Stark thm-4500 Operating instructions

Original
Operating and maintenance
manual
Back broom

Sivu 2 / 21
General
Congratulations on the purchase of your STARK Back broom!
For us, the long lifecycle and efficiency of your new equipment is a priority. To keep the broom 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 broom, please contact us by e-mail: [e-mail]
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.

Sivu 3 / 21
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 BACK BROOM .............................................................................................7
6. USING THE BACK BROOM.............................................................................................................8
6.1. Attaching the broom to the base machine........................................................................................ 8
7. OPERATING THE BACK BROOM ....................................................................................................9
7.1. Using the back broom........................................................................................................................ 9
7.2. Overload switch............................................................................................................................... 10
7.3. Changing the brush rings................................................................................................................. 11
7.4. Changing the broom roller .............................................................................................................. 13
7.5. Adjusting the chain.......................................................................................................................... 14
8. MAINTENANCE OF THE BACK BROOM .......................................................................................16
8.1. General safety precautions for the use and maintenance.............................................................. 16
8.2. Tightening torque............................................................................................................................ 16
8.3. Daily maintenance........................................................................................................................... 16
8.4. Maintenance after first 10 hours of operation ............................................................................... 16
8.5. Maintenance at 50-working hour intervals or on a weekly basis ................................................... 16
8.6. Lubrication points............................................................................................................................ 17
9. HYDRAULICS................................................................................................................................19
10. WARRANTY POLICY .................................................................................................................21

Sivu 4 / 21
1. DECLARATION OF CONFORMITY
The original manufacturer’s EC declaration of conformity:
Generic product name: Back broom
Models: STARK THM 4500
Manufacturer:
Lametal Ltd
Kaskenviertäjäntie 2 73100 LAPINLAHTI, Finland
tel. [phone]
Declares that the above-mentioned equipment meets 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

Sivu 5 / 21
2. PURPOSE OF USE
The back brooms are intended for sweeping of streets, yards and areas small and large.
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
WARNING! Rotating rollers!
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 later section 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! Pressurized hydraulic hoses and components!

Sivu 6 / 21
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 back broom:
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 back broom and comply with the warranty policy. To facilitate the supply of spare parts, always inform
the manufacturer/retailer of the model and serial number of the back broom (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 retailer.
Contact information for STARK maintenance services:
tel. [phone], e-mail [e-mail]
tel. [phone], e-mail [e-mail]

Sivu 7 / 21
5. MAIN PARTS OF THE BACK BROOM
Picture 2. Main parts of the back broom
1) Back broom’s frame
2) Propeller shaft
3) Angle gear box
4) Front propeller shaft
5) Rotating triangle
6) Hydraulic cylinder
7) Broom roller
8) Chain
9) Brush ring
10) Support wheel
11) Chain’s protective plate

Sivu 8 / 21
6. USING THE BACK BROOM
When attaching the back broom 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 back broom to a new base machine.
Make sure that the base machine allows the installation of the back broom. The back broom is attached to the base
machine’s rear lifter.
Minimum requirements of the base machine:
-3-point attachment
-2-action hydraulic valve for rotating the broom. Broom has ½” connectors.
-The broom is attached to 540 rpm or 1000 rpm outing by propeller shaft.
6.1. Attaching the broom to the base machine
The back broom is attached to the back of the base machine by 3-point attachments. The machine is connected to a
hydraulic system. Hydraulic circuit diagrams can be found in a later section in this manual.
Before using the back broom, MAKE SURE all locking cotters are secured and intact.
When coupling back broom 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. 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.
3. Reverse the base machine near the broom. Attach the support beams to the broom. Apply parking brake.
4. Back broom is attached to the coupler on the base machine. Attach the broom to the base machine. Make sure all the
cotters are locked.
5. Attach the propeller shaft the base machines power take-off (540 r/min or 1000 r/min). Make sure that the propeller
shaft has its protective covers in their proper places. Attach the hydraulic hoses.
6. Check carefully the attachment’s, the base machine’s and the fitting’s trajectory for collision. Make sure that the
needed space for hydraulic hoses and -attachments is adequate.
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.

Sivu 9 / 21
7. OPERATING THE BACK BROOM
Check following before using the back broom:
-Broom is installed properly to the base machine
-All locking cotters are in place
-Hydraulic hoses are attached properly
-Hoses are intact
-There are no oil leaks in attachment
-All functions are in order
-Learn the functions of the back broom in an enclosed area before actual usage.
-Observe all unusual activity and oil leaks when operating the back broom.
7.1. Using the back broom
1. Make sure that the attachment and the base machine are compatible in terms of mechanical solutions,
hydraulics and electricity.
2. The back broom is attached to the coupler on the base machine. Reverse the base machine near the device
and lower the support beams. Attach the back broom 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. Lift back brooms front support legs. Lock them in upward position with locking cotters.
6. Check carefully the attachment’s, the base machine’s and the fitting’s trajectory for collision. Make sure that the
needed space for hydraulic hoses and -attachments is adequate.
7. Keep the back broom in suitable distance from ground (picture 3). Brush ring should bend approx. 20mm. Do
not press the broom too hard with a base machine. Brush rings wear down faster and the attachment could
be damaged!
8. The maximum rotational speed of the broom roller is 300 r/min. Gear ratio for the broom roller us 1:1,4
(retardant). Adjust the power out-take (540 r/min or 1000 r/min) and the engine’s rotational speed so that the
max. rotational speed of the broom roller is not exceeded.
9. Adjust the driving speed and the rotational speed of the broom appropriate for the amount of sand / trash.
10. Back brooms horizontal propeller shafts are equipped with overload switch. Their max. torque is 900 Nm. It is
forbidden to replace to overload switch with a stronger torque switch.
11. Stay alert for any abnormal behaviour and oil leaks also during driving.

Sivu 10 / 21
Picture 3. Suitable height for the brush ring
7.2. Overload switch
Load on the back broom must be reduced when the overload switch opens. Slow down the driving speed or stop
completely until the overload switch operates normally. Overload switch is a safety mechanism which can be damaged
when used incorrectly. Warranty does not cover propeller shaft equipped with overload switch. (Picture 4)
Picture 4. Overload switch

Sivu 11 / 21
7.3. Changing the brush rings
1) Detach the protective case for the chain. (Picture 5)
2) Loosen the chain and remove it. (Picture 6)
3) Detach 2 pc of M12 bolts from the locking plate. (4 pc, pictures 7 and 8)
4) Detach the bearing’s snap ring from the axle. (Picture 9)
5) Secure the broom roller with 2 support beams to the floor before removing the end plates. Detach the end
plate’s bolts (5 pc) and remove the end plate. (Picture 10)
6) Detach the bolts of the locking flange. (Picture 11)
7) Remove the brush- and the middle rings. When moving the support beams make sure that the back broom
doesn’t rest solely on the middle bushing. This can break the bushing.
8) Install double brush rings to the ends of the broom rollers. (Picture 12)
9) Assemble in a reverse order.
Picture 5. Protective case of the chain Picture 6. Removing the chain
Picture 7. Bolts of the locking plate Picture 8. Cogwheel

Sivu 12 / 21
Picture 9. Snap ring of the bearing Picture 10. Bolts of the end plate
Picture 11. Bolts of the locking flange
Picture 12. Install double brush rings to the ends of the broom rollers

Sivu 13 / 21
7.4. Changing the broom roller
The broom roller is attached to the middle support with a bolt-on bearing housing. The broom roller can be fully removed
after removing the end plate by detaching the bearing housings from the middle support. (Picture 13)
At the side of the middle support there is a bearing which can be changed after the broom roller’s axle is removed.
Remove the locking flange and pull the bearing off its housing. (Picture 14)
Picture 13. Broom rollers Picture 14. Bearing of the middle support

Sivu 14 / 21
7.5. Adjusting the chains
The back broom has a chain at both sides, which transfers the power between the propeller shaft and the broom roller’s
axle. Check chains for tightness after every 50 operating hours. If chains are too loose, they will be needlessly strained.
If chains are too tight, they will strain cogwheels and axles’bearings.
Chains are behind their protective cases. Adjusting the chains:
1. Remove the protective case and the cover plate of the propeller shaft. (Picture 15)
2. Loosen 2 locking bolts (picture 16) and the nut under the chain tightener (picture 17).
3. Rotate the nut over the chain tightener to tighten the chain (picture 17).
4. Suitable tightness for the chain: press the chain in the middle with a force of a approx. 20 kg. Chain should yield
about 10-15 mm (picture 18).
5. Tighten the locking bolts and reattach the protective case.
Picture 15. Protective case of the chain and cover plate Picture 16. Locking bolts
Picture 17. Chain tightener’s nuts Picture 18. Suitable tightness for the chain

Sivu 15 / 21
7.6. Removing the back broom from the base machine
1. Lower the back broom down on an even surface on its support legs (picture 19).
2. Adjust the support wheels so that the brush rings don’t touch the ground.
3. Turn off the base machine, apply the parking brake and depressurize the system.
4. Detach the hydraulic hoses and protect hose ends with plugs.
5. Unlock the coupling mechanism and detach the device.
6. 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 irrigation system’s hoses. If possible, store the unit inside.
Picture 19. Properly supported back broom
7.7. Transferring the back broom
When transferring the attachment lift the brush rings and the support legs and reduce the speed if needed, especially on
bumpy, uneven roads. Base machine or the attachment can be damaged due to excessive speed.

Sivu 16 / 21
8. MAINTENANCE OF THE BACK BROOM
8.1. General safety precautions for the 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. Take into account 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 daily:
-Hydraulic hoses and components for possible leaks
-General mechanical functioning
8.4. Maintenance after first 10 hours of operation
-Lubricate, preferably with a NLGI-2 grease or equivalent (see instructions in later sections)
-Check all bolts and nuts for tightness (table 1)
8.5. Maintenance at 50-working hour intervals or on a weekly
basis
-Lubricate, preferably with a NLGI-2 grease or equivalent (see instructions in later sections)
-Check the mechanical condition of the device for bends, distortions or breaches
-Check fastening bolts for tightness (table 1)
-Check the chain for tightness (section 7.5.)
-Lubricate the propeller shaft (section 8.8.)

Sivu 17 / 21
8.6. Lubrication points
1. Grease nipples for the hydraulic cylinder
2. Grease nipples for the support wheel’s crank
3. Grease nipples for the support wheels
4. Grease nipples for the chain
Picture 21. Lubrication points Picture 22. Lubrication points
Picture 23. Lubrication points
Picture 20. Lubrication points
1
2
3
4

Sivu 18 / 21
8.7. Adding oil to the angle gear box
-Angle gear box in the middle has oil inside. The amount of oil is checked with a plug located at a side of the
gear box (red arrow). Old oil is removed from the emptying plug located under the gear box (blue arrow).
(Picture 24)
-The oil must be at least at the level of the plug when the attachment is horizontally aligned.
-Oil type for the gear box: transmission oil ISO WG 150 / SAR 90. Amount of approx. 4 liters.
-Oil must be changed after the first 50 hours. After that oil must be changed after every 500 operating hours or
after 2 years.
-Detach angle gear box from the frame. Open the filling cap of the gear box. Drain the old oil carefully from the
case. Pour fresh oil into the case, check the condition of the seal washer and close the cap carefully.
Picture 24. Angle gear box
8.8. Propeller shafts
The back broom has three propeller shafts. Shaft’s grating must be lubricated after every 8 operating hours. Add grease
to the grating until it starts to pour out. (Picture 25)
Propeller shaft’s shape tubes need to be greased regularly, after every 50 operating hours. Vaseline spray is suitable for
greasing (for example Würth HHS2000 or similar).
Picture 25. Propeller shaft's grating

Sivu 19 / 21
9. HYDRAULICS
The back broom can be connected in two different ways, either with two (figure 1) or four (figure 2) hoses. When
connecting with two hoses, the hydraulics of the basic machine is connected to quick connectors and a separate switch
is used to choose whether the broom is rotated or turned. When connecting with four hoses, a rotation cylinder and the
rolling of the engine are connected separately to the hydraulics of the basic machine. This means that the lifting and
rotating of the broom can be done with the hydraulics of the basic machine, and no separate control valve is needed.
The rotation speed of the broom is adjusted with the valve shown on figure 1. The suitable position is usually found
between 5 and 8. If there is a flow controller in the basic machine, the speed control valve can be set to position 10.
SH = Cylinder hydraulics MH = Motor hydraulics
Figure 1. 2-hose hydraulics

Sivu 20 / 21
Figure 2. 4-hose hydraulics