Scarab Merlin Operator's Manual
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Scarab Merlin Operator's Manual

Hydrostatic truck-mounted sweepers
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  • Page 2 MAIN FEATURES OF A TYPICAL SCARAB SWEEPER SIDE L-P WATER PUMP LOCKER LOADING & STRAINERS HATCH WATER TANK DOOR Scarab Merlin WANDER HOSE FUEL TANK EXTERNAL HOPPER WATER TANK LEVEL GAUGE & DOOR CONTROLS ALWAYS ON NEARSIDE OF VEHICLE RIGHT HAND...
  • Page 3 Original Issue ...... April 2007 Amdt. 1 ........Jan. 2010 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.

  • Page 4: General Information

    MERLIN ........

  • Page 5: Table Of Contents

    SCARAB HYDROSTATIC TRUCK-MOUNTED SWEEPERS TABLE OF CONTENTS Para Title Page GENERAL INFORMATION ....................1 TABLE OF CONTENTS (THIS PAGE)...................2 HEALTH AND SAFETY ADVICE..................3 EXPLANATION OF SWITCH OPERATING SYMBOLS ............4 OPERATING ADVICE ......................6 THE CANbus SYSTEM......................7 DESCRIPTION OF MAIN CONTROL PANEL ..............8 DESCRIPTION OF AUXILIARY CONTROL PANEL ............13...

  • Page 6: Health And Safety Advice

    THE FOLLOWING POINTS ARE OBSERVED AT ALL TIMES: • AT NO TIME SHOULD UNQUALIFIED PERSONNEL BE PERMITTED TO OPERATE OR WORK ON THE SCARAB SWEEPER. • BEFORE DRIVING THE VEHICLE ENSURE THAT ALL RELEVANT VEHICLE CHECKS HAVE BEEN CARRIED OUT, THAT ALL EQUIPMENT IS STOWED AND THAT THE BRUSHES HAVE BEEN RAISED.

  • Page 7: Explanation Of Switch Operating Symbols

    SCARAB HYDROSTATIC TRUCK-MOUNTED SWEEPERS ADDITIONAL SAFETY ADVICE SYMBOLS CHECK IN NEUTRAL CHECK ALL FIRM LEVEL USE CAB OR DO NOT VEHICLE SWITCHES CLEAR TO GROUND HOPPER DRIVE WITH BEFORE OFF BEFORE RAISE BODY ONLY SAFETY PROP BODY UP DRIVING STARTING...
  • Page 8 SCARAB HYDROSTATIC TRUCK-MOUNTED SWEEPERS SWITCH OPERATING SYMBOLS SUCTION FAN - ON / BOOST BRUSH SPEED ADJUSTMENT FRONT BRUSH - RAISE / LOWER FRONT BRUSH - IN / OUT FRONT BRUSH + WATER SPRAY - ON HOPPER BODY - RAISE / LOWER SAFETY INTERLOCK - HOPPER &...

  • Page 9: Operating Advice

    * All switches EXCEPT Panel ON/STANDBY, Work-lights and Beacons are disabled. OPERATING ADVICE Please remember, the information provided in this handbook is designed to ensure that the Scarab sweeper operates both safely and efficiently. A poorly maintained machine will become unreliable, inefficient and potentially dangerous. Always observe the recommended maintenance and safety related advice provided.

  • Page 10: The Canbus System

    SCARAB HYDROSTATIC TRUCK-MOUNTED SWEEPERS THE CANbus SYSTEM (* INDICATES OPTIONAL EQUIPMENT The CANbus system comprises two control panels (main and auxiliary) and a number of control nodes (normally seven). 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.

  • Page 11: Description Of Main Control Panel

    SCARAB HYDROSTATIC TRUCK-MOUNTED SWEEPERS MAIN PANEL SWITCH DESCRIPTIONS Switch functions are described from Left to Right and Top to Bottom. Switches that are fully enabled ONLY when the Master Switch is ON or Sweep Mode is ON are identified by the following symbols.
  • Page 12 SCARAB HYDROSTATIC TRUCK-MOUNTED SWEEPERS HYDROSTATIC GEARBOX SWITCH - Press to engage hydrostatic drive. The RED LED lights when in conventional drive mode and the GREEN LED indicates when the vehicle is in hydrostatic drive mode. ENGINE SPEED DECREASE - Press and hold until engine speed has reduced to the required level.
  • Page 13 SCARAB HYDROSTATIC TRUCK-MOUNTED SWEEPERS LIQUID CRYSTAL DISPLAY AMBIENT LIGHT FUNCTION IS NOT APPLICABLE (LCD SCREEN) SENSOR IN THIS SWEEPER CONFIGURATION SPARE (OPTIONS) SWEEP MODE When in Sweep Mode: SPARE (OPTIONS) UPPER LINE = FAN SPEED ENGINE SPEED LOWER LINE = ROAD SPEED / WARNINGS...
  • Page 14 SCARAB HYDROSTATIC TRUCK-MOUNTED SWEEPERS SIDE-BRUSH ‘DOWN’ PRESSURE SWITCH - Press to allow a controlled amount of pressure to the top of the brush lift ram and increase the brush’s surface pressure. Use in conjunction with the air-pressure regulator. The red LED illuminates when the feature is selected. Will affect both side brushes, when both selected, on dual sweep machines.
  • Page 15 SCARAB HYDROSTATIC TRUCK-MOUNTED SWEEPERS LIQUID CRYSTAL DISPLAY AMBIENT LIGHT FUNCTION IS NOT APPLICABLE (LCD SCREEN) SENSOR IN THIS SWEEPER CONFIGURATION SPARE (OPTIONS) SWEEP MODE When in Sweep Mode: SPARE (OPTIONS) UPPER LINE = FAN SPEED ENGINE SPEED LOWER LINE = ROAD SPEED / WARNINGS...

  • Page 16: Description Of Auxiliary Control Panel

    SCARAB HYDROSTATIC TRUCK-MOUNTED SWEEPERS REAR DOOR OPEN SWITCH - Press and hold down simultaneously with the safety interlock switch to open the rear door. Red LED illuminates when the switch is operated. Ensure that the suction fan is OFF. The door cannot open while the fan is running due to low pressure in the hopper.
  • Page 17 SCARAB HYDROSTATIC TRUCK-MOUNTED SWEEPERS LIQUID CRYSTAL DISPLAY AMBIENT LIGHT (LCD SCREEN) SENSOR MAIN PANEL SWEEP MODE When in Sweep Mode: SPARE (OPTIONS) SPARE (OPTIONS) UPPER LINE = FAN SPEED ENGINE SPEED LOWER LINE = ROAD SPEED / WARNINGS H-P WATER PUMP *...

  • Page 18: Rear-Mounted Nozzle Option

    SCARAB HYDROSTATIC TRUCK-MOUNTED SWEEPERS REAR-MOUNTED SUCTION NOZZLE OPTION It is possible to equip Magnum models with a special hopper door assembly that incorporates a pair of rear-mounted suction nozzles and their associated high-pressure water spray bars. The inclusion of this option in the vehicle specification requires a different main control panel to the standard layout.

  • Page 19: Additional Controls And Instruments

    SCARAB HYDROSTATIC TRUCK-MOUNTED SWEEPERS ADDITIONAL CONTROLS & INSTRUMENTS Do not exceed a pressure of 2.5 bar when adjusting brush pressure settings. Failure to comply will result in drastically reduced brush life. AIR-PRESSURE REGULATOR Used to adjust the amount of up/...

  • Page 20: Operating Modes

    SCARAB HYDROSTATIC TRUCK-MOUNTED SWEEPERS OPERATING MODES There are two driving modes, Normal & Hydrostatic (Sweep), these are selected using the SWEEP MODE switch on the control panel. This switch has two LEDs, one green and one red. These are used to indicate which drive mode is currently in operation as follows: •...

  • Page 21: Suction Fan Boost-Setting

    SCARAB HYDROSTATIC TRUCK-MOUNTED SWEEPERS To stop and stow the sweep gear, return the switch 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 FORWARD is resumed.

  • Page 22: Selecting Normal-Drive Mode

    SCARAB HYDROSTATIC TRUCK-MOUNTED SWEEPERS SELECTING NORMAL DRIVE MODE 1. To return to Normal Drive, proceed as follows: Bring the vehicle to a complete stop and apply the hand brake. Move the Multi-Function Switch (located on the auxiliary control panel) to the Sweep Master Switch OFF position to stop and lift all sweeping equipment to the stowed position.

  • Page 23: Discharging The Hopper (Tipping)

    SCARAB HYDROSTATIC TRUCK-MOUNTED SWEEPERS DISCHARGING THE HOPPER (TIPPING) OPERATING THE REAR DOOR ENSURE THAT ALL PERSONNEL ARE CLEAR OF THE DOOR. Ensure that the suction fan is turned OFF and that there is room for the door to open fully.

  • Page 24: Operating The Hopper

    SCARAB HYDROSTATIC TRUCK-MOUNTED SWEEPERS OPERATING THE HOPPER THE HOPPER PROP MUST ALWAYS BE USED WHEN THE HOPPER IS IN THE RAISED POSITION. FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY. BEFORE RAISING THE HOPPER, ENSURE THAT THE VEHICLE IS ON FIRM, LEVEL GROUND AND THAT THERE ARE NO OVERHEAD OBSTRUCTIONS.

  • Page 25: External Controls

    SCARAB HYDROSTATIC TRUCK-MOUNTED SWEEPERS USING THE EXTERNAL CONTROLS 1. To raise the hopper, press and hold the Hopper Raise button until the hopper is in the fully raised position. When the hopper is raised a warning to this effect is displayed on the control panel’s LCD screen.

  • Page 26: Using The Auxiliary Hydraulic Pump

    SCARAB HYDROSTATIC TRUCK-MOUNTED SWEEPERS USING THE AUXILIARY HYDRAULIC PUMP In the event of hydraulic system failure, an auxiliary (manually operated) hydraulic pump is fitted, to enable the rear door and hopper to be operated manually. This is located on the Left Hand side of the vehicle, adjacent to the hopper suction spigot.
  • Page 27 SCARAB HYDROSTATIC TRUCK-MOUNTED SWEEPERS HOPPER (ELECTRICAL SYSTEM OPERATIONAL) THE HOPPER PROP MUST ALWAYS BE USED WHEN THE HOPPER IS IN THE RAISED POSITION. FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY. BEFORE RAISING THE HOPPER, ENSURE THAT THE VEHICLE IS ON FIRM, LEVEL GROUND AND THAT THERE ARE NO OVERHEAD OBSTRUCTIONS.
  • Page 28 SCARAB HYDROSTATIC TRUCK-MOUNTED SWEEPERS ARROW KEY FUNCTIONS ENTER....... (SAFETY INTERLOCK SWITCH) EXIT......(AUX. SIDE BRUSH SWITCH) SCROLL UP ....(WIDESWEEP PRESSURE SWITCH) SCROLL DOWN..(HOPPER DOWN SWITCH) Fig. 6 Using the Main panel in Program Mode 3. Using the scroll up/down switches, select the HYDRAULIC NODE and press enter then refer to Fig.
  • Page 29 SCARAB HYDROSTATIC TRUCK-MOUNTED SWEEPERS To Open/Close the Rear Door 1. Ensure that the vehicle’s gearbox is in neutral and that the ignition is ON. 2. On the main control panel, simultaneously press switches, marked in red on the accompanying diagram. Fig. 6 3.

  • Page 30: Wander Hose & Wander Booms

    SCARAB HYDROSTATIC TRUCK-MOUNTED SWEEPERS WANDER HOSE & WANDER BOOMS Scarab truck-mounted sweepers are equipped with either the standard wander hose, or the optional rear-mounted Wander Boom. USING THE WANDER HOSE 1. Move the Multi-Function Switch (located on the auxiliary control panel) to the Sweep Master Switch OFF position to stop and any active equipment.
  • Page 31 SCARAB HYDROSTATIC TRUCK-MOUNTED SWEEPERS SUPPORT SPRING ASSEMBLY SUPPORT CRADLE & RETAINING HOOK FAN BOOST & DUST SUPPRESSION ACCESS CONTROLS PLATE DETACHABLE NOZZLE STOWAGE & NOZZLE LOCKING CLAMP (x2) STANDARD WANDER HOSE PULL DOWN AT THIS END TO CLEAR REAR-MOUNTED BOOM ASSEMBLY...

  • Page 32: Using The Low-Pressure Water Pump

    SCARAB HYDROSTATIC TRUCK-MOUNTED SWEEPERS USING THE LOW-PRESSURE WATER PUMP Unless the ground is wet, always use the dust suppression sprays. Before using the dust suppression system, ensure you have sufficient water in the tank. Select the spray jets and sweep pattern you require.

  • Page 33: Using The Optional High-Pressure Water Pump

    SCARAB HYDROSTATIC TRUCK-MOUNTED SWEEPERS USING THE OPTIONAL HIGH-PRESSURE WATER PUMP HIGH PRESSURE WATER CAN BE HAZARDOUS, ALWAYS WEAR GOGGLES OR SUITABLE EYE PROTECTION WHEN OPERATING WITH HIGH PRESSURE WATER. EXERCISE EXTREME CARE WHEN USING THE LANCE, DO NOT DIRECT THE JET AT OTHER PEOPLE.

  • Page 34: Oil Level / Draining

    SCARAB HYDROSTATIC TRUCK-MOUNTED SWEEPERS OIL LEVEL 1. The level of the oil in the pump’s crankcase should be checked on a regular basis (See “RECOMMENDED OPERATOR’S ROUTINE MAINTENANCE” on page 33.)and topped up as necessary. There is a combined filler cap/dipstick on the top of the pump body (Refer to Fig.
  • Page 35 SCARAB HYDROSTATIC TRUCK-MOUNTED SWEEPERS 4. Set the wash-assist valve to the ON position and switch on the high-pressure pump. The fan-wash jet will start. 5. With fan-wash still running, turn the Suction Fan ON and wait until clear water is being ejected. Return the control valve to the OFF position, stop the High-pressure Pump and then stop the Fan.

  • Page 36: Recommended Operator's Routine Maintenance

    RECOMMENDED OPERATOR’S ROUTINE MAINTENANCE It is important that the following routine maintenance procedures are carried out as directed. This will help to ensure that your Scarab sweeper performs at the optimum level of safety and efficiency. Refer to the paragraphs immediately following this schedule and to the Table of Contents (Page 2) for more detailed information.
  • Page 37 Detailed instructions covering the servicing of your Scarab sweeper are published in Scarab Workshop Manual Z028603. The fitting of genuine Scarab parts is highly recommended. The use of alternatives might compromise the performance and reliability of your sweeper and could invalidate your warranty.

  • Page 38: Key Maintenance Procedures

    SCARAB HYDROSTATIC TRUCK-MOUNTED SWEEPERS KEY MAINTENANCE PROCEDURES CLEANING THE SUCTION FAN AND SCREENS FAILURE TO COMPLY WITH THE FOLLOWING COULD RESULT IN SERIOUS INJURY. 1. BEFORE WORKING ON THE MACHINE POSITION IT ON FIRM, LEVEL GROUND, APPLY HANDBRAKE AND, IF REQUIRED, RAISE THE HOPPER, STOP ENGINE & REMOVE IGNITION KEY.

  • Page 39: Suction Nozzle Clearances

    SCARAB HYDROSTATIC TRUCK-MOUNTED SWEEPERS SUCTION NOZZLE CLEARANCES Inspect the suction nozzle flaps to verify that they are in good condition and do not show excessive wear. Adjust as necessary to achieve the correct flap to ground clearances (Refer to Fig. 14).

  • Page 40: Draining & Cleaning The Water Strainers

    SCARAB HYDROSTATIC TRUCK-MOUNTED SWEEPERS DRAINING & CLEANING THE WATER PUMP STRAINERS Both the low-pressure and, if fitted, the high-pressure water pump are fitted with strainers to ensure that foreign matter does not enter the pump. The following steps detail the recommended cleaning procedure.

  • Page 41: Manual Greasing

    SCARAB HYDROSTATIC TRUCK-MOUNTED SWEEPERS MANUAL GREASING & LUBRICATION Carry out manual greasing in accordance with the appropriate schedule (Page 33). and by referring to Fig. 17 Suction Nozzle Assembly Side Brush Assemblies Hopper Ram (Viewed from Above) Door Hinge Pivot Rod x2...
  • Page 42 SPRAY BAR VALVE LEFT HAND SECOND HOPPER SIDE BRUSH RAISE BUTTON (RHD ONLY) LEFT HAND AUXILIARY HAND PUMP SUCTION NOZZLE Fig. 18 Main Features of a Typical Scarab Truck-mounted Sweeper Operator’s Manual - CANbus 2 Models Amdt. 1 - 26 January 2010...

  • Page 43: Recommended Lubricants & Consumables

    RECOMMENDED LUBRICANTS AND CONSUMABLE PARTS DESCRIPTION SPECIFICATION QUANT SCARAB PART Hydraulic Oil Derwent 32 5 litres 005005 Hypoid Gear Oil (Scarab Transfer Box) 85W/90 5 litres 005003 Multi-purpose grease (Grease Points) Super Lithium 2 400 g 005007 Motor Oil (for High-pressure Water Pump)

  • Page 44: Legionella Statement

    • Direct sunlight. RECOMMENDATIONS The water dust-suppression system used on all Scarab sweepers is of a TOTAL LOSS type i.e. there is no re-cycled water stored on the vehicle. Provided that the water tank is replenished regularly with mains water, the...
  • Page 45 SCARAB HYDROSTATIC TRUCK-MOUNTED SWEEPERS OPERATOR’S NOTES Operator’s Manual - CANbus 2 Models Amdt. 1 - 26 January 2010...
  • Page 46 SCARAB HYDROSTATIC TRUCK-MOUNTED SWEEPERS Operator’s Manual - CANbus 2 Models Original Issue - 26 January 2010...
  • Page 48 Scarab Sweepers Limited Pattenden Lane, Marden, Kent TN12 9QD Telephone: 01622 831006 Fax: 01622 832417 International: +44 (0)1622 831006 International +44 (0)1622 832417 e-mail: scarab@scarab-sweepers.com Web site: www.scarab-sweepers.com Publication Z032193 © Scarab Sweepers Limited 2010...

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