FT 09 FIRE PHASE

RUNWAY VACUUM SWEEPER AK 445

OBJECTIVE 1. To explain the technical data, description, operation and maintenance work of Runway Vacuum Sweeper (Faun KUKA AK 445 TERRA Jet). REFERENCE 2. PU 202012 Faun Kuka AK 445 Terra Jet.

CONTENTS 3. Technical Data - Chassis. The technical data of the chassis may see from the attached original literature of the manufacturer. 4. Body: a. b. c. d. e. f. g. h. i. Engine No. 2 make: Type: Power output: Fuel tank, capacity: Starting clutch, make: Wedge belt drive for blower: Wedge belt drive for hydraulic pump: Blower, air through output: Air intake: Daimler Benz AG CM 407 178 h.p 150 liters Metalluk 8KA 28/z No. belt 13 No. belt 2 450. / min 500 mm 0

j. Pneumatic System. Connected to the air compressor of the aggregate engine. Air compressed air tank additional 40: 1 k. Pressurized Water System. 2 pressurized water tanks. Contents 600 liters each. l. Hydraulic System. Engine-driven hydraulic pump, double control unit and 4 told telescopic cylinder as well as two pressure cylinders. m. n. 5. Oil tank: Rated contents: 55 liters. Electrical system: Connected to the vehicles 12 volt system. Starter 24 Volts.

Characteristics Values: a. Collection width of the blow/suction head with collecting roller b. Working speed according to degree of dust/dirt: c. Capacity of the rubbish container: 2100 mm, with two wheel supports, slew able, type pressure at 5 ats 0 40 km/h approx 4.5 M

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Description of Vehicle Pneumatic System: a. The pneumatic drive for the sweeper broom and the collecting shaft comes from the air compressor of the blower motor via valves and auxiliary air tanks. b. The drive can be interrupted via shut-off valves 1. The air is fed to the air cylinders of the collecting shaft or of the collecting roller via a precision regulating valve. To save wear tear on the supporting wheels of the collecting shaft, it is possible to adjust the precision regulating valve to leave a certain pressure cushion in the pneumatic system so that the supporting wheels do not bear the full weight but only part of the weight, the rest being borne by compressed air. c. This pressure is set by turning the lever back in the lift direction . To save having to carry out this sensitive and precise procedure every time the shaft is lifted or lowered, an adjustable stop screw is attached to the precision regulating valve. d. Shut-off valve 2, which is fitted behind an adjustable pressure reducing valve (2.5 5.0 at), is automatically actuated when the water taps are opened or closed so that incorrect operation is impossible. From this line between the pressure reducing valve and air shut-off valve 2, there is a branch off line to the manometer (while hand) so that it is always know what water pressure is available when the machine is ready for operation.

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Description of Vehicle Pressurized Water System: a. The pressure tested pressurized water tanks are filled via a filling tap and a quick release coupling. The filling tap is connected to an overflow and ventilation valve on the top side of the container by an arrangement of rods; it is also connected with the shuts off valve described above in such a way when the container is being filled the filling tap and the over flow valve are open so that the remaining compressed air can escape together with the air displaced by filling. b. When the tanks are full, i.e. when water comes out of the over flow valve, first shut-off the supply and then shut the taps on the vehicle. A sealed 3.5 at safety valve located on the top container correction prevents the container from being overloaded. c. The water for dampening down dust is tapped off the bottom of the tank and conduced via a filter and via a connection lay out located in the drivers can to the fulljet nozzles at the back of the upper section of the suction shaft. d. If the filter is to be cleaned when the water tank is full, first close the shut-off valve located directly in front of the filter, this valve normally remains open.

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Description of Vehicle Hydraulic System: a. Tipping Hydraulic System. The tipping hydraulic system comprises a hydraulic pump driven by the main engine of the vehicle, the tipping cylinder for the container, the cylinder for locking, opening and closing the discharge door, the valve and the fittings such as hydraulic hoses, pipe lines and screwed joints. b. Opening the Door and Tipping the Container: (1) Releasing the opening the door and tipping the container are hydraulic functions powered by the same hydraulic pump that is drive by the engine of the vehicle. (2) Engage the auxiliary drive lever of the gear box when the gear lever is in neutral and allow the engine of the vehicle to run at a little over idling speed. (3) On the right-hand side of the vehicle there is a double Control Unit: move the handle of this unit to the position Door Open. This first 69

automatically release the door locking device, subsequent to which the door opens. (4) The second handle marked Container; actuates are tipping mechanism of the rubbish container. (5) Closing the door and lowering the container are the same procedures in reverse. 9 Broom Hydraulic System. The broom hydraulic system comprises a hydraulic pump driven via wedge-belt transmission, the oil motor to drive the broom roller, the valve and the fillings such as oil tank with return flow filter, hydraulic hoses, pipelines and screwed joints. 10. Blower Air Circulation: a. Through the pressure connection of the blower (Square rubber sealing flange, easily visible when the container is raised) the air is conducted to the rear of the Vehicle via a duct located in the bottom of the container. From there the noses with a clear interior diameter of 250 mm to an exit slot in the blow/suction shaft which functions as a blower nozzle. b. Located in front of the blower nozzle is the suction shaft. This also stretches over the full width of the vehicle, i.e. 2100 mm. The air re-enters here carrying with it the dirt, dust and other foreign bodies already accelerated by the blower airstreams from the ground surface through two suction hoses and into the collecting container. On their way into the container, the sweeping pass the spraying zone with the attached spray nozzles. Suitable deflection plates now direct the cleaned air through the detachable screen located in the top part of the collecting container and through the following suction duct to the round intake pipe of the blower (easily visible on the right-hand side when the container is in the raised position). c. The screen is designed only to sort out light material such as leaves, paper and the like. 11. Collector with Sweeping Roller. Between the blower jet and the suction intake there is a full-width, 2100 mm sweeping roller, which guarantees 100% collection of sweepings when larger amounts of dust, litter etc, are to be cleared. This facility can be controlled direct from the drivers cab. The ground pressure of the roller can be regulated between 0-4 at by means of a pressure reducing valve with manometer. 12. Electrical System: a. The special body entails the following supplementary facilities to the vehicles own electrical system. b. I mechanical telethermometer for measuring the water temperature of the second drive engine. c. d. 13. I pull switch with control lamp for rotating warning beacon. The illumination for the instruments is switched on by means of a pull switch.

Operating and Control Instruments: a. The sketch on page 11 shows how and where the instruments for essential components are arranged and what significance they have. b. All driving instruments are located on a control panel in the drivers cab between the two seats in such a way as to be easily observable and accessible without in any way affecting the operators driving ability or impairing his attention. All levers, switches etc. Which must be operated prior to after using the machine is located outside the drivers cab, 70

14. Operation the Chassis. Pay close attention to the attached literature of the chassis supplier and also strictly observe all standard measure for operating a normal diesel driven truck. 15. Operation the Body: a. Assuming that all fuels and other operating materials (Fuel tank arrangement) have, prior to operation of the vehicle been topped up in accordance with the servicing procedures described below, or that the levels of such materials in their respective tanks have been checked, the procedures for operating the machine are as follows: b. Start engines no 2 with the push button starter: Slowly accelerate the engine with the Manual accelerator paying special attention to the oil pressure. c. Use the time that the engine is warning up to make a tour of inspection around the vehicle: Important: Do not forget to engage the handbrake. d. Release the suspension on the rear blow/suction shaft so that this can be towered when the regulating valve is actuated. If required, switch on the spraying system from the drivers cab (the while hand must show pressure). e. Lower the blow/suction shaft by means of the regulator valve. Since the spraying system was switched on first, all dust now sucked up will be moistened and cleaning operations can begin. f. Cover the area to be cleaned backwards and forwards in slightly overlapping strips or by direct visual control. On the return pass, check the standard of the work on the previous trip. When the water supply is exhausted, this is signaled by a sharp increase in dust. g. Important Operation of the sweeping roller. When the blower motor is running, lower the blow/suction shaft by means of the regulating valve. The sweeping roller runs and is lowered by means of the 4 way cock and can then be set to the desired load pressure. h. Do not overload the vehicle if heavy material such as gravel, peoples etc, is to be checked up. Stop collecting when the material has reached two thirds of the clear height under the screen and empty the container before. i. The driving speed during clearing operations depends on the amount of dust, rubbish etc, on the ground. It can be raised to up 40 km/n depending on the amount of dirt to be cleaned. Slow driving at up to 6 km/n guarantees that all normal, dust, dirt and litter type rubbish will be softy collected. j. When working in rain, which means that a great deal of water is also picked up, note that the container can become full very quickly. On no account must be vehicle become overloaded by excessive collection of water. Similarly when operating the machine in wet or rainy weather, the spray water system should either not be switched on at all or be turned down to a minimum. It is possible to regulate the water consumption rate to a certain degree by only partially opening the operating lever next to the drivers seat. Further more it is possible to adjust the pressure reducing valve to change the basic rate of water consumption: this is, however, not advisable since the makers have designed the system for the normal pressure of 3.5 at. k. The container is to be emptied at the location allocated for that purpose. Stop the vehicle and engage the handbrake; do not forget to switch off the blower motor prior to raising the container. Then, having switched on the hydraulic pump (auxiliary power unit of the vehicle). Operated the levers to raise the container and open the door.

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l. Switch off the hydraulic pump by means of the auxiliary power unit lever, reenter the drivers cab and drive forwards for about 5 meters very slowly and care fully with a gentle for on the clutch. Very important, on uneven terrain there is a danger that the base frame of the chassis may become deformed when the container is in the raised position. m. It is necessary to drive forwards a little in order to make sure that the door can recluse properly after dumping a large amount of rubbish. It is not necessary to drive the similar. Then lower the empty container. Carry out all procedures swiftly but sensitively and do not use raw force. The lowered container must sit full flush on its supporting base and the door must also close properly. 16. Operation General Tips: a. It will not always be necessary to run the engine at its highest speed. Lower engine speeds are sufficient for slower driving and smaller amount of dust, rubbish etc. Lower engine speeds mean less wear, lower fuel consumption and reduced noise. The engine speed ranges are marked on the tachometer. On no account must the maximum engine speed be exceeded. When the container is in the raised position, the blower must only be driven with the lowest possible engine speed to avoid possible damage to the engine and to the driving mechanism. b. After lengthy cleaning operations refill the water tank even if it is still party full; this avoids unnecessary return journeys to base. Filling the water tank is controlled by one lever only, which eliminates the possibility of incorrect operation and the water system is ready for operation immediately a after the filling tap has been closed. When the water tap is completely full, the water is already at operating pressure. Should however compressed air have been released by opening the tap while the water tank was partly empty and the filling tap had been set to the filling tap had been set to the filling position without actually taking in any water, it will last a little longer until the cushion of compressed air has reformed (while hard on the indicator). 17. Maintenance Work Chassis. For maintenance work, also see the literature provided by the chassis manufacturer. Besides this, in the case heavy work with a great deals of dust it is advisable to check the air filter of the driving engine daily. 18. Maintenance Work the Body: a. Drive Engine No. 2 Main Maintenance indicator show when it is necessary to service the filter. When the air flow resistance of a dry air filter has reached the max permissible valve as a result of dirt accumulation, the device draws attention to the fact that servicing is necessary. b. As more and more dirt accumulates in the filter cartridges, a growing red field is visible through the window in the Maintenance indicator, while the engine is running. The filter is due for servicing. When the red field in the window of the device locks into its end position, i.e it remains fully visible even when the engine is at a standstill. After exchanging the dirty cartridge for a new or regenerated cartridge, reset the red indicator field to zero by means of the return button, i.e a neutral area will be visible instead of the red field. c. Conscientious maintenance work on the engine considerably lengthen its service life as does attention to cleanliness when exchanging or topping up engine oil; prior to filling oil, remove dust from all neighboring parts of the engine so that no dust or foreign bodies can get inside the engine. Keep the engine free of dust. d. The belt drive is composed of wedge belts that must be kept taut , for this reason always make sure that the tensioning roller is providing the belts with the correct tension, otherwise there will be excessive wear of the belts. The belts are correctly tensioned by the makers when the vehicle is delivered. 72

e. The accelerating clutch with the belt pulley is filled with a certain quantity of ball weights as a transmission medium. These ball weights are equally distributed among the individual chambers, for this reason if is advisable not to attempt to dismantle this clutch but to send the whole aggregate back to the makers works. f. Every two years at the latest, the clutch should be sent in to a specialized workshop, (preferably back to the makers) to be dismantled, cleaned, inspected and reassembled together with new lubricants, if the blower bearing need to be opened because of excessive noise or to renew the lubricating grease (see lubricating schedule for hours of operation). Proceed as follow. g. Never use a chisel or a screw driver to extract the bearing; use copper or hardwood utensils. Never damage or distort the cage. In the case of adaptors, draw the adaptor sleeve firmly onto the shaft; some grooved nuts. h. Every blower is fitted with a fixed bearing and a free floating bearing to allow for expansion of the shaft; the fixed bearing is located on the drive side. Re-check the adaptor sleeve once more after the bearing has run in. When reassembling bearing, gently rock the ball race on by hand using grease, do not fill the housing up to more than half full with grease. Both too much grease and too little grease, result in the bearing running hot. Protect bearings or on ball races, exchange the bearing immediately. 19. Maintenance Work Pneumatic System: a. This should from time to time be emptied of water the aid of the valves located in the two air tanks. In the case of normal temperatures, it is enough to empty the system of water once a month. The valves should be through being opened when pressure is available to ensure a powerful blow through. Every six months, remove the air cylinders for lifting the blow/suction shaft, dismantle and clean then and grease the pickings. b. The pressure level can be controlled on the braking manometer of the vehicle at the front and, for the body, by the red hand when the collecting broom is in the raised position (Operating panel between the seats). c. In connection with the braking system itself, se the special regulating of the vehicle makers. The compressed air maintenance unit consists of the pressure reducing valve, the compressed air filter and the compressed air lubricator. 20. Pressure Reducing Valve. The primary pressure is reduced with the aid of the hand wheel. (Clockwise rotation = pressure increase). The secondary pressure should be 6.5 bars. It is read off at the pressure gauge, on the instrument box. 21. Compressed Air Filter. The compressed air filter has the task of removing impurities from the compressed air and absorbing condensed water. The condensed water must not exceed the marker line on the glass container. The condensed water is drained at the drain valve. (Clockwise rotation = open) A sintered metal filter traps dust and small rust particles. This filter must be cleaned at regular intervals as described below. a. Remove the filter bowl by removing the screw. Remove the sink red metal filter, wash it in loroethylence, paraffin or petrol and blow it through with compressed air from inside to the outsiders. CAUTION. Only clean the filter bowl, plastic sections and ceramic sections with warm soapy water. On no account must triohlorocthylene, perchloroethy, acetone or similar solvent be used.

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Compressed Air Lubricator: a. The compressed air lubricator is designed to enrich the compressed air with a fine oil mist. b. The quantity of oil metered is regulated at the adjusting screws; it should be approximately 1 drop of air every 5 minutes. c. The glass container is provided with marking showing the maximum oil level and minimum oil level. OIL-TYPE ISO VG 10/E.G. SHELLS TELLUS OIL ESSO SPIN ESSO 10.

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Return Line Filter: a. Unscrew the filter cover 1 and remove the filter bowl 2 together with filter cartridge 3. Remove the filter cartridge by turning it and, at the same time pulling it, out of the filter bowl. b. Remove any residual oil from the bowl and rinse the bowl with petroleum ether. Fit a new cartridge in the filter bowl. c. Filter change intervals: first charges after 40 and 250 hours of operation, then every 750 hours of operation.

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Venting Filter: a. Filter change intervals: first changes after 40 and 250 hours of operation, then every 750 hours of operation. b. If it is necessary to unscrew hydraulic pipes, do not forget to support the container and the door with wooden beams. The hydraulic system must be free of leaks at all points. c. If the system does not empty despite there being sufficient oil, first check whether the release valve on the tipping cylinder for the highest emptying angle of the container is possibly stuck so that the pressure flows unused into the return line. If possible, do not change the adjustment of the release bar; it is correctly adjusted when the pressure is switched off immediately prior to the cylinder reaching the top and stop. It might then be necessary to check the pressure relied valve. Never carry out work on the pipe and valve system except when the container is in its rest position or suitably supported and the door is closed or safety held open or when the motor is running. d. Pay extremely careful assembly to cleanliness when re connecting pipe lines and parts, otherwise the result is very fast wear and tear of all collars, packing and valve seats.

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Blower Air Circulation: a. Once a week spray through all air ducts when the container is in the raised condition and the door is opens: spray from front to back so that the water cannot run into the blower. When the container is in the raised, inspect and clean blower and wash out any accumulated dirt between the blades of the fan never operate that fan when it is not properly balanced. b. Once a month, check the rubber seals between the blower and the rubbish container when the container is in the raised position as well as when to seals have contact. The seals should be subject to slight pressure, especially on the ground suction channel. If not, either underlay than or insert new rubber strips.

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c. According to the degree of litter collected, the screen in the container must be folded down and sprayed clean once a day or at least once every week. The rubbish container itself should be sprayed out once each time it is emptied, since the water tank must be refilled in any case. 26. Electrical System: a. If the road sweeper is often used at night, check over the electrical system once a week. b. Check the functioning of all lamps, alarm system control devises and fuses. c. Never mend fuses, if a fuse blows again after it has been replaced, try to trace the cause, never try to remedy the damage by inserting a stronger fuse or by mending a fuse as this may lead to serious damage to the battery and the generator. 27. Operating Unit: a. Control elements and warning instrument must be functioning properly and must run easily. Once a year. Dismantle the Bowden Cable for engine speed adjustment and re-insert with fresh grease. b. If the friction brake on the regulating valve for lifting and lowering the blow/suction shaft no longer stays in the desired position, this cab is reset to the desired degree of friction by tightening the nut. Check the indicating correctly. It the instrument does not properly indicate Zero, and then it is almost certainly defective. The operating hours counter not only serves to monitor engine speed but also to ensure that all maintenance work is carried out at the correct times in compliance with the regulations of the engine manufacturer. Keep a drivers log book and enter daily the operating hours, the distance driven, the number of times the container was emptied, etc. The most comprehensive operating and maintenance instructions are of no avail if the personnel entrusted with the operation of the machine is not prepared to get the best out of the machine by proper treatment and operation and to adapt all instructions recommendation to correspond to local conditions. Only if this is done can the machine produce its highest performance during a long service life with minimum downtime. 28. Assembly and Operating Instructions for Metallic Starting and Safety Churches: a. Construction: The star-shaped blade fan (1) of the clutch, which is located on the drive shaft, divides the clutch housing (2) into compartments of equal volume. Those are filled with weights (3); either completely full or only party full depending on performance requirements. When the drive shaft turns, the ball weights are set moving in a circular orbit. The resulting centrifugal force presses them against the clutch housing. During starting, the outer part of the clutch is driven via rolling friction between the ball weights and the clutch housing with some slippage. After starting is completed, the driving force is transmitted without any slippage, if the safety moment is exceeded, the clutch beings to slip. b. Instruction for Installing the Clutch. The hub of the clutch must be drawn onto the cleaned and lightly oiled shaft of the engine without undue delay. Avoid knocks and do not use raw force. c. Instruction for Initial Operation. Following assembly, the clutch housing must be able to move freely in both directions on the driving shaft. Prior to initial operation, and especially after long storage, check the oil level in accordance with the following maintenance Instructions and lubricate if necessary. 75

d. Instruction for Maintenance. Clutches with sealed plain bearing or anti friction bearing with shaft seals (identifiable by the shaft seals and by the three oil screw); the clutch is supplied ready for operation including ball weights and oil. The cavity is filled to approx, 50% with oil and thus, on regular operation (approx, T start per day), it is enough to renew the oil once a year, for this purpose the clutch is fitted with three lubricating screw. To renew the oil, unscrew two screws, then with a high pressure oil guns, press in oil through one of the holes until it begins to flow out of the other hole. The intervals between oil renewals may be amended in accordance with the frequency with which the clutch is started. 29. Lubricants never use Grease and Never Rinse Out with Cleaning Agents when installed on the Engine: a. Use non-ageing gear oils with high pressure properties and a viscosity of approx 150-220/400. b. We recommended the following particularly well tested lubricants: Calipsol Calipsol Bison Oil HSR. 92 TMII 2 Esso Spart. EP 220 Mobil Mobil Gear 530 Valvoline Valvolone WA 15 Supplier Designation

30. Instruction for Assembling the Clutch. Check the ball weights, add further weight if necessary and pay careful attention to equal distribution of the weights among the individual compartments when re-assembling. Fill the housing approx. Half full with oil. Replace the clutch cover using sealing compound and bolt into place. 31. Performance Adjustment. The performance of the Petalluk clutch is determined by, among other things, the total weight of the ball weights. It is possible to in crease or reduces performance by adding or removing ball weights (Example: performance can be increased by 100% by increasing the total weight of the ball weight by approx 10%). State the factory number to be found in the clutch housing on all inquiries. 32. Roller Brush Drive: a. b. Lift suction nozzle and lock with two eyebolts. Let down broom roller: (1) (2) (3) = = = Control screw Drain plug Max oil level

CAUTION: Strictly observe the above lubrication instruction! Use prescribed lubricant for repeated lubrication. Never mix two different sorts of lubricant. The operator of the vehicle is advised that the reliability of servo mainly depends on the strict observance of the prescribed lubricants and the lubrication and control intervals. We have to refuse any guarantees and liability for distortions and damages caused by using improper lubricants and by not observing the present operating and maintenance instruction.

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