SM74

WARRANTY
For Self- Propelled Sweepers
S B Manufacturing warrants that new equipment manufactured by it and delivered hereunder will be free
of defects in material and workmanship for the earlier of twelve (12) months from delivery to, or the
accumulation of 1,000 hours of service by the initial user. Any sweepers placed into service through the
dealers rental fleet shall constitute the initial user phase of the in service date.

The Purchaser shall be obligated to promptly report any failure to conform to this warranty to the Com-
pany by phone, in writing or e-mail within the applicable period, whereupon the Company shall, at its
option, correct such nonconformity, by suitable repair to such equipment or, furnish a replacement part
F.O.B. point of shipment, provided the Purchaser has stored, installed, maintained and operated such
equipment in accordance with good industry practices and has complied with specific recommendation
of the Company. The company shall not be liable for any repairs, replacements, or adjustments to the
equipment of any costs of labor performed by the purchaser or others without the company’s prior
written approval.

This warranty does not apply to failures occurring as a result of abuse, misuse, negligent repairs, corro-
sion, erosion and normal wear and tear, alterations or modification made to the product without express
written consent of the company, or failure to follow the recommended operating practices and mainte-
nance procedures as provided in the equipment’s operating and maintenance publications. Accessories
or equipment furnished by the company, but manufactured by others,
including, but not limited to, engines, tires, batteries, engine electrical equipment, hydraulic transmis-
sions, and carriers, shall carry whatever warranty the manufacturers have conveyed to the company
and which can be passed on to the purchaser.

The Company makes no other warranty or representation of any kind whatsoever, express or implied,
except that of title, and all implied warranties, including any warranty of merchantability and fitness for a
particular purpose, are hereby disclaimed.

Correction by the company of nonconformities whether patent or latent, in the manner and for the period
of time provided above, shall constitute fulfillment of all liabilities of the company for such nonconformities,
whether based on contract, warranty, negligence, indemnity, strict liability or otherwise with respect to or
arising out of such equipment.

The purchaser shall not operate equipment which is considered to be defective, without first notifying
the company in writing of its intention to do so Any such use of equipment will be at the purchaser’s sole
risk and liability.

S B Manufacturing Incorporated
3707 West McCormick
Wichita, Kansas 67213
 Table of Contents:
Page
Maintenance
Definition of Equipment 2 Air Cleaner 11

General Safety Notes 3 Hydraulic System 12-13

Operator Safety Placards 4 Brakes 15

Operator Qualification Sheet 5 General Inspection (Fasteners & Frame) 15

Engine Starting Procedures Engine Inspection 15

Starting Engine 6
Tires 15
Stopping Engine 6
Storage of the Machine 15
Warming the Engine 6
Daily Inspection 15
Normal Engine Operation 6
Core Drive 15
Cold Weather Starting 7
Lubrication
Lubrication & Maintenance Service Intervals 8 Rear Axle Assembly 13

Driving the Superior Broom Gear Box & Front Axle 14

Gear Selection 9
Drive Shaft 14
Emergency Stopping 9
Broom Replacement 16
Adjusting Seat 6
Wiring Diagram / Broom Joy Stick 17
Traveling Forward or in Reverse 9
Hydraulic Hose Schematic 18
Parking the Superior Broom 16 Air Conditioning System 19-25
Control Locations 9-10

Towing 15

Broom Operation
Operation of the Sweeping Core 10

Adjusting Sweeping Angle 10

Adjusting Sweeping Down Force 10

Turning the Broom Core Motor On/Off 10

Sweeping Tips 11

Pg.1
Definition of Equipment -

Self-propelled commercial road construction and maintenance sweepers.

Designed with a rear engine and fully enclosed cabs intended for use by a Single Operator.
Innovative hydraulic and electrical systems which provide both accuracy and durability for the equipment owners.

Pg.2
 Safety

Recognize Safety Information

This is the safety-alert symbol. When you see this symbol on
your machine or in this manual, be alert to the potential for
personal injury.
Follow recommended precautions and safe operating practices.

Understand Signal Words

A signal word - DANGER, WARNING, or CAUTION - is used
with the safety-alert symbol.
DANGER identifies the most serious hazards.
DANGER or WARNING safety signs are located near specific
hazards.
General precautions are listed on CAUTION safety signs.
CAUTION also calls attention to safety messages in this
manual.

Follow Safety Instructions

Carefully read all safety messages in this manual and on your
machine.
Keep safety signs in good condition.
Replace missing or damaged safety signs.
Be sure new equipment components and repair parts include
the current safety signs. Replacement safety signs are avail-
able from your Superior Broom dealer.

Learn how to operate the machine and how to use controls

properly. Do not let anyone operate without instruction.

Keep your machine in proper working condition.

Unauthorized modifications to the machine may impair the func-
tion and/or safety and affect machine life.

If you do not understand any part of this manual and need

assistance, contact your Superior Broom dealer.

Pg.3
 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.
! Read and understand the following warning
labels before operating this machine!
If you do not understand these warnings, do not oper-
ate this machine!
Although a high travel speed is available with the Supe-
rior Broom, we caution all operators to use good judg-
ment while roading this machine, especially on rough
roads.

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 Do not allow bystanders near the rotating brush, seri-
the operator in place so that ous injury may result.
the roll bar can protect the
operator. Adjust the slack
out of the seat belt by pull-
ing the unused portion of
the belt to the left. The belt
should fit snug over the
operator’s hips.

Be observant of people walking in front of the broom

while in operation. Small rocks can soon become mis-
siles capable of serious injury or loss of an eye.

Keep Riders Off Machine:

Only allow the operator on
the machine. Keep riders off.
! WARNING ! Riders on machine are sub-
ject to injury such as being
DO NOT START ENGINE WITH struck by foreign objects and
CONTROL PEDAL DEPRESSED thrown off of machine.
Riders also obstruct
operator’s view resulting in
The pedal beside the operator’s right foot is not a throttle. machine being operated in
If this pedal is depressed while starting the engine, the an unsafe manner.
machine could move forward or backward before the
operator is ready. This could cause injury to bystanders
and/or damage to property.

Pg.4
 Practice Safe Maintenance!
Keep Service Area Clean And Dry.

Understand service procedure before doing work.

Never lubricate or service machine while it is moving.

Keep hands, feet, and clothing from power-driven parts.

Disengage all power and operate controls to relieve pressure.

Lower equipment to the ground, stop the engine, remove the key and allow the machine to cool.

Securely support any machine elements that must be raised for service work.

Keep all parts in good condition and properly installed. Fix damage immediately. Replace worn or broken parts.
Remove any buildup of grease, oil, or debris.

Disconnect battery ground cable (-) before making adjustments on electrical systems or welding on machine.

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 responsibil-
ity 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.

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

Pg.5
Start up and propelling: Should the engine die when operating under load, im-
Caution: operator must be seated with seat belt mediately disengage the transmission and restart the
properly secured while engine is running. engine. Overheating of turbocharger parts may occur
when oil flow is suddenly stopped.

5. Check all gauges for normal engine operation. If

Seat Belt gauges indicate other than normal conditions, stop
the engine and determine the cause.

To stop the engine, bring the throttle lever to the idle

position, then turn the ignition key counter clockwise to
the “OFF” position.

IMPORTANT: Before stopping an engine that has been

operating at working load, idle engine at least 2 min-
utes at 1000-1200 rpm to cool hot engine parts.

Seat adjustment lever Warming Engine

IMPORTANT: To assure proper lubrication, operate en-
gine at or below 1200 rpm with no load for 1-2 minutes.
Before starting the engine, adjust the seat to a comfort- Extend this period 2-4 minutes when operating at tem-
able operating position. The seat position can be ad- peratures below freezing.
justed by moving the lever that is located under the front
edge of the seat. 1. Check oil pressure gauge as soon as engine starts.
If gauge needle does not rise above minimum oil
The following engine startup procedures are also in- pressure specification of 15.0 PSI within 5 seconds,
cluded in the Engine Operators Manual that is included stop the engine and determine the cause. Normal
with your Superior Broom delivery packet. The engine oil pressure is 50 PSI at rated full load speed
operator’s manual provided by the engine manufacture (1800-2500 rpm) with oil at normal operating tem-
takes precedence over the following instructions. perature of 240°F.
2. Watch coolant temperature gauge. Do not place en-
CAUTION: Before starting the engine in a confined gine under full load until it is properly warmed up.
building, install proper outlet exhaust ventilation equip- The normal engine coolant temperature range is
ment. Always use safety approved fuel storage contain- 180°-202°F.
ers.
NOTE: It is a good practice to operate the engine under
NOTE: If temperature is below 32°F (0°C), it may be a lighter load and at lower speeds than normal for
necessary to use cold weather starting aids (See the first few minutes after start-up.
COLD WEATHER OPERATION, later in this section).
1. Perform all prestarting checks outlined in the engine Normal Engine Operation:
operators manual. Observe engine coolant temperature and engine oil
2. Shift the transmission to neutral & set parking brake. pressure. Temperatures and pressures will vary with
3. Move the throttle lever to 1/3 open. changing operating conditions, temperatures, and loads.
4. Turn the key switch clockwise to crank the engine. Normal engine coolant operating temperature range is
When the engine starts, release the key so that it 180°-202°F.
returns to the “ON” position. If coolant temperature rises above 234°F, reduce load
on engine. Unless temperature drops quickly, stop en-
IMPORTANT: If the key switch is released before the gine and determine cause before resuming operation.
engine starts, wait until the starter and the engine stops Operate the engine under a lighter load and at slower
turning before re-engaging the starter. This will prevent than normal speed for first 15 minutes after start-up.
possible damage to the starter and/or flywheel. DO NOT run engine at slow idle. IMPORTANT: Should
the engine die while operating under load, immediately
Do not operate the starter for more than 30 seconds at remove load and restart the engine. Overheating of the
a time, to do so may overheat the starter. If the engine turbocharger parts may occur when oil flow is stopped.
does not start the first time, wait at least 2 minutes be- Stop engine immediately if there are any signs of en-
fore trying again. If engine does not start after four at- gine malfunction.
tempts, see Trouble-shooting Section in the Engine
Manual. Pg.6
Symptoms that may be early signs of engine problems The engine “Operator’s and Maintenance Manual” are
are: supplied by the engine manufacture and are included
Sudden drop in oil pressure in the Superior Broom “Owner/Operators” delivery
Abnormal coolant temperatures packet. However in the event the engine manual be-
Unusual noise or vibration comes lost or separated from the broom operator’s
Sudden loss of power manual the following information needs to be recorded.
Excessive black exhaust
Excessive fuel consumption ++++++++++++++++++++++++++++++
Excessive oil consumption
Fluid leaks Perkins Engine Serial No:_______________________

Cold Weather Starting: ++++++++++++++++++++++++++++++

Engines may be equipped with coolant heaters, or ether
injectors as a cold weather starting aid. Starting aids CAT Engine Serial No:_________________________
are required below 32°F. They will enhance starting per-
formance above these temperatures and may be ++++++++++++++++++++++++++++++
needed to start applications that have high parasitic
loads during cranking and acceleration to idle. The John Deere data plate is located on the right-hand
side of the cylinder block behind the fuel filter. Each
CAUTION: Ether injector starting fluid is highly flam- engine has a 13-digit serial number and a model num-
mable. DO NOT use starting fluid on engines equipped ber.
with air intake heaters.
DO NOT use starting fluid near fire, sparks, or flames. John Deere Engine Serial No:_____________________
DO NOT incinerate or puncture a starting fluid container.
John Deere Engine Model No: __________________
Using correct grade of oil (per engine and machine
operator’s manual) is critical to achieving adequate cold In additon to the above engine information, the injec-
weather cranking speed. tion pump make, model, and serial number should also
be recorded.
1. If a block heater is used, proceed with a normal start-
ing sequence as outlined in the “Start up and propel- Make:________________________________________
ling” paragraph on page 5.
2. If an ether injector is used, proceed with a normal Model:________________________________________
starting sequence as outlined in the “Start up and
propelling” paragraph on page 5. Activate the ether Serial No. __________________________________
injector button as the starter is being engaged.
Other information on the data plate:________________
Additional information on cold weather operation is avail-
able from your authorized servicing dealer. _____________________________________________

Service - engine _____________________________________________

Check engine oil level at the start of each day before
using the broom. _____________________________________________

Change engine oil and filter the first time before reach-
ing 100 hours of operation, then every 250 hours there-
after.

Refer to engine manual for additional information con-

cerning time intervals and specifics.

Pg.7
Service intervals - Refer to the engine owners manual for the recommended service intervals.

Lubrication and Maintenance Service Intervals Important: recommended ser-

vice intervals are for normal op-

500 Hour/12- Months

250 Hour/6-Months
erating conditions. Service more

First 150 Hours

Procedure

First 50 Hours

2000 Hour/24-

As Required
often if engine is operated under

M onths
adverse conditions. Neglecting

Daily
Service Item / Area maintenance can result in fail-
ures or permanent damage to
the engine.
Check Engine Oil and Coolant level x
Hydraulic Oil level x
Fuel Filter/Water Separator Bow l x
Air Cleaner Dust Unloader Valve & Indicator x
Fluid Level in Tw o-Speed Gearbox x
Engine Mounts x
Manual Belt Tensioner and Belt Wear x
Brake Pads f or Wear x
Air Intake Hoses, Connections, & System x
Automatic Belt Tensioner and Belt Wear x
Engine Electrical Ground Connection x
Cooling System x
* Crankshaf t Vibration Damper (6.8 L Eng.) x
Check and Adjust Engine Valve Clearance x
Change Tw o-Speed Gearbox Oil (#1) x
Engine Oil and Replace Oil Filter x x
Hydraulic Oil and Replace Filter x x
Filters x
Lubricate Rear Axle Assembly (10 Lube Points) x
Drive Shaf t (3 Lube Points) x
Repack Wheel Bearings x
Service Service Fire Extinguisher x
Service Battery x
Cle an Clean Crankcase Vent Tube x
Flush Cooling System x
Replace Replace Fuel Filter Element x x
Replace Air Cleaner Elernents x x
Replace Fan Belt x
Tes t Coolant Solution Analysis - Add or Replace x
Pressure Test Cooling System x
Test Thermostats x
Add Coolant x
Inspect Perf orm Visual Walkaround Inspection x
Rear Axle Pivot Bushings x
Boxes that are shaded, are engine service areas
1. Change tw o-speed gearbox oil every 200 hours af ter initial 100 hour oil change.
(*) Applies to John Deere engine only

Pg.8
The Superior Broom is hydrostatically driven. The di- 1. To start the engine refer to the Start up procedures
rectional control is achieved through use of dual con- on page 5.
trol pedals located near the operator’s right foot. Keep the brake pedal depressed while starting
Left pedal directs the machine forward and the right the engine. Do not place your foot on the direc-
pedal directs the machine in reverse. tional control pedal until the engine is running
and the transmission has been shifted into gear.
Caution
2. Choose the desired gear using the two-speed
The distance the pedal is depressed governs the selector switch (item 14 in the illustration below)
located on the control console.
rate of travel speed. The pedals will return to neutral
Low range is normally used while sweeping in or-
when the pressure is released.
der to maintain sufficient engine RPM to run the
hydraulics.
IMPORTANT Operate the machine in low range until the opera-
Familiarize yourself with all controls before tor is familiar with the machine. High range is used
operating this machine. during light sweeping and while roading the ma-
1. Down pressure gauge chine and not sweeping.
2. Down pressure control (“T” handle) 3. After gear selection, raise engine RPM to about half
3. Engine gauges & system controls throttle. Release parking brake. Slowly depress con-
4. Throttle trol pedal in the desired direction. Engine speed may
5. Horn button be adjusted to obtain desired travel speed.
6. Ingnition switch 4. Do not propel this machine with the parking brake
7. Parking brake light engaged. This will damage the front brake assem-
8. Broom control joystick blies and void the warranty. This type of operation
9. Windshield wiper is considered abuse.
10. Parking brake 5. Do not overspeed! Although a high travel speed is
11. Brake pedal available with the Superior Broom, we caution all
12. Forward control pedal operators to use good judgment while roading the
13. Reverse control pedal machine, especially on rough roads.
14. Two Speed selector switch 6. If the control pedal is released while traveling, the
15. Driving light switch machine will slow down rapidly. This is called “dy-
16. Water spray switch namic braking’. Using dynamic braking at low
17. Strobe light switch speeds is fine as long as the operator is ready to
18. Cab Blower switch use the brake pedal (Item 11) if needed. At higher
speeds, however, the operator must use the brake
pedal in conjunction with the hand throttle and con-
trol pedal in order to minimize strain on the drive
train. This will prolong the life of the entire drive
train.
7. Do not reverse the direction of travel while the broom
is in motion. This will damage the drive train and
void the warranty. This type of operation is consid-
ered to be abuse.
10

1 3 4
7 9 8 2

18

12
11

13
5
6
15 16 17 14
Pg.9
Operation of the Sweeping Core: Right / Left Operation Of Broom:
The electronic joystick control located to the right of The core may be set at any angle from 35 left to 35
the operator, controls all functions of the sweeping core. right, simply by moving the Joystick side to side.
Refer to the illustration below.
Power is supplied to the Joystick when the Ignition Raise / Lower Broom:
switch is turned on. To raise the core, pull the Joystick back. To lower the
core for sweep mode push the joystick forward and
Broom On / Broom Off: release. (Broom does not have positive down pressure)
The core motor is turned on & off by the top button on
the Joystick as shown in the illustration. Float Position:
When Joystick lever is moved forward the brush core
is automatically in float position.
The float pressure may be adjusted by moving slide to
adjust pressure. (Fig. 1 )
Broom On / Broom Off
The “Float” position will allow the core to maintain the
ideal contact with the road
while allowing it to float
over bumps or contours in
the road surface.

Proper pressure setting

for the brush float position
is very important.
A pressure gauge located
at the top right of opera-
tors control panel indi-
cates float pressure when
broom is running and on
sweeping surface.(Fig. 2)

In the raised position the

gauge will normally read about
750 PSI. (X)
The recommended sweeping
pressure will be 150 PSI less,
(550 PSI) in the sweeping po-
sition with the brush making
contact with the street surface.
Fig. 2
These pressure settings are
only examples and your settings may vary.
(X)-150 = PSI sweeping pressure
(example) = 700 - 150 = Gauge @ 550 PSI.
A diagram showing the wiring connections between the Caution: Over use of the positive down pressure set-
Joystick and the hydraulic Solenoid Valve manifold is ting will cause excessive wear and shorten the life of
shown on page 16. the broom.

The lower PSI reading on pressure gauge means more

down pressure on brush and the higher the PSI read-
ing means less pressure on the brush. Broom Speed
is adjusted by raising or lowering engine rpm.

Note: engine speed must be maintained at a minimum

of 1500 RPM for sweeping operations.
Under average sweeping conditions, a higher engine
speed will be advantageous.

Pg.10
Sweeping Tips: Maintenance:
If the broom starts to “hop” or “bounce”, the propelling The manufacture has endeavored to build the Superior
speed is too high, slow the machine down, but maintain Broom as maintenance free as possible. The service
high engine speed. Slowing the forward speed of the points are easily accessible and are similar to those on
machine down will prevent you from having to make a many other types of construction equipment. This sec-
second pass with the broom. tion will cover many of these points in some detail and
will briefly mention those which should be standard on
In areas where the dirt is “caked”, try to clean it by go- all equipment.
ing over it a second or third time. If this does not clear
the dirt, use the float control pressure valve to apply Air Cleaner:
more pressure on the brush. In most cases, the float The air cleaner is one of the most important compo-
pressure setting will yield the best results. nents of this machine. Due to the extremely dusty con-
ditions in which this machine operates, the air cleaner
When changing the direction of travel, allow the ma- must be maintained constantly. This machine is
chine to come to a complete stop before moving the equipped with a dry type dual element air cleaner, vane
directional control pedal. Failure to completely stop the type pre-cleaner and a restriction type service indicator
machine before changing direction can cause prema- as standard equipment.
ture failure of the drive components. If the dust cloud
becomes so thick that it obscures your vision of the Under average conditions, the air cleaner will need to
road, use the water sprinkling system (if installed), or be serviced every
stop the machine until the dust clears. If possible, angle three to four hours.
the sweeper so that the dust and debris is swept down- When the clear ring
wind. on the service indica-
tor turns red, the air
Caution cleaner must be ser-
viced immediately.
The operator must be aware at all times of any people, The following proce-
vehicles, or any other objects which might be in the path dures must be fol-
of flying debris from the sweeper. The sweeper can lowed to ensure long engine life.
throw small rocks and other objects several feet. This
debris can cause serious injury to people and damage To service: Loosen the clamp which secures the end
to property. Always check that the area around and in
front of the broom core is free of obstructions before
adjusting the broom angle or activating the core. P r e - Clamp
cleaner
NO RIDERS
! WARNING !
UNDER NO CIRCUMSTANCES SHOULD Dust
PASSENGERS BE ALLOWED TO RIDE Unloader
ON THIS MACHINE. Valve
THERE ARE NO SAFETY PROVISIONS ON THIS
MACHINE FOR PASSENGERS.
FAILURE TO HEED THIS WARNING COULD RESULT IN
SERIOUS INJURY OR DEATH!

E n d

cover. Remove the end cover and the wing nut that se-
cures the filer element. Carefully slide the element out
of the canister. 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 ele-
ment. Clean the dirt from the inside of the canister and
the end cover. Hold the element so that the opening is
on top, with your other hand, gently pat the side of the
element to loosen the dirt. Do not tap the element
Pg.11
against a hard surface as this can cause damage to passed through a heat exchanger. The following speci-
the element itself. Air pressure may be used to clean fications are for testing and informational purposes only.
dirt from the element, but the air-pressure must be re- If a problem develops with the pump or motor, we
duced to less than 30 PSI. Using an air nozzle, clean strongly advise that it be taken to an authorized repair
the element from the inside, moving the nozzle up and center.
down in the direction of the pleats. Do not direct the
air-stream against the outside surface of the element, Displacement: 2.48 cubic inches
as it will force the dirt through the element fabric, result- Volume: Approx. 34 GPM @ 2500 RPM
ing in damage. Maximum pressure: 4500 PSI.
Continuous pressure: 3000 PSI.
Maximum case pressure: 75 PSI.
Caution Continuous case pressure: 50 PSI.
When using compressed air, clear the area of bystand- Charge pressure: 220-240 PSI.
ers, guard against flying chips, and wear personal pro-
tection equipment including eye protection. Caution!
The element may be cleaned by the following proce- When it becomes necessary to add or change oil in this
dure: If element is coated with oil or soot, wash in a system, extra care must be taken to protect the fluid
solution of warm water and filter element cleaner. from contamination. Take every precaution when chang-
Let the element soak at least 15 minutes, then agitate ing a filter or a hose. Clean the area of the machine
gently to flush out dirt. Rinse element thoroughly from where the replacement will take place. Never leave a
the inside with clean water. Use an element cleaning port uncovered on the pump or motor where dirt can
gun or a free running hose. Keep the pressure under enter the system. The slightest contamination can cause
40 PSI to avoid damage to the element. Allow the ele- the pump and / or motor to fail.
ment to dry completely before using. This usually takes
from one to three days. Power steering:
A single hydraulic pump supplies oil for both the power
Do not oven dry or use drying agents. Protect element steering and the core functions. A load sensing priority
from freezing until dry. The element must be inspected valve supplies the orbital type steering unit with 5 GPM
before it is reinstalled. Hold a bright light inside the ele- max. (on demand). This steering unit supplies oil to ei-
ment and check carefully for holes. Discard any ele- ther side of the two-way steering cylinder as directed
ment that shows the slightest hole. by the operator. Return oil is passed through a 10 mi-
cron filter before entering the reservoir.
Be sure that the outer screen is not dented. Vibration
will quickly wear a hole in the filter. Make sure the filter Core functions:
gasket is in good condition. If gasket is damaged or The core drive uses a drive motor with a splined shaft
missing, replace the element. Seal the element in a plas- which couples to a hub mounted inside the core
tic bag and store in a shipping container to protect frame.Hydraulic oil is supplied to this motor by the same
against dust and damage. pump that supplies oil for the power steering. Oil is sup-
plied at the rate of 12-18 GPM, depending on engine
Hydraulic System: speed. This oil is routed directly to a control manifold
The hydraulic system on this machine operates the hy- with electronically controlled valves.
drostatic drive, power steering, and all core functions. It
incorporates two supply pumps sharing the same res-
ervoir. In order to simplify the description of this sys- The open center passage in the valve is closed off when
tem, it will be separated into three different parts. a spool is fully shifted. Hydraulic oil will flow directly to
the power core passage, making oil available to all work
Hydrostatic drive: ports. If two or more spools are fully shifted at the same
This system utilizes a variable displacement pump and time, the oil will flow to the path of least resistance, and
fixed displacement motor. Oil, supplied from the reser- the hydraulic cylinder or motor with the lightest load will
voir, passes through a 10 micron filter before entering begin to function first.
the pump. High pressure oil is supplied to the motor
through high pressure hoses. A hot oil shuttle has been This valve is equipped with a non-adjustable relief valve.
installed between the pump and motor to ensure that a This relief setting governs all hydraulic oil pressure used
specific amount of oil is removed from the high pres- to operate core functions. Restrictor fittings are used in
sure loop so that it may be replaced by cooler oil. the hydraulic lines attached to the lift and shift cylinders
The hot oil removed from the loop by the shuttle is routed in order to meter the flow thus controlling the speed of
back to the pump where it will join the unused oil in the expansions and contraction.
case drain. The case drain from the motor is routed to
Pg.12
join this return flow. All oil returning to the reservoir is Lubrication:
On standard applications, the oil is routed from the valve Rear Axle Assembly:
to the core motor and returned to the reservoir through There are ten lubrication points located on the rear axle
a 10 micron filter. This routing allows for single direc- assembly. Use a standard automotive type grease on
tion core operation only. This is done to maintain core each of these. While
balance on the pivot type core suspension used on this servicing these points,
machine. This is the most efficient manner in which to inspect all ball joints
obtain the superior cleaning capabilities of this machine. and rod ends for slack.
The following specifications relate to the hydraulic pump If slack is found in any
used on the power steering and core functions. These part of this suspension,
figures may be of service if trouble shooting becomes Steering cylinder pivot, including bolster pivot
necessary. lube two (2) places. bushings, replace all
worn parts.
Displacement: 2.77 cubic inch
Volume: Approx. 30 GPM @ 2500 RPM Tie-rod Ball Joints:
Priority controlled flow: 5 GPM Lube @ two (2) loca-
tions, one (1) place
Hydraulic maintenance: each side.
1. Replace the disposable filter elements after the first
50 hours of service, and every 500 hours thereafter.
2. Always maintain sufficient hydraulic oil in the reser-
voir as indicated in the level sight glass on the left
side on the hydraulic tank. When it becomes neces-
sary to add or replace oil in the system, use an oil
King Pins:
comparable to CONOCO 46 Super Hydraulic Oil
Lube @ four
or equivilant, which is in the machine at the time of (4)
delivery. locations, two
3. Periodically check all hydraulic hoses. If any hose (2) places
feels “spongy” or shows signs of wear or chafing it each side.
must be replaced. As a general guide, if you are un-
sure 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, cleanli-
ness must be stressed during this type of mainte-
nance. Contamination of this system will cause pump
and / or motor failure. Avoid servicing hydraulic sys- Steering Ball Joints:
tem in the field where a clean environment cannot lube (1) one location.
be controlled.
4. Due to the dusty conditions in which this machine
operates, the heat exchanger and radiator must be
cleaned every 4 to 8 hours of service, depending on
sweeping conditions. If either one becomes clogged
with dirt, it will overload the cooling capacity of the
other, causing both the engine and hydraulic system
to operate at higher than acceptable temperatures.
Use water or compressed air directed from the en-
gine side of the radiator to remove dirt build up. The
engine must be completely stopped while perform-
ing this maintenance. Inspect radiator and heat ex-
changer for dirt deposits and / or damage before re-
suming operation.

Caution

Do not attempt to clean radiator or heat exchanger while The grease zerk for the steering cylinder pivot bracket
engine is running. If hands or equipment come in con- is accessed through a hole in the bottom of the axle
tact with spinning fan blades, serious injury will result.Pg.13tube.
Engine must be completely stopped.
 Check pivot bushing for wear. Brakes:
Grease_ This machine is equipped with four-wheel hydraulic
brakes and a mechanical parking brake. The operation
Steering axle bolster of the brakes should be tested daily.
and mount
Everyday, before this machine is to be operated, check
the brake pedal “feel”, much the same way as on an
automobile. The pedal should be firm when depressed.
If the pedal feels “spongy”, it probably means that there
is air in one or more brake lines. If the brake pedal goes
Both the steering axle and drive shaft should be ser-
all the way to the mechanical stop, there is either a leak-
viced every time the engine is serviced, this is the mini-
ing line, low fluid in the reservoir, or the brake shoes
mum service interval. A more frequent servicing of these
are worn out. If the brake pedal does not feel firm, the
components will extend their service life.
brakes must be serviced prior to operating this machine.
Gear Box & Front Axle
The master cylinder is located directly in front of the
Front Axle brak e pedal.
Check the fluid
level periodically, Master Cylinder
especially if the
brake lines show
signs of leakage.
If it becomes
Gear Box necessary to add
or change the
brake fluid, use a
Check the fluid level in the gearbox every 25 hours or
fluid with a DOT
sooner if signs of leakage appear. Change the lubricat-
3 rating.
ing oil after the first 100 hours and then every 200 hours
thereafter. Drain the oil while the unit is warm. Replace
Inspect brake lines every 50 hours (minimum) for leaks
with SAE 85W-140W gear oil, up to the oil level plug.
and / or damage. Replace front and rear brake hoses
Service the front axle in the same manner as the trans-
every two years. Use standard automotive procedures
mission. The axle bearings do not receive lubrication
for “bleeding” the brakes if it becomes necessary.
from the gear oil. Periodically remove the axle shafts
and repack the bearings.The rear axle also uses SAE
Caution
85W-140W gear oil.
Do not allow this machine to be operated with faulty
There is no cause for alarm if either of these compo-
brakes. This will put the operator in extreme danger
nents is leaking oil through their breathers after they
and could cause bodily injury and property damage.
have been serviced. The breather allows overflow if the
unit was overfilled. This leakage will stop when the
Inspect mechanical parking brake linkage for proper ad-
proper level is achieved. With proper maintenance and
justment, routing and / or damage every 50 hours (mini-
operation, these components will last the entire life of
mum).
the machine.
Fasteners:
Drive shaft
Like any construction equipment, this machine requires
periodic tightening of fasteners.

During normal engine service intervals, check all nuts

and bolts, clevis pins, and clamps. Start at the front of
the machine and work to the rear. The following list con-
tains several of the more critical fasteners to be checked.
Lube
Do not limit your inspection to these fasteners.
Check the condition of the following fasteners.
There are three lubrication points on the drive shaft.
1. Rear bolster mount bolts
These also require standard automotive type grease.
2. Bolster pivot pin bolts
While servicing drive shaft, check for loose fasteners
3. Tie rod end lock nuts
and slack in the U-joint.
4. Steering cylinder rod end lock nut
Pg.14
 5. Steering cylinder mount bolt engine fan inspection and replacement be done ev-
6. Steering wheel nut ery 300-400 hours. The dusty environment the broom
7. Brake cylinder mount bolts is operating in will result in erosion of the fan blades.
8. Brake pedal pivot bolt The fan will need to be replaced when the blades dete-
9. Core pivot bearings riorate to the point that they do not provide enough air-
10. Core motor mount bolts (and lock rings on movement or they become operationally unsafe. This
direct drive cores). fan blade erosion is considered to be normal wear on
11. Pillow block bearing mount bolts this type of equipment.
12. Hydrostatic pedal linkage clevis pins
13. Gearbox mount bolts Tires:
14. Pump drive mount bolts The tire manufacture recommends a tire pressure of
15. Engine mount bolts 50 PSI. This will provide the longest tire life. A lower
16. Radiator mount bolts
pressure will provide a more comfortable ride, and make
17. Front axle mount bolt
rough road conditions easier to negotiate.
This is just a partial list of the bolts on this machine,
Checking your air pressure monthly can help you avoid
these should be inspected on a regular basis, the rest
dangerous tire conditions and save money.
of the fasteners on the machine should also be checked
periodically. Proper inflation pressure is essential for achieving maxi-
mum performance and mileage. Improper tire inflation
Frame, Gussets and Welds: pressure can cause severe internal tire damage, which
The frame on this machine was designed to withstand can lead to sudden tire failure and resulting in serious
normal operating conditions, however under abusive personal injury or death.
type use, components and welds can fail. Periodically
check all frame welds and gussets for development of Improper inflation pressure may result in rapid or irregu-
fatigue cracks. Failure to inspect and maintain the frame lar wear. Pressures should always be checked when
and it’s components could result in damage to the equip- the tires are cold and at least monthly. Under normal
ment and serious injury to the operator. tire operation, approximately 1psi of tire pressure will
escape every month. Also, for every 10 degrees F
Core Drive: change in ambient temperature, tire pressure will
The Superior Broom direct drive core is laser aligned at change by approximately 1psi.
the factory and does not need adjusting. If the drive
hub begins to show uneven or excessive wear the core Storage:
will need to be readjusted. A laser alignment tool and When storing the Superior Broom outside, it is recom-
instructions are available from the factory. mended that a light coating of oil be sprayed on the
wire bristles of the broom core to retard rusting. This
Towing: only applies to the optional wire cores.
The Superior Broom may be towed in case of emer- Before shutting the engine off, raise the broom off the
gency. ground to prevent a flat spot forming during storage.
The transmission must be shifted into neutral The electrically controlled hydraulic manifold will hold
before towing. the lift cylinder in the raised position.
A shift lever is located just under the cab entrance
platform. A lock pin must be removed and the handle Daily Inspection:
moved forward to place the transfer case in neutral 1. Visually inspect the entire machine for damage and
position for towing. fluid leaks.
The machine is not designed to be towed at highway 2. Check all fluid levels; engine oil, radiator and hydraulic
speeds. Towing should only be performed to move the reservoir.
machine short distances. To operate machine after tow- 3. Check wheels and tires for excessive wear or dam-
ing, shift gearbox back into gear by pulling shift lever age, also check air pressure and lug nut tightness.
back and replacing lock pin into shift bracket. If ma- 4. Check air cleaner service indicator (service if indi-
chine will not operate, check to make sure gearbox is cated).
fully engaged and shift lever pin has been replaced. 5. Seat belt, core cover and rubber rock guard should
be installed and serviceable.
Engine: 6. Lights, windshield wipers, reverse alarm, etc., must
The normal engine operation and maintenance proce- be in operating condition.
dures are covered in a separate manual, which is fur- 7. Test brakes before operating this machine.
nished by the engine manufacture.
Important: due to the dusty conditions that the Supe-
rior Broom operates in, it is recommended that the Any defects or damage found during this inspection must
be repaired before operation.
Pg.15
Tube Brush Replacement Instructions: 8. Install the pillow block bearing on the right side of
the core using the original mounting bolts.
The Model SM80 Superior Broom uses a one piece 9. Raise the core. Slide the core to the left as far as it
tube brush, 32” x 96”. will go. Using a pry bar, slide it back to the right until
the bolts on the end cap will clear the hydraulic hose
1. Place brush in float position from operator’s sta- fittings.
tion. Place safety stands under the lift arms. Re- 10.Install the Dodge “D-Lok” bearing on the spindle se-
move the two ½” bolts holding the pillow block bear- curely. This “D-Lok” is all that maintains core align-
ing using a ¾” socket or end wrench. ment.
Pull the brush assembly away from the brush drive
motor.
Important:
Lift brush core cover up so brush assembly is easy
to remove from under the machine. Do not slide the core drive coupler all the way onto
the splined shaft of the core drive motor.
There should be 1-1/2” of shaft extending past the pil-
low block bearing race that is located at the opposite
end of the broom core.

Note: make certain you have full contact with the brush
drive hub and the splined drive shaft of the brush drive
motor.
A good measurement to follow is allow 1” clearance
between the bolt head on the brush end plate and the
hydraulic fitting coming off the hydraulic drive motor.

The drive hub should be mounted so the hub splines

do not entirely cover the splines on the core motor.

2. Remove the four long bolts from end plate with a

9/16” end wrench or socket. Inside the tube are
three (3) compression plate bolts. Loosen all three
bolts with a 3/8” hex head wrench. Do not remove
bolts only loosen them. On the opposite end of the
broom loosen the same three hex head bolts. You
do not need to remove the flat end plate to loosen
these bolts.
After the compression plates have been loosened,
pull the entire core frame from the inside of the
brush.
3. Slide the core frame inside the new brush until the
end plate is flat against the end of the brush. Tighten
the three (3) hex head bolts on each end and re-
place the end plate with four (4) long bolts.
4. Using emery cloth or sandpaper, clean the spindles
to remove any burs or tar which may interfere with Do not try to readjust the motor mount unless it be-
bearing installation. comes damaged or otherwise unserviceable. The align-
5. Raise the core support frame and slide the rebuilt ment on this mount is preset at the factory. If it does
core under the sweeper. The core will have to come become necessary to realign the mount contact the fac-
in from an angle in order to be started over the motor tory for the lazer alignment kit and instructions.
mount. Once the core has been started onto the
motor mount, swing the right side under the right
support frame.
6. Lower the support frame slowly until the motor
mount is centered in the core.
7. Using a back and forth twisting motion, pull the core
onto the splined shaft.
Pg.16
Pg.17
 (Serial # 917343 & UP)

BYPASS CHECK VALVE

Valve-01-50600-018
Tee-01-50600-019

OIL COOLER
01-50000-060T4B
05-50000-060T4
HYDRASTAT
FOOT PEDAL
01-50000-092B

DOWN PRESSURE
GAUGE
01-93000-001

CONCENTRIC
PUMP
11-50800-002

GEAR BOX MTR.

11-50800-008-15

FILTER
01-50600-004M

HYDRASTAT
01-50600-009R

2 - SPEED GEARBOX
01-50000-087
CORE MTR. SHIFT CYL.
01-50600-001B 01-50000-033
STEERING UNIT
01-50600-011

SIDE SHIFT CYL.

STEERING CYL. 11-39000-003
01-50000-003 LIFT CYL.
11-50000-036

Pg. 18
Preventative Maintenance Procedures For The Air Conditioning System

Preventative maintenance is a result of the need to efficiently curb the cost of keeping your vehicle’s air condi-
tioning system functioning properly. Logic would dictate that you not wait until it breaks to fix it. Very few of us
have any hesitation in recognizing the need to regularly change the engine oil and oil filter to prolong the life of
our engines. Lubrication, wheel alignment, tire replacement, brake adjustment, and fluid level checks are just a
few of the areas that are checked, repaired, and/or maintained on a regular basis. The ever increasing recogni-
tion of a need for proper vehicle maintenance in order to run a cost efficient business, coupled with the rising
dependency on air conditioned vehicles, and the high cost of downtime, have combined to create a growing
demand for a sensible maintenance program for A/C systems.

The logical approach is to adopt a regular service procedure based on the concept of prolonging the life of the
expensive components used in the A/C system. These are generally recognized as the compressor, evaporator
coil, and condenser coils. The expansion valve is not ultra-expensive, but changing the receiver-drier and prop-
erly evacuating the system can usually extend its service life. The receiver-drier is the service component that is
designed to protect the expansion valve in virtually all A/C systems. It is expendable and its function is compa-
rable to the engine oil filter.

This manual is designed to make you comfortable with basic air conditioning concepts. With this newfound or
renewed understanding of vehicle A/C systems, it should be easier for you to recognize the validity of the
proposed preventative maintenance program.

We shall approach the preventative maintenance program by first discussing the basic scientific principles that
enable A/C systems to function. We shall then proceed through a discussion of system components and refrig-
erant flow patterns. This will allow you to better understand and hopefully approach the service and trouble-
shooting procedures that follow with a firm. Logical grasp of the functions of the components and how they
interact with each other. We shall also look at the safety considerations that you should be aware of in working
with the A/C systems. It is also very important that we discuss the service tools that will enhance your servicing
of the A/C system.

It should be noted that the procedures contained herein are not just applied A/C theory, but are tried and tested
methods. Even if you have years of A/C repair experience, hopefully you will benefit by the information and
procedures outlined in this manual.

Recommended Preventative Maintenance Procedure

The following procedures are set forth in a manner that will allow both the beginner and the expert to utilize the
contents successfully. After you have followed these steps a few times, they should become second nature.

When you approach a vehicle for preventative maintenance or for service due to a complaint, you will find it
beneficial to install your manifold set (gauges) immediately. There is no other reliable means of determining
exactly how well or poorly a system is functioning. It is also recommended that you hook-up both the high side
and low side test hoses each time. Just hooking up one side will not positively indicate the performance of the
other.

Manifold Hook-Up
Systems with Screw Type Service Valves

1. Remove the protective caps from the service ports.

2. Connect the test hose ends onto the service ports:
Blue hose on the low side or suction side
Red hose on the high side or discharge side
3. Hook the center hose to the recovery machine.

Visual Inspection
Visually inspect the vehicle’s A/C components for signs of failure, excessive wear, or any condition that might
lead to a component failure, such as:

1. Belt – check for proper tension, signs of fraying, cracking, or slippage as well as alignment.
2. Clutch – look for signs of excess heating or scaling which could be due to improper voltage, slippage of
the belt, weakening clutch plate fingers, defective bearing.

Pg.19
 3. Hoses – check for wear spots, rubs, brittleness, weather-cracking, excessive heat exposure, and signs
of leaking which might be indicated by oily spots on hoses or fittings.
4. Condenser – check for indications of airflow restrictions, i.e., bent fins, bugs dirt, and debris.
5. Drier sight-glass (a & b vehicle running, c & d vehicle not running).
a. Bubbles – indicating possible low refrigerant condition.
b. Clear – indicates either no refrigerant or at least a full charge (overcharge is still possible).
c. Cloudy – brown residual coating indicative of desiccant deterioration or severe moisture contamination
(system must be flushed – see flush procedure).
d. Oily streaks – indicating oil contamination usually compressor burnout (system must be flushed – see
flush procedure).
6. Evaporator Coil – check for indications of airflow restrictions such as bent fins, dirt, foreign debris, and
dirty filter.
7. Drain Hose – check to ensure unrestricted water flow.

Electrical System Checks

It is recommended that you run an electrical system check to ensure that the system can operate in all available
modes. The electrical system includes the blowers, safety switches, thermostat, and electro-magnetic clutch.
To check the electrical system:
1. Turn on the A/C fan switch. Fans should blow on all available speeds; if not blowing check circuit
breaker, blower switch, blower motor, and wiring.
2. Turn the thermostat to colder position. The electro-magnetic clutch should engage (you can usually
hear it engage if engine is not running). If it fails to engage, check voltage at the thermostat, then trace
through safety switches to clutch assembly to find open circuit. Upon finding any faulty component,
repair or replace as necessary.

If electrical components seem in order, you are ready to crank the vehicle and run system to determine the
condition of the A/C system.

A/C System Performance Checks

To evaluate the performance and/or condition of any A/C system properly, it is necessary to run the vehicle’s
engine so that the compressor can pump the refrigerant through the various components enabling you to deter-
mine if a problem exists. This evaluation should be carried out on any vehicle that you are working on. Failure to
do this could result in the customer having to bring the vehicle back due to a problem you could have solved
earlier or, at the very least, your having to repeat certain steps such as evacuating.

Evaluating the A/C Components

1. Crank the vehicle – run 1200 to 1500 RPM.
2. Turn the A/C system on (fan, thermostat).
3. Check gauge reading and unit performance (duct temperature, clutch cycling, etc.) to see if the unit is
performing as it should be. If it is not, you will have to trouble-shoot the unit (refer to Troubleshooting
The A/C System).

Normal gauge readings are as follows:

Low side (suction) 10-25 PSI High side (discharge) 250-270 PSI

These readings are dependent on many external factors including ambient temperature, humidity and tempera-
ture inside cab. If the readings are in the normal operating range, you may proceed to the Drier Change
Procedure. If the readings are not proper, you should trouble-shoot the system and correct the problem.

Drier Change Procedure

1. With vehicle’s engine turned off, open both manifold hand valves and recover refrigerant using manu-
facturers recommended procedures.
2. With refrigerant discharged, make any necessary repairs to the system, then remove old drier, and
install new drier by hooking the line from condenser to the inlet side and the line to the expansion valve
to the outlet side. Do not assume that the old drier was hooked-up correctly. Failure to do so will result
in a system malfunction. (Note: The inlet side of the drier should be marked “IN” or should have a flow
indication label that shows which side is the inlet.)
3. Use only heavy-duty high capacity receiver-driers. (The desiccant content of many driers is insufficient
for use on an annual preventative maintenance basis. Many suppliers are using driers with an automo-
tive type bag desiccant. Care should be exercised when choosing your supplier because your mainte-
nance is no better than the drier you use.)
4. Proceed to Refrigerant Oil Maintenance Procedures.
Pg.20
Refrigerant Oil Maintenance Procedures
As with any moving part, lubrication is the key to long life. The single most neglected aspect of A/C system
maintenance is that of maintaining the proper amount of oil in the unit (11 oz. in new system).
1. The refrigerant oil in the compressor travels with the refrigerant throughout the system to lubricate all of
its components.
2. The receiver-drier absorbs some of the refrigerant oil (approximately 2 oz).
3. A/C systems leak refrigerant and refrigerant oil; therefore, adding refrigerant and not adding oil is asking
for major component failures.
4. Measuring oil level in the compressor will not always give you a true measurement of the oil in the system
(i.e. oil could have been pumped out of the compressor up to the point of restriction which might be the
drier expansion valve).
5. Flushing the system with propellant (such as nitrogen) and draining the oil from the compressor is the
only sure way to cure an over or under charge of oil.
6. When you discharge the refrigerant from a system, oil is also discharged.
7. Consistency is the key to maintaining the proper oil level.

To avoid having to flush the system every time it is serviced, we have adopted guidelines that will ensure proper
oil level in the system if applied regularly. They are:

1. If you discharge (or leak out) the refrigerant and change the drier, add 4 oz. of refrigerant oil. To further
break this down, the drier is accountable for 2 oz. and the refrigerant charge is accountable for 2 oz.
This also takes into consideration the oil lost due to system leakage or seepage.
2. If the oil is contaminated (compressor burnout or drier desiccant breakdown), the system must be
flushed and a complete charge of oil added. (See Flush Procedure.)
3. Oil should be kept clean and dispensed from a clean measuring device.
4. If you have access to pressurized oil charge (either in the 4 oz. cans or through a service center with
bulk A/C refrigerant oil), you will not have to measure and pour. Otherwise, measure and pour the oil into
either the drier or compressor prior to evacuating the system.

You should now have a basic understanding of the importance of refrigerant oil to the A/C system and how to
maintain it properly. You can now proceed to Evacuating and Charging Procedures.

Evacuating and Charging Procedures

The purpose of evacuating a system is to remove the air and moisture from the system. It is foolish to change
any of the refrigeration components in an A/C system without evacuating the system.
An evacuation of 2 to 5 minutes is not sufficient to ensure a clean system. Moisture is the #1 enemy of an A/C
system and we must boil it out of the system. This can only be accomplished by lowering the pressure in the
system, which lowers the boiling point of water so it is vaporized through the boiling process. This is the process
we commonly refer to as “pulling the vacuum” or evacuation.
Since this is such an important process, we must approach it and apply it with the utmost care. To ensure that
we are doing a proper job, let us first evaluate the vacuum pump and its capacity. Then we will go through the
evacuation and charging process step-by-step with explanations along the way.

Evaluating Your Vacuum Pump

Most vacuum pumps will have tags that state their capacities. This tag should tell you the CFM (cubic feet per
minute) that the pump is capable of. It may also give its micron rating which is basically a measurement of the
pump’s deep vacuum ability. Knowing the capability of your pump is extremely important, because this will be
used to determine the length of time you have to run the pump during the evacuation process unless you use a
micrometer. (Micrometers are somewhat expensive and ultra-sensitive as well as something that not every
shop has available. If you do have one you should follow the instructions for the specific unit you have.) As most
shops will not have micrometers available, we shall set a time schedule for evacuation based on the average
time needed to sufficiently evacuate a system by a vacuum pump rating.

Evacuating Schedule
1.2 to 2 CFM Pump 45 minutes
3 CFM Pump 30 minutes
5 CFM Pump 15 minutes

This time schedule assumes that the pump is “vacuuming” at its rated capacity. Periodically, it will be in your best
interest to test the vacuum pump (see step 2) to confirm its capability of boiling water.

Pg.21
Evacuating the System
With manifold set hooked-up (as described in MANIFOLD HOOK-UP section) and refrigerant drained out of the
system (as detailed in DRIER CHANGE PROCEDURE), you are now ready to proceed with the evacuation
process. Note: If you are not using pressurized oil charge, you need to add the proper amount of oil prior to
evacuating the system.

1. With both handles on the manifold set wide open, hook the center hose to the suction port of the
vacuum pump.

2. Switch on the vacuum pump.

3. Evacuate the system for the proper amount of time as determined by the size of the vacuum pump you
are using as discussed previously.
4. If you desire to run a vacuum test on the system for leaks proceed as follows:
a. Run vacuum pump for approximately 5 minutes.
b. Close manifold set handles.
c. Switch off vacuum pump.
d. Note gauge readings (which should be into vacuum).
e. Allow to sit for 2 minutes.
f. Any rise in pressure could indicate a leak (refer to Leak Testing The System).
g. No rise in pressure would indicate a relatively tight system (though not a 100% absolute test as
vacuum can sometimes close minute leaks which will reopen once system is pressurized). You
can reopen manifold set (wide open) and continue to pull vacuum for the allotted time as deter-
mined by the size of the vacuum pump.
5. After pulling for the proper amount of time:
a. Shut off the manifold set.
b. Shut off the vacuum pump.
c. Proceed to Charging the System.

Charging the System

The procedure for charging an A/C system is merely finalizing the evacuation process. That is to say, that you
can’t properly charge a system unless you remove the air from the system. Adding refrigerant to a system’s
existing refrigerant is merely patchwork.

The charging procedures are:

1. Hook the center hose of manifold set to oil charge if using pressurized oil charge. If not, you would have
already added oil prior to evacuation and you should proceed to step 5.
2. Purge air from the center hose.
3. With vehicle engine turned off, open the high side manifold handle.
4. Shoot the proper amount of oil in to the system.
5. Hook the center hose to the refrigerant supply.
6. Purge air from the center hose as in step 2.
7. Charge approximately 1 lb. of refrigerant into the system on the high side of the system.

Remember: The vehicle is not running. What should happen is the following:
a. The high side gauge should rise to supply pressure, which is usually 60 to 90 PSI.
b. The low side gauge should rise to equal the high side reading. This is without the vehicle running, so
equalization indicates that the expansion valve has opened. But if, for example, the high side reads 70
PSI and the low side reads 30 PSI, changes are that the expansion valve is not going to function
properly or that another restriction exists in the system. You should find and correct this problem right
now. This step is a good static test on the expansion valve and should be regarded as such.
c. If both sides indicate equalization close high side gauge, start the engine (1200-1500 RPM), turn the A/
C system on high speed, thermostat at coldest setting.
d. Make sure the condenser is operating properly.
e. Open the low side of the manifold set and charge with 2 lbs. of 134a refrigerant.
f. Shut off the low side of manifold set.
a. Run the system to ensure that the system is operating properly. (Refer to A/C System Performance
Check.)
b. If satisfied that the system is functioning properly, shut off the vehicle, and remove the test hoses
carefully, realizing that the pressure indicated on gauges is the pressure present in the hoses.
c. Cap the service ports.

Pg.22
Summary
We have now completed the evacuation and charging procedures that are necessary (not optional) to complete
a successful maintenance or service job. This may seem like a lot of steps to go through, but the explanation is
a lot longer than the actual work process. If we condensed the entire P.M. Procedure it would look like this:

1. Evaluate A/C system – electrical and refrigeration.

2. Change the receiver-drier and any other defective parts.
3. Evacuate the system.
4. Charge system with oil and refrigerant.

Flushing The System

Flushing the system is a procedure that must be performed if any of the following conditions exist:

1. compressor burn-out or failure

2. drier desiccant breakdown
3. extreme moisture contamination
4. high side restriction
5. you are unsure of oil contents of system
6. system has been open for lengthy period

These conditions dictate flushing the system to ensure a proper service.

Nitrogen has become the primary flushing agent due to:

1. the environmental taboo on releasing CFC-based refrigerants to the atmosphere

2. the dry characteristic of nitrogen
3. the high pressure available with nitrogen
4. ease with which nitrogen may be obtained

Flushing Procedure
Flushing with nitrogen is easily accomplished if you remember the following:

1. Never flush through any of the following major components: drier, expansion valves, or compressor.
2. Regulate the pressure to 150-250 PSI.
3. Adapt the air nozzle to the end of the test hose coming off of the regulator. (Note: check burst pressure
on the hose and be sure it can withstand regulated pressure.)
4. Always cover the end of the hose or unit being flushed to avoid spraying oil and contaminants every-
where.

Bearing in mind the above recommendations, you can now flush the system following the normal refrigerant
flow pattern in the following steps:

1. Flush from the discharge hose fitting (at compressor) through the condenser to the fitting at inlet of
drier.
2. Flush from the fitting at the outlet of the drier to the inlet of the expansion valve.
3. Flush from the suction hose fitting at the compressor to the outlet fitting of the expansion valve.
4. Flush the evaporator coil separately.

Note: Always cover the outlet fitting of the component or hose being flushed with rags or shop towels to minimize
mess and hazard to yourself and others.

Properly flushing the system will remove virtually all of the oil in the system except that in the compressor. If you
are reusing the old compressor, you should drain the oil from it and replace it. If you are installing a new
compressor, it will have the proper amount of oil in it from the manufacturer. Remember that you must add oil to
the system to compensate for the hose and coil lengths (see Evacuating and Charging Procedures).

Note: if a condition warrants flushing the system, a drier change should be considered mandatory.

Leak Testing The System

The safest and most practical method of leak detection is the electronic leak detector. It will detect leaks as
slight as ¼ pound per year (according to the manufacturers). The system can be pressurized with refrigerant
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(although expensive and also condemned by environmentalists) or nitrogen (recommended). Nitrogen will give
a higher internal pressure and will carry latent freon (that freon present in the system) to the point of leakage.
This higher pressure makes it possible to detect smaller leaks that would be hard using only refrigerant bottle
pressure. The manifold set should always be used when leak testing a system, as this will give you instant
reference to the amount of pressure you have in the system (recommended pressure not to exceed 250 PSI).

The procedure is as follows:

1. Hook the manifold set to the system.

2. Hook the center hose (supply hose) to the refrigerant or nitrogen source.
3. With the vehicle engine turned off, open the suction side of the manifold set. This will allow nitrogen or
refrigerant to fill the system to the supply or regulated pressure.
4. Close the manifold set handle.
5. Use an electronic leak detector on the system to find the leakage area and the pinpoint leak.
6. Upon finding the leak, make necessary repairs.

There are other methods of leak detection such as halide torch, soap bubbles, dye colored refrigerant, or
vacuum test.

When you lose refrigerant due to leakage, you also lose refrigerant oil. This causes:

1. Possible strain on the compressor.

2. Air and moisture replacement of the lost refrigerant.
3. Premature saturation of the drier desiccant material.
4. The tasks of the refrigerant not to be carried on, such as condensation, evaporation, or oil transporting
for lubrication purposes.

Therefore, leaks must be found and corrected and the system must be properly serviced to minimize the effects
that air and moisture have on A/C systems.

Troubleshooting The A/C System

Troubleshooting Procedures Defined

Troubleshooting makes use of logic and your knowledge of component function to pinpoint the cause for any
irregular operating condition. When you are evaluating an A/C system, this generally requires going through the
steps as outlined under “Manifold Hook-up”, “Visual Inspection”, and “Electrical System Checks” in the Recom-
mended P.M. Section Procedures.

Initial Steps
When you are called on to troubleshoot a system, it is important that you gather any information that you can
from the operator. This information may be useful in helping you find the source of the problem, as well as
keeping you from overlooking a problem that takes time to develop (such as freezing-up). If the operator can
only say “the A/C doesn’t work,” this gives young insight as to the direction to start looking for the problem. If
possible, locating and curing the problem. He will benefit by having an A/C system that performs properly and
you will avoid a “comeback”.

Patchwork Can Mean Comebacks

After you have gathered all of the information that you can, use it to help evaluate the system. While this
information is sometimes helpful, do not let it cause you to skip steps in the evaluation procedures previously
outlined. The operator is usually not an A/C mechanic, so you need to use your knowledge to pinpoint and
correct the problem (or problems). EXAMPLE: an operator writes up a vehicle A/C as freezing-up. You know that
last week you had to change the thermostat on a vehicle just like this one to cure a freeze-up problem. You
change the thermostat and consider the problem solved. When you fail to hook-up the gauges and run the
proper evaluation checks, you run the risk of overlooking the real problem. In the case of freezing-up, it could be
caused by a number of things, such as low refrigerant charge, restricted drier, or a restricted expansion valve,
as well as a malfunctioning thermostat. Following the evaluation procedures would have positively identified this
problem.

You should also be aware of the fact that a system may have more than one problem. There could be electrical
problems and refrigerant system problems present at the same time. Do not overlook these possibilities be-
cause it will cause a comeback.

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TROUBLE SHOOTING 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.

Suction Discharge Possible Problem

Low High 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 create flashing. Condition
indicated by an extreme differential in temperature at the point of restriction.

Low Low 1. Possible restriction between drier and suction side of compressor.
2. Low refrigerant charge – bubbles in sight glass.
3. Restriction at drier or expansion valve – sight glass usually clear.

High High 1. Air in system.

2. Overcharged system (oil or refrigerant).
3. Condenser fan not working.
4. Air flow restriction on condenser.

High Low 1. Weak compressor – indicated by accelerating the engine and watching the suction and
discharge readings. Normally, suction moves lower and discharge side should rise.
2. Expansion valve flooding or stuck open – this would cause high and low sides
to become less distinguishable.

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