Operator, Parts, & Service Manual
Contents
1. 51 2 Wre R Red mo L shite dh blac O Blue2. 51 2 Wre R Red mo L shite dh blac Ons Part No Description Comments 1 4 101 SERIAL PL FACTORY 210101 SERIAL NO PL TOMCAT 2 4 10 HOOD 1 3 4 MAIN BODY 1 4 4 10 2 STRIP BUMPER 12 FT SECTION 1 5 4 D2A HANDLEBAR 4 22 INCL 4 22A 4 D2B HARDWARE 4 6 4 D2B BLACK PLASTIC CLAMP 4 122 INCL 4 122A 4 122B HARDWARE 8 1 4 24 HOOD LATCH COMPLETE 2 PC WTH RMETS 1 8 4 D6A HOOD CABLE 1 9 4 08 BATTERY TRAY 1 10 4 D8A BATTERY TRAY LINER 1 1 4 31 HINGE 23 3 4 55 1 D 4 132 HANDLE BAR WELDMENT P N4 D1INCL ITEMS 2 13 16 19202630 6 36 1 4 B4A CLUTCH LEVER P N 4 134 INCL ITEMS 19202630636 1 14 4 140 BUMPER INCLUDES HARDWARE OPTIONAL 1 15 4 1 0 RUBBER HOOD STOP 2 16 4 370 CLUTCH BRAKE CABLE 1 4 371 CLUTCH CABLE RETURN SPRING 1 18 4 379 CLUTCH CABLE ADJ NUT 1 19 4 387 TUBE PLUG 1 20 4 388 CLUTCH TENSION SPRING 1 21 H 1032HCN HCN 10 32 7 22 H B003 1 4 20 X 3 4 2 23 H B005 14 20 10 24 1305 HCS Y4 20 8 25 H1901 FB CASHD 1 4 20 X 12 4 26 H2259 CB 5 16 18 X 112 1 27 H 250HCN HCN 14 20 50 28 H 28679 PPH 4 40 X 12 4 29 129049 PPH 10 32 X 12 8 30 13300
3. must light turns off battery is fully be vertical to open the hopper charged PAGE SHORTLIST OF DOS AND DON TS SIDE BROOM ADJUSTMENT Very Important Your side broom must not be squashed flat but must look like this RIGHT The broom must be mounted in the top hole of the broom shaft and the adjusting screw must be screwed in so broom just touches the floor in front WRONG If adjusted too flat your machine s Side broom will shut itself off periodically to cool down the motor You will sweep poorly and severely damage the side broom GOTTA SWEEP GREAT No kidding This is the world s best walk behind sweeper If your sweeper isn t sweeping just great seems hard to use or is making funny noises Something is Wong Here is what to do 1 Read this book 2 Call your dealer for info or service If you forgot your dealers name call the Factory toll free 800 634 4060 and we will give you his name and phone number PAGE 3 IDENTIFYING THE CONTROLS 1 2 V Main Broom Position Lever Side Broom Position Lever Main Power On Off Switch On single switch machines this switch has three positions and can also turn on the side broom Side Broom On Off Switch Not found on single switch machines Clutch and Brake Lever Adjustable Handlebar Handlebar Adjustment Clamps 4 Filter Shaker Crank Hood Latch Side Broom Adjustment Knob Battery Anderse
4. 02 MAIN BROOM LIFT BROOM LAT ARM ARM ASSY P N 4 449 ASSY P N 4 415 lt W 20 IDLER ARM ASSY LIFT SUPT ASSY P N 4 435 P N 4 423 Part No Description Comments Qy 1 4 BODY 1 2 4 13 INNER SIDE PANEL 1 3 4 302 BELT 3V X 475 1 4 4 316 BROOM DRIVE PULLEY 1 5 4 37 IDLER PULLEY 1 6 4 318 IDLER PULLEY 1 7 4 319 TENSION SPRING 1 8 4 360 REVERSE IDLER ARM 1 9 4 366 BUSHING IDLER ARM 1 10 4 376 BROOM LIFT LEVER 1 1 4 371 BROOM LIFT SHAFT 1 D 4 380 LIFT LEVER BASE LT 1 B 4 382 ROTARY LINK BASE 1 14 4 385 LIFT LEVER COLLAR 1 b 4 386 LIFT LEVER SPRING 1 16 4 40105 MAN BROOM 1 4 410 BROOM SUSP ARM 1 18 4 410 SET COLLAR 1 19 4 4 BROOM DRIVE BEARING P N 4 415 INCL P N 4 42 amp P N 4 416 1 20 4 416 BROOM LATERAL ARM P N 4 415 INCL P N 4 412 P N 4 416 1 21 4 420 BROOM DRIVER INCLUDES KEY SET SCREWS AND ROLL PINS 1 22 4 421 SUPPORT BLOCK 1 23 4 4230 3 4 X T X 12 FLG BEARING P N 4 423 INCL P N 4 423B L 4 423B R amp 4 4230 1 24 4 423B L SUPPORT BRACKET TABS P N 4 423 INCL P N 4 423B L 4 423B R amp 4 4230 1 25 4 423B R SUPPORT BRACKET TABS P N 4 423 INCL P N 4 423B L 4 423B R amp 4 4230 1 26 4 430 IDLER ARM P N 4 435 INCL 4 430 4 432 4 432A HARDWARE 1 27 4 432 IDLER
5. 1 Turn off machine and unplug battery ground 2 Raise side broom off of ground with Fiber should touch the ground in an 11 OClock control lever to 5 OClock pattern as shown here 3 Turn side broom adjustment knob FRONT OF MACHINE clockwise until broom is as high as it will go ONT OMNA a Operating Tip The Knob will be easier to turn if you pull on the broom lever at the same time this relieves pressure from the adjustment 4 Pull clevis pin from side broom and remove broom New broom has replacement plastic mount included so no need to unscrew the old 5 If your machine s side broom mounting Shaft has more than one mounting hole for the broom pin always use the top hole 6 Lower broom with motor off and turn adjustment control until broom pattern shows OClock to 5 OClock contact pattern see next column roused 5 r 17 TO ADJUST DRIVE CHAIN i The drive chain drives the rear wheels If it is too loose it will come off of the drive sprocket 5 DETAIL A If itis too tight the chain will bind and or the clutch lever will become hard to operate In 4 1 Broom Adjuster either case the chain will make popping mi is in the front right noises that show chain adjustment is needed corner of engine compartment Turn A properly adjusted c
6. normally by fastest means This means that emergency orders will generally cost the customer more than normal orders In both cases the customer is responsible for all freight costs PAGE 15 Wiring Schematics For machines after Serial No BY 2220 with Side Broom Circuit Breaker Battery D Volt Main Relay Main Broom Motor M2 Side Broom Motor F1 Side Broom Circuit Breaker 6 Amp M2 22 Main Circuit Breaker 80 Amp 51 Safety Switch 52 Master Switch S3 Side Broom Switch H Hour Meter C Battery Charger Ep G M Plug Side Broom Harness N LZ EO m wW R B 51 52 53 Wre R gis D m it ES i c Black PAGE IGA DON Wiring Schematics For machines after Serial No CI 3200 with Single Electrical Switch for Main and Side Brooms Battery D Volt 1 Main Relay M1 Main Broom Motor 2 Side Broom Motor F1 Side Broom Circuit Breaker 6 Amp M2 F2 Main Circuit Breaker 80 Amp S1 Safety Switch 52 Main and Side Broom Switch Hour Meter G R C Battery Charger G Grey 50 Connector P P L Plug Side Broom Harness Warning Light Unit H E R O Tate BI B
7. 1 Remove the black filter cover There are three screws at the rear Cover fits into a slot at the front Then check for improper seal between filter and body Filter is taped to the filter element support grill Part No 4 505 with double sided carpet tape This seal must be tight Check filter for pinhole leaks and repair or replace as needed You can pull filter and its mounting grid straight out of the machine once the filter cover is removed You can also inspect the filter from undeneath the machine PAGE 14 SPARE PARTS BOOK Walk Behind Sweepers Spare parts are sold through authorized Dealers If you have forgotten your dealer s name or you have moved the machine to a new location please Call us at 1 800 634 4060 or Fax us at 1 866 901 3335 and we will re establish a dealer contact for you TO ORDER PARTS Please provide the machine s Serial No with your order Normally ordinary parts orders are shipped out the same day the order is received EMERGENCY ORDERS Within the Continental United States We can supply any part that weighs under 70105 within 3 business days not counting weekends or National Holidays However if parts are ordered on an Emergency basis this means that we will ship them by fastest means generally by air courier service at the customers expense FREIGHT Wthin the United States the normal shipment method is by customer choice while the emergency shipment method is by RPS choice
8. Normally a main broom with one and a half inches or less of fiber will not sweep as well as a new broom W recommend the Vee type filter pattern which is able to fit the hopper fuller than the Spiral type filter pattern MAIN BROOM REPLACEMENT Vote that you do not need to reverse the broom periodically as on other brands because our broom suspension does not bend and splay the outerfibers of the broom TO REPLACE MAIN BROOM 1 Turn off machine and unplug battery connector Shake the filter 2 Raise main broom off ground with broom lever Remove dirt hopper and broom access door 3 screws Unbolt broom as shown 3 in photo Pull out old broom Push on new broom being careful to line up the slot on the broom with the driver s slots Push the broom all the way in 7 Make sure Vee of the Vee broom points forward when viewed from the top O U 99 MAIN BROOM Spiral Broom Does not sweep as well as Vee Broom Remove 1 Hopper 2 Access Panel 3 Idler Arm 1 Bolt and then remove 4 the old Broom SPECIAL NOTE Always park the main broom when machine is not in use If you leave the main broom on the floor for an extended period without turning it you will put a flat spot in its fiber This will cause broom bounce and bad sweeping PAGE 10 MACHINE MAINTENANCE SIDE BROOM ADJUSTMENT TO REPLACE SIDE BROOM Side broom will not sweep if it is flat on the
9. 4 1 28 H 13053 HCS 5 16 18 X 3 4 1 29 13103 HCS 3 8 16 X 3 4 1 30 H 19901 FB CASHD 1 4 20 X 12 1 31 H 250HCN HCN 14 20 50 32 H 25328 SSS CP 1 4 20 X 3 8 1 33 H 29048 RPH 10 32 X 12 2 34 H 3DHCN HCN 5 16 18 4 35 H 31810 HW IO X 12 1 36 H 33008 FW3 8 USS 1 37 H 33074 FW 10 SAE 2 38 H 33620 LW5 16 1 39 H370D NYLOK 8 32 1 40 H 37024 NYLOK 3 8 16 1 41 H 37408 KN 10 32 1 2 42 H K14320 3 16 X 11 4 KEY PAGE 20 PAGE 24 Item Part No Description Comments Qty 1 4 108 DOOR MNT ANGLE 1 2 4 11 MAIN BODY 1 3 4 18 R INNER SIDE PANEL 1 4 4 14 SKIRT PLATE RT 1 5 4 15 SKIRT PLATE REAR 1 6 4 16 CASTER MTG BRACKET 1 7 4 117 FRONT CROSS PANEL 1 8 4 118B HOPPER BODY 1 9 4 19 BROOM ACCESS HATCH 4 118 INCL 4 4 27 5 130 SEALS HARDWARE 1 1 4 20 REAR INNER PANEL LT 1 1 4 23 INNER CURVED PANEL 1 D 4 D7 HANDLE 2 B 7 1308 6 CASTER BLACK 1 7 1306 6 CASTER GREY 4 4 135 LF PANEL GUSSET 1 b 4 141 HDPE HOPPER SLIDE 2 6 4 142 ROLLER 2 4 143 ROLLER BRACKET 2 1 4 384 ATTENUATOR 1 19 4 421 SUPPORT BLOCK 1 20 4 441 BROOM MOUNTING BLOCK 1 21 4 514 HOPPER FLOOR SEAL P N 4 550 INCLUDES ITEMS 21222324 6 25 1 22 4 55 RIGHT FLOOR SEAL 1 23 4 516 REAR FLOOR SEAL 1 24 4 51 CORNER FL
10. DRUM P N 4 435 INCL 4 430 4 432 4 432A HARDWARE 1 28 4 432A IDLER DRUM SPACER P N 4 435 INCL 4 430 4 432 4 432A HARDWARE 1 29 4 436 ADJ BROOM LIFT P N 4 449 INCL ITEMS 10 112 14 53334395152 amp HD 1 30 4 437 BROOM LONG LINK 1 31 4 438 BROOM ROTARY LINK 1 32 4 439 BROOM CRANK LINK 1 33 4 448 HANDLE GRIP 1 34 H 10436 0010 4 X 114 SPRING PIN I 35 H 10436 0105 3 8 X 11 4 SPRING PIN 2 36 13103 HCS 3 8 16 X 3 4 2 37 13213 HB 1 2 X 2 12 1 38 H 19901 FB CASHD 1 4 20 X 12 D 39 2250 218 1 2 X CLEVIS PIN 1 40 H 250HCN HCN 1 4 20 50 41 25283 555 CP 10 32 XT 1 42 25328 SSS 14 20 X 3 8 3 43 25435 SSS CP 5 16 X 1 4 1 44 26316 SB 5 16 X 3 4 SS 1 45 H 29570 FHP 1 4 20 2 46 H 33008 FW3 8 SAE 4 47 H 33622 LW3 8 3 48 H 36106 HN 3 8 16 1 49 37018 NYLOK 14 20 2 50 37030 NYLOK 12 13 1 51 45285 CLIP 9 2 52 50102 FW5 8 X 15 16 1 53 H 65035 3 32 X 7 8 COTTER PIN 3 54 H 70001 HCS 1 4 20 X 12 SS 2 55 H 71063 LWY4 SS 2 56 H K1432 3 16 X 1 2 KEY 1 57 H ZCP 54 3 8 X 112 CLEVIS PIN 1 PAGE 26 CLUTCH DONUT 4 332 tem Part No Description Comments Qy 1 4 MAIN BODY 1 2 4 113 R INNER SIDE PANEL 1 3 4 20 REAR INNER PANEL LT 1 4 4 25 MOTOR SUPT BRACKE
11. Part No Description Comments Qy 1 4 BODY 1 2 4 125 MOTOR SUPT BRACKET 1 3 4 28 BATTERY TRAY 1 4 4 D8A BATTERY TRAY LINER 1 5 4 136 HD BLACK WEBBING P N 4 136 INCL 4 136A 4 3B7 amp 4 B7A 1 6 4 B7 BATTERY BUCKLE P N 4 136 INCL 4 136A 4 137 amp 4 137 _ 1 7 4 B7A TRIGLIDE P N 4 136 INCL 4 136 4 137 amp 4 137 1 8 4 201 DVTWN SHAFT MOTOR 1 9 4 20B MOTOR CRADLE 1 10 4 210 TERMINAL CLIP 1 1 4 227 LOWBATTERY LIGHT 1 D 4 229 3 POS ROCKER SWTCH 1 4 231 SAFETY SHUT OFF SWTCH 1 14 4 232 CIR BREAKER 2V 80A 1 15 4 233 DV SOLENOID 1 16 4 235 CIR BREAKER 2V 6A 1 17 4 240 HOUR METER 1 18 4 244 BATTERY CHARGER 1 19 4 251 SUB LEAD BATTERY TO GREY 50 CONN NOT SHOW 1 20 4 251 SUB LEAD BATTERY GREY 50 CONN NOT SOMN 1 21 4 252 SUB HARNESS GREY 50 TO 80 AMP BREAKER NOT SON 1 22 4 253 SUB HARNESS 80 AMP BREAKER TO SOLENOID NOT SHONN 1 23 4 254 SUB LEAD SOLENOID TO MAIN MOTOR NOT SHONN 1 24 4 255 SUB HARNESS MAIN WRING HARNESS NOT SHOW 1 25 4 256 GREY 50 CONNECTOR WTH CONTACTS NOT SHOW 2 26 4 260 GREY 50 CONNECTOR HOUSING ONLY NOT SHOW 2 27 4 270 BATTERY 12 VOLT B5 AH 1 28 H1032HCN HCN 10 32 1 29 H 3051 HCS 5 16 18 X 12 2 30 HB053 HCS 5 16 18 X 3 4 5 31 H 19901 FB CASHD 1 4 20 X 1 2 D 32 H250HCN HCN 1 4 20 50 33 29048 RPH 10 32 X 1 2 6 34 H 29055 RPH 10 32 X 5 8 2 35 H 3DHCN HCN 5 16 18 4 36 133074 FW 10 SAE 2 37 133080 FW5 16 SAE 4 38 H 33620 LW5 16 6 39 13610
12. SURE CONNECTIONS TO THE BATTERY ARE TIGHT Loose connections will cause arcing which will eat into and destroy the battery terminals 7 WATCH THE GREASE Never put grease on the inside of the connector The grease will cause arcing and deterioration of the connector You can put grease on the outside of the terminal after it is mounted to the battery 8 DO NOT HAMMER ON THE BATTERY OR ITS CONNECTORS Batteries are heavy but fragile Hammering the posts on the battery can break the connectors inside Use a puller to remove connectors not a hammer or screwdriver 9 DO NOT STORE BATTERY ON A CONCRETE FLOOR Doing so can cause quick discharge and even damage to the battery Store the battery on wood cardboard or other self insulating material PAGE MACHINE MAINTENANCE BATTERIES The highest maintenance item on your machine will be its storage battery Please read the About Batteries section of this book MAIN BROOMS Replace the main brooms when they stop sweeping to your standards We recommend you use our brooms They are made for your machine Our brand of broom has a precision plastic core that is carefully balanced and has machined insert points so the broom fits tightly on the machine s hubs Brooms made by will fit companies to fit our machines are often made with rough drain pipe cores They often bounce even when new Bouncing brooms do not sweep A new main broom has two and a half inches of fiber on it
13. tube has not become disconnected It will do this to save the motor and gear drive Check the side broom motor PROBLEM MAIN BROOM WORKS BUT MAIN BROOM DOES NOT TURN 1 2 3 Check to see if something is caught in main broom such as strapping This material will wind itself around the edges of the broom locking it up and causing the belt to slip Check both drive belts for wear and adjustment Check the Main Broom Belt Tensioner The belt tensioner moves constantly to take up slack in the belt as the broom moves up and down with floor irregularity It should be greased with chassis grease every two years To grease Unscrew vertical Allen head retaining screw Item B BEFORE unscrewing lateral Allen head screw Item A Otherwise you can damage the main broom arm Remove lateral screw A and insert grease in arms Oilite bearing Reassemble Do not overtighten lateral screw or arm will bind Screw in B once position of is correct PROBLEM MOTOR RUNS BUT MACHINE WILL NOT SELF PROPEL 1 Pw Make sure belt between motor and transmission is adjusted properly See if clutch slips If so adjust following the procedure in this book If adjustment cannot make clutch work properly Replace the rubber clutch donut Check chain and sprocket on differential axle PAGE 13 TROUBLESHOOTING GUIDE PROBLEM BROOMS ROTATE BUT MACHINE DOES NOT SWEEP WELL 1 Main Broom may be worn out While machine can swe
14. 2 HN 14 20 4 40 36106 HN 3 8 16 1 41 437015 NYLOK 10 32 4 42 71063 LW14 SS 4 PAGE SWEEPER MAINTENANCE RECORDS Operator s Name Week Of Maintenance Monday Tuesday Wednesday Thursday Friday Daily Park Machine with Brooms Up Shake Filter with Crank Remove and Empty Hopper Open Hood Plug In Charger to IOV Outlet Clean Machine with Pledge and Cloth Check Main Broom for Debris Weekly Check Battery Water Level Inspect Floor Seals Check Clutch Adjustment Inspect Main and Side Brooms Monthly Lubricate the Front Caster Remove Main Broom and Inspect Check Wring Connections Inspect Battery Terminals Shake Filter with Crank for I minute Annual Install Wear Pack Inspect the Belt Tension Spring Supervisor Call 1 800 634 4060 for assistance PAGE 31 Eighteen 18 Months PARTS Replacement parts will be supplied free for 18 months or 750 hours from date of delivery to customer This parts warranty includes all parts on the machine except normal wear parts These exceptions are The brooms main and side The neoprene floor and hopper seals The filter cleaning crank s safety pin which is a fail safe device The side broom fuse on units so equipped The two rubber drive bel
15. 8 FW3 8 SAE 1 31 H33066 FW 4 SAE 4 32 H3612 HN 1 4 20 14 33 H 37006 NYLOK 44 40 4 34 H3705 NYLOK 10 32 8 35 H37018 NYLOK 1 4 20 2 36 137021 NYLOK 5 16 18 1 37 H 71063 LWY4 SS D 38 H 72683 FHP 10 32 X 5 8 4 PAGE 18 He COMPLETE FILTER ELEMENT P N 4 500 Air System PAGE 1 Part Description Comments Qy 1 4 MAIN BODY 1 2 4 15 MOTOR SUPT BRACKET 1 3 4 201 DV TWN SHAFT MOTOR 1 4 4 201 MOTOR CRADLE 1 5 4 210 TERMINAL CLIP 1 6 4 232 CIR BREAKER 12V 80A 1 1 4 233 DV SOLENOID 1 8 4 301 MAIN DRIVE PULLEY 1 9 4 501 FILTER HOOD 1 10 4 502 FILTER ELEMENT P N 4 502 INCL P N 4 502K SEAL 1 1 4 503A FILTER WEIGHT ROD P N 4 503 INCL SET OF 9 RODS 9 D 4 505 FILTER GRILL 1 B 4 506 FILTER BEATER BAR 1 14 4 507 BEATER BAR 1 5 4 509 BEATER BAR HANDLE 1 16 4 511 BLOWER HOUSING 1 N 4 52 BLOWER WHEEL 1 18 4 5B BLOWER DOOR 1 19 4 520 BLOWER HOSE 1 20 4 521A FILTER SEPARATOR PIN4 521INCL SET OF 9 SEPARATORS 9 21 4 522 DOOR LATCH INCLUDES SET OF 2 1 22 H 002 12 DBL SIDED TAPE P N4 502KINCL P NH 002 amp H 048 1 23 00287 375 COLLAR 1 24 048 3 16 PVC P N 4 502K INCL P N H 002 amp H 048 1 25 1032 HCN 10 32 15 26 10436 00106 HXMS 10 32 X 1 27 H 10436 00107 FB 8 32 3
16. ACT ORY CA Operator Parts amp Service Manual Model 34 Industrial Sweeper R P S Corporation Phone 1 800 634 4060 P O Box 368 Fax 1 866 632 6961 Racine Wisconsin 53401 www factorycat com SAFETY WARNING 5 A LCAREFULLY BEFORE OPERATING ADJUSTING OR p IS MACHINE CHARGING THE BATTERY WILL PRODUCE EXPLOSIVE HYDROGEN GAS Do not smoke or allow an open flame near a charging battery Do not charge battery with the hood lid of the machine closed or hydrogen gas may accumulate within DRESS SAFELY Do not wear rings or metal wrist watches while working on this machine They can cause an electrical short which in turn can cause burns Do not work on this machine while wearing a tie scarf or other dangling neckwear These can tangle in the rotating brooms belts and pulleys and cause serious injury or even death ERATE TRE SAFETY SWITCH MA INTEN ANCE PROCEDURES AS 0 This safety switch stops the motors whenever the hood lid is raised FOR REPAIR AND HIS BOOK 0 li DO NOT USE THIS MACHINE AS A STEP LADDER OR CHAT MACHINE IS HEAVY DO NOT LIFT UNAIDED DO NOT USE HANDLEBAR AS LIFTING POINT DO NOT WORK ON UNDERSIDE OF MACHINE WITHOUT PROPERLI SUPPORTING UNIT WAKE SURE HOOD LID IS CURED IF YOU WORK UNDER ITAROUND OTHER PEOPLE Another person may accidentally bump the lid in its over center position causing it to come down on you while you work beneath it IF YOU PLAN TO LEAVE YO
17. HARDWARE 1 5 4 378 BROOM LIFT SHAFT 1 6 4 381 LIFT LEVER BASE RT 1 7 4 385 LIFT LEVER COLLAR 1 8 4 386 LIFT LEVER SPRING 1 9 4 402 SIDE BROOM POLYPROPYLENE P N 4 402 INCLUDES P N 4 404 1 10 4 404 SIDE BROOM CLUTCH PLATE P N 4 402 INCLUDES P N 4 404 1 1 4 436 ADJ BROOM LIFT 1 D 4 441 BROOM MOUNTING BLOCK 1 B 4 442 SIDE BROOM ARM 1 14 4 443 BROOM RETAINING PLATE 1 5 4 444 BROOM SAFETY DRIVE CPLG 1 16 4 445A BROOM MOTOR MOUNT P N 4 445 INCL ITEMS 15 16 17 18 amp HARDWARE 1 U 4 445B BROOM 5 1 8 4 445 DRIVE BEARING 2 19 4 446 GROMMET 3 8 ID X 1 12 OD X 375 2 20 4 448 HANDLE GRIP 1 21 4 456 SIDE BROOM LONG LINK 1 22 4 457 ADJ USTMENT KNOB 1 23 4 55 RIGHT FLOOR SEAL 1 24 4 526 RH SEAL STRIP 1 25 H 10436 0010 1 4 X 114 SPRING PIN 1 26 H 10436 0105 3 8 X 11 4 SPRING PIN 1 27 H 19901 CASHD 1 4 20 X 1 2 7 28 H 2250 218 2 CLEVIS PIN 1 29 H 250HCN HCN 14 20 50 30 H 25328 SSS CP 1 4 20 X 3 8 2 31 H 29055 10 32 X 5 8 4 32 H 29576 FHP 14 20 X 13 4 4 33 H 36104 HN 5 16 18 1 34 37015 NYLOK 10 32 4 35 37018 NYLOK 14 20 8 36 37021 5 16 18 2 37 38558 HCS M6 10 X 14 3 38 45285 HITCH PIN CLIP 9 2 39 H 50102 FW5 8 X 15 16 1 40 70001 HCS 1 4 20 X 2 SS 2 41 H 71063 LWY4 SS 5 42 H 72916 PPH SMS 8 X 3 4 SS 3 43 H HAIR4 4 HAIR PIN 1 44 H ZCP154 3 8 X 11 2 CLEVIS PIN 1 45 H ZCP44 14 X 112 CLEVIS PIN 1 PAGE 24 Main Broom Assy
18. OOR SEAL 1 25 4 58 BROOM FLOOR SEAL 1 26 4 525 HOPPER SEAL STRIP 1 21 4 526 RH SEAL STRIP 1 28 4 527 REAR SEAL STRIP 1 29 4 528 CORNER SEAL STRIP 1 30 4 529 CURTAIN CLAMP 1 3l 5 130 SIDE DOOR LATCH 1 32 H 10436 0105 3 8 X 1 14 SPRING PIN 1 33 1213 12 13 X 2 12 2 34 13003 74 20 X 3 4 2 35 13055 HCS 5 16 18 4 36 H 19901 FB CASHD 1 4 20 X 12 29 37 H 250HCN HCN 14 20 50 38 H 29055 RPH 10 32 X 5 8 28 39 H 29570 FHP 1 4 20 2 40 29576 FHP 14 20 X 13 4 4 41 H 3302 FWI 2 SS 2 42 H 33078 FW1 4 SAE 2 43 33080 FW5 16 SAE 4 44 7070 HN 3 8 16 SS 8 45 H 36102 HN 1 4 20 8 46 H 36104 HN 5 16 18 4 47 37015 NYLOK 10 32 35 48 37018 NYLOK 14 20 8 49 37030 2 13 2 50 70001 HCS 14 20 X 12 SS 21 51 H 70 103 HCS 3 8 16 X 3 4 SS 8 52 H 33620 LW5 16 4 53 H 71063 LWY4 SS 23 54 H 71067 LW3 8 SS 8 55 H 71671 HXMS 10 32 X 2 SS 10 PAGE 2 DRIVE TUBE ASSY 4 445 Side Broom Assy SIDE BROOM MOTOR ASSY P N 4 425 tem Part No Description Comments 1 4 111 MAIN BODY 1 2 4 18 R INNER SIDE PANEL 1 3 4 220 SIDE BROOM MOTOR P N 4 425 INCL ITEMS 3 15 16 17 18 amp HARDWARE 1 4 4 376 BROOM LIFT LEVER P N 4 455 INCL ITEMS 4 5 6 7 8 19 amp
19. T 1 5 4 201 DV TWN SHAFT MOTOR 1 6 4 201B MOTOR CRADLE 1 7 4 210 TERMINAL CLIP 1 8 4 301 MAIN DRIVE PULLEY 1 9 4 31 BELT 4L260 1 10 4 312 TRANS INPUT PULLEY P N 4 375 INCL COMPLETE TRANSMISSION ASSY 1 1 4 313 REAR WHEEL CAPSTAN 1 1 4 3 CLUTCH MTG BRACKET 1 B 4 320 BROOM DRIVE PULLEY 1 4 4 330 CLUTCH WHEEL ASSY CLUTCH DONUT ORDERED SEPARATE IS P N 4 332 1 5 4 340 BRAKE SHOE 1 1 4 350 DIFFERENTIAL AXLE 1 Y 4 352 BEARING 4 18 4 353 REAR TIRE STANDARD 2 19 4 354 DRIVE CHAIN W MASTER LINK 1 20 4 358 REAR TIRE WDE OPTIONAL 2 21 4 362 TRANS HOUSING 1 22 4 364A FLANGE 175 ID P N 4 364 INCLUDES SET OF 2 8 23 10436 00135 3 8 X 4 12 CLEVIS PIN 1 24 13003 HCS 14 20 X 3 4 4 25 H 13051 HCS 5 16 18 X 12 2 26 H 13053 HCS 5 16 18 X 3 4 16 27 15220 1 2 13 X4 14 1 28 19901 FB CASHD 14 20 X 1 2 18 29 250 HCN 14 20 50 30 25153 SSS CP 8 32 X 1 4 4 31 H 25435 SSS CP 5 16 X 1 4 2 32 H 312HCN HCN 5 16 18 4 33 H 33080 FW5 16 SAE 4 34 H 33620 LW5 16 16 35 36102 HN 14 20 4 36 36104 HN 5 16 18 1 37 H 36204 J N 5 16 18 4 38 37030 NYLOK 2 13 1 39 65076 18 X I COTTER PIN 1 40 68015 SNAPRING 3 4 2 41 71063 LWY4 SS 4 42 H K14320 3 16 X 11 4 KEY 5 43 P50352 FW17 32 4 PAGE 28 PAGE 29 tem
20. UR MACHINE FOR EVEN A TURN OFF THE WAIN POWER SWITCH AND SET THE PARKING BRAKE SHORTLIST OF DOCS AND DON TS 1 10 G0 Pullonthe 2 10 T0 Letgoofthe 3 10 SWEEP main clutch lever gently to propel clutch lever to roll to a stop broom has to be on the floor the machine forward Pull Push down and forward on Use left hand lever to lower it harder to go faster the lever to set the brake Pull lever back then to right 5 DON TRUN BATTERY ALL THE WAY DOW 1 The machine will begin to slow and a red light will come on when battery is about to go dead When this happens stop Sweeping immediately and go back to base to recharge If battery runs down too low the 4 TO SWEEP The side Single switch controls main automatic on board charger broom has to be on the floor broom and side broom On will not pick it up again unless Use right hand lever to lower two switch models use right you run the charge through it Pull lever back then to left hand switch for side broom two charge cycles BATTERY NEEDS WATER Check battery water every two weeks Fill half way to ring with distilled water Do not overfill Do not let acid spill on battery or on n 4 machine If it does flush A Tp RECHARGE Open the With water and sprinkle KEEP GRANK VERTICAL 1 4 A with baking soda on the Before emptying hopper turn green light will turn on when fast 10 times
21. ber that running the battery down too low will require recharging the battery twice to pick it back up again PAGE OPERATING TIPS The machine can only pick up dirt when it runs over it It can not pick up dirt while sitting still Some bulky articles are hard to pick up and require a lot of floor space in front of the article to give the main broom a chance to grab the item Sweeping smart means avoiding dead ends If you have to back up the machine out of a corner you will probably leave some dirt behind Slow down if the floor is very dirty or if you notice the machine is not picking everything up The machine can only transfer so many pounds of material per minute RATING INSTRUCTIONS PLEASE CAREFULLY READ WARNINGS ON PAGE TWO OF THIS MANUAL Refer to Page 4 for location of controls 2 To make the machine move under its own power without sweeping Turn on Main Switch Make sure both brooms are off ground See Steps 5 amp 6 Below Gently pull clutch lever handle bar towards you You can regulate speed by varying how hard you pull on this lever 3 Stop Let go of the clutch lever To stop machine when going down hill set parking brake by pushing the clutch lever down and forward This locks rear wheels 4 To Sweep Main broom only Pull main broom lever to the right to lower broom to the floor Broom will drop causing lever to move toward front of machine Note that the ma
22. can cause quicker discharge 2 KEEP THE BATTERY FULL OF WATER A low water level can ruin the battery very quickly Water should always cover the plates inside the battery You see the tops of them when you remove the cap Many batteries have rings that are visible inside the cell holes In these batteries fill to ring We recommend you use only distilled water The minerals in ordinary water can coat the lead plates Shortening battery life 3 CHARGE THE BATTERY WTH THE CAPS IN PLACE Do not remove the caps for a normal charge These caps include proper venting and will keep the charging process from projecting a thin layer of acid on Surrounding machine parts 4 If you must use an external charger be sure to unplug the Andersen connector before doing so Otherwise you can damage the red light warning system Do not use an external charger that is too big for the battery or wrong voltage Charger must be 2V and must not put out more than 25 amps 5 ACID Batteries contain corrosive sulfuric acid As mentioned above leave the vented caps in place when charging so acid will not bubble out ofthe battery Take care that acid does not fall on the Steel surfaces of the machine eventually it will cause the machine to rust Treat acid spills with water to dilute the acid To clean up use solution of water and baking soda applied with a small brush Keep using the solutino until the fizzing stops This will neutralize the acid 6 MAKE
23. chine will not sweep unless broom is lowered to the ground 5 To Sweep Main and side brooms Pull side broom lever to the left to lower brush to the floor Broom will drop causing lever to move toward front of machine Then turn on the side broom Operating Tip When side broom is in use the broom should contact the floor from about 11 O Clock until about 5 O Clock See Page 11 for illustration The adjuster is under the hood 19 as shown Page 4 10 Turn the knob clockwise to raise the broom NOTE Side Broom does not work by itself Main broom must be down if sweeper is to pick up anything Clutch and Brake Lever Stop Brake Neutral on Pull the lever toward you to go forward The harder you pull the faster the machine will go Release the lever to coast to a stop Push this lever down towards the ground and then forward to engage the brake You do not normally need to use the brake to Stop Always use the brake when you park the machine and pick the brooms up off of the floor to avoid Flat Spotting them Main Broom Control Broom Lowered Broom Raised Pull main broom lever toward you and then toward the center of the machine This releases the catch and permits the main broom to drop To bring the main broom back up again pull lever from Lock position into Release position PAGE 6 OPERATING INSTRUCTIONS 6 To Sweep a Wet Floor If you are goin
24. cuit breaker has probably tripped The usual reason for this is that the side broom is adjusted improperly and has too much down pressure Breaker will automatically reset See Sidebroom Adjustment in this book Page 11 To Remove The Dirt Hopper CRANK should be vertical before removing or replacing the hopper drawer Otherwise you may break the safety pin on the crank mechanism Underside of Machine Handle Bar Asm Not Shown SAFETY TIP Recharging 1 Always Off Machine and Set Parking Brake before Charging Always Leave the Hood Lid Open PAGE 7 OPERATING INSTRUCTIONS 10 Recharging Battery Built In Battery Charger ff your machine is equipped with a built in battery charger simply turn off the machine set the brake open the hood lid and plug in the charger to a wall outlet with the correct voltage In North America our chargers are usually equipped for a single phase 110V 60Hz operation the same power as used in houses The three prong plug requires a grounded outlet Do not use without grounding The built in charger is completely automatic Its electronic circuitry will tell it when the battery is charged and shut itself off After the battery achieves correct voltage the charger will give a polish to the battery by shifting to high voltage input for a limited period of time The green light on the right hand side of the charging unit will glow when the charger is p
25. ep with as little as one half inch of main broom fiber main broom should have 10 of fiber or more to sweep really well Main Broom bounces This will cause skipping over debris If this occurs broom must be replaced Cause of broom bounce is generally bent fiber on one side causing broom to become oval This in turn is caused by leaving the broom on the ground for long periods of time without broom rotating which will bend the fiber Asecond cause is use of a mainbroom that is made incorrectly For this reason avoid will fit main brooms made by other manufacturers to fit our machines Our design requires brooms in perfect balance and perfectly round Check rubber flap on lip of the hopper This piece is very important to good sweeping and must be in good condition or machine will throw debris forward of machine If flap is torn or missing replace with a new part Hopper s Rubber Flap MACHINE SWEEPS UP DEBRIS FINE BLOWS DUST 4 5 Filter is dirty Wth power off turn crank 20 times to clean filter is shut off Open air shutoff control Filter is clogged from mud Remove and inspect filter Clean if necessary by shaking and vaccuuming the filter Air leaks Check and replace neoprene floor seals as needed Is fan turning with main motor Has set screw come out of fan PROBLEM MACHINE SWEEPS RATHER CONTROL PICKS UP DUST BUT BLOWS IT INTO THE ENGINE COMPARTMENT
26. g to sweep a wet surface you Should do so with the air system shut off Otherwise the vaccuum fan will pull water into the filter making it muddy and hard to clean To shut off the air to the filter open the small door at the end of the back painted filter housing Page 4 12 NOTE Remember to close the air shut off door again when youre back on dry pavement or you ll blow outdust wherever you sweep 7 Unload Hopper When machine stops sweeping well the hopper is full Turn off the machine Then turn the shaker crank handle at the rear of the machine about ten times The handle should then be left in the vertical position This cleans the filter Finally pull the dirt hopper all the way out of the machine It has a handle on each side When you put the hopper back make sure crank handle is straight up and down or the cleaning mechanism will prevent the hopper from sliding back in 8 Watch out for low battery NOTE The Sweeper will shut itself off when the battery gets too low Low voltage could otherwise damage the motors Ared warning light Page 4 Item 18 warns you just before battery is completely discharged Don t get caught with a dead battery Return back to base for a recharge early Batteries vary in their energy capacity OEM batteries usually offer between three and five hours of service on a charge 9 Side Broom s Circuit Breaker If the side broom stops by itself its protective cir
27. hain leaves about 1 4 to A clockwise to raise 1 2 inch of slack as shown Y broom To adjust the chain it is not necessary to remove the battery if you use the right tools 1 Turn off machine and unplug Andersen connector To adjust drive chain 2 Pull clutch lever all the way closed lever touching loosen clutch wheel bolt handlebar and tie or tape it into that position y and pull its axle up or down 3 Use a 3 4 combination wrench on left side of bolt that goes thru the clutch wheel Use a 3 4 ratchet socket wrench on the right side No more than 1 2 inch of play 4 bolt and pull up on it with the in chain measured here 5 Tighten bolt 6 Test unit Chain should not bind the clutch lever Some slack is required action and should not slap against the rear cover PAGE 11 MACHINE MAINTENANCE CLUTCH AND BRAKE ADJUSTMENT As explained in How it Works Page 5 the clutch and brake operate with the same control and by way of the same clutch donut If the clutch slips 1 Inspect the clutch donut If in good repair then adjust If donut looks melted then replace it got too hot from slipping 2 To adjust clutch Loosen the nut at the end of the cable where it enters the handlebar housing Also loosen the nut inside the handlebar housing Now tighten the outer nut until the clutch engages and the machine starts to c
28. justment 1 Adjust clutch first 2 Test brake 3 If brake does not hold loosen the 4 bolts holding the brake shoe to the transmission body and push shoe forward 4 Re tighten 4 bolts 5 Retest If you can not adjust succesfully replace clutch donut To Tighten Brake Shoe Hold Down Bolts Front of Machine TROUBLESHOOTING GUIDE Check for Cause of Problem in Order Shown PROBLEM MAIN MOTOR WILL NOT RUN Check that the hoods safety switch Page 4 17 is firmly down Check battery voltage Mhen voltage is too low circuit breaker will cut out Check for loose circuit wiring Check for defective on off switch Check for defective relay Check for defective circuit breaker Check and replace motor brushes Check also for burnt motor armature PROBLEM SIDE BROOM MOTOR WILL NOT RUN MAIN BROOM IS OK n th m by hand If no then Red Fuse Holder or Circuit 1 Check In Line fuse This is in the wiring harness Breaker is under this edge 2 3 4 If you can rotate the side broom by hand then on early machines and mounts under the hood on the left hand under side lip of the body Current machines use a circuit breaker Situated in the same location Check too see that the wiring harness on the side broom arm has not become disconnected Check the side broom switch Check broom motor 1 2 Check that the drive connector inside bearing
29. lugged in provided that the charger is also plugged in properly The green light will go out at the end of the charge cycle External Battery Charger If you use an external battery charger unplug Andersen connector before beginning charge Open hood and follow the charger instructions NOTE Some battery chargers are not automatic and will not shut off when battery is fully charged You can seriously damage a battery by overcharging it BATTERY SAFETY WARNINGS Charging a battery produces explosive hydrogen gas Leave the hood lid of the machine open while the battery is charging to avoid buildup of gas inside machine Do not smoke or expose open flame or spark to area around battery during charging Follow the instructions that came with your charger Many chargers are not automatic and can over heat the battery if not properly set Watch for battery acid If acid gets in the eye wash out with water for twenty minutes and call a physician PAGE 8 ABOUT BATTERIES do not recommend use of anything but a deep cycle battery one made to run a long time between recharging An automotive battery designed to be recharged by the cars alternator right after short use will give poor service We do not recommend use of a battery that weighs more than 1205 since this could make steering difficult GENERAL RULES FOR BATTERY CARE 1 KEEP THE BATTERY CLEAN Dirt on the battery transmits electricity and
30. n Connector Vaccuum Bypass Dust Filter Access Plate Hour Meter or optional Battery Condition Meter On Board Electronic Battery Charger Clutch amp Brake Cable Adjustment Safety Shut Off Switch operated by closing the hood Low Battery Light PAGE HOW IT WORKS 1 Main Broom which is tubular in shape and extends across width of machine rotates in direction shown pushing dirt and debris into hopper 2 Side broom when used picks up dirt in corners and pushes it toward the middle of the machine where the main broom picks it up FORWARD MOTION OF SWEEPER BRINGS DIRT TO RAPIDLY ROTATING MAIN BROOM MAIN BROOM KICKS IT UP TO HOPPER 3 The main broom creates dust The automatic vaccuum system sucks up this dust then the filter catches it The filter empties into the hopper It is cleaned by turning the crank at the rear of the machine which shakes the filter clean A drive system is provided Pulling the lever on the handlebar operates a clutch wheel The clutch wheel drives both rear wheels via a differential axle A parking brake is provided It stops the clutch wheel from turning which locks up both rear wheels Power for the main broom vaccuum fan and drive system all comes from a large electric motor A second motor drives the side broom The battery must be recharged after extended use It will run the machine for about 3 45 hours on a charge Remem
31. reep forward Loosen the outer nut one turn from that point Tighten the inner nut Test NOTE The brake should adjust automatically with the clutch If the clutch still works OK but the brake does not or vice versa follow steps on right side of this page If kept adjusted the clutch donut should last several years To replace the donut 1 Turn off the machine and unplug the battery Remove the rear protective panel to have access to rear axle 2 Remove the master link in the drive chain This link is visibly different from the others Removing the master link permits removal of the chain 3 Remove clutch cable end from the clutch fork 4 Remove the transmission from machine 4 bolts from bottom 5 Remove the clutch fork from the machine by removing the mounting pin 6 Remove the clutch wheel from the fork 7 the three bolts that hold the clutch wheel together to remove the donut 8 Install new donut on clutch wheel Be sure you mount clutch wheel concentric on axle 9 Reverse procedure to install PAGE 12 Clutch Adjustment When set properly machine should not creep in neutral but lever should begin to take hold when lever is depressed 12 or so set neutral a thin business card should just barely fit between clutch donut wheel and drive spindle capstan Adjust clutch at handlebar Clutch Donut Drive Spindle Business Card Adjusting Nut Location Brake Ad
32. ts LABOR 3 Months from date of delivery to customer TRAVEL 1 Month from date of delivery to customer Abuse and deliberate misuse are not covered Warranty is granted at the entire option of manufacturer RPS A13 Rev1298 PAGE 32 Wiring Schematics For machines after Serial No BY 2220 with Side Broom Circuit Breaker Battery D Volt Main Relay M1 Main Broom Motor M2 Side Broom Motor F1 Side Broom Circuit Breaker 6 Amp M2 22 Main Circuit Breaker 80 Amp 51 Safety Switch 52 Master Switch S3 Side Broom Switch H Hour Meter C Battery Charger G Grey 50 Connector P Plug Side Broom Harness Le B G 51 S2 53 ECT 4 4 H c ul Bb Blue Wiring Schematics For machines after Serial No CI 3200 with Single Electrical Switch for Main and Side Brooms Battery D Volt 1 Main Relay M1 Main Broom Motor 2 Side Broom Motor F1 Side Broom Circuit Breaker 6 Amp M2 F2 Main Circuit Breaker 80 Amp S1 Safety Switch 52 Main and Side Broom Switch Hour Meter G R C Battery Charger G Grey 50 Connector P P L Plug Side Broom Harness Warning Light Unit H E R O Tate BI B
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