PowerBoss CORE 50 Owner'S Manual Download

Page: 67 / 78

Owner’s Manual

PowerBoss, Inc. A Member of the Hako Group ©

2007

PowerBoss

CORE 50 Sweeper Scrubber

Page

PowerBoss

The Power of Clean

TROUBLESHOOTING (CONTINUED)

PROBLEM

CAUSE

SOLUTION

Hydraulic gear pump failure
(Continued).

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.

Hydraulic variable
displacement pump failure.

Pump leaking.

Replace seals.

Relief valve(s) stuck.

Clean or replace relief
valve(s) at the pump.

Drive coupling malfunction.

Replace defective gears.

Control linkage out of
adjustment

Check to see if linkage is
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 fittings tight.

Summary of Contents for CORE 50

Page 1: ...PowerBoss Inc 50 50 Owner s Manual Sweeper Scrubber A Member Of The Hako Group CORE CORE techsupport powerboss com Technical Service 800 982 7141 PB 4100004 Rev 05 07 07...

Page 2: ...rBoss Inc The Model and Serial Numbers of your machine are shown on the nameplate mounted on the machine This information is needed when contacting Technical Support or ordering parts For your conveni...

Page 3: ...Switch 13 Horn 13 Fuel Level Gauge 13 Ammeter 13 Oil Pressure 13 Hour Meter 13 Engine Coolant Temperature Gauge 13 Throttle 13 Directional Control Pedal 14 Parking Brake 14 Headlight Switch 14 Solutio...

Page 4: ...els 20 Rotary Trash Relocator RTR 20 OPER AT I NG P ROCEDURES Pre Operation Checks 21 Starting 21 Slowing And Stopping 21 Operating On Grades 22 Sweeping 22 Emptying The Hopper 22 Using The Rotary Tra...

Page 5: ...r Removal 32 Air Filter Cleaning 32 Air Filter Inspection 32 Air Filter Installation 32 Battery Cleaning 33 Battery Replacement 33 Circuit Breakers 33 Fuses 33 Fuel System 34 Checking The LPG Fuel Loc...

Page 6: ...7 Checking The Main Squeegee Adjustment 47 Caster Adjustment 48 Pitch Adjustment 48 Turning Or Replacing The Main Squeegee Rubber 49 Main Squeegee Tool Removal 50 Main Squeegee Tool Install 50 Inner S...

Page 7: ...Leaving Debris 59 Hopper Does Not Rise Or Lower 60 Hopper Does Not Rotate Or Rotates Slowly 60 Scrubhead W ill Not Lower 60 Scrubhead Motors W ill Not Turn 61 Poor W ater Pick Up 61 Detergent Solution...

Page 8: ...rranted for six 6 months Travel is eligible for warranty consideration the first thirty 30 days after installation The same provisions and exclusions apply to travel coverage as to labor and part elig...

Page 9: ...eath WARNING To warn of hazards or unsafe practices which could result in severe personal injury or death CAUTION To warn of hazards or unsafe practices which could result in minor personal injury ATT...

Page 10: ...various parts of the sweeper are highly visible safety reminders which should be read and observed Make sure the decals are replaced if they become illegible or damaged The decal below is located in t...

Page 11: ...per Scrubber Page 9 PowerBoss The Power of Clean SAFETY DECALS Continued Part Number 301728 Part Number 301732 High Dump Hopper Shroud of Radiator Part Number 301729 Impeller Part Number 301730 Impell...

Page 12: ...ngerous due to the highly explosive hydrogen gas they emit 1 Before starting the engine make sure that You have read and understand the operation manual You are securely seated in the operator s seat...

Page 13: ...keep the hopper raised 5 When servicing or repairing the fuel system Work in a properly ventilated area do not smoke or allow an open flame near the fuel system Never bypass safety components unless...

Page 14: ...block or chock behind the wheels when parking on inclines 4 Use special care when traveling on wet surfaces 5 Observe all proper procedures for operation and maintenance of the sweeper as outlined in...

Page 15: ...n the tank for gasoline and diesel models only The fuel gauge for LPG models does not function The gauge on the LPG tank must be used to determine the remaining fuel The battery gauge indicates the ch...

Page 16: ...stops move the foot pedal past neutral and into the opposite position Use for emergency stops only Constant use of this braking method may result in damage to the drive components This machine is equi...

Page 17: ...tor stops The hand lever beside the operator s left leg my be lowered to provide a float position for the main broom The float position may be used on extremely uneven floors Extreme use of the float...

Page 18: ...ressure is applied with the knob turned to the left the heaviest to the right Once set it is not necessary to change this knob as the scrubhead is raised and lowered Each time the brushes are activate...

Page 19: ...tops the scrub brushes stop rotating and solution flow is interrupted until travel resumes This prevents flooding the floor and prevents excessive brush wear and floor damage 6 Drive forward slowly Us...

Page 20: ...Loosen and remove the drain plug 8 Drain the tank completely and reinstall the plug 9 Reposition the drain hose on its storage tray To clean the recovery tank after draining proceed as follows The rec...

Page 21: ...Grasp the filter canister housing and unscrew Remove the housing The element is inside of the housing and can be removed for cleaning and inspection 3 Reinstall the element and housing 4 Open the valv...

Page 22: ...ty debris locate the dump door filter shaker switch at the left side of the instrument panel Press and hold the left side of the switch until the dump door has opened To lower the hopper push the leve...

Page 23: ...e sit in the operator s seat and make sure the parking brake is locked 1 Make sure the directional control pedal is in the neutral position 2 Make sure the throttle is in the idle position 3 LP and Ga...

Page 24: ...he directional control pedal to position the machine so that the space between the machine and the container or dumpster is adequate to raise the hopper 4 Reduce the engine speed 5 Pull back the lever...

Page 25: ...trailer and apply the parking brake 2 Tie the machine down using the tie down holes in the frame behind both the front wheels and in the rear center of the frame Attach the tie downs to the frame only...

Page 26: ...elease the latch on the retaining door for the LP tank and open the door 2 Remove the hose fitting from the tank and slide the tank out 1 Place the tank base first into the tank cavity below the opera...

Page 27: ...ockwise the front forward end of the rubber will be raised Turning the knob counterclockwise will lower the front edge The second adjustment is the spring alignment By adjusting the spring anchor pin...

Page 28: ...quipment and components This section contains the following information to help you give your sweeper the maintenance attention it requires A Planned Maintenance Chart Service Instructions for Require...

Page 29: ...er to the engine manual furnished with this manual AIR INTAKE SYSTEM X Empty rubber dust cup of air filter element X Clean air filter NOTE Clean more often in dusty conditions X Replace air filter ELE...

Page 30: ...uid strainer in reservoir X Inspect hydraulic oil cooler fins and clean as needed if so equipped X Blow out hydraulic oil cooler fins with compressed air if so equipped SWEEPING COMPONENTS X Inspect b...

Page 31: ...an or replace as needed X Inspect the hopper flaps for wear or damage and replace as needed X Inspect hopper side and frame seals for wear or damage Adjust or replace as needed STEERING X Check for le...

Page 32: ...lubricate as needed X Check anti static drag chain on rear wall of broom chamber for damage or excessive wear Replace as needed X Check side broom lift cable and brake cable for wear IMPELLER X Check...

Page 33: ...e Section Air Intake System Electrical System Fuel System Coolant System Lubrication System All basic maintenance tasks are listed with their recommended frequencies on the Planned Maintenance Chart i...

Page 34: ...er housing 2 Use an air hose to blow out the air filter Air pressure should be 100 psi or less AIR FILTER INSPECTION 1 After you clean the air filter check it for holes by passing a light bulb in side...

Page 35: ...t button in the center of the breaker The circuit breaker is located on the instrument panel beside the ignition switch FUSES The individual circuits are protected by automotive style fuses in a fuse...

Page 36: ...ck immediately If the engine simply turns over this indicates the fuel filter lock is operating correctly 1 Never attempt to perform any service on the equipment or components until the engine is OFF...

Page 37: ...u will need to repeat these steps until water flushed from the radiator runs out clear 7 Inspect and clean the radiator cap 8 Inspect and reconnect the hoses 9 Refill the radiator with coolant NOTE NO...

Page 38: ...and replace with a new one 6 Dispose of the oil and oil filter in an approved manner 7 Remove the engine oil cap add oil in the amounts listed in the engine manual then secure the cap 8 Clean all oil...

Page 39: ...PowerBoss Inc A Member of the Hako Group 2007 PowerBoss CORE 50 Sweeper Scrubber Page 37 PowerBoss The Power of Clean Dump Arm Mounts Grease 100 Lubrication Type of Lubrication Frequency In Hours LUB...

Page 40: ...ow the reservoir 4 Remove the drain plug located on the bottom rear of the reservoir and allow the fluid to drain 5 Discard the fluid in an approved manner then replace and retighten the drain plug 6...

Page 41: ...ay encounter creeping problems from time to time Creeping means the machine moves backward or forward when the forward reverse pedal is in neutral A grinding noise when the engine is shut down is also...

Page 42: ...needed until the wheel remains motionless 10 Retighten all the locking nuts and bolts 11 Turn the engine off and lower the machine to the floor 12 Reattach wires properly to lockout switch Test switc...

Page 43: ...OM ADJUSTMENT 1 Drive the machine onto the test surface with the main broom in the RAISED position 2 Set the parking brake and position the main broom float handle in the NORMAL UP position 3 Push the...

Page 44: ...ut counter clockwise to allow space for adjustment 7 Make a lower or higher adjustment with the knob as required 8 Retighten the wingnut 9 Raise the main broom float lever to NORMAL UP position 10 Rep...

Page 45: ...ht side of the hex bar 3 Grasp the hex bar with a wrench and rotate it to raise or lower the left end of the main broom The right end of the broom remains fixed All adjustments affect the left end of...

Page 46: ...u 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 the fa...

Page 47: ...ctuator and insert it into the hole on the opposite side of the remaining pin while putting tension on the cable Make sure the repositioned pin goes through the loop in the cable inside of the plastic...

Page 48: ...until the brush retainer bar is accessible 3 Lift the bar and turn the broom clockwise about one eighth of a turn until the lock pins in the broom disengage from the drive plate 4 Install the new bro...

Page 49: ...cess to the left brush unlatch the engine frame and swing it open completely Secure with the locking pin Access to the left brush is now easier CHECKING THE MAIN SQUEEGEE ADJUSTMENT 1 On a level floor...

Page 50: ...tch adjusting screws on the squeegee support arm There are two adjusting screws Loosen all four locking nuts 2 per screw and back the nuts away from the bracket several turns 4 At the forward end of e...

Page 51: ...f thickness turn the rubber to an unused edge in the order indicated 1 Front Lower Edge 2 Opposite Lower Edge 3 Front upper Edge and 4 Opposite Upper Edge Removal and replacement instructions follow T...

Page 52: ...eegee tool up and onto the mounting plate 3 Secure the squeegee tool assembly by tightening the aluminum hand knobs completely INNER SQUEEGEE REPLACEMENT The inner squeegee is a component of the rear...

Page 53: ...sed air tapped against the floor or washed with soap and water 1 If blown out with compressed air use 100 psi or less 2 If washed with soap and water use 40 psi water pressure or less FILTER REPLACEME...

Page 54: ...sary FLAP REPLACEMENT Flaps located at the entrance lip of the hopper must be replaced when worn or damaged The flap panels may be replaced separately 1 Park the machine on a level surface and engage...

Page 55: ...the seal straight up while bolting the retainer bar in place The seal should extend in front of the retainer bar after installation Be certain that the seal edges are aligned to prevent twisting of th...

Page 56: ...evis Back the nut away from the clevis several turns 5 Using the 9 16 wrench turn the threaded bar by grabbing the hex section at the center If view from the rear of the machine turning the bar counte...

Page 57: ...chain bolted to the back wall of the broom chamber This should remain in contact with the floor at all times Inspect the chain every 200 operating hours Replace if at least one link does not drag the...

Page 58: ...alve slowly Fuel line broken or obstructed Blow fuel line out with compressed air Dirty air filter Clean or replace air filter NOTE On machines with LPG fuel also check the following Fuel tank type do...

Page 59: ...elease brake Tow valve open Close tow valve Directional control pedal jammed damaged or not adjusted properly Clear jam or adjust linkage Low hydraulic fluid level Add hydraulic fluid Hydraulic fluid...

Page 60: ...correct position Machine creeps in neutral Directional control pedal return spring is out of adjustment Perform the adjustment procedures Brushes do not turn or turn very slowly Hydraulic system probl...

Page 61: ...l worn Replace Skirt clearance from floor exceeds Adjust clearance Dust control filters clogged Clean filters Filter seals worn or missing Replace Poor seal contact at hopper lid or impeller inlet Vis...

Page 62: ...ED PROBLEM CAUSE SOLUTION Hopper does not raise or lower Hydraulics system problem Control Valve Gear Pump Relief Valve See Hydraulics Systems Problems in this section Scrubhead will not lower Fuse bl...

Page 63: ...d switch wires Connect wires Loose connection of plug at coil Connect Defective coil Replace Defective scrubhead switch Replace Poor water pick up Recovery tank is full Empty the tank if foaming badly...

Page 64: ...creen Machine is stopped Machine must be moving for solution to flow Drive machine forward Delivery lines clogged Clear lines Pump not operating Inspect connections Solution valve not opening Check an...

Page 65: ...ch on console Reconnect wiring or replace switch Loose wire s at forward relay Check connections and function Loose or defective connection at coil Check coil and wiring Squeegee will not raise in rev...

Page 66: ...bore Valve seals leaking Replace seals O rings leaking Replace O rings Relief valve stuck open Clean or replace relief valve Hydraulic motor failure Motor leaking Replace seals Drive link malfunction...

Page 67: ...aulic system Maintain correct hydraulic fluid level in reservoir Keep suction hose fittings tight Hydraulic variable displacement pump failure Pump leaking Replace seals Relief valve s stuck Clean or...

Page 68: ...stem noisy Air in system Check fluid level in reservoir check for loose connections or leaks Relief valve dirty or damaged Clean or replace Loose suction line Tighten fittings Clogged suction filter o...

Page 69: ...Owner s Manual R PowerBoss Inc A Member of the Hako Group 2007 PowerBoss CORE 50 Sweeper Scrubber Page 67 PowerBoss The Power of Clean Notes...

Page 70: ...ustment Service Instructions 41 Broom Main Switch 15 Broom Side Switch 15 Brushes Main Scrub 16 C Caster Adjustment Service Instructions 48 Changing Engine Oil Service Instructions 36 Changing Solid T...

Page 71: ...eplacement Service Instructions 53 Front Frame Seal Service Instructions 53 Fuel Level Gauge 13 Fuel System Service Instructions 34 Fuses Service Instructions 33 G Gauge Engine Coolant Temperature 13...

Page 72: ...29 Pedal Directional Control 14 Pitch Adjustment Service Instructions 48 Planned Maintenance Chart 26 Planned Maintenance Chart Air Intake System 27 Planned Maintenance Chart Coolant System 27 Planne...

Page 73: ...41 Service Instructions Caster Adjustment 48 Service Instructions Changing Engine Oil 36 Service Instructions Changing Solid Tires 54 Service Instructions Changing The Hydraulic Fluid 38 Service Inst...

Page 74: ...ctions Reverse Flow Flushing 35 Shaker Button Hopper Filter 19 Side Broom Angle Adjustment Service Instructions 45 Side Broom Height Wear Adjustment Service Instructions 45 Side Broom Replacement Serv...

Page 75: ...hooting Hydraulic Control Valve Failure 64 Troubleshooting Hydraulic Gear Pump Failure 64 Troubleshooting Hydraulic Motor Failure 64 Troubleshooting Hydraulic System Noisy 66 Troubleshooting Hydraulic...

Page 76: ...52753PL4 POWERSOL 500 4 X 1GAL CASE 952755PL POWERSOL 500 5 GAL 952757PL POWERSOL 500 55 GAL 952805PL POWERSOL 500 PART A 5 GAL 952807PL POWERSOL 500 PART A 55 GAL 952815PL POWERSOL 500 PART B 5 GAL 9...

Page 77: ...rubber tire marks General Description About Powersol 700 General Description About Powersol 700 General Description About Powersol 700 General Description About Powersol 700 Controlled industrial Emul...

Page 78: ...rd toward perfection in our little corner of the process of bringing you the best you can buy Please fill out the form below and comment on how you found our manuals Thank you Name____________________...

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