Mahlers Wasp G1 User manual

Version |B
Wasp G1
Sweeper Wasp G1
INSTRUCTION MANUAL

2 (40) Bruksanvisning Geting G1_B_EN
Registration
User manual: This user manual contains instructions for the care and maintenance of the Geting
G1, manufactured by Mähler & Söner AB in Rossön, Sweden.
Instruction reg. no.: 31-10010
Date: 16-12-2009
Revision: B
Rev. date: 15-7-2011
Manufacturer: AB Mähler & Söner
Hotingsvägen 40
S-880 51 Rossön, Sweden
Telefon: [phone]
Fax: [phone]
http://www.mahlers.se/
Copyright: © AB Mähler & Söner

Mähler & Söner AB registration page
Equipment name: Geting G1
Machine type: Sweeper
Registration number: 31-10010
Language: English
Project number: 31-10010
Date: 16-12-2009
Produced by: Tommy Eliasson
Approved by: Mähler & Söner
Owner of manual: AB Mähler & Söner
Hotingsvägen 40
S-880 51 Rossön
Sweden
Telephone: [phone]
Fax: [phone]
Copyright: © AB Mähler & Söner
Information: http://www.mahlers.se/

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Contents
1Foreword 5
2Safety precautions 6
2.1 Warnings 6
2.2 Symbols 7
2.3 General safety precautions 8
2.4 Safety precautions 10
3Technical description 12
3.1 Function 12
3.2 Technical data 14
3.3 Working area 15
3.4 Hydraulic system 15
3.5 Alternative hydraulic operation 15
3.6 Control panel 16
3.7 Electrical system 18
3.8 Chassis 18
3.9 Hopper 19
3.10 Side brushes 19
3.11 Watering system 20
4Hitching up 21
4.1 Description 21
4.2 Hitching to towing vehicle 21
5Operation 22
5.1 Checks before sweeping 22
5.2 Adjusting sweeping width 22
5.3 Adjusting side brushes 22
5.4 Replacing the side brushes 23
5.5 Roller housing 23
5.6 Replacing brush strips 24
5.7 Adjusting the ground pressure 24
5.8 Sweeping 25
5.9 Moving from site to site 25
5.10 Emptying refuse 26
5.11 Parking 26
6Maintenance 27
6.1 Lubrication 28
6.2 Maintenance measures and intervals 28
6.3 Lubrication points 30
6.4 Hydraulic system 31
6.5 Watering system 31
6.6 Welding 31
7At end of season 32
8Trouble-shooting 33
9Reference information 34
9.1 Spare parts 34
9.2 Diagrams 34
9.3 Miscellaneous 34

1 Foreword This user manual contains a technical description, operating instructions,
maintenance instructions and general safety precautions for working with
or near the Geting G1 sweeper.
The Geting G1 is designed and manufactured for commercial use and
may only be used as a tool for sweeping up gravel, stones and refuse.
The Geting G1 is produced in three versions, of which the base version
has its own hydraulic system, and the hydraulic pump is connected to the
power take-off on the towing vehicle. As an alternative, a second version
has quick connectors that allow the sweeper to be connected to the
hydraulic system of the towing vehicle. The third version is like the base
version but has its own overrun brakes.
Before starting work it is important to read through and understand the
relevant safety rules.
Only personnel who are trained or well acquainted with the equipment
may operate or work on the Geting G1.
Improper use of the machinery and equipment can lead to personal injury
or damage to the machine. This could endanger product safety and lead to
accidents or incidents.
To supplement this manual please refer to the instructions provided by
the manufacturer of the machine/vehicle and relevant suppliers.
Mähler & Söner AB, Rossön.

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2 Safety
precautions
2.1 Warnings This manual uses warnings and symbols to clearly highlight information
that relates to user safety and avoiding problems with the equipment.
These symbols are used in this manual to indicate hazards that could
cause personal injury. There are three different grades of warning:
danger, warning and caution.
Danger indicates that there are risks that could
cause personal injury, death and/or significant
damage to nearby buildings and machinery.
Warning indicates that there are risks that could
cause personal injury and/or significant damage to
nearby buildings and machinery.
Caution indicates that there are risks that could
cause personal injury and damage to property.
Important technical information is highlighted as follows:
Notes indicate technical information. There is a risk
of damage to machinery if this information is
ignored.
NOTE
!
CAUTION
!
WARNING
!
DANGER
!

2.2 Symbols Key to symbols that are used in this manual:
Safety helmet
A safety helmet must be worn to avoid head injuries.
Safety footwear
Safety footwear must be worn to prevent injury to feet and toes.
Safety gloves
Safety gloves must be worn to avoid hand injuries.
Safety glasses
Safety glasses must be worn to avoid eye injuries.
Hearing protection
Hearing protection must be worn to avoid hearing damage.

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2.3 General safety
precautions Because the equipment has many different functions it is important to be
aware of safety issues in the workplace and when using the equipment.
The sweeper has many moving parts. It is hydraulically operated, and
some sections of these instruction call for manual intervention, e.g.
during maintenance and troubleshooting. This means that special
attention must be given to safety while the equipment is in operation.
Situations of higher risk can occur during use, and to avoid these it is
important that:
You follow the instructions in this manual.
Personnel are trained in operation, maintenance and safety.
Equipment and tools are provided that are suited to the task.
The owner and supervisors take responsibility for ensuring that
safety routines and precautions are drawn up and followed by all
personnel.
Signs that warn, prohibit or provide information are not hidden,
damaged or removed.
2.3.1 Personnel Only trained personnel may use and maintain the Geting G1. The owner
and supervisors are responsible for ensuring that effective safety routines
and precautions are drawn up and followed by personnel. It is important
to inform yourself and others about the risks associated with tasks, so
they can be avoided in a suitable manner.
2.3.2 Workplace Do not allow unauthorised personnel to stray into or around the working
area of the machine.
The risk zone extends 1 metre around the machine
Steps must be taken during maintenance and repair to avoid personal
injury and damage to materials.
Keep the workplace tidy and clean, mainly to avoid the risk of anyone
tripping or slipping.
Check that lighting is set up correctly. Shadows, poor lighting and unlit
areas in the workplace can be irritating and make work more difficult.
Also avoid positioning lighting so that it creates glare.
Immediately report all incidents and accidents to the relevant supervisor.
Consult a doctor or other medical staff in the event of any personal
injury.
WARNING
!

2.3.3 Clothing Protective clothing is essential. Always wear appropriate work clothing.
Remember that loose or baggy clothing could create a hazard.
Always wear:
Safety footwear.
Safety gloves.
Safety glasses, especially when removing components of the
hydraulic system, welding or using cutting equipment.
2.3.4 Noise level Hearing protection must be worn when hand tools are being used for
maintenance or repairs.
2.3.5 Safety before and
during operation Machines that use hydraulic equipment can move unexpectedly when
they start up and the system is pressurised. The risk is greatest when the
system has been switched off in the middle of a working cycle and is then
switched on again.
Always check that there are no leaks from the hydraulic system.
Spraying oil can cause injury, especially to the eyes.
Make sure that no one is inside the sweeper’s working area. No one
is allowed inside the working area of the sweeper when the motor
is running.
Check that there is no damage to the machine. Repair any damage
before starting the machine.
Always raise the brushes before crossing railway lines or moving
the machine to another site.
Never climb on to the sweeper or towing vehicle while moving.
2.3.6 Symbols and signs Signs that warn, prohibit or provide information must not be hidden or
altered. If a sign is damaged and unreadable it must be replaced with a
new one.

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2.3.7 Safety prior to
maintenance Careful preparation is required before carrying out maintenance:
Always mark out the area where maintenance is to be carried out.
Switch off the machine/vehicle that the sweeper is hitched to.
Check that the ignition switch and isolating switch are turned off.
Find out the weight limits of gantry cranes and their range of free
movement.
Once these checks have been completed the person carrying out the
maintenance can start work.
Maintenance must only be carried out by authorised
personnel.
2.4 Safety
precautions
Read the instruction manual carefully. The machine may only be
used by personnel who have received training on the machine
and are familiar with its operation.
Connect the brake to the towing vehicle if traffic regulations require
this. (Tractors may travel at up to 40 kph if the towed trailer has
no brakes, as long as the gross weight of the towing vehicle is not
exceeded.)
Before driving, always check that the sweeper is securely hitched
up, and that rear lights, brake lights and indicators all work
correctly.
Avoid reversing over kerbs and the like or on to soft ground that the
wheels could sink into. Take care when driving off kerbs.
When travelling from site to site, the container should be slightly
raised, but it must always be supported at the sides by the rear of
the chassis. Never drive with the hopper fully raised.
Check carefully that no one is behind the machine before starting to
empty it.
Never stand underneath the hopper when it is raised. If this is
necessary for maintenance, use a gantry crane or the like to
support the container first.
If servicing is carried out when the hopper is in the raised position
or the towing vehicle is running, make sure that no one is in the
driver’s seat or within reach of the control box.
WARNING
!

Never climb on to the machine or go near the side brushes when
they are rotating.
Before unhitching the sweeper, check that the support wheel is
lowered and secured. Park the machine on level ground.
The hydraulic system safety valves are sealed to prevent tampering
and must not be adjusted.
WARNING DECAL
Figure 1:Warning decal “Danger: rotating brush”
Figure 2: Warning decal “Do not stand under raised container”
These decals are attached to both sides of the machine.
Please order new ones if they have been damaged or are missing.
“Danger: rotating brush”
Art. no. 10003103
“Do not stand under raised
container”
Art. no. 10003104

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3 Technical
description
3.1 Function The Geting G1 consists of a complete chassis (1) that is coupled by a tow
hitch (2) to a towing vehicle. The base version has its own hydraulic
system, and the hydraulic pump is connected to the power take-off on the
towing vehicle. As an alternative, a second version has quick connectors
that allow the sweeper to be connected to the hydraulic system of the
towing vehicle.
The Geting G1 is pulled by a towing vehicle and the side brushes (3)
rotate, sweeping gravel, stones and refuse into a collector (4) between the
brushes.
The swept area of the side brushes is watered by means of nozzles (5)
connected to a water tank (6) to reduce the spread of dust.
The refuse is brushed into a row directly in front of the working area of
the sweeper roller (7). When the brush strips (8) on the sweeper roller
reach the refuse it is picked up cleanly and thrown into the hopper.
When the hopper (9) is full, both it and the roller housing (10) can be
raised into the transport position. The sweeper can then be towed to a
container, and emptied by raising and tipping the hopper.
At the rear of the sweeper is a rubber hatch (11) for inspecting and
cleaning the hopper.
The Geting G1 can be operated from the driver’s seat of the towing
vehicle using a control panel.
Vehicle requirements
The towing vehicle must have a minimum towing capacity of 20DIN and
be equipped with a PTO rated for 540 rpm, or hydraulic drive coupling.

Figure 3:G1 sweeper, side view.

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Figure 4:G1 sweeper, top view.
3.2 Technical data
Description
Geting G1
Dimensions and weight
Length
2425 mm
Width
1350 mm
Height
1100 mm
Weight
900 kg
Wheels
Tyre size
5.00 x 8-10 ply
Air pressure
6.5 bar (kg/cm2)
Sweeping data
Sweeping width
1600–1900 mm
Side brushes
Ø 760, h = 265 mm
Brush strips, width
950 mm
Sweeper roller
Ø 690 mm
Hopper
Tipping height clearance
1500 mm
Hopper capacity
700 litres
Watering
Water tank
200 litres
Water nozzles
4
Hydraulic system
Displacement
45 l
Working pressure, sweeping
100 bar
Max. pressure
150 bar
Oil filter
10 µ
Air filter
5 µ
Noise level
Equivalent continuous measured in driver’s cab.
Closed cab
81 dB(A)
Open cab
88 dB(A)
Vibration
Operator is unaffected by vibration from machine.
Suitable towing vehicle
Min. 20 DIN
Max. pull on tow bar
1700 kg
Max. pressure on tow ball
300 kg
Rating plate

The rating plate and the CE plate are located on the left side of the machine, near the
front of the lifting arm. These show the machine’s serial number and manufacturer’s
number. Please state these numbers when ordering spare parts or making enquiries
about servicing.
3.3 Working area The Geting G1 is intended for sweeping streets, paths, cycleways, car
parks and other open spaces. It is a well-proven design and has a rugged,
uncomplicated construction. The Geting G1 is designed for use with most
commercially available tractors, compact tractors and implement carriers.
3.4 Hydraulic systemThe base machine has a complete, self-contained hydraulic system.
A gearbox mounted on the hydraulic pump mates with the PTO drive
shaft on the towing vehicle.
The hydraulic system operates at an oil flow of 25–30 litres/minute,
which is obtained with a PTO speed of around 450 rpm (max. 540rpm).
The hoses from the hydraulic pump are connected to a tank and valve
block. The hydraulic tank is located in front of the hopper. The tank has a
sight glass with built-in thermometer as well as a breather filter that
allows the oil level to be topped up.
A spin-on return oil filter is located between the valve block and tank.
The hydraulic system is controlled electrically by manually operated
valves on the control panel in the driver’s cab.
The valves can also be operated directly by hand in an emergency by
depressing the yellow centre button by about 5 mm. (Applies to all valves
except that for raising the hopper.)
The valve block has a pressure relief valve to provide overload
protection, and a gauge port for checking system pressure, if needed.
The brush motors are connected in series. The left side brush is first in the
circuit and the sweeper roller is last.
The hydraulic cylinders for the side brushes and hopper are connected in
parallel, and their lifting efforts are balanced so that the side brushes are
raised before the hopper.
See attached hydraulic diagram on page 35.
3.5 Alternative
hydraulic
operation The Geting G1 can also be configured for towing vehicles that do not
have a PTO.
A hydraulic motor, known as a flow converter, is mounted on the tow
hitch and connected by quick connectors to the hydraulic connectors on
the towing vehicle. The sweeper’s pump is connected directly to the
hydraulic motor.

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3.6 Control panel This is mounted inside the towing vehicle and used to operate the
sweeper. A mounting plate with supply socket for the control panel is
installed in the driver’s cab. Power is supplied to the socket on the
mounting plate using wire with a cross-section of 2.5 mm2run from the
isolating switch on the towing vehicle.
Remember to fit a fuse holder.
If there is already a supply socket in the towing vehicle this may be used
as long as it is rated for up to 16 amps.
It must be possible to isolate the supply.
The knob on the left controls the water and the brushes. On the braked
version the knob on the left only controls the brushes and there is a fourth
knob on the right that controls the water. The braked version also has a
toggle switch that controls the reversing lock for the overrun brakes.
The middle knob raises and lowers the hopper. The first knob must be in
the off position in order to use this function.
NOTE
!

The knob on the right is used for emptying and closing the hopper. The
first knob must be in the off position in order to use this function.
Figure 5:Settings for G1 sweeper
1
2
3
4
5
6
7
8

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Posn.
Function
1
Water on, brushes off
2
Off
3
Brushes on, water on
4
Brushes on, water off
5
Lower hopper
6
Raise hopper
7
Close hopper
8
Empty hopper
3.7 Electrical system
3.7.1 Lighting The electrical system is rated for a 12-volt supply. Power is taken from
the towing vehicle through a cable with 7-pin plug, which is connected to
the matching socket on the towing vehicle. This supplies the rear lights,
brake lights, indicators, fog lights and working lights.
Bulbs
Location
Watts
Fitting
Rear lights
10
15 s
Brake lights
21
15 s
Indicators
21
15 s
Fog lights
21
15 s
Working lights
21
15 s
3.8 Chassis The Geting G1 has a robust chassis made from square tube. The front
section provides a strong mounting for the tow hitch. It also has a jockey
wheel that is used when parking the sweeper and makes it easier to hitch
the sweeper to the towing vehicle.
One version of the G1 has an overrun brake like that used on trailers. This
model has a parking brake that should be used when the sweeper is not in
use.

3.9 Hopper The hopper is supported on bushings in both lifting arms and has an
opening at the rear where the roller housing is attached.
Once the hopper has been raised it is tipped into the emptying position by
means of a hydraulic cylinder on each lifting arm. To create as wide an
opening as possible the stub shafts support lifting arms that raise the
roller housing for emptying.
Rubber guides are attached to the bottom edges of the hopper on each
side. These strips drag along the ground and guide the refuse towards the
hopper to ensure effective collection. They should be replaced when the
brushes are replaced.
The hopper has two support wheels to protect the rubber guides from
excessive wear when driving over drains or irregularities in the road.
3.10 Side brushes Each side brush is mounted on its own brush plate and is connected to a
hydraulic motor by means of a carrier plate.
Each motor mounting is bolted to two-piece brush arm that pivots around
a point just in front of the wheels. The brush arms can be adjusted
sideways to give the desired sweeping width.
The motor mounting has a labyrinth seal that prevents cord, steel wire
and the like from becoming entangled around the drive shaft. The brush
arms are suspended by chains from the lifting cylinders.
The side brushes are independently sprung to ensure good sweeping
performance with a minimum of wear. Light contact pressure also
reduces the power demand on the towing vehicle, which is important
when a small towing vehicle is used.

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3.11 Watering
system If there is a risk of dust formation the swept area of the side brushes can
be sprayed with water to bind the dust during sweeping.
The water is drawn from a water tank, through a filter, by an electric
water pump. The water pump provides a flow rate of around 7 litres/min.
A vent in the cap on the water tank prevents a vacuum from building up
inside the tank.
The water tank and piping that make up the watering system are made
from stainless steel.
The water runs from the pump into a spray pipe. This has an inner and
outer spray nozzle for each side roller. The pipe is plugged at each end.
The plugs can be removed to allow flushing of the pipe.
The pump is of the membrane type and can be run dry for a short period
of time without suffering damage. The water filter should be inspected
and flushed regularly, as the pump is susceptible to contamination and the
filter must be in good condition.
The system must be drained if there is a risk of the
water freezing and damaging the piping, pump or
valve.
A drain tap is fitted in the middle of the spray pipe. When the tank is
empty, run the water pump until no more water flows out. Unscrew and
empty the filter.
NOTE
!