GMI-255

 DIRECTOR GENERAL BORDER ROADS

GENERAL MAINTENANCE INSTRUCTION NO. 255

ON OPERATION AND MAINTENANCE OF

SNOW SWEEPER WITH PLOUGH MAKE OVERAASEN SNOW REMOVAL SYSTEM   MODEL OVERAASEN RS 200 SNOW SWEEPER WITH OVERAASEN EP 6 SNOW PLOUGH

INTRODUCTION:

(a)        Snow Sweeper with Plough Make Overaasen Snow Removal System   Model Overaasen RS 200 with snow plough EP 6 is powered by Turbocharged, water cooled, diesel engine type RS 200 6R 1100C30 fitted with cold starting device. The eqpt is used to clear the snow, small debris from the roads and air port runways.

(b)        This GMI gives the technical specification and know how on the operation, maintenance and repair procedure of Snow Sweeper with Plough Make Overaasen Snow Removal System   Model Overaasen RS 200 with snow plough EP 6 to ensure maximum performance and safe/satisfactory operation. Compliance with procedures given in this GMI will enable to get desired maximum service from the equipment.

(c)        Maintenance of Snow Sweeper with Plough Make Overaasen Snow Removal System   Model Overaasen RS 200 with snow plough EP 6 will lead to long life, trouble free operation and less frequent break down and also to reduce maintenance cost. The periodic maintenance must be carried out according to the ‘Periodic Maintenance Schedule’ described in this GMI. Daily care, inspection, and periodic maintenance are essential for preventing troubles and accidents to ensure satisfaction and safe operation for prolonging the operating life of the equipment. The information in this GMI overlaps the user manual and there is detailed information about that is needed for maintenance and repair. All information and instructions given in this GMI is based on the latest Operator’s manual and service booklet provided by the firm.

 AIM:     The instructions are issued as guidelines for general, preventive maintenance schedule and lubrication of Snow Sweeper with Plough Make Overaasen Snow Removal System   Model Overaasen RS 200 with snow plough EP 6 for regular attention to keep the equipment in good mechanical condition which must be strictly followed.

ACTION BY:

(a)	User unit:   To carryout periodic inspection regular/periodical maintenance as laid down in this instruction and record the tasks done in log book.
(b)	Field Workshop :
	(i)	To monitor maintenance schedule and oil changes as per periodical maintenance laid down in the maintenance instructions and to check the record of maintenance including lubrication.
	(ii)	To advise the user unit in respect of any lapse noticed.
(c)	Mobile Maintenance Team:  To ensure that proper maintenance is carried out and submit report accordingly to Task Force Commander and OC Wksp for their necessary action.

DETAILS:

            This instruction includes the following aspects:-        

(a)	Operating Procedure – Do’s and Don’ts..	Appendix ‘A’
(b)	Maintenance.	Appendix ‘B’
(c)	Technical Specification.	Appendix ‘C’
(d)	Oil filling capacity/recommended lubricants for change.	Appendix ‘D’

                                                                                                            (Devendra Dhagarra)

                                                                                                            EE (E&M)

                                                                                                            Jt Director (Tech)

                                                                                                            For Dir Gen Border Roads

                                                                                                           

                                                                                                                        Appendix ‘A’

OPERATING PROCEDURE - DO’s & DON’Ts

1.      The Snow Sweeper with Plough Make Overaasen Snow Removal System   Model Overaasen RS 200 with snow plough EP 6 is solely designed for performance, efficiency and results on air port runways. This snow sweeper uses fiber glass compound materials to provide an advanced and innovative concept in terms of components, surfaces, and aerodynamics.  

         The leading-edge brush units are fully automatic brush adjustment combined with this machine. Overaasen Snow Sweeper with Plough is self-monitoring control system, with on-board diagnostics, also means that maintenance of the sweepers is easier and more cost-effective. For unimpeded maintenance access, the single-piece, hinged engine enclosures, rotate backward exposing the entire engine.  

2.      Incorrect and careless handling of the sweeper can cause injury or lead to dangerous situation. The following operations /functions are particularly dangerous.

           

i)	Raising and lowering the brush.
ii)	Rotating brush.
iii)	Air nozzles.
iv)	High-pressure hoses and associated components.

 3.        Never stand in the vicinity of the brush when the engine is running. Before carrying out work on the snow sweeper:-

i)	Stop the engine and remove the key.
ii)	Turn off the main switch.
iii)	If the snow sweeper is coupled to a tractor vehicle, remove the vehicle’s ignition key and apply the parking brake.
iv)	Engage the emergency stop switches.
v)	Open and close the engine cover.

4.      When opening and closing engine cover check that nobody is in the vicinity of the engine cover before opening  and nobody must stay under the engine cover while closing it.

5.      Use the emergency stop switches in emergencies. Emergency stop switches are to be found on the control panel and behind the left/right wheel covers in the rear end of the machine.

6.      Use the snow sweeper with great care in order to avoid personal injury or damage to equipment and property.

7.      Pay attention to the direction of the air nozzles so that the snow does not cause damage or injury.

8.      When the engine is started, only qualified personnel may remain within the danger zone following all the required safety precaution.

9.      Always use hearing protection when the snow sweeper is running.

10.    Always use gloves when handling the brush cassettes. The brushes are pointed and sharp.

11.    Close all hatches on the sweeper before starting the engine. Pay particular attention if a hatch has to be opened while the engine is running.

12.    Cordon off the danger zone when test-driving the snow sweeper.

13.    The brush must be raised during transport. It must only be in operation when performing, work.

14.    Stop the engine and turn off all electronic equipment before refuelling.

15.    Check hydraulic hoses regularly.

16.    Maintenance or repairs must not be performed on the machine when it is running.

17.    Do not leave the engine running when stationary in an enclosed room. The exhaust fumes contain toxic carbon monoxide. Carbon monoxide is invisible and odorless. As a result, it is difficult to detect the gas before it is too late. The gas is heavier than air, and accumulates in depression and at floor level.

18.    When repairs are carried out on the engine, transmission, or hydraulic system, it is very important to keep the workplace clean and tidy. After repair, it is important to check that the snow sweeper is working as it should, that the replaced components are in order and that there are no leaks.

19.    It is dangerous to remain in the vicinity of the brush and air nozzles during operation. Stones, gravel and other particles are ejected from the machine with great force. The jets of air are very powerful. There is risk of personal injury.

20.    The rear wheel steering is powered by hydraulics. The snow sweeper’s engine must always be running when driving the truck i.e. to ensure that the rear wheel steering is active.

21.    Before moving the sweeper, start the truck’s engine and fill the air brake system. Then push the red parking valve on the snow sweeper to release the parking brake.  Check that no emergency stop switch is pressed in emergency stop switch in the cab of scania. Open the service hatch and turn on the main switch. Switch on the sweeper switch in the cabin and wait until system is ready.

22     For starting the engine at low temperatures, never use liquid or gaseous starting aids such as Start Pilot, ether or similar when starting the engine. This can result in severe injuries and damage. Start the engine at low temperature with fully charged batteries and without pre-heating, the engine will start at ambient temperatures down to -25°C However, it is advisable to use the engine heater at ambient temperatures below -5°C, to reduce emissions, make starting easier and avoid unnecessary wear on the engine.

         Connect the engine heater and the battery charger to the mains, 230 V (10 A) when the engine is stationary at low temperatures. This is to ensure easier start-up and to reduce wear and cold related damage. The engine heater socket and battery charger socket are located inside the service hatch on the left side of the sweeper.

23.    If batteries are discharged, jump starting can be performed by connecting to external 24 V batteries or by connecting another eqpt with the same system voltage to the jump start socket located to the right of the battery box. During jump starting, the snow sweeper’s regular batteries must be connected. If another eqpt is used when starting with jumper cables, ensure that the eqpt and the snow sweeper is not in contact with each other, as this can cause damage in the assisting eqpt electrical system.

        

i)	Open the service hatch; check that the snow sweeper’s batteries are connected, and that the battery cable clamps are securely fixed.
ii)	Turn off the main switch.
iii)	Connect the jumper cable to a supporting 24 V battery If using clamps instead of jump start socket, first connect the (+) Plus pole and then the (-) Minus pole.    Check that the jumper cables are connected to the battery with the correct polarity.
iv)	Connect the jumper cable to the jump start socket on the sweeper.
v)	Turn on the main switch.
vi)	Wait a few minutes, to let the voltage difference between the batteries even out.
vii)	Start the  snow sweeper’s engine.
viii)	Disconnect the negative clamp on the jumper cable from the external start battery/helping eqpt.
ix)	Disconnect the jumper cable from the jump start socket on the  snow sweeper.
x)	Disconnect the (+) positive clamp on the jumper cable from the external starter. battery/helping eqpt

24.    If the engine does not start immediately, do not let the starter motor to run for more than 20 seconds at a time. Wait 60 seconds before next starting attempt to let the starter motor to cool down.

25.    If there is no engine symbol and no sweeper icon picture on the display immediate take following action:-

i)	Switch off the sweeper switch.
ii)	Check that the main switch is on.
iii)	Check that the emergency stop switch is released.
iv)	Check that the manoeuvre cable is connected between the truck and the snow sweeper.
v)	Switch on snow sweeper switch again.

26.    Check that nobody is in the vicinity of the brush or blower before selecting reset and preheat. There is risk of personal injury. If the engine’s coolant temperature is lower than +0°C, the snow sweeper must be preheated before work may begin. Select OK to reset position and start the preheat sequence. The brush and blower move into transport position and the preheat sequence starts.

27.    It is possible to abort the reset position and preheat sequence. Only the engine will run and the rear wheel steering will be active. No manoeuvre hydraulics, brush or the blower will be active. During the reset position and preheat sequence, the brush and blower rotate and the engine speed increases from idle. The display shows the coolant and hydraulic oil temperatures and a green brush/blower symbol. Snow sweeper is now in transport position.

 

Appendix ‘B’

MAINTENANCE

General

1       Schedule and perform maintenance according to the maintenance schedule. Keep records over performed maintenance tasks and repairs. That is the key to have full control over the machine.

2.      Maintenance of the snow sweeper is divided in to daily and preventive maintenance. Ensure that the snow sweeper is standing on a flat surface when checking oil levels. Stop the engine and turn off the main switch. If the snow sweeper is coupled to tractor vehicle, apply the parking brake and remove the starter key.

Refuel

3.      The engine must be turned off during refueling.

4.      AdBlue® is not a fuel additive and must not be added to the diesel tank. If AdBlue® gets to the fuel tank, this could lead to engine damage. Do not allow fuel or water to get into the AdBlue® tank. That could damage the exhaust gas after treatment system.

5.      Fill fuel via the filler pipe on one of the fuel tanks.

6.      Fill AdBlue® via the filler pipe for the AdBlue® tank.

Check Connectors

7.      Check that the trailer brake couplers, trailer light cable, EBS cable and the control cable are not damaged.

8.      Check that the connectors, hoses and cables are free from snow and ice.

Check Sweeper

9.      Check that there are:

i)	No loose or missing parts.
ii)	Abnormal noises or vibrations when operating the snow sweeper.
iii)	No damages.
iv)	No Leaks.

        

10.    Check that all functions work as they are intended to. Any Abnormal operation should be taken care of immediately.

Clean Sweeper

11.    Defrost the sweeper when too much snow and ice have built up on the machine.

12.    Wash the sweeper when too much debris and dust have built up on the machine. Do not spray close with water at high pressure (>50 Bar) on sensitive parts.

Engine

13.    Wait until the engine is cold before carrying out maintenance work on the engine to avoid risk of burns.

14.    Check that the engine oil level is between the marks on the dipstick. If the level is at or below the lower marking, top up to the upper marking with engine oil as per the lubrication chart.

15.    There is a risk of damage to the catalytic converter or the engine if the oil level is too high. Always drain off excess oil.

Coolant Level

16.    The coolant system is under pressure, particularly if the engine is hot. There is a risk for hot coolant spraying out when opening the cap on the expansion tank or any component in the cooling system.

17.    Allow the engine to cool before opening the cap. Wear gloves and protective eye wear when opening. Slowly turn the cap half a turn to allow pressure to escape.

i)	MTU Engine:  Check that the coolant reaches the lower part of the filling neck. Top up if necessary.
ii)	Scania engine:  Check that the coolant reaches the middle of the level tube.

Air filter indicator

18.    The air filter indicator is mechanical and shows the lowest pressure that has occurred in the intake manifold. The indicator is placed on right side on the inlet air tube between the air filter and the turbocharger.

        

i)	Check that the indicator is intact. Wipe it off with damp rag and read off the indicator. If the indicator piston inside the indicator is within the red field, the air filter must be changed.
ii)	Reset the air filter indicator after that the air filter is replaced. Press the yellow diaphragm on the end of the indicator to reset the indicator piston.

Electrical System

19.    Check that all lights work when they are activated.

20.    Check that the lights are clean and undamaged.

Hydraulic System

21.    During all work with hydraulic systems and components, high demands are stipulated regarding cleanliness. In many of the components, e.g. valves and pumps, the fit is very narrow in order for the system to work.   For this reason, even very small contaminants can have a disruptive impact on functionality. The hydraulic system incorporates a filter to catch contaminant. The hydraulic system is under high pressure. Following to be ensured:-

i)	Ensure that the hydraulic hoses are correctly connected to the hydraulic cylinders.
ii)	Ensure that the hydraulic system is de-pressurised before connecting the hydraulic hoses.
iii)	Couplings and connections for various hydraulic components must be marked in order to avoid incorrect function. If they are incorrectly connected, the function will be reversed. (e.g. raise/lower)
iv)	Check hydraulic hoses and pipes regularly, and replace them if they are damaged or aged. New hoses and pipes must satisfy the technical requirements of the hydraulic system.
v)	Use appropriate aids when looking for leaks in the hydraulic system in order to avoid damage.
vi)	Fluids (hydraulic fluid) that leak under high pressure can penetrate the skin and cause serious injury.
vii)	Lower all equipment/unit, relieve the pressure in the system and stop all motors before commencing any work on the hydraulic system.
viii)	Warning signs must never be removed. If a warning sign becomes illegible, it must be replaced.

Distance to the deflector cover

           

22.    Remove snow and ice from the brush and brush cover before performing any work on the brush.

23.    Check the deflector cover position with the template for the brush. The distance between the deflector cover and the brush should be between 15-25 mm.

24.    Adjust the deflector cover position with turnbuckles.

Manual Brush Pattern Adjacent

25.    Be careful when manually adjusting the brush pattern. If the brush pattern is too large, there is a danger that the brushes will touch the deflector and damage it. It also increases the brush wear and reduces the brush service life.

Appendix’C’

TECHNICAL SPECIFICATION

Engine

Engine MTU
a)	Producer	:	MTU
b)	Engine Type RS 200	:	6R 1100 C30
c)	Emission level	:	EU Stage IV/ Euromot 4
d)	Assembly model	:	470.907
e)	Cylinder configuration	:	In-line 6
f)	Displacement, total	:	10,6 Ltr
g)	Power rating at 1700 rpm	:	280 kW
h)	Torque at 1300 rpm	:	1900 Nm
j)	Valve clearance, cold engine	:	Inlet 0,40 ± 0,05 mm
	Approx. +20˚C	:	Exhaust 0,60 ± 0,05 mm
k)	Firing order	:	1-5-3-6-2-4
l)	Direction of rotation	:	Counter clockwise when looking at the Fly wheel
m)	Cold start limit	:	-30˚ C @ Battery charging level 75%
Alternative engine Scania
a)	Producer	:	Scania
b)	Engine Type RS 200	:	DC 13 387 A 257 kW
c)	Emission level	:	EU Stage IV / Euromot 4
d)	Assembly model	:	470.907
e)	Cylinder configuration	:	In-line 6
f)	Displacement, total	:	12,7 Ltrs
g)	Max. Speed	:	2100 rpm
h)	Torque at 1250 rpm	:	1800 Nm
j)	Valve clearance, cold engine	:	Intake 0,45 mm
k)	Approx. +20˚C	:	Exhaust 0,70 mm
l)	Firing order	:	1-5-3-6-2-4
m)	Direction of rotation	:	Counter clockwise when looking at the fly wheel
n)	Cold start limit	:	-30˚ C @ Battery charging level 75%
Exhaust After treatment
a)	Type	:	SCR (Selective Catalytic Reduction)
b)	Additive	:	AdBlue®/ DEF
c)	Exhaust silencer and catalytic converter	:	SCR and DOC Catalytic converter
Electrical system
a)	System voltage	:	24 V
b)	Batteries	:	2 X 12 V, 170 Ah
c)	Alternator amperage	:	100 A
d)	Starter motor output	:	7kW
e)	Control system	:	Danfoss PLUS+1®
Hydraulics
a)	Blower pump	:	Variable piston, Danfoss H1P210
b)	Brush pump	;	Variable piston, Danfoss H1P250
c)	Manoeuvre pump	:	Variable load sensing piston, Danfoss KRR045
d)	Rear Wheel steering pump	:	Gear type, SN+2/11
e)	Emergency/ Service pump	:	Electro-hydraulic gear pump
f)	Directional valves	:	Closed center, Danfoss PVG32
g)	Blower motor	:	Axial piston, Danfoss 90M100
h)	Brush motor	:	Radial piston, Rotary Power SMA 0480 E1
Noise
a)	Cabin	:	74,5dBA
b)	Outside	:	105,1 dBA
Brakes
a)	Brake System	:	Dual- circuit air operated drum brakes
b)	EBS system	:	Haldex EB+Gen3
Rear Wheel Steering
a)	Producer	:	Vehicle systems Engineering
b)	Type	:	ETS with 1 steered axle
c)	Hydraulic source	:	Engine mounted pump
Rear Wheels
a)	Number of wheels	:	2
b)	Dimensions	:	425/65 R22.5
c)	Tyre pressure	:	9 Bar
Support  Wheels
a)	Number of wheels	:	2
b)	Dimensions	:	7.5/10 14 P.R
c)	Tyre pressure	:	9 Bar
Volumes
a)	Fuel Tank	:	1.000 Ltr
b)	AdBlue® tank	:	40 Ltrs (MTU),  38 Ltrs (Scania)
c)	Engine Oil	:	Approx. 34-37 Ltrs
d)	Cooling system	:	Approx. 35 Ltrs
e)	Hydraulic oil tank	:	150 Ltrs
f)	Blower bearing	:	Approx. 2.9 Ltrs
Oil and fluid Specification
Engine MTU
a)	Engine Oil	:	Mercedes-Benz228.5/51 (Statoil Max Way Ultra 10W-40)
b)	Coolant 50% Pure water	:	Mercedes-Benz 325.0
c)	50% anti- Freeze	:	Fuchs Anti Freeze (red)
Engine Scania
a)	Engine Oil	:	Scania LDF,(Statoil Max Way Ultra 10W-40)
b)	Coolant 50% Pure water	:	Scania antifreeze G40 (red) OR
c)	50% anti- Freeze	:	Fuchs Antifreeze long life (Pink)OR
d)	(Drain system when filling with  a new type of coolant)	:	Fuchs Antifreeze Premium G40 (purple)
e)	Diesel	:	EN 590as 2010 et seq. < 10 ppm sulphur OR
f)	Sulphur-free commercial diesel fuel	:	ASTM D975< 15 ppm sulphur,Gel point min- 25°C (CFPP)
g)	AdBlue®, also called DEF, Diesel	:	NOx reduction agent in accordance with
h)	Exhaust Fluid,	:	Standard DIN 70070/ ISO 22241
j)	Silicon grease	:	Special grease. Often included in the filter kit
k)	Hydraulic oil	:	Viscosity: ISO VG 46 Statoil Hydraway HVXA 46 OR at Temp below -15° C Hydraway HVXA 32
l)	Synthetic transmission oil	:	75 W 90 API GL-4
m)	(Blower bearing)	:	Statoli Gearway S5

           

                                                                                                                                    Appendix ‘D’

OIL FILLING CAPACITIES AND PERIODICITY FOR CHANGE

RS200 Snow Sweeper Equipment (With Euro 3 Engine)
Item	Manufacture		Grade	Quantity	Change
Engine Oil	Scania	:	LDF3	45 Ltr	250 Hrs
	L&T	:	Scania Oil LDF-3 10W-40(P410) MOQ - Part No 2405797SC
	Castrol	:	Vecton Long Drain 10W-40 SLD
	Shell	:	Rimula R6 MS
Coolant	Scania	:	Anti Freeze & Corrosion Inhibitor (50/50)	35 Ltr	500Hrs/ 1 year
	L&T	:	Readymade coolant Part No 2292029SC
AD Blue Tank	Scania	:	DEF- Diesel Exhaust Fluid.	40 Ltr	As & When required
	L&T	:	Diesel Exhaust Fluid. Part No: U31441133SC.
Hydraulic  Tank	Scania	:	Hydraulic Oil.    Viscosity: ISO VG 46.	150 Ltr	500Hrs/ 1 year
	L&T	:	Hydraulic Oil.    Part No: W31241173.
Blower Bearing	Scania	:	Synthetic Transmission Oil. 75W90 API GL 4.	2.9 Ltr	500Hrs/1 year
	L&T	:	75W-90 Oil.  Part No: 2125303SC.
Wheel Bearing, steering, Knuckle Bearing, Brake Aut, Slack Adjuster brake arm bearing.	Scania	:	BPW Special Long Life Grease.	As & When required.
Lubrication.	Scania	:	Grease (EP 2)	As & When required.
	L&T	:	Grease  Part No:  X31241174.

G370 Truck (With Euro 6 Engine)
Item	Manufacture		Grade	Quantity	Change
Engine Oil	Scania	:	5W-40 (Scania LDF4).	43.5 Ltr	250 Hrs
	L&T	:	Scania  LDF-4 Engine oil. Part No: 2574927SC.
	Castrol	:	Vecton Fuel Saver 5W-30 E6/E9.
	Shell	:	Rimula Ultra.
Gear Box	Scania	:	SAE 75W-90.	14.5L -17.5 Ltr	1000Hrs
	L&T	:	75W-90 Oil.  Part No: 2125303SC.
	Castrol	:	Spirax S6 AXME.
	Shell	:	Spirax  MX.

Power Steering Oil	Scania	:	ATF Dexron II, Dexron III.	03 Ltr	As & When required
	Castrol	:	Protector Series TQ/TQD.
	Shell	:	ATF II D.
Clutch Oil	Scania	:	SAE J 1703 (D.O.T. 3/ 4 Brake Fluid).	0.4 Ltr	As & When required
	Castrol	:	Castrol UBF DOT3.
	Shell	:	Shell Brake & Clutch Fluid.
Central Gear (Front Axle)	Scania	:	SAE 75W-140.	10.5 Ltr	1000 Hrs.
Central Gear (Rear Axle)	L&T	:	75W-140 Oil  Part No 2125329SC.	12 Ltr	1000 Hrs.
Hub Reduction Gear (Front)	Castrol	:	Syntrax Long Life.	2-4 Ltr	1000 Hrs.
Hub Reduction Gear (Rear)	Shell	:	Spirax S6 AXME.	2-4 Ltr	1000 Hrs.
SCR Redundant	Scania	:	Ad blue/ DEF/ARLA 32.	As & When required.
	L&T	:	Diesel Exhaust Fluid (AdBlue).             Part No: U31441133SC
Chassis Lubrication	Scania	:	NLGI2.	As & When required.
	L&T	:	Grease.  Part No: X31241174.
Coolant	Scania	:	Anti Freeze & Corrosion Inhibitor.	40 Ltr	500Hrs/1 year.
	L&T	:	Coolant.  Part No 2186292SC.
Cab Tilt Pump- Mechanical	Scania	:	ATF Dexron II, Dexron III.	02 Ltr	As & When required.
	Castrol	:	Protector Series TQ/TQD.
	Shell	:	ATF II D.
Cab Tilt Pump- Electrical	Scania	:	ATF Dexron II, Dexron III.	02 Ltr	As & When required.
	Castrol	:	Protector Series TQ/TQD.
	Shell	:	ATF II D.

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