Chapter 2 Machine Maintenance.

This chapter outlines daily and scheduled periodic maintenance.

Clean the machine prior to carrying out the operator checks and ALWAYS ensure the hopper safety stay is in position before working under the hopper assembly.

General Workshop Procedures

When any repair work is carried out on the machine the following procedures and instructions should always be observed.

Separating components and joints

When dismantling components, never insert screwdrivers or similar tools between the joint faces to separate the two parts. If this is done, damage will be caused to the joint faces, which will eventually result in oil, coolant or other fluid leakage at that joint. Where a component is tight, carefully tap around the joint using a soft faced hammer to achieve separation. If the two mating faces are sealed by a gasket, it is essential that the gasket is replaced if there is any doubt about its condition. Prior to reassembly the mating faces must be perfectly clean, with all traces of old gasket removed.

On initial assembly, washers are generally used under certain bolt heads and under all nuts. In the course of routine machine servicing, some of these washers may have been overlooked and/or omitted. As a general rule adopt the following logic whenever a component is removed and refitted. Any fastening which will rotate against a component or housing in the course of tightening should always have a washer between it and the relevant component or housing. Locknuts are used on many fastenings on the machine, and these can be re-used in noncritical areas, providing resistance can be felt when the locking portion passes over the bolt or stud thread. When LOCTITE is used on the threads of a bolt that is to be re-used, the old LOCTITE should be cleaned off with a wire brush and/or a suitable solvent, and fresh LOCTITE, of the specified type, applied on reassembly. Generally, all nuts and bolts used on Green Machines are of metric standard. The bolts are sized according to their diameter and length. For example an M10 x 25 bolt is 10 mm in diameter and 25 mm in length. Nuts and bolts are also graded according to their strength. Most metric fasteners used have standard thread pitches, but fine-pitched threads are used on a few items (e.g. steering ball joint bolt). Metric fastenings have a grade number stamped on the bolt head, whereas the nuts may have the grade number on the face or side of the nut. The higher the number, the greater the strength of the bolt or nut. The strength requirement for replacement fasteners on all Green Machines is as follows.
Hexagon head bolts Grade 8.8 minimum Hexagon head bolts (special applications) Grade 10.9

Nuts, bolts and related fastenings

It is quite common for certain nuts and bolts to be corroded or seized, particularly on exposed parts of the machine, or in areas where a nut or bolt has not been removed for some time. The use of releasing fluid (penetrating oil) may help if the nut or bolt is liberally soaked and left for some time before attempting to unscrew it. If this method fails, it may be necessary to use a careful application of heat, or to actually cut off the nut or bolt shank with a hacksaw.

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Socket head bolts Nuts

Grade 12.9 minimum Grade 8 minimum

Tightening torques
Specific torque settings for critical components are given in the Specifications at the beginning of the relevant Chapter. Where a torque setting is not listed the nut or bolt concerned should be tightened securely. The following chart can be used as a tightening torque guide according to bolt size.
Figure 2-2 Test lead (EW193) allows solenoids to be individually energized to bypass the machine management unit.

Size M6 M8 M10 M12 M14

Nm 9 to 12 19 to 28 38 to 54 68 to 96 109 to 154

lbf ft 6 to 9 14 to 21 28 to 40 50 to 71 80 to 140
Figure 2-3 Burst Valve Tool (AT023) allows removal of anti-burst valves (where fitted) in hydraulic rams.

Workshop tools
Individual spanner/wrench types and sizes, to be used for normal repair and servicing work are not specifically listed, as it is assumed that the technician undertaking the work will have a reasonable understanding of the general tools required and their usage. Some procedures in this Manual however, entail the use of special tools, such as two or three-legged pullers, extraction tools etc. Some special tools available are:Figure 2-4 Bush removal tool (JG006) allows removal of wear bushes from brush arm linkages.

Figure 2-5 Wear gauge (AT023) used for checking wear limits on front axle.

Figure 2-6 Wear gauge (AT024) also used for checking wear limits on front axle. Figure 2-1 Test Lead (EW197) used for testing solenoids under load.

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A separate publication (YM055) Operators Machine Check List is also supplied and details the daily and weekly requirements of the operator. The service schedule summary (YM053) out lines the following:
Every 6 weeks or 250 operating hours, whichever occurs sooner. Every 18 weeks or 750 operating hours, whichever occurs sooner. Annually or every 2,000 operating hours, whichever occurs sooner.

Figure 2-7 Hydraulic pressure test kit (HK003).

The daily operator maintenance is covered in the companion Operators Manual (YM052) and will not be repeated here. When carrying out routine services, we would recommend you refer first to the Service Schedule summary (YM053). This is because the service schedule summary lists the items in an order that is convenient to carry out. By contrast, the next section of this manual is ordered by the system or sub-system. Hence use the Service Schedule summary (YM053) when servicing, and refer to the procedures below when you need more detail of how to perform a particular step.

Figure 2-8 Low Level Water Sensor Tester (AT028).

For reasons of safety as well as the efficient completion of the repair operation, always use the tool described in the relevant procedure.

Environmental requirements
When disposing of used oil, antifreeze and other contaminated liquids or consumables, strict environmental requirements must be adhered to. Do not pour contaminated liquids or fluids down drains into the general sewage system or in to the ground to soak away. Facilities for professional disposal of waste oil and contaminated liquids are often available and can be accessed by contacting a local environmental health department or similar agency for further advice.

Service Procedures
Precautions and general instructions
Note the following points before carrying out any of the following servicing procedures: Refer to the specifications at the start of this Chapter for information on torque settings, specific clearances, lubricants and capacities. Ensure that all replacement parts are of the correct type and specification. This is critically important when replacing any components in the hydraulic system. Service kits comprising all materials necessary for each service interval are obtainable from Applied Sweepers or your local Green Machine dealer.

Service Schedule
A service schedule summary (YM053) is provided as a companion publication to this manual. It details the operations and maintenance that should be performed by the technician.

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23

Refer to the safety considerations listed in the preliminary sections of this manual before starting work.

Brake Fluid Reservoir Check fluid level.

! ! ! !

Do not work under the hopper unless the safety bar is in place. Before tipping the cab ensure there are no loose objects inside the cab. Always check that all warning and caution labels are present and legible. Remove the ignition key for all the following operations unless there are specific instructions to the contrary.

Figure 2-9 Check brake fluid level.

Observe all relevant environmental regulations when disposing of used oils and contaminated consumables. Ensure that the machine has undergone a thorough wash down and is completely clean prior to commencing any service work. Where visual inspection indicates that component replacement is necessary, refer to the relevant Chapters of this manual for specific details.

Check brake fluid level by looking at the brake fluid reservoir positioned in front of the steering wheel. The fluid should be between the low & high mark. If the fluid is low top up by using specified type of brake fluid.

Cab Pivots Grease.

Please refer to item 6 of Figure 2-44 on page 38 for grease point locations.

1 Cab and controls.

Every 6 weeks or 250 hours.
Beacon Light Check Operation.
Check operation of rotating beacon. Check operation of knock-down hinge. Replace bulb if required.

Cab Mountings & Clamp Check Security.

Figure 2-10 Check cab lock-down plate for correct fitment.

Camera Check Operation.

If a reversing camera is fitted, then check screen clarity and alignment of field of view.

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Introduction

Panel lights & gauges check operation.

Figure 2-11 Adjust camera position on rear of hopper using a screwdriver if required.

Doors Lubricate.
Lubricate door hinges, handles, locks and latches using light lubricating oil and check for correct operation.

Front light cluster Check operation.

Check bulb operation on both main and dipped beams, and also turn-signal and side-light functions.
Figure 2-12 Panel lights & gauges.

Horn, reverse alarm and voice warning check operation.

Check horn on steering column stalk, back-up alarm and voice warning (Caution Sweeper Approaching 2nd position of the same console switch as the beacon.)

A Fuel Gauge B Main Head Light Beam Indicator C Parking Brake Indicator (Red) D Left/Right Indicator (Green) E Battery Charge Light (Amber) F Engine Oil Light (Red) G Engine RPM H Engine Pre-heat (Amber) I Engine Temperature

Check operation of warning lights, fuel and temperature gauges and tachometer/hour meter.

Parking Brake Grease & Inspect.

Check operation of parking brake warning light on dash. Lubricate cable using light lubricating oil. Check cable tightness and segment lever operation. Adjust cable if required. See Chapter 4.

Rear light cluster Check operation.

Check operation of rear lights, rear turn signals, stop lights and back-up reversing light.

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Windshield Wash/Wipe - Check condition & operation.

Check wiper blades. Replace when worn. Check windscreen washer water level, jets, and spray pattern for correct operation.

2 Engine, fuel and cooling systems.

Every 6 weeks or 250 hours.
Engine oil change.
To assist oil flow and aid the draining of sludge, it is preferable to drain the oil when the engine is warm. Clean the area around the engine oil filler cap then remove the cap.

Side Mirrors Check condition & positioning.

Every 18 weeks or 750 hours.

Brush Down-Pressure Valve Check function.
Check by putting machine in Work Mode 1 & Forward Drive, brush arms & nozzle come down. Loosen Brush float valve lock nut & unscrew valve, brushes will go down, screw valve clockwise brushes will go up.

Heater Fan Check Operation.

Ensure machine has been run for a while, push heater switch to 1st position and rotate heater control knob to heat position (Red), hot air should be felt at heater vents. Rotate heater control knob to cold position (Blue), cooler air should be felt at heater vents. Push heater switch to 2nd position and increased air should be felt at heater vents.
Figure 2-13 Engine Oil Filler Cap

Clean the area around the sump drain plug, unscrew, and drain the oil into a container. Check the condition of the sump plug washer and replace if necessary. When the oil has drained, refit the sump plug and tighten securely. Fill the engine with the specified type and quantity of engine oil, through the oil filler tube. (see Engine Oil Specifications on page 234 for more details).

Seatbelt Check Operation & Condition.

Check integrity of seat belt by pulling out complete length of belt & check material ensuring there are no cuts or tears. To check operation of latch, pull sharply on belt, belt should lock.

Windshield Electric Heater Check Operation.

Switch on the screen heater using the switch on the console. The screen should feel slightly warm to the touch after several minutes. The heater should switch off automatically after 10 minutes.
Figure 2-14 Engine Oil Dipstick

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Introduction

Pull out the engine oil dipstick and wipe it clean, Re insert the dipstick, then withdraw it again and check the oil level. Top up as required to bring the level up to the upper "MAX" mark on the dipstick. Refit the oil filler cap on completion.

Engine oil filter change.

Initially slacken the oil filter using a strap, clamp or chain wrench. Then unscrew it the rest of the way by hand. Be prepared for oil spillage. Clean the filter sealing area on the engine, and then apply a light coating of engine oil to the sealing ring of the new filter. Screw the filter into position and lighten it securely by hand only - do not use any tools. Start the engine and check for leaks around the filter sealing ring. Switch the engine off, recheck the engine oil level and top up as required.
Figure 2-16 Unscrew the wing bolt and withdraw the filter element.

Air filter housing clean.

Air filter minder check reading.

Figure 2-17 thoroughly clean the inside of the air cleaner housing.

Figure 2-15 Check the air filter minder when the engine is running.

The air filter element should be cleaned and serviced when the reading on the air filter minder enters the red sector (25" of water) or when there is an indication from the IQAN display unit in the cab.

Air filter element remove.

If the air filter minder indicates that the air filter is dirty, then do the following:
Figure 2-18 Clean and inspect the evacuation valve and check for signs of wear or tearing.

Air filter element replace.

Fit a new air filter element if required and reassemble the components in reverse order.

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Radiator coolant check level.

Figure 2-19 Reset the air filter minder by pressing the button in the end. Check ALL warnings on the MDM are clear.

Air intake Pre-Filter Clean.

Figure 2-22 Check coolant level.

If necessary top up the mixture with 50:50 mixture of water and ethylene glycol.

Ensure that the engine is cold before removing the filler cap.

Radiator coolant - check mixture strength. !

Make sure that the engine is cold before removing the filler cap.

Figure 2-20 Clean dirt from the Pre-Filter outlet ducts with a soft brush.

Radiator clean matrix and screen.

A 50/50 mixture of water and ethylene glycol antifreeze must be maintained in the cooling system at all times to provide adequate protection against freezing, corrosion, and the build up of scale deposits.

Figure 2-23 Hydrometer used to measure coolant mixture strength.

Figure 2-21 Radiator matrix & screen.

Clean the Radiator matrix & screen on a daily basis to ensure that cooling of the engine and hydraulic system remains constant. If using a pressure washer to clean the radiator matrix, then ensure that the spray nozzle is kept at least 12 inches (300 mm) away from the matrix to minimise damage to the cooling fins.

The mixture strength can be accurately checked by measuring the specific gravity of the coolant using a proprietary hydrometer (available from an automotive parts store). With the engine COLD, carefully twist the filler cap to release any pressure that may be in the system. Once all pressure is released remove the cap from the radiator header tank and take a sample of the coolant using the hydrometer.

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Introduction

If the hydrometer reading indicates that the mixture strength is significantly below the specified ratio, it may be necessary to partially drain the cooling system and top up with a concentration of antifreeze. Once the correct strength is reached, then all subsequent topping up can then be done with a 50/50 antifreeze mixture.

Allow the air to bleed, and then tighten the vent plug when fuel that is free from air bubbles flows from the vent. The second fuel filter is an in-line element which is mounted on the outlet pipe from the fuel tank.
A Inline fuel filter B Isolation Valve C Fuel Tank A

Every 18 weeks or 750 hours.

Air Intake Pipe check integrity.
Check the tightness of the air filter housing mountings and the condition and security of the intake pipes, hoses and clamps.

C B

Fuel filter elements.

There are two fuel filters fitted to the fuel system. The on-engine element is a throwaway screw-on cartridge type and is mounted on a bracket at the front of the cylinder head. Wipe the filter housing and element exterior clean and place a container beneath to collect spilled fuel. Unscrew the filter element from the housing by hand, if this proves difficult then use a strap, clamp or chain wrench. Clean the filter sealing ring area in the housing, apply a light coating of engine oil to the sealing ring of the new filter and screw on.

Figure 2-25b Inline Fuel Filter.

Please note that a number of machines were built with top off-take fuel tanks these do not have an isolation valve fitted. Start the engine and check for fuel leaks.

Fan belt Inspect & Check Tension.

Check the condition of the fan belt over its entire length turning the engine as necessary by means of the fan blades. If there are any signs of cracks, splits or other deterioration, the belt should be replaced. If the belt condition is satisfactory, check the tightness by pressing the belt with moderate thumb pressure at a point midway between the crankshaft and alternator pulleys. The fan belt deflection should be 7 to 9 mm (0.28 to 0.35 in.) when the belt is pressed in the middle of the span.

Figure 2-24 Fuel Filter Bleed.

Turn the ignition to the start position to energize the electric fuel pump. Slacken the vent stud on the top of the filter body and ensure all air is bled out of the system.

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Remove the filler cap from the radiator header tank (b), and position a suitable container beneath the bottom hose connection at the radiator. Slacken the clamp, disconnect the hose and allow the coolant to drain. When the radiator has drained, reposition the container under the left hand side of the engine.

Figure 2-26 Engine Fan Belt Adjustment.

If adjustment is necessary, slacken the alternator mounting bolt (b) and adjustment bolt (a) and move the alternator as required until the correct belt tension is obtained. Hold the alternator in this position and tighten the adjustment bolt (a), then the mounting bolt (b).

Annually or 2,000 hours.

Fuel pipes, hoses and clamps inspect.
Closely inspect all metal fuel pipes and flexible hoses and check the tightness of all hose clamps and union nuts. Replace any suspect components as necessary.

Figure 2-28 Engine coolant drain tap.

Unscrew the engine coolant drain tap located in front of the engine oil filter and allow the coolant to drain. To flush the system, close the drain tap, reconnect the bottom hose and fill the system with plain water. Refit the radiator filler cap. Start the engine and allow it to warm up. Stop the engine, allow it to cool fully, then drain the system again. Repeat as necessary until only clean water, free from corrosion and scale deposits, emerges. If the recommended antifreeze mixture has been used, and the system has been drained and flushed regularly, the above procedure will be sufficient to remove all corrosion and scale. If, however, the system has been neglected, a proprietary de-scaling agent may be needed and should be used in accordance with the instructions supplied with the product.

Radiator coolant drain, flush, refill.

Figure 2-27 Coolant Bleed Hose Routing

Important: To avoid an air lock in the engine cooling system when topping up or filling, it is important that the bleed hose (a) from the radiator top hose is on the rise to the radiator header tank (b).

On completion, check that the drain tap is securely closed and that the bottom hose clamp is tight. Then fill the system with 50:50 antifreeze/water as previously described.

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Radiator, hoses and clamps inspect.

Carefully examine all radiator and cooling system hoses for signs of cracks, splits or coolant seepage. Renew any suspect hoses. Also check for any signs of chafing against adjacent components and ensure that all clamps are tight.

Valve clearances check, adjust where required. !

The engine must be cold for the following procedures. Figure 2-30 Valve clearances

Disconnect the crankcase breather hose from the cylinder head cover and move aside all other hoses and attachments.

Insert a feeler blade equal to the specified valve clearance between the rocker arm and valve stem of the first valve to be checked (See item 3 in figure above). The feeler blade should be a firm sliding fit. The valve clearances (engine cold) should be:
Inlet & Exhaust.. ...........................0.145 to 0.185mm ........................... (0.0059-0.0076 in.)

Figure 2-29 Cylinder head cover.

If adjustment is required, slacken the rocker arm adjuster locknut and turn the adjuster screw as required until the clearance is correct. Hold the screw in this position and tighten the locknut. Repeat the procedure on the second valve for that cylinder. Rotate the crankshaft as described above and repeat the measurement procedure for cylinder No. 2 & 3 and if necessary carry out the adjustment procedure as described. On completion, check the condition of the cylinder head cover gasket and renew if necessary. Refit the cylinder head cover, secure with the domed nuts and reconnect the disconnected components.

Unscrew the four dome nuts and remove the cylinder head cover and gasket. Starting with No 1 cylinder (at the timing gear end of the engine), turn the engine crankshaft by means of the radiator cooling fan, in the normal direction of rotation (anti-clockwise as viewed from the flywheel end), until both inlet and exhaust valves are rocking. Turn the crankshaft back and forth slightly and observe the valve movement. If both valves move, the cylinder is on the exhaust stroke turn the crankshaft a further 3600 in the same direction, to bring that cylinder to the compression stroke, which is the required position for adjustment. If the valves do not move when the crankshaft is turned back and forth, the cylinder is already on the compression stroke, and the valves are ready for adjustment.

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3 Hydraulics.
Every 6 weeks or 250 hours.
Hydraulic oil check level

The auxiliary pressure circuit filter should be changed at the first service and thereafter when the indicator on the filter body enters the red sector. Please note this filter indicator is not a tell-tail type gauge- the engine must be running to view if the filter element is clogged or not. The condition indicator will return to green when the engine is switched off.

Hydraulic pressure filter element change if required.

Figure 2-31 Check level of hydraulic oil.

Top up reservoir as necessary. See page 234 for oil specifications.

Hydraulic hoses, couplings check for leaks and condition.

Start and run the machine and check around the filter assembly for any oil leaks. Check all hose connections and fittings for hydraulic oil leaks. Check all hydraulic cylinders for hydraulic oil leaks. Check all hydraulic motor shafts for oil leaks. Check all hoses for signs of chaffing.
Figure 2-33 Auxiliary Pressure Filter

Place an oil drain container below the filter. Remove the stud from the bottom of the canister and take out the element (HC058). Pour the oil residue from the filter housing into a clean container and check for any metal particulate. Any large particles of metal particulate indicate a wearing auxiliary pump. Remove the old seal and clean the canister, fit a new element and sealing ring, refit and tighten.

Hydraulic pressure filter indicator check.

Annually or 2,000 hours

Hydraulic Oil Drain, flush, refill.
The hydraulic oil should be replaced annually to ensure that the system remains clean and free of particulate. The viscosity of the oil is also important as this assists with reducing wear on the system components.

Figure 2-32 Check filter is green when engine is running.

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Drain hydraulic tank by removing the drain plug situated on the lower right hand side of the hydraulic tank. Replace the return line filter and strainers as detailed below. Refit drain plug & refill hydraulic tank to specified level using 15W40 Turbo Diesel motor oil and start machine. Work machine checking all functions until hydraulic oil has reached working temperature. If the old oil was contaminated then drain off hydraulic oil once more and refill to flush out the system. See page 82 for detailed flushing procedures.

Hydraulic Suction Strainers for auxiliary and steering pumps replace.

Drain off hydraulic tank as described above. Ensure top of hydraulic tank is clean. Remove the inspection plate on top of the hydraulic tank.

Hydraulic return line filter replace element.

To replace the return line filter firstly ensure that the area around the top of the hydraulic tank is clean.
Figure 2-35 Strainer removal.

Unscrew the two strainers connections and discard.

from

their

Fit new strainer elements ensuring they are tight. Inspect inside of the hydraulic tank for cleanliness. Clean out using a lint-free cloth only. Replace inspection plate ensuring that a new gasket is fitted and ensuring that the securing bolts are tight. Refill hydraulic tank to specified level and test.
Figure 2-34 Remove return line filter from hydraulic tank.

Remove the return line filter housing cap, and twist the filter to free its seal. Remove the filter bypass unit from the top of the filter for fitting to the new filter element, discard old element. Refit bypass unit to the new filter element, lubricate any seals with hydraulic oil and insert new filter element into filter housing. Push filter into housing to ensure that the filter is positioned correctly. Refit cap, checking sealing o: ring.

4 IQAN Electronic Control systems.

Every 6 weeks or 250 hours
Safety SwitchesCheck Operation, clean activating arm, lift rubber sealing boot and spray with WD40 type lubricant.

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that the MDM activated.

FAN

BOOST

screen

is

While in the above condition, the brush speed control knob (Item D in Figure 4-5 ) can also be activated to ensure that full speed range is available.

Every 18 weeks or 750 hours

Figure 2-36 Fan Access Door Safety Switch

Open access door to reveal linkage and rubber boot to ensure that the mechanism is clean and free from all debris and is free to operate. Lubricate the mechanism.

Figure 2-38 XT2 AO (Cab)

Check XT2 slave module indicator lights (both XT2 units). Green light (a) indicates power on, blinking orange (b) OK, blinking red (b) fault. See page 66 for details of XT2 faults.

Figure 2-37 Hopper Safety Switch

Remove cover plate to reveal linkage and rubber boot to ensure that the mechanism is clean and free from all debris and is free to operate. Lubricate the mechanism.

IQAN MMU Check suction fan & brush speed range

Check the range of the suction fan speed is between 0 and 2,550 rpm.

Speeds above 2,800 rpm can lead to damage to the fan including the loss of fan blades and excess wear.

To check the fan speed range, run the engine, select work mode 1 and select forward drive. Activate the fan switch and turn the fan speed control knob (Item C in Figure 4-5 on page 89). As the fan speed rises above 2400 rpm check

Figure 2-39 XT2 A1T (Chassis)

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Introduction

Every 18 weeks or 750 hours

Battery Grease terminals.
Battery terminals can have a build up of verdigris that can cause electrical problems. Hence terminals should be checked, cleaned and lightly greased with electrical grease and the battery leads replaced.

Starter Solenoid Clean & Grease terminals.

Figure 2-40 XS AO (Cab roof)

Check XS expansion module indicator lights. Green light (A) indicates power on and burns continuously. The heart green light (C) and arrow green light (B) blink alternately indicating all is normal. Should a fault occur in the unit, the heart green light (C) is extinguished and the fault is indicated on the arrow light (B) via a series of flashes. See page 66 for details of XS faults.

Starter terminals can have a build up of verdigris that can cause electrical problems. Hence terminals should be checked, cleaned and lightly greased with electrical grease and the starter leads replaced

Wiring Looms Inspect.

Wiring looms should be inspected to ensure that they are secure, no damage to the looms can be seen, that the looms are not under stress or have moved to a component that may get hot and that all loom connections are secure.

5 Electrical systems.
Every 6 weeks or 250 hours
Battery Check Electrolyte levels.
Using an electrolyte bulb, check the condition of the battery electrolyte and top up the battery accordingly. Battery acid is a hazardous substance and therefore all safety precautions should be taken when handling and topping up the battery.

6 Chassis, suspension, steering, brakes & wheels.

Every 6 weeks or 250 hours
Steering Bell Cranks Grease & Inspect.
Please refer to item 11 of Figure 2-44 on page 38 for grease point locations.

Wiring lubricate studs.

All wiring earth studs should be inspected for security and cleanliness and a light coat of electrical grease applied.

Front trailing Arms Grease & Inspect.

Please refer to item 2 of Figure 2-44 on page 38 for grease point locations.

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Front Hub Top Bearing / Axle Beam Grease.

Please refer to items 9, 13 & 14 on Figure 2-44 on page 38 for grease point locations.

Check the wear pattern and condition of the tyres. Tyre tread depth should be within legal limits.

Tracking Cylinder Pivot Grease & Inspect.

Please refer to item 12 on Figure 2-44 on page 38 for grease point locations.

Every 18 weeks or 750 hours

Steering Arms & Ball Joints Check integrity.
Replace ball joint and components if worn.

Rear Trailing Arms Grease & Inspect.

Please refer to item 15 on Figure 2-44 on page 38 for grease point locations.

Front Axle Check Wear

It is important to ensure that wear on the front axle does not exceed design limits. Axles with excessive wear will experience tracking problems and in some cases handling problems. To carry out a wear measurement the following procedure should be adopted: Ensure that the axle is fully & correctly extended. Place a suitable jack under the axle on the left hand side of the vehicle. Place a suitable jack under the right hand brush arm support bracket. Jack the front wheels off the ground. Remove the right hand shock absorber lower pin.

Brakes Check Operation.

With the engine running and the machine selected to transit: a. Select forward drive. b. Place your left foot on the foot brake and depress the pedal to apply the brake. c. Release the hand brake. d. Carefully increase the engine rpm via the accelerator pedal until the machine starts to creep forward. e. If the machine creeps forward very easily with little increase in engine rpm, the brakes will either need adjusting or the brake pads inspected and/or changed. f. With the machine still selected to transit and forward drive selected, apply the hand brake.

g. With your left foot now OFF the foot brake, again slowly increase the engine speed until the machine creeps forward. Again if little engine speed increase was needed, the hand brake mechanism should be adjusted and the test repeated.

Figure 2-41 Use of axle wear gauges.

Wheels & Tyres Inspect.

Check wheel nuts are torqued to the correct tightness (100-105 Nm / 74-77 lb/ft). Check tyres are inflated to the correct pressure (4.5 bar 65 psi).

Using checking gauge AT023 (available as a special tool from your local Green Machine dealer), check vertical clearance between the outer & inner telescopic sections. The gauge should not enter more than 50mm. Using checking gauge AT024, check horizontal clearance between the outer & inner telescopic sections. The gauge should not enter more than 50mm and the gauge upper edge must be

36

Introduction

up against the inner roof wall of the box section. On completion of the check, replace right hand shock absorber lower pin. Lower and remove jacks. If wear limits are exceed, the wear plates on the axle should be replaced. To replace the wearplates, the whole axle will need to be returned to the factory or a new axle ordered.

Suspension Springs & Dampers Inspect. B

A
Figure 2-43 Brake shoe service limit.

Figure 2-42 Suspension spring & Damper. C

Once the lining thickness has reached 2.0mm (3/32) at its thinnest point, the brake shoe should be replaced.

A Check bushes and pins for wear, renew as required. B Check for signs of oil leakage, or damage to piston. C Check the spring for condition, corrosion and signs of damage.

Brake drum wear:

To check the brake drum wear you must first have the brake drum thickness as from new. This is 9mm for the rear drum and 8mm for the front drum. Once this has been verified you must then take a measurement from the worn drum. The wear allowance on the drum is 1.5mm surface wear or 3mm wear on the diameter, if this is exceeded the brake drum should be replaced. It is also important to check for damage to the brake drum surface, such as uneven wear, heat cracking or glazing.

Brake Shoes & Drums Inspect.

Brake Shoe Wear:

The brake shoes should be inspected at regular intervals during servicing. They should be checked for damaged parts and free movement of the parking brake mechanism. The thickness of the linings can be checked by sight through the inspection holes at the rear of the back plate.

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Figure 2-44 Grease Point locations.

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Greasing Points 1 Brush Arms 4 Upper & 4 Lower 2 Trailing Arms 1 left & 1 right 3 Hopper Door Ram 1 Left & 1 Right 4 Hopper Rams 1 Upper Right & 1 Upper Left 5 Hopper Rams - 1 Lower Right & 1 Lower Left 6 Cab Pivots 1 Left & 1 Right 7 Brake cables 2 8 Brush Arm Swivels 1 Left & 1 Right 9 King Pin Housing 1 Left & 1 Right 10 Water Tank Door Hinge 1 Left 11 Bell Crank Levers 1 Left & 1 Right 12 Tracking Cylinders 2 Left & 2 right 13 Axle Beam Uppers 1 14 Axle Beam Lower 1 15 Rear Trailing Arms 1 Left & 1 Right 16 Suction Fan Inspection Door Safety Switch Lubricate with electrical lubricant. 17 Hopper Raise Safety Switch Lubricate with electrical lubricant.

Brush motors clear debris from shafts.

Check and clear away any debris that has accumulated around the brush motor shafts and check the shaft seals for damage or oil leaks.

Front Flap check wear.

Visually inspect the front flap for wear. The front flap plays an important part in ensuring that good suction is maintained. When the flap has worn to about 1/3 of its original length it should be replaced.

Front Flap Adjuster

Clean Threads, lubricate & check operation.

Suction nozzle skids check wear & adjust where required.

Check for excessive wear and damage. Skid height adjustment can be checked by ensuring that the Skids are positioned level with the Horseshoe wear plate. If required adjust by using fixing bolts.

Suction nozzle polyurethane horseshoe check wear & replace where required.
Position nozzle in the up position, and then measure the thickness of the polyurethane skid. The skid is 38mm (1 ) deep when new. Change the skid when its thickness is less than the service limit of 15mm (9/16 ).

7 Sweeping Systems
Every 6 weeks or 250 hours
Brushes check wear.
When checking the brush wear it is important to note that when the brush has worn about 2/3 of its length it becomes ineffective at sweeping and therefore should be replaced.

Hopper Safety Prop Inspect.

Check pivot bolt and locking nut is secure. Check prop alignment and straightness.

Brush link arms grease.

Please refer to item1 of Figure 2-44 on page 38 for grease point locations.

Hopper Raise Cylinders Grease & Inspect.

Please refer to items 4 & 5 of Figure 2-44 on page 38 for grease point locations.

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Hopper Door Lift Cylinder Grease & Inspect.

Please refer to item 3 of Figure 2-44 on page 38 for grease point locations.

Also check the external cleanliness and damage.

drain

tube

for

Hopper Drain Seal Inspect.

Hopper screens Inspect.

Figure 2-45 Check hopper door mesh for wear or damage.

Figure 2-47 Hopper drain seal.

Hopper Cyclones Inspect.

Check for free movement of the cyclones. Repair or replace if necessary (see Chapter 10). Check cyclone bearings for wear. Check for debris caught around the spinner shafts.

Hopper Door Seal Inspect.

Hopper Drain Mesh Clean & Inspect.

Figure 2-48 Check hopper door seal for damage. Replace as necessary.

Suction fan check condition.

Open the suction fan casing access door and check wear, condition and cleanliness. Inspect the fan by removing the inspection cover on the right hand side front end of the hopper.

Figure 2-46 Check internal drain mesh for cleanliness and damage.

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Introduction

Figure 2-51 Check fasteners are secure.

Figure 2-49 Fan inspection cover removed.

Every 18 weeks or 750 hours.

Brush Lift Cylinders Inspect.
Check cylinder pivots for wear and integrity. Check cylinders and couplings for leaks.

Replace suction fan when wear appears excessive or damage is detected.

Brush Reach Cylinders Inspect.

Check cylinder pivots for wear and integrity. Check cylinders and couplings for leaks.

Suction Nozzle Suspension Inspect.

Check condition of ball joints and chains.

Suction Nozzle Hydraulic Lifting Rams Inspect. Wander-hose Inspect.

Figure 2-50 View of fan looking through the inspection panel access. Inspect for damage and excessive wear.

Suction fan casing check condition.

Check all welds and outer surface of the fan casing for signs of excessive wear, damage or deterioration. Change as required.

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8 Water dust suppression system.

Every 6 weeks or 250 hours
Water Spray Jets on brushes Clean filters.

Water Tank Drain Cap Clean filter.

Figure 2-54 Water Tank Drain Cap.

Disconnect the water pump supply hose from the tank cap by pressing the tab on the side of the connector (cap shown removed for clarity).

Water Tank Safety Chain & Strap Check Integrity.

Figure 2-52 Brush Water Jet in-line filter

Every 18 weeks or 750 hours

Low Water Level Switch Check Operation.
To check that the sensor is functioning correctly, drain the water tank by removing the filter housing cap. Ensure that the tracking is fully IN. Run engine, release hand brake and select work Mode 1. Position the rotary water pump switch to position 1 or 2. Put fwd/neu/rev lever into the forward position. The water pump should not run. Now place the low lever sensor into a container of water and the pump should run. If there is any doubt regarding the sensor, test kit AT028 will establish the fully functionality of the sensor.

Water Spray Jet in front hose Clean filters.

Figure 2-53 Water Jet for suction hose.

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Introduction

Cloud Maker Spray System Check Rotating Head is Functioning

Every 18 weeks or 750 hours

Figure 2-55 Cloud maker head assembly.

9 Air conditioning
Every 6 weeks or 250 hours
Check operation
Check operation to see if cold air is being generated.

Figure 2-56 Pressure pump Installation.

Check base plate bolts for tightness.

11 Street Washer option.

To be issued later.

Every 18 weeks or 750 hours

Check integrity of components, hoses and compressor belt tension.

12 Central lubrication option

Every 6 weeks or 250 hours
To be issued later

10 Pressure Washer option.

Every 6 weeks or 250 hours
Check integrity of pressure hoses. Check lance trigger operation and spray jet. Check & clean manifold filter. Check hydraulic inlet & outlet unions on top of hydraulic tank for tightness.

Every 18 weeks or 750 hours

Road Test
A full road and functional test should be performed after any service work has been performed.

Introduction

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