQUEEGEE LIFT ADJUSTMENTS There are no provisions for adjustment of the squeegee lift If the squeegee is not raising and lowering properly it is due to bent or worn part or parts Inspect the lift assembly and other related systems for bent or worn parts and replace as necessary SQUEEGEE LIFT ELECTRICAL CIRCUIT Although the squeegee lift is a manual lift there is an electrical circuit that it is tied to When the squeegee lever is moved it actuates a switch This switch send a signal to the control ler telling it that the squeegee is down on the floor When it sees this signal it turns on the vacuum motor When the squeegee lever is moved to lift the squeegee up the switch in no longer depressed and the signal going to the controller is interrupted When the controller no longer sees the signal for the vacuum motor it runs the vacuum motor for 21 additional seconds to clear any excess water from the squeegee hose and then it turns off the vacu um motor Magnum Service Manual V1 0 4 1 A SQUEEGEE LIFT SYSTEM BLANK THIS PAGE WAS INTENTIONALLY LEFT BLANK lt lt Magnum Service Manual V1 0 _ RECOVERY SYSTEM 4 RECOVERY SYSTEM The recovery system of the Magnum series is powered by a 24 volt 550 watt vac
113. unt of time the valve is on for This is controlled by the solution potentiometer on the control panel 4 BRUSH PRESSURE GAUGE This icon is a bar graph representation of the desired brush pressure It is divided into 5 segments and each segment indicates more pad pressure 5 VACUUM MOTOR This icon indicates the controller is receiving an input to run the vacuum motor 6 HIGH THROTTLE This icon indicates one or more throttle inputs such as the green handle bar buttons or the reverse switch were activated when the machine was powered on Make sure no buttons or switches are depressed and cycle the power to the machine SCREEN 2 To access screen 2 push the green page button on the con trol panel once 7 KEY SWITCH HOUR METER This hour meter represents the total number of hours the ma chine has been powered on This does not mean however that the machine has been used this long just that it has had the power on for the time indicated 7 KEY SWITCH HOUR METER 8 BATTERY METER 8 BATTERY METER This meter shows the charge level of the batteries in the machine This gauge is designed to read properly while the machine is in use and therefore will vary during usage of the machine Magnum Service Manual V1 0 13 3 13 COMPUTER CONTROL SYSTEM SCREEN 3 To access this from screen 1 press the green page button twice 9 BATTERY METER This meter shows the charge level of the batteries in the mach
114. uum motor The recovery tank is designed with a large lid to facilitate 10096 access for complete clean ing out the recovery tank when use of the machine is finished The vacuum motor draws air in through the squeegee tool through the squeegee hose and into recovery tank The water travels with the air flowing through the system and falls out of the air when it reaches the recovery tank The air then passes through the vacuum saver and out through the vacuum motor The recovery tank is equipped with a clear lid that allows the operator to observe the conditions inside the recovery tank as well as the recovery water level inside Inside the recovery tank there are 4 major components The recovery lid drain saver vacuum float and the water baffle RECOVERY LID The recovery lid is made from 1 8 thick stainless steel with a clear dome The dome is to provide you with the ability to see the condition of the recovery tank dur ing operation DRAIN SAVER The drain saver is located inside the recovery tank and is accessed by open ing the recovery lid It is designed to collect large debris that is picked up by the squeegee so it does not settle in your recovery tank or clog the drain hose Magnum Service Manual V1 0 5 1 RECOVERY SYSTEM VACUUM FLOAT The vacuum float assembly is located inside the recovery tank and is accessed by opening the re covery tank lid The float assembly stops the flow of air in the event that the re
115. y on GO TO PAGE 2 Magnum Service Manual V1 0 COMPUTER CONTROL system 3 MAGNUM BUSS RELAY DIAGNOSTIC FLOW CHART 2 of 2 From Page 1 A Repair break in the wiring between terminal 86 black wire and the negative buss bar YES Is there battery voltage across these terminals Using a voltmeter set the meter to DC volts Measure the voltage between terminals 85 red wire and each of the negative buss bar circuit breaker terminals with the key on Is there battery voltage at both circuit breaker terminals YES NO Is there battery voltage at either circuit breaker terminal YES NO Using voltmeter set the meter to DC volts Measure the voltage between terminals 85 red wire and the negative batterv terminal on the controller Is there batterv voltage across these terminals YES NO Repair connection between terminal 87 and the positive buss bar Repair break in wiring between the negative buss bar and the circuit breaker From Page 2 Is there batterv voltage across these terminals2 VES NO Using a voltmeter set the meter to DC volts Connect the probe of the meter to the buss bar with a clip on your meter probe With the positive lead of your meter measure the voltage at terminal 30 red wire ff on the buss re
116. y transistors and not relays so they are different to diagnose than a tradi tional control system An important thing to be aware of is when an output Is turned off there can be as much of 80 of the voltage present at the output when you measure it with a meter The voltage that is present comes from the continuity test that the control ler continually runs on some of the output circuits This a very low amp signal that can register on your meter but is not enough amperage to power a motor or other accessory To consider an output to be or activated it must be 95 of battery voltage SOLUTION SOLENOID AUX 3 The solution solenoid output of the controller provides a ground to the solution solenoid valve The positive voltage feed to the solenoid valve comes from the switched B power from the controller on pin 8 of the 14 pin Molex connector at the controller Magnum Service Manual V1 0 COMPUTER CONTROL SYSTEM 3 PROGRAMMING We use the same controllers on nearly all of our machines The controller s embedded computer needs a set of instructions to operate the machine The instructions are the program the computer runs and we can modify this program by changing it s parameters This is what makes it possible to use the same controller in most of our machines but have each one of them react differently By changing these parameters we can make the piece of equipment function in different ways An example of this is by changi

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