Broce FMJ470 Operation & Maintenance Manual

Front mount 4-wheel construction sweeper

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Operation & Maintenance

FMJ470

Front Mount

4-Wheel Construction Sweeper

Broce Manufacturing Co. Inc.

1460 South 2nd Avenue Dodge City, KS 67801

PHONE (580) 227-3711

FAX (580) 227-2165

parts@brocebroom.com

M-F 7:00 AM-6:00 PM CST

1-866-283-2759

www.brocebroom.com

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Page 1 Operation & Maintenance FMJ470 Front Mount 4-Wheel Construction Sweeper Broce Manufacturing Co. Inc. 1460 South 2nd Avenue Dodge City, KS 67801 PHONE (580) 227-3711 FAX (580) 227-2165 parts@brocebroom.com M-F 7:00 AM-6:00 PM CST 1-866-283-2759 www.brocebroom.com...
Page 3 The Warranty and Limitations of Liability are found in the Warranty pages enclosed in the Parts and Operators Manuals. Broce Manufacturing Co. Inc. reserves the right to make design changes or modifications to Broce products at any time without incurring any obligation to make similar changes or modifications to previously sold units. If this Document is not signed and returned to Broce Manufacturing Co. Inc., the warranty begins at the date of delivery to the Dealership.
Page 5 Our obligation under the warranty is expressly limited, at our option, to the replacement or repair at Broce Manufacturing of Dodge City, KS or at a service facility designated by us. We are not responsible for unauthorized repairs or replacements. Any implied or statutory warranties, including any warranty of merchantability or fitness for a particular purpose, are expressly limited to duration of this written warranty.
Page 6 NOTICE: THIS VEHICLE DOES NOT CONFORM TO ALL SAFETY AND EMISSIONS STANDARDS APPLICABLE TO ON-ROAD VEHICLES IN THE UNITED STATES. OPERATOR QUALIFICATIONS Operation of this equipment shall be limited to competent and experienced persons. In addition, anyone who will operate or work around this equipment must use good common sense.
Page 8: Table Of Contents
HYDRAULIC TEMP SCREEN.........24-25 HYDRAULIC SYSTEM..............27-30 MAINTENANCE ENGINE AIR CLEANER............31 CABIN AIR CLEANER............32 SERVICE SCHEDULE............33 RADIATOR & HEAT EXCHANGER........34 LUBRICATION..............35-36 LUBRICATION CHART............37 FASTENERS, CORE DRIVE, ETC........38 ENGINE, TIRE..............39 AIR CONDITIONER PREVENTIVE........40 TROUBLESHOOTING- A/C SYSTEM.........41 WARNING: Cancer and Reproductive Harm www.P65Warnings.ca.gov BROCE FMJ470...
Page 9 TABLE OF CONTENTS A/C WARRANTY................42 BROOM WAFER REPLACEMENT..........43-44 TROUBLESHOOTING..............45-48 SCHEMATICS (Wiring Diagram)..........49-51 SCHEMATICS (Hydraulic Diagram)..........52-56 WARNING: Cancer and Reproductive Harm www.P65Warnings.ca.gov BROCE FMJ470...
Page 10: Safety Precautions
A careful operator is the best insurance against an accident. The complete observance of one simple rule would prevent many thousand serious injuries each year. Never attempt to clean, oil, or adjust a machine while it is in motion! WARNING: Cancer and Reproductive Harm www.P65Warnings.ca.gov BROCE FMJ470...
Page 11 TRAVEL SPEED MUST BE GOVERNED BY GOOD JUDGMENT. DO NOT OVERSPEED Although a high travel speed is available with the Broce Broom, we caution all operators to use good judgment, especially on rough terrain. WARNING:...
Page 12 NO RIDERS! UNDER NO CIRCUMSTANCES SHOULD PASSENGERS BE ALLOWED TO RIDE ON THIS MACHINE. WARNING: Cancer and Reproductive Harm www.P65Warnings.ca.gov BROCE FMJ470...
Page 13: Machine Specifications
..............2 Speed Hydraulic Motor Broom Angle ..............35° Degrees Steering ..............Hydraulic Orbital Fuel Capacity ..............30 Gallons Hydraulic Oil Capacity ..............25 Gallons Speed ..............18 mph Water Capacity ..............145 Gallons WARNING: Cancer and Reproductive Harm www.P65Warnings.ca.gov BROCE FMJ470...
Page 14 * 2 Quarts is approximate. Fill to the level of the filler plug. ATTENTION R-134a A/C Refrigerant Factory Charge: John Deere = 3.0 lb (1.36kg) Ester Oil Change: Compressor = 8.0 oz System = 4.0 oz WARNING: Cancer and Reproductive Harm www.P65Warnings.ca.gov BROCE FMJ470...
Page 15: Machine Operations
MACHINE OPERATION The Broce Broom is hydro-statically driven. The directional control is achieved through the use of the Forward & Reverse pedal, located near the operator’s foot. Arrows on the pedals indicate direction of travel. Rate of travel is governed by the distance the pedal is depressed and the throttle position.
Page 16: Inspection
2. Turn the key switch to the starting position (all the way forward). Add fuel as necessary using the hand operated throttle near the operator’s right hand. Release the key switch when the engine starts. Do not exceed 1500 RPM until the hydraulic fluid has warmed up. WARNING: Cancer and Reproductive Harm www.P65Warnings.ca.gov BROCE FMJ470...
Page 17: Startup Procedure
Do not propel this machine with the parking brake engaged. This will damage the rear brake assemblies Do not over speed! Although a high rate of travel is available with a Broce Broom, we caution all operators to use good judgment, especially on rough terrain.
Page 18: Sweeping Core
SIDE TO SIDE OPERATION OF BROOM The sweeper is equipped with a side shift mechanism which allows the broom to move 14” to the left or right. This function is activated with the side shift joystick. WARNING: Cancer and Reproductive Harm www.P65Warnings.ca.gov BROCE FMJ470...
Page 19 • Ensure that the operator of the machine is properly trained and follows all safety procedures described in this manual. WARNING: Cancer and Reproductive Harm www.P65Warnings.ca.gov BROCE FMJ470...
Page 20: Display Screen
The ENTER key also brings up the soft keys. Press once to display the left and right arrows. Press twice to display all the soft keys. Press three times to hide all the soft keys. WARNING: Cancer and Reproductive Harm www.P65Warnings.ca.gov BROCE FMJ470...
Page 21 DISPLAY SCREEN Main Screen Hydraulic Hydraulic Engine Speedometer Pressure Temperature Temperature (MPH Gauge) Fuel Running Level Engine Battery Tachometer Hours Gallon Power Power Per Hour (RPM Gauge) Gauge WARNING: Cancer and Reproductive Harm www.P65Warnings.ca.gov BROCE FMJ470...
Page 22: Screens
This screen show how many hour each filter has been used. Please referance the manual when to change each one. Active Faults Screen This screen shows all current active faults and how many times the fault has been shown. WARNING: Cancer and Reproductive Harm www.P65Warnings.ca.gov BROCE FMJ470...
Page 23 Additional Screens Historic Faults Screen This screen shows the history of all faults that have been displayed since the machine has been running and how many times the fault has been shown. WARNING: Cancer and Reproductive Harm www.P65Warnings.ca.gov BROCE FMJ470...
Page 24 DISPLAY SCREEN Hydraulic Temp Hydraulic Temperature Hydraulic Temperature The hydraulic temperature should not exceed 210 If the temperature exceeds 210 F you will receive a warning message shown on Fig.1.2 below. Fig. 1.2 WARNING: Cancer and Reproductive Harm www.P65Warnings.ca.gov BROCE FMJ470...
Page 25 If you suspect an injury, no matter how minor it may seem, get medical attention immediately. Failure to do so can lead to gangrene and loss of limb. WARNING: Cancer and Reproductive Harm www.P65Warnings.ca.gov BROCE FMJ470...
Page 27: Hydraulic System
The priority flow is 4 gpm. The steering unit is an orbital type metering valve that supplies oil to the steering cylinders and also has power beyond capabilities that are used to control the brush functions. WARNING: Cancer and Reproductive Harm www.P65Warnings.ca.gov BROCE FMJ470...
Page 28 Placement of the dial will also determine speed of the broom rotation. Side Shift Function: Actuation of the side shift joystick will move the broom from left to right. WARNING: Cancer and Reproductive Harm www.P65Warnings.ca.gov BROCE FMJ470...
Page 29 Suction Filter: There are two suction filters. The main pump suction filter is a 7 micron spin-on filter. The auxiliary pump suction filter is a 100 mesh with a 5psi bypass. WARNING: Cancer and Reproductive Harm www.P65Warnings.ca.gov BROCE FMJ470...
Page 30 Hoses & Adapters: All hose adapters are boss O-ring/flat face in the cylinders, valves, steering unit, pumps, and motors. All the hoses are flat-face type design. System Plumping: The system plumbing diagrams can be found in the Hydraulic Section of the parts manual. WARNING: Cancer and Reproductive Harm www.P65Warnings.ca.gov BROCE FMJ470...
Page 31: Maintenance
MAINTENANCE ENGINE AIR CLEANER The manufacturer has endeavored to build the Broce Broom as maintenance free as possible. The service points are easily accessible and are similar to those on many types of construction equipment. This section will cover many of these points in some detail and will briefly mention those which should be standard on all equipment.
Page 32: Cabin Air Cleaner
The air cleaner provides clean air to the air cleaner system. Inspect the service indicator daily. Inspect the service indicator daily. When the clear ring on the service indicator turns red, the air filter must be replaced immediately. Clamp Cabin Air Filter WARNING: Cancer and Reproductive Harm www.P65Warnings.ca.gov BROCE FMJ470...
Page 33: Service Schedule
Again, cleanliness must be stressed during this type of maintenance. Contamina- tion of this system will cause pump and/or motor failure. Avoid servicing hydraulic system components in the field where cleanliness of the environment cannot be controlled. WARNING: Cancer and Reproductive Harm www.P65Warnings.ca.gov BROCE FMJ470...
Page 34: Radiator & Heat Exchanger
Use water or compressed air directed from the engine side of the radiator to remove dirt build up. The engine must be completely stopped while performing this maintenance. Inspect radiator and heat exchanger for dirt deposits and/or damage before resuming operation. WARNING: Cancer and Reproductive Harm www.P65Warnings.ca.gov BROCE FMJ470...
Page 35: Lubrication
10 hours of operation. Lube Rear Axle Assembly Side Shift: Lubricate the upper and lower pivots bosses every 10 hours of operation. There are 4 places on the side shift mechanism. Lube Lube WARNING: Cancer and Reproductive Harm www.P65Warnings.ca.gov BROCE FMJ470...
Page 36 “one-shot” of grease at 250 hour intervals is recommended. Seals are often destroyed by over-greas- ing sealed bearings. Engine Lubrication Refer to the Engine Manufacturer’s manual (included) for recommendation and pro- cedures for servicing the engine. WARNING: Cancer and Reproductive Harm www.P65Warnings.ca.gov BROCE FMJ470...
Page 37: Lubrication Chart
MAINTENANCE LUBRICATION CHART BROCE BROOM LUBRICATION CHART Initial (Hours) Thereafter (Hours) ITEM ReMARKS 1000 Engine Oil Change Oil Differential Change Oil Check Hydraulic Disposable Replace Filter Hydraulic Oil Replace GREASE ZERKS Tie Rod End Lubricate Steering Cylinder Lubricate Mount Core/Brush...
Page 38: Fasteners, Core Drive, Etc
After alignment, tighten both set-screws and jam nuts as well as the lock collar on the pillow block bearing at the other end of the broom core. WARNING: Cancer and Reproductive Harm www.P65Warnings.ca.gov BROCE FMJ470...
Page 39: Engine, Tire
Inflate tires to manufacturer’s recommended pressure as specified on the tire sidewall. This will provide the longest tire life. A lower pressure will provide a more comfortable ride, and make rough off-highway conditions easier to negotiate, but is not recommended. WARNING: Cancer and Reproductive Harm www.P65Warnings.ca.gov BROCE FMJ470...
Page 40: Air Conditioner Preventive
7. Cabin return air filter is located on the left hand side of the seat base. Inspect the filter and replace if necessary. Broce thanks you for purchasing our unit/s. It is our endeavor to provide you with a quality A/C unit with trouble-free service.
Page 41: Troubleshooting- A/C System
ATTENTION R-134a A/C Refrigerant Factory Charge: John Deere = 3.0 lb (1.36kg) Ester Oil Change: Compressor = 8.0 oz System = 4.0 oz WARNING: Cancer and Reproductive Harm www.P65Warnings.ca.gov BROCE FMJ470...
Page 42: A/C Warranty
MAINTENANCE Warranty Claim Form for Broce A/C Systems and Components Ambient temperature before repairs were made:____________________________ Static Pressure before repair is made: High:_____________ Low:______________ Running Pressure before repair is made:__________________________________ Any odd or unusual noises before repairs are made: ________________________...
Page 43: Broom Wafer Replacement
BROOM WAFER REPLACEMENT BROOM WAFER REPLACEMENT The standard Broce Broom core uses 10” x 32” flat wafers and metal spacers. The standard eight-foot core requires approximately 54 wafers and 53 metal spacers (this will vary by wafer manufacturer and type of end-caps ordered on broom). The amount of wafers required as well as specific installation instructions may be ob- tained from the wafer manufacturer.
Page 44 If you have any questions regarding these procedures or would like to obtain the core service ring and stand, please contact your nearest dealer or call us direct at (620) 227-8811. Core Service Ring and Stand WARNING: Cancer and Reproductive Harm www.P65Warnings.ca.gov BROCE FMJ470...
Page 45: Troubleshooting
TROUBLESHOOTING Before troubleshooting can be done, characteristics of normal operation of this machine must be understood. As discussed earlier in this manual, this system uses an open center control valve. This can lead to the belief that a problem may exist when in fact, the system is operating normally.
Page 46 These 2. Loose circle bearings must be extremely tight (zero tolerance). Any gaps whatsoever can cause bouncing. 2. Tighten circle bearings underneath the circle. WARNING: Cancer and Reproductive Harm www.P65Warnings.ca.gov BROCE FMJ470...
Page 47 Core motor shaft broken 1. Over use of positive 1. Replace motor. down pressure feature (Too much side load) 2. Core misaligned 2. Replace motor. Re- align motor mount. Refer to Maintenance section for procedures. WARNING: Cancer and Reproductive Harm www.P65Warnings.ca.gov BROCE FMJ470...
Page 48 No hydraulic power 1. Broken shaft or coupler 1. Refer to hydrostatic including steering and in hydrostatic pump trouble shooting sec- hydrostatic drive. tion in Sauer-Danfoss Manual. WARNING: Cancer and Reproductive Harm www.P65Warnings.ca.gov BROCE FMJ470...
Page 49: Schematics (Wiring Diagram)
SCHEMATICS (Wiring Diagram) WARNING: Cancer and Reproductive Harm www.P65Warnings.ca.gov BROCE FMJ470...
Page 50 To Chassis Ground Switch High Speed Fan Relay Fan Speed White Black Resistor Purple Yellow Orange H M L Orange Fan Switch Motor Blower Assembly Power In From OEM Wire - KEYED WARNING: Cancer and Reproductive Harm www.P65Warnings.ca.gov BROCE FMJ470...
Page 51 1 2 3 4 5 6 7 8 9 10 1112 13 14 15 16 17 1819 20 21 22 23 24 25 26 27 28 29 30 31 PINK 31 PIN VEHICLE GRAY INTERFACE WHITE GRAY THROTTLE PINK WHITE WARNING: Cancer and Reproductive Harm www.P65Warnings.ca.gov BROCE FMJ470...
Page 52: Schematics (Hydraulic Diagram)
SCHEMATICS (Hydraulic Diagram) Broom Motor WARNING: Cancer and Reproductive Harm www.P65Warnings.ca.gov BROCE FMJ470...
Page 53 SCHEMATICS (Hydraulic Diagram) WARNING: Cancer and Reproductive Harm www.P65Warnings.ca.gov BROCE FMJ470...
Page 54 SCHEMATICS (Hydraulic Diagram) Tank WARNING: Cancer and Reproductive Harm www.P65Warnings.ca.gov BROCE FMJ470...
Page 55 SCHEMATICS (Hydraulic Diagram) WARNING: Cancer and Reproductive Harm www.P65Warnings.ca.gov BROCE FMJ470...
Page 56 513422 Main Pump Hose Assembly 513426 Auxiliary Pump Hose Assembly 513392 Left Setting Cylinder Hose Assembly Piston Side 513390 Right Setting Cylinder Hose Assembly Piston Side 513394 Steering Cylinder Crosslink Hose Assembly WARNING: Cancer and Reproductive Harm www.P65Warnings.ca.gov BROCE FMJ470...
Page 57 NOTES ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ WARNING: Cancer and Reproductive Harm www.P65Warnings.ca.gov BROCE FMJ470...
Page 58 State of California to cause cancer, birth defects, and other reproductive farm. Wash hands after handling. For more information, vist: www.P65Warnings.ca.gov Broce Manufacturing Co. Inc. 1460 South 2nd Avenue Dodge City, KS 67801 PHONE (580) 227-3711 FAX (580) 227-2165 parts@brocebroom.com...