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14204SL - Toro Media

1. Figure 8 4 Drive roller shaft 5 Lock nut 4 used 1 Locking collar 2 Set screw 3 Blind hole FRONT Figure 9 1 Drive roller 2 Idler roller 3 LH conveyor frame 4 Rotation direction Chassis Floor Conveyor Belt Figure 10 Idler roller Drive roller LH conveyor frame assembly Conveyor bed assembly RH conveyor frame assembly Floor conveyor belt PONHA ONG To remove and replace the floor conveyor belt removal of the left side conveyor frame is recommended This procedure allows the hydraulic motor and drive chain components to remain in place on the right side convey or frame Removal Fig 10 1 Position machine ona level surface If ProPass is at tached to tow vehicle apply tow vehicle parking brake stop engine and remove key from the ignition switch Chock wheels to prevent ProPass machine from mov ing 2 Disconnect electrical power to ProPass machine Chassis Scraper assembly Cap screw 4 used Page 5 10 9 Flat washer 8 used 10 Lock nut 4 used 11 Flange head screw 10 used 12 Flange nut 10 used 3 Remove rear option assembly twin spinner or con veyor from machine 4 Remove drive guards idler guards bottom guard and front rinse guard from frame see Bed Guards in this section 5 On both sides of machine loosen tension on floor conveyor belt
2. Figure 13 1 LH conveyor frame assembly 8 Cap screw 4 used 2 Conveyor bed assembly 9 Flat washer 8 used 3 RH conveyor frame assembly 10 Lock nut 4 used 4 Floor conveyor belt 11 Flange head screw 10 used 5 Idler roller 12 Flange nut 10 used 6 Drive roller 13 Tensioner rod 7 Scraper assembly To remove and replace the idler roller take up bearings removal of the left side conveyor frame and the floor conveyor belt is necessary Once these items are re moved access to the left side take up bearing is pos sible The idler roller needs to be removed from the right side take up bearing before the right side bearing can be removed from the frame Chassis Page 5 14 Jam nut Flat washer Take up bearing Locking collar Set screw Grease fitting ProPass 200 Disassembly Fig 13 1 Position machine on a level surface If ProPass is at tached to tow vehicle apply tow vehicle parking brake stop engine and remove key from the ignition switch Chock wheels to prevent ProPass machine from mov ing 2 Remove left side conveyor frame and the floor con veyor belt see Floor Conveyor Belt in this section 3 If right side idler roller take up bearing is to removed remove idler roller from right side conveyor frame see Idler and Drive Rollers in this section 4 Remove take up bearings from frame using Figure 13 as a guide Assembly Fig 13 1 Apply antiseize lubricant to the groo
3. If your ProPass is equipped with the hydraulic power pack see the Hydraulic Testing section of Chapter 6 Hydraulic Power Pack for hydraulic testing procedures ProPass 200 RS EE O a N Cx gt N This page is intentionally blank ProPass 200 Page 3 25 Hydraulic System Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Hydraulic Compo nents 1 Before removing any components from the hydraulic system position ProPass machine on a level surface Engage tow vehicle parking brake stop engine and re move key from the ignition switch If ProPass is equipped with wireless controller power off wireless controller 2 Clean machine before disconnecting removing or disassembling any hydraulic components Make sure hydraulic components hoses connections and fittings are cleaned thoroughly Always keep in mind the need for cleanliness when working on hydraulic equipment Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved and all rotating machine parts must be stopped See Relieving Hydraulic Sys tem Pressure in the General Information section of this chapter 3 Putcaps or plugs on any hydraulic lines hydraulic fit tings and components left open or exposed to prevent system contamination 4 Put labels on disconnected hydraulic lines and hoses for proper installati
4. 0 0c eee eee eee 6 Adjust Manifold Relief Valve 6 HYDRAULIC TESTING 00 eee eee 8 Combined Hydraulic Power Pack Gear Pump Flow and System Relief Pressure Tests 8 Hydraulic Power Pack Gear Pump Flow 10 SERVICE AND REPAIRS 0202055 12 po pis ASR SRD dh RR RNA O ANO E ER eee 12 Power Pack Hydraulic Tank 14 Power Pack Gear Pump 0005 16 Power Pack Gear Pump Service 18 Power Pack Relief Valve 004 20 Power Pack Battery eee aeeee 22 EATON SERIES 26 GEAR PUMP PARTS and REPAIR MANUAL x oOo O O HE gt E T ProPass 200 Page 6 1 Hydraulic Power Pack Power Pack Engine Specifications Item Description Make Designation Honda Model GX340 4 Cycle OHV Gasoline Engine Bore 3 465 88 mm Stroke 2 520 64 mm Total Displacement 23 7 in 389 cc Direction of Rotation Counterclockwise viewed from PTO end Fuel Regular Unleaded Gasoline with less than 10 Ethanol Fuel Capacity 6 4 U S Quarts 6 1 Liters Governor Centrifugal Mechanical Low Idle no load 1400 RPM High Idle no load 3750 RPM Engine Oil API SJ or higher Engine Oil Viscosity See Operator s Manual Crankcase Oil Capacity 1 2 U S Quarts 1 1 Liters Starter 12 VDC Alternator Regulator 12 VDC Alternator O
5. P02 A B POL OPTION SOLENOID P03 FLOOR SOLENOID OPTION SOLENOID Figure 8 Page 4 8 PROPASS 200 MAIN VALVE WIRE HARNESS STANDARD HYDRAULIC CONTROLS ProPass 200 OPTION SWITCH FLOOR SWITCH T o wi System PROPASS 200 PENDANT WIRE HARNESS STANDARD HYDRAULIC CONTROLS Figure 9 ProPass 200 Page 4 9 Electrical System POL FLOOR FORWARD P01 BASE UNIT po5 OPTION FORWARD P03 POWER LEAD YELLOW POWER LEAD FLOOR FORWARD OPTION FORWARD PROPASS 200 BULKHEAD WIRE HARNESS ELECTRONIC HYDRAULIC CONTROLS Figure 10 Electrical System Page 4 10 ProPass 200 T t Ko wi System This page is intentionally blank ProPass 200 Page 4 11 Electrical System Special Tools Order special tools from your Toro distributor Some tools may also be available from a local supplier Multimeter The multimeter can test electrical components and cir cuits 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 The high impedance internal resistance of a digital me ter in t
6. 2 2 Multiply by 5 9 ProPass 200 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 e g Nylock nut hardness of the surface underneath the fastener s head or similar condition which affects the installation Fastener Identification Grade 1 Grade 5 Inch Series Bolts and Screws Figure 1 Using a Torque Wrench with an Offset Wrench Use of an offset wrench e g crowfoot wrench will affect torque wrench calibration due to the effective change of torque wrench length When using a torque wrench with an offset wrench multiply the listed torque recommen dation 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 recommen dation Example The measured effective leng
7. Before Operating 1 Review and understand the contents of the Opera tors Manuals before starting and operating the ma chine Become familiar with the controls and know how to stop the machine and engine quickly Additional cop ies of the Operator s Manual are available on the inter net 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 ma chine Also tighten any loose nuts bolts or screws to en sure machine is in safe operating condition While Operating 1 The operator should be in the operators position when operating the tow vehicle and ProPass machine Stay away from the ProPass when the floor and rear op tion twin spinner or side conveyor system are en gaged 2 Do not run engine that powers the ProPass in a con fined area without adequate ventilation Exhaust fumes are hazardous and could possibly be deadly 3 Do not touch engine muffler or exhaust pipe while engine is running or soon after itis stopped These areas could be hot enough to cause burns 4 If abnormal vibration is detected stop operation of the ProPass immediately and determine source of vibration Correct problems before resuming the use of the machine 5 While operating the ProPass may exceed noise lev els of 85dB A at the operator position Hearing protec tion is recommended for prolonged exposure
8. 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 ProPass 200 REFER TO THE OPERATOR S MANUAL FOR OPER ATING MAINTENANCE AND ADJUSTMENT IN STRUCTIONS For reference insert a copy of the Operator s Manual and Parts Catalog for your machine into Chapter 2 of this service manual Additional copies of the Operator s Manual and Parts Catalog are avail able on the internet at www Toro com The Toro Company reserves the right to change product specifications or this publication without notice Way Part No 14204SL Service Manual ProPass 200 This safety symbol means DANGER WARNING or CAUTION PERSONAL SAFETY INSTRUC TION When you see this symbol carefully read the instructions that follow Failure to obey the instructions may result in personal injury NOTE A NOTE will give general information about the correct operation maintenance service testing or re pair of the machine IMPORTANT The IMPORTANT notice will give im portant instructions which must be followed to pre vent damage to systems or components on the machine The Toro Company 2014 This page is intentionally blank ProPass 200 Table Of Contents Chapter 1 Safety General Safety Instructions 1 2 Safety and Instruction Decals 1 4 Chapter 2 Product Records
9. Safety Page 1 4 ProPass 200 Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS 00 00 sees 1 MAINTENANCE 00 0c eee eee eee 1 oe EQUIVALENTS AND CONVERSIONS 2 Decimal and Millimeter Equivalents 2 ss U S to Metric Conversions 2 sa TORQUE SPECIFICATIONS 0000 3 E Fastener Identification sce aes 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 000 e ee ee eee 6 Product Records Insert Operator s Manuals and Parts Catalog for your ProPass at the end of this chapter Additionally insert Installation Instructions Operator s Manuals and Parts Catalogs for any accessories that have been installed on your ProPass at the end of this section Maintenance Maintenance procedures and recommended service in tervals for your ProPass are covered in the Operator s Manual Refer to this publications when performing reg ular equipment maintenance Several maintenance pro cedures have break in intervals identified in the Operator s Manuals If machine is equipped with the hy draulic power pack refer to the Engine Owner s Manual
10. Read the General Precautions for Removing and Installing Hydraulic System Components in the Service and Repairs section of Chapter 3 Hydraulic System Before disconnecting any hydraulic compo nents operate all hydraulic controls to relieve system pressure and avoid injury from pressur ized hydraulic oil See Relieving Hydraulic Sys tem Pressure in the General Information section of Chapter 3 Hydraulic System 3 Thoroughly clean junction of hydraulic lines and gear pump fittings Disconnect hydraulic lines from gear pump Install caps or plugs in hose tube and pump fit tings to prevent contamination and leakage of hydraulic oil 4 Support gear pump to prevent it from falling during removal 5 Remove two 2 cap screws and flat washers that se cure pump to flange adapter 6 Slide gear pump from spider coupling and remove pump with coupling jaw attached from the machine IMPORTANT To prevent damage to hydraulic pump DO NOT hit coupling jaw or pump shaft with a hammer during coupling jaw removal or installa tion 7 Loosen set screw that secures coupling jaw to gear pump shaft Use puller to remove coupling jaw from shaft Locate and retrieve key from pump shaft 8 If necessary remove fittings from pump and discard fitting O rings Fig 10 Installation Fig 9 1 If fittings were removed from gear pump lubricate and place new O rings onto fittings Fig 10 Install and tighten fittings into pump
11. Start the power pack engine and run at high idle 3750 RPM Allow the battery to charge for at least three 3 minutes Record the battery voltage After running the engine for at least three 3 minutes battery voltage should be at least 0 50 volt higher than initial battery voltage An example of a charging system that is functioning At least 0 50 volt over initial battery voltage Initial Battery Voltage 12 30 v Battery Voltage after 3 Minute Charge 12 85 v Hydraulic Power Pack lt oO o sa Ss 2s a Adjustments Adjust Manifold Relief Valve The hydraulic relief valve manifold includes an adjust able relief valve for system relief Fig 1 If adjustment to this valve is necessary follow the following proce dure NOTE Do not remove relief valve from the hydraulic manifold for adjustment Never adjust the relief valve with the hydraulic system pressurized Hydraulic oil may spray out of the valve with the cap off Personal injury may result Always install the cap and tighten before pressurizing the system 1 Locate relief valve on control manifold 2 Loosen jam nut on relief valve to allow adjustment on the valve 3 To increase pressure setting turn the adjustment socket on the valve in a clockwise direction A 1 8 turn on the socket will make a measurable change in relief pressure 4 To decrease pressure setting turn the adjustment socket on the valve in a counterclockwise d
12. The valve should go in easily without bind ing C Torque cartridge valve using a deep well socket to 25 ft lb 34 N m 2 If fittings were removed from manifold lubricate and place new O rings onto fittings Fig 10 Install and tighten fittings into manifold ports see Hydraulic Fitting Installation in the General Information section of Chapter 3 Hydraulic System 3 Position relief valve manifold to engine mount plate and secure with two 2 cap screws and flange nuts ProPass 200 Page 6 21 4 Remove caps and plugs from hoses tube and mani fold fittings Connect hydraulic lines to manifold see Hy draulic Hose and Tube Installation in the General Information section of Chapter 3 Hydraulic System 5 Check oil level in the hydraulic tank and add correct oil if necessary Figure 13 1 Relief valve manifold 3 O ring 2 Straight fitting 4 used 4 O ring 25 ft lb 34 N m Figure 14 1 Relief valve manifold 3 Seal kit 2 Relief valve Hydraulic Power Pack E oo sa Ss 25 a Power Pack Battery The battery is the heart of the electrical system With regular and proper service battery life can be extended Additionally battery and electrical component failure can be prevented POTENTIAL HAZARD Either the battery terminals or metal tools could short against metal vehicle components WHAT CAN HAPPEN Sparks can cause the battery gasses to explode Damaged cables co
13. for additional engine specific maintenance procedures ProPass 200 Page 2 1 Product Records and Maintenance Decimal and Millimeter Equivalents Equivalents and Conversions Fractions Decimals mm Fractions Decimals mm 1 64 0 015625 0 397 33 64 0 515625 13 097 1 32 0 03125 0 794 17 32 0 538125 13 494 3 64 0 046875 1 191 35 64 0 546875 13 891 1 16 0 0625 1 588 9 16 0 5625 14 288 5 64 0 078125 1 984 37 64 0 578125 14 684 3 32 0 09375 2 381 19 32 0 59375 15 081 7 64 0 109275 2 778 39 64 0 609375 15 478 1 8 0 1250 3 175 5 8 0 6250 15 875 9 64 0 140625 3 572 41 64 0 640625 16 272 5 32 0 15625 3 969 21 32 0 65625 16 669 11 64 0 171875 4 366 43 64 0 671875 17 066 3 16 0 1875 4 762 11 16 0 6875 17 462 13 64 0 203125 5 159 45 64 0 703125 17 859 7 32 0 21875 5 556 23 32 0 71875 18 256 15 64 0 234375 5 958 47 64 0 734375 18 653 1 4 0 2500 6 350 3 4 0 7500 19 050 17 64 0 265625 6 747 49 64 0 765625 19 447 9 32 0 28125 7 144 25 32 0 78125 19 844 19 64 0 296875 7 541 51 64 0 796875 20 241 5 16 0 3125 7 938 13 16 0 8125 20 638 21 64 0 328125 8 334 53 64 0 828125 21 034 11 32 0 34375 8 731 27 32 0 84375 21 431 23 64 0 359375 9 128 55 64 0 859375 21 828 3 8 0 3750 9
14. sure test results F Ifreliefvalve pressure needs adjustment see Ad just Manifold Relief Valve in the Adjustments section of this chapter If adjustments to the relief valve do not change the relief pressure consider that the re lief valve cartridge is leaking or damaged which may also affect the gear pump flow measured above only enough to get a system relief pressure read 12 If gear pump flow reading from step 10 above is low ing and relief valve operation is normal IMPORTANT Do not fully restrict oil flow through tester In this test the flow tester is posi tioned before the relief valve Pump damage can occur if the oil flow is fully restricted A Check gear pump suction line for restriction B Check gear pump flow at gear pump fitting see Hydraulic Power Pack Gear Pump Flow in this sec tion C Watch pressure gauge carefully while slowly closing the tester flow control valve until the relief valve opens 13 When testing is complete disconnect tester from the hydraulic hose and manifold fitting Reconnect hose to manifold fitting D System pressure should be approximately 2000 PSI 138 bar as the relief valve lifts E oO O o sa Ss 25 a ProPass 200 Page 6 9 Hydraulic Power Pack Hydraulic Power Pack Gear Pump Flow Using Tester with Flowmeter and Pressure Gauge The power pack gear pump flow test listed below should be performed after first determining that the system re lief valve
15. IMPORTANT If fitting is non ferrous material e g brass fitting use installation torque for aluminum port e 3 q a cs gt Fitting Fitting Port Side Installation Torque Into Installation Torque Into Dash Size Thread Size Steel Port Aluminum Port 7 16 20 13 to 17 ft lb 18 to 23 N m 7 to 9 ft lb 10 to 12 N m 9 16 18 23 to 29 ft lb 32 to 39 N m 11 to 15 ft lb 15 to 20 N m 3 4 16 46 to 58 ft lb 63 to 78 N m 23 to 29 ft lb 32 to 39 N m 1 7 8 14 69 to 85 ft lb 94 to 115 N m 35 to 43 ft lb 48 to 58 N m 0 12 11 16 12 105 to 129 ft lb 143 to 174 N m 53 to 65 ft lb 72 to 88 N m 14 13 16 12 139 to 171 ft lb 189 to 231 N m 70 to 86 ft lb 95 to 116 N m 16 15 16 12 153 to 187 ft lb 208 to 253 N m 76 to 94 ft Ib 103 to 127 N m 20 15 8 12 213 to 261 ft lb 289 to 353 N m 107 to 131 ft lb 145 to 177 N m Figure 18 ProPass 200 Page 3 11 Hydraulic System Hydraulic Schematics FLOOR VALVE SOLENOID OPTION SOLENOID VALVE e ex OPTION CONTROL VALVE SPINNER MOTORS HYDRAULIC POWER PACK NOTE The hydraulic schematic shown above includes the hydraulic power pack as the hydraulic supply source If your ProPass uses hydraulic supply from the tow vehicle the vehicle includes the hydraulic pump re lief valve and hydraulic reser
16. Pressure in the General Information section of this chapter 5 Relieve hydraulic system pressure 6 Clean floor motor and all hydraulic connections at motor Label hydraulic lines for assembly purposes 7 Disconnect hydraulic hoses from hydraulic fittings on floor 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 8 Remove cap screw item 11 and flat washer item 12 that secure sprocket item 4 to floor motor shaft 9 Loosen two 2 set screws item 15 that secure sprocket to floor motor shaft Slide sprocket from shaft Locate and retrieve woodruff key item 17 from motor shaft 10 Support floor motor to prevent it from falling 11 Remove two 2 cap screws item 9 and lock nuts item 10 that secure floor motor to frame Remove floor motor from machine 12 If hydraulic fittings are to be removed from floor mo tor mark fitting orientation to allow correct assembly Remove fittings from motor and discard O rings Installation Fig 39 1 If fittings were removed from floor motor 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 Infor mation section of this chapter 2 Position floor motor to frame and secure with two 2 cap screw
17. This page is intentionally blank ProPass 200 Page 3 37 Hydraulic System Floor Motor Loctite 242 Antiseize Loctite 242 Vol E j Lubricant Loctite 242 Antiseize Lubricant Direction Of Rotation Figure 39 1 Drive chain 7 Flat washer 2 used 13 Square key 2 Hydraulic floor motor 8 Lock nut 14 Spacer 3 Sprocket 9 Cap screw 2 used 15 Set screw 2 used per sprocket 4 Sprocket 10 Lock nut 2 used 16 Master link 5 Idler sprocket 11 Cap screw 17 Woodruff key 6 Cap screw 12 Flat washer 18 Drive roller shaft Removal Fig 39 2 Remove guards from frame to allow access to floor 7 motor see Bed Guards in the Service and Repairs sec 1 Position machine ona level surface If ProPass is at tion of Chapter 5 Chassis tached to tow vehicle apply tow vehicle parking brake stop engine and remove key from the ignition switch 3 Loosen cap screw and lock nut that secure idler Chock wheels to prevent ProPass machine from mov sprocket to frame Move idler sprocket to remove ten ing sion from drive chain Hydraulic System Page 3 38 ProPass 200 4 Locate and remove master link item 16 from drive chain Note direction of master link clip for assembly pur poses Remove drive chain A CAUTION Before disconnecting any hydraulic compo nents operate all hydraulic controls to relieve system pressure and avoid injury from pressur ized hydraulic oil See Relieving Hydraulic Sys tem
18. W R method Fig 11 A Using awrench tighten the swivel nut onto the fit ting until light wrench resistance is reached approxi mately 30 in Ib B Mark the swivel nut and fitting body Hold the hose tube with a wrench to prevent it from turning C Use asecond wrench to tighten the nut to the cor rect Flats From Wrench Resistance F F W R The markings on the nut and fitting body will verify thatthe connection has been properly tightened Fitting Dash Size Hose Tube Side Thread Size Size F F W R 4 1 4 in nominal hose or tubing 1 2 to 3 4 6 3 8 in 1 2 to 3 4 8 1 2 in 1 2 to 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 JIC FLARED FITTING ADJUSTABLE TYPE SHOWN Figure 10 Mark Nut Final and Fitting Position Body Initial Extend Line Position AT WRENCH RESISTANCE AFTER TIGHTENING Figure 11 Installation Torque 7 16 20 10 to 14 ft lb 14 to 18 N m 9 16 18 15 to 21 ft lb 21 to 28 N m 3 4 16 33 to 41 ft lb 45 to 55 N m 7 8 14 43 to 53 ft lb 59 to 71 N m 11 16 12 66 to 82 ft lb 90 to 111 N m 13 16 12 80 to 98 ft lb 109 to 132 N m 15 16 12 90 to 110 ft lb 122 to 149 N m Figure 12 Hydraulic System Page 3 8 ProPass 200 Hydraulic O Ring Face Seal ORFS Fitting Installation SAE Straight Thread O Ring Fitting into Component Port NOTE ProPass machines with serial numbers above 310001000 use O ring face seal fittings U
19. at idler roller shaft see Drive Roller Bear ings in this section 6 Remove tension on floor drive chain by loosening cap screw and lock nut on drive chain idler sprocket see Floor Motor Drive in this section ProPass 200 7 Remove fasteners four 4 cap screws washers and lock nuts that secure scraper assembly item 7 to conveyor frame Remove scraper assembly 8 On left side of machine loosen bearing locking collar on both idler and drive roller shafts see Drive Roller Bearings and Idler Roller Bearings in this section To prevent personal injury make sure that hop per assembly is properly supported as it is raised from the machine Hopper assembly without hy draulic components weighs approximately 200 pounds 91 kg IMPORTANT When raising the hopper assembly from the frame lift at corners of hopper to prevent bending the hopper walls Also take care to not damage hydraulic lines electrical harness or other components while raising the hopper 9 Remove fasteners that secure hopper assembly with gate assembly to machine frame Fig 11 Once all fasteners have been removed raise the hopper as sembly enough so that left side of conveyor frame can be removed Support hopper above the machine 10 Remove fasteners five 5 cap screws and flange nuts that secure conveyor bed assembly item 2 to left side of conveyor frame 11 Remove fasteners that secure left side of conveyor frame to tow vehicle o
20. 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 fit ting to 60 of listed 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 O ring Figure 13 Fitting Fitting Port Side Installation Torque Into Installation Torque Into Dash Size Thread Size Steel Port Aluminum Port 7 16 20 15 to 19 ft lb 21 to 25 N m 9 to 11 ft lb 13 to 15 N m 9 16 18 34 to 42 ft lb 47 to 56 N m 20 to 26 ft lb 28 to 35 N m 3 4 16 58 to 72 ft lb 79 to 97 N m 35 to 43 ft lb 48 to 58 N m 7 8 14 99 to 121 ft lb 135 to 164 N m 60 to 74 ft lb 82 to 100 N m 11 16 12 134 to 164 ft lb 182 to 222 N m 81 to 99 ft lb 110 to 134 N m 13 16 12 160 to 196 ft lb 217 to 265 N m 96 to 118 ft lb 131 to 160 N m 15 16 12 202 to 248 ft lb 274 to 336 N m 121 to 149 ft lb 165 to 202 N m 15 8 12 247 to 308 ft lb 335 to 410 N m 149 to 183 ft lb 202 to 248 N m Figure 14 ProPass 200 Page 3 9 Hydraulic System e gt q Ea cs gt lt E o N gt n Adjustable Fitting Fig 15 1 Make sure all threads and sealing surfaces of fitting and component port are free of burrs nicks scratches or any foreign material 2 A
21. for signs of deterioration or damage 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 be sure 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 2 wrenches 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 el bow 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 Before disconnecting or performing any work on hydraulic system relieve all pressure in system see Relieving Hydraulic System Pressure in this section 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 in jected into the skin it must be surgically re moved within a few hours by a doctor familiar with this type of injury Gangrene
22. may result from such an injury Hydraulic Hose and Tube Installation O Ring Face Seal Fittings NOTE ProPass machines with serial numbers above 310001000 use O ring face seal fittings Fig 7 Use the following information when installing hydraulic hoses and tubes to O ring face seal fittings 1 Make sure threads and sealing surfaces of the hose tube and the fitting are free of burrs nicks scratches or any foreign material 2 Asapreventative measure against leakage it is rec ommended that the face seal O ring be replaced any time the connection is opened Make sure the O ring is installed and properly seated in the fitting groove Lightly lubricate the O ring with clean hydraulic oil 3 Place the hose tube against the fitting body so that the flat face of the hose tube sleeve fully contacts the O ring in the fitting Hydraulic System Page 3 6 Figure 7 1 Hydraulic hose tube 3 O ring 2 Swivel nut 4 Fitting body ProPass 200 4 Thread the hose tube swivel 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 recom mended installation torque shown in Figure 9 This tight ening process will require the use of an offset wrench e g crowfoot wrench Use of an offset wrench will af fect torque wrench calibration due to the effective length change of the torque wrench Tightening torque when using a torque wrench with an offset wrench
23. of the spinner will allow access to screws used to secure spinner motor to spinner frame A Remove cap screw item 21 and lock washer item 22 that secure spinner disk and hub to spinner motor shaft B Remove three 3 cap screws item 24 and lock nuts item 26 that secure spinner disk to hub C Remove spinner assembly from spinner frame 6 Loosen two 2 set screws item 27 that secure hub item 25 to spinner motor shaft Remove hub from mo tor shaft Locate and retrieve woodruff key from motor shaft 7 Support spinner motor to prevent it from falling 8 Remove four 4 cap screws item 22 and lock wash ers item 23 that secure spinner motor to spinner frame Lower motor from spinner frame and remove from ma chine 9 If necessary remove hydraulic fittings from spinner motor Remove and discard O rings from fittings NOTE For spinner motor service information use same procedure as described in Rear Option Motor Ser vice in this section ProPass 200 Page 3 43 Installation Fig 42 1 Ifremoved install hydraulic fittings with new O rings into the spinner motor ports see Hydraulic Fitting Instal lation in the General Information section of this chapter 2 Position spinner motor to spinner frame and secure with four 4 cap screws item 22 and lock washers item 23 3 Apply antiseize lubricant to spinner motor shaft 4 Position woodruff key to slot in spinner motor shaft and then
24. or hydraulic power pack The con trol manifold includes cartridge valves for control of the rear option twin spinner or conveyor and floor circuits Control manifold pressure compensator valve EC1 is used to provide priority flow in the required amount to the floor motor while allowing excess flow to be used for op eration of the rear option motors If the floor circuit is not engaged the pressure compensator valve directs all of the hydraulic flow toward the rear option motors and re turn to the hydraulic reservoir Control manifold proportional flow valve PV1 is a prior ity type flow regulator with pressure compensated by pass flow Priority hydraulic flow from this valve is to the rear option motors Based on wireless remote settings electrical voltage to valve PV1 is supplied by the base unit Valve PV1 includes manual adjustment for ma chine operation should the wireless controller be lost damaged or faulty NOTE The schematic symbols for the pressure com pensator valve EC1 and proportional flow valve PV1 include lines above and below the valve symbols which designate infinite positioning of the valve spools These valves appear to be two 2 position valves but in opera tion the valves will shift to provide necessary flow to both the floor motor and to the rear option motors based on control settings Control manifold proportional solenoid valve SP1 is used to allow flow to the floor motor Based on wirel
25. pin from axle spindle 7 Remove nut retainer spindle nut and spindle washer that secure wheel hub to spindle Slide wheel hub with bearings from spindle 8 Disassemble wheel hub A Pull 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 Inspect wheel bearings Check the bearing cones and bearing cups for wear pitting or other damage Replace worn or damaged parts E If necessary use a press to remove wheel studs from hub ProPass 200 Installation Fig 16 1 Clean all parts thoroughly before reassembly 2 Assemble wheel hub onto the same spindle from which it was removed 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 Ifwheel studs were removed from hub press new studs into hub Make sure that head of stud is fully to hub surface C Pack both bearing cones with grease Install greased inner bearing into the cup on inboard side of the wheel hub D Fill hub approximately 50 full of grease IMPORTANT The seal must be pressed in so itis flush with the end of the hub The lip of the seal must face the bearing E Lubricate the inside of a new seal and press it into the wheel hub 3 Install t
26. ports see Hydraulic Fitting Installation in the General Information section of Chapter 3 Hydraulic System ProPass 200 Page 6 17 2 Install key to the pump shaft Apply antiseize lubri cant to gear pump shaft 3 Slide coupling jaw fully onto pump shaft Apply Loc tite 242 or equivalent to coupling jaw set screw Se cure coupling jaw to pump shaft with set screw 4 Make sure that spider coupling item 26 is posi tioned into coupling jaw on engine shaft 5 Align coupling jaw on pump shaft with spider coup ling in engine coupling jaw Insert coupling jaw on pump shaft into spider coupling and align gear pump mounting holes with flange adapter holes 6 Secure gear pump to flange adapter with two 2 cap screws and flat washers 7 Remove plugs from hydraulic hose tube and pump fittings Connect hydraulic lines to gear pump see Hy draulic Hose and Tube Installation in the General Infor mation section of Chapter 3 Hydraulic System 8 Check oil level in the hydraulic tank and add correct oil if necessary 9 Start the engine and operate at idle speed until air is out of hydraulic system 10 Stop the engine and recheck oil level in tank Add correct oil if necessary Figure 10 1 Gear pump 5 O ring 2 O ring 6 Hydraulic fitting 3 Hydraulic fitting 7 O ring 4 O ring Hydraulic Power Pack E O O o sa Es Fs a Power Pack Gear Pump Service 25 to 28 ft lb 34 to 38 N m F
27. s are faulty Rear option hydraulic lines are not connected Wireless remote settings are incorrect Control manifold proportional flow valve PV1 is faulty An electrical problem exists see Chapter 4 Electrical System Rear option hydraulic motor s are faulty ProPass 200 Floor does not function machines with standard Floor control valve setting is not adjusted properly hydraulics i Floor solenoid valve is faulty An electrical problem exists see Chapter 4 Electrical System Hydraulic floor motor is faulty Floor does not function machines with electronic Wireless remote settings are incorrect hydraulics NOTE Check wireless remote LCD display and base unit LED s for help in troubleshooting Control manifold proportional solenoid valve SP1 is faulty An electrical problem exists see Chapter 4 Electrical System Hydraulic floor motor is faulty 2 E q a cs gt lt ProPass 200 Page 3 23 Hydraulic System Testing The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the circuits during various operational checks see the Special Tools section in this chapter IMPORTANT All obvious areas such as oil supply filter binding linkages loose fasteners or improper adjustments must be checked before assuming that a hydraulic component is the source of the problem B
28. slide hub item 25 onto shaft 5 Position spinner assembly into spinner frame and align mounting holes in spinner with hub on motor shaft 6 Secure spinner assembly to hub with three 3 cap screws item 24 and lock nuts item 26 7 Secure spinner disk to spinner motor shaft with cap screw item 21 and lock washer item 22 8 Apply Loctite 242 or equivalent to threads of set screws item 27 Install and tighten set screws to secure hub to motor shaft 9 Remove all caps or plugs that were placed on hy draulic hoses and fittings during disassembly 10 Using labels placed during motor removal correctly install hydraulic hoses to hydraulic fittings on spinner motor Tighten connections See Hydraulic Hose and Tube Installation in the General Information section of this chapter Hydraulic System E gt q ta cs gt lt Conveyor Motor Antiseize Lubricant Figure 43 1 Cap screw 2 used per bearing 8 Idler roller 15 Drive roller 2 Flange nut 2 used per bearing 9 Conveyor cover 16 Set screw 3 Adjuster plate 2 used 10 Conveyor belt 17 Conveyor motor 4 Flange head screw 2 used 11 Hydraulic hose 2 used 18 Lock nut 2 used 5 Jam nut 4 used 12 O ring 19 Flange nut 2 used 6 Flange bearing 3 used 13 Hydraulic straight fitting 2 used 20 Woodruff key 7 Bearing guard 3 used 14 O ring 21 Motor spacer plate Hydraulic System Page 3 44 Pr
29. the Service and Repairs section of Chapter 3 Hydraulic System Hydraulic Power Pack Page 6 20 ProPass 200 3 Thoroughly clean junction of hydraulic lines and re lief valve manifold fittings 4 Label all hydraulic lines for assembly purposes 5 Disconnect hydraulic lines from manifold fittings Install caps or plugs in hoses tube and manifold fittings to prevent contamination and leakage of hydraulic oil 6 Remove two 2 cap screws and flange nuts that se cure manifold to engine mount plate 7 Remove relief valve manifold from machine 8 Ifnecessary remove hydraulic fittings from manifold Discard removed O rings 9 If necessary remove relief valve from manifold with a deep well socket Fig 14 Note location of O rings and backup rings on valve Remove and discard re moved seal kit Installation 1 If relief valve was removed from manifold install re lief valve Fig 14 A Lubricate new O rings and backup rings of seal kit with clean hydraulic oil and install on cartridge The O rings and backup rings must be arranged properly on the cartridge valve for proper operation and sealing IMPORTANT Use care when installing the relief valve Slight bending or distortion of the stem tube can cause binding and malfunction Make sure that deep well socket fully engages the valve base B Lubricate cartridge threads with clean hydraulic oil Thread cartridge valve carefully into correct man ifold port
30. the hydraulic circuits and com ponents used on this machine see Hydraulic Schemat ics in this chapter No ProPass functions operate Rear option does not function machines with standard hydraulics Rear option does not function machines with electronic hydraulics NOTE Check wireless remote LCD display and base unit LED s for help in troubleshooting Hydraulic System Page 3 22 Possible Causes Hydraulic lines are not connected to tow vehicle machines that use hydraulic flow from tow vehicle Hydraulic lines to tow vehicle are not connected correctly machines that use hydraulic flow from tow vehicle Hydraulic reservoir level is low Electrical power to ProPass hydraulic components is not available e g power harness not connected to tow vehicle tow vehicle key not ON fuse is faulty vehicle battery is discharged Tow vehicle has a hydraulic problem machines that use hydraulic flow from tow vehicle Hydraulic power pack relief valve is stuck open or faulty machines that have hydraulic power pack Hydraulic power pack gear pump is faulty machines that have hydraulic power pack An electrical problem exists see Chapter 4 Electrical System Rear option hydraulic lines are not connected Rear option control valve setting is not adjusted properly Rear option solenoid valve is faulty An electrical problem exists see Chapter 4 Electrical System Rear option hydraulic motor
31. to reduce the potential of permanent hearing damage 6 Do not leave the ProPass unattended when it is run ning Safety Page 1 2 To reduce the potential for injury or death comply with the following safety instructions 3 Make sure that the tow vehicle is carefully selected to assure the best performance and safe operation of the ProPass machine 4 Make sure that the operator is familiar with tow ve hicle and ProPass operation 5 Make sure that ProPass is properly secured to tow vehicle before operating 7 If ProPass is equipped with a wireless controller al ways be inline of sight with the machine when operating adjusting or programming the wireless controller 8 Make sure that the ProPass load is distributing evenly to prevent shifting of contents 9 Before leaving the operator s position of the tow vehicle A Stop on level ground B Make sure that ProPass floor is stopped and then disengage spinner system C Ensure that tow vehicle traction lever is in neutral set parking brake stop engine and remove key from ignition switch 10 Before disconnecting the ProPass tow behind chassis from the tow vehicle park on level surface en sure that the front tongue jack is in the support position and chock wheels ProPass 200 Maintenance and Service 1 The Operator s Manual provides information regard ing the operation general maintenance and mainte nance intervals for your ProPass mac
32. weighs approximately 130 pounds 59 kg 3 Support walking beam assembly to prevent it from shifting during removal 4 Remove cap screws flat washers and flange nuts that secure walking beam bearings to frame cross mem ber 5 Carefully lower walking beam assembly and remove from machine 6 Clean bearings and pivot areas of walking beam ProPass 200 Page 5 21 Installation Fig 17 1 Slide bearings onto walking beam pivots Position walking beam assembly under machine Make sure that grease fittings in bearings are orientated toward the ground 2 Carefully raise walking beam assembly and align bearings with frame cross member 3 Secure walking beam bearings to cross member with cap screws flat washers and flange nuts 4 Carefully lower machine to ground 5 Grease walking beam bearings Chassis This page is intentionally blank Chassis Page 5 22 ProPass 200 Chapter 6 Hydraulic Power Pack Table of Contents POWER PACK ENGINE SPECIFICATIONS 2 POWER PACK HYDRAULIC SPECIFICATIONS 3 GENERAL INFORMATION 2055 4 Engine Owner s Manual 0005 4 Installation Instructions 000 4 Paris Catalog asas a te ssa rea ee ais 4 Hydraulic Schematics 0 0c eae eee 4 ELECTRICAL SYSTEM QUICK CHECKS 5 Battery Test Open Circuit Test 5 Charging System Test 00 cece eeeee 5 ADJUSTMENTS
33. will be lower than the listed installation torque see Using a Torque Wrench with an Offset Wrench in the Torque Specifica tions section of Chapter 2 Product Records and Main tenance 5 If a torque wrench is not available or if space at the swivel nut prevents use of a torque wrench an alternate method of assembly is the Flats From Wrench Resist ance F F W R method Fig 8 A Using a wrench tighten the swivel nut onto the fit ting until light wrench resistance is reached approxi mately 30 in lb B Mark the swivel nut and fitting body Hold the hose tube with a wrench to prevent it from turning Fitting Dash Size Hose Tube Side Thread Size 9 16 18 C Use asecond wrench to tighten the nut to the cor rect 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 Size F F W R 4 1 4 in nominal hose or tubing 1 2 to 3 4 6 3 8 in 1 2 to 3 4 8 1 2 in 1 2 to 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 Mark Nut Final and Fitting Position Body Initial Extend Line Position AT WRENCH RESISTANCE AFTER TIGHTENING e gt q EA cs gt Figure 8 Installation Torque 18 to 22 ft lb 25 to 29 N m 11 16 16 13 16 16 1 14 13 16 12 17 16 12 111 16 12 Figure 9 ProPass 200 Page 3 7 27 to 33 ft lb 37 to 44 N m 37 to 47 ft lb 5
34. 1 to 63 N m 60 to 74 ft lb 82 to 100 N m 85 to 105 ft lb 116 to 142 N m 110 to 136 ft lb 150 to 184 N m 140 to 172 ft lb 190 to 233 N m Hydraulic System Hydraulic Hose and Tube Installation JIC Flared Fittings NOTE ProPass machines with serial numbers below 310001000 use JIC flared fittings Fig 10 Use the fol lowing information when installing hydraulic hoses and tubes to JIC flared fittings 1 Make sure threads and sealing surfaces of the hose tube and the fitting are free of burrs nicks scratches or any foreign material 2 Thread hose tube swivel nut onto fitting by hand While holding the hose tube with a wrench use a torque wrench to tighten swivel nut to the recommended instal lation torque shown in Figure 12 If fitting is non ferrous material e g brass use 50 of listed torque values This tightening process will require the use of an offset wrench e g crowfoot wrench that will affect torque 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 Specifica tions section of Chapter 2 Product Records and Main tenance 3 If a torque wrench is not available or if space at the swivel nut prevents use of a torque wrench an alternate method of assembly is the Flats From Wrench Resist ance F F
35. 2 used Woodruff key 1 used per motor Disconnect seal kit Lock washer 1 used per motor Cap screw 1 used per motor Cap screw 4 used per motor Page 3 42 a Antiseize Lubricant Loctite 242 Lock washer 4 used per motor Cap screw 3 used per hub Hub 2 used Lock nut 3 used per hub Set screw 2 used per hub Spinner disk 2 used Carriage bolt 2 used per paddle Left curved paddle 3 used Flange nut 2 used per paddle Right curved paddle 3 used Spinner frame ProPass 200 Removal Fig 42 1 Position machine on a level surface If ProPass is at tached to tow vehicle apply tow vehicle parking brake stop engine and remove key from the ignition switch Chock wheels to prevent ProPass machine from mov ing Before disconnecting any hydraulic compo nents operate all hydraulic controls to relieve system pressure and avoid injury from pressur ized hydraulic oil See Relieving Hydraulic Sys tem Pressure in the General Information section of this chapter 2 Relieve hydraulic system pressure 3 Clean spinner motor and all hydraulic connections at motor Label hydraulic lines for assembly purposes 4 Disconnect hydraulic hoses from hydraulic fittings on spinner motor Allow hydraulic oil to drain from lines into asuitable container Put caps or plugs on open hydraulic lines and fittings to prevent contamination 5 Remove spinner assembly Removal
36. 525 7 8 0 8750 22 225 25 64 0 390625 9 922 57 64 0 890625 22 622 13 32 0 40625 10 319 29 32 0 90625 23 019 27 64 0 421875 10 716 59 64 0 921875 23 416 7 16 0 4375 11 112 15 16 0 9375 23 812 29 64 0 453125 11 509 61 64 0 953125 24 209 15 32 0 46875 11 906 31 32 0 96875 24 606 31 64 0 484375 12 303 63 64 0 984375 25 003 1 2 0 5000 12 700 1 1 000 25 400 1 mm 0 03937 in 0 001 in 0 0254 mm U S to Metric Conversions To Convert Into Multiply By Linear Miles Kilometers 1 609 Measurement Yards Meters 0 9144 Feet Meters 0 3048 Feet Centimeters 30 48 Inches Meters 0 0254 Inches Centimeters 2 54 Inches Millimeters 25 4 Area Square Miles Square Kilometers 2 59 Square Feet Square Meters 0 0929 Square Inches Square Centimeters 6 452 Acre Hectare 0 4047 Volume Cubic Yards Cubic Meters 0 7646 Cubic Feet Cubic Meters 0 02832 Cubic Inches Cubic Centimeters 16 39 Weight Tons Short Metric Tons 0 9078 Pounds Kilograms 0 4536 Ounces Avdp Grams 28 3495 Pressure Pounds Sq In Kilopascal 6 895 Pounds Sq In Bar 0 069 Work Foot pounds Newton Meters 1 356 Foot pounds Kilogram Meters 0 1383 Inch pounds Kilogram Centimeters 1 152144 Liquid Volume Quarts Liters 0 9463 Gallons Liters 3 785 Liquid Flow Gallons Minute Liters Minute 3 785 Temperature Fahrenheit Celsius 1 Subract 32 Product Records and Maintenance Page 2
37. Connect charger cables to the battery Make sure a good connection is made 4 Charge the battery following the battery charger manufacturer s instructions 5 Occasionally check the temperature of the battery electrolyte If the temperature exceeds 125 F 52 C or the electrolyte is violently gassing or spewing the charging rate must be lowered or temporarily stopped 6 Three 3 hours prior to the end of the charging mea sure the specific gravity of a battery cell once per hour The battery is fully charged when the cells are gassing freely at a low charging rate and there is less than a 0 003 change in specific gravity for three 3 consecu tive readings Battery Storage If the vehicle will be stored for more than thirty 80 days remove the battery and charge it fully Either store it on the shelf or on the vehicle Leave the cables discon nected if it is stored on the vehicle Store the battery in a cool atmosphere to avoid quick deterioration of the charge in the battery To prevent the battery from freez ing make sure it is fully charged Hydraulic Power Pack E O O O sa Es 2s a This page is intentionally blank Hydraulic Power Pack Page 6 26 ProPass 200
38. INGS 6 Power Lead Wire Harness 0 6 Hydraulic Power Pack Power Lead Wire Harness 00 cece eee eee 6 Intermediate Power Wire Harness 7 Main Valve Wire Harness Standard Hydraulic Controls 0 cece eee eee 8 Pendant Wire Harness Standard Hydraulic Controls instar ee eee eA 9 Bulkhead Wire Harness Electronic Hydraulic Controls msi sida beta dete lanes goed 10 SE SPECIAL TOOLS 000 iii 12 Es TROUBLESHOOTING 000 000e eee es 14 as COMPONENT TESTING 0000000 16 E Stop Button Machines with Electronic Hydraulic Controls assau 16 Pendant Assembly Machines with Standard Hydraulic Controls aaua aaea 17 Wireless Remote Machines with Electronic Hydraulic Controls assau 18 Wireless Remote Base Unit Machines with Electronic Hydraulic Controls 20 Hydraulic Solenoid Valve Coils 21 ProPass 200 Page 4 1 Electrical System This page is intentionally blank Electrical System Page 4 2 ProPass 200 General Information Operator s Manual The Operator s Manual provides information regarding the operation general maintenance and maintenance intervals for your ProPass machine Refer to the Opera tor s Manual for additional information when servicing the machine Machine Hydraulic Control ProPass 200 machines use either standard hydraulic controls or electronic hydraulic control
39. O ring 19 O ring 6 Straight hydraulic fitting 2 used 13 Flat washer 2 used 20 Clamp plate 3 used 7 Straight hydraulic fitting 4 used 14 Lock washer 2 used 21 Control panel guard Hydraulic System Page 3 32 ProPass 200 Removal Fig 33 1 Position machine on a level surface If ProPass is at tached to tow vehicle apply tow vehicle parking brake stop engine and remove key from the ignition switch Chock wheels to prevent ProPass machine from mov ing 2 Disconnect emergency stop button connector from machine wire harness Remove control panel guard from front of ProPass to allow access to control mani fold Before disconnecting any hydraulic compo nents operate all hydraulic controls to relieve system pressure and avoid injury from pressur ized hydraulic oil See Relieving Hydraulic Sys tem Pressure in the General Information section of this chapter 3 Relieve hydraulic system pressure 4 Clean control manifold and all hydraulic connections at manifold Label all control manifold hydraulic and electrical connections for assembly purposes 5 Disconnect wire harness connectors from solenoid valves on manifold 6 Disconnect hydraulic hoses from hydraulic fittings on control manifold Allow hydraulic oil to drain from lines into a suitable container Put caps or plugs on open hy draulic lines and fittings to prevent contamination 7 Remove two 2 cap screws item 16 lock washers and flat wa
40. Power Pack Hydraulic Specifications 6 3 General Information 0000eee 6 4 Electrical System Quick Checks 6 5 Adjustments 0 cee eee eee eee es 6 6 Hydraulic Testing cee eee eee eee 6 8 Service and Repairs 0000 eee 6 12 EATON SERIES 26 GEAR PUMP PARTS and REPAIR MANUAL Product Records and Maintenance System E Ea cs gt lt Electrical System Hydraulic Power Pack This page is intentionally blank ProPass 200 Chapter 1 Safety Table of Contents GENERAL SAFETY INSTRUCTIONS 2 Before Operating 00cc eee eee eee 2 While Operating 00 cece eee eee 2 Maintenance and Service 045 3 SAFETY AND INSTRUCTION DECALS 4 ProPass 200 Page 1 1 Safety General Safety Instructions The ProPass 200 has been tested and certified by TORO for compliance with existing safety standards and specifications Although hazard control and acci dent 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 trans port maintenance and storage of the machine Improp er use or maintenance of the machine can result in injury or death To reduce the potential for injury or death com ply with the following safety instructions
41. US Gal Min 38 L Min 2800 PSI 190 Bar Floor Motor Eaton fixed displacement geroler motor Displacement per revolution 22 7 in 371 cc Twin Spinner Motors Rear Option Eaton fixed displacement geroler motor Displacement per revolution 1 8 in 29 cc Conveyor Motor Rear Option Eaton fixed displacement geroler motor Displacement per revolution 1 8 in 29 cc NOTE Iftow vehicle provides hydraulic supply use tow vehicle hydraulic specifications for information regard ing hydraulic flow and relief pressure to the ProPass If hydraulic power pack provides hydraulic supply see Chapter 6 Hydraulic Power Pack Assembly for inform ation regarding hydraulic circuit flow and relief pressure specifications Hydraulic System Page 3 2 ProPass 200 General Information Operator s Manual The Operator s Manual provides information regarding the operation general maintenance and maintenance intervals for your ProPass machine Refer to that publi cation for additional information when servicing the ma chine ProPass Hydraulic Supply Hydraulic supply for the ProPass machine is either provided by the tow vehicle or a hydraulic power pack If tow vehicle provides hydraulic supply use tow vehicle hydraulic specifications for information regarding hy draulic flow and relief pressure to the ProPass If hy draulic power pack provides hydraulic supply see Chapter 6 Hydraulic Power Pack Assembly for inform ation reg
42. adjust hydraulic flow to the floor and rear op tion twin spinner or conveyor motors Fig 19 A pendant electrical control allows the operator to ener gize the floor and rear option motors from the operator position of the tow vehicle The ProPass hydraulic sys tem with standard hydraulic controls can function whenever hydraulic flow is available from the tow vehicle or hydraulic power pack If neither the floor motor or rear option twin spinner or conveyor motors are engaged hydraulic flow bypasses the motors and returns directly to the hydraulic reservoir The floor and rear option will remain in the stationary po sitions NOTE Typically the rear option twin spinner or con veyor is engaged before the floor is started When the operator engages the rear option twin spin ner or conveyor motors the rear option solenoid valve is energized which directs hydraulic flow to the rear op tion control valve The rear option control valve directs hydraulic flow to the rear option motors based on the control valve setting to allow the option to operate at the correct speed for topdressing material to be delivered System hydraulic flow in excess of the rear option con trol valve setting is returned to the reservoir Return from the rear option motors is routed to the reservoir as well Hydraulic circuit pressure is controlled by the system re lief valve either on the tow vehicle or hydraulic power pack Floor Circuit Machine
43. alues All torque values are based on non lubri cated fasteners 8 5 a De fe astm 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 ProPass 200 Table of Contents Chapter 3 Hydraulic System SPECIFICATIONS 000 eee eee 2 SPECIAL TOOLS 0 20 0 eee e eee es 20 GENERAL INFORMATION 2055 3 TROUBLESHOOTING 00002 eee eee 22 Operator s Manual 0c eee eee eeee 3 TESTING acess artes ate Awe ake aoe aes 24 ProPass Hydraulic Supply 3 SERVICE AND REPAIRS 000005 26 Hydraulic Hose Kit Tow Vehicle to ProPass 3 General Precautions for Removing and Machine Hydraulic Control 4 Installing Hydraulic System Components 26 Rear Option us stare es casca paira sata Pe ete 5 Check Hydraulic Lines and Hoses 27 Relieving Hydraulic System Pressure 5 Hydraulic Control Machines with Standard Hydraulic Hoses 0 cece ee eee 6 Hydraulic Controls 00000 28 Hydraulic Hose and Tube Installation O Ring Control Valve Service Machines with Standard Face Seal Fittings 00000 6 Hydraulic Controls 000005 30 Hydraulic Hose and Tube Installation JIC Flared Solenoid Valve Assembly Machines with Standard FIttingS upa sinta eee etna one ae 8 Hyd
44. and Maintenance Product Records 00 ce eee ceca 2 1 Maintenance 0200 cee eee eee 2 1 Equivalents and Conversions 2 2 Torque Specifications eee eee 2 3 Chapter 3 Hydraulic System SPECHIGALIONS s 2455 asia Gla epa Thea The 3 2 General Information 00e ee eeee 3 3 Hydraulic Schematics 00000 eee 3 12 Hydraulic Flow Diagrams Standard Hydraulic ControlS pesagi niate daa ed a a a 3 14 Hydraulic Flow Diagrams Electronic Hydraulic CONIOIS sce eee passada ra d o 3 16 Special TOONS as views eevee eves cel 3 20 Troubleshooting 0 eee eee 3 22 TESTING cias hated goed okie espere Phe ated TA 3 24 Service and Repairs 002 0000e 3 26 EATON CHAR LYNN S SERIES GENERAL PURPOSE MOTORS PARTS and REPAIR MANUAL EATON CHAR LYNN R SERIES GENERAL PURPOSE GEROLER MOTOR REPAIR INFORMATION ProPass 200 Chapter 4 Electrical System General Information 00e eee 4 3 Electrical Schematics 0005 4 4 Wire Harness Drawings 05 4 6 Special Tools cece eee neces 4 12 Troubleshooting 0 cee eee eee ee 4 14 Component Testing 0 00eeeee 4 16 Chapter 5 Chassis General Information 0000eee 5 3 Service and Repairs 00e eee 5 4 Chapter 6 Hydraulic Power Pack Power Pack Engine Specifications 6 2
45. and bolt tube that secure bracket opposite the oil filter 4 Make sure that battery filler caps are on tightly 5 Remove battery from chassis to a service area This will minimize possible battery damage and allow better access for battery inspection and service IMPORTANT Be careful to not damage terminal Figure 15 posts or cable connectors when removing the bat 1 Battery 5 Flange nut 2 used 2 Cap screw 2 used 6 Battery bracket tery cables 3 Flat washer 2 used 7 Mounting strap 4 Bolt tube 2 used 8 Hydraulic oil filter Hydraulic Power Pack Page 6 22 ProPass 200 Battery Inspection and Maintenance POTENTIAL HAZARD Battery electrolyte contains sulfuric acid which is a deadly poison and it causes severe burns WHAT CAN HAPPEN If you carelessly drink electrolyte you could die or if it gets onto your skin you will be burned HOW TO AVOID THE HAZARD Do not drink electrolyte and avoid contact with skin eyes or clothing Wear safety glasses to shield your eyes and rubber gloves to protect your hands Fill the battery where clean water is always available for flushing the skin Always RE CONNECT the positive red battery cable be fore reconnecting the negative black cable Follow all instructions and comply with all safe ty messages on the electrolyte container 1 Check for cracks caused by overly tight or loose hold down rod Replace battery if cracked and leaking 2 Check battery te
46. arding hydraulic circuit flow and relief pressure specifications o SE Ez Aa gt N NOTE See Specifications in this chapter for tow vehicle hydraulic supply recommendations Hydraulic Hose Kit Tow Vehicle to ProPass The hydraulic hose kit used when a ProPass receives its hydraulic supply from a tow vehicle includes a check valve in the return hose assembly item 6 in Figure 1 Ifthe check valve is removed from the return hose make sure that the arrow on the check valve is directed toward the tow vehicle Also when connecting the hydraulic hoses to the tow vehicle use the check valve to identify the return hose for correct installation TOW VEHICLE Figure 1 1 Hydraulic hose supply 5 O ring 2 Hydraulic hose return 6 Check valve 3 Dust cap 7 O ring 4 Male coupler ProPass 200 Page 3 3 Hydraulic System Machine Hydraulic Control ProPass 200 machines use either standard hydraulic controls or electronic hydraulic controls to allow the op erator to change machine settings Standard Hydraulic Controls Machines with standard hydraulic controls include manual hydraulic controls on the front of the ProPass hopper to adjust hydraulic flow to the floor and rear op tion twin spinner or conveyor motors Fig 2 A pendant electrical control allows the operator to ener gize the floor and rear option motors from the operator position of the tow vehicle Electronic Hydraulic Controls Machines with
47. ay result in personal injury 3 Torque lug nuts in a criss cross pattern from 70 to 90 ft lb 95 to 122 N m 4 If removed install walking beam assembly to ma chine see Walking Beam Assembly in this section 5 Carefully lower machine to ground Chassis Wheel Bearing Service Tow Chassis See Text for Tightening Procedure As YO AS K SX Figure 16 NOTE The outer hub and wheel bearings can be re moved with the walking beam attached to the ProPass machine If the inner hub needs to be removed walking beam removal is necessary see Walking Beam As sembly in this section Removal Fig 16 1 Position ProPass on a level surface attached to tow ing vehicle Apply vehicle parking brake stop engine and remove key from the ignition switch Chock Pro Pass wheels to prevent machine from moving 2 Jack or hoist ProPass from ground and support ma chine with appropriate jack stands 3 If inner wheel bearings are to be serviced remove walking beam from machine see Walking Beam As sembly in this section 4 Remove wheel assembly see Wheel Assemblies in this section 5 Carefully pry dust cap from wheel hub Chassis Bearing cup 2 used per hub 1 Walking beam axle 5 2 Hub 2 used per axle 6 Dust cap 3 Bearing cone 2 used per hub 7 Spindle washer 4 Seal 8 Spindle nut Page 5 18 9 Nut retainer 10 Cotter pin 11 Wheel stud 5 used per hub 6 Remove cotter
48. correct each cell reading For each 10 F 6 C above 80 F 27 C add 0 004 to the spe cific gravity reading For each 10 F 6 C below 80 F 27 C subtract 0 004 from the specific gravity read ing Example Cell Temperature 100 F Cell Gravity 1 245 ADD 20 above 80 F 0 008 Correction to 80 F 1 253 C If the difference between the highest and lowest cell specific gravity is 0 050 or greater or the lowest cell specific gravity is less than 1 225 charge the bat tery Charge at the recommended rate and time giv en in Battery Charging or until the specific gravity of all cells is 1 225 or greater with the difference in spe cific gravity between the highest and lowest cell less than 0 050 If these charging conditions can not be met replace the battery 2 Perform a high discharge test with an adjustable load tester This is one of the most reliable means of testing a battery as it simulates the cold cranking test Acommercial bat tery load tester is required to perform this test A CAUTION Follow the battery load tester manufacturer s instructions when using a load tester A Check the voltage across the battery terminals prior to testing the battery If the voltage is less than 12 0 VDC recharge the battery before load testing B Make sure the battery terminals are free of corro sion Hydraulic Power Pack Page 6 24 C Ifthe battery has been charged apply a 150 amp load for fifteen 15 sec
49. draulic Controls 35 ft Ib RS E a 47 N m 12 to 14 ft lb 16 to 18 N m 20 to 26 ft lb gue 27 to 35 N m 17 Figure 36 1 Control manifold 7 Coil nut 13 Check valve 4 used 2 Proportional flow valve PV1 8 Solenoid coil 4 used 14 Orifice plug 0 068 3 Solenoid valve SV1 9 Coil spacer 15 Orifice plug 0 040 4 Solenoid valve SP1 10 Coil nut 16 Orifice plug 0 020 2 used 5 Pressure compensator valve EC1 11 Plug 4 used 17 6 plug 2 used 6 Solenoid coil 12 4 plug 6 used NOTE Solenoid valve SV1 and the upper solenoid coil on solenoid valve SP1 are not used in the ProPass 200 hydraulic system Hydraulic System Page 3 34 ProPass 200 NOTE The hydraulic manifold shown in Figure 36 uses several zero leak plugs These plugs have a tapered sealing surface on the plug head that is designed to re sist vibration induced plug loosening The zero leak plugs also have an O ring to provide a secondary seal If zero leak plug removal is necessary lightly rap the plug head using a punch and hammer before using an allen wrench to remove the plug the impact will allow plug removal with less chance of damage to the socket head of the plug When installing plugs into the manifold torque plugs to the values identified in Figure 36 NOTE See Hydraulic Solenoid Valve Coils in Chapter 4 Electrical System for information on testing the solenoid coils Before continuing further read and become fa m
50. drive roller shaft Fig 8 A Slide locking collar to bearing assembly and drive roller shaft B Using blind hole in locking collar as an impact point lock collar by striking it with a punch in the dir ection of drive roller shaft rotation C Apply Loctite 242 or equivalent to threads of set screw Install and tighten set screw to secure locking collar to drive roller shaft 3 Onboth sides of machine apply tension to floor con veyor belt at idler roller shaft Fig 7 A Retain tensioner rod with wrench to prevent it from turning B Tighten adjusting jam nut to apply tension to floor conveyor belt If locking jam nut is in original position adjusting jam nut can be tightened until locking jam nut is secure C Repeat for other side of machine Make sure that adjustments on both sides of the machine are equal 4 Lubricate conveyor roller bearings at grease fittings 5 Secure all removed guards to frame see Bed Guards in this section IMPORTANT Before adjusting conveyor belt ten sion check for trapped spreading material between conveyor bed belt and rollers Clean machine as re commended in Operator s manual 6 Check and adjust conveyor belt tension as needed refer to Operator s Manual ProPass 200 Page 5 9 Figure 7 1 Tensioner rod 2 Locking jam nut 3 Adjusting jam nut 4 Take up bearing
51. e 9 Flange nut 2 used 16 Flat washer 2 used 2 Spider coupling 10 Cap screw 2 used 17 Cap screw 2 used 3 Jaw coupling gear pump 11 R clamp 2 used 18 Flat washer 10 used 4 Square key 12 Engine wire harness 19 Flat washer 2 used 5 Engine 13 Generator bracket 20 Lock nut 4 used 6 Flange adapter 14 Lock nut 2 used 21 Cap screw 2 used 7 Engine mount plate 15 Cap screw 2 used 22 Cap screw 4 used 8 Mount bracket 4 used Engine Removal Fig 5 2 To prevent unexpected machine operation discon nect the negative battery cable from the battery termin 1 Position machine on a level surface If ProPass is at al Position disconnected negative cable away from the tached to tow vehicle apply tow vehicle parking brake negative battery terminal stop engine and remove key from the ignition switch Chock wheels to prevent ProPass machine from mov ing Hydraulic Power Pack Page 6 12 ProPass 200 The engine and exhaust system may be hot Avoid possible burns allow engine to cool be fore removing the engine 3 If engine is to be disassembled it may be easier to drain oil from engine before removing engine from ma chine 4 Disconnect positive cable from starter solenoid ter minal 5 Support gear pump to prevent it from moving as en gine is removed from machine Remove two 2 cap screws and flat washers that secure gear pump to flange adapter Fig 6 NOTE Ground cable is secured wit
52. eck wireless remote LCD display and base Make sure that floor start up procedure has been q unit LED s for help in troubleshooting correcily completed with remote o TT System Wireless remote has timed out due to thirty 30 minutes of inactivity Wireless remote settings are incorrect Proportional solenoid valve coil SP1 or circuit wiring is faulty Hydraulic problem exists see Chapter 3 Hydraulic System Wireless remote is faulty Base unit is faulty ProPass 200 Page 4 15 Electrical System Component Testing For accurate resistance and or continuity checks elec trically disconnect the component being tested from the circuit e g unplug the wire harness connector from component before checking continuity on the compon ent terminals When testing electrical components for continu ity with a multimeter ohms setting make sure that power to the circuit has been disconnected E Stop Button Machines with Electronic Hydraulic Controls On ProPass machines with electronic hydraulic con trols the E stop button is used to disconnect battery power to the machine The E stop button is a normally closed switch that is located on the control panel guard Fig 16 The E stop button is a two 2 position switch with two 2 terminals that can be tested with a multimeter Make sure that electrical power to the E stop button is discon nected before testing the button Disconnect E stop but
53. ecure conveyor motor shaft to conveyor cover 9 Slide conveyor motor from drive roller and remove motor and motor spacer item 21 from machine Locate and retrieve woodruff key item 20 from motor shaft 10 Ifnecessary remove hydraulic fittings from conveyor motor Remove and discard O rings from fittings NOTE For conveyor motor service information see Rear Option Motor Service in this section Installation Fig 43 1 Ifremoved install hydraulic fittings with new O rings into the conveyor motor ports see Hydraulic Fitting Installation in the General Information section of this chapter 2 Apply antiseize lubricant to conveyor motor shaft 3 Place woodruff key item 20 to slot in conveyor mo tor shaft Position motor spacer item 21 to motor flange and then slide motor shaft into drive roller 4 Align motor mounting holes with conveyor cover and secure motor with two 2 flange head screws item 19 and lock nuts item 18 5 Apply Loctite 242 or equivalent to threads of set screw item 16 Tighten set screw to secure drive drum to motor shaft 6 Remove all caps or plugs that were placed on hy draulic hoses and fittings during disassembly 7 Using labels placed during motor removal correctly install hydraulic hoses to hydraulic fittings on conveyor motor Tighten connections See Hydraulic Hose and Tube Installation in the General Information section of this chapter 8 Adjust conveyor belt refe
54. ed 21 6 plug 7 R clamp 3 used 15 Straight hydraulic fitting 22 Flange head screw 7 used 8 45 hydraulic fitting 2 used Removal Fig 7 1 Position machine ona level surface If ProPass is at tached to tow vehicle apply tow vehicle parking brake stop engine and remove key from the ignition switch Chock wheels to prevent ProPass machine from mov ing 2 Read the General Precautions for Removing and Installing Hydraulic System Components in the Service and Repairs section of Chapter 3 Hydraulic System Before disconnecting any hydraulic compo nents operate all hydraulic controls to relieve system pressure and avoid injury from pressur ized hydraulic oil See Relieving Hydraulic Sys tem Pressure in the General Information section of Chapter 3 Hydraulic System Hydraulic Power Pack Page 6 14 ProPass 200 3 Remove twin spinner or other option from machine 4 Thoroughly clean junction of hydraulic lines and hy draulic tank fittings Disconnect hydraulic lines from tank Install caps or plugs in hose and tank fittings to pre vent contamination and leakage of hydraulic oil 5 Place a suitable container under the hydraulic tank to collect hydraulic oil Remove plug item 21 from bot tom of tank and drain hydraulic tank Discard O ring from plug 6 Disconnect hoses from the hydraulic fittings in tank Allow hoses to drain into a suitable container Install caps or plugs in hoses and pump fittin
55. efore disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved and all rotating machine parts must be stopped See Relieving Hydraulic Sys tem Pressure in the General Information section Failure to use gauges with recommended pres sure PSI rating as listed in test procedures could result in damage to the gauge and possible personal injury from leaking hot oil All testing should be performed by two 2 people One person should be in the seat to oper ate the machine and the other should monitor testing equipment and record test results Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure Do not use hands to search for leaks use paper or cardboard Hydraulic fluid escap ing under pressure can have sufficient force to penetrate the skin and cause serious injury If fluid is injected into the skin it must be surgical ly removed within a few hours by a doctor famil iar with this type of injury Gangrene may result from such an injury Hydraulic System Page 3 24 Precautions for Hydraulic Testing 1 Clean machine thoroughly before disconnecting or disassembling any hydraulic components Always keep in mind the need for cleanliness when working on hy draulic equipment Hydraulic system contamination will cause excessive wear of hydraulic components 2 Put metal caps or plugs on all hydraulic lines left open or exp
56. electronic hydraulic controls include a wireless remote to electrically adjust hydraulic flow to the floor and rear option twin spinner or conveyor mo tors Fig 3 The remote allows initial adjustment of the floor and rear option motors as well as making adjust ments possible while the machine is operating An E Stop button on the machine disables the electrical system to prevent unexpected machine operation If there should be a problem with the wireless remote ProPass machines with electronic controls have manual override adjustments on the driver side of the hydraulic system that will allow continued operation Fig 4 A control knob is used to adjust floor speed and a flat blade screwdriver can be used to adjust the rear option speed Figure 2 1 Floor control 3 Pendant harness 2 Rear option control Figure 3 1 Wireless remote 3 Power lead harness 2 E Stop button 4 Optional power pack Figure 4 1 Control knob 2 Screwdriver slot Hydraulic System Page 3 4 ProPass 200 Rear Option The ProPass includes the twin spinner that is used for topdressing Fig 5 The twin spinner uses two 2 hy draulic motors for operation The cross conveyor and swivel is available as an option for delivery of material from the ProPass hopper Fig 6 The conveyor uses one 1 hydraulic motor for operation The ProPass hydraulic system is used to operate either of th
57. emove battery cover on rear of remote and replace batteries noting polarity marks in remote for proper installation of batteries NOTE Holding down the remote ALL STOP and OP TION STOP buttons simultaneously results in display of battery life expectancy Electrical System Page 4 18 LCD Display The wireless remote LCD display can be used to identify activity between the remote and the base unit LCD dis play messages are included on the following page Figure 20 1 LCD display 10 Floor start button 2 Controller status LED s 11 Floor stop button 3 All start button 12 Floor speed increase 4 ON OFF button 13 Floor speed decrease 5 Store button 14 Option start button 6 Preset 1 button 15 Option stop button 7 Preset 2 button 16 Option speed increase 8 Preset 3 button 17 Option speed decrease 9 All stop button Figure 21 3 Battery location 1 Rear of remote 2 Battery cover ProPass 200 ProPass 200 Page 4 19 Electrical System q S wi System Wireless Remote Base Unit Machines with Electronic Hydraulic Controls The base unit is a solid state electrical device that re ceives signal inputs from the wireless remote and uses those inputs to control machine electrical operation The base unit is attached to the front hopper wall next to the hydraulic control manifold Fig 22 Inputs from t
58. ese rear options Relieving Hydraulic System Pressure Before disconnecting any hydraulic compo nents operate all hydraulic controls to relieve system pressure and avoid injury from pressur ized hydraulic oil Before disconnecting or performing any work on the ProPass hydraulic system all pressure in the hydraulic system must be relieved Position machine on a level surface Turn tow vehicle key switch to OFF and allow engine to stop If ProPass is equipped with hydraulic power pack make sure that power pack engine is turned off ProPass 200 Page 3 5 Figure 5 Figure 6 Make sure that the ProPass has electrical power and that controls are operational With the tow vehicle en gine not running use the pendant control or wireless controller to energize the hydraulic solenoids for the floor and rear option twin spinner or conveyor motors After both hydraulic functions have been energized turn tow vehicle key switch OFF and remove key from igni tion switch Hydraulic System SE 3S Ez Cx gt N lt 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 hose damage and deterio ration Some hoses are more susceptible to these conditions than others Inspect all machine hydraulic hoses frequently
59. ess remote settings electrical voltage to valve SP1 is sup plied by the base unit Solenoid valve SP1 includes manual adjustment for machine operation should the wireless controller be lost damaged or faulty NOTE Control manifold solenoid valve SV 1 is not used in ProPass 200 machines This valve is included in the manifold for use on other machines that also use this same manifold If neither the floor motor or rear option twin spinner or conveyor motors are engaged none of the hydraulic control manifold solenoid valve coils are energized Hy draulic flow is prevented through the unshifted solenoid valves causing the pressure compensator valve EC1 and proportional flow valve PV1 to shift These two 2 valves route hydraulic flow back to the hydraulic reser voir bypassing the floor and rear option motors The floor and rear option will remain in the stationary posi tions ProPass 200 Page 3 17 NOTE Typically the rear option twin spinner or con veyor is engaged before the floor is started When the operator engages the rear option twin spin ner or conveyor the solenoid coil on proportional flow valve PV1 is energized by an output from the base unit The shifted PV1 valve directs hydraulic flow to the rear option motors To allow the proper motor speed the base unit supplies the necessary voltage to the PV1 solenoid coil based on settings of the wireless remote Flow from the PV1 valve is proportional
60. eterioration Make all neces sary repairs before operating the machine 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 in jected into the skin it must be surgically re moved within a few hours by a doctor familiar with this type of injury Gangrene may result from such an injury 2 E q a cs gt r ProPass 200 Page 3 27 Hydraulic System Hydraulic Control Machines with Standard Hydraulic Controls Hydraulic tee fitting 3 used Panel Floor control valve Rear option control valve Hydraulic hose Hydraulic hose Hydraulic hose Hydraulic hose Hydraulic cap DONDARON Hydraulic System Figure 26 Hydraulic tube 4 used Valve spacer 2 used Cap screw 4 used Hydraulic tube Rubber grommet Lock nut Flat washer Hydraulic adapter Hydraulic adapter Page 3 28 Cap screw 4 used Hydraulic tee fitting 90 hydraulic fitting 2 used Straight hydraulic fitting 3 used Hydraulic tee fitting Floor solenoid valve Hydraulic supply hose Hydraulic return hose Rear option solenoid valve ProPass 200 Disassembly Fig 26 1 Position machine on a level surface If ProPass is at tached to tow vehicle apply tow
61. f this LED is blinking red an over temperature situation exists The TX RX LED will be amber when the base unit is communicating with the wireless remote If this LED is not illuminated check for obstructions preventing line of sight transmission with wireless remote and make sure that wireless remote is active It may be necessary to re associate the wireless remote with the base unit The POWER LED will be amber when power exists to the base unit If this LED is either red or green an intern al base unit problem exists Figure 22 1 Base unit 4 Front hopper wall 2 Screw 2 used 5 Hydraulic manifold 3 Flange nut 2 used 6 Bulkhead wire harness Figure 23 1 Base unit 4 TX RX LED 2 Out LED 5 Power LED 3 Health LED Electrical System Page 4 20 ProPass 200 Hydraulic Solenoid Valve Coils The ProPass hydraulic system uses several hydraulic solenoid valve coils for system control When the sole noid coils are energized hydraulic valve shift occurs to control hydraulic flow Two 2 identical solenoid valve assemblies are used on machines with standard hydraulic controls Fig 24 The solenoid valve coils used on these assemblies are identical Machines with electronic hydraulic controls use two 2 different solenoid valve coils Fig 25 The double coils used on the solenoid valves are identical coils The single coil used on the proportional flow valve is a differ ent coil Testing of the hydra
62. 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 ProPass 200 Page 2 5 NOTE The nominal torque values listed above are based on 75 of the minimum proof load specified in SAE J1199 The tolerance is approximately 10 of the nominal torque value Product Records and Maintenance N cs o o o o cs o am and Maintenance Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Thread Size Square Head HexSocket 716 20unr oszton b coz 14Nm Grade 5 1 2 20 UNF 80 10 ft lb f 108 14 N m 5 16 18 UNC 215 35in lb f 145 20 in lb Grade 5 3 8 16 UNC 35 10 ft lb 18 3 ft lb 108 14 N m Class 8 8 M12 X 1 5 80 10 ft lb f 108 14 N m Class 8 8 For steel wheels and non lubricated fasteners Thread Cutting Screws Thread Cutting Screws Zinc Plated Steel Zinc Plated Steel Thread Threads per Inch Size Baseline Torque Type A Type B 1 2 1 1 Type 1 Type 23 or Type F Thread Size Baseline Torque No 6 32 UNC 20 5in lb No 8 32 UNC 30 5in lb as 16 7i No 10 24 UNC 38 7 in lb 1 4 20 UNC 85 15 in lb 5 16 18 UNC 110 20 in lb Hole size material strength material thickness and fin ish must be considered when determining specific 3 8 16 UNC 200 100 in lb torque v
63. gs to prevent con tamination 7 Remove two 2 flange head screws item 22 and flange nuts item 2 securing the hose bracket to the hy draulic tank Support the hose bracket and attached hy draulic hoses to prevent the assembly from falling 8 Support the hydraulic tank to prevent it from moving 9 Remove four 4 flange head screws item 3 and flange nuts item 12 that secure the hydraulic tank to the machine 10 Remove hydraulic tank from the machine 11 If fitting removal is necessary mark fitting orientation to allow correct assembly Remove fittings and strainer from hydraulic tank Fig 8 Discard removed O rings Installation Fig 7 1 If fittings were removed from hydraulic tank lubricate and place new O rings onto fittings Install fittings into tank openings making sure that fitting orientation is as noted during removal Tighten fittings see Hydraulic Fit ting Installation in the General Information section of Chapter 3 Hydraulic System 2 Position hydraulic tank to the machine and secure with four 4 flange head screws item 3 and flange nuts item 12 ProPass 200 Page 6 15 3 Align the hose bracket and attached hydraulic hoses to the hydraulic tank bracket Secure the hose bracket with two 2 flange head screws item 22 and flange nuts item 2 4 Remove plugs from hydraulic hoses and tank fit tings Connect hydraulic hoses to hydraulic tank fittings see Hydraulic Hose and T
64. h engine mounting screw under starter motor 6 Remove four 4 cap screws flat washers and lock nuts that secure engine to mount plate Note location of ground cable cap screws and washers for assembly purposes To prevent personal injury make sure that engine is properly supported as it is removed from the machine Engine assembly including flange ad apter weighs approximately 100 pounds 46 kg 7 Carefully slide engine assembly with flange adapter attached away from gear pump until the pump jaw coupling disengages from the spider coupling Remove engine assembly from machine 8 Ifnecessary loosen set screw in jaw coupling on en gine shaft and slide coupling from shaft Locate and re trieve square key 9 Remove engine parts and attachments as neces sary to repair the engine Engine Installation Fig 5 1 Position machine on a level surface 2 Make sure that all parts removed from the engine during maintenance or rebuilding are properly installed to the engine ProPass 200 Page 6 13 3 Ifjaw coupling was removed from engine shaft apply antiseize lubricant to shaft Insert square key into shaft keyway and then slide jaw coupling onto shaft Align jaw coupling flush with the end of the shaft and secure with set screw 4 Position engine with flange adapter attached onto machine frame Make sure that spider coupling is posi tioned into coupling jaw on engine shaft 5 Carefully slide engine as
65. h of torque wrench offset wrench TORQUE CONVERSION FACTOR A B Figure 3 Product Records and Maintenance a e t D am z E 3 2 a and Maintenance Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series Grade 1 5 amp SAE Grade 1 Bolts Screws Studs amp SAE Grade 5 Bolts Screws Studs amp SAE Grade 8 Bolts Screws Studs amp Thread Size 8 with Thin Sems with Regular Height Nuts Sems with Regular Height Nuts Sems with Regular Height Nuts Height Nuts SAE J995 Grade 2 or Stronger Nuts SAE J995 Grade 2 or Stronger Nuts SAE J995 Grade 5 or Stronger Nuts 147 23 339 56 599 79 100 10 1130 113 140 15 1582 169 65 10 734 113 115 12 1299 136 160 17 1808 192 105 15 1186 169 200 25 2260 282 300 30 3390 339 128 17 1446 192 225 25 2542 282 325 33 3672 373 6 32 UNC 6 40 UNF 8 32 UNC 8 36 UNF 10 24 UNC 10 32 UNF 1 4 20 UNC 48 7 1 4 28 UNF 5 16 18 UNC 115 15 5 16 24 UNF 138 17 w N a a e N o NI co w o I I I I I I ES w N N N N N a D N N a wo N oo fo to NI oO oo e a w H H H H H N N w w N N N a a N 28 16UNO 1622 NOTE Reduce torque values listed in the table above NOTE The nominal torque values listed above for by 25 for lubricated fasteners Lubricated fasteners Grade 5 and 8 fasteners are based on 75 of the mini are defined as threads coa
66. he rear option Hydraulic circuit pressure is controlled by the system re lief valve either on the tow vehicle or hydraulic power pack Hydraulic System 2 53 Ea D gt r Hydraulic Flow Diagrams Electronic Hydraulic Controls REAR OPTION CIRCUITS TWIN SPINNER OR CONVEYOR PLUG PLUG FLOOR MOTOR LAY cvi cv2 cv3 cva 1 Bo om IDT bao lt r SPINNER MOTORS EC1 gt J E ORF1 X t 0 040 ja 4 Bel wy CONTROL i MANIFOLD ee CONVEYOR MOTOR Y O Lin HYDRAULIC POWER PACK SP1 is not energized PV1 is energized Both EC1 and PV1 shift to allow flow Working Pressure to rear option motors Return Excess and return flow will be routed FI to hydraulic reservoir OW Hydraulic System Page 3 16 ProPass 200 Rear Option Circuits Twin Spinner or Conveyor Machines with electronic hydraulic controls include a wireless remote to electrically adjust hydraulic flow to the floor and rear option twin spinner or conveyor mo tors Fig 20 A hydraulic control manifold is used to control circuit hydraulic flow from the hydraulic oil supply source tow vehicle
67. he voltage mode will make sure that excess cur rent is not allowed through the meter This excess current can cause damage to circuits not designed to carry it Dielectric Lubricant Sealant Dielectric lubricant should be used to prevent corrosion of non sealed connection terminals To ensure com plete coating of terminals liberally apply lubricant to both component and wire harness connector plug con nector to component unplug connector reapply lubri cant to both surfaces and reconnect harness connector to component Connectors should be thoroughly packed with lubricant for effective results Toro Part Number 107 0342 Skin Over Grease Special non conductive grease which forms a light pro tective skin to help waterproof electrical switches and contacts Toro Part Number TOR50547 Electrical System Page 4 12 Figure 11 Figure 12 Figure 13 ProPass 200 Battery Terminal Protector Aerosol spray that should be used on battery terminals to reduce corrosion problems Apply battery terminal protector after the battery cable has been secured to the battery terminal Toro Part Number 107 0392 Battery Hydrometer Use the battery hydrometer when measuring specifi gravity of battery electrolyte Obtain this tool locally ProPass 200 Cc Page 4 13 Figure 14 Figure 15 Electrical System System T o E wi Troubleshooting Remove all jewelry especially rings a
68. he wheel hub onto the axle spindle taking care to not damage seal in wheel hub 4 Install greased outer bearing cone spindle washer and spindle nut onto spindle shaft DO NOT fully tighten the nut or install the cotter pin IMPORTANT Most wheel bearing failures can be at tributed to improper bearing adjustment normally due to the bearings being adjusted too tight Follow the following adjustment process to prevent prema ture bearing problems ProPass 200 Page 5 19 5 Adjust wheel bearings as follows A While rotating the wheel hub by hand torque the spindle nut from 75 to 100 in lb 8 5 to 11 3 N m to set the bearings Then loosen the nut until the hub has endplay B Again while rotating the wheel hub by hand torque the spindle nut from 15 to 20 in lb 1 7 to 2 3 N m After tightening make sure that the wheel hub does not have any free play C Install nut retainer with slot aligned to cotter pin hole in spindle Install cotter pin 6 Fill dust cap approximately half full of grease Install dust cap Failure to maintain proper lug nut torque could result in failure or loss of wheel and may result in personal injury 7 Install wheel assembly see Wheel Assemblies in this section Make sure that lug nuts are torqued in a criss cross pattern from 70 to 90 ft lb 95 to 122 N m 8 If removed install walking beam assembly to ma chine see Walking Beam Assembly in this section 9 Carefully lower
69. he wireless remote are monitored by the base unit Outputs from the base unit to the floor and rear option twin spinner or conveyor solenoid valve coils are controlled based on the inputs received by the base unit NOTE Use the wireless remote LCD display to make sure that association exists between base unit and wire less remote see Wireless Remote Machines with Elec tronic Hydraulic Controls in this section The base unit does not connect to an external computer or hand held device can not be re programmed and does not record any fault data Because of the solid state circuitry built into the base unit there is no reliable method to test it The base unit 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 base unit disconnect the wire harness connector from the base unit before performing any welding on the ma chine LED Operation Four 4 status diagnostic LED s can be used to de termine the state of the base unit Fig 23 The OUT LED will be green when an output is active This LED will be amber if there is an output issue If this LED is not illuminated check the wireless remote LED s and LCD display for correct remote operation The HEALTH LED will pulse green when communica tion between the base unit and the wireless remote is functioning If this LED is blinking amber an internal base unit problem exists I
70. hine Refer to this publication for additional information when servicing the machine 2 Before servicing or making adjustments position ProPass machine on a level surface Engage tow ve hicle parking brake stop engine and remove key from the ignition switch If ProPass is equipped with wireless controller power off wireless controller On ProPass mounted to a tow behind chassis chock wheels to pre vent it from moving 3 If equipped press the E stop button to disable the ProPass electrical system before working on the ma chine Pull the button out when machine is to be returned to use 4 Make sure machine is in safe operating condition by keeping all nuts bolts and screws tight 5 Never store the machine or fuel container inside where there is an open flame such as near a water heat er or furnace 6 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 7 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 ProPass 200 Page 1 3 8 Before disconnecting any hydraulic co
71. igure 11 1 Cap screw 8 used 7 Seal 12 Body 2 Washer 4 used 8 Wear plate 13 Backplate 3 Front plate 9 Key 14 Washer 4 O ring 2 used 10 Drive gear 15 Seal 5 Plug 11 Idler gear 16 Retaining ring 6 Backup gasket NOTE For service of the power pack gear pump see the Eaton Series 26 Parts and Repair Manual at the end of this chapter Hydraulic Power Pack Page 6 18 ProPass 200 This page is intentionally blank oOo 6 O Es z Te ProPass 200 Page 6 19 Hydraulic Power Pack Power Pack Relief Valve Figure 12 1 Hydraulic relief valve manifold 6 Cap screw 2 used 10 Gear pump 2 Hydraulic hose 7 Flange nut 2 used 11 Oil filter 3 Hydraulic hose 8 Straight hydraulic fitting 4 used 12 Hydraulic hose from tank 4 Hydraulic tube 9 Engine mount plate 13 Hydraulic hose to tank 5 Hydraulic hose Removal Fig 9 1 Position machine on a level surface If ProPass is at tached to tow vehicle apply tow vehicle parking brake stop engine and remove key from the ignition switch Before disconnecting any hydraulic compo Chock wheels to prevent ProPass machine from mov nents operate all hydraulic controls to relieve ing system pressure and avoid injury from pressur ized hydraulic oil See Relieving Hydraulic Sys tem Pressure in the General Information section of Chapter 3 Hydraulic System 2 Read the General Precautions for Removing and Installing Hydraulic System Components in
72. iliar with General Precautions for Removing and Installing Hydraulic System Components in this section Cartridge Valve Service If manifold is connected to machine hydraulic system operate all hydraulic controls to relieve system pressure and avoid injury from pressur ized hydraulic oil before removing manifold com ponents See Relieving Hydraulic System Pres sure in the General Information section of this chapter 1 If control manifold is connected to machine hydraulic system relieve hydraulic system pressure before servi cing the manifold 2 Make sure control manifold is clean before removing any of the cartridge valves from the control manifold 3 If cartridge valve is solenoid operated remove nut securing solenoid coil to the cartridge valve Carefully slide coil off the valve IMPORTANT Use care when handling the cartridge valve Slight bending or distortion of the stem tube can cause binding and malfunction When remov ing cartridge valve from manifold make sure that deep well socket fully engages the valve base 4 Remove cartridge valve from manifold using a deep socket wrench Note correct location for O rings seal ing rings and backup rings on valve Remove seal kit from cartridge valve and discard removed seals ProPass 200 Page 3 35 5 Visually inspect the port in the manifold for damage to the sealing surfaces damaged threads and contami nation 6 Visually inspect cartridge valve f
73. intervals for your ProPass machine Refer to this public ation for additional information when servicing the ma chine Parts Catalog The Parts Catalog can be used to provide general disas sembly and assembly information for the chassis on your ProPass machine Refer to this publication for additional information when servicing the machine ProPass 200 Page 5 3 Chassis Service and Repairs Bed Guards Figure 1 1 Bottom guard 7 Front rinse guard 12 Cap screw 2 used 2 RH drive guard 8 Shoulder nut 2 used 13 Cap screw 3 Guard cap 9 Lanyard 2 used 14 Screw retainer 4 LH idler guard 10 Flat washer 2 used 15 Cap screw 5 RH idler guard 11 Rivet 2 used 16 Flange nut 6 LH drive guard Chassis Page 5 4 ProPass 200 Disassembly Fig 1 1 Position machine on a level surface If ProPass is at tached to tow vehicle apply tow vehicle parking brake stop engine and remove key from the ignition switch Chock wheels to prevent ProPass machine from mov ing 2 If front rinse guard is to be removed from machine with electronic controls Fig 2 A Disconnect E stop button from machine wire harness B Remove fasteners that secure control panel guard to machine Remove control panel guard C Remove the two 2 cap screws lock washers and flat washers that secure hydraulic control mani fold to rinse guard D Raise and support hydraulic manifold away from rinse guard 3 Using Figure 1 a
74. irection A 1 8 turn on the socket will make a measurable change in relief pressure 5 Tighten jam nut on relief valve 6 Recheck relief pressure and readjust as needed If adjustments to the relief valve do not change the relief pressure consider that the relief valve cartridge is leak ing or damaged Figure 1 1 Relief valve manifold 3 Gear pump 2 Relief valve Figure 2 1 Relief valve cartridge 3 Adjustment socket 2 Jam nut Hydraulic Power Pack Page 6 6 ProPass 200 This page is intentionally blank oOo 6 O Es z Te ProPass 200 Page 6 7 Hydraulic Power Pack Hydraulic Testing The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the circuits during various operational checks Information regard ing special tools for hydraulic testing is in the Special Tools section of Chapter 3 Hydraulic System IMPORTANT To prevent possible personal injury or machine damage when conducting hydraulic tests review the Precautions for Hydraulic Testing in the Testing section of Chapter 3 Hydraulic System Combined Hydraulic Power Pack Gear Pump Flow and System Relief Pressure Tests Using Tester with Flowmeter and Pressure Gauge The power pack gear pump fl
75. is operating correctly see Hydraulic Power Pack Gear Pump Flow and System Relief Pressure Tests in this section The following procedure is used to identify the gear pump flow directly from the pump out let 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately ten 10 minutes 2 Position machine on a level surface If ProPass is at tached to tow vehicle apply tow vehicle parking brake stop engine and remove key from the ignition switch Chock wheels to prevent ProPass machine from mov ing Make sure that key switch on power pack engine is in the OFF position Also make sure the hydraulic tank is full Prevent personal injury and or damage to equip ment Read all WARNINGS CAUTIONS and Pre cautions for Hydraulic Testing in the Testing sec tion of Chapter 3 Hydraulic System 3 Thoroughly clean junction of both ends of hydraulic tube and fittings on gear pump and relief valve manifold Fig 4 Disconnect tube from both pump fitting and manifold fitting Then remove hydraulic tube 4 Install hydraulic tester pressure and flow in series between the gear pump fitting and the manifold fitting Make sure that tester flow arrow points from the gear pump fitting and toward the manifold Also make sure flow control valve on the tester is fully open 5 Make sure that ProPass controls for the floor and the twin spinner are disengaged 6 Start power pack engine and r
76. lat washer 8 used 25 Flange head screw 12 used 6 Walking beam assembly 2 used 16 Flange nut 8 used 26 Front brace 7 Wheel assembly 4 used 17 Grease fitting 4 used 27 Hitch pin 8 Cap screw 2 used 18 Flange head screw 8 used 28 Lynch pin 9 Flat washer 4 used 19 Flange head screw 6 used 29 Lug nut 5 used per wheel 10 Lock nut 2 used 20 Flange nut 6 used NOTE The outer wheels can be removed with the walking beam item 6 attached to the ProPass ma chine If an inner wheel needs to be removed walking beam removal is necessary see Walking Beam As sembly in this section Chassis Page 5 16 ProPass 200 Wheel Removal Fig 15 1 Position ProPass on a level surface attached to tow ing vehicle Apply vehicle parking brake stop engine and remove key from the ignition switch Chock Pro Pass wheels to prevent machine from moving 2 Jack or hoist ProPass from ground and support ma chine with appropriate jack stands 3 If removal of inner wheel assemblies is necessary remove walking beam assembly from machine see Walking Beam Assembly in this section 4 Loosen and remove five 5 lug nuts from wheel to be removed 5 Pull wheel from walking beam assembly ProPass 200 Page 5 17 Wheel Installation Fig 15 1 Position wheel to wheel hub 2 Secure wheel to wheel hub with five 5 lug nuts Failure to maintain proper lug nut torque could result in failure or loss of wheel and m
77. ld port by hand until the top O ring is met The valve should go into manifold port easily without binding D Torque cartridge valve using a deep socket wrench to value identified in Figure 36 9 If cartridge valve is solenoid operated carefully install solenoid coil to the cartridge valve Secure coil to valve with nut and torque nut to 60 in lb 6 8 N m 10 If problems still exist after manifold assembly re move cartridge valve and clean again or replace valve Hydraulic System SE o O a V Cx gt N lt Check Valve Service The ProPass control manifold includes four 4 check valves used for circuit control Check valve location is identified in Figure 37 Remove check valves from mani fold for cleaning or replacement Replace seal kit on check valves if removed from manifold Torque check valves from 12 to 14 ft lb 16 to 18 N m when in stalling them into manifold NOTE Check valves CV3 and CV4 are not used in the ProPass 200 hydraulic system Refer to Hydraulic Schematics in this chapter for circuit location of check valves Orifice Service The control manifold includes four 4 orifice fittings that thread into specific manifold ports Access to these ori fice plugs requires removal of the manifold plug Orifice locations are shown in Figure 38 NOTE Orifice fitting ORF3 is not used in the ProPass 200 hydraulic system Refer to Hydraulic Schematics in this chapter for circuit location of the
78. ls When ener gized these solenoid valves allow hydraulic flow to en gage the floor and rear option twin spinner or conveyor motors NOTE See Hydraulic Control Machines with Standard Hydraulic Controls in this section for information on re moving the solenoid valve assembly from the machine Before continuing further read and become fa miliar with General Precautions for Removing and Installing Hydraulic System Components in this section For cartridge valve service procedures see Hydraulic Control Manifold Machines with Wireless Control Mod els in this section Refer to Figure 32 for cartridge valve and solenoid coil nut installation torque NOTE See Hydraulic Solenoid Valve Coils in Chapter 4 Electrical System for information on testing the solenoid coils E aa o G r A Figure 31 1 Floor solenoid valve 2 Option solenoid valve 2 E g cs gt lt 60 in Ib 6 7 N m Figure 32 1 Nut 4 Seal kit 2 Solenoid coil 5 Manifold 3 Cartridge valve ProPass 200 Page 3 31 Hydraulic System Hydraulic Control Machines with Electronic Hydraulic Controls Figure 33 1 Hydraulic hose 8 Female quick disconnect 15 Cap screw 3 used 2 Hydraulic hose 9 Male quick disconnect 16 Cap screw 2 used 3 Hydraulic hose 10 45 hydraulic fitting 2 used 17 O ring 4 Hydraulic control manifold 11 Tube clamp 12 used 18 Seal kit 5 Hydraulic hose 12
79. ls when the switch is in the OFF posi tion as shown in Figure 17 There should be continuity between the switch terminals when the switch is in the ON position If switch testing determines that a switch is faulty re move switch from junction box and replace switch Fig 18 Make sure that wire harness connectors are at tached to correct switch terminals Fig 19 ProPass 200 Page 4 17 Figure 17 3 Junction box 4 Wire harness Rear option switch 2 Floor switch NAAN Y Figure 18 1 Rear option switch 5 Pop rivet 2 used 2 Floor switch 6 Switch boot 2 used 3 Junction box 7 Washer 4 Switch guard 8 Wire harness TOP VIEW OF SWITCHES WHITE WHITE WIRE WIRE REO E P BLACK TT WIRE OFF POSITION GREEN WIRE OFF POSITION 1 Figure 19 1 Spinner switch 2 Floor switch Electrical System q o 2 wi System Wireless Remote Machines with Electronic Hydraulic Controls The wireless remote is a solid state electrical device that sends radio frequency RF signal inputs to the machine wireless remote base unit for control of machine electri cal operation The wireless remote has sufficient range to send an PF signal to the remote base unit from the tow
80. ly Refer to this publication for additional information when servicing the engine Installation Instructions The Installation Instructions provides information re garding the operation general maintenance and main tenance intervals for the Hydraulic Power Pack assembly on your ProPass machine Refer to this pub lication for additional information when servicing the machine Parts Catalog The Parts Catalog can be used to provide general disas sembly and assembly information for the Hydraulic Power Pack assembly on your ProPass machine Refer to this publication for additional information when servic ing the machine Hydraulic Schematics The hydraulic schematics for ProPass machines equipped with the Hydraulic Power Pack assembly are included in Chapter 4 Hydraulic System Hydraulic Power Pack Page 6 4 monly available in many service shops Special tools are described in the Honda Workshop Manual The cost of the test equipment and the specialized nature of some repairs may dictate that engine work be done at an engine repair facility Some service and repair parts for the Honda engine in the Power Pack assembly are supplied through your Au thorized TORO Distributor If no parts list is available be prepared to provide your distributor with the Toro model and serial number ProPass 200 Electrical System Quick Checks Battery Test Open Circuit Test Use a multimeter to measure the voltage between the ba
81. machine to ground Chassis Walking Beam Assembly Tow Chassis TK a 240 to 292 ft Ib 322 to 396 N m 135 to 165 ft Ib 183 to 223 N m Floor assembly Hitch Hitch clevis Jack Walking beam bearing 4 used Walking beam assembly 2 used Wheel assembly 4 used Cap screw 2 used Flat washer 4 used 0 Lock nut 2 used SONHA BON Chassis Figure 17 Cap screw 2 used Flat washer 4 used Lock nut 2 used Cap screw 8 used Flat washer 8 used Flange nut 8 used Grease fitting 4 used Flange head screw 8 used Flange head screw 6 used Flange nut 6 used Page 5 20 94 to 116 ft lb 128 to 157 N m 70 to 90 ft Ib 95 to 122 N m Top cross member 2 used Frame brace Cross member 2 used Lock nut 20 used Flange head screw 12 used Front brace Hitch pin Lynch pin Lug nut 5 used per wheel ProPass 200 Removal Fig 17 1 Position ProPass on a level surface attached to tow ing vehicle Apply vehicle parking brake stop engine and remove key from the ignition switch Chock Pro Pass wheels to prevent machine from moving 2 Jack or hoist ProPass from ground and support ma chine with appropriate jack stands To prevent personal injury and machine damage make sure that walking beam assembly is prop erly supported as it is removed from the machine Walking beam assembly including wheel as semblies
82. mponent 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 9 Make sure that electrical power harness from tow ve hicle is disconnected before working on the machine s electrical system 10 If major repairs are ever needed or assistance is de sired contact your Authorized Toro Distributor 11 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 12 When changing tires or performing other service on your ProPass machine use correct hoists and jacks Make sure machine is parked on a solid level surface such as a concrete floor with the hopper empty Always chock or block wheels Use appropriate stands to sup port the raised machine If the machine is not properly supported the machine may move or fall which may re sult in personal injury Safety Safety and Instruction Decals Numerous safety and instruction decals are affixed to the ProPass 200 If any decal becomes illegible or dam aged install a new decal Decal part numbers are listed in your Parts Catalog
83. n twin spinner or conveyor mo tors Fig 21 A hydraulic control manifold is used to control circuit hydraulic flow from the hydraulic oil supply source tow vehicle or hydraulic power pack The con trol manifold includes cartridge valves for control of the rear option twin spinner or conveyor and floor circuits Control manifold pressure compensator valve EC1 is used to provide priority flow in the required amount to the floor motor while allowing excess flow to be used for op eration of the rear option motors If the floor circuit is not engaged the pressure compensator valve directs all of the hydraulic flow toward the rear option motors and re turn to the hydraulic reservoir Control manifold proportional flow valve PV1 is a prior ity type flow regulator with pressure compensated by pass flow Priority hydraulic flow from this valve is to the rear option motors Based on wireless remote settings electrical voltage to valve PV1 is supplied by the base unit Valve PV1 includes manual adjustment for ma chine operation should the wireless controller be lost damaged or faulty NOTE The schematic symbols for the pressure com pensator valve EC1 and proportional flow valve PV1 include lines above and below the valve symbols which designate infinite positioning of the valve spools These valves appear to be two 2 position valves but in opera tion the valves will shift to provide necessary flow to both the floor mot
84. nd watches before doing any electrical trouble shooting or testing Disconnect the battery cables unless the test requires battery voltage For effective troubleshooting and repairs there must be a good understanding of the electrical circuits and com ponents used on this machine see Electrical Schemat ics in this chapter If the machine has any interlock switches by passed reconnect the switches for proper safety and trouble shooting Possible Causes No ProPass functions operate machines with standard Electrical power to ProPass components is not hydraulics No ProPass functions operate machines with electronic hydraulics NOTE Check wireless remote LCD display and base unit LED s for help in troubleshooting Rear option does not function machines with standard hydraulics Electrical System Page 4 14 available e g power harness not connected to tow vehicle tow vehicle key not ON vehicle battery is discharged Pendant is not connected to ProPass connector One or both of the fuses 15 Amp is faulty Hydraulic problem exists see Chapter 3 Hydraulic System E stop button is not pulled out Electrical power to ProPass components is not available e g power harness not connected to tow vehicle tow vehicle key not ON vehicle battery is discharged In line fuse 15 Amp is faulty Wireless remote has not been turned ON Wireless remote has timed out due to thirty 30 minute
85. nto fittings Install and properly tighten fit tings into component openings see Hydraulic Fitting Installation in the General Information section of this chapter B Lubricate and position new O rings to fittings Use labels placed during the removal process to properly install hydraulic lines to fittings see Hydrau lic Hose and Tube Installation in the General Infor mation section of this chapter C Make sure that wire harness connectors are se cured to solenoid coils 2 Install hydraulic guard to machine Fig 27 ProPass 200 Page 3 29 Hydraulic System Control Valve Service Machines with Standard Hydraulic Controls ProPass machines with standard hydraulic controls use two 2 control valves for adjusting the speed of the floor and rear option twin spinner or conveyor motors These control valves are located on the front of the hop per Fig 29 NOTE See Hydraulic Control Machines with Standard Hydraulic Controls in this section for information on re moving the control valve from the machine Disassembly Fig 30 NOTE A seal kit is available for the control valve If wear or damage exists to the control valve body side lever or compensator spool control valve assembly re placement is necessary 1 Loosen set screw and slide handle from side lever 2 Remove retaining rings that secure side lever in the control valve body 3 Slide seal retainers from side lever 4 Pull side lever from cont
86. oPass 200 Removal Fig 43 1 Position machine on a level surface If ProPass is at tached to tow vehicle apply tow vehicle parking brake stop engine and remove key from the ignition switch Chock wheels to prevent ProPass machine from mov ing 2 Loosen conveyor belt tension A Loosen cap screws item 1 and flange nuts item 2 that secure adjuster plates item 3 and flange bearings item 6 to conveyor cover B Loosen jam nuts item 5 and flange head screws item 4 that adjust location of adjuster plates which will loosen conveyor belt tension Before disconnecting any hydraulic compo nents operate all hydraulic controls to relieve system pressure and avoid injury from pressur ized hydraulic oil See Relieving Hydraulic Sys tem Pressure in the General Information section of this chapter 3 Relieve hydraulic system pressure 4 Clean conveyor motor and all hydraulic connections at motor Label hydraulic lines for assembly purposes 5 Disconnect hydraulic hoses from hydraulic fittings on conveyor motor Allow hydraulic oil to drain from lines into a suitable container Put caps or plugs on open hy draulic lines and fittings to prevent contamination 6 Support drive roller item 15 to prevent it from shift ing 7 Loosen set screw item 16 that secures drive roller to conveyor motor shaft ProPass 200 Page 3 45 8 Remove two 2 flange head screws item 19 and lock nuts item 18 that s
87. on after repairs are completed 5 Note the position of hydraulic fittings especially el bow fittings on hydraulic components before removal Mark parts if necessary to make sure they will be aligned properly when installing hydraulic hoses and tubes Hydraulic System Page 3 26 After Repair or Replacement of Hydraulic Compo nents 1 Check oil level in the hydraulic reservoir and add cor rect oil if necessary Drain and refill hydraulic system reservoir and change oil filter if component failure was severe or system is contaminated 2 Lubricate O rings and seals with clean hydraulic oil before installing hydraulic components 3 Make sure caps or plugs are removed from the hy draulic tubes hydraulic fittings and components before reconnecting 4 Use proper tightening methods when installing hy draulic hoses and fittings see Hydraulic Hose and Tube Installation and Hydraulic Fitting Installation in the Gen eral Information section of this chapter 5 After disconnecting or replacing any hydraulic com ponents operate machine functions slowly until air is out of hydraulic system 6 Check for hydraulic oil leaks Shut off engine and cor rect leaks if necessary Check oil level in hydraulic reser voir and add correct oil if necessary ProPass 200 Check Hydraulic Lines and Hoses IMPORTANT Check hydraulic lines and hoses daily for leaks kinked lines loose mounting supports wear loose fittings or d
88. onds to remove the surface charge Use a battery load tester following the manufacturer s instructions D Measure the temperature of the electrolyte in the center cell E Connecta battery load tester to the battery termi nals following the manufacturer s instructions Connect a digital multimeter to the battery terminals F Apply atest load of 150 amps one half the battery CCA performance for fifteen 15 seconds G Take a battery voltage reading after fifteen 15 seconds then remove the load Record this test volt age reading H Using the table below determine the minimum test voltage for the cell temperature reading Minimum Battery Electrolyte Test Voltage Temperature it 306 70 F and up 21 C and up 60 F 16 C 9 4 50 F 20 F 7 C To Ifthe test voltage is below the minimum replace the battery If the test voltage is at or above the mini mum return the battery to service ProPass 200 Battery Charging To minimize possible damage to the battery and allow the battery to be fully charged the slow charging meth od is presented here This charging method can be ac complished with a constant current battery charger which is available in most service shops Follow the battery charger manufacturer s instructions when using a battery charger NOTE Using specific gravity of the battery cells is the most accurate method of determining battery condition 1 Determine the bat
89. operly adjusted chain should allow for free rotation of drive components 13 Secure guards to frame See Bed Guards in the Ser vice and Repairs section of Chapter 5 Chassis FRONT gt Figure 40 3 RH conveyor frame 4 Rotation direction 1 Drive roller 2 Idler roller Hydraulic System o 55 v Cx gt N Floor Motor Service Loctite 601 250 in lb 28 N m Figure 41 1 Cap screw 4 used 7 Bearing race 2 Mounting flange 8 Thrust bearing 3 Exclusion seal 9 Output shaft 4 Back up ring 10 Housing 5 Pressure seal 11 Seal 3 used 6 Seal 12 Spacer plate NOTE For service of the conveyor motor see the Eaton Char Lynn S Series General Purpose Motors Parts and Repair Manual at the end of this chapter Hydraulic System Page 3 40 300 in Ib 34 N m 13 Drive 14 Geroler assembly 15 End cap 16 Cap screw 7 used 17 Poppet 2 used ProPass 200 RS EE O a N Cx gt N This page is intentionally blank ProPass 200 Page 3 41 Hydraulic System Twin Spinner Motors Antiseize Lubricant Quick disconnect male Quick disconnect female Hydraulic hose Hydraulic tee fitting Hydraulic hose Hydraulic hose Hydraulic hose O ring 10 90 hydraulic fitting 11 Plug LONDARON Hydraulic System Straight hydraulic fitting 4 used Figure 42 Cap O ring O ring O ring O ring Spinner motor
90. or and to the rear option motors based on control settings Control manifold proportional solenoid valve SP1 is used to allow flow to the floor motor Based on wireless remote settings electrical voltage to valve SP1 is sup plied by the base unit Solenoid valve SP1 includes manual adjustment for machine operation should the wireless controller be lost damaged or faulty NOTE Control manifold solenoid valve SV 1 is not used in ProPass 200 machines This valve is included in the manifold for use on other machines that also use this same manifold If neither the floor motor or rear option twin spinner or conveyor motors are engaged none of the hydraulic control manifold solenoid valve coils are energized Hy draulic flow is prevented through the unshifted solenoid valves causing the pressure compensator valve EC1 and proportional flow valve PV1 to shift These two 2 valves route hydraulic flow back to the hydraulic reser voir bypassing the floor and rear option motors The floor and rear option will remain in the stationary posi tions ProPass 200 Page 3 19 NOTE Typically the rear option twin spinner or con veyor is engaged before the floor is started When the operator engages the floor conveyor the solenoid coil on solenoid valve SP1 is energized by an output from the base unit The shifted SP1 valve directs hydraulic flow to the floor motor To allow the proper mo tor speed the base unit supplies
91. or conveyor belt If locking jam nut is left in posi tion applying correct tension to conveyor belt will be easier during assembly C Repeat for other side of machine Chassis Bearing assembly Drive roller shaft Cap screw 4 used per bearing Page 5 8 7 Alignment plate 8 Idler roller shaft 4 If right side bearing is to be removed from machine remove drive chain and sprocket from drive roller see Floor Motor Drive in this section 5 Loosen and remove locking collar from drive roller shaft Fig 8 NOTE Direction of normal roller rotation is shown in Figure 9 as viewed from left side of conveyor A Loosen set screw in locking collar B Using blind hole in locking collar as an impact point unlock collar by striking it with a punch in the opposite direction of drive roller shaft rotation C Slide locking collar from bearing assembly and drive roller shaft NOTE If LH bearing is being removed from machine leave alignment plate item 7 tightened to conveyor frame if possible This will reduce the need for re align ing bearing during assembly 6 Remove four 4 lock nuts item 3 that retain bearing assembly to conveyor frame Remove bearing from drive roller shaft and frame Leave cap screws in frame ProPass 200 Assembly Fig 6 1 Slide bearing onto cap screws that are inserted into frame Secure bearing to frame with four 4 lock nuts item 3 2 Install and tighten locking collar to
92. or damaged sealing surfaces and contamination A Contamination may cause valves to stick or hang up Contamination can become lodged in small valve orifices or seal areas causing malfunction B If valve sealing surfaces appear pitted or dam aged the hydraulic system may be overheating or there may be water in the system A CAUTION Use eye protection such as goggles when using compressed air 7 Clean cartridge valve using clean mineral spirits Submerge valve in clean mineral spirits to flush out con tamination Particles as fine as talcum powder can affect the operation of high pressure hydraulic valves If car tridge design allows use a wood or plastic probe to push the internal spool in and out 20 to 30 times to flush out contamination Be extremely careful not to damage car tridge Use compressed air for cleaning 8 Install the cartridge valve into the manifold A Lubricate new seal kit components with clean hy draulic oil and install on valve The O rings sealing rings and backup rings must be arranged properly on the cartridge valve for proper operation and sealing B Dip assembled cartridge into clean hydraulic oil IMPORTANT Use care when handling the valve cartridge Slight bending or distortion of the stem tube can cause binding and malfunction When installing cartridge valve into manifold make sure that deep well socket fully engages the valve base C Thread cartridge valve carefully into manifo
93. orifice fittings Figure 37 3 Check valve CV3 4 Check valve CV4 1 Check valve CV1 2 Check valve CV2 CFHF 32193 05 Figure 38 3 Orifice ORF3 0 068 1 Orifice ORF1 0 040 2 Orifice ORF2 0 020 Hydraulic System Page 3 36 4 Orifice ORF4 0 020 ProPass 200 RS EE O a N Cx gt N
94. ose connected from the system cir cuit to the inlet side of the hydraulic tester 2 LOAD VALVE A simulated working load is created in the circuit by turning the valve to restrict flow 3 PRESSURE GAUGE Glycerine filled 0 to 5000 PSI gauge to provide operating circuit pressure 4 FLOW METER This meter measures actual oil flow in the operating circuit with a gauge rated from 1 to 15 GPM 5 to 55 LPM Figura 5 OUTLET HOSE A hose from the outlet side of the hydraulic tester connects to the hydraulic system circuit 6 FITTINGS An assortment of hydraulic fittings are in cluded with this kit Toro Part Number TOR214678 Hydraulic System Page 3 20 ProPass 200 Hydraulic Test Fitting Kit This kit includes a variety of O ring Face Seal fittings to Toro Test Fitting Kit enable you to connect test gauges into the system TOR4079 Tool Number The kit includes tee s unions reducers plugs caps ae rs and male test fittings toe Mee Mee mer x Toro Part Number TOR4079 mag f ertt z Figure 24 O ring Kit This kit includes O rings in a variety of sizes for face seal and port seal hydraulic connections It is recom mended that O rings be replaced whenever a hydraulic connection is loosened Hydraulic Toro Part Number 117 2727 Figure 25 ProPass 200 Page 3 21 Hydraulic System Troubleshooting For effective troubleshooting and repairs there must be a good understanding of
95. osed during testing or removal of compo nents 3 The engine must be in good operating condition Use a phototac to determine engine speed when performing a hydraulic test Engine speed will affect the accuracy of the tester readings 4 When using hydraulic tester with pressure and flow capabilities the inlet and the outlet hoses must be prop erly connected and not reversed to prevent damage to the hydraulic tester or machine components 5 When using hydraulic tester with pressure and flow capabilities open load valve completely in the tester to minimize the possibility of damaging components 6 Install fittings finger tight and far enough to make sure that they are not cross threaded before tightening them with a wrench 7 Position tester hoses to prevent rotating machine parts from contacting and damaging the hoses or tester 8 Check oil level in the hydraulic reservoir After con necting test equipment make sure hydraulic reservoir is full 9 Check control linkages for improper adjustment binding or broken parts 10 All hydraulic tests should be made with the hydraulic oil at normal operating temperature 11 Before returning machine to use make sure that hy draulic reservoir has correct fluid level ProPass Hydraulic Testing If your ProPass uses hydraulic flow from a tow vehicle refer to service information for the tow vehicle to determ ine testing procedures for flow and relief pressure on your ProPass
96. ove guard cap and RH drive guard from frame to allow access to floor drive components Fig 4 3 Loosen cap screw and lock nut that secure idler sprocket item 5 to frame Move idler sprocket to re move tension from drive chain 4 Locate and remove master link item 16 from drive chain Note direction of master link clip for assembly pur poses Remove drive chain 5 Loosen set screws item 15 that secure sprocket to shaft of drive roller Slide sprocket from shaft Remove square key item 13 from shaft Figure 4 1 Guard ca 6 Lanyard 2 used NOTE If floor motor item 2 needs to be removed see 2 Cap fected 3 used 7 eaten nut 2 isa Floor Motor in the Service and Repairs section of 3 a drive Rida A 8 Pt 2 used 4 Cap screw 2 use 9 Screw retainer Chapter 3 Hydraulic System 5 Flat washer 2 used Assembly Fig 3 1 Apply antiseize lubricant to drive roller shaft FRONT gt 2 Position square key to slot in drive roller shaft and then slide sprocket item 3 onto shaft 3 Fit drive chain onto floor motor sprocket drive roller sprocket and idler sprocket Install master link item 16 to drive chain and secure ends with master link clip Make sure that the closed end of the master link clip is facing the direction of chain rotation Figure 5 i y 1 Drive roller 3 RH conveyor frame NOTE Direction of normal roller rotation is shown in 2 Idler roller 4 Ro
97. ow test should be per formed to make sure that the ProPass hydraulic circuits have adequate hydraulic flow and the system relief pressure test identifies if the relief valve adjustment is correct These hydraulic tests can be done with the same tester connections as described below Procedure for the Combined Power Pack Gear Pump Flow and System Relief Pressure Tests 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately ten 10 minutes 2 Position machine on a level surface If ProPass is at tached to tow vehicle apply tow vehicle parking brake stop engine and remove key from the ignition switch Chock wheels to prevent ProPass machine from mov ing Make sure that key switch on power pack engine is in the OFF position Also make sure the hydraulic tank is full Prevent personal injury and or damage to equip ment Read all WARNINGS CAUTIONS and Pre cautions for Hydraulic Testing in the Testing sec tion of Chapter 3 Hydraulic System 3 Thoroughly clean junction of hydraulic supply hose and relief valve manifold fitting on right side of manifold Fig 3 Disconnect supply hose from manifold fitting 4 Install hydraulic tester pressure and flow in series with the disconnected hose and the manifold fitting Make sure that tester flow arrow points from the mani fold fitting and toward the disconnected hose Also make sure flow control valve on the tester is f
98. r ProPass 200 Page 3 13 ProPass 200 Hydraulic Schematic Electronic Hydraulic Controls All solenoids are shown as de energized NOTE The hydraulic hose kit used when a ProPass re ceives its hydraulic supply from a tow vehicle includes acheck valve in the return hose assembly see Hydraul ic Hose Kit in the General Information section of this chapter Hydraulic System SE Bo O a V Cx gt I Hydraulic Flow Diagrams Standard Hydraulic Controls REAR OPTION CIRCUIT TWIN SPINNER SHOWN FLOOR OPTION SOLENOID SOLENOID 4 VALVE p ex OPTION E et 1 CONTROL VALVE A 3 iS SPINNER MOTORS HEHE HO CF La6 lt a HYDRAULIC POWER PACK Option solenoid valve is energized Excess and return flow will be routed to hydraulic reservoir FLOOR CIRCUIT FLOOR OPTION SOLENOID SOLENOID VALVE ex OPTION CONTROL VALVE SPINNER cr HYDRAULIC POWER PACK Both floor solenoid valve and option solenoid valve are energized Excess and return flow will be routed to hydraulic reservoir Working Pressure Return Flow Hydraulic System Page 3 14 ProPass 200 Rear Option Circuit Twin Spinner or Conveyor Machines with standard hydraulic controls include manual hydraulic controls on the front of the ProPass hopper to
99. r to conveyor belt tension ing procedure in ProPass 200 Operator s Manual Hydraulic System o SE Ez Aa gt N r Rear Option Motor Service Loctite 277 250 in lb 28 N m 235 to 250 in Ib 27 to 28 N m Figure 44 1 Cap screw 7 used 7 Housing 13 Pressure seal 2 Endcap 8 Output shaft 14 Backup ring 3 Seal 3 used 9 Woodruff key 15 Mounting flange 4 Geroler assembly 10 Thrust bearing 16 Exclusion seal 5 Spacer plate 11 Bearing race 17 Cap screw 4 used 6 Drive 12 Seal The hydraulic motor used for the ProPass rear option twin spinner or conveyor is the same basic motor re gardless of which option exists The left side spinner mo tor has a hydraulic case drain hose attached to a 90 fitting installed in the end cap The right side spinner mo tor and conveyor motor do not use a case drain hose so the end cap includes a plug NOTE For service of a twin spinner or conveyor motor see the Eaton Char Lynn R Series General Purpose Geroler Motor Repair Information at the end of this chapter Hydraulic System Page 3 46 ProPass 200 Chapter 4 Electrical System Table of Contents GENERAL INFORMATION 205 3 Operator s Manual 2 2 0e cence 3 Machine Hydraulic Control 3 ELECTRICAL SCHEMATICS 205 4 ProPass with Standard Hydraulic Controls 4 ProPass with Electronic Hydraulic Controls 5 WIRE HARNESS DRAW
100. r tow chassis 12 Support idler roller drive roller and conveyor bed as sembly to prevent them from moving 13 Carefully slide left side of conveyor frame from idler and drive rollers and remove left side of frame 14 Rotate conveyor belt so that section of belt without the v guide on the bottom of the belt is around idler roller Slide conveyor belt from idler and drive rollers and remove belt from machine Installation Fig 10 IMPORTANT Before conveyor belt installation re move all trapped spreading material from conveyor bed belt and rollers 1 Install conveyor belt to ProPass in the reverse order of removal noting the following items A Make sure that v guide on bottom of conveyor belt is in the guides of both idler and drive rollers ProPass 200 AON Page 5 11 B Inspect rubber skirts that seal the hopper and conveyor belt If skirts are worn or damaged replace them before installing hopper assembly C As hopper assembly is lowered to machine frame take care so that hydraulic lines electrical harness or other components are not damaged D Make sure to lock bearing collars by striking blind hole in locking collar with a punch in the direction of shaft rotation Also apply Loctite 242 or equival ent to threads of locking collar set screws before in stalling set screws in collars E Before installing drive guards idler guards bot tom guard and front rinse guard to machine adjust conve
101. raulic Controls 00000 31 Hydraulic O Ring Face Seal ORFS Fitting Hydraulic Control Machines with Electronic Installation 0 0 RES A eee 9 Hydraulic Controls 000005 32 Hydraulic JIC Flared Fitting Installation 11 Hydraulic Control Manifold Machines with HYDRAULIC SCHEMATICS 00055 12 Electronic Hydraulic Controls 34 Standard Hydraulic Controls 12 Floor Motor 6 0ee cece eee eee eee 38 Electronic Hydraulic Controls 13 Floor Motor Service 0 cece e ees 40 HYDRAULIC FLOW DIAGRAMS STANDARD Twin Spinner Motors 0000e eee eee 42 HYDRAULIC CONTROLS 14 Conveyor Motor 0000 c eee eee eee 44 Rear Option Circuit Twin Spinner or Conveyor 14 Rear Option Motor Service 46 Floor Circuit a usassem gar a eee 14 EATON CHAR LYNN S SERIES GENERAL HYDRAULIC FLOW DIAGRAMS ELECTRONIC PURPOSE MOTORS PARTS and REPAIR MANUAL HYDRAULIC CONTROLS 16 EATON CHAR LYNN R SERIES GENERAL Rear Option Circuits Twin Spinner or Conveyor 16 PURPOSE GEROLER MOTOR REPAIR Floor Circuiti ssa saias Pa ga ara ear Pane ant ade 18 INFORMATION ProPass 200 Page 3 1 Hydraulic System SE o Cm V Cx gt N lt Specifications Item Description Tow Vehicle Hydraulic Supply Minimum Supply 6 US Gal Min 23 L Min 2000 PSI 138 Bar Maximum Supply 10
102. re 3 Electrical System Page 4 4 ProPass 200 Machines with Electronic Hydraulic Controls REAR OPTION PV1 q o Ka wi System CONTROL MANIFOLD WIRELESS REMOTE POWER LEAD HARNESS INCLUDES 15 AMP IN LINE FUSE TOW VEHICLE HYDRAULIC POWER LEAD POWER PACK HARNESS POWER LEAD HARNESS NOTE Electrical power is provided by either the tow vehicle or the hydraulic power pack Figure 4 ProPass 200 Page 4 5 Electrical System Wire Harness Drawings J02 BATTERY BATTERY J02 BATTERY A B P02 15A FUSE PROPASS 200 POWER LEAD WIRE HARNESS FROM TOW VEHICLE Figure 5 BATTERY NEGATIVE BATTERY YELLOW BATTERY PROPASS 200 POWER LEAD WIRE HARNESS FROM HYDRAULIC POWER PACK Figure 6 Electrical System Page 4 6 ProPass 200 PROPASS 200 INTERMEDIATE POWER WIRE HARNESS Figure 7 System T o 2 wi ProPass 200 Page 4 7 Electrical System Pos REMOTE CONNECTION POWER CONNECTION REMOTE CONNECTION Electrical System P01 POWER CONNECTION J01 CHASSIS GROUND 15A FUSE
103. rench is not available or if space at the port prevents use of a torque wrench an alternate meth od 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 the lock nut with a second wrench to the listed F F F T Step 4 in Fig ure 16 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 0 25 6 3 8 in 1 50 0 25 8 1 2 in 1 50 0 25 10 6 8 in 1 50 0 25 12 3 4 in 1 50 0 25 16 1 in 1 50 0 25 a Se 1 Lock nut 3 O ring 2 Back up washer Figure 16 Hydraulic System Page 3 10 ProPass 200 Hydraulic JIC Flared Fitting Installation JIC Flared Fitting into Component Port NOTE ProPass machines with serial numbers below 310001000 use JIC flared fittings Fig 10 Use the fol lowing information when installing JIC flared fittings When installing a JIC flared fitting into a component port follow the same procedures as listed in Hydraulic O Ring Face Seal ORFS Fitting Installation SAE Straight Thread O Ring Fitting into Component Port found earlier in this section The only difference needed for installation of JIC flared fittings is the tightening torque JIC FLARED FITTING ADJUSTABLE TYPE SHOWN Use the following torque values when installing JIC flared fittings into a steel or aluminum component port Figure 17
104. ries are OFF 2 Position the battery on the battery base with its posts toward the hydraulic oil filter 3 Secure positive cable red to positive battery post with flange head screw and flange nut 4 Position bolt tube cap screw flat washer and flange nut to battery bracket and battery tray opposite the oil fil ter Tighten cap screws and flange nuts on both sides of the battery bracket to secure the battery to the machine 5 Connect a digital multimeter set to amps between the negative battery post and the negative cable black connector The reading should be less than 0 1 amp If the reading is 0 1 amp or more the power pack electrical system should be tested and repaired 6 Secure negative cable black to negative battery post with flange head screw and flange nut 7 Apply battery terminal protector see Special Tools in this chapter on battery posts and cable connectors to reduce corrosion after connections are made Hydraulic Power Pack E oO O o QL ss 2s a Battery Testing 1 If battery caps can be removed conduct a hydrome ter test of the battery electrolyte IMPORTANT Make sure the area around the cells is clean before opening the battery caps A Measure the specific gravity of each cell with a hydrometer Draw electrolyte in and out of the hydrometer barrel prior to taking a reading to warm up the hydrometer At the same time take the tem perature of the cell B Temperature
105. rive chain and sprocket from drive roller see Floor Motor Drive in this section B On right side conveyor frame loosen bearing locking collar on drive roller shaft see Drive Roller Bearings in this section C Slide drive roller from bearing and remove from machine 4 lf idler roller is to be removed A On right side conveyor frame loosen bearing locking collar on idler roller shaft see Idler Roller Bearings in this section B Slide idler roller from bearing and remove from machine ProPass 200 Page 5 13 Installation Fig 12 IMPORTANT During roller installation do not lock bearing collars on idler and roller shafts until after both sides of conveyor frame are assembled and rollers are centered in the frame 1 Insert removed roller into bearing on right side con veyor frame Do not lock bearing collar or install set screw in collar at this time 2 Install the floor conveyor belt and left side conveyor frame to machine see Floor Conveyor Belt in this sec tion During assembly make sure to center the rollers in the frame to lock the bearing collars and to install set screws in collars on both sides of idler and drive roller bearings 3 If drive roller was removed from right side conveyor frame install sprocket and drive chain to drive roller see Floor Motor Drive in this section 4 Grease all four 4 bearings after installation is com plete Chassis Idler Roller Take Up Bearings
106. rminal posts for corrosion Use ater minal brush or steel wool to clean corrosion from the bat tery terminal posts IMPORTANT Before cleaning the battery tape or block the vent holes to the filler caps and make sure the caps are on tightly 3 Check for signs of wetness or leakage on the top of the battery which might indicate a loose or missing filler cap overcharging loose terminal post or overfilling Also check the battery case for dirt and oil Clean the battery with a solution of baking soda and water then rinse it with clean water 4 Check that the cover seal is not broken away Re place the battery if the seal is broken or leaking 5 Ifbattery caps can be removed check the electrolyte level in each cell If the level is below the tops of the plates in any cell fill all cells with distilled water to the bottom of the cap tubes or fill line Charge at 3 amps for 15 minutes to allow sufficient mixing of the electro lyte 6 Make sure battery cables battery connections and the battery hold down components are in good condi tion Also make sure the battery tray is clean and re painted if necessary ProPass 200 Page 6 23 FILLER CAPS CAP TUBES CORRECT gt ELECTROLYTE LEVEL Figure 16 Battery Installation Fig 15 IMPORTANT To prevent possible electrical prob lems install only a fully charged battery 1 Make sure the ignition switch on the power pack en gine and all accesso
107. rol valve body Remove O rings from side lever 5 Remove plugs from control valve body Slide com pensator spring and spool from body 6 Clean control valve components 7 Inspect side lever compensator spool and control valve body for wear or damage Replace control valve assembly if damage exists to these components Assembly Fig 30 1 Lubricate new seal kit components with clean hy draulic oil and install new O rings on side lever and plugs 2 Dip compensator spool and side lever into clean hy draulic oil 3 Install plug into the control valve body port opposite the bore for the compensator spool Then slide lubric ated compensator spool into body Insert spring and in stall second plug into control valve body 4 Slide lubricated side lever into control valve body Fit seal retainer and retaining ring to both ends of side lever to secure side lever in control valve body 5 Slide handle into side lever and secure with set screw Hydraulic System Page 3 30 1 PARON Figure 29 Floor control valve 2 Option control valve Figure 30 Body 7 O ring Set screw 8 Side lever Handle 9 Plug with O ring Retaining ring 10 Compensator spring Seal retainer 11 Compensator spool O ring ProPass 200 Solenoid Valve Assembly Machines with Standard Hydraulic Controls Two 2 identical solenoid valve assemblies are used on machines with standard hydraulic contro
108. s item 9 and lock nut item 10 3 Apply antiseize lubricant to floor motor shaft ProPass 200 Page 3 39 4 Position woodruff key to slot in floor motor shaft and then slide sprocket item 4 onto shaft 5 Install cap screw item 11 and flat washer item 12 into end of floor motor shaft 6 Slide sprocketto end of motor shaft so that it contacts flat washer 7 Apply Loctite 242 or equivalent to threads of set screws item 15 Install and tighten set screws to secure sprocket to motor shaft 8 Remove all caps or plugs that were placed on hy draulic hoses and fittings during disassembly 9 Using labels placed during motor removal correctly install and tighten hydraulic hoses to hydraulic fittings on floor motor see Hydraulic Hose and Tube Installation in the General Information section of this chapter 10 Fit drive chain onto floor motor drive roller shaft and idler sprockets Install master link item 16 to drive chain and secure ends with master link clip Make sure that the closed end of the master link clip is facing the direction of chain rotation NOTE Direction of normal roller rotation is shown in Figure 40 as viewed from right side of conveyor 11 Check that chain is aligned to sprockets If alignment adjustment is necessary move sprocket on roller drive shaft as needed 12 Move idler sprocket to tension the drive chain Se cure idler sprocket by tightening cap screw and lock nut A pr
109. s a guide remove necessary bed guards from frame to allow access to floor drive com ponents Assembly Fig 1 1 Secure all removed bed guards to frame using Fig ure 1 as a guide 2 If front rinse guard was removed from machine with electronic controls secure hydraulic manifold control panel guard and E stop button to machine Fig 2 PaPONs ProPass 200 Page 5 5 MACHINES WITH ELECTRONIC HYDRAULIC CONTROLS Figure 2 E stop button 7 Hydraulic manifold Control panel guard 8 Cap screw 2 used Screw 2 used 9 Lock washer 2 used Flange nut 2 used 10 Flat washer 2 used Flat washer 2 used 11 Front rinse guard Cap screw 2 used Chassis Floor Motor Drive Loctite 242 Loctite 242 Drive chain Hydraulic floor motor Sprocket Sprocket Idler sprocket Cap screw DA BON Chassis Antiseize Lubricant Direction Of Rotation Figure 3 Flat washer 2 used Lock nut Cap screw 2 used Lock nut 2 used Cap screw Flat washer Page 5 6 Loctite 242 Antiseize Lubricant Square key Spacer Set screw 2 used per sprocket Master link Woodruff key Drive roller shaft ProPass 200 Disassembly Fig 3 1 Position machine on a level surface If ProPass is at tached to tow vehicle apply tow vehicle parking brake stop engine and remove key from the ignition switch Chock wheels to prevent ProPass machine from mov ing 2 Rem
110. s of inactivity Wireless remote batteries are discharged Wireless remote and base unit are not associated NOTE There may be a short delay for base fault to be listed in display Hydraulic problem exists see Chapter 3 Hydraulic System Wireless remote is faulty Base unit is faulty Rear option switch in pendant is OFF Rear option switch in pendant is faulty Rear option solenoid valve coil or circuit wiring is faulty Hydraulic problem exists see Chapter 3 Hydraulic System ProPass 200 Rear option does not function machines with Wireless remote has not been turned ON electronic hydraulics NOTE Start button on remote must be pushed twice to Wireless remote has timed out due to thirty 30 activate rear option Also check wireless remote LCD Minutes of inactivity display and base unit LED s for help in troubleshooting Wireless remote settings are incorrect Proportional flow valve coil PV1 or circuit wiring is faulty Hydraulic problem exists see Chapter 3 Hydraulic System Wireless remote is faulty Base unit is faulty Floor does not function machines with standard Floor switch in pendant is OFF hydraulics E Floor switch in pendant is faulty Floor solenoid valve coil or circuit wiring is faulty Hydraulic problem exists see Chapter 3 Hydraulic System Floor does not function machines with electronic Wireless remote has not been turned ON hydraulics NOTE Ch
111. s to allow the op erator to change machine settings Machines with standard hydraulic controls include manual hydraulic controls on the front of the ProPass hopper to adjust hydraulic flow to the floor and rear op tion twin spinner or conveyor motors Fig 1 A pendant electrical control allows the operator to ener gize the floor and rear option from the operator position of the tow vehicle Machines with electronic hydraulic controls include a wireless remote to electrically adjust hydraulic flow to the floor and rear option twin spinner or conveyor mo tors Fig 2 The remote allows initial adjustment of the floor and spinner motors as well as making adjustments possible while the machine is operating An E Stop but ton onthe machine disables the electrical system to pre vent unexpected machine operation 1 Floor control 2 Rear option control Figure 1 3 Pendant harness 1 Wireless remote 2 E Stop button ProPass 200 Page 4 3 Figure 2 3 Power lead harness 4 Optional power pack Electrical System q o wi System Electrical Schematics Machines with Standard Hydraulic Controls PENDANT ASSEMBLY SWITCH REAR OPTION SWITCH 15A FUSE REAR OPTION SOLENOID NOTE Electrical power is provided by either the tow vehicle or the hydraulic POWER power pack SUPPLY Figu
112. s with standard hydraulic controls include manual hydraulic controls on the front of the ProPass hopper to adjust hydraulic flow to the floor and rear op tion twin spinner or conveyor motors Fig 19 A pendant electrical control allows the operator to ener gize the floor and rear option motors from the operator position of the tow vehicle The ProPass hydraulic sys tem with standard hydraulic controls can function whenever hydraulic flow is available from the tow vehicle or hydraulic power pack If neither the floor motor or rear option twin spinner or conveyor motors are engaged hydraulic flow bypasses the motors and returns directly to the hydraulic reservoir The floor and rear option will remain in the stationary po sitions ProPass 200 Page 3 15 Figure 19 3 Pendant harness 1 Floor control 2 Rear option control NOTE Typically the rear option twin spinner or con veyor is engaged before the floor is started When the operator engages the floor motor the floor solenoid valve is energized which directs hydraulic flow to the floor control valve The floor control valve directs hydraulic flow to the floor motor based on the control valve setting to allow the floor to operate at the correct speed for topdressing material to be delivered to the rear option twin spinner or conveyor System hydraulic flow in excess of the floor control valve setting along with floor motor return flow is available for t
113. sa preventative measure against leakage it is rec ommended that the O ring be replaced any time the connection is opened 3 Lightly lubricate the O ring with clean hydraulic oil Fitting threads should be clean with no lubricant applied 4 Turn back the lock nut as far as possible Make sure the back up washer is not loose and is pushed up as far as possible Step 1 in Figure 16 IMPORTANT Before installing fitting into port de termine port material If fitting is to be installed into an aluminum port installation torque is reduced 5 Install the fitting into the port and tighten finger tight until the washer contacts the face of the port Step 2 in Figure 16 6 To put the fitting in the desired position unscrew it by the required amount but no more than one full turn Step 3 in Figure 16 7 Hold the fitting in the desired position with a wrench and use a torque wrench to tighten the fitting to the rec ommended installation torque shown in Figure 14 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 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 atorque w
114. se the follow ing information when installing O ring face seal fittings Non Adjustable Fitting Fig 13 1 Make sure all threads and sealing surfaces of fitting and component port are free of burrs nicks scratches or any foreign material 2 Asapreventative measure against leakage it is rec ommended that the O ring be replaced any time the connection is opened 3 Lightly lubricate the O ring with clean hydraulic oil Fitting threads should be clean with no lubricant applied IMPORTANT Before installing fitting into port de termine 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 recom mended installation torque shown in Figure 14 NOTE Use of an offset wrench e g crowfoot wrench will affect torque 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 Records and Maintenance to determine necessary con version information 5 Ifa torque wrench is not available or if space at the port prevents use of a torque wrench an alternate meth od of assembly is the Flats From Finger Tight F F F T method A Install the
115. sembly toward the gear pump until the pump jaw coupling engages the spider coupling 6 Secure gear pump to flange adapter with two 2 cap screws and flat washers Fig 6 NOTE Make sure that ground cable is secured with en gine mounting screw under starter motor 7 Install four 4 cap screws flat washers and lock nuts through the mount plate and engine mounting holes Se cure ground cable with cap screw on starter motor side of engine closest to shaft side of engine Tighten fasten ers to secure engine to mount plate 8 Check and adjust engine oil level as needed NOTE If engine oil level is low engine will not run 9 Connect positive cable to starter solenoid terminal 10 Connect negative battery cable to negative battery terminal Figure 6 1 Engine 7 Flat washer 2 Pump jaw coupling 8 Cap screw 3 Spider coupling 9 Gear pump 4 Engine jaw coupling 10 Flat washer 2 used 5 Square key 11 Cap screw 2 used 6 Flange adapter 12 Generator bracket Hydraulic Power Pack lt O O sa Es 2s a Power Pack Hydraulic Tank Figure 7 1 Hydraulic relief valve manifold 9 Hydraulic hose 16 Hydraulic gear pump 2 Flange nut 9 used 10 Filter head 17 Straight hydraulic fitting 3 Flange head screw 4 used 11 Hydraulic hose 18 Battery tray 4 Hydraulic tank assembly 12 Flange nut 4 used 19 Battery 5 Hose bracket 13 Oil filter 20 O ring 6 R clamp 3 used 14 Cap screw 2 us
116. shers that secure manifold to machine frame Remove control manifold assembly from the machine 8 If necessary remove hydraulic fittings and O rings from manifold Discard all removed O rings Installation Fig 33 1 If fittings were removed from manifold lubricate and place new O rings onto fittings Install and properly tighten fittings into manifold openings See Hydraulic Fit ting Installation in the General Information section of this chapter 2 Position manifold assembly to the machine frame Secure assembly to the frame with two 2 cap screws item 16 lock washers and flat washers ProPass 200 Page 3 33 3 Remove caps and plugs from disconnected hydrau lic lines and manifold fittings 4 Lubricate and position new O rings to fittings on manifold Use labels placed during the removal process to properly install hydraulic lines to manifold fittings see Hydraulic Hose and Tube Installation in the General In formation section of this chapter 5 Connect wire harness connectors to solenoid valves on manifold 6 Install control panel guard to front of ProPass Con nect emergency stop button connector to machine wire harness Figure 34 1 Pressure hose 45 3 Control panel guard 2 Return hose 90 Figure 35 3 Solenoid coil option 1 Control manifold 2 Solenoid coil floor Hydraulic System o SE Ez D3 gt N Hydraulic Control Manifold Machines with Electronic Hy
117. tation direction Figure 5 as viewed from right side of conveyor 4 Check that chain is aligned to sprockets If alignment adjustment is necessary move sprocket on drive roller shaft as needed 5 Apply Loctite 242 or equivalent to threads of set screws item 15 Tighten set screws to secure sprocket to drive roller shaft 6 Move idler sprocket item 5 to tension the drive chain Secure idler sprocket by tightening cap screw and lock nut A properly adjusted chain should allow for free rotation of drive components 7 Secure RH drive guard and guard cap to frame Fig 4 ProPass 200 Page 5 7 Chassis Drive Roller Bearings Loctite 242 N Loctite 242 Figure 6 1 Set screw 2 Locking collar 3 Lock nut 4 used per bearing Par Use this procedure for service of the drive roller bear ings at the rear of the machine Disassembly Fig 6 1 Position machine ona level surface If ProPass is at tached to tow vehicle apply tow vehicle parking brake stop engine and remove key from the ignition switch Chock wheels to prevent ProPass machine from mov ing 2 Remove guards from frame to allow access to idler roller and drive roller components see Bed Guards in this section 3 On both sides of machine loosen tension on floor conveyor belt at idler roller shaft Fig 7 A Retain tensioner rod with wrench to prevent it from turning B Loosen adjusting jam nut to remove tension on flo
118. ted with a lubricant such as mum proof load specified in SAE J429 The tolerance is engine oil or thread sealant such as Loctite 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 ProPass 200 Standard Torque for Dry Zinc Plated and Steel Fasteners Metric Series Regular Height Nuts Thread Size Class 8 or Stronger Nuts Class 8 8 Bolts Screws and Studs with 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 96 10 in lb 1085 113 N cm 133 14 in lb 1503 158 N cm M6 X 1 0 M8 X 1 25 19 2 ft lb 26 3 N m 28 3 ft lb 38 4 N m M12 X 1 75 66 7 ft lb 90 10 N m 93 10 ft lb 126 14N 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 Ib 450 46 ft Ib 610 62 N m 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
119. tery charge level from either its open specific gravity or circuit voltage Battery Charge Specific Level Gravity Open Circuit Voltage 12 68 12 45 12 24 12 06 11 89 100 E ST E 2 Determine the charging time and rate using the bat tery charger manufacturer s instructions or the fol lowing table Battery Battery Charge Level Reserve Percent of Fully Charged Capacity nts 80 or 3 8 hrs 7 5 hrs 11 3 hrs 15 hrs less 3 amps 3amps 3amps 3 amps 81 to 125 5 3 hrs 10 5hrs 15 8hrs 21 hrs 4amps 4amps 4amps 4 amps 11 hrs 16 5 hrs 22 hrs Samps 5amps 5 amps 126 to 5 5 hrs 170 5 amps 171 to 5 8hrs 11 5 hrs 17 3 hrs 23 hrs 250 6 amps 6amps 6amps 6 amps above 6 hrs 12 hrs 18 hrs 24 hrs 250 10 amps 10 amps 10 amps 10 amps ProPass 200 Page 6 25 Do not charge a frozen battery because it can ex plode and cause injury Let the battery warm to 60 F 16 C before connecting to a charger Charge battery in a well ventilated place to dissi pate gases produced from charging These gases are explosive Keep open flame and electrical spark away from the battery Do not smoke Unplug the charger from the electrical outlet before connecting or disconnecting the charger leads from the battery posts Nausea may result if the gases are inhaled 3 Follow the battery charger manufacturer s in structions
120. testing is complete connect wire harness electrical connector to the solenoid valve coil STANDARD HYDRAULIC CONTROL MANIFOLD O DRAFO Figure 24 1 Manifold 2 1 960 solenoid coil ELECTRONIC HYDRAULIC CONTROL MANIFOLD Figure 25 Manifold 3 2 2 450 solenoid coil 1 960 solenoid coil Electrical System T o o wi System This page is intentionally blank Electrical System Page 4 22 ProPass 200 Chapter 5 Chassis Table of Contents GENERAL INFORMATION 2055 3 Operator s Manual 2 00c cece ee 3 Parts Catalog 0 cc cece eee eee 3 SERVICE AND REPAIRS 000000055 4 Bed Guards sense napetie iira paie 4 Floor Motor Drive 0c cece eee eee 6 Drive Roller Bearings 0 0 eee 8 Floor Conveyor Belt 0020 e eens 10 Idler and Drive Rollers 0004 12 Idler Roller Take Up Bearings 14 Wheel Assemblies Tow Chassis 16 Wheel Bearing Service Tow Chassis 18 Walking Beam Assembly Tow Chassis 20 ProPass 200 Page 5 1 Chassis This page is intentionally blank Chassis Page 5 2 ProPass 200 General Information Operator s Manual The Operator s Manual provides information regarding the operation general maintenance and maintenance
121. th of the torque wrench distance from the center of the handle to the center of the square drive is 18 The measured effective length of the torque wrench with the offset wrench installed distance from the center of the handle to the center of the offset wrench is 19 The calculated torque conversion factor for this torque wrench with this offset wrench would be 18 19 0 947 ProPass 200 Page 2 3 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 PT D D oe 88 ae Ness lt I 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 Offset wrench Torque wrench effective length of torque wrench A E i a effective lengt
122. the necessary voltage to the SP1 solenoid coil based on settings of the wireless remote Flow from the SP1 valve is proportional to cur rent applied to the valve coil by the base unit System hy draulic flow in excess of the floor valve setting is available for the rear option Return from the rear option motors is routed to the reservoir Check valve CV1 along with orifice fittings ORF1 and ORF2 are included in the floor circuitto ensure that pres sure compensator valve EC1 provides the necessary flow to the floor motor Hydraulic circuit pressure is controlled by the system re lief valve either on the tow vehicle or hydraulic power pack Figure 21 3 Power lead harness 4 Optional power pack 1 Wireless remote 2 E Stop button Hydraulic System SE Bo V Cx gt I Special Tools Order the following special tools from your Toro Distributor Hydraulic Pressure Test Kit Use to take various pressure readings for diagnostic tests Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools A high pressure hose is provided for remote readings Contains one each 1000 PSI 70 Bar 5000 PSI 350 Bar and 10000 PSI 700 Bar gauges Toro Part Number TOR47009 Figure 22 Hydraulic Tester Pressure and Flow Use to test hydraulic circuits and components for flow and pressure capacities This tester includes the follow ing 1 INLET HOSE H
123. to current ap plied to the valve coil by the base unit System hydraulic flow in excess of the rear option control valve setting is returned to the reservoir Return from the rear option motors is routed to the reservoir as well Orifice fitting ORF4 is included in the rear option circuit to ensure that proportional flow valve PV1 provides the necessary flow to the rear option motors Hydraulic circuit pressure is controlled by the system re lief valve either on the tow vehicle or hydraulic power pack Figure 20 3 Power lead harness 4 Optional power pack 1 Wireless remote 2 E Stop button Hydraulic System SE Bo O a V Cx gt I FLOOR CIRCUIT PLUG PLUG gt LAY V LB o Ti RF cv3 CV4 SPINNER MOTORS CONTROL MANIFOLD CONVEYOR MOTOR 6 A A Yo HYDRAULIC E 3 POWER PACK SP1 and PV1 are both energized Both EC1 and PV1 shift to allow proportional flow to rear option and floor motors Working Pressure Excess and return flow will be directed to Return hydraulic reservoir Flow Hydraulic System Page 3 18 ProPass 200 Floor Circuit Machines with electronic hydraulic controls include a wireless remote to electrically adjust hydraulic flow to the floor and rear optio
124. ton connector from machine wire harness Check the continuity of the button by connecting a multimeter ohms setting across the button harness connector ter minals There should not be continuity infinite ohms between the connector terminals when the button is pressed in When the button is pulled out there should be continuity zero ohms between the connector ter minals If E stop button testing determines that the button is faulty remove button from control panel guard and re place button assembly Make sure that wire harness connector is attached to the button after testing and or replacement Figure 16 1 E Stop button 3 Control panel guard 2 Screw 2 used Electrical System Page 4 16 ProPass 200 Pendant Assembly Machines with Standard Hydraulic Controls The pendant assembly allows the machine operator to engage the rear option twin spinner or conveyor and the floor from the tow vehicle operator s position The pendant assembly includes two 2 switches the junc tion box and the wire harness Fig 17 Both of the switches used in the ProPass pendant are two 2 position switches with two 2 terminals To ac cess the switch terminals for testing remove the cover from the bottom of the junction box Make sure that elec trical power to the switches is disconnected before test ing the switches Use a multimeter to check the switch for continuity There should not be continuity between the switch termina
125. ttery terminals Set multimeter to the DC volts setting The battery should be at a temperature of 60 to 100 F 16 to 38 C The ignition key should be off and all accessories turned off Connect the positive meter lead to the positive battery post and the negative meter lead to the negative battery post NOTE This test provides a relative condition of the bat tery Load testing of the battery will provide additional and more accurate information see Battery Service in the Service and Repairs section of this chapter Charging System Test This is a simple test used to determine if a charging sys tem is functioning It will tell you if the charging system has an output but not its capacity Use a digital multimeter set to DC volts Connect the positive multimeter lead to the positive battery post and the negative multimeter lead to the negative bat tery post Keep the test leads connected to the battery posts and record the battery voltage NOTE Upon starting the engine the battery voltage will drop and then should increase once the engine is running NOTE Depending upon the condition of the battery charge and battery temperature the battery voltage will increase at different rates as the battery charges ProPass 200 Page 6 5 Voltage Measured Battery Charge Level Fully charged 100 75 charged 12 68 V or higher 12 45 V 12 24 V 50 charged 12 06 V 25 charged 11 89 V 0 charged
126. ube Installation in the Gener al Information section of Chapter 3 Hydraulic System 5 Install new O ring on plug item 21 used to drain hy draulic tank Install plug in tank 6 Fill hydraulic tank with new hydraulic oil 7 Install twin spinner or other option to machine Figure 8 1 Hydraulic tank 7 O ring 2 Strainer 8 6 plug 3 O ring 9 Dipstick 4 O ring 10 O ring 5 45 hydraulic fitting 11 45 hydraulic fitting 6 O ring 12 O ring Hydraulic Power Pack E oO O o sa Ss 25 a Power Pack Gear Pump Figure 9 1 Hydraulic relief valve manifold 10 Filter head 2 Flange nut 9 used 11 Hydraulic hose 3 Flange head screw 4 used 12 Flange nut 4 used 4 Hydraulic tank assembly 13 Oil filter 5 Hose bracket 14 Cap screw 2 used 6 R clamp 3 used 15 Straight hydraulic fitting 7 R clamp 3 used 16 Hydraulic gear pump 8 45 hydraulic fitting 2 used 17 Straight hydraulic fitting 9 Hydraulic hose 18 Battery tray Hydraulic Power Pack Page 6 16 Battery Cap screw 7 used Flange adapter Key Coupling jaw gear pump Hydraulic hose Hydraulic hose Spider coupling Coupling jaw engine ProPass 200 Removal Fig 9 1 Position machine on a level surface If ProPass is at tached to tow vehicle apply tow vehicle parking brake stop engine and remove key from the ignition switch Chock wheels to prevent ProPass machine from mov ing 2
127. uld short against metal ve hicle components and cause sparks HOW TO AVOID THE HAZARD When removing or installing the battery do not allow the battery terminals to touch any metal parts of the vehicle Always DISCONNECT the negative black bat tery cable before disconnecting the positive red cable Always CONNECT the positive red battery cable before connecting the negative black cable Do not allow metal tools to short between the battery terminals and metal parts of the ve hicle Always keep the battery retaining components secure to protect the battery Battery Specifications BCI Group Size U1 300 Amp Cranking Performance at 0 F 18 C 28 Minutes Reserve Capacity at 80 F 27 C Electrolyte Specific Gravity Fully charged 1 265 corrected to 80 F 27 C Discharged less than 1 240 Removal Fig 15 1 Position machine ona level surface If ProPass is at tached to tow vehicle apply tow vehicle parking brake stop engine and remove key from the ignition switch Chock wheels to prevent ProPass machine from mov ing Make sure that key switch on power pack engine is in the OFF position 2 Disconnect negative black cable from battery first to prevent short circuiting the battery other components or operator s hands Then disconnect positive red cable 3 Loosen cap screw and flange nut that secure the bat tery bracket closest to hydraulic oil filter Remove cap screw flat washer flange nut
128. ulic solenoid valve coils can be done with the coil installed on the hydraulic valve The coil height can be used to identify the resistance of the coil Testing 1 Position machine on a level surface If ProPass is at tached to tow vehicle apply tow vehicle parking brake stop engine and remove key from the ignition switch Chock wheels to prevent ProPass machine from mov ing 2 Locate solenoid coil that is to be tested on hydraulic control manifold 3 Disconnect wire harness electrical connector from the hydraulic solenoid valve coil that is to be tested Fig 24 or 25 NOTE Prior to taking small resistance readings witha digital multimeter short the meter test leads together The meter may display a small resistance value usually 0 5 ohms or less This resistance is due to the internal resistance of the meter and test leads Subtract this val ue from from the measured value of the component you are testing 4 Using a multimeter ohms setting measure resis tance between the two 2 connector terminals on the solenoid valve coil The resistance for the solenoid coils is identified below ProPass 200 Page 4 21 5 If solenoid coil resistance is incorrect replace sole noid coil see Solenoid Valve Assembly Machines with Standard Hydraulic Controls or Hydraulic Control Mani fold Machines with Electronic Hydraulic Controls in the Service and Repairs section of Chapter 3 Hydraulic System 6 When
129. ully open 5 Make sure that ProPass controls for the floor and the twin spinner are disengaged Hydraulic Power Pack Page 6 8 Figure 3 1 Relief valve manifold 2 Fitting 3 Hydraulic supply hose 6 Start power pack engine and run at low idle speed Check for hydraulic leakage at tester connections and correct before proceeding with test 7 Move throttle so engine is running at high idle speed 3750 RPM 8 Watch tester flow and pressure gauges carefully while slowly closing the flow control valve on the tester until the pressure gauge reads 800 PSI 55 bar 9 Monitor the flow gauge to determine the gear pump output GPM LPM When gear pump output has been determined open control valve on tester move throttle to low idle speed and shut off engine Record flow gauge test results 10 Flow gauge reading for a gear pump in good condi tion should be approximately 6 0 GPM 22 7 LPM ProPass 200 11 If gear pump flow is less than 5 2 GPM 19 7 LPM E When relief valve pressure has been determined check system relief valve for possible leakage as fol open control valve on tester move throttle to low idle lows speed and shut off engine Record relief valve pres A Leave hydraulic tester pressure and flow in stalled as listed above Make sure flow control valve on tester is fully open B Start power pack engine and run at high idle speed 3750 RPM IMPORTANT Close flow control valve on tester
130. un at low idle speed Check for hydraulic leakage at tester connections and correct before proceeding with test 7 Move throttle so engine is running at high idle speed 3750 RPM Hydraulic Power Pack Page 6 10 8 Watch tester flow and pressure gauge carefully while slowly closing the flow control valve on the tester until the pressure gauge reads 800 PSI 55 bar 9 Monitor the flow gauge to determine the gear pump output GPM LPM When gear pump output has been determined open control valve on tester move throttle to low idle speed and shut off engine Record flow gauge test results 10 Flow gauge reading for a gear pump in good condi tion should be approximately 6 0 GPM 22 7 LPM 11 If gear pump flow is less than 5 2 GPM 19 7 LPM or a pressure of 800 PSI 55 bar cannot be obtained check for restriction in the pump intake line If line is not restricted remove gear pump and repair or replace as necessary 12 When testing is complete disconnect tester from the gear pump fitting and the manifold fitting Reconnect hy draulic tube to gear pump and manifold fittings FRONT Figure 4 1 Gear pump 2 Relief valve manifold 3 Hydraulic tube ProPass 200 This page is intentionally blank oOo 6 O Es z Te ProPass 200 Page 6 11 Hydraulic Power Pack Service and Repairs Engine GROUND CABLE CONNECTION Figure 5 1 Jaw coupling engin
131. utput 18 amp Engine Dry Weight 84 U S pounds 38 kg NOTE The Honda engine included with the ProPass Power Pack is equipped with a low oil shutdown system that disables the ignition system if the oil level should fall below the safe limit Hydraulic Power Pack Page 6 2 ProPass 200 Power Pack Hydraulic Specifications Item Description Gear Pump Eaton gear pump Model 26001 Displacement per revolution 0 40 in 6 6 cc Circuit Relief Pressure 2000 PSI 138 bar Hydraulic Tank Capacity 8 7 U S Gallons 32 9 Liters Hydraulic Oil See Power Pack Installation Instructions Hydraulic Filter Spin on cartridge type x oOo 6 O Es z Te ProPass 200 Page 6 3 Hydraulic Power Pack General Information This Chapter gives information about specifications and repair of the engine and hydraulic components used in the ProPass Hydraulic Power Pack assembly General maintenance procedures are described in your Traction Unit Operator s Manual Information on engine troubleshooting testing disas sembly and assembly is identified in the Honda Work shop Manual that is available from Honda Most engine repairs and adjustments require tools which are com Engine Owner s Manual The engine Owner s Manual provides information re garding the operation general maintenance and main tenance intervals for the Honda GX340 engine on your ProPass Hydraulic Power Pack assemb
132. vehicle operator position The wireless remote uses two 2 LED s to indicate re mote operation The green LED flashes when a base unit signal is being sent to the remote The green LED will also illuminate when a remote button is pressed The amber LED flashes when a signal is being received from the remote base unit The amber LED will illuminate when one or more base unit outputs are active Button Operation NOTE Refer to the Operator s Manual for detailed in formation on wireless remote operation Pressing the ON OFF button turns the machine base unit ON or OFF for ProPass operation The ALL START button is used to begin ProPass rear option twin spinner or conveyor and floor operation Four 4 buttons are used to control the floor start stop increase floor speed and decrease floor speed Four 4 buttons are used to control the rear option twin spinner or conveyor start stop increase rear option speed and decrease rear option speed The ALL STOP button stops floor and rear option opera tion Four 4 buttons are used for preset programming for the ProPass Three 3 presets can be made to allow quick option speed values for the floor and rear option The STORE button allows the presets to be adjusted Wireless Remote Batteries The wireless remote is powered by four 4 AA alkaline batteries When the low battery power warning is dis played on the remote LCD display the batteries should be replaced R
133. vehicle parking brake stop engine and remove key from the ignition switch Chock wheels to prevent ProPass machine from mov ing 2 Remove hydraulic guard from machine to allow ac cess to hydraulic controls Fig 27 Before disconnecting any hydraulic compo nents operate all hydraulic controls to relieve system pressure and avoid injury from pressur ized hydraulic oil See Relieving Hydraulic Sys Figure 27 tem Pressure in the General Information section of this chapter 2 Screw 2 used 5 Flat washer 2 used 3 Flange nut 4 used 1 Hydraulic guard 4 Cap screw 2 used 3 Relieve hydraulic system pressure o s a CS a ae Cx gt N lt 4 Before removing any control system components thoroughly clean all hydraulic connections For assem bly purposes label hydraulic and electrical connections zenn es at components that are to be removed Clie Le TER DA GDS O J 5 Remove control system components as needed us ing Figure 26 as a guide Allow hydraulic oil to drain from disconnected hydraulic lines into a suitable container Put caps or plugs on open hydraulic lines and fittings to prevent contamination Assembly Fig 26 1 Install all removed control system components using Figure 26 as a guide Figure 28 re s 1 Supply hose 45 3 Return hose 90 A If fittings were removed lubricate and place new 2 piace La 4 Option a EA O rings o
134. ves of the take up bearing before installing the bearing to the channels of the conveyor frame 2 Install take up bearing to frame using Figure 13 asa guide Do not tighten locking or adjusting jam nuts until conveyor belt is properly adjusted 3 Ifidler roller was removed insert idler roller into take up bearing on right side conveyor frame Do not lock bearing collar or install set screw in collar at this time 4 Install the floor conveyor belt and left side conveyor frame to machine see Floor Conveyor Belt in this sec tion During assembly make sure to center the rollers in the frame to lock the bearing collars and to install set screws in collars on both sides of idler and drive roller bearings 5 Grease all four 4 bearings after assembly is com plete 1 Tensioner rod 2 Locking jam nut ProPass 200 Page 5 15 Figure 14 3 Adjusting jam nut 4 Take up bearing Chassis Wheel Assemblies Tow Chassis NS ee 94 to 116 ft Ib yr me 128 to 157 N m 240 to 292 ft Ib 322 to 396 N m 135 to 165 ft Ib 183 to 223 N m SD VAZA 70 to 90 ft Ib we 95 to 122 N m Figure 15 1 Floor assembly 11 Cap screw 2 used 21 Top cross member 2 used 2 Hitch 12 Flat washer 4 used 22 Frame brace 3 Hitch clevis 13 Lock nut 2 used 23 Cross member 2 used 4 Jack 14 Cap screw 8 used 24 Lock nut 20 used 5 Walking beam bearing 4 used 15 F
135. voir that are used for the ProPass NOTE The rear option is either the twin spinner two motors or the cross conveyor one motor Hydraulic System Page 3 12 CONVEYOR MOTOR Co ProPass 200 Hydraulic Schematic Standard Hydraulic Controls All solenoids are shown as de energized NOTE The hydraulic hose kit used when a ProPass re ceives its hydraulic supply from a tow vehicle includes a check valve in the return hose assembly see Hydraul ic Hose Kit in the General Information section of this chapter ProPass 200 PLUG LAY PLUG V LB xX FLOOR MOTOR Y Cv3 cva svi Es s2 ORFS 0 068 op K Cy SPINNER MOTORS Pv E HO CONTROL MANIFOLD o CONVEYOR MOTOR o HYDRAULIC POWER PACK NOTE The hydraulic schematic shown above includes the hydraulic power pack as the hydraulic supply source If your ProPass uses hydraulic supply from the tow vehicle the vehicle includes the hydraulic pump re lief valve and hydraulic reservoir that are used for the ProPass NOTE The rear option is either the twin spinner two motors or the cross conveyor one moto
136. yor belt tension and tracking refer to Operat or s Manual F Make sure that rake tines on gate assembly are not scratching the floor belt after assembly is com plete G Grease all four 4 bearings after installation is complete Figure 11 Drive roller shaft 5 Flange nut 16 used Drive roller bearing 6 Screw 16 used Idler roller bearing 7 Hopper assembly Idler roller shaft 8 Belt rotation direction Chassis Idler and Drive Rollers Figure 12 Idler roller Drive roller Scraper assembly Cap screw 4 used LH conveyor frame assembly Conveyor bed assembly RH conveyor frame assembly Floor conveyor belt PONHA ONG To remove and replace the idler and drive rollers remov al of the left side conveyor frame and the floor conveyor belt is necessary Once these items are removed either roller can be removed from the bearing in the right side conveyor frame Chassis Page 5 12 9 Flat washer 8 used 10 Lock nut 4 used 11 Flange head screw 10 used 12 Flange nut 10 used ProPass 200 Removal Fig 12 1 Position machine on a level surface If ProPass is at tached to tow vehicle apply tow vehicle parking brake stop engine and remove key from the ignition switch Chock wheels to prevent ProPass machine from mov ing 2 Remove left side conveyor frame and the floor con veyor belt see Floor Conveyor Belt in this section 3 If drive roller is to be removed A Remove d

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