Toro RT600 Traction Unit User manual

Toro RT600 Traction Unit User manual
Form No. 3386-335 Rev A
RT600 Traction Unit
Model No. 25430A—Serial No. 315000001 and Up
Model No. 25430C—Serial No. 315000001 and Up
Model No. 25430W—Serial No. 315000001 and Up
Register at www.Toro.com.
Original Instructions (EN)
*3386-335* A
WARNING
CALIFORNIA
Proposition 65 Warning
This product contains a chemical or chemicals
known to the State of California to cause cancer,
birth defects, or reproductive harm.
The engine exhaust from this product
contains chemicals known to the State of
California to cause cancer, birth defects,
or other reproductive harm.
Because in some areas there are local, state, or federal
regulations requiring that a spark arrester be used on the
engine of this machine, a spark arrester is available as
an option. If you require a spark arrester, contact your
Authorized Toro Service Dealer.
Figure 1
Important: It is a violation of California Public
Resource Code Section 4442 to use or operate the engine
on any forest-covered, brush-covered, or grass-covered
land without a spark arrester muffler maintained in
working order, or the engine constricted, equipped, and
maintained for the prevention of fire. Other states or
federal areas may have similar laws.
1. Location of the model and serial number plate
Model No.
Serial No.
Genuine Toro spark arresters are approved by the USDA
Forestry Service.
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.
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.
Figure 2
1. Safety alert symbol
Introduction
This manual uses 2 words to highlight information.
Important calls attention to special mechanical information
and Note emphasizes general information worthy of special
attention.
This machine is designed to dig trenches in soil to bury
cabling and piping for various applications. It is not intended
to cut rock, wood, or any other material other than soil.
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.
Contents
Safety ........................................................................... 3
............................................................................ 4
Electrical Line Safety ............................................... 6
Gas Line Safety ....................................................... 6
Communication Line Safety...................................... 6
Water Line Safety .................................................... 6
Safety and Instructional Decals ................................. 7
Product Overview .........................................................14
Controls ...............................................................15
Instrument Cluster..............................................15
You may contact Toro directly at www.Toro.com for product
and accessory information, help finding a dealer, or to register
your product.
Whenever you need service, genuine Toro parts, or additional
information, contact an Authorized Toro Service Dealer
or Toro Customer Service and have the model and serial
numbers of your product ready. Figure 1 illustrates the
location of the model and serial numbers on the product.
Write the numbers in the space provided.
© 2014—The Toro® Company
8111 Lyndale Avenue South
Bloomington, MN 55420
2
Contact us at www.Toro.com.
Printed in the USA
All Rights Reserved
Safety
Traction Controls ...............................................18
Attachment Control Panel....................................19
Operator Seat and Seat Belt .................................20
Specifications ........................................................21
Attachments/Accessories........................................21
Operation ....................................................................22
Preparing for Work.................................................22
Adding Fuel to the Engine .......................................22
Checking the Engine Oil Level .................................23
Checking the Hydraulic Fluid Level ...........................24
Inspecting the Machine Daily ...................................25
Starting the Engine .................................................25
Setting the Engine Speed .........................................25
Stopping the Engine ...............................................26
Breaking in a New or Rebuilt Engine .........................26
Operating the Machine in Extreme
Conditions.........................................................26
Operating the Parking Brake ....................................27
Driving and Stopping the Machine ............................27
Operating the Transmission .....................................28
Preparing to Operate the Machine.............................29
Using the Backfill Blade...........................................29
Transporting the Machine........................................30
Completing the Work for the Day .............................31
Completing the Project ...........................................31
Maintenance .................................................................32
Recommended Maintenance Schedule(s) ......................32
Premaintenance Procedures ........................................33
General Safety........................................................33
Lubrication ...............................................................33
Greasing the Machine .............................................33
Engine Maintenance ..................................................35
Accessing the Engine ..............................................35
Servicing the Engine Oil and Filter............................37
Servicing the Air-cleaner System...............................39
Fuel System Maintenance ...........................................42
Servicing the Fuel System ........................................42
Electrical System Maintenance ....................................45
Maintaining the Battery ...........................................45
Drive System Maintenance .........................................48
Servicing the Tires ..................................................48
Servicing the Axles and the Transmission ...................49
Cooling System Maintenance ......................................54
Servicing the Cooling System ...................................54
Belt Maintenance ......................................................58
Servicing the Engine Drive Belt ................................58
Replacing the Engine Drive Belt ...............................59
Hydraulic System Maintenance ....................................61
Servicing the Hydraulic System.................................61
ROPS Maintenance ....................................................64
Checking and Servicing the ROPS.............................64
Cleaning ...................................................................65
Removing Dirt and Debris from the Machine .............65
Storage ........................................................................66
Preparing for Seasonal Storage .................................66
Troubleshooting ...........................................................67
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 (Figure 2), which means Caution,
Warning, or Danger—personal safety instruction. Failure
to comply with the instruction may result in personal
injury or death.
Important: This machine was manufactured according
to the appropriate regulatory standards in effect at the
time of manufacture. Modifying this machine in any
way may cause it to be out of compliance with those
standards and with the instructions in this Operator’s
Manual. Modifications to this machine should be made
only by an Authorized Toro Service Dealer.
WARNING
Welding, cutting, or drilling cast ductile iron parts
of the machine could cause them to break during
operation, which in turn could result in injury or
death.
Do not weld, cut, or drill to repair or to attach items
to cast ductile iron parts on this machine.
Always follow all safety instructions to avoid serious injury
or death.
You can prevent and are responsible for injuries occurring to
yourself and to others and for damage to property.
Do not use this machine for applications other than those
which are described in this manual.
Before operating this machine for the purpose of trenching,
drilling, or other construction work, it is your responsibility
to know where all utility lines are buried in the project area
and to avoid them.
Always ensure that all local utility companies mark
the location of their lines. In the USA and Canada,
call a “One-call System Directory” service. In the
USA, call 811 or your local number. If you do not know
your local number, call the national number (USA and
Canada only) at 1-888-258-0808. Also, contact any utility
companies that are not participants of the “One-call
System Directory” service.
Check with local authorities for all laws and regulations that
require you to locate and avoid existing utilities.
Refer to the following table for the proper utility line and the
corresponding utility line color (USA and Canada only):
3
Utility Line
Color
Electric
Red
Telecommunication, alarm or signal, cables,
or conduit
Orange
Natural gas, oil, steam, petroleum, or other
gaseous or flammable material
Yellow
Sewer and drain
Green
Drinking water
Blue
Reclaimed water, irrigation, and slurry lines
Purple
Temporary survey markings
Pink
Proposed excavation limits
White
• Before operating the machine with an attachment, ensure
that the attachment is properly installed.
• Use extra care when handling fuels. They are flammable
and vapors are explosive.
– Use only an approved container.
– Do not remove the fuel cap or add fuel with the
engine running. Allow the engine to cool before
fueling. Do not smoke near the machine while the
engine is running.
– Do not refuel or drain the machine indoors.
• Check that the operator's presence controls, safety
switches, and shields are attached and functioning
properly. Do not operate the machine unless these
controls, switches, and shields are functioning properly.
After locating all the utility lines, carefully dig a hole to the
utility line to verify the location and the depth of the line.
General Operation
• Always wear a seat belt when operating a machine with
a ROPS.
Training
• Do not run an engine in an enclosed area.
• Read the Operator's Manual and other training material. If
the operator(s) or mechanic(s) cannot read English, it is
the owner's responsibility to explain this material to them.
• Do not operate the machine without the guards securely
in place. Ensure that all interlocks are attached, adjusted
properly, and functioning property.
• Become familiar with the safe operation of the equipment,
operator controls, and safety signs.
• Decrease the ground speed of the machine and use
• All operators and mechanics should be trained. The
caution when making turns and crossing roads and
sidewalks.
owner is responsible for training the users.
• Never let children or untrained people operate or service
• Do not operate the machine while under the influence
the equipment. Local regulations may restrict the age of
the operator.
of alcohol or drugs.
• Ensure that the area is clear of other people before
• Ensure that you understand the hand signals used on the
operating the machine. Stop the machine if anyone enters
the area.
job site. Follow the instructions of the signal person.
• Excessive vibration from a trencher or a plow can cause a
Preparation
trench, an overhang, or a high bank to collapse, resulting
in possible injury or death.
• Before using the machine, have the area marked for
underground utilities, and do not dig in marked areas.
Also, be aware of the location of objects and structures
that may not be marked, such as underground storage
tanks, wells, and septic systems.
• If your view of the work area is not clear, always have a
signal person direct the movement of the machine.
• Do not leave a running machine unattended. Stop the
engine and remove the key whenever you leave the
machine.
• Evaluate the terrain to determine what accessories and
attachments are needed to properly and safely perform
the job. Use only accessories and attachments approved
by the manufacturer.
• Use only Toro-approved attachments. Attachments can
change the stability and the operating characteristics of
the machine.
• Mark the job site clearly and keep bystanders away.
• Review the job site hazards, safety and emergency
• Watch for traffic when operating the machine near or
across roadways.
procedures, and personnel responsibilities with all
workers before beginning the work.
• Ensure that you operate the machine in areas where there
• Wear appropriate clothing, including hard hat, safety
are no obstacles in close proximity to you. Failure to
maintain an adequate distance from trees, walls, and other
barriers while operating the machine may result in injury
and/or damage. Operate the machine only in areas where
there is sufficient clearance for you to safely maneuver
the product.
glasses, long pants, safety shoes, and hearing protection;
some jobs may also require that you wear a reflective vest
and/or a respirator. Secure long hair, loose clothing, and
jewelry to prevent them from getting tangled in moving
parts.
4
• Check for overhead clearances (i.e., branches, doorways,
• Locate the pinch point areas marked on the machine and
•
electrical wires) before driving under any objects, and do
not contact them.
attachments, and keep hands and feet away from these
areas.
Lightning can cause severe injury or death. If lightning
is seen or thunder is heard in the area, do not operate
the machine; seek shelter.
• Move all attachments into the transport position.
Maintenance and Storage
• Lower the attachment(s), stop the engine, wait for all
Slope Operation
moving parts to stop, and remove the key whenever you
adjust, clean, or repair the machine.
Slopes are a major factor related to loss-of-control and
tip-over accidents, which can result in severe injury or death.
All slopes require extra caution.
• Avoid operating this machine on slopes, if possible.
• Keep all movements on slopes slow and gradual. Do not
make sudden changes in speed or direction.
• Avoid starting or stopping the machine on a slope. If the
machine loses traction, keep the heavy end of the machine
uphill and proceed slowly, straight down the slope.
• Avoid turning the machine on slopes. If you must turn,
turn slowly and keep the heavy end of the machine uphill.
• Do not operate the machine near drop-offs, ditches, or
embankments. The machine could suddenly turn over if
a tire goes over the edge of a cliff or ditch, or if an edge
caves in.
• Do not touch parts that may be hot from operation.
Allow them to cool before attempting to maintain, adjust,
or service the machine.
• Clean debris from attachments, drives, mufflers, and
engine to help prevent fires. Clean up oil and fuel spills.
• Let the engine cool before storing, and do not store the
machine near an open flame.
•
•
•
•
Park the machine on level ground.
Do not allow untrained personnel to service the machine.
Use jack stands to support components when required.
Carefully release pressure from components with stored
energy.
• Keep hands and feet away from moving parts. If possible,
do not make adjustments with the engine running.
Rollover Protection Structure (ROPS)
System
• Keep all parts in good working condition and all hardware
• Before operating a machine with a ROPS (rollover
• Keep nuts and bolts tight. Keep all equipment in good
•
•
•
•
•
tightened. Replace all worn or damaged decals.
protection structure), ensure that the seat belt is in good
condition and is securely attached to the machine.
Inspect the ROPS at the interval recommended in this
manual or when the ROPS has been in an accident.
Repair a damaged ROPS using only genuine Toro
replacement parts; do not repair or modify the ROPS.
Check carefully for overhead clearances (i.e. branches,
doorways, electrical wires) before driving under any
objects and do not contact them.
Do not remove the ROPS except when servicing or
replacing it.
Do not add weight to the machine that exceeds the gross
weight displayed on the ROPS label.
condition.
•
•
•
•
Do not tamper with safety devices.
Keep the machine clean and free of debris.
Clean up oil or fuel spills.
Use extra care when handling fuels. They are flammable
and vapors are explosive.
– Use only an approved container.
– Do not remove the fuel cap or add fuel when the
engine is running. Allow the engine to cool before
refueling. Do not smoke.
– Do not refuel the machine indoors.
– Do not drain the fuel indoors.
– Do not store the machine or a fuel container inside
where there is an open flame, such as near a water
heater or furnace.
Transporting Safety
When you transport the machine to or from the job site,
observe the following safety precautions:
• Do not carry passengers on the machine.
• Keep all bystanders away while you are moving the
machine.
• Use care when loading or unloading the machine into a
trailer or truck.
• Watch for traffic when you are crossing roadways with
the machine.
– Do not fill a container while it is inside a vehicle,
trunk, pickup bed, or any surface other than the
ground.
– Keep container nozzle in contact with the tank during
filling.
• Use only genuine Toro replacement parts.
• Disconnect the battery before making any repairs.
Disconnect from the negative battery terminal first and
5
Gas Line Safety
from the positive last. Connect to the positive first and to
the negative last.
• Charge the battery in an open well ventilated area, away
WARNING
from spark and flames. Unplug the charger before
connecting or disconnecting it from the battery. Wear
protective clothing and use insulated tools.
If you damage a gas line, an immediate explosion
and fire hazard could occur. Leaking gas is both
flammable and explosive and may cause serious
injury or death.
• 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.
• Do not smoke while operating the machine.
• Battery gases can explode. Keep cigarettes, sparks, and
• Shut off the machine and remove the key.
flames away from the battery.
• Keep your body and hands away from pin hole leaks
• Remove all individuals from the work area.
or nozzles that eject high-pressure hydraulic fluid. Use
cardboard or paper to find hydraulic leaks; never use
your hands. Hydraulic fluid escaping under pressure can
penetrate skin and cause injury, requiring surgery within
a few hours by a qualified surgeon; otherwise, gangrene
may result.
• Immediately contact the proper emergency and
utility authorities to secure the area.
Communication Line Safety
• Allow the machine to cool before storing it.
CAUTION
If you damage the fiber-optic cable and look into
the exposed highly-intense light, you may harm
your eyes.
Electrical Line Safety
WARNING
• Shut off the machine and remove the key.
If you leave the seat of the machine or touch
any part of the machine when it is charged with
electricity, serious injury or death could result.
• Remove all individuals from the work area.
• Immediately contact the proper emergency and
utility authorities to secure the area.
Do not leave the seat of the machine if the machine
is charged with electricity.
Water Line Safety
Note: Immediately contact the proper emergency and utility
authorities to secure the area in the case that the machine is
charged and you cannot leave the seat of the machine.
If you damage a water line, a potential flood hazard
could occur.
Note: It is possible to strike a utility line without the machine
becoming charged.
• Shut off the machine and remove the key.
• Remove all individuals from the work area.
• It is likely (but not always the case) that the power-source
• Immediately contact the proper emergency and
interrupter or breaker will trip, but to ensure your safety,
consider that the machine may be conducting electricity.
utility authorities to secure the area.
• Do not attempt to leave the machine.
Note: You will be safe as long as you do not leave the
seat of the machine.
• Touching any part of the machine while contacting the
ground may electrically ground you.
• Do not allow another individual to touch or approach the
machine when it is charged.
6
Safety and Instructional Decals
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 lost.
Figure 3
Decal Map (Top view)
1. Decal 125-8470 (under the
hood)
5. Decal 125-8472
9. Decal 125-8475
2. Decal 125-8483
3. Decal 125-6683
4. Decal 125-8484
6. Decal 125-6695
7. Decal 125-8471
8. Decal 125-8478
10. Decal 125-8473
11. Decal 125-6691
12. Decal 125-6699
7
13. Decal 125-6698
Figure 4
Decal Map (Left-side view)
1. Decal 125-8479
3. Decal 125-8482 (2)
5. Decal 125-8478
7. Decal 125-6689
2. Decal 125-4963
4. Decal 125-8481 (2)
6. Decal 117-2718
8. Decal 125-8480
117-2718
125-6683
125-4963
1. Warning—do not touch hot surfaces.
1. Pull out for fastest speed
4. Decrease speed
2. Increase speed
5. Push in for slowest speed
3. Engine speed
8
125-6691
125-6689
1. Slope hazard—do not shift gears while the machine is on a
slope.
1. Warning—keep away from 2. Cutting/dismemberment
hot surfaces.
hazard, fan—keep away
from moving parts; keep
all guards and safety
devices in place.
125-6695
9. Engage the vibratory plow
1. Trencher chain—forward
2. Backfill blade—pivot left
10. Trencher chain—reverse
3. Backfill blade—raise
11. Backfill blade—tilt right
4. Backfill blade—pivot right
12. Backfill blade—tilt left
5. Backfill blade—float
6. Backfill blade—lower
7. Fast forward
13. Trencher—lower
14. Trencher—raise
15. Rear steering left
8. Fast reverse
16. Rear steering right
9
125-6698
1. Slow
2. Clutch
3. Fast
5. Machine direction of
motion
6. Fast reverse
7. Shift (low range)
4. Fast forward
8. Shift (high range)
125-6699
1. Warning—read the Operator’s Manual.
6. Warning—wear hearing protection.
2. Warning—do not operate the machine unless you are trained.
7. Explosion hazard; electric shock hazard—do not dig until you
have called local utilities.
8. Read the Operator’s Manual for information on starting the
engine—1) Engage the parking brake; 2) Set the traction and
attachments to the Neutral position; 3) Turn the key to the
engine Start position.
3. Warning—always wear a seat belt when operating the
machine.
4. Warning—keep bystanders away from the machine.
9. Read the Operator’s Manual for information on stopping the
engine—1) Park the machine on a level surface; 2) Engage
the parking brake; 3) Set the traction and attachments the
Neutral position; 4) Lower the attachments; 5) Turn the key to
the engine Stop position; 6) Remove the key from the ignition.
5. Warning—keep away from moving parts; keep all guards and
safety devices in place.
10
125-8472
1. Engine—stop
3. Engine—start
2. Engine—run
125-8470
1. Disconnect the battery.
3. On
2. Off
4. Warning—read the
Operator’s Manual.
125-8473
125-8471
1. Use front wheel steering only when moving the machine
forward in 4th gear.
11
1. Explosion hazard—wear
eye protection.
3. Fire hazard—keep open
flames away.
2. Chemical burn
hazard—flush affected
area with water and seek
medical help.
4. Poison hazard—keep
children away from the
battery.
125-8479
1. Burn hazard from contents under pressure—read the
Operator’s Manual.
125-8475
1. Engage the parking brake.
125-8480
2. Disengage the parking
brake.
1. Warning—do not climb on ROPS.
125-8478
1. Diesel fuel
125-8481
1. Hydraulic supply
12
Battery Symbols
Some or all of these symbols are on your battery.
125-8482
1. Hydraulic return
1. Explosion hazard
6. Keep bystanders a safe
distance from the battery.
2. No fire, open flame, or
smoking.
7. Wear eye protection;
explosive gases can
cause blindness and other
injuries.
3. Caustic liquid/chemical
burn hazard
4. Wear eye protection
8. Battery acid can cause
blindness or severe burns.
9. Flush eyes immediately
with water and get medical
help fast.
5. Read the Operator's
Manual.
125-8483
1. Read the Operator’s Manual for hydraulic oil information.
125-8484
1. 12-volt receptacle
13
10. Contains lead; do not
discard
Product Overview
Figure 5
Left side of machine
1. Nose panel
5. Backfill blade
2. Left side panel
6. Operator walkway
3. Grab handles
4. ROPS enclosure
7. Fuel reservoir
8. Steps
14
Figure 6
Right side of machine
1. Grab handles
4. Steps
2. Right side panel
5. Hydraulic fluid sight gauge
3. Hydraulic fluid tank
6. Hydraulic-tank cap
Controls
1
5
Become familiar with all the controls (Figure 7) before you
start the engine and operate the machine.
2
6
3
7
Instrument Cluster
The warning and indicating lights (except the engine-intake
preheat light) come on when you turn the key switch to the
Run position before you start.
4
Warning Lights
1. Engine-intake preheat
light
5. Parking-brake set light
The locations of these lights are shown in Figure 7.
2. Restricted
hydraulic-pressure filter
light
6. Controls-in-neutral light
3. Restricted air-cleaner light
7. Low engine-oil pressure
light
4. Restricted hydraulic-return
filter light
8. Low hydraulic-pressure
light
G022146
Figure 7
Instrument Cluster Lights
15
8
• Restricted hydraulic-pressure filter light—This
Gauges
light turns on when the engine is running and the
hydraulic-pressure filter is restricted. If the engine is
running and this light turns on, stop the machine and
replace the hydraulic-pressure filter.
The locations of these gauges are shown in Figure 8.
1
2
3
4
5
6
• Restricted air-cleaner light—This light turns on when
the engine is running and the air cleaner is restricted. If
the engine is running and this light turns on, stop the
engine and replace the air-cleaner element.
• Restricted hydraulic-return filter light—This
light turns on when the engine is running and the
hydraulic-return filter is restricted. If the engine is
running and this light turns on, stop the machine and
replace the hydraulic-return filter.
G022145
Figure 8
Instrument Cluster Gauges
• Low engine-oil pressure light—This light turns on
when the engine is running and the engine-oil pressure
is below the normal operating range. If the engine is
running and this light turns on, stop the engine and check
the engine-oil level.
• Low hydraulic-pressure light—This light turns on
when the engine is running and there is a loss of hydraulic
pressure. If the engine is running and this light turns on,
stop the engine, check the hydraulic fluid level, and check
the hydraulic system for leaks.
1. Engine-coolant
temperature gauge
4. Engine hourmeter
2. Voltmeter
5. Fuel-level gauge
3. Engine tachometer
6. Hydraulic-fluid
temperature gauge
• Engine-coolant temperature gauge—This gauge
indicates the temperature of the coolant in the engine
cooling system. The temperature ranges and the
conditions that they indicate are as follows:
Indicating Lights
The locations of these lights are shown in Figure 7.
• Engine-intake preheat light—This light turns on when
you turn the key switch to the On position and the intake
air is too cold to start the engine. When the intake air is
warm enough for the engine to start, the light turns off,
and you can then start the engine.
• Parking-brake set light—This light turns on when you
turn the key to the On position and engage the parking
brake.
•
• Controls-in-neutral light—This light turns on when
you turn the key switch to the On position and the
following controls are in the Neutral or the Stop position:
– Traction control pedal
– Utility-traction lever
– Attachment control lever
•
•
16
Note: If the needle of this gauge indicates that the
coolant temperature is 116°C (241°F) or higher, stop the
engine and allow it to cool. Then check the following:
the coolant level, the radiator (for debris inside), the
thermostat, and the condition of and tension on the drive
belt.
– 82°C (179°F) or lower: Low temperature
– 82 to 115°C (180° to 240°F): Normal operating
temperature
– 116°C (241°F) or higher: High temperature
Voltmeter—This gauge indicates the voltage of the
battery or of the battery and the alternator. The voltage
ranges of the voltmeter indicate the following conditions
about the electrical system:
– 11.4 volts or less: Low voltage for the battery
– 11.5 to 12.5 volts: Normal voltage for the battery
– 13.8 to 14.4 volts: Normal voltage for the battery and
the alternator (with the machine running)
– 14.5 volts or more: High voltage for the battery and
the alternator (with the machine running)
Note: You must stop the engine before you check
the charging system.
Engine tachometer—This gauge indicates the engine
speed in revolutions per minute (rpm). Each number on
the gauge represents 1000 rpm, and each space equals
200 rpm.
Engine hourmeter—This gauge indicates the total
number of operating hours of the machine to a tenth of
• Engine Stop—Turn the key to this position to the
an hour. Use the hourmeter to measure the operating
hours between machine service intervals.
stop the engine, de-energize the electrical system, and to
remove the key.
• Fuel-level gauge—This gauge indicates the amount of
• Engine Run—Turn the key to this position to energize
fuel in the fuel tank.
the electrical system. The key returns to this position
after you release the key from the Start position.
• Hydraulic-fluid temperature—This gauge indicates the
temperature of the hydraulic fluid in the system.
• Engine Start—Turn the key to this position to start the
engine.
Parking Brake Switch
Parking brake switch—Push the switch up to apply the
parking brake (Figure 9); push the switch down to release
the parking brake pedal.
Throttle Knob
Use the throttle knob (Figure 11) to change the engine speed
as follows:
Figure 11
1. Throttle button
2. Throttle knob
Figure 9
3. Throttle lock
4. Electrical socket
1. Parking brake switch
• Push the button at the center of the knob while pulling
the knob up to increase the engine speed.
Note: The parking brake automatically engages when the
engine stops.
• Push the button at the center of the knob while pushing
the knob down to decrease the engine speed.
Key Switch
• Rotate the knob counterclockwise to make a small
increase in the engine speed.
The key switch (Figure 10) has the following 3 positions:
• Rotate the knob clockwise to make a small decrease
in the engine speed.
Throttle Lock
Use the throttle lock (Figure 11) as follows to hold the throttle
in position while you are operating the machine:
• Rotate the throttle lock clockwise to lock the throttle in
position.
• Rotate the lock counterclockwise to release the throttle.
• Tighten the lock to prevent moisture from entering the
cable and to prevent the cable from freezing in cold
weather.
12-volt Electrical Socket
Figure 10
Use the 12-volt electrical socket (Figure 11) to power personal
electronic equipment, such as a cell phone, a radio, or a GPS
device.
1. Key switch
17
Traction Controls
Important: The traction control pedal, the
utility-traction lever, and the attachment control lever
must be in the Neutral position before you can start
the engine.
Important: You must sit in the operator seat to move
the traction controls from the Neutral position and move
the machine; otherwise, the engine will stop in 1 second.
Note: Operation of the traction control pedal overrides
operation of the utility-traction lever.
Traction Control Pedal
The traction control pedal (Figure 12) controls the direction
of travel and the speed of the machine.
Figure 13
1. Handle
5. Utility-traction lever
(neutral)
2. Drive mode switch
(transport)
6. Utility-traction lever
(reverse)
3. Drive mode switch (work)
7. Transmission range switch
4. Utility-traction lever
(forward)
Use the utility-traction lever as follows:
• To move the machine forward, push the lever forward
(away from you).
• To move the machine rearward, pull the lever rearward
(toward you).
Figure 12
1. Heel pedal (reverse)
2. Toe pedal (forward)
Note: The farther you push or pull the lever, the faster the
machine moves.
To control the direction of travel and the speed of the
machine, do the following:
• Push the toe pedal forward to move the machine
forward.
• Push the heel pedal down to move the machine in
reverse.
• For maximum speed, fully push the pedal.
• To reduce the speed of the machine or to stop the
machine, move the pedal toward the Neutral position.
Note: The lever locks into position when you release the
lever.
Drive Mode Switch
The drive mode switch (Figure 13) controls the hydraulic
pressure to the traction motor and has 2 positions: the
transport mode and the work mode.
Important: Do not change from one drive mode to
another while the machine is moving.
Note: The drive mode switch is used in conjunction with
the transmission range switch.
Utility-traction Lever
Note: The Neutral position for the utility-traction lever is
detented. You must move the lever out of the detent to move
the lever forward or rearward.
To operate the drive mode switch, do the following:
• Pull the switch rearward (toward you) for work mode.
• Push the switch forward (away from you) for transport
mode.
The utility-traction lever (Figure 13) has 3 positions: Forward,
Neutral, and Reverse.
18
Transmission Range Switch
• Pull the joystick back to raise the blade.
The transmission range switch (Figure 13) is used to control
the gear reduction range of the transmission, and it has 2
positions (high and low).
• Push the joystick to the right (away from you) to swing
the blade to the right.
• Pull the joystick to the left (toward you) to swing the
blade to the left.
Important: Do not shift between the transmission
ranges while the machine is moving.
Backfill Blade Tilt Lever
Note: The transmission range switch is used in conjunction
with the drive mode switch.
Use the backfill blade tilt lever (Figure 14) to tilt the blade.
Operate the lever as follows:
To operate the transmission range switch, do the following:
• Push this lever to the right (away from you) to tilt the
• Press the switch to the right (near you) for low range.
• Press the switch to the left (away from you) for high range.
blade down on the right.
• Pull the control lever to the left (toward you) to tilt the
blade down on the left.
Attachment Control Panel
Attachment Control Lever
The attachment control panel is located on the right side of
the operator seat (Figure 14).
Note: Use the attachment control lever (Figure 14) for the
trencher.
Operate the control lever as follows:
• Push this lever to the right (away from you) to lower the
attachment.
• Pull the lever to the left (toward you) to raise the
attachment.
Note: When you release the lever, the machine maintains
the attachment position.
Rear Wheel Steering Control Lever
Use the rear wheel steering control lever (Figure 14) to steer
the rear wheels.
• Push the lever to the right (away from you) to turn the
rear wheels to the right.
• Pull the lever to the left (toward you) to turn the rear
wheels to the left.
Note: You can turn the front wheels by using the steering
wheel only.
Rear Attachment Control Lever
Figure 14
1. Backfill-blade joystick
The rear attachment control lever is located on the right side
of the operator seat as shown in Figure 15.
4. Attachment control
2. Trencher chain
5. Rear-wheel steering
direction/cable plow speed
control
control
3. Backfill tilt control
Backfill Blade Joystick
Use the backfill blade joystick (Figure 14) to float, raise, lower,
and angle the backfill blade. Operate the joystick as follows:
• Push the joystick partially forward to lower the blade.
• Push the joystick all the way forward to float the blade.
19
Operator Seat and Seat Belt
Seat Interlock System
WARNING
The seat interlock system protects the operator
from injury.
Do not disable the seat interlock system.
Figure 15
1. Fast forward chain speed
4. Slow reverse chain speed
or slow plow vibration
2. Slow forward chain speed
5. Fast reverse chain speed
or fast plow vibration
The seat interlock system requires the operator to sit in the
operator seat while operating this machine.
Note: The neutral indicator light turns on when you turn the
key switch to the On position and both the utility-traction
control and attachment control levers are in the Neutral
position.
3. Neutral position
• Cable plow operation (optional)—move the control
Note: If the operator does not remain seated when the
utility-traction lever is not in the Neutral position, the engine
will stop in 1 second. Do not lay a heavy object on the seat or
tamper with the seat interlock system in any way.
lever to control the cable plow as follows:
– Move the control lever rearward to actuate the
vibration of the blade; move the control lever fully
rearward to increase the vibration.
Forward and Rearward Seat Control
– Move the control lever to the Neutral position to
decrease and stop the vibration.
To move the operator seat (Figure 16) forward or rearward,
pull the control bar to the left to adjust the seat forward or
rearward.
Note: Moving the control lever forward beyond the
Neutral position has no function.
• Trencher operation—move the control lever to control
the trencher as follows:
– Move the control lever forward to actuate the digging
chain in the forward direction.
– Move the control lever fully toward the front to
increase the chain speed.
– Move the control lever to the Neutral position to
stop the chain.
– Move the control lever rearward to reverse the
digging chain direction.
Note: You must sit in the operator seat to move the
attachment control lever from the Neutral position;
otherwise, the engine will stop in 1 second.
Figure 16
1. Control bar
2. Seat lever
Seat Pivot Control
To rotate the seat, pull the seat lever up and rotate the seat
to the desired position.
20
Specifications
Seat Belt
Note: Specifications and design are subject to change
without notice.
WARNING
Operating the machine without the rollover
protection system (ROPS) securely in place can
result in serious injury or death if the machine rolls
over.
Basic Machine Dimensions and Weight Data
• Ensure that the roll bar is securely in place.
• Always wear a seat belt with the ROPS in place.
• Ensure that the operator seat is properly secured
to the machine.
Note: Regulations in some localities require that seat belts on
construction machines be 76 mm (3 inch) wide. Check with
local authorities regarding the requirements for seat belts.
Wheel base
149.8 cm (59.0 in)
Overall height (to the top of
the ROPS)
243.8 cm (96.0 in)
Overall width (at the tires)
170.2 cm (67.0 in)
Minimum ground clearance
30.5 cm (12.0 in)
Turning radius (2-wheel
steering)
464.8 cm (183 in)
Turning radius (4-wheel
steering)
294.6 cm (116 in)
Weight (without attachments)
2,494 kg (5,500 lb)
• To fasten the seat belt, insert the tab end into the left
buckle.
Attachments/Accessories
Note: Ensure that the tab end and the buckle are
securely fastened.
A selection of Toro approved attachments and accessories is
available for use with the machine to enhance and expand
its capabilities. Contact your Authorized Service Dealer or
Distributor or go to www.Toro.com for a list of all approved
attachments and accessories.
• To release the seat belt, push the button on the buckle.
Battery-disconnect Switch
The battery-disconnect switch is located behind the right
engine cowl (Figure 17); use it to electrically disconnect the
battery from the machine.
Figure 17
1. Battery On position
2. Battery Off position
• Rotate the battery disconnect clockwise to the On
position.
• Rotate the battery disconnect counterclockwise to the
Off position.
21
Operation
cold flow characteristics, which aid in starting the engine and
help prevent clogging the fuel filter.
Note: Determine the left and right sides of the machine
from the normal operating position.
Using summer-grade fuel above 20° F (-7°C) contributes
toward a longer fuel pump life and increased power compared
to using winter-grade fuel.
Preparing for Work
WARNING
Before operating the machine on the job site, review the
following items:
• Gather all relevant information available about the job
site before you begin working.
• Review all blueprints and other plans, and identify all
existing or proposed structures, characteristics of the
landscape, and other proposed jobs in the area scheduled
at the same time as your job.
•
Fuel is harmful or fatal if swallowed. Long-term
exposure to fuel vapors can cause serious injury
and illness.
• Avoid prolonged breathing of vapors.
• Keep your face away from nozzle and fuel tank
or conditioner opening.
• Keep fuel away from your eyes and skin.
Note the following items at the job site:
– Changes in elevation in the proposed work area
– The condition and type of soil in the proposed work
area
– Locations of structures, water, railroad tracks, and
other obstructions that you will need to work near
or around
– Utility markers, meters, and poles
– If the work site is near or on a roadway with traffic,
call the local authorities regarding proper safety
procedures and regulations.
– Access to the site
Call your local One-Call service (811 in the US) or the
One-Call referral number (888-258-0808 in the US and
Canada) and ask the participating utility companies to
locate and mark their underground utility lines. Also call
utility providers that are not part of the One-Call system.
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.
• Fill the fuel tank outdoors in an open area when
the engine is cold. Wipe up any fuel that spills.
• Never fill the fuel tank inside an enclosed trailer.
• Never smoke when handling fuel, and stay away
from an open flame or where fuel fumes may be
ignited by a spark.
• Store fuel in an approved container, and keep
it out of the reach of children. Never buy more
than a 30-day supply of fuel.
• Do not operate without entire exhaust system in
place and in proper working condition.
Adding Fuel to the Engine
In certain conditions, fueling can release static electricity and
cause a spark, which can ignite the fuel vapors. A fire or
explosion from fuel can burn you and others and can damage
property.
• Always place fuel containers on the ground, away from
your vehicle before filling.
• Do not fill fuel containers inside a vehicle or on a truck
or trailer bed, because interior carpets or plastic truck
bed liners may insulate the container and slow the loss
of any static charge.
• When practical, remove the equipment from the truck
or trailer, and refuel the equipment with its wheels on
the ground.
• If refuelling the equipment with its wheels on the ground
is not possible, then refuel such equipment on a truck or
trailer from a portable container rather than from a fuel
dispenser nozzle.
• If you must use a fuel dispenser nozzle, keep the nozzle in
contact with the rim of the fuel tank or container opening
at all times until fueling is complete.
Use ultra-low sulfur diesel (ULSD) fuel in the engine. Using
other fuels can cause a loss of engine power and high fuel
consumption.
Important: Do not use kerosene or gasoline instead of
diesel fuel; otherwise, you will damage the engine.
Use only diesel fuel for the machine that meets Specification
D975 of the American Society for Testing and Materials
International. See your diesel fuel distributor.
Use only clean, fresh diesel fuel or biodiesel fuels with low
(<500 ppm) or ultra low (<15 ppm) sulfur content. The
minimum cetane rating should be 40. Purchase only enough
fuel that you expect to use within 30 days to ensure that it
stays fresh.
Fuel tank capacity: 75.7 L (20 US gal)
Use summer-grade diesel fuel (No. 2-D) at temperatures
above 20°F (-7°C) and winter-grade diesel fuel (No. 1-D or
No. 1-D/2-D blend) below 20°F (-7°C). Using winter-grade
fuel at lower temperatures provides a lower flash point and
22
Using Biodiesel Fuel
Note: Remove the cap slowly to reduce the air
pressure buildup.
This machine can also use a biodiesel blended fuel of up
to B20 (20% biodiesel, 80% 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.
• Biodiesel blends may be damage painted surfaces.
• Use B5 with a biodiesel content of 5% or less in cold
weather.
• Check seals, hoses, gaskets that come in contact with the
fuel, as they may degrade over time.
• The fuel filter may become plugged for a time after
converting to a biodiesel fuel blend.
• Contact your distributor for more information about
biodiesel fuel.
2. Fill the fuel tank to the bottom of the neck to allow
the fuel room to expand.
Note: The fuel tank capacity is 75.7 L (20 US gal).
3. Install the fuel tank cap and tighten it securely by hand.
Checking the Engine Oil Level
Service Interval: Before each use or daily
The engine is shipped with oil in the crankcase; however,
check the oil level before and after you first start the engine.
Use only high-quality SAE 15W-40 heavy-duty engine oil with
an API classification of CH-4 or higher.
While SAE 15W-40 oil with an API classification of CH-4 or
higher is recommended for most climates, refer to Figure 19
for oil viscosity recommendations for extreme climates.
Storing Fuel
°C -40 -30 -20 -10 0 10 20 30 40 50
°C -40 -22 -2 14 32 50 58 86 104 122
If you store fuel in a storage tank, it can accumulate foreign
material or water. Keep the fuel storage tank outside, and
keep the fuel as cool as possible. Remove water from the fuel
in the storage container at regular intervals.
All Seasons
15W-40
Winter Conditions
10W-30
Filling the Fuel Tank
Arctic Conditions
Note: Fill the fuel tank of the machine at the end of each day
to prevent condensation in the fuel tank.
1. Clean around the fuel-tank cap (Figure 18), and remove
the cap from the tank.
5W-30
°C -40 -30 -20 -10 0 10 20 30 40 50
°C -40 -22 -2 14 32 50 58 86 104 122
G022415
Figure 19
Note: Limited use of low-viscosity oils such as SAE 10W-30
with an API classification of CH-4 or higher can be used for
easier starting and providing sufficient oil flow at ambient
temperatures below -5°C (23°F). However, continuous use of
low viscosity oil can decrease engine life because of wear.
Toro Premium Engine Oil is available from an Authorized
Toro Service Dealer in either 15W-40 or 10W-30 viscosity
with API classification CH-4 or higher. See the Parts Catalog
for part numbers. Also, refer to the Engine Operator's Manual,
included with the machine, for further recommendations.
Important: If the oil level in the crankcase is too low
or too high and you run the engine, you may damage
the engine.
1. Remove the right-side panel; refer to Removing the
Side Panels (page 35).
2. Remove the dipstick (Figure 20) and wipe it clean with
a clean cloth (Figure 20).
Figure 18
1. Fuel cap
2. Filler neck
23
High Viscosity Index/Low Pour Point Anti-wear
Hydraulic Fluid, ISO VG 46 (cont'd.)
Pour Point, ASTM D97
-37°C (-34°F) to -45°C (-49°F)
11 or better
FZG, Fail stage
Water content (new fluid)
Industry Specifications:
Vickers I-286-S (Quality Level),
Vickers M-2950-S (Quality
Level), Denison HF-0
Note: Many brands of hydraulic fluids are almost colorless,
making it difficult to spot leaks. A red dye additive for the
hydraulic system oil is available in 20 ml (0.68 oz) bottles.
One bottle is sufficient for 15.1 to 22.7 L (4.0 to 6.0 US gal)
of hydraulic oil. Order part no. 44-2500 from an Authorized
Toro Service Dealer.
Figure 20
1. Dipstick
500 ppm (maximum)
2. Dipstick tube
3. Insert the dipstick fully into the dipstick tube, then
remove the dipstick (Figure 20).
1. Park the machine on a level surface, and put all the
attachments in the transport position.
4. Read the oil level on the dipstick.
2. Stop the engine, set the parking brake, and remove the
ignition key.
• If the oil level is too low, slowly pour a small
amount of the specified oil into the oil-filler neck
(Figure 43), wait 3 minutes; refer to step 1 in Filling
the Engine with Oil (page 39).
3. Check the hydraulic fluid level in the sight gauge
located at the side of the hydraulic reservoir (Figure 21).
• If the oil level is too high, drain the excess oil until
you obtain the correct oil level on the dipstick;
refer to Draining the Engine Oil (page 38).
5. Repeat steps 2 through 4 until the oil level is correct.
6. Install the dipstick and oil-fill cap securely.
7. Install the right-side panel; refer to Installing the Side
Panels (page 36).
Checking the Hydraulic Fluid
Level
Service Interval: Before each use or daily
Use Toro Premium All-season Hydraulic Fluid (available
in 5-gallon pails or 55-gallon drums. See the parts catalog or
an Authorized Toro Service Dealer for part numbers).
If Toro hydraulic fluid is not available, you may use an
equivalent hydraulic fluid, provided that it meets all the
following material properties and industry specifications. Do
not use a synthetic hydraulic fluid. Consult with your
lubricant distributor to identify a satisfactory product.
High Viscosity Index/Low Pour Point Anti-wear
Hydraulic Fluid, ISO VG 46
Figure 21
Material Properties:
Viscosity, ASTM D445
1. Fill level (midpoint)
St @ 40°C (104°F): 44 to 48
3. Hydraulic fluid
2. Sight gauge
St @ 100°C (212°F): 7.9 to 8.5
Viscosity Index ASTM
D2270
140 to 160
Note: The hydraulic fluid level should be between the
Add and Full marks on the sight gauge.
24
Note: If the machine is equipped with a backhoe,
ensure that the engine shutoff control is pulled up.
4. If the hydraulic fluid level is below the Add mark,
remove the fill cap (Figure 21), add the specified
hydraulic fluid to raise the fluid level up to the Full
mark, and install the fill cap.
6. Pull the throttle lever out to the 1/2 Throttle position.
Note: In extreme hot or cold weather, take the
necessary precautions; refer to Operating the Machine
in Extreme Conditions (page 26).
Inspecting the Machine Daily
Inspect the following items on the machine each day before
you start the engine:
• Check for leaks under the machine, and repair all leaks.
• Check the tires for wear, damage, and low pressure.
• Check the machine for debris, especially around the
engine.
•
•
•
•
•
7. Turn the key switch to the On position, and check that
the controls-in-neutral, the parking-brake warning, and
the oil-pressure warning lights illuminate.
Note: The engine comes with an glow plug air
system that sense the inlet air temperature. If the air
temperature is cold, the wait-to-start warning light
alerts the operator to wait for the intake air to warm up
before starting. When the intake air is at the proper
temperature for starting the engine, the warning light
turns off.
Note: Ensure that the area near the engine is clean so
that the engine cools properly.
Clean or replace any safety or instructional decal that
cannot be read.
Clean machine components that you, the operator, use.
Remove any loose items from the machine.
Check the machine for broken, damaged, loose, or
missing parts. Replace, tighten, or adjust these parts
before you operate the machine.
Repair or replace all damaged ROPS and seat belt parts.
8. Turn the key switch halfway between the On and
Start positions, and check that the warning lights on
the instrument cluster are working properly; refer to
Instrument Cluster (page 15).
9. Turn the key switch to the Start position.
Note: If the engine starts and then stops, do not
turn the key switch to the Start position again until the
starter motor has stopped turning.
Starting the Engine
Important: Do not operate the starter motor until
it stops turning. Do not operate the starter motor
for more than 30 seconds at one time. Allow the
starter motor to cool for 30 seconds before you
operate it again. When you engage the starter
motor, you should see white or black smoke
coming from the exhaust pipe; if you do not, check
the fuel supply.
WARNING
Before starting the engine, sit in the operator seat,
fasten the seat belt, apply the parking brake, and
ensure that the transmission direction control and
digging control levers are in the Neutral position.
Warn all persons around you that you are starting
the engine.
10. When the engine starts, check the instruments to
ensure that the gauge readings are correct. If any of
the warning lights turn on, stop the engine and check
the problem.
Note: The seat interlock system prevents you from starting
and operating the machine unless your are sitting in the
operator seat. If you do not remain seated and the control
levers are not in the Neutral position, the system will stop
both the ground drive and the attachment drive in 1 second.
Do not set a weighted object on the seat, bypass the seat
interlock system, or tamper with the system.
1. Check the oil level; refer to Checking the Engine Oil
Level (page 23).
2. Ensure that the battery-disconnect switch is in the On
position.
3. Adjust the seat position and fasten the seat belt.
11. Run at the engine at 1000 rpm until the coolant is
warm.
12. Cycle all the machine components before operating the
machine, and check all the controls and components to
ensure that they are working properly.
Note: If the engine is new or newly rebuilt, refer to
Breaking in a New or Rebuilt Engine (page 26).
Setting the Engine Speed
Note: Ensure that the seat is facing forward.
4. Set the parking brake switch to the On position.
5. Ensure that all control levers are in the Neutral or the
Stop position and that the hand throttle is in the Idle
position.
Note: Do not run the engine at a low idle speed for long
periods of time, because it causes a low operating temperature
that can allow acids and deposits to form in the engine oil.
Note: For maximum life and machine performance, operate
the engine at full throttle whenever the conditions allow you
to safely do so.
Note: The controls-in-neutral light will illuminate.
25
Breaking in a New or Rebuilt
Engine
• To increase the engine speed, push the throttle center
button while pulling out the throttle (Figure 22).
During the first 20 hours of operation of a new or rebuilt
engine, do the following:
• Keep the engine at a normal operating temperature.
• Do not run the engine at low idle speeds for long periods
of time.
• Operate the machine with normal loads for the first 8
hours.
• Do not use special “break-in” lubricating oil. Use the
specified oil; refer to Checking the Engine Oil Level (page
23) and Changing the Engine Oil Filter (page 39).
Operating the Machine in
Extreme Conditions
Both hot and cold weather place unusual demands upon
the machine and the attachments. You can minimize
temperature-related problems on the machine by performing
the following steps:
Figure 22
1. Throttle button
2. Throttle knob
3. Throttle lock
Hot Weather
1. Clean all dirt and debris from the radiator, hydraulic oil
cooler, and engine area to ensure that there is proper
air flow to cool the engine.
• To decrease the engine speed, push the throttle center
button while pushing in the throttle.
2. Wipe any debris from the air inlets in the hood side
panels.
• To finely increase the engine speed, rotate the throttle
knob counterclockwise.
3. Use lubricants that have the correct viscosity.
• To finely decrease the engine speed, rotate the throttle
4. Check the air cleaner dust valve more frequently in
extremely dusty conditions.
knob clockwise.
5. Check the condition of the fan drive belt. Replace it if
it is cracked or worn.
Stopping the Engine
6. Operate the machine at an appropriate engine speed
and transmission range for the operating conditions;
do not overload the engine.
1. Park the machine on level ground, if possible.
Important: If you must temporarily park the
machine on a slope or an incline, position the
machine at a right angle to the slope, with the
front of the machine toward the bottom of the hill.
Ensure that the machine is behind an object that
will not move.
7. Test the radiator cap before the hot weather begins;
replace the cap if it is damaged.
8. Maintain the correct coolant level in the reservoir and
in the radiator, and ensure that there is a mixture of
50% ethylene glycol and 50% water in the cooling
system.
2. Support or lower all attachments to the ground.
3. Set the parking brake.
Cold Weather
4. If the machine has been operating under a heavy load,
decrease the engine speed to 1/4 throttle for 2 minutes
to evenly cool the engine.
Operating your machine in cold weather requires special
attention to prevent serious damage to the machine.
Performing the following procedures will extend the service
life of your machine:
5. Push the throttle lever to the Slow position, and turn
the key switch to the Off position.
1. Clean the battery and ensure that it is fully charged.
Note: A fully charged battery at -17ºC (0ºF) has
only 40% of the normal starting power. When the
temperature decreases to -29ºC (-20ºF), the battery has
only 18% of the normal power remaining.
6. If you leave the machine unattended, remove the key
from the ignition switch.
26
Driving and Stopping the
Machine
2. The machine comes with a maintenance-free battery.
If you use a different battery and add water to it when
the temperature is below 0ºC (32ºF), ensure that you
charge the battery or run the engine for about 2 hours
to prevent the battery from freezing.
Using the Traction Control Pedal
3. Inspect the battery cables and terminals. Clean the
terminals, and apply a coat of grease on each terminal
to prevent corrosion.
The traction control pedal controls the direction of travel
and the speed of the machine.
• To move the machine forward, push down on the toe
4. Ensure that the fuel system is clean and free of water.
Use the proper fuel for cold weather.
pedal.
• To move the machine in reverse, push down on the heel
Note: Prevent wax and condensation from building
up in the fuel tank by filling up the fuel tank at the end
of each day.
pedal.
Note: To increase the speed, push down farther on the
pedal; to decrease the speed, allow the pedal to move up
toward the Neutral position.
5. Check the coolant mixture before you operate the
machine in cold weather. Use only a 50% ethylene
glycol and 50% water mixture in the cooling system
year round.
Using the Utility-traction Lever
This control lever allows you to finely adjust the direction
of travel and the speed of the machine during trenching,
plowing, or boring.
6. Before operating the machine, move it at low speed
and actuate each hydraulic control several times to
warm the oil.
Important: The engine and the hydraulic system
must be at operating temperature before you
perform any work with it.
Note: Keep the digging chain free of mud and snow
to prevent it from freezing after operation.
Operating the Parking Brake
1. Push the parking brake switch (Figure 23) up to apply
the parking brake.
Figure 24
1. Utility-traction lever
WARNING
To avoid injury, remain in the operator seat to
operate the machine.
Note: If you do not remain in the operator seat, the engine
will stop in 1 second.
Figure 23
1. Release the parking brake.
1. Parking brake
2. Move the lever out of the Neutral detent position and
to one of the positions as follows:
2. Push the parking switch down to release the parking
brake.
• Move the lever forward (toward the front of the
machine) to move the machine forward.
Note: The parking brake automatically engages when
you stop the engine.
• Move the lever rearward (toward the rear of the
machine) to move the machine in reverse.
27
Operating the Transmission
Note: Move the lever completely forward or rearward
for the maximum speed.
3. Release the lever.
Operating the Drive Mode Switch
Note: The lever is held in place front-to-rear by
friction in order to maintain a constant speed.
This toggle switch (Figure 25) controls the mode for the
hydraulic motor and has 2 positions: Transport and Work.
Select the desired operating position. Push the switch to
the rear (toward you) to set to Work speed (W), or push the
switch forward (away from you) to set to Transport speed (T).
4. Return the lever to the Neutral position to stop the
machine.
Note: The ground drive foot control overrides the
traction adjustment control lever. If you use the foot
pedal, you must move the traction adjustment control
lever to the Neutral position to release the override and
return the lever to normal operation.
Stopping the Machine
WARNING
Jumping on or off the machine can cause an injury.
When you get on or off the machine, always face the
machine, use the hand rails and steps, move slowly.
This machine has hydrostatic braking. When you remove
your foot from the ground drive foot pedal or move the
utility-traction control back to Neutral, the machine stops.
Always apply the parking brake after you stop the machine
and before you stop the engine.
Figure 25
1. Drive mode switch
2. Utility-traction lever handle
1. Move to level ground, if possible.
Operating the Transmission Range
Switch
Important: If you must temporarily park the
machine on a slope or an incline, position the
machine at a right angle to the slope, with the
front of the machine toward the bottom of the hill.
Ensure that the machine is behind an object that
will not move.
This rocker switch (Figure 26) also has 2 positions: High and
Low speed ranges. These ranges are used in conjunction with
the ground speed control.
Press the switch to the right (toward you) for low range, or
press the switch to the left (away from you) for high range. To
shift the transmission, stop the machine (the traction control
pedals and utility-control lever in the Neutral position) with
the controls-in-neutral light illuminated.
2. Support or lower all attachments to the ground.
3. Set the parking brake.
4. To stop the engine, refer to Stopping the Engine (page
26).
Important: The transmission will not shift between
ranges unless the machine has stopped moving.
5. At the end of the workday, fill the fuel tank at the end
of each work day to prevent condensation and moisture
in the tank.
28
• Ensure that the ROPS and the seat belt are properly
installed and in good working order.
• Ensure that all instruments, the controls-in-neutral light,
and the all warning lights are working properly.
• Ensure that all controls are working properly in a clear,
open area.
Note: The controls-in-neutral light will turn on when the
key switch is in the On position and the utility-traction lever
is in the Neutral position.
1. Warm up the engine.
Figure 26
1. Low range
2. Pull the throttle out to the Full position.
2. High range
3. Raise the equipment and any attachments (trencher,
plow, etc.).
4. Release the parking brake.
The machine has a 2-mode hydrostatic drive with a 2-range
transmission to provide 4 forward and reverse speeds. Select
the gear combination most appropriate for the operation that
you will perform.
Note: You must remain seated in the operator seat
before you move the engine; otherwise, the engine will
stop in 1 second.
Note: The utility-traction lever controls the speed of
the machine. The farther that you move the lever from
the Neutral position, the faster the machine moves.
WARNING
The machine can roll uncontrolled if the traction
controls are in the Neutral position.
Important: Control the speed of the machine
travel with the utility-traction lever, not the throttle.
Stop the machine and set the parking brake before
shifting the transmission control.
5. Check the indicator lights frequently.
• First gear: With the drive mode switch in the Work
•
•
•
Using the Backfill Blade
position, press the transmission range switch to the right
(near you) to select the transmission into Low range.
Second gear: With the drive mode switch in the Work
position, press the transmission range switch to the left
(away from you) to select the transmission into High
range.
Third gear: With the drive mode switch in the Transport
position, press the transmission range switch to the right
(near you) to select the transmission into Low range.
Fourth gear: With the drive mode switch in the
Transport position, press the transmission range switch
to the left (away from you) to select the transmission into
High range.
Gear
Drive Mode
Transmission
Range
1st
Work
Low
2nd
Work
High
3rd
Transport
Low
4th
Transport
High
Important: Operate the controls only while sitting in
the operator seat.
Use the backfill blade to return the spoils into the trench.
You control the backfill blade with joystick and the backfill
blade lever control as shown in Figure 27.
Preparing to Operate the
Machine
Figure 27
1. Joystick
After starting the engine but before operating the machine at
the work site, do the following:
29
2. Tilt lever
To operate the backfill blade, do the following:
• To raise the backfill blade: Move the joystick rearward.
• To lower the backfill blade: Move the joystick partially
forward.
• To angle the backfill blade to the right: Move the joystick
G023080
to the right.
Figure 28
• To angle the backfill blade to the left: Move the joystick
to the left.
10. Fasten the rear of the machine to the trailer using
chains and a binder (Figure 28).
• To hold the backfill blade: Keep the joystick in the Hold
(neutral) position.
Note: Use the rear axle to secure the rear of the
machine.
• To float the backfill blade: Move the joystick fully forward.
• To tilt the backfill blade down on the right: Move the tilt
11. Measure the distance from the ground to the highest
point of the machine.
lever right (away from you).
• To tilt the backfill blade down on the left: Move the tilt
Note: You must know the clearance height of the
machine.
lever left (toward you).
Note: For best results when backfilling the spoils while
parallel to the trench, make 2 or 3 passes over the spoil pile
with the blade.
12. Remove the blocks from the front and rear trailer
wheels.
13. After you have driven a few miles, stop the truck and
check your load.
Note: If the spoil pile is large, operate the machine at a right
angle to the trench.
Note: Ensure that the chains are still tight and that the
machine has not moved on the trailer.
Transporting the Machine
Unloading the Machine from a Trailer
Be sure that you understand the safety rules and laws for the
area in which you are using the machine. Ensure that both
the truck and the machine are equipped with the proper
safety equipment.
1. Block the front and rear trailer wheels.
2. Remove the blocks from the front and rear wheels of
the machine.
3. Remove the straps from the machine.
Loading the Machine onto a Trailer
4. Start the engine.
1. Ensure that the trailer and the ramp can support both
your weight and the weight of the machine.
5. Ensure that the attachments are in the Transport
position.
2. Always have the attachments ready to transport when
you are loading or unloading the machine.
6. Slowly move the machine off the trailer.
3. Block the front and rear wheels of the trailer.
Lifting the Machine with a Spreader Bar
4. Slowly and carefully move the machine onto the trailer.
1. Attach a crane lift cable to the single-lift point of a
spreader bar.
5. Lower the attachments to the trailer.
2. Attach 2 of the lift cables on one end of the spreader
bar to a lifting bar placed under the rear of the machine
frame.
6. Engage the parking brake.
7. Stop the engine and remove the key.
8. Block the front and rear wheels of the machine.
3. Attach the remaining 2 spreader bar lift cables to a
lifting bar placed under the front of the machine frame.
9. Fasten the front of the machine to the trailer using
straps and a binder (Figure 28).
4. Carefully and slowly lift the machine, and lower it to
the desired location.
Note: Use the front axle to secure the machine.
Moving a Non-functioning Machine
Repair a non-functioning machine on the job site, if possible.
Otherwise, you must determine whether you can move the
machine without further damaging it.
30
Completing the Work for the
Day
If you must tow the machine, perform the following steps
using caution:
Note: If you do not have a rigid drawbar, use 2 towing
machines. Attach a tow chain each to the front and rear
towing machines. Use the front towing machine to move the
non-functioning machine and the rear towing machine to
stop the non-functioning machine.
When you complete your work for the day, do the following:
1. Backfill the spoils in the part(s) of the trench in which
you are finished working.
2. Move the machine to a safe and stable location.
Note: This machine has hydrostatic braking. When you stop
the engine, the brakes automatically engage.
3. Move all levers to the Neutral position.
4. Engage the parking brake.
1. Disconnect the hydraulic hose from the parking brake
cylinder as shown in Figure 29.
5. Lower all attachments to the ground.
Note: Plug the open end of the hose to prevent the
hydraulic fluid from leaking out.
6. Let the machine idle for a few moments to cool it
down.
7. Shut off the engine, wait for all moving part to stop,
and remove the ignition key.
8. Turn the battery disconnect switch to the Disconnect
position.
Completing the Project
1. After you complete the project, return the spoils back
into the trench with the backfill blade; refer to Using
the Backfill Blade (page 29).
2. Return the spoils into the trench.
A. Move the machine to the end of the trench, a few
feet (meters) away from the spoil pile.
Figure 29
1. Parking brake cylinder
hydraulic fitting
3. Hand pump fitting
connected to the cylinder
fitting
2. Hydraulic brake hose
4. Hand pump
B.
Aim the machine at the outer edge of the pile.
C.
Adjust the backfill blade to fit the slope of the
ground.
D.
Move the outer edge of the spoil pile toward the
trench.
Note: Make at least 2 passes at the pile to move
it.
2. Connect a hydraulic-hand pump capable of producing
350 psi to the brake cylinder (Figure 29).
E. Repeat the steps above for the spoil pile on the
other side of the trench.
3. Operate the hand pump until the brakes are released.
F.
4. Move the utility-traction lever to the Neutral position.
Float the backfill blade over the length of the
trench.
3. Spray the dirt and mud off the machine with water.
Note: You can move the machine up to 8 km/h (5
mph) and a distance up to 1.6 km (1 mile) away. To
transport a disabled machine more than 1.6 km (1 mile),
you must use a suitable trailer; refer to Transporting the
Machine (page 30).
Note: Do not spray the console or electrical
components with water.
4. Transport the machine from the completed work site;
refer to Transporting the Machine (page 30).
5. Tow the machine to the transport vehicle or to a site
where you can repair the machine.
6. Disconnect the hand pump and connect the hose
to the parking brake cylinder before transporting or
making any repairs.
31
Maintenance
Recommended Maintenance Schedule(s)
Maintenance Service
Interval
Maintenance Procedure
After the first 100 hours
• Check the oil level in the wheel hubs.
• Check the oil level in the front and rear axles.
• Check the oil level in the transmission.
After the first 200 hours
• Change the wheel hub oil.
• Change the oil in the axles.
• Change the oil in the transmission and rear axle.
Before each use or daily
•
•
•
•
•
•
•
Check the engine oil level.
Check the hydraulic fluid level in the reservoir.
Grease the machine.
Check the engine oil level.
Check the restricted air-cleaner light for a restricted air cleaner.
Check the tires and wheels for damage.
Check the coolant level in the reservoir.
Every 50 hours
•
•
•
•
Check and clean the dust valve.
Check the fuel-water separator for water and sediment.
Maintain the proper air pressure in the tires.
Check the coolant level in the radiator.
Every 200 hours
• Grease the front and rear axles.
Every 250 hours
•
•
•
•
•
•
Every 300 hours
• Clean the axle breather for each axle.
• Check the condition of the coolant system components. Clean dirt and debris from
them and repair or replace the components as necessary.
Every 500 hours
•
•
•
•
•
•
Grease the drive shaft.
Replace the secondary fuel filter.
Replace the primary fuel filter.
Change the hydraulic-pressure filter.
Change the hydraulic-return filter.
Check and maintain the ROPS; check it after an accident.
Every 1,000 hours
•
•
•
•
•
•
Change the wheel hub oil.
Change the oil in the axles.
Change the oil in the transmission and rear axle.
Check the concentration of the coolant.
Check the tension on the engine drive belt.
Change the hydraulic fluid and clean the breather.
Every 2,000 hours
• Clean the cooling system.
Change the engine oil.
Change the engine oil filter.
Check the oil level in the wheel hubs.
Check the oil level in the front and rear axles.
Check the oil level in the transmission.
Check the condition of the engine drive belt.
32
Premaintenance
Procedures
Lubrication
General Safety
Grease Type: Lithium-based grease.
Greasing the Machine
Greasing the Front and Rear Axles
WARNING
Improperly servicing or repairing the machine can
cause injury or death.
Service Interval: Every 200 hours
1. Clean the grease fittings with a rag.
If you do not understand the service procedures for
this machine, contact an Authorized Toro Service
Dealer or the service manual for this machine.
2. Connect the grease gun to the grease fittings for the
upper and lower pivots; apply 2 or 3 pumps of grease
to each fitting (Figure 30 and Figure 31).
Note: There are 2 grease fittings at the axle pivot for
each tire.
WARNING
Raised equipment on the machine without an
operator can cause injury or death.
Before you leave the operating area, always support
or lower the equipment to the ground and stop the
engine.
WARNING
Replace all covers and guards after you service or
clean the machine. Never operate the machine
without the covers or guards in place.
1. Park the machine on a level surface.
2. Lower all attachments and stop the engine, and remove
the key.
3. Allow the engine to cool 2 or 3 minutes.
Figure 30
Front axle
4. Remove the right-side panel; refer to Removing the
Side Panels (page 35).
1. Grease fitting (upper pivot) 2. Grease fitting (lower pivot)
5. Rotate the battery-disconnect switch to the Off
position.
33
Figure 31
Rear axle
Figure 32
1. Grease fitting (upper pivot) 2. Grease fitting (lower pivot)
1. Grease fitting (forward
universal joint)
3. Grease fitting (back
universal joint)
2. Grease fitting (sliding joint)
3. Wipe up any excess grease.
Greasing the Driveshaft
3. Connect the grease gun to the grease fitting for the
universal joint at the forward end of the drive shaft,
and apply 2 or 3 pumps of grease to the fitting.
Service Interval: Every 500 hours
1. Clean the grease fittings with a rag.
4. Connect the grease gun to the grease fitting for the
universal joint at the back end of the drive shaft, and
apply 2 or 3 pumps of grease to the fitting.
2. Connect the grease gun to the grease fitting for the
slide coupling at the at the forward end of the drive
shaft, and apply 2 or 3 pumps of grease to the fitting
(Figure 32).
5. Wipe up any excess grease.
Greasing the Backfill Blade
Service Interval: Before each use or daily
1. Clean the grease fittings with a rag.
2. Connect the grease gun to the upper and lower grease
fittings for the lift cylinder, and apply 3 pumps of
grease to each fitting (Figure 33).
34
Engine Maintenance
Before maintaining the engine, perform the following steps:
1. Park the machine on level ground, lower all
attachments, and stop the engine.
2. Remove the ignition key and allow the engine to cool
for 2 or 3 minutes.
Accessing the Engine
Removing the Side Panels
1. If the optional backhoe is installed, perform the
following substeps to remove the left side panel;
otherwise, skip to step 2:
Figure 33
1. Grease fittings
A. At the left side of the machine, remove the
retaining pin from the front end of the walkway
(Figure 34).
2. Lift cylinder
3. Wipe up any excess grease.
Figure 34
1. Retaining pin
B.
2. Walkway
Pivot the walkway away from the machine as
shown in Figure 34.
2. Pull up on the hand grip of the panel latch, and swing
the latch free from the anchor bracket (Figure 35).
35
6. If the backhoe is installed on the machine, do the
following substeps:
A. Rotate the front end of the walkway to its original
position (Figure 34).
B.
Align the hole in the walkway with the hole in the
walkway support bracket (Figure 34).
C.
Install the retaining pin through the holes.
Removing the Nose Panel
1. Remove both the left side panel and the right side
panel from the machine; refer to Removing the Side
Panels (page 35).
2. If the backhoe is installed on the machine, do the
following substeps; otherwise, skip to step 3.
Figure 35
A. Remove the hairpin from the seat lock pin (Figure
37).
3. Anchor bracket
1. Side panel
2. Panel latch
3. Lift the side panel straight up and remove it from the
machine (Figure 35).
Installing the Side Panels
1. Align the left side panel with the left side of the
machine and the right side panel with the right side
of the machine.
2. Align the tabs at the top of the side panel with the
receiver brackets on the machine (Figure 36).
Figure 37
1. Hairpin
Figure 36
1. Tab
2. Side panel
3. Receiver brackets
3. Lower the side panel straight down.
2. Seat lock pin
B.
Remove the seat lock pin from the frame of the
backhoe and the seat post (Figure 37).
C.
Pivot the seat post upward, and insert the
seat-lock pin through the holes in the frame of
the backhoe to hold the seat up to make room for
removing the nose panel (Figure 37).
Note: Install the seat lock pin and hairpin in the
backhoe frame to hold the seat up position.
Note: Ensure that the tabs of the side panel align into
the receiver brackets on the machine.
3. Remove the 4 bolts at the bottom of the left and right
sides of the nose panel (Figure 38).
4. Pull the hand grip of the panel latch outward, then pivot
it up until it aligns in the anchor bracket (Figure 35).
5. Release the latch handle.
36
Note: When you install the nose panel from the
machine when the optional backhoe is attached, gently
push the hoses in the front of the nose panel forward
while lowering the panel into place.
3. Secure the nose panel to the machine with the 4 bolts
that you removed during step 3 of Installing the Nose
Panel (page 37).
4. If the backhoe is installed on the machine, do the
following substeps:
A. Remove the seat lock pin and lower the seat post
to the operating position (Figure 37).
B. Install the seat lock pin through the holes in the
frame of the backhoe and the seat post (Figure
37).
C. Install the hairpin into the hole in the seat lock
pin (Figure 37).
5. Install the left and right side panels on the machine;
refer to Installing the Side Panels (page 36).
Figure 38
Servicing the Engine Oil and
Filter
1. Bolts
4. Lift the nose panel up and off the machine (Figure 39).
The engine is shipped with oil in the crankcase; however,
check the oil level before and after you first start the engine.
The crankcase capacity is 11.0 L (11.6 US qt) with the filter.
Use only high-quality SAE 15W-40 heavy-duty engine oil with
an API classification of CH-4 or higher.
While SAE 15W-40 oil with an API classification of CH-4 or
higher is recommended for most climates, refer to Figure 40
for oil viscosity recommendations for extreme climates.
°C -40 -30 -20 -10 0 10 20 30 40 50
°C -40 -22 -2 14 32 50 58 86 104 122
All Seasons
15W-40
Winter Conditions
Arctic Conditions
Figure 39
10W-30
5W-30
°C -40 -30 -20 -10 0 10 20 30 40 50
°C -40 -22 -2 14 32 50 58 86 104 122
G022415
Note: When you remove the nose panel from the
machine when the optional backhoe is attached, gently
push the hoses in the front of the nose panel forward
while lifting the nose panel upward.
Figure 40
Note: Limited use of low-viscosity oils such as SAE 10W-30
with an API classification of CH-4 or higher can be used for
easier starting and providing sufficient oil flow at ambient
temperatures below -5°C (23°F). However, continuous use of
low viscosity oil can decrease engine life because of wear.
Installing the Nose Panel
1. Align the nose panel over the radiator of the machine.
2. Lower the nose panel down and onto the machine
(Figure 39).
Toro Premium Engine Oil is available from an Authorized
Toro Service Dealer in either 15W-40 or 10W-30 viscosity
with API classification CH-4 or higher. See the Parts Catalog
37
Changing the Engine Oil
for part numbers. Also, refer to the Engine Operator's Manual,
included with the machine, for further recommendations.
Service Interval: Every 250 hours
Checking the Engine Oil Level
Draining the Engine Oil
1. Run the engine a few minutes before changing the oil
to warm it.
Service Interval: Before each use or daily
Note: The best time to check the engine oil is when the
engine is cool before it has been started for the day, if
possible. If the oil level is at or below the Add mark on the
dipstick, add oil to the engine to bring the oil level up to the
Full mark. Do not overfill. If the oil level is between the Full
and Add marks on the dipstick, you do not need to add oil.
Note: Warm oil flows better and carries more
contaminants.
2. Remove the right side panel; refer to Removing the
Side Panels (page 35).
3. Place a drain pan that has a minimum capacity of 8.4
L (8.9 US qt) under the engine-oil drain fitting (Figure
42).
1. Ensure that the machine is on a level surface.
2. Lower all attachments, set the parking brake, stop the
engine, and remove the key.
Note: If you have run the engine, allow at least 10
minutes for the engine oil to settle in the crankcase.
3. Remove the right side panel; refer to Removing the
Side Panels (page 35).
4. Remove the dipstick and wipe clean it with a clean
cloth (Figure 41).
Figure 42
1. Engine-oil tank
3. Cap
2. Drain fitting
4. Drain pan
4. Remove the cap from the drain fitting and allow the
engine oil to drain completely (Figure 42).
Note: Removing the oil-fill cap from the filler neck
helps to drain the engine oil (Figure 43).
Figure 41
1. Dipstick
2. Dipstick tube
5. Insert the dipstick into the dipstick tube, pull the
dipstick out again, and read the oil level on the dipstick
(Figure 41).
Note: The oil level on the dipstick should be between
the H (high) mark and L (low) mark.
6. If the oil level is below the L (low) mark, remove the
fill cap and add oil until the level reaches the H (high)
mark.
Figure 43
Important: Do not overfill the engine with oil.
1. Filler neck
2. Oil-fill cap
7. Install the dipstick.
8. Install the right side panel; refer to Installing the Side
Panels (page 36).
3. Funnel
5. Clean the mating surfaces of the cap and the drain
fitting.
38
6. Install the cap onto the drain fitting (Figure 42).
3. Rotate the oil filter counterclockwise and remove the
oil filter (Figure 44).
Filling the Engine with Oil
Note: Recycle the used oil filter according to local
codes.
1. Remove the oil-fill cap from the filler neck by pulling
the cap upward (Figure 42).
2.
3.
4.
5.
6.
7.
4. Use a clean rag to wipe clean the surface of the oil
cooler, where the oil filter seats.
Note: Use a funnel with a flexible hose to direct the
engine oil into the engine.
Fill the crankcase with approximately 7.0 L (7.4 US
qt) of the specified engine oil; refer to Servicing the
Engine Oil and Filter (page 37).
Install the oil-fill cap.
Start the engine, run it at idle for about 2 minutes, and
check for oil leaks.
Stop the engine and remove the key.
Wait for 2 or 3 minutes and check the oil level; refer to
steps 2 through 6 in Checking the Engine Oil Level
(page 23).
Install the side panel; refer to Installing the Side Panels
(page 36).
5. Fill the new oil filter with the specified engine oil, allow
the filter element to saturate with the oil, and then pour
out the excess oil.
6. Apply a thin layer of the engine oil to the seal of the
new oil filter.
7. Align the new oil filter to the oil-filter adapter and
rotate the filter clockwise until the seal of the oil filter
contacts the oil cooler (Figure 44).
Note: Do not use an oil filter wrench to install the
new oil filter. The wrench can dent an oil filter, causing
a leak.
8. Hand tighten the oil filter an additional 1/2 turn
(Figure 44).
Changing the Engine Oil Filter
9. Remove the small oil pan from under the oil filter.
Service Interval: Every 250 hours
1. Remove the right side panel; refer to Removing the
Side Panels (page 35).
2. Place a small drain pan under the oil filter and the
oil-filter adapter (Figure 44).
10. Check the engine oil level; refer to Checking the Engine
Oil Level (page 38).
11. Install the side panel; refer to Installing the Side Panels
(page 36).
Servicing the Air-cleaner
System
Important: Do not remove the elements from the
machine to check for a restriction; always follow the
instructions in the following procedures.
Note: Do not replace an old air cleaner element with an
element that is more than 5 years old; check the date of
manufacture on the end cap of the element.
Note: Every time you service the air cleaner system, ensure
that all hose connections and flanges are air tight. Replace
all damaged parts.
Servicing the Dust Valve
Service Interval: Every 50 hours
Squeeze the sides of the dust valve to release any collected
water, dust, or dirt from the valve (Figure 45).
Note: Ensure that there are no obstructions inside the dust
valve.
Figure 44
1. Oil cooler
3. Hydraulic-fluid tank
2. Oil filter
39
Removing the Air-cleaner Cover
1. Remove the left side panel; refer to Removing the Side
Panels (page 35).
2. Pull the latch for the air-cleaner cover outward (Figure
45).
3. Rotate the cleaner cover counterclockwise so that the
dust cap is at the 7 o’clock position (Figure 47).
Figure 45
1. Latch
2. Air-cleaner cover
3. Dust valve
Checking the Restricted Air-cleaner
Light
Service Interval: Before each use or daily
Figure 47
1. Start the engine; refer to Starting the Engine (page 25).
1. Latch
2. Check the restricted air-cleaner light on the instrument
cluster (Figure 46).
2. Air-cleaner cover
3. Dust cap
4. Pull the air-cleaner cover away from the cleaner housing
to remove the cover.
5. Clean the inside of the cover with a clean damp cloth.
Figure 46
1. Restricted air-cleaner light
2. Instrument cluster
3. Replace the air-cleaner element(s) as follows:
A. Replace the primary air-cleaner element; refer to
Replacing the Primary Element (page 41).
B.
Repeat steps 1 and 2.
C.
If the restricted air-cleaner light still comes on,
replace the secondary air-cleaner element; refer to
Replacing the Secondary Element (page 41).
40
Installing the Air-cleaner Cover
6. Insert the new primary air-cleaner element into the
air-cleaner housing (Figure 48).
1. Align the dust cap on the air-cleaner cover to the 7
o’clock position.
Note: Ensure that the air-cleaner element is fully
seated in the housing.
2. Align the air-cleaner cover onto the cleaner housing.
7. Install the air-cleaner cover; refer to Installing the
Air-cleaner Cover (page 41).
3. Rotate the air-cleaner cover clockwise so that the dust
cap is at the 8 o’clock position (Figure 45).
8. Check the restricted air-cleaner light; refer to Checking
the Restricted Air-cleaner Light (page 40).
4. Push the latch for the air-cleaner cover inward until the
cover is fully seated (Figure 45).
5. Install the left side panel; refer to Installing the Side
Panels (page 36).
Replacing the Secondary Element
Note: Replace the secondary air-cleaner element after you
have replaced the primary air-cleaner element 3 times or if
the air-cleaner restriction light comes on while the engine is
running and you have already replaced primary air-cleaner
element.
Replacing the Primary Element
Important: Replace the primary air-cleaner element
when the restricted air-cleaner light comes on.
Important: Do not clean either the primary element
or the secondary element.
1. Remove the air-cleaner cover; refer to Removing the
Air-cleaner Cover (page 40).
1. Remove the air-cleaner cover; refer to Removing the
Air-cleaner Cover (page 40).
2. Pull the primary air-cleaner element outward and
remove it from the air-cleaner housing (Figure 48).
2. Pull the primary air-cleaner element outward and
remove it from the air-cleaner housing; refer to
Replacing the Primary Element (page 41).
Pull the secondary air-cleaner element outward and
remove it from the air-cleaner housing. (Figure 49).
Figure 48
1. Primary air-cleaner element
Note: Discard the old air-cleaner element.
3. Use a clean damp cloth to clean the inside of the
cleaner housing.
Figure 49
1. Secondary air-cleaner element
4. Use a light to inspect the new element for damage; if
the element is damaged, replace it.
Note: Discard the old air-cleaner element.
Note: Check the date of manufacture on the end of
the new air-cleaner element. Do not install an element
that is more than 5 years old.
3. Clean the inside of the cleaner housing with a clean,
damp cloth.
5. Write the current date and the engine hours on the end
of the element with a permanent marking pen.
4. Insert the new secondary air-cleaner element into the
air-cleaner housing (Figure 49).
41
Fuel System
Maintenance
Note: Ensure that the secondary element is fully
seated in the housing.
5. Insert the primary air-cleaner element into the air-filter
housing; refer to Replacing the Primary Element (page
41).
Servicing the Fuel System
Note: Ensure that the primary element is fully seated
in the housing.
Draining the Fuel-water Separator
6. Install the air-cleaner cover; refer to Installing the
Air-cleaner Cover (page 41).
Service Interval: Every 50 hours
1. Remove the left side panel; refer to Removing the Side
Panels (page 35).
7. Check the restricted air-cleaner light; refer to Checking
the Restricted Air-cleaner Light (page 40).
2. Place a small drain pan under the secondary fuel filter
(Figure 50).
Figure 50
1. Secondary-fuel filter
2. Drain valve
3. Rotate the drain valve at the bottom of the secondary
fuel filter 2 or 3 turns counterclockwise, and drain any
water and sediment from the fuel-water separator of
the fuel filter (Figure 50).
Note: If the fuel-water separator has any water or
sediment, drain the water and sediment from the fuel
tank; go to step 2.
4. When clean fuel appears, rotate the drain valve
clockwise until it is closed (Figure 50).
Note: Do not overtighten the drain valve.
5. Bleed the fuel system; refer to Bleeding the Fuel System
(page 44).
6. Install the left side panel; refer to Installing the Side
Panels (page 36).
Draining Water from the Fuel Tank
1. Place a drain pan under the drain plug in the fuel tank.
2. Unscrew the drain plug from the fuel tank and drain
the water (Figure 51).
42
Replacing the Fuel Filters
Replacing the Secondary Fuel Filter
Service Interval: Every 500 hours
1. Remove the left side panel; refer to Removing the Side
Panels (page 35).
2. Remove the secondary fuel filter and fuel-water
separator as follows:
Figure 51
1. Fuel tank
A. Clean the secondary fuel filter and the surrounding
area.
3. Drain pan
2. Drain plug
3. When clean fuel appears, install the drain plug and
tighten it securely (Figure 51).
B.
Completely drain the fuel-water separator; refer to
Draining the Fuel-water Separator (page 42).
C.
Firmly grasp the secondary fuel-filter element,
rotate the water sensor counterclockwise, and
remove the water sensor (Figure 53).
4. Check the fuel tank drain plug for leaks.
Note: Retain the water sensor, but discard the
O-ring.
Siphoning Water from the Fuel Tank
Note: Siphoning water from the fuel tank is an alternative
to draining water from the fuel tank; refer to Draining Water
from the Fuel Tank (page 42).
1. Remove the fuel cap from the fuel tank (Figure 52).
Figure 52
1. Intake hose (bottom of the
tank)
3. Siphoning equipment
2. Fuel cap
4. Drain pan
Figure 53
2. Route the intake hose of the siphoning equipment
through the filler neck of the fuel tank and to the
bottom of the tank (Figure 52).
1. Filter adapter
6. Hose clamp
2. Secondary filter element
7. Arrow
3. O-ring
8. Primary fuel filter
4. Water sensor
9. Fitting
5. Fuel hose
3. Direct the discharge hose of the siphoning equipment
into a drain pan (Figure 52).
D.
4. Siphon the tank until clean fuel appears.
5. Remove the siphoning equipment from the tank.
Firmly grasp the secondary fuel-filter element,
rotate it counterclockwise, and remove it from the
filter adapter (Figure 53).
Note: Discard the filter element.
6. Install the fuel cap onto the filler neck of the fuel tank
(Figure 52).
E. Clean the filter adapter with a clean rag.
Important: Do not use a filter wrench to
tighten the filter. You could damage the filter
and cause a leak.
43
Bleeding the Fuel System
3. Install the secondary fuel filter and fuel-water separator
as follows:
WARNING
A. Apply a thin film of clean fuel to the seal on the
fuel-filter element.
B.
Align the new secondary filter element to the filter
adapter (Figure 53).
C.
Rotate the secondary filter element until the seal
contacts the filter adapter, then rotate the filter
element an additional 3/4 turn.
D.
The fuel system is under high pressure. Bleeding
the system without proper precautions and training
could result in injury to you from injected fluid or
fire or explosion.
Read the Engine Owner’s Manual for the proper
bleeding procedure or contact your Authorized Toro
Service Dealer.
Slip the new O-ring over the water sensor (Figure
53).
E. Align the water sensor to the bottom of the
secondary fuel filter (Figure 53).
Note: Remove air from the fuel system whenever you do any
of the following:
F.
• Drain the fuel-water separator
Firmly grasp the secondary filter element, and
rotate the water sensor clockwise until it is hand
tight (Figure 53).
• Replace the fuel filter
• Run the engine until the fuel tank is empty
4. Bleed the fuel system; refer to Bleeding the Fuel System
(page 44).
1. Ensure that both the engine and the exhaust system
are cool.
5. Start the engine and check for leaks at the fuel filter.
2. Ensure that the fuel tank is 1/4 full.
6. Install the left side panel; refer to Installing the Side
Panels (page 36).
3. Rotate the battery-disconnect switch clockwise to the
On position.
4. Locate the priming button on the top of the filter
adapter for the secondary fuel filter (Figure 54).
Replacing the Primary Fuel Filter
Service Interval: Every 500 hours
1. Remove the left side panel; refer to Removing the Side
Panels (page 35).
2. Place clean rags under the primary fuel filter.
3. Loosen the hose clamps and separate the primary fuel
filter from the fuel hoses (Figure 53).
Note: Do not remove the hose clamps from the hoses.
Note: Discard the fuel filter.
4. Align the new primary fuel filter to the hoses with the
arrow printed on the filter pointing forward (Figure 53).
5. Slip the hoses over the hose fitting of the primary fuel
filter, and tighten the hose clamps (Figure 53).
6. Bleed the fuel system; refer to Bleeding the Fuel System
(page 44).
Figure 54
1. Priming button
7. Start the engine and check for leaks at the fuel filter.
8. Install the left side panel; refer to Installing the Side
Panels (page 36).
2. Filter adapter
5. Press down and release the priming button repeatedly
until you feel resistance (Figure 54).
6. Start the engine; refer to Starting the Engine (page 25).
Note: If the engine does not start after priming the
fuel system and making several attempts to start the
engine, bleed the high-pressure fuel lines; refer to your
engine owner’s manual or contact your Authorized
Toro Service Dealer for assistance.
44
Servicing the Battery
Electrical System
Maintenance
WARNING
Exposure to battery acid or a battery explosion can
cause serious personal injury.
Maintaining the Battery
Before you service a battery, always wear face
protection, protective gloves, and protective
clothing.
Accessing the Battery
Remove the battery cover as follows:
1. Ensure that the battery-disconnect switch is in the Off
position; refer to Battery-disconnect Switch (page 21).
WARNING
A battery contains sulfuric acid, which can cause
serious burns; and they can produce explosive
gases.
• Avoid contact with skin, eyes, or clothing; flush
affected areas with water.
• If taken internally, drink large quantities of water
or milk. Do not induce vomiting. Seek medical
attention immediately.
• Keep sparks, flames, and lit cigarettes and cigars
away from the battery.
• Ventilate the battery when you are charging it or
using it in an enclosed area.
• Wear eye protection when working near a
battery.
• Wash your hands after handling a battery.
• Keep the battery out of the reach of children.
2. Remove the bolt that secures the battery cover to the
ROPS plate (Figure 55).
Note: The battery cover is located between the
utility-traction control and the left fender.
1
2
3
1
2
4
5
WARNING
A frozen battery can be explosive, causing personal
injury to you or others in the area, if you try to
charge the battery or try to jump start the battery
and run the engine.
6
G021669
Figure 55
1. Bolts
4. ROPS plate
2. Flange
5. Fender
3. Battery cover
6. Operator platform
To prevent the battery electrolyte from freezing,
keep the battery fully charged.
WARNING
Sparks or a flame can cause hydrogen gas in a
battery to explode.
3. Remove the 3 bolts that secure the battery cover to
the operator platform, and remove the battery cover
(Figure 55).
When you disconnect the battery cables, always
disconnect the negative (-) cable first.
Install the battery cover as follows:
When you connect the battery cables, always
connect the negative (-) cable last.
1. Align the holes in the mounting flanges for the battery
cover with the holes in the operator platform around
the battery (Figure 55).
Do not short-circuit the battery posts with a metal
object.
2. Secure the battery cover to the ROPS plate with a bolt
(Figure 55).
Do not weld, grind, or smoke near a battery.
3. Secure the battery cover to the operator platform with
the 3 bolts that you previously removed (Figure 55).
Note: The electrical system in this machine is 12 volts.
45
Connecting a Booster Battery
Note: If the engine starts and then stops, do not
operate the starter motor until the starter motor stops
turning. Do not operate the starter motor for more
than 30 seconds at one time. Wait 30 seconds before
operating the starter motor to cool the motor and to
build up the charge in the battery.
WARNING
Charging the battery produces gasses that can
explode.
8. When the engine starts, have the other person
disconnect the negative (-) jumper cable from the frame
and then disconnect the positive (+) jumper cable.
Never smoke near the battery and keep sparks and
flames away from battery.
Note: This procedure requires 2 people to perform. Ensure
that the person making the connections wears the proper face
protection and protective gloves and clothing.
Charging the Battery
1. Ensure that all controls are in the Neutral position and
that the parking brake is in the On position.
WARNING
Charging the battery produces gasses that can
explode.
2. Sit in the operator seat and have the other person make
the connections.
Note: Ensure that the jumper battery is a 12-volt
battery.
Never smoke near the battery, and keep sparks and
flames away from the battery.
Important: If you are using another machine
for power, ensure that the 2 machines are not
touching each other.
Important: Always keep the battery fully charged. This
is especially important to prevent battery damage when
the temperature is below 32°F (0°C).
3. Prepare to start the engine; refer to steps 1 through 6
of Starting the Engine (page 25).
1. Clean the exterior of the battery case and the battery
posts.
4. Remove the cover from the jump post (Figure 56).
Note: Connect the leads of the battery charger to
battery posts before connecting the charger to the
electrical source.
2. Connect the positive lead of the battery charger to the
positive-battery post (Figure 57).
4
2
3
1
Figure 56
1. Jumper-cable clamp
(positive)
4. Jumper-cable clamp
(negative)
2. Jump post
5. Cover
G003792
Figure 57
3. Ground point (alternator
nut)
1. Positive-battery post
3. Red (+) charger lead
2. Negative-battery post
4. Black (-) charger lead
5. Connect the positive (+) jumper cable to the jump post
(Figure 56).
3. Connect the negative lead of the battery charger to the
negative-battery post (Figure 57).
6. Connect the negative (-) jumper cable to a ground
point, such as the nut at the pivot point for the
alternator (Figure 56).
4. Connect the battery charger to the electrical source.
Important: Do not overcharge the battery.
Note: Charge the battery as shown in the following
table:
7. Start the engine; refer to steps 7 through 10 in Starting
the Engine (page 25).
46
Battery Charging Table
Charger Setting
Charging Time
4 to 6 amperes
30 minutes
25 to 30 amperes
10 to 15 minutes
5. When the battery is fully charged, unplug the charger
from the electrical source, then disconnect the charger
leads from the battery posts (Figure 57).
Replacing a Fuse
1. Remove the right side panel; refer to Removing the
Side Panels (page 35).
2. Rotate the battery-disconnect switch counterclockwise
to the Off position (Figure 58).
Figure 59
1. Fuse block
4. Rotate the battery-disconnect switch clockwise to the
On position (Figure 17).
5. Install the right side panel; refer to Installing the Side
Panels (page 36).
Figure 58
1. Battery-disconnect switch
in the On position
2. Battery-disconnect switch
in the Off position
3. Replace the open (blown) fuse in the fuse block with a
new fuse that has an equivalent amperage value (Figure
59).
47
Drive System
Maintenance
Note: Before you add air, ensure that the tire is
properly installed on the machine, or put the wheel in a
restraining device, such as a tire inflation cage.
2. Remove the cap from the valve stem.
Servicing the Tires
3. Attach the self-locking chuck of the air hose to the
valve stem.
4. When inflating the tire while it is mounted to the
machine, stand behind the tread of the tire.
WARNING
Exploding tires and/or rim parts can cause injury
or death.
Note: Ensure that all persons are away from the side
of the tire before you start to add air.
Keep yourself and others out of the area of danger.
Stand on the tread side of the tire. Always fill
the tires to the correct air pressure, and follow
the instructions in this manual for adding air or
servicing the tires.
5. Open the remote shutoff valve to inflate the tire to the
specified pressure, then close the valve.
Important: Do not inflate the tire more than the
recommended pressure.
6. Remove the air chuck from the valve stem.
7. Install the cap on the valve stem.
WARNING
Do not weld the wheel or rim with the tire installed.
Welding with an explosive air/gas mixture can
ignite, causing serious injury or death, regardless of
whether the tire is inflated or deflated.
Maintaining the Tires and Wheels
Always have a qualified tire technician service the tires and
wheels of this machine. To prevent accidents, use a restraining
device (such as a tire inflation cage), the correct equipment,
and the correct procedure.
Removing the air or breaking the bead is not
adequate; you must completely remove the tire from
the rim before welding.
Important: There are 2 different tire-tread pattern and
wheel combinations; the left-side tires and the right-side
tires are different. Ensure that the tread direction of the
tire and the valve stem in the wheel are correctly aligned
before installing the tire to the rim.
WARNING
An explosive separation of the tire and/or rim parts
can cause injury or death.
Have a qualified tire mechanic service the tire.
Checking the Tires and Wheels
Service Interval: Before each use or daily
1. Check each tire for embedded objects, separated plies,
missing tread, bulges, or a damaged bead, and replace
it, if necessary.
2. Check each wheel for signs of unusual bending or
damage, and replace it, if necessary.
Figure 60
Maintaining the Air Pressure in the
Tires
1. Left-side tire
3. Right-side tire
2. Forward
4. Valve stem
Service Interval: Every 50 hours
Torquing the Wheel Nuts
Important: Maintain the air pressure in the tires at 310
kPa (45 psi).
1. Ensure that the mounting flange of the wheel is flush
against the mounting flange of the axle.
1. Measure the air pressure in the tires; if the tire pressure
is not at the recommended pressure, complete the rest
of this procedure.
2. Incrementally torque the wheel nuts for each wheel
as follows:
Important: Use an air hose with a remote shutoff
valve and a self-locking chuck.
A. Torque the all wheel nuts to 100 N-m (75 ft-lb) in
the sequence shown in Figure 61.
48
Figure 62
1. Wheel hub
4. Drain pan
2. Oil port at the 9 o’clock
position
5. Oil port at the 3 o’clock
position (alternative)
3. Plug
3. Stop the engine, set the parking brake, and remove the
ignition key.
4. Place a drain pan under the drain port in the wheel hub
(Figure 62).
5. Remove the plug from the wheel hub (Figure 62).
6. Check that the oil level is at the bottom of the threads
of the oil port (Figure 62).
Figure 61
• If the oil level is too high, allow the oil to drain
B.
C.
from the oil port.
Torque all the nuts to 200 N-m (150 ft-lb) in the
sequence shown in Figure 61.
• If the oil level is too low, add oil to the wheel hub
through the oil port; refer to step 6 in Changing
the Wheel Hub Oil (page 49).
Torque all the nuts to 300 N-m (225 ft-lb) in the
sequence shown in Figure 61.
7. Check the condition of the O-ring on the plug.
Servicing the Axles and the
Transmission
Note: Replace the O-ring if it is worn or damaged.
8. Install the plug in the oil port of the wheel hub (Figure
62).
9. Repeat steps 2 through 8 for the other wheel hubs.
Checking the Oil Level in the Wheel
Hubs
Changing the Wheel Hub Oil
Service Interval: After the first 100 hours
Service Interval: After the first 200 hours
Every 250 hours
Every 1,000 hours
Note: Have another person help you align the oil plugs in
the axles when you service the axle oil.
Oil specification: SAE 80W140 API classification level GL4
Wheel hub oil capacity: approximately 0.62 L (0.65 US qt)
1. Ensure that the machine is on a level surface and that
all the attachments are in the transport position.
Toro Premium Gear Oil is available from an Authorized Toro
Service Dealer. See the parts catalog for part numbers.
2. Move the machine forward or backward until the plug
for the wheel hub is at either the 3 o’clock or 9 o’clock
position (Figure 62).
Note: If possible, change the oil when it is warm.
1. Move the machine forward or backward until the oil
plug for the wheel hub is at the 6 o’clock position
(Figure 63).
49
Figure 64
Front Axle
1. Pinion housing (front axle)
3. Plug
2. Sight port
Figure 63
1. Wheel hub
4. Oil port at the 3 o’clock
position
2. Oil port at the 6 o’clock
position
5. Plug
3. Drain pan
6. Oil servicing equipment
2. Place a drain pan under the oil port of the wheel hub
(Figure 63).
3. Remove the plug and drain the oil from the planetary
(Figure 63).
Figure 65
Rear Axle
4. Check the condition of the O-ring for the plug.
1. Plug
Note: Replace the O-ring if it is worn or damaged.
3. Pinion housing (rear axle)
2. Site port
5. Move the machine forward or backward until the oil
plug for the wheel hub is either at the 3 o’clock or the 9
o’clock position (Figure 63).
3. Look through the sight port and check that the oil level
in the axle is level with the bottom of the threads of
the port (Figure 64 and Figure 65).
6. Add the specified oil to the wheel hub through the oil
port until the oil level is at the bottom of the threads
of the port.
7. Install the plug in the oil port of the wheel hub.
Note: Use a flashlight and a mirror to help you see
the oil level.
8. Repeat this procedure for the other wheel hubs.
• If the oil level is too high, allow the oil to drain
from the sight port.
• If the oil level is too low, add oil to the pinion
Checking the Oil Level in the Axles
housing and axle through the sight port; refer to
steps 6 and 7 in Changing the Oil in the Axles
(page 51).
Service Interval: After the first 100 hours
Every 250 hours
4. Clean the threads of the sight plug.
1. Place a drain pan under the pinion housing of the axle.
5. Apply PTFE thread sealing tape to the threads of the
plug.
2. Remove the plug from the sight port in the pinion
housing of the axle.
6. Install the sight plug into the sight port in the pinion
housing of the axle (Figure 64 and Figure 65).
50
Changing the Oil in the Axles
3. Clean the threads of the plugs.
Service Interval: After the first 200 hours
4. Apply PTFE thread sealing tape to the threads of the
plugs.
Every 1,000 hours
5. Install one of the plugs into the drain port (Figure 68
and Figure 69).
Oil specification: SAE 80W140 API classification level GL4
Front axle oil capacity: approximately 3.8 L (4.0 US qt)
Rear axle oil capacity: approximately 3.8 L (4.0 US qt)
Toro Premium Gear Oil is available from an Authorized Toro
Service Dealer. See the parts catalog for part numbers.
1. Place a drain pan under the pinion housing of the axle
(Figure 66 and Figure 67).
Figure 68
Front Axle
4. Plug
2. Pinion housing
5. Sight port
4. Plug (sight port)
2. Pinion housing
5. Sight port
3. Plug (drain port)
Figure 66
Front Axle
1. Drain port
1. Oil servicing equipment
3. Drain pan
Figure 69
Rear Axle
Figure 67
Rear Axle
1. Plug
4. Pinion housing
2. Drain port
5. Sight port
1. Plug
3. Plug (drain port)
2. Oil servicing equipment
4. Sight port
6. Fill the pinion housing and axle with the specified oil
through the sight port until the oil is level with the
threads at the bottom of the port (Figure 68 and Figure
69).
3. Drain pan
7. Wait a few minutes for the oil to settle, then add more
oil as necessary.
2. Remove the plugs from the sight port and the drain
port of the pinion housing (Figure 66 and Figure 67).
Note: Continue to add oil until the oil level stabilizes
and is at the bottom of the threads of the sight port.
Note: Allow the oil to drain completely from the
pinion housing and axle.
8. Install the remaining plug into the sight port of the
pinion housing (Figure 68 and Figure 69).
51
Checking the Oil Level in the
Transmission
Service Interval: After the first 100 hours
Every 250 hours
1. Place a drain pan under the back side of the
transmission housing (Figure 70).
Figure 71
1. Sight port
4. Plug
2. Drain port
5. Drain pan
3. Transmission housing
Figure 70
1. Plug
3. Transmission housing
2. Sight port
4. Drain pan
2. Remove the plugs from the drain port and the sight
port in the transmission housing (Figure 71).
Note: Allow the oil to drain completely from the
pinion housing and axle.
3. Clean the threads of the plugs.
2. Remove the plug from the sight port in the transmission
(Figure 70).
4. Apply PTFE thread-sealing tape to the threads of the
plugs.
3. Look through the sight port and check that the oil level
in the transmission is level with the bottom of the
threads of the port (Figure 70).
5. Install one of the plugs into the drain port of the
transmission (Figure 72).
Note: Use a flashlight and a mirror to help you see
the oil level.
• If the oil level is too high, allow the oil to drain
from the sight port.
• If the oil level is too low, add oil to the transmission
through the sight port; refer to steps 6 and 8 in
Changing the Oil in the Transmission (page 52).
4. Clean the threads of the sight plug.
5. Apply PTFE thread sealing tape to the threads of the
plug.
Figure 72
6. Install the sight plug into the sight port of the
transmission housing (Figure 70).
1. Sight port
4. Drain pan
2. Plug
5. Oil servicing equipment
3. Transmission housing
Changing the Oil in the Transmission
Service Interval: After the first 200 hours
6. Fill the transmission with the specified oil through the
sight port until the oil is level with the threads at the
bottom of the port (Figure 72).
Every 1,000 hours
Oil specification: SAE 80W140 API classification level GL4
7. Wait a few minutes for the oil to settle, then add more
oil as necessary.
Transmission oil capacity: approximately 1.7 L (1.8 US qt)
Toro Premium Gear Oil is available from an Authorized Toro
Service Dealer. See the parts catalog for part numbers.
Note: Continue to add oil until the oil level is stabilizes
and at the bottom of the threads of the sight port.
8. Install the remaining plug in the sight port of the
transmission (Figure 72).
Note: If possible, change the oil when it is warm.
1. Place a drain pan under the back side of the
transmission housing (Figure 71).
52
Cleaning the Axle Breathers
Important: Wear face protection when using
compressed air.
Service Interval: Every 300 hours
6. Install the breather in the front axle (Figure 73).
1. Clean the area around the breathers with a cleaning
solvent (Figure 73 and Figure 74).
7. Install the breather in the rear axle (Figure 74).
Figure 73
1. Front axle
3. Breather fitting
2. Breather port
Figure 74
1. Rear axle
3. Breather fitting
2. Breather port
2. Remove the breather from the front axle (Figure 73).
3. Remove the breather from the rear axle (Figure 74).
4. Clean the breathers with a cleaning solvent.
5. Use compressed air to dry the breathers.
53
Cooling System
Maintenance
Servicing the Cooling System
Coolant specification: a mixture of 50% ethylene glycol
and 50% water
Engine and Radiator coolant capacity: 17.2 L (18.2 US qt)
Figure 75
1. Reservoir
WARNING
If you remove the radiator cap from a hot engine,
hot coolant could spray, causing scalding.
2. Coolant level (halfway
between the Add and Full
marks)
Note: Ensure that the coolant level is between the
Add mark and the Full mark on the reservoir (Figure
75).
• Wear face protection when opening the radiator
cap.
• Allow the cooling system to cool down to below
50°C (120°F) before removing the radiator cap.
5. Add the specified coolant until the coolant level is
halfway between the Add mark and the Full mark on
the reservoir.
• Follow the instructions for checking and
maintaining the engine cooling system.
Note: Ensure that the coolant solution is thoroughly
mixed before filling the reservoir.
6. Install the right side panel; refer to Installing the Side
Panels (page 36).
WARNING
Coolant is toxic.
Checking the Coolant Level in the
Radiator
• Keep coolant away from children and pets.
• If you are not re-using the coolant, dispose of it
according to local environmental regulations.
Service Interval: Every 50 hours
Checking the Coolant Level in the
Reservoir
WARNING
If the engine has been running, the radiator will
pressurized and the coolant inside will be hot. If
you remove the cap, coolant may spray out, causing
severe burns.
Service Interval: Before each use or daily
Note: Do not remove the radiator filler cap during this
procedure.
• Do not remove the radiator cap to check coolant
levels.
1. Park the machine on a level surface, stop the engine,
and remove the ignition key.
• Do not remove the radiator cap when the engine
is hot. Allow the engine to cool for at least 15
minutes or until the radiator cap is cool enough
to touch without burning your hand.
2. Allow the engine to cool.
3. Remove the right side panel; refer to Removing the
Side Panels (page 35).
4. Check the coolant level in the reservoir (Figure 75).
Note: The cooling system is filled with antifreeze having a
mixture of 50% ethylene glycol and 50% water.
1. Park the machine on a level surface, stop the engine,
and remove the ignition key.
2. Allow the engine to cool.
3. Remove the nose panel; refer to Removing the Nose
Panel (page 36).
4. Open the vent valve for the engine (Figure 76).
54
Checking the Condition of Cooling
System Components
Service Interval: Every 300 hours
Check the condition of the cooling system for leaks, damage,
dirt, and loose hoses, and clamps. Clean, repair, tighten, and
replace the components as necessary.
Checking the Concentration of the
Coolant
Figure 76
1. Radiator cap
Service Interval: Every 1,000 hours
3. Vent valve
Test the concentration of ethylene glycol based antifreeze in
the coolant . Ensure that the coolant is a mixture of 50%
ethylene glycol and 50% water.
2. Filler neck
5. Remove the radiator cap from the filler neck of the
radiator and check the coolant level (Figure 76 and
Figure 77),
Note: An antifreeze having a mixture of 50% ethylene
glycol and 50% water will protect the engine to -37°C (-34°F)
throughout the year.
Note: The coolant should be up to the filler neck.
Check the concentration of the coolant mixture to ensure that
it is a mixture of 50% ethylene glycol and 50% water.
Cleaning the Cooling System
Service Interval: Every 2,000 hours/Every 2 years
(whichever comes first)
Draining the Coolant from the System
Important: Do not pour coolant onto the ground or into
an unapproved container that can leak.
1. Remove the left and right side panels and the nose
panel; refer to Removing the Side Panels (page 35) and
Removing the Nose Panel (page 36).
Figure 77
1. Reservoir
3. Coolant level (bottom of
radiator neck)
2. Coolant level (halfway
between the Add and Full
marks)
4. Radiator cap
2. Remove the radiator cap (Figure 76 and Figure 77).
3. Place a drain pan with a minimum capacity of 20 L (5.3
gallons) under the open end of the drain hose (Figure
78).
Note: The coolant capacity of both the engine and
the radiator is 17.2 L (18.2 US qt).
6. If the coolant level is low, add coolant until the level is
up to the bottom of the filler neck (Figure 77).
Important: Do not overfill the radiator.
Note: If the radiator coolant level is low and the
coolant reservoir level is at the Full mark, check for air
leaks in the hose between the radiator and the coolant
reservoir.
7. Close the vent valve.
8. Install the radiator filler cap, ensuring that it is tightly
sealed.
9. If the air temperature is below 0°C (32°F), mix the
ethylene glycol and water completely by running the
engine at operating temperature for 5 minutes.
55
Figure 79
1. Coolant system cleaning
solution
2. Funnel
Figure 78
1. Drain hose
D.
3. Radiator shroud (lower-left
area)
3. Filler neck (radiator)
Close the vent valve.
Important: Do not install the radiator cap.
E. Operate the engine for 5 minutes or until the
coolant temperature gauge in the instrument
cluster indicates 82°C (180°F), then stop the
engine (Figure 80).
2. Drain valve
4. Open the drain valve on the radiator, and allow the
coolant to drain completely.
Note: Dispose of the used coolant properly according
to local codes.
5. Close the drain valve (Figure 78).
Flushing the Cooling System
Engine and radiator coolant capacity: 17.2 liter (18.2 US
qt)
Figure 80
1. Condition the cooling system as follows:
A. Ensure that the coolant is drained from the
radiator and that the drain valve is closed.
B.
Open the vent valve (Figure 76).
C.
Add a cooling system cleaning solution to the to
the radiator through the filler neck (Figure 79).
CAUTION
The cleaning solution is hot and can
cause burns.
Stay away from the discharge end of the
coolant drain hose.
Note: Use cleaning solution of sodium carbonate
and water (or a commercially available equivalent).
Follow the directions that come with the cleaning
solution.
F.
Open the drain valve and drain the cleaning
solution into a drain pan (Figure 78).
G.
Close the drain valve.
2. Flush the cooling system as follows:
A. Open the vent valve (Figure 76).
B.
56
Fill the radiator with clean water (Figure 81).
Figure 81
1. Filler neck
2. Funnel
3. Clean water
Figure 82
C.
Close the vent valve.
D.
Operate the engine for 5 minutes or until the
coolant temperature gauge in the instrument
cluster indicates 82°C (180°F), then stop the
engine.
1. Coolant level (at the
bottom of the filler neck)
2. Filler neck
4. Close the vent valve.
5. Install the radiator cap.
CAUTION
6. Install the nose panel; refer to Installing the Nose Panel
(page 37).
The water is hot and can cause burns.
Stay away from the discharge end of the
coolant drain hose.
7. Fill the coolant reservoir with coolant up to the Full
mark.
8. Install the coolant reservoir cap.
E. Open the drain valve (Figure 78) and drain the
water into a drain pan.
F.
G.
3. Coolant (a mixture of 50%
ethylene glycol and 50%
water)
9. Start the engine and run it at half throttle for 5 minutes.
If the water drained from the radiator is dirty,
perform steps 2-A through 2-E until the water
drained from the radiator is clean.
10. Stop the engine and remove the key.
11. Wait 30 minutes, then check the fluid level in the
coolant reservoir. If it is low, add coolant.
Close the drain valve.
12. Install the side panels; refer to Installing the Side Panels
(page 36).
Filling the System with Coolant
Important: Fill the cooling system properly to prevent
air locks in the cooling passages. Failing to vent the
cooling system properly can damage it.
Note: Use a mixture of 50% ethylene glycol and 50% water
in the machine. The lowest ambient operating temperature
for this mixture is above -37°C (-34° F). If the ambient
temperature is lower, adjust the mixture. Use a mixture of
ethylene glycol and water in the machine all year.
1. Remove the radiator cap (Figure 76 and Figure 77).
2. Open the vent valve (Figure 76).
3. Fill the cooling radiator with the specified coolant
mixture until the fluid level is up to the top of the filler
neck (Figure 82).
Note: The coolant capacity of both the engine and
the radiator is 17.2 L (18.2 US qt).
57
Belt Maintenance
Servicing the Engine Drive
Belt
WARNING
Stop the engine and remove the ignition key before
you begin to perform any maintenance or repair
work.
WARNING
Contacting a rotating belt can cause serious injury
or death.
Always stop the engine and remove the ignition key
before working near belts.
Checking the Condition of the Belt
Service Interval: Every 250 hours
1. Remove the right-side panel; refer to Removing the
Side Panels (page 35).
Figure 83
2. Inspect the belt for cuts, cracks, loose cords, grease, oil,
twisting, or signs of abnormal wear.
3. Press the belt down at the midway point between the
fan pulley and the alternator pulley as shown in Figure
83.
Note: Replace the belt if it is excessively worn or
damaged; refer to Installing the Belt (page 60).
Note: The range of belt deflection between the
straight edge and the belt should be 7 to 9 mm (0.28 to
0.35 inches) under a load of 10 kg (22 lb).
3. Install the right-side panel; refer to Installing the Side
Panels (page 36).
4. If the tension of the belt is above or below the specified
range, adjust the drive belt tension; refer to Adjusting
the Tension of the Belt (page 58).
Checking the Tension of the Belt
Service Interval: Every 1,000 hours
5. Install the right side panel; refer to Installing the Side
Panels (page 36).
1. Remove the right side panel; refer to Removing the
Side Panels (page 35).
2. Place a straight edge over the drive belt and across the
pulleys (Figure 83).
Adjusting the Tension of the Belt
1. Loosen the nut and bolt at the pivot point for the
alternator (Figure 84).
58
4. Loosen the engine bolt and the alternator mounting
bracket.
5. Move the alternator toward the engine to loosen
the belt enough so that you can remove it from the
alternator pulley (Figure 84).
6. Remove the belt from the grooves of the alternator,
the fan, and the crankshaft pulleys.
7. Remove the 4 bolts that secure the fan guard to the fan
shroud (Figure 85).
Figure 84
1. Adjustment bolt
3. Alternator
2. Nut (alternator pivot point)
4. Bolt (alternator pivot point)
2. Loosen the adjustment bolt on the alternator (Figure
84).
Figure 85
Left side of the machine
3. Loosen the bolt on the mounting bracket on the engine
(if necessary).
1. Bolts
4. Move the alternator away from the engine to increase
the belt tension; move the alternator toward the engine
to decrease the belt tension (Figure 84).
5. Tighten the alternator adjustment bolt (Figure 84).
6. Check the tension of the belt; refer to Checking the
Tension of the Belt (page 58).
7. If the belt tension is correct, tighten the nut and bolt at
the pivot point for the alternator (Figure 84); otherwise
repeat steps 2 through 6.
8. Switch the battery disconnect switch to the On
position; refer to Battery-disconnect Switch (page 21).
9. Install the right side panel; refer to Installing the Side
Panels (page 36).
Replacing the Engine Drive
Belt
Figure 86
Right side of the machine
Removing the Belt
1. Bolts
1. Remove the left and right side panels; refer to
Removing the Side Panels (page 35).
3. Fan guard mounting tab
(4)
2. Fan shroud
2. Loosen the nut and bolt at the pivot point for the
alternator (Figure 84).
8. Rotate the fan guard counterclockwise around the drive
shaft of the fan until the opening in the guard is at the
4 o’clock position.
3. Loosen the adjustment bolt on the alternator (Figure
84).
59
Installing the Belt
9. At the 4 o’clock position of the fan shroud, align the
belt between the tip of the fan blade and the opening
in the shroud (Figure 87).
1. Align the belt between 2 of the fan blades, and carefully
push the belt forward and down until it is in front of
the fan (Figure 88).
2. Move a fan blade to the 4 o’clock position.
3. Align the belt between the tip of the fan blade and the
opening in the shroud (Figure 87).
4. Move the belt rearward and past the tip of the fan blade.
5. Repeat steps 2 through 4 for the remaining fan blades.
6. Align the belt in the grooves of the alternator, the fan,
and the crankshaft pulleys.
7. Rotate the fan guard clockwise around the drive shaft
of the fan until the opening in the guard is at the 6
o’clock position (Figure 85).
G021658
1
2
3
8. Secure the fan guard to the fan shroud (Figure 85).
4
9. Adjust the tension of the belt; refer to Adjusting the
Tension of the Belt (page 58).
Figure 87
1. Fan blade
2. Belt
3. Fan shroud
4. Fan guard
Note: Ensure that the belt is aligned in the grooves of
the pulleys.
10. Move the belt to the forward side of the fan blade.
11. Rotate the fan counterclockwise and repeat steps 9 and
10 for the remaining fan blades.
12. Align the belt between 2 of the fan blades, then
carefully pull the belt rearward and up until you can
remove it from the machine (Figure 88).
Figure 88
60
Changing the Hydraulic Fluid
Hydraulic System
Maintenance
Service Interval: Every 1,000 hours
Draining the Hydraulic Reservoir
Servicing the Hydraulic
System
1. Park the machine on a level surface, and put all the
attachments in the transport position.
2. Stop the engine, set the parking brake, and remove the
ignition key.
The machine comes from the factory with a full hydraulic
fluid reservoir that contains approximately 75.7 L (20.0 US
gal) of high-quality hydraulic fluid. Check the level of the
hydraulic fluid before you start the engine for the first
time, and daily thereafter.
Note: Drain the hydraulic fluid reservoir when the
fluid is warm, if possible.
3. Remove the fill cap/breather from the fill tube (Figure
89).
Use Toro Premium All-season Hydraulic Fluid (available
in 5-gallon pails or 55-gallon drums. See the parts catalog or
an Authorized Toro Service Dealer for part numbers).
If Toro hydraulic fluid is not available, you may use an
equivalent hydraulic fluid, provided that it meets all the
following material properties and industry specifications. Do
not use a synthetic hydraulic fluid. Consult with your
lubricant distributor to identify a satisfactory product.
Note: Toro does not assume responsibility for damage
caused by improper substitutions, so use only products from
reputable manufacturers.
High Viscosity Index/Low Pour Point Anti-wear
Hydraulic Fluid, ISO VG 46
Material Properties:
Viscosity, ASTM D445
St @ 40°C (104°F): 44 to 48
Figure 89
St @ 100°C (212°F): 7.9 to 8.5
Viscosity Index ASTM
D2270
140 to 160
Pour Point, ASTM D97
-37°C (-34°F) to -45°C (-49°F)
FZG, Fail stage
Water content (new fluid)
Industry Specifications:
1. Hydraulic reservoir
3. Fill tube
2. Sight gauge
4. Fill cap/breather
4. Place a container that can hold a minimum of 75.7 L
(20.0 US gal) under the hydraulic reservoir drain plug
(Figure 90).
11 or better
500 ppm (maximum)
Vickers I-286-S (Quality Level),
Vickers M-2950-S (Quality
Level), Denison HF-0
Note: Many brands of hydraulic fluids are almost colorless,
making it difficult to spot leaks. A red dye additive for the
hydraulic system oil is available in 20 ml (0.68 oz) bottles.
One bottle is sufficient for 15.1 to 22.7 L (4.0 to 6.0 US gal)
of hydraulic oil. Order part no. 44-2500 from an Authorized
Toro Service Dealer.
Note: If ambient operating temperatures exceed 110°F,
contact Toro for fluid recommendations.
Figure 90
1. Hydraulic reservoir
4. Drain pan
2. Drain port
5. Forward
3. Plug
61
4. Install the right-side panel; refer to Installing the Side
Panels (page 36).
5. Remove the drain plug from the hydraulic reservoir
(located underneath the reservoir), and drain the
reservoir (Figure 90).
5. Clean the fill cap/breather with solvent.
Note: The capacity of the reservoir is approximately
75.7 L (20.0 US gal); the capacity of the complete
system is approximately 98.4 L (26.0 US gal).
6. Install the fill cap/breather (Figure 91).
7. Start the engine and let it idle for approximately 2
minutes.
6. Examine the condition of the O-ring on the drain plug.
8. Stop the engine and remove the ignition key.
Note: Replace the O-ring if it is worn or damaged.
9. Check around the pressure and return filters for leaks.
7. Install the drain plug (Figure 90).
10. Check the drain plug for leaks.
Important: Change the hydraulic-pressure
and hydraulic-return filters when you change
the hydraulic fluid; refer to Changing the
Hydraulic-pressure Filter (page 62) and Changing
the Hydraulic-return Filter (page 63).
11. Check the level of the hydraulic fluid and fill the
reservoir to the middle of the sight glass as needed.
Changing the Hydraulic-pressure Filter
Service Interval: Every 500 hours
Filling the Hydraulic-fluid Reservoir
Note: You can access the hydraulic-pressure filter from
under the right side of the machine, behind the hydraulic
reservoir (Figure 92).
1. Fill the hydraulic-fluid reservoir with the specified
hydraulic fluid until the fluid level is at the midpoint of
the sight gauge (Figure 91).
1. Place a container under the hydraulic-pressure filter
(Figure 92).
Figure 92
1. Container suitable for
hydraulic fluid
Figure 91
1. Fill level (midpoint)
3. Hydraulic-pressure filter
2. Sharp object
3. Hydraulic fluid
2. Sight gauge
2. Puncture the bottom of the hydraulic-pressure filter,
and allow the residual hydraulic fluid to drain into the
container (Figure 92).
2. Remove the right-side panel; refer to Removing the
Side Panels (page 35).
Note: Use a tapered-center punch or awl to puncture
the filter case.
3. Remove the breather hose, clean and inspect it, then
install the hose.
62
3. Rotate the hydraulic-pressure filter counterclockwise
and remove the filter (Figure 92).
2. Puncture the bottom of the hydraulic-pressure filter
and allow the residual hydraulic fluid to drain in the
container (Figure 93).
Note: Discard the filter.
Note: Use a tapered-center punch or awl to puncture
the filter case.
4. Apply a thin layer of the specified hydraulic fluid to
the O-ring of the new filter.
3. Rotate the hydraulic-return filter counterclockwise and
remove the filter (Figure 93).
Important: Do not use a filter strap wrench to
tighten the filter. A strap wrench can dent the
filter, causing it to leak.
Note: Discard the filter properly.
5. Install the new filter.
4. Apply a thin layer of the specified hydraulic fluid to
the O-ring of the new filter.
Note: Use your hands to tighten the filter an additional
half turn after the filter makes contact with the filter
head.
Important: Do not use a filter strap wrench to
tighten the filter. A strap wrench can dent the
filter, causing it to leak.
6. Check the level of the hydraulic fluid in the hydraulic
reservoir; refer to Checking the Hydraulic Fluid Level
(page 24).
5. Install the new filter.
Note: Use your hands to tighten the filter an additional
half turn after the filter makes contact with the filter
head.
7. Start the engine and let it idle for 1 or 2 minutes.
8. Stop the engine.
6. Check the level of the hydraulic fluid in the hydraulic
reservoir; refer to Checking the Hydraulic Fluid Level
(page 24).
9. Check for leaks around the filter area.
10. Check the level of the hydraulic fluid in the hydraulic
reservoir, and add fluid, if necessary.
7. Start the engine and run it at idle for 1 or 2 minutes.
8. Stop the engine and remove the key.
Changing the Hydraulic-return Filter
9. Check around the filter for leaks.
Service Interval: Every 500 hours
10. Check the fluid level of the hydraulic reservoir, and add
fluid, if necessary.
Note: You can access the hydraulic-return filter from
underneath the rear of the machine (Figure 93).
1. Place a container under the hydraulic-pressure filter
(Figure 93).
Figure 93
1. Container suitable for
hydraulic fluid
3. Hydraulic return filter
2. Sharp object
63
ROPS Maintenance
2. Check that the 4 bolts that secure the seat to the chassis
of the machine are torqued to 5.4 to 6.8 N-m (48 to 60
in-lb); refer to Figure 95.
Checking and Servicing the
ROPS
Checking and Caring for the Seat Belt
Before you operate the machine, always ensure that the ROPS
and the seat belt are properly installed and in good working
order.
1. Check the seat belt for damage, and replace all parts
that are damaged.
2. Ensure that the mounting bolts for the seat belts are
tight.
Figure 95
3. Keep the seat belts clean using only soap and water.
1. Bolt
Note: Do not immerse the seat belts in bleach or dye,
because this weakens the belt material.
3. Check that the bolts and nuts that attach the seat-belt
retractor and buckle to the seat are torqued to 7.8 to
9.6 N-m (69 to 85 in-lb); refer to Figure 96.
Checking and Maintaining the ROPS
Service Interval: Every 500 hours
Important: If any part of the ROPS system is damaged,
replace it before you operate the machine.
1. Check that the 8 bolts that secure the ROPS bar to the
chassis of the machine are torqued to 24.4 to 26.1 N-m
(216 to 231 in-lb); refer to Figure 94.
Figure 96
1. Seat-belt retractor
2. Bolt
3. Nut
4. Buckle
Note: Replace any parts that are worn or damaged.
4. Inspect the ROPS for cracks, rust, or holes in the
ROPS and component parts.
Note: Age, weather, and accidents cause damage to
the ROPS and ROPS parts. If you have any doubts
about the ROPS system, contact an Authorized Toro
Service Dealer.
Figure 94
1. ROPS bar
2. Bolt
64
Replacing a Damaged ROPS System
Cleaning
If the ROPS system has been damaged in an accident, such
as a rollover or hitting an overhead object during transport,
replace any damaged ROPS components to restore the ROPS
system to its original level of protection.
Removing Dirt and Debris from
the Machine
After an accident, check the following items for damage:
Important: Operating the engine with blocked screens,
dirty or plugged cooling fins, and/or cooling shrouds
removed, will result in engine damage from overheating.
• The ROPS bar
• Operator seat
1. Lower all attachments and set the parking brake.
• Seat belt mounting
• Seat belt
2. Stop the engine, remove the key, and wait for all moving
parts to stop before leaving the operating position.
Before you operate the machine, replace all damaged ROPS
components; contact an Authorized Toro Service Dealer.
3. Wipe away dirt and debris from the air cleaner.
4. Clean any dirt and debris buildup on the engine with a
brush or blower.
Important: Do not try to weld or straighten a damaged
ROPS bar.
Important: It is preferable to blow dirt out, rather
than washing it out. If water is used, keep it away
from electrical items and hydraulic valves. Do
not use a high-pressure washer. High-pressure
washing can damage the electrical system and
hydraulic valves or deplete grease.
65
Storage
3. Start the engine and run it at idle speed for
approximately 2 minutes.
Preparing for Seasonal
Storage
4. Stop the engine.
5. Flush the fuel tank with fresh, clean diesel fuel.
6. Secure all the fuel system fittings.
For storage over 30 days, prepare the machine, the
attachments, and the engine as follows:
7. Service the air cleaner; refer to Servicing the Air-cleaner
System (page 39).
8. Seal the air cleaner inlet and the exhaust outlet with
plastic and weatherproof tape.
Preparing the Machine and
Attachments
9. Check the anti freeze protection and add a 50%
ethylene glycol and 50% water solution of anti-freeze
as needed for the expected minimum temperature in
your area.
1. Thoroughly clean the machine and all the attachments;
refer to Removing Dirt and Debris from the Machine
(page 65).
2. Lower all the attachments and set the parking brake.
3. Stop the engine, remove the key, and wait for all moving
parts to stop before leaving the operating position.
4. Check the tire pressure and adjust it, if necessary; refer
to Maintaining the Air Pressure in the Tires (page 48).
5. Check all fasteners and tighten them as necessary.
6. Grease all fittings and pivot points and wipe up any
excess grease; refer to Greasing the Machine (page 33).
7. Repair any dents in the machine or the attachments,
and lightly sand and paint areas that are bare, scratched,
chipped, or rusted. Paint is available from an
Authorized Toro Service Dealer.
8. Service the battery and the cables as follows:
A. Remove the battery terminals from the battery
posts.
B.
Clean the battery, terminals, and posts with a wire
brush and baking soda solution.
C.
Coat the cable terminals and battery posts with
Grafo 112X skin-over grease (Toro Part No.
505-47) or equivalent grease.
D.
Slowly recharge the battery every 60 days for 24
hours to prevent lead sulfation of the battery.
9. Check and tighten all bolts, nuts, and screws. Repair or
replace any part that is damaged.
10. 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.
11. Cover the machine to protect it and keep it clean.
Preparing the Engine
1. Remove dirt and grime from the external parts of the
engine. Clean dirt and chaff from the outside of the
engine cylinder-head fins and blower housing.
2. Change the engine oil and the oil filter; refer to
Changing the Engine Oil (page 38).
66
Troubleshooting
Problem
The starter does not crank.
Possible Cause
1. The electrical connections are
corroded or loose.
1. Check the electrical connections for
good contact.
2.
3.
4.
5.
2.
3.
4.
5.
A fuse is blown.
A fuse is loose.
The battery is discharged.
The relay or switch is damaged.
6. The starter or starter solenoid is
damaged.
7. Internal engine components have
seized up.
1. The engine cranks but will not start.
Replace the fuse.
Install the fuse.
Charge the battery or replace it.
Contact your Authorized Service
Dealer.
6. Contact your Authorized Service
Dealer.
7. Contact your Authorized Service
Dealer.
1. The starting procedure is incorrect.
1. Refer to Starting the Engine in
Operation.
2. The fuel tank is empty.
3. The fuel shutoff valve is closed.
4. There is dirt, water, stale fuel, or
incorrect fuel in the fuel system.
5. The fuel line is clogged.
6. There is air in the fuel.
2. Fill the fuel tank with fresh fuel.
3. Open the fuel shutoff valve.
4. Drain and flush the fuel system; add
fresh fuel.
5. Clean or replace the fuel line.
6. Bleed the nozzles and check for air
leaks at the fuel hose connections
and fittings between the fuel tank and
engine.
7. Check the fuse, glow plugs, and wiring.
8. Check the battery, oil viscosity, and
starting motor (contact your Authorized
Service Dealer).
9. Service the air cleaning system
elements.
10. Replace the fuel filter.
11. Drain the fuel system, replace the fuel
filter, and add fresh fuel having the
proper grade for ambient temperature
conditions. You may need to warm up
the entire machine.
12. Contact your Authorized Service
Dealer.
13. Contact your Authorized Service
Dealer.
7. The glow plugs do not operate.
8. The cranking speed is slow.
9. The air cleaning system elements are
dirty.
10. The fuel filter is clogged.
11. The fuel is not the proper grade for
cold-weather use.
12. The engine has low compression.
13. The injection nozzles or pump are
malfunctioning.
The engine starts but does not keep
running.
Corrective Action
1. The fuel tank vent is restricted.
1. Loosen the cap. If the engine runs with
the cap loosened, replace the cap.
2. There is dirt or water in the fuel system.
2. Drain and flush the fuel system; add
fresh fuel.
3. Replace the fuel filter.
4. Bleed the nozzles and check for air
leaks at fuel hose connections and
fittings between the fuel tank and the
engine.
5. Drain the fuel system, replace the fuel
filter, and add fresh fuel having the
proper grade for ambient temperature
conditions. You may need to warm up
the entire machine.
6. Contact your Authorized Service
Dealer.
3. The fuel filter is clogged.
4. There is air in the fuel.
5. The fuel is not the proper grade for
cold-weather use.
6. The fuel pump is damaged.
67
Problem
The engine runs but knocks or misses.
Possible Cause
1. There is dirt or water in the fuel system.
1. Drain and flush the fuel system; add
fresh fuel.
2. The engine overheats.
2. Check the engine oil level and add oil
as needed; also check and service the
coolant system, if necessary.
3. Bleed the nozzle and check for air
leaks at the fuel hose connections and
the fittings between the fuel tank and
the engine.
4. Contact your Authorized Service
Dealer.
5. Contact your Authorized Service
Dealer.
6. Contact your Authorized Service
Dealer.
7. Contact your Authorized Service
Dealer.
8. Contact your Authorized Service
Dealer.
3. There is air in the fuel.
4. The injection nozzles are damaged.
5. The engine has low compression.
6. The injection pump timing is incorrect.
7. There is excessive carbon buildup.
8. The engine has internal wear or
damage.
The engine is overheated.
1. The coolant level is too low.
1. Check the coolant level and add
coolant to the system.
2. The air flow to the radiator is restricted.
3. The engine oil level is either too low or
too high.
4. The machine is under an excessive
load.
2. Inspect and clean the radiator screen.
3. Either add or drain the engine oil until
the oil level is at the Full mark.
4. Reduce the load on the machine;
operate the machine at a slower
ground speed.
5. Drain and flush the fuel system, then
add fresh fuel.
6. Contact your Authorized Service
Dealer.
7. Contact your Authorized Service
Dealer.
8. Contact your Authorized Service
Dealer.
9. Contact your Authorized Service
Dealer.
5. There is improper fuel in the fuel
system.
6. The thermostat is damaged.
7. The fan belt is loose or broken.
8. The injection timing is incorrect.
9. The coolant pump is damaged.
There is excessive black smoke in the
exhaust.
Corrective Action
1. The engine is under an excessive load.
1. Reduce the ground speed of the
machine.
2. The air cleaning system elements are
dirty.
3. There is improper fuel in the fuel
system.
4. The injection pump timing is incorrect.
2. Service the air cleaning system
elements.
3. Drain and flush the fuel system, then
add fresh fuel.
4. Contact your Authorized Service
Dealer.
5. Contact your Authorized Service
Dealer.
6. Contact your Authorized Service
Dealer.
5. The injection pump is damaged.
6. The injection nozzles are damaged.
68
Problem
There is excessive white smoke in the
exhaust.
Possible Cause
1. The key was turned to the Start position
before the glow plug light turned off.
1. Turn the key to the Run position and
allow the glow plug light to turn off
before starting the engine.
2. The engine temperature is low.
2. Check the thermostat and replace it if
necessary.
3. Check the fuse, glow plugs, and wiring.
4. Contact your Authorized Service
Dealer.
5. Contact your Authorized Service
Dealer.
6. Contact your Authorized Service
Dealer.
3. The glow plugs are not operating.
4. The injection pump timing is incorrect.
5. The injection nozzles are damaged.
6. The engine has low compression.
The engine loses power.
1. The engine is under an excessive load.
1. Reduce the ground speed of the
machine.
2. The engine oil level is either too low or
too high.
3. The air cleaning system elements are
dirty.
4. There is dirt or water in the fuel system.
2. Either add or drain the engine oil until
the oil level is at the Full mark.
3. Service the air cleaning system
elements.
4. Drain and flush the fuel system; add
fresh fuel.
5. Check the engine oil level and add oil
as needed; also check and service the
coolant system, if necessary.
6. Bleed the nozzle and check for air
leaks at the fuel hose connections and
the fittings between the fuel tank and
the engine.
7. Contact your Authorized Service
Dealer.
8. Loosen the cap. If the engine runs with
the cap loosened, replace the cap.
9. Contact your Authorized Service
Dealer.
10. Contact your Authorized Service
Dealer.
5. The engine overheats.
6. There is air in the fuel.
7. The engine has low compression.
8. The fuel tank vent is restricted.
9. The injection pump timing is incorrect.
10. The injection pump is damaged.
The machine does not drive.
Corrective Action
1. The parking brake is engaged.
1. Release the parking brake.
2. The hydraulic fluid level is low.
3. The tow valves are open.
4. The pump and/or motor is damaged.
2. Add hydraulic fluid to the reservoir.
3. Close the tow valves.
4. Contact your Authorized Service
Dealer.
5. Contact your Authorized Service
Dealer.
5. The relief valve is damaged.
69
Notes:
70
Notes:
71
Underground
Equipment
The Toro Underground Warranty
A Limited Warranty
Conditions and Products Covered
The Toro Company and its affiliate, Toro Warranty Company, pursuant
to an agreement between them, jointly warrant your Toro Underground
Equipment (“Product”) to be free from defects in materials or workmanship.
Where a warrantable condition exists, we will repair the Product
at no cost to you including diagnostics, labor, and parts.
The following warranty applies from the date the Product is delivered to the
original retail purchaser or rental owner.
Products
RT600, RT1200, DD2024, and
DD4045
All Other Engine Powered Base
Units and Fluid Mixers
All Serialized Attachments
Rock Hammer
Engines
Warranty Period
2 years or 1500 operating hours,
whichever occurs first
1 year or 1000 operating hours,
whichever occurs first
1 year
6 months
Through engine manufacturers:
2 years or 2000 operating hours,
whichever occurs first
Instructions for Obtaining Warranty Service
You are responsible for notifying the Underground Dealer from whom you
purchased the Product as soon as you believe a warrantable condition
exists. If you need help locating a Underground Dealer, or if you have
questions regarding your warranty rights or responsibilities, you may
contact us at:
Toro Customer Care
Toro Warranty Company
8111 Lyndale Avenue South
bulbs, belts, tracks or tires, digging teeth, digging booms, digging,
drive, or track chains, track pads, drive sprockets, idlers, rollers,
blades, cutting edges, or other ground engaging components.
•
Failures caused by outside influence. Conditions considered to be
outside influence include, but are not limited to, weather, storage
practices, contamination, use of unapproved fuels, coolants, lubricants,
additives, water, or chemicals, etc.
•
Failure or performance issues due to the use of fuels (e.g. gasoline,
diesel, or biodiesel) that do not conform to their respective industry
standards.
•
•
Normal noise, vibration, wear and tear, and deterioration.
•
Hauling expenses, travel time, mileage, or overtime associated with
transporting product to the authorized Toro dealer.
Normal “wear and tear” includes, but is not limited to, damage to seats
due to wear or abrasion, worn painted surfaces, scratched decals, etc.
Parts
Parts scheduled for replacement as required maintenance in the
Operator’s Manual,are warranted for the period of time up to the scheduled
replacement time for that part. Parts replaced under this warranty are
covered for the duration of the original product warranty and become the
property of Toro. Toro will make the final decision whether to repair any
existing part or assembly or replace it. Toro may use remanufactured parts
for warranty repairs.
Maintenance is at Owner’s Expense
Bloomington, MN 55420-1196
Toll Free at 855-493-0088 (U.S. Customers)
1-952-948-4318 (International Customers)
Owner Responsibilities
As the Product owner, you are responsible for required maintenance and
adjustments stated in your Operator's Manual. Failure to perform required
maintenance and adjustments can be grounds for disallowing a warranty
claim.
Items and Conditions Not Covered
Not all product failures or malfunctions that occur during the warranty
period are defects in materials or workmanship. This warranty does not
cover the following:
Engine tune-up, lubrication, cleaning and polishing, replacement of filters,
coolant, and completing recommended maintenance are some of the
normal services Toro products require that are at the owner’s expense.
General Conditions
Repair by an Authorized Toro Underground Dealer is your sole remedy
under this warranty.
Neither The Toro Company nor Toro Warranty Company is liable for
indirect, incidental or consequential damages in connection with the
use of the Toro Products covered by this warranty, including any
cost or expense of providing substitute equipment or service during
reasonable periods of malfunction or non-use pending completion
of repairs under this warranty. Except for the Emissions warranty
referenced below, if applicable, there is no other express warranty. All
implied warranties of merchantability and fitness for use are limited to
the duration of this express warranty.
•
Product failures which result from the use of non-Toro replacement
parts, or from installation and use of add-on, or modified non-Toro
branded accessories and products. A separate warranty may be
provided by the manufacturer of these items.
•
Some states do not allow exclusions of incidental or consequential
damages, or limitations on how long an implied warranty lasts, so the above
exclusions and limitations may not apply to you. This warranty gives you
specific legal rights, and you may also have other rights which vary from
state to state.
Product failures which result from failure to perform recommended
maintenance and/or adjustments. Failure to properly maintain your
Toro product per the Recommended Maintenance listed in the
Operator’s Manual can result in claims for warranty being denied.
Note regarding engine warranty:
•
Product failures which result from operating the Product in an abusive,
negligent, or reckless manner.
•
Parts subject to consumption through use unless found to be defective.
Examples of parts which are consumed, or used up, during normal
Product operation include, but are not limited to: brakes, filters, lights,
The Emissions Control System on your Product may be covered by
a separate warranty meeting requirements established by the U.S.
Environmental Protection Agency (EPA) and/or the California Air Resources
Board (CARB). The hour limitations set forth above do not apply to the
Emissions Control System Warranty. Refer to the Engine Emission Control
Warranty Statement supplied with your product or contained in the engine
manufacturer’s documentation for details.
Countries Other than the United States or Canada
Customers who have purchased Toro products exported from the United States or Canada should contact their Toro Distributor (Dealer) to obtain
guarantee policies for your country, province, or state. If for any reason you are dissatisfied with your Underground Dealer’s service or have difficulty
obtaining guarantee information, contact the Toro importer.
Australian Consumer Law: Australian customers will find details relating to the Australian Consumer Law either inside the box or at your local Toro
Dealer.
374-0292 Rev A
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