Broce Manufacturing Company, Inc.

WARRANTY REGISTRATION

Purchased From (Dealership)

Company: ___________________________________________________
Address: ___________________________________________________
City: _________________________ State: ____ ZIP: ________
Delivery Date to Dealer: ___ / ___ / ___ Unit Hours: _______________
Model Number: __________ Serial Number: ____________

Purchaser

Company: ___________________________________________________
Address: ___________________________________________________
City: _________________________ State: ____ ZIP: ________
Delivery Date to Owner: ___ / ___ / ___ Unit Hours: _____________

Purchaser - Type of Business

Construction/Highway Rental Asphalt Contractor
Equipment Dealer Municipality Other

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 of Liability are found in the Warranty pages enclosed in the Parts
and Operators Manuals.

3. Broce Manufacturing Co. Inc. reserves the right 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 Co. Inc., the warranty begins
at the date of delivery to the Dealership.

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, Kansas warrants 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 designated 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
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 Employer’s Signature Employee’s Signature

 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
free of obstructions before
ANDadjusting
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:

See Engine Manufacturer’s Manual (included) for 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 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 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 operated locking throttle near the operator’s right hand.
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
sweeping is normally achieved at manufacturer’s recommended engine speed
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
rapidly. This is called “Dynamic Braking”. 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. The core should be in the raised position and the core switch in the “LOCK”
position before stopping the engine. This prevents the core from drifting down to
the ground and creating a “flat spot” in the brushes while the machine is parked.
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
must be set prior to leaving the operator’s seat.

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 “SWEEP” position and pull the
joystick to the “RAISE” 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 “FLOAT” position. The
“FLOAT” 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 “POSITIVE DOWN PRESSURE”.
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 “BROOM ON”
position.

9
 MACHINE OPERATION

SWEEPING TIPS

Optimal sweeping is normally achieved at manufacturer’s

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

1. If the broom starts to “hop” or “bounce”, the propelling speed is too high, reduce
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. In areas where the dirt is “caked”, try to clean it by going over it a second or third
time. If this doesn’t clear the dirt, use the “Positive Down Pressure” feature. In
most cases, the “Float” position will yield the best results.

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: 2” X 10” double acting 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: 2” X 8” double acting cylinder

SHIFT CYLINDER: 2” X 16” double acting 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 !
Make sure all three valves are in the “OPEN” position before
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.

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 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
maintained constantly. If the air cleaner is not serviced properly, the machine’s
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
necessary however, no more than “one-shot” of grease
at 250 hour intervals is recommended. Seals are often
destroyed by over-greasing sealed bearings.

ENGINE LUBRICATION

Refer to the Engine Manufacturer’s manual (included)

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
daily. If the pedal feels “spongy”, 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’s recommended 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

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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

The standard Broce Broom core uses 10” x 32” flat wafers and metal spacers. Two
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. Install the end cap using two (2) 1/2” x 3” all thread bolts in two of the holes
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
its full stroke. When the brush is in “FLOAT” position, the cylinder speed will be
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
“relieving.” Move the handle to the “FLOAT” of “RAISE” position to restart the brush
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. Move handle to “FLOAT”
sweeping pressure position

2. Too much material to move 2. Move handle to “FLOAT”

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
“hops” while 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. Move handle to “FLOAT”
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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HD+ 90 VV-S
Tandem roller with two vibrating roller drums
Tandem rollers Series HD+ / Series H185

HIGHLIGHTS HD+ Machine dimensions

Total length (L) mm 4600
> Diesel engine with high power and low
sound level Width (B) mm 1800

Total height (H) mm 3050

> Pressure sprinkler system with 2 water Drum width (X) mm 1680/1680
pumps; spray nozzles visible from driver
seat Height loading, min. (Hl) mm 2185

> Driver seat including steering wheel and

instrument panel can be rotated and
moved
> Clear view of drum surface, its outer edge
and working environment
> Crab steering to increase working width
> Hydrostatic all-wheel drive for excellent
hill climbing ability

EU Stage
IIIA / EPA
Tier 3
TECHNICAL DATA Unit HD+ 90 VV-S
EQUIPMENT
Weights
Operating weight with cab kg 9860 OPTIONAL EQUIPMENT
Operating weight with ROPS kg 9700
Operating weight, max. kg 12380
Static linear load, front/rear kg/cm 29,8/28,9

Machine dimensions
Total length mm 4600
Total height with cab mm 3050
Height loading, min. mm 2185
Wheel base mm 3400
Total width with cab mm 1800
Max. working width mm 1850
Ground clearance, left/right mm 790/790
Turning radius, inside mm 5250

Drum dimensions
Drum width, front/rear mm 1680/1680
Drum diameter, front/rear mm 1200/1200
Drum thickness, front/rear mm 17/17
Drum type, front smooth/divided
Drum type, rear smooth/divided
Track offset, left/right mm 170

Diesel engine
Manufacturer DEUTZ
Version TCD 2012 L04 2V
Number of cylinders 4
Power rat. ISO 14396, kW/PS/rpm 100,0/136,0/2300
Power rating SAE J1349, kW/HP/rpm 100,0/134,0/2300
Emission standard EU Stage IIIA / EPA Tier 3

Drive
Speed, working gear km/h 0-6,0
Speed, transportation gear km/h 0-12,0
Regulation, infinitely variable Hammtronic
Climbing ability, vibration on/off % 35/40

Vibration
Vibration frequency, front, I/II Hz 42/55
Vibration frequency, rear, I/II Hz 42/55
Amplitude, front, I/II mm 0,61/0,39
Amplitude, rear, I/II mm 0,61/0,39
Centrifugal force, front, I/II kN 84/94
Centrifugal force, rear, I/II kN 84/94

Steering
Oscillation angle +/- ° 10
Steering, type Articulated steering
Tandem rollers / Series HD+ EU Stage IIIA / EPA Tier 3/ HD+ 90 VV-S 05.17 2233226 en-GB V3
Sprinkler system
Water sprinkler, type Pressure

Tank capacity/Fill capacity

Fuel tank, capacity L 150
Water tank, capacity L 834

Sound level
Acoustic power LW(A), sticker
Acoustic power LW(A), measured
108
107
Further data on request / subject to change
Illustrations may contain optional features.

HAMM AG
Hammstraße 1
D-95643 Tirschenreuth
Tel. +49 9631 80-0
Fax +49 9631 80-111
www.hamm.eu
 PS360C
Pneumatic Tire
Compactor

Cat® 3054C Turbocharged Diesel Engine

Gross Power 98 kW 130 hp
Maximum Operating Weight 25 000 kg 55,115 lb
Rolling Width 2.28 m 7' 6"
 Reliability and Versatility You Can Depend On
These machines are ideal for applications such as wear courses and binder courses as well as
compaction of natural soils and materials with lime or cement.

Engine Propel System Operator’s Station

The PS360C pneumatic compactor is
powered by the 98 kW (130 hp)
Caterpillar® 3054C turbocharged diesel
engine. The Cat 3054C engine meets
U.S. EPA Tier 2 engine emission
standards. The high torque, low rpm
engine provides power and fuel
efficiency.
Page 4
The hydrostatic propel system
combines smooth starts and stops with
plenty of torque. The “High Drive”
concept does not use any chains. The
drive motors, secondary brake and
hoses are protected within the machine
frame. An oscillating front and rear
suspension design reduces bridging
over soft spots regardless of terrain.
Page 4
The PS360C provides a spacious and
comfortable working environment with
controls, levers, switches and gauges
positioned to maximize productivity.
The low profile of the water tank and
the sloped engine hood provide good
visibility to the front and rear of the
machine.
Page 5

New feature

Performance and reliability you can depend on.

The PS360C Pneumatic Compactor establishes new
standards for productivity and reliability in the
compaction industry. A durable Cat
engine, large ballast tank and the
world’s largest and most dedicated
dealer support system ensure the
PS360C Pneumatic Compactor will
provide maximum utilization. The PS360C
will achieve outstanding compaction results
regardless of the application with its proven
suspension design and flexible weight adjustment.

2
Ballasting
The ballast compartments are
positioned with a calculated balance of
wheel to weight ratio. Internal-frame
baffles help prevent surges when water
ballast is used.
Page 5
Ground Contact Pressures
Ground contact pressures are measured
across the width of the tires. Changing
the tire pressure or altering the ballast
capacity will allow the PS360C to meet
specific job requirements.
Page 9, 10, 11

Standard 500 hour oil service interval

Caterpillar Product Link System (CPLS)
Serviceability
The engine compartment offers easy
access to the powertrain components.
Routine maintenance points are
grouped together and easily accessible
though the large engine compartment
opening. Two gas struts assist in raising
the engine hood. Visual indicators for
the radiator coolant, hydraulic oil tank
level and air cleaner provide easy
verification.
reduces maintenance costs.
Page 6
The PS360C includes an electrical
harness to accept the optional
Caterpillar Product Link System.
The Caterpillar Product Link System
simplifies machine tracking by
providing location and hour updates to
assist in scheduling of routine service.
Consult your Caterpillar® Dealer for
purchasing information regarding which
Product Link version fits your needs.
3
Caterpillar® 3054C Turbocharged Engine
High-tech four cylinder engine provides outstanding performance and fuel economy.

Turbocharged engine for top

performance and efficiency, even at
high altitude with no derating required
up to 2134 m (7,000 ft).
Direct injection fuel system provides
individually metered high-pressure
injection of fuel for maximum
efficiency.
High displacement to power ratio
ensures long life and exceptional
reliability.
Engine oil cooler maintains the
integrity of the oil to provide a cool
operating engine.
Dual fuel filters and a water separator
provide superior protection for the
injection system.
Glow-Plug ignition assists in cold
weather starting.

Propel System
The “High Drive System” combines smooth starts and stops with plenty of torque.

Hydrostatic transmission provides

R
smooth direction and speed control, no
chains are used.
Hydraulic motors, secondary brakes,
and drive lines are positioned high
inside the machine frame, limiting
contamination and damage.
Remote drive-train flushing system
supplies cool hydraulic oil to the brakes
and axles to provide extended
drive-train life.
Two-speed throttle switch provides
job-site versatility to suit working
conditions.

4
Operator’s Station
Ergonomic design for maximum operator productivity while offering unmatched comfort.

Spacious and comfortable working

environment with controls, levers,
switches and gauges positioned to
maximize productivity.
Durable suspension seat (optional) or
non-suspension seat offers day-long
comfort.
Gauges and controls move with the
operator console and seat for easy
operation.
Instrument panel includes indicators for
hour meter, transmission oil
temperature, engine coolant
temperature, engine oil pressure and
fuel level.
Multi-position operator station
(optional) slides into three different
positions and the seat pivots 30˚ in
either direction to provide maximum
visibility.

Ballast Compartment
Ballast options allow the machine to be tailored to specific weight capacities.

Maximum operating weight of

25 000 kg (55,115 lb) provides
versatility for thick lifts.

Ballast compartments accommodate

water, sand or steel in order to provide
varying weight capacities.

Integrated baffles prevent surges when

water ballasted.

Large cover plates on the operator’s

platform provide fill points for sand or
R
steel. The water fill port can be
accessed from ground level.

Bolt-on side cover allows quick

removal of sand or steel ballast. Water
ballast can be emptied through a drain
valve located on the chamber.

5
Serviceability
Less time on maintenance means more time on the job.
Optional Equipment
Standard and optional equipment may vary, contact your Caterpillar® dealer for details.
Sliding Operator’s Station includes a
multi-position control console that slides
into three locked positions: left, center
and right. The operator’s seat also rotates
30º in either direction.
Suspension Seat is a mechanical seat
that has vertical height and weight
adjustments with armrests.
Speedometer is calibrated in kilometers
per hour (km/h) and miles per hour
(mph) on an analog dial.
Roading Light Package includes
taillights and parking lights with
flashers.
6
Tire Wetting System allows solvent to
be sprayed on the tire surfaces. The
system includes a 19 L (5 gal) emulsion
tank, electric pump and spray nozzles for
each tire.
Sun Canopy includes a sheet-metal
structure that shields the operator’s
station from the sun. The structure is
attached to the ROPS.
Heat Retention Shields include a belt-
type material that traps heat in order to
prevent asphalt from adhering to the tire
surfaces.
Routine maintenance points are
grouped in the engine compartment.
Ground level servicing simplifies
maintenance.
Visual restriction indicators for the
hydraulic oil filter and air filter.
Simplified access to the power-train
through the engine hood.
Color-coded and numbered wires
wrapped in nylon braid ensure system
integrity and help simplify
troubleshooting.
Grouped pressure taps with
quick-connect fittings simplify
troubleshooting.
Remote lubrication fittings decrease
maintenance time.
Combined Ballast consists of four
internal ballast blocks weighing 4064 kg
(8,960 lb), two steel blocks weighing
446 kg (982 lb) that are bolted to the front
bumper, and two sets of of 51 mm (2")
thick steel ballast plates weighing 3084 kg
(6,600 lb). This option combined with wet
sand ballast provides an operating weight
of 25 022 kg (55,115 lb).
Spare Tire and Wheel includes a
14/70 x 20, 20-ply tire and rim.
Dimensions

A Operating length 4.87 m 16' F Height at steering wheel 2.53 m 8' 4"
B Compaction width 2.28 m 7' 6" G Height at ROPS 3.20 m 10' 6"
C Frame width 2.15 m 7' 1" Turning radius (outside) 6.7 m 22'
D Wheel base 3.65 m 12' Turning radius (inside) 3.47 m 11' 5"
E Ground clearance 252 mm 10" Tire overlap 58 mm 2.25"

G
F B C

E
D
A

Weights (approximate)
Operating weight includes lubricants, coolant, 80 kg (175 lb) operator, full fuel tank, and full hydraulic system.

Operating Weights
Condition Total Weight Weight Per Wheel
Shipping 8 500 kg 18,740 lb 1215 kg 2,675 lb
With maximum water ballast 13 500 kg 29,760 lb 1930 kg 4,250 lb
With maximum steel ballast 15 995 kg 35,265 lb 2285 kg 5,040 lb
With maximum wet sand ballast 18 500 kg 40,785 lb 2645 kg 5,830 lb
With water ballast and steel ballast 20 000 kg 44,090 lb 2855 kg 6,300 lb
With wet sand ballast and steel ballast 25 000 kg 55,115 lb 3570 kg 7,870 lb

PS360C specifications 7
Engine Transmission Steering
Four-stroke cycle, four cylinder Cat ® Two speed hydrostatic propel system. A The automotive-type steering wheel and
3054C ATAAC turbocharged diesel hydrostatic pump provides oil to two column are integral with the operator’s
engine. This engine meets U.S. EPA hydrostatic motors that are mounted sliding platform and allow steering from
Tier 2 engine emission specifications. above the drive axles. The drive shafts multiple positions. Priority-demand
connect the motors to the axles. hydraulic power-assist steering system
Ratings at RPM kW hp A single propel lever located on the provides smooth, firm handling.
Gross power 2,200 98 130 control console provides smooth Each front wheel individually turns to
hydrostatic control of the infinitely produce true tracking through turns.
Ratings of Caterpillar® machine engines variable speeds in forward and reverse.
are based on standard air conditions of Minimum turning radius:
25°C (77°F) and 99 kPa (29.32" Hg) dry Speeds (forward and reverse): Inside edge 3.47 m 11' 5"
barometer. Power is based on using 35° 1st 0 - 8 km/h 0 - 5 mph Outside edge 6.70 m 22'
API gravity fuel having an LHV of 2nd 0 - 18 km/h 0 - 11 mph
42,780 kJ,kg (18,390 Btu/lb) when used
at 30°C (86°F) [ref. a fuel density of
838.9 g/L (7.001 lb/U.S. gal)]. Net
power advertised is the power available
at the flywheel when the engine is Brakes Wheels and Tires
equipped with air cleaner, muffler and Primary brake features The size of the three front tires and four
alternator. No derating required up to  Closed-loop hydrostatic drive system rear tires are 14/70 x 20 20 ply. The tires
2134 m (7,000 ft). provides dynamic braking during provide 58 mm (2.25") of overlap. The
machine operation. rear tires extend 58 mm (2.25") beyond
The following ratings apply at 2,200 Secondary brake features the frame. Each tire is equipped with a
RPM when tested under the specified  The secondary brakes are cocoa mat. The cocoa mat keeps the tire
standard conditions for the specified spring-applied and hydraulically surface coated with water or emulsion in
standard: released. The wet, multiple disc brakes order to prevent asphalt or soil from
are actuated by a switch on the control adhering to them. The cocoa mats can be
Net Power kW hp console. They are also activated retracted and positioned above the tires
EEC80/1269 93 125 automatically if pressure is lost in the when they are not needed.
ISO 9249 93 125 brake circuit or when the engine is
SAE J1349 92 124 shut off.
Brake systems meet SAE J1472 practice and EN 500
requirement.
Dimensions
Bore 105 mm 4.12"
Stroke 127 mm 5"
Displacement 4.4 L 268 cu. in.

Electrical System Frame Instrumentation

The 24-volt electrical system includes
two maintenance-free Cat batteries,
color-coded and numbered wiring
wrapped in nylon braid. The system
includes a 55-amp alternator.
The chassis is a rigid welded frame that
supports the engine, transmission and
sheet metal. The frame is designed to
evenly distribute the machine weight
between the front and rear axles.
Integrated baffle plates prevent surging
when using water ballast.
The front control console includes the
start switch, alternator indicator light,
coolant temperature gauge, engine oil
pressure gauge, hydraulic oil temperature
gauge and hour meter. The side console
includes the propel lever, speed selector
switch, spray system controls, horn and
secondary brake switch.

8 PS360C specifications
Ballast Considerations Water System Service Refill Capacities
and Ground Contact The pressurized water system is Liters U.S.
efficient and reliable. The system Gallons
Pressures includes stainless steel distribution bars Fuel Tank 200 52
The most common method of changing located over the front and rear tires and Engine Crankcase 7.3 1.9
ground contact pressure is to vary the retractable cocoa mats for each tire. Hydraulic Tank 90 23.7
tire pressure. Another means to change Cooling System 28 7.2
ground contact pressure is to alter the The pressurized system includes triple Differential 7.5 2
ballast. The ballast compartments are water filtration and a powerful Cat Tire Watering System 394 104
positioned with a calculated balance of water pump. Cat water pumps are Emulsion Tank 19 5
wheel to weight ratio. Internal-frame designed to provide long life.
baffles help prevent surges when water
ballasted. A polyethylene water tank is located at
the front of the machine on the
The ballast blocks provide a low center operator’s platform. A water level
of gravity, resulting in good stability. gauge is on the tank within easy sight of
The ballast blocks are positioned in the the operator.
bottom of the mainframe near the center
of the machine.

Average Ground Contact Pressures

14/70x20, 20-Ply Tires

20-Ply Tires
Tire Pressure kPa 241 310 379 448 517 586 655 724 758
psi 35 45 55 65 75 85 95 105 110
Average Wheel Load Ground Contact Pressures and Contact Areas
1540 kg (3,390 lb) GCP kPa 296 338 345 372 400 448 469 469 489
psi 43 49 50 54 58 65 68 68 71
CA cm2 509 446 437 405 377 336 322 322 308
in2 79 69 68 63 58 52 50 50 48
1930 kg (4,250 lb) GCP kPa 317 345 365 386 413 455 469 489 496
psi 46 50 53 56 60 66 68 71 72
CA cm2 596 548 517 490 457 415 403 386 381
in2 92 85 80 76 71 64 63 60 59
2505 kg (5,510 lb) GCP kPa 338 372 393 413 441 469 510 517 524
psi 49 54 57 60 64 68 74 75 76
CA cm2 725 658 624 592 555 523 480 474 468
in2 112 102 97 92 86 81 74 73 73
2865 kg (6,300 lb) GCP kPa 351 379 413 434 455 496 524 531 565
psi 51 55 60 63 66 72 76 77 82
CA cm2 797 739 677 645 616 564 535 528 496
in2 124 115 105 100 95 88 83 82 77
3575 kg (7,870 lb) GCP kPa 372 407 427 462 482 524 558 558 572
psi 54 59 62 67 70 76 81 81 83
CA cm2 940 860 819 758 725 668 627 627 612
in2 146 133 127 117 112 104 97 97 95
GCP—Ground Contact Pressure CA—Ground Contact Area

PS360C specifications 9
Actual Ground Contact Pressures
Actual Ground Contact Pressures are measured across the width of the tire. The charts include wheel path overlap.

Tire Inflation
Pressures

345 kPa (50 psi)

483 kPa (70 psi)
621 kPa (90 psi)
758 kPa (110 psi)

0 0
10 69
Ground Contact

Ground Contact
20 138

Pressures (kPa)
Pressures (psi)

30 207
40 276
50 345
60 414
70 483
80 552
90 621
100 689
110 758
120 827
130 896
140 965
150 1034

1215 kg (2,675 lb) wheel load – Standard machine empty

0 0
10 69
Ground Contact

Ground Contact
20 138

Pressures (kPa)
Pressures (psi)

30 207
40 276
50 345
60 414
70 483
80 552
90 621
100 689
110 758
120 827
130 896
140 965
150 1034

1930 kg (4,250 lb) Wheel Load – Maximum water ballast only

0 0
10 69
Ground Contact

Ground Contact
Pressures (kPa)

20 138
Pressures (psi)

30 207
40 276
50 345
60 414
70 483
80 552
90 621
100 689
110 758
120 827
130 896
140 965
150 1034

2285 kg (5,040 lb) Wheel Load – Maximum steel ballast only

10 PS360C specifications
Actual Ground Contact Pressures
Actual Ground Contact Pressures are measured across the width of the tire. The charts include wheel path overlap.

Tire Inflation
Pressures

345 kPa (50 psi)

483 kPa (70 psi)
621 kPa (90 psi)
758 kPa (110 psi)

0 0
10 69
Ground Contact

Ground Contact
20 138

Pressures (kPa)
Pressures (psi)

30 207
40 276
50 345
60 414
70 483
80 552
90 621
100 689
110 758
120 827
130 896
140 965
150 1034

2645 kg (5,830 lb) Wheel Load – Maximum wet sand ballast only
0 0
10 69
Ground Contact

Ground Contact
20 138

Pressures (kPa)
Pressures (psi)

30 207
40 276
50 345
60 414
70 483
80 552
90 621
100 689
110 758
120 827
130 896
140 965
150 1034

2855 kg (6,300 lb) Wheel Load – Maximum water ballast and steel ballast
0 0
10 69
Ground Contact

Ground Contact

20 138
Pressures (kPa)
Pressures (psi)

30 207
40 276
50 345
60 414
70 483
80 552
90 621
100 689
110 758
120 827
130 896
140 965
150 1034

3570 kg (7,870 lb) Wheel Load – Maximum wet sand ballast and steel ballast

PS360C specifications 11
Caterpillar offers a comprehensive line of pneumatic tire compactors.
Contact your local Caterpillar® dealer to learn more about the complete line of Caterpillar
Paving Products.

PS150C Pneumatic Compactor

Operating Weight
Standard Machine 4885 kg 10,775 lb
Maximum Ballast 12 940 kg 28,535 lb
Heavy Weight Option
Standard Machine 4955 kg 10,925 lb
Maximum Ballast 17 273 kg 38,000 lb
Rolling Width 1.74 m 5' 9"
Gross Power 75 kW 100 hp

© 2008 Caterpillar
All Rights Reserved.
www.cat.com
SAFETY.CAT.COMTM

Featured machines in photography may include optional equipment.

Materials and specifications are subject to change without notice.

CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow” and the POWER EDGE trade dress, as well as corporate
QEHQ1102-01 (03/08) and product identity used herein, are trademarks of Caterpillar and may not be used without permission.
A WIRTGEN GROUP COMPANY

Highway Class
SUPER 2100-3
Extendedora sobre orugas

Anchura de extendido máx. 13,0 m

Rendimiento de extendido máx. 1100 t/h
Anchura de transporte 2,55 m www.voegele.info
 SUPER 2100-3
Potente, económica y silenciosa
La SUPER 2100-3 es la extendedora más
potente de la generación de máquinas
“Guión 3” de VÖGELE. La modernísima
extendedora se caracteriza por su diseño
orientado al futuro, mayor confort y elevado
rendimiento con un mínimo consumo.
En la concepción de la generación “Guión 3”,
los ingenieros de desarrollo del producto
dieron especial importancia a los aspectos
ecológicos, económicos y ergonómicos.
En este sentido, el paquete “VÖGELE EcoPlus”,
p. ej., hace posible reducir significativamente el
consumo de carburante así como las emisiones
de ruidos.
También el sistema de mando ErgoPlus 3 fue
complementado para la generación “Guión 3”
con una serie de características adicionales,
ergonómicas y funcionales. Así, la consola de
mando del conductor dispone ahora, por ejemplo,
de una pantalla a color especialmente grande,
que hace posible una visualización brillante incluso
bajo condiciones luminosas poco favorables.
2 | highway class www.voegele.info
SUPER 2100-3
Los nuevos desarrollos de VÖGELE se basan
siempre en las necesidades que se presentan en
la práctica. Con “AutoSet Plus” hacemos ahora
todavía más eficientes, confortables y, con ello,
también cualitativamente mejores los procesos
decisivos en la obra. Tanto la continuación del
trabajo tras una interrupción del extendido como
el desplazamiento de la extendedora en la obra
son mucho más sencillos con “AutoSet Plus“.
Con el sistema de comunicación “PaveDock
Assistant” y el rodillo de empuje con suspension
elástica “PaveDock” se dispone de una perfecta
combinación que garantiza la máxima precisión
en la transferencia de la mezcla.
Todas sus características convierten esta máquina
de la Highway Class en una auténtica extendedora
SUPER.
3
 SUPER 2100-3
Los highlights
de la
SUPER 2100-3
Extendedora sobre orugas
de la Highway Class con
amplia gama de aplicaciones
en anchuras de extendido
de hasta 13,0 m
4 | highway class
Concepto de accionamiento
de alto rendimiento y bajo
consumo también en servicio
de plena carga y en todas las
zonas climáticas
Equipamiento de Alimentación óptima gracias
reducción de emisiones a la gran tolva, el rodillo
“VÖGELE EcoPlus” para de empuje con suspensión
disminuir claramente el elástica “PaveDock” y el
consumo de carburante sistema de comunicación
y las emisiones de ruidos “PaveDock Assistant”
www.voegele.info
Highlights
Sistema de mando Todas las reglas de extendido
ErgoPlus 3 con gran combinables con la tecnología
cantidad de funciones de la alta compactación
de confort y automáticas
5
 SUPER 2100-3

Eficiente y potente
con bajo consumo

La fuerza motriz de la extendedora de la
Highway Class es el potente motor diésel
de seis cilindros con 179 kW.
Gestión de motores inteligente con modo ECO
y el equipamiento de reducción de emisiones
“VÖGELE EcoPlus“ hacen posible un reducido
consumo de carburante y un servicio silencioso.
Pequeña entrada — máxima salida, todos los
componentes motrices, incluido el generador
de corriente trifásica, son alimentados mediante
el engranaje central de distribución de las
bombas y trabajan con la máxima eficiencia.
concepto de accionamiento
Trenes de orugas de gran tracción transforman
eficientemente la potencia de accionamiento en
fuerza de avance.

6 | highway class www.voegele.info 7

 SUPER 2100-3
Técnica de accionamiento moderna
Tres componentes principales forman la
unidad de accionamiento de la SUPER 2100-3:
un moderno motor diésel refrigerado por líquido,
un engranaje de distribución de las bombas
abridado directamente al motor y un radiador
de múltiples circuitos de grandes dimensiones.
La fuerza que impulsa el equipo de potencia
de VÖGELE es el motor diésel Cummins de alto
rendimiento del tipo QSB6.7-C240. Este motor
de seis cilindros presta 179 kW a 2000 rpm.
Si bien, para muchas aplicaciones ya es suficiente
el modo ECO economizador de carburante.
Con él, la SUPER 2100-3 todavía dispone de 168 kW.
Además, con sólo 1700 rpm, el funcionamiento
de la máquina es especialmente silencioso.
Un radiador de múltiples circuitos de grandes
dimensiones procura que la unidad de
accionamiento pueda trabajar siempre a máximo
8 | highway class
rendimiento. Junto con la innovadora conducción
SUPER 2100-3i
concepto de accionamiento
del aire y el ventilador regulado, las temperaturas
se mantienen siempre en el rango óptimo, lo que
colabora determinantemente a la larga vida útil del
motor diésel y del aceite hidráulico. Otra ventaja: Aire de sobrealimentación
La máquina se puede utilizar sin problema en todas
las regiones climáticas del mundo.
Todos los consumidores hidráulicos son abastecidos
con aceite hidráulico directamente a través del Refrigerante
engranaje de distribución de las bombas. Esto tiene
la ventaja de que todas las bombas hidráulicas
y válvulas están reunidas en un punto y, con ello,
son fácilmente accesibles para realizar los trabajos
de mantenimiento. Incluso el generador de alto
rendimiento para el calentamiento de la regla está Radiador de aceite hidráulico
abridado directamente al engranaje de distribución
de las bombas y, gracias a la refrigeración de aceite
integrada, carece totalmente de mantenimiento y
es muy silencioso.
El radiador de múltiples circuitos de grandes dimensiones está subdividido en tres sectores.
A través del mismo, el líquido refrigerante del motor, el aire de sobrealimentación y el aceite
hidráulico se mantienen a una temperatura óptima.
Potente y económico motor diésel de Potente generador de accionamiento
6 cilindros de Cummins con modo ECO. directo y refrigerado por aceite que hace
posible un calentamiento rápido y regular
El modo ECO con 1700 rpm es suficiente
de la regla de extendido. El accionamiento
para muchas aplicaciones, reduce los
del generador de la generación “Guión 3” se
costes de explotación y hace posible un
realiza directamente a través del engranaje
funcionamiento especialmente silencioso.
de distribución de bombas, por lo que carece
de mantenimiento.
www.voegele.info 9
 SUPER 2100-3
Equipamiento “VÖGELE EcoPlus”
El concepto de accionamiento de la generación
“Guión 3” se encuentra absolutamente bajo
el lema “menos consumo — menos emisiones —
menos costes”. En este sentido, gracias a
la incorporación de una serie de medidas,
1 2
Caja de transferencias que tiene capacidad
de desembragar las bombas hidráulicas
Cuando la extendedora está parada, p. ej. durante
tiempos de espera, todas las bombas hidráulicas para
“tracción”, “cintas transportadoras y sinfines de distribución”
1 y “compactación” se desembragan automáticamente.
Esta función reduce considerablemente el consumo de
carburante. Gracias a la reducción de la carga remolcada,
3 el arranque de la extendedora a bajas temperaturas
exteriores es mucho mejor.
3 4
Circuito de temperatura de aceite hidráulico
controlado
Una conmutación de bypass hace posible alcanzar
rápidamente la temperatura de servicio óptima del aceite
hidráulico. Lo que, por su parte, permite trabajar con
la extendedora de forma más rápida y con menos consumo
de carburante. Si la temperatura del aceite supera el
margen óptimo de 50 a 70 °C, una conmutación de bypass
desvía el aceite por el refrigerador de múltiples circuitos.
10 | highway class www.voegele.info
el innovador paquete de reducción de emisiones
Antriebskonzept
accionamiento
“VÖGELE EcoPlus” hace posible la disminución
significativa del consumo de carburante y de
las emisiones de ruido.
concepto de
Accionamiento del támper con consumo
energético optimado
El accionamiento del támper es alimentado por
una bomba de cilindrada variable. Ésta transporta
exclusivamente la cantidad exacta de aceite
necesaria para cada velocidad de giro del támper.
Ni más ni menos.
Ventilador con velocidad variable
El ventilador de velocidad variable adapta su velocidad
de giro automáticamente a la carga del motor y
a la temperatura exterior. El ventilador se acciona por
acoplamiento líquido. Al contrario que los ventiladores
de accionamiento hidráulico, este tipo de accionamiento
se caracteriza por tener una eficiencia energética mucho
mejor y ser mucho más silencioso.
11
 SUPER 2100-3
Eficiente transformación
de la potencia del accionamiento
Accionamientos individuales hidráulicos de
alto rendimiento son componentes esenciales
del concepto de accionamiento de VÖGELE.
Con nuestras extendedoras trabajamos de forma
muy productiva con un alto nivel de rendimiento.
Los sistemas hidráulicos del accionamiento
de traslación, el transporte y distribución
del material, así como los sistemas de
compactación están dispuestos en circuitos
cerrados independientes y, con ello,
consiguen el mejor rendimiento posible.
El largo tren de orugas tiene una gran
superficie de apoyo para conseguir la máxima
tracción. Esto garantiza una propulsión
constante, incluso en los terrenos más difíciles.
12 | highway class
Los accionamientos están directamente
Antriebskonzept
accionamiento
incorporados en el tambor del tren de orugas
y consiguen así transformar la potencia del
accionamiento en velocidad de trabajo sin
pérdida alguna.
concepto de
Marcha recta estable y toma precisa de
las curvas por medio de los accionamientos
individuales regulados electrónicamente
en los dos trenes de orugas.
 os robustos deflectores situados delante del
L
tren de orugas liberan el carril confiablemente
de mezcla derramada. Los deflectores incluso
se pueden subir o bajar hidráulicamente con
la opción “AutoSet Plus”.
www.voegele.info 13
 SUPER 2100-3

Excelente calidad de extendido

gracias a la perfecta
gestión de material

Un flujo de material continuado es muy
importante para un extendido sin interrupciones
y de alta calidad. Por eso, en la concepción de
nuestras extendedoras damos gran importancia
a una gestión de material profesional.
Un mando sencillo y una gran claridad para
el equipo de extendido se encuentran siempre
en el centro de nuestros desarrollos.
gestión de material
Con el “PaveDock Assistant”, VÖGELE ofrece
una solución innovadora para estandarizar y
simplificar el proceso de comunicación entre
el conductor de la extendedora y el del camión.

14 | highway class www.voegele.info 15

 SUPER 2100-3
Gran tolva receptora
Como todas las extendedoras VÖGELE,
la SUPER 2100-3 también se alimenta de
un modo limpio, seguro y rápido.
16 | highway class
La puerta frontal hidráulica de la tolva (opcional)
se encarga de que se use toda la mezcla en el
proceso de transporte de material.
La gran tolva receptora tiene una capacidad
de 14 toneladas, por lo que siempre se dispone
de suficiente mezcla para el extendido, incluso
en las condiciones de alimentación más
complejas, por ejemplo, bajo los puentes.
El material se alimenta fácilmente a través
de las paredes de la tolva, que son profundas
y muy salientes horizontalmente, así como
mediante sus resistentes faldones delanteros.
Los rodillos de empuje para camiones, muy
anchos y montados en suspensión oscilante,
permiten una alimentación cómoda y suave
mediante el vehículo transportador de la mezcla
incluso en curvas.
Para la adaptación a los camiones de mezcla
más diversos, los rodillos de empuje montados
en suspensión oscilante pueden desplazarse
75 ó 150 mm hacia delante.
Distribución exacta del material
en toda la anchura de trabajo
La altitud del sinfín de distribución se puede
regular hidráulicamente de forma continua en la
SUPER 2100-3 hasta en 15 cm, incluso durante
15 cm
La altura del sinfín de distribución, incluidos los
soportes de rodamientos y chapas limitadoras
del túnel, puede ajustarse hidráulicamente
hasta 15 cm en toda la anchura de extendido.
Esto optimiza la distribución de la mezcla, incluso
en el extendido de capas finas, así como en
diferentes espesores de extendido dentro de
un tramo de la obra.
www.voegele.info
el extendido. Esto hace posible una adaptación
gestión de material
rápida y sencilla a diferentes espesores de
extendido en toda la anchura de trabajo.
Las cintas transportadoras y los sinfines de
distribución con potentes accionamientos
hidráulicos independientes permiten un
elevado rendimiento de extendido de hasta
1100 toneladas por hora.
Los sinfines de distribución con diámetros
de aletas especialmente grandes (480 mm),
aseguran un óptimo aporte de la mezcla incluso
con grandes cantidades de extendido.
El ajuste hidráulico de la altura de los sinfines
de distribución, incluyendo los soportes de
rodamientos y las chapas limitadoras del túnel,
permite el desplazamiento a un nuevo tramo de
la obra sin trabajos de adaptación, que cuestan
mucho tiempo y dinero.
17
 SUPER 2100-3

“PaveDock Assistant”: “PaveDock” amortigua choques

el sistema de comunicación eficientemente

gestión de material
Acoplar: El camión se acerca Parar: El camión tiene que detenerse. Subir el volquete:
a la extendedora y se acopla. El camión está acoplado. El camión sube el volquete.

Bajar el volquete:
El camión baja el volquete.
La extendedora se desplaza:
Alejarse: El camión se aleja
El símbolo puede aparecer en unión
de la extendedora.
con las indicaciones.

“PaveDock Assistant” es el sistema de comunicación Alternativamente al rodillo de empuje montado En combinación con la función “PaveDock Assistant”,
entre el conductor de la extendedora y el del camión. oscilante, VÖGELE ofrece también “PaveDock”, el rodillo de empuje con suspensión elástica
Éste hace posible una transferencia de la mezcla un rodillo de empuje con suspensión elástica. maximiza la seguridad del proceso durante la
Parar Acoplar Subir el volquete
a la extendedora especialmente rápida y segura. De esta forma, los golpes del camión se compensan transferencia de la mezcla: un sensor en el rodillo
Elementos esenciales son los semáforos, dispuestos de forma todavía más eficiente y segura y no se de empuje avisa cuando el camión se ha acoplado
en la extendedora, y los elementos de mando trasladan al revestimiento extendido. a la extendedora. Los semáforos señalizadores
correspondientes, situados en la consola de mando muestran automáticamente el símbolo de parada.
ErgoPlus 3 del conductor. El conductor del camión puede reaccionar
inmediatamente.
La extendedora dispone de dos semáforos fijados
a la derecha e izquierda del techo. Con su ayuda,
el conductor de la extendedora puede indicar
claramente qué acciones ha de realizar el conductor
del camión de mezcla (p. ej. ir marcha atrás, parar Bajar el volquete Alejarse
o volcar la mezcla). Gracias a su elevada colocación
y el disponer de dos semáforos, para el conductor
del camión queda garantizada la buena visibilidad
de la señal desde cualquier posición.

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 SUPER 2100-3

Desarrollos automáticos con

“AutoSet Plus”
Con “AutoSet Plus” hacemos procesos decisivos Con sólo pulsar una vez la tecla de ejecución, programa de extendido. Este programa puede ser

SUPER 1800-3i
Plus
en la obra todavía más eficientes, confortables y, la extendedora se prepara de forma rápida activado y utilizado siempre que se desee.
en consecuencia, de mejor calidad. y segura para el desplazamiento en la obra

“AutoSet Plus” dispone de dos prácticas funciones
automáticas. La función de desplazamiento
y transporte facilita la continuación del trabajo
en diferentes tramos de obra o después del
transporte de la extendedora.
AutoSet
o para ser transportada y, posteriormente, basta Con las dos funciones de confort de “AutoSet Plus”,
volver a pulsar la tecla para que la máquina vuelva las tareas rutinarias se automatizan, por lo que
a la posición de trabajo previamente memorizada. los desarrollos de trabajo se pueden realizar más
rápida y controladamente. De esta forma, los
La función de programas de extendido hace posible proyectos de construcción se realizan con mayor
1 // “AutoSet Plus”:
a los operarios guardar los parámetros ajustados rapidez y seguridad.
función de desplazamiento
en la máquina y ponerlos en el menú como un
Desplazamiento de la
extendedora en la obra
más rápido y seguro.

No se pierde ningún ajuste

entre el extendido y el
desplazamiento.

No se producen daños en
el sinfín de distribución ni
en los deflectores situados
delante del tren de orugas.

2 // “AutoSet Plus”:
programas de extendido

Ajuste automático de la
extendedora.

Memorización de todos los

parámetros relevantes para
el extendido.

Selección de los programas

de extendido guardados.

Calidad repetible.

20 | VÖGELE SUPER 1803-3i | Highway class

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 SUPER 2100-3

Función de Programas de extendido

desplazamiento “AutoSet Plus”
“AutoSet Plus”

SUPER 1800-3i
Plus
“AutoSet Plus” es especialmente útil cuando

AutoSet
la máquina se ha de desplazar frecuentemente 1 2
en una obra.

Con sólo pulsar una vez la tecla de ejecución,

el sinfín de distribución, la puerta frontal
hidráulica de la tolva y los deflectores situados
delante del tren de orugas se colocan en la
posición más elevada. La regla y los cilindros
niveladores pueden ponerse en posición de
transporte. Adicionalmente, la regla se bloquea
hidráulicamente en esta posición. Las cintas
transportadoras invierten la marcha por un
corto periodo de tiempo, con lo que se evita
que la mezcla caiga al suelo durante la marcha.
Después del desplazamiento, volviendo a pulsar 3 4
una vez la tecla de ejecución todo vuelve a la
posición de trabajo previamente guardada.

De esta manera no se pierde ningún ajuste

al cambiar de la posición de extendido a la de
transporte. Además se evitan efectivamente
los daños en la máquina.

1. La función de desplazamiento en la
obra “AutoSet Plus“ se inicia con sólo
pulsar una vez la tecla de ejecución.
2. Subir / bajar la regla.
3. Bloquear / desbloquear la regla.
4. Cilindros niveladores en posición
de transporte / último valor ajustado.
5. Subir / bajar el sinfín de distribución.
6. Invertir la marcha de las cintas
transportadoras durante un corto
período de tiempo.
7. S
 ubir / bajar los deflectores delante
de los trenes de orugas.
8. Subir la puerta frontal.
La función automática para los programas de
extendido hace posible a los operarios crear
programas de extendido determinados. De esta
5 6 forma pueden guardarse todos los parámetros
importantes para el extendido en una capa
determinada, p. ej. en una capa de base de
hormigón asfáltico de 18 cm de espesor.
En la pantalla de la consola de mando del conductor,
éste guarda los valores ajustados de los sistemas
de compactación (velocidad de giro del támper
y las vibraciones, presión del listón de presión),
la altura de los sinfines de distribución, la posición
de los cilindros niveladores, el ajuste de la descarga
de la regla y la velocidad de extendido.
Además, también registra el perfil de caída
transversal ajustado y la temperatura de la regla
de extendido. Con otros datos sobre la mezcla
utilizada, el espesor y la anchura de extendido
completa las informaciones.
Los programas de extendido guardados pueden
seleccionarse a través del menú y utilizarse en
todo momento. De esta forma queda garantizado
que cuando se repite el mismo caso se trabaja
con los mismos ajustes y se consigue la misma
calidad.

7 8

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 SUPER 2100-3

El concepto de mando ErgoPlus 3

Incluso la mejor máquina con la tecnología más moderna sólo puede desarrollar todo su potencial
si se maneja de forma fácil y lo más intuitiva posible. Al mismo tiempo, debe ofrecer a los operarios
puestos de trabajo ergonómicos y seguros. Por eso, el concepto de mando ErgoPlus 3 se centra en
la persona. Con ello, los usuarios de las extendedoras VÖGELE tienen siempre el control total de la

ErgoPlus 3
máquina y de la obra.

En las páginas siguientes encontrará ejemplos acompañados de más información sobre las múltiples
funciones del sistema de mando ErgoPlus 3. Éste abarca la plataforma de mando, las consolas de mando
del conductor y de la regla y el sistema de nivelación Niveltronic Plus.

24 | highway class www.voegele.info 25

25
 SUPER 2100-3

La consola de mando
ErgoPlus 3 del conductor

ErgoPlus 3
“Control total para el conductor”
26 | highway class www.voegele.info 27
 SUPER 2100-3

La consola de mando ErgoPlus 3 La consola de mando del conductor está

diseñada conforme a las necesidades de la
ErgoPlus 3 permite notar y activar las teclas
de función incluso con guantes de trabajo.
Grupo de funciones 1:

Grupo de funciones 2:
Transporte de material y marcha

Regla

del conductor práctica y es extremadamente clara. Todas las

funciones están resumidas en grupos lógicos,
Si se pulsa la tecla, se activa inmediatamente
la función. De ello se ocupa el principio “Touch
Grupo de funciones 3: Tolva receptora y dirección

de tal forma que el operario también encuentra and Work”. La función deseada se realiza Grupo de funciones 4: Pantalla para la supervisión y adaptación de ajustes básicos

la función correspondiente donde espera que directamente — sin tener que volver a confirmar.

ErgoPlus 3
esté.

Función de marcha en vacío

La función de marcha en vacío permite limpiar

o calentar las cintas transportadoras, los sinfínes
de distribución y el támper.

La pantalla de la consola de mando del conductor

La pantalla a color dispone de una superficie de gran contraste, que ofrece una
Inversión de la marcha de la cinta transportadora legibilidad clara también con malas condiciones luminosas. Las informaciones
más importantes se visualizan en el primer nivel del menú, p. ej. la altura de los
Para evitar que caiga suciedad de la mezcla en los cilindros niveladores y el nivel de llenado de las cintas transportadoras. Otros
cambios de la extendedora — así como al final de ajustes, como la velocidad del támper y la vibración o la cantidad transportada
un tramo de obra — se puede invertir la marcha de por los sinfines de distribución se pueden ajustar en la pantalla de un modo muy
la cinta transportadora con sólo pulsar una tecla. sencillo. También se recibe a través de la pantalla la información sobre datos del
La cinta se mueve marcha atrás en un tramo corto motor diésel, como el consumo de combustible o las horas de servicio.
y se para automáticamente.

“PaveDock Assistant” (opcional)

Función de desplazamiento “AutoSet Plus” (opcional)
Con la ayuda del semáforo “PaveDock Assistant”,
Con la función de desplazamiento “AutoSet Plus”, la extendedora se prepara el conductor de la extendedora puede indicar
para el desplazamiento de forma rápida y segura con sólo pulsar una tecla. claramente qué acciones ha de realizar el
Una vez efectuado el desplazamiento, basta pulsar nuevamente la tecla conductor del camión de mezcla (p. ej. ir marcha
para regresar a la posición de trabajo previamente guardada. De esta manera atrás, parar, volcar la mezcla). La señal pertinente
no se pierde ningún ajuste al cambiar de la posición de extendido a la de se emite directamente desde la consola de
transporte. Además se evitan efectivamente los daños durante el desplazamiento. mando ErgoPlus 3 del conductor.

Motor diésel con fases del número de revoluciones

Selección de los distintos modos de servicio de la extendedora
Para el motor diésel existen tres fases de número de revoluciones: MIN,
Todas las funciones importantes de extendido pueden regularse directamente ECO y MAX. La fase deseada se puede ajustar fácilmente usando las teclas
desde la consola de mando ErgoPlus 3 a través de teclas específicas. Al pulsar de flecha. En el modo ECO se pueden realizar muchas obras. Gracias al
la tecla, la extendedora cambia, tanto hacia arriba como hacia abajo, al modo régimen reducido del motor, el nivel de ruido se limita considerablemente,
de servicio más próximo en el orden: “Neutro“, “Desplazamiento obra“, y se ahorra combustible.
“Posicionamiento“ y “Extendido“. Por medio de un diodo luminoso se indica
cuál es el modo de servicio que está seleccionado.

Descarga de la regla (opcional)

Mando seguro en trabajos nocturnos
Esta tecla activa (se enciende un LED) o desactiva la descarga de la regla.
La presión de descarga de la regla, así como el balance, se muestran en la
Para que el conductor pueda operar la
pantalla. La descarga de la regla sólo está activa si la regla se encuentra en
extendedora de forma segura también
la posición de flotación.
en trabajos nocturnos, cuando empieza
a oscurecer se enciende automáticamente
la iluminación de fondo antideslumbrante.

28
28 | | highway class
universal class 29 | universal class www.voegele.info 30 www.voegele.info 31
 SUPER 2100-3

La consola de mando ErgoPlus 3

de la regla
La calidad del extendido surge en la regla. Con ErgoPlus 3, el operario de la regla

ErgoPlus 3
Por eso, el manejo sencillo, y por tanto seguro, domina el proceso de extendido, ya que
de todas las funciones de la regla es un factor todas las funciones están dispuestas de
decisivo para un extendido de alta calidad. un modo claramente comprensible y visible.

La consola de mando de la regla

La consola de mando de la regla está diseñada de un modo práctico y adecuado para la obra.
Sus funciones se pueden activar mediante las teclas impermeables de corto recorrido.
Los aros permiten pulsar bien las teclas de función incluso “a ciegas” y con guantes de trabajo.
Los datos importantes de la máquina y de la regla también se pueden activar y ajustar en la
consola de mando de la regla.

La pantalla de la consola de mando de la regla

En la pantalla de las dos consolas de mando se puede supervisar y controlar tanto el lado
izquierdo de la regla como el derecho. El usuario puede modificar de forma rápida y sencilla
los parámetros técnicos de la máquina, como p. ej. la velocidad de rotación del támper o la
velocidad de la cinta transportadora. Gracias a una estructura de menú clara y a unos símbolos
unívocos y fácilmente comprensibles, utilizar la pantalla es una tarea sencilla y segura.

Ajustes del perfil de caída transversal con sólo pulsar una tecla

El perfil de caída transversal puede ajustarse cómodamente a través de la consola de mando

de la regla con sólo pulsar una tecla. Al activar la tecla de más o de menos, el valor ajustado
del perfil de caída transversal se visualiza en la pantalla.

Ajuste del ancho de la regla ergonómico en dos velocidades

El ajuste del ancho de la regla se realiza ahora sin ningún esfuerzo mediante el “SmartWheel”
antideslizante. Se puede realizar en dos velocidades: lenta, para seguir exactamente un canto,
por ejemplo, o rápida, para extender y retraer la regla rápidamente.

Óptima visibilidad también en la oscuridad

La consola de mando de la regla dispone de un diseño especial

para la noche. Este diseño ilumina el fondo de las teclas durante
el crepúsculo o en la oscuridad, de tal forma que pueden evitarse
los errores de mando. Adicionalmente, la iluminación por diodos
luminosos LED de alta potencia, orientada hacia abajo, proporciona
la visibilidad óptima para realizar todos los procesos en torno al
panel lateral.

32 | highway class www.voegele.info 33

 SUPER 2100-3

VÖGELE Niveltronic Plus

El sistema automático de nivelación VÖGELE ofrece una amplia selección de sensores
Niveltronic Plus es un desarrollo interno preparados para la práctica que permiten usar de
de JOSEPH VÖGELE AG y está basado forma versátil el sistema Niveltronic Plus. Tanto en

en numerosos años de experiencia en la
tecnología de nivelación. Mando sencillo,
precisión y fiabilidad son sus características
para superar a la perfección cualquier trabajo
de nivelación.
El sistema completamente integrado está
óptimamente adaptado a la técnica de
maquinaria de las extendedoras SUPER.
Así, por ejemplo, todos los cables y conexiones
están integrados en el interior de la máquina
tractora y la regla, con lo que se evitan
casi por completo posibles daños en estos
componentes.
ErgoPlus 3
la construcción o rehabilitación de aparcamientos
como en rotondas o autovías, VÖGELE tiene el
sensor correcto para cada situación de la obra.
Los sensores se pueden recambiar rápida y
fácilmente, pues Niveltronic Plus reconoce
automáticamente cada uno de los sensores
conectados, lo que simplifica la configuración
para el usuario.

Lado izquierdo de la regla Lado derecho de la regla

El valor mostrado en centímetros indica El valor mostrado en centímetros indica

la altura del cilindro nivelador izquierdo. la altura del cilindro nivelador derecho.

Indica el valor nominal Indica el valor nominal

introducido para el sensor introducido para el sensor
izquierdo. Con excepción derecho. Con excepción
del sensor de inclinación del sensor de inclinación
transversal, para el que se transversal, para el que se
indica el valor porcentual, indica el valor porcentual,
todos los valores se todos los valores se
presentan en mm. presentan en mm.

Indica el tipo de sensor Indica el tipo de sensor

seleccionado para el lado seleccionado para el lado
izquierdo. En el ejemplo derecho. En el ejemplo
se muestra el símbolo de se muestra el símbolo de
un sensor de ultrasonidos un sensor de ultrasonidos
en exploración del suelo. en exploración del suelo.

Indicación del valor Indicación del valor

real medido actualmente. real medido actualmente.

Indicación de la sensibilidad Indicación de la sensibilidad

ajustada para el sensor empleado. ajustada para el sensor empleado.

34 | highway class www.voegele.info 35

 SUPER 2100-3
1.
2.
La plataforma de mando ErgoPlus 3
1. E
 sta cómoda plataforma de mando ofrece
una visibilidad perfecta de todos los puntos
más importantes de la extendedora, por
ejemplo, la tolva de material, el indicador
de dirección y la regla.
2. La colocación de los asientos y la clara
disposición de la plataforma ofrecen una visión
inmejorable del túnel de los sinfines, lo que
permite que el conductor controle, en todo
momento, el nivel de mezcla delante de la regla.
36
36 | | highway class
mini class
3. 
4.
3. Trabajo cómodo
El asiento y la consola de mando del conductor
en la plataforma, así como las consolas de mando
de la regla pueden adaptarse mas fácilmente
a los deseos de los usarios.
4. Un sitio para cada cosa
La plataforma de mando está claramente
estructurada, ordenada y ofrece al conductor
un puesto de trabajo profesional. La consola
de mando del conductor se puede proteger
con una cubierta a prueba de golpes y
agresiones deliberadas.
5.
6.
5. El
 techo fijo ofrece la protección adecuada
El moderno techo de plástico reforzado con
fibra de vidrio ofrece la perfecta protección
contra la lluvia y el sol.
6. Concepto de servicio universal
Todas las extendedoras “Guión 3” tienen
un concepto de mantenimiento universal
con los mismos intervalos de servicio.
www.voegele.info
www.voegele.info
ErgoPlus 3
7. 
8.
7. Subir cómodamente y con seguridad
La pasarela y el ascenso central confortable
de la regla de extendido facilitan un acceso
seguro y cómodo a la plataforma de mando.
8. Consola de mando de la regla ergonómica
La altura y la posición de la consola pueden
ajustarse muy fácilmente. La pantalla a color
de gran contraste se puede leer bien desde
cualquier ángulo.
37
37
 SUPER 2100-3

Reglas de extendido
para todo tipo de aplicación
Con su enorme fuerza de avance y rendimiento de
Las reglas extensibles AB 500 y AB 600 son especialmente
extendido, la SUPER 2100-3 es la máquina ideal para

Reglas de extendido
adaptables y, por tanto, idóneas para diferentes anchos
extender en grandes anchuras. Para conseguir un resultado
de extendido y firmes irregulares. Su guía telescópica
de extendido ideal en todos los campos de aplicación,
monotubular, robusta y muy precisa, permite un ajuste
VÖGELE ofrece reglas de extendido que trabajan con
estable y fiable de la anchura de la regla. Incluso en toda
alta precisión en todos los sistemas de compactación.
la anchura, los tubos telescópicos sólo se extienden hasta
Se comercializa la regla fija SB 250, así como las reglas
la mitad, con lo que el sistema de la regla está dotado de
extensibles AB 500 y AB 600.
una gran rigidez.

Ambas reglas extensibles para la SUPER 2100-3 se

pueden adquirir con támper y vibradores (TV) así como
con la tecnología de alta compactación VÖGELE con uno
o dos listones de presión (TP1/TP2). Especialmente para
el extendido de capas intermedias y de base con valores de
compactación máximos se dispone de las reglas extensibles
AB 500 y AB 600 en la variante TP2 Plus.

La regla fija SB 250, con su anchura máxima de extendido

de 13,0 m, aporta las condiciones óptimas para un extendido
potente y económico en grandes obras. En la versión TVP2,
de compactación especialmente alta, la SB 250 consigue
valores máximos de compactación. Gracias a las piezas
extensibles hidráulicas (75 cm), la anchura de trabajo puede
ajustarse de forma variable en un ámbito total de 1,5 m.

Superficie uniforme mediante el calentamiento regular de

las chapas alisadoras, los listones del támper y los listones
de presión.

Clara reducción en el tiempo de calentamiento de la

calefacción eléctrica, ya en la marcha en ralentí del motor
mediante una gestión inteligente del generador.

En modo automático, la activación a intervalos, que

suministra energía de forma alterna a cada una de las
mitades de la calefacción de la regla, cuida el motor y
ahorra combustible.

38 | VÖGELE SUPER 1803-3i | Highway class

38 | highway class www.voegele.info 39
 SUPER 2100-3

Las reglas para la SUPER 2100-3

Reglas de extendido
AB 500 TV Anchura máxima de trabajo Gama de anchuras de extendido
De 2,55 a 5,0 m extensible de forma gradual.
Ampliable hasta 8,5 m con extensiones mecánicas.

Sistemas de compactación
AB 500 TV con támper y vibración
AB 500 TP1 con támper y 1 listón de presión
AB 500 TP2 con támper y 2 listones de presión
2550 mm AB 500 TP2 Plus con támper y 2 listones de presión
5000 mm para una compactación muy alta
8500 mm

AB 600 TV Anchura máxima de trabajo Gama de anchuras de extendido

De 3,0 a 6,0 m extensible de forma gradual.
Ampliable hasta 9,5 m con extensiones mecánicas.

Sistemas de compactación
AB 600 TV con támper y vibración
AB 600 TP1 con támper y 1 listón de presión
AB 600 TP2 con támper y 2 listones de presión
AB 600 TP2 Plus con támper y 2 listones de presión
3000 mm
para una compactación muy alta
6000 mm
9500 mm

SB 250 TV Anchura máxima de trabajo Gama de anchuras de extendido

Anchura base 2,5 m, ampliable con extensiones
mecánicas hasta 13,0 m.
Gracias a las piezas extensibles hidráulicas (75 cm),
la anchura de trabajo puede ajustarse de forma variable
en un ámbito total de 1,5 m.

2500 mm Sistemas de compactación

1500 mm 1500 mm 1500 mm 1500 mm 1500 mm 1500 mm SB 250 TV con támper y vibración
SB 250 TP1 con támper y 1 listón de presión
750 mm 13000 mm 750 mm SB 250 TP2 con támper y 2 listones de presión
SB 250 TVP2 con támper, vibración y 2 listones de presión

40 | highway class www.voegele.info 41

 SUPER 2100-3

Todos los datos de un vistazo

Todas las dimensiones en mm

Datos
L*= depende de la regla de extendido,
consulte las especificaciones

2100

3100
3860
3 3
0- 0-
170 210 210
R R
PE PE
SU SU

12,5° 14,5° 305

3060 1970
5355 2550
L* 3265

Accionamiento Tren de orugas Grupos de transporte de material Reglas de extendido

Motor motor de 6 cilindros refrigerado por líquido Velocidades Sinfines de distribución 2, con aletas intercambiables y sentido SB 250 anchura básica 2,5 m
Fabricante Cummins Extendido hasta 25 m/min., regulable progresivamente de rotación reversible anchura máxima (TV/TP1) 13,0 m
Modelo QSB6.7-C240 Desplazamiento hasta 4,5 km/h, regulable progresivamente Diámetro 480 mm Versiones de la regla TV, TP1, TP2, TP2 Plus (AB 500, AB 600),
Potencia Accionamiento accionamientos hidráulicos individuales TVP2 (SB 250)
Nominal 179 kW a 2000 rpm (según DIN) Tolva receptora independientes Espesor de extendido hasta 40 cm (SB 250)
Modo ECO 168 kW a 1700 rpm Número de revoluciones hasta 79 rpm regulable progresivamente Calentamiento por resistencias eléctricas
Capacidad 14 t
Normativa sobre (mando manual o automático) Alimentación generador de corriente trifásica
Anchura 3265 mm
gases de escape normativa europea Fase 3a, Cota de nivel regulable hidráulicamente de forma
Altura de alimentación 615 mm (fondo de la tolva)
norma estadounidense EPA Tier 3 progresiva unos 15 cm Dimensiones de transporte y pesos
Rodillos de empuje
Depósito de carburante 400 l Lubricación equipo de lubricación central con bomba
para camiones Longitud tractor y regla de extendido
de engrasado de accionamiento eléctrico
Estándar suspendidos oscilantes AB 500/AB 600 TV 6,65 m
Tren de orugas Posicionamento regulable longitudinalmente a 75 mm o 150 mm TP1/TP2/TP2 Plus 6,8 m
Reglas de extendido
Opcional con suspensión elástica (“PaveDock”) SB 250 TV/TP1/TP2/TVP2 6,55 m
Orugas con zapatas de goma
Superficie de apoyo 3060 mm x 305 mm AB 500 anchura básica 2,55 m Pesos tractor y regla de extendido
Grupos de transporte de material extensible hasta 5,0 m AB 500 TV en anchura de extendido hasta 5,0 m 21,9 t
Dispositivo de tensión bloque de resortes
anchura máxima (TV/TP1/TP2) 8,5 m en anchura de extendido hasta 8,5 m 26 t
Lubricación Cintas transportadoras 2, con listones de arrastre intercambiables y
AB 600 anchura básica 3,0 m
de las roldanas de por vida sentido de marcha reversible brevemente
extensible hasta 6,0 m
Accionamiento Accionamiento accionamientos hidráulicos individuales
anchura máxima (TV/TP1/TP2) 9,5 m
de traslación hidráulico, accionamientos individuales independientes
anchura máxima (TP2 Plus) 8,5 m
independientes entre sí regulados Velocidad de marcha hasta 37 m/min, regulable
electrónicamente progresivamente (mando manual o automático)

Leyenda: AB = regla extensible TV = con támper y vibración TP1 = con támper y 1 listón de presión TVP2 = con támper, vibración y 2 listones de presión Reservado el derecho a realizar modificaciones técnicas.
SB = regla fija TP2 = con támper y 2 listones de presión TP2 Plus = con támper especial, 2 listones de presión y pesos adicionales

42 | highway class www.voegele.info 43

A WIRTGEN GROUP COMPANY

Su código QR de VÖGELE
para llegar directo a
la “SUPER 2100-3” en
Internet.

JOSEPH VÖGELE AG
Joseph-Vögele-Str. 1 Teléfono: +49 (0)621 8105 0
67075 Ludwigshafen · Germany Fax: +49 (0)621 8105 461
marketing@voegele.info www.voegele.info

® ERGOPLUS, InLine Pave, NAVITRONIC, NAVITRONIC Basic, NAVITRONIC Plus, NIVELTRONIC, NIVELTRONIC Plus, RoadScan, SprayJet, VÖGELE, VÖGELE PowerFeeder, PaveDock,
PaveDock Assistant, AutoSet, AutoSet Plus, AutoSet Basic, ErgoBasic y VÖGELE-EcoPlus son marcas comunitarias registradas de JOSEPH VÖGELE AG, Ludwigshafen/Rhein, Alemania.
PCC es una marca alemana registrada de JOSEPH VÖGELE AG, Ludwigshafen/Rhein, Alemania. ERGOPLUS, NAVITRONIC Plus, NAVITRONIC BASIC, NIVELTRONIC Plus, SprayJet, VISION,
VÖGELE, VÖGELE PowerFeeder, PaveDock, PaveDock Assistant, AutoSet, AutoSet Plus, AutoSet Basic y VÖGELE-EcoPlus son marcas de JOSEPH VÖGELE AG, Ludwigshafen/Rhein,
Alemania, registradas en la oficina estadounidense de patentes y de marcas. El contenido de este folleto es sólo informativo y no es vinculante. La compañía se reserva el derecho a hacer
cambios técnicos y de construcción. En algunas imagenes se muestran también componentes opcionales.

2517379 ES/02.16