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ROSCO CHALLENGER 7 BROOM Operations ,Service & Parts Manual SN 130991 PDF DOWNLOAD
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ROSCO CHALLENGER 7 BROOM Operations, Service & Parts Manual SN 130991 PDF DOWNLOAD
ROSCO A LeeBoy Company CHALLENGER 7 BROOM
MANUAL No. 1015054-03
This manual applies to Serial Number 130991 and above.
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Description
ROSCO CHALLENGER 7 BROOM Operations, Service & Parts Manual SN 130991 PDF DOWNLOAD
FILE DETAILS:
ROSCO CHALLENGER 7 BROOM Operations, Service & Parts Manual SN 130991 PDF DOWNLOAD
Language : English
Pages : 236
Downloadable : Yes
File Type : PDF
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DESCRIPTION:
ROSCO CHALLENGER 7 BROOM Operations, Service & Parts Manual SN 130991 PDF DOWNLOAD
Refueling Precautions
• Do NOT overfill the fuel tank as overflow creates a fire hazard when spilled on hot components.
• DO NOT smoke when refueling and never refuel when the engine is running. Fuel is highly flammable and should be handled with care. Death or serious injury can occur due to explosion and/or fire.
• DO NOT fill tank to capacity. Allow room for expansion to reduce the risk of fuel expanding and spilling from the tank.
• Tighten fuel cap securely. Should fuel cap be lost, replace it with an original manufacturer’s approved cap. Pressurization of the tank may result from use of non-approved cap.
• Prevent fires by keeping the machine clean of accumulated debris, grease, and spilled fuel.
• Use ultra-low sulfur diesel fuel (ULSD) only
Battery Precautions
• Keep all sparks and flames away from batteries, as gas given off by electrolytes is explosive.
• Acid propelled by an explosion can cause blindness if it comes in contact with eyes. Always wear safety glasses when working near batteries.
• If you come in contact with battery electrolyte solution, wash off immediately. Chemicals can cause burns.
• Always disconnect the battery ground cable before working on the electrical system to avoid injury from spark or short circuit. Electrical shock and burns can occur.
• To avoid electrolyte loss, DO NOT tip batteries more than 45 degrees. • Use jumper cables ONLY as directed in Section 5 (Maintenance). Improper use can result in battery explosion or unexpected machine motion
Starting and Stopping Precautions
• Check all around the machine to ensure there are no people working on the machine or in its path before starting. DO NOT start until area is clear. Death or serious injury can occur to bystanders from being crushed under a moving machine.
Parking Precautions • Park machine on level ground whenever possible and apply the parking brake.
• Before leaving operator’s station:
1. Turn off all accessories.
2. Set parking brake.
3. Shut off engine.
• Always remove ignition key when leaving the machine parked or unattended
Operating Precautions
• Always comply with local regulations regarding industrial equipment on public roads and highways.
• Know and use the hand signals required for a particular job. Know who has the responsibility for signaling.
• Make sure that all lights and reflectors comply with state and local regulations. Ensure that they are clean, in good working order, and can be seen clearly by all traffic.
• DO NOT ride on attachments.
• Check all gauges and warning instruments for proper operation. If malfunctions are found, shut down the machine and report the problem for resolution. If the failure causes loss of steering control, loss of brake control, or loss of engine power, stop motion as quickly as possible.
Apply parking brake and turn off the machine. Keep the machine securely parked until the failure is corrected or the machine can be safely transported.
TABLE OF CONTENTS:
ROSCO CHALLENGER 7 BROOM Operations, Service & Parts Manual SN 130991 PDF DOWNLOAD
ROSCO A LeeBoy Company CHALLENGER 7 BROOM
MANUAL No. 1015054-03
This manual applies to Serial Number 130991 and above.
tHUMB iNDEX....................................................... 3 Safety............................................................ 13 Safety Precautions............................................ 16 Machine Precautions........................................... 19 Hot Material Precautions.................................. 19 Hydraulic Systems Precautions............................. 19 Refueling Precautions..................................... 20 Battery Precautions....................................... 20 Starting and Stopping Precautions......................... 20 Parking Precautions....................................... 20 Operating Precautions..................................... 20 Storage Precautions....................................... 21 Maintenance Precautions................................... 21 Tire Precautions ......................................... 22 Safety Decals................................................. 23 Safety Decals Care........................................ 24 Decal Installation (Sticker Type)......................... 24 Decal Installation (Top Protected) ....................... 24 One Year Limited Warranty..................................... 26 Contact Information........................................... 27 Specification Charts.......................................... 28 Torque Specifications......................................... 31 Standard Inch Fasteners................................... 31 Metric Fasteners.......................................... 32 Hydraulic Fittings........................................ 32 Determining Proper Torque................................. 33 Components Overview........................................... 39 Climate-Controlled Cab.................................... 39 Engine ................................................... 39 Electrical System ........................................ 40 Hydrostatic Drive System ................................. 40 Brush Control and Quick-Change Core System................ 40 Machine Overview.............................................. 41 Control Panel................................................. 42 Upper Control Panel........................................... 43 Heat and Air Conditioning..................................... 43 General Information........................................... 47 Receiving the Machine......................................... 47 Initial and Daily Inspection.............................. 47 Start-Up Procedure............................................ 48 Cold Weather Starting..................................... 48 Stopping the Engine....................................... 49 Emergency Stop Button..................................... 49 Cab Comfort................................................... 49 Driving the Broom............................................. 49 Steering.................................................. 49 Transmission Selector Lever............................... 50 Stopping and Braking...................................... 50 PV101 PowerView™ Display...................................... 50 Keypad Functions.......................................... 51 Basic Navigation.......................................... 51 Screen Quadrants.......................................... 52 Other Menu Options........................................ 52 Utilities Menu............................................ 53 Fault Conversion.......................................... 54 Faults and Warnings....................................... 54 PV101 Parameter List...................................... 55 Starting to Sweep............................................. 56 Joystick Controls......................................... 56 Brush Lift/Float ......................................... 57 Brush Swing............................................... 57 Brush Forward/Reverse..................................... 57 Brush Speed............................................... 57 Brush Down Pressure....................................... 57 Dust Suppression System................................... 58 Sweeping Guidelines........................................... 58 Quick-Change Brush Core....................................... 59 Transporting the Broom........................................ 59 Options....................................................... 60 Brushes................................................... 60 Cab Radio/CD.............................................. 60 Front Windshield Washer and Rear Wiper/Washer Assembly.... 60 Spare Tire and Mount...................................... 60 Cold Weather Package...................................... 60 Suspension Seat........................................... 60 Cab Air Quality Kit....................................... 61 Rearview Camera System.................................... 61 Magnetic Cup Holder....................................... 61 Maintenance Schedule.......................................... 65 Routine Maintenance........................................... 66 Preparing Machine for Maintenance......................... 66 Every 10 Hours or Daily Routine Maintenance .............. 66 Every 50 Hours or Weekly Routine Maintenance.............. 66 Every 100 Hour or Monthly Maintenance..................... 66 Every 250 Hours or Quarterly Routine Maintenance.......... 66 Every 500 Hours or Semi-Annual Routine Maintenance........ 67 Every 1000 Hours or Annual Routine Maintenance............ 67 Machine Lubrication........................................... 67 Lubrication Points........................................ 68 Lubrication points are shown below:...................... 68 Engine Maintenance............................................ 69 Check Engine Oil.......................................... 69 Change Engine Oil and Filter.............................. 69 Inspect Cooling System.................................... 70 Air Filter................................................ 70 Fuel System................................................... 71 Fuel Filter............................................... 71 Water Separator........................................... 72 Electrical System............................................. 72 Battery Servicing......................................... 72 Check Battery Electrolyte Level .......................... 73 Alternator................................................ 74 Lighting.................................................. 74 Cold Weather Starting..................................... 74 Dielectric Grease......................................... 75 Fuse Box Panel ........................................... 76 Hydraulic System.............................................. 76 Check Hydraulic Oil Level ................................ 77 Change Hydraulic Oil and Filter........................... 77 Change Hydraulic Oil Strainer............................. 78 Hydraulic Pump and Motor.................................. 78 Priority Relief Valve..................................... 79 Brush Drive Relief Valve.................................. 80 Dust Suppression System....................................... 81 Chassis Maintenance........................................... 81 Tires and Wheels.......................................... 81 Change Tires ............................................. 82 Repack Wheel Bearings..................................... 82 Change Drive Axle Oil..................................... 82 Brakes.................................................... 83 Park Brake Adjustment..................................... 83 Component Replacement ........................................ 83 Replace Batteries......................................... 83 Weldment...................................................... 84 Winterizing for Storage....................................... 85 Periodic Maintenance in Storage........................... 86 Removing from Storage..................................... 86 Troubleshooting............................................... 87 Hydraulic Motor Installation Start-Up Procedure........... 87 Troubleshooting Chart..................................... 88 PV101 Diagnostic Trouble Code (DTC) Chart..................... 91 Main Wire Harness (1 of 2).................................... 99 Main Wire Harness (2 of 2)....................................101 Engine Auxiliary Panel........................................103 Engine Wiring Harness (1 of 2)................................105 Engine Wiring Harness (2 of 2)................................107 Controls Console (1 of 2).....................................109 Controls Console (2 of 2).....................................111 Joystick, Controls, Broom.....................................113 Manifold Wire Harness.........................................115 Rear Lights/Water Wire Harness................................117 Hydraulic System w/1012744 Manifold...........................119 Hydraulic System w/1013970 Manifold...........................121 Quick Reference Guide.........................................125 Frame.........................................................126 Drive Axle Assembly (1 of 3)..................................128 Drive Axle Assembly (2 of 3)..................................130 Drive Axle Assembly (3 of 3)..................................132 Rear Axle Assembly............................................134 HD Brush Frame................................................136 HD Lift Linkage...............................................138 HD Spray Bar..................................................140 HD Hose Kit...................................................142 Water Spray Tank and Mounting.................................144 Engine Assembly - Radiator and Hoses..........................146 Engine Assembly - Intake and Exhaust..........................148 Engine Assembly (1 of 2)......................................150 Engine Assembly (2 of 2)......................................152 Engine Cover Assembly.........................................154 Fuel Tank Assembly............................................156 Air Conditioning/Heater Group.................................158 Air Conditioning/Heater Kit...................................160 Air Conditioning/Heater Kit...................................162 Cab Door Assembly (1 of 2)....................................164 Cab Door Assembly - Latch (2 of 2)............................166 Cab Door Holder and Striker...................................168 Windshield Wiper/Defrost Fan and Controls.....................170 Seat Assembly - Standard......................................172 Steering Assembly ............................................174 Hydraulic Brake...............................................176 Parking Brake.................................................178 Joystick Control Mounting.....................................180 Instrument Panel..............................................182 Fuse Panel....................................................184 Cab Interior - Covers and Decals..............................186 Lights and Mirrors............................................188 Hydraulic Tank Assembly.......................................190 Hydraulic Manifold............................................192 Hydraulic Hoses - Bulkhead and Destroke (1 of 3)..............194 Hydraulic Hoses - Steering (2 of 3)...........................196 Hydraulic Hoses - Pumps, Motors and Filters (3 of 3)..........198 Option - 8 Ft. HD Brush Frame.................................200 Option - 8 Ft. HD Hose Kit....................................202 Option - Front Windshield Washer..............................204 Option - Rear Windshield Wiper and Washer.....................206 Option - Spring Seat Assembly.................................208 Option - Stereo Assembly......................................210 Option - Spare Tire and Mount.................................212 Alphabetical Parts Index......................................214 Safety............................................................ 13 Safety Precautions............................................ 16 Machine Precautions........................................... 19 Hot Material Precautions.................................. 19 Hydraulic Systems Precautions............................. 19 Refueling Precautions..................................... 20 Battery Precautions....................................... 20 Starting and Stopping Precautions......................... 20 Parking Precautions....................................... 20 Operating Precautions..................................... 20 Storage Precautions....................................... 21 Maintenance Precautions................................... 21 Tire Precautions ......................................... 22 Safety Decals................................................. 23 Safety Decals Care........................................ 24 Decal Installation (Sticker Type)......................... 24 Decal Installation (Top Protected) ....................... 24 Limited Warranty Policy........................................... 26 Contact Information........................................... 27 Specification Charts.......................................... 28 Torque Specifications......................................... 31 Standard Inch Fasteners................................... 31 Metric Fasteners.......................................... 32 Hydraulic Fittings........................................ 32 Determining Proper Torque................................. 33 Components Overview............................................... 39 Climate-Controlled Cab........................................ 39 Engine ................................................... 39 Electrical System ........................................ 40 Hydrostatic Drive System ................................. 40 Brush Control and Quick-Change Core System................ 40 Machine Overview.............................................. 41 Control Console............................................... 42 Upper Control Panel........................................... 43 Heat and Air Conditioning..................................... 43 General Information............................................... 47 Receiving the Machine......................................... 47 Initial and Daily Inspection.............................. 47 Start-Up Procedure............................................ 48 Cold Weather Starting..................................... 48 Stopping the Engine....................................... 49 Emergency Stop Button..................................... 49 Cab Comfort................................................... 49 Driving the Broom............................................. 49 Steering.................................................. 49 Transmission Selector Lever............................... 50 Stopping and Braking...................................... 50 PV101 PowerView™ Display...................................... 50 Keypad Functions.......................................... 51 Basic Navigation.......................................... 51 Screen Quadrants.......................................... 52 Other Menu Options........................................ 52 Utilities Menu............................................ 53 Fault Conversion.......................................... 54 Faults and Warnings....................................... 54 PV101 Parameter List...................................... 55 Starting to Sweep............................................. 56 Joystick Controls......................................... 56 Brush Lift/Float ......................................... 57 Brush Swing............................................... 57 Brush Forward/Reverse..................................... 57 Brush Speed............................................... 57 Brush Down Pressure....................................... 57 Dust Suppression System................................... 58 Sweeping Guidelines........................................... 58 Quick-Change Brush Core....................................... 59 Transporting the Broom........................................ 59 Options....................................................... 60 Brushes................................................... 60 Cab Radio/CD.............................................. 60 Front Windshield Washer and Rear Wiper/Washer Assembly.... 60 Spare Tire and Mount...................................... 60 Cold Weather Package...................................... 60 Suspension Seat........................................... 60 Cab Air Quality Kit....................................... 61 Rearview Camera System.................................... 61 Magnetic Cup Holder....................................... 61 Maintenance Schedule.............................................. 65 Routine Maintenance........................................... 66 Preparing Machine for Maintenance......................... 66 Every 10 Hours or Daily Routine Maintenance .............. 66 Every 50 Hours or Weekly Routine Maintenance.............. 66 Every 100 Hour or Monthly Maintenance..................... 66 Every 250 Hours or Quarterly Routine Maintenance.......... 66 Every 500 Hours or Semi-Annual Routine Maintenance........ 67 Every 1000 Hours or Annual Routine Maintenance............ 67 Machine Lubrication........................................... 67 Lubrication Points........................................ 68 Lubrication points are shown below:...................... 68 Engine Maintenance............................................ 69 Check Engine Oil.......................................... 69 Change Engine Oil and Filter.............................. 69 Inspect Cooling System.................................... 70 Air Filter................................................ 70 Fuel System................................................... 71 Fuel Filter............................................... 71 Water Separator........................................... 72 Electrical System............................................. 72 Battery Servicing......................................... 72 Check Battery Electrolyte Level .......................... 73 Alternator................................................ 74 Lighting.................................................. 74 Cold Weather Starting..................................... 74 Dielectric Grease......................................... 75 Fuse Box Panel ........................................... 76 Hydraulic System.............................................. 76 Check Hydraulic Oil Level ................................ 77 Change Hydraulic Oil and Filter........................... 77 Change Hydraulic Oil Strainer............................. 78 Hydraulic Pump and Motor.................................. 78 Priority Relief Valve..................................... 79 Brush Drive Relief Valve.................................. 80 Dust Suppression System....................................... 81 Chassis Maintenance........................................... 81 Tires and Wheels.......................................... 81 Change Tires ............................................. 82 Repack Wheel Bearings..................................... 82 Change Drive Axle Oil..................................... 82 Brakes.................................................... 83 Park Brake Adjustment..................................... 83 Component Replacement ........................................ 83 Replace Batteries......................................... 83 Weldment...................................................... 84 Winterizing for Storage....................................... 85 Periodic Maintenance in Storage........................... 86 Removing from Storage..................................... 86 Troubleshooting............................................... 87 Hydraulic Motor Installation Start-Up Procedure........... 87 Troubleshooting Chart..................................... 88 PV101 Diagnostic Trouble Code (DTC) Chart..................... 91 Main Wire Harness (1 of 2)........................................ 99 Main Wire Harness (2 of 2)....................................101 Engine Auxiliary Panel........................................103 Engine Wiring Harness (1 of 2)................................105 Engine Wiring Harness (2 of 2)................................107 Controls Console (1 of 2).....................................109 Controls Console (2 of 2).....................................111 Joystick, Controls, Broom.....................................113 Manifold Wire Harness.........................................115 Rear Lights/Water Wire Harness................................117 Hydraulic System w/1012744 Manifold...........................119 Hydraulic System w/1013970 Manifold...........................121 Quick Reference Guide.............................................125 Frame.........................................................126 Drive Axle Assembly (1 of 3)..................................128 Drive Axle Assembly (2 of 3)..................................130 Drive Axle Assembly (3 of 3)..................................132 Rear Axle Assembly............................................134 HD Brush Frame................................................136 HD Lift Linkage...............................................138 HD Spray Bar..................................................140 HD Hose Kit...................................................142 Water Spray Tank and Mounting.................................144 Engine Assembly - Radiator and Hoses..........................146 Engine Assembly - Intake and Exhaust..........................148 Engine Assembly (1 of 2)......................................150 Engine Assembly (2 of 2)......................................152 Engine Cover Assembly.........................................154 Fuel Tank Assembly............................................156 Air Conditioning/Heater Group.................................158 Air Conditioning/Heater Kit...................................160 Air Conditioning/Heater Kit...................................162 Cab Door Assembly (1 of 2)....................................164 Cab Door Assembly - Latch (2 of 2)............................166 Cab Door Holder and Striker...................................168 Windshield Wiper/Defrost Fan and Controls.....................170 Seat Assembly - Standard......................................172 Steering Assembly ............................................174 Hydraulic Brake...............................................176 Parking Brake.................................................178 Joystick Control Mounting.....................................180 Instrument Panel..............................................182 Fuse Panel....................................................184 Cab Interior - Covers and Decals..............................186 Lights and Mirrors............................................188 Hydraulic Tank Assembly.......................................190 Hydraulic Manifold............................................192 Hydraulic Hoses - Bulkhead and Destroke (1 of 3)..............194 Hydraulic Hoses - Steering (2 of 3)...........................196 Hydraulic Hoses - Pumps, Motors and Filters (3 of 3)..........198 Option - 8 Ft. HD Brush Frame.................................200 Option - 8 Ft. HD Hose Kit....................................202 Option - Front Windshield Washer..............................204 Option - Rear Windshield Wiper and Washer.....................206 Option - Spring Seat Assembly.................................208 Option - Stereo Assembly......................................210 Option - Spare Tire and Mount.................................212 Alphabetical Parts Index......................................214
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