ONYX JX-600 Propane Floor Burnisher User Manual

ONYX JX-600 Propane Floor Burnisher User Manual

This Guide provides necessary instructions on machine operation and maintenance. Before operation or use of this machine, please carefully read and understand this Guide.

Website: https://www.onyxsolutions.store/
No further notice will be given for possible change of specification and parts.

Machine Information:

Please fill in when installing for future reference.

Model number: _
Machine serial number: ____
Sales representative: ____
PO number: __
Date PO placed: _
Installation Date: __

PARTS ORDERING

When ordering the replacement parts, please refer to the ONYX website at www.onyxsolutions.com. Use of the published Illustrated Parts Lists (IPL’s) to identify the correct part number required is required to support accuracy of parts ordering.

Machine IPL’s can be found at the top of the SHOP page of the ONYX website. Before matching parts or accessories, please firstly determine your machine model and serial number. You can order parts and accessories from any authorized service center or dealer by telephone at 704-827-9368, or email us at sales@onyxsolutions.com

WARRANTY CLAIMS

ONYX Warranty Statement (policy) and Warranty Claim form can be found on the SUPPORT page of the ONYX website, https://www.onyxsolutions.store/support.

TECHNICAL SUPPORT

Technical support is available by submitting a HELP TICKET on the CONTACT US page of the ONYX website, https://onyxsolutions.odoo.com/contact.

PROTECT THE ENVIRONMENT

Please abandon the old machine components such as packaging material, battery,
etc. and toxic liquid such as anti-freezing agent and oil according to your local regulations on waste disposal and on the premise of maintaining environmental safety.
Please ensure to carry out the recycling well.

12703 Commerce Station Dr • Suite 200
Huntersville, NC 28078
704.827.9368

SAFETY PRECAUTIONS

WARNING: Failure to read the Operator Manual prior to operating or attempting any service or maintenance procedure to your machine could result in death or injury to you or others, or damage to the machine or to other property. You must have training in the operation of this machine before using it. If you or your operator/operators cannot read English, have this manual explained fully before attempting to operate this machine.

WARNING: It is the owner/operator’s responsibility to ensure that the air-exchange system installed in any location where a propane floor care machine is being operated is of sufficient capacity and quality to support the use of such a machine. OSHA and other County, State, or Federal Agencies publish guidelines on this subject that are usually most readily found in the possession of the respective owners and/or parent companies of any location or chain of locations. Failure on the part of the owner/operator to ensure that a propane floor care machine can be operated safely in a given location may lead to injury, sickness or even loss of life.

WARNING: This product contains one or more chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.

SAFETY INFORMATION

The following terms and symbols are used to identify statements of potential hazards which affect safety of yourself and others. Read and observe all safety statements found on this Operator Manual and on your engine.

DANGER:
The signal word DANGER indicates a hazardous situation which, if not avoided according to the instruction found in this Operator Manual or on your machine, will result in death or serious bodily injury.

WARNING:
The signal word WARNING indicates a hazardous situation which, if not avoided according to the instruction found in this Operator Manual or on your machine, could result in death or serious bodily injury.

CAUTION:
The signal word CAUTION indicates a hazardous situation which, if not avoided according to the instruction found in this Operator Manual or on your machine, could result in minor or moderate injury or damage to your engine or property.

DESCRIPTION OF SAFETY SYMBOLS

The following safety symbols are used on the product and in this manual to alert the operator of potential safety hazards. Read them carefully, and understand their meaning.

Indicates DANGER, WARNING, or CAUTION

Read Operator Manual before operating his machine. Failure to follow directions could result in death or serious injury.

Engine exhaust contains carbon monoxide, an odorless and deadly gas. Follow all Carbon Monoxide Safety instructions in this Operator Manual, Propane Engine Supplemental Operator Manual, and on machine. Failure to follow directions could result in death or serious injury.

Do NOT touch hot muffler, exhaust pipe, or cylinder. These parts are extremely hot from operation and may remain hot after operation. Severe burn or injury could occur if you touch these parts.

Propane is highly flammable. Follow all Propane Safety instructions in this Operator Manual, Propane Engine Supplemental Operator Manual, and on machine. Failure to follow directions could result in death or serious injury.

Wear eye and hearing protection when operating this machine.

There are rotating pads and parts under machine frame, which can cause serious injury. Keep hands and feet away.

PROPANE SAFETY

This machine is powered by an engine that uses propane fuel. Additional information about propane basics, propane cylinders, filling propane cylinders, and storing and transporting propane cylinders is provided in the “Propane” section of this operator manual. The following propane safety instructions should be fully understood and followed at all times when using this machine or propane cylinders. Failure to follow directions could result in death or serious injury.

DANGER: Propane is a highly flammable fuel. Cigarette lighters, pilot lights, and any other sources of ignition can create an explosion when in contact with propane. All sources of ignition should be extinguished or removed entirely from the work area. DO NOT SMOKE in the vicinity of a propane powered engine, machine, or propane cylinder.\

DANGER: NEVER release or bleed propane inside any building or other enclosed space or near an open pit. Check for fuel leaks and damage to the propane cylinder prior to operating machine and storage. Turn off service valve on propane cylinder when machine is not in use. Always store propane cylinder in an approved outside location. It is UNLAWFUL to store a propane cylinder inside a building.

DANGER: NEVER release or bleed propane inside any building or other enclosed space or near an open pit. Check for fuel leaks and damage to the propane cylinder prior to operating machine and storage. Turn off service valve on propane cylinder when machine is not in use. Always store propane cylinder in an approved outside location. It is UNLAWFUL to store a propane cylinder inside a building

WARNING: If you smell propane gas, shut off the machine and turn off service valve on propane cylinder and move machine outside. Determine the source of the leak before using it again.

WARNING: Escaping propane can freeze skin and cause frostbite and damage eyesight. Always wear safety gloves and safety glasses when filling propane cylinders.

CARBON MONOXIDE (CO) SAFETY

This machine and the engine that powers it have been specifically calibrated to operate safely in indoor spaces. This is accomplished by calibrating the engine to run with a very “lean” air/fuel ratio which minimizes the production of carbon monoxide. Additionally, a catalyst muffler is   provided with the engine which specifically targets and eliminates carbon monoxide.

In order to maintain a safe working environment, and minimize risk of carbon monoxide poisoning, the following safety information and instruction in this section must be strictly adhered to:

DANGER: All LPG (Liquid Propane Gas) powered engines, including this engine, produce Carbon Monoxide (CO), a DEADLY, colorless, odorless, tasteless, non-irritating, and poisonous gas. Failure to provide for proper venting of CO produced during the operation of combustion  powered engines may result in SERIOUS INJURY OR DEATH to the operator and those in the contaminated area.

DANGER: Do not operate this machine without catalyst muffler installed

DANGER: Do not tamper with regulator or other settings which would alter air/fuel ratio

WARNING: Dangerous carbon monoxide emissions from this engine will increase greatly due to a dirty air cleaner. Follow the engine manufacturer’s air cleaner service instructions.

The purpose of this section is to provide helpful information to explain how carbon monoxide can be managed to reduce risk of carbon monoxide poisoning:

• Potential effects of CO exposure
• Industry guidelines for acceptable CO exposure
• Measuring CO exposure
• Understanding factors that determine CO exposure
• Methods to reduce CO exposure

POTENTIAL EFFECTS OF CARBON MONOXIDE EXPOSURE

DANGER: Symptoms of carbon monoxide (CO) poisoning include headaches, irritability, confusion, dizziness, drowsiness, visual disturbance, nausea, vomiting, asphyxiation, or lack of consciousness. If you or any bystander experience any of these symptoms, shut off the machine immediately and go outside for fresh air. Do NOT operate the machine again until it has been tested by a qualified technician.

The toxic effects of carbon monoxide in the blood are the result of tissue hypoxia (lack of oxygen). Carbon monoxide combines with hemoglobin to form carboxyhemoglobin. Since CO and oxygen react with the same group in the hemoglobin molecule, carboxyhemoglobin is incapable of carrying Oxygen. The affinity of hemoglobin for CO is 200 to 240 times greater than for oxygen. The extent of saturation of hemoglobin with CO depends on the concentration of the gas, the quantity of inspired air and on the time of exposure. The severity depends on the state of activity of the individual and his tissue oxygen needs.
The effects of CO can be experienced at different exposure levels, depending on the health of the individual. Conditions that affect the tolerance of the individual are smoking, age, temperature, humidity, and other conditions.

According to Harrison’s Principles of Internal Medicine 7th edition:

• No symptoms will develop at a concentration of 0.01 % CO (100ppm) in inspired air, since this will not raise blood saturation above 10 %.
• Exposure to 0.05% (500ppm) for 1 hour during light activity will produce a blood concentration of 20% carboxyhemoglobin and result in a mild or throbbing headache.
• Greater activity or longer exposure causes a blood saturation of 30 to 50 %. At this point head ache, irritability, confusion, dizziness, visual disturbance, nausea, vomiting, and fainting can be experienced.
• Exposure for one hour to concentrations of 0.1 % (1000ppm) in inspired air the blood will contain 50 to 80% carboxyhemoglobin which results in coma, convulsions, respiratory failure and death.
• On inhalation of high concentrations of CO, saturation of the blood proceeds so rapidly that unconsciousness may occur suddenly without warning.

INDUSTRY GUIDELINES FOR ACCEPTABLE CARBON MONOXIDE EXPOSURE

Limits for permissible exposure to Carbon Monoxide vary substantially from region to region. Consult local, regional, and national workplace safety standards to determine limits for carbon monoxide exposure in your area, prior to use of any propane machines.

The current Occupational Safety and Health Administration (OSHA) Permissible Exposure Limit (PEL) for CO is 35 ppm, as an 8-hour time weighted average (TWA). This is computed by making measurements at intervals over 8 hours, then adding the sums of the concentrations and the intervals, and dividing by 8 hours. For example:

Time intervals = 8 HR
Total ppm = 400
Time Weighted Average (TWA) = 400 ppm / 8 HR = 50 PPM/Hr

The current National Institute for Occupational Health and Safety (NIOSH) has determined that concentrations above the 1,200 ppm is “immediately dangerous to life and health” (IDLH). NIOSH defines the IDLH exposure level as the concentration that could result in irreversible health effects or death, or prevent escape from the contaminated environment within 30 minutes.

MEASURING CARBON MONOXIDE EXPOSURE

WARNING: Deployment of a monitor/detector is essential for the safe operation of any equipment that has the potential to produce carbon monoxide.CO sensors/detectors became available on the mass market around 1978. The main differences between the technologies involved are battery or electric and Semiconductor or Biomimetic types. Detectors for carbon monoxide (CO) are manufactured and marketed for use in either the home or occupational industrial settings. The detectors for home use are devices that will sound an alarm before CO concentrations in the home become hazardous. There is an Underwriters Laboratories, Inc., performance standard (UL 2034) for residential CO detectors. Detectors currently available on the market are battery-powered, plugin, or hardwired. Some models incorporate a visual display of the parts per million (ppm) concentration of CO present in the home. For more information on CO detectors for home use, call the Consumer Product Safety Commission:

Commission Hotline at 1-800-638-2772

CO detectors for use in residential settings are not designed for use in workplace settings. Monitoring requirements in an occupational setting are different from monitoring requirements inthe home. In the workplace, it is frequently necessary to monitor a worker’s exposure to carbon monoxide over an entire work shift and determine the time-weighted average (TWA) concentration of the exposure. It may also be necessary to have carbon monoxide monitors with alarm capabilities in the workplace. The direct reading instruments are frequently equipped with audio and/or visual alarms and may be used for area and/or personal exposure monitoring. Some have microprocessors and memory for storing CO concentration readings taken during the day. It is significant to note that some of the devices mentioned for workplace CO monitoring are not capable of monitoring TWAs, and not all are equipped with alarms. The appropriate monitor must be chosen on an application-by-application basis. For more information on the availability of workplace CO monitors or their application, call the National Institute for Occupational Safety and Health at 1-800-35-NIOSH (1-800-356-4674).

UNDERSTANDING FACTORS THAT DETERMINE CARBON MONOXIDE LEVELS

The primary factors that ultimately determine the expected level of Carbon Monoxide in a space where a propane machine is operating are as follows:

• Room air volume
• Air Exchange Rate (ventilation rate)
• Carbon Monoxide Production Rate

Room air volume can be determined by multiplying the length, width, and height of a room, and thenreducing for any material in the room. For example:

A room that is 100 ft x 100 ft with a 10 ft ceiling has a volume of: 100 x 100 x 10 = 100,000 cubic feet, when empty. If the room consists of 80% open air, and 20% material, the total room air volume = 100,000 * 80% = 80,000 cubic feet.

Air Exchange Rate is a measure of the room’s ventilation. Air exchange rate is typically measured in terms of the qty of air changes per hour (ACPH). In other words, the Air Exchange Rate when expressed as ACPH, measures the frequency (per hour) that the room’s air is replaced by fresh air. The higher the ACPH, themore frequently air is being ventilated, for example:

In a room with ACPH = 6, the room’s air would be completely extracted and replaced by fresh air 6 times every hour, or once every 10 minutes.

Here are some air exchange rates, expressed in ACPH, that would be expected in different types of industrial and commercial spaces:

Carbon Monoxide Production Rate is, itself, the result of several factors:

• The total flow of engine exhaust, which is determined by the relative amount of engine load of application
• The amount of Carbon Monoxide present in the exhaust, expressed as PPM
• The quantity of propane engines in operation

A 603cc propane engine under normal operating conditions (50% of maximum load) will produce total exhaust at a rate of 13 CFM (cubic feet per minute), with Carbon Monoxide making up 50 PPM of the total exhaust.

Therefore, the CO production rate (in CFM) is calculated as follows: Qty of Engines Exhaust Flow per Engine (CFM) CO Level of Exhaust (PPM)

Calculating the CO production rate of one 603cc engine operating under normal conditions is as follows: 1 engine 13 cubic ft / min per engine 50 / 1,000,000 = 0.00065 cubic feet/min

Knowing all of these factors, we can calculate the equilibrium carbon monoxide level of a room (in PPM) as follows:
Total CO production rate (in cubic feet / min) Air Exchange Rate (expressed in minutes)
1,000,000 Room air volume (in cubic feet)

This table shows the calculated equilibrium carbon monoxide level under different examples with varying inputs:

Example No.| Qty of Engines| CO in Exhaust (PPM)| Exhaust Flow per Engine (CFM)| Total CO Production Rate (CFM)| Air Exchange Rate (ACPH)| Air Ex- change Time (min)| Room Air Volume, ft3| Room CO Level (PPM)
---|---|---|---|---|---|---|---|---
1| 1| 50| 13| 0.00065| 3| 20| 80000| 0.163
2| 5| 50| 13| 0.00325| 3| 20| 80000| 0.813
3| 5| 50| 13| 0.00325| 3| 20| 80000| 8.13
4| 5| 50| 13| 0.00325| 1| 60| 80000| 24.4
5| 5| 500| 13| 0.0325| 1| 60| 80000| 244

There are several important notes to take away from these calculations:

• More engines running in a space leads to higher room CO level. This is shown comparing Examples No. 1 & 2.
• Smaller room size leads to higher room CO level. This is shown comparing Examples No. 2 & 3.
• Lower ventilation (Air Exchange Rate) leads to higher room CO level. This is shown comparing Examples No. 3 & 4.
• Higher CO level in the exhaust leads to higher room CO level. This is shown comparing Examples No. 4 & 5.

DANGER: Operating this machine or any propane powered engine in a space with NO ventilation (a sealed space), is guaranteed to result in dangerously high level of CO, that will cause serious injury or death to the operator and bystanders. Never operate the machine in a sealed space with no ventilation.

METHODS TO REDUCE CARBON MONOXIDE EXPOSURE

Reviewing the above section, we already know that to reduce CO exposure the following action should be taken:

• Limit the quantity of engines running in a space.
• Insure adequate ventilation. Higher ventilation rates (higher air exchange rate) will always result in lower CO exposure.
• Insure proper maintenance and performance of engine to avoid high CO content in engine exhaust.
• All of these tips are especially important to follow when using the machine in small spaces.

This section offers additional considerations and best practices to reducing Carbon Monoxide exposure:

• Air Exchange and CO Diffusion
• Application Considerations
• Examples of CO Management in Spaces
• Maintenance of Equipment

AIR EXCHANGE AND CO DIFFUSION

The most reliable method to prevent CO Poisoning is to ensure all the CO produced is vented outside. With wood stoves or gas heaters this is performed with ductwork that carries the exhaust and CO outside. Non-stationary combustion type equipment must be used in such a way that CO is not allowed to rise to a harmful or dangerous level. CO does not readily dissipate or mix with air on its own. Air currents can “stir” the CO and dilute the concentration or ppm values by mixing it with the available air. When using equipment over a large area in a short time “stirring” occurs as you walk, or to say it another way, your Effective Operating Zone is large. When activity is concentrated to a smaller area as in a stripping application, the Effective Operating Zone is small, and “stirring” must be forced by the use of fans to increase the Effective Operating Zone and reduce high concentrations of CO. “Air” exchange rates (air exchange is defined as the exhausting of internal air to the external atmosphere), the size of the Effective Operating Zone, amount of CO produced, level of human activity, and the duration of exposure are all factors in the determination of the production of carboxyhemoglobin and the amount of CO blood saturation.

TYPE OF WORK CONSIDERATIONS

Different types of work (applications) present varying risk of CO exposure. The highest risk is associated with types of work that require slow movement, such as floor stripping or polishing. Due to slow movement, the activity and engine exhaust is concentrated to a relatively small area which results in higher CO levels for the operator. Types of work that require high movement, such as burnishing, will naturally stir the air and diffuse the engine exhaust and result in lower CO levels for the operator.

The term “Effective Operating Zone” is used to visualize this concept. The Effective Operating Zone can be defined by the amount of area covered during a given time frame. Small Effective Operating Zones result the greatest risk of CO Exposure.

When using equipment over a large area in a short time, as in most burnishing applications, your Effective Operating Zone is large. When activity is concentrated to a smaller area as in stripping applications, the Effective Operating Zone is small and stirring or CO mixing MUST be forced by the use of fans to increase the Effective Operating Zone and reduce high concentrations of CO. The Effective Operating Zone can be defined as the area covered in a given time.

WARNING: When the Effective Operating Zone is small, fans must be used to force the mixing/ stirring of air and reduce high concentrations of CO

WARNING: Proper ventilation must be combined with air mixing/stirring to reduce CO to a safe level.

EXAMPLES OF CO MANAGEMENT IN SPACES

MODEL 1: Worst Case CO Management

Model 1 illustrates the worst case of CO management for several reasons:

• The room is not properly ventilated
• The air in the room is not mixed/stirred with any fans
• The type of work shown (stripping) requires low speed movement and results in a smaller “Effective Operating Zone”.

Note: Even though the room is large, due to these worst practices, the engine exhaust is concentrated near the operator, resulting in high CO exposure.

MODEL 2: Poor CO Management

Model 2 illustrates a slightly improved case of CO management, compared with Model 1, because air ventilation is introduced. As a result, the Effective Operating Zone is slightly increased and slightly lower levels of CO concentration would be expected. However, because air is not mixed/stirred, and because the type of work shown (stripping) requires low speed movement, there is still a potential risk of high CO exposure. The CO cloud is still concentrated in a small area. Note the “Dividing Zone” shown above, this is the line where airflow changes direction. Because all of the CO exists on one side of the dividing zone, only half of the room’s ventilation is effectively evacuating CO.

MODEL 3: Better CO Management

Model 3 illustrates an even more improved case of CO management, compared with Model 2, because the air is being mixed/stirred with fan(s). Notice the CO concentration and the Effective Operating Zone (Expanded to the Dividing zone) due to the forced air mixing. The CO cloud is still concentrated on one side of the Dividing zone. As in Model 2, because all of the CO exists on one side of the dividing zone, only half of the room’s ventilation is effectively evacuating CO.

MODEL 4: Best CO Management

Model 4 illustrates the best case of CO management, because the forced mixing/stirring of air causes the diffusion of CO across the Dividing zones, and maximizes the Effective Operating Zone. This method maximizes the amount of diffusion and maximizes the amount of CO that will be effectively evacuated by the room’s ventilation, and thus minimizes the operator’s potential exposure to CO.

Maintenance of Equipment

There are several components and systems on the propane engine of this equipment that ensure minimal CO output:

Catalytic Muffler: A three-way type catalytic converter to scrub CO, Hydro Carbons (HC), and Nitrous Oxide (NOx) from the engine exhaust providing the lowest possible emissions.

Propane Fuel System: The regulator/carburetor of this engine (the fuel system) are specifically calibrated for the engine to run with a very “lean” air/fuel ratio which minimizes the production of carbon monoxide.

Air Cleaner: The engine is equipped with an air-cleaner that filters dust and contaminates from the air used for combustion, resulting in a full and clean burn during engine ignition

WARNING: The proper maintenance of equipment is vital to safe operation. LPG engines are dependent on engine tune up, and air filter replacement. CO concentration (production) skyrockets when the air to fuel ratio becomes fuel rich. Follow the recommended Maintenance found in the Engine Operator Manual as well as in this Operator Manual.

GENERAL OPERATION SAFETY

DANGER: Severe burn or injury could occur if you touch the hot muffler, exhaust pipe, or cylinder. Do NOT Touch these hot parts.

WARNING: Any alterations or modifications of this engine could result in damage to the engine or injury to the operator or other bystanders. Alterations or modifications not authorized by the manufacturer voids any and all warranties and liabilities.

WARNING: To avoid injury or property damage, DO NOT leave the machine where it can be tampered with or started by persons untrained in its operation.

WARNING: Moving parts of this machine can cause serious injury and/or damage. Do not allow contact of clothing, hair, hands, feet, or other body parts with the rotating pad. Keep other people away from the machine while it’s in operation. DO NOT leave the machine or engine running unattended.

WARNING: Operate the machine at a slow or moderate pace. DO NOT run when operating the machine.

WARNING: Substantial damage to the floor, the machine, or personnel may result if the machine is operated with the pad off center, damaged or missing. Do not operate the machine if the pad is off center, damaged or missing

WARNING:  Operating an engine that has loose parts could result in injury or property damage. DO NOT operate this engine if there are loose parts. Inspect the engine for loose parts frequently. This will promote safe operation and a long engine life.

WARNING: Vibration from machinery may cause numbness or tingling of the fingers in certain people. Smoking, dampness, diet, and heredity may contribute to the symptoms. Wearing warm clothing, gloves, exercising and refraining from smoking can reduce the effects of vibration. If the symptoms still persist, discontinue operation of the machine.

WARNING: Keep bystanders away from the engine while it is in operation

WARNING: Injury to the eyes and/or body can occur if protective clothing and/or equipment is not worn while using this engine. Always wear safety goggles and safety clothing while using this machine.

WARNING: Long or continuous exposure to high noise levels may cause permanent hearing loss. Always wear hearing protection while using this machine.

WARNING: Injury to the operator or bystanders could occur if the machine’s power is on while changing the buffing pad or making machine adjustments. Never try to change the buffing pad or attempt to make machine adjustments while the engine is running.

PROPANE BASICS

• Propane is commonly available and has proven to be a dependable, safe, economical, and clean burning fuel. It can be used as a household fuel, industrial fuel, and fuel for internal combustion engines. Propane has been used as a fuel since 1910.
• The molecular formula of propane is C3H8, and it is in the family of liquefied petroleum gases (LP gases). The other LP gases include butane, propylene, butadiene, butylene, isobutylene and mixtures thereof.
• At atmospheric pressure, propane boils at -44 degrees Fahrenheit, meaning it typically exists as a vapor. However, when contained under pressure, such as in a propane cylinder, it can exist as a liquid.
• Propane is naturally odorless, but includes an additive odorant, usually mercaptan, which gives it a distinct odor similar to rotten eggs or skunk.
• Vapor propane is heavier than air, meaning it will settle in low areas such as along the ground or in drains.

PROPANE CYLINDERS (TANKS)

WARNING: Only use D.O.T. certified propane cylinders intended for engine fuel applications. NEVER use a cylinder not intended engine fuel applications. DO NOT substitute cylinders that are used with a barbecue grill, etc.

WARNING: DO NOT tamper with cylinder gauges or safety relief valves.

WARNING: At time of propane cylinder fill or exchange, ensure tank is in operable condition and meets all certification requirements. Discontinue use of any cylinder that is damaged or rusted or does not comply with certification requirements. Your propane service company will assist with compliance.

Propane cylinders are constructed according to ASME and Federal DOT #4ET20 pressure safety codes. All valves and fittings are UL Listed. Propane gas is noncorrosive and will not rust the inside of a cylinder. It is recommended to have propane cylinders inspected regularly during re-fill by an authorized National LP Gas Association propane dealer. The fuel cylinder is supplied directly from the manufacturer and is void of propane.

Propane cylinders are constructed to function in specific configurations. The primary configuration options are:

• Propane Withdrawal: Vapor or Liquid
• Cylinder Orientation: Horizontal or Vertical

IMPORTANT: Different cylinder configurations are not interchangeable. This machine uses Vapor cylinders with Vertical orientation.

PROPANE CYLINDERS (TANKS)

**CAUTION:** Do not use incorrect propane cylinders, such as liquid withdrawal cylinders for fork lift trucks or other liquid withdrawal applications.

CAUTION: Use only vertical orientation propane cylinders. Always install cylinders on the machine in the proper orientation ****

**CAUTION:** Failure to use a proper cylinder or failure to install cylinder in proper orientation will result in liquid propane withdrawal and cause damage the regulator.

FILLING PROPANE CYLNDERS

WARNING: Propane cylinders should only be filled by your propane provider or by individuals who have been properly trained and certified.

WARNING: Escaping propane can freeze skin and cause frostbite and damage eyesight. Always wear safety gloves and safety glasses when filling propane cylinders.

**CAUTION:** Overfilling propane cylinders is the number one cause of damage to the propane fuel system. This fuel system is designed to run off vapor propane, not liquid propane. When the cylinder is overfilled, liquid propane will enter the fuel system and can damage lock-off and regulator, in addition to causing the engine to run poorly or not at all. This voids the warranty on affected parts of the engine. To avoid problems, read and understand fully, the section “FILLING PROPANE CYLINDERS”.

**CAUTION:** Only use HD-5 grade propane to operate this engine.

**CAUTION:** Propane cylinders must be purged at the time of the first fill. Your propane suppliers should be familiar with this operation and will provide this service. Purging instructions are provided in section below

The maximum fill volume of a propane cylinder is ALWAYS considered 80% of the total cylinder volume to allow for expansion and to ensure proper vapor withdrawal from the cylinder.

For example, if your propane cylinder is referred to as a “20 lb cylinder”, this means that when the propane cylinder is 80% full, the weight of the propane is 20 lb.

Cylinders should be filled in the vertical position. When filling a propane cylinder, the fixed liquid level gauge should be opened (unscrewed counterclockwise) so it can be used to determine when propane has reached 80% full. As propane is added during filling, vapor will escape the small hole in this gauge. When the cylinder reaches 80% full, the escaping propane will turn to liquid propane. When this happens, the filling should be immediately stopped and the gauge should be closed (turned clockwise).

PURGING PROPANE CYLINDERS

**CAUTION:** New containers may contain vapor, air, or other contaminants. It is essential that these be removed before filling the container and placing it into service. Air in the container will cause abnormally high pressure, with the result that the pressure relief valve may open. Air in the system is also likely to cause lean mixture, making ignition difficult. If a cylinder is suspected of being depressurized or open to the atmosphere for a period of time, it must be re-purged as if it were a new container.

Symptoms of a non-purge cylinder:

• Relief valve opens due to over pressurized cylinder creating hazardous situation.
• Moisture in the cylinder.
• Machine operates initially but shuts down when fuel mixture becomes too lean.

To purge a container, the following steps should be taken

1. Purging of containers should be performed in an approved area (see NFPA 05 8) using NPGA #13 3.89(a) procedure.
2. Determine if the container pressure is zero. Should the cylinder contain only pressurized air, the air may be vented directly to the atmosphere through the service valve using an adapter and the outage valve. Pressurize the container to approximately 15 psig with LP-gas vapor. Never purge with liquid LP-gas! To do so will cause the moisture vapor to chill and remain in the cylinder. LP gas liquid also expands 270 times to vapor making the purge process ineffective. Use LP-gas vapor only!
3. Make the connection to the quick coupler (A purge manifold system is most effective). Fully open the cylinder service valve as well as the outage valve. Vent to a safe atmosphere. A vent stack is recommended.
4. On Overfill Prevention Device cylinders, the purge time is increased as a result of the new valve design. Opening the outage valve will help improve the speed of the purge.
5. Repeat #3 and #4 for a total of FIVE purges.
6. Re-pressurize the container with odorized LP-gas vapor to 15 psig.
7. The container is now ready to be filled with LP-gas.
8. Once filled, check all fittings and tank openings for leaks using an approved leak detector solution.
9. The container is now ready to be placed in service. Add DOT and OSHA labels

STORING & TRANSPORTING PROPANE CYLINDERS

The NFPA Technical Committee prohibits the storage of such containers in buildings. There are few exceptions to this rule. In other words, propane tanks should NOT be stored in buildings used by the public or frequented by anyone passing through or who is working in the building. Full or empty, never leave tanks in small enclosed areas. The tank(s) must be in a secure, tamper- proof storage enclosure that provides safety from accident or vandalism.

Propane cylinders should always be transported either secured to the machine using cylinder straps, or secured in an upright position during transportation.

MACHINE SPECIFICATIONS

Engine Size: 603 CC
Pad Diameter; 21 in. / 24 in. / 27 in.
Net Weight: 272
Gross Weight: 330 lb
Packaged Dimension: 52 in. (L) x 30 in. (W) x 44 in. (H)
Front Wheels: 6 x 1.5 in. (x2
Pulley   Ratio: 4:8
Belt: BX51
Engine Idle RPM: 2000
Engine MAX RPM: 2900 to 3500
PAD RPM: 1000 to 1800
Propane Cylinder: 20 LB Vertical Vapor

COMPONENTS & CONTROL

1. Engine

2. Catalytic Muffler

3. Machine Deck

4. Shroud

5. Shroud Seal

6. Front Bearing Housing

7. Belt Tensioner

8. Battery

9. Electronic Box & Cover

10. Propane Tank

11. Tank Strap

12. Propane Hose w/ REGO Valve

13. Handle

14. Grips

15. Bonnet Filter
    

16. Engine Throttle Control

17. Clutch Handles*

18. Handle Adjustment Knob

19. Hour Meter / Tachometer

20. Headlight Switch*

21. Water Switch*

22. Ignition Switch & Key

23. Pad

24. Pad Holder

25. Front Wheels

26. Rear Casters

27. Dust Bag*

28. Dust Chute*
    

OPERATION

**CAUTION:** OVERHEATING is a major cause of engine failure. Keep the engine clean and free of debris build up.

**CAUTION:** Low oil levels and dirty oil account for most of the other failures. Follow the engine manual’s recommended oil change sch

PREPARATION

1. Check engine oil level according to Engine Operator Manual
2. Ensure propane cylinder has been properly filled according to section “Filling Propane Cylinders”
3. Check for any sign of wear or damage such as cracks, corrosion, punctures, etc. to the fuel system including propane cylinder, fuel hoses, fittings, regulator, carburetor, and electrical components.
4. Ensure main service valve on propane cylinder is closed (turned clockwise).
5. Screw the REGO fitting of the high-pressure propane hose onto the cylinder service valve and hand tighten. This connection MUST be tight and secure and fully seated to function.
6. Ensure propane tank is secured with clamping strap
7. Ensure handle is secure and at a comfortable position
8. Ensure all machine parts (belt, pad, handle, wheels, etc.) are in place and secure.
9. Ensure the pad is at least 1/3 inch thick, and that the pad holder is tight.
10. Ensure the pad driver is secure to the drive shaft.
11. Ensure the battery cable is connected.

STARTING THE ENGINE

WARNING: Before attempting to start engine, become familiar with all controls of the machine.

1. Slowly open the main service valve on propane cylinder to the fully open position.

2. Set throttle to Idle position.

3. Ensure machine is rocked back on its rear casters, so the pad is not in contact with the floor.

4. Turn Ignition Switch to “Start”, which will engage starter. Allow cranking for a maximum of 6 seconds or until the engine fires. If engine fails to fire on the first attempt, repeat this step. It will likely fire on the second attempt due to internal fuel priming.
   **CAUTION:** Serious starter damage will result if starter is engaged for more than 6 seconds, and will void warranty.

5. Once engine has started, slowly increase throttle. Allow for a warm-up period for 30 Seconds before applying full load to the engine.

Note : If the engine fails to start, see the Troubleshooting Gu

STOPPING ENGINE

Normal Stop
Follow these stopping procedures under normal use, including when the engine will be stored or transported:

1. Set throttle to Idle position.
2. Close the service valve on propane cylinder (turn clockwise fully).
3. Allow the remaining propane in the regulator and fuel hose to be consumed by engine, until engine stops.
4. Turn engine key switch to off.
5. Disconnect fuel line from propane cylinder.
6. If storing or transporting the machine, follow instructions in section “STORING & TRANSPORTING PROPANE CYLINDERS”

Immediate Stop
Follow these stopping procedures only when an immediate stop is required:

1. Turn engine key switch to off.
2. lose the service valve on propane cylinder (turn clockwise fully).
3. Disconnect fuel line from propane cylinder.

HANDLE ADJUSTMENT

The handle on this machine can be adjusted to several heights, to accommodate different sized operators and different operator preferences. To adjust the handle:

1. Stop the engine.
2. Loosen the Handle Adjustment Knob, until the Handle is allowed to pivot freely. Note: Do not fully remove this knob.
3. Adjust the Handle to desired position.
4. Tighten the Handle Adjustment Knob

WHEEL POSITION ADJUSTMENT

The position of the two front wheels has significant affect on the performance and handling of the machine, including:

Pad pressure = The amount of force the pad has against the floor Forward
propulsion = The feeling of forward pull or drive caused by pad friction
Machine torque = The feeling that the machine wants to constantly turn, usually toward the left

When your machine was assembled, the wheels were installed in positions determined to allow for best performance under most conditions. However, depending on floor type, floor finish type, pad type, and operator preference, these wheel positions can be changed to affect machine performance.

For the purpose of clarity, the following terms will be used in this section:

Forward = closer to the front of the machine
Rearward = closer to the rear of the machine
Up = closer to the sky
Down = closer to the ground
Left = the left side when viewed from the Operator’s position
Right = the right side when viewed from the Operator’s position

Through wheel adjustment, the following changes can be made to the machine performance:

Desired Change

1. Increase pad pressure
2. Decrease pad pressure
3. Increase forward propulsion
4. Decrease forward propulsion
5. Increase machine torque
6. Decrease machine torque

Adjustment to Make

1. Move both wheels (left and right) Rearward
2. Move both wheels (left and right) Forward
3. Offset the two wheels, so the right wheel is Higher (more “up”) than left
4. Align the two wheels, so the left and right wheel are the same height
5. Move both wheels (left and right) Down
6. Move both wheels (left and right) Up

To change the wheel position:

1. Stop the engine.

2. Adjust handle position to highest position and rock machine back, until handle grips are resting on ground.
   **CAUTION:** Whenever working on a machine in the rocked back position, ask an assistant to hold the handle and prevent the machine from falling forward.

3. Remove the small cotter pin / hair pin from the wheel axle.

4. Remove the wheel axle.

5. Remove the wheel and any spacer.

6. Reposition the wheel and spacer in desired hole.

7. Insert the wheel axle.

8. Insert the cotter pin / hair pin.

MAINTENANCE

WARNIN: To ensure personal safety, adjustments should ONLY be made by a qualified technician or an authorized service enter.

WARNIN: Prior to any maintenance, ensure engine is turned off and disconnect spark plug wire from spark plug. Never attempt service or maintenance on a running engine.

MAINTENANCE SCHEDULE

For engine maintenance instructions and service intervals, refer to Engine Operator Manual

| Daily| 25hr| 200hr
---|---|---|---
Check Engine Oil Level| X| |
Check for Loose Hardware| X| |
Check for Fuel or Oil Leakage| X| |
Check/Clean Intake Air Filter| X| |
Check/Clean Bonnet Filter| X| |
Check, Clean, and/or Replace Dust Bag| X| |
Check Pad| X| |
Check Shroud & Shroud Seal| X| |
Check Engine Mounts| | X|
Check Belt for Wear or Slippage| | X|
Check Pulleys, Drive Shaft, and Bearings| | X|
Check Wheels & Bearings| | X|
Overall Checkup at Authorized Service Center| | | X

Battery Specs:

Battery Specs:|
---|---
Model| HJTZ5S-30-GFP
Volltage (V)| 12.8
Capacity (Ah)| 3
Weight| 0.7 kg / 1.5 lb
Charging Current| 0.5A to 15A
Charging Voltage| 14.4 0.5 V
Cold Cranking Amps| 180
Cycle Life| ≥1000

The equipment uses an onboard charging system integrated within the wiring harness which charges battery during normal use.

battery can be recharged offline with any off-the-shelf battery charger with the following specs:
Voltage = 12 volts
Charging Amperage = 0.5 to 15 Amps

Battery Charging Procedures:

1. Disconnect the plastic battery cable terminal on equipment, and remove battery from equipment.
2. Connect the charger clamps to the battery posts:
   • Red clamp on the positive “+” post
   • Black clamp on the negative “-” (ground) post
3. If the charger has settings, set the output voltage and amperage within the ranges noted above.
4. Plug in the battery charger to standard wall outlet in a well ventilated area.
5. For best results, leave the charger connected for minimum of 8 hours.
6. Disconnect battery from charger by reversing steps 5-2
7. Reinstall battery on equipment, and connect the plastic battery cable terminal.

DUST COLLECTION MAINTENANCE

If equipped with a dust collection system, the dust bag should be serviced frequently as follows:

1. Stop engine.
2. Remove the bag from the dust chute, but pulling the elbow out of the dust chute.
3. Unzip the back of the bag.
4. Empty the contents of the bag into a garbage receptacle and shake out any debris. This is best done outside.
5. Reinstall the bag onto the dust chute, and secure the bag to machine via the rope loop and velcro on bag.

Note: The bag will remain functional for approximately 20-30 cycles, after which the bag should be replaced.

HOW TO CHANGE PAD

1. Stop the engine.

2. Adjust handle position to highest position and rock machine back, until handle grips are resting on ground.
   WARNING: Whenever working on a machine in the rocked back position, ask an assistant to hold the handle and prevent the machine from falling forward.

3. Remove the Pad Holder by turning it counterclockwise.

4. Remove the Pad, by pealing it off of the gripper surface

5. Install a new Pad onto the gripper surface, paying attention to keep it centered and aligned with the gripper surface.

6. Reinstall the Pad Holder, and tighten it by turning it clockwise.

STORAGE

Take the following steps when storing the machine:

1. Ensure the ignition switch is turned to “off”.
2. Remove the propane tank, and store in an approved outside location.
3. Disconnect battery cable connectors, to prevent battery drain. When disconnected, the battery will keep its charge in storage for approximately 12 months.
4. Store machine in an indoor, climate controlled location with low humidity.

TROUBLESHOOTING

Note: When troubleshooting, always first check for simple causes which may at first seem too obvious. For example, an engine unable to start may be caused by an empty propane cylinder or an unopened service valve.

battery.
Battery cable is disconnected.| Connect battery cable at connector.
Igntion switch faulty.| Check switch, replace if necessary.
Faulty Starter.| Check starter, replace if necessary.
Damaged or disconnected wire in wiring harness.| Check wiring harness to identify faulty connection, replace or reconnect as required.
Numerous other causes.| See engine manual or dealer.
Engine turns over, but does not start or run.| Propane cylinder is empty.| Refill cylinder or replace with full cylinder.
Main fuel service valve on propane cylinder is closed.| Manually open main fuel service valve on propane cylinder.
REGO fitting (fuel hose to cylinder connector) is not fully seated.| Manually close main fuel service valve. Disconnect REGO fitting. Reconnect and hand tighten to ensure secure connector is fully seated. Slowly open main fuel service valve.
Propane cylinder OPD (overflow pro- tection device) has been triggered.| Manually close main fuel service valve. Disconnect REGO fitting. Wait 5 seconds. Reconnect and hand tighten to ensure secure connector is fully seated. Slowly open main fuel service valve.
Propane regulator out of adjustment or faulty.| Have certified dealer inspect regulator and adjust or replace.
Poor quality propane causes deposits of particles in regulator or valves.| Have certified dealer inspect regulator and clean or replace. Service engine valves according to engine manual instructions. Contact propane supplier to pro­vide clean HD5 propane.
Spark plug not firing.| Replace spark plug.
Faulty oil pressure switch.| Check or replace oil pressure switch.
Numerous other causes.| See engine manual or dealer.
Propane regulator freezes and prevents flow of propane.| Liquid propane is entering regulator.| ·    Ensure cylinder is designed for VAPOR withdrawal.

·    Ensure cylinder is designed for the correct orientation (horizontal or vertical).

·    Ensure cylinder is installed in correct orientation. Make sure locator pin is inserted into positioning slot on cylinder collar, and follow orientation arrow indica­tions/labels on cylinder.

·    Ensure propane cylinder is not overfilled.

·    Ensure use of application does not allow operating angles to exceed equipment OEM instructions.

Low ambient temperature.| It is normal condition for propane regulator to operate at colder temperature than ambient, which may cause condensation or frost formation depending on ambient temperature and humidity levels.

propane main fuel service valve. Check fuel lines, REGO fitting, and regulator for any leaks.
Propane consumption is abnormally

h

high.

time” below.

| Refer to section “Inconsistent or short cylinder run
Low ambent temperature.| It is normal condition for propane cylinder to operate at colder temperature than ambient, which may cause condensation or ice formation depending on ambient temperature and humidity levels.
Inconsistent or short cylinder run time.| Propane cylinders not filled consistently.| Use cylinders that are properly and consistently filled to the 80% maximum level.
Propane regulator out of a

adjustment or faulty.

| Have certified dealer inspect regulator and adjust.
Dirty air filter.| Service air filter.
Excessive engine load.| See engine manual or dealer.
Excessive engine RPM| See engine manual or dealer.
Engine backfires, difficult to start, reduced power, over-heating, or other poor performance| Propane regulator out of adjustment or faulty.| Have certified dealer inspect regulator and adjust.
Propane flow restricted.| Refer to section “Engine turns over, but does not start or run”, above.
Dirty air filter.| Service air filter.
Dirty propane filter.| Service propane filter.
Ignition system faulty.| Check or replace ignition coils.
Poor compression.| See engine manual or dealer.
Engine timing issue.| See engine manual or dealer.
Cooling Fins Clogged.| See engine manual or dealer.
Numerous causes.| See engine manual or dealer.
Excessive machine vibration.| Pad is not centered on pad driver.| Remove pad and reinstall, paying attention to center it on pad driver.
Pad driver is damaged.| Inspect pad driver and replace if necessary.
Front end bearings are worn/damaged.| Inspect front end bearings and replace if necessary.
Clutch failure.| Blown fuse.| Check fuses in Electronic Box and replace if necessary.
Disconnected wire at clutch.| Check wires that connect the actual clutch to the wiring harness. Reconnect if necessary.
Disconnected wire under ignition switch.| Check wires that connect clutch handles to wiring harness located under the ignition switch. Reconnect if necessary.

dealer inspect regulator and adjust.
Engine monitor is faulty.| Replace engine monitor.
Battery does not hold a charge.| Battery is faulty.| Replace battery.
Battery is not being charged during machine running.| Faulty voltage regulator.| Replace voltage regulator.
Damaged or disconnected wire in wiring harness.| Check wiring harness to identify faulty connection, replace or reconnect as required.

References

• onyxsolutions.com
• Home | ONYX Technology Powering A Cleaner Future
• HOME | www.onyxsolutions.com
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