Windsor VOYAGER 2 User manual

VGR2 98448 02/11/02
DD
MODEL POWER SOURCE
VGR2 BATTERY
Ending with Serial# 1000081027
Read instructions before operating the machine.
Antes de usar la maquina lea atentamente el libro de instrucciones.
Lire attentivement le mode d’emploi avant la mise en service de la machine.
Vor Inbetriebnahme der Maschine Bedienungsanweisung lesen.
Leggere queste istruzioni prima di usare la macchina.
®

MACHINE DATA LOG
VGR2 98448 7/1/97
2
Data Log / Table of Contents...............................2
Technical Specifications ......................................3
Safety Precautions...............................................4
Battery Installation & Removal.............................5
Battery Information...............................................6
Operation Controls...............................................7
Operations............................................................8
A
ccessory Tools and Maintenance......................9
Maintenance.........................................................10
Maintenance.........................................................11
Propel Handle Assembly......................................12
MODEL - _____________________________________
DATE OF PURCHASE - _________________________
SERIAL NUMBER - ____________________________
SALES REPRESENTATIVE - ____________________
DISTRIBUTOR NAME - _________________________
OPERATIONS GUIDE NUMBER – 98848
Copyright 1996 Windsor Industries, Printed in U.S.A.
Drive and Brush Assembly...................................14
Pump, Vac, Manifold and
Brush Motor Assemblies......................................16
Rear Tower Electrical Assemblies.......................18
Handle, Microswitch and
Cable Assemblies ................................................20
Control Panel Assemblies....................................22
Vac Shoe Assembly.............................................24
Tank, Cover and Hardware..................................26
Wiring Diagram ....................................................28
Warranty...............................................................30
TABLE OF CONTENTS

TECHNICAL SPECIFICATIONS
VGR2 98448 7/1/97 3
ITEM MEASURE
Electric Propelling Motor (1)-1/4 hp DC (186 watts) with solid state
variable speed forward and reverse with
safety shut-off.
Electric Vacuum Motors (2)- 3 stage, 1.3 hp (970 watts), 5.7 inch
(14.5cm) diameter motors in parallel,
provide 152 cfm (4.25m/min.), 74 inches
(188 cm) water lift total. Electric shut-off.
Electric Brush Motors (1)- 0.4 hp (298 watts) permanent
magnet, DC.
Electrical 36 Volt DC
Batteries (3)- 12 volt, @ 185 A/H, in a (Optional)
removable battery pack.
Solution Pump 100 PSI, diaphragm style pump
Cleaning Speed Variable speeds from 0-130 ft/min
(39.6m/min) Transport 0-130; Cleaning
0-110
Solution Capacity 40 gallons (151 ltr)
Recovery Capacity 35 gallons (132 ltr)
Brush Speed 1000 RPM
Vacuum Shoe 28” (71 cm) wide, cast aluminum, tension
pulley adj., floating and pivoting.
Wheels:
Front: (2) 10” dia. (25 cm) by 2.5” wide (6.4 cm)
Rear: (2) 4” dia. (10 cm) casters
Weight:
Empty: 240 lbs. (109 kg)
W/ Batteries 645 lbs. (260 kg)
Length 60” (152 cm)
Storage Position 52” (132 cm)
Height 43” (109 cm)
Width 30” (76 cm)
SIDE VIEW
TOP VIEW

VGR2 98448 7/1/97
4
IMPORTANT SAFETY INSTRUCTIONS
When using a battery powered appliance, basic precaution
must always be followed, including the following:
READ ALL INSTRUCTIONS BEFORE USING THIS MACHINE.
To reduce the risk of fire, electric shock, or injury:
Do not use outdoors or expose to moisture.
Do not operate in standing water.
Machines can cause a fire when operated near flammable vapors or materials. Do not operate this
machine near flammable fluids, dust, vapors or gas. Do not pickup burning materials such as cigarettes
or matches.
Operate this machine only from the rear of the machine.
Maintenance and repairs must be done by qualified personnel.
Store machine inside. Keep the electrical components of the machine dry.
Wear eye protection when working near batteries. Do not put any type of metal objects across the
battery terminals or on top of the batteries.
Lead acid batteries generate gasses which can cause an explosion. Keep sparks and flames away
from the batteries. Charge the batteries only in well ventilated area.
Make sure all warning and caution labels are legible and properly attached to the machine.
Maintain adjustments on machine as per specifications noted in the owner’s guide.
SAVE THESE INSTRUCTIONS
IMPORTANT SHIPPING NOTE
Carefully unpack your Voyager and inspect it for shipping damage. Any damages which occurred
during shipping are the responsibility of the carrier, who must be notified immediately.
!
WARNING:

BATTERY INSTALLATION & REMOVAL (W/ BATTERY CART)
VGR2 98448 7/1/97 5
WEAR EYE PROTECTION AND PROTECTIVE CLOTHING WHEN WORKING
WITH BATTERIES.
BATTERY INSTALLATION AND REMOVAL
FOLLOW THE PROCEDURES CAREFULLY.
1. Remove the vac shoe hose from tank, lay dome back and slowly open tank to upright position.
2. Install (3) batteries in machine by placing them in battery tray liner provided. (See diagram page 6)
3. Connect battery wires according to diagram on page 6.
INSTALLATION OF BATTERIES
FOLLOW PROCEDURES CAREFULLY, BE SURE TO KEEP HANDS AND
FEET CLEAR FROM ROLLING BATTERY TRAY.
1. Make sure the battery door is open.
2. Roll the Battery Cart up to the front of the machine, (aligning the front of the two frames).
3. Push the cart until the latches lock into the tabs on the front of the machine frame.
4. Pull the handle on the Battery Tray. (This releases the locking mechanism on the cart.) Fig 1 & 2
5. Push the batteries into the machine until the locking mechanism on the frame is engaged. (This can be heard
by a “Snapping” sound.) Fig 1.
6. Press the foot pedal on the front of the cart and roll the cart from the machine.
7. Attach battery cable from the batteries to receptacle on front of machine by pressing down on right hand side
of locking bracket. (p/n 140190)
REMOVAL OF BATTERIES
BEFORE REMOVING BATTERY TRAY PLEASE FOLLOW THE INSTRUCTION SHEET 98439.
If you did not receive this sheet please contact Windsor Industries for this instruction sheet.
FOLLOW PROCEDURES CAREFULLY, BE SURE TO KEEPS HANDS AND
FEET
1. Make sure the battery door is open.
2. Disconnect battery cable from receptacle on front of machine.
3. Roll the cart up to the front of the machine aligning the front of the two frames.
4. Push the cart until the latches lock into the tabs located on the front of the machine. (The tabs cannot be seen
when batteries are installed.)
5. The latches are engaged when a “Snapping” sound is heard. Pull the handle on the tray. (This releases the
locking mechanism on the machine frame.) (Fig 1 & 2) Continue to pull handle until the battery pack rolls and
locks onto cart. (The locking mechanism is engaged when a “Snapping” sound is heard.)
6. Press the foot pedal located on the cart and roll the batteries and cart away from the machine.
!
WARNING:
!
CAUTION:
!
CAUTION:
AB
CD
E
F
!
CAUTION:
A
BD
GF
A
B
D
G
F
12
4
5
140190
(
REF
)
FIG. 1
Key P/N Description
1 VCT CART, BATTERY REMOVAL
2 78243 TRAY, VGRB BATTERY LINER
3 78369 TRAY ASSEMBLY BATTERY
4 02143 (3) BATTERY, 12 VOLT
5 02267 CHARGER, 36 VOLT
* NOTE: ONLY THE NEW “VCT”
CART AND NEW TRAY ASSEMBLY
WILL WORK WITH THE VOYAGER
2. PREVIOUS CARTS AND TRAYS,
IN ANY COMBINATION, WILL NOT
WORK.
C
E

BATTERY INFORMATION
VGR2 98448 7/1/97
6
BATTERY MAINTENANCE
1. When cleaning batteries use a solution of baking
soda and water. (Do not allow cleaning fluid to
enter inside battery cells.)
2. Keep a proper electrolyte level in the battery
cells.
3. Wipe down the battery tops at least once a
week. If a cell should accidentally overflow,
clean it immediately.
4. Test the battery connection with a hydrometer at
least once a week.
5. Ensure that all connections are tight and that all
corrosion is removed.
6. Every 4 to 6 months remove batteries from the
machine and clean the battery compartment.
7. Follow the Safety Procedures.
ACCESSORIES
02143 Battery. 12V DC, 185 Amp Hour
00267 Charger, automatic 36V (20 amp) 115V
02264 Charger, automatic 36V (20 amp) 230V
INTERNATIONAL
VCT Battery cart system for service
78243 Battery tray liner
VXK Battery Exchange Kit
ACCESSORY TOOLS:
DHTK Deluxe Hand Tool Kit
DDH Double Dry Hand Tool
HFT 14” Flip Tool
SW Standard Wand
SW-PRO Professional Wand
39128 12” Hose set
BATTERY CHANGING PROCEDURE:
Charge the batteries once battery level indicator is
near the level “0”. Do not let the batteries
completely drain before changing. Avoid charging
the batteries before the amber light comes on.
DO NOT SMOKE, HAVE OPEN FLAMES, OR
SPARKS NEAR BATTERIES AT ANY TIME.
WEAR EYE PROTECTION AND PROTECTIVE
CLOTHING WHEN WORKING WITH BATTERIES.
CHARGE BATTERIES IN A WELL VENTILATED
AREA WITH BATTERY DOOR OPEN.
1. Use a 36 volt, 20 amp maximum output, D.C.
charger which turns itself off when the batteries
are fully charged. The charger must have a
connector that matches the machine’s battery
connection.
2. Read the instructions and warnings provided by
the battery charger manufacturer.
3. Set the charger in a well ventilated area on a
level surface. Make sure cords will easily reach
outlets on both machine and wall.
4. Connect the charger to D.C. outlet on the
machine first.
5. Connect the A.C. power cord to properly
grounded wall socket. NEVER MAKE THE A.C.
CONNECTION FIRST, HAZARDOUS SPARKS
MAY RESULT.
6. After the batteries are completely charged,
disconnect the charger from the A.C. wall
socket.
7. Once the charger is disconnected from the A.C.
wall socket it is safe to disconnect the charger
from the machine.
8. When batteries are
fully charged, check
the electrolyte level by
removing the caps on
top of batteries. If
necessary, fill the
cells with distilled
water as shown in the
diagram to the right.
Be careful not to
overfill the cells.
!
WARNING:
!
WARNING:
!
WARNING:
VIEW: Looking down on machine.
NOTE: Following you will
find the recommended
battery arrangement for the
VOYAGER2
ANDERSON
Molex
connector
FRONT OF
MACHINE

OPERATION CONTROLS
VGR2 98448 7/1/97 7
1. Brush Height Adjustment. Raises and adjusts
the height if the brush.
2. Vac Shoe Lift Lever. Lifts the vac shoe up or
down and switches vac motor off and on.
3. Battery Charge Meter. Indicates the level of
charge that the batteries are holding.
4. Main Power Switch. Turns ON and OFF the
machine.
5. Drive Handle Control Connection. This is
where Drive Control Connection Assembly is
attached to rear panel.
6. Drive Motor Circuit Breaker. 16 amp Protects
the dirve motor mechanism.
7. Vac Motor Circuit Breaker. 35 amp Protects
the vacuum motors.
8. Brush Motor Circuit Breaker. 15 amp
Protects the brush motor.
9. Accessory Tool Hookup. Used for various
auxiliary cleaning tools.
10. Spray Position Switch. Controls the spray
adjustment between manifold and accessory
tools.
11. Hour Meter. Records the use time.
12. Pump Switch. Turns ON and OFF the pump
40
GAL
30
GAL
20
GAL
10
GAL
5
GAL
SEE BELOW
DRAIN
TO VAC SHOE
SIGHT
FILL
TUBE
1
2
34
VOYAGER DRIVE CONTROLS
1. The speed the machine will travel is regulated by
the knob located on the controls which are found
on the main handle. Turn the knob to the right to
increase the speed of the machine.
2. Squeezing one or both of the control levers will
propel the machine forward are the selected
speed.
3. Releasing both control levers will stop the
machine.
4. Pressing forward on the levers moves the
machine backwards at the selected speed.

OPERATIONS
VGR2 98448 7/1/97
8
Fill the solution tank to the desired level according to the marked
gauge on the clear hose on the right side of the tank.
DO NOT FILL PAST THE INLET LIP.
IF A BUCKET IS USED TO FILL THE TANK, BE SURE IT IS CLEAN. DO NOT OVERFILL TO AVOID
POSSIBLE DISTORTION OF THE FLEXSOLDIAPHRAGM OR SOLUTION TANK. DO NOT USE WATER
TEMPERATURE THAT EXCEEDS 140°
°°
°F (60°
°°
°C). LIQUID DETERGENTS ARE PREFERRED, however if a
powered detergent is used, be sure it is fully dissolved. NOTE: If suitable powered detergent is used, premix
with hot water before filling the solution tank.
DO NOT PUT DEFOAMER, SOLVENTS, SPOTTER OR PRESPRAY
CHEMICALS IN THE SOLUTION TANK.
The internal parts of the pump used in the extractor are suitable for use with most carpet cleaning chemicals.
However, it is susceptible to chemical attack from cleaning substances, such as hydrocarbon solvents and
chlorinate bleaches. These noncombustible materials are not of the type normally used for carpet cleaning.
CHEMICALS:
SUITABLE CHEMICALS NONCOMPATIBLE CHEMCIALS
Alkalis Soaps Aldehydes Chlorinated Hydrocarbons
Detergents Vinegar Aromatic Hydrocarbons Lysol*
Hydroxides D-Limonene @SP Butyls Methyl Ethel Ketone (MEK)
@ When properly diluted Carbon Tetrachloride Perchorethylene (perc)
* Registered Trademark Chlorox* Phenolics
Chlorinated Bleaches Trichlorethylene
FILLING THE VOYAGER
1. Remove the Dome.
2. Use a CLEAN bucket or hose to fill solution tank with hot water not to exceed 140°F (60°C). Do not fill above lower tank lip. Add non-
foaming carpet extraction chemical at recommended proportion. NOTE: If suitable powdered detergent is used, premix with hot
water filling the solution tank.
BEGIN CLEANING
1. Adjust handle to comfortable position at waist level.
2. Turn solution valve, located on bottom of rear position.
3. Turn MAIN POWER switch ON.
4. Adjust SPEED CONTROL KNOB on handle to set desired maximum speed.
5. Turn SOLUTION switch ON.
6. Lower BRUSH using left hand lever until contact with carpet is reached. Brush motor will start automatically.
NOTE: Incorrect brush height may trip circuit breaker or cause belt slippage. To correct, raise brush and reset circuit breaker
located on rear panel.
7. Lower VACUUM using right hand lever. Vacuum motor will start automatically.
8. Depress SPEED LEVER to propel machine. Speed is controlled by lever up to the maximum set on CONTROL KNOB.
NOTE: For protection, the Voyager will not operate in reverse when brush is on.
CLEANING PROCEDURE
1. Operate machine in parallel passes, overlapping 2 inches on each pass. Turn SOLUTION switch OFF on turns. Propel machine gently
into turns. Abnormal turns may activate vacuum motor shut-off. Clean perimeter last.
2. Run machine more slowly over spots or extremely soiled areas.
3. Use right side of VOYAGER when cleaning against walls.
4. Turn SOLUTION switch OFF 3 feet before completing a cleaning pass to ensure all solution is vacuumed from carpet.
CAUTION: WHILE OPERATING MACHINE, CHECK FOR EXCESSIVE FOAM BUILD-UP IN RECOVERY TANK. IF EXCESSIVE
FOAM IS PRESENT, ADD DEFOAMER SOLUTION TO RECOVERY TANK OR EMPTY RECOVERED SOLUTION.
5. To speed dry, use a WINDBLOWER fan and ensure building ventilation system is ON.
6. Empty recovery tank when full by releasing dump hose and removing stopper. NOTE: Vacuum motor will stop if recovery tank is full.
7. Turn MAIN POWER switch OFF after use.
NOTE: Check the Circuit Breaker if the Voyager does not start.
TOP VIEW OF TANK
SOLUTION TANK RECOVERY TANK
!
CAUTION:
!
WARNING:

ACCESSORY TOOLS & MAINTENANCE
VGR2 98448 7/1/97 9
ACCESSORY
1. Attach the auxiliary solution hose to the output nipple A.
2. Disconnect hose at vac shoe using and connect vac hose using
coupler (22071) that is included with Voyager machine.
3. Turn the solution control valve B to
4. Press the Pump switch “ON”.
5. Lower the vac lever to the “ON” position to start the vac motor.
6. Make sure the solution control valve is returned to the
7. position before using the Voyager for self-contained
carpet cleaning.
CLEANUP AND STORAGE
Empty the Recovery Tank directly into the floor drain. After each use, rinse tank (including the float-off) with fresh
water. Periodically inspect the recovery tank and decontaminate if necessary, using a Hospital Guide Virucide or
a 1-10 bleach to water solution. This will dissipate the exposure to blood born or infectious contamination. Waste
water shoud be disposed of properly. Clean the inside of the recovery dome also.
Empty the Solution Tank by detaching the sight hose and empty directly into the floor drain.
Flush the Solution System with 1 gallon of CLEAN water.
Never allow recovered solution to remain in tank when not in use; nor allow
usused solution to remain in the solution tank when in storage. Inspect and
clean the filter located at the pump port. Remove and rinse with hot water.
PERIODIC MAINTENANCE
EVERY TWO WEEKS:
Clean the solution system by diluting 2 gallons of clean water with a quart of white vinegar (acetic acid) in the
solution tank. Run the solution through the system to remove chemical buildups which could eventually cause it to
plug up.
EVERY 500 HOURS:
Oil the front drive wheel bearings by removing the phillips screw “A” and by
loosening the (2) set screws “B” located on the outside of wheel assembly. Slide
the wheel off the axle and apply 6 drops of 10W oil to bearings. Be careful not to
lose the key in shaft.
INSPECTION
Remove the batteries (using the battery cart if available) before making any
adjustments or repiars to the Voyager2.
To expose working parts for inspection, lay dome back on handle, grasp tank at solution opening and tilt the tank
forward until “NOSE” of tank rests on floor.
A
B
!
CAUTION:
A
B
!
WARNING:

ACCESSORY TOOLS & MAINTENANCE
VGR2 98448 7/1/97
10
ONLY QUALIFIED MAINTENANCE PERSONNEL ARE TO FERFORM THE
REPAIRS.
Remove the batteries (using the “Battery Cart” if available) before making any adjustments or repairs to the
Voyager2.
WHEN REPLACING THE ELECTRICAL PARTS REFER TO THE MACHINE
WIRING DIAGRAM FOR PORPER CONNECTIONS.
REAR PANEL REMOVAL
Remove the vac shoe hose from tank, lay dome back, remove handle and open the front battery door. Open the
tank slowly to upright position. Remove (2) top and (2) bottom screws on rear panel.
TANK REPAIR
The tanks are made of Polyethylene. Small holes or crack can be repaired by using heat. Apply low heat from a
torch to the damaged are until the material is softened. Use a screw driver blade or other flat head metal tool to
seal damaged area.
VACUUM MOTOR REMOVAL
1. Turn main power off.
2. Remove the rear Control Panel and open tank to upright position.
3. Disconnect the hose from the vac motor intake.
4. Disconnect the vac motor leads from the terminal couplers & ground
post.
5. Remove the (3) screws holding the vac motor to the rear frame and
remove the vac motor.
6. To inspect the motor brushes, remove the brush holder assembly.
Brushes should be replaced when worn to 3/8 inch or about 750
operating hours. After second brush replacement, armature
commutator should be checked for pitting and concentricity. Vacuum
motors can be repaired, but such repairs should be made by a
qualified motor repair shop.
7. Clean out dust using a vacuum to prevent injury to eyes or
contamination of the bearings.
SOLUTION PUMP REMOVAL
1. Turn main power off.
2. Disconnect the two pump wire leads.
3. Remove (4) screws holding the pump to the main frame.
4. Lift the pump out to access solution inlet and disconnect from the pump head.
Refer to the pump drawing page 16 for replacement parts.
BELT / BRUSH ASSEMBLY REMOVAL
1. Turn main power off.
2. Use brush height adjustment lever to lower brush to its lowest
position.
3. Remove the belt guard.
4. Now remove the brush pulley guard.
5. Loosen tension in belt by moving idler pulley clockwise.
Simultaneously remove belt from motor pulley, while holding idler
pulley. Once belt has been removed from motor pulley, slowly let
idler pulley rotate counterclockwise. Do not loosen spring.
6. Remove the screw from each end of the brush shaft.
7. Swing the brush assembly out of the housing to remove the belt.
!
WARNING:
!
CAUTION:
CARBON
BRUSHES
CARBON BRUSH
P/N 140066
FIG. A (ACTUAL SIZE)
BRUSH MOTOR
PULLEY (REF.)
IDLER PULLEY
(REF.)
BRUSH
PULLEY
(REF.)
BELT
11027
(REF.)

MAINTENANCE
98448 07/1/97 11
MANIFOLD / SPRAY JETS
To prevent clogged jets due to alkaline build-up, the spray system should be flushed with 1 gallon of clean hot
water at the end of each work day. The VOYAGER2 is equipped with “quick change” jets that can be easily
removed for cleaning. To remove – push jet in and rotate. Do not use pins or wire to remove obstruction as this
will damage jet and alter spray pattern.
1 66095 PLUG, 1/8 NPT HEX BRASS
2 44052 JETBODY, BRASS W/SEAL
3 54138 MANIFOLD ASM, 3 JET
4 40033 HOSEBARB, 1/4 MPT X 3/8 90D
5 66052 PIN, 1/8 X 1.0 ROLL
6 73576 SPRING, 2” X .600 OD
7 44060 JET, 8002 MINI-QUICK REPLACEMENT
8 44051 JET SEAL, MINI QUICK
9 54162 MANIFOLD A
VAC SHOE TRACKING
To adjust shoe tracking, move eyebolts in or out to increase or decrease spring force, respectively, until desired
tracking is reached.
VAC SHOE DOWNPRESSURE
NOTE: DOWNPRESSURE IS FACTORY SET AND SHOULD NOT REQUIRE ADJUSTMENT.
If adjustment of downpressure is required, turn black knob on top of vac shoe clockwise to increase
downpressure and counterclockwise to decrease downpressure.
VAC SHOE ANGLE
NOTE: THE ANGLE OF THE VAC SHOE IS FACTORY
SET AND SHOULD NOT REQUIRE ADJUSTMENT.
Periodically inspect the vac shoe angle by resting it
on a hard, flat surface. Use a square to verify a 90°
angle between the floor and vertical surface of the
vac shoe.
If adjustment is required, remove one socket on each
lower arm (from the vac shoe or bracket) and turn
clockwise or counterclockwise to change the angle to
the recommended 90°. Attach the socket on each
arm to its respective location and recheck the angle
using the square. Repeat if necessary.
SIDE VIEW OF VAC SHOE
CASTER ASM.
REF.
DOWNPRESSURE KNOB
REF.
VAC SHOE
REF.
VAC SHOE
TRACKING
VAC SHOE
PIVOT ASM.
REF.
PIVOT ASM.
REF.
SOCKET
ARM
REF.
ADJUSTMENT
N
UTS. REF.
VAC SHOE
REF.
90°
S
Q
UARE
VERTICAL
SURFACE
OF VAC
SHOE
96
“Quick
Change
Jets”
1
1
5
3
4
7
8
2
FLAT SURFACE

PROPEL HANDLE ASSEMBLY
98448 11/8/00
12
16
1
2
4
23
26
25
3
24
28
19
27
20
21
22
15
12
13
12
7
18
6
30
29
5
11
15
8
17
9
30
10
14
29
VIEW: CONNECTION DETAIL
Colo
r
AWG Position
Blue 20 1
Black 20 2
Brown 20 3
Orange 20 4
White 20 5
Red 20 6
28
27

PARTS LIST
98448 11/8/00 13
REF PART NO. QTY DESCRIPTION SERIAL NO.
FROM NOTES:
1 27551 1 COVER, PROPEL HANDLE
2 70406 4 SCREW, 10B X 3/8 PHSM BLK
3 87018 4 WASHER, #10 X 9/16 OD
4 57236 2 NUT, 10-32 HEX NYLOCK BLK
5 71116 1 SUPPORT, LEVER PIVOT
6 67271 2 ROD, HANDLE LEVER PILOT
7 51186 2 LEVER, PROPEL CTRL HANDLE
8 66184 1 PIN, CLEVIS 1/4 X 2.438
9 62705 1 PLATE ASSEMBLY, PROP. CTRL.
10 70209 2 SCR, 10-32 X 1.75 PHMS
11 36136 1 GUIDE, LEVER CENTERING
12 14866 2 BUSHING, PROPEL CONTROL
13 73236 1 SPRING, COMP. .36D X .12L X .04W
14 66191 1 PIN, CLEVIS 3/16 X 1/2
15 80604 2 RING, RUE COTTER 1/4”
16 72087 1 SWITCH, 36VDC SPST ILLUM.
17 57028 4 NUT, 10-24 TINNERMAN
18 48043 1 KNOB, PT26/32 SPEED CONTROL
19 880092 1 WIRE ASM, HANDLE TO POWER
20 57024 1 NUT, 3/8-27 PANEL
21 70084 1 SET SCREW, 8-32 X 3/16 KCP
22 66183 1 PIVOT, POTENTIOMETER
23 36123 2 GRIP, CLP HANDLE, X 9.5”
24 51184 2 LOCK, HANDLE ADJUSTMENT
25 70228 4 SCREW, 10-32 X 1/4 PHSM
26 38183 1 HANDLE, VGRB MAIN
27 88748 1 WIRE ASM., VGR. HANDLE
28 27554 1 CONN., MOLEX 6 PIN RECEPT. (M)
29 70088 4 SCR, 10-32 X 1/2 PPHMS
30 87016 6 WASHER, #10 LOCK EXT. STAR
Installation and adjustment of potentiometers for drive control speed
STEP PROCEDURE
1Turn the speed potentiometer fully clockwise. (Max. speed)
2Measure the potentiometer resistance at connector (#27) BROWN and BLACK wires. The
resistance should measure 2200-2800 ohms in neutral, 4800-5000 ohms in forward, and 0-200
ohms in reverse. If adjustment is necessary loosen set screw (#21) and adjust potentiometer T for
2500 ohms in Neutral. Tighten set screw (#21).
3Turn the main switch power on.
4If the machine moves when control lever is in neutral adjust the direction potentiometer until
movement stops.

DRIVE & BRUSH ASSEMBLY
98448 7/1/97
14

DRIVE BRUSH ASSEMBLY
VGR2 98448 7/14/99 15
Replacement of Drive Motor brushes (p/n 40063):
1. Using a standard head screwdriver, remove cap
covering brush inlet.
2. Using a pair of needle nosed pliers, gently remove brush (including spring) and replace with new part.
REF PART
NO. QTY DESCRIPTION SERIAL NO. FROM NOTES:
1 89078 2 WHEEL, 10” X 2 –1/2” BORE
2 81003 3 FLANGETTE, 1” BEARING PAIR
3 70305 4 SCREW, 5/16-18 X 3/4 HHCS
4 57113 4 NUT, 5/16-18 NYLOCK PLTD
5 81002 3 BEARING, 1” BORE
6 29156 1 DIFFERNTIAL
7 48052 2 KEY, 1/4 X 1/4 X 2-1/2
8 87008 2 WASHER, 1/4 ID X 1-1/4 OD
9 41288 1 HOUSING, BRUSH
10 27569 1 CHAIN, #40 1/2 PITCH X 39
11 27343 1 CHAIN, MASTER LINK, #40 1/2
12 73567 1 SPROCKET, #40 11 TOOTH
13 53610 1 MOTOR ASM, VGR 36V
14 70432 4 SCREW, 5/16-24 HHCS SS
15 87166 4 WASHER, 5/16 EXT. LOCK
16 87090 8 WASHER, 1/4 ID X 3/4 OD PLTD
17 41320 1 HOUSING ASSEMBLY
18 70104 2 SCREW, 3/8-16 X 3/4 BHMS
19 12022 1 BRUSH, VGRB
20 09019 2 BEARING, BRUSH
21 57104 7 NUT, 10-32
22 73606 2 SPACER, .50 OD X .38 ID X .260 L
23 64103 1 PULLEY, BRUSH VGRB
24 27607 1 COVER, BRUSH CORE
25 03091 1 AXLE, BRUSH DRIVE
26 36175 1 GUARD, VOYAGER SPLASH
27 67106 1 RETAINER, SPLASH GUARD
28 70088 7 SCREW, 10-32 X 1/2 PPHMS
29 73578 1 SPRING, 4.00 .75 OD EXT
30 87025 4 WASHER, 1/4 LOCK EXT STAR
31 70011 4 SCREW, 1/4-20 X 5/8 PPHMS
32 09025 2 BEARING, 1/2 ID NYLINER
33 67094 2 RING, 1/2 EXT. SNAP
34 70088 8 SCREW, 10-32 X 1/2 PPHMS SS
35 67098 1 RING, TOLERENCE
36 140063 1 BRUSH SET, 36V VGR DRIVE
37 70267 1 SHOULDER BOLT, 5/16 OD X 1.25
38 64101 1 PULLEY ASM., VGR 1000017315
39 87029 1 WASHER, 5/16 FLAT SAE
40 87030 1 WASHER, 3/8 ID X 3/4 OD NYL
41 73307 1 SPRING, COMP. .88D X 1.4L X .1W
42 57047 1 NUT, 1/4-20 NYLOCK PLTD
43 67093 1 RING, 1 1/8 INT. SNAP
44 87074 1 WASHER, WAVE
45 12508 1 BRUSH ASM, VGR
46 62820 1 PLATE, VGR PULLEY 1000024542

PUMP, VAC, MANIFOLD & BRUSH MOTOR ASSEMBLIES
VGR2 98448 02/11/02
16
Replacement of Motor brushes (#28)
CAUTION:
1. Using a standard head screw driver,
remove cap covering brush inlet.
2. Using a pair of needle nose pliers,
gently remove brush (including
spring) and replace with new part.
*NOTE: HOSES ARE MARKED AS SUCH
TO CLARIFY FLOW PATH OF SOLUTION,
NOTE: ORDER (73785) TO GET
REPLACEMENT SCREEN FOR STRAINER
(73573) ITEM 20.
11
25
18 13
*45
624 26
30
13
*38
(REF)
SEE VALVE
A
SM PAGE 16
13
24
6
*45
(REF)
27
22
3
6
27
1
23
28AB
2
35 1716
14
33
15
48
13
23
36
34
*38
32
10
18
13
40
31
29
39
41
8
9
20
TO #12 PAGE 26
10
18
13
8
44
21
43
37 5
7
REPLACEMENT PART FOR THIS ITEM 19
ON PAGE 17
18
13
12
42
TURN POWER OFF.

PUMP, VAC, MANIFOLD & BRUSH ASSEMBLIES
VGR2 98448 02/11/02 17
REF PART
NO. QTY DESCRIPTION SERIAL
NO. NOTES:
1 53622 1 MOTOR ASM, 36VDC VGR2
2 64022 1 PULLEY, POLY-V BELT
3 70074 2 SET SCREW, 10-32 X 1/4 KCP
4 99873 2 TAPE, 5/8 X 1/4 X 3” PORON
5 20005 2 CLAMP, 5/16 NYLON
6 70011 16 SCREW, 1/4-20 X 5/8 HHCS
7 70088 1 SCREW, 10-32 X 1/2 PPHMS
8 57104 12 NUT, 10-32 W/ STAR WASHER
9 14454 1 BRACKET, VALVE
10 22003 2 COUPLER, 3/8 FPT X FPT
11 70253 4 SCREW, 10-32 X 1.25 PHMS
12 39486 1 HOSE, 3/8 NYLOBRAID X 2”
13 20042 6 CLAMP, 3/8 HOSE (D-SLOT)
14 18031 2 CASTER, 4” HARD SWIVEL
15 70305 8 SCREW, 5/16-18 X 3/4 HHCS
16 62394 2 PLATE, SPRING HOOK
17 73240 2 SPRING, 1/2 X 2.25L EXTENSION
18 40034 4 HOSEBARB, 3/8 MPT X 3/8 90D
19 65166 1 PUMP ASM, 36VDC VGR2
20 73573 1 STRAINER, 3/8 NPT 80 MESH
21 880101 1 WIRE ASM, VGR MAIN POWER
22 70329 4 SCREW, 1/4-20 X 3/4 PHMS
23 70066 5 SCREW, 10-32 X 3/4 PPHMS
24 87025 12 WASHER, 1/4 LOCK EXT STAR
25 87018 4 WASHER, #10 X 9/16 OD
26 73566 6 SPACER, 1/2 OD X 3.0 W/ 1/4-20
27 57047 4 NUT, 1/4-20 NYL SELF LOCK
28A 140066 1 BRUSH, 36V VGR BRUSH MTR
28B 140462 1 BRUSH SET, CCL MOTOR 53202 1000083040
29 73576 1 SPRING, 0.6 OD X 2.0L COMPR
30 53782 2 VAC MOTOR ASM, 36VDC
31 66095 2 PLUG, 1/8 MPT HEX BRASS
32 54139 1 MANIFOLD ASM, VGR 3-JET
33 87067 8 WASHER, 5/16 LOCK INT STR.
34 14902 1 BRACKET, VGR MANIFOLD
35 11027 1 BELT, BRUSH DRIVE ASSEMBLY
36 40033 1 HOSEBARB, 1/4 MPT X 3/8 90D
37 34270 1 FRAME, VGR2 MAIN
38 39204 1 HOSE, 3/8 NYLOBRAID X 29”
39 44060 3 JET, 8002 MINI-QUICK
40 66052 1 PIN, 1/8 X 1” ROLL
41 44052 3 JETBODY, MINI-QUICK W/ SEAL
42 34308 1 FRAME, VGR2 REAR
43 70261 2 SCREW, 6-32 X 1.0 PHMS PLTD.
44 57116 2 NUT, 6-32 E/ STAR WASHER
45 39365 1 HOSE ASM, 3/8 ID NYLOBR X 25
PUMP HEAD REPLACEMENT
(65151) VALVE ASM
(84145) DIAPHRAM ASM.
(29188)
PUMP REPLACEMENT PARTS

REAR TOWER ELECTRICAL ASSEMBLIES
VGR2 98448 7/1/97
18
33
3
11
8
5
33
3
11
4REAR TOWER
CUTAWAY
DETAIL “A”
22
13
19
16 18 1
20
17
14
21
SUPPLIED W/ VALVE ASM.
INSTALLED ON OUTSIDE OF
COVER.
84140 – VAVLE ASM.
PARTS BREAKDOWN
2
1
24
23
32
NOTE: SUPPLIED WITH RELAY
15
7
26
10 231
27
29 1
REF.
25
TO #*45
PAGE
14
28
TO #*38
PAGE
14
12 96
30
SEE DETAIL “A
”
NOTES:
LOCATE @ PORT MARKED “P” OR “2”
LOCATE @ PORT MARKED “A” OR “1”
2
1

REAR TOWER ELECTRICAL ASEMBLIES
VGR2 98448 3/2/98 19
REF PART
NO. QTY DESCRIPTION SERIAL
NO. NOTES:
1 40038 HOSEBARB, 1/4 MPT X 3/8 H 45DEG.
2 51184 LOCK, HANDLE ADJ.
3 57125 NUT, 5/16-24 HEX JAM
4 62561 PLATE, NEGATIVE POST
5 67005 RIVET, 1/8 OD WHT AL
6 70162 SCREW, 10-32 X 3/8 PHMS SS
7 70228 SCREW, 10-32 X 1/4 PHMS SS
8 70289 SCREW, STUD, 5/16-18 X 2.12 BRASS
9 87016 WASHER, #10 LOCK EXT STAR
10 87018 WASHER, #10 X 9/16 OD
11 87092 WASHER, 5/16 X 3/4 BRASS
12 84140 VALVE ASM, 36V
13 22072 COUPLING, 1/4 ANCHOR
14 31016 ELBOW, 1/4 NPT
15 87095 WASHER, #10 FLAT PLTD.
16 56012 NIPPLE, 1/4 FPT QD
17 56014 NIPPLE, 1/4 CLOSE
18 56048 NIPPLE, 1/4 X 1.75
19 78308 TEE, 1/4 STREET
20 84003 VALVE, 115V LP 2-WAY SOL
21 84065 VALVE, 1/4 FPT BALL
22 36019 GROMMET, 5/16 ID X 9/16 GRV.
23 57116 NUT, 6-32 W/ STAR WASHER
24 14020 TERMINAL BLOCK, 115V (3-4-3)
25 57106 NUT, 8-32 W/ STAR WASHER
26 73734 SPACER, .166ID X .313OD X .75L
27 27672 CONTROLLER, 36VDC PROPEL MOTOR
28 57047 NUT, 1/4-20 NYLOCK PLTD.
29 67315 RELAY, 36VDC 100AMP HVY DUTY
30 36020 GROMMET, 5/8 ID X 1.12 OD
31 70488 SHOULDER BOLT, 5/16 OD X 3/4 L
32 87029 WASHER, 5/16 FLAT SAE
33 57113 NUT, 5/16-18 NYLOCK PLTD

HANDLE, MIRCOSWITCH AND CABLE ASSEMBLIES
VOYAGER 98448 05/18/01
20
NOTE: FOR BRUSH AND REVERSE SWITCHES, ALIGN THE TWO SWITCHES AND CHECK TO
SEE THAT THE ACTUATOR TABS ARE EVEN TO WITHIN 1/16 INCH. IF REQUIRED, BEND THE
LOWER TAB UP TO MATCH THE HIGHER TAB.
INSTALL THE SWITCHES WITH THE SCREWS LOOSE ENOUGH TO ALLOW THE TOP SCREW
TO SLIDE IN THE MOUNTING SLOT. WITH THE LEVER IN THE TOP POSITION, SLIDE THE
SWITCHES BACK UNTIL THEY BOTH CLICK, TIGHTEN THE SWITCHES IN THIS POSITION.
HOLD
BEND UP
ALIGN
&
SHOWN.
789
6
11
12
10
1
REF.
2
REF.
1
19
2
18
4
5
3
BRUSH HOUSING
REF.
12
10
11
6
9
13
17 1615
1
REF.
87
2
REF.
3
REF.
4
REF.
5
REF.
3
REF.
4
REF.
5
REF.
VIEW: LEFT SIDE OF
REAR PANEL VIEW: RIGHT SIDE OF REAR PANEL
18
14
19
20
20
BR
US
H
&
REVER
S
E
S
WIT
C
H