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71

Maintenance and Service

5

Maintenance and Ser-
vice

General information

It is essential to pay attention 
to the information in Chapter 
“Safety Information” before 
completing any service or 
maintenance work!

By adhering to the maintenance work 
recommended by us, you can be sure 
that the vehicle is always ready to be 
put into operation.
Maintenance and repair work neces-
sary on a daily and weekly basis can be 
carried out by a driver trained to com-
plete the work, all other PowerBoss 
system maintenance may only be com-
pleted by personnel who are corre-
spondingly qualified and trained. In 
case of doubt, please contact your 
nearest PowerBoss service center or 
authorized PowerBoss dealer. Failure 
to observe this annuls any rights to 
claims under the terms of guarantee in 
respect of resulting damage or conse-
quential damage.
Always specify the serial number, indi-
cated on the rating plate when making 

any inquiries and orders for spare parts, 
refer to Section 1.7.

5.1

PowerBoss system mainte-
nance

PowerBoss system maintenance:
• ensures the PowerBoss working ve-

hicle is always ready for operation 
(preventive maintenance),

• minimizes operating costs, mainte-

nance and repair costs,

• ensures the vehicle has a long ser-

vice life.

The PowerBoss system maintenance 
describes the specific technical work 
necessary for the individual modules 
and defines the intervals for the mainte-
nance tasks. Individual parts which 
must be changed during maintenance 
tasks are defined and stipulated in 
spare parts kits.

PowerBoss system maintenance, 

 

customer:
Work to be carried out by the customer 
according to the service and mainte-
nance instructions in the operating 
manual (daily and weekly). Operating 
personnel are given the necessary in-
struction by specialists when the vehi-
cle is delivered.

PowerBoss system maintenance I:
(Every 250 operating hours or at least 
once a year)

 

Must be completed by a skilled techni-
cian in an authorized PowerBoss ser-
vice center according to the vehicle-
specific system maintenance with a 
spare parts kit.

PowerBoss system maintenance II:
(Every 500 operating hours or at least 
once a year)

 

Must be completed by a skilled techni-
cian in an authorized PowerBoss ser-
vice center according to the vehicle-
specific system maintenance with a 
spare parts kit.

PowerBoss system maintenance 
III/S:
(Safety check, every 1000 operating 
hours or at least once a year)

 

Must be completed by a skilled techni-
cian in an authorized PowerBoss ser-
vice center according to the vehicle-
specific system maintenance with a 
spare parts kit.

Summary of Contents for Admiral 40D

Page 1: ...Instruction Manual Admiral 40D 7580 13 ...

Page 2: ... that only original spare parts are used for any necessary maintenance and repair work Only ori ginal spare parts can guarantee long reliable equipment operation We reser ve the right to make technical improve ments Valid from April 2011 PowerBoss Inc 175 Anderson Street NC 28315 U S A Telephone 910 944 2105 Fax 910 944 740 Intended use The Admiral 40 D is a scrubber drier ve hicle conceived for w...

Page 3: ...orized PowerBoss service centers and confirmed in the Maintenance Report which serves as a warranty logbook The following are excluded from the terms of warranty wear and tear through overuse defective fuses im proper handling and use or unauthori zed modifications Claims under the terms of warranty are annulled when damage occurs to the vehicle resulting from the use of parts or accessories not e...

Page 4: ... 22 3 Operation 23 3 1 Method of operation 23 3 1 1 Scrubbing unit 23 3 1 2 Squeegee 25 3 1 3 Suction turbines suction 25 3 1 4 Pre sweep Vacuum unit option 25 3 1 5 Fresh water tank 26 3 1 6 Recovery tank 27 3 1 7 Traction drive 27 3 1 8 Brakes 28 3 1 9 Batteries and charger 29 3 1 10 Options 30 3 2 Operating and indicator elements 34 3 2 1 Operating elements in the driver s cab 34 3 2 2 Left han...

Page 5: ...6 Recovery tank 91 5 6 1 Emptying the recovery tank 92 5 6 2 Cleaning the recovery tank 92 5 6 3 Cleaning the draining hose cap 93 5 6 4 Cleaning the air intake filter 94 5 6 5 Cleaning the openings to the fresh water tank 94 5 7 Scrubbing unit 95 5 7 1 Changing the brushes 95 5 7 2 Installing new rubber deflector strips 96 5 8 Squeegee 97 5 8 1 Cleaning the squeegee 97 5 8 2 Disassembling the squ...

Page 6: ...tion Safety information persons or property Safety information to prevent the development of haz ardous situations resulting from ignoring or failing to follow instructions or prescribed work procedures Note the machine Important information on handling the equipment in order to maintain its functionality Ecological hazard the environment Ecological hazard through the use of substances which repre...

Page 7: ...e all the information during work The vehicle may only be operated maintained and repaired by persons trained by PowerBoss or authorized to do so by PowerBoss Particular attention should be paid to the information regarding safety Technical expertise is the key to pre venting errors when operating the equipment and ensuring trouble free operation The operating manual must always be kept at the ope...

Page 8: ... have proven their ca pability to operate the vehicle to the contractor or person appointed by him and have been explicitly charged by him to operate the vehi cle Before starting work operating per sonnel must be fully familiar with all adjustment operating and control el ements as well as their respective function It is too late to do this when the vehicle is actually in operation The warning lab...

Page 9: ...orized used of the vehicle lock the drive by removing the key from the key switch When transporting the vehicle the motors must be shutdown Only open empty recovery tanks The scrubber drier may only be driv en on hard surfaced sufficiently non slip ground e g asphalt con crete which is free of oil water snow etc The vehicle may only be driven on gradients to a maximum of 6 for a maximum of five mi...

Page 10: ...from the accumulation of dirt viruses bacteria etc It is not permitted to use aggressive and corrosive cleaning agents Allow the vehicle to dry after being cleaned e g over the weekend The vehicle must be checked by a recognized technical expert in re spect of operational safety at rea sonable intervals we recommend at least one a year particularly with re gard to protective equipment and locks an...

Page 11: ...te but recharge them as soon as possible Only refill distilled water When the cells are in good condition never refill the battery acid Spilled battery acid must never enter the sewage system in its initial form it must be neutralized beforehand Pay attention to legal requirements and local directives For further safety information see supplementary sheet 88 60 2554 Notes on driving batteries ...

Page 12: ...y approved batteries may be installed at the intended position To prevent creeping currents al ways keep the batteries clean and dry and protect from contamination e g from metal dust Never lay any metallic objects or tools on batteries Risk of short cir cuit and deflagration Ensure sufficient ventilation in the charging area when charging the batteries Otherwise there is a risk of explosion The s...

Page 13: ...nhale or swallow the content of batteries Health hazard Do not allow batteries to get into the environment Risk of contaminating the ground and water In accordance with symbol with the crossed out gar bage bin these batteries must not be disposed of in domestic waste Return and recycling of old batteries must be agreed on with the autho rized PowerBoss dealer in accor dance with national requireme...

Page 14: ...egible Missing or illegible labels must be replaced immediately Company logo Fig 1 1 Fig 2 1 Read the operating manual maximum gradient and ban on cleaning using a high pressure washer Fig 1 2 Rating plate Fig 1 3 The rating plate is in the driv er s cab at the bottom on the flap of the left hand electrical compartment Fig 1 1 2 3 ...

Page 15: ... Safety Information Drive direction selector Forwards or reverse Fig 2 4 Release parking brake Fig 2 5 Apply parking brake Fig 2 6 Maximum water temperature for water to be filled Fig 2 7 Fig 2 7 4 5 6 1 ...

Page 16: ... the hose which hangs to the left of this label Waste water drain age Fig 3 9 The waste water is drained via the hose which hangs to the right of this label No waste water drainage Fig 3 10 The flap serves ex clusively for cleaning and maintenance of the recovery tank Fig 3 9 9 8 10 ...

Page 17: ...cepted when these units are used Before starting the vehicle up for the first time the batteries to be used must be fully charged properly by imple menting the initial battery charge routine PowerBoss as sumes no liability for damage to the battery caused by a fault when the battery is charged for the first time The seat console must be piv oted open during the battery charging process to prevent ...

Page 18: ...and remove the key Installing the brushes The brush locks supplied loose in the vehicle s accessories kit must be as sembled on the brushes in accordance with Figure 6 1 Fig 5 1 Deflector 2 Deflector lock 3 Grip 1 Open the deflector Fig 5 1 take hold of the grip Fig 5 3 raise the deflector Fig 5 1 pivot it for wards and outwards and lower it service position 2 Slide the brush under the brush head ...

Page 19: ...k closed Lock open Fig 7 Installing the drive plates with pad 1 Turn the drive plate over and place the pad on the contact surface press on and fix in place with the center lock 2 Lock the drive plate with the pad in the catches as described in Sec tion Installing the brushes Brush selection The scrubber drier must be equipped with the brushes and pads from the ac cessories program according to th...

Page 20: ...he squeegee is raised automatical ly 9 Close the rear doors Adjusting the squeegee The squeegee must be set up on a level floor according to the conditions in which it is to be used The squeegee must stand vertically on the floor ad justed at the factory The sealing strip Fig 8 3 should bend slightly to the rear when the vehicle is in operation Support rollers Fig 8 5 limit its move ment toward th...

Page 21: ...be adjusted as follows according to the driver s weight according to the angle of the seat backrest according to the longitudinal direc tion forward and back Adjusting to the driver s weight Adjust the lever at the top right of the backrest lighter driver pivot the lever upwards heavier driver pivot the lever down wards Fig 9 Adjusting the angle of the seat back rest Turn the knob on the bottom ri...

Page 22: ...n 3 1 5 and Section 5 5 1 Only use cleaning agents non foaming suitable for the vehi cle s vendor We recommend using our clean and care prod ucts which are specially bal anced for the vehicles 3 Check the battery charge and re charge as necessary refer to Sec tion 5 4 1 Before starting the vehicle for its first working operation carry out an initial battery charging routine refer to Section 2 2 4 ...

Page 23: ...r is a ride on machine designed for the economic cleaning of large floor areas in buildings A seat contact ensures that the vehicle can only be operated when an operator is seated on the driver s seat The most important vehicle elements are described below 3 1 1 Scrubbing unit Fig 13 2 Two circular brushes which can be changed without the need of tools en sure a high cleaning performance They are ...

Page 24: ... can be vacuumed up better The deflectors can be raised if neces sary This is the case for basic cleaning for example where the floor only needs to be scrubbed when wet and the solu tion is not vacuumed up but allowed to soak in instead To raise the deflector take hold of the grip Fig 13 6 raise it and hook the locking hooks Fig 13 4 in the recesses in the grip above it Fig 13 5 Proceed in the sam...

Page 25: ...rbines are located on the rear panel of the fresh water tank and can be accessed after opening the rear doors The suction turbines are switched on and off automatically when lowering and raising the squeegee re spectively A float switch in the recovery tank switches the suction turbine off au tomatically on reaching the maximum fill height 3 1 4 Pre sweep Vacuum unit op tion Fig 16 1 The optional ...

Page 26: ...cap and secure it to fill the tank Fill water max 122 F and add the cleaning agent in accordance with the manufac turer s instructions Lower the cap again to close it Only use cleaning agents non foaming suitable for the vehi cle s vendor We recommend using our clean and care products which are specially bal anced for the scrubber drier Observe the correct dosage of the cleaning agent The correct ...

Page 27: ...eat on the left hand side when facing the front The recovery tank is a tank partitioned by a mem brane panel and has a volume of ap prox 81 9 gal The waste water is fed to the recovery tank via the squeegee by means of a vacuum A float switch at the top of the recovery tank switches the suction turbine off automatically as soon as the maximum tank fill level is reached In this case the control lam...

Page 28: ...e relates to a drum brake which acts hydraulically on the rear wheels It is actuated by a foot ped al The parking brake is actuated me chanically via brake cables It is applied by means of the foot pedal to the left of the steering column and released using the safety catch in the steering column Fig 15 2 3 4 1 5 6 ...

Page 29: ...ion against total dis charge the scrubber drier is equipped with a total discharge signal transducer TSG It is integrated in the electronic system and set up at the factory for PzS batteries service indicator No 5 If other batteries are used the total discharge signal trans ducer must be adjusted This adjustment work should only be performed at an authorized PowerBoss service center The trough bat...

Page 30: ...ing lights 3 Cab safety roof 4 Flashing beacon 5 Spraying vacuuming tool 6 Side collision protection here short version because the side scrubbing unit option is installed 6a left hand side 6b right hand side 7 Side scrubbing unit Fig 16 6 2 4 2 1 5 7 6a 6b 3 ...

Page 31: ...ess with spraying and vacuuming tools A holder can be installed on the left hand side of the vehicle to fix the spraying vacuuming tool Two holes are already drilled in the left hand side of the vehicle for this The fol lowing belong to the spraying vacu uming tool Floor scrubbing and vacuuming tool 7009 Suction and spraying hose 7766 Tool holder and attachment parts 7311 10 The corresponding butt...

Page 32: ... to protect the scrubber drier from dam age cause by collisions The side collision protection can be disassem bled quickly without the need of any tools The long version is used when the scrubber drier is operated without the side scrubbing unit option in stalled long steel bar on left and right hand sides The short version is used when the side scrubbing unit option is installed long steel bar on...

Page 33: ...33 Operation Fig 17 2 1 ...

Page 34: ... in the driver s cab 1 Steering wheel 2 Left hand operating panel 3 Safety catch to release the parking brake 4 Parking brake 5 Direction switch forwards reverse 6 Right hand operating panel 7 Service brake 8 Accelerator to drive forwards and backwards Fig 18 2 3 4 8 7 6 5 1 ...

Page 35: ... brake Tread on the pedal slightly Press the catch down Release the pedal Parking brake Fig 18 4 The pedal to the left of the steering column serves to apply the parking brake to the rear wheels When the parking brake is applied the corresponding control lamp on the operating panel Fig 19 4 lights up red If the driving direction switch is actu ated while the parking brake is ap plied a pulsating b...

Page 36: ... 5 to set the direction of trav el forwards or reverse Forwards or reverse according to the driving direction switch setting Press the accelerator forward and down slowly Release the pedal The speed is au tomatically reduced slowly The ve hicle rolls to a stop until reaching its zero setting To stop securely apply the service brake Fig 18 7 The speed for forward drive is ap prox 5 0 mph and for re...

Page 37: ...is on red the brake is applied 5 Alarm indicator When the control lamp is on red a functional fault has occurred 6 Operating hour counter and service indicator 7 Battery and charge control indicator 8 Button for brush pressure 9 Button for brush drive 10 Button for squeegee and suction tur bine 11 Button for simultaneous activation of the scrubbing unit and vacuuming function 12 Buttons for contro...

Page 38: ...e The individual buttons and functions are described in detail below Indicator for recovery tank maximum fill level Fig 19 2 The yellow con trol lamp lights up when the recovery tank has reached its maximum fill level Also a beep signal is issued every 15 seconds In this case a float switch switches the suction turbine off and the squeegee is raised Indicator for dirt hopper and front flap of pre ...

Page 39: ...for further de tails refer to page 43 key switch Fig 20 6 The operating hours ap pear after this The counter only operates when con sumers are switched on e g hydraulic or brush motor suction turbine or pre sweep vacuum unit At the same time a red dot flashes at the bottom right of the display Service indicator Fig 19 6 The four digit LED serves for a more accurate determination of function faults...

Page 40: ...pproximately one minute re mains until the entire vehicle shuts down automatically Drive back to the charger in good time Take the distance to the charger into account Button for brush pressure Fig 19 8 This button is used to increase the brush pressure This may be nec essary when the area to be cleaned is extremely dirty The pressing force can be increased to max 119 lbs If the function is active...

Page 41: ...vated deactivated in the correct sequence of use suction tur bine brush rotation fresh water supply and lowering or raising the brushes and squeegee When the vehicle is ready for use in accordance with require ments it can be set into operation sim ply and quickly by pressing the button When the button has been pressed the green control lamp lights up Buttons con trolling the fresh water supply Fi...

Page 42: ...ity previously set remains unaltered last station memo ry Button to increase fresh water quantity Fig 19 15 The button serves to increase the fresh water quantity supplied to the brushes The fresh water quantity can be increased in seven stages see above The selected stage remains programmed last station memory even if the vehicle is switched off temporarily Button for simultaneous activation of p...

Page 43: ...unit on off 5 Button to switch side scrubbing unit option on off 6 Key switch 7 Horn 8 Button for chemical dosage option 9 Reduce quantity of cleaning agent 10 Button to switch chemical dosage option on off 11 Increase quantity of cleaning agent 12 Button for dirty water treatment sys tem 13 Switch for working lights 14 Switch for flashing beacon Fig 20 2 1 4 6 5 7 9 10 11 12 8 13 14 3 ...

Page 44: ...e filter system on and off The filter system belongs to the op tional pre sweep vacuum unit Button to switch pre sweep vacuum unit on off Fig 20 4 This button is used to switch the pre sweep vacuum unit on and off Button for side scrubbing unit Fig 20 5 This button is used to activate the side scrubbing unit After press ing the button the side scrubbing brush starts or stops rotating and the side ...

Page 45: ...ce technician so that the fault can be cleared quickly For an overview of diagnostic codes refer to Section 3 5 1 Example When a functional fault actually occurs an acoustic signal is also issued and the red control lamp on the alarm indicator Fig 19 5 lights up 3 Operating hour indicator Continual display Example During operation the dots flash in the display 4 Control digits optional In the case...

Page 46: ...tity of cleaning agent Fig 20 11 On pressing this button the amount of cleaning agent added to the fresh water is increased Button for dirty water treatment system Fig 20 12 The dirty water treatment is an option which will not be of fered in future Switch for working lights Fig 20 13 This switch switches the working lights on or off This occurs even without the key switch being turned on The work...

Page 47: ...sh water tank 2 Filter sieve 3 Fresh water tank filling neck 4 Lid lock 5 Cover recovery tank 6 Cover fresh water tank 7 Rear door right 8 Rear panel frame 9 Rear door left 10 Fresh water draining hose 11 Waste water draining hose 12 Rear panel frame lock Fig 21 3 4 2 6 5 11 10 12 9 8 7 1 ...

Page 48: ... place The lid lock functions in the same way on the fresh water tank and recov ery tank Rear doors Fig 21 7 9 Open the rear doors to access the draining hoses for waste water and fresh water Waste water draining hose Fig 21 11 The draining hose for waste water hooked is in the left hand rear door Only drain off waste water through this hose at an appropriate location refer to Section 5 6 1 Fresh ...

Page 49: ...49 Operation 13 Seat console 14 Electrical compartments 15 Side door 16 Battery trough Fig 22 13 14 15 16 ...

Page 50: ... square wrench The electrical compartments are not provided in the sense of glove compartments Side door Fig 22 15 The side doors are located to the left and right of the trough battery The doors must be pivoted open in order to change the battery trough refer to Sec tions 5 4 3 and 5 4 4 Battery trough Fig 22 16 The battery trough contains the 18 indi vidual battery cells and serves to en able a ...

Page 51: ...lug to the vehicle switch the key switch to off lock position 0 beforehand The vehicle is equipped with a safety shutdown via a seat contact dead man s switch This means that it is essential for operating personnel to be seated in the driver s seat to be able to operate the vehicle Ensure that the driving direction switch is in its neutral setting refer to accelerator for driving forwards and back...

Page 52: ...the key in the key switch coun terclockwise to lock position 0 and remove the key Press the left foot on the parking brake pedal to park the vehicle Always apply the parking brake and remove the key before get ting out of the vehicle 3 3 4 Cleaning If the pre sweep vacuum and vacuum ing tool options are installed a total of six cleaning programs are available for selection 1 Sweeping option 2 Swee...

Page 53: ...left hand operating panel Various functions can be switched on or off with the following buttons according to the conditions at the location of use Fig 24 Increase brush pressure Fig 24 1 Fresh water feed on off Fig 24 3 Reduce fresh water quantity Fig 24 2 Increase fresh water quantity Fig 24 4 Wet scrubbing and vacuuming dry This program is the standard cleaning program for this vehicle Press th...

Page 54: ...g information and warning signs Press the Button for the brush drive button Fig 19 9 on the left hand operating panel Various functions can be switched on or off with the following but tons according to the conditions at the location of use Reduce water quantity Fig 24 2 Increase water quantity Fig 24 4 Fresh water feed on off Fig 24 3 Increase brush pressure Fig 24 1 Vacuuming dry Press the Butto...

Page 55: ...loor is scrubbed with a clean ing agent dosage appropriate to the degree of soiling whereby the squeegee is raised Let the cleaning solution work into the floor for 5 to 10 minutes accord ing to the manufacturer s informa tion Then scrub the floor again with the squeegee lowered Observe the correct dosage of the cleaning agent Information on dos age is provided on the cleaning agent container Use ...

Page 56: ... the vehicle off Turn the key from position 1 to lock position 0 The vehicle is no longer ready to operate Remove the key from the key switch Apply the parking brake 3 3 6 Loading and transporting the vehicle Refer to Section 5 13 ...

Page 57: ...efer to Sections 5 6 1 and 5 6 2 Observe the applicable laws and local regulations when dis posing of cleaning agents 4 Check the fresh water filter refer to Section 5 5 4 5 Check the sealing strips and suction hose refer to Section 5 8 6 Check the electrical equipment functions and settings 7 Clean the vehicle refer to Section 5 12 It is not permitted to clean the vehicle with a pressure washer o...

Page 58: ...itch has been tripped The motor has overheated for eign bodies have possibly jammed between the brush and shaft e g tape and such Check the brushes for foreign bodies and remove them as necessary Allow the motor to cool down If the problem reoccurs determine the cause of overheating contact an autho rized PowerBoss service center if nec essary 1 2 6 1 Brushes remain stopped because the anti blocki...

Page 59: ...ed because the anti blocking system has been tripped Foreign bodies e g tape or such block the side scrubbing brush Check the side scrubbing brush for foreign bodies and remove them as necessary 1 3 6 2 Side brush holding attach ment has been switched off because the anti blocking system has been tripped Foreign bodies between the side scrubbing unit and machine Check the side scrubbing unit for f...

Page 60: ...ocking system has been tripped Foreign bodies e g tape or such block the rotary brush Check the rotary brush for foreign bodies and remove them as necessary 2 2 6 2 Rotary brush holding attach ment has been switched off because the anti blocking system has been tripped Foreign bodies e g tape or such between the rotary brush and machine Check the rotary brush holding attachment for foreign bodies ...

Page 61: ...viewed to the front of the vehicle stops because the anti blocking system has been tripped Foreign bodies e g tape or such block the side brush Check the side brushes for foreign bodies and remove them as necessary 3 4 5 1 Hydraulic motor is too hot Hydraulic motor switches to 50 power output Engine is overloaded possibly after driving up slopes Parking brake was actuated while driving Allow the m...

Page 62: ...e in 44 5 49 6 Vehicle width with pre sweep vacuum unit option in 49 6 Vehicle width with side scrubbing unit option in 49 6 Working width Brush head in 40 2 Squeegee in 49 6 with pre sweep vacuum unit option in 54 3 with side scrubbing unit option in 46 5 Area coverage Theoretical at 4 4 mph ft h 76854 Weights Dead weight without driving batteries without options without driver lbs 1559 Total wei...

Page 63: ... drive mode max 1 min 15 Climbing capacity work mode max 5 min 6 Outer turning circle diameter without with pre sweep vacuum unit option ft 11 0 13 9 Turning in aisle Minimum aisle width without with pre sweep vacuum unit option ft 7 9 9 3 Operating time with one battery charge h approx 5 Traction drive Drive motor P2 W 2000 Gear oil fill quantity gal SAE 0 7 SAE 90 63 Technical Data ...

Page 64: ...ing torque of wheel nuts front rear lb ft 103 3 103 3 Brakes Service brake Hydraulic Drum brakes at rear with automatic adjustment diameter width in 7 1 1 6 Brake fluid e g ATE gal 0 1 Parking brake Cable brake at rear adjustable diameter width in 7 1 1 6 Tank volume Membrane panel tank fresh waste water gal 81 9 81 9 Flow rate adjustable from to gal min 0 5 1 8 64 Technical Data ...

Page 65: ...Specific contact pressure normal increased psi 0 20 0 25 Suction turbines Power consumption speed W rpm 635 13867 Air flow rate ft3 h 8475 Vacuum psi mmwc 2 94 2030 Electrical installation Power supply VDC 36 Type of current DC Nominal power total W 3600 4000 Protection class VDE 0700 III Battery compartment length width height in 37 4 24 0 18 3 65 Technical Data ...

Page 66: ...KpA dB A 2 Vibration The weighted effective value of the vibration established in accordance with ISO 5349 1 to which the upper limbs hand arm are exposed under normal working conditions is m s2 2 5 The weighted effective value of the vibration and shock established in accor dance with ISO 2631 1 to which the body feet and seat area are exposed under normal working conditions is m s2 0 5 ...

Page 67: ... time h 12 14 Chemical dosing system Order number 7564 02 Cab safety roof including rear view mirror Order number 7582 Working lights 2 pieces Order number 7584 02 V W 2 x 24 70 Flashing beacon V 36 For installation on the cab safety roof Order number 7585 02 For installation on a pole when no cab safety roof is available Order number 7585 10 Side collision protection Long version without side scr...

Page 68: ...ubbing and vacuuming tool Order number 7009 Vacuuming and spraying hose length 16 4 ft Order number 7766 Tool holder and attachment part Order number 7311 10 Additional tools for using the suction hose hand held vacuum cleaner Adapter to connect the following tools Order number 7893 Suction hose length 9 8 ft Order number 7880 Suction pipe length 4 3 ft Order number 7881 Suction nozzle with rubber...

Page 69: ...ZH 1 487 KAT U Fan motor W 234 Extractor fan speed rpm 3200 Air flow rate ft3 h 11830 Vacuum in brush space mmwc 8 0 Rotary brush drive motor P1 P2 W 612 550 Rotary brush length diameter in 27 6 9 8 Rotary brush minimum diameter in 7 1 Rotary brush speed rpm 510 Sweeping pattern width in 1 2 2 0 Side brush drive motor P1 W 2x100 Side brush diameter in 15 7 Side brush speed rpm 105 ...

Page 70: ...ion of dirt Order number 7588 SIC PA 6 grain 180 gray 2 pieces for basic cleaning and very heavy accumulation of dirt Order number 7590 Brushes continued SIC PA 6 12 grain 120 green 2 pieces for basic cleaning and extreme accumulation of dirt Order number 7591 Superpads Drive plates pad holders 2 pieces with centerlock Order number 7592 Pads brown 2 pieces for routine cleaning Order number 7594 05...

Page 71: ...nd repair costs ensures the vehicle has a long ser vice life The PowerBoss system maintenance describes the specific technical work necessary for the individual modules and defines the intervals for the mainte nance tasks Individual parts which must be changed during maintenance tasks are defined and stipulated in spare parts kits PowerBoss system maintenance customer Work to be carried out by the...

Page 72: ...ours PowerBoss System Maintenance I 1250 operating hours Workshop Stamp completed on at _________________ operating hours PowerBoss System Maintenance II 1500 operating hours Workshop Stamp completed on at _________________ operating hours PowerBoss System Maintenance I 1750 operating hours Workshop Stamp completed on at _________________ operating hours PowerBoss System Maintenance III S 2000 ope...

Page 73: ...ng agent fill fresh water o Before or after operation Check the properties of the deflectors to the right and left and repair them or replace the deflector rub ber left and right as necessary o Check the service brake in terms of its functionality and for signs of leaks repair as necessary o Check the parking brake in terms of its functionality and for signs of leaks repair as necessary o Check th...

Page 74: ...fter the end of operation Empty the recovery tank o Clean the recovery tank o Clean the air intake filter waste water filter o Clean the fresh water filter o Check the battery charge recharge as necessary o Activity Interval Daily ...

Page 75: ... them as necessary o Check the side scrubbing brush and water deflectors and complete any repairs or order spare parts and replace them as necessary o Check the squeegee particularly the rear sealing strip is clean and for signs of damage and wear and complete any repairs or order spare parts and replace them as necessary o Check the recovery tank through the inspection hole at the top for signs o...

Page 76: ...rease the rotary joint o Check the service brake for leaks check the main brake cylinder and actuating rods clear any defects o Check the brake fluid in the service brake top up as necessary bleed Note brake fluid must be changed every 2 years o Subject the service brake to a brake tests clear any defects as necessary o Check the parking brake for actuating play repair as necessary o Subject the s...

Page 77: ...de scrubbing unit check correct function of water retaining ring fan belt side scrub bing brush functions and correct adjustment replace if necessary o Check the recovery tank particularly the lid sealing quality and filter sieve o Change the O rings in the draining hose and dosing valves o Check the suction hose is fitted properly and for signs of damage clear any defects as necessary o Test the ...

Page 78: ...f wear and foreign bodies e g tape wire etc replace rotary brush if necessary o Pre sweep vacuum unit Check the brush swings smoothly o Pre sweep vacuum unit Check the sweeping pattern o Pre sweep vacuum unit Check the rotary brush setting adjust if necessary o Pre sweep vacuum unit Check the sealing strips in the brush space change any defective seal ing strips o Pre sweep vacuum unit Check the s...

Page 79: ...ce of all signs and labels o Check the vehicle is clean clean it if necessary o Test drive and test all function and safety relevant components including brake tests o Inspection label o Logbook o On request against separate account driver training o Activity Interval Every 250 operating hours ...

Page 80: ...the brake linings as necessary o Check the output of the hydraulic motor forwards reverse clear defects as necessary o Check the carbon brushes of the hydraulic motor replace if necessary o Check the brush motor output left and right clear defects as necessary o Check the carbon brushes of the brush motors replace if necessary o Check the side scrubbing unit drive clear defects as necessary o Chec...

Page 81: ...ary o Change the brake fluid in the service brake Note brake fluid must be changed every 2 years o Check the parking brake including pedal lock and control lamp clear any defects o Grease the rotary joint of the traction drive 2 lubrication points accessible from the bottom o Clean the carbon dust from the electric motors of the wheel brush suction turbine and rotary brush drives and check the car...

Page 82: ... and charge control indicator including TSG indicator in left operating panel 2 Battery connection cable 3 Battery plug in vehicle socket 4 Battery plug disconnected 5 Seat console open 6 Fill level indicator for battery acid and distilled water 7 Aquamatic plug 8 Battery interconnection cable 9 Insulation cap 10 Fitting hole in battery trough 11 Battery cell individual battery 12 Wiring diagram F...

Page 83: ...o liability for damage to the battery caused by a fault when the battery is charged for the first time There must be sufficient venti lation in the charging area risk of explosion The seat console Fig 25 5 must be open during the bat tery charging process to pre vent the development of explo sive oxyhydrogen Only use the original charger Pay attention that the insula tion is not initially damaged ...

Page 84: ...e Spilled battery acid must never enter the sewage system in its initial form it must be neutral ized beforehand e g diluted with plenty of water or ab sorbed with granulate Checking the acid density and volt age of each cell These points must be checked and cor rected at regular intervals within the scope of PowerBoss system mainte nance by an authorized service center Also refer to the informati...

Page 85: ...afety roof lift the trough battery out on the left hand side of the bat tery The cab safety roof has a recess Fig 26 4 for the lifting gear rope 5 Guide the lifting gear from the left to the battery and hang the hooks in the fitting holes on the battery trough Fig 26 7 6 Lift the battery trough out of the vehi cle using the lifting gear Fig 26 2 1 3 2 4 5 6 7 ...

Page 86: ...ab safety roof is provided with a recess Fig 26 4 for the lifting gear rope When installing the trough bat tery use appropriate lifting gear The battery may only be in stalled using lifting gear by properly trained personnel Connect the battery plug Fig 26 6 and vehicle socket Fig 26 5 to each other Ensure they are connected firmly 5 4 5 Disposing of batteries Used batteries with the recycling sym...

Page 87: ... discharge signal transducer TSG is in tegrated in the electronic system and setup at the factory for battery type PzS armor plate insulation digit in the ser vice indicator No 5 If other batteries are used the total discharge signal transducer must be adjusted The total discharge signal transducer may only be adjust ed by an authorized Power Boss service center Also refer to Section 3 1 9 ...

Page 88: ...ce and Service 5 5 Fresh water tank 1 Lid seal 2 Cap 3 Opening to recovery tank airing and venting 4 Fresh water tank 5 Fresh water filter 6 Ball cock 7 Screw cap 8 Fresh water draining hose Fig 27 4 1 2 5 6 8 3 7 ...

Page 89: ...uidelines provided by the water supply company The vehicle must not be connected directly to a pub lic drinking water supply to pre vent chemicals getting into the drinking water supply A brief connection is permitted how ever if a backflow preventer with pipe aerator is installed in the supply line A backflow pre venter of the type EA 3 or EA 2 must be installed 1 Open the rear doors on the left ...

Page 90: ...the fresh water draining hose Fig 27 8 and lower it slowly 5 Unscrew the screw cap Fig 27 7 The quantity drained can be regulat ed by turning the screw cap and piv oting the cap open fully if necessary 6 When the fresh water tank has been completely emptied screw the cap shut again and attach the draining hose again 7 Close the rear panel frame 8 Close the left and right rear doors When disposing ...

Page 91: ...91 Maintenance and Service 5 6 Recovery tank 1 Cap 2 Lid seal 3 Recovery tank 4 Air intake filter 5 Screw cap 6 Waste water draining hose 7 Cleaning flap Fig 29 6 4 7 3 1 2 5 ...

Page 92: ...can be regulat ed by turning the cap and pivoting the cap open fully if necessary 6 When the recovery tank has been completely emptied screw the cap shut again and attach the draining hose again If the recovery tank is extreme ly dirty begin cleaning the tank straight away 7 Close the rear panel frame 8 Close the left and right rear doors 5 6 2 Cleaning the recovery tank Clean the recovery tank Fi...

Page 93: ...t dirt viruses bacteria etc when cleaning the container 9 After finishing cleaning the tank close the flap and push the run off plate back in place 10 Unhook the waste water draining hose Fig 29 6 lower it slowly and open the cap Fig 29 5 11 Run fresh water in the recovery tank through the open cap using a water hose output pressure approx 5 to 6 bar and in doing so also flushing the draining hose...

Page 94: ... clean with water Remove the filter sieve com pletely to clean it During cleaning and operation pay attention that no water and no particles of dirt get into the suction pipe and into the suc tion turbines 2 Dry the filter sieve after cleaning Do not replace when dripping wet 5 6 5 Cleaning the openings to the fresh water tank The openings between the recovery and fresh water tank Fig 31 2 serve f...

Page 95: ...ush head Fig 32 2 according to the instructions refer to Section 2 3 1 Please refer to Chapter 4 or our spare parts catalogue on our internet site at www powerboss com for brushes etc 5 7 1 Changing the brushes Check the brushes on the brush head weekly for signs of wear When the brushes have worn to a bristle length of 0 6 in the brushes must be replaced refer to Section 2 3 1 Before working on t...

Page 96: ...3 3 in the vehicle s driving direction for wards until the clamping rail hooks Fig 33 4 are freed and the clamp ing rail Fig 33 3 can be removed away from the vehicle 3 Remove the old rubber deflector strips Fig 33 2 4 Position the new rubber deflector strips Fig 33 2 in place 5 Mount the clamping rail Fig 33 3 from the outside and slide back by hand so that the clamping rail hooks Fig 33 4 engage...

Page 97: ...queegee 1 Insert the key in the key switch and turn the key switch on 2 Lower the squeegee Press the but ton for the squeegee and suction tur bine so that the green control lamp lights up Fig 34 3 Switch off the key switch and remove the key 4 Open the rear doors 5 Pull the suction hose from the con nection nozzle Fig 34 3 of the squeegee 6 Loosen the wing nuts Fig 34 2 on the holding attachment 7...

Page 98: ...ew or reversed sealing strips in the reverse working se quence Pay attention that both sealing strips front and rear touch the floor when mounted 5 Tighten the knurled nuts Fig 34 8 evenly starting from the center and working on alternate sides There must be no bends in the sealing strip 6 Disassemble the front sealing strip Fig 35 in the same way Fig 35 7 After changing the sealing strips check t...

Page 99: ...e to lower the support roller 4 Check the squeegee contact surface and adjust if necessary 5 Tighten the counternuts on each support roller Fig 34 7 5 9 Pre sweep vacuum unit option Set the key switch to position 0 for all maintenance and repair work to prevent starting up the vehicle inadvertently 5 9 1 Emptying the dirt hopper The dirt hopper must be emp tied and cleaned at least once a day If t...

Page 100: ...not properly engaged the Indi cator for dirt hopper and front flap of pre sweep vacuum unit lamp Fig 19 3 lights up The pre sweep vacuum unit does not work 5 9 2 Dust vacuum The filter system of the dust vacuum use category U is located in the filter case above the dirt hopper Fig 36 2 The filter case is movable the move ment linked to that of the dirt hopper Fig 36 2 in order to be able to shake ...

Page 101: ...r an appro priate dust mask Drop the panel air filter Fig 37 2 a few times from a suitable height onto a sol id surface Ensure the filter ribs are not damaged The surface must not have any irregularities Do not let the panel air filter Fig 37 2 drop at a slant Do not install panel air filters Fig 37 2 which have dam aged filter ribs Installing the panel air filter The panel air filter Fig 37 2 mus...

Page 102: ...y a hex nut 5 Slide the side brush including the de flector plate down slightly on the brush shaft The side brush contact surface is correct when approx 1 3 of the side brush circumference makes contact with the ground 6 Tighten the socket screw and lock it with the hex nut Disassembling the side brush 1 Refer to Section Adjusting the side brush contact Point 1 4 2 Pull the side brush including de...

Page 103: ...e edges are parallel The short sides of the rectangle should measure 1 2 2 0 in If the sweeping pattern is broader than 2 0 in the brush pressure is too high If the sweeping pattern is narrower than 1 2 in the brush pressure is too low The shape of the sweeping pattern must be a rectangle and not trapeze or wedge shaped If the sweeping pattern is not correct it must be adjusted refer to Section Se...

Page 104: ...2 Press the button to switch pre sweep vacuum unit on off Fig 20 4 to lower the side brush and rotary brush 3 Turn the key switch to position 0 and remove the key The rotary brush and side brush remain lowered 4 Pivot the right hand side flap up 5 Unscrew the knurled screw for the brush swing arm Fig 39 2 6 Pull off the brush swing arm Fig 39 5 7 Unscrew the knurled screw for the brush space cover...

Page 105: ...act points for the jack lifting power 2 0 t are on the frame in front of the rear wheels 2 Remove the wheel nuts Fig 40 1 3 Pull off the wheel Fig 40 2 4 Fit a wheel Fig 40 2 5 Screw on and tighten the wheel nuts Fig 40 1 5 10 2 Changing the front wheel The procedure to change the front wheel is analog to changing the rear wheels 1 Apply the jack at the front centered to the vehicle s front frame ...

Page 106: ...When these fuses blow the vehicle is out of operation This is not indicated by an alarm signal on the operating panel the suction turbines 35A high cur rent fuse the water pump and relief valve for the water supply 10A plug in fuse the hydraulic motor 160A current limiter in the drive control the extractor fan for the pre sweep vacuum unit option 20A plug in fuse the agitating motor for the pre sw...

Page 107: ...he key The vehicle may only be cleaned us ing a water hose operating pressure approx 5 to 6 bar and only from top to bottom It is not permitted to clean the vehicle with a pressure washer or steam blaster Do not aim the jet of water directly at openings slits electronic compo nents operating panels or seals It is not permitted to use aggressive and corrosive cleaning agents Allow the vehicle to dr...

Page 108: ... of the scrubber drier without battery without options and without driver 1559 lbs Total weight of the scrubber drier with battery and full fresh water tank without driver 3940 lbs When loading onto a truck or some thing similar by means of a loading ramp the ramp angle must not ex ceed 15 Squeegee brush head and side brush and rotary brush of the pre sweep vacuum unit option must be raised Fig 41...

Page 109: ... another vehicle or trailer it must be secured against rolling away Lash the vehicle down secure ly The vehicle is provided with attach ment points lashing eyes on the left and right hand side to do this at the rear of the frame and on the sides at the height of the entry area Fig 41 1 2 Towing the vehicle If it should become necessary to tow the scrubber drier only do it on a level floor and at a...

Page 110: ... property of PowerBoss or its original manufacturer whichever the case may be PowerBoss disclaims any implied warranty including the warranty of mer chantability and the warranty of fitness for a particular purpose PowerBoss assumes no responsibility for any special incidental orconsequen tial damages This limited warranty is applicable only in the U S A and Canada and is exten ded only to the ori...

Page 111: ...umatic Vacuums three years parts one year labor EX 12 and EX 12H one year parts one year labor Battery Operated Group Three years parts two years labor ninety days travel not to exceed two hours Exceptions Sweepers one year parts one year labor ninety days travel not to exceed two hours Replacement parts ninety days Batteries 0 3 months replacement 4 12 months pro rate Polypropyl Plastic Tanks ten...

Page 112: ...Excellence Meets Clean PowerBoss Inc 175 Anderson Street Aberdeen NC 28315 U S A Telephone 910 944 2105 Fax 910 944 740 88 10 2980 ...

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