Form No.
Introduction Thank you for purchasing a Toro product. All of us at Toro want you to be completely satisfied with your new product, so feel free to contact your local Authorized Service Dealer for help with service, genuine replacement parts, or other information you may require. Whenever you contact your Authorized Service Dealer or the factory, always know the model and serial numbers of your product.
Contents Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safe Operating Practices . . . . . . . . . . . . . . Slope Chart . . . . . . . . . . . . . . . . . . . . . . . . . Safety and Instruction Decals . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loose Parts . . . . . . . . . . . . . . . . . . . . . . . . . Installing the Valve Lever . . . . . . . . . . . . . Activating the Battery . . . . . . . . . . . . . . . . Specifications . . . . . .
Safety Improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert symbol, which means CAUTION, WARNING, or DANGER—“personal safety instruction.” Failure to comply with the instruction may result in personal injury or death. Safe Operating Practices This product is capable of amputating hands and feet. Always follow all safety instructions to avoid serious injury or death.
Safety • Watch for traffic when operating near or crossing roadways. • Use slow speed on slopes. Before starting the engine, put the pump selector lever in the slow (turtle) position so that you will not have to stop or shift while on the slope. • Use extra care when loading or unloading the traction unit onto a trailer or truck. • Do not touch parts which may be hot from operation. Allow them to cool before attempting to maintain, adjust, or service.
Safety Children • Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the traction unit and the work activity. Never assume that children will remain where you last saw them. • Keep children out of the work area and under the watchful care of another responsible adult. • Be alert and turn the traction unit off if children enter the area. • Before and while backing, look behind and down for small children. • Never carry children.
Safety Slope Chart 5
Safety Safety and Instruction Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost. 4 7 1 6 # 93-6680 # 93-7814 8 5 2 # 93-9084 3 # 98-8219 # 85-4730 # 98-8235 # 98-4682 9 # 98–8220 # 93-6681 5 # 80-8010 # 98-4677 # 98-9051 # 99-3157 Figure 1 1. Fast 2. Traction drive 3. Slow 6 4. Entanglement hazard 5. Stay away from moving parts 6. Use only diesel fuel 7. Lift point 8.
Assembly Loose Parts Note: Use the chart below to verify that all parts have been shipped. DESCRIPTION QTY. Traction Unit 1 Valve Lever 1 Key 2 USE Install valve lever Start engine Installing the Valve Lever Activating the Battery 1. The traction unit is shipped with a dry battery. Bulk electrolyte with 1.260 specific gravity must be purchased from a local battery supply outlet. Thread the lever into the pump selector valve (Fig. 2). Note: 2.
Assembly 3. Lift the battery off of its platform. 4 2 POTENTIAL HAZARD • Battery electrolyte contains sulfuric acid which is a deadly poison and it causes severe burns. 3 1 WHAT CAN HAPPEN • If you drink electrolyte you could die, or, if it gets onto your skin, you will be burned. HOW TO AVOID THE HAZARD • Do not drink electrolyte and avoid contact with skin, eyes or clothing. Wear safety glasses to shield your eyes and rubber gloves to protect your hands.
Assembly 10. Install the battery onto its platform (Fig. 3). 11. Secure the battery in the chassis with the bars and nuts removed previously (Fig. 3). 12. Connect the positive (red) cable to the positive (+) battery post (Fig. 3). Slide the rubber cover over the battery post. 13. Connect the negative (black) cable to the negative (–) battery post (Fig. 3). Note: Ensure that the battery cables do not contact any sharp edges or each other. 14. Install the battery cover (Fig. 3).
Specifications Note: Specifications and design are subject to change without notice. Width 40.5 inches (103 cm) Length 60 inches (152 cm) Height 49 inches (125 cm) Weight 1722 lbs (781 Kg) Operating capacity (with a 200 lb operator) 515 lbs (234 Kg) Tipping capacity (with a 200 lb operator) 1030 lbs (467 Kg) Wheelbase 28 inches (71 cm) Dump height (with standard bucket) 48.
Check Before Operating Stability Data The following table lists the maximum slope recommended for the traction unit in the positions listed in the table. Slopes over the listed degree may cause the traction unit to become unstable. The data in the table assumes that the loader arms are fully lowered and that the factory installed tires are on the traction unit, inflated to the recommended pressure; raised arms and other tire types or pressure may affect the stability.
Before Operating Before operating, check the fuel and oil level, remove debris from the traction unit, and check the tire pressure. Also, ensure that the area is clear of people and debris. You should also know and have marked the locations of all utility lines. 5. Install the fuel tank cap securely. Wipe up any fuel that may have spilled. If possible, fill the fuel tank after each use. This will minimize possible buildup of condensation inside the fuel tank.
Check Before Operating Draining Water from the Fuel Filter Drain water or other contaminants from the fuel filter daily. 1. Stop the engine and remove the key. 2. Open the rear access cover; refer to Opening the Rear Access Cover, page 26. 3. Turn the drain valve until the water runs out of the filter (Fig. 6). Note: The fuel filter is located near the bottom of the fuel tank. 3. Open the rear access cover; refer to Opening the Rear Access Cover, page 26. 4. Clean around the oil dipstick (Fig.
Check Before Operating Checking the Cooling System The cooling system is filled with a 50/50 solution of water and permanent ethylene glycol anti–freeze. Check the level of coolant at the beginning of each day, before starting the engine. 1 m–4591 Figure 8 1. Filler Cap POTENTIAL HAZARD • Coolant is hot and pressurized. WHAT CAN HAPPEN • Discharge of hot pressurized coolant can cause severe burns.
Check Before Operating 9. Remove and store the cylinder locks (refer to Using the Cylinder Locks, page 22), and lower the loader arms. 1 2 Checking the Hydraulic Fluid Check the hydraulic fluid level before the engine is first started and after every 25 operating hours. m–4596 Hydraulic Tank Capacity: 17.25 gal.
Check Before Operating 1 m–1872 Figure 10 1.
Operation Traction Unit Overview Figure 11 contains a front and back view of the traction unit. Familiarize yourself with all of the traction unit components listed in Figure 11. 6 17 14 4 15 14 5 6 4 13 12 3 2 7 11 10 m-4592 8 1 16 9 m-4599 Figure 11 1. 2. 3. 4. 5. Mount plate Tilt cylinder Auxiliary hydraulic couplers Loader arms Front access cover 6. 7. 8. 9. Fuel tank Wheel Lift cylinder Operator platform 10. 11. 12. 13. Rear access cover (open) Engine Air filter Control panel 14. 15.
Operation Controls Become familiar with all the controls (Fig. 12) before you start the engine and operate the traction unit. 3 1 5 2 4 To turn, move the lever located on the side you want to turn back toward the neutral position while keeping the other lever engaged. The farther you move the traction control levers in either direction, the faster the traction unit will move in that direction. To slow or stop, move the traction control levers to neutral. 6 7 m–4388 Figure 12 1. 2. 3. 4.
Operation Move the speed selector lever to the slow (turtle) position to set the auxiliary hydraulics to high speed and the traction drive, loader arms, and attachment tilt to low speed. more hydraulic flow you divert to the auxiliary hydraulics, the slower the traction unit hydraulics will move. Note: POTENTIAL HAZARD • If the speed selector lever is moved while the traction unit is in motion, the traction unit will either stop suddenly or accelerate quickly.
Operation the trencher does work best if you set it close to nine–o’clock so that the traction unit will creep slowly when trenching. Note: The flow divider control can be fixed in place by turning the knob on the control clockwise until it contacts the dial (Fig. 13). Indicator Lights The indicator lights warn you in the case of a system malfunction and, in the case of the glow plug light, indicate that the glow plugs are on. Figure 14 illustrates the four indicator lights. 1 3 2 down.
Operation Note: A warm or hot engine may be started without waiting for the light to turn off. IMPORTANT: Do not engage the starter for more than 10 seconds at a time. If the engine fails to start, allow a 30 second cool-down period between attempts. Failure to follow these instructions can burn out the starter motor. 6. Move the throttle lever to the desired setting. IMPORTANT: If the engine is run at high speeds when the hydraulic system is cold (i.e.
Operation Moving a Non-functioning Traction Unit IMPORTANT: Never tow or pull the traction unit. Rotating the wheels manually will cause damage to the hydraulic wheel motors. 1. Stop the engine. 2. Lift the traction unit off the ground, using the two lift points (Fig. 15), and move it onto a trailer. 2. Raise the loader arms to the fully raised position. 3. Stop the engine. 4. Position a loader arm cylinder lock over each lift cylinder rod (Fig. 16). 5.
Operation 1 3 2 4 1 2 1 2 m–4055 Figure 18 1. Mount plate 2. Receiver plate m–4601 Figure 17 1. Hydraulic hoses 2. Cylinder locks 6. 3. Hairpin cotter 4. Clevis pin Installing and Removing Attachments Connecting an Attachment Raise the loader arms while tilting back the mount plate at the same time. IMPORTANT: The attachment should be raised enough to clear the ground, and the mount plate should be tilted all the way back. 7. Stop the engine. 8. Engage the quick attach pins (Fig. 19). 9.
Operation IMPORTANT: Ensure that all foreign matter is cleaned from the hydraulic connections before making connections. 3. Remove the protective covers from the hydraulic couplers on the traction unit. Connect the covers together to prevent contamination during operation. 4. Slide the collars back on the hydraulic couplers and connect the attachment couplers to the traction unit couplers. POTENTIAL HAZARD • Hydraulic fluid escaping under pressure can penetrate skin and cause injury.
Maintenance Service Interval Chart Service Operation Hydraulic Fluid—check level Each Use 8 Hours Initial 25 Hours 75 Hours 100 Hours 200 Hours X Hydraulic Filter—change Initial X X X (Initial at 50) Engine Oil—change1 Engine Oil Filter—change (150 hours or every other oil change)1 150 hrs Wheel Nuts—tighten Initial Chassis—grease2 Primary Air or replace X Filter—clean1 X Safety Air Filter—replace1 600 hrs Engine RPM (idle & full throttle)—check X Fuel—drain3 X Hydraulic lines—che
Maintenance POTENTIAL HAZARD • If you leave the key in the ignition switch, someone could start the engine. WHAT CAN HAPPEN • Accidental starting of the engine could seriously injure you or other bystanders. HOW TO AVOID THE HAZARD • Remove the key from the ignition switch and and disconnect negative battery cable from battery before you do any maintenance. Opening the Access Covers 1 Removing the Front Access Cover 1.
Maintenance 5. Gently slide the primary filter out of the air cleaner body (Fig. 22). Avoid knocking the filter into the side of the body. Do not remove the safety filter, unless you intend to replace it as well. 6. Inspect the primary filter for damage by looking into the filter while shining a bright light on the outside of the filter. Holes in the filter will appear as bright spots. If the filter is damaged, discard it; otherwise, clean it. 2 1 IMPORTANT: Never attempt to clean the safety filter.
Maintenance Changing the Oil 2. If the safety filter is being replaced, carefully slide it into the filter body (Fig. 22). 1. 3. Carefully slide the primary filter over the safety filter (Fig. 22). Ensure that it is fully seated by pushing on the outer rim of the filter while installing it. Start the engine and let it run for five minutes. This warms the oil so it drains better. 2.
Maintenance 4. Allow a minute or two for the oil to be absorbed by filter material, then pour off the excess oil. 5. Apply a thin coat of new oil to the rubber gasket on the replacement filter (Fig. 24). 1 2 m-4593 3 3 Figure 23 1. Clamp 2. Oil drain tube 7. 8. 9. 3. Plug Open the rear access cover; refer to Opening the Rear Access Cover, page 26. 1 2 m–1256 Remove the oil fill cap and slowly pour approximately 80% of the specified amount of oil in through the valve cover. 1. Oil filter 2.
Maintenance Never re-install a dirty filter. 1. Lower the loader arms and stop the engine. Remove the key. 2. Shut off the fuel valve on the bottom of the fuel tank (Fig. 29). 3. Open the rear access cover; refer to Opening the Rear Access Cover, page 26. 4. Open the drain valve (Fig. 27) and drain the fuel from the fuel filter into a suitable container and dispose of it properly. 5. Remove the fuel filter with a filter wrench (Fig. 27). m–4396 Figure 25 2 1 m–4056 Figure 26 Figure 27 1.
Maintenance Bleeding the Fuel System Draining the Fuel Tank Bleeding the air from the fuel system in any of the following situations: • Initial start up of a new traction unit or a traction unit that has been stored. • After the engine has ceased running due to lack of fuel. • After maintenance has been performed on the fuel system components. 1. Open the rear access cover; refer to Opening the Rear Access Cover, page 26. 2.
Maintenance Note: Now is the best time to install a new fuel filter because the fuel tank is empty. 7. Install the fuel line onto the fuel filter. 8. Slide the hose clamp close to the fuel filter to secure the fuel line. 9. 8. Install the replacement hydraulic filter onto the filter adapter. Tighten it clockwise until the rubber gasket contacts the filter adapter, then tighten the filter an additional 1/2 turn (Fig. 30). 9. Clean up any spilled fluid. 10.
Maintenance 4. Remove the front access cover, refer to Removing the front access cover, page 26. IMPORTANT: Do not substitute automotive oil or severe hydraulic system damage may result. POTENTIAL HAZARD • Hydraulic fluid escaping under pressure can penetrate skin and cause injury. 5. Place a large drain pan under the traction unit that can hold at least 17 gal. (67 l). 6. Remove the drain plug from the bottom of the hydraulic tank and allow the fluid to completely drain out.
Maintenance 2. 1 2 3 Remove the filler caps from the battery and connect a 3 to 4 amp battery charger to the battery posts. Charge the battery at a rate of 4 amperes or less for 4 hours (12 volts). Do not overcharge the battery. 1262 Figure 31 1. Filler caps 2. Lower part of tube 3. 3. Plates POTENTIAL HAZARD • Charging the battery produces gasses. WHAT CAN HAPPEN • Battery gasses can explode.
Maintenance 6. Check the tire pressure; refer to Tire Pressure, page 15. 7. Charge the battery; refer to Servicing the Battery, page 33. 8. Flush the fuel tank with fresh, clean diesel fuel 9. Check and tighten all bolts, nuts, and screws. Repair or replace any part that is damaged. 10. Paint all scratched or bare metal surfaces. Paint is available from your Authorized Service Dealer. 11.
Troubleshooting PROBLEM The starter does not crank. The engine cranks, but will not start. 36 POSSIBLE CAUSES CORRECTIVE ACTION 1. The electrical connections are corroded or loose. 1. Check the electrical connections for good contact. 2. A fuse is blown or loose. 2. Correct or replace the fuse. 3. The relay or switch is damaged. 3. Contact your Authorized Service Dealer. 4. The battery is discharged. 4. Charge the battery or replace it. 5. A damaged starter or starter solenoid. 5.
Troubleshooting PROBLEM The engine cranks, but will not start (continued). The engine starts, but does not keep running. POSSIBLE CAUSES CORRECTIVE ACTION 8. Slow cranking speed. 8. Check the battery, oil viscosity and starting motor (contact your Authorized Service Dealer). 9. The air cleaner element is dirty. 9. Clean or replace. 10. Low compression. 10. Contact your Authorized Service Dealer. 11. The injection nozzles are damaged. 11. Contact your Authorized Service Dealer. 12.
Troubleshooting PROBLEM The engine runs, but knocks or misses. The engine will not idle. 38 POSSIBLE CAUSES CORRECTIVE ACTION 1. Dirt, water, stale fuel, or incorrect fuel is in the fuel system. 1. Drain and flush the fuel system; add fresh fuel. 2. Engine overheating. 2. See ENGINE OVERHEATS. 3. There is air in the fuel. 3. Bleed nozzles and check for air leaks at the fuel hose connections and fittings between the fuel tank and engine. 4. The injection nozzles are damaged. 4.
Troubleshooting PROBLEM The engine g overheats. The engine loses power. POSSIBLE CAUSES CORRECTIVE ACTION 1. More coolant is needed. 1. Check and add coolant. 2. Restricted air flow to the radiator. 2. Inspect and clean the radiator screen with every use. 3. The crankcase oil level is incorrect. 3. Fill or drain to the full mark. 4. Excessive loading. 4. Reduce load; use lower ground speed. 5. The thermostat is damaged. 5. Contact your Authorized Service Dealer. 6.
Troubleshooting PROBLEM Excessive black smoke from exhaust. e aust Excessive white smoke from exhaust. Traction unit does not drive. 40 POSSIBLE CAUSES CORRECTIVE ACTION 1. The air cleaner element is dirty. 1. Clean or replace. 2. The injection pump timing is incorrect. 2. Contact your Authorized Service Dealer. 3. Incorrect fuel is in the fuel system. 3. Drain the fuel system and refill with specified fuel. 4. The injection nozzles are damaged. 4.
Troubleshooting 41
T The Toro Company warrants your Toro SiteWorkT Systems Product (“Product”) to be free from defects in materials or workmanship for the period of time listed below. Where a warrantable condition exists, Toro will repair the Product at no cost to you including diagnosis, labor, parts, and transportation. This warranty begins on the date the Product is delivered to the original retail purchaser.
