Stark KAH 2000 S Operating instructions

Original
Operating and maintenance
manual
Bucket Sweeper (S-models)

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General
Congratulations on the purchase of your STARK bucket sweeper!
For us, the long lifecycle and efficiency of your new equipment is a priority. To keep the sweeper in top working
condition, read this manual carefully before using the equipment.
STARK products are engineered and manufactured in Finland, and each of them is equipped according to the needs of
the customer.
Never let anyone operate or maintain the device without reading this manual carefully! Always make sure that safety
precautions are observed in use and maintenance. Keep this manual for future reference and make sure to hand it over
to a new owner.
The cornerstones of the product development of STARK attachments are quality, durability and economy. The products
are engineered to be high-performing, safe and durable in professional use. Any feedback on our products is welcome
and contributes to the further development of our products. If you have any questions about the use or maintenance of
the bucket sweeper, please contact us by e-mail: [email protected]
Visit our webpage www.stark.fi for the complete product range, including new products.
The manufacturer reserves the right for structural and technical changes without prior notice. Therefore, some pieces of
information given in the manual may have changed after printing this manual.
Read before use
Make sure you know your equipment before you start using it.
Equipment may be operated only by an individual who is thoroughly familiar with its use.
All operators must be properly instructed before use and maintenance of the equipment. Use by
individuals with insufficient instructions may pose serious risks to the operators themselves, to
the environment and the equipment.
When coupling the attachment to the base machine, make sure:
-that all locking cotters are intact and in order
-there is no pressure in the hydraulic system
-that hydraulic hoses are intact
-there is no skin contact to hydraulic oil when connecting hydraulic hoses
-not to pull by the hydraulic hoses, but only by the hydraulic fitting
During operation, pay attention to:
-safe, appropriate travel speed
-other traffic, people and animals
-danger zones and objects that block your view
-children
NEVER use the machine, if there is someone in the danger zone.
NEVER go under the attachment.

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Table of contents
General.................................................................................................................................................2
Read before use ...................................................................................................................................2
1. DECLARATION OF CONFORMITY......................................................................................................4
2. PURPOSE OF USE..............................................................................................................................5
3. SAFETY PRECAUTIONS......................................................................................................................5
4. IDENTIFICATION INFORMATION AND SPAREPARTS ........................................................................6
4.1. Identification plate ............................................................................................................................ 6
4.2. Maintenance services........................................................................................................................ 6
5. MAIN PARTS OF THE BUCKET SWEEPER ..........................................................................................7
6. USING THE BUCKET SWEEPER..........................................................................................................8
6.1. Attaching the bucket sweeper to a base machine ............................................................................ 8
7. OPERATING THE BUCKET SWEEPER.................................................................................................9
7.1. Operating instructions....................................................................................................................... 9
7.2. Adjusting the brush roller height..................................................................................................... 10
7.3. Replacing the brush rings ................................................................................................................ 11
7.4. Transferring the bucket sweeper .................................................................................................... 11
7.5. Detaching the bucket sweeper from the base machine ................................................................. 12
7.6. Accessories ...................................................................................................................................... 12
8. MAINTENANCE OF THE BUCKET SWEEPER....................................................................................13
8.1. General safety precautions for use and maintenance .................................................................... 13
8.2. Tightening torque............................................................................................................................ 13
8.3. Daily maintenance........................................................................................................................... 13
8.4. Maintenance after first 10 hours of operation ............................................................................... 13
8.5. Maintenance after every 50 hours of operation or weekly ............................................................ 13
8.6. Lubrication points............................................................................................................................ 14
9. Hydraulics.......................................................................................................................................15
9.1. 2- hose hydraulics............................................................................................................................ 16
9.2. Combi hydraulics ............................................................................................................................. 17
9.3. Combi hydraulics with side brush.................................................................................................... 18
9.4. Combi hydraulics with side brush and high-pressure washer......................................................... 19
9.5. 4-hose hydraulics............................................................................................................................. 20
9.6. 4-hose hydraulics with side brush................................................................................................... 21
9.7. 4-hose hydraulics with two side brushes and high-pressure washer ............................................. 22
10. WARRANTY POLICY ......................................................................................................................23

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1. DECLARATION OF CONFORMITY
The original manufacturer’s EC declaration of conformity:
Generic product name: Bucket sweeper
Models: STARK KAH 2000 S, KAH 2500 S, KAH 3000S
Manufacturer:
Lametal Ltd
Kaskenviertäjäntie 2 73100 LAPINLAHTI, Finland
tel. [phone]
Declares that the above-mentioned equipment meet the provisions of Directive 2006/42/EC on machinery and, where
applicable, comply with the standards
•SFS-EN ISO 12100-1,
•SFS-EN ISO 12100-2
•SFS-EN 1050
The person authorized to compile technical documentation:
Lassi Mehtonen
Managing director
Kaskenviertäjäntie 2
73100 Lapinlahti, FINLAND

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2. PURPOSE OF USE
Bucket sweepers are intended for cleaning streets and yards of different size.
3. SAFETY PRECAUTIONS
Make sure you know your equipment before you start using it. Equipment may be operated only by an individual who is
thoroughly familiar with its use.
Before connecting hydraulics to the base machine, make sure that:
-there is no-one between the attachment and the base machine
-the base machine is turned off and the parking brake is on.
When coupling the attachment to the base machine, make sure that:
-all locking cotters are intact and in order
-hydraulic hoses are intact
-there is no skin contact to hydraulic oil when connecting hydraulic hoses
-you do not to pull by the hydraulic hoses, but only by the hydraulic fitting.
During operation, pay attention to:
-safe, appropriate travel speed
-other traffic, people and animals
-danger zones and objects that block your view
-children
-use of turn signal when driving
NEVER use the machine, if there is someone in the danger zone
NEVER go under the attachment
During maintenance, the hydraulics of the base machine MUST be turned off. The base machine MUST also be turned
off and the parking brake MUST be applied. The equipment must be properly supported, if maintenance can only be
performed by going under the equipment. Never go under the equipment if it is not properly supported.
Daily maintenance:
-Check general condition of structures, make repairs if needed
-Check the hydraulic hoses and fittings, and replace damaged parts
After every 50 hours of operation:
-lubricate points specified in section 8.6. of this manual
-check all bolts and nuts for tightness
Check all bolts, nuts and hydraulic fittings for tightness after the first day of operation!
If the equipment is not likely to be used for a longer period of time, clean it thoroughly after use and lubricate as
instructed.
WARNING! Rotating rollers!
WARNING! Pressurized hydraulic hoses and components!

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4. IDENTIFICATION INFORMATION AND
SPAREPARTS
4.1. Identification plate
Identification plate is placed on the side of the equipment. The plate includes contact information, machine type, year of
manufacture, serial number and weight. (See an example of an identification plate in picture 1 below).
The first four numbers in the serial number indicate the month and year of manufacture (month first). The remaining five
numbers constitute the machine tracking number, which is stored in the manufacturer’s database (13971 in the example
below).
Picture 1. Identification plate
Take down the machine type and the serial number of your bucket sweeper:
Product and model _______________________________Serial number___________________________________
4.2. Maintenance services
When replacing parts, use original, manufacturer spare parts only. By using original spare parts, you ensure dependable
operation of the bucket sweeper and comply with the warranty policy. To facilitate the supply of spare parts, always
inform the manufacturer/dealer of the model and serial number of the bucket sweeper (marked in the identification plate)
when you order spare parts.
For more information on maintenance and spare parts, please contact the STARK maintenance and spare part services
or your dealer.
Contact information for STARK maintenance services:
tel. [phone], e-mail [e-mail]
tel. [phone], e-mail [e-mail]

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5. MAIN PARTS OF THE BUCKET SWEEPER
Picture 1. Main parts of the device
1) Bucket sweeper frame
2) Brush frame arm
3) Brush frame lifting cylinder
4) Brush roller
5) Adjustment pole
6) Bolt-on mudguard
7) Brush rings
8) Wear blade

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6. USING THE BUCKET SWEEPER
When attaching the bucket sweeper for the first time, make sure it is compatible with the base machine by following the
instructions below. Always check the compatibility when attaching the bucket spreader to a new base machine.
6.1. Attaching the bucket sweeper to a base machine
The bucket sweeper is attached to the base machine by bolt-on STARK FIT quick hitchers which in turn are attached to
the floating frame. The machine is connected to a hydraulic system. Hydraulic circuit diagrams are shown in section 9 in
this manual. Ask your dealer for available STARK FIT quick hitches.
Before using the bucket sweeper, MAKE SURE all locking cotters are secured and intact.
When coupling the bucket sweeper to the base machine, please pay attention to the instructions on the use of the base
machine.
1. Make sure that the attachment and the base machine are compatible in terms of mechanical solutions,
hydraulics and electricity.
2. Apply parking brake. The bucket sweeper is attached to the coupler on the base machine (e.g. a loader). Attach
the bucket sweeper to the base machine, and make sure the locking cotters are secured.
3. Turn off the base machine and make sure the parking brake is applied.
4. Make sure there is no pressure in the base machine hydraulic system. When connecting, always make sure the
hydraulic connectors are clean and the hoses are intact.
5. Check carefully the movement paths between the coupling mechanism, the base machine and the attachment
for collisions. Check also the space needed for hydraulic hoses and connectors. Check that the brush roll
rotates in the direction of the bucket. If not, switch hose locations in the base machine.
6. The rotating speed of the brush roller can be adjusted by the flow control valve. Usually, appropriate speed is
set by using positions 2-10. If the base machine has a flow control feature, turn the flow control valve to position
10.
7. During first hours of operating the attachment, bolts, nuts and connectors might loosen up. Retighten them
after the first day of operating the attachment.

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7. OPERATING THE BUCKET SWEEPER
Before using the bucket sweeper, make sure:
-the bucket sweeper is installed correctly
-all locking pins are in place
-hydraulic hoses are connected properly
-hoses are intact
-there are no oil leaks
-all functions are working properly
-you have tested the functions of the bucket sweeper in a closed area before starting to work with it
7.1. Operating instructions
1. Check that the attachment and the base machine are compatible in terms of mechanical solutions, hydraulics
and electricity.
2. The bucket sweeper is connected to the base machine’s quick hitching (e.g. front loader). Apply the parking
brake. Connect the bucket sweeper to the base machine and make sure the pins are properly locked.
3. Turn off the base machine and make sure the parking brake is applied.
4. Make sure there is no pressure in the base machine hydraulic system. When installing, always check that the
hydraulic fittings are clean, and hoses are intact.
5. Check carefully the movement paths between the attachment mechanism, the base machine and the
attachment for collisions. Check also the space needed for hydraulic hoses and fittings.
6. Check that the brush roll rotates in the direction of the bucket. If not, switch hose locations in the base machine.
7. The rotating speed of the brush roller can be adjusted by the flow control valve. Usually, appropriate speed is
set by using positions 2-10. If the base machine has a flow control feature, turn the flow control valve to position
10.
8. Adjust the driving speed, motor rotation speed and brush roller rotation speed in accordance to the brushing
need. The bush roller rotation speed is adjusted by the flow control valve.
9. Using the adjustment poles, adjust the brush at the appropriate height from the ground. In the appropriate
height the brush rings are pressed approx. 20mm against the ground . (picture 3).
10. Keep the bucket in the middle position when using Pin Float so that the bucket rests on its lip blade and support
wheels, following bumps and curves of the road closely. Do not press the bucket against the ground with
flotation.
11. Stay alert for any abnormal behaviour and oil leaks also during driving.

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Picture 3. Appropriate height of the brush roller
7.2. Adjusting the brush roller height
The height of the brush roller is set by adjusting the adjustment poles (picture 3). When the brush rings start to wear,
lower the brush roller so that brush rings are pressed appr. 20mm against the road. When the diameter of the brush
rings is 50cm, they need to be replaced (picture 4). NB! Make the same adjustments with both poles. Otherwise the
brush rings will wear unevenly.
Picture 4. When the diameter is 50cm, the brush rings need to be replaced.
Adjustment pole

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7.3. Replacing the brush rings
1. Support the brush roller with two mounting brackets.
2. Detach the bearing and the brush roller flange (picture 5).
3. Unfasten the brush roller flange plate (picture 6).
4. Pull the brush rings out. When moving the mounting brackets, be careful not to put the entire weight of the brush roller
on the motor-side.
5. Install new brush rings by working in a reverse order.
Picture 5. Brush roller bearing fastening bolts
Picture 6. Brush roller flange fastening bolts
7.4. Transferring the bucket sweeper
Lift the bucket sweeper high enough and reduce speed if needed, especially on bumpy, uneven roads. The bucket
sweeper or the base machine can be damaged due to excessive speed.

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7.5. Detaching the bucket sweeper from the base machine
1. Lower the bucket sweeper down on an even surface. Lift the brush roller so that the brush rings are not pressed
against the ground.
2. Turn off the base machine, apply the parking brake and depressurize the system.
3. Detach the hydraulic hoses and protect hose ends with plugs.
4. Unlock the coupling mechanism and detach the device.
5. If the equipment is not likely to be used for a longer period of time, clean it thoroughly after operating and
lubricate as instructed. Remove water from containers and hoses. Remove irrigation nozzles and store them
inside. If possible, store the device indoors.
7.6. Accessories
The following accessories are available for the bucket sweeper:
-Low-pressure watering system, with container size 155L
-High-pressure dust suppression system with high pressure pump, with container size 155L in model KAH 2000
S, and with size 255L in models KAH 2500S and KAH 3000 S.
-Support rollers
-Side brush with hydraulic lifting (right and left side)
-Mechanical side mover
-Pin Float -fitting
-High pressure washer
Note about the watering system:
1. Use fresh water only in the watering system.
2. Water is sprinkled to the area to be cleared to suppress dusting. Place and point the nozzles for the best
possible result. The nozzles can be placed and pointed, for example, towards road edges, where dusting is
likely to be heavier.
3. The total of 7 hoses and nozzles are delivered; hoses can be taken into and out of use as needed.
4. The amount of water consumption depends on the number of nozzles. One nozzle consumes appr. 1L/min.
5. If the watering system is not likely to be used for a longer period of time, it is advisable to run a mixture of
cooling liquid and water through the system in order to prevent corrosion. After this, make sure the container
and hoses are empty. Remove the nozzles and keep indoors.

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8. MAINTENANCE OF THE BUCKET
SWEEPER
8.1. General safety precautions for use and maintenance
-Comply with existing laws and regulations and the instructions given in this manual.
-Never go under an unsecured device.
-Always apply the parking brake of the base machine before performing any actions on the device.
-Only use tools that are in proper working order.
-Be careful with the pressurized hydraulic hoses and components.
-Make sure there is no pressure in the hydraulic system, including the pressure accumulator.
-Make sure hydraulic fluids or greases do not leak to the ground.
-Use all necessary personal protectors.
8.2. Tightening torque
Nm (strength 8.8)
M4
3,3
M5
6,5
M6
11,3
M8
27,3
M10
54
M12
93
M14
148
M16
230
M18
329
M20
464
M22
634
M24
798
M27
1176
M30
1597
M33
2161
M36
2778
M39
3597
Table 1. Tightening torque
8.3. Daily maintenance
In order to prevent further damages, it is important to inspect the device visually for possible defects. Inspect at least the
following on a daily basis:
-hydraulic hoses and components for possible leaks
-general mechanical functioning
8.4. Maintenance after first 10 hours of operation
-Lubrication, recommended quality NLGI-2 grade grease or equivalent (see section 8.6)
-Check the bolts for the tightness (table 1)
8.5. Maintenance after every 50 hours of operation or weekly
-Lubrication, recommended quality NLGI-2 grade grease or equivalent (see section 8.6)
-Check the mechanical condition of the device for bends, distortions or breaches
-Check the bolts for the tightness (table 1)

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8.6. Lubrication points
Picture 8. Location of grease nipples
Picture 9. Grease nipple for the bearing
1) Grease nipples for the hydraulic cylinders
2) Grease nipples for the floating pins
3) Grease nipple for the bearing

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9. Hydraulics
The bucket sweeper can be connected to a 2-hose or a 4-hose hydraulic system. The device is equipped with a complex
closed hydraulic system, which has been tested and adjusted by the manufacturer. Any repairs to the system are to be
performed by replacing one component at a time by a professional in hydraulics. Any alterations or modifications to the
hydraulic system are on the sole responsibility of the client.
Max. pressure: 200 bar
Max. oil flow: 100l/min.
Max. return line back pressure 80 bar
The brush rotation speed is adjusted by the flow control valve. If the base machine has a flow control feature, the control
valve in the attachment can be set to position 10.
The bucket sweeper is connected to a 2-hose or a 4-hose hydraulic system.
In Combi hydraulics, lowering the brush roller and rotation of the motor is operated on the second flow direction of the
hydraulic block, and lifting the brush roller is operated on the reverse flow direction.

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9.1. 2- hose hydraulics
Figure 1. 2-hose hydraulics
A –Base machine control block
B –6/2-valve
C –Brush frame lift cylinders
D –Brush roller motor
E –Flow control valve

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9.2. Combi hydraulics
Figure 2. Combi hydraulics
A –Base machine control block
B –Brush frame lift cylinders
C –Brush roller motor
D –Flow control valve

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9.3. Combi hydraulics with side brush
Figure 3. Combi hydraulics with side brush
A –Base machine control block
B –6/2 valve
C –Brush frame lift cylinders
D –Brush roller motor
E –Flow control valve
F –Side brush, brush lift cylinder
G –Side brush, brush rotation motor

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9.4. Combi hydraulics with side brush and high-pressure washer
Figure 4. Combi hydraulics with side brush and high-pressure washer
A –Base machine control block
B –6/2 valve
C –Brush frame lift cylinders
D –Brush roller motor
E –Flow control valve
F –Side brush, brush lift cylinder
G –Side brush, brush rotation motor
H –High pressure pump

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9.5. 4-hose hydraulics
Figure 5. 4-hose hydraulics
A –Base machine control block
B –Base machine control block 2
C –Brush frame lift cylinders
D –Brush roller motor
E –Flow control valve