Windsor PowerTec20 PT-20 User manual

Operator Safety Instructions
Read the instruction manual before operating this
mach i ne.
Operate this machine only from the rear of machine.
~ ~~~~ ~~~
Use caution when operating the machine on a ramp
or incline. Do not turn or leave this machine unattended
on a ramp or incline.
~ ~ ~~
Machine can cause an explosion when operated near
flammable vapors and materials.
'
Store machine inside. Keep the electrical components
of the machinedry.
~ ~ ~~
Lead acid batteries generate gases which can cause
an explosion. Keep sparks and flames away from the
batteries. Charge the batteries only in a well ventilated
area.
~ ~ ~~ ~~ ~
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.
Maintenance and repairs must be done by qualified
personnel only. Maintain adjustments on machine
as per specifications noted inthe service manual.
Make sure all warning and caution labels are legible
and properly attached to the machine.
2

CONTROL
HANDLE SOLUTION
“ON”
LIGHT
I
SOLUTION
CONTROL
LEVER
BATTERY
CONDITION
LIGHTS
MAIN
SWITCH
BRUSH
“ON”
LIGHT
LIGHTED
VACUUM
SWITCH
TRAVERSE
CONTROL
HANDLE
Controls flow of cleaning solution to floor.
Light “ON” indicates solution valve is open.
Indicates charge condition of batteries
-
4 green lights - full charge - approximately 4 112 hours run time.
1 green light - approximately 112 hour run time left.
Switches on main drive motor and brush.
Light
“ON” indicates brush is turning.
Lighted switch indicates vac motor ison.
3

, MACHINE PREPARATION
BAITERIES
1. Install batteries and connect battery
cablesas shown.
RE
FRONT
MfARN/NG: Provide proper ventilation and
leave cover open when charging batteries.
2. Charge the batteries before using the
machine. (See Battery Charging Pro-
cedure)
BRUSH/DRIVE PAD ASSEMBLY
1. Removebrushcover.
2. Position brush under drive plate and lift
brush to engage drive lugs in recesses
in plate.
A quick clockwise motion will
lock brushto drive plate.
CLEANING SOLUTION
1. Fill machine with hot water and add
cleaning chemical at the proportion
notedon the container.
CAUTION: Always use a low rudsing
cleaning chemical designed for use in
automatic hard surfacefloor scrubbers.
NOTE This pedal can also be used to
Increase brush pressure to the floor.
This can be done by pulling up on the
pedal and locking it in one of the posi
-
tions on the brush adjustment bracket.
2. Switch on brush motor by turning the
mainswitch clockwise.
CAUTION: Do not leave brush running
on floor while machineis stationary.
3. Switchon vacuum switch.
4. Push solution lever forward. NOTE: The
amount of solution can be regulated
during operation depending on the type
of floor and the traverse speed of the
machine.
5. Push down on front of squeegee pedal
to release the latch arm and lower
squeegeeassembly to floor.
CAUTION: Always lift squeegee before
movingthe machlnein REVERSE to pre -
vent damageto squeegee blades.
OPERATINO THE MACHINE
BRUSH/DRIVE PAD CONTROL
1. Push down and slightly to the left on
brush lift arm to lower brush to floor
(right hand pedal).
8. To go FORWARD press down on the
traverse handle.
To
STOP releasethe traverse handle and
pull back on the control handle.
To
REVERSE machine lift up on traverse
handle.
4
REGULAR MAINTENANCE
BEFORESTARTING WORK PERIOD
1. Disconnect battery charger. NOTE Dis -
connect the “AC” power cord from the
wall receptacle before removing the
“DC” chargerplugfrom machine.
2. Check water level In batteries. Add
distilledwater as needed.
3. Attach brush or drive padto drive plate.
4. Check vac motor and float for proper seal.
5. Check vac hose connectionat squeegee
shoe.
8. Check squeegee bladesfor wear.
7. Fill machine with hot water and add
cleaning chemical at the proportions
notedon the container.
NOTE Use a low
sudsing cleaner designed for use in
automatic hard surface floor scrubbers.
BEFORE STORING MACHINE AT
THE END
OF WORK PERIOD:
1. Drain both solution and recovery tanks
and rinseclean.
2. Lift out vac motor and float assembly
to allow recoverytank to air dry.
3. Remove brush or drive pad from drive
plate and store upsidedown or hang on
wall.
4. Wipe down exterior of machine with
damp cloth.
5. Raise squeegee assembly to “store”
position.
8. Charge batteries.(See Battery Charging
Procedure)
BATTERIES - CHAROINQ
AND MAINTENANCE
BAITERY CHARGING PROCEDURE
WARNING: Lead acid batteries generate
gases which can causean explosion. Keep
sparks and flames away from batteries.
NO
SMOKING. Always wear eye protection
when working near batteries. Charge the
batteries only inawell ventilated area.
1. Set the charger on aflat level surface.
2. Lift up battery compartment cover. Leave
cover up during charging cycle.
3. Connect the “DC” charger plug to the
connector on the machine.
NOTE A
safety overrideswitch isactivated when
the
“DC’ charge plug Isconnected. This
prevents all panel circuits on the machine
from accidentally being switched on
during chargingcycle.
4. Connect charger “AC” plug to properly
grounded outlet that has correct voltage
for the charger.
5. The charger supplied by Windsor is
totally automaticand shuts
off when the
batteries are fully charged.
NOTE: Refer to the charger manual for
detailedcharging information.
8. After charging check electrolyte level Of
the batteries. Add distilled water to the
levelas shown indlagram. (upper right)

BATTERY MAINTENANCE
1. Keep tops of batteries clean and dry.
Use a damp cloth with a weak SOlutlOn
of baking soda or ammonia and water.
Use a clean dry cloth to wipe battery
tops dry after cleaning.
2. If corrosion(white deposits) appears on
the battery terminals and cable clamps,
removeand clean. Use a batteryterminal
and connectorcleaning tool.
BATTERY TERM I N AL CLEANE R
2. Check motor brushes - when worn to
318" lengthreplace both brushes.
3. Keep the battery electrolyte at the
correct level
- approximately 114 " below
bottom of filler tube of each cell. Dis
-
tilled water should be added, as needed,
AFTER chargingcycle.
WARNING: Do not allow electrolyte
level to drop below the tops of the plates.
SERVlClNQ THE PT-20
SCRUBBER
CAUTION: Before making any adjust -
ments or repairs to the machine.. .
1. Only qualified maintenance personnel
are to performrepairs.
2. Make sure battery charger is dlscon -
nected.
3. Makesure all switches are " OFF "
4. Removebatteries as requiredor dlscon-
nect main battery leads from batteries
when making repairs to electrical system.
VACUUM MOTOR
1. Disconnect motor leads from connector
and lift out vac motor.
DRIVE CHAIN
1. Remove left side skirt and side panel.
2. To remove chain, remove retaining clip
and pull out master link.
3. To adjust chain tension ...
A. Remove traversedrive pulley.
2. Remove pulley to allow removal of left
3. Remove right hand pivot bolt, bushing
hand lift arm.
and lift arm.
4. To check gear unit oil level - remove
Inspection plug; oil should be at the
bottom of hole.
To add 011, remove fill
plug and add 90 welght oil as needed.
B. Loosen lock nut and back out screw
(I) turn.
C. Use a hammer and punch to rotate
the eccentric bushing to tighten or
loosenthe drive chain.
TRAVERSE DRIVE MOTOR
1. Remove lower right handside skirt.
2. Disconnect motor leads from terminal
block.
3. Remove snap ring from end of motor
pivot shaft.
QEAR UNIT
1. Loosen belt tension screw and remove
belts.
5

4. Lift out motor - check motor brushes.
When worn to 318" replace brushes.
DIFFERENTIAL ASSEMBLY
NOTE: The differential assembly, traverse
drive motor and brush gear unit can be
removed as a total unit for servicing, if
required.
1. Lay machine on side or build tripod
supports for each side of machine to
hold unit upright as shown.
3. Removeaxle hub clamps. Lift off assem -
bly and lay on bench to service.
WHEEL/DIFFERENTIAL
AXLE ASSEMBLY
1. Remove bolt holdingwheel to axle.
2. Remove wheel from axle. Use wheel
puller,
if needed, being careful not to
damage threads incenter hole of axle.
3. To remove axle and bearings from hub...
A. Removesnap ring from hub.
B. Use an arbor press or hammer and
block of wood to removebearing and
axle.
2. Removeboits from brush lift arm bracket
and traverse drive connecting arm.
C. To remove roiler bearing from hub,
use a piece of
314" dia. tube to drive
out bearing.
SQUEEQEEASSEMBLY
To remove squeegeeassembly.. .
1. Depresspedal to raise squeegee.
2. Pull retaining pinfrom locator stud.
3. Pushdown on squeegee toremove from
drag arm and slide squeegee to the right
to disengage right hand stud from arm.
4. When installing or replacing squeegee
blades make sure the smooth
slde of the
blade is next to the squeegee casting.
5. Squeegee support caster - with
squeegee assembly setting perpendicular
to the floor surface, adjust caster to a
clearance of approximately
1/8" between
bottom of caster and the floor.
As the
squeegee blades wear, adjust caster to
maintainthis dimension.
1/0"
6. The angle of the squeegee can be
changed with the adjusting screw. Turn
screw clockwise to tilt squeegee forward
and counterclockwise to tilt rearward.
Tighten lock nut after making adjustment.
7. Squeegee pressurecan be changed with
the adjusting screw.
To Increase pressure
turn counterclockwise, to decrease
pressure turnclockwise.
6

2. After installing new belt check for clear -
ance betweentraverse pulley and brush
BRUSH ANGLE
ADJUSTMENT
CAUTION: Operatingthe machinewith
excessive pressure on the squeegee will
cause abnormal wear on the squeegee
blades.
BRUSH DRIVE BELT
1. Removetraverse drive belt by rolling belt
off pulley.
2. Loosen belt tension adjusting screw and
remove brush drive belt. After readjust
-
ing belt tension, make sure lock nut on
adjusting screw Istight.
‘\
TRAVERSE DRIVE BELT
1. With operating handle in neutral position,
roll belt off pulley. Replaceas required.
drive belt. The pulley should not be in
contact with the belt when the traverse
handle isinthe neutralposition.
- -- - - - ~ ~
1. Start the brush motor and lower the
brush slowly to the floor. When the rear
of the brush
“A” touches the floor, the
To adjust clearance:
A. Removeleft side panel. front of the brush
“8” should be about
3/16” from the floor.
B. Loosen lock nuts on link rod. Adjust 2. BY releasing the foot lift pedal the
bracketon link rod so pulley does not Springswill allow the brush to rest com -
contact belt. Retighten lock nuts on pletely on the floor.
link rod.
A. If the brush vibrates while in opera-
tlon Increasedirtanu “B”.
B. If the machinepulls to the left during
operation decreasedlrtanu “B”.
3. The springs (C) should be adjusted so as
to maintain thedistances
as shown.
4. To change brush inclination, IOOSen nut
(D) and turn tie - rod (E) until the correct
angle Isreached.
A

' VAC, BATTERY, TANK
7
VAC, BATTERY, TANK
REV PARTNO. mnitvion
/ 32
9 70280 Stud, 1/4 Turn Fastener
10 70076
Scr, 10 - 32 x 1 FHMS
11 51074 Lug,
Shroud Mounting
12 48012 Knob, 5/16
- 18
8

17
A
I
16
9

' MA I NFRAME WITANKS
38
I
34
37 36 35
/
39
41' io
13 14, "1
46

SQUEEGEE w/ARM
59 69
21
1
- - -
I
__ . . . .-.-. . , . , . . . - . ..
. . ~
11

~ONTROLS ( MECHANICAL )
KEY PART NO. DESCRIPTION
1 05029 Arm. Drive Linkage Adj
2 70015 Scr. 1/4 - 20 x 314 HHMS
3 87090 Washer, 1/4 ID x 3/4 OD
4 14492 Bushing, .25 ID x .37 OD x .25
5 70270 Scr, 1/4
- 20 x 3/4 HHCS
6 05030 Arm, Drive Linkage
7 70260 Scr., M6x 16 HHMS
8 87087 Washer, M6x 25
9 14493 Bushing, .25
ID x .37 OD
10 57105 Nut, 1/4 - 20 Hex w/Star Washer
11 05033 Arm, LinkageTransfer
12 14491 Bushing, .25
ID x .62 OD
14 73268 Spring, Drive Linkage
15 57117 Nut. 5/16
- 24 Hex
16 67114 Rod, Drive Linkage
17 87096 Washer, 5/16 Int Lock
- Lite
18 27277 Clevis, 5/16
- 24 UNF Rod
19 66116 Pin Clevis, 114x 314
20 66121 Pin, 3/32 x 112Cotter
21 70273 Shoulder Bolt, 318 x 1 .OO
22 87003 Washer, 318 ID x 718 OD
23 90002 Yoke, PT - 20 Drive Linkage
24 57112 Nut, 5/16
- 18 Flange
25 57104 Nut. 10
- 32w/Star Washer
26 67122 Rod, Drive Linkage
27 14509 Bracket, RH Drive Handle Mtg
28 62190 Plate, PT
- 20 Support
29 62211 Plate, Drive Handle Arm
30 70085 Scr, 1/4
- 20 x 112 PHMS
32 61102 Panel, PT
- 20 Control
33 70054 Scr, 8
- 32 x 3/8 FHMS
34 38131 Handle, PT
- 20 Drive
35 36084 Grip, PT
- 20 Drive
36 48030 Knob, PT
- 20 Solution Lever
37 38133 Handle, PT
- 20 Main
. 38 70057 Scr, 1/4 - 20 x 1 .OO RHMS
13 70265 Scr, 1/4
- 20 x 314 SHCS
31 57047 Nut, 1/4 - 20 Lock
CONTROLS (MECHANICAL)
7
5
/ 28
\
‘25
-\
l5 \
\
47
\
48
49
Controls(Mechanical)continued
I KEY PARTNO. DESCRIPTION I
45 70245 Scr, 4 - 40 x 314 PHMS
46 72053 Switch, 125VDC SPST No Lever
47 57100 Nut, 4
- 40 Hex
48 14519 Bracket, Solution Cable Mtg
49 27289 Cable,
PT - 20 Solution
50 70085 1/4
- 20 x 112 PHMS
51 70024 Scr,
#8 x 112Sheet Metal
52 70279 Scr, MOBSheet Metal PH
53 87029 Washer, 5/16 ID x 3/4 O D
12

48 49 50

14 21
‘IAL
- 39

PT.20 LABELS
PART NO. DESCRIPTION LOCATION I
inside cover
On handle I 50378 Instruction Card
I
I 9387 Maintenance Under hood I
15

-;:"BRUSH DRIVE
I.
74 - Reduction Gearbox Assembly
BRUSH DRIVE 1
16
KEY PART NO. DESCRIPTION t
53 67112 Rod, Turnbuckle Sliding
55 66105 Pin, Turnbuckle
56 67104 Ring, 518
Ext Snap H - D
57 70260 Scr, M6x 16
58 87056 Washer, M6
59 20068 Clamp, PT-20 Brush
60 73317 Shim, 12mm Dia.
61 73318 Shim, 15mm Dia.
62 73319 Spring, PT-20 Brush Lock
63A 02095 Brush, PT-20 Nylon
638 02096 Brush, PT
- 20 Polypro
63C 02097 Brush, PT-20 Extra Aggressive
630 02098 Pad Driver, PT - 20 ,
64 59020 0-Ring, 4125
65 57133 Nut, M24x 2 Lock
66 73320 Shim, M47x 0.3
67 67144 Ring, M47 Int Snap
68 73313 Seal, M30
x 47 x 7 Oil
69 36090 Gear, Reduction Pinion
70 67143 Ring, M60 Ext Snap
71 62202 Plate, PT-20 Brush Holder
72 70304 Scr, 1/4-20 x 1.25
FHWS
73 51076 Lug, Brush Mounting
74 36076 Gearbox Asm, PT-20 Reduction
54 57022 Nut, 3/8-16 Lock

I' " Product Modification
Pi - 20 BATTERY SC RU B B ER
Beginning with Serial #I700 the following changes
were made
to the brush drive as shown on Page 16
in the .service manual. Retain this notice in your
manual for reference when ordering replacement
parts.
1. Key #44 - Changed to rod with lock nuts,
replacing the snap rings.
2. Keys #1 - 2 - 3 - 4 - 6 - 35 - 72 - 73 - 74 - 75 - 76 - 77 - Changed
drive plate,
brush drive lock, and new gear unit
assembly.
37
38
43 42 41 40 39
I
b- I
18 (Rev. 3/91)

PROBLEM
No power.
Vacuum motor
does not run.
Brush motor
does not run.
Solution light
does notwork.
Batterycharge
levelIndicator
lights.
PROBABLECAUSE
Circuit breaker tripped.
Batterycables corroded
at batteryterminals.
Faulty main switch.
Faulty safety override
micro switch.
Faulty solenoid.
Circuit breaker tripped.
Loose connections.
Faulty vac circuit
breaker.
Faultyvac switch.
Motor brushes worn.
Circuit breaker tripped.
Loose connection.
Faulty solenoid.
Faulty drive motor.
Faulty circuit breaker.
Looseconnections.
Faulty solution light.
Light stay on with
solution lever in
“OFF” position.
No light are on with
main switchon.
Loose connections.
I 7 J.
CORRECTIVEACTION
Reset brush motorcircuit breaker (50 amp).
1. Clean battery cable clamps and battery terminals.
2. Check voltage at points A and
B. Voltage should be 22/26 VDC.
1. Check voltage at points A and C. Voltage should be22/26 VDC.
2. Turn main switch on and check voltage at points A and D. Voltage should be
With main switch
“ON” check voltage at points A and E and A and F. Voltage should
be 22/26 VDC. If no voltage at A and F remove leads and check micro switch for
continuity. Should be continuity
in normal position and nocontinuity when switch
lever isactivated.
With main switch on (solenoid energized)check voltage at points
A and G - voltage
should be 22/26 VDC.
If novoltage replace solenoid.
Reset vac motor circuit breaker.
Check motor lead connections at terminal block and inline connector near vac
motor. Keepall connections tight.
With main switch on check voltage at points A and H and A and
I. If no voltage,
check continuity of circuit breaker. Replace as needed.
Remove leads and check switch for continuity. Replace as needed.
Check motor brushes. Replace when worn to
W8“. Check vac motor by securing
motor and applying
24 VDC to motor leads. No load amp draw of motor should be
15 amp.
Reset
(50 amp) brush motor circuit breaker.
Check motor leads at terminal block connection (located under right hand lower
side panel) tighten set screws as needed.
With mainswitch on check ouput voltage at points A and
G. Voltage should be
22/26 VDC.
Check motor brushes
- replace when worn to 3/8“. With batteries fully charged
and motor secured, apply batteryvoltage direct to motor.
No load amp draw of motor
should be 12 to 13amps.
Reset (6amp) battery circuit breaker.
Check for loose electrical connections at terminal block, solution switch, and
solution light.
Remove light and apply direct battery voltage (24 VDC)
to light. Replace light as needed.
Adjust solution light switch.
22/26 VDC.
If no voltage remove leads and check switch for continuity,
Check (6amp) battery circuit breaker. Reset
if tripped.
1. Check electrical connections at circuit breaker.
2. Check voltage at inlineconnector at PC Board. Should be 22/26 VDC.
17