Professional Documents
Culture Documents
at all times. READ, UNDERSTAND, and FOLLOW the Safety and Operations Instructions contained in this manual before operating the equipment.
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SECTION 4 MAINTENANCE
About Maintenance.............................................................................................................................................4.1 Cleaning...............................................................................................................................................................4.2 Sweeper Fluid Maintenance................................................................................................................................4.3 Lubrication Schedule..........................................................................................................................................4.4 Filters....................................................................................................................................................................4.5 Seals......................................................................................................................................................................4.6 Hopper..................................................................................................................................................................4.7 version 1 09/10 2010 SCHWARZE INDUSTRIES, INC.
SECTION 5 TROUBLESHOOTING
Loss Of Vacuum Power - Sweeper Not Picking Up..........................................................................................5.1 Excessive Runner Wear - Head Not Gliding Properly......................................................................................5.2 Head Drifting Down............................................................................................................................................5.3 Unusual Noise Or Vibration................................................................................................................................5.4 Sweeper Engine...................................................................................................................................................5.5 Dust Suppression System.....................................................................................................................................5.6 Hydraulic System................................................................................................................................................5.7 Gutter Broom.......................................................................................................................................................5.8
SECTION 6 PARTS
12V Standard Unit..............................................................................................................................................6.1 24V Standard Unit..............................................................................................................................................6.2 Frame Assembly..................................................................................................................................................6.3 Skid Tie Down Kit...............................................................................................................................................6.4 Install, IH Truck Kit...........................................................................................................................................6.5 Install, FSR Isuzu Truck Kit..............................................................................................................................6.6 Install, Universal Truck Kit...............................................................................................................................6.7 Install, Conventional Chassis Extension...........................................................................................................6.8 Install, Cabover Chassis Extension...................................................................................................................6.9 Install, Isuzu Conventional Chassis Extension...............................................................................................6.10 Install, Isuzu Cabover Chassis Extension.......................................................................................................6.11 12V Isuzu Console Assembly............................................................................................................................6.12 56 Gallon Fuel Tank Assembly.........................................................................................................................6.13 Install, Battery Box Assembly..........................................................................................................................6.14 LH Toolbox Assembly.......................................................................................................................................6.15 RH Toolbox Assembly.......................................................................................................................................6.16 Head, LH Pickup..............................................................................................................................................6.17 Head, RH Pickup.............................................................................................................................................6.18 Install, Head Assembly, LH Pickup.................................................................................................................6.19 Install, Head Assembly, RH Pickup................................................................................................................6.20 Head, LH Caster Assembly..............................................................................................................................6.21 2010 SCHWARZE INDUSTRIES, INC. version 1 09/10
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CHASSIS TYPE CHASSIS SERIAL NO. SWEEPER SERIAL NUMBER SWEEPER MODEL POWER MODULE ENGINE TYPE POWER MODULE ENGINE SERIAL NO. HYDRAULIC PUMP TYPE BEACON TYPE GUTTER BROOM MOTOR TYPE PRESSURIZED WATER SYSTEM PUMP TYPE JOB NO.
MANUFACTURED BY:
__________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________
SOLD AND SERVICED BY:
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CHASSIS TYPE CHASSIS SERIAL NO. SWEEPER SERIAL NUMBER SWEEPER MODEL POWER MODULE ENGINE TYPE POWER MODULE ENGINE SERIAL NO. HYDRAULIC PUMP TYPE BEACON TYPE GUTTER BROOM MOTOR TYPE PRESSURIZED WATER SYSTEM PUMP TYPE JOB NO.
MANUFACTURED BY:
__________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________
SOLD AND SERVICED BY:
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CALIFORNIA PROPOSITION 65
WARNING
Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
Always start and operate the engine in a well-ventilated area; If in an enclosed area, vent the exhaust to the outside; Do not modify or tamper with the exhaust system.
As an owner of off-road diesel engine equipment and/or an employer, you may have an obligation, under the California Occupational Safety and Health Act or Proposition 65, to warn persons exposed to diesel engine exhaust and/or other Proposition 65 chemicals in and around your workplace. See California Health and Safety Code section 25249.5, Title 22 of the California Code of Regulations at section 1200, et seq., and Title 8 of the California Code of Regulations section 5194.
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Procedures for clearing obstructions from the suction inlet tube Prior to removing the intake hose, locate the sweeper in an area conducive to safe work practice. Assure the sweeper is parked with the brakes set the auxiliary and chassis engine off. On occasion suction inlet tube may become clogged with obstructions such as debris and mud (using larger amounts of water in the intake of the sweeping head will assist in removing dirt or mud clogging without removal of intake tube). Caution: Exercise care when cleaning the inlet tube as sharp objects (hypodermic needles, glass, etc) or hazardous materials may be present. Wear the appropriate protective equipment. To clear an obstruction: Remove the flexible intake tube at the bottom end, which is connected to the sweeping head, and clear tube obstructions from the lower end.
A series sweeper will have quick V clamp or band clamp enabling the operator to disconnect the bottom of the intake tube from the sweeping head and clear any potential obstructions. S series sweepers will have is a removable band clamp enabling the operator to disconnect the bottom of the intake tube from the sweeping head and clear any potential obstructions. Reconnect the flexible intake tube to the sweeping head and check for proper operation. DO NOT raise the hopper and attempt to clean the obstruction from the top of the suction tube as a potential pinch point is created between the hopper and the top of the suction tube.
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INTRODUCTION
Your new Schwarze GS6 SERIES sweeper incorporates the very latest in sweeper manufacturing technology. This sweeper was designed to clean surfaces with a high rate of efficiency and minimize operational costs. A single fan is used to create both the air pressure and the suction which power the sweeping function. This volume of air, which is pumped at a high velocity into the sweeper pickup head, provides its superior sweeping performance. This sweeper uses a closed loop or regenerative air system to accomplish debris pickup. Part of the fans forced air may be vented out of the fan housing, which provides increased performance over competitive models. You will find this design is much more dependable and requires less maintenance than that of broom sweepers. To obtain the best use of the sweepers equipment, we strongly recommend that the operator be required to thoroughly read, understand and follow all of the applicable information in this Manual prior to and during the operation of this sweeper. Daily cleaning and strict adherence to the units routine maintenance schedules are major factors in keeping your unit in like-new condition. Ensuring that both service personnel and operators become familiar with the information unique to this make and model of sweeper will greatly contribute to costeffective operation and many years of quality service. Our goal at Schwarze Industries is always 100% customer satisfaction. Were confident youll find this new sweeper to be the best built on the market, and its backed by a company with a service commitment thats second to none. If you need help, dont hesitate to call. Many ideas for improvements to previous models have come from users in the field. If you have an idea or suggestion on how we might make our product even better, please let us know by calling toll free, 1-800-879-7933.
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CUSTOMER ASSISTANCE
Schwarze Industries is noted for its commitment to customer satisfaction. In addition to many Authorized Dealers located throughout the country, Schwarze Industries also maintains a fully stocked factory service center in Huntsville, Alabama. In the event you need parts or service, call your nearest Authorized Dealer. Their name and number can be found on the Sweeper Information Sheet, located in the front of this manual. In the unlikely event that your local dealer is unable to provide the assistance you require, call us at our home office in Huntsville, Alabama. We have a state-of-the-art fabrication and production facility and a complete service and refurbishing center with an inventory of over $500,000 in spare parts. In most cases, same day shipping and overnight delivery is available. To speak with our parts team representatives, call 1-800-879-7933. To assure prompt delivery and processing of your parts order, please have the following information ready before calling: Type and serial numbers for the chassis, power module engine and the sweeping unit. (This information is also located on the Sweeper Information Sheet in the front of this manual). The part number(s), description(s) and the quantity desired. (Please indicate any relevant particulars such as whether the part is for the right or left, front or rear). Shipping instructions: Tell us how you want your order shipped (e.g., next day air, second day air, truck, freight, etc.). When left unspecified, orders are shipped UPS. Truck freight is used when weight restrictions apply.
Every effort is made to ship all in-stock parts on the same day the order is placed when received before 12:00 noon Central Time. Orders received after noon are shipped on the following business day. For customer convenience, orders may be faxed to the Schwarze factory 24 hours per day . The parts departments fax number is 1-256-851-1210.
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WARRANTY INFORMATION
When a Schwarze GS6 SERIES sweeper is purchased, it is important that all warranty forms for the chassis, sweeper, and auxiliary engine be filled out and sent to the appropriate component manufacturer. Failure to do so may result in costly delay or denial should a warranty claim be made. Warranty claims are handled by our parts department. Before any warranted parts may be returned for warranty credit, however, authorization by a Schwarze representative must first be obtained. Also, once the authorization has been granted, the defective part MUST be returned to us. This policy allows for efficient parts shipping and account crediting. For your convenience, we accept MasterCard and Visa. If credit card payment is not used, orders will be shipped C.O.D. unless prior arrangements have been made with our accounting department. Once received, shipments should be examined immediately. Any shortage or damage should be noted on the freight bill or express receipt BEFORE the parts are accepted from the carrier. Immediate notification to us of such shortage or damage is also required. If you still have questions with the service or operation of your sweeper after consulting the maintenance and troubleshooting sections of this manual, call us toll-free and we will provide you with additional instruction. At Schwarze Industries we are truly committed to your complete satisfaction with our products and services. If you have any suggestions, please call our toll-free number: 1-800-879-7933. We are only a toll-free phone call away.
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SAFETY GUIDELINES
1. Do not operate sweeping unit without fan exhaust hose in place. 2. When lowering hopper, beware of the pinch point. (A pinch point is the area between any two objects where a crushing injury may occur when one or both of the objects move. In this instance, the pinch point is the area between the hopper and the frame.) 3. Do not dump hopper unless you are on level ground. Dump only with truck in NEUTRAL and with emergency brake engaged. Do not dump hopper over an open pit or dock. 4. Make certain that safety stops (provided with unit) are in place at the dump cylinders whenever you are working under the raised hopper. 5. To prevent accidental starting of the auxiliary engine, remove the auxiliary engine keys and/or disconnect the auxiliary engine battery cable when working on or near the auxiliary engine or its drive belts. 6. Remove truck ignition keys whenever you are working under truck. 7. Do not remove any of the belt guards, or work near drive belts, while wearing loose clothing or jewelry. 8. Do not inspect the fan or come near the fan housings back plate opening when the auxiliary engine is running. 9. Drain water system when temperature could fall below freezing. 10. AUXILIARY ENGINE CAUTION: Water and antifreeze must be pre-mixed in a 1:1 ratio before filling the engines cooling system. Failure to premix components can cause engine failure and will invalidate the engines warranty. Consult the engine owners manual for maintenance schedules. 11. If your unit is equipped with dual steering, drive the sweeper from the right side only when you are using the right side broom. Do not exceed 15 mph when steering from the right side. 12. Always use the proper tools for every job and keep your equipment in good condition. 13. Refer to the chassis and sweeper engine Owners Manuals for additional, important safety guidelines.
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SECTION 1
GS6 SERIES
SAFetY
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1.1
CAUTION
The lowest level of Safety Message; warns of possible injury. Decals located on the Equipment with this Signal Word are Black and Yellow. Serious injury or possible death! Decals are Black and Orange.
WARNING
DANGER
READ, UNDERSTAND, and FOLLOW the following Safety Messages. Serious injury or death may occur unless care is taken to follow the warnings and instructions stated in the Safety Messages. Always use good common sense to avoid hazards.
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SCHWARZE GS6 SERIES SAFETY DANGER Never operate the Sweeper until you have read and completely understand this Manual, the Truck Operators Manual, the Auxiliary Engine Operators manual, and each of the Safety Messages found in these Manuals and those affixed to the Sweeper and its components. Learn how to stop the Sweepers engines suddenly in an emergency. Never allow inexperienced or untrained personnel to operate the Truck and Sweeper without supervision. Make sure the operator has fully read and understood the manuals prior to operation.
PELIGRO!
Si no lee Ingles, pida ayuda a alguien que si lo lea para que le traduzca las medidas de seguridad.
i LEA EL INSTRUCTIVO!
In addition to the design and configuration of this Sweeper, including Safety Signs and Safety Equipment, hazard control and accident prevention are dependent upon the awareness, concern, prudence, and proper training of personnel involved in the operation, transport, maintenance, and storage of the machine. Refer also to Safety Messages and operation instruction in each of the appropriate sections of the Truck and Auxiliary Engine Manuals. Pay close attention to the Safety Signs affixed to the Sweeper. PARTS INFORMATION Schwarze Sweepers use balanced and matched system components for broom carriers, brooms, suction heads, and other components. These parts are made and tested to Schwarze specifications. Non-genuine or will fit parts do not consistently meet these specifications. The use of non-genuine or will fit parts may reduce Sweeper performance, void Sweeper warranties, and present a safety hazard. Use genuine Schwarze Sweeper parts for economy and safety. SEE YOUR SCHWARZE DEALER
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WARNING
Always maintain the safety decals in good readable condition. If the decals are missing, damaged, or unreadable, obtain and install replacement decals immediately. Consult your authorized sales representative for decal replacements. All Safety Shields, Guards and other Protective Safety devices should be used and maintained in good working condition. All safety devices should be inspected carefully at least daily for missing or broken components. NEVER REMOVE PROTECTIVE SHIELDS AND GUARDS! NEVER MODIFY OR CUT PROTECTIVE SHIELDS OR GUARDS! When shields or guards are removed to access areas for maintenance, they must be replaced and be in good condition before operating. Missing, broken, or worn shields, guards, and other protective devices must be replaced at once and prior to operation to reduce the possibility of injury or death from thrown objects, entanglement, or contact. The Sweeper must be equipped with a fire extinguisher, rated for all fires, in an accessible and visible area. The fire extinguisher should be inspected routinely by a certified inspector for operational use and replaced as needed. Never obstruct access to the fire extinguisher.
DANGER
WARNING
1.2
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SCHWARZE GS6 SERIES SAFETY DANGER WARNING NEVER use drugs or alcohol immediately before or while driving or operating the Sweeper. Drugs and alcohol will affect an operators alertness and coordination and therefore affect the operators ability to operate the Sweeper safely. Before operating the Sweeper, an operator on prescription or over-the counter medication must consult a medical professional regarding any side effects of the medication that would hinder their ability to operate the Sweeper safely NEVER knowingly allow anyone to operate this Sweeper when their alertness or coordination is impaired. Serious injury or death to the operator or others could result if the operator is under the influence of drugs or alcohol. Always wear OSHA approved Personal Protective Equipment (PPE) while operating, servicing, repairing, and/or cleaning the Sweeper. PPE is designed to provide bodily protection during such activities. Personal Protective Equipment includes: Protective Eye Wear Steel Toed Safety Footwear Gloves Hearing Protection Close Fitted Clothing Hard Hat-When working around a raised hopper. Respirator-Depending on conditions and material being swept or cleaned. Specialized protective equipment may be required if dangerous or hazardous material is being swept by or cleaned from the Sweeper. Prolonged operation of the Sweeper may cause operator boredom and/or fatigue affecting the safe operation of the Sweeper. It is recommended that the operator take scheduled work breaks to help prevent these potentially impaired operating conditions. If possible, completely shut down the Sweeper,exit the cab and move around stretching your arms and legs . Never operate the Sweeper in a fatigued or bored mental state that impairs proper and safe Sweeper operation.
CAUTION
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SCHWARZE GS6 SERIES OWNERS MANUAL CAUTION PROLONGED EXPOSURE TO LOUD NOISE MAY CAUSE PERMANENT HEARING LOSS! Sweeper operation can often be noisy enough to cause permanent hearing loss. We recommend that you always wear hearing protection if the noise in the Operators position exceeds 80db. Noise over 85db over an extended period of time will cause severe hearing loss. Noise over 90db adjacent to the Operator over an extended period of time will cause permanent or total hearing loss. Note: Hearing loss from loud noise [from sweepers, chain saws, radios, and other such sources close to the ear] is cumulative over a lifetime without hope of natural recovery. Do not operate, or perform maintenance to, the Sweeper while wearing loose fitting clothing. Entanglement of loose clothing with the rotating elements can result in serious injury or death. Stay clear of all rotating elements at all times.
DANGER
1.3
WARNING
Use available Sweeper hand holds and steps to exit the Sweeper. Make sure you have solid footing before stepping down. Be careful of your step and use extra caution when mud, ice, snow, or other matter has accumulated on the steps or handrails. Never rush to exit or jump off the Sweeper. Do not attempt to mount the Sweeper or Truck while the machine is moving Never attempt to mount a runaway Sweeper. Serious injury or death may occur from being run over by a moving Sweeper.
DANGER
DANGER
BEFORE leaving the Trucks seat, always engage the parking brake and/or set the Trucks transmission in parking gear, stop the engine, remove the key, and wait for all moving parts to stop. Never dismount a Truck that is moving or while the Truck and Auxiliary engines are running. Operate the Sweeper controls from the Truck seat only.
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WARNING
Always wear a seat belt while driving the Sweeper during operation and transport Serious injury or even death could result from falling out of the Truck or from being involved in a collision. Start the Truck and Auxiliary engines only when seated and belted in the Trucks operator seat. Operate the Sweeper controls only while properly seated with the seat belt secured around you. Inadvertent movement of the Truck and/or Sweeper components may cause serious injury or death to the operator and passersby. Read the Truck and Auxiliary Engine operators manuals for proper starting instructions. Use the right side steering only for sweeping, and never while exceeding 15 MPH. For travel, the Sweeper must be driven from the LEFT side ONLY. If the Sweeper is to be operated from the right hand side, make sure the Sweepers mirrors are aligned for visibility from the right hand side steering position. Sweep only in conditions where you have clear visibility of the area being swept in daylight or with adequate artificial lighting. Never sweep in darkness of foggy conditions where you cannot clearly see at least 50 feet in front and to the sides of the Sweeper. Make sure that you can clearly see and identify passersby, steep slopes, ditches, drop-offs, overhead obstructions, power lines, oversized debris and foreign objects. If you are unable to see these types of items, discontinue sweeping until visibility improves.
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SCHWARZE GS6 SERIES OWNERS MANUAL Transport the Sweeper only at safe speeds. Serious accidents and injuries can result from driving this Sweeper at unsafe speeds. Become familiar with the driving characteristics of the Truck and how it handles before operating or transporting on streets and highways. Make sure the Trucks steering, brakes, and wheels are in good condition and operate properly. Before transporting the Sweeper determine the safe transport speeds for you and the machine. Make sure you abide by the following rules:
WARNING
1. Test the Sweeper at a slow speed and increase the speed slowly. Apply the brakes smoothly to determine the stopping characteristics of the Truck equipped with the Sweeper. As you increase the speed of the Truck, the stopping distance increases. Determine the maximum safe transport speed for you and the Sweeper. When driving down a hill or on wet or rain slick roads, the braking distance increases: use extreme care and reduce your speed. Do not operate the Sweeper with weak or faulty brakes. Obey all traffic laws and regulations. Never exceed the posted speed limit. The Sweeper has a high center of gravity that may be further increased when carrying a loaded hopper and/or a full water tank. Use extreme caution when transporting at highway speeds. Slow down for sharp corners to avoid tipping or turning the Sweeper over. Only transport the Sweeper at the speeds determined as safe and which allow or proper control of the machine while driving and stopping during an emergency. When operating in traffic, use the Sweepers directional indicator or signal lights to indicate your movement. Always use the Sweepers flashing signal lights and other equipped warning features to alert motorist of your presence and slow moving speed when sweeping in traffic. Be Aware of Traffic Around You and Watch Out for the Other Guy.
2. 3. 4. 5.
WARNING
When transporting the Sweeper between locations, follow all local traffic laws and regulations. Disengage all Sweeper controls, raise all sweeping components, gutter brooms, sweeper heads, make sure the hopper is completely lowered, an disengage all warning signals prior to entering vehicle traffic. Before starting to sweep, the sweeping components must be engaged and operating at the rated speed before moving forward. Sweeping debris before the Sweeper has reached its rated operation speed may result in debris binding between the sweeping components or obstruction in the suction tubes. version 1 09/10
WARNING
WARNING
Do not exceed the rated operating speed for the Truck and Auxiliary engines Excessive operating speeds can cause engine and Sweeper component failures resulting in possible serious injury or death.
WARNING
Sweep at a speed that allows you to safely operate and control the Sweeper. Safe sweeping speed depends on street condition and the type and amount of debris being collected. Normal ground speed range is between 1 and 3 mph. Slow down for corners, curbs, parked cars, protruding signs and other obstacles. Use slow traveling speeds when operating on or near steep slopes, ditches, drop-offs, overhead obstructions, power lines, or when debris and foreign objects are to be avoided. KEEP AWAY FROM ROTATING ELEMENTS including the Sweeper gutter brooms and sweeping head to prevent entanglement and possible serious injury or death. Be aware that rotating elements can pull bystanders into the Sweeper.
DANGER
Never reach outside the Truck cab to pick up a foreign item or to clear an obstacle such as a tree limb or road sign impeding passage. Stop the Sweeper, shut down all sweeping components, wait for all moving parts to come to a complete stop, then exit the cab to handle objects that are hindering Sweeper operation and passage. Do not operate the Sweeper if excessive vibration or noise exists. Shut down the Sweeping components and the Truck and Auxiliary engines. Inspect the Sweeper to determine the source of the vibration or noise. If brooms are loose, damaged, or missing, replace them immediately. Do not operate the Sweeper until all necessary repairs have been performed and the Sweeper operates smoothly. Operating the Sweeper with excessive vibration can result in component failure and broken objects being thrown outward at high velocities. To reduce the possibility of property damage, serious injury, or even death, never operate the Sweeper with missing or damaged components. Never attempt to sweep debris that is too large for the Sweeper to pick up (oversized objects such as broken limbs and discarded tires). Such objects may plug the sweeping components and cause serious mechanical damage to the Sweeper. If possible, carefully place such objects out of the Sweeper and traffic path until properly removed by another means.
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SCHWARZE GS6 SERIES OWNERS MANUAL DANGER WARNING DANGER Objects such as wire, cable, rope, and chain can become entangled in the rotating parts of the sweeping components causing mechanical damage. Entangled items caught in the brooms can sling outward possibly injuring or entangling the operator or passersby. Any objects that might become entangled in a sweeping component and those which could plug the suction tubes should be removed from the area before beginning to sweep. Upswept debris, piled debris, and water puddles left behind the Sweeper might pose a driving hazard to vehicle traffic colliding with the debris or losing traction on the material. It is recommended to post warning signs alerting drivers of the Sweepers presence and the need to reduce vehicle speed. If such hazards are left behind following the Sweepers passage, the area should be swept a second time and any remaining hazards removed by an alternative method. Do Not raise the Sweepers broom components when passersby are within 25 feet Make sure that the gutter brooms and sweeper brooms have come to a complete stop before raising the brooms from the street surface. Raising the sweeping components exposes the rotating brooms creating a potentially serious hazard from thrown objects by the brooms or from direct broom contact. Air enters the fan housing inlet with great force. Caution should be used when the power module is running and the hopper is raised. To avoid being pulled into the fan, do not wear loose clothes or position yourself or allow others near the fan housing inlet. Possible injury or death could occur from being pulled into the fan.
DANGER
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SCHWARZE GS6 SERIES SAFETY Use extreme caution when dumping contents of the Sweeper. Be aware of bystanders and animals in the area. Select a dump site on level ground and clear of overhead obstructions that could be hit when raising the hopper. Serious injury or death to the operator, bystanders and animals could occur if precautions are not taken when dumping the contents of the hopper. When positioning the truck at the dump station, choose an accessible location only on level ground. Raising the hopper on unlevel ground increases the possibility of tipping. Make sure the area is clear of ground and overhead obstructions. Never raise the hopper bin unless you can clearly see all overhead structures. Make sure you stay clear of all utility lines. Make sure the outriggers contact solid stable ground before raising the hopper. Stay in the cab of the sweeper with the windows rolled up when dumping the hopper. Use care when positioning the Sweeper to the dump station. Your vision, especially to the side and rear of the Sweeper may be reduced by the size of the Sweeper. Use side and rear view mirrors to aid vision. If you cannot see the dump site clearly, stop the Truck and examine the area. If necessary, request assistance to guide you while backing the Truck into position. If the hopper will be in the raised position for more time than is normally required to dump, or if someone is going to get under the hopper for repair, maintenance, cleaning or any other reason, secure the safety prop into position. Never drive the Sweeper with the hopper in the raised position. Traveling with the hopper in the raised position increases the chances of colliding with overhead obstructions. In addition, the center of gravity of the Sweeper is higher with a raised hopper, making the unit more prone to tipping over.
DANGER
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SCHWARZE GS6 SERIES OWNERS MANUAL DANGER Do not allow the Sweeper to come in contact with potentially dangerous and/or hazardous material. Such hazards may include, but are not exclusively limited to, the following: Fire Hazards- Fuel spills, burning material. Chemical Hazards- Chemical spills, discarded chemical containers, batteries. Biological Hazards- Decaying Carcasses, BioMedical Waste. Radioactive Hazards-Radioactive Waste, Radioactive Material. Cutting Hazards-Broken Glass, Lumber with Protruding Nails. Carcinogenic Materials-Asbestos. Corrosive Materials-Batteries, Acids and Bases.
In most areas, these types of material require special handling requirements for safe collection and proper disposal and should not be collected by the Sweeper, nor can they be disposed of in a general landfill site like most swept waste. Contact the appropriate authority for the collection and disposal requirements of such dangerous and/or hazardous material. Always wear required OSHA approved Personal Protective Equipment (PPE when coming in contact with and removing potentially dangerous and hazardous material that has been collected by the Sweeper or which is obstructing one or more Sweeper components. Pay close attention to dangerous and hazardous material including, but not exclusively limited to, chemicals, decaying carcasses, and sharp objects. Never sweep into hot or burning debris. A burning object, even as small as a lit cigarette, has the potential of igniting the collected waste inside the hopper, possibly destroying the Sweeper and inflicting serious injury or death to the operator or passersby. Verbal communication near a Sweeper is difficult and dangerous. Operating instructions and sweeping directions should be made prior to starting the Sweeper Unclear and misunderstood communication may lead to operator and bystander injury or death and equipment damage. If communication by the operator is necessary, completely shutdown and exit the Sweeper. Never allow anyone to approach the Sweeper while in operation. Never allow children to play on, under, or around the Sweeper nor allow children to operate Sweeper controls. Children can slip or fall off the Sweeper and be injured or killed. Children can cause the Sweeper components to shift or fall crushing themselves or others.
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SCHWARZE GS6 SERIES SAFETY WARNING Allow Sweeper passengers only in situations where their presence is involved in the sweeping operation (operator training, supervision, maintenance inspection). Never carry passengers whos presence distracts from the safe operation or transport of the Sweeper. Passengers must be seated securely and belted in the cabs passenger seat. Never allow any person to ride on any other location of the Sweeper during operation or transport. Extreme caution should be used by the Sweeper operator when operating near passersby. Stop sweeping if anyone comes within 25 feet of the Sweeper to prevent possible passerby injury or death from being struck from a thrown object, entanglement with the brooms, or run over. Under certain conditions, the Sweepers brooms are capable of propelling objects up to 25 feet. Be extremely careful when sweeping large dense objects, such as gravel or broken glass, that might become propelled and cause bodily injury to passersby or damage to property such as windows and vehicles. Make sure that no bystander, animal or obstruction such as a vehicle, building, or street sign are behind the Sweeper when backing up. The design of the Sweeper impairs operator rear vision when backing. Use extreme caution to ensure that the Sweeper is not backed into the path of pedestrian or vehicle traffic Serious injury or death and property damage could result from running into, being crushed by, or run over by a Sweeper. Make sure no bystanders or animals are within 25 feet of the Sweeper when dumping contents from or cleaning the hopper. Hopper contents, which may exceed several thousand pounds, could fall and crush a bystander or an animal resulting in possible injury or death. Do not operate the sweeper or start the auxiliary engine with the sweeper broom cover open or missing. The broom can throw objects or entanglement in the rotating broom can result in bodily injures.
WARNING
DANGER
DANGER
Do not operate the sweeper or start the auxiliary engine with the sweeper cover (doors) open or with the shields removed or missing. Entanglement in the elevator chains and rotating gears can result in serious bodily injures.
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SCHWARZE GS6 SERIES OWNERS MANUAL Stay clear of hopper when it is being dumped. Make sure that no coworkers or bystanders are near the hopper when it is being raised or lowered. Serious injury could result from entanglement with the hopper dump mechanism.
DANGER
Avoid body contact with collected debris in the hopper. Use protective WARNING clothing including gloves and eye protection when servicing or working in or around hopper. Collected debris in the hopper can cut or puncture resulting in serious bodily injuries and the transmittal of diseases. Use extreme caution when operating the Sweeper in traffic. To alert motorist of the Sweepers presence, the Sweeper is equipped with warning signals, flashing lights, and a built-in arrow board. Optional electrical lights, flashers and a warning barlight, strobe, or beacon may be positioned on top of the cab. Use all equipped warning signals to alert motorist and pedestrians of the Sweepers presence and relatively slow speed. Serious injury or death and property damage may occur if a vehicle collides with the Sweeper. Before starting a sweeping operation, make sure all the warning signal lights are connected, visible and working. Routinely inspect the Sweepers headlights, brake lights, backup lights, and turn signal lights for operational condition. Immediately repair non-functioning lighting. Always follow all local traffic regulations while operating the Sweeper. Always turn on all safety lights and flashers when you operate the Sweeper. It is recommended that you preset the beacon/strobe light switches to ON, so lights go on whenever the auxiliary engine is ON and lights go OFF whenever the auxiliary engine is turned OFF. This presetting action has the additional benefit of alerting the operator if the auxiliary engine is inadvertently left ON.
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1.4
WARNING
Do not modify or alter this Sweeper. Do not permit anyone to modify or alter this Sweeper, any of its components or any Sweeper function. Use extreme care when climbing onto the Sweeper to perform repairs, maintenance, and cleaning. Use proper stands and ladders to access areas that cannot be reached from ground level. Slipping and falling off the Sweeper can cause serious injury or death. Never attempt to repair, lubricate, adjust, clean, remove obstructions or perform any other type of service to any Sweeper component while the Sweeper is in motion or while the Auxiliary and/or Truck engine is running. Completely shut down the sweeping components and the Truck and Auxiliary engines and wait for all motion to come to a complete stop before servicing the Sweeper.
DANGER DANGER
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SCHWARZE GS6 SERIES OWNERS MANUAL DANGER Never leave the Sweeper unattended while the hopper bin is in the raised position Accidental operation of the lifting lever or a hydraulic failure may cause a sudden drop of the unit which could result in injury or death by crushing. If the hopper must be raised for a purpose other than the time required to normally dump, or if someone is going to get under the hopper for any reason, always secure the hopper safety prop into position. Never crawl under the hopper bin while the hopper is in the raised position unless properly secured with the safety prop in position. Accidental operation of a lifting lever or hydraulic failure may cause a sudden drop of the unit with injury or death by crushing. Use proper protective equipment (gloves, safety eye wear, face shield, arm protection, possible respirator or particle mask) when handling gutter and sweeper brooms during replacement, adjustment, and maintenance. Broom bristles, which are sharp and coarse, could inflict puncture and stab wounds to the hands, arms, and/or eyes if proper protective equipment is not worn. Never crawl under any raised Sweeper component (gutter broom, sweeper head,suction head, hopper bin) unless the component is securely supported or blocked up and hydraulic pressure relieved. Accidental operation of the lifting lever or hydraulic failure may cause a sudden drop of the unit with possible injury or death by crushing. Escaping pressurized hydraulic oil generated by hydraulic pumps has the potential to inflict serious injury and possible death. Never attempt to repair a pump or hose or tighten a connection while the system is pressurized. Always shut down the Truck and Auxiliary engines and relieve hydraulic oil pressure before performing any repairs to the hydraulic system. Hydraulic pressure must be relieved from the Sweepers hydraulic circuit prior to doing any maintenance or repair work and when the Sweeper is parked at the end of the day. Place the Sweepers gutter brooms, sweeper broom, suction head, and outriggers on the ground or securely blocked up with the safety pins installed. Make sure the hopper bin is lowered onto the chassis or secured in the raised position with the safety prop in position. Turn off the Truck and Auxiliary engines then engage the hydraulic remote cylinders several times to relieve hydraulic pressure prior to performing any maintenance or repair work.
DANGER
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SCHWARZE GS6 SERIES SAFETY WARNING WARNING DANGER WARNING DANGER Water pressure generated by the high pressure water pump has the potential to inflict serious injury and death. Never attempt to repair a pump or hose or tighten a connection while the system is pressurized. Always shut down the Truck and Auxiliary engines and relieve water pressure by activating the system before performing any repairs to the high pressure water system. NEVER work on or near any engine component that has generated heat until it has cooled down. Use extra caution around the exhaust manifold near the water valve and the turbo charger manifold tubes. NEVER check or replenish the fluid levels of the Truck and Auxiliary engine coolant or hydraulic circuit oil levels until sufficient time has passed (up to 2 hours) to allow the system to cool down Contact with a hot engine component or operating fluid may result in serious injury from burns, scalding and possible death. Never remove debris from or unclog jams in the suction hoses, gutter brooms, pickup brooms, and all other areas of the Sweeper until both the Truck and Auxiliary Engines have been completely shutdown, all sweeping components have come to a complete stop and are lowered to ground level and hydraulic pressure relieved. Always wear PPE when removing collected material from the Sweeper. Serious injury or death may occur if any of these precautions are not followed when removing plugged or jammed sweeping components. Use extreme caution when working in confined areas of the hopper bin or water tank for an extended period of time. Confined work areas may pose a danger because of the physical constraints imposed on the body. Routinely exit the confine to stretch and correct posture to prevent physical stress imposed on the body before bodily injury occurs. Use extreme caution when entering confined areas of the hopper bin to perform repairs, maintenance, and cleaning. Depending on any hazardous contents and or fumes contained within the hopper bin, specialized Personal Protective Equipment such as a specialized respirator, artificial oxygen source, and protective body suit may be required. Always use the buddy system when hazardous or oxygen depleting material is contained within the hopper. Never enter an enclosed area without Personal Protective Equipment if contents are unknown, possible injury and death may result if required precautions are not taken.
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SCHWARZE GS6 SERIES OWNERS MANUAL Use extreme caution when refueling the Sweeper, fuel is highly flammable and explosive if not handled safely. Always follow these precautions to reduce the dangers involved in refueling: Completely shut down the Truck and Auxiliary Engines before refueling. Do Not refuel while smoking or near an open flame. Do Not store Sweeper with fuel in the tank in a building where fumes can reach an ignition source. To prevent a fire and explosion caused by static electric discharge while filling the tank, use a plastic funnel. Avoid using a funnel that has a metal screen or filter. Avoid spilling fuel. Fuel is expensive and can damage plastic and painted surfaces. Clean up spilled fuel immediately. Store fuel and all oils at a site protected from moisture, dirt, and other contaminants
DANGER
1. 2. 3. 4. 5. 6. DANGER
Never run the Truck or Auxiliary engine in a closed building or without adequate ventilation. The exhaust fumes can be hazardous and deadly to your health. If it is necessary to run the Truck or Auxiliary engine in an enclosed area, remove the exhaust fumes from the area to the outdoors with an exhaust pipe extension If you do not have an exhaust pipe extension, or if it is not possible to use one (Sweeping within a building), open doors and circulate outside air into the area. Engine Exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the state of California to cause cancer and birth defects or other reproductive harm.
WARNING
DANGER
Do not operate this Sweeper with hydraulic oil or fuel leaking. Oil and fuel are expensive and their presence could present a hazard. Do not check for leaks with your hand! Use a piece of heavy paper or cardboard. High-pressure oil streams from breaks in the line could penetrate the skin and cause tissue damage including gangrene. If oil does penetrate the skin, have the injury treated immediately by a physician knowledgeable and skilled in this procedure. Always read carefully and comply fully with the manufacturers instructions when handling fuels, oils, solvents, cleansers, and any other chemical agent.
WARNING
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SCHWARZE GS6 SERIES SAFETY Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the state of California to cause cancer and birth defects or other reproductive harm. Wash Hands after handling.
WARNING
WARNING
Remove the negative battery cable from the battery before performing any maintenance on the electrical system to prevent an accidental circuit shorting and sparks. Sparks can result in wiring damaged, fire or personal injury.
DANGER WARNING
Use caution when working around the hopper doors. Do not let the doors fall uncontrolled onto bystanders or coworkers. Use the door locks to hold the doors open while cleaning or performing maintenance in or around the hopper. Before conducting maintenance on the sweeper stop the truck, place the transmission in park and set the parking brake. Turn the Truck engine and the auxiliary engine off and remove the keys to prevent inadvertent or accidental starting of the engines. Unexpected engine start up or truck movement can result in serious bodily injuries or death.
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1.5
Sec. 5 (a) Each employer (1) shall furnish to each of his employees employment and a place of employment which are free from recognized hazards that are causing or are likely to cause death or serious physical harm to his employees; (2) shall comply with occupational safety and health standards promulgated under this Act. (b) Each employee shall comply with occupational safety and health standards and all rules, regulations and orders issued pursuant to this Act which are applicable to his own actions and conduct. OSHA Regulations OSHA regulations state in part: At the time of initial assignment and at least annually thereafter, the employer shall instruct every employee in the safe operation and servicing of all equipment with which the employee is, or will be involved.
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SCHWARZE GS6 SERIES SAFETY Employer Responsibilities: To ensure employee safety during Truck and Sweeper operation, it is the employers responsibility to: 1. Train the employee in the proper and safe operation of the Truck and Sweeper. 2. Require that the employee read and fully understand the Truck and Sweeper Operators manual. 3. Permit only qualified and properly trained employees to operate the Truck and Sweeper. 4. Maintain the Truck and Sweeper in a safe operational condition and maintain all shields and guards on the equipment. 5. Ensure the Truck is equipped with a functional seat belt and require that the employee operator securely fasten the safety belt at all times. 6. Forbid the employee operator to carry additional riders on the Truck or Sweeper. 7. Provide the required tools to maintain the Truck and Sweeper in a good safe working condition and provide the necessary support devices to secure the equipment safely while performing repairs and service. 8. Require that the employee operator stop sweeping if bystanders or passersby come within 25 yards. Child Labor Under 16 Years of Age Some regulations specify that no one under the age of 16 may operate power machinery. It is your responsibility to know what these regulations are in your own area or situation. (Refer to U.S. Dept. of Labor, Employment Standard Administration, Wage & Home Division, Child Labor Bulletin #102.)
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SECTION 2
GS6 SERIES
SYSTEM & COMPONENT
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2.1
Specifications
2.1.1
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2.1.2
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2.1.3
Sweeper Specifications
General Specifications: Sweeping Width (2 Gutter Brooms)....................134 (3,505 mm) Sweeping Width (1 Gutter Broom).....................107 (2,896 mm) Sweeping Width (Pickup Head Only)...................80 (2,286 mm) Travel Width....................................................................96 inches Height.............................................................................114 inches Hopper Lifting Capacity..................................................10,000 lb. Minimum GVWR............................................................26,000 lb. Wheelbase........................................................Chassis-Dependent Chassis: A selected truck chassis is provided to give adequate ratings of all components compatible with hopper capacity. Option of cab over or conventional type. Turning radius and wheelbase dependent on chassis and hopper size. Consult factory for detailed requirements. Hopper: Volumetric Capacity.....................................7.8 cu. yds. (5.96 m3) Dump Angle...............................................................................46 Floor Angle..................................................................................3 Dust Separator........................................Self-Cleaning Centrifugal Lifting....................................................Twin Hydraulic Cylinders Hopper Dump Door.....................Open/Close/Lock Hydraulically Inspection Doors.........................One on Each Side of the Hopper Material........................................Stainless Steel with 3/16 Floor Safety Prop..........................Dual Steel Bars Located Under Body Blower System: Drive...........................Direct via a 5-Groove, Banded Power Belt Construction............................................Abrasion Resistant Steel Housing Liner...........................................Bolt-In Corded Rubber Mounting......................................Double Sealed Bearing Spindle Vacuum Enhancer................................For Heavy / Light Material Sweeping Head: Type............................Dual Chambered, Full-Width Blast Orifice Operating Direction......................................Forward and Reverse Suspension.........................................Adjustable Spring-Balanced Length...................................................................80 (2,286 mm) Pressure Hose Diameter........................................14 (355.6 mm) Suction Hose Diameter.........................................14 (355.6 mm) Hose Construction...................................................3/8 (9.5 mm) Wire-Reinforced Molded Rubber Sweeping Head Area............................2,000 sq. in. (12,903 cm2) Controls................................................Hydraulic Open and Close Skids.............................................Double Wide Tungsten Carbide Construction............................................Abrasion-Resistant Steel Inlet and Outlet Transitions Electrical System: Voltage................................................................................24 Volt Auxiliary-Engine Alternator........................................45 Amperes Protection..........................................Re-Settable Circuit Breakers Water System: Tank Capacity...........................................250 Gallons (946 liters) Construction..............................................................Polyethylene Pump........................................5 Stage Diaphragm Electric Pump Controls...............................................................................In-Cab Filter..................................................200 Mesh Screen, Cleanable Fill Diameter........................................................2.5 (63.5 mm) Fill Hose.......................25 ft. w/ 2.5-inch NST Hydrant Coupling Mounting......................................................................Removable Low-Water Warning...............................................Indicator Light Gutter Broom(s): Type................................................5-Segment Plastic Disposable Location....................Right and Left, Forward of Sweeping Head Diameter...................................................................39 (991 mm) Drive...........................Hydraulic Torque Motor with Relief Valve Controls...............................................................................In-Cab Broom Material.............................................Vertical Steel Digger Mounting.......................................................Trailing Arm Design Suspension.................................................Torque-Sensing Spring Wear Adjustment...........................................................Automatic Speed.......................................................Variable, Non-Reversing Impact Protection.................................................................Spring Tilt Angle Adjustment.....................Manual or Remote (Optional) Hydraulic System: Pump Capacity..........................................6.9 gpm (26.1 L / min.) Drive............................................................................Direct Gear Maximum Pressure........................................2,500 PSI (172 bar.) Reservoir.....................................................................22.5 gallons Filter................................................................10-Micron Spin-On Controls..............................................................Electro Hydraulic Valve Banks.........................................Electrical Cartridge Valves Protection.....................................................Pressure Relief Valve Auxiliary Hydraulic System: Type.....................................Gear Type, Driven by Electric Motor Function...................Raise / Lower Hopper, Open / Close Hopper Door, Raise Brooms and Sweeping Head. Paint: One coat of sealer primer and 2 coats of DuPont Imron 5000 polyurethane in standard white color. Optional Equipment: Dual steering, cab-mounted barlight beacon, arrow board, washdown system, special lighting, ether cold starting aid, engine block heater, load weight indicator, automatic lube system, and others. Consult the factory for a listing of all currently available options.
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2.2
SCHWARZE GS6 SERIES OWNERS MANUAL Once inside the hopper, a number of strategically placed water nozzles may be used to decrease the amount of airborne dust. As the dust comes in contact with the water spray, it becomes heavy. The dust and debris-laden air slows down when entering the large volume of the hopper, so heavier objects fall to the hopper bottom. The air is then drawn through a screen in the top of the hopper that removes any remaining lighter objects. Only fine particles of dust remain to be pulled through the screen and into the dust separator in the front of the hopper. As air is pulled from the dust separator by the fan, it develops a spiraling action and centrifugal force throws the remaining fine dust against the walls of the separator, returning it through slots to the hopper bottom. The fan then draws the cleaned air from the dust separator back into the fan housing and the cycle begins again. For your convenience and safety, the Schwarze GS6 sweeper is controlled via a console located in the cab of the truck. This console allows for remote operation of the hydraulic, dust suppression, and lighting systems, as well as the sweepers auxiliary engine. This outside panel safely positions the operator away from the rear of the sweeper, and allows adequate viewing of the dump area. Your new Schwarze GS6 sweeper may also be factory equipped with a number of options. In addition, some options may be added to the sweeper after leaving the factory. For more details about the many available options, contact a Schwarze Industries sales representative at 1-800-879-7933.
2.3
Hydraulic System
The hydraulic system is comprised of electrical control switches, hydraulic pumps, control valves, hoses, motors and hydraulic cylinders. Energy is transmitted from the sweepers auxiliary engine to the hydraulic pump unit by means of a direct-drive gear. The pump unit circulates pressurized fluid through hoses and control valves throughout the system. The hydraulic system is controlled by electrical switches mounted on the control panel in the trucks cab. These switches control the hydraulic control valves mounted on a manifold, which route the flow of high pressure hydraulic fluid. The hydraulic manifold is internally configured with the directional valves positioned in series. The directional valves control hydraulic functions for the hopper, sweeping head, right gutter broom and left gutter broom. An auxiliary hydraulic unit, consisting of a separate hydraulic pump and control switches, enables the sweepers hydraulic devices to function when the power module engine is not operating. The unit is mounted to the sweeper frame just behind the power module and connected to the sweepers hydraulic system. This auxiliary system is intended to be used for maintenance applications and in emergency conditions. The auxiliary hydraulic pump is needed if the power module engine runs out of fuel or when an emergency shutdown situation occurs. Without it, the sweeper head, brooms and any other device which normally function when the power module engine is running would not operate. The auxiliary unit can be used to power the broom out or in, raise the sweeper head, raise the hopper or open the hopper door for maintenance or cleaning. Under normal sweeper operating conditions, the main hydraulic unit mounted on the power module should be used to operate these hydraulic devices.
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2.4
Electrical System
The Schwarze GS6 employs a standard 24 volt electrical system. The system is protected by an 80 ampere, self-resetting circuit breakers (attached to the battery box) and resettable circuit breakers (in the console box).
2.4.1
In addition to other safety features, a backup warning alarm is standard. The high-pitched backup alarm warns bystanders that the sweeper is moving in reverse.
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2.5
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2.6
Console
The central control panel is mounted in a console in the truck cab. For operator safety and convenience, all controls are within easy reach of the driver/operator, whether operating from the left or right side position. This console allows remote operation of all hydraulics, dust control water systems and lighting systems, as well as the power module engine for the sweeper. These controls are all electrically operated. All electrical elements in the system are protected by resettable circuit breakers. In addition, to the controls on the sweepers console, there is a digital engine control system to monitor many items such as tachometer, oil pressure gauge, water temperature gauge, hour meter, and voltmeter.
2.7
2.7.1
Auxiliary Engine
The sweeper engine, which is diesel-powered, is mounted on an adjustable frame tray called the engine skid, and is normally fueled by the trucks main fuel tank. Power produced by the engine is transmitted to the fan by a drive belt. For safety and convenience, all controls and gauges for the sweeper engine are located inside the cab on the central console. For detailed information on the sweepers engine, consult the engines Owners Manual which is attached separately.
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2.7.2
2.7.3
Fan
The Schwarze-exclusive Whisper Wheel SM is a centrifugal, backward curving fan. This unique design results in reduced fan noise and requires less auxiliary engine horsepower to operate. The fan produces the air pressure and vacuum required for the sweeper to operate. It is a balanced, reinforced, abrasion-resistant fan on a bearing-mounted drive shaft. Construction is of heavy steel. The fan is propelled by the power module engine, and is located within the fan housing attached to the rear of the power module.
WARNING
Air enters the fan housing inlet with great force. Caution should be used when the power module is running and the hopper is up. To avoid being pulled into the fan, do not wear loose clothes or position yourself near the fan housing inlet.
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2.7.4
Fan Housing
The fan housing is mounted to the rear of the power module. Because of the sand blast effect of the airborne material traveling through the dust separation chamber and into the fan housing, the inside of the fan housing is protected by a bolt-on replaceable rubber liner. A sweeping condition bleeder, located in the fan housings snout, can be used to restrict the flow of air entering the sweeping head. The bleeder is a damper door operated by an electric actuator. A switch on the control panel console mounted in the truck cab operates the actuator. During normal operating conditions, the bleeder door is closed and air from the fan is forced into the sweeper head. In sweeping conditions where there are concentrations of leaves or other light debris, the force of the blast orifice air pushing against the rear side of the main curtain prevents light debris from entering the head. By opening the bleeder door, air from the fan is diverted away from the sweeping heads pressure chamber and exhausted out of the sweeper. The air flow pressure is decreased in the pressure chamber and blast orifice, which relieves pressure against the rear side of the main curtain. This allows light debris to push under the main curtain and into the sweeper head.
2.8
Sweeping Head
The sweeping head is the actual sweeping component of the air sweeper. It is attached to the underside of the frame by drag arms, tension springs, and two hydraulic cylinders that are mounted on each side of the sweeper head. The hydraulic cylinders and tension springs control the vertical movement of the head. A switch mounted on the control console in the truck cab operates the cylinders. The sweeping head is connected to the fan housing and hopper by two hoses, one on the pressure side and one on the vacuum side. On the pressure side, the hose runs from the fan housing to the pressure inlet tube on the head. One end of the vacuum hose is connected to the suction inlet tube on the head, and the other end attaches to a frame transition tube that the hopper intake tube seats against. Both hoses are held in place by a metal band at the top and bottom of each hose.
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2.8.1
2.9
Hopper
The sweepers hopper is designed to contain the materials collected during the sweeping operation. It is constructed of heavy gauge steel and shaped to distribute the load evenly and centrally over the rear axle. A welded frame mounted on the truck chassis supports the hopper, as well as the hydraulic cylinders which enable it to dump directly behind the rear wheels. Access doors on both sides of the hopper allow objects too large to be picked up by the sweeper head to be placed directly into the hopper. These side access doors also provide a clean, convenient means of washing out the hopper.
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2.10
Available Options
The following sections detail options that may be installed on your particular sweeper. Gutter Brooms Gutter Broom Extension Override (GEO) Dual Steering Front Spray Bar Camera System Hopper Deluge Hand Hose Hopper Drain Magnet Sound Suppression Package High Volume Washdown Load Weight Indicator Power Tilt Availability of options may change without notice. Please consult your Schwarze dealer for a list of currently available options.
2.10.1
Gutter Brooms
The Schwarze GS6 may be equipped with one or two rotating hydraulic brooms to complement the air sweeper system. They are designed to dig debris loose from the gutter, or similar areas, and direct it across into the path of the sweeping head. Brooms may be mounted on both the left and right sides of the sweeper under the chassis, to the rear of the cab. They are suspended from the frame on hydraulically controlled arms, and are operated from the control console within the truck cab. The hydraulic motors which turn the broom heads are mounted inside a disc on the end of each arm. When not in use, the brooms are hydraulically held and locked in position under the sweeper and off the pavement. This unique design enables the sweeper to have a minimum width and yet provide the maximum ground clearance possible when the brooms are in the traveling position.
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2.10.2
2.10.3
2.10.4
Dual Steering
The dual steering components in the truck are designed to allow the driver/operator to drive the sweeper from either the right or left side. The major components, which are duplicated on both sides are the steering wheels and columns (with self-cancelling turn signal levers), the brake pedals and the accelerators.
2.10.5
Camera System
The optional camera system may be used to increase an operators field of vision. A camera is mounted below the right water reservoir just behind the gutter broom. The camera is mounted to point forward and down. This angle allows observation of the gutter brooms operation as well as provides a view of approaching curb line obstacles. A second camera, mounted at the rear of the hopper, views what is directly to the rear of the sweeper. When the sweeper is shifted into reverse, the picture on the dash-mounted monitor automatically switches to the rear view. Both cameras provide a wide field of vision.
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2.10.6
Hand Hose
A hand hose designed to clean areas inaccessible to the sweeper head, such as shallow catch basins, highway medians, railings, etc., may be attached to the rear of the sweeper. It operates from fan-produced vacuum within the hopper. The hand hose is a piece of flexible tubing that is 12-1/2 feet long and 8 inches in diameter. One end is mounted to a transition plate, which pivots across a hole in the rear of the hopper. The free end is fitted with a 52-inch aluminum nozzle. A hinged boom suspends the weight of the hose, providing the operator with greater control. A suction inlet block-off plate, stored on the side of the power module, is used to increase suction when a very heavy concentration of debris must be removed.
2.10.7
Magnet
A magnet may be mounted to the front of the sweeper to remove objects that may damage truck tires and cause down time for the sweeper. Two types of magnets are available: A bar magnet, which is raised and lowered using an electric actuator. Objects picked up by this type of magnet must be removed manually. An encased magnet, which uses actuators to raise and lower as well as dump objects from the bottom of the magnet.
2.10.8
2.10.9
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2.10.10
Hopper Deluge
A tube protruding from the outer skin of the rear dump door is connected to two large water nozzles positioned inside the hopper. A 2-1/2 fire hose, supplied with the hopper deluge system, may be attached to both the tube and a fire hydrant. When the hydrant is opened, the inside of the hopper is washed with a massive amount of pressurized water. This deluge blasts free most dirt and stubborn grime adhering to the inside of the hopper and hopper screen, simplifying and shortening the sweepers cleanup.
2.10.11
Hopper Drain
Although certain instances may require that liquid picked up by the sweeper be removed to a specified dump site. Often, it would be preferable to return any unwanted liquid, such as rain water, to the sweeping surface to reduce load weight/mass and permit longer dumping intervals. An optional drain located in the rear door offers the capability of draining liquid from the hopper while the sweeper is operating. This allows the sweeper to be operated in a business-as-usual fashion even during wet weather.
2.10.12
2.10.13
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SECTION 3
GS6 SERIES
SWEEPER OPERATION
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3.1
3.1.1
Included with this manual is a Maintenance Schedule Photocopy Originals Pack. We suggest that you remove the master copy from this binder and store it in a file to keep it accessible and clean. Photocopies can then be made to use for regular inspections, and the completed forms can be compiled in a notebook to give you a comprehensive inspection record of your sweeper.
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3.1.2
3.2
3.2.1
Console Controls
Sweeping operations are controlled from the cab console control panel. Switches toggle differently depending upon the sweeper devices they control. Most sweeper devices requiring simple activation and deactivation are operated with 2-position ON and OFF switches. These devices perform the following functions: Safety features (warning lights and safety flashers) Dust Suppression Other devices require a 3-position switch. These switches are used for components which employ extension and retraction or direction reversal. In many instances, one or both of the activation positions are momentary ON, meaning the switch will stay in that position only as long as it is manually held there. When released, the switch will automatically return to the center OFF position. On the following page is a table which lists the sweeper functions and their switch positions.
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3.2.2
WARNING
Before starting the engine in a confined area, verify that proper outlet exhaust ventilation equipment is installed. Always use safety approved fuel storage and piping.
1. 2.
Perform all pre-starting checks in the Start-Up Checklist. Turn the key switch clockwise to crank the engine.
3.
CAUTION
A buzzer will sound until the auxiliary engine reaches operational oil pressure.
When the engine starts, release the key so that it returns to the ON position. The sweeper is equipped with a shutdown system that requires a 10 second delay before attempting to restart the auxiliary engine. To prevent possible damage to the starter and/or flywheel: If you release the key switch BEFORE the engine starts, you MUST wait until the starter and engine come to a complete stop before attempting to restart the auxiliary engine.
CAUTION 4.
Activate the electric throttle. Check all gauges for normal engine operation. If operation is not normal, stop the engine and try to determine the cause of the problem.
5.
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CAUTION 1. 2.
To assure proper lubrication, warm the engine by operating it at 1200 RPM with NO LOAD for 1 to 2 minutes. When operating at temperatures below freezing, extend this period to 2 to 4 minutes.
Check the oil-pressure gauge as soon as the engine starts. If the gauge needle does NOT rise above the minimum oil-pressure specification of 103 kPa (1.03 bar; 15 PSI) within 5 seconds, stop the engine and try to determine the cause of the insufficient oil pressure. Normal engine oil pressure is 380 103 kPa (3.80 bar 1.03 bar; 55 15 PSI) at rated full-load speed (1800-2500 RPM) with oil at the normal operating temperature of 105 C (220F). Watch the coolant temperature gauge. Do NOT place the engine under full load until it is properly warmed up. The normal engine coolant temperature range is 82-94C (180-202F).
We advise operating the engine under a lighter load and at lower speeds than normal for the first few minutes after start-up.
IDLING THE ENGINE Avoid unnecessary engine idling and NEVER allow the engine to idle longer than 5 minutes. Prolonged idling could cause the engine coolant to fall below its normal range, in turn causing the following conditions: Crankcase oil dilution due to incomplete fuel combustion Formation of gummy deposits on valves, pistons and piston rings Rapid accumulation of engine sludge and unburned fuel in the exhaust system
Slow idle for this engine is set at 850 RPM at the factory. If you must leave the engine running more than 3 or 4 minutes, make sure the engine speed is at 1200 RPM.
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3.2.3
WARNING
In all sweepers containing the dual steering option, a switch must be toggled to designate the steering position that is to be empowered. Depending upon the truck model, this switch may be located in either the trucks dash or sweeper console.
WARNING
For travel, the sweeper must be driven from the left side only.
3.2.4
1. 2.
The auxiliary engine must be running, or the ignition switch turned on and the auxiliary pump switch held in the On position, before operating the sweeping head switch.
Push the switch so that the sweeping head lowers. Continue to hold the switch until the sweeping head rests fully on the sweeping surface. When the switch is released, it will return to the center, neutral position. To raise the sweeping head, push the switch in the opposite direction, continuing to hold the switch while the sweeping head raises. When the sweeping head bottoms against the upstops, release the switch. Again, it will return to the center, neutral position.
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SCHWARZE GS6 SERIES SWEEPER OPERATION 3. 4. The front flap is controlled by a control panel switch on the cab console. The switch is identified by the legend symbol shown below.
RAISE LOWER
The sweeping head is equipped with a front flap that is opened and closed hydraulically. To open the front flap, hold the front flap open switch. The in-cab indicator will show you the position of the flap. The flap may be raised to prevent leaves or light debris from being pushed in front of the head by the flap when it is down. Once the desired position is attained, release the switch. Closing the front flap is accomplished by using the same procedure and actuating the opposite side of the switch.
3.2.5
Light/Heavy Operation
The bleeder door is controlled by a control panel switch on the cab console. The switch is identified by the legend symbol shown below.
The control panel switch controls an actuator that opens and closes a damper door located in the exhaust of the fan housing, which may be used to direct all of the airflow down the pressure hose and into the head, or to divert a portion of the airflow to an exhaust located directly beneath the fan housing.. Only in instances of light debris or leaves is the bleeder door opened. For normal sweeping of curb and gutter streets, the damper door should be in the heavy or just slightly open position. This directs all or most of the airflow to the sweeping head, producing maximum blast in the sweeping heads blast orifice. When sweeping leaves or other light material, the damper door should be in the light position, allowing some of the airflow to be exhausted. This decreases the volume of airflow through the blast orifice, reducing the air pressure exerted against the rear of the front curtain and permits debris to pass beneath the front curtain more easily. It is possible to sweep both light and heavy material in one pass. This is accomplished by opening and closing the damper as you sweep. By practicing this method, you will become proficient with the various types of material.
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3.2.6
Gutter Broom EXtension Use the following procedure to operate the gutter broom under normal conditions in which street gutters are accessible. The gutter brooms are designed to be full-floating. If you encounter an obstruction on the surface, the broom automatically lifts to go over it. As broom bristles wear away, the broom lowers to maintain contact with the surface. 1. 2. Start the auxiliary engine by following the procedures outlined in Section 2.2.2, AUXILIARY ENGINE START-UP. Push the gutter broom switch(es) down to the RUN position. The gutter broom is lowered to the ground, begins to run, and extends to its normal operating position for sweeping.
OPTIONAL GUTTER BROOM EXTENSION OVERRIDE (GEO) The next part of the procedure concerns use of an optional feature that allows you to adjust a gutter broom from its normal operating position inward, toward the centerline of the truck, so it can scrub the area the main broom will sweep. This feature is helpful if you encounter stubborn debris stuck to the surface in the path of the main broom.The gutter broom GEOs are controlled by a control panel switch located on the cab console. The switch is identified by the legend symbol shown below.
3. 4.
Toggle the gutter broom GEO switch up for retracting the gutter broom. The gutter broom will retract inward, toward the centerline of the truck, where it can pre-scrub material stuck to the surface in the path of the sweeping head. To return a gutter broom to its normal operating position, toggle the gutter broom GEO switch down. This will extend the broom. The gutter broom extends outward to its normal operating position for sweeping.
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SCHWARZE GS6 SERIES SWEEPER OPERATION OPTIONAL GUTTER BROOM TILT CYLINDER The next part of the procedure concerns an optional feature the gutter broom tilt cylinder. Control panel switches on the cab console activate cylinders on a gutter broom arm. If this sweeper has this feature, the operator is able to control the angle of broom-disc tilt via these switches. If your sweeper does not include this feature, proceed to GUTTER BROOM RETRACTION. The gutter broom remote tilt is controlled by a control panel switch located on the cab console. The switch is identified by the legend symbol shown below. Note: The gutter broom must be down and running to activate the tilt function.
5. 6.
Toggle the gutter broom tilt switch to the UP position, and hold the switch in that position until the broom is tilted to the desired angle. Release the gutter broom tilt switch. When you release the switch it returns to the center, neutral, OFF position. Resume sweeping operations. After the curb is scrubbed, toggle the gutter broom tilt switch in the opposite direction and hold the switch in that position until the broom is correctly tilted for its normal sweeping pattern. Release the gutter broom tilt switch. When you release the switch it returns to the center neutral OFF position.
7. 8.
NOTE: The gutter brooms must be on the ground running to actuate gutter broom tilt. For optimum travel clearance, always return the broom tilt to normal tilt before retracting the broom.
GUTTER BROOM RETRACTION 9. 10. On the cab console control panel, toggle the gutter broom switch to OFF. The broom stops rotating but will remain extended to its normal operating position. On the cab console control panel, toggle the gutter broom switch to the UP position. Hold the switch in the UP position until the broom is fully retracted.
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3.2.7
Hopper Operation
Two sets of controls one located on the control panel inside the cab and one mounted to the front of the power module are provided for hopper operation. When dumping, always use the outside set of controls. By being out of the cab and to the side of the sweeper, the operator is provided a better view of the dumping operation. To ensure that this safer dumping procedure is followed, unless specially equipped, the outside hopper control set is the only one that contains the switch that allows the opening of the rear dump door. The in-cab hopper control consists of a single dump switch. This switch is for maintenance convenience and must only be used to raise or lower the hopper. IN-CAB HOPPER CONTROLS The hopper may be raised and lowered by a control panel switch located on the cab console. The switch is identified by the legend symbol shown below.
CAUTION
The auxiliary engine must be running, or the ignition switch turned on and the auxiliary pump switch held in the ON position, before operating the hopper dump switch. Due to the electrical load generated when using the auxiliary pump, it is best to run the auxiliary engine whenever possible.
CAUTION
This switch should only be used to raise or lower the hopper for maintenance purposes, never to dump the hopper.
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SCHWARZE GS6 SERIES SWEEPER OPERATION 1. Push the cab console control panel switch to the UP position. After a momentary pause the hopper will begin to raise. Continue to hold the switch in the UP position until the hopper has been raised. When the switch is released, it will return to the center neutral position.
If the safety prop has been lowered into place, it must be returned to its travel position before attempting to lower the hopper.
2.
To lower the hopper, push the cab console control panel switch in the DOWN position. Continue to hold the switch to the DOWN position until the hopper has firmly seated itself against the intake and fan seals.
OUTSIDE HOPPER CONTROLS (optional) The outside hopper controls are located on the front of the power module just behind the cab.
1. 2.
The auxiliary engine must be running, or the ignition switch turned on and the auxiliary pump switch held in the ON position, before operating the hopper dump switch. Due to the electrical load generated when using the auxiliary pump, it is best to run the auxiliary engine whenever possible.
Start the auxiliary engine following the procedures outlined in Section 2.2.2, AUXILIARY ENGINE START-UP. Locate the outside hopper control panel and note the three switches labeled DUMP, DOOR and LIGHTS.
The rear dump door must be opened first, and closed last, in the dump procedure.
3.
Toggle the LIGHTS switch to the ON position. Push the DOOR switch to the UP position. Continue to hold the switch in the UP position until the rear door is fully raised. When the switch is released, it will return to the center neutral position.
4.
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CAUTION
To ensure safe dumping, always use the outside hopper dump controls.
5.
Push the DUMP switch to the UP position. Continue to hold the switch in the UP position until the hopper is fully raised. When the switch is released, it will return to the center neutral position.
WARNING
If you open the rear door or raise the hopper for more time than is normally required to dump, or you are going to get under the hopper for any reason, always secure the safety props into position.
The hoppers safety prop is accessible when the hopper is completely raised. It is located in the left fender well. It is designed to unhook from its retainer on the hopper frame and swing down into a stop on the frame. A handle is provided to aid the operator in positioning the prop into the stop.
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3.2.8
Magnet Operation
The magnet is controlled by a control panel switch located on the cab console. The switch is identified by the legend symbol shown below.
If the magnet is to be lowered or raised, the ignition switch must be turned to the ON position.
1. 2.
Push the cab console control switch to the DOWN position. Continue to hold the switch in the DOWN position, holding it in place for a few moments to be sure the magnet has fully lowered. The magnet will automatically stop when it reaches the proper distance from the ground. When the switch is released, it will return to the center, neutral, position. Begin sweeping. When the magnet is no longer required, push the cab console control switch to the UP position, holding it in place until the magnet is fully raised.
3.
If the unit is equipped with an encased magnet, material on the bottom of the magnet may be dumped by operating a control panel switch located on the cab console. The switch is identified by the legend symbol shown below.
This switch controls an actuator which lifts the inner magnet from the bottom of the outer case, releasing any objects which have been attracted there. If the unit is equipped with one of the bar type magnets, objects must be manually removed.
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3.2.9
If the boom is hydraulic, the auxiliary engine must be running to power the hydraulics.
2.
To release the hand hose boom from its catch, choose one:
If the boom contains a spring, pull down on the hose and swing the boom free. If the boom contains an hydraulic cylinder, use the toggle switch located in the hand hose handle to extend the cylinder. Lower the end of the boom, allowing it to swing free of its catch. 3. Locate the hopper transition cover plate in the upper right corner of the rear door. Pull down on the handle latches on either side of the hopper transition cover plate. Swing it open and to the far right. Now swing the hose suction transition plate to cover the hole in the hopper door. Secure the hose suction transition plate in place, using the handle latches
4. 5. 6.
WARNING
Never point the hand hose nozzle toward another person. Serious injury could result!
When a very heavy concentration of debris must be removed, installation of the block-off plate may be needed. The plate is used to block off the hoppers intake tube, resulting in an increase in hand hose suction. The plate is stored on the right side of the power module. 7. 8. Locate the block-off plate inside the toolbox at rear of truck. Remove the block-off plate from the toolbox.
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WARNING
Never insert the block-off plate while the engine is running at high RPMs. Keep hands away from dangerous pinch area.
9. 10.
Raise the hopper (see Section 2.4.2, HOPPER OUTSIDE CONTROLS) just enough to insert the block-off plate onto the top of the frames transition. Lower the hopper.
When using the hand hose in or around water, never hold the end of the nozzle completely under the waters surface. Doing so will draw water up into the nozzle until the water pressure is equal to the suction within the hopper. When this occurs, the blower fan cannot draw air through the fan inlet and all suction is lost. Position the nozzle to where both liquid and air are vacuumed
3.2.10
1. 2. 3. 4.
Locate the labeled warning light and/or flasher switch(es) on the cab console control panel. Toggle the switch(es) to ON. Complete the sweeping operation. On the cab console control panel, toggle the warning light and/or flasher switch(es) to OFF.
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3.2.11
3. 4. 5.
On the cab console control panel, locate the switch(es) for the nozzle(s) needed for spraying in this operation. Toggle the dust suppression switch(es) to ON. Begin the sweeping operation. When the sweeping operation is complete, toggle the dust suppression system switches to OFF. If certain nozzles are regularly used in sweeping operations, leave those nozzles ON when you turn off the water system (by toggling the water-pump switch to OFF).
7.
Toggle OFF the switch for the water-pump electric drive motor.
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3.3
Sweeping
WARNING Use the right side steering only for sweeping, and never for travel exceeding 15 MPH.
The following assumes that this sweeper is equipped with dual steering, and is being used for a standard application, i.e., pavement and street cleaning. When driving to or from a job site, the driver should operate the truck from the left side. It is both safer and easier to operate at highway speeds from the left side; right side operation should be reserved only for sweeping operations. 1. 2. Stop the truck in a safe area and set the parking brake. Take the truck transmission out of gear (putting it in neutral). From the cab console control panel, toggle the warning light and safety flasher switches to the ON position. Temporarily exit the cab to attach the slow moving vehicle emblem to the rear of the sweeper. Realign the sweepers mirrors for the right hand steering position. Switch driving positions, being sure to toggle the dual steering switch so that the right steering position is empowered. Begin sweeping operations.
3. 4. 5.
6. 7.
WARNING
Slow down for corners, parked cars, and when near protruding posts and other solid obstacles that could cause damage to the sweeper or truck.
Objects which are too large to be drawn up through the vacuum tube should be avoided or picked up by hand. Unless they are very large, these items can be deposited into the hopper through the side access door. Sweeping through standing water or over wet pavement will not damage the sweeper. An advantage of this sweeper is that it will rapidly sweep up large amounts of water. This adds even more versatility to the machine. Under conditions where there is a large amount of water on the pavement, the hopper will need to be emptied more frequently.
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3.4
Dumping
GETTING TO THE DUMP SITE
WARNING
Use the right side steering only for sweeping, never for travel exceeding 15 MPH.
If you are operating the sweeper from the right side and the dump site is NOT at the sweeping site, do the following: 1. 2. 3. 4. 5. Stop the truck in a safe area and set the parking brake. Take the truck transmission out of gear (putting it in neutral). From the cab console control panel, toggle the warning light and safety flasher switches to OFF. Temporarily exit the cab to remove the slow moving vehicle emblem. Realign the sweepers mirrors for the left hand steering position. Switch driving positions, being sure to toggle the dual steering switch so that the left steering position is empowered.
6.
1. 2. 3.
CAUTION
Check the overhead clearances before lifting the hopper. Never move the sweeper with the hopper in the raised position.
Drive to a firm level surface at the dumping site. Set the parking brake. Take the truck transmission out of gear (putting it in neutral). If the auxiliary engine has been shut down for travel, restart the auxiliary engine following the procedures outlined in Section 2.2.2, AUXILIARY ENGINE START-UP. Adjust the auxiliary engine throttle to approximately 1200 RPM.
4. 5.
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CAUTION 6.
The auxiliary engine must be running, or the ignition switch turned on and the auxiliary pump switch held in the ON position, before operating the hopper dump switch. Due to the electrical load generated when using the auxiliary pump, it is best to run the auxiliary engine whenever possible. To ensure safe dumping, always use the outside hopper dump controls.
Locate the outside hopper control panel and note the three switches labeled DUMP, DOOR and LIGHTS.
In the dumping procedure, the rear dump door must be opened first and closed last.
7.
Toggle the LIGHTS switch to the ON position. Push the DOOR switch to the UP position. Continue to hold the switch in the UP position until the rear door is fully raised. When the switch is released, it will return to the center neutral position. Push the DUMP switch to the UP position. Continue to hold the switch in the UP position until the hopper is
8. 9.
WARNING
If you open the rear door or raise the hopper for more time than is normally required to dump, or you are going to get under the hopper for any reason, always secure the safety props into position.
The hoppers safety prop is accessible when the hopper is completely raised. It is located in the left fender well. It is designed to unhook from its retainer on the hopper frame and swing down into a stop on the frame. A handle is provided to aid the operator in positioning the prop into the stop.
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SCHWARZE GS6 SERIES OWNERS MANUAL 10. 11. 12. Once the hopper has been emptied of debris, push the DUMP switch to the DOWN position. Continue to hold the switch in the DOWN position until the hopper is fully lowered and rests against the fan and intake seals. When the switch is released, it will return to the center, neutral, position. Push the DOOR switch to the DOWN position. Continue to hold the switch in the DOWN position until the rear door has completely closed. When the switch is released, it will return to the center neutral position. Toggle the LIGHTS switch to the OFF position.
3.5
WARNING
Exercise caution when cleaning moving mechanisms. Before you begin this operation, verify that: The truck is out of gear The parking brake is engaged
NEVER work under a raised hopper without lowering the safety prop into position. Allow at least half an hour at the end of a days sweeping to properly clean the unit.
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SCHWARZE GS6 SERIES SWEEPER OPERATION 1. 2. While engines cool down at fast idle, on the outside hopper controls, toggle the following switches: Door: OPEN Hopper: UP The rear door opens and the hopper raises. On the cab console control panel, toggle the following switches: Left gutter broom: RUN Right gutter broom: RUN The brooms drop and extend to their normal operating position. After the brooms are lowered to the sweeping surface, toggle the following switches: Left gutter broom: OFF Right gutter broom: OFF Do NOT raise the brooms. Thoroughly hose down the brooms, center dirt deflector, sweeping head and hopper. While the hopper is raised, wash the inside of the sweeping heads suction hose. On the cab console control panel, toggle these switches in the following sequence: Left gutter broom: UP Right gutter broom: UP The gutter brooms retract to their travel positions. On the outside hopper controls, toggle the following switches: Door: CLOSE Hopper: DOWN The rear door closes and the hopper lowers. Turn the auxiliary engine OFF. Hose down the unit to completely rinse away all dirt and dust. When you rinse off the auxiliary engine, do NOT spray water directly into the pre-cleaner.
3.
4. 5. 6.
7.
8. 9.
CAUTION
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SCHWARZE GS6 SERIES OWNERS MANUAL 10. 11. 12. 13. Clean away debris that may have become wound around the gutter brooms. Lubricate all daily lubrication points (see Section 3.4, LUBRICATION SCHEDULES). Check the odometer and hour meter and perform any other needed lubrication. In freezing weather perform the following: Check both engines to make sure they contain enough environmentally safe antifreeze to safe guard against freezing before the next sweeping operation. Check both engines to make sure they contain enough environmentally safe antifreeze to safe guard against freezing before the next sweeping operation. Winterize the dust suppression system (see Section 3.13.7, DUST SUPPRESSION SYSTEM WINTERIZING). Inspect the sweeper for loose hardware, oil leaks, burned-out bulbs or fuses, tire wear and inflation, and so on. Adjust and repair, as needed.
14.
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NOTES:
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SECTION 4
GS6 SERIES
MAINTENANCE
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SCHWARZE GS6 SERIES OWNERS MANUAL Dust Suppression System Maintenance...........................................................................................................4.14 Water Reservoir Refill...........................................................................................................................4.14.1 Water Manifold Solenoid Cleaning.......................................................................................................4.14.2 Y Strainer Cleaning/Replacement......................................................................................................4.14.3 Water Pump Maintenance.....................................................................................................................4.14.4 Water Pump Pressure Check.................................................................................................................4.14.5 Water Nozzle Cleaning/Replacement...................................................................................................4.14.6 Dust Suppression System Winterizing..................................................................................................4.14.7
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4.1
About Maintenance
In this part of the Schwarze GS6 manual we include checking, adjustment and/or replacement procedures for all major sweeper systems and devices. For some systems and devices,such as daily examination of the Y strainer, maintenance is regular and ongoing. For others, we include a beginning statement to tell you when adjustment or replacement is necessary. For example, when water flow is restricted at the right or left gutter broom, the dust suppression system nozzles should be cleaned or replaced. For many components, we also include a table of maintenance tasks and identify the section(s) of the manual to access for related procedures.
4.1.1
Maintenance Logs
To help you keep your Schwarze GS6 in top operating condition, we have provided maintenance logs (for weekly and occasional maintenance) to complement the Start-Up Checklist used before every sweeper operation. You will find all these forms in Appendix B, Inspection and Maintenance Forms Photocopy Originals Packet. We suggest that you remove the maintenance log master copies from this binder and store them in a file to keep them accessible and clean. Photocopies can be made available for regular maintenance. You complete each form by: Recording the sweeper identification number Recording the date Checking off inspection/maintenance tasks Signing your name Additionally, each form has a Comments section for: Providing detailed information on a listed item Noting information about items not listed Noting additional concerns Specifying a needed replacement part Recording the date a replacement part is ordered The completed forms can be compiled in a notebook. Over time, this will come to represent a comprehensive inspection maintenance record for your sweeper.
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4.1.2
Maintenance Schedules
Daily Maintenance (Every 8 Hours)
The following table tells you where to look in the manual to find procedures for specific daily-maintenance tasks: Clean the sweeper. Follow the lubrication schedule for the fan shaft bearings, hopper and dump door hinges, gutter brooms, and seals. Check sweeping head flaps for wear, replacing as necessary. Check sweeping head skids, adjust and rotate to keep wear even. Check sweeping head intake and exhaust hoses, rotate to keep wear even. Check the gutter broom pattern. Clean the gutter broom and remove any wire, string or rope that has become wrapped around the disc or gutter broom motor shaft. Inspect and adjust gutter broom down-pressure. Check the Y strainer. Check / clean the nozzles. Inspect the air filters air restriction indicator. Check oil on both the auxiliary and chassis engines. Check radiator fluid levels. Check hydraulic fluid levels. Check the dust suppression system reservoirs water level and fill as needed. Rinse the auxiliary engines radiator fins. 2.5, End-of-Shift Clean-Up / Maintenance 3.4, Lubrication Schedules 3.10.3, Sweeping Head Flap Check/ Replacement 3.10.1, Skid Plate Adjustment/Replacement 3.10.7, Sweeping Head Hose Rotation 3.11.1, Gutter Broom Pattern Check
3.11.3, Gutter Broom Down-Pressure Adjustment 3.14.3, Y Strainer Cleaning/Replacement 3.14.6, Nozzle Cleaning 3.5, Filters See Engine Manufacturers Manual 3.12.1, Hydraulic Tank Fill-up 3.13.1, Water Reservoir Refill
Occasional Maintenance
The following table tells you where to look in the manual to find procedures for specific occasional-maintenance tasks: Check fan and fan housing liner for wear. Check fan drive belt for wear and tension Replace the gutter broom bristles when they become worn to approximately 8 inches in length. Winterize the dust suppression system. 2010 SCHWARZE INDUSTRIES, INC. 3.9.1, Fan Housing Check 3.8.1, Drive Belt Tension Adjustment 3.11.9, Gutter Broom Bristles Replacement 3.13.7, Dust Suppression System Winterizing version 1 09/10
4.2
Cleaning
Cleaning is an important part of any maintenance program because it extends the life of the sweeper by reducing rust and part abrasion. For a general description of cleaning procedures see Section 2.5, End of Shift Clean-Up/Maintenance.
4.3
Hydraulic System
The hydraulic oil level should be maintained such that it is kept at the full mark as measured with the hopper down. Check by using the sight level gauge, which is located on the left side of the reservoir. Change the hydraulic oil after the first 500 hours of operation, then every 2000 hours thereafter. If the hydraulic fluid becomes cloudy, water has contaminated the system and the hydraulic fluid needs to be changed (after determining the source of the water contamination and correcting it). If the sweeping unit is operated in particularly dusty conditions, the hydraulic filters will need to be changed more often. For detailed maintenance procedures of the hydraulic system, see Section 3.12, HYDRAULIC SYSTEM MAINTENANCE.
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4.4
Lubrication Schedule
Refer to the following table for correct sweeper lubrication. Item 1. Dump Door Hinges 2. Hopper/Frame Hinge 3. Gutter Broom Arm U-Joint 4. Fan Seal, Intake Seal, and RearDoor Seal Frequency Monthly Monthly 120 hours of operation As required Lubricant Grease with lithium-based grease. Grease with lithium-based grease. Grease with lithium-based grease. Lubricate with a rubber protectant or grease to prevent drying and loss of resilience.
4.5
Filters
Because of the dusty conditions under which a sweeper operates, filters are considered a priority maintenance item. Failure to properly follow filter change schedules may result in poor performance or costly component replacement.
CAUTION
Do not clean air filter with high pressure air. Clean or change the air filter only when the air restriction indicators need to service window has changed colors. Serious engine damage can occur as a result of air cleaner over-servicing.
For air filter change and service information, please see the Owners Manual for the auxiliary engine. 2010 SCHWARZE INDUSTRIES, INC. version 1 09/10
4.6
Seals
It is important that the sweepers seals on the fan housing be kept in the best condition possible. These include the seals on the suction hose inlet, around the hoppers inspection door opening and on the rear door. Pickup power is vacuum-dependent, so a tight seal can make a significant difference in pickup ability. Maintain resilience by keeping the seals well lubricated with a good grade of petroleum-based jelly or grease. Lubrication of the side inspection door seals is unnecessary. For longer seal life, when the sweeper is parked for an extended period of time, leave the dump door and all inspection doors open and raise the hopper several inches so their seals can regain their shape. Eventually the seals will become worn or non-resilient and must be replaced.
FAN SEAL
Replacement:
1. Use a gasket scraper, putty knife or screwdriver to remove the seal from its sweeper component. Get the metal surface as clean as possible. Be sure it is free of all dirt, old glue, and seal material. 2. Liberally apply a coat of weather-strip-type adhesive onto the new seal and body component. Allow the adhesive to set up for several minutes (follow the adhesive manufacturers instructions) and the put the new seal in place.
INTAKE SEAL
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4.7
Hopper
The hopper is one of the central components of the GS6 sweeper. To ensure the longest possible useful lifetime, it is extremely important to clean it after each shift and to let it air dry with the hopper up whenever possible.
4.8
Auxiliary Engine
For detailed information on the power module (auxiliary) engine, consult its Owners Manual. Engine parts for the auxiliary engine must be purchased through your industrial engine dealer.
4.8.1
4.8.2
Replacement:
1. Remove the sweeper engines keys and/or disconnect the battery cable to prevent the sweeper engine from being started accidentally. 2. Follow the procedures outlined in steps 1-4 in Section 3.8.1, DRIVE BELT TENSION ADJUSTMENT. 3. Turn the jackscrew nuts so the engine skid is pushed toward the fan shaft.
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SCHWARZE GS6 SERIES MAINTENANCE 4. As the engine skid moves toward the fan shaft, the drive belt will become loose enough to be slipped from its pulleys. 5. Remove the three 3/8 bolts and lock washers from the stub shaft pulley bushing. 6. Insert two of the 3/8 bolts into the two tapped holes of the stub shaft pulley bushing. 7. Tighten the bolts evenly, alternating from one to the other. This will push the pulley off the stub shaft pulley bushing. 8. Remove the pulley and its bushing from the stub shaft. 9. Remove the bearing plate from the end of the auxiliary engine. Inspect the plate for irregularities. If none are found, the bearing plate may be used again. 10. Remove the old stub shaft from the end of the auxiliary engine. 11. Clean the flywheel and replacement stub shaft using lacquer thinner. 12. Fasten the replacement stub shaft to the auxiliary engine using 32 ft. lbs. of torque on each bolt. 13. Use a dial indicator and ensure that the stub shaft is in-line with the crankshaft. The stub shaft must be no more than .008 off-center. 14. Place the replacement bearing onto the end of the stub shaft. Using a piece of pipe placed over the stub shafts end, drive the bearing down the stub shaft until it rests against its seat. 15. Slip the bearing plate down the stub shaft and onto the bearing. 16. Bolt the bearing plate to the auxiliary engine. 17. Slide the stub shaft pulley and its taper-lock bushing onto the end of the stub shaft.
18. Insert the bolts through the taper-lock bushings flange and into the pulley. Alternate turning the three bolts so the pulley is pulled onto the bushing evenly. 19. Check the alignment of the pulleys, using a string or straight edge, from the face of one pulley to the face of the other to determine whether the pulleys are in line with each other.
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SCHWARZE GS6 SERIES OWNERS MANUAL 20. If the pulleys are misaligned, back the stub shaft pulley off its bushing, move both in the proper direction for alignment, then retighten the bushing/pulley bolts. 21. Inspect the drive belt for wear and replace it with a new one if needed. 22. Slide the drive belt onto the stub shaft and fan shaft pulleys. 23. Adjust the drive belt tension as outlined in Section 3.8.1, DRIVE BELT TENSION ADJUSTMENT. 24. Replace the belt guard.
4.9
4.9.1
Adjustment:
The auxiliary engine, along with its engine skid, can be moved in the direction of the fan shaft (to loosen or remove the belt) or away from the fan shaft (to tighten the belt). 1. Remove the belt guard. 2. Loosen (do not remove) the bolt which holds each of the four outer corners of the engine skid to the top of the power module platform. 2010 SCHWARZE INDUSTRIES, INC. version 1 09/10
SCHWARZE GS6 SERIES MAINTENANCE 3. Locate the threaded rods known as jack screws.
Before adjusting the jackscrews, it is always a good idea to mark the present position of the engine skid, both at the front and rear, on the power module platform. This will allow you to determine how far the engine skid has been moved and whether the center line of the auxiliary engine is still parallel with the fan shaft.
4. Loosen the jackscrews jam nuts. 5. By running the adjustment nuts in or out, the engine skid may be moved toward or away from the shaft. Alternate adjusting the jackscrew nuts front to rear so that movement of the engine skid is even and the engine skid does not become misaligned. If you turn the front jackscrew three revolutions, then turn the rear jackscrew three revolutions. 6. When proper belt tension is achieved, re-thread the loose adjustment nuts tightly against their power module platform tabs. (If youre adjusting the engine away from the fan shaft, these would be the inner adjustment nuts; toward the fan shaft, these would be the outer adjustment nuts.) Tighten any loose jam nuts back against their respective adjustment nuts. 7. Tighten the four tie-down bolts at the corners of the engine skid.
Once the four tie-down bolts have been tightened, release the tension on the jackscrews.
8. Start the sweeper engine. Squealing or abnormal vibrations indicate low belt drive tension. Adjust as needed. 9. Re-bolt the belt guard back into position.
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4.9.2
Removal:
1. Remove the sweeper engines keys and/or disconnect the battery cable to prevent the sweeper engine from being started accidentally. 2. Follow the procedures outlined in steps 1-4 in Section 3.8.1, DRIVE BELT TENSION ADJUSTMENT. 3. Turn the jackscrew nuts so the engine skid is pushed toward the fan shaft. 4. As the engine skid moves toward the fan shaft, the drive belt will become loose enough to be slipped from its pulleys.
Replacement:
1. Inspect the pulley grooves for burrs and other irregularities that may cause abnormal belt wear. Correct as required.
2. Slip the replacement belt into position. 3. Tighten the jackscrew nuts so the engine skid is pulled away from the fan shaft. 4. Continue to tighten until the belt has 1/2 deflection between the pulleys using 30 lbs. of pressure (roughly the equivalent of pressing down on the belt with your thumb.) 5. Check the alignment of the pulleys, using a string or straight edge, from the face of one pulley to the face of the other. This will allow you to determine whether the pulleys are in line with each other.
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For slight misalignment, the pulleys may be repositioned on their respective shafts. If greater adjustment is needed than pulley repositioning can achieve, the entire engine/engine skid assembly must be moved to obtain alignment. The slotted tie-down holes of the engine skid allow a limited amount of forward-back movement.
6. Once proper pulley alignment is achieved, run the jam nuts back against their respective jackscrew nuts. 7. Tighten the four tie-down bolts at the corners of the engine skid.
Once the four tie-down bolts have been tightened, release the tension on the jackscrews.
8. Start the sweeper engine. Squealing or abnormal vibrations indicate low belt drive tension. Adjust as needed. 9. Re-bolt the belt guard back into position.
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4.9.3
2. Remove the sweeper engines keys and/or disconnect the battery cable TAPPED BUSHING HOLES to prevent the sweeper engine from being started accidentally. 3. Remove the 3/8 bolts and flat washers from around the fan housing back plate. 4. Pull the back plate free the fan housing. 5. Remove the three 3/8 bolts and lock washers from the fan bushing. FAN BUSHING REMOVAL 6. Insert two of the 3/8 bolts into the two tapped holes of the fan bushing. 7. Tighten the bolts evenly, alternating from one to the other. This will push the fan off the fan bushing. 8. Use a gear puller to remove the fan bushing from the fan shaft. The fan shaft key will come off with the bushing. 9. Slide the fan off the fan shaft. 10. Relieve the belt tension by following steps 1 through 4 of REMOVAL in Section 3.8.2, DRIVE BELT REPLACEMENT. 11. Unbolt the drive pulley from its taper-lock bushing. Remove both from the end of the fan shaft. 12. Remove fan spindle and replace with new unit. 13. Re-install fan and back plate.
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Replacement:
1. Slide the drive pulley and its taper-lock bushing onto the end of the fan shaft. 2. Insert the bolts through the taper-lock bushings flange and into the pulley. Alternate turning the three bolts so the pulley is pulled onto the bushing evenly. 3. Check the alignment of the pulleys, using a string or straight edge, from the face of one pulley to the face of the other to determine whether the pulleys are in line with each other. 4. If the pulleys are misaligned, back the fan shaft drive pulley off its bushing, move both in the proper direction for alignment, then retighten the bushing/pulley bolts. 5. Inspect the drive belt for wear and replace it with a new one if needed. 6. Slide the drive belt onto the engine and fan shaft pulleys. 7. Adjust the drive belt tension as outlined in Section 3.8.1, DRIVE BELT TENSION ADJUSTMENT. 8. Inspect the fan for wear and replace it with a new one if needed. 9. Follow the steps outlined under REPLACEMENT in Section 3.9.2, FAN REPLACEMENT section of this manual. 10. Swing the hopper safety prop back into its travel position. 11. Reconnect the engines battery cable, lower the hopper and check the operation of the sweeper.
4.10
Fan Housing
The fan housing directs the flow of air from the fan to the sweeping head. To provide the maximum performance from the fan, the fan housing and drive components should be checked for wear regularly. When signs of wear occur on a component, replace it as soon as possible.
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4.10.1
Inspection:
1. Raise the hopper and lower the safety prop into position. 2. Remove the sweeper engines keys and disconnect the battery cable to prevent the engine from accidently starting. 3. Remove the back plate. 4. Using a flashlight, inspect the fan blades, fan bushing, fan housing liner bolts and the fan housing liner for wear. 5. If no excess wear or abnormal wear is evident, replace the back plate, swing the hoppers safety prop back into its stored travel position and reconnect the battery cables.
4.10.2
Fan Replacement
If a worn fan is causing reduced sweeping efficiency, it should be replaced promptly. The fan shaft bearings have a life expectancy of roughly 2500 hours. When a fan replacement becomes necessary near the end of the bearings life expectancy, the bearings should likewise be replaced. Replacing both components will eliminate the need to perform two, identical labor operations, and avoid downtime in close succession. Exceptions to fan/bearing replacement: If you sweep in extremely sandy conditions, or do not use the sweepers water system, you may have to replace fans more often than bearings. If the proper bearing lubrication procedures arent followed, you may have to replace bearings more often than fans.
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Disassembly:
1. Raise the hopper and lower the safety prop into position. 2. Remove the sweeper engines keys and/or disconnect the battery cable to prevent the sweeper engine from being started accidentally. 3. Remove the 3/8 bolts and washers from around the back cover plate and lift it off. 4. Remove the 3/8 bolts and lock washers from the fans bushing. 5. Reinsert two 3/8 bolts into the tapped holes of the bushing. Tighten these bolts evenly. This will push the fan off the bushing. 6. Use a gear puller to remove the bushing from the fan shaft. 7. Remove the fan from the fan shaft and fan housing.
TAPPED BUSHING HOLES
SK-1463
8. While the fan is out, check the rubber liner inside the fan housing. If signs of excessive wear are rsion 10 0 05/ 8 apparent, replace the liner by following the steps outlined in Section 3.9.3, FAN HOUSING LINER REPLACEMENT. Failure to replace the relatively inexpensive liner could result in having to replace the more expensive fan housing later.
Replacement:
1. Inspect the end of the fan shaft. Remove any burrs or rust from the shaft end with sandpaper. 2. 3. 4. 5. 6. Place the fan on the fan shaft and push it back into the fan housing. Inspect the bushing. If the bushing is not cracked or otherwise damaged, the original bushing may be reused. Apply an anti-seize agent to the tapered area of the bushing. Slip the key into the bushing/fan shaft keyway. Position the fan bushing onto the fan shaft while aligning it with the shaft key as well as the fan. Spread the bushing apart if necessary remember, it will crack if it is overspread.
7. Drive the fan bushing onto the fan shaft until approximately 1/4 of the shaft extends from the face of the bushing. (Use a rubber hammer or a wooden block and metal hammer to drive the bushing on.)
8. Insert the three 3/8 bolts with lock washers through the untapped bushing holes and into the tapped holes of the fan. Finger tighten the bolts. Do not tighten the bolts so as to secure the fan to the fan shaft.
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SCHWARZE GS6 SERIES OWNERS MANUAL 9. Apply strip caulk, or a similar sealing agent, to the face of the fan housing. 10. Install the back cover plate (it may be necessary to move the fan and its bushing further into the fan housing before the back cover plate can be mounted). Before tightening the bolts, pull the fan back until it contacts the back cover plates inlet ring. Using the available slack, center the cover plates inlet ring in the fans orifice. Feel around the perimeter of the inlet ring to confirm an even gap or fit. Tighten the cover plate bolts.
11. Move the fan back onto the fan shaft. A gap distance will have to be determined (see illustration). The ideal gap distance is 1/4 from the cover plate orifice to the narrowest part of the fans orifice. 12. Position the fan on the fan shaft, taking into consideration that, as the fan is tightened onto its bushing, it will travel roughly 1/4 toward the cover plates orifice. 13. While holding the fan in position on the fan shaft, tap the fan bushing along the fan shaft and into the fans hub. 14. When the fan bushing is snug inside the fans hub, insert the 3/8 bolts and tighten the fan onto the fan bushing. As the bolts are tightened and the fan is drawn onto the bushing, the fan should move 1/4 toward the cover plate. . 15. Turn the fan to determine if the two orifices rub as the fan rotates. If the orifices touch, mark the bushings present position on the fan shaft (so it may later be used as a reference point). Remove the fan from its bushing and follow steps 12-16 to remount the fan further into the fan house. If the orifices do not touch, proceed on to step 16. 16. When the fan is properly mounted, swing the hopper safety prop into its stowed position and lower the hopper. Start the auxiliary engine and, again, listen for sounds of contact between the cover plate orifice and fan orifice. If none are audible, the unit is ready to sweep. If, however, sounds are detected, the hopper should be raised and the fan readjusted.
4.10.3
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Disassembly:
1. Follow steps 1-7 of DISASSEMBLY in Section 3.9.2, FAN REPLACEMENT. 2. Unscrew the 3/8 nuts from around the outside of the fan housing and remove the elevator bolts holding the rubber liner in place. Note the condition of the fan housing liner bolts. Worn bolts should be discarded and replacements used upon reinstallation. 3. Remove the worn liner in one piece if possible. Save it to use as a template to mark the new liners hole pattern.
Replacement:
1. Place the old liner on top of the replacement liner material and mark the length and the hole pattern with spray paint. 2. Cut the liner material to length and use a hole punch or drill to make the holes. 3. Notice that the replacement liner hole pattern is different at each end. Be sure you position the liner so that its holes match the hole pattern of the fan housing. 4. Start by installing the elevator bolts which hold the rubber liner to the top of the fan housing, and then continue installing the remainder of the elevator bolts, working out and down from the top of the fan housing.
5. Check the fan blades for wear, and replace the fan if needed. To replace the fan, follow steps 1-16 of REPLACEMENT in Section 3.9.2, FAN REPLACEMENT.
4.11
Sweeping Head
proper ma e a The sweeping head is dependent upon forced air and vacuum to achieve debris pickup. Without proper pro id t e si d s maintenance and replacement of parts due to normal wear, the sweeping head cannot provide the desired sweeping results.
nt n
The Schwarze GS6 is equipped with a sweeping head. Many of the maintenance procedures outlined in the following sections apply to the sweeping head.
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4.11.1
Removal/Replacement:
UPPER CHAMBER LOWER CHAMBER
SK-1465
1. Locate the skid plates on either side of the sweeping head. Note that studs, welded to the sweeping head, protrude through slots in the skid plates. The skid UPPER CHAMBER plates are held in place against the head by the nuts and washers on these studs. BLAST ORIFICE 2. With the sweeping head raised, remove the skid plates nuts and washers and LOWER 2" TO 2-1/2" 1-1 1/4" CHAMBER FROM SWEEPING set them aside for later use. SURFACE 3. Pull the old skid from the side of the sweeping head and replace it with the new skid plate. 4. Remount the nuts and washers that were removed earlier. Screw them down against the skid plate, but do late not tighten them until the new skid plate is in the proper position.
s p te, b Remember: Whenever skid plate adjustment is necessary, the blast orifice must remain 2 to 2-1/2 from the sweeping surface. Less than 2, and the air stream becomes choked down. More than 2-1/2 and the blast Remember Whe ever ski velocity of the air striking the sweeping surface is lost.
Never adjust the skid plates to extend the life of the flaps. When the flaps can no longer maintain a satisfactory N d t t seal, they should be replaced. Adjusting the skid plates may affect the sweeping efficiency due to the change in i i y blast orifice-to-ground distance.
Adjustment:
CAUTION Do not adjust the skid plates so far up that the heads blast orifice is less than 2 from the sweeping surface.
1. Raise the sweeping head and locate the skid plates on either side. 2. 3. 4. 5. Loosen the 5/8 nuts on each of the sweeping head skid plates.
de eac distance. skid p . S surface Slide each skid plate up or down its slots to achieve the required blast orifice-to-sweeping
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Sc
A 0
Please note that these adjustments be made only under extreme all erfor other times, Just as making should th frontal area shor er increases h conditions avy weepIn ng ance the ma normally recommended adjustments will usually suffice. Prolonged usage with the above adjustments will fronta area talle inc eases sweepi performance i li hter debris Thi ad us men require flap replacement when readjustment to normal conditions made. e a comp ished by pe fo ming the oppositeis f the
4.11.2
a l other t mes, th Spring normally Adjustment ecommended ad Sweeping Head Tension plac en when head readjus men to norma condi springs. ons is Near the four corners of the sweeping are the sweeper head tension made. These help the sweeping head float by relieving some of its weight from the sweeping surface. If the springs are adjusted correctly, by grasping the front corner of the sweeping head with your hand, you should be able to move it slightly with roughly 40 lbs. of upward lif Although operator preference varies, this is normally the optimal setting Less tension shortens runner life. More tension SWEEP N HE D TE SION creates a possibility that the head may bounce on irregular surfaces, which will S T break the suction seal.
Mai te
FINE ADJUSTMENT