Windsor VGR2 Operating Instructions Manual

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MODEL POWER SOURCE

VGR2 BATTERY

Beginning with Serial# 1000081028

Read instructions before operating the machine.

98953 05/05/05

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MACHINE DATA LOG/TABLE OF CONTENTS

MODEL

- _____________________________________

TABLE OF CONTENTS

DATE OF PURCHASE - _________________________ SERIAL NUMBER - ____________________________ SALES REPRESENTATIVE - ____________________ DISTRIBUTOR NAME - _________________________

Data Log / Table of Contents ............................ 2

Technical Specifications ................................... 3

Safety Precautions ........................................... 4

Battery Installation & Removal .......................... 5

Battery Information........................................... 6

Operation Controls........................................... 7

Operations....................................................... 8

Accessory Tools and Maintenance .................... 9

Maintenance .................................................... 10

Service Schedule ............................................. 13

Propel Handle Assembly. ..................................14

Drive and Brush Assembly................................16

Pump, Vac, Manifold and

Brush Motor Assemblies ...................................18

Rear Tower Electrical Assemblies ......................20

Handle, Microswitch and

Cable Assemblies.............................................22

Control Panel Assemblies .................................24

Vac Shoe Assembly..........................................26

Tank, Cover and Hardware ................................28

Wiring Diagram .................................................30

Warranty..........................................................31

98953 02/14/04

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TECHNICAL SPECIFICATIONS

ITEM MEASURE

Electric Propelling Motor (1)-1/4 hp DC (186 watts) with solid state

variable speed forward and reverse with safety shut-off.

Electric Vacuum Motors (2)- 3 stage, 1.3 hp (970 watts), 5.7 inch

(14.5cm) diameter motors in parallel, provide 152 cfm (4.25m/min.), 74 inches (188 cm) water lift total. Electric shut-off.

Electric Brush Motors (1)- 0.4 hp (298 watts) permanent Electrical 36 Volt DC

Batteries (3)- 12 volt, @ 185 A/H, in a (Optional) Solution Pump 100 PSI, diaphragm style pump

Cleaning Speed Variable speeds from 0-130 ft/min

Solution Capacity 40 gallons (151 ltr) Recovery Capacity 35 gallons (132 ltr) Brush Speed 1000 RPM Vacuum Shoe 28” (71 cm) wide, cast aluminum, tension

Wheels: Front: (2) 10” dia. (25 cm) by 2.5” wide (6.4 cm)

Rear: (2) 4” dia. (10 cm) casters Weight: Empty: 240 lbs. (109 kg) W/ Batteries 645 lbs. (260 kg) Length 60” (152 cm) Storage Position 52” (132 cm) Height 43” (109 cm) Width 30” (76 cm)

magnet, DC.

removable battery pack.

(39.6m/min) Transport 0-130; Cleaning 0-110

pulley adj., floating and pivoting.

SIDE VIEW

TOP VIEW

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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:

Do not use outdoors or expose to moisture. Do not operate in standing water. Machines can cause a fire when operated near flammable vapors or materials. Do not operate this

machine near flammable fluids, dust, vapors or gas. Do not pickup burning materials such as cigarettes or matches.

Operate this machine only from the rear of the machine. Maintenance and repairs must be done by qualified personnel. Store machine inside. Keep the electrical components of the machine dry. Wear eye protection when working near batteries. Do not put any type of metal objects across the

battery terminals or on top of the batteries. Lead acid batteries generate gasses which can cause an explosion. Keep sparks and flames away

from the batteries. Charge the batteries only in well ventilated area. Make sure all warning and caution labels are legible and properly attached to the machine. Maintain adjustments on machine as per specifications noted in the owner’s guide.

SAVE THESE INSTRUCTIONS

IMPORTANT SHIPPING NOTE

Carefully unpack your Voyager and inspect it for shipping damage. Any damages which occurred during shipping are the responsibility of the carrier, who must be notified immediately.

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BATTERY INSTALLATION & REMOVAL (W/ BATTERY CART)

WARNING:

CAUTION:

(REF)

Key

P/N

Description

* NOTE: ONLY THE NEW “VCT”

WEAR EYE PROTECTION AND PROTECTIVE CLOTHING WHEN WORKING

BATTERY INSTALLATION AND REMOVAL

1. Remove the vac shoe hose from tank, lay dome back and slowly open tank to upright position.

2. Install (3) batteries in machine by placing them in battery tray liner provided. (See diagram page 6)

3. Connect battery wires according to diagram on page 6.

INSTALLATION OF BATTERIES

WITH BATTERIES.

FOLLOW THE PROCEDURES CAREFULLY.

FOLLOW PROCEDURES CAREFULLY, BE SURE TO KEEP HANDS AND FEET CLEAR FROM ROLLING BATTERY TRAY.

1. Make sure the battery door is open.

2. Roll the Battery Cart up to the front of the machine, (aligning the front of the two frames).

3. Push the cart until the latches lock into the tabs on the front of the machine frame.

4. Pull the handle on the Battery Tray. (This releases the locking mechanism on the cart.) Fig 1 & 2

5. Push the batteries into the machine until the locking mechanism on the frame is engaged. (This can be heard by a “Snapping” sound.) Fig 1.

6. Press the foot pedal on the front of the cart and roll the cart from the machine.

7. Attach battery cable from the batteries to receptacle on front of machine by pressing down on right hand side of locking bracket. (p/n 140190)

1 VCT CART, BATTERY REMOVAL 2 78243 TRAY, VGRB BATTERY LINER 3 78369 TRAY ASSEMBLY BATTERY 4 02143 (3) BATTERY, 12 VOLT

5 02267 CHARGER, 36 VOLT

CART AND NEW TRAY ASSEMBLY WILL WORK WITH THE VOYAGER

2. PREVIOUS CARTS AND TRAYS, IN ANY COMBINATION, WILL NOT

WORK.

FIG. 1

140190

REMOVAL OF BATTERIES BEFORE REMOVING BATTERY TRAY PLEASE FOLLOW THE INSTRUCTION SHEET 98439. If you did not receive this sheet please contact Windsor Industries for this instruction sheet.

1. Make sure the battery door is open.

2. Disconnect battery cable from receptacle on front of machine.

3. Roll the cart up to the front of the machine aligning the front of the two frames.

4. Push the cart until the latches lock into the tabs located on the front of the machine. (The tabs cannot be seen when batteries are installed.)

5. The latches are engaged when a “Snapping” sound is heard. Pull the handle on the tray. (This releases the

locking mechanism on the machine frame.) (Fig 1 & 2) Continue to pull handle until the battery pack rolls and locks onto cart. (The locking mechanism is engaged when a “Snapping” sound is heard.)

6. Press the foot pedal located on the cart and roll the batteries and cart away from the machine.

FOLLOW PROCEDURES CAREFULLY, BE SURE TO KEEPS HANDS AND FEET

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BATTERY INFORMATION

WARNING:

NOTE:

Following you will

ANDERSON

Molex

FRONT OF

VIEW: Looking down on machine.

find the recommended battery arrangement for the VOYAGER2

BATTERY CHANGING PROCEDURE:

Charge the batteries once battery level indicator is near the level “0”. Do not let the batteries completely drain before changing. Avoid charging the batteries before the amber light comes on.

DO NOT SMOKE, HAVE OPEN FLAMES, OR SPARKS NEAR BATTERIES AT ANY TIME.

WEAR EYE PROTECTION AND PROTECTIVE CLOTHING WHEN WORKING WITH BATTERIES.

MACHINE

connector

BATTERY MAINTENANCE

1. When cleaning batteries use a solution of baking soda and water. (Do not allow cleaning fluid to enter inside battery cells.)

2. Keep a proper electrolyte level in the battery cells.

3. Wipe down the battery tops at least once a week. If a cell should accidentally overflow, clean it immediately.

4. Test the battery connection with a hydrometer at least once a week.

5. Ensure that all connections are tight and that all corrosion is removed.

6. Every 4 to 6 months remove batteries from the machine and clean the battery compartment.

7. Follow the Safety Procedures.

ACCESSORIES

02143 Battery. 12V DC, 185 Amp Hour 00267 Charger, automatic 36V (20 amp) 115V 02264 Charger, automatic 36V (20 amp) 230V

INTERNATIONAL

VCT Battery cart system for service 78243 Battery tray liner VXK Battery Exchange Kit

ACCESSORY TOOLS:

DHTK Deluxe Hand Tool Kit DDH Double Dry Hand Tool HFT 14” Flip Tool 89227 Standard Wand 89226 Deluxe Professional Wand 39128 12” Hose set

CHARGE BATTERIES IN A WELL VENTILATED AREA WITH BATTERY DOOR OPEN.

1. Use a 36 volt, 20 amp maximum output, D.C. charger which turns itself off when the batteries are fully charged. The charger must have a connector that matches the machine’s battery connection.

2. Read the instructions and warnings provided by the battery charger manufacturer.

3. Set the charger in a well ventilated area on a level surface. Make sure cords will easily reach outlets on both machine and wall.

4. Connect the charger to D.C. outlet on the

machine first.

5. Connect the A.C. power cord to properly grounded wall socket. NEVER MAKE THE A.C.

CONNECTION FIRST, HAZARDOUS SPARKS MAY RESULT.

6. After the batteries are completely charged, disconnect the charger from the A.C. wall socket.

7. Once the charger is disconnected from the A.C. wall socket it is safe to disconnect the charger from the machine.

8. When batteries are fully charged, check the electrolyte level by removing the caps on top of batteries. If necessary, fill the cells with distilled water as shown in the diagram to the right. Be careful not to overfill the cells.

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OPERATION CONTROLS

DRAIN

TO VAC SHOE

SIGHT

SEE BELOW

1. Brush Height Adjustment. Raises and adjusts the height if the brush.

2. Vac Shoe Lift Lever. Lifts the vac shoe up or down and switches vac motor off and on.

3. Battery Charge Meter. Indicates the level of charge that the batteries are holding.

4. Main Power Switch. Turns ON and OFF the machine.

5. Drive Handle Control Connection. This is where Drive Control Connection Assembly is attached to rear panel.

6. Drive Motor Circuit Breaker. 16 amp Protects the dirve motor mechanism.

7. Vac Motor Circuit Breaker. 35 amp Protects the vacuum motors.

8. Brush Motor Circuit Breaker. 15 amp Protects the brush motor.

9. Accessory Tool Hookup. Used for various auxiliary cleaning tools.

10. Spray Position Switch. Controls the spray adjustment between manifold and accessory tools.

11. Hour Meter. Records the use time.

12. Pump Switch. Turns ON and OFF the pump

FILL

TUBE

GAL

30 GAL

20 GAL

GAL

5 GAL

VGR2 98953 12/18/01

VOYAGER DRIVE CONTROLS

1. The speed the machine will travel is regulated by the knob located on the controls which are found on the main handle. Turn the knob to the right to increase the speed of the machine.

2. Squeezing one or both of the control levers will propel the machine forward are the selected speed.

3. Releasing both control levers will stop the machine.

4. Pressing forward on the levers moves the machine backwards at the selected speed.

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OPERATIONS

SOLUTION TANK

RECOVERY TANK

CAUTION:

WARNING:

Fill the solution tank to the desired level according to the marked gauge on the clear hose on the right side of the tank.

DO NOT FILL PAST THE INLET LIP.

TOP VIEW OF TANK

IF A BUCKET IS USED TO FILL THE TANK, BE SURE IT IS CLEAN. DO NOT OVERFILL TO AVOID POSSIBLE DISTORTION OF THE FLEXSOL  DIAPHRAGM OR SOLUTION TANK. DO NOT USE WATER TEMPERATURE THAT EXCEEDS 140°F (60°C). LIQUID DETERGENTS ARE PREFERRED, however if a

powered detergent is used, be sure it is fully dissolved. NOTE: If suitable powered detergent is used, premix with hot water before filling the solution tank.

DO NOT PUT DEFOAMER, SOLVENTS, SPOTTER OR PRESPRAY CHEMICALS IN THE SOLUTION TANK.

The internal parts of the pump used in the extractor are suitable for use with most carpet cleaning chemicals. However, it is susceptible to chemical attack from cleaning substances, such as hydrocarbon solvents and chlorinate bleaches. These noncombustible materials are not of the type normally used for carpet cleaning.

CHEMICALS:

SUITABLE CHEMICALS NONCOMPATIBLE CHEMCIALS

Alkalis Soaps Aldehydes Chlorinated Hydrocarbons Detergents Vinegar Aromatic Hydrocarbons Lysol* Hydroxides D-Limonene @ SP Butyls Methyl Ethel Ketone (MEK)

@ When properly diluted Carbon Tetrachloride Perchorethylene (perc)

* Registered Trademark Chlorox* Phenolics

Chlorinated Bleaches Trichlorethylene

FILLING THE VOYAGER

1. Remove the Dome.

2. Use a CLEAN bucket or hose to fill solution tank with hot water not to exceed 140°F (60°C). Do not fill above lower tank lip. Add non-

foaming carpet extraction chemical at recommended proportion. NOTE: If suitable powdered detergent is used, premix with hot

water filling the solution tank.

BEGIN CLEANING

1. Adjust handle to comfortable position at waist level.

2. Turn solution valve, located on bottom of rear position.

3. Turn MAIN POWER switch ON.

4. Adjust SPEED CONTROL KNOB on handle to set desired maximum speed.

5. Turn SOLUTION switch ON.

6. Lower BRUSH using left hand lever until contact with carpet is reached. Brush motor will start automatically.

NOTE: Incorrect brush height may trip circuit breaker or cause belt slippage. To correct, raise brush and reset circuit breaker located on rear panel.

7. Lower VACUUM using right hand lever. Vacuum motor will start automatically.

8. Depress SPEED LEVER to propel machine. Speed is controlled by lever up to the maximum set on CONTROL KNOB.

NOTE: For protection, the Voyager will not operate in reverse when brush is on.

CLEANING PROCEDURE

1. Operate machine in parallel passes, overlapping 2 inches on each pass. Turn SOLUTION switch OFF on turns. Propel machine gently into turns. Abnormal turns may activate vacuum motor shut-off. Clean perimeter last.

2. Run machine more slowly over spots or extremely soiled areas.

3. Use right side of VOYAGER when cleaning against walls.

4. Turn SOLUTION switch OFF 3 feet before completing a cleaning pass to ensure all solution is vacuumed from carpet.

CAUTION: WHILE OPERATING MACHINE, CHECK FOR EXCESSIVE FOAM BUILD-UP IN RECOVERY TANK. IF EXCESSIVE FOAM IS PRESENT, ADD DEFOAMER SOLUTION TO RECOVERY TANK OR EMPTY RECOVERED SOLUTION.

5. To speed dry, use a WINDBLOWER fan and ensure building ventilation system is ON.

6. Empty recovery tank when full by releasing dump hose and removing stopper. NOTE: Vacuum motor will stop if recovery tank is full.

7. Turn MAIN POWER switch OFF after use.

NOTE: Check the Circuit Breaker if the Voyager does not start.

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ACCESSORY TOOLS & MAINTENANCE

CAUTION:

WARNING:

ACCESSORY

1. Attach the auxiliary solution hose to the output nipple A.

2. Disconnect hose at vac shoe using and connect vac hose using coupler (22071) that is included with Voyager machine.

3. Turn the solution control valve B to

4. Press the Pump switch “ON”.

5. Lower the vac lever to the “ON” position to start the vac motor.

6. Make sure the solution control valve is returned to the

7. position before using the Voyager for self-contained

carpet cleaning.

CLEANUP AND STORAGE

Empty the Recovery Tank directly into the floor drain. After each use, rinse tank (including the float-off) with fresh water. Periodically inspect the recovery tank and decontaminate if necessary, using a Hospital Guide Virucide or a 1-10 bleach to water solution. This will dissipate the exposure to blood born or infectious contamination. Waste water shoud be disposed of properly. Clean the inside of the recovery dome also.

Empty the Solution Tank by detaching the sight hose and empty directly into the floor drain. Flush the Solution System with 1 gallon of CLEAN water.

Never allow recovered solution to remain in tank when not in use; nor allow usused solution to remain in the solution tank when in storage. Inspect and clean the filter located at the pump port. Remove and rinse with hot water.

PERIODIC MAINTENANCE

EVERY TWO WEEKS:

Clean the solution system by diluting 2 gallons of clean water with a quart of white vinegar (acetic acid) in the solution tank. Run the solution through the system to remove chemical buildups which could eventually cause it to plug up.

EVERY 500 HOURS:

Oil the front drive wheel bearings by removing the phillips screw “A” and by loosening the (2) set screws “B” located on the outside of wheel assembly. Slide the wheel off the axle and apply 6 drops of 10W oil to bearings. Be careful not to lose the key in shaft.

INSPECTION

Remove the batteries (using the battery cart if available) before making any adjustments or repiars to the Voyager2.

To expose working parts for inspection, lay dome back on handle, grasp tank at solution opening and tilt the tank forward until “NOSE” of tank rests on floor.

VGR2 98953 12/18/01

+ 21 hidden pages

Windsor VGR2 Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual