Windsor VOYDU1 User Manual

Model: VOYDU

10086130 VOYXDU

10086150

Carpet Extractor

Operating Instructions (ENG)

86292490-AB 01/23/09

MACHINE DATA LOG/OVERVIEW

MODEL _______________________________________ DATE OF PURCHASE __________________________ SERIAL NUMBER ______________________________ SALES REPRESENTATIVE # _____________________

YOUR DEALER

Name: __________________________________________________________________________________________________

Address: _______________________________________________________________________________________________

Phone Number: _________________________________________________________________________________________

The Voyager Duo is a battery powered carpet extractor intended for commercial use. The Voyager Duo applies a cleaning solution onto a carpeted floor, sweeps and scrubs the carpet

with two counter-rotating brushes and then vacuums the soiled water back into the recovery tank.

OVERVIEW

86292490 VOYAGER DUO 08/20/07

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.................................. 3-4

Components...................................................... 3-5

Drive Controls ................................................... 3-6

Scrub Controls .................................................. 3-8

Machine Operation............................................ 3-11

Pre-Run Machine Inspection........................ 3-11

Starting Machine ..........................................3-11

Emergency Stop Procedures....................... 3-11

Filling Solution Tank..................................... 3-12

Normal Scrubbing.........................................3-12

To Begin Scrubbing...................................... 3-13

Priming Pump...............................................3-13

To Stop Scrubbing........................................3-13

Emptying and Cleaning Tanks..................... 3-14

MAINTENANCE

Service Schedule.............................................. 4-1

Batteries............................................................4-2

Scrub Deck........................................................ 4-6

Scrub Brushes................................................... 4-7

Scrub Motor....................................................... 4-8

Actuator Removal /Replacement ......................4-9

Circuit Protection............................................... 4-10

Solution Strainer & Pump(Basic) ...................... 4-11

Solution Strainer & Pump(Deluxe).................... 4-13

Drive Assembly .................................................4-17

Vacuum............................................................. 4-19

Transporting Machine .......................................4-22

Machine Troubleshooting.................................. 4-23

TABLE OF CONTENTS

PARTS LIST

Brush Deck........................................................5-1

Brush Deck Actuator .........................................5-3

Brush Deck Motor..............................................5-5

Brush Deck Mounting........................................5-7

Brush Deck Shroud...........................................5-9

Brush Deck Lift..................................................5-11

Control Handle ..................................................5-13

Control Panel-Lower (Basic) .............................5-15

Control Panel-Lower (Deluxe)...........................5-17

Control Panel-Upper (Basic) .............................5-19

Control Panel-Upper (Deluxe)...........................5-21

Control Panel Mounting.....................................5-23

Cover-Front .......................................................5-25

Decal .................................................................5-27

Frame-Lower.....................................................5-29

Frame-Upper.....................................................5-31

Recovery Tank..................................................5-33

Recovery Tank Handle (Basic) .........................5-35

Recovery Tank Handle (Deluxe)....................... 5-37

Solution-Chemical Tanks (Deluxe)....................5-39

Solution Pump...................................................5-41

Solution-Chemical Pump (Deluxe)....................5-43

Solution-Chemical Valves (Deluxe)...................5-45

Solution Tank ....................................................5-47

Spray Jets .........................................................5-49

Spray Jet Valves (Basic)................................... 5-51

Spray Jet Valves (Deluxe).................................5-53

Wheel and Drive Assembly...............................5-55

Vacuum Shoe....................................................5-57

Vacuum (Basic).................................................5-61

Vacuum (Deluxe)...............................................5-63

Wiring-Battery....................................................5-65

Wiring-Control Panel (Basic).............................5-67

Wiring-Control Panel (Deluxe) ..........................5-69

Wiring-Main Harness (Basic) ............................5-71

Wiring-Harness (Deluxe)...................................5-72

Wiring Diagram (Basic) .....................................5-73

Wiring Diagram (Deluxe)...................................5-74

Hose Diagram (Basic).......................................5-75

Hose Diagram (Deluxe).....................................5-76

Suggested Spare Parts.....................................5-77

Accessories.......................................................5-77

OPTIONS & SERIAL NUMBERS

Battery Cart.......................................................6-2

Battery Cart-Latch and linkage..........................6-4

Battery Cart – Tray............................................ 6-6

Battery Exchange Option ..................................6-8

Emergency Stop-Option....................................6-10

Serial Numbers..................................................6-12

Warranty

86292490 VOYAGER DUO 11/15/08

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.

The model and serial number of your machine are located below the battery compartment of the machine.

1-1

MODEL _____________________________________ DATE OF PURCHASE ________________________ SERIAL NUMBER ____________________________ SALES REPRESENTATIVE # ___________________

86292490 VOYAGER DUO 08/20/07

The SAFETY section contains important information regarding hazard or unsafe practices of the machine. Levels of hazards are 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. They are listed in this general order:

- Batteries

- Scrub Brushes

- Service Schedule

- Machine 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.

- 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 – If this column has an (*) and a Reference number, see the SERIAL NUMBERS page in the back of your manual. If column has two asterisk (**), call manufacturer for serial number. The serial number indicates the first machine the part number is applicable to. The main illustration shows the most current design of the machine. When a boxed illustration is shown, it displays the older design.

- 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 an 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. Do not use on surfaces having a gradient of over 2 degrees.

SAVE THESE INSTRUCTIONS

86292490 VOYAGER DUO 08/20/07

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 - Hazards or unsafe practices which COULD re sult in severe personal injury or death.

CAUTION - Hazards or unsafe practice s 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.

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.

2-2

86292490 VOYAGER DUO 08/20/07

SAFETY LABEL LOCATION

NOTE: These drawings indicate the location of safety labels on the machine. If at any time the labels become illegible, promptly replace them.

SOLUTION WARNING 86244300

(PRV NO. 500955)

FRONT PANEL CAUTION 86013310

BATTERY CAUTION 86252520

(PRV NO. 80885)

PINCH CAUTION

86243830

(PRV NO. 500663)

86292490 VOYAGER DUO 08/20/07

2-3

NOTES:

2-4

86292490 VOYAGER DUO 08/20/07

TECHNICAL SPECIFICATIONS - BASIC

ITEM DIMENSION/CAPACITY

Nominal Power 1855 W Rated Voltage 36 Volts DC Rated Amperage 51.5 amps Batteries 3 X12 Volt 195-215 AH @ 20 hr. rate Battery Compartment Dimensions 23.5 in. x 15.5 in. x 16.5 in. tall

(600 mm x 400 mm x 420 mm) Propelling Motor .75 HP (560 W) Mass (GVW) 1042 lbs (473 kg) Weight Empty Without Batteries 418 lbs (190 kg) Solution Control Metered flow with automatic shut-off in neutral and

reverse Spray Pump Pressure 100 psi (688 Kpa) Solution Capacity 31.4 gal (120 Liter) Spray Jets - Interim 2 Jets with total flow of 0.24 gal/min (0.9 Liter/min) Spray Jets - Extraction

Recovery Capacity 21 gal (79 Liter) Vacuum Motors 2 x .75 Hp (560 W) Scrub Brush Diameter 3.38” Inch (85.5 mm) Scrub Brush Motor 1 x .5 Hp (375 W) Scrub Brush Pressure Floating Scrub Brush Speed 1084 rpm Tires 9 in. (228mm) Solid Gray non-marking Foundation Pressure 596 psi (4.2 Mpa) Maximum (Transport) Speed Propel = 2.4 mph (3.8 Km/hr) Scrubbing Speed Interim = 110 Ft/min (2.0 Km/hr)

Theoretical Coverage (with 2” Overlap) Interim = 12100 ft²/hr (1125 M²/hr) Frame Construction Powder coated steel

Minimum Aisle U-Turn Width 62.5 in. (1.6 Meter) Maximum Rated Climb And Descent Angle 6 degrees

4 Jets with total flow of 1.05 gal/min (4.0 Liter/min)

Extract = 55 Ft/min (1.0 Km/hr)

Extract = 6050 ft²/hr (562 M²/hr)

86292490 VOYAGER DUO 08/20/07

3-1

TECHNICAL SPECIFICATIONS - DELUXE

ITEM DIMENSION/CAPACITY

Nominal Power 2002 W Rated Voltage 36 Volts DC Rated Amperage 56 amps Batteries 3 X12 Volt 195-215 AH @ 20 hr. rate Battery Compartment Dimensions 23.5 in. x 15.5 in. x 16.5 in. tall

(600 mm x 400 mm x 420 mm) Propelling Motor .75 HP (560 W) Mass (GVW) 1106 lbs (502 kg) Weight Empty Without Batteries 429 lbs (195 kg) Solution Control Metered flow with automatic shut-off in neutral and

0:1reverse Spray Pump Pressure 100 psi (688 Kpa) Solution Capacity 31.4 gal (120 Liter) Spray Jets - Interim 2 Jets with total flow of 0.24 gal/min (0.9 Liter/min) Spray Jets - Extraction 4 Jets with total flow of 1.05 gal/min (4.0 Liter/min) Recovery Capacity 21 gal (79 Liter) Vacuum Motors 2 x .75 Hp (560 W) Scrub Brush Diameter 3.38” Inch (85.5 mm) Scrub Brush Motor 1 x .5 Hp (375 W) Scrub Brush Pressure Floating Scrub Brush Speed 1084 rpm Tires 9 in. (228mm) Solid Gray non-marking Foundation Pressure 596 psi (4.2 Mpa) Maximum (Transport) Speed Propel = 2.4 MPH (3.8 Km/hr) Scrubbing Speed Interim = 110 Ft/min (2.0 Km/hr)

Extract = 55 Ft/min (1.0 Km/hr) Theoretical Coverage (with 2” Overlap) Interim = 9900 ft²/hr (920 M²/hr)

Extract = 4950 ft²/hr (460 M²/hr) Frame Construction Powder coated steel Minimum Aisle U-Turn Width 62.5 in. (1.6 Meter) Maximum Rated Climb And Descent Angle 6 degrees Chemical Tank “A” Capacity 2.06 Gal (7.78L) Chemical Tank “B” Capacity 0.55 Gal (2.09L) Chemical “A” Mix Ratio 16:1 Nominal Chemical “B” Mix Ratio 64:1 Nominal

3-2

86294290 VOYAGER DUO 08/20/07

TECHNICAL SPECIFICATIONS

ITEM MEASURE

Height 43 inches (1100 mm) Length 59 inches (1500 mm) Width 32 inches (800 mm) Width of scrub path 24 inches (600mm)

WIDTH

LENGTH

SPECIAL NOTES:

The sound pressure level at the operator’s ear was measured to be 70.5 dBA. This was a nearfield, broadband 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 Pa.

86292490 VOYAGER DUO 08/20/07

The weighted root mean square acceleration at the operator’s arms was measured to be below 2.5m/s 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.

3-3

HOW THIS MACHINE WORKS

The Machine is a battery powered, self-propelled Carpet Maintainer and Carpet Extractor intended for commercial use.

The machine is designed to maintain your carpet using the Encapsulating Interim Carpet Cleaning Process. By using the Interim Carpet Maintainer in conjunction with Windsor Red Carpet Encapsulating Interim Cleaning (W450-4) or Encapsulating Interim Cleaning with Carpet Protection (W455-4) chemical solution, you can perform a regular light cleaning and grooming of your carpet very quickly, and have the carpet dry and ready for traffic within 30 minutes.

The machine is also designed to restore your carpet using carpet extraction chemicals. The machine is designed to apply cleaning solution onto carpeted floor, scrub the carpet with two counter-rotating brushes, and then vacuum the soiled water back into the recovery tank.

DELUXE ONLY

The machine can be used to perform a “One step” or “Two step” carpet restoration. Using the “One step” process, the carpet is restored with a deep extraction chemical. Using the “Two step” process, the carpet is first scrubbed with a pre-spray and then scrubbed again with a neutralizing rinse.

The machine's primary systems are the solution system, chemical injection system (Deluxe), scrub system, recovery system and operator control system.

The function of the solution system is to store water and deliver solution to the appropriate spray jets. The solutions system consists of the solution tank, strainer, pump, solenoid valves, spray jets and controls. The solution tank stores water until it is delivered through the strainer and pump to the solenoid valves and spray jets. The strainer protects the pump from debris. The solenoid valves automatically prevents solution flow unless the scrub brushes are turned on and the machine is being propelled forward. The solution pump switch controls the cleaning solution flow.

DELUXE ONLY

The function of the chemical injection system is to deliver the appropriate chemical into the solution system to be applied to the carpet. The chemical injection system consists of the “A” chemical tank, “B” chemical tank, chemical selector valve, chemical pump, and the mixing sector. The “A” chemical tank stores either encapsulating interim chemical, prespray “Two step” chemical or neutralizing rinse “Two step” chemical. The “B” chemical tank stores the deep extraction chemical. The chemical selector valve controls which chemical is delivered into the system depending on the function knob on the control panel. The chemical pump draws from the tanks and delivers it into the solution system. The mixing sector allows the chemical to thoroughly mix with the water before being delivered to the carpet.

The function of the scrub system is to scrub the carpet, mix the cleaning solution with the soil and lift and groom the carpet pile. The scrub system consists of two cylindrical brushes, motor, lift actuator, and controls. The brushes scrub the carpet as the motor drives the brushes. The counter-rotating action of the brushes grooms the carpet pile. The rotor actuator switch controls the lift actuator and brush motor to lower the deck and turn the motor on, or raise the deck and turn the motor off. The brush motor will automatically turn off when the throttle switches are in neutral.

The function of the recovery system is to vacuum the soiled water back into the recovery tank. The recovery system consists of the va cuum shoes, vacuum motor(s), float ball filter, recovery tank and controls. The vacuum shoes extract the dirty solution from the carpet as the machine moves forward. The vacuum motor(s) provide suction to draw the dirty solution off the floor and into the recovery tank. The float ball filter protects the vacuum fan from debris and foam. The recovery tank stores the dirty solution.

The function of the operator control system is to control the direction and speed of the machine. The control system consists of the reverse switch, throttle switch, speed control knob, propel controller, and drive wheels. The reverse switch signals forward or reverse direction. The propel controller interprets signals from the throttle switches, and speed control knob to command the drive wheels to propel or slow the machine.

3-4

86292490 VOYAGER DUO 08/20/07

COMPONENTS

1. Control Panel-Drive/Scrub

2. Front Cover

3. Solution Tank

4. Recovery Tank

5. Solution Fill Cover

6. Recovery Dome

7. Scrub Deck

8. Recovery Drain Hose

9. Solution Drain Hose

10. Vacuum Shoes

11. Chemical Tank “A” (Deluxe)

12. Chemical Tank “B” (Deluxe)

13. Accessory Vacuum Port (Deluxe)

14. Accessory Water Port (Deluxe)

15. Accessory Port Cover (Deluxe)

16. Switch, Chemical Prime and flush

for “A” and “B” Systems (Deluxe)

86292490 VOYAGER DUO 08/20/07

3-5

DRIVE CONTROLS

1. Key Switch

2. Reverse Switch

3. Throttle Switches

5. Battery Discharge Indicator

6. Hour Meter

7. E-Stop Button (Deluxe)

4. Speed Control Knob

3-6

86292490 VOYAGER DUO 08/20/07

DRIVE CONTROLS

1. KEY SWITCH

Controls the power for machine functions. To turn the machine power on, rotate key clockwise. To turn the machine off, rotate key counterclockwise.

2. REVERSE BUTTON

Controls the direction of travel of the vehicle. To travel in reverse, press the button and press either of the throttle switches. To travel forward, release the button are press either of the throttle switches.

3. THROTTLE SWITCHES

Propel the vehicle with the speed control knob setting selected. Pressing either of the switches causes the machine to travel in the direction selected by the Reverse Button.

To travel, press either of the throttle switches. To stop travel, release both throttle switches.

4. SPEED CONTROL KNOB Controls the speed of the machine. Speed range B is intended for carpet extraction. Speed A is intended for

interim carpet cleaning. Faster speeds are recommended for transport only, not scrubbing. To increase speed, turn the knob clockwise. To decrease speed, turn the knob counter clockwise. Speeds can be adjusted at any time, whether machine is moving or not.

5. BATTERY DISCHARGE INDICAT OR

Indicates the charge level of the batteries. The meter display is divided into 10 vertical bars. All bars illuminated indicate full charge. Bars flashing near

the left side indicate the batteries should be charged. Further operation of the machine could damage the machine and the batteries. Bars flashing also indicate that machine has been left unattended with key on for more than 15 minutes. Turn key off then on to reset.

6. HOUR METER

Records the number of hours the machine has been in operation (scrubbing). This informatio n is useful in determining when to service the machine.

7. EMERGENCY STOP SWITCH (DELUXE)

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.

86292490 VOYAGER DUO 08/20/07

3-7

SCRUB CONTROLS

3-8

1. Solution Pump Switch 3. Function Switch

2. Solution Pump Indicator

86292490 VOYAGER DUO 08/20/07

SCRUB CONTROLS

1. SOLUTION PUMP SWITCH

Controls power to the spray pump. If the throttle is in neutral, or reverse control button is in reverse position, the flow is automatically interrupted.

This feature prevents application of solution without scrubbing it into carpet.

2. SOLUTION PUMP INDICATOR LIGHT

The solution pump indicator light is illuminated green when the pump is on.

3. SCRUB DECK ROTARY SWITCH (BASIC)

Raises and lowers the scrub deck, and turns the scrub brush motors on and off, and controls the solution solenoids.

For interim or “A” mode, rotate the function knob to the “A” position. The scrub deck will lower and the scrub motor will turn on and the interim solenoid will open and spray will flow through the interim jets. The brush motor will automatically turn off in neutral. The interim solenoid will shut off in neutral or reverse.

To raise the deck, turn off the brush motor and solenoid(s). Rotate the knob to the off position to the far counter clockwise position.

For extraction or “B” mode, rotate the function knob to the “B” position. The scrub deck will lower and the scrub motor will turn on and the extraction solenoid and interim solenoid will open an d spray will flow through the extraction and interim jets and the vacuum motor will run. The brush motor will automatically turn off in neutral. The extraction and interim solenoid will shut off in neutral or reverse.

To raise the deck, turn off the brush motor and solenoid(s). Rotate the knob to either the off position to the far counter clockwise position, or rotate the knob to the far clockwise position to the accessory mode so that the vacuum motor continues to run to keep any excess soiled solution from dripping back onto the floor.

To use the machine with an accessory hand tool or wand, rotate the knob fully clockwise to the accessory position. Only the vacuum motor and pump will run. Connect the solution hose of the accessory tool to the solution accessory port. The fitting is 1/8” male quick disconnect. If needed to adapt to 1/4” male quick disconnect (see Suggested Spare Parts for part number).

To connect the vacuum hose, disconnect the hose assembly from the lower connection of the “Y” tube junction. Use adaptor to join the two hose cuffs together (See Accessories page).

86292490 VOYAGER DUO 08/20/07

3-9

SCRUB CONTROLS

SCRUB DECK ROTARY SWITCH (DELUXE)

Raises and lowers the scrub deck, and turns the scrub brush motors on and off, and controls the solution solenoids.

For interim/pre-spray “A” mode, rotate the function knob to the “A” position. The “A” chemical will be drawn from its tank and delivered to the solution system. The scrub deck will lower and the scrub motor will turn on and the interim/pre-spray solenoid will open and spray will flow through the jets. The brush motor will automatically turn off in neutral. The spray solenoid will shut off in neutral or reverse.

To raise the deck, turn off the brush motor and solenoid(s). Rotate the knob to the off position to the far counter clockwise position.

For extraction or “B” mode, rotate the function knob to the “B” position. The “B” chemical will be drawn from its tank and delivered to the solution system. The scrub deck will lower and the scrub motor will turn on and the extraction solenoid and interim/pre-spray solenoid will open and spray will flow through the extraction and interim jets and the vacuum motor will run. The brush motor will automatically turn off in neutral. The extraction and interim/pre-spray solenoid will shut off in neutral or reverse.

To use the machine with an accessory hand tool or wand rotate the knob fully clockwise to the accessory position. Only the vacuum motor and pump will run. Connect the solution hose of the accessory tool to the solution accessory port. The fitting is 1/8” male quick disconnect. If needed to adapt to 1/4” male quick disconnect (see Suggested Spare Parts for part number). NOTE: The

accessory port is only supplied with water from the solution tank. No chemical is injected.

To connect the vacuum hose, open the accessory port cover and insert the wand vacuum hose fully into the port.

3-10

86292490 VOYAGER DUO 08/20/07

PRE-RUN MACHINE INSPECTION

Do a pre-run inspection to find possible problems that could cause poor performance or lost time from breakdown. Follow the same procedure each time to avoid missing steps.

NOTE: See maintenance section for pre-run machine inspection checklist items.

STARTING MACHINE

NOTE: Perform pre-run machine check before operating machine.

FOR SAFETY: Before starting machine, make sure that all safety devices are in place and operating properly.

1. Turn the machine power on by turning key switch clockwise to the “I” (on) position.

2. Check the position of the Reverse Button to

make sure the machine will travel in the direction intended.

3. Check the position of the speed control knob to make sure the machine will travel at the intended speed.

4. Press either throttle Switch.

MACHINE OPERATION

EMERGENCY STOP PROCEDURES

1. Release both the throttle switches.

2. Turn machine power off with key switch by

turning key switch counterclockwise to t he “o” (off) position.

DELUXE

1. Release both the throttle switches.

2. Turn machine power off with key switch by

turning key switch counterclockwise to t he “o” (off) position.

3. Push E-Stop button in.

4. To reset the E-stop button, rotate counter

clockwise and the switch will pop back out.

86292490 VOYAGER DUO 08/20/07

MACHINE OPERATION

FILLING SOLUTION TANK FOR SAFETY: Before leaving or servicing

machine; stop on level surface, turn off machine and remove key.

1. Turn the machine power off.

2. Remove the front cover and the solution fill lid.

3. Fill the solution tank with clean water. (See the

Technical Specifications chart for exact capacity). The water must not be hotter than 140° F (60°C) to prevent damage to the tank.

4. Replace the solution fill lid and front cover.

DELUXE

1. Turn the machine power off.

2. Remove the front cover and the solution fill lid.

3. Fill the “A” tank with either encapsulating

interim carpet cleaning or prespray chemical.

4. Fill the “B” tank with extraction chemical.

5. Turn machine power on.

6. Prime chemical system by holding the prime

switch to the “A” position for 30 seconds then holding the prime switch to the “B” position for 30 seconds. If using only one chemical tank, prime only that system.

explosion or fire. Do not use flammable materials in the tanks.

Flammable materials can cause an

NORMAL SCRUBBING

Plan the scrubbing pattern in advance. For efficient operation, the runs should be the longest possible without turning, stopping, or raising or lowering scrub deck. The longest track is around the perimeter of the area to be cleaned and a collapsing rectangle pattern is most efficient.

In order to achieve the best possible results, the area which is to be cleaned, should be vacuumed before scrubbing. Large debris, strings and wire must be removed to prevent being caught in brushes.

If the machine is allowed to stand in neutral with the scrub deck down for more than 2 seconds, the solutions flow stops and brush motor stops. When forward travel is resumed, the solution flow and the scrub brush motor will continue. Overlap the brush path and avoid transporting over previously cleaned areas.

RECOMMENDED SCRUBBING PATH

3-12

86292490 VOYAGER DUO 08/20/07

TO BEGIN SCRUBBING When operating the machine around people, pay

close attention for unexpected movement. Use extra caution around children.

1. Turn machine power on.

2. Position rotary switch to the position matching

the process to be preformed, and the chemical that was added to the solution tank or chemical tank (Deluxe), either interim or interim/pre-spray (Deluxe) or extraction cleaning.

3. Check position of reverse button and the position speed control knob so that the machine is set to travel in the direction and the speed intended.

4. Drive machine forward to begin scrubbing.

MACHINE OPERATION

TO STOP SCRUBBING

1. While scrubbing turn off the pump switch to stop

spraying solution. Continue to scrub and recover the solution for an additional pass.

2. Allow the throttle switches to return to neutral.

3. Rotate the selector switch to the accessory

position so that the vacuum motor continues to run and evacuate the system. This will also raise the deck and vacuum shoes.

4. Turn the rotary switch to the off position by rotating the selector switch clockwise. Turn machine power off.

DELUXE

1. While scrubbing turn off the pump switch to stop

spraying solution. Continue to scrub and recover the solution for an additional pass.

2. Allow the throttle switches to return to neutral.

3. Rotate the selector switch to the accessory

position so that the vacuum motor continues to run and evacuate the system. This will also raise the deck and vacuum shoes.

4. Turn the rotary switch to the off position by rotating the selector switch clockwise. Turn machine power off.

FOR SAFETY: Before leaving or servicing machine: stop on level surface, turn off machine and remove key.

FOR SAFETY: When using machine, go slow on inclines and slippery services.

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3-13

MACHINE OPERATION

SOLUTION DRAIN HOSE

EMPTYING AND CLEANING SOLUTION TANK

1. Park the machine next to a floor drain. Drain

hose is at the rear of the machine.

2. Turn the machine power off.

3. Remove the top of the hose from the barb mount

and lower hose in direction of the drain. Do not stand in front of end of hose. Solution will come out with force.

4. Remove the front cover and solution fill cover.

5. Flush the solution tank out with clean water and

run several gallons of clean water through both spray jet systems. Do not use water hotter than 140°F (60°C) to clean tank or damage may occur.

6. Replace the drain hose to the barbed fitting.

7. If machine is to be stored, leave the solution fill

cover off.

EMPTYING AND CLEANING CHEMICAL TANKS AND SYSTEM (DELUXE)

1. Turn the machine power off.

2. Park the machine next to a floor drain. The tanks are located at the front of the machine.

3. Remove the cap and straw from each chemical bottle and install the closed caps.

4. Remove the tanks by lifting off the solution fill tower.

5. The chemical can remain in the tank or be disposed of properly. Remove one cap at a time and dispose of chemical. Rinse tanks with clean water.

6. Rinse the chemical system by putting the straws and caps in clean water. Push the prime/flush switch for 30 seconds in each direction, “A” and “B”.

EMPTYING AND CLEANING REOVERY TANK

1. Park the machine next to a floor drain. Drain

hose is at the front of the machine.

2. Turn the machine power off.

3. Remove front cover. Remove hose assembly

from mounting hook. Place the end of the hose at the drain and slowly remove the cap. Do not stand in front of hose end. Soiled solution will come out with force.

4. Remove dome lid.

5. Flush the recovery tank out with clean water.

Do not use water hotter than 140°F (60°C) to clean tank or damage may occur.

6. Replace the drain hose cap and place hose back on hook. Replace front cover.

7. If machine is to be stored, leave the recovery dome off.

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86292490 VOYAGER DUO 08/20/07

NOTES:

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3-1

MACHINE OPERATION

SERVICE SCHEDULE

MAINTENANCE

Check water level of batteries after charging; add distilled water if necessary. Check brushes for proper installation. Check for securely attached drain hose, plug and cap. Check that solution fill lid seals tightly Visually check for damaged or worn tires. Check all throttle, direction and speed controls for proper operation. Observe spray pattern and clean jets if necessary. Prime chemical system for 30 seconds for each chemical. Clean brushes and check wear. Clean underside of scrub deck. Clean out solution tank. Clean out recovery tank. Clean and inspect solution filter strainer. Store with solution fill lid and recovery dome off tanks to allow tanks to dry. Clean outside of tank, check for damage. Flush chemical system Charge batteries.

Clean off top of batteries. Check battery cells with hydrometer. Check battery connections are tight.

Clean battery cases and battery compartment. Grease appropriate zerks (grease fittings). Clean pivot points on scrub deck. Check all motors for carbon brush wear. Check motor commutators.

BEFORE EACH WORK PERIOD

* *

* * *

* * * * *

* *

* * *

* * * * *

AFTER EACH

WORK

PERIOD

HRS

100

HRS

200

HRS

4-1

86292490 VOYAGER DUO 08/20/07

MAINTENANCE-BATTERIES

Battery Connector 5. “Y” Tube

Battery Connector 6a. Recovery Hose - Basic

Batteries 6b. Recovery Hose - Deluxe

Prop Rod and Catch

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4-2

MAINTENANCE-BATTERIES

BATTERIES

The batteries provide the power to operate the machine. The batteries require regular maintenance to keep them operating at peak efficiency.

The machine batteries will hold their charge for long periods of time, but they can only be charged a certain number of times. To get the greatest life from the batteries, charge them when their charge level reaches 25% of a full charge. Use a hydrometer to check the charge level.

Do not allow the batteries to remain in a discharged condition for any length of time. Never expose a discharged battery to temperatures below freezing. Discharged batteries will freeze causing cracked cases. Do not operate the machine if the batteries are in poor condition or if they have a charge level below 25% (specific gravity below 1.155).

Keep all metallic objects off the top of the batteries, as they may cause a short circuit. Replace worn or damaged cables and terminals.

Check the electrolyte level in each battery cell before and after charging the batteries. Never add acid to the batteries, use distilled water. Do not allow water level to fall below the battery plates. Portions of plates exposed to air will be destroyed. Do not overfill. Keep plugs firmly in place at all times.

4-3

86292490 VOYAGER DUO 08/20/07

When servicing machine, avoid contact with battery

acid.

Batteries emit hydrogen gas. Explosion or fire can result. Keep sparks and open flame away. Keep covers open when charging.

Wear eye protection and protective clothing when

working with batteries.

Charge batteries in a well ventilated area.

BATTERY MAINTENANCE

1. When cleaning the batteries, use a solution of

baking soda and water. Do not allow the cleaning fluid to enter the battery cells, electrolyte will be neutralized.

2. Maintain the proper electrolyte level in each

battery cell. If a cell should accidentally overflow, clean immediately.

3. Wipe off the top of the batteries at least once a

week.

4. Test battery condition with a hydrometer at least

once a week.

5. Ensure that all connections are tight and all

corrosion removed.

6. Every 4 to 6 months, remove that batteries from

the machine and clean the battery cases and battery compartment.

CHECKING BATTERY SPECIFIC GRAVITY

Use a hydrometer to check the battery specific gravity.

CHECKING GRAVITY A. Hydrometer B. Battery

NOTE: Do not take readings immediately after adding distilled water, if the water and acid are not thoroughly mixed, the reading may not be accurate.

Check the hydrometer readings against this chart.

SPECIFIC GRAVITY

@ 80

1.265 100% CHARGED

1.225 75% CHARGED

1.190 50% CHARGED

1.155 25% CHARGED

1.120 DISCHARGED

NOTE: If the readings are taken when the battery electrolyte is any temperature other than 80°F (27°C), the reading must be temperature corrected.

To find the corrected specific gravity reading when the temperature of the battery electrolyte is other than 80°F (27°): Add (+) to the specific gravity reading 0.004 (4 points), for each 10°F (6°C) above 80° (27°C). Subtract (-) from the specific reading 0.004 (4 points), for each 10°F (6°C) below 80°F (27°C).

Battery Check

BATTERY CONDITION

F (27°C)

86292490 VOYAGER DUO 08/20/07

MAINTENANCE-BATTERIES

CHARGING BATTERIES

When servicing machine, avoid contact with battery acid.

Batteries emit hydrogen gas. Explosion or fire can result. Keep sparks and open flame away. Keep covers open when charging.

Wear eye protection and protective clothing when working with batteries.

Charge batteries in a well ventilated area.

Use a 36 volt, 20 amp maximum output DC charger which will automatically shut off when the batteries are fully charged.

1. Empty recovery tank.

2. Stop the machine in a clean, well ventilated area

next to the charger.

3. Turn “OFF” machine.

FOR SAFETY: Before leaving or servicing machine; stop on level surface, turn off machine and remove key.

4. Unplug the machine from the battery pack.

Remove front cover. Disconnect recovery hose from “Y” tube. Raise recovery tank and verify prop rod latch is safely engaged.

Batteries emit hydrogen gas. Explosion or fire can result. Keep sparks and open flame away. Keep covers open when charging.

5. Check the electrolyte level in each battery cell.

Before charging, add just enough distilled water to cover the plates. After charging is complete, add just enough distilled water to bring up the level to the indicator ring. If the water level is too high before charging, normal expansion rate of the electrolyte may cause an overflow resulting in a loss of battery acid balance and damage the machine.

4-4

MAINTENANCE-BATTERIES

6. Replace the battery caps, and leave them in place while charging.

7. Unplug the machine connector from the battery.

FOR SAFETY: When charging, connect the charger to the batteries before connecting the charger to the AC wall outlet. Never connect the charger to the AC wall outlet first. Hazardous sparks may result.

8. Plug the charger connector into the battery

connector. Connect the charger AC plug to a wall outlet. The charger gauge should indicate that the batteries are charging.

9. When the batteries are fully charged, disconnect the charger from the AC wall outlet, then disconnect the charger from the batteries.

10. Connect the machine to the battery connector.

11. Check the electrolyte level. It should be up to

the indicator ring. If necessary, add distilled water.

12. Lower recovery tank by safely disengaging the prop rod latch and slowly lowering. Replace the hose and “Y” tube connection. Replace front cover.

4-5

86292490 VOYAGER DUO 08/20/07

CHANGING BATTERIES

Stop the machine in a clean area next to the charger. Turn off machine.

FOR SAFETY: Before leaving or servicing the machine; stop on level surface, turn off machine and remove key.

1. Disconnect machine from battery pack.

2. Raise recovery tank and engage prop rod latch.

3. Disconnect main positive lead and secure cable

terminals away from batteries.

4. Loosen both terminals on each jumper cable and remove one at a time.

5. Prepare a suitable site to place the batteries.

6. Attach suitable battery lifting device and lift batteries from the machine.

Batteries are a potential environmental hazard. Consult your battery supplier for safe disposal methods.

RED

BLK

REAR OF MACHINE

1. Scrub Deck Lift Actuator

2. Scrub Brush Motor

MAINTENANCE-SCRUB DECK

3. Scrub Brushes

4. Retaining Clip

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4-6

MAINTENANCE-SCRUB DECK

SCRUB HEAD The dual cylindrical scrub head is designed to scrub

chemical into the carpet. The two counter rotating brushes raise the pile of the carpet, giving it a lush groomed appearance.

MAINTENANCE

Scrub brushes should be exchanged front to back every 50 hours to ensure even wear. Scrub brushes should be replaced as a set when bristle length wears to height of yellow Perform Alert

SCRUB BRUSH REMOVAL

The scrub brushes are removed from the right side of the machine.

1. Raise the scrub deck to the storage position.

2. Pull out on the bottom of the retaining clip.

3. The brush assembly and end cap should drop

down. Then pull the brush down far enough to clear the bottom of the housing.

4. Pull brush out with a rocking motion to free brush from drive hub.

bristles.

SCRUB BRUSH REPLACEMENT

1. Lift the drive side of the brush and push it onto

drive hub until a positive stop is felt. The brush cannot be installed until the brush is fully seated on the drive hub.

2. Pull out on the bottom of the retaining clip.

3. Line up the end cap with the flats to each side.

4. Slide brush up into the retaining clip until it clicks

in place.

4-7

86292490 VOYAGER DUO 08/20/07

+ 106 hidden pages

Windsor VOYDU1 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual