198] GO, 82,90 Sexes vis SWEEPER/SCRUI SCRUBBER TSS/90 HC © TSS/90 © TSS/80. ISS/90 HC * ISS/90 ¢ ISS/80 CSS/90 HC * CSS/90 * CSS/80 OPERATION MAINTENANCE PARTS AAR BROOKS & PERKINS » «5 HANDLING TECHNOLOGIES DIVISION ox(_ ANDERSON & TAYLOR STREETSIP.O. BOX 1227 i ABERDEEN, NORTH CAROLINA 28315 USA 919-944-2167/TWX:510-939-33: a 8003847 HTIFARSTS 2687409 ‘ DECEMBER ‘89\ FomnerGoss” : TABLE OF CONTENTS SAFETY sicmsnnene St 4, INTRODUCTION... Ww 1-4. General 14 1-2. Scope, 14 1-4. Standard Feature: 12 1-6. Terms and Abbreviations 13 2. SPECIFICATIONS ...... 24. General 2:2. Model Specifications 3. OPERATION 34. General 3-2. Theory of Operation 34. Major Components. 3-47. Controls and Indicator 3-89. Pre-Operation Check 3-81. General Operatior 3-100. Sweeping .. 3-110. Scrubbing. 3-121. Transporting 3-124, Additional Options. 4, MAINTENANCE. 41. General 4-3.__ Preventive Maintenance 4-4. Maintenance Procedures. 45. Engine 4-46, Electrical System 4-23. Coolant System 4-28. Hydraulic System 4-39. Impelier 4-44. Sweeping Componer 4-58. Scrub and Water Pickup Components. 4-75. Hoppers 4-87. Tanks 4-90. Steering 4-91. Parking Brak 493. Tires |. TROUBLESHOOTING... "6. Gone 4-97. Miscellaneous Maintenance 5-1. General 63. Ordering Parts . 6-8. Return Paris - Procedure. Figure 1. Frame Assembly, Figure 2, Engine Covers Figure 3. Instrument Panel. Figure 4. Directional Control Figure 5. Steering Assembly Figure 6. Axle, Brakes and Wheels . Figure 7. Michelin Tire Assembly Figure 8. Lights Figure 9. Engine - Toyota . Figure 10. Engine - Perkins Diesel Figure 11. Engine - 4 Cylinder Kubota Diesel 7 Figure 12. Engine - 3 Cylinder Kubota Diesel Figure 13. Engine - Ford . Figure 14. Radiator (Toyota), and Mounts Figure 15. Radiator (Toyota), Shrouds and Mounts (Heavy Duty)... 6-42 Figure 16. Radiator (Perkins), Shrouds and Mounts 6-40 Figure 18. Radiator (Ford), Shrouds and Mounts . Figure 19. Air Cleaner - Toyota Figure 20. Air Cleaner - Perkins.. Figure 21. Air Cleaner - Kubota .. Figure 22. Cooling Coll Figure 23. Battery AAR Brooks & Perkins December 15, 1969FonerGos Figure 24. Fuel System . Figure 25. impeller (Heavy ty TABLE OF CONTENTS Figure 51. Heavy Duty Curb Broom Guard Figure 26. Exhaust - Toyota ____ Figure 52. Wet Sweep Bypas: ~~ Figure 27, Exhaust - Perkins Figure 53. Scrubhead Lift and Solution (Full Size) Delivery .. 6-122 Figure 28. Exhaust Kubota Figure 54. Side Scrub Brush .. 6-126 Figure 29. Hydraulic Hoses— Figure 55. Squeegee .. 6-128 High Dump Models ... Figure 56. Squeegee Switch Box........6-130 Figure 30, Hydraulic Hoses— Figure 57. Squeegee Lift. 6-132 Low Dump Models Figure $8. High Capacity Figure 31. Hydraulic Valve. Solution Tank 6-134, Figure 32. Hydraulic Reservoir .. 6-78 Figure 59. Full Size Solution Tank ......6-136 Figure 33. Main Broom =f Figure 60. Mid Size Solution Tank ......6-138 Figure 34. Side Broom -f Figure 61. Solution and Recovery Figure 35. Low Dump Arm Assembly . 6-84 Tank Level Indicator Figure 36. High Dump Arm Assembly. 6-86 Figure 62. Squeegee Wand Figure 37. Safety Arm Assembly Figure 63. Water Recycling System. Figure 38. Figure 64. Extended Solution System.6-146 Figure 39. Figure 65. Cab .. Figure 66. Windshield Wiper .. Figure 40. Figure 67. Heater/Defroster Figure 41. Figure 68. Cab Pressurizer ’ Figure 69, Overload Guard 4 Figure 42. Figure 70. Front Bumper Figure 43. (TSS and SW Models) Figure 44. Hopper Fire Indicator Figure 45. Clogged Filter Indicator......6-104 7. MANUFACTURER'S LITERATURE... 7-1 Figure 46. PowerPacker™ .. Figure 47. 8. SERVICE BULLETINS Figure 48, Figure 49. 9. INDEX seve Figure 50. Vacuumized Curb Broom (Hopper Detail .. AAR Brooks & Perkins December 15, 1989 ~~PowerBoss™ Sweeper/Scrubber This manual contains information for several Use this page to determine what information in the models of the Power Boss™ sweeper/scrubber. manual is applicable to your sweeper/scrubber. __—The combination of special features and options checked off below identifies your particular unit. Unit Serial Number MODEL: OTss/90 HC SCRUB 1 Nylon OTss/90 BRUSH: C1 Nylo-grit OTss/80 G Strato-grit ‘O1ss/a0 He Olss/90 SIDE Polypropolene clss/e0 BROOM: — 0 Nylon Ocssig0 He | Ocss/e0 OPTIONS: UI Power Packer™ Ocss/so G Power Stacker™ 1D Blower Attachment ENGINE: O Gasoline G Vacuum Wand Attachment OG U Snow Plow O Diesel 0 Bucket Attachment 0 Overhead Guard ENGINE O Ford (4 cylinder) 1D Side Scrub Brush ( MANU- T Toyota (4 cylinder) 1 Side Sweep Broom t FACTURE: —O Perkins (4 cylinder) 0 Side Broom Guard 1D Kubota (4 cylinder) 0 Water Extension System 1 Kubota (3 cylinder) 0 Wet-Sweep By-Pass C Water Recycling System HOPPER: Ol Multi-Level High Dump 1D Squeegee Wand Attachment CD Low Dump © Hopper Dolly 1 Manual Lift Out B Lights OCab TIRES: 0 Michelin Pneumatic 1D Cab Heater O Solid 0 Cab Defroster/Fan D Solid Soft Shoe G Windshield Wiper 0 Solid Nonmarking G Cab Air Pressurizer 0 Special Scrubber Compound G Fire in Hopper Indicator 1 Clogged Fiter indicator ——E Recovery Tank Warning ——— —-MAIN-BROOM--G- Nylon ———- BRISTLES: 0 Proex 0 Solution Tank Warning G Proex and Wire D Hand Parking Brake O Natural Fiber U Timed Filler Shaker 1D Pure Nylon Fire Extinguisher O Steel Adjustable/impact Seat © Union Fiber & Wire Mix G Stainless Steel Tanks Vacuumized Side Broom Heavy Duty Radiator | 1 Automatic Engine Shutdown(LIMA (NORTH AMERICA ONLY) AAR Brooks & Perkins Corp. (B&P) warrants that the PowerBoss® machine will be free from defects in material and workmanship for a period of 24 months or 2,000 operating hours on rider units, 12 months or 500 operating hours on walk-behind units from date of installation, _.whichever.comes first. Written notice of any claimed defect must be given. to B&P withinthe warranty period and within thirty (30) days after such defect is discovered. Liability under this ‘warranty is limited to either replacing or repairing, at B&P's election, any part or parts deemed defective after examination by B&P or an Authorized Service Representative. Any PowerBoss® machine or any of its parts returned by customer to B&P or an Authorized Serv- ice Representative via prepaid transportation and which is found to be defective, will be re- paired or replaced and returned to customer via prepaid surface transportation within the Continental U.S. On the other hand, should a part be found not defective, inspection and han- dling charges may be charged to the customer by B&P or an Authorized Service Representa- uve. * For one hundred eighty (180) days from date of installation, B&P will provide repair labor, at no charge, solely through an Authorized Service Representative. Thereafter, labor will be charged. This warranty does not extend to any PowerBoss® machine, or its parts, that have been abject to misuse, accident or improper handling, installation, maintenance or application, nor ives it extend to PowerBoss® machine and/or parts which have been repaired or altered out- side B&P’s plant or the facility of Authorized Service Representative. This warranty does not apply to routine wearable parts of the PowerBoss® machine such as brushes, flaps, filters, seals, points, plugs, hoses or similar items. Moreover, this warranty does not extend to any PowerBoss® machine or part replaced or repaired under this warranty. Only replacement parts supplied by B&P are warranted for 30 days alter installation. The warranty for optional engines shall be limited to the warranty extended to B&P by the supplier. seed sea ‘THE WARRANTY SET FORTHHEREINISIN LIEU OF AND EXCLUDES ANY AND ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, ARISING BY OPERATION OF LAW OR OTHERWISE, INCLUDING, BUT NOT LIMITED TO, ANY IMPLIED WARRANTY OF MER- (CHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, AND CUSTOMER WAIVES ANY OBLIGATION OR LIABILITY OF B&P ARISING IN TORT OR STRICT LIABILITY IN TORT, OR FOR LOSS OR USE, REVENUE OR PROFIT WITH RESPECT TO PowerBoss® MACHINE ANDIOR PARTS FOR ANY LIABILITY OF CUSTOMER TO ANY THIRD PARTY, OR FOR OTHER DIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES.SAFETY High dump and low dump hopper High dump hopper Sad MM Stay Clear Ce Corea oe ey ars GENERAL INSTRUCTIONS To ensure the safety of both the operator + Keep your hands and body clear of and the equipment, the sweeper/scrubber moving parts, especially when the should be operated and maintained by only hopper or lift arms are partially or fully trained authorized personnel. Ali matfunc- raised. “| _tioning-equipment should be-removed from —»_Make-sure others in the area stay clear service until any necessary repairs and ad- of the equipment and moving parts. justments have been completed. + Never attempt to dump debris from a ‘The following DANGER, WARNING, CAU- dock or mezzanine. Dump from ground TION, and ATTENTION comments shouldbe tevel only. observed at all time. 3. When leaving the sweeper/scrubber un- C A attended: ae + Place the controls in OFF position. 1. Keep cigarettes, matches, and all other + Set the parking brake. flame sources away from the sweeper! + Shut off the engine. scrubber. Gasoline, LP gas, and diesel fuel are highly flammable. Lead acid bat- 4. During cleaning and maintenance: teries are equally dangerous due to the highly explosive hydrogen gas they emit. + Always stop the engine and set the parking brake before servicing. + Never use detergents or cleansers that are flammable or combustible. Awaanine «Never Inflate a preumatc tre without using a safety cage. __| 1. Before starting the engine, make sure that: Lock and support the scrubhead as- : ‘sembly in raised position. — + Your are securely seated in the opera- NOTE: Later models with electric scrub tor's seat. head do not have a separate lock. + The parking brake is tocked. + Donotattemptany impeller adjustment * The directional control pedal is in neu- unless you have shut of the engine. tral. Never place your hands near the intake + The throttle is in idle. hoses or inlet when the engine is run- + Hydraulic controls are in OFF position. ning. + With high dump models, always en- 2. - During operation: gage the safety armbefore getting under C) solar 33the hopper. Donotrely on the hydraulic cylinder to keep the hopper raised. + Work ina properly ventiiated area, do notsmoke, or allowan open flame near the fuel system. + Never bypass safely components un- less you are testing them. + Never bypass the fuel filter lock or oil pressure switch, except when testing them (and always reconnect them after testing). + Wear gloves to disconnect the tank coupling. 7 6._Donotoperate an LPG poweredsweeper! When servicing or repairing the fuel sys- | ___tem: asesgegeeLeLteLiL SAFETY position the hopper over the dumpster or tecepticle. Driving with the hopper rasied teduces visibility and creates conditions for striking overhead objects, throwing the ___Machine off balance, and other hazards. 2. Travel slowly on grades. 3. Place a 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 opera- tion and maintenance of the sweeper! sctubber, as outlined in this manual. 6. Remain alert at all times to people and ‘scrubber when any component in the fuel system is malfunctioning or leaking. 7. Replace any defective safety components before operating the sweeper/scrubber. Accaution 1, Do not drive with the hopper in the raised position except the few feet necessary to equipment in and around your area of op- eration. ATTENTION! 1. Do not operate the #2 RTA lever before the #1 light iluminates. 84All PowerBoss™ sweepers and sweeper! scrubbers have been designed ant safety as a top priority. The safety informa- tion given in this manual is for the protection _ of the operator, the maintenance people and the equipment. Notice and strictly adhere to SAFETY ‘SAFETY SYMBOLS Listed below are five symbols and their meanings used in this manual. The symbols —)~ are fisted in order of seriousness with the strongest listed first. However, all safety symbols and decals should be strictly ob- served to prevent personal harm or injury as well as damge to equipment. all safety instruction given in this manual and on the sweeper/scrubber. Axpancer DANGER: To warn of immediate harzards which will It in-severe-personal-injury-oF death Awwarnina WARNING: To warn of harzards or unsafe practices ‘which could result in severe personal injury or death. AccauTion CAUTION: To warm of harzards or unsafe practices which could result in minor personal injury. ATTENTION ATTENTION! To warn of practices which could result in extensive equipment damage. NOTE NOTE To direct your attention to important equipment information or special instructions for preventing dam- age to equipment. SAFETY DECALS Decals directly attached to various parts of the sweeper/scrubber are highly visible safety reminders which should be read and observed. If decals become damaged or il- legible replace immediately. The following are illustrations of the decals and their loca- tion on the sweeper/sorubber. stDrive compartment Solution tank 9. Do Not Use Flammable Cleaning Materials SAFETY DECALS For Your Salely And Safety O1 Others: DO NOT Operate Machine Unless Operation Manual 's Read And Understood. Unless Authorized And Trained. In Areas With Flammable Or Explosive Conditions. Without Adequate Ventilation. aw Inspect Vehicle For Fuel Leakage. Ne ac eo Drive Slowly On inclines And Slippery Suttaces. . Do Nat Power Dump Hopper Unless Vehicl ‘Onk Level Suttace. Before Leaving Vehicle: Lock Parking Br Engine, And Remove Key. Impeller errand From Fan PCT Lit Re EUeeard eee eer i Por} ‘Shroud of radiator rere et ered Fees eee ERC ¢Ponerekoss”___ntropuction CONTENTS 4. INTRODUCTION 1 1-4. Standard Features .... 1-2 1-1. General aI 1-6. Terms and Abbreviations. 13 1-2. Scope. 1 AAR Brooks & Perkins December 15, 1989| i | | | Goss" 1-1. GENERAL. The PowerBoss™ sweeper/ scrubber is a superior product, designed and built for the long haul, The PowerBoss™ sweeper/ scrubber performs two jobs simultaneously dou- bling worker productivity. This is all accomplished with safety as the number one priority. To assure the safety of the operator and equipment follow all safety instructions exactly. The Safety instructions are found at the front of the manual, 1-2, SCOPE. This technical manual provides information to assist both the operator and mainte- nance personnel. The information is divided into the following sections: Introduction The Introduction list each PowerBoss™ sweeper/ scrubber coveredinthisman- ual and summarizes the special features they pos- sess. Specifications The Specifications section lists: specifications for each model of the PowerBoss™ indicating capacities, capa- bilities, and other basic infor- mation. —________INTRODUCTION—____ Maintenance The Maintenance section contains preventive mainte- nance charts and service instructions forrequiredmain- tenance tasks. ‘Troubleshooting The Troubleshooting section contains a troubleshooting chart to assist you in identity- which may occur during the operation of your equipment. Parts ‘The Parts section contains parts lists and exploded views of all machine components and options. Manufacturer's The Manufacturer's Litera- Literature ture section contains infor- mation supplied by manutac- tures forpurchased parts and assemblies used on The PowerBoss™, ‘This section is available to store all service Bulletins required to keep this manual up to date and accurate, ‘Service Bulletins Operation ——The~Operation section 1o-_—__——-— cates and describes all con- trols and components on the PowerBoss™ as well as giv- ing operating instructions for each, Index ‘The index contains an alpha- betical listing of information found in this manual and a reference to the page on which that information can cai be found. AAR Brooks & Perkins December 15, 1989 4 ing-and-correeting problems ———Fomerboss” INTRODUCTION 1-3. Nine models of PowerBoss™ sweeper/ Conventional Sweeper/Scrubbers: scrubbers as well as their options are covered in this manual, see figure 1-1. The information given CSS/90 HC ___-in this manual is true for all. models unless. other-____css/gq________ wise noted. Those models are: css/80 Total Sweeper/Scrubbers: 1-4. STANDARD FEATURES. The Power- Boss™ combines all features necessary to make TSS/90 HC an efficient reliable product, see figure 1-2. The TSS/90 following lists contain those features which are. TSS/80 standard. Intermediate Sweeper/Scrubbers: 1-5. The features listed below are standard on all units: ISS/90 HC Iss/90 + Rugged one-piece unitized frame —___Issgo__- Reliable hydraulic drive with premium, easy to. service components + Transverse mid-engine design for stability | | Figure 1-1. The PowerBoss™ | | AAR Brooks & Perkins December 15, 1989PomerGoOss’____wrropuerion 1-6. TERMS AND ABBREVIATIONS. The fol- + Single rear wheel drive andssteering forexcep- _lowing terms and abbreviations are used through tional maneuverability out this manual. + Efficient and effective direct throw sweeping + Squeegee automatically ralses when uritbacks CSS Conventional Sweeper/Scrubber up FS Full Size + Parabolic squeegee for effective water pick up HC High Capacity + Four cylinder, liquid cooled engine HD High Dump. + Floating brooms, brushes, and squeegees for ISS Intermediate Sweeper/Scrubber uneven surfaces LD Low Dump + Positive-seal, quick change filter LP Liquid Propane + Quick release squeegees and scrub brushes MS Mid Size + Oversize clean out doors on recovery tanks RTR Rotary Trash Relocator + Application designed air system TSS Total Sweeper/Scrubber Aptian a ate Transverse Igned Braking) Mid-Engine Alt System Configuration Convenient Controls ‘Stool Tanks Unitized Premium Frame industrial Hydraulle Tires and One Piece System Wheels Quick Change Quick Change ‘Sweep or Scrub Disposable Brush (Optional on Broom ‘Some Models) Figure 1-2. PowerBoss™ Features ‘AAR Brooks & Perkins December 15, 1989 13onerBoss” SPECIFICATIONS _CONTENTS | 2. SPECIFICATIONS 2-1. General... 2-2. Model Specificat ‘AAR Brooks & Perkins December 15, 1989PonerGoss: 2-1. GENERAL, This section contains specifica- tions for each of the nine models covered in this manual. The specifications are given for reference only. Refer to the operation and maintenance sections of this manual to find specific procedures and safely information. ‘SPECIFICATIONS 2:2, MODEL SPECIFICATIONS. Specifications given in this section are in U.S. Customary units with metric equivalents in parentheses. Anillustra- tion of each model is shown along with the speci- fications, see figures 2-1 through 2-3. cf ‘AAR Brooks & Perkins December 15, 1989 2PomerGoss” SPECIFICATIONS 2-3. Total Sweeper/Scrubber. : «le Va TSS/90 HC (with Optional High Dump) ‘TSS/90 (with Optional High Dump) Figure 2-1. Total Sweeper/Scrubbers. TSS/90 HC Tss/90 Tss/80 \ BRAKES: Mochanical drum Mecha drum Mechanical rum (Front two tires) (Front two tires) (Front wo tires) DIMENSIONS: Length 119.97 in (9032 mm) | 118.97 in (2930 mm) 114.58 in 2910 mm} Width 60.12 in (1527 mm) 60.12 in (1527 mm) £84.12 in (1375 mm) Height $58.00 in (1473 ram) 157.00 in (1448 mm) 57.00 in (1448 mm) Height (with over head guard) 87.00 (2210 mm) 87.00 in (2210 mm) £87.00 in (2210 mm) Height (wih cab) 83.50 in (2121 mm) 18350 in (2121 mm) £83.50 in (2124 mom) ENGINE: Gasoline ATSHP (95.4 kw) 47.SHP (35.4 kw) ATSHP (95.4 Kw) LPs ATSHP (25.4 kw) 47 SHP (95.4 kw) A7SHP (25.4 kw) Diesel AGHP (34.3 kw) ASHP (34.3 kw) S2HP (23.9 kw) [FLUID CAPACITIES ae eee se aera EEE eee Fuel tank 8921 0.3) 8921 (3031) 8¢a1 031) Radiator Baten Sgt (2.81) aqh28)) Total coolant system Bar) at (5.71) Bat 57) Hydraulic Fluid Reservoir 6 gal 2271) 6 gat (22.7) 6 gal (22.7) FRAME; Unitized construction, 3/16 inch (4.8 mm) steal pl | (Reiniorced at stress points) HOPPER: Volume 161° (45 >) 16 (45 me) 1448 (39m) ( ‘AAR Brooks & Perkins 22 December 15, 1983onerGoss SPECIFICATIONS = 7200 ib (544-kg)— 120016 (544-kg) (1524 mim) max. nelght] HYDRAULIC Wheet motor Char-Lynn 4000 Series | Char-Lynn 4000 Series | Char-Lynn 4000 Series (15 Introy) (15 in?rev) Broom & brush motors Char-lynn H Series | CharLyan H Series | Char-Lynn H Series Propulsion pump ‘Cessna Var-dsplacomant Piston Pump (1.24 in'rov) ‘Accessories pump Cessna goat pump Cossna gear pump Cessna gear pump (84in%) (24int) (84 ns) Directional control valve Gessna Gessna Gossna System filer Donaldson 10 micron | Donaldson 10 micron | Donaldson 10 micron Hoat exchanger One-piece tubular col } One-piece tubuiarcol | One-piece tubuiar col RECOVERY TANK CAPAGITY: 100 gal (378.5 60 gal (227) 65 gal (2461) ‘SCRUBBING: Main scrub brushes (diameter) 16:in (408 mmm) 18in (406 m) 141n (356 mm) Side scrub brushes (diameter) (408 mm) 16.n (406 m) 141m (356 mm) Scrub path 48a (1219 mm) 48 in (1219 mm) 42.n (1087 mm) Scrub path [with sie scrub brush) | 58 in (1422 mm) 56 in (1422 mm) 50 in (1270 mm) Scrub coverage (4inchover lap at | 77,500 %t (7200 m*) | 77,5001" (7200 m*) | 67,000 ft (6224 m*) ‘4 mph(area/hou) (__ Servd coverage 91,500 48 (@500 m') | 91,5001 (@500m") | 77,5001 (7200 m*) {with side scrub brush) SOLUTION TANK: 100 gal (978.5) 65 gal (246) 68 gal 2571) SQUEEGEE: Rear 50 in (1270 mm) 50 in (1270 mm) Abin (1118 mm) STEERING: Cam and tover ‘Gam and lever Cam and lover (Paar whee!) (Rear whoo!) (Rear whos!) SWEEPING: Main broom (¢iamoter) 14 in (356 mm) 14 in (356 mm) 14 in (356 mm) ‘Sie broom (diameter) 24in (610 mm) 24 in (610 mm) 24:n (610 mm) ‘Sweep path (main broom) Sweep path (wilh sde broom) Sweep cove ‘TURNING RADIUS (Lott Hand): VACUUM SYSTEM: Impelier WEIGHT: Net (Low Dump) Not (High Dump) Shipping (Low Dump) Shipping (High Dump) 4B'n (1219 mm) 60 in (1524 mm) 198,600 #? (12876 m) 178,000 t* (16536 m*) 16 in (406 mm) 85.75 in (2178 mm) High-speed 9 jn (228 mm) 2475 fo (1576 kg) £3800 Bb (1724 ka) 3875 Ib (1758 ka} 4200 Io (1805 kg) 48 in (1219 mm) 60 in (1524 mm) 198,600 It? (12876 m*) 478,000 ft (16596 m*) 16 in (406 mm) 82 in (2083 mm) High-spood 9 in (228 mm) 13375 tb (1831 ka) 3700 Ib (1678 kg) 3775 lb (1712 kg) 4100 Io (1860 kg) 42in (1087 mm) 54 in (1872 mm) 118,800 (11036 m?) 154,000 12 (14715 m*) 16 in (408 mm) 81 in (2057 mm} High-speed 9 in (228 mm) 2300 fo (1497 kg) 3600 b (1633 ka) 3700 b (1678 ko) 4000 B (1814 kg) AAR Brooks & Perkins December 15, 1! 989(POOGRGOSS”___srecirications 24, Intermediate Sweeper/Scrubber. 18/80 (with Optional ‘and Side Broom) 188/99 (with Optional Side 158/90 HC (with Optionat Broom snd Overhead Guard) ‘Side Broom) Figure 2-2. Intermediate Sweeper/Scrubbers. 1ss/90 HO Iss/90 1ss/80 BRAKES: Mechanical drum Mechanical drum Mechanica! drum (Front two tres) (Front two tres) (Front two tires) DIMENSIONS, Length 95 in (2613 mm) 91 in (2311 mm) 91 in 2311 mm) Width 84 in (1372 mm) 54 in (1972 mm) 48: (1218 mm) Hoight ‘58 in (1473 mm) 57 in (1448 mm) 57 in (1448 mm) Height (with over head guard) 87 in (2210 mm) 87 in (2010 mm) 87 in (2210 mm) Height (with cap) 83.5 in (2121 mm) 8355 in (2121 mm) 835 in (2121 mm) ENGINE: Gasoline AT.5 HP (25.4 kw) 47.5 HP (35.4 kw) 47S HP (95.4 kw) SESE Hp sesbeee eee LEELE 475HP.5.4k0) | _475HP (35.4kw) | _47.5 HP (35.44m)__| Diese! 48.0 HP (34.3 kw) 46.0 HP (94.3 kw) 2 HP (23.9 kw) FLUID CAPACITIES: Fuel tank, 8 gal (90.3) 8 gai (90.8) 89al (30.3) Radiator ‘Sat (2.81) ‘Sat (2.81) Bat (2.81) Total cooiant system BatE.7N) 6g G.7)) 6q6.7)) Hydraulic Fluid Reservoir 6 gal (22.7) 6gal 22.7) 6 gal (22.7) FRAME: Unitized construction, 9/16 inch (4.8 mm) steol plate (Reinforced at stress points) ‘AAR Brooks & Perkins a December 15, 1989_omorboss” SPECIFICATIONS 188/90 HC 188/90 tss/e0 [HOPPER =| aa Volume 71 (2m) 71° (2m) 64 (17 m) Weight limit 400 to (184 Kg) “400 Ib (181 kg) 800 Ib (136 ko) Low dump Standard Standard Standard HYDRAULICS: ‘Wheel motor Char-Lynn 4000 Series | Char-Lynn 4000 Series | Ghar-Lynn 4000 series (5 intirev) (15 intrev) (15 intrev) Broom & Brush CChar-Lynn H series (Char-Lynn H series Chat-Lyn H series Propulsion pump Cessna Var-displacement Piston Pump (12.4 in'rov) ‘Accessories pump Cessna (.84 In%rev) Cossna (84 intrev) | Cessna (84 in'nov) Directional contol valve Cessna Cessna Cessna ‘System fiter Donaldson 10 micron | Donaldson 10 micron | Donaldson 10 micron Heat exchanger One-piece tubular coll | One-piece tubviar col | One-piece tubular coil RECOVERY TANK CAPACITY: 100 gal (9378.51) 60 gal (227) 65 gal (246) ING: ‘Main Scrub brushos (diameter) in (408 mm) 16 in 406m) 44 in (856 mm) ‘Side Scrub brushes (ciameter) (408 mm) 16 in (406 m) 44 in (356 mm) ‘Sorub path (1219 mm) 48 in (1219 mm) 42 in (1067 mm) ‘Serub path (with side scrub brushes) (1422 mm) 56 in (1422 mm) 50 n (1270 mm) ‘Scrub coverage 77500 ft (7200 m?) 77001 (7200 m#) | 67,0001" (6224 m*) [(é inch over lap at 4 mph (rea/nour}) \\ Serub coverage £91,500 in (850m?) 191,500 tt (8500 m*) 77,500 (7200 m*) (with side scrub brush) ‘SOLUTION TANK: 100 gal (378.5 1) 65 gal (246 68 gal (2571) ‘SQUEEGEE: Rear 50 in (1270 mm) 50 in (1270 am) 44 in (1148 mm) STEERING: (Cam and lover (Cam and lever ‘Cam and lever (Rear whee!) (Rear whee) ‘Rear whee!) ‘SWEEPING: Main broom (diameter) 141i (956 mm) 1410 (356 mm) 14m (356 mm) ‘Side broom (diameter) 24 in (610 mm) 24 in (610 mm) 24 in (610 mm) ‘Sweep path (main broom) (1219 mm) 48.0 (1219 mm) 42 in (1057 mm) Sweop path (wit side broom) (1524 mm) 60 in (1524 mm) 54 in (1372 mm) ‘Sweep coverage 75,500 ft (7200 rm?) 77500 {i (7200m") | 67,000 I (6224 m*) —Sweep coverage (wits — 95000 ti? (8825 me) —|-—95 000 882s m*y —|-—-77;500 1 (7200 me) {areath) (8 inch overlap at 4 mph) TIRES (diameter): 16 in (408 mm) 16 in (406 mm) 18 in (406 mm) ‘TURNING RADIUS (Left Hand): £85.75 In (2178 mm) £82 in (2083 mm) 21 in (2057 mm) VACUUM SYSTEM: impeiior High-speed 9 in (228 mm) | High-speed 9 in (228 mm)| High-speed 9 in (228 mm) WEIGHT: Not 8300 fb (1497 kg) 3200 Bo (1452 ka} 3100 (1408 ko) Shipping ‘3700 tb (1678 ko) 3600 tb (1633 kp) £3500 fo (1588 ko) Ce AAR Brooks & Perkins December 15, 1989(Pomereoss” SPECIFICATIONS 2-5. Conventional Sweeper/Scrubbers. we CSS/90 (with Optional Side Broom and Overhead Guard) Figure 2-3. Conventional Sweeper/Scrubbers. cssi90 HC cssia0 cssvso BRAKES: Mechanical drum ‘Mechanical drum Mechanical drum {Front two tires) {Front two tires) (Front two tires) DIMENSIONS: Length 95 in (2413 mm) 91 in (2311 mm) 91 in (2811 mm) Wieth 4 in (1372 mm) 54 in (1372 mm) 48 in (1219 mm) Height 58 in (1473 mm) 57 in (1448 mm) 57 in (1448 mm) Height (with over head guard) 87 in (2210 men) 87 in (2010 mm) 87 in (2210 mn) Weight (with cap) 83.5 in (2121 mm) 8355 in (2121 mm) 835 in (2121 mm) ENGINE: Gasoline 47.5 HP (35.4 kw) 47.5 HP (35.4 kw) 47.5 HP (35.4 kw) Pe 47 5 HP (35-4440) —]- Hi —| 47.5 HP (25.4 kw) — Diesel 46.0 HP (24.3 kw) 46.0 HP (34.3 kw) 32 HP (23.9 kw) FLUID CAPACITIES: Fuel tank 8 gai (30.3) gal 30.31) 8 gal (3031) Radiator aqesh 3qteen 3qt (2.8!) Tota! coolant system 8a 6.7) 6atG7)) 6a 67) Hydraulic Fivid Reservoir 6 gal 2271) Goal 22.7) 6 gal 22.7) FRAME: Unitized construction, 3/16 in (4.8 mm) stool plato (Reinlorced at stress points) | ‘AAR Brooks & Perkins 26 December 15, 1989DomnerGoss” SPECIFICATIONS ‘CSS/90 HE cssve0 | cssve0 A = — Volume 610 (17m) Gt (57 my 511° (.14 m4) Weight limit ~ = _ Manual tt out ‘Standard Standard Standard HYDRAULICS: ‘Whee! motor ‘Char-Lynn 4000 Series | Char-Lynn 4000 Series | Char-Lynn 4000 sorios (15 larev) (15 in?rov) (15 nrrev) Broom & Brush CharlynnH series | Char-Lynn H sores Char-Lynn H series Propuision pump Cessna Vari-diplacomont Piston Pump (12.4 in?rev) ‘Accessories pump Gossna (84 in Cessna (84 intev) Directional contol valve Cossna Cessna System ther Donaldson 10 micron | Donaldson 10 micron Heat exchanger One-piece tubviarcoll | One-piece tubuiareall | One-piece tubuiar col RECOVERY TANK CAPACITY: 100 9a1 78.5) 60 gal (2271) 65 gal 246 ) ‘SCRUBBING: Main Scrvb brushes (diameter) 16 in (408 mm) 16 a (408m) 141n (356 mm) Side Scrub brushes (diameter) 16 in (406 mm) 16 in (406 mm) 14 in (856 mma) Scrub path 48;n (1219 mm) 48 in (1219 mem) 42 in (1087 men) ‘Scrub path 156 in (1422 mmm) ‘56 in (1422 mm) 50in (1270 mm) (wit side scrub brushos) ] Scrub coverage 77,5006 (720m?) | 77.5001" (7200 m*) | 67,0001" (6224 m*) {{ (inch overlap at 4 mph (area/hour) Scrub coverage £1,800 in (8500m*) 191,500 1 (8500 m*) 77,500 (7200 mt) (with sido serub brush) ‘SOLUTION TANK: 100 gal (378.5 ) 65 gal 246 }) 68 gal (257) SQUEEGEE: Roar 50 in (1270 mm) 50 in (1270 mm) 44in (1118 mm) STEERING: Cam and ever Cam and lever (Roar wha (Rear wines!) SWEEPING: Main broom (diamotor) 14 in (956 mm) 14 in (256 mm) 14 in (356 mm) Side broom (ciameter) 24in (610mm) 24 in (610 mm) 24 n (610 mm) ‘Swoop path (main broom) 48n (1219 mm) 48 n (1219 mm) 42 in (1087 me) ‘Sweep path (with side broom) 60 in (1524 mm) 60 in (1524 mm) 54 in (1372 mm) | Sweep coverage | 77.5004 (7200 m) | 7.50018 (7200 m*) _|__ 67,000. (6224 m*)_ ‘Sweep coverage (wih side broom) | 95,000 1 (8825 m") | 95,000 (8825 m) | 77,500 8 (7200 m") areas) (6 inch overlap at 7.5 mph) TIRES (diameter: 16 in (406 mm) 16:in (408 mm) 16 in (408 mm) TURNING RADIUS (Loft Hand): 85.76 in (2178 mm) 82 n (2083 mm) 81 in (2057 mm) ‘VACUUM SYSTEM: Impolior High-speed 9 in (228 mm) | High-speed 9 in (228 mm) | High-speed 9 in (228 mm) WEIGHT: Net £2950 hb (1338 kg) 2850 (1208 kg) £2800 tb (1270 kg) Shipping $3450 Bb (1585 kg) 3250 Bb (1474 kg) 3200 (1452 kg) ( AAR Brooks & Perkins December 15, 1989 aonerGoss” OPERATION 3-1. GENERAL. This section contains operating Instructions for nine models of the PowerBoss™ sweeperiscrubbers and their available options. Disregard any Information which does not periain, to your model. Read this entire section before attempting to operate the sweeper/scrubber. Then follow all operating Instruction exactly to assure the safety and long life of this product. sweeper/scrubbers combine two separate func- tions in one unit: sweeping and scrubbing. The sweeping system using a main broom, a side broom (optional on some models) and an applica- tion designed air system cleans surfaces thor- ‘ughly and efficiently without creating a dust prob- sem. The side broom creates a wider sweeping Path by pushing dirt and debris into the path of the main broom. The main broom then throws all dirt Side Broom (Optional on Some Models) and debris in its path into the hopper. The scrub- bing system takes water (with soap) from the solution tank and puts it on the floor where the scrub brushes do the cleaning. Then the vacuum system, with the help of the squeegees, picks up the water and puts itinto the recovery tank leaving the floor virtually dry. 3-3. The two functions sweeping and scrubbing 3-2, THEORY_OF OPERATION. PowerBoss™ —— canbe used individually or in combination’suct as: sweeping, scrubbing, double-scrubbing orsweep- ing/scrubbing. This makes the PowerBoss™ the mostefficient, economical, and versatile unit avail- able. 3-4, MAJOR COMPONENTS. Abrief explanation of all major components and systems is provided in.the following paragraphs. For the location of major components see figure 3-1. impotior Solution Serub Brushes ee Figure 3-1. Major Components ‘AAR Brooks & Perkins December 15, 1989 atFomnerGoss” 3-5. _Alrintake System, Engines are equipped with a dry cartridge type air filter with a rubber dust cup In the housing. The filters are readily acces- OPERATION 3-9. Fuses. The fuses are located in four fuse holders on the instrument control panel, see figure 3-2. L ._All engines. on have two-stages Donaldson fiters. 3-6. | CoolantSystem. Engine coolantis stored ina three quart radiator and circulates through the hoses and engine block which bring the total system capacity to six quarts. A spring-loaded valve in the radiator pressure cap, designed to open at 14 psi, closes the outlet to the overflow Pipe. 3-7, Electrical System, cranking amps and is maintenance free. 1. 30.amp Main Fuse 2 20amp Filter Shakar Motors, Horn, Fuel Gauge, Option Connector 3. 15.amp ii Prossure Gauge, Water Temperature Gauge, Hour Mater 15 amp Hoad Lights, Tail Lights, —Gauge Lights 7 3-10, Instruments. Gauges and indicator lights include ‘an ammeter, hour meter, fuel gauge, oll Pressure gauge, water temperature indicator and ‘scrubhead position indicator when equipped. For descriptions of these basic instruments and vari- ‘us accessory instruments, refer to paragraph 3- 47. 3-11. Sorubhead Lift Actuator. On al scrubbers, a scrubhead down pressure gauge is supplied to, indicate to the operator when the scrub brushes ‘touch the floor and visually displays how much ___3-8,__ Battery. The battery has 12 vols, 325 cold ___pressure_is_being_applied_to the floor._It-also___ indicates when the brushes are raised. Figure 3-2. Fuses AAR Brooks & Perkins 32 December 15, 1989 C fC. OPERATION omoarGoss 3-12, Engine. Engines on the PowerBoss™ 3-19. Diesel. Major fuel system components for have the following features:4cylinder, iquidcooled, _desel fueled engines are. ¢ aa a" cA” SRE a uuu CEES + Fuel tank 3-13. Gasoline Engines. + Fuel water trap + Fuel filter 90 Series - 47.5HP + Fuel lift pump 80Series - 47.5HP + Fuel injection pump Fuel injectors 3-14. Diesel Engines, 3-20. Hoppers. To contain dust and fine debris 90 Series = - 46 HP within the hopper all machines are equipped with 80 Series - S2HP both a frame seal and side seals. 9-15. For additional information on a specific 3-21, High-Dump models have hoppers made of ——engine-reter- to-the- manufacturer's titerature-fur-——12- GA steel nished in this manual. 3-22. Low-Dump models have hoppers made of 3-16. Fuel System. Fuel from the @-gallon 12 GA steel. ‘capacity tank moves through the disposable inline filters to the engine. The fuel supply is monitored 3-23. Manual Lift Out Hoppers are constructed 1 a fuel gauge. Fuel system characteristics of from aluminium. “-yasoline, LPG, and diesel engines are listed be- low. 3-24. Rotary Trash Relocator, The rotary trash relocator (RTR®) on high dump models increases 3-17. Gasoline. Major fuel system components _the debris holding capacity of the hopper extend- for gasoline fueled engines are: ing the sweeping time before dumping. By rotating the hopper about halfway through the dump rota- + Fuel tank tion, the debris at the lip of the hopper moves to the + Fuel filter front wall, leaving the entrance area clear to re- + Mechanical fuel pump ceive and hold more debris. + Carburetor + Manually operated carburetor choke 3:25. Hydraulle System. Hydraulic fluid is pumped from an elght-gallon capacity reservoir. 3-18. Liquid Propane Gas (LPG). Major fuel ___The fluid passes through a 100 mesh suction ~_ 8yStem components for LPG fueled engines are: strainer into supply lines which circulate fluid through two systems: the propulsion system and + Fuel tank the accessory system. Fluid returns through aheat + Pressure reliet valve/tuel filter exchanger and a filter equipped with a condition + Vacuum lock off valve gauge. | + Combination water heated vaporizer and | primary regulator 3.26. Propelling System. The major component | + Combination carburetor and secondary of the propelling system is a variable displacement regulator piston pump protected by relief valves. The pump AAR Brooks & Perkins. December 15, 1989 33Fonerkoss” sends fluid to drive the wheel motor which controls the forward and reverse speed of the machine, as well as dynamic braking. 3-27. |. The major compo- ent of the accessories system is a gear pump. ‘The gear pump protected by a relief valve sends fluld through a control valve to raise and lower the hopper, to rotate the hopper (on high dump mod- els), and to drive brooms, brushes and other accessories. Brooms and brushes are driven by Gerotor-type high torque, low speed motors. Hop- per is raised, lowered, and rotated (on multi-level high dump) by hydraulic cylinders. 3-28. Lubrication System. Grease fittings are OPERATION 3-33, Steering, Brakes, and Tires. 3-34. Steering. PowerBoss™ sweeper/scrub- steering through the rear wheel. 3-35. Brakes, PowerBoss™ sweeper/scrubbers are equipped with a parking brake, mechanically ‘operated by a cable which connects to drum brakes on the two front wheels. 3-36. Tires PowerBoss™ sweeper/scrubbers use an interchangeable, two-piece, bolt together cast rim for mounting tires. For more detailed information related to dimensions and pressure requirements, refer to the Specifications and Main- located in the following areas: _____ tenance sections of this. manual. Impeller bearing housing Steering link arm Steering fork assembly Pillow blocks supporting dump arms. 3-29. For detailed information on lubrication re- quirements and the lubrication points and grease fittings, refer to the Maintenance section of this manual. 3-30. Scrub and Water Pick-Up Components. The PowerBoss™ sweeper/scrubbers have three rotary quick change scrub brushes. An optional side scrub brush is available for all scrubber models, providing a wider scrub path. 3-31. Water Pick-Up Components. Two side squeegees and one main rear squeegee provide water pick-up The side squeegees keep the water ——onds-without-tools- It is bumper protected; and —— in front of the main squeegee and control water during tums, 3-32. Capabilities. Scrub paths and coverages are listed by model in the Specifications section of this manual. 3-37. Sweep Components. Together the brooms and skirt take dirt debris and litter from the floor and throw it into the hopper. (3-38. Main Broom. The main broom has the following features: One-piece, cylindrical, and disposable Runs at constant RPM Can be changed in less than five minutes {s raised and lowered from operator com- partment + Floats for uneven surfaces + Adjusts for pressure and wear 3-39, Side Broom. The rotary one-piece dispos- able side broom on TSS model (optional on ISS and CSS models) can be quickly changed in sec- adjustable for angle, pressure, and wear. 3-40. Skirts. Skirts on the bottom of each broom door and at the back of the broom chamber help contain the dust inside the sweeping and vacuum ing compartment. AAR Brooks & Perkins 34 December 15, 1989 bers are-designed.with-standard.cam-and-leverFonerGoss 3-41. Capabilities. Sweep paths and coverages are listed by model in he Specifications section of OPERATION following is a list of all controls and indicators with a brief description, see figure 3-3 for locations. ~—this-manual—— 3-42, Tanks. Solution and recovery tanks are housed in the same unit. The recovery tank is equipped with over-sized clean out doors to facli- tate draining and sludge removal. The drain hose for the recovery tank is located inside the left scrubhead access door on Its storage bracket. 3-43. Capacities. Size and capabilities of hopper and tanks vary and are listed by model in the Specification section of this manual. 3-48, _Alr Control Knob (TSS and ISS Only). ‘The air contro! knob is located beneath the choke knob on gasoline-fueled machines and beneath the engine stop knob on diesel-fueled machines. This knob should remain pushed all the way in for normal sweeping and scrubbing. in heavy dust conditions or when sweeping outdoors, pull the knob all the way out to divert all vacuum for sweeping, 3-49. Ammeter. The ammeter indicates the charging current which is being sent to the battery —3-44._Vacuum System—The vacuum system is by the alternator.tt also indicates the discharge of q ‘comprised of an impeller, belts, filters and shakers. 3-45. Impeller and Belts. The vacuum system operates from three basic components: one high speed 9 inch belt driven impeller and two hoses “ane to the hopper and one to the recovery tank). fe impeller provides water pickup through the rear squeegee and dust control from the filters in the hopper. The air is expelled over the heat exchanger outside the engine compartment. 3-46. Filter and Shakers, |SS and TSS models are equipped with a manifold which controls dust and water pickup. The air flow bias is operated from the drive compartment. + TSS models have two fully enclosed, posi- tive sealed, quick-change filters providing 100 8q. ft, of filtering area and two electric current being used by the sweeper/scrubber when the alternator is not charging. 3-50. Blower Control. To activate the blower pull out on blower control knob. 3-51. BrakePedal, Themechanical drumbrakes ‘on the two front wheels are used primarily for parking the machine and are operated by the brake pedal. Always chock wheels if machine Is parked on an incline, 3-52, Broom and Brush Control Lever. The broomand brush control leverto the lett of the main broom handle activates the brooms and scrub brushes. Even though both brooms and brushes are rotating each can be lowered independently. 9-53. Cab Fan Switch. This switch turns the fan ————shakers-for cleaning the filters. —————orrand off. —— + ISS models have one fully enclosed, posi- tive sealed, quick-change filter providing 50 sq. ft. of filtering area and an electric shaker for cleaning the filter. 3-47. CONTROLS AND INDICATORS. All con- trols and indicators are highly visible and conven- ‘ently ocated for operator use. The operation of all Antrols is explained later in this section. The 3-54. Cab Heater Switch. This switch turns the cab heater fan on and off. 3-55. Cab Pressurizer Control. This switch activates the cap pressurizer. 3-56. Choke Knob. The choke knob on gaso- line-powered machines is connected to a cable which controls the engine choke. AAR Brooks & Perkins December 15, 1989 35(-Oner . Fuel Gauge 27. Wator Recycling Switches Figure 3-3. Controls and Inaicators OPERATION {High umes 28. Solution Dalivery Lever (High 29. Squeegee Flocker Swit Hoppe’ Lever (Low Dum)” 30. Scrub Head Switch Broom. and Brush Control Lever ————#7--Turn Signal Lever_—___--—-31--Ar Gono Knob (78a $8) ——————— Main Broom Lever 48. Directional Control Pedal 32. Scrub Head Position Gauge 3. Cab Heator Switch 19. Brake Pedal 38. Choke Knob (Gasoiine Engine) Hopper Height Indicator (ATR) ‘Giow Plug Switch (Diesel) ‘Stop Cable (Diesel Engine) Hopper Rotation indicator (ATR) loppor Fittor Shaker Button 24, Glow Light (Desa) ‘Ammeter Hand Brake 35. Hopper Fito Warning Oil Pressure Gauge 23. Blower Control 36. Recovery Tank Warning Light Coolant Temperature Gauge 24. Remote Hopper Shut Off Solution Tank Waring Ligit = Light Switeh 25. Cab Pressurizer Control 87. logged Filter Indicator ‘Side Broom Lever 28, Windshield Wipor Switch 38. Throttio 36 AAR Brooks & Perkins December 15, 1989,onerkoss” + Pullthe knob out for ald in cold starting the 3-57. Clogged Filter Indicator. This indicator alerts the operator to the need to shake the filters. 3-58. Coolant Temperature Gauge. The en- gine coolant temperature gauge registers the tem- perature of engine coolant. Temperatures above 210°F indicate an overheating engine. 3-59. Directional Control-Pedal. The direc- tional control pedal controls the speed and direc- tion of the machine. It is also used for slowing or OPERATION the hopper. This leveris spring loaded tothe center off position. There is also a detent in the dump — position to-hold-the hopper inthe raised position: — 3-67. Hopper Helght indicator (ATR). Light 1 iluminates when the hopper reaches the minimum height required to use the ATR feature. 3-68. Hopper Rotation Indicator(RTR@). Light 2illuminates when the hopper reaches the rotation stop point. 3-69, Ignition Switch, The four position ignition switch is used to start the engine. —— stopping the machine during normal operation. ——3-70,—Light- Switch (optional). This-switefr is 3-60 Fuel Level Gauge. The fuel level gauge indicates the amount of fuel remaining in the tank. 3-61. Hand Brake (optional). This brake is 1 dfor parking. it operates the mechanical drum branes on the front two wheels and is engaged by liting up on the lever. 3-62. Horn. The hom is activated by pressing the hom button located on the right side of the instrument panel. 3-63. Hour Meter. The hour meter records the number of hours the machine has been operated, providing a helpful guide for performing routine maintenance tasks. 3-64. Hopper Fire Indicator. The hopper fire per. 3-65. Hopper Levers 1 & 2. (High Dump) The two far left levers on the front control panels are used to raise (up to 60 inches) and dump the hopper. The levers are spring loaded to the center off position. 3°65. Hopper Lever, (Low Dump) The left lever Ae front control panel is used to raise anddump used to turn the lights on and off. 3-71. Main Broom Lever. The main broom lever to the immediate left of the instrument panel raises and lowers the main broom. 3-72. Oll Pressure. The engine oil pressure gauge ranges from 0 to 60 psi. A reading below 7 psi indicates problems which may result in dam- age to the machine. 3-73. Parking Brake. The parking brake oper- ates the mechanical drum brakes on the front two wheels and is engaged by the brake pedal. 3-74. Recovery Tank Warning Light. Thislight illuminates when the recovery tank is full. 3-75. Recycling Pump Switches (2). These “indicator illuminates wher a fire exists in the hop: switches are used to activate when using the Water Recycling or Water Exten- sion Systems. 3-76. Remote Hopper Shut-Off. The remote hopper shut-off is used when sweeping areas which are wel. This stops the flow of air in the hopper from going through the filters and getting them wet. As use of the filters is not required to control dust in these areas. To activate the hopper shut-off pull the knob out . AAR Brooks & Perkins December 15, 1989 37FonoerGoss” 3-77. Soap Metering Pump Switch. The soap ‘metering pump switchs used in conjunetion with the water recyciing to regulate the amount of soap OPERATION * The throttle should be in the IDLE position when starring the engine and immediately before shutdown. ‘added -to-the-water. — 3-78. Scrubhead Position Gauge. The scrub- head position gauge Indicates the scrubhead position (raised, lowered) and the amount of pres- Sure exerted on the sorubhead in the lowered position. Pressure variable is from 0 to 300 pounds. 3-79, Scrubhead Switch, The sorubhead raise andlower switch isaspring-centered rocker switch. ‘The switch raises and lowers the scrubhead and provides variable pressure to the scrubhead in the lowered position. 3-80, Side Broom Lever. The side broom lever to the right of the instrument panel raises and lowers the side broom, 3-81. Solution Delivery Lever. The solution dolivery lever stops, starts, and regulates the flow of clean water solution to the floor for scrubbing. The amount of solution dispensed increases as the lever is moved forward, varying the flow rate between 0 gallons per minute (in the OFF position) and 3 gallons per minute (in the SOLUTION ON. FULL position). 3-82. Solution Tank Warning Light. This light indicates the solution tank is empty. 3-83. Squeegee Switch. The squeegee rocker switch raises, lowers, and locks the squeeges. -—~-9-84.—-Stop-Cable:The-stop-cable—is-used-on— diesel engines to stop the engine by shulting off the fuel flow. The stop cable knob should be pulled out only after turing off the key switch, to prevent running down the battery. 3-85. Throttle. The throttle adjusts the er speed from idle to the normal operating speed. + The throttle should be in the FUN position ‘during normal operation to insure proper broom speed and dust control (RUN on sweeper/scrubbers and NORMAL on sweepers). 3-86. Timed Filter Shaker. This button is used to activate the filter shakers prior to dumping or as needed for cleaning the dust control filters. When the filter shaker button is pushed in, the timer will automatically shake the fiters for approximately 20 seconds. This button should only be pushed at idle and the hopper is raised approximately 4 inches above the ground, 3-87. Wet Sweep By-Pass. This by-pass ac- complishes the same result as the remote hopper shut-off. It stops the flow of wet air in the hopper from passing through the filters when sweeping wet areas. To achieve this, open the vent located on top of the hopper, see figure 3-4, Wet Sweep By-Pass. Vent Figure 3-4. Wet Sweep By-Pass AAR Brooks & Perkins December 15, 1989 a8 —___when the machine is stopped, the engine speedis —___— rNRonorGoss 3-88. Windshield Wiper Switch. to oper choke knob. "3-89, PRE-OPERATION CHECK. Prior to oper ating any PowerBoss™ sweeper/scrubber check the following: A WARNING If fluids are hot allow engine or system to coo! before checking fluid levels. OPERATION tothe START position; then release. When the engine is rum Diesel Engine: Push in the engine stop knob. Turn the ignition switch to the first position; thenpress glow plugswitch (shown in figure 3-3) for approximately 15-20 seo- onds. Tur the ignition switch to the START position and release. 4. Engine oil level. NOTE 2. Engine coolant level. 3, Hydraulic fluid level For both gasoline and diesel engines, 4. Fuel level If the engine falls to start do not con- 5. Brakes, steering and directional controls tinue eranking more than ten seconds, 6. Floor for wet spots caused by leaks. Adwarnina Flulds are to be replenished only when ( > engine Is off. ATTENTION! Equipmentcan be damagedifitisused while fluld levels are Incorrect 3-90. Any problems found with the equipment mustbe corrected before attempting to operate the sweeper/scrubber. 3-91, GENERAL OPERATION. proceed as follows: Awaanie Always be seated In the operator's seat with the parking brake locked when starting the engine. 1. Putthe directional control pedal in neutral. (2. Put the throttle in the IDLE position, \2 3. Gasoline Engine: Pull the choke knob out (if engine is cold). Turn the ignition switch Allow the starter motor to cool be- tween attempts. 4, Allow the engine to warm up approximately ‘two minutes. 3-93. Driving. To drive the sweeper/sorubber, refer to figure 3-5 and proceed as follows: 4. Move the throttle from the IDLE to the RUN position. 2. Unlock the parking brake. 3. Move the machine forward or backwards as follows: a) Forward. Apply pressure to the front of the directional control pedal, increasing pressure to increase speed. 'b) Reverse. Apply pressure to the rear of the pedal, increasing pressure to increase speed. NOTE ‘The sweeper/scrubberisequipped with a speed IImiter, a stop under the pedal which can be raised or lowered to re- duce or Increase maximum speed. ‘AAR Brooks & Perkins December 15, 1989 38OPERATION NOTE: Directional contro! pedal Is shown In the neutral position. Figure 3-5. Directional and Brake Controls 3-94. Slowing, Stopping and Parking. To slow or stop the machine proceed as follows: 3-95. Slowing, Return the directional pedal to the neutral position. 3-96. Stopping. Return the directional pedal to _ the neutral position and coast to a stop or push the directional pedal in the opposite direction the machine is moving until the machine comes to a stop. 3-97. Parking. When parking the sweeper/scrub- ber engage the parking brake by pressing down on the pedal and tilting it forward. To disengage the parking brake apply pressure to the back of the pedal and release. If hand lever brake, engage by pulling up on the lever. Disengage by pushing the button at the end of the lever in and lowering the lever. 3-88. Operating on grades. Observe the follow- Ing rules when operating this machine on a grade. “Travel slowly. 2. Exercise extreme caution when traveling across or turning on grades. 3-99. The following options are available for op- erator safety and convenience: hand lever brake, back up alarm, engine running beeper, Grammer seat, curb broom spo! light, brake lights, turn signals, stud mounted or flush mounted head- AAR Brooks & Perkins December 15, 1989 3-10 myPonerGoss lights, red rotating light, over head guard, cab and accessories. For more information on these and other options see paragraph 3.124 3-100. SWEEPING, 3-101. Main Broom. To operate the main broom proceed as follows: 1. Lower the main broom. This is done by positioning the main broom lever in the NORMAL position for even floor surfaces or FLOAT position for extremely uneven surfaces. When not sweeping position the lever int he RAISED position. OPERATION should be placed in the RAISED position. -2.Both_the_side_broom_and_main broom are _____ activated by putting the broom and brush contro! lever in the ON position. The'side broom can not be engaged independently. 3-103. Hopper. The hopper holds all debris picked up when sweeping, To assist in utilizing all available space in the hopper a PowerPacker™ sweeping aid can be mounted inside the lip. The PowerPacker™ is a hydraulically driven auxiliary broom which huris lighter liter and trash to the forward portion of the hopper during the sweeping operation. This reduces the frequency of needed dumping andincreases overallpertormance. Dump NOTE Extensive use of the float position re- duces the Ilfe of brooms. ,, 2. Activate the main broom only by putting the broom and brush control lever in the SIDE BROOM OFF position. To stop the broom return the lever to the center OFF position. NOTE Even though the brooms and brushes are both rotating each Is lowered inde- pendently. 3._ Drive the sweeper!scrubber over the area to the swept as explained in paragraph 3-93. the hopper by following the appropriate set of procedures. A CAUTION Do not leave the hopper In the ralsed position for an extended period of time. NOTE Ahopper fire warning Indicators avall- able for all models. 3-104. High Di is. Empty the hopper as follows, see figure 3-6: 1. Drive the machine to the dumping area. 2. Use the directional control peda! to posi- _8-102. Side Broom. The side broom also known ‘as the curb broom Is used to widen the sweep path tween the machine and the container or and to clean close to walls and other obstructions. dumpster is adequate to raise the hop- A heavy duty side broom guard is available to per. protect the side broom when brushing against obstacles. In areas of heavy dust a vacuumized side broom attachment can be used. This sealed enclosure provides optimum dust control. To operate the side broom follow these steps: —tion-the-machine-so-that-the-space-be~ NOTE Broom control lever must be in center off position, 1. Place the side broom lever in the LOWER 3. Move the throttle to the IDLE position. position, When not sweeping the Jever ‘AAR Brooks & Perkins December 15, 1989 aFonerGoss 3-105. OPERATION 6. At this point, shake filters for 20-30 seconds. Pull back Lever 2 to DUMP position to rotate the hopper forward and empty the debris. 7. After hopper empties, push Lever 2 for- ward to RETURN position until the hop- per rotates and stops. 8. Slowlybackmachine away from dumpster approximately 5 ft. 9. Push Lever 1 forward to the LOWER position until the hopper stops. Aotacy Trash Relocator (ATRG). The RTR@isa standard feature on high-dump models. Figure 3-6. High Dump Hopper 4. Pull back Lever 1 to RAISE position and hold unti the bottom of the hopperis high enough to clear the top of the container (60 inch maximum). A warnine Never place your hands or other body parts near the fiftarms when the hopper Is operating. 5. _ Use the directional controipedal to stowiy and carefully move the machine forward Until the hopper is properly positioned to dump debris into the container. Accaution IIs unsafe to travel an extended dis tance with the hopper raised. Travel only the distance necessary to position the hopper. ~The two lever system with corresponding indicator lights is used to raise and rotate the hopper. This relocates the trash within the hopper to increase the holding capacity and make dumping neces- sary less frequently. Operate as follows: 1. Use the directional control pedalto stop the machine on a level surface. 2. Move the throttle to IDLE position, 3. Move the broom lever to the OFF position. NOTE As you complete steps four and five, observe the two red lights labeled 1 and 2 in the upper left corner of the control panel, + Light7 Hiluminates when the hopper reaches the minimum helght re- quired to use the RTR@ feature. + Light2 illuminates when the hopper teaches the rotation stop point. 4, Pullback Lever 1 tothe RAISE position and hold until Light 1 tiluminates, then release. ‘AAR Brooks & Perkins December 15, 1989 a2PomerGoss” A WARNING around the hopper. 5. Pull back Lever 2 to DUMP position and hold until Light 2 illuminates, then release. NOTE This rotates the hopper, causing debris to move from the rear entrance to the front wall of the hopper. Rotating be- yond this point will cause debris to be dumped from the hopper. ‘Make sure nooneis nthe area under or. OPERATION 6. Push Lever 2 forward to RETURN position until the hopper rotates back and stops, 7. Push Lever 1 forward to the LOWER posi- tion until the hopper returns to the normal ( ‘operating position. 8. Move the throttle back fo RUN and resume ‘sweeping. 3-106. Low Dump Model. Empty the hopper as follows, see figure 3-7: 1, Drive the machine to the dumping area. NOTE Broom control lever must be in center off position. — Bawarnine Never attempt to dump debris off a dock or mezzanine. Dump onto ground surface only. 3. Push the throttle to the IDLE position. SA Figure 3-7. Low Dump Hopper 4, Pull back the lever marked DUMP from its center off pos*ion until the hopper raises and locks in dump position. Debris will empty onto floor. 5. With the hopper in the raised position, press the filter shaker button for 20 to 30 seconds to shake the dust from the hopper filter(s). 6. Use the directional contro! pedal to slowly “feet. A wannine Ils unsafe to travel an extended dis- tance with the hopper ralsed. Travel only the distance necessary to clear the debris area. AAR Brooks & Perkins December 15, 1989 343 back the machine a distance of about five _omer Goss” A WARNING Never place your hands or other body __parts under a ralsed or partially ralsed OPERATION 3-108. Vacuum Attachment. The vacuum at- tachment is designed to clean elevated surfaces and areas where the PowerBoss™ is unable to drive, see figure 3-9, This is especially usefull in hopperuniess the safely armisinplace. 7. Use the directional control pedalto stop the machine, then release the DUMP lever to retum It tits center off position. 8. Pull the throttle back to RUN and resume sweeping. 3-107, Manual Lift-Out Models, Empty the hopper as follows, see figure 3-8: Drive the machine to the dumping area. 2. Grasp the handles on top of the hopper. 3. Lift the hopper straight up (about 3 in) until the support brackets clear the frame. 4, Move the hopper back and dump it out. 5. Replace hopper. NOTE ithe debris in the hopper Is too heavy, the hopper can be rotated and partially dumped to make It lighter. ~~ tank follow these stey ~—~dust laden areas. To operate the vacuum, open the hopper lid, close the vacuum door (at the front of the dust filter housing) and attach the vacuum hose. With the parking brake locked, move the throttle to the run position. The vacuum is now ready for use. Figure 3-9. Vacuum Attachment 3-109. Blower. The blower blows debris from hard to reach areas into the path of the sweeper, see figure 3-10. To operate the blower, remove the wand from the hanger and pull the blower control knob. 3-110. SCRUBBING. 3-111. Filling Solutton Tank. To fil the solution 1. Make sure the air control knob is pushed in (on TSS and ISS models). 2. Drive to the solution filling site. 3. Park the machine on a level area and lock the parking brake. AAR Brooks & Perkins December 15, 1989 344PonerGoss’ Figure 3-10. Blower 4, Make sure the solution delivery valve is closed. 5. Open the top side door of the machine and fill the top tank with cleaning water solu- tion. 6. When the tank is full, close the top door. A warns Never use detergents or cleaners that are flammable or combustible. __3-112._Maln_Scrub_Brushes._To operate the _____ main scrub brushes follow these steps: 1. Lower the scrubheads to the floor with the scrubhead switch. Obtain the correct pres- ‘sure for the floor conditions by noting pres- sure shown on the scrubhead position ‘gauge. The scrubheads are raised with the same switch. OPERATION NOTE a. For normal scrubbing, the main broom and side broom remain in the raised position. NOTE To sweep simultaneously lower the brooms at this time, see paragraph 3- 100 for instructions. 2. Activate the scrub brushes by putting the broom and brush control lever in the SIDE BROOM OFF position. Stop the brushes by _retuming_the lever tothe center-off ____ position. NOTE Even though the brooms and brushes are both rotating each Is lowered Inde- pendently, 3. Lowerthe squeegee and lockitin the down position with the squeegee switch, The squeegee can also be raised with the same ‘switch, 4, Start the flow of solution to the floor. To dispense solution push the solution deliv- ery lever forward. To stop the flow of solu- tion pull the lever back to the OFF position. ‘The amountof solution dispensedincreases as the lever is moved forward, varying the —flow rate between-0 gallons per-minute {in————-—- the OFF position) and gallons per minute (in the SOLUTION ON FULL position). 5. Drive forward slowly. NOTE Do not drive in reverse with the squee- gee down. ‘AAR Brooks & Perkins December 15, 1989 345FomGRrGBoss” A ‘CAUTION Use care when driving on wet surfaces. Always travel slowly on grades. 9-113. Side Scrub Brush. To use the side scrub brush (optional on some models) in conjunction with the main scrub brushes, proceed as follows: 1. Complete step 1 from paragraph 3-112. 2. Lower the side scrub brush by positioning the side broom lever in the LOWER slot. To. OPERATION 2. Make multiple passes over the same area of floor as conditions dictate. ._Lower.and lock the squeegee in.the down ——____ ‘A caution position with the squeegee switch for the final pass. The squeeges can be raised with the same switch, 3-115, Squeegee Wand. This attachment allows ‘the operator to vacuum up spills and standing water in areas which the PowerBoss™ can not maneuver, see figure 3-11. To operate the squee- gee wand, follow these steps: 1, Remove the hose from the squeegee tool. _________ rasa the scrub brush retumntheleverto the __2._Attach the adapter to the hose, ___ RAISED position. 3. Activate the main scrub brushes and the side scrub brush by placing the broom and brush control lever in the ON position. To ‘stop both return the lever to the OFF posi- tion. 4. Complete steps 3, 4 and 5 paragraph 3- 112. NOTE Do not drive in reverse with the squee- gee down, Accaution Use care when driving on wet surtaces. ~~“Ax caution Always travel slowly on grades. 3-114, Double Scrubbing. For double scrubbing proceed as follows: 1, Follow the procedures in paragraph 3-112 for scrubbing without lowering the squee- gee to the floor. 3. Connectthe squeegee wandto the adapter. 4, Set the engine at high Idle and vacuum. Figure 3-11. Squeegee Wand 3-116. Air Control. During normal sweeping and scrubbing the air control knob should be pushed in all the way. In heavy dust conditions or when sweeping outdoors pull the knob all the way out to divert all vacuum to sweeping. ‘AAR Brooks & Perkins December 15, 1989 346ooerboss” OPERATION 3-117. Water Extension, The water extension . Filthe solutiontankusingthe typicalamount system doubles the area which can be scrubbed of soap. -—with-out-emptying-the-recovery-tank-and-refiling the solution tank with clean water and soap. This 2. Fill the soap tank, see figure 3-12. is accomplished by using the same water solution twice to clean the floor. To use the water extension 8. Follow normal procedures for scrubbing option follow these steps: found in paragraph 3-112 until the solution tank is empty. Solution tank warning light NOTE ‘or recovery tank warning light will illumi- nate (optional). Water Extension Is designed for light cleaning only. Do not use this system 4. Turnon the two recycling pump switches In areas with a lot of oll or heavy bulld to pump the water from the recovery tank up on the floor. back to the floor. Then turn on the soap metering pump and adjust itto the appro- 4, Puttwice the typical amount of soap in the ______ priate rate for the conditions, This systern solution tank. will recycle the recovery tank water sev- eral times. This can continue until the 2. Follow the normal procedure for scrub- soap tank is emply. bing, paragraph 3-112, unti! the solution tank is empty. Solution tank warning light 5. Drain and clean the recovery tank as ex- ¢ ‘or recovery tank warning light wil ilumi- plained in paragraph 3-119 and 3-120. \ nate (optional). 3. Tum on the two recycling pump switches. This will pump the dirty water in the recov- ery tank through the filter and back to the floor. Use the water from the recovery tank to clean the floor approximately the same length of time it took to use all the water from the solution tank, 4, Drain and clean the recovery tank as ex- plained in paragraph 3-119 and 3-120. ~3-118Water Recycling The-water-reoycling-—— system allows the operator to clean many times the typical area before emptying the recovery tank and refiling the solution tank. This is achieved by using the same water again and again but adding extra soap to maintain the cleaning power. The Water recycling system is designed for light clean- ing only. Do notuse this cleaning methodin areas «3-119. Draining the Recovery Tank. Follow with a lot of oll or heavy build up on the fioor. To use these steps to drain the recovery tank, see figure this system follow these steps: 3-13, Figure 3-12. Soap Tank | ‘AAR Brooks & Perkins | December 15, 1989, 3417_Mmaximum reach. Figure 3-13. Recovery Tank Drain Park the machine on a level surface with the left rear of machine beside the drain site. Engage the parking brake. .. Turn off the engine. Open the left scrubhead access door. Remove the flexible drain hose from its storage hook. Pull out the drain hose for Place the drain hose at the floor drain ‘opening, grate or on the ground. Loosen and remove the drain plug. Drain the tank completely and reinstall the plug. OPERATION 9. Reposition the drain hose on its storage hook. the recovery rank processed as follows: NOTE The recovery tank should be cleaned after each shift. 1. After draining the recovery tank, park the machine so the rear access doors are Positioned over the drain opening or grate, or on the ground. _____2._Engage the parking brake. 3. Shut off the engine. 4. Remove the two access doors located at the rear of the unit, see figure 3-14, Figure 3-14. Recovery Tank Access Doors 5. Remove the drain hose and position it over the floor drain opening. a18 AAR Brooks & Perkins December 15, 1989 3-120. Cleaning the Recovery Tank. TocleanOPERATION 2. Apply the parking brake, _3._Tie.the machine. down using the tie down holes in the frame behind both front wheels and eye bolts located at rear of frame, see figure 3-16. NOTE Attach the tle downs to the frame only. Figure 3-15. Ball Float Assembly 6. Remove the drain plug. 7. Spray the recovery tank with clean water, flushing all sludge out the access doors. 8. Remove the ball float assembly, see figure 3-15. Clear holes in the bottom of the ball float assembly, rinse and reinstall. 9. Reinstall the drain plug. 10. Reposition the hose on the storage rack. Figure 3-16. Tie Down Holes 11. Reinstall the access doors. 3-121. TRANSPORTING THEPOWERBOSS™, _&123. Pushing. Push the machine from the front of rear using bumpers only. "3-122. Loading. To load the PowerBoss™ on ATTENTIONN another vehicle or trailer proceed as follows: Do not tow or push the machine a dis- Aivasnins tance of more than .5 miles or faster than one mile perhour. Exceeding these Exercise extreme caution when travel- restrictions may eause damage to the Ing on grades. hydraulic system. If towing will exceed : the above restrictions, the rear wheel 1 Hoe the machine on the traller or ve- must be ralsed or supported by a dolly. le. SY ‘AAR Brooks & Perkins December 15, 1989 319onerboss’ 3-124, ADDITIONAL OPTIONS. The following options are available on all models of the Power- Boss™. See figure 3-17 for the locations of these ‘options and their controls. 3-125. -PowerStacker™. The PowerStacker™ forklift attachment can be used on all high dump models. This options replaces the hopper when the PowerBoss™ is not being used to clean the floor. The PowerStacker™ lifts and moves loaded pallets weighing up to 800 pounds (363 kg). To operate the forklift use the hopper controls. 3-126, Flush Mounted Head Lights. Available on all TSS models. 3-127. Stud Mounted Head Lights. Available (on all ISS and CSS models. 3-128. Curb Broom Spot Lights. Available on all models. 3-129, Brake Lights. Available on all models. 3-10. TurnSignalswith 4-Way Flasher. Avail- able on all models. 3-131. models. Rotating Red Light. Available on all OPERATION 3-132. Back Up Alarm. Available on all mod- els. 3-133. _ Engine Running Beeper. Available on all models. 9-134, Grammer Seat. Not available on ma- chines with the cab option. 3-135. Overhead Guard. Available on all mod- els. 3-136. Cab. Available on all models. 3-137. Windshield Wiper. Available on all models with the cab option. ‘3-138. Cab Heater. Available on all models, with the cab option. 3-139. Fan/Detroster. Available on all models with the cab option. 3-140. Cab Pressurizer. Available on all mod- els with the cab option, 3-141. Hopper Dolly. Recommended with all low dump models. AAR Brooks & Perkins jeeteasg December 15, 1989(POmGrEOSS"____orerarion —— SIE Fire Extinguisher Side Scrub Brush and Squeegee Figure 3-17. Options AAR Brooks & Perkins ‘December 15, 1989 aePonerGboss” MAINTENANCE CONTENTS 44 -4:58:~Serub-and Water a Pickup Components. a4 4-75. Hoppers 4-4, Maintenance Procedures 45 4-87. Tanks 4-5. Engine. 46 4-90. Steering 4-16. Electrical System 49 4-91. Parking Brake 4-23. Coolant System 414 4-93. Tires. 4-28. Hydraulic System 415 4-97. Miscellaneous Maintenance Tast 4-102. Lubrication AAR Brooks & Perkins December 15, 1989omerboss’ 441, GENERAL. This ection contains mainte- nance information and instructions for ali models of the PowerBoss™ sweeper/scrubbers and their options. This information is divided into two major categories; preventive maintenance and mainte- nance procedures. The preventive maintenance program is designed to provide a longer life and Continued effectiveletticient cleaning for your PowerBoss™. The maintenance procedures are provided to assist the service personnel when performing maintenance tasks. Maintenance charts, lubrications charts, electrical schematics and hydraulic schematics have all been includedin this section for easy reference when performing maintenance tasks. +2. Regular maintenance on your sweeper! scrubber results in better more efficient cleaning and a prolonged life. When performing any main- tenance or repair task on the equipment observe fn nnn fMAMINFENAN Ge all safety precautions. The following waming is especially important and is repeated throughout the section. A warnne Never attempt to perform any service ‘on the equipment or its components until the engine Is OFF, the parking brake Is LOCKED and the wheels are ‘CHOCKED. 4-3. PREVENTIVE MAINTENANCE. A pre- ventive maintenance chart has been developed for quick reference by maintenance personnel, see table 4-1. Procedures forthe tasks listed in this chart will be found later in this section, (Self ex- planatory functions are not listed.) To assure that alltasks are completed on schedule, keepa record of all maintenance tasks performed and date completed. See table 4-2 at the end of this section, Table 4-1. Maintenance Chart Service/Task {Pertormed by maintenance personnel) Frequency (Hours) 8 50 100 | 250 | 500 ENGINE: For additional maintenance requirements refer to the engine manual furnished with this manual. GASOLINE Tune up Change oil & filter Change fuel fiter Air fter - clean dust cup - clean element - change element ‘AAR Brooks & Potkins December 15, 1989 atPomerGoss MAINTENANCE Table 4-1. Maintenance Chart - Contd. ¢ | Service/Task Frequency (Hours) |___ (Performed by maintenance personnel) 8_| 50 _| 100 [250 [500 J | GASOLINE - Contd. Check PCV (Change as required) ° Check fan belt (Change as required) ° Adjust vaives* Pressure wash the engine e LPG inspect system for leaks and proper connections . Tune up . Change oil & titer e Change fuel filter . ‘Air titer —— clean dust cup © - clean element o - change element . Check PCV (Change as required) . Check fan belt (Change as required) e Adjust valves" ¢ Pressure wash the engine e DIESEL Change oil & fier e Fuel filter - change e - drain water separator e Airfiter —- clean dust cup o - clean element e - change element ° Check PCV (Change as required) . Check fan belt (Change as required) ° Adjust valves* Pressure-wash the-engine ~ — |} - ELECTRICAL SYSTEM: Check electrolyte level in batteries (Fill as needed) e i Hydrometer Test . Clean battery ° Inspect wiring and cables ° co AAR Brooks & Perkins “2 December 15, 1989FonGarGoss” Table 4-1. Maintenance Chart - MAINTENANCE Contd. ESPASHSASat=_ 0/2 aantapOSORSAG BAAR DEERE EAI EADE QDRESEEOPEEBEAREAEHGEH —Frequency-(Hours) (Performed by maintenance personnel) 8 | 50 | 100 250 | 500 COOLANT SYSTEM: Check coolant level (Fill as needed) Inspect and blow out radiator fins (Make sure radiator is cool) Drain and flush coolant system Pressure test cooling system and cap HYDRAULIC SYSTEM: ______Check hydraulic reservoir gauge (Fill as needed) Blow off or pressure wash cooling coil Change filter breather cap ‘Change hydraulic fluid and filter Check function of directional contro! pedal (Adjust as needed) Be ‘Clean hydraulic fluid strainer in reservoir Inspect swivels on drive motor ‘Check for damage or leaking hoses ‘SWEEPING COMPONENTS: inspect brooms for wear; remove strings and debris from bristles and drive assembly (Replace as necessary) Inspect broom chamber door seals and broom skiris (Adjust or replace as needed) Rotate main broom end to end Perform main broom adjustment test (Adjust as needed) Check side broom lift cable (Adjust or replace as needed) | _ ~~ Inspect the main broom idler bearing ‘SCRUB AND WATER PICKUP COMPONENTS: Inspect scrub brushes for wear (Replace as needed) Inspect main squeegee flare (Adjust as needed) Check main squeegee for wear (Tum or replace as needed) ‘Check squeegee caster for wear (Replace as needed) (J Check squeegee lift (Adjust or replace as required) coo i AAR Brooks & Perkins December 15, 1989 43PooocrREoSss” MAINTENANCE Table 4-1. Maintenance Chart - Contd. i Service/Task Frequency (Hours) (Performed by maintenance personnel) 8] 50 | 100 [250 | 500 HOPPERS: Check hopper fiters (Clean or replace as needed) e Inspect filler gaskets . Check hopper clearance from floor (Adjust as needed) . Inspect hopper lid gaskets for proper seal . (Adjust or replace as needed) Inspect hopper flaps for wear or damage e (Replace as required) Inspect hopper side and frame seals for wear or damage ° (Adjust or replace as needed) Lubricate pillow blocks supporting dump mechanism e Check RTR™ lights for adjustments (if applicable) . ‘TANKS: Adjust solution delivery vaive linkage e Clean and inspect recovery tank ball float and drain hose Check squeegee tool and vacuum hose for clogs Inspect clean out doors for leaks: coo STEERING: Lubricate steering gear box Lubricate steering link arm Lubricate steering fork assembly Check steering gear box for wear (Adjust as needed) PARKING BRAKE: Check for proper functioning and adjust as needed Check brake cable for wear (Replace as required) | TIRES: Visually inspect for wear and damage e (Repair or replace as needed) ‘Check pneumatic ties for proper air pressure ° (Adjust inflation as needed) rn ‘AAR Brooks & Perkins “ December 15, 1989‘PODGRBoOSS” MAINTENANCE € Table 4-1. Maintenance Chart - Contd, _Service/Task — Frequency (Hours) — (Performed by maintenance personnel) 8 | 50 | 100 | 250 | 500 MISCELLANEOUS: inspect latches and hinges . (Tighten and lubricate as needed) Check anti-static drag chain on rear wall of broom e chamber for damage or excessive wear (Replace as needed) IMPELLER: tubricate e ‘Check belt tension and alignment (Adjust as needed) ° ( A \\ 44. MAINTENANCE PROCEDURES. The WARNING maintenance procedures outlined in this manual have been developed to assist maintenance per- ” Never bypass safety components be- sonnel with the up keep and repair of Power- fore operating the sweeper/scrubber. Boss™ sweeper/scrubbers. Heed all safety in- A ‘structions when servicing the PowerBoss™. WARNING Adwannine Replace any defective safety compo- nent before operating the sweeper/ Never attempt to perform any service scrubber. ‘on the equipment or components until nels Ke Awannne the engine Is OFF, the parking brake is LOCKED, and’ the wheels are —During-repair or servicing-of the fuel system, work in a properly ventilated area and do not smoke or allow an open flame near the fuel system. Never operate an LPG powered A sweeper/scrubber when any compo- WARNING nent In the fuel system Is malfunction- Ing or leaking. When disconnecting the LPG tank coupling, always wear gloves. LPG fuel can freeze bare hands. AAR Brooks & Perkins December 15, 1989 45FonerGoss” A WARNING Under no circumstances should the fuel fliterlock or the oll pressure switch MAINTENANCE 3. Tumonthefuelatthetankandcheckforleaks, ‘Diesel Engines. Diesel engines do not require periodic tune ups as do gasoline and LPG. be bypassed; ~except~ when testing ~——-~—engines. However, oll change, Titer replacement them. After testing, always reconnect them. Bypassing the fuel fliter lock or the oil pressure switch after testing creates a potential fire hazard. 4-5. ENGINE. For maintenance information ot covered in this manual, refer to the manufac- turer’s engine manual provided. NOTE Fill the fuel tank at the end of each shift andother scheduled maintenance is needed. Refer to table 4-1 In this section for more information. 4-7. _ Inspect for leaks (LPG). 1. Place soapy water around all connections between the tank and the carburetor. 2. Watch for bubbling. 3. Tighten or replace connections as needed. Changing the Fuel Filter. to prevent condensation from forming Gasoline Engine, In the fuel tank. Use clean gasoline of at least 85 octane. 1. Locate the in-line disposable filter approxi: mately half way between the gasoline tank 4-6. Tune Up. and the carburetor. 2. Remove the two attaching clamps. Gasoline and LPG Engines. 3. Replace the filter and reattach the two clamps. C 1. Change spark plugs. (See manufacturer's 4. Bleed the fuel lines, 1 literature.) | 2. Inspect spark plug wires and boots for LPG Engine. cracks and fraying. (Replace as needed.) 3. Change and set ignition points, if appii- 1. Located the fuel filter in the same housing cable. (See manufacturer's literature.) as the relief vaive close to the tank. 4. Change rotor. 2. Turnoffthe gas flow and open the housing. 5. Inspect distributor cap for cracks and cor- 3. Clean or replace the cloth element as roded contacts. (Replace as needed.) needed. 6. Checkand setttiming. (See manufacturer's 4, Bleed the fuel ines. literature.) NOTE LPG, Sweeper/scrubbers which run on LPG are-equipped witha vacuum activated {uel____—Performthis task on LPG engines only Saecee shutoff system. The shutoff uses vacuum pressure from the engine manifold to open the fuel flow. ‘When the engine Is stopped there Is no vacuum pressure; consequently the fuel flow is cut off. To change the fuel shutoff, follow these steps: 1. Shut off the fuel flow at the tank. 2. Locate the fuel shutoff in the fuel line be- tween the tank and the vaporizer. If troubleshooting Indicates a problem with the fuel flow. This Is nota preven- tive maintenance procedure. Diesel Engine. 1. Openthe topandside engine accessdoors. 2. Loosen the vent plug and open the water trap to drain the fuel. ‘AAR Brooks & Perkins aa December 15, 1989PonerGoss 3. Remove the filter element and the trap from the filter head. 4. “ment and clean it. 5. Lubricate the O-ring and spin the bow! onto a new filter element. Lubricate the O-ring and spin the new fitter element, with the clean bowl, onto the fitter head. Bleed the fuel lines. Remove the water trap bow! from the ele- MAINTENANCE NOTE ——Hand-priming-may-take-four-or-five- minutes, but the entire process should be completed with care. Otherwise, the engine may fall to start. 9. Loosen the unions located at the injector ends of the high pressure fuel pipes. 10. Put the accelerator in the full-open posi- tion. Make sure the stop control is in the 4-9. Priming the Fuel System. (Diesel) RUN position. 11. Use the starter motor to rotate the engine 1. Locate the fuel pipe on top of the fuel filter Until fuel oll without air bubbles flows from cover and unscrew it two or three turns. the fuel pipes. This may require up to 60 ‘seconds of rotation, depending upon rota- _____________NOTe tion “speed_and-the-effestiveness-of the. bleeding operation just outlines. Do not confuse this plpe with the fuel 12, Secure the union on the fuel pipes and start return pipe to the tank. the engine. 2. Locate the hydraulic head locking screw. NOTE {It is on the side of the fuel injection pump body). : Loosen the fuel injection pump air vent screws on the governor housing. Use the lever of the fuel lift pump to prime the fuel system. iyouare unable to operate the priming lever, turn the engine a complete revo- lution until fuel bleeds from the vent points free of alr bubbles. 5. Tighten connections as follows: First the ‘pump head locking Screw, then the gover- for air vent screws. Loosen the pipe union nutat the inlet of the fuel injection pump. Use the lever on the lift pump to prime the system When fuel without air bubbles bleeds around the threads, revtighten the pipe union, ___filter cover fuel pipe, then the fuel injection __ ifthe engine starts but stopsattera few minutes, repeat the bleeding process and check for leaks and weak connec- tlons, ——4-40.—-Cleaning the Water Trap {Perkins} ——~ Lift the engine hood. Clean the outside of the water trap thor- oughly. Remove the retaining bolt from the center of the water trap head. Cones the bowl and clean it in cleaning luid, eS oye NOTE Do not use gasoline to clean the bowl. 5. 6. Refill the bowl with clean fuel, Position and hold the water trap bowl under the trap head and secure it with the retain- ing bolt, Bieed the fuel system as outlined under Priming the Perkins Diesel Fuel System. ‘AAR Brooks & Perkins December 15, 1989 47“TOP" is positioned correctly, pointing up. {Including pin holes) replace the filter. PonerGoss MAINTENANCE 4-11. Draining the Water Trap (Kubota) 6. Tighten the ring clamp. C 1. Loosen the knob on the bottom of the trap Gvelle Cleaning unit. ———2:—Wailforthe watertodrainand watch forthe ——~1-—tocate the air iter, diesel fuel which wil! follow. 2. Unscrew the ring clamp. 3, When the diesel fueibegins to drain tighten 3. Remove the dust cup and pull the rubber the drain knob. pplug out of the cup (if so equipped). 4, Empty the contents, 4-12. Clean/Change the Alr Filter. See figure 44. NOTE NOTE The following steps mustbe completed periodically on heavy duty three stage Do not operate the machine without fitters. the alr filter element in place. 7. Use an air hose to blow all dirt and dust Daily Cleaning from the filter. (Air pressure should be 100 psi or less, 4. Locate the air filter. 2. Unscrew the ring clamp. NOTE 3, Remove the dust cup and pull the rubber Plug out of the cup (if so equipped). After cleaning th 4, Empty the contents. holes by puttinga light inside the filter, 5. Replace the dust cup. Ensure the word ‘see figure 4-2. If any holes are found ¢ Figure 4-1. Att Filter AAR Brooks & Perkins December 15, 1989 rnonerGoss” Figure 4-2. Air Filter Check 8. Wipe out the air cleaner housing with a damp cloth. Make sure all dirt is removed. 9. Replace the filter with the fins at the tar end of the housing. Do not damage fins. NOTE the old filters being used Inspectthe rear gasket before replacing. 10. Replace wing nut and tighten. 11. Replace the dust cup. Ensure the word “TOP” is positioned correctly, pointing up. 12. Tighten the ring clamp, 13. Check the condition of intake hoses and clamps. 4-13, Check PCV. Remove valve. Blow (by mouth) into the engine side of the valve. Air should pass freely. Blow (by mouth) into the intake side of the valve. The valve should close. Sop MAINTENANCE 4. Iteitherstep 20r3 do notfunction as stated replace the valve. 4-14, Check the fan belt. 1. Check tension. See manufacturer's litera- ture for the correct tension, 2. Inspect the belt for cracks, glazing or fray- ing. Replace as required, 4-15. Adjust Valves. See manufacturers litera- ture. 4-16. ELECTRICAL SYSTEM, — Wiring and cables should be replaced immediately if found damaged to prevent shorting or electrical shock. Replace the battery when minimum requirements can no longer be maintained, A WARNING Never attempt to perform any service ‘on the equipment or components until the engine Is OFF, the parking brake Is LOCKED, andthe wheels are CHOCKED. 4-17. Schematics are included to to assist main- tenance personnel when servicing the Power- Boss™, see figures 4-3 through 4-6. 4-18, Check Electrolyte Level. 1. Remove cell caps. 2. Visually check the level of each cell. The electrolyte should just touch the bottom of the fill tube, see figure 4-7, 4-19. Hydrometer Test. The specific gravity of each cell in a fully charged battery should be 1.260. Variations in this reading must not exceed 10%. 4-20. Clean Battery, 1. Combine baking soda andwaterin astrong solution. 2, Brush the solution over the battery top, including terminals andcable clamps. Make AAR Brooks & Perkins December 15, 1989 49FonerGoss” MAINTENANCE a ee Horn { a, So Un | 15Amp MTR, Pu Filter Light swith motors ob, {nears Regulator Diese! Solenoid | Sitch 30 Amp Starter: ts) oi 4} _______ Gauge | —} Fe ‘Ammeter Fuse “~N Battery Ba Figure 4-3. Kubota (Diesel) Engine Electrical Schematic 4-10 ‘AAR Brooks & Perkins December 15, 1989FonerBoss” MAINTENANCE Please refer to addendum at the back of this manual. Figure 4-4. Toyota Engine Electrical Schematic ‘AAR Brooks & Perkins December 15, 1989 raPomerGOSs"_____ Maintenance To be supplied at a later date. ( Figure 4-5. Ford Engine Electrical Schematic C ‘AAR Brooks & Perkins gaat December 15, 1989om mBoss” MAINTENANCE To be supplied at a later date. Figure 4-6. Perkins Engine Electrical Schematic AAR Brooks & Perkins December 15, 1989Fomnerkoss” Electrolyte Level Cell Tube Figure 4-7. Electrolyte Level MAINTENANCE 3. Install the fuse holder cap by turning the ( cap clockwise. NOTE Remember torepositiontherubberring under the fuse holder eap. 4-23. COOLANTSYSTEM. The normat operat- ing temperature of the engine is 180°-200°F (82°- 93°C). Abnormally high operating temperatures and overfiow loss are symptoms of a clogged radiator, the core clogged with rust and sludge or the fins clogged with dirt and debris. To clear the ‘system first flush with a cleaning compound, sec- ond reverse flow flush the system. sure the solution does not enter the bat- tery. 3. Using a wire brush, clean the terminal posts and cable clamps. 4. Apply a thin coating of vasoline to the terminals and cable clamps. 4-21. Battery Replacement. A caution Remove the negative battery cable before you remove the positive battery cable. This Is done to prevent acciden- tal electrical shorting which can result In personal injury. 1. Disconnect the negative (-) cable and then the positive (+) cable. 2, Remove the battery. ___-3_install new battery. — j 4. Connect the positive (+) battery c | then the negative (-) cable. | 4-22. Fuse Replacement. 1, Remove the blown tuse by tuming the tuse holder cap counterclockwise. 2. Insert the correct amperage fuse into the fuse holder cap. Aware Never attempt to perform any service on the equipment or components until the engine Is OFF, the parking brake Is. LOCKED, and the wheels are CHOCKED. 4-24, Coolant Level. The correct coolant level In the radiator is ¥,* below the top of the radiator (excluding the fill neck), see figure 4-8. Figure 4-8. Coolant Level 4-25. Blow OutRadiator Fins. Aliow the radia- tor to cool before cleaning with compressed air. Clean by blowing air from the side opposite the engine fan. AAR Brooks & Perkins a4 December 15, 1989PomnerBoss” MAINTENANCE 4-26, Drain and Flush Radiator. 1. Atthe engine, disconnect the hoses. 2. Make sure the radiator cap is on tight, --1.--Start and run engine for-40 minutes to-heat——-3—-Using-a hose clamp, clamp-a flushing gun the system. 2. Shut off engine. 8. Open drain cack and allow the system to drain, 4. Close the drain cock and refill the system with water. Start the engine and let run until the upper radiator hose is hot. Shut off engine. Open drain cock and allow the system to drain, NO NOTE It the water Is dirty repeat steps 4 through 7. 8. Close drain cock. 8. Refill system with 50% glycol /50% water, 27, Reverse Flow Flushing. See figure 4-9, Flushing Gun Drain Hosd Figure 4-9. Reverse Flow Flushing onto the lower hose. 4. Turn on the water and fil 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 reapply the air pressure. You 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. 4-28. HY! The hydrautic system drives most major components on the PowerBoss™., For component locations and hose conections, refer to figures 4-10 through 4-12. A WARNING Never attempt to perform any service on the equipment or components until the engine Is OFF, the parking brake is LOCKED and ‘the wheels are CHOCKED. 4-29. Checking thefluld reservoir. See figure 4-13. Inspect the sight gauge (4) with the hopper in the down position and the machine cool. Fill as needed. Hydraulic fluid should fil */, of the sight glass. 4-30. Filling the Fluld Reservoir The reservoir is located inside the machine and Is accessible through the top side door, 1. Remove the cooler/breather cap (1) lo- cated on top of reservoir. 2. Fillthe reservoir two thirds full with fluid that meets the viscosity specifications indicated ‘AAR Brooks & Perkins, December 15, 1989 aeFonerGoss” MAINTENANCE Figure 4-10. Hydraulic Component Locations below, then replace the filler cap (1). The is filled with 15W40 oll from the reserve factory. NOTE Do not use transmission fluid in place of hydraulic fluld, Brooks & Perkins recommended Cheveron Dello 400. Hydraulic Fluid Viscosity Specifications: SUS @100°F 510-560 SUS @210°F = 78-84 4-31. Maintaining Cooling Coll Efficiency. The cooling coil is located at the exitport of the impeller fan and utilizes exhausted impeller air to cool the hydraulic fluid. To maintain its efficiency, petiodi- cally blow off the cooling coil with compressed air and pressure wash the cooling coil every 100 hours of operation. ‘AAR Brooks & Parkins a6 December 15, 1989MAINTENANCE 4-32, Changing the Hydraulic Fluld 3. Remove the drain plug located on the bottom rear of the reservoir and allow the 1. Turn off the engine an engage the parking fluid to drain. brake. 4. Discard the fluid, then replace and re- 2. Place a drain pan on the floor below the tighten the drain plug. teservolr 5. Remove the filiervbreather cap (1) located ‘on top of the reservoir (3) and fill the reservoir with approved hydraulic fluid. AAR Brooks & Perkins December 15, 1989 aFomerGoss” MAINTENANCE Figure 4-12. Hydraulic Hose Connections (Low Dump) — NOTE 4-83. Changing the Hydraulic Fluld Filter — This will require six gallons of fluid. 1. Tumoffthe engine and engage the parking brake. 6. Check the 2. Remove the oil filter cartridge (5) from the proper two- . mount and discard. 7. Install a new fllerfbreather cartridge. 3. Apply a thin coating of fluid to the seal of a 8. Check the drain plug for leakage. new filter element, ‘AAR Brooks & Perkins ae December 15, 1988PomerGoss” oon ene Filer/Breather Cap Access Plata Hydraulic Reservoir Hydraulic Level Sight Gauge Hydraulic Fitor Hydraulic Fiter Condition Indicator MAINTENANCE Figure 4-13. Hydraulic Fluid Reservoir 4. Thread onto the mount and hand tighten. 5. Tighten an additional one-half turn alter the seal is comletely seated. NOTE Do not over tighten. 6. Start the machine, shut toff, then check for leakage. 4-34. Changing the Hydraulle Fluld Strainer 1. Remove the eight bolts which hold the acoess plate (2) to the reservolr (3). 2, Liftthe access plate (2) from the top of the _reservoir (3). seinsnnaseabhtatas 3. Inside grasp the strainer and turn counter 4 5. clockwise to remove. ‘Clean andinspectthe strainer. (Change as required.) Replace the strainer and the access plate. 4-35. Adjusting the Directional Control Re- turnSpring. See figure 4-14. You may encounter “creeping” problems from time to time. Creeping [ms 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 an indicator that the directional control return spring needs adjusting. If this occurs perform the procedure which follows. 1. Onlow dump models, remove the hopper. On high dump models raise and engage hopper safety arm, A CAUTION For maintenance on high dump mod- els, do not rely on the hydraulic cylin- der to keep the hopper raised. Always engage the safety arm before golng —under-the-hoppet 2. Turn off engine, engage parking brake, and chock both wheels. 3. Jack the rear of the mac so that the rear tire just clears the floor. Use two jack stands to support the machine, DO NOT USE JACK ALONE TO HOLD THE MA- CHINE UP. 4, ifan assistant is not available to watch the rear wheel, use a mirror to allow you to see the rear wheel. ‘AAR Brooks & Perkins December 15, 1989 a9MAINTENANCE Figure 4-14, Adjustment Bracket 5. Locale the forward/reverse adjustment bracket mounted beneath the pump on the pump mounting plate. 6. Slightly loosen the bolt on the center of the bracket (1). 7. Now loosen the locking nut (3) on each of the adjusting bolts (3) on the side of the bracketclosestto the pump mounting plate. 8. From the operator's seat, start the engine and run at hai throttle. 8. Turn the adjusting bolts while watching the rear wheel. Continue to adjust until the rear wheel does not tum in either direction. 10. Fully open throttle. Push the directional. control pedal forward and backward to be ‘sure pump stays in neutral. Check wheel again and adjust as needed unti the wheel remains motionless. 11. Retighten all the locking nuts and the bolts. 12. Turn engine off and lower the machine to the floor. 4-36. Adjusting Machine Speed. See figure 415. To limit the speed of the machine, simply reposi- tion the speed limiter, a bolt underneath the direc- tional control pedal which can be moved in or out. Be sure that the directional contro! pedal contacts the speed limiter bolt before the pump control arm hits the pump stop. al Fittings. swivel fittings on top of the motor and the case

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