R
PROPANE POWERED HIGH SPEED
BURNISHER/STRIPPE
Operating Instructions
MODELS:
L21H13 10023000 LS30H13 10023110 L21K13 10023010
L24H13 10023040 L21K17 10023020 L24K17 10023060
L27H13 10023080 L24ER22 10023030 L27K17 10023090
LS30H13 10023110 L27ER22 10023070
C
86039180 05/23/07
Read these instructions before using the machine
MACHINE DATA LOG/OVERVIEW
Name: __________________________________________________________________________________________________
Address: _______________________________________________________________________________________________
Phone Number: _________________________________________________________________________________________
MODEL _______________________________________
DATE OF PURCHASE __________________________
SERIAL NUMBER ______________________________
SALES REPRESENTATIVE # _____________________
DEALER NAME ________________________________
OPERATIONS GUIDE NUMBER ___________________
PUBLISHED
__________________________________________
Copyright 2002 Windsor Industries, Printed in USA
YOUR DEALER
For the name and address of your dealer contact: Windsor Industries
OVERVIEW
The Lightning is a propane powered, high speed, burnisher/stripper intended for commercial use.
The burnisher model buffs most hard floor surfaces with the use of special pads. The stripper
model applies stripping solution to the floor to remove any sealant, floor finishing, etc.
LIGHTNING 86039180 05/23/07
2
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
OPERATIONS
Machine Operation........................................3-1
Before Operating the Machine...................3-1
Emergency Stopping Procedure................3-2
Transporting/Storing Machine....................3-2
Propane Fuel System. ...............................3-3
Changing oil...............................................3-3
Adjusting Belt Tension...............................3-3
Refueling/Storing Cylinders. ......................3-3
MAINTENANCE
Service Schedule..........................................4-1
Installing or Removing Pad...........................4-2
Installing or Removing Pad Driver ................4-2
Machine Troubleshooting..............................4-3
TABLE OF CONTENTS
GROUP PARTS LIST
21” Deck Group. ...........................................5-1
24” Deck Group. ...........................................5-3
27” Deck Group. ...........................................5-5
30” Stripper Group........................................5-7
Kawasaki Fuel Block.....................................5-9
Kawasaki Wiring......................................... 5-10
Kawasaki Fuel System. .............................. 5-11
Honda Fuel System.................................... 5-12
Kill Switch ................................................... 5-13
Clutch and Switch.......................................5-14
Belt Chart/Notes ......................................... 5-15
Warranty..................................................... 5-16
LIGHTNING 86039180 05/23/07
3
HOW TO USE THIS MANUAL
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 Windsor
dealers.
When placing an order for parts, the
machine model and machine serial number are
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 2002 Windsor Industries, Printed in USA
The model and serial number of your machine is on
the bottom back-end of the machine.
1-1
LIGHTNING 86039180 05/23/07
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.
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.
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.
- PRV NO. – reference number.
- 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.
NOTE: If a service or option kit is installed on your
machine, be sure to keep the KIT INSTRUCTIONS
which came with the kit. It contains replacement
parts numbers needed for ordering future parts.
IMPORTANT SAFETY INSTRUCTIONS
!
When using a propane powered appliance, basic precaution
must always be followed, including the following:
READ ALL INSTRUCTIONS BEFORE USING THIS MACHINE.
WARNING:
To reduce the risk of fire, explosion, 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.
Maintenance and repairs must be done by qualified personnel.
Only trained operators should be allowed to operate propane powered floor machines.
If the machine is not working properly, has been dropped, damaged, left outdoors, or dropped into
water, return it to an authorized service center.
Check fuel cylinder for overfill before taking it into the building or placing it in storage.
Install fuel cylinder in a well ventilated place.
Be aware of possible leaks of propane gas if odor is present.
If the machine is stored inside a building, remove the fuel cylinder & store properly outside.
Secure fuel cylinders when being transported. If attached to the machine service valves should be
OFF.
Never store fuel cylinders in a vehicle, building, or area where they may exposed to high temperature
Do not operate the machine with any openings blocked. Keep openings free of debris that may reduce
airflow.
Machine can cause a fire when operating near open flames or sparks.
This machine is suitable for commercial use, for example in hotels, schools, hospitals,
factories, shops and offices for more than normal housekeeping purposes.
Remove fuel cylinder and disengage the starter before cleaning or servicing.
Before the machine is discarded, the fuel cylinder must be removed and properly disposed of.
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.
When leaving unattended, switch off or lock the main power switch to prevent unauthorized use.
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
LIGHTNING 860389180 05/23/07
2-1
HAZARD INTENSITY LEVEL
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
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 or 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
Fuel cylinders emit propane gas. Explosion or fire can result. Keep sparks and open flame away.
Do not smoke around fuel cylinders.
! WARNING
Remove fuel cylinder before working on machine. Only qualified personnel should work on
machine. Always wear eye protection and protective clothing when working on machine.
2-2
LIGHTNING 860389180 05/23/07
Your machine is shipped ready for your operation,
with exception of fuel cylinder. For hazard and safety
issues, the cylinders are sent with no fuel. Prior to
operation have your cylinder filled at a reputable
propane dealer.
! CAUTION
The fuel cylinder supplied with this machine is a
DOT 4E240 propane cylinder. Cylinders not branded
with DOT 4E240 on the top collar should not be
used. Never use a cylinder from a barbecue, etc. on
this machine.
The capacity of the 4E240 cylinder is 20lbs., 80% of
the total water capacity. Never overfill the cylinder.
BEFORE OPERATING THE MACHINE:
1. Check fuel cylinders: Check for overfill before
taking them into the building.
To check a cylinder for overfill:
a. Take it to a safe area outside.
b. Open the fixed liquid level gauge.
(bleeder valve)
c. Observe the gas from the valve:
1. If White cloud – Overfilled
2. If Clear vapor – Safe
d. If overfilled, allow to vent until vapor is
Clear in color.
2. Check Oil level: Check level prior to starting
engine and daily before using machine. Use
specified oil if necessary to add. DO NOT OVER
FILL OIL LEVEL, to do so may cause damage to
the engine, thus voiding warranty.
When checking oil refer to the specific engine
manufacturers instruction manual, as some
engines differ in correct procedure.
Use 10W30 oil.
3. Check Air Filter: Be sure the carburetor air filter
is free of dust/oil, etc. NOTE: Dirty filters is the
most frequent cause of elevated toxic emissions.
Check and clean recoil dust filter if necessary.
(see specific engine owners manual)
4. Check Pad & Pad Driver.
5. Adjust handle height: Use a 9/16 wrench to
loosen and tighten pivot points. Most find it
necessary to adjust the handle to “belt height”
for optimum control.
6. Install Fuel Cylinder: Take machine to a well
ventilated area. Check cylinder for overfill. (see
step 1) Install cylinder on machine with tank
strap. Connect the fuel cylinder to the machine
using “Rego” connection. Tighten “hand-tight”.
NOTE: Careful not to cross thread the Rego
connection. Open the service valve slowly. Be
alert for propane leaks. To remove cylinder
reverse the procedure.
MACHINE OPERATIONS
STARTING PROCEDURES
Burnisher:
1. Tilt machine back on rear casters so pad is off
the floor.
2. Slowly open the service valve on the fuel
cylinder. NOTE: opening the service valve too
quickly may cause the excess flow valve to stop
the flow of propane. If this occurs, close the
service valve, wait a few seconds and re-open it
SLOWLY!
3. Push the throttle lever to the choke position and
engage the starter by using the start button.
(NOTE: If equipped with key switch, start by
turning the key) Do not engage starter for more
than 20 seconds at a time, allow 10-20 seconds
between attempts to start the engine.
4. When engine starts, ease the throttle ba ck to
running position.
! WARNING
DO NOT run engine with throttle in the choke
position. Excessive harmful emissions will be
produced putting you and others in harms way.
5. Increase throttle to about ¾ and carefully lower
the machine pad to the floor while walking
forward slowly.
Optional: Electric Clutch
If equipped with and optional clutch, move throttle to
slow and engage the clutch by squeezing the
“trigger switch” on the operation handle. Move the
throttle to ¾ speed, slowly lower pad to the floor
while walking forward slowly.
LIGHTNING 86039180 05/23/07
3-1
MACHINE OPERATIONS
STARTING PROCEDURES
Stripper:
! CAUTION
This machine is only as fast as you allow it to be. It
is imperative that you keep the floor wet with
stripping solution while stripping and remove the
sludge quickly and completely. Rinsing thoroughly
before re-coating with sealer or floor finish.
1. Clear all areas of all displays. Remove any dust
and stickers from floor.
2. Prepare stripping solution according to
instructions on label.
3. Apply solution to the floor using a mop or other
method of application. KEEP FLOOR WET
WITH SOLUTION.
4. Allow 10 minutes or so for solution to penetrate
floor coating.
5. Using a “doodle bug” scrape the edg es clear of
floor finish.
6. Begin stripping with the machine. (one pass is
generally all that is needed).
7. Follow the machine with recovery of sludge and
damp mop. NOTE: rinse floor thoroughly.
Keep both models moving. Running the machine in
one place for more than a few seconds may damage
the floor.
! WARNING
Exhaust emissions contain harmful toxic gases. The
worst being carbon monoxide. Do not operate the
machine in confined areas for prolonged times.
Always make certain that adequate ventilation is
had.
! CAUTION
Never engage clutch in the fast run position or with
the pad on the floor, this may cause damage to the
clutch and the floor.
! WARNING
Be careful not to allow the machine to come in
contact with loose tiles or other obstruction on the
floor. The pad is turning at approximately 2000
RPM. If loose objects are hit by revolving pad they
could become dangerous missiles.
EMERGENCY STOPPING PROCEDURE
In case of an emergency, the machine can be
brought to an instant stop by:
1. Pull the throttle back to stop position or turn key
switch to OFF, if equipped.
2. Close service valve on the fuel cylinder.
3. If the machine is equipped with a “Kill Switch”,
activate the switch.
! CAUTION
The engine may backfire when stopped in this
manner.
STOPPING PROCEDURE
1. Close the service valve on the fuel cylinder while
the engine is running. This serves to “purge” the
fuel system of all flammable gas.
2. Tilt the machine back on it’s rear caster and
allow the engine to run until it stops.
3. Turn the key switch OFF if equipped.
Do not leave the machine unattended while the
engine is running for long periods of time. If
necessary to leave the machine for short periods to
move a display etc. move the throttle lever to idle
position and tip machine back on the rear caster.
It has been the accepted practice to start buffing
from the right side of the aisles. Most smaller
machines are offset to the right to allow buffing close
on that side.
TRANSPORTING/STORING MACHINE
When transporting the machine from one site to
another, secure the machine with the fuel cylinder
installed and the service valve OFF. Allow the
engine to cool down some before loading the
machine for transport.
When storing the machine, remove the propane
cylinder and store outside. (see pg. 3-3 for Storage
of Fuel Cylinders) Perform all daily maintenance
procedures. Store machine in a cool, dry, secure
area where it will not be damaged by other traffic.
Tilt the machine back on the rear caster with the pad
off of the floor.
3-2
LIGHTNING 86039180 05/23/07
PROPANE FUEL SYSTEM
! WARNING
Adjustments and repairs to the propane fuel system
can only be made by properly trained and certified
Service Technicians.
! WARNING
Improper adjustments will cause increased toxic
emissions of carbon monoxide and may result in
carbon monoxide poisoning.
CHANGING OIL
The manufacturer recommends 10W30 oil.
1. Run engine for 5 minutes to warm the oil.
2. Make sure machine is on level surfa ce, pad on
the floor. Place container under drain and open
the oil drain valve. Allow oil to drain completely.
3. Close drain valve and add 1 qt. Of 10W30 motor
oil. Check level and add if necessary.
4. Replace oil-fill cap assembly. Hand tighten only.
! CAUTION
DO NOT over fill oil and never run engine with low
oil level, this could cause damage to the engine
voiding your warranty.
NOTE: When checking oil, remove dip stick, wipe
clean, then reinsert the dip stick into the engine. DO
NOT SCREW IN (check engine manufacturer
manual for recommended procedure). Remove dip
stick and observe oil level as indicated on dip stick.
ADJUSTING BELT TENSION
Tools required for this procedure are:
- ¾” (19mm) open end wrench
1. Loosen mounting bolt on top side of machine
2. Rotate adjusting nut counter clockwise with
3. While holding the tension on the adjusting nut,
4. Check belt tension by pinching belt together.
- 15/16” (24mm) deep well socket
deck while holding adjusting nut on underside of
deck. NOTE: the mounting bolt must be
loosened before adjustment can be made.
socket to apply tension to belt.
tighten the mounting bolt on top of the deck.
Belt should depress only ½” (12mm)
Mounting Bolt
Machine Base
Tensioner
Tensioning Gauges
Idler Pulley
Adjusting Nut
LIGHTNING 86039180 05/23/07
MACHINE OPERATIONS
REFUELING/STORING CYLINDERS
The following information refers to regulations within
the United States of America and Canada. For other
countries, the owner must assure that the required
regulations are met.
National Fire Protection Association (NFPA) has
established standards for the storage and handling
of liquefied petroleum gasses. This standard is
NFPA 58.
Liquefied propane will expand 270 times into
flammable vapor, which is used as fuel for propane
engines. Proper training is recommended for those
operating propane powered machines in order to
limit the hazards related to the handling and storage
of propane fuel cylinders.
REFUELING
The capacity of the 4E240 cylinder is 20lbs., 80% of
the total water capacity. Never overfill the cylinder.
Have the cylinder filled at a reputable propane
dealer.
Do not attempt to repair a propane cylinder yourself.
Return the cylinder to your propane dealer for
authorized service.
STORING
Propane fuel cylinders whether full or empty should
be stored outside the building in a secure cylinder
storage cabinet in accordance with NFPA 58 5-4.2.1
! CAUTION
Vertical Propane fuel cylinders must always be
stored in a vertical position. This position assures
that the discharge from the pressure relief valve or
other items will be largely vapor and not liquid which
will expand to 270 times to flammable vapor.
The manufacturer reminds you that the fuel
cylinders should be removed from the machine
and placed in the proper storage cabinets
outside the building.
NOTE: Local authorities may have additional
requirements for storage of fuel cylinders. Always
check with the local authorities for these additional
requirements.
3-3
MAINTENANCE
! WARNING
Before attempting any maintenance procedures on
the machine, close the service valve on the fuel tank
and stop the engine.
! CAUTION
Repairs and adjustments to the fuel system must be
made by an authorized, properly trained service
technician.
To keep the machine in good working condition,
simply follow the daily, weekly, and monthly
maintenance procedures.
Keeping the machine clean and free from
accumulated dust, lint, and oil allows free air flow
across the engine to cool the engine properly.
Always use clean recoil dust filters. These can be
cleaned by washing them in a flow of water and
shaking dry. Extra filters may be ordered from
customer service.
IMPORTANT: Preventative maintenance is the
responsibility of the operator.
DAILY MAINTENANCE
(every 4 hours of operation)
1. Check oil level (use 10W30 oil only).
2. Clean recoil filter.
3. Check & Clean carburetor air filter.
4. Check belt tension by pinching belt together.
Belt should deflect only ½” (13mm).
5. Make sure all components are secure an d tight.
(pad holder, fuel cylinder, etc.)
6. Check pad driver and pad, daily. (clean or
replace)
7. Clean machine, if compressed air is available
blow dust from machine and engine,
concentrating on the inside of engine shrouds.
Wash undercarriage.
WEEKLY MAINTENANCE
(every 20 hours of operation)
1. All checks made on a daily basis plus:
4-1
LIGHTNING 86039180 05/23/07
2. Change oil and oil filters at 50 hours of service.
Use 10W30 Motor Oil or other no ash motor oils
designed for use in propane engines. Use of
non-recommended oil may void the engine
warranty. (see engine manual supplied with
documentation).
3. Check for loose nuts and/or bolts on entire
machine.
4. Examine all propane fuel components for leaks
or wear. Replace if necessary.
5. Grease wheels. Use white lithium grease only
and no more than 1 pump of grease. More
grease than recommended will push the seals
and dust covers out, allowing dust and other
foreign materials to penetrate the bearing,
shortening the life of the bearings as well as
allowing grease to drop from the wheels to the
floor.
MONTHLY MAINTENANCE
(every 80 hours of operation)
1. Perform all daily and weekly services.
2. Torque head bolts.
3. Check valve clearance.
4. Torque valve cover bolts.
5. Inspect spark plug. Replace if necessary.
6. Remove engine shroud and clean cooling fins.
NOTE: Consult specific engine owner’s manual for
the above steps 2-6.
QUARTERLY MAINTENANCE
(every 250 hours of operation)
1. Perform all of the monthly maintenance items.
2. Have engine serviced by authorized service
center. Including emissions check.
Keep a log book of all maintenance and repairs
performed on your machine.
INSTALLING OR REMOVING PAD
DRIVER OR PADS
Consult an authorized distributor to assist you in
selecting the correct pad for your specific needs.
Pad driver installation:
1. Tip machine on the right side (dip stick down).
2. Place pad driver on drive shaft and spin pad
driver clockwise to install.
Pad Removal & Installation:
1. Tilt machine back on rear caster or service
position.
2. Remove center-lock from pad driver.
3. Remove pad from pad holder.
4. Center new pad on pad driver & secure with
center-lock ring.
Pad driver removal:
1. Apply down pressure on bell of machine deck.
2. Use ¾” open end wrench on top of drive shaft
exposed on top of deck.
3. Strike wrench with rubber mallet to break loose
the shaft from the pad driver. (counter-clockwise)
4. Remove pad driver by spinning it off counterclockwise.
MAINTENANCE
LIGHTNING 86039180 05/23/07
4-2
MACHINE TROUBLESHOOTING
PROBLEM.
Will not start No fuel or dirt in fuel line See engine owners manual for servicing.
Blown head gasket NOTE: ONLY properly trained service technicians
Dirty air cleaner
Faulty spark plug
Defective ignition coil
Hard to start No fuel or dirt in fuel line See engine owners manual for servicing.
Engine overload
Dirty air cleaner
Faulty spark plug
Blown head gasket
Regulator need adjustment
Insufficient vacuum
Lacks Power Improper valve clearance See engine owners manual for servicing.
Dirt in fuel line
Faulty spark plug
Improper oil level
Worn rings
Odor of burned rubber Belt out of adjustment See “Adjusting Belt Tension” pg. 3-3
Engine overheats Incorrect oil level See engine owners manual for servicing.
Engine overload
High fuel consumption Faulty spark plug See engine owners manual for servicing.
Dirty air cleaners
Machine stops suddenly Out of fuel Change fuel cylinders
Faulty spark plugs Clean adjust or replace spark plug
Incorrect pad size Replace with proper pad
Low oil Add oil (see pg. 3-3)
CAUSE SOLUTION
Engine overload Should adjust or repair fuel system.
Fuel system out of
adjustment
Spark plug or head bolts
loose
Timing, Coil or Valves
need adjustment
Build up of dirt inside
engine shroud
Improper fuel system
adjustment
Pad not centered on pad
driver
Center pad or pad driver
4-3
LIGHTNING 86039180 05/23/07
MACHINE TROUBLESHOOTING
4
PROBLEM.
Excess vibration
CAUSE SOLUTION
Bolts loose on engine or
deck
Incorrect oil level Check and adjust oil level
Engine overload See engine owners manual for servicing.
Dirty filter See engine owners manual for servicing.
Faulty spark plug See engine owners manual for servicing.
Pad not centered or
damaged pad
Tighten all bolts
Center or replace pad
LIGHTNING 86039180 05/23/07
4-
21” DECK GROUP
1
2
7A
7B
7C
12
6A
6B
8
5
(4)
9A
9B
4
10
11
26
21
3
27
25A
25B
24
23
22
13
5-1
14
20
19A
19B
28
15
18
17
16
LIGHTNING 86039180 05/23/07
21” DECK PARTS LIST
2
REF PART NO. PRV NO. QTY DESCRIPTION
1 86262580 07093 1 FOAM HAND GRIPS
2 86262570 07083 1 FM HANDLE
3 N/A ref ENGINE OWNER’S MANUAL
4 86262830 07129 1 KEY SWITCH
5 86263140 07089 1 PLASTIC HOLDER
6A 86261970 07039 1 BATTERY BOX
6B 86261880 07068 1 6” KEY SWITCH BRACKET
7A 86262800 07086 1 KAWASAKI 17HP
7B 86262730 07123 ref HONDA 390 13HP
7C 86263030 07066 ref ONAN E124
8 86263200 07018 1 PULLEY 3.5
9A 86261980 07067 1 BATTERY CONNECTOR E124
9B 86262010 07116 ref BATTERY CONNECTOR KAWASAKI
10 86261960 07038 1 BATTERY 12VOLT
11 86262770 07017 1 HOUR METER
12 86262380 07001 1 DECK 21” BLUE
13 86262050 07150 1 BUMPER MOULDING
14 86243840 500664 1 LABEL, LIGHTNING PRPN WINDSOR
15 86262600 07022 1 FRONT BEARING ASSY. COMPLETE
16 86263210 07019 1 PULLEY 6.2
17 86262090 07027 1 BX40 BELT
18 86262300 07023 1 CENTER LOCK
19A 86263540 07014 2 WHEEL 6” W/BKT
19B 86263530 07013 ref WHEEL (ONLY) Service Only
20 86263100 07084 1 PAD DRIVER 21” FLEX
21 86262280 07015 2 CASTER 3”
22 86262560 07151 1 FLANGE
23 86262780 07016 1 IDLER PULLEY
24 86263460 07121 1 TENSIONER
25A 86262930 07063 1 LP TANK (ALUM)
25B 86262920 07025 ref LP TANK (STEEL)
26 86263520 07048 1 VELCRO TAPE
27 86263470 07002 1 THROTTLE CABLE
28 86263070 07079 1 PAD DRIVER 21” FLEX COMPLETE
29 86262330 07111 - CHOKE CABLE Not Shown
30 86262720 07024 - HONDA STARTER (110 VOLT) Not Shown
SERIAL NO.
FROM
Comes with
NOTES:
literature
NOTE: For engine information not listed in this standard manual parts list, refer to appropriate Engine
Owner’s Manual.
LIGHTNING 86039180 05/23/07
5-
24” DECK GROUP
1
2
7A
7B
7C
7D
12
6A
6B
8
5
(4)
9A
9B
9C
4
10
11
26
21
3
27
25A
25B
24
23
22
13
5-3
14
16A
16B
16C
20
19A
19B
15
17A
17B
17C
LIGHTNING 86039180 05/23/07
28
18
24” DECK PARTS LIST
4
REF PART NO. PRV NO. QTY DESCRIPTION
1 86262580 07093 1 FOAM HAND GRIPS
2 86262570 07083 1 FM HANDLE
3 N/A ref ENGINE OWNER’S MANUAL
4 86262830 07129 1 KEY SWITCH
5 86263140 07089 1 PLASTIC HOLDER
6A 86261970 07039 1 BATTERY BOX
6B 86261880 07068 1 6” KEY SWITCH BRACKET
7A 86262800 07086 1 KAWASAKI 17HP
7B 86262730 07123 ref HONDA 390 13HP
7C 86263040 07131 ref ONAN P248
7D 86263030 07066 ref ONAN E124
8 86263200 07018 1 PULLEY 3.5
9A 86261980 07067 1 BATTERY CONNECTOR E124
9B 86262010 07116 ref BATTERY CONNECTOR KAWASAKI
9C 86262000 07092 ref BATTERY CONNECTOR ONAN P248
10 86261960 07038 1 BATTERY 12VOLT
11 86262770 07017 1 HOUR METER
12 86262390 07032 1 DECK 24” BLUE
13 86262050 07150 1 BUMPER MOULDING
14 86243840 500664 1 LABEL, LIGHTNING PRPN WINDSOR
15 86262600 07022 1 FRONT BEARING ASSY. COMPLETE
16A 86263210 07019 1 PULLEY 6.2 Onan P248
16B 86263250 07090 ref PULLEY 8.5
16C 86263240 07055 ref PULLEY 7.0 Kawasaki
17A 86262110 07028 1 BX42 BELT Onan P248
17B 86262140 07031 ref BX45 BELT
17C 86262120 07069 ref BX43 BELT
18 86262300 07023 1 CENTER LOCK
19A 86263540 07014 2 WHEEL 6” W/BKT
19B 86263530 07013 ref WHEEL (ONLY) Service Only
20 86263120 07104 1 PAD DRIVER 24” FLEX
21 86262280 07015 2 CASTER 3”
22 86262560 07151 1 FLANGE
23 86262780 07016 1 IDLER PULLEY
24 86263460 07121 1 TENSIONER
25A 86262930 07063 1 LP TANK (ALUM)
25B 86262920 07025 ref LP TANK (STEEL)
26 86263520 07048 1 VELCRO TAPE
27 86263470 07002 1 THROTTLE CABLE
28 86263080 07080 1 PAD DRIVER 24” FLEX COMPLETE
29 86262330 07111 - CHOKE CABLE Not Shown
30 86262720 07024 - HONDA STARTER (110 VOLT) Not Shown
31 86261860 07109 - 20HP REGULATOR BRACKET Not Shown
32 86262340 07117 - CHOKE BRACKET Not Shown
SERIAL NO.
FROM
Comes with
Honda, Onan
NOTES:
literature
E124
NOTE: For engine information not listed in this standard manual parts list, refer to appropriate Engine
Owner’s Manual.
LIGHTNING 86039180 05/23/07
5-
27” DECK GROUP
1
2
7A
7B
7C
7D
12
6A
6B
8
5
(4)
9A
9B
9C
4
10
11
26
21
3
27
25A
25B
24
23
22
13
5-5
14
16A
16B
20
19A
19B
28
15
18
17A
17B
LIGHTNING 86039180 05/23/07
27” DECK PARTS LIST
6
REF PART NO. PRV NO. QTY DESCRIPTION
1 86262580 07093 1 FOAM HAND GRIPS
2 86262870 07083 1 FM HANDLE
3 N/A ref ENGINE OWNER’S MANUAL
4 86262830 07129 1 KEY SWITCH
5 86263140 07089 1 PLASTIC HOLDER
6A 86261970 07039 1 BATTERY BOX
6B 86261880 07068 1 6” KEY SWITCH BRACKET
7A 86262800 07086 1 KAWASAKI 17HP
7B 86262730 07123 ref HONDA 390 13HP
7C 86263040 07131 ref ONAN P248
7D 86263030 07066 ref ONAN E124
8 86263200 07018 1 PULLEY 3.5
9A 86261980 07067 1 BATTERY CONNECTOR E124
9B 86262010 07116 ref BATTERY CONNECTOR KAWASAKI
9C 86262000 07092 ref BATTERY CONNECTOR ONAN P248
10 86261960 07038 1 BATTERY 12VOLT
11 86262770 07017 1 HOUR METER
12 86262400 07033 1 DECK 27” BLUE
13 86262050 07150 1 BUMPER MOULDING
14 86243840 500664 1 LABEL, LIGHTNING PRPN WINDSOR
15 86262600 07022 1 FRONT BEARING ASSY. COMPLETE
16A 86263230 07034 1 PULLEY 9.4
16B 86263250 07090 ref PULLEY 8.5
17A 86262200 07054 1 BX51 BELT
17B 86262190 07035 ref BX50 BELT
18 86262300 07023 1 CENTER LOCK
19A 86263540 07014 2 WHEEL 6” W/BKT
19B 86263530 07013 ref WHEEL (ONLY) Service Only
20 86263110 07085 1 PAD DRIVER 27” FLEX
21 86262280 07015 2 CASTER 3”
22 86262560 07151 1 FLANGE
23 86262780 07016 1 IDLER PULLEY
24 86263460 07121 1 TENSIONER
25A 86262930 07063 1 LP TANK (ALUM)
25B 86262920 07025 ref LP TANK (STEEL)
26 86263520 07048 1 VELCRO TAPE
27 86263470 07002 1 THROTTLE CABLE
28 86263090 07081 1 PAD DRIVER 27” FLEX COMPLETE
29 86262330 07111 - CHOKE CABLE Not Shown
30 86262720 07024 - HONDA STARTER (110 VOLT) Not Shown
31 86261860 07109 - 20HP REGULATOR BRACKET Not Shown
32 86262340 07117 - CHOKE BRACKET Not Shown
SERIAL NO.
FROM
Comes with
Honda, Onan
Kawasaki,
Honda, Onan
Kawasaki,
NOTES:
literature
E124
Onan P248
E124
Onan P248
NOTE: For engine information not listed in this standard manual parts list, refer to appropriate Engine
Owner’s Manual.
LIGHTNING 86039180 05/23/07
5-
30” STRIPPER GROUP
6A
6B
6C
4
1
2
36
3
37
34
10
9
12
38
11
17
15
7
14
8
5A
5B
13A
13B
16
33
32
29
31
35
14
30
29
5-7
24
18A
18B
21
23
22
19
20
26
25
LIGHTNING 86039180 05/23/07
27A
27B
28
30” STRIPPER PARTS LIST
8
REF PART NO. PRV NO. QTY DESCRIPTION
1 86262580 07093 1 FOAM HAND GRIPS
2 86262570 07083 1 FM HANDLE
3 86233140 07089 1 PLASTIC HOLDER
4 86262830 07129 1 KEY SWITCH
5A 86261970 07039 1 BATTERY BOX
5B 86261880 07068 1 6” KEY SWITCH BRACKET
6A 86263030 07066 1 ONAN E124
6B 86262730 07123 ref HONDA 390 13HP
6C 86262800 07086 ref KAWASAKI 17HP
7 86262310 07046 1 CENTRIFUGAL SWITCH
8 86262180 07078 1 BX49 BELT
9 86262740 07112 1 HOOD ASSY. TWIN (ALUM) BLUE
10 86262500 07107 1 EXPANDED METAL PLATE 4.5 X 14
11 86262680 07120 2 GEAR BOX TWIN HEAD
12 86263260 07108 1 PULLEY 7.0 X 5/8
13A 86261980 07067 1 BATTERY CONNECTOR ONAN E124
13B 86262010 07116 1 BATTERY CONNECTOR KAWASAKI 17HP
14 86262690 07077 1 HANDLE GUSSETT
15 86262700 07105 1 HEAT SHIELD FOIL MATERIAL
16 86262770 07017 1 HOUR METER
17 86262710 07106 1 HEAT SHIELD SUPPORT PLATE
18A 86262040 07072 2 BRUSH PLATE CLAMP
18B 86263380 07071 2 SPRING CLIP
19 86263480 07170 1 TRANSPORT WHL – FRNT SPRT
20 86262840 07149 1 KEY STOCK ¼ X 3
21 86262970 07060 2 MOUNTING PLATE TWIN HEAD
22 86261920 07061 2 ALUMINUM HUB
23 86262320 07057 2 CENTRAL FLEX
24 86263410 07169 1 STRIP BRUSH (1 SET)
25 86262940 07075 6 LUGS L-800
26 86262280 07015 1 CASTER 3”
27A 86263460 07121 1 TENSIONSER
27B 86262780 07016 1 IDLER PULLEY
28 86263370 07110 1 SPLASH GUARD TRACKER
29 86262440 07070 2 DELRIN BEARING 1”
30 86263550 07040 2 WHEEL 10” AIR FILLED
31 86263560 07152 2 WHEEL SPACER ½”
32 86263490 07082 1 TWIN HEAD STRIP FRAME
33 86261960 07038 1 BATTERY 12VOLT
34 86263520 07048 2 VELCRO TAPE
35 86263470 07002 1 THROTTLE CABLE
36 86262920 07025 1 LP TANK (STEEL)
37 N/A ref Engine Owner’s Manual
38 86243840 500664 1 LABEL, LIGHTNING PRPN WINDSOR
39 86263430 07097 - SUPPORT Not Shown
40 86262340 07117 - CHOKE BRACKET Not Shown
41 86263220 07026 - PULLEY 3.0 Not Shown
SERIAL NO.
FROM
Comes with
NOTES:
Literature
NOTE: For engine information not listed in this standard manual parts list, refer to appropriate Engine
Owner’s Manual.
LIGHTNING 86039180 05/23/07
5-
KAWASAKI FUEL LOAD BLOCK
REF PART NO. PRV NO. QTY DESCRIPTION
1 86262270 07134 1 CARBURETOR ASSEMBLY
2 86262620 07103 1 FUEL LOAD BLOCK
3 86263340 07156 1 RUBBER CAP ¼
4 86262790 07135 1 INSULATOR
5 86263510 07007 1 VACUUM TEE
6 86262650 07132 1 GASKET AIR FILTER
7 86263420 07155 1 STUD M-6 X 130
8 86262030 07100 1 BRASS PLUG 1/8
9 86261870 07101 1 3/8 HOSE X ¼ MP ELBOW
10 86262660 07133 1 GASKET AIR FILTER
SERIAL NO.
FROM
Note: For engine information not listed in the standard parts list, refer to the appropriate engine parts
manual.
5
3
NOTES:
7
10
10
2
1
4
6
1
8
9
5-9
LIGHTNING 86039180 05/23/07
KAWASAKI WIRING DIAGRAM
0
M
-
12 V BATTERY
+
STARTER
BLUE
KEY SWITCH
-
-
ENGINE HARNESS
CONNECTOR
SWITCH
-
YELLOW
BLUE BLUE
-
-
-
BY-PASS DIODE
LOW OIL PRESSURE
CUTOFF SWITCH (NO)
HOUR METER
CHARGING SYSTEM
ALT
STATOR
FUEL LOCKOFF
YELLOW
BLUE FEMALE CONNECTOR
TO STARTER SOLENOID
BLUE
BLUE MALE CONNECTOR
TO ELECTRIC LOCK OFF
BLUE FEMALE
RED
BLUE FEMALE CONNECTOR
TO VOLTAGE REGUALTOR
YELLOW LOOP TO
STARTER SOLENOID
CONNECTOR
BLUE PIGGY BACK
CONNECTOR
BLUE FEMALE
CONNECTOR
LIGHTNING 86039180 05/23/07
LOW OIL PRESSURE
NOTE: RED WIRE CONNECTS
TO LEFT SIDE OF SWITCH. ALL
OTHER WIRES CONNECT TO
RIGHT SIDE OF SWITCH
SWITCH
5-1
KAWASAKI FUEL SYSTEM
REF PART NO. PRV NO. QTY DESCRIPTION
1 86263270 07012 1 QUICK COUPLER
2 86262900 07006 1 LP HOSE TO TANK
3 86262530 07009 1 FITTING ¼ X 90 STREET ELBOW
4 86262760 07003 1 HOSE, VAC
5 86262610 07004 1 FUEL HOSE
6 86262540 07010 1 FITTING 3/8 BARB X 3/8 MP
7 86263320 07118 1 REGULATOR
8 86262630 07113 1 FUEL LOCK W/FILTER 12VOLT
9 86262550 07011 1 FITTING 1/4BARB X 1/4MP
SERIAL NO.
FROM
NOTE: For engine information not listed in this Standard Parts List, refer to the appropriate Engine
Parts Manual.
6
5
4
NOTES:
7
2
9
8
3
5-11
LIGHTNING 86039180 05/23/07
HONDA FUEL SYSTEM
2
REF PART NO. PRV NO. QTY DESCRIPTION
1 86263270 07012 1 QUICK COUPLER
2 86262900 07006 1 LP HOSE TO TANK
3 86262530 07009 1 FITTING ¼ X 90 STREET ELBOW
4 86262760 07003 3 HOSE, VAC
5 86262610 07004 1 FUEL HOSE
6 86262540 07010 1 FITTING 3/8 BARB X 3/8 MP
7 86263310 07064 1 REGULATOR
8 86262880 07065 1 LOCKOFF
9 86262330 07011 2 FITTING 1/4BARB X 1/4MP
10 86262520 07008 1 FITTING 3/8 FLARE X 1/4MP
11 86263500 07042 1 VAC TEE
12 86262890 07005 1 LP HOSE REG TO LOCK
SERIAL NO.
FROM
NOTE: For engine information not listed in this Standard Parts List, refer to the appropriate Engine
Parts Manual.
NOTES:
1
2
4
3
4
4
11
5
6
7
9
10
9
12
8
LIGHTNING 86039180 05/23/07
5-1
KILL SWITCH ASSEMBLY
REF PART NO. PRV NO. QTY DESCRIPTION
1 86261930 07056 1 ARM & SPRINGS (2 EACH)
2 86263450 07050 1 SWICTH MICRO (KILL)
SERIAL NO.
FROM
NOTE: For engine information not listed in this Standard Parts List, refer to the appropriate Engine
Parts Manual.
2
NOTES:
1
5-13
LIGHTNING 86039180 05/23/07
CLUTCH AND SWITCH ASSEMBLY
4
REF PART NO. PRV NO. QTY DESCRIPTION
1 86261930 07056 1 ARM & SPRINGS (2 EACH)
2 86263440 07049 1 SWITCH (CLUTCH)
3 86262360 07047 1 CLUTCH SWITCH ASM. COMPLETE
4 86263350 07044 1 SPACER
5 86262460 07045 1 ELECTRIC CLUTCH
6 86262350 07043 1 CLUTCH ARM
SERIAL NO.
FROM
NOTE: For engine information not listed in this Standard Parts List, refer to the appropriate Engine
Parts Manual.
1
NOTES:
2
4
3
5 5
LIGHTNING 86039180 05/23/07
5-1
BELT CHART/NOTES
PART NO. PRV NO. DESCRIPTION NOTES:
86262060 07052 BX34 BELT
86262070 07041 BX36 BELT
86262080 07020 BX38 BELT
86262090 07027 BX40 BELT
86262100 07021 BX41 BELT
86262110 07028 BX42 BELT
86262120 07069 BX43 BELT
86262130 07030 BX44 BELT
86262140 07031 BX45 BELT
86262150 07148 BX46 BELT
86262160 07091 BX47 BELT
86262170 07053 BX48 BELT
86262180 07078 BX49 BELT
86262190 07035 BX50 BELT
86262200 07054 BX51 BELT
86262210 07029 BX52 BELT
86262220 07037 BX53 BELT
86262230 07036 BX54 BELT
86262240 07073 BX55 BELT
86262250 07074 BX56 BELT
86262260 07087 BX58 BELT
MACHINE PRV MACHINE NO.
10023000 L21H13 86262090 07027 86262110 07028
10023020 L21K17 86262090 07027 86262110 07028
10023040 L24H13 86262140 07031 86262170 07053
10023030 L24ER22 86262110 07028 86262130 07030
10023060 L24K17 86262120 07069 86262150 07148
10023080 L27H13 86262200 07054 - 10023070 L27ER22 - N/A 86262260 07087
10023090 L27K17 86262190 07035 86262210 07029
10023110 LS30H13 86262180 07078 - N/A
10023110 LS30H13 86262180 07078 - N/A
STANDARD CLUTCH
BELT PART NO.
STANDARD CLUTCH
BELT PRV NO.
W/ELECTRIC CLUTCH
BELT PART NO.
W/ELECTRIC CLUTCH
BELT PRV NO.
5-15
LIGHTNING 86039180 05/23/07
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