Toro ProPass 200 Service Manual
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Toro ProPass 200 Service Manual

Toro ProPass 200 Service Manual

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See also: Operator's 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 OPER-
ATING, MAINTENANCE AND ADJUSTMENT IN-
STRUCTIONS. For reference, insert a copy of the
Operator's Manual and Parts Catalog for your machine
into Chapter 2 of this service manual. Additional copies
of the Operator's Manual and Parts Catalog are avail-
able on the internet at www.Toro.com.
The Toro Company reserves the right to change product
specifications or this publication without notice.
This safety symbol means DANGER, WARNING,
or CAUTION, PERSONAL SAFETY INSTRUC-
TION. When you see this symbol, carefully read
the instructions that follow. Failure to obey the
instructions may result in personal injury.
NOTE: A NOTE will give general information about the
correct operation, maintenance, service, testing or re-
pair of the machine.
IMPORTANT: The IMPORTANT notice will give im-
portant instructions which must be followed to pre-
vent damage to systems or components on the
machine.
E The Toro Company - - 2014
Part No. 14204SL
Service Manual
ProPass
R
200

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  • Page 1 The Toro Company reserves the right to change product specifications or this publication without notice. IMPORTANT: The IMPORTANT notice will give im- portant instructions which must be followed to pre- vent damage to systems or components on the machine.
  • Page 2 This page is intentionally blank. ProPass 200...

  • Page 3: Table Of Contents

    ..... . . 3 -- 26 MANUAL EATON (CHAR--LYNN) S--SERIES GENERAL PURPOSE MOTORS PARTS and REPAIR MANUAL EATON (CHAR--LYNN) R--SERIES GENERAL PURPOSE GEROLER MOTOR REPAIR INFORMATION ProPass 200...
  • Page 4 This page is intentionally blank. ProPass 200...

  • Page 5: General Safety Instructions 1

    ....SAFETY AND INSTRUCTION DECALS ..ProPass 200 Page 1 - - 1 Safety...

  • Page 6: General Safety Instructions

    General Safety Instructions The ProPass 200 has been tested and certified by TORO for compliance with existing safety standards WARNING and specifications. Although hazard control and acci- dent prevention partially are dependent upon the design To reduce the potential for injury or death, and configuration of the machine, these factors are also comply with the following safety instructions.

  • Page 7: Maintenance And Service

    ProPass electrical system before working on the ma- machine, use genuine Toro replacement parts and ac- chine. Pull the button out when machine is to be returned cessories. Replacement parts and accessories made to use.

  • Page 8: Safety And Instruction Decals

    Safety and Instruction Decals Numerous safety and instruction decals are affixed to the ProPass 200. If any decal becomes illegible or dam- aged, install a new decal. Decal part numbers are listed in your Parts Catalog. Safety Page 1 - - 4...

  • Page 9: Product Records

    Operator’s Manuals. If machine is equipped with the hy- draulic 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

    Equivalents and Conversions 0.09375 Product Records and Maintenance Page 2 - - 2 ProPass 200...

  • Page 11: Torque Specifications

    For critical applications, as determined reduced by 25% for lubricated fasteners to achieve by Toro, either the recommended torque or a torque that the similar stress as a dry fastener. Torque values may is unique to the application is clearly identified and spe- also have to be reduced when the fastener is threaded cified in this Service Manual.
  • Page 12 The specific torque value should be determined based on the fastener size, the aluminum or base material strength, length of thread engagement, etc. Product Records and Maintenance Page 2 - - 4 ProPass 200...
  • Page 13 The specific torque value should be determined based on the fastener size, the aluminum or base material strength, length of thread engagement, etc. ProPass 200 Page 2 - - 5 Product Records and Maintenance...
  • Page 14 Conversion Factors in- -lb X 11.2985 = N- -cm N- -cm X 0.08851 = in- -lb ft- -lb X 1.3558 = N- -m N- -m X 0.7376 = ft- -lb Product Records and Maintenance Page 2 - - 6 ProPass 200...

  • Page 15: General Information 3

    ....... INFORMATION ProPass 200 Page 3 - - 1 Hydraulic System...

  • Page 16: Specifications

    ProPass. If hydraulic power pack provides hydraulic supply, see Chapter 6 -- Hydraulic Power Pack Assembly for inform- ation regarding hydraulic circuit flow and relief pressure specifications. Hydraulic System Page 3 - - 2 ProPass 200...

  • Page 17: General Information

    TOW VEHICLE Figure 1 1. Hydraulic hose (supply) 5. O- -ring 2. Hydraulic hose (return) 6. Check valve 3. Dust cap 7. O- -ring 4. Male coupler ProPass 200 Page 3 - - 3 Hydraulic System...
  • Page 18 Machine Hydraulic Control ProPass 200 machines use either standard hydraulic controls or electronic hydraulic controls to allow the op- erator to change machine settings. Standard Hydraulic Controls Machines with standard hydraulic controls include manual hydraulic controls on the front of the ProPass hopper to adjust hydraulic flow to the floor and rear op- tion (twin spinner or conveyor) motors (Fig.

  • Page 19: Rear Option

    Position machine on a level surface. Turn tow vehicle key switch to OFF and allow engine to stop. If ProPass is equipped with hydraulic power pack, make sure that power pack engine is turned off. ProPass 200 Page 3 - - 5 Hydraulic System...

  • Page 20: Hydraulic Hoses

    Tube Installation in this section). If the hose has an el- bow at one end, tighten the swivel nut on that end before tightening the nut on the straight end of the hose. For additional hydraulic hose information, refer to Toro Service Training Book, Hydraulic Hose Servicing (Part Number 94813SL).
  • Page 21 85 to 105 ft--lb (116 to 142 N--m) 1 7/16 -- 12 110 to 136 ft--lb (150 to 184 N--m) 1 11/16 -- 12 140 to 172 ft--lb (190 to 233 N--m) Figure 9 ProPass 200 Page 3 - - 7 Hydraulic System...
  • Page 22 66 to 82 ft--lb (90 to 111 N--m) 1 3/16 -- 12 80 to 98 ft--lb (109 to 132 N--m) 1 5/16 -- 12 90 to 110 ft--lb (122 to 149 N--m) Figure 12 Hydraulic System Page 3 - - 8 ProPass 200...
  • Page 23 202 to 248 ft--lb (274 to 336 N--m) 121 to 149 ft--lb (165 to 202 N--m) 1 5/8 -- 12 247 to 303 ft--lb (335 to 410 N--m) 149 to 183 ft--lb (202 to 248 N--m) Figure 14 ProPass 200 Page 3 - - 9 Hydraulic System...
  • Page 24 1.00 + 0.25 6 (3/8 in.) 1.50 + 0.25 8 (1/2 in.) 1.50 + 0.25 10 (5/8 in.) 1.50 + 0.25 12 (3/4 in.) 1.50 + 0.25 16 (1 in.) 1.50 + 0.25 Hydraulic System Page 3 - - 10 ProPass 200...
  • Page 25 153 to 187 ft--lb (208 to 253 N--m) 76 to 94 ft--lb (103 to 127 N--m) 1 5/8 -- 12 213 to 261 ft--lb (289 to 353 N--m) 107 to 131 ft--lb (145 to 177 N--m) Figure 18 ProPass 200 Page 3 - - 11 Hydraulic System...

  • Page 26: Hydraulic Schematics

    FLOOR MOTORS MOTOR HYDRAULIC POWER PACK CONVEYOR MOTOR ProPass 200 Hydraulic Schematic Standard Hydraulic Controls All solenoids are shown as de- -energized NOTE: The hydraulic schematic shown above includes NOTE: The hydraulic hose kit used when a ProPass re- the hydraulic power pack as the hydraulic supply ceives its hydraulic supply from a tow vehicle includes source.
  • Page 27 (0.020) CONTROL MANIFOLD CONVEYOR MOTOR HYDRAULIC POWER PACK ProPass 200 Hydraulic Schematic Electronic Hydraulic Controls All solenoids are shown as de- -energized NOTE: The hydraulic schematic shown above includes NOTE: The hydraulic hose kit used when a ProPass re- the hydraulic power pack as the hydraulic supply ceives its hydraulic supply from a tow vehicle includes source.

  • Page 28: Hydraulic Flow Diagrams: Standard Hydraulic Controls

    SPINNER FLOOR MOTORS MOTOR HYDRAULIC POWER PACK Both floor solenoid valve and option solenoid valve are energized. Excess and return flow will be routed to hydraulic reservoir. Working Pressure Return Flow Hydraulic System Page 3 - - 14 ProPass 200...

  • Page 29: Rear Option Circuit (Twin Spinner Or Conveyor)

    The floor and rear option will remain in the stationary po- pack. sitions. ProPass 200 Page 3 - - 15 Hydraulic System...

  • Page 30: Hydraulic Flow Diagrams: Electronic Hydraulic Controls

    SP1 is not energized. PV1 is energized. Working Pressure Both EC1 and PV1 shift to allow flow to rear option motors. Return Excess and return flow will be routed Flow to hydraulic reservoir. Hydraulic System Page 3 - - 16 ProPass 200...
  • Page 31 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.
  • Page 32 SP1 and PV1 are both energized. Both EC1 and PV1 shift to allow proportional Working Pressure flow to rear option and floor motors. Excess and return flow will be directed to Return hydraulic reservoir. Flow Hydraulic System Page 3 - - 18 ProPass 200...
  • Page 33 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.

  • Page 34: Special Tools

    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.
  • Page 35 This kit includes O--rings in a variety of sizes for face seal and port seal hydraulic connections. It is recom- mended that O--rings be replaced whenever a hydraulic connection is loosened. Toro Part Number: 117- -2727 Figure 25 ProPass 200 Page 3 - - 21...

  • Page 36: Troubleshooting

    NOTE: Check wireless remote LCD display and base unit LED’s for help in troubleshooting. Control manifold proportional flow valve (PV1) is faulty. An electrical problem exists (see Chapter 4 -- Electrical System). Rear option hydraulic motor(s) are faulty. Hydraulic System Page 3 - - 22 ProPass 200...
  • Page 37 Control manifold proportional solenoid valve (SP1) is NOTE: Check wireless remote LCD display and base faulty. unit LED’s for help in troubleshooting. An electrical problem exists (see Chapter 4 -- Electrical System). Hydraulic floor motor is faulty. ProPass 200 Page 3 - - 23 Hydraulic System...

  • Page 38: Testing

    Gangrene may result If your ProPass is equipped with the hydraulic power from such an injury. pack, see the Hydraulic Testing section of Chapter 6 -- Hydraulic Power Pack for hydraulic testing procedures. Hydraulic System Page 3 - - 24 ProPass 200...
  • Page 39 This page is intentionally blank. ProPass 200 Page 3 - - 25 Hydraulic System...

  • Page 40: Service And Repairs 3

    5. Note the position of hydraulic fittings (especially el- bow fittings) on hydraulic components before removal. Mark parts if necessary to make sure they will be aligned properly when installing hydraulic hoses and tubes. Hydraulic System Page 3 - - 26 ProPass 200...

  • Page 41: Check Hydraulic Lines And Hoses

    If fluid is in- jected into the skin, it must be surgically re- moved within a few hours by a doctor familiar with this type of injury. Gangrene may result from such an injury. ProPass 200 Page 3 - - 27 Hydraulic System...
  • Page 42 7. Hydraulic hose 16. Flat washer 25. Hydraulic supply hose 8. Hydraulic hose 17. Hydraulic adapter 26. Hydraulic return hose 9. Hydraulic cap 18. Hydraulic adapter 27. Rear option solenoid valve Hydraulic System Page 3 - - 28 ProPass 200...

  • Page 43: Information

    Hose and Tube Installation in the General Infor- mation section of this chapter). C. Make sure that wire harness connectors are se- cured to solenoid coils. 2. Install hydraulic guard to machine (Fig. 27). ProPass 200 Page 3 - - 29 Hydraulic System...

  • Page 44: Information

    4. Slide lubricated side lever into control valve body. Fit seal retainer and retaining ring to both ends of side lever to secure side lever in control valve body. 5. Slide handle into side lever and secure with set screw. Hydraulic System Page 3 - - 30 ProPass 200...

  • Page 45: Information

    4 -- Electrical System for information on testing the solenoid coils. 25 ft- -lb (34 N- -m) Figure 32 1. Nut 4. Seal kit 2. Solenoid coil 5. Manifold 3. Cartridge valve ProPass 200 Page 3 - - 31 Hydraulic System...
  • Page 46 6. Straight hydraulic fitting (2 used) 13. Flat washer (2 used) 20. Clamp plate (3 used) 7. Straight hydraulic fitting (4 used) 14. Lock washer (2 used) 21. Control panel guard Hydraulic System Page 3 - - 32 ProPass 200...

  • Page 47: Information

    2. Position manifold assembly to the machine frame. Secure assembly to the frame with two (2) cap screws Figure 35 (item 16), lock washers and flat washers. 1. Control manifold 3. Solenoid coil: option 2. Solenoid coil: floor ProPass 200 Page 3 - - 33 Hydraulic System...
  • Page 48 17. #6 plug (2 used) 6. Solenoid coil 12. #4 plug (6 used) NOTE: Solenoid valve SV1 and the upper solenoid coil on solenoid valve SP1 are not used in the ProPass 200 hydraulic system. Hydraulic System Page 3 - - 34...

  • Page 49: Information

    10.If problems still exist after manifold assembly, re- ing rings and backup rings on valve. Remove seal kit move cartridge valve and clean again or replace valve. from cartridge valve and discard removed seals. ProPass 200 Page 3 - - 35 Hydraulic System...
  • Page 50 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.
  • Page 51 This page is intentionally blank. ProPass 200 Page 3 - - 37 Hydraulic System...

  • Page 52: Floor Motor

    3. Loosen cap screw and lock nut that secure idler Chock wheels to prevent ProPass machine from mov- sprocket to frame. Move idler sprocket to remove ten- ing. sion from drive chain. Hydraulic System Page 3 - - 38 ProPass 200...

  • Page 53: Information

    2. Position floor motor to frame and secure with two (2) cap screws (item 9) and lock nut (item 10). 1. Drive roller 3. RH conveyor frame 2. Idler roller 4. Rotation direction 3. Apply antiseize lubricant to floor motor shaft. ProPass 200 Page 3 - - 39 Hydraulic System...

  • Page 54: Eaton (Char--Lynn) S--Series General

    17. Poppet (2 used) 6. Seal 12. Spacer plate NOTE: For service of the conveyor motor, see the Eaton (Char--Lynn) S--Series General Purpose Motors Parts and Repair Manual at the end of this chapter. Hydraulic System Page 3 - - 40 ProPass 200...
  • Page 55 This page is intentionally blank. ProPass 200 Page 3 - - 41 Hydraulic System...

  • Page 56: Twin Spinner Motors

    31. Flange nut (2 used per paddle) 10. 90 hydraulic fitting 21. Cap screw (1 used per motor) 32. Right curved paddle (3 used) 11. Plug 22. Cap screw (4 used per motor) 33. Spinner frame Hydraulic System Page 3 - - 42 ProPass 200...

  • Page 57: Information

    9. If necessary, remove hydraulic fittings from spinner motor. Remove and discard O--rings from fittings. NOTE: For spinner motor service information, use same procedure as described in Rear Option Motor Ser- vice in this section. ProPass 200 Page 3 - - 43 Hydraulic System...

  • Page 58: Conveyor Motor

    19. Flange nut (2 used) 6. Flange bearing (3 used) 13. Hydraulic straight fitting (2 used) 20. Woodruff key 7. Bearing guard (3 used) 14. O- -ring 21. Motor spacer plate Hydraulic System Page 3 - - 44 ProPass 200...

  • Page 59: Information

    7. Loosen set screw (item 16) that secures drive roller to conveyor motor shaft. 8. Adjust conveyor belt (refer to conveyor belt tension- ing procedure in ProPass 200 Operator’s Manual). ProPass 200 Page 3 - - 45 Hydraulic System...

  • Page 60: Eaton (Char--Lynn) R--Series General

    90 chapter. fitting installed in the end cap. The right side spinner mo- tor and conveyor motor do not use a case drain hose so the end cap includes a plug. Hydraulic System Page 3 - - 46 ProPass 200...

  • Page 61: Electrical Schematics 4

    ....Hydraulic Solenoid Valve Coils ....ProPass 200 Page 4 - - 1 Electrical System...
  • Page 62 This page is intentionally blank. Electrical System Page 4 - - 2 ProPass 200...

  • Page 63: General Information

    ProPass machine. Refer to the Opera- tor’s Manual for additional information when servicing the machine. Machine Hydraulic Control ProPass 200 machines use either standard hydraulic controls or electronic hydraulic controls to allow the op- erator to change machine settings. Machines with standard hydraulic controls include...

  • Page 64: Electrical Schematics

    SWITCH REAR OPTION WHITE 15A FUSE SOLENOID VALVE 15A FUSE BLACK WHITE NOTE: Electrical power is provided by POWER either the tow vehicle or the hydraulic SUPPLY power pack. Figure 3 Electrical System Page 4 - - 4 ProPass 200...
  • Page 65 IN- -LINE FUSE TOW VEHICLE HYDRAULIC POWER LEAD POWER PACK HARNESS POWER LEAD NOTE: Electrical power is provided by HARNESS either the tow vehicle or the hydraulic power pack. Figure 4 ProPass 200 Page 4 - - 5 Electrical System...

  • Page 66: Wire Harness Drawings

    Wire Harness Drawings BLACK WHITE WHITE PROPASS 200 POWER LEAD WIRE HARNESS (FROM TOW VEHICLE) Figure 5 BLACK YELLOW PROPASS 200 POWER LEAD WIRE HARNESS (FROM HYDRAULIC POWER PACK) Figure 6 Electrical System Page 4 - - 6 ProPass 200...

  • Page 67: Intermediate Power Wire Harness

    BLACK WHITE PROPASS 200 INTERMEDIATE POWER WIRE HARNESS Figure 7 ProPass 200 Page 4 - - 7 Electrical System...

  • Page 68: Main Valve Wire Harness (Standard Hydraulic Controls)

    BLACK WHITE GREEN WHITE BROWN PROPASS 200 MAIN VALVE WIRE HARNESS STANDARD HYDRAULIC CONTROLS Figure 8 Electrical System Page 4 - - 8 ProPass 200...

  • Page 69: Pendant Wire Harness Standard Hydraulic Controls

    GREEN OPTION SWITCH WHITE WHITE FLOOR SWITCH BLACK PROPASS 200 PENDANT WIRE HARNESS STANDARD HYDRAULIC CONTROLS Figure 9 ProPass 200 Page 4 - - 9 Electrical System...

  • Page 70: Bulkhead Wire Harness Electronic Hydraulic Controls

    BASE UNIT YELLOW PINK BLACK BASE UNIT BLACK BLACK BLUE BLACK GREEN PROPASS 200 BULKHEAD WIRE HARNESS ELECTRONIC HYDRAULIC CONTROLS Figure 10 Electrical System Page 4 - - 10 ProPass 200...
  • Page 71 This page is intentionally blank. ProPass 200 Page 4 - - 11 Electrical System...

  • Page 72: Special Tools

    The multimeter can test electrical components and cir- cuits for current (amps), resistance (ohms) or voltage. Obtain this tool locally. NOTE: Toro recommends the use of a DIGITAL Volt-- Ohm--Amp multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital me- ter in the voltage mode will make sure that excess cur- rent is not allowed through the meter.
  • Page 73 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 Figure 14 Battery Hydrometer Use the battery hydrometer when measuring specific gravity of battery electrolyte.

  • Page 74: Troubleshooting

    Rear option switch in pendant is OFF. hydraulics). 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). Electrical System Page 4 - - 14 ProPass 200...
  • Page 75 Wireless remote settings are incorrect. Proportional solenoid valve coil (SP1) or circuit wiring is faulty. Hydraulic problem exists (see Chapter 3 -- Hydraulic System). Wireless remote is faulty. Base unit is faulty. ProPass 200 Page 4 - - 15 Electrical System...

  • Page 76: Component Testing

    2. Screw (2 used) place button assembly. Make sure that wire harness connector is attached to the button after testing and/or replacement. Electrical System Page 4 - - 16 ProPass 200...

  • Page 77: Pendant Assembly (Machines With Standard Hydraulic Controls)

    3. Junction box 7. Washer 4. Switch guard 8. Wire harness TOP VIEW OF SWITCHES WHITE WHITE WIRE WIRE POSITION BLACK WIRE POSITION GREEN WIRE Figure 19 1. Spinner switch 2. Floor switch ProPass 200 Page 4 - - 17 Electrical System...

  • Page 78: Wireless Remote (Machines With Electronic Hydraulic Controls)

    NOTE: Holding down the remote ALL STOP and OP- TION STOP buttons simultaneously results in display of battery life expectancy. Figure 21 1. Rear of remote 3. Battery location 2. Battery cover Electrical System Page 4 - - 18 ProPass 200...
  • Page 79 During floor operation, the current floor speed in percent. OPT XX% During rear option operation, the current rear speed in percent. SW STUCK Remote button is stuck. XXXXXX XXXXXX identifies the button that is stuck. ProPass 200 Page 4 - - 19 Electrical System...

  • Page 80: Wireless Remote Base Unit

    The POWER LED will be amber when power exists to the base unit. If this LED is either red or green, an intern- al base unit problem exists. Electrical System Page 4 - - 20 ProPass 200...

  • Page 81: Hydraulic Solenoid Valve Coils

    The resistance for the solenoid coils is identified below: Solenoid Coil Height Resistance 1.960” (49.8 mm) 7.1 ohms Figure 25 2.450” (62.2 mm) 4.5 ohms 1. Manifold 3. 1.960” solenoid coil 2. 2.450” solenoid coil ProPass 200 Page 4 - - 21 Electrical System...
  • Page 82 This page is intentionally blank. Electrical System Page 4 - - 22 ProPass 200...

  • Page 83: Information

    ... . Wheel Bearing Service (Tow Chassis) ..Walking Beam Assembly (Tow Chassis) ..ProPass 200 Page 5 - - 1 Chassis...
  • Page 84 This page is intentionally blank. Chassis Page 5 - - 2 ProPass 200...

  • Page 85: General Information

    The Parts Catalog can be used to provide general disas- sembly and assembly information for the chassis on your ProPass machine. Refer to this publication for additional information when servicing the machine. ProPass 200 Page 5 - - 3 Chassis...

  • Page 86: Service And Repairs

    9. Lanyard (2 used) 14. Screw retainer 4. LH idler guard 10. Flat washer (2 used) 15. Cap screw 5. RH idler guard 11. Rivet (2 used) 16. Flange nut 6. LH drive guard Chassis Page 5 - - 4 ProPass 200...
  • Page 87 3. Screw (2 used) 9. Lock washer (2 used) 4. Flange nut (2 used) 10. Flat washer (2 used) 5. Flat washer (2 used) 11. Front rinse guard 6. Cap screw (2 used) ProPass 200 Page 5 - - 5 Chassis...

  • Page 88: Floor Motor Drive

    15. Set screw (2 used per sprocket) 4. Sprocket 10. Lock nut (2 used) 16. Master link 5. Idler sprocket 11. Cap screw 17. Woodruff key 6. Cap screw 12. Flat washer 18. Drive roller shaft Chassis Page 5 - - 6 ProPass 200...
  • Page 89 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. ProPass 200 Page 5 - - 7 Chassis...

  • Page 90: Drive Roller Bearings

    6. Remove four (4) lock nuts (item 3) that retain bearing easier during assembly. assembly to conveyor frame. Remove bearing from C. Repeat for other side of machine. drive roller shaft and frame. Leave cap screws in frame. Chassis Page 5 - - 8 ProPass 200...
  • Page 91 Operator’s manual. 6. Check and adjust conveyor belt tension as needed FRONT (refer to Operator’s Manual). Figure 9 1. Drive roller 3. LH conveyor frame 2. Idler roller 4. Rotation direction ProPass 200 Page 5 - - 9 Chassis...

  • Page 92: Floor Conveyor Belt

    Chock wheels to prevent ProPass machine from mov- cap screw and lock nut on drive chain idler sprocket (see ing. Floor Motor Drive in this section). 2. Disconnect electrical power to ProPass machine. Chassis Page 5 - - 10 ProPass 200...
  • Page 93 1. Install conveyor belt to ProPass in the reverse order of removal noting the following items: A. Make sure that v--guide on bottom of conveyor belt is in the guides of both idler and drive rollers. ProPass 200 Page 5 - - 11 Chassis...

  • Page 94: Idler And Drive Rollers

    Once these items are removed, either roller can be removed from the bearing in the right side conveyor frame. Chassis Page 5 - - 12 ProPass 200...
  • Page 95 A. On right side conveyor frame, loosen bearing locking collar on idler roller shaft (see Idler Roller Bearings in this section). B. Slide idler roller from bearing and remove from machine. ProPass 200 Page 5 - - 13 Chassis...

  • Page 96: Idler Roller Take Up Bearings

    The idler roller needs to be removed from the right side take up bearing before the right side bearing can be removed from the frame. Chassis Page 5 - - 14 ProPass 200...
  • Page 97 5. Grease all four (4) bearings after assembly is com- plete. ProPass 200 Page 5 - - 15 Chassis...

  • Page 98: Wheel Assemblies (Tow Chassis)

    NOTE: The outer wheels can be removed with the walking beam (item 6) attached to the ProPass ma- chine. If an inner wheel needs to be removed, walking beam removal is necessary (see Walking Beam As- sembly in this section). Chassis Page 5 - - 16 ProPass 200...
  • Page 99 -lb (95 to 122 N- -m). 5. Pull wheel from walking beam assembly. 4. If removed, install walking beam assembly to ma- chine (see Walking Beam Assembly in this section). 5. Carefully lower machine to ground. ProPass 200 Page 5 - - 17 Chassis...

  • Page 100: Wheel Bearing Service (Tow Chassis)

    Replace worn or damaged parts. 4. Remove wheel assembly (see Wheel Assemblies in E. If necessary, use a press to remove wheel studs this section). from hub. 5. Carefully pry dust cap from wheel hub. Chassis Page 5 - - 18 ProPass 200...
  • Page 101 IMPORTANT: Most wheel bearing failures can be at- tributed to improper bearing adjustment, normally due to the bearings being adjusted too tight. Follow the following adjustment process to prevent prema- ture bearing problems. ProPass 200 Page 5 - - 19 Chassis...

  • Page 102: Walking Beam Assembly (Tow Chassis)

    18. Flange head screw (8 used) 28. Lynch pin 9. Flat washer (4 used) 19. Flange head screw (6 used) 29. Lug nut (5 used per wheel) 10. Lock nut (2 used) 20. Flange nut (6 used) Chassis Page 5 - - 20 ProPass 200...
  • Page 103 4. Remove cap screws, flat washers and flange nuts that secure walking beam bearings to frame cross mem- ber. 5. Carefully lower walking beam assembly and remove from machine. 6. Clean bearings and pivot areas of walking beam. ProPass 200 Page 5 - - 21 Chassis...
  • Page 104 This page is intentionally blank. Chassis Page 5 - - 22 ProPass 200...

  • Page 105: Power Pack Engine Specifications 6

    ......EATON SERIES 26 GEAR PUMP PARTS and REPAIR MANUAL ProPass 200 Page 6 - - 1 Hydraulic Power Pack...

  • Page 106: Power Pack Engine Specifications

    NOTE: The Honda engine included with the ProPass Power Pack is equipped with a low oil shutdown system that disables the ignition system if the oil level should fall below the safe limit. Hydraulic Power Pack Page 6 - - 2 ProPass 200...

  • Page 107: Power Pack Hydraulic Specifications

    0.40 in (6.6 cc) Circuit Relief Pressure 2000 PSI (138 bar) Hydraulic Tank Capacity 8.7 U.S. Gallons (32.9 Liters) Hydraulic Oil See Power Pack Installation Instructions Hydraulic Filter Spin--on cartridge type ProPass 200 Page 6 - - 3 Hydraulic Power Pack...

  • Page 108: General Information

    Power Pack assembly are supplied through your Au- sembly and assembly is identified in the Honda Work- thorized TORO Distributor. If no parts list is available, be shop Manual that is available from Honda. Most engine prepared to provide your distributor with the Toro model repairs and adjustments require tools which are com- and serial number.

  • Page 109: Information

    = 12.85 v NOTE: Depending upon the condition of the battery Difference = +0.55 v charge and battery temperature, the battery voltage will increase at different rates as the battery charges. ProPass 200 Page 6 - - 5 Hydraulic Power Pack...

  • Page 110: Adjustments

    Figure 2 1. Relief valve cartridge 3. Adjustment socket 2. Jam nut Hydraulic Power Pack Page 6 - - 6 ProPass 200...
  • Page 111 This page is intentionally blank. ProPass 200 Page 6 - - 7 Hydraulic Power Pack...

  • Page 112: Hydraulic Testing

    6.0 GPM (22.7 LPM). make sure flow control valve on the tester is fully open. 5. Make sure that ProPass controls for the floor and the twin spinner are disengaged. Hydraulic Power Pack Page 6 - - 8 ProPass 200...
  • Page 113 13.When testing is complete, disconnect tester from the valve opens. hydraulic hose and manifold fitting. Reconnect hose to manifold fitting. D. System pressure should be approximately 2000 PSI (138 bar) as the relief valve lifts. ProPass 200 Page 6 - - 9 Hydraulic Power Pack...

  • Page 114: Hydraulic Power Pack Gear Pump Flow

    2. Relief valve manifold Check for hydraulic leakage at tester connections and correct before proceeding with test. 7. Move throttle so engine is running at high idle speed (3750 RPM). Hydraulic Power Pack Page 6 - - 10 ProPass 200...
  • Page 115 This page is intentionally blank. ProPass 200 Page 6 - - 11 Hydraulic Power Pack...

  • Page 116: Service And Repairs

    Chock wheels to prevent ProPass machine from mov- ing. Hydraulic Power Pack Page 6 - - 12 ProPass 200...
  • Page 117 4. Engine jaw coupling 10. Flat washer (2 used) during maintenance or rebuilding are properly installed 5. Square key 11. Cap screw (2 used) 6. Flange adapter 12. Generator bracket to the engine. ProPass 200 Page 6 - - 13 Hydraulic Power Pack...

  • Page 118: Information

    Pressure in the General Information section Installing Hydraulic System Components in the Service of Chapter 3 - - Hydraulic System. and Repairs section of Chapter 3 -- Hydraulic System. Hydraulic Power Pack Page 6 - - 14 ProPass 200...

  • Page 119: Information

    12. O- -ring Chapter 3 -- Hydraulic System). 2. Position hydraulic tank to the machine and secure with four (4) flange head screws (item 3) and flange nuts (item 12). ProPass 200 Page 6 - - 15 Hydraulic Power Pack...

  • Page 120: Power Pack Gear Pump

    16. Hydraulic gear pump 25. Hydraulic hose 8. 45 hydraulic fitting (2 used) 17. Straight hydraulic fitting 26. Spider coupling 9. Hydraulic hose 18. Battery tray 27. Coupling jaw (engine) Hydraulic Power Pack Page 6 - - 16 ProPass 200...

  • Page 121: Information

    O--rings onto fittings (Fig. 10). Install and 3. Hydraulic fitting 7. O- -ring 4. O- -ring tighten fittings into pump ports (see Hydraulic Fitting Installation in the General Information section of Chapter 3 -- Hydraulic System). ProPass 200 Page 6 - - 17 Hydraulic Power Pack...

  • Page 122: Power Pack Gear Pump Service

    11. Idler gear 16. Retaining ring Backup gasket NOTE: For service of the power pack gear pump, see the Eaton Series 26 Parts and Repair Manual at the end of this chapter. Hydraulic Power Pack Page 6 - - 18 ProPass 200...
  • Page 123 This page is intentionally blank. ProPass 200 Page 6 - - 19 Hydraulic Power Pack...

  • Page 124: Information

    Pressure in the General Information section Installing Hydraulic System Components in the Service of Chapter 3 - - Hydraulic System. and Repairs section of Chapter 3 -- Hydraulic System. Hydraulic Power Pack Page 6 - - 20 ProPass 200...

  • Page 125: Information

    Chapter 3 -- Hydraulic System). 1. Relief valve manifold 3. Seal kit 2. Relief valve 3. Position relief valve manifold to engine mount plate and secure with two (2) cap screws and flange nuts. ProPass 200 Page 6 - - 21 Hydraulic Power Pack...

  • Page 126: Power Pack Battery

    5. Flange nut (2 used) 2. Cap screw (2 used) 6. Battery bracket tery cables. 3. Flat washer (2 used) 7. Mounting strap 4. Bolt tube (2 used) 8. Hydraulic oil filter Hydraulic Power Pack Page 6 - - 22 ProPass 200...
  • Page 127 6. Make sure battery cables, battery connections and the battery hold down components are in good condi- tion. Also, make sure the battery tray is clean and re- painted if necessary. ProPass 200 Page 6 - - 23 Hydraulic Power Pack...
  • Page 128 If the voltage is less than 12.0 VDC, recharge the battery before load testing. B. Make sure the battery terminals are free of corro- sion. Hydraulic Power Pack Page 6 - - 24 ProPass 200...
  • Page 129 11.5 hrs 17.3 hrs 23 hrs 6 amps 6 amps 6 amps 6 amps above 6 hrs 12 hrs 18 hrs 24 hrs 10 amps 10 amps 10 amps 10 amps ProPass 200 Page 6 - - 25 Hydraulic Power Pack...
  • Page 130 This page is intentionally blank. Hydraulic Power Pack Page 6 - - 26 ProPass 200...

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