Scarab Merlin Manual

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

Part No. SCAZ037886 8.6.00 E&OE
Merlin and Magnum HydrostaticOperating Instructions
MAIN FEATURES
MERLIN
HYDROSTATIC
1
2
3
4
5
6
7
8
MERLIN
HYDROSTATIC
LIN
OSTATIC
3
9
10 11
12
13
14 15
16
17
18
1. Water tank
2. Locker
3. Side loading hatch
4. Door open/close ram
5. Rear wander hose (standard)
6. Fuel tank
(orientation determined on chassis type)
7. Low pressure water pump and valves
8. Central brush assembly
9. Low pressure and/or high pressure spray bar
10. High pressure front spray bar shut-off valve (option)
11. Pneumatic system cabinet
12. Main hydraulic valve block access cover
13. Hydraulic oil cooler location
14. Side brush assembly
15. Suction nozzle assembly
16. Auxiliary hand pump
17. High pressure retractable hose (option)
(orientation determined on chassis type)
18. Rear door locking mechanism

Part No. SCAZ037886 8.6.00 3 E&OE
Merlin and Magnum HydrostaticOperating Instructions
ENGLISH
Merlin and Magnum Hydrostatic
Operating Instructions
Incorporating Operator’s Basic Maintenance Information
Part No. SCAZ037886
Version: 8.6.00 ...................................... 13th May 2019
To get the latest version of this Operator’s Manual visit our website www.scarab-sweepers.com/links/opsmerlmag
This manual is published by the Technical Publications Department of Scarab Sweepers Ltd. and every effort
is made to ensure that the information it contains is correct at the time of publication. Due to a policy of
continuous development, however, the Company reserves the right to alter the specification and to supply
when so altered without reference to illustrations and descriptions in this manual.
Scarab Sweepers Limited.
Pattenden Lane, Marden, Tonbridge, Kent TN12 9QD, United Kingdom
T: [phone] - F: [phone]
E: [email protected] - W: www.scarab-sweepers.com
Registered in England No. 1823459 - VAT No. GB 374 5002 68
Registered Office: Pattenden Lane, Marden, Tonbridge, Kent TN12 9QD, United Kingdom Copyright ©2019 Scarab Sweepers Limited

Part No. SCAZ037886 8.6.00 4 E&OE
Merlin and Magnum HydrostaticOperating Instructions
General information
WARNING - Voltage sensitive components.
Do not use a boost starter / super star, a boosted start will burn out the vehicles electronic control nodes, if batteries are not charged always use a
fresh set.
Typical weights, dimensions and capacities
Gross Vehicle Weight (GVW) * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 to 18 tonne
Gross Vehicle Weight (GVW) Magnum *. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 to 18 tonne
Overall Height (hopper lowered)* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3000 to 3500mm
Overall Length * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5640 to 7500mm
Overall Width (brushes stowed) * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2500mm
Hopper Gross Volume *. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5³ to 8.2³ Gross
Tank Capacities*
Fuel Tank *. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Typically 100 to 150 litres
Hydraulic Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 litres
Water Tank * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 900 litres to 4500 litres
Noise Levels
In cab . . . . . . . . . . . . . . . . . . . . . . . . . . Between 70 - 84 dB(A) dependent on operating speed
External . . . . . . . . . . . Maximum LWA of 114 dB(A) in accordance with directive 2000/14/EC
Vibration
Description. . . . All dynamic prime moving components are resiliently mounted to minimise
vibrations.In accordance with 2006/42/EC as amended.
Whole body . . . . . . . . . . . . . . . . . . . . . Equipment does not exceed 0.5 m/s² (RMS, weighted)
Hand Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equipment does not exceed 2.5 m/s² (VTV)
* Dependent upon model
In view of the fact that many variables such as chassis and machine
specification affect the weight and dimensions of the finished machine,
it is not possible to quote these precise details. If this type of information
is required, please contact our Technical Sales staff giving your
sweeper’s Serial Number.
Towing
Serious damage to the transmission will result if the vehicle is towed while the gearbox is
engaged.
If towing is necessary, it is imperative that the prop shaft is disengaged from the differential or
that the rear wheels are clear of the ground before making any attempt to tow the vehicle.
Identification Plates
The SERIAL NUMBER PLATE is located on the rear face of the left hand suction nozzle spigot.
The Serial Number will comprise four numerical digits only (for example 5843).
For the location of the vehicle’s VIN PLATE and CHASSIS NUMBER, refer to the chassis
manufacturers’ documentation.
Limitations of Use
The Scarab Merlin, Merlin XP and Magnum are classified as truck-mounted heavy-duty suction
road sweepers and, as such, are intended only for operation in the sweeping and associated roles
for which they have been expressly designed.
The sweeper bodywork is integrated to the truck/carrier vehicle, and is therefore not
demountable.
Applicability
This manual covers the operating requirements of the Scarab Merlin, Merlin XP and Magnum
Hydrostatic sweepers with the CANbus 3 system.
CB Radios and other electrical equipment used in the sweeper should be properly suppressed
(EMC) to prevent the possibility of interference in the sweeper’s electronic system.
CB Radios and other electrical equipment used in the sweeper should be
properly suppressed (EMC) to prevent the possibility of interference in the
sweeper’s electronic system.
Warning

Part No. SCAZ037886 8.6.00 5 E&OE
Merlin and Magnum HydrostaticOperating Instructions
Table of contents
Title Page
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Table of contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Health and Safety advice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hazard awareness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Operating advice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Safety support props . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
The CANbus system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Main control panel switch functions . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Auxiliary control panel switch functions . . . . . . . . . . . . . . . . . . . . . . . . 12
Hopper remote control switch box functions . . . . . . . . . . . . . . . . . . . 13
The LCD monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Additional controls and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Brush pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Controls for overhead wander boom . . . . . . . . . . . . . . . . . . . . . . . 15
Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Engaging hydrostatic drive (Manual gearbox trucks) . . . . . . . . . . . . . 16
Sweeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Suction fan boost setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Climbing Gradients . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Reverting to normal drive mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
CNG IVECO with Allison gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Engage hydrostatic drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Disengage hydrostatic drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Discharging the hopper (tipping) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Using the auxiliary hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Title Page
Standard wander hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Using the standard wander hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Using the rear mounted wander hose . . . . . . . . . . . . . . . . . . . . . . . . . 24
Using the overhead wander boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Using the Dust Suppression System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Filling the water tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Using the low pressure water system . . . . . . . . . . . . . . . . . . . . . . . . . 26
Using the high pressure water system . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Hand lance detergent option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Retractable hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Clearing a blockage in the suction path . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Recommended operator’s routine maintenance . . . . . . . . . . . . . . . . . . . 30
Key maintenance procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Cleaning the suction fan and screen . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Hydraulic oil tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Topping-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Suction nozzle clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Side brushes and skirts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Removing and cleaning the water filter element(s) . . . . . . . . . . . . . . 34
Manual greasing and lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
LCD monitor - Options screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Button function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Screen menu description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Operator’s notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Part No. SCAZ037886 8.6.00 6 E&OE
Merlin and Magnum HydrostaticOperating Instructions
Health and Safety advice
In the interests of your health and safety, it is important that the following points are observed at all times.
• Only trained operatives should be allowed to drive or work on this machine.
• Before driving the machine ensure that all relevant machine checks have been
carried out, that all equipment is stowed.
• Do not overload the hopper.
• Do not drive the machine with the hopper in the raised position, even if the
hopper is empty.
• Always use the safety prop to support a raised hopper, other than during
discharging.
• Never work under a raised cab or hopper unless the appropriate safety prop is in
position.
• Before operating either the hopper tip or rear door controls, ensure that there is
sufficient clearance and that it is safe to do so. Ensure that all personnel are clear
of the rear door.
• Before working on the machine, ensure that it is on firm, level ground. Apply the
handbrake, stop the engine and remove the ignition key.
• Always wear the appropriate personal protection equipment when operating or
working on the machine.
• Before starting the engine ensure that all controls are switched off and that the
machine is in neutral.
• Keep long hair, loose clothing and body parts away from moving parts on the
machine.
• High pressure water can be hazardous. Always wear suitable face protection
when operating the high pressure water pump and when using the lance.
• Do no direct the water jet at other persons. Beware of electrical installations on
public buildings and lamp posts etc. Always exercise extreme caution in public
places.
• The driver’s seat should always be correctly adjusted as to give a good posture
when driving. Do not adjust seat whilst driving.
• The mirrors should be adjusted so the driver has good all round view of the
machine sides and sweeping equipment.
• When operating the machine in any mode always be aware of objects and people
in the immediate vicinity, especially at the rear of the machine when reversing.
• Whatever the situation, remember that the rules of the traffic and road safety
must be observed.
• Whilst operating this machine the safety and well being of other people in the
immediate vicinity are the sole responsibility of the operator.
• Never ride on any part of the machine other than in the seats in the driver’s cab.
The universal safety symbol as well as red text is used throughout this handbook and when encountered the related information must be adhered to.
Refers to important information.
Identifies cautionary information and specific procedures when required.
Refers to visual examination to confirm the condition or status of a specific item.
Other symbols not shown here may be used throughout this handbook. When encountered, they must be observed.
Remember, failure to comply can result in serious injury.

Part No. SCAZ037886 8.6.00 7 E&OE
Merlin and Magnum HydrostaticOperating Instructions
Hazard awareness
All operators and workshop personnel should be aware of the physical and biological risks that are inherent in the operation of a road sweeper. The risk falls
into two main categories as follows:
• Risks represented by the sweeper and its various systems.
• Risks represented by the sweeper's operating environment.
Both have the potential for exposure to a variety of hazards, ranging from hot surfaces to infectious diseases, that can occur during day-to-day operation,
while carrying out adjustments or when involved with the general maintenance and servicing activities on the vehicle.
Typical vehicle-related hazards are:
• Exposure to hot surfaces and sharp edges.
• Exposure to moving parts.
• Exposure to various fluids (including some hot and/or pressurised).
• Exposure to surface contamination resulting from general operating conditions.
Typical environmental hazards are:
• Exposure to sharp objects (e.g. broken glass, discarded hypodermic syringes) while operating or working on the vehicle.
• Exposure to various infectious diseases (e.g. Legionnaire's, Weil's, Hepatitis, Tetanus) while operating or working on the vehicle.
Safety precautions
When using external equipment such as the high-pressure water lance, or when dealing with potentially hazardous situations while sweeping (e.g. unblocking
a suction nozzle), always wear the appropriate Personal Protection Equipment (PPE) and exercise extreme caution if required to handle any of the material
being swept.
Before working on the vehicle, subject it to a thorough steam cleaning or high-pressure hot water wash using appropriate detergents etc.
Even after taking all reasonable steps to reduce the risk from the hazards described, always wear the appropriate Personal Protection Equipment (PPE) when
carrying out sweeping duties or when working on the vehicle. This includes:-
Safety gloves, including where necessary cut resistant knitted Kevlar. Earplugs or ear defenders as appropriate.
Safety boots or shoes with protective soles and toecaps. Eye/face protection, if necessary full face mask with under chin lip.
Respiratory masks. High visibility jackets or waistcoats.
Overalls or coveralls.

Part No. SCAZ037886 8.6.00 8 E&OE
Merlin and Magnum HydrostaticOperating Instructions
Operating advice
Please remember, the information provided in this handbook is designed to ensure that the Scarab sweeper operates both safely and efficiently.
The design of this machine is for the removal of spoil on traffic areas, also litter collection, using the wander hose.
A poorly maintained machine will become unreliable, inefficient and potentially dangerous. Always observe the recommended maintenance and safety
related advice provided.
Unless it is wet or raining, ALWAYS use the low-pressure water spray system when sweeping. This will not only reduce the amount of dust generated, it
will also ensure more efficient collection of material. This is because wet material is heavier and will drop more readily from the air stream inside the
hopper. If swept dry more of the finer material will pass through the screen, wearing out the fan blades on its way back to the environment behind you.
Operators should be trained in the following elements:
• Health and safety observations/notices
• Transit driving
• In-cab and external controls
• Hopper safety/cab prop use
• Brush setting
• Nozzle flap adjustment
• Correct sweeping operations
• Low and high pressure water systems
• Load discharge (tipping)
• Daily, weekly maintenance schedules
• End of day cleaning, ie: suction fan, fan screen and machine body
Operator training can be provided by Scarab Sweepers upon request.
The LCD monitor’s USB connection is for uploading/downloading information (ONLY) and must not be used for any other purpose.
It is the responsibility of employers to carry out they own risk assessment for the machine, operators or other persons using or affected by the machine
and equipment.
Various safety, hazard and user information labels are fixed to the machine. These must be observed.
Only personnel qualified in the relevant disciplines should be allowed to work on any of the machines HYDRAULIC SYSTEM.
For information regarding vehicle operation and maintenance, refer to the chassis manufactures handbook.

Part No. SCAZ037886 8.6.00 9 E&OE
Merlin and Magnum HydrostaticOperating Instructions
Safety support props
Door safety prop
Auto ratchet hopper prop
Ensure the prop is
correctly positioned
within the ratchet rack
When inserting the
door prop, ensure it is
correctly positioned
in the locating slot

Part No. SCAZ037886 8.6.00 10 E&OE
Merlin and Magnum HydrostaticOperating Instructions
The CANbus system
The CANbus system comprises two control panels (main and auxiliary) an LCD monitor and a number of control nodes. The system controls and monitors all
sweeper functions and maintains a log of various operating parameters such as operating hours and any fault conditions that might occur.
Switches: The various types of switch function are grouped in two ways. Firstly they are colour coded as follows:
Amber = Electrical functions such as lighting.
Red = Critical functions (e.g. Engage Hydrostatic Drive).
Green =Sweepingfunctions.
Blue =WaterSprayfunctions.
Each switch illuminates a function-related symbol on the LCD monitor (only installed equipment will be displayed). Each symbol is greyed-out until its switch
is activated. When a switch is activated the appropriate symbol will illuminate according to system status as illustrated.
Not selected
Pre-selected
Water pre-selected
Brush and water
pre-selected
Equipment working
Not selected
Pre-selected
Additional water
selected
Nozzle and additional
water pre-selected
Equipment working.
Centre blue when
additional water active
Nozzle tilt selected
Not selected
Pre-selected
Equipment working
Side brush and suction
nozzle water ON
Central brush water ON
Side brush shown in
the working position
Work light ON
Suction fan ON (2000rpm)

Part No. SCAZ037886 8.6.00 11 E&OE
Merlin and Magnum HydrostaticOperating Instructions
Main control panel switch functions
Switch functions are described from Left to Right and Top to Bottom.
F1 / F2 - Press to activate special options.
System Start - Press to start/stop the system and engage/disengage hydrostatic drive.
Brush Speed (-) - Press to decrease brush speed. Brush speed remains set until reset.
Brush Speed (+) - Press to increase brush speed, Brush speed remains set until reset
Left/Right Side Brush - Press to start the side-brush.
Left/Right Suction Nozzle Raise/Lower - Press to lower the suction nozzle.
Central Brush (Wide sweep) - Press to start the central brush.
Left/Right Work Light - Press to turn ON/OFF.
Left/Right Side Brush and Suction Nozzle Water - Press to start the side-brush and suction nozzle
dust-suppression.
Central Brush (Wide sweep) Water - Press to start the dust-suppression spray for the central brush.
Increase/Decrease Engine Speed - Press and hold down to reduce/increase the speed of the vehicles engine. A single press of the either switch will
adjust engine speed by 50 RPM. Current engine speed is displayed along the top of the LCD monitor.
Left/Right Suction Nozzle - Additional Water (Option) - Press to start the additional water jets for the suction nozzle.

Part No. SCAZ037886 8.6.00 12 E&OE
Merlin and Magnum HydrostaticOperating Instructions
Auxiliary control panel switch functions
Forward/Reverse Lever - Lift collar to release from Neutral and move the lever in the desired direction to activate
the hydrostatic transmission. All active equipment will stop and retract to its stowage position when reverse is
selected, redeploying when reverse is disengaged.
High Pressure Water Pump (Option) - Press to start.
Suction Fan - Press to start the Suction Fan (approximately 2000 rpm on standard models and 2900 rpm on
high speed models).
Cruise Control - With the accelerator pedal depressed to the desired speed, press to activate cruise control.
Nozzle Tilt (Locking Mode) - Press to tilt the suction nozzle for larger items.
Suction Fan ‘Boost’ - With the Suction Fan ON, press to activate the fan boost mode. This increases fan speed
to approximately 2200 rpm on standard models.
On high speed models fan speed is 3150 rpm. To increase speed to 3400rpm press and hold until a red outer
appears on the fan symbol graphic. See Page 14.
Favourite Setting - Press to memorise your preferred sweeping set-up. Hold the switch down until a ‘beep’
sounds. Thereafter, whenever the switch is pressed at system start-up, the memorised configuration will be
automatically pre-selected/restarted. Repeat to over-ride with a new configuration.
Multi-Function Lever - ON (deploys all selected sweeping equipment). To stop and raise all sweeping equipment,
return the lever to the OFF position.
In the ON position the lever can be used to control the side brushe(s) and suction nozzle(s). These additional
positions i.e. Left, Right and Back, return to the central position when released.
The brush and nozzle functions are controlled as follows:
On Left Hand Drive Vehicles
Move the lever to the left to swing OUT, and to the right to swing IN the side brush(es).
On machines fitted with variable extend and retraction, move the lever momentarily in the desired direction to ‘nudge’ the brush(es).
On Right Hand Drive Vehicles
Move the lever to the right to swing OUT, and to the left to swing IN the side brush(es).
On machines fitted with variable extend and retraction, move the lever momentarily in the desired direction to ‘nudge’ the brush(es).
Nozzle Tilt Function
Move the lever back to momentarily tilt the suction nozzle or close it from TILT OPEN position.
On machines with variable nozzle-tilt, move the lever back to ‘nudge’ the suction nozzle DOWN from the TILT OPEN position.
Forward
Neutral
Reverse
Multi-function lever
OFF
ON
Nozzle tilt
Side
brush
Side
brush

Part No. SCAZ037886 8.6.00 13 E&OE
Merlin and Magnum HydrostaticOperating Instructions
Hopper remote control switch box functions
The hopper Raise/Lower and rear door Open/Close switches are located on the remote control box. This
is stowed in the cab, between the driver’s seat and door and is connected to a socket via a coiled lead.
In the interest of health and safety and to avoid possible damage to the sweeper or adjacent
structures, it is essential that the remote hopper/door controls are not activated from within the
cab. Always use these controls outside of the vehicle from a vantage point that affords a good view
of the sweeper and its immediate surroundings.
The hopper prop must always be in the deployed position when working under a raised hopper.
Failure to do so could result in serious injury.
The door prop must always be used when working under a raised rear door.
Hopper Raise - Press and hold down to raise the hopper.
Hopper Lower - Press and hold down to lower the hopper.
Rear Door Open - Press and hold down until the door is Fully open (at approximately 90° to the rear
face of the hopper).
Ensure that the suction fan is OFF. The door cannot open while the fan is running due to the low
pressure created within the hopper.
Rear Door Close - Press and hold down until the door is fully closed and the latching cycle has
finished.
Option
SAFETY INTERLOCK
This switch must be
pressed in and held before
any of the control
switches are operated.

Part No. SCAZ037886 8.6.00 14 E&OE
Merlin and Magnum HydrostaticOperating Instructions
The LCD monitor
The sweeping monitor displays information on the current status of the sweeper while it is in sweep mode, by indicating which items of equipment are active,
plus other relevant information ie: fluid levels, fan speed and temperatures, it also alerts the user to any warnings by means of appropriate flashing symbols
and, when appropriate, a warning buzzer. For warnings identified by , stop and investigate the cause. The accompanying illustration shows the range of
information/alert symbols that can be displayed, however it should be noted that warning symbols (*) only illuminate when a specific condition occurs.
+
M
!
NODE Software Error !
[phone]
i
Flashes across screen when
Node software is incompatible *
Suction fan
OFF ON Boost
Fan speed Engine speedOption OptionTime
Wander hose active
High pressure water
ON No water
Brush speed
Fast Slow
Low hydraulic oil level *
Drive modes
Manual Hydrostatic
Hopper overload
warning *(option)
Fan speed indicator
2000rpm 3400rpm
Hydraulic oil temperature warning *
Cruise control active
Assign node *
Service reminder *
Fault active *
Hopper raised *
Low water level *
(Dust suppression system)

Part No. SCAZ037886 8.6.00 15 E&OE
Merlin and Magnum HydrostaticOperating Instructions
Additional controls and instruments
Brush pressure
Do not exceed a pressure of 2.5 bar when adjusting brush pressure settings. Failure to comply will result in drastically reduced brush life.
q- Air Pressure Regulator - Used to adjust the amount of up/down thrust applied to
the brush(es) ¤.
w- Air Pressure Gauge - Indicates the amount of pressure being applied to the
brush(es) ¤.
e- Central Brush (Wide sweep) Pressure Switch - Turns function ON/OFF.
r- Side brush Pressure Switch - Turns function ON/OFF.
¤ This function is only effective while the relevant brushes are deployed.
Controls for overhead wander boom (option)
These are mounted just above the wander boom handle and consist of two buttons for selecting fan extra-boost speed
(3rd Speed) of approx. 2500 rpm and/or the low-pressure dust suppression water supply. Engine speed will
automatically increase to 1500 rpm when fan 3rd Speed is selected.
The fan and engine speed do not change if high speed fan option is fitted.
Push button in to activate (button locks-in). Turn in direction of arrows to release.
12 3 4 21
Side brush controls
mounted in cab
Central brush controls
mounted on subframe

Part No. SCAZ037886 8.6.00 16 E&OE
Merlin and Magnum HydrostaticOperating Instructions
Operating Modes
Refer to the health and Safety Information on Page 6
There are two driving modes, Normal and Hydrostatic (Sweep), these are selected using the sweep mode switch on the control panel. The selected drive
mode is indicated on the LCD monitor as follows:
Normal Drive Mode
Hydrostatic (Sweep) Drive Mode
Reducing Noise Levels and Fuel Consumption:
Although it is important to always operate within the engine’s optimum speed range, there are times when it is possible to reduce engine speed to the
lower end of this, thereby reducing noise levels. This is most beneficial when sweeping at night, or in areas sensitive to noise pollution. Sweeping at reduced
engine speeds can be achieved most satisfactorily when sweeping light or sparsely distributed materials. Experience will enable the operator to vary
engine speed, according to sweeping conditions, without affecting sweeping performance.
It should be noted that the operator also benefits from reduced noise levels within the cab and that any reduction in engine speed, also results in a
corresponding reduction in fuel consumption.
Engaging hydrostatic drive (Manual gearbox trucks)
Engine ON and air tanks full before attempting to engage hydrostatic drive mode. The hydrostatic gearbox will not engage unless the vehicle is
stationary.
1. Switch on the hazard warning beacons.
2. Stop the vehicle, apply the parking brake and select Neutral.
3. With the engine running, depress the clutch pedal and press the Sweep Mode switch.
When hydrostatic drive engages, the symbol will change to the and a number of symbols, representing the installed sweeping equipment will
appear superimposed on the truck graphic, displayed on the LCD monitor.
If the Hydrostatic Gearbox fails to engage properly, the symbol will flash and a buzzer will sound intermittently, press the Sweep Mode switch and
release the clutch. Drive the vehicle slightly forward and repeat steps 2 and 3.
4. Select the highest forward gear available and release the clutch pedal. The vehicle is now in hydrostatic drive and may be driven using the hydrostatic
control lever (See Page 12) without use of the vehicles clutch or gear lever.
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Part No. SCAZ037886 8.6.00 17 E&OE
Merlin and Magnum HydrostaticOperating Instructions
Sweeping
1. Switch on suction fan (approx. 2000 or 2900 rpm) or ‘Boost’ (approx. 2200, 3150 or 3400 rpm) as required.
If ‘Boost’ is selected (See Page 18) remember that increased engine speed might be necessary.
Fan speed can be confirmed by referring to the LCD screen.
2. Select the desired configuration of sweeping equipment and water sprays if required, either manually or by pressing the Favourite Settings button
to recall your preferred arrangement. Switch on work lights if required.
Be aware that too much reduction of engine speed can adversely affect suction performance.e vehicle is stationary.
3. Move the multi-function lever (located on the auxiliary control panel) to the ON position to start and deploy the pre-selected sweeping
equipment.
To stop and stow the sweep gear, return the lever to OFF. The sweeping equipment will raise to the stowed position and all water spray
jets will stop, this will also occur automatically as soon as REVERSE is engaged, reverting to the original configuration as soon as REVERSE
is disengaged.
4. Operate the multi-function lever to swing the side brushes OUT. The multi-function lever can also be used to control nozzle-tilt
(See Page 12 for operating details).
5. Set the required engine speed by means of the engine speed controls on the main panel (normal operation can be
conducted at between the default engine speed and 1800 rpm according to prevailing conditions). The switches adjust engine
speed up or down in 50 rpm increments or can be held down for greater adjustment.
6. Select Forward drive using the hydrostatic control lever, release the parking brake and slowly depress the throttle pedal to
move and start sweeping.
Whatever the situation, remember that the rules of traffic and road safety must be observed.
Hydrostatic Braking - Sweep Mode Only.
This allows the vehicle to slow-down rapidly when the accelerator pedal is released, eliminating the need to use the footbrake in certain conditions. Even
though this feature is available it is still advisable to always use the footbrake when stopping.
The footbrake must always be used for emergency braking.
Never press brake and accelerator pedals at the same time.
OFF
ON
ON
Nozzle tilt
Side
brush
Side
brush

Part No. SCAZ037886 8.6.00 18 E&OE
Merlin and Magnum HydrostaticOperating Instructions
Suction fan boost setting
When required, boost settings are available for the suction fan. This increases fan speed and is used when sweeping heavy material. To operate the fan at
the Boost settings, carry out the following procedure:
1. Press the suction fan ‘Boost’ switch . See Page 12.
2. Adjust engine speed as necessary, by means of the controls on the main panel, until the fan is at the desired rpm using the lowest engine
speed to achieve this.
Climbing Gradients
When sweeping up hill it might be necessary to increase engine speed to maintain sweeping performance. It is advisable to do this before you start to climb
the hill.
The amount of increase will depend on a range of variable factors:
(a) The individual characteristics of the engine.
(b) The current hopper load.
(c) The current sweeping load (e.g. light or heavy material).
(d) The angle of the gradient.
To increase engine speed, do one of the following:
•Use the engine speed-setting controls . This method is most useful when a prolonged increase in engine speed is required.
•Use the throttle pedal. To temporarily over-ride the pre-set engine speed (this method is more convenient for brief increases in engine speed as
engine speed will automatically revert to the pre-set value when the throttle pedal is returned to its previous position).

Part No. SCAZ037886 8.6.00 19 E&OE
Merlin and Magnum HydrostaticOperating Instructions
Reverting to normal drive mode
1. Move the multi-function lever (located on the auxiliary control panel) to the OFF position. This will stop and raise all sweeping equipment
to the stowed position. The sweeping equipment symbols displayed on the LCD monitor will change back to grey, indicating that they are
no longer active.
For safety reasons, if the multi-function lever is left in the ON position at this point the sweeping equipment will not activate when sweep mode
is later resumed. If this occurs the lever will need to be place in the OFF position when sweep mode is resumed.
2. Switch the suction fan OFF.
3. Bring the vehicle to a complete stop and apply the hand brake. Place the hydrostatic control lever in neutral.
Whatever the situation, remember that the rules of traffic and road safety must be observed.
4. Depress the clutch (engine speed will drop to idle).
5. With the clutch depressed, press the sweep mode switch , holding it down until the drive symbol changes. When hydrostatic drive disengages, the
symbol will change to the . The symbols displayed on the LCD monitor representing the installed sweeping equipment will also extinguish.
If the hydrostatic gearbox fails to disengage properly, the will flash and a buzzer will sound intermittently. Press the sweep mode switch and release
the clutch. Drive the vehicle slightly forward and repeat steps 2, 3 and 4.
6. Select vehicles neutral gear and release the clutch.
As soon as you no longer represent a hazard turn of the beacons
OFF
ON
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Part No. SCAZ037886 8.6.00 20 E&OE
Merlin and Magnum HydrostaticOperating Instructions
CNG IVECO with Allison gearbox - Engaging and disengaging hydrostatic drive
Engine ON and air tanks full before attempting to engage hydrostatic drive mode.
The hydrostatic gearbox will not engage unless the vehicle is stationary.
Engage hydrostatic drive
1. Switch on the hazard warning beacons.
2. Stop the vehicle, apply the parking brake,
3. Press neutral button ‘N’ on the Allison transmission selector.
4. Keep brake pedal pressed, this will keep engine revs at tick over.
5. Select hydrostatic mode using the sweep mode switch .
6. Ensure that you are in hydrostatic mode, this symbol should not be flashing on the LCD monitor.
7. Keep brake pedal pressed so engine revs are below 900rpm.
8. Press the drive button ‘D’ on the Allison transmission selector.
9. On the dash gear 4will show.
If the gear 4is flashing on the dash then the Allison gearbox has not engaged.
Press the sweep mode switch to disengage hydrostatic mode.
Repeat process from step 3.
10. Hydrostatic drive is established when the gear 4 on the dash is not flashing.
Sweeper is now in hydrostatic drive mode and you can prepare for sweeping.
Disengage hydrostatic drive
1. Stop the vehicle, apply the parking brake.
2. Press the brake pedal to lower the engine revs.
3. When engine revs are below 900rpm, press the neutral button ‘N’ on the Allison transmission selector.
4. Press the sweep mode switch and will show on the LCD monitor.
Sweeper is now in normal drive mode and you can prepare for transit driving.
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