STEWART-AMOS Starfire S-5 Safety, Operation & Maintenance Manual Download Page 53 | Manualshive

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Sweeper Co.

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CAUTION: The entire hydraulic oil system must be of the same
viscosity grade.

Grease

The recommended grease for this sweeper is Whitmore Novagard EP 2 multipurpose grease or
equivalent.

Lubrication and Maintenance

IMPORTANT: Maintenance includes inspection and replacement of worn parts as required.

WARNING: Before servicing the sweeper follow a proper Equipment
Lockout procedure as described in the Safety section. Serious
personal injury or death may result otherwise!

NOTE: To service the chassis or auxiliary engine, refer to the manufacturer's manual included
with your sweeper.

For Auxiliary Engine service locations, see Figure 5: Service Locations on Auxiliary Engine

Daily

(Refer also to the engine manual that comes with your sweeper for locations).

1. Check oil and coolant levels on the engine.
2. Do a walk around inspection to check all linkages cotter pins and bolts for looseness or

missing.

3. Check hydraulic oil level in the hydraulic oil tank. The sight glass is located on the front

of the hydraulic oil tank on the driver’s side of the vehicle.

4. Check the hydraulic oil breather filter, located on tank, for cleanliness.
5. Inspect the Air Restriction Indicator on the engine air filter. For longer engine life it is

strongly recommended to change the air filter element at regular intervals. The Air
Restriction Indicator gives you a guideline of when changing is needed.

6. Lubricate the elevator bearings.
7. Lubricate the main broom bearing.

WARNING: Do not pull on hydraulic oil cooler outlet hose when
servicing. This may cause the cooler to leak.

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Summary of Contents for Starfire S-5

Page 1: ...Sweeper Co 1 Last Update July 2013 Starfire S 5t Sweeper Body Safety Operations and Maintenance Manual Sweeper Co SN 5005 UP ...

Page 2: ...Sweeper Co 2 Last Update July 2013 ...

Page 3: ...For Emergencies 20 Never Use Starting Fluid 20 Wear Protective Clothing 20 Protect Against Noise 20 Handle Chemical Products Safely 20 Dispose Of Waste Properly 21 Practice Safe Maintenance 21 Work In Ventilated Area 22 Avoid High Pressure Fluids 22 Avoid Heating Near Pressurized Fluid Lines 23 Remove Paint Before Welding Or Heating 23 Service Cooling System Safely 23 Avoid Harmful Asbestos Dust 2...

Page 4: ... 34 Lighting System 35 Hydraulic System 35 Water System 35 Controls 36 Engine Controls 37 Figure 2 Engine Control Box 38 Sweeper Control 39 Sweeper Controls 39 LH Gutter Broom tilt Up Down 39 Beacon Lights On 39 RH Gutter Broom Tilt Up Down 39 Brooms Up Down 39 GB Lights On GB MB Lights On 39 Sweep Forward Sweep Reverse 39 Hopper Up Down 40 Water 40 Hopper Dump Retract 40 LH Gutter Broom Up Down 4...

Page 5: ...ne 54 Every 50 Hours 54 Every 250 Hours 54 Every 500 Hours 55 Every 1000 Hours 55 Adjustments 56 Gutter Broom Angle Adjustment 56 Correct Gutter Broom Angle 56 Adjust Tilt Angle 56 Adjust Front to Back Angle 56 Gutter Broom Pressure 57 Correct Gutter Broom Pressure 57 Adjusting Gutter Broom Pressure 57 Sweeping Width 57 Gutter Broom Impact Protection Spring 58 Figure 6 Gutter Broom Assembly 59 Fig...

Page 6: ... 68 Carbide Drag Shoe Replacement 68 Figure 12 Carbide Drag Shoe 69 Elevator Chain Replacement 69 Figure 13 Elevator 71 Bottom Liner Replacement 72 Top Liner Replacement 72 Main Broom Hydraulic Motor Replacement 72 Gutter Broom Hydraulic Motor Replacement 73 Elevator Hydraulic Motor Replacement 73 Hydraulic Pressure Adjustment 74 Figure 14 Hydraulic Valves 74 Stall Switch Adjustment 75 Lubrication...

Page 7: ...y the DEALERS REPRESENTATIVE Then remove from manual and returned to the following address Sweeper Co 2700 Paxton St P O Box 2043 Harrisburg PA 17105 Failure to return the completed and signed Pre Delivery Inspection and In Service Date Registration forms to the above address may void all warranties ...

Page 8: ...n Broom Bearing Set Screws Main Broom Chains Main Broom Suspension Turnbuckle Elevator Mounts Elevator Bearings Elevator Canopy Elevator Extension Canopy Hooper Door Cylinders Water Tank Straps Gutter Broom Mounts Gutter Broom Pins Gutter Broom Plates Gutter Broom Linkage Gutter Broom Segments Engine Skid Mounting Engine Mounts Hydraulic Pump Mount Bell Housing Mount Plate Hydraulic Tank Mount Hyd...

Page 9: ...Lift Cyl LH Gutter Broom Motor LH Gutter Broom Retract Cyl MB ELEV Lift Cyl Main Broom Motor Elevator Motor Hopper Dump Cyl Hopper Door Cyl Hydraulic Tank Site Gauge Magnetic Drain Plugs Hydraulic Filter Hydraulic Filter Manifold Fluid Levels Chassis Engine Transmission Differential Brake Fluid Power Steering Engine Air Filter Radiator Tire Pressures Rear psi Front psi Sweeper Engine Oil Hydraulic...

Page 10: ...vator Down Position GB Front to Back Angle GB Side To Side Angle GB Suspension GB Sweeping Path Rear Camera Adjustment GB Camera Adjustment Monitor Adjustment Work Light Adjustment Chassis Mirrors Operations Lights Brakes LH Turn Signal RH Turn Signal Tail Lights ID Bar LH Rear Door Marker LH Upper Rear Corner Marker RH Rear Door Marker RH Upper Rear Corner Marker License Plate Backup Light Back W...

Page 11: ... Bar Shutoff Valve Rear Spray Bar Rear Bar Shutoff Valve LH GB Spray Bar LH GB Shutoff Valve RH GB Spray Bar RH GB Shutoff Valve Test all sweeping functions at Aux Eng operating rpm 2400 rpm and hyd temp 150 F MB Pattern _______ LH GB Pattern _______ RH GB Pattern _______ GB to MB Overlap _______ LH GB Retract _______ RH GB Retract _______ Hopper Dump Retract _______ Hopper Lift Lower _______ Broo...

Page 12: ..._ __________________________________________ __________________________________________ Phone include area code __________________________________________ Date Unit Delivered __________________________________________ In Service Date __________________________________________ Contact Name __________________________________________ Signature __________________________________________ This form MUST...

Page 13: ...Sweeper Co 13 Last Update July 2013 ...

Page 14: ...Sweeper Co 14 Last Update July 2013 Safety ...

Page 15: ...onment and reduce injuries The operator must become familiar with safe operating procedures and use the equipment in the fashion that it was intended Routine inspections and maintenance will prevent premature wear expensive downtime and ensure that the equipment functions as it is intended Recognize Safety Information This is the safety alert symbol When you see this symbol in the manual or on you...

Page 16: ... run position and work hydraulic functions to relieve any residual pressure in the hydraulic system 5 Remove keys from ignition 6 Store keys in pocket or in a safe controlled area 7 Place an OUT OF SERVICE sign on the steering wheel using a non reusable fastener 8 Place an OUT OF SERVICE sign on the front window 9 Disconnect negative terminal from battery Hopper Port Restrictors To control the dec...

Page 17: ...tion only 2 Keep all riders off the machine 3 Keep all safety shields in place 4 Ensure the area is clear of any persons or possible obstructions 5 Do not wear loose clothing or jewelry 6 Do not leave the vehicle before it is brought to a complete stop and the parking brake is applied 7 Be cautious while driving with an unevenly distributed load 8 Inspect for overhead hazards e g power lines befor...

Page 18: ...are wired direct to chassis lights and come on with chassis lights 5 Beacon and or Strobe Lights The switch is installed in the sweeper control box inside the cab The lights are mounted on the front and rear canopy of sweeper 6 Gutter Broom Lights These lights are used for work lights and are mounted at both gutter brooms The switch is found on the control box in the cab 7 Main Broom Light This li...

Page 19: ...n proper working condition Unauthorized modifications to the machine may impair the function and or safety and affect machine life If you do not understand any part of this manual and need assistance contact your dealer PREVENT BYPASS STARTING Do not start engine by shorting across starter terminal Start engines only from operator s station with transmission in park HANDLE FUEL SAFELY AVOID FIRES ...

Page 20: ...ntion of the operator Do not wear radio or music headphones while operating machine PROTECT AGAINST NOISE Prolonged exposure to loud noise can cause impairment or loss of hearing Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises HANDLE CHEMICAL PRODUCTS SAFELY Direct exposure to hazardous chemicals can cause serious...

Page 21: ...y mislead someone into drinking from them Do not pour waste onto the ground down a drain or into any water source Air conditioning refrigerants escaping into the air can damage the Earth s atmosphere Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants Inquire on the proper way to recycle or dispose of Waste from y...

Page 22: ...umes from the area with an exhaust pipe extension If you do not have an exhaust pipe extension open the doors and get outside air into the area AVOID HIGH PRESSURE FLUIDS Escaping fluid under pressure can penetrate the skin causing serious injury Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines Tighten all connections before applying pressure Search for leaks wi...

Page 23: ...soldering or using a torch Do all work outside or in a well ventilated area Dispose of paint and solvent properly Remove paint before welding or heating If you sand or grind paint avoid breathing the dust Wear an approved respirator If you use solvent or paint stripper remove stripper with soap and water before welding Remove solvent or paint stripper containers and other flammable material from a...

Page 24: ...ous as long as airborne dust containing asbestos is not generated Avoid creating dust Never use compressed air for cleaning Avoid brushing or grinding materials containing asbestos When servicing wear an approved respirator A special vacuum cleaner is recommended to clean asbestos If not available apply a mist of oil or water on the material containing asbestos Keep bystanders away from the area S...

Page 25: ...hen engine is running DO NOT smoke while filling fuel tank or servicing fuel system IMPORTANT The fuel tank is vented through the filler cap If a new filler cap is required always replace it with an original vented cap Fill fuel tank at the end of each day s operation to prevent condensation in tank as moist air cools and freezes during cold weather Store diesel fuel in plastic aluminum or steel c...

Page 26: ...Sweeper Co 26 WARRANTY ...

Page 27: ...on its products previously manufactured Stewart Amos Sweeper Co WARRANTY POLICY Stewart Amos Sweeper Co provides warranty to the original purchaser of a new product that the same is free from defects in materials and workmanship that may cause performance failures subject to the conditions stated herein The warranty is limited to a period of one 1 year from the date of the original purchase or 100...

Page 28: ...Sweeper Co 28 5 All warranty repairs reimbursable must be performed by an authorized dealer using Stewart Amos Sweeper Co approved replacement parts Failure to repair properly voids future warranty ...

Page 29: ... which are under separate warranties from their respective manufacturers Service for these components can be obtained from their service facilities in the United States In some circumstances extended warranties are available at an extra cost Please contact your Stewart Amos Sweeper Co dealer for information on these extended warranties GENERAL INFORMATION AND PROCEDURES 2 Ensure the IN SERVICE DAT...

Page 30: ...TS WITHOUT IMPOSING ANY OBLIGATION UPON ITSELF TO INSTALL THEM ON ITS PRODUCTS PREVIOUSLY MANUFACTURED RETURN OF GOODS AUTHORIZATION PROCEDURE 1 If parts are required for a unit under warranty they will initially be invoiced to the dealer If Stewart Amos Sweeper Co requires the failed parts back for warranty evaluation a Returned Goods Authorization number RGA will be issued for the return of the ...

Page 31: ...Sweeper Co 31 ...

Page 32: ...Sweeper Co 32 General Specifications ...

Page 33: ...ensures that you are assisted as efficiently and quickly as possible Figure 1 Serial Number Plate Mounted Specifications Weight Freightliner M2 chassis approx 23 180 lbs Front M2 chassis approx 6 900 lbs Rear M2 chassis approx 16 120 lbs Suspension M2 chassis Full time air ride Suspended height M2 chassis approx 40 to top of frame Overall Length based on 156 wheelbase 284 Sweeping Width w two gutt...

Page 34: ...hassis Elevator Squeegee type system Hydraulic direct drive Variable speed and reversible Main Broom Mandrel Chevron Strip Mandrel diameter 11 in Mandrel length 58 in Filled diameter 36 Segment material Polypropylene Hydraulic direct drive Variable speed and reversible Gutter Broom No of brooms 2 Diameter 54 in No of segments 5 per broom Hydraulic direct drive Variable speed and reversible Broom a...

Page 35: ... working light Hydraulic System Tank Capacity 45 US Gallons Pump Tandem gear Pump Capacity 10 gpm 12 gpm 2000 rpm Controls Electric over hydraulic Hydraulic drive motors All interchangeable Hydraulic fluid cooler Air to oil electric Water System Gutter broom spray system Tank capacity 350 US Gallons Tank material Polyethylene Electric pump 1 3 6 gpm Water system material All plastic non corrosive ...

Page 36: ...Sweeper Co 36 Controls ...

Page 37: ...er specified minimum oil pressure of 69 kPa 10 psi the automatic engine shut off system will be activated 4 Coolant Temperature Gauge If the auxiliary engine coolant temperature rises above 1000 C 2120 F the automatic engine shut off system will be activated 5 Ignition Key Switch This main power switch starts the auxiliary engine enabling all sweeping functions See Operating Auxiliary Engine a Glo...

Page 38: ...Sweeper Co 38 Figure 2 Engine Control Box ...

Page 39: ...roximity switch with the HOPPER UP DOWN function to prevent the hopper from interfering with the elevator and will not function unless the light in the center of the switch is on When the brooms are down they are designed to float to accommodate uneven pavement 5 GB LIGHTS ON GB MB LIGHTS ON This is a three position switch which controls both gutter broom lights and main broom lights When switch i...

Page 40: ...old the switch in the HOPPER RETRACT position until the hopper is fully retracted At any time in the dumping cycle the switch can be released and the hopper will hold that position The switch is interlocked through a proximity switch with the BROOMS UP DOWN function to prevent the hopper from interfering with the elevator function This switch will not function unless the light in the center of the...

Page 41: ...Sweeper Co 41 12 ELECTRIC THROTTLE Push switch up to increase auxiliary engine rpm and down to reduce rpm ...

Page 42: ...Sweeper Co 42 Figure 3 Sweeper Control Box to SN 5002 and up ...

Page 43: ...Sweeper Co 43 ...

Page 44: ...Sweeper Co 44 Operation ...

Page 45: ...does not start on the first try wait for 30 seconds before trying again 6 Once the engine is running check the gauges Allow the engine to warm up at 1000 rpm for 10 minutes IMPORTANT When the auxiliary engine is no longer required to run the sweeper controls let the engine run at low idle for three to five minutes before shutting the engine off This allows the engine to properly cool CAUTION If th...

Page 46: ...ater tank is equipped with a 3 air gap to help prevent damage to the water tank when filling from a hydrant as well as siphoning back to hydrant However care must be taken when filling from a high pressure source 2 From curb side open the water shut off C Access to the fill hose is gained at the right front of canopy on the sweeper Figure 4 Water Tank ...

Page 47: ...s the WATER ON switch to the ON position The water pump will begin operating to activate pressure spray to the front rear spray bar and the gutter broom nozzles WARNING Ensure all observers are clear of the sweeper at a minimum distance of 10 feet NOTE If the main broom and or elevator become plugged with debris push the SWEEP FORWARD REVERSE switch to the centre position Then reverse the rotation...

Page 48: ... Serious damage may result otherwise WARNING Never use hopper safeties with material in the hopper Safeties will not hold a loaded hopper 3 When in position place the sweeper transmission lever in neutral and engage the parking brake The hopper functions will not work unless the park brake is applied 4 Elevate the hopper by pressing the HOPPER RAISE LOWER switch to the RAISE position until the des...

Page 49: ...Sweeper Co 49 ...

Page 50: ...ler c Broom bolts d Elevator bolts e Set screws f Wheel nuts For every 25 hours for the first 100 hours 1 Check and tighten g Suspension bolts h Main broom coupler i Broom bolts j Elevator bolts k Set screws l Wheel nuts 2 Inspect all areas of sweeper periodically to ensure long term life and reliability Practicing regular routine maintenance will payback in minimal operating costs and less down t...

Page 51: ...into the filter housing until all nozzles blow air 4 Remove dust suppression water filter canister and leave off for winter 5 If sweeping in winter months do not use water system if below freezing temperatures If water system is used it must be purged using the method stated above before temperature drops below freezing 6 Engine Maintain and service engine as per the engine manual provided with th...

Page 52: ...hile filling the fuel tank Diesel Engine Oil Refer to the original engine manufacturer s recommendations Coolant Refer to the original engine manufacturer s recommendations 50 water and 50 ethylene glycol base antifreeze should be used year round WARNING Use extreme care when removing radiator filler caps Remove only when coolant temperature is below the boiling point Hydraulic Oil The recommended...

Page 53: ...e Daily Refer also to the engine manual that comes with your sweeper for locations 1 Check oil and coolant levels on the engine 2 Do a walk around inspection to check all linkages cotter pins and bolts for looseness or missing 3 Check hydraulic oil level in the hydraulic oil tank The sight glass is located on the front of the hydraulic oil tank on the driver s side of the vehicle 4 Check the hydra...

Page 54: ...ry engine initial change only 4 Replace the hydraulic oil filter in the auxiliary engine initial change only 5 Lubricate gutter broom pivot points 6 Lubricate main broom arms 7 Lubricate drag shoe links Every 250 Hours 1 Replace the hydraulic oil filter 2 Replace the oil breather filter 3 Replace the auxiliary engine oil and filter 5 Engine Oil Dipstick 6 Engine Oil Fill Cap 7 Coolant Fill Cap 8 E...

Page 55: ...he sweeper until hydraulic oil is warm 2 Stop the engine 3 Remove both magnetic drain plugs from the bottom of the oil reservoir one on each side Drain the oil into a large container 4 Clean and reinstall both magnetic drain plugs 5 Replace the reservoir breather filter 6 Replace the hydraulic filter 7 Fill reservoir with hydraulic oil as recommended from the pump manufacturer IMPORTANT If Hydraul...

Page 56: ...gle may need modification from time to time The attack angle should be set to 3º 5º for normal sweeping Adjust Tilt Angle Refer to Figure 6 Gutter Broom Assembly also Refer to Figure 7 Gutter Broom Pattern 1 Loosen angle adjustment lock nut B to allow movement of the angle adjustment turnbuckle C 2 To increase the tilt angle of the gutter brooms decrease the length of turnbuckle C To decrease the ...

Page 57: ...o Figure 6 Gutter Broom Assembly 1 Loosen turnbuckle lock nut I on suspension turnbuckle H 2 To increase down pressure on gutter broom lengthen the turnbuckle to reduce down pressure shorten the turnbuckle By lengthening or shortening the turnbuckle will affects spring D which increases or lowers gutter broom pressure to compensate for wear 3 Tighten lock nut I on suspension turnbuckle H Sweeping ...

Page 58: ...y also Refer to Figure 7 Gutter Broom Pattern Each gutter broom is equipped with an impact protection spring A to protect it from side impact damage There is no adjustment for this spring NOTE The wider the sweeping path the greater the possibility of damaging the broom linkages from impacts ...

Page 59: ...Sweeper Co 59 Figure 6 Gutter Broom Assembly ...

Page 60: ...Sweeper Co 60 Figure 7 Correct Broom Pattern ...

Page 61: ...ntrolled by the tension on the suspension spring F while the shock absorber E applies down pressure To adjust the down pressure 1 Loosen the lock nut on turnbuckle D 2 Lengthen the turnbuckle to increase the down pressure and shorten the turnbuckle to decrease down pressure Figure 8 Main Broom Assembly ...

Page 62: ...nd of the travel 4 Once bolt D has been adjusted tighten lock nut E 5 Tighten bolts C Center Idler Shaft 1 Loosen bolts on bearing H 2 Loosen lock nut G 3 Tighten bolt F until desired chain tension is reached 4 Tighten bolts on bearing H 5 Tighten lock nut G NOTE The correct tension on new elevator chain and sprockets only is 1 3 deflection on the chain between shaft L and shaft J NOTE Partially w...

Page 63: ...Sweeper Co 63 Refer to Figure 9 Elevator Chain Adjustment ...

Page 64: ...Sweeper Co 64 REPAIR AND MAINTENANCE ...

Page 65: ...3 bolts holding retaining ring A to the mandrel B 3 Lower retaining ring A onto the mandrel end shaft 4 Pull worn broom strips out the side of machine 5 Clean the C channel before inserting the new strips 6 As each strip is removed from the mandrel immediately replace with a new strip this keeps the mandrel in balance and is easier to rotate to the next strip Ensure the new broom strips slide into...

Page 66: ... shaft F with emery cloth to prevent bearing from hanging up when removing 5 Slide bearing assembly B off end of broom shaft F A Bearing Puller may have to be used 6 Install new bearing assembly reversing the procedure for removal Ensure that the bearing grease nipple E is pointing towards the rear of machine 7 Centre the broom between the rear drag shoes by moving bearing B on the main broom shaf...

Page 67: ...ag shoe C 3 Install new carbide drag shoe and bolts B Figure 12 Carbide Drag Shoe Elevator Chain Sprocket Shaft Replacement Refer to Figure 13 Elevator 1 Remove rear canopy 2 Remove elevator canopy and canopy extension NOTE the procedure given is for one side only and must be repeated for the opposite side 3 Loosen top shaft bolts C ...

Page 68: ...iners are welded NOTE Bottom shaft and bearings P should never require adjusting This shaft is preset at the factory 11 Install new chain K making sure the squeegee attachment links are aligned 12 Adjust top shaft first using adjustment bolts D until proper chain tension is achieved NOTE When adjusting top shaft make sure both sides move equally 13 Adjust center shaft using adjustment bolt F until...

Page 69: ...Sweeper Co 69 Figure 13 Elevator ...

Page 70: ...vator canopy and canopy extension 3 Remove bolts from top liner 4 Pull liner out from the top of elevator 5 Replace liner 6 Reinstall elevator canopy and canopy extension 7 Reinstall rear canopy Main Broom Hydraulic Motor Replacement 1 Lower broom to floor 2 Disconnect chain coupler by disconnecting master link 3 Disconnect hydraulic lines to motor 4 Remove motor bolts 5 Replace motor 6 Reinstall ...

Page 71: ... Replace motor 11 Reinstall and tighten motor mounting bolts 12 Using a floor jack lift gutter broom mounting plate onto shaft 13 Tighten taper lock bushing evenly tightening mounting plate to shaft 14 Reinstall center mount bolts 15 Tighten all plate and mount bolts 16 Reinstall gutter broom segment Elevator Hydraulic Motor Replacement 1 Remove drive chain mount cover 2 Disconnect drive chain 3 L...

Page 72: ...of valve 2 Loosen the lock nut on the relief valve 3 Take engine to 2 000 rpm 4 Push hopper lift switch and raise hopper until cylinders are bottomed 5 While holding switch read pressure gauge 6 Turn relief screw clockwise to increase pressure and counter clockwise to lower pressure 7 Adjust pressure to a maximum of 2 850 psi 8 Tighten the lock nut on the relief valve ...

Page 73: ...Loosen lock nut on the relief valve 3 Take engine to 2 000 rpm 4 Push hopper dump switch and dump hopper until cylinders are bottomed 5 While holding switch read pressure gauge 6 Turn relief screw clockwise to increase pressure and counter clockwise to lower pressure 7 Adjust pressure to a maximum of 2 350 psi 8 Tighten the lock nut on the relief valve ...

Page 74: ...er dump switch on control panel and dump hopper until cylinders are bottomed 3 With a small Allan wrench turn inner adjuster out until stall alarm in cab begins to activate 4 Turn adjuster in opposite direction until stall alarm in cab is not activated 5 Replace retaining screw on DIN connector ...

Page 75: ...Sweeper Co 75 Electrical Activation Sequences at Valve Connectors ...

Page 76: ...Sweeper Co 76 Lubrication and Maintenance Check List ...

Page 77: ...tion Indicator AFRI for BOTH Engines If AFRI shows that the airflow through filter is too low change the air filter and RESET the Indicator Write the Date and Hours on the new filter and Note the change on this form by putting a circle around the filter changed today TRUCK AUXILIARY 5 Check ALL tires for proper inflation and tread wear 6 Check that Back up Alarm Lights and Strobes are working prop...

Page 78: ... Be sure engine is cool before washing DO NOT use high pressure to wash radiators or hydraulic oil cooler fins 3 Grease elevator shaft bearings and main broom stub shaft bearing with EP2 grease Note the shafts should be rotating while being greased to insure proper distribution of lubricant 4 Check for and remove any tape string etc wound around broom motor shafts 5 Inspect for any damage and any ...

Page 79: ...eration of the vehicle including the chassis the chassis Owners Manual and the diesel particulate filter Refuel with ULTRA LOW Sulfur Highway Diesel ONLY 2 Perform the DAILY ROUTINE 3 Grease the pivot point on the main broom and gutter broom arms 4 Perform an extra thorough cleaning of the hydraulic oil cooler 5 Service truck chassis refer to Owners Manual 6 Inspect for any damage and any loose it...

Page 80: ...ictate Sweeper S N Date Hours Miles This CHECKLIST PERFORMED BY Done 1 Change BOTH engine oils AND filters Write Date and Hours on filter housings 2 Replace hydraulic oil filter Write Date and Hours on filter housing 3 Clean hydraulic oil tank breather filter 4 Inspect for any damage and any loose items such as wires fittings pins nuts and bolts Correct problem and or NOTE below NOTES and REMARKS ...

Page 81: ...eper S N Date Hours Miles This CHECKLIST PERFORMED BY Done 1 Perform a 250 hour Maintenance Routine 2 Change Hydraulic Oil per Manual 3 Grease chassis per Owners Manual including front steering linkage U joints bearings and king pins 4 Check elevator chain for adjustment 5 Inspect for any damage and any loose items such as wires fittings pins nuts and bolts Correct problem and or NOTE below NOTES ...

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Page 130: ...HYD ENGINE IGNITION ...

Page 131: ...LH GB RETRACT IN LH GB LH GUTTER BROOM ELEVATOR STALL WARNING H GUTTER BROOM H GUTTER BROOM UP ...

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Page 133: ...H GB EXTEND H GB RETRACT RH SWEEP H SWEEP H SWEEP REV H GB H GB ...

Page 134: ...HOPPER PROX SWITCH ELEVATOR PROX SWITCH BEACON GB WORK LIGHT MB WORK LIGHT STABILIZER PROX SWITCH STABILIZER PROX SWITCH PROX SENSOR POWER SENSOR GROUND HYD COOLER FAN H GB TILT A H GB TILT B ...

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Page 148: ...88 32209 WASHOUT CONNECTION 4 88 42085 SAFETY PROP 2 88 1560 BOLT 2 88 32205 SADDLE STRAP 2 88 32207 WATER FILLER 1 88 1546 BOLT 2 88 1640 NUT 2 88 52205 WATER TANK ADAPTOR 1 88 62103 U BOLT MOUNT PLATE 6 88 1116 HYDRANT HOSE 2 88 42103 CENTER DRAG SUPPORT 2 88 42101 CENTER DRAG RUBBER 1 88 42114 FILL RELIEF RUBBER 1 88 1087 3 PROXIMITY SWITCH 2 88 62014 FENDER FLARE RETAINER 2 88 1026 WORK LIGHT ...

Page 149: ...92 1025 STROBE 1 92 1005 DOOR LATCH 6 92 31609 REAR DOOR 2 92 1520 WASHER 24 92 1501 NUT 24 92 1031 HINGE 12 92 1579 BOLT 48 92 1503 NUT 8 92 1822 WASHER 8 92 1843 BOLT 8 92 1520 WASHER 24 92 1501 NUT 24 92 31601 REAR CANOPY 1 92 1750 INSERT 24 92 1028 CLEARANCE LIGHT 4 92 1131 GROMMET 4 92 1152 CAMERA 2 92 1002 ID BAR 1 92 1136 BACKUP LIGHT 2 92 1134 GROMMET 6 92 1024 BACKUP ALARM 1 92 1132 BRAKE...

Page 150: ...HING 1 94 1560 BOLT 2 94 1061 CYLINDER 2 94 1558 BOLT 4 94 32912 HOPPER STONE SHIELD 1 94 32910 DRAIPER MOUNT 1 94 32911 DRAIPER RUBBER 1 94 1173 CHAIN 2 94 33001 HOPPER LIFT FRAME 1 96 1185 BUSHING 8 96 1623 PIN 6 96 1985 CYLINDER 1 96 1604 COTTER PIN 6 96 3210 CYLINDER 2 96 42813 SCISSOR ROLLER 4 96 1074 SNAP RING 16 96 62812 CENTER PIN 8 96 62811 SCISSOR PIN 16 96 32815 LOWER ANCHOR SECTION LEG...

Page 151: ...8 1018 SUSPENSION SPRING 2 98 41221 LINK 1 98 1540 BOLT 2 98 1670 WASHER 3 98 61205 LINKAGE MOUNT LEFT 1 98 61305 LINKAGE MOUNT RIGHT 1 98 1642 NUT 2 98 1640 NUT 2 98 1503 NUT 2 98 1022 TURN BUCKLE 2 98 1559 BOLT 5 98 1822 WASHER 3 98 1379 CYLINDER 2 98 1537 BOLT 3 98 1556 BOLT 2 98 1507 NUT 7 98 1508 NUT 1 98 1574 BOLT 1 98 1042 QUICK LINK 4 98 1019 RETRACT SPRING 1 98 1526 WASHER 2 98 1185 BUSHI...

Page 152: ...LL CRANK LEFT 1 102 41421 MAIN BROOM LIFT STRAP 2 102 1822 WASHER 4 102 1670 WASHER 4 102 1537 BOLT 4 102 41417 PIN 2 102 31405 LIFT BELL CRANK RIGHT 1 102 1549 BOLT 4 102 1671 WASHER 6 102 41401 PIN 2 102 1043 CYLINDER 2 102 1681 KEY 1 102 1986 CYLINDER 2 102 1016 MAIN BROOM STRIP SET 1 102 1030 BEARING 1 102 34501 MAIN BROOM LEFT ARM LEFT 1 102 1546 BOLT 6 102 1046 SHOCK 2 102 3243 HYDRAULIC MOT...

Page 153: ...4 1508 NUT 2 104 41431 BACKING 2 104 1530 BOLT 4 104 42067 DIRT DEFLECTOR RUBBER 2 104 34501 LH BROOM ARM 1 106 64505 SUPPORT 2 106 64506 BRUSH ATTACHMENT 2 106 64503 LH DRAG BRUSH HOLDER 1 106 64507 RETAINER 2 106 1016 BRUSH STRIP 2 106 34502 RH BROOM ARM 8 106 64504 RH DRAG BRUSH HOLDER 1 106 80134 VALVE ASSEMBLY 1 107 1293 MANIFOLD 1 107 2001 HOPPER LIFT CYLINDER VALVE 1 107 1989 LH GUTTER BROO...

Page 154: ...88 HYDRAULIC OIL FILTER BASE 1 110 1452 HOSE MB MOTOR TO VALVE 1 110 1489 HOSE SUCTION 1 110 1985 HOPPER TILT CYLINDER 1 110 1441 HOSE HOPPER TILT ROD TO CROSS 1 110 1442 HOSE HOPPER TILT HEAD TO CROSS 1 110 1443 HOSE HOOPER DOOR CYLINDER 4 110 1987 HYDRAULIC OIL FILTER 1 110 1986 ELEVATOR DRAG SHOE CYLINDER 4 110 1490 HOSE MB CYLINDER T TO ELEVATE CYLINDER T 4 110 1491 HOSE ELEVATE CYLINDER TO DR...

Page 155: ...CLAMP 2 116 1049 INTAKE HOSE 30 116 42527 ENGINE CONTROL BOX 1 116 1154 EXHAUST CLAMP 1 116 42404 THROTTLE MOUNT 1 116 1118 ENGINE 1 116 3203 HYDRAULIC PUMP 1 116 1524 WASHER 4 116 1545 BOLT 4 116 1387 THROTTLE ACTUATOR 1 116 1299 THROTTLE GUIDE 1 116 1388 THROTTLE ACTUATOR CABLE 1 116 1108 FUEL FILTER 1 116 1106 ENGINE OIL FILTER 1 116 1390 ENGINE OUTER AIR FILTER 1 116 1175 RAIN CAP 1 116 1176 M...

Page 156: ...30 BOLT 30 120 1520 WASHER 60 120 1501 NUT 50 120 43105 BOTTOM LINER 1 120 41744 END STRAP 1 120 41776 RUBBER SEAL 2 120 41710 HOLD DOWN 2 120 1713 BOLT 7 120 41772 BOTTOM RUBBER 1 120 33109 ELEVATOR CHAIN 2 122 43113 TOP SHAFT 1 122 1149 SHAFT KEY 6 122 1039 RUBBER SPROCKET 6 122 41738 SHAFT SPACER 6 122 41740 LOCK PLATE 12 122 1544 BOLT 42 122 1503 NUT 70 122 43109 BOTTOM SHAFT 2 122 1501 NUT 14...

Page 157: ... 126 1166 HOSE 50 126 62216 GB SPRAY BAR 2 126 1167 HOSE BARB FITTING 2 126 1168 U BOLT 8 126 42205 SPRAY BAR HANGER 4 126 1169 HOSE CLAMP 28 126 3232 WATER PUMP 1 126 1117 WATER FILTER HOUSING 1 126 1172 WATER FILTER ELEMENT 1 126 1159 BALL VALVE 1 126 1160 NIPPLE 1 126 42727 ENGINE CONTROL BOX 1 127 1092 TACHOMETER HOUR METER 1 127 1095 IGNITION SWITCH 1 127 1090 OIL PRESSURE GAUGE 1 127 1091 WA...

Page 158: ...HARNESS 1 136 62508 REAR LIGHT HARNESS 1 137 62509 POWER HARNESS 1 138 42501 ADAPTER PLATE 1 139 1546 BOLT 1 139 42502 SUPPORT POST 1 139 1505 NUT 1 139 1531 BOLT 7 139 1520 WASHER 4 139 1501 NUT 7 139 42503 TOP MOUNT 1 139 42506 BOX MOUNT PLATE 1 139 62501 OFFSET POST 1 139 1194 KNOB 2 139 PART DESCRIPTION QTY PG NO 1002 ID BAR 1 92 1005 DOOR LATCH 4 90 1005 DOOR LATCH 6 92 1005 DOOR LATCH 1 94 1...

Page 159: ...NDER 2 110 1062 SITE GAUGE 1 114 1074 SNAP RING 16 96 1078 LINEAR ACTUATOR OPTION 1 100 1090 OIL PRESSURE GAUGE 1 127 1091 WATER TEMP GAUGE 1 127 1092 TACHOMETER HOUR METER 1 127 1094 SHUTDOWN MODULE 1 127 1095 IGNITION SWITCH 1 127 1101 SHOCK MOUNT 4 134 1104 OIL PRESSURE SENDER 1 116 1106 ENGINE OIL FILTER 1 116 1108 FUEL FILTER 1 116 1116 HYDRANT HOSE 2 88 1116 HOSE 35 126 1117 WATER FILTER HOU...

Page 160: ... 94 1175 RAIN CAP 1 116 1176 MUFFLER 1 116 1177 HYDRAULIC TANK BREATHER 1 114 1178 FILL CAP 1 114 1179 MAGNETIC DRAIN PLUG 2 114 1185 BUSHING 18 94 1185 BUSHING 8 96 1185 BUSHING 4 98 1185 BUSHING 4 102 1185 BUSHING 8 104 1185 PLUG 1 126 1193 FUSE 5 amp F6 1 130 1194 KNOB 2 139 1203 HOSE CLAMP 4 126 1204 BALL VALVE 4 126 1260 CLAMP 1 116 1266 MANDREL END PLATE 2 102 1287 MANIFOLD 1 108 1291 DUMP V...

Page 161: ... T 2 110 1456 HOSE MB ROD TO T 2 110 1466 HOSE FRONT OF PUMP TO LH VALVE 1 110 1467 HOSE PUMP TO VALVE 1 112 1468 HOSE VALVE RETURN TO COOLER T 1 110 1469 HOSE COOLER TO FILTER 1 110 1488 HOSE ELEVATOR MOTOR TO VALVE 1 110 1489 HOSE SUCTION 1 110 1490 HOSE MB CYLINDER T TO ELEVATE CYLINDER T 4 110 1491 HOSE ELEVATE CYLINDER TO DRAG SHOE CYLINDER 4 110 1492 HOSE VALVE RETURN TO T 1 112 1493 HOSE HO...

Page 162: ...20 WASHER 60 120 1520 WASHER 4 139 1521 WASHER 12 104 1522 WASHER 6 90 1524 WASHER 4 116 1525 WASHER 2 100 1526 WASHER 2 98 1527 WASHER 4 124 1529 WASHER 12 90 1530 BOLT 13 94 1530 BOLT 4 104 1530 BOLT 30 120 1531 BOLT 144 122 1531 BOLT 7 139 1534 BOLT 8 104 1535 BOLT 17 88 1537 BOLT 5 88 1537 BOLT 3 98 1537 BOLT 4 102 1537 BOLT 2 104 1539 BOLT 8 118 1540 BOLT 12 88 1540 BOLT 2 98 1540 BOLT 20 100...

Page 163: ...61 BOLT 1 98 1562 BOLT 2 104 1574 BOLT 1 98 1575 BOLT 8 104 1579 BOLT 48 92 1579 BOLT 8 94 1581 WASHER 1 98 1583 NUT 4 94 1591 SCREW 6 88 1604 COTTER PIN 6 96 1604 COTTER PIN 8 102 1604 COTTER PIN 2 124 1623 PIN 6 96 1640 NUT 2 88 1640 NUT 2 98 1642 NUT 2 98 1670 WASHER 4 88 1670 WASHER 3 98 1670 WASHER 20 100 1670 WASHER 4 102 1670 WASHER 2 104 1671 WASHER 6 102 1671 WASHER 6 102 1671 WASHER 8 11...

Page 164: ...AG SHOE 2 104 1976 MAIN BROOM MANDREL 1 102 1985 CYLINDER 1 96 1985 HOPPER TILT CYLINDER 1 110 1985 ELEVATOR CYLINDER 2 124 1986 CYLINDER 2 102 1986 ELEVATOR DRAG SHOE CYLINDER 4 110 1987 HYDRAULIC OIL FILTER 1 110 1987 HYDRAULIC FILTER 1 114 1988 HYDRAULIC OIL FILTER BASE 1 110 1988 FILTER BASE 1 114 1989 LH GUTTER BROOM LIFT CYLINDER VALVE 1 107 1989 RH GUTTER BROOM CYLINDER VALVE 1 107 1990 FLO...

Page 165: ...R 1 100 3243 HYDRAULIC MOTOR 1 102 3243 HYDRAULIC MOTOR 2 110 3243 HYDRAULIC MOTOR 2 112 3243 HYDRAULIC MOTOR 1 118 3248 BUSHING 1 100 6635 HOSE 2 124 6636 HOSE 2 124 11535 CAMERA CABLE 2 92 31402 RH DRAG BELL CRANK 1 102 31403 LH DRAG BELL CRANKI 1 102 31405 LIFT BELL CRANK RIGHT 1 102 31406 LIFT BELL CRANK LEFT 1 102 31501 FRONT CANOPY 1 90 31502 DOOR 2 90 31601 REAR CANOPY 1 92 31602 ENGINE AIR...

Page 166: ...G 4 1 96 32901 HOPPER 1 94 32904 PIN 1 94 32910 DRAIPER MOUNT 1 94 32911 DRAIPER RUBBER 1 94 32912 HOPPER STONE SHIELD 1 94 33001 HOPPER LIFT FRAME 1 96 33101 ELEVATOR FRAME 1 118 33101 ELEVATOR FRAME 1 124 33103 TOP LINER 1 120 33104 LIFT ARM 2 124 33109 ELEVATOR CHAIN 2 122 34501 MAIN BROOM LEFT ARM LEFT 1 102 34501 LH BROOM ARM 1 106 34502 MAIN BROOM LEFT ARM RIGHT 1 102 34502 RH BROOM ARM 8 10...

Page 167: ...WN 1 92 42114 FILL RELIEF RUBBER 1 88 42147 CENTER DRAG RUBBER 1 88 42201 SPRAY BAR 2 126 42205 SPRAY BAR HANGER 4 126 42310 HOSE TIE STRAP 2 114 42404 THROTTLE MOUNT 1 116 42501 ADAPTER PLATE 1 139 42502 SUPPORT POST 1 139 42503 TOP MOUNT 1 139 42506 BOX MOUNT PLATE 1 139 42527 ENGINE CONTROL BOX 1 116 42531 PANEL DECAL 1 134 42727 ENGINE CONTROL BOX 1 127 42813 SCISSOR ROLLER 4 96 42905 DOOR LIN...

Page 168: ...D 1 88 62011 REAR SKIRT BACKING 1 88 62012 SKIRT 1 88 62014 FENDER FLARE RETAINER 2 88 62103 U BOLT MOUNT PLATE 6 88 62119 LH AXLE SUPPORT 1 88 62121 RH AXLE SUPPORT 1 88 62121 RH FRONT SIDE SHIELD 1 88 62216 GB SPRAY BAR 2 126 62501 OFFSET POST 1 139 62505 BOX 1 134 62506 SWEEPER CONTROL BOX 1 134 62506 PANEL 1 134 62507 AUXILIARY BOX MOUNTING PLATE 1 130 62508 REAR LIGHT HARNESS 1 137 62509 POWE...

Page 169: ...SUPPORT 2 106 64506 BRUSH ATTACHMENT 2 106 64507 RETAINER 2 106 80120 VALVE ASSEMBLY 1 108 80129 MAIN BROOM COUPLER 1 102 80133 ELEVATOR DRIVE SYSTEM 1 118 80134 VALVE ASSEMBLY 1 107 80207 AUX CONTROL BOX 1 130 1087 3 PROXIMITY SWITCH 2 88 3213 3 SHORT MANDREL SHAFT 1 102 7 LINKS 3 8 X 2 CHAIN 1 98 ...

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