Form No.
Revision History Revision Date -- 2011 A 02/2018 Description Initial Issue. Added revision history. © THE TORO COMPANY 2018 This document and all information contained herein is the sole property of The Toro Company (and/or its affiliated companies). No intellectual property rights are granted by the delivery of this document or the disclosure of its content.
Reader Comments The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we encourage user feedback. Please comment on the completeness, accuracy, organization, usability, and readability of this manual by an e-mail to servicemanuals@toro.
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Part No. 10179SL (Rev. A) Service Manual (Model 07066) Pro Sweep Preface The purpose of this publication is to provide the service technician with information for troubleshooting, testing and repair of major systems and components on the Pro Sweep (Model 07066). REFER TO THE OPERATOR’S MANUAL FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. Space is provided in Chapter 2 of this book to insert the Operator’s Manual and Parts Catalog for your machine.
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2 4 5 5 Chapter 2 -- Product Records and Maintenance Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equivalents and Conversions . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . 2 -2 -2 -2 -- 1 1 2 3 Chapter 3 -- Hydraulic System Chapter 5 -- Chassis Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 2 General Information . . . .
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Safety Table of Contents SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Service . . . . . . . . . . . . . . . . . . . . JACKING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . SECURING PRO SWEEP TO TOW VEHICLE . . . . SAFETY AND INSTRUCTION DECALS . . . . . . . . . .
Safety Instructions The Pro Sweep is designed and tested to offer safe service when operated and maintained properly. Although hazard control and accident prevention partially are dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern and proper training of the personnel involved in the operation, transport, maintenance and storage of the machine. Improper use or maintenance of the machine can result in injury or death.
1. Before servicing or making adjustments, empty Pro Sweep hopper and position sweeper on a level 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. 7. If hopper is raised, install hopper safety support on lift cylinder to ensure that unexpected shifting of sweeper frame does not occur. 2.
Jacking Instructions CAUTION 1 When changing tires or performing other service, use correct hoists and jacks to support sweeper. Make sure machine is parked on a solid level surface such as a concrete floor. Always chock or block wheels. Use appropriate jack stands to support the raised machine. If the machine is not properly supported 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.
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). Safety Securing Pro Sweep to Tow Vehicle 1 2 Figure 2 1. Hitch pin 2. Hairpin clip Safety and Instruction Decals Numerous safety and instruction decals are affixed to the Pro Sweep. If any decal becomes illegible or damaged, install a new decal. Part numbers for replacement decals are listed in your Parts Catalog.
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Chapter 2 Product Records and Maintenance PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . Fastener Identification . . . . . . . . . . . . . . . . . . . . . . .
Equivalents and Conversions 0.
Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in this Service Manual. These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Service Manual.
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series) Thread Size # 6 -- 32 UNC Grade 1, 5 & 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) in--lb in--lb N--cm 10 + 2 13 + 2 147 + 23 # 6 -- 40 UNF # 8 -- 32 UNC 13 + 2 25 + 5 282 + 30 # 8 -- 36 UNF # 10 -- 24 UNC 18 + 2 30 + 5 339 + 56 # 10 -- 32 UNF SAE Grade 5 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger N
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Fasteners) Class 8.8 Bolts, Screws and Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws and Studs with Regular Height Nuts (Class 10 or Stronger Nuts) M5 X 0.8 57 + 6 in--lb 644 + 68 N--cm 78 + 8 in--lb 881 + 90 N--cm M6 X 1.0 96 + 10 in--lb 1085 + 113 N--cm 133 + 14 in--lb 1503 + 158 N--cm M8 X 1.25 19 + 2 ft--lb 26 + 3 N--m 28 + 3 ft--lb 38 + 4 N--m M10 X 1.
Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Thread Size Square Head Hex Socket 1/4 -- 20 UNC 140 + 20 in--lb 73 + 12 in--lb 5/16 -- 18 UNC 215 + 35 in--lb 145 + 20 in--lb 3/8 -- 16 UNC 35 + 10 ft--lb 18 + 3 ft--lb 1/2 -- 13 UNC 75 + 15 ft--lb 50 + 10 ft--lb Recommended Torque** 7/16 -- 20 UNF Grade 5 65 + 10 ft--lb 88 + 14 N--m 1/2 -- 20 UNF Grade 5 80 + 10 ft--lb 108 + 14 N--m M12 X 1.25 Class 8.
Chapter 3 Hydraulic System Table of Contents Pro Sweep Page 3 -- 1 Hydraulic System GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Hydraulic Hose and Tube Installation . . . . . . . . . . 3 Hydraulic Fitting Installation . . . . . . . . . . . . . . . . . . . 4 Relieving Hydraulic System Pressure . . . . . . . . . .
General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Pro Sweep machine. Refer to that publication for additional information when servicing the machine. Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather, sun, chemicals, very warm storage conditions or mishandling during operation and maintenance.
Hydraulic Hose and Tube Installation (O--Ring Face Seal Fitting) 1. Make sure threads and sealing surfaces of the hose/ tube and the fitting are free of burrs, nicks, scratches or any foreign material. C. Use a second wrench to tighten the nut to the correct Flats From Wrench Resistance (F.F.W.R.). The markings on the nut and fitting body will verify that the connection has been properly tightened. 2.
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. 5. If a torque wrench is not available, or if space at the port prevents use of a torque wrench, an alternate method of assembly is the Flats From Finger Tight (F.F.F.T.) method. 2.
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. As a preventative measure against leakage, it is recommended that the O--ring be replaced any time the connection is opened. Lock Nut 3. Lightly lubricate the O--ring with clean hydraulic oil. Fitting threads should be clean with no lubricant applied. Back--up Washer 4. Turn back the lock nut as far as possible.
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. Make sure that the sweeper has electrical power and that sweeper control module is energized (control module Time Out and Power LED’s are both illuminated). With the tow vehicle engine not running, press all remote transmitter buttons to energize the solenoids on the hydraulic control manifold.
Hydraulic Schematic LIFT CYLINDER Hydraulic System OFFSET CYLINDER CONTROL MANIFOLD Pro Sweep Hydraulic Schematic All solenoids are shown as de--energized Pro Sweep Page 3 -- 7 Hydraulic System
Hydraulic Flow Diagrams LIFT CYLINDER OFFSET CYLINDER CONTROL MANIFOLD (ENERGIZED) (ROTATING) Brush Circuit Brush Rotating Shown Working Pressure Return Flow Hydraulic System Page 3 -- 8 Pro Sweep
Brush Circuit NOTE: Hydraulic flow and relief pressure for the Pro Sweep are determined by the tow vehicle. LIFT CYLINDER OFFSET CYLINDER CONTROL MANIFOLD Hydraulic System When the tow vehicle hydraulics are engaged for the sweeper, hydraulic flow from the tow vehicle goes to the sweeper control manifold (port P) through the hydraulic inlet hose.
LIFT CYLINDER (EXTENDING) OFFSET CYLINDER CONTROL MANIFOLD (DE--ENERGIZED) (ENERGIZED) (DE-ENERGIZED) Sweeper Raise/Hopper Dump Circuits Working Pressure Return Flow Hydraulic System Page 3 -- 10 Pro Sweep
Sweeper Raise/Hopper Dump Circuits NOTE: Hydraulic flow and relief pressure to the Pro Sweep are determined by the tow vehicle. LIFT CYLINDER OFFSET CYLINDER CONTROL MANIFOLD Hydraulic System When the tow vehicle hydraulics are engaged for the sweeper, hydraulic flow from the tow vehicle goes to the sweeper control manifold (port P) through the hydraulic inlet hose.
LIFT CYLINDER (RETRACTING) OFFSET CYLINDER CONTROL MANIFOLD (ENERGIZED) (DE-ENERGIZED) (DE-ENERGIZED) Sweeper Lower Circuits Working Pressure Return Flow Hydraulic System Page 3 -- 12 Pro Sweep
Sweeper Lower Circuits NOTE: Hydraulic flow and relief pressure to the Pro Sweep are determined by the tow vehicle. LIFT CYLINDER OFFSET CYLINDER CONTROL MANIFOLD Hydraulic System When the tow vehicle hydraulics are engaged for the sweeper, hydraulic flow from the tow vehicle goes to the sweeper control manifold (port P) through the hydraulic inlet hose.
LIFT CYLINDER OFFSET CYLINDER (EXTENDING) CONTROL MANIFOLD (SHIFTED) (LOWER COIL ENERGIZED FOR RH OFFSET) Sweeper Offset Circuits (Offset to Right Shown) Working Pressure Return Flow Hydraulic System Page 3 -- 14 Pro Sweep
Sweeper Offset Circuits When the tow vehicle hydraulics are engaged for the sweeper, hydraulic flow from the tow vehicle goes to the sweeper control manifold (port P) through the hydraulic inlet hose.
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. The successful operation of the Pro Sweep depends 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. A hydraulic system with an excessive increase in heat or noise has a potential for failure.
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 offset cylinders affected as well).
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.
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 sequence 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 and offset cylinder affected as well).
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.
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Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components After Repair or Replacement of Components 1. Before removing any parts from the hydraulic system, empty sweeper hopper and position sweeper on a level surface. Chock sweeper wheels to prevent sweeper from moving. If sweeper is attached to tow vehicle, apply tow vehicle parking brake, stop engine and remove key from the ignition switch. 1.
Check Hydraulic Lines and Hoses WARNING Hydraulic System 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 with this type of injury. Gangrene may result from such an injury.
Brush Motor 94 to 116 ft--lb (128 to 157 N--m) 1 2 5 3 4 6 9 10 11 12 13 8 14 7 17 20 RIGHT 15 17 16 19 FRONT 18 Figure 13 1. 2. 3. 4. 5. 6. 7. Brush housing Coupling cover (2 used) Lock washer (8 used) Cap screw (8 used) Lock nut (2 used) Flat washer (2 used) Carriage bolt (6 used) 8. 9. 10. 11. 12. 13. 14. Coupling assembly Hydraulic hose (2 used) O--ring (2 used) Hydraulic fitting (2 used) O--ring (2 used) Cap screw (2 used) Hydraulic brush motor 15. 16. 17. 18. 19. 20.
2. Relieve sweeper hydraulic system pressure. 3. Clean brush motor and hydraulic connections. Label hydraulic lines for assembly purposes. 4. Disconnect hydraulic hoses from hydraulic fittings on brush motor. Allow hydraulic oil to drain from lines into a suitable container. Put caps or plugs on open hydraulic lines and fittings to prevent contamination. 5. Remove upper coupling cover from brush housing. 6. Remove all caps or plugs that were placed on hydraulic lines and fittings during disassembly. 7.
Brush Motor Service 11 12 10 9 3 13 14 15 16 18 17 19 20 1 2 3 4 22 to 26 ft--lb (30 to 35 N--m) 5 3 6 3 7 3 8 Figure 16 1. 2. 3. 4. 5. 6. 7. Cap screw (5 used) End cover Ring seal Commutator seal Commutator and ring assembly Manifold Stator 8. 9. 10. 11. 12. 13. 14. Wear plate Drive link Coupling shaft Woodruff key Bushing Thrust bearing Thrust washer 15. 16. 17. 18. 19. 20.
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Hydraulic Control Manifold 1 6 8 7 9 5 4 3 9 10 3 7 11 2 RIGHT FRONT Figure 17 1. 2. 3. 4. Main frame Cap screw (2 used) Flat washer (4 used) Hydraulic control manifold Hydraulic System 5. 6. 7. 8. Lock nut (2 used) Hydraulic hose O--ring Hydraulic hose (2 used) Page 3 -- 28 9. O--ring 10. Hydraulic hose (2 used) 11.
Removal (Fig. 17) Installation (Fig. 17) 1. Position sweeper on a level surface with dump hopper empty and fully lowered. Chock sweeper wheels to prevent sweeper from moving. If sweeper is attached to tow vehicle, apply tow vehicle parking brake, stop engine and remove key from the ignition switch. 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).
Hydraulic Control Manifold Service FRONT UP 20 ft--lb (27 N--m) 17 25 ft--lb (34 N--m) 1 60 in--lb (6.8 N--m) 2 16 15 60 in--lb (6.8 N--m) 3 6 14 4 5 7 7 8 13 9 20 ft--lb (27 N--m) 12 11 20 ft--lb (27 N--m) 6 20 ft--lb (27 N--m) 10 60 in--lb (6.8 N--m) 7 2 18 35 ft--lb (47 N--m) UP 20 ft--lb (27 N--m) FRONT 2 19 25 ft--lb (34 N--m) 20 Figure 19 1. 2. 3. 4. 5. 6. 7. Orifice (0.
Hydraulic Manifold Service (Fig. 19) CAUTION Use eye protection such as goggles when using compressed air for cartridge valve cleaning. 1. Make sure the control manifold is clean before removing any cartridge valve. 2. If solenoid cartridge is being serviced, remove nut securing solenoid to the cartridge valve. Carefully slide solenoid off the valve.
Lift Cylinder RIGHT FRONT 2 5 6 3 4 7 3 1 5 Figure 20 1. Main sweeper frame 2. Lift cylinder 3. Cap screw Hydraulic System 4. Pivot pin 5. Lock nut Page 3 -- 32 6. Pitch frame 7.
Removal (Fig. 20) Installation (Fig. 20) 1. Position sweeper on a level surface with dump hopper empty and fully lowered. Chock sweeper wheels to prevent sweeper from moving. If sweeper is attached to tow vehicle, apply tow vehicle parking brake, stop engine and remove key from the ignition switch. 1. If removed, install hydraulic check valve fitting and new O--ring into lift cylinder (Fig. 21) (see Hydraulic Fitting Installation in the General Information section of this chapter).
Lift Cylinder Service 1 2 7 3 4 8 10 11 5 12 9 250 to 300 ft--lb (339 to 407 N--m) 6 Figure 22 1. 2. 3. 4. Wear ring Seal O--ring Tube 5. 6. 7. 8. Rod O--ring Backup ring Retaining ring 9. 10. 11. 12. Head Wiper Lock nut Piston Disassembly (Fig. 22) Spanner wrench 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: 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 a vise by clamping vise on the clevis of the shaft. Carefully slide head assembly and piston assembly onto the rod. 4. Thread lock nut (item 11) onto rod. Torque lock nut from 250 to 300 ft--lb (339 to 407 N--m). 5. Remove rod assembly from vise.
Offset Cylinder 7 RIGHT 4 FRONT 1 5 3 8 10 4 9 3 6 5 2 Figure 24 1. 2. 3. 4. Offset cylinder Hitch tongue Pivot pin (2 used) Cap screw (2 used) Hydraulic System 5. Flange nut (2 used) 6. Bracket 7. Hydraulic hose (2 used) Page 3 -- 36 8. O--ring 9. 90o hydraulic fitting (2 used) 10.
Removal (Fig. 24) Installation (Fig. 24) 1. Position sweeper on a level surface with dump hopper empty and fully lowered. Chock sweeper wheels to prevent sweeper from moving. If sweeper is attached to tow vehicle, apply tow vehicle parking brake, stop engine and remove key from the ignition switch. 1. If fittings were removed from offset cylinder, lubricate and place new O--rings onto fittings. Install fittings into port openings using marks made during the removal process to properly orientate fittings.
Offset Cylinder Service 1 2 5 7 9 10 12 3 15 4 1 6 30 to 35 ft--lb (41 to 47 N--m) 8 11 13 14 Figure 25 1. 2. 3. 4. 5. Grease fitting Tube Lock nut Wear ring Capseal Hydraulic System 6. 7. 8. 9. 10. Piston Spacer O--ring O--ring Backup washer Page 3 -- 38 11. 12. 13. 14. 15.
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. 1. Make sure all cylinder components are thoroughly cleaned before assembly. 2. Mount offset cylinder securely in a vise by clamping on the clevis end of the tube. Use of a vise with soft jaws is recommended. 3. Loosen head from tube: A.
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Chapter 4 Electrical System Table of Contents Pro Sweep Page 4 -- 1 Electrical System GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 3 SAFETY INTERLOCK SYSTEM . . . . . . . . . . . . . . . . .
General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Pro Sweep machine. Refer to that publication for additional information when servicing the machine. Electrical Diagrams The electrical schematic, circuit drawings and wire harness drawings for the Pro Sweep are located in Chapter 6 -- Electrical Diagrams.
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. For effective troubleshooting and repairs, there must be a good understanding of the electrical circuits (see Chapter 6 -- Electrical Diagrams) and components used on this machine.
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).
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.
Safety Interlock System CAUTION Do not disconnect the Pro Sweep proximity switches or dump beeper. They are for the operator’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 operating the sweeper. The Pro Sweep safety interlock system ensures the following: 1. The brush will not rotate when the dump hopper is in the raised position. 2.
Adjustments Proximity Switches The Pro Sweep uses five (5) identical inductive proximity switches to control sweeper operation. These proximity switches are normally open and close when a sweeper frame component is 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.
Component Testing For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g. unplug the relay wire harness connector before doing a continuity check on relay). CAUTION When testing electrical components for continuity with a multimeter (ohms setting), make sure that power to the circuit has been disconnected. Fuse The Pro Sweep uses a single 20 amp fuse for circuit protection. The fuse holder is located in the wire harness (Fig. 4).
Dump Beeper The dump beeper sounds to notify the operator and bystanders 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). 4 2 3 5 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. 1 2.
Relays 8 9 5 4 10 3 7 2 6 1 RIGHT FRONT 14 13 12 11 Figure 8 1. 2. 3. 4. 5. Cover Flat washer (3 used) Cap screw (3 used) Cap screw (8 used) Flat washer (8 used) 6. 7. 8. 9. 10. Lock nut (8 used) Hopper Height Select relay Logic Inverter relay Broom relay Up Function Select relay 11. 12. 13. 14.
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 so hitch home proximity switch is open), the hopper can only be raised to the turn--around position. When the Hopper Height Select relay is energized (hitch home proximity switch is closed), the hopper can be raised to the transport position and the hopper dump function is allowed.
Proximity Switches 4 5 5 4 RIGHT 3 2 FRONT 6 7 8 1 4 5 5 4 9 Figure 10 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 The Pro Sweep uses five (5) identical inductive proximity switches to control sweeper operation. These proximity switches are normally open and close when a sweeper frame component is positioned near the target end of the switch.
The offset lockout 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. LOWERED POSITION The broom enable proximity switch is located on the LH switch plate in the hole identified with number 7. This switch is used to engage the brush.
4. If a proximity switch LED does not function correctly: C. Make sure that gap between end of proximity switch and frame sensing plate is from 0.110” to 0.170” (2.8 to 4.3 mm). If necessary, adjust proximity switch (see Proximity Switches in the Adjustments section). A. Disconnect sweeper power harness from tow vehicle. Then, disconnect the proximity switch connector from the sweeper wire harness. Reconnect sweeper power harness to tow vehicle. D.
Solenoid Valve Coil The hydraulic system on the Pro Sweep uses five (5) solenoid valve coils on the hydraulic control manifold (Fig. 13). Testing 1 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 2. To ensure that electrical power is removed from Pro Sweep, disconnect sweeper power harness from tow vehicle.
Remote Transmitter The remote transmitter (Fig. 14) is a solid state electrical device that sends radio frequency (RF) signal inputs to the sweeper control module for operator control of machine electrical operation. The remote transmitter has sufficient range to send an RF signal to the control module from the tow vehicle operator position. When a button on the remote transmitter is pressed, the LED on the remote should flicker.
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 module is attached to the frame in front of the RH wheel (Fig. 15). 2 Inputs from the remote transmitter are monitored by the control module. Output to machine relays and hydraulic solenoid valve coils are controlled based on the inputs received by the control module.
Service and Repairs Solenoid Valve Coil 2 60 in--lb (6.8 N--m) 3 1 6 7 4 8 9 11 FRONT UP 10 6 5 60 in--lb (6.8 N--m) 60 in--lb (6.8 N--m) Figure 17 1. 2. 3. 4. Solenoid valve (SV1) Hydraulic manifold Solenoid relief valve (SRV) Coil spacer 5. 6. 7. 8. Nut Solenoid coil Nut Solenoid valve (SV2) 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. 4.
Chapter 5 Chassis Table of Contents Chassis SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Securing Pro Sweep to Tow Vehicle . . . . . . . . . . . 3 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4 Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Wheel Bearings . . . . . . . . . . . . . . . . .
Specifications Item Description Tires Size Pressure 26.5 x 14 -- 12, 4 Ply, Tubeless 12.
General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Pro Sweep machine. Refer to that publication for additional information when servicing the machine. Securing Pro Sweep to Tow Vehicle While operating or servicing the Pro Sweep, make sure that hitch pin is properly positioned in tow vehicle hitch and sweeper tongue. Hitch pin should be secured with hairpin clip (Fig. 1). 1 Chassis 2 Figure 1 1.
Service and Repairs Wheels RIGHT FRONT 70 to 90 ft--lb (95 to 122 N--m) 1 3 6 2 5 7 63 to 77 ft--lb (86 to 104 N--m) 8 4 Figure 2 1. Main frame 2. Lug nut (5 used per wheel) 3. Wheel and tire assembly Chassis 4. Wheel hub 5. Axle 6. Cap screw (4 used) Page 5 -- 4 7. Support washer (4 used) 8.
Wheel Removal (Fig. 2) Wheel Installation (Fig. 2) 1. Position sweeper on a level surface with dump hopper empty and lowered. Have sweeper attached to towing vehicle, apply vehicle parking brake, stop engine and remove key from the ignition switch. Chock sweeper wheels to prevent sweeper from moving. 1. Position wheel to wheel hub. 2. Secure wheel to sweeper with five (5) lug nuts. 3. Carefully lower machine to ground. 2.
Wheel Bearings 2 See text for tightening procedure 4 6 7 1 8 11 3 12 13 5 9 10 Figure 3 1. 2. 3. 4. 5. Axle Grease seal Inner bearing cone Inner bearing cup Wheel hub Chassis 6. 7. 8. 9. Lug bolt (5 used) Outer bearing cup Outer bearing cone Lug nut (5 used) Page 5 -- 6 10. 11. 12. 13.
Removal (Fig. 3) Installation (Fig. 3) 1. Position sweeper on a level surface with dump hopper empty and lowered. Have sweeper attached to towing vehicle, apply vehicle parking brake, stop engine and remove key from the ignition switch. Chock sweeper wheels to prevent sweeper from moving. 1. Clean all parts thoroughly before reassembly. 2. Assemble wheel hub: A. If bearing cups were removed from the wheel hub, press inner and outer cups into the hub until they seat against the hub shoulder. 2.
Servicing the Brush Housing RIGHT FRONT 1 2 5 3 4 Figure 4 1. Saddle frame 2. Roller Chassis 3. Hydraulic brush motor 4. Brush Page 5 -- 8 5.
To perform service on the brush housing, brush assembly or roller, the following procedure can be used. These steps will reduce the chance that brush housing components will fall or shift during the service process. 1. Position sweeper on a level surface with dump hopper empty and lowered. Have sweeper attached to towing vehicle, apply vehicle parking brake, stop engine and remove key from the ignition switch. Chock sweeper wheels to prevent sweeper from moving. 2.
Brush 94 to 116 ft--lb (128 to 157 N--m) 4 5 18 3 Antiseize Lubricant 2 29 1 6 7 26 8 13 Antiseize Lubricant 9 10 1 14 23 15 28 RIGHT 12 20 19 25 FRONT 27 5 24 11 14 5 22 21 5 16 17 Loctite #242 61 to 85 in--lb (6.9 to 9.6 N--m) Figure 5 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
6. After raising hopper and placing lift cylinder stop, retrieve brush assembly from under machine. 7. Loosen three (3) set screws that secure bearings to brush shaft. Slide bearing and bearing flanges from both 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. Position square key in brush shaft. Slide coupling jaw onto drive end of brush shaft. 9.
Brush Housing 1 94 to 116 ft--lb (128 to 157 N--m) 2 94 to 116 ft--lb (128 to 157 N--m) 3 2 3 8 7 6 4 7 RIGHT 9 10 4 5 6 11 FRONT Figure 8 1. 2. 3. 4. Saddle frame Cap screw Lock nut Flange bushing (2 used per mount) Chassis 5. 6. 7. 8. Pivot mount (2 used) Grease fitting (1 used per mount) Thrust washer Brush housing Page 5 -- 12 9. Cap screw 10. Flat washer 11.
Removal (Fig. 8) 4. Position brush housing under raised hopper. 1. Position sweeper on a level surface with dump hopper empty and lowered. Have sweeper attached to towing vehicle, apply vehicle parking brake, stop engine and remove key from the ignition switch. Chock sweeper wheels to prevent sweeper from moving. 5. Slowly lower hopper to position saddle frame to brush housing (see Servicing the Brush Housing in this section). 2.
Roller Antiseize Lubricant 3 Antiseize Lubricant 1 2 15 2 14 5 6 RIGHT 5 4 12 FRONT 7 13 8 11 Loctite #242 9 10 125 to 165 in--lb (14.2 to 18.6 N--m) Figure 10 1. 2. 3. 4. 5. Roller scraper Carriage screw (8 used) Roller Brush housing Flange nut (10 used) Chassis 6. 7. 8. 9. 10. Bearing flange (2 used per bearing) Locking collar (2 used) Set screw (1 per collar) Bearing (2 used) Lock nut (2 used per bearing) Page 5 -- 14 11. 12. 13. 14. 15.
Removal (Fig. 10) Installation (Fig. 10) 1. Position sweeper on a level surface with dump hopper empty and lowered. Have sweeper attached to towing vehicle, apply vehicle parking brake, stop engine and remove key from the ignition switch. Chock sweeper wheels to prevent sweeper from moving. 1. Clean roller shaft ends and apply 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.
Frame Assembly 9 RIGHT 3 4 17 18 2 16 15 FRONT 4 17 3 4 15 9 14 2 6 12 2 2 1 4 13 4 7 8 5 10 11 Figure 12 1. 2. 3. 4. 5. 6. Main frame Cap screw (4 used) Pivot pin (2 used) Flange nut (6 used) Pitch frame Pivot pin 7. 8. 9. 10. 11. 12. Cap screw (2 used) Pivot pin (2 used) Hardened spacer (2 used) Pivot saddle Carriage bolt Pivot pin 13. 14. 15. 16. 17. 18. Lock nut Saddle frame Cap screw Lift cylinder Lock nut Link Disassembly (Fig. 12) Assembly (Fig. 12) 1.
Chapter 6 Electrical Diagrams Table of Contents Electrical Diagrams 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) . . . . . . . . . . . . . .
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CAP NOTE: NO OTHER MACHINE FUNCTIONS WILL WORK WHEN LEARN SHUNT WIRES ARE CONNECTED.
CONTROL MODULE Model: Model: 44538 07066 TestedtotoCompl Comply y Tested WithFCC FCCStandar Standards ds With FO R HO ME OOR R OOFFIC S EE FOR HOME FFICEEUUS NN1 16 62 25 5 Canada Canada 3575APFB1 3575APFB1 Made Made in in U.S U.S.A. .A.
CONTROL MODULE Model: Model: 44538 07066 ON Tested TestedtotoCompl Comply y With WithFCC FCCStandar Standards ds FO FORRHO HOME ME OOR R OFFIC O FFICE E UUS S EE NN1 16 62 25 5 Canada Canada 3575APFB1 3575APFB1 Made Made in in U.S U.S.A. .A.
CONTROL MODULE Model: 44538 07066 Model: ON Tested TestedtotoCompl Comply y With WithFCC FCCStandar Standards ds FO FOR R HO HOME ME OOR R OOFFIC FFICEEUUS S EE NN1 16 62 25 5 Canada Canada 3575APFB1 3575APFB1 Made in in U.S U.S.A. Made .A.
CONTROL MODULE Model: Model: 44538 07066 Tested TestedtotoCompl Comply y With WithFCC FCCStandar Standards ds FORRHOME HO MEOR O ROOFFIC FO FFICEEUUSSEE (ENERGIZED) NN1 16 62 25 5 Canada Canada 3575APFB1 3575APFB1 Made in in U.S U.S.A. Made .A. LED’S ILLUMINATED CONTROL MODULE CAP ON (ENERGIZED) ON ON ON 115-- 9062 (ENERGIZED) REMOTE TRANSMITTER HOPPER DUMP BUTTON PRESSED AND HELD AFTER DUMP SEQUENCE (SWITCH CLOSED) (SWITCH LED ILLUMINATED) (ENERGIZED) Electrical Power Exists to Pro Sweep.
CONTROL MODULE Model: Model: 44538 07066 Tested TestedtotoCompl Comply y With WithFCC FCCStandar Standards ds FO FORRHO HOME MEOORROOFFIC FFICEEUUSSEE NN1 16 62 25 5 Canada Canada 3575APFB1 3575APFB1 ON Made Made in in U.S.A. U.S .A.
CONTROL MODULE Model: Model: 44538 07066 Tested TestedtotoCompl Comply y With WithFCC FCCStandar Standards ds FO FORRHO HOME MEOORROOFFIC FFICEEUUSSEE NN1 16 62 25 5 Canada Canada 3575APFB1 3575APFB1 Made Made in in U.S.A. U.S .A. LED’S ILLUMINATED (ENERGIZED) ON (ENERGIZED) CONTROL MODULE CAP (ENERGIZED) ON 115-- 9062 REMOTE TRANSMITTER NO BUTTONS PRESSED Electrical Power Exists to Pro Sweep. Remote Transmitter Sweeper Down Button Pressed and Released. Latched Relays Keep Circuit Energized.
CONTROL MODULE Model: 44538 07066 Model: (ENERGIZED) Tested TestedtotoCompl Comply y With WithFCC FCCStandar Standards ds FO FOR R HO HOME MEOORROOFFIC FFIC EEUUSSEE NN1 16 62 25 5 Canada Canada 3575APFB1 3575APFB1 Made in in U.S U.S.A. Made .A. LED’S ILLUMINATED (SWITCH CLOSED) (SWITCH LED ILLUMINATED) (ENERGIZED) ON ON CONTROL MODULE CAP ON ON 115-- 9062 REMOTE TRANSMITTER OFFSET RIGHT BUTTON PRESSED AND HELD PRESSED Electrical Power Exists to Pro Sweep.
BLUE BLACK RED Pro Sweep Power Wire Harness Page 6 -- 11
CONTROL MODULE CONTROL MODULE Pro Sweep Main Wire Harness Drawing Page 6 -- 12
PINK PINK PINK BROWN BLUE BLACK BROWN BLACK YELLOW BROWN BLACK BLACK PINK PINK PINK VIOLET YELLOW BLUE RED BLACK BLUE PINK GRAY BLACK PINK ORANGE BLACK BLACK BLACK ORANGE YELLOW WHITE PINK BLACK WHITE PINK CONTROL MODULE BLACK PINK BLUE PINK BLACK BLUE WHITE ORANGE BLACK TAN WHITE BLACK WHITE GRAY PINK RED ORANGE GRAY PINK WHITE GREEN TAN YELLOW GREEN BLACK YELLOW BLACK PINK ORANGE YELLOW BLACK GRAY YELLOW BLACK ORANGE PINK DUMP BEEPER Pro Sweep Main Wire Harness Diagram
