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Pro Sweep 5200

1. BRUSH MOTOR 2 7 CI REV CONTRO MANIFOLD HOPPER DUMP INPUT PRESSURE LIFT CYLINDER RETRACTING BRUSH MOTOR 2 7 CI REV Page 3 8 MANIFOLD HOPPER LOWER Hopper Dump Lower Circuits Working Pressure Return Flow Pro Sweep 5200 Hopper Dump Lower Circuits NOTE Hydraulic flow and relief pressure to the Pro Sweep 5200 are determined by the tow vehicle Hydraulic flow from the tow vehicle goes to the control manifold port P through the hydraulic input hose When the sweeper brush motor is not engaged and the lift cylinder is stationary hydraulic flow from the vehicle is directed by the un energized demand solenoid valve S2 to return to the tow vehicle through control manifold port T and the return to tank hose Hopper Dump When the hopper switch is pressed to dump both the hopper up S1 and demand S2 solenoid valves in the hydraulic control manifold are energized The valve shift of S2 prevents hydraulic flow return to the tow vehicle The valve shift of S1 allows oil flow past the check valve in the control manifold out of control manifold port CYL and to the lift cylinder Hydraulic pressure against the lift cylinder rod extends the cylinder and dumps the hopper The check valve fitting attached to the lift cylinder allows oil flow to bypass the orifi
2. Testing NOTE Prior to taking small resistance readings with a digital multimeter short the meter test leads together Figure 6 The meter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal resistance of the meter and test leads Subtract this val ue from from the measured value of the component you are testing a O o D wi 1 Verify coil resistance between terminals 85 and 86 with a multimeter ohms setting Resistance should be from 70 to 90 ohms 2 Connect multimeter ohms setting leads to relay ter minals 30 and 87 Ground terminal 86 and apply 12 VDC to terminal 85 The relay should make and break continuity between terminals 30 and 87 as 12 VDC is applied and removed from terminal 85 3 Disconnect voltage from terminal 85 and multimeter lead from terminal 87 4 Connect multimeter ohms setting leads to relay ter minals 30 and 87A Apply 12 VDC to terminal 85 The relay should break and make continuity between termi nals 30 and 87A as 12 VDC is applied and removed from terminal 85 5 Disconnect voltage and multimeter leads from the relay terminals Pro Sweep 5200 Page 4 7 Electrical System Fuse The Pro Sweep 5200 uses a single 20 amp fuse for cir cuit protection The fuse holder is located in the wiring harness Fig 7 Testing Remove fuse from the fuse holder for testing Fuse should have continuity be
3. GN Power Current P42 3 GROUND gt Bk Control Current P42 2 POWER 5 PK Indicator Current P42 1 BRAKE OUTPUT BU Page 6 5 Page 6 6 VEHICLE POWER VEHICLE GROUND VEHICLE POWER VEHICLE GROUND BRAKE PRESSED REMOTE HARNESS P1 C P2 C P11 A P11 B BN BN lt o o gt BK HOPPER DOWN SWITCH ii HOPPER LOWERING 2 HOPPER DOWN RELAY 5 87o l 3 P1 J P2 J P5 A FEY P5 B PK UUU 5 8N P24 GN GN GN BK 85 80 3 she S dl BRUSH MOTOR S3 P21 o Y Yx o 1 6 py 4 2 ON TE ca v iet rey 2185 88 5 P1 D P2 D P7 A P7 B P25 ec PA VIO VIO VIO LT T BK 87 1 i BRUSH RELAY HOPPER UP S1 a o gt gt vio NOT ENERGIZED 5 8 NOT ENERGIZED PK 4 HYDRAULIC 7 PAN 8 SOLENOID BK RO MANIFOLD BRUSH SWITCH A 8 Y E OR LOGIC DIODE P26 5 P1 B P2 B P6 A P6 8 P22 OR OR OR TTT BK 2 DOWN DEMAND 32 PK A uP o gt gt 0R PI E P2 E P4 A P4 8 gt z W cs W W BK 2 HOPPER DOWN S4 PK lt ENERGIZED aA 4 o ee enl HOPPER SWITCH POWER HARNESS 3 P23 g9 gt bY J31 P2 A P2 A A B P1 A P1 A 2 SWEEP _ lt PK ES TRANS FUSE 20 AMP x 7 P1 H P2 H y PA W rYY
4. 13 General Precautions for Removing and Installing Hydraulic System Components 13 Check Hydraulic Lines and Hoses 13 Brush Motor 14 Brush Motor Service 16 Hydraulic Control Manifold 18 Hydraulic Control Manifold Service 20 Lift Cylinder 2 ete e eerte 22 Lift Cylinder Service_ 24 PARKER TORQLINK SERVICE PROCEDURE Pro Sweep 5200 Page 3 1 Hydraulic System General Information Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather sun chemicals very warm storage condi tions or mishandling during operation and maintenance These conditions can cause damage or premature dete rioration Some hoses are more susceptible to these conditions than others Inspect the hoses frequently for signs of deterioration or damage When replacing a hydraulic hose be sure that the hose is straight not twisted before tightening the fittings This can be done by observing the imprint on the hose Use two wrenches hold the hose straight with one wrench and tighten the hose swivel nut onto the fitting with the other wrench Hydraulic Fitting Installation O Ring Face Seal 1 Make sure both threads and sealing surfaces are free of burrs nicks scratches or any foreign material 2 Make sure the o ring is install
5. 11 a o 2 wi Electrical Diagrams The electrical schematic and wire harness drawings for the Pro Sweep 5200 are located in Chapter 6 Electrical Diagrams Special Tools Multimeter The multimeter can test electrical components and cir cuits for current amps resistance ohms or voltage NOTE Toro recommends the use of a DIGITAL Volt Ohm Amp multimeter when testing electrical circuits The high impedance internal resistance of a digital me ter in the voltage mode will make sure that excess cur rent is not allowed through the meter This excess current can cause damage to circuits not designed to carry it Figure 1 Pro Sweep 5200 Page 4 1 Electrical System Troubleshooting Remove all jewelry especially rings and watches before doing any electrical trouble shooting or testing Disconnect the power har ness from the vehicle unless the test requires For effective troubleshooting and repairs you must have a good understanding of the electrical circuits see Chapter 6 Electrical Diagrams and components used on this machine If the machine has the interlock switch by passed it must be reconnected for proper troubleshooting and safety battery voltage Brush rotates but should not when dump hopper is Hopper down proximity switch is malfunctioning or raised faulty Brush relay is faulty Hopper switch or circuit wiring is faulty Logic diode is faulty H
6. 11 Hydraulic System This page is intentionally blank Hydraulic System Page 3 12 Pro Sweep 5200 Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components 1 Before removing any parts from the hydraulic sys tem empty sweeper hopper and position sweeper on a level surface Chock sweeper wheels to prevent sweep er from moving If sweeper is attached to tow vehicle engage tow vehicle parking brake stop engine and re move key from the ignition switch 2 Clean machine before disconnecting removing or disassembling any hydraulic components Make sure hydraulic components hoses connections and fittings are cleaned thoroughly Always keep in mind the need for cleanliness when working on hydraulic equipment Operate all sweeper hydraulic controls to relieve system pressure and to avoid injury from pres surized hydraulic oil See Relieving Hydraulic System Pressure in the General Information sec tion of this chapter 3 Put caps or plugs on any hydraulic lines hydraulic fit tings or hydraulic components left open or exposed to prevent hydraulic system contamination 4 Put labels on disconnected hydraulic lines and hoses for proper installation after repairs are completed 5 Note the position of hydraulic fittings especially el bow fittings on hydraulic components before removal Mark parts if necessary to make sure they will be
7. 8 731 27 32 0 84375 21 431 23 64 0 359375 9 128 55 64 0 859375 21 828 3 8 0 3750 9 525 7 8 0 8750 22 225 25 64 0 390625 9 922 57 64 0 890625 22 622 13 32 0 40625 10 319 29 32 0 90625 23 019 27 64 0 421875 10 716 59 64 0 921875 23 416 7 6 0 4375 11 112 15 16 0 9375 23 812 29 64 0 453125 11 509 61 64 0 953125 24 209 15 32 0 46875 11 906 31 32 0 96875 24 606 31 64 0 484375 12 303 63 64 0 984375 25 003 1 2 0 5000 12 700 1 1 000 25 400 1 mm 0 03937 in 0 001 in 0 0254 mm U S to Metric Conversions To Convert Into Multiply By Linear Miles Kilometers 1 609 Measurement Yards Meters 0 9144 Feet Meters 0 3048 Feet Centimeters 30 48 Inches Meters 0 0254 Inches Centimeters 2 54 Inches Millimeters 25 4 Area Square Miles Square Kilometers 2 59 Square Feet Square Meters 0 0929 Square Inches Square Centimeters 6 452 Acre Hectare 0 4047 Volume Cubic Yards Cubic Meters 0 7646 Cubic Feet Cubic Meters 0 02832 Cubic Inches Cubic Centimeters 16 39 Weight Tons Short Metric Tons 0 9078 Pounds Kilograms 0 4536 Ounces Avdp Grams 28 3495 Pressure Pounds Sq In Kilopascal 6 895 Pounds Sq In Bar 0 069 Work Foot pounds Newton Meters 1 356 Foot pounds Kilogram Meters 0 1383 Inch pounds Kilogram Centimeters 1 152144 Liquid Volume Quarts Liters 0 9463 Gallons Liters 3 785 Liquid Flo
8. 1 TRANS P1 H P2 H P3 A W BK P5 8 i S Y Hy is rm ds i i OFFSET ACTUATOR 1 ve gt Y OPTION P1 F 8 nRk d BK 4 P1 G P2 G o GY GY GY P43 J42 443 R PK4 BREAKER 20AMP NOT SERVICEABLE J44 BK P41 1 GN BRAKE CONTROLLER P42 4 BRAKE INPUT 5 GN P42 3 GROUND 5 BK P42 2 POWER 1 gt Pk P42 1 BRAKE OUTPUT BU B P2 C P2 C h e P3 A PSMA ey A YYYA 8 ELECTRIC BRAKE RIGHT P32 5 A MM B B KEY TO WIRE COLORS ELECTRIC BRAKE LEFT P51 BRAKE CONTROL HARNESS 5 R RED BK BLACK GN GREEN OR ORANGE a Y YELLOW BR BROWN GY GRAY PK PINK P3 B P3 B 5 W WHITE BU BLUE VIO VIOLET BK BK a T TAN BRAKE HARNESS OPTION Pro Sweep 5200 Brush Circuit Power Current Control Current Indicator Current VEHICLE POWER VEHICLE GROUND VEHICLE POWER VEHICLE GROUND BRAKE PRESSED REMOTE HARNESS P1 C P2 C P11 A P11 B BN BN o o BK HOPPER DOWN SWITCH i HOPPER DOWN RELAY n s n _ 87a 3 P1 J P2 J PETA pine P5 A P5 B Pk UUU en P24 S GN GN GN TTT 8K 89 EE 3 1 30 87 BRUSH MOTOR S3 P21 o Y Y lt 5 ed BU 2 St l 30 AS m OFF 2 et a
9. 1 5 Safety and Instruction Decals 1 5 Chapter 2 Product Records and Maintenance Product Records_ 2 1 Maintenance 2 1 Equivalents and Conversions 2 2 Torque Specifications 2 3 Chapter 3 Hydraulic System General Information 4 2 Hydraulic Schematic_ 4 5 Hydraulic Flow Diagrams_ 4 6 Troubleshooting 4 10 Service and Repairs_ 4 13 PARKER TORQLINKTM SERVICE PROCEDURE Pro Sweep 5200 Chapter 4 Electrical System Electrical Diagrams_ Special Tools Troubleshooting Safety Interlock System Component Testing Service and Repairs_ Chapter 5 Chassis Specifications General Information Service and Repairs_ Chapter 6 Electrical Diagrams Electrical Schematic_ Circuit Drawings Wire Harness Drawings_ Product Records and Maintenance a O o o U Electrical Hydraulic System Diagrams This page is intentionally blank Pro Sweep 5200 Chapter 1 TORO
10. Figure 10 1 Roller scraper 6 Bearing flange 2 used per bearing 2 Carriage screw 8 used 7 Locking collar 2 used 3 Roller 8 Set screw 2 used 4 Brush housing 9 Bearing 2 used 5 Flange nut 10 used 10 Lock nut 4 used Chassis Page 5 12 ANTISIEZE LUBRICANT 125 to 155 in Ib 14 1 to 17 5 N m 11 Flat washer 4 used 12 Roller adjustment plate 2 used 13 Carriage screw 4 used 14 Adjuster key 2 used 15 Carriage screw 2 used Pro Sweep 5200 Removal Fig 10 1 Position sweeper on a level surface with dump hop per empty and lowered Have sweeper attached to tow ing vehicle engage vehicle parking brake stop engine and remove key from the ignition switch Chock sweep er wheels to prevent sweeper from moving 2 Remove flange nuts and carriage screws that secure roller scraper to roller adjustment plates Remove roller scraper from machine IMPORTANT When fully lowered the sweeper is supported by the roller To service the roller raise the sweeper slightly before carefully loosening fas teners that secure roller assembly To prevent personal injury make sure that roll er is supported as it is removed from the ma chine Roller weighs approximately 80 pounds 36 3 kg 3 Support roller to prevent it from shifting 4 Note location of roller adjustment plates and adjuster keys for reassembly purposes 5 Remove flange nuts that secure roller adjustment plates and adjuste
11. Preface The purpose of this publication is to provide the service technician with information for troubleshooting testing and repair of major systems and components on the Pro Sweep 5200 REFER TO THE OPERATOR S MANUAL FOR OPER ATING MAINTENANCE AND ADJUSTMENT INSTRUCTIONS Space is provided in Chapter 2 ofthis book to insert the Operator s Manual and Parts Catalog for your machine Additional copies of the Operator s Manual and Parts Catalog are available on the internet at www Toro com The Toro Company reserves the rightto change product specifications or this publication without notice Part No 05137SL Rev A Service Manual Pro Sweep 5200 This safety symbol means DANGER WARNING or CAUTION PERSONAL SAFETY INSTRUC TION When you see this symbol carefully read the instructions that follow Failure to obey the instructions may result in personal injury NOTE A NOTE will give general information about the correct operation maintenance service testing or re pair of the machine IMPORTANT The IMPORTANT notice will give im portant instructions which must be followed to pre vent damage to systems or components on the machine O The Toro Company 2005 2009 This page is intentionally blank Pro Sweep 5200 Table Of Contents Chapter 1 Safety Safety Instructions 1 2 Jacking lInstructions 1 4 Securing Pro Sweep 5200 to Tow Vehicle
12. Safety Table of Contents SAFETY INSTRUCTIONS 2 Before Operating 2 While Operating 2 Maintenance and Service 3 JACKING INSTRUCTIONS 4 SECURING PRO SWEEP 5200 TO TOW VEHICLE 5 SAFETY AND INSTRUCTION DECALS 5 Pro Sweep 5200 Page 1 1 Safety Safety Instructions The Pro Sweep 5200 is designed and tested to offer safe service when operated and maintained properly Although hazard control and accident prevention par tially are dependent upon the design and configuration of the machine these factors are also dependent upon the awareness concern and proper training of the per sonnel involved in the operation transport mainte nance and storage of the machine Improper use or maintenance of the machine can result in injury or death To reduce the potential for injury or death comply with the following safety instructions Before Operating 1 Read and understand the contents of the Operator s Manual before starting and operating the machine Be come familiar with the controls and know how to stop the sweeper quickly Additional copies of the Operator s Manual are available on the internet at www Toro com 2 Keep all shields safety devices and decals in place If a shield safety device or decal is defective illegible or damaged repair or replace it before operating the machine Also tighten
13. tervals for the Pro Sweep 5200 are covered in the Oper ator s Manual Refer to that publication when performing regular equipment maintenance Pro Sweep 5200 Page 2 1 Product Records and Maintenance Decimal and Millimeter Equivalents Equivalents and Conversions Fractions Decimals mm Fractions Decimals mm 1 64 0 015625 0 397 33 64 0 515625 13 097 1 32 0 08125 0 794 17 32 0 53125 13 494 3 64 0 046875 1 191 35 64 0 546875 13 891 116 0 0625 1 588 9 16 0 5625 14 288 5 64 0 078125 1 984 37 64 0 578125 14 684 3 32 0 09375 2 381 19 32 0 59375 15 081 7 64 0 109275 2 778 39 64 0 609375 15 478 1 8 0 1250 3 175 5 8 0 6250 15 875 9 64 0 140625 3 572 41 64 0 640625 16 272 5 32 0 15625 3 969 21 32 0 65625 16 669 11 64 0 171875 4 366 43 64 0 671875 17 066 3 16 0 1875 4 762 11 16 0 6875 17 462 13 64 0 203125 5 159 45 64 0 703125 17 859 7 32 0 21875 5 556 23 32 0 71875 18 256 15 64 0 234375 5 953 47 64 0 734375 18 653 1 4 0 2500 6 350 3 4 0 7500 19 050 17 64 0 265625 6 747 49 64 0 765625 19 447 9 32 0 28125 7 144 25 32 0 78125 19 844 19 64 0 296875 7 541 51 64 0 796875 20 241 5 16 0 3125 7 938 13 16 0 8125 20 638 21 64 0 328125 8 334 53 64 0 828125 21 034 11 32 0 34375
14. 3 4 16 UNF 115 15 165 25 224 34 7 8 9 UNC 140 20 225 25 305 34 7 8 14 UNF 155 25 260 30 353 41 e mee aee mer e wame a7 9 cm s me 38 16UNG 1612 2 acr m ese mec ea s memme sea n acne oss e e se i ie N o N N N a O N N o o A A NOTE Reduce torque values listed in the table above by 25 for lubricated fasteners Lubricated fasteners are defined as threads coated with a lubricant such as engine oil or thread sealant such as Loctite NOTE Torque values may have to be reduced when installing fasteners into threaded aluminum or brass The specific torque value should be determined based on the fastener size the aluminum or base material strength length of thread engagement etc Product Records and Maintenance Page2 4 Rev A NOTE The nominal torque values listed above for Grade 5 and 8 fasteners are based on 75 of the mini mum proof load specified in SAE J429 The tolerance is approximately 10 of the nominal torque value Thin height nuts include jam nuts Pro Sweep 5200 Standard Torque for Dry Zinc Plated and Steel Fasteners Metric Fasteners Regular Height Nuts Thread Size M5 X 0 8 57 6in lb 96 10 in lb Class 8 8 Bolts Screws and Studs with Class 8 or Stronger Nuts 644 68 N cm 78 8 in lb 881 90 N cm 1085 113 N cm Class 10 9 Bolts Screws and Studs with Regular
15. FUSE a LU YELLOW alpog OFFSET GRAY a ACTUATOR POWER P92 BLACK BLACK sd E 2 pan S 3 x x O 3 3 3 2 m m m 3 m a Pro Sweep 5200 T1 1 P CA Main Wire Harness P03 06 P07 P05 04 BRAKE DEMAN HOPPER UP BRUSH HOPPER DOWN HOPPER DOWN HARNESS SOLENOID SOLENOID SOLENOID SWITCH SOLENOID 2 SI 3 4 Page 6 7 Page 6 8 P21 BRUSH SWITCH P22 HOPPER P01 SWITCH TRAILER HARNESS P23 OFFSET SW ITCH BRUSH SW HOPPER SWITCH gt FFSET SWITCH P24 P22 P23 BRUSH RELAY 12 3 4 5 6 7 8 12 3 4 5 6 1 8 1234567 8 e A e TS im E sa lu x o zi Z gt gt S z amp E n a a 3 o Lu g R YELLOW LOGIC DIODE 0 ORANGE BLACK BLACK Lu E L 2E z z 6 d l PINK gt lt PINK 4 PINK SP HOPPER DOWN RELAY p25 3 BLACK 4g BLUE 5 BROWN x Zz a GRAY KR YELLOW 2 BLACK BRUSH RELAY pa GREEN 44 VIOLET 3 ES oz 8 e of A ex POWER DEMAND SOLENOID BRUSH SOLENOID HOPPER UP SOLENOID HOPPER DOWN SOLENOID GROUND OFFSET ACTUATOR OFFSET ACTUATOR TRAILER HARNESS Pro Sweep 5200 Control Box Wire Harness J32 VEHICLE GROUND P92 MAIN HARNESS JA VEHICLE POWER P31 BRAKE CONTROL HARNESS
16. to remain on the ground 5 Raise hopper and place cylinder stop on lift cylinder to secure sweeper frame 6 Perform necessary service on removed compo nent s 7 Once necessary service has been completed posi tion serviced component s under raised hopper 8 Remove cylinder stop from lift cylinder Slowly lower hopper to correctly position component s to be installed 9 Install component s to machine see Brush Brush Housing and or Roller in this section Chassis Brush Antisieze Lubricant Loctite 242 125 to 155 in lb 14 1 to 17 5 N m Figure 5 1 Carriage screw 11 Cap screw 2 used 21 Side angle plate 2 used 2 Top rubber shield 12 Hydraulic brush motor 22 Side rubber shield 2 used 3 Lock nut 2 used 13 Coupler jaw 23 Side shield plate 2 used 4 Top shield plate 14 Set screw 2 used per jaw 24 Front rubber shield 5 Flange nut 15 Coupler spider 25 Front shield plate 6 Flat washer 2 used 16 Flat washer 3 used per bearing 26 Front angle plate 7 Carriage bolt 3 used per bearing 17 Lock nut 3 used per bearing 27 Carriage screw 8 Cap screw 18 Set screw 28 Square key 9 Lock washer 19 Bearing with locking collar 29 Brush 10 Coupler cover 2 used 20 Bearing flange 2 used per bearing 30 Brush housing Removal Fig 5 1 Position sweeper on a level surface with dump hop per empty and lowered Have sweeper attached to tow ing vehicle engage vehicle parking bra
17. BLUE BRAKE CONTROL HARNESS BLACK 91 J32 VEHICLE GROUND MAIN HARNESS RED e L e FUSIBLE LINK 9 1 331 VEHICLE POWER SPI gt Pro Sweep 5200 Power Wire Harness Page 6 9
18. Height Nuts Class 10 or Stronger Nuts 133 14 in lb 1503 158 N cm M6 X 1 0 M8 X 1 25 M10 X 1 5 19 2 ft Ib 38 4 ft lb M12X 1 75 M16 X 2 0 M20 X 2 5 NOTE Reduce torque values listed in the table above by 25 for lubricated fasteners Lubricated fasteners are defined as threads coated with a lubricant such as engine oil or thread sealant such as Loctite 66 7 ft lb 166 17 ft lb 325 33 ft lb NOTE Torque values may have to be reduced when installing fasteners into threaded aluminum or brass The specific torque value should be determined based on the fastener size the aluminum or base material strength length of thread engagement etc Pro Sweep 5200 26 3 N m 90 10 N m 93 10 fi lb 126 14 N m 225 23 N m 229 23 ft lb 310 31 N m 450 46 ft lb 610 62 N m Page 2 5 28 3 ftHb 38 4 Nm NOTE The nominal torque values listed above are based on 75 of the minimum proof load specified in SAE J1199 The tolerance is approximately 10 of the nominal torque value Product Records and Maintenance Product Records o Oo c c 7 S E xe el Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Thread Size Grade 5 1 2 20 UNF 80 10 ft lb 108 14 N m 5 16 18UNC 215 35in lb 145 20 inb Grade 5 3 8 16 UNC 35 10 ft lb 18 3 ft lb M12X 1 25 80 10 ft b 108 14 N m Class 8 8 M12X1 5 8
19. See Relieving Hydraulic System Pressure in the General Information sec tion of this chapter 2 Relieve sweeper hydraulic system pressure 3 Clean brush motor and hydraulic connections Label hydraulic lines for assembly purposes 4 Disconnect hydraulic lines from hydraulic fittings on brush motor Allow hydraulic oil to drain from lines into a suitable container Put caps or plugs on open hydraulic lines and fittings to prevent contamination 5 Remove upper coupling cover from brush housing 6 Support brush motor Remove two 2 cap screws item 14 flat washers item 7 and lock nuts item 6 that secure motor to frame Pull brush motor with coupling jaw attached from the machine IMPORTANT To prevent damage to hydraulic motor DO NOT hit coupling jaw or motor with a hammer during coupling jaw removal or installation 7 Loosen set screw that secures coupling jaw to brush motor shaft Use puller to remove coupler from motor shaft Locate and retrieve key from motor shaft 8 If required remove hydraulic fittings and o rings from the wheel motor Discard o rings Installation Fig 8 1 If removed install hydraulic fittings with new o rings into the brush motor ports see Hydraulic Fitting Installa tion in the General Information section of this chapter 2 If coupling jaw was removed from motor position key into shaft keyway and slide coupling jaw onto shaft Make sure that coupling spider is positioned
20. a a a WENNE P1 D j P2 D P7 A P7 8 P25 gt Bele VIO vo VIO e BK B74 BRUSH RELAY HOPPER UP 81 EM pt ee UU o gt gt vyo n Eis ENERGIZED NOT ENERGIZED 8 8 ENERGIZED PK Os dt HYDRAULIC 7 ars B SOLENOID BK Ae ond MANIFOLD BRUSH SWITCH A 8 Y D OR LOGIC DIODE P26 P1 B P2 B P6 A P6 B P22 3 OR lt OR o BK 2 DOWN DEMAND S2 PK lt ENERGIZED UP l lon P1 P2 P4 A P4 B o W W W TTT 8K 5 8 HOPPER DOWN S4 PK lt 4 y e II js HOPPER SWITCH POWER HARNESS 3 P23 g gt 6Y J31 P2 A P2 A A 8 P1 A 2 SWEEP lt _ ee PK TRANS FUSE 20 AMP 2 y y PH P2 H y P3A Ww CY EK PSB oy Pe4 1 OFFSET ACTUATOR v g Y OPTION P2 P2 P1 F P1 F 5 ms p gs Pk BK D K BK a 4 P1 G P2 G o GY GY GY TRANSPORT SWITCH OPTION BK PB A PB A A B BU Fert y EE y BU BU PAM ELECTRIC BRAKE RIGHT P62 gt A T B n KEY TO WIRE COLORS ELECTRIC BRAKE LEFT P51 BRAKE CONTROL HARNESS 5 R RED BK BLACK GN GREEN OR ORANGE a Y YELLOW BR BROWN GY GRAY PK PINK P3 B PB B 5 W WHITE BU BLUE VIO VIOLET BK BK o T TAN BRAKE HARNESS OPTION P43 J42 443 R PK BREAKER 20AMP NOT SERVICEABLE J44 BK P41 1 GN ir me Pro Sweep 5200 BRAKE CONTROLLER Hopper Dump Circuit P42 4 BRAKE INPUT 5
21. aligned properly when reinstalling hydraulic hoses and tubes Check Hydraulic Lines and Hoses Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure Use paper or cardboard not hands to search for leaks Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury If fluid is in jected into the skin it must be surgically re moved within a few hours by a doctor familiar with this type of injury Gangrene may result from such an injury Pro Sweep 5200 Page 3 13 After Repair or Replacement of Components 1 If component failure was severe or if hydraulic sys tem is contaminated drain entire hydraulic system Drain and flush all hoses and components Also drain and refill tow vehicle hydraulic system reservoir and change oil filter 2 Lubricate o rings and seals with clean hydraulic oil before installing hydraulic components 3 Make sure caps or plugs are removed from the hy draulic tubes hydraulic fittings and components before reconnecting 4 Use proper tightening methods when installing hy draulic hoses and fittings see Hydraulic Fitting Installa tion in the General Information section of this chapter 5 After repairs are completed but before operating the sweeper check oil level in the hydraulic reservoir of the tow vehicle and add correct oil if necessary 6 After disconnecting or replacin
22. is away from washer and hub has end play Finally while rotating hub tighten slotted hex nut from 15 to 20 in lbs 1 7 to 2 3 N m 6 Install cotter pin through axle spindle hole Install dust cap to hub Failure to maintain proper lug nut torque could result in failure or loss of wheel and may result in personal injury 7 Install wheel assembly see Wheel Installation in this section 8 Carefully lower machine to ground Chassis Servicing the Brush Housing Figure 4 1 Saddle frame 3 Hydraulic brush motor 5 Brush housing 2 Roller 4 Brush Chassis Page 5 6 Pro Sweep 5200 To perform service on the brush housing brush assem bly or roller the following procedure can be used These steps will reduce the chance that brush housing compo nents will fall or shift during the service process 1 Position sweeper on a level surface with dump hop per empty and lowered Have sweeper attached to tow ing vehicle engage vehicle parking brake stop engine and remove key from the ignition switch Chock sweep er wheels to prevent sweeper from moving 2 With brush housing resting on the ground remove fasteners that secure component s that are to be re moved see Brush Brush Housing and or Roller in this section 3 Support component s to prevent it them from shift ing position Pro Sweep 5200 Page 5 7 4 Start tow vehicle Slowly raise sweeper hopper while allowing brush housing component s
23. switch Chock sweep Manual er wheels to prevent sweeper from moving 2 Disassemble frame as needed using Figure 11 as a guide Chassis Page 5 14 Pro Sweep 5200 Chapter 6 TORO Electrical Diagrams Table of Contents ELECTRICAL SCHEMATIC Electrical Schematic o ooooooo 3 CIRCUIT DRAWINGS Brush elle HT er Micra eR ata A 4 Hopper Dump Circuit 5 Hopper Lower Circuit 6 WIRE HARNESS DRAWINGS Main Wire Harness_ 7 Control Box Wire Harness 8 Power Wire Harness 9 S 0 1 3 SE 5b os wa Pro Sweep 5200 Page 6 1 Electrical Diagrams This page is intentionally blank Electrical Diagrams Page 6 2 Pro Sweep 5200 VEHICLE POWER VEHICLE GROUND VEHICLE POWER VEHICLE GROUND BRAKE PRESSED REMOTE HARNESS P1 C P2 C P11 A P11 8 BN BN E BK HOPPER DOWN SWITCH EET A HE NTS gts K pm SHOWN IN UP POSITION 2 HOPPER DOWN RELAY 5 87a 3 P1 4 P2 4 P5 A P5 B PK gt BN P24 9 GN GN GN GN TA BK aiid Ba 5 3e 27 a7 BRUSH MOTOR P21 o Y Y lt o S3 pk lt l o BU S b i 30 T NG 87 PIE OFF 86 88 x 5 P1 D P2 D P7 A P7 8 P2
24. 0 10 ftHb f 108 14 N m Class 8 8 For steel wheels and non lubricated fasteners Thread Cutting Screws Thread Cutting Screws Zinc Plated Steel Zinc Plated Steel Thread Threads per Inch Size Baseline Torque Type A Type B 1 2 4 4 Type 1 Type 23 or Type F Thread Size Baseline Torque No 6 32 UNC 20 5 in lb Co 2 55 No 8 32 UNC 30 5 in lb 16 47 i No No hes os omen No 10 24 UNC 38 7 in lb 1 4 20 UNC 85 15 in lb 5 16 18 UNC 110 20 in lb Hole size material strength material thickness 4 finish must be considered when determining specific torque 3 8 16 UNC 200 100 in lb values All torque values are based on non lubricated fasteners Conversion Factors in lb X 11 2985 N cm N cm X 0 08851 in lb ft lb X 1 3558 N m N m X 0 7376 ft Ib Product Records and Maintenance Page 2 6 Pro Sweep 5200 Chapter 3 TORO Hydraulic System Table of Contents GENERAL INFORMATION 2 Hydraulic Hoses_ 2 Hydraulic Fitting Installation 2 Relieving Hydraulic System Pressure 4 Securing Sweeper to Tow Vehicle 4 HYDRAULIC SCHEMATIC_ 5 HYDRAULIC FLOW DIAGRAMS 6 Br sh Circult 4 sata eink tine eit 6 S Hopper Dump Lower Circuits 8 TROUBLESHOOTING 10 gt SERVICE AND REPAIRS_
25. 5 I gt ex PAPA VIO VIO VIO Y BK 870 1 BRUSH RELAY HOPPER UP Date acted ae o gt gt vo A e S1 SHOWN IN UP POSITION 8 6 PK PERO b Ts HYDRAULIC 7 CAR 8 SOLENOID BK CY MANIFOLD BRUSH SWITCH A 8 Y D OR LOGIC DIODE P28 5 P1 B P2 B PO A P6 B P22 OR OR OR FA BK 2 DOWN DEMAND PK UP de 52 9 OR 1 P1 E P2 E P4 A P4 B o W W W FAN BK 5 6 HOPPER DOWN PK se o V C lO cd HOPPER SWITCH POWER HARNESS 3 P23 g gt gt 6Y J31 R P2 A P2 A R A B PK P1 A P1 A PK PK 2 SWEEP FUSE 20 AMP MS y PI ge P2H y ESA W CYY Y BK PB EGA 1 OFFSET ACTUATOR VS Y OPTION J32 P2 B P2 B P1 F P1 F 8 8K BK SK BK SK AK 4 P1 G P2 G o GY GY GY TRANSPORT SWITCH OPTION BK E P3 A P3 A A B BU 2x BU BU BU ARAA ELECTRIC BRAKE RIGHT P52 5 f MTA 8 a KEY TO WIRE COLORS ELECTRIC BRAKE LEFT P51 BRAKE CONTROL HARNESS 5 R RED BK BLACK GN GREEN OR ORANGE a Y YELLOW BR BROWN GY GRAY PK PINK P3 B P3 B 5 W WHITE BU BLUE VIO VIOLET BK BK a T TAN BRAKE HARNESS OPTION P4 4 J43 3 NL bis BREAKER 20AMP NOT SERVICEABLE J44 BK P41 1 GN BRAKE CONTROLLER pare Pro Sweep 5200 BRAKE INPUT 5 GN i P42 3 cRouNp 2 gk Electrical Schematic P42 2 POWER TB Relays are shown as de energized P42 1 BRAKE OUTPUT BU All ground wires are black Page 6 3 Page6 4 VEHICLE POWE
26. 5 16 1 in 0 75 0 25 Hydraulic System Page 3 2 Pro Sweep 5200 SAE Straight Thread O Ring Port Non adjustable 1 Make sure both threads and sealing surfaces are free of burrs nicks scratches or any foreign material 2 Always replace the o ring seal when this type of fit ting shows signs of leakage 3 Lubricate the o ring with a light coating of oil 4 Install the fitting into the port and tighten it down full length until finger tight 5 Tighten the fitting to the correct Flats From Finger Tight F F F T Size F F F T 4 1 4 in nominal hose or tubing 1 00 0 25 6 3 8 in 1 50 0 25 8 1 2 in 1 50 0 25 10 5 8 in 1 50 0 25 12 3 4 in 1 50 0 25 16 1 in 1 50 0 25 NOTE Installation torque values for non adjustable fit tings are listed in Figure 4 These torque values should only be used when a fitting can be accessed with a socket Use of an offset wrench e g crowfoot wrench will affect torque wrench accuracy and should not be used SAE Straight Thread O Ring Port Adjustable 1 Make sure both threads and sealing surfaces are free of burrs nicks scratches or any foreign material 2 Always replace the o ring seal when this type of fit ting shows signs of leakage 3 Lubricate the o ring with a light coating of oil 4 Turn back the jam nut as far as possible Make sure the back up washer is not loose and is pushed up as far as possible Step 1 5 Install the f
27. R VEHICLE GROUND VEHICLE POWER VEHICLE GROUND BRAKE PRESSED POWER HARNESS J31 P2 A P2 A A ee 8I gt FUSE 20 AMP P 4 J32 P2 B P2 B BK mm BK B P1 A Pk P1 F R8K gt REMOTE HARNESS OPTION P1 C P2 C P11 A P11 B A A A A A A A A BN A A BN gt gt gt r a HOPPER DOWN SWITCH ADA mi PT TT T HOPPER DOWN 2 HOPPER DOWN RELAY 5 J 870 P1 J P2 4 P5 A P5 B PK TUDO PON P24 C mms CN GN o e BK 85 86 ji ty S Edd BRUSH MOTOR S3 o ENERGIZED 1 4 P gt BU CATA 30 87 PERDER i285 88 P1 D P2 D P7 A P7 B P25 PA 8k lt PA VIO VIO VIO PERYA BK 876 BRUSH RELAY HOPPER UP S1 ENERGIZED y NOT ENERGIZED De HYDRAULIC SOLENOID pec eee BK K MANIFOLD U U gt py or t LOGIC DIODE P26 5 P1 B P2 B P6 A P6 B 1 P22 OR e OR OR BK 1 2 DOWN DEMAND 82 T PK ENERGIZED 5 l UP o gt gt 1 P1 E P2 E P4 A P4 B o W W w W MMN BK 8 HOPPER DOWN 34 1 5 i PK 4 o W E Meets HOPPER SWITCH kas sii AAA 3 1 P23 g9 gt GY P1 A 1 2 SWEEP PK PK
28. Y x PSB o P 4 1 OFFSET ACTUATOR ve gt Y OPTION J32 P2 B P2 B P1 F P1 F 5 BK e Bk BK BK BK 4 P1 G P2 G o GY GY GY TRANSPORT SWITCH OPTION BK P2 C P2 C P3 A P3 A A MM B BU BU BU BU ELECTRIC BRAKE RIGHT PB2 E AIN B ER KEY TO WIRE COLORS ELECTRIC BRAKE LEFT P51 BRAKE CONTROL HARNESS 5 R RED BK BLACK GN GREEN OR ORANGE a Y YELLOW BR BROWN GY GRAY PK PINK P3 B P3 B 5 W WHITE BU BLUE VIO VIOLET BK BK T 2 TAN BRAKE HARNESS OPTION P43 J42 443 R PK4 BREAKER 20AMP NOT SERVICEABLE J44 BK P41 1 GN BRAKE CONTROLLER P42 4 BRAKE INPUT 5 GN P42 3 GROUND 5 BK P42 2 POWER gt PK P42 1 BRAKE OUTPUT BU Pro Sweep 5200 Hopper Lower Circuit Power Current Control Current Indicator Current P02 POWER P03 HARNESS P08 BRAKE 04 OFFSET HARNESS HOPPER DOWN ACTUATOR SOLENOID S4 05 BRUSH SOLENOID S3 06 DEMAND SOLENOID S2 P01 CONTROL BOX HARNESS 07 HOPPER UP SOLENOID S1 P11 HOPPER DOWN SWITCH es o o 9 a Bere ee eee a5 sis Fe moss cR 2565255 SEZSECI Loa TZ oo O POI CONTROL BOX HARNESS W l bl m Segle E gt ta 0 Of Z NE PINK z
29. any loose nuts bolts or screws to ensure machine is in safe operating condition While Operating 1 Operator should be in the operators position when operating the tow vehicle and sweeper Stay away from the sweeper when the brush is engaged 2 Make sure that hitch pin is properly positioned in tow vehicle and sweeper Hitch pin should be secured with hairpin clip 3 Donotruntow vehicle engine in a confined area with out adequate ventilation Exhaust fumes are hazardous and could possibly be deadly 4 Do not touch tow vehicle engine muffler or exhaust pipe while engine is running or soon after it is stopped These areas could be hot enough to cause burns 5 If abnormal vibration is detected stop tow vehicle and sweeper immediately and determine source of vibration Correct problems before resuming the use of Sweeper Safety Page1 2 Rev A To reduce the potential for injury or death comply with the following safety instructions 3 Make sure that the tow vehicle is carefully selected to assure the best performance and safe operation of the Pro Sweep 5200 4 Assure sweeper interlock system functions correctly So sweeper brush does not rotate unless dump hopper is lowered 5 Make sure that operator is familiar with tow vehicle operation 6 While operating the Pro Sweep 5200 may exceed noise levels of 85dB A at the operator position Hearing protection is recommended for prolonged exposure to reduce the p
30. be rotating When the hopper switch is pushed to lower the hopper down solenoid S4 is energized allowing the raised hopper to contract the lift cylinder The hopper down proximity switch prevents the sweeper brush from rotat ing until the hopper is fully lowered Figure 4 Testing 1 Hopper switch The hopper switch terminals are marked as shown in Figure 5 The circuitry of this switch is shown in the chart below With the use of a multimeter ohms setting the switch functions may be tested to determine whether continuity exists between the various terminals for each switch position Verify continuity between switch termi nals SWITCH NORMAL OTHER POSITION CIRCUITS CIRCUITS BACK OF SWITCH MIDDLE NONE NONE Figure 5 LOWER Electrical System Page4 6 Pro Sweep 5200 Brush and Hopper Down Relays The electrical system of the Pro Sweep 5200 includes two relays the brush relay and the hopper down relay These relays are identical and are located in the control box enclosure The brush relay is used to de energize the brush motor solenoid S3 when the hopper up down switch is pushed to raise When the brush relay is not energized brush motor operation is possible The energized hopper down relay allows current to the brush switch when the hopper down switch is closed hopper lowered If the hopper is raised the hopper down relay will not be energized to prevent brush opera tion
31. ce in the fitting for proper lift cyl inder extension Pro Sweep 5200 Page 3 9 When the hopper switch is released solenoid valves S1 and S2 in the hydraulic manifold are de energized The load holding check valve in the control manifold and the de energized solenoid valve S4 prevent oil flow from the lift cylinder so the hopper remains in the raised dump position Hopper Lower When the hopper switch is pressed to lower the hopper down S4 solenoid valve in the hydraulic control man ifold is energized The valve shift of S4 allows a path for oil flow from the lift cylinder The weight of the dump hop per and frame cause the lift cylinder to retract and the dump hopper to lower Oil flow from the retracting lift cyl inder returns to the control manifold port CYL past S4 out manifold port T and returns to the tow vehicle The orifice in the lift cylinder check valve fitting restricts oil flow from the cylinder to provide for proper lift cylinder retraction speed While lowering if the hopper switch is released sole noid valve S4 will de energize and oil flow from the lift cylinder will cease The hopper will remain in the partial ly lowered position Hydraulic System Ze E 2 SZ EO Problem Possible Cause aaa aaa TET O Troubleshooting The cause of an improperly functioning hydraulic sys tem is best diagnosed with the use of proper testing equipment and a thorough understanding of the co
32. de 2 Clean brush shaft and apply antisieze lubricant to shaft Slide bearing flanges bearing and locking collar to each end of brush shaft Do not tighten set screw in locking collar 3 Position square key in brush shaft Slide coupling jaw onto drive end of brush shaft 4 Position brush assembly under raised hopper 5 Slowly lower hopper to position brush assembly to brush housing see Servicing the Brush Housing in this section 6 Secure bearing flanges to brush housing with car riage bolts item 7 flat washers item 16 and lock nuts item 17 Center brush in brush housing NOTE Normal brush rotation is clockwise as viewed from left side of sweeper 7 Using a punch and hammer rotate locking collar in the direction of normal brush rotation to tighten collar 8 Place coupler spider into coupling jaw on brush shaft 9 Install hydraulic brush motor to brush housing see Hydraulic Brush Motor Installation in the Service and Repairs section of Chapter 3 Hydraulic System Make sure that coupling jaws have a gap between coupler jaw valleys from 830 to 930 21 1 to 23 6 mm Apply Loc tite 4242 or equivalent to threads of coupling set Screws Secure coupling jaws to motor shaft and brush shaft by torquing set screws from 125 to 155 in lb 14 1 to 17 5 N m Fig 7 Figure 6 1 Brush 4 Retaining ring 4 used 2 Flange nut 4 used 5 Carriage screw 4 used 3 Brush drive 2 used 6 Brush ax
33. e wiring harness 3 Check the continuity of the switch by connecting a multimeter ohms setting across the switch connector terminals NOTE Before checking switch continuity clean target end of switch to make sure that there is no metallic de bris on the switch that could prevent correct switch op eration 4 With the switch cam positioned near the target end of the switch dump hopper lowered Fig 11 there should be continuity across the switch terminals 5 When the switch cam is positioned away from the tar get end of the switch dump hopper raised Fig 11 there should be no continuity across the switch termi nals IMPORTANT Proper proximity switch operation re quires aluminum switch spacer that positions the switch away from the sweeper frame If switch is re moved from machine make sure that switch spacer is installed between switch and frame 6 Replace proximity switch as needed Reconnect Switch to machine wiring harness P O HE M M Figure 10 Mounting spacer 9 Spacer 10 Cap screw 11 Switch cam 12 Cam spacer 13 Flat washer 14 Cap screw 15 Flange nut 3 used W H Figure 11 Switch cam weight Carriage screw 3 used Lock nut 2 used Flat washer 2 used Hopper down switch Switch spacer Cap screw 2 used 1 Hopper down switch 2 Switch cam dump hopper lowered 3 Switch cam dump hopper raised Electrical System Page 4 10 Pro Sweep 5200 Service and Repai
34. ected hose and fitting 5 Connect hydraulic hose with new o ring to hydraulic fitting on lift cylinder Tighten hose connection Hydraulic System L F i v ES I E o Y gt YN Lift Cylinder Service 250 to 300 ft Ib 339 to 407 N m Figure 16 1 Wear ring 6 O ring 10 Wiper 2 Seal 7 Backupring 11 Breather plug 3 O ring 8 Retaining ring 12 Piston 4 Tube 9 Head 13 Lock nut 5 Rod Disassembly Fig 16 1 Remove oil from the lift cylinder into a drain pan by slowly pumping the cylinder rod Plug ports and clean the outside of the lift cylinder IMPORTANT Prevent damage when clamping the lift cylinder into a vise clamp on the pivot only 2 Mount lift cylinder in a vise so that the shaft end tilts up slightly 3 Using a spanner wrench rotate head item 9 clock wise until the edge of the retaining ring appears in the tube opening Insert a screwdriver under the beveled edge of the retaining ring to start the retaining ring through the tube opening Rotate the head counter clockwise to remove retaining ring item 8 as shown in Figure 17 4 Grasp end of rod extract rod assembly and head by carefully twisting and pulling on the rod Hydraulic System Page 3 24 Rev A Spanner wrench Retaining ring Figure 17 IMPORTANT Do not clamp vise jaws against rod surface Protect rod surface before mounting in vise 5 Mount rod securely in a vise by clamping vise o
35. ed air for cleaning 7 Reinstall the cartridge valve into control manifold A Lubricate new seal kit components with clean hy draulic oil and install on valve The o rings sealing rings and backup rings must be arranged properly on the cartridge valve for proper operation and sealing IMPORTANT Use care when handling the valve cartridge Slight bending or distortion of the stem tube can cause binding and malfunction B Thread cartridge valve carefully into correct man ifold port The valve should go in easily without bind ing C Torque cartridge valve using a deep socket to val ues identified in Figure 14 8 If solenoid cartridge was removed carefully install solenoid coil onto the cartridge valve Install nut and torque nut to 36 inb 4 1 N m 9 After assembly if problems still exist remove valve and clean again or replace valve Hydraulic System 2 FE O 0 ES EO Lift Cylinder Figure 15 1 Main sweeper frame 5 Locknut 8 O ring 2 Lift cylinder 6 Pitch frame 9 Check valve fitting 3 Cap screw 7 Hydraulic hose 10 O ring 4 Pivot pin Hydraulic System Page 3 22 Pro Sweep 5200 Removal Fig 15 1 Empty sweeper hopper and position sweeper on a level surface Chock sweeper wheels to prevent sweep er from moving If sweeper is attached to tow vehicle engage tow vehicle parking brake stop engine and re move key from the ignition switch Operate all sweeper hydraulic cont
36. ed and properly seated in the groove It is recommended that the o ring be re placed any time the connection is opened 3 Lubricate the o ring with a light coating of oil 4 Put the tube and nut squarely into position on the face seal end of the fitting and tighten the nut until finger tight 5 Mark the nut and fitting body Hold the body with a Before disconnecting or performing any work on hydraulic system relieve all pressure in system See Relieving Hydraulic System Pres sure in this section Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure Use paper or cardboard not hands to search for leaks Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury If fluid is injected into the skin it must be surgi cally removed within a few hours by a doctor familiar with this type of injury Gangrene may result from such an injury Nut Sleeve Figure 1 wrench Use another wrench to tighten the nut to the cor Final rect Flats From Finger Tight F F F T The markings on Position the nut and fitting body will verify that the connection has Mark Nut been tightened and Body Initial Size FRET Extend Line Position 4 1 4 in nominal hose or tubing 0 75 0 25 Finger Tight After Proper Tightening 6 3 8 in 0 75 0 25 8 1 2 in 0 75 0 25 10 5 8 in 1 00 0 25 Figure 2 12 3 4 in 0 75 0 2
37. eels zim suck ARR REG eR 3 Wheel Bearings 4 Servicing the Brush Housing 6 Br sh ovre a MATA TTT 8 Brush Housing 10 Roller su 226266 238x006 0 5102 ee cete partes 12 Frame Assembly 14 Pro Sweep 5200 Page 5 1 Chassis Specifications Item Description Tires Size 26 5 x 14 12 4 Ply Tubeless Pressure 12 5 PSI 862 Bar Wheel Lug Nut Torque 70 to 90 ft lb 95 to 122 N m General Information Securing Pro Sweep 5200 to Tow Vehicle While operating or servicing the Pro Sweep 5200 make sure that hitch pin is properly positioned in tow vehicle hitch and sweeper tongue Hitch pin should be secured with hairpin clip Fig 1 Chassis Page 5 2 1 Hitch pin Figure 1 2 Hairpin clip Pro Sweep 5200 Service and Repairs Wheels 70 to 90 ft Ib 95 to 122 N m Figure 2 1 Main frame 3 Wheel and tire assembly 4 Wheel hub 2 Lug nut 5 used per wheel Wheel Removal Fig 2 Wheel Installation Fig 2 1 Position sweeper on a level surface with dump hop 1 Position wheel to wheel hub per empty and lowered Have sweeper attached to tow ing vehicle engage vehicle parking brake stop engine and remove key from the ignition switch Chock sweep er wheels to prevent sweeper from moving Ah WARNING Failure to maintain proper lug nut torque 2 Jack or hoist sweeper fro
38. er that secures wheel hub to spindle Slide wheel hub with bearings from spindle 7 Disassemble wheel hub A Pull grease seal out of the wheel hub Discard Seal B Remove bearing cones from both sides of wheel hub Clean bearings in solvent Clean inside of hub C If necessary remove bearing cups from hub us ing a hammer and punch D Inspect wheel bearings Check the bearing cones and bearing cups for wear pitting or other damage Replace worn or damaged parts Pro Sweep 5200 Page 5 5 Installation Fig 3 1 Clean all parts thoroughly before reassembly 2 Assemble wheel hub A If bearing cups were removed from the wheel hub press inner and outer cups into the hub until they seat against the hub shoulder B Pack both bearing cones with grease Install greased inner bearing into the cup on inboard side of the wheel hub C Fill hub approximately 5096 full of grease IMPORTANT The grease seal must be pressed in so it is flush with the end of the hub The lip of the seal must face the bearing D Lubricate the inside of a new grease seal and press it into the wheel hub 3 Install the wheel hub onto the axle spindle taking care to not damage grease seal in wheel hub 4 Install greased outer bearing cone washer and slotted hex nut onto spindle shaft 5 While rotating the wheel hub by hand torque the slotted hex nut from 75 to 180 in Ib 8 5 to 20 3 N m to seat bearings Loosen nut until it
39. g any hydraulic com ponents operate machine functions slowly until air is out of system 7 Check for hydraulic oil leaks Shut off tow vehicle en gine and correct leaks if necessary Check oil level in hy draulic reservoir and add correct oil if necessary Check hydraulic lines and hoses daily for leaks kinked lines loose mounting supports wear loose fittings weather deterioration and or chemical deterioration Make all necessary repairs before operating sweeper Hydraulic System 2 F h y ES I E o Y Brush Motor 67 to 83 ft Ib 91 to 112 N m Figure 8 1 Brush housing 8 Coupling assembly 14 Hydraulic brush motor 2 Coupling cover 2 used 9 Hydraulic hose 2 used 15 Flat washer 6 used 3 Lock washer 10 O ring 2 used 16 Lock nut 6 used 4 Capscrew 11 Hydraulic fitting 2 used 17 Flange bearing 2 used 5 Lock nut 2 used 12 O ring 2 used 18 Square key 6 Flat washer 2 used 13 Cap screw 2 used 19 Brush 7 Carriage bolt 6 used Hydraulic System Page 3 14 Pro Sweep 5200 Removal Fig 8 1 Empty sweeper hopper and position sweeper on a level surface Chock sweeper wheels to prevent sweep er from moving If sweeper is attached to tow vehicle engage tow vehicle parking brake stop engine and re move key from the ignition switch Operate all sweeper hydraulic controls to relieve system pressure and to avoid injury from pres surized hydraulic oil
40. igital multimeter short the test leads together The me ter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal re sistance of the meter and test leads Subtract this value from from the measured value of the component you are testing 4 Measure resistance between the two coil connector terminals Resistance of the solenoid coil should be approximately 7 6 ohms 5 If solenoid coil needs replacement see Solenoid Valve Coil in the Service and Repairs section of this chapter 6 Reconnect electrical connector to the solenoid valve coil 1 Hopper up solenoid S1 2 Demand solenoid S2 Pro Sweep 5200 Page 4 9 Figure 9 tiki 3 Brush solenoid S3 4 Down solenoid S4 Electrical System a o 2 U E o Y gt Hopper Down Proximity Switch The Pro Sweep 5200 uses a proximity switch as an inter lock device to prevent brush operation rotation when the dump hopper is raised This switch is normally open and closes when the pitch frame moves the switch cam near the target end of the switch dump hopper low ered The switch is mounted on the main sweeper frame Fig 10 Testing 1 Position sweeper on a level surface with dump hop per lowered If sweeper is attached to towing vehicle engage vehicle parking brake stop engine and remove key from the ignition switch 2 Locate hopper down switch Disconnect switch from machin
41. ing is faulty a LZ o 2 wi Hydraulic problem exists see Chapter 3 Hydraulic System 4 3 Electrical System Safety Interlock System Do not disconnect the Pro Sweep 5200 hopper down proximity switch It is for the operator s protection Check operation of the switch daily to make sure the interlock system is operating correctly If the switch is not operating properly adjust or replace it before operating the sweep er The safety interlock system of the Pro Sweep 5200 en sures that the brush will not rotate when the dump hop per is in the raised position Interlock system operation is described in the Pro Sweep 5200 Operator s Manual Testing procedures for the interlock system hopper down proximity switch and brush relay are included in the Component Testing sec tion of this Chapter Electrical System Page 4 4 Pro Sweep 5200 Component Testing For accurate resistance and or continuity checks elec trically disconnect the component being tested from the circuit e g unplug the switch connector before doing a continuity check on switch When testing electrical components for continu ity with a multimeter ohms setting make sure that power to the circuit has been disconnected Brush Switch The brush switch is used to turn the sweeper brush on by energizing the brush motor solenoid S3 and the de mand solenoid S2 When the brush switch is in the off position the brush solenoid is n
42. into cou pling jaw on brush shaft 3 Position and support brush motor to the frame Make sure to align coupling jaw on motor shaft with coupling spider Pro Sweep 5200 Page 3 15 4 Align motor shaft with brush shaft Secure brush mo tor to frame with two 2 cap screws item 14 flat wash ers item 7 and lock nuts item 6 Torque lock nuts from 67 to 83 ft lb 91 to 112 N m 5 Position coupling jaw on motor shaft to allow a gap between coupler jaw valleys from 830 to 930 21 1 to 23 6 mm Fig 10 Apply Loctite 2242 or equivalent to threads of coupling set screw Secure coupling jaw to motor shaft by torquing set screw from 125 to 155 in lb 14 1 to 17 5 N m 6 Remove caps or plugs that were put on any hydraulic lines or fittings during disassembly 7 Install hydraulic hoses to hydraulic fittings on brush motor Tighten connections 8 Install upper coupling cover to brush housing 125 to 155 in Ib 14 1 to 17 5 N m Figure 9 Hydraulic brush motor 5 Brush Key 6 Square key Coupling jaw 7 Setscrew Coupling spider Pen 830 to 930 21 1 to 23 6 mm Figure 10 4 Motor coupling jaw 5 Motor shaft 1 Brush shaft 2 Brush coupling jaw 3 Coupling spider Hydraulic System 5 LE v gt r E o L2 YN Brush Motor Service 22 to 26 ft lb 30 to 35 N m Figure 11 1 Cap screw 5 used 8 Wear plate 15 Inner seal 2 End cover 9 Dr
43. item 7 from between pivot mount and brush housing 8 If necessary remove flange bushings from pivot mounts Discard bushings if removed Installation Fig 8 1 If flange bushings were removed from pivot mounts press new bushings fully into mounts 5 Secure pivot mounts to frame with cap screws item 2 and lock nuts item 3 Torque lock nuts from 45 to 55 ft lb 61 to 75 N m 6 Install hydraulic brush motor to brush housing see Hydraulic Brush Motor Installation in the Service and Repairs section of Chapter 3 Hydraulic System Make sure that coupling jaws have a gap between coupler jaw valleys from 830 to 930 21 1 to 23 6 mm Apply Loc tite 4242 or equivalent to threads of coupling set Screws Secure coupling jaws to motor shaft and brush shaft by torquing set screws from 125 to 155 in lb 14 1 to 17 5 N m Fig 9 7 Lubricate grease fittings on pivot mounts see Oper ator s Manual Antisieze Lubricant Antisieze 6 Lubricant 125 to 155 m 14 1 to 17 5 N m Figure 9 2 Place thrust washer and then pivot mount on both 1 Hydraulic brush motor 5 Brush brush housing pins 2 Key 6 Square key 3 Coupling jaw 7 Set screw 2 per jaw 3 Position brush housing under raised hopper 4 Coupling spider 4 Slowly lower hopper to position brush housing to saddle frame see Servicing the Brush Housing in this section Pro Sweep 5200 Page 5 11 Chassis Roller ANTISIEZE LUBRICANT
44. itting into the port and tighten finger tight until the washer contacts the face of the port Step 2 6 To put the fitting in the desired position unscrew it by the required amount but no more than one full turn Step 3 7 Hold the fitting in the desired position with a wrench and turn the jam nut with another wrench to the correct Flats From Finger Tight F F F T Step 4 Size F F F T 4 1 4 in nominal hose or tubing 1 00 0 25 6 3 8 in 1 50 0 25 8 1 2 in 1 50 0 25 10 5 8 in 1 50 0 25 12 3 4 in 1 50 0 25 16 1 in 1 50 0 25 Pro Sweep 5200 Page 3 3 Fiting Sie tration Torque 60 66 ft lb 81 89 N m 81 87 ft lb 110 117 N m 121 131 ft lb 164 177 N m Figure 4 Lock Nut ncc Back up Washer Ring Figure 5 Figure 6 Hydraulic System 9 E LE v ES I E o 4 gt YN Relieving Hydraulic System Pressure Operate all sweeper hydraulic controls to relieve system pressure and to avoid injury from pres surized hydraulic oil See Relieving Hydraulic System Pressure in the General Information sec tion of this chapter Securing Sweeper to Tow Vehicle Fig 7 While servicing the Pro Sweep 5200 make sure that the hitch pin is properly positioned in tow vehicle hitch and sweeper tongue Hitch pin should be secured with hair pin clip Hydraulic System Page3 4 Before disconnecting or performing a
45. ive link 16 Backup washer 3 Ring seal 10 Coupling shaft 17 O ring 4 Commutator seal 11 Woodruff key 18 Housing 5 Commutator and ring assembly 12 Bushing 19 Bearing 6 Manifold 13 Thrust bearing 20 Seal 7 Stator 14 Thrust washer NOTE For service of the hydraulic brush motor see the Parker TorqlinkTM Service Procedure at the end of this chapter Hydraulic System Page 3 16 Pro Sweep 5200 2 35 O 0 S fo This page is intentionally blank Pro Sweep 5200 Page 3 17 Hydraulic System Hydraulic Control Manifold Figure 12 1 Main frame 2 Cap screw 2 used Removal Fig 12 1 Empty sweeper hopper and position sweeper on a level surface Chock sweeper wheels to prevent sweep er from moving If sweeper is attached to tow vehicle engage tow vehicle parking brake stop engine and re move key from the ignition switch Operate all sweeper hydraulic controls to relieve system pressure and to avoid injury from pres surized hydraulic oil See Relieving Hydraulic System Pressure in the General Information sec tion of this chapter Hydraulic System 3 Flat washer 4 used 4 Hydraulic control manifold Page 3 18 5 Locknut 2 used 2 Relieve sweeper hydraulic system pressure NOTE The ports on the control manifold are marked to identify hydraulic hose connections Example P is the pump connection port See Hydraulic Schematic to identify the function of the hydraulic lines and ca
46. ke stop engine and remove key from the ignition switch Chock sweep er wheels to prevent sweeper from moving 2 Remove hydraulic brush motor from brush housing see Hydraulic Brush Motor Removal in the Service and Repairs section of Chapter 3 Hydraulic System Re move coupler spider item 15 Chassis Page 5 8 NOTE If desired brush housing with brush installed can be removed from sweeper to allow brush removal see Brush Housing Removal in this section 3 Remove carriage bolts item 7 flat washers item 16 and lock nuts item 17 that secure bearing flanges to brush housing 4 Refer to Servicing the Brush Housing in this section for procedure to remove brush from brush housing Pro Sweep 5200 5 After raising hopper and placing lift cylinder stop re trieve brush assembly 6 Loosen set screws item 14 that secure coupling jaw to brush shaft Slide coupling jaw from brush Locate and retrieve square key from brush shaft 7 To remove bearing from brush shaft A Loosen set screw that secures locking collar to shaft NOTE Normal brush rotation is clockwise as viewed from left side of sweeper B Using a punch and hammer rotate locking collar in the opposite direction of normal brush rotation to loosen collar C Slide bearing flanges locking collar and bearing from brush shaft 8 Disassemble brush using Figure 6 as a guide Installation Fig 5 1 Assemble brush using Figure 6 as a gui
47. le Antisieze Lubricant Antisieze 6 Lubricant 125 to 155 in Ib 14 1 to 17 5 N m Apply Loctite 4242 or equivalent to set screw and Figure 7 torque set screw from 125 to 155 in lb 14 1 to 17 5 a oi brush motor s Erbe N m to secure locking collar to brush shaft 3 COLBIIRG jaw 7 Set S i A per jaw 4 Coupling spider Pro Sweep 5200 Page 5 9 Chassis Brush Housing 45 to 55 ft Ib 61 to 75 N m Figure 8 1 Saddle frame 4 Flange bushing 7 Thrust washer 2 Cap screw 5 Pivot mount 8 Brush housing 3 Lock nut 6 Grease fitting 2 used Chassis Page 5 10 Pro Sweep 5200 Removal Fig 8 1 Position sweeper on a level surface with dump hop per empty and lowered Have sweeper attached to tow ing vehicle engage vehicle parking brake stop engine and remove key from the ignition switch Chock sweep er wheels to prevent sweeper from moving 2 Remove hydraulic brush motor from brush housing see Hydraulic Brush Motor Removal in the Service and Repairs section of Chapter 3 Hydraulic System 3 Support brush housing to prevent it from shifting 4 Remove cap screws item 2 and lock nuts item 3 that secure pivot mounts to frame 5 Refer to Brush Housing Service in this section for procedure to remove brush housing from saddle frame 6 After raising hopper and placing lift cylinder stop re trieve brush housing 7 Remove pivot mounts from brush housing Locate and retrieve thrust washers
48. low Excessive dirt and debris on hydraulic components Oil is contaminated or too light Brush motor is worn or damaged Hydraulic system on tow vehicle is malfunctioning Brush motor will not turn Hydraulic hose s to tow vehicle are not connected Control manifold brush solenoid S2 is not being energized or car tridge is faulty Control manifold demand solenoid S3 is not being energized or cartridge is faulty Internal brush motor components are damaged Electrical problem exists see Chapter 4 Electrical System Hydraulic System Page 3 10 Pro Sweep 5200 Problem Possible Cause Dump hopper will not lift or lifts Hydraulic hose s to tow vehicle are not connected slowly Hydraulic oil level in tow vehicle reservoir is low Lift cylinder is binding Sweeper frame components are binding Check valve fitting on lift cylinder is faulty Control manifold demand solenoid S3 is not being energized or cartridge is faulty Control manifold hopper up solenoid S1 is not being energized or cartridge is faulty l l l I I I I I I I I I I I I I I I I I I I I I I Hydraulic system on tow vehicle is malfunctioning I Electrical problem exists see Chapter 4 Electrical System Dump hopper raises but will not Control manifold hopper down cartridge S4 is faulty stay up 2 FE O 0 ES zo Control manifold check valve leaks Pro Sweep 5200 Page 3
49. m plete hydraulic system A hydraulic system with an excessive increase in heat or noise has a potential for failure Should either of these conditions be noticed immediately stop the machine turn off the engine locate the cause of the trouble and correct it before allowing the machine to be used again Continued use of an improperly functioning hydraulic system could lead to extensive hydraulic component damage The charts that follow contain information to assist in troubleshooting There may possibly be more than one cause for a machine malfunction The successful operation of the Pro Sweep 5200 de pends on the hydraulic system of the tow vehicle When troubleshooting a sweeper hydraulic problem make sure that the tow vehicle hydraulic system is evaluated as well NOTE When troubleshooting a hydraulic problem on the Pro Sweep 5200 inspect tow vehicle hydraulic sys tem if both sweeper brush motor and lift cylinder are mal functioning If one sweeper hydraulic component appears to be malfunctioning check that component Hydraulic oil leaks Foaming hydraulic fluid Hydraulic system operates hot Hydraulic fitting s or hose s are loose or damaged Hydraulic oil level in tow vehicle reservoir is low l l l O ring s or seal s are missing or damaged i l i Hydraulic system has wrong kind of oil l Hydraulic system on tow vehicle is malfunctioning Hydraulic oil level in tow vehicle reservoir is
50. m ground and support ma could result in failure or loss of wheel and may chine with blocking or jack stands see Operator s result in personal injury Manual and Jacking Instructions in Chapter 1 Safety 2 Secure wheel to sweeper with five 5 lug nuts Alter nately torque lug nuts from 70 to 90 ft lb 95 to 122 N m 3 Loosen and remove five 5 lug nuts from wheel to be removed 4 Pull wheel from sweeper P 3 Lower machine to ground Pro Sweep 5200 Page 5 3 Chassis Wheel Bearings Axle Grease seal Inner bearing cone Inner bearing cup Wheel hub GQ PONS Chassis COND Figure 3 Lug bolt 5 used Outer bearing cup Outer bearing cone Lug nut 5 used Page 5 4 See text for tightening procedure 10 Washer 11 Slotted hex nut 12 Cotter pin 13 Dust cup Pro Sweep 5200 Removal Fig 3 1 Position sweeper on a level surface with dump hop per empty and lowered Have sweeper attached to tow ing vehicle engage vehicle parking brake stop engine and remove key from the ignition switch Chock sweep er wheels to prevent sweeper from moving 2 Jack or hoist sweeper from ground and support ma chine with blocking or jack stands see Operator s Manual and Jacking Instructions in Chapter 1 Safety 3 Remove wheel assembly see Wheel Removal in this section 4 Carefully pry dust cap from wheel hub 5 Remove cotter pin from axle spindle 6 Remove slotted hex nut and wash
51. n the flats ofthe pivot Remove lock nut item 13 and carefully slide piston and head from the rod Pro Sweep 5200 IMPORTANT When removing seal components be careful not to scratch or damage piston or head 6 Remove and discard seal kit components from the head and piston Inspection CAUTION Use eye protection such as goggles when using compressed air 1 Wash all parts in solvent Dry parts with compressed air 2 Inspect internal surface of tube for deep scratches out of roundness and bending Replace if worn or damaged 3 Inspect rod piston and head for excessive pitting scoring or wear Replace any worn or damaged parts Assembly Fig 16 1 Coat new seal kit components with clean hydraulic oil IMPORTANT When installing seal components be careful not to scratch or damage piston or head 2 Install new seals to the head and piston Pro Sweep 5200 Page 3 25 Rev A IMPORTANT Do not clamp vise jaws against rod surface Protect rod surface before mounting in vise 3 Mount rod securely in a vise by clamping vise on the pivot end ofthe shaft Carefully slide head assembly and piston assembly onto the rod 4 Thread lock nut item 13 onto rod Torque lock nut from 250 to 300 ft Ib 339 to 407 N m 5 Remove rod assembly from vise IMPORTANT Prevent damage when clamping the tube into a vise clamp on the pivot end only 6 Mounttube in a vise so that the rod end tilts up sligh
52. ny work on the sweeper hydraulic system all pressure in the hydraulic system must be relieved With the hopper fully lowered turn tow vehicle key switch to OFF and allow engine to stop To relieve sweeper hydraulic system pressure turn tow vehicle key switch to ON engine not running Press brush switch on and off Press hopper switch to both raise and lower After cycling the switches return tow vehicle key switch to OFF and remove key from the igni tion switch Figure 7 2 Hairpin clip 1 Hitch pin Pro Sweep 5200 Hydraulic Schematic INPUT PRESSURE REQUIR INPUT 7 8 GPM RELIEF PRESSURE 2000 PSI BRUSH MOTOR 2 7 CI REV Pro Sweep 5200 Page 3 5 CONTROL MANIFOLD Pro Sweep 5200 Hydraulic Schematic All solenoids are shown as de energized Hydraulic System 2 F i v ES I E o Y Hydraulic Flow Diagrams EHICLE a LIFT INPUT PRESSURE YLINDER REQUIREMENTS s y do ENERGIZED S3 INPUT Mela 8 GPM RELIEF PRESSURE 2000 PSI RETURN TO TANK ENERGIZED CONTROL MANIFOLD BRUSH MOTOR 2 7 CI REV Brush Circuit Brush Rotating Shown Working Pressure Return Flow Hydra
53. ocation noted during removal 6 Center roller between bearings NOTE Normal roller rotation is counter clockwise as viewed from left side of sweeper 7 Using a punch and hammer rotate locking collars in the direction of normal roller rotation to tighten collars 8 Apply Loctite 242 or equivalent to threads of set Screws item 8 Install set screws into collars and torque from 125 to 155 in lb 14 1 to 17 5 N m to secure lock ing collars to roller shaft 9 Check that roller is free to rotate and no binding ex ists 10 Position roller scraper to machine Install carriage screws and flange nuts that secure roller scraper to roll er adjustment plates 11 Check roller height and roller scraper clearance and adjust if necessary see Operator s Manual Chassis Frame Assembly Figure 11 1 Main frame 8 Pivot pin 14 Saddle frame 2 Cap screw 9 Tow hook plate 15 Cap screw 3 Pivot pin 10 Pivot saddle 16 Lift cylinder 4 Lock nut 11 Carriage bolt 17 Lock nut 5 Pitch frame 12 Pivot pin 18 Link 6 Grease fitting 13 Lock nut 19 Hardened spacer 2 used 7 Cap screw Disassembly Fig 11 Assembly Fig 11 1 Position sweeper on a level surface with dump hop 1 Assemble frame using Figure 11 as a guide per empty and lowered Have sweeper attached to tow UM ing vehicle engage vehicle parking brake stop engine 2 Lubricate pivot point grease fittings see Operator s and remove key from the ignition
54. opper is raised brush should only rotate when hopper is fully lowered Brush does not rotate Hopper down proximity switch is malfunctioning or faulty Problem with power or ground from vehicle other sweeper functions affected as well Fuse 20 Amp is faulty other sweeper functions affected as well Brush switch or circuit wiring is faulty Brush relay or circuit wiring is faulty Hopper down relay or circuit wiring is faulty Logic diode is faulty Demand solenoid valve coil S2 or circuit wiring is faulty Brush solenoid valve coil S3 or circuit wiring is faulty Hydraulic problem exists see Chapter 3 Hydraulic System Electrical System Page 4 2 Pro Sweep 5200 Dump hopper does not raise Dump hopper does not lower Pro Sweep 5200 Page Possible Causes Fuse 20 Amp is faulty other sweeper functions affected as well Problem with power or ground from vehicle other sweeper functions affected as well Hopper switch or circuit wiring is faulty Demand solenoid valve coil S2 or circuit wiring is faulty Hopper up solenoid valve coil S1 or circuit wiring is faulty Hydraulic problem exists see Chapter 3 Hydraulic System Fuse 20 Amp is faulty other sweeper functions affected as well Problem with power or ground from vehicle other sweeper functions affected as well Hopper switch or circuit wiring is faulty Hopper down solenoid valve coil S4 or circuit wir
55. ot energized The switch includes an indicator light that will illuminate when the brush switch is in the on position This switch is located in the control box enclosure Fig 2 NOTE If the hopper is in the raised position or if the hopper switch is pushed to raise the brush motor sole noid S3 will be de energized regardless of brush switch position SE 5 Q 5 oo S Ww Testing The brush switch terminals are marked as shown in Fig ure 3 The circuitry of this switch is shown in the chart be low With the use of a multimeter ohms setting the Figure 2 switch functions may be tested to determine whether 1 Brush switch continuity exists between the various terminals for each switch position Verify continuity between switch termi nals ri SWITCH NORMAL OTHER POSITION CIRCUITS CIRCUITS ON f 23 5 e 28 4 BACK OF SWITCH Figure 3 Pro Sweep 5200 Page 4 5 Electrical System Hopper Switch The hopper switch is used to raise or lower the hopper by energizing solenoids S1 hopper up or S4 hopper down This switch is located in the control box enclo sure Fig 4 When the hopper switch is pushed to raise the hopper the demand solenoid S2 and the hopper up solenoid S1 are energized These energized solenoids allow hydraulic flow to extend the lift cylinder and raise the hopper Additionally the brush relay is energized which ensures that the sweeper brush will not
56. otential of permanent hearing damage 7 Before leaving the operator s position of the tow ve hicle A Stop sweeper brush B Ensure that vehicle traction lever is in neutral set parking brake stop engine and remove key from ignition switch C Make sure that dump hopper is lowered 8 Park on level surface empty hopper and chock sweeper wheels before disconnecting Pro Sweep 5200 from tow vehicle Pro Sweep 5200 Maintenance and Service 1 Before servicing or making adjustments empty Sweeper hopper and position sweeper on a level sur face Chock sweeper wheels to prevent it from moving If sweeper is attached to tow vehicle engage tow ve hicle parking brake stop engine and remove key from the ignition switch 2 Make sure machine is in safe operating condition by keeping all nuts bolts and screws tight 3 Make sure all hydraulic line connectors are tight and all hydraulic hoses and lines are in good condition be fore applying pressure to the hydraulic system 4 Keep body and hands away from pin hole leaks in hy draulic lines that eject high pressure hydraulic fluid Use cardboard or paper to find hydraulic leaks Hydraulic fluid escaping under pressure can penetrate skin and cause injury Hydraulic fluid accidentally injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result 5 Before disconnecting any hydraulic component or pe
57. r keys to brush housing 6 Refer to Brush Housing Service in this section for procedure to remove roller assembly from brush hous ing 7 After raising hopper and placing lift cylinder stop re trieve roller assembly 8 To remove bearings from roller A Remove set screw item 8 that secures locking collar to roller shaft NOTE Normal roller rotation is counter clockwise as viewed from left side of sweeper B Using a punch and hammer rotate locking collar item 7 in the opposite direction of normal roller rota tion to loosen collar C Remove carriage screws item 13 flat washers item 11 and lock nuts item 10 that secure bearing flanges to roller adjustment plate D Slide bearing flanges locking collar and bearing from roller Pro Sweep 5200 Page 5 13 Installation Fig 10 1 Clean roller shaft ends and apply antisieze lubricant to shaft ends Place adjustment plate bearing flanges bearing and locking collar onto each end of roller shaft Do not tighten set screws in locking collars 2 Secure bearing flanges to roller adjustment plate with carriage screws item 13 flat washers item 11 and lock nuts item 10 3 Position roller assembly under raised hopper 4 Slowly lower hopper to position roller assembly to housing see Servicing the Brush Housing in this sec tion 5 Secure adjustment plates and adjuster keys to brush housing with carriage screws and flange nuts using l
58. rforming any work on the hydraulic system all pres sure in system must be relieved See Relieving Hydrau lic System Pressure in the General Information section of Chapter 3 Hydraulic System 6 If hopper is to be raised make sure that sweeper is not placed in the offset position Pro Sweep 5200 Page 1 3 7 If hopper is raised install lift cylinder stop to ensure that unexpected shifting of sweeper frame does not oc cur 8 Disconnect electrical power harness from tow ve hicle before servicing the sweeper 9 If major repairs are ever needed or assistance is de sired contact an Authorized Toro Distributor 10 At the time of manufacture the machine conformed to all applicable safety standards To assure optimum performance and continued safety certification of the machine use genuine Toro replacement parts and ac cessories Replacement parts and accessories made by other manufacturers may result in non conformance with the safety standards and the warranty may be voided 11 When changing tires or performing other service use correct blocks hoists and jacks Make sure ma chine is parked on a solid level floor such as a concrete floor with the hopper empty and lowered Have sweeper attached to towing vehicle engage vehicle parking brake stop engine and remove key from the ignition Switch Always chock or block wheels Use jack stands or solid wood blocks to support the raised machine If the machine is not prope
59. rly supported by blocks or jack stands the machine may move or fall which may result in personal injury see Jacking Instructions Safety Jacking Instructions When changing tires or performing other ser vice use correct blocks hoists and jacks to support sweeper Make sure machine is parked on a solid level surface such as a concrete floor Always chock or block wheels Use jack stands or solid wood blocks to support the raised ma chine If the machine is not properly supported by blocks or jack stands the machine may move or fall which may result in personal inju ry 1 Position sweeper on a level surface with dump hop per empty and lowered Have sweeper attached to tow ing vehicle engage vehicle parking brake stop engine 1 Wheel 2 Frame jacking point and remove key from the ignition switch Chock sweep er wheels to prevent it from moving Figure 1 2 Position jack securely under the main sweeper frame Fig 1 Do not use the axle as a jacking point 3 Carefully jack machine off the ground 4 Position jack stands or hardwood blocks under the main frame to support the sweeper Safety Page1 4 Pro Sweep 5200 Securing Pro Sweep 5200 to Tow Vehicle While operating or servicing the Pro Sweep 5200 make sure that hitch pin is properly positioned in tow vehicle hitch and sweeper tongue Hitch pin should be secured with hairpin clip Fig 2 Figure 2 1 Hitch pin 2 Hairpin clip Safety and In
60. rols to relieve system pressure and to avoid injury from pres surized hydraulic oil See Relieving Hydraulic System Pressure in the General Information sec tion of this chapter 2 Relieve sweeper hydraulic system pressure 3 Disconnect hydraulic hose from hydraulic fitting on lift cylinder Locate and discard o ring from between hose and fitting Allow hose to drain into a suitable con tainer 4 Plug disconnected hose and fitting to prevent con tamination 5 Remove lock nuts item 5 and cap screws item 3 that are used to retain lift cylinder pivot pins item 4 to sweeper frame To prevent personal injury make sure that lift cylinder is supported as it is removed from the machine Lift cylinder weighs approximately 43 pounds 19 5 kg 6 Support lift cylinder and slide pivot pins from the lift cylinder and machine frame 7 Remove lift cylinder from the machine 8 If needed remove hydraulic check valve fitting and o ring from the lift cylinder Discard o ring Pro Sweep 5200 Page 3 23 Installation Fig 15 1 If removed install hydraulic check valve fitting and new o ring into lift cylinder 2 Position lift cylinder to the machine mounting points Make sure the port of the lift cylinder faces the front of the machine 3 Align lift cylinder mounting holes with frame mounts Install pivot pins Secure pivot pins to frame with cap screws and lock nuts 4 Remove plugs from disconn
61. rs Solenoid Valve Coil A solenoid valve coil on the hydraulic control manifold Fig 12 can be replaced without opening the hydraulic system Removal 1 Position sweeper on a level surface with dump hop per lowered If sweeper is attached to towing vehicle engage vehicle parking brake stop engine and remove key from the ignition switch 2 Disconnect the machine wiring harness electrical connector from the solenoid coil to be replaced 3 Remove the nut from the spool assembly 4 Slide the coil assembly from the spool assembly Dis card the coil assembly 5 Clean all corrosion or dirt from the spool assembly Installation 1 Slide new coil assembly onto the spool assembly 2 Install the nut onto the spool assembly and torque nut 36 in lb 4 1 N m do not over tighten 3 Connect the machine wiring harness electrical con nector to the solenoid coil Pro Sweep 5200 Page 4 11 36 in lb age 4 1 N m Figure 12 1 Solenoid valve coil S2 2 Solenoid valve coil S3 3 Solenoid valve coil S4 4 Solenoid valve coil S1 5 Nut Electrical System a LZ o 2 wi This page is intentionally blank Electrical System Page 4 12 Pro Sweep 5200 Chapter 5 TORO Chassis Table of Contents SPECIFICATIONS 2 GENERAL INFORMATION 2 Securing Pro Sweep 5200 to Tow Vehicle 2 SERVICE AND REPAIRS_ 3 Wh
62. rtridge valves at each manifold port location 3 Label all control manifold electrical and hydraulic connections for assembly purposes 4 Disconnect wire harness electrical connectors from solenoid valves on control manifold 5 Clean control manifold and manifold hydraulic con nections Disconnect hydraulic hoses from manifold fit tings Pro Sweep 5200 6 Allow disconnected hydraulic lines to drain into a suitable container Put caps or plugs on disconnected hoses and fittings to prevent contamination Discard any removed o rings 7 Support control manifold to prevent it from falling Remove two 2 cap screws flat washers and lock nuts that secure hydraulic manifold to the frame mounting bracket 8 Remove hydraulic manifold from the machine 9 Remove hydraulic fittings from manifold as needed Fig 13 Discard any removed o rings Installation Fig 12 1 Lightly oil new o rings for all removed hydraulic fit tings Install hydraulic fittings to control manifold see Hydraulic Fitting Installation in the General Information section of this chapter 2 Position hydraulic manifold to the frame mounting bracket Install cap screws washers and lock nuts but do not fully tighten 3 Make sure all hydraulic connections ports and fit tings are clean 4 Remove caps or plugs that were put on hydraulic lines or fittings during disassembly 5 Lightly oil new o rings for hydraulic fitting and hose location
63. s 6 Correctly connect hydraulic lines to the manifold Properly tighten all hydraulic connections see Hydrau lic Fitting Installation in the General Information section of this chapter 7 Secure hydraulic manifold to machine by tightening cap screws and lock nuts 8 Reconnect solenoid valve electrical connectors Pro Sweep 5200 Pon Page 3 19 Figure 13 5 O ring 5 Hydraulic fitting Hydraulic fitting 6 O ring S O ring 7 Hydraulic manifold Hs O ring Hydraulic System Hydraulic Control Manifold Service 36 in Ib P di NM 4 1 N m 20 to 25 ft lb 27 to 34 N m R Ty le Figure 14 1 Check valve 3 Solenoid coil 5 Solenoid valve S1 S3 and S4 ports 2 Demand solenoid S2 port 4 Nut 6 Hydraulic lift control manifold NOTE The ports on the manifold are marked for easy identification of components Example P is the pump connection port See Hydraulic Schematics to identify the function of the hydraulic lines and cartridge valves at each port Hydraulic System Page 3 20 Pro Sweep 5200 Hydraulic Manifold Service 1 Make sure the control manifold is clean before re moving any cartridge valve 2 If solenoid cartridge is being serviced remove nut securing solenoid to the cartridge valve Carefully slide solenoid off the valve Operate all sweeper hydraulic controls to relieve system pressure and to avoid injury from pres surized hydraulic oil See Relie
64. struction Decals Numerous safety and instruction decals are affixed to the Pro Sweep 5200 If any decal becomes illegible or damaged install a new decal Part numbers for replace ment decals are listed in your Parts Catalog Order re placement decals from your Authorized Toro Distributor Pro Sweep 5200 Page1 5 Safety This page is intentionally blank Safety Page 1 6 Pro Sweep 5200 Chapter 2 TORO Product Records and Maintenance Table of Contents o 0 D Q PRODUCT RECORDS 1 Standard Torque for Dry Zinc Plated and 9 S MAINTENANCE anaa 1 Steel Fasteners Inch Series 4 Kd EQUIVALENTS AND CONVERSIONS 2 Standard Torque for Dry Zinc Plated and 9 E Decimal and Millimeter Equivalents 2 Steel Fasteners Metric Fasteners 5 3 U S to Metric Conversions_ 2 Other Torque Specifications 6 In TORQUE SPECIFICATIONS 3 Conversion Facfors 6 Fastener ldentification 3 Product Records Insert Operator s Manual and Parts Catalog for your Pro Sweep 5200 at the end of this chapter Additionally if any optional equipment or accessories have been installed to your machine insert the Installation Instruc tions Operator s Manuals and Parts Catalogs for those options at the end of this chapter Maintenance Maintenance procedures and recommended service in
65. t ly IMPORTANT When installing the head into the tube pay careful attention to the retaining ring slot in the tube to insure that the backup ring does not lodge in the slot 7 Coat all internal lift cylinder parts with a light coating of clean hydraulic oil Slide rod assembly into tube being careful not to damage the seals 8 Secure head in tube by installing retaining ring item 8 Align retaining ring hole in the head with the access slot in the tube Insert the retaining ring hook into the hole and rotate head clockwise until the retaining ring is completely pulled into the tube and the ends are cov ered Apply silicone sealer to barrel access slot Hydraulic System a FE G 0 S zo This page is intentionally blank Hydraulic System Page 3 26 Pro Sweep 5200 Chapter 4 TORO Electrical System Table of Contents ELECTRICAL DIAGRAMS 1 SREGIAE TOOLS it is ida 1 TROUBLESHOOTING 2 SAFETY INTERLOCK SYSTEM 4 COMPONENT TESTING 5 Brush Switch 5 Hopper Switch 6 Brush and Hopper Down Relays 7 RUSO coepit uS A aja 8 Diode Assembly 8 Solenoid Valve Coil 9 Hopper Down Proximity Switch 10 SERVICE AND REPAIRS_ 11 Solenoid Valve Coil
66. t etc The standard method of verifying torque shall be per formed by marking a line on the fastener head or nut and mating part then back off fastener 1 4 of a turn Measure the torque required to tighten the fastener until the lines match up Class 8 8 Class 10 9 Metric Bolts and Screws Figure 2 Product Records and Maintenance Product Records o Oo c c o S E xe e Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series SAE Grade 8 Bolts Screws Studs amp Sems with Regular Height Nuts SAE Grade 5 Bolts Screws Studs amp Sems with Regular Height Nuts SAE J995 Grade 2 or Stronger Nuts SAE J995 Grade 5 or Stronger Nuts ELEME mx mm Mm mm wan Grade 1 5 amp 8 with Thin Height Nuts SAE Grade 1 Bolts Screws Studs amp Sems with Regular Height Nuts SAE J995 Grade 2 or Stronger Nuts Thread Size 6 32 UNC 147 23 6 40 UNF 8 32 UNC 8 36 UNF 10 24 UNC 339 56 10 32 UNF 1 4 20 UNC 48 7 599 79 1 4 28 UNF 65 10 734 113 5 16 18 UNC 115 15 105 15 1186 169 5 16 24 UNF 138 17 128 17 1446 192 3 8 16 UNC 16 2 3 8 24 UNF 7 16 14 UNC 27 3 7 16 20 UNF 29 3 430 45 583 61 600 60 813 81 475 48 644 65 667 66 904 89 1 2 13 UNC 30 3 1 2 20 UNF 5 8 11 UNC 65 10 88 12 119 16 5 8 18 UNF 75 10 95 15 129 20 3 4 10 UNC 93 12 140 20 190 27
67. tween fuse terminals Diode Assembly The diode assembly used in the Pro Sweep 5200 allows current flow to the demand solenoid S2 when the brush switch is turned on Additionally the diode pre vents current flow to the brush motor solenoid S3 when the hopper switch is moved to the raise position The diode plugs into the wire harness in the control box en closure Diode Test The diode Fig 8 can be tested using a digital multime ter diode test or ohms setting and the table to the right Electrical System Page 4 8 Figure 7 1 Fuse holder Figure 8 1 Diode 3 Female terminal 2 Male terminal Multimeter Black Lead on Terminal Multimeter Red Lead on Terminal Continuity mae M e RE Eee i ae T Pro Sweep 5200 Solenoid Valve Coil The hydraulic system on the Pro Sweep 5200 uses four 4 solenoid valve coils on the hydraulic control manifold Fig 9 Testing NOTE The solenoid does not have to be removed from the cartridge valve for testing 1 Make sure tow vehicle ignition switch is in the OFF position or that Pro Sweep power harness is unplugged from tow vehicle Unplug solenoid valve coil electrical connector 2 Apply 12VDC source directly to the solenoid coil Lis ten for solenoid to switch on 3 Remove 12VDC source from the solenoid coil Lis ten for solenoid to switch off NOTE Prior to taking small resistance readings with a d
68. ulic System Page 3 6 Pro Sweep 5200 Brush Circuit NOTE Hydraulic flow and relief pressure for the Pro Sweep 5200 are determined by the tow vehicle Hydraulic flow from the tow vehicle goes to the control manifold port P through the hydraulic input hose When the sweeper brush motor is not engaged and the lift cylinder is stationary hydraulic flow from the vehicle is directed by the un energized demand solenoid valve S2 to return to the tow vehicle through control manifold port T and the return to tank hose NOTE The hopper must be lowered for the Pro Sweep 5200 brush to operate Pro Sweep 5200 Page 3 7 When the brush switch is pressed to engage both the demand S2 and brush S3 solenoid valves in the hy draulic control manifold are energized The valve shift of S2 prevents hydraulic flow return to the tow vehicle The valve shift of S3 allows oil flow out of control manifold port MP and to the brush motor causing rotation of the sweeper brush Oil return from the brush motor is routed to control manifold port MR out control manifold port T and returns to the tow vehicle Hydraulic System Ze E 5 SZ EO TOW VEHICLE REQUIREMENTS INPUT RELIEF PRESSURE 2000 PSI TOW VEHICLE REQUIREMENTS INPUT 7 8 GPM RELIEF PRESSURE 2000 PSI Hydraulic System S2 qh ENERGIZED A ENERGIZED S1 LIFT CYLINDER EXTENDING
69. ving Hydraulic System Pressure in the General Information sec tion of this chapter IMPORTANT Use care when handling the cartridge valve Slight bending or distortion of the stem tube can cause binding and malfunction 3 Remove cartridge valve with a deep socket wrench Note correct location for o rings sealing rings and backup rings Remove and discard seal kit from valve 4 Visually inspect the manifold port for damage to the sealing surfaces damaged threads and contamination 5 Visually inspect cartridge valve for damaged sealing surfaces and contamination A Contamination may cause valves to stick or hang up Contamination can become lodged in small valve orifices or seal areas causing malfunction B If valve sealing surfaces appear pitted or dam aged the hydraulic system may be overheating or there may be water in the system CAUTION Use eye protection such as goggles when using compressed air for cartridge valve cleaning Pro Sweep 5200 Page 3 21 CAUTION stored fluid to be released suddenly 6 Clean cartridge valve by submerging valve in clean mineral spirits to flush out contamination Particles as fine as talcum powder can affect the operation of high pressure hydraulic valves If cartridge design allows use a wood or plastic probe to push the internal spool in and out 20 to 30 times to flush out contamination Be ex tremely careful not to damage cartridge Use com press
70. w Gallons Minute Liters Minute 3 785 Temperature Fahrenheit Celsius 1 Subract 32 2 Multiply by 5 9 Product Records and Maintenance Page2 2 Rev A Pro Sweep 5200 Torque Specifications Recommended fastener torque values are listed in the following tables For critical applications as determined by Toro either the recommended torque or a torque that is unique to the application is clearly identified and spe cified in this Service Manual These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Ser vice Manual The following factors shall be considered when applying torque cleanliness of the fastener use of a thread sealant e g Loctite degree of lubrication on the fastener presence of a prevailing torque feature hardness of the surface underneath the fastener s head or similar condition which affects the installation Fastener Identification Grade 1 Grade 5 Inch Series Bolts and Screws Figure 1 Pro Sweep 5200 Page 2 3 As noted in the following tables torque values should be reduced by 25 for lubricated fasteners to achieve the similar stress as a dry fastener Torque values may also have to be reduced when the fastener is threaded into aluminum or brass The specific torque value should be determined based on the aluminum or brass material strength fastener size length of thread en gagemen

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