Toro 7066 User Manual

Preface

The purpose of this publication is to provide the service technician with information for troubleshooting, testing andrepairof major systemsandcomponents on thePro Sweep (Model 07066).

REFER TOTHE OPERATOR’SMANUAL FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. Spaceis providedin Chapter 2of this book to insert the Operator’s Manualand Parts Catalog for your machine. Additional copies of the Operator’s Manual and Parts Catalog are available on the internet at www.Toro.com.

TheToroCompany reservesthe rightto change product specifications or this publication without notice.

Part No. 10179SL

Service Manual

(Model 07066)

Pro Sweep

This safety symbol means DANGER, WARNING, or CAUTION, PERSONAL SAFETY INSTRUCTION. When you see this symbol, carefully read the instructions that follow. Failure to obey the instructions may result in personal injury.

NOTE: ANOTE willgive general information about the

correct operation, maintenance, service, testing or repair of the machine.

IMPORTANT: The IMPORTANT notice will give im portantinstructionswhichmustbefollowedtoprevent damage to systems or components on the machine.

E The Toro Company -- 2011

This page is intentionally blank.

Pro Sweep

Chapter 1 -- Safety

Safety Instructions 1 -- 2..........................

Jacking Instructions 1 -- 4.........................

Securing Pro Sweep to Tow Vehicle 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 3 -- 2........................

Hydraulic Schematic 3 -- 7........................

Hydraulic Flow Diagrams 3 -- 8....................

Troubleshooting 3 -- 16...........................

Service and Repairs 3 -- 22.......................

PARKER TORQLINK

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 Diagrams

Electrical Schematic 6 -- 3........................

Circuit Drawings 6 -- 4............................

Wire Harness Drawings 6 -- 11....................

SafetyProduct Records

and Maintenance

System

Hydraulic

SystemDiagrams

Electrical

Chassis

Electrical

Pro Sweep

This page is intentionally blank.

Pro Sweep

Chapter 1

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

Pro Sweep Page 1 -- 1 Safety

Safety Instructions

The Pro Sweep is designed and tested tooffer 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 maintenanceof themachine canresult ininjury or death. To reduce the potential for injury or death, comply with the following safety instructions.

Before Op erating

WARNING

To reduce the potential for injury or death, complywith the following safetyinstructions.

1. Read and understand the contents of the Operator’s Manual before operating the machine. Become 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 inplace. If a shield, safety device or decal is defective, illegible or damaged, repair or replace it before operating the machine.

3. Make sure that any loose nuts, bolts or screws are tightened toensurethat themachine is insafeoperating 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 isproperly positioned intow vehicle and sweeper. Hitch pin should be secured with hairpin clip.

4. Make sure that the tow vehicle is carefully selected to assure the best performance and safe operation of the Pro Sweep.

5. Assuresweeper interlocksystem functionscorrectly 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.

6. While operating, the Pro Sweep may exceed noise levels of 85dB(A) at the operator position. Hearing protection is recommended for prolonged exposure to reduce the potential of permanent hearing damage.

7. Before leaving the operator’s position of the tow vehicle:

3. Donotrun tow vehicleengineinaconfinedareawithout adequateventilation. Exhaust fumes arehazardous 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

Page 1 -- 2

A. Stop sweeper brush by shutting off vehicle hydraulic flow to the sweeper.

B. Make sure that dump hopper is lowered. C. Ensure that vehicletractionleverisin neutral,ap-

ply parking brake, stop engine and remove key from ignition switch.

8. Position sweeper on level surface, empty hopper and chock sweeper wheels before disconnecting Pro Sweep from tow vehicle.

Pro Sweep

Maintenance and Service

1. Before servicing or making adjustments, empty Pro Sweep hopper and position sweeper on alevel surface. Chock sweeper wheels to prevent it from moving. If sweeper is attached to tow vehicle, apply tow vehicle 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 before applying pressure to the hydraulic system.

4. Keepbodyandhands away frompinholeleaksinhydrauliclines that ejecthigh 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 performing any work on the hydraulic system, all pressureinsystem mustbe relieved.See RelievingHydraulic 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.

7. If hopper is raised, install hopper safety support on lift cylinderto ensure that unexpectedshifting of sweeper frame does not occur.

Safety

8. Disconnect electrical power harness from tow vehicle before servicing the sweeper.

9. If major repairs areever needed or assistance isdesired, 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 accessories. Replacement parts and accessories made by other manufacturers may result in non-conformance with the safety standards, and the warranty may be voided.

1 1.When changing tires or performing other service, use correct hoists and jacks. Make sure machine is parked on a solid level surface such as a concrete floor with the hopper empty and lowered. Have sweeper attached to towing vehicle, apply vehicle parking brake, stop engine andremove key from theignition switch. Always chock or block wheels. Use appropriate jack stands to support the raised machine. If the machine is not properly supported by appropriate jack stands, the machine may moveor fall, which may result in personal injury (see Jacking Instructions in this chapter).

Pro Sweep Page 1 -- 3 Safety

Jacking Instructions

CAUTION

When changing tires or performing other service, use correct hoists and jacks to support sweeper.Make suremachineis parked on a solid level surface such asaconcrete floor.Always chock or block wheels. Use appropriate jack standsto supportthe raisedmachine.If themachine is not properlysupported by appropriate jack stands, the machine may move or fall, which may result in personal injury.

1. Position sweeper on a level surface with dump hopper empty and lowered. Have sweeper attached totowing vehicle, apply vehicle parking brake, stop engine and remove key from the ignition switch. Chock sweeper wheels to prevent it from moving.

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 appropriate jack stands under the main frame to support the sweeper.

Figure 1

1. Wheel 2. Frame jacking point

Safety

Page 1 -- 4

Pro Sweep

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. 2).

1. Hitch pin 2. Hairpin clip

Safety and Instruction Decals

Safety

Figure 2

Numerous safety and instruction decals are affixed to the Pro Sweep. If any decal becomes illegible or damaged,install anew decal. Part numbersfor replacement decals are listed in your Parts Catalog. Order replacement decals from your Authorized Toro Distributor.

Pro Sweep Page 1 -- 5 Safety

This page is intentionally blank.

Safety

Page 1 -- 6

Pro Sweep

Product Records and Maintenance

Table of Contents

PRODUCT RECORDS 1.........................

MAINTENANCE 1...............................

EQUIVALENTS AND CONVERSIONS 2...........

Decimal and Millimeter Equivalents 2............

U.S. to Metric Conversions 2...................

TORQUE SPECIFICATIONS 3....................

Fastener Identification 3.......................

Using a Torque Wrench with an Offset Wrench 3..

Standard Torque for Dry, Zinc Plated and

Steel Fasteners (Inch Series) 4...............

Standard Torque for Dry, Zinc Plated and

Steel Fasteners (Metric Fasteners) 5...........

Other Torque Specifications 6..................

Conversion Factors 6..........................

Chapter 2

Product Records

and Maintenance

Product Records

InsertOperator’sManualandPartsCatalogforyourPro Sweep at the end of this chapter.Additionally,if any optional equipment or accessories have been installed to your machine, insert the Installation Instructions, Operator’s Manuals and Parts Catalogs for those options at the end of this chapter.

Maintenance

Maintenanceproceduresandrecommendedserviceintervals for the Pro Sweep are covered inthe Operator’s Manual.Refertothatpublicationwhenperformingregular equipment maintenance.

Pro Sweep Page 2 -- 1 Product Records and Maintenance

Equivalents and Conversions

0.09375

Product Records and Maintenance

Page 2 -- 2

Pro Sweep

Torque Specifications

Recommended fastener torque values are listed in the followingtables. For criticalapplications,as determined byToro,eithertherecommendedtorqueor a torque that is unique to theapplication is clearly identified andspecified in this Service Manual.

These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which donot havea specific requirementidentified inthisService 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 onthe fastener,presence of aprevailing torquefeature, hardnessofthe surface underneath thefastener’shead or similar condition which affects the installation.

Fastener Identification

Asnotedinthefollowingtables,torquevaluesshouldbe 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 engagement, etc.

The standard method of verifying torque shall be performed by marking a line on the fastener (head or nut) and mating part, then back off fastener 1/4 of a turn. Measurethetorque required totightenthefastener until the lines match up.

Product Records

and Maintenance

Grade 1 Grade 5 Grade 8

Inch Series Bolts and Screws

Figure 1

Using a Torque Wrench with an Offset Wrench

Useofan offsetwrench(e.g.crowfootwrench) willaffect torquewrench calibrationdue to theeffectivechange of torquewrenchlength. When using atorquewrenchwith an offset wrench, multiply the listed torque recommendation by the calculated torque conversion factor (Fig.

3) to determine proper tightening torque. Tightening torque when using a torque wrench with an offset wrench will be lower than the listed torque recommendation.

Example: The measured effective length of the torque wrench (distance from the center of the handle to the center of the square drive) is 18”.

Themeasuredeffectivelengthofthetorquewrenchwith the offset wrench installed (distance from the center of the handle to the center of the offset wrench) is 19”.

Class 8.8 Class 10.9

Metric Bolts and Screws

Figure 2

If the listed torque recommendation for a fastener is from 76 to 94 ft--lb, the proper torque when using this torque wrench with an offset wrench would be from 72 to 89 ft--lb.

(effective length of

torque wrench)

(effective l ength of torque

wrench + offset wrench)

TORQUE CONVERSION FACTOR = A / B

Torque wrenchOffset wrench

The calculated torque conversion factor for this torque wrenchwith this offsetwrenchwould be 18/19 = 0.947.

Pro Sweep Page 2 -- 3 Product Records and Maintenance

Figure 3

Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series)

Thread Size

# 6 -- 32 UNC

# 6 -- 40 UNF

# 8 -- 32 UNC

# 8 -- 36 UNF

#10--24UNC

#10--32UNF

1/4 -- 20 UNC 48 + 7 53 + 7 599 + 79 100 + 10 1130 + 113 140 + 15 1582 + 169

1/4 -- 28 UNF 53 + 7 65 + 10 734 + 113 115 + 12 1299 + 136 160 + 17 1808 + 192

5/16 -- 18 UNC 115 + 15 105 + 15 1186 + 169 200 + 25 2260 + 282 300 + 30 3390 + 339

5/16 -- 24 UNF 138 + 17 128 + 17 1446 + 192 225 + 25 2542 + 282 325 + 33 3672 + 373

3/8 -- 16 UNC 16 + 2 16 + 2 22 + 3 30 + 3 41 + 4 43 + 5 58 + 7

Grade 1, 5 &

8withThin

Height Nuts

in--lb in--lb N--cm in--lb N--cm in--lb N-- cm

10 + 2 13 + 2 147 + 23

13 + 2 25 + 5 282 + 30

18 + 2 30 + 5 339 + 56

ft--lb ft--lb N--m ft--lb N--m ft--lb N--m

SAE Grade 1 Bolts, Screws, Studs &

Sems with Regular Height Nuts

(SAE J995 Grade 2 or Stronger Nuts)

SAE Grade 5 Bolts, Screws, Studs &

Sems with Regular Height Nuts

(SAE J995 Grade 2 or Stronger Nuts)

15 + 2 169 + 23 23 + 3 262 + 34

17 + 2 192 + 23 25 + 3 282 + 34

29 + 3 328 + 34 41 + 5 463 + 56

31 + 4 350 + 45 43 + 5 486 + 56

42 + 5 475 + 56 60 + 6 678 + 68

48 + 5 542 + 56 68 + 7 768 + 79

SAE Grade 8 Bolts, Screws, Studs &

Sems with Regular Height Nuts

(SAE J995 Grade 5 or Stronger Nuts)

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 + 12 140 + 20 190 + 27 265 + 27 359 + 37 375 + 38 508 + 52

3/4 -- 16 UNF 115 + 15 165 + 25 224 + 34 300 + 30 407 + 41 420 + 43 569 + 58

7/8 -- 9 UNC 140 + 20 225 + 25 305 + 34 430 + 45 583 + 61 600 + 60 813 + 81

7/8 -- 14 UNF 155 + 25 260 + 30 353 + 41 475 + 48 644 + 65 667 + 66 904 + 89

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: The nominal torque values listed above for Grade 5and 8 fasteners are based on 75% of the minimumproof loadspecified in SAEJ429. The toleranceis approximately +

10% of the nominal torque value. Thin

height nuts include jam nuts.

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

Page 2 -- 4

Pro Sweep

Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Fasteners)

Class 8.8 Bolts, Screws and Studs with

Thread Size 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 + 6in--lb 644 + 68 N--cm 78 + 8in--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 + 2ft--lb 26 + 3N--m 28 + 3ft--lb 38 + 4N--m M10 X 1.5 38 + 4ft--lb 52 + 5N--m 54 + 6ft--lb 73 + 8N--m

M12 X 1.75 66 + 7ft--lb 90 + 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: The nominal torque values listed above are based on 75% of the minimum proof load specified in SAEJ1199.Thetoleranceis approximately + nominal torque value.

10%ofthe

Product Records

and Maintenance

Pro Sweep Page 2 -- 5 Product Records and Maintenance

Other Torque Specifications

SAE Grade 8 Steel Set Screws

Recommended Torque

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 + 3ft--lb 1/2 -- 13 UNC 75 + 15 ft--lb 50 + 10 ft--lb

Thread Cutting Screws

(Zinc Plated Steel)

Type 1, Type 23 or Type F

Thread Size Baseline Torque*

No. 6 -- 32 UNC 20 + 5in--lb

Wheel Bolts and Lug Nuts

Thread Size

7/16 -- 20 UNF

Grade 5

1/2 -- 20 UNF

Grade 5

M12 X 1.25

Class 8.8

M12 X 1.5

Class 8.8

** For steel wheels and non--lubricated fasteners.

Thread Cutting Screws

(Zinc Plated Steel)

Thread

Size

No. 6 18 20 20 + 5in--lb

Threads per Inch Type A Type B

Recommended Torque**

65 + 10 ft--lb 88 + 14 N--m

80 + 10 ft--lb 108 + 14 N--m

Baseline Torque

No. 8 -- 32 UNC 30 + 5in--lb

No. 10 -- 24 UNC 38+ 7in--lb

1/4 -- 20 UNC 85 + 15 in--lb

5/16 -- 18 UNC 110 + 20 in--lb

3/8 -- 16 UNC 200 + 100 in--lb

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--lb

No. 8 15 18 30 + 5in--lb No. 10 12 16 38 + 7in--lb No. 12 11 14 85 + 15 in--lb

*Holesize,material strength,materialthickness&finish must be considered when determining specific torque values. All torque values are based on non--lubricated fasteners.

Product Records and Maintenance

Page 2 -- 6

Pro Sweep

Table of Contents

GENERAL INFORMATION 2.....................

Operator’s Manual 2..........................

Hydraulic Hoses 2............................

Hydraulic Hose and Tube Installation 3..........

Hydraulic Fitting Installation 4...................

Relieving Hydraulic System Pressure 6..........

Securing Pro Sweep to Tow Vehicle 6...........

HYDRAULIC SCHEMATIC 7.....................

HYDRAULIC FLOW 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...............................

Lift Cylinder Service 34........................

Offset Cylinder 36.............................

Offset Cylinder Service 38......................

PARKER TORQLINK

SERVICE PROCEDURE

Chapter 3

Hydraulic System

System

Hydraulic

Pro Sweep Hydraulic SystemPage 3 -- 1

General Information

Operator’s Manual

The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervalsforyourProSweepmachine.Refertothatpublication for additional information when servicing the machine.

Hydraulic Hoses

Hydraulichoses aresubject to extremeconditions such aspressure differentials during operationandexposure to weather, sun, chemicals, very warm storage conditionsormishandlingduringoperationandmaintenance. These conditions can cause hose damageand deterioration. Some hoses are more susceptible to these conditions than others. Inspect all machine hydraulic hoses frequently for signs of deterioration or damage:

WARNING

Beforedisconnecting or performinganywork on hydraulic system, relieve all pressure in system (seeRelieving Hydraulic SystemPressurein this section).

Hard, cracked, cut, abraded, charred, leaking or otherwise damaged hose.

Kinked, crushed, flattened or twisted hose. Blistered, soft, degraded or loose hose cover. Cracked, damaged or badly corroded hose fittings.

When replacing a hydraulic hose, besure that the 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 section). If the hose has an elbow at one end, tighten the swivel nut on that end before tightening the nut on the straight end of the hose.

For additional hydraulic hose information, refer to Toro Service Training Book, Hydraulic Hose Servicing (Part Number 94813SL).

Keepbodyand handsawayfrompinhole leaksor 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 surgically removed within a few hours by a doctor familiar withthistypeofinjury.Gangrenemayresultfrom such an injury.

Pro SweepHydraulic System Page 3 -- 2

Hydraulic Hose and Tube Installation (O--Ring Face Seal Fitting)

1. Makesurethreads and sealingsurfacesofthe hose/ tube and the fittingare free of burrs, nicks,scratches or any foreign material.

2. Asa preventative measureagainstleakage,itis recommended that the face seal O--ring be replaced any time the connection is opened. Make sure the O--ring is installedandproperlyseatedinthefittinggroove.Lightly lubricate the O--ring with clean hydraulic oil.

3. Place the hose/tube against the fitting body so that theflatfaceofthe hose/tubesleevefullycontactstheO-ring in the fitting.

4. Thread theswivel nut onto the fitting by hand. While holding the hose/tube with a wrench, use a torque wrench to tighten the swivel nut to the recommended installation torque shown in Figure 3. 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 torque when usingatorquewrenchwithanoffsetwrenchwillbelower than the listed installation torque (see Using a Torque Wrench with an Offset Wrenchin the Torque Specificationssection ofChapter 2 -- ProductRecords and Maintenance).

C. Useasecond wrench to tighten the nut to the c orrect Flats From Wrench Resistance (F.F.W.R.). The markingsonthenutandfittingbodywillverifythatthe connection has been properly tightened.

Size F.F.W.R.

4 (1/4 in. nominal hose or tubing) 1/2 to 3/4 6 (3/8 in.) 1/2to 3/4 8 (1/2 in.) 1/2to 3/4 10 (5/8 in.) 1/2 to 3/4 12 (3/4 in.) 1/3 to 1/2 16 (1 in.) 1/3 to 1/2

Swivel Nut

Tube or Hose

O--ring

Fitting Body

Figure 1

System

Hydraulic

5. If a torque wrench is not available or if space at the swivelnutpreventsuse of a torquewrench,analternate method of assembly is the Flats From Wrench Resistance (F.F.W.R.) method (Fig. 2).

Mark Nut

and Fitting

Body

Final

Position

A. Usingawrench,tightentheswivelnutontothefittinguntillightwrenchresistanceis reached(approxi-

Extend Line

mately 30 in--lb). B. Mark the swivel nut and fitting body. Hold the

hose/tube with a wrench to prevent it from turning.

AT WRENCH RESISTANCE

Figure 2

Fitting Dash Size Hose/Tube Side Thread Size Installation Torque

4 9/16 -- 18 18to22ft--lb(25to29N--m) 6 11/16 - - 16 27to33ft--lb(37to44N--m)

8 13/16 -- 16 37to47ft--lb(51to63N--m) 10 1--14 60 to 74 ft--lb (82 to 100 N--m) 12 13/16--12 85 to 105 ft--lb (116 to 142 N--m)

Initial Position

AFTER TIGHTENING

16 17/16--12 110 to 136 ft--lb (150 to 184 N--m) 20 1 11/16 -- 12 140 to 172 ft--lb (190 to 233 N--m)

Figure 3

Pro Sweep Hydraulic SystemPage 3 -- 3

Hydraulic Fitting Installation (SAE Straight Thread O--Ring Fitting into Component Port)

Non--Adjustable Fitting (Fig. 4)

1. Make sure all threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material.

2. Asa preventative measureagainstleakage,itis recommended that the O--ring be replaced any time the connection is opened.

3. Lightly lubricate the O--ring with clean hydraulic oil. Fittingthreadsshouldbe clean withnolubricantapplied.

IMPORTANT: Before installing fitting into port, determine port material. If fitting is to be installed into an aluminum port, installation torque is reduced.

4. Install the fitting into the port. Then, use a torque wrench and socket to tighten the fitting to the recommended installation torque shown in Figure 5.

NOTE: Useof an offsetwrench (e.g. crowfoot wrench) will affecttorque wrench calibration due to the effective length change of the torque wrench. Tightening torque when using a torque wrench with an offset wrench will be less than the recommended installation torque. See Using a Torque Wrench with an Offset Wrench in the Torque Specifications section of Chapter 2 -- Product RecordsandMaintenancetodeterminenecessaryconversion information.

5. If a torque wrench is not available, or if space at the portpreventsuseofatorquewrench, an alternate method 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 port material is aluminum, tighten fitting to 60% of listed F.F.F.T.

Size F.F.F.T.

4 (1/4 in. nominal hose or tubing) 1.00 + 6(3/8in.) 1.50+ 8(1/2in.) 1.50+ 10 (5/8 in.) 1.50 + 12 (3/4 in.) 1.50 + 16 (1 in.) 1.50 +

Fitting

O--ring

0.25

Figure 4

Fitting

Dash Size

Fitting Port Side

Thread Size

Installation Torque Into

Steel Port

Installation Torque Into

Aluminum Port

4 7/16 -- 20 15to19ft--lb(21to25N--m) 9to11ft--lb(13to15N--m) 5 1/2 -- 20 18to22ft--lb(25to29N--m) 11to15ft--lb(15to20N--m) 6 9/16 -- 18 34to42ft--lb(47to56N--m) 20to26ft--lb(28to35N--m)

8 3/4 -- 16 58to72ft--lb(79to97N--m) 35to43ft--lb(48to58N--m) 10 7/8 -- 14 99 to 121 ft--lb (135 to 164 N--m) 60 to 74 ft--lb (82 to 100 N--m) 12 11/16--12 134 to 164 ft--lb (182 to 222 N--m) 81 to 99 ft--lb (110 to 134 N--m) 14 13/16--12 160 to 196 ft--lb (217 to 265 N--m) 96 to 118 ft--lb (131 to 160 N--m) 16 15/16--12 202 to 248 ft--lb (274 to 336 N--m) 121 to 149 ft--lb (165 to 202 N--m) 20 15/8--12 247 to 303 ft--lb (335 to 410 N--m) 149 to 183 ft--lb (202 to 248 N--m)

Figure 5

Pro SweepHydraulic System Page 3 -- 4

Adjustable Fitting (Fig. 6)

1. Make sure all threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material.

2. Asa preventative measureagainstleakage,itis recommended that the O--ring be replaced any time the connection is opened.

3. Lightly lubricate the O--ring with clean hydraulic oil. Fittingthreadsshouldbe clean withnolubricantapplied.

4. Turnback thelock nutas far as possible. Make sure the back up washer is notloose andis pushedup asfar as possible (Step 1 in Figure 7).

IMPORTANT: Before installing fitting into port, determine port material. If fitting is to be installed into an aluminum port, installation torque is reduced.

Lock Nut

Back--up Washer

O--ring

Figure 6

5. Install the fitting into the port and tighten finger tight until the washer contacts the face of the port (Step 2 in Figure 7). Make sure that the fitting does not bottom in the port during installation.

6. To putthefittingin the desiredposition,unscrewitby the required amount to align fitting with incoming hose or tube, but no more than one full turn (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 affecttorque wrench calibration due to the effective length change of the torque wrench. Tightening torque when using a torque wrench with an offset wrench will be lower than the listed installation torque (see Using a Torque Wrench with an Offset Wrench in the Torque Specifications section of Chapter 2 -- Product Records and Maintenance).

8. If a torque wrench is not available, or if space at the portpreventsuseofatorquewrench, an alternate method of assembly is the Flats From Finger Tight (F.F.F.T.) method. Hold the fitting in the desired position with a wrench and,if port material is steel, tighten thelock nut witha secondwrench to thelisted F.F.F.T (Step4 inFigure7). If portmaterial is aluminum,tighten fitting to60% of listed F.F.F.T .

Step 3Step 1

Step 2 Step 4

Figure 7

System

Hydraulic

Size F.F.F.T.

4 (1/4 in. nominal hose or tubing) 1.00 + 6(3/8in.) 1.50+ 8(1/2in.) 1.50+ 10 (5/8 in.) 1.50 + 12 (3/4 in.) 1.50 + 16 (1 in.) 1.50 +

0.25

Pro Sweep Hydraulic SystemPage 3 -- 5

Relieving Hydraulic System Pressure

CAUTION

Before disconnecting any hydraulic components, operate all sweeper hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil.

Beforedisconnectingorperformingany work on thePro Sweep hydraulic system, all pressure in the hydraulic system must be relieved. Position sweeper on a level surfacewithdumphopperemptyandfullylowered. Turn tow vehicle key switchto OFFand allowengine tostop.

Securing Pro Sweep to Tow Vehicle

Whileservicingthe Pro Sweep, makesurethatthehitch pin is properly positioned in tow vehicle hitch and sweeper tongue (Fig. 8). Hitch pin should be secured with hairpin clip.

Make sure that the sweeper has electrical power and thatsweeper controlmodule isenergized (controlmodule Time Out and Power LED’s are both illuminated). Withthetowvehicleenginenotrunning,pressallremote transmitter buttons to energizethe solenoids on the hydraulic control manifold. After all functions have been energized,makesuretowvehiclekey switch is OFF and key is removed from ignition switch.

Figure 8

1. Hitch pin 2. Hairpin clip

Pro SweepHydraulic System Page 3 -- 6

Hydraulic Schematic

OFFSET

CYLINDER

LIFT CYLINDER

CONTROL

MANIFOLD

System

Hydraulic

Pro Sweep Hydraulic SystemPage 3 -- 7

Pro Sweep

Hydraulic Schematic

All solenoids are shown as de--energized

Hydraulic Flow Diagrams

OFFSET

CYLINDER

LIFT CYLINDER

CONTROL

MANIFOLD

(ENERGIZED)

(ROTATING)

Brush Circuit

Brush Rotating Shown

Working Pressure Return

Flow

Pro SweepHydraulic System Page 3 -- 8

Brush Circuit

NOTE: Hydraulic flow and relief pressure for the Pro

Sweep are determined by the tow vehicle. When the tow vehicle hydraulics are engaged for the

sweeper,hydraulic flowfromthe tow vehiclegoesto the sweeper control manifold (port P) throughthe hydraulic inlet hose. If the sweeper brush motor is not engaged (sweeper is raised above the transport height) and the lift and offset cylinders are stationary, hydraulic flow from the tow vehicle is directed by the control manifold pressure compensator valve EC and the de--energized solenoid valve SRV to return to the tow vehicle through control manifold port T and the return to tank hose (Fig.

9).

Brush Engage

OFFSET

CYLINDER

LIFT CYLINDER

CONTROL MANIFOLD

When the sweeper is below the transport height, solenoidvalveSRVin the hydrauliccontrolmanifoldis energized. In this sweeperposition, energized SRV shifts to preventhydraulicflowreturntothetowvehiclewhenthe towvehiclehydraulicsareengaged.Hydraulicflowfrom 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 brush motor is routed to control manifold port M2, out control manifold port T and returns to the tow vehicle.

During sweeper brush operation, solenoid valve SRV also functions as a circuit relief valve. If brush circuit pressure reaches 2500 PSI (172 bar), SRV will shift to reduce circuit pressure.

Brush Disengage

The brush can be disengaged either by shutting off hydraulicflowfromthetowvehicleorbyraisingthesweeper to the transport position.

(DE--ENERGIZED)

Figure 9

System

Hydraulic

Pro Sweep Hydraulic SystemPage 3 -- 9

OFFSET

CYLINDER

LIFT CYLINDER (EXTENDING)

CONTROL

MANIFOLD

(DE--ENERGIZED)

ENERGIZED)

(DE--

(ENERGIZED)

Sweeper Raise/Hopper Dump Circuits

Working Pressure Return Flow

Pro SweepHydraulic System Page 3 -- 10

Sweeper Raise/Hopper Dump Circuits

NOTE: Hydraulic flow and relief pressure to the Pro

Sweep are determined by the tow vehicle. When the tow vehicle hydraulics are engaged for the

10).

Sweeper Raise

OFFSET

CYLINDER

LIFT CYLINDER

CONTROL MANIFOLD

When the tow vehicle hydraulics are engaged and the remote transmitter sweeper up button is pressed and held, solenoid valve SV3 in the hydraulic control manifold is energized. The valve shift of SV3 directs oil flow past the check valve in de--energized valve SV2, out of control manifold port Cand to the lift cylinder. Hydraulic pressure against the lift cylinder piston extends the cylinder to raise the hopper. The check valve fitting attached 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 valveRVfunctionsasacircuitrelief valve. If circuit pressure reaches 2000 PSI (138 bar) while the sweeper is being raised, RV will shift to reduce circuit pressure.

When the transmitter sweeper up button is released or whenthesweepergets to transport(sweepernotoffset) orturn around (sweeperisoffset)height, solenoidvalve SV3inthehydraulic manifold isde--energized, stopping the raise function. The check valve in de--energized valve SV2 prevents oil flow from the lift cylinder so the sweeper remains in the raised position.

Hopper Dump

(DE--ENERGIZED)

Figure 10

System

Hydraulic

Ifthesweeper is inthetransportheightposition (sweeper not offset), the remote transmitter dump sequence is entered and then the hopper dump button is pressed andheld,thesweeperhopperwillfullyraisetoemptythe hopper. Control manifold solenoid valve SV3 is energized to allow oil flow to the lift cylinder. De--energized valveSV2andreliefvalveRVfunction thesametodump the hopper as during the sweeper raise function.

Pro Sweep Hydraulic SystemPage 3 -- 11

OFFSET

CYLINDER

LIFT CYLINDER (RETRACTING)

CONTROL

MANIFOLD

(ENERGIZED)

ENERGIZED)

(DE--

(DE-ENERGIZED)

Sweeper Lower Circuits

Working Pressure Return

Flow

Pro SweepHydraulic System Page 3 -- 12

Sweeper Lower Circuits

NOTE: Hydraulic flow and relief pressure to the Pro

Sweep are determined by the tow vehicle. When the tow vehicle hydraulics are engaged for the

11).

Sweeper Lower

OFFSET

CYLINDER

LIFT CYLINDER

CONTROL MANIFOLD

When the remote transmitter sweeper down button is pressed, solenoid valve SV2 in the hydraulic control manifold is energized. The 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 orificein the lift cylinder check valve fitting restricts oilflow fromthe cylinderto controllift cylinder retraction speed.

While lowering, if the remote transmitter sweeper up or stopbutton are pressed,solenoidvalve SV2 willde--energize and oil flow from the lift cylinder will cease. The sweeper will stop lowering and remain in position.

As the sweeper is being lowered, relief valve RV functions as a circuit relief valve. If circuit pressure reaches 2000 PSI (138 bar), RV will shift to reduce circuit pressure.

Sweeper Float

After the sweeper has been fully lowered to the ground, solenoid valve SV2 will continue to be energized. The shifted valve will allow lift cylinder and sweeper movement so the sweeper head can follow ground surface contours.

(DE--ENERGIZED)

Figure 11

System

Hydraulic

Pro Sweep Hydraulic SystemPage 3 -- 13

OFFSET

CYLINDER

(EXTENDING)

LIFT CYLINDER

CONTROL

MANIFOLD

(SHIFTED)

(LOWER COIL

ENERGIZED

FORRHOFFSET)

Sweeper Offset Circuits

(Offset to Right Shown)

Working Pressure Return Flow

Pro SweepHydraulic System Page 3 -- 14

Sweeper Offset Circuits

NOTE: Hydraulic flow and relief pressure to the Pro

Sweep are determined by the tow vehicle. When the tow vehicle hydraulics are engaged for the

12).

Offset Right

When the remote transmitter offset right button is pressed and held, the lower coil for solenoid valve SV1 inthe hydrauliccontrol manifoldwill beenergized. If the towvehiclehydraulics are engagedforthesweeper,the shifted SV1 allows a path foroil flowto the barrel end of the offset cylinder.

Oil flow through shifted SV1 is directed through the checkvalve in counterbalancevalve CB2,outof control manifold port R and to the barrel end of the offsetcylinder. As circuit pressure increases, a manifold sensing line shifts counterbalance cartridge CB1 to allow a return path for oil from the rod end of the offset cylinder. The offset cylinder will extend to cause the sweeper to offsettothe right.Oilfrom therodend oftheoffset cylinder returns to the tow vehicle through shifted SV1, control manifold port T and the return to tank hose.

Oil flow through shifted SV1 is directed through the checkvalve in counterbalancevalve CB1,outof control manifold portL and to the rod end of the offset cylinder. As circuit pressure increases, a manifold sensing line shifts counterbalance cartridge CB2 to allow a return pathfor oil fromthe barrel endof the offsetcylinder.The offsetcylinder will retract to cause the sweeper to offset to the left. Oil from the barrel end of the offset cylinder returns to the tow vehicle through shifted SV1, control manifold port T and the return to tank hose.

Controlmanifoldorifice OR1 (0.050)andrelief valve RV function the same in offset left as during offset right.

When the transmitter offset left button is released, the upper coil for solenoid valve SV1 will de--energize and oilflowto the offset cylinder willcease.Thesweeperwill remain in position.

LIFT CYLINDER

OFFSET

CYLINDER

CONTROL MANIFOLD

System

Hydraulic

OrificeOR1(0.050)inthecontrolmanifoldexiststocontrol the extending speed of the offset cylinder.

Asthe sweeperis beingoffset,relief valveRV functions as a circuit relief valve.If circuit pressure reaches 2000 PSI (138 bar), RV will shift to reduce circuit pressure.

When thetransmitter offset right button is released, the lower coil for solenoid valve SV1 will de--energize and oilflowto the offset cylinder willcease.Thesweeperwill remain in position.

Offset Left

Whentheremotetransmitteroffsetleftbuttonispressed andheld,theupper coil for solenoidvalveSV1in the hydraulic control manifold will be energized. If the tow vehicle hydraulics are engaged for the sweeper, the shiftedSV1allowsa path foroilflowtotherod end of the offset cylinder.

Pro Sweep Hydraulic SystemPage 3 -- 15

(DE--ENERGIZED)

Figure 12

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 ornoisehasapotentialforfailure.Shouldeitherofthese conditions be noticed, immediately stop the machine, turn off the engine of the tow vehicle, locate the cause ofthe troubleand correct itbefore allowing themachine to beused again. Continued use of an improperlyfunctioninghydraulicsystemcouldleadtoextensivehydraulic component damage.

The charts that follow contain information to assist in troubleshooting. There may possibly be more than one cause for a machine malfunction.

Problem Possible Cause

Hydraulic oil leaks. Hydraulic fitting(s) or hose(s) are loose or damaged.

O--ring(s) or seal(s) are missing or damaged.

Foaming hydraulic fluid. Hydraulic oil level in tow vehicle reservoir is low.

Thesuccessful operation ofthe Pro Sweepdepends 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, inspect tow vehicle hydraulic system if sweeperbrushmotor,offsetcylinder andliftcylinderare all malfunctioning. If one sweeper hydraulic circuit appears to bemalfunctioning (e.g.the brushcircuit and lift cylinder are working but the offset cylinderwill notfunction), check the non--functioning circuit and its components.

Hydraulic system has wrong kind of oil. Hydraulic system on tow vehicle is malfunctioning.

Hydraulic system operates hot. Hydraulic oil level in tow vehicle reservoir is low.

Excessive dirt and debris on Pro Sweep hydraulic components. Hydraulic oil is contaminated or too light. Brush motor is worn or damaged. Hydraulic system on tow vehicle is malfunctioning.

Pro SweepHydraulic System Page 3 -- 16

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.

System

Hydraulic

Pro Sweep Hydraulic SystemPage 3 -- 17

Problem Possible Cause

Sweeper will not lift or lifts slowly. Control module has gone to time--out due to inactivity of remote

transmitter. Hydraulic hose(s) to tow vehicle are not connected (brush motor

and offset cylinder affected as well). Tow vehicle hydraulics are not engaged to Pro Sweep (brush motor

and offset cylinder affected as well). 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. 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 faulty. Hydraulic system on tow vehicle is malfunctioning (brush motor and

offset cylinder affected as well). An electrical problem exists that prevents operation of control mod-

ule or remote transmitter (see Troubleshooting in Chapter 4 -- Electrical System).

Lift cylinder is damaged.

Pro SweepHydraulic System Page 3 -- 18

Problem Possible Cause

Sweep hopper will not dump. Remote transmitter dump sequence not followed.

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

Sweeper is in the offset position. Sweeper not in transport height when remote transmitter dump se-

quence was entered. Hydraulic hose(s) to tow vehicle are not connected (brush motor

and offset cylinder affected as well). Tow vehicle hydraulics are not engaged to Pro Sweep (brush motor

coil SV3 from being energized (see Troubleshooting in Chapter 4 -Electrical System).

System

Hydraulic

Sweeper raises, but will not stay up. NOTE: Control manifold cartridge

cannot provide an absolutely perfect seal. The dump hopper may eventually lower if left in the raised position. Use lift cylinder safety support when dump hopper is raised.

offset cylinder affected as well). An electrical problem exists that prevents operation of control mod-

ule or remote transmitter (see Troubleshooting in Chapter 4 -- Electrical System).

Lift cylinder is damaged. Control manifold SV2 cartridge is leaking or faulty.

Pro Sweep Hydraulic SystemPage 3 -- 19

Problem Possible Cause

Sweeper will not move to or from the offset position.

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

Hydraulic hose(s) to tow vehicle are not connected (brush motor and lift cylinder affected as well).

Tow vehicle hydraulics are not engaged to Pro Sweep (brush motor and lift cylinder 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 cylinder is damaged. An electrical problem exists that prevents operation of control mod-

ule or remote transmitter (see Troubleshooting in Chapter 4 -- Electrical System).

Pro SweepHydraulic System Page 3 -- 20

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System

Hydraulic

Pro Sweep Hydraulic SystemPage 3 -- 21

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 system, empty sweeper hopper and position sweeper on a levelsurface.Chocksweeperwheelstopreventsweeper from moving. If sweeper is attached to tow vehicle, apply tow vehicle parking brake, stop engine and remove 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 thoroughly cleaned. Always keep in mind the need for cleanliness when working on hydraulic equipment.

CAUTION

Before disconnecting any hydraulic components, operate all sweeper hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. See Relieving Hydraulic System Pressure in the General Information section of this chapter.

After Repair or Replacement of Components

1. If component failure was severe or if hydraulic system 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 hydraulic lines, hydraulic fittings and components before reconnecting.

4. Use proper tightening methods when installing hydraulichoses andfittings (see Hydraulic Fitting Installation in the General Information section of this chapter).

5. After repairs are completedbut beforeoperating the sweeper,check oil level in the hydraulic reservoir ofthe tow vehicle and add correct oil if necessary.

6. After disconnecting or replacing any hydraulic components, operate machine functions slowly until air is out of system.

3. Putcapsorplugsonany hydraulic lines,hydraulicfittings or hydraulic components left open or exposed to prevent hydraulic system contamination.

4. Putlabelsondisconnectedhydraulichosesforproper installation after repairs are completed.

5. Note the position of hydraulic fittings (especially elbow fittings) on hydraulic components before removal. Markpartsifnecessary to makesuretheywillbealigned properly when reinstalling hydraulic hoses.

7. Checkforhydraulic oil leaks. Shutofftowvehicleengine and correct leaks if any are discovered. Check oil level in hydraulic reservoir and add correct oil if necessary.

Pro SweepHydraulic System Page 3 -- 22

Check Hydraulic Lines and Hoses

WARNING

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 surgically removed within a few hours by a doctor familiar withthistypeof injury.Gangrene may resultfrom such an injury.

Before using sweeper,check hydraulic hoses for leaks, kinked lines, loose mounting supports, wear, loose fittings or any other deterioration. Make all necessary repairs before operating sweeper.

System

Hydraulic

Pro Sweep Hydraulic SystemPage 3 -- 23

Brush Motor

94to116 ft--lb

(128 to 157 N--m)

10 11

RIGHT

FRONT

Figure 13

1. Brush housing

2. Coupling cover (2 used)

3. Lock washer (8 used)

4. Cap screw (8 used)

5. Lock nut (2 used)

6. Flat washer (2 used)

7. 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

Removal (Fig. 13)

1. Position sweeper on a level surface with dump hopper empty and fully lowered. Chock sweeper wheels to preventsweeper from moving.If sweeper isattached to tow vehicle, apply tow vehicle parking brake, stop engine and remove key from the ignition switch.

15. Flat washer (6 used)

16. Lock nut (6 used)

17. Bearing flange (4 used)

18. Square key

19. Brush assembly

20. Bearing assembly

CAUTION

Pro SweepHydraulic System Page 3 -- 24

2. Relieve sweeper hydraulic system pressure.

3. Cleanbrushmotor and hydraulic connections.Label hydraulic lines for assembly purposes.

4. Disconnecthydraulichosesfromhydraulicfittingson brush motor. Allow hydraulic oil to drain from lines into asuitablecontainer.Putcapsorplugsonopenhydraulic lines and fittings to prevent contamination.

5. Remove upper coupling cover from brush housing.

6. Remove all caps or plugs that were placed on hydraulic lines and fittings during disassembly.

7. Using labels placed during motor removal, correctly installhydraulic hosesto hydraulic fittings on brushmotor.Tightenconnections (see Hydraulic Hose and Tube Installation in the General Information section of this chapter).

8. Install upper coupling cover to brush housing.

6. Support brush motor. Remove two (2) cap screws (item13),flat washers(item6)andlocknuts(item5)that secure motor to frame. Pull brush motor (with coupling jaw attached) from the machine.

IMPORTANT: To prevent damage to hydraulic motor,DONOThitcoupling jawormotorwithahammer during coupling jaw removal or installation.

7. Loosenset screw thatsecurescoupling jaw tobrush motorshaft.Usepuller to remove couplingjawfrommotor shaft. Locate and retrieve woodruff key from motor shaft.

8. If required, remove hydraulic fittings and O--rings from the wheel motor. Discard O--rings.

Installation (Fig. 13)

1. Ifremoved,installhydraulicfittingswith new O--rings intothebrushmotorports(seeHydraulicFittingInstallation in the General Information section of this chapter).

2. If coupling jaw was removed from motor,apply antiseizelubricanttomotor shaft. Positionwoodruffkeyinto shaft keyway and slide coupling jaw onto shaft. Make sure that coupling spideris positioned into coupling jaw on brush shaft.

61 to 85 in--lb

(6.9 to 9.6 N--m)

1. Hydraulic brush motor

2. Woodruff key

3. Coupling jaw

4. Coupling spider

Antiseize

Lubricant

Loctite #242

Figure 14

5. Brush assembly

6. Square key

7. Set screw

Antiseize

Lubricant

System

Hydraulic

3. Align coupling jaw on motor shaft with coupling spider. Position and support brush motor to the frame.

4. Alignmotorshaft with brush shaft.Securebrushmotorto frame withtwo (2) capscrews (item 13),flatwashers(item6)and lock nuts(item5).Torquelocknutsfrom 94 to 116 ft--lb (128 to 157 N--m).

5. Position coupling jaw on motor shaft to allow a gap betweencoupler jaw valleysfrom0.830” to0.930”(21.1 to23.6mm) (Fig. 15).ApplyLoctite#242 (or equivalent)

1. Brush shaft

2. Brush coupling jaw

3. Coupling spider

tothreads ofcoupling set screw.Secure couplingjaw to motor shaft by torquing set screw from 61 to 85 in--lb (6.9 to 9.6 N--m).

Pro Sweep Hydraulic SystemPage 3 -- 25

0.830” to 0.930”

(21.1 to 23.6 mm)

Figure 15

4. Motor coupling jaw

5. Motor shaft

Brush Motor Service

22 to 26 ft--lb

(30to35N--m)

Figure 16

1. Cap screw (5 used)

2. End cover

3. Ring seal

4. Commutator seal

5. Commutator and ring assembly

6. Manifold

7. Stator

8. Wear plate

9. Drive link

10. Coupling shaft

11. Woodruff key

12. Bushing

13. Thrust bearing

14. Thrust washer

NOTE: For service of the hydraulic brush motor, see

the Parker Torqlink

Service Procedure at the end of

this chapter.

15. Inner seal

16. Backup washer

17. O--ring

18. Housing

19. Bearing

20. Seal

Pro SweepHydraulic System Page 3 -- 26

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System

Hydraulic

Pro Sweep Hydraulic SystemPage 3 -- 27

Hydraulic Control Manifold

RIGHT

FRONT

1. Main frame

2. Cap screw (2 used)

3. Flat washer (4 used)

4. Hydraulic control manifold

Figure 17

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)

Pro SweepHydraulic System Page 3 -- 28

Removal (Fig. 17)

Installation (Fig. 17)

CAUTION

2. Relieve sweeper hydraulic system pressure.

3. Thoroughly clean control manifold and manifold hydraulic connections.

NOTE: Theportsonthe control manifoldaremarked to identify hydraulic hose connections. Example: P is the pump connection port (see Hydraulic Schematic in this chapterto identify thefunction of thehydraulic lines and cartridge valves at each manifold port location).

4. Label all control manifold electrical and hydraulic connections for assembly purposes.

1. Lightly oil new O--rings for all removed hydraulic fittings. 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 that securemanifold toframe. Donot fully tighten fasteners.

3. Make sure all hydraulic connections, ports and fittings are clean.

4. Remove caps or plugs that were put on hydraulic hoses and fittings during manifold removal.

5. Lightly oil new O--rings for hydraulic fitting and hose locations and install O--rings in fitting.

6. Using labels placed during manifold removal, correctly connect hydraulic hoses to the manifold fittings. Properly tighten all hydraulic connections (see HydraulicHoseandTubeInstallationintheGeneralInformation section of this chapter).

7. Secure hydraulic manifold to machine by tightening cap screws and lock nuts.

8. Using labels placed during manifold removal, connect wire harness electrical connectors to solenoid valves on control manifold.

System

Hydraulic

5. Disconnect wire harness electrical connectors from solenoid valves on control manifold.

6. Disconnect hydraulic hoses from manifold fittings.

7. Allow disconnected hydraulic hoses to drain into a suitable container. Put caps or plugs on disconnected hosesandfittingstopreventcontamination.Discardany removed O--rings.

8. Support c ontrol 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.

1. O--ring

2. Hydraulic fitting

3. O--ring

4. O--ring

5. Hydraulic fitting

Figure 18

6. O--ring

7. Hydraulic manifold

8. 90

hydraulic fitting

9. 90

hydraulic fitting

Pro Sweep Hydraulic SystemPage 3 -- 29

Hydraulic Control Manifold Service

FRONT

25 ft--lb

(34 N--m)

60 in--lb

(6.8 N--m)

20 ft--lb

(27 N--m)

60 in--lb

(6.8 N--m)

35 ft--lb

(47 N--m)

20 ft--lb

(27 N--m)

(6.8 N--m)

20 ft--lb

(27 N--m)

60 in--lb

20 ft--lb

(27 N--m)

20 ft--lb

(27 N--m)

FRONT

25 ft--lb

(34 N--m)

1. Orifice (0.050) (OR1)

2. #4 zero leak plug

3. Solenoid valve (SV1)

4. Coil spacer

5. Nut

6. Solenoid coil

7. #4 zero leak plug

Figure 19

8. Solenoid valve (SV2)

9. Solenoid valve (SV3)

10. Solenoid coil

11. Nut

12. Relief 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

Pro SweepHydraulic System Page 3 -- 30

NOTE: The ports on the manifold are marked for easy

identification of components. Examples: P is the pump connection port and OR2 is the location for an orifice (See Hydraulic Schematic to identify the function of the hydraulic lines and cartridge valves at each port).

Hydraulic Manifold Service (Fig. 19)

1. Make sure the control manifold is clean before removing any cartridge valve.

CAUTION

Use eye protection such as goggles when using compressed air for cartridge valve cleaning.

CAUTION

2. If solenoid cartridge is being serviced, remove nut securing solenoid to the cartridge valve. Carefully slide solenoid off the valve.

CAUTION

WARNING

If control manifold is attached to sweeper, make surethat sweeper isfullylowered before loosening hydraulic lines, cartridge valves or plugs fromcontrolmanifold. If sweeper isnotfullylowered as manifold components are loosened, sweeper may drop unexpectedly.

IMPORTANT: Use care when handling the cartridge valve. Slight bending or distortion of the stem tube can cause binding and malfunction.

3. Remove cartridgevalve with adeep 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 or contamination.

5. Visuallyinspectcartridge valvefordamaged sealing surfaces and contamination.

Abrupt movement of internal 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 affect the operation of high pressure hydraulic valves. If cartridge design allows, usea woodor plastic probe to pushthe internal spool in andout20to 30 times toflushoutcontamination. Be extremely careful to not damage cartridge. Use compressed air for cleaning.

7. Install the cartridge valve into control manifold: A. Lubricatenewsealkitcomponents with cleanhy-

draulic oil and install on valve. The O--rings, sealing ringsandbackuprings mustbearrangedproperlyon the cartridge valve forproper 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. Threadcartridgevalvecarefullyintocorrectmanifoldport. Thevalve should goin easilywithout binding.

C. Torquecartridgevalve usingadeepsockettovalues identified in Figure 19.

8. If solenoid cartridge was removed, carefully install

solenoid coil onto the cartridge valve. Install nut and torque nut to 60 in--lb (6.8 N--m) (do not over tighten).

9. After assembly, if problems still exist, remove valve

and clean again or replace valve.

System

Hydraulic

A. Contaminationmaycausevalves to stick orhang up.Contaminationcanbecomelodgedinsmallvalve orifices or seal areas causing malfunction.

B. If valve sealing surfaces appear pitted or damaged, the hydraulic system may be overheating or there may be water in the system.

Pro Sweep Hydraulic SystemPage 3 -- 31

Lift Cylinder

RIGHT

FRONT

1. Main sweeper frame

2. Lift cylinder

3. Cap screw

4. Pivot pin

5. Lock nut

Figure 20

6. Pitch frame

7. Pivot pin

Pro SweepHydraulic System Page 3 -- 32

Removal (Fig. 20)

Installation (Fig. 20)

CAUTION

2. Relieve sweeper hydraulic system pressure.

WARNING

Make sure that sweeper is fully lowered before loosening hydraulic hose from lift cylinder. If sweeperisnotfullylowered as hose is loosened, sweeper may drop unexpectedly.

1. If removed, install hydraulic check valve fitting and

new O--ring into lift cylinder (Fig. 21)(see Hydraulic FittingInstallationintheGeneralInformationsectionofthis chapter).

2. Position lift cylinderto themachine mountingpoints.

Make sure the port of the lift cylinder faces the front of the machine.

3. Align lift cylindermounting holeswith framemounts.

Install pivot pins. Secure pivot pins to frame with cap screws and lock nuts.

4. Remove plugs from disconnected hose and fitting.

5. ConnecthydraulichosewithnewO--ring tohydraulic

fitting on lift cylinder. Tightenhose connection (see Hydraulic Hose and Tube Installation in the General Information section of this chapter).

6. Lubricate grease fittings on lift cylinder.

System

Hydraulic

3. Disconnect hydraulic hose from hydraulic fitting on liftcylinder(Fig.21).LocateanddiscardO--ringfrombetweenhoseandfitting.Allowhosetodrainintoasuitable container.

4. Plugdisconnectedhoseandliftcylinderfittingtoprevent contamination.

5. Remove lock nuts (item 5) and cap screws (item 3) thatareusedto retain lift cylinderpivotpins(items4 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.

1. Lift cylinder

2. Breather

3. O--ring

Figure 21

4. Check valve fitting

5. O--ring

6. Hydraulic hose

8. If needed, remove hydraulic check valve fitting and O--ring from the lift cylinder (Fig. 21). Discard O--ring.

Pro Sweep Hydraulic SystemPage 3 -- 33

Lift Cylinder Service

250 to 300 ft--lb

(339 to 407 N--m)

Figure 22

1. Wear ring

2. Seal

3. O--ring

4. Tube

5. Rod

6. O--ring

7. Backup ring

8. Retaining ring

Disassembly (Fig. 22)

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 clevis 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) clockwise 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 of rod; extract rod assembly by carefully twisting and pulling on the rod.

9. Head

10. Wiper

11. Lock nut

12. Piston

Spanner wrench

Retaining ring

Figure 23

IMPORTANT: Do not clamp vise jaws against rod surface.

5. Mount rod securely in avise by clamping viseon the clevis ofthe shaft. Remove lock nut (item 11) andcarefully slide piston and head from the rod.

Pro SweepHydraulic System Page 3 -- 34

IMPORTANT: When removing seal components, be careful to not scratch or damage piston or head.

6. Remove and discard seal kit components from the head and piston.

Inspection

3. Mount rod securely in avise by clamping viseon 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.

CAUTION

Useeye protection suchas goggles whenusing compressed air

1. Wash all cylinder parts in solvent. Dry parts with compressed air.

2. Inspect internal surface of tube for deep scratches, out--of--roundness and bending.

3. Inspect rod, piston and head for excessive pitting, scoring or wear.

4. Ifcylinder componentsare foundto be wornor damaged, replace cylinder.

Assembly (Fig. 22)

1. Coat new seal kit components with clean hydraulic oil.

IMPORTANT: When installing seal components, be careful to not scratch or damage piston or head.

2. Install new seals to the head and piston.

IMPORTANT: Prevent damage when clamping the tube into a vise; clamp on the clevis only.

6. Mounttubein a vise sothattherodend tilts upslight-

ly.

IMPORTANT: When installing the head into the tube, pay careful attention to the retaining ring slot in the tube to ensure that the backup ring does not lodge in the slot.

7. Coat allinternal lift cylinder parts with a light coating

ofcleanhydraulicoil.Sliderodassemblyintotubebeing careful to not damage the seals.

8. Secure head in tubeby installingretaining ring(item

8). A. Align retaining ring hole in the head with the ac-

cess slot in the tube. B. Inserttheretaining ring hookinto the holeandro-

tate head clockwise until the retaining ring is completelypulledintothetubeandtheendsarecovered.

C. Apply silicone sealer to tube access slot.

System

Hydraulic

IMPORTANT: Do not clamp vise jaws against rod surface.

Pro Sweep Hydraulic SystemPage 3 -- 35

Offset Cylinder

RIGHT

FRONT

1. Offset cylinder

2. Hitch tongue

3. Pivot pin (2 used)

4. Cap screw (2 used)

Figure 24

5. Flange nut (2 used)

6. Bracket

7. Hydraulic hose (2 used)

8. O--ring

9. 90

10. O--ring

hydraulic fitting (2 used)

Pro SweepHydraulic System Page 3 -- 36

Removal (Fig. 24)

Installation (Fig. 24)

CAUTION

2. Relieve sweeper hydraulic system pressure.

3. To preventcontaminationofhydraulicsystem during offsetcylinder removal, thoroughlyclean exteriorof cylinder and fittings.

NOTE: Toeaseinstallation,labelthehydraulichosesto show their correct position on the offset cylinder.

1. Iffittingswereremovedfromoffsetcylinder,lubricate

and place new O--rings onto fittings. Install fittings into port openings using marks made during the removal process to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter).

2. Position offset cylinder to the machine mounting

points.Makesuretheportsof the offsetcylinderfacethe hitch tongue.

3. Align offset cylinder mounting holes with frame

mounts. Install pivot pins and secure with cap screws and flange nuts.

4. Remove plugs from disconnected hoses and cylin-

der fittings.

5. Connect hydraulic hoses with new O--rings to hy-

draulic fittings on offset cylinder. Tighten hose connections (see Hydraulic Hose and Tube Installation in the General Information section of this chapter).

6. Lubricate grease fittings on offset cylinder.

System

Hydraulic

4. Removehydraulichosesfromoffsetcylinder.Locate and discard O--rings from between hoses and fittings. Allow hoses to drain into a suitable container.

5. Plug disconnected hoses and offset cylinder fittings to prevent contamination.

6. Removeflangenuts(item5)andcapscrews (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. Ifhydraulic fittingsare to beremoved from offsetcylinder,mark fittingorientation to allow correct assembly. Remove fittings from cylinder and discard O--rings.

Pro Sweep Hydraulic SystemPage 3 -- 37

Offset Cylinder Service

1. Grease fitting

2. Tube

3. Lock nut

4. Wear ring

5. Capseal

30 to 35 ft--lb

(41to47N--m)

Figure 25

6. Piston

7. Spacer

8. O--ring

9. O--ring

10. Backup washer

11. Retaining ring

12. Seal

13. Head

14. Wiper

15. Rod

Pro SweepHydraulic System Page 3 -- 38

Disassembly (Fig. 25)

Assembly (Fig. 25)

1. Remove oil from offset cylinder into a drain pan by slowly pumping the cylinder rod. Plug both ports and clean the outside of the cylinder.

IMPORTANT: Prevent damage when clamping the cylinder in a vise; clamp on the clevis only.

2. Mount offsetcylinder securely in a vise by clamping onthe clevis endofthe tube. Useofa vise withsoftjaws is recommended.

3. Loosen head from tube: A. Use a spanner wrench to rotate head clockwise

untiltheedgeoftheretaining ring appears inthetube opening.

B. Insert a screwdriver under the beveled edge of the retaining ring to start the retaining ring through the tube opening.

C. Rotatetheheadcounter--clockwisetoremoveretaining ring from tube and head.

4. Extractrod with head andpistonby carefully twisting

and pulling on the shaft.

IMPORTANT: Do not clamp vise jaws against the rod surface.

5. Mount rod assembly securely in a vise by clamping

ontheclevisoftherod. Removelocknutandpistonfrom the rod. Slide head off the rod.

1. Make sure all cylinder components are thoroughly cleaned before assembly.

2. Coat new seal kit components with clean hydraulic oil.

IMPORTANT: When installing seal components to piston and head, be careful to not scratch or damage piston or head.

A. Install new seals and O--rings to the piston. B. Installnew seals,O--ring and back--up ring to the

head.

IMPORTANT: Do not clamp vise jaws against the rod surface.

3. Mount rodsecurely in a vise by clamping on the clevis of the rod.

A. Coat shaft with clean hydraulic oil. B. Carefully slide head and piston onto the rod. Se-

cure piston to shaft with lock nut. C. Torque lock nut from 30 to 35 ft--lb (41 to 47

N--m).

IMPORTANT: When installing the head into the tube, pay careful attention to the retaining ring slot in the tube to ensure that the backup ring does not lodge in the slot.

System

Hydraulic

IMPORTANT: When removing seal components, be careful to not scratch or damage piston or head.

6. Removeanddiscard allsealkitcomponentsfromthe

piston and the head.

CAUTION

Useeye protection suchas goggles whenusing compressed air

7. Wash all cylinder parts in clean solvent. Dry parts

with compressed air. Do not wipe parts dry with paper towels or cloth. Lint in a hydraulic system will cause damage.

8. Carefullyinspectinternalsurface of tubefordamage

(deep scratches, out--of--round, etc.). Inspect rod and pistonforevidenceofexcessivescoring,pitting or wear. Replaceoffsetcylinderifinternalcomponentsarefound to be worn or damaged.

4. Lubricate head and piston with clean hydraulic oil. Carefully slide shaft assembly into cylinder tube.

IMPORTANT: Prevent damage when clamping the cylinder’s tube in a vise; clamp on the clevis only.

5. Mount offset cylinderin a vise withsoft jaws.Secure head in tube:

A. Align retaining ring hole in the head with the access slot in the tube.

B. Inserttheretaining ring hookinto the holeandrotate head clockwise until the retaining ring is completely pulled into the tube and the ring ends are covered.

C. Apply silicone sealer to tube access slot.

Pro Sweep Hydraulic SystemPage 3 -- 39

This page is intentionally blank.

Pro SweepHydraulic System Page 3 -- 40

Table of Contents

GENERAL INFORMATION 2.....................

Operator’s Manual 2..........................

Electrical 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.........................

Chapter 4

Electrical System

System

Electrical

Pro Sweep Page 4 -- 1 Electrical System

General Information

Operator’s Manual

Electrical Diagrams

The electrical schematic, circuit drawings and wireharnessdrawingsforthe Pro SweeparelocatedinChapter 6 -- Electrical Diagrams.

Special Tools

Multimeter

The multimeter can test electrical components and circuits 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. Thehighimpedance(internalresistance)ofadigitalmeter in the voltage mode will make sure that excess current is not allowed through the meter. This excess current can cause damage to circuits not designed to carry it.

Figure 1

Electrical System

Page 4 -- 2

Pro Sweep

Troubleshooting

CAUTION

Remove all jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Disconnect the sweeper power harness from the vehicle unless the test requires battery voltage.

Foreffectivetroubleshooting and repairs,theremustbe a good understanding of the electrical circuits (see Chapter6 -- ElectricalDiagrams) and componentsused on this machine.

If the machine has any interlock switches by--passed, theymustbe reconnected forpropersafetyandtroubleshooting.

Problem

No sweeper functions operate. Electrical power from tow vehicle is not available (e.g.

Brush does not rotate. Sweeper is raised (brush should only rotate when

Possible Causes

sweeper power harness not connected to tow vehicle, tow vehicle key not ON, vehicle battery is discharged).

Sweeper fuse (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.

sweeper is below the transport position).

System

Electrical

Broom enable proximity switch is out of adjustment. Broom enable proximity switch or circuit wiring is faulty. Broom relay or circuit wiring is faulty. Solenoid valve coil (SRV) or circuit wiring is faulty. Hydraulic problem exists (see Chapter 3 -- Hydraulic

System).

Brush rotates (but should not) when sweeper is raised above the turn around position.

Pro Sweep Page 4 -- 3 Electrical System

Broom enable proximity switch is out of adjustment. Broom enable proximity switch or circuit wiring is faulty. Broom relay or circuit wiring is faulty.

Problem Possible Causes

Sweeper does not raise at all. Control module has timed out due to 30 minutes of

inactivity. Turn around position proximity switch is out of

adjustment (sweeper not directly behind tow vehicle). Transport position proximity switch is out of adjustment

(sweeper directly behind tow vehicle). Diode D3 is faulty. Up Function Select relay or circuit wiring is faulty. Turn around position proximity switch or circuit wiring

is faulty (sweeper not directly behind tow vehicle). Transport position proximity switch or circuit wiring is

faulty (sweeper directly behind tow vehicle). Solenoid valve coil (SV3) or circuit wiring is faulty. Hydraulic problem exists (see Chapter 3 -- Hydraulic

System). Remote transmitter 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 will raise to the turn around and transport positions but does not raise to dump position.

Control module is faulty (other functions affected as well).

Sweeper is offset (not directly behind tow vehicle). Hitch home proximity switch is out of adjustment. Transport position proximity switch is out of

adjustment. Hitch home proximity switch or circuit wiring is faulty. Transport position proximity switch or circuit wiring is

faulty. Hopper Height Select relay or circuit wiring is faulty.

Sweeper not in transport height position when transmitter dump sequence is entered.

Transmitter button dump sequence not entered correctly.

Hitch Home Verify for Dump relay or circuit wiring is faulty.

Electrical System

Page 4 -- 4

Pro Sweep

Problem Possible Causes

Sweeper does not lower. Control module has timed out due to 30 minutes of

inactivity. Hopper safety support is installed on lift cylinder. Diode D1 is faulty. Down Float Latch relay or circuit wiring is faulty. Down Latch Release relay or circuit wiring 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) (SV1) or circuit wiring is faulty. Hydraulic problem exists (see Chapter 3 -- Hydraulic

System).

System

Electrical

Pro Sweep Page 4 -- 5 Electrical System

Safety Interlock System

CAUTION

Do not disconnect the Pro Sweep proximity switchesordumpbeeper.Theyarefortheoperator’s protection. Check operation of the switches and beeper daily to make sure the interlock system is operating correctly. If any switch or the beeper is not operating properly, adjust or replace it before operatingthe sweeper.

ThePro Sweepsafety interlocksystem ensures the following:

1. The brush willnot rotate when the dumphopper isin the raised position.

2. The dump hopper cannot be emptied when the sweeper is in the offsetposition (not directly behind the tow vehicle).

3. Thedumpbeeperwillsoundwhenemptyingthehopper.

Interlock system operation is described in the Pro Sweep Operator’s Manual. Testing procedures for the interlock system proximity switches and dump beeper are included in the Component Testing section of this Chapter.

Electrical System

Page 4 -- 6

Pro Sweep

Adjustments

Proximity Switches

ThePro Sweep usesfive(5) identical inductiveproximityswitchestocontrolsweeperoperation.These proximity switches are normally open and close when a sweeperframe componentis positioned near the target end of the switch. The switches incorporate a LED on the cable end of the switch. The LED illuminates when the switch is in the closed position. The switches are mounted on the main sweeper frame in three (3) locations. Refer to Proximity Switches in the Component Testing section for additional switch information.

0.110 to 0.170” (2.8 to 4.3 mm)

Proximity Switch Adjustment

1. Position sweeper on a level surface with dump hopperempty andlowered. Have sweeperattached totowing vehicle with the sweeper positioned directly behind the tow vehicle (not offset). Engage vehicle parking brake, stop engine and remove key from the ignition switch.Chocksweeperwheelstopreventsweeperfrom moving.

2. Thetarget surface endof proximityswitch should be from0.110”to0.170” (2.8 to4.3 mm) fromsensingplate on sweeper (Figs. 2 and 3).

3. If necessary, loosen jam nuts on switch and adjust switch location to allow proper clearance between switch and sensing plate.

4. After adjustment, torque jam nuts from 165 to 195 in--lb (18.7 to 22.0 N--m). After tightening jam nuts, check that clearance between end of proximity switch and sensing plate has not changed.

5. Afteradjustmentis complete,makesurethatproximity switch connector is plugged into sweeper wire harness.

1. Main frame

2. Pitch frame

Figure 2

3. Proximity switch

0.110 to 0.170” (2.8 to 4.3 mm)

System

Electrical

Figure 3

1. Main frame

2. Tongue hitch

3. Proximity switch

Pro Sweep Page 4 -- 7 Electrical System

Component Testing

For accurateresistance and/or continuity checks,electricallydisconnect thecomponent being testedfrom the circuit(e.g.unplug therelaywire harness connectorbefore doing a continuity check on relay).

Fuse

The Pro Sweep uses a single 20 amp fuse for circuit protection.Thefuseholderislocatedinthe wireharness (Fig.4).If the fuseisfaultyor missing, noelectricalpower will be available for sweeper operation.

Testing

Remove fuse from the fuse holder for testing. Fuse should have continuity between fuse terminals.

CAUTION

Whentesting electrical components for continuity with a multimeter (ohms setting), make sure that power to the circuit has been disconnected.

Diode Assemblies

Three (3) diode assemblies are used in the Pro Sweep to provide logic for the control module functions. Diode D1provideslogiccontrolforthesweeper downfunction. Diodes D2 andD3 providelogic controlfor thesweeper up function. All of these diodes plug into the wire harness and are located near the offset cylinder.

Diode Testing

Thediode (Fig.5) can be tested usinga digitalmultimeter (diode test setting) and the table to the right.

Figure 4

1. Fuse holder

Figure 5

1. Diode

2. Male terminal

Multimeter

Red Lead (+)

on Terminal

Female Male YES

Multimeter

Black Lead (--)

on Terminal

3. Female terminal

Continuity

Electrical System

Page 4 -- 8

Male Female NO

Pro Sweep

Dump Beeper

The dump beeper soundsto notify the operator andbystanders when the sweeper is raised for the hopper dump function. The beeper is attached to the frame in front of the RH wheel (Fig. 6).

Testing

1. Position sweeper on a level surface with dump hopper 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. Remove cover from frame to access dump beeper.

4. Disconnect wire harness connector from beeper.

IMPORTANT: Make sure to observe polarity on the beeperterminalswhentesting. Damage to thebeeper may result from an improper connection.

5. Correctly connect 12VDC source to the beeper terminals (Fig. 7).

6. Beeper should sound as long as 12VDC is connected to the beeper terminals.

RIGHT

FRONT

1. Cover

2. Cap screw (3 used)

3. Washer (3 used)

Figure 6

4. Dump beeper

5. Tinnerman nut (3 used)

System

Electrical

7. Disconnect voltage source from the beeper. Reconnect wire harness connector to beeper.

8. Securecovertoframe.Connectsweeperpowerharness to tow vehicle.

1. Top view

2. Bottom view

Figure 7

3. Positive (+) terminal

4. Negative (--) terminal

Pro Sweep Page 4 -- 9 Electrical System

Relays

RIGHT

FRONT

1. Cover

2. Flat washer (3 used)

3. Cap screw (3 used)

4. Cap screw (8 used)

5. Flat washer (8 used)

6. Lock nut (8 used)

7. Hopper Height Select relay

8. Logic Inverter relay

9. Broom relay

10. Up Function Select relay

The electrical system of the Pro Sweep includes eight (8) relays used to control sweeper operation.These relays are identical and are attached to the frame in front of the RH wheel (Fig. 8). Relays can be identified by a tag on the wire harness. Refer to circuit drawings in Chapter 6 -- Electrical Diagrams for additional relay information.

Relay Operation

The Broom relay is used to control the energizing of hydraulicmanifold solenoid (SRV).When the Broomrelay is notenergized (broom enable proximity switch open), solenoid (SRV) willnot be energized and the broom will bestationary(notrotating).WhentheBroomrelayisenergized (broom enable proximity switch closed), solenoid (SRV) will be energized to allow hydraulic flow to the broom motor so the broom will rotate.

Figure 8

11. Offset Lockout relay

12. Down Latch Release relay

13. Down Float Latch relay

14. Hitch Home Verify for Dump relay

The Down Latch Release and Down Float Latch relays are used to control the sweeper down function. These relaysensurethat the sweeper continuestolowerwhen the operator presses the remote transmitter sweeper downbutton.Therelays are also usedtostopthe loweringofthe sweeper whentheoperator presses eitherthe stop or up button on the remote transmitter.

The Logic Inverter relay is used to stop the sweeper down function. During normal sweeper operation, the Logic Inverter relay is energized bythe remote receiver which allows the operator to initiate the sweeper down function with the remote transmitter.When the operator pressestheremotetransmitterstopbutton,theLogicInverter relay is de--energized which causes the sweeper down function to stop.

Electrical System

Page 4 -- 10

Pro Sweep

TheUpFunctionSelectrelayisusedtocontroltheenergizing of hydraulic manifold solenoid (SV3) to raise the sweeper.WhentheUpFunctionSelectrelayis notenergized,solenoid (SV3)can beenergized by the operator for the hopper dump function. When the Up Function Select relay is energized, solenoid (SV3) can be energized by the operator for the sweeper up function.

The Hopper Height Select relay is used control the height that the hopper can be raised. When the Hopper Height Select relay is not energized (sweeper is offset sohitch homeproximity switch isopen), the hoppercan only be raised to the turn--around position. When the Hopper Height Select relay is energized (hitch home proximity switch is closed), the hopper canbe raised to the transport position and the hopper dump function is allowed.

TheHitchHomeVerifyfor Dump relay is usedtoprevent the hopper dump function when the sweeper is offset (not directly behind the tow vehicle). When the Hitch Home Verify for Dump relay is not energized (sweeper is offset so hitch home proximity switch is open), the hopper dump function is disabled. When the Hitch Home Verify for Dump relay is energized (hitch home proximity switch is closed), the hopper dump function is allowed.

4. Verify coil resistance between terminals 85 and 86 with a multimeter (ohms setting).Resistance should be from 70 to 90 ohms.

5. Connectmultimeter(ohmssetting)leadstorelayterminals 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.

6. Disconnect voltage from terminal 85 and multimeter lead from terminal 87.

7. Connectmultimeter(ohmssetting)leadstorelayterminals 30 and 87A. Apply +12 VDC to terminal 85. The relay should break and make continuity between terminals 30 and 87A as +12 VDC is applied and removed from terminal 85.

8. Disconnect voltage and multimeter leads from the relay terminals.

9. Secure relay to mounting bracket and connect wire harness connector to relay.

10.Securecover to frame. Connect sweeper power harness to tow vehicle.

TheOffsetLockoutrelayisusedtopreventoffsettingthe sweeperwhenthedumphopperisraised.WhentheOffsetLockout relay isnotenergized (hopperraisedso offset lockout proximity switch is open), sweeper offset (both right and left) is disabled. The energized Offset Lockout relay also causes the dump beeper to sound. WhentheOffsetLockoutrelayis energized(hopperlowered so offset lockout proximity switch is closed), sweeper offset is allowed.

Relay Testing

1. Position sweeper on a level surface with dump hopper 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 powerisremovedfromProSweep, disconnectsweeper power harness from tow vehicle.

2. Remove cover from frame to access relays (Fig. 8).

3. Locaterelaythatistobe tested.Disconnectwireharnessconnectorfromrelay.Removerelayfrommounting bracket for testing.

NOTE: Prior to taking small resistance readings with a digital multimeter, short the meter test leads together. The meterwill display a small resistance value (usually

0.5 ohms or less). This resistance is due to the internal resistanceof the meterand test leads.Subtractthis valuefrom fromthe measured valueof the componentyou are testing.

1. Coil terminal

2. Common terminal

Figure 9

868587A 87

3. Normally closed term.

4. Normally open term.

System

Electrical

Pro Sweep Page 4 -- 11 Electrical System

Proximity Switches

RIGHT

FRONT

1. LH switch plate

2. Offset lockout switch (hole 5)

3. Turn around position switch (hole 1)

4. Lock nut (2 used per switch)

5. Lock washer (2 used per switch)

6. RH switch plate

Proximity Switch Operation

The turn around position proximity switch is located on theRH switch plate in the holeidentified with number 1.

Figure 10

7. Transportposition switch (hole 3)

8. Broom enable switch (hole 7)

9. Hitch home switch

This switch is used to identify the dump hopper turn around height position when the sweeper is offset (not positioneddirectly behind thetow vehicle). Thesensing platefortheturnaroundpositionswitchisagussetatthe top of the pitch frame.

Thetransport position proximityswitch is locatedon the RHswitchplateinthehole identified withnumber3.This switch is used to identify the dump hopper transport height position when the sweeper is positioned directly behindthetowvehicle (not offset). The sensingplatefor thetransport positionswitch isa gussetat thetop ofthe pitch frame.

Electrical System

Page 4 -- 12

Pro Sweep

The offsetlockout proximity switch is located on the LH switch plate in the hole identified with number 5. This switch is used to prevent the offset operation while the dump hopper is in a raised position. The sensing plate for the offset lockout switch is a pitch frame gusset.

Thebroom enableproximity switchis locatedon the LH switch plate in the hole identified with number 7. This switch is used to engage the brush. The sensing plate for the broom enable switch is a pitch frame gusset.

The hitch home proximity switch is located on the front of the frame nearthe hitch tongue pivot pin.This switch isusedtoidentify whenthesweeperispositioneddirectly behind the tow vehicle (not offset).The sensing plate for the hitch home switch is a plate on the hitch tongue.

Proximity Switch Testing

1. Position sweeper attached to tow vehicle on a level surfacewithdump hopper emptyandsweeper lowered. Engagevehicle parkingbrake, stop engineand remove key from the ignition switch. Chock sweeper wheels to prevent sweeper from moving.

2. Dependingon which proximityswitch is tobetested, position the sweeper as listed below (Figs. 11 and 12). In this sweeper position,the LED on cable endof proximityswitchshould beilluminatedwhenelectricalpower is available to sweeper.

LOWERED POSITION

TURN AROUND POSITION

TRANSPORT POSITION

(SWEEPER NOT OFFSET)

System

Electrical

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): Sweeper lowered.

BroomEnableSwitch(number7):Sweeperlowered. Hitch Home Switch: Sweeper not offset.

3. Dependingon which proximityswitch is tobetested, position the sweeper as listed below (Figs. 11 and 12). In this sweeper position,the LED on cable endof proximity switch should not be illuminated when electrical power is available to sweeper.

Turn Around Position Switch (hole number 1): Sweeper offset and raised to turn around position.

Transport Position Switch (number 3): Sweeper not offset and raised to transport position.

Offset Lockout Switch (number 5): Sweeper not offsetandraised slightly higherthantransport position.

Figure 11

SWEEPER SWEEPER NOT

OFFSET OFFSET

Figure 12

Broom Enable Switch (number 7): Sweeper not offset and raised to transport position.

Hitch Home Switch: Sweeper offset.

Pro Sweep Page 4 -- 13 Electrical System

4. Ifa proximity switchLED does notfunctioncorrectly: A. Disconnectsweeperpowerharnessfrom tow ve-

hicle.Then,disconnecttheproximity switch connector from the sweeper wire harness. Reconnect sweeper power harness to tow vehicle.

B. Using a multimeter, verify that the sweeper wire harness connector terminal for the appropriate wire has12VDCwhen electrical power exists tosweeper and sweeper is positioned as listed below.

Turn Around Position Switch (hole number 1): Violetharnesswirehas12 VDC when sweeperis lowered and offset.

Transport Position Switch (number 3): Yellow harness wire has 12 VDC when sweeper is lowered and not offset.

Offset Lockout Switch (number 5): Pink harness wire has 12 VDC in any sweeper position.

Broom Enable Switch (number 7): Pink harness wire has 12 VDC in any sweeper position.

C. Make sure that gap between end of proximity switch and frame sensing plate is from 0.110” to

0.170”(2.8to 4.3 mm). Ifnecessary,adjustproximity switch (see Proximity Switches in the Adjustments section).

D. Make sure that sweeper wire harness ground wire (black) is closed to ground.

E. If harness wire has system voltage present and gap is correct but switch LED did not function, replace proximity switch. Make sure that switch is properlyadjusted (see ProximitySwitchesin the Adjustments section).

5. After testing iscomplete, make surethat switch connector is plugged into sweeper wire harness. Connect sweeper power harness to tow vehicle.

Hitch Home Switch: Pink harness wire has 12 VDC in any sweeper position.

PROXIMITY SWITCH STATUS CHART

KEY TO CHART

O Proximity Switch Open (LED OFF) X

Proximity Switch Closed (LED ON)

MACHINE FUNCTION

Sweeper in Offset Position with Sweeper Head Below Turn Around Position

Sweeper in Offset Position with Sweeper Head At TurnAround Position

Sweeper NOT in Offset Position with Sweeper Head Below TurnAround Position X XXOX

Sweeper NOT in Offset Position with Sweeper Head Between TurnAround and Transport Position

Sweeper NOT in Offset Position with Sweeper HeadAt Transport Position

Sweeper NOT in Offset Position with Sweeper Head Above Transport Position OXOOO

PROXIMITY SWITCH

TurnAround Position Switch (hole 1)

Transport Position Switch (hole 3)

Offset Lockout Switch (hole 5)

Broom Enable Switch (hole 7)

HitchHomeSwitch

X OOO

O OO

XXX

X X

Electrical System

Sweeper Head TurnAround Position is from 8 1/2” to 10 1/2” (215.9 to 266.7 mm) from Ground

Sweeper Head Transport Position is from 13 1/4” to 15 1/4” (336.6 to 387.4 mm) from Ground

Page 4 -- 14

Pro Sweep

Solenoid Valve Coil

Thehydraulicsystemonthe ProSweepusesfive(5)solenoidvalve coilson the hydraulic control manifold(Fig.

13).

Testing

1. Position sweeper on a level surface with dump hopper 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.

NOTE: Thesolenoid coil does not have to be removed from the cartridge valve for testing.

3. Unplug wire harness connector from solenoid valve coil.

NOTE: Prior to taking small resistance readings with a digitalmultimeter,shortthetestleads together.The meter will display a small resistance value (usually 0.5 ohms or less). This resistance is due to the internal resistanceof themeter andtest leads.Subtract this value fromfromthemeasuredvalueofthecomponent you are testing.

4. Using a multimeter (ohms setting), measure resistancebetween thetwo connector terminals on thesolenoid coil. The resistance for the solenoid coils is identified below:

RIGHT FRONT

1. Solenoid SV1

2. Solenoid SV2

Figure 13

3. Solenoid SV3

4. Solenoid SRV

System

Electrical

Solenoid Coil

Resistance

SV1 (2 coils used) 7.1 ohms

SV2 8.6 ohms SV3 8.6 ohms

SRV 7.1 ohms

5. If solenoid coil needs replacement, see Solenoid Valve Coil in the Service and Repairs section of this chapter.

6. Connect wire harness connector to the solenoid valve coil.

7. Connect sweeper power harness to tow vehicle.

Pro Sweep Page 4 -- 15 Electrical System

Remote Transmitter

Theremotetransmitter(Fig.14)isasolidstateelectrical device that sends radio frequency (RF) signal inputs to the sweeper control module for operator control of machine electrical operation. The remote transmitter has sufficientrangetosend an RFsignalto the controlmodule from the tow vehicle operator position.

Whena button ontheremote transmitter ispressed,the LED on theremote shouldflicker.If the machinecontrol moduleisenergized(controlmoduleTimeOutandPower LED’s are both illuminated) and a remote transmitter button is pressed, the corresponding control module LEDshould illuminate andthecontrol moduleRFactivity LED should flicker.

If the control module is energized (control module Time Out and Power LED’s are both illuminated) and the tow vehicle hydraulics are engaged, remote button functions are as follows:

PressingtheSweeper Up buttoncausesthesweeper to raise. The Sweeper Up button can also be used to stop the sweeper from lowering.

PressingtheSweeperDownbuttoncausesthesweeper tolower.PressingtheSweeperUportheStopbuttonwill stop the lower function.

The remote transmitter is powered by three (3) AAA alkaline batteries. If the range of the remote transmitter has diminished or the transmitter LED does not flicker when a button is pressed, the batteries should be replaced.

To replace the remote transmitter batteries:

1. Remove six (6) screws that secure the rear cover to the remote transmitter.

2. Lift rear cover from remote transmitter.

3. Remove batteries from remote transmitter and replace with three (3) new AAA alkaline batteries. Make suretonote battery directionwheninstalling batteries in transmitter.

4. Place rear cover on remote transmitter and secure with six (6) screws.

Pressing the OffsetRight buttoncauses the sweeper to offsettotheright.Thesweeperwillcontinuetooffsetuntil the button is released.

Pressing the Offset Left button causes the sweeper to offsettothe left. Thesweeperwill continuetooffsetuntil the button is released.

Pressing the Stop button causes any active function to be disabled.

NOTE: Whenthestop button onthe remote transmitter is pressed, therewill bea three (3) second delay before thestopLEDonthecontrol module illuminates. Also, for approximately five (5) seconds after the stop button is pressed,the control modulestopLED will remainilluminated and no other remote transmitter operations can be performed.

Pressing the Hopper Dump button with the sweeper in thetransportpositioninitiatesastartingsequencetofully raise the hopper for dumpingcollected material. This sequence(see Operator’sManual) isnecessary toprevent unintentional dumping. After pressing the Hopper Dump button, other transmitter buttons are inactive for approximately five (5) seconds.

1. Remote LED

2. Sweeper Up button

3. Sweeper Down button

4. Offset Right button

Figure 14

5. Offset Left button

6. Stop button

7. Hopper Dump button

Electrical System

Page 4 -- 16

Pro Sweep

Control Module

The control module is a solid state electrical device that receives signal inputs from the remote transmitter and uses those inputs to control sweeper electrical operation.The control moduleis attached totheframe infront of the RH wheel (Fig. 15).

Inputs from theremote transmitterare monitored by the controlmodule. Outputto machine relaysand hydraulic solenoid valve coils are controlled based on the inputs received by the control module.

To begin sweeper operation, providing electrical power to the sweeper power harness is used to turn on or “wakeup” thecontrol module.The controlmodule Time Outand PowerLED’sshould bothbe illuminated during sweeper operation (Fig. 16).

Whena remote transmitterbutton is pressed,the correspondingcontrol moduleLED should illuminateand the control module RF activity LED should flicker (Fig. 16).

NOTE: Because of the normal RF activity in the environment,thecontrol module RFactivityLEDmay flicker or be illuminated at any time during machineoperation. Machine operation will onlybe controlled by the remote transmitter that is recognized by the control module.

NOTE: Whenthestop button onthe remote transmitter is pressed, therewill bea three (3) second delay before the control module stop LED illuminates. Also, the controlmodule stop LEDwillremain illuminated andnoother remote transmitter operations can be performed for approximately five (5) seconds.

1. Control module

Figure 15

2. LED location

Model: 07066

TestedtoComply With FCC Standards

FORHOMEOROFFICEUSE

Canada 3575APFB1

N1625

Made in U.S.A.

System

Electrical

The control module includes a timer to allow machine

operationfor 30minutes afterthe lastcontrol input(e.g. remotetransmitter button pressed).If no inputsare provided to the control module during this time period, the controlmodule w ill shutoff all sweeperelectrical power.

The control module does not connect to an external computer or hand held device, cannot be re--programmed and does not record any fault data.

Because of the solid state circuitry built into the control

115--9062

module,thereisnoreliablemethodtotest it.Themodule may be damaged if an attempt is made to test it with an electrical test device, such as a digital multimeter.

IMPORTANT: To prevent damage to the Pro Sweep electrical system, disconnect the electrical power

1. Sweeper up LED

2. Sweeper down LED

3. Offset right LED

4. Offset left LED

5. Stop LED

Figure 16

6. Hopper dump LED

7. Time out LED

8. Power LED

9. RF activity LED

harnessfromthetowvehicle before performing any welding on the machine.

Pro Sweep Page 4 -- 17 Electrical System

Service and Repairs

Solenoid Valve Coil

60 in--lb

(6.8 N--m)

60 in--lb

(6.8 N--m)

1. Solenoid valve (SV1)

2. Hydraulic manifold

3. Solenoid relief valve (SRV)

4. Coil spacer

Figure 17

5. Nut

6. Solenoid coil

7. Nut

8. Solenoid valve (SV2)

FRONT

60 in--lb

(6.8 N--m)

9. Solenoid valve (SV3)

10. Solenoid coil

11. Nut

The solenoid valve coils on the hydraulic control manifold (Fig. 17) can be removed and installed 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, 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. Disconnectthemachinewire harness electricalcon-

nector from the solenoid coil to be removed.

Electrical System

Page 4 -- 18

4. Remove the nut from the cartridge valve.

5. Slide the solenoid c oil from the cartridge.

6. Clean all corrosion or dirt from the cartridge stem.

Installation

1. Slide solenoid coil onto the cartridge stem.

2. Install the nut onto the cartridge and torque nut 60 in--lb (6.8 N--m) (do not over tighten).

3. Connect the machine wire harness electrical connector to the solenoid coil.

Pro Sweep

Table 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...........................

Chapter 5

Chassis

Pro Sweep Page 5 -- 1 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)

Pro SweepPage 5 -- 2Chassis

General Information

Operator’s Manual

Securing Pro Sweep to Tow Vehicle

While operating or servicingthe ProSweep, 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).

Figure 1

1. Hitch pin 2. Hairpin clip

Chassis

Pro Sweep Page 5 -- 3 Chassis

Service and Repairs

Wheels

RIGHT

FRONT

70 to 90 ft--lb

(95 to 122 N--m)

1. Main frame

2. Lug nut (5 used per wheel)

3. Wheel and tire assembly

63 to 77 ft--lb

(86 to 104 N--m)

Figure 2

4. Wheel hub

5. Axle

6. Cap screw (4 used)

7. Support washer (4 used)

8. Flange nut (4 used)

Pro SweepPage 5 -- 4Chassis

Wheel Removal (Fig. 2)

Wheel Installation (Fig. 2)

1. Position sweeper on a level surface with dump hopperempty andlowered. Have sweeperattached totowing vehicle, apply vehicle parking brake, stop engine andremove keyfrom theignition switch.Chock sweeper wheels to prevent sweeper from moving.

2. Jack orhoist sweeper fromground and support machine with appropriate jack stands (see Operator’s Manualand Jacking Instructionsin Chapter 1 -- Safety).

3. Loosenandremovefive(5)lugnutsfromwheeltobe removed.

4. Pull wheel from sweeper.

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 failureor loss of wheel andmay result in personal injury.

4. Torque lug nutsinacriss--crosspatternfrom70to90 ft--lb (95 to 122 N--m).

Chassis

Pro Sweep Page 5 -- 5 Chassis

Wheel Bearings

1. Axle

2. Grease seal

3. Inner bearing cone

4. Inner bearing cup

5. Wheel hub

See text for

tightening procedure

Figure 3

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

Pro SweepPage 5 -- 6Chassis

Removal (Fig. 3)

Installation (Fig. 3)

1. Position sweeper on a level surface with dump hopperempty andlowered. Have sweeperattached totowing vehicle, apply vehicle parking brake, stop engine andremove keyfrom theignition switch.Chock sweeper wheels to prevent sweeper from moving.

2. Jack orhoist sweeper fromground and support machine with 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 washer 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. Take care to not damage hub as bearing cups are removed.

D. Inspectwheelbearings.Checkthebearingcones and bearing cups for wear, pitting or other damage. Replace worn or damaged parts.

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. 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 greasedinnerbearingintothecup on inboard sideof the wheel hub.

D. Fill hub approximately 50% 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.

E. 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-lb (8.5 to 20.3 N--m) toseatbearings.Loosen nut until itisawayfromwasher andhubhasend play.Finally,whilerotating hub, tighten slotted hex nut from 15 to 20 in--lbs (1.7 to 2.3 N--m).

Chassis

E. Ifnecessary,useapresstoremovelugboltsfrom hub.

6. Install cotter pin through axle spindle hole. Install

dust cap to hub.

WARNING

Failure to maintain proper lug nut torque could result in failureor loss of wheel andmay result in personal injury.

7. Installwheelassembly(seeWheelInstallationinthis

section).

8. Carefully lower machine to ground. Make sure that

lug nuts are torqued in a criss--cross pattern from 70 to 90 ft--lb (95 to 122 N--m).

Pro Sweep Page 5 -- 7 Chassis

Servicing the Brush Housing

RIGHT

FRONT

1. Saddle frame

2. Roller

Figure 4

3. Hydraulic brush motor

4. Brush

5. Brush housing

Pro SweepPage 5 -- 8Chassis

To perform service onthe brushhousing, brushassemblyorroller,the followingprocedurecanbeused.These stepswillreduce the chance thatbrushhousingcomponents will fall or shift during the service process.

1. Position sweeper on a level surface with dump hopperempty andlowered. Have sweeperattached totowing vehicle, apply vehicle parking brake, stop engine andremove keyfrom theignition switch.Chock sweeper wheels to prevent sweeper from moving.

2. With brush housing resting on the ground, remove fasteners that secure component(s) that are to be removed (see Brush, Brush Housing and/or Roller in this section).

3. Supportcomponent(s)topreventit(them)fromshifting position.

4. Starttowvehicle.Slowlyraisesweeperhopperwhile

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 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

Pro Sweep Page 5 -- 9 Chassis

Brush

94to116 ft--lb

(128 to 157 N--m)

Antiseize Lubricant

RIGHT

FRONT

Antiseize

Lubricant

61 to 85 in--lb

(6.9 to 9.6 N--m)

Loctite #242

1. Carriage screw

2. Top rubber shield

3. Lock nut (2 used)

4. Top shield plate

5. Flange nut

6. Flat washer (2 used)

7. Carriage bolt (3 used per bearing)

8. Cap screw (4 used per cover)

9. Lock washer (4 used per cover)

10. Coupler cover (2 used)

11. Cap screw (2 used)

12. Hydraulic brush motor

13. Coupler jaw

14. Set screw (2 used per jaw)

15. Coupler spider

16. Flat washer (3 used per bearing)

17. Lock nut (3 used per bearing)

18. Brush housing

19. Bearing assembly

20. Bearing flange (2 used per bearing)

Removal (Fig. 5)

1. Position sweeper on a level surface with dump hopperempty andlowered. Have sweeperattached totowing vehicle, apply vehicle parking brake, stop engine andremove keyfrom theignition switch.Chock sweeper wheels to prevent sweeper from moving.

2. Remove hydraulic brush motor from brush housing (seeHydraulic Brush MotorRemovalin the Serviceand Repairs section of Chapter 3 -- Hydraulic System). Remove coupler spider (item 15).

Figure 5

21. Side angle plate (2 used)

22. Side rubber shield (2 used)

23. Side shield plate (2 used)

24. Front rubber shield

25. Front shield plate

26. Front angle plate

27. Carriage screw

28. Square key

29. Brush assembly

3. Loosensetscrews (item14)thatsecurecouplingjaw tobrushshaft.Slide coupling jaw fromshaft.Locateand retrieve square key from brush shaft.

NOTE: If desired, brush housing (with brush installed) can be removed from sweeper to allow brush removal (see Brush Housing Removal in this section).

4. Remove carriage bolts (item 7), flat washers (item

16) and lock nuts (item 17) that secure bearing flanges to brush housing.

Pro SweepPage 5 -- 10Chassis

5. Support brush assembly to prevent it from moving. Follow Servicing the Brush Housing procedure in this section to remove brush from brush housing.

6. After raising hopper and placinglift cylinderstop, retrieve brush assembly from under machine.

7. Loosen three (3) set screws that secure bearings to brushshaft.Slidebearing andbearingflangesfromboth ends of shaft.

8. Disassemble brush using Figure 6 as a guide.

Installation (Fig. 5)

1. Assemble brush using Figure 6 as a guide. Torque flange nuts from 27 to 33 ft--lb (37 to 44 N--m).

8. Positionsquarekeyinbrushshaft.Slidecouplingjaw

onto drive end of brush shaft.

9. Place coupler spider into coupling jaw on brush

shaft.

10.Install hydraulic brush motor to brush housing (see

Hydraulic Brush Motor Installation in the Service and Repairs section of Chapter 3 -- Hydraulic System).

11.Make sure that coupling jaws have a gap between

coupler jaw valleys from 0.830” to 0.930” (21.1 to 23.6 mm). Apply Loctite #242 (or equivalent) to threads of coupling set screws. Secure coupling jaws to motor shaft and brush shaft by torquing setscrews from 61 to 85 in--lb (6.9 to 9.6 N--m) (Fig. 7).

2. Thoroughly clean brush shaft surface. If necessary, remove nicks or burrs on shaft with emery cloth or fine file. Apply antiseize lubricant to shaft.

3. Slide bearing flanges and bearing assembly to each end of brush shaft with bearing set screws orientated to outside of brush. Do not tighten bearing set screws at this time.

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 carriage bolts (item 7), flat washers (item 16)and locknuts (item 17). Center brush between bearings.

7. Secure the bearings to the brush shaft as follows: A. Position the bearing collar so that a set screw is

directlyoppositethesplitinthebearingsleeve.Tightenthree(3)setscrewsinbearingsothattheyarefinger tight. 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 setscrews 1/4 turn.

1. Brush

2. Flange nut (2 used)

3. Cap screw (2 used)

Figure 6

Antiseize

Lubricant

27 to 33 in--lb

(37to44N--m)

4. Key (4 used)

5. Washer (4 used)

6. Brush axle

Antiseize Lubricant

Chassis

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 properlytorquebearingsetscrews.Whentightening

61 to 85 in--lb

(6.9 to 9.6 N--m)

Loctite #242

set screws, the torque is correct when the long end of the allen wrench contacts the torque indicator.

D. Finally,starting with thesetscrewthatisopposite from the split in the sleeve, torque all set screws 66

1. Hydraulic brush motor

2. Key

3. Coupling jaw

4. Coupling spider

Figure 7

5. Brush

6. Square key

7. Set screw (2 per jaw)

in--lb (7.5 N--m).

Pro Sweep Page 5 -- 11 Chassis

Brush Housing

94to116 ft--lb

(128 to 157 N--m)

94to116 ft--lb

(128 to 157 N--m)

RIGHT

FRONT

1. Saddle frame

2. Cap screw

3. Lock nut

4. Flange bushing (2 used per mount)

Figure 8

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

Pro SweepPage 5 -- 12Chassis

Removal (Fig. 8)

4. Position brush housing under raised hopper.

1. Position sweeper on a level surface with dump hop-

perempty andlowered. Have sweeperattached totowing vehicle, apply vehicle parking brake, stop engine andremove keyfrom theignition switch.Chock sweeper wheels to prevent sweeper from moving.

2. Remove hydraulic brush motor from brush housing

(seeHydraulic Brush MotorRemovalin the Serviceand 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. Follow Servicing the Brush Housing procedure in

thissectiontoremove brushhousingfromsaddleframe.

6. After raising hopper and placinglift cylinderstop, re-

trieve brush housing from under machine.

7. Remove cap screw (item 9), flat washer (item 10)

andhardenedspacer(item 11)fromfrontbrushhousing pin.

8. Remove pivot mounts from brush housing. Locate

andretrieve thrustwashers (item7) frombetween pivot mount and brush housing.

5. Slowly lower hopper to position saddle frame to brush housing (see Servicing the Brush Housing in this section).

6. Secure pivotmounts to framewith cap screws(item

2)andlocknuts(item3).Torquelocknutsfrom94to116 ft--lb (128 to 157 N--m).

7. Install hydraulic brush motor to brush housing (see Hydraulic Brush Motor Installation in the Service and RepairssectionofChapter 3 -- HydraulicSystem).Make surethatcouplingjaws have a gapbetweencouplerjaw valleys from 0.830” to 0.930” (21.1 to 23.6 mm). Apply Loctite #242 (or equivalent) to threads of coupling set screws. Secure coupling jaws to motor shaft and brush shaft by torquing set screws from 61 to 85 in--lb (6.9 to

9.6 N--m) (Fig. 9).

8. Lubricate grease fittings on pivot mounts.

Antiseize

Lubricant

Antiseize Lubricant

9. 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.

2. Place thrust washer and then pivot mount on both

brush housing pins.

3. Securefrontpivotmountwithhardenedspacer(item

11), flat washer (item 10) and cap screw (item 9).

61 to 85 in--lb

(6.9 to 9.6 N--m)

1. Hydraulic brush motor

2. Key

3. Coupling jaw

4. Coupling spider

Chassis

Loctite #242

Figure 9

5. Brush assembly

6. Square key

7. Set screw (2 per jaw)

Pro Sweep Page 5 -- 13 Chassis

Roller

Antiseize

Lubricant

Antiseize

Lubricant

RIGHT

FRONT

1. Roller scraper

2. Carriage screw (8 used)

3. Roller

4. Brush housing

5. Flange nut (10 used)

Loctite #242

125 to 165 in--lb

(14.2 to 18.6 N--m)

Figure 10

6. Bearing flange (2 used per bearing)

7. Locking collar (2 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)

Pro SweepPage 5 -- 14Chassis

Removal (Fig. 10)

Installation (Fig. 10)

1. Position sweeper on a level surface with dump hop-

perempty andlowered. Have sweeperattached totowing vehicle, apply vehicle parking brake, stop engine andremove keyfrom theignition switch.Chock sweeper wheels to prevent sweeper from moving.

2. Removeflangenutsandcarriagescrewsthatsecure

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 fasteners that secure roller assembly.

CAUTION

To prevent personal injury,make sure that roller is supported as it is removed from the machine. Roller weighs approximately 80 pounds (36.3 kg).

3. Support roller to prevent it from shifting.

1. Clean roller shaft ends and apply antiseize 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 section).

5. Secureadjustmentplatesandadjusterkeystobrush housing with carriage screws and flange nuts using location 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 andhammer,rotate locking collars in the direction of normal roller rotation to tighten collars.

4. Notelocationofroller adjustment plates andadjuster

keys for reassembly purposes.

5. Remove flange nuts that secure roller adjustment

plates and adjuster keys to brush housing.

6. Refer to Brush Housing Service in this section for

procedure to remove roller assembly from brush housing.

7. After raising hopper and placinglift cylinderstop, re-

trieve roller assembly from under machine.

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

(item7)intheoppositedirectionofnormalrollerrotation to loosen collar.

C. Remove carriage screws (item 13), flat washers (item11)and lock nuts (item 10) that secure bearing flanges to roller adjustment plate.

8. Apply Loctite #242 (or equivalent) to threads of set screws(item8).Installsetscrewsintocollarsandtorque from125to165 in--lb (14.2to18.6N--m)tosecurelock- ing collars to roller shaft.

9. Check that roller is free to rotate and no binding exists.

Chassis

10.Position roller scraper to machine. Install carriage screwsand flange nutsthat secure rollerscraper toroller adjustment plates.

11.Check roller height and roller scraper clearance and adjust if necessary (see Operator’s Manual).

D. Slide bearing flanges, locking collar and bearing from roller.

Pro Sweep Page 5 -- 15 Chassis

1. Roller shaft

2. Bearing flange

Figure 11

3. Locking collar

Frame Assembly

RIGHT

FRONT

Figure 12

1. Main frame

2. Cap screw (4 used)

3. Pivot pin (2 used)

4. Flange nut (6 used)

5. Pitch frame

6. Pivot pin

7. Cap screw (2 used)

8. Pivot pin (2 used)

9. Hardened spacer (2 used)

10. Pivot saddle

11. Carriage bolt

12. Pivot pin

Disassembly (Fig. 12)

1. Position sweeper on a level surface with dump hopperempty andlowered. Have sweeperattached totowing vehicle, engage vehicle parking brake, stop engine andremove keyfrom theignition switch.Chock sweeper wheels to prevent sweeper from moving.

NOTE: Iflift cylinder is to be removed, see Lift Cylinder Removal in the Service and Repairs section of Chapter 3 -- Hydraulic System.

2. Disassemble frame as needed using Figure 12 as a guide.

13. Lock nut

14. Saddle frame

15. Cap screw

16. Lift cylinder

17. Lock nut

18. Link

Assembly (Fig. 12)

1. Assemble frame using Figure 12 as a guide.

2. Lubricate pivot point grease fittings.

Pro SweepPage 5 -- 16Chassis

Table of Contents

ELECTRICAL SCHEMATIC

Electrical Schematic 3.........................

CIRCUIT DRAWINGS

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.................

Chapter 6

Electrical Diagrams

Pro Sweep Electrical DiagramsPage 6 -- 1

Diagrams

Electrical

This page is intentionally blank.

Pro SweepElectrical Diagrams Page 6 -- 2

CAP

NOTE: NO OTHER MACHINE FUNCTIONS

WILLWORK WHEN LEARN SHUNT

WIRESARE CONNECTED.

CONTROL MODULE

CAP

Pro Sweep

Electrical Schematic

Relays are shown as de--energized All ground wires are black

Page 6 -- 3

CONTROL MODULE

Model: 44538

Model: 07066

Tested to Co mply

Tes te d t o Com pl y

With FCC Standards

With FCC Standar ds

FOR HOME O R OFFICE USE

FOR HOME OR OFFICE USE

N1625

Canada

Mad e i n U. S .A.

3575APFB1

Made in U.S.A.

LED’S

ILLUMINATED

115--9062

REMOTE TRANSMITTER

BUTTON

PRESSED

CONTROL MODULE

CAP

Pro Sweep

Brush Circuit

Page 6 -- 4

Power Current Control Current

SWITCH CLOSED (LED ILLUMINATED)

WHEN SWEEPER HEAD IS BELOW THE

TRANSPORT HEIGHT

(ENERGIZED)

Electrical Power Exists to Pro Sweep. Sweeper Is Below Transport Height Position. Brush Will Rotate if Tow Vehicle Hydraulics

Are Engaged.

Note: Other Circuits Are Completed During

Brush Operation. See Chapter 4 -- Electrical System for Additional Circuit Information.

CONTROL MODULE

Model: 44538

Model: 07066

Tested to Co mpl y

Tes te d t o Com ply

With FCC Standar ds

With FCC Standards

FORHOMEOROFFICEUSE

N1625

Canada

Mad e in U.S .A .

3575APFB1

Made in U.S.A.

ILLUMINATED

LED’S

115--9062

REMOTE TRANSMITTER

PRESSED

(SWITCH CLOSED)

(SWITCH LED ILLUMINATED)

CONTROL MODULE

(ENERGIZED)

CAP

(ENERGIZED)

SWEEPER

UP BUTTON

PRESSED AND HELD

(SWITCH CLOSED)

(SWITCH LED ILLUMINATED)

Electrical Power Exists to Pro Sweep. Sweeper Directly Behind Tow Vehicle (Can Raise to

Transport Height Position).

Remote Transmitter Sweeper Up Button Pressed. Sweeper Will Raise to Transport Height if Tow

Vehicle Hydraulics Are Engaged.

Pro Sweep

Sweeper Raise Circuit (To Transport Heigh t )

Power Current Control Current

Page 6 -- 5

CONTROL MODULE

Model: 07066

Model: 44538

Tes te d t o Com pl y

Tested to Co mply

With FCC Standar ds

With FCC Standards

FORHOMEOROFFICEUSE

FOR HOME OR OFFICE USE

N1625

Canada

Canada 3575APFB1

3575APFB1

Made in U.S.A.

Mad e i n U. S .A.

ILLUMINATED

LED’S

115--9062

REMOTE TRANSMITTER

PRESSED

SWEEPER

UP BUTTON

PRESSED AND HELD

CONTROL MODULE

(SWITCH CLOSED)

(SWITCH LED ILLUMINATED)

CAP

(ENERGIZED)

Electrical Power Exists to Pro Sweep. Sweeper in Off--Set Position (Can Raise to

Turn Around Height Position). Remote Transmitter Sweeper Up Button Pressed. Sweeper Will Raise to Turn Around Height if

Tow Vehicle Hydraulics Are Engaged.

Pro Sweep

Sweeper Raise Circuit (To Turn Around Height)

Power Current Control Current

Page 6 -- 6

CONTROL MODULE

Model: 44538

Model: 07066

Tes te d t o Com pl y

Tested to Co mply

With FCC Standar ds

With FCC Standards

FORHOMEOROFFICEUSE

N1625

Canada

3575APFB1

Made in U.S.A.

Mad e in U. S .A.

ILLUMINATED

(ENERGIZED)

LED’S

115--9062

REMOTE TRANSMITTER

HOPPER

DUMP BUTTON

PRESSED

AND HELD

AFTER DUMP

SEQUENCE

PRESSED

(SWITCH CLOSED)

(SWITCH LED ILLUMINATED)

CONTROL MODULE

(ENERGIZED)

CAP

(ENERGIZED)

Electrical Power Exists to Pro Sweep. Sweeper Directly Behind Tow Vehicle and In

Transport Height Position.

Remote Transmitter Dump Sequence Entered and

Then Hopper Dump Button Pressed.

Hopper Dump Will Occur if Tow Vehicle Hydraulics

Are Engaged.

Pro Sweep

Hopper Dump Circuit

Power Current Control Current

Page 6 -- 7

CONTROL MODULE

Model: 44538

Model: 07066

Tes te d t o Com pl y

Tested to Co mply

With FCC Standar ds

With FCC Standards

FORHOMEOROFFICEUSE

N1625

Canada

Canada 3575APFB1

3575APFB1

Mad e i n U. S .A.

Made in U.S.A.

ILLUMINATED

LED’S

115--9062

REMOTE TRANSMITTER

SWEEPER

DOWN

BUTTON

PRESSED

(ENERGIZED)

CONTROL MODULE

CAP

(ENERGIZED)

PRESSED

Pro Sweep

Sweeper Lower Circuit (Initiation)

Power Current Control Current

Page 6 -- 8

Electrical Power Exists to Pro Sweep. Remote Transmitter Sweeper Down Button

Pressed.

Sweeper Will Lower if Tow Vehicle Hydraulics

Are Engaged.

CONTROL MODULE

Model: 44538

Model: 07066

Tes te d t o Com pl y

Tested to Co mply

With FCC Standar ds

With FCC Standards

FORHOMEOROFFICEUSE

N1625

Canada

Canada 3575APFB1

3575APFB1

Mad e i n U. S .A.

Made in U.S.A.

ILLUMINATED

LED’S

115--9062

REMOTE TRANSMITTER

NO BUTTONS PRESSED

(ENERGIZED)

CONTROL MODULE

CAP

(ENERGIZED)

NOTE: TO DE--ENERGIZE THE HOPPER DOWN (SV2)

SOLENOID, THE REMOTE TRANSMITTER STOP OR

SWEEPER UP BUTTON CAN BE PRESSED. EITHER OF

THESE INPUTS WILL ENERGIZE THE DOWN LATCH

RELEASE RELAY CAUSING THE DOWN FLOAT LATCH

RELAYAND HOPPER DOWN (SV2) SOLENOID TO

DE--ENERGIZE.

Electrical Power Exists to Pro Sweep. Remote Transmitter Sweeper Down Button

Pressed and Released. Latched Relays Keep CircuitEnergized.

Sweeper Will Lower if Tow Vehicle Hydraulics

Are Engaged.

Pro Sweep

Sweeper Lower Circuit

Power Current Control Current

Page 6 -- 9

CONTROL MODULE

Model: 07066

Model: 44538

Tes te d t o Com pl y

Tested to Co mply

With FCC Standar ds

With FCC Standards

FORHOMEOROFFICEUSE

N1625

Canada

Canada 3575APFB1

3575APFB1

Made in U.S.A.

Mad e i n U. S .A.

ILLUMINATED

LED’S

(SWITCH CLOSED)

(SWITCH LED ILLUMINATED)

(ENERGIZED)

115--9062

REMOTE TRANSMITTER

OFFSET

RIGHT BUTTON

PRESSED

AND HELD

PRESSED

CONTROL MODULE

CAP

Pro Sweep

Sweeper Offset Circuit (Offset Right Shown)

Power Current Control Current

Page 6 -- 10

Electrical Power Exists to Pro Sweep. Remote Transmitter Offset Right Button

Pressed.

Sweeper Will Offset to the Right if Tow

Vehicle Hydraulics Are Engaged.

Toro 7066 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Preface

Table Of Contents

Safety Instructions

Before Op erating

While Operating

Maintenance and Service

Jacking Instructions

Securing Pro Sweep to Tow Vehicle

Safety and Instruction Decals

Product Records

Maintenance

Equivalents and Conversions

Torque Specifications

Fastener Identification

Using a Torque Wrench with an Offset Wrench

Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series)

Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Fasteners)

Other Torque Specifications

Conversion Factors

General Information

Operator’s Manual

Hydraulic Hoses

Relieving Hydraulic System Pressure

Securing Pro Sweep to Tow Vehicle

Hydraulic Schematic

Hydraulic Flow Diagrams

Brush Circuit

Sweeper Raise/Hopper Dump Circuits

Sweeper Lower Circuits

Sweeper Offset Circuits

Troubleshooting

Service and Repairs

General Precautions for Removing and Installing Hydraulic System Components

Check Hydraulic Lines and Hoses

Brush Motor

Brush Motor Service

Hydraulic Control Manifold

Hydraulic Control Manifold Service

Lift Cylinder

Lift Cylinder Service

Offset Cylinder

Offset Cylinder Service

General Information

Operator’s Manual

Electrical Diagrams

Special Tools

Troubleshooting

Safety Interlock System

Adjustments

Proximity Switches

Component Testing

Fuse

Diode Assemblies

Dump Beeper

Relays

Proximity Switches

Solenoid Valve Coil

Remote Transmitter

Control Module

Service and Repairs

Solenoid Valve Coil

Specifications

General Information

Operator’s Manual

Securing Pro Sweep to Tow Vehicle

Service and Repairs

Wheels

Wheel Bearings

Servicing the Brush Housing

Brush

Brush Housing

Roller

Frame Assembly

Electrical Schematic

Brush Circuit

Sweeper Raise Circuit (To Transport Heigh t )