Download 636 Green Operators Manual

Green Machines
Model 636HS
Operators Manual
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Issue 4 – May 2008
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The manufacturers of the Green Machines:
Green Machines
Bankside • Falkirk • FK2 7XE• United Kingdom
Phone (01324)611666 • Fax (01324)611886
International Tel: (+44)1324-611666 Fax: (+44) 1324-611886
A Tennant Company
701 North Lilac Drive
Minneapolis, MN USA
You’re local Green Machines Distributor:
Parts information and other product support information are available at our web-site:
www.greenmachines.com
Fill in your user details here, and keep in a secure place:
My user name:__________
My password: __________
My Chassis Number: __________
636HS Green Machines
Operators Manual
Part Number: YM052
Issue 4
3
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Table of contents
Table of contents ................................................................................................................................................5
Chapter 1 Introduction. ........................................................................................................................................9
How to use this manual. ...................................................................................................................................11
Important Safety Information. ...........................................................................................................................12
Know your Machine ..........................................................................................................................................13
End of chapter ..................................................................................................................................................13
Chapter 2 Before You Start................................................................................................................................15
2.1 Always top ten ............................................................................................................................................17
2.2 Never top ten ..............................................................................................................................................17
2.2.1 Operator check list for the 636 Green Machines......................................................................................18
2.2.2 Key Maintenance Procedures – Cleaning the Suction Fan ......................................................................19
2.3 How the machine works..............................................................................................................................19
2.4 Get to know your machine ..........................................................................................................................21
2.5 Setting the brush angle...............................................................................................................................22
2.6 Changing the brushes.................................................................................................................................22
2.7 Adjusting the nozzle flap.............................................................................................................................23
2.8 Setting the nozzle height ............................................................................................................................23
Setting up .....................................................................................................................................................23
Adjusting for wear .........................................................................................................................................24
End of chapter ..................................................................................................................................................24
Chapter 3 Getting Started ..................................................................................................................................25
3.1 Adjusting the driving controls ......................................................................................................................25
3.2 Learning about the switches .......................................................................................................................26
3.2.1 Switch column......................................................................................................................................26
3.2.2 Multifunction lever switch .....................................................................................................................27
3.3 Driving the machine ....................................................................................................................................27
3.3.1 Movement modes ................................................................................................................................27
3.3.2 Speed control (accelerator) pedal ........................................................................................................28
3.3.3 Braking ................................................................................................................................................28
3.3.4 Wheel tracking .....................................................................................................................................28
3.3.5 Gauges and warning lights ..................................................................................................................29
3.3.6 Forward / Neutral / Reverse.................................................................................................................29
3.3.7 Starting and Stopping the engine.........................................................................................................30
3.3.8 Going up and down pavement curbs ...................................................................................................30
3.3.9 Brush/Nozzle – Raising in Transit Mode ..............................................................................................31
3.4 Using the sweep mode ...............................................................................................................................31
3.4.1 Switching to sweep mode ....................................................................................................................31
3.4.2 Water system.......................................................................................................................................31
3.4.3 Setting the brush height .......................................................................................................................33
3.4.4 Moving the brushes sideways ..............................................................................................................34
3.4.5 Setting impeller/brush speed ...............................................................................................................34
3.4.6 Tilting the hopper .................................................................................................................................35
3.5 Whoosh hose..............................................................................................................................................36
3.5.1 Using the whoosh hose........................................................................................................................36
3.5.2 Unblocking a blocked whoosh hose.....................................................................................................37
3.6 Cab comfort ................................................................................................................................................37
3.6.1 Cab temperature..................................................................................................................................37
3.6.2 Other devices.......................................................................................................................................37
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Issue 4 – May 2008
3.7 Electronic control system (“brain”) ..............................................................................................................38
3.7.1 “Brain” & display ..................................................................................................................................38
3.7.2 To set the engine speed during WORK mode......................................................................................39
3.7.3 “Slave” .................................................................................................................................................40
3.8 Safety features and procedures..................................................................................................................41
3.9 Fuse boxes .................................................................................................................................................42
End of chapter ..................................................................................................................................................43
Chapter 4 Operator Checks ...............................................................................................................................45
4.1 Daily operator checks .................................................................................................................................47
4.2 Weekly operator checks .............................................................................................................................49
End of chapter ..................................................................................................................................................49
Chapter 5 Options & Accessories .....................................................................................................................51
5.1 Rear-view camera (Optional) ......................................................................................................................53
Functions and Operation ..............................................................................................................................53
5.2 Pressure Washer (Optional) .......................................................................................................................55
5.3 Street Washer Model – 636SW ..................................................................................................................56
Introduction...................................................................................................................................................56
Preparing to Street Wash .............................................................................................................................56
Returning the machine to SWEEP mode ......................................................................................................58
Using the Pressure Wash Lance (where fitted).............................................................................................58
5.4 Air Conditioning (Optional)..........................................................................................................................59
5.5 Automatic Greasing (Optional)....................................................................................................................60
Introduction...................................................................................................................................................60
Operation......................................................................................................................................................60
Maintenance .................................................................................................................................................60
Fault Finding.................................................................................................................................................61
5.6 Winter Equipment - Optional.......................................................................................................................61
Introduction...................................................................................................................................................61
Operation......................................................................................................................................................62
Fitting and Maintenance ...............................................................................................................................63
5.7 Acto Bac .....................................................................................................................................................63
5.8 Ice X ...........................................................................................................................................................63
End of chapter ..................................................................................................................................................63
Chapter 6 The wash down .................................................................................................................................65
End of chapter ..................................................................................................................................................68
Chapter 7 Fault finding ......................................................................................................................................69
Machine is not picking up/poor suction thereby leaving a trail ......................................................................71
Brush bounce ...............................................................................................................................................71
Debris/trash tends to be left on the sides of the sweep path.........................................................................71
Electrical failure ............................................................................................................................................71
Overheating engine ......................................................................................................................................71
Hydraulic oil overheating ..............................................................................................................................71
Water sprays not working .............................................................................................................................71
Smoking Engine ...........................................................................................................................................71
Engine will not turn over on start..................................................................................................................72
Ignition/charging light fails to go out on start up ............................................................................................72
Excessive vibration during sweeping ............................................................................................................72
Wheel spin on uneven ground ......................................................................................................................72
End of chapter ..................................................................................................................................................72
Chapter 8 General Specifications......................................................................................................................73
8.1 Machine ......................................................................................................................................................75
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Issue 4 – May 2008
8.2 Engine ........................................................................................................................................................75
8.3 Fuel (Diesel) ...............................................................................................................................................75
8.4 Speed .........................................................................................................................................................75
8.5 Noise ..........................................................................................................................................................75
8.6 Suction System...........................................................................................................................................76
8.7 Dust suppression system............................................................................................................................76
8.8 Brushes ......................................................................................................................................................76
8.9 Tires & Wheels 636HS ...............................................................................................................................76
8.10 Hopper......................................................................................................................................................76
8.11 Electrical System ......................................................................................................................................76
8.12 Hydraulic System......................................................................................................................................76
8.13 Pressure Washer - Option ........................................................................................................................77
8.14 Vibrations..................................................................................................................................................77
End of chapter ..................................................................................................................................................77
Chapter 9 Chassis Plate Identification..............................................................................................................79
9.1 Chassis Plate..............................................................................................................................................81
End of chapter ..................................................................................................................................................81
Chapter 10 Vehicle Rescue & Transportation ..................................................................................................83
10.1 Rescue .....................................................................................................................................................85
10.2 Transportation ..........................................................................................................................................85
End of chapter ..................................................................................................................................................86
Table of Contents
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Issue 4 – May 2008
Chapter 1 Introduction.
Introduction
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Issue 4 – May 2008
Machines distributor listed at the front of
this book.
How to use this
manual.
Please read the manual fully and follow all safety
advice before using your machine.
Welcome to the 636HS Green Machines
Workshop Manual. We have written this
manual to help you maintain and repair
your Green Machines correctly and above
all, safely. Please read the appropriate
chapter in the manual carefully before
working on your Green Machines.
This manual is aimed at service
technicians, auto mechanics or vehicle
fitters having an appropriate level of trade
skills including a working knowledge of
basic mechanical principles, hydraulic,
braking, steering and electrical systems etc.
and having access to properly equipped
vehicle maintenance facilities.
Throughout this manual you will see
areas where particular attention must be
paid to avoid death, physical injury or
damage to you or your machine. Please
read these points carefully and follow the
instructions.
Your Green Machines should have been
supplied with the following:
Operator’s Manual (YM044).
Service Schedule (YM043)
Parts Catalogue (YM045)
Kubota Engine Manual
Warranty Card
In addition, the following publications can
be purchased separately:
Kubota Engine Workshop Manual (YM047)
Kubota Engine Parts Catalogue (YM048)
If you need help, or if any of these are
missing, please contact your local Green
Introduction
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Issue 4 – May 2008
Never make non-approved modifications.
Important Safety
Information.
Always apply local Heath & Safety and
workshop procedures.
Always ensure that the machine is in a safe
condition prior to commencing work.
Ensure that all waste and used parts are
handled and disposed of in line with
environmental legislation.
Switch the engine off and remove the
ignition key before working on the
machine.
Always fit the safety prop before working
under the hopper area.
Always use the specified jacking points.
Always clean the machine prior to work
commencement.
Always ensure that all work/ modifications/
adjustments are fully recorded in the
equipment files.
Always maintain the machine in
accordance with the manufacturer’s
recommendations.
Never leave the machine unattended with
the engine running.
Never put fingers or loose clothing near
moving parts.
Never run the engine in an enclosed space.
Never open the coolant cap when the
engine is hot (you may be scalded)
Never run the engine with the fan casing
impeller door open, the front suction hose
off, or when the cab is tilted.
Never wash the machine with the engine
running.
Never fit parts of unknown origin or quality
Never use oils, fluids or fuels not specified
by the manufacturer
Introduction
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Issue 4 – May 2008
Know your Machine
Throughout this manual, left and right hand sides apply when sitting in the cab, looking
forward.
Figure 1-1 Right hand side
Figure 1-2 Left hand side
End of chapter
Introduction
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Issue 4 – May 2008
Chapter 2 Before You Start
Before starting please read the following safety advice, it is provided for your safety, the safety of
others and for the correct and efficient use of the Green Machines Sweeper 636.
Before You Start
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Issue 4 – May 2008
2.1 Always top ten
5. Open the coolant cap when the
engine is hot (you may be scalded).
1. Carry out the daily checks, before
using the Sweeper.
2. Wash the machine down at the end
of each shift.
3. Ensure that any defects are
reported as soon as they are found.
4. Switch the engine off while the
machine is being refueled.
5. Remove the ignition key if leaving
the machine unattended.
6. Switch the engine off before
opening the machine side covers.
7. Before trying to clear a blockage,
switch the engine off and remove
the ignition key.
6. Run the engine with the fan casing
impeller door open, the front suction
hose off, when the side cover is
open, or when the cab is tilted.
7. Wash the machine with the engine
running.
8. Leave the cab without engaging
neutral and applying the hand
brake.
9. Drive up and down pavement curbs
at too high a speed or too oblique
an angle.
10. Make non-approved modifications or
use the machine in any other way
than that shown or demonstrated by
an official representative of Green
Machines (A Tennant Company).
8. Be aware of your surroundings while
sweeping.
9. Use water sprays under dry
conditions.
10. Ensure that the machine receives
the correct maintenance in
accordance with the manufacturers
recommendations.
2.2 Never top ten
1. Try and clear the blockage with the
engine running.
2. Leave the machine unattended with
the engine running.
3. Put fingers or loose clothing near
moving parts.
4. Run the engine in an enclosed
space.
Before You Start
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Issue 4 – May 2008
2.2.1 Operator check list for the 636 Green
Machines
Detailed operator checks procedure is described in section 4.
Detailed machine wash down procedure is described in section 6 & Section 2.2.2.
Daily Action
Before
After Shift
Shift Start
Finish
Maintenance Procedure
End of
Week
Action
Tilt the hopper, applying the safety stay. Switch engine off and
remove the ignition key.
Check hydraulic oil level – top up if required.
Check engine oil level – top up if required.
Check water tank is full.
Check diesel tank is full.
Check engine coolant header tank – top up as required.
Check window washer bottle is full.
Check engine Filter Minder is set to GREEN.
Check ALL vehicle lights, beacon and audible warning devices.
Check brush wear – replace as required.
Check nozzle height and side skids.
Check tyre pressure and condition.
Check all safety devices.
Check all machine functions prior to leaving depot.
Check all panels are in place and secure and the wander hose
is correctly located.
Wash vehicle including ALL hopper screens and cyclones.
Avoid directing high-pressure water at electrical components &
connections.
Clean radiator mesh screen and check radiator is clear. If
required wash radiator carefully with a low-pressure jet.
Clean dust suppression water filter during machine wash down.
Clean fan blades with scraper provided. See section 2.2.2.
Carry out a general inspection of the machine wiring, flexible
hoses and piping for security and integrity.
Carry out inspection of hopper door and hopper inlet.
Report any defects as soon as they are found.
Never wash down the engine with the engine running, as it may ingest water causing major engine
damage.
Before You Start
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Issue 4 – May 2008
2.2.2 Key
Maintenance
Procedures –
Cleaning the Suction
Fan
Warnings: Failure to comply could result in
serious injury.
1. Before working on the machine
position it on a firm, level ground,
apply handbrake, stop engine and
remove ignition key.
2. Always use the hopper stay to
support a raised hopper.
3. The fan is an extremely heavy
rotating mass. Never attempt to slow
or stops its rotation by using the
hands or by inserting any item into
the fan chamber, even at low
speeds.
4. Before removing the suction fan
access panels, ensure that the
engine is off and the engine is off
and the ignition key is removed.
5. Always wear suitable eye protection
when using a hand lance.
1. Switch off the engine and remove
the ignition keys.
2. Ensure the suction fan is stopped.
3. Undo the catches on the inspection
cover on the right hand side of the
hopper with the special key
provided.
4. Open the inspection cover to expose
the fan impeller.
5. Using a high-pressure water jet and
the special scraper provided,
thoroughly clean the fan. Pay
particular attention to the inside
curve of each impeller blade and to
the area around the hub.
6. Refit the inspection cover and
ensure the latches are engaged.
7. Carefully stow the special latch key.
Figure 2-1 Cleaning the suction fan
2.3 How the machine
works
The machine works due to the air moving
through it. The following scheme shows the
flow of air through the machine. The two
front brushes sweep dirt, trash and debris
into the center of the machine, so that the
airflow can pick these up and deposit them
into the hopper
The air and debris mixture to swirl in a
cyclonic action inside the hopper in order to
cause the debris to separate out, falling into
the lower part of the hopper and allowing
the air to return to atmosphere through
exits in the top of the hopper. There are 3
separating actions in the hopper:
•
•
•
The initial entry cyclonic action which
is aided by swirl plates in the rear of
the hopper;
Screens in the hopper which prevent
light material such ad dry leaves and
paper from escaping;
The final cyclone spinners located in
the top of the hopper, which
separate out small dust particles.
As long as the airflow is maintained, the
machine will work correctly. If the machine
does not pick up or leaves a trail, this
means the air is not flowing correctly
through the machine. Always bear in mind
this notion of airflow.
Before You Start
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Issue 4 – May 2008
Figure 2-2 Air flow
Before You Start
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Issue 4 – May 2008
2.4 Get to know your machine
Before You Start
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Issue 4 – May 2008
Figure 2-3 Know your machine
2.5 Setting the
brush angle
This operation usually only requires to be
requires to be carried out when the
machine is installed. The requirement is to
set the angle of the brushes so that they
sweep the debris into the central part of the
machine, where the airflow will pick it up.
To do so, the brushes need to be tilted so
as to touch the ground as shown on figure
2-4.
Figure 2-5 Roll angle adjustment
3. Loosen the four screws shown on
figure 2-6 to adjust the pitch angle.
The front two screws are located in
slots.
Figure 2-6 Pitch angle adjustment
Figure 2-4 Brush set up
1. Remove the plastic brush cover.
2. Loosen the top nut shown on figure
2-4 to adjust the roll angle (usually 5
degrees).
2.6 Changing the
brushes
1. Remove the plastic brush cover,
and then loosen the six M8 fixing
screws shown figure 2-6 using the
tools provided.
Before You Start
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Issue 4 – May 2008
In light duty conditions (paper litter), very
little, or no flap vibration is required.
In heavy duty conditions (wet sand), rather
more flap vibration is required.
To set the flap vibration:
•
Select sweep mode, engage
FORWARD drive and set the FAN
speed to 2200rpm. Commence
sweeping.
•
From inside the cab you should just
be able to hear the flap vibrating.
•
If the flap requires adjustment,
STOP the machine, apply the
PARKING brake, put the DRIVE
lever in NEUTRAL. Go to the front of
the machine and turn the black
adjuster knob (try one complete turn
per adjustment), CLOCKWISE to
increase vibration activity and ANTICLOCKWISE to decrease.
•
Re-check for satisfactory sweeping
performance and re-adjust as
necessary.
•
Ensure that the adjuster is locked
after setting.
Figure 2-7 Changing brushes
2. Turn the brush until the head of the
screws pass through the keyhole.
Now replace the old brush with the
new one, and turn the brush until
the screws are located at the end of
the keyhole slots. Turn the right
hand brush clockwise (looking down
on the brush) and turn the left hand
brush anticlockwise.
3. Tighten the flange screws.
2.7 Adjusting the
nozzle flap
Ensure that drive is in NEUTRAL and
PARKING BRAKE is applied prior to
adjusting FLAP
2.8 Setting the
nozzle height
Figure 2-8 Adjustable nozzle
The suction nozzle contains a rubber flap,
the vibrating movement and position of
which is designed to optimize suction
efficiency. The flap position and vibrating
movement can be adjusted by turning the
black adjustment knob located on the right
hand, upper surface of the suction nozzle.
Setting up
The two chilled iron skids (a) should be set
with their lower wear surfaces level with the
horse show polyurethane (plastic) wear
surface (c).
Before You Start
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Issue 4 – May 2008
Figure 2-9 Nozzle set up
The nozzle is designed to float lightly on the
ground in the lowered position, being
supported by the hydraulic cylinder. The
nozzle is automatically raised when Transit,
Brush Lift or Reverse is selected.
Adjusting for wear
The side (a) skids can be adjusted via the
M16 adjustment screws (b).
End of chapter
Before You Start
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Issue 4 – May 2008
Chapter 3 Getting Started
If the machine is set correctly and has been cleaned in the manner prescribed, you will
continued performance for the whole of the shift.
The most common problem experienced by machine operators is that the machine does not
pick up, and leaves a trail. Usually, this means either the machine has not been set correctly
or there is an airflow restriction (please see 2.3 – How the machine works).
If you experience problems with the machine not picking up debris/trash, refer
to section 7 – Fault Finding.
3.1 Adjusting the
driving controls
Adjust the backrest with the upper lever at
the right hand side of the seat. As shown in
figure 3-2.
1. Your seat is adjustable.
Move the seat forward or backward using
the lever on the seat on the right hand side.
As shown in figure 3-1
To adjust the tilt (thigh support adjustment)
use the lower lever at the right hand side of
the seat.
Adjust the suspension setting of the seat by
adjusting the lever below the seat, in the
middle. Pull out knob to obtain more
leverage and move towards left for
increasing driver weight. As shown in figure
3-1.
Figure 3-2 Back and tilt adjustment
2. Adjust the height of the steering
wheel using the lever shown in figure
3-3.
Figure 3-1 Seat adjustment
Getting Started
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Issue 4 – May 2008
3.2 Learning about
the switches
3.2.1 Switch column
You have probably noticed the switch
column on your right hand side. Here is an
overview of the functions it provides.
Figure 3-3 Steering wheel adjustment
3. Please note that the cab includes a
seatbelt.
4. It is possible to lock the doors from
the inside of the cab. Moving the
catch down unlocks the door,
moving the catch up locks it.
Figure 3-4 Dock lock
Ensure that the catches are in the
down position prior to leaving the cab.
If the door is locked from the inside it
is not possible to unlock from the
outside using the key.
Figure 3-5 Switch column
Getting Started
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Issue 4 – May 2008
Figure 3-7 Main beam
Pushing the lever up flashes the main
beam, what ever the position of the column
switch.
Figure 3-8 Multifunction lever switch
3.3 Driving the
machine
Please note that in the United Kingdom a
full B driving license is required to drive the
636 machine. For other countries please
check with your local distributor.
3.3.1 Movement modes
Before actually driving the machine, you
need to know about its movement modes.
Figure 3-6 Switch column overview
3.2.2 Multifunction lever
switch
The steering column multifunction lever
switch is similar to the ones used in cars.
Pushing the lever forwards or backwards
controls the indicators. Pushing the lever
down controls the main beam. (The lights
will turn on only if the appropriate column
switch is on).
The machine has three main movement
modes, which you can select on the 3position rocker switch at the top of the
switch column on the right hand side of the
windscreen.
Figure 3-9 Transit/Sweep/Brush Lift switch
Getting Started
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Issue 4 – May 2008
1. Transit mode is used to drive the
machine at high speed (from the storage
depot to the sweeping site), up to 32 km/h
(20 mph). The brushes and nozzle are
raised when using this mode. Please note
the machine will not travel at high speed
until the front wheels have tracked out,
thereby increasing the overall vehicle
stability. The operation takes about 10
seconds, and will be performed
automatically as the machine starts gaining
speed. For short distance traveling from
one sweeping zone to another, it may be
more efficient to use Brush lift mode (see 3
below).
2. Sweep mode (work 1) only enables lowspeed drive, up to 15 km/h (9 mph). The
front wheels are tracked-in to enable
sweeping access to narrow alleyways. The
brushes and suction nozzle are
automatically deployed when sweep mode
is selected.
3. Brush lift mode (work 2) is used to
travel at low speed over short distances
when not sweeping. Indeed, it is sometimes
not good use of time to use transit mode for
short distance travel, as the front wheels
have to track out and then back in. The
Brush lift mode is similar to Sweep mode
(same max. speed) except the brushes and
nozzle are raised and the limited slip
differential system is engaged.
It is important to check that the front
wheels are fully tracked in before
sweeping close to a wall or curb. If not
fully tracked in tire damage may result.
3.3.2 Speed control
(accelerator) pedal
The pedal is located right of the center on
the floor. The same pedal is used for both
forward and reverse motion.
Pressing the pedal gently will cause the
machine to move forward or backward
depending on the setting of the
Forward/Reverse lever. If the lever is set to
Neutral, then pressing the accelerator will
simply speed up the engine.
Figure 3-10 Accelerator pedal
3.3.3 Braking
Releasing the accelerator pedal will cause
the machine to slow down by automatically
applying hydraulic braking.
The brake pedal operates on the rear
brakes.
The handbrake also operates on the rear
brakes, and should always be applied when
leaving the cab. A buzzer sounds if
Forward or Reverse is selected with the
handbrake applied to remind you to release
it.
3.3.4 Wheel tracking
The 636 is equipped with a variable track
width front axle. This enables the machine
to operate in narrow passageways (1.1m
machine width) during low speed (15 km/h
max.) Sweep (Work) mode.
In high speed (32 km/h max.) Transit mode,
the front wheel track width is increased to
1.33m over wheels. This increases
machine stability at high speed.
Tracking (changing the front wheel track
width) is automatically controlled by the
MDM electronic control system.
Getting Started
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Issue 4 – May 2008
1. TRACKING-OUT – Changing from
WORK to TRANSIT
Reduce machine speed to 5 km/h (3.1
mph) (walking speed) and select Transit.
When Transit is selected, Tracking-out
does not start until the accelerator pedal is
depressed when the machine is in Forward
and a speed of, at least, 4.5 km/h (2.8 mph)
is reached.
3.3.5 Gauges and warning
lights
The MDM then limits the maximum speed
to 5 km/h (3.1 mph) until tracking-out is
complete (about 10 sec.). A speed of 32
km/h (20 mph) is then permitted. During
tacking the following message will appear
on the MDM display CAUTION – SPEED
RESTRICTION – WHEEL TRACKING
OPERATING.
2. TRACKING-IN – Changing from
TRANSIT to WORK
Figure 3-11 Gauges and warning lights
Reduce the vehicle speed to 5 km/h (3.1
mph) and select work. Tracking-in does not
start until a speed of at least 2.5 km/h (1.6
mph) is achieved. The MDM will then
control the speed to a maximum of 3 km/h
until Tracking-in is complete. Speeds of up
to 15 km/h are then permitted. Again,
during Tracking-in the MDM display will
show the tracking message.
In addition the IQAN system also monitors
machine condition and will provide
warnings and information on the graphic
display (see Section 3.7).
3.3.6 Forward / Neutral /
Reverse
The front joystick switch on the front of the
control arm enables you to choose from
Forward, Neutral and Reverse mode.
Raise the safety ring while moving the
joystick from Neutral mode.
Figure 3-12 Joystick
Remember always to engage Neutral and apply
the handbrake before leaving the cab.
Getting Started
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Issue 4 – May 2008
3.3.7 Starting and
Stopping the engine
The wheels should start tracking out
(if not already tracked out) as you
are gaining speed, provided that you
are in Transit mode.
(For switch location see Section 3.2)
1. Engage Neutral
2. Get into transit mode
In Transit mode, you should drive
the machine almost as you would
drive a car with automatic
transmission. Remember the
machine has features such as a
seatbelt, a rear-view camera display
(where fitted – same use as a rear
view mirror) and indicators
Figure 3-13 Transit/Sweep/Brush Lift switch
3. Turn the ignition key
Figure 3-14 Ignition
4. When engine fires, leave it running
at low speed idle for 3 minutes, (In
cold weather leave on low speed idle
for 6 minutes), to allow hydrostatic
transmission oil to warm up.
Figure 3-15 Beacon switch
5. Switch on the rear camera display
(top left – where fitted).
6. Switch on the flashing beacon.
Whenever the vehicle is moving the
flashing beacon should always be
on.
7. Release the handbrake.
8. Engage Forward or Reverse.
9. Press gently on the speed control
pedal and the vehicle will start
moving. Always try to release the
speed control pedal slowly, so as to
get a smooth braking action.
Releasing the speed control pedal
too fast will cause harsh braking.
Figure 3-16 Rear view camera display
10. Stopping the engine. Prior to
switching off the engine directly from
Sweep mode (high engine speed),
first engage Transit mode and idle
the engine for 3 minutes before
switching off, in order to cool the
turbo.
3.3.8 Going up and down
pavement curbs
Never go up or down a pavement curb with
the brushes and nozzle down (always use
Brush Lift mode).
Never drive up and down pavement curbs
at too high a speed or too oblique an angle.
In exceptional circumstances when
mounting curb’s, one wheel may lose
traction due to uneven weight distribution.
In Brush Lift mode a limited slip differential
system is automatically engaged to prevent
the vehicle from coming to a stop due to
that wheel spinning.
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Issue 4 – May 2008
Figure 3-19 Transit/Sweep/Brush Lift switch
3.4.2 Water system
The machine is equipped with 3 dust
suppression water spray systems. The
water system deploys only when you are in
Sweep mode and Forward is selected.
Figure 3-17 Curb climbing
The dust suppression is supplied from
water tanks via a manifold, mesh filter and
an electric pump which are located at the
rear of the machine and can be accessed
by swinging open the rear water tank.
Cloudmaker
Figure 3-18 Curb climbing
3.3.9 Brush/Nozzle –
Raising in Transit Mode
After the machine has been parked up for
some time in Transit mode with the wheels
tracked out, the brushes and/or nozzle may
drop. To raise these before driving off, carry
out the following operation.
Start the engine and allow it to warm up,
move the mode switch into Sweep mode,
move the Forward/Neutral/Reverse joystick
into Forward and then into Neutral. This will
cause the IQAN to apply Brush/Nozzle Lift
for 4 s. Return the mode switch to transit.
3.4 Using the sweep
mode
A high-speed rotary atomizer, which
produces a cloud of very fine droplets in
front of the suction nozzle. These fine
droplets are very effective for suppressing
fine dust particles.
When sweep mode is selected the rotary
atomizer will descend with the Nozzle into
its working position and it will start rotating.
When the water rotary control switch is
moved to Position 1 (Sun symbol), a cloud
of atomized water will appear at the
Cloudmaker rotating spray head. In
Positions 0 (Heavy Rain symbol) and 2
(Light Rain symbol), the water supply to the
Cloudmaker water supply is switched off
(via a solenoid valve), but the Cloudmaker
motor continues to rotate in order to keep
the sintered spray head clean.
3.4.1 Switching to sweep
mode
With the engine running, use the top left
switch on the switch column to switch to
Sweep mode (switch in middle position.
Figure 3-20 Water rotary control switch
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Brush Spray Jets
System Protection
When the water rotary switch is in Positions
1 or 2, you can set the amount of water
supplied to the brushes by turning this
control needle valve (to your left).
If the water tank runs dry a sensing switch
will turn off the water pump.
If the Cloudmaker motor speed drops below
50% the MMU system will switch off
Cloudmaker and display an instruction to
switch off the water supply to Cloudmaker
(by turning the rotary control switch to
position 0 or 2). Inform your Supervisor.
Cloudmaker may be damaged if it is
supplied with water when it is not rotating.
Cloudmaker must be rotating before it is
fed water.
When using the brushes in a dry area,
make sure you use the front water jets.
Figure 3-21 Control valve
The jet can be cleaned by removing the jet
holder (half turn).
Suction Pipe Spray Jet
With spray water inside the suction pipe to
reduce mud build up in “sticky” conditions
when the rotary control switch is set to
Positions 1 and 2.
The spray jet is located on the right hand
side of the suction pipe just above the
suction hose. It can only be accessed for
maintenance by tilting the cab.
The following table shows the
recommended water control switch
positions for various sweeping conditions,
and the subsequent actions.
Hopper Drain
Provided the hopper drain switch (located
above the right hand switch column) is in
the ON position (switch down & lit), the
hopper drain will automatically open when
Sweep mode is engaged. The drain will
close when the suction stops.
Figure 3-23 Hopper drain switch
In certain sweeping conditions e.g. wet
weather conditions whilst sweeping in a
sensitive Pedestrianised area, it may be
required to close the drain even with the
suction fan operating. This can be achieved
by switching OFF the drain switch. In this
situation, in very wet conditions, water will
build up very quickly inside the hopper and
the machine may have to be taken to a
suitable discharge area.
If the water system does not work, check
the water tank level at the back of the
vehicle behind the hopper skirt (refer to
fault finding section if the water system still
does not work).
Figure 3-22 Control switch positions
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Issue 4 – May 2008
Filling the Water Tank(s)
Ensure water tank is in the stowed position.
Undo the cap on the top of the rear water
tank and insert a hose of 30mm (1.2 in.)
maximum outside diameter to allow
sufficient space for venting. Do not use too
high a flow or the water may enter the tank
faster than the air can be vented causing
damage to the tank.
Figure 3-24 Water tank level
The water mesh filter, located under the rear
water tank, must be cleaned regularly.
Always drain all water from the tank
when conditions are frosty.
To swing out the water tank, undo the
safety chain and then use the lever shown
on figure 3-23.
Sweeping on uneven Ground
When sweeping on exceptionally uneven
ground, one wheel may spin due to uneven
weight distribution. If this happens, engage
Brush Lift mode, in which case a limited slip
differential system will automatically be
engaged preventing wheel slip. Move to
even ground and re-engage Sweep mode.
3.4.3 Setting the brush
height
In order to sweep correctly, the brush
height needs to be set correctly. You do not
need to set the brush height each time you
engage sweep mode, but remember the
brushes require adjusting as they wear.
Figure 3-25 Water tank safety chain & lever
You may swing out the rear water tank in
order to:
•
•
•
•
The metal knob located on the left hand
side of your seat adjusts the brushes
height.
Clean the radiator
Get access to the water pump
Get access to the mesh filter
Get access to the water drain
In frosty weather all water must be drained
from the water tank in order to protect the
pump, filter, pipes and tanks. Swing out the
rear water tank to access the drain.
Figure 3-26 Brush height adjuster
Ensure the rear water tank is in the
stowed (home) position and securely
latched with the safety chain engaged
before driving the machine or tilting the
hopper.
Unlock the locking ring under the knob,
adjust and re-tighten the locking ring.
Use figure 3-25 to check the brush height.
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Issue 4 – May 2008
Figure 3-27 Brush height
3.4.4 Moving the brushes
sideways
There are two small joysticks on the control
arm. Each of them controls one brush. You
may use this feature when driving next to a
wall to clean as close to the wall as
needed. The swept track can vary from
1200mm (47.2 in) to 1800mm (70.9 in).
Figure 3-29 Impeller/brush rotary controls
Use the right hand side control to set the
brush rotation speed. The brush speed
should be set to the minimum speed
necessary to provide clean sweeping for
the forward speed being used.
The maximum brush rotational speed is
130RPM +/- 10%.
Use the left hand side control to set the
impeller rotation speed (the IQAN displays
the current speed).
The vacuum fan impeller speed should be
set to below 2400 rpm for normal sweeping.
Figure 3-28 Brush joysticks
The widest swept track available is
sometimes too wide for the sweeping
conditions. If debris/trash tends too be left
on the sides of the sweep path, try
narrowing the swept path. (Also, see
section 7 – Faultfinding).
3.4.5 Setting
impeller/brush speed
On the right hand side switch column are
the two rotary controls, shown in figure 329.
The speed can be set to above 2400 rpm
(boost) for a short time (up to 5 minutes).
When in boost the machine management
unit (MMU) will display a countdown bar
graph. If the speed is not reduced to under
2400 rpm within 5 minutes, the MMU will
shut off the fan and a buzzer will sound. To
reset the MMU fan speed limiting system
the machine must be stopped and the
Forward/Neutral/Reverse switch moved to
the Neutral position. The machine can then
be re-started and the impeller speed
reduced to below 2400 rpm.
To reset the MMU fan boost speed limiter
within a boost cycle, reduce the fan speed
below 2400rpm for at least 30 seconds or
the machine must be stopped and neutral
selected for 5 seconds on the
Forward/Neutral/Reverse lever (as above).
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Issue 4 – May 2008
The MMU will restrict boost to a maximum
of 5 boost periods per hour. After 5 boost
periods, the fan speed will be limited for the
remaining part of the hour to approximately
2300rpm.
To turn the impeller on/off while sweeping,
use the appropriate column switch.
Figure 3-31 Hopper over center catches
Simply pull to unlock the catch and
ensure the catch is fully open before
attempting to raise the hopper.
Figure 3-30 Impeller switch
For normal sweeping the impeller speed
does not need to be greater than 2400 rpm.
Figure 3-32 Unlock catch
The machine may be operated for short
periods of time with the impeller above this
speed (up to 2700 rpm) but if the impeller
speeds greater than 2400 rpm are
continually required then the machine is
being over-tasked or has a blockage (see
section 8 – fault finding).
3.4.6 Tilting the hopper
Figure 3-33 Opening catch
2. Switch to sweep mode (so that the
engine revs. are high enough to tilt
the hopper).
There are two situations where you will
need to tilt the hopper:
•
•
In order to empty it (unlock catches)
In order to access the fan casing or
engine (do not unlock catches)
Figure 3-34 Sweep/Transit/Brush Lift switch
In order to empty the hopper
1. Before you tilt the hopper, always
unlock both over center catches, as
shown in figure 3-28.
3. Engage neutral.
4. Press the hopper switch (up) until
the hopper is fully tilted.
Figure 3-35 Hopper switch
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Issue 4 – May 2008
Figure 3-36 Hopper raised
Figure 3-38 Safety stay in position
5. Remove all remaining debris/trash
from the inside of the hopper, using
the scraper provided (inside the right
hand access door).
6. Before lowering the hopper ensure
that the rear water tank is closed to
prevent the hopper door from
damaging the water tank.
7. Press the hopper switch (down) until
the hopper is in its normal position.
8. For manual tilt of the hopper see
section 10.
Before tilting the hopper ensure that the
machine is on level ground.
In order to access the engine of the fan
casing
When tilting the hopper to access the
engine area, do not unlock the two over
center catches. Always make sure the
hopper safety stay is in place before
leaning into the engine bay.
Put the safety stay in its position as shown
in figures 3-35 & 3-36.
Always remember to remove and re-stow
the safety stay prior to lowering the
hopper.
3.5 Whoosh hose
3.5.1 Using the whoosh
hose
The whoosh hose is fitted to the machine to
allow the operator better flexibility.
Use the whoosh hose to clean an area you
cannot sweep directly using the machine
(between cars).
1. Switch off the engine and apply the
handbrake.
2. Open the left hand access cover on
the front of the hopper.
3. Unclip and remove the blanking
plate.
Figure 3-37 Hopper safety stay
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Issue 4 – May 2008
3.6 Cab comfort
3.6.1 Cab temperature
Use the knob on your left hand side, figure
3-37, to set the level of the cab heating
system.
Figure 3-39 Whoosh hose suction spigot
4. Fit the whoosh adaptor to the suction
spigot and clip in place.
5. Restart the engine and start the
suction fan via the whoosh switch.
Figure 3-41 Temperature knob
The switch turns the heater fan on/off.
Figure 3-40 Whoosh switch
6. Hold the whoosh by the handle.
Figure 3-42 Heater switch
Air vents are located on both sides of the
cab.
3.5.2 Unblocking a
blocked whoosh hose
Under normal operating conditions the hose
should function effectively. However it is
possible that the hose may become
blocked.
To clear a blocked hose:
Figure 3-43 Air vents
1. Switch to Sweep mode.
2. Remove the whoosh hose from its
stowage.
3. Slowly and carefully squeeze the
hose along its full length until the
blockage is found.
4. Squeeze carefully the blockage area
until the blockage is heard the
impeller casing.
See also 5.3 for Air Conditioning option.
3.6.2 Other devices
Radio/CD player
A comprehensive manual is provided along
with the machine. Here is summary of the
functions provided by the radio/CD player.
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Issue 4 – May 2008
•
Figure 3-44 Radio/CD player
For Instructions on the Radio/CD player
please refer to the manufacturer’s manual.
Soft drink can holder
The XT2 and XS are the “slaves”,
and take orders from the MDM and
actually control the different
elements of the machine. ONE XT2
is located inside the back panel of
the cab, on the left hand side and
one on the chassis frame, under the
cab on the right hand side. The XS is
located on the rear let hand ceiling of
the cab roof.
The MMU is also sometimes referred to by
its proprietary name, IQAN.
3.7.1 “Brain” & display
Shown in figure 3-46 is a view of the MDM
(located top right of the windshield)
Figure 3-45 Soft drink can holder
Please note a storage net is fitted on the
seat molding.
Figure 3-46 MDM
The windscreen is electrically heated for
de-misting. Because of the high current
draw it switches off automatically after 10
minutes.
With the machine on and running, the
Display will show the operational window
corresponding to current movement mode
(Transit, Sweep, Brush lift mode).
3.7 Electronic
control system
(“brain”)
Pressing the Escape key will enter the
Menu System. There are five different
menus:
The 636 is controlled by an electronic
Machine Management system (MMU) using
four main modules:
•
The MDM is the “brain” of the 636.
It has a graphic display and several
function keys. It is located top right
of the windshield.
•
•
•
•
•
In the sub menus, use the Escape key to
return to the previous menu level. Use the
function keys (F1, F2 and F3) to select the
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Information menu
Settings menu
Measure menu (workshop use only)
Properties menu (factory use only)
38
Issue 4 – May 2008
different functions in the sub menus (above
each key is a tab displaying the key
function).
3.7.2 To set the engine
speed during WORK mode
1. With the engine running, the
work/transit switch in WORK mode
and the Forward / Neutral / Reverse
lever in any position.
sound and the engine speed will
automatically be reduced to 2600. To
cancel the buzzer and reset the MMU
engine speed control, enter the engine
speed menu (See 3.7.2. 1 to 4) and
scroll down the speed to under 2600.
6. When sweeping uphill it may be
necessary to increase the engine
speed in order to obtain more power.
See 3. above. When the hill climb is
complete the engine speed should
be reduced back to your original
value.
The VACUUM FAN SPEED is shown on
the display; however you cannot set the
impeller speed using the IQAN unit.
(VACUUM FAN SPEED is set using the
rotary speed control on the switch panel on
your right hand side). See section 3.4.5.
Figure 3-47 IQAN – F1 Select
2. Press F1 (select)
3. Use Up and Down keys to select the
engine speed (between 1200 and
2800 rpm) (but see 5. below).
4. Choose between:
•
•
•
•
OK (F1): confirm the new speed
Cancel (F2): the engine comes back
to its previous speed
Reset (F3): the engine speed is set
to 2200 rpm (Default value)
The engine speed should normally
be set to below 2600 rpm.
Figure 3-48 Vacuum fan switch
If you try to start the machine with Forward
or Reverse engaged, the IQAN will disable
the transmission for safety reasons.
Engage Neutral to be able to use the
transmission again.
5. High speed boost (above 2600) is
available but is limited by the
Machine Management Unit (MMU) to
10 minutes maximum and a
maximum of 3 10 minute periods per
hour.
Figure 3-49 IQAN – Transmission disabled
When boost speed (above 2600) is
selected a countdown bar graph will
appear on the MMU display. If the
engine speed is not reduced below
2600 within 10 minutes a buzzer will
If either of the following occurs a beeper will
start and the MDM will display the message
shown in figure 3-50.
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Issue 4 – May 2008
•
•
•
Engine coolant temperature reaches
115°C.
Hydraulic oil temperature reaches
95°C.
Engine air filter blocked.
and refer to Section 7 (faultfinding). If you
cannot resolve the problem, do not try to
start the engine again and contact your
supervisor).
3.7.3 “Slave”
Figure 3-51 shows a view of one of the
XT2’s (located inside the back panel of the
cab, on the left hand side).
The XT2’s have two LED’s:
•
•
Figure 3-50 IQAN – Engine system fault
If the above message should appear the
following actions should be taken:
•
•
•
•
•
•
Switch off the engine.
Check the air filter minder (AFM)
(located in the engine compartment
on the intake pipe between the air
cleaner and the engine turbo). If the
air filter has blocked, the AFM will
have tripped and be showing a red
ring (normal is green). The air filter
element will then require changing,
and the AFM resetting (Service
personnel task).
If the AFM is showing green, then
the fault will be high temperature,
either engine coolant or hydraulic oil.
Check the coolant header tank for
correct coolant level (located above
and beside the fuel tank at the front
of the engine compartment).
Check the hydraulic reservoir for
correct fluid level (left hand side of
vehicle, mid wheel base).
Allow the cooling system to cool
down and check the debris guard –
screen is clean (located between the
engine cooling fan and the radiator).
The green LED indicates the power
is on.
The other LED indicates the XT2
status:
o Yellow flashing means the
status is normal (no errors)
Red flashing means an error has occurred.
Figure 3-51 XT2 - Cab
The other XT2 is located on the chassis
under the cab.
Whenever the MDM requires you to stop
the vehicle, please do so. Stop the engine
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Issue 4 – May 2008
The flashing warning beacon on top of the
machine can fold if hit by an obstacle when
driving under a low roof. Excluding the
folding beacon, the machines height is
19800mm (78 in). You will notice when the
beacon folds as it will flash through the cab
rear window.
Figure 3-52 XT2 - Chassis
The XS slave unit is located in a recess at
the rear, left hand side of the cab head
lining. The XS has three LED’s:
•
•
The top green LED indicates the
power is on.
The middle and bottom LED’s
indicates the XS status:
o Middle and top flashing
alternately means the status
is normal (no errors)
o Middle and bottom flashing
means an error has occurred.
Figure 3-54 Beacon switch
Using the flashing beacon and the lights
according to local regulations.
Tilting the cab
The can be tilted for maintenance reasons,
and should never be tilted otherwise.
Before driving the machine, always make
sure the cab lockdown bracket on the right
hand side of the machine, as shown in
figure 3-55a is secured and that the safety
hook on the left hand side of the machine is
engaged see figure 3-55b.
Figure 3-53 XS
3.8 Safety features
and procedures
Figure 3-55a Lockdown Must be Secured
Some of the information in this section has
been covered in other sections, but has
been repeated for your safety and the
safety of others.
Folding beacon
Figure 3-56b Hook Must Be Engaged
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Issue 4 – May 2008
Important safety notes summary
Always remember the Do’s and Don’ts
(Sections 2.2 & 2.3)
Always make sure that all the machine
labels are in place, intact and readable.
Always apply the handbrake and remove
the ignition key when leaving the vehicle.
Always make sure the cab safety switch
is secured before driving the machine.
Always be aware of the machine gauges
and beacons.
Never work under the hopper without the
safety stay being on (remember to
remove the safety stay before lowering
the hopper).
Always carry out a full operator check at
the beginning of each shift (see section 4
and check list in section 2).
Figure 3-57 Fuse Box 1
Always carry out a full wash down
procedure at the end of each shift (see
section 6 and check list in section 2).
No welding repairs should be carried out
on the machine without disconnecting
electronic components (see section 10).
If in doubt use the faultfinding guide in
section 7.
Always report any defects.
3.9 Fuse boxes
There are four fuse boxes on the vehicle.
The three component fuse boxes are
located on the right hand side of the
vehicle, next to the windscreen. Unclip the
cover to access the fuses.
Figure 3-58 Fuse Box 2
Use figures 3-56, 3-57 and 3-58 to identify
which element the fuse protects.
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Issue 4 – May 2008
Figure 3-60 View on fuse box
In addition there is a Battery fuse box
located above the battery next to the
coolant header tank. This box contains
three 40amp and one 60amp fuse. These
can be accessed by unscrewing the lid of
the box. When replacing the lid ensure that
the seal is intact.
End of chapter
Figure 3-59 Fuse Box 3
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Chapter 4 Operator Checks
Operator Checks
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Always carry out the operator checks
with the engine stopped and when the
machine is clean.
4.1 Daily operator
checks
1. Start the engine and tilt the hopper.
Apply the hopper safety stay.
Switch off the engine.
Under no circumstances should
anyone work under the hopper without
the safety stay being in place.
The operator checks should be carried out
at the beginning of each shift.
Figure 4-1 shows a view of the left hand
side of the machine.
2. Remove the left hand side panel.
Store it in a safe place as it is fragile.
3. Check hydraulic oil (located on oil
reservoir between front and rear
wheels). Oil type – Turbo Diesel
Engine Oil 15W40 Grade API
CF/AECA 2.
Figure 4-3 Hydraulic oil level
4. Open the left hand side access door.
Top up hydraulic oil as required.
Figure 4-1 Operator checks
Figure 4-4 Hydraulic tank
5. Replace the left hand side panel.
6. Check brake fluid reservoir level (in
front of the steering wheel).
Note: by that time the engine oil should
have settled enough for you to check the
level.
7. Check engine oil (yellow dipstick
gauge).
Figure 4-2 Fan inspection access cover
Operator Checks
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Issue 4 – May 2008
Figure 4-8 Fuel tank
11. Check the filter minder (once the
filter minder has switched to red, it
will stay red, even when the engine
is switched off).
Figure 4-5 Dip stick
8. Top up engine oil as required.
Figure 4-6 Engine oil
9. Top up main dust suppression water
tank. (Back if the vehicle, behind
debris skirt).
Figure 4-9 Filter minder
Figure 4-10 is a view of the elements
located behind the cab.
Figure 4-7 Rear water tanks
10. Top up fuel tank. (Open right hand
side access door).
Figure 4-10 Rear view of cab
12. Check the engine coolant header
tank. Top up as required with 50/50
Permanent Ethylene Glycol/water
mixture. (Behind the cab).
Operator Checks
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Issue 4 – May 2008
Figure 4-11 Engine coolant header tank
13. Checks lights and beacon.
14. Check brush wear – replace as
required.
15. Check nozzle height – The sole of
the polyurethane wear plate should
be 10mm above the ground.
16. Check tires for correct pressure (see
section 8.9) and condition.
17. Look around the machine checking
for damage.
18. Check all safety devices.
4.2 Weekly operator
checks
1. Clean water filter
Figure 4-12 Water filter
2. Check tires for wear.
End of chapter
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Issue 4 – May 2008
Chapter 5 Options & Accessories
Options & Accessories
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Monitor
5.1 Rear-view
camera (Optional)
7. POWER LED
When the red LED is turned on, it
indicates power on.
The rear-view camera is used like an
interior rear-view mirror.
When reverse is selected, the image
shown by the camera will be shown
on the monitor.
Rear-view camera (on the hopper).
8. Power ON/OFF switch
▲+, ▼-, CONTROL BUTTON
These control buttons are used to
scroll up and down to select menu
options.
9. “MENU” Button
Figure 5-1 Rear-view camera
If necessary, carefully clean the camera
lens using a soft cloth.
Rear-view camera display (left hand side in
the cab).
If you press the “MENU” button, the
following list of options will be shown
on the monitor.
PICTURE
SYSTEM
OPTION
CLOCK
The menu list will disappear if no
selection is chosen in 2 seconds.
10. SEL.
SELECT CONTROL BUTTON
Use these buttons in order to select
the option.
Figure 5-2 Rear-view camera display
Functions and Operation
11. Camera selector button.
Enables selection of CA1 and CA2.
The OSD indicates which camera is
currently operating.
12. REMONTE CONTROL SENSOR
The monitor can be operated via
remote control. If using remote
Figure 5-3 Monitor functions
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Issue 4 – May 2008
Remote Control
control, ensure that the IR on the
remote is facing the monitor.
How to select your monitor
requirements
PICTURE CONTROL
1. Press the “MENU” button.
2. Select “PICTURE”.
3. Move the cursor to the “CONTRAST,
BRIGHT, COLOUR, SHARP AND
TINTS” with the SEL button.
4. Press the “▲+ or ▼-“ button.
5. Select one of the five options.
6. Press the “MENU” button.
SYSTEM CONTROL
1. Press the “MENU” button.
2. Select “SYSTEM”.
3. Move the cursor to the “INPUT,
COLOUR, SYSTEM, BLUE BLACK,
LANGUAGE” with the SEL button.
4. Press the “▲+ or ▼-“ button.
5. Select one of the five options.
6. Press the “MENU” button.
OPTION CONTROL
1. Press the “MENU” button.
2. Select “SEL”.
3. Move the cursor to the
“HORIZONTAL, VERTICAL” with the
SEL button.
4. Press the “▲+ or ▼-“ button.
5. Select one of the two options.
6. Press the “MENU” button.
CLOCK CONTROL
1. Press the “MENU” button.
2. Select “CLOCK”.
3. Move the cursor to the “TIME, ON
TIME, OFF TIME, ATTENTION, CHTIME” with the SEL button.
4. Press the “▲+ or ▼-“ button.
5. Select one of the five options.
6. Press the “MENU” button.
Figure 5-4 Remote control functions
1. MODE
Press the mode button for the
following options for picture settings;
Standard, Soft, Vivid, Light and
Personal.
2. POWER (Power switch)
Press this button to turn on and off
the monitor.
3. MUTE (Mute)
Press this button to mute, press it
again or ▲+ or ▼- to resume normal
sound.
4. CALL
This button displays which camera is
being viewed.
5. TIMER
The timer can be set to automatically
switch off the monitor (120 minutes
maximum).
6. E/G
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Issue 4 – May 2008
Press this button to select either
English or German.
DO NOT spray close to engine air intake
stack inlet, as this can cause permanent
damage to the engine.
7. CALE
Press this button to show calendar
by Year, Month, Day and Week.
Press ▲ or ▼ to make relevant
adjustments.
Avoid jetting electrical areas on the
machine (wiring, plugs, sockets, electrical
junction boxes, safety switches & lights).
Avoid close jetting of the tires as the highpressure jet may damage the side walls.
8. VIDEO (CA1/CA2 shift)
The pressure washer takes its water from
the dust suppression tanks via a filter. This
filter should be carefully cleaned
periodically. If the water tank should run
dry, switch off the pressure washer
immediately.
Press this button to shift between
CA1 and CA2.
This button flips the
picture horizontally.
The oil reservoir may require topping up
from time to time. There is a sight glass for
checking the oil level. Use Turbo Diesel
Engine Oil 15W40 Grade API CF/ACEA 2.
This button flips the
picture vertically.
5.2 Pressure Washer
(Optional)
The pressure washer is used to clean the
machine. It comprises a hydraulically driven
high pressure pump (90 Bar) which pumps
water to the spray nozzle via a hand held
lance. Always hold the lance with 2 hands.
The pressure washer is started by
operating the switch with the “Lance-spray”
symbol. The engine must be running with
the mode in sweep position (mid position)
and the Forward/Neutral/Reverse lever in
Neutral. The Lance id removed from the
holder and the hose is pulled out from the
storage area. Point the Lance spray nozzle
towards the ground and pull the Lance
trigger.
Figure 5-5 Pressure washer lance
Figure 5-6 Pressure washer switch
DO NOT point the spray nozzle at people
or animals, as the high pressure spray can
cause serious injury.
In frosty weather drain down the water
system to protect pump, filter, pipes and
tanks.
After use, switch off the pressure washer
switch and carefully stow the hose and
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Issue 4 – May 2008
lance in their respective storage locations,
behind the suction fan door.
reason the machine cannot sweep when
street washing.
Figure 5-7 Pressure washer lance stowed
The hopper contains a special filtration
cartridge that is located inside the hopper,
laid along its floor. The cartridge is
protected by a guard and can be withdrawn
from the side of the hopper for cleaning.
When the extra water in the hopper is used
up, a 3-way valve can be turned to allow
the water in the dust suppression tanks to
be used.
Never point the spray at people or
animals.
5.3 Street Washer
Model – 636SW
Introduction
The Street Washer 636SW is a dual
function machine, which can perform both
functions of Sweeping and Street Washing.
The machine cannot Sweep and Street
Wash simultaneously. However changing
over from one function to the other is
relatively quick does not involve the use of
tools.
The street washer comprises a highpressure reciprocating piston water pump
driven by a hydraulic motor. The pump
feeds high-pressure water to a folding
boom spray bar located at the front of the
machine. Operating one of the brush
control joysticks can hydraulically slew this
spray bar from side to side. The joystick
changes function when Street Wash is
selected. The spray bar is hinged in the
center and will fold to avoid damage if it
accidentally contacts an obstacle when
moving in the forward direction. The spray
bar can be folded up and stowed out of the
way in front of the cab windscreen when
the machine is being used as a sweeper.
Preparing to Street Wash
The hopper must be emptied (tip the
hopper) and thoroughly washed out. Check
that the hopper filter is clean by undoing the
toggle clamps on the right hand side of the
hopper and withdrawing the cartridge.
Clean the textile sleeve. Undo the screw
cap and withdraw the stainless steel mesh
filter. Clean the mesh filter if necessary.
Fold down the hopper fan duct sealing
diaphragm (to prevent water surging out of
the hopper into the suction fan casing
during braking).
Figure 5-8 Street Washer
Because street washing requires large
amounts of water, extra water has to be
loaded onto the machine. The water is
loaded into the refuse hopper. This is the
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Figure 5-9 Fan duct sealing diaphragm
Figure 5-10 3-way valve & filter
Lower the hopper.
If a pressure washer is fitted, turn the high
pressure 3-way valve on left hand side of
the machine to “Street Washer” position –
open the LH access panel.
Check the pump inlet filter for cleanliness
(located above the rear left hand
suspension spring/damper unit). Swing out
the rear dust suppression water tank.
Open the hopper fill/vent point on the left
hand side of the hopper intake duct. Insert
a 30mm water hose and fill the hopper up
to the level of the fill point – about 380
liters. DO NOT over fill. Close the filler/vent
cover. DO NOT fill the hopper through the
hopper door as over filling may occur,
which will overload the vehicle.
DO NOT over fill
Figure 5-11 3-way valve
DO NOT fill the hopper through the
hopper door
Fold down the spray bar at the front of the
machine and lock in place.
Ensure that the FAN switch on the right
hand column switched to OFF and that the
brush speed control is set to the zero
speed.
In frosty weather drain down the water
system to protect pump, filter, pipes and
tanks.
Fill the rear dust suppression water tank
using a 30mm hose – about 9 Liters.
Move the 3-way valve to the “Hopper”
position – located above the rear left hand
suspension spring/damper (swing out the
rear water tank).
Start the engine, engage Sweep mode and
switch on Street Washer (switch is on the
header). Engage forward drive on the
Forward/Neutral/Reverse lever switch.
Figure 5-12 Pressure Washer/Street Washer
Switch
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Issue 4 – May 2008
The sprays on the spray bar will start
spraying – it may take 1 or 2 minutes to
obtain a full spray pattern with the fan
sprays meeting. If full spray is not available
within 2 minutes, switch off the Street
Washer and check for blockages and
correct valve pressure.
DO NOT run the street washer pump fir
periods in excess of 2 minutes with no
water passing through the pump, as
permanent damage to the pump will result.
Use the left hand Brush control joystick on
the control arm to slew the spray bar from
side to side. Operating the spray bar at
angle will wash debris to one side of the
washed path.
The spray bar fan sprays should just meet
at the ground. If there are gaps between
the sprays, raise the spray bar using the
rotary height adjuster at the rear of the
spray bar suspension bracket.
The water in the hopper will provide about
25 minutes of street washing. When the
hopper becomes empty, this will be
indicated by the sprays becoming
intermittent. If the street washing task is not
completed an extra 12 or 8 minutes of
street washing can be obtained by using
the water in the dust suppression water
tanks (there are 2 of these connected
together). The water is accessed by
swinging open the rear water tank and
turning the 3-way valve to “Water Tank”.
Close the rear water tank. The street
washer pump will not draw water from the
dust suppression water tanks.
DO NOT run the street washer pump for
periods of 2 minutes with no water
passing through the pump
DO NOT let the high pressure sprays
impinge on people or animals
DO NOT continue to operate the Street
Washer pump when there is no water in
the system
Returning the machine to
SWEEP mode
Ensure the hopper is empty water. If a
significant amount of water (more than 50
or 60mm) still remains in the hopper, drain
it out by deploying the “wet weather”
drogue on the front left hand side of the
hopper.
Tip the hopper and fold up and stow the fan
ducting seal diaphragm.
Ensure that the 3-way valve (above the
suspension spring) is set to “WATER
TANK” to prevent dirty water from the
hopper accidentally entering the dust
suppression water circuit.
Ensure the STREET WASHER switch on
the header switch panel is switched to OFF.
Switch the fan switch to ON.
Select SWEEP mode, set up fan and brush
speeds and commence sweeping.
Using the Pressure Wash
Lance (where fitted)
DO NOT let the high pressure impinge on
people or animals.
Ensure that the front 3-way valve (located
behind the left hand access panel) is set to
“PRESSURE LANCE” and that the rear 3way valve is set to “WATER TANK”.
DO NOT continue to operate the Street
Washer pump when there is no water in
the system.
Check that there is sufficient water in the
rear water tank.
Select SWEEP mode and check that the
engine speed is above 1800rpm.
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Issue 4 – May 2008
circulation fan blends re-circulated air with
fresh air.
Switch the Pressure Lance switch to
“PRESSURE LANCE”.
Ensure that the handbrake is set and that
the Forward/Neutral/Reverse control is set
to Neutral.
Open the left hand access panel and
withdraw the pressure lance and unreel
sufficient hose. Using both hands hold the
pressure lance firmly and pointing the spray
nozzle towards the ground, press the
trigger.
DO NOT run the high pressure pump for
sustained periods with the pressure
lance trigger closed, as the pump will be
on high pressure bypass and will
eventually overheat.
DO NOT run the pump with no water in
the system.
DO NOT run the high pressure pump for
sustained periods with the pressure
lance trigger closed
DO NOT run the pump with no water in
the system
Prior to tilting cab ensure that Street
Washer spray bar is folded up and parked.
Fold up spray bar before tilting
5.4 Air Conditioning
(Optional)
The Air Conditioning (AC) operates via an
engine driven compressor which is
equipped with an electro magnetic
engagement clutch.
The air is cooled in an evaporative located
behind the drivers headrest. A circulation
fan passes air through the evaporator and
along a roof duct on the right hand roof rail.
The air exits at 2 ducts in this area. The
ducts have directional grilles which can be
altered to direct the flow if air. The
Figure 5-13 Air conditioning vents
The excess heat is rejected on a condenser
heat exchanger mounted on the outside,
front area of the roof. Electrically operated
twin fans circulate cooling through the
condenser.
Prior to switching on the AC, ensure that
the Heater Control on the left hand side of
the drivers seat is turned off. The heater air
circulation fan will automatically be
switched off when the AC is switched on.
The AC is switched on via the AC switch
(snowflake symbol) on the right hand switch
column of the cab. It has 2 positions. Use
position 1 for normal cooling and position 2
for boost. The engine must be running. The
window and the roof latch should be closed
when the AC is operating to prevent all
cooled air from escaping from the cab and
being replaced with hot air from outside. In
hot, humid conditions water will condense
on the evaporator surface. The water
escapes to the outside of the cab via a
drain duct. Water dripping from this duct
under the cab is quite normal.
Figure 5-14 Air conditioning switch
Ensure that the cab window and roof
hatch are closed when the AC is
switched on
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Issue 4 – May 2008
5.5 Automatic
Greasing (Optional)
Introduction
The Interlube AC lubrication system has
been specifically designed to provide
reliable and virtually maintenance free
service. The AC lubricator and its
accessories are ruggedly constructed for
faultless operation in the most demanding
applications.
The AC system is wired via a relay to the
vehicle “SWEEP” mode system. The
lubrication system only operates when the
machine is in SWEEP mode and with the
Forward/Neutral/Reverse switch in
Forward. In operation the cam rotates
operating each pumping unit in turn
injecting a measured amount of lubricant
into each supply line. During operation a
green indicator light shows on the reservoir
top cover. To check for satisfactory
operation, press the TEST button on top of
the unit. This will start the motor and the
paddle can be seen to rotate in the
reservoir. It will rotate once in about 3
minutes before re-setting to its normal 1
rotation every 12 minute period.
A 2A inline fuse is used.
The pump cycle time is 12 minutes and is
not adjustable.
Maintenance
Figure 5-15 Automatic greasing location
In common with other electro mechanical
devices however, proper operation
procedures must be carefully observed.
Operation
The AC lubricating system comprises an
electrically operated lubricator and a loom
of tubing connecting each chassis bearing
to its own respective pumping unit. The
lubricator consists of a 1.25 liter reservoir,
housing the electronic control, electric
motor and drive. The top cover incorporates
a filler cap for semi-fluid grease. Housed in
the reservoir is a twin-blade impeller
designed to draw grease evenly into the
pumping chamber and give a full visual
indication of cam rotation. Attached to the
reservoir is a carcass ring, which houses
the cams and pumping units (red
0.010cc/shot, green 0.015cc/shot, yellow
0.025cc/shot, blue 0.040cc/shot, silver
0.060cc/shot and black 0.100cc/shot). This
machine is fitted with 34, blue
(0.040cc/shot) pumping units.
As an owner of an Interlube AC system the
only maintenance you should find
necessary is to periodically check the
reservoir lubricant level, topping up with the
recommended lubricant as necessary, and
occasionally checking the condition of loom
connections.
At all times observe the following for fault
free operation.
•
•
•
Use semi-fluid grease specification
NGLI 000EP.
Ensure stored lubricant is kept clean
at all times.
After filling the reservoir make sure
the filler cap is secured.
If the system should fail to operate
satisfactorily the following diagnostic and
remedial advice will help to identify and
correct any fault.
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Issue 4 – May 2008
Fault Finding
rotating replace motor/gearbox
assembly.
All lubrication points are dry
One or more (but not all) lubricant
points are dry
13. Cause: The lubricant reservoir is
empty.
Action: Refill the reservoir and
ensure that all supply pipes are free
from air.
1. Cause: Pipes supplying the dry
lubrication points have worked loose
from their connection.
Action: Check pipe connections and
re-connect where necessary. Ensure
sufficient tubing allowance,
particularly on King Pins and other
moving lubrication points.
14. Cause: The reservoir has been filled
with an unsuitable lubricant.
Action: Drain the reservoir and
thoroughly flush the system using a
light mineral oil. DO NOT USE
SOLVENT CLEANERS. Refill with
the correct grade lubricant.
15. Cause: The power supply has failed
and the indicator light will not
illuminate.
Action: Check the main supply.
Check 2A fuse, which must be fitted
to protect the installation. If the fuse
has blown there may be a fault with
the supply to the unit. Check the
cable for damage/short circuits
before fitting another fuse. Check
continuity of wiring to the unit.
16. Cause: The printed circuit board has
failed.
Action: Check main power supply
(see A3 above). Check power in at
+ve and –ve on PCB. Check power
out on PCB at MM (to motor). NB
Power out is AC. If no power out,
replace PCB.
17. Cause: The motor/gearbox assembly
has failed.
Action: Check for correct AC supply
to motor (see A4 above). If power
supply is correct but motor not
2. Cause: Pipes supplying the dry
lubrication points are damaged or
crushed.
Action: Install new pipes, re-routing if
necessary to avoid repeat damage.
3. Cause: No output from pumping
units due to blockage.
Action: Empty the reservoir and
replenish with new, clean lubricant of
a suitable grade. Fit new pumping
units. Do not attempt to clean and
reuse blocked units could result in
further problems resulting in damage
to bearings.
5.6 Winter
Equipment - Optional
Introduction
636 can be fitted with the following optional
winter equipment:
1.
2.
3.
4.
Front Snowbrush.
Front Straight Plow Blade.
Front V Plow Blade
Rear Gritter
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Issue 4 – May 2008
In order to fit these options, the machine
must have special preparations fitted at the
factory.
The Winter Equipment must be fitted and
removed from the machine by a suitably
qualified mechanic, who will ensure that the
control system is correctly activated (and
de-activated on removal)
The Front Snowbrush is powered by the
Suction Fan hydraulic system. A selector
switch and solenoid valve(s) re-directs the
flow of oil from the Suction Fan to the
Snowbrush. Note it is essential that the
Snowbrush switch is NOT selected when
the Snowbrush hoses are disconnected
from the quick-connect couplings as this
will direct the oil to a dead end causing the
pressure relief valve to operate
continuously. This will lead to the
overheating of the oil and possible damage
to the hydraulic pump. The fitting mechanic,
on removal of the equipment, must deactivate the selector switch system, or, on
earlier machines de-activate the solenoids
by inserting the dummy loom.
The rear Gritter is powered by the Front
Sidebrush system. A selector switch and
solenoid valve re-directs the flow of oil from
the Sidebrushes to the Gritter. Again it is
essential that the Gritter switch is NOT
selected when the Gritter is not on the
vehicle or dead-heading of the circuit will
occur. The fitting mechanic, on removal of
the equipment, must de-activate the
selector switch system, or, on earlier
machines de-activate the solenoids by
inserting the dummy loom.
The Snowplough Blades can be slewed
using the Sidebrush slewing system (The
joysticks on the control pod). The right hand
system is used for the Straight blade and
the right hand and left hand systems are
used for the V Blade.
Operation
The equipment will only operate when the
machine is in Sweep (Work) Mode (See
section 3.4) with the
Forward/Neutral/Reverse selector in
Forward.
To operate the Snowbrush, operate switch
(Item 1) and control speed with Fan Speed
Potentiometer (Snowbrush is connected to
Items 7&8).
Figure 5-16 Switch location
Item 1 – Snowbrush switch
Item 2 – Gritter switch
Figure 5-17 Connector locations
Items 7&8 – Hydraulic connectors for
Snowbrush
Items 9&10 – Hydraulic connectors for Straight
Plough Blade
Items 9, 10, 11&12 – Hydraulic connectors for V
Plough
To operate the Gritter, operate switch (Item
2) and control speed with Brush Speed
Potentiometer (Gritter is connected to Items
5&6).
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Issue 4 – May 2008
Equipment) or on later vehicles the
appropriate isolation switch must be
activated.
T
5.7 Acto Bac
Figure 5-18 Connector locations
Item 4 – Electrical socket for lights on Gritter Box
Items 5&6 – Hydraulic connectors for gritter
The Straight Plough is connected to
connectors (Items 9, 10, 11&12) and is
controlled by both Brush Joysticks.
Acto bac is an environmentally friendly
product which when added to the dust
suppression water system.
1. Helps to reduce fungal growth in the
water system.
2. Has a high germ kill rate.
3. Leaves a pleasant fragrance after
being applied.
4. Improves dust suppression.
5.8 Ice X
Ice X is an environmentally friendly de-icer
which;
Figure 5-18 Hydraulic Control Block
Item 3 – Hydraulic Control Block
When the Winter Equipment is fitted the
Suction Nozzle must be raised up by the
chains to prevent it dragging on the ground
whilst using the Winter Equipment.
Fitting and Maintenance
The Winter Equipment must only be fitted
and removed from the 636 machine by a
suitably qualified mechanic.
After fitting or removal the machine’s
control system must be configured (deconfigured) for correct operation of the
hydraulic system.
This involves activating (de-activating) the
solenoid valves which re-direct oil from the
Fan and Sidebrush systems to the Front
Snowbrush and Gritter.
The appropriate solenoid electrical
connections must be connected (and
disconnected upon removal of the Winter
5.
6.
7.
8.
De-ices frozen paths or sidewalks.
Stops the formation of ice.
Prevents snow from settling.
Remains effective for days
(Assuming no rainfall occurs).
The Ice X is added to the water tank in a
neat solution and is sprayed onto the
ground via the front brush sprays.
End of chapter
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Issue 4 – May 2008
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Issue 4 – May 2008
Chapter 6 The wash down
.
The Wash Down
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Issue 4 – May 2008
The Wash Down
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Issue 4 – May 2008
At the end of each shift it is important to
wash the machine and components
correctly using a fresh water hose.
Always remove ignition key before
starting to strip the machine down.
1. Unlatch the hopper door and tip out
any debris, which may be in the
hopper. Leave the hopper in the up
position. Fit the hopper safety stay.
2. Switch the engine off and remove
the ignition key. (DO NOT WASH
THE MACHINE WITH THE ENGINE
RUNNING).
3. With the engine switched off open
the side access doors and remove
the plastic side covers and store in a
safe place. Wash out the nozzle
suction pipe and down the inside
casing and down the inside of the
suction hose. Wash the area around
the engine bay.
Figure 6-2 Hopper cyclone ‘can’ area
5. Put the screens back and wash the
outside of the hopper.
6. Lift out the radiator screen and clean
thoroughly. Re-fit the screen.
Figure 6-3 Radiator screen
Figure 6-1 fan casing
4. Wash inside the hopper. Hinge down
the hopper door screen and wash
thoroughly. Also wash out the
cyclones, paying particular attention
to inside the hopper cyclone ‘can’
area and the cyclone entry swirl
vanes on the top of the cyclone can.
7. Swing out rear water tank and wash
the radiator matrix taking care not to
damage the cooling fins.
8. Ensure that the rear water tank is
swung closed before lowering the
hopper to avoid the hopper door
damaging the water tank.
9. Clean the suction fan – see section
2.2.2.
10. Wash the rest if the machine
checking that the area around the
hydraulic tank is clean, taking care
not to jet wash close to the hydraulic
oil filler/vent.
The Wash Down
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Issue 4 – May 2008
Figure 6-4 Hydraulic oil filter
11. Check area between hydraulic tank
and hydraulic pump.
12. Refit the side panels, start the
engine and lower the hopper. Switch
off the engine.
Ensure that the water tank is closed
before lowering hopper
End of chapter
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Chapter 7 Fault finding
Fault Finding
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Issue 4 – May 2008
Always remember, when trying to fault
find, switch the machine ff, remove
ignition keys, carry out the necessary
actions. Restore the machine to its
normal running conditions before
rechecking the machine.
Machine is not picking
up/poor suction thereby
leaving a trail
(Remember the notion of airflow; see
section 2.3 How the machine works)
1.
2.
3.
4.
5.
6.
Blockage in front suction hose
Hopper is getting full (see 3.4.6)
Front nozzle is set too low/high
Suction impeller casing blocked
Engine revs. too low/high (see 3.6.1)
Machine traveling too fast for
conditions
7. Cyclones blocked (see section 5)
Brush bounce
2. Radiator fins damaged
3. Poor washing around engine area
4. Possibly incorrect fuel (see section
8)
5. Low engine coolant level (see
section 4)
6. Incorrect coolant used (use 50/50
permanent anti-freeze/water all year)
(see section 8)
7. Radiator screen blocked (see
section 6 item 6)
8. Ensure that the fan belt is not
damaged or incorrectly adjusted.
Hydraulic oil overheating
1. Low hydraulic oil level (see section
4)
2. Incorrect hydraulic oil in system
3. Radiator dirty or blocked
4. Radiator screen blocked (see
section 5 item 6)
5. Ensure that the fan belt is not
damaged or incorrectly adjusted
Water sprays not working
1. Brushes set too low (see 3.4.3)
2. Brush speed too low in relation to
machine speed (see 3.4.5)
Debris/trash tends to be
left on the sides of the
sweep path
1. Brush angle incorrect (see 2.6)
2. Brush sweep path set too wide (see
3.4.4)
Electrical failure
1. Ensure that work 1 and forward gear
are selected and the pump Is
switched on.
2. No water in tank
3. Blocked jet in line filter
4. Blocked jet
5. Pump suction pipe disconnected at
tank drain pipe
6. Blocked tank suction strainer
7. Water pump defective
Smoking Engine
Example: lights or IQAN not working)
7. Check fuse boxes (see 3.6.3)
8. Check the status LED’s of the IQAN
XT2 (see 3.6.1)
Overheating engine
1.
2.
3.
4.
Dirty air filter element (black smoke)
Incorrect fuel used (see section 8)
Burning oil (blue smoke)
Leaking cylinder head gasket
(white/misty smoke)
5. Faulty Turbo (black or blue smoke &
lack of power)
1. Radiator blocked or partially blocked
Fault Finding
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Issue 4 – May 2008
Engine will not turn over
on start
1. Possible flat battery
To access engine compartment
when the engine won’t start, use the
manual hopper tilt system (See
section 10)
Ignition/charging light
fails to go out on start up
1. Broken fan belt
2. Slipping or loose fan belt
Excessive vibration during
sweeping
1. Suction fan impeller is damaged
2. Fan casing is blocked
3. A piece of debris has become
trapped in the fan casing
Having carried out the basic fault
finding as above, if the fault is
not found the symptoms should
be reported to your supervisor
and engineer/fitter as soon as
possible.
Wheel spin on uneven
ground
1. Machine is in Sweep or Transit
mode
Engage Brush Lift mode. This will cause
the limited slip differential to be engaged.
End of chapter
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Issue 4 – May 2008
Chapter 8 General Specifications
General Specifications
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8.1 Machine
Engine oil Capacity:
Dimensions:
Capacity:
6L
Type:
15W40 API CF4/ACEA2
Length Overall:
3530mm (141 in)
(Including brushes)
Engine Coolant:
Length over body: 3200mm (126 in)
Capacity:
13 L
Width over body:
Type:
50/50 mix of Ethylene Glycol
Permanent
1130mm (44.5 in)
Width over wheels: 1370mm (54 in)
with track extended
8.3 Fuel (Diesel)
Height:
1980mm (78 in)
excluding folding beacon
Wheelbase
Grade:
45 minimum cetane rating.
Low sulphur (below 0.05%)
1400mm (55.1 in)
Fuel tank capacity: 55 L (14.5 US gal.)
Front wheel track is variable
980 to 1220mm (38.6 in to 48 in)
8.4 Speed
Weight: 636HS
Transit Mode:
0 to 40 km/h (25 mph)
(Depending on market)
Curb Weight
1900 kg (4188 lb)
(ready for sweeping)
Payload
Transit Mode:
0 to 32 km/h (20 mph)
(In restricted countries)
550 kg (1212 lb)
Gross Vehicle Weight 2450 kg (5400 lb)
8.2 Engine
Type: Kubota D1105T – four cylinders,
water cooled turbo diesel
Typical rpm:
2400, can be raised to
2800rpm
Max Power:
31.3kW (42 hp)
Displacement:
1498cc (91.4 cu. In.)
Sweeping Mode:
Brushes Down
0 to 13 km/h (8 mph)
Sweeping Mode:
Brushes Up
0 to 16 km/h (10 mph)
Reverse:
0 to 6 km/h (4 mph)
8.5 Noise
The machine complies with in-cab noise
levels in accordance with 98/37EC and the
sound power measurement to 2000/14/EC
is 107 dBLwa.
General Specifications
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Issue 4 – May 2008
8.6 Suction System
High flow, through fan suction system with
cyclonic dust separation. Twin contrarotating floating brushes with in-cab
adjustment of height, and independent
joystick control of brush swept path width.
8.7 Dust
suppression system
Electric Pump:
Wheel nut tightening torque: 145 to 150 Nm
(107 to 110 lb.ft)
8.10 Hopper
Capacity:
1000 L (264 US gal.)
Clearance for tipping:
1.4m (55 in)
8.11 Electrical
System
12V, 5 L/min
12V battery, 70 A.h, heavy duty.
Twin water tank capacity: Total 190L
(49 US gal.)
European norm. number:
Mesh filtration system with fast-dump drain.
Cloud Rotary Mist Generator: 12V, Brushless DC motor with sintered plastic spray
head
Flow Rate for Cloudmaker: 15 L/hour
750mm (28.5 in)
Min swept track:
1200mm (47.2 in)
Max swept track:
2050mm (80.7 in)
Auxiliaries:
Gear type auxiliary pump with pressure
compensated variable flow control for
suction and brush motors.
Liners:
Solenoid valve control of hydraulic
cylinders.
155/70 R12C – Rating
104/102
Inflation pressure:
Transmission:
Ge-roller wheel motors (4 wheel drive).
8.9 Tires & Wheels
636HS
Size:
8.12 Hydraulic
System
Closed center hydrostatic drive with servo
controlled variable output swash plate
pump.
8.8 Brushes
Diameter:
566041051
Steering:
Gear type pump driven off engine fuelpump drive with hydrostatic steering unit
incorporating cylinder protection valves.
6.5 bar (94 psi)
Not fitted (tubeless tires)
General Specifications
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Issue 4 – May 2008
Oil Type:
Turbo Diesel Engine Oil 15W40 Grade API
CF/ACEA 2.
8.13 Pressure
Washer - Option
Type:
Hydraulically driven high pressure piston
pump. The gear type hydraulic motor is
connected to the 636’s auxiliary hydraulic
system via a solenoid operated valve.
Water flow:
13 L/min.
Max. water pressure:
90 Bar
Reservoir capacity:
The pressure washer draws its water from
the 636’s dust suppression water
reservoirs. With full reservoirs a wash
period of 10 minutes can be sustained.
Water pump lubrication:
Turbo Diesel Engine Oil 14W40 Grade API
CF/ACEA 2.
8.14 Vibrations
The operating controls and whole body
vibration levels comply with the Machinery
Safety Directive 98/37/EC.
Hand/Arm vibration id below 2.5m/s2 and
whole body vibration is below 0.5 m/s2.
End of chapter
General Specifications
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Issue 4 – May 2008
Chapter 9 Chassis Plate
Identification
Chassis Plate Identification
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9.1 Chassis Plate
Figure 9-1 Chassis Plate
End of chapter
Chassis Plate Identification
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Issue 4 – May 2008
Chapter 10 Vehicle Rescue &
Transportation
Vehicle Rescue & Transportation
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10.1 Rescue
In case of an emergency or transmission
failure it is preferable to rescue the machine
with an uplifting rescue vehicle.
Once the rescue valve on the inner side of
the transmission pump has been turned
through 90° the machine may be winched
onto the rescue vehicle.
The machine may be towed at slow speed
(5 mph maximum) for short distances (2
miles maximum) using a solid tow bar.
Again the rescue valve must be opened.
Note: whilst being towed with the engine
stopped, power steering will not be
available. Manual steering will be available
provided the steering hoses are intact.
In order to access the engine compartment
when the engine won’t start, use the
manual hopper tilt system. There is a
manual pump located on the right hand
side of the machine. The pump handle is
stowed inside the right hand side access
cover. Insert the handle in the pump and
start pumping, the hopper will tilt. If it is
necessary to lower the hopper manually,
there is a needle valve in front of the pump,
which can be released. Be especially
careful when lowering the hopper by
this method, ensuring that all personnel
are clear of the hopper lowering zone
and that the casing access door is
closed. Remember to close this valve
after use or the power tilt system will not
operate.
It is very important that the following
actions are carried out before any welding
takes place on the 636.
3. Disconnect the positive and negative
battery terminals.
4. Disconnect the engine speed sensor
at the left hand side, on the bell
housing.
5. Disconnect the vehicle speed sensor
at the left hand rear wheel motor.
6. Disconnect the vacuum fan sensor
(fan casing).
7. Disconnect every connector on the
main and auxiliary hydraulic blocks,
left and right hand respectively.
8. Disconnect the earth post (right
hand) next to the electrical box
(gray) under the cab floor.
Failure to carry out these instructions will
damage the machines electronic control
system.
DO NOT tow the machine at
speeds of over 5 mph or for a
distance greater than 2 miles.
10.2 Transportation
Vehicle unladen weight 1950kg.
When transporting the machine, it shall be
secured by means of suitable straps as
follows.
Front Wheels:
One strap per wheel to
a REARWARD lashing
point.
Rear Wheels:
One strap per wheel to
a FORWARD lashing
point.
Front of Body:
Two straps from towing
eye to FORWARD and
OUTWARDS lashing
points.
Rear of Body:
One strap from each
end of the lower crossmember to an
OUTWARDS and
Vehicle Rescue & Transportation
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Issue 4 – May 2008
REARWARDS lashing
point.
Figure 10-1 Lashing points
End of chapter
86
Vehicle Rescue & Transportation
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