STEWART-AMOS STARFIRE S-4C Guide

Stewart-Amos
Owner’s Manual
STARFIRE S-4C
SAFETY, OPERATION MAINTENANCE MANUAL
SN 4001AND UP
LAST UPDATED MARCH 2016

LAST UPDATED MARCH 2016

I. Table of Contents
SAFETY...............................................................................................................................................1
General Safety Guideline.................................................................................................................3
Equipment Lockout.........................................................................................................................4
Hopper Port Restrictors...................................................................................................................4
General Safety Precautions..............................................................................................................5
Safety Features...............................................................................................................................6
Safety Instructions..........................................................................................................................7
Safety Alert Symbols.....................................................................................................................15
Chassis Driver Safety Instructions...................................................................................................15
Operator Safety Instructions..........................................................................................................16
Maintenance Safety Instructions....................................................................................................20
Warranty Information.......................................................................................................................23
Stewart-Amos Sweeper Co. –WARRANTY POLICY...........................................................................23
ITEMS NOT COVERED BY WARRANTY.............................................................................................24
ITEMS COVERED BY SEPARATE WARRANTIES..................................................................................24
Customer Assistance.....................................................................................................................25
General Specifications.......................................................................................................................27
Serial Number Location.................................................................................................................29
Engine (auxiliary)* ........................................................................................................................30
Elevator........................................................................................................................................30
Main Broom .................................................................................................................................30
Gutter Broom...............................................................................................................................30
SWEEPER STARTUP PROCEDURES AND OPERATION............................................................................31
Engine Controls ............................................................................................................................34
Sweeper Controls..........................................................................................................................35
Chassis.........................................................................................................................................37
Sweeping .....................................................................................................................................39
Dumping ......................................................................................................................................40
Shutting Down the Sweeper..........................................................................................................42
Rapid Reference Operating Outline................................................................................................42
Engine Break-In.............................................................................................................................43
LAST UPDATED MARCH 2016

Sweeper Break-In..........................................................................................................................43
Recommended Operating Equipment ............................................................................................44
Winterizing Your S–4 Sweeper.......................................................................................................45
General Sweeper Maintenance Checks ..............................................................................................47
Fuel, Lubricants, and Coolants.......................................................................................................50
Adjustments.................................................................................................................................54
Gutter Broom...............................................................................................................................54
Gutter Broom Pressure .................................................................................................................55
Sweeping Width ...........................................................................................................................56
Main Broom Pressure....................................................................................................................59
Elevator Chain Adjustment............................................................................................................60
REPAIR AND MAINTENANCE..............................................................................................................63
Gutter Broom Segment Replacement.............................................................................................65
Main Broom Strip Replacement.....................................................................................................65
Main Broom Bearing Replacement.................................................................................................66
Carbide Drag Shoe Replacement....................................................................................................67
Elevator Chain, Sprocket/Shaft Replacement..................................................................................67
Bottom Liner Replacement............................................................................................................70
Top Liner Replacement..................................................................................................................70
Main Broom Hydraulic Motor Replacement....................................................................................70
Gutter Broom Hydraulic Motor Replacement .................................................................................71
Hydraulic Pressure Adjustment......................................................................................................72
Lubrication and Maintenance Check List ............................................................................................75
PARTS MANUAL...............................................................................................................................85
MAINFRAME.................................................................................................................................88
FRONT CANOPY ............................................................................................................................90
REAR CANOPY...............................................................................................................................91
HOPPER........................................................................................................................................94
SCISSOR........................................................................................................................................96
GUTTER BROOM UPPER SECTION...................................................................................................98
GUTTER BROOM LOWER SECTION ............................................................................................... 100
MAIN BROOM............................................................................................................................. 102
LAST UPDATED MARCH 2016

80134 VALVE.............................................................................................................................. 106
80120 VALVE.............................................................................................................................. 107
DRIVERS SIDE HYDRAULIC SCHEMATIC......................................................................................... 107
PASSENGER SIDE HYDRAULIC SCHEMATIC .................................................................................... 110
AUX ENGINE............................................................................................................................... 112
AUX ENGINE FRAME.................................................................................................................... 114
ELEVATOR .................................................................................................................................. 116
ELEVATOR LIFT............................................................................................................................ 122
WATER SYSTEM .......................................................................................................................... 124
ENGINE CONTROL BOX................................................................................................................ 126
AUXILIRY CONTROL..................................................................................................................... 128
REAR LIGHT HARNESS.................................................................................................................. 130
SWITCH BOX HARNESS................................................................................................................ 131
SWEEPER CONTROL PANEL.......................................................................................................... 132
VALVE HARNESS ......................................................................................................................... 134
BODY HARNESS........................................................................................................................... 135
POWER CABLE ............................................................................................................................ 136
S-4 DECALS..................................................................................................................................... 139
INDEX BY PAGE........................................................................................................................... 157
INDEX BY PART# ............................................................................................................................. 163
LAST UPDATED MARCH 2016

LAST UPDATED MARCH 2016

Stewart-Amos Sweeper Co. Starfire S-4c Owner’s Manual Page 1
SAFETY

Stewart-Amos Sweeper Co. Starfire S-4c Owner’s Manual Page 2

Stewart-Amos Sweeper Co. Starfire S-4c Owner’s Manual Page 3
General Safety Guideline
Safety is always of prime importance when operating any type of machine or vehicle in the vicinity of
people. All persons working with this unit are to be knowledgeable of the safety practices and features
detailed in this section.
Safety Is a Shared Responsibility
Safety is everyone’s responsibility. Working together with Safety as the prime objective will insure a
safe work environment and reduce injuries.
The operatormust become familiar with safe operating procedures and use the equipment in the
fashion that it was intended. Routine inspections and maintenance will prevent prematurewear,
expensive downtime and ensure that the equipment functions as it is intended.
Recognize Safety Information
This is the safety alert symbol. When you see this symbol in the manual or on your machine, be alert to
the potential forpersonal injury.
DANGER: Identifies the most serious hazard
WARNING: identifies a potential hazard if safety precautions are
not take
CAUTION: Identifies a general safety precaution

Stewart-Amos Sweeper Co. Starfire S-4c Owner’s Manual Page 4
Equipment Lockout
It is strongly recommended that a commonly known Equipment Lockout procedure be enforced at your
work environment. This is a series of precautions designed to protect any personnel that is inspecting,
cleaning, or repairing the equipment. The Lockout Procedure should include the following.
1. Apply Parking Brake.
2. Place hopper, hopper door in secure positions so that they cannot accidentally fall. If required,
install additional blocking devices such as hopper safety pins.
3. Turn off Auxiliary Engine.
4. With auxiliary engineoff, turn key to run position and work hydraulic functions to relieve any
residual pressure in the hydraulicsystem.
5. Remove keys from ignition.
6. Store keys in pocket or in a safe controlled area.
7. Place an "OUT OF SERVICE" sign on the steering wheelusing a non-reusable fastener.
8. Place an "OUT OF SERVICE" sign on the front window.
9. Disconnect negative terminal from battery.
Hopper Port Restrictors
To control the decent of the hopper under all conditions port restrictors are used in the hopper lift
cylinders. These port restrictors are sized to give a controlled decent of the hopper even if a hydraulic
hose would rupture with a full hopper at the top of its travel. The hopperwould come back to the at rest
position with minimal damage to the equipment.
DANGER: Do not remove or modify any port restrictors

Stewart-Amos Sweeper Co. Starfire S-4c Owner’s Manual Page 5
General Safety Precautions
Before Operating Machine
1. Read the operators manual and the engine manual to familiarize yourselfwith safe operating
practices before operating the machine.
2. Read the chassis operator’s manual thoroughly to familiarize yourself with safe operating
practices before operating machine.
3. Be sure all observers are clearof the machine and at a safe distance.
4. Ensure mirrors, windows, lights, and monitor equipment (if equipped), are clean and adjusted
properly at all times.
5. Do not enter hopper unless engine is shut off, key is removed and there is a note posted
indicating not to start the engine. (See Equipment Lockout).
When Operating Machine
1. Operate controls from the operator’s station only.
2. Keep all riders off the machine.
3. Keep all safety shields in place.
4. Ensure the area is clear of any persons or possible obstructions.
5. Do not wear loose clothing or jewelry.
6. Do not leave the vehicle before it is brought to a complete stop and the parking brake is applied.
7. Be cautious while driving with an unevenly distributed load.
8. Inspect for overhead hazards (e.g. power lines) before raising the hopper.
9. Raise the hopper only on level ground.
10. Ensure the hopper has completely lowered and the hopper door is closed before moving the
vehicle. Do not move vehicle with hopper up.
11. Do not stand under the hopper when it is in the dump position.
When Servicing Machine
1. Follow the Equipment Lockout procedure described above.
2. Install safety pins into holes in slide frame to prevent scissor frame from moving when servicing
under the hopper. (See Safety Features).
3. Never work under a loaded hopper even with safety pins installed.

Stewart-Amos Sweeper Co. Starfire S-4c Owner’s Manual Page 6
Safety Features
This machine is equipped with many safety features. To operate this equipment safely, it is imperative
to be aware of these functions. Please read all of the features listed, as the order they are presented
does not reflect the degree of importance. Some safety features listed are options and MAYor MAY
NOT be on your unit.
If there are concerns, report to your supervisor or maintenance department.
1. Decals - These must be clean and visible at all times.
2. Mirrors - A variety of mirrors, including large convex ones, are to help ensure adequate rear
vision. These must be properly adjusted, clean and visible at all times!
3. Cameras –All machines are equipped with side and rear cameras, if so equipped, they must be
in properworking order at all times. The rear camera option is also wired to the chassis
transmission, when the chassis is shifted into reversethe rearcamera will automatically activate
and will go off automatically when chassis is shifted out of reverse.
4. Marker Lights - There is 1 marker lamp on each side of the sweeperand an ID bar at the back on
the elevator cover. Marker lights are wired direct to chassis lights and come on with chassis
lights.
5. Beacon and/or Strobe Lights - The switch is installed in the sweeper control box insidethe cab.
The lights are mounted on the front and rear canopy of sweeper.
6. Gutter Broom Lights - These lights are used for work lights and are mounted at both gutter
brooms. The switch is found on the control box in the cab.
7. Main Broom Light - This light is used for a work light and is mounted on the drivers side at the
back above the main broom. The switch forthis work light is combined with the gutter broom
light switch in the 3rd position.
8. Backup Alarm - When the truck is put into reverse this alarm sounds. The alarm is mounted to
the rear canopy frame.
9. Hopper Safety Prop - If any work is to be done undera lifted hopper, insert props into the main
frame rollerrails. This will restrict any movement of the scissors frame sliders, thus keeping the
hopper stable. NEVERuse the safety pins to hold a LOADED HOPPER!
10. Arrow Board (option) - A separate control box mounted in the cab controls the arrow board
mounted on the rear of the sweeper. A switch and pattern selector with indicatorlights
controls the order the light pattern.
11. Fire Extinguisher (option) - This is located in the cab behind the driver’s seat.
12. First Aid Kit (option) - This is located inside the cab behind the driver’s seat.

Stewart-Amos Sweeper Co. Starfire S-4c Owner’s Manual Page 7
Safety Instructions
Carefully read all safety messages in this manual and
on your machine safety signs.
Keep safety signs in good condition. Replace missing
or damaged safety signs. Be sure new equipment
components and repair parts include the current safety
signs. Replacement safety signs are available from
your dealer.
Learn how to operate the machine and how to use
controls properly. Do not let anyone operate without
instruction.
Keep your machine in proper working condition.
Unauthorized modifications to the machine may impair
the function and/or safety and affect machine life.
If you do not understand any part of this manual
and need assistance, contact your dealer.
PREVENT BYPASS STARTING
Do not start engine by shorting across starter terminal.
Start engines only from operator's station with transmission
in park.
HANDLE FUEL SAFELY-AVOIDFIRES
Handle fuel with care: It is highly flammable. Do not
refuel the machine while smoking or when near open
flame or sparks.
Always stop engine before refueling machine. Fill fuel
tank outdoors.
Prevent fires by keeping machine clean of accumulated
trash, grease, and debris. Always clean up spilled fuel.

Stewart-Amos Sweeper Co. Starfire S-4c Owner’s Manual Page 8
PREPARE FOR EMERGENCIES
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisherhandy.
Keep emergency numbers for doctors, ambulance
service, hospital, and fire department nearyour
telephone.
NEVER USE STARTING FLUID
Starting fluid is highly flammableand can cause
serious damage to engines.
WEAR PROTECTIVE CLOTHING
Wear close fitting clothing and safety equipment
appropriate to the job.
Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones
while operating machine.
PROTECT AGAINSTNOISE
Prolonged exposure to loud noise can cause
impairment or loss of hearing.
Wear a suitable hearing protective devicesuch as
earmuffs or earplugs to protect against objectionableor
uncomfortable loud noises.
HANDLE CHEMICAL PRODUCTS SAFELY
Direct exposure to hazardous chemicals can cause
serious injury. Potentially hazardous chemicals used
with this equipment includesuch items as
lubricants, coolants, paints, and adhesives.
A Material Safety Data Sheet (MSDS) provides specific
details on chemical products: physical and health
hazards, safety procedures, and emergency response
techniques.

Stewart-Amos Sweeper Co. Starfire S-4c Owner’s Manual Page 9
Check the MSDS before you startany job using a
hazardous chemical. That way you will know exactly
what the risks are and how to do the job safely. Then
follow procedures and recommended equipment.
(See your dealer for MSDS on chemical
products used with this equipment.)
DISPOSE OF WASTE PROPERLY
Improperly disposing of waste can threaten the
environment and ecology. Potentiallyharmful waste
used with this equipment include such items as
oil, fuel, coolant, brake fluid, filters, and batteries.
Use leak proof containers when draining fluids. Do not
use food or beverage containers that may mislead
someone into drinking from them.
Do not pour waste onto the ground, down a drain, or
into any water source.
Air conditioning refrigerants escaping into the air can
damage the Earth’s atmosphere. Government
regulations may require a certified air conditioning
service center to recover and recycle used air
conditioning refrigerants.
Inquire on the proper way to recycle or dispose of
Waste from your local environmental or recycling center,
or from your dealer.
PRACTICE SAFE MAINTENANCE
Understand service procedure before doing work. Keep
area clean and dry.
Never lubricate, service, or adjust machine while it is
moving. Keep hands, feet, and clothing from power-
driven parts. Disengage all power and operate controls
to relieve pressure. Lower equipment to the ground.
Stop the engine. Remove the key. Allow machine to
cool.

Stewart-Amos Sweeper Co. Starfire S-4c Owner’s Manual Page 10
Securely support any machine elements that must be
raised for service work.
Keep all pats in good condition and properly installed.
Fix damage immediately. Replace worn or broken
parts. Remove any buildup of grease, oil, or debris.
Disconnect battery ground cable (-) before making
adjustments on electrical systems or welding on
machine.
WORK IN VENTILATED AREA
Engine exhaust fumes can cause sickness ordeath. If it
is necessary to run an engine in an enclosed area,
remove the exhaust fumes from the area with an
exhaust pipe extension.
If you do not have an exhaust pipe extension, open the
doors and get outside air into the area.
AVOID HIGH-PRESSURE FLUIDS
Escaping fluid under pressure can penetrate the skin
causing serious injury.
Avoid the hazard by relieving pressurebefore
disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.
Search for leaks with a piece of cardboard. Protect
hands and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any
fluid injected into the skin must be surgically removed
within a few hours or gangrene may result. Doctors
unfamiliar with this type of injury should reference a
knowledgeable medical source.

Stewart-Amos Sweeper Co. Starfire S-4c Owner’s Manual Page 11
AVOID HEATING NEAR PRESSURIZED
FLUID LINES
Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to
yourself and bystanders. Do not heat by welding,
soldering, or using atorch near pressurized fluid lines
or other flammable materials. Pressurized lines can be
accidentally cut when heat goes beyond the immediate
flame area.
REMOVE PAINT BEFORE WELDING OR
HEATING
Avoid potentially toxicfumes and dust.
Hazardous fumes can be generated when paint is
heated by welding, soldering, or using a torch.
Do all work outside orin a well ventilated area.
Dispose of paint and solvent properly.
Remove paint before welding orheating:
If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
If you use solvent or paint stripper, remove stripper
with soap and water before welding. Remove
solvent or paint stripper containers and other
flammable material from area. Allow fumes to
disperse at least 15 minutes before welding or heating.
SERVICE COOLING SYSTEM SAFELY
Explosive releaseof fluids from pressurized cooling
system can cause serious burns.
Shut off engine. Only remove filler cap when cool
enough to touch with bare hands. Slowly loosen cap to
first stop to relieve pressure before removing
completely.

Stewart-Amos Sweeper Co. Starfire S-4c Owner’s Manual Page 12
AVOID HARMFUL ASBESTOS DUST
Avoid breathing dust that may be generated when
handling components containing asbestos fibers.
Inhaled asbestos fibers may cause cancer.
Components in products that may contain asbestos
fibers are brake pads, brake band and lining
assemblies, clutch plates, and some gaskets. The
asbestos used in these components is usually found in
a resin or sealed in some way. Normal handling is not
hazardous as long as airborne dust containing
asbestos is not generated.
Avoid creating dust. Never use compressed air for
cleaning. Avoid brushing or grinding materials containing
asbestos. When servicing, wear an approved
respirator. A special vacuum cleaner is recommended
to clean asbestos. If not available, apply a mist of oil or
water on the material containing asbestos.
Keep bystanders away from the area.
STAY CLEAR OF ROTATING EQUIPMENT
Entanglement in rotating equipment can cause serious
injury or death. Keep shields in place at all times.
Wear close fitting clothing. Stop the engine before
making adjustments or performing any type service on
the equipment.

Stewart-Amos Sweeper Co. Starfire S-4c Owner’s Manual Page 13
DIESEL FUEL STORAGE
Proper fuel storage is critically important. Use clean storage and transfer tanks. Periodically drain water
and sediment from bottom of tank. Store fuel in a convenient place away from buildings.
IMPORTANT: DO NOT store diesel fuelin galvanized containers. Diesel fuelstored in galvanized
containers reacts with zinccoating on container to form zinc flakes. If fuel contains water, a zincgel will
also form. The gel and flakes will quickly plug fuelfilters, damage injection nozzles and injection pump.
DO NOT use brass-coated containers forfuel storage. Brass is an alloy of copper and zinc.
FILLING FUEL TANK
CAUTION: Handle fuel carefully. Do not fill the fuel tank when engine is running. DO NOT
smoke while filling fuel tank or servicing fuel system.
IMPORTANT: The fuel tank is
vented through the filler cap. If a new
filler cap is required, always replace
it with an original vented cap.
Fill fuel tank at the end of each day’s operation to
prevent condensation in tank as moist air cools
and freezes during cold weather.
Store diesel fuel in plastic, aluminum, orsteel
containers specifically coated for diesel fuel storage.
Avoid storing fuel overlong periods of time. If fuel is stored formore than a month prior to use, or there
is a slow turnover in fuel tank or supply tank, add a fuel conditioner to stabilize the fuel and prevent
water condensation. Fuelconditioner also reduces fuel gelling and controls wax separation during cold
weather.
Consult your engine distributor or servicing dealer for recommendations and local availability. Always
follow manufacturer’s directions on label.

Stewart-Amos Sweeper Co. Starfire S-4c Owner’s Manual Page 14
Read and understand these safetysections before operating or servicing the sweeper. Learn how to
stop the sweeper’s engines suddenly in an emergency. Only persons who have read the manuals and
have been properly trained should operate the sweeper.
• Do not operate the sweeping unit without having the sweeping hood hoses in place.
• Remove the truck’s ignition keys whenever working under the truck or sweeper.
• Open (turn off) the optional battery disconnect switch (located beside the battery tray) when
working on or nearthe auxiliary engine. This is to prevent an
accidental starting or cranking of the auxiliary engine.
• Do not dump the hopperunless it is on level ground. When you dump, the truck must be in
“PARK” and the emergency brake must be engaged. Do not try to dump the hopper over
a dock or open pit.
• Whenever working under a raised hopper, make sure the safety chocks (provided with the
unit) are in place at the dump cylinders.
• Whenever the hopper is lowered, beware of the area between the hopper and the frame. This
is where a crushing injury may occur when either the hopper or the frame moves.
• Do not remove any of the belt guards, or work near drive belts while wearing any jewelry or
loose clothing.
• To keep the engines in good condition, always use the proper tools for the job you are
performing.
• Additional important safety guidelines are located in the Owner’s Manuals for the chassis and
sweeper engine.
Safety is of the utmost importance. Most accidents can be avoided by being aware of the conditions,
the area and the equipmentbeingoperated. Always observe reasonable precautions and be a safe
and careful operator.