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

2

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

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.

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.

2

.

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

2

1

6

9

5

7

8

10

15

13

14

12

11

4

3

16

10

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

5

2

4

3

3

1

6

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

2

3

1

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 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). 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

3

-

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

11

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.

86292490 VOYAGER DUO 08/20/07

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.

3-14

86292490 VOYAGER DUO 08/20/07

NOTES:

5

86292490 VOYAGER DUO 08/20/07

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

50

HRS

100

HRS

200

HRS

4-1

86292490 VOYAGER DUO 08/20/07

MAINTENANCE-BATTERIES

1.

Battery Connector 5. “Y” Tube

2.

Battery Connector 6a. Recovery Hose - Basic

3.

Batteries 6b. Recovery Hose - Deluxe

4.

Prop Rod and Catch

86292490 VOYAGER DUO 08/20/07

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

+

RED

RED

++

-

BLK

-

BLK

-

BLK

REAR OF
MACHINE

1. Scrub Deck Lift Actuator

2. Scrub Brush Motor

MAINTENANCE-SCRUB DECK

3. Scrub Brushes

4. Retaining Clip

86292490 VOYAGER DUO 08/20/07

1

2

4

3

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.

TM

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

8

Do not use a pressure
washer to clean around

the brush motors. Use tap pressure only.
TO REPLACE SCRUB BRUSH MOTORS

1. With the scrub deck in the lowered position,

remove the deck cover and disconnect brush
motor wiring connector from harness.

2. Remove the motor and end bracket assembly
from the deck.

3. Separate brush motor from end brackets.

4. Reverse to reassemble.

86292490 VOYAGER DUO 08/20/07

MAINTENANCE-SCRUB DECK

BRUSH MOTOR CARBON BRUSH
REPLACEMENT

1. Scribe alignment mark on motor barrel to motor

cap. Remove two bolts.

2. Remove end cap from motor.

NOTE: Motors contain two wave washers in
cap. Do not lose these.

3. Release brush from spring tension. Re move
screw connecting brush wire lead to brush
holder. Clean brush holder to insure free
movement.

4. Retract spring and install new brush. Install
connector screw and lead.

5. When all new brushes are installed. Place all in
retracted position, held into brush holder by
spring tension.

6. Carefully place end cap onto bearing on motor
shaft.
NOTE: Use care to assure wave washer
alignment.

7. With end cap in partially installed position,
release all brushes to contact position with
motor commutator.

NOTE: Failure to insure all brushes are released
will result in motor failure.

8. Reset end cap and realign with scrib e marks on
motor barrel. Reinstall the two attach bolts from
cap into base.

9. Maintain alignment between motor barrel base
and cap.

4-

MAINTENANCE-SCRUB DECK

ACTUATOR SCRUB DECK
REMOVAL/REPLACEMENT

FOR SAFETY: Before leaving or servicing
machine, stop on a level surface. Turn off
machine.

1. Lower scrub deck. Remove the front cover and
raise recovery tank.

2. Disconnect electrical connector.

3. Remove the clevis pin retaining the bottom of

the acutator.

4. Remove the clevis pin retaining the top of the
acutator.

5. Reverse for re-installation.

SCRUB DECK ACTUATOR ADJUSTMENT

The actuator will need to be adjusted when
replaced.

To adjust the actuator:

1. While holding actuator barrel to prevent it from

spinning, apply power to the actuator such that it
is fully extended. Positive power to white wire,
and negative/ground to black. Limit switch
within actuator will stop it.

2. With actuator fully extended, attach to the top
bracket.

3. At the bottom mount align the mounting hole
with the center of the slot, turn the barrel in or
out enough to align connection to bracket.

4. Connect actuator electrical plug.

5. Check travel of actuator during operation.

4-9

86292490 VOYAGER DUO 08/20/07

MAINTENANCE-CIRCUIT PROTECTION

0

1

1. CIRCUIT BREAKERS

Circuit breakers interrupt the flow of power in the
event of an electrical overload. When a circuit
breaker is tripped, reset it by pressing the
exposed button. If a circuit breaker continues to
be found and corrected.

30 Amp. Protects the vacuum motor.

30 Amp. Protects the vacuum motor.
22 Amp. Protects the scrub brush

motor.
25 Amp. Protects the propel motor.
3 Amp. Protects the machine

controls, pump and actuator

86292490 VOYAGER DUO 08/20/07

4-1

MAINTENANCE-SOLUTION STRAINER & PUMP - BASIC

1

1. Pump

2. Solution Strainer

2

3

4

5

3. Solenoid Valves

4. Jets- Interim

5. Jets-Extraction

4-11

86292490 VOYAGER DUO 08/20/07

MAINTENANCE-SOLUTION STRAINER & PUMP - BASIC

(

)

(

)

1. SOLUTION STRAINER

The solution strainer is located on the front of
the machine under the front cover. The strainer
protects the pump, solenoid valve and jets from
debris. If there is little or no solution flow to the
ground, check the strainer for debris. Clean the
solution strainer. To remove the strainer, turn
the bottom part of the strainer counterclockwise
until the bottom is separated. Clean out the
debris from the wire mesh and the bowl and re­assemble. Make sure the O-ring gasket is in
place when re-assembled.

2. PUMP

The pump is located on the front of the machine
under the front cover. The pump delivers
solution from the tank to the scrub deck.

To repair or replace pump:

1. Remove front cover.

2. Remove hoses connecting the pump.

3. Remove screws that secures pump to

3. SOLENOID VALVE

The solenoid valves are mounted on the front of
the scrub deck, on left side.

The solenoid valves shuts off solution flow to
jets whenever scrubbing stops or in reverse. To
repair or replace solenoid valve, remove screws
that secure it to deck.

mounting plate.

PUMP HEAD REPLACEMENT

86136450 PRV 65151

4. JETS

VALVE ASM

86137240 PRV 84145

The two sets of jets are located in front of the
scrub deck.

The jets spray cleaning solution onto the carpet.
The spray pattern should be checked regularly
and if jets become clogged they should be
cleaned or replaced immediately.

To clean jets:

1. Remove jet from jet body by rotating it

counterclockwise.

2. Blow debris back through orifice if possible.
Do not use pointed object to unplug jet. This
will damage jet and cause improper spray
pattern and solution flow through jets.

3. If jet cannot be cleaned by blowing debris
back through its orifice, submerge jet in
small container of acetic acid and let soak
for up to six hours.

4. After soaking jet, use a soft brush to remove
debris and rinse thoroughly.

5. Install jet in jet body by rotating it clockwise
firmly into place.

6. For lower flow in extraction “B” other jets are
available. ( see Suggested Spare Parts).

PUMP REPLACEMENT PARTS

DIAPHRAGM

ASM.

86292490 VOYAGER DUO 08/20/07

4-12

MAINTENANCE- SOLUTION STRAINER & PUMP - DELUXE

2

1

5

1. Pump

2. Solution Strainer

3. Solenoid Valves

4. Jets-Interim

4-13

7

4

6

3

5. Jets-Extraction

6. A-B Chemical Valve

7. Chemical Pump

86292490 VOYAGER DUO 08/20/07

MAINTENANCE-SOLUTION STRAINER & PUMP - DELUXE

(

)

(

)

1. SOLUTION STRAINER

The solution strainer is located under the
recovery tank. The strainer protects the pump,
solenoid valve and jets from debris. If there is
little or no solution flow to the ground, check the
strainer for debris. Clean the solution strainer.
To remove the strainer, turn the bottom part of
the strainer counterclockwise until the bottom is
separated. Clean out the debris from the wire
mesh and the bowl and re-assemble. Make
sure the O-ring gasket is in place when re­assembled.

2. PUMP

The pump is located on underside of the
recovery tank. The pump delivers solution from
the tank to the scrub deck.

To repair or replace pump:

1. Remove bracket assembly from the bottom

side of the recovery tank.

2. Remove hoses connecting the pump.

3. Remove screws that secures pump to

mounting plate.

3. SOLENOID VALVE
The solenoid valves are mounted on the front of

the scrub deck, on left side.
The solenoid valves shuts off solution flow to

jets whenever scrubbing stops or in reverse. To
repair or replace solenoid valve, remove screws
that secure it to deck.

PUMP HEAD REPLACEMENT

86136450 PRV 65151

4. JETS

VALVE ASM

86137240 PRV 84145

The two sets of jets are located in front of the
scrub deck.

The jets spray cleaning solution onto the carpet.
The spray pattern should be checked regularly
and if jets become clogged they should be
cleaned or replaced immediately.

To clean jets:

1. Remove jet from jet body by rotating it

counterclockwise.

2. Blow debris back through orifice if possible.
Do not use pointed object to unplug jet. This
will damage jet and cause improper spray
pattern and solution flow through jets.

3. If jet cannot be cleaned by blowing debris
back through its orifice, submerge jet in
small container of acetic acid and let soak
for up to six hours.

4. After soaking jet, use a soft brush to remove
debris and rinse thoroughly.

5. Install jet in jet body by rotating it clockwise
firmly into place.

6. For lower flow in extraction “B” other jets are
available. (See Accessories page).

PUMP REPLACEMENT PARTS

DIAPHRAGM

ASM.

86292490 VOYAGER DUO 08/20/07

4-14

MAINTENANCE SOLUTION STRAINER & PUMP - DELUXE

5. A-B CHEMICAL PUMP & CHEMICAL PUMP

1. The chemical tank “A” holds either

encapsulating interim chemical or pre-spray
chemical. Tanks should be cleaned weekly.
Extra chemical should be stored using the
blank cap instead of the straw cap.

2. The chemical tank “B” hold the deep
extraction chemical. The tank should be
cleaned weekly. Extra chemical should be
stored using the blank cap instead of the
straw cap.

3. The chemical selector valve switche s
between the “A” and “B” chemical being
pumped through the chemical mixing section
and delivered to the solution system,
depending on the position of the function
switch on the control panel. The selector
valve chemical pump, and chemical mixing
section should be flushed with clean water
after each use. Drain water through both
the “A” and “B” cap and straws by putting
them in water and pressing the “A” and “B”
prime/flush switch each way for 30 seconds.

4-15

86292490 VOYAGER DUO 08/20/07

NOTES:

86292490 VOYAGER DUO 08/20/07

4-16

MAINTENANCE-DRIVE ASSEMBLY

1. Drive Assembly

2. Grease Points

3. Drive Motor

1

32

2

4-17

86292490 VOYAGER DUO 08/20/07

DRIVE MOTOR CARBON BRUSH REPLACEMENT

Do not use a pressure washer to clean around
the motors. Use tap pressure only.

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

1. Disconnect batteries from machine.

2. Disconnect the electrical connection to the

traction motor.

MAINTENANCE- DRIVE ASSEMBLY

3. Remove brush cap.

4. Release brush from spring tension. Re move

screw connecting brush wire lead to brush
holder. Clean brush holder to insure free
movement.

7. Install new brush and reinstall connecting screw
and lead.

8. When all new brushes are installed. Place all in
retracted position, held into brush holder by
spring tension.

9. Carefully replace brush cap.

86292490 VOYAGER DUO 08/20/07

4-18

MAINTENANCE-VACUUM

1. Vacuum Shoes

2. Vacuum Glides

3. Vacuum Shoe Retainer Knobs

5

6

1

2

23

4

4. “Y” Tube

5. Float Ball and Screen

6. Vacuum Motor

4-19

86292490 VOYAGER DUO 08/20/07

VACUUM SHOES

The dual offset vacuum shoes are designed to
extract soiled solution from the carpet. The plastic
vacuum shoe glides minimize wear to flooring.

MAINTENANCE

The vacuum shoes should be removed and cleaned
daily to ensure maximum recovery.

VACUUM SHOE REMOVAL

1. Unscrew retainer knob from right side vacu um
shoe.

2. Pull vacuum shoe forward until it is free from
pivot pin.

3. Remove vacuum hose from top of vacuum shoe

4. Repeat to remove left side vacuum shoe.

5. Inspect or repair as necessary and reinstall.

86292490 VOYAGER DUO 11/15/08

MAINTENANCE-VACUUM

TO CLEAN VACUUM SHOES

1. With the vacuum shoes in the raised position,

turn key switch “off”.

2. Remove vacuum shoes.

3. Flush vacuum shoes from top with water. If

necessary, clean blockage from narrow opening
with a scraper or similar device.

4. Vacuum shoe glides may be removed for
cleaning (or replaced) by removing the three
pins that secure them to metal vacuum shoes.

RECOVERY TANK FLOAT SHUT-OFF

When water is no longer being vacuumed from the
floor and the vacuum fan is operating, the ball float
has engaged. The vacuum motors will not vacuum
water with recovery tank full. The recovery tank
must be drained.

1. The float shut-off screen can be cleaned in or
out of the machine.

2. To clean the float shut-off while it is inside the
machine wipe material off screen then rinse.
Check that the ball is also clean and moves
freely.

3. To remove the float shut-off, grasp the elbow
with one hand tilt and pull the float screen
assembly to pull it off the elbow.

4. To install, place one hand on the elbow, and
then tilt and push the float screen assembly over
the elbow.

4-20

MAINTENANCE-VACUUM

Vacuu

otor Carbo

TO REPAIR OR REPLACE VACUUM MOTOR(S)

1. Remove the front cover, drain the recovery tank

and disconnect the vacuum hose assembly from
the “Y” tube.

2. Raise the recovery tank and safely engage the
prop rod latch.

3. Disconnect electrical connector from the
vacuum motor(s) and connecting hoses.

4. Unbolt the bracket and vacuum motor assembly
and remove from tank.

5. Remove the vacuum motor from the bracket.

6. Reverse steps to install. Make sure the gaskets

fit and seal properly as you reassemble.

m M

Carbon
Brushes

If armature commutator is grooved, extremely pitted or not
concentric, the motor will need to be replaced or sent to a
qualified service center.

Important:

These brushes wear quicker as the length shortens due to
increased heat. Spring inside brush housing will dama ge
motor if brushes are allowed to wear away completely.

n Brushes

End Cap

3

[9.5mm]

Periodically check the length of the carbon brushes. Replace
both carbon brushes when either is less than 3/8" (9.5mm)
long.

8

4-21

86292490 VOYAGER DUO 08/20/07

PUSHING MACHINE
The machine may be pushed for short distances at

speeds not to exceed 5 mph. Be careful to avoid
damaging machine. The machine may be pushed by
hand from the rear.

NOTE: To avoid damage caused by regenerative
voltage, disconnect traction motor before towing or
pushing machine.

MAINTENANCE-TRANSPORTING

PREPARATION FOR LOADING /UNLOADING
TRAILER

Before loading or unloading machine from trailer,
remove vacuum shoes to eliminate interference.
Scrub head must be in the up position before
loading.

NOTE: When transporting the machine on a trailer
or in a truck, in addition to using tie-downs, be sure
to block the tires to prevent the machine from rolling.

86292490 VOYAGER DUO 08/20/07

4-22

MACHINE-TROUBLESHOOTING

PROBLEM CAUSE SOLUTION

No power to machine

Battery disconnected Check all battery cable connections
Battery cables corroded Clean connections

Faulty key switch Replace switch

Little or no propel

Machine does not change
speeds

Forward speed only
Reverse speed only

Poor scrubbing
performance

Little or no solution flow to
the floor

Low battery charge Charge batteries
Machine turned on with propel

trigger not in neutral position
Tripped circuit breaker Reset circuit breaker and check brush
Controller overheated Allow cool down period
Loose motor connection Check wires and connections from

Faulty throttle circuit or
potentiometer
Faulty brake circuit Check wires connections

Faulty speed control circuit or
potentiometer

Faulty forward/reverse switch Replace switch
Debris caught in scrub brushes Remove debris

Low scrub brush down pressure Check brush wear
Low battery charge Charge batteries

Solution tank empty Fill solution tank
Solution pump turned off Turn on pump
Solution strainer plugged Clean solution strainer
Solution system plumbing

obstructed
Pump obstructed Clean or replace pump

Solution solenoid valve obstructed
or stuck
Jet(s) obstructed Clean or replace jet(s)

Faulty pump circuit or pump Check wiring, connections, and pump.
Faulty solenoid Check solenoid valve

Allow pedal to return to neutral.
Restart

controller to motor
Check wires and connections from throttle
to controller and potentiometer resistance

Check wires, connections and pot

Clear obstruction from plumbing

Clean or replace valve

Brush motors do not run, or
run slowly

down/up
No chemical flow (Deluxe) Tank(s) empty Fill with prime chemicals

Chemical pump not primed Prime ch emical pump
Chemical system obstruction Rinse system with water

4-23

Circuit breaker(s) tripped Reset circuit beaker(s) and check brush

pressure.

Low battery charge Charge battery
Fault brush circuit or motor Check wires, connections and motor
Worn brush motor brushes Replace brushes, check commutator

Actuator circuit breaker tripped Reset breaker Scrub deck will not go
Faulty actuator circuit or actuator Check wires, connections and actuator

86292490 VOYAGER DUO 08/20/07

PARTS LIST

86292490 VOYAGER DUO 08/20/07

BRUSH DECK

5-1

86292490 VOYAGER DUO 08/20/07

BRUSH DECK

REF PART NO. PRV NO. QTY DESCRIPTION

1 86223780 70896 8 SCR, M4X8, SET, ISO4029,CP,BLK
2 86224170 730410 2 SHAFT, 6.2MM BRUSH DRIVE
3 86012800 - 2 SHAFT ASM, BRUSH END CAP
4 86012830 - 1 SHAFT ASM DRIVE 24”
5 86223520 67598 3 RING, 28MM INT SNAP PHOSPHATE
6 86223310 64116 1 PULLEY, 5MM HTD, 18T, 12.7 ID
7 86215250 11049 1 BELT, 2S 5MM HTD, 15W, 128T
8 86224660 730393 1 SPRING, TENSIONER

9 86173330 87513 1 WASHER, M5 FLAT, ISO7093 SS
10 86014990 - 4 SCR, M5X20, SHCS ISO4762, SS
11 86215870 140914 1 BRKT, TENSIONER ARM
12 86012780 - 2 PULLEY ASM, 5MM HTD 22T
13 86230690 12532 2 BRUSH, EXTRACTOR 24”
14 86223490 67468 3 RING, 10MM EXT SNAP, DIN 471
15 86224130 730394 1 SHAFT, TENSIONER
16 86219380 41546 1 HOUSING, BRUSH DRIVE
17 86223320 64117 2 PULLEY, 32T, 5MM HTD
18 86012790 - 2 SHAFT ASM, BRUSH DRIVE
19 86172970 70911 3 SCR, M5X12, PHLP FHMS, ISO7046, SS
20 86222870 620103 1 PLATE, BRUSH DRIVE COVER
21 86217800 32060 1 EXTRUSION, DUAL BRUSH 24”
22 86219390 41548 1 HOUSING, BRUSH CLIP
23 86173350 87515 4 WASHER, M5, FLAT, ISO7089, SS
24 86172980 70912 2 SCR, KA50X10, PT OHS, WN14112, PLTD
25 86224630 730380 2 SPRING, BRUSH CLIP
26 86277130 70795 10 SCR, 5/16-18 X 1.00 CARRIAGE SS

SERIAL NO.

FROM

NOTES:

86292490 VOYAGER DUO 08/20/07

5-2

BRUSH DECK ACTUATOR

3

6

5

4

2

1

7

5-3

1

8

7

86292490 VOYAGER DUO 08/20/07

BRUSH DECK ACTUATOR

REF PART NO. PRV NO. QTY DESCRIPTION

1 86008670 80606 2 COTTER, 3/8” RING

2 86091930 141037 1 BRKT, ACTUATOR MOUNT

3 86276780 70728 2 SCR, 5/16-18 X 3/4 HHCS SS

4 86279130 87083 2 WASHER, 5/16 SPLIT LOCK PLTD

5 86010670 87029 2 WASHER, 5/16 FLAT SS

6 86011800 - 1 ACTUATOR, 36VDC 2.75 STRK

7 86248970 81406 2 PIN, CLEVIS 3/8 X 2.00 PLTD

8 86278910 87003 1 WASHER, 3/8 ID X 7/8 OD SS

SERIAL NO.

FROM

NOTES:

86292490 VOYAGER DUO 08/20/07

5-4 5-4

BRUSH DECK MOTOR

5-5

86292490 VOYAGER DUO 08/20/07

BRUSH DECK MOTOR

REF PART NO. PRV NO. QTY DESCRIPTION

1 86273750 70011 6 SCR, 1/4-20 X 5/8 HHCS SS

2 86173340 87514 6 WASHER, SPLIT LOCK, 1/4 SS

3 86010630 87013 6 WASHER, 1/4 ID X 5/8 OD SS

4 86215880 140929 2 BRKT, MOTOR MOUNT

5 86222130 53275 1 MOTOR, 36VDC

6 86222290 57308 4 NUT, 5/16-18 HEX NYLOCK SS

7 86217250 22105 2 COUPLER, 1/2” JAW

8 86217260 22106 1 COUPLER, SPIDER

9 86172960 70910 2 SCR, SET, M6X8, SH, ISO4029,SS
10 86225790 87504 4 WASHER, 5/16 X .63 SS

SERIAL NO.

FROM

NOTES:

86292490 VOYAGER DUO 08/20/07

5-6

BRUSH DECK MOUNTING

6

2

2

6

1

9

5

6
2

4

8

4

3

5-7

86292490 VOYAGER DUO 08/20/07

BRUSH DECK MOUNTING

REF PART NO. PRV NO. QTY DESCRIPTION

1 86259420 87232 2 WASHER,THRUST .51IDX1ODBRO

2 86010670 87029 8 WASHER, 5/16 FLAT SS

3 86295600 - 1 BRKT, BRUSH DECK PIVOT, LEFT

4 86277130 70795 6 SCR, 5/16-18 X 1.00 CARRIAGE SS

5 86088110 730443 1 STRAP, SHROUD LATCH

6 86270830 57023 8 NUT, 5/16-18 HEX NYLOCK SS

7 86277030 70780 2 SCR, 5/16-18 X 1.25 CARRIAGE SS

8 86228990 09153 2 BEARING, FLNGD, .314IDX.502OD

9 86295610 - 1 BRKT, BRUSH DECK PIVOT, R

SERIAL NO.

FROM

NOTES:

86292490 VOYAGER DUO 08/20/07

5-8

BRUSH DECK SHROUND

2

1

9

1

3

4

5-9

5

8

7

6

86292490 VOYAGER DUO 01/22/09

BRUSH DECK SHROUD

REF PART NO. PRV NO. QTY DESCRIPTION

1 86161800 46-802531 1 LATCH, CONCEALED KEEPER

2 86273790 70016 2 SCR, 6-32 X 3/4 PPHMS

3 86274520 70233 1 SCR, #10 X 3/8 PH HI-LO PLT

4 86279190 87095 1 WASHER, #10 FLAT PLTD

5 86059910 270167 1 COVER, DECK

6 86012200 - 1 FOAM SPACER, SHROUD, 5/16 T

7 86270920 57049 2 NUT, 6-32 HEX NYLOCK SS

8 86012190 - 2 FOAM SPACER, SHROUD, 3/4 T

9 86006400 67380 2 RIVET, 5.32 OF X 1/8 GRIP

SERIAL NO.

FROM

NOTES:

86292490 VOYAGER DUO 08/20/07

5-10

BRUSH DECK LIFT

13

6

1

3

2

4

5

16

14

12

12

4

4

15

5

19

17

7

8

9

18

10

11

5-11

86292490 VOYAGER DUO 10/23/08

BRUSH DECK LIFT

REF PART NO. PRV NO. QTY DESCRIPTION

1 86290700 - 4 SCR, 5/16-18 X 1.0 FHCS SS

2 86228990 09153 4 BEARING, FLNGD,.314ID X .502OD

3 86259420 87232 4

4 86010670 87029 13 WASHER, 5/16 FLAT SS

5 86270830 57023 5 NUT, 5/16-18 HEX NYLOCK SS

6 86012900 - 2 SCR, 1/4-20 X 4.5 CARRIAGE SS

7 86088420 71154 4 SUPPORT, COUNTERBALANCE

8 86013020 - 2 SPRING, COMP .97DX2.5LX.13W

9 86231280 14400 2 BUSHING, .377IDX.627ODX.63
10 86010810 87191 2 WASHER, 1/4 ID X 1.0 OD FLAT SS
11 86271870 57290 2 NUT, 1/4-20 HEX NYLCK THIN SS
12 86276780 70728 9 SCR, 5/16-18 X 3/4 HHCS SS
13 86294810 - 1 ASSY, LIFT ARM, RIGHT, REAR
14 86294580 - 1 LIFT ARM LEFT, FRONT
15 86294800 - 1 BRKT, ACTUATOR LIFT
16 86294560 - 1 LIFT ARM RIGHT, FRONT
17 86294820 - 1 ASSY, LIFT ARM, LEFT, REAR
18 86259400 87205 1 WASHER, THRUST.51ID X1 ODBRO
19 86256130 730402 1 STRAP, STATIC, .2T X 1W X 3L

WASHER, THRUST .51D X 1
ODBRO

SERIAL NO.

FROM

NOTES:

86292490 VOYAGER DUO 10/23/08

5-12

CONTROL HANDLE

9

2A
2B

1

8

3

6

4

5

7

10

5-13

86292490 VOYAGER DUO 08/20/07

CONTROL HANDLE

REF PART NO. PRV NO. QTY DESCRIPTION

1 86277050 70782 4 SCR, 5/16-18 X 3/4 SHCS SS
2A 86238730 38307 1 HANDLE, LEFT
2B 86238740 38308 1 HANDLE, RIGHT

3 86240990 41431 2 HOUSING, BUTTON

4 86254920 730153 2 SPRING, COMP .24OD X 1.25X.018

5 86277070 70784 2 SCR, 4-40 X 5/8 PPHMS

6 86231480 140504 2 BUTTON, PROPEL

7 86277060 70783 4 SCR, 8.32 X 7/8 PHTC TYPE 23

8 86257230 730125 2 SWITCH, SPST MOM NO W/LEVER

9 86004120 38312 - PROPEL HANDLE ASM LEFT
10 86004130 38313 - PROPEL HANDLE ASM RIGHT

SERIAL NO.

FROM

NOTES:

86292490 VOYAGER DUO 08/20/07

5-14

CONTROL PANEL - LOWER - BASIC

17

14

18

1

2

1

15

3

4

5

6

7

8

10

9

12

11

5-15

16

13

5

86292490 VOYAGER DUO 12/08/07

CONTROL PANEL - LOWER - BASIC

REF PART NO. PRV NO. QTY DESCRIPTION

1 86002010 14942 2 BOOT, 3/8 CIRCUIT BREAKER

2 86008900 80845 3 BOOT, SEAL-PUSH BTN 7/16-28

3 86237900 35278 3 GASKET, .125T X .37W X 23L

4 86005530 54154 1 METER, 12-48 VDC LED HOUR

5 86255900 73538 4 STANDOFF, 6-32 X 5/8 HEX NYL

6 86251360 67166 1 RELAY, 36VDC 100A

7 86005810 57245 2 NUT, 1/4-20 HEX NYLOCK SS

8 86230080 141044 1 BRKR, 22AMP 250VAC, 50VDC

9 86001910 14606 2 BRKR, 30A 50VDC CIRCUIT
10 86001920 14607 1 BRKR, 25A 50VDC CIRCUIT
11 86002000 14717 1 BRKR, 3 AMP 1681-090-300
12 86007190 72161 1 SWITCH KEY DPST
13 86229770 140805 1 BLOCK, SHUNT MOUNT
14 86273880 70030 2 SCR, 8-32 X 1.25 PPHMS
15 86295670 - 1 PANEL, CONTROL
16 86270850 57026 2 NUT, 8-32 HEX NYLOCK
17 86012910 - 1 CONTROLLER, I DRIVE
18 86250160 66321 1 PLUG, .875”

SERIAL NO.

FROM

NOTES:

86292490 VOYAGER DUO 12/08/07

5-16

CONTROL PANEL – LOWER – DELUXE

16

1

17

1

2

18

4

15

3

5

6

7

8

9

12

13

11

10

5-17

14

6

86292490 VOYAGER DUO 08/20/07

CONTROL PANEL - LOWER - DELUXE

REF PART NO. PRV NO. QTY DESCRIPTION

1 86002010 14942 2 BOOT, 3/8 CIRCUIT BREAKER

2 86008900 80845 3 BOOT, SEAL-PUSH BTN 7/16-28

3 86237900 35278 3 GASKET, .125T X .37W X 23L

4 86250160 66321 1 PLUG, .875”

5 86005530 54154 1 METER, 12-48 VDC LED HOUR

6 86255900 73538 4 STANDOFF, 6-32 X 5/8 HEX NYL

7 86251360 67166 1 RELAY, 36VDC 100A

8 86005810 57245 2 NUT, 1/4-20 HEX NYLOCK SS

9 86230080 141044 1 BREAKER, 22A 250VAC, 50VDC
10 86001910 14606 2 BREAKER, 30A 50VDC CIRCUIT
11 86001920 14607 1 BREAKER, 25A 50VDC CIRCUIT
12 86007190 72161 1 SWITCH KEY DPST
13 86002000 14717 1 BREAKER, 3 AMP
14 86229770 140805 1 BLOCK, SHUNT MOUNT
15 86270850 57026 2 NUT, 8-32 HEX NYLOCK
16 86012910 - 1 CONTROLLER, I DRIVE
17 86273880 70030 2 SCR, 8-32 X 1/25 PPHMS
18 86295670 - 1 PANEL, CONTROL
19 86296100 - 1 ASM, DC CONVERTER

SERIAL NO.

FROM

NOTES:

86292490 VOYAGER DUO 10/02/07

5-18

CONTROL PANEL - UPPER - BASIC

9

10

1

4

2

5

3

7

6

8

5-19

86292490 VOYAGER DUO 08/20/07

CONTROL PANEL - UPPER - BASIC

REF PART NO. PRV NO. QTY DESCRIPTION

1 86006310 66335 1 POTENTIOMETER, 50K OHMS

2 86251360 67166 2 RELAY, 36VDC 100A

3 86005810 57245 4 NUT, 1/4-20 HEX NYLOCK SS

4 86012670 - 1 METER, BATTERY, PG TRUE CHG

5 86255900 73538 2 STANDOFF, 6-32 X 5/8 HEX NYL

6 86014690 - 1 SWITCH, ROTARY CAM, 4 POS

7 86257180 72207 1 SWITCH, MOMEMTARY, DPDT, WHITE

8 86257150 72197 1 SWITCH, SPDT P-BUTTON

9 86026010 82522 1 LIGHT ASM, INDICATOR
10 86242110 48088 1 KNOB, .90 OD X .25 COLLET

SERIAL NO.

FROM

NOTES:

86292490 VOYAGER DUO 08/20/07

5-20

CONTROL PANEL – UPPER - DELUXE

10

11

1

12

4

5

9

7

13

5

8

2

3

6

5-21

86292490 VOYAGER DUO 12/08/07

CONTROL PANEL - UPPER - DELUXE

REF PART NO. PRV NO. QTY DESCRIPTION

1 86006310 66335 1 POTENTIOMETER, 50K OHMS

2 86251360 67166 2 RELAY, 36VDC 100A

3 86005810 57245 4 NUT, 1/4-20 HEX NYLOCK SS

4 86012670 - 1 METER, BTRY, PG TRUE CHRG

5 86255900 73538 6 STANDOFF, 6-32 X 5/8 HEX NYL

6 86014690 - 1 SWITCH, ROTARY CAM, 4 POS

7 86257180 72207 1 SWITCH, MOMENTARY, DPDT, WHT

8 86257150 72197 1 SWITCH, SPDT P-BUTTON

9 86251410 67506 1 RELAY, 15A, 36V MINI
10 86026010 82522 1 LIGHT ASM, INDICATOR
11 86242110 48088 1 KNOB, .90 OD X .25 COLLET
12 86254640 82810 2 SPACER, .25 OD X .171 ID X .25
13 86300140 - 1 ASM, DC CONV. ** WAS 862961 00

** CALL MANUFACTURER FOR SERIAL NUMBER.

SERIAL NO.

FROM

NOTES:

86292490 VOYAGER DUO 12/03/07

5-22

CONTROL PANEL MOUNTING

2

1

3

4

5-23

86292490 VOYAGER DUO 08/20/07

CONTROL PANEL MOUNTING

REF PART NO. PRV NO. QTY DESCRIPTION

1 86276290 70626 7 SCR, #10 X 3/4 PPHST HI-LO BLK

2 86294250 - 7 WASHER, .19 ID X .5 X .09TK BLK

3 86072110 141056 1 BRKT, BACK, CONTROL PANEL

4 86274290 70162 2 SCR, 10-32 X 3/8 PPHMS SS

SERIAL NO.

FROM

NOTES:

86292490 VOYAGER DUO 10/15/07

5-24

COVER - FRONT

1

2

3

8

5

6

4

7

5-25

86292490 VOYAGER DUO 08/20/07

COVER - FRONT

REF PART NO. PRV NO. QTY DESCRIPTION

1 86271870 57290 4 NUT, 1/4-20 HEX NYLCK THIN SS

2 86010630 87013 4 WASHER, 1/4ID X 5/8 OD SS

3 86270990 57090 2 NUT, 10-32 HEX NYLOCK SS

4 86290740 - 2 BRKT, FRONT LATCH

5 86278390 73866 2 SPACER, 1/2ODX.219IDX1/2 NYLO

6 86006830 70386 2 SCR, 10-32 X 1.0 PPHMS

7 86062310 270155 1 COVER, FRONT, 24 IN DUO

8 86010650 87018 2 WASHER, #10 X 9/16 OD

SERIAL NO.

FROM

NOTES:

86292490 VOYAGER DUO 08/20/07

5-26

DECAL

1

2

7

6

3

4

5

5-27

86292490 VOYAGER DUO 08/20/07

DECAL

REF PART NO. PRV NO. QTY DESCRIPTION

1 86013290 - 1 LABEL, BASIC CONTROL

2 86013310 - 1 LABEL, EXTRACTORS, BREAKERS

3 86013650 - 1 LABEL, VOYAGER, LEFT

4 86013660 - 1 LABEL, VOYAGER, RIGHT

5 86004970 50990 1 LABEL, WINDSOR LOGO DOMED

6 86013330 - 1 LABEL, SOL FILL, 30 GAL

7 86014330 - 1 LABEL, CHARGER CONNECTION

SERIAL NO.

FROM

NOTES:

86292490 VOYAGER DUO 08/20/07

5-28

FRAME - LOWER

1

3

4

5-29

2

6

5

86292490 VOYAGER DUO 08/20/07

FRAME - LOWER

REF PART NO. PRV NO. QTY DESCRIPTION

1 86276780 70728 2 SCR, 5/16-18 X 3/4 HHCS SS

2 86293740 - 2 CASTER, 4” SWIVEL, 300# CPCTY

3 86091890 141022 1 BRKT, FRAME, CASTER MNT

4 86092550 34468 1 FRAME, TRANSAXLE MTG

5 86271840 57285 8 NUT, 5/16-18 HEX NYLCK THIN SS

6 86010670 87029 8 WASHER, 5/16 FLAT SS

SERIAL NO.

FROM

NOTES:

86292490 VOYAGER DUO 08/20/07

5-30

FRAME - UPPER

1

6

2

3

1

1

3

1

4

5

5-31

86292490 VOYAGER DUO 08/20/07

FRAME - UPPER

REF PART NO. PRV NO. QTY DESCRIPTION

1 86276780 70728 4 SCR 5/16-18 X 3/4 HHCS SS

2 86276490 70670 5 SCR, 5/16-18 X 5/8 HHCS SS

3 86010670 87029 7 WASHER, 5/16 FLAT SS

4 86012890 - 1 WELDMENT, FRAME MAIN

5 86277460 70847 2 SCR, 5/16-18 X 5/8 BSHCS SS

6 86279630 87212 2 WASHER, .344IDX1.13ODX09TPLT

SERIAL NO.

FROM

NOTES:

86292490 VOYAGER DUO 08/20/07

5-32

RECOVERY TANK

1

2

3

-A-

7

6

4

25

13

14

-A-

9

8

11

10

12

18

15

15

23

20

10

21

24

19

86292490 VOYAGER DUO 12/12/08

19

21

10

16

17

17

RECOVERY TANK

REF PART NO. PRV NO. QTY DESCRIPTION

1 86274220 70134 1 SCR, 6-32 X 5/8 PPHMS SS

2 86003340 28062 1 DOME, 13 X 11

3 86246080 51368 1 LANYARD, 18.0 W/LOOP & EYE

4 86014810 - 1 NUT, 6-32 ACORN SS

5 86004010 35274 1 GASKET, DOME EDGE

6 86199840 090-12A 1 FLOAT SCREEN CAGE ASSY

7 86227120 04095 1 ADAPTER, FLOAT 30 DEG

8 86293240 - 1 TUBE ASM RECOVERY FLOAT

9 86002380 20046 1 CLAMP, 2.25” WORM GEAR
10 86002400 20064 4 CLAMP, 2.0” WORM GEAR X 312W
11 86240130 39560 1 HOSE, P-TRAP 45 DEF
12 86292750 - 1 SOLUTION TANK
13 86290830 - 2 SCR, 5/16-18 X 1.25 SHCS SS
14 86238460 36259 2 HOOK, STRAP
15 86270830 57023 5 NUT, 5/16-18 HEX NYLOCK SS
16 86013350 - 1 BRKT, RECOVERY HINGE
17 86276490 70670 7 SCR, 5/16-18 X 5/8 HHCS SS
18 86012160 - 1 BRKT, TANK STIFFENER
19 86237650 35219 2 GASKET, 1 1/2 COMPRESSION
20 86004440 39717 1 CAP, DRAIN HOSE
21 86005660 57033 2 NUT, 1.5 SLIP JOINT
22 OPEN
23 86004260 39472 1 HOSE, 1.5 X 24.0 DRAIN
24 86089630 78490 1 TUBE, 1.5 PVC X 24.0
25 86246070 51352 1 LANYARD, DRAIN HOSE

SERIAL NO.

FROM

NOTES:

86292490 VOYAGER DUO 05/14/08

5-34

RECOVERY TANK HANDLE - BASIC

16

17

7

13

8

9

14

6

12

11

10

15

9

8

7

6

1

2

3

5

4

5-35

18

19

86292490 VOYAGER DUO 08/20/07

RECOVERY TANK HANDLE - BASIC

REF PART NO. PRV NO. QTY DESCRIPTION

1 86217470 270800 1 COVER, ACCESSORY PORT

2 86290950 - 1 ASSEMBLY, BRKT, FRONT, LEFT

3 86226740 73215 4 SPACER, 3/8 X .265 X 1/4 NYL

4 86277640 70893 4 SCR, 1/4-20 X 3/4 PTHMS SS

5 86290730 - 2 LATCH, FRONT COVER

6 86010630 87013 6 WASHER, 1/4 ID X 5/8 OD SS

7 86271870 57290 6 NUT 1/4-20 HEX NYLCK THIN SS

8 86010670 87029 3 WASHER, 5/16 FLAT SS

9 86276490 70670 3 SCR, 5/16-18 X 5/8 HHCS SS
10 86290850 - 1 SCR, M5 X 25 HHMS SS
11 86010650 87018 1 WASHER, #10 X 9/16 OD
12 86013990 - 1 BRKT, COVER
13 86291740 - 1 ASSEMBLY, BRKT, FRONT, RIGHT
14 86276290 70626 2 SCR, #10X3/4 PPHST HI-LO BLK
15 86010800 87189 2 WASHER, .2IDX.500 BLK SS
16 86008650 80604 2 COTTER, 1/4" RING
17 86222620 66891 1 PIN, 5MM DIA X 85MM L
18 86002400 20064 1 CLAMP, 2.0 WORM GEAR X .312W
19 86281980 39549 1 HOSE, 1/2ID WIRE BOUND X 5”

SERIAL NO.

FROM

NOTES:

86292490 VOYAGER DUO 08/20/07

5-36

RECOVERY TANK HANDLE - DELUXE

5-37

86292490 VOYAGER DUO 04/03/08

RECOVERY TANK HANDLE - DELUXE

REF PART NO. PRV NO. QTY DESCRIPTION

1 86224770 739989 1 SPRING, TORSION

2 86279170 87093 1 WASHER, #10 X 1.0 FLAT

3 86295160 - 1 GASKET, ACSY PORT COVER

4 86010650 87018 3 WASHER, #10 X 9/16 OD

5 86290850 - 1 SCR, M5 X 25 HHMS SS

6 86008650 80604 2 COTTER, 1/4" RING

7 86222620 66891 1 PIN, 5MM DIA X 85MM L

8 86010630 87013 6 WASHER 1/4 ID X 5/8 OD SS

9 86271870 57290 6 NUT, 1/4-20 HEX NYLOCK THIN SS
10 86290950 - 1 ASSEMBLY, BRKT, FRONT, LEFT
11 86002400 20064 2 CLAMP, 2.0” WRM GEAR X .312W
12 86297600 - 1 HOSE ASM, 1.5 BLK VAC X 6.5
13 86290730 - 2 LATCH, FRONT COVER
14 86226740 73215 4 SPACER, 3/8 X .265 X 1/4 NYL
15 86277640 70893 4 SCR, 1/4-20 X 3/4 MS SS
16 86293920 - 1 BRKT, PRIMER SWITCH
17 86295720 - 1 LABEL, PRIMING
18 86010670 87029 3 WASHER, 5/16 FLAT SS
19 86276490 70670 3 SCR, 5/16-18 X 5/8 HHCS SS
20 86007210 72165 1 SWITCH, DPDT 3-PSTN ROCKER
21 86270990 57090 2 NUT, 10-32 HEX NYLOCK SS
22 86295830 - 1 HOSE, 1/4ID NYLOBRAID X 41”
23 86002400 20064 1 CLAMP, 2.0” WORM GEARX.312W
24 86197520 40011 1 HOSEBARB, 1/8MPT X 1/4 DL
25 86217270 22110 1 COUPLER, ACC PORT VACUUM
26 86278910 87003 1 WASHER, 3/8 ID X 7/8 OD SS
27 86200820 270-11A 1 NIPPLE, 1/8FPT QD MALE BRASS
28 86294880 - 1 BRKT, ACC PORT COVER
29 86291740 - 1 ASSEMBLY, BRKT, FRONT, RIGHT
30 86275470 70484 2 SCR, 10-32 X 5/8 PPHMS SS
31 86010800 87189 2 WASHER, M8 SPLIT LOCK
32 86276290 70626 2 SCR, #10X3/4 PPHST HI-LO BLK
33 86217470 270800 1 COVER, ACCESSORY PORT
34 86005580 56012 1 NIPPLE, 1/4 FPT QD *(1,2,3,4)
35 86197300 14079 1 BUSHING, 1/8 FPT X 1/4 MPT HEX *(1,2,3,4)
36 86247720 56032 1 NIPPLE, 1/8 CLOSE *(1,2,3,4)
37 86200810 270-11 1 NIPPLE, 1/8 FPT QD FEM BRASS *(1,2,3,4)

* SEE SERIAL NUMBER PAGE.

SERIAL NO.

FROM

NOTES:

86292490 VOYAGER DUO 04/03/08

5-38

SOLUTION – CHEMICAL TANKS - DELUXE

2

12

1

13

11

10

9

8

3

4

5

6

7

14

86292490 VOYAGER DUO 08/20/07

5-39

SOLUTION – CHEMICAL TANKS - DELUXE

REF PART NO. PRV NO. QTY DESCRIPTION

1 86295330 - 1 CAP, DISPENSING, 9.50 TUBE

2 86295280 - 2 CAP, STORAGE

3 86295310 - 1 CAP, DISPENSING, 6.50 TUBE

4 86236590 34448 2 FOOT FILTER

5 86088710 75495 1 TANK, EXTRACT CHEMICAL

6 86274400 70194 4 SCR, 1/4-20 X 5/8 BHCS

7 86294870 - 1 BRKT, CHEMICAL TANKS

8 86012760 - 1 STRAINER, 1/2 FPT, 80 MESH

9 86001530 40039 2 HOSEBARB, 1/2MPTX1/2 HOSE 90
10 86297610 - 1 HOSEBARB, 1/4MPTX1/4 90D NYL
11 86233090 20016 1 CLAMP, 1/4 HOSE
12 86088690 75494 1 TANK, INTERIM CHEMICAL
13 86295710 - 1 LABEL, CHEMICAL TANKS

SERIAL NO.

FROM

NOTES:

86292490 VOYAGER DUO 08/20/07

5-40

SOLUTION PUMP

25

27

18

20

25

13

12

11

10

24

13

18

19

20

24

14

7

24

11

12

1

26

2

7

8

9

10

15

16

17

24

25

24

3

5

6

24

4

28

29

30

31

24

DELUXE PUMP

7

23

9

21

22

5-41

BASIC PUMP

86292490 VOYAGER DUO 01/22/09

SOLUTION PUMP

REF PART NO. PRV NO. QTY DESCRIPTION

1 86006580 70085 1 SCR, 1/4-20 X 1/2 PPHMS SS DL

2 86292230 - 1 COVER, PUMP

3 86012690 - 1 BRKT, PUMP MTG

4 86240500 40095 1 HOSEBARB, 1/4MPT X 3/8 90D NYL

5 86010670 87029 2 WASHER, 5/16 FLAT SS

6 86276490 70670 2 SCR, 5/16-18 X 5/8 HHCS SS

7 86001530 40039 3 HOSEBARB, 1/2MPT X 1/2 HOSE 90

8 86012760 - 1 STRAINER, 1/2 FPT, 80 MESH

- 86005870 59021 - O-RING, FILTER SEAL RON-VIK

- 86136800 73839 - SCREEN, 100 MESH STRAINER DEEP

9 86197940 40027 1 HOSEBARB, 3/8MPTX1/2 90D DL
10 86250920 65142 1 PUMP, 36VDC 100PSI
11 86010650 87018 4 WASHER, #10 X 9/16 OD
12 86270990 57090 4 NUT, 10-32 HEX NYLOCK SS
13 86197290 14076 1 BUSHING, 3/8 MPT X 1/4 FPT HEX
14 86200820 270-11A 1 NIPPLE, 1/8NPT QD MALE BRASS
15 86247720 56032 1 NIPPLE, 1/8 CLOSE
16 86197300 14079 1 BUSHING, 1/8 FPT X 1/4 MPT HEX
17 86290000 - 1 VALVE, BYPASS, 125 PSI ADJ
18 86197730 78024 1 TEE, 1/4 BRANCH
19 86197760 78308 1 TEE, 1/4 STREET
20 86197500 40009 1 HOSEBARB, 1/4MPT X 1/4 DL
21 86197980 40055 1 HOSEBARB, 1/2 MPT X 1.0 90D NU
22 86282050 39562 1 HOSE, 1.0 ID X 1/8W X 21 CLR
23 86233110 20018 1 CLAMP, 1.0” WORM GEAR
24 86233150 20042 6 CLAMP, 3/8 HOSE (D-SLOT)
25 86233090 20016 1 CLAMP, 1/4 ID HOSE
26 86010630 87013 1 WASHER, 1/4 ID X 5/8 OD SS
27 86240360 40065 1 HOSEBARB, 1/4 MPT X 1/4 9D DL
28 86005580 56012 1 NIPPLE, 1/4 FPT QD *(1,2,3,4)
29 86197300 14079 1 BUSHING, 1/8 FPT X 1/4 MPT HEX *(1,2,3,4)
30 86247720 56032 1 NIPPLE, 1/8 CLOSE *(1,2,3,4)
31 86200810 270-11 1 NIPPLE, 1/8 FPT QD FEM BRASS *(1,2,3,4)

* SEE SERIAL NUMBER PAGE.

SERIAL NO.

FROM

NOTES:

86292490 VOYAGER DUO 10/08/08

5-42

SOLUTION – CHEMICAL PUMP - DELUXE

1

2

4

3

12

5

13

-B-

11

10

-A-

15

-B-

8

16

9

-C-

17

13

-C-

6

-A-

14

9

7

5-43

86292490 VOYAGER DUO 10/20/07

SOLUTION – CHEMICAL PUMP – DELUXE

REF PART NO. PRV NO. QTY DESCRIPTION

1 86010670 87029 2 WASHER, 5/16 FLAT SS

2 86276490 70670 2 SCR, 5/16-18 X 5/8 HHCS SS

3 86295370 - 1 CLAMP, 1-1/4 P CUSHIONED

4 86270830 57023 1 NUT, 5/16-18 HEX NYLOCK SS

5 86293710 - 1 PUMP, CHEMICAL, 85 PSI

6 86274290 70162 2 SCR, 10-32 X 3/8 PPHMS SS

7 86293970 - 1 BRKT, COVER

8 86006520 70052 2 SCR, 8-32 X 3/8 PPHMS SS

9 86295810 - 2 HOSEBARB, 1/8 MPT X 1/8
10 86293720 - 1 VALVE, 3-WAY, 36 VDC
11 86295290 - 1 ELBOW, SWVL, 6MM QC X 1/8 MPT
12 86294280 - 1 BRKT, CHEMICAL PUMP
13 86297460 - 4 CLAMP, 1/4” NYLON RATCHET
14 86298040 - 1 FILTER, INLINE, 1/8 HOSE BARB
15 86264860 05153 1 ANCHOR, CABLE TIE #8 MOUNT
16 86238490 81388 1 GROMMET 3/8 ID X 1/8 GROOVE
17 86197400 31022 1 ELBOW, 1/8 NPT STREET

SERIAL NO.

FROM

NOTES:

86292490 VOYAGER DUO 10/20/07

5-44

SOLUTION – CHEMICAL VALVES - DELUXE

11

10

12

-A-

1

2

3

4

5

-A-

8

6

5-45

9

8

7

86292490 VOYAGER DUO 08/20/07

SOLUTION - CHEMICAL VALVES - DELUXE

REF PART NO. PRV NO. QTY DESCRIPTION

1 86273980 70066 4 SCR, 10-32 X 3/4 PPHMS SS

2 86010650 87018 8 WASHER, #10 X 9/16 OD

3 86293950 - 1 SWITCH, PRESSURE

4 86295650 - 1 CROSS, 1/8 NPT

5 86013030 - 2 VALVE, 36VDC SOLENOID, 1/8FPT

6 86197750 78161 2 TEE, 1/8 NPT STREET RUN

7 86006520 70052 4 SCR, 8-32 X 3/8 PPHMS SS

8 86247720 56032 2 NIPPLE, 1/8 CLOSE

9 86295250 - 1 BRKT SOLUTION BYPASS
10 86295550 - 1 ORIFICE, SOLUTION BYPASS
11 86240610 44104 5 HOSEBARB, 1/8MPT X 1/4H 90D
12 86233090 20016 5 CLAMP, 1/4 ID HOSE

SERIAL NO.

FROM

NOTES:

86292490 VOYAGER DUO 08/20/07

5-46

SOLUTION TANK

11

5

6

27

7

8

4

3

2

3

10

11

13

9

16

16

25

23

12

11

19

31

13

1

24

23

18

22

13

23

19

19

20

30

17

11

21

26

5-47

15

13

14

16

28

31

11

27

13

11

86292490 VOYAGER DUO 04/11/08

21

23

26

29

DELUXE

SOLUTION TANK

REF PART NO. PRV NO. QTY DESCRIPTION

1 86011820 - 1 GASKET, INLET CAP

2 86011810 - 1 RETAINER, INLET CAP

3 86290370 - 2 WASHER D, .346 ID X .105T

4 86276760 70724 1 SCR, 5/16-18 X 1.25 BSHCS SS

5 86006860 70403 2 SCR, #10 X 1/2 PPHST TYPE B SS

6 86010650 87018 2 WASHER, #10 X 9/16 OD

7 86290830 - 1 SCR, 5/16-18 X 1.25 SHCS SS

8 86238460 36259 1 HOOK, STRAP

9 86292760 - 1 TANK, SOLUTION
10 86011400 - 1 BRKT, SOLUTION HINGE
11 86010670 87029 12 WASHER, 5/16 FLAT SS
12 86013700 - 1 WELDMENT, LIFT SIDE
13 86276490 70670 12 SCR, 5/16-18 X 5/8 HHCS SS
14 86276070 70593 2 SCR, 5/16-18 X 3/4 CARRIAGE SS
15 86239630 41429 1 HINGE, COVER TO TANK
16 86270830 57023 9 NUT, 5/16-18 HEX NYLOCK SS
17 86006560 70083 1 SCR, 5/16-18 X 1 HHCS SS NP
18 86259420 87232 1 WASHER, THRUST .51IDX1ODBR
19 86259410 87206 2 WASHER, THRUST.51IDX1ODX.063
20 86290190 - 1 BRKT, PROP ROD CATCH
21 86271840 57285 1 NUT, 5/16-18 HEX NYLOCK THN SS
22 86259910 89265 1 WHEEL, BATTERY TRAY
23 86228990 09153 2 BEARING, FLNGD, .314D X .502D
24 86274720 70264 1 SCR, 5/16-18 X 1.5 HHCS SS
25 86276380 70639 2 SCR, 5/16-18 X 1.25 SSSCU
26 86011630 - 1 PLATE, PROP ROD
27 86217540 279994 1 COVER, SOLUTION TANK
28 86007020 70673 1 SCR, 5/16-18 X 1.25 HHCS SS NP
29 86295730 - 1 BRKT, PROP ROD CATCH
30 86293700 - 1 SPACER, .75 X .322 ID X .38L
31 86197040 57264 1 NUT, 5/16-18 HEX ACORN PLTD

SERIAL NO.

FROM

NOTES:

86292490 VOYAGER DUO 04/11/08

5-48

SPRAY JETS

15

14

1

2

4

8

13

12

11

3

-B­5

-A-

-A-

6

7

8

-B-

5-49

10

9

86292490 VOYAGER DUO 08/20/07

SPRAY JETS

REF PART NO. PRV NO. QTY DESCRIPTION

1 86197640 40064 4 HOSEBARB, 1/8” FPT X 1/4"
2 86233090 20016 6 CLAMP, 1/4 ID HOSE
3 86227200 04007 1 ADPTR 1/8MPTX1/8FPT BS AD
4 86197750 78161 2 TEE, 1/8 NPT STREET RUN
5 86240610 44104 2 HOSEBARB, 1/8MPT X 1/4H 90D
6 86013200 - 2 JET, MINI PROMAX 11004
7 86012550 - 2 JET, PROMAX, 11001
8 86270830 57023 4 NUT, 5/16-18 HEX NYLOCK SS

9 86276070 70593 2 SCR, 5/16-18 X 3/4 CARRIAGE SS
10 86295590 - 1 PLATE, BUMPER
11 86091870 141017 1 BRKT, JET, DUAL
12 86004570 44067 4 JET BODY, MINI PROMAX BODY
13 86010670 87029 2 WASHER, 5/16 FLAT SS
14 86010820 87192 4 WASHER, 7/16 X 3/4 X .19 RBR
15 86197400 31022 2 ELBOW, 1/8NPT STREET

SERIAL NO.

FROM

NOTES:

86292490 VOYAGER DUO 08/20/07

5-50

SPRAY JET VALVES - BASIC

5-51

86292490 VOYAGER DUO 08/20/07

SPRAY JETS VALVES - BASIC

REF PART NO. PRV NO. QTY DESCRIPTION

1 86270830 57023 2 NUT, 5/16-18 HEX NYLOCK SS

2 86010670 87029 2 WASHER, 5/16 FLAT SS

3 86014250 - 1 ORIFICE, .052 ID, .281 OD

4 86197520 40011 3 HOSEBARB, 1/8MPT X 1/4 DL

5 86013030 - 2 VALVE, 36VDC SOLENOID, 1/8 FPT

6 86197400 31022 1 ELBOW, 1/8NPT STREET

7 86247720 56032 1 NIPPLE, 1/8 CLOSE

8 86197750 78161 1 TEE, 1/8 NPT STREET RUN

9 86013070 - 1 BRACKET, DUO VALVE MOUNT
10 86006520 70052 4 SCR, 8-32 X 3/8 PPHMS SS
11 86233090 20016 3 CLAMP, 1/4 ID HOSE

SERIAL NO.

FROM

NOTES:

86292490 VOYAGER DUO 08/20/07

5-52

SPRAY JET VALVES - DELUXE

10

1

3

2

4

6

7

11

5

12

8

14

13

3

10

6

10

9

5

15

5-53

86292490 VOYAGER DUO 08/20/07