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.
⊂∈
⊂∈
⊂∈
⊂∈
⊂∈ 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.

3
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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.

GREEN MACHINES 400 SERIES WORKSHOPMANUAL-ISSUE 2-PARTNUMBERYM019
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Introduction
1
Contents
Machine maintenance
Section
ThisChaptercontainscomprehensiveprocedurescoveringall
aspectsofservicingandmaintenanceofthe400 Series Green
Machine.
Theserviceschedulelistsalltheservicerequirementsandthe
timeintervalsatwhichthevariousactionsshouldbeperformed.For
referencepurposes,alistoftheactionsthatmustbecarriedoutbythe
machineoperatoratthestartandfinishofeachdailyshiftarealso
provided.FulldetailsoftheseproceduresaregivenintheOperators
Manual.
Theserviceprocedurescontaindetailedinstructionsonhowto
performalltheserviceactionsrequired.AswiththemainChaptersof
thismanual,theserviceproceduresaregroupedintosimilarSections,
eachcoveringaspecificareaofthemachine.
The 400 Series Green Machine is designed to operate in
extreme environmental conditions, however, for reliable
performance it is essentialthattheservicerequirementscontained
in this Chapter are strictly adhered to. Also, to eliminate
unnecessary down-time, a philosophy of preventative
maintenance based on critical visual inspectionmustbeadopted.
Specifications
Engine,fuelandexhaust
Valveclearances(cold):
Inletandexhaust .............................................................................. 0.145to0.185mm(0.0059to0.0073in)
Engineoil:
Type ................................................................................................ TurboDieselengineoil,viscositySAE15W/40,to
APISG/CDorbetter
Capacity ........................................................................................... 3.0litres(0.8USgallons)
Radiatorcoolant:
Type ................................................................................................ 50/50mixture-antifreezewater
Capacity ........................................................................................... 4.0litres(1.05USgallons)
Fanbelt:
Adjustment....................................................................................... Approximately10.0mm(0.39in)deflectionat
longestrunofbeltundermoderatefingerpressure
Fueltankcapacity .................................................................................. 9.4litres(2.5USgallons)
Fueltype ............................................................................................... Diesel(ASTMD975cetaneNo.40minimum)
Hydraulicsystem
Hydraulicoil:
Type ................................................................................................ TurboDieselengineoil,viscositySAE15W/40,to
APISG/CDorbetter
Capacity:
Non-DEAmachines .................................................................... 7.2litres(1.9USgallons)
DEAmachines ........................................................................... 7.6litres(2.0USgallons)
Mainfilterelement:
Type ................................................................................................ AppliedSweepersPartNo.HC058
Specification ..................................................................................... 10micronfiltration(absolute),210bar(3000psi)
collapsepressure,non-bypass
DEAsub-manifoldpressurefilter(whereapplicable):
Type ................................................................................................ Minipressurefilter(refertoAppliedSweepersfor
PartNo.)
Specification ......................................................................................... 10micronfiltration(absolute),non-bypass
Introduction
Serviceschedule
Serviceprocedures
Precautionsandgeneralinstructions 1
Enginefuelandexhaust 2
Hydraulicsystem 3
Watersystem 4
Suctionsystemandbrushassembly 5
Roadwheelsandaxles 6
Rideonseat 7
Handlesandcontrols 8
Electricalsystem 9
DogExcrementAttachment(DEA) 10
AddendumtoChapter1 11

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Systempressures:
Mainsystempressure(measuredattestpoint“PS”) ............. 192bar(2800psi)
Softreversepressure(measuredattestpoint“MBX”) ........... 71bar(1050psi)
Watersystem
Watertankcapacity ................................................................. 50litres(13.2USgallons)(nominal)
Roadwheelsandaxles
Tyrepressures ........................................................................ 3.1bar(45psi)
Brakeshoefrictionliningminimumthickness ............................ 1.0mm(0.039in)
Electricalsystem
Alternatornoloadvoltage ........................................................ 18voltsAC(minimum),atmaximumenginespeed
DEAunit
Vacuumpumpdrivebeltadjustment .......................................... Approximately10.0mm(0.39in)deflectionatlongestrunof
beltundermoderatefingerpressure
Torquesettings Nm lbfft
Cylinderheadcovernuts .......................................................... 3.9to5.9 2.9to4.3
Impellerbolt ........................................................................... 126 93
Axlenut .................................................................................. 70to75 52to55
Differentialbolts ...................................................................... 26to29 19to21
Service schedule
Every use
Note:TheactionslistedinthisSectionaretobeperformedbythe
machineoperator.RefertoOperatorsManualforspecificdetails.
At the start of each daily shift
Checktheengineoillevelandtopupwhererequired.
Checkthehydraulicoillevelandtopupwhererequired.
Checkthecoolantlevelintheradiatorheadertankandtopup
whererequired.
Checkthatthewatertankisfullandtopupwhererequired.
Checktheoperationofthewaterpumpandsprayjets.
Checkthatthedieseltankisfullandtopupwhererequired.
Checkthattheinnersockandouterbagsareclean.
Checktheconditionofthebrushesandreplacewhererequired.
Check,andifrequiredadjust,thefrontnozzleheight.
Check,andifrequiredadjust,thebrushheight.
Checktheoperationoftheflashingbeacon,audiblebeepers,
andallexternallights.
At the end of each daily shift
Stripmachineinaccordancewithoperatorsmanualand:-
Thoroughlywashtheenginearea.
Thoroughlywashtheradiatormatrix.
Thoroughlywashthefancasingandtrunking,thesuction
nozzleandsuctionhose.
Thoroughlywashthedustbags,innerbagsandnylonsock(as
applicable).
ThoroughlywashandblowdrytheDEAcontainerfilter(where
fitted).
Thoroughlywashtheseatmechanism(414RSonly).
Thoroughlywashthemachineexterior.
Removeandcleanthewatersprayjetsandfilters.
ChecktheoperationoftheDEAwatervalve/sprayjet(where
fitted).
Removeandcleantheairfilterhousingendcap.
ChecktheconditionoftheWhooshhose(wherefitted).
ChecktheconditionoftheDEAsuctionhoses(wherefitted)
Checktheconditionandpositionofthewingmirrorsand
adjustwhererequired(414RS/424HS & TR).
Withenginerunningathalfthrottle,checkthereadingonthe
airfilterminder.
Checktheoperationofthefoeward/reversedrivelever.
Checktheoperationofthebrakingsystem.
Checktheoperationoftheparking/secondarybrake(414
RS , 424HS & TR).
Checktheoperationofthesoftreversecontrol.
Checktheoperationofthereversestopcontrol(wherefitted).
Checktheoperationofthebrushliftleverandcables(where
fitted)
ChecktheoperationoftheDEAsystem(wherefitted).

GREEN MACHINES 400 SERIES WORKSHOPMANUAL-ISSUE2-PARTNUMBERYM019
PAPAGE1.3
Every 3 weeks or 200 hours
(which-ever comes first)
Note:TheactionslistedinthisSectionaretobeperformedbya
fitter/technician.
Engine, fuel and exhaust (Section 2)
Changetheengineoil.
Changetheengineoilfilter(every6weeks/200hours).
Checktheoperationoftheairfilterminder.
Renewtheairfilterelement(whererequired).
Checktheconditionandsecurityofthe air inlet pipe and
clamps.
Cleanthefueltankstrainer.
Checktheconditionofthefuelpipes,hosesandclamps.
Checktheconditionofthefuelfilterelementandreplacewhere
necessary.
Checktheconditionandadjustmentofthefanbelt.
Checktheconditionandsecurityoftheradiatorhosesand
clamps.
Checktheradiatorcoolantmixturestrength.
Hydraulic system (Section 3)
Checkthehydraulicoillevelandtopupwhererequired.
Clearanydebrisfromthebrushmotorshafts.
Water system (Section 4)
Removeandcleanthewatersprayjetsandfilters.
Removethewatertankdraincapandcleanthesuctionfilter.
Suction system and brush assembly (Section 5)
Check the front castors for wear and grease the swivel
bearingsandaxlespindles.
Lubricatethefrontcastoradjustersandsetthefrontnozzle
height.
Lubricate,andwhererequiredadjust,thefrontflapandcable.
Greasethebrushtopandbottomlinkarmpivots.
Greasethespiderpivotpinandcheckthesecurityofthelynch
pin.
Checktheconditionoftheimpellerandwearplates,andcheck
thetightnessoftheimpellerretainingbolt.
Checkthatallwarninglabelsarepresentandlegible.
Lubricatethezipofthedustbag.
Road wheels and axles (Section 6)
Greasethedifferentialaxlebearings.
Checktheconditionandoperationofthebagtrolleycastor
(S2Donly).
Ride on seat (Section 7)
Greasetherearcastorforkswivelbearings.
Removethetrailerguiderollersandcheckforfreedomand
wear.Ensureguiderollersaredirtfree.
Checkallpivotpointsonthetowbar,trailerandseatmechanism
forfreedomandsecurity.
Handles and controls (Section 8)
Lubricatetheparking/secondarybrakelinkage.
Lubricate,andwhererequiredadjust,thethrottlecable.
Lubricateandwhererequiredadjust,thebrushspeedcontrol
cable.
Lubricate and where required adjust, the brush lift cable
(wherefitted).
Lubricatethedriveleveranddriverodlinkageandpivots.
Check,andwhererequiredadjust,thedriverodlinkage,and
checkdriveandbrakingoperation.
Lubricate,test,andwhererequiredadjust,theenginemanual
stopcable.
Checktheoperationofthesoftreversecontrol.
Checktheoperationofthereversestopcontrol(wherefitted).
Electrical system (Section 9)
Checkthebatteryelectrolytelevelandtopupwherenecessary.
Checkthechargingcircuitandalternatoroutput.
Checktheoperationofallcontrolpanelwarninglights.
Checktheoperationoftheflashingbeacon,audiblebeepers,
andallexternallights.
Dog Excrement Attachment (DEA) (Section 10)
ChecktheconditionoftheDEAcontainerfilterandreplaceas
necessary.
Checktheconditionofthesuctionhoses.
Checktheoperationofthewatervalveandsprayjet.
ChecktheoperationoftheDEAsystem.
Every 12 weeks or 600 hours
(whichever comes first)
Inadditiontoalltheactionsdescribedpreviously,carryoutthe
following.
Note:TheactionslistedinthisSectionaretobeperformedbya
fitter/technician.
Engine, fuel and exhaust (Section 2)
Replacethefuelfilterelement.
Thoroughlycleantheradiatormatrixusingcompressedair.
Hydraulic system (Section 3)
Check the condition tightness of all hydraulic hoses and
unions.
Suction system and brush assembly (Section 5)
Lubricatethefancasingstudsandthesludgedoorhinges.
Road wheels and axles (Section 6)
Checktheconditionoftheroadwheelsandtyresandadjustthe
tyrepressures.
Checkthetightnessofthedifferentialbolts.

GREEN MACHINES 400 SERIES WORKSHOPMANUAL-ISSUE2-PARTNUMBERYM019
PAPAGE1.4
Ride on seat (Section 7)
Checktheoperationoftheseatmechanismlockingassembly
andrearcastorlockingpin.
Checkthetightnessofallseatmechanismnutsandbolts.
Checktheconditionoftherearcastorandcheckthetread
depth.
Electrical system (Section 9)
Check the condition of all electrical wiring and check all
terminalsforcorrosion.
Lubricatetheignitionswitchandgreasethebatteryandstarter
solenoidterminals.
Dog Excrement Attachment (DEA) (Section 10)
Checktheconditionandadjustmentofthevacuumpump
drivebelt.
Every 6 months or 800 hours (which-
ever comes first)
Inadditiontoalltheactionsdescribedpreviously,carryoutthe
following.
Note:TheactionslistedinthisSectionaretobeperformedbya
fitter/technician.
Engine, fuel and exhaust (Section 2)
Drain,flushandrefillthecoolingsystem.
Checktheenginevalveclearancesandadjustwhererequired.
Checkthefuelinjectorinjectionpressure.
Hydraulic system (Section 3)
Changethehydraulicoilfilterelement(initiallychangeafter
first8weeksonanewmachine).
Carryoutahydraulicsystempressurecheck.
Suction system and brush assembly
(Section 5)
Checktheconditionofthefrontnozzlehorseshoewearplate.
Checkthedustbagconditionandlaunder/repairwhererequired.
Road wheels and axles (Section 6)
Greasethegearboxassembly.
Checktheconditionoftheparking/secondarybrakeshoesand
drum(414RSonly).
Every 12 months or 2000 hours
(whichever comes first)
Inadditiontoalltheactionsdescribedpreviously,carryoutthe
following.
Note:TheactionlistedinthisSectionistobeperformedbya
fitter/technician.
Hydraulic system (Section 3)
Changethehydraulicoil.
Dog Excrement Attachment (DEA) (Section 10)
Replacethehydraulicmanifoldpressurefilter.
Service procedures
1 Precautions and
general instructions
Notethefollowingpointsbeforecarryingoutanyofthe
followingservicingprocedures:
Refer to the specifications at the start of this Chapter for
informationontorquesettings,specificclearances,lubricants
andcapacities.
Ensurethatallreplacementpartsareofthecorrecttypeand
specification.Thisiscriticallyimportantwhenreplacingany
componentsinthehydraulicsystem.Servicekitscomprising
allmaterialsnecessaryforeachserviceintervalareobtainable
fromAppliedSweepersLimited.
Refertothesafetyconsiderationslistedinthepreliminary
sectionsofthismanualbeforestartingwork.
Removetheignitionkeyandpulloutthemanualstop
controlforallthefollowingoperationsunlessthereare
specificinstructionstothecontrary.
Observeallrelevantenvironmentalregulationswhendisposing
ofusedoilsandcontaminatedconsumables.
Toimproveaccessandassistwithvisualinspections,remove
thedustbags,downwardbagflangeandbacktrunkingbefore
carryingoutanyofthefollowingprocedures.(RefertoOperators
Manual).
Ensurethatthemachinehasundergoneathoroughwash
down and is completely clean prior to commencing any
servicework.
Wherevisualinspectionindicatesthatcomponentreplacement
isnecessary,refertotherelevantChaptersofthismanualfor
specificdetails.

GREEN MACHINES 400 SERIES WORKSHOPMANUAL-ISSUE2-PARTNUMBERYM019
PAPAGE1.5
2 Engine, fuel and
exhaust
Every 3 weeks or 200 hours
Engine oil change
1To assist oil flow and aid the draining of sludge, it is
preferabletodraintheoilwhentheengineiswarm.
2Cleantheareaaroundtheengineoilfillercapthenremove
thecap(Fig.1.1).
3Unscrewthesumpdrainpluganddraintheoilintoa
container.
4Checktheconditionofthesumpplugwasherandreplace
ifnecessary.
5Whentheoilhasdrained,refitthesumpplugandtighten
securely.
6Filltheenginewiththespecifiedtypeandquantityof
engineoil,throughtheoilfillertube.
7Pullouttheengineoildipstickandwipeitclean.Re-insert
thedipstick,thenwithdrawagainandchecktheoillevel.Topup
asrequiredtobringtheleveluptotheupper“MAX”markonthe
dipstick(Fig.1.2).Refittheoilfillercaponcompletion.
Engine oil filter change (every 200 hours)
8Removethewatertankandenginecover(seeChapter2).
Notethatitisnotstrictlynecessarytoremovethewatertank,but
whenremoved,greateraccessisprovidedtoallcomponentsfor
visual inspection and for this reason, tank removal is
recommended.
9Initially slacken the oil filter using a proprietary filter
removaltool,thenunscrewittherestofthewaybyhand
(Fig.1.3).Bepreparedforoilspillage.
10 Cleanthefiltersealingareaontheengine,thenapplya
lightcoatingofengineoiltothesealingringofthenewfilter.
11 Screwthefilterintopositionandtightenitsecurelyby
handonly-donotuseanytools.
12 Refittheenginecoverandwatertank.
13 Starttheengineandcheckforleaksaroundthefilter
sealingring.
14 Switchtheengineoff,rechecktheengineoillevelandtop
upasrequired.
Air filter minder check
15 Using a rag, or preferably a surgical rubber glove,
completelycoverthewiremeshairintakeontheundersideofthe
airfilterhousing.Forimprovedaccess,removetheplasticWhoosh
hosecarrier(wherefitted)fromthebracketadjacenttotheair
filterhousing.
16 Starttheengineandallowittorunforashorttime.Check
thattheyellowindicatorontheairfilterminderhasmovedfullyup
intotheredsectorofthegauge.Checkalsothattheredwarning
lightonthecontrolpanelhasilluminated.
17 Switchofftheengine,presstheairfilterminderreset
buttonandcheckthattheyellowindicatorreturnstozero.Remove
theragorgloveand,whereapplicable,refittheWhooshhose
carrier.
18 Iftheoperationoftheunitwasnotasdescribed,checkthe
conditionandsecurityofthevacuumhose,theairfilterhousing
andtheairinletpipesandhoses.Replaceanysuspectcomponents
andrepeatthecheck.
19 Ifaproblemstillexists,replacetheairfilterminder.
Air filter element and air inlet components
20 Theairfilterelementshouldbereplacedwhenthereading
on the air filter minder indicates 25” of water and/or the red
warninglightonthecontrolpanelilluminates.
21 Releasethespringclipsandliftofftheairfilterend
cap(Fig.1.4).
Fig. 1.1 Engine oil dipstick (A) and filler cap (B).
Fig.1.2Engineoilmaximumandminimumlevelmarkings.
Fig. 1.3 Slacken the oil filter using a filter removing tool.

GREEN MACHINES 400 SERIES WORKSHOPMANUAL-ISSUE2-PARTNUMBERYM019
PAPAGE1.6
22 Unscrewthewingboltandwithdrawthefilterelement
(Figs.1.5and1.6).
23 Withdrawtheendcapinnersectionandthoroughlyclean
bothparts,aswellastheairfilterhousingitself(Figs1.7and1.8).
24 Fitanewairfilterelementandreassemblethecomponents
inreverseorder.Ensurethattheendcapisfittedwiththeword
“TOP”uppermost(Fig.1.9).
25 Checkthetightnessoftheairfilterhousingmountingsand
theconditionandsecurityoftheintakepipes,hosesandclamps.
Fuel tank strainer, pipes, hoses and clamps
26 Unscrewthefueltankfillercapandwithdrawthestrainer
fromthefillerneck(Fig.1.10).
27 Clean the strainer using a suitable solvent and dry
thoroughly.
28 Refitthestrainerandfillercap.
29 Closelyinspectallmetalfuelpipesandflexiblehosesand
checkthetightnessofallhoseclampsandunionnuts.Replace
anysuspectcomponentsasnecessary.
Fan belt check and adjustment
30 Remove the engine cover by releasing the two stud
fasteners.
31 Checktheconditionofthefanbeltoveritsentirelength,
turningtheengineasnecessarybymeansofthefanblades.If
thereareanysignsofcracks,splitsorotherdeterioration,thebelt
shouldbereplaced(seeChapter3).
Fig. 1.4 Release the spring clips and lift off the air filter
end cap.
Fig. 1.6 Remove the filter element from the housing. Fig.1.7Withdrawtheendcapinnersectionfromthecap.
Fig.1.8Thoroughlycleanbothpartsandthefilterhousing
itself.
Fig. 1 9 Ensure that the end cap is fitted with the word
“TOP” uppermost.
Fig. 1.5 Unscrew the air filter element wing bolt.

GREEN MACHINES 400 SERIES WORKSHOPMANUAL-ISSUE2-PARTNUMBERYM019
PAPAGE1.7
32 Ifthebeltconditionissatisfactory,checkthetightnessby
pressing the belt with moderate thumb pressure at a point
midwaybetweenthecrankshaftandalternatorpulleys
(Fig.1.11).Thefanbeltdeflectionshould be as given in the
specifications.
33 Ifadjustmentisnecessary,slackenthealternatormounting
andadjustmentboltsandmovethealternatorasrequireduntilthe
correctadjustmentisobtained.Holdthealternatorinthisposition
andtightentheadjustmentbolt,thenthemountingbolt.
34 Refittheenginecoveraftercompletingtheremainderof
theserviceprocedures.
Radiator, hoses and clamps
35 Removetheenginecover(ifstillinplace)byreleasingthe
twostudfastenersandcarefullyexamineallradiatorandcooling
systemhosesforsignsofcracks,splitsorcoolantseepage.
Renewanysuspecthoses.
36 Also check for any signs of chafing against adjacent
componentsandensurethatallclampsaretight.
37 Attheintervalsspecified,thoroughlycleantheradiator
matrixusingcompressedair.
38 Refittheenginecoveraftercompletingtheremainderof
theserviceprocedures.
Radiator coolant mixture strength
39 A50/50mixtureofwaterandethyleneglycolantifreeze
mustbemaintainedinthecoolingsystematalltimestoprovide
adequateprotectionagainstfreezing(dependingonlocalclimate),
corrosion,andthebuildupofscaledeposits.
40 The mixture strength can be accurately checked by
measuringthespecificgravityofthecoolantusingaproprietary
hydrometeravailablefromautomotivepartsstockists(Fig.1.12).
41 Removethefillercapfromtheradiatorheadertankand
takeasampleofthecoolantusingthehydrometer.
Warning!Makesurethattheengineiscoldbeforeremoving
thefillercap.
42 Ifthehydrometerreadingindicatesthatthemixturestrength
issignificantlybelowthespecifiedratio,itmaybenecessaryto
partially drain the cooling system and top up with a neat
concentrationofantifreeze.Oncethecorrectstrengthisrestored,
allsubsequenttoppingupcanthenbedonewitha50/50water/
antifreezemixture.
Every 12 weeks or 400 hours
Fuel filter element
43 Thefuelfilterislocatedattherearleft-handsideofthe
machine,belowtheradiator.
44 Turnoffthefuelsupplybyturningthefuelcockonthefilter
body90ºtotheleftsothefuelcockleverishorizontal.
45 Wipecleanthefilterbowlexteriorandplaceacontainer
beneaththebowltocollectspilledfuel.
46 Unscrewtheretainingringandremovethefilterbowlfrom
thefilterbody(Fig.1.13).
47 Withdrawthefilterfromitslocation(Fig.1.14).
48 Thoroughlycleanthefilterbowlandchecktheconditionof
thesealingO-ring.ReplacetheO-ringifthereareanysignsof
deterioration.
Fig. 1.10 Withdraw the fuel tank strainer from the filler
neck.
Fig. 1.11 Fan belt adjustment.
1. Alternator adjustment bolt.
2. Alternator pulley.
3. Alternator front mounting bolt.
A. Fan belt deflection checking point.
Fig. 1.12 Check the coolant mixture strength using a
hydrometer.

GREEN MACHINES 400 SERIES WORKSHOPMANUAL-ISSUE2-PARTNUMBERYM019
PAPAGE1.8
49 Checktheconditionofthefilterelement.Theelement
mustbereplacedattheintervalshownintheserviceschedule,or
atearlierintervalsifthereisanysignofcontamination.
50 Locatethefilterintothefilterbody,thenrefitthefilterbowl
andsecurewiththeretainingring.
51 Turnonthefuelsupplybymeansofthefuelcock,then
slackentheairventplugonthefrontofthefilterbody(Fig.1.15).
52 Allowtheairtobleed,thentightentheventplugwhenfuel
freefromairbubblesflowsfromthevent.
Radiator matrix
53 Removetheenginecover(ifstillinplace)byreleasingthe
twostudfastenersandcarefullyexamineallradiatorandcooling
systemhosesforsignsofcracks,splitsorcoolantseepage.
Renewanysuspecthoses.
54 Thoroughlycleantheradiatormatrixusingcompressed
air.
55 Refittheenginecoveraftercompletingtheremainderof
theserviceprocedures.
Every 6 weeks or 800 hours
Radiator coolant change
56 Remove the engine cover by releasing the two stud
fasteners.
57 Forimprovedaccesstotheradiatorbottomhose,remove
theairfilterassembly(seeChapter3).
58 Removethefillercapfromtheradiatorheadertank,then
positionasuitablecontainerbeneaththebottomhoseconnection
attheradiator.
59 Slackentheclamp,disconnectthehoseandallowthe
coolanttodrain.
60 Whentheradiatorhasdrained,repositionthecontainer
undertheleft-handsideoftheengine.
61 Unscrewtheenginecoolantdraintaplocatedalongsidethe
engineoildipstickandallowthecoolanttodrain.
62 Toflushthesystem,closethedraintap,reconnectthe
bottomhoseandfillthesystemwithplainwater.Refitthefillercap
andairfilterassembly.Starttheengineandallowittowarmup.
63 Stoptheengine,allowittocoolfully,thendrainthesystem
again.Repeatasnecessary until only cleanwater,freefrom
corrosionandscaledeposits,emerges.
64 Iftherecommendedantifreezemixturehasbeenused,and
thesystemhasbeendrainedandflushedregularly,theabove
procedurewillbesufficienttoremoveallcorrosionandscale.If,
however,thesystemhasbeenneglected,aproprietaryde-scaling
agentmaybeneededandshouldbeusedinaccordancewiththe
instructionssuppliedwiththeproduct.
65 Oncompletion,checkthatthedraintapissecurelyclosed
andthatthebottomhoseclampistight,thenfillthesystemas
previouslydescribed.
66 Refittheenginecoveraftercompletingtheremainderof
theserviceprocedures.
Valve clearances
Note:Theenginemustbecoldforthefollowingprocedures.
67 Remove the engine cover by releasing the two stud
fasteners.
68 Disconnect the crankcase breather hose from the
cylinder head cover and move aside all other hoses and
attachments(Fig.1.16).
69 Unscrewthetwodomenutsandremovethecylinderhead
coverandgasket.
70 Theinstallationarrangementoftheengineinthe414
machinemakesitdifficulttodeterminetheTDConcompression
positionforNo.1cylinder,whichistherequiredpositionforvalve
clearanceadjustment.Toovercomethisproblem,thefollowing
procedurecanbeadopted.
Fig. 1.14 Withdraw the filter from its location.
Fig.1.15 Slacken the air vent plug on the frontof the filter
body to bleed the fuel filter.
Fig. 1.13 Unscrew the retaining ring and remove the filter
bowl from the filter body.

GREEN MACHINES 400 SERIES WORKSHOPMANUAL-ISSUE2-PARTNUMBERYM019
PAPAGE1.9
71 StartingwithNo1cylinder(atthetiminggearendofthe
engine),turntheenginecrankshaft.bymeansoftheradiatorfan,
inthenormaldirectionofrotation(anti-clockwiseasviewedfrom
theflywheelend),untilbothinletandexhaustvalvesareclosed.
72 Turnthecrankshaftbackandforthslightlyandobserve
thevalvemovement.Ifbothvalvesmove,thecylinderisonthe
exhauststroke-turnthecrankshaftafurther360ºinthesame
direction,tobringthatcylindertothecompressionstroke,which
istherequiredpositionforadjustment.Ifthevalvesdonotmove
whenthecrankshaftisturnedbackandforth,thecylinderis
alreadyonthecompressionstroke,andthevalvesarereadyfor
adjustment.
73 Insertafeelerbladeequaltothespecifiedvalveclearance
betweentherockerarmandvalvestemofthefirstvalvetobe
checked.Thefeelerbladeshouldbeafirmslidingfit(Fig.1.17).
74 Ifadjustmentisrequired,slackentherockerarmadjuster
locknutandturntheadjusterscrewasrequireduntiltheclearance
iscorrect.Holdthescrewinthispositionandtightenthelocknut.
75 Repeattheprocedureinparagraph74onthesecondvalve
forthatcylinder.
76 Repeattheprocedureinparagraph71and72forcylinder
No.2andcarryouttheadjustmentprocedureasdescribed.
77 Oncompletion,checktheconditionofthecylinderhead
covergasketandrenewifnecessary.
78 Refitthecylinderheadcover,securewiththedomednuts
andreconnectthedisconnectedcomponents.
79 Refittheenginecoveraftercompletingtheremainderof
theserviceprocedures.
Fuel injector injection pressure
80 Accuratecheckingand,ifnecessary,overhaulofthefuel
injectorsshouldbecarriedoutbyanauthorisedKubotaservice
agent,ordieselinjectionrepairfacility.RefertoChapter3for
injectorremovalandrefittingprocedures.
Fig. 1.16 Crankcase breather hose (A) and cylinder head
cover nuts (B). Fig. 1.17 Check the valve clearance (3) using a feeler blade between the rocker arm and valce stem.
3 Hydraulic system
Every 3 weeks or 100 hours
Hydraulic oil level check
1Unscrewthehydraulictankfillercapassemblyandwipe
cleantheintegralcapdipstick.
2Re-insertthedipstick(withoutscrewingthecapdown)
thenwithdrawagainandcheckthelevel.
3Ifnecessary,topupwiththespecifiedoiltobringthelevel
uptothe“MAX”markonthedipstick(Fig.1.18).
4Refitthecapandscrewitfullyintoplace.
Fig. 1.18 Hydraulic tank dipstick maximum and minimum
level markings.
Brush motors
5Cleantheareabetweenthebrushmotorsandbrushtop
plateandremoveanystringorothercollecteddebrisfromthe
motorshafts(Fig.1.19).
6Inspectthebrushmotorsforanysignsofhydraulicoil
leakagefromtheshaftsealsandcheckthesecurityofallfastenings.
Correctanydefectsfound.
Fig.1.19 Clean the areabetween the brush motorsand
topplateandremoveanystringorotherdebrisfrom the
motor shafts.

GREEN MACHINES 400 SERIES WORKSHOPMANUAL-ISSUE2-PARTNUMBERYM019
PAPAGE1.10
Every 12 weeks or 400 hours
Hoses and couplings
7Removethewatertankandenginecover(seeChapter2).
8Examineeachhydraulichoseforsignsofdamageinthe
formofcuts,splitsor abrasions and also check forsignsof
chafingonadjacentcomponentsoranyindicationofoilleakage.
Replace any suspect hoses immediately ensuring that all
replacementsmeettherequiredhydraulichosespecification
(seeChapter4).
9Checkthatallhoseretainingbandsareinplaceand
secure.
10 Checkthetightnessofallhosecouplingsatthefollowing
connections:
A).Brushmotors.
B).Hydraulictank(Fig.1.20).
C).Hydraulicblockassembly.
D).Hydraulicpump.
E).Drivemotor.
F).Oilcooler.
G.)Quick-releasecouplings(wherefitted).
11 Refittheenginecoverandwatertankaftercompletingthe
remainderoftheserviceprocedures.
Fig. 1.20 Check the tightness of all hose couplings such
as these at the hydraulic tank.
Every 6 weeks or 800 hours
Caution:Ensureabsolutecleanlinesswhenworkingonany
partofthehydraulicsystem.
Hydraulic oil filter element change
12 Removethewatertankandenginecover(seeChapter2).
13 Thoroughlycleantheexteriorofthefilterbowlandthe
hydraulicblockassemblyintheareaofthefilterbowllocation.
14 Positionacontainerbeneaththefiltertocollectescaping
oil.
15 Unscrewthefilterbowlandremoveit,togetherwiththe
filterelement,fromthehydraulicblock(Fig.1.21).Itmaybe
necessarytouseastrapwrenchtoinitiallyslackenthefilterbowl.
16 Removeanddiscardtheoldelement,thencleanthefilter
bowlinasuitablesolvent(Fig.1.22).Drythoroughlywithalint-free
clothorpreferablywithdrycompressedair.
17 ChecktheconditionoftheO-ringsealinthehydraulic
blockandreplaceifthereisanysignofdeterioration,orifany
signofoilseepagearoundthefilterbowlwasnoticedpriorto
removal(Fig.1.23).
18 Insertanewfilterelementofthespecifiedtypeintothe
bowl(refertotheSpecificationsinthepreliminarysectionsofthis
manualforfiltertypedetails).Screwthebowlbackintopositionon
thehydraulicblockandtightenthebowlsecurely,byhandonly.
19 Refittheenginecoverandwatertankaftercompletingthe
remainderoftheserviceprocedures.
Fig. 1.21 Remove the hydraulic filter bowl and filter
element, from the hydraulic block.
Fig.1.22Removeand discard theoldelement,thenclean
the filter bowl in a suitable solvent.
Warning! It is essential that the correct type of filter
elementisfitted.Useonlyagenuinereplacement(Applied
SweepersPartNo.HC058)oranalternativeofidentical
specification.The useofan inferioritem maycause
seriousdamagetothehydraulicsystemandwillinvalidate
anyexistingmachinewarranty.
Fig. 1.23 Check the condition of the O-ring seal in the
hydraulic block and replace if there is any sign of
deterioration.