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Owner's Manual for MASTERCRAFT models including: 28, 36, D-900G 36 Inch Battery And Gas Operated Sweepers, D-900G, 36 Inch Battery And Gas Operated Sweepers, And Gas Operated Sweepers, Operated Sweepers, Sweepers
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DocumentDocumentThis Owner's Manual is provided and hosted by Appliance Factory Parts. MASTERCRAFT D-900G Owner's Manual Shop genuine replacement parts for MASTERCRAFT D-900G Find Your MASTERCRAFT Sweeper Parts - Select From 5 Models -------- Manual continues below -------- READ AND FOLLOW A LL I NSTRUCTI ONS, WARNI NGS & CAUTI ONS BEFORE USI NG THI S BATTERY SWEEPER S A FETY, OPERATI ON & M AI NTENANCE M ANUAL DEBRI SM ASTERTM 28" & 36" BATTERY & GAS OP ER A TED S W EEP ER S This unit is intended for commercial use. The purpose of this manual is to inform the operator of the basic operating and safety procedures that must be followed when operating, adjusting and maintaining the sweeper. The machine has been developed and manufactured to ensure an excellent performance and the utmost comfort and ease of operation in a variety of working conditions. This sweeper will afford you many years of trouble-free operating satisfaction, provided it is given proper care. All parts have passed rigid quality control standards prior to being assembled to produce the finished product. Prior to packaging, the sweeper was again inspected for assurance of flawless assembly. Your sweeper is protectively packed to prevent damage in shipment. We recommend that upon delivery, unpack the sweeper and inspect it for any possible damage. Only a visual examination will reveal damage that may have occurred. If damage is discovered, immediately notify the transportation company that delivered your sweeper. As a shipper, we are unable to report claims for concealed damage. You must originate any claims within 5 days. This manual is for your protection and information. PLEASE READ CAREFULLY since failure to follow precautions could result in discomfort or injury. Read this manual completely before operating this sweeper. It is important to follow all instructions in the manual to prevent the possibility of injury or damage to the user and/or sweeper. READ A LL I NSTRUCTI ONS BEFORE OPERATI NG THI S SWEEPER PAGE 1 28" & 36" Sweeper - PN 447404 -Printed in USA 08/22/07 I M PORTANT S A FETY I NSTRUCTI ONS WARNI NG: To Reduce t he Risk of Fir e, Elect r ic Shock or Injur y : Elect r ic shock could occur if used on wet sur f aces. DO NOT expose t o r ain - St or e Indoor s When using this sweeper, basic precautions should always be followed, including the following: 1) This is NOT a toy. Close attention is necessary when used around or near children. 2) Use only as described in this safety manual. Use only the manufacturer's recommended attachments and accessories. 3) DO NOT use this sweeper if it is not working as it should, because it has been dropped, damaged, left outdoors or dropped into water, contact an authorized service center or factory. 4) Keep hair, loose clothing, fingers, and all parts of body away from openings and moving parts 5) DO NOT use this sweeper to pick-up cables, straps, wire or similar materials or operate near cables, wire or similar materials. 6) DO NOT pick up anything that is smoking or burning such as cigarettes, matches, or hot ashes. 7) DO NOT use this sweeper to pick up liquids. 8) Turn OFF all the controls when not in use, left unattended or before make repairs on the sweeper. 9) DO NOT use where anesthetics and oxygen are used. 11) Before servicing or cleaning this sweeper, always turn the unit OFF. 10) Replace damaged or worn parts immediately with genuine original equipment parts to maintain safety and to protect your limited warranty. USE OF THI S SWEEPER The DebrisMasterTM is designed with brush and vacuum system. It is for cleaning dry surfaces EXCLUSIVELY. The manufacturer will accept no responsibility for damage caused by improper use of the sweeper. Dropping, unreasonable bumping across thresholds and other misuses may result in damage to the unit which will not be covered by the warranty. Should damage to this sweeper occur, it should NOT be used until it is repaired by the manufacturer or an authorized service center. The sweeper should be operated by qualified and authorized personnel only. If you are working in a particularly dusty environment (for instance; sawmills; cement factories; marble processing factories), it is recommended you wear a mask, protective goggles, and gloves. ! NEVER: Use the sweeper to transport people. ! NEVER: Touch the moving parts of the machine. ! NEVER: Remove the sweeper's guards when it is running. UNPACKI NG I NSTRUCTI ONS This sweeper is shipped on one or two pallets. If you have a battery unit the batteries and charger are on the second pallet. The side brush, handle and upper cover are not attached. Before using the sweeper they must be installed. Unpack this sweeper with the utmost care to avoid any damage that may have occurred. Once it has been unpacked, inspect for any damaged. DO NOT use this sweeper if damage is discovered, contact your distributor immediately. Contents of First Pallet: ! DebrisMasterTM Sweeper ! Side Brush ! Bag with Hardware (Ignition Key; Bolts; Nuts; Screws; etc) ! Manual and Part List Contents of Second Pallet: ! Battery Charger ! Battery ATTENTI ON: ALWAYS KEEP THE SWEEPER OUT OF CHILDREN'S REACH. PAGE 2 2 8 " Sw e e pe r 1) Untighten and remove the nuts and bolts on both sides of the handle. Carefully install the handle in place on the brackets. 2) Line up the holes in the handle with the holes in the bracket 3) Replace 2 bolts and nuts on each side and tighten. The extra bolts and nut are packed in the bag with hardware. 4) Attach handle cover to the handle using the hardware provide in the plastic bag if it was not shipped attached. 36 " Sw e e pe r 1) Lift up on the handle carefully, set in place on the brackets. 2) Tighten the handle bolt and nut on each side of the handle. There are two bolts and nut on each side of the handle the extra bolts and nuts are packed in the bag with hardware. 3) Attach handle cover to the handle if was not shipped attached. H A N DLE I NSTALLATI ON 1) Make sure the brush lift lever is in the OFF position. 2) Remove the screw from the side brush drive shaft. 3) Fit the brush on the shaft. 4) Attach screw and washer. Tighten. SIDE BRUSH I NSTALLATI ON 1) Check to level of oil in the engine. 2) Fill the fuel tank with unleaded gas and check the oil. 3) Make sure the switch located on the engine is turned OFF, otherwise you will not be able to operate the stop key on the control panel. 4) Make sure the side brush is OFF. 5) Switch the accelerator lever to start and open up the fuel tap. 6) If the engine is cold, use the choke level and then operate the start handle. 7. Once the engine starts running, shut OFF the choke lever. 8) Use the accelerator to reach the required speed. GAS UNI TS PREPARI NG & STARI NG THE ENGI NE FOR OPERATI ON D A N GER : Gas is highly inf lam m able. Keep f uel in cont ainer s designed f or t his purpose. Before filling t he sweeper wit h gas m ove t he sweeper t o well v ent ilat ed ar ea and t ur n OFF t he engine. DO NOT SM OKE. If a f uel spill occur s DO NOT at t em pt t o st ar t t he engine, wait for t he vapor t o evaporat e. PAGE 3 BATTERY UNI TS BATTERY I NSTALLATI ON & RECHARGI NG WARNI NG: When handling or wor k ing near bat t er ies, NEVER place any t hing on t op of bat t er ies. This could cause spar k ing and creat e an explosion hazard. When inst alling or servicing bat t eries alway s wear prot ect ive clot hing, plus eye and face prot ect ion. Bat t eries cont ain acid t hat can cause severe burns on cont act . Note: The battery shipped with your sweeper is already charged. Inst allat ion 1) Be sure the ignition key is in the OFF position. 2) Carefully set battery into the battery tray. 3) Attach the connector with the red wire to the (+) terminal on the battery and connector with the black wire on the (-) terminal. 4) Install battery cover. (See Below) Re cha rging 1) Be sure the ignition key is in the OFF position. Sa f e t y Pre ca ut ions 2) Plug the charger into the charger plug located on the right hand side of the control panel. 3) Plug charger into 110V outlet. 4) The charge will automatically turn OFF when the battery is fully charged. ! The battery MUST be recharged when the RED LIGHT comes on. ! DO NOT store the sweeper when the battery is discharged. ! Check battery connections to make sure they are tight and there is NO corrosion. ATTENTI ON: When operat ing t his sweeper, if t he bat t ery needs t o be recharged, t he sweeper will st op aut om at ically. COV ER I NSTALLATI ON 1. Set the battery cover over the battery compartment making sure the front of the cover is seated in front groove of the battery compartment. Note: On the 36" sweeper the cover fits over the air inlet knob. 2. Lineup each knob with the holes in the cover and chassis. Tighten knobs. NOTE: There is a adjustable nut on back of the chassis that can be if there is a problem tightening the knob. PAGE 4 Traction Lever Airflow Adjustment Knob Side Brush Control Lever SWEEPER CONTROLS Con t r ol Pa n e l Side Brush Control Lever: Push lever down to turn ON the side brush. Push lever up to turn OFF the side brush. Key Switch: Starts and turns off all the sweeper's functions including the Main Brush. Fan Indicator Light Indicates that the fan is in use. Push Botton Suction Impeller: Activates the suction Impeller. Traction Lever: Squeeze this lever to start the sweeper moving. Airflow Adjustment Knob: Opens and closes the air valve when regulating the airflow. (36" Sweeper Only) Voltage Indicator Light Indicates the sweeper's power levels. Ba t t e r y Sw e e pe r s On ly Battery Charger Socket: Plug for battery charger. Battery Charge Indicator Lights: Green: Battery is charged. Yellow: Battery is running down, recharge as soon as possible. Red: DO NOT operate, batteries must be recharged. Follow these instructions to obtain the best cleaning results from the sweeper and OPERATI NG keep damage to a minimum. 1) When picking up light but bulky To St a r t Op e r a t in g Th e P R OCEDU R ES debris (sheets of paper, leaves, etc.) Sw e e p e r : raise the front part of the sweeper by pressing down the handle so that the 1) Check to make sure that the side 4) Push the Side Brush Control Lever sweeper can tackle the rubbish. brush is OFF. down to lower and turn ON the side brush. 2) DO NOT use the sweeper to pickup wires, ropes, and straps or to soak up any liquids. 2) Turn the Key Switch to ON 3) Battery units have a 10 seconds delay while the battery voltage level is checked. 5) Squeeze the Traction Lever (on right) to move the sweeper forward and start cleaning. 3) Operate the Filter Shaker at the end If the voltage is at the correct charge of your work (see pg 6). level the Main Brush will turn ON. 6) Squeeze Debris Flap Lever (on left) for removal of large debris. 4) Check to make sure the Main Brush is correctly adjusted (see pg 7). CAUTI ON: DO NOT leav e sweeper unat t ended when it is r unning or on sloping surf aces,t here is NO brak e t o k eep it f rom rolling. Bef or e leav ing t he sweeper t ur n it OFF and r em ov e t he k ey. PAGE 5 CLEANI NG OUT FRONT & REAR WASTE BINS CAUTI ON: Tur n OFF all cont r ols bef or e cleaning out t he wast e bins. Wast e m ust be disposed of in st r ick accor dance t o t he law. Re m ova l of Fr on t Bin Re mova l of Re a r Bin 1) Lift and turn the waste bin locks. 1) Lift and turn the waste bin locks. 2) Grasp both handles and grip located on 2) Grasp the handle and pull the waste bin the front part of the waste bin. out of the sweeper. 3) Pull upward to remove the waste bin. 3) Empty the waste bin. 4) Empty the waste bin. Re inst a ll Re a r Bin Re in s t a ll Fr on t Bin 1) Place the waste bin back in the sweeper from the top. 2) Lock in place by turning and lowering the waste bin locks. 1) Place the waste bin back into the sweeper. 2) Lock in place by turning and lowering the waste bin lock. CLEANI NG & REPLACI NG FI LTER The filter is one of the sweepers main components and is essential to its operation. It is important to follow filter maintenance procedures to obtain the best cleaning results. If you notice that dust forms when the sweeper is operating, check the filter. Cle a n in g Filt e r Us in g Filt e r Sh a k e r : 1) Using the manual lever, push down on it as the filter vibrates, dirt and dust will fall into to waste bin. To Re m ove Th e Filt e r : 1) Remove the rear waste bin. 2) Turn the two levers holding filter in place and lift out the filter. 2) Repeat this operation several times. Note: If dust still forms when the sweeper is operating, remove and clean the filter. Cle a n in g in He a vy Du s t En vir on m e n t s : When using the sweeper particularly in a dusty environment (cement factories, sawmills, marble processing factories), use the filter shaker more frequently. Cle a n in g t h e Filt e r : It is recommended to periodically remove the filter and clean it out with a blast of air or a vacuum cleaner. 3) Clean the filter with a blast of air or vacuum cleaner. 4) Reinstall the filter. NOTE: The filter features an arrow that shows the direction in which it should be fitted. Re pla cin g t h e Filt e r : Every 200 hours of work, the filter must be replaced. 1) Remove the filter (See instructions under Cleaning the Filter). 2) Install a NEW filter and make sure the gasket and filter are dust tight. PAGE 6 ADJUSTING & REPLACI NG M AIN & SIDE BRUSHES Adjust ing M a in Brush Re pla cing M a in Brush Adjust ing Side Brush 1) Remove the top cover. 2) Untighten locknut, and turn adjusting handle clockwise to increase pressure and counterclockwise to decrease pressure. 3) The adjusting handle works like a ratchet. Note: When the lever is pulled up it can be rotated without changing the brush adjustment. 4) Tighten locknut and replace cover. The Main Brush is made in 3 sections, each section is divided in half. To Remove Main Brush: 1) Remove the front waste bin. 2) Unscrew and remove the 6 screws holding the main brush sections in place. 3) Remove dissembled brush. To I n s t a ll M a in Br u s h : 1) Take a brush section and place it around the shaft, securing the section with the brush screws. 1) Loosen the adjusting screws. 2) Use the slots to position the brush at the required height. 3) Tighten the two adjusting screws. Re pla cing Side Brush 1) Lift the front part of the sweeper. 2) Untighten the brush screw and removing the brush. 3) Replace the brush and secure with the screw and washer. 2) Repeat this operation for each brush section. Note: Make sure the brush spins and directs dirt and debris to the center of the sweeper. 3) Replace front waste bin. PAGE 7 REPLACI NG & A DJUSTI NG BELTS Re pla cing t he Be lt s: 1) Remove the top cover and front waste bin. 2) Remove the right wheel. 3) Loosen the screws that secure the bumper and right side guard in place and remove side guard. Now you can replace the damaged belt. Re pla cin g Ce n t e r Be lt 1) Remove Side Brush Drive Belt from the 2-Groove Pulley. 3) Remove Main Brush Drive Belt from the groove of the Main Brush Drive Pulley and 2-Groove Pulley. 4) Replace with a NEW Main Brush Drive Belt. Re pla cing Side Be lt 1) Remove Side Brush Drive Belt from the 2-Groove Pulley. 2) Loosen Side Arm Pin and let the hooks of Side Arm come out of the idle toothed ring. 3) Remove Side Brush Drive Belt from the Side Arm. 4) Replace the Side Brush Belt. 5) Hook Side Arm to the idle toothed ring. 6) Tighten Side Arm Pin. 7) Place Side Brush Belt on 2-Groove Pulley. Re pla cing Drive Be lt 1) Loosen the Main Brush Drive Pulley screw and take it out of the reduction unit shaft, paying attention not to lose the key. 2) Unscrew Reduction Drive Pulley screw and take it out of the reduction unit shaft, paying attention not to lose the key. 3) Remove Drive Belt. 4) Place the NEW Drive Belt on the Drive Shaft Pulley. 5) Install Reduction Drive Pulley on the reduction unit along with the belt. 5) Position Side Brush Belt on the 2Groove Pulley. REPLACI NG M OTOR FAN 1) Remove the cover. 5) Untighten the four motor screws. 2) Disconnect the battery cables and 6) Replace the motor by carrying out remove the battery. Carefully set aside. the above operations in reverse order. 3) Disconnect the power supply cords of the motor from the plug. 4) Remove the stop for the cable holder from the motor. Note: Make sure the motor is mounted level with the fan. CAUTI ON When connect ing t he m ot or, respect t he polarit y. PAGE 8 REPLACI NG SI DE A ND CENTER FLA P S Re pla ce Out e r Side Fla ps 1) Remove the rear wheels and the relevant side guards. 2) Loosen the Flap Frame Screws that secure the flaps to frame. 3) Install a NEW Outer Side Flap in the same direction that it was removed. 4) Tighten screws and replace rear wheel. Re pla ce Inne r Side Fla ps 1) Lift the front part of the sweeper and loosen Inner Flap Screws that secure the flaps to the frame. 2) Install a NEW Inner Side Flap in the same direction that it was removed. 4) Tighten screws and replace rear wheel. Re pla ce Ce n t e r Fla p 1) Remove rear wheels and the relevant side guard. 2) Remove the rear door. 3) Loosen the two Flap Pins located on the sides of the frame. 4) Grasp the Center Flap and pull it outward. 5) Fit a NEW flap in the same direction it was removed. 6) Insert the points into holes and tighten Flap Pins. PAGE 9 REPLACI NG TRACTI ON AND SIDE BRUSH CA BLES Tr a ct ion Ca ble To Remove Traction Cable: 1) Remove the upper cover. 2) Loosen the security dowel located on the cable fixing pin. 3) Pull the cable out of the fixing pin and remove the adjustment screw mounted on the handle. 4) Press the handle and pull the cable out of its sheath. To Install NEW Traction Cable: 1) Fit one end of the NEW cable into the handle adjustment screw (i.e. the end without the blocking ball). 2) Insert the cable into its sheath. 3) Hook the blocking ball to the handle. 4) Slot the cable through the turned adjustment screw, secured to the frame and then through the fixing pin. 5) Tighten the security dowel. Adjust the cable with the two adjustment screws. Side Br u s h Lif t in g Ca ble To Remove Side Brush Cable: 1) Remove the upper cover and the front waste bin. 2) Remove the front bumper, right wheel and right side guard. 3) Loosen the cable clamp. 4) Loosen security dowel on the fixing pin. 5) Remove the handle from the support and open it up. 6) Pull the cable out of the two sheaths. To Install NEW Side Brush Cable: 1) Put the cable inside the handle. 2) Close handle and fix it to the support. 3) Insert the cable into its sheath. 4) Secure one end of the cable in place with the clamp and the other end with the fixing pin. 5) Adjust cable with the two adjustment screws. ROUTI NE M AI NTENANCE CAUTI ON: Alway s t ur n OFF t he sweeper bef or e per f or m ing any m aint enance. All m aint enance m ust be carried out by com pet ent personnel or an aut horized service cent er. _____________________________________________________ M a int e na nce On Eve r y Eve r y Eve r y C_h_e_c_k _L_is_t __________________D_e_liv_e_r_y ____1_0 _H_r_s ___5_0_H_r_s___1_0 _0 _H_rs_ Check Battery Liquid X X Check Belts X Grease in the Reduction Unit X X Tighten Nuts and Screws X Brushes for Wear X Gaskets for Leaks and Wear X C_h_e_c_k _th_a_t _pa_r_ts_a_r_e _in_w_o_r_kin_g_o_r_de_r____X__________________________ WARNI NG: When washing of f t he scr ubber DO NOT use a J et of Wat er. The cov er and bin M UST be r em ov er bef or e cleaning. PAGE 10 _____________________________________________________________________________ 28" 36" Description DM-700B DM-900B _____________________________________________________________________________ Side Brush Width 331/2" 381/2" Side Brush Length 471/4" 471/4" Handle Height 37" 37" Main Brush Cleaning Width 201/2" 281/4" Side and Center Brush Cleaning Width 291/2" 351/2" Bin Capacity 1.3 Cu Ft 1.7 Cu Ft Filter Surface 13.452 Ft 21.522 Ft Noise Level 72dB 72dB Main Voltage 12V 12V Installed Power 400W/40A 400W/40A Battery 12V/115A 12V/115A _____________________________________________________________________________ S W EEP ER SPECI FI CATI ON WIRING DI AGRAM 1) Battery Charger Plug 2) Battery 3) Filter Shaker Vibrator 4) Electric Motor 5) 50 A Fuse 6) Filter Shaker Button 7) 1.25A / 250V Fuse 8) Key Switch PAGE 11 TROUBLE SHOOTI NG GUI DE Address: 777 South Street P.O. Box 2310 Newburgh, N Y 12550-0606 TEL: (800) 835-7812 (845) 565-8850 FAX: (800) 752-6883 (845) 565-9392 URL: www.mastercraftusa.com E-mail: mail@mastercraftusa.com CAUTI ON: Alway s t ur n t he sweeper OFF bef or e ser v icing. PROBLEM : M a in br u s h n ot w or k in g. CA U SE: SOLUTI ON: 1) Belt is broken. 2) Motor burnt out. 3) Wire is detached. 4) Circuit board damaged. 1) Replace belt. 2) Replace motor. 3) Check and reattach. 4) Check and replace. PROBLEM : Side br u s h n ot w or k in g. CA U SE: SOLUTI ON: 1) Belt is broken. 1) Replace belt. PROBLEM : Ba t t e r y w ill n ot s t a y ch a r ge d. CA U SE: SOLUTI ON: 1) Liquid is insufficient. 2) Battery terminal is loose. 1) Add liquid. 2) Tighten terminal. PROBLEM : Du s t blow in g f r om f a n . CA U SE: SOLUTI ON: 1) Filter is damaged. 2) Filter not correctly installed. 3) Gasket is worn. 1) Replace filter. 2) Install correctly. 3) Replace gasket. PROBLEM : Br u s h e s w e a r pr e m a t u r e ly . 1) Brushes are to low. 1) Adjust brushes. PROBLEM : Du s t f or m s du r in g ope r a t ion . CA U SE: SOLUTI ON: 1) Flaps are worn. 2) Filter is clogged. 1) Replace flaps. 2) Clean filter. PROBLEM : M ot or doe s n ot w or k . CA U SE: SOLUTI ON: 1) Motor is damaged or burnt out. 2) Wire is disconnected. 3) Impeller is clogged or blocked 1) Replace motor. 2) Check and reconnect wire. 3) Clean impeller. PROBLEM : Sw e e pe r w ill n ot s t a r t . CA U SE: SOLUTI ON: 1) Battery terminals are disconnected. 2) Battery need to be recharged. 3) Fuse is blown. 4) Gas tank empty. 1) Check and reconnect terminals. 2) Charge battery. 3) Replace fuse. 3) Refill tank. WARNI NG: Repair s should only be per f or m ed by an aut hor ized ser v ice cent er. 28" & 36" Sweeper - PN 447404 -Printed in USA 08/22/07 PAGE 12