TornadoOperation and Maintenance ManualFor Commercial Use Only

LR 30 Floorkeeper Automatic ScrubberCatalog No.

99440For parts list see L9440BAPEffective 9/19/2005

Form No. L9440BA Revised 9/05 2005 Tornado Industries All rights reserved.

TORNADO® INDUSTRIES7401 W. LAWRENCE AVENUE

CHICAGO, IL 60706(708) 867-5100 FAX (708) 867-6968

www.tornadovac.com

2

NOTES

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This illustrated instruction book covers:MODEL 99440SERIES ASIZE 30"VOLTS (CHARGER) 36VAMPS (CHARGER) 20CAPACITY 30 GAL. (114L)

All specifications are subject to change without notice.

TABLE OF CONTENTSWARRANTY 4INTRODUCTION 5SAFETY INSTRUCTIONS 6GROUNDING INSTRUCTIONS 7UNIT CONTROLS AND INDICATORS 8INSTALLATION 10SQUEEGEE 10BRUSHES 11PRE START-UP 12FILLING SOLUTION TANK 12PREVENTATIVE MAINTENANCE PROGRAM 13BATTERY CARE 13BATTERY REMOVAL 14BATTERY CHARGING 15BATTERY SAFETY PRECAUTIONS 16SQUEEGEE BLADES 17SQUEEGEE ADJUSTMENT 19SOLUTION PUMP INTAKE FILTER 20RECOVERY TANK 20SOLUTION TANK 21VACUUM MOTOR 21LUBRICATING YOUR MACHINE 22MOTOR BRUSH REPLACEMENT 22TROUBLESHOOTING INSTRUCTIONSCOMMON ISSUES 23TROUBLESHOOTING CHART 25LCD DISPLAY DIAGNOSTIC ERROR CODES 27PREVENTATIVE MAINTENANCE CHECKLIST 29REPLACEMENT ITEMS & ACCESSORIES 30

4

Thank you for choosing Tornado products. We are proud to offer the mostcomplete line of commercial and industrial cleaning equipment in the industry.

Our reputation for quality, innovation and durability is unsurpassed.* Effective January 1st, 2005. Terms subject to change without notice.1) Windshear™ Blower-Dryer, Insulation Blowers, T191, T201, T12/1, CV 30, CV 38, CW 50, CW

100, Pro PAC Vacs, Duo-Upright Carpetkeepers™, Gas & Electric Pressure Washers, and allchargers are warranted for 1 (one) year for both parts and labor.

2) Warranties on all riding sweepers including the ICC1, KM 100/100 R, KMR 1250, and KMR1700 are 24 months parts/6 months labor OR 1000 hours of operation, whichever comesfirst. Warranties on the 75/140 & 90/140 are 24 months parts/12 months’ labor OR 1,000hours of operation whichever comes first.

3) All non-wear item parts purchased after warranty expiration are warranted for 90 days.4) Warranty starts from the date of sale to the consumer or, at Tornado’s discretion, 6 months

after dealer purchased the unit from Tornado, whichever comes first.

Note: Tornado, The Latest Dirt, Floorkeeper, Carpetkeeper, Carpetrinser, Carpetrinser/Dryer,Headmaster, Taskforce, PAC-VAC, T-Lite, Glazer, Windshear, Max-Vac, CV 30, CV 38, andTrot-Mop are trademarks of Tornado Industries.

1-800-VACUUMSChicago area: (708) 867-5100

Fax: (708) 867-69687401 W. Lawrence Avenue

Chicago, IL 60706

5

INTRODUCTION

Congratulations on the purchase of your new Tornado LR 30 The LR 30 combines manyadvanced features to maximize reliability, performance, and ease of use.

The most notable addition is the incorporation ofthe industry’s first fully functional digital control anddisplay system on an automatic floor scrubber.With it, you’ll be able to easily and accuratelymonitor an assortment of system settings andconditions. Tornado’s new digital controller has aunique soft-start feature that increases bothefficiency and powertrain lifespan.

Its patented, tough rotomolded structural housingserves as a multi-function one-piece frame,making this new model Floorkeeper both morerugged and much lighter than conventional metal-frame models.

This new LR 30’s simplified wiring harness usesquick-disconnects, and combined with the digital controller and error code generation on itsLCD display, makes servicing and troubleshooting easy.

Additional features include integral 30-gallon solution and recovery tanks, a sealed,maintenance-free ¾ hp transaxle, and easy-access batteries. Solution flow is preciselycontrolled by an adjustable flow rate pump, unlike gravity-feed systems that change flow basedon tank fill level. Vacuum power can be set for hands-free automatic operation, off to conservebattery power when double-scrubbing, and constant-on for use with the optional hand toolaccessory set. The new LR 30 automatic scrubber was designed and built to exceed yourneeds for durability and serviceability in demanding commercial environments.

This manual is designed to instruct your personnel in the operation, maintenance and methodsof troubleshooting on your Tornado LR 30. Please read through this manual and keep it handyto ensure that you get maximum satisfaction and value from this new advance in floor care.

OBSERVE THESE PRECAUTIONS FOR SAFE USE OF THIS MACHINE

• Back the machine down inclines or ramps. Do not store machine on inclines.• Make certain that the power switch is OFF before removing or installing brushes.• Use care when working on electrical terminals —short circuits can cause burns and

throw sparks.• Disconnect both positive and negative battery terminals before attempting any

adjustment or maintenance. Brush or traction drive motors and drive components couldcause injury if started while being worked on.

• Charge batteries in a ventilated room where gases cannot accumulate. Gases given offduring charging could ignite in a confined space. Make certain that the top covers areopen when charging so gases cannot accumulate.

• Battery acid can cause injury to the eyes or burn the skin.

6

Safety Instructions

When using this machine, basic precautions should always be followed. Read all instructionsbefore using this machine.

WARNING: To reduce the risk of fire, electric shock, or injury:

Turn off all controls, unplug from power source and allow unit to cool down before attemptingany maintenance or adjustment. Turn off and disconnect battery clip when not in use.Do not expose to rain or submerge in water. Store indoors. Do not use pressurized water toclean machine. Do not use machine on stairs.Do not allow to be used as a toy. This machine is to be used by adults only.Use only as described in this manual.If machine does not appear to be working properly or has been dropped, left outdoors,submerged, or damaged in any way, refer to the troubleshooting steps detailed in this manual.Keep hair, loose clothing, fingers, and all parts of body away from openings and moving parts.Do not put any object into openings. Do not use with any opening blocked. Keep openings freeof dust, lint, hair, and anything that may reduce airflow.Do not pick up anything with this machine that is burning or smoking, such as cigarettes,matches, or hot ashes.Do not pick up flammable or combustible liquids, such as gasoline or petroleum solvents, or usemachine where they may be present.When using the charger supplied with this machine, do not handle cord or plug with wet hands.Unroll the charger AC power cord before plugging it into a grounded outlet. Do not pull or carryby cord, use cord as handle, close a door on cord, or pull cord around sharp edges or corners.Do not run machine over cord. Keep cord away from heated surfaces.Check power cord for signs of crushing, cutting or heat damage. If replacement of plug or cordis needed, use only identical replacement parts.Keep all connections dry and off the ground. Do not allow electrical cords to contact water. Donot use extension cords with this product. Do not unplug charger by pulling on cord. To unplug,grasp plug, not cord.Any repairs performed on this machine should be done by Tornado Authorized ServicePersonnel.Do not operate the unit when fatigued or under the influence of alcohol or drugs.The manufacturer cannot be held responsible for any damage/injury caused to persons orproperty because of improper procedures used which are not specified in this manual.

SAVE THESE INSTRUCTIONS

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WARNING: Failure to adhere to any of the instructions provided in thismanual could result in serious bodily injury or property damage!

BEFORE OPERATING MACHINE:Read this manual completely before attempting to operate machine. This manual has importantinformation for the use and safe operation of the machine. Keep this manual on file and handy.If additional information is needed, please contact your local distributor or contact us at:TORNADO INDUSTRIES Phone: (708) 867-51007401 W. LAWRENCE AVE. Fax: (708) 867-6968CHICAGO, IL 60706 Internet Address: http://www.tornadovac.com

GROUNDING INSTRUCTIONSThe charger supplied with this machine must be grounded. If it should malfunction or breakdown, grounding provides a path of least resistance for electrical current to reduce the risk ofelectric shock. This appliance is equipped with a cord having an equipment-groundingconductor and grounding plug. The plug must be plugged into an appropriate outlet that isproperly installed and grounded in accordance with all local codes and ordinances.

WARNING: Improper connection of the equipment-grounding conductor can result in electricshock. Check with a qualified electrician or service person if you are in doubt as to whether theoutlet is properly grounded. Do not modify the plug provided with the appliance; if it will not fitthe outlet, have a proper outlet installed by a qualified electrician. This appliance is for use on anominal 120-volt circuit, and has a grounding plug that looks like the plug illustrated in sketch A.A temporary adapter that looks like the adapter illustrated in sketches B and C may be used toconnect this plug to a 2-pole receptacle as shown in sketch B if a properly grounded outlet isnot available. The temporary adapter should be used only until a properly grounded outlet(sketch A) can be installed by a qualified electrician. The green-colored rigid ear, lug or the like,extending from the adapter must be connected to a permanent ground such as a properlygrounded outlet box cover. Whenever the adapter is used, it must be held in place by a metalscrew.

SKETCH A SKETCH B SKETCH C

8

Unit Controls and Indicators

Control Panel

1. Variable Drive Speed Control Knob

2. 3-Position Vacuum Motor Switch:

Automatic – Controlled by transaxle

Off – for double-scrubbing floors

On – for stationary hand tool recovery

3. LCD Display

See page 9 for display capabilities

4. Brush Position Switch

5. Solution Flow Rate Knob

6. Display Mode Button

Rear Controls

7. Solution Filler Plug

8. Solution Level Sight Tube

9. Squeegee Control Lever

10. Solution Tank Drain Hose

11. Dual Reverse Buttons

12. Emergency Stop Switch

13. Locking Keyswitch

14. Dual Drive Levers

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Unit Controls and Indicators

Display Screens

Use the Display Mode Button (to the right of the display) to toggle between three uniquescreens. Each screen displays a different set of icons and numerical readouts to give you usefulinformation about your machine’s operating status. For particulars on diagnostic fault codeinformation, see page 26.

10

INSTALLATION

Squeegee1. Make sure the Squeegee Control Lever is

lifted to the UP position.

The Rocker (squeegee mount) is alreadyinstalled on the Bracket. Loosen the twoSqueegee Locking Knobs enough to allowit to slide onto the Rocker.

2. Insert the Squeegee Assembly fully, bentends forward, onto the Rocker. Tighten thetwo Squeegee Locking Knobs securely.

Notice that the Squeegee Assemblyshould be free to rotate slightly from sideto side, allowing the Squeegee to followfloor contours.

3. Insert the hose end into the squeegeeassembly nozzle throat. Press downtightly.

4. To ensure that both the ends andthe center of the Squeegee Blades areevenly loaded, loosen the RockerAdjustment Knobs. Lower the SqueegeeAssembly to the floor by pulling theSqueegee Control Lever down, then rotatethe Squeegee Assembly until the entirelength of the rear Blade is in even contactwith the floor. Tighten the Rocker Knobs.

IMPORTANT: Never store the machine withthe Squeegee in the down position. This candamage the Squeegee Blades and affectwater pick-up.

The Squeegee is not designed to pick upwater while backing up. When backing themachine, raise the squeegee to avoid the riskof damaging the rubber edges or upsetting theRocker tilt adjustment.

11

INSTALLATION

Brushes

1. Raise the Brush Housing using the switchon the control panel. (Emergency Switchpulled out, and Keyswitch turned on.) Oncethe Housing is fully up, turn off theKeyswitch.

2. Place Brushes or Pad Holders under thecover. Locate the Brush Coupler. Pull up theBrushes to lock them in place.

Brush Housing Skirt Adjustment

3. When properly adjusted, the Brush HousingSkirt prevents the rotating brushes fromflinging solution off to the sides, where theSqueegee may not be able to reach.

Power the Brush Housing down so that theBrushes or Pads contact the floor. Locateand unscrew the two Skirt Locking Knobs,and slide the Skirt evenly down to just clearthe floor. Retighten both knobs.

As Pads or Brushes wear, or whenever the Pads or Brushes are removed or replaced,recheck for proper Skirt clearance.

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PRE START-UP

Make sure the Emergency Stop Switch ispulled out. Turn the Keyswitch on. The LCDDisplay should light and show the batterycharge level.

Lower the brushes to test for rotation. TheBrush motors will automatically turn on whenBrushes are lowered. Raise the Brushes.

Shut the Keyswitch off and connect the batterycharger to the Charging System Connector.Batteries should be fully charged prior to firstuse.

Filling the Solution Tank

1. Always empty the Recovery Tank beforefilling the Solution Tank. This will eliminateoverfilling of the Recovery Tank.

2. Remove the Solution Tank Filler Plug byunscrewing its wing nut just far enough toloosen its fit in the hole.

3. Fill the Solution Tank no higher than thetop of the clear Sight Tube.

4. Replace the Filler Plug and tighten its wingnut.

Please Note:Before you begin using your new LR 30, noticethat the charging connector is underneath theCover / Recovery Tank. This is a safetyfeature to ensure that the Cover is open tofreely vent battery gases during charging. Asthe Recovery Tank fills, it will becomeincreasingly difficult to raise it in order toperform battery or component service. Do notattempt to lift the Cover / Recovery Tankwhenever it contains more than a few gallonsof liquid. Empty the Recovery Tank first.

What to do when the batteries become fullydischarged while in use:Under low battery charge conditions, provisionhas been made to retain drive power evenafter the vacuum motor system hasautomatically shut down. When the vacuum motor shuts off, set its switch to off. Raise theBrush Housing fully up to shut off the Brush motors and Solution Pump, conserving energy.Drive the unit to a floor drain at once and empty the Recovery Tank. Return the unit to yourbattery charging station and recharge the batteries.

13

TORNADO LR 30PREVENTATIVE MAINTENANCE PROGRAM

IntroductionThis section is designed to instruct your personnel in methods of maintenance on the TornadoLR 30. By following these procedures, repair costs and down time will be greatly reduced.These procedures are for simple repairs that can easily be done by your own personnel.

WARNINGBattery acid is toxic and corrosive; avoid bodilycontact.

First Aid:

EYES: Wash with liberal quantities of runningwater for 15 minutes.

SKIN: Flush area with plentiful amounts ofrunning water.

INGESTION: Give milk to drink, DO NOT inducevomiting, call a physician.

SPILLS: Wash with water or neutralize withsodium carbonate or bicarbonate(baking soda).

Battery Care

Batteries must be checked daily. The water levelmust be maintained at least 1/4” above top of cellplates in each battery.

1. Raise top cover and lock in place.

2. If you use a hydrometer to check chargelevel in each cell, check this before addingwater.

3. Remove battery caps and fill each cell 1/4”-1/2” above the tops of the lead plates.

NOTE: Fill batteries with distilled water only. Thiswill increase battery life substantially.

CAUTIONDo not overfill the battery cells. Do not use a hoseor pail. If batteries are accidentally overfilled,remove excess water with a hydrometer or similardevice. Dispose of excess in accordance with local,state and federal regulations.

14

MAINTENANCE

3. After filling batteries, replace the batterycaps. Using baking soda or ammonia andwater solution, saturate a cloth and wring untildrip dry. Use this cloth to wipe the battery tops.

4. The battery terminals and should be coatedwith a protective lubricant to prevent cor-rosion.

WARNINGAvoid accidental contact with battery terminals andpossible electrical shock. Replace any protectiveplastic terminal covers after battery maintenance.

Battery Removal

Should batteries need to be removed for any reason, use two people to perform these tasks!

1. Completely drain the Recovery Tank.

2. Disconnect the vacuum motor connector,

gas spring bracket, float switch connectors,

and recovery hose. Ensure that no

connections remain.

3. Remove the three cotter and clevis pins at

the side of the cover, and remove the cover.

4. Note battery positions and all wiring

connections before disconnecting wires!

15

MAINTENANCE

Battery Charging

The charger is fully automatic:

1. It turns on when plugged in.

2. It switches to equalizing charge.

3. It shuts off when it reaches full charge or when batteries are defective.

NOTE: It is recommended that new batteries be fully discharged at least once (more in somecases) to enable batteries to hold a full charge.

The batteries must be charged after each use of 3 or more hours. Failure to do so will result inshortened running time.

To charge the batteries, raise top cover and lock in position.

WARNINGTo avoid explosion keep covers open during charge to insure proper ventilation ofgases.

1. Connect charger cable by plugging it intoAndersen connector located under rear topcover.

2. Plug AC cord into proper electricalreceptacle. The red “CHARGER ON” light willautomatically come on along with the“INCOMPLETE” light, meaning batteries arebeing charged.

3. The charger will automatically turn off whenthe batteries are charged to their maximumcapacity. The “CHARGER ON” light will go outwhen the charge cycle is complete.

4. To stop the charge cycle push the “INTERRUPT” button. (Do not unplug A.C. cord while thecharger is on.)

5. Check the lights on the battery charger after charger shuts off (“CHARGER ON” light shouldnot be lit):

A. Green light: Batteries are fully charged and are in good condition.

B. Amber light: All cells are OK but the total battery capacity is reduced. This usually indi-cates that the batteries are aging.

C. Red light: The battery capacity is low and the entire charger/battery system needs to beinspected by a qualified Tornado serviceman.

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Always observe the following personal safety precautions when working with leadacid batteries.

A. Someone should be within range of your voice and close enough to come to your aidwhen you work on battery operated machinery, such as your LR 30.

B. Have plenty of fresh running water, soap, or baking soda nearby in case battery acidcontacts skin, eyes, or clothing.

C. Wear complete eye protection and clothing protection.

D. If battery acid contacts skin or clothing, wash immediately with soap and water or bakingsoda and water. If acid contacts eyes, immediately flood eyes with cold running water for atleast ten minutes and get professional medical attention as soon as possible.

E. Never smoke or allow sparks or flame in the vicinity of batteries. Batteries give off hydrogengas while charging. To prevent an explosive condition, always charge batteries in a well-ventilated area.

F. Use caution when using metal tools around batteries. Only use tools with an insulatingcoating in good condition to prevent short circuits.

G. Remove personal effects such as rings, watches, bracelets, etc. when working on batteryoperated machinery. Rings or watches can cause a short circuit, which will throw sparks tocause an explosion hazard and produce enough heat to cause a severe burn.

H. Never charge a frozen battery. Charging a frozen battery may result in explosion.

I. Always disconnect the AC supply cord from its outlet and the DC connector from the batterybefore attempting any maintenance or cleaning of the batteries or battery-operatedequipment.

THE FOLLOWING CAUTIONS AND PROCEDURES MUST BE OBSERVEDTO MAXIMIZE BATTERY LIFE:

• New batteries should be given a full charge before they are first used because it is difficult todetermine how long the batteries have been stored.

• Limit the use of new batteries to two hours for the first five charge/discharge cycles. Newbatteries are not capable of their rated output until approximately thirty charge/dischargecycles.

• Do not excessively discharge batteries. Observe the battery charge gage and discontinueoperation when gage reads low. Excessive discharge can cause polarity reversal ofindividual cells, resulting in complete battery failure shortly thereafter.

• Check the level of electrolyte in batteries weekly. Maintain the proper electrolyte level byadding distilled water as necessary. Add water to cover the tops of the lead plates ¼" to ½".

• Do not overfill batteries.• Clean tops of batteries with a clean cloth wetted with ammoniated window cleaner

(Windex ® or equivalent). Dry batteries with a fresh cloth.• Old batteries will require more frequent additions of water than newer batteries.

17

MAINTENANCE

Squeegee Blades

1. If a squeegee blade is worn or ripped, raisethe Squeegee and remove the entirealuminum Squeegee Assembly from theRocker. Disconnect the vacuum hose, loosenboth Squeegee Locking Knobs and slide theSqueegee out.

2. Unscrew both Star Knobs at either end ofthe Squeegee, and remove the Rollers.

3. Pull off the plastic End Caps at both ends ofthe Squeegee.

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MAINTENANCE

Squeegee Blades

4. Pull out each Blade from one end. Bothfront and rear Blades have two workingedges.Flip each blade for a new edge when worn.Replace Blades once both edges are worn.

4. Clean squeegee blades with a dampcloth. And slide them into place. Therear Blade is longer than the front, andoverlaps it evenly on each end.

5. Replace the plastic end components,and remount the Squeegee Assemblyonto the Rocker. Connect the vacuumhose to the Squeegee Assembly.

19

MAINTENANCE

Squeegee Adjustment

Removal of the Squeegee Assembly forcleaning or blade servicing will not normallyrequire Squeegee tilt readjustment. However,after remounting the Squeegee, Blade contactshould be visually checked for evenness byfirst driving or pushing the machine forward afew inches with the Squeegee down.

Look at the rear blade to ensure that both theends and the center are evenly loaded. Thefront blade should also be contacting evenlyacross its length. If readjustment is needed,loosen the Rocker Adjustment Knobs. Rotatethe Squeegee Assembly. Correct adjustmentis made when both Squeegee Blades restevenly on the floor. Tighten the Rocker Knobsand raise the Squeegee Assembly to itsstorage position.

IMPORTANT: Never store the machine withthe Squeegee in the down position. This candamage the Squeegee Blades and affectwater pick-up.

For Smooth Floors:

Use the standard rear squeegee bladeK62732060.

For Rough Floors:

Use rear squeegee blade K62732150.

20

MAINTENANCE

Solution Pump Intake Filter

NOTE: A dirty or clogged filter will greatlyreduce cleaning solution flow, and decrease theability of the machine to clean floors properly!Do not remove or modify this filter element, as itprotects the Solution Pump from potentialdamage.

Inspect the Solution Filter periodically asfollows:

1. Grip the main body and turn the front-facing wings counterclockwise. The twocomponents will separate to expose themesh filter element inside.

2. Carefully clean the filter element, orreplace it.

3. Reassemble the two halves.

Solution and Recovery (Vacuum) Tanks

The Recovery Tank System Features:The Recovery Tank is depressurized by theVacuum Motor, and pulls spent solution anddebris from the Squeegee into its interior. Astand pipe prevents water intake into the VacMotor, and a Float Sensor prevents Vac Motoroperation once the Recovery Tank is full.

Draining the Recovery Tank:

1. Position the machine at a floor drain orother drain area.

2. Remove the drain hose from its clamp onthe Brush Housing, and lift it high.

3. Unscrew the wing nut at the hose enduntil the plug becomes loose and can bepulled out. Be careful to remove only theplug, not the metal tube surrounding it.

4. Lower the hose and insert the end intothe waste receptacle.

5. Once the flow stops, replace the plugand stow the hose back into position.

For more extensive cleaning of the tank,remove the Top Cover Lid and flush out thetank with clean water as necessary.

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MAINTENANCE

Draining Solution Tank:

1. Locate drain hose at rear of unit andposition over floor drain or container.

2. Pull the corded ball out of position toexpose the hole.

3. Lower the hose and position it over adrain. Once flow has stopped, replacethe ball to close the tube. Tuck drainhose back onto its hook.

NOTE:Flush and clean both tanks after each use, andallow to air dry to eliminate odors andcorrosion of vacuum motor.

Vacuum MotorTo service vacuum motor (which is mounted tothe underside of the Cover/Recovery Tank):

1. Drain the Recovery Tank and raise it to theopen position.

2. Disconnect wires to the Vacuum Motor,noting connections for later reattachment.

3. Remove three motor mounting screws.4. Remove motor and inspect the mounting

gasket carefully before reinstallation.Replace the gasket if necessary.

22

MAINTENANCE

Lubricating Your Machine

Once a month grease swivel casters with agrease gun. Each caster has one fitting on theswivel area. Wipe off excess grease.

Motor Brush Replacement

Use the appropriate hour meter on the LCD Display to monitor runtimes for each motor.Tornado recommends changing motor brushes at the intervals specified below in order to avoidpotential damage to the commutator. Replacement brushes need to be inspected and changedmore often due to commutator wear. Always permanently record any brush inspections andreplacements you make.

Don’t attempt to use the Motor Fault Error feature of the LCD Display as a signal that motorbrushes need changing. A Motor Fault that occurs directly from brush wear would also indicatea high risk of motor damage.

Motor Recommended Motor Brush Change IntervalTransaxle 1800 hours initially, 900-1400 hours for replacementsBrush 2600 hours initially, 1300-2000 hours for replacementsVacuum 600-650 hours initially, 400-500 hours for replacements

23

TORNADO LR 30TROUBLESHOOTING INSTRUCTIONS

This section is designed to instruct your personnel in methods of troubleshooting on theTornado LR 30. Common maintenance-related issues are noted below, followed by a fullTroubleshooting Chart.

Vacuum System - Poor SuctionDuring machine operation, if the vacuummotor is running but the solution is not beingpicked up, do the following:

1. With the vacuum motor on, place yourhand over the vacuum hose intake. Ifsuction is strong, a blockage is in thesqueegee throat.

Clear this blockage by pushing ascrewdriver, or any similar tool,downward through the top of thesqueegee throat.

2. Check for a loose intake hoseconnection, creating an air leak.

3. Check for a clogged mesh intake screen on the standpipe inside the Recovery Tank.

4. Check to see that the ball closure is in place on the end of the Recovery Tank drainhose.

5. Check to see that the Recovery Tank Cover disk is seated properly on its gasket.

6. Check to see that the liquid shutoff unit is properly seated at rear of recovery tank.

Since the entire Recovery Tank is placed under vacuum by the Vacuum Motor, each fitting andother entry point should be examined for potential air leakage or blockage.

NOTE: Performing these maintenance procedures will avoid problems with the recovery systemrequiring outside repair service. Always be very sure the vacuum system is clear of anyblockage before calling for service.

Vacuum System - Vacuum Motor Inoperative

1. The Recovery Tank is full. When the Recovery Tank is full, the Liquid Shutoff closes andstops the Vacuum Motor to prevent water from entering it.

2. If the Recovery Tank is not full, use the Troubleshooting Chart to diagnose problems withthe shutoff switch, motor, connectors, etc.

24

TROUBLESHOOTING

Poor Solution Flow

If an inadequate supply of solution is reaching the floor, check the solution hoses for kinks.These hoses are connected to the brush drive assembly. If there are no kinks in the solutionhoses, pull the hoses from the brush cover fittings and check the entire line for blockage.

Electrical Problems

If Brush Motors do not run, check the following:

1. Emergency Stop is pulled out.

2. Key Switch is in ON position.

3. Brushes are in down position.

4. Check the circuit breaker button located on the bottom of the main Controller Box.

Batteries Not Holding Charge

Check that the batteries have been given enough charging time to reach their full charge. Thiswill vary according to condition of the batteries.

Check the lights on the battery charger after charger shuts off:

A. Green light — Batteries are fully charged and are in good condition.

B. Amber light — All cells are OK but the total battery capacity is reduced. This usuallyindicates that the batteries are aging.

C. Red light — The battery capacity is low and the entire charger-battery system needs to beinspected by a qualified serviceman.

The automatic charger is designed to keep batteries at optimum operating charge levels.

NOTE: If red light comes on, inspect battery connections and water level.

Check each cell with a hydrometer before and after charging to determine it batteries are weak.Do not charge or use batteries when the liquid in any one or more cells measures less than1.150 specific gravity. A fully charged battery should read 1.270 or better after cooling 1/2 hour.

Batteries that have been properly charged yet still do not reach a full charge should bereplaced. One defective battery can weaken the other batteries. Replace the defective battery ifthe battery pack is less than two years old. If over two years, replace the entire battery pack.

25

TROUBLESHOOTING

Daily Battery Maintenance Precautions• Add distilled water only.• Never add acid.• Keep vent caps tight when operating.• Keep battery tops clean and dry.• Keep water level 1/4” above cell plates.• Keep excessive heat and metal items away from batteries.• Use a TORNADO charger with correct voltage and current rating.

TROUBLESHOOTING CHARTPROBLEMS POSSIBLE CAUSE AND CORRECTIVE ACTIONUnit completely inoperative • Wiring harness disconnected from batteries.

Connect as detailed in wiring diagram.• Batteries discharged.

Charge and service the batteries as detailed this manual.• Circuit breakers tripped due to overload.

Wait several minutes, then reset circuit breakers.• Emergency Stop button pushed.

Pull button out to run.• Keyswitch set to “OFF”.

Turn key to “ON”.• Faulty components or circuitry.

Consult authorized Tornado Service Center.Unit moves forward but notreverse

• Faulty component or circuitry.Consult authorized Tornado Service Center.

Unit does not move forwardor reverse

• Batteries discharged.Charge and service the batteries as detailed this manual.

• Circuit breakers tripped due to overload.Wait several minutes, then reset circuit breakers.

• Faulty components or circuitry.Consult authorized Tornado Service Center.

Unit pulls to one side • One (not both) brush motor inoperative.Faulty brush motor or circuitry.Consult authorized Tornado Service Center.

Vacuum motor does notoperate

• Circuit breaker tripped due to overload.Wait several minutes, then reset circuit breaker.

• Vacuum switch in ”OFF” position.Move switch to “MAIN” or “AUTO” position.

• Recovery tank full.Drain recovery tank as detailed in this manual.

• Faulty vacuum motor or circuitry.Consult authorized Tornado Service Center.

26

TROUBLESHOOTING CHART – continuedPROBLEMS POSSIBLE CAUSE AND CORRECTIVE ACTIONInoperative vacuum, brushmotors, and solution pump

• Brushes in “up” position.Lower brushes.

• Circuit breakers tripped due to overload.Wait several minutes, then reset circuit breaker.

• Faulty components motor or circuitry.Consult authorized Tornado Service Center.

Vacuum motor operates, butthere is little or no suction atsqueegee

• Recovery tank cover is loose or missing.Tighten or replace.

• Recovery hose is loose or disconnected.Connect or tighten.

• Blockage in recovery hose.Clear blockage by backflushing with garden hose.

• Blockage in squeegee throat.Clear blockage with screwdriver or similar instrument.

• Blockage on vacuum motor intake screen.Clear blockage with wet cloth.

Brush motors do not operate • Circuit breaker tripped due to overload.Reduce brush motor load by adjusting brush pressure,increasing solution, or changing to a less aggressivepad. Wait several minutes, reset circuit breaker thenresume operation.

• Brushes in “up” position.Lower brushes.

• Faulty brush motor or circuitry.Consult authorized Tornado Service Center.

Inadequate run time • Excessive brush pressure.Reduce brush pressure as detailed this manual.

• Improper charging and/or battery maintenance.Charge/service batteries as instructed in this manual.

• Old batteries.Batteries have a finite useful life. Test regularly, andreplace batteries periodically.

• Faulty charger.Consult authorized Tornado Service Center.

Inadequate solution flow atbrushes

• Solution tank empty.Fill solution tank.

• Circuit breaker tripped due to overload.Wait several minutes, then resume operation.

• Solution hoses blocked or kinked.Inspect and correct problem.

• Solution knob turned off.Turn solution knob fully clockwise.

• Faulty pump or circuitry.Consult authorized Tornado Service Center.

27

TROUBLESHOOTING

Diagnostic Fault Codes

Error codes displayed in the LCD Display indicate that the Electronic Control System may bedetecting problems with electrical connections, worn parts, power system controls, or batteries.Be sure to write down the error code before calling your Authorized Tornado Distributor, ServiceCenter, or the Tornado Technical Service Department.

NOTE: Most of these codes are internal errors and cannot be rectified externally. They areprovided for diagnostic reference only.

Error Codes Available in the LCD Display

CodeFamily

Code Type Code Description Code

00xx,01xx,02xx Internal EEPROM Codes EEPROM program checksum error 2 - Contact Tornado 0003

Running rom check error 0100

EEPROM program checksum error 1 - Contact Tornado 0204

07xx Switch Reference Codes 2.5V reference error 0705

High switch reference error 0706

08xx Throttle Codes Throttle - High reference error 0810

Throttle - Maximum wiper difference error 0811

Throttle - Maximum pull-down difference error 0812

Throttle - Maximum pull-safe difference error 0813

Throttle - Reference error 0814

Throttle - Low reference error 0815

Throttle - High reference error (ISO error) 0816

Throttle - Low reference error (ISO error) 0817

Throttle - Both LCD module and TRIO unit have throttles 0818

0A01 Power Down Code Power down error 0A01

0B0B Internal EEPROM Code EEPROM - Queue has overflowed 0B0B

1310 Supply Over Current Excessive current trip 1310

150x Solenoid Brake Codes Brake Fault 1 - Solenoid brake circuit is open. 1500

Brake Fault 2 - Solenoid brake circuit is open. 1501

Brake over current error 1507

1600 High Battery Voltage High battery voltage 1600

170x Internal Relay Codes Relay monitor fault 1704

Relay Fault 1 - Relay stuck closed 1705

Relay Fault 2 - Relay fault on Brush/Vacuum bridge circuit 1706

180x Watchdog Codes Watchdog tripped 1800

Watchdog voltage reference error - Watchdog reading high 1802

1B20 Internal Code Current Measuring Error 1B20

1D02 Throttle Spec Modified Front end reconfiguration change trip 1D02

1E0x Inhibit Codes Inhibit active 1E03

Secondary inhibit active 1E04

210x Internal Codes Internal counter error 2102

Internal counter error 2 2103

2C0x Low Battery Codes Low battery voltage 2C00

Low battery error - 2 2C01

Battery lockout trip 2C02

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2D01 Internal Code No output drive 2D01

2F01 Throttle displaced code Throttle Input displaced 2F01

310x Bridge supply Codes Low bridge voltage - possible short circuit at outputs 3100

Traction bridge fault 3101

Brush/Vac bridge fault 3102

Waiting for bridge to charge 3103

32xx, 36xx Internal processor codes Stack overflow 3201

No internal timers 3210

Internal timer out of range 3211

A to D conversion not completed before next start of conversion. 3212

Unknown A/D MUX channel 3213

ADC module is not ready 3214

Trip sense not active (Test trip latch 1 error) 3601

Micro trip output active (Test trip latch 2 error) 3602

Fault left sense not active (Test trip latch 3 error) 3603

Failed to trip when overvoltage trip forced (Test trip latch 8 error) 3608

Failed to reset when overvoltage trip reset (Test trip latch 9 error) 3609

Failed to trip when micro trip output forced (Test trip latch 10 error) 360A

Failed to reset when micro trip output reset (Test trip latch 11 error) 360B

Failed to trip when watchdog not pumped (Test trip latch 12 error) 360C

Test trip latch 13 360D

Test trip latch 14 360E

700x Freewheel Codes Startup with freewheel activated 7000

Freewheel activated in drive mode 7001

750x LCD Comms codes LCD Module communications timeout 7500

LCD Module settings corrupt 7501

760x Brush Motor codes Brush motor disconnected 7600

Brush current foldback - brushes running at current limit for 20 seconds 7601

Brush current foldback - 2 - brush current exceeds 150A 7602

Brush current foldback - 3 - hardware trip, possible short circuit on brush output 7603

Brush inhibit active 7604

770x Vacuum Motor Codes Vacuum motor disconnected 7700

Vacuum current foldback 7701

Vacuum current foldback - 2 7702

Vacuum current foldback - 3 7703

780x Traction Motor Codes Traction Motor Open Circuit Fault 7800

Traction overcurrent error 7801

Traction motor in foldback state 7802

7901 Emergency stop/BB codes Emergency stop error 7900

Belly button switch activated 7901

900x Customer specific codes 9000

NOTE: Most of these codes are internal errors and cannot be rectified externally. Contact yourAuthorized Tornado Distributor, Service Center, or the Tornado Technical Service Department.

29

MODEL 99440PREVENTIVE MAINTENANCE CHECKLIST

DAILY MAINTENANCESTART OF OPERATION

• Unplug charger from system circuitry.• Close all plugs and covers to both liquid tanks to seal. Fill the Solution Tank as needed, and

ensure that the Recovery Tank is empty.• Give the machine a general visual inspection.

END OF OPERATION• Clean and wipe squeegee blades. Lift and lock them clear of the floor.• For safety, make sure both Keyswitch and Emergency Switch are off.• Drain and flush both tanks and leave fillers and drains open to air dry. This will help eliminate

odors and minimize Vacuum Motor corrosion.• Add distilled water to battery cells if required.• Charge the batteries.

WEEKLY MAINTENANCECheck the specific gravity of fully-charged battery cells: allow a 30 minute cool-down aftercharging (specific gravity should be 1.270 to 1.280). Use a hydrometer to check.

MONTHLY MAINTENANCE• Lubricate lift mechanisms (both brush and squeegee) with a light oil.• Adjust the brush pressure (mercury switch) if needed.• Check for wear or damage of brushes, pads and squeegee blades, replace if necessary.• Clean all battery terminals with baking soda and water.• Check batteries for damage, acid spills, cracks.• Lubricate lever pivots and mechanisms, and check for looseness.• Check the drain gaskets for wear and damage, replace if necessary.• Make sure all electrical connections are tight.• Clean and lubricate the caster wheels.

SEMI-ANNUAL MAINTENANCE• Check all motors, especially check for carbon brush wear. Replace if necessary.• Grease all bearings.

ANNUAL MAINTENANCE• Tighten all loose linkages, screws and nuts on entire machine.

CLEANING THE LR 30Although the LR 30 has an exceptionally tough and chemical-resistant body, it houses

sophisticated electronics and wiring systems. To avoid the chance of shorting or corrodingelectrical components or connectors, clean the body with a damp sponge or brush only. Do not

expose the unit to rain, hose or power spray, runoff, or poured water rinsing.

30

REPLACEMENT ITEMS AND ACCESSORIESLR 30 Floorkeeper Automatic Scrubber

Catalog # Description ShippingWeight

Replacement Items99172 16” Black Firm Poly Scrub Brush (2 required) 10#

K62732150 Standard Squeegee Set 2#Optional Items

99173 16” Green Grit Brush (2 required) 8#90676 Wet Pick-Up Attachment Set 9#99154 16” Pad Holder (2 required) 8#

K62732090 Oil Resistant Squeegee Set 3#