NSS WARHORSE User manual

OPERATION MANUAL
WARHORSE
IMPORTANT SAFETY INSTRUCTIONS
WARNING: Failure to observe these instructions can cause
personal injury to machine operator or bystanders.
WARNING: Asphyxiation Hazard. An
improperly maintained engine can produce
excessive levels of carbon monoxide.
Excessive levels of carbon monoxide can
make you sick or cause death. NEVER
operate machine in an area less than 5,000
square feet for more than 15 minutes unless
there is adequate ventilation.
WARNING: Fire or explosion hazard.
NEVER use with flammable or
combustible materials, such as gasoline,
kerosene, or other fuels or volatile
solvents to clean floor.
NEVER operate this machine in an
explosive atmosphere.
INTENDED USE
This machine is intended for commercial use,
burnishing floors in an indoor, well-ventilated
environment. NSS does not recommend using this
machine for any other purpose.
FOR SAFETY:
• ALWAYS read and understand all instructions before
operating or servicing machine.
• ALWAYS use this machine ONLY as described in this
manual.
• NEVER attempt to operate this machine unless you
have been trained in its operation.
• NEVER allow an untrained person to operate machine.
• NEVER attempt to operate this machine if it is not
working properly or has been damaged in any manner.
• NEVER let go of the handles when the machine is
operating.
• NEVER disconnect or modify any switches or safety
devices.
• NEVER service machine near fire or flame.
• NEVER operate this machine with any air opening
blocked. Keep all air openings free of dust, lint, hair, etc.
• NEVER allow this machine to be used as a toy. Close
attention is necessary when used by or near children.
• ALWAYS keep face, fingers, hair or any other body
part or loose clothing away from any machine
opening or moving part (revolving pad & pad driver).
• ALWAYS use extreme caution when operating the
machine on a ramp or loading/unloading this machine
into or out of a truck/trailer. Use extreme caution if the
ramp is wet, oily, or covered with cleaning chemicals.
• ALWAYS turn the machine off when attaching pads.
• ALWAYS be sure that the ramp is secured to the
vehicle before attempting to load/unload.
• NEVER stop or turn the machine on a ramp or incline.
• NEVER attempt to climb a grade or operate this
machine on a ramp or incline of more than 8 degrees.
• NEVER park or store the machine near a dock, on
ramps, near a furnace, boiler, open flame, or other
high heat source.
• NEVER expose the machine to rain, snow, or
extreme temperatures.
• NEVER store any items on this machine.
• ALWAYS store this machine indoors in a dry, cool
area.
• ALWAYS store or transport LP fuel tank in the
upright position.
• ALWAYS use only tank and connections provided
with the Warhorse. This tank is fitted only for vapor
withdrawal, not liquid. It has safety features (check
valves, etc.) that are not found in tanks regularly
found in an LP supplier’s yard.
• NEVER fill tank with any fuels other than propane
HD-5 Spec. carburetor grade. Do not use blends or
butane.
• ALWAYS have a qualified LP dealer fill the tank.
The dealer can be found in the yellow pages under
“Gas Liquefied Petroleum”.
• NEVER store propane tank where unauthorized
personnel may tamper with it.
• NEVER alter or change the fuel system as incorrect
fuel mixture or gas leakage may result.
• ALWAYS check fuel system components and hoses
for leaks before operating.
• NEVER tip the engine on either side. Engine oil can
enter the air cleaner and cause the engine to run rich
and shut down.
• ALWAYS allow the engine time to cool before
performing any maintenance as hot parts can cause
severe burns.
ALL REPAIR SERVICE MUST BE PERFORMED BY AN NSS AUTHORIZED DISTRIBUTOR/
SERVICE STATION USING ONLY NSS ORIGINAL EQUIPMENT PARTS.
SAVE THESE INSTRUCTIONS
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MACHINE INSPECTION
• Carefully unpack the Warhorse and recycle all
packing materials.
• Inspect machine for damage or missing components.
If damage is found, contact the local freight company
to file a freight claim.
MACHINE COMPONENTS
Engine
The Warhorse is equipped with an engine specially
manufactured to use LP (propane) gas as the fuel
source. The engine manufacturer and size
(displacement) may vary. Observe the name on the
engine and refer to the manual provided with this
machine by the engine manufacturer.
Fuel Tank
The Warhorse is equipped with a “vapor” withdrawal
type fuel tank with a fuel gauge. It is referred to as a 20
lb. (9Kg.) tank. Empty and full weights are stamped on
the side of the tank. Do not use other tanks.
Solenoid Valve and Pressure Regulator
The solenoid valve is an electrical control that stops the
flow of LP (propane) gas when the key switch is turned
off. The pressure regulator controls the amount and
pressure of the LP (propane) gas flowing to the engine.
This regulator is preset by the engine manufacturer and
is not adjustable.
Battery
The Warhorse is equipped with a 12 volt “gel” starting
battery that requires no water additions. The charge is
maintained by the built-in engine charging system.
Pad Driver System
The Warhorse 27 flexible pad driver is powered by a
dual “V” belt and pulley system. The Warhorse 20/21
flexible pad driver is powered by a single “V” belt and
pulley system. A centrifugal clutch transfers the power
of the engine to the belt and pulley system. The clutch
is not engaged when the engine is at idle speed.
Pad Driver
The Warhorse is equipped with a flexible pad driver with
a spring clip pad holder. Use approved hair or synthetic
type pads in sizes 20 in.(51 cm), 21 in.(53 cm), or 27 in.
(69 cm). Consult your local NSS authorized distributor
for more complete pad application advice.
Units with Dust Control System
Weekly, check vac hose connections at the Flexiwall
Shield and cloth filter bag. When the filter bag is more
than one-half (1/2) full, empty, shake out, then replace
back in the machine. Inspect Flexiwall Shield for dents,
cracks, and wear. A damaged Flexiwall Shield will
greatly reduce the burnishing and dust control
capabilities. Dirt build up on the brush should be
removed.
Control Handles
The Warhorse has two (2) bicycle type handles for
the operator to control the direction of the machine.
Dead-man Safety Lever
There is a “dead-man” safety lever next to each
control handle. These levers control the speed of the
engine during operation. When the operator releases
these levers, they return the engine to idle speed.
This allows the clutch to “idle” and the pad driver
stops rotating. Always operate at full speed to have
maximum power and engine cooling.
Key Switch and indicator Light
Below the control handle is the key switch that turns
the engine on and off. This machine is equipped with
a 12 volt electric starter. There is an indicator light
next to the key switch. The light is ON whenever the
key switch is turned ON. If you leave the key switch
turned ON for an extended length of time, the battery
will go dead.
Hour Meter
On the right side of the chassis is the hour meter.
This meter records the time (hours) that the motor is
running. This time record is very critical to the
performance of scheduled maintenance procedures.
Do not attempt to modify or disconnect this meter.
Emissions Sensor
The Warhorse is equipped with an emissions sensor.
It measures the level of certain emissions in the
engine exhaust. The monitor and warning levels are
preset by the manufacturer.
• If emissions in the exhaust gasses approach the
preset safe levels, the sensor light will signal a
warning to the operator to turn off the engine and
service the machine.
• If the operator continues to run the machine in this
condition, the sensor will shut down the engine.
• If the engine is shut down due to improper
emissions levels:
• Turn the key switch off, close the tank valve
and take the machine outside.
• Open doors and windows to increase the fresh
air oxygen (O2) and reduce carbon monoxide
(CO) levels in the building. Check oil level,
clean top precleaner, and air filter (refer to
maintenance chart). Contact your local NSS
authorized distributor or engine service center
for assistance.
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Carbon Monoxide (CO)
Various levels of carbon monoxide are present in the
exhaust gases of all internal combustion engines.
Carbon monoxide is an odorless, colorless and
tasteless gas.
WARNING: An improperly maintained engine can
produce excessive levels of carbon monoxide.
Excessive levels of carbon monoxide can make you
sick or cause death.
INITIAL MACHINE SET-UP
Engine
The Warhorse engine is shipped with oil in the engine
crankcase. Always check the oil level before you start
the engine. Use 10w30 or 15w40 motor oil with an API
designation of SG. The valve and hose clamp under the
engine must be closed securely or oil will leak out of the
engine. Refer to the manual provided by the engine
manufacturer.
Fuel Tank
The Warhorse fuel tank is shipped empty. New tanks
must be purged by an authorized LP (propane) gas
distributor before use.
• Keep tank upright at all times. Do not overfill tank.
• The fuel tank must be filled with the proper type (HD-
5) and amount of LP (propane) gas. Refer to the
operators manual provided by the engine
manufacturer.
• The hose connection from the pressure regulator to
the fuel tank fitting must be tight.
• Do not damage threads by overtightening or cross
threading.
• The fuel tank must be securely attached to the
machine by the clamp during operation.
• Always turn the key switch to OFF then shut the valve
on the propane tank to turn the machine off.
• Always remove the fuel tank from the machine and
place tank outside in an upright position in a secure,
tamper-proof, steel mesh storage cabinet. Check with
your local fire marshal.
DAILY USE
Burnishing Methods
The Warhorse is designed to dry burnish or to spray
buff (non-Vac-Trac models only) a hard surface floor.
Each procedure may be performed with a 20 in. (51
cm), 21 in. (53 cm), or 27 in. (69 cm) hair type or
synthetic type pad. Consult your local NSS authorized
distributor for more complete chemical/pad application
advice.
Burnishing Path
The Warhorse pad driver extends past the frame of
the machine. This extension allows burnishing the
edge of the floor near obstructed areas (walls or
shelving).
• Sweep and dust mop the floor to remove dirt and
debris before burnishing. Accumulations of dirt or
debris on the floor will reduce machine
performance.
• Some spills or stains may need to be precleaned
before burnishing. Consult your local NSS
authorized distributor for procedures and more
complete chemical advice.
Daily Preparation
• Inspect machine for damage, loose or missing
parts.
• Check oil level in crankcase.
• Clean air precleaner on top of engine and air
cleaner filter.
• Remove fuel tank from locked storage container
and bring to machine. Install tank in position and
secure with clamp.
• The hose connection from the pressure regulator to
the fuel tank must be tight.
• Note: Do not damage threads by over tightening or
cross threading.
• Tilt machine back to rest on small wheels to obtain
access to pad driver.
• If necessary change or install new pad on pad
driver. Secure pad with pad holding cup.
WORK COMPLETION
• Always turn OFF key-switch then shut the valve on
the propane tank.
• Remove the key when work has been completed or
if machine is left unattended at any time.
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MANDATORY PERIODIC
MAINTENANCE
It is important for you to maintain a record of the
amount of machine operating hours in order to perform
this machine maintenance. The maintenance
procedures shown in the chart on the following page
must be performed at the designated intervals. Failure
to perform maintenance procedures will result in poor
machine performance, component damage and may
void the warranty. We recommend the service
procedures be performed by an NSS authorized service
center or the authorized service center for the engine
manufacturer.
Always turn the key switch OFF, shut tank valve,
and remove key before performing any
maintenance.
Authorized Repair Service
Repair service for this machine must be performed by
an NSS authorized service center or the authorized
service center for the engine manufacturer. Repairs
performed by any unauthorized company will void the
machine and engine warranty. If you require assistance
finding an authorized service center, please contact
NSS Enterprises.
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PERIODIC MACHINE MAINTENANCE SCHEDULE
MAINTENANCE FREQUENCY
MAINTENANCE
OPERATION
Break
in
after
first
25
hours
Every
day or
every
8
hours
Every
50
hours Every month
Every
100
hours
Every
200
hours
Every
500
hours
Every
1,000
hours
Inspect machine (engine, pad,
pad driver, etc.) z1
Check oil level z
Clean air precleaner (top) z2
Clean air cleaner foam
wrapper z2
Clean cylinder cooling fins z
Change engine oil and oil
filter. zz
Lubricate wheels and pad
driver bearings zz
Check starting battery
connections z
Replace air cleaner element
and foam wrapper
z2
Adjust engine valve clearance z3z3
Clean spark arrestor z4
z4
Replace LPG filter z3
Clean duty solenoid (20” & 21”
models only)
z3
Replace spark plugs z
Replace oxygen sensor
z3
Replace catalytic muffler (27”
model only) z3
Clean cylinder heads
z3
Replace duty solenoid (20” &
21” models only) z3
1. Check for oil, fuel, and exhaust leaks, loose parts and unusual noises and vibrations.
2. Do not oil filters.
3. Must be performed by a qualified mechanic according to the engine Service Manual.
4. Remove and clean — take machine outside and operate 15 minutes to expel buildup — replace.
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TROUBLESHOOTING
PROBLEM CORRECTIVE ACTION
1. The engine
fails to crank. a. Clean and tighten the positive (+) and negative (-) battery cable connections at the battery and at the engine.
b. Recharge the battery. Refer to the equipment or battery manufacturer’s
recommendations
2. The engine
cranks slowly. a. Clean and tighten the positive (+) and negative (-) cable connections at the battery and at the engine.
b. Recharge the battery. Refer to the equipment or battery manufacturer’s
recommendations.
c. Chang engine oil to oil having the proper viscosity for the ambient
temperature.
3. The engine
cranks but
fails to start.
a. Fill the LPG container if low on fuel, or if over-filled, return to filling
station for adjustment.
b. Check, and if necessary, reconnect the fuel line to the vapor-withdrawal
fitting on the LPG container.
c. Slowly open any closed fuel shut-off valves.
d. Service the air cleaner. Do not soak with oil!
e. Clean the cooling air precleaner (top).
f. Check to make sure the spark plug cable is on tight.
g. Replace the spark plug.
h. Check the oil level and add oil if necessary.
i. Check both ends of the vacuum hose to make sure it is on tight.
j. Reconnect any loose wiring.
k. Make sure the proper type of LPG container is being used. The
container must have a vapor-withdrawal fitting to supply the engine.
4. The engine
runs and then
stops.
a. Check the LPG container and fill as necessary. On cold days, the LPG
container may have to be kept at least half-full to provide the rate of
vaporization necessary to keep up with the engine fuel demand.
b. Check, and if necessary, reconnect the fuel line to the vapor-withdrawal
fitting on the LPG container.
c. Check the engine oil level and add oil as necessary. Drain excess oil if
the level is above the dipstick Full mark.
d. Clean spark arrestor.
5. The engine
lacks power. a. Service the air cleaner.
b. Check the LPG container and fill as necessary. On cold days, the LPG
container may have to be kept at least half-full to provide the rate of
vaporization necessary to keep up with the engine fuel demand.
c. Clean the spark arrestor.
6. The engine
exhausts
black smoke.
a. Service the air cleaner
7. The engine
misfires. a. Replace the spark plugs. Check connections.
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NOTES:
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NSS®Enterprises, Inc.
3115 Frenchmens Road, Toledo, Ohio 43607
PHONE [phone] FAX [phone]
NSS ® Enterprises, Inc. European Distribution Centre
Unit II, Pinfold Trading Estate * 55 Nottingham Road
STAPLEFORD, NOTTINGHAM NG9 8AD ENGLAND U.K.
PHONE: [phone] * FAX: [phone]
Warhorse 20/21/27 Orig. 3/98 Rev A 08/02 9096502
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