Toro Pro Sweep 07066 Service Manual Download Page 33

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Pro Sweep

Hydraulic System

Page 3 -- 17

Problem

Possible Cause

Brush motor will not turn.

Control module has gone to time--out due to inactivity of remote

transmitter.

Sweeper is raised above transport height.

Hydraulic hose(s) to tow vehicle are not connected (lift cylinder and

offset cylinder affected as well).

Tow vehicle hydraulics are not engaged to Pro Sweep (lift and off-

set cylinders affected as well).

An electrical problem exists that prevents SRV solenoid coil on

control manifold from being energized (see Troubleshooting in

Chapter 4 -- Electrical System).

Control manifold SRV solenoid cartridge is faulty.

Control manifold EC cartridge is faulty.

Hydraulic brush motor is faulty.

An electrical problem exists that prevents operation of control mod-

ule or remote transmitter.

Hydraulic System

Summary of Contents for Pro Sweep 07066

Page 1: ... Manual and Parts Catalog are available on the internet at www Toro com The Toro Company reserves the right to change product specifications or this publication without notice 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 ...

Page 2: ...Pro Sweep This page is intentionally blank ...

Page 3: ...ydraulic Flow Diagrams 3 8 Troubleshooting 3 16 Service and Repairs 3 22 PARKER TORQLINKTM SERVICE PROCEDURE Chapter 4 Electrical System General Information 4 2 Special Tools 4 2 Troubleshooting 4 3 Safety Interlock System 4 6 Adjustments 4 7 Component Testing 4 8 Service and Repairs 4 18 Chapter 5 Chassis Specifications 5 2 General Information 5 3 Service and Repairs 5 4 Chapter 6 Electrical Diag...

Page 4: ...Pro Sweep This page is intentionally blank ...

Page 5: ...fety Chapter 1 Safety Table of Contents SAFETY INSTRUCTIONS 2 Before Operating 2 While Operating 2 Maintenance and Service 3 JACKING INSTRUCTIONS 4 SECURING PRO SWEEP TO TOW VEHICLE 5 SAFETY AND INSTRUCTION DECALS 5 Safety ...

Page 6: ...e Pro Sweep 5 Assure sweeper interlock system functions correctly so sweeper brush does not rotate unless sweeper is positioned below the transport position 6 Make sure that operator is familiar with tow vehicle operation 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 hi...

Page 7: ... Chapter 3 Hydraulic System 6 If hopper is to be raised make sure that sweeper is not placed in the offset position 7 If hopper is raised install hopper safety support on lift cylinder to ensure that unexpected shifting of sweep er frame does not occur 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 c...

Page 8: ...ck stands the machine may move or fall which may result in personal injury 1 Position sweeper on a level surface with dump hop per empty and lowered Have sweeper attached to tow ing vehicle apply vehicle parking brake stop engine and remove key from the ignition switch Chock sweep er wheels to prevent it from moving 2 Position jack securely under the main sweeper frame Fig 1 Do not use the axle as...

Page 9: ...Hitch pin should be secured with hairpin clip Fig 2 1 Hitch pin 2 Hairpin clip Figure 2 2 1 Safety and Instruction Decals Numerous safety and instruction decals are affixed to the Pro Sweep If any decal becomes illegible or dam aged install a new decal Part numbers for replacement decals are listed in your Parts Catalog Order replace ment decals from your Authorized Toro Distributor Safety ...

Page 10: ...Pro Sweep Page 1 6 Safety This page is intentionally blank ...

Page 11: ...ed and Steel Fasteners Metric Fasteners 5 Other Torque Specifications 6 Conversion Factors 6 Product Records Insert Operator s Manual and Parts Catalog for your Pro Sweep at the end of this chapter Additionally if any op tional equipment or accessories have been installed to your machine insert the Installation Instructions Oper ator s Manuals and Parts Catalogs for those options at the end of thi...

Page 12: ...0 09375 Pro Sweep Page 2 2 Product Records and Maintenance Equivalents and Conversions ...

Page 13: ...nd mating part then back off fastener 1 4 of a turn Measure the torque required to tighten the fastener until the lines match up Fastener Identification Figure 1 Grade 1 Grade 5 Grade 8 Inch Series Bolts and Screws Figure 2 Class 8 8 Class 10 9 Metric Bolts and Screws Using a Torque Wrench with an Offset Wrench Use of an offset wrench e g crowfoot wrench will affect torque wrench calibration due t...

Page 14: ...22 3 30 3 41 4 43 5 58 7 3 8 24 UNF 17 2 18 2 24 3 35 4 47 5 50 6 68 8 7 16 14 UNC 27 3 27 3 37 4 50 5 68 7 70 7 95 9 7 16 20 UNF 29 3 29 3 39 4 55 6 75 8 77 8 104 11 1 2 13 UNC 30 3 48 7 65 9 75 8 102 11 105 11 142 15 1 2 20 UNF 32 4 53 7 72 9 85 9 115 12 120 12 163 16 5 8 11 UNC 65 10 88 12 119 16 150 15 203 20 210 21 285 28 5 8 18 UNF 75 10 95 15 129 20 170 18 230 24 240 24 325 33 3 4 10 UNC 93...

Page 15: ... 10 N m 93 10 ft lb 126 14 N m M16 X 2 0 166 17 ft lb 225 23 N m 229 23 ft lb 310 31 N m M20 X 2 5 325 33 ft lb 440 45 N m 450 46 ft lb 610 62 N m 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 in...

Page 16: ...b Wheel Bolts and Lug Nuts Thread Size Recommended Torque 7 16 20 UNF Grade 5 65 10 ft lb 88 14 N m 1 2 20 UNF Grade 5 80 10 ft lb 108 14 N m M12 X 1 25 Class 8 8 80 10 ft lb 108 14 N m M12 X 1 5 Class 8 8 80 10 ft lb 108 14 N m For steel wheels and non lubricated fasteners Thread Cutting Screws Zinc Plated Steel Thread Size Threads per Inch Baseline Torque Size Type A Type B Baseline Torque No 6 ...

Page 17: ...OW DIAGRAMS 8 Brush Circuit 8 Sweeper Raise Hopper Dump Circuits 10 Sweeper Lower Circuits 12 Sweeper Offset Circuits 14 TROUBLESHOOTING 16 SERVICE AND REPAIRS 22 General Precautions for Removing and Installing Hydraulic System Components 22 Check Hydraulic Lines and Hoses 23 Brush Motor 24 Brush Motor Service 26 Hydraulic Control Manifold 28 Hydraulic Control Manifold Service 30 Lift Cylinder 32 ...

Page 18: ...e hose is straight not twisted before tightening the fittings This can be done by observing the imprint layline on the hose Use two wrenches when tightening a hose hold the hose straight with one wrench and tighten the hose swivel nut onto the fitting with the second wrench see Hydraulic Hose and Tube Installation in this sec tion If the hose has an elbow at one end tighten the swivel nut on that ...

Page 19: ...e Torque Specifica tions section of Chapter 2 Product Records and Main tenance 5 If a torque wrench is not available or if space at the swivel nut prevents use of a torque wrench an alternate method of assembly is the Flats From Wrench Resist ance F F W R method Fig 2 A Using a wrench tighten the swivel nut onto the fit ting until light wrench resistance is reached approxi mately 30 in lb B Mark t...

Page 20: ...ds and Maintenance to determine necessary con version information 5 If a torque wrench is not available or if space at the port prevents use of a torque wrench an alternate meth od of assembly is the Flats From Finger Tight F F F T method A Install the fitting into the port and tighten it down full length until finger tight B If port material is steel tighten the fitting to the listed F F F T If p...

Page 21: ...Step 3 in Figure 7 7 Hold the fitting in the desired position with a wrench and use a torque wrench to tighten the lock nut to the recommended installation torque shown in Figure 5 This tightening process will require the use of an offset wrench e g crowfoot wrench Use of an offset wrench will affect torque wrench calibration due to the effective length change of the torque wrench Tightening torqu...

Page 22: ...OFF and allow engine to stop Make sure that the sweeper has electrical power and that sweeper control module is energized control mod ule Time Out and Power LED s are both illuminated Withthetowvehicle enginenotrunning press allremote transmitter buttons to energize the solenoids on the hy draulic control manifold After all functions have been energized make sure tow vehicle key switch is OFF and ...

Page 23: ...Pro Sweep Hydraulic System Page 3 7 Hydraulic Schematic Hydraulic Schematic Pro Sweep All solenoids are shown as de energized CONTROL MANIFOLD LIFT CYLINDER OFFSET CYLINDER Hydraulic System ...

Page 24: ...Pro Sweep Hydraulic System Page 3 8 Hydraulic Flow Diagrams Working Pressure Return Flow Brush Rotating Shown CONTROL MANIFOLD LIFT CYLINDER OFFSET CYLINDER Brush Circuit ENERGIZED ROTATING ...

Page 25: ...transport height sole noid valve SRV in the hydraulic control manifold is ener gized In this sweeper position energized SRV shifts to prevent hydraulic flow return to the tow vehicle when the tow vehicle hydraulics are engaged Hydraulic flow from the tow vehicle is then directed out of control manifold port M1 to the brush motor This flow causes rotation of the sweeper brush Oil return from the br...

Page 26: ...Pro Sweep Hydraulic System Page 3 10 Working Pressure Return Flow Dump Circuits CONTROL MANIFOLD LIFT CYLINDER OFFSET CYLINDER ENERGIZED EXTENDING DE ENERGIZED Sweeper Raise Hopper DE ENERGIZED ...

Page 27: ...xtends the cyl inder to raise the hopper The check valve fitting at tached to the lift cylinder allows oil flow to bypass the orifice in the fitting for proper lift cylinder extension As the hopper is being raised control manifold relief valve RV functions as a circuit relief valve If circuit pres sure reaches 2000 PSI 138 bar while the sweeper is being raised RV will shift to reduce circuit press...

Page 28: ...Pro Sweep Hydraulic System Page 3 12 Working Pressure Return Flow CONTROL MANIFOLD LIFT CYLINDER OFFSET CYLINDER DE ENERGIZED RETRACTING ENERGIZED DE ENERGIZED Sweeper Lower Circuits ...

Page 29: ... valve shift of SV2 allows a path for oil flow from the lift cylinder The weight of the dump hopper and sweeper frame cause the lift cylinder to retract allowing the sweeper to lower to the ground The orifice in the lift cylinder check valve fitting restricts oil flow from the cylinder to control lift cylinder retraction speed While lowering if the remote transmitter sweeper up or stop button are ...

Page 30: ...weep Hydraulic System Page 3 14 Working Pressure Return Flow Offset to Right Shown CONTROL MANIFOLD LIFT CYLINDER OFFSET CYLINDER Sweeper Offset Circuits EXTENDING FOR RH OFFSET SHIFTED LOWER COIL ENERGIZED ...

Page 31: ...nd the return to tank hose Orifice OR1 0 050 in the control manifold exists to con trol the extending speed of the offset cylinder As the sweeper is being offset relief valve RV functions as a circuit relief valve If circuit pressure reaches 2000 PSI 138 bar RV will shift to reduce circuit pressure When the transmitter offset right button is released the lower coil for solenoid valve SV1 will de e...

Page 32: ...hen trouble shooting 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 inspect tow vehicle hydraulic system if sweeper brush motor offset cylinder and lift cylinder are all malfunctioning If one sweeper hydraulic circuit ap pears to be malfunctioning e g the brush circuit and lift cylinder...

Page 33: ...ted as well Tow vehicle hydraulics are not engaged to Pro Sweep lift and off set cylinders affected as well An electrical problem exists that prevents SRV solenoid coil on control manifold from being energized see Troubleshooting in Chapter 4 Electrical System Control manifold SRV solenoid cartridge is faulty Control manifold EC cartridge is faulty Hydraulic brush motor is faulty An electrical pro...

Page 34: ...ts are binding Check valve fitting on lift cylinder is faulty An electrical problem exists that prevents control manifold solenoid coil SV3 from being energized see Troubleshooting in Chapter 4 Electrical System Control manifold solenoid cartridge SV3 is faulty Control manifold solenoid cartridge SV2 is faulty Control manifold relief valve RV is leaking or faulty Control manifold cartridge EC is f...

Page 35: ...oblem exists that prevents control manifold solenoid coil SV3 from being energized see Troubleshooting in Chapter 4 Electrical System Control manifold solenoid cartridge SV3 is faulty Control manifold solenoid cartridge SV2 is faulty Control manifold relief valve RV is leaking or faulty Control manifold cartridge EC is faulty Hydraulic system on tow vehicle is malfunctioning brush motor and offset...

Page 36: ...linder affected as well Sweeper is raised above transport height Offset cylinder is binding Sweeper frame components are binding An electrical problem exists that prevents coil on control manifold solenoid valve SV1 from being energized see Troubleshooting in Chapter 4 Electrical System Control manifold solenoid cartridge SV1 is faulty Control manifold cartridge CB1 and or CB2 are faulty Offset cy...

Page 37: ...Pro Sweep Hydraulic System Page 3 21 This page is intentionally blank Hydraulic System ...

Page 38: ...ic hoses for prop er 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 aligned properly when reinstalling hydraulic hoses After Repair or Replacement of Components 1 If component failure was severe or if hydraulic sys tem is contaminated drain entire ...

Page 39: ...r 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 Before using sweeper check hydraulic hoses for leaks kinked lines loose mounting supports wear loose fit tings or any other deterioration Make a...

Page 40: ...ng assembly Figure 13 FRONT RIGHT 94 to 116 ft lb 128 to 157 N m 2 3 6 8 9 10 11 13 1 5 7 12 14 15 16 17 18 19 4 17 20 Removal Fig 13 1 Position sweeper on a level surface with dump hop per empty and fully lowered Chock sweeper wheels to prevent sweeper from moving If sweeper is attached to tow vehicle apply tow vehicle parking brake stop en gine and remove key from the ignition switch CAUTION Bef...

Page 41: ...Position woodruff key into shaft keyway and slide coupling jaw onto shaft Make sure that coupling spider is positioned into coupling jaw on brush shaft 3 Align coupling jaw on motor shaft with coupling spi der Position and support brush motor to the frame 4 Align motor shaft with brush shaft Secure brush mo tor to frame with two 2 cap screws item 13 flat wash ers item 6 and lock nuts item 5 Torque...

Page 42: ...te 9 Drive link 10 Coupling shaft 11 Woodruff key 12 Bushing 13 Thrust bearing 14 Thrust washer 15 Inner seal 16 Backup washer 17 O ring 18 Housing 19 Bearing 20 Seal Figure 16 3 19 18 17 16 15 13 12 14 5 4 2 1 3 7 8 22 to 26 ft lb 30 to 35 N m 3 3 3 6 11 10 9 20 NOTE For service of the hydraulic brush motor see the Parker TorqlinkTM Service Procedure at the end of this chapter ...

Page 43: ...Pro Sweep Hydraulic System Page 3 27 This page is intentionally blank Hydraulic System ...

Page 44: ...ld 1 Main frame 2 Cap screw 2 used 3 Flat washer 4 used 4 Hydraulic control manifold 5 Lock nut 2 used 6 Hydraulic hose 7 O ring 8 Hydraulic hose 2 used 9 O ring 10 Hydraulic hose 2 used 11 Hydraulic hose 2 used Figure 17 FRONT RIGHT 3 4 1 2 5 3 6 7 8 9 10 11 7 9 ...

Page 45: ...rol 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 9 Remove hydraulic manifold from the machine 10 Remove hydraulic fittings from manifold as needed Fig 18 Discard any removed O rings Installation Fig 17 1 Lightly oil new O rings for all removed hydraulic fit tings Install hydraulic fittings to con...

Page 46: ...f valve RV 13 Counterbalance valve CB1 CB2 14 Nut 15 Solenoid relief valve SRV 16 Pressure compensator valve EC 17 Hydraulic manifold 18 Shuttle valve SH 19 Orifice 0 060 OR2 20 6 zero leak plug Figure 19 25 ft lb 34 N m 60 in lb 6 8 N m 25 ft lb 34 N m 20 ft lb 27 N m 20 ft lb 27 N m 20 ft lb 27 N m 60 in lb 6 8 N m 2 3 6 8 9 10 11 13 1 5 12 14 15 16 4 2 2 6 18 19 20 7 20 ft lb 27 N m 35 ft lb 47...

Page 47: ...aces and contamination A Contamination may cause valves to stick or hang up Contamination can become lodged in smallvalve 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 CAUTION...

Page 48: ...Pro Sweep Hydraulic System Page 3 32 Lift Cylinder 1 Main sweeper frame 2 Lift cylinder 3 Cap screw 4 Pivot pin 5 Lock nut 6 Pitch frame 7 Pivot pin Figure 20 FRONT RIGHT 2 3 6 1 5 7 4 3 5 ...

Page 49: ...ift cylinder pivot pins items 4 and 7 to sweeper frame CAUTION 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 ...

Page 50: ...t 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 23 4 Grasp end ...

Page 51: ... a vise by clamping vise on the clevis of the shaft Carefully slide head assembly and piston assembly onto the rod 4 Thread lock nut item 11 onto rod Torque lock nut from 250 to 300 ft lb 339 to 407 N m 5 Remove rod assembly from vise IMPORTANT Prevent damage when clamping the tube into a vise clamp on the clevis only 6 Mount tube in a vise so that the rod end tilts up slight ly IMPORTANT When ins...

Page 52: ...Offset Cylinder 1 Offset cylinder 2 Hitch tongue 3 Pivot pin 2 used 4 Cap screw 2 used 5 Flange nut 2 used 6 Bracket 7 Hydraulic hose 2 used 8 O ring 9 90o hydraulic fitting 2 used 10 O ring Figure 24 FRONT RIGHT 2 3 6 1 5 4 3 4 5 7 8 9 10 ...

Page 53: ...nuts item 5 and cap screws item 4 that are used to retain offset cylinder pivot pins item 3 to sweeper frame 7 Support offset cylinder and slide pivot pins from the cylinder and machine frame 8 Remove offset cylinder from the machine 9 If hydraulic fittings are to be removed from offset cyl inder mark fitting orientation to allow correct assembly Remove fittings from cylinder and discard O rings I...

Page 54: ...inder Service 1 Grease fitting 2 Tube 3 Lock nut 4 Wear ring 5 Capseal 6 Piston 7 Spacer 8 O ring 9 O ring 10 Backup washer 11 Retaining ring 12 Seal 13 Head 14 Wiper 15 Rod Figure 25 2 3 6 8 9 10 11 13 1 5 7 12 14 15 4 1 30 to 35 ft lb 41 to 47 N m ...

Page 55: ...efully inspect internal surface of tube for damage deep scratches out of round etc Inspect rod and piston for evidence of excessive scoring pitting or wear Replace offset cylinder if internal components are found to be worn or damaged Assembly Fig 25 1 Make sure all cylinder components are thoroughly cleaned before assembly 2 Coat new seal kit components with clean hydraulic oil IMPORTANT When ins...

Page 56: ...Pro Sweep Hydraulic System Page 3 40 This page is intentionally blank ...

Page 57: ...trical Diagrams 2 SPECIAL TOOLS 2 TROUBLESHOOTING 3 SAFETY INTERLOCK SYSTEM 6 ADJUSTMENTS 7 Proximity Switches 7 COMPONENT TESTING 8 Fuse 8 Diode Assemblies 8 Dump Beeper 9 Relays 10 Proximity Switches 12 Solenoid Valve Coil 15 Remote Transmitter 16 Control Module 17 SERVICE AND REPAIRS 18 Solenoid Valve Coil 18 Electrical System ...

Page 58: ...ire har ness drawings for the Pro Sweep 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 Obtain this tool locally NOTE Toro recommends the use of a DIGITAL Volt Ohm Amp multimeter when testing electrical circuits The high impedance internalresistance ofa digitalme ter in the...

Page 59: ...e 20 Amp is faulty Control module has timed out due to 30 minutes of inactivity Wires for remote transmitter learn function are plugged together Remote transmitter batteries are discharged Remote transmitter and control module are not synchronized Hydraulic problem exists see Chapter 3 Hydraulic System Remote transmitter is faulty Control module is faulty Brush does not rotate Sweeper is raised br...

Page 60: ...lem exists see Chapter 3 Hydraulic System Remote transmitter is faulty other functions affected as well Control module is faulty other functions affected as well Sweeper will raise to the turn around position but does not raise to the transport or dump position Sweeper is offset not directly behind tow vehicle Hitch home proximity switch is out of adjustment Transport position proximity switch is ...

Page 61: ...ring is faulty Solenoid valve coil SV2 or circuit wiring is faulty Hydraulic problem exists see Chapter 3 Hydraulic System Sweeper offset does not function Control module has timed out due to 30 minutes of inactivity Offset lockout proximity switch is out of adjustment Offset Lockout relay or circuit wiring is faulty Offset lockout proximity switch or circuit wiring is faulty Solenoid valve coil s...

Page 62: ... it before operating the sweep er The Pro Sweep safety interlock system ensures the fol lowing 1 The brush will not rotate when the dump hopper is in the raised position 2 The dump hopper cannot be emptied when the sweeper is in the offset position not directly behind the tow vehicle 3 The dump beeper willsound when emptying the hop per Interlock system operation is described in the Pro Sweep Oper...

Page 63: ...er positioned directly behind the tow vehicle not offset Engage vehicle parking brake stop engine and remove key from the ignition switch Chock sweeper wheels to prevent sweeper from moving 2 The target surface end of proximity switch should be from 0 110 to 0 170 2 8 to 4 3 mm from sensing plate on sweeper Figs 2 and 3 3 If necessary loosen jam nuts on switch and adjust switch location to allow p...

Page 64: ...ll be available for sweeper operation Testing Remove fuse from the fuse holder for testing Fuse should have continuity between fuse terminals 1 Fuse holder Figure 4 1 Diode Assemblies Three 3 diode assemblies are used in the Pro Sweep to provide logic for the control module functions Diode D1 provides logic control for the sweeper down function Diodes D2 and D3 provide logic control for the sweepe...

Page 65: ...Remove cover from frame to access dump beeper 4 Disconnect wire harness connector from beeper IMPORTANT Make sure to observe polarity on the beeper terminals when testing Damage to the beep er may result from an improper connection 5 Correctly connect 12VDC source to the beeper ter minals Fig 7 6 Beeper should sound as long as 12VDC is con nected to the beeper terminals 7 Disconnect voltage source...

Page 66: ...is not energized broom enable proximity switch open solenoid SRV will not be energized and the broom will be stationary not rotating When the Broom relay is en ergized broom enable proximity switch closed sole noid SRV will be energized to allow hydraulic flow to the broom motor so the broom will rotate The Down Latch Release and Down Float Latch relays are used to control the sweeper down functio...

Page 67: ...itch is closed sweeper offset is allowed Relay Testing 1 Position sweeper on a level surface with dump hop per lowered If sweeper is attached to towing vehicle apply vehicle parking brake stop engine and remove key from the ignition switch To ensure that electrical power is removed from Pro Sweep disconnect sweeper power harness from tow vehicle 2 Remove cover from frame to access relays Fig 8 3 L...

Page 68: ...ates when the switch is in the closed position The switches are mounted on the main sweeper frame in three 3 loca tions Fig 10 Proximity Switch Operation The turn around position proximity switch is located on the RH switch plate in the hole identified with number 1 This switch is used to identify the dump hopper turn around height position when the sweeper is offset not positioned directly behind...

Page 69: ...ending on which proximity switch is to be tested position the sweeper as listed below Figs 11 and 12 In this sweeper position the LED on cable end of proxi mity switch shouldbeilluminated when electricalpower is available to sweeper Turn Around Position Switch hole number 1 Sweeper offset and lowered Transport Position Switch number 3 Sweeper not offset and lowered Offset Lockout Switch number 5 S...

Page 70: ...d wire black is closed to ground E If harness wire has system voltage present and gap is correct but switch LED did not function re place proximity switch Make sure that switch is properly adjusted see Proximity Switches in the Ad justments section 5 After testing is complete make sure that switch con nector is plugged into sweeper wire harness Connect sweeper power harness to tow vehicle PROXIMIT...

Page 71: ...a digital 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 Using a multimeter ohms setting measure resis tance between the two connector terminals on the sole noid coil Th...

Page 72: ...ontinue to offset until the button is released Pressing the Stop button causes any active function to be disabled NOTE When the stop button on the remote transmitter is pressed there will be a three 3 second delay before the stop LED on the control module illuminates Also for approximately five 5 seconds after the stop button is pressed the control module stop LED will remain illumi nated and no o...

Page 73: ...ssed there will be a three 3 second delay before the control module stop LED illuminates Also the con trol module stop LED will remain illuminated and no oth er remote transmitter operations can be performed for approximately five 5 seconds The control module includes a timer to allow machine operation for 30 minutes after the last control input e g remote transmitter button pressed If no inputs a...

Page 74: ...rface with dump hop per lowered If sweeper is attached to towing vehicle apply vehicle parking brake stop engine and remove key from the ignition switch 2 To ensure that electrical power is removed from Pro Sweep disconnect sweeper power harness from tow vehicle 3 Disconnect the machine wire harness electrical con nector from the solenoid coil to be removed 4 Remove the nut from the cartridge valv...

Page 75: ...le of Contents SPECIFICATIONS 2 GENERAL INFORMATION 3 Operator s Manual 3 Securing Pro Sweep to Tow Vehicle 3 SERVICE AND REPAIRS 4 Wheels 4 Wheel Bearings 6 Servicing the Brush Housing 8 Brush 10 Brush Housing 12 Roller 14 Frame Assembly 16 Chassis ...

Page 76: ...Pro Sweep Page 5 2 Chassis Specifications Item Description Tires Size 26 5 x 14 12 4 Ply Tubeless Pressure 12 5 PSI 86 kPa Wheel Lug Nut Torque 70 to 90 ft lb 95 to 122 N m ...

Page 77: ...als for your Pro Sweep machine Refer to that pub lication for additional information when servicing the machine Securing Pro Sweep to Tow Vehicle While operating or servicing the Pro Sweep 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 1 Hitch pin 2 Hairpin clip Figure 1 2 1 Chassis ...

Page 78: ...Wheels 1 Main frame 2 Lug nut 5 used per wheel 3 Wheel and tire assembly 4 Wheel hub 5 Axle 6 Cap screw 4 used 7 Support washer 4 used 8 Flange nut 4 used Figure 2 FRONT RIGHT 70 to 90 ft lb 95 to 122 N m 3 2 4 1 5 6 7 8 63 to 77 ft lb 86 to 104 N m ...

Page 79: ...rt ma chine with appropriate jack stands see Operator s Manual and Jacking Instructions in Chapter 1 Safety 3 Loosen and remove five 5 lug nuts from wheel to be removed 4 Pull wheel from sweeper Wheel Installation Fig 2 1 Position wheel to wheel hub 2 Secure wheel to sweeper with five 5 lug nuts 3 Carefully lower machine to ground WARNING Failure to maintain proper lug nut torque could result in f...

Page 80: ... Grease seal 3 Inner bearing cone 4 Inner bearing cup 5 Wheel hub 6 Lug bolt 5 used 7 Outer bearing cup 8 Outer bearing cone 9 Lug nut 5 used 10 Washer 11 Slotted hex nut 12 Cotter pin 13 Dust cup 6 7 3 2 5 4 1 8 11 9 10 12 13 See text for tightening procedure ...

Page 81: ... 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 If lug bolts were removed from hub press new bolts into hub Make sure that head of bolt is fully to hub surface C Pack both bearing cones with grease Install greased inner bearing into the cup on inboard side of the wheel hub D Fill hub approximately 50 full of grease...

Page 82: ...Pro Sweep Page 5 8 Chassis Servicing the Brush Housing 1 Saddle frame 2 Roller 3 Hydraulic brush motor 4 Brush 5 Brush housing Figure 4 FRONT RIGHT 3 2 5 4 1 ...

Page 83: ...d 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 4 Start tow vehicle Slowly raise sweeper hopper while allowing brush housing component s to remain on the ground 5 Raise hopper and place cylinder stop on lift cylinder to secure sweeper frame 6 Perform necessary s...

Page 84: ...4 25 22 26 27 28 29 8 10 9 Loctite 242 61 to 85 in lb 6 9 to 9 6 N m Antiseize Lubricant Antiseize Lubricant 14 94 to 116 ft lb 128 to 157 N m Removal Fig 5 1 Position sweeper on a level surface with dump hop per empty and lowered Have sweeper attached to tow ing vehicle apply vehicle parking brake stop engine and remove key from the ignition switch Chock sweep er wheels to prevent sweeper from mo...

Page 85: ...ht Make sure that brush is still centered between bearings B Starting with the set screw that is opposite from the split in the sleeve tighten all set screws 1 4 turn C Again starting with the set screw that is opposite from the split in the sleeve tighten all set screws an additional 1 4 turn NOTE A replacement bearing includes an allen wrench and torque indicator that can be used to properly tor...

Page 86: ... Flange bushing 2 used per mount 5 Pivot mount 2 used 6 Grease fitting 1 used per mount 7 Thrust washer 8 Brush housing 9 Cap screw 10 Flat washer 11 Hardened spacer Figure 8 FRONT RIGHT 94 to 116 ft lb 128 to 157 N m 2 3 6 1 5 7 4 2 3 4 6 7 94 to 116 ft lb 128 to 157 N m 8 9 10 11 ...

Page 87: ... removed Installation Fig 8 1 If flange bushings were removed from pivot mounts press new bushings fully into mounts 2 Place thrust washer and then pivot mount on both brush housing pins 3 Secure front pivot mount with hardened spacer item 11 flat washer item 10 and cap screw item 9 4 Position brush housing under raised hopper 5 Slowly lower hopper to position saddle frame to brush housing see Ser...

Page 88: ...used 8 Set screw 1 per collar 9 Bearing 2 used 10 Lock nut 2 used per bearing 11 Flat washer 2 used per bearing 12 Roller adjustment plate 2 used 13 Carriage screw 2 used per bearing 14 Adjuster key 2 used 15 Carriage screw 2 used Figure 10 FRONT RIGHT 6 7 3 2 4 1 8 2 5 5 9 10 11 14 15 12 13 125 to 165 in lb 14 2 to 18 6 N m Antiseize Lubricant Loctite 242 Antiseize Lubricant ...

Page 89: ...ormal 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 Installation Fig 10 1 Clean roller shaft ends and apply antiseize lubricant to shaft ends Place adjustment plate bearing flanges bearing and locking collar onto each ...

Page 90: ... 17 18 9 4 4 4 4 4 2 2 2 3 15 17 Disassembly Fig 12 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 NOTE If lift cylinder is to be removed see Lift Cylinder Removal in the Service and Repairs section...

Page 91: ...RAWINGS Brush Circuit 4 Sweeper Raise Circuit To Transport Height 5 Sweeper Raise Circuit To Turn Around Height 6 Hopper Dump Circuit 7 Sweeper Lower Circuit Initiation 8 Sweeper Lower Circuit 9 Sweeper Offset Circuit 10 WIRE HARNESS DRAWINGS Power Wire Harness 11 Main Wire Harness Drawing 12 Main Wire Harness Diagram 13 Electrical Diagrams ...

Page 92: ...Pro Sweep Electrical Diagrams Page 6 2 This page is intentionally blank ...

Page 93: ...Page 6 3 Electrical Schematic Pro Sweep Relays are shown as de energized All ground wires are black CAP CONTROL MODULE CAP NOTE NO OTHER MACHINE FUNCTIONS WIRES ARE CONNECTED WILL WORK WHEN LEARN SHUNT ...

Page 94: ...US E Canada 3575APFB1 Model 07066 N 1 6 2 5 Made in U S A ILLUMINATED ON ON LED S BUTTON PRESSED NO Electrical Power Exists to Pro Sweep Sweeper Is Below Transport Height Position SWITCH CLOSED LED ILLUMINATED ENERGIZED ENERGIZED WHEN SWEEPER HEAD IS BELOW THE CAP Brush Will Rotate if Tow Vehicle Hydraulics Are Engaged CONTROL MODULE TRANSPORT HEIGHT Note Other Circuits Are Completed During Brush ...

Page 95: ...TE TRANSMITTER 115 9062 Tested to Comply With FCC Standards FOR HOME OR OFFICE US E Canada 3575APFB1 Model 07066 N 1 6 2 5 Made in U S A ILLUMINATED ON ON LED S ON ON SWEEPER PRESSED UP BUTTON PRESSED Sweeper Raise Circuit To Transport Height Power Current Control Current Pro Sweep CAP SWITCH CLOSED ENERGIZED SWITCH LED ILLUMINATED SWITCH CLOSED SWITCH LED ILLUMINATED ENERGIZED ENERGIZED ENERGIZED...

Page 96: ...ONTROL MODULE REMOTE TRANSMITTER 115 9062 Tested to Comply With FCC Standards FOR HOME OR OFFICE US E Canada 3575APFB1 Model 07066 N 1 6 2 5 Made in U S A ILLUMINATED ON ON LED S ON ON PRESSED Sweeper Raise Circuit To Turn Around Height Power Current Control Current Pro Sweep CAP SWITCH CLOSED SWITCH LED ILLUMINATED ENERGIZED ENERGIZED ENERGIZED Sweeper Will Raise to Turn Around Height if Tow Vehi...

Page 97: ...ort Height Position Tested to Compl y With FCC Standar ds FOR HOME OR OFFICE USE Canada 3575APFB1 Model 44538 N 1 6 2 5 Made in U S A CONTROL MODULE REMOTE TRANSMITTER 115 9062 Tested to Comply With FCC Standards FOR HOME OR OFFICE US E Canada 3575APFB1 Model 07066 N 1 6 2 5 Made in U S A ILLUMINATED ON ON LED S ON HOPPER PRESSED AND HELD DUMP BUTTON PRESSED AFTER DUMP SEQUENCE ON SWITCH CLOSED SW...

Page 98: ...r ds FOR HOME OR OFFICE USE Canada 3575APFB1 Model 44538 N 1 6 2 5 Made in U S A CONTROL MODULE REMOTE TRANSMITTER 115 9062 Tested to Comply With FCC Standards FOR HOME OR OFFICE US E Canada 3575APFB1 Model 07066 N 1 6 2 5 Made in U S A ILLUMINATED ON ON LED S ON ON SWEEPER BUTTON PRESSED DOWN PRESSED Sweeper Will Lower if Tow Vehicle Hydraulics Are Engaged ENERGIZED ENERGIZED ENERGIZED CONTROL MO...

Page 99: ...062 Tested to Comply With FCC Standards FOR HOME OR OFFICE US E Canada 3575APFB1 Model 07066 N 1 6 2 5 Made in U S A ILLUMINATED ON ON LED S BUTTONS PRESSED NO Sweeper Will Lower if Tow Vehicle Hydraulics Are Engaged ENERGIZED ENERGIZED ENERGIZED CONTROL MODULE Keep Circuit Energized SOLENOID THE REMOTE TRANSMITTER STOP OR SWEEPER UP BUTTON CAN BE PRESSED EITHER OF DE ENERGIZE NOTE TO DE ENERGIZE ...

Page 100: ...ted to Comply With FCC Standards FOR HOME OR OFFICE US E Canada 3575APFB1 Model 07066 N 1 6 2 5 Made in U S A ILLUMINATED ON ON LED S ON ON CAP ENERGIZED CONTROL MODULE Electrical Power Exists to Pro Sweep Remote Transmitter Offset Right Button Pressed Sweeper Will Offset to the Right if Tow Vehicle Hydraulics Are Engaged REMOTE TRANSMITTER OFFSET PRESSED AND HELD RIGHT BUTTON PRESSED SWITCH CLOSE...

Page 101: ...Page 6 11 Pro Sweep Power Wire Harness BLACK RED BLUE ...

Page 102: ...Page 6 12 Pro Sweep Main Wire Harness Drawing CONTROL MODULE CONTROL MODULE ...

Page 103: ...W TAN GREEN BLACK YELLOW BLACK ORANGE BLACK YELLOW BLACK ORANGE GRAY ORANGE GRAY WHITE PINK BLACK BLUE WHITE TAN WHITE BLUE RED BLACK PINK BLACK BLACK ORANGE WHITE PINK BLACK PINK BLACK PINK PINK YELLOW BLUE YELLOW BROWN BLACK PINK BROWN BLACK BLACK BLUE PINK BROWN PINK PINK GRAY BLACK BLACK PINK ORANGE WHITE BLACK CONTROL MODULE DUMP BEEPER ...

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