PowerBoss commander t82 europe User Manual Download Page 92

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Commander T Series PB# 4100032

Rev.C 03/12

Page 92

TROUBLESHOOTING CHART

PROBLEM

POSSIBLE CAUSE(S)

SOLUTION(S)

Hydraulic drive motor failure.

Insufficient oil supply

Fill Reservoir

Motor leaking.

Replace seals.

Drive pump coupler failed

Replace

Key on motor shaft failed

Replace key

Drive hub failed

Replace

Output shaft malfunction.

Replace output shaft and bearings.

Hydraulic gear pump failure.

Pump leaking.

Replace seals or RR Pump

Drive coupler failed

Replace

Gears worn or scored.

Rebuild pump or RR Pump

Relief valve stuck.

Clean or replace (at control valve).

Oil supply low.

Check and fill.

Oil strainer clogged.

Replace strainer (inside reservoir).

Incorrect oil.

Use recommended viscosity oil.

Damage due to entry of air into hydraulic

system.

Maintain correct hydraulic fluid level

in reservoir. Keep suction hose fittings

tight..

TROUBLESHOOTING

Summary of Contents for commander t82 europe

Page 1: ...T Series PB 4100032 Rev B 09 11 PowerBoss Inc Copyright 2011 Page 1 User Manual Commander T Series Models T82 T82 Europe T90 Gasoline LP Diesel PowerBoss Inc A Member Of The Hako Group PB 4100032 Rev...

Page 2: ...us know We are working hard toward perfection in our corner of the process to bring you the best you can buy Please copy the form below fill out and comment on how you found our catalog Thank you Name...

Page 3: ...t 2011 Page 3 Comments Information is optional Please return to Manager Publishing Department International PowerBoss Inc 175 Anderson Street Aberdeen North Carolina 28315 USA Phone 800 982 7141 Toll...

Page 4: ...by facing the direction of forward travel The front of the engine or engine fan faces the rear of the machine Some hardware considered to be common or locally available has been omitted from the part...

Page 5: ...________________ Engine Serial Number ____________________________ Sales Rep ______________________________________ Date of Install ___________________________________ All information contained in thi...

Page 6: ...ch 320 cm SCRUBBING SYSTEM Scrub path 42 inch 107 cm 48 inch 122 cm Scrub deck pressure 300 lbs 136 kg 300 lbs 136 kg Brush speed 250 rpm 250 rpm Solution tank capacity 68 gal 257 L 100 gal 378 5 L Re...

Page 10: ...TION 16 CLEAN AIR 16 LOWER EMISSIONS 16 SAFER WORK ENVIRONMENT 16 CLEAN ENERGY 16 CLEAN ENERGY 16 SAFETY INFORMATION 17 IMPORTANT SAFETY INSTRUCTIONS 17 FOR SAFETY DURING OPERATION 17 FOR SAFETY WHEN...

Page 11: ...ROL 32 SQUEEGEE SWITCH 32 SOLUTION LEVER 32 SOLUTION TANK EMPTY INDICATOR 32 RECOVERY TANK FULL INDICATOR 32 DEBRIS HOPPER DUMP CONTROLS 34 HIGH DUMP 34 Lever 1 34 Lever 2 34 HOPPER UNLOCK BUTTON 34 R...

Page 12: ...QUEEGEE WAND OPTION 45 BLOWER OPTION 46 TRANSPORTING THE MACHINE 46 Using a Trailer or Transport Vehicle 46 Pushing the Machine 46 PREVENTATIVE MAINTENANCE 47 INTRODUCTION 47 SCHEDULED MAINTENANCE CHA...

Page 13: ...pecifications 62 Maintaining Hydraulic Oil Cooler Efficiency 62 Changing The Hydraulic Fluid 62 Changing The Hydraulic Fluid Filter 63 SWEEP COMPONENTS 64 Broom Door Flap Inspection 64 Broom Door Flap...

Page 14: ...PER 78 Hopper Filter Removal 78 Hopper Filter Cleaning 79 Hopper Filter Replacement 79 Flap Replacement 80 Frame Seal Replacement 80 Front Frame Seal 80 Side Frame Seal 80 Floor Clearance 81 Vacuum Ga...

Page 15: ...ICS SYSTEM Roomy open cockpit with extra comfort Adjustable high back seat with arm rests Power steering Comfortable pedal controls placement Full instrumentation for all functions DEBRIS HANDLING SYS...

Page 16: ...operated available bio diesel fuel can be used in Kubota engine SAFER WORK ENVIRONMENT Orange machines are highly visible to others in the workplace simple controls reduce operator error one button sc...

Page 17: ...use machine if it is not in proper operating condition FOR SAFETY DURING OPERATION Keep hands and feet clear of moving parts while machine is in operation Make sure all safety devices are in place an...

Page 18: ...repairs and maintenance Use PowerBoss supplied replacement parts SAFETY SYMBOLS Five symbols are used throughout this manual to emphasize various levels of safety information These symbols and the me...

Page 19: ...which should be observed to protect you and others from harm and injury and to prevent damage to the equipment SAFETY DECALS Decals directly attached to various parts of the unit are highly visible sa...

Page 20: ...011 Commander T Series PB 4100032 Rev C 03 12 Page 20 Located at the Impeller Part Number 301729 Located on the Secondary Lift Arm Part Number 301732 Located on the shroud of the radiator Part Number...

Page 21: ...32 Rev C 03 12 PowerBoss Inc Copyright 2011 Page 21 Located on the shroud of the radiator Part Number 301728 Located on the Lift Arm Part Number 301731 Located on the shroud of the radiator Part Numbe...

Page 22: ...hydrogen gas they emit WARNING Do not operate an LP powered sweeper when any component in the fuel system is malfunctioning or leaking WARNING Before starting the engine make sure that You have read a...

Page 23: ...nect the tank coupling WARNING During cleaning and maintenance Always stop the engine and set the parking brake before servicing Never use detergents or cleansers that are flammable or combustible Nev...

Page 24: ...wing the machine off balance and other hazards CAUTION Travel slowly on grades CAUTION Place a block or chock behind the wheels when parking on inclines CAUTION Use special care when traveling on wet...

Page 25: ...ight switch turns on and off the lights MACHINE OPERATION HOUR METER The hour meter records the number of hours the machine has been operated providing a helpful guide for performing routine maintenan...

Page 26: ...ent that the engine water temperature rises above 226 degrees or oil pressure drops below 7 psi this switch will pop out and shut the engine off CAUTION When the Murphy switch is tripped it indicates...

Page 27: ...N IGNITION SWITCH DIRECTION CONTROL PEDAL FUEL LEVEL GAUGE ENGINE OIL PRESSURE VOLTMETER AMP GAUGE ENGINE COOLANT TEMPERATURE GAUGE HOUR METER SEAT ADJUSTMENT BRAKE PEDAL HORN LIGHT SWITCH MURPHY SWIT...

Page 28: ...perature rises above 226 degrees or oil pressure drops below 7 psi Shut down the unit and perform the required service CAUTION When the check engine indicator illuminates it indicates a service issue...

Page 29: ...SWITCH DIRECTION CONTROL PEDAL FUEL LEVEL GAUGE ENGINE OIL PRESSURE VOLTMETER AMP GAUGE ENGINE COOLANT TEMPERATURE GAUGE HOUR METER SEAT ADJUSTMENT BRAKE PEDAL HORN LIGHT SWITCH THROTTLE GAS AND LP PA...

Page 30: ...broom and scrub brushes may be raised or lowered independently NOTE The CE models are equipped with auto broom shutoff which prevents brooms from operating when hopper is raised MAIN BROOM HANDLE The...

Page 31: ...M HANDLE BROOM CONTROL LEVER SIDE BROOM HANDLE IMPELLER STOP CONTROL IMPELLER LEVER SCRUB DECK GAUGE SOLUTION LEVER SQUEEGEE SWITCH SOLUTION TANK EMPTY INDICATOR RECOVERY TANK FULL INDICATOR SWEEPING...

Page 32: ...sts the amount of vacuum supplied to the squeegee and hopper Push the control in for normal operation with equal vacuum supplied to the hopper and the squeegee Pull out the control cable to limit the...

Page 33: ...NGINE HOPPER CONTROL AND INDICATOR LOCATIONS HOPPER UNLOCK BUTTON SOLUTION TANK EMPTY INDICATOR RECOVERY TANK FULL INDICATOR SIDE BROOM HANDLE MAIN BROOM HANDLE BROOM CONTROL LEVER IMPELLER LEVER IMPE...

Page 34: ...pper to it original position NOTE The engine must be running to dump and return the hopper The hopper must be raised to rotate the hopper HOPPER UNLOCK BUTTON If equipped the unlock hopper button must...

Page 35: ...through the filter is restricted The clogged filer indicator is standard on CE models FIRE IN THE HOPPER INDICATOR GAS AND LP CLOGGED FILTER INDICATOR IMPELLER STOP CONTROL FILTER SHAKER BUTTON IMPELL...

Page 36: ...ngine starts release the key CAUTION If the engine fails to start do not continue cranking for more than ten seconds Allow the starter motor to cool between attempts 4 Release the parking brake OPERAT...

Page 37: ...ignition key clockwise to the start position When the engine starts release the key and the Murphy switch CAUTION If the engine fails to start do not continue cranking for more than ten seconds Allow...

Page 38: ...ver back to the SIDE BROOM OFF position 4 Turn on the vacuum impeller Push the impeller lever forward to the on position 5 Drive the machine over the area to be swept MACHINE OPERATION EMPTYING THE HO...

Page 39: ...distance necessary to position the hopper 6 Shake the filters for 20 30 seconds Pull back Lever 2 to the DUMP position to rotate the hopper forward and empty the debris 7 After the hopper empties push...

Page 40: ...n and hold until Light 1 illuminates then release WARNING Make sure no one is in the area under or around the hopper 4 Pull back Lever 2 to the DUMP position press and hold the unlock hopper button if...

Page 41: ...he CE model is equipped with a timed filter shaker that will automatically shake the filter for a predetermined time when the button is pressed 4 Place the broom control lever in the ON position and r...

Page 42: ...is raised by same switch Press to Raise position NOTE The scrubhead gauge is a visual indication of the scrub deck position and not the amount of pressure on the floor Starting Solution Flow 3 Push th...

Page 43: ...e 2 Make sure the solution delivery valve is closed via the solution lever 3 Open the top door of the machine and remove the plug the Auto fill Assembly Connect a garden hose to the AutoFill Assembly...

Page 44: ...the required reach to the access 6 Place the end of the drain hose on or in the approved drain access 7 Loosen and remove the drain plug 8 Drain the tank completely and reinstall the plug 9 Repositio...

Page 45: ...k completely and reinstall the drain plug 10 Return the drain hose to the storage hook at the left side scrub door area beneath the floor pan 11 Replace the 9 access caps removed in step four SQUEEGEE...

Page 46: ...ydraulic system If towing will exceed the above restrictions the rear wheel must be raised or supported by a dolly MACHINE OPERATION BLOWER OPTION The blower can move debris from hard to reach areas i...

Page 47: ...ing information to help you give your sweeper scrubber the maintenance attention it requires A Scheduled Maintenance Chart Preventative Maintenance Instructions for Required Scheduled Maintenance Task...

Page 48: ...equirements refer to the engine manual AIR INTAKE SYSTEM X Empty rubber dust cup of air filter element X Check air filter indicator X Clean air filter NOTE Clean more often in dusty conditions X Repla...

Page 49: ...Lubricate type grease X Hood Latches Hinges Lubricate type oil IMPELLER X Check for hydraulic fluid leaks HYDRAULIC SYSTEM X Check hydraulic reservoir and fill as needed X Replace breather cap filter...

Page 50: ...X Perform main broom adjustment test and adjust as needed X Inspect the side broom for wear and adjust as needed Replace main and side brooms as needed Main Broom needs to be replaced if bristles are...

Page 51: ...Repair or replace as needed X Check and tighten lug nuts torque to 100 ft lbs MISCELLANEOUS X Inspect latches and hinges Tighten and lubricate as needed X Check anti static drag chain on rear wall of...

Page 52: ...attempt to perform any service on the equipment or components until the engine if OFF the parking brake is LOCKED and the wheels are CHOCKED PREVENTATIVE MAINTENANCE Air Intake System Check Air Filter...

Page 53: ...3 Locate the air filter and loosen the retaining clamp 4 Remove the dust cup 5 Pull the rubber plug out of the dust cup and empty the contents NOTE The Diesel engine has a wing nut holding the air fi...

Page 54: ...nts check the elements for holes by passing a light bulb inside it PREVENTATIVE MAINTENANCE Air Filter Installation 1 Wipe out the air cleaner housing with a damp cloth Be sure all dirt is removed 2 I...

Page 55: ...clean the terminal posts and cable clamps 4 Apply a thin coating of petroleum jelly to the terminals and cable clamps Battery Replacement CAUTION Remove the negative battery cable before you remove t...

Page 56: ...he reset button in the center of the breaker The circuit breakers are located on the instrument panel below the steering wheel Fuses Fuses are located in the fuse panel behind the hopper on the fire w...

Page 57: ...ing them WARNING Replace any defective safety components before operation the sweeper WARNING During repair or servicing of the fuel system work in a properly ventilated area and do not smoke or allow...

Page 58: ...e lower hose 4 Turn on the water and fill the radiator 5 To keep from damaging the radiator apply air pressure slowly and carefully 6 Shut off the air pressure refill the radiator with water and reapp...

Page 59: ...pan 3 Remove the used oil filter and replace with a new one 4 Dispose of the oil and oil filter in an approved manner 5 Remove the engine oil cap add oil in the amounts listed in the engine manual the...

Page 60: ...ed with oil every 500 hours There are numerous hinges and latches make sure to lubricate all of the following Engine cover Top Gas Tank Cover Side Door and Latch Main Broom Doors Scrub Doors and Latch...

Page 61: ...lic cylinders to keep the hopper raised Always engage the safety arm before servicing the hopper 4 Shut off the engine and engage the parking brake 5 Locate and grease the hopper lift arm lubrication...

Page 62: ...t acceptable add hydraulic fluid PREVENTATIVE MAINTENANCE Maintaining Hydraulic Oil Cooler Efficiency Your machine is equipped with a hydraulic oil cooler it is integrated with the radiator and utiliz...

Page 63: ...8 Check the drain plug for leakage Changing The Hydraulic Fluid Filter 1 Turn off the engine and engage the parking brake 2 Unscrew the oil filter cartridge from the mount and discard in an approved...

Page 64: ...for wear and damage Flap clearance should be 3 18 mm above the floor 3 Worn and damaged flaps should be replaced immediately to maintain proper dust control Broom Door Flap Replacement and Adjustment...

Page 65: ...pedal just enough to turn on brush motor 5 Allow about 45 seconds for the broom to operate then deactivate the broom motor and raise the broom NOTE Test time will vary according to the test surface u...

Page 66: ...The adjustment knob is located in the engine compartment on the broom rod pivot 3 Turn the broom adjusting knob clockwise one eighth turn to free the wing nut 4 Turn the wing nut counter clockwise to...

Page 67: ...hex shaped adjustment bar on the left rear wall of the broom chamber underneath the machine 2 Loosen the retaining bolt on the right side of the hex bar 3 Grasp the hex bar with a wrench and rotate it...

Page 68: ...on you can either rotate the old broom end to end and re install it or you can install a new broom Slide the main broom into the broom chamber and align the broom with the metal drive hub located at t...

Page 69: ...om Angle Adjustment The angle adjustment is controlled with a bolt located on the inside of side broom arm assembly 1 Loosen the lock nut 2 Turn the adjusting bolt until the broom is at the optimum an...

Page 70: ...side broom handle in LOWER position 3 Loosen the side broom adjusting nuts located on the exterior of the side broom arm assembly 4 Adjust the side broom height be sliding the broom assembly up or do...

Page 71: ...t PREVENTATIVE MAINTENANCE Side Broom Replacement NOTE Broom should be replaced if bristles worn to a length of 3 inches 7 62 cm or less NOTE The side broom features a quick release mechanism which en...

Page 72: ...spring using a downward motion and the brush will release from the driver 4 Install the new brush by positioning the socket in the brush with the driver the on the scrub motor 5 Lift the brush until...

Page 73: ...ght and left side squeegee blades 3 Remove the bolts washers and lock nuts holding both lift arms to the scrub deck PREVENTATIVE MAINTENANCE 4 Loosen the jam nut securing the rod end to the lift arms...

Page 74: ...arm to the scrub deck on both sides using the screws washers and lock nuts 9 Tighten the lock nut securing the rod ends to the lift arms both sides 10 Close scrub doors and turn scrub deck on shut sc...

Page 75: ...r wood as a feeler gauge for this procedure This is a starting reference PREVENTATIVE MAINTENANCE 8 Locate the squeegee lift arms on each side of the machine 9 Loosen the bolt which attaches the upper...

Page 76: ...r indicated 1 Front Lower Edge 2 Opposite Lower Edge 3 Front upper Edge and 4 Opposite Upper Edge Removal and replacement instructions follow This procedure can be performed with the squeegee tool on...

Page 77: ...attach the hand knobs one on each side to the squeegee frame supports 4 Connect the quick release pin to the squeegee 5 Connect the vacuum hose to the squeegee PREVENTATIVE MAINTENANCE Inner Squeegee...

Page 78: ...the hopper hood and raise the hood 2 Disconnect the wire harnesses leading to the filter shaker motors 3 Remove the four bolts securing the each shaker motor assembly to the hopper 4 Remove the shake...

Page 79: ...hed with soap and water use 40 psi water pressure or less NOTE Make sure the filter is thoroughly dried while standing on its side before installing in the hopper Do not install or use a wet filter Dr...

Page 80: ...s to the front edge of the engine pan Install a new seal by folding it in half to align the holes Doubled edge with holes goes on the bottom Support the seal straight up while bolting the retainer bar...

Page 81: ...ce of 3 8 89 cm from the floor to the rear hopper entrance lip The front of the hopper should be adjusted so that the front bumper aligns with the hopper frame where the two meet When properly adjuste...

Page 82: ...ys engage the safety arm before servicing the hopper 2 Loosen the mounting bolts in the gasket mount Move the assembly toward the hopper Tighten the bolts Test and repeat if necessary PARKING BRAKE No...

Page 83: ...s 7 Turn the clevis clockwise three or four complete turns 8 Tighten the jam nuts and re install the clevis ends onto the bar 9 Adjust the knurled handle on the parking brake lever Cable Adjustment fo...

Page 84: ...he tire on the machine Rear Tire The rear tire is a special traction rubber compound press on type tire MISCELLANEOUS ADJUSTMENTS Anti Static Chain Adjustment Each machine is equipped with an anti sta...

Page 85: ...ce battery Machine out of fuel Refuel Fuel filter plugged Clean or replace filter Fuel line broken or obstructed Blow fuel line out with compressed air Dirty air filter Clean or replace air filter Pro...

Page 86: ...arking brake is on Release brake Directional control pedal jammed damaged or not adjusted properly Clear jam or adjust linkage Tow valve in tow position Move to drive position Low hydraulic fluid leve...

Page 87: ...section Motor Control valve Gear pump Relief valve Brush switch not on Press to on position Foot pedal not depressed Press to forward position Little or no vacuum in brush compartment Filters clogged...

Page 88: ...in hose from impeller Repair leak clear obstruction or replace hose Squeegee out of adjustment Adjust squeegee Engine not operating at high speed Check Throttle Switch Position Impeller failure Check...

Page 89: ...otor failure See Hydraulics System Problems Squeegee will not lower Loose or defective squeegee switch on console Reconnect wiring or replace switch Loose wire s at foot pedal Connect Foot pedal switc...

Page 90: ...and adjust if necessary Sweeper unit leaving debris Hopper full Dump hopper Broom s out of adjustment Adjust Broom bristles worn Check broom for wear and adjustment Poor performance of broom drive mec...

Page 91: ...nding Lubricate or adjust arm linkage Hopper does not rotate or rotates too slowly Hopper load too heavy Dump more frequently Hydraulics system problem See Hydraulics System Problems in this section C...

Page 92: ...Output shaft malfunction Replace output shaft and bearings Hydraulic gear pump failure Pump leaking Replace seals or RR Pump Drive coupler failed Replace Gears worn or scored Rebuild pump or RR Pump R...

Page 93: ...s binding unfastened Charge pump gears worn or scored Replace defective gears Damage due to entry of air into hydraulic system Maintain correct hydraulic fluid level in reservoir Keep suction hose fit...

Page 94: ...warranted items become the sole property of Minuteman International or PowerBoss or its original manufacturer whichever the case may be PowerBoss disclaims any implied warranty including the warranty...

Page 95: ...cals or damage to property or loss of income due to malfunctions of the product If a difficulty develops with this machine you should contact the dealer from whom it was purchased This warranty gives...

Page 96: ...The Power of Clean PowerBoss Is A Full Line Manufacturer Of Sweepers and Scrubbers For Industrial Facilities...

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