NOTICE: THIS VEHICLE DOES NOT CONFORM TO ALL

SAFETY AND EMISSIONS STANDARDS APPLICABLE TO

ON-ROAD VEHICLES IN THE UNITED STATES.

OPERATOR QUALIFICATIONS
Operation of this equipment shall be limited to competent and experienced persons. In
addition, 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 of the 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 AND WILL VOID FACTORY WARRANTY.

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
 TABLE OF CONTENTS

SAFETY PRECAUTIONS......................................................................................1-3

MACHINE SPECIFICATIONS ..............................................................................4-5

Engine ............................................................................................................4
Hydraulics ......................................................................................................4
Fluid Capacities .............................................................................................5

MACHINE OPERATION ........................................................................................6-11

Controls ..........................................................................................................6
Daily Inspection .............................................................................................7
Startup Procedure ...........................................................................................7-8
Sweeping Core ...............................................................................................9-10
Towing ...........................................................................................................11

HYDRAULIC SYSTEM DETAILS ........................................................................12-16

Hydrostatic Drive ...........................................................................................12
Loop Flushing Circuit ....................................................................................12
Steering Circuit ..............................................................................................12
Brush Control .................................................................................................13
System Description ........................................................................................14-15
Test Procedures ..............................................................................................16

MAINTENANCE & SERVICE ...............................................................................17-42

Air Cleaner .....................................................................................................17-18
Hydraulic System ...........................................................................................18
Radiator and Heat Exchanger ........................................................................19
Lubrication .....................................................................................................20-22
Brakes ............................................................................................................22
Core Drive ......................................................................................................23
Engine ............................................................................................................24
Tires ...............................................................................................................24
Storage ...........................................................................................................24
Air Conditioning Maintenance ......................................................................25-28
Broom Wafer Replacement............................................................................30-32
Troubleshooting .............................................................................................33-36

SCHEMATICS .........................................................................................................37-60
Wiring Diagrams ............................................................................................37-54
Hydraulics Diagrams .....................................................................................55-60
 SAFETY PRECAUTIONS

! CAUTION !
1. Keep all shields in place.

2. Stop machine, turn off engine and remove key to repair or clean.

3. Keep hands, feet, and clothing away from 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.

6. Check for hydraulic leaks with a piece of paper and not your hands. Hydraulic oil
under pressure can cause serious injury!

BE A SAFE OPERATOR BY
THINKING BEFORE ACTING AND
! BY READING YOUR OPERATORS !
MANUAL.

! 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 equipement,
there are many conditions that cannot be completely safe guarded against without
interfering with resonable accessibility and efficient operation.

A careful operator is the best insurance against an accident.

The complete observance of one simple rule would prevent many thousand serious
injuries each year.

Never attempt to clean, oil, or adjust a machine while it is in motion!

1
 SAFETY PRECAUTIONS
BEFORE OPERATING THIS
! MACHINE !
Read this manual completely. It contains information on safety and
maintenance procedures which must be followed to insure years of
trouble free service.

WARNING STATEMENTS
READ AND UNDERSTAND THE FOLLOWING
! WARNING LABELS BEFORE OPERATING !
THIS MACHINE

! WARNING !
OPERATOR MUST BE SEATED WITH SAFETY BELT ADJUSTED
PROPERLY & 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 seat 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 operator s hips.

! WARNING !
TRAVEL SPEED MUST BE GOVERNED BY
GOOD JUDGMENT. DO NOT OVERSPEED!

Although a high travel speed is available with the Broce Broom, we caution all operators
to use good judgment, especially on rough terrain.

! WARNING !
DO NOT OPERATE CORE UNLESS CHAIN
GUARD IS INSTALLED

On Chain Drive cores, the chain guard must be installed and be in serviceable condition
at all times when the broom is operating. This guard is designed to prevent personal
injury and to protect the chain from foreign debris.

2
 SAFETY PRECAUTIONS

! WARNING !
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 objects
several feet. This debris can cause serious injury to people and
damage to property. Always check that the area around, and in front
of theWARNING
broom core is STATEMENTS ANDadjusting
free of obstructions before DECALS the broom
angle or activating the core.

! WARNING !
NO RIDERS!
UNDER NO CIRCUMSTANCES SHOULD PASSENGERS BE
ALLOWED TO RIDE ON THIS MACHINE.
THERE ARE NO SAFETY PROVISIONS ON THIS MACHINE FOR PASSENGERS.
FAILURE TO HEED THIS WARNING COULD RESULT IN SERIOUS INJURY OR
DEATH.

! WARNING !
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 eyes.

3
 MACHINE SPECIFICATIONS

Engine Specifications:

Hydraulic System Specifications:

PROPEL PUMP

Displacement at MAX Angle ........................................................................................ 46 cc (2.8 CU IN)

Rated Speed .............................................................................................................................. 4000 RPM
MAX Speed .............................................................................................................................. 4100 RPM
MIN Speed ................................................................................................................................. 500 RPM
Case Pressure Continuous .......................................................................................... 1.7 BAR (25 PSI)
Case Pressure MAX ................................................................................................... 5.2 BAR (75 PSI)
System Pressure Continuous ................................................................................. 210 BAR (3000 PSI)
System Pressure MAX .......................................................................................... 345 BAR (5000 PSI)
Inlet Vacuum Continuous ........................................................................................... .8 BAR (5 IN Hg)
Inlet Vacuum MAX .................................................................................................. .7 BAR (10 IN Hg)
Charge Pressure Setting ............................................................................................. 19.5 BAR (283 PSI)
System Pressure Setting ........................................................................................... 280 BAR (4060 PSI)
Approximate Flow at 2400 RPM .................................................................................................. 26 GPM

PROPEL MOTOR

Displacement ................................................................................................................. 46 cc (2.8 CU IN)

Rated Speed .............................................................................................................................. 3600 RPM
MAX Speed .............................................................................................................................. 3600 RPM
Case Pressure Continuous .......................................................................................... 1.7 BAR (25 PSI)
Case Pressure MAX ................................................................................................... 5.2 BAR (75 PSI)
System Pressure Continuous ................................................................................. 210 BAR (3000 PSI)
System Pressure MAX .......................................................................................... 345 BAR (5000 PSI)

AUXILIARY PUMP

Displacement ............................................................................................................... 38 cc (2.32 CU IN)

MAX Speed .............................................................................................................................. 2500 RPM
MAX Continuous Pressure .......................................................................................................... 3000 PSI
Approximate Flow at 2400 RPM
Priority (Steering and Broom) ............................................................................................... 3 GPM
Secondary (Broom Rotation) ............................................................................................... 18 GPM
MAX Pressure Setting (Priority) ................................................................................................. 1600 PSI
MAX Pressure Setting * (Secondary).......................................................................................... 3000 PSI

*Relief Valve in the Broom Rotation Valve

4
 MACHINE SPECIFICATIONS
FLUID CAPACITIES

Component Fluid Type Quantity

DYNA-PLEX 21C Cursa Hydraulic Oil
Hydraulic Tank Multifunctional Medium 27 Gal.

Fuel #2 Diesel 27 Gal.

Radiator ETHYLENE GLYCOL 50/50 MIX 2.5 Gal.
API Classification CI-4, CE or CD
Engine Crankcase 10 Qts.
CCMC Specification D4 or D5
Rear Axle 85/140 Gear Lube 2 Qts. *

2-Speed Gear Box 85/140 Gear Lube 2 Qts. *

* 2 Quarts is approximate. Fill to the level of the filler plug.

ATTENTION
R-134a A/C Refrigerant
Factory Charge:
Kubota = 3.0 lb 2.0 oz (1.417 kg)
John Deere = 3.0 lb 2.0 oz (1.417 kg)
Caterpillar = 2.0 lb 12.0 oz (1.247 kg)
Cummins = 2.0 lb 10.0 oz (1.191 kg)

Ester Oil Charge:

Compressor = 8.0 oz
System = 4.0 oz

5
 MACHINE OPERATION
The Broce Broom is hydrostatically driven. The directional control is achieved through

the machine forward. Heel down shifts the travel to reverse. Rate of travel is governed
by the distance the pedal is depressed and the throttle position. The pedal will return to
neutral when the pressure is released.

Familiarize yourself with the following controls before operating this machine.

1. Brake pedal
2. Directional Control
3. Broom on/off
4. Locking throttle
5. Parking brake (lower left side of seat)
6. Ignition switch
7. Two speed shifter
8. Broom Control Joystick
9. Broom Core Lock Switch

9 8

6 4 3

6
 MACHINE OPERATION
DAILY INSPECTION
Prior to initial startup of the machine each day, the following inspection checks must be
performed:

1. Visually inspect the entire machine for damage and fluid leaks. Repair critical
items before machine is used.

2. Check all fluid levels; engine oil, radiator, and hydraulic reservoir, etc. Fill fluid
reservoirs if necessary.

3. Check wheels and tires for excessive wear or damage; also check air pressure and
lug nut tightness.

4. Check pre-cleaner bowl and air cleaner service indicator and service if indicated.

5. Chain guard, seat belt, core cover, and rubber rock guard should be installed and
serviceable.

6. Lights, windshield wipers, reverse alarm, etc., must be in operating condition.

7. Test brakes before operating this machine. Refer to BRAKES area in the
MAINTENANCE Section in this manual for details.

8. Check water system filters, nozzles screens and cycle system.

Any defects or damage found during this inspection must be repaired before
operating this machine.

MACHINE STARTUP

! CAUTION !
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. Turn the key switch to the starting position (all the way to the right). Add fuel as
necessary using the hand oper
Release the key switch when the engine starts.

! IMPORTANT !
Do not exceed 1500 RPM until the hydraulic fluid has warmed up.

7
 MACHINE OPERATION

3. Choose the desired gear using the two-speed shifter located on the right-hand side
of the dashboard. Low gear is normally used while sweeping in order to maintain
sufficient RPM, to run the hydraulics. Leave the two-speed in Low gear until the
operator is familiar with the machine. High gear is used for travel only. Optimal

of 1800-2000 rpm in Low gear with forward travel speed of 2 ½ - 5 mph.

4. After gear selection, raise engine RPM to about half throttle. Release parking
brake. Slowly depress control pedal in the desired direction. Engine speed may
be adjusted to obtain desired travel speed.

! IMPORTANT !
Do not propel this machine with the parking brake engaged. This will damage the
rear brake assemblies.

5. Do not over speed! Although a high rate of travel is available with the Broce
Broom, we caution all operators to use good judgment, especially on rough
terrain.

6. If the control pedal is released while traveling, the machine will slow down
Using Dynamic Braking at low
speeds is fine as long as the operator is ready to use the brake pedal if needed.

7. Do not reverse the direction of travel while the broom is in motion. This could
damage the drive train and cause brush distortion and imbalance.

8.
position before stopping the engine. This prevents the core from drifting down to

These flat spots can cause the broom to bounce or hop while sweeping.

9. To stop the engine, turn the key back to the center position. The parking brake

8
 MACHINE OPERATION
SWEEPING CORE OPERATION

RAISE/LOWER/FLOAT DETENT

To raise the sweeping core, place the broom core lock

switch on the dash in the position and pull the
joystick to the position until the core is raised all
the way. The joystick will return to the center position and
core height will be maintained.

To lower the core during normal sweeping conditions,

push the joystick to the position. The
position will allow the core to maintain the
ideal contact with the surface to be swept while allowing it
to float over bumps or contours. This valve is equipped
with a feature called .
It should only be used under the heaviest sweeping
conditions. The down pressure adjustment range is
between the center position and the float detent position.
To adjust the core height downward, slowly move the
handle from the toward the float position. The core will
begin to move downward. Release the handle when the Proper Sweeping Height
desired height has been achieved. The figure shows the
optimum broom height for most sweeping conditions. Using the proper height will also
extend the life of the broom.

! IMPORTANT !
The operator must maintain continuous adjustment on the core while the down
pressure option is being used. This feature does not allow the core to float over
contours in the surface to be swept. Therefore, the operator must constantly make
these adjustments. Overuse of the positive down pressure feature will cause
excessive wear and shorten the life of the broom. We recommend using the float
detent feature during all but the heaviest sweeping conditions.

RIGHT/LEFT OPERATION OF BROOM

The broom core may be set at any angle from 45 left to 45 right, simply moving the
handle in the corresponding direction. Release the handle when the desired angle is
achieved.

BROOM ON/OFF

The Broom Core motor is activated when the handle is moved to the
position.

9
 MACHINE OPERATION

SWEEPING TIPS

recommended engine speed of 1800-2000 rpm in Low gear with

forward travel of 2 ½ - 5 mph.

1.
the forward travel speed, but maintain high engine speed. Slowing the forward
travel speed of the machine down will help prevent you from having to make a
second pass over the sweeping area with the broom.

2.
Positive Down Pressure
mo Float

3. 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.

4. If the dust cloud becomes so thick that it obscures your vision, 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.

5. Ensure that the operator of the machine is properly trained and follows all safety
procedures described in this manual.

10
 MACHINE OPERATION
TOWING:
The Broce Broom may be towed without removing the drive shaft, but it is critical to
ensure that the gearbox is in neutral to prevent serious damage. Use caution while
towing since the broom does not have a suspension system to absorb the bumps.

1. Ensure gearbox lever on dash is in Neutral posi-

tion. Start engine, shift to Neutral and carefully
move control pedal forward and back slightly to
ensure Neutral position.

2. Release Parking Brake.

3. Raise and Lock broom core.

5
4. Secure tow bar to towing vehicle and connect
safety chains and lights.

5. Turn steering cylinder valve (under front bumper)

to OPEN position to allow front wheels turn freely OPEN VALVE FOR TOWING (VALVE CLOSED IN PHOTO)

while towing.

6. If tow bar is equipped with SURGE BRAKE:

a) Turn valve on tow bar to OPEN.

b) Turn valve on master cylinder (under

front, left floorboard of broom) to
CLOSED position.

- DO NOT EXCEED 45 MPH WHILE TOWING.

- DO NOT TOW WITH WATER IN THE SPRAY TANK.

- RESET THE VALVES FOR BROOM OPERATION.

6a
SURGE BRAKE ONLY - OPEN VALVE FOR TOWING (VALVE CLOSED IN PHOTO)

6b
SURGE BRAKE ONLY - CLOSE VALVE FOR TOWING (VALVE OPEN IN PHOTO)

11
 HYDRAULIC SYSTEM DETAILS
The Hydraulic System on this machine operates the hydrostatic drive, loop flushing
circuit, steering circuit, brush functions, and brush rotation. It employs two supply
pumps sharing the same reservoir. In order to simplify the description of this system, it
will be separated into five parts.

Hydrostatic Drive:

The basic hydrostatic drive system has evolved over the years, beginning with
Sundstrand then to Eaton and now current production machines are equipped with Sauer-
Danfoss drives. A current schematic and trouble-shooting guide are included in this
manual.

This system utilizes a Sauer-Danfoss variable displacement piston pump and a fixed
displacement piston motor. Oil, supplied from the reservoir, passes through a 10-micron
filter with a bypass setting of 3 psi, before entering the pump. Pressurized oil from the
pump is delivered to the motor by high pressure hoses.

Machines with serial number 90188 and higher are equipped with a Sauer-Danfoss
hydrostatic drive system.

Eaton and Sauer-Danfoss components are available from the factory, including the latest
revisions and recommend that customer repaired units be upgraded.

Loop Flushing 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.
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 Manufacturing Co.,
Inc. for exchange of new or rebuilt components or repair authorization.

Steering 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 1600 psi. The steering unit is an orbital
type metering valve that supplies oil to the steering cylinder and also has power beyond
capabilities that are used to control the brush functions.

12
 HYDRAULIC SYSTEM DETAILS
Brush Functions:

Forward movement of the joystick lever will lower the

core. Pushing the lever all the way forward until it
locks, puts the core in the preferred float mode.
Pulling the lever back will raise the core. Movement to
the right will rotate the core to the right, and movement
to the left will rotate the core to the left.

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 10-
micron filter with a bypass setting of 25 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 upon 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 located aft of the
joystick. Moving the lever forward will turn on the brush. Pull the lever back to stop
brush rotation. Oil flows from a-port on the rotation valve to upper port on the core
motor to receive counterclockwise rotation, b-port is plugged. The hose on the lower port
of the motor returns the oil to the return manifold, filters it, and returns it to the tank. On
units equipped with dual rotation, b-port on rotation valve sends oil to the lower port on
the motor for clockwise 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, is filtered,
and returned to the tank.

There are two types of core motors used for broom 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 an external drive, a-port on the rotation valve flows to the
front port on the core drive motor, the rear port flows back to the return manifold, is
filtered, and returned to the tank. B-port on the rotation valve is plugged.

13
 HYDRAULIC SYSTEM DETAILS
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 3 gpm.
The exhaust flow of approximately 23 gpm powers the brush rotation valve.

STEERING UNIT: The steering unit is an open center type motor that has power
beyond and dead steering capabilities. The power beyond capability is used to power the
brush functions and dozer blade control valve if equipped.

STEERING CYLINDER:

BRUSH FUNCTION VALVE: The brush function valve is a two-spool monoblock

design that receives its oil supply from the steering unit power beyond port.

LIFT CYLINDER:

SHIFT CYLINDER:

BRUSH ROTATION VALVE: The brush control valve is a single spool, two-position,
monoblock design valve.

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, SAE
styles mount with a splined shaft used on the internal drive cores.

RETURN FILTERS: The return filter is a 10-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 control valve, the curb sweeper
control valve, the broom 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 !

starting the engine. If the return valve is closed, the return

filter housing will be destroyed.

14
 HYDRAULIC SYSTEM DETAILS
RESERVOIR: The hydraulic reservoir has a 27 US gallon capacity, with an inlet
strainer (100 mesh), lockable cap, sight level indicator with thermometer, suction screen
in the bottom outlet (100 mesh), and shut-off ball valves.

HOSES AND ADAPTERS: Starting with Serial Number 90188, all hose adapters are
boss O-ring/flat face in the cylinders, valves, steering unit, pumps, and motors. The tank
outlets remain piped through the shut-off valves, then change to flat-face type adapters.
All the hoses are flat-face type design.

References are made in the parts manual sections to hydraulic hoses and adapters. These
references are for informational purposes only. Broce Manufacturing does not normally
sell hydraulic hoses or adapters through the parts department. Please source these parts
locally.

SYSTEM PLUMBING: The system plumbing diagrams can be found in the Hydraulic
Section of the parts manual.

NOTE: All standard machines are equipped with the positive down pressure
feature. If you would like to defeat this feature, use the following procedure.

1. Disconnect the lower hose on the core lift cylinder and allow the oil to drain, then
reconnect it.

2. Disconnect the hose from A-port on spool #1 on the two-spool valve and connect
a breather in the end of the hose.

3. Remove the hose adapter from the spool valve and install a 6 Boss O-ring plug.

4. Secure the loose hose to the other hoses with a wire tie.

Note: 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 of the system.

15
 HYDRAULIC SYSTEM DETAILS

SYSTEM TEST PROCEDURES:

Run engine about 1/2 throttle when taking pressure readings.

Checking the pressure on the steering circuit can be done as described below:

1. 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. Tee into the pressure port on the steering motor, then fully stroke the steering
cylinder and read the pressure. It should read 1500 psi.

3. Remove the 8 Boss O-ring plug on the inlet side, in the face of the two-spool
valve, and insert a pressure gauge. Fully stroke either cylinder and check the
pressure. The gauge should read 1500 psi.

4. There are pressure ports on the base of each of the cylinders. Remove the 1/4 IPT
plug and insert a pressure 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 the lever to the right position and hold. The gauge should read
1500 psi.

Check the pressure of the rotation valve in the following ways:

1. 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 the ground, system pressure will be
about 600 psi. Putting down pressure on the brush until it stalls will raise the
pressure and the gauge should read 3000 psi.

2. Remove the 10 Boss O-ring plug in the face of the brush rotation valve, in line
with the relief valve. Turn the brush on and repeat above procedure.

3. Tee into A-port on the rotation valve and repeat the test procedure above.

16
 MAINTENANCE
The manufacturer 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 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
! IMPORTANT !
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 air cleaner must be

engine life will be reduced. This machine is equipped with a dry type air cleaner,
bowl type pre-cleaner, and a restriction type service indicator as standard
equipment.

An optional dual element air cleaner and/or a vane type pre-cleaner are also available.

Under normal 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 ensure 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 Service Indicator
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 machine is equipped with a dual element air cleaner,
DO NOT remove the safety element until you are ready to
replace it! DO NOT attempt to clean the safety element!
It is strictly a disposable type element.

Clean the dirt from the inside of the canister and the end
cover. Hold the element so that the opening is on top, and
with your other hand, gently pat around the sides of the
element to loosen the dirt. DO NOT tap the element
against a hard surface as this can cause damage to the
element itself. Air pressure may be used to clean dirt from End Cover
Filter
the element, but the air pressure must be reduced to less Element Clamp
than 30 PSI. Using an air nozzle, clean the element from
the inside, moving the nozzle up and down in the direction

17
 MAINTENANCE
of the pleats. DO NOT direct the air stream against the outside surface of the element, as
it will force the dirt through the element fabric, resulting in damage.

! CAUTION !
When using compressed air, clear the area of bystanders, guard against flying
debris, and wear personal protection equipment including eye protection.

To Clean Element:

If the element is coated with oil or soot, wash in a solution of warm water and filter
element cleaner (equal to R36571 Filter Element Cleaner). Let the element soak at least
15 minutes, then agitate gently to flush out dirt. Rinse the element thoroughly from the
inside with clean water. Use an element cleaning gun or a free running hose. Keep the
pressure under 40 PSI to avoid damage to the element. Allow the element to dry
completely before using. This usually takes from one to three days. DO NOT oven-dry
or use drying agents. Protect element from freezing until dry. The element must be
inspected for damage before it is reinstalled. Hold a bright light inside the element and
check carefully for holes. Discard any element that shows the slightest hole. Be sure that
the outer screen is not dented. Vibration will quickly wear a hole in the filter. Make sure
the filter gasket is in good condition. If gasket is damaged or missing, replace the
element. Seal the element in a plastic bag and store in a shipping container to protect
against dust and damage.

Service Schedule:

DAILY: A restriction indicator is installed on the outside of the air cleaner. This
restriction lets the operator know if the air cleaner element is dirty. Check and/or clean
air intake element daily at a minimum, more often if necessary depending upon sweeping
conditions.

250 HOUR: Replace both service element and safety element every 250 hours or sooner
if needed or damaged.

HYDRAULIC SYSTEM
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 of the hydraulic tank. When it is time to add or
replace oil in the system, refer to the Machine Specifications section for recommended
hydraulic oil specifications.

Periodically check all hydraulic hoses. As a general guide, if unsure of the condition of a
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 of failure. Again,

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 MAINTENANCE
cleanliness must be stressed during this type of maintenance. Contamination of this
system will cause pump and/or motor failure. Avoid servicing hydraulic system
components in the field where cleanliness of the environment cannot be controlled.

RADIATOR AND HEAT EXCHANGER

! CAUTION !
Do not attempt to clean the radiator or heat exchanger while the engine is running.
If hands or equipment come in contact with spinning fan blades, serious injury will
result. Engine must be completely stopped.

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 upon 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.

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 MAINTENANCE
LUBRICATION
BOLSTER ASSEMBLY

Use standard automotive type grease on each Oil Light Bushings

of these lubrication points. While servicing
these points, inspect all ball joints and rod ends
for slack. If slack is found in any part of this
suspension, including the bolster pivot
bushings, replace the worn parts. Refer to
figure on right for lubrication points on Bolster
Assembly.

STEERING CYLINDER

Lube upper and lower mounts and steering shaft tie

rod ends.

Lube

Front Axle Assembly

DRIVE SHAFT

There are three lubrication points on the

drive shaft. These also require standard
automotive type grease. While servicing
the drive shaft, check for loose fasteners
and slack in the U-joints. Replace worn
parts as necessary.

Both the front suspension and the drive Lube

shaft should be serviced every time the
engine is serviced. More frequent
servicing of these components will
extend their life.

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 MAINTENANCE
TWO-SPEED GEAR BOX

Check the fluid level in the Two-Speed Gear Box and

differential every 100 hours or sooner if signs of leakage
appear. Change the lubricating oil after the first 25 hours
and then every 1000 hours thereafter. Drain the oil while the
unit is warm. Replace with SAE 80W-140W gear oil, up to
the oil level plug.

Two-Speed Gear Box

DIFFERENTIAL
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.

CORE/BRUSH BEARING

This is a sealed bearing and may require no lubrication

throughout its service life. If lubrication is deemed
-
at 250 hour intervals is recommended. Seals are often
destroyed by over-greasing sealed bearings.

ENGINE LUBRICATION

for recommendation and procedures for servicing the engine.

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 MAINTENANCE

BROCE BROOM LUBRICATION CHART

Initial (Hours) Thereafter (Hours)
Q
ITEM T REMARKS 25 50 100 100 250 500 1000
Y
Engine Oil 1 Change Oil O O
Two-Speed Gear Box 1 Change Oil O Check O
Differential 1 Change Oil O Check O
Hydraulic Disposable
1 Replace O O
Filter
Hydraulic Oil 1 Replace O
GREASE ZERKS
Tie Rod End 2 Lubricate O
Steering Cylinder
1 Lubricate O
Mount
Knuckle 4 Lubricate O
U-Joints 2 Lubricate O
Core/Brush Bearing 1 Lubricate O
Drive Line Assembly 1 Lubricate O

BRAKES:
This machine is equipped with self-adjusting four-
wheel hydraulic brakes with a mechanical parking
brake. The operation of the brakes should be tested
there may be air in
one or more of the brake lines and 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 Master Cylinder Access
frequently, especially if the brake lines show signs of
leakage. Drain and replace brake fluid with DOT 3
fluid every two years.

Inspect brake lines every 50 hours of operation for leaks and/or damage. Replace front
and rear brake hoses every two (2) years. Inspect mechanical parking brake linkage for
proper adjustment, routing and/or damage ever 50 hours.

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 MAINTENANCE

! 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.

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
and tighten as needed.

FRAME, GUSSETS, AND WELDS:

The frame on this machine was designed to withstand normal operating conditions,
however under abuse components and welds can fail. Periodically check all frame welds
and gussets for development of fatigue and stress cracks.

CORE DRIVE:
The direct drive uses a core motor with a splined shaft
that fits a hub fastened inside the broom core mandrel. Hub
The direct drive core is preset at the factory and does not
normally need adjusting unless the drive hub begins to
show uneven or excessive wear. To adjust, remove the
broom from the machine and remove all of the wafers
from the core frame (see Broom Wafer Replacement
Set-screws
Section for details on removing the broom core and
wafers). Loosen the lock bolts and lock collars slightly.
Install the core mandrel 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 Direct Drive Core
the lock collar on the pillow block bearing at the other end
of the broom core.

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 MAINTENANCE
ENGINE:
The normal engine operation and maintenance procedures are covered in a separate
manual, which is furnished by the engine manufacturer.

! 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 operating environment will cause quicker than normal erosion or 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:
Inflate tires to manufacturer pressure as specified on the tire sidewall.
This will provide the longest tire life. A lower pressure will provide a more comfortable
ride, and make rough off-highway conditions easier to negotiate, but is not
recommended.

STORAGE:
If storing the Broce Broom for more than 30 days:

1. Change engine oil.

2. Charge battery and disconnect terminal leads.
3. Fill fuel tank and add fuel stabilizer.
4. Add small amount of oil into cylinders and crank engine a few times.
5. Grease all pivot pins and perform standard lubrication procedures.
6. Apply grease to all exposed cylinder rods.
7. Retract all cylinder rods.

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 MAINTENANCE

Air Conditioner Preventive Maintenance

A well maintained A/C system would save on downtime and premature component
failures.

Weekly inspections or every 2 days in severe environments should include:

1) Inspect compressor clutch drive belts (tightness, wear).

2) Inspect compressor-mounting brackets (bolts, alignment).
3) Inspect mounting hardware on evaporator unit and condensers.
4) Inspect air intake filter. Clean or replace filter.
5) Inspect evaporator and condenser coils. Clean using air pressure. (DO NOT
USE WATER OR PRESSURE WASHER).
6) Inspect hose and wire harness for proper routing. Leaks and wear.

Helpful Hints

Make sure the evaporator intake area is not obstructed (i.e. toolboxes, clothing, lunch
boxes, etc.)

Manual thermostat on our system, when rotated clockwise to the stop position will not
allow A/C 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 ¼ turn.

Broce thanks you for purchasing our unit/s. It is our endeavor to provide you with a
quality A/C unit with trouble-free service.

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 MAINTENANCE

TROUBLESHOOTING THE A/C SYSTEM

Troubleshooting Chart
The following chart lists some of the common problems that plague A/C 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.

A/C TROUBLESHOOTING CHART

SUCTION DISCHARGE POSSIBLE PROBLEM

1. Restriction between the discharge of the compressor and inlet of receiver

drier. Check condenser and condenser lines for a point of restriction that may
LOW HIGH
create flashing. Condition indicated by an extreme differential in temperature
at the point of restriction.

1. Possible restriction between drier and suction side of compressor.

LOW LOW 2. Low refrigerant charge _ bubbles in sight glass.

3. Restriction at drier or expansion valve _ sight glass usually clear.

1. Air in system.

2. Overcharged system (oil or refrigerant).

HIGH HIGH
3. Condenser fan not working.

4. Air flow restriction on condenser

1. Weak compressor _ indicated by accelerating the engine and watching the

suction and discharge readings. Normally, suction moves lower and
discharge side should rise.
HIGH LOW
2. Expansion valve flooding or stuck open _ this would cause high and low
sides to become less distinguishable.

ATTENTION
R-134a A/C Refrigerant
Factory Charge:
Kubota = 3.0 lb 2.0 oz (1.417 kg)
John Deere = 3.0 lb 2.0 oz (1.417 kg)
Caterpillar = 2.0 lb 12.0 oz (1.247 kg)
Cummins = 2.0 lb 10.0 oz (1.191 kg)

Ester Oil Charge:

Compressor = 8.0 oz
System = 4.0 oz

26
MAINTENANCE

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 MAINTENANCE

Warranty Claim Form for Broce A/C Systems

and Components

Ambient temperature before repairs were

made:________________________________

Static Pressure before repair is made: High:_________________ Low:_____________

Running Pressure before repair is made:_____________________________________

Any odd or unusual noises before repairs are made:

______________________________________________________________________

______________________________________________________________________

How much refrigerant was recovered:______________________________________lbs.

Automated flush of system (by flush mechanic) Yes:______________ No:____________

Manual flush (by tech changing oil and/or drier) Yes:_____________ No:_____________

Repairs made and parts replaced:

_______________________________________________________________________

_______________________________________________________________________

Ambient temperature after repairs are made:____________________________________

How much refrigerant was charged:__________lbs. __________oz. (Virgin or Recovered)

Static Pressure: High:_____________ Low:______________

Running Pressure: High:____________Low: ______________

Vent Temperature:_________________________________________________________

Cab Temperature:_________________________________________________________

Broom S/N:______________________________________________________________

Hr.:_____________________________________________________________________

Date:___________________________________________________________________

Company or Facility who made repairs:

________________________________________________________________________

Technicians initials:________________________________________________________

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MAINTENANCE

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 MAINTENANCE

BROOM WAFER REPLACEMENT

wo
different lengths of cores are available. The standard eight-foot core requires
approximately 54 wafers and 53 metal spacers (this will vary by wafer manufacturer and
type of end-caps ordered on broom). The ten foot core requires 68 wafers and 66 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 manufacturer.

DIRECT DRIVE CORES (Standard Equipment):

1. With the core resting on or near the ground, remove the bolts securing the pillow
block bearing to the core support frame.
2. 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.
3. Angle the core toward the rear of the machine and slide it out from under the
sweeper.
4. Clean the spindle from the lock ring out using an emery cloth or sandpaper.
5. Loosen the setscrew and remove the lock ring and pillow block bearing.
6. Remove the spindle and install the Broce Core Service Ring in its place.
7. Remove the end cap from the drive end of the core.
8. Refer to Steps 11 through 20 of the chain drive section for core disassembly and
rebuild procedures.
9. Raise the core support frame and slide the rebuilt core under the sweeper. The
core will have to come in from an angle in order for it 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.
10. Lower the support frame slowly until the motor mount is centered in the core.
11. Using a back and forth twisting motion, pull the core onto the splined shaft.
12. Install the pillow block bearing on the right side of the core using the original
mounting bolts.
13. 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.
14. 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 of this mount is preset at the factory. If it does become
necessary, refer to the alignment procedures in the MAINTENANCE section of this
manual.

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 MAINTENANCE
CHAIN DRIVEN CORES (Optional):
1. Remove the chain guard.
2. 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 locking
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 spindle.
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 in place of the spindle.
10. Remove the end cap at the opposite end of the core.
11. Using a hoist or winch with a minimum capacity of 1,000 lbs., raise the core
approximately 6 to 8 inches off the ground.
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 wafers as this could
result in a fire.
13. Lower the core and remove the service ring. Re-install the spindle. Loosen the
four bolts securing the end cap until they are flush with the inside of the 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. If 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.
15. 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 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 wafer, finish out with a wafer. When
assembling a half poly/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 poly/half wire core, the pattern should be; poly wafer,
spacer, wire wafer, spacer, and then repeat the sequence. If this pattern ends at
the top with a wire wafer, substitute a poly wafer.
Each wafer has a locking tab located on the inside of the crimp ring. This tab
will lock the wafer against the core frame tubes to keep it from 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.

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 MAINTENANCE
17.
which are 180 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 diagonal fashion until the end cap is tightly secured to the core.
18. 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. 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.
19. 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.
20. Using emery cloth or sandpaper, clean both spindles to remove any burs or tar
which may interfere with sprocket or bearing installation.
21. Install the sprocket as using the flat washers as spacers. The sprocket must be
installed in this manner in order to ensure proper chain alignment.
22. Slide the rebuilt core back under the sweeper.
23. 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 the bearings are secure, raise the core, and align
the chain drive. Once the chain drive alignment has been achieved, recheck the
lock rings to ensure that they are secure and reinstall the chain guard.

If you have any questions regarding these procedures or would like to obtain the core
service ring and stand, please contact your nearest dealer or call us direct at (620)
227-8811.

Core Service Ring and Stand

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 MAINTENANCE

TROUBLESHOOTING
Before troubleshooting can be done, characteristics of normal operation of this machine
must be understood. As discussed earlier in this manual, this system uses an open center
control valve. This can lead to the belief that a problem may exist when in fact, the
system is operating normally.

NORMAL OPERATION

With the engine running approximately 1/2 throttle and the core motor turned off, the lift
and shift cylinders will actuate quickly and smoothly. Once the core motor is started, the
cylinder action will slow down dramatically. In fact, if the core is not contacting the
ground, the shift cylinder may not move at all unless the engine is at full throttle. The lift
cylinder should be able to lift the core slowly off the ground but will probably not reach

approximately half of what it is if the brush is not spinning. When slight positive down
pressure is applied to the broom core, the shift cylinder performance should improve
slightly but the lift cylinder performance will remain basically unchanged. As more
down pressure is added, the core will eventually stop spinning. The system will be
.
spinning.

Although these characteristics may sound less than adequate, in real working applications
they are almost unnoticeable. Most of the time that small angle adjustments are made,
the brush is in use and the cylinder operation is adequate. Most full swing left to right
angle adjustments are made while turning the machine around or while lining the
machine up for sweeping. It is best at these times to not have the brush spinning in order
to prevent throwing debris in an unwanted direction. Approximately 95% of all sweeping
is done in the float position. There is generally no reason to lift the brush while
sweeping. Most lifting is done when the sweep has been completed and the sweeper is
ready to be repositioned. The brush is normally turned off at this time.

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 MAINTENANCE
COMMON PROBLEMS

PROBLEM PROBABLE CAUSE SOLUTION

Brush stalls while 1. Too much positive down 1.

sweeping pressure position

2. Too much material to move 2.

Make two passes
3. Weak Pump
3. Check system
pressure
4. Relief valve stuck open
4. Check relief valve
5. Worn hub or shaft (Broken
key on chain drive core 5. Replace hub and/or motor
motor)

6. Internal leakage in motor 6. Follow steps 1-5. If all

checks out, replace motor.

Brush bounces or 1. Worn/loose core mount pins 1. Drill out and replace
le and/or worn mount bushings bushings and pins that
sweeping mount the lift cylinder and
the core hanger. These
must be extremely tight
(zero tolerance). Any gaps
whatsoever can cause
bouncing.

2. Loose circle bearings 2. Tighten circle bearings

underneath the circle.

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 MAINTENANCE
PROBLEM PROBABLE CAUSE SOLUTION

Broom Core drifts 1. Too much material to sweep 1.

from preset angle position and make two
while sweeping passes.
2. Leakage in shift cylinder
2. Test system pressure. If
pressure OK, rebuild or
replace cylinder.

Broom will not stay 1. Loose or worn Float Detent 1. Check, tighten or replace
in FLOAT position detent assy.

Core motor shaft seal 1. String line wrapped around 1. Remove string line and
leak shaft reseal motor

2. Over use of positive down 2. Reseal motor. Instruct

pressure feature (Too much operator to use down
side load) pressure only when
necessary.

3. Core misaligned 3. Re-align motor mount.

Refer to Maintenance
section for procedures.

Core motor shaft 1. Over use of positive down 1. Replace motor. Instruct
broken pressure feature (Too much operator to use down
side load) pressure feature only when
necessary.

2. Core misaligned 2. Replace motor. Re-align

motor mount. Refer to
Maintenance section for
procedures.

Return filter blown 1. Shut-off valve closed at start 1. Replace filter and housing.
or housing broken up. Open all shut-off valves
before starting engine.

2. Core cover can bounce

2. Core cover contacts filter while sweeping or driving
while driving and/or and bump filter. Adjust
sweeping shift cylinder clevis 2-3
turns outward.

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 MAINTENANCE
PROBLEM PROBABLE CAUSE SOLUTION

Hydraulic System 1. Relief valve stuck open 1. Check relief valve.

has very little power.
Power steering 2. Weak pump 2. Check system pressure.
operates OK.

No hydraulic power 1. Bad gear pump 1. Replace gear pump.

including steering but
hydrostatic system
seems OK.

No hydraulic power 1. Broken shaft or coupler in 1. Refer to hydrostatic trouble

including steering hydrostatic pump shooting section in Sauer-
and hydrostatic drive. Danfoss Manual.

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