Toro ProPass 200 User manual

FormNo.3392-986RevB

HydraulicPowerPack

ProPass200TopDresser

ModelNo.44713—SerialNo.315000001andUp

InstallationInstructions

ThisproductcomplieswithallrelevantEuropeandirectives.Fordetails,pleaseseetheDeclarationof

Incorporation(DOI)atthebackofthispublication.

WARNING

CALIFORNIA

Proposition65Warning

TheengineexhaustfromthisproductcontainschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,orotherreproductiveharm.

Batteryposts,terminals,andrelatedaccessoriescontainleadandlead

compounds,chemicalsknowntotheStateofCaliforniatocausecancerand

reproductiveharm.Washhandsafterhandling.

Safety

SafetyandInstructionalDecals

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyarea

ofpotentialdanger.Replaceanydecalthatisdamagedorlost.

decal115-2047

115-2047

1.Warning—donottouchthehotsurface.

decal119-6844

119-6844

1.Cutting/dismembermenthazardofhand,conveyor—stay

awayfrommovingparts,keepallguardsandshieldsin

place.

decal119-6807

119–6807

1.Warning—nostep

8111LyndaleAvenueSouth

Bloomington,MN55420

Registeratwww.T oro.com.OriginalInstructions(EN)

PrintedintheUSA

AllRightsReserved*3392-986*B

decal119-6829

119–6829

1.ReadtheOperator'sManual.

2.Maximumloadof907kg(2000lb)resultsinanaxleweight

of1,530kg(3320lb)andatongueweightof145kg(320

lb).

3.Emptyhopperhasanaxleweightof599kg(1320lb)anda

tongueweightof48kg(105lb).

Installation

CAUTION

BeforeattemptingtoinstalltheProPass-11

HPHydraulicPowerPack,ensurethat:

•TheProPassislocatedonrmlevel

ground.

•TheProPassjackstandislowered.

•Allexternalhydraulicandelectricalpower

sourcesaredisconnected.

•TheProPassshouldbepreventedfrom

unexpectedmovementbyblockingthe

wheelsatthefrontandtherear.

•UseanassistantwhenliftingthePower

Packassembly.

1.FollowingtheinstructionsgivenintheOperator’s

Manualforthemachine.RemovetheTwin

Spinneroptionandsecurethehydraulicpower

andreturnhoses.

Note:ProPassmodelsmanufacturedafterApril

2005featureapre-drilledchassisrearwall.If

yourProPassispre-drilledskipinstructions

2-13.

2.CheckthattheProPasschassisrearwallis

cleartomountthehydraulictank.

Note:Twomountingboltsmustberemoved

fromthechassisrearwalltoallowthehydraulic

tanktobemounted.Usetheboltsformounting

thetank.

3.Removethehydraulictankassemblyfromthe

crate.

4.Supportthehydraulictankfromunderneathand

positionthetankagainsttheProPasschassis

rearwall.Thetankshouldbecenteredevenly

fromlefttorightandshouldbepositioned

vertically(Figure1).

g013856

Figure1

1.Hydraulictank

5.Ensurethattheinletandoutletttingsandthe

hoseguidemountingbracketalltcleanlywithin

theroundholesintheProPasschassisrearwall

(Figure2).

g013857

Figure2

1.Holesinthechassis

6.Ensurethatthehydraulictankislevel.

7.UsingC-clamps,orsimilardevices,temporarily

clampthehydraulictankrmlyinplaceonthe

ProPasschassisrearwall.

8.Recheckthatthehydraulictankislevel.

9.Markthepositionofthehydraulictankmounting

holesontotheProPasschassisrearwall.

10.Un-clampandremovethehydraulictank.

11.Centerpunchthepositionofthemarkedholes.

12.Drilla7/16inchdiameterholethroughthe

ProPasschassisrearwallineachmarkedand

punchedposition.

13.De-burreachhole.

14.EnsurethattheProPassHitchTubeiscleanand

freefromdirtordebris.

15.Unpacktheengineassembly.

16.Loosen,butdonotremove,the2boltsand

nutssecuringtheenginemountbracketstothe

enginemountingplate(Figure3).

g013858

Figure3

1.Mountingbolts(2)

17.Removethetwonutsholdingthebatteryhold

downstrapsinplaceandsetthenuts,washers

andbolttubeofftotheside(Figure4).

g013861

Figure4

1.Batteryholddownstrap2.Batteryholddownbolt(2)

18.Removethebatteryfromitspositiononthe

assemblyandrestthelteronthebaseplate.

19.Chargethebattery;refertoActivatingand

ChargingtheBattery(page10).

20.Sincetheengineassemblyisheavy,positioning

ofthiscomponentcanbedifcult.Withthehelp

ofanassistant,positiontheengineassembly

ontotheProPasshitchtube.Ensurethatthe

enginemountbracketsstraddlethehitchtube

(Figure5andthattherearoftheenginemount

plateisapproximately25mm(1inch)fromthe

ProPasshitchtubereceiver(Figure6).

g013911

Figure5

1.Hitchtube

g013859

Figure6

1.Oneinch

21.Insertthe2bolts(1/2x3inches)throughthe

enginemountbracketholesensuringthata

atwasheristtedagainsteachouterfaceof

theenginemountbracketandensuringthat

theboltspassclearbeneaththebottomofthe

ProPasshitchtube.Handtightenthe2nuts(1/2

inch)(Figure7).

g013860

Figure7

1.Hitchtube2.Mountingbolts(2)

22.Adjusttheenginemountbracketsothatitis

tighttothehitch.Fullytightenthetwobolts

securingtheenginemountbracketstothe

enginemountingplate(Figure8).

23.Checkthattheenginemountingplateislevel

andfullytightenthe2bolts(1/2x5inches)

throughtheenginemountbracketlowerholes.

24.Placethebatteryontothebatterytray,

positioningtheterminalsasshowninFigure8.

25.Positionthebatteryholddownonthebattery

(Figure8).

26.Holdthebatterymountstraparoundthe

undersideofthehitchtube(Figure8).

27.Ontherightside,installabatteryboltthrough

thewasher,batterymountstrap,enginemount

plate,batterytrayandholddown.Looselyinstall

aangenut(Figure8).

Note:Makesuretheboltsareinstalledfrom

thebottom.

28.Ontheleftside,installabatteryboltthrough

thewasher,batterymountstrap,enginemount

plate,batterytray,batterybolttube,andhold

down.Looselyinstallaangenut(Figure8).

29.Makesureeverythingisconcentricandtighten

thenuts

g013862

Figure8

1.Batterybolt(2)4.Batterymountstrap

2.Washer(2)5.Flangelocknut(2)

3.Bolttube

30.Unpackthehoseguide,hydraulicreturnhose

(hose#3),hydraulicsuctionhose(hose#4),4

bolts(1/4x3/4inch)and4locknuts(1/4inch).

Note:Removethehosesecuredtothehose

guide,hydraulicreturnhoseandhydraulic

suctionhoseforshipping.

31.Using2bolts(1/4x3/4inch)andange

locknuts,attachthehoseguidetothebracket

onthehydraulictank(Figure9).

g013863

Figure9

1.Hoseguide

Note:Twomountingboltsmustberemoved

fromthechassisrearwalltoallowthehydraulic

tanktobemounted.Usetheboltsformounting

thetank.

32.Unpack4bolts(3/8x1inch)andnylonlocknuts.

Supportingthehydraulictankfrombelow,pass

thehoseguideandhydraulichoses#3and#4

throughthelargecentralholeintheProPass

chassisrearwallandlocatethehydraulictank

againstthechassisrearwall.T emporarily

clamp,orbolt,thehydraulictankinplace.

Note:Thehoseguideshouldbefedthrough

thecenterholeonthefrontsideofthechassis.

Twopeoplemayberequired

33.Installthehydraulicreturnhose(#3)andthe

hydraulicsuctionhose(#4)totheappropriate

ttingsonthehydraulictank.

Note:Hose#3andhose#4donothavethe

samettingssoeachhosewillonlytintothe

correctttinginthehydraulictank.

Note:Whenmountingthehoses,makesure

thereisadequateclearancetothetires.

34.Thehoseguideshouldsitontopofthetabfrom

theverticallegofthebatterytray(Figure10).

Iftheholesinthehoseguidedonotmatchthe

holesinthebatterytraytab,thehoseguide

lengthmaybeadjustedbylooseningthebolts

attachingthehoseguidetothehydraulictank

bracketandslidingthehoseguideforwardor

totherearasrequired.

g013864

Figure10

1.Hoseguide

35.Attachthehoseguidetothebatterytraytab

using2bolts(1/4x3/4inch)andangelocknuts

(Figure10).

36.MountthehydraulictanktotheProPasschassis

rearwallusingthebolt(3/8x1inch),nylon

locknutsandatwashers.Also,usethe

mountingboltspreviouslyremoved.Tightenthe

fasteners.

37.Connecthydraulichose#3tothelteroutlet

(Figure11).

g013865

Figure11

1.Filteroutlet2.Hydraulichose#3

38.Connecthydraulichose#4tothesuctionsideof

thehydraulicpump(Figure12).

g013908

Figure12

1.Hydraulicpump2.Hydraulichose#4

39.OntheSHversion,model44701,removethe

fastenerssecuringthecovertothefrontofthe

ProPassandsetthecoveraside(Figure13).

g013845

Figure13

1.Cover

40.Identifythepressureandreturnconnectionson

theProPassbasemodel.RefertoFigure14

fortheSHversionsandFigure15fortheEH

versions.

g014215

Figure14

1.Pressure2.Return

g259001

Figure15

1.Return2.Pressure

41.Ifpressureandreturnhoseswerepreviously

installedatthelocationsshowninFigure14and

Figure15,removethem.

Note:Makesurethehosesdonotcontactany

hot,sharpormovingparts.Trytoattainasmuch

clearancefromthemuferaspossible.

42.Connectthehydraulichosestothehydraulic

controlpanel.RefertoFigure14andFigure16

ontheSHversionsandFigure15andFigure

17ontheEHversions.

g013867

Figure16

1.Hoserouting

g013866

Figure17

1.Hoserouting

43.Tightenallofthehydraulicconnectionsand

fasteners.

44.RettheProPassTwinSpinnerassembly.

45.Connecttheblackcableandtheblackpre-routed

cabletothebatterynegativeterminalandthe

whitecableandtheredpre-routedcabletothe

batterypositiveterminal.

46.Plugtheintermediatewiringharnessintothe

powerharnessconnectorontheProPass

(Figure18orFigure19).

g013946

Figure18

1.Powerharness2.Intermediatewiring

harness

g013948

Figure19

1.Powerharness2.Intermediatewiring

harness

Operation

CAUTION

Ensurethatallcontrolsystemsareturnedoff

whenworkingonthePowerPack.

EngineOil

Important:TheengineisshippedWITHOUTOIL

(exceptforresidualoilaftertestingatthefactory).

Refertotheengineownersmanualforadditional

information.

Theengineisshippedfromthefactorywithoutoil

soitmustbelledwithapproximately1,005cm3(34

ounces)ofoilbeforestarting.Checkthelevelofoil

beforetheengineisrststartedanddailythereafter.

Theengineusesanyhigh-qualityoilhavingthe

AmericanPetroleumInstitute-APl-“service

classication"SJ,SLorequivalent.Oilviscosity

-weight-mustbeselectedaccordingto

ambienttemperature.Figure20illustratesthe

temperature/viscosityrecommendations.

g018667

Figure20

1.Positionthemachinesothattheengineislevel.

2.Cleantheareaaroundtheoilllercap/dipstick.

3.Removetheoilllercap/dipstickbyrotatingit

counterclockwise.

4.Wipethedipstickcleanandinsertitintotheller

port.Donotscrewitintotheport.

5.Removethedipstickandcheckthelevelofthe

oil.

6.Ifthelevelisnearorbelowthelowerlimitmark

onthedipstick,addonlyenoughoiltoraiselevel

totheupperlimitmark.Rechecklevelofoil.Do

notoverll.

7.Installtheoilllercap/dipstickandwipeupany

spilledoil.

Important:Makesuretheengineoilisatthe

properlevel.Iftheengineoillevelisnotcorrect,

theenginewillcrankbutwillnotstart.

HydraulicSystem

Themachineisshippedfromthefactorywithout

hydraulicuidsoitmustbelledwith32.9L(8.7U.S.

gallons)ofhighqualityhydraulicuid.Checkthelevel

ofhydraulicoilbeforethemachineisrststartedand

dailythereafter.Therecommendedhydraulicuids

areasfollows:

ToroPremiumTransmission/HydraulicTractorFluid

(Availablein5gallonpailsor55gallondrums.Seeparts

catalogorT orodistributorforpartnumbers.)

Alternateuids:IftheTorouidisnotavailable,other

petroleum-basedUniversalTractorHydraulicFluids

(UTHF)maybeusedprovideditsspecicationsfall

withinthelistedrangeforallthefollowingmaterial

propertiesanditmeetsindustrystandards.Wedo

notrecommendtheuseofsyntheticuid.Consult

withyourlubricantdistributortoidentifyasatisfactory

productNote:Torowillnotassumeresponsibilityfor

damagecausedbyimpropersubstitutions,souse

onlyproductsfromreputablemanufacturerswhowill

standbehindtheirrecommendation.

Important:Thehydraulicsystemwillnot

completelyllwithuiduntilthesystemis

poweredup.Thehydraulicuidmustthereforebe

checkedandtoppedupafterinitialrunning.

Note:T orowillnotassumeresponsibilityfordamage

causedbyimpropersubstitutions,souseonly

productsfromreputablemanufacturerswhowillstand

behindtheirrecommendation.

MaterialProperties:

Viscosity,ASTMD445cSt@40degreesC

55to62

cSt@100degreesC

9.1to9.8

ViscosityIndexASTM

D2270

140to152

PourPoint,ASTMD97-35degreesFto-46

degreesF

IndustrySpecications:

APIGL-4,AGCOPoweruid821XL,FordNewHolland

FNHA-2-C-201.00,KubotaUDT,JohnDeereJ20C,

Vickers35VQ25,andVolvoWB-101/BM

Note:Manyhydraulicuidsarealmostcolorless,

makingitdifculttospotleaks.Areddyeadditivefor

thehydraulicsystemoilisavailablein2/3oz(20ml)

bottles.Onebottleissufcientfor15to22L(4to

6USgallons)ofhydraulicoil.Orderpartnumber

44-2500fromyourAuthorizedT oroDistributor.

FillingtheFuelTank

FuelTankCapacity:6.1L(1.6gallons)

RecommendedFuel:

•Forbestresults,useonlyclean,fresh(lessthan

30daysold),unleadedgasolinewithanoctane

ratingof87orhigher(R+M)/2ratingmethod).

•Ethanol:Gasolinewithupto10%ethanol

(gasohol)or15%MTBE(methyltertiarybutyl

ether)byvolumeisacceptable.Ethanoland

MTBEarenotthesame.Gasolinewith15%

ethanol(E15)byvolumeisnotapprovedforuse.

Neverusegasolinethatcontainsmorethan10%

ethanolbyvolume,suchasE15(contains15%

ethanol),E20(contains20%ethanol),orE85

(containsupto85%ethanol).Usingunapproved

gasolinemaycauseperformanceproblemsand/or

enginedamagewhichmaynotbecoveredunder

warranty.

•Donotusegasolinecontainingmethanol.

•Donotstorefueleitherinthefueltankorfuel

containersoverthewinterunlessafuelstabilizer

isused.

•Donotaddoiltogasoline.

ActivatingandCharging

theBattery

Useonlyelectrolyte(1.265specicgravity)toll

batteryinitially.

1.Cleanthetopofthebatteryandremovethevent

caps(Figure21).

Important:Donotaddelectrolytewhilethe

batteryisinthemachine.Youcouldspillit,

causingcorrosion.

g001196

Figure21

1.Ventcaps

2.Carefullylleachcellwithelectrolyteuntilthe

platesarecoveredwithabout6mm(1/4inch)of

uid(Figure22).

g001197

Figure22

1.Electrolyte

3.Allowapproximately20to30minutesforthe

electrolytetosoakintotheplates.Rellas

necessarytobringtheelectrolytetowithinabout

6mm(1/4inch)ofthebottomofthellwell

(Figure22).

WARNING

Chargingthebatteryproducesgasses

thatcanexplode.

Neversmokenearthebatteryandkeep

sparksandamesawayfrombattery.

4.Connecta3to4ampbatterychargertothe

batteryposts.Chargethebatteryatarateof

3to4ampsuntilthespecicgravityis1.250

orhigherandthetemperatureisatleast16

degreesC(60degreesF)withallcellsgassing

freely.

5.Whenthebatteryischarged,disconnectthe

chargerfromtheelectricaloutletandbattery

posts.

Note:Afterthebatteryhasbeenactivated,

addonlydistilledwatertoreplacenormalloss,

althoughmaintenance-freebatteriesshouldnot

requirewaterundernormaloperatingconditions.

WARNING

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandlead

compounds,chemicalsknownto

theStateofCaliforniatocause

cancerandreproductiveharm.Wash

handsafterhandling.

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