Toro ProPass 200 Service Manual

Page 1

Part No. 14204SL

Service Manual

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 OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. 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 available on the internet at www.Toro.com.

The Toro Company reserves the right to change product specifications or this publication without notice.

ProPass

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

NOTE: A NOTE will give general information about the

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

IMPORTANT: The IMPORTANT notice will give important instructions which must be followed to prevent damage to systems or components on the machine.

200

E The Toro Company -- 2014

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This page is intentionally blank.

ProPass 200

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Table Of Contents

Chapter 1 -- Safety

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

Safety and Instruction Decals 1 -- 4................

Chapter 2 -- Product Records and Maintenance

Product Records 2 -- 1...........................

Maintenance 2 -- 1...............................

Equivalents and Conversions 2 -- 2................

Torque Specifications 2 -- 3.......................

Chapter 3 -- Hydraulic System

Specifications 3 -- 2..............................

General Information 3 -- 3........................

Hydraulic Schematics 3 -- 12......................

Hydraulic Flow Diagrams: Standard Hydraulic

Controls 3 -- 14...............................

Hydraulic Flow Diagrams: Electronic Hydraulic

Controls 3 -- 16...............................

Special Tools 3 -- 20.............................

Troubleshooting 3 -- 22...........................

Tes t ing 3 - - 24...................................

Service and Repairs 3 -- 26.......................

EATON (CHAR--LYNN) S--SERIES GENERAL

PURPOSEMOTORS PARTS andREPAIR MANUAL EATON (CHAR-- LYNN) R--SERIES GENERAL

PURPOSE GEROLER MOTOR REPAIR

INFORMATION

Chapter 4 -- Electrical System

General Information 4 -- 3........................

Electrical Schematics 4 -- 4.......................

Wire Harness Drawings 4 -- 6.....................

Special Tools 4 -- 12.............................

Troubleshooting 4 -- 14...........................

Component Testing 4 -- 16........................

Chapter 5 -- Chassis

General Information 5 -- 3........................

Service and Repairs 5 -- 4........................

Chapter 6 -- Hydraulic Power Pack

Power Pack Engine Specifications 6 -- 2............

Power Pack Hydraulic Specifications 6 -- 3..........

General Information 6 -- 4........................

Electrical System Quick Checks 6 -- 5..............

Adjustments 6 -- 6...............................

Hydraulic Testing 6 -- 8...........................

Service and Repairs 6 -- 12.......................

EATON SERIES 26 GEAR PUMP PARTS and REPAIR

MANUAL

SafetyProduct Records

Hydraulic

Electrical

and Maintenance

System

ProPass 200

Chassis

Hydraulic

Power Pack

Page 4

This page is intentionally blank.

ProPass 200

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Chapter 1

Safety

Table of Contents

GENERAL SAFETY INSTRUCTIONS 2............

Before Operating 2............................

While Operating 2............................

Maintenance and Service 3....................

SAFETY AND INSTRUCTION DECALS 4..........

Safety

ProPass 200 Page 1 -- 1 Safety

Page 6

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 accident prevention partially are dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern and proper training ofthe personnel involved in the operation,transport, maintenance and storage of the machine. Improper use or maintenance of the machine can result in injury or death.To reduce the potential for injury or death, comply with the following safety instructions.

Before Operating

WARNING

To reduce the potential for injury or death, comply with the following safety instructions.

1. Review and understand the contents of the Operator’s Manuals before starting and operating the machine. Become familiar with the controls and know how to stop the machine and engine quickly. Additional copies of the Operator’s Manual are available on the internet at www.Toro.com.

2. Keep all shields, safety devices and decals in place. If a shield, safety device or decal is defective, illegible or damaged, repair or replace it before operating the machine. Also tighten any loose nuts, bolts or screws to ensure machine is in safe operating condition.

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 option (twin spinner or side conveyor) system are engaged.

2. Do not run engine that powers the ProPass in a confined area without adequate ventilation. Exhaust fumes are hazardous and could possibly be deadly.

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 vehicle 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, always bein line 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:

3. Do not touch engine, muffler or exhaust pipe while engine is running or soon after it is 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 levels of 85dB(A) at the operator position. Hearing protection is recommended for prolonged exposure to reduce the potential of permanent hearing damage.

6. Do not leave the ProPass unattended when it is running.

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, ensure that the front tongue jack is in the support position and chock wheels.

ProPass 200Page 1 -- 2Safety

Page 7

Maintenance and Service

1. The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your ProPass machine. 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 vehicle 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 prevent it from moving.

3. If equipped, press the E--stop button to disable the ProPass electrical system before working on the machine.Pullthebuttonoutwhenmachineistobereturned 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 heater or furnace.

6. Make sure all hydraulic line connectors are tight and all hydraulic hoses and lines are in good condition before applying pressure to the hydraulic system.

7. Keep body and hands away frompin hole leaks in hydraulic 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 fluidaccidentally 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.

8. Before disconnecting any hydraulic component or performing any work on the hydraulic system, all pressure in system must be relieved. See Relieving Hydraulic System Pressure in the General Information section of Chapter 3 -- Hydraulic System.

Safety

9. Make sure that electrical power harness from tow vehicle is disconnected before working on the machine’s electrical system.

10.If major repairs are ever needed or assistance is desired, 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 accessories. 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 support the raised machine. If the machine is not properly supported, the machine may move or fall, which may result in personal injury.

ProPass 200 Page 1 -- 3 Safety

Page 8

Safety and Instruction Decals

Numerous safety and instruction decals are affixed to the ProPass 200. If any decal becomes illegible or damaged, install a new decal. Decal part numbers are listed in your Parts Catalog.

ProPass 200Page 1 -- 4Safety

Page 9

Product Records and Maintenance

Table of Contents

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

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

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

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

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

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

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

Using a Torque Wrench with an Offset Wrench 3..

Standard Torque for Dry, Zinc Plated and

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

Standard Torque for Dry, Zinc Plated and

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

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

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

Chapter 2

and Maintenance

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 intervals for your ProPass are covered in the Operator’s Manual. Refer to this publications when performing regular equipmentmaintenance. Severalmaintenance procedures have break--in intervals identified in the Operator’s Manuals. If machine is equipped with the hydraulic power pack, refer to the Engine Owner’s Manual for additional engine specific maintenance procedures.

ProPass 200 Page 2 -- 1 Product Records and Maintenance

Page 10

Equivalents and Conversions

0.09375

ProPass 200Page 2 -- 2Product Records and Maintenance

Page 11

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 specified in this Service Manual.

These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Service Manual. 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 o r similar condition which affects the installation.

Fastener Identification

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 engagement, etc.

The standard method of verifying torque shall be performed by marking a line on the fastener (head or nut) and mating part, then back off fastener 1/4 of a turn. Measure the torque required to tighten the fastener until thelinesmatchup.

and Maintenance

Product Records

Grade 1 Grade 5 Grade 8

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 recommendation by the calculated torque conversion factor (Fig.

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

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

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”.

Class 8.8 Class 10.9

Metric Bolts and Screws

Figure 2

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

(effective length of

torque wrench)

(effective length of torque

wrench + offset wrench)

TORQUE CONVERSION FACTOR = A / B

Torque wrenchOffset wrench

The calculated t orque conversion factor for this torque wrench with this offset wrench would be 18 / 19 = 0.947.

ProPass 200 Page 2 -- 3 Product Records and Maintenance

Figure 3

Page 12

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

Grade 1, 5 &

Thread Size

#6--32UNC

#6--40UNF 17 + 2 192 + 23 25 + 3 282 + 34

#8--32UNC

#8--36UNF 31 + 4 350 + 45 43 + 5 486 + 56

#10--24UNC

#10--32UNF 48 + 5 542 + 56 68 + 7 768 + 79

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

1/4 -- 28 UNF 53 + 7 65 + 10 734 + 11 3 115 + 12 1299 + 136 160 + 17 1808 + 192

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

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

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

8withThin

Height Nuts

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

10 + 2 13 + 2 147 + 23

13 + 2 25 + 5 282 + 30

18 + 2 30 + 5 339 + 56

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

SAE Grade 1 Bolts, Screws, Studs &

Sems with Regular Height Nuts

(SAE J995 Grade 2 or Stronger Nuts)

SAE Grade 5 Bolts, Screws, Studs &

Sems with Regular Height Nuts

(SAE J995 Grade 2 or Stronger Nuts)

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

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

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

SAE Grade 8 Bolts, Screws, Studs &

Sems with Regular Height Nuts

(SAE J995 Grade 5 or Stronger Nuts)

3/8 -- 24 UNF 17 + 2 18 + 2 24 + 3 35 + 4 47 + 5 50 + 6 68 + 8

7/16 -- 14 UNC 27 + 3 27 + 3 37 + 4 50 + 5 68 + 7 70 + 7 95 + 9

7/16 -- 20 UNF 29 + 3 29 + 3 39 + 4 55 + 6 75 + 8 77 + 8 104 + 11

1/2 -- 13 UNC 30 + 3 48 + 7 65 + 9 75 + 8 102 + 11 105 + 11 142 + 15

1/2 -- 20 UNF 32 + 4 53 + 7 72 + 9 85 + 9 11 5 + 12 120 + 12 163 + 16

5/8 -- 11 UNC 65 + 10 88 + 12 119 + 16 150 + 15 203 + 20 210 + 21 285 + 28

5/8 -- 18 UNF 75 + 10 95 + 15 129 + 20 170 + 18 230 + 24 240 + 24 325 + 33

3/4 -- 10 UNC 93 + 12 140 + 20 190 + 27 265 + 27 359 + 37 375 + 38 508 + 52

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

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

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

NOTE: Reduce torque values listed in the table above by 25% for lubricated fasteners. Lubricated fasteners are defined as threads coated with a lubricant such as engine oil or thread sealant such as Loctite.

NOTE: The nominal torque values listed above for Grade 5 and 8 fasteners are based on 75% of the minimum proof load specified in SAE J429. The tolerance is 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.

ProPass 200Page 2 -- 4Product Records and Maintenance

Page 13

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

Class 8.8 Bolts, Screws and Studs with

Thread Size

M5 X 0.8 57 + 6in--lb 644 + 68 N--cm 78 + 8in--lb 881 + 90 N --cm

M6 X 1.0 96 + 10 in--lb 1085 + 113 N --cm 133 + 14 in--lb 1503 + 158 N--cm

M8 X 1.25 19 + 2ft--lb 26 + 3N--m 28 + 3ft--lb 38 + 4N--m

M10 X 1.5 38 + 4ft--lb 52 + 5N--m 54 + 6ft--lb 73 + 8N--m

M12 X 1.75 66 + 7ft--lb 90 + 10 N--m 93 + 10 ft--lb 126 + 14 N--m

M16 X 2.0 166 + 17 ft--lb 225 + 23 N--m 229 + 23 ft--lb 310 + 31 N--m

M20 X 2.5 325 + 33 ft--lb 440 + 45 N--m 450 + 46 ft--lb 610 + 62 N--m

NOTE: 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.

Regular Height Nuts

(Class 8 or Stronger Nuts)

NOTE: The nominal torque values listed above are

based on 75% of the minimum proof load specified in SAE J1199. The tolerance is approximately + nominal torque value.

Class 10.9 Bolts, Screws and Studs with

Regular Height Nuts

(Class 10 or Stronger Nuts)

10% of the

and Maintenance

Product Records

ProPass 200 Page 2 -- 5 Product Records and Maintenance

Page 14

Other Torque Specifications

SAE Grade 8 Steel Set Screws

Recommended Torque

Thread Size

Square Head Hex Socket

1/4 -- 20 UNC 140 + 20 in--lb 73 + 12 in--lb

5/16 -- 18 UNC 215 + 35 in--lb 145 + 20 in--lb

3/8 -- 16 UNC 35 + 10 ft--lb 18 + 3ft--lb

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

Thread Cutting Screws

(Zinc Plated Steel)

Type 1, Type 23 or Type F

Thread Size Baseline Torque*

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

Wheel Bolts and Lug Nuts

Thread Size

7/16 -- 20 UNF

Grade 5

1/2 -- 20 UNF

Grade 5

M12 X 1.25

Class 8.8

M12 X 1.5

Class 8.8

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

Thread Cutting Screws

(Zinc Plated Steel)

Thread

Size

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

Threads per Inch

Typ e A Typ e B

Recommended Torque**

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

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

Baseline Torque*

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

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

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

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

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

Conversion Factors

in--lb X 11.2985 = N--cm N--cm X 0.08851 = in--lb

ft--lb X 1.3558 = N--m N--m X 0.7376 = ft--lb

No. 8 15 18 30 + 5in--lb

No. 10 12 16 38 + 7in--lb

No. 12 11 14 85 + 15 in--lb

* Hole size, material strength, material thickness and fin-

ish must be considered when determining specific

torque values. All torque values are based on non--lubri-

cated fasteners.

ProPass 200Page 2 -- 6Product Records and Maintenance

Page 15

Table of Contents

Chapter 3

Hydraulic System

SPECIFICATIONS 2............................

GENERAL INFORMATION 3.....................

Operator’s Manual 3..........................

ProPass Hydraulic Supply 3....................

Hydraulic Hose Kit (Tow Vehicle to ProPass) 3....

Machine Hydraulic Control 4...................

Rear Option 5................................

Relieving Hydraulic System Pressure 5..........

Hydraulic Hoses 6............................

Hydraulic Hose and Tube Installation (O--Ring

Face Seal Fittings) 6........................

Hydraulic Hose and Tube Installation (JIC Flared

Fittings) 8..................................

Hydraulic O--Ring Face Seal (ORFS) Fitting

Installation 9................................

Hydraulic JIC Flared Fitting Installation 11.........

HYDRAULIC SCHEMATICS 12...................

Standard Hydraulic Controls 12.................

Electronic Hydraulic Controls 13................

HYDRAULIC FLOW DIAGRAMS: STANDARD

HYDRAULIC CONTROLS 14...................

Rear Option Circuit (Twin Spinner or Conveyor) 14

Floor Circuit 14...............................

HYDRAULIC FLOW DIAGRAMS: ELECTRONIC

HYDRAULIC CONTROLS 16...................

Rear Option Circuits (Twin Spinner or Conveyor) 16

Floor Circuit 18...............................

SPECIAL TOOLS 20............................

TROUBLESHOOTING 22........................

TESTING 24...................................

SERVICE AND REPAIRS 26.....................

General Precautions for Removing and

Installing Hydraulic System Components 26....

Check Hydraulic Lines and Hoses 27............

Hydraulic Control (Machines with Standard

Hydraulic Controls) 28.......................

Control Valve Service (Machines with Standard

Hydraulic Controls) 30.......................

Solenoid Valve Assembly (Machines with Standard

Hydraulic Controls) 31.......................

Hydraulic Control (Machines with Electronic

Hydraulic Controls) 32.......................

Hydraulic Control Manifold (Machines with

Electronic Hydraulic Controls) 34..............

Floor Motor 38................................

Floor Motor Service 40........................

Twin Spinner Motors 42........................

Conveyor Motor 44............................

Rear Option Motor Service 46..................

EATON (CHAR--LYNN) S--SERIES GENERAL

PURPOSE MOTORS PARTS and REPAIR MANUAL

EATON (CHAR--LYNN) R--SERIES GENERAL

PURPOSE GEROLER MOTOR REPAIR INFORMATION

System

Hydraulic

ProPass 200 Page 3 -- 1 Hydraulic System

Page 16

Specifications

Item Description

Tow Vehicle Hydraulic Supply

Minimum Supply 6 US Gal/Min (23 L/Min) @ 2000 PSI (138 Bar) Maximum Supply 10 US Gal/Min (38 L/Min) @ 2800 PSI (190 Bar)

Floor Motor Eaton fixed displacement geroler motor

Displacement (per revolution) 22.7 in

Twin Spinner Motors (Rear Option) Eaton fixed displacement geroler motor

Displacement (per revolution) 1.8 in

Conveyor Motor (Rear Option) Eaton fixed displacement geroler motor

Displacement (per revolution) 1.8 in

(371 cc)

NOTE: If tow vehicle provides hydraulic supply, use tow vehicle hydraulic specifications for information regarding hydraulic flow and relief pressure to the ProPass. If hydraulic power pack provides hydraulic supply, see Chapter 6 -- Hydraulic Power Pack Assembly for information regarding hydraulic circuit flow and relief pressure specifications.

(29 cc)

ProPass 200Page 3 -- 2Hydraulic System

Page 17

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 publication for additional information when servicing the machine.

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 hydraulic flow and relief pressure to the ProPass. If hydraulic power pack provides hydraulic supply, see Chapter 6 -- Hydraulic Power Pack Assembly for information regarding hydraulic circuit flow and relief pressure specifications.

NOTE: See Specifications in this chapter for tow vehicle hydraulic supply recommendations.

System

Hydraulic

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). If the 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.

Figure 1

1. Hydraulic hose (supply)

2. Hydraulic hose (return)

3. Dust cap

4. Male coupler

5. O--ring

6. Check valve

7. O--ring

TOW VEHICLE

ProPass 200 Page 3 -- 3 Hydraulic System

Page 18

Machine Hydraulic Control

ProPass 200 machines use either standard hydraulic controls or electronic hydraulic controls to allow the operator to change machine settings.

Standard Hydraulic Controls

Electronic Hydraulic Controls

Machines with electronic hydraulic controls include a wireless remote to electrically adjust hydraulic flow to the floor and rear option (twin spinner or conveyor) motors (Fig. 3). The remote allows initial adjustment of the floor and rear option motors as well as making adjustments possible while the machine is operating. An E--Stopbuttononthemachinedisablestheelectrical system to prevent unexpected machine operation.

If there should be a problem with the wireless remote, ProPass machineswith electronic controls have manual override adjustments on the driver side of the hydraulic system that will allow continued operation (Fig. 4). A control knobis used to adjust floor speed and a flat blade screwdriver can be used to adjust the rear option speed.

1. Floor control

2. Rear option control

Figure 2

3. Pendant harness

Figure 3

1. Wireless remote

2. E--Stop button

3. Power lead harness

4. Optional power pack

Figure 4

1. Control knob 2. Screwdriver slot

ProPass 200Page 3 -- 4Hydraulic System

Page 19

Rear Option

The ProPass includes the twin spinner that is used for topdressing (Fig. 5). The twin spinner uses two (2) hydraulic 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 these rear options.

Figure 5

System

Hydraulic

Figure 6

Relieving Hydraulic System Pressure

Make sure that the ProPass has electrical power and

CAUTION

Before disconnecting any hydraulic components, operate all hydraulic controls to relieve system pressure and avoid injury from pressurized 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 powerpack engine is turned off.

ProPass 200 Page 3 -- 5 Hydraulic System

that controls are operational. With the tow vehicle engine 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 ignition switch.

Page 20

Hydraulic Hoses

Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather, sun, chemicals, very warm storage conditions or mishandling during operation and maintenance. These conditions can cause hose damage and deterioration. Some hoses are more susceptible to these conditions than others. Inspect all machine hydraulic hoses frequently for signs of deterioration or damage:

WARNING

Before disconnecting or performing any work on hydraulic system, relieve all pressure in system (see Relieving Hydraulic System Pressure in this section).

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

Kinked, crushed, flattened or twisted hose.

Blistered, soft, degraded or loose hose cover.

Cracked, damaged or badly corroded hose fittings.

When replacing a hydraulic hose, 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 elbow at one end, tighten the swivel nut on that end before tightening the nut on the straight end of the hose.

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

Keep body and hands awayfrom 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 removed within a few hours by a doctor familiar with this type of injury. Gangrene 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. As a preventative measure against leakage, it is recommended 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 theflatfaceofthehose/tubesleevefullycontactstheO-ring in the fitting.

1. Hydraulic hose/tube

2. Swivel nut

Figure 7

3. O--ring

4. Fitting body

ProPass 200Page 3 -- 6Hydraulic System

Page 21

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 recommended installation torque shown in Figure 9. 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 wrenchwill 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).

C. Useasecondwrenchtotightenthenuttothecorrect Flats From Wrench Resistance (F.F.W.R.). The markings onthe nut andfitting body willverify 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

5. If a torque wrench is not available or if space at the swivel nut prevents use of a torque wrench, an alternate

Mark Nut

and Fitting

Body

Final

Position

method of assembly is the Flats From Wrench Resistance (F.F.W.R.) method (Fig. 8).

A. Using a wrench, tighten the swivel nut onto the fitting until light wrench resistance is reached (approximately 30 in--lb).

B. Mark the swivel nut and fitting body. Hold the

AT WRENCH RESISTANCE

Extend Line

Figure 8

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

Fitting Dash Size Hose/Tube Side Thread Size Installation Torque

4 9/16 -- 18 18to22ft--lb(25to29N--m)

6 11/16 -- 16 27to33ft--lb(37to44N--m)

8 13/16 -- 16 37to47ft--lb(51to63N--m)

10 1--14 60 to 74 ft--lb (82 to 100 N--m)

12 13/16--12 85to105ft--lb(116to142N--m)

16 17/16--12 110to136ft--lb(150to184N--m)

Initial Position

AFTER TIGHTENING

System

Hydraulic

20 1 11/16 -- 12 140 to 172 ft--lb (190 to 233 N--m)

ProPass 200 Page 3 -- 7 Hydraulic System

Figure 9

Page 22

Hydraulic Hose and Tube Installation (JIC Flared Fittings)

NOTE: ProPass machines with serial numbers below

310001000 use JIC flared fittings (Fig. 10). Use the following 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 installation 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 Specifications section of Chapter 2 -- Product Records and Maintenance).

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 Resistance (F.F.W.R.) method (Fig. 11).

Siz e 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

and Fitting

Body

Final

Position

A. Using a wrench, tighten the swivel nut onto the fitting until light wrench resistance is reached (approxi-

Extend Line

mately 30 in--lb).

AT WRENCH RESISTANCE

AFTER TIGHTENING

B. Mark the swivel nut and fitting body. Hold the hose/tube with a wrench to prevent it from turning.

Figure 11

C. Use a second wrench to tighten the nut to the correct Flats From Wrench Resistance (F.F.W.R.). The markings onthe nut and fitting body will verify that the connection has been properly tightened.

Fitting Dash Size Hose/Tube Side Thread Size Installation Torque

4 7/16 -- 20 10to14ft--lb(14to18N--m)

6 9/16 -- 18 15to21ft--lb(21to28N--m)

8 3/4 -- 16 33to41ft--lb(45to55N--m)

10 7/8 -- 14 43to53ft--lb(59to71N--m)

12 11/16--12 66to82ft--lb(90to111N--m)

14 13/16--12 80 to 98 ft--lb (109 to 132 N--m)

Initial Position

16 15/16--12 90to110ft--lb(122to149N--m)

Figure 12

ProPass 200Page 3 -- 8Hydraulic System

Page 23

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. Use the following 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. As a preventative measure against leakage, it is recommended 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, determine port material. If fitting is to be installed into an aluminum port, installation torque is reduced.

4. Install the fitting into the port. Then, use a torque wrench and socket to tighten the fitting to the recommended installation torque shown in Figure 14.

NOTE: Use of an offset wrench (e.g. crowfoot wrench) will affect torque wrench calibration d ue 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 UsingaTorqueWrenchwithanOffsetWrenchinthe Torque Specifications section of Chapter 2 -- Product Records and Maintenance to determine necessary conversion information.

5. If a torque wrench is not available, or if space at the port prevents use of a torque wrench, an alternate method of assembly is the Flats From Finger Tight (F.F.F.T.) method.

A. Install the fitting into the port and tighten it down full length until finger tight.

B. If port material is steel, tighten the fitting to the listed F.F.F.T. If port material is aluminum, tighten fitting to 60% of listed F.F.F.T.

Siz e F.F.F.T.

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

Fitting

O--ring

0.25

Figure 13

System

Hydraulic

Fitting

Dash Size

Fitting Port Side

Thread Size

4 7/16 -- 20 15to19ft--lb(21to25N--m) 9to11ft--lb(13to15N--m)

6 9/16 -- 18 34to42ft--lb(47to56N--m) 20to26ft--lb(28to35N--m)

8 3/4 -- 16 58to72ft--lb(79to97N--m) 35to43ft--lb(48to58N--m)

10 7/8 -- 14 99 to 121 ft--lb (135 to 164 N--m) 60 to 74 ft--lb (82 to 100 N--m)

12 11/16--12 134 to 164 ft--lb (182 to 222 N--m) 81 to 99 ft--lb (110 to 134 N--m)

14 13/16--12 160 to 196 ft--lb (217 to 265 N--m) 96to118ft--lb(131to160N--m)

16 15/16--12 202 to 248 ft--lb (274 to 336 N--m) 121 to 149 ft--lb (165 to 202 N--m)

20 15/8--12 247 to 303 ft--lb (335 to 410 N-- m) 149 to 183 ft--lb (202 to 248 N--m)

ProPass 200 Page 3 -- 9 Hydraulic System

Installation Torque Into

Steel Port

Figure 14

Installation Torque Into

Aluminum Port

Page 24

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. As a preventative measure against leakage, it is recommended 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 aspossible(Step1inFigure16).

IMPORTANT: Before installing fitting into port, determine 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 (Step3inFigure16).

7. Hold the fitting in the desired position with a wrench and use a torque wrench to tighten the fitting to the recommended 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).

1. Lock nut

2. Back--up washer

Step 2 Step 4

Figure 15

3. O--ring

Step 3Step 1

Figure 16

8. If a torque wrench is not available, or if space at the port prevents use of a torque wrench, an alternate method of assembly is the Flats From Finger Tight (F.F. F.T.) method. 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 Figure 16). If port material is aluminum, tighten fitting to 60% of listed F.F.F.T.

Si z e F. F. F. T.

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

0.25

ProPass 200Page 3 -- 10Hydraulic System

Page 25

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 following 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.

Use the following torque values when installing JIC flared fittings into a steel or aluminum component port.

IMPORTANT: If fitting is non--ferrous material (e.g. brass fitting), use installation torque for aluminum port.

JIC FLARED FITTING

(ADJUSTABLE TYPE SHOWN)

Figure 17

Fitting

Dash Size

Fitting Port Side

Thread Size

Installation Torque Into

Steel Port

Installation Torque Into

Aluminum Port

4 7/16 -- 20 13to17ft--lb(18to23N--m) 7to9ft--lb(10to12N--m)

6 9/16 -- 18 23to29ft--lb(32to39N--m) 11to15ft--lb(15to20N--m)

8 3/4 -- 16 46to58ft--lb(63to78N--m) 23to29ft--lb(32to39N--m)

10 7/8 -- 14 69to85ft--lb(94to115N--m) 35to43ft--lb(48to58N--m)

12 11/16--12 105 to 129 ft--lb (143 to 174 N--m) 53to65ft--lb(72to88N--m)

14 13/16--12 139 to 171 ft--lb (189 to 231 N--m) 70to86ft--lb(95to116N--m)

16 15/16--12 153 to 187 ft--lb (208 to 253 N--m) 76 to 94 ft--lb (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

System

Hydraulic

ProPass 200 Page 3 -- 11 Hydraulic System

Page 26

Hydraulic Schematics

HYDRAULIC POWER PACK

FLOOR SOLENOID VALVE

FLOOR CONTROL VALVE

FLOOR

EX CF

MOTOR

OPTION SOLENOID VALVE

OPTION

EXCF

CONTROL VALVE

SPINNER MOTORS

CONVEYOR

MOTOR

ProPass 200

Hydraulic Schematic

Standard Hydraulic Controls

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, relief 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 motor).

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 Hydraulic Hose Kit in the General Information section of this chapter).

ProPass 200Page 3 -- 12Hydraulic System

Page 27

PLUGPLUG

FA FB LA LB O T1

CV1 CV2 CV3 CV4

ORF4

(0.020)

FLOOR

MOTOR

CONTROL

MANIFOLD

SP1

S2 S1 S2 S1

EC1

ORF1

(0.040)

SV1

ORF3

(0.068)

ORF2

(0.020)

PV1

SPINNER MOTORS

System

Hydraulic

CONVEYOR

MOTOR

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, relief 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 motor).

ProPass 200 Page 3 -- 13 Hydraulic System

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 acheckvalveinthereturnhoseassembly(seeHydraulic Hose Kit in the General Information section of this chapter).

Page 28

Hydraulic Flow Diagrams: Standard Hydraulic Controls

REAR OPTION CIRCUIT (TWIN SPINNER SHOWN)

FLOOR CIRCUIT

HYDRAULIC POWER PACK

FLOOR SOLENOID VALVE

FLOOR CONTROL VALV E

FLOOR

EX CF

MOTOR

Option solenoid valve is energized. Excess and return flow will be routed to hydraulic reservoir.

OPTION SOLENOID VALV E

OPTION

EXCF

CONTROL VALVE

SPINNER MOTORS

HYDRAULIC POWER PACK

FLOOR SOLENOID VALVE

FLOOR CONTROL VALV E

FLOOR

EX CF

MOTOR

Both floor solenoid valve and option solenoid valve are energized. Excess and return flow will be routed to hydraulic reservoir.

OPTION SOLENOID VALV E

OPTION

EXCF

CONTROL VALVE

SPINNER MOTORS

Working Pressure

Return Flow

ProPass 200Page 3 -- 14Hydraulic System

Page 29

Rear Option Circuit (Twin Spinner or Conveyor)

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 option (twin spinner or conveyor) motors (Fig. 19). A pendant electrical control allows the operator to energize the floor and rear option motors from the operator position of the tow vehicle. The ProPass hydraulic system 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, hydraulicflow bypasses the motors and returns directly to the hydraulicreservoir. The floor and rear option will remain in the stationary positions.

NOTE: Typically, the rear option (twin spinner or conveyor) is engaged before the floor is started.

1. Floor control

2. Rear option control

Figure 19

3. Pendant harness

When the operator engages the rear option (twin spinner or conveyor) motors, the rear option solenoid valve is energized which directs hydraulic flow to the rear option 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 control 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 s ystem relief valve either on the tow vehicle or hydraulic power pack.

Floor Circuit

NOTE: Typically, the rear option (twin spinner or conveyor) 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 the rear option.

Hydraulic circuit pressure is controlled by the system relief valve either on the tow vehicle or hydraulic power pack.

System

Hydraulic

ProPass 200 Page 3 -- 15 Hydraulic System

Page 30

Hydraulic Flow Diagrams: Electronic Hydraulic Controls

REAR OPTION CIRCUITS (TWIN SPINNER OR CONVEYOR)

CONTROL

MANIFOLD

PLUGPLUG

FA FB LA LB O T1

CV1 CV2 CV3 CV4

SP1

S2 S1 S2 S1

EC1

ORF1

(0.040)

SV1

ORF3

(0.068)

(0.020)

PV1

ORF2

ORF4

(0.020)

FLOOR

MOTOR

SPINNER MOTORS

CONVEYOR

MOTOR

HYDRAULIC POWER PACK

SP1 is not energized. PV1 is energized. Both EC1 and PV1 shift to allow flow to rear option motors. Excess and return flow will be routed to hydraulic reservoir.

Working Pressure

Return Flow

ProPass 200Page 3 -- 16Hydraulic System

Page 31

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) motors (Fig. 20). A hydraulic control manifold is used to control circuit hydraulic flow from the hydraulic oil supply source (tow vehicle or hydraulic power pack). The control 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 operation 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 return to the hydraulic reservoir.

Control manifold proportional flow valve (PV1) is a priority--type flow regulator with pressure compensated bypass 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 machine operation should the wireless controller be lost, damaged or faulty.

NOTE: The schematic symbols for the pressure compensator 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 operation, the valves will shift to provide necessary flow to both the floor motor and to the rear option motors based on control settings.

NOTE: Typically, the rear option (twin spinner or conveyor) is engaged before the floor is started.

When the operator engages the rear option (twin spinner 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 to current applied 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 f rom 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 relief valve either on the tow vehicle or hydraulic power pack.

System

Hydraulic

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 supplied by the base unit. Solenoid valve (SP1) includes manual adjustment for machine operation should the

1. Wireless remote

2. E--Stop button

Figure 20

3. Power lead harness

4. Optional power pack

wireless controller be lost, damaged or faulty.

NOTE: Control manifold solenoid valve SV1 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. Hydraulic 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 reservoir, bypassing the floor and rear option motors. The floor and rear option will remain in the stationary positions.

ProPass 200 Page 3 -- 17 Hydraulic System

Page 32

FLOOR CIRCUIT

CONTROL

MANIFOLD

PLUGPLUG

FA FB LA LB O T1

CV1 CV2 CV3 CV4

SP1

S2 S1 S 2 S1

EC1

ORF1

(0.040)

SV1

ORF3

(0.068)

ORF2

(0.020)

PV1

ORF4

(0.020)

FLOOR

MOTOR

SPINNER MOTORS

CONVEYOR

MOTOR

HYDRAULIC POWER PACK

SP1 and PV1 are both energized. Both EC1 and PV1 shift to allow proportional flow to rear option and floor motors. Excess and return flow will be directed to hydraulic reservoir.

Working Pressure

Return Flow

ProPass 200Page 3 -- 18Hydraulic System

Page 33

Floor Circuit

Machines with electronic hydraulic controls include a wireless remote to electrically adjust hydraulic flow to the floor and rear option (twin spinner or conveyor) motors (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 control manifold includes cartridge valves for control of the rear option (twin spinner or conveyor) and floor circuits.

NOTE: Typically, the rear option (twin spinner or conveyor) 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 motor speed, the base unit supplies the necessary voltage to the SP1 solenoid coilbased on settingsof the wireless remote. Flow from the SP1 v alve is proportional to current applied to the valve coil by the base unit. System hydraulic flow in excess of the floor valve setting is available for the rear option. Return from the r ear option motors is routed to the reservoir.

Check valve CV1 along with orifice fittings ORF1 and ORF2 are included in the floor circuit to ensure that pressure compensator valve (EC1) provides the necessary flow to the floor motor.

Hydraulic circuit pressure is controlled by the system relief valve either on the tow vehicle or hydraulic power pack.

System

Hydraulic

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 supplied by the base unit. Solenoid valve (SP1) includes manual adjustment for machine operation should the

1. Wireless remote

2. E--Stop button

Figure 21

3. Power lead harness

4. Optional power pack

wireless controller be lost, damaged or faulty.

NOTE: Control manifold solenoid valve SV1 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.

ProPass 200 Page 3 -- 19 Hydraulic System

Page 34

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

Hydraulic Tester (Pressure and Flow)

Figure 22

Use to test hydraulic circuits and components for flow and pressure capacities. This tester includes the follow ing:

1. INLET HOSE: Hose connected from the system circuit 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. PRESSUREGAUGE:Glycerinefilled0to5000PSI 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(5to55LPM).

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 included with this kit.

Toro Part Number: TOR214678

Figure 23

ProPass 200Page 3 -- 20Hydraulic System

Page 35

Hydraulic Test Fitting Kit

This kit includes a variety of O--ring Face Seal fittings to enable you to connect test gauges into the system.

The kit includes: tee’s, unions, reducers, plugs, caps and male test fittings.

Toro Part Number: TOR4079

O--ring Kit

This kit includes O--rings in a variety of sizes for face seal and port seal hydraulic connections. It is recommended that O--rings be replaced whenever a hydraulic connection is loosened.

Toro Part Number: 117--2727

Figure 24

System

Hydraulic

Figure 25

ProPass 200 Page 3 -- 21 Hydraulic System

Page 36

Tr oubleshooting

For effective troubleshooting and repairs, there must be a good understanding of the hydraulic circuits and components used on this machine (see Hydraulic Schematics in this chapter).

Problem

No ProPass functions operate. Hydraulic lines are not connected to tow vehicle

Possible Causes

(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 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.

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(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 200Page 3 -- 22Hydraulic System

Page 37

Problem Possible Causes

Floor does not function (machines with standard hydraulics).

Floor does not function (machines with electronic hydraulics). NOTE: Check wireless remote LCD display and base unit LED’s for help in troubleshooting.

Floor control valve setting is not adjusted properly.

Floor solenoid valve is faulty.

An electrical problem exists (see Chapter 4 -- Electrical System).

Hydraulic floor motor is faulty.

Wireless remote settings are incorrect.

Control manifold proportional solenoid valve (SP1) is faulty.

An electrical problem exists (see Chapter 4 -- Electrical System).

Hydraulic floor motor is faulty.

System

Hydraulic

ProPass 200 Page 3 -- 23 Hydraulic System

Page 38

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 mustbe checked before assuming that a hydraulic component is the source of the problem.

WARNING

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 System Pressure in the General Information section.

CAUTION

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 hydraulic equipment. Hydraulic system contamination will cause excessive wear of hydraulic components.

2. Put metal caps or plugs o n all hydraulic lines left open or exposed during testing or removal of components.

3. Theenginemustbeingoodoperatingcondition.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 properly 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.

Failure to use gauges with recommended pressure (PSI) rating as listed in test procedures could result in damage to t he gauge and possible personal injury from leaking hot oil.

CAUTION

All testing should be performed by two (2) people. One personshould be in the seat to operate the machine and the other should monitor testing equipment and record test results.

WA RNING

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 escaping under pressure can have sufficient force to penetrate the skin and cause serious injury. If fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with t his type of injury. Gangrene may result from such an injury.

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 connecting 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 hydraulic 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 determine testing procedures for flow and relief pressure on your ProPass.

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 200Page 3 -- 24Hydraulic System

Page 39

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System

Hydraulic

ProPass 200 Page 3 -- 25 Hydraulic System

Page 40

Service and Repairs

General Precautions for Removing and Installing Hydraulic System Components

Before Repair or Replacement of Hydraulic Components

1. Before removing any components from the hydraulic system, position ProPass machine on a level surface. Engage tow vehicle parking brake, stop engine and remove 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.

WARNING

After Repair or Replacement of Hydraulic Components

1. Check oil level in the hydraulic reservoir and add correct 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 hydraulic tubes, hydraulic fittings and components before reconnecting.

4. Use proper tightening methods when installing hydraulic hoses and fittings (see Hydraulic Hose and Tube Installation and Hydraulic Fitting Installation in the General Information section of this chapter).

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

6. Check for hydraulic oil leaks. Shut off engineand correct leaks if necessary. Check oil level in hydraulic reservoir and add correct oil if necessary.

3. Put caps or plugs on any hydraulic lines, hydraulic fittings and components left open or exposed to prevent system contamination.

4. Put labels on disconnected hydraulic lines and hoses for proper installation after repairs are completed.

5. Note the position o f hydraulic fittings (especially elbow fittings) on hydraulic components before removal. Mark parts if necessary to make sure they will be aligned properly when installing hydraulic hoses and tubes.

ProPass 200Page 3 -- 26Hydraulic System

Page 41

Check Hydraulic Lines and Hoses

WARNING

Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not hands, to search for leaks. Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury. If fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type of injury. Gangrene may result from such an injury.

IMPORTANT: Check hydraulic lines and hoses daily for leaks, kinked lines, loose mounting supports, wear, loose fittings or deterioration. Make all necessary repairs before operating the machine.

System

Hydraulic

ProPass 200 Page 3 -- 27 Hydraulic System

Page 42

Hydraulic Control (Machines with Standard Hydraulic Controls)

RIGHT

FRONT

1. Hydraulic tee fitting (3 used)

2. Panel

3. Floor control valve

4. Rear option control valve

5. Hydraulic hose

6. Hydraulic hose

7. Hydraulic hose

8. Hydraulic hose

9. Hydraulic cap

Figure 26

10. Hydraulictube(4used)

11. Valve spacer (2 used)

12. Cap screw (4 used)

13. Hydraulic tube

14. Rubber grommet

15. Lock nut

16. Flat washer

17. Hydraulic adapter

18. Hydraulic adapter

19. Cap screw (4 used)

20. Hydraulic tee fitting

hydraulic fitting (2 used)

21. 90

22. Straight hydraulic fitting (3 used)

23. Hydraulic tee fitting

24. Floor solenoid valve

25. Hydraulic supply hose

26. Hydraulic return hose

27. Rear option solenoid valve

ProPass 200Page 3 -- 28Hydraulic System

Page 43

Disassembly (Fig. 26)

1. Position machine on a levelsurface.IfProPassisattached to tow vehicle, apply tow vehicle parking brake, stop engine and remove key from the ignition switch. Chock wheels to prevent ProPass machine from moving.

2. Remove hydraulic guard from machine to allow access to hydraulic controls (Fig. 27).

CAUTION

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

3. Relieve hydraulic system pressure.

4. Before removing any control system components, thoroughly clean all hydraulic connections. For assembly purposes, label hydraulic and electrical connections at components that are to be removed.

5. Remove control system components as needed using 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.

A. If fittings were removed, lubricate and place new O--rings onto fittings. Install and properly tighten fittings into component openings (see Hydraulic Fitting Installation in the General Information section of this chapter).

1. Hydraulic guard

2. Screw (2 used)

3. Flange nut (4 used)

1. Supply hose (45o)

2. Floor control valve

Figure 27

4. Cap screw (2 used)

5. Flat washer (2 used)

Figure 28

3. Return hose (90o)

4. Option control valve

System

Hydraulic

B. Lubricate and position new O--rings to fittings. Use labels placed during the removal process to properly installhydraulic lines to fittings (see Hydraulic Hose and Tube Installation in the General Information section of this chapter).

C. Make sure that wire harness connectors are secured to solenoid coils.

2. Install hydraulic guard to machine (Fig. 27).

ProPass 200 Page 3 -- 29 Hydraulic System

Page 44

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 hopper (Fig. 29).

NOTE: See Hydraulic Control (Machines with Standard Hydraulic Controls) in this section for information on removing the control valve from the machine.

Disassembly (Fig. 30)

NOTE: A seal kit is available f or the control valve. If

wear or damage exists to the control valve body, side lever or compensator spool, control valve assembly replacement is necessary.

1. Loosen set screw and slide handle from side lever.

Figure 29

1. Floor control valve 2. Option control valve

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 control valve body. Remove O--rings from side lever.

5. Remove plugs from control valve body. Slide compensator 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 hydraulic oil and install new O-- r ings on side lever and plugs.

2. Dip compensator spool and side lever into clean hydraulic oil.

3. Install plug into the control valve body port opposite the bore for the compensator spool. Then, slide lubricated compensator spool into body. Insert spring and install second plug into control valve body.

1. Body

2. Set screw

3. Handle

4. Retaining ring

5. Seal retainer

6. O--ring

Figure 30

7. O--ring

8. Side lever

9. Plug with O-- ring

10. Compensator spring

11. Compensator spool

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.

ProPass 200Page 3 -- 30Hydraulic System

Page 45

Solenoid Valve Assembly (Machines with Standard Hydraulic Controls)

Two (2) identical solenoid valve assemblies are used on machines with standard hydraulic controls. When energized, these solenoid valves allow hydraulic flow to engage 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 removing the solenoid valve assembly from the machine.

CAUTION

Before continuing further, read and become familiar 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 Models) in this section. Refer to Figure32forcartridgevalve and solenoid coil nut installation torque.

NOTE: See Hydraulic Solenoid Valve Coils in Chapter 4 -- Electrical System for information on testing the solenoid coils.

Figure 31

1. Floor solenoid valve 2. Option solenoid valve

60 in-- lb

(6.7 N-- m)

25 ft-- lb

(34 N-- m)

System

Hydraulic

ProPass 200 Page 3 -- 31 Hydraulic System

1. Nut

2. Solenoid coil

3. Cartridge valve

Figure 32

4. Seal kit

5. Manifold

Page 46

Hydraulic Control (Machines with Electronic Hydraulic Controls)

RIGHT

FRONT

1. Hydraulic hose

2. Hydraulic hose

3. Hydraulic hose

4. Hydraulic control manifold

5. Hydraulic hose

6. Straight hydraulic fitting (2 used)

7. Straight hydraulic fitting (4 used)

Figure 33

8. Female quick disconnect

9. Male quick disconnect

hydraulic fitting (2 used)

10. 45

11. Tubeclamp(12used)

12. O--ring

13. Flat washer (2 used)

14. Lock washer (2 used)

15. Cap screw (3 used)

16. Cap screw (2 used)

17. O--ring

18. Seal kit

19. O--ring

20. Clamp plate (3 used)

21. Control panel guard

ProPass 200Page 3 -- 32Hydraulic System

Page 47

Removal (Fig. 33)

2. Disconnect emergency stop button connector from machine wire harness. Remove control panel guard from front of ProPass to allow access to control manifold.

CAUTION

3. Relieve hydraulic system pressure.

3. Remove caps and plugs from disconnected hydraulic 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 Information section of this chapter).

5. Connect wire harness connectors to solenoid valves on manifold.

6. Install control panel guard to front of ProPass. Connect emergency stop button connector to machine wire harness.

System

Hydraulic

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 hydraulic lines and fittings to prevent contamination.

7. Remove two (2) cap screws (item 16), lock washers and flat washers 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 Fitting Installation in the General Information section of this chapter).

1. Pressure hose (45o)

2. Return hose (90

)

FRONT

Figure 34

3. Control panel guard

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 Hydraulic System

1. Control manifold

2. Solenoid coil: floor

Figure 35

3. Solenoid coil: option

Page 48

Hydraulic Control Manifold (Machines with Electronic Hydraulic Controls)

25 ft --lb

(34 N-- m)

35 ft-- lb

(47 N-- m)

60 in-- lb

(6.7 N-- m)

25 ft --lb

(34 N-- m)

35 ft-- lb

(47 N-- m)

25 ft--lb

(34 N--m)

25 ft-- lb

(34 N-- m)

20 ft-- lb

(27 N-- m)

12 to 14 ft--lb

(16to18N--m)

1. Control manifold

2. Proportional flow valve (PV1)

3. Solenoid valve (SV1)

4. Solenoid valve (SP1)

5. Pressure compensator valve (EC1)

6. Solenoid coil

NOTE: Solenoid valve SV1 and the upper solenoid coil

on solenoid valve SP1 are not used in the ProPass 200 hydraulic system.

20 ft-- lb

(27 N-- m)

Figure 36

7. Coil nut

8. Solenoid coil (4 used)

9. Coil spacer

10. Coil nut

11. Plug (4 used )

12. #4 plug (6 used)

20 to 26 ft--lb

(27to35N--m)

13. Check valve (4 used)

14. Orifice plug (0.068)

15. Orifice plug (0.040)

16. Orifice plug ( 0.020) (2 used)

17. #6 plug (2 used)

ProPass 200Page 3 -- 34Hydraulic System

Page 49

NOTE: ThehydraulicmanifoldshowninFigure36uses

several zero leak plugs. These plugs have a tapered sealing surface on the plug head that is designed to resist 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.

CAUTION

Before continuing further, read and become familiar with General Precautions for Removing and Installing Hydraulic System Components in this section.

Cartridge Valve Service

CAUTION

5. Visually inspect the port in the manifold for damage to the sealing surfaces, damaged threads and contamination.

6. Visually inspect cartridge valve for 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. Ifvalvesealingsurfaces appear pitted or damaged, the hydraulic system m ay be overheating or there may be water in the system.

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 contamination. Particlesas fine as talcumpowder can affect the operation of high pressure hydraulic valves. If cartridge 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 cartridge. Use compressed air for cleaning.

System

Hydraulic

If manifold is connected to machine hydraulic system, operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulicoil before removing manifold components. See Relieving Hydraulic System Pressure in the General Information section of this chapter.

1. If control manifold is connected to machine hydraulic system, relieve hydraulic system pressure before servicing 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 slidecoiloffthevalve.

IMPORTANT: Use care when handling the cartridge valve. Slight bending or distortion of the stem tube can cause binding and malfunction. When removing 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, sealing rings and backup rings on valve. Remove seal kit from cartridge valve and discard removed seals.

8. Install the cartridge valve into the manifold:

A. Lubricate new seal kit components with clean hydraulic 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 manifold 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, remove cartridge valve and clean again or replace valve.

ProPass 200 Page 3 -- 35 Hydraulic System

Page 50

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 manifold 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 orifice plugs requires removal of the manifold plug. Orifice locationsareshowninFigure38.

NOTE: Orifice fitting ORF3 is not used in the ProPass 200 hydraulic system.

1. Check valve CV1

2. Check valve CV2

Figure 37

3. Check valve CV3

4. Check valve CV4

Refer to Hydraulic Schematics in this chapter for circuit location of the orifice fittings.

1. Orifice ORF1 (0.040)

2. Orifice ORF2 (0.020)

Figure 38

3. Orifice ORF3 (0.068) 4. Orifice ORF4 (0.020)

ProPass 200Page 3 -- 36Hydraulic System

Page 51

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System

Hydraulic

ProPass 200 Page 3 -- 37 Hydraulic System

Page 52

Floor Motor

Loctite #242

Antiseize

Lubricant

Antiseize Lubricant

Direction

Of Rotation

FRONT

RIGHT

1. Drive chain

2. Hydraulic floor motor

3. Sprocket

4. Sprocket

5. Idler sprocket

6. Cap screw

Removal (Fig. 39)

1. Position machine on a level surface. If ProPass is attached to tow vehicle, apply tow vehicle parking brake, stop engine and remove key from the ignition switch. Chock wheels to prevent ProPass machine from moving.

Figure 39

7. Flat washer (2 used)

8. Lock nut

9. Cap screw (2 used)

10. Lock nut (2 used)

11. C ap screw

12. Flat washer

13. Square key

14. Spacer

15. Set screw (2 used per sprocket)

16. Master link

17. Woodruff key

18. Drive roller shaft

2. Remove guards from frame to allow access to floor motor (see Bed Guards in the Service and Repairs section of Chapter 5 -- Chassis).

3. Loosen cap screw and lock nut that secure idler sprocket to frame. Move idler sprocket to remove tension from drive chain.

ProPass 200Page 3 -- 38Hydraulic System

Page 53

4. Locate and remove master link (item 16) from drive chain. Notedirection of masterlink clip forassembly purposes. Remove drive chain.

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.

CAUTION

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.

6. Slide sprocket to end of motor shaft so that it contacts flat washer.

7. Apply Loctite #242 (or equivalent) to threads of set screws (item15). Install andtighten set screws to secure sprocket to motor shaft.

8. Remove all caps or plugs that were placed on hydraulic 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. Secure idler sprocket by tightening cap screw and lock nut. A properly adjusted chain should allow for free rotation of drive components.

System

Hydraulic

12.If hydraulic fittings are to be removed from floor motor, mark fitting orientation to allow correct assembly.

13.Secure guards to frame (see Bed Guards in the Service and Repairs section of Chapter 5 -- Chassis).

Remove fittings from motor and discard O--rings.

Installation (Fig. 39)

FRONT

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 Information section of this chapter).

2. Position floor motor to frame and secure with two (2) cap screws (item 9) and lock nut (item 10).

1. Drive roller

2. Idler roller

Figure 40

3. RH conveyor frame

4. Rotation direction

3. Apply antiseize lubricant to floor motor shaft.

ProPass 200 Page 3 -- 39 Hydraulic System

Page 54

Floor Motor Service

Loctite #601

250 in --lb (28 N-- m)

300 in--lb

(34 N--m)

1. Cap screw (4 used)

2. Mounting flange

3. Exclusion seal

4. Back--up ring

5. Pressure seal

6. Seal

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.

Figure 41

7. Bearing race

8. Thrust bearing

9. Output shaft

10. Housing

11. Seal (3 used)

12. Spacer plate

13. Drive

14. Geroler assembly

15. End cap

16. Cap screw (7 used)

17. Poppet (2 used)

ProPass 200Page 3 -- 40Hydraulic System

Page 55

This page is intentionally blank.

System

Hydraulic

ProPass 200 Page 3 -- 41 Hydraulic System

Page 56

Twin Spinner Motors

Antiseize

Lubricant

RIGHT

FRONT

1. Quick disconnect (male)

2. Quick disconnect (female)

3. Hydraulic hose

4. Hydraulic tee fitting

5. Straight hydraulic fitting (4 used)

6. Hydraulic hose

7. Hydraulic hose

8. Hydraulic hose

9. O--ring

hydraulic fitting

10. 90

11. Plu g

Antiseize

Lubricant

Loctite #242

Figure 42

12. Cap

13. O--ring

14. O--ring

15. O--ring

16. O--ring

17. Spinner motor (2 used)

18. Woodruff key (1 used per motor)

19. Disconnect seal kit

20. Lock washer (1 used per motor)

21. Cap screw (1 used per motor)

22. Cap screw (4 used per motor)

23. Lock washer (4 used per motor)

24. Cap screw (3 used per hub)

25. Hub (2 used)

26. Lock nut (3 used per hub)

27. Set screw (2 used per hub)

28. Spinner disk (2 used)

29. Carriage bolt (2 used per paddle)

30. Left curved paddle (3 used)

31. Flange nut (2 used per paddle)

32. Right curved paddle (3 used)

33. Spinner frame

ProPass 200Page 3 -- 42Hydraulic System

Page 57

Removal (Fig. 42)

Installation (Fig. 42)

CAUTION

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 a suitable container. Put caps or plugson open hydraulic lines and fittings to prevent contamination.

5. Remove spinner assembly. Removal 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.

1. If removed, install hydraulic fittings with new O--rings into the spinner motor ports (see Hydraulic Fitting Installation 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 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 (item27). Install andtighten set screws to secure hubtomotorshaft.

9. Remove all caps or plugs that were placed on hydraulic 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).

System

Hydraulic

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 motor 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 washers (item 23) that secure spinner motor to spinner frame. Lower motor from spinner frame and remove from machine.

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 Service in this section.

ProPass 200 Page 3 -- 43 Hydraulic System

Page 58

Conveyor Motor

Loctite #242

Antiseize

Lubricant

1. Cap screw (2 used per bearing)

2. Flange nut (2 used per bearing)

3. Adjuster plate (2 used)

4. Flange head screw (2 used)

5. Jam nut (4 used)

6. Flange bearing (3 used)

7. Bearing guard (3 used)

Figure 43

8. Idler roller

9. Conveyor cover

10. Conveyor belt

11. Hydraulichose(2used)

12. O--ring

13. Hydraulic straight fitting (2 used)

14. O--ring

15. Drive roller

16. Set screw

17. Conveyor motor

18. Lock nut (2 used)

19. Flange nut (2 used)

20. Woodruff key

21. Motor spacer plate

ProPass 200Page 3 -- 44Hydraulic System

Page 59

Removal (Fig. 43)

8. Remove two (2) flange head screws (item 19) and lock nuts (item 18) that secure 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.

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.

CAUTION

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 hydraulic lines and fittings to prevent contamination.

6. Support drive roller (item 15) to prevent it from shifting.

7. Loosen set screw (item 16) that secures drive roller to conveyor motor shaft.

10.If necessary,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. If removed, 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 andthenslidemotorshaftintodriveroller.

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 hydraulic 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 (refer to conveyor belt tensioning procedure in ProPass 200 Operator’s Manual).

System

Hydraulic

ProPass 200 Page 3 -- 45 Hydraulic System

Page 60

Rear Option Motor Service

Loctite #277

250 in --lb (28 N--m)

Figure 44

1. Cap screw (7 used)

2. End cap

3. Seal (3 used)

4. Geroler assembly

5. Spacer plate

6. Drive

7. Housing

8. Output shaft

9. Woodruff key

10. Thrust bearing

11. Bearing race

12. Seal

The hydraulic motor used for the ProPass rear option (twin spinner or conveyor) is the same basic motor regardless of which option e xists. The left sidespinner motor has a hydraulic case drain hose attached to a 90 fitting installed in the end cap. The right side spinner motor and conveyor motor do not use a case drain hose so the end cap includes a plug.

235 to 250 in-- lb

(27 to 28 N--m)

13. Pressure seal

14. Backup ring

15. Mounting flange

16. Exclusion seal

17. Cap screw (4 used)

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.

ProPass 200Page 3 -- 46Hydraulic System

Page 61

Table of Contents

GENERAL INFORMATION 3.....................

Operator’s Manual 3..........................

Machine Hydraulic Control 3...................

ELECTRICAL SCHEMATICS 4...................

ProPass with Standard Hydraulic Controls 4......

ProPass with Electronic Hydraulic Controls 5.....

WIRE HARNESS DRAWINGS 6..................

Power Lead Wire Harness 6...................

Hydraulic Power Pack Power Lead

Wire Harness 6.............................

Intermediate Power Wire Harness 7.............

Main Valve Wire Harness (Standard Hydraulic

Controls) 8.................................

Pendant Wire Harness (Standard Hydraulic

Controls) 9.................................

Bulkhead Wire Harness (Electronic Hydraulic

Controls) 10................................

SPECIAL TOOLS 12............................

TROUBLESHOOTING 14........................

COMPONENT TESTING 16......................

E--Stop Button (Machines with Electronic

Hydraulic Controls) 16.......................

Pendant Assembly (Machines with Standard

Hydraulic Controls) 17.......................

Wireless Remote (Machines with Electronic

Hydraulic Controls) 18.......................

Wireless Remote Base Unit (Machines with

Electronic Hydraulic Controls) 20..............

Hydraulic Solenoid Valve Coils 21...............

Chapter 4

Electrical System

System

Electrical

ProPass 200 Electrical SystemPage 4 -- 1

Page 62

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ProPass 200Electrical System Page 4 -- 2

Page 63

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 Operator’s Manual for additional information when servicing the machine.

Machine Hydraulic Control

ProPass 200 machines use either standard hydraulic controls or electronic hydraulic controls to allow the operator to change machine settings.

Machines with electronic hydraulic controls include a wireless remote to electrically adjust hydraulic flow to the floor and rear option (twin spinner or conveyor) motors (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 button on the machine disables the electrical system to prevent unexpected machine operation.

1. Floor control

2. Rear option control

1. Wireless remote

2. E--Stop button

Figure 1

3. Pendant harness

Figure 2

3. Power lead harness

4. Optional power pack

System

Electrical

ProPass 200 Electrical SystemPage 4 -- 3

Page 64

Electrical Schematics

Machines with Standard Hydraulic Controls

PENDANT

ASSEMBLY

FLOOR

SWITCH

GREEN

FLOOR

SOLENOID

VALVE

WHITE

BLACK

REAR

OPTION

SWITCH

WHITE

NOTE: Electrical power is provided by either the tow vehicle or the hydraulic power pack.

Figure 3

15A FUSE

WHITE

POWER SUPPLY

15A FUSE

BLACK

REAR OPTION

SOLENOID

VALV E

BLACK

ProPass 200Electrical System Page 4 -- 4

Page 65

Machines with Electronic Hydraulic Controls

E--STOP

BUTTON

FLOOR

SP1

(LOWER

COIL)

BASE

UNIT

WIRELESS

REMOTE

NOTE: Electrical power is provided by either the tow vehicle or the hydraulic power pack.

CONTROL

MANIFOLD

Figure 4

REAR OPTION PV1

TOW VEHICLE

POWER LEAD

HARNESS

POWER LEAD

HARNESS

INCLUDES

15 AMP

IN--LINE FUSE

HYDRAULIC

POWER PACK

POWER LEAD

HARNESS

System

Electrical

ProPass 200 Electrical SystemPage 4 -- 5

Page 66

Wire Harness Drawings

P01

BLACK

WHITE

Figure 5

P02

J01

WHITE

PROPASS 200 POWER LEAD WIRE HARNESS (FROM TOW VEHICLE)

J02

P01

BLACK YELLOW

Figure 6

P02

J02

RED

PROPASS 200 POWER LEAD WIRE HARNESS (FROM HYDRAULIC POWER PACK)

J01

ProPass 200Electrical System Page 4 -- 6

Page 67

BLACK

WHITE

Figure 7

PROPASS 200 INTERMEDIATE POWER WIRE HARNESS

System

Electrical

ProPass 200 Electrical SystemPage 4 -- 7

Page 68

BLACK WHITE

GREEN WHITE

BROWN

BLACK

Figure 8

BLACK

PROPASS 200 MAINVALVEWIREHARNESS STANDARD HYDRAULIC CONTROLS

BLACK

ProPass 200Electrical System Page 4 -- 8

Page 69

P01

J03

J02

J04

J01

P01

Figure 9

GREEN

WHITE

BLACK

PROPASS 200 PENDANT WIRE HARNESS STANDARD HYDRAULIC CONTROLS

J01

OPTION SWITCH

J02

J03

FLOOR SWITCH

J04

System

Electrical

ProPass 200 Electrical SystemPage 4 -- 9

Page 70

BASE UNIT

BASE

UNIT

BLACK

Figure 10

YELLOW

PINK

BLACK

BLUE

GREEN

PROPASS 200 BULKHEAD WIRE HARNESS ELECTRONIC HYDRAULIC CONTROLS

ProPass 200Electrical System Page 4 -- 10

Page 71

This page is intentionally blank.

System

Electrical

ProPass 200 Electrical SystemPage 4 -- 11

Page 72

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 circuits for current (amps), resistance (ohms) or voltage. Obtain this tool locally.

NOTE: Toro recommends the use of a DIGITAL Volt-Ohm--Amp multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital meter in the voltage mode will make sure that excess current is not allowed through the meter. This excess current can cause damage to circuits not designed to carry it.

Figure 11

Dielectric Lubricant/Sealant

Dielectric lubricant should be used to prevent corrosion of non--sealed connection terminals. To ensure complete coating of terminals, liberally apply lubricant to both component and wire harness connector, plug connector to component, unplug connector, reapply lubricant 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 protective skin t o help waterproof electrical switches and contacts.

Toro Part Number: TOR50547

Figure 12

Figure 13

ProPass 200Electrical System Page 4 -- 12

Page 73

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 specific gravity of battery electrolyte. Obtain this tool locally.

Figure 14

Figure 15

System

Electrical

ProPass 200 Electrical SystemPage 4 -- 13

Page 74

Tr oubleshooting

CAUTION

Remove all jewelry, especially rings and watches, before doing any electrical troubleshooting 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 components used on this machine (see Electrical Schematics in this chapter).

If the machine has any interlock switches by--passed, reconnect the switches for proper safety and troubleshooting.

Problem

No ProPass functions operate (machines with standard hydraulics).

No ProPass functions operate (machines with electronic hydraulics). NOTE: Check wireless remote LCD display and base unit LED’s for help in troubleshooting.

Possible Causes

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).

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) minutes of inactivity.

Rear option does not function (machines with standard hydraulics).

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 200Electrical System Page 4 -- 14

Page 75

Problem Possible Causes

Rear option does not function (machines with electronic hydraulics). NOTE: Start button on remote must be pushed twice t o activate rear option. Also, check wireless remote LCD display and base unit LED’s for help in troubleshooting.

Floor does not function (machines with standard hydraulics).

Floor does not function (machines with electronic hydraulics). NOTE: Check wireless remote LCD display and base unit LED’s for help in troubleshooting.

Wireless remote has not been turned ON.

Wireless remote has timed out due to thirty (30) minutes of inactivity.

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.

FloorswitchinpendantisOFF.

Floor switch in pendant is faulty.

Floor solenoid valve coil or circuit wiring is faulty.

Hydraulic problem exists (see Chapter 3 -- Hydraulic System).

Wireless remote has not been turned ON.

Make sure that floor start--up procedure has been correctly completed with remote.

Wireless remote has timed out due to thirty (30) minutes of inactivity.

System

Electrical

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 Electrical SystemPage 4 -- 15

Page 76

Component Testing

For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g. unplug the wire harness connector from component before checking continuity on the component terminals).

E--Stop Button (Machines with Electronic Hydraulic Controls)

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

CAUTION

On ProPass machines with electronic hydraulic controls, 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).

TheE--stopbuttonisatwo(2)positionswitchwithtwo (2) terminals that can be tested with a multimeter. Make sure that electrical power to the E--stop button is disconnected before testing the button. Disconnect E--stop button connector from machine wire harness. Check the continuity of the button by connecting a multimeter (ohms setting) across the button harness connector terminals. There should not be continuity (infinite ohms) between the connector terminals when the button is pressed in. When the button is pulled o ut, there should be continuity (zero ohms) between the connector terminals.

If E--stop button testing determines that the button is faulty, remove button from control panel guard and replace button assembly. Make sure that wire harness connector is attached to the button after testing and/or replacement.

FRONT

1. E--Stop button

2. Screw (2 used)

Figure 16

3. Control panel guard

ProPass 200Electrical System Page 4 -- 16

Page 77

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 junction 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 access the switch terminals for testing, remove the cover from the bottom of the junction box. Make sure that electrical power to the switches is disconnected before testing the switches. Use a multimeter to check the switch for continuity. There should not be continuity between the switch terminals when the switch is in the OFF position 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, remove switch from junction box and replace switch (Fig.

18). Make sure that wire harness connectors are attached to correct switch terminals (Fig. 19).

1. Rear option switch

2. Floor switch

Figure 17

3. Junction box

4. Wire harness

1. Rear option switch

2. Floor switch

3. Junction box

4. Switch guard

TOP VIEW OF SWITCHES

WIRE

BLACK

WIRE

OFF

POSITION

Figure 18

5. Pop rivet (2 used)

6. Switch boot (2 used)

7. Washer

8. Wire harness

WHITE

WIREWHITE

GREEN

WIRE

OFF POSITION

System

Electrical

ProPass 200 Electrical SystemPage 4 -- 17

Figure 19

1. Spinner switch 2. Floor switch

Page 78

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 electrical operation. The wireless remote has sufficient range to send an RF signal to the remote base unit from the tow vehicle operator position.

The wireless remote uses two (2) LED’s to indicate remote 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.

LCD Display

The wireless remote LCD display can be used to identify activity between the remote and the base unit. LCD display messages are included on the following page.

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 operation.

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 displayed on the remote LCD display, the batteries should be replaced. Remove 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 OPTION STOP buttons simultaneously results in display of battery life expectancy.

Figure 20

1. LCD display

2. Controller status LED’s

3. All start button

4. ON/OFF button

5. Store button

6. Preset 1 button

7. Preset 2 button

8. Preset 3 button

9. All stop button

10. Floor start button

11. Floor stop button

12. Floor speed increase

13. Floor speed decrease

14. Option start button

15. Option stop button

16. Option speed increase

17. Option speed decrease

1. Rear of remote

2. Battery cover

Figure 21

3. Battery location

ProPass 200Electrical System Page 4 -- 18

Page 79

Displayed Message Meaning

ASSOC PENDING Association between remote and base unit has yet to be made.

ASSOC ACTIVE Associationattemptbetweenremoteandbaseunitisinprogress.

CLR CHAN SCAN Ascantofindaclearchannelisinprogress.

POW UP BUNIT Thebaseunitisbeingpoweredup.

ASSOC SUCCESS Association between remote and base unit has been made.

ALL STORE Store all currently set values into memory.

OPTION STORE Store the current rear option settings into memory.

FLOOR STORE Store the current floor settings into memory.

PRESET 1 STORE Store the current PRESET 1 setting into memory.

PRESET 2 STORE Store the current PRESET 2 setting into memory.

PRESET 3 STORE Store the current PRESET 3 setting into memory.

WAITING FOR BASE Remote is waiting for a response from the base unit (NOTE: Make

sure that E--Stop button is pulled out and all electrical components are connected).

COMMAND POW DOWN Operator has pressed the ON/OFF button to power down.

LOWBATPOWDOWN Cyclic warning that the remote batteries are low and need to be

changed.

INACTIV POW DOWN Automatic shutdown after thirty (30) minutes of remote button in-

activity.

SOFTWARE VER XX Software version XX is being used.

BAT XX% BUMPS XX

Remaining battery life in percentage. Number of base unit messages per second being received. NOTE: See Operator’s Manual for procedure to access these display features.

CHANNEL X Channel in Ghz currently being used for communication between

remote and base unit. NOTE: If area interference prevents reliable remote communications, re--associating the remote to the base unit might access different channel with less interference (see Operator’s Manual for association procedure).

HHELD ID XXXXXX Identity of the wireless remote. NOTE: See Operator’s Manual for

procedure to access this display feature.

BUINT ID XXXXXX Identity of the base unit. NOTE: See Operator’s Manual for proced-

ure to access this display feature.

FLRS XX% OPTS XX%

Display of the stored floor speed or rear option speed percents after initially pressing floor start or option start button. The operator can either accept the stored setting or change it before starting the floor or rear option by pressing the start button a second time.

System

Electrical

FLR XX% OPT XX%

SW STUCK XXXXXX

ProPass 200 Electrical SystemPage 4 -- 19

During floor operation, the current floor speed in percent. During rear option operation, the current rear speed in percent.

Remote button is stuck. XXXXXX identifies the button that is stuck.

Page 80

Wireless Remote Base Unit (Machines with Electronic Hydraulic Controls)

The base unit is a solid state electrical device that receives 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 the 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 wireless remote (see Wireless Remote (Machines with Electronic 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.

1. Base unit

2. Screw (2 used)

3. Flange nut (2 used)

Figure 22

4. Front hopper wall

5. Hydraulic manifold

6. Bulkhead wire harness

FRONT

IMPORTANT: To prevent damage to the base unit, disconnect the wire harness connector from the base unit before performing any welding on the machine.

LED Operation

Four (4) status/diagnostic LED’s can be used to determine 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 communication between the base unit and the wireless remote is functioning. If this LED is blinking amber, an internal base unit problem exists. If 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.

1. Base unit

2. Out LED

3. Health LED

Figure 23

4. TX/RX LED

5. Power LED

The POWER LED will be amber when power exists to the base unit. If this LED is either red or green, an internal base unit problem exists.

ProPass 200Electrical System Page 4 -- 20

Page 81

Hydraulic Solenoid Valve Coils

The ProPass hydraulic system uses several hydraulic solenoid valve coils for system control. When the solenoid 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 a ssemblies 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 different coil.

Testing of the hydraulic 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.

Test i ng

2. Locate solenoid coil that is to be tested on hydraulic control manifold.

5. If solenoid coil resistance is incorrect, replace solenoid coil (see Solenoid Valve Assembly (Machines with Standard HydraulicControls) or Hydraulic Control Manifold (Machines with Electronic Hydraulic Controls) in the Service and Repairs section of Chapter 3 -- Hydraulic System).

6. When testing is complete, connect wire harness electrical connector to the solenoid valve coil.

STANDARD HYDRAULIC CONTROL MANIFOLD

Figure 24

1. Manifold 2. 1.960” solenoid coil

System

Electrical

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 with a 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 value from from the measured value of the component you are testing.

4. Using a multimeter (ohms setting), measure resistance between the two (2) connector terminals on the solenoid valve coil. The resistance for the solenoid c oils is identified below:

Solenoid Coil Height

Resistance

1.960” (49.8 mm) 7.1 ohms

2.450” (62.2 mm) 4.5 ohms

ELECTRONIC HYDRAULIC CONTROL MANIFOLD

Figure 25

1. Manifold

2. 2.450” solenoid coil

3. 1.960” solenoid coil

ProPass 200 Electrical SystemPage 4 -- 21

Page 82

This page is intentionally blank.

ProPass 200Electrical System Page 4 -- 22

Page 83

Table of Contents

GENERAL INFORMATION 3.....................

Operator’s Manual 3..........................

Parts Catalog 3...............................

SERVICE AND REPAIRS 4......................

Bed Guards 4................................

Floor Motor Drive 6...........................

Drive Roller Bearings 8........................

Floor Conveyor Belt 10........................

Idler and Drive Rollers 12......................

Idler Roller Take Up Bearings 14................

Wheel Assemblies (Tow Chassis) 16............

Wheel Bearing Service (Tow Chassis) 18........

Walking Beam Assembly (Tow Chassis) 20.......

Chapter 5

Chassis

ProPass 200 Page 5 -- 1 Chassis

Chassis

Page 84

This page is intentionally blank.

ProPass 200Page 5 -- 2Chassis

Page 85

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 this publication for additional information when servicing the machine.

Parts Catalog

The Parts Catalog can be used to provide general disassembly 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

Chassis

Page 86

Service and Repairs

Bed Guards

RIGHT

FRONT

1. Bottom guard

2. RH drive guard

3. Guard cap

4. LH idler guard

5. RH idler guard

6. LH drive guard

7. Front rinse guard

8. Shoulder nut (2 used)

9. Lanyard (2 used)

10. Flat washer (2 used)

11. Rivet (2 used)

Figure 1

12. Cap screw (2 used)

13. Cap screw

14. Screw retainer

15. Cap screw

16. Flange nut

ProPass 200Page 5 -- 4Chassis

Page 87

Disassembly (Fig. 1)

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.

MACHINES WITH ELECTRONIC

HYDRAULIC CONTROLS

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 manifold to rinse guard.

D. Raise and support hydraulic manifold away from rinse guard.

3. Using Figure 1 as a guide, remove necessary bed guards from frame to allow access to floor drive components.

Assembly (Fig. 1)

1. Secure all removed bed guards to frame using Figure 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).

1. E--stop button

2. Control panel guard

3. Screw (2 used)

4. Flange nut (2 used)

5. Flat washer (2 used)

6. Cap screw (2 used)

Figure 2

7. Hydraulic manifold

8. Cap screw (2 used)

9. Lock washer (2 used)

10. Flat washer (2 used)

11. Front rinse guard

Chassis

ProPass 200 Page 5 -- 5 Chassis

Page 88

Floor Motor Drive

Loctite #242

Antiseize

Lubricant

Antiseize Lubricant

FRONT

Direction

Of Rotation

RIGHT

1. Drive chain

2. Hydraulic floor motor

3. Sprocket

4. Sprocket

5. Idler sprocket

6. Cap screw

Figure 3

7. Flat washer (2 used)

8. Lock nut

9. Cap screw (2 used)

10. Lock nut (2 used)

11. C ap screw

12. Flat washer

13. Square key

14. Spacer

15. Set screw (2 used per sprocket)

16. Master link

17. Woodruff key

18. Drive roller shaft

ProPass 200Page 5 -- 6Chassis

Page 89

Disassembly (Fig. 3)

2. Remove 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 remove tension from drive chain.

4. Locate and remove master link (item 16) from drive chain. Notedirection of masterlink clip forassembly purposes. 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.

NOTE: If floor motor (item 2) needs to be removed, see Floor Motor in the Service and Repairs section of Chapter 3 -- Hydraulic System.

Assembly (Fig. 3)

1. Apply antiseize lubricant to drive roller shaft.

2. Position square key to slot in drive roller shaft and then slide sprocket (item 3) onto shaft.

1. Guard cap

2. Cap screw (3 used)

3. RH drive guard

4. Cap screw (2 used)

5. Flat washer (2 used)

FRONT

Figure 4

6. Lanyard (2 used)

7. Shoulder nut (2 used)

8. Rivet (2 used)

9. Screw retainer

3. Fit drive chain o nto 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.

NOTE: Direction of normal roller rotation is shown in 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).

1. Drive roller

2. Idler roller

Figure 5

Chassis

3. RH conveyor frame

4. Rotation direction

ProPass 200 Page 5 -- 7 Chassis

Page 90

Drive Roller Bearings

Loctite #242

RIGHT

FRONT

1. Set screw

2. Locking collar

3. Lock nut (4 used per bearing)

Figure 6

4. Bearing assembly

5. Drive roller shaft

6. Cap screw (4 used per bearing)

7. Alignment plate

8. Idler roller shaft

Loctite #242

Use this procedure for service of the drive roller bearings at the rear of the machine.

Disassembly (Fig. 6)

1. Position machine on a level surface. If ProPass is attached to tow vehicle, apply tow vehicle parking brake, stop engine and remove key from the ignition switch. Chock wheels to prevent ProPass machine from moving.

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 floor conveyor belt. If locking jam nut is left in position, applying correct tension to conveyor belt will be easier during assembly.

C. Repeat for other side of machine.

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 Figure9asviewedfromleftsideofconveyor.

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 p ossible. This will reduce the need for re--aligning 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.

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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 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 direction 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. On both sides of machine, apply tension to floor conveyor 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 tension, check for trapped spreading material between conveyor bed, belt and rollers. Clean machine as recommended in Operator’s manual.

1. Tensioner rod

2. Locking jam nut

1. Locking collar

2. Set screw

3. Blind hole

Figure 7

Figure 8

3. Adjusting jam nut

4. Take up bearing

Chassis

4. Drive roller shaft

5. Lock nut (4 used)

6. Check and adjust conveyor belt tension as needed (refer to Operator’s Manual).

ProPass 200 Page 5 -- 9 Chassis

1. Drive roller

2. Idler roller

FRONT

Figure 9

3. LH conveyor frame

4. Rotation direction

Page 92

Floor Conveyor Belt

RIGHT

FRONT

1. LH conveyor frame assembly

2. Conveyor bed assembly

3. RH conveyor frame assembly

4. Floor conveyor belt

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 conveyor frame.

Removal (Fig. 10)

1. Position machine on a level surface. If ProPass is attached to tow vehicle, apply tow vehicle parking brake, stop engine and remove key from the ignition switch. Chock wheels to prevent ProPass machine from moving.

2. Disconnect electrical power to ProPass machine.

Figure 10

5. Idler roller

6. Drive roller

7. Scraper assembly

8. Cap screw (4 used)

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 conveyor) 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 at idler roller shaft (see Drive Roller Bearings 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 200Page 5 -- 10Chassis

Page 93

7. Remove fasteners (four (4) cap screws, washers and lock nuts) that secure scraper assembly (item 7) to conveyor frame. Remove scraper assembly.

B. Inspect rubber skirts that seal the hopper and conveyor belt. If skirts are worn or damaged, replace them before installing hopper 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).

CAUTION

To prevent personal injury, make sure that hopper assembly is properly supported as it is raised from the machine. Hopper assembly (without hydraulic 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 thatsecure hopper assemblywith gate assembly to machine frame (Fig. 11). Once all fasteners have been removed, raise the hopper assembly enough so that left side of conveyor frame can be removed. Support hopper above the machine.

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 withapunchinthedirectionof shaft rotation. Also, apply Loctite #242 (or equivalent) to threads of locking collar set screws before installing set screws in collars.

E. Before installing drive guards, idler guards, bottom guard and front rinse guard to machine, adjust conveyor belt tension and tracking (refer to Operator’s Manual).

F. Make sure that rake tines on gate assembly are not scratching the floor belt after assembly is complete.

G. Grease all four (4) bearings after installation is complete.

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 or tow chassis.

12.Support idler roller, drive roller and conveyor bed assembly 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, remove 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:

1. Drive roller shaft

2. Drive roller bearing

3. Idler roller bearing

4. Idler roller shaft

Chassis

Figure 11

5. Flange nut (16 used)

6. Screw (16 used)

7. Hopper assembly

8. Belt rotation direction

A. Make sure that v-- guide on bottom of conveyor belt is in the guides of both idler and drive rollers.

ProPass 200 Page 5 -- 11 Chassis

Page 94

Idler and Drive Rollers

RIGHT

FRONT

1. LH conveyor frame assembly

2. Conveyor bed assembly

3. RH conveyor frame assembly

4. Floor conveyor belt

To remove and replace the idler and drive rollers, removal 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.

Figure 12

5. Idler roller

6. Drive roller

7. Scraper assembly

8. Cap screw (4 used)

9. Flat washer (8 used)

10. Lock nut (4 used)

11. Flange head screw (10 used)

12. Flange nut (10 used)

ProPass 200Page 5 -- 12Chassis

Page 95

Removal (Fig. 12)

Installation (Fig. 12)

2. Remove left side conveyor frame and the floor conveyor belt (see Floor Conveyor Belt in this section).

3. If drive roller is to be removed:

A. Remove drive chain and sprocket from drive roller(seeFloorMotorDrive 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. If 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).

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 a re centered in the frame.

1. Insert removed roller into bearing on right side conveyor 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 section). 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 complete.

B. Slide idler roller from bearing and remove from machine.

Chassis

ProPass 200 Page 5 -- 13 Chassis

Page 96

Idler Roller Take Up Bearings

RIGHT

FRONT

1. LH conveyor frame assembly

2. Conveyor bed assembly

3. RH conveyor frame assembly

4. Floor conveyor belt

5. Idler roller

6. Drive roller

7. Scraper assembly

8. Cap screw (4 used)

9. Flat washer (8 used)

10. Lock nut (4 used)

11. Flange head screw (10 used)

12. Flange nut (10 used)

13. Tensioner rod

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 removed, access to the left side take up bearing is possible. 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.

Figure 13

Loctite #242

14. Jam nut

15. Flat washer

16. Take up bearing

17. Locking collar

18. Set screw

19. Grease fitting

ProPass 200Page 5 -- 14Chassis

Page 97

Disassembly (Fig. 13)

2. Remove left side conveyor frame and the floor conveyor 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 grooves 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 as a guide. Do not tighten locking or adjusting jam nuts until conveyor belt is properly adjusted.

3. If idler 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 section). 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 complete.

1. Tensioner rod

2. Locking jam nut

Figure 14

3. Adjusting jam nut

4. Take up bearing

Chassis

ProPass 200 Page 5 -- 15 Chassis

Page 98

Wheel Assemblies (Tow Chassis)

RIGHT

FRONT

240 to 292 ft--lb

(322 to 396 N-- m)

135 to 165 ft--lb

(183 to 223 N--m)

94 to 116 ft--lb

(128 to 157 N--m)

70 to 90 ft--lb

(95 to 122 N-- m)

1. Floor assembly

2. Hitch

3. Hitch clevis

4. Jack

5. Walking beam bearing (4 used)

6. Walking beam assembly (2 used)

7. Wheel assembly (4 used)

8. Cap screw (2 used)

9. Flat washer (4 used)

10. Lock nut (2 used)

11. Cap screw (2 used)

12. Flat washer (4 used)

13. Lock nut (2 used)

14. Cap screw (8 used)

15. Flat washer (8 used)

16. Flange nut (8 used)

17. Grease fitting (4 used)

18. Flange head screw (8 used)

19. Flange head screw (6 used)

20. Flange nut (6 used)

NOTE: The outer wheels can be removed with the

walking beam (item 6) attached to the ProPass machine. If an inner wheel needs to be removed, walking beam removal is necessary (see Walking Beam Assembly in this section).

Figure 15

21. Top cross member (2 used)

22. Frame brace

23. Cross member (2 used)

24. Lock nut (20 used)

25. Flange head screw (12 used)

26. Front brace

27. Hitch pin

28. Lynch pin

29. Lug nut (5 used per wheel)

ProPass 200Page 5 -- 16Chassis

Page 99

Wheel Removal (Fig. 15)

Wheel Installation (Fig. 15)

1. Position ProPass on a level surface attached to towing vehicle. Apply vehicle parking brake, stop engine and remove key from the ignition switch. Chock ProPass wheels to prevent machine from moving.

2. Jack or hoist ProPass from ground and support machine with appropriate jack stands.

3. If removal of inner wheel assemblies is necessary, remove walking b eam 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.

1. Position wheel to wheel hub.

2. Secure wheel to wheel hub with five (5) lug nuts.

WARNING

Failure to maintain proper lug nut torque could result in failure or loss of wheel and may 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 machine (see Walking Beam Assembly in this section).

5. Carefullylowermachinetoground.

ProPass 200 Page 5 -- 17 Chassis

Chassis

Page 100

Wheel Bearing Service (Tow Chassis)

See Text for

Tightening Procedure

1. Walking beam axle

2. Hub (2 used per axle)

3. Bearing cone (2 used per hub)

4. Seal

5. Bearing cup (2 used per hub)

6. Dust cap

7. Spindle washer

8. Spindle nut

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 Assembly in this section).

Figure 16

9. Nut retainer

10. Cotter pin

11. Wheel stud (5 used per hub)

6. Remove cotter 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.

Removal (Fig. 16)

2. Jack or hoist ProPass from ground and support machine with appropriate jack stands.

3. If inner wheel bearings are to be serviced, remove walking beam from machine (see Walking Beam Assembly in this section).

4. Remove wheel assembly (see Wheel Assemblies in this section).

5. Carefully pry dust cap from wheel hub.

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 using 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 200Page 5 -- 18Chassis