Service Manual

ManualsBrandsToro ManualsCompact LoaderToro 22300

Sitework Systems

Form No. 492-9216

Wheeled

Compact Utility Loader

Service Manual

Chain Drive / 4-Paw Gas / 4-Paw Diesel

Summary of content (602 pages)

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Sitework Systems Wheeled Compact Utility Loader Service Manual Chain Drive / 4-Paw Gas / 4-Paw Diesel Form No.
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ABOUT THIS MANUAL This service manual was written expressly for Toro service technicians. The Toro Company has made every effort to make the information in this manual complete and correct. Basic shop safety knowledge and mechanical/electrical skills are assumed. The Table of Contents lists the systems and the related topics covered in this manual. For service information on drive systems, please refer to the Hydro-Gear BDP-10A/16A/21L Pump service manual (form no.
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REVISIONS Revision 000 . . . . . . . . . . . . .
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TABLE OF CONTENTS ALL UNITS SAFETY INFORMATION General Information....................................................................................................................1/1-1 Think Safety First.......................................................................................................................1/1-1 ALL UNITS SPECIFICATIONS General Specifications...............................................................................................................2/1-1 Dimensions.......
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TABLE OF CONTENTS CHAIN DRIVE DRIVE SYSTEM cont.
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TABLE OF CONTENTS CHAIN DRIVE ELECTRICAL cont.
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TABLE OF CONTENTS 4-PAW GAS ELECTRICAL cont.
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TABLE OF CONTENTS 4-PAW DIESEL HYDRAULICS cont.
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TABLE OF CONTENTS 4-PAW DIESEL ELECTRICAL Ignition Switch �� 6/5-1 Purpose �� 6/5-1 Location �� 6/5-1 How It Works ��
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SAFETY INFORMATION General Information ! This symbol means WARNING or PERSONAL SAFETY INSTRUCTION read the instruction because it has to do with your safety. Failure to comply with the instruction may result in personal injury or even death. Avoid fires and explosions... Avoid spilling fuel and never smoke while working with any type of fuel or lubricant. Wipe up any spilled fuel or oil immediately. Never remove the fuel cap or add fuel when the engine is running.
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SAFETY INFORMATION Hydraulics Safety • Inspect all hydraulic line connectors and fittings. Make sure all hydraulic hoses and lines are in good condition before applying pressure to the system. • Keep body and hands away from pin hole leaks or nozzles that eject high pressure hydraulic fluid. Use cardboard or paper to find hydraulic leaks. Hydraulic fluid escaping under pressure can penetrate the skin and cause injury.
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SPECIFICATIONS General Specifications Model Spark plug 220 22311 Champion Premium Gold 2071 or Champion RC12YC (or equivalent) Spark plug Gap 220D, 320D 322 22300 22304 22302 22303 22305 All Years: Champion RC12YC (or equivalent) or 2001: Champion Premium Gold 2071 0.030” (0.
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SPECIFICATIONS Dimensions A. Overall operating height, fully raised / 91.2” (2317mm) B. Hinge pin height, fully raised / 66.0” (1676mm) C. Overall height / 48.7” (1237mm) D. Overall length / 82.2” (2088mm) E. Dump angle / 34º F. Dump height / 47.0” (1194mm) G. Reach, fully raised / 26.0” (660mm) H. Bucket rollback, ground position / 19º I. J. K. X. X. X. X. Bucket rollback, fully raised / 97º Wheelbase / 28.0” (711mm) Overall width / 40.5” (1029mm) Ground Clearance, front / 5.
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SPECIFICATIONS Engine Model Specifications 220 22311 22317 Kohler Command model CH20S, 4-cycle, air cooled, 2 cylinder, horizontal crankshaft, over head valves, 12VDC solenoid shift electric starter, 15 amp alternator and voltage regulator, high capacity air cleaner 222 22300 22304 Kohler Command CH22, 4-cycle, air cooled 2 cylinder, horizontal crankshaft, overhead valve, hydraulic valve lifters, cast iron cylinder liners, 12VDC solenoid shift electric starter, 15 amp alternator and voltage regula
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SPECIFICATIONS Performance Model 220 22311 22317 222 220D, 320D 322 22300 22304 22302 22303 22305 Tip Capacity (per SAE J732) 760 lbs (345kg) w/o operator 1030 lbs (467kg) with 200 lbs (91kg) operator Operating Capacity (per SAE J818) 380 lbs (172kg) w/o operator 515 lbs (234kg) with 200 lbs (91kg) operator Speed Weight 2/1-4 0-3 mph (0-4.8km/hr) forward or reverse (infinitely variable) 0-3.7 mph (0-6.
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SPECIFICATIONS Hydraulic System Model 220 22311 22317 222 220D, 320D 322 22300 22304 22302 22303 22305 Pressure 3000 psi 3250 psi 3000 psi 3225 psi (207 bar) (224 bar) (207 bar) (222 bar) system relief system relief system relief system relief pressure pressure pressure pressure Low Flow 3.7 GPM (14.0 L/min) 4.0 GPM (15.3 L/min) 8.5 GPM (32.2 L/min) 10.8 GPM (40.9 L/min) High Flow (@3600 RPM) Hydraulic Pump Displacements 323 22312 3000 psi (207 bar) system relief pressure 3.7 GPM (14.
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SPECIFICATIONS Electrical System 220 222 220D, 320D 322 Model 22311 22317 22300 22304 22302 22303 22305 Battery 12 volt, 380cca min. @ 0ºF (-18ºC) 12 volt, 340cca min. @ 0ºF (-18ºC) 12 volt, 380cca min. @ 0ºF (-18ºC) 12 volt, 435cca @ 0ºF (-18ºC) 12 volt, 380cca min. @ 0ºF (-18ºC) Alternator 12 VDC 15 amp with regulator 12 VDC 14.
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SPECIFICATIONS Torque Specifications Fastener Identification Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in the service manual. These torque specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in the service manual.
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SPECIFICATIONS SPECIFICATIONS Standard Torque Torque for for Dry, Dry, Zinc Zinc Plated, Plated, and and Steel Steel Fasteners Fasteners (Inch (Inch Series) Standard Series) Thread Size Grade 1, 5, & SAE Grade 1 Bolts, Screws, SAE Grade 5 Bolts, Screws, SAE Grade 8 Bolts, Screws, 8 with Thin Studs, & Sems with Regular Studs, & Sems with Regular Studs, & Sems with Regular Height Nuts Height Nuts (SAE J995 Height Nuts (SAE J995 Height Nuts (SAE J995 Grade 2 or Stronger Nuts) Grade 2 or Stronger Nuts) Grade
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SPECIFICATIONS SPECIFICATIONS Standard Torque for Dry, Zinc and Steel Fasteners (Metric Series) Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners) Thread Size Class 8.8 Bolts, Screws, and Studs with Regular Height Nuts (Class 8 or Strong Nuts) Class 10.9 Bolts, Screws, and Studs with Regular Height Nuts ( Class 10 or Strong Nuts) M5 X 0.8 57 ± 5 in-lb 640 ± 60 N-cm 78 ± 7 in-lb 885 ± 80 N-cm M6 X 1.0 96 ± 9 in-lb 1018 ± 100 N-cm 133 ± 13 in-lb 1500 ± 150 N-cm M8 X 1.
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SPECIFICATIONS SPECIFICATIONS Other Torque Torque Specifications Specifications Other Wheel Bolts and Lug Nuts SAE Grade 8 Steel Set Screws Recommended Torque Thread Size Square Head Hex Socket 1/4 - 20 UNC 140 ± 20 in-lb 73 ± 12 in-lb 5/16 - 18 UNC 215 ± 35 in-lb 145 ± 20 in-lb 3/8 - 16 UNC 35 ± 10 ft-lb 18 ± 3 ft-lb 1/2 - 13 UNC 75 ± 15 ft-lb 50 ± 10 ft-lb Thread Size Recommended Torque** 7/16 - 20 UNF Grade 5 65 ± 10 ft-lb 88 ± 14 N-m 1/2 - 20 UNF Grade 5 80 ± 10 ft-lb 108 ± 14
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SPECIFICATIONS SPECIFICATIONS Equivalentsand and Conversions Conversions Equivalents Decimal and Millimeter Equivalents Fractions Decimals mm 1/64 0.015625 0.397 0.03125 0.794 3/64 0.046875 1.191 0.0625 1.588 5/64 0.078125 1.984 0.9375 2.381 1/32 1/16 3/32 1/8 0.1250 3.175 9/64 0.140625 3.572 0.15625 3.969 11/64 0.171875 4.366 0.1875 4.762 5/32 3/16 13/64 7/32 15/64 1/4 17/64 9/32 19/64 5/16 21/64 11/32 23/64 3/8 25/64 13/32 27/64 7/16 5.159 5.556 0.234375 5.953 0.
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SPECIFICATIONS SPECIFICATIONS U.S. Conversions U.S.totoMetric Metric Conversions To Convert Into Linear Measurement Miles Yards Feet Feet Inches Inches Inches Kilometers Meters Meters Centimeters Meters Centimeters Millimeters Area Square Miles Square Feet Square Inches Acre Square Kilometers Square Meters Square Centimeters Hectare Volume Cubic Yards Cubic Feet Cubic Inches Cubic Meters Cubic Meters Cubic Centimeters 0.7646 0.02832 16.
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ALL UNITS/GENERAL 5. Raise the front of the machine (Fig. 0003). Raising the Traction Unit 1. Raise the loader arm 6” – 12” (15 – 30cm) off the ground. 2. Turn off the machine and remove the key. 3. Lift the rear of the machine (Fig. 0001). Fig. 0003 DSC-0105a 6. Position jackstands under the front 2 corners of the machine. Remove the floor jack (Fig. 0004). Fig. 0001 DSC-0100a 4. Position jackstands under the rear 2 corners of the machine. Remove the floor jack (Fig. 0002). Fig. 0004 DSC-0107a 7.
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ALL UNITS/GENERAL 4. Install the two cartages into the counterbalance valve body (Fig. 0007). 98-9050 Counterbalance Valve Rebuild 1. Secure the counterbalance valve in a vise. 2. Remove both cartridges from the valve (Fig. 0005). Fig. 0007 Fig. 0005 IMG-0180a IMG-0180a 3. Replace the o-rings and back-up rings on each of the cartridges (Fig. 0006). A B Fig. 0006 A. O-rings (3) 3/1-2 IMG-0188 B.
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ALL UNITS/GENERAL 4. Replace the o-rings and back-up rings on both cartridges (Fig. 0010). 99-3040 Counterbalance Valve Rebuild A 1. Secure the counterbalance valve in a vise. 2. Remove both cartridges from the valve (Fig. 0008). B Fig. 0010 A. O-rings (3) Fig. 0008 IMG-0188a B. Back-up rings (3) IMG-0190a 5. Replace the o-ring on the needle valve (Fig. 0011). 3. Remove the needle valve assembly (Fig. 0009). Fig. 0011 Fig.
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ALL UNITS/GENERAL 6. Install the needle valve into the valve body (Fig. 0012). Fig. 0012 IMG-0191a 7. Install the two cartages into the valve body (Fig. 0013). Fig.
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ALL UNITS/GENERAL 3. Remove the 4-spool return springs (Fig. 0016). 99-3070 4-Spool Valve Rebuild (Diesel) 1. Remove the two neutral safety switches from the spring covers (Fig. 0014). Fig. 0016 Fig. 0014 IMG-0438a IMG-0440a 4. Remove the 2 switch block mounts from the 4-spool valve (Fig. 0017). 2. Remove the 4 return spring covers from the bottom of the 4-spool valve (Fig. 0015). Fig. 0017 Fig.
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ALL UNITS/GENERAL 5. Remove the 2 detents for the neutral safety switches (Fig. 0018). Fig. 0018 IMG-0443a 6. Remove the 4 operator assemblies from the spool valve (Fig. 0019). Remove the gaskets from the operator assemblies. 7. Remove the 4-spool valves from the valve body (Fig. 0020). Fig. 0020 8. Remove the relief valve from the valve body (Fig. 0021). Fig. 0021 Fig.
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ALL UNITS/GENERAL 9. Remove the 3 check valves from the valve body (Fig. 0022). 11. Remove the plug from the valve body (Fig. 0024). Fig. 0024 Fig. 0022 10. Remove check valve located on the bottom of the valve body (Fig. 0023). Fig. 0023 IMG-0455a IMG-0451a 12. Remove the 8 o-rings from the valve ports (Fig. 0025). Check the o-rings for cuts and/or chafing. If there are signs of damage, the spools may be damaged and need replacing. Discard the o-rings after inspection. IMG-0452a Fig.
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ALL UNITS/GENERAL 4-Spool Valve Assembly (Fig. 0026): I A B D C K H F E G J L M I G/J N Fig. 0026 A. B. C. D. E. F. G. Return spring cover (4) Return spring cover o-ring (2) Neutral safety switch detent (2) Return spring (4) Neutral safety switch mounting block (2) Spool (4) Check valve (4) 3/1-8 H. I. J. K. L. M. N.
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ALL UNITS/GENERAL 14. Install new o-rings into the grooves in the valve bores (Fig. 0027). 16. Replace the o-ring on the pressure relief valve and install it into the 4-spool valve housing (Fig. 0029). IMG-0468a Fig. 0027 15. Disassemble the relief valve and inspect it for wear or damage. Avoid changing the location of the pressure adjusting screw. Reassembly as shown (Fig. 0028). Fig. 0029 17.
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ALL UNITS/GENERAL 18. Replace the o-ring on the plug and install the plug into the 4-spool valve body (Fig. 0031). Fig. 0031 20. Replace the o-ring on the remaining check valve and install it in the port on the bottom of the valve body (Fig. 0033). IMG-0455a Fig. 0033 19. Replace the o-ring on the 3 check valves and install them into the 4-spool valve body (Fig. 0032). Fig. 0032 21. Lubricate the 4-spools and carefully insert them through the o-rings and into the valve body (Fig. 0034).
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ALL UNITS/GENERAL 22. Inspect the rubber boot for cracks and damage; re place as neede. Apply grease to the ball on all 4 of the operator assemblies (Fig. 0035). 24. Install the 2 detents for the neutral safety switches (Fig. 0037). Fig. 0037 Fig. 0035 23. Install a gasket onto each of the 4 operator assemb lies. Install each operator assembly onto the 4-spool valve body (Fig. 0036). 25. Install new o-rings onto the two switch block mounts.
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ALL UNITS/GENERAL 26. Lubricate and install the 4-spool return springs (Fig. 0039). Fig. 0039 IMG-0486a 27. Install the o-rings on the 2 outer return spring covers. Install the two outside return spring covers onto the 4-spool valve body (Fig. 0040). 28. Install the 2 inside spool return spring covers onto the 2 switch block mounts (Fig. 0041). Fig. 0041 29. Install the two neutral safety switches in the two switch block mounts (Fig. 0042). Fig. 0042 Fig.
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ALL UNITS/GENERAL 3. Remove the two Allen screws that secure the actuator lever (Fig. 0045). 99-3072 Selector Valve Rebuild 1. Remove the two Allen cap screws securing the detent cover to the valve body (Fig. 0043). Fig. 0045 Fig. 0043 IMG-0196a IMG-0194a 2. Remove the detent assembly (Fig. 0044). Fig.
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ALL UNITS/GENERAL 4. Lift up on the actuator arm assembly (Fig. 0046). This will release the actuator lever from the spool (Fig. 0047). 5. Carefully remove the spool from the valve body (Fig. 0048). Fig. 0048 Fig. 0046 IMG-0199a IMG-0198a 6. Remove the plug and o-ring from the valve body (Fig. 0049). Fig. 0047 IMG-0197a Fig.
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ALL UNITS/GENERAL 7. Carefully remove the 2 spool seal o-rings from the groove in each end of the valve body and discard (Fig. 0050). 10. Install a new o-ring on the plug. Install the plug into the valve body (Fig. 0052). Fig. 0052 Fig. 0050 IMG-0205a IMG-0202a 8. Flush and clean the valve housing with a cleaning solvent and air dry. Inspect the valve and valve components. Replace if nicks, scratches, wear, or contamination are present. 11. Carefully slide the spool into the valve body (Fig. 0053).
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ALL UNITS/GENERAL 12. Position a gasket over the spool. Install the actuator lever through the hole in the spool and then up to the valve body (Fig. 0054). 14. Install a new o-ring on the plate and slide the plate over the spool up to the valve body (Fig. 0056). Fig. 0056 Fig. 0054 13. Install 2 Allen screws to secure the actuator lever to the valve body (Fig. 0055). 15. Install the detent assembly (Fig. 0057). Fig. 0057 Fig.
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ALL UNITS/GENERAL 16. Slide a gasket over the detent assembly and then position the detent cover over the detent (Fig. 0058). 100-4163 Hydraulic Cylinder Rebuild 1. Clean away all dirt and other foreign substance from openings, particularly at the head of the hydraulic cylinder. 2. Clamp the tilt cylinder barrel in a vise (Fig. 0060). Fig. 0058 IMG-0212a 17. Install 2 Allen cap screws to secure the detent cover to the valve body (Fig. 0059). Fig.
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ALL UNITS/GENERAL 3. Use a spanner wrench installed in the holes pro vided. Unscrew the head (counterclockwise from the ram end) (Fig. 0062). Hydraulic Cylinder Assembly (Fig. 0064): A B C Fig. 0064 Fig. 0062 IMG-0374a 4. Pull out the cylinder rod to remove the piston and head assembly from the barrel (Fig. 0063). Fig. 0063 IMG-0375a 5. Remove the barrel from the vise. 3/1-18 A. Barrel B. Piston D IMG-0376a C. Head D.
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ALL UNITS/GENERAL INSPECT BARREL ASSEMBLY: Visually inspect the inside bore for scratches and pits. There should be no scratches or pits deep enough to catch the fingernail. Scratches that catch the fingernail but are less than 0.5” (1.27cm) and primarily in the circumferential direction are acceptable provided they cannot cut the piston seal. In the event that an unacceptable condition occurs, the cylinder should be replaced. 7. Remove the second back-up washer (Fig. 0066). 6.
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ALL UNITS/GENERAL 9. Separate the inner seal from the PSP seal and remove the PSP seal (Fig. 0068). 11. Remove the piston wear ring (Fig. 0070). Fig. 0070 Fig. 0068 12. Loosen two set screws located on the piston (Fig. 0071). 10. Remove the inner seal (Fig. 0069). Fig. 0069 3/1-20 IMG-0384a IMG-0380a IMG-0382a Fig.
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ALL UNITS/GENERAL 13. Install the rod end in a bench vise. With a spanner wrench, remove the piston from ram shaft (Fig. 0072). 15. Remove the o-ring dust seal from the head (Fig. 0074). Fig. 0074 Fig. 0072 IMG-0389a IMG-0388a 14. Visually inspect for material defects and contamina tion. All piston seals and o-rings must be replaced with new parts. 16. Remove the back-up o-ring from the head (Fig. 0075). Piston Assembly (Fig. 0073): A B C D E F C Fig. 0075 Fig. 0073 A. Wear Ring B. Piston C.
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ALL UNITS/GENERAL 17. Remove the o-ring from the head (Fig. 0076). Fig. 0076 19. Remove both wear rings from inside the head (Fig. 0078). IMG-0392a Fig. 0078 18. Remove the head from the ram shaft (Fig. 0077). Fig. 0077 20. From the other side of the head assembly, remove the wiper seal (Fig. 0079). IMG-0393a Fig.
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ALL UNITS/GENERAL 21. Remove the seal from inside the head assembly (Fig. 0080). 24. Visually inspect for material defects and contamina tion. All seals and o-rings must be replaced with new parts (Fig. 0082 and Fig. 0083). Note: Upon assembly lubricate the head and all seals with 10W-30 oil prior to installation. Head Assembly (Inside Seals) D A B C Fig. 0080 E E IMG-0396a 22. Remove the back-up washer from inside the head assembly (Fig. 0081). IMG-0399a Fig. 0082 A. Wiper Seal B. Back-up Washer C.
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ALL UNITS/GENERAL 25. Install the two wear rings inside the head (Fig. 0084). Fig. 0084 IMG-0407a 26. Twist the seal into a “C” shape and allow it to snap into the groove (Fig. 0085). 27. Install the back-up washer next to the seal (Fig. 0086). Fig. 0086 IMG-0411a 28. Install the wiper seal in the groove of the head assembly (Fig. 0087). Note: The groove of the seal faces toward the barrel side of the head. Fig. 0087 Fig.
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ALL UNITS/GENERAL 29. Install the outer o-rings onto the head assembly: a. Install protective plastic or tape over the threads of the head assembly to protect the o-rings from damage (Fig. 0088). c. Remove the protective plastic or tape and install the back-up o-ring onto the head (Fig. 0090). Fig. 0090 Fig. 0088 IMG-0413a IMG-0415a d. Install the o-ring dust seal next to the back-up o-ring (Fig. 0091). b. Lubricate and install an o-ring in the groove of the head assembly (Fig. 0089). Fig.
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ALL UNITS/GENERAL 30. Place the cylinder rod into a vise and install pro tective plastic or tape over the threads (Fig. 0092). Fig. 0092 32. Remove the protective tape/plastic from the threads. 33. Apply a small quantity of thread locking compound (blue) to the cylinder rod threads (Fig. 0094). IMG-0419a Fig. 0094 31. Lubricate and install the head assembly on the ram (Fig. 0093). Fig. 0093 34. Loosely install the piston until hand tight or fully seated on the threads (Fig. 0095). IMG-0420a Fig.
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ALL UNITS/GENERAL 35. Using a spanner wrench, tighten the piston onto the cylinder rod (Fig. 0096). Fig. 0096 IMG-0425a 36. Tighten the 2 set screws on the piston to secure (Fig. 0097). 37. Lubricate and install the wear ring onto the piston (Fig. 0098). Fig. 0098 38. Install a back-up washer onto the piston (Fig. 0099). Fig. 0099 Fig.
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ALL UNITS/GENERAL 39. Install the inner PSP seal (Fig. 0100). Fig. 0100 41. Install the o-ring over the PSP seal, make sure the o-ring sits flat and is not twisted (Fig. 0102). IMG-0430a Fig. 0102 40. Install the PSP seal (Fig. 0101). Fig. 0101 42. Install the second back-up washer (Fig. 0103). IMG-0431a Fig.
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ALL UNITS/GENERAL 43. If possible, the piston/seal assembly should sit at least one hour to allow the seals to elastically restore. 44. Install the cylinder rod assembly into the barrel (Fig. 0104). 104-4221 Flow Divider Valve Rebuild 1. Loosen the set screw securing the handle to the flow divider spool. Remove the handle (Fig. 0106). Fig. 0106 Fig. 0104 IMG-0375a 45. Using a spanner wrench, tighten the head into the barrel (Fig. 0105). 2.
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ALL UNITS/GENERAL 3. Remove the spring and manifold from the flow divider body (Fig. 0108). 5. Remove the spool from the valve body (Fig. 0110). Fig. 0110 Fig. 0108 IMG-0527a IMG-0525a 4. Remove a snap ring and an o-ring from either end of the flow divider spool. There is one on each side of the valve body (Fig. 0109). 6. Remove the o-rings and the back-up o-rings from the flow divider and discard (Fig. 0111): A B C DE E D C B Fig. 0111 Fig. 0109 3/1-30 IMG-0526a A. Spool B. Snap ring (2) C.
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ALL UNITS/GENERAL 7. Flush the valve body with a solvent and then com pressed air to clean it out. Inspect the manifold and flow divider for any scratches or wear. 10. Install an o-ring and a snap ring on each side of the flow divider (Fig. 0114). 8. Install the o-rings and back-up rings onto the spool (Fig. 0112). Fig. 0114 Fig. 0112 IMG-0529a IMG-0531a 11. Install a new o-ring on each plug. Install a plug into the side opposite the spool (Fig. 0115). 9. Lubricate the o-rings and seals.
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ALL UNITS/GENERAL 12. Install the spring and manifold into the valve body (Fig. 0116). Fig. 0116 IMG-0535a 14. Install the handle into the spool and tighten the set screw to secure (Fig. 0118). Fig. 0118 IMG-0537a 13. Install the second plug into the manifold port (Fig. 0117). Fig.
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ALL UNITS/GENERAL 3. Remove the 4 operator assemblies from the spools (Fig. 0121). 105-6246 4-Spool Valve Rebuild (Chain Drive) 1. Remove the 4 return spring covers from the bottom of the 4-spool valve (Fig. 0119). Fig. 0121 Fig. 0119 IMG-0492a IMG-0494a 4. Pull the 4-spools out of the valve body (Fig. 0122). 2. Remove the spool return springs (Fig. 0120). Fig. 0122 Fig.
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ALL UNITS/GENERAL 5. Remove the relief valve from the valve body (Fig. 0123). Fig. 0123 IMG-0497a 6. Remove the 3 check valves from the valve body (Fig. 0124). 7. Remove the check valve located on the bottom of the valve body (Fig. 0125). Fig. 0125 8. Remove the plug from the valve body (Fig. 0126). Fig. 0126 Fig.
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ALL UNITS/GENERAL 9. Remove and inspect the 8 spool seal o-rings (4 on the top, 4 on the bottom) for cuts or chafing (Fig. 0127). Fig. 0127 IMG-0503a 10. Some 4-spool valves have a pressure relief installed on the back of the valve housing. If a plug is located on the back of the housing, remove it (Fig. 0128). Fig.
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ALL UNITS/GENERAL 11. Flush and clean the valve housing with a cleaning solvent and air dry. Inspect the 4-spools for nicks, scratches, wear, or contamination. 4-Spool Valve Assembly (Fig. 0129): F I E A B C D F J/H K L G H M Fig. 0129 A. B. C. D. E. F. G. Spool spring cap (4) Spool spring cap gasket (4) Spool spring (4) Spool (4) Plug Spool o-ring (8) Check valve 3/1-36 H. I. J. K. L. M.
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ALL UNITS/GENERAL 12. Lubricate and install new o-rings into the grooves in the top and bottom spool ports (4 ports on top and 4 ports on bottom) (Fig. 0130). Fig. 0130 14. Lubricate and install a new o-ring on the pressure relief valve. Install the pressure relief valve in the 4-spool valve (Fig. 0132). IMG-0507a 13. Disassemble the relief valve and inspect it for wear or damage. Avoid changing the location of the pressure adjusting screw. Reassembly as shown (Fig. 0131). Fig. 0132 IMG-0508a 15.
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ALL UNITS/GENERAL 16. Lubricate and install a new o-ring onto the plug. Install the plug into the valve body (Fig. 0134). Fig. 0134 18. Lubricate and install a new o-ring onto the remaining check valve, Install the check valve into the port located on the bottom of the valve body (Fig. 0136). IMG-0510a Fig. 0136 17. Lubricate and install a new o-ring onto each of the 3 check valves. Install the 3 check valves into the front face of the valve body (Fig. 0135). Fig.
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ALL UNITS/GENERAL 20. Apply grease to the ball on all 4 operator assemblies (Fig. 0138). Fig. 0138 IMG-0480a 21. Position a gasket between the 4 operator assemb lies and the valve body. Install the 4 operator assemblies to the valve body (Fig. 0139). Fig. 0139 Toro Wheeled CUL Service Manual IMG-0482a 22. Lubricate the 4-spool return springs and install them to the 4-spools (Fig. 0140). Fig. 0140 IMG-0514a 23. Position a gasket between the 4 return spring covers and the valve body.
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ALL UNITS/GENERAL 24. If the 4-spool valve uses an external pressure relief valve: lubricate a new o-ring and install it on the external pressure relief valve. Install the external pressure relief valve in the back of the valve body (Fig. 0142). 105-7867 Hydraulic Cylinder Rebuild 1. Clean away all dirt or other foreign substance from openings, particularly at the head end of the hydraulic cylinder. 2. Clean out any material in the locking slot (Fig. 0143). Fig. 0142 IMG-0517a Fig. 0143 IMG-0318a 3.
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ALL UNITS/GENERAL 4. Install a spanner wrench in the holes located on the head. Rotate the head counter-clockwise until the beveled edge of the retaining ring appears in the milled locking slot of the barrel. Insert a flat blade screwdriver between the beveled edge of the retaining ring and the milled locking slot (Fig. 0145). 6. Pull the cylinder rod assembly out of barrel (Fig. 0147). Fig. 0147 Fig. 0145 IMG-0322a IMG-0325a 7. Remove the barrel from the vise. Hydraulic Cylinder Assembly (Fig.
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ALL UNITS/GENERAL INSPECT ROD: There should be no scratches or pits deep enough to catch the fingernail. Pits that go to the base metal are unacceptable. Scratches that catch the fingernail but are not to the base metal, 0.5” (1.27 cm) long and primarily in the circumferential direction are acceptable provided they cannot cut the rod seal. Chrome should be present over the entire surface of the rod and the lack thereof is unacceptable.
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ALL UNITS/GENERAL 10. Remove the back-up seal from the piston assembly (Fig. 0151). 12. Slide the piston off the end of the rod (Fig. 0153). Fig. 0153 Fig. 0151 11. Remove the nut securing the piston to the cylinder rod (Fig. 0152). 13. Remove the o-ring from the rod (Fig. 0154). Fig. 0154 Fig.
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ALL UNITS/GENERAL 14. Remove the o-ring from the head (Fig. 0155). Fig. 0155 IMG-0336a 15. Remove the flat back-up ring from the head (Fig. 0156). Fig. 0156 3/1-44 IMG-0337a 16. Slide the head off the end of the ram (Fig. 0157). Fig. 0157 IMG-0338a 17. Remove the wiper seal from inside the head (Fig. 0158). Fig.
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ALL UNITS/GENERAL 18. Remove the wear seal from inside the head (Fig. 0159). Head Assembly (Fig. 0160): C A B D E Fig. 0160 Fig. 0159 IMG-0341a 19. Thoroughly rinse the inside of the head with a clean ing solvent. Rinse and clean all internal components of foreign material with a lint-free rag. A. O-ring B. Flat back-up ring C. Head IMG-0342a D. Wear Seal E. Wiper Seal Piston Assembly (Fig. 0161): 20. Visually inspect for material defects and contamina tion.
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ALL UNITS/GENERAL 21. Twist the wear ring into a “C” shape and allow it to snap into the inside groove of the head (Fig. 0162). 23. Install the flat back-up seal into the deepest groove in the head. The flat back-up seal is installed against the ram side of the groove (Fig. 0164). Note: The groove in the seal faces toward the barrel side of the head. Fig. 0164 Fig. 0162 IMG-0349a IMG-0347a 22. Install the wiper seal so that the lip of the seal is installed in the groove inside the head (Fig. 0163).
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ALL UNITS/GENERAL 25. Install the wear ring into the widest groove on the piston (Fig. 0166). 27. Install the seal into the narrowest groove of the piston on top of the back-up ring (Fig. 0168). Note: Lubricate all parts during assembly. Fig. 0166 IMG-0354a Fig. 0168 26. Install the back-up ring into the narrowest groove on the piston (Fig. 0167). IMG-0356a 28. Secure the cylinder rod into a vise. 29.
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ALL UNITS/GENERAL 30. Slide the head onto the cylinder rod (Fig. 0170). Fig. 0170 IMG-0357a 31. Install the o-ring in the groove on the rod. Remove the tape or plastic cover from the threads (Fig. 0171). 32. Slide the piston onto the cylinder rod (Fig. 0172). Fig. 0172 33. Install the nut onto the end of the rod (Fig. 0173). Torque the nut to 100-120 ft-lbs. (135.6-162.7 Nm). Fig. 0173 Fig.
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ALL UNITS/GENERAL 34. Remove the rod from the vise and secure the cylinder barrel into the vise. 35. Install the ram assembly into the cylinder barrel by rotating the head assembly while pushing the head into the barrel (Fig. 0174). 37. Insert the tab end of the retaining ring through the notch in the barrel and into the hole in the groove of the head. Place the spanner wrench onto the head assembly (Fig. 0176). Fig. 0176 Fig. 0174 IMG-0366a 36.
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ALL UNITS/GENERAL 108-4710 Hydraulic Tandem Pump Rebuild Note: Protect all exposed sealing areas and open cavities from damage, foreign material and chemicals. 2. Secure the pump in a vise. 3. Mark the pump housing with a “V” that crosses over all sections of the housing (Fig. 0179). Note: Remove and discard all seals, o-rings and gaskets and replace with new when reassembling. 1. Remove the key from the keyway in the pump shaft (Fig. 0178). Fig. 0179 IMG-0217a 4.
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ALL UNITS/GENERAL 5. Remove the cover of the pump from the pump assembly (Fig. 0181). Fig. 0181 IMG-0219a 6. Remove the cap gasket from the pump housing (Fig. 0182). Fig. 0182 Toro Wheeled CUL Service Manual IMG-0220a 7. Mark the rear 5 gpm bushing assembly with a single line that extends onto the pump housing (Fig. 0183). Fig. 0183 IMG-0221a 8. Remove the rear bushing from the pump housing assembly (Fig. 0184). Fig.
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ALL UNITS/GENERAL 9. Remove the drive gear (gear with splines) from the pump assembly (Fig. 0185). Fig. 0185 11. Using a needle nose pliers grab the center of the inner small bushing and lift it partially out of the pump housing (Fig. 0187). IMG-0223a Fig. 0187 10. Remove the driven gear from the pump assembly (Fig. 0186). Fig. 0186 12. Mark the inner small bushing assembly with a line that extends out onto the pump housing. This line should be on the opposite side as the previous marking (Fig. 0188).
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ALL UNITS/GENERAL 13. Remove the inner small bushing from the pump housing (Fig. 0189). 15. Remove the o-ring from the housing (Fig. 0191). Fig. 0191 Fig. 0189 14. Lift the pump housing off the 11 gpm pump shaft cover (Fig. 0190). 16. Remove the drive link from the drive gear (Fig. 0192). Fig. 0192 Fig.
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ALL UNITS/GENERAL 17. Mark the large pump bushing assembly with a “V” all the way down onto the pump shaft cover (Fig. 0193). Fig. 0193 IMG-0231a 18. Remove the large pump bushing assembly from the pump shaft cover (Fig. 0194). Fig. 0194 19. Remove the snap ring from the pump cover (Fig. 0195). Fig. 0195 20. With the cover secured so the inside of the cover is facing up, remove the shaft seal from the inside of the pump cover (Fig. 0196). IMG-0232a Fig.
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ALL UNITS/GENERAL 21. Install a new shaft seal in the pump cover so that the spring side of the seal is facing the housing side of the pump cover (Fig. 0197). 23. Install the snap ring into the pump cover (Fig. 0199). Fig. 0199 Fig. 0197 IMG-0240a IMG-0238a 24. Remove the bushing from the drive gear and driven gear shafts (Fig. 0200). 22. Carefully drive the seal into the cover until it is seated (Fig. 0198). Fig. 0200 Fig.
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ALL UNITS/GENERAL 25. Remove the drive gear from the bushing (Fig. 0201). Fig. 0201 27. Inspect the gear surface of both of the bushings for damage (Fig. 0203). IMG-0242a Fig. 0203 26. Remove the driven gear from the bushing (Fig. 0202). Fig. 0202 28. Inspect the drive gear and driven gear surfaces for damage (Fig. 0204). IMG-0243a Fig.
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ALL UNITS/GENERAL 29. Remove the back-up ring from the top and bottom bushings (Fig. 0205). Fig. 0205 31. Install the gear seal with the lip side of the gasket facing away from the groove of the bushing (Fig. 0207). IMG-0246a Fig. 0207 30. Remove the gear seal from the top and bottom bushings (Fig. 0206). IMG-0249a 32. Install the back-up ring into the bushing so that it rests in the lip of the gear seal (Fig. 0208). Note: Lubricate all surfaces on reassembly. Fig. 0208 Fig.
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ALL UNITS/GENERAL 33. Repeat the previous 2 steps for the second bushing. 34. Making note of the markings on the bushing assembly, install the drive gear into the bushing (Fig. 0209). 36. Install the second bushing onto the 2 gears (Fig. 0211). Fig. 0211 Fig. 0209 IMG-0252a 35. Install the driven gear into the bushing (Fig. 0210). 37. Making note of the marks on the 11gpm pump, slide the drive gear shaft of the 11gpm pump assembly into the mounting flange (Fig. 0212). Fig. 0212 Fig.
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ALL UNITS/GENERAL 38. Inspect both gear surfaces of both 5 gpm bushings for damage (Fig. 0213). 40. Inspect the drive link for damage (Fig. 0215). Fig. 0215 Fig. 0213 39. Inspect the drive and driven gears for damage (Fig. 0214). 41. Install the drive link onto the drive gear of the 11gpm pump assembly (Fig. 0216). Fig. 0216 Fig.
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ALL UNITS/GENERAL 42. Install an o-ring into the groove in the housing mounting flange face (Fig. 0217). Fig. 0217 IMG-0267a 43. Making note of the markings on the housing and mounting flange, install the pump housing over the 11 gpm pump assembly and onto the mounting flange (Fig. 0218). 44. Making note of the markings, install the 5gpm pump inner bushing (Fig. 0219). Fig. 0219 45. Install the 5gpm pump drive gear into the pump assembly (Fig. 0220). Fig. 0220 Fig.
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ALL UNITS/GENERAL 46. Install the 5gpm pump driven gear into the pump assembly (Fig. 0221). Fig. 0221 IMG-0271a 47. Making note of the markings on the 5gpm assembly, slide the outer bushing into place over the gears (Fig. 0222). 48. Install an o-ring in the cover mounting surface of the housing (Fig. 0223). Fig. 0223 IMG-0274a 49. Install the housing cover onto the housing (Fig. 0224). Note: The pump shaft may have to rotate to seat the 5 gpm pump bushing onto the drive link. Fig. 0224 Fig.
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ALL UNITS/GENERAL 50. Install 4 bolts to secure the housing cover to the housing. Torque the 4 bolts 19 – 23 ft-lbs. (25.8 – 31.2 Nm) (Fig. 0225). 98-4732 cross-referenced to 104-7422 4-Spool Valve Rebuild (used on Chain Drive 22304) 1. Remove the 4 return spring covers from the bottom of the 4-spool valve (Fig. 0227). Fig. 0225 IMG-0277a 51. Install the key into the keyway on the pump shaft (Fig. 0226). Fig. 0227 IMG-0279a 2. Remove the spool return springs (Fig. 0228). Fig. 0226 IMG-0278a Fig.
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ALL UNITS/GENERAL 3. Remove the operator assemblies from the top side of the 4-spool valve (Fig. 0229). Fig. 0229 5. Remove the pressure regulator from the valve. Remove, inspect and then discard the o-ring (Fig. 0231). IMG-0281a Fig. 0231 4. Remove the 4-spools from the valve housing (Fig. 0230). IMG-0283a 6. Disassemble, clean and inspect the pressure regulator for wear of damage. Avoid changing the location of the adjusting screw. Reassembly the regulator (Fig. 0232).
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ALL UNITS/GENERAL 7. Remove, inspect and then discard the 8 spool o-rings (4 on top, 4 on bottom) (Fig. 0233). Fig. 0233 IMG-0286a 8. Remove the 3 check valves (Fig. 0234). Fig. 0234 3/1-64 9. Replace the check valve o-ring on all 3 check valves (Fig. 0235). Fig. 0235 IMG-0297a 10. Install the 3 check valves (Fig. 0236). IMG-0294a Fig.
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ALL UNITS/GENERAL 11. Carefully install 8 new o-ring into the 4-spool ports (4 o-rings on top, 4 o-rings on bottom) (Fig. 0237). Fig. 0237 13. Install the pressure regulator assembly into the valve body (Fig. 0239). IMG-0287a 12. Install a new o-ring on the pressure regulator assembly (Fig. 0238). IMG-0290a Fig. 0239 14. The initial adjustment of the pressure regulator screw should be 3/8” (9.5mm) from the shoulder of the regulator body to the end of the screw threads (Fig. 0240). A Fig.
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ALL UNITS/GENERAL 15. Lubricate the spools and insert them into the valve body (Fig. 0241). Fig. 0241 17. Install the 4 operator assemblies onto the valve body so that the ball in the operator assembly is captured inside the socket (hole) in the spool (Fig. 0243). IMG-0299a Fig. 0243 16. Apply grease to the 4 ball/sockets inside the 4 operator assemblies (Fig. 0242). Fig. 0242 3/1-66 IMG-0302a IMG-0303a 18. Install the 4-spool return springs (Fig. 0244). Fig.
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ALL UNITS/GENERAL 19. Install the 4-spool return spring covers (Fig. 0245). 99-3077 Auxiliary Valve Rebuild 99-3077 Auxiliary Valve Removal 1. Remove the neutral safety switch, if present, from the spring covers (Fig. 0246). Fig. 0245 IMG-0307a Fig. 0246 DSCN-2474a 2. Remove the two Allen cap screws and the detent cover, exposing the detent sleeve (Fig. 0247). Fig.
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ALL UNITS/GENERAL 3. Cover the detent assembly with a clean shop towel and remove the detent sleeve. 5. Remove the detent ball housing and return spring (Fig. 0250). CAUTION: The detent balls are spring-loaded and may become projectiles – wear safety glasses (Fig. 0248). Fig. 0250 Fig. 0248 DSCN-2476a DSCN-2457a 6. Remove the two Allen cap screws and the safety switch mounting-block (Fig. 0251). 4. Remove the detent block (Fig. 0249). Fig. 0251 Fig.
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ALL UNITS/GENERAL 7. Remove the neutral safety switch detent (Fig. 0252). Fig. 0252 DSCN-2438a 8. Remove the two Allen cap screws and the operator assembly (Fig. 0253). Fig. 0253 DSCN-2433a 9. Remove the spool from the body (Fig. 0254). Fig. 0254 DSCN-2430a 10. Remove the two O-rings from the valve body (Fig. 0255). Fig. 0255 IMG-0202a 11. Flush and clean the valve housing with a cleaning solvent and air dry. Inspect the valve and valve components.
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ALL UNITS/GENERAL 3. Replace the O-rings on the pressure relief valve and install it into the valve housing (Fig. 0258). 99-3077 Auxiliary Valve Assembly 1. Install new o-rings into the grooves in the valve bores (Fig. 0256). DSCN-2418a Fig. 0258 Fig. 0256 IMG-0203a 2. Disassemble the relief valve and inspect it for wear or damage. Reassemble as shown (Fig. 0257). Fig. 0257 4.
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ALL UNITS/GENERAL 5. Lubricate the spool and carefully insert it into the valve body (Fig. 0260). Fig. 0260 7. Install the operator assembly onto the valve body making sure the ball end is inserted into the hole in the spool (Fig. 0262). DSCN-2430a Fig. 0262 6. Inspect the rubber boot for cracks and damage; replace as needed. Apply grease to the ball end on the operator assembly (Fig. 0261). Fig. 0261 Toro Wheeled CUL Service Manual DSCN-2427a DSCN-2433a 8.
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ALL UNITS/GENERAL 9. Install a new o-ring onto the switch block and mount to the valve body using two Allen cap screws (Fig. 0264). 11. Place a new o-ring into the flat side of the detent block and slide it over the detent spring (Fig. 0266). Fig. 0266 Fig. 0264 10. Lubricate and install the detent ball housing and return spring (Fig. 0265). 12. Install a new o-ring onto the detent block (Fig. 0267). Fig. 0267 Fig.
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ALL UNITS/GENERAL 13. Place the detent spring and large ball into the detent ball housing (Fig. 0268). Fig. 0268 DSCN-2482a 14. Apply lightweight grease to hold the balls in place during assembly. Place the small detent balls into the holder. Use a steel rod to push the center ball down into the holder against the spring pressure until the detent balls retract (Fig. 0269). 15. Then, position the sleeve (large inside diameter first) over the detent balls (Fig. 0270). Fig. 0270 16.
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ALL UNITS/GENERAL THIS PAGE INTENTIONALLY LEFT BLANK.
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CHAIN DRIVE/DRIVE SYSTEM 6. Raise the front of the machine (Fig. 0274). Drive Chain Replacement Drive Chain Removal 1. Park CUL on a level surface. 2. Raise the loader arm 6” - 12” (15 - 30cm) off the ground. 3. Turn off the machine and remove the key. 4. Lift the rear of the machine (Fig. 0272). Fig. 0274 DSC-0105 7. Position jackstands under the front 2 corners of the machine. Remove the floor jack (Fig. 0275). Fig. 0272 DSC-0100 5. Position jackstands under the rear 2 corners of the machine.
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CHAIN DRIVE/DRIVE SYSTEM 8. Lower the loader arm. 9. Using a 1/2” socket, remove the 2 bolts securing the chain cover to the main frame (Fig. 0276). 11. Rotate the wheels until the master link on the chain is visible (Fig. 0278). Fig. 0278 Fig. 0276 DSC-0191a 10. Remove the chain cover for the chain being serviced (Fig. 0277). 12. Using a 13/16” socket, remove the 5 lug nuts securing the rear wheel to the rear hub (Fig. 0279). Fig. 0279 Fig.
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CHAIN DRIVE/DRIVE SYSTEM 13. Remove the rear wheel from the rear hub (Fig. 0280). Fig. 0280 DSC-0122a 14. Using a 3/4” socket and wrench, loosen the 4 nuts and bolts securing the axle retaining bracket to the main frame (Fig. 0281). Fig. 0281 15. Using a 1-1/4” wrench, loosen the jam nut on each of the 2 chain tensioning bolts (Fig. 0282). Fig. 0282 16. Using a 1-1/8” socket, loosen the 2 chain tensioning bolts.
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CHAIN DRIVE/DRIVE SYSTEM 17. Remove the clip from the master chain link (Fig. 0284). Fig. 0284 DSC-0136a 18. Remove the retainer from the master chain link (Fig. 0285). Fig. 0285 4/1-4 DSC-0138a 19. Remove the master chain link from the chain (Fig. 0286). Fig. 0286 DSC-0141a 20. Remove the chain from the wheel sprockets (Fig. 0287). Fig.
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CHAIN DRIVE/DRIVE SYSTEM 21. Inspect the chain assembly. Replace if damaged or worn (Fig. 0288). Fig. 0288 DSC-0149a 22. Inspect the front and rear sprockets. Replace if damaged or worn (Fig. 0289). Fig.
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CHAIN DRIVE/DRIVE SYSTEM Drive Chain Installation 1. Route one end of the chain around the top of the front wheel sprocket. Route the other end of the chain around the top of the rear wheel sprocket. The two ends should come together on the bottom of the chain routing (Fig. 0290, Fig. 0291 and Fig. 0292). Fig. 0292 DSC-0159a 2. Install the master chain link into one end of the chain (Fig. 0293). Fig. 0290 DSC-0156a Fig. 0293 Fig.
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CHAIN DRIVE/DRIVE SYSTEM 3. Install the other side of the master link through the other end of the chain (Fig. 0294). Fig. 0294 DSC-0161a 4. Install the master link retainer onto the master chain link (Fig. 0295). 5. Install the clip onto master chain link to secure (Fig. 0296). Fig. 0296 6. Slide the rear wheel onto the rear hub (Fig. 0297). Fig. 0297 Fig.
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CHAIN DRIVE/DRIVE SYSTEM 7. Using a 13/16” socket, install 5 lug nuts to secure the rear wheel to the rear hub. Torque the lug nuts to 50 ft-lbs. (68 Nm) (Fig. 0298). 9. Using a 1/2” socket, install 2 bolts to secure the chain cover to the main frame (Fig. 0300). Fig. 0300 Fig. 0298 8. Position the chain cover to the main frame (Fig. 0299). Fig. 0299 10. Turn the front wheel on one side of the traction unit until the upper span of the drive chain is tight. 11.
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CHAIN DRIVE/DRIVE SYSTEM 12. Continuing tightening, or loosening, the tensioning bolts until there is 1-1/2” to 2-1/2” (3.8 to 6.4cm) between the bottom of the chain guard and the top of the chain on each side of machine (Fig. 0302). 14. Use a 1-1/4” crows foot wrench to torque the 2 jam nuts to 30 ft-lbs. (41 Nm) (Fig. 0304). Fig. 0304 Fig. 0302 DSC-0181a 13.
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CHAIN DRIVE/DRIVE SYSTEM 16. Torque the 4 nuts to 75 ft-lbs. (102 Nm) (Fig. 0306). Front Axle Replacement Front Axle Removal 1. Park CUL on a level surface 2. Raise the loader arm 6” - 12” (15 - 30cn) off the ground. 3. Turn off the machine and remove the key. 4. Lift the rear of the machine (Fig. 0307). Fig. 0306 DSC-0588a 17. Apply general purpose oil (10W30) to the upper and lower chain spans. 18.
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CHAIN DRIVE/DRIVE SYSTEM 6. Raise the front of the machine (Fig. 0309). 8. Raise the loader arms to the fully raised position. 9. Turn off the engine and remove the key. 10. Remove the loader arm cylinder locks located on the hydraulic auxiliary lines (Fig. 0311). Fig. 0309 DSC-0105a 7. Position jackstands under the front 2 corners of the machine. Remove the floor jack (Fig. 0310). Fig. 0311 DSC-0448a 11. Position a loader arm cylinder lock over each lift cylinder rod (Fig. 0312). Fig.
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CHAIN DRIVE/DRIVE SYSTEM 12. Secure each loader arm cylinder lock with a clevis pin and hairpin cotter (Fig. 0313). 15. Remove the chain cover (Fig. 0315). Fig. 0315 Fig. 0313 DSC-0271a DSC-0456a 13. Lower the loader arm until the loader arm end of the cylinder rods are resting on the cylinder locks. 16. Rotate the wheels until the master chain link is visible (Fig. 0316). 14. Using a 1/2” socket, remove the 2 bolts securing on of the chain covers to the main frame (Fig. 0314). Fig. 0316 Fig.
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CHAIN DRIVE/DRIVE SYSTEM 17. Using a 13/16” socket, remove the 5 lug nuts secur ing the front wheel to the front hub (Fig. 0317). Fig. 0317 DSC-0272a 18. Remove the front wheel from the front hub (Fig. 0318). Fig. 0318 Toro Wheeled CUL Service Manual DSC-0274a 19. Remove the clip from the master chain link (Fig. 0319). Fig. 0319 DSC-0282a 20. Remove the retainer from the master chain link (Fig. 0320). Fig.
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CHAIN DRIVE/DRIVE SYSTEM 21. Remove the master chain link from the chain (Fig. 0321). 23. Remove the protective bearing cap (Fig. 0323). Fig. 0323 Fig. 0321 DSC-0289a DSC-0285a 24. Remove the bearing cap (Fig. 0324). 22. Remove the chain from the front wheel sprocket (Fig. 0322). Fig. 0324 Fig.
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CHAIN DRIVE/DRIVE SYSTEM 27. Remove the washer (Fig. 0327). 25. Remove the cotter pin (Fig. 0325). Fig. 0325 DSC-0294a 26. Using a 1-1/8” socket, remove the castle nut (Fig. 0326). Fig. 0327 28. Remove the bearing (Fig. 0328). Fig. 0328 Fig.
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CHAIN DRIVE/DRIVE SYSTEM 29. Remove the front hub and sprocket assembly from the axle (Fig. 0329). Fig. 0329 DSC-0302a 30. Repeat steps 13 – 28 to remove the front wheel, chain, hub and sprocket from the opposite side of the machine. 32. Using a 1-1/4” socket, loosen the jam nuts on the 2 chain tensioning bolts (Fig. 0331). Fig. 0331 DSC-0518a 33. Remove the front axle assembly from the main frame (Fig. 0332). 31.
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CHAIN DRIVE/DRIVE SYSTEM 34. Clean and lubricate the threads of the 2 chain ten sioning bolts (Fig. 0333). 36. Remove the 2 axle brackets (Fig. 0335). DSC-0532a Fig. 0335 Fig. 0333 DSC-0527a 35. Using a 1-1/8” socket, remove the chain tensioning bolts, jam nuts and washers from the axle assembly. Remove the jam nut from each of the chain tension ing bolts (Fig. 0334). Front Axle Assembly (Fig. 0336): B B C D E C D E A Fig. 0336 Fig. 0334 Toro Wheeled CUL Service Manual DSC-0528a A.
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CHAIN DRIVE/DRIVE SYSTEM 3. Apply anti-seize compound to the 2 chain tensioning bolts (Fig. 0339). Front Axle Installation 1. Thread a jam nut onto each of the chain tensioning bolts approximately 3/4 of the way up the threads (Fig. 0337). Fig. 0339 Fig. 0337 DSC-0538a 2. Slide 2 washers up to the jam nut on each of the chain tensioning bolts (Fig. 0338). 4. Position an axle bracket to the axle aligning it with the chain tensioning bolt mounting holes.
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CHAIN DRIVE/DRIVE SYSTEM 5. Repeat step 4 to install the other axle bracket (Fig. 0341). Fig. 0341 7. Position the axle brackets so the mounting holes align with the mounting holes in the main frame (Fig. 0343). DSC-0546a Fig. 0343 DSC-0548a 6. Slide the front axle assembly into the main frame (Fig. 0342). Fig.
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CHAIN DRIVE/DRIVE SYSTEM 8. Loosely install 4 bolts, washers and nuts securing the 2 axle brackets to the main frame (Fig. 0344). Fig. 0344 4/1-20 DSC-0509a Note: One washer under the bolt head, one washer under the nut (Fig. 0345 and Fig. 0346). Fig. 0345 DSC-0551a Fig.
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CHAIN DRIVE/DRIVE SYSTEM 9. Inspect the hub and sprocket. If worn or damaged, replace. Refer to “Sprocket Replacement” on page 4/1-35. 13. Slide the front hub and sprocket assembly onto the axle (Fig. 0349). 10. Inspect the seals and bearings. If worn or damaged, replace. Refer to “Front Axle Hub Rebuild” on page 4/1-46. 11. Apply grease to the inside of the seal (Fig. 0347). Fig. 0349 DSC-0326a 14. Slide the outer bearing over the axle and into the hub (Fig. 0350). Fig. 0347 DSC-0317a 12.
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CHAIN DRIVE/DRIVE SYSTEM 15. Slide a washer over the axle (Fig. 0351). Fig. 0351 17. Using a 1-1/8” socket, tighten the nut to seat the bearings then back it off. Back off nut so first slot in nut aligns with hole in axle (Fig. 0353). DSC-0329a Fig. 0353 DSC-0333a 16. Thread the castle nut onto the axle (Fig. 0352). 18. Install a cotter pin in the hole in the axle (Fig. 0354). Fig. 0352 DSC-0332a Fig.
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CHAIN DRIVE/DRIVE SYSTEM 19. Install the bearing protector (Fig. 0355). Fig. 0355 21. Install the protective bearing cap (Fig. 0357). DSC-0338a 20. Using general purpose grease, fill the inner cavity of the hub assembly (Fig. 0356). Fig. 0357 DSC-0341a 22. Repeat steps 9 - 21 to install the sprocket and hub assembly on the opposite side of the machine. 23. Route the chain around the top of the front wheel sprocket (Fig. 0358). Fig. 0356 DSC-0340a Fig.
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CHAIN DRIVE/DRIVE SYSTEM 24. Install the master chain link into one end of the chain (Fig. 0359). Fig. 0359 DSC-0343a 26. Install the master link retainer onto the master chain link (Fig. 0361). Fig. 0361 DSC-0346a 25. Install the other end of the master link through the other end of the chain (Fig. 0360). Fig.
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CHAIN DRIVE/DRIVE SYSTEM 27. Install the clip onto the master chain link to secure (Fig. 0362 and Fig. 0363). 28. Slide the front wheel onto the wheel hub (Fig. 0364). Fig. 0364 Fig. 0362 DSC-0348a Fig.
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CHAIN DRIVE/DRIVE SYSTEM 29. Using a 13/16” socket, install 5 lug nuts to secure the front wheel to the front hub. Torque the lug nuts to 50 ft-lbs. (68 Nm) (Fig. 0365 and Fig. 0366). 30. Position the chain cover to the main frame (Fig. 0367). Fig. 0367 Fig. 0365 DSC-0354a DSC-0352a 31. Using a 1/2” socket, install 2 bolts to secure the chain cover to the main frame (Fig. 0368). Fig. 0366 DSC-0353a Fig.
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CHAIN DRIVE/DRIVE SYSTEM 32. Repeat steps 23 - 31 to install the opposite chain and wheel assembly. 36. Use a 1-1/4” crows foot wrench to torque the 2 jam nuts to 30 ft-lbs. (41 Nm) (Fig. 0371). 33. Turn the front wheel on one side of the traction unit until the upper span of the drive chain is tight. 34. Using a 1-1/8” wrench, turn the two chain tensioning bolts evenly to tighten the chain (Fig. 0369). Fig. 0371 Fig. 0369 DSC-0183a DSC-0590a 37.
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CHAIN DRIVE/DRIVE SYSTEM 38. Torque the 4 nuts to 75 ft-lbs. (102 Nm) (Fig. 0373). Sprocket & Wheel Hub Sprocket & Chain Inspection Note: It is not necessary to raise the machine and remove wheels to inspect the sprockets or chain. 1. Using a 1/2” socket, remove the 2 bolts securing the chain cover to the main frame (Fig. 0374). Fig. 0373 DSC-0588a 39. Apply general purpose oil (10W30) to the upper and lower chain spans. 40.
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CHAIN DRIVE/DRIVE SYSTEM 3. Inspect the chain assembly. Replace if damaged or worn (Fig. 0376). Fig. 0376 DSC-0249a 5. Install the chain cover and tighten the bolts (Fig. 0378 and Fig. 0379). Fig. 0378 DSC-0262a Fig. 0379 DSC-0264a 4. Inspect the front and rear sprockets. If wear is indi cated on the front or rear sprocket, both sprockets and the chain should be replaced (Fig. 0377). Note: The wheel assembly was removed for photo purposes. Fig.
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CHAIN DRIVE/DRIVE SYSTEM 4. Rotate the wheels so the master link on the chain is visible (Fig. 0382). Rear Sprocket & Wheel Hub Removal 1. Raise the machine off the floor. Refer to “Raising the Traction Unit” on page 3/1-1. 2. Using a 1/2” socket, remove the 2 bolts securing the chain cover to the main frame (Fig. 0380). Fig. 0382 Fig. 0380 DSC-0191a DSC-0196 5. Using a 13/16” socket, remove the 5 lug nuts secur ing the rear wheel to the rear hub (Fig. 0383). 3. Remove the chain cover (Fig. 0381).
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CHAIN DRIVE/DRIVE SYSTEM 6. Remove the rear wheel from the rear hub (Fig. 0384). Fig. 0384 DSC-0195a 7. Using a 3/4” socket and wrench, loosen the 4 nuts and bolts securing the axle retaining bracket to the main frame (Fig. 0385). Fig. 0385 8. Using a 1-1/4” wrench, loosen the jam nut on each of the 2 chain tensioning bolts (Fig. 0386). Fig. 0386 9. Using a 1-1/8” socket, loosen the 2 chain tensioning bolts.
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CHAIN DRIVE/DRIVE SYSTEM 10. Remove the clip from the master chain link (Fig. 0388). Fig. 0388 DSC-0196a 12. Remove the master chain link from the chain (Fig. 0390 and Fig. 0391). Fig. 0390 DSC-0200a Fig. 0391 DSC-0201a 11. Remove the retainer from the master chain link (Fig. 0389). Fig.
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CHAIN DRIVE/DRIVE SYSTEM 13. Remove the chain from the wheel sprockets (Fig. 0392). Fig. 0392 15. Place a hub puller (Toro part #TOR6006) onto the hub and secure it with the previously removed lug nuts (tapered end of the lug nuts facing out) (Fig. 0394). DSC-0203a Fig. 0394 14. Loosen the wheel motor shaft nut with a 1-1/2” socket (Fig. 0393). Fig. 0393 16. Using a 1-1/2” socket, pull the hub off the wheel motor shaft (Fig. 0395). DSC-0205a Fig.
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CHAIN DRIVE/DRIVE SYSTEM 17. Remove the lug nuts and remove the hub puller (Fig. 0396). 19. Remove the rear hub assembly (Fig. 0398). Fig. 0398 Fig. 0396 DSC-0216a DSC-0213 18. Remove the wheel motor shaft nut and discard (Fig. 0397). Fig.
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CHAIN DRIVE/DRIVE SYSTEM 3. Remove the sprocket from the rear hub. Discard the hub (Fig. 0401). Sprocket Replacement Sprocket Removal 1. Place the rear hub assembly in a vise (Fig. 0399). Fig. 0399 DSC-0222a 2. Using a 3/4” socket and wrench, remove the 5 bolts and nuts securing the sprocket to the rear hub (Fig. 0400). Fig. 0400 Toro Wheeled CUL Service Manual Note: The hub and wheel motor shaft nut must be discarded and replaced with new. Fig. 0401 DSC-0226a 4. Inspect the sprocket.
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CHAIN DRIVE/DRIVE SYSTEM 3. Torque the 5 bolts and nuts to 75 ft-lbs. (102 Nm) (Fig. 0404). Sprocket Installation 1. Install a sprocket onto the new hub (Fig. 0402). Fig. 0404 Fig. 0402 DSC-0233a DSC-0231a 2. Using a 3/4” socket and wrench, install 5 bolts and nuts to secure the sprocket to the rear hub (Fig. 0403). Fig.
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CHAIN DRIVE/DRIVE SYSTEM Rear Sprocket & Wheel Hub Installation 3. Install the new wheel motor shaft nut and torque to 325 ± 25 ft-lbs. (441 ± 34 Nm) (Fig. 0407). 1. Ensure the wheel motor shaft key is installed (Fig. 0405). Fig. 0407 Fig. 0405 DSC-0240a DSC-0218a 4. Route the chain around the top of the rear wheel sprocket (Fig. 0408).
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CHAIN DRIVE/DRIVE SYSTEM 5. Install the master chain link into one end of the chain (Fig. 0409). Fig. 0409 DSC-0242a 6. Install the other end of the master link through the other end of the chain (Fig. 0410). Fig. 0410 4/1-38 DSC-0243a 7. Install the master link retainer onto the master chain link (Fig. 0411). Fig. 0411 DSC-0244a 8. Install the clip onto the master chain link to secure (Fig. 0412). Fig.
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CHAIN DRIVE/DRIVE SYSTEM 9. Install the wheel and tire assembly (Fig. 0413). Fig. 0413 Toro Wheeled CUL Service Manual 10. Install the lug nuts and torque to 50 ft-lbs. (68 Nm) (Fig. 0414 and Fig. 0415). DSC-0259a Fig. 0414 DSC-0260a Fig.
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CHAIN DRIVE/DRIVE SYSTEM 11. Position the chain cover to the main frame (Fig. 0416). Front Sprocket & Wheel Hub Removal 1. Raise the machine off the floor. Refer to “Raising the Traction Unit” on page 3/1-1. 2. Using a 1/2” socket, remove the 2 bolts securing the chain cover to the main frame (Fig. 0418). Fig. 0416 DSC-0171 12. Using a 1/2” socket, install 2 bolts to secure the chain cover to the main frame (Fig. 0417). Fig. 0418 DSC-0270a 3. Remove the chain cover (Fig. 0419). Fig.
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CHAIN DRIVE/DRIVE SYSTEM 4. Rotate the wheels until the master chain link is visible (Fig. 0420). Fig. 0420 DSC-0119a 5. Using a 13/16” socket, remove the 5 lug nuts secur ing the front wheel to the front hub (Fig. 0421). Fig. 0421 Toro Wheeled CUL Service Manual DSC-0272a 6. Remove the front wheel from the front hub (Fig. 0422). Fig. 0422 DSC-0274a 7. Remove the clip from the master chain link (Fig. 0423). Fig.
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CHAIN DRIVE/DRIVE SYSTEM 8. Remove the retainer from the master chain link (Fig. 0424). Fig. 0424 4/1-42 DSC-0283a 9. Remove the master chain link from the chain (Fig. 0425 and Fig. 0426). Fig. 0425 DSC-0284a Fig.
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CHAIN DRIVE/DRIVE SYSTEM 10. Remove the chain from the front wheel sprocket (Fig. 0427). 12. Remove the bearing protector (Fig. 0429). Fig. 0429 Fig. 0427 11. Remove the bearing protector cap (Fig. 0428). 13. Remove the cotter pin (Fig. 0430). Fig. 0430 Fig.
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CHAIN DRIVE/DRIVE SYSTEM 14. Using a 1-1/8” socket, remove the castle nut (Fig. 0431). 16. Remove the bearing (Fig. 0433). Fig. 0433 Fig. 0431 17. Remove the front hub and sprocket assembly from the axle shaft (Fig. 0434). 15. Remove the washer (Fig. 0432). Fig. 0432 4/1-44 DSC-0300a DSC-0295a DSC-0298a Fig.
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CHAIN DRIVE/DRIVE SYSTEM 18. Place the front hub assembly in a vise and ensure that debris does not get into the opening by placing a rag in it (Fig. 0435). 20. Remove the sprocket from the front hub (Fig. 0437). Fig. 0437 Fig. 0435 DSC-0309a DSC-0305a 21. Inspect the sprocket. If worn or damaged, it must be replaced. 19. Using a 3/4” socket and wrench, remove the 5 bolts and nuts securing the sprocket to the front hub (Fig. 0436). Fig. 0436 Toro Wheeled CUL Service Manual 22.
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CHAIN DRIVE/DRIVE SYSTEM 2. Remove the wheel bearings and inspect them for pitting, galling, or overheating. (Fig. 0440). Front Axle Hub Rebuild Front Axle Hub Assembly (Fig. 0438): A B C D C B Fig. 0440 Fig. 0438 A. Bearing seal B. Bearing (2) IMG-0565a IMG-0562a C. Cup bearing race (2) D. Hub 3. Inspect the cup bearing race for pitting, galling, or overheating (Fig. 0441). 1. Remove the wheel bearing seal (Fig. 0439). Fig. 0441 Fig.
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CHAIN DRIVE/DRIVE SYSTEM 4. If a cup bearing race needs replacing, remove it by tapping it out of the hub with a punch (Fig. 0442). Fig. 0442 IMG-0564a 5. When installing a cup bearing race use a brass punch or soft metal punch to drive it in. Make sure it is seated completely (Fig. 0443). 6. Pack the inner bearing with grease and install to the seal side of the hub (Fig. 0444). Fig. 0444 7. Install the seal with the cupped side facing out (Fig. 0445). Fig. 0445 Fig.
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CHAIN DRIVE/DRIVE SYSTEM 8. Install the seal into the hub until it is square and flush with the top of the bore (Fig. 0446). Front Sprocket & Wheel Hub Installation 1. Install a sprocket onto the hub (Fig. 0447). Fig. 0446 IMG-0570a Fig. 0447 DSC-0310a 9. Pack the other bearing with grease and install to the nut side of the hub. 2. Install 5 bolts and nuts to secure the sprocket to the front hub (Fig. 0448). Fig.
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CHAIN DRIVE/DRIVE SYSTEM 3. Using a 3/4” socket and wrench, torque the 5 bolts and nuts to 75 ft-lbs. (102 Nm) (Fig. 0449). 5. Grease the axle seal surface (Fig. 0451). Fig. 0451 Fig. 0449 6. Install the front hub and sprocket assembly onto the axle (Fig. 0452). 4. Grease the inside of the seal (Fig. 0450). Fig. 0450 Toro Wheeled CUL Service Manual DSC-0322a DSC-0312a DSC-0317a Fig.
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CHAIN DRIVE/DRIVE SYSTEM 7. Install the outer bearing (Fig. 0453). Fig. 0453 9. Install the castle nut (Fig. 0455). DSC-0327a DSC-0329a Fig. 0456 4/1-50 DSC-0330a 10. Using a 1-1/8” socket, tighten the nut to seat the bearings then back it off. Back off nut so first slot in nut aligns with hole in axle (Fig. 0456). 8. Install the washer (Fig. 0454). Fig. 0454 Fig.
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CHAIN DRIVE/DRIVE SYSTEM 11. Install a cotter pin (Fig. 0457). Fig. 0457 13. Using general purpose grease, fill the inner cavity of the hub assembly (Fig. 0459). DSC-0336a Fig. 0459 12. Install the bearing protector (Fig. 0458). Fig. 0458 14. Install the bearing protector cap (Fig. 0460). DSC-0338a Fig.
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CHAIN DRIVE/DRIVE SYSTEM 15. Route the chain around the top of the front wheel sprocket (Fig. 0461). Fig. 0461 DSC-0342a 16. Install the master chain link into one end of the chain (Fig. 0462). Fig. 0462 4/1-52 DSC-0343a 17. Install the other end of the master link through the other end of the chain (Fig. 0463). Fig. 0463 DSC-0345a 18. Install the master link retainer onto the master chain link (Fig. 0464). Fig.
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CHAIN DRIVE/DRIVE SYSTEM 19. Install the clip onto the master chain link to secure (Fig. 0465). Fig. 0465 21. Using a 13/16” socket, install 5 lug nuts to secure the rear wheel to the rear hub. Torque the lug nuts to 50 ft-lbs. (68 Nm) (Fig. 0467). DSC-0349a Fig. 0467 20. Slide the front wheel onto the wheel hub (Fig. 0466). Fig. 0466 22. Position the chain cover to the main frame (Fig. 0468). DSC-0351a Fig.
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CHAIN DRIVE/DRIVE SYSTEM 23. Using a 1/2” socket, install 2 bolts to secure the chain cover to the main frame (Fig. 0469). Checking the Drive Chain Tension 1. With the bucket installed, lower it until it raises the front tires off of the ground. 2. Stop the engine and remove the key. 3. Turn the front wheel forward on one side of the traction unit until the top span of the drive chain is tight. 4. Measure the distance between the bottom of the chain guard and the lower chain span (Fig. 0470). Fig.
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CHAIN DRIVE/DRIVE SYSTEM Adjusting the Drive Chain Tension 1. With the bucket installed, lower it until it raises the front tires off of the ground. 2. Stop the engine and remove the key. 5. Turn the front wheel on one side of the traction unit until the upper span of the drive chain is tight. 6. Adjust the chain tensioning bolt until the distance between the bottom of the chain guard and the lower chain span is within 1-1/2” to 2-1/2” (3.8 to 6.35cm) (Fig. 0473). 3.
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CHAIN DRIVE/DRIVE SYSTEM 8. Tighten the nuts securing the axle retaining bracket to the frame. Torque them to 75 ft-lbs. (102 Nm) (Fig. 0475). Wheel Motor Replacement Wheel Motor Removal Note: Upon removal, all seals, o-rings and gaskets should be replace. During installation, lightly lubricate all seals, o-rings and gaskets with clean petroleum jelly prior to assembly. Note: The following procedures show removal of the left wheel motor.
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CHAIN DRIVE/DRIVE SYSTEM 5. Using a 13/16” socket, remove the 5 lug nuts that secure the rear wheel to the rear hub (Fig. 0479). 3. Remove the chain cover (Fig. 0477). Fig. 0477 DSC-0357a Fig. 0479 4. Rotate the wheels until the master link on the chain is visible (Fig. 0478). Fig. 0478 6. Remove the rear wheel from the rear hub (Fig. 0480). DSC-0119 Fig.
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CHAIN DRIVE/DRIVE SYSTEM 7. Remove the clip from the master chain link (Fig. 0481). Fig. 0481 DSC-0362a 8. Remove the retainer from the master chain link (Fig. 0482). Fig. 0482 4/1-58 DSC-0363a 9. Remove the master chain link from the chain (Fig. 0483). Fig. 0483 DSC-0364a 10. Remove the chain from the rear wheel sprocket (Fig. 0484). Fig.
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CHAIN DRIVE/DRIVE SYSTEM 11. Using a 1-1/2” socket, loosen the lock nut from the wheel motor shaft (Fig. 0485). Fig. 0485 DSC-0369a 12. Slide a wheel hub puller (Toro part no. TOR6006) onto the wheel hub studs (Fig. 0486). Fig. 0486 Toro Wheeled CUL Service Manual DSC-0370a 13. Install the 5 lugs nuts backward (taper side facing out) onto the studs (Fig. 0487). Fig. 0487 DSC-0371a 14. Using a 1-1/2” socket, break the hub assembly free of the wheel motor shaft (Fig. 0488). Fig.
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CHAIN DRIVE/DRIVE SYSTEM 15. Remove the puller from the hub. 18. Position a drain pan under the wheel motor. 16. Remove the lock nut from the wheel motor shaft and discard (Fig. 0489). 19. Mark the hydraulic line nut on the front port of the counterbalance valve with a “C” (Fig. 0491). Fig. 0489 DSC-0373a 17. Remove the hub and sprocket assembly from the wheel motor shaft (Fig. 0490). Fig. 0490 Fig. 0491 20.
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CHAIN DRIVE/DRIVE SYSTEM 21. Using a 1-1/8” offset wrench, remove the hydraulic line from the front wheel motor fitting (Fig. 0493). Fig. 0493 23. Using a 1-1/8” offset wrench, loosen the hydraulic line nut from the rear counterbalance valve fitting (Fig. 0495). DSC-0383a Fig. 0495 22. Remove the hydraulic line (Fig. 0494). Fig. 0494 24. Using a 1-1/8” offset wrench, remove the hydraulic line from the rear wheel motor fitting (Fig. 0496). DSC-0388a Fig.
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CHAIN DRIVE/DRIVE SYSTEM 25. Using a 1-1/16” socket, remove both fittings from the wheel motor ports (Fig. 0497). Fig. 0497 DSC-0395a 26. Cap the hydraulic line, counterbalance valve fitting and wheel motor ports to prevent debris from contaminating the system (Fig. 0498). 27. Support the wheel motor with a floor jack (Fig. 0499). Fig. 0499 28. Using a 3/4” socket, remove the 4 bolts securing the wheel motor housing to the main frame (Fig. 0500). Fig. 0500 Fig.
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CHAIN DRIVE/DRIVE SYSTEM 29. With the wheel motor resting on the floor jack, slide the floor jack toward the opposite side of the machine to remove the wheel motor from the main frame (Fig. 0501). Lower the floor jack and slide it out from under the machine to remove the wheel motor (Fig. 0502). Fig. 0501 DSC-0404a Fig. 0502 DSC-0405a 30. To service the existing wheel motor, refer to the Parker Hydraulics Service Manual (Toro Form No. 492-4753).
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CHAIN DRIVE/DRIVE SYSTEM 3. Position the wheel motor shaft through the opening in the frame (Fig. 0505). Wheel Motor Installation 1. Set the wheel motor onto a floor jack with the ports facing up (Fig. 0503). Fig. 0505 Fig. 0503 DSC-0405a 2. Slide the floor jack under the machine. Raise the floor jack and angle the wheel motor shaft up (Fig. 0504). 4.
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CHAIN DRIVE/DRIVE SYSTEM 5. Loosely install 4 wheel motor mounting bolts (Fig. 0507). Fig. 0507 8. Position the previously removed hydraulic line (marked “C”) to the counterbalance valve and front wheel motor fitting (Fig. 0509). DSC-0411a Fig. 0509 6. Remove the floor jack. 7. Remove plugs from ports and fittings. Using a 1-1/16” socket, install 2 fittings into the wheel motor ports (Fig. 0508). 9. Loosely install the hydraulic line nut to the front wheel motor fitting (Fig. 0510). Fig. 0510 Fig.
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CHAIN DRIVE/DRIVE SYSTEM 10. Position the other hydraulic line to the rear wheel motor fitting and loosely install the hydraulic line nut to the rear wheel motor fitting (Fig. 0511). Fig. 0511 DSC-0421a 11. Using a 1-1/8” offset wrench, tighten the hydraulic line nut to the rear counterbalance valve fitting (Fig. 0512). Fig. 0512 4/1-66 DSC-0423a 12. Using a 1-1/8” offset wrench, loosely install the hydraulic line nut marked with a “C” to the front counterbalance valve fitting (Fig. 0513). Fig.
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CHAIN DRIVE/DRIVE SYSTEM 14. Using a 1-1/8” offset wrench, tighten the hydraulic line nut to the front counterbalance valve fitting (Fig. 0515). 16. Start the engine. Operate the machine slowly in forward and reverse motion to purge the air from the hydraulic drive circuit. 17. Check for leaks at the hydraulic connections. 18. Turn off the engine and remove the key. 19. Place the rear hub assembly in a vise (Fig. 0517). Fig. 0515 DSC-0426a 15.
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CHAIN DRIVE/DRIVE SYSTEM 21. Remove the sprocket from the rear hub. Discard the hub (Fig. 0519). Fig. 0519 DSC-0226a 22. Place a new hub in a vise. 23. Position the sprocket onto the new hub (Fig. 0520). 24. Install 5 bolts and nuts to secure the sprocket to the hub (Fig. 0521). Fig. 0521 25. Using a 3/4” socket and wrench, torque the 5 bolts and nuts to 75 ft-lbs. (102 Nm) (Fig. 0522). Fig. 0522 Fig.
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CHAIN DRIVE/DRIVE SYSTEM 26. Ensure the wheel motor shaft key is installed (Fig. 0523). Fig. 0523 DSC-0218a Note: Prior to installing the drive hub, make sure the wheelmotor shaft and inner drive hub are clean, degreased and free of paint to ensure a proper fit-up and positioning between the drive hub and wheel motor shaft. 28. Install a new nut onto the wheel motor shaft (Fig. 0525). Fig. 0525 DSC-0435a 29. Using a 1-1/2” socket, torque the wheel motor nut to 323 ± 25 ft-lbs. (441 ± 34 Nm) (Fig.
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CHAIN DRIVE/DRIVE SYSTEM 30. Route the chain around the top of the rear wheel sprocket (Fig. 0527). Fig. 0527 DSC-0438a 32. Install the master link retainer onto the master chain link (Fig. 0529). Fig. 0529 DSC-0442a 31. Install the master link into the ends of the chain (Fig. 0528). Fig.
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CHAIN DRIVE/DRIVE SYSTEM 33. Install the clip onto the master chain link to secure (Fig. 0530 and Fig. 0531). Fig. 0530 DSC-0443 34. Slide the wheel and tire assembly onto the wheel hub studs (Fig. 0532). Fig. 0532 DSC-0259a 35. Install the 5 lug nuts (Fig. 0533). Fig. 0531 DSC-0445 Fig.
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CHAIN DRIVE/DRIVE SYSTEM 36. Using a 3/4” socket, torque the 5 lug nuts to 50 ftlbs. (68 Nm) (Fig. 0534). Fig. 0534 38. Using a 1/2” socket, install 2 bolts to secure the chain cover to the main frame (Fig. 0536). DSC-0261a 37. Position the chain cover to the main frame (Fig. 0535). Fig. 0536 DSC-0176a 39. Check and adjust the drive chain tension. Refer to “Checking the Drive Chain Tension” on page 4/1-54. 40. If the right wheel motor was installed, reinstall the battery.
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CHAIN DRIVE/HYDRAULICS Counterbalance Valve Replacement 5. Secure each loader arm cylinder lock with a clevis pin and hairpin cotter (Fig. 0539). Counterbalance Valve Removal Note: Upon removal, all seals, o-rings and gaskets should be replace. During installation, lightly lubricate all seals, o-rings and gaskets with clean petroleum jelly prior to assembly. 1. Raise the loader arms to the fully raised position. 2. Turn off the engine and remove the key. 3.
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CHAIN DRIVE/HYDRAULICS 8. Remove the battery from the frame (Fig. 0541). Fig. 0541 DSC-0458a 9. Using a 1/2” wrench and socket, remove the nut from the fuel tank mounting bolt (Fig. 0542). 10. Remove the fuel tank mounting bolt (Fig. 0543). Fig. 0543 11. Remove the fuel tank mounting plate (Fig. 0544). Fig. 0544 Fig.
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CHAIN DRIVE/HYDRAULICS 12. Remove the fuel tank and set it on the operator’s stand (Fig. 0545). Fig. 0545 14. Using a 1-1/8” offset wrench, remove the hydraulic line nut from the front upper counterbalance valve fitting (Fig. 0547). DSC-0469a Fig. 0547 13. Using a 1-1/8” offset wrench, remove the hydraulic line nut from the rear upper counterbalance valve fitting (Fig. 0546). Fig. 0546 15.
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CHAIN DRIVE/HYDRAULICS 16. Using a 1-1/8” offset wrench, loosen the hydraulic line nut from the front wheel motor fitting. Swing the hydraulic line away from the counterbalance valve so the lower rear counterbalance valve nut can be accessed (Fig. 0549). 18. Using a 7/16” wrench and socket, remove the nut from the bolt securing the counterbalance valve to the frame (Fig. 0551). Fig. 0551 Fig. 0549 DSC-0482a DSC-0479a 17.
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CHAIN DRIVE/HYDRAULICS 19. Remove the counterbalance valve mounting bolt, washer and spacer (Fig. 0552). Fig. 0552 DSC-0488a Note: The spacer is located between the counter balance valve and the frame (Fig. 0553). Fig. 0553 20. Remove the counterbalance valve from the machine (Fig. 0554). Fig. 0554 21. Transfer the hydraulic fittings from the old counter balance valve to the new counterbalance valve (Fig. 0555). DSC-0487a Fig.
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CHAIN DRIVE/HYDRAULICS 3. Loosely install the hydraulic line nut to the rear upper counterbalance valve fitting (Fig. 0558). Counterbalance Valve Installation 1. Position the counterbalance valve into the machine aligning the valve fittings with the existing hydraulic lines (Fig. 0556). Fig. 0558 Fig. 0556 DSC-0497a DSC-0490a 4. Loosely install the hydraulic line nut to the front upper counterbalance valve fitting (Fig. 0559). 2.
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CHAIN DRIVE/HYDRAULICS 5. Using a 1-1/8” offset wrench, tighten the hydraulic line nut securing the hydraulic line to the lower rear counterbalance valve fitting (Fig. 0560). 7. Insert the spacer between the counterbalance valve and frame (Fig. 0562). Fig. 0562 Fig. 0560 6. Swing the hydraulic line (coming from the wheel motor) into position so it aligns with the lower front counterbalance valve fitting. Loosely install the hydraulic line nut to the lower front counterbalance valve fitting (Fig. 0561).
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CHAIN DRIVE/HYDRAULICS 9. Using a 7/16” wrench and socket, install a nut onto the counterbalance valve mounting bolt (Fig. 0564). 12. Position the fuel tank mount plate (Fig. 0566). Fig. 0566 Fig. 0564 DSC-0506a DSC-0482a 13. Install the fuel tank mount bolt (Fig. 0567). 10. Using a 1-1/8” offset wrench, tighten the 3 remaining hydraulic line nuts to the counterbalance valve fittings and the hydraulic line nut to the front wheel motor fitting. 11.
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CHAIN DRIVE/HYDRAULICS 14. Using a 1/2” wrench and socket, install a nut onto the fuel tank mount bolt (Fig. 0568). Fig. 0568 16. Position the battery clamp onto the battery and against the frame. Install a wing nut, washer and carriage bolt securing the battery clamp to the frame. Connect the positive and then the negative battery cable to the battery (Fig. 0570). DSC-0465a Fig. 0570 DSC-0457a 15. Position the battery into the frame (Fig. 0569). 17.
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CHAIN DRIVE/HYDRAULICS 19. Remove the loader arm cylinder locks from the cylinder rods (Fig. 0572). 21. Lower the loader arms. 22. Check the hydraulic fluid level. Fill the hydraulic tank per specifications. 23. Turn the machine on and run it to purge air from the system. Check for leaks. 24. Turn the engine off. 25. Check and add hydraulic fluid to the hydraulic tank as required. Fig. 0572 DSC-0452a 20. Reinstall the loader arm cylinder locks onto the hydraulic auxiliary lines (for storage) (Fig.
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CHAIN DRIVE/HYDRAULICS 3. Remove the bolt and lock washer securing the left control arm to the 4-spool valve. Remove the left control arm (Fig. 0576). 4-Spool Valve Replacement 4-Spool Valve Removal Note: Upon removal, all seals, o-rings and gaskets should be replace. During installation, lightly lubricate all seals, o-rings and gaskets with clean petroleum jelly prior to assembly. 1. Remove the 4 screws retaining the cover plate around the 4-Spool Valve (Fig. 0574). Fig. 0576 DSC-2849a 4.
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CHAIN DRIVE/HYDRAULICS 5. Place and absorbent towel under the 4-spool valve. 8. Remove both left hand counterbalance valve hy draulic line nuts from the 4-spool valve (Fig. 0580). 6. Remove the hydraulic line from the machine (Fig. 0578). Fig. 0580 Fig. 0578 PICT-9996a 7. Remove the hydraulic line nut from the fitting located on the right hand side of the 4-spool valve (Fig. 0579). 9. Remove the 2 hydraulic cylinder line T-fittings from the fittings on the 4-spool valve (Fig. 0581). Fig. 0581 Fig.
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CHAIN DRIVE/HYDRAULICS 10. Remove both right hand counterbalance valve hy draulic line nuts from the 4-spool valve (Fig. 0582). Fig. 0582 12. Remove the auxiliary valve hydraulic line nut and the auxiliary relief hydraulic line nut from the 4-spool valve T-fitting (Fig. 0584). DSC-2834a Fig. 0584 11. Remove the 2 hydraulic tilt cylinder lines from the 4-spool valve (Fig. 0583). Fig. 0583 13. Remove the 2 bolts securing the manual tube r-clamps to the control panel (Fig. 0585).
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CHAIN DRIVE/HYDRAULICS 14. Remove the manual tube assembly. 17. Remove the auxiliary relief hydraulic line (Fig. 0588). 15. Remove the third bolt and 2 washers securing the 4-spool valve assembly to the control panel (Fig. 0586). Fig. 0588 Fig. 0586 DSC-2739a DSC-2742a 18. Remove the 4-spool valve from the machine (Fig. 0589). 16. Lower the 4-spool valve and loosen the hydraulic line nut from the auxiliary relief fitting (Fig. 0587). Fig. 0589 Fig.
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CHAIN DRIVE/HYDRAULICS 19. Loosen the jam nut and set screw on the 3 remain ing handles (Fig. 0590). Fig. 0590 DSC-2753a 20. Remove the 3 remaining handles from the 4-spool valve (Fig. 0591). Fig. 0591 Toro Wheeled CUL Service Manual DSC-2750a 21. Remove the 2 bolts and spacer blocks from one end of the 4-spool valve (Fig. 0592). Fig. 0592 DSC-2764a 22. Remove the bolt and spacer block from the other end of the 4-spool valve (Fig. 0593). Fig.
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CHAIN DRIVE/HYDRAULICS 23. Remove the relief valve from the 4-spool valve (Fig. 0594). Fig. 0594 25. If the 4-spool valve is being serviced, remove all the fittings before servicing (Fig. 0596). To service the 4-spool valve, refer to “105-6246 4-Spool Valve Rebuild (Chain Drive)” on page 3/1-33. DSC-2773a Fig. 0596 DSC-2779a 24. Remove the relief valve o-ring from the 4-spool valve (Fig. 0595). Fig.
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CHAIN DRIVE/HYDRAULICS 26. If the 4-Spool valve is being replaced, transfer all the fittings and markings to the new 4-Spool valve. 4-Spool Valve Installation 1. Before installing the 4-Spool valve back in the frame, leave the two 90º fittings loose (Fig. 0598). 4-Spool Valve (Fig. 0597): B C D E F A G C D E F Fig. 0597 A. B. C. D. E. F. G.
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CHAIN DRIVE/HYDRAULICS 3. Install the relief valve assembly on the 4-spool valve housing (Fig. 0600). Fig. 0600 5. Install the 4 handles. Adjust the 2 drive handles so they are at the same height and adjust the 2 lift handles so they are at equal heights (Fig. 0602). DSC-2786a Fig. 0602 4. Loosely install the 3 spacers and bolts to the valve body (Fig. 0601). DSC-2804a 6. Tighten the jam nuts on the three levers (Fig. 0603). Note: The different size spacer is located at the top. Fig. 0603 Fig.
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CHAIN DRIVE/HYDRAULICS 7. Remove the left control lever assembly that routes under the drive lever controls (Fig. 0604). 9. Insert the 4-spool Valve through the front opening of the frame up into the upper frame assembly and rest on top of air cleaner assembly (Fig. 0606). Note: This will be reinstalled after the 4-spool valve is installed and the hydraulic lines are connected. Fig. 0606 Fig. 0604 DSC-2816a DSC-2806a 10. Route the auxiliary relief valve metal line around the choke cable (Fig. 0607).
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CHAIN DRIVE/HYDRAULICS 11. Loosely install the relief valve hydraulic line nut on the longer end of the hydraulic line to the relief valve (Fig. 0608). 13. Loosely install a bolt and washer through the upper frame into the spool valve (Fig. 0610). Fig. 0610 Fig. 0608 12. Thread the nut on the other end of the auxiliary relief valve line to the T-fitting on the 4-spool valve (Fig. 0609). Tighten both nuts on the auxiliary relief valve hydraulic line. 14.
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CHAIN DRIVE/HYDRAULICS 15. Install the auxiliary valve hydraulic line nut to the 4-spool valve t-fitting (Fig. 0612). Fig. 0612 DSC-2729a 16. Install the 2 hydraulic tilt cylinder lines to the 4-spool valve (Fig. 0613). 17. Install all 4 counterbalance valve hydraulic lines to the 4-spool valve fittings (Fig. 0614). Fig. 0614 DSC-2834a 18. Install the two hydraulic lift cylinder t-fittings to the 4-spool valve fittings (Fig. 0615).
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CHAIN DRIVE/HYDRAULICS 19. Tighten the 3 bolts securing the 4-spool valve to the spacer blocks and the 3 bolts securing the 3 spacer blocks to the control panel (Fig. 0616). 21. Position the test port hydraulic line to the selector valve fitting and the fitting on the left side of the 4-spool valve. Install the two hydraulic line nuts to secure (Fig. 0618 and Fig. 0619). Note: The fitting on the selector valve may need to be loosened to position the hydraulic hard line.
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CHAIN DRIVE/HYDRAULICS 22. Position the lift arm lever to the 4-spool valve. Install a bolt and lock washer to secure (Fig. 0620). Fig. 0620 DSC-2849a 23. Position the control panel plate on the control panel (Fig. 0621). 24. Install 4 screws to secure the plate to the control panel (Fig. 0622). Fig. 0622 DSC-2852a 25. Check the hydraulic fluid level and add if necessary. 26. Start the machine and check for leaks. 27. Purge air from the system. 28.
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CHAIN DRIVE/HYDRAULICS Hydraulic Filter Head Replacement 3. Remove the hydraulic fluid return hose from the fitting (Fig. 0625). Hydraulic Filter Head Removal 1. Start the unit, raise the lift arm all the way up and install the cylinder locks (Fig. 0623). Lower the lift arm cylinder onto the locks. Fig. 0625 DSC-2936a 4. Remove the hydraulic fluid filter from the filter head assembly (Fig. 0626). Fig. 0623 DSC-2932a 2.
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CHAIN DRIVE/HYDRAULICS 5. Loosen the straight fitting (Fig. 0627). Fig. 0627 7. Remove the straight fitting and the 45º elbow fitting from the filter head assembly (Fig. 0629). DSC-2939a Fig. 0629 DSC-2954a 6. Remove the filter head assembly from the hydraulic tank return port (Fig. 0628). Fig.
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CHAIN DRIVE/HYDRAULICS 3. Tighten the straight fitting with a wrench (Fig. 0632). Hydraulic Filter Head Installation 1. Install the straight fitting and the 45º elbow fitting (leave loose, do not tighten) on the filter head assembly (Fig. 0630). Note: The body of the filter head assembly has arrows on it. The arrows should be pointing toward the straight fitting. Fig. 0632 DSC-2939a 4. With the hose clamp on the hydraulic fluid return hose, slide the hydraulic fluid return hose on the 45º elbow fitting.
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CHAIN DRIVE/HYDRAULICS 5. Position and tighten the hose clamp securing the hydraulic fluid return hose to the 45º elbow fitting (Fig. 0634). 8. Clean up any spilled fluid. 9. Start the engine and let it run for about two minutes to purge air from the system. 10. Stop the engine and check for leaks. 11. Check the fluid level in the hydraulic tank. If necessary, add hydraulic fluid to raise the level to between the marks on dipstick. 12. Do not over-fill the tank. 13. Start the unit and raise the lift arm.
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CHAIN DRIVE/HYDRAULICS 2. Tag or mark the 2 selector valve hydraulic lines and the 2 auxiliary valve hydraulic lines (Fig. 0638). Auxiliary Valve & Selector Valve Replacement Auxiliary Valve & Selector Valve Removal Note: The auxiliary valve and selector valve are removed as an assembly (Fig. 0636). C D A A B B Fig. 0638 A. B. C. D. Fig. 0636 A.
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CHAIN DRIVE/HYDRAULICS 4. Remove the tie strap that holds the two hydraulic hoses to the fitting between the two valves (Fig. 0640). Fig. 0640 PICT-9943a 5. Remove the hydraulic hard line connected to the 90º fitting located on the left side of the selector valve (Fig. 0641). 6. Remove the hydraulic hard line connected to the 90º fitting located on the right side of the auxiliary valve (Fig. 0642). Fig. 0642 7.
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CHAIN DRIVE/HYDRAULICS 8. Remove the auxiliary valve and selector valve assembly from the upper frame (Fig. 0644). 10. Separate the valves from the straight fitting (Fig. 0646). A Fig. 0644 PICT-9952a C B Fig. 0646 A. Auxiliary valve B. Selector valve PICT-9957a C. Straight Fitting 9. Loosen the jam nut on the straight fitting located between the valves (Fig. 0645). 11. Remove the Auxiliary bracket from the auxiliary valve (Fig. 0647). Fig. 0645 PICT-9954a Fig.
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CHAIN DRIVE/HYDRAULICS 12. Remove the two screws and washer securing the auxiliary lever and mount to the valve (Fig. 0648). Auxiliary Valve & Selector Valve Installation 1. Loosely install the auxiliary lever and mount to the auxiliary valve with a bolt and washer. Note: The washer is located between the auxiliary mount and the auxiliary valve (Fig. 0649). Fig. 0648 PICT-9961a Fig. 0649 PICT-9970a 2. Loosely install a second bolt through the auxiliary mount and into the valve spool (Fig. 0650). Fig.
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CHAIN DRIVE/HYDRAULICS 3. Position the auxiliary bracket over the handle and onto the auxiliary valve (Fig. 0651). 5. Loosely install the selector valve onto the straight fitting (Fig. 0653). Note: Do not tighten at this point. You may need to adjust the spacing between the two valves to match the mounting holes on the machine. Fig. 0651 PICT-9959a 4. Install the straight fitting into the auxiliary valve (Fig. 0652). Fig. 0653 PICT-9973a 6.
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CHAIN DRIVE/HYDRAULICS 7. Position two short spacers between the auxiliary valve and the auxiliary bracket. Insert two bolts through the auxiliary valve, spacers and bracket (Fig. 0655). Fig. 0655 PICT-9977a 9. Install and tighten the hydraulic metal lines to the fittings on the auxiliary and selector valve (Fig. 0657 and Fig. 0658). Tighten the straight fitting between the two valves. Fig. 0657 PICT-9944a Fig. 0658 PICT-9947a 8. Position the valve assembly to the upper frame (Fig. 0656).
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CHAIN DRIVE/HYDRAULICS 10. Tighten the 4 bolts, spacers, washers, nuts securing the valve assembly to the upper frame (Fig. 0659). Fig. 0659 PICT-9980a 11. Install the hydraulic lines to the auxiliary valve (Fig. 0660). Fig. 0660 12. Install the hydraulic lines to the selector valve Fig. 0661). Fig. 0661 13. Install a tie strap around the two tilt cylinder hydrau lic lines and the straight fitting between the auxiliary and selector valves. Tighten and trim the excess (Fig. 0662).
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CHAIN DRIVE/HYDRAULICS 14. Plug the auxiliary valve safety switch into the harness connector (Fig. 0663). Lift Cylinder Replacement Lift Cylinder Removal A 1. Start the unit and raise the lift arm all the way up. Install a cylinder lock on the cylinder that you are not removing (Fig. 0664). B Fig. 0663 A. Switch PICT-9936 B. Harness Plug 15. Check the hydraulic fluid level. Add fluid if necessary. Fig. 0664 DSC-2889a 16. Start and run the machine to purge air from the system. 2.
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CHAIN DRIVE/HYDRAULICS 4. Remove the hydraulic hose from the upper fitting on the hydraulic cylinder (Fig. 0666). Fig. 0666 DSC-2894a Note: Install a plug and cap on the hose and cylinder fittings to help stop any oil leakage and prevent debris from entering the system (Fig. 0667). 5. Remove the hydraulic hose from the lower fitting on the hydraulic cylinder (Fig. 0668). Fig. 0668 6. Remove the shoulder bolt securing the upper pivot pin to the cylinder (Fig. 0669). Fig. 0669 Fig.
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CHAIN DRIVE/HYDRAULICS 7. Remove the pivot pin from the cylinder/loader arm pivot point (Fig. 0670). Fig. 0670 DSC-2906a 8. Remove the shoulder bolt securing the lower pivot pin to the cylinder (Fig. 0671). Fig. 0671 Toro Wheeled CUL Service Manual DSC-2907a 9. Remove the pivot pin from the main frame/cylinder pivot point (Fig. 0672). Fig. 0672 DSC-2908a 10. Remove the hydraulic cylinder from the machine (Fig. 0673). Fig.
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CHAIN DRIVE/HYDRAULICS 11. Remove the two 90º fittings from the lift cylinder (Fig. 0674 and Fig. 0675). Lift Cylinder Installation 1. Install the 2 hydraulic fittings in the lift cylinder. Position the fittings so they are facing each other (Fig. 0676). Note: The marked fitting goes into the port on the ram end of the cylinder barrel. Fig. 0674 DSC-2914a Fig. 0676 DSC-2916a 2. Position the lift cylinder in the machine with the ram end facing up (Fig. 0677). Fig. 0675 DSC-2915a 12.
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CHAIN DRIVE/HYDRAULICS 3. Align the barrel end of the cylinder with the main frame pivot point. Insert the pivot pin (Fig. 0678). 5. Install both hydraulic lines to the lift cylinder fittings. Ensure the marked hydraulic line is attached to the marked fitting (Fig. 0680). Note: Use double wrenches to prevent the fittings from spinning. Fig. 0678 DSC-2908a 4. Install a shoulder bolt to secure the pivot pin. Torque the shoulder bolt to 150 - 179 in-lbs (17 - 20 Nm) (Fig. 0679). Fig.
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CHAIN DRIVE/HYDRAULICS 6. Align the ram end of the cylinder with the loader arm pivot point. Insert the pivot pin into the pivot point (Fig. 0681). 8. Grease the top and bottom pivot pins and bushing assemblies (Fig. 0683). Note: If the holes on the ram end of the cylinder and the lift arm pivot point are not aligned, start the unit and raise the lift arm. Remove the cylinder lock and carefully align the holes so that the pivot pin can be installed.
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CHAIN DRIVE/HYDRAULICS Tilt Cylinder Replacement (New Style) 2. Support the attach plate. Remove the pivot pin from the tilt cylinder/attach plate pivot (Fig. 0686). A B Fig. 0684 A. New style tilt cylinder DSC-3929a Fig. 0686 DSC-2855a B. Old style tilt cylinder 3. Remove the cable tie securing the hydraulic lines to the tilt cylinder barrel (Fig. 0687). Tilt Cylinder Removal 1. Remove the shoulder bolt from the lower pivot pin (Fig. 0685). Fig. 0687 Fig.
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CHAIN DRIVE/HYDRAULICS 4. Position a drain pan under the front of the machine. Remove the hydraulic lines from the tilt cylinder fittings (Fig. 0688). Allow the hydraulic fluid to drain into the drain pan. 6. Remove the pivot pin and the tilt cylinder from the machine (Fig. 0690). Fig. 0690 Fig. 0688 DSC-2864a DSC-2859a 5. Remove the shoulder bolt from the upper pivot pin (Fig. 0689). Fig.
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CHAIN DRIVE/HYDRAULICS 7. Remove the two 90º fittings from the tilt cylinder (Fig. 0691 and Fig. 0692). Tilt Cylinder Installation 1. Install the 2 hydraulic fittings in the tilt cylinder. Orientate the fittings so they face away from the ram end of the cylinder (Fig. 0693). Fig. 0691 DSC-2867a Fig. 0693 DSC-2874a 2. Position the barrel end of the tilt cylinder to the loader arm. Install a pivot pin (Fig. 0694). Fig. 0692 DSC-2868a 8.
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CHAIN DRIVE/HYDRAULICS 3. Install a shoulder bolt to secure the pivot pin. Torque the shoulder bolt to 150 – 170 in-lbs. (17 - 20 Nm) (Fig. 0695). 5. Lift the attach plate and align the cylinder ram to the attach plate. Install a pivot pin (Fig. 0697). Fig. 0697 Fig. 0695 DSC-2855a DSC-2877a 4. Install the hydraulic lines to the tilt cylinder fittings (Fig. 0696). 6. Install a shoulder bolt to secure the pivot pin. Torque the shoulder bolt to 150 – 170 in-lbs. (17 – 20 Nm) (Fig. 0698).
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CHAIN DRIVE/HYDRAULICS 7. Install a cable tie around the cylinder barrel and hydraulic lines to secure (Fig. 0699). 10. Check the hydraulic fluid and add as necessary. 11. Start the machine and purge the air from the system. Check for leaks. 12. Check the hydraulic fluid and add as necessary. Fig. 0699 DSC-2884a 8. Remove the drain pan. 9. Grease the upper and lower pivot pin and bushing assemblies (Fig. 0700). Fig.
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CHAIN DRIVE/LOADER ARM 4. Using a 1/2” socket, remove the 3 bolts retaining the 3 pivot pins to the attach plate (Fig. 0703). Loader Arm Replacement Loader Arm Removal 1. Raise the loader arm 6” - 8” (15 - 20cm) away from frame and position attach plate flat (horizontally) (Fig. 0701). Fig. 0703 DSC-1383w 5. Remove the center pivot pin (Fig. 0704). Fig. 0701 DSC-1380a 2. 4-Paw machines: Remove the hood. 3. Support the attach plate with a floor jack (Fig. 0702). Fig. 0704 Fig.
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CHAIN DRIVE/LOADER ARM 6. Remove the RH and LH pivot pins (Fig. 0705 and Fig. 0706). 7. Remove the attach plate (Fig. 0707). Fig. 0707 Fig. 0705 DSC-1395w DSC-1392w 8. Using a 1/2” socket, remove the bolt securing the upper tilt cylinder pivot pin to the tilt cylinder (Fig. 0708). Fig. 0706 DSC-1394w Fig.
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CHAIN DRIVE/LOADER ARM 9. Remove the upper pivot pin (Fig. 0709). Note: Support the cylinder with one hand as you remove the upper pivot pin. 11. Mark the hydraulic lines to the flush face couplers with an M for male and F for female relating to the couplers (Fig. 0711). Fig. 0711 Fig. 0709 DSC-1403a DSC-1401w 10. Lay the tilt cylinder alongside the unit (Fig. 0710). 12. Place an oil pan underneath the couplers to catch drainage. 13.
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CHAIN DRIVE/LOADER ARM 14. Using a 1-18” wrench remove the hydraulic line to the female (F) flush face coupler (Fig. 0713). 15. Using a 1-1/4” wrench and 1-5/16” wrench remove the nut from the male flush face coupler (Fig. 0714) and remove the male flush face coupler (Fig. 0715). Note: Use a plug to protect the line from contami nation. Fig. 0713 4/3-4 Fig. 0714 DSC-1411a Fig.
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CHAIN DRIVE/LOADER ARM 16. Using a 1-5/16” wrench remove the nut from the female flush face coupler (Fig. 0716) and remove the female flush face coupler (Fig. 0717). Fig. 0716 17. Remove the drain pan. 18. Using a properly rated strap or chain and hoist, support the cross-member of the loader arm (Fig. 0718). DSC-1414a Fig. 0718 DSC-1418a 19.
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CHAIN DRIVE/LOADER ARM 20. Remove the left and right lift cylinder pin from the loader arm (Fig. 0720). Fig. 0720 DSC-1422a 22. Remove the loader arm from the machine (Fig. 0722). Fig. 0722 DSC-1425a 21. Remove the left and right loader arm pivot pin from the frame (Fig. 0721). Fig.
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CHAIN DRIVE/LOADER ARM 3. Inspect the attach plate for wear or damage. Re place as necessary (Fig. 0725). Loader Arm Installation 1. Inspect the loader arm and pivot pins for wear or damage. Replace as necessary (Fig. 0723). Fig. 0725 Fig. 0723 DSC-1448a 2. Inspect the hydraulic cylinder yolks for wear or damage. Replace as necessary (Fig. 0724). 4. Install the loader arm onto the unit, aligning the pivot points on the loader arm with the pivot points on the upper frame (Fig. 0726). Fig. 0726 Fig.
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CHAIN DRIVE/LOADER ARM 5. Install a pivot pin through the frame and loader arm pivot point (Fig. 0727). Fig. 0727 8. Repeat for the opposite side. 9. Using a 1/2” socket, install 4 bolts to secure the pivot pins to the upper frame and lift cylinders on both sides of the machine. Torque the bolts to 19 ft-lbs. (26 Nm) (Fig. 0729 and Fig. 0730). DSC-1462a 6. Repeat for the opposite side. Fig. 0729 DSC-1466a Fig. 0730 DSC-1467a 7.
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CHAIN DRIVE/LOADER ARM 10. Remove the support from the loader arm. 11. Position the female flush face coupler into the out side hole of the coupler bracket on the loader arm (Fig. 0731). Fig. 0731 Note: Upon removal, all seals, o-rings and gaskets should be replaced. During installation, lightly lubricate all seals, o-rings and gaskets with clean petroleum jelly prior to assembly. 13. Position the male flush face coupler into the coupler bracket on the loader arm (Fig. 0733). DSC-1468a Fig. 0733 12.
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CHAIN DRIVE/LOADER ARM 15. Using a 1-1/8” wrench install the hydraulic line (F) to the female flush face coupler (Fig. 0735). Fig. 0735 17. With the fittings facing up toward the engine, position the tilt cylinder in the center of the loader arm (Fig. 0737). DSC-1479a Fig. 0737 16. Using a 1-1/8” wrench install the hydraulic line (M) to the male flush face coupler (Fig. 0736). Fig. 0736 18. Install the upper pivot pin through the tilt cylinder yoke and loader arm bracket (Fig. 0738). DSC-1481a Fig.
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CHAIN DRIVE/LOADER ARM 19. Install a bolt to secure the pivot pin to the cylinder yoke. Torque the bolt to 19 ft-lbs. (26 Nm) (Fig. 0739). 21. Install the right and left side pivot pins into the pivot points (Fig. 0741). Fig. 0741 Fig. 0739 20. Position the attach plate to the loader arm pivot points (Fig. 0740). Fig. 0740 Toro Wheeled CUL Service Manual DSC-1489a DSC-1485a DSC-1487a 22. Align the tilt cylinder ram with the attach plate center pivot point.
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CHAIN DRIVE/LOADER ARM 23. Using a 1/2” socket, install 3 bolts securing each of the pivot pins to the attach plate (2) and the tilt cylinder ram (1) (Fig. 0743). 25. Remove the floor jack. 26. 4-Paw machines: Install the hood. 27. Start the machine. Raise and lower the loader arm. 28. Check the hydraulic fluid level and add if necessary. 29. Grease the pivot points (using #2 general purpose luthium grease): Left side (Fig. 0745) Fig. 0743 DSC-1493a 24. Torque the 3 pivot pin bolts to 19 ft-lbs.
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CHAIN DRIVE/LOADER ARM Attach plate (Fig. 0746) Fig. 0746 DSC-1498a Right side (Fig. 0747) Fig.
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CHAIN DRIVE/GAS ENGINE 6. Position a loader arm cylinder lock over each lift cylinder rod (Fig. 0749). Gas Engine Replacement Gas Engine Removal 1. Start the engine and let it run for five minutes to warm the engine oil. 2. Park the traction unit so that the drain side (rear left corner) is slightly lower than the opposite side to ensure that the oil drains completely. 3. Raise the loader arms to the fully raised position. 4. Turn off the engine and remove the key. 5.
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CHAIN DRIVE/GAS ENGINE 8. Lower the loader arm until the loader arm end of the cylinder rods are resting on the cylinder locks. 12. Open the drain valve by turning it counterclockwise pulling out as you turn (Fig. 0753). 9. Place a drain pan under the rear left corner of the machine to drain the engine oil into. 10. Uncap the engine oil drain valve (Fig. 0751). Fig. 0753 Fig. 0751 DSC-0594a 11. Place one end of a hose on the drain valve and the other end in the drain pan (Fig. 0752). DSC-0599a 13.
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CHAIN DRIVE/GAS ENGINE 15. Remove the battery from the frame (Fig. 0755). Fig. 0755 17. Mark the hydraulic pump lines and port locations F and R (Fig. 0757): DSC-0458a Fig. 0757 F: Front hydraulic line DSC-0604a R: Rear hydraulic line 16. Turn the fuel shut off valve to the OFF position (Fig. 0756). 18. Place an absorbent towel under the hydraulic pump. 19. Using a 15/16” wrench, remove the front hydraulic line from the pump fitting (Fig. 0758). Fig. 0756 DSC-0647a Fig.
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CHAIN DRIVE/GAS ENGINE 20. Using a 15/16” wrench, remove the rear hydraulic line from the pump fitting (Fig. 0759). Fig. 0759 DSC-0607a 21. Cap the lines and fittings so debris does not enter the system (Fig. 0760). Fig. 0760 4/4-4 DSC-0609a 22. Loosen the hose clamps on the front suction hose (Fig. 0761). Fig. 0761 DSC-0610a 23. Slide the front suction hose off the hydraulic pump suction fitting (Fig. 0762). Fig.
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CHAIN DRIVE/GAS ENGINE 24. Loosen the hose clamps on the rear suction hose (Fig. 0763). 26. Cap all hydraulic lines, hoses and fittings to prevent debris from entering the system. 27. Using a 1/2” socket, remove the 4 nuts and lock washers securing the muffler to the engine manifold (Fig. 0765 and Fig. 0766). Fig. 0763 DSC-0613a 25. Slide the rear suction hose off the hydraulic pump suction fitting (Fig. 0764). Fig. 0764 Toro Wheeled CUL Service Manual DSC-0614a Fig. 0765 DSC-0620a Fig.
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CHAIN DRIVE/GAS ENGINE 28. Using a 1/2” socket, remove the 2 bolts securing the muffler bracket to the engine (Fig. 0767). Fig. 0767 DSC-0622a 29. Remove the muffler (Fig. 0768). Fig. 0768 30. Using an 8mm socket, loosen the throttle cable clamp (Fig. 0769). Fig. 0769 31. Remove the throttle cable from the clamp and unhook it from the engine throttle lever (Fig. 0770). DSC-0623a Fig.
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CHAIN DRIVE/GAS ENGINE 32. Loosen the air cleaner cover knob from the air cleaner cover (Fig. 0771). Fig. 0771 DSC-0631a 33. Remove the air cleaner cover from the engine (Fig. 0772). Fig. 0772 Toro Wheeled CUL Service Manual DSC-0632a 34. Using an 8mm socket, loosen the choke cable clamp (Fig. 0773). Fig. 0773 DSC-0774a 35. Remove the choke cable from the clamp and unhook it from the engine choke lever (Fig. 0774). Fig.
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CHAIN DRIVE/GAS ENGINE 36. Using a 1/2” socket, remove the 2 front bolts secur ing the engine mount to the main frame and discard them (Fig. 0775). 38. Slide the fuel line off the fuel filter. Allow the fuel to drain into an approved container (Fig. 0777). Fig. 0777 Fig. 0775 37. Slide the fuel line hose clamp away from the fuel filter (Fig. 0776). 39. Unplug the wire harness connector from the engine (Fig. 0778). Fig. 0778 Fig.
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CHAIN DRIVE/GAS ENGINE 40. Using a 13mm socket, remove the bolt securing the ground wire to the engine (Fig. 0779). Fig. 0779 DSC-0656a 41. Using a 13mm socket, remove the nut securing the positive battery cable and the red harness wire to the starter solenoid (Fig. 0780). 42. Remove the positive battery cable from the starter solenoid (Fig. 0781). Fig. 0781 43. Remove the red harness wire from the starter solenoid (Fig. 0782). Fig. 0782 Fig.
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CHAIN DRIVE/GAS ENGINE 44. Using a 1/2” socket, remove the 2 rear bolts secur ing the engine mount to the main frame and discard the bolts (Fig. 0783). Fig. 0783 DSC-0662a 45. Place suitable lumber on the operator’s stand to receive the engine. Slide the engine out toward the rear. Rest the back of the engine on the lumber (Fig. 0784). 46. Hook chains to the engine lift points (Fig. 0785). Attach a properly rated hoist to the chains. Raise the hoist to apply tension to the chains. Fig. 0785 47.
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CHAIN DRIVE/GAS ENGINE 48. Slide the hose clamp away from the fuel filter (Fig. 0787). Fig. 0787 50. Rotate the engine until the 2 hydraulic pump coupler set screws are accessible through the opening in the pump mount (Fig. 0789). DSC-0733a Fig. 0789 DSC-0680a 49. Remove the fuel filter from the fuel line (Fig. 0788). 51. Using an 8 point 1/4” socket, loosen the 2 hydraulic pump coupler set screws (Fig. 0790). Fig. 0788 DSC-0734a Fig.
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CHAIN DRIVE/GAS ENGINE 52. Using a 5/8” socket, remove the 4 bolts securing the pump mount to the engine (Fig. 0791). Fig. 0791 DSC-0683a 54. Remove the key from the crankshaft keyway (Fig. 0793). Fig. 0793 DSC-0690a 53. Remove the hydraulic pump and mount assembly from the crankshaft (Fig. 0792). Fig.
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CHAIN DRIVE/GAS ENGINE 55. Using a 9/16” socket and wrench, remove the 4 bolts and nuts securing the engine to the engine mount (Fig. 0794 and Fig. 0795). 56. Separate the engine mount from the engine (Fig. 0796). Fig. 0796 Fig. 0794 DSC-0694a DSC-0678a Left side 57. Remove the dust cap from the oil drain valve (Fig. 0797). Fig. 0795 DSC-0679a Fig.
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CHAIN DRIVE/GAS ENGINE 58. Using a 15/16” wrench, remove the oil drain valve from the engine (Fig. 0798 and Fig. 0799). Gas Engine Installation 1. Apply pipe sealant to the threads of the oil drain valve (Fig. 0800). Fig. 0798 DSC-0697a Fig. 0800 Fig. 0799 DSC-0703a DSC-0698a 59. For engine service, refer to applicable Kohler service manual.
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CHAIN DRIVE/GAS ENGINE 2. Install the engine oil drain valve finger tight. Use a 15/16” wrench to tighten the drain valve an additional 2-1/2 turns past finger tight (Fig. 0801 and Fig. 0802). 3. Position the engine mount to the engine (Fig. 0803). Fig. 0803 Fig. 0801 DSC-0710a DSC-0705a 4. Using a 9/16” socket and wrench, install 4 bolts and nuts securing the engine to the engine mount (Fig. 0804). Fig. 0802 DSC-0707a Fig.
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CHAIN DRIVE/GAS ENGINE 5. Torque the engine mount bolts to 30 ± 3 ft-lbs. (40.67 + 4 Nm) (Fig. 0805). Fig. 0805 DSC-0714a 6. Install the dust cap onto the oil drain valve (Fig. 0806). 7. Install the key into the crankshaft keyway (Fig. 0807). Fig. 0807 8. Apply anti-seize to the engine crankshaft (Fig. 0808). Fig. 0808 Fig.
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CHAIN DRIVE/GAS ENGINE 9. Align the coupler with the crankshaft keyway. Position the hydraulic pump and mount assembly onto the crankshaft (Fig. 0809). Fig. 0809 DSC-0727a 10. Install 4 bolts securing the pump mount to the engine (Fig. 0810). Fig. 0810 11. Use a 5/8” socket to tighten the 4 bolts securing the pump mount to the engine. Torque the 4 bolts to 216 ± 25 in-lbs. (24.4 + 2.8 Nm) (Fig. 0811). Fig. 0811 12. Using an 8 point 1/4” socket, tighten the 2 hydraulic pump coupler set screws.
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CHAIN DRIVE/GAS ENGINE 13. Hook chains to the engine lift points (Fig. 0813). Attach a properly rated hoist to the chains. Raise the hoist to apply tension to the chains. 16. Remove the chains and hoist (Fig. 0815). Fig. 0815 Fig. 0813 DSC-0736a DSC-0700a 14. Place suitable lumber on the operator’s stand. 17. Slide the engine into position in the main frame so the engine mount plate mounting holes align with the mounting holes in the main frame (Fig. 0816). 15.
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CHAIN DRIVE/GAS ENGINE 18. Using a 1/2” socket, loosely install 4 new engine mounting bolts to secure the engine to the main frame (Fig. 0817 and Fig. 0818). 19. Torque the 4 engine mounting bolts to 350 ± 50 inlbs. (39.5 + 5.6 Nm) (Fig. 0819). Fig. 0819 Fig. 0817 DSC-0746a DSC-0740a 20. Slide the black battery cable onto the ground bolt (Fig. 0820). Fig. 0818 DSC-0741a Fig.
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CHAIN DRIVE/GAS ENGINE 21. Slide the black harness ground wire onto the ground bolt (Fig. 0821). Fig. 0821 DSC-0748a 22. Slide the star washer onto the ground bolt (Fig. 0822). Fig. 0822 4/4-20 DSC-0750a 23. Using a 13mm socket, install the ground bolt assembly into the engine block (Fig. 0823). Fig. 0823 DSC-0753a 24. Torque the ground bolt to 200 ± 25 in-lbs. (22.6 + 2.8 Nm) (Fig. 0824). Fig.
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CHAIN DRIVE/GAS ENGINE 25. Plug the harness connector into the engine con nector (Fig. 0825). Fig. 0825 DSC-0754a 26. Slide the fuel line onto the fuel filter (Fig. 0826). Fig. 0826 27. Slide the hose clamp into place to secure the fuel filter (Fig. 0827). Fig. 0827 28. Turn the fuel shut-off valve to the ON position (Fig. 0828). DSC-0758a Fig.
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CHAIN DRIVE/GAS ENGINE 29. Slide the red harness wire onto the starter solenoid (Fig. 0829). Fig. 0829 31. Using a 1/2” socket, install a nut to secure the red battery cable and red harness wire to the starter solenoid (Fig. 0831). DSC-0764a Fig. 0831 30. Slide the red battery cable onto the starter solenoid (Fig. 0830). Fig. 0830 4/4-22 DSC-0765a DSC-0766a 32. Remove the air cleaner cover (Fig. 0832). Fig.
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CHAIN DRIVE/GAS ENGINE 33. Hook the choke cable z-bend into the choke linkage on the engine (Fig. 0833). Fig. 0833 DSC-0771a 34. Slide the choke cable into the cable clamp aligning the previous indention on the cable with the choke cable clamp (Fig. 0834). Fig. 0834 Toro Wheeled CUL Service Manual DSC-0802a 35. Push the throttle linkage over and hook the throttle cable z-bend into the throttle linkage (Fig. 0835). Fig. 0835 DSC-0806a 36.
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CHAIN DRIVE/GAS ENGINE 37. Position the air cleaner cover onto the engine (Fig. 0837). Fig. 0837 DSC-0780a 39. Install the 2 manifold gaskets (Fig. 0839 and Fig. 0840). Fig. 0839 DSC-0782a Fig. 0840 DSC-0784a 38. Install the air cleaner cover knob to secure (Fig. 0838). Fig.
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CHAIN DRIVE/GAS ENGINE 40. Position the muffler onto the engine manifold studs aligning the muffler bracket mounting holes with the mounting holes on the engine (Fig. 0841). 42. Loosely install 4 lock washers and nuts securing the muffler to the engine manifold studs (Fig. 0843). Fig. 0843 Fig. 0841 41. Loosely install 2 bolts securing the muffler bracket to the engine (Fig. 0842). 43. Use a 1/2” socket to tighten the 4 muffler manifold nuts (Fig. 0844). Fig. 0844 Fig.
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CHAIN DRIVE/GAS ENGINE 44. Use a 1/2” socket to torque the 2 bolts securing the muffler bracket to the engine to 200 ± 25 in-lbs. (23 ± 3 Nm) (Fig. 0845). 46. Position the hose clamp and tighten to secure the suction hose to the fitting (Fig. 0847). Fig. 0847 Fig. 0845 45. Slide one of the hydraulic suction hoses onto the hydraulic pump suction fitting (Fig. 0846). 47. Slide the second hydraulic suction hose onto the other hydraulic pump suction fitting (Fig. 0848). Fig. 0848 Fig.
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CHAIN DRIVE/GAS ENGINE 48. Position the hose clamp and tighten to secure the suction hose to the fitting (Fig. 0849). 50. Connect the positive and then the negative battery cable to the battery. Position the battery clamp on the battery up against the frame. Install the carriage bolt, washer and wing nut securing the battery clamp to the frame (Fig. 0851). C Fig. 0849 DSC-0801a D A B Fig. 0851 DSC-0810a 49. Position the battery into the main frame (Fig. 0850). A. Negative battery cable C.
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CHAIN DRIVE/GAS ENGINE 52. Use a 15/16” wrench to tighten the hydraulic line nut to the fitting (Fig. 0853). 54. Use a 15/16” wrench to tighten the hydraulic line nut to the fitting (Fig. 0855). Fig. 0853 Fig. 0855 DSC-0812a 53. Install the hydraulic line (marked with and F) to the front hydraulic pump fitting (also marked with an F) (Fig. 0854). DSC-0814a 55. Fill the engine with oil. 56. Check the hydraulic fluid level: Hydraulic Tank Capacity: 17.25 US gallons (67 liters) a.
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CHAIN DRIVE/GAS ENGINE 57. Turn the machine on and run it to purge air from the system. Check for leaks. 61. Reinstall the loader arm cylinder locks onto the hydraulic auxiliary lines (for storage) (Fig. 0858). 58. Raise the loader arm to remove pressure from the loader arm cylinder locks. 59. Remove the clevis pin and cotter pin from the loader arm cylinder locks (Fig. 0856). Fig. 0858 DSC-0449a 62. Lower the loader arms. 63. Turn the engine off. Fig. 0856 DSC-0455a 64.
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CHAIN DRIVE/GAS ENGINE THIS PAGE INTENTIONALLY LEFT BLANK.
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CHAIN DRIVE/ELECTRICAL Ignition Switch How It Works Purpose This component provides the proper switching for the starter, ignition, accessories, and safety circuits. Detents inside the ignition switch give it 3 positions: OFF, RUN, and START. The START position is spring loaded so the cylinder automatically returns to RUN once the key is released. Location Testing The ignition switch is mounted on the right hand side of the upper frame assembly (Fig. 0859). 1.
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CHAIN DRIVE/ELECTRICAL Relay Testing Purpose 1. Disconnect the relay from the harness. The chain drive wheeled traction unit uses one relay to direct current flow to the start circuit of the unit. 2. Verify the coil resistance between terminals 85 and 86 with a multimeter (ohms setting). Resistance should be from 70 to 90 ohms. There should be continuity between terminals 87a and 30 (Fig. 0862).
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CHAIN DRIVE/ELECTRICAL Fuses How It Works Purpose The fuse block is where the wires that carry 12 volts meet the wires that need 12 volts to operate a compon ent or function. The fuse makes the connection between the 12 volt wire carrying the current and the 12 volt wire that needs the current. Fuses are used in the circuits to limit damage in the event of excessive current flow.
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CHAIN DRIVE/ELECTRICAL Auxiliary Neutral Switch How It Works Purpose The switch has a spring loaded ball. When the auxiliary hydraulic valve is in the neutral position, the ball moves into a machined notch located in the spool. The normally closed switch then provides a ground to the start circuit. When the auxiliary lever is moved out of neutral, the spool pushes against the ball end of the switch and opens the ground circuit which prevents the engine from starting.
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CHAIN DRIVE/ELECTRICAL Hour Meter How It Works Purpose The digital hour meter is an electronic clock. It is not repairable or resettable (Fig. 0867). The digital hour meter displays engine run time and is a service reminder. When the engine is off, the hour meter displays the number of operation hours that have been logged on the traction unit. After 50 hours and then every 100 hours thereafter (that is 150, 250, 350, etc.) the screen displays CHG OIL to remind you to change the engine oil.
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CHAIN DRIVE/ELECTRICAL 4. Position a loader arm cylinder lock over each lift cylinder rod (Fig. 0869). Battery Replacement Battery Removal 1. Raise the loader arms to the fully raised position. 2. Turn off the engine and remove the key. 3. Remove the loader arm cylinder locks located on the hydraulic auxiliary lines (Fig. 0868). Fig. 0869 DSC-0452a 5. Secure each loader arm cylinder lock with a clevis pin and hairpin cotter (Fig. 0870). Fig. 0868 DSC-0448a Fig.
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CHAIN DRIVE/ELECTRICAL 6. Lower the loader arm down until the loader arm end of the cylinder rods are resting on the cylinder locks. 7. Disconnect the negative and then the positive battery cable. Remove the wing nut, washer and carriage bolt securing the battery clamp to the frame. Remove the battery clamp (Fig. 0871). D Battery Installation 1. Position the battery into the frame (Fig. 0873). C A B Fig. 0871 Fig. 0873 DSC-0447a A. Negative battery cable C. Wing nut, washer, B.
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CHAIN DRIVE/ELECTRICAL 3. Turn on the machine and raise the loader arm up to relieve pressure from the cylinder locks. 7. Store the loader arm cylinder locks by installing them on the hydraulic auxiliary lines (Fig. 0877). 4. Turn off the engine and remove the key. 5. Remove the clevis pin and cotter pin securing each loader arm cylinder lock to the cylinder rod (Fig. 0875). Fig. 0877 DSC-0448 8. Lower the loader arms. Fig. 0875 DSC-0456a 6.
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CHAIN DRIVE/ELECTRICAL Electrical Schematic 22311 / 22317 . . F1 30A F2 VIOLET 25A RED B HOUR METER VIOLET IGNITION GREEN S WHITE M START RELAY GND GREEN G BLACK 5 3 WHITE BLUE START OFF B+R B+S M+G IGNITION SWITCH RUN ENGINE SCHEMATIC MAG START OIL REG B+ SPARK PLUG AC AC OIL SWITCH + IGNITION MODULES FUEL SOLINIOD SPARK PLUG SOLINOID SHIFT STARTER Toro Wheeled CUL Service Manual VIOLET AUX. VAVLE CLOSED WHEN IN DETENT 4 1 GREEN VIOLET RED – Fig.
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CHAIN DRIVE/ELECTRICAL THIS PAGE INTENTIONALLY LEFT BLANK.
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4-PAW GAS/DRIVE SYSTEM Front Wheel Motor Replacement 6. Raise the front of the machine (Fig. 0881). Front Wheel Motor Removal 1. Park CUL on a level surface. 2. Raise the loader arm 6” - 12” (15 - 30cm) off the ground. 3. Turn off the machine and remove the key. 4. Lift the rear of the machine (Fig. 0879). Fig. 0881 DSC-3924a 7. Position jackstands under the front corners of the machine. Remove the floor jack (Fig. 0882). Fig. 0879 DSC-0100a 5.
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4-PAW GAS/DRIVE SYSTEM 8. Lower the loader arm. 9. Using a 13/16” socket, remove 5 lug nuts securing the rear wheel to the wheel hub (Fig. 0883). 11. Using a 13/16” socket, remove 5 lug nuts securing the front wheel to the wheel hub (Fig. 0885). Fig. 0885 Fig. 0883 DSC-0834a DSC-0831a 12. Remove the wheel from the wheel hub (Fig. 0886). 10. Remove the wheel from the wheel hub (Fig. 0884). Fig. 0886 Fig.
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4-PAW GAS/DRIVE SYSTEM 13. Using a 1/2” socket, remove the 4 bolts securing the hose cover to the main frame (Fig. 0887). 15. Using a 1-1/2” socket, loosen, do not remove, the patch lock nut on the front wheel motor shaft (Fig. 0889). Note: In 2004 there was a running change from the castle nut and cotter pin (22312 serial #240000200 and lower) to a patch lock nut (22312 serial #240000201 and higher) for retaining the wheel motors. Fig. 0887 DSC-0838a 14. Remove the hose cover (Fig. 0888). Fig.
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4-PAW GAS/DRIVE SYSTEM 17. Install 5 lug nuts (reversed) to secure the hub puller to the wheel hub (Fig. 0891). Fig. 0891 DSC-0923a 18. Using a 1-1/2” socket, rotate the center puller bolt to break the hub free of the wheel motor shaft (Fig. 0892). 19. Remove the 5 lug nuts and the puller from the hub (Fig. 0893). Fig. 0893 20. Remove the patch lock nut from the wheel motor shaft and discard (Fig. 0894). Fig. 0894 Fig.
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4-PAW GAS/DRIVE SYSTEM 21. Remove the hub from the wheel motor shaft and discard (Fig. 0895). Fig. 0895 24. Using a 1-1/8” wrench, loosen the left hand upper hydraulic line from the bulkhead fitting in the main frame (Fig. 0897). DSC-0927a Fig. 0897 22. Place a drain pan under the front wheel motor. 23. Using a 1-1/8” wrench, remove the upper hydraulic line from the upper wheel motor fitting (Fig. 0896). 25. Rotate the upper hydraulic line out and allow the fluid to drain in the drain pan (Fig. 0898).
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4-PAW GAS/DRIVE SYSTEM 26. Using a 1/1/8” wrench, remove the lower hydraulic line from the lower wheel motor fitting (Fig. 0899). Fig. 0899 DSC-0933a 27. Allow the fluid to drain into the pan (Fig. 0900). 28. Using a 1-1/16” socket, remove the 2 wheel motor fittings (Fig. 0901). Fig. 0901 DSC-0940a 29. Cap the lines, fittings and ports to prevent debris from contaminating the system. 30. Support the wheel motor with a floor jack (Fig. 0902). Fig. 0900 DSC-0934a Fig.
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4-PAW GAS/DRIVE SYSTEM 31. Using a 3/4” socket, remove the 4 bolts securing the wheel motor to the mainframe (Fig. 0903). Front Wheel Motor Installation Note: Upon removal, all seals, o-rings and gaskets should be replaced. During installation, lightly lubricate all seals, o-rings and gaskets with clean petroleum jelly prior to assembly. 1. Place the wheel motor onto a floor jack with the fittings facing to the side. Position the wheel motor under the main frame (Fig. 0905). Fig. 0903 DSC-0943a 32.
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4-PAW GAS/DRIVE SYSTEM 3. Loosely install 4 wheel motor mounting bolts (Fig. 0907). Fig. 0907 5. Remove the floor jack. 6. Using a 1-1/16” socket, install the 2 wheel motor fittings (Fig. 0909). DSC-0951a Fig. 0909 4. Using a 3/4” socket, tighten and torque the 4 mount ing bolts to 75 ± 8 ft-lbs. (102 ± 11 Nm) (Fig. 0908). Fig. 0908 7. Using a 1-1/8” wrench, install the lower hydraulic line to the lower wheel motor fitting (Fig. 0910). DSC-0952a Fig.
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4-PAW GAS/DRIVE SYSTEM 8. Rotate the upper hydraulic line into position aligning it with the upper wheel motor fitting. Use a 1-1/8” wrench to install the upper hydraulic line to the upper wheel motor fitting (Fig. 0911 and Fig. 0912). 9. Use a 1-1/8” wrench to tighten the front upper hydraulic line to the bulkhead fitting in the main frame (Fig. 0913). Fig. 0913 Fig. 0911 DSC-0964a DSC-0962a 10. Start the machine.
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4-PAW GAS/DRIVE SYSTEM Note: Prior to installing the drive hub, make sure the wheel motor shaft and inner drive hub are clean, degreased and free of paint to ensure a proper fit between the drive hub and wheel motor shaft. 12. With the key installed in the wheel motor shaft (Fig. 0914), slide a new hub onto the wheel motor shaft (Fig. 0915). Fig. 0914 DSC-0965a 13. Install a new patch lock nut onto the wheel motor shaft. Torque the patch lock nut to 325 ± 25 ft-lbs. (441 ± 34 Nm) (Fig. 0916).
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4-PAW GAS/DRIVE SYSTEM 15. Loosely install 4 bolts to secure the hose cover to the main frame (Fig. 0918). 17. Slide the front wheel onto the wheel hub (Fig. 0920). Fig. 0920 Fig. 0918 16. Using a 1/2” socket, tighten the 4 bolts, securing the hose cover to the main frame (Fig. 0919). 18. Loosely install 5 lug nuts (tapered side in) (Fig. 0921). Fig. 0921 Fig.
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4-PAW GAS/DRIVE SYSTEM 19. Torque all 5 lug nuts to 50 + 5ft-lbs. (68 + 7 Nm) (Fig. 0922). Fig. 0922 DSC-0975a 20. Slide the rear wheel onto the wheel hub (Fig. 0923). Fig. 0923 21. Loosely install 5 lug nuts (tapered side in) (Fig. 0924). Fig. 0924 DSC-0977a 22. Torque all 5 lug nuts to 50 + 5ft-lbs. (68 + 7 Nm) (Fig. 0925). DSC-0976a Fig. 0925 DSC-0978a 23. Check the hydraulic fluid level and add fluid if necessary. 24. Remove from jackstands and test operate unit.
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4-PAW GAS/DRIVE SYSTEM 6. Raise the front of the machine (Fig. 0928). Rear Wheel Motor Replacement Rear Wheel Motor Removal 1. Park CUL on a level surface. 2. Raise the loader arm 6” - 12” (15 - 30cm) off the ground. 3. Turn off the machine and remove the key. 4. Lift the rear of the machine (Fig. 0926). Fig. 0928 DSC-3924a 7. Position jackstands under the front 2 corners of the machine. Remove the floor jack (Fig. 0929). Fig. 0926 DSC-0100a 5.
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4-PAW GAS/DRIVE SYSTEM 8. Lower the loader arm. 9. Using a 13/16” socket, remove 5 lug nuts securing the rear wheel to the wheel hub (Fig. 0930). 11. Using a 13/16” socket, remove 5 lug nuts securing the front wheel to the wheel hub (Fig. 0932). Fig. 0932 Fig. 0930 DSC-0834a DSC-0831a 12. Remove the wheel from the wheel hub (Fig. 0933). 10. Remove the wheel from the wheel hub (Fig. 0931). Fig. 0933 Fig.
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4-PAW GAS/DRIVE SYSTEM 13. Using a 1/2” socket, remove the 4 bolts securing the hose cover to the main frame (Fig. 0934). 15. Using a 1-1/2” socket, loosen, do not remove, the patch lock nut on the rear wheel motor shaft (Fig. 0936). Note: In 2004 there was a running change from the castle nut and cotter pin (22312 serial #240000200 and lower) to a patch lock nut (22312 serial #240000201 and higher) for retaining the wheel motors. Fig. 0934 DSC-0836a 14. Remove the hose cover (Fig. 0935). Fig.
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4-PAW GAS/DRIVE SYSTEM 17. Install 5 lug nuts (reversed) to secure the hub puller to the wheel hub (Fig. 0938). Fig. 0938 DSC-0845a 18. Using a 1-1/2” socket, rotate the center puller bolt to break the hub free of the wheel motor shaft (Fig. 0939). 19. Remove the 5 lug nuts and the puller from the hub (Fig. 0940). Fig. 0940 20. Remove the patch lock nut from the wheel motor shaft and discard (Fig. 0941). Fig. 0941 Fig.
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4-PAW GAS/DRIVE SYSTEM 21. Remove the hub from the wheel motor shaft and discard (Fig. 0942). Fig. 0942 24. Using a 1-1/8” wrench, loosen the rear upper hydraulic line from the bulkhead fitting in the main frame (Fig. 0944). DSC-0849a Fig. 0944 22. Place a drain pan under the rear wheel motor. 23. Using a 1-1/8” wrench, remove the upper hydraulic line from the upper wheel motor fitting (Fig. 0943). 25. Rotate the upper hydraulic line out and allow the fluid to drain in the drain pan (Fig. 0945). Fig.
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4-PAW GAS/DRIVE SYSTEM 26. Using a 1/1/8” wrench, remove the lower hydraulic line from the lower wheel motor fitting (Fig. 0946). Fig. 0946 DSC-0854a 27. Allow the fluid to drain into the drain pan (Fig. 0947). 28. Using a1-1/16” socket, loosen the 2 wheel motor fittings (Fig. 0948). Fig. 0948 DSC-0857a 29. Cap the hydraulic lines and fittings to prevent debris from contaminating the system. 30. Support the wheel motor with a floor jack (Fig. 0949). Fig. 0947 DSC-0856a Fig.
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4-PAW GAS/DRIVE SYSTEM 31. Using a 3/4” socket, remove the 4 bolts securing the wheel motor to the main frame (Fig. 0950). 33. To service the existing wheel motor, refer to “Parker / Ross Wheel Motor Service Manual” (Toro Form No. 492-4753). 34. If a new wheel motor is being installed, remove the 2 wheel motor fittings and transfer them to the new wheel motor (Fig. 0952). Fig. 0950 DSC-0860a 32. Using the floor jack, lower the wheel motor out of the frame (Fig. 0951). Fig.
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4-PAW GAS/DRIVE SYSTEM 3. Loosely install 4 wheel motor mounting bolts (Fig. 0955). Rear Wheel Motor Installation Note: Upon removal, all seals, o-rings and gaskets should be replaced. During installation, lightly lubricate all seals, o-rings and gaskets with clean petroleum jelly prior to assembly. 1. Place the wheel motor onto a floor jack with the fittings facing to the side. Position the wheel motor under the main frame (Fig. 0953). Fig. 0955 DSC-0873 4.
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4-PAW GAS/DRIVE SYSTEM 5. Remove the floor jack. 6. Using a1-1/16” socket, tighten the 2 wheel motor fittings (Fig. 0957). Fig. 0957 DSC-0875a 7. Using a 1/1/8” wrench, install the lower hydraulic line to the lower wheel motor fitting (Fig. 0958). Fig. 0958 8. Rotate the upper hydraulic line into position aligning it with the upper wheel motor fitting. Use a 1-1/8” wrench to install the upper hydraulic line to the upper wheel motor fitting (Fig. 0959). Fig. 0959 9.
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4-PAW GAS/DRIVE SYSTEM 10. Start the machine. Allow the air to purge from the hydraulic system. Check the wheel motor, hydraulic lines and fittings for leaks. 13. Install a new patch lock nut onto the wheel motor shaft. Torque the patch lock nut to 325 ± 25 ft-lbs. (441 ± 34 Nm) (Fig. 0963). 11. Turn the machine off and remove the key.
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4-PAW GAS/DRIVE SYSTEM 15. Loosely install 4 bolts to secure the hose cover to the main frame (Fig. 0965). 17. Slide the front wheel onto the wheel hub (Fig. 0967). Fig. 0967 Fig. 0965 16. Using a 1/2” socket, tighten the 4 bolts securing the hose cover to the mainframe (Fig. 0966). 18. Loosely install 5 lug nuts (tapered side in) (Fig. 0968). Fig. 0968 Fig.
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4-PAW GAS/DRIVE SYSTEM 19. Torque all 5 lug nuts to 50 + 5 ft-lbs. (68 + 7 Nm) (Fig. 0969). Fig. 0969 DSC-0975a 20. Slide the rear wheel onto the wheel hub (Fig. 0970). Fig. 0970 21. Loosely install 5 lug nuts (tapered side in) (Fig. 0971). Fig. 0971 DSC-0977a 22. Torque all 5 lug nuts to 50 + 5 ft-lbs. (68 + 7 Nm) (Fig. 0972). DSC-0976a Fig. 0972 DSC-0978a 23. Check the hydraulic fluid level and add fluid if necessary. 24. Remove from jackstands and test operate unit.
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4-PAW GAS/HYDRAULICS Left Hand Counterbalance Valve Replacement 5. Position a loader arm cylinder lock over each lift cylinder rod (Fig. 0974). Left Hand Counterbalance Valve Removal 1. Park CUL on a level surface. 2. Raise the loader arms to the fully raised position. 3. Turn off the engine and remove the key. 4. Remove the loader arm cylinder locks located on the hydraulic auxiliary lines (Fig. 0973). Fig. 0974 DSC-0452a 6.
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4-PAW GAS/HYDRAULICS 7. Lower the loader arm until the loader arm end of the cylinder rods are resting on the cylinder locks. 10. Lift the rear of the machine (Fig. 0978). 8. Loosen the 4 swell latches securing the hood to the main frame (Fig. 0976). Fig. 0978 Fig. 0976 DSC-0982a DSC-0100a 11. Position jackstands under the rear 2 corners of the machine. Remove the floor jack (Fig. 0979). 9. Remove the hood (Fig. 0977). Fig. 0979 Fig.
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4-PAW GAS/HYDRAULICS Note: Lower the loader arms. 14. Using a 13/16” socket, remove 5 lug nuts securing the left rear wheel to the wheel hub (Fig. 0982). 12. Raise the front of the machine (Fig. 0980). Fig. 0982 Fig. 0980 DSC-0831a DSC-3924a 15. Remove the wheel from the wheel hub (Fig. 0983). 13. Position jackstands under the front corners of the machine. Remove the floor jack (Fig. 0981). Fig. 0983 Fig.
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4-PAW GAS/HYDRAULICS 16. Place a drain pan under the location of the left counterbalance valve. 19. Using a 1-1/8” offset wrench, remove the hydraulic line nut from the front upper counterbalance valve fitting (Fig. 0986). 17. Mark the hydraulic lines on the counterbalance valve with and F and an R (Fig. 0984). Fig. 0986 Fig. 0984 F: Front hydraulic line DSC-0987a DSC-0985a R: Rear hydraulic line 20.
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4-PAW GAS/HYDRAULICS 21. Set hydraulic line fitting marked F to the side. 22. Using a 1-1/8” offset wrench, remove the hydraulic line nut from the front lower counterbalance valve fitting (Fig. 0988). 24. Using a 1-1/8” offset wrench, remove the hydraulic line nut from the top fitting on the counterbalance valve (Fig. 0990). Fig. 0990 Fig. 0988 DSC-0991a 23. Using a 1-1/8” offset wrench, remove the hydraulic line nut from the bottom fitting on the counterbalance valve (Fig. 0989). 25.
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4-PAW GAS/HYDRAULICS 26. Remove the washer from the counterbalance valve mounting bolt (Fig. 0992). Fig. 0992 DSC-1000a 27. Remove the counterbalance valve assembly, mounting bolt, washer and spacer from the frame (Fig. 0993). 28. Remove the mounting bolt, washer and spacer from the counterbalance valve (Fig. 0994). Fig. 0994 DSC-1066a 29. Transfer 4 of the 6 hydraulic fittings from the old counterbalance valve to the new counterbalance valve (Fig. 0995).
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4-PAW GAS/HYDRAULICS Left Hand Counterbalance Valve Assembly (Fig. 0996). Left Hand Counterbalance Valve Installation Note: Upon removal, all seals, o-rings and gaskets should be replaced. During installation, lightly lubricate all seals, o-rings and gaskets with clean petroleum jelly prior to assembly. 1. Position the counterbalance valve inside the frame. 2. Loosely install the bottom hydraulic hard line nut (Fig. 0997). AB C D B E Fig. 0996 A. Nut B. Washer (2) C. Spacer DSC-1065a D.
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4-PAW GAS/HYDRAULICS 4. Loosely install the hydraulic hard line nut marked R to the lower fitting on the front of the counterbalance valve (Fig. 0999). Fig. 0999 DSC-1015a 5. Install the mounting bolt and washer through the counterbalance valve (Fig. 1000). 6. Position the spacer in between the counterbalance valve and the frame. Slide the bolt through the spacer and frame (Fig. 1001). Fig. 1001 7. Install a washer onto the mounting bolt (Fig. 1002). Fig. 1002 Fig.
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4-PAW GAS/HYDRAULICS 8. Using a 7/16” socket and wrench, install a nut onto the counterbalance valve mounting bolt (Fig. 1003). Fig. 1003 10. Position the hydraulic hard line marked F to the counterbalance valve and bulkhead fitting. Using a 1-1/8” offset wrench, install the hydraulic line nut to the bulkhead fitting (Fig. 1005). DSC-1027a Fig. 1005 9. Using a 1-1/8” offset wrench, tighten the 3 hydraulic hard lines to the counterbalance valve fittings (Fig. 1004). Fig. 1004 11.
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4-PAW GAS/HYDRAULICS 12. Start the machine. Allow the air to purge from the hydraulic system. Check the hydraulic lines and fittings for leaks. Remove the drain pan. 16. Torque all 5 lug nuts to 50 + 5 ft-lbs. (68 + 7 Nm) (Fig. 1009). 13. Turn the machine off and remove the key. 14. Slide the rear wheel onto the wheel hub (Fig. 1007). Fig. 1009 DSC-0978a 17. Check the hydraulic fluid level and add fluid if necessary. Fig. 1007 DSC-0976a 18. Remove the unit from the jackstands. 15.
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4-PAW GAS/HYDRAULICS Right Hand Counterbalance Valve Replacement 4. Position a loader arm cylinder lock over each lift cylinder rod (Fig. 1011). Right Hand Counterbalance Valve Removal 1. Park CUL on a level surface. 2. Raise the loader arms to the fully raised position. 2. Turn off the engine and remove the key. 3. Remove the loader arm cylinder locks located on the hydraulic auxiliary lines (Fig. 1010). Fig. 1011 DSC-0452a 5.
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4-PAW GAS/HYDRAULICS 6. Lower the loader arm until the loader arm end of the cylinder rods are resting on the cylinder locks. 9. Lift the rear of the machine (Fig. 1015). 7. Loosen the 4 swell latches securing the hood to the main frame (Fig. 1013). Fig. 1015 Fig. 1013 DSC-0982a DSC-0100a 10. Position jackstands under the rear 2 corners of the machine. Remove the floor jack (Fig. 1016). 8. Remove the hood (Fig. 1014). Fig. 1016 Fig.
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4-PAW GAS/HYDRAULICS Note: Lower the loader arms. 13. Using a 13/16” socket, remove 5 lug nuts securing the right rear wheel to the wheel hub (Fig. 1019). 11. Raise the front of the machine (Fig. 1017). Fig. 1019 Fig. 1017 DSC-1036a DSC-3924a 14. Remove the wheel from the wheel hub (Fig. 1020). 12. Position jackstands under the front corners of the machine. Remove the floor jack (Fig. 1018). Fig. 1020 Fig.
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4-PAW GAS/HYDRAULICS 15. Disconnect the negative and then the positive battery cable from the battery (Fig. 1021). 17. Remove the battery (Fig. 1023). Fig. 1023 Fig. 1021 16. Remove the battery hold-down and retainer (Fig. 1022). Fig. 1022 18. Using a 1/2” wrench and socket, remove the 2 bolts and nuts securing the battery tray to the frame. Remove the bolt securing the inside of the tray to the frame (Fig. 1024). DSC-1039a Fig.
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4-PAW GAS/HYDRAULICS 19. Remove the battery tray (Fig. 1025). Fig. 1025 22. Mark the hydraulic lines connected to the bulkhead with an F and an R (Fig. 1027). DSC-1043a Fig. 1027 F: Front hydraulic line DSC-1045a R: Rear hydraulic line 20. Place a drain pan under the location of the left counterbalance valve. 21. Mark the hydraulic lines on the counterbalance valve with and F and an R (Fig. 1026). Fig. 1026 23.
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4-PAW GAS/HYDRAULICS 24. Using a 1-1/8” offset wrench, remove the hydraulic line nut from the front counterbalance valve fitting (Fig. 1029). Fig. 1029 DSC-1051a 25. Set the hydraulic line marked F to the side. 26. Using a 1-1/8” offset wrench, remove the hydraulic line nut from the rear counterbalance valve fitting (Fig. 1030). 27. Using a 1-1/8” offset wrench, remove the hydraulic line nut from the bottom fitting on the counterbalance valve (Fig. 1031). Fig. 1031 28.
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4-PAW GAS/HYDRAULICS 29. Using a 7/16” socket and wrench, remove the nut from the bolt securing the counterbalance valve to the main frame (Fig. 1033). Fig. 1033 DSC-1061a 30. Remove the washer from the counterbalance valve mounting bolt (Fig. 1034). Fig. 1034 Toro Wheeled CUL Service Manual DSC-1063a 31. Remove the counterbalance valve assembly, mounting bolt, washer and spacer from the frame (Fig. 1035). Fig. 1035 DSC-1064a 32.
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4-PAW GAS/HYDRAULICS 33. Transfer 4 of the 6 hydraulic fittings from the old counterbalance valve to the new counterbalance valve (Fig. 1037). Right Hand Counterbalance Valve Installation Note: The 2 spool fittings do not get transferred. They come with the new counterbalance valve. Note: Upon removal, all seals, o-rings and gaskets should be replaced. During installation, lightly lubricate all seals, o-rings and gaskets with clean petroleum jelly prior to assembly. 1.
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4-PAW GAS/HYDRAULICS 4. Loosely install the hydraulic hard line nut marked R to the counterbalance valve fitting (Fig. 1041). 6. Install a washer onto the mounting bolt (Fig. 1043). Fig. 1043 Fig. 1041 5. Position the spacer in between the counterbalance valve and the frame. Install the mounting bolt and washer through the counterbalance valve, spacer and frame (Fig. 1042). 7. Using a 7/16” socket and wrench, install a nut onto the counterbalance valve mounting bolt (Fig. 1044). Fig. 1044 Fig.
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4-PAW GAS/HYDRAULICS 8. Using a 1-1/8” offset wrench, tighten the 3 hydraulic hard lines to the counterbalance valve fittings (Fig. 1045). Fig. 1045 DSC-1081a 9. Position the hydraulic hard line marked F to the counterbalance valve and bulkhead fitting. Using a 1-1/8” offset wrench, install the hydraulic line nut to the bulkhead fitting (Fig. 1046). 10. Using a 1-1/8” offset wrench, install the other end of the hydraulic hard line marked F to the counter balance valve fitting (Fig. 1047). Fig.
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4-PAW GAS/HYDRAULICS 12. Install the side of the battery tray to the side of the frame with 2 bolts and 2 nuts. Install the bottom of the battery try to the bottom of the frame with a bolt (Fig. 1049). Fig. 1049 DSC-1087a 13. Position the battery in the battery tray (Fig. 1050). Fig. 1050 14. Install the battery hold-down and battery straps to secure the battery by inserting the ends of the battery straps in the slots located in the battery tray (Fig. 1051). Fig. 1051 15.
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4-PAW GAS/HYDRAULICS 16. Start the machine. Allow the air to purge from the hydraulic system. Check the hydraulic lines and fittings for leaks. Remove the drain pan. 20. Torque all 5 lug nuts to 50 + 5ft-lbs. (68 + 7 Nm) (Fig. 1055). 17. Turn the machine off and remove the key. 18. Slide the rear wheel onto the wheel hub (Fig. 1053). Fig. 1055 DSC-1091a 21. Remove the unit from the jackstands. Fig. 1053 DSC-1037a 22. Raise the loader arms; remove and re-stow the loader arm cylinder locks. 23.
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4-PAW GAS/LOADER ARM 4. Using a 1/2” socket, remove the 3 bolts retaining the 3 pivot pins to the attach plate (Fig. 1058). Loader Arm Replacement Loader Arm Removal 1. Raise the loader arm 6” - 8” (15 - 20cm) away from frame and position attach plate flat (horizontally) (Fig. 1056). Fig. 1058 DSC-1383w 5. Remove the center pivot pin (Fig. 1059). Fig. 1056 DSC-1380a 2. 4-Paw machines: Remove the hood. 3. Support the attach plate with a floor jack (Fig. 1057). Fig. 1059 Fig.
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4-PAW GAS/LOADER ARM 6. Remove the RH and LH pivot pins (Fig. 1060 and Fig. 1061). 7. Remove the attach plate (Fig. 1062). Fig. 1062 Fig. 1060 DSC-1392w DSC-1395w 8. Using a 1/2” socket, remove the bolt securing the upper tilt cylinder pivot pin to the tilt cylinder (Fig. 1063). Fig. 1061 DSC-1394w Fig.
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4-PAW GAS/LOADER ARM 9. Remove the upper pivot pin (Fig. 1064). Note: Support the cylinder with one hand as you remove the upper pivot pin. 11. Mark the hydraulic lines to the flush face couplers with an M for male and F for female relating to the couplers (Fig. 1066). Fig. 1066 Fig. 1064 DSC-1403a DSC-1401w 10. Lay the tilt cylinder alongside the unit (Fig. 1065). 12. Place an oil pan underneath the couplers to catch drainage. 13.
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4-PAW GAS/LOADER ARM 14. Using a 1-18” wrench remove the hydraulic line to the female (F) flush face coupler (Fig. 1068). 15. Using a 1-1/4” wrench and 1-5/16” wrench remove the nut from the male flush face coupler (Fig. 1069) and remove the male flush face coupler (Fig. 1070). Note: Use a plug to protect the line from contami nation. Fig. 1068 5/3-4 Fig. 1069 DSC-1411a Fig.
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4-PAW GAS/LOADER ARM 16. Using a 1-5/16” wrench remove the nut from the female flush face coupler (Fig. 1071) and remove the female flush face coupler (Fig. 1072). Fig. 1071 17. Remove the drain pan. 18. Using a properly rated strap or chain and hoist, support the cross-member of the loader arm (Fig. 1073). DSC-1414a Fig. 1073 DSC-1418a 19.
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4-PAW GAS/LOADER ARM 20. Remove the left and right lift cylinder pin from the loader arm (Fig. 1075). Fig. 1075 DSC-1422a 22. Remove the loader arm from the machine (Fig. 1077). Fig. 1077 DSC-1425a 21. Remove the left and right loader arm pivot pin from the frame (Fig. 1076). Fig.
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4-PAW GAS/LOADER ARM 3. Inspect the attach plate for wear or damage. Re place as necessary (Fig. 1080). Loader Arm Installation 1. Inspect the loader arm and pivot pins for wear or damage. Replace as necessary (Fig. 1078). Fig. 1080 Fig. 1078 DSC-1448a 2. Inspect the hydraulic cylinder yolks for wear or damage. Replace as necessary (Fig. 1079). 4. Install the loader arm onto the unit, aligning the pivot points on the loader arm with the pivot points on the upper frame (Fig. 1081). Fig. 1081 Fig.
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4-PAW GAS/LOADER ARM 5. Install a pivot pin through the frame and loader arm pivot point (Fig. 1082). Fig. 1082 8. Repeat for the opposite side. 9. Using a 1/2” socket, install 4 bolts to secure the pivot pins to the upper frame and lift cylinders on both sides of the machine. Torque the bolts to 19 ft-lbs. (26 Nm) (Fig. 1084 and Fig. 1085). DSC-1462a 6. Repeat for the opposite side. Fig. 1084 DSC-1466a Fig. 1085 DSC-1467a 7.
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4-PAW GAS/LOADER ARM 10. Remove the support from the loader arm. 11. Position the female flush face coupler into the out side hole of the coupler bracket on the loader arm (Fig. 1086). Fig. 1086 Note: Upon removal, all seals, o-rings and gaskets should be replaced. During installation, lightly lubricate all seals, o-rings and gaskets with clean petroleum jelly prior to assembly. 13. Position the male flush face coupler into the coupler bracket on the loader arm (Fig. 1088). DSC-1468 Fig. 1088 12.
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4-PAW GAS/LOADER ARM 15. Using a 1-1/8” wrench install the hydraulic line (F) to the female flush face coupler (Fig. 1090). Fig. 1090 17. With the fittings facing up toward the engine, position the tilt cylinder in the center of the loader arm (Fig. 1092). DSC-1479a Fig. 1092 16. Using a 1-1/8” wrench install the hydraulic line (M) to the male flush face coupler (Fig. 1091). Fig. 1091 18. Install the upper pivot pin through the tilt cylinder yoke and loader arm bracket (Fig. 1093). DSC-1481a Fig.
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4-PAW GAS/LOADER ARM 19. Install a bolt to secure the pivot pin to the cylinder yoke. Torque the bolt to 19 ft-lbs. (26 Nm) (Fig. 1094). 21. Install the right and left side pivot pins into the pivot points (Fig. 1096). Fig. 1096 Fig. 1094 20. Position the attach plate to the loader arm pivot points (Fig. 1095). Fig. 1095 Toro Wheeled CUL Service Manual DSC-1489a DSC-1485a DSC-1487a 22. Align the tilt cylinder ram with the attach plate center pivot point.
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4-PAW GAS/LOADER ARM 23. Using a 1/2” socket, install 3 bolts securing each of the pivot pins to the attach plate (2) and the tilt cylinder ram (1) (Fig. 1098). 25. Remove the floor jack. 26. 4-Paw machines: Install the hood. 27. Start the machine. Raise and lower the loader arm. 28. Check the hydraulic fluid level and add if necessary. 29. Grease the pivot points (using #2 general purpose luthium grease): Left side (Fig. 1100) Fig. 1098 DSC-1493a 24. Torque the 3 pivot pin bolts to 19 ft-lbs.
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4-PAW GAS/LOADER ARM Attach plate (Fig. 1101) Fig. 1101 DSC-1498a Right side (Fig. 1102) Fig.
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4-PAW GAS/LOADER ARM THIS PAGE INTENTIONALLY LEFT BLANK.
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4-PAW GAS/ENGINE 5. Position a loader arm cylinder lock over each lift cylinder rod (Fig. 1104). Engine Replacement Engine Removal 1. Park the CUL on a level surface. 2. Raise the loader arms to the fully raised position. 3. Turn off the engine and remove the key. 4. Remove the loader arm cylinder locks located on the hydraulic auxiliary lines (Fig. 1103). Fig. 1104 DSC-0452a 6. Secure each loader arm cylinder lock with a clevis pin and hairpin cotter (Fig. 1105). Fig. 1103 DSC-0448a Fig.
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4-PAW GAS/ENGINE 7. Lower the loader arm until the loader arm end of the cylinder rods are resting on the cylinder locks. 11. Open the drain valve (push in, turn counterclockwise and pull out) (Fig. 1108). 8. Place a drain pan under the rear left corner of the machine to drain the engine oil. 9. Uncap the engine oil drain valve (Fig. 1106). Fig. 1108 Fig. 1106 DSC-1092a DSC-1095a 12. When the oil has drained completely, close the drain valve and remove the hose. Replace the dust cap. 13.
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4-PAW GAS/ENGINE 14. Turn both fuel shut off valves to the OFF position (Fig. 1110). Fig. 1112 Fig. 1110 DSC-1103a DSC-1096a 16. Using a 13mm socket, remove the 2 mounting bolts securing the muffler to the engine (Fig. 1113). 15. Using a 1/2” socket, remove the 4 exhaust manifold mounting nuts and lock washers (Fig. 1111 and Fig. 1112). Fig. 1113 Fig.
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4-PAW GAS/ENGINE 17. Remove the muffler assembly from the machine (Fig. 1114). 20. Using a 15/16” wrench, remove the hydraulic line marked F from the front hydraulic pump fitting (Fig. 1116). Note: Use a plug to protect the line from contami nation. Fig. 1114 DSC-1112a 18. Place an absorbent towel under the hydraulic pump area. 19. Slide the 2 thermal sleeves up away from the hydraulic pump fittings. Mark the 2 hydraulic lines F and R (Fig. 1115): Fig. 1116 DSC-1115a 21.
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4-PAW GAS/ENGINE 22. Using a 5/16” socket, loosen the hose clamp secur ing the front suction hose to the hydraulic pump fitting (Fig. 1118). Fig. 1118 DSC-1118a 24. Using a 5/16” socket, loosen the hose clamp secur ing the rear suction hose to the hydraulic pump fitting (Fig. 1120). Fig. 1120 DSC-1121a 23. Slide the suction hose off the pump fitting (Fig. 1119). 25. Slide the suction hose off the pump fitting (Fig. 1121). Note: Use a plug to protect the line from contami nation.
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4-PAW GAS/ENGINE 26. Using an 8mm socket, loosen the throttle cable clamp (Fig. 1122). Fig. 1122 DSC-1123a 27. Remove the throttle cable from the clamp and unhook the z-bend from the throttle linkage (Fig. 1123). 28. Using an 8mm socket, loosen the choke cable clamp (Fig. 1124). Fig. 1124 29. Remove the choke cable from the clamp and unhook the z-bend from the choke linkage (Fig. 1125). Fig. 1125 Fig.
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4-PAW GAS/ENGINE 30. Slide the boot off the starter solenoid terminal. Using a 13mm socket, remove the nut from the starter solenoid terminal (Fig. 1126). 32. Remove the harness wire from the solenoid terminal (Fig. 1128). Fig. 1128 Fig. 1126 31. Remove the red battery cable from the solenoid terminal (Fig. 1127). Fig. 1127 Toro Wheeled CUL Service Manual DSC-1140a DSC-1134a DSC-1138a 33. Using a 15mm socket, remove the bolt and star washer securing the ground wires to the engine block (Fig. 1129).
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4-PAW GAS/ENGINE 34. Remove the cable tie securing the hour meter wire winding to the spark plug wire (Fig. 1130). Fig. 1130 DSC-1159a 35. Unwind the hour meter wire from the spark plug wire (Fig. 1131). Fig. 1131 5/4-8 DSC-1162a 36. Disconnect the wire harness connector from the engine (Fig. 1132). Fig. 1132 DSC-1163a 37. Using a 5/16” socket, loosen the hose clamp on the air cleaner intake hose (Fig. 1133). Fig.
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4-PAW GAS/ENGINE 38. Slide the air cleaner intake hose off the air cleaner adapter (Fig. 1134). Fig. 1134 DSC-1165a 39. Slide the fuel line hose clamp away from the fuel filter (Fig. 1135). Fig. 1135 40. Slide the fuel line off the fuel filter. Allow excess fuel to drain into a proper receptacle (Fig. 1136). Fig. 1136 41. Using a 1/2” socket, remove the 4 mounting bolts securing the engine plate to the main frame. Discard the 4 mounting bolts (Fig. 1137). DSC-1167a Fig.
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4-PAW GAS/ENGINE 42. Place suitable lumber on the operator stand to receive the engine (Fig. 1138). Fig. 1138 DSC-1175a 43. Slide the engine back onto the lumber on the operator stand (Fig. 1139). Fig. 1139 44. Using a properly rated hoist and chains, lift the engine out of the frame (Fig. 1140). Fig. 1140 45. Rotate the engine crankshaft until the 2 hydraulic pump coupler set screws are accessible through the opening in the pump mount (Fig. 1141). DSC-1177a Fig.
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4-PAW GAS/ENGINE 46. Using a 1/4” 8-point socket, loosen the 2 hydraulic pump coupler set screws (Fig. 1142). Fig. 1142 DSC-1185a 47. Using a 5/8” socket, remove the 4 bolts securing the pump mount to the engine (Fig. 1143). Fig. 1143 Toro Wheeled CUL Service Manual DSC-1187a 48. Remove the hydraulic pump and mount assembly from the crankshaft (Fig. 1144). Fig. 1144 DSC-1191a 49. Remove the key from the crankshaft keyway (Fig. 1145). Fig.
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4-PAW GAS/ENGINE 50. Using a 9/16” socket and wrench, remove the 4 bolts and nuts securing the engine to the engine mount plate (Fig. 1146 and Fig. 1147). 51. Separate and remove the engine mount from the engine (Fig. 1148). Fig. 1148 Fig. 1146 DSC-1203a DSC-1196a 52. Remove the dust cap from the oil drain valve (Fig. 1149). Fig. 1147 DSC-1197a Fig.
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4-PAW GAS/ENGINE 53. Using a 15/16” wrench, remove the oil drain valve from the engine (Fig. 1150). Engine Installation 1. Apply pipe sealant to the threads of the oil drain valve. Install the engine oil drain valve finger tight (Fig. 1151). Fig. 1150 DSC-1208a 54. For engine service, refer to the proper Kohler engine service manual. Fig. 1151 DSC-1213a 2. Use a 15/16” wrench to tighten the drain valve an additional 2-1/2 turns past finger tight (Fig. 1152). Fig.
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4-PAW GAS/ENGINE 3. Install the dust cap onto the oil drain valve (Fig. 1153). 5. Position the engine mount to the engine (Fig. 1155). Fig. 1155 Fig. 1153 DSC-1220a DSC-1216a 4. Hook chains to the engine lift points (Fig. 1154). Attach a properly rated hoist to the chains. Raise the hoist to apply tension to the chains. Fig.
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4-PAW GAS/ENGINE 6. Using a 9/16” socket and wrench, install 4 bolts and nuts securing the engine to the engine mount (Fig. 1156). 7. Torque the engine mount bolts to 30 ± 3 ft-lbs. (41 ± 4 Nm) (Fig. 1158). Fig. 1158 Fig. 1156 Note: One of the bolts and nuts is installed from the bottom, the other 3 from the top (Fig. 1157). 8. Install the key into the crankshaft keyway (Fig. 1159). Fig. 1159 Fig.
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4-PAW GAS/ENGINE 9. Apply anti-seize to the engine crankshaft (Fig. 1160). Fig. 1160 11. Install 4 bolts securing the pump mount to the engine. Use a 5/8” socket to tighten the 4 bolts securing the pump mount to the engine. Torque the 4 bolts to 216 ± 25 in-lbs. (24 ± 3 Nm) (Fig. 1162). DSC-1237a Fig. 1162 10. Position the hydraulic pump and mount assembly onto the crankshaft, aligning the keyway in the pump coupler with the key in the crankshaft keyway (Fig. 1161). Fig. 1161 12.
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4-PAW GAS/ENGINE 13. Place suitable lumber on the operator’s stand. 14. Raise the hoist and position the engine onto the lumber. Remove the chains and hoist from the engine (Fig. 1164). 16. Using a 1/2” socket, loosely install 4 new mounting bolts securing the engine plate to the main frame (Fig. 1166). Fig. 1166 Fig. 1164 DSC-1254a DSC-1247a 17. Torque the 4 engine plate mounting bolts to 20 - 26 ft-lbs. (27 - 35 Nm) (Fig. 1167). 15.
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4-PAW GAS/ENGINE 18. Slide the fuel line onto the fuel filter (Fig. 1168). Fig. 1168 20. Slide the air cleaner intake hose onto the air cleaner adapter (Fig. 1170). DSC-1310a Fig. 1170 19. Slide the fuel line hose clamp into position to secure the fuel line to the filter (Fig. 1169). Fig. 1169 21. Position the hose clamp and use a 5/16” socket to tighten the hose clamp securing the air cleaner intake hose to the adapter (Fig. 1171). DSC-1312a Fig.
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4-PAW GAS/ENGINE 22. Connect the wire harness connector to the engine (Fig. 1172). Fig. 1172 DSC-1317a 23. Wind the hour meter wire around the spark plug wire (Fig. 1173). Fig. 1173 24. Install a cable tie securing the hour meter wire wind ing to the spark plug wire (Fig. 1174). Fig. 1174 25. Install the star washer, negative battery cable, and wire harness ground cable onto the ground bolt (Fig. 1175). DSC-1320a Fig.
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4-PAW GAS/ENGINE 26. Using a 15mm socket, install the ground bolt and star washer securing the negative battery cable, and wire harness ground wire to the engine block (Fig. 1176). 28. Install the harness wire and red battery cable to the solenoid terminal. (Fig. 1178). Fig. 1178 Fig. 1176 DSC-1333 DSC-1430a 29. Using a 13mm socket, install the nut to the starter solenoid (Fig. 1179). 27. Open the 2 fuel shut-offs (Fig. 1177). Fig. 1179 Fig.
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4-PAW GAS/ENGINE 30. Slide the boot onto the starter solenoid terminal (Fig. 1180). 32. Position the choke cable under the cable clamp (Fig. 1182). Fig. 1180 Fig. 1182 DSC-1338a 31. Install the choke cable z-bend into the choke linkage (Fig. 1181). Fig. 1181 Toro Wheeled CUL Service Manual DSC-1339a DSC-1340a 33. Position the choke lever in the open position. Push the choke cable toward the linkage (Fig. 1183). Fig.
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4-PAW GAS/ENGINE 34. Using an 5/16” socket, tighten the choke cable clamp (Fig. 1184). Fig. 1184 DSC-1341a 35. Install the throttle cable z-bend into the throttle linkage clamp (Fig. 1185). Fig. 1185 5/4-22 DSC-1342a 36. Position the throttle cable under the throttle cable clamp (Fig. 1186). Fig. 1186 DSC-1343a 37. Position the throttle lever in the slow position. Push the throttle cable toward the linkage (Fig. 1187). Fig.
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4-PAW GAS/ENGINE 38. Using an 5/16” socket, tighten the throttle cable clamp (Fig. 1188). Fig. 1188 40. Position the muffler onto the engine manifold studs aligning the muffler bracket mounting holes with the mounting holes on the engine (Fig. 1190). DSC-1344a Fig. 1190 39. Install 2 new manifold gaskets, placing the flat side of the gasket against the engine (Fig. 1189). Fig. 1189 41. Loosely install 2 bolts securing the muffler bracket to the engine (Fig. 1191). DSC-1346a Fig.
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4-PAW GAS/ENGINE 42. Loosely install 4 lock washers and 4 nuts securing the muffler to the engine manifold studs (Fig. 1192). Fig. 1192 DSC-1355a 43. Use a 13mm socket to tighten the 4 muffler manifold nuts. Torque the 2 bolts securing the muffler bracket to the engine to 200 ± 25 in-lbs. (23 ± 3 Nm) (Fig. 1193). 44. Install the rear suction hose onto the rear pump fitting (Fig. 1194). Fig. 1194 45.
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4-PAW GAS/ENGINE 46. Slide the front suction hose onto the front pump fitting (Fig. 1196). Note: Upon removal, all seals, o-rings and gaskets should be replaced. During installation, lightly lubricate all seals, o-rings and gaskets with clean petroleum jelly prior to assembly. 48. Install the hydraulic line (marked with and R) to the rear hydraulic pump fitting (Fig. 1198). Fig. 1196 DSC-1362a 47.
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4-PAW GAS/ENGINE 50. Install the hydraulic line (marked with and F) to the front hydraulic pump fitting (Fig. 1200). 52. Connect the positive and then the negative battery cable to the battery. Position the battery clamp on the battery up against the frame (Fig. 1202). A B Fig. 1200 DSC-1366a Fig. 1202 DSC-1369a A. Negative battery cable B. Positive battery cable 51. Use a 15/16” wrench to tighten the hydraulic line nut to the fitting (Fig. 1201). 53. Remove the absorbent towels. Fig.
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4-PAW GAS/ENGINE 54. Fill the engine with oil: a. Remove the oil fill cap and slowly pour approximately 80% of the specified amount of oil in through the valve cover. b. Clean around the oil dipstick (Fig. 1203). c. Pull out the dipstick and wipe the metal end clean (Fig. 1203). 55. Check the hydraulic fluid level: Hydraulic Tank Capacity: 17.25 US gallons (67 l) a. Use 10W-30 or 15W-40 detergent, diesel engine oil (API service CH-4 or higher). b.
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4-PAW GAS/ENGINE 56. Verify/adjust engine RPM to the following (refer to Kohler engine service manual): 61. Reinstall the loader arm cylinder locks onto the hydraulic auxiliary lines (for storage) (Fig. 1207). Maximum engine speed (full throttle) to 3600 ± 75 RPM. Minimum engine speed (idle) to 1400 ± 200 RPM. 57. Install the hood. 58. Raise the loader arm all the way up to remove pressure from the loader arm cylinder locks. 59. Remove the clevis pin and cotter pin from the loader arm cylinder locks (Fig.
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4-PAW GAS/ELECTRICAL Ignition Switch (P/N 103990) How It Works Purpose Detents inside the ignition switch give it 3 positions: OFF, RUN, and START. The START position is spring loaded so the cylinder automatically returns to RUN once the key is released. This component provides the proper switching for the starter, ignition, accessories, and safety circuits. Testing Location The ignition switch is mounted on the right hand side of the upper frame assembly (Fig. 1208). 1.
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4-PAW GAS/ELECTRICAL Relay How It Works Purpose A relay is an electrically actuated switch. The 4-Paw Gas Wheeled Compact Utility Loader uses two relays: a start relay and a kill relay. 1. Coil: Terminals 85 and 86 are connected to a coil. Applying 12 volts to these terminals energizes the coil turning it into an electromagnet.
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4-PAW GAS/ELECTRICAL Testing Fuses 1. Disconnect the relay from the harness. Purpose 2. Verify the coil resistance between terminals 85 and 86 with a multimeter (ohms setting). Resistance should be 70 to 90 ohms. There should be continuity between terminals 87a and 30 (Fig. 1212). Fuses are used in the circuits to limit damage in the event of excessive current flow. If a fuse fails, look for a short circuit, a corroded/poor connection, or any component that appears to have been overheated.
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4-PAW GAS/ELECTRICAL How It Works Location The fuse block is where the wires that carry 12 volts meet the wires that need 12 volts to operate a compon ent or function. The fuse makes the connection between the 12 volt wire that needs the current. There are 2 neutral safety switches. They are threaded into the lower portion of the 4-spool hydraulic valve, located under the upper frame assembly (Fig. 1215). Testing A failed fuse will often be discolored or melted.
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4-PAW GAS/ELECTRICAL Auxiliary Neutral Switch How It Works Purpose The switch has a spring loaded ball. When the hydraulic auxiliary valve is in neutral position, the ball moves into a machined notch located in the spool. The normally closed switch then provides a ground to the start circuit. When the auxiliary lever is moved out of neutral, the spool pushes against the ball end of the switch and opens the ground circuit which prevents the engine from starting.
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4-PAW GAS/ELECTRICAL Hour Meter/Tachometer How It Works Purpose The digital inductive hour meter is an electronic clock and RPM gauge. It is not repairable or resettable (Fig. 1219). The hour meter displays engine run time and is a service reminder. When the engine is running, it also displays the speed of the engine in revolutions per minute (rpm). After 50 hours and then every 100 hours thereafter (that is at 150, 250, 350, etc.) the screen displays CHG OIL to remind you to change the oil.
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4-PAW GAS/ELECTRICAL Electrical Schematics 22318 - 2010, 2009, 2008, 2007 Fig.
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4-PAW GAS/ELECTRICAL 22318 - 2006, 2005 22312 - 2005, 2004, 2003 Fig.
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4-PAW GAS/ELECTRICAL 22312 - 2004, 2003 22305 - 2002, 2001 Toro Wheeled CUL Service Manual 3325-579 22312-2004 Fig.
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. . BK BK OR OR BK BK Y PK PK F1 30A VIO GN VIO F2 25A K2 (KILL RELAY) R W R R VIO VIO W GN R SW5 IGNITION 2 3 B R BU K1 (START RELAY) GN SW3 (VALVE) AUX. VALVE CLOSED WHEN IN DETENT Y OR 5 I HOUR METER 1 S 4 A GY OR SW2 (NEUTRAL) SWITCH CLOSED IN NEUTRAL DETENT BN GND 10A F3 SW1 (NEUTRAL) SWITCH CLOSED IN NEUTRAL DETENT PK OR HEADLIGHT CONNECTOR A B 5 2 4 3 1 5 2 4 3 3322-896 22305-2000 1 5/5-10 + Fig.
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4-PAW DIESEL/DRIVE SYSTEM Front Wheel Motor Replacement 6. Raise the front of the machine (Fig. 1226). Front Wheel Motor Removal 1. Park CUL on a level surface. 2. Raise the loader arm 6” - 12” (15 - 30cm) off the ground. 3. Turn off the machine and remove the key. 4. Lift the rear of the machine (Fig. 1224). Fig. 1226 DSC-3924a 7. Position jackstands under the front corners of the machine. Remove the floor jack (Fig. 1227). Fig. 1224 DSC-0100a 5.
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4-PAW DIESEL/DRIVE SYSTEM 8. Lower the loader arm. 9. Using a 13/16” socket, remove 5 lug nuts securing the rear wheel to the wheel hub (Fig. 1228). 11. Using a 13/16” socket, remove 5 lug nuts securing the front wheel to the wheel hub (Fig. 1230). Fig. 1230 Fig. 1228 DSC-0834a DSC-0831a 12. Remove the wheel from the wheel hub (Fig. 1231). 10. Remove the wheel from the wheel hub (Fig. 1229). Fig. 1231 Fig.
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4-PAW DIESEL/DRIVE SYSTEM 13. Using a 1/2” socket, remove the 4 bolts securing the hose cover to the main frame (Fig. 1232). 15. Using a 1-1/2” socket, loosen, do not remove, the patch lock nut on the front wheel motor shaft (Fig. 1234). Note: In 2004 there was a running change from the castle nut and cotter pin (22312 serial #240000200 and lower) to a patch lock nut (22312 serial #240000201 and higher) for retaining the wheel motors. Fig. 1232 DSC-0838a 14. Remove the hose cover (Fig. 1233). Fig.
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4-PAW DIESEL/DRIVE SYSTEM 17. Install 5 lug nuts (reversed) to secure the hub puller to the wheel hub (Fig. 1236). Fig. 1236 DSC-0923a 18. Using a 1-1/2” socket, rotate the center puller bolt to break the hub free of the wheel motor shaft (Fig. 1237). 19. Remove the 5 lug nuts and the puller from the hub (Fig. 1238). Fig. 1238 20. Remove the patch lock nut from the wheel motor shaft and discard (Fig. 1239). Fig. 1239 Fig.
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4-PAW DIESEL/DRIVE SYSTEM 21. Remove the hub from the wheel motor shaft and discard (Fig. 1240). Fig. 1240 24. Using a 1-1/8” wrench, loosen the left hand upper hydraulic line from the bulkhead fitting in the main frame (Fig. 1242). DSC-0927a Fig. 1242 22. Place a drain pan under the front wheel motor. 23. Using a 1-1/8” wrench, remove the upper hydraulic line from the upper wheel motor fitting (Fig. 1241). 25. Rotate the upper hydraulic line out and allow the fluid to drain in the drain pan (Fig.
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4-PAW DIESEL/DRIVE SYSTEM 26. Using a 1/1/8” wrench, remove the lower hydraulic line from the lower wheel motor fitting (Fig. 1244). Fig. 1244 DSC-0933a 27. Allow the fluid to drain into the pan (Fig. 1245). 28. Using a 1-1/16” socket, remove the 2 wheel motor fittings (Fig. 1246). Fig. 1246 DSC-0940a 29. Cap the lines, fittings and ports to prevent debris from contaminating the system. 30. Support the wheel motor with a floor jack (Fig. 1247). Fig. 1245 DSC-0934a Fig.
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4-PAW DIESEL/DRIVE SYSTEM 31. Using a 3/4” socket, remove the 4 bolts securing the wheel motor to the mainframe (Fig. 1248). Front Wheel Motor Installation Note: Upon removal, all seals, o-rings and gaskets should be replaced. During installation, lightly lubricate all seals, o-rings and gaskets with clean petroleum jelly prior to assembly. 1. Place the wheel motor onto a floor jack with the fittings facing to the side. Position the wheel motor under the main frame (Fig. 1250). Fig. 1248 DSC-0943a 32.
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4-PAW DIESEL/DRIVE SYSTEM 3. Loosely install 4 wheel motor mounting bolts (Fig. 1252). Fig. 1252 5. Remove the floor jack. 6. Using a 1-1/16” socket, install the 2 wheel motor fittings (Fig. 1254). DSC-0951a Fig. 1254 4. Using a 3/4” socket, tighten and torque the 4 mount ing bolts to 75 ± 8 ft-lbs. (102 ± 11 Nm) (Fig. 1253). Fig. 1253 7. Using a 1-1/8” wrench, install the lower hydraulic line to the lower wheel motor fitting (Fig. 1255). DSC-0952a Fig.
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4-PAW DIESEL/DRIVE SYSTEM 8. Rotate the upper hydraulic line into position aligning it with the upper wheel motor fitting. Use a 1-1/8” wrench to install the upper hydraulic line to the upper wheel motor fitting (Fig. 1256 and Fig. 1257). 9. Use a 1-1/8” wrench to tighten the front upper hydraulic line to the bulkhead fitting in the main frame (Fig. 1258). Fig. 1258 Fig. 1256 DSC-0964a DSC-0962a 10. Start the machine. Allow the air to purge from the hydraulic system.
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4-PAW DIESEL/DRIVE SYSTEM Note: Prior to installing the drive hub, make sure the wheel motor shaft and inner drive hub are clean, degreased and free of paint to ensure a proper fit between the drive hub and wheel motor shaft. 12. With the key installed in the wheel motor shaft (Fig. 1259), slide a new hub onto the wheel motor shaft (Fig. 1260). Fig. 1259 DSC-0965a 13. Install a new patch lock nut onto the wheel motor shaft. Torque the patch lock nut to 325 ± 25 ft-lbs. (441 ± 34 Nm) (Fig. 1261).
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4-PAW DIESEL/DRIVE SYSTEM 15. Loosely install 4 bolts to secure the hose cover to the main frame (Fig. 1263). 17. Slide the front wheel onto the wheel hub (Fig. 1265). Fig. 1265 Fig. 1263 16. Using a 1/2” socket, tighten the 4 bolts, securing the hose cover to the main frame (Fig. 1264). 18. Loosely install 5 lug nuts (tapered side in) (Fig. 1266). Fig. 1266 Fig.
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4-PAW DIESEL/DRIVE SYSTEM 19. Torque all 5 lug nuts to 50 + 5ft-lbs. (68 + 7 Nm) (Fig. 1267). Fig. 1267 DSC-0975a 20. Slide the rear wheel onto the wheel hub (Fig. 1268). Fig. 1268 21. Loosely install 5 lug nuts (tapered side in) (Fig. 1269). Fig. 1269 DSC-0977a 22. Torque all 5 lug nuts to 50 + 5ft-lbs. (68 + 7 Nm) (Fig. 1270). DSC-0976a Fig. 1270 DSC-0978a 23. Check the hydraulic fluid level and add fluid if necessary. 24. Remove from jackstands and test operate unit.
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4-PAW DIESEL/DRIVE SYSTEM 6. Raise the front of the machine (Fig. 1273). Rear Wheel Motor Replacement Rear Wheel Motor Removal 1. Park CUL on a level surface. 2. Raise the loader arm 6” - 12” (15 - 30cm) off the ground. 3. Turn off the machine and remove the key. 4. Lift the rear of the machine (Fig. 1271). Fig. 1273 DSC-3924a 7. Position jackstands under the front 2 corners of the machine. Remove the floor jack (Fig. 1274). Fig. 1271 DSC-0100a 5.
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4-PAW DIESEL/DRIVE SYSTEM 8. Lower the loader arm. 9. Using a 13/16” socket, remove 5 lug nuts securing the rear wheel to the wheel hub (Fig. 1275). 11. Using a 13/16” socket, remove 5 lug nuts securing the front wheel to the wheel hub (Fig. 1277). Fig. 1277 Fig. 1275 DSC-0834a DSC-0831a 12. Remove the wheel from the wheel hub (Fig. 1278). 10. Remove the wheel from the wheel hub (Fig. 1276). Fig. 1278 Fig.
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4-PAW DIESEL/DRIVE SYSTEM 13. Using a 1/2” socket, remove the 4 bolts securing the hose cover to the main frame (Fig. 1279). 15. Using a 1-1/2” socket, loosen, do not remove, the patch lock nut on the rear wheel motor shaft (Fig. 1281). Note: In 2004 there was a running change from the castle nut and cotter pin (22312 serial #240000200 and lower) to a patch lock nut (22312 serial #240000201 and higher) for retaining the wheel motors. Fig. 1279 DSC-0836a 14. Remove the hose cover (Fig. 1280). Fig.
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4-PAW DIESEL/DRIVE SYSTEM 17. Install 5 lug nuts (reversed) to secure the hub puller to the wheel hub (Fig. 1283). Fig. 1283 DSC-0845a 18. Using a 1-1/2” socket, rotate the center puller bolt to break the hub free of the wheel motor shaft (Fig. 1284). 19. Remove the 5 lug nuts and the puller from the hub (Fig. 1285). Fig. 1285 20. Remove the patch lock nut from the wheel motor shaft and discard (Fig. 1286). Fig. 1286 Fig.
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4-PAW DIESEL/DRIVE SYSTEM 21. Remove the hub from the wheel motor shaft and discard (Fig. 1287). Fig. 1287 24. Using a 1-1/8” wrench, loosen the rear upper hydraulic line from the bulkhead fitting in the main frame (Fig. 1289). DSC-0849a Fig. 1289 22. Place a drain pan under the rear wheel motor. 23. Using a 1-1/8” wrench, remove the upper hydraulic line from the upper wheel motor fitting (Fig. 1288). 25. Rotate the upper hydraulic line out and allow the fluid to drain in the drain pan (Fig. 1290).
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4-PAW DIESEL/DRIVE SYSTEM 26. Using a 1/1/8” wrench, remove the lower hydraulic line from the lower wheel motor fitting (Fig. 1291). Fig. 1291 DSC-0854a 27. Allow the fluid to drain into the drain pan (Fig. 1292). 28. Using a1-1/16” socket, loosen the 2 wheel motor fittings (Fig. 1293). Fig. 1293 DSC-0857a 29. Cap the hydraulic lines and fittings to prevent debris from contaminating the system. 30. Support the wheel motor with a floor jack (Fig. 1294). Fig. 1292 DSC-0856a Fig.
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4-PAW DIESEL/DRIVE SYSTEM 31. Using a 3/4” socket, remove the 4 bolts securing the wheel motor to the main frame (Fig. 1295). 33. To service the existing wheel motor, refer to “Parker / Ross Wheel Motor Service Manual” (Toro Form No. 492-4753). 34. If a new wheel motor is being installed, remove the 2 wheel motor fittings and transfer them to the new wheel motor (Fig. 1297). Fig. 1295 DSC-0860a 32. Using the floor jack, lower the wheel motor out of the frame (Fig. 1296). Fig.
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4-PAW DIESEL/DRIVE SYSTEM 3. Loosely install 4 wheel motor mounting bolts (Fig. 1300). Rear Wheel Motor Installation Note: Upon removal, all seals, o-rings and gaskets should be replaced. During installation, lightly lubricate all seals, o-rings and gaskets with clean petroleum jelly prior to assembly. 1. Place the wheel motor onto a floor jack with the fittings facing to the side. Position the wheel motor under the main frame (Fig. 1298). Fig. 1300 DSC-0873 4.
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4-PAW DIESEL/DRIVE SYSTEM 5. Remove the floor jack. 6. Using a1-1/16” socket, tighten the 2 wheel motor fittings (Fig. 1302). Fig. 1302 DSC-0875a 7. Using a 1/1/8” wrench, install the lower hydraulic line to the lower wheel motor fitting (Fig. 1303). Fig. 1303 8. Rotate the upper hydraulic line into position aligning it with the upper wheel motor fitting. Use a 1-1/8” wrench to install the upper hydraulic line to the upper wheel motor fitting (Fig. 1304). Fig. 1304 9.
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4-PAW DIESEL/DRIVE SYSTEM 10. Start the machine. Allow the air to purge from the hydraulic system. Check the wheel motor, hydraulic lines and fittings for leaks. 13. Install a new patch lock nut onto the wheel motor shaft. Torque the patch lock nut to 325 ± 25 ft-lbs. (441 ± 34 Nm) (Fig. 1308). 11. Turn the machine off and remove the key.
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4-PAW DIESEL/DRIVE SYSTEM 15. Loosely install 4 bolts to secure the hose cover to the main frame (Fig. 1310). 17. Slide the front wheel onto the wheel hub (Fig. 1312). Fig. 1312 Fig. 1310 16. Using a 1/2” socket, tighten the 4 bolts securing the hose cover to the mainframe (Fig. 1311). 18. Loosely install 5 lug nuts (tapered side in) (Fig. 1313). Fig. 1313 Fig.
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4-PAW DIESEL/DRIVE SYSTEM 19. Torque all 5 lug nuts to 50 + 5 ft-lbs. (68 + 7 Nm) (Fig. 1314). Fig. 1314 DSC-0975a 20. Slide the rear wheel onto the wheel hub (Fig. 1315). Fig. 1315 21. Loosely install 5 lug nuts (tapered side in) (Fig. 1316). Fig. 1316 DSC-0977a 22. Torque all 5 lug nuts to 50 + 5 ft-lbs. (68 + 7 Nm) (Fig. 1317). DSC-0976a Fig. 1317 DSC-0978a 23. Check the hydraulic fluid level and add fluid if necessary. 24. Remove from jackstands and test operate unit.
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4-PAW DIESEL/HYDRAULICS 4-Spool Valve Replacement (Diesel) 4-Spool Valve Removal 5. Remove the two bolts and nuts securing the air cleaner assembly to the mounting bracket (Fig. 1319). Note: Upon removal, all seals, o-rings and gaskets should be replace. During installation, lightly lubricate all seals, o-rings and gaskets with clean petroleum jelly prior to assembly. 1. Park the machine on a level surface. 2. Turn the machine off and remove the key. 3. Unlatch and open the engine rear cover. 4.
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4-PAW DIESEL/HYDRAULICS 7. Remove the 3 bolts and nuts securing the indicator lamp mounting bracket to the upper frame assembly (Fig. 1321). 9. Remove the bottom jam nut from each of the 4 control levers on the 4-spool valve and then remove the 4 control levers (Fig. 1323). Fig. 1321 Fig. 1323 DSC-3053a 8. Mark the wiring plugs and indicator lights to aid reassembly (Fig. 1322). Remove the lamp mount from the upper frame assembly. 10.
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4-PAW DIESEL/HYDRAULICS 11. Remove the throttle control assembly from the control panel (Fig. 1325). Fig. 1325 13. Remove the inlet hydraulic line assembly from the top of the flow control valve and the 4-spool valve (Fig. 1327). DSC-3061a Fig. 1327 12. Remove the metal hydraulic test port line from the fitting located on the left side of the 4-spool valve (Fig. 1326). Fig. 1326 Toro Wheeled CUL Service Manual DSC-3064a DSC-3065a 14.
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4-PAW DIESEL/HYDRAULICS 15. Remove the return hydraulic line nut from the fitting on the right side of the 4-spool valve (Fig. 1329). Fig. 1329 DSC-3073a 16. Loosen the auxiliary return hydraulic line nut from the fitting located on the right side of the auxiliary valve (Fig. 1330). 17. Loosen the auxiliary hydraulic line nut from the fitting on the 4-spool valve (Fig. 1331). Fig. 1331 18. Remove the hydraulic line from the machine (Fig. 1332). Fig. 1332 Fig.
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4-PAW DIESEL/HYDRAULICS 19. Mark one of the tilt cylinder hydraulic lines and fittings located on the 4-spool valve (Fig. 1333). Fig. 1333 DSC-3090a 20. Remove the 2 tilt cylinder hydraulic lines from the fittings on the 4-spool valve (Fig. 1334). Fig. 1334 Toro Wheeled CUL Service Manual DSC-3088a 21. Remove the 2 hydraulic lines coming from the right side counterbalance valve (Fig. 1335). Fig. 1335 DSC-3095a 22. Remove the 2 hydraulic lines coming from the left side counterbalance valve (Fig.
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4-PAW DIESEL/HYDRAULICS 23. Loosen the 3 bolts and remove the nuts securing the 4-spool valve to the upper frame assembly (Fig. 1337). Fig. 1337 DSC-3099a 24. Remove the top bolt, washer and spacer securing the 4-spool valve to the frame (Fig. 1338). Fig. 1338 6/2-6 DSC-3102a 25. Remove the remaining two bolts, washers, spacers, and the mount bracket from the upper frame assembly (Fig. 1339). Fig. 1339 DSC-3108a 26. Carefully lower the 4-spool valve onto the top of the engine (Fig. 1340).
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4-PAW DIESEL/HYDRAULICS 27. Cut the plastic ties securing the lift cylinder hydraulic line and the wiring harness with the two wire plugs for the neutral safety switches (Fig. 1341). 29. Remove the 4-spool valve from the machine (Fig. 1343). Fig. 1343 Fig. 1341 DSC-3124a DSC-3110a Note: Place protective caps and plugs on the valve fittings and hydraulic lines to protect them from any contamination. 28. Unplug the two neutral safety switch plugs (Fig. 1342). Fig.
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4-PAW DIESEL/HYDRAULICS 4-Spool Valve (Fig. 1344). 4-Spool Valve Installation 1. Position the 4-spool valve on top of the engine (Fig. 1345). AB BC E FG H I J K D F GH I L L Fig. 1344 DSC-3131a A. Attachment Tilt Lever H. Left Side CounterB. Traction Control balance Valve Lever (2) I. Lift Cylinder Line C. Loader Arm Lever J. Flow Control Line D. Hydraulic Return Line K. Test Port Line E. Auxiliary Valve Line L. Neural Safety Switch (2) F. Tilt Cylinder Line G.
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4-PAW DIESEL/HYDRAULICS 3. Install 3 cable ties to secure the neutral switches to the harness and the harness wires to the right hand lift cylinder hydraulic line (Fig. 1347). Fig. 1347 DSC-3141a 4. Position the valve up into the control panel. Install a bolt into the upper right hand mounting hole. Position the longest spacer between the valve and control panel. Install a nut onto the bolt to secure (Fig. 1348). 5.
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4-PAW DIESEL/HYDRAULICS 7. Install the 4 hydraulic counterbalance valve lines to the 4-spool valve fittings (Fig. 1351). Fig. 1351 9. Position the auxiliary valve return hydraulic line to the auxiliary valve and 4-spool valve and loosely install the line nuts (Fig. 1353). DSC-3091a Fig. 1353 8. Install 2 hydraulic tilt cylinder lines to the 4-spool valve. Note: The top line and fitting were previously marked (Fig. 1352). 10.
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4-PAW DIESEL/HYDRAULICS 11. Install the hydraulic return line to the straight fitting on the end of the 4-spool valve (Fig. 1355). Fig. 1355 13. Position the inlet hydraulic flow control line to the top of the flow control valve and the 4-spool valve fitting (Fig. 1357). DSC-3073a Fig. 1357 12. Install the 2 lift cylinder hydraulic line T-fittings to the 4-spool valve (Fig. 1356). Fig. 1356 14.
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4-PAW DIESEL/HYDRAULICS 15. Position the throttle control lever assembly into the control panel (Fig. 1359). Fig. 1359 DSC-3061a 16. Install two bolts and nuts to secure the throttle control lever assembly to the control panel (Fig. 1360). 17. Thread the 4 control levers into the 4-spool valve (Fig. 1361). Fig. 1361 18. Install a jam nut on each lever to secure the lever to the 4-spool valve (Fig. 1362). Fig. 1362 Fig.
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4-PAW DIESEL/HYDRAULICS 19. Connect the harness plugs to the indicator lights (previously marked) (Fig. 1363). Fig. 1363 21. Position the air cleaner assembly into the chassis in the position located above and to the left of the engine (Fig. 1365). DSC-3055a Fig. 1365 20. Position the indicator lamp mount to the control panel. Install 3 bolts and nuts to secure the lamp mount to the control panel (Fig. 1364). Fig. 1364 Toro Wheeled CUL Service Manual DSC-3053a DSC-3052a 22.
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4-PAW DIESEL/HYDRAULICS 23. Slide the air cleaner hose onto the engine intake. Position the hose clamp and tighten to secure (Fig. 1367). Hydraulic Auxiliary, Selector & Flow Divider Valves Hydraulic Auxiliary, Selector & Flow Divider Valves Removal Note: Upon removal, all seals, o-rings and gaskets should be replace. During installation, lightly lubricate all seals, o-rings and gaskets with clean petroleum jelly prior to assembly. 1. Mark the hydraulic line and fitting on the flow divider valve (A) (Fig.
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4-PAW DIESEL/HYDRAULICS 2. Mark the two hydraulic lines and fittings on the selector valve (B & C) (Fig. 1369). Fig. 1369 DSC-2962a 3. Mark the two hydraulic lines and fittings on the auxiliary valve (D & E) (Fig. 1370). Fig. 1370 Toro Wheeled CUL Service Manual DSC-2965a 4. Remove the hydraulic line from the flow divider valve fitting (marked ‘A’) (Fig. 1371). Fig. 1371 DSC-2968a 5. Remove the hydraulic line nut from the fitting located on top of the flow divider valve (Fig. 1372). Fig.
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4-PAW DIESEL/HYDRAULICS 6. Remove the two hydraulic selector valve lines from the fittings marked ‘B’ & ‘C’ (Fig. 1373). Fig. 1373 DSC-2972a 7. Remove the two hydraulic auxiliary valve lines marked ‘D’ & ‘E’ (Fig. 1374). Fig. 1374 8. Remove the hydraulic return line nut from the fitting located on the side of the auxiliary valve (Fig. 1375). Fig. 1375 9. Place plugs and caps on the hydraulic lines and fittings to protect the system from contamination (Fig. 1376). DSC-2973a Fig.
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4-PAW DIESEL/HYDRAULICS 10. Unplug the auxiliary safety switch from the harness located under the auxiliary valve (Fig. 1377). Fig. 1377 DSC-2983a 11. Remove the 6 bolts, spacers, washers, and nuts securing the valves to the upper frame assembly (Fig. 1378). Fig. 1378 Toro Wheeled CUL Service Manual DSC-2977a 12. Remove the auxiliary, selector, and flow divider valves from the upper frame assembly (Fig. 1379). Fig. 1379 DSC-2986a 13.
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4-PAW DIESEL/HYDRAULICS 14. Remove the hydraulic line (F) from the t-fitting located between the auxiliary and the selector valves (Fig. 1381). 16. Remove the flow divider valve from the fitting (Fig. 1383). Fig. 1383 Fig. 1381 15. Loosen the jam nut on the flow divider valve fitting (Fig. 1382). 17. Loosen the jam nut on the t-fitting between the selector and auxiliary valves (Fig. 1384). Fig. 1384 Fig.
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4-PAW DIESEL/HYDRAULICS 18. Remove the selector valve from the t-fitting (Fig. 1385). Fig. 1385 DSC-2997a B Fig. 1386 A. Auxiliary Valve B. Selector Valve Fig. 1387 DSC-3006a Note: For auxiliary valve rebuild instructions, refer to “99-3077 Auxiliary Valve Rebuild” on page 3/1-67. 19. Valve assembly separated (Fig. 1386): A 20. Remove the bolt and nut securing the handle to the auxiliary valve (Fig. 1387). C DSC-2999a C.
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4-PAW DIESEL/HYDRAULICS Hydraulic Auxiliary, Selector & Flow Divider Valves Installation 3. Install the flow divider valve to the fitting on the selector valve; leave the jam nut loose (Fig. 1390). 1. Position the handle to the auxiliary valve. Loosely install a bolt and nut to secure the handle to the auxiliary valve (Fig. 1388). Fig. 1390 Fig. 1388 DSC-3006a DSC-3001a 4. Position the auxiliary, selector, and the flow divider valve assembly to the upper frame (Fig. 1391). 2.
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4-PAW DIESEL/HYDRAULICS 5. Position a spacer between the frame and the aux iliary valve. Install a bolt through the valve and the spacer (Fig. 1392). Fig. 1392 7. Tighten the two jam nuts: one located between the flow divider valve and the selector valve (Fig. 1394) and the other on the t-fitting between the selector valve and auxiliary valve (Fig. 1395). DSC-3010a Fig. 1394 DSC-3017a Fig. 1395 DSC-3019a 6.
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4-PAW DIESEL/HYDRAULICS 8. Install the hydraulic line nut to the fitting located on the side of the auxiliary valve (Fig. 1396). Fig. 1396 DSC-3927a 9. Install the two hydraulic lines (D & E) from the bulkhead coupler assemblies to the auxiliary valve (Fig. 1397). 10. Install the hydraulic line (F) to the t-fitting between the auxiliary and selector valve (Fig. 1398). Fig. 1398 11. Route the hydraulic line (F) between the two tilt cylinder hydraulic lines (Fig. 1399). Fig. 1399 Fig.
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4-PAW DIESEL/HYDRAULICS 12. Connect the hydraulic line (F) to the bottom of the flow divider valve (Fig. 1400). Fig. 1400 14. Install the (B & C) hydraulic lines to the selector valve. Make sure the two hydraulic lines are routed to the inside of the hydraulic line going from the t-fitting to the flow divider valve (Fig. 1402). DSC-3032a Fig. 1402 DSC-3039a 13. Install the hydraulic line nut to the fitting on top of the flow divider valve (Fig. 1401). 15.
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4-PAW DIESEL/HYDRAULICS 16. Adjust the auxiliary valve lever by pulling it back to the handle and tighten the bolt and nut (Fig. 1404). Hydraulic Lift Cylinder Replacement (Old Style) Note: The front grill was removed for photo purposes. Note: Upon removal, all seals, o-rings and gaskets should be replace. During installation, lightly lubricate all seals, o-rings and gaskets with clean petroleum jelly prior to assembly. Hydraulic Lift Cylinder Removal Fig. 1404 DSC-3046a 1.
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4-PAW DIESEL/HYDRAULICS 2. Mark the upper hydraulic hose and cylinder fitting (A) (Fig. 1406). Fig. 1406 4. Install a plug and cap on the hydraulic hose and cylinder fitting to prevent contamination and assist in stopping oil leakage (Fig. 1408). IMG-0090a Fig. 1408 3. Remove the hydraulic hose from the upper cylinder fitting (Fig. 1407). Fig. 1407 5. Remove the hydraulic hose from the lower cylinder fitting (Fig. 1409). IMG-0091a Fig.
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4-PAW DIESEL/HYDRAULICS 6. Install a plug and cap on the hydraulic hose and cylinder fitting to prevent contamination and assist in stopping oil leakage (Fig. 1410). 8. Remove the pivot pin from the ram end of the cylinder (Fig. 1412). Fig. 1412 Fig. 1410 7. Remove the shoulder bolt securing the upper pivot pin to the cylinder ram (Fig. 1411). 9. Remove the shoulder bolt securing the lower pivot pin to the barrel end of the cylinder (Fig. 1413). Fig. 1413 Fig.
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4-PAW DIESEL/HYDRAULICS 10. Support the cylinder and remove the pivot pin from the barrel end of the cylinder (Fig. 1414). Fig. 1414 IMG-0098a 11. Remove the lift cylinder from the machine (Fig. 1415). Fig. 1415 Toro Wheeled CUL Service Manual 12. Remove the two 90 degree fittings from the lift cylinder (Fig. 1416). Fig. 1416 IMG-0102a 13.
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4-PAW DIESEL/HYDRAULICS 3. Install a pivot pin through the barrel end pivot point and frame (Fig. 1419). Hydraulic Lift Cylinder Installation 1. Install 2 hydraulic fittings into the lift cylinder. Posi tion the fittings so they face each other (Fig. 1417). Fig. 1419 Fig. 1417 IMG-0102a 2. Position the lift cylinder in the machine with the ram end facing up, aligning the pivot points on the cylinder with the pivot points on the frame and loader arm (Fig. 1418). 4.
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4-PAW DIESEL/HYDRAULICS 5. Install the hydraulic lines to the lift cylinder fittings, with the hydraulic line (A) installed to the upper cylinder fitting (Fig. 1421). 7. Align the pivot pin through hole with the mounting hole in the cylinder. Install a shoulder bolt to secure the pivot pin. Torque the shoulder bolt to 150 to 179 in-lbs. (17 – 19 Nm) (Fig. 1423). Note: Use double wrenches to prevent the hose from twisting while tightening. Fig. 1423 Fig. 1421 IMG-0108a IMG-0107a 6.
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4-PAW DIESEL/HYDRAULICS Hydraulic Tilt Cylinder Replacement (Old Style) Note: The front grill was removed for photo purposes. Hydraulic Tilt Cylinder Removal 1. Park the machine on a level surface, turn it off and remove the key. 2. Remove the shoulder bolt securing the lower pivot pin to the ram end of the tilt cylinder (Fig. 1426). A B Fig. 1425 A. New style tilt cylinder DSC-3929a B. Old style tilet cylinder Fig. 1426 IMG-0113a 3. Support the attach plate.
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4-PAW DIESEL/HYDRAULICS 4. Remove the cable tie securing the hydraulic hoses to the tilt cylinder barrel (Fig. 1428). 6. Place a drain pan under the front end of the machine to catch the hydraulic fluid from the hydraulic hoses. 7. Remove the hydraulic hoses from the tilt cylinder fittings. Allow the hydraulic fluid to drain into the drain pan (Fig. 1430). Fig. 1428 IMG-0116a 5. Remove the cable tie securing the hydraulic hoses together (Fig. 1429). Fig. 1430 IMG-0122a 8.
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4-PAW DIESEL/HYDRAULICS 10. Support the tilt cylinder and remove the upper pivot pin. Remove the tilt cylinder from the machine (Fig. 1432). Fig. 1432 Hydraulic Tilt Cylinder Installation 1. Install 2 hydraulic fittings in the tilt cylinder. Orient the fittings so they face away from the rod end of the cylinder (Fig. 1434). IMG-0125a Fig. 1434 IMG-0127a 11. Remove the two 90 degree fittings from the tilt cylinder (Fig. 1433). 2.
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4-PAW DIESEL/HYDRAULICS 3. Align the pivot pin through hole with the mounting hole in the cylinder. Install a shoulder bolt to secure the pivot pin. Torque the shoulder bolt to 150 to 170 in-lbs. (17 – 19 Nm) (Fig. 1436). 5. Lift the attach plate and align the cylinder ram to the attach plate pivot point. Install a pivot pin (Fig. 1438). Fig. 1438 Fig. 1436 IMG-0134a IMG-0131a 4. Install the hydraulic lines to the tilt cylinder fittings (Fig. 1437). 6.
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4-PAW DIESEL/HYDRAULICS 7. Install a cable tie around the tilt cylinder hydraulic hoses (Fig. 1440). Fig. 1440 IMG-0137a 9. Grease the pivot pins and bushings using general purpose grease (Fig. 1442 and Fig. 1443). Fig. 1442 IMG-0140a Fig. 1443 IMG-0141a 8. Install a cable tie around the cylinder barrel and hydraulic hose (Fig. 1441). Fig. 1441 IMG-0139a 10. Check the hydraulic fluid level and add as necessary. 11. Start the machine and check for leaks. 12. Purge air form the system. 13.
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4-PAW DIESEL/HYDRAULICS Left Hand Counterbalance Valve Replacement 4. Mark the hydraulic lines on the bulkhead F and R (Fig. 1446). Left Hand Counterbalance Valve Removal Note: Upon removal, all seals, o-rings and gaskets should be replace. During installation, lightly lubricate all seals, o-rings and gaskets with clean petroleum jelly prior to assembly. 1. Remove the Radiator. Refer to “Radiator Removal” on page 6/4-92. 2.
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4-PAW DIESEL/HYDRAULICS 6. Place absorbent towel inside the chassis under the left hand counterbalance valve. 7. Using a 1-1/8” offset wrench, remove the hydraulic line nut marked F from the bulkhead fitting (Fig. 1448). 9. Lay the (F) hydraulic line to the side in the chassis. 10. Using a 1-1/8” offset wrench, remove the hydraulic line nut marked R from the front, bottom counter balance valve fitting (Fig. 1450). Fig. 1450 Fig. 1448 8.
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4-PAW DIESEL/HYDRAULICS 12. Using an 11/16” wrench, remove the lift cylinder t-fitting from the lower fitting on the 4-spool vale (Fig. 1452). 14. Using a 1-1/8” crowfoot wrench, loosen the hydraulic line nut on the 90 degree fitting on the bottom of the counterbalance valve (Fig. 1454). Fig. 1452 Fig. 1454 DSC-1811a 13. Using a 1-1/8” crowfoot wrench, remove the left hand counterbalance valve line nut from the lower fitting on the 4-spool valve (Fig. 1453). 15.
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4-PAW DIESEL/HYDRAULICS 16. Using a 7/16” socket and nut, remove the bolt, wash er, spacer, washer and nut securing the left hand counterbalance valve to the frame (Fig. 1456). 18. Transfer 4 of the 7 fittings from the old counter balance valve to the new counterbalance valve (Fig. 1458). Note: The 2 spool fittings and the tow valve do not get transferred. They come with the new counterbalance valve. Fig. 1456 DSC-1828a 17. Slide counterbalance valve out.
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4-PAW DIESEL/HYDRAULICS Left Hand Counterbalance Valve Installation 1. Position the counterbalance valve near the frame. Snug fit the hydraulic line nut to the bottom counter balance valve fitting (Fig. 1460). 3. Loosely install the hydraulic hard line nut (R) to the fitting located on the front, bottom of the counter balance valve (Fig. 1462). Fig. 1462 Fig. 1460 DSC-1850a DSC-1840a 4. Loosely install the hydraulic hard line nut (R) to the bulkhead fitting (R) (Fig. 1463). 2.
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4-PAW DIESEL/HYDRAULICS 5. Using a 1-1/8” crowfoot wrench, tighten the hydraulic line nut to the 90 degree fitting located on the bottom of the counterbalance valve (Fig. 1464). 7. Install the bolt assembly into the slot on the counter balance valve (Fig. 1466). Note: Position the spacer between the counter balance valve and the frame. Fig. 1464 DSC-1855a Fig. 1466 DSC-1832a 6. Install a washer and spacer onto the counterbalance valve mounting bolt (Fig. 1465). 8.
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4-PAW DIESEL/HYDRAULICS 9. Using a 7/16” socket and wrench, install a nut onto the mounting bolt (Fig. 1468). Fig. 1468 11. Position the other end of the hydraulic line marked F to the bulkhead fitting marked F. Using a 1-1/8” wrench, install the hydraulic line nut to the bulkhead fitting (Fig. 1470). DSC-1864a Fig. 1470 10. Position the hydraulic line marked F to the counter balance valve fitting marked F (front, top) and loosely install the nut to the fitting (Fig. 1469). Fig. 1469 12.
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4-PAW DIESEL/HYDRAULICS 13. Using an 11/16” wrench, install the lift cylinder t-fitting onto the 4-spool valve fitting (Fig. 1472). 16. Slide the fan onto the fan adapter (Fig. 1473). Fig. 1473 Fig. 1472 DSC-1777a DSC-1811a 17. Using a 7/16” socket, install 4 bolts and lock wash ers securing the fan to the fan adapter. Torque the 4 bolts to 100 ± 10 ft-lbs. (136 ± 14 Nm) (Fig. 1474). 14. Tighten the hydraulic line nuts as follows: a. Top fitting on counterbalance valve using a 1-1/8” wrench b.
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4-PAW DIESEL/HYDRAULICS Right Hand Counterbalance Valve Replacement 3. Remove the fan (Fig. 1476). Right Hand Counterbalance Valve Removal Note: Upon removal, all seals, o-rings and gaskets should be replace. During installation, lightly lubricate all seals, o-rings and gaskets with clean petroleum jelly prior to assembly. 1. Remove the Radiator. Refer to “Radiator Removal” on page 6/4-92. 2. Using a 7/16” socket, remove the 4 bolts and lock washers securing the fan to the fan adapter (Fig. 1475). Fig.
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4-PAW DIESEL/HYDRAULICS 5. Place absorbent towel inside the chassis under the right hand counterbalance valve. 8. Using a 1-1/8” offset wrench, remove the hydraulic line nut from the bulkhead fitting marked R (Fig. 1480). 6. Using a 1-1/8” crowfoot wrench, remove the rear wheel motor hydraulic line nut from the upper fitting on the front of the counterbalance valve (both marked F) (Fig. 1478). Fig. 1480 Fig. 1478 DSC-1893a DSC-1884a 9.
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4-PAW DIESEL/HYDRAULICS 10. Using a 13/16” offset wrench, remove the tilt cylinder hydraulic line from the 4-spool valve fitting (Fig. 1482). 12. Using a 1-1/8” wrench, remove the hydraulic line nut from the fitting located on the top of the counter balance valve (Fig. 1484). Fig. 1482 Fig. 1484 DSC-1903a 11. Using a 1-1/8” crowfoot wrench, remove the counter balance valve hydraulic line nut from the 4-spool valve fitting (Fig. 1483). Fig.
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4-PAW DIESEL/HYDRAULICS 14. Slide the counterbalance valve assembly out the rear of the chassis so that the 2 hydraulic lines that are still attached can be accessed and removed (Fig. 1486). Fig. 1486 16. Support the counterbalance valve using a 1-1/16” wrench on the 90 degree fitting located on the bottom of the counterbalance valve. Use a 1-1/8” wrench to remove the hydraulic line nut from the counterbalance valve fitting (Fig. 1488). DSC-1914a Fig. 1488 15.
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4-PAW DIESEL/HYDRAULICS 18. Transfer 4 of the 7 hydraulic fittings from the old counterbalance valve to the new counterbalance valve (Fig. 1490). Right Hand Counterbalance Valve Installation Note: The 2 spool fittings and the tow valve do not get transferred. They come with the new counterbalance valve. 1. Position the counterbalance valve inside the chassis aligning the fitting on the bottom of the valve with the hydraulic line coming from the 4-spool valve.
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4-PAW DIESEL/HYDRAULICS 3. Slide the counterbalance valve assembly into position in the chassis. Loosely install the other hydraulic line nut coming from the 4-spool valve to the fitting located on top of the counterbalance valve (Fig. 1494). 5. Loosely install the 4-spool valve hydraulic line nut to the 4-spool valve fitting (Fig. 1496). Fig. 1496 Fig. 1494 DSC-1933a 4. Loosely install the rear wheel motor hydraulic line nut to the rear bulkhead fitting (marked with an R) (Fig. 1495). 6.
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4-PAW DIESEL/HYDRAULICS b. The lower fitting located on the front surface of the counterbalance valve (the line coming from the rear wheel motor) (Fig. 1498) 8. Loosely install the front wheel motor hydraulic line nut to the front bulkhead fitting (Fig. 1500). Fig. 1500 Fig. 1498 7. Loosely install the front wheel motor hydraulic line nut to the lower fitting located on the front surface of the counterbalance valve (the line coming from the front wheel motor) (Fig. 1499). 9.
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4-PAW DIESEL/HYDRAULICS 10. Install the bolt assembly into the lower slot on the counterbalance valve. Position the spacer between the counterbalance valve and the frame (Fig. 1502). 12. Using a 7/16” socket and wrench, install a nut onto the mounting bolt (Fig. 1504). Fig. 1504 Fig. 1502 11. Install a washer onto the mounting bolt (Fig. 1503). Fig. 1503 13.
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4-PAW DIESEL/HYDRAULICS 14. Using a 1-1/8” wrench, tighten the hydraulic line nut to the fitting located on the top surface of the counterbalance valve (Fig. 1506). 16. Using a 1-18” crow’s foot wrench, tighten the hydrau lic line nut to the 4-spool valve fitting (Fig. 1508). Fig. 1508 Fig. 1506 15. Using a 1-1/8” wrench, tighten the front and rear hydraulic line nuts to the bulkhead fittings (Fig. 1507). 17.
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4-PAW DIESEL/HYDRAULICS 18. Remove the absorbent towel. 21. Install the radiator. Refer to “Radiator Installation” on page 6/4-97. 19. Slide the fan onto the fan adapter (Fig. 1510). 22. Start the machine. Allow the air to purge from the hydraulic system. Check the hydraulic lines and fittings for leaks. 23. Turn the machine off and remove the key. 24. Check the hydraulic fluid level and add if necessary. Fig. 1510 DSC-1777a 20.
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4-PAW DIESEL/HYDRAULICS 4. Using a 9/16” socket, loosen the idler arm nut (Fig. 1514). Hydraulic Tandem Pump Replacement Hydraulic Tandem Pump Removal 1. Remove the radiator. Refer to “Radiator Removal” on page 6/4-92. 2. Using a 7/16” socket, remove the 4 bolts and lock washers securing the fan to the fan adapter (Fig. 1512). Fig. 1514 DSC-1610a 5. Slide the idler arm inward. Remove the belt from the idler pulley (Fig. 1515). Fig. 1512 DSC-1604a 3. Remove the fan (Fig. 1513). Fig. 1515 Fig.
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4-PAW DIESEL/HYDRAULICS 6. Slide the idler arm fully outward (Fig. 1516). Fig. 1516 8. Using a 1/4” 8-point socket, loosen the 2 pump coupler set screws (Fig. 1518). DSC-1612a Fig. 1518 7. Using a 22mm socket, rotate the engine until the pump coupler set screws are accessible (Fig. 1517). DSC-1757a 9. Place absorbent towel under the pump. 10. Loosen the hose clamp on the front pump suction hose (Fig. 1519). Fig. 1517 DSC-1613a Fig.
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4-PAW DIESEL/HYDRAULICS 11. Slide the front suction hose off the pump fitting (Fig. 1520). 13. Slide the rear suction hose off the pump fitting (Fig. 1522). Note: plug both hoses to prevent contamination. Fig. 1520 DSC-1617a Fig. 1522 12. Loosen the hose clamp on the rear pump suction hose (Fig. 1521). DSC-1619a 14. Mark the hydraulic pump lines and fittings F and R (Fig. 1523): F. Front hydraulic line R. Rear hydraulic line Fig. 1521 DSC-1618a Fig.
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4-PAW DIESEL/HYDRAULICS 15. Using a 15/16” wrench, remove the front hydraulic line from the pump fitting (Fig. 1524). Fig. 1524 DSC-1624a 16. Using a 15/16” wrench, remove the rear hydraulic line from the pump fitting (Fig. 1525). Fig. 1525 DSC-1625a 17. Using a 9/16” wrench, remove the 2 pump mounting bolts (Fig. 1526). Fig. 1526 DSC-1626a 18. Slide the pump assembly out of the chassis (Fig. 1527). Fig. 1527 DSC-1639a 19.
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4-PAW DIESEL/HYDRAULICS 3. Apply anti-seize compound to the pump shaft (Fig. 1530). Hydraulic Tandem Pump Installation 1. Turn the engine until the 2 pump coupler set screws are positioned at approximately 1 o’clock and 3 o’clock (Fig. 1528). Fig. 1530 Fig. 1528 DSC-1747a DSC-1750a 4. Install the pump shaft into the pump pulley aligning the key in the shaft with the keyway in the pulley (Fig. 1531). 2. Ensure the key is installed in the pump shaft keyway (Fig. 1529). Fig. 1531 Fig.
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4-PAW DIESEL/HYDRAULICS 5. Apply thread locking compound to the 2 pump mounting bolts (Fig. 1532). Fig. 1532 DSC-1752a 6. Using a 9/16” wrench, install the 2 pump mounting bolts (Fig. 1533). 7. Using a 1/4” 8-point socket, tighten the 2 pump coupler set screws (Fig. 1534). Fig. 1534 8. Slide the idler arm inward (Fig. 1535). Fig. 1535 Fig.
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4-PAW DIESEL/HYDRAULICS 9. Route the belt around the idler arm pulley (Fig. 1536). Fig. 1536 DSC-1760a 10. Move the idler arm outward to apply tension to the fan belt. Refer to “Checking the Alternator Belt Tension” on page 6/4-60. While applying tension, use a 9/16” socket to tighten the idler arm nut (Fig. 1537). 11. Slide the rear suction hose onto the rear pump suction fitting (Fig. 1538). Fig. 1538 12. Slide the front suction hose onto the front pump suction fitting (Fig. 1539). Fig. 1539 Fig.
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4-PAW DIESEL/HYDRAULICS 13. Position the 2 hose clamps and tighten to secure the 2 suction hoses (Fig. 1540). 15. Using a 15/16” wrench, install the front hydraulic line to the front pump fitting (Fig. 1542). Fig. 1540 Fig. 1542 DSC-1770a 14. Using a 15/16” wrench, install the rear hydraulic line to the rear pump fitting (Fig. 1541). 16. Slide the fan onto the fan adapter (Fig. 1543). Fig. 1543 Fig.
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4-PAW DIESEL/HYDRAULICS 17. Using a 7/16” socket, install 4 bolts and lock wash ers securing the fan to the fan adapter. Torque the 4 bolts to 100 ± 10 ft-lbs. (136 ± 14 Nm) (Fig. 1544). 19. Check and fill the Hydraulic fluid as necessary: • Hydraulic Tank Capacity: 17.25 gal. (67 l) • Use 10W-30 or 15W-40 detergent, diesel engine oil (API service CH-4 or higher). a. Clean the area around the filler neck of the hydraulic tank (Fig. 1545). b.
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4-PAW DIESEL/HYDRAULICS THIS PAGE INTENTIONALLY LEFT BLANK.
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4-PAW DIESEL/LOADER ARM 4. Using a 1/2” socket, remove the 3 bolts retaining the 3 pivot pins to the attach plate (Fig. 1548). Loader Arm Replacement Loader Arm Removal 1. Raise the loader arm 6” - 8” (15 - 20cm) away from frame and position attach plate flat (horizontally) (Fig. 1546). Fig. 1548 DSC-1383w 5. Remove the center pivot pin (Fig. 1549). Fig. 1546 DSC-1380a 2. 4-Paw machines: Remove the hood. 3. Support the attach plate with a floor jack (Fig. 1547). Fig. 1549 Fig.
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4-PAW DIESEL/LOADER ARM 6. Remove the RH and LH pivot pins (Fig. 1550 and Fig. 1551). 7. Remove the attach plate (Fig. 1552). Fig. 1552 Fig. 1550 DSC-1392w DSC-1395w 8. Using a 1/2” socket, remove the bolt securing the upper tilt cylinder pivot pin to the tilt cylinder (Fig. 1553). Fig. 1551 DSC-1394w Fig.
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4-PAW DIESEL/LOADER ARM 9. Remove the upper pivot pin (Fig. 1554). Note: Support the cylinder with one hand as you remove the upper pivot pin. 11. Mark the hydraulic lines to the flush face couplers with an M for male and F for female relating to the couplers (Fig. 1556). Fig. 1556 Fig. 1554 DSC-1403a DSC-1401w 10. Lay the tilt cylinder alongside the unit (Fig. 1555). 12. Place an oil pan underneath the couplers to catch drainage. 13.
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4-PAW DIESEL/LOADER ARM 14. Using a 1-18” wrench remove the hydraulic line to the female (F) flush face coupler (Fig. 1558). 15. Using a 1-1/4” wrench and 1-5/16” wrench remove the nut from the male flush face coupler (Fig. 1559) and remove the male flush face coupler (Fig. 1560). Note: Use a plug to protect the line from contami nation. Fig. 1558 6/3-4 Fig. 1559 DSC-1411a Fig.
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4-PAW DIESEL/LOADER ARM 16. Using a 1-5/16” wrench remove the nut from the female flush face coupler (Fig. 1561) and remove the female flush face coupler (Fig. 1562). Fig. 1561 17. Remove the drain pan. 18. Using a properly rated strap or chain and hoist, support the cross-member of the loader arm (Fig. 1563). DSC-1414a Fig. 1563 DSC-1418a 19.
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4-PAW DIESEL/LOADER ARM 20. Remove the left and right lift cylinder pin from the loader arm (Fig. 1565). Fig. 1565 DSC-1422a 22. Remove the loader arm from the machine (Fig. 1567). Fig. 1567 DSC-1425a 21. Remove the left and right loader arm pivot pin from the frame (Fig. 1566). Fig.
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4-PAW DIESEL/LOADER ARM 3. Inspect the attach plate for wear or damage. Re place as necessary (Fig. 1570). Loader Arm Installation 1. Inspect the loader arm and pivot pins for wear or damage. Replace as necessary (Fig. 1568). Fig. 1570 Fig. 1568 DSC-1448a 2. Inspect the hydraulic cylinder yolks for wear or damage. Replace as necessary (Fig. 1569). 4. Install the loader arm onto the unit, aligning the pivot points on the loader arm with the pivot points on the upper frame (Fig. 1571). Fig. 1571 Fig.
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4-PAW DIESEL/LOADER ARM 5. Install a pivot pin through the frame and loader arm pivot point (Fig. 1572). Fig. 1572 8. Repeat for the opposite side. 9. Using a 1/2” socket, install 4 bolts to secure the pivot pins to the upper frame and lift cylinders on both sides of the machine. Torque the bolts to 19 ft-lbs. (26 Nm) (Fig. 1574 and Fig. 1575). DSC-1462a 6. Repeat for the opposite side. Fig. 1574 DSC-1466a Fig. 1575 DSC-1467a 7.
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4-PAW DIESEL/LOADER ARM 10. Remove the support from the loader arm. 11. Position the female flush face coupler into the out side hole of the coupler bracket on the loader arm (Fig. 1576). Fig. 1576 Note: Upon removal, all seals, o-rings and gaskets should be replaced. During installation, lightly lubricate all seals, o-rings and gaskets with clean petroleum jelly prior to assembly. 13. Position the male flush face coupler into the coupler bracket on the loader arm (Fig. 1578). DSC-1468a Fig. 1578 12.
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4-PAW DIESEL/LOADER ARM 15. Using a 1-1/8” wrench install the hydraulic line (F) to the female flush face coupler (Fig. 1580). Fig. 1580 17. With the fittings facing up toward the engine, position the tilt cylinder in the center of the loader arm (Fig. 1582). DSC-1479a Fig. 1582 16. Using a 1-1/8” wrench install the hydraulic line (M) to the male flush face coupler (Fig. 1581). Fig. 1581 18. Install the upper pivot pin through the tilt cylinder yoke and loader arm bracket (Fig. 1583). DSC-1481a Fig.
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4-PAW DIESEL/LOADER ARM 19. Install a bolt to secure the pivot pin to the cylinder yoke. Torque the bolt to 19 ft-lbs. (26 Nm) (Fig. 1584). 21. Install the right and left side pivot pins into the pivot points (Fig. 1586). Fig. 1586 Fig. 1584 20. Position the attach plate to the loader arm pivot points (Fig. 1585). Fig. 1585 Toro Wheeled CUL Service Manual DSC-1489a DSC-1485a DSC-1487a 22. Align the tilt cylinder ram with the attach plate center pivot point.
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4-PAW DIESEL/LOADER ARM 23. Using a 1/2” socket, install 3 bolts securing each of the pivot pins to the attach plate (2) and the tilt cylinder ram (1) (Fig. 1588). 25. Remove the floor jack. 26. 4-Paw machines: Install the hood. 27. Start the machine. Raise and lower the loader arm. 28. Check the hydraulic fluid level and add if necessary. 29. Grease the pivot points (using #2 general purpose luthium grease): Left side (Fig. 1590) Fig. 1588 DSC-1493a 24. Torque the 3 pivot pin bolts to 19 ft-lbs.
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4-PAW DIESEL/LOADER ARM Attach plate (Fig. 1591) Fig. 1591 DSC-1498a Right side (Fig. 1592) Fig.
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4-PAW DIESEL/LOADER ARM THIS PAGE INTENTIONALLY LEFT BLANK.
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4-PAW DIESEL/ENGINE 4. Using a 1/2” socket, loosen the 2 bolts securing the rear access door to the frame (Fig. 1595). Engine Replacement Engine Removal 1. Remove the radiator. Refer to “Radiator Removal” on page 6/4-92. 2. Using a 7/16” socket, remove the 4 bolts and lock washers securing the fan to the fan adapter (Fig. 1593). Fig. 1595 DSC-1970a 5. Lift the rear access door and remove it from the machine (Fig. 1596). Fig. 1593 DSC-1604a 3. Remove the fan assembly (Fig. 1594). Fig. 1596 Fig.
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4-PAW DIESEL/ENGINE 6. Position a drain pan under the oil drain line or hose. Using a 1/4” socket, loosen the hose clamp securing the oil drain plug to the oil drain line (Fig. 1597). 8. Cut the cable tie securing the 2 fuel lines (Fig. 1599). Fig. 1599 Fig. 1597 DSC-1978a DSC-1976a 9. Slide the fuel line hose clamp away from the fuel filter fitting (Fig. 1600). 7. Remove the oil drain plug (Fig. 1598). Fig. 1600 Fig.
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4-PAW DIESEL/ENGINE 10. Remove the fuel line from the fuel filter fitting and drain the fuel out of the fuel tank into a proper receptacle (Fig. 1601). 12. Slide the fuel line off of the fuel tank fitting (Fig. 1603). Fig. 1603 Fig. 1601 11. Slide the fuel line hose clamp away from the fuel tank fitting (Fig. 1602). 13. Using a 3/8” socket, loosen the air cleaner hose clamp (Fig. 1604). Fig. 1604 Fig.
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4-PAW DIESEL/ENGINE 14. Slide the air cleaner hose off the intake manifold (Fig. 1605). 16. Remove the air cleaner assembly (Fig. 1607). Fig. 1607 Fig. 1605 15. Using a 1/2” wrench, loosen the 2 nuts securing the air cleaner bracket to the frame (Fig. 1606). 17. Disconnect the fuel solenoid from the harness (Fig. 1608). Fig. 1608 Fig.
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4-PAW DIESEL/ENGINE 18. Using a 7mm socket remove the nut that secures the glow plug power wire to the glow plug bus bar (Fig. 1609). Fig. 1609 DSC-2000a 19. Remove the glow plug power wire from the glow plug bus bar (Fig. 1610). Fig. 1610 Toro Wheeled CUL Service Manual DSC-2002a 20. Using a 7/16” socket, remove the nut from the bolt securing the throttle cable r-clamp to the fuel filter bracket (Fig. 1611). Fig. 1611 DSC-2061a 21.
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4-PAW DIESEL/ENGINE 22. Slide the throttle cable out of the throttle cable clamp swivel (Fig. 1613). 24. Remove the operator’s manual tube (Fig. 1615). Fig. 1615 Fig. 1613 DSC-2067a DSC-2064a 23. Unplug the water temperature sensor terminal (Fig. 1614). Fig.
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4-PAW DIESEL/ENGINE 25. Using a 1/2” socket, remove the 4 bolts securing the battery cover to the frame (Fig. 1616 and Fig. 1617). 26. Remove the battery cover (Fig. 1618). Fig. 1618 Fig. 1616 DSC-2071a DSC-2068a 27. Disconnect the negative battery cable from the battery (Fig. 1619). Fig. 1617 DSC-2069a Fig.
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4-PAW DIESEL/ENGINE 28. Lift up the red boot covering the positive battery cable connection. Disconnect the positive battery cable from the battery (Fig. 1620). 30. Slide the red boot off the starter terminal (Fig. 1622). Fig. 1622 Fig. 1620 DSC-2082a DSC-2076a 31. Using a 12mm socket, remove the nut from the starter terminal (Fig. 1623). 29. Using a 17mm socket, remove the bolt securing the ground wires to the chassis (Fig. 1621). Fig. 1623 Fig.
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4-PAW DIESEL/ENGINE 32. Remove the lock washer from the starter terminal (Fig. 1624). Fig. 1624 DSC-2085a 33. Remove the positive battery cable from the starter terminal (Fig. 1625). Fig. 1625 Toro Wheeled CUL Service Manual DSC-2086a 34. Remove the harness wire terminal form the starter terminal (Fig. 1626). Fig. 1626 DSC-2088a 35. Unplug the starter connector from the fusible link (Fig. 1627). Fig.
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4-PAW DIESEL/ENGINE 36. Unplug the harness wire (blue) from the solenoid terminal (Fig. 1628). Fig. 1628 38. Using a 1/4” socket, remove the self tapping screw and washer securing the harness wire r-clamp to the frame (Fig. 1630). DSC-2095a Fig. 1630 37. Using a Phillips screw driver, remove the screw securing the oil sensor wire to the oil sensor (Fig. 1629). Fig. 1629 6/4-10 DSC-2091a DSC-2096a 39. Unplug the dynamo (alternator) wires from the harness wires (Fig. 1631). Fig.
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4-PAW DIESEL/ENGINE 40. Using a 1/4” wrench, remove the screw securing the spark arrester to the muffler (Fig. 1632). 42. Place an absorbent towel under the hydraulic pump. 43. Loosen the hose clamp on one of the pump suction hoses (Fig. 1634). Fig. 1632 DSC-2100a Fig. 1634 41. Remove the spark arrester from the muffler (Fig. 1633). Fig. 1633 44. Slide the suction hose off the pump fitting (Fig. 1635). DSC-2102a Fig.
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4-PAW DIESEL/ENGINE 45. Loosen the hose clamp on the other pump suction hose (Fig. 1636). Fig. 1636 47. Mark the hydraulic pump lines and fittings (Fig. 1638): Fig. 1638 DSC-2106a F: Front fitting and line DSC-2108a R: Rear fitting and line 46. Slide the suction hose off the pump fitting (Fig. 1637). Note: Plug both lines to prevent contamination. Fig. 1637 6/4-12 DSC-2107a 48. Using a 15/16” wrench, remove the front hydraulic line from the pump fitting (Fig. 1639). Fig.
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4-PAW DIESEL/ENGINE 49. Using a 15/16” wrench, remove the rear hydraulic line from the pump fitting (Fig. 1640). Fig. 1640 Toro Wheeled CUL Service Manual 50. Using a 1/2” socket, remove the 4 engine mount mounting bolts and washers (Fig. 1641 and Fig. 1642). DSC-2113a Fig. 1641 DSC-2122a Fig.
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4-PAW DIESEL/ENGINE 51. Discard the 4 mounting bolts, but retain the 4 washers for installation. 54. Position engine on a suitable workstation and disconnect the chain from the 2 engine lift points. 52. Place suitable lumber on the operator’s platform. Slide the engine backward so that it rests on the lumber being careful to clear the muffler tail pipe from the hole in the frame (Fig. 1643). 55. Using a 5/16” socket, remove the hose clamp from the top radiator hose (Fig. 1645). Fig. 1645 Fig.
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4-PAW DIESEL/ENGINE 57. Remove the previously disconnected lower radiator hose from the engine (Fig. 1647). 59. Slide the idler arm inward (Fig. 1649). Fig. 1649 Fig. 1647 DSC-0056a DSC-0054a 60. Remove the belt from the idler pulley (Fig. 1650). 58. Using a 9/16” socket, loosen the idler arm nut (Fig. 1648). Fig. 1650 Fig.
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4-PAW DIESEL/ENGINE 61. Using a 22mm socket, rotate the engine until the pump coupler set screws are accessible (Fig. 1651 and Fig. 1652). 62. Using a 1/4” 8-point socket, loosen the 2 pump coupler set screws (Fig. 1653). Fig. 1653 Fig. 1651 DSC-0060a DSC-0068a 63. Using a 1/2” socket, remove the 4 pump mount mounting bolts and lock washers (Fig. 1654). Fig. 1652 DSC-0058a Fig.
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4-PAW DIESEL/ENGINE 64. Remove the pump, pump mount/idler assembly (Fig. 1655). Fig. 1655 66. Use a 22mm socket on the opposite end of the en gine to prevent the engine from rotating (Fig. 1657). Using a 1/2” socket, remove the 2 screws securing the engine pulley to the flywheel adapter (Fig. 1658). DSC-0063a Fig. 1657 DSC-0068a Fig. 1658 DSC-0066a 65. Remove the fan belt (Fig. 1656). Fig.
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4-PAW DIESEL/ENGINE 67. Remove the engine pulley and adapter spacer from the flywheel adapter (Fig. 1659). 69. Remove the flywheel adapter (Fig. 1661). Fig. 1661 Fig. 1659 68. Using a 15mm socket, remove the 5 bolts and lock washers securing the flywheel adapter to the engine (Fig. 1660). 70. Using a 13mm wrench, loosen the lower muffler mounting bolt (Fig. 1662). Fig. 1662 Fig.
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4-PAW DIESEL/ENGINE 71. Using a 1/2” wrench and socket, remove the 3 upper muffler mounting bolts, lock washers and nuts (Fig. 1663). 73. Remove the manifold gasket (Fig. 1665). Fig. 1665 Fig. 1663 DSC-0083a DSC-0079 74. Remove the previously loosened lower muffler mounting bolt and discard (Fig. 1666). 72. Remove the muffler (Fig. 1664). Fig. 1666 Fig.
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4-PAW DIESEL/ENGINE 75. Remove the cotter pin securing the rod linkage to the engine stop lever (Fig. 1667). Fig. 1667 77. Using a 13mm socket, remove the 2 bolts and lock washers securing the solenoid mount to the engine block (Fig. 1669). DSC-0086 Fig. 1669 76. Remove the rod linkage from the engine stop lever (Fig. 1668). Fig. 1668 78. Remove the solenoid and mount from the engine (Fig. 1670). DSC-0089 Fig.
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4-PAW DIESEL/ENGINE 79. Slide the hose clamp away from the #3 injector and remove the fuel line (Fig. 1671 and Fig. 1672). Fig. 1671 DSC-2251a 80. Using a 9/16” wrench, remove the water temperature sensor from the engine (Fig. 1673). Fig. 1673 DSC-2255a 81. Using a 1/4” socket, loosen the hose clamp from the engine oil drain line (Fig. 1674). Fig. 1672 DSC-2253a Fig.
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4-PAW DIESEL/ENGINE 82. Remove the engine oil drain line (Fig. 1675). 84. Support the engine. 85. Using a 17mm socket, remove the 4 bolts and lock washers securing the engine plate mount to the engine (Fig. 1677). Fig. 1675 DSC-2261a 83. Position an approved engine hoist and connect a chain to the 2 engine lift points (Fig. 1676). Fig. 1677 DSC-2264a 86. Using a 9/16” socket and an 11/16” wrench, remove the bolts and nuts from the engine mount (Fig. 1678). Fig. 1676 DSC-2262a Fig.
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4-PAW DIESEL/ENGINE 87. Remove the flat washers (Fig. 1679). Fig. 1679 89. Remove the engine mount washers (Fig. 1681). DSC-2269a 88. Remove the snubbing washers (Fig. 1680). Fig. 1680 Fig. 1681 90. Remove the engine mount plate from the engine mount (Fig. 1682). DSC-2271a Fig.
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4-PAW DIESEL/ENGINE 91. Using a 12mm socket, remove the lower starter mounting bolt and lock washer (Fig. 1683). Fig. 1683 93. Remove the r-clamp from the breather hose and retain it to transfer to the breather hose on the new engine (Fig. 1685). DSC-2276a Fig. 1685 92. Using a 17mm socket, remove the bolt securing the breather hose R clamp to the engine mount plate and engine block. Using a 17mm socket, remove the remaining 2 bolts and lock washers (Fig. 1684). 94.
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4-PAW DIESEL/ENGINE 95. Clean, inspect and replace any parts of the engine mount assembly showing evidence of wear (Fig. 1687 and Fig. 1688). Fig. 1687 96. If the rubber engine mounts need to be replaced: They are not interchangeable. They are identified by the following: • The rubber mounts located on the flywheel end of the mount assembly have a blue identification mark and has a lip underneath the flange (Fig. 1689). DSC-2289a Fig.
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4-PAW DIESEL/ENGINE Engine Installation 1. Secure the new engine with an approved hoist. 4. Apply thread locking compound to the breather hose r-clamp mounting bolt (no washer). Apply thread locking compound to the 2 engine plate mounting bolts with lock washers (Fig. 1693 and Fig. 1694). 2. Slide the r-clamp onto the breather hose (Fig. 1691). Fig. 1691 Fig. 1693 DSC-2302a Fig. 1694 DSC-2311a DSC-2443 3. Position and lower the engine into the engine mount assembly (Fig. 1692). Fig.
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4-PAW DIESEL/ENGINE 5. Install the mounting bolt (no washer) through the breather hose r-clamp and engine mount plate and into the engine block to secure (Fig. 1695). Install the 2 engine plate mounting bolts with lock washers through the engine mounting plate and into the engine block to secure (Fig. 1696). 6. Using a 17mm socket, torque the 3 engine mount plate bolts to 38 + 4 ft-lbs. (51.5 + 5.4 Nm) (Fig. 1697). Fig. 1697 Fig. 1695 DSC-2306a DSC-2447a 7.
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4-PAW DIESEL/ENGINE 10. Install the 4 mounting bolts (with lock washers) to secure the engine mount plate to the engine block. Torque to 38 + 4 ft-lbs. (51.5 + 5.4 Nm) (Fig. 1701). 8. Position the engine mount plate (Fig. 1699). Fig. 1699 DSC-2310a Fig. 1701 9. Apply thread locking compound to the 4 engine mount plate mounting bolts (with lock washers) (Fig. 1700). Fig. 1700 6/4-28 DSC-2311a DSC-2315a 11. Install the engine mount washer (Fig. 1702). Fig.
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4-PAW DIESEL/ENGINE 12. Install the snubbing washer (Fig. 1703). Fig. 1703 14. Install the bolt (Fig. 1705). DSC-2318a 13. Install the flat washer (Fig. 1704). Fig. 1704 Toro Wheeled CUL Service Manual Fig. 1705 DSC-2320a 15. Loosely install the nut (Fig. 1706). DSC-2319a Fig.
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4-PAW DIESEL/ENGINE 16. Using a 9/16” socket and 11/16” wrench, tighten the engine mount assembly (Fig. 1707). 18. Install the engine oil drain plug (Fig. 1709). Fig. 1709 Fig. 1707 19. Using a 1/4” socket, tighten the hose clamps securing the engine oil drain line and engine oil drain plug (Fig. 1710). 17. Install the engine oil drain line (Fig. 1708). Fig. 1708 DSC-2327a Fig.
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4-PAW DIESEL/ENGINE 20. Apply pipe sealant to the threads on the water temperature sensor (Fig.1711). Fig. 1711 DSC-2455a 21. Install the water temperature sensor. Use a 9/16” wrench to tighten (Fig. 1712). Fig. 1712 Toro Wheeled CUL Service Manual DSC-2457a 22. Slide the fuel line onto the #3 injector barb. Slide the hose clamp into position to secure (Fig. 1713). Fig. 1713 DSC-2460a 23. Apply thread locking compound to the 2 fuel solenoid assembly mounting bolts (Fig. 1714). Fig.
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4-PAW DIESEL/ENGINE 24. Position the fuel solenoid assembly to the engine block (Fig. 1715). Fig. 1715 DSC-2463a 25. Install the 2 fuel solenoid mounting bolts. Torque to 19 + 2 ft-lbs. (25.76 + 2.7 Nm) using a 13mm socket (Fig. 1716). Fig.
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4-PAW DIESEL/ENGINE 26. With the fuel solenoid spring loose, position the fuel stop so it is up against the fuel stop adjusting screw. If the solenoid rod end does not align with the hole in the fuel stop (Fig. 1717), loosen the fuel solenoid jam nut (Fig. 1718) and rotate the solenoid rod in or out (Fig. 1719) until it can be inserted into the fuel stop (Fig. 1720). Tighten the jam nut to secure the fuel solenoid rod (Fig. 1721). Fig. 1717 Fig. 1718 Toro Wheeled CUL Service Manual Fig.
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4-PAW DIESEL/ENGINE 27. Install a cotter pin into the solenoid rod to secure (Fig. 1722). Fig. 1722 29. Position the fuel filter assembly to the engine aligning the bracket mounting holes on the fuel filter assembly with the bracket mounting holes on the engine mount. Install 2 bolts and nuts to secure the fuel filter bracket to the engine mount (Fig. 1724). DSC-2478a Fig. 1724 DSC-2483a 28. Slide the fuel filter hose onto the fuel barb on the engine (Fig. 1723). 30.
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4-PAW DIESEL/ENGINE 31. Slide the hose clamp into position to secure the fuel line to the engine (Fig. 1726). 33. Using a 13mm socket, loosely thread a new lower muffler mounting bolt and washer into the engine block (Fig. 1728). Note: Do not tighten the bolt. Leave it loose enough to slide the muffler bracket onto it. Fig. 1726 DSC-2487a 32. Lower muffler mounting bolt: A special bolt with high temperature thread locking compound that is factory applied (Fig. 1727). Fig. 1728 DSC-2495a 34.
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4-PAW DIESEL/ENGINE 35. Slide the manifold gasket onto the 3 mounting bolts (Fig. 1730). Fig. 1730 DSC-2503a 36. Position the muffler to the engine by sliding the lower muffler bracket onto the lower muffler mounting bolt (Fig. 1731). 37. Slide the muffler manifold onto the 3 mounting bolts (Fig. 1732). Fig. 1732 38. Install 3 nuts and lock washers onto the muffler manifold mounting bolts (Fig. 1733). Fig. 1733 Fig.
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4-PAW DIESEL/ENGINE 39. Using a 1/2” wrench and socket, tighten the 3 upper muffler mounting bolts, lock washers and nuts (Fig. 1734). 41. Apply thread locking compound to the 5 flywheel adapter mounting bolts (Fig. 1736). Fig. 1736 Fig. 1734 40. Using a 13mm wrench, tighten the lower muffler mounting bolt (Fig. 1735). 42. Position the Flywheel adapter to the flywheel (Fig. 1737). Fig. 1737 Fig.
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4-PAW DIESEL/ENGINE 43. Using a 15mm socket, install 5 bolts and lock washers securing the flywheel adapter to the flywheel (Fig. 1738 and Fig. 1739). 44. Torque the 5 mounting bolts to 19 ± 2 ft-lbs. (26 ± 3 Nm) (Fig. 1740). Note: Use a 22mm socket or wrench on the oppo site end of the engine to prevent the engine from turning while tightening the flywheel adapter mounting bolts. Fig. 1740 DSC-2522a 45. Apply thread locking compound to pump pulley shoulder bolts (Fig. 1741). Fig.
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4-PAW DIESEL/ENGINE 46. Position adapter spacer and pump pulley to the flywheel adapter (Fig. 1742). Fig. 1742 DSC-2570a 47. Install the 2 pump pulley mounting bolts (Fig. 1743). Fig. 1743 48. Torque the 2 pump pulley mounting bolts to 15 -19 ft-lbs. (20 - 26 Nm) (Fig. 1744). Fig. 1744 49. Rotate the engine so the pump mount set screws are located at the 1 o’clock and 4 o’clock positions (Fig. 1745). DSC-2526a Fig.
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4-PAW DIESEL/ENGINE 50. Place the fan belt around pump pulley (Fig. 1746). Fig. 1746 52. Apply thread locking compound to the 4 pump mount mounting bolts (Fig. 1748). DSC-2575a Fig. 1748 51. Rotate the pump shaft so that the key in the pump shaft will align with the keyway in the pump pulley (Fig. 1747). 53. Apply anti-seize to the pump shaft (Fig. 1749). Fig. 1749 Fig.
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4-PAW DIESEL/ENGINE 54. Slide the pump shaft into the pump pulley aligning the key with the keyway (Fig. 1750). Fig. 1750 56. Continue sliding the pump shaft into the pump pulley. Align the pump mount assembly mounting holes with the mounting holes located on the engine. Install 4 pump mount assembly mounting bolts and lock washers (Fig. 1752). DSC-2578a Fig. 1752 DSC-2582a 55. Route the fan belt around the upper pulley on the pump mount assembly (Fig. 1751). 57.
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4-PAW DIESEL/ENGINE 58. Using a 1/4” 8-point socket, tighten the 2 pump coupler set screws (Fig. 1754). 60. Route the belt around the idler pulley (Fig. 1756). Fig. 1756 Fig. 1754 61. Move the idler arm outward to apply tension to the fan belt. While applying tension, use a 9/16” socket to tighten the idler arm nut (Fig. 1757). 59. Slide the idler arm inward (Fig. 1755). Fig. 1755 DSC-2588a Fig.
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4-PAW DIESEL/ENGINE 62. Check and adjust the alternator belt tension. Refer to “Checking the Alternator Belt Tension” on page 6/4-60. 63. Place suitable lumber on the operator’s platform. Raise the engine and place it on the lumber (Fig. 1758). Fig. 1758 66. Remove the lumber from the operators platform. 67. Using a 1/2” socket, Install 4 new special cap screws and washers to secure the engine mount to the frame (Fig. 1760).
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4-PAW DIESEL/ENGINE 69. Slide the rear suction hose onto the rear pump fitting (Fig. 1762). Fig. 1762 DSC-2557a 70. Position the hose clamp and tighten to secure (Fig. 1763). Fig. 1763 6/4-44 DSC-2558a 71. Slide the front suction hose onto the front pump fitting (Fig. 1764). Fig. 1764 DSC-2560a 72. Position the hose clamp and tighten to secure (Fig. 1765). Fig.
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4-PAW DIESEL/ENGINE 73. Route the rear hydraulic pump line between the two suction hoses and under the pump to the hydraulic line fitting side of the pump. Route the front hydraulic pump line in front of the front suction line and under the pump to the hydraulic line fitting side of the pump (Fig. 1766). 75. Install the front hydraulic pump line to the front hydraulic pump fitting (Fig. 1768). Fig. 1768 Fig. 1766 DSC-2562a DSC-2569a 76. Slide the fan onto the fan adapter (Fig. 1769). 74.
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4-PAW DIESEL/ENGINE 77. Using a 7/16” socket, install 4 bolts and lock wash ers securing the fan to the fan adapter. Torque the 4 bolts to 100 ± 10 ft-lbs. (136 ± 14 Nm) (Fig. 1770). 79. Using a 1/4” wrench, install a screw to secure the spark arrester to the muffler (Fig. 1772). Fig. 1772 Fig. 1770 78. Slide the spark arrester onto the muffler (Fig. 1771). Fig. 1771 6/4-46 DSC-2612a DSC-2608a DSC-2609a 80. Plug the dynamo (alternator) wires into the harness wires (Fig. 1773). Fig.
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4-PAW DIESEL/ENGINE 81. Using a 1/4” socket, install the self tapping screw and washer securing the harness wire r-clamp to the frame (Fig. 1774). 83. Plug the harness wire (blue) onto the solenoid terminal (Fig. 1776). Fig. 1776 Fig. 1774 82. Using a Phillips screw driver, install the screw securing the oil sensor wire to the oil sensor (Fig. 1775). 84. Plug the starter connector into the fusible link (Fig. 1777). Fig. 1777 Fig.
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4-PAW DIESEL/ENGINE 85. Install the harness wire terminal onto the starter terminal (Fig. 1778). Fig. 1778 DSC-2622a 86. Install the positive battery cable onto the starter terminal (Fig. 1779). Fig. 1779 6/4-48 DSC-2623a 87. Install a lock washer onto the starter terminal (Fig. 1780). Fig. 1780 DSC-2624a 88. Using a 12mm socket, install a nut onto the starter terminal (Fig. 1781). Fig.
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4-PAW DIESEL/ENGINE 89. Position the red protective boot over the starter terminal (Fig. 1782). Fig. 1782 DSC-2628a 90. Apply thread locking compound to the ground bolt (Fig. 1783). Fig. 1783 Toro Wheeled CUL Service Manual DSC-2630a 91. Slide the negative battery cable onto the ground bolt (Fig. 1784). Fig. 1784 DSC-2631a 92. Slide the harness ground wire onto the ground bolt (Fig. 1785). Fig.
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4-PAW DIESEL/ENGINE 93. Using a 17mm socket, install the ground bolt to the engine mount plate, securing the ground wires to the engine mount (Fig. 1786). 95. Install the glow plug power wire onto the glow plug bus bar terminal (Fig. 1788). Fig. 1788 Fig. 1786 94. Plug the temperature sensor terminal onto the temperature sensor (Fig. 1787). 96. Using a 7mm socket, install a nut to secure the glow plug power wire to the glow plug bus bar (Fig. 1789). Fig. 1789 Fig.
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4-PAW DIESEL/ENGINE 97. Plug the fuel solenoid into the harness (Fig. 1790). Fig. 1790 99. Install the negative battery cable onto the negative battery terminal (Fig. 1792). DSC-2643a Fig. 1792 98. Install the positive battery cable onto the positive battery terminal. Cover the connection with the red protective boot (Fig. 1791). Fig. 1791 Toro Wheeled CUL Service Manual DSC-2645a DSC-2647a 100. Position the battery cover over the battery (Fig. 1793). Fig.
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4-PAW DIESEL/ENGINE 101. Using a 1/2” socket, install the 4 bolts securing the battery cover to the frame (Fig. 1794). 103. Position the r-clamp on the throttle to the mounting hole in the fuel shut-off bracket (Fig. 1796). Note: The short bolts are installed on the top and the long bolts are installed on the bottom. A A B B Fig. 1794 A. Short bolts (2) Fig. 1796 DSC-2654a DSC-2651a 104. Install a bolt through the r-clamp and bracket (Fig. 1797). B. Long bolts (2) 102.
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4-PAW DIESEL/ENGINE 105. Position the throttle lever into the slow position (Fig. 1798). Fig. 1798 DSC-2656a 106. Slide the throttle cable into the throttle cable clamp swivel (Fig. 1799). Fig. 1799 107. Insert the throttle cable clamp into the throttle linkage lever (Fig. 1800). Fig. 1800 108. Using a 7/16” wrench, loosely install a nut onto the cable clamp swivel securing it to the throttle linkage (Fig. 1801). DSC-2659a Fig.
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4-PAW DIESEL/ENGINE 109. Move the throttle lever to the fast position (Fig. 1802). Fig. 1802 111. Use 5/16” and 1/2” wrenches to tighten the swivel screw securing the throttle cable in the swivel (Fig. 1804). DSC-2664a Fig. 1804 110. Hold the throttle linkage in the fast position (Fig. 1803). Fig. 1803 112. Use 7/16” and 1/2” wrenches to tighten the cable clamp swivel nut securing it to the throttle linkage (Fig. 1805). DSC-2665a Fig.
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4-PAW DIESEL/ENGINE 113. Slide the lower radiator hose onto the engine flange (Fig. 1806). Fig. 1806 DSC-2668a 115. Slide the upper radiator hose onto the engine flange (Fig. 1808). Fig. 1808 DSC-2670a 114. Position the hose clamp and tighten to secure (Fig. 1807). 116. Position the hose clamp and tighten to secure (Fig. 1809). Fig. 1807 Fig.
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4-PAW DIESEL/ENGINE 117. Position the air cleaner assembly hose onto the engine air intake (Fig. 1810). Fig. 1810 119. Position the air intake hose clamp and tighten to secure the air intake hose to the engine intake (Fig. 1812). DSC-2672a Fig. 1812 118. Position the air cleaner bracket onto the mounting bolts located on the frame (Fig. 1811). Fig. 1811 120. Using a 1/2” wrench, tighten the 2 nuts securing the air cleaner bracket to the frame (Fig. 1813). DSC-2674a Fig.
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4-PAW DIESEL/ENGINE 121. Slide the fuel line onto the fuel tank fitting (Fig. 1814). Fig. 1814 DSC-2683a 122. Position the fuel line hose clamp to secure (Fig. 1815). Fig. 1815 Toro Wheeled CUL Service Manual DSC-2684a 123. Slide the fuel line onto the fuel filter fitting (Fig. 1816). Fig. 1816 DSC-2685a 124. Position the fuel line hose clamp to secure (Fig. 1817). Fig.
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4-PAW DIESEL/ENGINE 125. Install a cable tie to secure the 2 fuel lines just below the fuel filter fitting (Fig. 1818). 127. Fill the engine with oil: • Oil Type: Diesel engine oil (API service CD or higher) • Crankcase Capacity: w/filter, 0.84 gal. (3.2 l) a. Remove the oil fill cap and slowly pour approximately 80% of the specified amount of oil in through the valve cover. b. Check the oil level. c. Slowly add additional oil to bring the level to the upper mark/hole on the dipstick. d.
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4-PAW DIESEL/ENGINE 129. Check and fill the Hydraulic fluid: • Hydraulic Tank Capacity: 17.25 gal. (67 l) • 135. Position the rear access door onto the unit (Fig. 1821). Use 10W-30 or 15W-40 detergent, diesel engine oil (API service CH-4 or higher). a. Clean the area around the filler neck of the hydraulic tank (Fig. 1820). b. Remove the cap from the filler neck and check the fluid level on the dipstick (Fig. 1820). A B Fig. 1821 DSC-2692a 136.
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4-PAW DIESEL/ENGINE 137. Close and secure the rear access door (Fig. 1823 and Fig. 1824). Checking the Alternator Belt Tension A Fig. 1823 DSC-2696a Fig. 1825 fig. EEAB...17B A. 0.28 to 0.35” (7.0 to 9.0mm) 1. Measure the deflection (A) by depressing the belt halfway between the fan drive pulley and alternator pulley at the specified force of 22 lbs. (98 N, 10kgf). 2.
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4-PAW DIESEL/ENGINE 4. Using a 9/16” socket, loosen the idler arm nut (Fig. 1828). Fan Belt Replacement Fan Belt Removal 1. Remove the radiator. Refer to “Radiator Removal” on page 6/4-92. 2. Using a 7/16” socket, remove the 4 bolts and lock washers securing the fan to the fan adapter (Fig. 1826). Fig. 1828 DSC-1610a 5. Slide the idler arm inward. Remove the belt from the idler pulley (Fig. 1829). Fig. 1826 DSC-1604a 3. Remove the fan (Fig. 1827). Fig. 1829 Fig.
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4-PAW DIESEL/ENGINE 8. Using a 1/4” 8-point socket, loosen the 2 pump coupler set screws (Fig. 1832). 6. Slide the idler arm fully outward (Fig. 1830). Fig. 1830 DSC-1612a Fig. 1832 7. Using a 22mm socket, rotate the engine until the pump coupler set screws are accessible (Fig. 1831). DSC-1757a 9. Place absorbent towel under the pump. 10. Loosen the hose clamp on the front pump suction hose (Fig. 1833). Fig. 1831 DSC-1613a Fig.
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4-PAW DIESEL/ENGINE 11. Slide the front suction hose off the pump fitting (Fig. 1834). 13. Slide the rear suction hose off the pump fitting (Fig. 1836). Note: Plug the hoses to prevent contamination. Fig. 1834 DSC-1617a Fig. 1836 12. Loosen the hose clamp on the rear pump suction hose (Fig. 1835). Fig. 1835 14. Mark the hydraulic pump lines and fittings F and R (Fig. 1837): F. Front hydraulic line R. Rear hydraulic line DSC-1618a Fig.
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4-PAW DIESEL/ENGINE 15. Using a 15/16” wrench, remove the front hydraulic line from the pump fitting (Fig. 1838). Fig. 1838 DSC-1624a 16. Using a 15/16” wrench, remove the rear hydraulic line from the pump fitting (Fig. 1839). Fig. 1839 6/4-64 DSC-1625a 17. Using a 9/16” wrench, remove the 2 pump mounting bolts (Fig. 1840). Fig. 1840 DSC-1626a 18. Slide the pump assembly out of the chassis (Fig. 1841). Fig.
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4-PAW DIESEL/ENGINE 19. Remove the fan belt from the upper pulley (Fig. 1842). 21. Remove the pump mount/idler assembly (Fig. 1844). Fig. 1844 Fig. 1842 DSC-1643a DSC-1628a 20. Using a 1/2” socket, remove the 4 pump mount assembly mounting bolts and lock washers (Fig. 1843). 22. To service the pump mount idler assembly, refer to “Pump Mount Assembly Rebuild” on page 6/4-103. 23. Remove the fan belt (Fig. 1845). Note: The bottom 2 mounting bolts are located below the pump mount opening.
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4-PAW DIESEL/ENGINE Fan Belt Installation 1. Route the fan belt around the fan pulley (Fig. 1846). Fig. 1846 3. Position the pump mount/idler assembly to the drive pulley. Route the belt around the drive pulley. Loosely install the 4 bolts and lock washers securing the pump mount/idler assembly to the engine block (Fig. 1848). DSC-1742a Fig. 1848 2. Apply thread locking compound to the 4 pump mount mounting bolts (Fig. 1847). DSC-1745a 4.
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4-PAW DIESEL/ENGINE 5. Turn the engine until the 2 pump coupler set screws are positioned at approximately 1 o’clock and 3 o’clock (Fig. 1850). 7. Apply anti-seize compound to the pump shaft (Fig. 1852). Fig. 1852 Fig. 1850 6. Ensure the key is installed in the pump shaft keyway (Fig. 1851). Fig. 1851 Toro Wheeled CUL Service Manual DSC-1750a DSC-1747a DSC-1749a 8. Install the pump shaft into the pump pulley aligning the key in the shaft with the keyway in the pulley (Fig. 1853). Fig.
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4-PAW DIESEL/ENGINE 9. Apply thread locking compound to the 2 pump mounting bolts (Fig. 1854). Fig. 1854 DSC-1752a 10. Using a 9/16” wrench, install the 2 pump mounting bolts (Fig. 1855). 11. Using a 1/4” 8-point socket, tighten the 2 pump coupler set screws (Fig. 1856). Fig. 1856 12. Slide the idler arm inward (Fig. 1857). Fig. 1857 Fig.
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4-PAW DIESEL/ENGINE 13. Route the belt around the idler arm pulley (Fig. 1858). Fig. 1858 DSC-1760a 14. Move the idler arm outward to apply tension to the fan belt. Refer to “Checking the Alternator Belt Tension” on page 6/4-60. While applying tension, use a 9/16” socket to tighten the idler arm nut (Fig. 1859). 15. Slide the rear suction hose onto the rear pump suction fitting (Fig. 1860). Fig. 1860 16. Slide the front suction hose onto the front pump suction fitting (Fig. 1861). Fig. 1861 Fig.
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4-PAW DIESEL/ENGINE 17. Position the 2 hose clamps and tighten to secure the 2 suction hoses (Fig. 1862). 19. Using a 15/16” wrench, install the front hydraulic line to the front pump fitting (Fig. 1864). Fig. 1862 Fig. 1864 DSC-1770a 18. Using a 15/16” wrench, install the rear hydraulic line to the rear pump fitting (Fig. 1863). 20. Slide the fan onto the fan adapter (Fig. 1865). Fig. 1865 Fig.
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4-PAW DIESEL/ENGINE 21. Using a 7/16” socket, install 4 bolts and lock wash ers securing the fan to the fan adapter. Torque the 4 bolts to 100 ± 10 ft-lbs. (136 ± 14 Nm) (Fig. 1866). 23. Check and fill the Hydraulic fluid as necessary: • Hydraulic Tank Capacity: 17.25 gal. (67 l) • Use 10W-30 or 15W-40 detergent, diesel engine oil (API service CH-4 or higher). a. Clean the area around the filler neck of the hydraulic tank (Fig. 1867). b.
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4-PAW DIESEL/ENGINE Fan Replacement Fan Installation Fan Removal 1. Slide the fan onto the fan adapter (Fig. 1870). 1. Remove the radiator. Refer to “Radiator Removal” on page 6/4-92. 2. Using a 7/16” socket, remove the 4 bolts and lock washers securing the fan to the fan adapter (Fig. 1868). Fig. 1870 DSC-1777a 2. Using a 7/16” socket, install 4 bolts and lock wash ers securing the fan to the fan adapter. Torque the 4 bolts to 100 ± 10 in-lbs. (11.3 ± 1 Nm) (Fig. 1871). Fig. 1868 DSC-1604a 3.
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4-PAW DIESEL/ENGINE Fuel Shut Down Solenoid Replacement 4. Remove the cotter pin from the end of the fuel shut down solenoid stop arm (Fig. 1874). Fuel Shut Down Solenoid Removal 1. Park the machine. Shut-off the engine and remove the key. 2. Open the rear access door (Fig. 1872). Fig. 1874 IMG-0161a 5. Remove the 2 bolts and nuts securing the solenoid to the mounting bracket (Fig. 1875). Fig. 1872 DSC-2696a Note: The air cleaner cover was removed for photo purposes. 3.
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4-PAW DIESEL/ENGINE Fuel Shut Down Solenoid Installation 6. Remove the solenoid (Fig. 1876). 1. Position the solenoid on the mounting bracket (Fig. 1877). Fig. 1876 IMG-0165a 7. To test the solenoid, refer to the Fuel Shut Down Solenoid Testing procedure on page 6/5-13. Fig. 1877 DSC-0165a 2. Install 2 bolts and nuts to secure the solenoid to the mounting bracket (Fig. 1878). Note: The air cleaner cover was removed for photo purposes. Fig.
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4-PAW DIESEL/ENGINE 3. Adjust the stop arm (Fig. 1879): a. Position the stop rod to the engine linkage. 4. Install a cotter pin into the end of the fuel shut down solenoid stop arm to secure (Fig. 1880). b. Loosen the stop rod jam nut. c. Push stop rod in and the engine linkage lever forward. d. Adjust the stop rod by threading it in or out of the solenoid until it falls into the engine linkage hole. e. Lock the jam nut. A B Fig. 1880 C 5.
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4-PAW DIESEL/ENGINE Glow Plug Replacement 6. Remove the glow plug bus bar and clean the area around the glow plugs to prevent debris from enter ing the engine. Glow Plug Removal 7. Use a 10mm socket to remove the glow plug(s) that need to be replaced (Fig. 1883). 1. Park the machine on a level surface. 2. Shut engine off and remove the key. 3. Allow the engine to cool. 4. Open the rear engine cover. 5.
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4-PAW DIESEL/ENGINE Glow Plug Installation Muffler Replacement 1. Thread the new glow plug(s) into the cylinder head (Fig. 1884). Muffler Removal 1. Remove the radiator. Refer to “Radiator Removal” on page 6/4-92. 2. Using a 7/16” socket, remove the 4 bolts and lock washers securing the fan to the fan adapter (Fig. 1886). Fig. 1884 IMG-0154a 2. Torque the glow plug(s) to 5.8 to 10.8 ft-lbs. (7.8 to 14.6 Nm) (Fig. 1885). Fig. 1886 DSC-1604a 3. Remove the fan assembly (Fig. 1887). Fig.
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4-PAW DIESEL/ENGINE 4. Using a 9/16” socket, loosen the idler arm nut (Fig. 1888). 6. Slide the idler arm outward (Fig. 1890). Fig. 1890 Fig. 1888 5. Slide the idler arm inward. Remove the belt from the idler pulley (Fig. 1889). 7. Using a 22mm socket, rotate the engine until the pump coupler set screws are accessible (Fig. 1891). Fig. 1891 Fig.
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4-PAW DIESEL/ENGINE 8. Using a 1/4” 8-point socket, loosen the 2 pump coupler set screws (Fig. 1892). 11. Slide the suction hoses off the pump fittings (Fig. 1894). Note: Plug the hoses to prevent contamination. Fig. 1892 DSC-1757a Fig. 1894 DSC-1620a 9. Place absorbent towel under the pump. 10. Loosen the hose clamps on the suction hoses (Fig. 1893). Fig. 1893 12. Mark the hydraulic pump hoses and fittings (Fig. 1895): F. Front hydraulic line R. Rear hydraulic line DSC-1616a Fig.
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4-PAW DIESEL/ENGINE 13. Using a 15/16” wrench, remove the front hydraulic line from the front pump fitting (Fig. 1896). Fig. 1896 DSC-1622a 14. Using a 15/16” wrench, remove the rear hydraulic line from the pump fitting (Fig. 1897). Fig. 1897 6/4-80 DSC-1625a 15. Using a 9/16” wrench, remove the 2 pump mounting bolts (Fig. 1898). Fig. 1898 DSC-1626a 16. Slide the pump assembly out of the chassis (Fig. 1899). Fig.
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4-PAW DIESEL/ENGINE 17. Remove the fan belt from the upper pulley (Fig. 1900). 19. Remove the pump mount/idler assembly (Fig. 1902). Fig. 1902 Fig. 1900 DSC-1643a DSC-1628a 20. Remove the fan belt (Fig. 1903). 18. Using a 1/2” socket, remove the 4 pump mount assembly mounting bolts and lock washers (Fig. 1901). Note: The bottom 2 mounting bolts are located below the pump mount opening. They bolt the bottom of the mount plate to the engine block. Fig. 1903 Fig.
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4-PAW DIESEL/ENGINE 21. Using a 13mm wrench, loosen the lower muffler mounting bolt (Fig. 1904). 23. Remove the muffler from the chassis (Fig. 1906). Fig. 1906 Fig. 1904 22. Using a 1/2” wrench and socket, remove the 3 manifold mounting bolts, lock washers and nuts (Fig. 1905). 24. Using a 13mm socket, remove the lower muffler mounting bolt and washer. Discard the bolt, save the washer for installation (Fig. 1907). Fig. 1907 Fig.
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4-PAW DIESEL/ENGINE 25. Using a 1/4” socket, remove the screw securing the spark arrestor to the muffler (Fig. 1908). Fig. 1908 DSC-1660a 27. Remove the old manifold gasket from the engine manifold (Fig. 1910). Fig. 1910 DSC-1671a 26. Remove the spark arrester from the muffler (Fig. 1909). Fig.
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4-PAW DIESEL/ENGINE Muffler Installation Note: Use a new lower muffler mounting bolt; reuse the washer (Fig. 1913). 1. Slide the spark arrester onto the muffler (Fig. 1911). Fig. 1913 Fig. 1911 DSC-1667a 2. Use a 1/4” socket to install the screw securing the spark arrester to the muffler (Fig. 1912). 3. Loosely install the lower muffler mounting bolt (new) and washer (Fig. 1914). Fig. 1914 Fig.
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4-PAW DIESEL/ENGINE 4. Insert 3 manifold mounting bolts into the engine manifold (Fig. 1915). 6. Position the muffler into the chassis. Slide the lower mounting bracket slot onto the mounting bolt that was previously loosely installed (Fig. 1917). Note: The bracket should be between the washer and the engine block. Fig. 1915 DSC-1672a 5. Position a new manifold gasket on the 3 manifold mounting bolts (Fig. 1916). Fig. 1917 DSC-1686a 7.
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4-PAW DIESEL/ENGINE 8. Using a 1/2” wrench and socket, tighten the 3 manifold mounting bolts and nuts. Torque them to 200 ± 25 in-lbs. (23 ± 3 Nm) (Fig. 1919). 10. Route the fan belt around the driven fan pulley (Fig. 1921). Fig. 1921 Fig. 1919 9. Using a 13mm wrench and socket, tighten the lower muffler mounting bolt. Torque to 19 ± 2 ft-lbs. (26 ± 3 Nm) (Fig. 1920). 11. Apply thread locking compound to the 4 pump mount mounting bolts (Fig. 1922). Fig. 1922 Fig.
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4-PAW DIESEL/ENGINE 12. Position the pump mount/idler assembly to the engine block. Route the belt around the drive pulley. Loosely install the 4 bolts and lock washers securing the pump mount/idler assembly to the engine block (Fig. 1923). 13. Turn the engine until the 2 pump coupler set screws are positioned at approximately 1 o’clock and 3 o’clock (Fig. 1924). Note: The bottom 2 mounting bolts are located below the pump mount opening and bolt the bottom of the pump mount to the engine block.
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4-PAW DIESEL/ENGINE 15. Apply anti-seize compound to the pump shaft (Fig. 1926). Fig. 1926 DSC-1750a 16. Install the pump into the pump pulley aligning the key in the pump shaft with the keyway in the pulley (Fig. 1927). 17. Apply thread locking compound to the 2 pump mounting bolts (Fig. 1928). Fig. 1928 18. Using a 9/16” wrench, install the 2 pump mounting bolts (Fig. 1929). Fig. 1929 Fig.
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4-PAW DIESEL/ENGINE 19. Using a 1/4” 8-point socket, tighten the 2 pump coupler set screws (Fig. 1930). Fig. 1930 DSC-1756a Fig. 1932 DSC-1759a Fig. 1933 Toro Wheeled CUL Service Manual DSC-1760a 22. Move the idler arm outward to apply tension to the fan belt. While applying tension, use a 9/16” socket to tighten the idler arm nut (Fig. 1933). 20. Slide the idler arm inward (Fig. 1931). Fig. 1931 21. Route the belt around the idler arm pulley (Fig. 1932).
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4-PAW DIESEL/ENGINE 23. Check and adjust the alternator belt tension. Refer to “Checking the Alternator Belt Tension” on page 6/4-60. 26. Position the 2 hose clamps and tighten to secure the 2 suction hoses (Fig. 1936). 24. Slide the rear suction hose onto the rear pump suction fitting (Fig. 1934). Fig. 1936 Fig. 1934 DSC-1765a DSC-1770a 27. Using a 15/16” wrench, install the rear hydraulic line to the rear pump fitting (Fig. 1937). 25.
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4-PAW DIESEL/ENGINE 28. Using a 15/16” wrench, install the front hydraulic line to the front pump fitting (Fig. 1938). Fig. 1938 30. Using a 7/16” socket, install 4 bolts and lock wash ers securing the fan to the fan adapter. Torque the 4 bolts to 100 ± 10 ft-lbs. (136 ± 14 Nm) (Fig. 1940). DSC-1776a Fig. 1940 29. Slide the fan onto the fan adapter (Fig. 1939). Fig. 1939 Toro Wheeled CUL Service Manual DSC-1781a 31. Install the radiator. Refer to “Radiator Installation” on page 6/4-97.
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4-PAW DIESEL/ENGINE 32. Check and fill the Hydraulic fluid as necessary: • Hydraulic Tank Capacity: 17.25 gal. (67 l) • Use 10W-30 or 15W-40 detergent, diesel engine oil (API service CH-4 or higher). Radiator Replacement Radiator Removal 1. Raise the loader arms to the fully raised position. a. Clean the area around the filler neck of the hydraulic tank (Fig. 1941). 2. Stop the engine and remove the key. b. Remove the cap from the filler neck and check the fluid level on the dipstick (Fig. 1941). 3.
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4-PAW DIESEL/ENGINE 4. Position a loader arm cylinder lock over each lift cylinder rod (Fig. 1943). 6. Lower the loader arms until they are resting on the cylinder locks. 7. Open the rear access door (Fig. 1945 and Fig. 1946). Fig. 1943 DSC-0452a Fig. 1945 DSC-1507a Fig. 1946 DSC-1508a 5. Secure each loader arm cylinder lock with a clevis pin and cotter pin (Fig. 1944). Fig.
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4-PAW DIESEL/ENGINE 8. Place a drain pan underneath the compartment hinge (on the platform) (Fig. 1947). Fig. 1947 DSC-1510a Fig. 1949 DSC-1511a Fig. 1950 6/4-94 DSC-1513a 11. Loosen the 4 self-tapping screws on the either side of the hood (2 RH and 2 LH) (Fig. 1950). 9. Loosen the radiator hose clamp (Fig. 1948). Fig. 1948 10. Remove the radiator hose from the hose flange and allow the fluid to drain into the pan (Fig. 1949).
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4-PAW DIESEL/ENGINE 12. Remove the hood from the machine (Fig. 1951). Fig. 1951 14. Remove the top radiator hose from the radiator (Fig. 1953). DSC-1516a Fig. 1953 13. Loosen the clamp securing the top radiator hose to the radiator (Fig. 1952). Fig. 1952 15. Slide the hose clamp that secures the overflow hose to the radiator filler neck away from the filler neck (Fig. 1954). DSC-1520a Fig.
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4-PAW DIESEL/ENGINE 16. Slide the overflow hose off the overflow flange (Fig. 1955). Fig. 1955 DSC-1527a 17. Remove the 4 mounting bolts located on either side of the radiator (2 RH and 2 LH) (Fig. 1956). Fig. 1956 6/4-96 DSC-1523a 18. Lift and tilt the radiator away from the machine (Fig. 1957). Fig. 1957 DSC-1528a 19. Loosen the hose clamp that secures the lower radiator hose to the radiator (Fig. 1958). Fig.
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4-PAW DIESEL/ENGINE 20. Remove the lower radiator hose from the radiator (Fig. 1959). Radiator Installation 1. To install the radiator mount to the radiator, refer to “Radiator Mount Installation” on page 6/4-102. 2. Position the radiator onto the machine (Fig. 1961). Fig. 1959 DSC-1530a 21. Remove the radiator assembly from the machine (Fig. 1960). Fig. 1961 DSC-1531a 3. Slide the lower radiator hose onto the bottom radiator flange (Fig. 1962). Fig. 1960 DSC-1531a 22.
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4-PAW DIESEL/ENGINE 4. Position the hose clamp and tighten to secure (Fig. 1963). Fig. 1963 DSC-1551a 5. Slide the radiator into the unit. Slide the top radiator hose onto the top flange on the radiator (Fig. 1964). Fig. 1964 6/4-98 DSC-1553a 6. Position the hose clamp and tighten to secure (Fig. 1965). Fig. 1965 DSC-1557a 7. Ensure that the hydraulic vent hose runs in front of the radiator and is not pinched under it (Fig. 1966). Fig.
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4-PAW DIESEL/ENGINE 8. Install the 4 mounting bolts securing either side of the radiator to the frame (2 RH and 2 LH) (Fig. 1967). 10. Position the overflow hose clamp to secure it to the flange (Fig. 1969). Fig. 1969 Fig. 1967 9. Slide the overflow hose onto the radiator overflow flange (Fig. 1968). 11. Slide the radiator hose onto the engine hose flange (Fig. 1970). Fig. 1970 Fig.
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4-PAW DIESEL/ENGINE 12. Position the hose clamp and tighten to secure (Fig. 1971). 14. Add coolant up to the cold fill line on the reservoir bottle. 15. With the radiator cap off, start the engine and let it run in a well ventilated area until the thermostat opens. When the thermostat opens the coolant mixture will begin to flow through the radiator. 16. Add more coolant into the radiator so the top of the radiator cores are covered with coolant (Fig. 1973). 17. Shut engine off and let engine cool.
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4-PAW DIESEL/ENGINE 20. Check for leaks. Radiator Mount Replacement 21. Position the hood onto the unit (Fig. 1975). Radiator Mount Removal 1. Using a 1/2” socket wrench, remove the 8 bolts and flat washers securing either side of the radiator mount to the radiator (4 RH and 4 LH) (Fig. 1977). Fig. 1975 DSC-1568a 22. Install 4 self-tapping screws on the either side of the hood (2 RH and 2 LH) to secure (Fig. 1976). Fig. 1977 DSC-1535a 2. Remove the radiator mount from the radiator (Fig. 1978).
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4-PAW DIESEL/ENGINE 3. Remove the radiator cap (Fig. 1979). Radiator Mount Installation 1. Position the radiator mount onto the radiator (Fig. 1980). Fig. 1979 DSC-1541a Fig. 1980 DSC-1544a 2. Using a 1/2” socket, install 8 bolts with flat washers securing both sides of the radiator mount to the radiator (4 RH and 4 LH) (Fig. 1981). Fig.
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4-PAW DIESEL/ENGINE Pump Mount Assembly Rebuild 1. Remove the bolt, flat washer, idler pulley, spacer, and nut securing the tensioner arm to the pump mount assembly (Fig. 1982). 3. Remove locknut, 2 washers, spacer, and bolt secur ing the bottom of the tensioner arm to the pump mount assembly (Fig. 1984). Fig. 1984 Fig. 1982 IMG-0634a IMG-0631a 4. Loosen the two square head set screws securing the pulley to the pump mount fan shaft (Fig. 1985). 2.
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4-PAW DIESEL/ENGINE 5. Remove the two locknuts and washers located on each end of the pump mount fan shaft (Fig. 1986). Fig. 1986 IMG-0638a 6. Remove the fan adapter from the fan shaft (Fig. 1987). 7. Remove the square key from the fan shaft (Fig. 1988). Fig. 1988 8. Remove the pulley from the fan shaft (Fig. 1989). Fig. 1989 Fig.
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4-PAW DIESEL/ENGINE 9. Remove the square key from the fan shaft (Fig. 1990). Fig. 1990 IMG-0647a 11. Turn the pump mount assembly over and drive out the other bearing (Fig. 1992). Fig. 1992 IMG-0650a 10. With a dead blow hammer, drive one of the bearings out of the housing (Fig. 1991). 12. Install a new bearing into the pump mount assembly (Fig. 1993). Fig. 1991 Fig.
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4-PAW DIESEL/ENGINE 13. Turn the assembly over and install the fan shaft into the pump mount assembly bearing (Fig. 1994). 15. Install a square key into the fan shaft (Fig. 1996). Fig. 1996 Fig. 1994 14. Using a driver, install a new bearing into the pump mount assembly until the bearing seats up against the fan shaft (Fig. 1995). 16. Install the pulley onto the fan shaft so that the pulley hub (with the square head set screws) faces the bearing (Fig. 1997). Fig. 1997 Fig.
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4-PAW DIESEL/ENGINE 17. Install a washer and a lock nut to secure the pulley to the fan shaft (Fig. 1998). Fig. 1998 IMG-0655a 18. Turn the pump mount assembly over and install a square key in the fan shaft (Fig. 1999). Fig. 1999 Toro Wheeled CUL Service Manual IMG-0642a 19. Slide the fan adapter onto the fan shaft with the flat hub side toward the bearing (Fig. 2000). Fig. 2000 IMG-0641a 20. Install a washer and lock nut to secure the fan adapter to the shaft (Fig. 2001). Fig.
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4-PAW DIESEL/ENGINE 21. Tighten both lock nuts until both the pulley and fan adapter seat up against the bearings (Fig. 2002). Fig. 2002 23. Install bolt with a washer through the bottom of the tensioner arm. Slide a spacer onto the bolt. Install the bolt/tensioner arm assembly onto the pump mount assembly. Slide a washer onto the bolt and install a lock nut. Tighten the lock nut ensuring there is still rotational movement on the tensioner arm (Fig. 2004). IMG-0638a 22.
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4-PAW DIESEL/ENGINE 25. Slide a washer onto a shoulder bolt. Slide the idler pulley onto the shoulder bolt with the hub facing away from the washer. Slide a spacer onto the bolt (Fig. 2006). Fan Drive Pulley, Rubber Coupler & Flywheel Adapter Replacement Fan Drive Pulley, Rubber Coupler & Flywheel Adapter Removal 1. Remove the hydraulic tandem pump. Refer to “Hydraulic Tandem Pump Removal” on page 6/2-53. D A B Fig. 2006 A. Spacer B. Pulley 2. Remove the fan belt from the driven fan pulley (Fig. 2008).
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4-PAW DIESEL/ENGINE 3. Using a 1/2” socket, remove the 4 pump mount assembly mounting bolts and lock washers (Fig. 2009). 5. Remove the fan belt (Fig. 2011). Note: The bottom 2 mounting bolts are located below the pump mount opening. They bolt the bottom of the mount plate to the engine block. Fig. 2011 DSC-1644a 6. Using a 1/2” socket, remove the 2 bolts securing the pulley to the flywheel adapter (Fig. 2012). Fig. 2009 DSC-1640 4. Remove the pump mount/idler assembly (Fig. 2010). Fig. 2012 Fig.
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4-PAW DIESEL/ENGINE 7. Remove the pulley and coupler assembly from the flywheel adapter (Fig. 2013). 9. Remove the flywheel adapter assembly from the flywheel (Fig. 2015). Note: The coupler spacer will fall away from the coupler as soon as the 2 mounting bolts are removed. Fig. 2015 Fig. 2013 DSC-1698a DSC-1701a 10. Using a 1/2” socket and wrench, remove the 2 bolts and nuts securing the rubber coupler assembly to the fan drive pulley (Fig. 2016). 8.
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4-PAW DIESEL/ENGINE 11. Remove the rubber couplers from the pulley (Fig. 2017). 13. Separate the 2 rubber couplers (Fig. 2019). Fig. 2019 Fig. 2017 14. Remove the 2 spacers from each rubber coupler (Fig. 2020). 12. Remove the coupler spacer (Fig. 2018). Fig. 2018 6/4-112 DSC-1711a DSC-1708a DSC-1709a Fig.
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4-PAW DIESEL/ENGINE 15. Remove the 2 set screws from the pulley hub (Fig. 2021). Fan Drive Pulley, Rubber Coupler & Flywheel Adapter Installation 1. Loosely install 2 set screws in the fan drive pulley hub (Fig. 2023). Fig. 2021 DSC-1715a 16. Inspect the pulley assembly components (Fig. 2022): E A A B KK CD C F F Fig. 2022 Bolt (2) Pulley Bolt (2) Coupler spacer (2) Rubber coupler (2) Spacer (4) 2. Insert 2 shoulder bolts into the fan drive pulley (Fig. 2024). G D A. B. C. D. E. F.
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4-PAW DIESEL/ENGINE 3. Slide the coupler spacer onto the 2 shoulder bolts (Fig. 2025). Fig. 2025 5. Insert 4 spacers into the rubber coupler assembly (opposite direction of each other, as shown) (Fig. 2027 and Fig. 2028). DSC-1717a Fig. 2027 DSC-1719a Fig. 2028 DSC-1720a 4. Position the two rubber couplers together (Fig. 2026). Fig.
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4-PAW DIESEL/ENGINE 6. Slide the rubber coupler assembly onto the 2 shoul der bolts so the non-flanged side of the spacers is installed first (Fig. 2029). Fig. 2029 DSC-1721a 7. Install 2 nuts onto the shoulder bolts securing the rubber coupler assembly to the fan drive pulley and coupler spacer (Fig. 2030). Fig. 2030 Toro Wheeled CUL Service Manual DSC-1724a 8. Using a 1/2” socket and wrench, torque the coupler shoulder bolts to 300 ± 30 in-lbs. (34 ± 3 Nm) (Fig. 2031). Fig. 2031 DSC-1726a 9.
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4-PAW DIESEL/ENGINE 10. Position the flywheel adapter to the flywheel (Fig. 2033). Fig. 2033 12. Using a 13mm wrench, torque the 5 flywheel adapter mounting bolts to 17 - 21 ft-lbs. (23 - 28 Nm) securing the flywheel adapter to the flywheel (Fig. 2035). DSC-1729a Fig. 2035 DSC-1732a 11. Loosely install the 5 flywheel adapter mounting bolts (Fig. 2034). 13. Apply thread locking compound to the 2 pulley/ coupler mounting bolts (Fig. 2036). Fig. 2034 DSC-1731a Fig.
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4-PAW DIESEL/ENGINE 14. Insert the 2 shoulder bolts through the flanged coupler spacers (Fig. 2037). Fig. 2037 16. Position the pulley and coupler assembly to the flywheel adapter. Using a 1/2” socket, install the 2 shoulder bolts securing the pulley and couplers to the flywheel adapter (Fig. 2039). DSC-1735a Fig. 2039 DSC-1739a 15. Slide the coupler spacer onto the 2 shoulder bolts (Fig. 2038). 17. Torque the 2 shoulder bolts to 300 ± 30 in-lbs. (34 ± 3 Nm) (Fig. 2040). Fig. 2038 DSC-1737a Fig.
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4-PAW DIESEL/ENGINE 18. Route the fan belt around the driven fan pulley (Fig. 2041). 20. Position the pump mount/idler assembly to the engine block. Route the belt around the fan drive pulley. Loosely install the 4 bolts and lock washers securing the pump mount/idler assembly to the engine block (Fig. 2043). Note: The bottom 2 mounting bolts are located below the pump mount opening and bolt the bottom of the pump mount to the engine block.
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4-PAW DIESEL/ELECTRICAL Ignition Switch How It Works Purpose This component provides the proper switching for the starter, Ignition, accessories, and safety circuits. Detents inside the ignition switch give it 3 positions: OFF, RUN, and START. The START position is spring loaded so the cylinder automatically returns to RUN once the key is released. Location Testing The ignition switch is mounted on the right hand side of the upper frame assembly (Fig. 2044). 1.
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4-PAW DIESEL/ELECTRICAL Relay How It Works Purpose A relay is an electrically actuated switch. The 4-Paw Diesel Wheeled CUL uses two relays. One to direct current flow to the start relay and the other to direct flow to the glow plug relay. 1. Coil: Terminals 85 and 86 are connected to a coil. Applying 12 volts to these terminals energizes the coil turning it into an electromagnet. Location The relays are located inside of the lower frame assem bly, to the right of the engine (Fig. 2046). A 2.
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4-PAW DIESEL/ELECTRICAL Testing 1. Disconnect the relay from the harness. 2. Verify the coil resistance between terminals 85 and 86 with a multimeter (ohms setting). Resistance should be from 70 to 90 ohms. There should be continuity between terminals 87a and 30 (Fig. 2048). 3. Connect the multimeter (ohms setting) leads to relay terminals 30 and 87. Ground terminal 86 and apply +12 VDC to terminal 85.
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4-PAW DIESEL/ELECTRICAL Fuses How It Works Purpose The fuse block is the point where the wires that carry 12 volts meet the wires that need 12 volts to operate a component or function. The fuse makes the connection between the 12 volt wire that needs the current. Fuses are used in the circuits to limit wiring damage in the event of excessive current flow. If a fuse fails, look for a short circuit, a corroded/poor connection, or any component that appears to have been overheated.
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4-PAW DIESEL/ELECTRICAL Neutral Safety Switches How It Works Purpose The switch has a spring loaded ball. When the 4-spool hydraulic valve control handles for forward and reverse are in the neutral position, the ball moves into a machin ed notch located in the spool. The normally closed switch then provides a ground to the start circuit.
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4-PAW DIESEL/ELECTRICAL Auxiliary Neutral Switch How It Works Purpose The switch has a spring loaded ball. When the auxiliary hydraulic valve is in the neutral position, the ball moves into a machined notch located in the spool. The normally closed switch then provides a ground to the start circuit. When the auxiliary lever is moved out of neutral, the spool pushes against the ball end of the switch and opens the ground circuit which prevents the engine from starting.
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4-PAW DIESEL/ELECTRICAL Hour Meter How It Works Purpose The digital hour meter is an electronic clock. It is not repairable or resettable (Fig. 2055). The digital hour meter displays engine run time and is a service reminder. When the engine is off, the hour meter displays the number of operation hours that have been logged on the traction unit. After 50 hours and then every 100 hours thereafter (that is 150, 250, 350, etc.) the screen displays CHG OIL to remind you to change the engine oil.
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4-PAW DIESEL/ELECTRICAL Indicator Lights Engine Oil Pressure Light Purpose The oil pressure light should come on when the ignition switch is in the RUN position with the engine not run ning. Also, it should light with the engine is running if the engine oil pressure drops below 4.3 PSI (0.3 kg/cm). To alert the operator in case of a system malfunction and, in the case of the glow plug light, indicate that the glow plugs are on.
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4-PAW DIESEL/ELECTRICAL Testing Indicator Lights 1. Apply 12 VDC to terminals A and B (Fig. 2057). 2. Ground terminals C and D (Fig. 2057). C A D B Fig. 2057 A. 1A(+) B. 2A(+) IMG-0576a C. 1B(-) D. 2B(-) 3. Both indicator lights should illuminate.
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4-PAW DIESEL/ELECTRICAL Glow Controller Location Purpose The glow controller is attached to the wire harness and is located under the 4-spool hydraulic valve above the engine (Fig. 2059). 1. When the ignition switch is placed in the RUN position, the controller energizes the glow plugs and lights the glow plug indicator lamp for 6 seconds (Fig. 2058). Fig. 2058 Note: The 4-spool valve has been removed for photo clarity. Fig. 2059 IMG-0552a 2.
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4-PAW DIESEL/ELECTRICAL Testing 1. Make sure there is power from the battery. 2. Disconnect the wire harness connector from the fuel stop solenoid to prevent the engine from starting. 3. Place ignition switch in the RUN position. Verify the following while in the RUN position: A. Glow plug indicator light is on. B. Glow plug relay is energized. C. Glow plugs are energized. D. Glow plug indicator light goes out and glow plugs de-energized after approximately 6 seconds. 5.
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4-PAW DIESEL/ELECTRICAL Fuel Shut Down Solenoid How It Works Purpose The fuel shut down solenoid has a coil wrapped around and iron core. Whenever 12 volts is applied to the coil, it becomes a magnet. The magnet pulls the linkage rod in. This moves the speed control plate on the injection pump (Fig. 2062). When the ignition switch is in the START position, the fuel shut down solenoid pulls the speed control plate on the injection pump to allow fuel to the engine.
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4-PAW DIESEL/ELECTRICAL Testing Troubleshooting The solenoid has 3 wires: • White wire is energized when the key is turned to the START position and energizes the Pull Coil to draw in the plunger and return spring, in turn moving the speed control plate. The white wire is spliced to the blue fusible link wire that is connected to the push-on terminal on the starter. • Red (or Pink) wire energizes the Hold Coil after the engine starts and the key is released to RUN position.
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4-PAW DIESEL/ELECTRICAL . . Electrical Schematics 22303 -2001, 2000, 1999 WIRE COLOR CODES KUBOTA DINGO SCHEMATIC SW5 IGNITION 4 2 1 5 3 A B S I R Y BK BN BU GN GY OR S OFF NO CONNECTION ON B+R+I+A START B+R+I+S HEADLIGHT CONNECTOR B I R A KEY SW B A BLACK BROWN BLUE GREEN GREY ORANGE PK R T VIO W Y PINK RED TAN VIOLET WHITE YELLOW F3 PK VIO VIO 10A F1 R 30A T KEY SWITCH P/N 111216 NOTE: SOME WIRE COLORS CHANGE AT REGULATOR CONNECTOR.
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4-PAW DIESEL/ELECTRICAL 22303 - 2006, 2005, 2003, 2002 Fig.
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4-PAW DIESEL/ELECTRICAL THIS PAGE INTENTIONALLY LEFT BLANK.
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Wheeled Compact Utility Loader Service Manual Chain Drive / 4-Paw Gas / 4-Paw Diesel Form No.