PowerBoss 9XRGASES, 9XRDSLES, 9XRLPES, 9XRLPESBR, 9XRGASESBR Service Manual

...

Service Manual Armadillo 9X Series

Models: 9XR, 9XR Europe, & 9XV

Gasoline, Lpg & Diesel Starting @ Serial No. 18168059

PowerBoss, Inc.

A Member Of The Hako Group

Page 1

PB# 4100033 Rev.* 06/10Armadillo 9X Series Sweeper

PB# 4100039 Rev. * 06/10

PREFACE

Thank you for your purchase of the now industry standard for sweepers. PowerBoss takes great pride in offering the most dependable, reliable and best value in industrial power sweepers and sweeper / scrubbers. We set the standard.

Our Publishing Department would like to hear from you. If you see any errors, omissions or something that needs clarication in this Service Manual please let us know. We are working hard toward perfection in our corner of the process to bring you the best you can buy. Please copy the form below, ll out and comment on how you found our catalog.

Thank you.

*Name______________________________________________________________________

*Title: ______________________________________________________________________

*Company Name: _____________________________________________________________

*Address: ____________________________________________________________________

*Country: ____________________________________________________________________

Type of equipment or model number: ______________________________________________

Comments:

*Information is optional. Please return to: Manager, Publishing Department, International PowerBoss, Inc. 175 Anderson Street Aberdeen, North Carolina 28315 USA

Phone (800) 982-7141 Toll Free (910) 944-2105 Local E-Mail - techsupport@powerboss.com

Page 2

PB# 4100039 Rev.* 06/10

Armadillo 9X Series Sweeper

PREFACE

This is the Spare Parts Catalog for the PowerBoss Armadillo SW/9X Series Sweeper. This catalog covers all Standard Armadillo 9X Series machine variations beginning May 2009. We believe this machine will provide excellent service for many years. However, the best results will be obtained if:

• The machine is operated with reasonable care.

• The machine is maintained regularly per the maintenance schedule provided in the User Manual.

• The machine is maintained with PowerBoss Inc. supplied or equivalent parts.

All right side and left side references to the machine (except for engine) are determined by facing the direction of forward travel. The front of the engine or engine fan faces the rear of the machine. Some hardware considered to be common or locally available has been omitted from the parts section to make this manual clear. Be sure to use equivalent hardware when replacement becomes necessary.

The Model and Serial Number of your machine is shown on the I.D. name plate. This information is needed when contacting Technical Support or when ordering parts. The I.D. plate is mounted on the console of the machine left of the operator. Adjacent the main broom adjustment access door.

Example I.D Plate;

Parts may be ordered by phone,fax or e-mail from any PowerBoss parts and service center. Before ordering parts or supplies, be sure to have your machine model number and serial number handy. For your convenience Fill out the data block below for future reference.

MACHINE DATA

Fill out at installation

Serial Number: ___________________________________

Engine Serial Number: ____________________________

Sales Rep.: ______________________________________

Date of Install: ___________________________________

*Note* Where No Part Number Is Listed In The Right Column Part Number Is The Same As The Left Column

All information contained in this catalog is current at the time of printing However, PowerBoss reserves the right to make changes at any time without notice.

Page 3

PB# 4100033 Rev.* 06/10Armadillo 9X Series Sweeper

TECHNICAL SPECIFICATIONS

Model Armadillo 9X series

Model No. 9XRGASES / 9XRLPES / 9XRDSLES / 9XRGASESBR / 9XRLPESBR / 9XRDSLESBR

/ 9XRDSLCE / 9XRLPGCE / 9XNDLXLP / 9XNDLXGAS / 9XKDLXDSL / 9XDLXLPBR / 9XDLXDSLBR / 9XDLXGASBR

DIMENSIONS & WEIGHT

Length . . . . . . . . . . . . . . . . . . 105 inch

Width . . . . . . . . . . . . . . . . . . . 60 inch

Height . . . . . . . . . . . . . . . . . . . 55.38 inch

Height w/ overhead guard . . . 81 inch

Height w/ cab . . . . . . . . . . . . . 81 inch

Weight . . . . . . . . . . . . . . . . . . 3500 lbs.

Minimum U-turn . . . . . . . . . . . 110 inch

SWEEPING SYSTEM

Productivity . . . . . . . . . . . . . . 184800 sq ft per hour

Sweep path. . . . . . . . . . . . . . . 62 inch

Main broom. . . . . . . . . . . . . . . 48 inch

Side broom . . . . . . . . . . . . . . . 24 inch

Second side broom. . . . . . . . . optional (72 inch path)

Hopper type . . . . . . . . . . . . . . RTR high dump

Hopper volume . . . . . . . . . . . . 22 cu ft

Hopper load capacity . . . . . . . 1500 lbs

Dust control . . . . . . . . . . . . . . 110 sq ft

High dump . . . . . . . . . . . . . . . 60 inch

RTR (rotary trash relocation) . yes

Page 4

PB# 4100039 Rev.* 06/10

Armadillo 9X Series Sweeper

CE DECLARATION OF CONFORMITY

DECLARATION OF CONFORMITY

Page 5

PB# 4100033 Rev.* 06/10Armadillo 9X Series Sweeper

TABLE OF CONTENTS

PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

TECHNICAL SPECIFICATIONS. . . . . . . . . . . . . 4

DIMENSIONS & WEIGHT . . . . . . . . . . . . . . . . . . . . . . . . 4

SWEEPING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

CE DECLARATION OF CONFORMITY . . . . . . . 5

SAFETY INFORMATION . . . . . . . . . . . . . . . . . . 8

IMPORTANT SAFETY INSTRUCTIONS. . . . . . . . . . . . . 8

FOR SAFETY DURING OPERATION. . . . . . . . . . . . . . . 8

FOR SAFETY WHEN SERVICING OR

MAINTAINING MACHINE . . . . . . . . . . . . . . . . . . . . . . . . 8

SAFETY SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SAFETY DECALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

BASIC POWERBOSS® SAFETY. . . . . . . . . . . . 10

TROUBLESHOOTING AND REPAIR. . . . . . . . . 12

OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

GENERAL SERVICE INFORMATION . . . . . . . . . . . . . . 12

TRANSPORTING THE MACHINE. . . . . . . . . . . . . . . 12

Using a Trailer or Transport Vehicle. . . . . . . . . . . 12

Pushing the Machine . . . . . . . . . . . . . . . . . . . . . . 12

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . 12

TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . 13

TROUBLESHOOTING PROCEDURES . . . . . . . . . . . . . 16

AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 16

Check Air Filter Service Indicator. . . . . . . . . . . . . 16

Air Filter Element Removal . . . . . . . . . . . . . . . . . 16

Air Filter Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . 16

Air Filter Inspection . . . . . . . . . . . . . . . . . . . . . . . 16

Air Filter Installation . . . . . . . . . . . . . . . . . . . . . . . 16

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . 17

Battery Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . 17

Battery Replacement . . . . . . . . . . . . . . . . . . . . . . 17

Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

COOLANT SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . 18

Blowing Out Radiator Fins . . . . . . . . . . . . . . . . . . 18

Reverse Flow Flushing. . . . . . . . . . . . . . . . . . . . . 18

LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Changing Engine Oil . . . . . . . . . . . . . . . . . . . . . . 18

LUBRICATION POINTS . . . . . . . . . . . . . . . . . . . . . . 19

Rear Drive Rotary Actuator . . . . . . . . . . . . . . . . . 19

Engine Mount Pivot . . . . . . . . . . . . . . . . . . . . . . . 19

Latches & Hinges . . . . . . . . . . . . . . . . . . . . . . . . . 19

Hopper Lift Arm Mounts . . . . . . . . . . . . . . . . . . . . 20

HYDRAULICS SYSTEM . . . . . . . . . . . . . . . . . . . . . . 21

Filling The Fluid Reservoir . . . . . . . . . . . . . . . . . . 21

Hydraulic Fluid Viscosity Specications . . . . . 21

Maintaining Hydraulic Oil Cooler Efciency . . . . . 21

Changing The Hydraulic Fluid . . . . . . . . . . . . . . . 21

Changing The Hydraulic Fluid Filter. . . . . . . . . . . 21

ADJUSTING THE DIRECTIONAL CONTROL

RETURN SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

HOPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

High Dump Hopper Removal . . . . . . . . . . . . . . . . 22

High Dump Hopper Replacement . . . . . . . . . . . . 22

Filter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Filter Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . 23

WEEP COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . 24

Broom Door Flap Inspection . . . . . . . . . . . . . . . . 24

Broom Door Flap Replacement and

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Main Broom Adjustment . . . . . . . . . . . . . . . . . . . . 24

Main Broom Height Adjustment . . . . . . . . . . . . . . 24

Main Broom Taper Adjustment . . . . . . . . . . . . . . . 25

Main Broom Replacement . . . . . . . . . . . . . . . . . . 25

Side Broom Angle Adjustment . . . . . . . . . . . . . . . 26

Side Broom Height (Wear) Adjustment . . . . . . . . 26

To Adjust The Side Broom Height

For a 9XR or 9XV model: . . . . . . . . . . . . . . . . 26

To Adjust The Side Broom Height

For a 9XR Europe model: . . . . . . . . . . . . . . . . 26

Side Broom Lift Cable Adjustment . . . . . . . . . . . . 26

Side Broom Replacement . . . . . . . . . . . . . . . . . . 26

Floor Clearance and Dump Angle Adjustment 27

Vacuum Gasket Mount Adjustment . . . . . . . . . . . 29

Flap Replacement . . . . . . . . . . . . . . . . . . . . . . . . 29

Frame Seal Replacement . . . . . . . . . . . . . . . . . . 29

Front Frame Seal . . . . . . . . . . . . . . . . . . . . . . 29

Side Frame Seal. . . . . . . . . . . . . . . . . . . . . . . 29

Page 6

PB# 4100039 Rev.* 06/10

Armadillo 9X Series Sweeper

TABLE OF CONTENTS (Continued)

PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Adjusting The Parking Brake Cable Length . . . . . 29

TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Changing Solid Tires . . . . . . . . . . . . . . . . . . . . . . 30

Changing Pneumatic Tires. . . . . . . . . . . . . . . . . . 30

MISCELLANEOUS ADJUSTMENTS. . . . . . . . . . . . . 30

Anti-Static Chain Adjustment . . . . . . . . . . . . . . . . 30

Latch and Hinge Maintenance . . . . . . . . . . . . . . . 30

Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

SCHEMATIC ELECTRICAL

W/KUBOTA V1505 . . . . . . . . . . . . . . . . . . . . . . . 31

SCHEMATIC ELECTRICAL W/GM 1.6L . . . . . . 32

SCHEMATIC ELECTRICAL 9XR EUROPE

W/KUBOTA V1505 . . . . . . . . . . . . . . . . . . . . . . . 33

TABLE OF CONTENTS

SCHEMATIC HYDRAULIC 9XR . . . . . . . . . . . . . 34

SCHEMATIC HYDRAULIC 9XR EUROPE . . . . . 35

SCHEMATIC HYDRAULIC 9XV . . . . . . . . . . . . . 36

WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Page 7

PB# 4100033 Rev.* 06/10Armadillo 9X Series Sweeper

SAFETY INFORMATION

IMPORTANT SAFETY INSTRUCTIONS

Operators must read and understand this manual before operating or maintaining this machine.

Do not operate this machine in ammable or explosive areas.

This machine is designed solely for removing dirt, dust and debris in an outdoor or indoor environment. PowerBoss does not recommend using this machine in any other capacity.

The following information below may cause a potential hazard to the operator and equipment. Read this manual carefully and be aware when these conditions can exist. Take necessary steps to locate all safety devices on the machine and train the personnel operating the machine. Report any machine damage or faulty operation immediately. Do not use machine if it is not in proper operating condition.

FOR SAFETY DURING OPERATION

Keep hands and feet clear of moving parts while machine is in operation.

that are below freezing temperatures.

FOR SAFETY WHEN SERVICING OR MAINTAINING MACHINE

Stop on level surface.

Disconnect the power to the machine when servicing.

Avoid moving parts. Do not wear loose jackets, shirts, or sleeves when working on machine.

Avoid contact with battery acid. Battery acid can cause burns. When working on or around batteries, wear protective clothing and safety glasses. Remove metal jewelry. Do not lay tools or metal objects on top of battery.

Authorized personnel must perform repairs and maintenance. Use PowerBoss supplied replacement parts.

SAFETY SYMBOLS

Five symbols are used throughout this manual to emphasize various levels of safety information. These symbols and the meaning of each are listed below.

Make sure all safety devices are in place and operate properly. All covers, doors and latches must be closed and fastened before use.

During operation, attention should be paid to other persons in the work area and especially if small children are present.

Components can cause an explosion when operated near explosive materials or vapor. Do not operate this machine near ammable materials such as solvents, thinners, fuels, grain dust, etc.

Store or park this machine on a level surface only. To prevent unauthorized use, machine should be stored or parked with the key removed.

This machine is designed for level operation only. Do not operate on ramps or inclines greater than 2%.

This machine is not suitable for picking up hazardous dusts.

Use caution when moving this machine into areas

DANGER

To warn of immediate hazards which will result in severe personal injury or death

WARNING

To warn of hazards or unsafe practices which could result in severe personal injury or death.

CAUTION

To warn of hazards or unsafe practices which could result in minor personal injury.

ATTENTION!

To warn of practices which could result in extensive equipment damage.

Page 8

PB# 4100039 Rev.* 06/10

Armadillo 9X Series Sweeper

NOTE: To direct your attention to important

Located on the High Dump Hopper:

equipment information or special instructions for preventing damage to equipment

Symbols at the top of the list are the strongest warnings. However, all symbols represent important information which should be observed to protect you and others from harm and injury, and to prevent damage to the equipment.

SAFETY DECALS

Decals directly attached to various parts of the sweeper are highly visible safety reminders which should be read and observed. Make sure the decals are replaced if they become illegible or damaged.

Located in the drive compartment: Part Number 301854

SAFETY INFORMATION

Located on the High Dump Hopper: Part Number 301732

Located on the shroud of the radiator: Part Number 301733

Located at the Impeller: Part Number 301729

Page 9

PB# 4100033 Rev.* 06/10Armadillo 9X Series Sweeper

SAFETY INFORMATION

BASIC POWERBOSS® SAFETY

PowerBoss® sweepers should never be operated unless:

1. The operator is trained and authorized to operate the equipment and,

2. The equipment is free of malfunctions. Malfunctioning equipment should be removed from service.

DANGER

Keep cigarettes, matches and all other ame sources away from the sweeper. Gasoline, LP gas and diesel fuel are highly ammable. Lead acid batteries are equally dangerous due to the highly explosive hydrogen gas they emit.

WARNING

Before starting the engine, make sure that:

* You are securely seated in the operator’s

seat.

* The parking brake is locked.

WARNING

When leaving the sweeper unattended:

* Place the controls in the OFF position.

* Set the parking brake.

* Shut off the engine.

WARNING

During cleaning and maintenance:

* Always stop the engine and set the parking

brake before servicing.

* Never use detergents or cleansers that are

ammable or combustible.

* Never inate a pneumatic tire without using a

safety cage.

* Do not attempt any impeller adjustment

unless you have shut off the engine. Never place your hands near the intake hoses or inlet when the engine is running.

* Always engage the safety arm before

servicing the hopper. Do not rely on the hydraulic cylinder to keep the hopper raised.

* The directional control pedal is in neutral.

* The throttle is in idle.

* Hydraulic controls are in the OFF position.

WARNING

During operation:

* Keep your hands and body clear of moving

parts, especially when the hopper or lift arms are partially or fully raised.

* Make sure others in the area stay clear of the

equipment and moving parts.

* Never attempt to dump debris from a dock or

mezzanine. Dump from ground level only.

* Never test for hydraulic hose leaks using

your hand or any other part of your body. High pressure leaks can be very dangerous and should only be checked using a piece or paper.

WARNING

When servicing or repairing the fuel system:

* Work in a properly ventilated area, do not

smoke or allow an open ame near the fuel system.

* Never bypass safety components unless you

are testing them.

* Never bypass the fuel lter lock, except when

testing them (and always reconnect them after testing).

* Wear gloves to disconnect the tank coupling.

Page 10

PB# 4100039 Rev.* 06/10

Armadillo 9X Series Sweeper

SAFETY INFORMATION

WARNING

Do not operate an LPG powered sweeper when any component in the fuel system is malfunctioning or leaking.

WARNING

Replace any defective safety components before operating the sweeper.

CAUTION

Do not drive with the hopper in the raised position except the few feet necessary to position the hopper over the dumpster or receptacle. Driving with the hopper raised reduces visibility and creates conditions for striking over-head objects, throwing the machine off-balance and other hazards.

CAUTION

Travel slowly on grades.

ATTENTION!

Do not operate the #2 RTR lever before the #1 light illuminates.

ATTENTION!

Never push or tow a machine faster than 6 mph.

ATTENTION!

Engage tow valve before towing or pushing.

CAUTION

Place a block or chock behind the wheels when parking on inclines.

CAUTION

Use special care when traveling on wet surfaces.

CAUTION

Observe all proper procedures for operation and maintenance of the sweeper, as outlined in this manual.

CAUTION

Remain alert at all times to people and equipment in and around your area of operation.

Page 11

PB# 4100033 Rev.* 06/10Armadillo 9X Series Sweeper

TROUBLESHOOTING AND REPAIR

OVERVIEW

This section provides information to assist in identifying maintenance trouble and provides possible causes and actions to correct the problem. The procedures provide service instructions for your 9X series sweeper. General service information provides good practices and for overall servicing the equipment. The troubleshooting table is organized in the following sections:

• Diesel Engine

• Hydraulic System

• Vacuum System

Additional troubleshooting information is provides in the Kubota Diesel Engine Operator and service Manuals and the GM1.6L Emission Control Service Manual, refer to these manuals for engine difculties.

NOTE: For a preventative maintenance schedule

refer to the 9X Series User Manual PB# 4100033

ATTENTION!

Do not tow or push the machine a distance of more than .5 miles (.80 kilometers) or faster than one mile per hour (1.61 km). Exceeding these restrictions may cause damage to the hydraulic system. If towing will exceed the above restrictions, the rear wheel must be raised or supported by a dolly.

TROUBLESHOOTING

This section provides information to assist in identifying maintenance trouble and provides possible causes and actions to correct the problem.

GENERAL SERVICE INFORMATION

TRANSPORTING THE MACHINE

Using a Trailer or Transport Vehicle

1. Position the machine on the transport vehicle or trailer and apply the parking brake.

2. Tie the machine down using the tie down holes in the frame behind both front wheels and in the rear center of the frame.

NOTE: Attach the tie downs to the frame only.

Pushing the Machine

Push the machine from the front or rear using the

bumpers only.

Page 12

PB# 4100039 Rev.* 06/10

Armadillo 9X Series Sweeper

+ 26 hidden pages

PowerBoss 9XRGASES, 9XRDSLES, 9XRLPES, 9XRLPESBR, 9XRGASESBR Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual