Scarab Magnum Operating And Maintenance Instructions Manual Download Page 5

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Part No. SCAZ037886 8.6.00

E&OE

Merlin and Magnum Hydrostatic

Operating Instructions

Table of contents

Title

Page

General information   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Table of contents  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Health and Safety advice  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Hazard awareness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Operating advice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Safety support props . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

The CANbus system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Main control panel switch functions . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Auxiliary control panel switch functions . . . . . . . . . . . . . . . . . . . . . . . . 12
Hopper remote control switch box functions . . . . . . . . . . . . . . . . . . . 13
The LCD monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Additional controls and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Brush pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Controls for overhead wander boom . . . . . . . . . . . . . . . . . . . . . . . 15

Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Engaging hydrostatic drive (Manual gearbox trucks)   . . . . . . . . . . . . . 16
Sweeping  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Suction fan boost setting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Climbing Gradients . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Reverting to normal drive mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
CNG IVECO with Allison gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Engage hydrostatic drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Disengage hydrostatic drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Discharging the hopper (tipping) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Using the auxiliary hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Title

Page

Standard wander hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Using the standard wander hose   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Using the rear mounted wander hose  . . . . . . . . . . . . . . . . . . . . . . . . . 24
Using the overhead wander boom  . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Using the Dust Suppression System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Filling the water tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Using the low pressure water system . . . . . . . . . . . . . . . . . . . . . . . . . 26

Using the high pressure water system . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Hand lance detergent option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Retractable hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Clearing a blockage in the suction path . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Recommended operator’s routine maintenance . . . . . . . . . . . . . . . . . . . 30
Key maintenance procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Cleaning the suction fan and screen . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Hydraulic oil tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Topping-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Suction nozzle clearances  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Side brushes and skirts   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Removing and cleaning the water filter element(s)  . . . . . . . . . . . . . . 34
Manual greasing and lubrication   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

LCD monitor - Options screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Button function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Screen menu description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Operator’s notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Summary of Contents for Magnum

Page 1: ...Merlin and Magnum Road Sweepers Hydrostatic Drive Operating and basic maintenance instructions This document contains important Health and Safety advice and must remain with the machine at all times ...

Page 2: ... tank orientation determined on chassis type 7 Low pressure water pump and valves 8 Central brush assembly 9 Low pressure and or high pressure spray bar 10 High pressure front spray bar shut off valve option 11 Pneumatic system cabinet 12 Main hydraulic valve block access cover 13 Hydraulic oil cooler location 14 Side brush assembly 15 Suction nozzle assembly 16 Auxiliary hand pump 17 High pressur...

Page 3: ...every effort is made to ensure that the information it contains is correct at the time of publication Due to a policy of continuous development however the Company reserves the right to alter the specification and to supply when so altered without reference to illustrations and descriptions in this manual Scarab Sweepers Limited Pattenden Lane Marden Tonbridge Kent TN12 9QD United Kingdom T 44 0 1...

Page 4: ...required please contact our Technical Sales staff giving your sweeper s Serial Number Towing Serious damage to the transmission will result if the vehicle is towed while the gearbox is engaged If towing is necessary it is imperative that the prop shaft is disengaged from the differential or that the rear wheels are clear of the ground before making any attempt to tow the vehicle Identification Pla...

Page 5: ...llison gearbox 20 Engage hydrostatic drive 20 Disengage hydrostatic drive 20 Discharging the hopper tipping 21 Using the auxiliary hydraulic pump 22 Title Page Standard wander hose 23 Using the standard wander hose 23 Using the rear mounted wander hose 24 Using the overhead wander boom 25 Using the Dust Suppression System 26 Filling the water tank 26 Using the low pressure water system 26 Using th...

Page 6: ...gh pressure water can be hazardous Always wear suitable face protection when operating the high pressure water pump and when using the lance Do no direct the water jet at other persons Beware of electrical installations on public buildings and lamp posts etc Always exercise extreme caution in public places The driver s seat should always be correctly adjusted as to give a good posture when driving...

Page 7: ... discarded hypodermic syringes while operating or working on the vehicle Exposure to various infectious diseases e g Legionnaire s Weil s Hepatitis Tetanus while operating or working on the vehicle Safety precautions When using external equipment such as the high pressure water lance or when dealing with potentially hazardous situations while sweeping e g unblocking a suction nozzle always wear th...

Page 8: ...e fan blades on its way back to the environment behind you Operators should be trained in the following elements Health and safety observations notices Transit driving In cab and external controls Hopper safety cab prop use Brush setting Nozzle flap adjustment Correct sweeping operations Low and high pressure water systems Load discharge tipping Daily weekly maintenance schedules End of day cleani...

Page 9: ...gnum Hydrostatic Operating Instructions Safety support props Door safety prop Auto ratchet hopper prop Ensure the prop is correctly positioned within the ratchet rack When inserting the doorprop ensureitis correctly positioned in the locating slot ...

Page 10: ...atic Drive Green Sweeping functions Blue Water Spray functions Each switch illuminates a function related symbol on the LCD monitor only installed equipment will be displayed Each symbol is greyed out until its switch is activated When a switch is activated the appropriate symbol will illuminate according to system status as illustrated Not selected Pre selected Water pre selected Brush and water ...

Page 11: ...ight Suction Nozzle Raise Lower Press to lower the suction nozzle Central Brush Wide sweep Press to start the central brush Left Right Work Light Press to turn ON OFF Left Right Side Brush and Suction Nozzle Water Press to start the side brush and suction nozzle dust suppression Central Brush Wide sweep Water Press to start the dust suppression spray for the central brush Increase Decrease Engine ...

Page 12: ...er whenever the switch is pressed at system start up the memorised configuration will be automatically pre selected restarted Repeat to over ride with a new configuration Multi Function Lever ON deploys all selected sweeping equipment To stop and raise all sweeping equipment return the lever to the OFF position In the ON position the lever can be used to control the side brushe s and suction nozzl...

Page 13: ...ew of the sweeper and its immediate surroundings The hopper prop must always be in the deployed position when working under a raised hopper Failure to do so could result in serious injury The door prop must always be used when working under a raised rear door Hopper Raise Press and hold down to raise the hopper Hopper Lower Press and hold down to lower the hopper Rear Door Open Press and hold down...

Page 14: ...ause The accompanying illustration shows the range of information alert symbols that can be displayed however it should be noted that warning symbols only illuminate when a specific condition occurs M NODE Software Error 44 1622 831006 i Flashes across screen when Node software is incompatible Suction fan OFF ON Boost Fan speed Engine speed Option Option Time Wander hose active High pressure water...

Page 15: ...unction ON OFF r Side brush Pressure Switch Turns function ON OFF This function is only effective while the relevant brushes are deployed Controls for overhead wander boom option These are mounted just above the wander boom handle and consist of two buttons for selecting fan extra boost speed 3rd Speed of approx 2500 rpm and or the low pressure dust suppression water supply Engine speed will autom...

Page 16: ...rator also benefits from reduced noise levels within the cab and that any reduction in engine speed also results in a corresponding reduction in fuel consumption Engaging hydrostatic drive Manual gearbox trucks Engine ON and air tanks full before attempting to engage hydrostatic drive mode The hydrostatic gearbox will not engage unless the vehicle is stationary 1 Switch on the hazard warning beaco...

Page 17: ...everting to the original configuration as soon as REVERSE is disengaged 4 Operate the multi function lever to swing the side brushes OUT The multi function lever can also be used to control nozzle tilt See Page 12 for operating details 5 Set the required engine speed by means of the engine speed controls on the main panel normal operation can be conducted at between the default engine speed and 18...

Page 18: ...cessary to increase engine speed to maintain sweeping performance It is advisable to do this before you start to climb the hill The amount of increase will depend on a range of variable factors a The individual characteristics of the engine b The current hopper load c The current sweeping load e g light or heavy material d The angle of the gradient To increase engine speed do one of the following ...

Page 19: ...an OFF 3 Bring the vehicle to a complete stop and apply the hand brake Place the hydrostatic control lever in neutral Whatever the situation remember that the rules of traffic and road safety must be observed 4 Depress the clutch engine speed will drop to idle 5 With the clutch depressed press the sweep mode switch holding it down until the drive symbol changes When hydrostatic drive disengages th...

Page 20: ...not be flashing on the LCD monitor 7 Keep brake pedal pressed so engine revs are below 900rpm 8 Press the drive button D on the Allison transmission selector 9 On the dash gear 4 will show If the gear 4 is flashing on the dash then the Allison gearbox has not engaged Press the sweep mode switch to disengage hydrostatic mode Repeat process from step 3 10 Hydrostatic drive is established when the ge...

Page 21: ... 1 With the vehicle correctly positioned in the discharge area Proceed as follows Before raising the hopper ensure that the vehicle is on firm level ground and that there are no overhead obstructions 2 Engine running Handbrake ON Vehicle in Neutral Multi function lever OFF 3 Select Hydrostatic drive See Page 16 The safety interlock must be pressed in conjunction with the following buttons 4 Open t...

Page 22: ...ot The pump handle is stowed in the cab It should be noted that it will require a substantial number of pumping cycles to complete the following operations The assistance of a second person is highly recommended 1 Engine OFF Handbrake ON 2 Turn ON the ignition do not start the engine Select sweep mode from the main panel 3 Insert the pump handle 4 Pressing the required function button on the Remot...

Page 23: ...dbrake On Sweep mode and multi function lever OFF 1 Remove the wander hose q attached to the rear door 2 Remove either of the blanking plate w from the rear door aperture and stow on the spare fasteners below 3 Attach the wander hose over the exposed aperture e using the captive fasteners 4 Suction fan ON For situations requiring maximum suction power for example when removing stubborn objects etc...

Page 24: ...e boom q from its stowed position w 3 Demount the hose assembly e from its stowage and swing out the entire assembly to the required position 4 Turn the wander hose control r ON always mounted on the drive side If water suppression is required place the multi function lever in the ON position On vehicles equipped with pneumatic assist use the UP Down controller t always mounted on the drive side t...

Page 25: ...stowage and attach suction tube w extra tubes can be added to give greater length 2 Unhook the overhead boom from its stowed position e 3 Suction Fan ON 4 Increased suction use the fan boost If water suppression is required place the multi function lever in the ON position and use button r on the hose assembly control block t An extra fan speed for the overhead boom can be selected use button y on...

Page 26: ...he system is in use e The side brush es are fitted with shut off valves r It is vital that the water system is drained totally if the air temperature is expected to fall to 0 c or below Fully draining the system Open tank drain valve t Open low pressure water shut off valve e Open water strainer valve u Open all brush shut off valves r When the water has stopped draining from the various taps Shut...

Page 27: ...perate any of the above options the vehicle must be in hydrostatic drive with sweep mode ON Press the high pressure water switch on the auxiliary control panel and open the appropriate valve s for the function s required Fan wash assist is only an aid to fan cleaning It is recommended that this option is used immediately following a days sweeping The fan should always be cleaned in accordance with...

Page 28: ...ed to a hose reel i When extending the hose a ratchet mechanism allows the reel to lock in place Further extending past the ratchet allows the reel to retract The position of the hose reel and hand lance is determined by the machine specification In certain cases the hand lance is fitted with a quick release coupling o It is vital that the water system is drained totally if the air temperature is ...

Page 29: ... further investigation of the suction system will need to be carried out 4 If the blockage is still present use a suitable implement a stout length of wood is ideal to remove the obstacle by pushing it downwards Always be aware of the risk from sharp objects and never place your hands into the blockage even when wearing gloves Exercise extreme caution when handling any items removed from the sucti...

Page 30: ...rtially open to allow air to circulate 9 Wash oil cooler ensuring that the fins are clean 10 Lubricate as appropriate all brush links pivot and nozzle wheel 11 Remove clean the L P and H P water filter elements 12 Clean the suction fan thoroughly using the scraper provided and high pressure water See Page 31 13 Conduct a thorough inspection of the fan assembly to verify its condition Report any de...

Page 31: ... scraper thoroughly clean all parts of the fan A steam cleaner or high pressure water from a remote source will greatly assist in cleaning severely contaminated fans 4 Refit the inspection covers and open the rear door Lower the screen Wash the screen using steam or high pressure water Raise the screen and close the rear door Never work under a raised rear door unless the prop is in the deployed p...

Page 32: ...Raise the hopper fully The hopper prop must always be in the deployed position when working beneath a raised hopper Failure to do so could result in serious injury 2 Using the appropriate size spanner remove the filler cap q 3 Top up with HPL 32 or an equivalent hydraulic oil to the appropriate level Pay particular attention the hopper orientation as indicated on the level label when filling 4 Rep...

Page 33: ...duce excellent results in most conditions Experience will determine if other settings are better suited to specific conditions 1 Vehicle stopped handbrake ON sweep mode ON activate the desired brush es in their working positions 2 Switch OFF ignition and remove the key Before proceeding ensure people and objects are clear of the brush area 3 Locate the appropriate valve s in the pneumatic cabinet ...

Page 34: ...wing steps detail the recommended cleaning procedure It will be necessary to place the shut off valve s t in the closed position 1 Unscrew the filter bowl q clockwise from the housing w and remove the element e 2 Wash out the element with clean water or replace if too contaminated 3 Before re assembling the unit apply some grease to the O seal r to ensure a water tight fit for the filter bowl 4 Re...

Page 35: ...anual greasing in accordance with the appropriate schedule on Page 30 and by referring to the accompanying diagrams shown here Central brush wide sweep Side brush assemblies Hopper ram viewed from below Hydrostatic gearbox prop shafts Hopper body and rear door Suction nozzle assembly Door hinge x 3 Locking clamp x 3 Pivot rod x 2 ...

Page 36: ...d 3 Hours Press to view hours logged 4 Return Press to return to previous screen 5 Encoder Turn to highlight required option press to enter Used in all screen modes Press to display side tabs from the sweeping mode screen 6 Camera Press to enable in forward drive rear view only 7 Hopper raise lower and rear door open close warning buzzer Press to disable Screen menu description Driver s fault code...

Page 37: ... 0 mins 0 hrs 0 mins 0 hrs 0 mins 0 hrs 0 mins 0 hrs 0 mins 0 hrs 00 00 CAN Error CAN N3 N4 N5 N6 Hours worked Displays the working time of various functions Service Hours only display when activated Driver fault codes Rotate the encoder to highlight either the CAN or desired Node Press the encoder to enter ...

Page 38: ...5 Error Node6 Error J1939 Error CAN Error ĂƩ s DŝŶ ĂƩ s DĂǆ 00 00 N4 3 4 16 17 22 31 35 36 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 CAN error screen Identifies location of system errors Highlighted in red when active Driver fault codes Entering a Node screen allows Pin Contact view Pin numbers with an active fault are highlighted in RED Open Circuit Short ...

Page 39: ... 00 00 0 RPM 0 0 Km h 00 00 V OFF OFF 00 00 EDC Displays the following current conditions Engine Speed Battery Voltage Pedal Position Parking Brake Position Clutch Position Road Speed Screen Settings Rotate the encoder to highlight the desired panel and press the encoder to enter the setting screen ...

Page 40: ...TE 00 00 0000 TIME 00 00 00 SET 24 00 24 00 Screen brightness setting Rotate the encoder to adjust the screen brightness 2 increments Pressing the MIN button adjusts the brightness to 10 Pressing the MAX button adjusts the brightness to 100 Time date setting Rotate the encoder to the desired panel and press Rotate to the correct Year Day Hour etc and press the set button Repeat above step as requi...

Page 41: ... fitted A green tick displays in the centre of screen icon when camera is activated NOTE This function allows rear viewing when the vehicle is in forward drive When reversing the rear view screen activates automatically Information Displays current Node program version Press button q to access the PDF viewing screen Follow the on screen directions Only to be used when vehicle is stationary NOTE On...

Page 42: ...ecks Highlight the appropriate panel and press the controller Main control panel button check Press the appropriate button on the main control panel As each button is pressed the corresponding graphic will illuminate A beep will sound if the function is fitted 00 00 00 00 WARNING WARNUNG ATTENTION ...

Page 43: ...Part No SCAZ037886 8 6 00 43 E OE Merlin and Magnum Hydrostatic Operating Instructions Auxiliary control panel button check Use the main control panel instructions to test buttons and joystick ...

Page 44: ...Part No SCAZ037886 8 6 00 44 E OE Merlin and Magnum Hydrostatic Operating Instructions Operator s notes ...

Page 45: ...Part No SCAZ037886 8 6 00 45 E OE Merlin and Magnum Hydrostatic Operating Instructions Operator s notes ...

Page 46: ...Part No SCAZ037886 8 6 00 46 E OE Merlin and Magnum Hydrostatic Operating Instructions Operator s notes ...

Page 47: ...Part No SCAZ037886 8 6 00 47 E OE Merlin and Magnum Hydrostatic Operating Instructions Operator s notes ...

Page 48: ...E Scarab Sweepers Limited Pattenden Lane Marden Kent TN12 9QD Telephone 01622 831006 Fax 01622 832417 International 44 0 1622 831006 International 44 0 1622 832417 e mail scarab scarab sweepers com Web site www scarab sweepers com ...

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