Windsor Lightning Battery Burnisher 10027100 User's Manual
Contents
1. 3 Check the other points indicated in the diagram above The high end should trip the circuit breaker Replace the pad pressure meter if the approximate amp ranges shown cannot be set SHAFT ADJUSTMENT If shaft is replaced make sure it is adjusted correctly upon installation This pad pressure meter adjustment is factory set Over the course of time it may become necessary to adjust this setting using the slotted connection on the shunt Slotted Connection From Meter To Meter Moves needle NOTE See wiring diagram for lead connections 4 2ENG 86038450 04 12 07 LUBRICATION amp SERVICE SCHEDULE The following symbols found throughout the manual indicate items requiring lubrication f APPLY GREASE a USE SPRAY LUBRICANT I USE ANTI SEIZE WHEN REPAIRING KA PERMANENT RED K THREAD LOCK TIGHT AXLE GREASING 1 2 STROKES OF MOBILTEMP 78 OR COMPATIBLE CLAY BASED OR CALCIUM BASED GREASE CAUTION Do not use pressure washers to clean sealed gear boxes or bearings If it becomes necessary to clean under machine with a pressure washer Ensure all items noted are re lubricated SERVICE SCHEDULE MAINTENANCE DAILY MONTHLY Check batteries after charging add water if necessary y Check pad wear to prevent buildup of chemicals Check pad driver system for damage Check bag filter2. 07 2 1ENG 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 A WARNING WARNING Hazards or unsafe practices which COULD result in severe personal injury or death A CAUTION CAUTION Hazards or unsafe practices which could result in minor personal injury or product or property damage FOR SAFETY To Identify actions which must be followed for safe operation of equipment Report machine damage or faulty operation immediately Do not use the machine if it is not in proper operating condition Following is information that signals some potentially dangerous conditions to the operator or the equipment Read this information carefully Know when these conditions can exist Locate all safety devices on the machine Please take the necessary steps to train the machine operating personnel FOR SAFETY DO NOT OPERATE MACHINE Unless Trained and Authorized Unless Operation Guide is Read and understood In Flammable or Explosive areas In areas with possible falling objects WHEN SERVICING MACHINE Avoid moving parts Do not wear loose clothing jackets shirts or sleeves when working on the machine Use Windsor approved replacement parts A WARNING Batteries emit hydrog
3. z Check handles switches and knobs for damage Store with pad off the floor hi Check batteries for corrosion cracks and evidence of overheating Check all bearings for noise Check skirt bumpers for damage and replace as necessary Grease wheels and casters if appropriate Check potentiometer speed control for adjustment Check overall performance of machine 86038450 04 12 07 4 3ENG MACHINE TROUBLESHOOTING PROBLEM CAUSE SOLUTION No power to machine Poor Cable Connection Clean battery cable clamps of any corrosion and tighten Test voltage at points G to B should be from 34 to 38 VDC Faulty Main Power Switch With the main power switch turned on test voltage at points D to B should be from 34 to 38 VDC Ifthere is no voltage remove leads and check switch for continuity Replace if necessary Pad motor won t run Circuit breaker has tripped Reset circuit breaker H Actuator Safety Switch With main power on pad lowered to floor switch bar pulled up test voltage at L wire 2 to B rear panel should be 34 to 38 VDC If not check and adjust or replace safety switch as necessary Faulty Relay With main power on pad lowered to floor and drive handle squeezed Test voltage at points F to B and A to B should be from 34 to 38 VDC When the relay is working it should make a clicking noise as the drive handle is
4. 6 7 4 1 2 3 4 5 Use a hydrometer to check the condition of each battery cell Check battery cable clamps Ensure clamps are tight on battery terminals Clean tops of batteries with a wet cloth and a solution of water and baking soda Wipe battery tops dry after cleaning Check pad lock for looseness or damage Check filter and filter seals Airflow should be unobstructed through filter Ensure that the pivot points and casters are properly lubricated Tighten any loose screws or nuts TO 6 MONTH MAINTENANCE Remove batteries clean battery tray and battery compartment Clean battery cable clamps and battery terminals Check the carbon motor brushes in the pad driver motor Use a vacuum to remove lint or dust build up from motor windings Grease axles AT THE END OF EACH WORK PERIOD BONN Wipe down the exterior of the machine Lower the deck Open the cover Charge the batteries See battery charging procedure on page 4 1 SHUNT ADJUSTMENT SHUNT ADJUSTMENT Cont Check the amp range when nuisance tripping of the circuit breaker indicates that the shunt may be out of adjustment Approx AMP RANGE 60 1 Connect a DC ampere meter to the positive battery lead Running the machine with a pad lower the pad to the floor until it is operating at 55 60 amps 2 Moving the wire in the slot adjust the pad pressure meter until the needle sets at the line between the green and red areas
5. LIGHTNING BATTERY POWERED HIGH SPEED BURNISHER Operating Instructions ENG Bedienungsanleitung GER MODEL L20 10027100 L20T 10027110 QUES l for Continuous Improvement Windsor s Quality Management System is Certified ISO 9001 Read these instructions before operating the machine Bitte lesen Sie diese Anleitungen bevor Sie die Maschine in Gebrauch nehmen 86038450 AV 10 20 08 PRV NO 98753 MACHINE DATA LOG MODEL DATE OF PURCHASE SERIAL NUMBER SALES REPRESENTATIVE Copvriaht 1995 Windsor Industries Printed in USA YOUR DEALER Name Address Phone Number 2ENG 86038450 04 12 07 Machine Data Log 00 222200nn nennen 2 Table of Contents 2222n nase nennnnnnnnnn 3 HOW TO USE THIS MANUAL How to use this Manual 1 1 SAFETY Important Safety Instructions nn 2 1 Hazard Intensity Level 2 2 OPERATIONS Component Controls 0 2 ccccccccsstessseeessneetseneeees 3 1 Machine Operation csccccccccsececesssssseeeseeesnnens 3 2 Pre Run Machine Inspection 3 2 Operating the Machine n 3 2 Filter Bad uns nu 3 2 Dust Control Skirt 20unn nennen 3 2 MAINTENANCE Battery Information 200042 nr rnnenneennnnn 4 1 Battery Connection unnennenennn 4 1 Battery Maintenance 22000 nn 4 1 Battery Ch
6. T SMOKE HAVE OPEN FLAMES OR SPARKS NEAR BATTERIES AT ANY TIME WEAR EYE PROTECTION AND PROTECTIVE CLOTHING WHEN WORKING WITH BATTERIES 86038450 04 12 07 BATTERY INFORMATION CHARGE BATTERIES IN A WELL VENTILATED AREA WITH DECK DOWN AND COVER OPEN 1 Use a 36 volt 20 amp maximum output D C charger that turns itself off when batteries are fully charged The charger must have a connector that matches the machine battery connection 2 Read the instructions and warnings provided by the battery charger manufacturer 3 Set the charger in a well ventilated area on a level surface Make sure cords will easily reach outlets on both machine and wall 4 Connect charger to D C outlet on machine first 5 Connect the A C power cord to properly grounded wall socket NEVER MAKE THE A C CONNECTION FIRST HAZARDOUS SPARKS MAY RESULT 6 After the batteries are completely charged disconnect the charger from the A C wall socket 7 Once the charger is disconnected from the A C wall socket it is safe to disconnect the charger from the machine 8 When the batteries are fully charged check the electrolyte level by removing the caps on top of the batteries If necessary fill the cells with distilled water as shown in the diagram below Be careful not to overfill cells Battery Cap a i Ly 1 vy Full when 1 4 from bottom of tube 4 1ENG MAINTENANCE WEEKLY MAINTENANCE 1 2 3
7. a of the machine DESCRIPTION column is a brief description of the part SERIAL NO FROM column indicates the first machine the part number is applicable to When the machine design has changed this column will indicate serial number of applicable machine The main illustration shows the most current design of the machine The boxed illustrations show older designs 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 NOTE The number on the lower left corner of the front cover is the part number for this manual 04 12 07 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 WIWUVNSN iNew 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 suitab
8. arging Procedure 4 1 Maintenance 244000nnennnennnnsnnnennnnn 4 2 Weekly Maintenance u 2244r nn 4 2 4 to 6 Month Maintenance nn 4 2 Ending Work Periods 22444m een 4 2 Shunt Adjustments 0ns2sur nennen 4 2 Shaft Adjustment 20nsnssnr nennen 4 2 EuBbrication el eb eevee ee eed A ts 4 3 Service Schedule cccesscccesceceeeeesstesseeeeeeeneteess 4 3 Machine Troubleshooting 4 4 TABLE OF CONTENTS GROUP PARTS LIST Chassis Drive Assembly Group 5 1 Deck Lift Mechanism nsnnnnn 5 3 Electrical Controls Group une 5 5 Handle Assembly 22002nnnnsnnnnsenennnnann 5 7 Hood Group m persira nan a a 5 9 Lift Linkage Group 21 cccceccceeeeeeeeeeeseseeesnetetseees 5 11 Wiring Schematic Non traction 5 13 Wiring Schematic Traction 5 15 Suggested Spare Parts nennen 5 18 Notes aeeiiaii adaa SADa 5 19 86038450 04 12 07 3ENG HOW TO USE THIS MANUAL This manual contains the following sections HOWTO 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 dealers When placing an or
9. der for parts the machine model and machine serial number are important Refer to the MACHINE DATA box which is filled out during the installation of your machine The MACHINE DATA box is located on the inside of the front cover of this manual MODEL DATE OF PURCHASE SERIAL NUMBER SALES REPRESENTATIVE Copyright 1995 Windsor Industries Printed in USA The model and serial number of your machine is on the bottom back end of the machine The SAFETY section contains important information regarding hazard or unsafe practices of the machine Levels of hazards is identified that could result in product or personal injury or severe injury resulting in death The OPERATIONS section is to familiarize the operator with the operation and function of the machine The MAINTENANCE section contains preventive maintenance to keep the machine and its components in good working condition They are listed in this general order Batteries Maintenance Shunt Adjustments Shaft Adjustment Lubrication Troubleshooting 1 1ENG 86038450 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 are
10. disconnected at V test the output voltage to the drive motor The output voltage at V should vary from 0 to 36V at R amp S as the control lever is squeezed Resistance of the potentiometer can be tested at the leads 4 amp 1 found at the potentiometer T The resistance should vary from 0 50K ohms Faulty drive control board Voltage at T1 P to T2 N should be from 34 to 38VDC If the voltage at T1 is good but the propel motor won t respond and all the tests above have been done replace the drive control board 4 4ENG 86038450 04 12 07 TROUBLESHOOTING PROBLEM CAUSE SOLUTION Drive controls cont Faulty motor Squeeze the control lever and test the voltage at U wire 27 amp 28 When the output voltage varies with the control lever but the motor does not respond and all the tests above have been done replace the motor Machine will not propel should be 22 to 26 VDC Loose Connection With main power on test voltage at terminal 30 X on Relay should be 34 to 38 VDC With switch on check voltage to wire side of resistor Y Should be 34 to 38 VDC Bad Relay With main power on test voltage at terminal 87 Z should be 34 to 38 VDC Faulty Resistor With main power on test voltage at terminal 85 AA 86038450 04 12 07 4 5ENG
11. en 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 A WARNING 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 WARNING ever allow metal to lie across battery tops 2 2ENG 86038450 04 12 07 COMPONENTS CONTROLS 10 11 12 13 14 Hour Meter Records machine use time Battery Condition Light Indicates the charge condition of batteries Main Power Switch Turns On and Off the machine Pad Pressure Meter Green Area indicates correct pad pressure range Burnishing Head Switch Raises and lowers burnishing head 3 Amp Circuit Breaker Thermal circuit breaker protects lift mechanism Press to reset Main Handle Handle Adjustment Lever Breaker 60 amp magnetic circuit breaker protects pad driver motor Press to reset Pad Motor Switch Bar Raising bar turns on pad driver motor Pad Adjustment Knob Rotating knob adjusts pad pressure Reverse Button Traction model only Propel bar must be squeezed and button pushed for reverse travel Speed Control Traction
12. le 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 exceeding 2 unless the optional parking brake is installed on the machine SAVE THESE INSTRUCTIONS 86038450 04 12
13. model only Knob rotated left to right for slow to fast speed 15 Amp Circuit Breaker Traction model only Protects transaxle 86038450 04 12 07 3 1 ENG MACHINE OPERATION PRE RUN MACHINE INSPECTION FILTER BAG 1 Disconnect the battery charger See battery The filter bag is accessed under the cover charging procedure 2 Close the cover DUST CONTROL SKIRT 3 To raise the deck Turn on the main power Replace skirt 86007290 PRV NO 730017 when switch and press the burnishing head switch worn torn or damaged in any way that allows dust 4 Turn or install a new burnishing pad as needed to escape NOTE Pad lock has left hand threads To loosen turn clockwise Nil fen F Be N Ensure Pad is Centered on Pad Driver Loosen Pad Lock and pull Pad to edge of Pad Driver in several directions 5 Check wheels and other pivot points for proper lubrication OPERATING THE MACHINE 1 If using a machine that is already set up check to make sure the pad is properly installed 2 Adjust the operating control handle to a comfortable position using the handle lock lever 3 Turn on the main power switch 4 Lower or raise deck by pressing burnishing head switch 5 The pad motor will only run when the burnishing head is lowered to within 3 inches of the floor The drive controls are shown on page 3 1 The pad pressure is adjusted using the knob at center of panel The operator monitors the amp draw usi
14. ng the meter located on the control panel and ensures that the needle remains in the green operating range See page 3 1 4 amp 11 To prevent possible damage to the floor surface always keep the machine moving while the pad is spinning No 8 When the pad motor switch bar is squeezed the pad motor runs 9 Return the machine to the battery charger when the battery light indicator light is amber Do not operate machine when indicator is flashing red 3 2ENG 86038450 04 12 07 BATTERY MAINTENANCE 1 When cleaning batteries use a solution of baking soda and water Do not allow cleaning fluid to enter inside battery cells 2 Keep a proper electrolyte level in battery cells 3 Wipe down the battery tops at least once a week Ifa cell should accidentally overflow clean immediately 4 Test battery condition with a hydrometer at least once a week 5 Ensure that all connections are tight and that all corrosion is removed 6 Every 4to 6 months remove batteries from the machine and clean the battery compartment BATTERY CHARGING PROCEDURE Charge the batteries once the amber charge level light comes on The amber light indicates that there is about 20 charge left in the batteries Do not let the batteries completely drain before charging Avoid charging the batteries before the amber light comes on The machine will run for hours on fully charged well maintained batteries AWARNING DO NO
15. squeezed Replace relay if the test voltage F to Bis OK If test voltage F to B is not OK check all wiring to pad motor relay Deck lift mechanism not working Circuit breaker has tripped Reset circuit breaker J Deck switch not working With main switch on test voltage at C 5 to C 2 should be 34 to 38 VDC If not check circuit breaker J and main power switch If the test voltage at C 5 toC 2 is 34 to 38 VDC the voltage at deck switch C 3 to C 6 should be 34 to 38 VDC when the deck switch is pressed to raise lower the pad If not replace deck switch Deck actuator not working If the deck switch tested OK but the deck lift actuator still is not working disconnect the white and black wires to actuator K and apply 36 VDC directly to actuator If the actuator does not respond replace actuator Handle switch not working Check power from E wire 1 to B Check switch continuity Drive Controls Circuit breaker has tripped Check if power at wire 26 If yes but breaker has no power at wire 28 either reset breaker Q or replace Bad switch es Check continuity at handle switch for non traction model Check continuity at propel switch or pad motor switch for traction model Replace as necessary Loose connection Check all connections of propel circuit especially at M N P R S amp T Check transaxle connection at U Faulty potentiometer With the drive motor
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