Controller Kit

1. Park the machine on a level surface.

2. Raise the hopper and secure it in place with the cylinder lock.

3. Disconnect the power connector from the traction unit.

4. Ensure that the machine is secure from movement before you begin the installation.

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Only When Upgrading

1. Remove the hardware securing the compartment cover and set it aside (Figure 1).

   

   Figure 1

   1. Bolt (5/16 x 1 inch)
   2. Washer
   3. Terminal nut (3/8 inch)
   4. Compartment

2. Disconnect the wire harness from all the components except the relays (Figure 2).

   

   Figure 2

   1. Relay
   2. Nut (1/4 inch)
   3. Wire harness
   4. Transceiver
   5. Washer
   6. Bolt (1/4 x 1-1/2 inches)
   7. Bolt (1/4 x 5/8 inch)

3. Remove all the hardware securing the components on the inside of the compartment (Figure 2).

4. Remove all the components except for the audio alarm from the compartment (Figure 2).

5. Remove the retaining nuts and washers from the front of the proximity sensors on the right side sensor plate and set them aside (Figure 3).

   

   Figure 3

   1. Retaining nut
   2. Washer
   3. Carriage bolt (3/8 x 1 inch)
   4. Right sensor plate
   5. Flange nut (3/8 inch)
   6. Proximity sensor

6. Remove the proximity sensors from the right sensor plate and set them aside.

7. Remove the carriage bolts and flange nuts securing the right sensor plate to the frame (Figure 3).

8. Remove the carriage bolts and flange nuts securing the left sensor plate to the frame (Figure 4).

   

   Figure 4

   1. Flange nut (3/8 inch)
   2. Left sensor plate
   3. Carriage bolt (3/8 x 1 inch)

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1. Locate and drill the following hole for the plug cap (Figure 5).

   

   Figure 5

   1. 7/32 inch diameter
   2. 267 mm (10-1/2 inches)
   3. 25 mm (1 inch)

2. Locate and drill the following holes for the fuse block and relay (Figure 6).

   

   Figure 6

   1. 64 mm (2-1/2 inches)
   2. 17 mm (21/32 inch)
   3. 15 mm (19/32 inch)
   4. 63 mm (2-15/32 inches)
   5. 91 mm (3-19/32 inches)
   6. 9/32 inch diameter

3. Locate and drill the following holes for the transmitter (Figure 7).

   Note: You can use the transmitter as a template.

   

   Figure 7

   1. 9/32 inch diameter
   2. 99 mm (3-29/32 inch)
   3. 14 mm (9/16 inch)
   4. 10 mm (3/8 inch)
   5. 113 (4-7/16 inch)

4. Locate and drill the following holes for the controller (Figure 8).

   Note: You can use the controller as a template.

   

   Figure 8

   1. 184 mm (7-1/4 inches)
   2. 304 mm (11-31/32 inches)
   3. 9/32 inch diameter
   4. 50 mm (1-31/32 inches)
   5. 188 mm (7-31/32 inches)

5. Locate and drill the following hole for the controller (Figure 9).

   

   Figure 9

   1. 185 mm (7-9/32 inches)
   2. 14 mm (9/16 inch)
   3. 6.8 mm (9/32 inch)

   Note: Ensure that you do not oversize the hole.

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Parts needed for this procedure:

Fuse decal	1
Electrical update decal	1

1. Ensure that the application surface is clean.

2. Locate and apply the fuse decal at the location shown (Figure 10).

   

   Figure 10

   1. 89 mm (3-1/2 inch)
   2. 44 mm (1-3/4 inch)

3. Apply the electrical update decal next to the serial tag on the machine.

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Parts needed for this procedure:

Radio transmitter	1
Radio controller	1
Indicator lamp	1
Relay	1
Bolt (1/4 x 1-1/8 inches)	8
Bolt (1/4 x 3/4 inch)	3
Bolt (#10 x 7/8 inch)	1
Flange nut (1/4 inch)	11
Locknut (#10)	1

1. Use the 4 bolts (1/4 x 3/4 inch) and flange nuts to secure the transceiver (Figure 11).

   

   Figure 11

   1. Transceiver
   2. Flange nut (1/4 inch)
   3. Bolt (1/4 x 3/4 inch)

2. Use the 4 bolts (1/4 x 3/4 inch) and flange nuts to secure the controller (Figure 12).

   

   Figure 12

   1. Controller
   2. Flange nut (1/4 inch)
   3. Bolt (1/4 x 3/4 inch)

3. Use the bolt (1/4 x 3/4 inch) and flange nut to secure the relay (Figure 13).

   

   Figure 13

   1. Flange nut (1/4 inch)
   2. Relay
   3. Bolt (1/4 x 3/4 inch)

4. Remove the fuse cap from the wire harness.

5. Use the 2 bolts (1/4 x 3/4 inch) and flange nuts to secure the fuse cap (Figure 14).

   

   Figure 14

   1. Flange nut (1/4 inch)
   2. Fuse block
   3. Bolt (1/4 x 3/4 inch)

6. Insert the connector through the mount hole in the cover panel (Figure 15).

   

   Figure 15

   1. Connector
   2. Retaining nut
   3. Lock washer
   4. Mounting hole
   5. Gasket
   6. Indicator light

   Note: Ensure that the gasket is installed between the cover and indicator light (Figure 15).

7. Use the retaining nut and lock washer to secure the indicator light to the mount hole in the cover panel (Figure 15).

8. Remove the plug cap from the wire harness.

9. Use the bolt (#10 x 7/8 inch) and locknut to secure the plug cap to the controller box (Figure 16).

   

   Figure 16

   1. Bolt (#10 x 7/8 inch)
   2. Plug cap
   3. Locknut (#10)

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Parts needed for this procedure:

Right sensor plate	1
Left sensor plate	1
Proximity sensor	1

1. Use the 2 carriage bolts (3/8 x 1 inch) and flange nuts to secure the right sensor plate to the machine (Figure 17).

   

   Figure 17

   1. Retaining nut
   2. Washer
   3. Right sensor plate
   4. Proximity sensor
   5. Carriage bolt (3/8 x 1 inch)
   6. Flange nut (3/8 inch)

2. Use the retaining nuts and washers to secure the proximity sensors that you removed earlier to the right sensor plate (Figure 17).

   Important: Ensure that you do not damage the front of the sensor when it is installed.

3. Use the carriage bolt (3/8 x 1 inch) and flange nut to secure the left sensor plate to the machine (Figure 18).

   

   Figure 18

   1. Proximity sensor
   2. Flange nut (3/8 inch)
   3. Left sensor plate
   4. Carriage bolt (3/8 x 1 inch)
   5. Washer
   6. Retaining nut

4. Use the retaining nut and washer to secure the proximity sensor included in the kit to the left sensor plate (Figure 18).

   Important: Ensure that you do not damage the front of the sensor when it is installed.

5. Set a 3.6 mm (0.14 inch) sensor gap to each sensor that you installed (Figure 19).

   

   Figure 19

   1. 3.6 mm (0.14 inch)

   Important: Ensure that you do not damage the front of the sensor when you set the sensor gap.

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Parts needed for this procedure:

Wire harness	1
Cable tie	10
Cable-tie clip	2

1. Route the wire harness onto the frame of the tow-behind vehicle (Figure 20).

   

   Figure 20

   Note: Ensure that you route the wire harness through the hose rings at the front of the tow-behind vehicle.

2. Use the cable-tie clips that are on the wire harness to secure it to the frame.

3. Follow the color code and connector keying to ensure that you are installing the appropriate connector to the component plug (Figure 21).

   

   Figure 21

   1. Fuse block
   2. Relay
   3. Transceiver (keyed)
   4. Audio alarm
   5. Controller (color coded and keyed)
   6. Controller (color coded and keyed)
   7. Plug cap

4. Connect the wire harness to the hydraulic manifold (Figure 22).

   

   Figure 22

   1. Hitch left (P21)
   2. Hitch right (P20)
   3. Hopper down (P18)
   4. Brush solenoid (P17)
   5. Hydraulic manifold
   6. Hopper up (P19)

5. Connect the wire harness to the appropriate proximity sensor (Figure 23 and Figure 24).

   

   Figure 23

   1. Proximity sensor
   2. Cable-tie clip
   3. Proximity sensor
   

   Figure 24

   1. Cable-tie clip
   2. Proximity sensor

6. Install the cable-tie clips to the left and right sensor plate (Figure 23 and Figure 24).

7. Insert the cable ties through the clip and around the wire harness connectors to secure it to the sensor plate (Figure 23) and Figure 24).

8. Use cable ties to secure the wire harness to the hydraulic hoses (Figure 25).

   

   Figure 25

   1. Cable tie
   2. Hydraulic hose

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Parts needed for this procedure:

Compartment cover

1

1. Connect the indicator light to the wire harness (Figure 26).

   

   Figure 26

   1. Connector
   2. Bolt (3/8 x 1 inch)
   3. Washer
   4. Terminal nut (3/8 inch)
   5. Compartment cover

2. Use the bolt (3/8 x 1 inch) and nut that you removed earlier to secure cover to the compartment (Figure 26).

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Parts needed for this procedure:

Handheld remote	1
AA battery	4

1. Remove the rubber bands securing the remote halves together, and remove the back cover.

2. Install the batteries into the terminal cradle observing proper polarity (Figure 27).

   

   Figure 27

   1. Batteries
   2. Cover
   3. Screw

   Note: The controller cannot function when the batteries are installed improperly.

3. Replace the cover and secure it with the 6 screws removed previously (Figure 27) and torque them to 1.5 to 1.7 N∙m (13 to 15 in-lb).

   Note: Do not overtighten the screws.

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To dump the hopper, press the hopper dump button 2 times (Figure 28).

Important: The sweeper must be directly behind the traction unit and in transport height before you can activate the dump sequence.

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To lower the hopper, press the sweeper down button (Figure 28). You can lower the hopper at any of the following positions:

• Hopper dump height

• Transport height

• Turn around height

  Note: When lowering the hopper from the dump position, you can stop the lower hopper function at any time by releasing the sweeper down button.

  Note: With the sweeper in the transport or turn around positions, the lower hopper function can be stopped at any time by pressing the sweeper up button.

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Standard Mode

To raise the sweeper in standard mode, press the sweeper up button. The hopper stops at the pre-defined height (Figure 28).

• Transport height (home position) is 13-1/4 to 15-1/4 inches.

• Turn around height (offset position) is 8-1/2 to 10-1/2 inches.

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Optional Mode

This mode allows the operator to adjust the sweeper to any desired height and it stops at the pre-defined heights.

Note: Refer toSwitching the Sweeper-Up Mode to switch to the optional mode.

To raise the sweeper in optional mode, press and hold the sweeper up button until the hopper reaches the desired height or stops at the pre-defined height (Figure 28).

• Transport height (home position) is 13-1/4 to 15-1/4 inches.

• Turn around height (offset position) is 8-1/2 to 10-1/2 inches.

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To offset the sweeper to the left, press and hold the offset left button (Figure 28). Releasing the button stops the movement to the left.

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To offset the sweeper to the right, press and hold the offset right button (Figure 28). Releasing the button stops the movement to the right.

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Pressing the stop button disables any active function.

Note: There is approximately a 3 second delay.

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The diagnostic light (Figure 29) is located on the compartment cover and indicates machine fault codes. After you turn the key to the RUN position, the diagnostic light illuminates for 5 seconds, turns off for 5 seconds, and then begins flashing 3 times a second until you push a button on the handheld remote. If the light turns on for 5 seconds and then starts blinking 10 times a second (with or without a 5 second pause) there is a fault with the machine; refer to Checking Fault Codes.

Note: The diagnostic light illuminates when you push a button on the handheld remote.

Note: If you press the button on the handheld remote when you start the machine, the light does not flash 3 times a second after it turns off for 5 seconds.

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Important: Read the entire procedure before attempting the association process.

The remote control must establish communications with the base unit before you can use the system. The remote control is associated to the system base unit before leaving the factory using the associate procedure. In situations where it is necessary to re-establish remote control-to-base unit communications (example: introducing a new or spare remote control to an existing base unit), you must perform the following procedure:

Note: Associating the remote control to a different base unit disassociates the remote control from the original base unit.

1. Remove power from the base unit.

2. Stand near the base unit in clear line-of-sight with the remote control in hand.

3. Simultaneously press and hold the OFFSET LEFT and OFFSET RIGHT buttons. The LED begins blinking about once per second.

4. Continue to hold both buttons until the LED begins blinking about twice per second.

5. Release the buttons.

6. Press and hold the OFFSET LEFT button. The LED begins blinking about twice per second.

7. Continue holding the OFFSET LEFT button and turn the key start to the RUN position. The LED turns solid if the procedure is successful.

   Note: This could take up to 20 seconds.

8. Release the OFFSET LEFT button.

   The system is ready for use with that remote control.

   

   Figure 30

   1. LED light
   2. Offset left
   3. Sweeper down
   4. Hopper dump
   5. Stop
   6. Sweeper up
   7. Offset right

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The sweeper-up button has 2 possible modes; standard and optional.

The standard mode allows the operator to raise the sweeper to the pre-defined heights with a single button push. Refer to Switching the Sweeper-Up Mode

The optional mode allows the operator to adjust the sweeper to any desired height and it stops at the pre-defined heights. Refer to Switching the Sweeper-Up Mode.

1. Remove the cover off the control module.

2. Unplug the 2 wire connections from the pigtail connector show in Figure 31.

3. Plug the 2 wire connections into the existing pigtail connector tethered to the wire harness.

4. Install the cover onto the control module.

   

   Figure 31

   1. Location of pigtails
   2. Optional-mode pigtail (tethered to the wire harness)
   3. Standard-mode pigtail

   Note: To return to standard mode, install the original pigtail connector.

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1. Remove the 6 screws from the back of the remote and remove the cover (Figure 32).

   Note: If possible, leave the rubber seal and steel gasket in the channel when removing the cover and batteries.

   

   Figure 32

   1. Batteries
   2. Cover
   3. Screw

2. Remove the discharged batteries and dispose of them in accordance with local regulations.

3. Install each new battery into a terminal cradle observing proper polarity.

   Note: The controller cannot function when the batteries are installed improperly.

4. If you accidentally removed the rubber seal and the steel gasket, replace them carefully into the channel in the handheld remote.

5. Install the cover and secure it with the 6 screws removed previously (Figure 32) and torque them to 1.5 to 1.7 N∙m (13 to 15 in-lb).

   Note: Do not overtighten the screws.

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