www.factorycat.com Operator, Parts, & Service Manual
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1. battery is fully be vertical to open the hopper charged PAGE SHORTLIST OF DOS AND DON TS EP SIDE BROOM ADJUSTMENT Very Important Your side broom must not be squashed flat but must look like this RIGHT The broom must be mounted in the top hole of the broom shaft and the adjusting screw must be screwed in so broom just touches the floor in front WRONG If adjusted too flat your machine s Side broom will shut itself off periodically to cool down the motor You will sweep poorly and severely damage the side broom GOTTA SWEEP GREAT No kidding This is the world s best walk behind sweeper If your sweeper isn t sweeping just great seems hard to use or is making funny noises Something is Wong Here is what to do L Read this book 2 Call your dealer for info or service If you forgot your dealers name call the Factory toll free 800 634 4060 and we will give you his name and phone number PAGE 3 IDENTIETING THE CONTROLS 1 2 V Main Broom Position Lever Side Broom Position Lever Main Power On Off Switch On single switch machines this switch has three positions and can also turn on the side broom Side Broom On Off Switch Not found on single switch machines Clutch and Brake Lever Adjustable Handlebar Handlebar Adjustment Clamps 4 Filter Shaker Crank Hood Latch Side Broom Adjustment Knob Battery Andersen Connector Vaccuum Bypas2. mo L a Wite dh blac Mrl ene
3. so with the air system shut off Otherwise the vaccuum fan will pull water into the filter making it muddy and hard to clean To shut off the air to the filter open the small door at the end of the back painted filter housing Page 4 Item 12 NOTE Remember to close the air shut off door again when you re back on dry pavement or you ll blow outdust wherever you sweep 7 To Unload Hopper When machine stops sweeping well the hopper is full Turn off the machine Then turn the shaker crank handle at the rear of the machine about ten times The handle should then be left in the vertical position This cleans the filter Finally pull the dirt hopper all the way out of the machine It has a handle on each side When you put the hopper back make sure crank handle is straight up and down or the cleaning mechanism will prevent the hopper from sliding back in 8 Watch out for low battery NOTE The Sweeper will shut itself off when the battery gets too low Low voltage could otherwise damage the motors A red warning light Page 4 Item 18 warns you just before battery is completely discharged Don t get caught with a dead battery Return back to base for a recharge early Batteries vary in their energy capacity OEM batteries usually offer between three and five hours of service on a charge 9 Side Broom s Circuit Breaker If the side broom stops by itself its protective circuit breaker has probably tripped The usu
4. ACT ORY CA Operator Parts amp Service Manual Model 34 Industrial Sweeper R P S Corporation Phone 1 800 634 4060 P O Box 368 Fax 1 866 632 6961 Racine Wisconsin 53401 www factorycat com SAFETY WARNING A LCAREFULLY BEFORE OPERATING ADJUSTING OR p IS MACHINE CHARGING THE BATTERY WILL PRODUCE EXPLOSIVE HYDROGEN GAS Do not smoke or allow an open flame near a charging battery Do not charge battery with the hood lid of the machine closed or hydrogen gas may accumulate within DRESS SAFELY Do not wear rings or metal wrist watches while working on this machine They can cause an electrical short which in turn can cause burns Do not work on this machine while wearing a tie scarf or other dangling neckwear These can tangle in the rotating brooms belts and pulleys and cause serious injury or even death ERATE TRE SAFETY SWITCH MA INTENANCE PROCEDURES AS 0 This safety switch stops the motors whenever the hood lid is raised FOR REPAIR AND HIS BOOK 0 P A DO NOT USE THIS MACHINE AS A STEP LADDER OR CHAT MACHINE IS HEAVY DO NOT LIFT TW UNAIDED DO NOT USE HANDLEBAR AS LIFTING POINT DO NOT WORK ON UNDERSIDE OF MACHINE WITHOUT PROPERLI SUPPORTING UNIT WAKE SURE HOOD LID I CURED IF YOU WORK UNDER ITAROUND OTHER PEOPLE Another person may accidentally bump the lid in its over center position causing it to come down on you while you work beneath it IF YOU PLAN TO LEAVE YOUR
5. ATTERY FULL OF WATER A low water level can ruin the battery very quickly Water should always cover the plates inside the battery You see the tops of them when you remove the cap Many batteries have rings that are visible inside the cell holes In these batteries fill to ring We recommend you use only distilled water The minerals in ordinary water can coat the lead plates shortening battery life 3 CHARGE THE BATTERY WTH THE CAPS IN PLACE Do not remove the caps for a normal charge These caps include proper venting and will keep the charging process from projecting a thin layer of acid on surrounding machine parts 4 If you must use an external charger be sure to unplug the Andersen connector before doing so Otherwise you can damage the red light warning system Do not use an external charger that is too big for the battery or wrong voltage Charger must be BV and must not put out more than 25 amps 5 ACID Batteries contain corrosive sulfuric acid As mentioned above leave the vented caps in place when charging so acid will not bubble out ofthe battery Take care that acid does not fall on the steel surfaces of the machine eventually it will cause the machine to rust Treat acid spills with water to dilute the acid To clean up use solution of water and baking soda applied with a small brush Keep using the solutino until the fizzing stops This will neutralize the acid 6 MAKE SURE CONNECTIONS TO THE BATTERY ARE TIGHT Loo
6. MACHINE FOR EVEN A WINUTE TURN OFF THE WAIN POWER SWITCH AND SET THE PARKING BRAKE WEE d SBORT LISBTOF DOCS AND DON TS 1 T0 G0 Pullonthe 2 10 T0 Letgoofthe 3 10 SWEEP The main clutch lever gently to propel clutch lever to roll to a stop broom has to be on the floor the machine forward Pull Push down and forward on Use left hand lever to lower it harder to go faster the lever to set the brake Pull lever back then to right 5 DON TRUN BATTERY ALL THE WAY DOW NE The machine will begin to slow and a red light will come on when battery is about to go dead When this happens stop Sweeping immediately and go back to base to recharge If battery runs down too low the 4 TO SWEEP The side Single switch controls main automatic on board charger broom has to be on the floor broom and side broom On will not pick it up again unless Use right hand lever to lower two switch models use right you run the charge through it Pull lever back then to left hand switch for side broom two charge cycles T BATTERY NEEDS WATER Check battery water every two weeks Fill half way to ring with distilled water Do not overfill Do not let acid spill on battery or on n 4 machine If it does flush s A Tp RECHARGE Openthe With Weter and sprinkle KEEP GRANK VERTICAL eda PA a A with baking soda on the Before emptying hopper turn green light will turn on when pi crank fast 10 times Crank must light turns off
7. al reason for this is that the side broom is adjusted improperly and has too much down pressure Breaker will automatically reset See Sidebroom Adjustment in this book Page 11 To Remove The Dirt Hopper CRANK should be vertical before removing or replacing the hopper drawer Otherwise you may break the safety pin on the crank mechanism Underside of Machine Handle Bar Asm Not Shown SAFETY TIP Recharging 1 Always Turn Off Machine and Set Parking Brake before Charging Always Leave the Hood Lid Open PAGE 7 OPERATING INSTRUCTIONS 10 Recharging Battery Built In Battery Charger ff your machine is equipped with a built in battery charger simply turn off the machine set the brake open the hood lid and plug in the charger to a wall outlet with the correct voltage In North America our chargers are usually equipped for a single phase 110V 60Hz operation the same power as used in houses The three prong plug requires a grounded outlet Do not use without grounding The built in charger is completely automatic Its electronic circuitry will tell it when the battery is charged and shut itself off After the battery achieves correct voltage the charger will give a polish to the battery by shifting to high voltage input for a limited period of time The green light on the right hand side of the charging unit will glow when the charger is plugged in provided that the charger is al
8. does not hold loosen the 4 bolts holding the brake shoe to the transmission body and push shoe forward 4 Re tighten 4 bolts 5 Retest If you can not adjust succesfully replace clutch donut To Tighten Brake Shoe m Hold Down Bolts Front of Machine TROUBLESHOOTING GUIDE Check for Cause of Problem in Order Shown PROBLEM MAIN MOTOR WILL NOT RUN NOU RWNe Check that the hoods safety switch Page 4 Item 17 is firmly down Check battery voltage Mhen voltage is too low circuit breaker will cut out Check for loose circuit wiring Check for defective on off switch Check for defective relay Check for defective circuit breaker Check and replace motor brushes Check also for burnt motor armature PROBLEM SIDE BROOM MOTOR WILL NOT RUN MAIN BROOM IS OK n th m by hand If no then Red Fuse Holder or Circuit L Check In Line fuse This is in the wiring harness Breaker is under this edge 2 3 4 If you can rotate the side broom by hand then on early machines and mounts under the hood on the left hand under side lip of the body Current machines use a circuit breaker situated in the same location Check too see that the wiring hamess on the side broom arm has not become disconnected Check the side broom switch Check broom motor 1 2 Check that the drive connector inside bearing tube has not become disconnected It will do this to save the motor and gea
9. e 10 of fiber or more to sweep really well Main Broom bounces This will cause skipping over debris If this occurs broom must be replaced Cause of broom bounce is generally bent fiber on one side causing broom to become oval This in turn is caused by leaving the broom on the ground for long periods of time without broom rotating which will bend the fiber A second cause is use of a mainbroom that is made incorrectly For this reason avoid will fit main brooms made by other manufacturers to fit our machines Our design requires brooms in perfect balance and perfectly round Check rubber flap on lip of the hopper This piece is very important to good sweeping and must be in good condition or machine will throw debris forward of machine If flap is torn or missing replace with a new part Hopper s Rubber Flap PROPEEN MACHINE SWEEPS UP DEBRIS FINE BUT BLOWS DUST 4 5 Filter is dirty Wth power off turn crank 20 times to clean filter Air is shut off Open air shutoff control Filter is clogged from mud Remove and inspect filter Clean if necessary by shaking and vaccuuming the filter Air leaks Check and replace neoprene floor seals as needed Is fan turning with main motor Has set screw come out of fan PROBLEM MACHINE SWEEPS RATHER CONTROL PICKS UP DUST BUT BLOWS IT INTO THE ENGINE COMPARTMENT 1 Remove the black filter cover There are three screws at the rear Cov
10. er fits into a slot at the front Then check for improper seal between filter and body Filter is taped to the filter element support grill Part No 4 505 with double sided carpet tape This seal must be tight Check filter for pinhole leaks and repair or replace as needed You can pull filter and its mounting grid straight out of the machine once the filter cover is removed You can also inspect the filter from undeneath the machine PAGE 14 SPARE PARTS BOOK Walk Behind Sweepers Spare parts are sold through authorized Dealers If you have forgotten your dealer s name or you have moved the machine to a new location please Call us at 1 800 634 4060 or Fax us at 1 866 901 3335 and we will re establish a dealer contact for you TO ORDER PARTS Please provide the machine s Serial No with your order Normally ordinary parts orders are shipped out the same day the order is received EMERGENCY ORDERS Within the Continental United States We can supply any part that weighs under 70lbs within 3 business days not counting weekends or National Holidays However if parts are ordered on an Emergency basis this means that we will ship them by fastest means generally by air courier service at the customers expense FREIGHT Wthin the United States the normal shipment method is by customer choice while the emergency shipment method is by RPS choice normally by fastest means This means that emergency orders will genera
11. es or less of fiber will not sweep as well as a new broom We recommend the Vee type filter pattern which is able to fit the hopper fuller than the Spiral type filter pattern MAIN BROOM REPLACEMENT Vote that you do not need to reverse the broom periodically as on other brands because our broom suspension does not bend and splay the outerfibers of the broom TO REPLACE MAIN BROOM 1 Turn off machine and unplug battery connector Shake the filter 2 Raise main broom off ground with broom lever Remove dirt hopper and broom access door 3 screws Unbolt broom as shown Item 3 in photo Pull out old broom Push on new broom being careful to line up the slot on the broom with the driver s slots Push the broom all the way in 7 Make sure Vee of the Vee broom points forward when viewed from the top ON U gt 99 MAIN BROOM MIRI Spiral Broom Does not sweep as well as Vee Broom Remove 1 Hopper 2 Access Panel 3 Idler Arm 1 Bolt and then remove 4 the old Broom SPECIAL NOTE Always park the main broom when machine is not in use If you leave the main broom on the floor for an extended period without turning it you will put a flat spot in its fiber This will cause broom bounce and bad sweeping PAGE 10 MACHINE MAINTENANCE SIDE BROOM ADJUSTMENT TO REPLACE SIDE BROOM Side broom will not sweep ifitis flat on the 1 Turn off machine and unplug battery grou
12. is lowered to the ground 5 To Sweep Main and side brooms Pull side broom lever to the left to lower brush to the floor Broom will drop causing lever to move toward front of machine Then turn on the side broom Operating Tip When side broom is in use the broom should contact the floor from about 11 OClock until about 5 OClock See Page 11 for illustration The adjuster is under the hood lid as shown Page 4 Item 10 Turn the knob clockwise to raise the broom NOTE Side Broom does not work by itself Main broom must be down if sweeper is to pick up anything Clutch and Brake Lever Stop Brake A Neutral on Pull the lever toward you to go forward The harder you pull the faster the machine will go Release the lever to coast to a stop Push this lever down towards the ground and then forward to engage the brake You do not normally need to use the brake to Stop Always use the brake when you park the machine and pick the brooms up off of the floor to avoid Flat Spotting them Main Broom Control Broom Lowered Broom Raised Pull main broom lever toward you and then toward the center of the machine This releases the catch and permits the main broom to drop To bring the main broom back up again pull lever from Lock position into Release position PAGE 6 OPERATING INSTRUCTIONS 6 To Sweep a Wet Floor If you are going to sweep a wetsurface you should do
13. lly cost the customer more than normal orders In both cases the customer is responsible for all freight costs PAGE 15 Wiring Schematics For machines after Serial No BY 2220 with Side Broom Circuit Breaker B Battery D Volt R1 Main Relay M1 Main Broom Motor M2 Side Broom Motor F1 Side Broom Circuit Breaker 6 Amp M2 F2 Main Circuit Breaker 80 Amp S Safety Switch S2 Master Switch S3 Side Broom Switch G R H Hour Meter C Battery Charger Ep G Ed M a P Plug Side Broom Harness R Kull c EO m wW R R G z Ilil B B 51 52 93 Wre R gis D m it ES i Ja c Black PAGE IGA P RU Wiring Schematics For machines after Serial No CI 3200 with Single Electrical Switch for Main and Side Brooms B Battery D Volt R1 Main Relay MI Main Broom Motor a M2 Side Broom Motor F1 Side Broom Circuit Breaker 6 Amp M2 F2 Main Circuit Breaker 80 Amp S Safety Switch C 2 Main and Side Broom Switch H Hour Meter G R C Battery Charger G Grey 50 Connector P P L Plug Side Broom Harness Warning Light Unit H E R O Tate FE BI B S1 2 Wre R Red
14. n too low will require recharging the battery twice to pick it back up again PAGEG OPERATING TIPS The machine can only pick up dirt when it runs over it It can not pick up dirt while sitting still Some bulky articles are hard to pick up and require a lot of floor space in front of the article to give the main broom a chance to grab the item Sweeping smart means avoiding dead ends If you have to back up the machine out of a corner you will probably leave some dirt behind Slow down if the floor is very dirty or if you notice the machine is not picking everything up The machine can only transfer so many pounds of material per minute jt RATING INSTRUCTIONS PLEASE CAREFULLY READ WARNINGS ON PAGE TWO OF THIS MANUAL Refer to Page 4 for location of controls 2 To make the machine move under its own power without sweeping Turn on Main Switch Make sure both brooms are off ground See Steps 5 amp 6 Below Gently pull clutch lever on handle bar towards you You can regulate speed by varying how hard you pull on this lever 3 ToStop Let go of the clutch lever To stop machine when going down hill set parking brake by pushing the clutch lever down and forward This locks rear wheels 4 To Sweep Main broom only Pull main broom lever to the right to lower broom to the floor Broom will drop causing lever to move toward front of machine Note that the machine will not sweep unless broom
15. nd 2 Raise side broom off of ground with Fiber should touch the ground in an 11 OClock control lever to 5 OClock pattern as shown here 3 Turn side broom adjustment knob FRONT OF MACHINE clockwise until broom is as high as it will go ONT OMNA a Operating Tip The Knob will be easier to turn if you pull on the broom lever at the same time this relieves pressure from the adjustment 4 Pull clevis pin from side broom and remove broom New broom has replacement plastic mount included so no need to unscrew the old one 5 If your machine s side broom mounting shaft has more than one mounting hole for the broom pin always use the top hole 6 Lower broom with motor off and turn adjustment control until broom pattern shows 1 OClock to 5 OClock contact pattern see next column Ium E V 17 TO ADJUST DRIVE CHAIN i i f The drive chain drives the rear wheels If it is too loose it will come off of the drive sprocket 5 DETAIL A If itis too tight the chain will bind and or the 5 rugs 11 clutch lever will become hard to operate In fh The Broom Adjuster either case the chain will make popping ql mE is in the front right noises that show chain adjustment is needed o sil corner of engine vad compartment Turn A properly adjusted chain leaves about 1 4 to m A clockwise to raise 12 inch of slack a
16. r drive Check the side broom motor PROBLEM MAIN BROOM WORKS BUT MAIN BROOM DOES NOT TURN 1 2 3 Check to see if something is caught in main broom such as strapping This material will wind itself around the edges of the broom locking it up and causing the belt to slip Check both drive belts for wear and adjustment Check the Main Broom Belt Tensioner The belt tensioner moves constantly to take up slack in the belt as the broom moves up and down with floor irregularity It should be greased with chassis grease every two years To grease Unscrew vertical Allen head retaining screw Item B BEFORE unscrewing lateral Allen head screw Item A Otherwise you can damage the main broom arm Remove lateral screw A and insert grease in arm s Oilite bearing Reassemble Do not overtighten lateral screw A or arm will bind Screw in B once position of A is correct PROBLEM MOTOR RUNS BUT MACHINE WILL NOT SELF PROPEL 1 pepe Make sure belt between motor and transmission is adjusted properly See if clutch slips If so adjust following the procedure in this book If adjustment cannot make clutch work properly Replace the rubber clutch donut Check chain and sprocket on differential axle PAGE 13 TROUBLESHOOTING GUIDE PROBLEM BROOMS ROTATE BUT MACHINE DOES NOT SWEEP WELL 1 Main Broom may be worn out While machine can sweep with as little as one half inch of main broom fiber main broom should hav
17. s Dust Filter Access Plate Hour Meter or optional Battery Condition Meter On Board Electronic Battery Charger Clutch Brake Cable Adjustment Safety Shut Off Switch operated by closing the hood Low Battery Light PAGE I KOH IT WORKS L MainBroom which is tubular in shape and extends across width of machine rotates in direction shown pushing dirt and debris into hopper 2 Side broom when used picks up dirt in corners and pushes it toward the middle of the machine where the main broom picks it up FORWARD MOTION OF SVEEPER BRINGS DIRT TO RAPIDLY ROTATING MAIN BROOM MAIN BROOM KICKS IT UP TO HOPPER 3 Themain broom creates dust The automatic vaccuum system sucks up this dust then the filter catches it The filter empties into the hopper It is cleaned by turning the crank at the rear of the machine which shakes the filter clean A drive system is provided Pulling the lever on the handlebar operates a clutch wheel The clutch wheel drives both rear wheels via a differential axle A parking brake is provided It stops the clutch wheel from turning which locks up both rear wheels Power for the main broom vaccuum fan and drive system all comes from a large electric motor A second motor drives the side broom The battery must be recharged after extended use It will run the machine for about 3 45 hours on a charge Remember that running the battery dow
18. s shown Y broom To adjust the chain it is not necessary to remove the battery if you use the right tools 1 Turn off machine and unplug Andersen connector i To adjust drive chain 2 Pull clutch lever all the way closed lever touching loosen clutch wheel bolt handlebar and tie or tape it into that position a Q y and pull its axle up or down 3 Use a 3 4 combination wrench on left side of bolt that goes thru the clutch wheel Use a 3 4 i ratchet socket wrench on the right side No more than 12 inch of play 4 Looser ie Cua bolt and pull up on it with the in chain measured here 5 Tighten bolt A 6 Test unit Chain should not bind the clutch lever Some slack is required action and should not slap against the rear cover PAGE 11 MACHINE MAINTENANCE CLUTCH AND BRAKE ADJUSTMENT As explained in How it Works Page 5 the clutch and brake operate with the same control and by way of the same clutch donut If the clutch slips 1 Inspect the clutch donut If in good repair then adjust If donut looks melted then replace it got too hot from slipping 2 To adjust clutch Loosen the nut at the end of the cable where it enters the handlebar housing Also loosen the nut inside the handlebar housing Now tighten the outer nut until the clutch engages and the machine starts to creep forward Loosen the outer nut one turn from that poin
19. se connections will cause arcing which will eat into and destroy the battery terminals 7 WATCH THE GREASE Never put grease on the inside of the connector The grease will cause arcing and deterioration of the connector You can put grease on the outside of the terminal after it is mounted to the battery 8 DO NOT HAMMER ON THE BATTERY OR ITS CONNECTORS Batteries are heavy but fragile Hammering on the posts on the battery can break the connectors inside Use a puller to remove connectors not a hammer or screwdriver 9 DO NOT STORE BATTERY ON A CONCRETE FLOOR Doing so can cause quick discharge and even damage to the battery Store the battery on wood cardboard or other self insulating material PAGES MACHINE MAINTENANCE BATTERIES The highest maintenance item on your machine will be its storage battery Please read the About Batteries section of this book MAIN BROOMS Replace the main brooms when they stop sweeping to your standards We recommend you use our brooms They are made for your machine Our brand of broom has a precision plastic core that is carefully balanced and has machined insert points so the broom fits tightly on the machine s hubs Brooms made by will fit companies to fit our machines are often made with rough drain pipe cores They often bounce even when new Bouncing brooms do not sweep A new main broom has two and a half inches of fiber on it Normally a main broom with one and a half inch
20. so plugged in properly The green light will go out at the end of the charge cycle External Battery Charger If you use an external battery charger unplug Andersen connector before beginning charge Open hood and follow the charger instructions NOTE Some battery chargers are not automatic and will not shut off when battery is fully charged You can seriously damage a battery by overcharging it BATTERY SAFETY WARNINGS Charging a battery produces explosive hydrogen gas Leave the hood lid of the machine open while the battery is charging to avoid buildup of gas inside machine Do not smoke or expose open flame or spark to area around battery during charging Follow the instructions that came with your charger Many chargers are not automatic and can over heat the battery if not properly set Watch for battery acid If acid gets in the eye wash out with water for twenty minutes and call a physician PAGE 8 ABOUT BATTERIES We do not recommend use of anything but a deep cycle battery one made to run a long time between recharging An automotive battery designed to be recharged by the cars alternator right after short use will give poor service We do not recommend use of a battery that weighs more than 2Olbs since this could make steering difficult GENERAL RULES FOR BATTERY CARE 1 KEEP THE BATTERY CLEAN Dirt on the battery transmits electricity and can cause quicker discharge 2 KEEP THE B
21. t Tighten the inner nut Test NOTE The brake should adjust automatically with the clutch If the clutch still works OK but the brake does not or vice versa follow steps on right side of this page If kept adjusted the clutch donut should last several years To replace the donut L Turn off the machine and unplug the battery Remove the rear protective panel to have access to rear axle 2 Remove the master link in the drive chain This link is visibly different from the others Removing the master link permits removal of the chain 3 Remove clutch cable end from the clutch fork 4 Remove the transmission from machine 4 bolts from bottom 5 Remove the clutch fork from the machine by removing the mounting pin 6 Remove the clutch wheel from the fork 7 Unboltthe three bolts that hold the clutch wheel together to remove the donut 8 Install new donut on clutch wheel Be sure you mount clutch wheel concentric on axle 9 Reverse procedure to install PAGE 12 Clutch Adjustment When set properly machine should not creep in neutral but lever should begin to take hold when lever is depressed 1 2 or so To set neutral a thin business card should just barely fit between clutch donut wheel and drive spindle capstan Adjust clutch at handlebar Clutch Donut Drive Spindle Business Card Adjusting Nut Location Brake Adjustment 1 Adjust clutch first 2 Test brake 3 If brake
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