How To Prepare the Machine For Operation. Clarke Mini-Max 28, Mini-Max 26, Mini-Max 30

How To Prepare the Machine For Operation

How To Handle the Packed Machine

The machine is packed in a specific package provided on a pallet so that it can be moved with a forklift.

WARNING: The packages cannot be placed on top of each other.

How to Unpack the Machine

1.

Remove the outer package.

2.

The machine is fixed on the pallet with banding straps and wooden blocks to prevent movement during shipment. Remove the bands and blocks.

3.

The MINI-MAX is shipped with the batteries already installed. The machine can be driven off of the pallet if the operator is thoroughly familiar with its operation.

4.

Lower the ramp. Release the parking brake and remove the machine. Avoid violent blows to the base unit.

4.

Keep the pallet for future transport necessities.

How to Install the Batteries

WARNING: The batteries are heavy. Lifting batteries without help could result in an injury. Get help to lift the batteries.

WARNING: Working with batteries can be dangerous. Always wear eye protection and protective clothing when working near batteries. NO

SMOKING!

WARNING: Hydrogen gas is formed during the charging operation and is explosive.

Only charge batteries in a well ventilated area with the seat base lifted.

WARNING: Pulling out the charger plug, with the timer on, will cause an arc and must be avoided.

The batteries are fitted in the appropriate compartment under the seat and under the recovery tank (figure 6). The

MINI-MAX uses six - 6 volt batteries. They must be handled by using appropriate lifting equipment suitable for the weight and for the coupler system. For maintenance and daily recharge of the batteries, it is necessary to follow all instructions given by the manufacturer.

For Battery Installation follow these steps (See figure 6):

1.

Make sure that the key switch is in the “OFF” position and the parking brake is set.

2.

Lift and rotate the base support of the seat forward.

3.

Lean the seat on to the steering wheel.

4.

Lift the front of the recovery tank and rotate it towards the rear until it locks in place.

5.

Put the batteries into position and connect the battery cables as shown in figure 7.

6.

Join the connector from the battery pack to the machine connector (see figure 8).

Clarke ® Operator's Manual -MINI MAX

Figure 6

Figure 7

Figure 8

7.

Unlatch the recovery tank support and carefully rotate it forward to the normal operating position.

8.

Lower the base support of the seat.

NOTE: Charge the batteries before using.

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How To Prepare the Machine For Operation

Battery Maintenance

The electrical power to operate the machine comes from the storage batteries. Storage batteries need preventative maintenance.

WARNING: Working with batteries can be dangerous. Always wear eye protection and protective clothing when working near batteries. NO

SMOKING!

To maintain the batteries in good condition, follow these instructions:

1.

Keep the electrolyte at the correct level. The correct level is between 1/4” (1/2 cm) below the bottom of the tube in each cell and above the tops of the plates.

Check the level of the electrolyte each time you charge the batteries (see figure 9).

NOTE: Check the level of electrolyte prior to charging the batteries. Be sure the plates in each cell are covered with electrolyte before charging. Do not top off the cells prior to charging the battery. Electrolyte expands during charging.

As a result, the electrolyte could overflow from the cells.

Always top off the cells with distilled water after charging.

CAUTION: Irreversible damage will occur to the batteries if electrolyte does not cover the plates. Keep the electrolyte at the correct level.

CAUTION:

CAUTION:

Machine damage and discharge across the tops of the batteries can occur if the batteries are over filled.

Do not fill the batteries up to the bottom of the tube in each cell.

Wipe any acid from the machine or the tops of the batteries. Never add acid to a battery after installation.

Batteries must be refilled with distilled water only. Do not use tap water as it may contain contaminants that will damage batteries.

2.

Keep the tops of the batteries clean and dry. Keep the terminals and connectors clean. To clean the top of the batteries, use a damp cloth with a weak solution of ammonia or bicarbonate of soda solution. To clean the terminals and connectors, use a terminal and connector cleaning tool. Do not allow ammonia or bicarbonate of soda to get into the batteries.

3.

Keep the batteries charged.

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Figure 9

Correct Fill

Clarke ® Operator's Manual -MINI MAX

How To Prepare the Machine For Operation

How to Charge the Batteries

WARNING: Charging the batteries in an area without adequate ventilation could result in an explosion. To prevent an explosion, charge the batteries only in an area with good ventilation.

WARNING: Lead acid batteries generate gases which could explode. Keep sparks and flames away from batteries. NO

SMOKING!

WARNING: Failure to disconnect the AC plug from the wall receptacle before connecting or disconnecting the

DC connector on the charger could result in an explosion. Always disconnect the AC plug from the wall receptacle before connecting or disconnecting the DC connector on the charger.

To charge the batteries, follow this procedure:

1.

Put the charger on a flat surface. Make sure the vents on the sides are at least two inches away from walls and other objects. Make sure there are no objects near the vents on the bottom of the charger.

2.

Make sure the key switch is in the “OFF” position.

3.

Set the parking brake by pushing on the pedal and pulling it backwards with your foot. Make sure the pedal is locked in position (see figure 10).

4.

Raise the seat base support.

5.

Disconnect the machine connector and the battery connector.

6.

Connect the battery charger connector to the battery pack connector in the machine (see figure 11).

NOTE: The MINI-MAX uses a battery adapter cable as an interface between the battery charger and the battery pack.

The adapter battery cable was delivered in the package with the machine. Connect the adapter cable to the charger and then to the battery pack. See the instruction booklet for the battery charger.

Recharging the Batteries (See figure 12)

Make sure the battery charger fits the installed batteries either for capacity or for type (lead/acid or GEL and equivalents).

WARNING: Never charge a GEL battery with an unsuitable battery charger.

Carefully follow the instructions given by the manufacturer of the batteries and battery charger.

Clarke ® Operator's Manual -MINI MAX

Figure 10

Figure 11

Figure 12

Page -11-

How To Prepare the Machine For Operation (cont.)

NOTE: To prevent permanent damage to the batteries, avoid their complete discharge. Never leave the batteries completely discharged, even if the machine is not being used. When recharging the batteries, keep the base support of the seat lifted. After every 20 recharging operations, check the level of the electrolyte and if necessary top off with distilled water.

Level Indicators for the Charge of the Batteries

The battery meter ( see figure 13) on the control panel has a digital read out with 4 fixed positions and also a blinking indicator. The numbers that appear on the display show the approximate charge level. 4 = maximum charge, 3 = 3/4 charge, 2 = 2/4 charge, 1 =

1/4 charge, 0 = (blinking) discharged battery.

Figure 13

3

NOTE: A few seconds after the meter reads “0” it will start blinking. The brush motors will then automatically switch off.

How To Install the Squeegee

To install the squeegee onto the machine, follow this procedure:

1. Insert the left stud bolt (1) on the squeegee into the left slotted hole in the support frame on the machine. Install the hair pin (2) into the stud bolt hole (see figure 14).

2. Attach the vacuum hose cuff to the squeegee hose fitting (see figure 15).

3. The squeegee assembly has a break away feature that is also used for mounting the squeegee on the right side. Loosen the spring loaded tension knob on the squeegee. Slide the stud with the washer and spring into the slotted hole in the support frame on the machine. The washer should be located above the support. Tighten the knob to apply the spring tension (see figure 16).

1

2

Figure 14

Figure 15

NOTE: To prevent damage to the squeegee or machine, the squeegee was designed to break away from the machine on the right side. If the squeegee is impacted and it breaks away from the machine, simply reinstall it by following step 3.

How to Adjust the Squeegee

During operation, the rear squeegee blade should have a constant 3/16” flare along the entire squeegee blade

(see figure 17).

1. The squeegee body can be tilted to adjust the squeegee blade flare in the middle to match the flare on the ends. To adjust the tilt, loosen the lock nut (3) on the adjusting bolt located on the left side of the squeegee (see figure 14).

2. Turn the adjusting bolt counter clockwise to increase the flare in the middle.

Figure 16

3. Turn the adjusting bolt clockwise to decrease the flare to the middle.

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3 /

16

”

Figure 17

Clarke ® Operator's Manual -MINI MAX

How To Prepare the Machine For Operation

4.

After making adjustments, retighten the lock nut.

5.

The amount of squeegee blade flare can be increased or decreased by adjusting the height of the two squeegee wheels

(see figure 18).

6.

Turn the squeegee wheel adjusting knobs clockwise to decrease the squeegee blade flare.

7.

Turn the squeegee wheel adjusting knobs counter clockwise to increase the squeegee blade flare.

NOTE: It is important that the right and left wheels are set properly in order for the squeegee to work parallel to the floor.

NOTE: As the rear squeegee blade wears, it can be rotated and/or flipped to obtain four good edges before having to change blades.

How to Install the Rotary Brush Head Unit (See figure 19)

To install the rotary brush head unit follow this procedure:

1.

Set the parking brake.

2.

Position the brush head unit on the left side of the machine.

3.

Align the mounting rails of the machine with the channels on the brush head unit (see figure 20).

4.

Turn the key switch to the “ON” position.

5.

Raise or lower the mounting rails on the machine using the brush up/down switch such that the channels on the brush head align in the vertical direction.

6.

Turn the key switch to the “OFF” position.

7.

Carefully slide the brush head unit into the machine until it stops.

NOTE: The electrical connections between the brush motors and the machine are connected automatically once the brush head is fully inserted into the machine.

8.

Rotate the two clamping studs (with knobs) located on the left side of the machine towards the inner part of the brush head unit (see figure 21).

9.

Secure the brush head unit into the machine by tightening the two knobs.

10. Attach the solution hose quick connect coupling to the machine

(see figure 22).

How to Install the Rotary Brushes

1.

Set the parking brake.

2.

Connect the battery pack connector into the machine connector.

3.

Turn the key to the “ON” position.

4.

Push the brush up/down switch to raise the brush head.

5.

Turn the key to the “OFF” position. Remove the key from the machine.

WARNING: Injury could occur if you do not remove the power source from the machine before you assemble the brushes.

Clarke ® Operator's Manual -MINI MAX

Figure 18

Figure 19

Figure 20

Figure 21

Figure 22

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How To Prepare the Machine For Operation

6.

With the brush base in the up position, insert the brushes into the seat of the plate under the base until the three buttons fit into the holes of the plate (see figure 23).

7.

Turn the brush so that the buttons are pushed towards the retaining springs until the brush is clamped into place. Figure

23 shows the correct direction to rotate the right side brush when installing the brush.

8.

The left brush has to be rotated in the opposite direction for installation.

WARNING: Use gloves to protect your hands when performing the steps listed above.

NOTE: It is recommended to swap daily the position of the right brush with the left brush or vice versa. If the brushes are old and show deformed bristles, then it is better to reassemble them in the same position (the right to the right side and the left to the left side). This will help avoid overload to the brush motors due to the inclination of the bristles, and also to avoid excessive vibrations

(see figure 24).

9.

To remove the brushes, reverse the appropriate procedure.

Figure 23

Figure 24

How to Install and Adjust the Brush Housings on the Rotary

Brush Head Unit

Follow this procedure to install the brush housings and side skirts:

1.

Mount the left brush housing onto the two studs on the brush head unit.

2.

Attach the brush housing to the brush head with the two knobs

(see figure 25).

Figure 25

3.

Follow steps 1 and 2 to mount the right brush housing to the brush head unit.

4.

To remove the brush housings, follow the above procedure in the reverse order.

Follow this procedure to adjust the side skirts:

1.

Loosen the two clamping knobs holding the brush housing on both sides of the brush head unit (see figure 25).

2.

With the brushes on the floor, position the skirts such that they are touching the floor with a slight flare to the outside. NOTE:

Too much flare on the side skirts will cause the brushes to interfere with the side skirts during operations.

3.

Tighten the clamping knobs on both brush housings.

How to Remove the Rotary Brush Head Unit

The rotary brush head unit is removed from the left side of the machine. To remove the rotary brush head unit, follow this procedure:

1, Set the parking brake.

2.

Turn the key switch to the “ON” position.

3.

Lower the brush head unit with the brush up/down switch such that the brushes just touch the floor.

4.

Turn the key switch to the “OFF” position.

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How To Prepare the Machine For Operation

5.

Remove the clamping knobs and the side brush housings with skirts from the brush head unit.

6.

Disconnect the solution hose quick connect coupling from the machine.

7.

Loosen the two knobs on the clamping studs located on the left side of the machine. Rotate the two studs outward from the center of the brush head unit.

8.

With the brushes still on the unit, carefully pull the brush head unit towards you and slide the unit out of the machine.

How to Install the Cylindrical Brush Head Unit (see figure 26)

To install the cylindrical brush head unit, follow this procedure:

1.

Se the parking brake.

2, Position the brush head unit on the left side of the machine, with the brushes, side skirts and hopper removed.

3.

Align the mounting rails of the machine with the channels on the brush head unit (see figure 27).

4.

Turn the key switch to the “ON” position.

5.

Raise or lower the mounting rails on the machine using the brush up/down switch such that the channels on the brush head align in the vertical direction.

6.

Turn the key switch to the “OFF” position.

7.

Carefully slide the brush head unit into the machine until it stops.

NOTE: The electrical connections between the brush motors and the machine are connected automatically once the brush head is fully inserted into the machine.

8.

Rotate the two clamping studs (with knobs), located on the left side of the machine, towards the inner part of the brush head unit (see figure 28).

9.

Secure the brush head unit into the machine by tightening the two knobs.

10. Attach the solution hose quick connect coupling to the machine

(see figure 29).

11. Install the brushes, hopper and side skirts.

How to Install the Cylindrical Brushes

1, Set the parking brake.

2.

Connect the battery pack connector into the machine connector.

3.

Turn the key to the “ON” position.

4.

Push the brush up/down switch to raise the brush head.

5.

Turn the key to the “OFF” position. Remove the key from the machine.

WARNING: Injury could occur if you do not remove the power source from the machine before you assemble the brushes.

Clarke ® Operator's Manual -MINI MAX

Figure 26

Figure 27

Figure 28

Figure 29

Page -15-

How To Prepare the Machine For Operation (cont.)

6.

Remove the side brush skirts by removing the hair pin and mounting pin (see figure 30 and 30A).

7.

With the brush head unit in the up position, remove the removable brush support hub by pushing downwards and then pulling it outwards (see figure 31).

8.

Insert the cylindrical brush into the brush head tunnel.

Align and insert the brush onto the driver hub on the opposite end.

9.

Insert the removable support hub into the brush. While inserting the support hub into the brush, align the cantilever retention spring into the slot on the support hub

(see figure 32).

10. Push the support hub plate downwards and then inwards to retain the support hub to the brush head.

11. Repeat steps 6-10 for installing the second brush.

12. Reinstall the side skirts.

WARNING: Use gloves to protect your hands when preforming the steps listed above.

13. To remove the brushes, reverse the appropriate procedures.

How to Install and Adjust the Side Skirts on the Cylindrical

Brush Head Unit

Follow this procedure to install the side skirts:

1.

Align slot in side skirt with mounting stud on brush head and install side skirt onto brush head unit (see figure 33).

2.

Install front mounting pin and insert hair pin (see figure 30 and 30A).

3.

To remove side skirt, follow the above procedure in reverse order.

Follow this procedure to adjust the side skirts:

1.

Loosen the lock nut on the vertical adjusting bolt located next to the front mounting pin (see figure 30).

2.

With the brushes on the floor, adjust the bolt such that the front end of the side skirt just skims the floor.

3.

Tighten the locking nut on the adjusting bolt.

How to Remove the Cylindrical Brush Head Unit

The cylindrical brush head unit is removed from the left side of the machine. To remove the cylindrical brush head unit, follow this procedure:

1.

Set the parking brake.

2.

Turn the key switch to the “ON” position.

3.

Raise the brush head unit with the brush up/down switch such that the brush head unit is at its up most position.

4.

Remove the side skirts, brushes and hopper.

5.

Lower the brush head unit with the brush up/down switch such that the brush head unit just touches the floor.

6.

Turn the key switch to the “OFF” position.

7.

Disconnect the solution hose quick connect coupling from the machine.

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Figure 30

Figure 30A

Figure 31

Figure 32

Figure 33

Clarke ® Operator's Manual -MINI MAX