305900 valve assembly

Transcription

[1_....)
*Brace
MANUFACTURING
MODELS
350 Series
COMPANY
Serial Numbers
405221 and higher
Revision Date: 01·01·04
Broce Manufacturing Company
1460 SOUTH SECOND AVENUE. DODGE CITY, KS 67801 U.S.A.
(620) 227·8811 Fax (620) 227·3012
www.brocebroom.com
•
•
•
Broce Manufacturing Company, Inc.
WARRANTY REGISTRATION
Purchased From (Dealership)
Company:
Address:
City:
ZIP:
State:
Delivery Date to Dealer: _/
_/
_
Unit Hours:
Model Number:
Serial Number:
Purchaser
Company:
Address:
City:
ZIP:
State:
Delivery Date to Owner:
~
/ _/
_
Unit Hours:
Purchaser - Type of Business
Construction/Highway
Equipment Dealer
I
I
Rental
Municipality
I I
I
I
I
I
Asphalt Contractor
Other
I
I
1.
The Purchaser has been instructed and/or has read the manual and understands proper preventive
maintenance, operation and safety precautions.
2.
The Warranty and limitations
Operators Manuals.
3.
Broce Manufactudng Co. Inc. reserves the dght to make design changes or modifications to Broce
products at any time without incurring any obligation to make similar changes or modifications to
previously sold units.
4.
If this Document is not signed and returned to Broce Manufacturing
the date of delivery to the Dealership.
of Liability are found in the Warranty pages enclosed in the Parts and
Co. Inc., the warranty begins at
I hereby acknowledge acceptance of above and conditions in the Warranty Policy
Purchaser/Owner:
Dealer Representative:
Broce Manufacturing Co. Inc.
1460 South 2nd Avenue
Dodge City, KS 67801
(877) 227-8811
BROCE MANUFACTURING
COMPANY
BROCE BROOM LIMITED TWELVE MONTH WARRANTY
For a period of twelve (12) months or 1,000 hours whichever comes first, from the
date of delivery of product to the original user, Broce Manufacturing of Dodge City,
Kansaswarrants each product to be free from manufacturing defects, subject to the
limitations contained in this policy, This limited warranty covers parts and labor.
This warranty does not apply to defect caused, in whole or in part, by unreasonable
use while in the possession of the user, including, but not limited to, failure to
properly set up product, failure to provide reasonable and necessary maintenance,
normal wear, routine tune ups or adjustments, improper handling, accidents,
operation at speed or load conditions contrary to published specifications, improper
or insufficient lubrication, or improper storage. This warranty is not a guarantee
that the performance of each product will meet the expectations of the purchaser.
Broce Manufacturing shall not be liable for consequential damage of any kind,
including, but not limited to: consequential labor costs or transportation charges in
connection with the replacement or repair of defective parts, lost time or expense
which may have accrued because of said defects. In no event shall Broce
Manufacturing's total liability hereunder exceed the product purchase price.
Many components used by Broce Manufacturing are subject to the warranties of
their respective manufacturers. These warranties will be considered void if the
product is modified or repaired in any way not expressly authorized, or if closed
components are disassembled prior to return. Closed components include, but are
not limited to gearboxes, hydraulic pumps, motors, cylinders and actuators.
Our obligation under the warranty is expressly limited, at our option, to the
replacement or repair at Broce Manufacturing of Dodge City, KS or at a service
facility destqnated by us. We are not responsible for unauthorized repairs or
replacements. Any implied or statutory warranties, including any warranty of
merchantability or fitness for a particular purpose, are expressly limited to duration
of this written warranty. We make no other express warranty. This warranty
cannot be extended, broadened, or changed except in writing by an authorized
officer of Broce Manufacturing.
Broce Manufacturing Co. Inc.
1460 South 2nd Avenue
Dodge City, KS 67801
(877) 227-8811
•
.!
BROCE BROOM MODEL 350
ESTIMATED DIMENSIONS
i.
(lllIMIIl)
I
61'
.' .
,
,
•
1-------135'-----------i
i-------170·---------i
f·
\.
,.
I
j.
;
•
l--
---75'-------1
•
•
•
•
TABLE OF CONTENTS
Main Frame Component Parts
1-2
Instrument Panel & Components
3-4
Seat and Suspension
5-6
Brake Control Assemblies
7-8
Hydrostatic Control Assemblies
9-10
Circle Frame and Components
11-12
Direct Drive Core Assembly
13-14
Chain Drive Core Assembly
15-16
Broom Core Wafers and Spacers
17-18
Bolster Assembly ...........•.....................................................................................................19-20
•
r ;
•
Front Axle Parts and Steering
21-22
Front Brake Assembly
23-24
Rear Axle & Drive Assembly
25-26
Rear Brake Assembly
27-28
Two Speed Gear Box
29-30
Model 44 Industrial Axle
31-32
Tow Bar Assembly
33-34
Cab Assembly
35-36
Roll Over Protection Structure & Related Parts
37-38
Fuel Tank Assembly
39-40
Decal Kit
42
HYDRAULIC SYSTEM DETAILS
44-54
Hydraulic System Components - Front Section
45-46
Hydraulic System Components - CabNalve Section
47-48
Hydraulic System Components - Variable Speed Option
49-50
Hydraulic System Components - Rear Section
51-52
Hydrostatic Drive System
53-54
TABLE OF CONTENTS (Cont.)
HYDRAULIC SYSTEM DETAILS (Cont.)
Rotation Valve Assembly
55-56
305900 Valve Assembly
57-58
ELECTRICAL SYSTEM & ACCESSORIES
60-74
Gauges & Senders
61-62
Windshield Wipers & Washer
63-64
Misc. Switches, Fuses, Etc
65-66
Lights & Horns
67-68
Heater/Defroster
69-70
Air Conditioning System
71-74
BROOM ACCESSORY
SYSTEMS
76-86
Water System Illustrations
77-78
Scraper Blade Illustrations
79-80
Scraper Blade Hydraulics
81-82
Curb Sweeper Illustrations
83-84
Curb Broom Hydraulics
85-86
ENGINES AND RELATED PARTS
88-96
RC-350 Engine
89-90
RCT-350 Engine
91-92
RJ-350 Engine
93-94
KR-350 Engine
95-96
CR-350
97-98
MAINTENANCE,
SPECIFICATIONS
•
AND WIRING DIAGRAMS
•
100+
•
•
•
.,.'
•
MAIN FRAME COMPONENT PARTS
•
•
•
•
MAIN FRAME COMPONENT PARTS
gtv.
Reference
Part No.
Description
1
F-201-R
Main Frame wi Decking
2
F-206-RS ..........•.....Main Deck·(Smooth)
F-206-R
Main Deck (Diamond Tread)
1
1
3
F-205-R
F-205-RW
Diagonal Deck (w/o Water System)
Diagonal Deck (wi Water System)
1
1
4
F-204-R
F-204-RW
Front Deck (w/o Water System)
Front Deck (wi Water System)
1
1
5
F-209-EX
F-209-R
Deck Step (Expanded Metal)
Deck Step (Diamond Tread)
1
1
6
850073
Rear Fender, LH
1
7
850072
Rear Fender, RH
1
8
852049-C
Fire Wall
1
9
See Roll Over
Protection
Roll Bar (2 Post)
1
10
F-202
Frame Step
1
11
203138
Seat Support Base (Non-suspension)
1
12
F-826
Front Fenders (pair)
1
13
VF-208-C
Hood Assembly
1
14
203254
Hood Support Linkage, (JD & Cummins)
1
15
001687
Hood Support Linkage, (JD & Cummins)
1
16
VF-317-B
Hinge, (Set of 2)
1
17
VF-803-R
Hood Catch (Rubber Strap only)
2
18
VF-319-RA
Catch Assembly (Complete)
2
19
F-811-R
Rock Guard
1
20
P-335-R
Rubber Hood Molding
1
•
2
1
INSTRUMENT PANEL AND COMPONENTS
•
•
•
3
•
•
INSTRUMENT PANEL AND COMPONENTS
Reference
Part No.
Description
1
.I-217-AR
Dash Housing
1
2
.I-218-R
Dash Back Cover
1
3
See Hydraulic
System - Front
Section
Power Steering Unit (Danfoss)
1
4
SM-249-D
Power Steering Unit Mount
1
5
305945
305950
Steering Column
Tilt Steering Column (No Conversion)
1
1
6
202052
Access Cover
1
7
S-253-R
Steering Wheel/Horn Assembly
1
9
See Electrical
Section
Ignition Switch
1
10
HS-230-A
HS-231-A
Shifter Assembly (2 Speed)
Shifter Cable (Not Shown)
1
1
11
See Electrical
Section
See Electrical
Section
Universal Accessory Switch
3
Lighted Rocker Switch (Not Shown)
1
12
See Electrical
Section
Wiper Switch
1
13
See Heater/
Defroster
Heater Switch (2 Speed)
1
14
304074
Access Cover Knob
1
15
N/A .............•...........
Horn Sender (Replace Column)
1
16
See Electrical
Section
Spare Key (pair)
1
•
4
Qty.
SEAT AND SUSPENSION COMPONENTS
•
•
5
•
SEAT AND SUSPENSION COMPONENTS
Part No.
Description
1
BS-1050
Seat Assembly
1
2
BS-1051
Back Rest
1
3
BS-1052
Seat Cushion
1
4
BS-1053l+R
Arm Rest Pad
2
6
C-211
C-211-SH
Retractable Seat Belt (Shown)
Retractable Seat Belt wI Shoulder
Harness (Not Shown)
1
7
•
aty·
Reference
C-211-RT
1
Tether Strap Set (for use wI Suspension
Seat)
1
8
T-213-R
Throttle Cable
1
9
852180
Hydraulic Control Cabinet
1
10
203183
Valve Box Cover
1
11
BS-1054
Suspension Assembly
1
Not Shown
203181
Hydraulic Control Cover Back
1
Not Shown
309456
Throttle Cable (Cat Engine)
1
•
6
•
BRAKE CONTROL ASSEMBLIES
11j;J,f/\
Y/)
3
ro\~
~
'/
4
,/h/
I
I
II !
Ii I
'I
8
I
10
•
•
7
•
•
BRAKE CONTROL ASSEMBLIES
Reference
Part No.
Description
1
B-240-B
Dual Master Cylinder
1
2
BM-24S-R
Master Cylinder Mount
1
3
B-284
Rubber Boot
1
4
K00001
Push Rod
1
5
B-238-R
Brake Pedal
1
6
B-241-R
Brake Pedal Pad
1
7
BM-244-R
Pedal Mount
1
8
B-242-R
Pedal Bushing
2
9
BLS-15
Brake Light Switch
1
10
PBS-13
Parking Brake Switch
1
11
PB-237
Parking Brake Cable
2
12
PB-233-C
Brake Lever Assembly
1
13
PB-229-C
Clevis (3/8" Fine Thread)
1
14
PB-235-C
Primary Parking Brake Cable
1
15
202091
Parking Brake Adjuster
1
16
344105
Tension Spring
1
Not Shown
F97935
Master Cylinder Repair Kit..
1
•
8
Oty.
HYDROSTATIC CONTROL ASSEMBLIES
.-
-- -------------,
,
,,
,,
i~
['
,,
,
,
,,
,,
,
,
:,
~,
~=~~~)
j
•
,':~
•
"
,
L
_
•
9
•
HYDROSTATIC CONTROL ASSEMBLIES
aty·
Reference
Part No.
Description
1
HC-22S-R
Control Pedal Assembly
1
2
HC-229-B
1/4" Clevis wI Pin (Note: Control Cable)
1
3
HC-228-B
Hydro-Back Boot
1
4
HC-228-HB
Hydro-Back Device
1
5
HC-228-E
Hydro-Back Cable
1
6
HC-22S-HA
Hand Control Kit (Note: Converts Foot
Control to Hand Control)
1
7
HC-228-0H
Hand Control Cable
1
8
309466
Heims End
1
•
•
10
CIRCLE FRAME & COMPONENTS
•
•
•
11
•
•
CIRCLE FRAME & COMPONENTS
Qty.
Reference
Part No.
Description
1
1a
C-102
C-102A
Circle Frame
1
Circle Frame w/Curb Broom Mount Bracket..1
2
See Hydraulic
Section
Shift Cylinder
1
3
See Hydraulic
Section
Lift Cylinder
1
4
B-103
Circle Bearing
9
5
D-20-R
Shock Absorber
1
6
D-21-R
Shock Pin
2
7
C-109
Hinge Pin
3
8
RC-19
Cylinder Pin
2
9
B-105
Bearing Bracket Assembly (qty as required).
10
B-104
Bearing Bracket
•
12
5
DIRECT DRIVE CORE ASSEMBLY
•
•
13
•
•
DIRECT DRIVE CORE ASSEMBLY
Reference
Part No.
Description
1
C-108-SPC
Core Support
1
2
0-12-8
Core Cover
1
3
OC-15-SPCA
0-15-SPC
Core wi Flat End Caps
Core wi Formed End Caps
1
1
4
0-17
Spindle
1
5
203010
0-16
End Cap ( Flat - Standard Equipment)
End Cap (Formed - Optional)
2
2
6
0-11
Support Bracket
2
7
See Hydraulic
Section
Hydraulic Motor (Core)
1
8
MR-16-SPC
Hydraulic Motor Mount (Core)
1
9
00-257 -R
Splined Hub
1
10
MR-16-LR
Lock Ring
2
11
0-13
Pillow Block Bearing
1
12
304129
Core Rock Guard
1
•
14
Qtv.
CHAIN DRIVE CORE ASSEMBLY
•
•
•
15
•
•
CHAIN DRIVE CORE ASSEMBLY
gtv.
Reference
Part No.
Description
1
C-10S-R
Core Support
1
2
0-12-8
Core Cover
1
3
0-15-S
Core
1
4
0-17
Spindle .............•.................................................2
5
0-16
End Cap
2
6
0-11
Support Bracket
2
7
MAB-16-B
Hydraulic Motor (Core)
1
8
MR-16-AR
Hydraulic Motor Mount (Core)
1
9
C-111
Sprocket (Drive)
1
10
C-1 09-AR
Sprocket (Idler)
1
11
C-110
Sprocket (Driven)
1
12
0-14-R
Roller Chain
1
13
0-13
Pillow Block Bearing
2
14
O-1S-R
Chain Guard
1
15
304129
Core Rock Guard
1
•
16
BROOM CORE WAFER & SPACERS
•
•
17
•
BROOM CORE WAFER & SPACERS
Reference
Part No.
Description
1
RW-503
10" x 32" Prostran Wafer
?
2
RW-504
10" x 32" Wire Wafer
?
3
RW-500
RW-501
RW-502
8' Set, Prostran Wafers wI Spacers
8' Set, Wire Wafer wI Spacers
8" Set, Half Prostran & Half Wire
wi Spacers
1
1
Oty.
1
4
CS-02
Core Service Stand
1
5
CS-01
Core Service Ring
1
Note: Some Machines ordered with Tube Brooms. Contact Factory Prior to Ordering
Brushesl
•
•
18
BOLSTER ASSEMBLY
•
•
19
•
•
BOLSTER ASSEMBLY
Reference
Part No.
Description
1
752002
Bolster Assembly, Complete
Serial Number 402415 and Higher
1
2
852001
Bolster Brace
1
3
203002
Bolster Pin
1
4
852002
Bolster A-Frame Assembly
1
5
852003
Bolster Support
1
6
309507
Oil light Bushing (1 1/4" x 1 1/2" x 1 1/2")
1
7
309505
Oil light Bushing (11/4"
1
8
309506
Oil light Bushing (1 1/4" x 11/2" x 2 114")
•
•
20
Qty.
x 1112" x 2")
1
FRONT AXLE ASSEMBLY
•
•
DO
EJ E5
L__ __
Ii
•
21
•
•
FRONT AXLE ASSEMBLY
Qty.
Reference
Part No.
Description
1
403090
Front Axle Assembly (6 Lug x 5 1/2)
1
2
203526
Steering Cylinder Assembly
1
4
403091
403092
Knuckle w/Spindle, LH
Knuckle wi Spindle, RH
1
1
5
BF4454
King Pin Cap
2
6
403093
Tie Rod Tube
1
7a
7b
BF4470
BF4471
Jam Nut, RH Thread
Jam Nut, LH Thread
1
1
8
BF4465L
Tie Rod End, RH Thread
1
9
203523
Lock Nut
2
10
BF4465R
Tie Rod End, LH Thread
1
11
203551
5eal
2
12
BF4461X
Inner Bearing Kit (w/Race)
2
13
203544
Hub Assembly, (6 Lug x 51/2)
2
14
69957B
Lug Nut
10
15
752547
Outer Bearing Kit (w/Race)
2
16
400195
Washer
2
17
203549
Lock Nut
2
18
203550
Hub Cap
2
19
BF4470
Jam Nut, RH Thread
1
20
BF4455
King Pin Kit
1
21
203520
Steering Cylinder Heims End
1
Not Shown
Not Shown
203553
304039
Steering Cylinder Seal Kit
Wheel - 6 Lug
1
1
•
22
5200-6000 LB FRONT BRAKE ASSEMBLY
•
•
23
•
•
5200-6000 LB FRONT BRAKE ASSEMBLY
Reference
Part No.
Description
1
203554
Complete Caliper Assembly wI Pads
1
2
203530
Friction Pads (Organic)
1
3
203531
1/4" - 28 Brass Bleed Screw
1
4
203532
1/8" Brass Bleed Screw Adapter
1
5
203533
Guide Bolt Sleeve O-ring
1
6 ............................•......203534
Guide Bolt Rubber Sleeve
1
7
203535
Guide Bolt Stainless Steel Sleeve
1
8
203536
Guide Bolt (M11 x 1.5) wI Thread Locker
1
9
203537
90 1/8" NPTto 3/16" F.I.F
1
10
203538
Caliper Piston 2 1/4" Stainless Steel
1
11
203539
Rubber Dust Boot
1
12
203540
Piston Rubber Seal
1
13
203541
1/8" NPT Brass Plug
1
14
203542
Caliper Mounting Bracket
1
15
203543
203544
12" Integral Rotor wI Hub (5 Lug x 51/2)
12" Integral Rotor wI Hub (6 Lug x 51/2)
1
1
16
203555
Wheel Stud
5 or 6
Not Shown
FA-306-R
Brake Hose
2
0
•
24
Qty.
REAR AXLE & DRIVE ASSEMBLIES
•
•
25
•
REAR AXLE & DRIVE ASSEMBLIES
Reference
Part No.
Description
1
PB-237
Parking Brake Cable
2
RA-293-R
RA-293-RA
RA-293-60
Rear
Rear
XHD
Dana
XHD
Dana
RA-293-60A
•
Qty.
2
Axle Assembly Dana 44 (5 lug)
1
Axle Assembly Dana 44 (6 lug)
1
Rear Axle Assembly (Optional - 5 lug)
Model 60
1
Rear Axle Assembly (Optional - 6 lug)
Model 60
1
3
4030S3
Cap U-Joint Dura-Axles
2
4
DS-299-C
Drive Line Assembly (Complete)
1
5
DS-29S-R
Universal Joint Assembly
2
6
TS-302-C
TS-302-CR
2-Speed Gearbox
2-Speed Gearbox (Reconditioned)
Subject to Availability
1
1
7
HS-231-A
Shift Cable
1
S
2031 09
Hydraulic Shift Linkage
1
9
HC-229-R
3/S" Clevis Assembly wi Pin
1
10
BL-296-R
Brake Line Assembly
1
11
RA-294-R
Breather
1
12
BL-297 -R
Brake Line Assembly
1
13
RA-295-C
Union Tee
1
14
111111
Shoulder Bolt
3
15
S50013
Shift Linkage Couple W/A
1
•
26
REAR BRAKE ASSEMBLY
•
•
27
•
•
•
REAR BRAKE ASSEMBLY
Reference
1
Part No.
4402AL
4402AR
Description
Backing Plate Assembly (Left)
Backing Plate Assembly (Right)
2
4414A
Shoe Set (Set of 4)
1
3
4408
Anchor
1
4
4409A
Return Spring (Front)
1
5
4409
Return Spring (Rear)
1
6
4406L
4406R
Wheel Cylinder (Left)
Wheel Cylinder (Right)
1
1
7
4407A
Push Rod
2
8
4411A
4411AR
Strut (Left)
Strut (Right)
1
1
9
4410
Spring
1
10
4418
Guide
1
11
4415
Cable
1
12
4413AL
4413AR
Parking Brake Lever (Left)
Parking Brake Lever (Right)
1
1
13
4401
Pin, Shoe Hold Down
2
14
4425
Hold Down Spring
2
15
4424
Cup, Hold Down
2
16
4416
Spacer
1
17
4417
Retainer
1
18
4419L
4419R
Adjusting Lever, (Left)
Adjusting Lever, (Right)
1
1
19
4423L
4423R
Adjusting Screw Assembly, (Left)
Adjusting Screw Assembly, (Right)
1
1
20
4426
Spring
1
21
4404A
403082
Brake Drum (5 Lug)
Brake Drum (6 Lug)
1
1
22
4427
Wheel Cylinder Repair Kit.
AlR
Not Shown
Not Shown
4400AL
4400AR
Complete Assembly, (Left)
Complete Assembly, {Right)
1
1
28
Qtv.
1
1
TS-302-C TWO SPEED GEARBOX
•
•
•
29
•
•
TS-302-C TWO SPEED GEARBOX
Reference
Part No.
Description
1
2S-11 A
Main Housing
1
2
2S-12
Housing Cover
1
3
2S-13
Bearing Cap
1
4
2S-14
Bearing & Seal Cap
1
5
2S-15
Vent Plug
1
6
2S-16
Bearing Assembly
1
7
2S-17
Pinion Gear wI Key
1
8
25-18
Input Shaft
1
9
25-19
Bearing Assembly
3
10
25-20
Shift Rail
1
11
25-21
Shift Fork
1
12
2S-22
Seal, Shift Rail
2
13
2S-23
Gear, High Range
1
14
25-24
Sliding Collar
1
15
25-25
Gear, Low Range
1
16
25-26
Output Shaft
1
17
25-27
Seal, Output Shaft
1
18
25-28
Output Flange
1
19
25-29
Jam Nut
1
20
25-30
Detent Kit
1
Not Shown
25-31
Shim Kit
1
•
30
Qty.
•
CD
1J
o
~
•
•
31
•
•
MODEL 44 INDUSTRIAL AXLE
Description
Reference
Part No.
1
2*.'
3*
4*
5*
6*
7*
8
9*
10
11*
12*
14
15**
16
17
18
19
20
21
22
23**
24**
25**
26**
27**
28"
29"
30
31
32
33*"
34···
35·"
36***
37***
459109 C94
Axle Housing
NSS
Gear & Pinion Set
706031X
Inner Pinion Bearing
NSS
Shim - Drive Pinion
30765
Baffle - Pinion Bearing
NSS
Shim - Pinion Bearing
706030X
Outer Pinion Bearing
30784
Slinger
35723
Pinion Seal
3-4-5761X
End Yoke Assembly
30186 ...................•.Washer- Pinion Nut
30185
Pinion Nut
343825
Cover - Carrier
34685
Gasket - Carrier Cover
36472
Plug - Cover
34279
Bolt - Cover (source locally)
NSS
Cap - Differ Bearing
NSS
Bolt - Differ Bearing Cap
706032XA ....•......... Differ Bearing Kit
NSS
Shim - Differ Bearing
32684
Differ Case
30187
Bolt - Drive Gear
NSS
Pinion - Differ
NSS
Differ - Gear
NSS
Thrust Washer - Differ Pinion
NSS
Thrust Washer - Differ Gear
NSS
Differ Shaft
13449
Lock - Differ Shaft
34616-1
Bolt - Brake Mounting
35704
Nut - Brake Mounting
34419
Seal- Shaft Inboard
36797
Retaining Ring - Wheel Bearing
565903
Bearing Assembly
35239
Seal - Shaft Outboard
35490A
Retainer - Oil Seal
26726A
Shaft - Axle Flange (5 lug)
403081
Shaft - Axle Flange (6 lug)
35491A
Bolt - Wheel
38
* Included in Kit Number 7066139X
** Included in Kit Number 706027X
... Included in Kit Number 26726A
... Included in Kit Number 403081
NSS - Not Sold Separately
•
32
Qty.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
..
1
4
1
1
1
10
1
1
1
1
1
1
8
8
2
2
2
2
2
2
2
5 or 6
•
TOW BAR ASSEMBLIES
•
~
:=~-1"
I
9'-= --
+-.
~.'_
j~
--'l
~
•
33
•
TOW BAR ASSEMBLIES
gtv.
Reference
Part No.
Description
1
4201P
4201B
Tow Bar wi 3" Pintle
Tow Bar wi 2 5/16" Receiver
1
1
2
K00003
Hitch, Shutoff Assembly Kit (Valve,
Hoses, and Fittings)
1
Tow Valve
1
3
305025
Note: Tow bars come as complete kit. Kit includes Mounts, Chains, and
Pin. Hitch Shutoff Assembly is separate. The Hitch Shutoff is for a safer
and easier way of towing the broom. All Broce Brooms are towable as long
as the Gearbox is in neutral, the Parking Brake is released, and the Shutoff
Valve is engaged.
•
•
34
•
CAB ASSEMBLY
J
~\!
0
~
[DO]
8
~
11
•
tID
~
35
•
•
•
CAB ASSEMBLY
Reference
Part No.
Description
1
P-315-B
345055
Cab Assembly, Complete
Cab Keys, (Sold as a Pair)
1
1
2
202116
Mirror Bracket, (2 per Side)
.4
3
P-353-R
West Coast Style Mirror (1 per Side)
2
4
P-352-B
Strut, (1 per Side)
2
5
309406
Ball for Strut
2
6
345051
Outside Door Handle (Paddle Style)
2
7
P-320-B
Striker Assembly
2
8
345053
Latch Assembly
2
9
345050
Inside Door Handle (Paddle Style)
2
10
304089
Door Seal, 14' per door
1
11
P-325-R
P-316-R
Window Rubber Molding, (As Required)
Floor Mat, 5' x 4' Blank
1
1
12
K00002
Door Tether Strap, Inside (1 per Side)
2
13
B239920C
Outside Grab Handle
1
Not Shown
345052
Inside Grab Handle
2
Not Shown
AC-708-R
Air Cleaner Assembly
1
Not Shown
AC-785-R
Air Cleaner Bonnet (Top Cap)
1
Not Shown
P10-3113
Air Cleaner End Cap
1
Not Shown
POO-3951
Air Cleaner Clamp
2
Not Shown
110-20027
Air Cleaner Flex Hose
1
Not Shown
P10-2114
Air Cleaner Vent
1
Not Shown
AC-709-R
Air Cleaner Filter
1
Qtv.
Note: Items 10 & 11 are sold by the foot. Floor mat is a "Cut to Fit" item.
•
36
ROLL OVER PROTECTION
STRUCTURE & RELATED PARTS
•
•
•
37
•
ROLL OVER PROTECTION
STRUCTURE & RELATED PARTS
Part No.
Description
1
P-310-R
Two-Post Roll Bar
1
2
852057
Canopy
1
3
See Seat &
Suspension
Seat Belt wi Shoulder Harness (Optional)
1
4
See Seat &
Suspension
Retractable Seat Belt (Standard)
1
5
C-211-RT
Tether Strap Set (For use wi Suspension
Seat)
1
Windshield Frame wi Molding
(Safety Glass Not Included. See Note)
1
6
•
Qtv.
Reference
P-312-R
7
P-356-R
Rear View Mirror
1
8
P-325-R
Offset Rubber Molding
1
9
P-355-R
Rubber Trim
1
Note:
1. Due to the abundant availability of automotive safety glass from local vendors
and the likelihood of breakage during shipment, the windshield frame is sold
w/o glass.
2. Seat belt tether straps MUST be used on suspension seats.
3. Items 8 & 9 are sold by the foot.
•
38
FUEL TANK ASSEMBl Y
•
I
6
•
39
•
•
FUEL TANK ASSEMBLY
Reference
Part No.
Description
1
852454
Fuel & Hydraulic Tank
1
2
T-703-BA
Hydraulic Cap
1
3
T-702-B
Fuel Cap
1
4
T-S05-R
Rubber Tank Pad
2
5
550-5
Sight Glass
1
6
344175
Fuel Gauge Assembly
1
•
•
40
Qty.
•
•
41
•
(.t.:.....
~,
(
.
'.;
"II)
v.""ir\./.lI,r~,,..-v.
...~ .•.
'
I
!~! '~t: ...~.:r.-,.v'·
,],<, '1)
I;
.
'""'
II
I.
1'.
.!. ~:
/. . ~,~'
~,/~/~\..,.~~.
,'1,'
. /J,
I
~i.
II~'
\.,I
I!.
0
r..
C)
)1
0
..J
Q)
(,)
e
CD
"0
"&~WAR'NING
I~
-I
«
o
w
c
.~
r_; "':-
C
..
co
II)
Q)
:,~'~~
...
Q.
·C
-...
U)
3t
I
·C
U
~
Q
ci
Z
1::
co
CL
i:
co
(,)
Q)
Q
0:::I
CO?
CO?
~
..J
::.:
Q)
(,)
C
e
.!
Q)
0:::
'""'
N
.;r
•
•
43
•
•
4W BROOM HYDRAULIC SYSTEM DETAILS
•
•
44
4W BROOM HYDRAULIC SYSTEM COMPONENTS
SERIAL NUMBER 404001 +
(Front Section)
•
•
Revision: 02/04/04
45
•
SERIAL NUMBER 404001+
(Front Section)
Reference
Part No.
Description
1
2
3
203526
208
305943
305972
MAB-16-B
5K000092
305944
305525
HF-278-R
HF-278-RAF25
216
305829
N/A
N/A
N/A
N/A
N/A
N/A
305818
305871
N/A
N/A
305841
305827
305824
305837
N/A
305198
305177
305177
26
N/A
27
305864
5teering Cylinder, 10"
Lift Cylinder
Core Motor, Direct Drive
5eal Kit for Direct Drive Core Motor
Core Motor, Chain Drive
5eal Kit, Chain Drive Motor
5teering unit
Hydraulic Manifold
Filter Element
Filter Assembly
5hift Cylinder
Hydraulic Fitting, FF1852T06-0S
Hydraulic Hose Assembly, 30"-1AASFRS & 1AAGFRBS
Hydraulic Hose Assembly, 30"-1AASFRS & 1AA6FRCG
Hydraulic Hose Assembly, 35"-1AASFRBS & 1AA6FRAS
Hydraulic Hose Assembly, 7S"-1AASFRS4 & 1AA6FRB6
Hydraulic Hose Assembly, 40"-1AA4FRB4 (2)
Hydraulic Hose Assembly, 32"-1AA4FRB4 & 1AA4FRC4
Hydraulic Fitting, FF1852T04-06
Hydraulic Hose Assembly, 94.5"-1AA12FR12 (2)
Hydraulic Fitting, Caterpillar 3E-7420
Hydraulic Fitting, 3474-20-20
Hydraulic Fitting, 900598-12
Hydraulic Fitting, 900598-8
Hydraulic Hose Assembly, 56"-1 AA6FRB6 (2)
RC-19
D-21-R
IC-4244
203553
Clevis Pin (Shift Cylinder)
Shock Pin (Lift Cylinder)
Seal Kit, Replaces PIN RC-20
Seal Kit - Steering Cylinder
4
5
6
•
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
25a
Not
Not
Not
Not
5hown
Shown
Shown
Shown
Note:
•
Qty.
If 5teering Cylinder Rod becomes damaged or broken,
Therefore the entire cylinder must be replaced.
Revision:
02104/04
46
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
..4
1
1
1
1
5
2
2
2
1
1
1
1
2
2
2
1
1
it is not economically
feasible
to replace.
(Cab-Valve Section)
•
•
•
Revision: 02/04/04
47
•
(Cab-Valve Section)
•
•
Reference
Part No.
Description
Qty.
20
305827
5
28
305763
Core Lock Solenoid
1
29
See Valve
Section
Control Valve
1
30
See Valve
Section
Rotation Valve
1
31
305818
1
32
NIA
Hydraulic Hose Assembly, 8" 1AA4FR4 & 1AA4FRB4
1
33
305848
1
34
305930
Restrictor, 156L8572
1
35
305818A
Hydraulic Fitting, FF1852T04-06 (Machined)
4
36
NIA
Hydraulic Hose Assembly, 50"-1AA4FRB4 & 1AA4FRC4
1
37
NIA
Hydraulic Hose Assembly, 27"-1AA6FRB6 & 1AA6FRA6
1
38
NIA
Hydraulic Hose Assembly, 20"-1AA12FR12 & 1AA12FRB12
1
39
305871
1
40
305840
1
41
305836
1
42
305872
1
43
305931
2
44
305932
1
45
NIA
1
Revision: 02104/04
48
VARIABLE SPEED OPTION
•
(Cab-Valve Section)
33
"""""'"' "OA'~.
\bffi23
sle
0 ~
••••••.......••.•••. T •. __ ~
:
.,.'f!!'rWr:v..At.
:.
•
'",
9
(W1f':'[l'GA)
!
S
_y
j
i
"..,."
•
•
Revision: 02/04/04
49
•
SERIAL NUMBER 404001 +
VARIABLE SPEED OPTION
(Cab-Valve Section)
•
•
Reference
Part No.
Description
-Qty.
20
305827
5
28
305763
Core Lock Solenoid
1
29
See Valve
Section
Control Valve
1
30
305981
Rotation Valve, Variable Speed
1
31
305818
1
32
N/A
Hydraulic Hose Assembly, 8" 1AA4FR4 & 1AA4FRB4
1
33
305848
1
34
305930
1
35
305818A
Hydraulic Fitting, FF1852T04-06 (Machined)
4
36
N/A
Hydraulic Hose Assembly, 50"-1 AA4FRB4 & 1AA4FRC4
1
37
N/A
Hydraulic Hose Assembly, 27"-1AA6FRB6 & 1AA6FRA6
1
38
N/A
1
39
305980
Variable Speed Rheostat
1
40
305840
3
41
305836
1
42
N/A
Hydraulic Hose Assembly, 80"-1 AA 12FRB12
1
43
305931
2
44
305932
1
45
N/A
1
46
N/A
Hydraulic Hose Assembly, 36"-1AA12FRB12
1
Note: Item #30 Replaces Rotation Valve on standard broom and is located under cab.
Hydraulic Hose Items #38, #42, and #46 replace Items #19, #38, and #72 of standard broom
hydraulic illustrations shown in this section.
Revision: 02104/04
50
(Rear Section)
•
To
Manifold
I
I
To Rot.
Valve
~~eering
•
Revision: 02/04104
51
•
•
•
(Rear Section)
Reference
Part No.
Description
gtv.
46
See Fuel Tank
Assembly
Fuel Tank & Hydraulic Tank
1
47
305767
305766
305768
Oil Cooler, RJ & RCT
Oil Cooler, CR
Oil Cooler, RC
1
48
See Next
Section
Hydraulic Pump
1
49....•...............See Next
Section
Fix Motor
1
50
HF-278-R
HF-278-RAF03
Filter Element
Filter Assembly, 3 psi.
2
1
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
305680
305843
N/A
N/A
306538
H-227-R
N/A
N/A
305869
305825
N/A
305849
305806
N/A
N/A
305880
N/A
N/A
305812
N/A
305199
N/A
N/A
N/A
N/A
N/A
Hydraulic Hose Assembly, 24"-1GA20FRA20 {2)
Hydraulic Hose Assembly, 27"-1GA16FR16
1 1/4" Ball Valve
1" Ball Valve
Hydraulic Hose Assembly, 21"-1AA12FR8 & 1AA8FRC8
Hydraulic Hose Assembly, 16.5"-1GA16FR16 {2)
Hydraulic Fitting, FF1868T16·20
Hydraulic Hose Assembly, 52"-1 AA 12FR12 & 1AA 12FRB12
Hydraulic Hose Assembly, 70"-1AA12FR12 & 1AA12FRB12
Hydraulic Hose Assembly, 12"-1GA16FR16 & 1GA16FRB16
Hydraulic Hose Assembly, 9"-1BA16FRA16 (2) {CAT.)
Hydraulic Hose Assembly, 11"-1BA16FRA16 (2) (JD.)
Hydraulic Hose Assembly, 13"-1BA16FRA16 (2) {CUM.)
1
1
1
1
1
2
1
1
1
3
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
Revision: 02104/04
52
HYDROSTATIC DRIVE SYSTEM
DAN FOSS HYDROSTATIC
COMPONENTS
•
•
•
53
•
•
HYDROSTATIC DRIVE SYSTEM
Qty.
Reference
Part No.
Description
1
305997
Variable Displacement
2
1508
O-Ring
1
3
355010
355011
Hydraulic Pump
Hydraulic Pump for Machines with
Gutter Brooms
1
1
Pump
1
1
4
305975
Fixed Displacement
5
305957
Neutral Safety Switch
1
6
1216
Bracket.
1
7
1215
Lever
1
8
1214
Centering Spring
1
Not Shown
0301
Front Seal (Same for Item 1 or 4)
1
Not Shown
4510017
Seal Kit for 305997
1
Note: Rebuilt Components Subject to Availability.
•
54
Motor
305901 ROTATION VALVE ASSEMBLY
•
o
•
55
•
•
305901 ROTATION VALVE ASSEMBLY
Reference
Part No.
Description
Qty.
1..................••............... 305901 ...........•....... Complete Valve Assembly
1
2
305966
Detent.
1
3
305961
Handle Kit
1
4
305052
Relief Cartridge
1
Not Shown
305967
Seal Kit.
1
•
•
56
305900 VALVE ASSEMBLY
•
•
•
57
•
305900 VALVE ASSEMBLY
Reference
Part No.
Description
1
305900
Complete Valve Assembly
1
2
305928
Float Detent
1
3
305927
Spring Center Detent
1
4
305959
Joystick Kit
1
Not Shown
305960
Load Check
1
Not Shown
305962
Seal Kit
1
•
•
58
Qty.
•
•
•
59
•
ELECTRICAL SYSTEM AND ACCESSORIES
•
•
60
GAUGES AND SENDERS
•
•
61
•
•
•
GAUGES AND SENDERS
Reference
Part No.
Description
Qty.
1
1-222-HO
Hour Meter
1
2
1-221-R
Oil Pressure Gauge
1
3
1-223-R
Fuel Gauge
1
4
1-220-V
Voltmeter
1
5
.I-219-R
Temperature Gauge (Engine)
1
6
1-222-B
307097
Tachometer
Tachometer (RCT-350 Model Only)
1
1
7
IS-219-R
307084
307088
Temperature Sender
Temperature Sender (CAT 3054C)
Temperature Sender (CAT 3054B)
1
1
1
8
.lS-219-WC
Temperature Sender wi Contact
Note: Use wi warning or shutdown system
1
IS-221-R
Oil Pressure Sender
1
10
IS-221-WC
Pressure Sender wi Contact
Note: Use wi warning or shutdown system
1
11
.I-228-R
Hydraulic Temperature Gauge
Note: Mechanical 12' Capillary
1
12
344257
Murphy Shutdown Unit
Note: Engine Safety Shutdown
1
13
344175
Fuel Sender
1
Items Not Shown
1-220-A
307255
1-224-R35
Ammeter
Buzz Light Assembly
Fuel Sender (35 gal. Tank)
1
1
1
9
:
•
62
WINDSHIELD
WIPERS & WASHER
•
•
63
•
WINDSHIELD WIPERS & WASHER
Reference
Part No.
Description
1
1-182-54MO
Wiper Motor
1
2
LE581022-1
Drive Arm
1
3
2-615-2218
2-615-2214
1-182-54
18" Blade (Canopy Windshield)
14" Blade (Rear)
Wiper Kit - Canopy Windshield
(Includes Motor, Blade, and Arm)
Rear Wiper Kit (Includes Motor, Blade,
and Arm)
1
1
1-182-54R
•
Qty.
1
1
4
2-615-15
Wiper Motor
1
5
BK721005
Wiper Motor Mount
1
6
2-615-19
Wiper Drive Arm (Tapered Motor Shaft)
1
7
2-615-60
Wiper Shaft & Arm Assembly
1
8
2-615-17
Pantograph Adapter & Gasket
1
9
721014
Link & Bolt Kit (Includes Bolts. Washers,
& Clips to Mount Motor)
1
10
2-615-24
Pantograph Drive Arm
1
11
2-615-2226
26" Blade
1
12
2-686-67
Two Speed Wiper Switch
1
13
66-01
66-01A
Washer Pump & Reservoir
Washer Kit (Includes Tubing & Hardware
for New Installation)
1
•
64
1
MISC. SWITCHES, FUSES, ETC.
•
•
•
65
•
•
MISC. SWITCHES, FUSES, ETC.
atv.
Reference
Part No.
Description
1
PBl-12
Warning light
1
2
PBS-13
Parking Brake Switch
1
3
46050-12
46050-10
46050-8
46050-6
Fuse
Fuse
Fuse
Fuse
1
1
1
1
4
307902
Relay - Air Conditioning Shutoff
1
5
46330
30 Amp Breaker
1
6
23836
1
7
WH46242
46243
40 Amp Maxi Fuse
50 Amp Maxi Fuse
1
1
8
WH-767-FH
Maxi Fuse Holder
1
9
X770050
Air Restrictor Sender (Air Cleaner Ind.)
1
10
BlS-15
Stop light Switch
1
11
76052
Pressure Switch (Air Conditioner Shutoff)
1
12
307044
307045
Ignition Switch
Key (pair)
1
1
13
307071
Core lock Switch
1
Not Shown
307235
Push Button Switch for Preheat (All Same)
1
Block
Block
Block
Block
•
66
(12 Fuse Capacity)
(10 Fuse Capacity)
(8 Fuse Capacity)
(6 Fuse Capacity)
LIGHTS - HORNS
•
•
•
67
•
•
LIGHTS - HORNS
Reference
Part No.
Description
1
9-50004-SBA
Driving Light.
AlR
2
4-75001
Turn Signal
2
3
6-70001
StoplTurn Signal
2
4
16-35800
Turn Signal Switch
1
5
23836
1
6
550
Flasher
1
7
550FH
Flasher Socket
1
8
LG-100-SBA
Light Group Kit w/950004-SBA
Driving Lights
Qtv.
See Note
9
7-40004
Am ber Beacon
AlR
10
3614A
Amber Strobe Light
AlR
11
RH-250
Reverse Alarm
1
12
LDA-50-1R
Reverse Alarm Switch
1
13
4-302
Traffic Horn
1
14
307031
Flush Mount Tail/Brake Lights
(Starting wi Serial Number 90044)
2
Note: Light Group Kit, Part Number LG-100-SBA, contains all signals,
switches, lights, and wiring harness required for field installation.
•
68
4W BROOM HEATER/DEFROSTER
•
•
69
•
•
4W BROOM HEATER/DEFROSTER
gtv.
Reference
Part No.
Description
1
403153
Case, Bottom/Side
1
2
403154
Coil
1
3
403155
Case, Top/Side
1
4
403156
Panel, Blower
1
5
403157
Resistor, 3 - Speed
1
6
403158
Housing, Blower
1
7
403159
Motor, CCW
1
8
403160
Wheel, Blower
1
9
403161
Ring, Venturi
1
10
403162
Hose, Vent Motor Blower
1
11
403163
Plenum, Heater
1
12
403164
Louver, 3" Round
2
13
403165
Plenum, Defrost
1
14
403166
Hose, Flex, Wire, Metal, 2.5" Dia
1
15
403167
Harness, Wire, Heater
1
16
403168
Switch, Rot 4 Position
:1
17
403169
Knob, Switch, Rotary
1
KIT
K00016
Heater/Defroster Kit (JD RJ-350)
1
KIT
K00017
Heater/Defroster Kit (Cummins RC-350)
1
KIT
K00018
Heater/Defroster Kit (CAT CR-350)
1
KIT
K00019
Heater/Defroster Kit (Cummins
Turbo RCT-350)
1
Heater/Defroster Kit (Kubota KR-350)
1
KIT
K00020
•
70
4W BROOM AIR CONDITIONING SYSTEM
•
Features:
•
•
•
•
255 CFM
Heavy Duty Powder Coated
Finish all steel case.
Low Profile for maximum
headroom.
Filtered, recirculated air.
•
1/.. ··20 • 112·
BOLT
1"'· FLAT WASHER
wIl/4-20 NUT
•
71
•
•
Qty.
Reference
Part No.
Description
1
403184
Cover, Evaporator
1
2
403180
Blower Assembly
1
3 .............................•.....403175
Coil, Evaporator
1
4
403174
Valve, Exp., Block, R134a
1
5
403183
Housing, Evaporator
1
6
403164
Louver, 3" Round
3
7
403177
Knob, Fan
1
8
403181
Decal, Fan
1
9
403173
Switch, Rotary
1
10
403176
Thermostat
1
11
403187
Bracket, Mounting, Exp. Valve
1
12
403178
Filter
1
13
403192
Drain Pan (Evaporator)
1
Not Shown
403182
TSTAT Knob
1
Not Shown
403185
Binary Switch
1
•
72
'l~-!Ml
~~,t,tc
•
./
•
•
73
•
•
Reference
Part No.
Description
1
403170
Compressor (Fits all Engine Models)
1
2
403179
Wiring Harness
1
3
403186
Dryer Clamp
1
4
403171
Receiver Dryer
1
5
403150
Condenser
1
6
304028
BL-0660
304027
304197
AlC
AlC
AlC
AlC
1
1
1
1
7
403019
3919624
203341
Pulley, RJ-350 (Shown)
Pulley, RC-350
Pulley, KR-350
1
1
1
8
203131
203118
Adjustment Arm, RJ-350 (Shown)
Adjustment Arm, CR-350
1
1
9
852127
403021
852038
852259
.852338
Compressor
Compressor
Compressor
Compressor
Compressor
1
1
1
1
1
Belt,
Belt,
Belt,
Belt,
•
74
Qty.
RJ-350 (Shown)
RC-350
CR-350 & RCT-350
KR-350
Mount,
Mount,
Mount,
Mount,
Mount,
RJ-350 (Shown)
RC-350
CR-350
RCT-350
KR-350
•
•
•
75
•
BROOM ACCESSORIES SYSTEMS
•
•
76
4W BROOM WATER SYSTEM
FILTER DETAIL
"..--t!.t-·-I
77
NOZZLE DETAIL
•
•
•
4W BROOM WATER SYSTEM
gtv.
Reference
Part No.
Description
1
201761
Strap
2
2
WS-145-D
Filler Cap, Plastic, 6" Dia
1
3
WS-143-D
low Profile Plastic Tank
1
4
WS-176-E
Tank Adapter (1114" Dia.)
1
5
345012
Plastic Pipe Fitting, 90°
3
6
306535
3/4" Ball Valve
1
7
306116B
Pipe Nipple
1
8
WS-148
Inline Strainer, Complete
1
9
345011
Plastic Pipe Fitting, Straight..
1
10
345010
2
11
WS-146
Pump
1
12
850025
Pump Mount
1
13
345009
2
14
306950
Check Valve
1
15
WS-154
Spray Bar Assembly
1
16
202101
Brace wI U Bolt
2
17
001716
Brace wi U Bolt
1
18
344999
Hose (sold by foot)
nla
19
1700-0044
Strainer Gasket
1
20
3800-0025
Strainer Screen
1
21
3351-0005
Strainer Cup
1
22
WS-155
Nozzle Assembly, Complete
8
23
WS-158
Nozzle Screen
8
24
TP8002
Spray Tip
8
25
1458
Cap
8
78
•
>..J
III
:!:
w
en
en
«
w
c
«
..J
III
•
~
W
D..
~
o
en
•
•
•
SCRAPER BLADE ASSEMBLY
Reference
Part No.
Description
1
850022
Blade WA (71/2"
2
SBA09796
Cutting Edge (High Carbon Steel)
1
3
850024
Blade Pivot WA
1
4
850023
Blade A-Frame WA
1
5
850026
Blade Lift Arm WA
1
6
850017
Lift Frame
1
7
850016
Frame Mount
1
8
201956
Frame Brace
1
9
SBA05437
Shift Cylinder
2
10
208
Lift Cylinder
1
11
SBA09126
Shoe Assembly
2
12
SBA08541
Pivot Pin Set (2 Pins)
1
13
SBA08562
Hinge Pin Set (2 Pins)
1
14
SBA09124
Eye Bolts (for springs)
3
15
SBA07017
Tip Spring
3
16
SBA08184
Cutting Edge Bolt Set
1
17
SBA02020
Marker Kit (not shown)
1
•
80
Qty.
scraper)
1
SCRAPER BLADE HYDRAULICS ASSEMBLY
/v'i
I
1
i~
:,~~;;5:;'::f:2~;:::
/!//
/
,//
<,
.. -c,
/ /
/
/ /,/
/
/~'J
>}:~;,'r~!"
La
9
1~
Note: Hydraulic Hoses and Aeroquip fittings not available through Broce Mfg. Parts
Oept.- Source Locally
81
•
•
SCRAPER BLADE HYDRAULICS ASSEMBLY
Reference
Part No.
Description
1
2
3
4
5
Sa
Sb
SBA05437
208
305900
305944
305525
203096
203093
Angle Cylinder
Lift Cylinder (208-R)
Control Valve
Steering Unit
Hydraulic Manifold
RH Foot Control Pedal
LH Foot Control Pedal
7
8*
9*
10*
11*
12*
13*
14*
15*
16*
17
18·
19*
20*
21*
309412
Linkage Kit
2
Hydraulic Hose Assembly, 104.5" #S, FRAS, FRS
1
Hydraulic Hose Assembly, 33.5" #S, FRBS, FRS
1
Hydraulic Hose Assembly, 94" #S, FRBS, FRS
1
Hydraulic Hose Assembly, 85" #4, FRB4, FR4
1
Hydraulic Hose Assembly, 88" #4, FRB4, FR4
1
Hydraulic Hose Assembly, 80" #4, 2-FRB4
1
Hydraulic Hose Assembly, 90" #4, 2-FRB4
1
Hydraulic Fitting, 4-4 Straight
4
Hydraulic Fitting, S-6 Straight
3
SBA01007
Scraper Control Valve
1
Hydraulic Fitting, S-8 90°
1
Hydraulic Fitting, 6-S Straight
1
2
305250
Quick Coupler (Male & Female Set)
2
1/4 St. Elbow .....................•............................................................... 2
2
1
305930
Orifice Plate
4
305925
Power Beyond Bushing
1
22*
23*
24*
25
26
Qty.
2
1
1
1
1
1
1
* Note: Hydraulic Hoses and Aeroquip fittings not available through Broce Mfg. Parts
Dept. - Source Locally
•
82
•
CURB SWEEPER ASSEMBLY
(Sweeper and Components)
:~~
,'.
e.
I
,
,
X,
,
....
9
<, ,
/'
"
,
•
83
•
•
•
•
CURB SWEEPER ASSEMBLY
(Sweeper and Components)
Reference
Part No.
Description
1
854005
Mounting Bracket
1
2
854001
Main Lift Arm
1
3
304299
304296
Curb Brush {Wire) ...............................•.............1
Curb Brush {Poly}
1
4
854004
Tilt Arm
1
5
854006
Hub Ext
1
6
854003
Motor Mount Bracket
1
7
204027
Broom Mounting Plate
1
8
204017
Lift and Tilt Cylinder Pin
2
9
204019
Motor Bracket Pin
1
10
204018
Accumulator Pin
1
11
204016
Pivot Pin
1
12
204005
Mounting Bracket Arm Pin
1
13
204008
Lift Cylinder Lower Pin
1
14
See Hydraulic
Section
Lift Cylinder
1
15
See Hydraulic
Section
Accumulator Cylinder
1
16
See Hydraulic
Section
Tilt Cylinder
1
17
See Hydraulic
Section
Hydraulic Motor
1
18
400910
C-Clip
4
19
400911
C-Clip
5
20
400912
C-Clip
2
84
Qty.
L-....
,1;;Ch;;1
Note: Hydraulic Hoses and Aeroquip fittings not available through Broce Mfg. Parts
Dept.- Source Locally
85
•
•
CURB BROOM HYDRAULICS ASSEMBLY
Reference
Part No.
1
2
3
4
5
6
7
8·
9*
10·
11·
12·
13·
14·
15·
1S·
17·
18·
19·
20·
21·
22·
23·
24·
25
26
27·
28·
29·
30·
31·
32
33*
34
35
Not Shown
305916
Broom Motor
305912
Shift Cylinder
305913
Tilt Cylinder
305914
Lift Cylinder
305915
Control Valve
305917
Flow Divider
305918
Accumulator
:
Hydraulic Hose Assembly, 1S"HL-1AA12FR12 & 1AA12FRB12
Hydraulic Fitting, FF18S8T12-10
Hydraulic Fitting, FF1852TOS-08
Hydraulic Hose Assembly, 52.5"HL-1AASFRS & 1AASFRBS
Hydraulic Fitting, FF18S8TOS-125
Hydraulic Hose Assembly, 32"HL-1AASFRS & 1AASFRBS
Hydraulic Hose Assembly, 81"HL-1AA4FRC4 & 1AA4FR4
Hydraulic Hose Assembly, 75.5"HL-1AAFR4 & 1AASFRB4
Hydraulic Hose Assembly, 74.5HL-1AA4FR4 & 1AASFRB4
Hydraulic Fitting, FF1852TOS-OS5
Hydraulic Hose Assembly, S8"HL-1AA4FR4 & 1AA4FRB4
Hydraulic Hose Assembly, 89"HL-1 AASFRBS (2)
Hydraulic Hose Assembly, 91"HL-1AASFRCS & 1AASFRBS
Hydraulic Fitting, FF1852TOS-105
Hydraulic Fitting, FF18S8T04-045
24S-4
Pressure Release
3057S3
Solenoid Valve
Hydraulic Fitting, FF18S8T04-0S5
Hydraulic Fitting, FF1852T04-0S5
Hydraulic Hose Assembly, 59"HL-1 AA4FR4 & 1AA4FRB4
C-205
Check Valve
5S01-4-45
Quick coupler
Hydraulic Fitting, CAT Tee
Plug, 900598
5S59-4
Dust Cap
754011
Charge Kit (Sold Separately)
Description
gty.
1
1
1
1
1
1
1
1
1
2
3
1
1
1
1
1
1
3
1
1
1
2
4
1
1
1
1
5
1
2
1
1
1
1
1
1
"Note: Hydraulic Hoses and Aeroquip fittings not available through Broce Mfg. Parts
Dept.- Source Locally
•
86
•
•
•
87
•
ENGINES AND RELATED PARTS
•
•
88
89
•
•
•
RC-350 ENGINE AND RELATED PARTS
Reference
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
Not Shown
Not Shown
Not Shown
Part No.
344034
344052
304097
305768
203159
203158
203156
CR-720-C
304104
304099
CR-723-B
203161
203184
203186
201385
344040
203123
JE-705-B
203157
JE-758-B
852077
CE-759-B
203105
AC-760-R
AC-760-B
AC-762-R
AC-763-R
DE-770-R
P182059
P119410
304059
304063
TT-771-R
850277
JR-724-G
P003951
AC-764-R
852075
P103113
P102980
CM-714-B
203164
203163
852080
304096
344121
203162
203187
344032
344029
344409
344411
344410
Description
Cummins Diesel Engine
Pump Drive (Complete)
Isolator Kit
Oil Cooler
Right Front Motor Mount
left Front Motor Mount
Right Rear Motor Mount
Radiator Assembly
lower Radiator Hose
Upper Radiator Hose
Radiator Cap
Radiator Saddle
lower Seal (Rubber)
left Side Oil Cooler Seal
Upper Seal (Rubber)
Tailpipe
Muffler Clamp
Muffler
left Rear Motor Mount
Head Pipe Clamp
Exhaust Pipe
Exhaust Gasket
Exhaust Heat Shield
Rubber Elbow (3" x 3")
Rubber Elbow (3 112" x 3")
Connecting Tube (long)
Connecting Tube (Short)
Air Cleaner (Dual Element)
Service Element
Safety Element
Enginair Precleaner
Sy-Klone Precleaner
Turbo II Precleaner
Oil Cooler Sleeve
Fan Guard
Clamp
Strap
Oil Cooler Mount
Cup
Air Cleaner Baffle
Engine Isolator Kit
:
Radiator Shroud
Upper Radiator Support
Bottom Radiator Support
Top Radiator Isolator
Bottom Radiator Isolator
Radiator to Motor Support
Right Side Oil Cooler Seal
Fan Spacer (Not Shown)
Cummins Fan (Not Shown)
Fan Belt
Oil Filter
Fuel Filter
90
Otv.
1
1
4
1
1
1
1
1
1
1
1
1
1
2
1
1
2
1
1
2
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
4
1
1
1
1
2
1
1
1
1
1
1
1
91
RCT-350 ENGINE AND RELATED PARTS
•
•
•
Reference
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
Not
Not
Not
Not
Not
Shown
Shown
Shown
Shown
Shown
Part No.
344059
303002
304097
305767
203300
203301
203302
JR-720-B
304103
304098
Call
203305
203188
203186
201389
344040
203123
JE-705-B
203303
JE-758-B
203308
344405
203105
304108
AC-760-B
203310
AC-763-R
DE-770-R
P182059
P119410
304059
304063
TT-771-R
852307
JR-724-G
P003951
AC-764-R
852076
P103113
P102980
CM-714-B
852136
203132
203304
304096
344121
203306
203187
304107
304106
203309
344035
344033
344407
344408
344406
Description
Cummins Diesel Engine
Pump Drive (Complete)
Isolator Kit
Oil Cooler
Left Front Motor Mount
Radiator Assembly
Lower Radiator Hose Coupling
Upper Radiator Hose
Radiator Cap
Radiator Saddle
Lower Seal (Rubber)
Left Side Oil Cooler Seal
Upper Seal (Rubber)
Tailpipe
Muffler Clamp
Muffler
Left Rear Motor Mount
Head Pipe Clamp
Exhaust Pipe
Exhaust Elbow
Exhaust Heat Shield
Rubber Elbow (3 1/2" x 3")
Connecting Tube (Long)
Connecting Tube (Short)
Service Element
Safety Element
Enginair Precleaner
Sy-Klone Precleaner
Turbo II Precleaner
Oil Cooler Sleeve
Fan Guard
Clamp
Strap
Oil Cooler Mount
Cup
Air Cleaner Baffle
Engine Isolator Kit
Radiator Shroud
Radiator to Motor Support
Bushing 2.5" to 2.25"
Elbow 3" to 2.5"
Lower Radiator Tube
Fan Spacer
Cummins Fan
Fan Belt
Oil Filter
Fuel Filter
92
Qty.
1
1
4
1
1
1
1
1
2
1
1
1
1
2
1
1
2
1
1
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
4
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
RJ-350 ENGINE AND RELATED PARTS
93
•
•
•
RJ-350 ENGINE AND RELATED PARTS
Reference
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
Not
Not
Not
Not
Not
Shown
Shown
Shown
Shown
Shown
Part No.
40450
N/A
344053
304097
305767
203128
203129
203125
JR-720-88
JR-722-88
JR-721-88
JR-723-8
203134
203184
203186
203185
344040
203123
JE-705-8
203126
JE-758-8
852078
JE-759-8
203105
AC-760-R
AC-760-8
304070
202152
DE-770-R
P182059
P119410
304059
304063
JR-724-G
P003951
AC-764-R
TT-771-R
P103113
P102980
CM-714-B
852136
203132
852079
304096
344121
203133
852076
852083
203187
311468
RE504836
RE62418
R123441
203276
Description
John Deere Diesel Engine
Drive Plate
Pump Drive, Complete
Isolator Kit
Oil Cooler
Radiator Assembly
Lower Radiator Hose
Upper Radiator Hose
Radiator Cap
Radiator Saddle
Lower Seal (Rubber)
Upper Seal (Rubber)
Tail Pipe
Muffler Clamp
Muffler
Head Pipe Clamp
Exhaust Pipe
Exhaust Gasket
Exhaust Heat Shield
Rubber Elbow (3.5" x 3")
Rubber Elbow (3" x 2.5")
Connecting Tube (6")
Service Element
Safety Element
Enginair Precleaner
Sy-Klone Precleaner
Fan Guard
Clamp
Strap
Turbo II Precleaner
Cup
Air Cleaner 8affle
Engine Isolator Kit
Radiator Shroud
Radiator to Mount Support
Oil Cooler Mount
Oil Cooler Sleeve
Right Side Oil Cooler Sleeve
John Deere Fan
Oil Filter
Fuel Filter
Belt
Air Pump Bracket
94
Qty.
1
1
1
4
1
1
1
1
1
1
1
1
1
1
2
1
1
2
1
1
2
1
1
1
1
1
1
2
1
1
1
1
1
1
1
2
1
1
1
4
.
1
1
1
1
1
1
1
1
1
1
1
1
1
95
•
•
•
KR-350 ENGINE AND RELATED PARTS
Reference
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
27a
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
Not
Not
Not
Not
Not
Not
Not
Not
Shown
Shown
Shown
Shown
Shown
Shown
Shown
Shown
Part No.
344064
N/A
303007
304097
305767
203330
203331
203335
JR~720-BB
CR-721-B
304099
JR-723-B
203333
203184
203186
203185
344040
203123
JE~705~B
203336
JE~758~B
852337
16299~1236~0
203105
304106
AC~760-B
304109
304111
203345
DE-770-R
P182059
P119410
304059
304063
JR~724-G
P003951
AC~764-R
TT~771~R
P103113
P102980
CM~714~B
852136
203132
203332
304096
344121
203334
852076
852340
203187
344025
203342
344550
16631-43560
304015
203346
203347
203348
Description
Kubota Diesel Engine
Drive Plate
Pump Drive, Complete
Isolator Kit
Oil Cooler
left Front Motor Mount
Radiator Assembly
lower Radiator Hose
Upper Radiator Hose
Radiator Cap
Radiator Saddle
lower Seal (Rubber)
left Side Oil Cooler Seal
Upper Seal (Rubber)
Tail Pipe
Muffler Clamp
Muffler
left Rear Motor Mount
Head Pipe Clamp
Exhaust Pipe
Exhaust Gasket
Exhaust Heat Shield
Rubber Elbow (3" x 2.5")
Reducer (2" x 1.75")
Connecting Tube
Service Element
Safety Element
Enginair Precleaner
!
Sy-Klone Precleaner
Fan Guard
Clamp
Strap
Turbo II Precleaner
Cup
Air Cleaner Baffle
Engine Isolator Kit
Radiator Shroud
Radiator to Mount Support
Oil-Cooler Mount
Oil Cooler Sleeve
Right Side Oil Cooler Sleeve
Kubota Fan
Fan Spacer
Oil Filter
Fuel Filter
Alternator/Engine Belt
Alternator Support Bracket
Alternator Adjustment Bracket
Alternator Bushing
96
Otv.
1
1
1
4
1
1
1
1
1
1
1
1
1
1
2
1
1
2
1
1
2
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
2
1
1
1
4
.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
~
~
lie
f~22/
..
:~VQ¥~
-/"'\rc::
.
¥~
-
~
~
0~
97
C:.J ~~~~6
I
4
</'
(1/
3054C ENGINE AND RELATED PARTS
•
ITEM
PART NUMBER
1
344062
CAT 3054C Diesel Engine
1
2
852045
305767
Oil Cooler Hose Guide Sleeve
1
1
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
•
203600
203601
852043
344508
Radiator Assembly
Lower Radiator Hose
Upper Radiator Hose
Oil Cooler Mount
203188
Lower Seal (Rubber)
203186
203189
344040
Upper Seal (Rubber)
203123
JE-705-B
JE-758-B
22
23
24
25
203105
AC-760-R
AC-760-B
33
34
304095
P003951
AC-764-R
TT-771-R
38
39
NS
NS
NS
Pipe
Gasket
Heat Shield
Elbow, 3" x 3"
Rubber Elbow, 3.5" x 3"
Connecting Tube, Long
PC-765-R
PC-711-R
P103113
P102980
344509
101-3770
5M8155
304196
1
1
1
1
1
1
1
2
1
1
1
2
202153
31
32
35
36
37
Muffler
Head Pipe Clamp
Heater Hose
Connecting Tube, Short
DE-770-R
P182059
P119410
PC-710-B
1
1
2
1
304195
202152
28
29
30
1
1
1
Tail Pipe
Muffler Clamp
Exhaust
Exhaust
Exhaust
Rubber
QUANTITY
1
344511
344510
853606
203187
853605
344031
26a
27
Oil Cooler
852042
20
21
26
DESCRIPTION
Service Element
Safety Element
Precleaner, 4"
1
1
1
1
1
1
1
1
1
Precleaner, Top
Precleaner Bowl
Engine Isolator Kit
Strap
Turbo II Precleaner
1
4
1
2
1
Cup
Air Cleaner Baffle
1
1
Radiator Cap
1
1
1
Clamp
CAT Fan
Fan Belt
Compressor
Belt, AlC Only
•
98
1
•
•
99
•
•
•
•
100
PREVENTIVE MAINTENANCE
BROOM SPECIFICATIONS
WIRING DIAGRAMS
•
•
•
IOl
•
•
•
102
Preventative Maintenance
A well maintained NC system would save on downtime and premature
component failures.
Weekly inspections or every 2 days in severe environments should include:
•
1.
2.
3.
4.
5.
Inspect compressor clutch drive belts (tightness, wear).
Inspect compressor-mounting brackets (bolts, alignment).
Inspect mounting hardware on evaporator unit and condensers.
Inspect air intake filter. Clean or replace filter.
Inspect evaporator and condenser coils. Clean using air pressure.
(DO NOT USE WATER OR PRESSURE WASHERS).
6. Inspect hose and wire harness for proper routing. Leaks and wear.
Helpful Hints
Make sure the evaporator air intake area is not obstructed (i.e. toolboxes,
clothing, lunch box, etc.)
Manual thermostats on our systems, when rotated clockwise to the stop
position will not allow the NC compressor clutch to cycle. The compressor
will run continuously and the evaporator coil will not defrost. REMEDY: Turn
the manual thermostat knob clockwise to the stop position, and then turn the
thermostat knob back counter clockwise % turn.
•
Broce thanks you for purchasing our units. It is our endeavor to provide you
with a quality NC unit with trouble free service.
103
•
HYDRAULIC COMPONENT SPECIFICATIONS
•
Propel Pump
Displacement at MAX Angle:
Rated Speed:
MAX Speed:
MIN Speed:
Case Pressure - Continuous:
Case Pressure - MAX:
System Pressure - Continuous:
System Pressure - MAX:
Inlet Vacuum - Continuous:
Inlet Vacuum - MAX:
Hg)
Charge Pressure Setting:
System Pressure Setting:
Approximate Flow at 2400 RPM
46 cc (2.8 CU IN)
4000 RPM
4100 RPM
500 RPM
1.7 BAR (25 PSI)
5.2 BAR (75 PSI)
210 BAR (3000 PSI)
345 BAR (5000 PSI)
.8 BAR Absolute (5 IN Hg)
.7 BAR Absolute (10 IN
19.5 BAR (283 PSI)
280 BAR (4060 PSI)
26GPM
Propel Motor
•
Displacement
Rated Speed:
MAX Speed:
Case Pressure Case Pressure System Pressure
System Pressure
46 cc (2.8 CU IN)
3600 RPM
3600 RPM
1.7 BAR (25 PSI)
5.2 BAR (75 PSI)
210 BAR (3000 PSI)
345 BAR (5000 PSI)
Continuous
MAX:
- Continuous:
- MAX:
Auxiliary Pump
38 cc (2.32 CU IN)
2500 RPM
3000 PSI
Displacement
MAX Speed:
MAX Continuous Pressure:
Approximate Flow at 2400 RPM
Priority (Steering and Broom)
Secondary (Broom Rotation)
MAX Pressure Setting (Priority):
MAX Pressure Setting * (Secondary)
3GPM
18 GPM
1600 PSI
3000 PSI
*Relief Valve in the Broom Rotation Valve
•
104
FLUID CAPACITIES
Fluid
Hydraulic Tank
DYNA-PlEX
21C CURSA HYDRAULIC OIL
27 Gal.
Must meet Caterpillar spec. T02 or Allison C3
Fuel
Radiator
Engine Crankcase
#2 DIESEL
27 Gal.
ETHYLENE GLYCOL 50/50 MIX
2.5 Gal
API Classification CE or CD
10 Qts
CCMC Specification
Rear Axle
2-Speed G-Box
• 2 Quarts is approximate.
D4 or D5
EP-90 GEAR LUBE
2 Qts·
EP-90 GEAR lUBE
2 Qts*
Fill to the level of the filler plug.
105
•
Broce Brooms
•
DYNA-PLEX 21C CURSA HYDRAULIC OIL
Dyna-Plex 21 C Cursa Hydraulic Oils are high quality; extra-inhibited oils
designed with hydrocrack Group II base oils, for use in multi-functional
applications where long oil life is required. These oils will give you steady,
reliable performance as a hydraulic medium.
Dyna-Plex 21 C Cursa Hydraulic Oils have been finely filtered to remove external
contamination and contain special O-Ring conditioners to prolong hydraulic
component life. Seal swell agents have been added to prevent leaks and
Cursa's demulsability characteristics enhance separation and removal of water.
These oils will supply 5000 hours of service before extreme oxidation problems
occur and also provide excellent resistance to foaming, rust and wear.
ASTM TEST
METHOD
MULTIFUNCTION
Viscosity @ 40oC,CST
Viscosity @ 100°C, CST
Viscosity Index
0445
0445
02270
46.00
9.75
200
Flash Point, COC, °C
Flash Point, COC, OF
Pour Point, °C (OF)
Color
GravitY,oAPI
092
092
097
01500
0287
200
392
-36 (-33)
Orange
32.0
Turbine Oil Oxidation
Copper Strip
Rust Test
Vane Pump, Mgs. Wt. Loss
Usable Temperature Range, OF
Maximum Hydra. Temperature, OF
Oielectric Strength, kv
RBOT, Minutes
Oemulsibility
0943
0130
0665
02882
5000+
LB
Pass
12
-10-110
205
35
950
40-40-0 (5)
PROPERTY
•
02272
01401
Meets or exceeds the following tests and requirements:
•
AFNOR E 48-603
B.F. Goodrich - 0152
Cincinnati Milacron - P-68 (light hydraulic oils), P-69, P-70
Oenison - HF-O, HF-1, HF-2
OIN - 51524, Part 2
FMC - High-Performance Hydraulic Oil
Ford - M-6C32
General Motors - LH-04-1, LH-06-1, LH-15-1
Jeffrey - #87
Lee Norse 100-1
Racine - Model S, variable volume vane pump
U.S. Steel-136,
127
Vickers - 1-286-S, M-2950-S, 35VQ25
HO-11/4-14-00
106
DYNA-PLEX 21 C EXTENDED DRAIN ANTI-FREEZE/ENGINE
COOLANT
Dyna-Plex 21 C Extended Drain Anti-Freeze/Engine Coolant is a premium quality
ethylene glycol based product. It is pre-diluted to a 50/50 mixture with de-ionized
water to provide excellent corrosion control and a deduction of scale buildup.
The corrosion inhibitor package eliminates the need for an initial charge of
supplemental coolant additive (SCA). The 50/50 dilution with de-ionized water
insures high water quality and eliminates the chance for error when mixing antifreeze with water in the field.
•
Dyna-Plex 21C Extended Drain Anti-Freeze gives the maximum protection and
performance available for heavy-duty diesel applications, while eliminating
potential water related problems. Advantages of this product include the highest
quality inhibitor package available and its ready to use convenience.
Universal recommends good maintenance practices to monitor inhibitor levels on
a regular basis by utilizing coolant analysis, which is an important aspect of
extending the life of this coolant/anti-freeze. This product meets or exceeds
manufacturer specifications for use in both heavy-duty diesel and automotive
applications.
Physical and
Chemical Properties
ASTM
Test Method
Specific Gravity @ 60°F
pH 50% Oilution
Reserve Alkalinity
Boiling Point
Flash Point
Freeze Point
Color
Foaming - Foam Volume, ml
Break Time, sec.
Composition (% by weight)
Total Glycols
Total Oe-ionized Water
Inhibitors and Oye
0-1122
0-1287
0-1121
0-1120
0-92
0-1177
0-1881
0-1881
Test
Specifications
1.110 - 1.145
10.0 - 10.4
5.0 ml min.
320°F min,
240°F min.
-34°F max.
OEM Standard Green
50 max.
5 max.
•
45.0% min.
53.0% max.
2.0% min.
Dyna-Plex 21 C Extended Drain Anti-Freeze/Engine
the following specifications:
Coolant meets or exceeds
American Society for Testing and Materials (ASTM)- 0-33-6; 0-4985; 0-4656
General Motors - GM 1899M; GM 1825M
Society for Automotive Engineers - SAE J 1941, J 1034
Cummins - 85T8-2; 90T8-4; Bulletin #3666132
Ford Motor Corporation - ESE M97B44A; ESE-M97B18-C
Chrysler Motors - MS7170
Detroit Diesel 7SE298
John Deere H24A2; H24C2
ATA Maintenance Council- RP-329
AF-1/9-12-01
107
•
NOTES:
_
•
•
•
108
•
•
•
•
Broce Broom Wiring Diagram
4W Canopy Broom Control Panel- JD
(RB>
8 GA.)
~1='==I~-t---oR04
87
75A Relay
2M
Tenninal
Strip
(RED 4
•
Solenoid
GA.)
o 0~
_ 3CA
(YELLOW1S
GA.)
•
I
To:SIarter
~~
To:Fue!
Pump
Solenoid
To: AI!emaIcr
end BaIIEfy
PLUG: To: Neutral
Safety Switm
To: Fuel Gauge
To: Fuel TIIIIk
(ORANGE 16
G......
)
To:SIart!!t
SolenoId
-
(ORAHGE_16_GA.I. __ .
.,_-Uo.._",_"......,_.,s...."..W-
To: water Temp EJemeot
--~--
To: Oil Pressure EJemenl
To: Altemalllr
To: AIIeme!or
•
------
ON
...... _....""""
(T1Idl. --~--.
+--'-"
terminal)
To: Oil Pressure SwiII:tl
To: Backup Alarm
...._-----To:
<-=..._
~(LLBLUE..t6·GA.)
t__j____L___j
To: Ignition SwiII:tl
To: Ignition SwiIdl
To: Temp GaJge
To: OU Gauge
To: Ignition SwiIx:h
Tach. Gauge
To: IgnIIlon
$WCIdl
TO: Hoof MeIer
(REO 16GA.
To: Backup
Alarm PlUG
•
..;
: .' ~ :
.
.
-'
.
•
•
Broce Broom Wiring Diagram
Dash Wiring Diagram
•
8-02-2002
To: Air-Heat
To: l00A
.--
las
harness
To:
Water
~::::......::....:::.::J._
Pump
Motor
Bre<)ker (AUX)
To: Dash
To: 75A Relay R4
-l
L--~----------------------------Fuse
('87)
To:Dash
Fuse
To:Dosh
Fuse
Block
Block
Block
r----------------
To:
Ughts
Water
Pump
Switch
To:
Brake
Switch
To:
Motor
To: Dash ,-~f----ts:l
Fuse
Block
To: Wiper
Uatar
To: Wiper
Wash Uotar
•
Ta:Dash
Fuse
Block
_......l="::':':"""":'-=--=4-
__
___J
Ignition
Switch
L---------------To:
Coil
To: 20A Terminal Strip (ll)
To: 30A Terminal Strip (17)
To: Harness
•
To: Harness
To: Harness
To: Harness
To: Oil Pressure Switch
To: Backup Alarm
PLUG: To: BaCkUpl
Alarm Switch
t=Jr---lC,IlRf""-"!O-Ll16"-'GA.
......_jJb.l
....
uLlie_t
....
erm.u.uw.i0",0 .....
1...Lh
....
o"'-us
...iuog~~
To:Dash
Fuse
Block
L.
-~-
•
•
•
Broce
U~ht Plu9
Left Reer
Broom
Diagram
Light Wiring Diagram
Dash Fuse Block
Ught Plu9
Right Reer
(yl0l£T
To: Core
To: RlQht Front Tum Slanol
~~n~ft
Wiring
Front Tum
ILl,
""W!
W(ISt.UAPII<!!!:~?
vc.u.uJO .. /. ....... ,::~:~
.'~
111 G4.
To: N/e
Swltcl'l
'!:"! •
I II
+ \...."
~!-.
I II
• .~~
J9
Valve
I Turn
..... ,
.~9, ':":'
. _
__
.•
Ught Switch
-:.-
Signal
I H 0 u sin
g
Hom ...
(Yru.OW 111 GA.)
Brake Uoht
Switch
To: Stereo
li:2!IIDl~
I
To: Boacon
Switch
~15LAOI lU GA.)
To: Hom
10.........
J9
..... ,
l£ik:llcflk:!j-(GRED!
11J1:I::]1~
To: Broom
Lock
SolencMd
0011'1 FUM Pane!
To: 0081'1
Ught.
(lUCK 1eGo\.)
To: Sock Up
Alarm Pluo
16 GA.l
To: Wota~
Pump SWltoh
To: Cobin Heeter
C«roat Switch
ac
(8LAC1< 16 GA.)
•
•
•
I
•
I
I
•
I
•
BROCE BROOM 350 SERIES
OPERATION & MAINTENANCE MANUAL
SELF·PROPELLED HIGHWAY SWEEPER
•
•
Broce Manufacturing
Co./1460
South Second Ave. I Dodge City, KS 678011 Phone: 620-227-8811
OPERATOR QUALIFICATIONS
Operation of this equipment shall be limited to competent and experienced persons. Inaddition, anyone who
will operate or work around this equipment must use good common sense. In order to be qualified, he or she
must also know and meet all other requirements, such as:
•
1. Some regulations specify that no one under the age of 16 may operate power machinery. It is
your responsibility to know what these regulations are in your area or situation.
2. Current OSHA regulations state in part: "At the time of initial assignment and at least annually
thereafter the employer shall instruct EVERY employee in the safe operation of servicing of all
equipment with which the employee is or will be involved."
3. Unqualified persons are to STAY OUT ofthe work area.
4. A person who has not read and understood all operating and safety instructions is not qualified
to operate the machinery.
FAILURE TO READ THIS MANUAL AND ITS SAFETY INSTRUCTIONS
IS A MISUSE OF THE EQUIPMENT.
SIGN OFF SHEET
As a requirement of OSHA, it is necessary for the employer to train the employee in the safe operation and
safety procedures with this equipment. We include this sign off sheet for your convenience and personal
recordkeeping.
Date
Employer's signature
Employee's signature
•
•
•
BE A SAFE OPERATOR
BY THINKING-BEFORE ACTING
AND
BY READING YOUR OPERATORS MANUAL
understand these warnings, do not operate this machine!
••••••••••••••••••••••••••••••
& AVOID ACCIDENTS &
Most accidents, whether they occur in industry, on
the farm, at home or on the highway, are caused by
the failure of some individual to follow simple and fundamental safety rules or precautions. For this reason
most accidents can be prevented by recognizing the
real cause and doing something about it before the
accident occurs.
Regardless of the care used in the design and construction of any type of equipment, there are many
conditions that cannot be completely safe guarded
against without interfering with reasonable accessibility and efficient operation.
•
!Read and understand the following warning labels before operating this machine! If you do not
A careful operator is the best insurance against an accident.
OPERATOR MUST BE SEATED
WITH SAFETY BELT PROPERLY
ADJUSTED & SECURE WHEN
ENGINE IS RUNNING
The seat belt and roll over protection structure were
designed to be used together to prevent operator injury in the event of an accident. The scat belt must be
worn at all times in order to hold the operator in place
so that the roll bar can protect the operator. Adjust
the slack out of the seat belt by pulling the unused
portion of the belt to the left. The belt should fit snug
over the operators hips.
••••••••••••••••••••••••••••••
DO NOT START ENGINE WITH
CONTROL PEDAL DEPRESSED
•••••••••••••••••••••••••••••
!!!BECAREFUL!!!
I.
KEEP ALL SHIELDS IN PLACE
2.
STOP MACHINE TO REPAIR OR CLEAN
3.
KEEP HANDS, FEET AND CLOTHING
POWER DRIVEN PARTS.
4.
KEEP OFF OF MACHINERY UNLESS A PLATFORM IS
PROVIDED. DO NOT CRAWL ON EQUIPMENT.
5.
WHEN EQUIPMENT BECOMES DISABLED, SHUT OFF
POWER BEFORE ATTEMPTING REPAIRS
AWAY FROM
The pedal beside the operator's right foot is not a
throttle. If this pedal is depressed while starting the
engine, the machine could move forward or backward
before the operator is ready. This could cause injury
to bystanders and/or damage to property.
• •••••••••••••••••••••••••••••
ROAD SPEED MUST BE GOVERNED
BYGOODJUDGEMEN~DONOT
6.
CHECK FOR HYDRUALIC LEAKS WITH A PIECE OF
PAPER AND NOT YOUR HANDS, HYDRAULIC OIL UNDER
PRESSURE CAN CAUSE SERIOUS INJURY!
•••••••••••••••••••••••••••••
&
•
BEFOREOPERATlNGTIDSMACHINE
&
Read this manual completely. It contains information
on safety and maintenance procedures which must be
followed to insure years of trouble free service.
OVERSPEED
These sweepers do not have an automotive type suspension. Due to the rigid suspension on this machine,
it will be affected by every bump or pot hole it runs
over. Although a high travel speed is available with the
Broce Broom, we caution all operators to use good
judgement while roading this machine, especially on
rough roads.
Start up and propelline
Caution: operator must be seated with seat belt
properly secured while engine is running.
IMPORTAi"lT
Familiarize yourself with the following controls
before operating this machine.
1.
Brake pedal
2.
Directional control pedal
3.
Hydraulic control levers
4.
Locking throttle
5.
Parking brake
6.
Ingnition switch
7.
Two speed shifter
•
•
The Broce Broom is hydrostatically driven. The directional control is achieved through the use of a control pedal, located near the operator's foot. Toe down
on the pedal directs the machine forward. Heel down
shifts the travel to reverse. Rate of travel is governed
by the distance the pedal is depressed. The pedal will
return to neutral when the pressure is released.
CAUTION
ThrotUe
1. Before starting the engine, be sure the parking
brake is set (pull handle up to vertical position),
the brake pedal should be depressed and the right
foot is not on the control pedal.
2. Tum the key switch to the start position, (all the
way to the right). Add fuel as necessary using the
hand operated locking throttle near the operator's
right hand. Release the key switch when the engine starts.
3. Choose the desired gear using the two-speed shifter
located on the right hand side of the dash
•
•
board. Low gear is normally used while sweeping
I WARNING I
in order to maintain sufficient engine RPM. to run
the hydraulics. Leave the two speed in first gear
DO NOT OPERATE
until the operator is familiar with the machine. High
CORE UNLESS CHAIN
gear is used during light sweeping and while
GUARD ISINSTALLED
roading the machine.
~
4. After gear selection, raise engine RPM. to about On chain drive cores, the chain guard must be installed
half throttle. Release parking brake. Slowly de- and be in serviceable condition at all times when the
press control pedal in the desired direction. En- broom is operating. This guard is designed to prevent
gine speed may be adjusted to obtain desired travel personal injury and to protect the chain from foreign
speed.
debris.
5. Do not propel this machine with the parking brake
RAISE I LOWER I FLOAT DETENT
engaged. This will damage the rear brake assemTo
raise
the core, move the handle to the "RAISE" poblies and void the warranty. This type of operasition until the core is raised all the way. The handle
tion is considered abuse.
will
return to the hold position and core height will be
6. Do not overspeed! Although a high travel speed is
maintained.
To lower the core during normal sweepavailable with the Broce Broom, we caution all
operators to use good judgement while roading ing conditions, move the handle to the "FLOAT DETEl't'T"
position. The "FLOAT" position will allow the core to
the machine, especially on rough roads.
7. If the control pedal is released while traveling, the maintain the ideal contact with the road while allowing
it to float over bumps or contours in the road surface.
machine will slow down rapidly. This is called "dyThis valve is equipped with a feature called "POSITIVE
namic braking'. Using dynamic braking at low
DOWN PRESSURE". It should only be used under the
speeds is fine as long as the operator is ready to
heaviest sweeping conditions. The down pressure aduse the brake pedal (ref: 1) ifneeded. At higher
justment is located between the hold position and the
speeds, however, the operator must use the brake float detent. To adjust the core height downward,
pedal in conjunction with the hand throttle and slowly move the handle from the hold position toward
control pedal in order to minimize strain on the the float position. The core will begin to move downdrive train. This will prolong the life of the entire ward. Release the handle when the desired height has
drivetrain.
been achieved.
8. Do not reverse the direction of travel while the
broom is in motion. This will damage the drive
!! IMPORTANT !!
train and void the warranty. This type of operation Operator must maintain continuous adjustment on core
is considered to be abuse.
while the down pressure option is being used. This
feature does not allow the core to float over contours
To stop the engine, turn the key back to the center in the road surface. Therefore the operator must conposition. The parking brake must be set prior to leav- stantly make these adjustments. If the broom core is
forced too close to the ground, the bristles will not
ing the operator's scat.
have the "flicking" action which is necessary to do a
proper
sweepingjob. This is why we recommend usOPERATION OFTHE SWEEPING CORE
ing the float detent during all but the heaviest sweeping
conditions.
All functions ofthe sweeping core are hydraulically
r
------
•
ill
•
operated. A three spool control valve is mounted to
the right ofthe operator. All functions are controlled
from this point. The front spool controls the operation
of the core motor. The rear spool controls the core
height and the center spool controls the angle ofthc
core.
&
CAUTION
Overuse of the positive down pressure feature will
cause excessive wear and shorten the life ofthe broom ..
RIGHT I LEFT OPERATION OF BROOM
The core may be set at any angle from 45° left to 45°
right, simply by moving the handle in the corresponding direction. Release the handle when the desired angle
is achieved.
UNDER NO CIRCUMSTANCES
PASSENGERS BE ALLOWED
ON THIS
THERE
BROOM ON I BROOM OFF
The core motor is activated when the handle is moved
to the "BROOM ON" position.
Note: engine speed must be maintained at a minimum
of 1500 RPM for sweeping operations. Under average sweeping conditions, a higher engine speed will
probably be advantageous.
SWEEPING TIPS:
If the broom starts to "hop" or "bounce", the propelling speed is too high, slow the machine down, but
maintain high engine speed. Slowing the forward speed
of the machine down, will prevent you from having to
make a second pass with the broom.
I n
areas where the dirt is "caked", try to clean it by going
over it a second or third time. If this does not clear the
dirt, use the "POSITIVE DOWN PRESSURE"
feature. In most cases, the float position will yield the
best results. When changing the direction of travel,
allow the machine to come to a complete stop before
moving the directional control pedal. Failure to completely stop the machine before changing direction can
cause premature failure of the drive components. If
the dust cloud becomes so thick that it obscures your
vision of the road, use the water sprinkling system (if
installed), or stop the machine until the dust clears. If
possible, angle the sweeper so that the dust and debris is swept downwind.
When operating a broom without an enclosed
cab, wear hearing and eye protection as well as a dust
mask that covers both the mouth and nose.
CAUTION
The operator must be aware at all times of any people,
vehicles, or any other objects which might be in the
path of flying debris from the sweeper. The sweeper
can throw small rocks and other objeets several feet.
This debris can cause serious injury to people and
damage to property. Always check that the area
around, and in front of the broom core are free of
obstructions before adjusting the broom angle or activating the core.
lULURE
SHOULD
TO RIDE
•
MACHINE.
ARE NO SAFIIrrY PROVISIONS
ON THIS
MACHINE
FOR PASSENGERS.
TO HEED THIS WARNINC
COULD RESULT
SERIOUS IN.lURY OR DEATHI
IN
MAINTENANCE
The manufacture has endeavored to build the Broce
Broom as maintenance free as possible. The service
points are easily accessible and are similar to those on
many other types of construction equipment. This section will cover many of these points in some detail and
will briefly mention those which should be standard on
all equipment.
AIR CLEANER:
The air cleaner is one of the most important components of this machine. Due to the extremely dusty conditions in which this machine operates, the aircleaner
must be maintained constantly. This machine is
equipped with a dry type air cleaner, bowl type precleaner, and a restriction type service indicator as standard equipment.
An optional dual element air cleaner and/or a
vane type pre-cleaner is also available.
Under average conditions, the air cleaner will
need to be serviced every three to
four hours. When the clear ring on
the service indicator turns red, the
air cleaner must be serviced immediately. The following procedures
must be followed to insure long engine life.
To service: remove and empty the pre-cleaner bowl.
This should be done every time the level of the dirt
reaches the service line
marked on the bowl itself.
Loosen the clamp which
secures the end cover.
Remove the end cover
and the wing nut that secures the filter element.
•
•
•
•
•
Carefully slide the element out of the canister. If the HYDRAULIC SYSTEM:
machine is equipped with a dual element air cleaner, The hydraulic system on this machine operates the
do not remove the safety element until you are ready hydrostatic drive, power steering, and all core functo replace it! Do not attempt to clean the safety ele- tions. It incorporates two supply pumps sharing the
ment. It is strictly a disposable type clement. Clean same reservoir. In order to simplify the description of
this system, it will be separated into three different parts.
the dirt from the inside of the canister and the end
cover. Hold the element so that the opening is on top,
Hydrostatic drive:
with your other hand, gently pat the side of the ele- This system utilizes a Eaton variable displacement
ment to loosen the dirt. Do not tap the clement against pump and fixed displacement motor. Oil, supplied from
a hard surface as this can cause damage to the ele- the reservoir, passes through a 10 micron filter before
ment itself Air pressure may be used to clean dirt from entering the pump. High pressure oil is supplied to the
the element, but the air-pressure must be reduced to motor through high pressure hoses. A hot oil shuttle
less than 30 PSI. Using an air nozzle, clean the ele- has been installed between the pump and motor to
ment from the inside, moving the nozzle up and down insure that a specific amount of oil is removed from
in the direction of the pleats. Do not direct the air- the high pressure loop so that it may be replaced by
stream against the outside surface of the element, as it cooler oil. The hot oil removed from the loop by the
will force the dirt through the element fabric, resulting shuttle is routed back to the pump where it will join
the unused oil in the case drain. The case drain from
in damage.
the motor is routed to join this return flow. All oil returning to the reservoir is passed through a heat exCAUTION
changer. The following specifications are for testing
When using compressed air, clear the area of bystandand informational purposes only. If a problem develers, guard against flying chips, and wear personal proops with the pump or motor, we strongly advise that it
tection equipment including eye protection.
be taken to an authorized Eaton repair center or reThe element may be cleaned by the following proce- turned to Broce Mfg., for exchange of new or rebuilt
dure:
components or repair authorization.
If element is coated with oil or soot, wash in a solution
of warm water and filter element cleaner (equal to Displacement:
2.8 cubic inches
R36571 Filter Element Cleaner). Let clement soak at Volume: Approximately 34 GPM @ 2500 RPM
least 15 minutes, then agitate gently to flush out dirt. Maximum pressure:
5000 PSI.
Rinse element thoroughly from the inside with clean Continuous pressure:
3000 PSI.
water. Usc an clement cleaning gun or a free running Maximum case pressure:
75 PSI.
hose. Keep the pressure under 40 PSI to avoid dam- Continuous case pressure:
50 PSI.
age to the element. Allow the element to dry com- Charge pressure:
220-240 PSI.
pletely before using. This usually takes from one to Maximum RPM:
5000 RPM
three days. Do not oven dry or use drying agents. Pro- Continuous RPM:
4000 RPM
tect element from freezing until dry. The element must Reliefsetting: two (2) relief's set @ 4000 PSI.
be inspected before it is reinstalled. Hold a bright light
CAUTION
inside the element and check carefully for holes. Discard any element that shows the slightest hole. Be sure When itbecomesnecessary to addorchangeoilin this system,
that the outer screen is not dented. Vibration will quickly extracaremustbe takentoprotectthe fluid from contaminawear a hole in the filter. Make sure the filter gasket is tion. Take every precaution when changing a filter or a
hose. For example: clean the area of the machine where
in good condition. If gasket is damaged or missing,
the
replacement will take place. Never leave a port
replace the element. Seal the element in a plastic bag
and store in a shipping container to protect against uncovered on the pump or motor where dirt can enter
the system. The slightest contamination can cause the
dust and damage.
pump and / or motor to fail.
Power steering:
A single hydraulic pump supplies oil for both the power
steering and the core functions. This pump has a built
in flow divider which supplies 4 GPM for the power
steering system. Priority in the flow divider is given to
the steering. Oil is supplied to an orbital type steering
unit. The steering unit supplies oil to either side of the
two-way steering cylinder as directed by the operator. Return oil is passed through a 10 micron f Iter before entering the reservoir. Pressure relief is set at 2,030
PSI in the hydraulic pump.
Core functions:
Hydraulic oil is supplied by the same pump that
supplies oil for the power steering. Oil is supplied at
the rate of 12-18 GPM, depending on engine speed.
This oil is routed directly to a three spool, parallel
circuit control valve. The first spool controls the core
motor. The second spool controls the shift cylinder.
The third spool controls the liftcylinder. The open center
passage in the valve is closed off when a spool is fully
shilled. Hydraulic oil will flow directly to the power
core passage, making oil available to all work ports.
If two or more spools are fully shifted at the same
time, the oil will flow to the path ofleast resistance,
and the hydraulic cylinder or motor with the lightest
load will begin to function first. This valve is equipped
with an adjustable 3000 PSI reliefvalve for the brush
function only. The brush lift and rotation functions have
seperate, non-adjustable, 1,000 PSI reliefvalves incorporated into each valve spool.
These relief setting govern all hydraulic oil pressure
used to operate core functions. Restrictor fittings are
used in the hydraulic lines attached to the lift and shill
cylinders in order to meter the flow thus controlling
the speed of expansions and contraction.
Two different types of core motors are used on these
machines, depending on the type of core drive utilized. The chain drive core uses a Ross Torqmotor
with a one inch keyed shaft for sprocket installation.
The direct drive system uses a Char-Lynn motor with
a splined shaft which couples to a hub mounted inside
the core frame. On standard applications, the oil is
routed from the valve to the core motor and returned
to the reservoir through a 10micron filter. This routing
allows for single direction core operation only. This is
done to main-
tain core balance on the pivot type core suspension
used on this machine. This is the most efficient manner
in which to obtain the superior cleaning capabilities of
this machine.
The following specifications relate to the hydraulic
pump used on the power steering and core functions.
These figures may be of service if trouble shooting
becomes necessary.
•
Displacement:
2.4 cubic inch
Volume: Approximately 22 GPM @ 2500 RPM
Maximum RPM:
3000 RPM
Reliefsetting:
2030 PSI
Priority controlled flow:
4 GPM
Hydraulic maintenance:
Replace the disposable filter elements after the first
50 hours of service, and every 500 hours thereafter.
Always maintain sufficient hydraulic oil in the reservoir
as indicated in the level sight glass on the left side on
the hydraulic tank. When it becomes necessary to add
or replace oil in the system, use an oil comparable to
Mobilfluid 423, which is in the machine at the time of
delivery.
Periodically check all hydraulic hoses. If any hose
feels "spongy" or shows signs of wear or chafing it
must be replaced. As a general guide, if you are unsure of the condition ofa hose for any reason, it should
be replaced before the machine is sent out on a job.
This will minimize downtime and expense associated
with this type offailure. Again, cleanliness must be
stressed during this type of maintenance. Contamination of this system will cause pump and / or motor
failure. Avoid servicing hydraulic system in the field
where a clean environment cannot be controlled.
Due to the dusty conditions in which this machine
operates, the heat exchanger and radiator must be
cleaned every 4 to 8 hours of service, depending on
sweeping conditions. If either one becomes clogged
with dirt, it will overload the cooling capacity of the
other, causing both the engine and hydraulic system to
operate at higher than acceptable temperatures. Use
water or compressed air directed from the engine side
of the radiator to remove dirt build up. The engine
must be completely stopped while performing this
maintenance. Inspect radiator and heat exchanger for
dirt deposits and / or damage before resuming operation.
•
•
•
CAUTION
Do not attempt to clean radiator or heat exchanger
while engine is running. Ifhands or equipment come in
contact with spinning fan blades, serious injury will
result. Engine must be completely stopped.
Both the front suspension and drive shaft should be
serviced every time the engine is serviced, this is the
minimum service interval. A more frequent servicing of
these components will extend their service life.
Two-speed gear box
Lubrication:
Bolster assembly
Lubrication of this machine is much the same as an
automobile. There are five lubrication points located
on the front suspension. Use a standard automotive
type grease on each of these. While servicing these
points, inspect all ball joints and rod ends for slack. If
slack is found in any part of this suspension, including
bolster pivot bushings, replace all worn parts.
•
Check the fluid level in the two-speed gearbox every
25 hours or sooner if signs ofleakage appears. Change
the lubricating oil after the first 25 hours and then every 100 hours thereafter. Drain the oil while the unit is
warm. Replace with SAE 80W-140W gear oil, up to
the oil level plug.
Oil Light Bushings
Steering cylinder
Lube upper and lower mount and steering shaft tie
rod end.
•
There are three lubrication points on the drive shaft.
These also require standard automotive type grease.
While servicing drive shaft, check for loose fasteners
and slack in the U-joint.
Service the axle in the same manner as the two-speed
transmission. The axle bearings do not receive lubrication from the gear oil. Periodically remove the axle
shafts and repack the bearings.
There is no cause for alarm if either of these
components is leaking oil through their breathers after
they have been serviced. The breather allows overflow if the unit was overfilled. This leakage will stop
when the proper level is achieved. With proper maintenance and operation, these components will last the
entire life of the machine.
Brakes:
This machine is equipped with four-wheel hydraulic
brakes and a mechanical parking brake. The operation of the brakes should be tested daily. Everyday,
before this machine is to be operated, check the brake
pedal "feel", much the same way as on an automobile.
The pedal should be firm when depressed. If the pedal
feels "spongy", it probably means that there is air in
one or more brake lines. If the brake pedal goes all
the way to the mechanical stop, there is either a leaking line, low fluid in the reservoir, or the brake shoes
are worn out. If the brake pedal does not feel firm, the
brakes must be serviced prior to operating this machine.
The master cylinder is located directly in
front of the brake pedal.
Remove the side dashboard cover to gain access for servicing it. Check
the fluid level periodically,
especially ifthe brake lines
show signs ofleakage. If
it becomes necessary to add or change the brake fluid,
us a fluid with a DOT 3 rating.
Inspect brake lines every 50 hours (minimum)
for leaks and / or damage. Replace front and rear brake
hoses every two years. Use standard automotive procedures for "bleeding" the brakes ifit becomes necessary.
CAUTION
Do not allow this machine to be operated with faulty
brakes. This will put the operator in extreme danger
and could cause bodily injury and property damage.
Inspect mechanical parking brake linkage for proper
adjustment, routing and I or damage every 50 hours
(minimum).
FASTENERS
Like any construction equipment, this machine requires
periodic tightening of fasteners.
During normal engine service intervals, check all nuts
and bolts, clevis pins, and clamps. Start at the front of
the machine and work to the rear. The following list
contains several of the more critical fasteners to be
checked. Do not limit your inspection to these fasteners.
Check the condition of the following fasteners.
1. Front bolster mount bolts
2. Bolster pivot pin bolts
3. Tie rod end lock nuts
4. Steering cylinder rod end lock nut
5. Steering cylinder mount bolt
6. Steering wheel nut
7. Brake cylinder mount bolts
8. Brake pedal pivot bolt
9. Core support pins
10. Circle bearing mount bolts
11. Core motor mount bolts (and lock rings on
direct drive cores).
12. Pillow block bearing lock rings
13. Pillow block bearing mount bolts
14. Hydrostatic pcdallinkage clevis pins
15. Gearbox mount bolts
16. Pump drive mount bolts
17. Engine mount bolts
18. Radiator mount bolts
19. Rear axle mount bolts
This is just a partial list of the bolts on this machine,
these should be inspected on a regular basis, the rest
of the fasteners on the machine should also be checked
periodically.
FRAME, GUSSETS Al~D WELDS
The frame on this machine was designed to withstand
normal operating conditions, however under abusive
type use, components and welds can fail. Periodically
check all frame welds and gussets for development of
fatigue cracks. Failure to inspect and maintain the frame
and it's components could result in damage to the
equipment and serious injury to the operator.
•
•
•
•
CORE DRIVE
Two types of core drives are available on the Broce
Broom, chain drive and direct drive. The chain drive
consists of a core motor with sprocket, an idler sprocket
and a plate sprocket mounted on the broom core.
The direct drive uses a core motor with a splined
shaft that fits a hub fastened inside the broom core
frame.
Chain drive alignment: Align the idler sprocket with
the core motor sprocket by adding or removing spacers behind the idler sprocket. The core sprocket is
aligned with the motor sprocket by sliding the core on
the shaft. Once the core is aligned,
lock in place with the lock collars located at each end
of the broom core. Install the roller chain and tension
with the idler sprocket. Caution: do not over-tighten
the chain. Debris picked up during operation of the
broom can cause the chain to over-tighten, causing
excessive side pressure on the bearings of the core
motor.
•
Direct drive: The direct drive core is preset at the
factory and does not need adjusting. If the drive hub
begins to show uneven or excessive wear the core will
need to be readjusted. To adjust, remove the broom from
the machine and remove all of the wafers from the core
frame. Loosen the
lock bolts and lock
collars slightly. Install
the core frame and position the motor so that the core
will slide on and off of the splined shaft easily. After
alignment, tighten both set-screws and jam nuts as well
as the lock collar on the pillow block bearing at the
other end of the broom core.
TOWING
(Check for towing procedures with hydrostatic
drive)
The Broce Broom may be towed to and from the job
site without removing the drive shaft. Use caution while
towing on rough roads since the broom does not have
a suspension system to absorb the bumps.
Ensure gearbox lever on dash is in Neutral position.
Release Parking Brake.
Raise and lock broom core.
Secure tow bar to towing vehicle and connect safety
chains and lights.
Turn steering cylinder valve (under front bumper) to
OPEN position to allow front wheels to turn freely
while towing.
Iftow bar is equipped with surge brake:
a) OPEN valve on tow bar
b) CLOSE valve on master cylinder under left, front
floorboard of broom.
Reset all valves after towing, prior to operation.
Do not tow with water in spray system tank.
Do not exceed 45 MPH when towing the broom.
Do not attempt sharp turns while towing.
ENGINE
The normal engine operation and maintenance procedures arc covered in a separate manual, which is
furnished by the engine manufacture. Important: due
to the dusty conditions that the Broce Broom operates in, it is recommended that the engine fan inspection and replacement be done every 300-400
hours. The dusty environment the broom is operating in will result in erosion of the fan blades. The fan
will need to be replaced when the blades deteriorate
to the point that they do not provide enough air-movement or they become operationally unsafe. This fan
blade erosion is considered to be normal wear on this
type of equipment.
TIRES
See sidewall of tire for manufacturer's recommended
pressure. This will provide the longest tire life. A lower
pressure will provide a more comfortable ride, and
make rough road conditions easier to negotiate.
STORAGE
•
When storing the Broce Broom outside, it is recommended that a light coating of oil be sprayed on the
wire bristles of the broom core to retard rusting. This
only applies to the optional wire cores.
Install an 8" length of angle iron between the lift cylinder barrel and the cylinder clevis. This is to prevent a
flat spot from forming on the broom core during storage.
1.
2.
3.
4.
5.
6.
7.
DAILY INSPECTION
Visually inspect the entire machine for damage and
fluid leaks.
Check all fluid levels; engine oil, radiator and hydraulic reservoir.
Check wheels and tires for excessive wear or damage, also check air pressure and lug nut tightness.
Check pre-cleaner bow I and air cleaner service
indicator (service ifindicated).
Chain guard, seat belt, core cover and rubber rock
guard should be installed and serviceable.
Lights, windshield wipers, reverse alarm, etc., must
be in operating condition.
Test brakes before operating this machine.
Any defects or damage found during this inspection
must be repaired before operation.
BROOM WAFER REPLACEMENT
There are many different techniques that may be used
when rebuilding the broom core. The following instructions involve the techniques and equipment employed
at Broce Mfg. Co. These instructions are to be used
as a guideline and are not designed to supersede any
instructions offered by the broom wafer manufacturer.
The standard Broce Broom core uses 10"x32"
flat wafers and metal spacers. Two different lengths of
cores are available. The seven-foot core requires a
refill set containing 49 wafers and 48 metal spacers.
The eight-foot cores require 54 wafers and 53 spacers. Convoluted wafers may be used on this core if
desired. The amount of wafers required as well as
specific installation instructions may be obtained from
the wafer manufacture.
~)
(]
BROCE CORE SERVICE STAt"ID
CHAIN DRIVE CORES
1.
2.
Remove the chain guard.
Loosen the idler sprocket or motor mount and adjusting
screw depending on the type of chain adjustment utilized.
3. Disconnect drive chain at the master link and remove
from the plate sprocket.
4. Using emery cloth, clean the broom core spindles on
both ends from the lock ring out.
5. Loosen set-screws and remove lock rings (counterclockwise) from both ends.
6. Lower the core support frame until the core rests on or
near the ground.
7. Remove the bolts securing the pillow block bearings to
the core support frame and slide the bearings off the
spindles.
8. Raise the core support frame and slide the used core out
from under the sweeper.
9. Remove the plate sprocket and spindle from the end of
the core and install the Broce Core Service Ring (part
#CS-02) in place ofthe spindle.
10. Remove the end cap at the opposite end of the core.
II. Using a hoist or winch with a minimum capacity of I,000
Ibs., raise the core approximately 6 to 8 inches off the
floor as shown in illustration ( ).
12. Using a pry bar or similar tool, start at the bottom of the
core and work the wafers loose. Do not attempt to use a
cutting torch to remove the wafer, as this could result in
a fire.
13. Lower the core and remove the service ring. Reinstall the
spindle. Loosen the four bolts securing the end cap until
they are flush with the inside ofthe core end plate. This
will leave approximately one inch of play in the end cap.
14. Using the Broce Core Service Stand, stand the core upright, with the end cap on the bottom. lf'this stand is not
available, fabricate a similar device, which will
securely hold the core in place. The stand is designed
for use on a hard level surface. It may be easily transported using a small forklift and is ideal for storing a
spare core.
IS. Locate the service stand approximately one foot from a
loading dock or other similar platform that will provide
stability and will enable you to reach the top of the core.
16. Begin filling the core with a ply wafer, and then a spacer.
Keep adding poly wafers and spacers in an alternate
sequence until the core is filled. If there is not enough
space left at the end for both a spacer and ply wafer,
finish out with a ply wafer to finish filling. When assembling a half poly and half wire core, or an all wire core,
begin with a poly wafer and end the fill with a poly wafer.
This will minimize unnecessary damage to the drive chain
and will add stability to the wire wafers near the end of
the core. When building a half-and-half core, the pattern
should be; poly wafer, spacer, wire wafer, spacer, and
then repeat the sequence.
•
•
•
•
17.
If this pattern ends at the top with a wire wafer, substitute a poly wafer.
Each wafer has a 10ckiD!~tab located on the inside of the
crimp ring. This tab will lock the wafer against the core
frame tubes to keep it form spinning on the core. To
ensure proper core balance, rotate this tab 90" from the
previous wafer. This will ensure even weight distribution on all four sides of the core.
Install the end cap using two Y1" x 3" all thread bolts in
two of the holes which are I80 apart. Slowly and evenly
tighten these until the end cap is close enough to the
core to install the standard mounting bolts. Start two of
the standard bolts with lock washers in the two remaining holes. Remove the two long bolts and install the
other two standard mounting bolts. Tighten all four bolts
evenly in a criss-cross fashion until the end cap is tightly
secured to the core.
The core must now be tipped over onto the ground so
that the core comes to rest laterally on the bristles. Clear
an area fifteen feet in all directions of the core of personnel and property before tipping the core. Always tip the
core by pushing it over; never attempt to push the core
over. Once the core begins to fall, get away from it in
case the stand falls off. Carelessness in this procedure
could result in serious bodily injury and/or property damage.
With the core resting on the ground, slide the stand off
of the spindle and tighten the end cap in the same fashion as before.
Using emery cloth or sandpaper, clean both spindles to
remove any burs or tar which may interfere with sprocket
or bearing installation.
Install the sprocket as shown using the flat washers as
spacers. The sprocket must be installed in this manner in
order to ensure proper chain alignment.
Slide the rebuilt core back under the sweeper.
Slide the pillow block bearings on the spindles until they
roughly line up with the core support frame. With the flat
part of the bearing up, slowly lower the core support
frame until it is close enough to line up and secure the
bearings with the original mounting bolts. When bearings are secure, raise the core, and refer to page -- ofthis
manual for chain drive alignment.
Once chain drive alignment has been achieved,
recheck the lock rings to ensure that they are secure
and reinstall the chain guard.
5.
6.
7.
8.
9.
0
18.
•
19.
20.
21.
22.
23.
24.
DIRECT DRIVE CORES
I.
2.
•
3.
4.
With the core resting on or near the ground, remove the
bolts securing the pillow block bearing to the core support frame.
Pull the core to the right side of the machine until you
feel the splined hub come off the shaft. At this time, the
core will be close to or touching the right support arm.
Angle the core toward the rear of the machine and slide
it out from under the sweeper.
Clean the spindle from the lock ring out.
10.
11.
12.
13.
14.
Loosen the setscrew and remove the lock ring and pillow block bearing.
Remove the spindle and install the Broce Core Service
Ring in its place.
Remove the end cap from the drive end of the core.
Refer to steps II through 20 of the chain drive section
for core disassembly and rebuild procedures.
Raise the core support frame and slide rebuilt core under
the sweeper. The core will have to come in from an angle
in order to be started over the motor mount. Once the
core has been started onto the motor mount, swing the
right side under the right support frame.
Lower the support frame slowly until the motor mount is
centered in the core.
Using a back and forth twisting motion, pull the core
onto the splined shaft.
Install the pillow block bearing on the right side of the
core using the original mounting bolts.
Raise the core. Slide the core to the left as far as it will go.
Using a pry bar, slide it back to the right until the bolts
on the end cap will clear the hydraulic hose fittings.
Install the lock ring on the spindle securely. This lock
ring is all that maintains core alignment.
Do not try to readjust the motor mount unless it becomes
damaged or otherwise unserviceable. The alignment on this
mount is preset at the factory. If it does become necessary,
refer to page (?) of this manual for alignment procedures.
If you have any questions regarding these procedures or
would like to obtain the core service stand and ring, please
contact your nearest dealer or call us direct at (620) 227-8811,
the part numbers are listed in the equipment options section
of this manual.
HYDRAULIC
SYSTEM:
The hydraulic system on this machine operates the hydrostatic drive, loop flushing circuit, steering and brush
functions, and brush rotation. It employees two supply pumps sharing the same reservoir. In order to
simplify the description of this system, it will be separated into five circuits.
HYDROSTATIC
•
DRIVE CIRCUIT:
This system utilizes a Sauer-Danfoss variable displacement pump and a fixed displacement motor. Oil,
supplied from the reservoir, passes through a lO-micron filter with a bypass setting of3 psi. Before entering
the pump. Pressurized oil from the pump is delivered to the motor by high pressure hoses.
LOOP FLUSHL~G CIRCUIT
The fixed displacement motor is equipped with a loop flushing valve that purges hot oil and/or contaminated
oil from the closed loop. This oil is routed back to the pump and joined with the case drain oil, then through
the heat exchanger and returned to the tank. The following specifications are for testing and informational
purposes only. If a problem develops with the pump or motor, we strongly recommend that they be taken
to an authorized Sauer-Danfoss repair center or returned to Broce Mfg. Co., Inc. for exchange of new or
rebuilt components or repair authorization.
STEERL~G CIRCUIT
Oil from the reservoir supplied to the work pump is pulled through a 100 mesh replaceable screen. The
pump has a built in flow divider, which delivers priority oil to the steering circuit and the exhaust flow to the
brush circuit The priority flow is 3 gpm. and the relief valve in the flow divider is set at 1500 psi. The
steering unit is an orbital type motor that supplies oil to the steering cylinder and also has power beyond
capabilities that are used to control brush functions.
•
BRUSH FUNCTIONS
The brush functions are controlled by a two spool valve, that is the lift and shift cylinders. The lift cylinder
spool control lever is the front lever. Moving the lever towards the operator will raise the core and moving
the lever away from the operator to the detent will lower core, beyond detent will lock in float. There is an
electrically controlled normal closed valve in the lift circuit. Itreplaces the manual lock previously used on
lift cylinder and in the on position will allow the cylinder to move freely up and down. Inthe off position the
core will raise but will not go down. When the machine is parked the core should be raised up and the
switch in the off position.
The shift cylinder control is the center lever, pushing the lever away moves core to the right, or ccw, pulling
lever too you moves core to the left, or cw,
•
•
(NOTE) Machines equipped with the two-spool valve, regardless of its usc, dozer blade or brush functions have small orifice plates set in the valve below the hose adapter to control function speed. These little
guys have feet made on the plates, when used in lift circuit the feet should be up and when used in the shift
circuit the feet should be down. In each application the orifice size is different, so they should not mixed up.
On machines equipped with joystick controls foreword movement of the lever will lower the core until you
hit the lock, and then you arc in float position. Pulling the lever back will raise the core. Movement to the
right will move the shift cylinder to the right or ccw; movement to the left will be left or cw,
The return oil from the steering unit and the brush function valve flow to the return manifold in separate
hoses. The return manifold is mounted directly on a 1O-micron filter with a bypass setting of25 psi., then
the filtered oil flows back to the tank.
BRUSH ROTATION
•
The exhaust flow from the work pump supplies oil to the rotation valve at a rate of 12-23 gpm, depending
on engine speed. The relief valve is enclosed in the rotation valve and the relief setting is 2650 psi. at 21
gpm The brush control lever is the rear lever, on machines with single directional control, moving lever away
from the operator will turn on the brush, pulling back to center will stop brush rotation. Oil flows from aport on rotation valve to upper port on core motor to receive ccw rotation, b-port is plugged. The hose on
the lower port of the motor returns the oil to the return manifold, filtered and returns to tank. On units
equipped with dual rotation, b-port on rotation valve sends oil to the lower port on the motor to get cw
rotation. The spool valve requires a change of the kit mounted on the rear of the valve to achieve dual
rotation. In either case return oil from the rotation valve flows from the outlet port on the valve to the return
manifold, filtered and returned to tank.
Their two types of core motors used for brush rotation, the internal drive type that is standard, and has a
replaceable splined hub mounted in the core frame, the other is the external chain drive.
On machines equipped with external drive, a-port on the rotation valve flows to the front port on core drive
motor, the rear port flows back to the return manifold, filtered and returned to tank. B-port on rotation
valve is plugged.
The following specifications relative to the work pump:
Displacement:
2.32 cubic inch
Volume
26 gpm. at 2600 rpm.
Maximum rpm. 3000 rpm.
Relief setting
1500 psi.
Priority flow
3 gpm.
Exhaust flow
23 gpm.
•
HYDROSTATIC
DRIVE
•
The basic hydrostatic drive system has evolved over the years, beginning with Sundstrand then to Eaton and
now current production is Sauer-Danfoss. A current schematic and trouble-shooting guide is included in this
manual.
Beginning with serial number90188 and up are equipped with Sauer-Danfoss hydrostatic components.
Eaton and Sauer-Danfoss components arc available from the factory, we have the latest revisions and
recommend that customer repaired units be upgraded.
CONTROL LINKAGE
Beginning with serial number 87512 a centering device, called a (hydro back ) became standard on all
machines. This device aids in controlling neutral, and is available in a retrofit kit PIN HB-OOI K for earlier
machines.
SYSTEM DESCRIPTION
•
PUMP
The hydraulic system operates on a 2.32 cubic inch gear pump that is mounted on the rear of the hydrostatic
pump. This pump produces approximately 26 gpm @ 2600 rpm., with a built in flow divider that provides
the priority flow to steering at 3gpm. The exhaust flow of approximately 23 gpm. powers the brush rotation
valve.
STEERING UNIT
The steering unit is a open center type motor that has power beyond, and dead steering capabilities. The
power beyond capabilities is used to power the brush functions and dozer blade control valves if equipped.
•
STEERING CYLINDER
•
2" x 10" double acting cylinder
BRUSH FUNCTION VALVE
The brush function control valve is a two-spool monoblock design that receives its oil supply from the
steering unit power beyond port. On standard machines the front lever controls the lift cylinder functions;
up,down, and float functions. The center lever controls the shift cylinder functions. Joystick controls are
optional, but use the same basic valve. Moving the joystick foreword to the detent will lower the core, past
the lock will be float, pulling towards the rear will raise the core.
Pushing to the right will move the core frame to the right or ccw, pulling towards the left will move core
frame to the left or cwo
LIFT CYLINDER
2" x 8" double aeting cylinder
sarrr CYLINDER
2" x 16" double acting cylinder
•
BRUSH ROTATION VALVE
The brush control valve is single spool, two position, monoblock design valve. It is the rear lever on the
control panel, moving the lever away from operator will turn the brush on, pulling back to center will turn the
brush off. As optional equipment a three-position valve is available, and it requires a different kit on the rear
of the valve and with that change, pulling the rear lever toward the operator will reverse the core rotation.
CORE MOTORS
There are two types of motors used on Broce Brooms. The first, a magneto style mount with a keyed shaft
used on chain drive units. The second, an sae style mount with a splined shaft used on the internal drive
cores. There are basically two sizes (displacement and physical size) of internal drive motors, first, the DD256-R used prior to serial number 86818. The second, the larger displacement is part number DD-256-C.
Starting with serial number 90 188 we changed to a Sauer-Danfoss motor that is totally interchangeable with
the original DD-256-C. The Sauer-Dan foss Part # is 305943
RETURN FILTER
•
The return filter is a IO-micron, spin-on type, with a 25 psi bypass attached to the return manifold.
The manifold is ported to accept return lines from the steering unit, the brush function valve, the dozer valve,
the curb sweeper, the rotation valve, and return line from the core motor.
SHUT-OFF VALVES
The ball valve mounted below the hydraulic tank closes the suction line to the work pump. There are two
valves mounted on the rear of the tank, the right one closes off the suction line to the hydrostatic pump, and
the left one closes off the return lines.
CAUTION: MAKE SURE ALL THREE VALVES ARE IN THE OPEN POSITION BEFORE STARTING ENGINE. IF THE RETURN VALVE IS CLOSED, THE RETURN FILTER HOUSING WILL BE
DESTROYED.
•
RESERVOIR
27 US gallons capacity, with inlet strainer (100 mesh), lockable cap, sight level indicator with thermometer,
suction screen in bottom outlet (100 mesh), and shut-off valves.
HOSE AND ADAPTERS
Starting with serial number 90188 , all hose adapters are boss o-ring I flat face in the cylinders. valves,
steering unit, pumps, and motors. The tank outlets remain pipe through the shut-off valves, then change to
flat face type adapters. All the hoses arc flat face type design.
SYSTEM PLUMBING
The diagram on the following page shows port location and use tor the steering unit, control valves, return
manifold, and brush motors.
PLEASE NOTE: The larger part of our customer base likes the positive down pressure feature
and all standard machines are so equipped. If you would like to defeat the feature, use the following procedure.
•
Disconnect the lower hose on the lift cylinder and allow the oil to drain then reconnect it. Disconnect the
hose from A-port on spool # 1 on two-spool valve and connect a breather in the end of the hose. Remove
hose adapter from spool valve and install a -6 Boss O-ring plug. Secure loose hose to others with a wire
tie.
Spool # 1 is the spool closest to valve inlet. A-port is the closest port to the control handle.
Eliminating the positive down pressure feature will have no other effect on the rest of the operating capabilities.
•
•
SPECIFIC TEST PROCEDURES
Run engine about Y:z throttle when taking pressure readings.
To check the pressure on the steering circuit can be done in many ways:
You may tee into the priority port on the work pump, then fully stroke the steering cylinder
and read the pressure. It should read 1500 psi.
2
You may tee into the pressure port on steering motor, then fully stroke the steering cylinder
and read the pressure. It should read 1500 psi.
3
You may remove -8 Boss O-ring plug on the inlet side, in the face of the two-spool valve, and
insert a gauge. Then, fully stroke either cylinder and check pressure. Gauge should read
1500 psi.
There are pressure ports in the base of each ofthe cylinders. Remove the 'i4 IPT plug and
insert a gauge. On the lift cylinder move the control lever to the raise position, and hold.
The gauge should read 1500 psi. On the shift cylinder move lever to the right position and
hold. Gauge should read 1500 psi.
4
To check the pressure of the rotation valve can be done the following ways:
•
You may tee into the exhaust port on the work pump, then move the rotation valve to the on
position.
If the brush is not in contact with ground, simply freewheeling, system pressure will be about
600 psi.
Putting down pressure on brush until it stalls will raise the pressure and the gauge should read
3000psi.
2
You may remove -10 Boss O-ring plug in the face of the brush rotation valve, its right in line
with the relief valve. Turn brush on and repeat above procedures.
3
•
You may tee into a-port on the rotation valve, and repeat test procedure.
MAINTE~'TANCEPROCEDURES ON ABROCE BROOMAIC
P.M. (Preventative Maintenance) is a result of the need to efficiently curb the cost of keeping your vehicle's air conditioning system functioning properly. Logic would dictate that you not wait until it breaks to fix it. Very few of us have any
hesitation in recognizing the need to regularly change the engine oil and oil filter to prolong the life of our engines.
Lubrication, wheel alignment, tire replacement, brake adjustment, and fluid level checks are just a few ofthe areas that are
checked, repaired, and/or maintained on a regular basis. The ever increasing recognition of a need for proper vehicle
maintenance in order to run a cost efficient business, coupled with the rising dependency on air conditioned vehicles, and
the high cost of downtime, have combined to create a growing demand for a sensible maintenance program for NC
systems.
•
The logical approach is to adopt a regular service procedure based on the concept of prolonging the life of the expensive
components used in the NC system. These are generally recognized as the compressor, evaporator coil, and condenser
coils. The expansion valve is not ultra-expensive, but its service life can usually be extended by changing the receiverdrier and properly evacuating the system. The receiver-drier is the service component that is designed to protect the
expansion valve in virtually all Ne systems. It is expendable and its function is comparable to the engine oil filter.
This manual is designed to make you comfortable with basic air conditioning concepts. With this newfound or renewed
understanding of vehicle AlC systems, it should be easier for you to recognize the validity of the proposed P.M. program.
We shall approach the P.M. program by first discussing the basic scientific principles that enable A/C systems to function. We shall then proceed through a discussion of system components and refrigerant flow patterns. This will allow
you to better understand and hopefully approach the service and troubleshooting procedures that follow with a firm.
Logical grasp of the functions of the components and how they interact with each other. We shall also look at the safety
considerations that you should be aware of in working with the NC systems. It is also very important that we discuss the
service tools that will enhance your servicing of the A/C system.
It should be noted that the procedures contained herein are not just applied AlC theory, but are tried and tested methods.
Even if you have years orNC repair experience, holpfully you will benefit by the information and procedures outlined in
this manual.
RECOMMENDED
P.M. PROCEDURE
The following procedures are set forth in a manner that will allow both the beginner and the expert to utilize the contents
successfully. After you have followed these steps a few times, they should become second nature.
•
When you approach a vehicle for P.M. or for service due to a complaint, you will find it beneficial to install your manifold
set (gauges) immediately. There is no other reliable means of determining exactly how well or poorly a system is functioning. It is also recommended that you hook-up both the
•
•
high side and low side test hoses each time. Because just hooking up one side will not positively indicate the performance
of the other.
MANIFOLD HOOK-IJP
Systems wjth Screw I}lle Servjce valyes
L
2.
3.
Remove the protective caps from the service ports.
Connect the test hose ends onto the service ports:
Blue hose on the low side or suction side
Red hose on the high side or discharge side
Hook the center hose to the recovery machine.
Visual Inspection
Visually inspect the vehicle's AlC components for signs of failure, excessive wear, or any condition that might lead to a
component failure, such as:
I.
2.
3.
4.
5.
•
6.
7.
Belt - check for proper tension, signs of fraying, cracking, or slippage as well as alignment.
Clutch -look for signs of excess heating or scaling which could be due to improper voltage, slippage of the
belt, weakening clutch plate fingers, defective bearing.
Hoses - check for wear spots, rubs, brittleness, weather-cracking, excessive heat exposure, and signs of
leaking which might be indicated by oily spots on hoses or fittings.
Condenser - check for indications of air flow restrictions, i.e., bent fins, bugs, dirt, and debris.
Drier sight-glass (a & b vehicle running, c & d vehicle not running).
a.
Bubbles - indicating possible low refrigerant condition.
b.
Clear - indicates either no refrigerant or at least a full charge (overcharge is still possible).
c.
Cloudy - brown residual coating indicative of desiccant deteriation or severe moisture contamination (system must be flushed - see flush procedure).
d.
Oily streaks - indicating oil contamination usually compressor burn-out (system must be flushed see flush procedure).
Evaporator Coil- check for indications of airflow restrictions such as bent fins, dirt, foreign debris, and dirty
filter.
Drain Hose ...check to ensure unrestricted water flow.
Electrical System Checks
It is recommended that you run an electrical system check to ensure that the system can operate in all available modes.
The electrical system includes the blowers, safety switches, thermostat, and electro-magnetic clutch. To check the
electrical system:
L
Turn on the AlC fan switch. Fans should blow on all available speeds; ifnot blowing check circuit breaker,
blower switch, blower motor, and wiring.
2.
Turn the thermostat to colder position. The electro-magnetic clutch should engage (you can usually hear it
engage if engine is not running). If it fails to engage, check voltage at the thermostat, then trace through
safety switches to clutch assembly to find open circuit. Upon finding any faulty component, repair or
replace as necessary.
•
If electrical components seem in order, you are ready to crank the vehicle and run system to determine the condition of the
AIC system.
NC System Performance Checks
To evaluate the performance and/or condition of any NC system properly, it is necessary to run the vehicle's engine so
that the compressor can pump the refrigerant through the various components enabling you to determine if a problem
exists. This evaluation should be carried out on any vehicle that you are working on. Failure to do this could result in the
customer having to bring the vehicle back due to a problem you could have solved earlier or, at the very least, your
having to repeat certain steps such as evacuating.
•
Evaluating the NC Comoonents
I.
2.
3.
Crank the vehicle - run 1200 to 1500 RPM.
Tum the NC system on (fan, thermostat).
Check gauge reading and unit performance (duct temperature, clutch cycling, etc.) to see ifthc unit is
performing as it should be. If it is not, you will have to trouble-shoot the unit (refer to TROUBLESHOOTINGTl-IENC SYSTEM).
Normal gauge readings are as follows:
Low side (suction)
10-25 psi
High side (discharge)
250-270 psi
These readings are dependent on many external factors including ambient temperature, humidity and temperature inside
cab. Ifthe readings are in the normal operating range, you may proceed to the DRIER CHANGE PROCEDURE. lf'the
readings are not proper, you should trouble-shoot the system and correct the problem.
DRffiRCHANGEPROCEDURE
I.
2.
3.
4.
With vehicle's engine turned ofT,open both manifold hand valves and recover refrigerant using manufacturers recommended procedures.
With refrigerant discharged, make any necessary repairs to the system. then remove old drier. and install
new drier by hooking the line from condenser to the inlet side and the line to the expansion valve to the
outlet side. Do not assume that the old drier was hooked-up correctly. Failure to do so will result in a
system malfunction. (Note: The inlet side ofthe drier should be marked "IN" or should have a flow
indication label that shows which side is the inlct.)
Use only heavy-duty high capacity receiver-driers. (The desiccant content of many driers is insufficient for
use on an annual P.M. basis. Many suppliers are using driers with an automotive type bag desiccant. Care
should be exercised when choosing your supplier because your maintenance is no better than the drier you
use.)
Proceed to REFRIGERANT OIL MAINTENANCE PROCEDURES.
•
REFRIGERM'TOIL MAINTENANCE PROCEDURES
As with any moving part, lubrication is the key to long life. The single most neglected aspect of NC system maintenance
is that of maintaining the proper amount of oil in the unit (II oz. in new system).
•
1.
•
2.
3.
4.
5.
6.
7.
The refrigerant oil in the compressor travels with the refrigerant throughout the system to lubricate all of its
components.
The receiver-drier absorbs some of the refrigerant oil (approximately 2 oz).
NC systems leak refrigerant and refrigerant oil; therefore, adding refrigerant and not adding oil is asking for
major component failures.
Measuring oil level in the compressor will not always give you a true measurement of the oil in the system
(i.e. oil could have been pumped out of the compressor up to the point of restriction which might be the drier
expansion valve).
Flushing the system with propellant (such as nitrogen) and draining the oil from the compressor is the only
sure way to cure an over or under charge of oil.
When you discharge the refrigerant from a system, oil is also discharged.
Consistency is the key to maintaining the proper oil level.
To avoid having to flush the system every time it is serviced, we have adopted guidelines that will ensure proper oil level
in the system ifapplied regularly. They are:
I.
2.
3.
4.
•
If you discharge (or leak out) the refrigerant and change the drier, add 4 oz. of refrigerant oil. To further
break this down, the drier is accountable for 2 oz. and the refrigerant charge is accountable for 2 oz. This
also takes into consideration the oil lost due to system leakage or seepage.
If the oil is contaminated (compressor burnout or drier desiccant breakdown), the system must be flushed
and a complete charge of oil added. (See Flush Procedure.)
Oil should be kept clean and dispensed from a clean measuring device.
If you have access to pressurized oil charge (either in the 4 oz. cans or through a service center with bulk N
C refrigerant oil), you will not have to measure and pour. Otherwise, measure and pour the oil into either the
drier or compressor prior to evacuating the system.
You should now have a basic understanding of the importance of refrigerant oil to the NC system and how to maintain it
properly. You can now proceed to EVACUATING AND CHARGING PROCEDURES.
EVACUATINGAND CHARGING PROCEDURES
The purpose of evacuating a system is to remove the air and moisture from the system. It is foolish to change any of the
refrigeration components in an NC system without evacuating the system. An evacuation of 2 to 5 minutes is not
sufficient to ensure a clean system. Moisture is the # I enemy of an NC system and we must boil it out of the system.
This can only be accomplished by lowering the pressure in the system, which lowers the boiling point of water so it is
vaporized through the boiling process. This is the process we commonly refer to as "pulling the vacuum" or evacuation.
Since this is such an important process, we must approach it and apply it with the utmost care. To ensure that we are
doing a proper job, let us first evaluate the vacuum pump and its capacity. Then we will go through the evacuation and
charging process step-by-step with explanations along the way.
Evaluating Your Vacuum Pump
Most vacuum pumps will have tags that state their capacities. This tag should tell you the CFM (cubic feet per minute)
that the pump is capable of. It may also give its micron rating which is basically a measurement of the pump's deep
vacuum ability. Knowing the capability of your pump is extremely important, because this will be used to determine the
length of time you have to run the pump during
•
the evacuation process unless you use a micrometer. (Micrometers are somewhat expensive and ultra-sensitive as well as
something that not every shop has available. If you do have one you should follow the instructions for the specific unit
you have.) As most shops will not have micrometers available, we shall set a time schedule for evacuation based on the
average time needed to sufficiently evacuate a system by a vacuum pump rating.
Evacuating
1.2 to 2 CFM Pump
3CFMPump
5CFMPump
Schedule
45 minutes
30 minutes
15 minutes
This time schedule assumes that the pump is "vacuuming" at it" rated capacity.
to test the vacuum pump (see step 2) to confirm its capability of boiling water.
Periodically,
•
it will be in your best interest
Vacuum Pump Test
1.
2.
3.
4.
5.
6.
7.
Fill a glass jar or container with approximately 2 inches of water.
Run the service hose from the vacuum pump port and insert in the top of the container (do not stick end in
the water).
Seal the top of the container with sticky tape or duct tape.
Switch on the vacuum pump.
If the vacuum pump is pulling 26 inches of vacuum or better, the water will boil and/or bubble immediately.
If the water does not boil, then the vacuum pump is not capable of pulling sufficient vacuum to properly
clean out the system and the pump must be replaced or repaired. Note: Be sure the top of container is
sealed sufficiently.
Test your vacuum pump periodically to ensure that it is doing a proper job.
Vacuum Pump Maintenance
L
2.
3.
Change the oil in your vacuum pump after every 25 to 30 system evacuations.
Use only Vacuum Pump Oil. Refrigerant oil is of a different viscosity and will not ensure a long vacuum
pump life.
Keep caps on the ports of your vacuum pump when not in use.
•
Now that you have a better understanding of the evacuation process and how to be sure the vacuum pump is properly
performing, you are ready to evacuate the system. (Note: You need not perform the above tests each time but performing
them periodically is strongly recommended.)
Evacuating
the System
With manifold set hooked-up (as described in MANIFOLD HOOK-UP section) and refrigerant drained out of the system
(as detailed in DRIER CHANGE PROCEDURE), you are now ready to proceed with the evacuation process. Note: If you
are not using pressurized oil charge, you need to add the proper amount of oil prior to evacuating the system.
l.
With both handles on the manifold
pump.
set wide open, hook the center hose to the suction port of the vacuum
•
l.
•
2.
3.
4.
Switch on the vacuum pump.
Evacuate the system for the proper amount of time as determined by the size of the vacuum pump you are
using as discussed previously.
If you desire to run a vacuum test on the system for leaks proceed as follows:
a.
Run vacuum pump for approximately 5 minutes.
b.
Close manifold set handles.
c.
Switch off vacuum pump.
d.
Note gauge readings (which should be into vacuum).
e.
Allow to sit for 2 minutes.
f
Any rise in pressure could indicate a leak (refer to LEAK TESTING THE SYSTEM).
g.
No rise in pressure would indicate a relatively tight system (though not a 100% absolute test as
vacuum can sometimes close minute leaks which will reopen once system is pressurized). You can
reopen manifold set (wide open) and continue to pull vacuum for the allotted time as determined by
the size of the vacuum pump.
After pulling for the proper amount oftime:
a.
Shut off the manifold set.
b.
Shut off the vacuum pump.
c.
Proceed to Charging the System.
Charjiinji the System
The procedure for charging an AlC system is merely finalizing the evacuation process. That is to say, that you can't
properly charge a system unless you remove the air from the system. Adding refrigerant to a system's existing refrigerant
is merely patchwork.
The charging procedures are:
•
I.
2.
3.
4.
5.
6.
7.
•
!look the center hose of manifold set to oil charge if using pressurized oil charge. Ifnot, you would have
already added oil prior to evacuation and you should proceed to step 5.
Purge air from the center hose.
With vehicle engine turned off, open the high side manifold handle.
Shoot the proper amount of oil in to the system.
Hook the center hose to the refrigerant supply.
Purge air from the center hose as in step 2.
Charge approximately I lb. of refrigerant into the system on the high side ofthe system. Remember: The
vehicle is not running. What should happen is the following:
a.
The high side gauge should rise to supply pressure, which is usually 60 to 90 psi.
b.
The low side gauge should rise to equal the high side reading. This is without the vehicle running,
so equalization indicates that the expansion valve has opened. But if, for example, the high side
reads 70 psi and the low side reads 30 psi, changes are that the expansion valve is not going to
function properly or that another restriction exists in the system. You should find and correct this
problem right now. This step is a good static test on the expansion valve and should be regarded
as such.
c.
lfboth sides indicate equalization close high side gauge, start the engine (1200-1500 RPM), tum the
AlC system on high speed, thermostat at coldest setting.
d.
Make sure the condenser is operating properly.
c.
Open the low side of the manifold set and charge with 2 lbs. of 134a refrigerant.
f.
Shut off the low side of manifold set.
a.
b.
c.
Run the system to ensure that the system is operating properly. (Refer to AlC SYSTEM PERFORMANCE CHECK.)
If satisfied that the system is functioning properly, shut off the vehicle, and remove the test hoses
carefully, realizing that the pressure indicated on gauges is the pressure present in the hoses.
Cap the service ports.
SummaI)'
•
We have now completed the evacuation and charging procedures that are necessary (not optional) to complete a successful maintenance or service job. This may seem like a lot of steps to go through, but the explanation is a lot longer
than the actual work process. lfwe condensed the entire P.M. Procedure it would look like this:
1.
2.
3.
4.
Evaluate AlC system - electrical and refrigeration.
Change the receiver-drier and any other defective parts.
Evacuate the system.
Charge system with oil and refrigerant.
FLUSHINGTHE SYSTEM
Flushing the system is a procedure that must be performed if any of the following conditions exist:
1.
2.
3.
4.
5.
6.
compressor bum-out or failure
drier desiccant breakdown
extreme moisture contamination
high side restriction
you are unsure of oil contents of system
system has been open for lengthy period
These conditions dictate flushing the system to ensure a proper service.
Nitrogen has become the primary flushing agent due to:
l.
2.
3.
4.
the environmental taboo on releasing CFC-based refrigerants to the atmosphere
the dry characteristic of nitrogen
the high pressure available with nitrogen
ease with which nitrogen may be obtained
•
Flushing Procedure
Flushing with nitrogen is easily accomplished if you remember the following:
1.
2.
3.
Never flush through any of the following major components: drier, expansion valves, or compressor.
Regulate the pressure to 150-250 psi.
Adapt the air nozzle to the end of the test hose coming off of the regulator. (Note: check burst pressure on
the hose and be sure it can withstand regulated pressure.)
•
I.
•
Always cover the end of the hose or unit being flushed to avoid spraying oil and contaminants everywhere.
Bearing in mind the above recommendations, you can now flush the system following the normal refrigerant flow pattern
in the following steps:
I.
2
3.
4.
Flush
Flush
Flush
Flush
from the discharge hose fitting (at compressor) through the condenser to the fitting at inlet of drier.
from the fitting at the outlet of the drier to the inlet of the expansion valve.
from the suction hose fitting at the compressor to the outlet fitting of the expansion valve.
the evaporator coil separately.
NOTE: Always cover the outlet fitting of the component or hose being flushed with rags or shop towels to minimize mess
and hazard to yourself and others.
Properly flushing the system will remove virtually all ofthe oil in the system except that in the compressor. lfyou are
reusing the old compressor, you should drain the oil from it and replace it. lfyou are installing a new compressor, it will
have the proper amount of oil in it from the manufacturer. Remember that you must add oil to the system to compensate
for the hose and coil lengths (see EVACUATING AND CHARGING PROCEDURES).
Note:
If a condition warrants flushing the system, a drier change should be considered mandatory.
LEAK TESTING THE SYSTEM
•
The safest and most practical method ofleak detection is the electronic leak detector. It will detect leaks as slight as 'l4
pound per year (according to the manufacturers). The system can be pressurized with refrigerant (although expensive
and also condemned by environmentalists) or nitrogen (recommended). Nitrogen will give a higher internal pressure and
will carry latent freon (that freon present in the system) to the point of leakage. This higher pressure makes it possible to
detect smaller leaks that would be hard using only refrigerant bottle pressure. The manifold set should always be used
when leak testing a system, as this will give you instant reference to the amount of pressure you have in the system
(recommended pressure not to exceed 250 psi).
The procedure is as follows:
I.
2.
3.
4.
5.
6.
Hook the manifold set to the system.
Hook the center hose (supply hose) to the refrigerant or nitrogen source.
With the vehicle engine turned off, open the suction side of the manifold set. This will allow nitrogen or
refrigerant to fill the system to the supply or regulated pressure.
Close the manifold set handle.
Use an electronic leak detector on the system to find the leakage area and the pinpoint leak.
Upon finding the leak, make necessary repairs.
There are other methods ofleak detection such as halide torch, soap bubbles, dye colored refrigerant, or vacuum test.
•
When you lose refrigerant due to leakage, you also lose refrigerant oil. This causes:
1.
2.
3.
4.
Possible strain on the compressor.
Air and moisture replacement of the lost refrigerant.
Premature saturation ofthe drier desiccant material.
The tasks of the refrigerant not to be carried on, such as condensation, evaporation, or oil transporting for
lubrication purposes.
••
Therefore, leaks must be found and corrected and the system must be properly serviced to minimize the effects that air
and moisture have on NC systems.
TROUBLESHOOTING THENC SYSTEM
Troubleshooting Procedures Defined
Troubleshooting makes use of logic and your knowledge of component function to pinpoint the cause for any irregular
operating condition. When you are evaluating an A/C system, this generally requires going through the steps as outlined
under "Manifold Hook-up", "Visual Inspection", and "Electrical System Checks" in the Recommended P.M. Section
Procedures.
Initial Steps
When you are called on to troubleshoot a system, it is important that you gather any information that you can from the
operator. This information may be useful in helping you find the source of the problem, as well as keeping you from
overlooking a problem that takes time to develop (such as freezing-up). If the operator can only say "the NC doesn't
work," this gives young insight as to the direction to start looking for the problem. Ifpossible, locating and curing the
problem. He will benefit by having an NC system that performs properly and you will avoid a "comeback".
Patchwork Can Mean Comebacks
After you have gathered all of the information that you can, use it to help evaluate the system. While this information is
sometimes helpful, do not let it cause you to skip steps in the evaluation procedures previously outlined. The operator is
usually not an NC mechanic, so you need to use your knowledge to pinpoint and correct the problem (or problems).
EXAMPLE: an operator writes up a vehicle NC as freezing-up. You know that last week you had to change the thermostat on a vehicle just like this one to cure a freeze-up problem. You change the thermostat and consider the problem
solved. When you fail to hook-up the gauges and run the proper evaluation checks, you run the risk of overlooking the
real problem. In the case of freezing-up, it could be caused by a number of things, such as low refrigerant charge,
restricted drier, or a restricted expansion valve, as well as a malfunctioning thermostat. Following the evaluation procedures would have positively identified this problem.
You should also be aware of the fact that a system may have more than one problem. There could be electrical problems
and refrigerant system problems present at the same time. Do not overlook these possibilities because it will cause a
comeback.
•
Troubleshootint,: Chart
•
The following chart lists some of the common problems that plague NC systems and refer them to the pressure readings
._on your test gauges. They are referred to as "low" or "high" due to the fact that different systems and conditions have
different normal readings.
TROUBLESHOOTING CHART
Suction
Discharge
Possible Problem
Low
High
I. Restriction between the discharge of the compressor and inlet of receiver drier.
Check condenser and condenser lines for a point of restriction that may create flashing. Condition indicated by an
extreme differential in temperature at the point of restriction.
Low
Low
I. Possible restriction between drier and suction side of compressor.
2. Low refrigerant charge - bubbles in sight glass.
3. Restriction at drier or expansion valve - sight glass usually clear.
•
High
High
I. Air in system.
2. Overcharged system (oil or refrigerant).
3. Condenser fan not working .
4. Air flow restriction on condenser.
lligh
Low
1. Weak compressor - indicated by accelerating the engine and watching the suction and discharge
readings. Normally, suction moves lower and discharge side should rise.
2. Expansion valve flooding or stuck open - this would cause high and low sides to become less distinguishable.
11/17/00
•

305900 valve assembly

Transcription

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