Toro Pro Sweep 5200 Service Manual Download | Manualshive

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Hydraulic Flow Diagrams

Return
Flow

Brush Circuit (Brush Rotating Shown)

LIFT

CYLINDER

CONTROL

MANIFOLD

(ENERGIZED)

(ENERGIZED)

2.7 CI/REV

Working Pressure

BRUSH MOTOR

Hydraulic System

Page 3 – 6

Pro Sweep 5200

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Summary of Contents for Pro Sweep 5200

Page 1: ...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...

Page 2: ...This page is intentionally blank Pro Sweep 5200...

Page 3: ...raulic Flow Diagrams 4 6 Troubleshooting 4 10 Service and Repairs 4 13 PARKER TORQLINKTM SERVICE PROCEDURE Chapter 4 Electrical System Electrical Diagrams 5 1 Special Tools 5 1 Troubleshooting 5 2 Saf...

Page 4: ...This page is intentionally blank Pro Sweep 5200...

Page 5: ...ontents 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 Safety Pro...

Page 6: ...est 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...

Page 7: ...lic 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 lift cylinder stop to ensure that unexpected shifting of sweeper frame...

Page 8: ...aised ma by blocks or jack stands the machine may 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 sto...

Page 9: ...with hairpin clip Fig 2 2 1 Figure 2 1 Hitch pin 2 Hairpin clip Safety and Instruction Decals Numerous safety and instruction decals are affixed to the Pro Sweep 5200 If any decal becomes illegible o...

Page 10: ...This page is intentionally blank Safety Page 1 6 Pro Sweep 5200...

Page 11: ...o 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 te...

Page 12: ...Rev A 0 09375 Pro Sweep 5200 Page 2 2 Product Records and Maintenance Equivalents and Conversions...

Page 13: ...er s head or similar condition which affects the installation As noted in the following tables torque values should be reduced by 25 for lubricated fasteners to achieve the similar stress as a dry fas...

Page 14: ...6 2 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...

Page 15: ...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 Product Records and Maintenance NOTE Reduce torque values listed in the table above NOTE The nominal torque...

Page 16: ...crews Thread Cutting Screws Zinc Plated Steel Zinc Plated Steel Type 1 Type 23 or Type F Thread Size Baseline Torque No 6 32 UNC 20 5 in lb No 8 32 UNC 30 5 in lb No 10 24 UNC 38 7 in lb 1 4 20 UNC 85...

Page 17: ...ush Circuit 6 Hopper Dump Lower Circuits 8 TROUBLESHOOTING 10 SERVICE AND REPAIRS 13 General Precautions for Removing and Installing Hydraulic System Components 13 Check Hydraulic Lines and Hoses 13 B...

Page 18: ...eject hydraulic fluid under high pressure Use paper or cardboard not hands penetrate the skin and cause serious injury If fluid is injected into the skin it must be surgi familiar with this type of in...

Page 19: ...f 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 bu...

Page 20: ...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...

Page 21: ...raulic Schematic Hydraulic Schematic Pro Sweep 5200 All solenoids are shown as de energized LIFT 2 7 CI REV CYLINDER CONTROL MANIFOLD BRUSH MOTOR Hydraulic System Pro Sweep 5200 Page 3 5 Hydraulic Sys...

Page 22: ...ydraulic Flow Diagrams Return Flow Brush Circuit Brush Rotating Shown LIFT CYLINDER CONTROL MANIFOLD ENERGIZED ENERGIZED 2 7 CI REV Working Pressure BRUSH MOTOR Hydraulic System Page 3 6 Pro Sweep 520...

Page 23: ...port T and the return to tank hose NOTE The hopper must be lowered for the Pro Sweep 5200 brush to operate When the brush switch is pressed to engage both the demand S2 and brush S3 solenoid valves i...

Page 24: ...Working Pressure Return Flow Hopper Dump Lower Circuits LIFT CYLINDER CONTROL MANIFOLD ENERGIZED ENERGIZED LIFT CYLINDER CONTROL MANIFOLD ENERGIZED HOPPER DUMP EXTENDING RETRACTING HOPPER LOWER BRUSH...

Page 25: ...ow to bypass the orifice in the fitting for proper lift cyl inder extension When the hopper switch is released solenoid valves S1 and S2 in the hydraulic manifold are de energized The load holding che...

Page 26: ...ng 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 ma...

Page 27: ...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 Hydraulic system on tow v...

Page 28: ...This page is intentionally blank Hydraulic System Page 3 12 Pro Sweep 5200...

Page 29: ...ydraulic 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 befor...

Page 30: ...Carriage bolt 6 used 8 Coupling assembly 9 Hydraulic hose 2 used 10 O ring 2 used 11 Hydraulic fitting 2 used 12 O ring 2 used 13 Cap screw 2 used 14 Hydraulic brush motor 15 Flat washer 6 used 16 Lo...

Page 31: ...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 In...

Page 32: ...late 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 11 3 19 18 17 16 15 13 1...

Page 33: ...Hydraulic System This page is intentionally blank Pro Sweep 5200 Page 3 17 Hydraulic System...

Page 34: ...e 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 NOTE The p...

Page 35: ...allation 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 al...

Page 36: ...old Figure 14 1 6 2 3 4 5 5 5 3 3 4 4 20 to 25 ft lb 27 to 34 N m 22 ft lb 30 N m 36 in lb 4 1 N m 22 ft lb 30 N m 22 ft lb 30 N m 22 ft lb 30 N m 36 in lb 4 1 N m 36 in lb 4 1 N m NOTE The ports on t...

Page 37: ...nternal spools can cause 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 aff...

Page 38: ...System Page 3 22 Lift Cylinder 1 Main sweeper frame 2 Lift cylinder 3 Cap screw 4 Pivot pin 5 Lock nut 6 Pitch frame 7 Hydraulic hose 8 O ring 9 Check valve fitting 10 O ring Figure 15 FRONT RIGHT 1...

Page 39: ...etain lift cylinder pivot pins item 4 to sweeper frame 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...

Page 40: ...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...

Page 41: ...rod securely in a vise by clamping vise on the pivotend 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 f...

Page 42: ...This page is intentionally blank Hydraulic System Page 3 26 Pro Sweep 5200...

Page 43: ...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 vo...

Page 44: ...n proximity switch is malfunctioning or faulty Brush relay is faulty Hopper switch or circuit wiring is faulty Logic diode is faulty Brush does not rotate Hopper is raised brush should only rotate whe...

Page 45: ...up solenoid valve coil S1 or circuit wiring is faulty Hydraulic problem exists see Chapter 3 Hydraulic System Dump hopper does not lower Fuse 20 Amp is faulty other sweeper functions affected as well...

Page 46: ...y 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...

Page 47: ...hat 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...

Page 48: ...ower 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 fu...

Page 49: ...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 1 Verify coil resistance b...

Page 50: ...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 har...

Page 51: ...h solenoid S3 ten for solenoid to switch off 2 Demand solenoid S2 4 Down solenoid S4 NOTE Prior to taking small resistance readings with a digital multimeter short the test leads together The me ter w...

Page 52: ...ion 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 t...

Page 53: ...al 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 f...

Page 54: ...This page is intentionally blank Electrical System Page 4 12 Pro Sweep 5200...

Page 55: ...CATIONS 2 GENERAL INFORMATION 2 Securing Pro Sweep 5200 to Tow Vehicle 2 SERVICE AND REPAIRS 3 Wheels 3 Wheel Bearings 4 Servicing the Brush Housing 6 Brush 8 Brush Housing 10 Roller 12 Frame Assembly...

Page 56: ...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 sweepe...

Page 57: ...ck 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 Safe...

Page 58: ...tening procedure Figure 3 1 Axle 6 Lug bolt 5 used 10 Washer 2 Grease seal 7 Outer bearing cup 11 Slotted hex nut 3 Inner bearing cone 8 Outer bearing cone 12 Cotter pin 4 Inner bearing cup 9 Lug nut...

Page 59: ...mbly 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 Insta...

Page 60: ...Pro Sweep 5200 Page 5 6 Chassis Servicing the Brush Housing 1 Saddle frame 2 Roller 3 Hydraulic brush motor 4 Brush 5 Brush housing Figure 4 2 3 1 5 4 FRONT RIGHT...

Page 61: ...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 hop...

Page 62: ...6 1 4 5 5 5 17 18 19 20 21 23 24 25 22 26 27 28 29 30 14 125 to 155 in lb 14 1 to 17 5 N m Loctite 242 Antisieze Lubricant 8 10 9 Removal Fig 5 1 Position sweeper on a level surface with dump hop per...

Page 63: ...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 viewe...

Page 64: ...Chassis Brush Housing 1 Saddle frame 2 Cap screw 3 Lock nut 4 Flange bushing 5 Pivot mount 6 Grease fitting 2 used 7 Thrust washer 8 Brush housing Figure 8 FRONT RIGHT 6 7 3 2 5 4 1 8 2 3 4 4 4 5 7 45...

Page 65: ...e removed from pivot mounts press new bushings fully into mounts 2 Place thrust washer and then pivot mount on both brush housing pins 3 Position brush housing under raised hopper 4 Slowly lower hoppe...

Page 66: ...ng 7 Locking collar 2 used 8 Set screw 2 used 9 Bearing 2 used 10 Lock nut 4 used 11 Flat washer 4 used 12 Roller adjustment plate 2 used 13 Carriage screw 4 used 14 Adjuster key 2 used 15 Carriage sc...

Page 67: ...ler 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...

Page 68: ...RIGHT 6 7 3 2 5 4 1 8 11 9 10 6 6 2 3 4 4 4 4 4 7 13 14 17 18 15 16 12 12 2 2 15 17 19 Disassembly Fig 11 1 Position sweeper on a level surface with dump hop per empty and lowered Have sweeper attache...

Page 69: ...EMATIC Electrical Schematic 3 CIRCUIT DRAWINGS Brush Circuit 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 Pr...

Page 70: ...This page is intentionally blank Electrical Diagrams Page 6 2 Pro Sweep 5200...

Page 71: ...Page 6 3 Electrical Schematic Pro Sweep 5200 Relays are shown as de energized All ground wires are black...

Page 72: ...Page 6 4 Brush Circuit Power Current Control Current Pro Sweep 5200 ENERGIZED NOT ENERGIZED HOPPER DOWN ENERGIZED ENERGIZED Indicator Current...

Page 73: ...Page 6 5 Hopper Dump Circuit Power Current Control Current Pro Sweep 5200 Indicator Current ENERGIZED ENERGIZED HOPPER RAISING NOT ENERGIZED ENERGIZED...

Page 74: ...Page 6 6 Hopper Lower Circuit Power Current Control Current Pro Sweep 5200 Indicator Current ENERGIZED HOPPER LOWERING NOT ENERGIZED NOT ENERGIZED...

Page 75: ...Page 6 7 Pro Sweep 5200 Main Wire Harness YELLOW BROWN WHITE VIOLET ORANGE BLACK GRAY BLACK BLACK GREEN PINK RED BLACK BLUE BLACK BLACK BLACK BLACK...

Page 76: ...6 8 Pro Sweep 5200 Control Box Wire Harness BLACK GRAY YELLOW GRAY YELLOW BLACK PINK WHITE PINK BROWN PINK BLACK VIOLET GREEN PINK VIOLET PINK VIOLET ORANGE YELLOW ORANGE PINK PINK BLACK YELLOW BLUE V...

Page 77: ...MAIN HARNESS VEHICLE GROUND VEHICLE POWER BLACK RED BLUE FUSIBLE LINK BRAKE CONTROL HARNESS VEHICLE GROUND MAIN HARNESS VEHICLE POWER Pro Sweep 5200 Power Wire Harness Page 6 9...

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