Windsor Lightning Battery Burnisher 10027100 - Manual (Page 12)

MACHINE TROUBLESHOOTING
86038450 04/12/07 4-4ENG
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. If there 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 squeezed. Replace relay if the test voltage F
to B is 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) to C
(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 & T. Check transaxle connection at U.
Faulty potentiometer.
With the drive motor disconnected at V, test the output
voltage to the drive motor. The output voltage at V
should vary from 0 to 36V at R & S as the control lever
is squeezed. Resistance of the potentiometer can be
tested at the leads 4 & 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.