TXL 2000 Tool Carrier

Model No. 22530-Serial No. 406500000 and Up

Model No. 22531-Serial No. 405540000 and Up

Introduction

This machine is a tool carrier intended for use in various earth and materials moving activities for landscaping and construction work. It is designed to operate a wide variety of attachments, each of which perform a specialized function. Using this product for purposes other than its intended use could prove dangerous to you and bystanders. Do not modify the machine or attachments.

Read this information carefully to learn how to operate and maintain your product properly and to avoid injury and product damage. You are responsible for operating the product properly and safely.

Visit www.Toro.com for product safety and operation training materials, accessory information, help finding a dealer, or to register your product.

Whenever you need service, genuine Toro parts, or additional information, contact an Authorized Service Dealer or Toro Customer Service and have the model and serial numbers of your product ready. Figure 1 identifies the location of the model and serial numbers on the product. Write the numbers in the space provided.

Important: With your mobile device, you can scan the QR code on the serial number decal (if equipped) to access warranty, parts, and other product information.

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Figure 1

  1. Model and serial number location

This manual identifies potential hazards and has safety messages identified by the safety-alert symbol (Figure 2), which signals a hazard that may cause serious injury or death if you do not follow the recommended precautions.

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Figure 2

Safety-alert symbol

This manual uses 2 words to highlight information. Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention.

It is a violation of California Public Resource Code Section 4442 or 4443 to use or operate the engine on any forest-covered, brush-covered, or grass-covered land unless the engine is equipped with a spark arrester, as defined in Section 4442, maintained in effective working order or the engine is constructed, equipped, and maintained for the prevention of fire.

The enclosed engine owner's manual is supplied for information regarding the US Environmental Protection Agency (EPA) and the California Emission Control Regulation of emission systems, maintenance, and warranty. Replacements may be ordered through the engine manufacturer.

Warning

CALIFORNIA

Proposition 65 Warning

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.

Use of this product may cause exposure to chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

Safety

Danger

There may be buried utility lines in the work area. Digging into them may cause a shock or an explosion.

Have the property or work area marked for buried lines and do not dig in marked areas. Contact your local marking service or utility company to have the property marked (for example, in the US, call 811 or in Australia, call 1100 for the nationwide marking service).

General Safety

Danger

There may be buried utility lines in the work area. Digging into them may cause a shock or an explosion.

Have the property or work area marked for buried lines and do not dig in marked areas. Contact your local marking service or utility company to have the property marked (for example, in the US, call 811 or in Australia, call 1100 for the nationwide marking service).

Always follow all safety instructions to avoid serious injury or death. Using this product for purposes other than its intended use could prove dangerous to you and bystanders.

  • Do not transport a load with the arms raised or extended; always transport loads close to the ground, with the loader arms retracted.

  • Slopes are a major factor related to loss-of-control and tip-over accidents, which can result in severe injury or death. Operating the machine on any slope or uneven terrain requires extra caution.

  • Operate the machine up and down slopes with the heavy end of the machine uphill and the load close to the ground and the loader arms retracted. Weight distribution changes with attachments. An empty load-bearing attachment makes the rear of the machine the heavy end, and a full load-bearing attachment makes the front of the machine the heavy end. Most other attachments make the front of the machine the heavy end.

  • Have the property or work area marked for buried lines and other objects, and do not dig in marked areas.

  • Read and understand the content of this Operator’s Manual before starting the engine.

  • Use your full attention while operating the machine. Do not engage in any activity that causes distractions; otherwise, injury or property damage may occur.

  • Never allow children or untrained people to operate the machine.

  • Keep your hands and feet away from the moving components and attachments.

  • Do not operate the machine without the guards and other safety protective devices in place and working on the machine.

  • Keep bystanders and pets away from the machine.

  • Stop the machine, shut off the engine, and remove the key before servicing, fueling, or unclogging the machine.

Improperly using or maintaining this machine can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety-alert symbol Graphic, which means Caution, Warning, or Danger—personal safety instruction. Failure to comply with these instructions may result in personal injury or death.

Safety and Instructional Decals

Graphic

Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or missing.
decalbatterysymbols

Battery Symbols

Some or all of these symbols are on your battery.

  1. Explosion hazard
  2. No fire, open flame, or smoking
  3. Caustic liquid/chemical burn hazard
  4. Wear eye protection.
  5. Read the Operator's Manual.
  6. Keep bystanders away from the battery.
  7. Wear eye protection; explosive gases can cause blindness and other injuries.
  8. Battery acid can cause blindness or severe burns.
  9. Flush eyes immediately with water and get medical help fast.
  10. Contains lead; do not discard
g269553

Figure 3

  1. 120-0625
decal120-0625

120-0625

  1. Pinch point, hand—keep hands away.
g269556

Figure 4

  1. 115-4855
  2. 139-1173
  3. 139-1164 (on both loader arms)
  4. 139-1159 (on both loader arms)
  5. 115-4858 (on both loader arms)
  6. 139-1158 (on both loader arms)
decal115-4855

115-4855

  1. Hot surface/burn hazard—wear protective gloves when handling the hydraulic couplers and read the Operator's Manual for information on handling hydraulic components.
decal115-4858

115-4858

  1. Crushing hazard of hands or feet—install the cylinder lock.
decal139-1158

139-1158

  1. Crushing hazard, from above, and pinching hazard—stay away from the bucket and loading arms.
decal139-1159

139-1159

  1. Warning—keep bystanders away.
decal139-1164

139-1164

  1. Crushing hazard from above, falling load—ensure that the quick-attach levers are locked.
decal139-1173

139-1173

  1. High-pressure fluid hazard, injection into the body—read the Operator’s Manual before performing maintenance.
g358916

Figure 5

  1. 139-5744
  2. 137-5420
  3. 136-4863
  4. 131-0710
  5. 139-4729
  6. 139-1162
  7. 115-4857
decal115-4857

115-4857

  1. Lower the loader arms.
  2. Dump the bucket.
  3. Raise the loader arms.
  4. Curl the bucket.
  5. Float the bucket on the ground.
decal136-4863

136-4863

  1. Attention—read the Operator’s Manual; Smart Load will engage and slow the traction speed when the attachment is raised; lower the attachment to drive quickly.
decal137-5420

137-5420

  1. Move forward
  2. Turn right
  3. Turn left
  4. Move rearward
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139-1162

  1. Warning—read the Operator’s Manual for the bucket maximum weight limit.
  2. Tipping hazard—do not drive the machine with the load raised or the arms extended; carry the load close to the ground with the arms retracted when driving.
decal139-4729

139-4729

  1. Retract the hydraulic cylinder (optional)
  2. Extend the hydraulic cylinder (optional)
  3. Attachment flow—Forward
  4. Extend the arms (telescoping model only)
  5. Attachment flow—Reverse
  6. Retract the arms (telescoping model only)
decal131-0710

131-0710

  1. Warning—read the Operator's Manual.
  2. Warning—receive training before operating the machine.
  3. Warning—wear hearing protection.
  4. Warning—engage the parking brake, lower the attachment to the ground, shut off the engine, and remove the key from the ignition before leaving the machine.
  5. Electrocution hazard, power lines—check for power lines in the area before using the machine.
  6. Crushing hazard—keep away from pinch points; read the Operator's Manual before servicing or performing maintenance.
  7. Cutting/severing hazard of hand or foot—wait for all moving parts to stop before servicing; keep away from moving parts; keep all guards and shields in place.
  8. Explosion hazard; electrocution hazard—call the local utilities hotline before beginning work in an area.
  9. Crushing hazard—keep away from the attachment when operating the machine; keep bystanders away from the machine.
  10. Tipping hazard—always move up or down slopes with the attachment lowered; never drive on a slope with the attachment raised; always operate with the heavy end uphill; always carry loads low; never jerk the control levers; use a steady, even motion.
  11. Tipping hazard—do not make fast turns; always check behind you before reversing the machine.
decal139-5744

139-5744

  1. Parking brake—engaged
  2. Parking brake—disengaged
  3. Fast
  4. Slow
  5. Engine—stop
  6. Engine—run
  7. Engine—start
  8. Horn
g275811

Figure 6

  1. 93-7814
  2. 137-5419
  3. 93-6681
  4. 115-4865
  5. 106-6755
decal93-6681

93-6681

  1. Cutting/dismemberment hazard, fan—stay away from moving parts.
decal93-7814

93-7814

  1. Entanglement hazard, belt—stay away from moving parts; keep all guards and shields in place.
decal106-6755

106-6755

  1. Engine coolant under pressure.
  2. Explosion hazard—read the Operator's Manual.
  3. Warning—do not touch the hot surface.
  4. Warning—read the Operator's Manual.
decal115-4865

115-4865

  1. Engine coolant
  2. Read the Operator's Manual.
decal137-5419

137-5419

g269557

Figure 7

  1. 137-7164
  2. 115-2047
  3. 139-1206
decal115-2047

115-2047

  1. Warning—do not touch the hot surface.
decal137-7164

137-7164

  1. Read the Operator’s Manual—rotate counterclockwise to disconnect the battery; rotate clockwise to connect the battery; the negative post is located below the switch; the positive post is located to the side of the switch.
decal139-1206

139-1206

  1. Read the Operator’s Manual for fuse information.
  2. Power socket
  3. Horn
  4. TEC controller
g269560

Figure 8

  1. 133-8062
decal133-8062

133-8062

g269558

Figure 9

  1. 137-5409 (on both loader arms)
decal137-5409

137-5409

g269559

Figure 10

  1. 125-6694
decal125-6694

125–6694

  1. Tie down location

Product Overview

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Figure 11

  1. Hood
  2. Auxiliary hydraulic couplers
  3. Mount plate
  4. Tie-down loop
  5. Lower loader arm
  6. Upper loader arm
  7. Track
  8. Fuel gauge
  9. Operator platform
  10. Auxiliary hydraulics lock switch
  11. Control panel
  12. Debris shield
  13. Cylinder lock

Control Panel

Become familiar with all the controls (Figure 12) before you start the engine and operate the traction unit.

g358927

Figure 12

  1. Reference bar
  2. Plug
  3. Parking brake switch
  4. InfoCenter
  5. Power socket
  6. Throttle switch
  7. Key switch
  8. Horn
  9. Traction control
  10. Joystick controls
  11. Loader arm/attachment-tilt lever
  12. Loader-valve lock

Key Switch

The key switch, used to start and shut off the engine, has 3 positions: OFF, RUN, and START. Refer to Starting the Engine.

Parking-Brake Switch

Press the parking-brake switch to engage and disengage the parking brake (Figure 12). The parking brake also engages automatically when you shut off the machine.

Throttle Switch

Press the switch forward for 2 or more seconds to set the throttle at HIGH IDLE; press the switch rearward for 2 or more seconds to set the throttle at LOW IDLE; or momentarily press the switch in either direction to increase or decrease the engine speed in 100-rpm increments.

Reference Bar

When driving the traction unit, use the reference bar as a handle and a leverage point for controlling the traction control and the joystick lever. To ensure smooth, controlled operation, do not take your hands off the reference bars while operating the machine.

Traction Control

g264835

Figure 13

  1. Reference bar
  2. Traction control

  • To move forward, move the traction control forward (Figure 14).

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    Figure 14

  • To move rearward, move the traction control rearward (Figure 15).

    Important: When reversing, look behind you for obstructions and keep your hands on the reference bar.

    g264831

    Figure 15

  • To turn right, rotate the traction control clockwise (Figure 16).

    g264833

    Figure 16

  • To turn left, rotate the traction control counterclockwise (Figure 17).

    g264832

    Figure 17

  • To stop the machine, release the traction control (Figure 13).

Note: The farther you move the traction control in any direction, the faster the machine moves in that direction.

Loader Arm/Attachment-Tilt Lever

  • To tilt the attachment forward, slowly move the lever to the right (Figure 18).

  • To tilt the attachment rearward, slowly move the lever to the left (Figure 18).

  • To lower the loader arms, slowly move the lever forward (Figure 18).

  • To raise the loader arms, slowly move the lever rearward (Figure 18).

g358939

Figure 18

  1. Lower the loader arms.
  2. Raise the loader arms.
  3. Tilt the attachment rearward.
  4. Tilt the attachment forward.

By moving the lever to an intermediate position (e.g., forward and left), you can move the loader arms and tilt the attachment at the same time.

Loader-Valve Lock

The loader-valve lock secures the loader arm/attachment-tilt lever so that you cannot push it forward. This helps to ensure that no one accidentally lowers the loader arms during maintenance. Secure the loader valve with the lock, in addition to the cylinder locks, any time you need to shut off the machine with the loader arms raised. Refer to Using the Cylinder Locks.

To set the lock, lift up on it so that it clears the hole in the control panel and swing it to the left, in front of the loader-arm lever, pushing it down into the locked position (Figure 19).

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Figure 19

  1. Loader arm/attachment-tilt lever
  2. Loader-valve lock

Joystick Controls

Primary-Attachment Switch

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Figure 20

  1. Hydraulic-attachment switch
  2. Forward hydraulic-flow direction
  3. Reverse hydraulic-flow direction

  • Press and hold the hydraulic-attachment switch up to operate a hydraulic attachment in the forward hydraulic-flow direction (Figure 20).

  • Release the secondary-attachment switch to stop the attachment.

  • Press and hold the hydraulic-attachment switch down to operate a hydraulic attachment in the reverse hydraulic-flow direction.

    Note: The primary-attachment switch is pressure sensitive; the further you press a switch, the faster the hydraulics flow for the attachment.

Loader Arm Extend/Retract Switch

Warning

Moving the machine while the loader arms are extended may affect the stability of the machine.

Minimize machine movement while the loader arms are extended.

g358952

Figure 21

  1. Loader arm extend/retract switch
  2. Extend loader arms
  3. Retract loader arms

  • Press the loader arm extend/retract switch (Figure 21) up to extend the loader arms.

  • Release the extend/retract switch to stop the loader arms.

  • Press the loader arm extend/retract switch down to retract the loader arms.

Note: The loader arm extend/retract switch is pressure sensitive; the further you press a switch, the faster the loader arms move.

Secondary-Attachment Switch

Use the secondary-attachment switch (Figure 22) to control certain optional attachments.

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Figure 22

  1. Secondary-attachment switch
  2. Extend/forward direction (left-detent position)
  3. Retract/reverse direction (right-detent position)

  • Push the secondary-attachment switch to the right until it locks into position to run a hydraulic attachment in the forward direction (Figure 22). Use the primary-attachment switch to control the function; refer to Primary-Attachment Switch.

  • Push the secondary-attachment switch to the center position to return to using the primary attachment function.

  • Push the secondary-attachment switch to the left until it locks into position to operate a hydraulic attachment in the reverse direction. Use the primary-attachment switch to control the function; refer to Primary-Attachment Switch.

Auxiliary-Hydraulics Lock Switch

Press and hold the primary-attachment switch on the joystick for more than 1 second, then use your right foot to press the auxiliary-hydraulics-lock switch to continue the full forward or reverse flow of the auxiliary hydraulics and free your hand for other controls (Figure 23).

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Figure 23

  1. Auxiliary-hydraulics lock switch

Fuel Gauge

This gauge measures the amount of fuel in the fuel tank(s).

InfoCenter Display

The InfoCenter LCD display shows information about your machine, such as the operating status, various diagnostics and other information about the machine (Figure 24). There is a splash screen and main information screen of the InfoCenter. You can switch between the splash screen and main information screen at any time by pressing any of the InfoCenter buttons and then selecting the appropriate directional arrow.

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Figure 24

  1. Indicator light
  2. Right button
  3. Middle button
  4. Left button

  • Left Button, Menu Access/Back Button—press this button to access the InfoCenter menus. You can use it to exit any menu that you are currently using.

  • Middle Button—use this button to scroll down menus.

  • Right Button—use this button to open a menu where a right arrow indicates additional content.

Note: The purpose of each button may change depending on what is required at the time. Each button is labeled with an icon displaying its current function.

InfoCenter Icon Description

GraphicMenu access
GraphicNext
GraphicPrevious
GraphicScroll down
GraphicEnter
GraphicChange the next value in the list
GraphicIncrease
GraphicDecrease
GraphicSave value
GraphicExit menu
GraphicCheck PIN entry
GraphicHour meter
GraphicAdjust digit
GraphicTransport-speed screen access
GraphicTransport speed—adjust the traction speed but maintain engine speed; refer to Setting the Maximum Transport Speed.
GraphicEngine-coolant temperature
GraphicEngine speed
GraphicBattery voltage
GraphicSmart Load is active; refer to Understanding the Smart Load System.
GraphicIndicates when scheduled service should be performed
GraphicSmart Power is active; refer to Understanding Smart Power® Traction.

Using the Menus

To access the InfoCenter menu system, press the menu access button Graphic while at the main screen. This will bring you to the main menu. Refer to the following tables for a synopsis of the options available from the menus:

Main Menu
Menu ItemDescription
FaultsThe Faults menu contains a list of the recent machine faults. Refer to the Service Manual or your Authorized Service Dealer for more information on the Faults menu and the information contained there.
ServiceThe Service menu contains information on the machine such as hours of use and other similar numbers.
DiagnosticsThe Diagnostics menu displays the state of each machine switch, sensor and control output. You can use this to troubleshoot certain issues as it will quickly tell you which machine controls are on and which are off.
SettingsThe Settings menu allows you to customize and modify configuration variables on the InfoCenter display.
AboutThe About menu lists the model number, serial number, and software version of your machine.
Service
Menu ItemDescription
HoursLists the total number of hours that the machine, engine, auxiliary hydraulics, and SmartPower have been on, as well as the number of hours for engine service and hydraulic service.
CountsLists the number of starts that the machine has experienced, the number of times the machine has warned that the engine temperature is too high, and the number of times the engine has shut off due to high temperatures.
Diagnostics
Menu ItemDescription
TractionIndicates the inputs and outputs for driving the machine.
AuxiliaryIndicates the inputs and outputs for engaging auxiliary hydraulics.
EngineIndicates the inputs and outputs for starting the engine.
BoomIndicates the inputs and outputs for extending and retracting the telescoping arms.
Settings
Menu ItemDescription
UnitsControls the units used on the InfoCenter; the menu choices are Imperial or Metric.
LanguageControls the language used on the InfoCenter.
BrightnessControls the brightness of the LCD display.
ContrastControls the contrast of the LCD display.
Smart PowerSmart Power prevents bogging down in heavy conditions by automatically controlling the machine speed and optimizing performance.
Protected MenusGrants access to protected menus.
Protect SettingsChanges whether a pin is required in Protected Menus.
Transport SpeedControls the maximum speed while in transport.
About
Menu ItemDescription
ModelLists the model number of the machine
SerialLists the serial number of the machine
SoftwareLists the system software revision of the machine.
DisplayLists the display software revision of the InfoCenter.

Setting the Maximum Transport Speed

For applications requiring a lower transport speed, you can adjust the maximum transport speed without affecting the engine speed.

  1. From the SPLASH SCREEN or HOME SCREEN, press the transport-speed screen access Graphic button (middle button) twice.

    g266967

    Figure 25

    1. Splash screen
    2. Home screen

  2. In the MAX SPEED SCREEN, adjust the maximum speed using the middle and right buttons.

    g267018

    Figure 26

Accessing Protected Menus

The TRANSPORT SPEED is adjustable within the SETTINGS MENU of the InfoCenter. These settings are in the Protected Menu.

Note: The factory default PIN code for you machine is either 0000 or 1234.If you changed the PIN code and forgot the code, contact your Authorized Service Dealer for assistance.

  1. From the MAIN MENU, use the center button to scroll down to the SETTINGS MENU and press the right button (Figure 27).

    g264775

    Figure 27

  2. In the SETTINGS MENU, use the center button to scroll down to the PROTECTED MENU and press the right button (Figure 28A).

    g264249

    Figure 28

  3. To enter the PIN code, press the center button until the correct first digit appears, then press the right button to move on to the next digit (Figure 28B and Figure 28C). Repeat this step until the last digit is entered and press the right button once more.

  4. Press the middle button to enter the PIN code (Figure 28D).

    Note: If the InfoCenter accepts the PIN code and the protected menu is unlocked, the word “PIN” displays in the upper right corner of the screen.

You can view and change the settings in the PROTECTED MENU. Once you access the PROTECTED MENU, scroll down to PROTECT SETTINGS option. Use the right button to change the setting. Setting the Protect Settings to OFF allows you to view and change the settings in the PROTECTED MENU without entering the PIN code. Setting the Protect Settings to ON hides the protected options and requires you to enter the PIN code to change the setting in the PROTECTED MENU.

Setting the Maximum Allowed Transport Speed

  1. In the SETTINGS MENU, scroll down to TRANSPORT SPEED and press the right button.

  2. Use the right button to increase the maximum transport speed (30% to 100%).

  3. Use the center button to decrease the maximum transport speed (30% to 100%).

  4. Press the left button to exit.

  5. When finished with the PROTECTED MENU, press the left button to exit to the MAIN MENU, then press the left button to exit to the RUN MENU.

Note: Specifications and design are subject to change without notice.

Model 22530

Width137 cm (54 inches)
Length251 cm (99 inches)
Height173 cm (68 inches)
Weight3034 kg (6,690 lb)
Operating capacity (35% of tipping capacity1) 

  • Arms retracted

  • Arms extended

907 kg (2,000 lb)
417 kg (920 lb)
Tipping capacity1 

  • Arms retracted

  • Arms extended

2592 kg (5,715 lb)
1188 kg (2,620 lb)
Wheelbase137 cm (54 inches)
Dump height (with standard bucket) 

  • Arms retracted

  • Arms extended

163 cm (64 inches)
226 cm (89 inches)
Reach—fully raised (with standard bucket) 

  • Arms retracted

  • Arms extended

66 cm (26 inches)
115 cm (45 inches)
Height to hinge pin (with standard bucket in highest position) 

  • Arms retracted

  • Arms extended

251 cm (99 inches)
312 cm (123 inches)

1. The operating capacity is calculated as 35% of the tipping capacity with a standard bucket and 75 kg (165 lb) operator, per ISO 14397-1. Other attachments will have different operating capacities; refer to the Operator’s Manual or load capacity decal for the attachment.

Model 22531

Width137 cm (54 inches)
Length251 cm (99 inches)
Height173 cm (68 inches)
Weight2828 kg (6,235 lb)
Operating capacity (35% of tipping capacity1)907 kg (2,000 lb)
Tipping capacity12592 kg (5,715 lb)
Wheelbase137 cm (54 inches)
Dump height (with standard bucket)163 cm (64 inches)
Reach—fully raised (with standard bucket)66 cm (26 inches)
Height to hinge pin (with standard bucket in highest position)251 cm (99 inches)

1. The operating capacity is calculated as 35% of the tipping capacity with a standard bucket and 75 kg (165 lb) operator, per ISO 14397-1. Other attachments will have different operating capacities; refer to the Operator’s Manual or load capacity decal for the attachment.

Attachments/Accessories

A selection of Toro-manufactured attachments and accessories is available for use with the machine to enhance and expand its capabilities. Contact your Authorized Service Dealer or authorized Toro distributor or go to www.Toro.com for a list of all Toro-manufactured attachments and accessories.

To ensure optimum performance, use genuine Toro replacement parts and accessories. Toro accepts no liability for machine damage or personal injury that results from the use of other manufacturer attachments. The user accepts the burden of these risks.

Operation

Note: Determine the left and right sides of the machine from the normal operating position.

Before Operation

Before Operation Safety

General Safety

  • Never allow children or untrained people to operate or service the machine. Local regulations may restrict the age or require certified training of the operator. The owner is responsible for training all operators and mechanics.

  • Become familiar with the safe operation of the equipment, operator controls, and safety decals.

  • Always engage the parking brake (if equipped), shut off the engine, remove the key, wait for all moving parts to stop, and allow the machine to cool before adjusting, servicing, cleaning, or storing the machine.

  • Know how to stop the machine and shut off the engine quickly.

  • Check that the safety switches, and shields are attached and functioning properly. Do not operate the machine unless they are functioning properly.

  • Locate the pinch-point areas marked on the machine and attachments; keep your hands and feet away from these areas.

  • Before operating the machine with an attachment, ensure that the attachment is properly installed. Read all the attachment manuals.

  • Evaluate the terrain to determine what accessories and attachments you need to properly and safely perform the job.

  • Have the property or work area marked for buried lines and other objects, and do not dig in marked areas; note the location of unmarked objects and structures, such as underground storage tanks, wells, and septic systems.

  • Inspect the area where you will use the equipment for uneven surfaces and hidden hazards.

  • Ensure that the area is clear of bystanders before operating the machine. Stop the machine if a bystander enters the area.

Fuel Safety

  • Use extreme care when handling fuel. It is flammable and its vapors are explosive.

  • Extinguish all cigarettes, cigars, pipes, and other sources of ignition.

  • Use only an approved fuel container.

  • Do not remove the fuel cap or fill the fuel tank while the engine is running or hot.

  • Do not add or drain fuel in an enclosed space.

  • Do not store the machine or fuel container where there is an open flame, spark, or pilot light, such as on a water heater or other appliance.

  • If you spill fuel, do not attempt to start the engine; avoid creating any source of ignition until the fuel vapors have dissipated.

  • Do not fill containers inside a vehicle or on a truck or trailer bed with a plastic liner. Always place containers on the ground, away from your vehicle before filling.

  • Remove the equipment from the truck or trailer and refuel it while it is on the ground. If this is not possible, then refuel from a portable container rather than a fuel-dispenser nozzle.

  • Keep the fuel-dispenser nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete. Do not use a nozzle lock-open device.

Adding Fuel

Recommended Fuel

Use only clean, fresh diesel fuel or biodiesel fuels with ultra low (<15 ppm) sulfur content. The minimum cetane rating should be 45. A cetane rating greater than 50 is preferred, especially at temperatures below -20°C (-4°F) or at elevations above 1500 m (5000 ft). Purchase fuel in quantities that you can use within 180 days to ensure fuel freshness.

Using non-ultra low sulfur fuel will damage the engine emissions system.

Use summer-grade diesel fuel (No. 2-D or No. 2-D S15) at temperatures above -10°C (14°F) and winter grade (No. 1-D or No. 1-D S15) below that temperature. Using winter-grade fuel at lower temperatures provides lower flash point and cold flow characteristics, which eases starting and reduces fuel filter plugging.

Using summer-grade fuel above -10°C (14°F) contributes toward longer fuel pump life and increased power compared to winter-grade fuel.

Important: Do not use kerosene or gasoline instead of diesel fuel. Failure to observe this caution will damage the engine.

Biodiesel Ready

This machine can also use a biodiesel blended fuel of up to B5 (5% biodiesel, 95% petrodiesel). The petrodiesel portion should be low or ultra low sulfur. Observe the following precautions:

  • The biodiesel portion of the fuel must meet specification ASTM D6751 or EN14214.

  • The blended fuel composition should meet ASTM D975 or EN590.

  • Painted surfaces may be damaged by biodiesel blends.

  • Use B5 (biodiesel content of 5%) or lesser blends in cold weather.

  • Monitor seals, hoses, gaskets in contact with fuel as they may degrade over time.

  • Fuel filter plugging may occur for a time after converting to biodiesel blends.

  • Contact your distributor for more information on biodiesel.

Filling the Fuel Tanks

Fuel tank capacity: 35 L (9.3 US gallons) per tank

  1. Park the machine on a level surface, engage the parking brake, and lower the loader arms.

  2. Shut off the engine and remove the key.

  3. Remove the fuel cap.

  4. Fill the tank with fuel up to the filler neck.

  5. Install the cap.

g358969

Figure 29

  1. Fuel gauge
  2. Fuel tank caps

Performing Daily Maintenance

Before starting the machine each day, perform the Each Use/Daily procedures listed in the .

Important: Check the hydraulic-fluid level and bleed the fuel system before starting the engine for the first time; refer to Checking the Hydraulic-Fluid Level and Bleeding the Fuel System.

During Operation

During Operation Safety

General Safety

  • Do not transport an attachment/load with the arms raised or extended; always transport the attachments/load close to the ground, with the loader arms retracted.

  • Do not exceed the rated operating capacity, as the machine may become unstable, which may result in loss of control. The operating capacity is reduced if you extend the loader arms to the point where you can see the striped decal inside the arms.

  • Attachments can change the stability and the operating characteristics of the machine.

  • For machines with a platform:

    • Lower the loader arms before stepping off the platform.

    • Do not try to stabilize the machine by putting your foot on the ground. If you lose control of the machine, step off the platform and away from the machine.

    • Do not place your feet under the platform.

    • Do not move the machine unless you are standing with both feet on the platform and your hands are holding onto the reference bars or the loader control.

  • Use your full attention while operating the machine. Do not engage in any activity that causes distractions; otherwise, injury or property damage may occur.

  • Look behind and down before backing up to ensure that the path is clear.

  • Never jerk the controls; use a steady motion.

  • The owner/user can prevent and is responsible for accidents that may cause personal injury or property damage.

  • Wear appropriate clothing including eye protection, long pants, substantial slip-resistant footwear, and hearing protection; also wear a respirator or dust mask in dusty conditions. Tie back long hair and do not wear loose clothing or loose jewelry.

  • Do not operate the machine when you are tired, ill, or under the influence of alcohol or drugs.

  • Never carry passengers and keep pets and bystanders away from the machine.

  • Operate the machine only in good light, keeping away from holes and hidden hazards.

  • Ensure that all the drives are in neutral before starting the engine. Start the engine only from the operator's position on the platform.

  • Use care when approaching blind corners, shrubs, trees, or other objects that may obscure vision.

  • Slow down and use caution when making turns and crossing roads and sidewalks. Watch for traffic.

  • Stop the attachment when you are not working.

  • Stop the machine, shut off the engine, remove the key, and inspect the machine if you strike an object. Make any necessary repairs before resuming operation.

  • Never run an engine in an enclosed area.

  • Never leave a running machine unattended.

  • Before leaving the operating position, do the following:

    • Park the machine on a level surface.

    • Lower the loader arms and disengage the auxiliary hydraulics.

    • Engage the parking brake.

    • Shut off the engine and remove the key.

  • Do not operate the machine when there is the risk of lightning.

  • Operate the machine only in areas where there is sufficient clearance for you to safely maneuver. Be aware of obstacles in close proximity to you. Failure to maintain adequate distance from trees, walls, and other barriers may result in injury as the machine backs up during operation if you are not attentive to the surroundings.

  • Check for overhead clearance (i.e., electrical wires, branches, and doorways) before driving under any objects and do not contact them.

  • Do not overfill the attachment and always keep the load level when raising the loader arms. Items in the attachment could fall and cause injury.

Slope Safety

  • Operate the machine up and down slopes with the heavy end of the machine uphill. Weight distribution changes with attachments. An empty load-bearing attachment makes the rear of the machine the heavy end, and a full load-bearing attachment makes the front of the machine the heavy end. Most other attachments make the front of machine the heavy end.

  • Raising or extending the loader arms on a slope affects the stability of the machine. Keep the loader arms in the lowered and retracted position when on slopes.

  • Slopes are a major factor related to loss of control and tip-over accidents, which can result in severe injury or death. Operating the machine on any slope or uneven terrain requires extra caution.

  • Establish your own procedures and rules for operating on slopes. These procedures must include surveying the site to determine which slopes are safe for machine operation. Always use common sense and good judgment when performing this survey.

  • Slow down and use extra care on hillsides. Ground conditions can affect the stability of the machine.

  • Avoid starting or stopping on a slope. If the machine loses traction, proceed slowly, straight down the slope.

  • Avoid turning on slopes. If you must turn, turn slowly and keep the heavy end of the machine uphill.

  • Keep all movements on slopes slow and gradual. Do not make sudden changes in speed or direction.

  • If you feel uneasy operating the machine on a slope, do not do it.

  • Watch for holes, ruts, or bumps, as uneven terrain could overturn the machine. Tall grass can hide obstacles.

  • Use caution when operating on wet surfaces. Reduced traction could cause sliding.

  • Evaluate the area to ensure that the ground is stable enough to support the machine.

  • Use caution when operating the machine near the following:

    • Drop-offs

    • Ditches

    • Embankments

    • Bodies of water

    The machine could suddenly roll over if a track goes over the edge or the edge caves in. Maintain a safe distance between the machine and any hazard.

  • Do not remove or add attachments on a slope.

  • Do not park the machine on a hillside or slope.

Utility Line Safety

  • If you strike a utility line, do the following:

    • Shut off the machine and remove the key.

    • Remove all individuals from the work area.

    • Immediately contact the proper emergency and utility authorities to secure the area.

    • If you damage a fiber-optic cable, do not look into the exposed light.

  • Do not leave the operator’s platform if the machine is charged with electricity. You will be safe as long as you do not leave the platform.

    • Touching any part of the machine may ground you.

    • Do not allow another individual to touch or approach the machine when charged.

    • Always assume the machine is charged if you strike an electrical or communication line. Do not attempt to leave the machine.

  • Leaking gas is both flammable and explosive and may cause serious injury or death. Do not smoke while operating the machine.

Starting the Engine

  1. Ensure that the battery-disconnect switch is in the ON position; refer to Using the Battery-Disconnect Switch.

  2. Ensure that the traction-control is in the NEUTRAL position.

  3. Insert the key into the key switch and turn it to the ON position.

  4. Turn the key to the START position. When the engines starts, release the key.

    Important: Do not engage the starter for more than 10 seconds at a time. If the engine fails to start, wait 30 seconds for the starter to cool down between attempts. Failure to follow these instructions could burn out the starter motor.

    Important: Running the engine at high speeds when the hydraulic system is cold (i.e., when the air temperature is at or below freezing) could damage the hydraulic system. When starting the engine in cold conditions, allow it to run at mid-throttle for 2 to 5 minutes before increasing it to high throttle.

    Note: If the outdoor temperature is below freezing, store the machine in a garage to keep it warmer and to aid in starting.

Driving the Machine

Use the traction controls to move the machine. The farther you move the traction controls in any direction, the faster the machine moves in that direction. Release the traction controls to stop the machine.

The throttle control regulates the engine speed as measured in rpm (revolutions per minute). Run the engine at high throttle for best performance. You can, however, use the transport speed control in the InfoCenter to operate the machine at lower speeds and retain full engine speed; refer to Setting the Maximum Transport Speed.

Shutting Off the Engine

  1. Park the machine on a level surface and lower the loader arms.

  2. Disengage the auxiliary hydraulics.

  3. Set the throttle to low idle.

  4. If the engine has been working hard or is hot, let it idle for 5 minutes before turning the key switch to the OFF position.

    Note: This helps to cool the engine before you shut it off. In an emergency, you can shut off the engine immediately.

  5. Turn the key switch to the OFF position and remove the key.

Caution

A child or untrained bystander could attempt to operate the traction unit and be injured.

Remove the key from the key switch when leaving the traction unit, even if just for a few seconds.

Using Attachments

This is a multipurpose machine intended for use in various activities. It is designed to operate safely with a variety of Toro-manufactured attachments, each of which performs a specialized function. Toro accepts no liability for machine damage or personal injury that results from the use of other manufacturers attachments. The user accepts the burden of these risks.

Read the attachment Operator’s Manual before you use the attachment.

Important: Attachments can change the stability and the operating characteristics of the machine.

Installing an Attachment

Important: Before installing the attachment, ensure that the mount plates are free of any dirt or debris and that the pins rotate freely. If the pins do not rotate freely, grease them.

  1. Position the attachment on a level surface with enough space behind it to accommodate the machine.

  2. Rotate the quick-attach levers outward to raise the quick-attach pins (Figure 30).

    g215372

    Figure 30

    1. Quick-attach lever
    2. Attachment mount plate

  3. Start the engine.

  4. Tilt the attachment mount plate forward.

  5. Position the mount plate into the upper lip of the attachment receiver plate (Figure 31).

    g215373

    Figure 31

    1. Mount plate
    2. Receiver plate

  6. Raise the loader arms while tilting back the mount plate at the same time.

    Important: Raise the attachment enough to clear the ground and tilt the mount plate all the way back.

  7. Shut off the engine and remove the key.

  8. Rotate the quick-attach levers inward, ensuring that the quick-attach pins are fully seated in the mount plate.

    Warning

    If you do not fully seat the quick-attach pins through the attachment mount plate, the attachment could fall off the machine, crushing you or bystanders.

    Ensure that the quick-attach pins are fully seated in the attachment mount plate.

Connecting the Hydraulic Hoses

Warning

Hydraulic fluid escaping under pressure can penetrate skin and cause injury. Fluid injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury; otherwise, gangrene may result.

  • Keep your body and hands away from pinhole leaks or nozzles that eject high-pressure hydraulic fluid.

  • Use cardboard or paper to find hydraulic leaks; never use your hands.

Caution

Hydraulic couplers, hydraulic lines/valves, and hydraulic fluid may be hot. If you contact hot components, you may be burned.

  • Wear gloves when operating the hydraulic couplers.

  • Allow the machine to cool before touching hydraulic components.

  • Do not touch hydraulic fluid spills.

If the attachment requires hydraulics for operation, connect the hydraulic hoses as follows:

  1. Shut off the engine and remove the key.

  2. Remove the protective covers from the hydraulic connectors on the machine.

  3. Ensure that all foreign matter is cleaned from the hydraulic connectors.

  4. Push the attachment female connector onto the male connector on the machine.

  5. Push the attachment male connector into the female connector on the machine.

  6. Confirm that the connection is secure by pulling on the hoses.

Removing an Attachment

  1. Park the machine on a level surface.

  2. Lower the attachment to the ground.

  3. Shut off the engine and remove the key.

  4. Raise the quick-attach pins by rotating the levers outward.

  5. If the attachment uses hydraulics, slide the collars back on the hydraulic couplers and disconnect them.

    Important: Connect the attachment hoses together to prevent hydraulic system contamination during storage.

    Caution

    Hydraulic couplers, hydraulic lines/valves, and hydraulic fluid may be hot. If you contact hot components, you may be burned.

    • Wear gloves when operating the hydraulic couplers.

    • Allow the machine to cool before touching hydraulic components.

    • Do not touch hydraulic fluid spills.

  6. Install the protective covers onto the hydraulic couplers on the machine.

  7. Start the engine, tilt the mount plate forward, and back the machine away from the attachment.

Understanding Smart Power® Traction

The Smart Power® function senses the load on the engine and adjusts the maximum traction speed while maintaining the engine speed so that you can optimize performance in powered attachments. For example, when using the trencher attachment, Smart Power reduces the traction speed so that you have maximum, continuous power while digging.

Engage the attachment hydraulics and slowly move the traction control to activate Smart Power.

Note: To use this function, ensure that Smart Power is set to ON in the Settings section of the InfoCenter; refer to InfoCenter Display. For some applications, such as digging and grading, the machine may perform better with Smart Power set to OFF.

Understanding the Smart Load System

When you raise the loader arms above a certain level (slightly above parallel to the ground), the Smart Load system will automatically reduce the maximum traction speed to 50%. The engine speed will remain the same.

Note: If the maximum traction speed is already set 50% or below in the InfoCenter, the traction speed will not automatically change.

For telescoping machines:

The Smart Load system also measures the hydraulic pressure in the loader arm cylinders to determine the maximum reach.

When you extend the loader arms to the maximum reach for the arm height and load weight, the InfoCenter will display the Smart Load icon (Figure 32) and flash the indicator light, an alarm will beep, and the arms will stop extending.

To extend the loader arms further, lighten the load.

g270732

Figure 32

After Operation

General Safety

  • Shut off the engine, remove the key, wait for all movement to stop, and allow the machine to cool before adjusting, cleaning, storing, or servicing it.

  • Clean debris from the attachments, drives, mufflers, and engine to help prevent fires. Clean up oil or fuel spills.

  • Keep all parts in good working condition and all hardware tightened.

  • Do not touch parts that may be hot from operation. Allow them to cool before attempting to maintain, adjust, or service the machine.

  • Use care when loading or unloading the machine into a trailer or truck.

Moving a Non-Functioning Machine

In an emergency, the machine can be moved forward by actuating the bypass valve in the hydraulic pump and pushing or towing the machine.

Important: Do not tow or pull the machine without bypassing the parking brake or you will damage the hydraulic system.

  1. Shut off the engine and remove the key.

  2. Remove the bottom plate; refer to Removing the Bottom Plate

  3. For each drive motor, remove the plug and install a screw (M8–1.25 x 40 mm) and washer (M8 x 16 mm) in its place (Figure 33). Hand-tighten the hardware.

    g263991

    Figure 33

    1. Remove this plug and install a screw and washer.
    2. Track drive motor

  4. Use hand tools to rotate the hardware clockwise until the brake is released or you cannot rotate the screw (Figure 32).

  5. On the left side of the hydraulic pump, rotate the 4 bypass valves 3 full turns counter-clockwise to open and allow the oil to bypass internally.

    Note: Do not open more than 3 turns. Because fluid is bypassed, you can slowly move the machine without damaging the transmission.

    g267326

    Figure 34

    1. Bypass valve

  6. Tow the machine as required using the tie-down locations (see Figure 37).

    Important: Do not push or tow the machine faster than 3 to 4.8 km/h (2 to 3 mph) for longer than 3 minutes, because you may damage the transmission. The bypass valves must be open whenever you push or tow the machine.

  7. Close the bypass valves and torque them to 70 N∙m (52 ft-lb).

  8. Remove the screw and install the plug into each track drive motor and torque to 8 to 12 N∙m (71 to 103 in-lb) before operating the machine.

  9. Replace any fluid lost during this procedure; refer to Replacing the Drive-Motor Planetary Gear Oil.

Hauling the Machine

Use a heavy-duty trailer or truck to haul the machine. Use a full-width ramp. Ensure that the trailer or truck has all the necessary brakes, lighting, and marking as required by law. Please carefully read all the safety instructions. Knowing this information could help you or bystanders avoid injury. Refer to your local ordinances for trailer and tie-down requirements.

Warning

Driving on the street or roadway without turn signals, lights, reflective markings, or a slow-moving-vehicle emblem is dangerous and can lead to accidents causing personal injury.

Do not drive the machine on a public street or roadway.

Selecting a Trailer

Warning

Loading a machine onto a trailer or truck increases the possibility of tip-over and could cause serious injury or death (Figure 35).

  • Use only full-width ramps.

  • Ensure that the length of ramp is at least 4 times as long as the height of the trailer or truck bed to the ground. This ensures that ramp angle does not exceed 15 degrees on flat ground.

g229507

Figure 35

  1. Full-width ramp(s) in stowed position
  2. Ramp is at least 4 times as long as the height of the trailer or truck bed to the ground
  3. H=height of the trailer or truck bed to the ground
  4. Trailer

Loading the Machine

Warning

Loading a machine onto a trailer or truck increases the possibility of tip-over and could cause serious injury or death.

  • Use extreme caution when operating a machine on a ramp.

  • Load and unload the machine with the heavy end up the ramp.

  • Avoid sudden acceleration or deceleration while driving the machine on a ramp as this could cause a loss of control or a tip-over situation.

  1. If using a trailer, connect it to the towing vehicle and connect the safety chains.

  2. If applicable, connect the trailer brakes.

  3. Lower the ramp(s).

  4. Lower the loader arms.

  5. Load the machine onto the trailer with the heavy end up the ramp, carrying loads low (Figure 36).

    • If the machine has a full load-bearing attachment (e.g., bucket) or a non-load-bearing attachment (e.g., trencher), drive the machine forward up the ramp.

    • If the machine has an empty load-bearing attachment or no attachment, back the machine up the ramp.

    g204457

    Figure 36

    1. Machine with full attachment or non-load-bearing attachment—drive the machine forward up the ramp(s).
    2. Machine with empty or no attachment—back the machine up the ramp(s).

  6. Lower the loader arms all the way down.

  7. Engage the parking brake (if equipped), shut off the engine, and remove the key.

  8. Use the metal tie-down loops on the machine to securely fasten the machine to the trailer or truck with straps, chains, cable, or ropes (Figure 37). Refer to local regulations for tie-down requirements.

    Important: Do not use the tie-down loops to lift the machine.

    g303494

    Figure 37

    1. Tie-down loops

Unloading the Machine

  1. Lower the ramp(s).

  2. Unload the machine from the trailer with the heavy end up the ramp, carrying loads low (Figure 38).

    • If the machine has a full load-bearing attachment (e.g., bucket) or a non-load-bearing attachment (e.g., trencher), back it down the ramp.

    • If the machine has an empty load-bearing attachment or no attachment, drive it forward down the ramp.

    g204458

    Figure 38

    1. Machine with full attachment or non-load-bearing attachment—back the machine down the ramp(s).
    2. Machine with empty or no attachment—drive the machine forward down the ramp(s).

Maintenance

Note: Download a free copy of the electrical or hydraulic schematic by visiting www.Toro.com and searching for your machine from the Manuals link on the home page.

Note: Determine the left and right sides of the machine from the normal operating position.

Maintenance Safety

Caution

If you leave the key in the switch, someone could accidently start the engine and seriously injure you or other bystanders.

Remove the key from the switch before you perform any maintenance.

  • Park the machine on a level surface, disengage the auxiliary hydraulics, lower the attachment, engage the parking brake (if equipped), shut off the engine, and remove the key. Wait for all movement to stop and allow the machine to cool before adjusting, cleaning, storing, or repairing it.

  • Clean up oil or fuel spills.

  • Do not allow untrained personnel to service the machine.

  • Use jack stands to support the components when required.

  • Carefully release pressure from components with stored energy; refer to Relieving Hydraulic Pressure.

  • Disconnect the battery before making any repairs; refer to Using the Battery-Disconnect Switch.

  • Keep your hands and feet away from the moving parts. If possible, do not make adjustments with the engine running.

  • Keep all parts in good working condition and all hardware tightened. Replace all worn or damaged decals.

  • Do not tamper with the safety devices.

  • Attachments can change the stability and the operating characteristics of the machine.

  • Use only genuine Toro replacement parts.

  • If any maintenance or repair requires the loader arms to be in the raised position, secure the arms in the raised position with the hydraulic-cylinder lock(s).

Recommended Maintenance Schedule(s)

Maintenance Service IntervalMaintenance Procedure
After the first 8 hours
  • Check and adjust the track tension.
    		•
    After the first 50 hours
  • Change the engine oil and filter.
  • Check and adjust the track tension.
    		•
    Before each use or daily
  • Grease the machine.(Grease immediately after every washing.)
  • Check and lubricate the quick-attach linkages using spray lubricant.
  • Check the air-filter-service indicator.
  • Check the engine-oil level.
  • Clean the tracks and check for excessive wear and proper tension.
  • Clean the screen, oil cooler, and front of the radiator (more often in dirty or dusty conditions).
  • Check the coolant level in the expansion tank.
  • Check and clean the radiator screen
  • Check the condition of the alternator belt.
  • Remove debris from the machine.
  • Check for loose fasteners.
    		•
    Every 25 hours
  • Check the hydraulic-fluid level.
  • Torque the loader arm adjustment screws (telescoping machines only).Check the torque whenever the lower loader arms rattle.
    		•
    Every 50 hours
  • Drain water and other contaminants from the fuel filter/water separator.
  • Check the battery condition.
  • Check and adjust the track tension.
    		•
    Every 100 hours
  • Clean and lubricate the underside of the traction controls.
  • Remove the air-cleaner cover and clean out debris.(Clean more often in dirty or dusty conditions.)
  • Check the cooling system hoses.
  • Adjust the alternator belt tension.
  • Check the hydraulic lines for leaks, loose fittings, kinked lines, loose mounting supports, wear, weather, and chemical deterioration.(Make necessary repairs before operating.)
  • Check for dirt buildup in the chassis.
  • Check the alternator/fan belt tension (refer to the engine owner’s manual for instructions).
    		•
    Every 400 hours
  • Change the engine oil and filter.(Service more frequently if conditions are extremely dusty or sandy.)
  • Replace the fuel filter canister.
  • Check the fuel lines and connections for deterioration, damage, or loose connections.
  • Replace the hydraulic oil and filters (if not using Toro fluid).
    		•
    Every 500 hours
  • Replacing the water separator filter.
  • Drain and clean the fuel tank(s)—Authorized Service Dealer only.
  • Replace the alternator belt—Authorized Service Dealer only
  • Replace the alternator/fan belt (refer to the engine owner’s manual for instructions).
    		•
    Every 800 hours
  • Change the engine coolant.
    		•
    Every 1,000 hours
  • Replace the drive-motor planetary gear oil.
  • Replace the hydraulic oil and filters (if using Toro fluid).
    		•
    Every 1,500 hours
  • Replace all moving hydraulic hoses.
    		•
    Yearly
  • Replace the air-cleaner filter.
    		•
    Yearly or before storage
  • Check and adjust the track tension.
  • Touch up chipped paint.
    		•
    Every 2 years
  • Replace all moving hydraulic hoses.
    		•

    Important: Refer to your engine owner’s manual for additional maintenance procedures.

    Pre-Maintenance Procedures

    Using the Cylinder Locks

    Warning

    The loader arms may lower when in the raised position, crushing anyone under them.

    Install the cylinder lock(s) before performing maintenance that requires raised loader arms.

    Installing the Cylinder Locks

    1. Remove the attachment.

    2. Raise the loader arms to the fully raised position.

    3. Shut off the engine and remove the key.

    4. Remove the 2 pins securing the cylinder lock to the posts on the side of the machine.

    5. Slide the cylinder lock over the lift-cylinder rod (Figure 39).

      g267536

      Figure 39

      1. Cylinder lock
      2. Lift-cylinder rod
      3. Pin (2)

    6. Repeat step 4 and 5 for the other side of the machine.

    7. Slowly lower the loader arms until the cylinder locks contact the cylinder bodies and rod ends.

    Removing and Storing the Cylinder Locks

    Important: Remove the cylinder locks from the rods and fully secure them in the storage position before operating the machine.

    1. Start the engine.

    2. Raise the loader arms to the fully raised position.

    3. Shut off the engine and remove the key.

    4. Remove the pins securing the cylinder locks.

    5. Place the cylinder locks on the posts on the sides of the machine and secure with the pins.

    6. Lower the loader arms.

    Accessing Internal Components

    Warning

    Opening or removing covers, hoods, and screens while the engine is running could allow you to contact moving parts, seriously injuring you.

    Before opening any of the covers, hoods, and screens, shut off the engine, remove the key from the key switch, and allow the engine to cool.

    Opening the Hood

    1. Raise the loader arms and install the cylinder lock.

    2. Shut off the engine and remove the key.

    3. Loosen the hood-locking screw (Figure 40).

      g260060

      Figure 40

      1. Hood-locking screw
      2. Hood-latch lever
      3. Hood

    4. Hold the hood down and release the 2 latches (Figure 40).

    5. Lift open the hood (Figure 40).

    Closing the Hood

    1. Lower the hood, and hold it down while you secure the latches..

    2. Tighten the hood-locking screw (Figure 40).

    3. Remove the cylinder locks and lower the loader arms.

    Opening the Rear-Access Cover

    1. Remove the fastener (Figure 41).

      g260061

      Figure 41

      1. Fastener

    2. Lift the rear-access cover up and secure the prop rod to access the internal components (Figure 41).

      g267537

      Figure 42

      1. Prop rod

    Removing the Rear Screen

    1. Open the rear-access cover; refer to Opening the Rear-Access Cover.

    2. Loosen the 2 bolts securing the bottom of the screen (Figure 43).

    3. Loosen the 2 knobs on the screen (Figure 43).

      g260063

      Figure 43

      1. Knob (2)
      2. Bolt (2)

    4. Lift the screen and remove it (Figure 43).

    Removing the Bottom Plate

    1. Remove the 2 bolts securing the bottom plate (Figure 44).

      g263690

      Figure 44

      1. Bottom plate
      2. Bolt

    2. Remove the bottom plate.

    Removing the Front Cover

    1. Raise the loader arms and secure them with the cylinder locks.

    2. Loosen the 2 bolts securing the front cover to the machine (Figure 45).

      g260062

      Figure 45

      1. Front cover
      2. Bolt (2)

    3. Slide the cover off the machine.

    4. When installing the cover, torque the bolts to 41 N∙m (30 ft-lb).

    Removing the Front Cover Assembly

    1. Raise the loader arms and secure them with the cylinder locks.

    2. Remove the 4 bolts securing the cover assembly to the machine (Figure 46).

      g303492

      Figure 46

      1. Bolt (4)
      2. Front cover assembly.

    3. Remove the cover assembly (Figure 46).

    Lubrication

    Lubricating the Machine

    Maintenance Service IntervalMaintenance Procedure
    Before each use or daily
  • Grease the machine.(Grease immediately after every washing.)
  • Check and lubricate the quick-attach linkages using spray lubricant.
    		•
    Every 100 hours
  • Clean and lubricate the underside of the traction controls.
    		•

    Grease Type: General-purpose grease.

    1. Park the machine on a level surface, engage the parking brake, and lower the loader arms.

    2. Shut off the engine and remove the key.

    3. Clean the grease fittings with a rag.

    4. Connect a grease gun to each fitting (Figure 47, Figure 48, and Figure 49).

      Note: Raise the loader arms before greasing the fittings in Figure 49.

      g261040

      Figure 47

      g261039

      Figure 48

      g264003

      Figure 49

    5. Pump grease into the fittings until grease begins to ooze out of the bearings (approximately 3 pumps).

    6. Wipe up any excess grease.

    7. Lubricate the quick-attach linkages using spray lubricant (Figure 50).

      g269591

      Figure 50

    Engine Maintenance

    Engine Safety

    • Shut off the engine before checking the oil or adding oil to the crankcase.

    • Do not change the engine governor setting or overspeed the engine.

    • Keep your hands, feet, face, clothing, and other body parts away from the muffler and other hot surfaces.

    Servicing the Air Cleaner

    Maintenance Service IntervalMaintenance Procedure
    Before each use or daily
  • Check the air-filter-service indicator.
    		•
    Every 100 hours
  • Remove the air-cleaner cover and clean out debris.(Clean more often in dirty or dusty conditions.)
    		•
    Yearly
  • Replace the air-cleaner filter.
    		•

    Check the air-cleaner body for damage, which could cause an air leak. Replace the body if it is damaged. Check the intake system for leaks, damage, or loose hose clamps.

    Service the air-cleaner filter only when the service indicator (Figure 51) requires it. Changing the air filter before it is necessary increases the chance of dirt entering the engine when you remove the filter.

    g009709

    Figure 51

    1. Air-cleaner indicator

    Important: Ensure that the cover is seated correctly and seals with the air-cleaner body.

    1. Replace the air cleaner (Figure 52).

      g253706

      Figure 52

      Note: Do not clean a used element; cleaning it can damage the filter media.

      Important: Never attempt to clean the safety filter (Figure 53). Replace the safety filter after every 3 primary filter services.

      g011505

      Figure 53

      1. Air-cleaner safety filter

    2. Reset the indicator (Figure 51) if it shows red.

    Servicing the Engine Oil

    Maintenance Service IntervalMaintenance Procedure
    After the first 50 hours
  • Change the engine oil and filter.
    		•
    Before each use or daily
  • Check the engine-oil level.
    		•
    Every 400 hours
  • Change the engine oil and filter.(Service more frequently if conditions are extremely dusty or sandy.)
    		•

    Engine-Oil Specifications

    Oil Type: Detergent diesel engine oil (API service CH-4 or higher)

    Crankcase Capacity: with filter 7.0 L (1.85 US gallons)

    Viscosity: See the table below.

    g261157

    Figure 54

    Checking the Engine-Oil Level

    1. Park the machine on a level surface, engage the parking brake, and lower the loader arms.

    2. Shut off the engine, remove the key, and allow the engine to cool.

    3. Open the hood.

    4. Clean the area around the oil dipstick and oil-fill cap (Figure 55).

      g302251

      Figure 55

      1. Oil-fill cap
      2. Oil dipstick

    5. Check the oil and add additional oil as needed (Figure 56).

      Important: Do not overfill the crankcase with oil; if the oil in the crankcase is too high and you run the engine, you may damage the engine.

      g264959

      Figure 56

    6. Close the hood.

    Changing the Engine Oil and Filter

    1. Start the engine and let it run for 5 minutes.

      Note: This warms the oil so that it drains better.

    2. Park the machine on a level surface.

    3. Raise the loader arms and secure with the cylinder locks; refer to Installing the Cylinder Locks.

    4. Engage the parking brake, shut off the engine, and remove the key.

    5. Drain the oil beneath the platform (Figure 57).

      Caution

      Components will be hot if the machine has been running. If you touch hot components, you may be burned.

      Use care to avoid touching hot components while changing the oil and/or filter.

      g261345g261346

      Figure 57

    6. Torque the drain plug to 46 to 56 N∙m (34 to 42 ft-lb).

    7. Open the hood and secure the prop rod (if applicable).

    8. Remove the front cover assembly; refer to Removing the Front Cover Assembly.

    9. Place a shallow pan or rag under the filter to catch oil.

    10. Change the oil filter (Figure 58).

      g031261

      Figure 58

    11. Remove the oil-fill cap and slowly pour approximately 80% of the specified amount of oil in through the valve cover.

    12. Check the oil level.

    13. Slowly add additional oil to bring the level to the upper hole on the dipstick.

    14. Replace the fill cap.

    15. Install the front cover assembly.

    16. Close the hood.

    Fuel System Maintenance

    Danger

    In certain conditions, fuel is extremely flammable and highly explosive. A fire or explosion from fuel can burn you and others and can damage property.

    Refer to Fuel Safety for a complete list of fuel related precautions.

    Draining the Water Separator

    Maintenance Service IntervalMaintenance Procedure
    Every 50 hours
  • Drain water and other contaminants from the fuel filter/water separator.
    		•

    1. Park the machine on a level surface, engage the parking brake, and lower the loader arms.

    2. Shut off the engine and remove the key.

    3. Open the rear access cover; refer to Opening the Rear-Access Cover

    4. Remove the rear screen; refer to Removing the Rear Screen

    5. Place a container under the water separator.

    6. Disconnect the wire harness from the water separator (Figure 59).

      g264250

      Figure 59

      1. Water separator
      2. Switch
      3. Drain valve

    7. Unscrew the switch from bottom of the filter canister and allow the water to drain (Figure 59).

    8. Install the switch (Figure 59).

    9. Connect the wire harness to the switch (Figure 59).

    10. Install the rear screen and tighten the knobs and bolts to secure it.

    11. Close the rear-access cover and install the fastener to secure it.

    12. Bleed the fuel system; refer to Bleeding the Fuel System.

    Replacing the Water Separator Filter

    Maintenance Service IntervalMaintenance Procedure
    Every 500 hours
  • Replacing the water separator filter.
    		•

    1. Park the machine on a level surface, engage the parking brake, and lower the loader arms.

    2. Shut off the engine and remove the key.

    3. Open the rear access cover; refer to Opening the Rear-Access Cover.

    4. Remove the rear screen; refer to Removing the Rear Screen.

    5. Disconnect the wire harness from the water separator.

    6. Unscrew the switch and drain the water separator (Figure 59).

    7. Clean the area where the filter mounts.

    8. Remove the filter and clean the mounting surface.

    9. Lubricate the gasket on the filter with clean oil.

    10. Install the filter by hand until the gasket contacts the mounting surface; then rotate an additional 1/2 turn.

    11. Install the switch to the filter.

    12. Connect the wire harness to the switch.

    13. Install the rear screen and tighten the knobs and bolts.

    14. Close the rear-access cover and install the fastener.

    Replacing the Fuel Filter Canister

    Maintenance Service IntervalMaintenance Procedure
    Every 400 hours
  • Replace the fuel filter canister.
    		•

    1. Park the machine on a level surface, engage the parking brake, and lower the loader arms.

    2. Shut off the engine and remove the key.

    3. Open the rear access cover; refer to Opening the Rear-Access Cover

    4. Remove the rear screen; refer to Removing the Rear Screen

    5. Place a clean container under the fuel filter canister (Figure 60).

      g261736

      Figure 60

      1. Fuel filter canister

    6. Remove the filter canister and clean the mounting surface.

    7. Lubricate the gasket on the new filter canister with clean oil.

    8. Fill the canister with fuel.

    9. Install the filter canister by hand until the gasket contacts the mounting surface, then rotate it an additional 1/2 turn.

    10. Install the rear screen and tighten the knobs and bolts to secure it.

    11. Close the rear-access cover and install the fastener to secure it.

    Checking the Fuel Lines and Connections

    Maintenance Service IntervalMaintenance Procedure
    Every 400 hours
  • Check the fuel lines and connections for deterioration, damage, or loose connections.
    		•

    Inspect the fuel lines and connections for deterioration, damage, or loose connections. Tighten any loose connections and contact your Authorized Service Dealer for assistance in fixing damaged fuel lines.

    Bleeding the Fuel System

    You must bleed the fuel system before starting the engine if any of the following situations have occurred:

    • Initial startup of a new machine

    • The engine has ceased running due to a lack of fuel.

    • Maintenance has been performed upon fuel-system components (e.g., filter replaced).

    Use the manual pump on the water separator to bleed air out of the fuel system.

    g263481

    Figure 61

    1. Manual pump

    Draining the Fuel Tank(s)

    Maintenance Service IntervalMaintenance Procedure
    Every 500 hours
  • Drain and clean the fuel tank(s)—Authorized Service Dealer only.
    		•

    Have an Authorized Service Dealer drain and clean the fuel tank(s).

    Electrical System Maintenance

    Electrical System Safety

    • Disconnect the battery before repairing the machine. Disconnect the negative terminal first and the positive last. Connect the positive terminal first and the negative last.

    • Charge the battery in an open, well-ventilated area, away from sparks and flames. Unplug the charger before connecting or disconnecting the battery. Wear protective clothing and use insulated tools.

    • Battery acid is poisonous and can cause burns. Avoid contact with skin, eyes, and clothing. Protect your face, eyes, and clothing when working with a battery.

    • Battery gases can explode. Keep cigarettes, sparks, and flames away from the battery.

    Servicing the Battery

    Maintenance Service IntervalMaintenance Procedure
    Every 50 hours
  • Check the battery condition.
    		•

    Using the Battery-Disconnect Switch

    1. Park the machine on a level surface, engage the parking brake, and lower the loader arms.

    2. Shut off the engine and remove the key.

    3. Open the rear-access cover.

    4. Turn the battery-disconnect switch to the ON or OFF position to perform the following:

      • To energize the machine electrically, rotate the battery-disconnect switch clockwise to the ON position (Figure 62).

      • To de-energize the machine electrically, rotate the battery-disconnect switch counterclockwise to the OFF position (Figure 62).

      g261512

      Figure 62

      1. Battery-disconnect switch—OFF position
      2. Battery-disconnect switch—ON position

    Removing the Battery

    1. Park the machine on a level surface, engage the parking brake, and lower the loader arms.

    2. Shut off the engine and remove the key.

    3. Remove the rear screen; refer to Removing the Rear Screen.

    4. Disconnect the negative (black) ground cable from the battery post (Figure 63). Retain the fasteners.

      g263732

      Figure 63

      1. Positive cable
      2. Bolt (3)
      3. Battery tray
      4. Battery
      5. Wing nut
      6. Negative cable

    5. Slide the rubber cover off the positive (red) cable.

    6. Disconnect the positive (red) cable from the battery post (Figure 63). Retain the fasteners.

    7. Loosen the 3 bolts securing the battery tray and remove the tray with the battery (Figure 63).

    8. Remove the wing nut and rod.

    9. Remove the battery.

    Charging the Battery

    Warning

    Charging the battery produces gasses that can explode.

    Never smoke near the battery and keep sparks and flames away from battery.

    Important: Always keep the battery fully charged (1.265 specific gravity). This is especially important to prevent battery damage when the temperature is below 0°C (32°F).

    1. Remove the battery from the machine; refer to Removing the Battery.

    2. Charge the battery for 4 to 8 hours at a rate of 3 to 4 A (Figure 64). Do not overcharge the battery.

      g003792

      Figure 64

      1. Positive battery post
      2. Negative battery post
      3. Red (+) charger lead
      4. Black (-) charger lead

    3. When the battery is fully charged, unplug the charger from the electrical outlet, then disconnect the charger leads from the battery posts (Figure 64).

    Cleaning the Battery

    Note: Keep the terminals and the entire battery case clean, because a dirty battery discharges slowly.

    1. Park the machine on a level surface, engage the parking brake (if equipped), and lower the loader arms.

    2. Shut off the engine and remove the key.

    3. Remove the battery from the machine; Removing the Battery.

    4. Wash the entire case with a solution of baking soda and water.

    5. Rinse the battery with clear water.

    6. Coat the battery posts and cable connectors with Grafo 112X (skin-over) grease (Toro Part No. 505-47) or petroleum jelly to prevent corrosion.

    7. Install the battery; refer to Installing the Battery.

    Installing the Battery

    1. Place the battery on the battery tray and secure it with the wing nut and rod (Figure 63).

    2. Install the battery tray to the machine and secure with the 3 bolts (Figure 63). Torque the bolts to 41 N∙m (30 ft-lb).

    3. Using the fasteners previously removed, install the positive (red) battery cable to the positive (+) battery terminal (Figure 63).

    4. Slide the red terminal boot onto the positive battery post.

    5. Using the fasteners previously removed, install the negative (black) battery cable to the negative (-) battery terminal (Figure 63).

    6. Install the rear screen.

    Servicing a Replacement Battery

    The original battery is maintenance-free and does not require service. For servicing a replacement battery, refer to the battery manufacturer’s instructions.

    Jump-Starting the Machine

    Warning

    Jump-starting the battery can produce gasses that can explode.

    Do not smoke near the battery, and keep sparks and flames away from battery.

    1. Open the rear-access cover; refer to Opening the Rear-Access Cover.

    2. Remove the rear screen; refer to Removing the Rear Screen.

    3. Check and clean corrosion from the battery terminals before jump-starting. Ensure that the connections are tight.

      Caution

      Corrosion or loose connections can cause unwanted electrical voltage spikes at any time during the jump-starting procedure.

      Do not attempt to jump-start the machine with loose or corroded battery terminals, or damage to the engine may occur.

      Danger

      Jump-starting a weak battery that is cracked or frozen or has a low electrolyte level or an open/shorted battery cell can cause an explosion, resulting in serious personal injury.

      Do not jump-start a weak battery if these conditions exist.

    4. Make sure that the booster battery is a good and fully charged lead-acid battery at 12.6 V or greater.

      Note: Use properly sized jumper cables with short lengths to reduce voltage drop between systems. Make sure that the cables are color coded or labeled for the correct polarity.

      Warning

      Batteries contain acid and produce explosive gases.

      • Shield your eyes and face from the batteries at all times.

      • Do not lean over the batteries.

      Note: Ensure that the vent caps are tight and level. Place a damp cloth, if available, over any vent caps on both batteries. Also ensure that the machines do not touch and that both electrical systems are off and at the same rated system voltage. These instructions are for negative ground systems only.

    5. Connect the positive (+) cable to the positive (+) terminal of the discharged battery that is wired to the starter or solenoid as shown in Figure 65.

      g012785

      Figure 65

      1. Positive (+) cable on discharged battery
      2. Positive (+) cable on booster battery
      3. Negative (–) cable on the booster battery
      4. Negative (–) cable on the engine block
      5. Booster battery
      6. Discharged battery
      7. Engine block

    6. Connect the other end of the positive (+) jumper cable to the positive terminal of the battery in the other machine.

    7. Connect an end of the negative (-) jumper cable to the negative post of the battery in the other machine.

    8. Connect the other end of the negative (-) jumper cable to a ground point, such as an unpainted bolt or chassis member.

    9. Start the engine in the other machine. Let it run a few minutes, then start your engine.

    10. Remove the cables in the reverse order of connection.

    11. Install the cover to the jump post.

    Servicing the Fuses

    The electrical system is protected by fuses. It requires no maintenance; however, if a fuse blows, check the component/circuit for a malfunction or a short. Figure 66 illustrates the fuse block location.

    g261921

    Figure 66

    ABCD
    EngineLogic-TecTelematicsSystem
    (25 A)(2 A)(2 A)(5 A)
    Starter solenoidPower pointDisplayHorn
    (20 A)(10 A)(10 A)(10 A)
    Accessory connectionAccessory connectionAccessory connection-
    (10 A)(10 A)(10 A)
    Tec powerTec powerTec powerTec power
    (7.5 A)(7.5 A)(7.5 A)(7.5 A)
    ----

    Note: If the machine does not start, either the main circuit or the control panel/relay fuse could be blown.

    Drive System Maintenance

    Replacing the Drive-Motor Planetary Gear Oil

    Maintenance Service IntervalMaintenance Procedure
    Every 1,000 hours
  • Replace the drive-motor planetary gear oil.
    		•

    Oil Type: SAE 85W-140 gear oil

    Capacity: 0.9 L (30 fl oz)

    1. Start the engine and drive the machine for 5 minutes.

      Note: This warms the gear oil so that it drains better.

    2. Park the machine on a level surface so that the drain plug is in the 6 o’clock position (Figure 67), engage the parking brake, and lower the loader arms.

    3. Shut off the engine and remove the key.

    4. Place a drain pan under the drive motor.

    5. Remove the check plug and the drain plug and allow the gear lubricant to drain (Figure 67).

      g267652

      Figure 67

      1. Check plug
      2. Drain plug

    6. Install the drain plug (Figure 67).

    7. Fill the drive motor with gear oil through the check hole until the oil is up to the bottom of the hole.

      g267669

      Figure 68

      1. Check plug
      2. Gear oil

    8. Install the check plug.

    9. Repeat for the other drive motor.

    10. Start the engine and drive the machine a few minutes.

    11. Park the machine on a level surface, engage the parking brake, shut off the engine and remove the key.

    12. Remove the check plugs and verify that the oil level is at the bottom of the oil-level check hole. Add oil as needed.

    13. Install the check plugs. Torque the check and drain plugs to 30 to 40 N∙m (22 to 30 ft-lb).

    Servicing the Tracks

    Maintenance Service IntervalMaintenance Procedure
    After the first 8 hours
  • Check and adjust the track tension.
    		•
    After the first 50 hours
  • Check and adjust the track tension.
    		•
    Before each use or daily
  • Clean the tracks and check for excessive wear and proper tension.
    		•
    Every 50 hours
  • Check and adjust the track tension.
    		•

    Cleaning the Tracks

    1. Park the machine on a level surface and engage the parking brake.

    2. With the bucket installed and angled downward, lower it into the ground so that the front of the traction unit lifts off the ground a few centimeters (inches).

    3. Shut off the engine and remove the key.

    4. Using a water hose or pressure washer, remove dirt from each track system.

    Important: Ensure that you use high-pressure water to wash only the track area. Do not use a high-pressure washer to clean the rest of the traction unit. Do not use high pressure water between the drive sprocket and the traction unit or you may damage the motor seals. High-pressure washing can damage the electrical system and hydraulic valves or deplete grease.

    Important: Ensure that you fully clean the road wheels, the front wheel, and the drive sprocket (Figure 69). The road wheels should rotate freely when clean.

    g261934

    Figure 69

    1. Track
    2. Front wheel
    3. Road wheel (4)
    4. Sectional drive sprocket
    5. Tensioner
    6. Rear wheel

    Checking the Track Tension

    1. Park the machine on a level surface and engage the parking brake.

    2. With the bucket installed and angled downward, lower it into the ground so that the front of the traction unit lifts off the ground a few centimeters (inches).

      Note: If you do not have a bucket, raise the machine and support it using jackstands rated for the weight of the machine; refer to Specifications.

      g263492

      Figure 70

      1. Road wheel
      2. Gap is 20 mm (0.8 inch).
      3. Track

    3. Shut off the engine and remove the key.

    4. Verify that the gap between the 2nd road wheel from the rear and the track is 20 mm (0.8 inch) as shown in Figure 70. If adjustment is needed, proceed to Adjusting the Track Tension

    Adjusting the Track Tension

    1. Park the machine on a level surface and engage the parking brake.

    2. Place a 15 x 15 cm (6 x 6 inch) block under the rear frame of the machine, directly behind the track being tensioned.

    3. With the bucket installed and angled downward, lower it into the ground so that the front of the traction unit lifts off the ground a few centimeters (inches) and the machine tips back onto the block until the track is completely off the ground.

      Note: If you do not have a bucket, raise the machine and support it using jackstands rated for the weight of the machine; refer to Specifications.

    4. Shut off the engine and remove the key.

    5. Loosen the 2 bolts and rotate the access cover open (Figure 71).

      g262055

      Figure 71

      1. Bolt
      2. Access cover

    6. Remove the locking bolt, spacer, and nut (Figure 72).

      g262056

      Figure 72

      1. Locking bolt
      2. Tensioning screw
      3. Spacer
      4. Nut

    7. Using a 1/2 inch drive ratchet, turn the tensioning screw until the gap between the road wheel and track is 20 mm (0.79 inch) as shown in Figure 70.

      Note: Turning the screw counter-clockwise tightens the track; turning the screw clockwise loosens the track.

    8. Align the notch in the tension screw to the nearest locking-bolt hole and secure the screw with the locking bolt, spacer, and nut (Figure 72.

    9. Repeat the procedure for the other track if needed.

    Replacing the Tracks

    Removing the Tracks

    1. Remove any attachments.

    2. Park the machine on a level surface, ensuring that 1 segment of the sprocket is not engaged with the track.

      g262081

      Figure 73

      1. Sprocket segment

    3. Lower the loader arms.

    4. Shut off the engine and remove the key.

    5. Raise the machine off the ground so that the bottom of the track is at least 10.2 cm (4 inches) off the ground. Support the machine using jack stands.

      Note: Use jack stands rated for your machine.

      Warning

      Mechanical or hydraulic jacks may fail to support the machine and cause serious injury.

      Use jack stands when supporting the machine.

    6. Remove the locking bolt, spacer, and nut (Figure 72).

    7. Using a 1/2-inch drive ratchet, release the drive tension by turning the tensioning screw clockwise (Figure 72 and Figure 74).

      g262083

      Figure 74

      1. Sprocket
      2. Track
      3. Front wheel
      4. Ratchet (1/2 inch)
      5. Road wheel (4)

    8. Remove the segment of the drive sprocket not engaged with the track.

      Important: If you do not remove the sprocket segment, it may be difficult to install a new track without damaging it.

      g262082

      Figure 75

      1. Screw (4)
      2. Sprocket segment

    9. Start the machine and disengage the parking brake.

    10. Move the traction control forward until a second segment of the sprocket is not engaged with the track.

    11. Shut off the engine and remove the key.

    12. Remove the sprocket segment (Figure 75).

    13. Start the machine and disengage the parking brake.

    14. Move the traction control forward until the last segment of the sprocket is not engaged with the track.

      Note: You do not need to remove this segment.

    15. Remove the track from the track frame.

    Installing the Tracks

    1. Wrap the new track around the front wheel (Figure 74).

    2. Push the track under and between the road wheels and wrap it around the rear tension wheel (Figure 74).

    3. Pry the track cleats onto the planetary housing.

    4. Start the engine and disengage the parking brake.

    5. Move the traction control forward until the drive sprocket segment engages with the track (Figure 76).

      g262086

      Figure 76

    6. Shut off the engine and remove the key.

    7. Apply thread-locking compound to the bolts of 1 drive sprocket segment that you removed and install the sprocket segment (Figure 75). Torque the bolts to 247 to 301 N∙m (182 to 222 ft-lb).

    8. Start the engine and disengage the parking brake.

    9. Move the traction control forward until both drive sprocket segments engage the track.

    10. Apply thread-locking compound to the bolts of the other drive sprocket segment that you removed and install the sprocket segment (Figure 76). Torque the bolts to 247 to 301 N∙m (182 to 222 ft-lb).

      Note: Install the sprocket so that the casting numbers in the sprocket face outward.

    11. Using a 1/2 inch drive ratchet, turn the tensioning screw counterclockwise until the gap between the road wheel and track is 20 mm (0.79 inch) as shown in Figure 70.

    12. Align the notch in the tension screw to the nearest locking-bolt hole and secure the screw with the locking bolt, spacer, and nut. Torque the locking bolt to 1,130 N∙cm (100 in-lb).

    13. Lower the machine to the ground.

    14. Repeat the procedure to replace the other track.

    15. Close the access cover and tighten the bolts (Figure 71). Torque the bolts to 41 N∙m (30 ft-lb).

    Cooling System Maintenance

    Cooling System Safety

    • Swallowing engine coolant can cause poisoning; keep out of reach from children and pets.

    • Discharge of hot, pressurized coolant or touching a hot radiator and surrounding parts can cause severe burns.

      • Always allow the engine to cool at least 15 minutes before removing the radiator cap.

      • Use a rag when opening the radiator cap, and open the cap slowly to allow steam to escape.

    Servicing the Cooling System

    Maintenance Service IntervalMaintenance Procedure
    Before each use or daily
  • Clean the screen, oil cooler, and front of the radiator (more often in dirty or dusty conditions).
  • Check the coolant level in the expansion tank.
    		•
    Every 100 hours
  • Check the cooling system hoses.
    		•

    Cleaning the Radiator Screen

    Maintenance Service IntervalMaintenance Procedure
    Before each use or daily
  • Check and clean the radiator screen
    		•

    Remove any buildup of grass, dirt or other debris from the radiator screen with compressed air.

    Checking the Engine-Coolant Level

    The cooling system is filled with a 50/50 solution of water and permanent ethylene-glycol antifreeze.

    1. Park the machine on a level surface, lower the loader arms, engage the parking brake, and shut off the engine.

    2. Remove the key from the key switch and allow the engine to cool.

    3. Open the hood.

    4. Check the coolant level in the expansion tank (Figure 77).

      Note: The coolant level should be at or above the mark on the side of the tank.

      g262375

      Figure 77

      1. Expansion tank
      2. Full mark

    5. If the coolant level is low, remove the expansion tank cap and add a 50/50 mixture of water and permanent ethylene-glycol antifreeze.

      Important: Do not overfill the expansion tank.

    6. Install the expansion-tank cap.

    Changing the Engine Coolant

    Maintenance Service IntervalMaintenance Procedure
    Every 800 hours
  • Change the engine coolant.
    		•

    Have an Authorized Service Dealer change the engine coolant yearly.

    If you need to add engine coolant, refer to Checking the Engine-Coolant Level.

    Belt Maintenance

    Checking and Adjusting the Alternator Belt Tension

    Maintenance Service IntervalMaintenance Procedure
    Before each use or daily
  • Check the condition of the alternator belt.
    		•
    Every 100 hours
  • Adjust the alternator belt tension.
    		•
    Every 500 hours
  • Replace the alternator belt—Authorized Service Dealer only
    		•

    1. Park the machine on a level surface, engage the parking brake, and lower the loader arms.

    2. Shut off the engine and remove the key.

    3. Open the hood.

    4. Apply 30 N (22 in-lb) of force to the alternator belt, midway between the pulleys (Figure 78).

      g031638

      Figure 78

      1. Alternator belt

    5. If the belt does not deflect 11 mm (7/16 inch), complete the following procedure to tension the belt:

      1. Loosen the bolt securing the alternator to the engine and the bolt securing the brace to the alternator.

      2. Insert a pry bar between the alternator and engine, and pry out at the alternator.

      3. When you obtain the proper tension, tighten the alternator and brace bolts to secure the adjustment.

    Controls System Maintenance

    Adjusting the Controls

    The factory adjusts the controls before shipping the machine. However, after many hours of use, you may need to adjust the traction control alignment, the NEUTRAL position of the traction control, and the tracking of the traction control in the full forward position.

    Contact your Authorized Service Dealer to adjust the controls of your machine.

    Hydraulic System Maintenance

    Hydraulic System Safety

    • Seek immediate medical attention if fluid is injected into skin. Injected fluid must be surgically removed within a few hours by a doctor.

    • Ensure that all hydraulic-fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to the hydraulic system.

    • Keep your body and hands away from pinhole leaks or nozzles that eject high-pressure hydraulic fluid.

    • Use cardboard or paper to find hydraulic leaks.

    • Safely relieve all pressure in the hydraulic system before performing any work on the hydraulic system.

    Relieving Hydraulic Pressure

    To relieve hydraulic pressure while the engine is on, disengage the auxiliary hydraulics and fully lower and retract the loader arms.

    To relieve the pressure while the engine is off, cycle the joystick between the forward positions to lower the loader arms (Figure 79).

    g358970

    Figure 79

    Hydraulic-Fluid Specifications

    Maintenance Service IntervalMaintenance Procedure
    Every 100 hours
  • Check the hydraulic lines for leaks, loose fittings, kinked lines, loose mounting supports, wear, weather, and chemical deterioration.(Make necessary repairs before operating.)
    		•
    Every 400 hours
  • Replace the hydraulic oil and filters (if not using Toro fluid).
    		•
    Every 1,000 hours
  • Replace the hydraulic oil and filters (if using Toro fluid).
    		•
    Every 1,500 hours
  • Replace all moving hydraulic hoses.
    		•
    Every 2 years
  • Replace all moving hydraulic hoses.
    		•

    Hydraulic-Tank Capacity: 57.7 L (15.25 US gallons)

    Use only 1 of the following fluids in the hydraulic system:

    • Toro Premium Transmission/Hydraulic Tractor Fluid (refer to your Authorized Service Dealer for more information)

    • Toro PX Extended Life Hydraulic Fluid (refer to your Authorized Service Dealer for more information)

    • If either of the above Toro fluids are not available, you may use another Universal Tractor Hydraulic Fluid (UTHF), but they must be only conventional, petroleum-based products. The specifications must fall within the listed range for all the following material properties and the fluid should meet the listed industry standards. Check with your hydraulic fluid supplier to determine if the fluid meets these specifications.

      Note: Toro will not assume responsibility for damage caused by improper substitutions, so use only products from reputable manufacturers who will stand behind their recommendations.

      Material Properties
      Viscosity, ASTM D445cSt at 40°C: 55 to 62
      cSt at 100°C: 9.1 to 9.8
      Viscosity index, ASTM D2270140 to 152
      Pour Point, ASTM D97-37 to -43°C (-35 to -46°F)
      Industry Standards
      API GL-4, AGCO Powerfluid 821 XL, Ford New Holland FNHA-2-C-201.00, Kubota UDT, John Deere J20C, Vickers 35VQ25 and Volvo WB-101/BM

      Note: Many hydraulic fluids are almost colorless, making it difficult to spot leaks. A red dye additive for the hydraulic system fluid is available in 20 ml (2/3 fl oz) bottles. One bottle is sufficient for 15 to 22 L (4 to 6 US gallons) of hydraulic fluid. Order Part No. 44-2500 from your Authorized Toro Dealer.

    Checking the Hydraulic-Fluid Level

    Maintenance Service IntervalMaintenance Procedure
    Every 25 hours
  • Check the hydraulic-fluid level.
    		•

    Important: Always use the correct hydraulic fluid. Unspecified fluids will damage the hydraulic system. Refer to Hydraulic-Fluid Specifications.

    1. Remove any attachments.

    2. Park the machine on a level surface and engage the parking brake.

    3. Raise the loader arms and install the cylinder locks.

    4. Shut off the engine and remove the key.

    5. Remove the front cover; refer to Removing the Front Cover.

    6. Clean the area around the filler neck of the hydraulic tank (Figure 80).

      g263507

      Figure 80

      1. Filler-neck cap

    7. Remove the filler-neck cap and check the fluid level on the dipstick (Figure 81).

      Note: The fluid level should be between the 2 notches of the dipstick while the arms are lowered or at the lower notch while the arms are raised.

      g263506

      Figure 81

      1. Filler neck
      2. Dipstick

    8. If the level is low, add enough fluid to raise it to the proper level.

    9. Install the filler-neck cap.

    10. Install the front cover.

    Replacing the Hydraulic Filters

    Important: Do not substitute an automotive oil filter; otherwise, severe hydraulic system damage may occur.

    1. Park the machine on a level surface, engage the parking brake, and lower the loader arms.

    2. Shut off the engine and remove the key.

    3. Raise the loader arms and install the cylinder locks.

    4. Remove the front cover; refer to Removing the Front Cover.

    5. Place a drain pan under the front filter and replace the filter (Figure 82).

      g263539

      Figure 82

    6. Clean up any spilled fluid.

    7. Open the rear access cover; refer to Opening the Rear-Access Cover

    8. Remove the rear screen; refer to Removing the Rear Screen.

    9. Place a drain pan under the rear filter and replace the filter (Figure 83).

      g263575

      Figure 83

    10. Clean up any spilled fluid.

    11. Start the engine and let it run for about 2 minutes to purge air from the system.

    12. Shut off the engine and check for leaks.

    13. Check the fluid level in the hydraulic tank; refer toChecking the Hydraulic-Fluid Level and add fluid to raise the level to mark on dipstick.

      Important: Do not overfill the tank.

    14. Install the front cover.

    15. Install the rear screen and tighten the knobs and bolts to secure it.

    16. Close the rear-access cover and install the fastener to secure it.

    17. Remove and store the cylinder locks and lower the loader arms.

    Changing the Hydraulic Fluid

    1. Park the machine on a level surface.

    2. Raise the loader arms and install the cylinder locks.

    3. Shut off the engine, remove the key, and allow the engine to cool.

    4. Remove the front cover; refer to Removing the Front Cover.

    5. Remove the hydraulic-tank cap and dipstick (Figure 84).

      g263506

      Figure 84

      1. Filler neck
      2. Dipstick

    6. Place a large drain pain capable of holding 57 L (15 US gallons) under the drain plug on the front of the machine (Figure 85).

      g303493

      Figure 85

      1. Drain plug

    7. Remove the drain plug and allow the oil to drain into the pan (Figure 85).

    8. When the oil is finished draining, install and tighten the drain plug.

      Note: Dispose of the used oil at a certified recycling center.

    9. Fill the hydraulic tank with hydraulic fluid; refer to Hydraulic-Fluid Specifications.

    10. Start the engine and let it run for a few minutes.

    11. Shut off the engine and remove the key.

    12. Check the hydraulic-fluid level and add fluid to fill the tank if necessary; refer to Checking the Hydraulic-Fluid Level.

    13. Install the front cover.

    Loader Maintenance

    Torquing the Loader Arm Adjustment Screws

    Telescoping Machines Only
    Maintenance Service IntervalMaintenance Procedure
    Every 25 hours
  • Torque the loader arm adjustment screws (telescoping machines only).Check the torque whenever the lower loader arms rattle.
    		•

    Check the torque whenever the lower loader arms rattle.

    1. Park the machine on a level surface.

    2. Shut off the engine, remove the key, and allow the engine to cool.

    3. On each loader arm, loosen the setscrew on the 4 adjustment screws (Figure 86).

      g263689

      Figure 86

      1. Adjustment screw

    4. Torque the adjustment screws to 27 N∙m (20 ft-lb).

    5. Check that the length of the adjustment screws that is protruding from the arms is equal side to side.

    6. Apply medium-strength thread-locking compound to the setscrews and tighten them until they just contact the adjustment screws.

      Important: Do not overtighten the setscrews; otherwise you may damage the adjustment screw threads.

    Cleaning

    Removing Debris

    Maintenance Service IntervalMaintenance Procedure
    Before each use or daily
  • Remove debris from the machine.
    		•

    Important: Operating the engine with blocked screens and/or cooling shrouds removed will result in engine damage from overheating.

    1. Park the machine on a level surface and lower the loader arms.

    2. Shut off the engine, remove the key, and allow the engine to cool.

    3. Open the hood and secure the prop rod.

    4. Clean any debris from the front and side screens.

    5. Wipe away debris from the air cleaner.

    6. Clean any debris buildup on the engine and in the oil cooler fins with a brush or blower.

      Important: Operating the engine with blocked screens and/or cooling shrouds removed will result in engine damage due to overheating.

    7. Clean debris from the hood opening, muffler, heat shields, and radiator screen (if applicable).

    8. Close the hood.

    Cleaning the Chassis

    Maintenance Service IntervalMaintenance Procedure
    Every 100 hours
  • Check for dirt buildup in the chassis.
    		•

    Over time, the chassis under the engine collects dirt and debris that must be removed. Using a flashlight, open the hood and inspect the area under the engine regularly. When the debris is 2.5 to 5 cm (1 to 2 inches) deep, clean the chassis.

    1. Park the machine on a level surface and lower the loader arms.

    2. Raise the front of the machine so that the machine is angled backward.

    3. Shut off the engine and remove the key.

    4. Remove the bottom plate; refer to Removing the Bottom Plate.

    5. Remove the front cover assembly; refer to Removing the Front Cover Assembly.

    6. Spray water into the chassis to clean out the dirt and debris.

      Note: The water will drain at the back of the machine.

      Important: Do not spray water into the engine.

    7. Grease the machine; refer to Lubricating the Machine.

    8. Install the bottom plate (Figure 44).

    9. Install the front cover assembly.

    10. Lower the machine.

    Storage

    Storage Safety

    • Shut off the engine, remove the key, wait for all moving parts to stop, and allow the machine to cool before storing it.

    • Do not store the machine or fuel near flames.

    Storage

    1. Park the machine on a level surface, engage the parking brake, and lower the loader arms.

    2. Shut off the engine and remove the key.

    3. Remove dirt and grime from the entire machine.

      Important: You can wash the machine with mild detergent and water. Do not pressure-wash the machine. Avoid excessive use of water, especially near the control panel, engine, hydraulic pumps, and motors.

    4. Service the air cleaner; refer to Servicing the Air Cleaner.

    5. Grease the machine; refer to Lubricating the Machine.

    6. Change the engine oil; refer to Servicing the Engine Oil.

    7. Charge the battery; refer to Charging the Battery.

    8. Check and adjust the track tension; refer to Servicing the Tracks.

    9. Check and tighten all fasteners. Repair or replace any worn, damaged, or missing parts.

    10. Paint all scratched or bare metal surfaces with paint available from your Authorized Service Dealer.

    11. Store the machine in a clean, dry garage or storage area. Remove the key from the ignition switch and keep it in a memorable place.

    12. Cover the machine to protect it and keep it clean.

    Troubleshooting

    ProblemPossible CauseCorrective Action
    The engine does not start.
    1. Dirt, water, stale fuel, or incorrect fuel is in the fuel system.
    2. The fuel filter is clogged.
    3. The improper fuel grade for cold weather is in the machine.
    4. The battery is discharged.
    1. Drain and flush the fuel system; add fresh fuel.
    2. Replace the fuel filter.
    3. Drain the fuel system and replace the fuel filter. Add fresh fuel of proper grade for ambient temperature conditions. You may need to warm the entire traction unit.
    4. Charge the battery or replace it.
    The engine loses power.
    1. The fuel tank is empty.
    2. There is air in the fuel.
    3. The engine is overheating.
    4. The engine load is excessive.
    5. The crankcase-oil level is incorrect.
    6. The air-cleaner filters are dirty.
    1. Fill the tank with fresh fuel.
    2. Bleed the fuel system and check for air leaks at fuel hose connections and fittings between the fuel tank and engine.
    3. Refer to “The engine overheats.”
    4. Reduce the load; use a lower ground speed.
    5. Fill or drain to the Full mark.
    6. Service the air filters.
    The engine starts but does not keep running.
    1. The fuel tank is empty.
    2. There is air in the fuel.
    3. The engine is overheating.
    4. The air-cleaner filters are dirty.
    1. Fill the tank with fresh fuel.
    2. Bleed the fuel system and check for air leaks at fuel hose connections and fittings between the fuel tank and engine.
    3. Refer to “The engine overheats.”
    4. Service the air filters.
    The engine overheats.
    1. The crankcase-oil level is incorrect.
    2. The alternator belt is broken or elongated.
    3. More coolant is needed.
    4. Concentration of antifreeze is too high.
    5. There is restricted air flow to the radiator.
    6. The inside of the radiator is corroded.
    7. The radiator or radiator cap is damaged.
    8. The thermostat is defective.
    9. The temperature gauge or sensor is defective.
    10. The engine load is excessive.
    11. The head gasket is damaged or there is water leakage.
    1. Fill or drain to the Full mark.
    2. Replace the belt or adjust the belt tension.
    3. Check and add coolant.
    4. Add water only or change to coolant with the specified mixing ratio.
    5. Inspect and clean the radiator screen.
    6. Clean or replace the radiator and parts.
    7. Replace the damaged parts.
    8. Check the thermostat and replace it if necessary.
    9. Check the temperature with a thermometer and replace the gauge or sensor if necessary.
    10. Reduce the load; use a lower ground speed.
    11. Replace damaged parts.
    The machine does not drive.
    1. The parking brake is engaged.
    2. The hydraulic-fluid level is low.
    3. The hydraulic system is damaged.
    4. The bypass valves are open.
    5. A traction pump drive coupler is loose or broken.
    6. Pump and/or wheel motor is damaged.
    7. The control valve is damaged.
    8. The relief valve is damaged.
    9. The cooling fans are damaged or disconnected.
    1. Disengage the parking brake.
    2. Add hydraulic fluid to the reservoir.
    3. Contact your Authorized Service Dealer.
    4. Close the bypass valves.
    5. Contact your Authorized Service Dealer.
    6. Contact your Authorized Service Dealer.
    7. Contact your Authorized Service Dealer.
    8. Contact your Authorized Service Dealer.
    9. Check fan connections or replace damaged parts.