Stark KH 1600 T Operating instructions

Original
Operating and maintenance
manual
Collecting sweeper

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General
Congratulations on the purchase of your STARK Collecting 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 ........................................................................7
4.1. Identification plate ............................................................................................................................ 7
4.2. Maintenance services........................................................................................................................ 7
5. MAIN PARTS OF THE COLLECTING SWEEPER...................................................................................8
6. ATTACHING THE COLLECTING SWEEPER........................................................................................10
6.1. Attaching the collecting sweeper to a base machine...................................................................... 10
7. OPERATING THE COLLECTING SWEEPER........................................................................................11
7.1. Operating manual............................................................................................................................ 11
7.2. Adjusting the height of the broom roller ........................................................................................ 12
7.3. Adjusting the side brushes .............................................................................................................. 13
7.4. Replacing the brush rings ................................................................................................................ 14
7.5. Replacing the side brushes.............................................................................................................. 16
7.6. Transferring the collecting sweeper................................................................................................ 16
7.7. Detaching the collecting sweeper ................................................................................................... 16
7.8. Irrigation system.............................................................................................................................. 17
7.9. Accessories for the collecting sweeper ........................................................................................... 17
8. MAINTENANCE OF THE COLLECTING SWEEPER.............................................................................18
8.1. General safety precautions for the use and maintenance.............................................................. 18
8.2. Tightening torque............................................................................................................................ 18
8.3. Daily maintenance........................................................................................................................... 18
8.4. Maintenance after first 10 hours of operation ............................................................................... 18
8.5. Maintenance at 50-working hour intervals or on a weekly basis ................................................... 19
8.6. Lubrication points............................................................................................................................ 19
9. HYDRAULICS...................................................................................................................................20
9.1. 2-hose hydraulics............................................................................................................................. 20
9.2. 4-hose hydraulics............................................................................................................................. 22
10. WARRANTY POLICY ......................................................................................................................23

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1. DECLARATION OF CONFORMITY
The original manufacturer’s EC declaration of conformity:
Generic product name: Collecting sweeper
Models: KH 1600 T, KH 2000 T, KH 1600 S, KH 2000 S, KH 2500 S
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, complies 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
Collecting sweepers are used 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
WARNING! Rotating rollers!
WARNING! Pressurized hydraulic hoses and components!

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After every 50 hours of operation:
-lubricate points specified in section 8.6.
-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.

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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 collecting 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 colleting 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 collecting 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 par[email protected]

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5. MAIN PARTS OF THE COLLECTING
SWEEPER
1) Frame of the collecting sweeper
2) Bottom plate
3) Broom roller
4) Floating beam
5) Protective case
6) Hydraulic cylinder
7) Front support wheel
8) Back support wheel
9) Brush lamellas
Picture 2. Main parts of the sweeper

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Picture 3. Main parts of the sweeper

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6. ATTACHING THE COLLECTING SWEEPER
When attaching the collecting 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 collecting sweeper to a new base machine.
6.1. Attaching the collecting sweeper to a base machine
The collecting sweeper is attached to the base machine by bolt-on STARK FIT quick hitches which in turn are attached
to the floating frame. The machine is connected to a 2- or 4-hose 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 collecting sweeper, MAKE SURE all locking cotters are secured and intact.
When coupling the collecting 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. 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. Apply parking brake.
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. Test the base machine and the loader by doing all movements to the end in order to make sure that the
sweeper won’t collide with the base machine. Check also the space needed for hydraulic hoses and connectors. Check
that the brush roll rotates in the direction of the sweeper. 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 the 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 COLLECTING SWEEPER
Before using the collecting sweeper, make sure:
-the sweeper is installed correctly
-all locking pins are in place
-hydraulic hoses are installed correctly
-hoses are intact
-there are no oil leaks
-all functions are working properly
-that you have learnt to operate the collecting sweeper in a closed area before actually starting to use it
7.1. Operating manual
1. Make sure that the attachment and the base machine are compatible in terms of mechanical solutions,
hydraulics and electricity.
2. The collecting sweeper is attached to the coupler on the base machine (e.g. a loader). Attach the sweeper to
the base machine, and make sure the locking cotters and pins 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.. Make sure that the hydraulic hoses and connectors have enough space.
6. Check that the brush roll rotates in the direction of the case and the side brushes (if used) rotate towards the
device. If not, switch hose locations in the base machine.
7. Broom roller’s rotational speed can be adjusted by a 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 driving speed, engine’s revolution speed and rotational speed of the broom roller to fit your working area.
9. Use the adjustment pole to set the brush at the appropriate height from the ground . In the appropriate height,
the brush rings are pressed approx. 20mm against the ground.
10. When possible keep the floatation in the centre so that the sweeper rests on its support wheels, following
slantings and other shapes on the road more closely. Do not lift or press the sweeper against the ground with a
lifting device.
11. Stay alert for any unusual behavior and oil leaks also during driving.

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Picture 4. Optimal height of the broom roller from the ground
7.2. Adjusting the height of the broom roller
The broom roller height is set by adjustment poles located at both ends of the sweeper (picture 4). When you adjust the
height, do it on both sides in equal measure. Otherwise the broom roller will be tilted, and the brush rings will wear
unevenly. In the optimal height, the brush rings are pressed approx. 20mm against the ground.
Adjustment pole

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7.3. Adjusting the side brushes
Side brushes are available as an accessory for both sides of the collecting sweeper. For the best possible operating
efficiency, adjust the side brush so that it will tilt to the front and to the outer side. (Picture 5)
Adjusting the side brush:
1. Adjusting the height and wear of the side brush: rotate the push arm
2. Tilting the brush to the side: Loosen the bolts, tilt the brush to the desired position, tighten the bolts
3. Tilting the brush to the front / back: Loosen the bolts, tilt the brush to the desired position, tighten the bolts
Picture 5. Adjusting the sidebrush

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7.4. Replacing the brush rings
Clean the device inside the casing carefully..
1) Open protective cases from both sides.
2) Detach the hydraulic hoses located inside the protective case (mark the hoses to make it easier to reattach them).
Protect the exposed hydraulic connectors with plugs.
3) Loosen the adjustment bolts in the bearing unit. Detach the cotter pin from the bottom of the adjustment pole and
remove the adjustment pole. The bearing unit does not need to be removed from the support plate. (Picture 6)
4) Support the left side of the broom roller before detaching the right side. Detach the three M12 bolts from the bearing
unit’s support plate and remove the lift arm. (Picture 7)
5) Remove M8 bolts from the engine’s support plate on the right side (picture 8). After this the broom roller is detached
from the frame.
6) Remove the brush rings. Pay attention to the order in which they were installed, since every other ring needs to be
turned 180 degrees.
7) The first six brush rings, located next to the engine case, cannot be turned, so the six brush rings near the engine
are all installed without turning them.
8) When brush rings are changed, reassemble the roller broom in reverse order. Remember to keep the hydraulic
connectors clean. In order to prevent jamming, it is advised to add e.g. copper paste between the bearing and the
roller axle.
Picture 6. Bearing unit and cotter pin
Picture 7. Detaching the bearing unit’s support plate
Cotter pin
Adjustment bolt

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Picture 8. Bolts of the engine’s support plate

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7.5. Replacing the side brushes
Remove the nuts at the bottom of the side brush (picture 9) and detach the brush. Attach a new brush.
Picture 9. Nuts of the side brush
7.6. Transferring the collecting sweeper
Lift the collecting sweeper high enough and reduce driving speed if needed, especially on bumpy roads. The collecting
sweeper or the base machine can be damaged due to excessive speed.
7.7. Detaching the collecting sweeper
1. Lower the collecting sweeper to an even ground. Lift the broom roller so that the brush rings are not pressed
against the ground.
2. Turn off the base machine, put on the parking brake and release pressure from the system.
3. Detach the hydraulic hoses and protect the couplings with plugs.
4. Open the mechanical lock and detach the sweeper.
5. If the sweeper is not used for a long period of time, it needs to be cleaned and lubricated properly before
storage. Make sure there is no water in the container or hoses. Store the equipment indoors, if possible.

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7.8. Irrigation system
Collecting sweeper can be upgraded with an irrigation system. The container size in the irrigation system can be either
155 l or 255 l. The irrigation system suppresses dusting, improves the cleaning result, greases the brushes and reduces
wearing. To improve dust suppression, detergent can be added to water. After operating, the containers can be emptied
by turning the tap next to the pump (picture 10).
Empty the water containers if the irrigation system is not likely to be used in the near future.
Only fresh water can be used in the irrigation system! Using salt water is strictly prohibited!
‘
Picture 10. Water pump and tap
7.9. Accessories for the collecting sweeper
-Wired controller + wires 12/24 V
-Right side brush, different versions for S- and T-models (includes a flow control valve)
-Left side brush, different versions for S- and T-models (includes a flow control valve)
-Hydraulic lift for the side brush
Dust binding
-Low-pressure irrigation system 155L - 255L, 12V –24V
-High-pressure irrigation system
-Side brush irrigation system
-Side brush high-pressure pipeline
-Extra nozzle for the high-pressure pipeline

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8. MAINTENANCE OF THE COLLECTING
SWEEPER
8.1. General safety precautions for the use and maintenance
-Comply with the 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 daily:
-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, as instructed in section 8.6
-Check the bolts for the tightness (table 1)

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8.5. Maintenance at 50-working hour intervals or on a weekly
basis
-Lubricate, preferably with a NLGI-2 grease or equivalent, as instructed in section 8.6
-Check the mechanical condition of the device for bends, distortions or breaches
-Check fastening bolts for tightness (table 1)
8.6. Lubrication points
1) Grease nipples of the hydraulic cylinder (Both sides of the sweeper)
2) Grease nipples of the front support wheel
3) Grease nipples of the floatation beam
4) Grease nipples of the back-support wheel
5) Grease nipples of the engine’s support plate (Both sides of the sweeper)
6) Grease nipples of the bearing unit
Picture 11. Lubrication points
Picture 12. Grease nipples of the bearing unit
6

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9. HYDRAULICS
The collecting 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.
The collecting sweeper is attached to the base machine with 2 or 4 hoses. In a 2-hose system (figures 1 and 2), the flow
control valve is used to choose whether to rotate the brushes or open/close the bottom plate. In a 4-hose system (figures
3 and 4), both actions can be controlled by the base machine’s hydraulics and a separate valve is not needed.
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.
M1 = Engine of the main brush M2 and M3 = Engines of the front brushes
P = Pressure hose T = Tank hose
9.1. 2-hose hydraulics
Figure 1. 2-hose hydraulics with one side brush