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.
Safety • Do not over-load the attachment and always keep the load level when raising the loader arms. Logs, boards, and other items could roll down the loader arms, injuring you. • Raising the loader arms on a slope will affect the stability of the machine. Whenever possible, keep the loader arms in the lowered position when on slopes. • Never jerk the control levers; use a steady motion. • • Keep your hands, feet, hair, and loose clothing away from any moving parts.
Safety • Do not operate near drop-offs, ditches, or embankments. The traction unit could suddenly turn over if a wheel goes over the edge of a cliff or ditch, or if an edge caves in. • If any maintenance or repair requires the loader arms to be in the raised position, secure the arms in the raised position with the hydraulic cylinder locks included with traction unit. • Do not operate on wet grass. Reduced traction could cause sliding. • Never run a traction unit inside a closed area.
Safety • Battery acid is poisonous and can cause burns. Avoid contact with skin, eyes, and clothing. Protect your face, eyes, and clothing when working with a battery. • Battery gases can explode. Keep cigarettes, sparks and flames away from the battery. • Keep your body and hands away from pin hole leaks or nozzles that eject high pressure hydraulic fluid. Use cardboard or paper to find hydraulic leaks.
Safety Slope Chart 6
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. RATED OPERATING CAPACITY 515 LBS. On Loader Cross Bar (Part No. 98–4682) Near Oil Fill (Part No. 85–4730) On Control Panel (Part No. 99–3157) On Front Control Panel (Part No. 98–4677) Inside Left Loader Arm (1) (Part No. 98–9051) On Front Control Panel (Part No. 98–8220) On Front Control Panel (Part No.
Assembly Loose Parts Note: Use the chart below to verify that all parts have been shipped. DESCRIPTION QTY. USE Traction Unit 1 Valve Lever 1 Key 2 Start engine Hydraulic oil filter 1 Break-in oil change Install valve lever 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. 1). Note: 2.
Assembly 3. Gently push the hydraulic hoses aside and lift the battery out of the chassis. 5. POTENTIAL HAZARD • Battery electrolyte contains sulfuric acid which is a deadly poison and it causes severe burns. Leave the covers off and connect a 3 to 4 amp battery charger to the battery posts (Fig. 4). Charge the battery at a rate of 4 amperes or less for 4 hours (12 volts). 4 2 3 WHAT CAN HAPPEN • If you drink electrolyte you could die or if it 1 gets onto your skin you will be burned.
Assembly 7. Slowly pour electrolyte into each cell until the level is once again up to the upper line on the battery case (Fig. 3) and install covers. 8. Install the battery into the chassis (Fig. 2). 9. Secure the battery in chassis with the bar and wing nuts removed previously (Fig. 2). 10. Using the bolt and wing nut supplied with the battery, connect the positive (red) cable to the positive (+) battery post (Fig. 2). Slide the rubber cover over the battery post. 11.
Specifications Overall width 40.5 inches (103 cm) Overall length 60.0 inches (152 cm) Overall height 49.0 inches (125 cm) Weight 1522 lbs (690 kg) Rated operating capacity (with 200 lb operator) 515 lbs (234 kg) Tipping capacity (with 200 lb operator) l030lbs (467kg) Wheelbase 28 inches (71 cm) Dump height (with std. bucket) 48.75 inches (124 cm) Reach – fully raised (with std. bucket) 26.0 inches Height to hinge pin 66.
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. Adding Fuel POTENTIAL HAZARD • In certain conditions gasoline is extremely flammable and highly explosive. WHAT CAN HAPPEN • A fire or explosion from gasoline can burn you, others, and cause property damage.
Check Before Operating Filling the Fuel Tanks 1. Park the traction unit on a level surface, lower the loader arms, and stop the engine. 2. Remove the key and allow the engine to cool. 3. Clean around the fuel tank caps and remove them. 4. Use a funnel and add unleaded regular gasoline to each fuel tank, until the level is 1/4 to 1/2 inch (6 mm to 13 mm) below the bottom of each filler neck. IMPORTANT: This space in the tank allows gasoline to expand. Do not fill the fuel tank completely full. 5.
Check Before Operating 7. Install the hood; refer to Installing the Hood, page 25. 8. Remove and store the cylinder locks (refer to Using the Cylinder Locks, page 20), and lower the loader arms. 1 2 m–4392 Checking the Hydraulic Fluid Figure 6 1. Filler neck cap Check the hydraulic fluid level before the engine is first started and after every 25 operating hours. 7. If the level is low, add enough fluid to raise it to the proper level. 8. Install the cap on the filler neck. 9.
Operation Traction Unit Overview Figure 8 contains a front and back view of the traction unit. Familiarize yourself with all of the traction unit components listed in Figure 8. 14 12 11 3 3 10 5 13 11 9 2 6 8 4 1 7 m–4393/4389 Figure 8 1. 2. 3. 4. Mount plate Tilt cylinder Loader arms Lift cylinder 5. 6. 7. 8. Fuel tank Wheel Operator platform Engine POTENTIAL HAZARD • The operator could fall off of the platform. WHAT CAN HAPPEN • The operator could be seriously injured.
Operation Controls Traction Control Levers Become familiar with all the controls (Fig. 9) before you start the engine and operate the traction unit. To move forward, move the traction control levers forward. To move rearward, move the traction control levers rearward. 5 3 1 2 To go straight, move both traction control levers equally. 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. 6 8 7 m–4388 Figure 9 1. 2.
Operation Pump Selector Lever Move the pump selector lever to the fast (rabbit) position to set the traction drive, loader arms, and attachment tilt to high speed and the auxiliary hydraulics to low speed. Move the pump 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. powering attachments; however, the two systems share the same hydraulic pumps. Using the flow divider control (Fig.
Operation IMPORTANT: If the engine is run at high speeds when the hydraulic system is cold (i.e., when the ambient air temperature is around freezing or lower), hydraulic system damage could occur. When starting the engine in cold conditions, allow the engine to run in the middle throttle position for 2 to 5 minutes before moving the throttle to fast (rabbit).
Operation • To turn, move the lever located on the side you want to turn toward the neutral position while keeping the other lever engaged. • 1. Stop the engine. 2. Lift the traction unit off the ground, using the two lift points (Fig. 11) and move onto a trailer. To slow or stop, move the traction control levers to neutral. Note: The farther you move the traction control levers in either direction, the faster the traction unit will move in that direction.
Operation 5. Secure each loader arm cylinder lock with a clevis pin and cotter pin (Fig. 12). 1 3 4 2 5 1 1 4 2 3 2 m–4397 m–4398 Figure 12 1. Cylinder lock 2. Lift cylinder 3. Hairpin cotter 4. Clevis pin 5. Lift cylinder rod Figure 13 1. Hydraulic hoses 2. Cylinder locks 3. Hairpin cotter 4. Clevis pin 6. Start the engine. Attachments 7. Slowly lower the loader arms until cylinder locks contact the cylinder body and rod end. Connecting an Attachment 8. Stop the engine.
Operation 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. 1 2 m–4055 Figure 14 1. Mount plate 6. 2. Receiver plate Raise the loader arms while tilting back the mount plate at the same time.
Operation 5. If the attachment uses hydraulics, slide the collar back on the hydraulic couplers and disconnect them. IMPORTANT: Connect the attachment hoses together to prevent hydraulic system contamination during storage. 6. Install the protective covers onto the hydraulic couplers on the traction unit. 7. Start the engine, tilt the mount plate forward, and back the traction unit away from the attachment.
Maintenance Service Interval Chart Service Operation Each Use Hydraulic Fluid–check level Initial 8 Hours 25 Hours 50 Hours 100 Hours 200 Hours 400 Hours X Hydraulic Fluid–change X Hydraulic Filter–change Engine Oil—check level Engine Initial X X Oil—change1 Initial X Engine Oil Filter–change (200 hours or every other oil change)1 X Wheel Nuts–tighten Initial Chassis—grease2 X Primary Air Filter—clean1 or replace X Safety Air Filter—replace1 X Spark Plug(s)—check X Engine RPM
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. Removing/Installing the Hood Removing the Hood Before performing many maintenance procedures, you will need to remove the hood. 1.
Maintenance 4. Gently slide the primary filter out of the air cleaner body (Fig. 17). Avoid knocking the filter into the side of the body. Do not remove the safety filter, unless you intend to replace it as well. 5. 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. IMPORTANT: Never attempt to clean the safety filter.
Maintenance 3. Lower the loader arms, chock the wheels, and stop the engine. Remove the key. POTENTIAL HAZARD • Components will be hot if the traction unit has been running. 8. Check the oil level; refer to Checking the Oil Level, page 14. 9. Slowly add additional oil to bring the level to the F (full) mark on the dipstick. 10. Replace the fill cap. Changing the Oil Filter WHAT CAN HAPPEN • Touching hot components can cause burns.
Maintenance 6. Install the replacement oil filter to the filter adapter. Turn the oil filter clockwise until the rubber gasket contacts the filter adapter, then tighten the filter an additional 1/2 turn (Fig. 19). 7. Fill the crankcase with the proper type of new oil; refer to Changing the Oil, page 26. 1 2 Servicing the Spark Plugs m–3876 Check the spark plugs after every 200 operating hours. Ensure that the air gap between the center and side electrodes is correct before installing each spark plug.
Maintenance 2 3 1 0.030 in. (0.76 mm) m–3215 Figure 21 1. Center electrode insulator 2. Side electrode 3. Air gap (not to scale) Installing the Spark Plugs m–4396 1. Thread the spark plugs into the spark plug holes. 2. Tighten the spark plugs to 20 ft-lb (27 N.m). 3. Push the wires onto the spark plugs (Fig. 20). Figure 22 Greasing the Traction Unit m–4056 Grease all pivot joints every 8 operating hours and immediately after every washing. Grease Type: General-purpose grease. Figure 23 4.
Maintenance Draining the Fuel Tanks 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 each fuel tank (Fig. 25). 3. Clamp the fuel line between the fuel tanks and the fuel filter to block the fuel flow. 4. Squeeze the ends of the hose clamps together and slide them away from the filter (Fig. 24). 5. Place a drain pan under the fuel lines to catch any leeks, then remove the filter from the fuel lines. 6.
Maintenance Note: Now is the best time to install a new fuel filter because the fuel tanks are empty. 6. Install the fuel line onto the fuel filter. 7. Slide the hose clamp close to the fuel filter to secure the fuel line. 8. Open the fuel valve on the bottom of each fuel tank. Servicing the Hydraulic System 8. Install the replacement hydraulic filter onto the filter adapter.
Maintenance 2. Raise the loader arms and install the cylinder locks; refer to Using the Cylinder Locks, page 20. 3. Stop the engine and remove the key. 4. Remove the hood; refer to Removing the Hood, page 25. POTENTIAL HAZARD • Hydraulic fluid escaping under pressure can penetrate skin and cause injury. WHAT CAN HAPPEN • Fluid accidentally injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result.
Maintenance 1 2 2. 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. 3. Install the filler caps after the battery is fully charged. 3 1262 Figure 27 1. Filler caps 2. Lower part of tube 2. 3. Plates POTENTIAL HAZARD • Charging the battery produces gasses.
Maintenance 6. Remove the spark plugs and check the condition of each; refer to Servicing the Spark Plugs, page 28. 15. Store the traction unit in a clean, dry garage or storage area. Remove the key from the ignition switch and keep it in a memorable place. 7. With the spark plugs removed from the engine, pour two tablespoons of engine oil into each spark plug hole. 16. Cover the traction unit to protect it and keep it clean. 8.
Troubleshooting PROBLEM Starter does not crank Engine g will not start,, starts hard,, or f il to fails t keep k running. i Engine g loses power. p Engine g overheats. Abnormal vibration. POSSIBLE CAUSES CORRECTIVE ACTION 1. Auxiliary hydraulics lever is not in neutral position. 1. Move lever to neutral position. 2. Battery is dead. 2. Charge the battery. 3. Electrical connections are corroded or loose. 3. Check electrical connections for good contact. 4. Relay or switch is defective.
Troubleshooting PROBLEM Traction unit does not drive. POSSIBLE CAUSES CORRECTIVE ACTION 1. Flow divider valve lever is in 9 o’clock position. 1. Move lever to the 12 to 10 o’clock position. 2. Hydro fluid level low. 2. Add hydro fluid to reservoir. 3. Traction pump drive coupler is loose or broken. 3. Contact Service Dealer. 4. Pump and/or wheel motor is defective or damaged. 4. Contact Service Dealer. 5. Control valve is defective or damaged. 5. Contact Service Dealer. 6.
Troubleshooting 37
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.
