Green Machines 400 Series Instruction manual

WorkshopManual
400 Series Green
Machine Suction
Sweeper
Issue 2
Green Machines Sweepers UK Ltd
www.greenmachines.com

GREEN MACHINES 400 SERIES WORKSHOPMANUAL-ISSUE2-PARTNUMBERYM019
PAPAGE0.1
Foreword
This Manual is a technical description of the 400 Series
machine, together with general specifications.
Illustrations are liberally used and are presented in a line
drawing format for clear recognition of components and component
locations. The illustrations are often grouped together where there
is a detailed sequence of operations to be performed.
AmastercontentslistispresentedonthispageandeachChapteralso
containsacontentslistoftheoperationscontainedinthatChapter.
Referencestothe“left”or“right”ofthemachineareinthesenseof
theoperatoratthecontrols,facingforwards.
Allinformation,illustrationsandspecificationscontainedinthis
manualarebasedonthelatestproductinformationavailableatthetimeof
publication.AppliedSweepersLimitedreservetherighttomakechangesto
theinformationhereinatanytime,withoutpriornotice.
Althougheverycarehasbeentakento ensurethattheinformation inthismanualis correct,
no liability can be accepted by Green Machines,or their subsidiary companies for loss,
damageorinjurycausedbyanyerrorsoromissionsintheinformationgiven.
Allrightsreserved.Reproductionortranslation,inwholeorinpart, in any form or by any
means,electronicormechanical,includingphotocopying,recordingorbyanyinformationstorage
orretrievalsystemisnotpermittedwithoutwrittenauthorisationfromGreen Machines.
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⊂∈ TheinformationcontainedinthisdocumentconformswhereverpossibletotheEuropean
MachineryDirective89/392/EECasamendedbyDirective91/368/EEC&93/44/EEC.
Contents PagePage
PagePage
Page
Preliminarysections
Forward 0.1
Workshopprocedures 0.2
Safetyconsiderationsandrelated
information 0.3
Generaldescription 0.3
Machineidentification 0.4
Generalspecifications 0.4
MeanTimeToRepairTimes 0.5
Principlecomponentweights 0.7
Tie-downpoints 0.19
Addendum 0.20
Chapter1-Machinemaintenance 1.1
Chapter2-Coversandbodypanels 2.1
Chapter3-Engine,fuelandexhaust 3.1
Chapter4-Hydraulicsystem 4.1
Chapter5-Watersystem 5.1
Chapter6-Suctionsystemandbrush
assembly 6.1
Chapter7-Roadwheelsandaxles 7.1
Chapter8-Ride-onseat 8.1
Chapter9-Handlesandcontrols 9.1
Chapter10-Electricalsystem 10.1
Chapter11-DogExcrementAttachment(DEA) 11.1
ThisPublicationNo.YM019
CompanionPublications:
KubotaEngineWorkshopManual-PartNo.PD054
EnginePartsCatalogue-PartNo.
MachineServiceSchedule-PartNo.YM004
Machine PartsCatalogue-PartNo.YM193
OperatorsManual-PartNo.YM036
Coverage
This manual applies to Green Machines 400 Series Green
Machine Suction Sweepers, Models 414 S2D (Walk behind) and
414 RS (Ride on seat). 424HS and TR.
Chapter 1 - Servicing CIN 74 - CIN 92.
Chapter 2 - Covers & Body Panels. CIN 74 - CIN 92.
Chapter 3 - Engine. CIN 74 - CIN 97.
Chapter 4 - Hydraulics. CIN 74 - CIN 108.
Chapter 5 - Water System. CIN 74 - CIN 116.
Chapter 6 - Suction & Brushes. CIN 74 - CIN 100.
Chapter 7 - Road Wheels & Axle. CIN 74 - CIN 108.
Chapter 8 - RS Seat CIN 74 - CIN 114.
Chapter 9 - Handles & Controls CIN 74 - CIN 116.
Chapter 10 - Electrical CIN 74 - CIN 116.
Chapter 11 - DEA CIN 74 - CIN 116.

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Workshop procedures
Whenanyrepairworkiscarriedoutonthemachinethe
followingproceduresandinstructionsshouldalwaysbeobserved.
Separating components and joints
Whendismantlingcomponents,neverinsertscrewdrivers
orsimilartoolsbetweenthejointfacestoseparatethetwoparts.
Ifthisisdone,damagewillbecausedtothejointfaces,whichwill
eventuallyresultinoil,coolantorotherfluidleakageatthatjoint.
Whereacomponentistight,carefullytaparoundthejointusinga
softfacedhammertoachieveseparation.
Ifthetwomatingfacesaresealedbyagasket,itisessential
thatthegasketisreplacediftheirisanydoubtaboutitscondition.
Priortoreassemblythematingfacesmustbeperfectlyclean,with
alltracesofoldgasketremoved.
Nuts, bolts and related fastenings
Itisquitecommonforcertainnutsandboltstobecorroded
orseized,particularlyonexposedpartsofthemachine,orinareas
whereanutorbolthasnotbeenremovedforsometime.Theuse
ofreleasingfluid(penetratingoil)mayhelpifthenutorboltis
liberally soaked and left for some time before attempting to
unscrewit.Ifthismethodfails,itmaybenecessarytouseacareful
applicationofheat,ortoactuallycutoffthenutorboltshankwith
ahacksaw.
Oninitialassembly,washersaregenerallyusedunder
certainboltheadsandunderallnuts.Inthecourseofroutine
machine servicing, some of these washers may have been
overlookedand/oromitted.Asageneralruleadoptthefollowing
logicwheneveracomponentisremovedandrefitted.Anyfastening
whichwillrotateagainstacomponentorhousinginthecourseof
tighteningshouldalwayshaveawasherbetweenitandtherelevant
componentorhousing.
Locknutsareusedonmanyfasteningsonthemachine,and
thesecanbere-usedinnon-criticalareas,providingresistance
canbefeltwhenthelockingportionpassesovertheboltorstud
thread.
WhenLOCTITEisusedonthethreadsofaboltwhichisto
bere-used,theoldLOCTITEshouldbecleanedoffwithawire
brush and/or a suitable solvent, and fresh LOCTITE, of the
specifiedtype,appliedonreassembly.
Apartfromcertainfasteningsontheaxle/differential,all
nutsandboltsusedon414machinesareofmetricstandard.The
boltsaresizedaccordingtotheirdiameterandlength.Forexample
anM10x25boltis10mmindiameterand25mminlength.Nuts
andboltsarealsogradedaccordingtotheirstrength.
Metricfasteningshaveagradenumberstampedonthebolt
head,whereasthenutsmayhavethegradenumberonthefaceor
sideofthenut. Inallcases,thehigherthenumberthegreaterthe
strengthoftheboltornut.
Thestrengthrequirementforreplacementfastenersonall
414machinesisasfollows.
Hexagonheadbolts Grade8.8minimum
Socketheadbolts Grade12.9minimum
Nuts Grade8minimum
Tightening torques
Specifictorquesettingsforcriticalcomponentsaregivenin
theSpecificationsatthebeginningof therelevantChapter.Where
atorquesettingisnotlistedthenutorboltconcernedshouldbe
tightenedsecurely.Thefollowingchartcanbeusedasatightening
torqueguideaccordingtoboltsize.
Size Nm lbfft
M6 9to12 6 to 9
M8 19to28 14to21
M10 38to54 28to40
M12 68to96 50to71
M14 109to154 80to140
Workshop tools
Individualspanner/wrenchtypesandsizes,tobeusedfor
normalrepairandservicingworkarenotspecificallylisted,asitis
assumedthatthetechnicianundertakingtheworkwillhavea
reasonableunderstandingofthegeneraltoolsrequiredandtheir
usage.SomeproceduresinthisManualhowever,entailtheuseof
specialtools,suchas twoorthree-leggedpullers,C-spannersetc.
Forreasonsofsafetyaswellastheefficientcompletionofthe
repairoperation,alwaysusethetooldescribedintherelevant
procedure.
Environmental requirements
When disposing of used oil, antifreeze and other
contaminated liquids or consumables., strict environmental
requirementsmustbeadheredto.Donotpourcontaminated
liquidsorfluidsdowndrainsintothegeneralsewagesystemorin
tothegroundtosoakaway.Facilitiesforprofessionaldisposalof
wasteoilandcontaminatedliquidsareoftenavailableandcanbe
accessedbycontactingalocalenvironmentalhealthdepartment
orsimilaragencyforfurtheradvice.

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The400 Series GreenMachineisacompact,self-contained
suction sweeper designed for effective cleaning of pedestrian
precincts andpavements/sidewalks.
ThemachineispoweredbyalowemissionKubotatwin
cylinderwater-cooleddieselengineof479cccapacity.Theengine
ismountedlongitudinallyinthemachinechassiswiththeflywheel
towardsthefrontofthemachine.
Connecteddirectlyontotheenginecrankshaftatthefront
is the impeller which supplies airflow and therefore suction
throughthemachine.Attherearoftheengine,connectedtothe
enginecrankshaftviaaflexiblecoupling,isahydraulicpump.The
pumpsupplieshydraulicfluidunderpressuretothebrushmotors
andtothemachinedrivemotor.
Withtheenginerunning,theimpellerwillbespinningat
crankshaftspeedprovidingcontinuoussuction.Hydraulicpower
forthebrushesanddrivemotorwillalsobeavailable.
Withthemachinemovingforwardandthebrushesoperating,
litteranddebrisissweptintothepathofthesuctionnozzletobe
suckedintothemachine.Thelitteranddebristhenpassthrough
theimpellerandfancasingbeingcompactedandbrokenupatthe
sametime.Thecompactedmatternowpassesthroughtheback
Thefollowingarealistofgeneralsafetyrelatedwarnings
andprocedurialinformation.Additionalwarningswillbefound
throughoutthismanualwhereaspecificoperationdictatesthata
warningisnecessary.Mostwarningsarecommonsense,butall
mustberead,understoodandfollowed.Failuretoheedaspecific
warningcouldresultinmachinedamageorpersonalinjury.
Alwaysensurethatalllocalsafetyproceduresareadheredto.
Alwaysensurethatthemachineisrenderedsafetoworkonbefore
carryingoutanyworkpackage.
Alwaysswitchofftheengineandremovetheignitionkeybefore
carryingout anyworkonoraroundtheengine,fancasingor
impeller,andbeforeremovingthebacktrunkingcomponents.
Donotremovethefillercapfromtheradiatorheadertankwhenthe
engineishot.
Keepyourfingers,hair,andanylooseclothingawayfrommoving
partsatalltimes.
Neverruntheengineinaconfinedspace.
Neverattempttoliftthemachineonyourown,seekthehelpofan
assistant.
Ifanypartofthemachineisraisedfromthegroundforaccess
underneath,ensurethatitisadequatelysupportedonsturdy
blocksorbysimilarmeans,andisinasafeandstablecondition.
Neverraisethemachine,lowerthehandlebarstotheground,or
moveitinany way from its normal upright position when the
engineisrunning.
Alwaysswitchtheengineoffwhenrefuellinganddon’tsmoke.
Safety considerations and related information
Neverrideonanypartofthemachineexceptontheseat(414RS
machinesonly).
Alwaysreadthroughthewholeprocedurefromstarttofinish
beforecarryingoutanyworkonthemachine.
Always record any work or modifications carried out on the
respectivemachineworkfile.
Whenservicing,alwaysadoptapreventativeapproachtothe
servicewherbythemachineisfullycheckedandanyadditional
defectsarerepairedbeforereleasingthemachine.
Whenorderingspares:
a.Alwaysusethecorrectpart.
b.Onlygenuinesparepartsshouldbeused.
c.Whenplacinganorderforsparesalwaysquote:
(i)Partnumber
(ii)Machinechassisnumber
(iii)MachineCINnumber
(iv)Requireddeliverytime
Themachinewarrantywillbeinvalidatedif:
a.Thecorrectmaintenanceproceduresarenotcarriedout
atthecorrectintervals.
b.Non-genuinepartsareused.
c. Unauthorised modifications are carried out on the
machine.
Seethewarrantycardsuppliedwiththemachineforfulldetails.
trunkingtobedepositedintoastandardplastictrash/rubbishbag/
sackattherearofthemachine.Cleanairthenpassesoutthrough
theouterbag.AlargeboreWhooshhoseisalsoavailabletoallow
localisedcleaningofinaccessibleareas.
Themachineisequippedwithawatersystemtodampen
downdustindrydustyconditions.Insuchconditions,thewater
systemwillimprovesweepingandsuctionperformance,and
reducethepossibilityofblockageinthecollectingbagorouterbag.
Themachinecontrolsarelocatedonthehandlebarsforeasy
access by the operator. For additional operator comfort and
machineefficiency,414RSmachinesareequippedwitharideon
seattoenabletheoperatortorideonthemachineduringmost
sweepingoperations.Theseatcanbefoldedandstowedallowing
themachinetobequicklyconvertedtoawalkbehindsweeper
whennecessary.
Anumberofoptionsareavailableincludingasnowplough
attachment, large capacity leaf bags and a Dog Excrement
Attachmentthatallowsefficientcollectionofanimalfouling,and
hygieniccleansingoftheaffectedarea.
Furtherdetailsofalltheindividualmachinesystemscanbe
foundatthebeginningofeachChapterconcernedwiththatsystem.
Machine general description

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Machine identification
A chassis plate is located on the front of the machine
chassison the right-hand side, just infront of the right-hand
wheel.
Thereisparticularinformationcontainedonthechassis
platewhichisrequiredwhenorderingreplacementpartsorwhen
dealingwithAppliedSweepersortheirofficialdistributors.
Inparticular,thefollowinginformationcontainedonthe
chassis plate should always be quoted when dealing with a
machine.
Chassisnumber
CINnumber
Enginenumber
General specifications
Note:Whereapplicable,additionalspecificationsrelatingtoservicingandrepairprocedureswillbefoundatthebeginningofthe
Chapterconcerned.
Dimensions and weights
Note:Refertotheinformationcontainedin‘Principlecomponentweights’laterinthisChapterforspecificweightsofindividual
components.
Overalllength:
414S2D .................................................................... 2.31mtrs(7.57ft)
414RS(withseatretracted) ................................... 2.31mtrs(7.57ft)
414RS(withseatextended) ................................... 3.06mtrs(10.03ft)
Overallwidth .............................................................. 0.84mtrs(2.75ft)
Sweptwidth ............................................................... 1.20mtrs(3.9ft)
Height ....................................................................... 1.13mtrs(3.7ft)
Machineturningcircle................................................. Aboutitsownaxis
Machinekerbweight:
414S2D ................................................................ 400kg(882.0lbs)
414RS(withoutDEA) ............................................ 460kg(1014.3lbs)
414RS(withDEA) ................................................. 482kg(1062.8lbs)
Capacities
Enginesump .............................................................. 3.0ltrs(0.80USgalls)
Coolingsystem .......................................................... 4.0ltrs(1.05USgalls)
Fueltank .................................................................... 9.4ltrs(2.5USgalls)
Watertank ................................................................. 50.0ltrs(13.2USgalls)(nominal)
Hydraulictank:
Non-DEAmachines ................................................ 7.2ltrs(1.9USgalls)
DEAmachines ....................................................... 7.6ltrs(2.0USgalls)

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Lubricants and fluids
Engineoil ................................................................... TurboDieselengineoil,viscositySAE15W/40,toAPISG/CDorbetter
Radiatorcoolant ......................................................... 50/50mixture-glycolantifreeze/water
Fuel ........................................................................ Diesel(ASTMD975cetaneNo.40minimum)
Hydraulicoil ............................................................... TurboDieselengineoil,viscositySAE15W/40,toAPISG/CDorbetter
Generalgreasing/lubrication:
Castorwheels,swivelbearings,brushlinkarms,
axle/differential,spiderpivotpin .............................. Multipurposegrease
Gearboxassembly.................................................. Graphiteorlithium/molygrease
Fancasingstuds,sludgedoor,parking/secondary
brakelinkage,throttlecable,drivelever/rodlinkage .. Engineoil
Enginemanualstopcontrol,brushspeedcontrol,
brushliftcables,ignitionswitch .............................. Penetratingspraylubricant
Batteryterminals,startersolenoidterminals.............. Petroleumjelly
Build standards
Noise ........................................................................ 81dB(A)at2800rpm
Vibration .................................................................... Measuredi.a.w.PrEn1033,ISO8662atmachinehandlegrips-notmore
than2.5m/s2
General ...................................................................... ConformitytorelevantsectionsofUK‘Construction&Use’regulations
A ENGINE TIME
(HRS)
1 EngineChange(Complete) 10.00
2 ReplaceStarterMotor 0.75
3 ReplaceStarterSolenoid 1.00
4 WaterPump(Engine) 1.50
5 ChangeInjectors(Two) 1.00
6 ChangeHeaterPlugs(Two) 0.75
7 ReplaceLeakingFuelPipes 0.50
8 ReplaceInjectionPump 1.00
9 ReplaceFanBelt 1.00
10 ReplaceStopSolenoid 0.25
11 ReplaceAlternator 0.50
12 PulleyFlexCouplingDrive 0.75
13 ReplaceOilSwitch 0.25
14 LiftPump 0.50
15 Radiator 1.00
16 RadiatorHoseTop 0.25
17 RadiatorHoseBottom 0.25
18 ReplaceEngineSump 7.00
19 ReplaceMuffler 0.50
B FUELSYSTEM
1 ReplaceFuelTank 1.00
2 ReplaceFuelFilterAssyComplete 0.50
3 ReplaceLeakingFuelHose 0.50
Mean Time To Repair Times
C TRANSMISSION/CHASSIS
1 ReplaceDifferentialComplete(RSTT040) 2.00
2 ReplaceDriveMotor 1.50
3 ReplaceWheelBearing(RSunit) 1.00
4 ReplaceWheelBearing(S2Dunit) 0.55
5 ReplaceBackPlateBrake 1.00
6 ReplaceGearPinion 1.00
7 ReplaceGearDrive 1.00
8 ReplaceDifferentialBolt 1.00
D HYDRAULICSYSTEM
1 ReplaceHydPump 0.75
2 ReplaceBrushMotor 0.75
3 ReplaceFlexCoupling 0.75
4 ReplaceOilCooler 0.50
5 ReplaceHydBlock 1.00
6 ReplaceHydTank 1.25
7 Replace(Repair)PumpElbow 0.50
8 ReplaceCetopValve 1.00
9 ReplaceReliefValveSoftReverse 1.25
10 SolenoidOnlySoftReverse 1.25
11 ReplaceRotaryValve 0.50
12 ReplaceMainReliefValve 0.50
13 ReplaceCounterBalanceValve(Fwd&Reverse) 0.50
14 Replace Needle Valve 0.50 (NEW)
1.00 (OLD)
15 ReplaceDifferentialSensingValve 0.50

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16 ReplaceShuttleValve 0.50
17 ReplaceHydHoseDM1toDM2 0.50
18 HydHoseSuction 0.50
19 HydHoseDriveMotortoBlock 0.75
20 HydHoseAnyOther 0.5
TO
1.00
E FRONTNOZZLEASSEMBLY
1 FrontNozzleReplacement 1.50
2 SpiderCastingReplacement 1.00
3 ReplaceSpiderPin 0.25
4 ReplaceCastorBush 0.75
5 ReplaceFrontCastorComplete 0.75
6 ReplaceAdjusterSideBrush 0.50
7 ReplaceHorseshoeWearplate 0.50
8 ReplaceCastingSupportBrushArm 0.75
9 ReplaceFrontFlap 0.50
10 ReplaceFrontFlapHingeAssembly 0.50
11 ReplaceBalanceWeight 0.25
F SIDEBRUSHASSEMBLY
1 ReplaceBrushArms,Pins,Hook 0.75
2 ReplaceBumperAssemblyBrush 0.75
3 ReplaceBrushTopPlate 0.50
4 ReplaceCompleteBrushAssembly 1.00
G CASING&ACCESSORIES
1 ReplaceCasing 3.00
2 ReplaceSludgeDoors&Fittings 0.50
3 ReplaceWearPlatesO/S-N/S-Bottom 0.50O/S,
1.00 N/S
4 ReplaceTopWearPlate 2.00
5 ReplaceFishplate 0.50
6 ReplacelmpellerAssembly 0.50
7 ReplacePTOShaft 3.50
H HANDLES&CONTROLS
1 ReplaceDriveLeverAssembly 0.50
2 ReplaceThrottleCableComplete 0.50
3 ReplaceBrushCableComplete 0.50
4 ReplaceIgnitionSwitchComplete 0.50
5 ReplaceOn/OffSwitch 0.50
6 ReplaceFilterMinder 0.75
7 ReplaceWarningLights 0.50
8 ReplaceFlapLever 0.50
9 ReplaceFlapCable 0.50
10 ReplaceStopCable 0.50
11 ReplaceHandleAssembly 2.00
12 ReplaceDriveRod 0.50
13 HandbrakeLever&RodAssemblyComplete 0.50
I SEATASSEMBLY414RS
1 SeatAssemblyComplete 0.50
2 SeatUprightAssembly 0.50
3 CastorForkAssembly 0.50
4 BearingForkAssembly 1.00
5 CamAssemblyLockingPlunger 1.00
6 GuideNylonLong 0.50
7 DamperComplete 0.25
8 TowBarAssembly 1.50
9 BearingSwivel 2.00
10 ReplaceRollers 0.30
J BAGTROLLEY414S2D
1 ReplaceBagTrolleyComplete 0.75
2 ReplaceCastorComplete 0.50
K ELECTRICALSYSTEM
1 ReplaceRectifier 0.50
2 ReplaceBeacon 0.50
3 ReplaceBeeperHorn 0.50
4 ReplaceBeeperFullReverse 0.25
5 ReplaceFrontLightsComplete 0.60
6ReplaceRearLightComplete 0.50
7 ReplaceBatteryCablePositive 0.25
8 ReplaceBatteryCableNegative 0.25
9 ReplaceWiringLoomMain 1.00
10 ReplaceWiringLoomAuxiliary 1.00
11 WiringLoomFrontLights 0.50
12 WiringLoomExtensionSocket 0.25
13 WiringLoomPanelAssembly 1.00
14 TimerfuelsolenoidCut-Off 0.25
15 ReplaceFuseBlock 0.75
L WATERSYSTEM
1 ReplaceWaterPump 0.50
2 ReplaceFrontBrushSprayJetHolder 0.25
3 ReplaceSprayJetHolderBag 0.25
M WHOOSHSYSTEM&FRONTHOSE
1 ReplaceWhooshHose 0.50
2 ReplaceWhooshHandleAssembly 0.25
3 ReplaceHoseCarrierBracket 0.50
4 ReplaceBoomComplete 0.50
5 ReplaceFrontHose 0.50
N COVER+FRONTBOX+WATERJACKET
1 ReplaceWaterJacket 2.00
2 ReplaceTopCover 1.00
3 ReplaceWhooshHoseHolder 0.25
4 ReplaceFrontBoxLid 0.75
5 ReplaceFrontBoxBase 1.00

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Tie-down points
Forsecuringthemachineduringtransportatiedownpointis
providedoneachsideofthemachinejustbehindthemainroadwheels.
Thetie-downpointontheleft-handsideisalug,incorporatedinthe
aircleanerassemblymountingbracket,andapproximatelyatthe
Tie-down point locations on the right-hand and left-hand sides of the machine.
sameheightasthefuelfilter.Ontheright-handsideasimilar
lug,atapproximatelythesameheightisincorporatedatthe
baseofthemainhandleassemblyatthepointwhereitattaches
tothechassis.

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ADDENDUM
ThisSectionistoallowfortheinsertionofanyadditionalinformationwhichmaybeissuedatalaterdate.