51-3606-1, 7/05 1 BIG DAWG Series Pickup Sweeper for Skid Steer Loaders Sweepster Serial Number__________________ 800-456-7100 www.paladinbrands.com Manual Number: 51-3606 Release Date: February 2005 Sweepster 2800 N. Zeeb Rd., Dexter, MI. 48130, United States of America 2 51-3606-1, 7/05 51-3606-1, 7/05 3 Table of Contents Section 1 ... Operation and Maintenance Section 2 ... Service Manual Section 3 ... Parts Manual Section 4 ... Appendix 4 51-3606-1, 7/05 51-3606-1, 7/05 Operation and Maintenance Manual Pick-Up Sweeper Big Dawg Series 5 6 51-3606-1, 7/05 51-3606-1, 7/05 7 TABLE OF CONTENTS OPERATION AND MAINTENEANCE Table of Contents Introduction ............................................................... 8 . Safety .....................................................9-13 Safety Information ............................................... 9-10 Safety Signs and Labels .................................... 11-12 Mounting and Dismounting ..................................... 13 Operation .............................................14-16 Operating Tips ........................................................ 14 Sweeper Installation ............................................... 15 Sweeper Removal ................................................... 16 Storage ................................................................... 16 Product Specifications .......................17-18 Specifications and Model Views ............................. 17 Product I.D. Information .......................................... 18 Maintenance ........................................19-24 Lubrication Points ................................................... 19 Brush Pattern Adjustment ....................................... 20 Brush Section Replacement ................................... 21 Chain Attachment ................................................... 22 Chain Adjustment ................................................... 22 Maintenance Schedule ........................................... 23 Hydraulic Inspection Guideline ................................ 23 Maintenance Log .................................................... 24 8 51-3606-1, 7/05 SAFETY SECTION INTRODUCTION Introduction Contacting SWEEPSTER Importance of this Manual If you have any questions about information in this manual or need to order parts, please call, write, fax or e-mail SWEEPSTER. Read this manual before attempting to operate the equipment. This operator’s manual should be regarded as part of the sweeper. Suppliers of both new and secondhand sweepers are advised to keep documentation indicating that this manual was provided with the sweeper. The manual contains information regarding installation, operation and maintenance required for this sweeper and optional equipment. It also includes detailed parts lists. SWEEPSTER, LLC. 2800 North Zeeb Road Dexter, Michigan 48130 Phone: (734) 996-9116 - (800) 456-7100 FAX: (734) 996-9014 e-mail: [email protected] For help with installation, operation or maintenance procedures, contact our Technical Service Department. Direct product questions and parts orders to our Sales Department. Purpose of Sweeper This sweeper is designed solely for use in construction cleanup, road maintenance, grounds maintenance and similar operations. Use in any other way is considered contrary to the intended use. Compliance with and strict adherence to operation, service and repair conditions, as specified by the manufacturer, are also essential elements of the intended use. This sweeper should be operated, serviced and repaired only by persons who are familiar with its characteristics and acquainted with relevant safety procedures. When ordering parts or accessories, be prepared to give the following information: •Sweeper model, serial number and date of purchase •Prime mover, make and model •Part number, description and quantity Terms Used in Manual Accident prevention regulations, all other generally recognized safety regulations and all road traffic regulations must be observed at all times. Right-hand, left-hand, front and rear are determined from the operator’s perspective (either the operator’s seat or standing behind a walk-behind unit), facing forward in the normal operating position. Any modifications made to this sweeper may relieve the manufacturer of liability for any resulting damage or injury. Prime mover refers to the tractor, truck, loader or tow vehicle that the sweeper is mounted on or towed by. Safety Alert Symbol Optional Equipment This safety alert symbol indicates important safety messages in this manual. When you see this symbol, be alert to the possibility of injury. Carefully read the message that follows and inform other operators. Installation instructions for optional equipment, if applicable, appear in the Service Manual Section. Specifications & Features Due to continuous product improvement, specifications and features may change without notice. Warranty To validate the warranty for this unit, fill out the warranty card or warranty pages located at the back of this manual. Then, send this information to SWEEPSTER. 51-3606-1, 7/05 9 SAFETY SECTION GENERAL SAFETY INFORMATION Safety Information Read this manual Read all safety information in this manual. All operators must read and understand the entire contents of this manual before sweeping. General safety practices are listed on Safety Information pages and specific safety information is located throughout this manual. Hazard Definitions Four hazard classifications are used in this manual. They are •Check prime mover tire pressure before sweeping. •Check tire ratings to be sure they match the prime mover load. Weigh the sweeper end of the prime mover, if necessary, to insure proper tire rating. •Remove from the sweeping area all property that could be damaged by debris flying from the sweeper. •Be sure all persons not operating the sweeper are clear of the sweeper discharge area. •Always wear proper apparel such as a long-sleeved shirt buttoned at the cuffs; safety glasses, goggles or a face shield; ear protection; and a dust mask. While sweeping: CAUTION - Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. WARNING -Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. DANGER - Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. IMPORTANT - Used for instructions when machine damage may be involved. Operation CAUTION - A sweeper is a demanding machine. Only fully trained operators or trainee operators under the close supervision of a fully trained person should use this machine. Before sweeping: •Learn sweeper and prime mover controls in an off-road location. •Be sure that you are in a safe area, away from traffic or other hazards. •Check all hardware holding the sweeper to the host machine, making sure it is tight. •Replace any damaged or fatigued hardware with properly rated fasteners. •Make sure all hydraulic hardware and hydraulic fittings are tight. •Replace any damaged or fatigued fittings or hoses. •When sweeping, adhere to all government rules, local laws and other professional guidelines for your sweeping application. •Before leaving the operators area for any reason, lower the sweeper to the ground. Stop the prime mover engine, set the brakes and remove the key from the ignition. •Minimize flying debris - use the slowest brush speed that will do the job. See Operation Section: Operating Tips. •Keep hands, feet, hair and loose clothing away from all moving parts. •Leave the brush hood (shield) and all other shields and safety equipment in place when operating the sweeper and prime mover. •Be aware of the extra weight and width a sweeper adds. Reduce travel speed accordingly. See Product Information Section. •When sweeping on rough terrain, reduce speed to avoid “bouncing” the sweeper. Loss of steering can result. •Never sweep toward people, buildings, vehicles or other objects that can be damaged by flying debris. •Only operate the sweeper while you are in the seat of the prime mover. The seat belt must be fastened while you operate the prime mover. Only operate the controls while the engine is running. Protective glasses must be worn while you operate the prime mover and while you operate the sweeper. •While you operate the sweeper slowly in an open area, check for proper operation of all controls and all protective devices. Note any needed repairs during operation of the sweeper. Report any needed repairs. 10 51-3606-1, 7/05 SAFETY SECTION GENERAL SAFETY INFORMATION Service & Repair - General CAUTION - Do not modify the sweeper in any way. Personal injury could result. If you have questions, contact your dealer or SWEEPSTER. Repair or adjust the sweeper in a safe area, away from road traffic and other hazards. Before adjusting or servicing the sweeper - lower the sweeper to the ground, stop the prime mover engine, set the brakes and remove the key from the ignition. When working on or around the sweeper, lower it to the ground or secure it with transport chains or cylinder-stop locks. Service & Repair - Hydraulic Safety Stop the prime mover engine and cycle control levers to release hydraulic pressure before servicing or adjusting sweeper hydraulic systems. WARNING - Escaping hydraulic fluid can have enough pressure to penetrate the skin, causing serious personal injury. Check lines, tubes and hoses carefully. Do not use your bare hand to check for leaks. Use a board or cardboard to check for leaks. Tighten all connections to the recommended torque. Do not bend high pressure lines. Do not strike high pressure lines, Do not install bent lines, bent tubes, or kinked hoses. Do not install damaged lines, damaged tubes, or damaged hoses. Repair loose lines, loose tubes, and loose hoses. Repair damaged lines, damaged tubes, and damaged hoses. Leaks can cause fires. See your SWEEPSTER dealer for repair or replacement parts. Replace the parts if any of the following conditions are present: •The end fittings are damaged or leaking. •The outer covering is chafed or cut. •The reinforcing wire layer is exposed. •The outer covering is ballooning locally. •The hose is kinked or crushed. •The armoring embedded in the outer cover. •The hoses have been pulled or stretched. Make sure that all clamps, guards, and shields are installed correctly. 51-3606-1, 7/05 11 SAFETY SECTION SAFETY SIGNS & LABELS Safety Signs and Labels There are several specific safety signs on this sweeper. The exact location of the hazards and the description of the hazards are reviewed in this section. Make sure that all the safety signs are legible. Clean the safety signs or replace the safety signs if you cannot read the words. Replace the illustrations if the illustrations are not legible. When you clean the safety signs, use a cloth, water and soap. Do not use solvent, gasoline, or other harsh chemicals to clean the safety signs. Solvents, gasoline, or other harsh chemicals will loosen the adhesive that secures the safety sign. Loose adhesive will cause the safety sign to fall. Replace any safety sign that is damaged or missing. If a safety sign is attached to a part that is replaced, install a safety sign on the replacement part. Contact your SWEEPSTER dealer for replacement safety signs. This warning label is located on the back of the brush hood near the center. WARNING - Do not operate or work on this machine or sweeper unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals and Owner’s Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your SWEEPSTER dealer for replacement manuals. Proper care is your responsibility. 12 51-3606-1, 7/05 SAFETY SECTION SAFETY SIGNS AND LABELS Safety Signs and Labels WARNING - Keep clear. Pivoting bucket can cause severe bodily harm. This warning label is located on the right and left hand side at the rear of the brush hood. WARNING - Keep clear. Pivoting bucket can cause severe bodily harm. This warning label is located on both sides of the brush head near the bucket. IMPORTANT - Only use indicated tie down points. Failure to do so may result in damage to machine 51-3606-1, 7/05 13 OPERATING SECTION MOUNTING & OPERATING TIPS Mounting and Dismounting •Get on the prime mover only at locations that are equipped with steps and/or handholds. Get off the prime mover only at the locations that are equipped with steps and/or handholds. Utilize the steps that are provided on the sweeper when you get on the prime mover and when you get off the prime mover. •Before you get on the prime mover, clean the steps and handholds. Inspect the steps and the handholds. Make all necessary repairs. •Face the prime mover whenever you get on the prime mover and whenever you get off the prime mover. •Maintain a three-point contact with the steps and the hand holds. NOTE - Three-point contact can be two feet and one hand. Three-point contact can also be one foot and two hands. •Do not get on a moving prime mover or on an operating sweeper. Do not get off a moving prime mover. •Never jump off the prime mover or off the sweeper. •Do not use any controls as handholds when you enter the operator’s compartment or when you exit the operator’s compartment. Operating Tips Before each Use Perform daily maintenance as indicated in the Maintenance Schedule. Run the prime mover and sweeper at a slow idle. Check for hydraulic leaks or other problems and make corrections, if necessary, before using the sweeper. See hydraulic inspection guideline. During Use WARNING - Avoid serious injury. Check for objects that could harm the operator or others if thrown by the sweeper. Remove these items before sweeping. Carry the sweeper low to the ground so that the operator has good visibility. Avoid any sudden movements from one side to the other side when you carry a sweeper. Avoid excessive downward pressure on the broom in order to prevent excessive wear. A two to six inch wide pattern is sufficient for most applications. Ensure that the motor and bearing plates are equally adjusted in order to prevent an uneven wear pattern. To adjust brush pattern see Maintenance Section. Directing Debris Observe wind direction. Sweeping with the wind makes sweeping more effective and helps keep debris off the operator. If necessary, use the dust suppression kit to suppress the dust. 14 OPERATION SECTION OPERATING TIPS Operating Tips Important - Avoid sweeper damage. Do not ram into piles. Use a dozer blade for this type of job. Brush, Engine & Travel Speeds Vary brush, engine and travel speeds to match sweeping conditions. Dirt & Gravel To keep dust at a minimum, plan sweeping for days when it is overcast and humid or after it has rained. Also, sweep so the wind blows at your back. Low brush speeds and moderate travel speeds work best for cleaning debris from hard surfaces. Brush speeds that are too fast tend to raise dust because of the aggressive sweeper action. Heavy Debris Travel slowly - less than 5 mph (8 kph) Sweep a path less than the full width of the sweeper. Increase engine speed if debris becomes very heavy. 51-3606-1, 7/05 51-3606-1, 7/05 15 OPERATION SECTION SWEEPER INSTALLATION Sweeper Installation 13. Move the coupler pins to the engaged position. WARNING - Improper attachment of sweeper could result in injury or death. Do not operate this machine until you have positive indication that the coupler pins are fully engaged. To check for engagement: 1. Keep the sweeper close to the ground. 2. While the lift arms are fully lowered, visually inspect the quick coupler to ensure that the coupler pins are fully extended through the corresponding holes of the sweeper mounting bracket. Installation 1. Position the pick up broom on a level surface. 2. Ensure that the coupler pins are in the disengaged position. 3. Enter the machine. 4. Fasten the seat belt. 5. Start the engine. 6. Disengage the parking break. 7. Tilt the quick coupler assembly forward. 8. Align the quick coupler assembly between the outer plates of the mounting bracket. Move the quick coupler assembly under the angled plate of the mounting bracket. Rack back on the broom. 9. Engage the parking brake. 10. Stop the engine. 11. Cycle controls to relieve any pressure within the auxiliary hydraulic lines. 12. Exit the machine. 14. Ensure that the quick disconnect couplings are clean. Connect auxiliary hydraulic lines for the broom to the prime mover. Twist the collar of the quick disconnect for one quarter of a turn in order to secure the hydraulic connections. 15. Attach shackle end of chains to SSL grab bars. See Chain Adjustment section for proper adjustment. 16. While the loader arms are lowered, visually inspect the quick coupler in order to ensure that the coupler pins are fully extended through the corresponding holes of the sweeper mounting bracket. WARNING - Improper attachment of sweeper could result in injury or death. Do not operate this machine until you have positive indication that the coupler pins are fully engaged. 16 51-3606-1, 7/05 OPERATION SECTION SWEEPER REMOVAL & STORAGE Sweeper Removal WARNING - Disengaging the coupler pins will release the sweeper from control of the operator. Serious injury or death may result from disengaging the sweeper when the sweeper is in an unstable position or carrying a load. Place the sweeper in a stable position before disengaging the coupler pins. IMPORTANT - Auxiliary hoses for the sweepers must be removed before the quick coupler is disengaged. Pulling the sweeper with the auxiliary hoses could result in damage to the prime mover or the sweeper. 1. Lower the pick up broom to the ground. 2. Place the direction control in NEUTRAL. Engage the parking brake. 3. Stop the engine. 4. Cycle controls to relieve any pressure within the auxiliary hydraulic lines. 5. Exit the machine. 6. Remove chains from the SSL grab bars. 7. Disconnect the auxiliary hydraulic lines from the prime mover. 8. Move the coupler pins to the DISENGAGED position. 9. Enter the machine. 10.Fasten the seatbelt. 11.Start the engine. 12.Disengage the parking brake. 13.As you slowly back away from the mounting bracket, tilt quick coupler assembly forward until the top of quick coupler assembly clears the angled plate. 14.Back away from the pick-up broom. Storage Never rest the broom on the bristles. Resting the broom on the bristles could cause the bristles to become deformed and unbalanced. Use stands in order to support the broom when the broom is not operating. IMPORTANT - Do not store the sweeper with weight on the brush. Weight will deform the bristles, destroy ing the sweeping effectiveness. To avoid this problem, place the sweeper on blocks or use stands. Do not store polypropylene brushes in direct sunlight. The material can deteriorate and crumble before the bristles are worn out. Keep polypropylene brush material away from intense heat or flame. 51-3606-1, 7/05 17 PRODUCT INFORMATION SECTION SPECIFICATIONS & MODEL VIEWS Product Information Section BDC Pick-Up Broom Maximum Weight with Bucket Specifications and Model Views 1220 lbs (BDC62) 1370 lbs (BDC74) 1525 lbs (BDC84) Actual Sweeping Width 62 inches (BDC62) 74 inches (BDC74) 84 inches (BDC84) Maximum length 65 inches (all models) Maximum Width 75 inches (BDC62) 87 inches (BDC74) 97 inches (BDC84) Maximum Hydraulic Oil Flow 25 gpm Maximum Hydraulic Oil Pressure 3000 psi Width Length 18 51-3606-1, 7/05 PRODUCT INFORMATION SECTION PRODUCT IDENTIFICATION INFORMATION Serial Number Plate Location For quick reference, record the serial number in the space that is provided below the illustration. The serial number plate is located on the back of the sweeper just above the bucket. Pick-Up Serial Number__________________________________ 51-3606-1, 7/05 19 MAINTENANCE SECTION LUBRICATION POINTS Lubrication Points The following grease fittings should be greased before each use. See figure for locations. 1. Core bearing ( 1 fitting ) 2. Caster ( 2 fittings ) 3. Bucket Pivot ( 1 fitting each ) 1 3 2 20 51-3606-1, 7/05 MAINTENANCE SECTION BRUSH PATTERN ADJUSTMENT Brush Pattern 1 A properly adjusted brush offers the best sweeper performance. To check the brush pattern: 1. Move the sweeper to a dusty, flat surface. 2. Set the prime movers parking brake and leave the engine running. 3. Start the sweeper at a slow speed; then, lower it so the boom arms bottom out. Run the sweeper in a stationary position for 10 seconds. 4. Raise the sweeper and back away; switch off the engine and remove the key. The brush pattern left in the dust should be 2-6 inches wide, running the length of the brush (1). Swept Area 2-6 in. 5. Adjust the brush pattern as necessary according to the following instructions. Adjusting Brush Pattern 2 Loosen four bolts on motor mounting plate and the four bolts on the bearing plate. Raise or lower sweeper body until the brush pattern is correct. (2 & 3) NOTE - To extend brush life make sure bolts on both sides are adjusted evenly. Bucket Adjustment Use the sight gauge located on back of sweeper/bucket to properly position bucket for maximum sweeping performance Ends of rods should be aligned for proper sweeping. (4) 4 3 51-3606-1, 7/05 21 MAINTENANCE SECTION REPLACING BRUSH SECTIONS Replacing Brush Sections 1. Remove four motor mount screws. Retain hardware for reinstallation. Remove motor mount. 2. Detach four bearing mount screws from side plate. Retain hardware for reinstallation. 3. Lift sweeper body leaving core on ground. 4. Remove the core hat plate. Retain hardware for reinstallation. 5. Remove old sections. 6. Install new sections by doing the following: a. Number the tubes on the core as 1, 2 and 3 (1). First Section b. Slide the first section onto the core with the drive pins on either side of tube 1. Make sure that the drive pins angle up (1). c. Place the second section on the core with the drive pins on either side of tube 2. Be sure the drive pins angle down (2). d. Put the third section on with the drive pins around tube 3. Be sure the drive pins angle up. e. Slide sections on until the core is full, making sure to alternate the tubes used and the direction of the drive pins. 7. Re-attach the core hat plate. 8. Lay core on ground. Lower body over core. 9. Attach bearing plate with previously removed hardware. 10.Attach motor mount with hardware removed in step one. Second Section 22 51-3606-1, 7/05 MAINTENANCE SECTION CHAIN INSTALLATION & ADJUSTMENT Attaching Chains 1. Install the sweeper to the prime movers quick attach mounting. See “Sweeper Installation”. 2. Attach chains to SSL grab bars. Using one 5/16 quick link, one 1/2 shackle and one 1 3/4 hairpin clip per side(2). 3. Attach chains to sweeper using one 5/16 wide jaw quick clip per side(3). Leave the chains loose with equal slack in both sides. Do not entangle hydraulic hoses. 4. Connect hydraulic hoses to prime mover remote hydraulics. CAUTION - Avoid equipment damage and personal injury. Chains must be of equal length and long enough to keep the sweeper level during dumping(4). Short chains may cause the sweeper body to tip back and damage the sweeper body. Adjusting Chains 1. Make sure chains are quite loose(1). 2. Raise the sweeper and then dump the bucket slowly. The sweeper will dump correctly if chains have the proper tension(4). If the sweeper tips down when test dumping, go to step 3. 3. Tighten both chains by the same amount but no more than two links each. 4. Repeat steps 2 and 3 until the sweeper dumps correctly(4). 51-3606-1, 7/05 23 MAINTENANCE SECTION MAINTENANCE SCHEDULE Maintenance Schedule Procedure Before Each Use After Each Use 100 Hours 500 Hours See Prime Mover Manual Brush pattern - Check (See Pattern Adj. Section) Fittings/hoses, hydraulic - Tighten - Check for damage Fittings, zerk - Grease (See Lubrication Points) See Below for Requirements Oil, hydraulic (Prime Mover) - Check Level - Check Cleanliness Hardware - Tighten Oil Cleanliness Requirements IMPORTANT - All hydraulic fluid shall be filtered before use in any SWEEPSTER product to obtain the ISO cleanliness standard of 17-14 or better. Unless explicitly specified otherwise. Fittings/Hoses Inspection Guideline Stop the prime mover engine and cycle control levers to release hydraulic pressure before servicing or adjusting sweeper hydraulic systems. Replace the parts if any of the following conditions are present: • WARNING - Escaping hydraulic fluid can have enough pressure to penetrate the shin, causing serious personal injury. The end fittings are damaged or leaking. • The outer covering is chafed or cut. • The reinforcing wire layer is exposed. • The outer covering is ballooning locally. Do not bend high pressure lines. Do not strike high pressure lines. Do not install bent lines, bent tubes, or kinked hoses. Do not install damaged lines, damaged tubes, or damaged hoses. • The hose is kinked or crushed. • The armoring embedded in the outer cover. • The hoses have been pulled or stretched. Repair loose lines, loose tubes, and loose hoses. Repair damaged lines, damaged tubes, and damaged hoses. Leaks can cause fires. See your SWEEPSTER dealer for repair or replacement parts. Check lines, tubes, and hoses carefully. Do not use your bare and to check for leaks. Use a board or cardboard to check for leaks. Tighten all connections to the recommended torque. Make sure that all clamps, guards, and shields are installed. 24 51-3606-1, 7/05 MAINTENANCE SECTION MAINTENANCE LOG Maintenance Record Use this log to record maintenance performed on the sweeper. Date Maintenance Procedure Performed Performed by Comments 51-3606-1, 7/05 Service Manual Pick-Up Broom Big Dawg Series 25 26 51-3606-1, 7/05 NOTES 51-3606-1, 7/05 27 TABLE OF CONTENTS SERVICE MANUAL Table of Contents Assembling the Broom .......................28-34 Motor Bucket Assembly ......................................... 28 Brush Core Assembly ........................................ 29-30 Gutterbroom Bushing .............................................. 31 Caster ..................................................................... 31 Flaps ...................................................................... 32 Side Brushes .......................................................... 32 Brush Head ............................................................. 33 Hydraulic Hoses ..................................................... 34 Lift Chains .............................................................. 34 Troubleshooting ..................................35-36 Optional Equipment ............................37-40 Gutterbroom Kit ................................................. 37-39 Dust Suppression Kit .............................................. 40 28 51-3606-1, 7/05 SERVICE MANUAL ASSEMBLING BRUSH MOTOR Assembling the Broom Motor Bucket Assembly 1 NOTE - Keep all hydraulic components capped, until ready for assembly, to avoid hydraulic contaminants. NOTE - Refer to Parts Manual for proper descriptions and part numbers. 1. Attach hex hub to motor using castellated nut and cotter pin. Tighten to proper torque(1). 2. Attach hydraulic fittings to motor ports(2). 3. Insert motor into motor mount bucket and attach using hardware(3). Tighten to 100ft/lbs. 2 3 51-3606-1, 7/05 29 SERVICE MANUAL ASSEMBLING BRUSH CORE Assembling the Broom 1 Brush Core Assembly 1. Install new sections by doing the following: a. Number the tubes on the core as 1, 2 and 3 (1). b. Slide the first section onto the core with the drive pins on either side of tube 1. Make sure that the drive pins angle up (1). c. Place the second section on the core with the drive pins on either side of tube 2. Be sure the drive pins angle down (2). First Section d. Put the third section on with the drive pins around tube 3. Be sure the drive pins angle up. e. Slide sections on until the core is full, making sure to alternate the tubes used and the direction of the drive pins. 2 2. Attach the core hat plate using three M10 x 25mm cap screws and three M10 lock washers. 3. Sections properly installed should form pockets as shown(3). Second Section 3 30 51-3606-1, 7/05 SERVICE MANUAL ASSEMBLING BRUSH CORE Assembling the Broom Brush Core Assembly (continued) 4 4. Attach bearing to bearing mount plate using four M10 x 35mm screws, four M10 flat washers, four M10 lock washers and four M10 nuts(4). 5. Finally slide bearing assembly onto core shaft and secure with one M8 x 25mm screw and one M8 lock washer(5). 5 51-3606-1, 7/05 31 SERVICE MANUAL ASSEMBLING CASTER & GUTTERBROOM BUSHING Assembling the Broom 1 Gutterbroom Bushing 1. Insert bushing into large hole behind caster(1). 2. Secure bushing using plate and three 3/16 x 3/4 pop rivets(2). Caster 1. Attach caster using four 3/8 x 1 1/4 screws, four 3/8 flat washers, and four 3/8 lock washers(1) 2 32 51-3606-1, 7/05 SERVICE MANUAL ASSEMBLING FLAPS & SIDE BRUSHES Assembling the Broom 1 Flaps 1. Install front flap using two support plates, six M6 x 25mm screws and six M6 inserts(1). NOTE - Flap should be trapped between support plates and rolled portion of hood. 2. Install fingers as shown. End fingers should be on outside of flaps. The two middle fingers should alternate, inside and outside(2). Side Brushes 1. Attach side brush brackets using two M8 x 20mm carriage bolts, two M8 lock washers and two M8 nuts. Brush will be installed after core installation(3). 2 Fingers 3 51-3606-1, 7/05 33 SERVICE MANUAL ASSEMBLING BRUSH HEAD Assembling the Broom 1 Brush Head 1. Lower brush core assembly into body(1). 2. Fasten bearing plate to side with four M10 x 30 screws, four M10 lock washers and four M10 flat washers. Nuts are welded to inside of brush hood side plate. Do not Tighten (1). 3. Lower core until screws bottom out in slot. Tighten hardware(2). 4. Insert pre-assembled motor bucket into core. Align hex hub on motor with hex shape inside core. Secure with four M10 x 30 screws, four M10 lock washers and four M10 flat washers. Nuts are welded to the inside of brush hood side plate. Fittings on motor should face top of machine as shown(3). 2 5. Attach side brushes using M8 nuts and M8 lock washers(3). 6. Install motor guard using 3/8 x 4 1/2 clevis pin and cotter pin. Secure using one M10 x 30 screw, one M10 lock washer and one M10 nut(3). 3 34 51-3606-1, 7/05 SERVICE MANUAL ASSEMBLING HYDRAULICS Assembling the Broom Hydraulic Hose 1 1. Attach 45° fitting end of each hose to fitting on motor(1). 2. Secure hose routing using hose clamp and M12 hardware(1). Lift Chains 1. Attach small quick link to one end of chain. 2. Attach larger quick link to opposite end of chain. 3. Attach small quick link to shackle and secure with hairpin(2). 4. Attach other end of chain to sweeper hooks(3). 2 3 51-3606-1, 7/05 35 SERVICE MANUAL TROUBLESHOOTING Brush Head Assembly Problem Motor for pick-up broom will not operate Possible Cause Auxiliary hydraulics control on prime mover is activated in the wrong position Hoses improperly connected to prime mover Hoses on prime mover are obstructed Hoses on broom are obstructed The motor has failed Sluggish broom operation Insufficient oil flow from the prime mover One or more seals have failed in the motor Hydraulic filter on prime mover is dirty The motor runs but the broom does not run Motor shaft has a sheared key Oil leaks from the motor One or more seals have failed in the motor Seals on the fittings are damaged Fittings are loose or damaged Hydraulic hoses are loose or damaged Brush rotates in wrong direction Hoses installed incorrectly Brush slows or stops when sweeping Brush pattern too wide Travel speed too fast Trying to sweep too much material at once Hydraulic motor is failing Brush wears very quickly Brush pattern is too wide 36 51-3606-1, 7/05 SERVICE MANUAL TROUBLESHOOTING Hydraulic Assembly Problem Excessive hydraulic oil temperature Possible Cause Low hydraulic oil level on the prime mover Hydraulic hoses are obstructed Hydraulic oil is dirty Quick couplers loose Hydraulic quick coupler leaks Quick coupler poppet is unseated 51-3606-1, 7/05 37 SERVICE MANUAL INSTALLING GUTTERBROOM Installing the Gutterbroom 1. Unpack parts and then compare them to the parts list. If you discover any shortages, contact SWEEPSTER or your dealer. Hydraulic Hose/Valve Assembly 11. Install 90° elbows to gutterbroom motor. See parts list for correct size. Swing Assembly 2. Place nylon bushing (1.75 I.D.) into center hole on sweeper beak. Place larger O.D. tube through bushing and secure at bottom with bail pin. 3. Slide smaller O.D. bent tube into larger tube secure with two M8 x 50mm screws and two M8 lock nuts. Use holes appropriate for size of sweeper. 4. Install split nylon bushing (white) into both ends of swing pivot. Slide retainer plate onto bent tube and then pivot with cross tube at top. Secure with bail pin through swing limit slot. See figure 2. 5. Slide quick release plate onto tube and secure with bail pin. See figure 3. Note: A 17/32 hole will need to be drilled into the front plate of the sweeper on both sides. Use the quick release pin provided and the quick release plate previously assembled to mark the appropriate location. Insert the pin through the hole closest to the tube and through the exsisting hole in the sweeper plate. 6. Attach quick release plate to sweeper using quick release pin, carriage bolt, and steel knob. See figure 4. Motor/Brush Assembly 12. Remove two plugs on left side of sweeper. Note: Early production sweepers may not have pre-drilled holes. If this is the case use Figure 7 to locate and drill two 5/16 holes. Fasten manifold block to sweeper using two M6 x 60mm screws, two M6 flat washers and two M6 lock nuts. 13. Install adapter fittings to manifold block as shown in parts diagram. 14. Install 1/4 hose to manifold and to gutterbroom motor. Secure with hose clips as shown in parts diagram. Use two M8 x 65mm screws, two M8 flat washers and two M8 lock nuts to fasten to tubes and one M8 x 25mm screw and M8 flat washer to fasten to weld nut in sweeper body. WARNING - Escaping hydraulic fluid can have enough pressure to penetrate the skin, causing serious personal injury. 15. Finally remove return hose from motor (hose closest to sweeper body) and connect to “T” port on block. Use short hose to connect empty port on broom motor to “P”port on block. 16. Be sure to tighten all connections to appropriate torque spec. found in back of manual. Failure to do so may cause O-Ring damage, leaks and possible injury. 7. Attach drive plate to bristle backing using four M8 x 50mm screws, eight M8 flat washers and four M8 lock nuts. Be sure bushing is facing down. Attach motor to brush using 5/16 x 1 screw and large washer. Swinging gutterbroom from side to side 8. 2. Swing brush to other side. Fasten motor mount plate to flange on motor using four M8 x 25mm screws, four M8 washers and four M8 lock nuts. See figure 1. Secure motor/brush assembly to swing pivot assembly using 3/4 clevis pin and cotter pin. See figure 6. 1. Remove quick release pin and knob. 3. Remove chain from key hole slot. Remove swing limit pin and rotate brush 180 degrees. Replace pin and chain 9. Attach chain assembly to motor mounting plate with quick link. See figure 6. 4. Remove quick release plate and flip over. Gussets should face up if brush is on left side and face down if on right side. 10. Attach other end through key hole slot at top of bent tube. See figure 6. 5. Fasten quick release plate to sweeper using knob, carriage bolt, and pin. 6. Change direction on valve. 38 51-3606-1, 7/05 SERVICE MANUAL INSTALLING GUTTERBROOM Figure 1 Figure 3 Figure 2 Figure 4 51-3606-1, 7/05 39 SERVICE MANUAL INSTALLING GUTTERBROOM Figure 6 Figure 5 Figure 7 40 51-3606-1, 7/05 SERVICE MANUAL INSTALLING SPRINKLER Installing the Dust Suppression Kit 1. Unpack parts and then compare them to the parts list. If you discover any shortages, contact SWEEPSTER or your dealer. Tank/Pump (If no tank go to step 8) 17. From this tee use the remaining 3/8 in. hose to connect to the pump. 18. If a gutterbroom is installed, insert a tee barb fitting into the hose installed in step 17. 19. Route 3/8 in. hose from tee inserted in step 18 to gutterbroom following hydraulic hose routing. See parts list diagram on page 41. 2. Position the tank on top of the sweeper body as far back as possible. Align the left-to-right centerlines of the tank and the sweeper. The outlet must face the left-hand side of the sweeper. 20. Install elbow nozzle and spray tip on to gutterbroom and connect hose. Secure with hose clamp. Use zip tie to secure hose to hydraulic lines. 3. Transfer holes from the tank to the sweeper. Switch Assembly 4. Drill 11/32 in. holes. 21. Find a convenient spot on the prime mover dash to place the toggle switch. Drill a hole with a 13/32 in. bit. Install the switch. 5. Secure the tank to the sweeper with washers and screws. 6. Install a 5/8 in. - 1/2 in. barb fitting on the tank outlet. 7. Connect the 5/8 in. hose to the barb fitting. Secure it with a 7/8 in. hose clamp. 8. Connect the filter to the pump. Place this assembly over the holes and secure it to the water tank (if applicable) with 4 screws, nuts and washers. IMPORTANT - Avoid mover damage. Check behind the dash to make sure that you will not drill into wires or other parts. 22. Attach the wire cord to wires on the pump using quick connect connectors. Black goes to black and white connects to red. 23. Route the wire cord to the toggle switch. 9. Attach a 5/8 in. - 1/2 in. barb fitting to the strainer. 10. Connect the 5/8 in. hose to the barb fitting. Secure it with a 7/8 in. hose clamp. 11. Connect a 3/8 in. barb fitting to pump. Secure with hose clamp. IMPORTANT - Avoid fire damage. Route wire away from hot and/or moving parts. 24. Strip 3 in. of insulation off the wire cord near the switch, taking care not to damage any wires. Cut the white wire. Attach both ends to wires on the toggle switch using butt end connectors. 12. Connect the 3/8 in. hose to the barb fitting. 25. Route the wire cord to the fuse box keeping it away from hot and/or moving parts. Nozzle/Hose Assembly 26. Connect the white wire to a 15-20 amp fuse or accessory on the ignition. 13. Attach nozzles to front plate of sweeper and secure with jam nut. Elbow nozzles at each end and tee nozzle in middle of sweeper. 14. Install nozzle tip and retainer to each nozzle. 15. Connect each nozzle with the 3/8 hose supplied. Secure with hose clamps. 16. Cut the hose that connects the two tee nozzles and insert a tee barb fitting. Secure with hose clamps. See parts list diagram on page 41. 27. Attach the black wire to the tractor frame using the terminal ring to ground the system. 51-3606-1, 7/05 Parts Manual Pick-Up Broom Big Dawg Series 41 42 51-3606-1, 7/05 NOTES 51-3606-1, 7/05 43 TABLE OF CONTENTS PARTS MANUAL Table of Contents Parts Lists ................................................................... 44-54 Sweeper Assembly ............................................ 44-45 Gutterbroom Assembly ...................................... 46-47 Dust Suppression Assembly.............................. 48-49 Bucket Assembly ................................................... 50 Motor Bucket Assembly ......................................... 51 Core Assembly .................................................. 52-53 Label Assembly ...................................................... 54 44 51-3606-1, 7/05 PARTS MANUAL SWEEPER ASSEMBLY Item Part Qty Description 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 1 1 2 2 2 3 8 6 2 6 12 12 1 5 1 4 4 12 2 2 1 1 2 4 1 2 2 4 1 1 1 1 1 1 1 1 1 31. 32. 33. 03-4072 07-0205 07-0210 07-0244 07-0290 07-1075 07-2950 07-2952 07-3311 07-3617 07-3737 07-3738 07-3745 07-3747 07-3749 07-3751 07-3754 07-4607 07-5294 07-5295 07-5830 07-6798 07-6521 13-10060 13-11561 13-11722 13-11734 13-11879 13-11998 13-12179 13-12167 13-11564 13-12185 13-12184 13-11721 28-9547 28-9548 Nylon, Bushing, 1.75 ID, 2.00 OD Pin, Cotter, 1/8 x 1 Clip, Hairpin, 14 Gauge x 1 3/4 Pin, Lynch, 1/4 Chain, 1/4, 39 Links Rivet, Pop, 3/16 x .626-.0750 Bolt, Carriage, M8-1.25 x 20mm Screw, M6-1 x 20mm Link, Quick, 5/16 Nut, Insert, M6 x 1, Hex Nut, Hex, M8-1.25 Washer, Lock, Split, M8 Washer, Flat, Cl 8.8, M10 Washer, Lock, Split, M10 Screw, HHC, Cl 10.9, M10-1.5 x 30mm Screw, HHC, CL10.9, M10-1.5 x 40mm Washer, Flat, Cl 8.8, M12 Washer, Flat, M8 Link, Quick, 5/16, Wide Jaw Shackle, Anchor, 1/2, 3000 lb Pin, Clevis, 3/8 x 4 1/2 Caster, Assembly, 10 x 2.75 Plate, Shim, 1/4 Inch Finger, Apron, HB48/60/72 Plate, Cover, Nylon, Bushing Plate, Support, Flap, Front, HBC74 & HBC84 Weld, Pin, 1 x 8, W/Hole Plate, Bracket, Mount, Brush, Side Weld, Motor, Guard, Hinged Weld, Sweeper, HBC62 Weld, Sweeper, HBC74 Weld, Sweeper, HBC84 Flap, Front, HBC62 Flap, Front, HBC74 Flap, Front, HBC84 Assembly, Side, Brush, Right Assembly, Side, Brush, Left Not Shown: 08-2266 Grease, Pennzoil, Pennlit, Equivalent for Caster Zerk Fittings. 51-3606-1, 7/05 45 PARTS MANUAL SWEEPER ASSEMBLY 28-9122 HBC62 28-9123 HBC74 28-9124 HBC84 3 9 30 20 5 19 32 4 31 2 10 27 21 24 28 18 12 11 8 29 26 13 33 14 15 7 22 A 16 14 17 6 25 23 1 DETAIL A 46 51-3606-1, 7/05 PARTS MANUAL GUTTERBROOM Item Part 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 01-0523 03-1939 03-1953 03-2126 03-4071 03-4072 03-4073 03-4073 03-4074 03-4075 07-0117 07-0238 07-0699 07-1714 07-3159 07-3311 07-3736 07-3739 07-3744 07-4597 07-4599 07-4604 07-4669 07-4748 07-5287 07-5380 07-5871 07-5872 09-0156 13-11589 13-11592 13-11599 13-11601 13-11903 13-12291 13-12374 13-12378 Qty Description 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 2 15 5 6 6 6 12 2 3 2 1 1 1 2 1 1 1 1 1 1 1 1 Gutterbroom, Woodback Fitting, Adaptor, 7/8MOR, 5/8MFS Fitting, Elbow, HP, 90°, 7/8MOR, 3/8MFS Fitting, Elbow, HP, 90°, 7/8MOR, 5/8MFS Motor, Hydraulic, 6.8 Cu. In Nylon, Bushing, 1 3/4 I.D., 2 O.D. Hose, 1/4 x 102, 3/8FFS, 9/16MORS Hose, 1/4 x 102, 3/8FFS, 9/16MORS Hose, 5/8 x 18, 5/8FFS, 90°, 5/8FFS Valve, 3-Way, Directional, Flow Divider, 3 GPM Bolt, Carriage, Gr5, 1/2 x 2 Chain, 3/16, 10 Links Pin, Cotter, 1/8 x 1 1/4 Screw, Cap, 5/16-18 x 1 Pin, Clevis, 3/4 x 3 3/4 Link, Quick, 5/16 Washer, Flat, M8 Screw, HHC, CL10.9, M8-1.25 x 25mm Screw, Cap, M8-1.25 x 50mm Clip Clip Nut, Hex, Lock, M8-1.25 Screw, Cap, M6-1 x 60mm Pin, Lock, 3/8 x 2 Screw, Cap, M8-1.25 x 65mm Pin, Hitch, Cotterless, 1/2 x 1 Extention, Spring, 8 3/4 x 1.375 Cast Iron, Knob, 2 9/16 Head, with 1/2-13 Hole Flange, Bearing, Nylon Weld, Arm, Gutterbroom Weld, Pivot, Gutterbroom Weld, Plate, Gutterbroom Weld, Motor, Mounting, Gutterbroom Washer, .34 x 1.8 x 10 Gauge Washer, Flat, 2 1/4 O.D. x 1 5/8 I.D. x 12 Gauge Weld, Pin Plate Weld, Chain Holder 51-3606-1, 7/05 47 PARTS MANUAL GUTTERBROOM 28-9134 Gutterbroom 16 25 17 12 21 27 19 20 37 30 16 24 22 C0 8 23 24 13 24 31 18 15 10 18 29 33 4 5 3 9 22 28 19 7 26 11 17 34 32 36 14 1 17 2 6 17 22 48 51-3606-1, 7/05 PARTS MANUAL DUST SUPPRESSION KIT Item Part 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 36. 37. 38. Qty Description 03-0076 1 Fitting, Nipple, BP, Close, 3/8 03-0457 1 Fitting, Barb, 3/8, 3/8MP 03-0819 1 Fitting, Reducerbushing, HP, 1/2, 3/8 03-1226 2 Fitting, Barb, HP, 5/8, 1/2MP 03-1326 1 Pump, Water, 2.1 G.P.M., 12 Volt 07-0140 4 Washer, Lock, #10 07-0343 1 Switch, Toggle, 2 Position 07-0413 5 Nozzle, Cap, Nylon 07-0414 5 Nozzle, Tip, Brass, 1.5 07-0532 1 Strainer, Water 07-0547 2 Clamp, Spring, 7/8, Hose 07-0549 14 Clamp, Spring, 5/8, Hose 07-0812 2 Terminal, Connector, 1/4, F, 16-14 07-0813 2 Terminal, Connector, 1/4, M, 16-14 07-0867 2 Terminal, Butt, 16-14 07-0917 15Ft Wire, 16 Gauge, 2 Connector 07-0926 1 Terminal, Spade, 6, 16-14 07-0927 1 Terminal, Ring, 1/4, 16-14 07-1430 4 Washer, Flat, #10 07-1973 4 Screw, Cap, 5/16-18 x 1 1/4 07-3150 1 Assembly, Tank, Water, 25 Gallon (28-9139 only) 07-3273 4 Washer, Lock, Split, 5/16 07-3275 4 Washer, Flat, 5/16 07-3869 2 Fitting, Barb, Tee, 3/8 07-4831 4 Screw, 2 x 3/4 07-4861 2 Nozzle, Tee, without Clamp 07-4862 3 Nozzle, Elbow, without Clamp 07-5127 25Ft Hose, Clear, Vinyl, 3/8 09-0028 5Ft Hose, Heater, 5/8 03-3537 5 O-Ring, #8 SAE, Straight, Threaded Port 03-1392 1 Valve, Shut-off, Ball, 1/2 03-0152 1 Fitting, Nipple, BP, Close, 1/2 51-3606-1, 7/05 49 PARTS MANUAL DUST SUPPRESSION KIT 28-9139 Dust Suppression Kit With Tank 28-9140 Dust Suppresson Kit No Tank 50 51-3606-1, 7/05 PARTS MANUAL BUCKET 28-9135 28-9136 28-9137 62 Inch Bucket 74 Inch Bucket 84 Inch Bucket 5 5 1 6 1 6 7 1 1 2 A 22 7 3 1 3 DETAIL A Item Part 1. 2. 3. 5. 6. 7. 07-3112 07-4454 07-4454 07-4454 07-3902 07-5342 07-5341 13-11809 13-11816 13-11602 13-12242 13-12243 13-12244 07-1764 07-1764 07-1764 Qty Description 2 6 7 8 1 1 1 1 1 1 1 1 1 6 7 8 Fitting, Zerk, 1/4-28, Self Tap Bolt, Plow, 1/2 x 1 1/2, 62 Inch Bolt, Plow, 1/2 x 1 1/2, 74 Inch Bolt, Plow, 1/2 x 1 1/2, 84 Inch Edge, Cut, Bolt on, 5/8 x 6, Dual Bevel, 62 Inch Edge, Cut, Bolt on, 5/8 x 6, Dual Bevel, 74 Inch Edge, Cut, Bolt on, 5/8 x 6, Dual Bevel, 84 Inch Weld, Mounting Bucket, 62 Inch Weld, Mounting Bucket, 74 Inch Weld, Mounting Bucket, 84 Inch Clean Grip, 62 Inch Clean Grip, 74 Inch Clean Grip, 84 Inch Nut, Hex, Gr8, 1/2-13, 62 Inch Nut, Hex, Gr8, 1/2-13, 74 Inch Nut, Hex, Gr8, 1/2-13, 84 Inch 51-3606-1, 7/05 51 PARTS MANUAL MOTOR BUCKET Motor Bucket 28-9119 11 13 12 4 14 10 9 3 17 5 16 1 18 2 15 6 Item Part 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 03-1939 03-4024 03-4469 03-4469 07-1044 07-3745 07-3747 07-3749 07-3755 07-3756 07-3759 07-4598 07-4600 07-4601 07-4610 07-5816 13-11887 13-11890 7 8 Qty Description 2 1 1 1 1 4 4 4 2 2 2 1 1 1 2 2 1 1 Fitting, Adaptor, HP, 7/8MOR, 5/8MFS Motor, Hydraulic, White, 24.9 Cu In Hose, 5/8 x 96, 100R2, 10MOR, 10FFS, 45° Hose, 5/8 x 96, 100R2, 10MOR, 10FFS, 45° Pin, Center, Gr2, 5/32 x 1 1/2 Washer, Flat, Cl 838, M10 Washer, Lock, Split, Med, M10 Screw, HHC, Cl 10.9, M10-1.5 x 30mm Nut, Hex, Cl 10, M12-1.75 Washer, Lock, Split, Med, M12 Screw, HHC, Cl 10.9, M12-1.75 x 35mm Clip Clip Clip Nut, Hex, Lock, Cl 10.9, M12-1.75 Screw, Socket Head, Cl 12.9, M12-1.75 x 35mm Weld, Motor, Mounting Hub, Hex, 2 1/2 x 1 1/4, Tapered Bore 52 51-3606-1, 7/05 PARTS MANUAL CORE ASSEMBLY Core Assembly Item Part 1. 2. 3. 4. 5. 6. 7. 8. 9. 12. 13. 14. 15. 01-0848 01-5847 07-2495 07-3738 07-3747 07-3749 07-3775 07-3777 07-4619 08-0067 13-11903 13-12205 13-12203 13-11880 13-12209 13-12751 Qty Description 4 1 11 13 1 1 8 1 1 1 1 1 1 1 Wire Sections (See below for quantity) Poly Sections (See below for quantity) Screw, HHC, Cl 8.8, M10-1.5 x 35mm Washer, Lock, Split, Med, M8 Washer, Lock, Split, Med, M10 Screw, HHC, Cl 10.9, M10-1.5 x 30mm Nut, Hex, Cl 8.8, M10-1.5 Screw, HHC, Cl 10.9, M8-1.25 x 20mm Washer, Flat, Cl 8.8, M10 Bearing, 1 1/4, 4 Bolt Washer, .34 x 1.8 x 10 Ga. Weld, Core, Hex Drive, 62 Weld, Core, Hex Drive, 74 Weld, Core, Hex Drive, 84 Plate, Bearing, Mounting Plate, Core, Hat Model Number Sections Needed HBC62M HBC62P HBC74M HBC74P HBC84M HBC84P 16 32 19 38 22 43 Poly, 16 Wire Poly Poly, 19 Wire Poly Poly, 21 Wire Poly 51-3606-1, 7/05 53 PARTS MANUAL CORE ASSEMBLY 28-9125 62 Core Assembly Mixed 28-9126 62 Core Assembly Poly 28-9127 74 Core Assembly Mixed 28-9128 74 Core Assembly Poly 28-9129 84 Core Assembly Mixed 28-9130 84 Core Assembly Poly 4 5 DETAIL B 14 ZERK FITTING MUST BE ON TOP. APPLY 08-2266 LUBRICANT TO BEARING AFTER INSTALLATION. 6 2 4 3 13 1 A B 15 7 DETAIL A 8 9 12 2 5 4 54 51-3606-1, 7/05 PARTS MANUAL LABELS Label Assembly 331 662 8 81 221 441 771 5 54 121 5 54 Item Part 1. 2. 3. 4. 5. 6. 7. 8. 50-0076-1 50-0252 50-0634 50-0642 50-0643 50-0644 50-0645 50-0652 Qty Description 2 1 1 1 4 2 1 1 Label, Warning, Pinch Point, Avoid Injury Label, Logo, Large, White, Die Cut Label, Serial #, Sweepster Label, Big Dawg, Decal, 8.375 x 8.625 Label, Tie Down Point, without Warning Label, Warning, Pinch Point Label, Warning, Read Manual, with Text Label, Bucket, Position Adjustment 51-3606-1, 7/05 Appendix Pick-Up Brooms Big Dawg Series 55 56 51-3606-1, 7/05 NOTES 51-3606-1, 7/05 57 TABLE OF CONTENTS APPENDIX Table of Contents Bolt Torque Specifications ....................................... 58 Hydraulic Fittings Torque Specifications ............. 59-60 Glossary ............................................................ 61-62 Warranty Information .......................................... 63-64 58 51-3606-1, 7/05 APPENDIX TORQUE SPECS. Foot-pounds may be converted to Newton Meters by multiplying by 1.35582 Foot-pounds may be converted to Inch-pounds by multiplying by 12. If the nut and screw are not the same grade, the lower grade will always be used. NOTE - Nylock nuts are utilized when greater resistance to vibrating loose is required, and greater operating temperatures are not a factor. In addition, like lock nuts, nylock nuts have a safety feature that if the bolt does vibrate loose, the nut will remain on the screw. Install nylock nuts to the standard torque shown above. 51-3606-1, 7/05 59 APPENDIX TORQUE SPECS Hydraulic Torque Specifications Face Seal: Assembly, Tube to Fitting Note - Face seal fittings have the most reliable sealing method and therefore, should be used whenever possible. Installation 1. Make sure threads and sealing surfaces are free of burrs, nicks, scratches, or any foreign materials. 2. Install proper SAE o-ring to end of fitting if not already installed. Ensure o-ring is fully seated and retained properly. 3. Lubricate o-ring with a light coating of clean hydraulic oil. 4. Position tube and nut squarely on face seal of fitting and tighten nut finger tight. 5. Using appropriate torquing device, tighten to given torque rating from the table below. Torque Values: SAE Dash Size Tube Side Thread Size In-lbs Ft-lbs -4 9/16 - 18 220 ± 10 18 ± 1 -6 11/16 - 16 320 ± 25 27 ± 2 -8 13/16 - 16 480 ± 25 40 ± 2 -10 1- 14 750 ± 35 63 ± 3 -12 1 3/16 - 12 1080 ± 45 90 ± 4 -16 1 7/16 - 12 1440 ± 90 120 ± 8 -20 1 11/6 - 12 1680 ± 90 140 ± 8 -24 2 - 12 1980 ± 100 165 ± 8 NOTE - ft-lb may be converted to NewMeters by multiplying by 1.35582. NOTE - in-lbs may be converted to Newton Meters by multiplying by 0.11298. 60 51-3606-1, 7/05 APPENDIX TORQUE SPECS. Hydraulic Torque Specifications Straight Thread O-ring Fitting: Assembly, Fitting to Port NOTE - Straight thread o-ring fittings are utilized to adapt hydraulic systems to motors, pumps, cylinders, and valves. Installation (Adjustable Fitting) 1. Make sure threads and sealing surfaces are free of burrs, nicks, scratches, or any foreign materials. 2. Install proper SAE o-ring on port end of fitting if not already installed. Ensure o-ring is fully seated and retained properly. 3. Lubricate o-ring with a light coating of clean hydraulic oil. 4. Back off nut as far as possible and push washer up as far as possible. (Figure 4 & 5) 5. Screw fitting into port. Hand tighten fitting until backup washer contacts face of port. (Figure 6) 6. To position the fitting, unscrew to desired position, but not more than one full turn. 7. Hold fitting in position with wrench. Using appropriate torquing device, tighten nut to given torque rating from the table in section. (Figure 7) Torque Values Fitting Size SAE Port Thread Size In-Lbs Figures 4, 5, 6 and 7 Ft-Lbs -4 7/16 - 20 190 ± 10 16 ± 1 -6 9/16 - 18 420 ± 15 35 ± 1 -8 3/4 - 14 720 ± 25 60 ± 2 -10 7/8 - 14 1260 ± 50 105 ± 5 -12 1 1/16 - 12 1680 ± 75 140 ± 6 -16 1 5/16 - 12 2520 ± 100 210 ± 8 -20 1 5/8 - 12 3100 ± 150 260 ± 12 -24 1 7/8 - 12 3800 ± 150 315 ± 12 NOTE - ft-lb may be converted to NewMeters by multiplying by 1.35582. NOTE - in-lbs may be converted to Newton Meters by multiplying by 0.11298. 51-3606-1, 7/05 61 APPENDIX GLOSSARY angle or angle assembly - portion of the sweeper that allows the brush head assembly to angle. manual angle kit - means of swinging the brush head assembly mechanically. BP - black pipe. mid pump unit - sweeper in which the pump is mounted on the mid PTO. brush head assembly - assembly that includes the core, hood, and brush frame. brush pattern - area of dirt removed from sweeping surface; with a properly adjusted sweeper; the pattern is the same width for the entire length. mounting assembly - portion of the sweeper that attaches to the prime mover; designed specifically for each prime mover. NPT - national pipe thread. note - indicates supplementary information. castellated - having battlements like a castle. OR - o-ring. caution - indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. core - weldment that holds brush sections. danger - indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. F - female. psi - pounds per square inch. PTO - power take off; shaft on the prime mover used to drive attachments. plate swing - swing assembly that includes a half-moon plate. power pack - auxiliary hydraulic package used when prime mover hydraulics do not have enough flow available. FS - face seal. front - side that is in front when facing the normal forward direction of travel of the machine. prime mover - refers to the tractor, truck, loader or other vehicle to which a sweeper is attached. qty - quantity. gpm - gallons per minute. HP - high pressure. quick change core - core designed in a way that allows brush sections to be changed without removing hoses from motors. hood - brush shield. rpm - revolutions per minute. hydraulic angle kit - means of swinging an assembly hydraulically. important - used for instructions when machine damage may be involved. rear - side that is in rear when facing the normal forward direction of travel of the machine. rear pump unit - sweeper in which the pump is mounted on a rear PTO. in. - inches. kph - kilometers per hour. lb - pounds. left-hand - side that is on the left when facing the normal forward direction of travel of the machine. lift cylinder - means of raising the brush head assembly hydraulically. lps - liters per second. M - male. retainer - removable plate or set of plates that keeps sections on the core. right-handed - side that is on the right when facing the normal forward direction of travel of the machine. section - single brush wafer. section set - replacement brush wafers. sprinkler system - system that sprays water ahead of the sweeper used to reduce dust. sprinkler tank - assembly that includes the water reservoir and mounting used in a sprinkler system. mm - millimeters. mph - miles per hour. stands - devices designed to keep the components off the ground when the sweeper is dismounted. 62 APPENDIX GLOSSARY swing or swing assembly - portion of the sweeper that allows the brush head assembly to angle. swing cylinder - means of angling the brush head assembly hydraulically. tank assembly, hydraulic - assembly that includes the hydraulic reservoir, filter and fittings; may also incorporate valves. warning - indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. weld - weldment. windrow - pile of debris. zerk - grease fitting. 51-3606-1, 7/05 51-3606-1, 7/05 63 APPENDIX WARRANTY REGISTRATION 64 51-3606-1, 7/05 APPENDIX WARRANTY INFORMATION SWEEPSTER LLC Limited 12 Month Warranty Thank you for purchasing a Sweepster, LLC. product. Warranty protection is valid only when this Warranty Registration is completed and signed by the customer and dealer, and mailed to Sweepster LLC. I hearby acknowledge that I have received a copy of the owners Limited Warranty and I accept the terms therein. For a period of 12 months from the date of delivery of product to the original user, Sweepster, LLC. warrants each product to be free from manufacturing defects, subject to the limitations contained in this policy. This warranty does not apply to defect caused, in whole or in part, by unreasonable use while in the possession of the user, including, but not limited to: failure to properly set up product; failure to provide reasonable and necessary maintenance; normal wear; routine tune ups or adjustments; improper handling or accidents; operation at speed or load conditions contrary to published specification; improper or insufficient lubrication; improper storage. This warranty is also not a guarantee that performance of each product will meet the expectations of the purchaser. Sweepster, LLC. shall not be liable for consequential damages of any kind, including, but not limited to: consequential labor costs or transportation charges in connection with the replacement or repair of defective parts; lost time or expense which may have accrued because of said defects. In no event shall Sweepster, LLC.’s total liability hereunder exceed the product purchase price. Sweepster, LLC. makes no warranty with respect to trade accessories or any component or accessory of the product which was not manufactured by Sweepster, LLC. including any purchased components of any kind. These are subject to the warranties of their respective manufacturers. The warranty will be considered void if the product or any part of the product is modified or repaired in any way not expressly authorized by Sweepster, LLC. or if closed components are disassembled prior to return. Closed components include, but are not limited to: gearboxes, hydraulic pumps, motors, cylinders, and actuators. Our obligation under the warranty is expressly limited, at our option, to the replacement or repair at Sweepster, LLC or at a service facility designated by us, or such part or parts as inspection shall disclose to have been defective. We are not responsible for unauthorized repairs or replacements. Any implied or statutory warranties, including any warranty of merchantability or fitness for a particular purpose, are expressly limited to the duration of this written warranty. We make no other express or implied warranty, nor is anyone authorized to make any on our behalf. This warranty cannot be extended, broadened, or changed except in writing by an authorized officer of Sweepster, LLC.