Toro Pro Sweep 5200 User manual

Part No. 05137SL (Rev. A)
Service Manual
Pro Sweep 5200
Preface
The purpose of this publication is to provide the service
technician with information for troubleshooting, testing
and repair of major systems and components on the Pro
Sweep 5200.
REFER TO THE OPERATOR’S MANUAL FOR OPER-
ATING, MAINTENANCE AND ADJUSTMENT
INSTRUCTIONS. Space is provided in Chapter 2 of this
book to insert the Operator’s Manual and Parts Catalog
for your machine. Additional copies of the Operator’s
Manual and Parts Catalog are available on the internet
at www.Toro.com.
The Toro Company reserves the right to change product
specifications or this publication without notice.
This safety symbol means DANGER, WARNING,
or CAUTION, PERSONAL SAFETY INSTRUC-
TION. When you see this symbol, carefully read
the instructions that follow. Failure to obey the
instructions may result in personal injury.
NOTE: ANOTE will give general information about the
correct operation, maintenance, service, testing or re-
pair of the machine.
IMPORTANT: The IMPORTANT notice will give im-
portantinstructionswhichmustbefollowedtopre-
vent damage to systems or components on the
machine.
EThe Toro Company -- 2005, 2009

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Pro Sweep 5200

Table Of Contents
Chapter 1 – Safety
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 2
Jacking Instructions .. . . . . . . . . . . . . . . . . . . . . . . . 1 – 4
Securing Pro Sweep 5200 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 . . . . . . . . . . . . . . . . . . . . . . . . 4 – 2
Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . 4 – 5
Hydraulic Flow Diagrams . . . . . . . . . . . . . . . . . . . . 4 – 6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 10
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 4 – 13
PARKER TORQLINKTM SERVICE PROCEDURE
Chapter 4 – Electrical System
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 2
Safety Interlock System . . . . . . . . . . . . . . . . . . . . . 5 – 4
Component Testing . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 5
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 5 – 11
Chapter 5 – Chassis
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 2
General Information . . . . . . . . . . . . . . . . . . . . . . . . 6 – 2
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 6 – 3
Chapter 6 – Electrical Diagrams
Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . 6 – 3
Circuit Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 4
Wire Harness Drawings . . . . . . . . . . . . . . . . . . . . . 6 – 7
SafetyProduct Records
and Maintenance
Hydraulic
System
Electrical
Chassis
Electrical
SystemDiagrams
Pro Sweep 5200

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Pro Sweep 5200

Chapter 1
Safety
Table of Contents
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 2
Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Maintenance and Service . . . . . . . . . . . . . . . . . . . . 3
JACKING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . 4
SECURING PRO SWEEP 5200 TO TOW VEHICLE 5
SAFETY AND INSTRUCTION DECALS . . . . . . . . . . 5
Safety
Pro Sweep 5200 Page 1 – 1 Safety

Rev. A Pro Sweep 5200
Page 1 -- 2
Safety
Safety Instructions
The Pro Sweep 5200 is designed and tested to offer
safe service when operated and maintained properly.
Although hazard control and accident prevention par-
tially are dependent upon the design and configuration
of the machine, these factors are also dependent upon
the awareness, concern and proper training of the per-
sonnel involved in the operation, transport, mainte-
nance and storage of the machine. Improper use or
maintenance of the machine can result in injury or
death. To reduce the potential for injury or death, comply
with the following safety instructions.
WARNING
To reduce the potential for injury or death,
comply with thefollowing safetyinstructions.
Before Operating
1. Read and understand the contents of the Operator’s
Manual before starting and operating the machine. Be-
come 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 in place.
If a shield, safety device or decal is defective, illegible
or damaged, repair or replace it before operating the
machine. Also tighten any loose nuts, bolts or screws to
ensure machine is in safe operating condition.
3. Make sure that the tow vehicle is carefully selected
to assure the best performance and safe operation of
the Pro Sweep 5200.
4. Assure sweeper interlock system functions correctly
so sweeper brush does not rotate unless dump hopper
is lowered.
5. Make sure that operator is familiar with tow vehicle
operation.
While Operating
1. Operator should be in the operators position when
operating the tow vehicle and sweeper. Stay away from
the sweeper when the brush is engaged.
2. Make sure that hitch pin is properly positioned in tow
vehicle and sweeper. Hitch pin should be secured with
hairpin clip.
3. Do not run tow vehicle engine in a confined area with-
out adequate ventilation. Exhaust fumes are hazardous
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.
6. While operating, the Pro Sweep 5200 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 ve-
hicle:
A. Stop sweeper brush.
B. Ensure that vehicle traction lever is in neutral, set
parking brake, stop engine and remove key from
ignition switch.
C. Make sure that dump hopper is lowered.
8. Park on level surface, empty hopper and chock
sweeper wheels before disconnecting Pro Sweep 5200
from tow vehicle.

Maintenance and Service
1. Before servicing or making adjustments, empty
sweeper hopper and position sweeper on a level sur-
face. Chock sweeper wheels to prevent it from moving.
If sweeper is attached to tow vehicle, engage tow ve-
hicle 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 be-
fore applying pressure to the hydraulic system.
4. Keep body and hands away from pin hole leaks in hy-
draulic lines that eject high 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 pres-
sure in system must be relieved. See Relieving Hydrau-
lic 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 lift cylinder stop to ensure
that unexpected shifting of sweeper frame does not oc-
cur.
8. Disconnect electrical power harness from tow ve-
hicle before servicing the sweeper.
9. If major repairs are ever needed or assistance is de-
sired, 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 ac-
cessories. Replacement parts and accessories made
by other manufacturers may result in non-conformance
with the safety standards, and the warranty may be
voided.
11. When changing tires or performing other service,
use correct blocks, hoists and jacks. Make sure ma-
chine is parked on a solid level floor such as a concrete
floor with the hopper empty and lowered. Have sweeper
attached to towing vehicle, engage vehicle parking
brake, stop engine and remove key from the ignition
switch. Always chock or block wheels. Use jack stands
or solid wood blocks to support the raised machine. If
the machine is not properly supported by blocks or jack
stands, the machine may move or fall, which may result
in personal injury (see Jacking Instructions).
Safety
Pro Sweep 5200 Page 1 – 3 Safety

Jacking Instructions
CAUTION
chine. If the machine is not properly supported
move or fall, which may result in personal inju-
2
1
When changing tires or performing other ser-
vice, use correct blocks, hoists and jacks to
support sweeper. Make sure machine is parked
on a solid level surface such as a concrete floor.
Always chock or block wheels. Use jack stands
or solid wood blocks to support the raised ma-
by blocks or jack stands, the machine may
ry.
1. Position sweeper on a level surface with dump hop-
per empty and lowered. Have sweeper attached to tow-
ing vehicle, engage vehicle parking brake, stop engine 1. Wheel 2.
Figure 1
Frame jacking point
and remove key from the ignition switch. Chock sweep-
er wheels to prevent it from moving.
2. Position jack securely under the main sweeper
frame (Fig. 1). Do not use the axle as a jacking point.
3. Carefully jack machine off the ground.
4. Position jack stands or hardwood blocks under the
main frame to support the sweeper.
Safety Page 1 – 4 Pro Sweep 5200

Securing Pro Sweep 5200 to Tow Vehicle
While operating or servicing the Pro Sweep 5200, make
sure that hitch pin is properly positioned in tow vehicle
hitch and sweeper tongue. Hitch pin should be secured
with hairpin clip (Fig. 2).
2
1
Figure 2
1. Hitch pin 2. Hairpin clip
Safety and Instruction Decals
Numerous safety and instruction decals are affixed to
the Pro Sweep 5200. If any decal becomes illegible or
damaged, install a new decal. Part numbers for replace-
ment decals are listed in your Parts Catalog. Order re-
placement decals from your Authorized T
oro Distributor.
Safety
Pro Sweep 5200 Page 1 – 5 Safety

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Safety Page 1 – 6 Pro Sweep 5200

Chapter 2
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
Product Records
Insert Operator’s Manual and Parts Catalog for your Pro
Sweep 5200 at the end of this chapter. Additionally, if
any optional equipment or accessories have been
installed to your machine, insert the Installation Instruc-
tions, Operator’s Manuals and Parts Catalogs for those
options at the end of this chapter.
Maintenance
Maintenance procedures and recommended service in-
tervals for the Pro Sweep 5200 are covered in the Oper-
ator’s Manual. Refer to that publication when performing
regular equipment maintenance.
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
Product Records
and Maintenance
Pro Sweep 5200 Page 2 – 1 Product Records and Maintenance

Rev. A
0.09375
Pro Sweep 5200
Page 2 -- 2
Product Records and Maintenance
Equivalents and Conversions

Torque Specifications
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 spe-
cified 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 Ser-
vice 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
on the fastener, presence of a prevailing torque feature,
hardness of the surface underneath the fastener’s head
or similar condition which affects the installation.
As noted in the following tables, torque values should be
reduced by 25% for lubricated fasteners to achieve
the similar stress as a dry 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 en-
gagement, etc.
The standard method of verifying torque shall be per-
formed by marking a line on the fastener (head or nut)
and mating part, then back off fastener 1/4 of a turn.
Measure the torque required to tighten the fastener until
the lines match up.
Product Records
and Maintenance
Fastener Identification
Grade 1 Grade 5 Grade 8
Inch Series Bolts and Screws
Class 8.8 Class 10.9
Metric Bolts and Screws
Figure 1 Figure 2
Pro Sweep 5200 Page 2 – 3 Product Records and Maintenance

Rev. A Pro Sweep 5200
Page 2 -- 4
Product Records and Maintenance
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series)
Thread Size
Grade 1, 5 &
8withThin
Height Nuts
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)
SAE Grade 8 Bolts, Screws, Studs &
Sems with Regular Height Nuts
(SAE J995 Grade 5 or Stronger Nuts)
in--lb in--lb N--cm in--lb N--cm in--lb N--cm
# 6 -- 32 UNC
1
0
+
2
1
3
+
2
1
4
7
+
2
3
15 + 2169 + 23 23 + 3262 + 34
# 6 -- 40 UNF
10 + 213 + 2147 + 23
17 + 2192 + 23 25 + 3282 + 34
# 8 -- 32 UNC
1
3
+
2
2
5
+
5
2
8
2
+
3
0
29 + 3328 + 34 41 + 5463 + 56
# 8 -- 36 UNF
13 + 225 + 5282 + 30
31 + 4350 + 45 43 + 5486 + 56
#10--24UNC
1
8
+
2
3
0
+
5
3
3
9
+
5
6
42 + 5475 + 56 60 + 6678 + 68
#10--32UNF
18 + 230 + 5339 + 56
48 + 5542 + 56 68 + 7768 + 79
1/4 -- 20 UNC 48 + 753 + 7599 + 79 100 + 10 1130 + 113 140 + 15 1582 + 169
1/4 -- 28 UNF 53 + 765 + 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
ft--lb ft--lb N--m ft--lb N--m ft--lb N--m
3/8 -- 16 UNC 16 + 216 + 222 + 330 + 341 + 443 + 558 + 7
3/8 -- 24 UNF 17 + 218 + 224 + 335 + 447 + 550 + 668 + 8
7/16 -- 14 UNC 27 + 327 + 337 + 450 + 568 + 770 + 795 + 9
7/16 -- 20 UNF 29 + 329 + 339 + 455 + 675 + 877 + 8104 + 11
1/2 -- 13 UNC 30 + 348 + 765 + 975 + 8102 + 11 105 + 11 142 + 15
1/2 -- 20 UNF 32 + 453 + 772 + 985 + 9115 + 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: 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.
NOTE: The nominal torque values listed above for
Grade 5 and 8 fasteners are based on 75% of the mini-
mum proof load specified in SAE J429. The tolerance is
approximately + 10% of the nominal torque value. Thin
height nuts include jam nuts.

Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Fasteners)
Thread Size
Thread Size
Class 8.8 Bolts, Screws and Studs with
Regular Height Nuts
Regular Height Nuts
(Class 8 or Stronger Nuts)
Class 10.9 Bolts, Screws and Studs with
Regular Height Nuts
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 1.5 38 + 4 ft–lb 52 + 5 N–m 54 + 6 ft–lb 73 + 8 N–m
M12 X 1.75 66 + 7 ft–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
Product Records
and Maintenance
NOTE: Reduce torque values listed in the table above NOTE: The nominal torque values listed above are
by 25% for lubricated fasteners. Lubricated fasteners based on 75% of the minimum proof load specified in
are defined as threads coated with a lubricant such as SAE J1199. The tolerance is approximately + 10% of the
engine oil or thread sealant such as Loctite. nominal torque value.
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.
Pro Sweep 5200 Page 2 – 5 Product Records and Maintenance

Other Torque Specifications
SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts
Thread Size
Thread Size
Recommended Torque
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
Thread Size Recommended Torque**
7/16 – 20 UNF
Grade 5
65 + 10 ft–lb 88 + 14 N–m
1/2 – 20 UNF
Grade 5
80 + 10 ft–lb 108 + 14 N–m
M12 X 1.25
Class 8.8
80 + 10 ft–lb 108 + 14 N–m
M12 X 1.5
Class 8.8
80 + 10 ft–lb 108 + 14 N–m
** For steel wheels and non–lubricated fasteners.
Thread Cutting Screws Thread Cutting Screws
(Zinc Plated Steel) (Zinc Plated Steel)
Type 1, Type 23 or Type F
Thread Size Baseline Torque*
No. 6 – 32 UNC 20 + 5 in–lb
No. 8 – 32 UNC 30 + 5 in–lb
No. 10 – 24 UNC 38 + 7 in–lb
1/4 – 20 UNC 85 + 15 in–lb
5/16 – 18 UNC 110 + 20 in–lb
3/8 – 16 UNC 200 + 100 in–lb
Thread
Size
Size
Threads per Inch
Baseline T
orque*Baseline Torque*
Type A Type B
No. 6 18 20 20 + 5 in–lb
No. 8 15 18 30 + 5 in–lb
No. 10 12 16 38 + 7 in–lb
No. 12 11 14 85 + 15 in–lb
* Hole size, material strength, material thickness & finish
must be considered when determining specific torque
values. All torque values are based on non–lubricated
fasteners.
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
Product Records and Maintenance Page 2 – 6 Pro Sweep 5200

Chapter 3
Hydraulic System
Table of Contents
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2
Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hydraulic Fitting Installation . . . . . . . . . . . . . . . . . . 2
Relieving Hydraulic System Pressure . . . . . . . . . . 4
Securing Sweeper to Tow Vehicle . . . . . . . . . . . . . 4
HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . 5
HYDRAULIC FLOW DIAGRAMS . . . . . . . . . . . . . . . . 6
Brush Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hopper Dump/Lower Circuits . . . . . . . . . . . . . . . . . 8
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 10
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 13
General Precautions for Removing and Installing
Hydraulic System Components . . . . . . . . . . . . . 13
Check Hydraulic Lines and Hoses . . . . . . . . . . . . 13
Brush Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Brush Motor Service . . . . . . . . . . . . . . . . . . . . . . . . 16
Hydraulic Control Manifold . . . . . . . . . . . . . . . . . . 18
Hydraulic Control Manifold Service . . . . . . . . . . . 20
Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Lift Cylinder Service . . . . . . . . . . . . . . . . . . . . . . . . 24
PARKER TORQLINKTM SERVICE PROCEDURE
Hydraulic
System
Pro Sweep 5200 Page 3 – 1 Hydraulic System

General Information
Hydraulic Hoses
Hydraulic hoses are subject to extreme conditions such
as pressure differentials during operation and exposure
to weather, sun, chemicals, very warm storage condi-
tions or mishandling during operation and maintenance.
These conditions can cause damage or premature dete-
rioration. Some hoses are more susceptible to these
conditions than others. Inspect the hoses frequently for
signs of deterioration or damage.
When replacing a hydraulic hose, be sure that the hose
is straight (not twisted) before tightening the fittings.
This can be done by observing the imprint on the hose.
Use two wrenches; hold the hose straight with one
wrench and tighten the hose swivel nut onto the fitting
with the other wrench.
Before disconnecting or performing any work
sure in this section.
to search for leaks. Hydraulic fluid escaping
under pressure can have sufficient force to
cally removed within a few hours by a doctor
WARNING
on hydraulic system, relieve all pressure in
system. See Relieving Hydraulic System Pres-
Keep body and hands away from pin hole leaks
or nozzles that eject hydraulic fluid under high
pressure. Use paper or cardboard, not hands,
penetrate the skin and cause serious injury. If
fluid is injected into the skin, it must be surgi-
familiar with this type of injury. Gangrene may
result from such an injury.
Hydraulic Fitting Installation
O–Ring Face Seal
1. Make sure both threads and sealing surfaces are
free of burrs, nicks, scratches or any foreign material.
2. Make sure the o–ring is installed and properly seated
in the groove. It is recommended that the o–ring be re-
placed any time the connection is opened.
3. Lubricate the o–ring with a light coating of oil.
Nut
Sleeve
Seal
Body
4. Put the tube and nut squarely into position on the Figure 1
face seal end of the fitting and tighten the nut until finger
tight.
5. Mark the nut and fitting body. Hold the body with a
wrench. Use another wrench to tighten the nut to the cor- Final
rect Flats From Finger Tight (F.F.F.T.). The markings on Position
the nut and fitting body will verify that the connection has Mark Nut
and Body
been tightened.
Initial
Size F.F.F.T. Extend Line Position
4 (1/4 in. nominal hose or tubing) 0.75 + 0.25 Finger Tight After Proper Tightening
6 (3/8 in.) 0.75 + 0.25
8 (1/2 in.) 0.75 + 0.25
10 (5/8 in.) 1.00 + 0.25 Figure 2
12 (3/4 in.) 0.75 + 0.25
16 (1 in.) 0.75 + 0.25
Hydraulic System Page 3 – 2 Pro Sweep 5200

SAE Straight Thread O–Ring Port – Non–adjustable
1. Make sure both threads and sealing surfaces are
free of burrs, nicks, scratches or any foreign material.
2. Always replace the o–ring seal when this type of fit-
ting shows signs of leakage.
3. Lubricate the o–ring with a light coating of oil.
O–Ring
4. Install the fitting into the port and tighten it down full Figure 3
length until finger tight.
5. Tighten the fitting to the correct Flats From Finger
Tight (F.F.F.T.).
Size F.F.F.T.
4 (1/4 in. nominal hose or tubing) 1.00 + 0.25
6 (3/8 in.) 1.50 + 0.25
8 (1/2 in.) 1.50 + 0.25
10 (5/8 in.) 1.50 + 0.25
12 (3/4 in.) 1.50 + 0.25
16 (1 in.) 1.50 + 0.25
Fitting Size Installation Torque
4 9–10 ft–lb (12–13 N–m)
6 20–21 ft–lb (27–28 N–m)
8 35–37 ft–lb (47–50 N–m)
10 60–66 ft–lb (81–89 N–m)
12 81–87 ft–lb (110–117 N–m)
16 121–131 ft–lb (164–177 N–m)
NOTE: Installation torque values for non–adjustable fit- Figure 4
tings are listed in Figure 4. These torque values should
only be used when a fitting can be accessed with a
socket. Use of an offset wrench (e.g. crowfoot wrench)
will affect torque wrench accuracy and should not be
used.
SAE Straight Thread O–Ring Port – Adjustable
1. Make sure both threads and sealing surfaces are
free of burrs, nicks, scratches or any foreign material.
2. Always replace the o–ring seal when this type of fit-
ting shows signs of leakage.
3. Lubricate the o–ring with a light coating of oil.
4. Turn back the jam nut as far as possible. Make sure
Lock Nut
Back–up Washer
the back up washer is not loose and is pushed up as far
as possible (Step 1). O–Ring
5. Install the fitting into the port and tighten finger tight Figure 5
until the washer contacts the face of the port (Step 2).
6. To put the fitting in the desired position, unscrew it by
the required amount, but no more than one full turn
(Step 3). Step 1
Step 4
Step 3
7. Hold the fitting in the desired position with a wrench
and turn the jam nut with another wrench to the correct
Flats From Finger Tight (F.F.F.T.) (Step 4).
Size F.F.F.T. Step 2
4 (1/4 in. nominal hose or tubing) 1.00 + 0.25
6 (3/8 in.) 1.50 + 0.25
8 (1/2 in.) 1.50 + 0.25
10 (5/8 in.) 1.50 + 0.25
12 (3/4 in.) 1.50 + 0.25
16 (1 in.) 1.50 + 0.25 Figure 6
Hydraulic
System
Pro Sweep 5200 Page 3 – 3 Hydraulic System

Relieving Hydraulic System Pressure
CAUTION
Operate all sweeper hydraulic controls to relieve
system pressure and to avoid injury from pres-
surized hydraulic oil. See Relieving Hydraulic
System Pressure in the General Information sec-
tion of this chapter.
Before disconnecting or performing any work on the
sweeper hydraulic system, all pressure in the hydraulic
system must be relieved. With the hopper fully lowered,
turn tow vehicle key switch to OFF and allow engine to
stop.
To relieve sweeper hydraulic system pressure, turn tow
vehicle key switch to ON (engine not running). Press
brush switch on and off. Press hopper switch to both
raise and lower. After cycling the switches, return tow
vehicle key switch to OFF and remove key from the igni-
tion switch.
Securing Sweeper to Tow Vehicle (Fig. 7)
While servicing the Pro Sweep 5200, make sure that the
hitch pin is properly positioned in tow vehicle hitch and
sweeper tongue. Hitch pin should be secured with hair-
pin clip.
2
1
Figure 7
1. Hitch pin 2. Hairpin clip
Hydraulic System Page 3 – 4 Pro Sweep 5200