Windsor FLX3, FLX3T, FLXSP3, FLXSP3T Operating Instructions Manual
SCRUBBER
IPX4
Operating Instructions
MODELS: FLX3
FLX3T
D
980087 07/19/03
FLXSP3
FLXSP3T
Read these instructions before using the machine
MACHINE DATA LOG/OVERVIEW
2
YOUR DEALER
Address:
MODEL _______________________________________
DATE OF PURCHASE__________________________
SERIAL NUMBER______________________________
SALES REPRESENTATIVE # ___________________
DEALER NAME________________________________
OPERATIONS GUIDE NUMBER __________________
PUBLISHED___________________________________
Copyright 2003 Windsor Industries, Printed in USA
Name:__________________________________________________________________________________________________
_______________________________________________________________________________________________
Phone Number:__________________________________________________________________________________________
OVERVIEW
The Flex3™ is a revolutionary rider type scrubber with four wheel articulated design for superior
maneuverability, simple operation, and low maintenance. The machine design permits access to
areas even traditional walk behind machines cannot reach. The squeegee design, location, and
steering geometry allows the operator to make tight turns while recovering full width of the scrub
path. Controls are logically designed for easy touch button operation, strategically laid out at the
operator’s fingertips, easily reached from a comfortable seat. In addition, the four wheel stance
continues the Windsor concept for operator comfort and stability. The Flex3™ was designed from
the ground up for ease of maintenance.
FLX3 980087 04/01/03
TABLE OF CONTENTS
3
Machine Data Log/Overview..........................2
Table of Contents...........................................3
HOW TO USE THIS MANUAL
How to use this Manual..................................1-1
SAFETY
Important Safety Instructions.........................2-1
Hazard Intensity Level...................................2-2
Safety Label Location.....................................2-3
OPERATIONS
Technical Specifications................................3-1
How the Machine Works ................................3-3
Components...................................................3-4
Controls..........................................................3-5
Machine Operation.........................................3-15
Pre-Run Machine Inspection......................3-15
Starting Machine.........................................3-15
Filing Machine.............................................3-15
Scrubbing....................................................3-16
Double Scrub..............................................3-17
Emptying & Cleaning Tanks.......................3-18
MAINTENANCE
Batteries.........................................................4-2
Low-Battery Shut-Down.................................4-4
Squeegee Adjustment....................................4-5
Adjusting Squeegee Pitch...........................4-5
Adjusting Deflection....................................4-5
Replace Rear Squeegee Blades...................4-6
Replace Front Squeegee Blades...................4-6
Scrub Head-Disk. ...........................................4-7
Scrub Brushes...............................................4-7
Replacement/Installing Scrub Brushes.........4-7
Scrub Head- Cylindrical.................................4-8
Differential Drive Chain..................................4-10
Drive Wheel Chain.........................................4-10
Brakes............................................................4-11
Tires and Wheels...........................................4-11
Vacuum Motors..............................................4-12
Brush Motors..................................................4-13
Towing or Pushing.........................................4-15
Machine Jacking............................................4-16
Machine Storage............................................4-16
Service Schedule...........................................4-17
Machine Troubleshooting...............................4-18
GROUP PARTS LIST
Brake.............................................................5-1
Control Panel.................................................5-3
Decal..............................................................5-5
Differential......................................................5-7
Electrical........................................................5-9
Floor...............................................................5-11
Forward/Reverse Pedal.................................5-13
Front Bumper – Disk.....................................5-15
Front Bumper - Cylindrical............................5-17
Front Frame...................................................5-19
Front Wheel...................................................5-21
Rear Frame...................................................5-23
Rear Wheel....................................................5-25
Recovery Tank .............................................5-27
Scrub Brush/Pad Driver................................5-29
Scrub Head – Cylindrical...............................5-31
Scrub Head – Cyl. Valve & Hopper...............5-33
Scrub Head – Disk ........................................5-35
Scrub Head Lift - Cylindrical..........................5-37
Scrub Head Lift - Disk...................................5-39
Seat................................................................5-41
Solution Hoses & Fittings..............................5-43
Solution Tank ................................................5-45
Squeegee - Standard....................................5-47
Squeegee - Tight...........................................5-51
Squeegee Lift ................................................5-55
Steering .........................................................5-57
Vacuum ........................................................5-59
Wiring – Battery.............................................5-61
Wiring – Control Panel...................................5-63
Wiring – Electrical Panel...............................5-65
Wiring – Front Frame....................................5-67
Wiring – Rear Frame.....................................5-69
Wiring – Schematic .......................................5-71
Suggested Spare Parts.................................5-72
EC Declaration of Conformity .......................5-73
Notes .............................................................5-75
Warranty........................................................5-76
FLX3 980087 07/19/03
HOW TO USE THIS MANUAL
1-1
This manual contains the following sections:
- HOW TO USE THIS MANUAL
- SAFETY
- OPERATIONS
- MAINTENANCE
- PARTS LIST
The HOW TO USE THIS MANUAL section will tell
you how to find important information for ordering
correct repair parts.
Parts may be ordered from authorized dealer. When
placing an order for parts, the machine model and
machine serial number is important. Refer to the
MACHINE DATA box, which is filled out during the
installation of your machine. The MACHINE DATA
box is located on the inside of the front cover of this
manual.
MODEL
DATE OF PURCHASE
SERIAL NUMBER
SALES REPRESENTATIVE #
DEALER NAME
OPERATIONS GUIDE NUMBER
PUBLISHED
Copyright 2003 Windsor Industries, Printed in USA
The model and serial number of your machine are
located approximately where indicated.
The OPERATIONS section is to familiarize the
operator with the operation and function of the
machine.
The MAINTENANCE section contains preventive
maintenance to keep the machine and its
components in good working condition. They are
listed in this general order:
- Batteries
- Squeegee Assembly
- Scrub Head
- Differential Drive Chain
- Drive Wheel Chain
- Brakes
- Tires and Wheels
- Vacuum Motors
- Brush Motors
- Towing and Pushing Machine
- Storage
- Service Schedule
- Troubleshooting
The PARTS LIST section contains assembled parts
illustrations and corresponding parts list. The parts
lists include a number of columns of information:
- REF – column refers to the reference
number on the parts illustration.
- PART NO. – column lists the part
number for the part.
- QTY – column lists the quantity of the
part used in that area of the machine.
- DESCRIPTION – column is a brief
description of the part.
- SERIAL NO. FROM – column indicates
the first machine the part number is
applicable to. When the machine design
has changed, this column will indicate
serial number of applicable machine.
The main illustration shows the most
current design of the machine. The
boxed illustrations show older designs. If
column has an asterisk (*), call
manufacturer for serial number.
- NOTES – column for information not
noted by the other columns.
The SAFETY section contains important information
regarding hazard or unsafe practices of the
machine. Levels of hazards is identified that could
result in product or personal injury, or severe injury
resulting in death.
NOTE: If a service or option kit is installed on your
machine, be sure to keep the KIT INSTRUCTIONS
that came with the kit. It contains replacement parts
numbers needed for ordering future parts.
NOTE: The 98# on the lower left corner of the front
cover is the part number for this manual.
FLX3 980087 04/01/03
2-1
IMPORTANT SAFETY INSTRUCTIONS
!
WARNING:
When using a battery powered appliance, basic precaution
must always be followed, including the following:
READ ALL INSTRUCTIONS BEFORE USING THIS MACHINE.
To reduce the risk of fire, electric shock, or injury:
Use only indoors. Do not use outdoors or expose to rain.
Use only as described in this manual. Use only manufacturer’s recommended components and
attachments.
If the machine is not working properly , has been dropped, damaged, left outdoors, or dropped into
water, return it to an authorized service center.
Do not operate the machine with any openings blocked. Keep openings free of debris that may reduce
airflow.
This machine is not suitable for picking up hazardous dust.
Machine can cause a fire when operating near flammable vapors or materials. Do not operate this
machine near flammable fluids, dust or vapors.
This machine is suitable for commercial use, for example in hotels, schools, hospitals,
factories, shops and offices for more than normal housekeeping purposes.
Maintenance and repairs must be done by qualified personnel.
If foam or liquid comes out of machine, switch off immediately .
Disconnect battery before cleaning or servicing.
Before the machine is discarded, the batteries must be removed and properly disposed of.
Make sure all warning and caution labels are legible and properly attached to the machine.
During operation, attention shall be paid to other persons, especially children.
Before use all covers and doors shall be put in the positions specified in the instructions.
When leaving unattended , secure against unintentional movement.
The machine shall only be operated by instructed and authorized persons.
When leaving unattended , switch off or lock the main power switch to prevent unauthorized use.
Only chemicals recommended by the manufacturer shall be used.
This appliance has been designed for use with the brushes specified by the manufacturer. The fitting
of other brushes may affect its safety.
SAVE THESE INSTRUCTIONS
FLX3 980087 04/01/03
HAZARD INTENSITY LEVEL
2-2
!
WARNING
!
WARNING
!
WARNING
The following symbols are used throughout this guide as indicated in their descriptions:
HAZARD INTENSITY LEVEL
There are three levels of hazard intensity identified by signal words -WARNING and CAUTION and FOR
SAFETY. The level of hazard intensity is determined by the following definitions:
WARNING - Hazards or unsafe practices which COULD result in severe personal injury or death.
! CAUTION
CAUTION - Hazards or unsafe practices, which could result in, minor personal injury or product or property
damage.
FOR SAFETY: To Identify actions, which must be followed for safe operation of equipment.
Report machine damage or faulty operation immediately. Do not use the machine if it is not in proper
operating condition. Following is information that signals some potentially dangerous conditions to the
operator or the equipment. Read this information carefully. Know when these conditions can exist. Locate
all safety devices on the machine. Please take the necessary steps to train the machine operating
personnel.
FOR SAFETY:
DO NOT OPERATE MACHINE:
Unless Trained and Authorized.
Unless Operation Guide is Read and understood.
In Flammable or Explosive areas.
In areas with possible falling objects.
WHEN SERVICING MACHINE:
Avoid moving parts. Do not wear loose clothing; jackets, shirts, or sleeves when working on the
machine. Use Windsor approved replacement parts.
! WARNING
Batteries emit hydrogen gas. Explosion or fire can result. Keep sparks and open flame away. Keep
solution tank in raised position when charging. Keep sparks and flames away from the batteries.
Do not smoke around batteries.
Disconnect batteries before working on machine. Only qualified personnel should work inside
machine. Always wear eye protection and protective clothing when working on or near batteries.
Avoid skin contact with the acid contained in the batteries.
Never allow metal to lie across battery tops.
FLX3 980087 04/01/03
SAFETY LABEL LOCATION
2-3
SAFETY DECAL
80814
LOCATED ON FRAME
SUPPORT WARNING 82448
LOCATED ON FRAME
BATTERY CAUTION 80885
BATTERY COMPARTMENT PLATE
FOR SAFETY
NOTE: These drawings indicate the location of safety labels on the Flex3TM. If, at any time, the labels become
illegible, promptly replace them.
SAFETY DECAL 81925
500700
LOCATED ON BACK SIDE OF FRONT
NEXT TO VACUUM INLET
SAFETY DECAL 81494
SAFETY DECAL 81505
SAFETY DECAL 82447
NEXT TO 82448 DECAL
FLX3 980087 04/01/03
TECHNICAL SPECIFICATIONS
SPECIAL NOTES:
The weighted root mean square acceleration at
ITEM DIMENSION/CAPACITY
Rated Voltage 36VDC
Rated Amperage 90 Amps
Batteries 6 x 6 Volt 360 AH @ 20hr rate
Scrub Brush Motors 2 x .75 hp (0.56 kW)
Vacuum Motor 2 x .75 hp (.056 kW) @ 18,000 rpm
Propelling Motor 2 hp (.745 kW) @ 2700 rpm, 27A
Mass (GVW) 2102 lbs. (953 kg)
Weight empty without batteries 914 lbs. (415 kg)
Solution Control Gravity feed, fully variable with automatic shut-
off in neutral
Solution tank capacity 35 gal. (132l)
Recovery tank capacity 35 gal. (132l)
Scrub brush diameter for 34 in. (86 cm) disk
scrub head
Scrub brush diameter for 34 in. (86 cm)
cylindrical scrub head
Scrub brush length for 34 in. (86 cm) cylindrical
scrub head
Scrub brush pressure 0-200 lbs. (0-91 kg)
Scrub brush speed (Disk) 200 rpm
Scrub brush speed (cyl) 800 rpm
Tires 4 x 16 in (40.64 cm) foam filled black knobby
Maximum speed 6.2 mile/hour (10k/hr)
Coverage 49,300 sq. ft/hr (4,590 sq. m/hr) at 3.5 mph
Frame construction Welded cold rolled steel and steel plate with
Brakes Dual self centering mechanical 6 in (15.24 cm)
Minimum aisle u-turn width 96 in (243.8 cm)
17 in (43.0 cm)
6 in (15.2 cm)
32 in. (81.3 cm)
standard.
(5.6k/hr) with 2 in (5 cm) overlap.
epoxy powder coat finish.
disc with hand lock parking brake.
The sound pressure level at the operator’s ear
was measured to be 76 dBA. This was a
nearfield, broad-band measurement taken in a
typical industrial environment on a tile floor. This
appliance contains no possible source of impact
noise. The instantaneous sound pressure level is
below 63 dBA.
3-1
FLX3 980087 04/01/03
the operator’s arms was measured to be below
2.5m/s². this was a tri-axial, third-octave-band
measurement made during normal operation on a
composite tile floor. The measurement and
related calculations were made in accordance
with ANSI S3.34-1986.
TECHNICAL SPECIFICATIONS
3-2
SQUEEGEE
WIDTH
HEAD
ITEM DIMENSION/CAPACITY
Height 44.5 in (113 cm)
Length with disk head 95.2 in (241.8 cm)
Length with cylindrical head 95.8 in (243.3 cm)
Width with standard squeegee 48.7 in (123.7 cm)
Width with tight squeegee 43.0 in (109.2 cm)
Width w/o squeegee 42.5 in (108.0 cm)
WIDTH
HEIGHT
TOP VIEW
RIGHT SIDE VIEW
LENGTH
FLX3 980087 04/01/03
HOW THE MACHINE WORKS
3-3
The Flex3TM is a battery powered, self-propelled,
hard floor scrubber intended for commercial use.
The appliance applies a cleaning solution onto a
hard floor, scrubs the floor with brushes, and then
vacuums the soiled water back into the recovery
tank.
The machine's primary systems are the solution
system, scrub system, recovery system, and
operator control system.
The function of the solution system is to store
cleaning solution and deliver it to the scrub system.
The solution system consists of the solution tank,
strainers, valve and controls. The solution tank
stores cleaning solution (water and detergent) until it
is delivered to the scrub system. The strainers
protect the valve from debris. The valve is a
solenoid type valve, which controls the delivery of
cleaning solution to the scrub system. The valve
automatically prevents solution flow unless the scrub
brushes are turned on and the machine is being
propelled. The solution control switch controls the
amount of cleaning solution delivered to the scrub
system by controlling the amount of time the valve is
open.
The function of the scrub system is to scrub the
floor. The disk scrub systems consists of two rotary
type disk scrub brushes, motors, scrub deck skirt, lift
actuator and controls. The brushes scrub the floor
as the motors drive the brushes. The brush drive
hubs allow the scrub brushes to follow irregularities
and changes in the floor without loosing contact with
the floor. The scrub deck skirts and side squeegees
control the cleaning solution on the floor so that the
squeegee can pick it up. The one touch switch
controls the motors and lift actuator to turn the
motors on and lower the deck, or turn the motors off
and raise the deck. The brush pressure switch
controls the down pressure on the scrub deck.
The scrub plus system consists of two cylindrical
type brushes, motors, scrub deck skirts, hopper, lift
actuator, and controls. The cylindrical scrub head is
designed to eliminate debris that may be caught in
the squeegee while scrubbing. Water is applied to
the first scrubbing brush turning in a clockwise
rotation when viewed from the right or operator’s
side of machine. The first brush scrubs dirt and
debris between the brushes. The second scrubbing
brush, turning in a counter clockwise rotation, picks
up debris and throws it into a removable hopper.
The larger debris that might catch under the
squeegee is collected in the hopper. Water is
allowed to drain out the hopper into the squeegee
path where it is recovered from the floor. The scrub
deck skirts control the cleaning solution on the floor
so that the squeegee can pick it up. The one touch
switch controls the motors and lift actuator to turn
the motors on and lower the deck, or turn the motors
off and raise the deck. The brush pressure switch
controls the down pressure on the scrub deck.
The function of the recovery system is to vacuum the
soiled water back into the recovery tank. The
recovery system consists of the squeegee, vacuum
motors, filter, recovery tank and controls. The
squeegee wipes the dirty solution off the floor as the
machine moves forward. The vacuum motors
provide suction to draw the dirty solution off the floor
and into the recovery tank. The filter protects the
vacuum fan from debris and foam. The recovery
tank stores the dirty solution.
The float switch in the tank activates the recovery
tank full indicator, shuts off the scrub motors and
solution flow, raises the scrub deck then squeegee,
and shuts off vacuum motor.
The function of the operator control system is to
control the direction and speed of the machine. The
directional control system consists of the
direction/speed control pedal, steering wheel, brake
pedal, propel controller, and drive wheels. The
direction/speed pedal signals forward or reverse
direction and speed. The controller interprets signals
from the direction/speed pedal to command the drive
wheel to propel or slow the machine. The steering
wheel articulates the machine to travel in the
direction desired by the operator. The brake can be
used to hold the machine on slopes.
FLX3 980087 04/01/03
COMPONENTS
3-4
1
8
5
7
6
4
9
12
1. Control Panel
2. Front Bumper
3. Electrical Cover
13
3
2
10
11
7. Recovery Tank Cover
8. Recovery Tank Drain Hose
9. Recovery Tank Drain Cap
4. Solution Tank
5. Solution Tank
Cover
6. Recovery Tank
10. Scrub Head
11. Solution Tank Drain Hose
12. Squeegee
13. Vacuum Motors
FLX3 980087 04/01/03
CONTROLS
3-5
3
5
7
4
10
2
1
1. Key Switch
2. Emergency Stop Button
6
9
8
14
8. Recycle Switch (Optional)
9. Recycle Indicator Light (Optional)
3. One Touch Switch
4. Brush Pressure Switch
5. Solution Control Switch
6. Vacuum/Squeegee Switch
7. Display Toggle Switch
• Information Screen 1
• Information Screen 2
• Hour Meter
• Fault Codes and Special Icons
• Battery Meter
10. Headlight Switch (Optional)
11. Brake Pedal
12. Parking Brake Knob
13. Directional Control Pedal and Speed
Reduction Feature
14. Horn Button
15. Steering Wheel
16. Steering Wheel Tilt Lever
17. Squeegee Camber Adjustment Knob
18. Squeegee Deflection Adjustment Knob
FLX3 980087 04/01/03
CONTROLS
3-6
18
15
12
11
13
16
17
FLX3 980087 04/01/03
CONTROLS
3-7
1. KEY SWITCH
Controls the power for the machine functions. To turn the machine power on, rotate key clockwise.
When the key is turned on the battery symbol will flash for 12 seconds while the system runs selfdiagnostics and returns scrub deck and squeegee to raised position, if necessary. The controller will
not respond to other commands until this routine is complete. To turn the machine power off, rotate
key counterclockwise.
INFORMATION DISPLAY
2. EMERGENCY STOP BUTTON
This safety feature is designed to cut all power to the machine at any time. To shut the machine
power off, push the Emergency Stop switch. To reset the machine, rotate the switch clockwise.
INFORMATION DISPLAY
FLX3 980087 04/01/03
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