STEWART-AMOS Starfire S-5t Guide

Sweeper Co.
1Last Update July 2013
Starfire S-5t Sweeper Body
Safety, Operations and Maintenance
Manual
Sweeper Co.
SN 5005 & UP

Sweeper Co.
2Last Update July 2013

Sweeper Co.
3Last Update July 2013
Table of Contents
Safety 14
Safety Is A Shared Responsibility 15
Recognize Safety Information 15
Equipment Lockout 16
Hopper Port Restrictors 16
General Safety Precautions 17
Before Operating Machine 17
When Operation Machine 17
When Servicing Machine 17
Safety Features 18
Follow Safety Instructions 19
Prevent Bypass Starting 19
Handle Fuel Safely-Avoid Fires 19
Prepare For Emergencies 20
Never Use Starting Fluid 20
Wear Protective Clothing 20
Protect Against Noise 20
Handle Chemical Products Safely 20
Dispose Of Waste Properly 21
Practice Safe Maintenance 21
Work In Ventilated Area 22
Avoid High-Pressure Fluids 22
Avoid Heating Near Pressurized Fluid Lines 23
Remove Paint Before Welding Or Heating 23
Service Cooling System Safely 23
Avoid Harmful Asbestos Dust 24
Stay Clear Of Rotating Equipment 24
Diesel Fuel Storage 25
Filling Fuel Tank 25
Warranty 26
Warranty Certificate 27
General Conditions 27
Items Not Covered By Warranty 28
Items Covered By Separate Warranty 28

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General Specifications 30
Serial Number Location 31
Figure 1: Serial Number Plate
Mounted Specifications 33
Auxiliary Engine/Sweeper Instrumentation 33
Engine (Auxiliary) 34
Dirt Hopper 34
Elevator 34
Main Broom 34
Gutter Broom 34
Lighting System 35
Hydraulic System 35
Water System 35
Controls 36
Engine Controls 37
Figure 2: Engine Control Box 38
Sweeper Control 39
Sweeper Controls 39
LH Gutter Broom tilt Up/Down 39
Beacon Lights On 39
RH Gutter Broom Tilt Up/Down 39
Brooms Up/Down 39
GB Lights On/GB/MB Lights On 39
Sweep Forward/Sweep Reverse 39
Hopper Up/Down 40
Water 40
Hopper Dump/Retract 40
LH Gutter Broom Up/Down 40
RH Gutter Broom Up/Down 40
Figure 3: Sweeper Control Box 41

Sweeper Co.
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Operation 44
Auxiliary Engine 45
Water Fill Up 46
Figure 4: Water Tank 46
Sweeping 47
Dumping 48
Break-In Period 50
Engine Break-In 50
Sweeper Break-In 50
Winterizing Your S-5t 51
Service 52
Fuel, Lubricants, and Coolants 52
Diesel Fuel 52
Diesel Engine Oil 52
Coolant 52
Hydraulic Oil 52
Grease 53
Lubrication and Maintenance 53
Daily 53
Figure 5: Service Locations On Auxiliary Engine 54
Every 50 Hours 54
Every 250 Hours 54
Every 500 Hours 55
Every 1000 Hours 55
Adjustments 56
Gutter Broom Angle Adjustment 56
Correct Gutter Broom Angle 56
Adjust Tilt Angle 56
Adjust Front to Back Angle 56
Gutter Broom Pressure 57
Correct Gutter Broom Pressure 57
Adjusting Gutter Broom Pressure 57
Sweeping Width 57
Gutter Broom Impact Protection Spring 58
Figure 6: Gutter Broom Assembly 59
Figure 7: Correct Broom Pattern 60
Main Broom Pressure 61
Figure 8: Main Broom Assembly 61
Elevator Chain Adjustment 62
Upper Drive Shaft Adjustment 62
Center Idler Shaft Adjustment 62
Figure 9: Elevator Chain Adjustment 63

Sweeper Co.
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Repair and Maintenance 65
Gutter Broom Segment Replacement 66
Main Broom Strip Replacement 66
Figure 10: Main Broom Assembly 67
Figure 11: Main Broom Arm Assembly 67
Main Broom Bearing Replacement 68
Carbide Drag Shoe Replacement 68
Figure 12: Carbide Drag Shoe 69
Elevator Chain Replacement 69
Figure 13: Elevator 71
Bottom Liner Replacement 72
Top Liner Replacement 72
Main Broom Hydraulic Motor Replacement 72
Gutter Broom Hydraulic Motor Replacement 73
Elevator Hydraulic Motor Replacement 73
Hydraulic Pressure Adjustment 74
Figure 14: Hydraulic Valves 74
Stall Switch Adjustment 75
Lubrication and Maintenance Check List 77

Sweeper Co.
7Last Update July 2013
DEALER FORMS
The following forms must be completed and signed by the DEALERS
REPRESENTATIVE. Then remove from manual and returned to the
following address:
Sweeper Co.
2700 Paxton St.
P.O. Box 2043
Harrisburg, PA 17105
Failure to return the completed and signed Pre Delivery Inspection and In
Service Date Registration forms to the above address may void all warranties.

Sweeper Co.
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Pre Delivery Inspection Checklist
To be filled out by the dealer prior to delivery to the end user.
Return this document to Stewart-Amos Sweeper Co. within 30 days of delivery to end user.
Dealer: End User:
Date: Serial #:
VIN: Mileage: Hours:
Bolts and Nuts Hopper Safety Supports ________
Hopper Safety Bolts __________
Chassis Suspension Sweeper Mounting
Drag Shoe Mounts Drag Shoe Link Pins
Drag Shoe Chains Main Broom Rock Shaft
Main Broom Suspension Shaft Main Broom Skirt
Main Broom Coupler Main Broom Shafts
Main Broom End Plates Main Broom Bearing
Main Broom Bearing Set Screws Main Broom Chains
Main Broom Suspension Turnbuckle Elevator Mounts
Elevator Bearings Elevator Canopy
Elevator Extension Canopy Hooper Door Cylinders
Water Tank Straps Gutter Broom Mounts
Gutter Broom Pins Gutter Broom Plates
Gutter Broom Linkage Gutter Broom Segments
Engine Skid Mounting Engine Mounts
Hydraulic Pump Mount Bell Housing Mount Plate
Hydraulic Tank Mount Hydraulic Valve Mounts
Battery Box Mount Aux. Engine Control Box
Aux. Engine Exhaust Pipe Aux. Engine Intake Rain Cap
Front Canopy Mount Rear Canopy Mount
Canopy Door Hinges Lights
Control Box Mounting Fuel Tank Mounting
Cotter Pins and Snap Rings
Scissor Snap Rings Hopper Door Cyl.
Hopper Door Pin Main Broom Cyl.
Hopper Tilt Cyl. Pins Main Broom Linkage
Hopper Lift Cyl. Pins Elevator Linkage

Sweeper Co.
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Hoses and Fittings
Tank to Pump (Suction) Pump to RH Stack Valve
RH Stack Valve Valve Stack Return Lines
Pump to LH Stack Valve LH Stack Valve
Hopper Lift Cyl. Hydraulic Cooler to Manifold
RH Gutter Broom Lift Cyl. RH Gutter Broom Motor
RH Retract Cyl. LH Gutter Broom Lift Cyl.
LH Gutter Broom Motor LH Gutter Broom Retract Cyl.
MB/ELEV Lift Cyl. Main Broom Motor
Elevator Motor Hopper Dump Cyl.
Hopper Door Cyl. Hydraulic Tank Site Gauge
Magnetic Drain Plugs Hydraulic Filter
Hydraulic Filter Manifold
Fluid Levels
Chassis Engine
Transmission
Differential
Brake Fluid
Power Steering
Engine Air Filter
Radiator
Tire Pressures
Rear (psi)
Front (psi)
Sweeper Engine Oil
Hydraulic Oil
Primary Air Filter
Secondary Air
Filter ___________________________
Radiator Level
Strength (-350)

Sweeper Co.
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Adjustments
RH Stack Valve Hydraulic Pressure (passengers side)
2850 psi @ 2000 rpm
LH Stack Valve Hydraulic Pressure (drivers side)
2350 psi @ 2000 rpm
LH Stack Valve Stall Switch 2300 psi @ 2000 rpm
Aux. Eng. High Ideal (2850 rpm) Aux. Eng. Low Ideal (850 rpm)
Hopper Proximity Switch Elevator Proximity Switch
Drag Shoes in Up Position (4” off ground) Main Broom Pattern
MB Suspension MB Centering
Elevator Down Position GB Front to Back Angle
GB Side To Side Angle GB Suspension
GB Sweeping Path Rear Camera Adjustment
GB Camera Adjustment Monitor Adjustment
Work Light Adjustment Chassis Mirrors
Operations
Lights
Brakes LH Turn Signal
RH Turn Signal Tail Lights
ID Bar LH Rear Door Marker
LH Upper Rear Corner Marker RH Rear Door Marker
RH Upper Rear Corner Marker License Plate
Backup Light Back Work Light
LH GB Work Light RH GB Work Light
Rear Strobe Front Strobe
High Beams Low Beams
Backup Alarm
Aux. Engine
Glow Plugs Starting
Tachometer/Hour Meter Oil Pres. & Set Point
Temperature & Set Point Throttle Cable/Actuator

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Sweeper Controls
Hopper Up/Down Dump/Ret.
MB/ELEV Up/Down MB/ELEV Sweep for/Rev
RH GB Tilt In/Out RH GB Independent Up
LH GB Tilt In/Out LH GB Independent Up
Water Sweeping Only Water Continuous
Camera Curb Side Camera Rear
Camera Reverse Monitor
Brooms Pickup in Reverse Elevator Stall Switch
Dust Suppression
Water Tank Bottom Fitting
Fill Valve Fill Valve Linkage
Water Pump Pump off When Brooms Up
Filter Housing Filter Screen
Shutoff Valve Front Spray Bar
Front Bar Shutoff Valve Rear Spray Bar
Rear Bar Shutoff Valve LH GB Spray Bar
LH GB Shutoff Valve RH GB Spray Bar
RH GB Shutoff Valve
Test all sweeping functions at Aux. Eng. operating rpm (2400 rpm) and hyd. temp. (150 F).
MB Pattern _______ LH GB Pattern _______
RH GB Pattern _______ GB to MB Overlap _______
LH GB Retract _______ RH GB Retract _______
Hopper Dump/Retract _______ Hopper Lift/Lower _______
Brooms Sweep For/Rev. _______ LH GB Independent Up _______
RH GB Independent Up _______ Brooms Up In Reverse _______
Rear Camera In Reverse _______ All Lights _______
Miscellaneous Items
Manuals in Cab Engine
Chassis
Parts Manual
Incomplete Vehicle Stickers
All Body Decals and Safety Warnings
Signature: Date:

Sweeper Co.
12 Last Update July 2013
IN SERVICE DATE REGISTRATION FORM
To be filled out by the dealer prior to delivery to the end user.
Return this document to Stewart-Amos Sweeper Co. within 30 days of delivery to end user.
Sweeper Body Serial Number: __________________________________________
(Found next to chassis VIN plate)
Customer Name: __________________________________________
Address: __________________________________________
__________________________________________
__________________________________________
Phone # (include area code): __________________________________________
Date Unit Delivered: __________________________________________
In Service Date: __________________________________________
Contact Name: __________________________________________
Signature: __________________________________________
This form MUST be completed and returned to Stewart-Amos Sweeper Co. for warranty
purposes.
FAILURE TO COMPLETE AND RETURN THIS FORM MAY RESULT IN DENIAL OF
WARRANTY CLAIMS.
Stewart-Amos Sweeper Co.
2700 Paxton Street
P.O. Box 2043
Harrisburg, PA 17105

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Safety

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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 operator must become familiar with safe operating procedures and use the equipment in the
fashion that it was intended. Routine inspections and maintenance will prevent premature wear,
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 for personal injury.
DANGER: Identifies the most serious hazard
WARNING: Identifies a potential hazard if safety precautions
are not taken
CAUTION: Identifies a general safety precaution

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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 can not accidentally fall. If
required, install additional blocking devices such as hopper safety pins.
3. Turn off Auxiliary Engine.
4. With auxiliary engine off, turn key to run position and work hydraulic functions to relieve
any residual pressure in the hydraulic system.
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 wheel using 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 hopper would come
back to the at rest position with minimal damage to the equipment.
DANGER: Do not remove or modify any port restrictors

Sweeper Co.
17 Last Update July 2013
General Safety Precautions
Before Operating Machine
1. Read the operators manual and the engine manual to familiarize yourself with 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 clear of 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.

Sweeper Co.
18 Last Update July 2013
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 MAY or 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 proper working order at all times. The rear camera option is also wired to the
chassis transmission, when the chassis is shifted into reverse the rear camera 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 sweeper and 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 inside
the 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 for this 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 under a lifted hopper, insert props into the
main frame roller rails. This will restrict any movement of the scissors frame sliders, thus
keeping the hopper stable. NEVER use 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 indicator
lights 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.

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FOLLOW 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-AVOID FIRES
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.

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PREPARE FOR EMERGENCIES
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance
service, hospital, and fire department near your
telephone.
NEVER USE STARTING FLUID
Starting fluid is highly flammable and 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 AGAINST NOISE
Prolonged exposure to loud noise can cause
impairment or loss of hearing.
Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises.
HANDLE CHEMICAL PRODUCTS SAFELY
Direct exposure to hazardous chemicals can cause
serious injury. Potentially hazardous chemicals used
with this equipment include such 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.