PowerBoss SW5X User manual

SW5X (Battery Version)
Model: PB40BL, PB40BH
Instruction Manual

Introduction
Please be advised explicitly that
we cannot accept any legal is-
sues out of the contents of this
manual.
If repair work has to be perfor-
med make sure that only genui-
ne spare parts are used; only
genuine spare parts may gua-
rantee a dependable machine.
Valid as of: March 2005
Dear customer,
It is our desire that the good cha-
racteristics of the SW5X should
justify the confidence you demon-
strated by making this purchase.
Before first operation of your
SW5X, read these instructions
carefully. The manual provides
valuable information about opera-
tion, service and maintenance.
The symbol as used in this manual
identifies items relevant to safety.
Please observe the safety provi-
sions (see chapter 1).
Before first operation of the machine,
read these instructions and safety in-
formation carefully and comply with
them.
2

Proper Use
The SW5X sweeper has been
exclusively designed for collecting
dry and moist matter from floor sur-
faces in e.g. factories, storage buil-
dings, parking ground and pedestri-
an areas. Using the machine
beyond this scope of application
will be deemed improper use; The
manufacturer cannot be held liable
for consequential damages.
The term of proper use also inclu-
des operation, maintenance and
repair work to be performed in com-
pliance with the manufacturer's
specifications.
The SW5X may be used by person-
nel only that are familiar with the
machine and aware of possible
hazards involved.
The applicable Accident Prevention
Regulations, Road Traffic
Regulations, and aspects of safety
and working medicine in vigour will
have to be complied with.
If modifications to the machine are
made in absence of the manufac-
turer's prior consent, the latter can-
not be held liable for damage resul-
ting from such unauthorized modifi-
cation.
The machine has not been
designed for collecting
dusts which are detrimental
to health or explosive.
Notes on warranty
The terms of the sales contract apply.
Damages are not subject to warranty
if they are due to non-compliance
with the maintenance and service
provisions. The maintenance work
has to be performed by an authorized
service center and confirmed in the
"Maintenance certificate" which is the
warranty document.
The following is excluded from war-
ranty:
fuses, natural wear, damages caused
by overload, inexpert handling and
unauthorised modification of the
machine. Moreover, any claim for
warranty cannot be accepted if dama-
ges at the machine are caused by fit-
ting
parts or accessories without prior
and explicit consent or by non-com-
pliance with the maintenance
instructions.
Inspection
Carefully unpack and inspect your
SW5X for shipping damage. Follow
unpacking instructions on shipping
pallet. Each unit has been tested
and thoroughly inspected before
shipment. Any damage is the res-
ponsibility of the delivery carrier who
should be notified immediately.
Proper Use
3

4 Operation . . . . . . . . . . . . . . . . . . . . .18
4.1 Controls . . . . . . . . . . . . . . . . . . . .18
4.2 Control Panel . . . . . . . . . . . . . . . .20
4.3 Empty Dirt Hopper . . . . . . . . . . . .24
4.4 Empty Dirt Hopper
Lift-Up Disposal . . . . . . . . . . . . . .24
4.5 Working with the machine . . . . . . .27
4.5.1 Switch Electro-Motor ON and
OFF . . . . . . . . . . . . . . . . . . . . . . .27
4.5.2 Sweep . . . . . . . . . . . . . . . . . . . . . .28
4.5.3 Stop and Park . . . . . . . . . . . . . . . .28
4.5.4 Displace . . . . . . . . . . . . . . . . . . . .28
4.5.5 Transport . . . . . . . . . . . . . . . . . . .28
5 Technical Data . . . . . . . . . . . . . . .29
6 Maintenance/Service . . . . . . . . .33
6.1 Maintenance Instruction . . . . . . . .33
6.2 Mount/Dismount Cylinder Broom .34
6.3 Adjust Sweeping Track . . . . . . . . .34
6.4 Sealing strips for Broom
Compartment . . . . . . . . . . . . . . . .36
6.5 Folding Apron Adjustment . . . . . . .36
6.6 Replace Side Brush . . . . . . . . . . .37
6.7 Dismount Plate Filter . . . . . . . . . .38
6.8 Basic Cleaning of Plate Filter . . . .40
6.9 V-Belt Drive . . . . . . . . . . . . . . . . . .41
6.9.1 Replace Cylinder Broom V-Belt . .42
6.9.2 Replace Side Brush V-Belt . . . . . .42
6.9.3 Replace Suction Fan V-Belt . . . . .42
6.10 Adjust Steering Chain Tension . . .42
6.11 Check Hydraulic Fluid and Refill . .42
6.11.1 Check Hydraulic Fluid . . . . . . . . . .42
6.11.2 Refill Hydraulic Fluid . . . . . . . . . . .42
6.12 Electric System . . . . . . . . . . . . . . .43
6.13 Maintenance Schedule . . . . . . . . .44
7 Spare Parts . . . . . . . . . . . . . . . . .46
Contents
Introduction/Proper Use
Notes on Warranty
Inspection
1 Safty Information . . . . . . . . . . . . .5
1.1 General Safety Information . . . . . . .5
1.2 Safety and Warning Symbols . . . . .6
1.2.1 Generally Applicable Symbols . . . .6
1.3 Labels at the Machine . . . . . . . . . .7
1.4 Operation/Safety Information . . . .10
1.5 Cleaning Informaton . . . . . . . . . . .11
1.6 Maintenance instructon . . . . . . . .12
2 Description . . . . . . . . . . . . . . . . .14
2.1 Functional Descripton . . . . . . . . . .14
2.2 Cylinder Broom . . . . . . . . . . . . . . .15
2.3 Side Brush . . . . . . . . . . . . . . . . . .15
2.4 Filter System/Dust Evacuation . . .15
2.5 Shaking System . . . . . . . . . . . . . .15
2.6 Steering . . . . . . . . . . . . . . . . . . . .15
2.7 Wheels . . . . . . . . . . . . . . . . . . . . .15
2.8 Brake . . . . . . . . . . . . . . . . . . . . . .16
2.9 Travel Drive Assembly . . . . . . . . .16
2.10 Hydraulic System Lift-Up
Disposal . . . . . . . . . . . . . . . . . . . .16
3 First Operation . . . . . . . . . . . . . .17
3.1 First Operation of Batteries . . . . . .17
3.2 Insert Batteries . . . . . . . . . . . . . . .17
4

Safety Information
1 Safety Information
1.1 General Safety Information
Apart from the instructions contained
in this manual, the general safety
instructions and accident prevention
regulations, as imposed by law will
have to be complied with. Do not put
the Manual aside without reading it
even if you used similar sweepers
before. Take the time to read them
now and save time later. Machines
with known defects must not be used.
It will be of essence to make yourself
familiar with all accessories and con-
trols and their functions before you
start working. Avoid the mess of
having to read this book while trying
to run the machine.
Using the machine in areas with
explosion hazard, on public roads
and places is prohibited.
The operator has to use the machine
within its design limits.
Shut the motors down before trans-
porting the machine.
Keep clear of hazard zone!
Before commencing work, the opera-
tor has to make sure that the SW5X
and its accessories are in proper and
safe condition.
Warning and instruction labels atta-
ched to the machine contain impor-
tant information about safe operation.
Illegible or lost labels have to be
replaced.
Make sure that all covers
are fitted before starting to
sweep.
Provide for sufficient
ventilation when sweeping
indoors (dust and
combustion gas).
Pinching and shearing ha-
zard. Provide for required
safe distance before lifting
or lowering the dirt hopper.
5

1.2 Safety and Warning Symbols
1.2.1Generally Applicable Symbols
All paragraphs in this manual refer-
ring to your personal safety, the safe-
ty of your machine and the environ-
ment protection are attributed one of
the following warning symbols:
Safety Information
Hazardous for....
persons and
goods
the machine
the environment
Description
dangerous situation
caused by misuse inaccurate adherence of instructions or
prescribed work routine
important information on handling the machine in order to
maintain operability
due to use of substances representing an inherent danger to
health of environment
Symbol
DANGER
CAUTION
Ecological hazard
6

1.3 Labels at the Machine
The following safety and information
signs are legibly attached to the
machine. Missing or illegible stickers
have to be replaced.
Folding apron (1)
Parking brake (2)
Nameplate
Minuteman/Powerboss/SW5X (3/4/5)
Read and observe operator's
Manual (7) Key switch (8)
Brake (9)
Noise power level (10)
82 dB (A)
Safety Information
Fig.1
7

1.3 Labels at the Machine
Fig. 2 Safety and information
signs
24 V label (15)
Battery charging (16)
The label is located under the seat
hood.
Rotating parts (14)
Cylinder broom wearing take-up (12)
Safety Information
8

1.3 Labels at the Machine
High-pressure cleaner (11)
Do not clean by means of
high pressure cleaner or
vapour jet.
Pinching hazard (6)
(Lifted-Up Disposal) Hydraulic fluid (13)
Safety Information
9

1.4 Operation/Safety
Information
Vacuum sweepers may be run by
qualified personnel only; such per-
sonnel will have to have evidenced
their qualification for running the
machine to the owner or his authori-
zed representative; operators explicit-
ly will have to be instructed by the
owner or his authorized representati-
ve to use the machine.
The machine may be used
for cleaning such surfaces
approved by the owner or
this authorised representa-
tive for operation of vacu
um sweepers.
Before starting the engine,
switch off all drives
Transporting persons on the machine
is prohibited. Ride-on machine types
are to be started with the driver being
seated.
Never leave the machine unattended
before the motors are off and the ma-
chine is protected against unintended
movements.
To prevent the machine from unautho-
rized use, pull the control key to block
all drives.
Shut down the motors before trans-
port of the machine. The driver has to
take account of local conditions and
when operating the sweeper he has
to watch out for other persons, espe-
cially children.
Do not open hood or
fairings with the machine
running.
This machine must not be
used as dust-evacuating
machine with dust filter in-
sert (separator) to collect
dusts which are hazardous
to health.
Compared to four-wheeled
vehicles, driving stability of
three-wheeled vehicles is
reduced. We thus recom-
mend:
- do not negotiate curves at
high speed.
- do not turn at slopes but
on level ground only
- ride up- or downhill
straight.
Safety Information
10

11
Warning and instruction la-
bels attached to the machi-
ne contain important infor-
mation about safe operation
Provide for sufficient venti-
lation when sweeping indo-
ors (dust and combustion
gas).
Proceed to filter shaking on-
ly if the dirt hopper is in clo-
sed position.
1.5 Cleaning Information
The machine is splash-proof (IPX3).
Do not clean the SW5X by
means of high pressure cle-
aner or vapour jet.
Proceed to cleaning of the
dirt hopper in regular inter-
vals to preclude formation of
bacterial deposits.
Safety Information

1.6 Maintenance Instructions
A good approach to prevention of
accidents is proper maintenance of
the machine.
Before proceeding to repair or main-
tenance work remove the key.
Use appropriate tools for maintenan-
ce, service, setting etc.
As far as aspects of safety are con-
cerned, spare parts will have to be at
least of the same quality as the genu-
ine spare parts.
Switch off the motors befo-
re maintaining the machine
or replacing parts of it. Turn
off the machine and pull the
key and additionally, discon-
nect the battery plug.
Check hydraulic hoses and
lines for leakage or dama-
ges in regular intervals. Re-
place defective hoses and
lines immediately.
Before changing wheels
protect the machine against
rolling by placing wedges.
Proceed to wheel changing
when the machine is on le-
vel and solid ground.
Do not repair the pneumatic
tires mounted to the machi-
ne yourself. Dismount the
wheel and take it to repair to
a tire workshop.
Use of other than the cylin-
der brooms and side brus-
hes approved by the manu-
facturer is not acceptable
(see technical data) since
use of other cylinder
brooms and side brushes
may affect your safety.
When handling lubrica-
ting agents, the appli-
cable regulations for
protection of the envi-
ronment and preven-
tion of fire have to be
complied with. Provide
for disposal of used oil
and grease in accor-
dance with the provi-
sions imposed by law.
Collect cleaning
agents, oil, fuel oil, gre-
ase etc. and provide for
adequate disposal. Wi-
pe away spilled sub-
stances.
Safety Information
12

Before commencing any
work on the electric system
disconnect battery (neg. le-
ad) of the SW5X and pull the
ignition key.
Do not keep batteries dis-
charged for a longer period;
always recharge them as
soon as possible.
Top with distilled water on-
ly. Never refill battery acid
in battery cells of perfect
condition.
Open the hood before char-
ging batteries; explosive ga-
ses may occur during the
charging procedure.
Keep batteries dry and cle-
an and clear of soiling such
as e.g. metallic dust to avo-
id leakage current.
Do not place metal objects
or tools onto batteries.
Short-circuit and deflagra-
tion hazard.
Spilled (straight) battery
acid must not get into the
sewage system before ha-
ving been neutralised. Com-
ply with the regulations im-
posed by law and observe
local provisions.
Battery acid is highly
caustic (keep clear of
children).
When checking the battery
acid level, wear safety glas-
ses. If acid splashes get in-
to the eyes rinse with clear
water for 15 minutes and
contact a doctor imme-
diately.
Use appropriate protective
means (e.g. protective glo-
ves or finger-stalls) when
handling battery acid.
Do not use open flames
(explosion hazard).
Do not eat, smoke or drink
in rooms where batteries
are charged to avoid dama-
ging your health. After work
with batteries wash your
hands thoroughly. Provide
for sufficient ventilation.
Safety Information
13

2 Description
2.1 Functional Description
Principle Model: PB40BL
The side brush is used to collect dirt
at borders and to enlarge the working
width as well as to increase the area
performance on large surfaces.
The cylinder broom casts the debris
overhead into the dirt hopper. The col-
lected fine dust is evacuated by the
suction fan and separated by a filter
system. The air returned into the envi-
ronment is clean.
Principle Model: PB40BH
Description
Fig.3
Fig.4
14

2.2 Cylinder Broom
The cylinder broom is equipped with
12 rows of bristles arranged in
V-shape.
The cylinder broom width amounts to
27.6 in. (700mm) and its diameter to
13.6 in. (345mm).
2.3 Side Brush
At the standard version, the side
brush is located at the front right of
the machine. The operator lifts and lo-
wers it by hand lever.
The side brush has a light inclination.
The swinging area of the side brush
arm is limited by stop screws.
The side brush is driven by V-belt.
For special application, fitting of a
second side brush at the left is possi-
ble.
2.4 Filter System / Dust
Evacuation
The filter system is located in the fil-
ter case above the dirt hopper. The
suction fan transports the fine dust
raised by the cylinder broom to the
plate filter where it is separated. The
fine dusts sets at the outsides of the
filter blades.
In case of heavy dust deve-
lopment, check and clean
the plate filter at regular
intervals.
2.5 Shaking System
Due to normal working vibration the
set dust partly falls off into the dirt
hoper. To ensure working in a dust-
free environment, however, actuate
the shaking system regularly, or after
request by the pilot lamp at the latest.
2.6 Steering
Steering is controlled mechanically
from steering wheel to front wheel via
chain. This chain is to be re-adjusted
as required.
2.7 Wheels
Front wheel: solid rubber tires
Rear wheels: solid rubber tires
Description
15

2.8 Brake
The SW5X is equipped with a service
brake.
This brake has been constructed as
shoe brake and equally serves as
parking brake.
It is located in the rear wheels and is
actuated via cables.
A special adjustment screw is situa-
ted at the right-hand rear wheel.
Any work at the braking
system has to be executed
by qualified persons in a
qualified workshop only.
2.9 Traction Drive Assembly
The SW5X is equipped with an electric
drive assembly with continuous regula-
tion.
2.10 Hydraulic System
(Lift-Up Disposal)
The hydraulic system comprises a
compact unit (hydraulic pump with
hydraulic tank), the hydraulic hoses
and a hydraulic cylinder.
Hydraulic fluid: Mobiloil DTE 15 M
The named hydraulic fluid has been
filled in the hydraulic system in the
factory.
Filling of hydraulic tank: 0.2 gal. (0.76
litre).
2.11 Battery Systems
Before commencing any
work on the electric system
disconnect the battery plug.
Do not use open flames
when handling batteries and
especially when checking
the battery acid level. Provi-
de for sufficient ventilation
in rooms where batteries
are charged. Spilled
(straight) battery acid must
not get into the sewage
system before having been
neutralised.
Comply with the regulations
imposed by law and obser-
ve local provisions.
Open the hood before char-
ging batteries; explosive ga-
ses may occur during the
charging procedure
2.11.1 Low Discharge Signal
Sender
Battery Charging Status Indicator
Upon turning ON by key switch, bat-
tery charging status is shown by dis-
play of green bars (Fig. 5/1). As the
battery discharges during operation,
the lighting green bars extinguish one
after another showing thus always the
current charge status of battery char-
ge.
Flashing of the last two green bars
indicates that operation will be stop-
ped soon. In order to preclude low
discharge of batteries, the sweeping
units are switched off and riding
speed reduced to 50% if battery is
discharged. The red LED (Fig. 5/4)
than flashes.
Setting Other Battery Types
Have the low discharge sig-
nal sender set to other bat-
tery types by qualified per-
sonnel only and in
approved qualified works-
hops only.
2.11.2 Hourmeter
The operating hours of the machine
appear in the display (Fig. 5/2); the
hourmeter will count only during wor-
king or transport ride; only full hours
are displayed).
Description
Fig. 5
16

3 First Operation
The SW5X has been extensively
tested and submitted to a functional
check before delivery.
Only qualified personnel of your local
contract dealer are allowed to pro-
ceed to first operation. After shipping
of the machine, we advise your con-
tract dealer. He will contact you to
make a date for briefing lessons.
3.1 First Operation of Batteries
To achieve the optimum performance
and a maximum service life, the bat-
teries must be given the initial charge
after filling.
Handling and function of the battery
charger is described in detail in the
instruction manual supplied with each
charger unit.
Since batteries and charger
units are matched, we re-
commend using batteries
and chargers as prescribed
by Minuteman. We can
grant full warranty only if
those units are being used.
Do not use the SW5X at am-
bient temperatures of more
than 105°F (40°C).
Do not start the machine at
temperatures of 32°F (0°C)
or less.
3.2 Insert Batteries
- Turn machine off and pull key.
- Secure machine by actuating par-
king brake.
- Fold up seat hood
- Insert battery
- Connect charging plug of the bat-
tery connection cable and cable of
the charger unit and proceed to in-
itial charging.
- After charging of the batteries, con-
nect charger plug (Fig.5b/2) and
device plug for electrical connec-
tion.
If the battery type setting at
the LDS should be incor-
rect, have the setting modi-
fied by qualified personnel
in an approved workshop.
Use admitted lifting and
transport devices. Make su-
re that lifting hooks do not
damage cells, connectors
or connecting cables.
First Operation
Fig.5a
Fig.5b
17

4 Operation
4.1 Controls
1 Actuator for folding apron
2 Service brake lock
3 Service brake/parking brake pedal
4 Drive pedal, reverse
5 Drive pedal, forward
6 Control panel
7 Seat adjustment
Operation
Fig.6
18

1 Actuator for folding apron
to open and close the folding apron
for collecting coarse dirt.
2 Service brake/parking brake lock
to lock the service brake/parking
brake. If locked, the service brake
works as parking brake. Release
the lock by depressing the service
brake pedal.
3 Service brake/parking brake pe-
dal
to actuate the service brake at the
rear wheels. Before leaving the ma-
chine unattended, engage the ser-
vice brake and lock.
4 Drive pedal, reverse
to change direction to reverse ride
with continuous regulation of riding
speed at the same time. If the dri-
ver releases the pedal it returns to
initial position and the machine
slows down to standstill.
5 Drive pedal, forward
to change direction to forward ride
with continuous regulation of riding
speed at the same time. If the dri-
ver releases the pedal it returns to
initial position and the machine
slows down to standstill.
6 Control panel
Refer to chapter "Control panel"
7 Seat adjustment
to adjust the seat position to drivers
of different height.
Adjust the seat so as to allow the
driver being comfortably seated and
attaining all elements required for
operation.
- Adjust seat lengthwise: push lever
slightly to the right and displace se-
at forwards or backwards to the re-
quired position. Then let the lever
catch again.
Operation
19

4.2 Control Panel
1 Cylinder broom lever
2 Release of lifted-up disposal func-
tion
3 Horn
4 TSG
5 Suction fan/shaking system knob
6 Flashlight (option)
7 Lighting (option)
8 Lift and lower (Lift-Up Disposal)
9 Side brush lever
10 Pilot lamp, parking brake
11 Battery charge status indicator/
Hourmeter
12 Pilot lamp, fan
13 Pilot lamp, shaking system
14 Key switch
Operation
Fig.7
20