Service Manual

ManualsBrandsToro ManualsSweepersPro Sweep 5200 Turf Sweeper

Table Of Contents

Part No. 05137SL (Rev. A)

Service Manual

Pro Sweep 5200

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 of this

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 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 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 befollowed topre-

vent damage to systems or components on the

machine.

E Th e Toro Company -- 2005, 2009

Summary of content (77 pages)

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Part No. 05137SL (Rev. A) Service Manual Pro Sweep 5200 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 OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. Space is provided in Chapter 2 of this book to insert the Operator’s Manual and Parts Catalog for your machine.
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Chapter 2 – Product Records and Maintenance Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equivalents and Conversions . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . 2–1 2–1 2–2 2–3 Chapter 3 – Hydraulic System Chapter 5 – Chassis Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 2 General Information . . . . . . . . . . . . . .
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Safety Table of Contents SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Service . . . . . . . . . . . . . . . . . . . . JACKING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . SECURING PRO SWEEP 5200 TO TOW VEHICLE SAFETY AND INSTRUCTION DECALS . . . . . . . . . .
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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 partially are dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern and proper training of the personnel involved in the operation, transport, maintenance and storage of the machine. Improper use or maintenance of the machine can result in injury or death.
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1. Before servicing or making adjustments, empty sweeper hopper and position sweeper on a level surface. Chock sweeper wheels to prevent it from moving. If sweeper is attached to tow vehicle, engage tow vehicle parking brake, stop engine and remove key from the ignition switch. 7. If hopper is raised, install lift cylinder stop to ensure that unexpected shifting of sweeper frame does not occur. 2. Make sure machine is in safe operating condition by keeping all nuts, bolts and screws tight. 9.
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Jacking Instructions CAUTION 1 When changing tires or performing other service, 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 machine. If the machine is not properly supported by blocks or jack stands, the machine may move or fall, which may result in personal injury. 1.
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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). Safety Securing Pro Sweep 5200 to Tow Vehicle 1 2 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 or damaged, install a new decal.
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Chapter 2 Product Records and Maintenance PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . Fastener Identification . . . . . . . . . . . . . . . . . . . . . . .
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Equivalents and Conversions 0.09375 Product Records and Maintenance Page 2 -- 2 Rev.
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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 specified 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 Service Manual.
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Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series) Thread Size # 6 -- 32 UNC Grade 1, 5 & 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) in--lb in--lb N--cm 10 + 2 13 + 2 147 + 23 # 6 -- 40 UNF # 8 -- 32 UNC 13 + 2 25 + 5 282 + 30 # 8 -- 36 UNF # 10 -- 24 UNC 18 + 2 30 + 5 339 + 56 # 10 -- 32 UNF SAE Grade 5 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger N
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Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Fasteners) Class 8.8 Bolts, Screws and Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws and Studs with Regular Height Nuts (Class 10 or Stronger Nuts) M5 X 0.8 57 + 6 in–lb 644 + 68 N–cm 78 + 8 in–lb 881 + 90 N–cm M6 X 1.0 96 + 10 in–lb 1085 + 113 N–cm 133 + 14 in–lb 1503 + 158 N–cm M8 X 1.25 19 + 2 ft–lb 26 + 3 N–m 28 + 3 ft–lb 38 + 4 N–m M10 X 1.
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Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Thread Size Square Head Hex Socket 1/4 – 20 UNC 140 + 20 in–lb 73 + 12 in–lb 5/16 – 18 UNC 215 + 35 in–lb 145 + 20 in–lb 3/8 – 16 UNC 35 + 10 ft–lb 18 + 3 ft–lb 1/2 – 13 UNC 75 + 15 ft–lb 50 + 10 ft–lb 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.
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Chapter 3 Hydraulic System Table of Contents Pro Sweep 5200 Page 3 – 1 Hydraulic System 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 . . .
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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 conditions or mishandling during operation and maintenance. These conditions can cause damage or premature deterioration. Some hoses are more susceptible to these conditions than others. Inspect the hoses frequently for signs of deterioration or damage.
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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 fitting shows signs of leakage. O–Ring 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. Size 4 (1/4 in. nominal hose or tubing) 6 (3/8 in.) 8 (1/2 in.) 10 (5/8 in.) 12 (3/4 in.) 16 (1 in.) F.F.F.T. 1.
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Relieving Hydraulic System Pressure CAUTION Operate all sweeper hydraulic controls to relieve system pressure and to avoid injury from pressurized hydraulic oil. See Relieving Hydraulic System Pressure in the General Information section of this chapter. Before disconnecting or performing any 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.
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LIFT CYLINDER CONTROL MANIFOLD BRUSH MOTOR 2.
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Hydraulic Flow Diagrams LIFT CYLINDER (ENERGIZED) (ENERGIZED) CONTROL MANIFOLD BRUSH MOTOR 2.
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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.
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LIFT CYLINDER (ENERGIZED) (EXTENDING) (ENERGIZED) CONTROL MANIFOLD HOPPER DUMP BRUSH MOTOR 2.7 CI/REV LIFT CYLINDER (RETRACTING) (ENERGIZED) CONTROL MANIFOLD HOPPER LOWER BRUSH MOTOR 2.
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Hopper Dump/Lower Circuits 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.
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Troubleshooting The cause of an improperly functioning hydraulic system is best diagnosed with the use of proper testing equipment and a thorough understanding of the complete 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.
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Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components After Repair or Replacement of Components 1. Before removing any parts from the hydraulic system, empty sweeper hopper and position sweeper on a level surface. Chock sweeper wheels to prevent sweeper from moving. If sweeper is attached to tow vehicle, engage tow vehicle parking brake, stop engine and remove key from the ignition switch. 1.
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Brush Motor 1 67 to 83 ft–lb (91 to 112 N–m) 3 2 4 5 6 9 7 10 11 8 12 13 RIGHT FRONT 15 19 17 14 16 18 Figure 8 1. 2. 3. 4. 5. 6. 7. Brush housing Coupling cover (2 used) Lock washer Cap screw Lock nut (2 used) Flat washer (2 used) Carriage bolt (6 used) Hydraulic System 8. 9. 10. 11. 12. 13. Coupling assembly Hydraulic hose (2 used) O–ring (2 used) Hydraulic fitting (2 used) O–ring (2 used) Cap screw (2 used) Page 3 – 14 14. 15. 16. 17. 18. 19.
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Removal (Fig. 8) 1. Empty sweeper hopper and position sweeper on a level surface. Chock sweeper wheels to prevent sweeper from moving. If sweeper is attached to tow vehicle, engage tow vehicle parking brake, stop engine and remove key from the ignition switch. CAUTION Operate all sweeper hydraulic controls to relieve system pressure and to avoid injury from pressurized hydraulic oil. See Relieving Hydraulic System Pressure in the General Information section of this chapter. 4.
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Brush Motor Service 11 13 12 10 9 3 14 15 16 18 17 19 20 1 2 3 4 22 to 26 ft–lb (30 to 35 N–m) 5 3 6 3 7 3 8 Figure 11 1. 2. 3. 4. 5. 6. 7. Cap screw (5 used) End cover Ring seal Commutator seal Commutator and ring assembly Manifold Stator 8. 9. 10. 11. 12. 13. 14. Wear plate Drive link Coupling shaft Woodruff key Bushing Thrust bearing Thrust washer 15. 16. 17. 18. 19. 20.
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Hydraulic Control Manifold 5 1 3 RIGHT 4 FRONT 3 2 Figure 12 1. Main frame 2. Cap screw (2 used) 3. Flat washer (4 used) 4. Hydraulic control manifold 5. Lock nut (2 used) Removal (Fig. 12) 2. Relieve sweeper hydraulic system pressure. 1. Empty sweeper hopper and position sweeper on a level surface. Chock sweeper wheels to prevent sweeper from moving. If sweeper is attached to tow vehicle, engage tow vehicle parking brake, stop engine and remove key from the ignition switch.
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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. 2 7 3 3 2 6 1 8. Remove hydraulic manifold from the machine. 4 9. Remove hydraulic fittings from manifold as needed (Fig. 13). Discard any removed o–rings. 1 2. Position hydraulic manifold to the frame mounting bracket. Install cap screws, washers and lock nuts but do not fully tighten. 1 2 3 Installation (Fig.
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Hydraulic Control Manifold Service 36 in–lb (4.1 N–m) 36 in–lb (4.1 N–m) 22 ft–lb (30 N–m) 4 3 4 36 in–lb (4.1 N–m) 3 22 ft–lb (30 N–m) 4 5 22 ft–lb (30 N–m) 20 to 25 ft–lb (27 to 34 N–m) 3 2 5 1 5 22 ft–lb (30 N–m) 6 Figure 14 1. Check valve 2. Demand solenoid (S2 port) 3. Solenoid coil 4. Nut 5. Solenoid valve (S1, S3 and S4 ports) 6. Hydraulic lift control manifold NOTE: The ports on the manifold are marked for easy identification of components.
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Hydraulic Manifold Service CAUTION 1. Make sure the control manifold is clean before removing any cartridge valve. CAUTION Operate all sweeper hydraulic controls to relieve system pressure and to avoid injury from pressurized hydraulic oil. See Relieving Hydraulic System Pressure in the General Information section of this chapter. Abrupt movement of internal spools can cause stored fluid to be released suddenly. 6.
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Lift Cylinder 2 RIGHT FRONT 6 9 10 3 4 4 5 7 8 3 1 5 Figure 15 1. 2. 3. 4. Main sweeper frame Lift cylinder Cap screw Pivot pin Hydraulic System 5. Lock nut 6. Pitch frame 7. Hydraulic hose Page 3 – 22 8. O–ring 9. Check valve fitting 10.
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Removal (Fig. 15) Installation (Fig. 15) 1. Empty sweeper hopper and position sweeper on a level surface. Chock sweeper wheels to prevent sweeper from moving. If sweeper is attached to tow vehicle, engage tow vehicle parking brake, stop engine and remove key from the ignition switch. 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.
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Lift Cylinder Service 11 1 2 7 3 4 8 10 13 5 12 9 250 to 300 ft--lb (339 to 407 N--m) 6 Figure 16 1. 2. 3. 4. 5. Wear ring Seal O--ring Tube Rod 6. 7. 8. 9. O--ring Backup ring Retaining ring Head 10. 11. 12. 13. Wiper Breather plug Piston Lock nut 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.
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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 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 of the shaft. Carefully slide head assembly and piston assembly onto the rod. 4. Thread lock nut (item 13) onto rod.
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Chapter 4 Electrical System Table of Contents Electrical System ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . 1 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 2 SAFETY INTERLOCK SYSTEM . . . . . . . . . . . . . . . . 4 COMPONENT TESTING . . . . . . . . . . . . . . . . . . . . . . . 5 Brush Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Hopper Switch . . . . . . . . . . . .
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Troubleshooting CAUTION Remove all jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Disconnect the power harness from the vehicle unless the test requires battery voltage. 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.
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Problem Possible Causes Dump hopper does not raise. 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). Dump hopper does not lower.
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Safety Interlock System The safety interlock system of the Pro Sweep 5200 ensures that the brush will not rotate when the dump hopper is in the raised position. CAUTION 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 sweeper.
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Component Testing For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g. unplug the switch connector before doing a continuity check on switch). CAUTION When testing electrical components for continuity 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 demand solenoid (S2).
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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 enclosure (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.
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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.
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Fuse The Pro Sweep 5200 uses a single 20 amp fuse for circuit protection. The fuse holder is located in the wiring harness (Fig. 7). 1 Testing Remove fuse from the fuse holder for testing. Fuse should have continuity between fuse terminals. Figure 7 1. Fuse holder 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.
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Solenoid Valve Coil The hydraulic system on the Pro Sweep 5200 uses four (4) solenoid valve coils on the hydraulic control manifold (Fig. 9). 2 4 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. 3 1 2. Apply 12VDC source directly to the solenoid coil. Listen for solenoid to switch on. 3.
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Hopper Down Proximity Switch The Pro Sweep 5200 uses a proximity switch as an interlock 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 lowered). The switch is mounted on the main sweeper frame (Fig. 10). 7 3. Check the continuity of the switch by connecting a multimeter (ohms setting) across the switch connector terminals.
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Service and Repairs Solenoid Valve Coil A solenoid valve coil on the hydraulic control manifold (Fig. 12) can be replaced without opening the hydraulic system. 2 5 Removal 36 in–lb (4.1 N–m) 1. Position sweeper on a level surface with dump hopper 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. 36 in–lb (4.
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Chapter 5 Chassis Table of Contents Chassis SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . .
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Specifications Item Description Tires Size Pressure 26.5 x 14 – 12, 4 Ply, Tubeless 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). 1 2 Figure 1 1. Hitch pin Chassis Page 5 – 2 2.
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Service and Repairs Wheels 1 70 to 90 ft–lb (95 to 122 N–m) Chassis 2 RIGHT FRONT 3 4 Figure 2 1. Main frame 2. Lug nut (5 used per wheel) 3. Wheel and tire assembly 4. Wheel hub Wheel Removal (Fig. 2) Wheel Installation (Fig. 2) 1. Position sweeper on a level surface with dump hopper empty and lowered. Have sweeper attached to towing vehicle, engage vehicle parking brake, stop engine and remove key from the ignition switch. Chock sweeper wheels to prevent sweeper from moving. 1.
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Wheel Bearings 2 4 See text for tightening procedure 6 7 1 8 11 3 12 13 5 9 10 Figure 3 1. 2. 3. 4. 5. Axle Grease seal Inner bearing cone Inner bearing cup Wheel hub Chassis 6. 7. 8. 9. Lug bolt (5 used) Outer bearing cup Outer bearing cone Lug nut (5 used) Page 5 – 4 10. 11. 12. 13.
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Removal (Fig. 3) Installation (Fig. 3) 1. Position sweeper on a level surface with dump hopper empty and lowered. Have sweeper attached to towing vehicle, engage vehicle parking brake, stop engine and remove key from the ignition switch. Chock sweeper wheels to prevent sweeper from moving. 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. 2.
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Servicing the Brush Housing 1 4 5 2 RIGHT 3 FRONT Figure 4 1. Saddle frame 2. Roller Chassis 3. Hydraulic brush motor 4. Brush Page 5 – 6 5.
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To perform service on the brush housing, brush assembly or roller, the following procedure can be used. These steps will reduce the chance that brush housing components will fall or shift during the service process. 1. Position sweeper on a level surface with dump hopper empty and lowered. Have sweeper attached to towing vehicle, engage vehicle parking brake, stop engine and remove key from the ignition switch. Chock sweeper wheels to prevent sweeper from moving. 2.
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Brush 5 2 3 30 29 4 1 6 7 Antisieze Lubricant 8 13 9 1 10 11 14 26 15 28 FRONT 19 27 25 5 24 5 23 22 16 17 20 RIGHT 12 14 18 21 5 Loctite #242 125 to 155 in–lb (14.1 to 17.5 N–m) Figure 5 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Carriage screw Top rubber shield Lock nut (2 used) Top shield plate Flange nut Flat washer (2 used) Carriage bolt (3 used per bearing) Cap screw Lock washer Coupler cover (2 used) 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
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5. After raising hopper and placing lift cylinder stop, retrieve brush assembly. 8. Place coupler spider into coupling jaw on brush shaft. 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. 9. Install hydraulic brush motor to brush housing (see Hydraulic Brush Motor Installation in the Service and Repairs section of Chapter 3 – Hydraulic System).
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Brush Housing 1 2 3 45 to 55 ft–lb (61 to 75 N–m) 2 5 4 3 4 7 7 4 4 6 5 RIGHT 8 FRONT Figure 8 1. Saddle frame 2. Cap screw 3. Lock nut Chassis 4. Flange bushing 5. Pivot mount 6. Grease fitting (2 used) Page 5 – 10 7. Thrust washer 8.
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Removal (Fig. 8) 1. Position sweeper on a level surface with dump hopper empty and lowered. Have sweeper attached to towing vehicle, engage vehicle parking brake, stop engine and remove key from the ignition switch. Chock sweeper wheels to prevent sweeper from moving. 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). 3. Support brush housing to prevent it from shifting. 6.
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Roller ANTISIEZE LUBRICANT ANTISIEZE LUBRICANT 1 2 15 3 2 14 5 5 6 RIGHT 4 5 7 13 8 12 FRONT 11 LOCTITE #242 9 10 125 to 155 in–lb (14.1 to 17.5 N–m) Figure 10 1. 2. 3. 4. 5. Roller scraper Carriage screw (8 used) Roller Brush housing Flange nut (10 used) Chassis 6. 7. 8. 9. 10. Bearing flange (2 used per bearing) Locking collar (2 used) Set screw (2 used) Bearing (2 used) Lock nut (4 used) Page 5 – 12 11. 12. 13. 14. 15.
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Removal (Fig. 10) Installation (Fig. 10) 1. Position sweeper on a level surface with dump hopper empty and lowered. Have sweeper attached to towing vehicle, engage vehicle parking brake, stop engine and remove key from the ignition switch. Chock sweeper wheels to prevent sweeper from moving. 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.
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Frame Assembly 4 18 RIGHT 12 19 17 2 6 4 16 FRONT 4 14 17 12 15 15 6 2 3 3 2 2 1 4 13 4 4 5 11 8 10 9 6 7 7 Figure 11 1. 2. 3. 4. 5. 6. 7. Main frame Cap screw Pivot pin Lock nut Pitch frame Grease fitting Cap screw 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. Pivot pin Tow hook plate Pivot saddle Carriage bolt Pivot pin Lock nut Saddle frame Cap screw Lift cylinder Lock nut Link Hardened spacer (2 used) Disassembly (Fig. 11) Assembly (Fig. 11) 1.
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Chapter 6 Electrical Diagrams Table of Contents 3 4 5 6 7 8 9 Electrical Diagrams ELECTRICAL SCHEMATIC Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DRAWINGS Brush Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hopper Dump Circuit . . . . . . . . . . . . . . . . . . . . . . . . Hopper Lower Circuit . . . . . . . . . . . . . . . . . . . . . . . . WIRE HARNESS DRAWINGS Main Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . . .
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Pro Sweep 5200 Electrical Schematic Relays are shown as de–energized All ground wires are black.
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(HOPPER DOWN) (ENERGIZED) (ENERGIZED) (NOT ENERGIZED) (ENERGIZED) Pro Sweep 5200 Brush Circuit Power Current Control Current Indicator Current Page 6 – 4
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(HOPPER RAISING) (NOT ENERGIZED) (ENERGIZED) (ENERGIZED) (ENERGIZED) Pro Sweep 5200 Hopper Dump Circuit Power Current Control Current Indicator Current Page 6 – 5
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(HOPPER LOWERING) (NOT ENERGIZED) (NOT ENERGIZED) (ENERGIZED) Pro Sweep 5200 Hopper Lower Circuit Power Current Control Current Indicator Current Page 6 – 6
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GREEN ORANGE BROWN VIOLET WHITE BLACK RED PINK YELLOW GRAY BLACK BLACK BLACK BLACK BLACK BLACK BLUE BLACK Pro Sweep 5200 Main Wire Harness Page 6 – 7
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GRAY YELLOW VIOLET PINK PINK VIOLET PINK YELLOW ORANGE BLACK PINK YELLOW WHITE BLACK PINK PINK BLACK BLUE PINK BROWN GRAY YELLOW BLACK GREEN VIOLET ORANGE VIOLET Pro Sweep 5200 Control Box Wire Harness Page 6 – 8
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VEHICLE GROUND MAIN HARNESS VEHICLE POWER MAIN HARNESS BLUE BRAKE CONTROL HARNESS BLACK VEHICLE GROUND RED FUSIBLE LINK VEHICLE POWER Pro Sweep 5200 Power Wire Harness Page 6 – 9