Model 255
Operator Manual
255 Rider Burnisher
2010 Edition: 1
R.P.S. Corporation
P.O. Box 241
Racine, Wisconsin 53401
Phone: 1-800-450-9824
Fax:
1-866-632-6961
How to use this manual
This manual contains the following sections:
- HOW TO USE THIS MANUAL
- SAFETY
- OPERATIONS
- MAINTENANCE
- PARTS LIST
The SAFETY section contains important information
regarding hazardous or unsafe practices of the
machine.
Levels of hazards are identified that could result
in product or personal injury, or severe injury
resulting in death.
The HOW TO USE THIS MANUAL section will
tell you how to find important information
for ordering the correct replacement parts.
The OPERATIONS section is to familiarize the
operator with the operation and function of the
machine.
Parts may be ordered from authorized dealers.
When placing an order for parts, the machine
model and serial number are important.
The MAINTENANCE section contains preventative
maintenance information to keep the machine and
its components in good working condition. They are
listed in this general order:
Refer to MACHINE INFORMATION on page one
of this manual, which is filled out during the
installation of your machine.
- Batteries
- Burnising Pads
- Cleaning Filter
- Service Schedule
- Machine Trouble Shooting
The serial number of your machine is located
on the lower half of steering tower of the
machine. (See Picture Below)
The PARTS LIST section contains assembled parts
illustrations and corresponding parts list. The parts
lists include the following columns of information:
-
ITEM - Refers to the reference
number on the parts illustration.
-
PART NO. - Lists the part number
for the part.
-
QTY - Lists the quantity of the part
used in that area of the machine.
SERIAL NUMBER PLATE
-
DESCRIPTION - Is a brief description
of the part.
-
COMMENTS -For information not
noted by the other columns.
NOTE: If a service or option kit is installed on your
machine, be sure to keep the KIT INSTRUCTIONS
which came with the kit. It contains replacement
part numbers needed for ordering future parts.
STANDARD WARRANTY POLICY (RPS Corporation)
RPS Corporation warrants its machines, parts and accessories to be free of manufacturer’s
defects for the periods specified below. Warranty will be granted at the sole discretion of
RPS Corporation and is subject to final claim and parts review by R.P.S. Corporation and its
vendors. This policy is effective January 1, 2010 and is subject to change on production units
at a future date.
COVERAGE, EXCLUSIONS AND LIMITATIONS:
Coverage:
All Models sold (Sweepers, Scrubbers, Burnishers)
Parts:
36 months / 1,500 hours on “Power On” hour meter
Labor:
12 months
Travel:
3 months (150 mile maximum)
Poly Tanks: 7 Years
OEM Parts: 3 months
Validity:
Fully completed Machine Delivery Form (online or fax) is on record at RPS.
Limitation:
Warranty will begin on date of machine installation to end-user or 6 months
after shipment from RPS Corp to the distributor if unsold at that time.
This warranty includes all parts on the machine except normal wear parts. Some of these
exceptions are:
1.
Any Brooms, Brushes, Pads or Pad Drivers including Center Clip Retainers
2.
Floor Seals, Wipers, Splash Curtains, Squeegees or Gaskets.
3.
Filters, Dust Collection Bags or Screens
4.
The safety pins design to fail in shear, which are a fail-safe device
5.
Belts, Hoses or Tubing.
6.
Caster Wheels, Tires or internal tire tubes.
7.
Vacuum motors with evidence of water/foam passage or more than 450
hours
8.
Lights (Strobe, Headlights or bulbs).
9.
The Batteries (see below).
 NOT COVERED: Routine maintenance, adjustments or parts damaged from
abuse, neglect, improper use of the machine, or lack of scheduled “daily,
weekly, monthly” maintenance in accordance with our published PM Sheets.
POLY TANKS: 7 Years Coverage against leakage due to manufacturer’s defect in materials or
workmanship. NOTE: Freight coverage for 3-Years under the parts section of warranty.
BATTERIES: Warranted through battery manufacturer for One (1) Year (prorated) from the date of
delivery. The battery manufacturer approves or denies the warranty coverage after analysis. We rely
on solely on their review. NOTE NOT COVERED: Damage from lack of water, failure to use OEM
charger, or non-distilled water.
Table of contents
Machine information form
Warranty registration form
Machine specifications
Common wear parts
Safety messages
!!Safety precautions!!
Machine controls and features
Controls and fuctions
Machine preparation
Machine setup
Operation
Pre-burnishing check list
One pass burnishing
Charging batteries
Maintenance
Preventative maintenance records
LCD screen menu display
Troubleshooting central command
Troubleshooting
Machine parts section
Page 1
Page 2
Page 3
Page 4
Page 5
Page 6
Page 7
Page 8
Page 9
Page 10
Page 11
Page 11
Page 11
Page 12
Page 13
Page 14-16
Page 17
Page 18-19
Page 20-21
Page 22-40
Machine Parts Illustration
Front wheel drive
Wheels and Rollers
20" Burniher Deck
27" Burnisher deck
Mounting deck
Steering Upright
Central Command
Top Front Components
Actuator Piviot
Actuator Vac box and Charger
Batteries and Covers
Pages 23-24
Pages 25-26
Pages 27-28
Pages 29-30
Pages 31-32
Pages 33-34
Pages 35-36
Pages 37-38
Pages 39-40
Pages 41-42
Pages 43-44
Machine information
Please fill this area out at the time of installation for future reference.
Model number_____________________________________________________________
Serial number:______________________________________________________________
Installation date:___________________________________________________________
Installing dealer:__________________________________________________________
Dealer contact: ___________________________________________________________
Address:____________________________________________________________________
City, state, zip: _____________________________________________________________
Phone number:_____________________________________________________________
This operator and parts manual should be considered a permanent part of the unit and should remain with the unit at
all times. This operator and parts manual covers all the tomcat 255 Series burnishers. You may find descriptions and
features that are not on your particular model. The information and specification included in this publication were in
effect at the time of printing. R.P.S. Corporation reserves the right to make changes without notice incurring any
obligation.
To register for warranty, fax your warranty registration form today!
PAGE 1
1-800-634-4060
Machine Install / Warranty Registration
Installing Dealer:
Installed By:
Location: (City, State):
Install Date:
End-User Company Name
www.factorycat.com
End-User Contact:
Address:
City/State:
Zip
Phone:
Fax:
Email:
Model:
Serial #:
Hour Meter:
BUYER’S REPRESENTATIVE HAS RECEIVED INSTRUCTION IN PROPER OPERATION OF THE FOLLOWING CONTROLS AND FEATURES:
SCRUBBERS
Filling solution tank, Solution tank sight tube, Solution drain hose or valve for flushing and freezing conditions
Adjusting controls & operation, Double scrubbing, Squeegee lift delay, vacuum switch (horn honking) and vacuum timer
Recovery tank draining & cleaning, vacuum screen removal and cleaning, drain saver basket emptied.
Shroud and pad/brush removal and installation
Side Wiper and Curtain adjustment and maintenance for water control
Solution valve and filter operation (removal and cleaning)
LCD display operation, 4 hour meters (key switch, brush, traction drive, vacuum)
Tank tilt back feature, only when both tanks are fully drained
Squeegee hose removal and checking for clogs
BURNISHERS
Train and have customer demonstrate proper removal and replacement of burnishing pad
Pad pressure gauge and proper operating range to avoid tripping the circuit breaker
SWEEPERS
Demonstrate proper removal and replacement of main broom and side brooms
Method for cleaning the dust filter, empting out the debris hopper and correct installation
Correct operation of the main broom and side broom levers, and understands to park with brushes in UP position
Trained on the “Wet-Sweep” bypass door and not to operate through standing water
ALL MACHINES
Checking battery electrolyte level and confirm monthly check that battery terminals are tight
Parking brake override
Charging operation and customer understands batteries have limited “cycles” and recharging = 1 cycle
Seat and steering wheel adjustment
Customer has read and understands the list of WARNINGS in the Operator manual
Battery and Machine Maintenance Guide posters hung up and reviewed
Manufacturer’s website is a good source of information and sign up for quarterly newsletters
In addition to the above items the buyers representative has received the operator’s manual and been advised to read the manual before
operating the machine.
Installed By (print)
Buyers Representative (print)
Signature
Signature
Buyer agrees to pay for any repairs, adjustments, or secondary training that manufacturer determines is excluded from the warranty.
COMPLETE AND FAX FORM TO 1-866-632-6961 or online www.factorycat.com
Specifications
255
CONSTRUCTION
Frame:
Rear Axle Capacity:
Rear Wheels (non-marking):
Front Wheel Drive Capacity:
Front Wheel (non-marking):
Dimensions: (L x W x H):
Weight (w/ batteries):
Weight (w/out batteries):
(10-gauge) 1/8” steel
5,200 pounds
(2) 12” x 3.5”
2,300 pounds
(1) 10” x 3”
54.5” x 25” x 50”
1,072 pounds
714 pounds
BURNISHING SYSTEM
Pad Diameter:
Pad Motor Power (standard):
Pad Motor Power (optional):
Pad Speed:
Pad Engagement:
Pad Pressure:
Pad Pressure Settings:
(1) 20 inches or 27 inches
(1) 4.0 hp
(1) 4.0 hp
2000 rpm
Direct on 20" and Dual Belt on 27"
0 - 75 pounds
Infinite
BATTERY SYSTEM
Battery ah rating: (std)
Battery ah rating: (opt)
Battery Run Time:
Charger (110v / 60 Hz / automatic):
(6) 245 ah
(6) 325ah or 395 ah
Up to 4 hours
36 volt / 25 amp
FILTERING SYSTEM
Vacuum Description:
Filtering Material:
Filter Rating:
Vacuum Power:
Airflow Rating:
PASSIVE or ACTIVE
Paper
1 Micron
0.75 hp (optional)
70 cfm
DRIVE SYSTEM
Transport Power:
Forward Speed Control:
Reverse Speed Control:
Braking System:
Minimum Aisle for U-Turn:
1.0 hp
0-4.5 mph
0-3 mph
Dynamic w/ Auto Parking Brake
56”
PRODUCTIVITY
Cleaning Rate/Hour (Max):
Cleaning Rate/Hour (Normal):
45,000 sq. ft./hr
34,817 sq. ft./hr
GENERAL
Sound Level:
Gradeability:
70 dBA at Driver's Position
11 degrees / 19%
PAGE 3
Common wear parts
Pad
Pad
Function
Results
20" Part
Number
27" Part
Number
Image ultra high
speed - beige
Ultra high speed
High speed buffing
And burnishing.
For high speed buffing
and burnishing. For
frequent burnishing on
soft to medium
finishes.
20-4221
27-4221
Luster lite - blue
Ultra high speed
buffing and
burnishing.
For burnishing soft
floor finishes. May be
used on a daily basis.
Ideally suited for top
dressing highly
polished floors.
20-4222
27-4222
Combo ultra
high speed
Ultra high speed
buffing and
burnishing.
Blended polyester and
natural fibers. For
frequent burnishing on
medium finishes.
20-4223
27-4223
Porko ultra high
speed
Ultra high speed
buffing and
burnishing.
Blended natural fiber
pad. For frequent
minimal burnishing on
hard finishes.
20-4224
27-4224
Porko elite
Ultra high speed
buffing and
burnishing.
Blended natural fiber
pad works on all UHS
machines. For minimal
burnishing on medium
to hard finishes.
20-4225
27-4225
Porko plus
Ultra high speed
buffing and
burnishing.
High content of
natural fibers. Ideal
for minimal burnishing
on hard finishes.
20-4226
27-4226
PAGE 4
Safety Messages
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 operating procedures and other safety
information in this manual. This information informs you of potential hazards that could hurt you or others.
It is not practical or possible to warn you of all the hazards associated with operating this unit.
You must use your own good judgment.
This is intended for commercial use. It is designed to be used on hard floors in an indoor environment,
with the recommended pads.
1. DO NOT OPERATE UNIT:
Unless trained and authorized.
Unless operator manual is read and understood.
If unit is not in proper operating condition.
2. WHEN OPERATING UNIT:
Remove loose objects from the floor that may be projected from the revolving burnisher pad.
Keep hands and feet away from revolving pads.
Do not operate machine where flammable liquids or gasses are present.
Use extreme caution when maneuvering.
3. BEFORE LEAVING:
Make sure machine is turned off.
Stop on level surfaces.
Disconnect batteries.
4. BEFORE SERVICING:
Stop on level surface, and secure machine.
Disconnect batteries.
PAGE 5
!! Safety Precaution!!
WARNING: Hazardous voltage. Shock, burns or
WARNING: Always use the charger provided by
electrocution can result. Always disconnect the
batteries before servicing machine.
the maufacurer 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
before charging. This will prevent damage to the
electronic speed controller.
WARNING: Batteries emit hydrogen gases. Explosion or
fire can result. Keep sparks and open flames away.
WARNING: Charge unit in a well ventilated area, and
keep battery compartment open when charging.
Explosion or fire could result.
WARNING: Understand the dynamic braking
WARNING: Battery acid can cause burns. Wear
protective eye wear and gloves when servicing
batteries.
WARNING: Do not park the machine on ramps
system before you operate the machine on
ramps. Machine does not coast.
or slopes.
WARNING: Do not store outdoors or pressure wash.
Prevent electronic components from getting wet.
WARNING: The use of parts and solutions other than
that recommended by the manufacturer may cause
damage or endanger people.
WARNING: Dress safely. Do not wear rings or metal wrist
watches while working on this machine. They can
cause an electrical short, which, can cause serious
burns. Do not work on this machine while wearing a
tie, scarf or other loose, dangling neckware or clothing.
These loose items can tangle in the rotating parts and
cause serious injury or even death.
WARNING: Do not operate the machine if
any parts have been removed or damaged.
WARNING: Do not remove, paint over, or
destroy warning decals. If warning decals
become damaged, they must be replaced.
WARNING: Do not operate machine in unsafe
condition. If the machine is in need of repair or
is in any way 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.
WARNING: This machine must only be
WARNING: Do not use the machine as a step ladder or
chair.
operated by trained operator. As part of his
or her training, they must read this manual
thoroughly. If extra copies are needed,
contact your local dealer.
WARNING: Only operate this machine from the
operators position. It was not designed to carry
passengers.
WARNING: Always turn off the machine,
before leaving it unattended.
WARNING: Do not operate this machine on ramps or
uneven surfaces. When climbing a ramp, always drive
the machine in forward straight up or down the ramp.
Never drive across the incline. Do not back down or
turn on ramps!
PAGE 6
WARNING: Do not operate over electrical
floor outlets. May result in serious injury.
Machine Controls and Features
1
2
8
9
10
11
12
3
13
7
14
6
15 16
5
4
26
17 18 19 20 21
22
23
24 25
27 28
29
30
37
33
34
31
35
32
36
PAGE 7
38
Controls and Fuctions
See figures (1-6) on page 7
1.
2.
3.
4.
5.
6.
7.
8.
Seat: Adjustable seat for operator comfort and ease of entry.
Steering wheel: Used to steer the machine.
Headlight: Helps you see in low light areas and to warn oncoming traffic.
Front wheel: Steers and propels machine.
Corner roller bumpers: helps prevent damage to machine when cleaning close to walls and other objects.
Lower roller bumpers: Helps prevent damage to deck.
Rear tires: Non-marking and extra wide tires for stability.
Battery compartment lid: Holds batteries, on board battery charger, vac box, and actuator tower
9.
10.
11.
12.
13.
14.
Horn button: sounds horn.
Adjustable steering: adjustable steering wheel for comfort and ease of entry.
Hour Meter: Keeps track of how many hours are on the machine.
Charge port: Gray 50 used to receive charger input. (Note: only use charger provided)
Foot pedal: Makes machine go and release pedal to stop.
Non slip floor plate: helps prevent slipping when getting on and off of machine.
15.
16.
17.
18.
19.
20.
21.
Burnisher motor: This motor drives the burnishing deck.
Adjustable Arm: Adjusts the pitch of the burnishing deck.
Shroud: The shroud contains dust created from burnishing.
Dust control hose: Two dust control hoses pull dust and debris from shroud to filter box.
Actuator: The actuator lifts and lowers the deck.
Belt Guard: The belt guard protects the belts and pulleys from debris.
Vacuum motor: Provides suction to vac box.
22.
23.
24.
25.
26.
Batteries: The machine comes with one set of six batteries.
Spring Adjustment Knob: Increases or decreases the pad pressure.
Actuator tower: Provides down pressure adjustment.
Onboard Charger: Plug charger into outlet to charge machine.
Vacuum box: Collects dust created from burnishing.
27.
28.
29.
30.
31.
32.
Burnishing deck pressure gauge: Settings green (safe operating range) - red (overload).
Burnishing motor bursh indicator: Indicates when the burnisher motor needs new brushes.
LCD screen display: Lists functions and settings of the machine.
Menu control: Scrolls through different options on the LCD display.
Forward/Reverse switch: Controls the direction of the traction motor.
One touch button: Activates the burnishing deck, and dust control system simultaneously.
33.
34.
35.
36.
37.
38.
Vacuum switch: Allows you to turn on vacuum motor seperate from the one touch botton.
Resetable 80 amp burnisher motor circuit breaker:
(+) 15 amp resetable circuit breaker: (15 amp) positive bus bar.
(-) 15 amp resetable circuit breaker: (15 amp) negative buss bar.
Key switch: Turns power to machine on and off.
Emergence shut off: (optional) Shuts machine down in a emergency.
PAGE 8
Machine Preparation
Uncrating machine
Connecting hoses
Carefully check the crate for any sign of damage. Batteries
are in the unit.
To uncrate the machine, remove banding from around the
crate. Take off the top and sides And dispose of properly.
Remove banding from machine. Remove the chocks around
the drive wheels. Fold down ramp, and roll machine off of
the base. Notify the carrier immediately if concealed
damage is discovered.
Your machine is also equipped with two vacuum
hoses which need to be connected for the dust
control to work properly.
1.
Turn all switches to the off position.
2. Hinge open the battery access lid to access the
rear of the filter box and fan connections.
3. Check to see if hoses are clamped down to the
shroud and the filter box securely. (you should not
be able to pull them off easily) if hoses are loose
tighten the hose clamp with a screwdriver.
(see below)
Connecting batteries
Your machine is equipped with (six) 6 volt,
Deep cycle batteries, which
Form a 36 volt system. Maximum battery
Dimensions are 7"w x 15"l x 15"h.
1.
Turn all switches to the off position and remove key.
2. Hinge open the battery access lid to access the battery
compartment.
3. All of the six battery cables are connected to the
batteries. Locate any loose ones and connect to the open
terminal. Tighten with 9/16" wrench. (see below)
4. Turn on main power switch and check the battery
condition meter to ensure correct installation. Charge
batteries if needed. (see: battery charging)
Front
4. Check to see if hoses are clamped down to the
shroud. Hose should have just enough slack to move up
and down with the scrub deck and not interfere with
other moving parts. (See below)
PAGE 9
MACHINE SETUP
ATTACHING PAD
1.
KEY SWITCH
Turn on machine power
2. Assure that the deck is raised to the up
position by verifying that the uni-touch button is
not depressed (A yellow ring will appear around
the side of the uni-touch button). Turn machine
power back off and remove key. (See right)
UNI-TOUCH BOTTON
3. Remove blue big mouth from pad holder.
BLUE BIG
MOUTH PAD CLIP
4. Place pad on top of locking clip and slide
both below burnishing deck directly into the
center of one burnishing disk. (see below)
PAD
5. With pad and clip directly in the center of the
burnishing disk push up and screw in the pad clip.
(Hand tighten only) (see below)
6. Run machine and check for vibraitons. If
deck vibrates badly the pad may not be
centered on disk correctly. Remove pad and
reistall pad in the center of disk.
BLUE BIG
MOUTH PAD CLIP
SHROUD AND SHROIUD CURTAIN
***FOR CORRECT PAD APPLICATION , CALL YOUR LOCAL DEALER***
PAGE 10
PAD
Operation
Operating hints
Read and understand the safety section on page
5 and 6 before operating machine.
One Pass
Burnishing
Pre- burnishing
Check list
Steps: (see below)
1. Check battery condition gauge on the
central command II LCD screen. (See below) To
check gauge push menu control button until
battery gauge appears. Make sure batteries are
fully charged before using.
1. Turn machine on with the key switch.
2. Lower burnishing head to the floor by simply
depressing the green "uni touch" button.
3. The dust control will activate automatically
when you begin burnishing.
4. Begin burnishing by depressing the foot
pedal slowly and then to the speed required,
the headlight will illuminate.
LCD SCREEN
6. Once the pad begins to move, check the
pressure gauge. Start burnishing with in the
green marks, do not use yellow marks without
management approval.
MENU
CONTROL
7. To operate machine in reverse, simply switch
the reverse switch to the reverse position, back
up alarm will sound ( if equiped) and your
speed is reduce to roughly 50% of forward
speed.
8. To stop the machine, let off the foot pedal,
and the machine will stop automatically.
2. Check condition of pad and make sure it is
securely in place.
3. Check hose connections from filter box to
fan and, from filter box to shroud. (See below)
5. Check condition of shroud curtain shroud
curtain needs to be in good condition for dust
control system to work properly. (See below)
1
6
2
4
5
7
PAGE 11
Battery charging
CAUTION: The following instructions are intended for the 36v charger
supplied with the machine. Do not use any other charger with this machine.
Charger speccifications
Output voltage of 36 volts.
Output current of 25 amps max.
Input voltage of 110 volts/60 Hz.
Automatic shut off circuit.
Made for deep cycle batteries.
Danger: always charge batteries in a well ventilated area.
Batteries emit hydrogen gas. Explosion or fire can result. Keep
sparks and flame away. Shield eyes when servicing batteries
and avoid contact with battery acid. Leave rear hood open
when charging!
1. Transport machine to a well ventilated area for charging.
2. Turn the machine off.
3. Hinge opens the battery access hood to expose the
batteries. (Caution: always wear eye protection when batteries
are exposed)
4. Check the water level in each battery. Do not charge the
machine unless the water is slightly higher than the plates. If
needed, add enough distilled water to just slightly cover the
plates. Do not over fill. Batteries can overflow during charging.
Replace caps before charging.
5. With the grey charger plug disconnected from the machine,
plug the charger power cord into a grounded 110 volt standard
wall outlet.
6. Connect the grey charger plug into the battery charging
port located on the lower portion of the steering tower.
7. The charger will automatically begin charging, and
automatically shut off when fully charged (check gauge)
8. After the charger has turned off, unplug the grey charger
plug from the machine and disconnect the charger from the
wall outlet.
9. Recheck the cell level after charging. If needed, add
distilled water up to the correct level. Be certain to replace the
caps securely and to wipe off the top of the batteries with a
clean cloth.
PAGE 12
Gray charger
plug
Maintenance
Daily Maintenance
1.
Check pad condition. (Replace if necessary)
2.
Check battery charge.
3.
Clean dust control filters.
4.
Check hoses and verify there are no clogs.
5.
Check pads for wear and replace if needed.
6.
Charge unit and verify that charger is operating
properly
Weekly Maintenance
1.
Check battery water level.
2.
Check condition of all three tires.
3.
Check condition of dust curtains on shroud.
4.
Check condition of dust control hoses.
5.
Check to see if vacuum exhaust is clear.
Monthly
Maintenance
1.
Check flex driver
2.
Check to see if battery cables are
tightened and clean. (Tighten if needed)
3.
Check parking brake
4.
Check condition of burnishing deck actuator.
5.
Check condition of burnishing deck drive belts
Yearly
Maintenance
1.
PAGE 13
Call your local dealer for yearly maintenance
Preventative maintenance records
CUSTOMER INFORMATION
CUSTOMER
ADDRESS
CITY
STATE
ZIP CODE
MACHINE INFORMATION
MODEL #
WORK ORDER#
BATTERY CONDITION
SERIAL #
HOUR METER:
Cell #1
Cell #2
Battery # 1 Hydrometer Reading
Battery # 1 Water Condition
Battery # 2 Hydrometer Reading
Battery # 2 Water condition
Battery # 3 Hydrometer Reading
Battery # 3 Water Condition
Battery # 4 Hydrometer Reading
Battery # 4 Water condition
Battery # 5 Hydrometer Reading
Battery # 5 Water Condition
Battery # 6 Hydrometer Reading
Battery # 6 Water Condition
Clean Battery Tops. Check Battery Cable and Terminal Condition
NOTES:
PAGE 14
Cell #3
Preventative maintenance records
PAD CONDITION
Pad
Good
Worn
Needs Replacement
Pad retainer
Good
Worn
Needs Replacement
Pad Holder Condition
Good
Worn
Needs Replacement
CLEAN AND/OR LUBRICATE
IN SPEC
REPAIR
PROBLEM
IN SPEC
REPAIR
PROBLEM
IN SPEC
REPAIR
PROBLEM
Burnishing Deck Linkage
CHECK OPERATION AND CONDITION OF:
Steering wheel Tilt Mechanism
Key Switch
Horn
Head Light
LCD Display
Page Button
Pad Pressure Adjustment
Foot Pedal
Reverse Switch
Back Up Alarm
Burnish Switch
Burnishing Deck Lift System
Pad Motors & Motor Brushes
Active Vacuum Switch
Vacuum Motor performance
Strobe Light
Battery Charger Connectors
Battery Charger
VISUALLY INSPECT:
Vacuum Motor Brushes
Vacuum Hoses
Brush skirts
Pad Motor Brushes
Pad Drive Belt Condition & Tension
Pad Driver Condition
Drive Wheel Condition
Rear Wheels Condition
All Rollers
PAGE 15
Preventative maintenance records
COMMENTS
Technician's Name
Technician's Signature
Date
Customer's Name:
Customer's Signature
Date
©2005 R.P.S. Corporation
PAGE 16
LCD Screen Menu Displays
1
2
SCREEN # 1
1
SCREEN # 2
3
4
5
6
8
SCREEN #1 W/ERROR CODE
1
7
2
*** USE GREEN MENU SELECTION BUTTON ON CONTROL PANEL TO CHANGE SCREENS***
1.
Battery level indicator - indicates the energy level remaining in the batteries. (Shown on all menu displays)
2.
Burnisher deck down pressure gauge - Indicates pressure on the burnishing pads.
3.
Key switch hour meter - tells you the total hours the machine has been on.
4.
Burnishing pad hour meter - tells you the total hours the burnishing motors have been used.
5.
Transport hour meter - tells you the total hours the drive system has been used.
6.
Vacuum/fan hour meter- Tells you the total hours the vacuum motor has been used.
7.
Error warning symbol - indicates when there ius machine fault,- Displays diagnostic error code.
8.
Diagnostic code - when the machine has detected an error it will display the warning symbol and a diagnostic
code which indicates what's wrong.
( For common error codes and descriptions see page 18)
PAGE 17
Troubleshooting Central Command
NOTE: This machine is operated by a sophisticated electronic "controller" that has many fail-safes within it. The
controller analyzes problems and displays a four-digit numeric code of what is wrong in the LCD window.
Most of these codes require a technician's attention. You should not attempt repairs you are uncomfortable
with, especially if you are not used to working on electronics.
The complete list of codes is published in the simplified electronic trobleshooting manual, which is available to
technical people. However, we have included the basic codes that you can usually resolve yourself.
1. 1500 ERROR. Parking brake circuit fault. Call a
technician.
7601 AND 7602 ERROR. Pad current over load. This
can can occur when the pads hit a bump in the
floor. To restart the pads, turn off the key and turn it
on again. To avoid this error, either slow down on
bumpy parts of the floor, or reduce downpressure on
the pads.
2.
3. 1600 ERROR. Voltage exceeds the maximum.
Either the batteries are mis-wired, or the charger is still
plugged into the machine.
4. 7700, 7701, 7702, AND 7703 ERROR. The vacuum
system has malfunctioned. Turn off key and turn on
again to clear. If the code does not clear call a
technician.
PAGE 18
Troubleshooting Central Command
5. 7900 AND 7901 ERROR. The emergency stop button
is depressed.
6. HIGH THROTTLE ERROR. You pressed the drive button
before turning on the key. Turn off the key, release
the drive button and try again.
7. 2C00 AND 2C01 ERROR. Low voltage warning.
Voltage has dropped down below the minimum
required to operate the machine. If you wait a few
minutes, the batteries may coast up a bit in voltage,
allowing you to drive very slowly to the recharge
station.
8. 7802 ERROR. The traction motor was used to climb
a ramp, and was running up the ramp for more than
the 60 seconds allowed for this. Turn off the key, turn
on again, and continue. You should not use this
machine to climb ramps so steep and so long that this
code comes up repeatedly, or you could overheat
the traction motor.
9. All other error codes. Turn off the key, and disconnect the positve battery cable from the batteries for more
than one minute (the time is needed to drain the controller's on-board capacitor). Reconnect the cables,
being sure that they are tight, if they are loose you will burn the battery cables or the battery. If you
overtighten the cables you can damage the battery's lead terminal.
10. If the problem cannot be solved by any of these solution's call your local dealer's service department.
PAGE 19
Trouble Shooting
Problem
Cause
Solution
No power, nothing operates.
Faulty key switch.
Batteries need charging.
Faulty battery.
Loose battery cable.
Main circuit breaker tripped.
Contact local servicing dealer.
See charging batteries.
Replace battery.
Tighten loose cable.
Wait 5 minutes for auto reset.
determine cause and correct.
Burnishing motor does not operate.
Burnishing deck is not down.
Foot pedal is not depressed.
Burnishing circuit breaker tripped.
Carbon brushes worn.
Faulty motor or wires.
Put deck down.
Engage foot pedal.
Wait 5 minutes for auto reset
Determine cause and correct.
Contact local servicing dealer.
Contact local servicing dealer.
Drive motor does not operate.
Recharge switch misadjusted.
Faulty speed controller or wires.
Faulty drive motor.
Faulty wiring.
Carbon brushes worn.
Contact local servicing dealer.
Contact local servicing dealer.
Contact local servicing dealer.
Contact local servicing dealer.
Contact local servicing dealer.
Dust control fan does not operate.
Faulty vacuum switch.
Vacuum circuit breaker tripped.
Try operating "white " toggle.
Wait 5 minutes for auto reset.
Determine cause and correct.
Contact local servicing dealer.
Contact local servicing dealer.
Faulty vacuum motor.
Carbon brushes worn.
Drive motor runs incorrectly.
Faulty speed controller or wires.
Faulty potentiometer.
Loose wires.
PAGE 20
Contact local servicing dealer.
Contact local servicing dealer.
Contact local servicing dealer.
Trouble Shooting
Problem
Cause
Solution
Poor dust control.
Main vacuum hose disconnected.
Burnishing deck hose disconnected.
Burnishing deck hose clogged.
Damaged main vacuum hose.
Damaged burnishing deck hose.
Filter clogged.
Filter door not closed tightly.
Filter door gasket faulty.
Filter full.
Torn shroud curtain.
Faulty vacuum Motor.
Battery charge is low.
Reconnect hose.
Reconnect hose.
Remove debris.
Contact local servicing dealer.
Contact local servicing dealer.
Clean out filters.
Adjust screw on door clamp to
tighten seal.
Contact local servicing dealer.
Remove debris.
Contact local servicing dealer.
Contact local servicing dealer.
Charge batteries overnight.
Poor burnishing quality.
Burnishing pads worn out.
Debris stuck to burnishing pad.
Torn burnishing pad.
Faulty disk pad motor.
Battery charge is low.
Replace pads.
Remove debris.
Replace pads.
Contact local servicing dealer.
Charge batteries overnight.
Burnishing scrub deck noisy.
Missing burnishing pad.
Burnishing pad worn out.
Torn curtain hitting burnishing disks.
Damaged shroud.
Replace pads.
Replace pads.
Contact local servicing dealer.
Fix or replace shroud.
Rear tires noisy.
Bearings dry.
Faulty hubs.
Grease bearings.
Contact local servicing dealer.
Poor traction.
Excessive burnishing pad.
Pressure.
Worn drive tire.
Reduce pressure with switch.
Batteries run down.
Batteries still down.
Batteries low on water.
Charge batteries twice
Contact local servicing dealer.
Fill with distilled water to 3/4" above
the lead plates.
Contact local servicing dealer.
Short run time.
Batteries over cycled.
PAGE 21
Contact local servicing dealer.
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