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Green Machines Model 636HS Operators Manual 1 Home Find... Go To.. Issue 4 – May 2008 2 Home Find... Go To.. 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 Home Find... Go To.. Home Find... Go To.. 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 Table of Contents Home Find... Go To.. 5 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 Table of Contents Home Find... Go To.. 6 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 Home Find... Go To.. 7 Home Find... Go To.. Issue 4 – May 2008 Chapter 1 Introduction. Introduction Home Find... Go To.. 9 Home Find... Go To.. 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 Home Find... Go To.. 11 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 Home Find... Go To.. 12 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 Home Find... Go To.. 13 Home Find... Go To.. 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 Home Find... Go To.. 15 Home Find... Go To.. 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 Home Find... Go To.. 17 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 Home Find... Go To.. 18 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 Home Find... Go To.. 19 Issue 4 – May 2008 Figure 2-2 Air flow Before You Start Home Find... Go To.. 20 Issue 4 – May 2008 2.4 Get to know your machine Before You Start Home Find... Go To.. 21 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 Home Find... Go To.. 22 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 Home Find... Go To.. 23 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 Home Find... Go To.. 24 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 Home Find... Go To.. 25 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 Home Find... Go To.. 26 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 Home Find... Go To.. 27 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 Home Find... Go To.. 28 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 Home Find... Go To.. 29 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. Getting Started Home Find... Go To.. 30 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 Getting Started Home Find... Go To.. 31 Issue 4 – May 2008 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 Getting Started Home Find... Go To.. 32 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. Getting Started Home Find... Go To.. 33 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). Getting Started Home Find... Go To.. 34 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 Getting Started Home Find... Go To.. 35 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 Getting Started Home Find... Go To.. 36 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. Getting Started Home Find... Go To.. 37 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 Getting Started Home Find... Go To.. Mode menu 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. Getting Started Home Find... Go To.. 39 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 Getting Started Home Find... Go To.. 40 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 Getting Started Home Find... Go To.. 41 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. Getting Started Home Find... Go To.. 42 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 Getting Started Home Find... Go To.. 43 Home Find... Go To.. Issue 4 – May 2008 Chapter 4 Operator Checks Operator Checks Home Find... Go To.. 45 Home Find... Go To.. Issue 4 – May 2008 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 Home Find... Go To.. 47 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 Home Find... Go To.. 48 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 Operator Checks Home Find... Go To.. 49 Home Find... Go To.. Issue 4 – May 2008 Chapter 5 Options & Accessories Options & Accessories Home Find... Go To.. 51 Home Find... Go To.. Issue 4 – May 2008 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 Options & Accessories Home Find... Go To.. 53 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 Options & Accessories Home Find... Go To.. 54 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 Options & Accessories Home Find... Go To.. 55 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 Options & Accessories Home Find... Go To.. 56 Issue 4 – May 2008 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 Options & Accessories Home Find... Go To.. 57 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. Options & Accessories Home Find... Go To.. 58 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 Options & Accessories Home Find... Go To.. 59 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. Options & Accessories Home Find... Go To.. 60 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 Options & Accessories Home Find... Go To.. 61 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). Options & Accessories Home Find... Go To.. 62 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 Options & Accessories Home Find... Go To.. 63 Issue 4 – May 2008 Options & Accessories Home Find... Go To.. 64 Issue 4 – May 2008 Chapter 6 The wash down . The Wash Down Home Find... Go To.. 65 Issue 4 – May 2008 The Wash Down Home Find... Go To.. 66 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 Home Find... Go To.. 67 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 The Wash Down 68 Home Find... Go To.. Issue 4 – May 2008 Chapter 7 Fault finding Fault Finding Home Find... Go To.. 69 Home Find... Go To.. 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 Home Find... Go To.. 71 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 Fault Finding Home Find... Go To.. 72 Issue 4 – May 2008 Chapter 8 General Specifications General Specifications Home Find... Go To.. 73 Home Find... Go To.. Issue 4 – May 2008 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 Home Find... Go To.. 75 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 Home Find... Go To.. 76 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 Home Find... Go To.. 77 Home Find... Go To.. Issue 4 – May 2008 Chapter 9 Chassis Plate Identification Chassis Plate Identification Home Find... Go To.. 79 Home Find... Go To.. Issue 4 – May 2008 9.1 Chassis Plate Figure 9-1 Chassis Plate End of chapter Chassis Plate Identification Home Find... Go To.. 81 Home Find... Go To.. Issue 4 – May 2008 Chapter 10 Vehicle Rescue & Transportation Vehicle Rescue & Transportation Home Find... Go To.. 83 Home Find... Go To.. Issue 4 – May 2008 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 Home Find... Go To.. 85 Issue 4 – May 2008 REARWARDS lashing point. Figure 10-1 Lashing points End of chapter 86 Vehicle Rescue & Transportation Home Find... Go To..