Information - Toro ProPass 200 Service Manual

NOTE: The hydraulic manifold shown in Figure 36 uses
several zero leak plugs. These plugs have a tapered
sealing surface on the plug head that is designed to re-
sist vibration induced plug loosening. The zero leak
plugs also have an O--ring to provide a secondary seal.
If zero leak plug removal is necessary, lightly rap the
plug head using a punch and hammer before using an
allen wrench to remove the plug: the impact will allow
plug removal with less chance of damage to the socket
head of the plug. When installing plugs into the manifold,
torque plugs to the values identified in Figure 36.
NOTE: See Hydraulic Solenoid Valve Coils in Chapter
4 -- Electrical System for information on testing the
solenoid coils.
CAUTION
Before continuing further, read and become fa-
miliar with General Precautions for Removing
and Installing Hydraulic System Components in
this section.
Cartridge Valve Service
CAUTION
If manifold is connected to machine hydraulic
system, operate all hydraulic controls to relieve
system pressure and avoid injury from pressur-
ized hydraulic oil before removing manifold com-
ponents. See Relieving Hydraulic System Pres-
sure in the General Information section of this
chapter.
1. If control manifold is connected to machine hydraulic
system, relieve hydraulic system pressure before servi-
cing the manifold.
2. Make sure control manifold is clean before removing
any of the cartridge valves from the control manifold.
3. If cartridge valve is solenoid operated, remove nut
securing solenoid coil to the cartridge valve. Carefully
slide coil off the valve.
IMPORTANT: Use care when handling the cartridge
valve. Slight bending or distortion of the stem tube
can cause binding and malfunction. When remov-
ing cartridge valve from manifold, make sure that
deep well socket fully engages the valve base.
4. Remove cartridge valve from manifold using a deep
socket wrench. Note correct location for O--rings, seal-
ing rings and backup rings on valve. Remove seal kit
from cartridge valve and discard removed seals.
ProPass 200
5. Visually inspect the port in the manifold for damage
to the sealing surfaces, damaged threads and contami-
nation.
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. If valve sealing surfaces appear pitted or dam-
aged, the hydraulic system may be overheating or
there may be water in the system.
Use eye protection such as goggles when using
compressed air.
7. Clean cartridge valve using clean mineral spirits.
Submerge valve in clean mineral spirits to flush out con-
tamination. Particles as fine as talcum powder can affect
the operation of high pressure hydraulic valves. If car-
tridge design allows, use a wood or plastic probe to push
the internal spool in and out 20 to 30 times to flush out
contamination. Be extremely careful not to damage car-
tridge. Use compressed air for cleaning.
8. Install the cartridge valve into the manifold:
A. Lubricate new seal kit components with clean hy-
draulic oil and install on valve. The O--rings, sealing
rings and backup rings must be arranged properly on
the cartridge valve for proper operation and sealing.
B. Dip assembled cartridge into clean hydraulic oil.
IMPORTANT: Use care when handling the valve
cartridge. Slight bending or distortion of the
stem tube can cause binding and malfunction.
When installing cartridge valve into manifold,
make sure that deep well socket fully engages
the valve base.
C. Thread cartridge valve carefully into 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, re-
move cartridge valve and clean again or replace valve.
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CAUTION
Hydraulic System