OPERATOR S MANUAL. Model MCT. Mechanical Power Broom

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Maximillian Lewis Watson
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OPERATOR S MANUAL Model MCT Mechanical Power Broom M-B

Box 200 New Holstein, WI 53061-0200 (920) 898-1560 or

3 Table of contents introduction safety Operator s Manual...3 Identification Numbers...3 Safety Alerts...5 Safety Decals...5 Operation Guidelines...5 Maintenance Guidelines...6 controls and features...7 setup and adjustments operation Pattern Adjustment...9 Pre-Start Checks...11 Travel Procedure...11 Operation...11 maintenance Maintenance Schedule...13 Lubrication...13 Filler Replacement Core Removal...13 Brush Removal...14 Brush Installation...14 Core Installation...15 storage...17 troubleshooting...17 specifications...19 service parts...21 parts lists WARRANTY DRAWINGs Publication: MCT M-B Companies, Inc. Copyright

operator s manual You must read, understand and comply with all the safety and operating instructions in this manual before attempting to set-up and operate your power broom.

5 operator s manual You must read, understand and comply with all the safety and operating instructions in this manual before attempting to set-up and operate your power broom. Failure to comply with the safety and operating instructions can result in loss of machine control, serious personal injury to you and/or bystanders, and risk of equipment and property damage. identification numbers When contacting your authorized dealer for information, replacement parts or service, you MUST have the model and serial number of your unit. Record the serial number in the space provided. The serial number plate/decal can be found in the location shown in Figure 1. INTRODUCTION Model Name/Number: Date Purchased: Serial #: Figure 1. Publication: MCT M-B Companies, Inc. Copyright

safety alerts Signal words and alert symbols notify of important safety precautions. SAFETY DANGER! Indicates a hazardous situation which, if not avoided, will result in serious injury or death.

7 safety alerts Signal words and alert symbols notify of important safety precautions. SAFETY DANGER! Indicates a hazardous situation which, if not avoided, will result in serious injury or death. WARNING! Indicates a hazardous situation which, if not avoided, could result in serious injury or death. CAUTION! Indicates a hazardous situation or unsafe practice which, if not avoided, could result in minor or moderate injury or property damage. safety decals Although reading this manual and the safety instructions it contains will provide you with the necessary basic knowledge to operate this equipment safely and effectively, we have placed several safety labels on the unit to remind you of this important information while you are operating your unit. All DANGER, WARNING, CAUTION, and instructional messages on your unit should be carefully read and obeyed. Bodily injury can result when these instructions are not followed. The information is for your safety and it is important. These labels will act as a constant visual reminder to you, and others who may use the equipment, to follow the safety instructions necessary for safe, effective operation. If any of these labels are lost or damaged, replace them at once. See you local dealer for replacements. PRE-START GUIDELINES Install any covers or guards which may have been removed for shipping purposes. Before starting equipment, walk around equipment, making a visual inspection that all safety devices are properly installed and secured. Check that all hardware, fasteners, hydraulic fittings, etc. are in good condition and properly fastened. Replace any fatigued or damaged items with proper replacements. Personnel who are not required to be in the work area should be kept away. Never start the equipment unless you are absolutely certain that everyone in the area is clear of the machine and aware it is being started. Follow the manufacturer s recommended start-up procedure. operation guidelines Read, understand and follow all instructions in the manual and on the unit before starting. To avoid serious injury or death, do not modify equipment. Any modifications made to equipment can be dangerous and can void equipment warranty. Never defeat a safety device to make a task easier. Always wear proper apparel when operating equipment; safety glasses, face shield or goggles, ear protection, and dust mask. Tie hair back. Never wear loose clothing or jewelry that could get caught in moving parts. Never operate equipment with covers or guards removed. Rotating parts can cause severe injury. Keep hands, feet, hair, jewelry and clothing away from all moving parts. Only allow responsible adults who are familiar with the instructions, to operate the unit (local regulations can restrict operator age). Clear the area of objects such as rocks, toys, wire, etc., which could be picked up and thrown. Be aware of surroundings. Be sure the area is clear of other people, bystanders or pets. Stop unit if anyone enters the area. Always look down and behind before and while traveling in reverse. Publication: MCT M-B Companies, Inc. Copyright

8 SAFETY Be aware of discharge direction and do not point discharge at anyone. Do not point the discharge at glass enclosures, automobiles, or windows. Always stand clear of the discharge area when operating this unit. Disengage all clutches and PTO s before starting engine. Never leave a running machine unattended. Always disengage the attachment and traction controls, lower the attachment, set the park brake, stop the engine and remove the ignition key before leaving the machine. Operate only in daylight or good artificial light. Never carry passengers. Do not operate the unit while under the influence of drugs, alcohol or other medication. Watch for traffic when operating near or crossing roadways. Use extra care when loading or unloading the unit into a trailer or truck. Keep in mind the operator is responsible for accidents occurring to other people or property. Data indicates that operators, age 60 years and above, are involved in a large percentage of power equipment-related injuries. These operators should evaluate their ability to operate the unit safely enough to protect themselves and others from injury. All operators should seek and obtain professional and practical instruction. Protect eyes, face and head from objects that may be thrown from unit. Wear appropriate hearing protection. Always wear substantial footwear and appropriate clothing. Wear footwear that improves traction on slippery slopes. DO NOT wear long scarves or loose clothing that could become entangled in moving parts. Abnormal Vibrations are a warning of trouble. Striking a foreign object can damage unit. Stop unit and engine. Wait for all moving parts to stop. Inspect unit and make any necessary repairs before restart. Never place your hands or any part of your body or clothing inside or near any moving part while unit is running. Stop engine before: refueling, cleaning, making adjustments or removing the attachment assembly. Follow the drive unit manufacturer s recommendations for wheel weights or counter weights. Make any adjustments before operating unit. Do not touch parts which may be hot from operation. Allow such parts to cool before attempting to service the unit. Before using, always visually check that hardware is present, intact and secure. Replace worn or damaged parts. Never operate the machine with damaged guards, or without safety protective devices in place. Follow the manufacturer s recommendations for towing weight restrictions and procedures. Original purchaser of this unit was instructed by the seller on safe and proper operation. If unit is to be used by someone other than original purchaser; loaned, rented or sold, ALWAYS provide this manual and any needed safety training before operation. The Operator must understand the functions and parameters of all controls and how to operate, as well as how to STOP in an Emergency. maintenance guidelines Maintain or replace safety and instruction decals/labels as necessary. Never run a unit in an enclosed area. Keep nuts and bolts tight and keep equipment in good condition Never tamper with safety devices. Check their proper operation regularly and make necessary repairs if they are not functioning properly. Keep unit free of debris and build-up. Clean up any oil spillage. Never make adjustments or repairs with the engine running unless specified otherwise in the engine manufacture s manual. Components are subject to wear, damage, and deterioration. Frequently check components and replace with the manufacturer s recommended parts, when necessary. Check control operation frequently. Adjust and service as necessary. Use only factory authorized parts when making repairs. Always comply with factory specifications on all settings and adjustments. Only authorized service locations should be utilized for major service and repair requirements. Never attempt to make your own repairs on this unit unless you have been properly trained. Improper service procedures can result in hazardous operation, equipment damage and voiding the manufacturer warranty. Stop engine on tractor and set parking brake before performing any adjustments on the machinery. Do not disassemble a pressurized system unless properly trained and equipped with adequate tooling. Escaping hydraulic fluid under pressure can have sufficient force to penetrate the skin, causing serious injury. Before operation, be sure that all hydraulic connections are tight and hoses are not damaged. Relieve pressure in system before making adjustments. Oils and fluids can be very hot under pressure. Use caution and allow the system to cool before beginning maintenance work. Never operate or pressurize one of these systems with worn or damaged components. Replace hoses, fittings, valves or other components which appear defective. Never adjust pressurized systems beyond recommended levels to achieve higher operating pressures. NEVER search for hydraulic leaks with only your hands. Use cardboard or a piece of wood. For engine equipped models, follow specific engine manufacturer s recommended service intervals for dirty/dusty environments. NOTE: All reference to left, right, front, or rear are given from the operator position and facing forward. Publication: MCT M-B Companies, Inc. Copyright 2011

9 controls and features controls Operation of the MCT Broom is accomplished with the prime mover s controls. Refer to the prime mover s Operation/Owner s Manual. features Refer to the Setup and Adjustments instruction, Specifications, and Parts Lists within this manual for information on the MCT Broom components and functions. Publication: MCT M-B Companies, Inc. Copyright

11 setup and adjustments Proper assembly, installation and adjustment of your power broom will increase the life of the brush and produces more efficient movement of material. Visually inspect the adjustments on the broom before each operating session and measure the adjustments once every 10 hours. pattern adjustment 1. Once the broom is mounted to the prime mover, park the unit on a flat level surface; preferably concrete or asphalt. 2. Loosen the jam nut on each end of the adjustment turnbuckle. See Figure Adjust the turnbuckle length to raise/lower broom so that the brush contact patch is approximately 3" wide from front to rear. Lengthening the turnbuckle will lower the broom, creating more contact. 4. Confirm adjustment by running the broom for about 30 seconds in the down position while stationary. Stop the broom and back the unit away. The cleaned area (contact patch) should be 2"-4" wide for the entire length of the broom. See Figure 2. Once the broom has been properly adjusted, a short operation period is recommended for break-in; approximately 15 minutes. After this break-in period, repeat the leveling procedure to ensure that it is correct. Jam Nut Turnbuckle Jam Nut Figure 2 Figure 1 Publication: MCT M-B Companies, Inc. Copyright

13 operation pre-startup checks IMPORTANT! You must read, understand and comply with all the safety and operating instructions in this manual before attempting to set-up and operate your power broom. Failure to comply with the safety and operating instructions can result in loss of machine control, serious personal injury to you and/or bystanders, and risk of equipment and property damage. 1. Visually inspect equipment and hardware to ensure that all parts are secure and all hardware is tightened and secure. 2. Check for oil leaks and loose hose connections. 3. Inspect the broom adjustments to ensure that the broom is level and that the brush pattern is set properly. Refer to the SETUP AND ADJUSTMENT section of this manual. 4. Inspect the bristle length to determine if replacement segments are needed. TRAVEL PROCEDURE Follow these instructions for extended travel (i.e. to and from the sweeping site): Set broom rotation control to the OFF position. Use the lift control to bring the broom to the fully raised position. Raise the broom support stands to the highest position and secure in place. operation IMPORTANT! The support stands should never be used for anything other than as stationary storage stands to hold the broom up while it is being stored. Ensure the support stands are raised to the highest position and secured in place. Sweep at a speed that is appropriate for the conditions and location. For heavy material such as gravel or stones, drive more slowly with a higher broom speed. For lighter material, drive faster with a lower broom speed. It may be necessary to increase broom contact pattern under some conditions. If the surface being swept is uneven and causes the broom to leave upswept patches, increase the pattern size to compensate. If the material being swept is dried-on or difficult to remove, such as mud or ice, it may be necessary to drive extremely slow to allow the broom to scrub the surface. Publication: MCT M-B Companies, Inc. Copyright

maintenance maintenance schedule Check adjustments every 10 hours Grease bearings after initial 10 hours, then every 200-300 hours thereafter. Grease pivot points every 50 hours 3.

Drive Sprocket Chain Driven Sprocket NOTE: Grease points are noted with an applicable decal.

15 maintenance maintenance schedule Check adjustments every 10 hours Grease bearings after initial 10 hours, then every hours thereafter. Grease pivot points every 50 hours 3. Loosen 1/2-13 x 3-3/4" socket head capscrew attaching chain tensioner and rotate tensioner until chain is slack. See Figure 2. Drive Sprocket Chain Driven Sprocket NOTE: Grease points are noted with an applicable decal. Tighten drive chain every 50 hours Lightly oil drive chain as needed Replace brush filler as needed lubrication Grease bearings and pivot points per the maintenance schedule using Chevron Ultra Duty II, Grade 2; or equivalent high-temp grease. There are minimum of (9) grease points on the unit; (4) in the frame tubes, (2) in the swing cylinder locking pins and (2) on the brush ends and (1) on the drive jackshaft end support bearing. There may be (2) additional grease fittings, one on each caster wheel assembly. Refer to the vendor literature within the PARTS LIST section of this manual for the lubrication recommendations of the drive gearbox manufacturer. filler replacement Core Removal 1. Lower broom until brush contacts the ground then loosen mechanical head anchor. 2. Remove (2) 3/8-16 x 1" hex head capscrews, lock washers, flat washers and chain guard from the brush frame. See Figure 1. Chain Tensioner Figure 2 4. Remove chain half-link and clip to disconnect chain ends. Remove drive chain. See Figure 3. Driven Sprocket Brush Frame Chain Guard Mounting Hardware Brush Frame Chain Figure 3 or Loosen set screws in sprocket on core hub and pull sprocket off hub shaft with chain. See Figure Remove (2) 7/16-14 lock nuts attaching each brush core support bearing to brush frame. Push the (2) 7/16-14 x 1-1/2 hex head capscrews inward on both bearings to detach core. See Figure Slide/roll brush and core assembly out the front of broom. Figure 1 Publication: MCT M-B Companies, Inc. Copyright

maintenance Brush Frame Driven Sprocket Core Support Bearing End Disc Brush Installation IMPORTANT! Proper wafer and spacer position must be followed to ensure proper balance on the core. 1.

Stand core in upright position on core support hub and begin filling by sliding a poly brush wafer and then a spacer down the full length of the core. a. Note the location of drive pin on inside ring of each brush wafer.

16 maintenance Brush Frame Driven Sprocket Core Support Bearing End Disc Brush Installation IMPORTANT! Proper wafer and spacer position must be followed to ensure proper balance on the core. 1. Protect core sprocket support hub from dirt or damage before setting core on end. 2. Stand core in upright position on core support hub and begin filling by sliding a poly brush wafer and then a spacer down the full length of the core. a. Note the location of drive pin on inside ring of each brush wafer. Position each wafer so its drive pin is positioned between the stop flanges. Rotate each subsequent wafer before installing so the position of its pin is staggered on the core by one stop flange. See Figure 6. Stop Flange Wafer Drive Pin Core Hub Core Brush Removal Figure 4 If core hub sprocket was not removed in step 4 of CORE REMOVAL, work on the non-driven end to replace brush wafers. NOTE: Support bearing does not need to be removed from hub. 1. Remove (3) 1/2-13 x 1" capscrews, lock washers and hub from end of core. Retain hub and mounting hardware. See Figure Remove (3) or (4) 5/16-18 x 3/4" capscrews, lock washers and end disc (wafer retainer plate) from end of core. Retain end disc and mounting hardware. See Figure Slide spent brush wafers and spacers off core and discard. Shown without support bearing for clarity. Figure 6 NOTE: The circular spacers have unconnected, overlapped ends. b. Position the overlap of the first spacer between the stop flanges, rotated one flange ahead of the drive pin location of the immediately preceding brush wafer. All subsequent spacers must follow the same staggered placement pattern. 3. Continue stacking the core in a wafer-spacer, wafer-spacer configuration until it is full, ending with a poly brush wafer. Core End Disc Hub NOTE: Always start and finish with a poly wafer. The last wafer should actually extend beyond the end of the core (Minimum 1/2 ) so the end disc compresses the spacers onto the core when tightened. 4. Install end disc on core with original hardware. See Figure 5. Figure 5 5. Install hub on core with original hardware. See Figure 5. Publication: MCT M-B Companies, Inc. Copyright 2012

17 maintenance Core Installation 1. Position refilled core in front of the broom head. Lift the broom high enough so that core clears the hood and the brush can be rolled/pushed back into its original position. 2. Lower broom down until slots in sides of brush frame align with support bearings on core support bearings. 3. At each end of broom, install (2) 7/16-14 x 1-1/2" hex head capscrews from inside brush frame and out through support bearing. Install (2) 7/16"-14 lock nuts to secure each support bearing to brush frame. See Figure 4. IMPORTANT! Tensioner must be on outside of chain. 4. Install chain over drive motor sprocket and driven core sprocket and connect with chain half-link and clip. See Figure 3. or Install chain over drive motor sprocket. Place driven sprocket in chain and install sprocket with chain on core hub shaft. Tighten set screws to secure sprocket on shaft. See Figure Rotate tensioner against chain to remove slack and then tighten 1/2-13 x 3-3/4" socket head capscrew to secure tensioner in position. See Figure Grease core support bearings and oil drive chain after installing core. 7. Install chain guard on brush frame and secure with (2) 3/8-16 x 1" hex head capscrews, lock washers and flat washers. See Figure 1. NOTE: Brush surface contact during initial operation and pattern adjustment will set all wafer drive pins up against the core stop flanges. See Figure Before placing machine back into service, adjust and test for proper brush pattern. Excessive and/or misaligned pattern can cause brush failure or premature wear. Refer to the SETUP AND ADJUSTMENTS section of the manual for pattern adjustment. Wafer Drive Pin Stop Flange Core Figure 7 Publication: MCT M-B Companies, Inc. Copyright

19 storage storage Always store the broom in a supported position, on its included stands, with the brush off the ground. If the bristles are stored in a deformed position for extended periods of time the broom will become severely out of balance. Store the broom in a location out of the sun and weather to prevent premature failure of plastic bristles. Bristles can become brittle when subjected to sunlight or repeated temperature changes. Disconnect all electrical connections between the broom and prime mover (mower/loader/tractor) for extended storage to prevent battery drain. Properly clean the unit before storage and remove dirt, debris, salt, etc. to extend paint life. If the unit is power-washed, all lubrication points should be greased before storage. troubleshooting Trouble Possible Cause Remedy Broom does not rotate. 1. Driveshaft not connected. 1. Check driveshaft. 2. Key missing on gearbox input. 2. Check rotation and replace key. 3. Key missing on gearbox output. 3. Check rotation and replace key. 4. Key missing on sprocket(s). 4. Check rotation and replace key. 5. Drive chain and/or sprockets damaged. 5. Remove guard and inspect drive chain and sprockets. 6. Core drive hub broken/damaged. 6. Remove guard and inspect hub. Broom rotates in wrong direction. 1. Incorrect gearbox installed. 1. Verify gearbox ratio and rotation. Bristles wearing unevenly. 1. Pattern adjustment not set. 1. Adjust with turnbuckle. 2. Broom mounting not level. 2. Adjust to level position. Brushes wearing very quickly. 1. Brush pattern too wide. 1. Adjust brush pattern to be 2-4 wide. Refer to the Setup and Adjustments section of this manual. Broom bounces during sweeping. 1. Travel speed too fast. 2. Broom unbalanced. Broom sweeping poorly. 1. Material is caked-on or frozen. 2. Uneven sweeping surface. 3. Material is too heavy. 4. Broom rotating too slowly. 5. Prime mover moving too fast. 6. Pattern adjustment incorrectly set. Broom does not angle. 1. No/Low hydraulic pressure/flow. 2. Swing cylinders seals failed. Broom producing excessive vibration. 1. Driveshaft not phased correctly. 2. Broom stored incorrectly. 3. Bearings worn out or improperly greased. 4. Material caked on or debris wrapped in brush. 1. Adjust travel speed for swept surface type. 2. Broom stored improperly or worn out. 1. Slow down and scrub surface. 2. Increase pattern to compensate. 3. Slow down prime mover speed. 4. Increase engine speed. 5. Slow down prime mover speed. 6. Adjust at turnbuckle. 1. Check prime mover operation. Check hydraulic oil level. 2. Replace swing cylinder seals. 1. Inspect driveshaft phase. 2. Replace wafers. 3. Replace bearings as necessary. Grease bearings. Refer to Maintenance section of this manual. 4. Inspect brush for build-up; wash and remove debris. Publication: MCT M-B Companies, Inc. Copyright

21 specifications Model: MCT Brush Diameter: 25" Brush Length: 4' (48"), 5' (60") Brush Drive: Driveshaft from prime mover PTO connects to broom gearbox (7:1 CCW Input or 8.25:1 CW Input) that drives jackshaft, sprockets and chain. Brush Speed: 200 RPM Maximum Brush Angle: Maximum 30 left/right of center Brush Filament: Poly (polypropylene), Wire (Steel) or Combo (Poly/Wire) Lift Method: Provided by prime mover. Swing Method: Manual Casters: 360 rotation of 8" semi-pneumatic tires Broom Hood: Covers 140 of brush circumference Mounting: No Mounting by M-B (Provided by customer.) Custom Mount Design by M-B (Applies to mounts not previously designed by MB.) Options: Hydraulic Swing (Cylinder only - Must be connected to prime mover hydraulics.) Dirt Deflector (Hood) Storage Stands 45 Gallon Sprinkler System for dust control. Application specific, requires evaluation. (Customer provides tank mounting location.) Sight/Guide Indicators Publication: MCT M-B Companies, Inc. Copyright

23 service parts Part Number Description Refill Kit, 25" x 4', Wafer, Poly Refill Kit, 25" x 4', Wafer, Alternating Poly/Wire Refill Kit, 25" x 4', Wafer, Wire Refill Kit, 25" x 4', Wafer, Poly/Wire Combo Refill Kit, 25" x 5', Wafer, Poly Refill Kit, 25" x 5, Wafer, Alternating Poly/Wire Refill Kit, 25" x 5', Wafer, Wire Refill Kit, 25" x 5', Wafer, Poly/Wire Combo Part Number Description Service Kit, Caster Wheel (Includes wheel mounting hardware) Bearing, Flange, Caster Mounting Storage Stand Clevis Pin, Storage Stand Hair Clip, Clevis Pin Paint, Spray, MB Yellow Paint, Spray, Black Primer, Spray Bearing, Support, Core Hub, Core Support (Driven End) Hub, Core Support Disc, Wafer Retainer, Core Bearing, Support, Core Drive Jackshaft Slinger-Rubber, Input Shaft, 7:1 & 8.25:1 Gearbox Gasket, Output Shaft Cover, 7:1 & 8.25:1 Gearbox (Leeson) Gasket, Output Shaft Cover, 8.25:1 Gearbox (Cleveland) Vent-Breather, 7:1 & 8.25:1 Gearbox (Leeson) Vent-Breather, 8.25:1 Gearbox (Cleveland) End Cap/Plug, 7:1 Gearbox End Cap/Plug, 8.25:1 Gearbox Seal, Input Shaft, 7:1 & 8.25:1 Gearbox Seal, Output Shaft, 7:1 Gearbox Seal, Output Shaft, 8.25:1 Gearbox Cylinder, Swing Seal Kit, Swing Cylinder Pin, Swing Please have your serial number (S/N) ready when contacting M-B Co. or an Authorized Dealer for replacement parts or service information. M-B Co. website: Wisconsin Ave. sales@m-bco.com P.O. Box 200 Phone: or New Holstein, WI FAX: Main Attachments Brush Dept Publication: MCT M-B Companies, Inc. Copyright

2 MCT Decals 9 1 12 13 3 7 M-B Companies,

27 MCT Decals Item Description Part Number Decal Sheet (Includes items 1-7) 1 Decal, DANGER, No Riders Decal, DANGER, Pinch Point Decal, WARNING, Moving Part/Guards Decal, CAUTION, Read Operator s Manual (M-B Co.) Decal, CAUTION, Read Operator s Manual (Non-M-B Co.) 5 Decal, Brush Pattern Decal, M-B Brush Refills Decal, Grease Decal, WARNING, Flying Debris Decal, WARNING, High Pressure Fluid Decal, WARNING, Pinch Point Decal, WARNING, Guard Missing (Located behind guard) 12 Decal, MB Logo, Black, Medium Decal, MB Logo, Black, Small M-B Companies, Inc. Copyright 2012 Publication: MCT

ELECTRIC MOTORS, GEARMOTORS AND DRIVES 501-147245 Gearbox Speed Reducers Installation, Lubrication and Maintenance Instructions Table of Contents WARNING/CAUTION Information.................2-3 General Operation.

28 ELECTRIC MOTORS, GEARMOTORS AND DRIVES Gearbox Speed Reducers Installation, Lubrication and Maintenance Instructions Table of Contents WARNING/CAUTION Information General Operation Installation Lubrication / Oil Capacities Maintenance Drive Shaft Recommendations Parts List M-B Companies, Inc. Copyright 2012 Publication: MCT

29 Gearbox WARNINGS AND CAUTIONS MEChANICAL WARNING IMPOR TANT INFORMA TION FOR GEAR REDUCERS PLEASE READ CAREFULL Y CAUTION The following WARNING and CAUTION information is supplied to you for your protection and to provide you with many years of trouble free and safe operation of your LEESON Electric product: Read ALL instructions prior to operating reducer. Injury to personnel or reducer failure may be caused by improper installation, maintenance or operation. WARNING Written authorization from LEESON Electric is required to operate or use reducers in man lift or people moving devices. Check to make certain application does not exceed the allowable load capacities published in the current catalog. Buyer shall be solely responsible for determining the adequacy of the product for any and all uses to which Buyer shall apply the product. The application by Buyer shall not be subject to any implied warranty of fitness for a particular purpose. For safety, Buyer or User should provide protective guards over all shaft extensions and any moving apparatus mounted thereon. The User is responsible for checking all applicable safety codes in his area and providing suitable guards. Failure to do so may result in bodily injury and/or damage to equipment. hot oil and reducers can cause severe burns. Use extreme care when removing lubrication plugs and vents. Make certain that the power supply is disconnected before attempting to service or remove any components. Lock out the power supply and tag it to prevent unexpected application of power. Reducers are not to be considered fail safe or self-locking devices. If these features are required, a properly sized, independent holding device should be utilized. Reducers should not be used as a brake. Any brakes that are used in conjunction with a reducer must be sized or positioned in such a way so as to not subject the reducer to loads beyond the catalog rating. Lifting supports including eyebolts are to be used for vertically lifting the gearbox only and no other associated attachments or motors. Use of an oil with an EP additive on units with backstops may prevent proper operation of the backstop. Injury to personnel, damage to the reducer or other equipment may result. Overhung loads subject shaft bearings and shafts to stress which may cause premature bearing failure and/or shaft breakage from bending fatigue, if not sized properly. CAUTION Test run unit to verify operation. If the unit tested is a prototype, that unit must be of current production. If the speed reducer cannot be located in a clear and dry area with access to adequate cooling air supply, then precautions must be taken to avoid the ingestion of contaminants such as water and the reduction in cooling ability due to exterior contaminants. Mounting bolts should be routinely checked to ensure that the unit is firmly anchored for proper operation. In the event of the resale of any of the goods, in whatever form, Resellers/Buyers will include the following language in a conspicuous place and in a conspicuous manner in a written agreement covering such sale: The manufacturer makes no warranties or representations, express or implied, by operation of law or otherwise, as to the merchantability or fitness for a particular purpose of the goods sold hereunder. Buyer acknowledges that it alone has determined that the goods purchased hereunder will suitably meet the requirements of their intended use. In no event will the manufacturer be liable for consequential, incidental or other damages. Even if the repair or replacement remedy shall be deemed to have failed of its essential purpose under Section of the Uniform Commercial Code, the manufacturer shall have no liability to Buyer for consequential damages. Resellers/Buyers agree to also include this entire document including the warnings and cautions above in a conspicuous place and in a conspicuous manner in writing to instruct users on the safe usage of the product. This information should be read together with all other printed information supplied by LEESON Electric. Phone: (262) Fax: (262) M-B Companies, Inc. Copyright 2012 Publication: MCT

30 INST ALLA TION INSTRUCTIONS General Operation 1. Run the motor which drives the reducer and check the direction of reducer output shaft rotation. Consult motor nameplate for instructions to reverse the direction of shaft rotation. 2. Attaching the load:on direct coupled installations, check shaft and coupling alignment between speed reducer and loading mechanism.on chain/sprocket and belt/pulley installation, locate the sprocket or pulley as close to the oil seal as possible to minimize overhung load. Check to verify that the overhung load does not exceed specifications published in the catalog. 3. high momentum loads: If coasting to a stop is undesirable, a braking mechanism should be provided to the speed reducer output or the driven mechanism. The system of connected rotating parts must be free from critical speed, torsional or other type vibration, no matter how induced.the responsibility for this system analysis lies with the purchaser of the speed reducer. If the reducer is painted, extreme care should be taken to mask the shaft extensions and the rubber seals. Paint on the shaft adjacent to the seal or on the seal lip will cause leakage. Installation Instructions The following instructions apply to standard Leeson Bravo type reducers with base or flange mounting in motorized and non-motorized single and double reduction options. 1. Mount the unit to a rigid flat surface using grade 5 or higher fasteners.the mounting fasteners should be the largest standard size that will fit in the base mounting hole. Shim as required under flange or base feet which do not lie flat against the mounting surface. 2. Carefully follow lubrication instructions and installation manual furnished with the gear reducer. All standard Bravo reducers are properly filled at LEESON with sufficient lubricant quantity for nearly any mounting position. Series : Series utilize a vent-free design and are Factory filled with synthetic semi-fluid grease formulated for lifetime lubrication & wide operating temperature range (+5F to +220F). It is not necessary to change the lubricant in reducer series unless the reducer is used in a severe environment. If these reducers will be used in severe environment or if lubricant must be replaced, contact LEESON. Series 534: Series 534 utilizes a vent and is Factory filled with Mobil ShC-634 oil, a synthesized hydrocarbon formulated for long life & wide operating temperature range (-25F to +220F). Do not confuse Mobil ShC-634 with Mobilgear 634. Mobilgear 634 is an EP type gear oil not suitable for use in the Bravo worm reducers. 3. Connect motor to speed reducer. Quill Input Style: Discard motor key. Use only special key provided with reducer. Step 1: Position key in reducer input worm bore. Apply anti-seize compound (included with reducer) to the motor shaft. Line up key with motor keyway and slip motor shaft into reducer worm bore. Step 2: Tighten the bolts (supplied) with lockwashers evenly for a solid fit between motor and reducer C Flange. Note: A bushing may be supplied for use between the motor shaft and the reducer input shaft.apply anti-seize compound to inside and outside of bushing. Do not operate the reducer without making sure it contains the correct amount of lubricant. Confirm that mounting position on nameplate matches application requirement. Do not overfill or underfill with oil, or injury to personnel, reducer or other equipment may result. A unit cannot be used as an integral part of a machine superstructure which would impose additional loads on the unit other than those imposed by the torque being transmitted either through a shaft-mounted arrangement, and any shaft mounted power transmitting device.(e.g.sprockets, pulleys, couplings) For safe operation and to maintain the unit warranty, when changing a factory installed fastener for any reason it becomes the responsibility of the person making the change to properly account for fastener grade, thread engagement, load, tightening torque and the means of torque retention. Lubrication Carefully follow lubrication instructions and installation manual furnished with the gear reducer. All standard Bravo reducers are properly filled at LEESON with sufficient lubricant quantity for nearly any mounting position. Change oil only when performing maintenance that requires gearbox disassembly or if the reducer is operated in a severe environment. If oil must be replaced in Series 534 reducers, use only Mobil ShC-634. Lubricant should be changed more often if gear reducer is used in a severe environment. (ie: humid, wet, caustic, etc) In the Food and Drug industry (including animal food), consult the lubrication supplier for recommendation of lubricants which are acceptable to the Food and Drug Administration and/or other authoritative bodies having jurisdiction. Do not mix different lubricants in the reducer. SPECIAL LUBRICATION REQUIREMENTS Sizes Reducer is mounted with input worm shaft vertical Input speed is sustained less than 900 RPM NOTE: The reducer may require modifications to assure proper lubrication in these applications. Contact LEESON for more detail. For lubrication requirements of helical reducers (primaries of helical worm reducers and ratio multipliers), contact LEESON Gearbox Lubrication Series type Grease (lbs) Oil (ounces) oz. = 1 pint 1 quart =.9463 liter 2 pints = 1 quart 1 gallon = liter 4 quarts = 1 gallon 1 lb =.4535 kg. 1 gallon = 128 oz. Phone: (262) Fax: (262) M-B Companies, Inc. Copyright 2012 Publication: MCT

31 INST ALLA TION INSTRUCTIONS Maintenance Your BRA VO reducer has been tested and adjusted at the factory. Dismantling or replacement of components must be done by LEESON to maintain the warranty. Inspect the vent plug often (Size 534 only) to insure it is clean and operating. Mounting bolts should be routinely checked to ensure that the unit is firmly anchored for proper operation. Seals: The BRA VO line of speed reducers utilize premium quality seals which are state-of-the-art in sealing technology. Seals are, however, a wear item and eventually need to be replaced. Replacement can easily be accomplished by following the procedure below. 1. Remove the worn seal without damaging the shaft surface or the seal bore. This can be done by drilling a.062 diameter hole in the seal casing (being careful not to drill into the bearing behind the seal). Screw a #10 sheet metal screw into the hole and pry out the seal. 2. Clean the seal bore of sealant. 3. Before installing the new seal, use electrical tape to cover any keyways on the shaft to prevent seal lip damage. 4. Grease the seal lips with bearing grease and apply a sealant to the seal bore. 5. Slide the seal onto the shaft being careful not to fold the inner lip over on any shaft steps. 6. Press the seal into its bore with a sleeve that presses on the seal casing, being careful to keep the seal square in its bore. If seal leakage has resulted in the loss of a significant amount of lubricant, it may be necessary to add more. Contact LEESON for more detail. 3;Z 54Z Z 49Z Always check for proper oil level after filling. Do not overfill or underfill with oil, or injury to personnel, reducer, or other equipment may result. Do not mix different oils in the reducer. ; 54 44Z 43Z 42Z 39 3; 3: 3: 55 54Z ;Z 4: Z : 3: R 4 SPV 35 45Z 53 4R Gearbox 59 45R 33 4; R 4 5 5: 55R ;R 8 54R : 44R 43R 42R BRAVO EXPLODED VIEW ITEM # DESCRIPTION 1 GEAR MODULE 2,2P OIL SEAL - OUTPUT 3 RCA SEAL PLUG 4,4P DRAIN PLUG 5 FL-SPACER 6 F-FLANGE 7 SOCKET head CAPSCREW 8 SOCKET head CAPSCREW 9,9P,9X OIL SEAL - NON-MOTORIZED INPUT horizontal BASE 11 SOCKET head CAPSCREW 12 REACTION ARM 13 RETAINING RING 14 SPACER 15 OUTPUT ShAFT - DOUBLE EXTENSION 16 OUTPUT ShAFT - SINGLE EXTENSION 17 KEY-OUTPUT (EXTENSION) 18 KEY-OUTPUT (INTERNAL) 19,19P,19X OIL SEAL - MOTORIZED INPUT 20,20P,20X INPUT ShAFT - NON-MOTORIZED INPUT 21,21P,21X KEY - INPUT (EXTENSION) 22,22P,22X KEY -INPUT (INTERNAL) 23,23P,23X GASKET 24 CONNECTOR ShAFT 25 KEY 26 KEY 27,27P,27X FLANGE - MOTORIZED INPUT 28 INPUT COVER 29 CONNECTOR FLANGE - DOUBLE REDUCTION 30 O-RING 31 SOCKET head CAPSCREW 32,32P,32X SOCKET head CAPSCREW 33,33P,33X hex head CAPSCREW 34 PRIMARY GEAR MODULE - DOUBLE REDUCTION 35 helical STEP MODULE - DOUBLE REDUCTION 36 SOCKET head CAPSCREW 37 NAMEPLATE 38 GASKET Specifications and prices are subject to change without notice. 3;R 5 Phone: (262) Fax: (262) LEESON ELECTRIC, S/5K/10-04/STL/Bh M-B Companies, Inc. Copyright 2012 Publication: MCT

501-147243 Gearbox Cleveland Gear MODULAR SPEED REDUCERS

33 Gearbox Lubrication Cleveland units are shipped dry. A mineral based or synthetic oil is available upon customer request. When shipped dry, before starting the unit, it must be filled to the level indicated and with the grade of oil called for by the application. Any supplier of industrial oil can meet these specifications with a standard product. Worm gearing has a high slide to roll ratio when compared with other types of gearing. With a high sliding component, it relies heavily on the generation of an oil wedge between the worm and gear. For most worm gear applications, an AGMA 7 compound oil is satisfactory. For low speeds, a higher viscosity, AGMA 8 compound will provide better service. Both are petroleum base, mineral oils compounded with 3% to 10% fatty oils. These are sometimes referred to as steam cylinder oils. The compounded lubricant provides a lower co-efficient of friction and better wear characteristics than a straight mineral oil. At the high temperatures and pressures prevailing in the contact area, a chemical reaction occurs on the bronze tooth surface. An unstable, copper oleate film will form a protective skin. Extreme pressure oils (EP oils) are another type of lubricant that uses a surface acting chemistry. Most EP oils use sulfur, phosphorus and/or chlorine additives. The EP oils are designed to work in steel on steel applications. When these oils are used with bronze under conditions of high temperature and pressure, the surface acting chemistry can damage the surface of the bronze. Synthetic lubricants are very common. Synthetic lubricants are more viscosity temperature stable than mineral oils. This allows one lubricant to provide adequate service over a broader temperature range. They have a longer life in service, increasing the oil change interval. They reduce wear and friction, increasing the life of the gear box. Efficiency increases of 10% of the lost power are possible. Under severe service, properly selected synthetics are outstanding. Many companies have found that, due to the advantages of synthetic lubricants, it is actually cheaper to buy the more expensive oil, even for normal applications. Oil Level The oil level in a reducer can be checked only when it is at rest, and it must be maintained at the proper level. Overfilling is to be avoided, as it causes excessive churning losses and may result in overheating. Oil Changes Oil in a new unit should be drained out at the end of two weeks and the case thoroughly flushed with a light oil to remove any foreign substances that may be detrimental to good operation. The original oil may be reused if good filtering facilities are available; otherwise, new oil should be used to refill the housing. After this, a change of oil every six months or 2,500 hours whichever occurs first, is recommended. Extremely severe or dirty conditions, as well as high humidity, will require more frequent oil changes. The use of synthetics can extend this period. At least one filling of the grease fittings between oil changes is recommended on all units equipped with grease fittings. In general, grease fittings are found on units having a vertical shaft, and either one or two fittings are required, depending upon the internal construction. Idle Time Cleveland units which are to stand idle for a long period of time before being used should be completely filled with oil to prevent corrosion due to internal condensation. Units in intermittent service should be operated for brief periods of time at least once a month to redistribute the oil and thereby protect the bearings and ground parts from rusting. This short run will also lubricate the shaft oil-seals and thereby prolong their life measurably. Speed High speeds above 1800 RPM usually require a change in oil level. Contact Cleveland Gear for information on input speeds in excess of 1800 RPM. M-B Companies, Inc. Copyright 2012 Publication: MCT

34 Gearbox Lubrication The following tables are Cleveland Gear s recommendations for worm gear lubricants. A general table such as this cannot cover all possible applications. If your application seems out of the ordinary, please contact the factory. WORM AGMA LUBRICANT NUMBER SPEED AMBIENT TEMPERATURE R.P.M. 15 TO 50 F 50 TO 125 F BELOW 600 #7 COMPOUNDED #8 COMPOUNDED ABOVE 600* #7 COMPOUNDED #7 COMPOUNDED RECOMMENDED PRODUCT AGMA NUMBER MINERAL SYNTHETIC #7 COMPOUNDED MOBIL 600W MOBIL SHC 634 CYLINDER OIL #8 COMPOUNDED MOBIL 600W MOBIL SHC 634 SUPER CYLINDER OIL Viscosity Ranges for AGMA Lubricants a Rust and Oxidation Equivalent Inhibited Gear Oils Viscosity Range b ISO Grade c AGMA Lubricant No. mm 2 /S (cst) at 40 C 7 Comp d 414 to Comp d 612 to a b c d Extracted from AGMA Specification-Lubrication of Industrial Enclosed Gear Drives (AGMA ) with the permission of the publisher, the American Gear Manufacturers Association, Suite 1000,1901 North Fort Myer Drive, Arlington, Virginia Viscosity System for Industrial Fluid Lubricants, ASTM Also British Standards Institute, B.S Industrial Liquid Lubricants ISO Viscosity Classification. International Standard, lso Comp. (Compounded Oils) contain 3% - 10% fatty or synthetic oils. AGMA Lubricant Number Per AGMA For ease of start up, heaters or use of synthetic oil may be required at low temperatures. * At rubbing speeds over 2,500 fpm, a spray lubrication system and/or synthetic lubricants may be required. Contact the factory for specific recommendations. NOTE: Viscosity ranges for AGMA Lubricant numbers are identical to those of ASTM M-B Companies, Inc. Copyright 2012 Publication: MCT

35 Gearbox Lubrication 1.33", 1.54",1.75", 2.06", 2.38" & 2.62", 3.00" & 3.25" CD 3.00" & 3.25" Solid Output Shaft Center Distance Worm Over Worm Under Center Distance Oil Capacity in Ounces Oil Capacity in Ounces Center Distance Oil Capacity in Ounces Worm Over Worm Under Center Distance Oil Capacity in Ounces Oil capacities shown are approximate. On installation, fill to plug level indicated. Center Distance Oil Capacity in Ounces Vertical Input M-B Companies, Inc. Copyright 2012 Publication: MCT

37 LIMITED WARRANTY Limited Warranty: Subject to the limitations set forth herein, M-B Companies, Inc. ( M-B ) warrants its products to be free from defects in material and workmanship for a period of twelve (12) months from the date of delivery of the product to its original owner, except that the warranty is twelve (12) months solely for the following products: Truck Mounted Pavement Marking Equipment, Airport Snow Removal Products, Attachment Products, Brushes, MSV Multi-Service Vehicles. Parts shall have a ninety (90) day warranty. This warranty is not transferable without the written consent of M-B. Notice: M-B s obligations under this Limited Warranty are conditioned on M-B receiving, within the warranty period, written notice from Buyer specifying the nature of any alleged defect and requesting corrective action by Seller. Remedies: M-B, at its option, will repair or replace, or provide a credit to Buyer for, defective warranted items. If requested by M-B, products or parts for which a warranty claim is made shall be returned, transportation prepaid, to M-B s factory. Buyer shall not return any product for repair, replacement or credit without M-B s advance written consent. Other Manufacturer s Warranty: On products furnished by M-B, but manufactured by any other manufacturer, the warranty of said manufacturer, if any, will be assigned to Buyer, if the said warranty is assignable. However, M-B does not represent or guarantee that such manufacturer will comply with any of the terms of the warranty of such manufacturer. Exclusions: Any improper use, operation beyond capacity, or substitution of parts not approved by M-B, or alteration or repair by others in such a manner as in M-B s judgment materially and/or adversely affects the product shall void this warranty. This warranty does not apply to defects caused by damage or unreasonable use while in the possession of the owner, including but not limited to: failure to provide reasonable and necessary maintenance, normal wear, routine tune ups or adjustments, improper handling or accidents, operation at speed or load conditions contrary to published specifications, improper or insufficient lubrication, or improper storage. Seller manufactures power brooms that mount to many makes and models of equipment. Seller attempts to ensure that the mounting frames fit correctly. However, the large number of tractor models, types and options currently available, compounded by frequent manufacturer design changes, may prevent Seller from supplying a frame that fits every unit correctly. Therefore, unless Buyer supplies drawing which detail the attachment points on the specific unit to which the broom will be mounted, Seller will not be responsible for the fit of the mounting frame. The batteries, tires, rubber material, brushes and material normally consumed in operation, and major components such as engines, air compressors, and hydraulic pumps and motors are excluded from this warranty but may be covered to the extent of any warranty received by M-B from its supplier if permitted by the terms of such warranty. Limitations of liability: M-B shall not be liable for any incidental, consequential, punitive or special damages of any kind, including, but not limited to, consequential labor costs or transportation charges in connection with the repair or replacement of defective parts, or lost time profits or expense which may have accrued because of said defect. M-B disclaims all other warranties, whether express or implied, including but not limited to any implied warranty of merchantability or fitness for a particular purpose. This warranty is exclusive remedy of buyer. This warranty cannot be extended, broadened or changed in any respect except in writing by an authorized officer of M-B. Notwithstanding anything in this warranty is to the contrary, in no event shall M-B s total liability hereunder exceed the purchased price of the particular product. M-B Companies, Inc. Copyright 2011

Worm Gear Reducers Installation, Lubrication and Maintenance Instructions

Worm Gear Reducers Installation, Lubrication and Maintenance Instructions Selection Information Read ALL instructions prior to operating reducer. Injury to personnel or reducer failure may be caused by improper installation, maintenance or operation. Written authorization from