Green Machines 525 Hi-Speed Operator's Manual
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Green Machines 525 Hi-Speed Operator's Manual

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525 Hi- Speed
English EN
Operators Manual
To view, print or download
YM044
the latest manual, visit:
Rev. 9 (2-2006)
www.tennantco.com/manuals
*YM137*
www.greenmachines.com

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  • Page 1 525 Hi- Speed English EN Operators Manual To view, print or download YM044 the latest manual, visit: Rev. 9 (2-2006) www.tennantco.com/manuals *YM137* www.greenmachines.com...
  • Page 2 This manual is furnished with each new model. It provides necessary operation and maintenance instructions. Read this manual completely and understand the machine before operating or servicing it. Read this manual completely and understand the machine before operating or servicing it. This machine will provide excellent service.
  • Page 3 ADDITIONAL DOCUMENTATION The Green Machine 525 is supplied with: • An Operators Manual • Service Schedule • Warranty Card • Kubota Engine Manual The above items are provided as part of a support package for the machine and everyone who is involved in Operating, Supervising and managing the machines and their tasking, should be made aware of the above documentation and the information contained therein.
  • Page 4 GREEN MACHINES OPERATORS MANUAL FOR ® The 525 Hi-Speed Green Machine Issue 9 – February 2006 Issue 9 February 2006...
  • Page 5 NOTE Throughout this manual, left and right hand sides apply when sitting in the cab, looking forward. Right hand side Left hand side Issue 9 February 2006...

  • Page 6: Table Of Contents

    CONTENTS SECTION 1 – BEFORE YOU START 1.1 Always top ten 1.2 Never top ten 1.2.1 Operator Check List 1.3 How the machine works 1.4 Things to avoid while sweeping 1.5 Get to know your machine 1.6 Setting the brush angle 1.7 Changing the brushes 1.8 Setting the nozzle height SECTION 2 –...
  • Page 7 SECTION 4– OPTIONS & ACCESSORIES 4.1 Rear-view camera 4.2 Pressure Washer 4.3 Street Washer 4.4 Air Conditioning 4.5 Dog Excrement Attachment (DEA) & (CSA) (Option) 4.6 Automatic Greasing 4.7 Acto bac 4.8 Ice X SECTION 5– THE WASH DOWN SECTION 6– FAULT FINDING SECTION 7–...

  • Page 8: Section 1 - Before You Start

    9. Drive up and down pavement kerbs 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. Issue 9...

  • Page 9: Operator Check List

    1.2.1 Operator Check List for the 525 Green Machine Detailed operator checks procedure is described in section 3 Detailed machine wash down procedure is described in section 5. Daily Action End of Maintenance Procedure Week Before After Shift Action Shift Start Finish Tilt the hopper, applying the safety stay.

  • Page 10: How The Machine Works

    1.3 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 centre of the machine, so that the airflow can pick these up and deposit them into the hopper.

  • Page 11: Get To Know Your Machine

    1.5 Get to know your machine Side access door Flashing beacon Hopper Air exit (knock down) ducts Hopper lid Work Debris lights skirt Dust suppression water tank Lights Rear lights Swing-out water tank catch Side panel Fan impeller Water spray Impeller drive motor...

  • Page 12: Setting The Brush Angle

    1.6 Setting the brush angle This operation usually only 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.

  • Page 13: Changing The Brushes

    1.7 Changing the brushes a. Remove the plastic brush cover, and then loosen the six M8 fixing screws shown on the picture using the tools provided. b. 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.

  • Page 14: Section 2 - Getting Started

    SECTION TWO GETTING STARTED If the machine is set correctly and has been cleaned in the manner prescribed you will get 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.

  • Page 15: Adjusting The Driving Controls

    2.1 Adjusting the driving controls a. Your seat is adjustable: Move the seat forward or backward using the lever below the seat on the right hand side. 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.

  • Page 16: Learning About The Switches

    2.2 Learning about the switches 2.2.1 Switch column You have probably noticed the switch column on your right hand side. Here is an overview of the functions it provides. Hopper Tip Transit / Sweep / Brush Lift (see 2.4.6) (see 2.3.1) AC where fitted Turn the impeller on/off (See 4.3)

  • Page 17: Multifunction Lever Switch

    2.2.2 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). Pushing the lever up flashes the main beam, whatever the position of the column switch.

  • Page 18: Driving The Machine

    the machine 2.3 Driving Please note that in the United Kingdom a full B driving license is required to drive the 525 machine. For other countries please check with your local distributor. 2.3.1 Movement modes Before actually driving the machine, you need to know about its movement modes. The machine has three main movement modes, - Transit mode which you can select on the 3-position rocker...

  • Page 19: Braking

    2.3.3 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.

  • Page 20: Gauges And Beacons

    2.3.5 Gauges and warning lights Diesel tank level High beam (front lights) (white / blue) Handbrake on (red) Indicators (green) No charge (red) Engine rev. Oil warning counter and (orange) hour clock Engine pre-heat (orange) Engine temperature gauge In addition the IQAN system also monitors machine condition and will provide warnings and information on the graphic display (see Section 2.7).

  • Page 21: Starting & Stopping The Engine

    2.3.7 Starting & Stopping the engine (for switch location see section 2.2) a. Engage Neutral b. Get into Transit mode - Transit mode - Sweep mode - Brush lift mode c. Turn the ignition key: 0. Off 1. Power on Engine pre-heat.

  • Page 22: Going Up Pavement Kerbs

    2.3.8 Going up and down pavement kerbs Never go up or down a pavement kerb with the brushes and nozzle down (always use Brush Lift mode) Never drive up and down pavement kerbs at too high a speed or too oblique an angle. Angle is too acute (less than 30 degrees) Proceed as shown on...

  • Page 23: Using The Sweep Mode

    2.4 Using the Sweep mode 2.4.1 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) 2.4.2 Water system While sweeping, set the water pump on/off with this switch Front water jets: When the water pump is on, you can set the amount of water provided to the brushes by turning this control valve (to your left)
  • Page 24 To swing out the water tank, undo the safety chain and then use the lever shown on the picture. You may swing out the rear water tank in order to: • clean the radiator • get access to the water pump •...

  • Page 25: Setting The Brush Height

    2.4.3 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. The metal knob located on the left hand side of your seat adjusts the brushes height.

  • Page 26: Setting Impeller/Brush Speed

    2.4.5 Setting impeller/brush speed To your left hand side are the two levers shown on the picture. Use the left hand side lever 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.

  • Page 27: Tilting The Hopper

    2.4.6 Tilting 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 the engine (do not unlock catches) In order to empty the hopper a.
  • Page 28 e. Remove all remaining debris/trash from the inside of the hopper, using the scraper provided (inside the right hand access door). f. Press the hopper switch (down) until the hopper is in its normal position. g. For manual tilt of the hopper see Section 9. Before tilting the hopper ensure that the machine is on level ground.

  • Page 29: Whoosh Hose

    2.5 Whoosh hose 2.5.1 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,…) 2.5.2 Unblocking a blocked whoosh hose Under normal operating conditions the hose should function effectively.

  • Page 30: Other Devices

    2.6.2 Other devices Radio/CD player A comprehensive manual is provided along with the machine. Here is a summary of the functions provided by the radio/CD player. Power on / off (PWR) Select button: Bass / Treble / Balance / Fader (SEL) Volume up / down for Bass / Treble / Balance / Fader (+/-) Loudness (LD) LCD display...

  • Page 31: Electronic Control System ("Brain")

    2.7 Electronic control system (“brain”) The 525 is controlled by an electronic Machine Management System (MMU) using two main modules: • The MDM is the “brain” of the 525. It has a graphic display and several function keys. It is located top right of the windshield.

  • Page 32: Setting Engine Speed

    2.7.2 To set the engine speed during WORK mode a. With the engine running, the work/transit switch in WORK mode and the Forward/Neutral/Reverse lever in any position. b. Press F1 (select) c. Use Up and Down keys to select the engine speed (between 1200 and 2800 rpm) (but see e. below) d.
  • Page 33 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. If either of the following occurs a beeper will start and the MDM will display the message shown below: •...

  • Page 34: Xt2 ("Slave")

    2.7.3 “Slave” The two LED’s Here is a view of the XT2 (located inside the back panel of the cab, on the left hand side) The XT2 is located inside the back panel of the cab, on the left hand side. It has two LED’s: •...

  • Page 35: Safety Features & Procedures

    2.8 Safety features & procedures Some of the information in this section has already been covered in other sections, but has been repeated for your safety and the safety of others. Folding beacon The flashing warning beacon on top of the machine can fold if hit by an obstacle when driving under a low roof.
  • Page 36 Important safety notes summary STOP Always remember the Do’s and Don’ts (Sections 1.2 and 1.3) Always make sure that all the machine labels are in place, intact and readable. Always apply handbrake and remove ignition key when leaving the vehicle. Always make sure the cab safety catch is secured before driving the machine.

  • Page 37: Fuse Boxes

    2.9 Fuse boxes There are two fuse boxes on the vehicle. They are located on the right hand side of the vehicle, next to the windscreen. Unclip the cover to access the fuses. Use the following pictures to identify which element the fuse protects. First fuse box Machine Management Unit Beacon, Voicebox, Horn, Heater...

  • Page 38: Section 3- Operator Checks

    SECTION THREE OPERATOR CHECKS Always carry out the operator checks with the engine stopped and when the STOP machine is clean 3.1 Daily Operator Checks The operator checks should be carried out at the beginning of each shift. Here is a view of the left hand side of the machine. Hinged side access door (both sides;...
  • Page 39 c. Check hydraulic oil (located on oil reservoir between front and rear wheels). Oil type – Turbo Diesel Engine Oil 15W40 Grade API CF/ACEA 2. Max. Fill Min. Fill d. Open the left hand side access door. Top up hydraulic oil as required e.
  • Page 40 i. Top up main dust suppression water tank. (back of the vehicle, behind debris skirt) j. Top up fuel tank.(open right hand side access door) k. Check the filter minder (once the filter minder has switched to red, it will stay red, even when the engine is switched off) Here is a view of the elements located behind the cab.

  • Page 41: Weekly Operator Checks

    m. Check lights and beacon n. Check brush wear – replace as required o. Check nozzle height – The sole of the polyurethane wear plate should be 10mm above the ground. p. Check tyres for correct pressure (see section 7.9) and condition. q.

  • Page 42: Section 4- Options & Accessories

    SECTION FOUR OPTIONS & ACCESSORIES 4.1 Rear-view camera (optional) The rear-view camera is used like an interior rear-view mirror. Rear-view camera (on the hopper) If necessary, carefully clean the camera lens using a soft cloth. LH/RH View Rear-view camera display (left hand side in the cab) Tint Turn on rear view camera display...
  • Page 43 Power ON/OFF switch, ▲ +, ▼ –, CONTROL BUTTON These control buttons are used to scroll up and down to select menu options. 3. “MENU” Button If you press the “MENU” button, the following list of options will be shown on the monitor. PICTURE SYSTEM OPTION...
  • Page 44 Remote Control 1. MODE Press the mode 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.

  • Page 45: Pressure Washer

    4.2 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 lance with 2 hands. DO NOT point the spray nozzle at people or animals, as the high pressure spray can cause serious injury.

  • Page 46: Street Washer

    4.3 Street Washer Model – 525SW Introduction The street washer 525SW is a dual function machine, which can perform both the 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 and does not involve the use of tools.
  • Page 47 STOP DO NOT fill the hopper through the hopper door. Fill the rear dust suppression water tank using a 30mm hose – about 130 litres. Move the 3 way valve, to the “Hopper” position – located above the rear left hand suspension spring/damper (swing out the rear water tank).
  • Page 48 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. DO NOT run the street washer pump for periods of 2 minutes with no water passing STOP through the pump.

  • Page 49: Air Conditioning

    4.4 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 heat exchanger located behind the drivers headrest. A circulation fan passes air through the evaporator and along a roof duct on the right hand roof rail.

  • Page 50: Dog Excrement Attachment (Dea) & (Csa) (Option)

    4.5 Dog Excrement Attachment (DEA) & (CSA) (Optional) The Dog Excrement Attachment (DEA or CSA) is designed to suck up anti-social deposits. It comprises a high speed, high suction vacuum pump driven by a hydraulic motor. The suction pump evacuates a stainless steel container.
  • Page 51 DEA Preparations 1. Insert DEA plastic sack into container. 2. Replace container. 3. Ensure water tank has sufficient water. 4. Add neat Acto-Bac to water tank, in the ration of 1:50 (3 litres for a full water tank). Using the DEA 1.

  • Page 52: Automatic Greasing

    4.6 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. In common with other electro mechanical devices however, proper operation procedures must be carefully observed.

  • Page 53: Acto Bac

    Action: Check main supply. Check 2A fuse, which must be fitted to protect the installation. If the fuse has blown there may 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. 4.

  • Page 54: Section 5- The Wash Down

    SECTION FIVE THE WASH DOWN At the end of each shift it is important to wash the machine and components correctly using a fresh water hose. Always remove the ignition key before starting to strip the machine down STOP 1. Unlatch the hopper door and tip out any debris which may be in the hopper. Leave the hopper in the up position.
  • Page 55 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. 7. Swing open rear water tank and wash the radiator matrix taking care not to damage the cooling fins. 8.

  • Page 56: Section 6- Fault Finding

    SECTION SIX FAULT FINDING Always remember, when trying to fault find, switch the machine off, remove the ignition keys, carry out the necessary actions. Restore the machine to its normal running conditions before STOP rechecking the machine. a. Machine is not picking up / poor suction thereby leaving a trail (remember the notion of airflow;...
  • Page 57 h. Smoking engine 1. Dirty air filter element (black smoke) 2. Incorrect fuel used (see section 7) 3. Burning oil (blue smoke) 4. Leaking cylinder head gasket (white/misty smoke) 5. Faulty Turbo (black or blue smoke & lack of power) i.

  • Page 58: Section 7- General Specifications

    SECTION SEVEN GENERAL SPECIFICATIONS 7.1 Machine Dimensions: Length – overall (including brushes) 3120mm (123 in) Length – over body 2730mm (108 in) Width – over body 1100mm (43.3 in) Width – over wheels with track extended 1340mm (52.8 in) Height – (excl. folding beacon) 1980mm (78 in) Wheelbase 1200mm (47.2 in)

  • Page 59: Noise

    7.5 Noise The machine complies with in-cab noise levels in accordance with 98/37EC and the sound power measurement to 2000/14/EC is 107dBLwa. 7.6 Suction system High flow, through fan suction system with cyclonic dust separation. Twin contra-rotating floating brushes with in-cab adjustment of height, and independent joystick control of brush swept path width.

  • Page 60: Hydraulic System

    7.12 Hydraulic system Transmission - Closed centre hydrostatic drive with servo controlled variable output swash plate pump. - Ge-roller wheel motors (4 wheel drive). Auxiliaries - Gear type auxiliary pump with pressure compensated variable flow control for suction and brush motors.

  • Page 61: Section 8 - Chassis Plate Indentification

    SECTION EIGHT CHASSIS PLATE INDENTIFICATION 525 CHASSIS NUMBER 0204258 Applied Sweepers LTD. Bankside Falkirk Scotland FK2 7XE Tel. 01324 611666 MODEL 1 - Year of manufacture 0204258 CHASSIS 2 - Month of manufacture XW1581 ENGINE 3 - Serial number C.I.N. Plate fitted to front right corner of 1988kg chassis with permanent rivets.

  • Page 62: Section 9 - Vehicle Rescue

    SECTION NINE VEHICLE RESCUE In case of an engine 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 90º the machine may be winched onto the rescue vehicle.

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