GENIUS 1400 AUTOMATIC SWEEPER
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1 GENIUS 1400 AUTOMATIC SWEEPER PARTS MANUAL REV A December 2002
2 GENIUS 1400-AUTOMATIC SWEEPER-DRIVE ASSY GENIUS 1400-AUTOMATIC SWEEPER-DRIVE ASSY 1 T Screw ISO x16 zb 2 2 T Washer uni x32x2,5 4 3 T Bearing RS 4 4 T Screw uni x30 zb 12 5 T Front and rear wheel hub TK T Superelastic wheel BA-MA-4.00x4 2 7 T Galvansied spacer Ø20x24x T Rear wheel hub TK T Screw TSCE uni x T Wheel drive ring gear Z45 P1/2" TK T Transmissiom chain 1/2" TK T Rear wheel support TK T Screw uni x T Screw TB CE iso x16 zb 4 15 T Left chain protection casing TK T Lock nut uni 985 M8 4
3 GENIUS 1400-AUTOMATIC SWEEPER-DRIVE ASSY 17 T Washer uni x T Support SBPFL T Screw iso x16 zb 2 20 T Right chain protection casing TK T Differential pinion Z12 P1/2" TK T Electric traction reducer TK 1400 Dual-Power 1 23 T Galv. right drive crossbeam support TK T Galv. left drive crossbeam support TK T Screw uni x25 zb 4 26 T Key uni x6x T Galvanised differential support TK T Washer 8X T Temperature sensor F11-95 NC 1 30 T Chain link 1/ T Washer uni X T Screw uni x20 zb T Lock nut M T Spacer 2
4 GENIUS 1400-AUTOMATIC SWEEPER-STEERING ASSY GENIUS 1400-AUTOMATIC SWEEPER-STEERING ASSY 1 T Block nut din 985 M12 zb 2 2 T Zinc-spacer Ø20x24x T Front wheel pivot TK T Front brake Ø 125 TK T Screw uni x25 zb 6 6 T Front brake hub TK T Superelastic wheel BA-MA-4.00x4 1 8 T Bearing RS 2 9 T Zinc-spacer Ø20x24x T Zinc-spacer Ø20x24x T Front wheel zinc-stand TK T Bushing 1 13 T Washer Ø T Screw, 3,9x T LED 2 16 T Chain TK /8" 1
5 GENIUS 1400-AUTOMATIC SWEEPER-STEERING ASSY 17 T Gasket under the dashboard T Backsending pivot 1 19 T Rocker bushing 2 20 T Rocker bushing 1 21 T Front- and backside wheel hub TK T Screw uni x T Trasco joint blocking flange TK T Bearing T Closing flange 1 26 T Screw uni x T Washer uni x14 zb 6 28 T Shim 15x22x T Spacer 1 30 T Ring nut M 35x1,5 guk 1 31 T Outer snap ring din 471 Ø T Universal joint 2 33 T Elastic pin din x T N Steering shaft 1 35 T Screw 6x T Washer uni x18x1, T Block nut din 985 M6 basso zb 4 38 T Inner snap ring Ø T Bearing RS 2 40 T Dashboard support TK T Deflecting drive direction/light/horn TK T Key switch 1 43 T Steer shaft TK T Screw TBCE iso x16 zb 1 45 T Steering wheel's cap 1 46 T Washer uni x40x2,5 zb 1 47 T Steer Ø T Steer damper 1 49 T Positions' turner 1 50 T Dashboard vibrating diaphragm manual TK T Speed Potentiometer 10K 1 52 T Turned adjuster Ø T Brake pedal cable dowel 1 54 T Washer uni x24 zb 2
6 GENIUS 1400-AUTOMATIC SWEEPER-STEERING ASSY 55 T Pivot ch.10 h T Nut uni 5588 M T Cable fixing pivot 1 58 T Buckle Ø 7 art. C T Bushing 4 60 T Dowel uni x T Traction spring TK Ø 8 x1x T Security brake pedal pivot 1 63 T Security brake pedal 1 64 T Bushing 1 65 T Outer snap ring din 471 Ø T Brake pedal 1 67 T Pedal cover V T Spring-attaching pivot 1 69 T Outer snap ring din 471 Ø T Pivot 1 71 T Brake's cable sheathing 1 72 T Command board TK 850/TK T Screw TE 8x T Brake flange TK T Joint 3/ T Column 3 78 T Flange 1 79 T Mobile knob 1 80 T Washer 8X T Washer 8X T Brake's cable 1 83 T Nut M T Screw, TBCE 6X T Washer 6x T Grey dashboard TK T Screw, TSTC 3x T Nut M T Spacer 1 A T Complete eccentric bushing assembly 1
7 GENIUS 1400-AUTOMATIC SWEEPER-BRUSH ASSY GENIUS 1400-AUTOMATIC SWEEPER-BRUSH ASSY 1 T Main brush flap door TK T Plastic insert ( female screw) 4 3 T Handwheel Ø 50 M8 1 4 T Right and left flap TK T Self tapping screw TC+ uni ,5x14,5 zb 4 6 T Lateral flap holder TK 1400 black 1 7 T Block nut din 985 M12 zb 1 8 T Main brush spacer TK1400 zin 1 9 T Bearing RS 1 10 T Main brush support TK T Inside snap ring din 472 Ø T Main brush spring TK 1400 Ø 25x T Screw uni x80 zb 1 14 T Main brush Ø 330x800 6R0.5/1.2 TK T Main brush 330x800 6R0.7/1.4 TK T Self tapping screw TC+ uni x45 zb 2 16 T Main brush removable arm 1 17 T Main brush driver TK
8 GENIUS 1400-AUTOMATIC SWEEPER-BRUSH ASSY 18 T Belt stretcher strap pin 1 19 T Main brush drive actuator TK T Washer uni x T Split pin AR 1 22 T Screw, uni x T Inner snap ring din 472 Ø T Roll schoulder bushing TK 1000S 2 25 T Main brush spring holder case TK T Main brush case spring TK T Nut uni 5588 M6 zb 1 28 T Toggle-joint M T Screw uni x T Main brush pulley TK T Washer uni x24x T Main brush spacer TK1400 zin 1 33 T Main brush driving hub TK T Collar C3 Ø T Screw uni x40 zb 4 36 T Washer uni x T Bushing 1 38 T Inserto filettato M4x T Main brush cooling engine pipe 1 40 T Screw TCTC uni x T Main brush engine protection TK T Main brush pin TK T Main brush engine TK T Screw TCCE uni x20 zb 5 45 T Key uni x5x T Key uni x4x T Main brush motor pulley TK T Main brush holder zinc-arm TK T Nut uni 5588 M T Belt POLY J T Key uni x5x T Screw TCCE uni x12 zb 1 53 T Hand-wheel 2 54 T Belt stretcher strap 1 55 T Snap ring 2
9 GENIUS 1400-AUTOMATIC SWEEPER-BRUSH ASSY 56 T Spacer 1 57 T Bearing T Belt strecther roll 1 59 T Belt strechter roll pin 1 60 T Screw TCCE uni x12 zb 1 61 T Belt stretcher spring 1 62 T Screw TB CE 8x T Washer uni x12x1,5zb 7 64 T Bearing RS T Washer 12x T Washer 6X T Fuse-box 1 68 T Fuse 1
10 GENIUS 1400-AUTOMATIC SWEEPER-SIDE BRUSH ASSY GENIUS 1400-AUTOMATIC SWEEPER-SIDE BRUSH ASSY Gear motor 24V 90W dx TK Right side brush motor zinc-support TK Screw TCCE 6x Key uni x5x Lateral brush TK 1400 Ø Washer 6x Screw TE FR 6x10 zb Screw TE FR 6x16 zb Gear motor AOMPI40 24V 90W sx TK Left side brush motor support TK Key 6x6x Elastic pin din x Lateral brush spring Brush shaft damper Screw TCCE 6x Nut uni 5588 M8 6
11 GENIUS 1400-AUTOMATIC SWEEPER-SIDE BRUSH ASSY Screw TE uni x35 zb Leftside brush shaft guide Lateral brush holder flange Outer snap ring din 471 d Right side brush shaft zinc-guide TK Nut uni 5588 M Axle joint M Brush lifting arm Lateral brush adjustment stand Nut uni 5588 M Foot 20x9 M6x Washer uni x18x1, Screw iso x16 zb Outer snap ring din 471 Ø Washer uni x Bushing Spring Bushing Knob Left side brush lifting arm Flange Block nut din 985 M6 basso zb Lateral brushs rotation zic-rod Screw TK Screw M8X Block nut din 985 M8 zb Washer uni X Screw M5X Washer uni X Spacer 2
12 GENIUS 1400-AUTOMATIC SWEEPER-CHASSIS ASSY GENIUS 1400-AUTOMATIC SWEEPER-CHASSIS ASSY 1 T Battery bridge section 16, 30 cm 3 2 T Belt support pin Ø 9 h T Intake FT T Screw TE FR 6x T Insulator mm 35 M6 CH T Battery disconnection key 100A 24V 1 7 T Battery connection cable TK T Washer uni x24x2,5 1 9 T Battery container 240 AH 1 T Battery container 140 AH DIESEL T Battery 12 V 45 AH 2 10 T Battery 12 V 120 AH semitraction 2 T Battery 12 V 140 AH semitraction 2 T Battery 6 V 240 AH 4 11 T Torsional spring 1 12 T Micro-switch (MS/10-Z15GQ) 2
13 GENIUS 1400-AUTOMATIC SWEEPER-CHASSIS ASSY 13 T Horn 24 V 1 14 T Screw TE FR 6,3x19 zb 1 15 T Flashlight 24vx220w 1 16 T Screw uni x T Accelerator bushing TK T Low lock nut din 985 M8 zb 2 19 T Galvanised accelerator connecting rod T Accelerator pedal TK T Gear for the accelerator potentiometer TK1000E 1 22 T Potentiometer for the accelerator 1 23 T Accelerator gear 1 24 T Screw uni x T Complete electrical equipment TK T Micro-switch 1 27 T Dowel 6x T Screw TCCE zb 5x T Nut uni 5588 M T Washer uni x12 zb 6 31 T Accelerator pedal support TK T Screw TBCE iso x10 zb 2 33 T Lock nut din 985 M T Screw TBCE 6x16 zb 6 35 T Bracket 1 36 T Washer uni x15 zb 2 37 T A Fuse 1 38 T Bin lifting control card TK T Power control card TK T Screw TE FR 6x T Remote control switch T106P 24V 100% 1 42 T Low lock nut din 985 M6 zb 5 43 T Washer uni x24x T Screw TE FR 6x T Washer uni x18x1, T Relay control card TK T Circuit board cover 1 48 T Screw 3,9x9, T Wiring diagram holder plate TK T A Emergency pushbutton TK
14 GENIUS 1400-AUTOMATIC SWEEPER-CHASSIS ASSY 51 T Complete red pushbutton Ø T Accelerator bushing 53 T Screw TBCE 6x16 zb 1 54 T Nut M T Washer 6x T Relay 1 57 T Non-slip platform 1 T WIRING FOR SOLENOID VALVE, DIESEL VERSION 1 (SEE MACHINE WIRING DIAGRAM)
15 GENIUS 1400-AUTOMATIC SWEEPER-HOPPER ASSY GENIUS 1400-AUTOMATIC SWEEPER-HOPPER ASSY 1 T Gearmotor T Key uni x3,7 1 3 T Worm screw support cover 1 4 T Bearing RS 2 5 T Self tapping TC+ uni x9.5 zb 4 6 T Micro-switch holder cam 1 7 T Screw 6x T Spacer TK T Screw TS CE uni x T Worm screw for rotation of the rear bin 1 11 T Worm screw support for the bin TK T Screw uni x20 zb 7 13 T Pawl for the helical wheel TK T Micro-switch IP67 OMRON D2VW-5L2A-1M 4 15 T Galv. micro support plaque for the bin TK T Screw uni x20 2
16 17 T Galv. spacer Ø 6x10x T Outer snap ring din 471 Ø T Connecting rod for bin rotation TK T Helical gear wheel for bin rotation TK T Glicodur bushing 30x34x T Pin 1 23 T Washer uni x T Screw 6x T Nut uni 5588 M T Washer uni x T Arm spacer TK T Nut M T Left side pin for the pin TK T Galv. right hand arm TK T Bin rotation system cover 1 32 T Screw TE FR 6x10 zb 2 33 T Rear bin gasket TK T Pin on transmission side for the bin TK T Washer uni x T Rear hopper TK T Plastic insert (nut screw) 6 38 T Self tapping screw TC+ uni ,5x14,5 zb 6 39 T Black flap lock for the bin TK T Rear bin flamp TK T Bushing GLYCODUR GLY.PG F 2 42 T Bin lifting arm 1 43 T Low lock nut din 985 M6 zb T Low nut 5589 M20x1.5 zb 1 45 T Rear bin lifting piston Ø.50-ST25-C T Delivery pipe 3/16" TK 1400 l T Dawty washer 1/8" 8 48 T Screw 1/8" 4 49 T Return pipe 3/16" TK1400 l T Fork complete with pin M20x T Dust-proof cover 1 52 T Right arm pin and cylinder TK T Screw TB CE iso x20 zb 3 54 T Washer uni x T Reduction 2 56 T WasherPVC 50x25x1,5 2
17 57 T Bronze bin lifting arm bushing TK T Bin rotation cable sheath 1 59 T Left side arm pin TK T Screw TCCE 5x10 zb 4 61 T Hydraulic power pack 1 62 T Bushing GLYCODUR GLY.PG 16x18x20 F 1 63 T Pump fixing bracket TK T Self tapping screw TC+uni 695 3,9x T Micro support TK T Screw TBCE 6X T Lock nut M T Nut M T Screw M3x T Screw M6x T Cable lug 1 72 T Screw M4x T Screw M8x10 2
18 GENIUS 1400-AUTOMATIC SWEEPER-FILTER/LIFT FLAP ASSY GENIUS 1400-AUTOMATIC SWEEPER-FILTER/LIFT FLAP ASSY 1 T Traction spring Ø23x3x T Butterfly opening driving lever TK T Block nut din 985 M8 basso zb 1 4 T Bushing 1 5 T Screw TE uni x T Flap lifting cable 1 7 T Clamp for fork M6 3 8 T Block nut din 985 M12 zb 1 9 T Washer uni x T Pivot 1 11 T Washer uni x T Plastic insert (female screw) T Front adjustable flap 1 T Front adjustable flap 14 T Fork 2 15 T Pin 1 16 T Front blocking-fllap holder TK T Self tapping screw TC+ uni ,5x14,5 zb 10
19 GENIUS 1400-AUTOMATIC SWEEPER-FILTER/LIFT FLAP ASSY 18 T Flap lifting sheathing 1 19 T Turned adjuster Ø T Cable centering pivot 1 21 T Outer snap ring din 471 Ø T Screw TSCE 6x T Screw uni x T Nut uni 5588 M T Cable fixing pivot 1 26 T Clamp Ø 7 art. C T Dowel uni x T Bushing 1 29 T Pedal cover V T Flap lifting pedal 1 31 T Side flaps TK T Side blocking-fllap holder TK T Screw TBCE 6x T Fixed backside flap 1 35 T Grey dashboard 2 36 T Unlooking filter handle 2 37 T Filter bearing frame 2 38 T Paper filter 2 T Polyester filter 39 T Fliter locking cover 1 40 T Complete locking TEK 4 41 T Fan Ø T Block nut din 982 M6 zb 8 43 T Screw TB Ce iso x20 zb 8 44 T Fan holder casing TK T Locking filter cover' gasket 1 46 T Motor Ø 77 24V 2 47 T Complete filter shaker electric motor 24V 2 48 T Self tapping screw TSP+ uni x32 zb 8 49 T Filter shaker bulk' protection cover 4 50 T Dowel uni x T Counterweight bushing for filter shaker 4 52 T Screw uni x12 zb T Filter shaker motor flange 4 54 T Motor Ø 63 24V G3800 W35 2
20 GENIUS 1400-AUTOMATIC SWEEPER-FILTER/LIFT FLAP ASSY 55 T Wire fixing rubber pad 2 56 T Washer uni x18x1, T Washer uni x T Washer uni x20x1, T Clamp 1 60 T Screw TSCE 10x T Unlooking filter handle 2 62 T Block nut M T Cable lug 2
21 GENIUS 1400-AUTOMATIC SWEEPER-MOTOR ASSY GENIUS 1400-AUTOMATIC SWEEPER-MOTOR ASSY 1 T Alternator belt guard TK T Alternator pulley fixing nut TK T Toothed belt 565-5M-25-HTD 1 4 T Alternator pulley HTD40-5M-25-6F TK T Screw TE 8X T Screw TE M10x T Alternator 28V-80A Ref T Tall lock nut M T Washer uni x T Alternator support TK T Screw TS CE uni x25 zb 4 12 T Galv. air-solenoid fixing bracket TK T Screw TEFR 6x T Pulley for the HONDA 6.5HP engine TK T Gear wheel for motor starting Z TK T Gear locking washer 1 17 T Screw TS CE uni x25 inox 1
22 GENIUS 1400-AUTOMATIC SWEEPER-MOTOR ASSY 18 T Complete starter 24V-300W-SX 1 19 T Screw TCCE 8x30 zb 2 20 T Spacer for alternator 1 21 T Key 5x5x T Galv. motor support plate HONDA 6.5HP 1 23 T Washer uni x T Low lock nut din 985 M8 zb T Washer uni x24x2, T Vibration damper MM 30x30 8x T Oil dipstick Gx T Spring washer uni x14 zb 4 29 T Screw TE uni x T Low lock nut din 985 M6 zb 2 31 T Alternator cooling fan with anti-clock. rotation 1 32 T Honda GX200-SX-4-OH engine 1 33 T Solenoid valve 1 34 T Bracket for oil pipe 1 35 T Fuel pipe for lead-free petrol 1 36 T Engine partition 1 37 T Fuel tank Lt T Fuel tank plug 1 39 T Screw TE 8X T Remote control switches' protection casing 1 41 T "ECO" hose clamp with 8 mm hole D.1 W T T Remote control switch holder bracket TK T Solenoid air motor beam-engine 1 45 T Solenoid belt TK T Solenoid spring TK T Solenoid K9B-36DL T Alternator belt tightener 1 49 T Silencer extension 1 50 T Tall lock nut M T Tapered washer DIN x T Fuel level sensor 1 53 T Temperature sensor F NC 1 54 T Tank fixing bracket 2 55 T Screw TEFR M6X10 2
23 GENIUS 1400-AUTOMATIC SWEEPER-MOTOR ASSY 56 T Screw TCCE M5X T Washer 5x T Screw TCTC 3X T Spring washer 2 60 T Screw TCTC 3X T Tall lock nut M T A Fan protection gred 1 63 T Cooling fan 1 64 T Screw TCTC 4x T Cable lug 1 66 T Nut M T Fuel filter 1 68 T Oil pipe 1 69 T Nipples 1/4 - M10x1, T Cap 1 71 T Clamp 1 72 T Screw TEFR M5X T Hose fitting 1 74 T Gasket 1 75 T Clamp 5 76 T Block nut M T Low lock nut din 985 M6 zb 4 78 T Air-conveyor gasket TK T Gas engine air-conveyor TK T Screw TB CE iso x16 zb 4 81 T Washer 6x18 4
24 GENIUS 1400-AUTOMATIC SWEEPER-EXTERNAL PARTS GENIUS 1400-AUTOMATIC SWEEPER-EXTERNAL PARTS 1 T Grey frame TK 1400 RAL T Red left hand body side panel TK T Grey left hand body side panel TK T Left bearing rib TK T Rear left bumper TK T Rear right bumper TK T Upper ventilation guard TK T Footboard TK T Washer uni x T Rear bin lifting stand TK T Screw TCCE uni x40 zb 8 11 T Low lock nut din 985 M6 zb 6 12 T Sound-proofing panel (DIESEL VERSION) 1 T Sound-proofing panel (DIESEL VERSION) 1 13 T Plastic insert 4 14 T Flashing light 2 15 T Lamp 25V /5W 2
25 GENIUS 1400-AUTOMATIC SWEEPER-EXTERNAL PARTS 16 T Right bearing rib 1 17 T Red right hand body side panel TK 1400 E 1 T Grey right hand body side panel TK 1400 E T Red right hand body side panel TK 1400 S T Grey right hand body side panel TK 1400 S 17A T Red right hand body side panel TK 1400 S DIESE 1 T Grey right hand body side panel TK 1400 S DIESEL 18 T Screw TB CE iso x16 zb 6 19 T Seat SC M4 TK DX T DX Right armrest kit for seat B7 SC74/M SX T SX Left armrest kit for seat B7 SC74/M T Front inside casing TK T Low lock nut din 985 M8 zb 4 23 T Handle 2 24 T Petrol label 1 T Diesel label 25 T Screw TB CE iso x20 zb 8 T Upper motor-hood, red TK 1400 T Upper motor-hood, grey TK T Upper motor-hood, red TK 1400 DIESEL 1 T Upper motor-hood, grey TK 1400 DIESEL 27 T Screw TE uni x T Washer uni x24x2, T Lock nut din 985 M10 zb 8 30 T Marbett hinge with diam. 6 holes 2 31 T Screw 6x16 zb 9 32 T Washer uni x T Galvanised seat holder frame TK T Galvanised seat holder frame TK T Screw uni x16 zb 4 35 T Rightside bumper TK T Vibration damper, 2 37 T Nut uni 5588 M T Block nut din 985 M10 zb 2 39 T Galvanised door hinge TK T Sound-proofing panel (DIESEL VERSION) 1 41 T Screw TB CE iso x16 zb 4 42 T Screw TE FR 6x10 6
26 GENIUS 1400-AUTOMATIC SWEEPER-EXTERNAL PARTS 43 T Leftside door TK T Washer uni x T Washer 6x18x1, T Grey left hand bumper TK T Wheel Ø 150x45 Ø T Single spotlight TK T Front red external casing TK T Front grey external casing TK T Right hand door TK T Buffer wheel bushing 2 52 T Nut TCCE 10x T Screw TE FR 6x T Hand-wheel Ø 30 M6x T Front spoiler TK T Self tapping screw 3,9X16 zb 6 57 T Screw TCCE 6X T Screw TCCE 6X T Front bumper TK T Low locknut M T Front yellow right hand galv. bumper TK T Front yellow left hand galv. bumper TK T Thermal reflector 1 T Sound-proofing panel (DIESEL VERSION) 64 T Conveyor thermal reflector panel 1 65 T Screw TEFR 8x16zb 6 66 T Lamp 12V 35/35W 1 67 T Spring 2 68 T Right hand side door guard T Screw TE 6x T Screw 3,5x14,5 4
27 Warranty Policy Limited Warranty Eagle Power Products (EPP) warrants new cleaning equipment against defects in material and workmanship under normal use and service to the original purchaser as detailed below. 10 Years Subject to the conditions stated below, EPP warrants polyethylene tanks and housings to be free from defects in materials and workmanship for a period of ten years. 3 Years Subject to the conditions stated below, EPP warrants all automatic scrubber components to be free from defects in materials and workmanship for a 3-year period. Parts replaced or repaired are warranted for the remainder of the original warranty period. 1 Year Subject to the conditions stated below, EPP warrants all other cleaning equipment components to be free from defects in materials and workmanship for a 1-year period. Parts replaced or repaired are warranted for the remainder of the original warranty period. Batteries are prorated for one year. EPP will furnish and charge for replacement parts, including transportation, to the original owner through an EPP authorized service center. If the part is returned within 30 days and is found defective, the owner will be credited for the cost of the replacement part including shipping and handling. Labor charges are covered for one year from the date of purchase if provided by an authorized EPP service center. Travel is covered for 90 days for battery operated equipment only. Wear items exempt from warranty include belts, carbon brushes, power cords, wheels, pad drivers, clutch plates, brushes, pads, handle grips, filters, screens, throttle cables, and squeegees. This warranty shall not apply to failures caused by misuse or abuse, improper maintenance as stated in the operation manuals, use of unauthorized repair parts, repairs by other than an EPP authorized service center, and damage in transit. EPP disclaims and denies any liability for any direct, indirect, special incidental or consequential damage which may be suffered as a result of sale, delivery, servicing, use, loss of any product, downtime, labor, freight, or other charges not expressly included herein. Date Purchased: Model Number: Serial Number: Please be sure to record this information. This information will be necessary for future warranty claims. Eagle Power Products Sales and Service Provided by: 1174 Northland Drive Mendota Heights, MN Fax
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