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Scarab's Re-Bodying Solutions - Mounting a Maven 65


Scarab's Re-Bodying Solutions - Mounting a Maven 65

With worldwide supply chain issues causing sizable delays in chassis availability for many, a lot of sweeper owners are having to find alternative solutions to keep their machines on the road. With some opting to extend the lifecycle of their vehicles by using Genuine Scarab Parts and Servicing Plans, further solutions are available to our domestic customers that include re-bodying existing chassis with new sweeper bodies. Depending on the application, a truck chassis may have the potential to last longer than the sweep components of the machine – therefore, in some circumstances, having the chassis stripped and fitted with a new Scarab skid unit is a bespoke and cost-effective way to keep a machine running in peak condition.

Undertaken at the Service Centre based at Scarab HQ, many domestic customers have already begun working with our cutting-edge After Sales team to assess the possibility of having their machines re-bodied. Scarab currently offers the all-new Maven 65 as a skid unit to customers in the UK and it is complete with a powerful, efficient Stage V engine that provides exceptional suction performance across any heavy-duty sweeping application. To take a closer look at the re-bodying process, we documented the stages of replacing a 2007 Scarab Mistral with an all-new Maven 65 for an existing customer – Gray Plant Hire.

Step 1:

Agreement reached between Gray Plant Hire and Scarab's Regional Sales Manager to replace the body of an existing customer machine. The 2007 Scarab Mistral, mounted to a 16-tonne Scania chassis is to be replaced by a brand-new Maven 65 skid unit.

Step 2:

Members of Scarab’s After Sales and Technical Engineering teams discuss the chassis requirements of the machine and ensure that the team is prepared for the re-mounting process.

Step 3:

The machine arrives at the Scarab Service Workshop to be prepared for the re-bodying work to be carried out.

Step 4:

The vehicle is assigned a bay in the Scarab Service Centre. Here, the team begin work removing some of the easily accessible components including the water tank, fuel tank and sweep components.

Step 5:

The team begins disconnecting the hopper, removing the bolts and hoses that connect it to the machine.

Step 6:

Once disconnected, the chassis is moved to the Scarab assembly line where a state-of-the-art crane is used to safely remove the hopper and place it onto a trolley. The hopper is then transported to storage and the chassis is sent back to the Service Workshop.

Step 7:

The vehicle returns to the Service Workshop and the team begins disconnecting the sweep components from the machine - removing fixtures and fittings to ease the removal process of the sub-frame.

Step 8:

With the fixings disconnected the sub-frame and auxiliary engine are safely removed from the chassis. Once it has been lifted out of place by the lift truck, it is mounted onto a sub-frame trolley, bolted into position and removed from the workshop.

Step 9:

Any final unwanted elements are removed from the chassis. Once complete, the vehicle is then cleaned and prepared to have the cab and chassis repainted in the customer's new livery colours.

Step 10:

The chassis returns from painting and work begins to mark out the proposed locations of the chassis brackets for the new Maven 65 skid to be mounted.

Step 11:

Scarab's latest generation CANbus control system is mounted into the cab, with the control panel and door-pod control system ergonomically laid out for the operator to make the most out of the system that provides comprehensive real-time feedback and control of operational functions.

Step 12:

The after-market fuel tank is replaced with a new, larger capacity Scarab issue and it is relocated to provide a more ergonomic configuration and provide space for a larger water tank to be supplied. The exhaust of the machine is also repositioned to allow for this adjustment.

Step 13:

The fuel and air tanks are tested to ensure there are no leaks.

Step 14:

The truck chassis is rewired with new electrical looms to transmit signals and electrical power around the machine so the operator can control the sweep gear.

Step 15:

The chassis brackets for mounting the sub-frame are fixed to the truck.

Step 16:

Using the lift truck, the sub-frame and auxiliary engine of the Maven 65 skid unit is lifted and manoeuvred into position. The Service Team guide it down and bolt into the chassis brackets.

Step 17:

Work begins to connect up the components of the machine, this includes removing the old electrical system and fitting it with new connectors.

Step 18:

Brackets to home the additional water tank are attached to the sub-frame. The team also develop a strategy to re-home the machine's batteries to a more ergonomic location.

Step 19:

The team develop a bespoke battery housing and fit it to the truck.

Step 20:

The additional 650 litre water tank is lifted onto the brackets and plumbed into the system.

Step 21:

The sweep components are connected to the control system.

Step 22:

Having plumbed the water system in and connected up the hoses across the machine, the hopper is lifted into place using the lift truck. Once again, the team carefully guide this into place before fixing it to the machine.

Step 23:

The machine undergoes a rigorous testing process to ensure each of its functions works as intended.

Step 24:

The machine heads back to Scarab's Paint Recs department to have any paint defects amended and conspicuity markings fitted to the rear.

Step 25:

The machine is run-up and tested one final time to confirm it is capable of delivering peak operational performance.

Step 26:

The machine is rigorously cleaned to ensure that it meets the high standards set of every machine that leaves the Scarab factory.

Step 27:

The machine is handed over to the customer.


The sweeper, now fitted with Scarab’s high-performance Maven 65, is set to deliver the next level of sweeping performance to the customer. With its increased hopper, fuel and water capacities, versatile sweep configuration and high-speed fan configuration, the customer has managed to upgrade their existing sweeper to one capable of delivering exceptional road cleansing performance.

On the project, Scarab’s Service Manager Marc Hickmott, reflected that “re-bodying an existing sweeper is the perfect way for customers to discover the performance of Scarab’s latest innovations, without having to worry about the uncertainty of waiting for a new truck chassis. In addition to this, it also does a little bit for the environment too! In the case of Gray Plant Hire, with our support, they plan on keeping a lot of the parts from their old Mistral to use to maintain the rest of their fleet of vehicles”.

To discover more about the eligibility of your machine to undergo the re-bodying process, or to find out more about our full range of After Sales solutions, get in contact with a member of the team today by calling +44 (0) 1622 83100 or emailing