Form No. 3364-915 Rev B TX 525 Compact Utility Loader Model No. 22323—Serial No. 310000001 and Up Model No. 22324—Serial No. 310000001 and Up G004222 To register your product or download an Operator's Manual or Parts Catalog at no charge, go to www.Toro.com.
Whenever you need service, genuine Toro parts, or additional information, contact an Authorized Service Dealer or Toro Customer Service and have the model and serial numbers of your product ready. Figure 1 identifies the location of the model and serial numbers on the product. Write the numbers in the space provided. This product complies with all relevant European directives, for details please see the separate product specific Declaration of Conformity (DOC) sheet.
Contents Drive System Maintenance ..................................... 36 Servicing the Tracks............................................ 36 Cooling System Maintenance .................................. 39 Servicing the Cooling System.............................. 39 Belt Maintenance.................................................... 40 Checking the Condition of the Hydraulic Pump Belt ...................................................... 40 Checking the Alternator/Fan Belt Tension ....................
Safety • Use extra care when handling fuels. They are flammable and vapors are explosive. – Use only an approved container – Never remove the fuel cap or add fuel with the engine running. Allow the engine to cool before refueling. Do not smoke. – Never refuel or drain the machine indoors. • Check that the operator’s presence controls, safety switches, and shields are attached and functioning properly. Do not operate unless they are functioning properly.
• Ensure that the area is clear of other people before operating the traction unit. Stop the traction unit if anyone enters the area. • Never leave a running traction unit unattended. Always lower the loader arms, stop the engine, set the parking brake, and remove the key before leaving. • Do not exceed the rated operating capacity, as the traction unit may become unstable which may result in loss of control. • Do not carry a load with the arms raised. Always carry loads close to the ground.
– Never fill a container while it is inside a vehicle, trunk, pick-up bed, or any surface other than the ground. • Clean debris from attachments, drives, mufflers, and engine to help prevent fires. Clean up oil or fuel spillage. • Let the engine cool before storing and do not store near flame. • Do not store fuel near flames or drain indoors. • Park the machine on level ground. Never allow untrained personnel to service the machine. • Use jack stands to support components when required.
Stability Data The following tables list the maximum slope recommended for the traction unit in the positions listed in the tables. Slopes over the listed degree may cause the traction unit to become unstable. The data in the tables assume that the loader arms are fully lowered; raised arms may affect the stability. In each attachment manual is a set of three stability ratings, one for each hill position.
Slope Indicator G011841 Figure 3 This page may be copied for personal use. 1. To determine the maximum slope you can safely operate the machine on, refer to the Stability Data section. Use the slope indicator to determine the degree of slope of hills before operating. Do not operate this machine on a slope greater than that specified in the Stability Data section. Fold along the appropriate line to match the recommended slope. 2. Align this edge with a vertical surface, a tree, building, fence pole, etc.
Safety and Instructional Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost. 93-6686 1. Hydraulic oil 2. Read the Operator’s Manual. 100-8822 1. Warning—do not carry passengers. 93-7814 1. Entanglement hazard, belt—stay away from moving parts. 114-9600 1. Read the Operator’s Manual. 100-4650 115-4020 1. Crushing hazard of hand—keep bystanders a safe distance from the machine. 2.
115-4861 1. Auxiliary hydraulics 2. Locked reverse (detent) 115-4857 1. Lower the loader arms. 2. Dump the bucket. 3. Forward 4. Neutral (off) 4. Curl the bucket. 5. Float the bucket on the ground. 3. Raise the loader arms. 115-4858 1. Crushing hazard of hands or feet—install the cylinder lock. 115-4862 1. Loader valve lock, unlocked 115-4859 1. Disengaged 2. Parking brake 2. Loader valve lock, locked 106-6755 3. Engaged 1. Engine coolant under pressure. 2.
Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 2. No fire, open flame, or smoking. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 5. Read the Operator’s Manual. 6. Keep bystandersa safe distance from the battery. 7. Wear eye protection; explosive gases can cause blindness and other injuries 8. Battery acid can cause blindness or severe burns. 9. Flush eyes immediately with water and get medical help fast. 10. Contains lead; do not discard. 115-4860 1.
115-0790 117–9905 1. Operator’s Manual location 6. Fuel gauge—diesel 11. Fast 2. Engine—start 7. Engine oil pressure 12. 3. Engine—run 4. Engine—stop 8. Battery 9. Engine temperature 13. 14. 5. Hour meter 10. Glow plug 15. 12 16. Tipping hazard—move the traction unit with the heavy end up hill; do not travel with the loader arms raised. Continuous variable setting 17. Tipping hazard—slow the traction unit when turning, do not travel fast when turning, look behind and down when reversing.
Controls Product Overview Become familiar with all the controls (Figure 5) before you start the engine and operate the traction unit. 1 2 3 4 5 9 g013016 6 10 7 11 8 12 Figure 5 1. Auxiliary hydraulics lever 2. 3. 4. 5. Key switch Hour meter Fuel gauge Indicator lights and glow plug switch 6. Throttle lever 7. Loader arm/attachment tilt lever 8. Parking brake lever 9. Traction control 10. Reference bar 11. Loader control reference bar 12.
Traction Control G008131 Figure 9 Figure 6 • To turn left, rotate the traction control counterclockwise (Figure 10). 1. Reference bar (does not move to give you a reference point and a fixed handle to hold while operating the traction unit) 2. Traction control (moves to control the machine) • To move forward, move the traction control forward (Figure 7). G008132 Figure 10 • To stop, release the traction control (Figure 6).
Auxiliary Hydraulics Lever To operate a hydraulic attachment in the forward direction, rotate the auxiliary hydraulics lever rearward and pull it down to the reference bar (Figure 13, number 1). To operate a hydraulic attachment in reverse direction, rotate the hydraulics lever rearward, then move it left into the upper slot (Figure 13, number 2). If you release the lever while in the forward position, the lever will automatically return to the neutral position (Figure 13, number 3).
Engine Oil Pressure Light Specifications If the engine oil pressure gets too low, this light illuminates and an audible alarm sounds. If this happens, stop the engine immediately and check the oil. If low, add oil and/or look for possible leaks. Note: Specifications and design are subject to change without notice.
Operation • The blended fuel composition should meet ASTM D975 or EN590. Note: Determine the left and right sides of the machine from the normal operating position. • Painted surfaces may be damaged by biodiesel blends. Important: Before operating, check the fuel and oil level, and remove debris from the traction unit. Also, ensure that the area is clear of people and debris. You should also know and have marked the locations of all utility lines.
Checking the Engine Oil Level DANGER In certain conditions during fueling, static electricity can be released causing a spark which can ignite the fuel vapors. A fire or explosion from fuel can burn you and others and can damage property. Service Interval: Before each use or daily • Always place fuel containers on the ground away from your vehicle before filling. 3. Open the hood. 1. Park the traction unit on a level surface, lower the loader arms, and stop the engine. 2.
Checking the Hydraulic Fluid Level Service Interval: Every 25 hours Hydraulic Tank Capacity: 12 US gallons (45.4 l) Use 10W-30 or 15W-40 detergent, diesel engine oil (API service CH-4 or higher). 1. Remove the attachment, if one is installed; refer to Removing an Attachment. 2. Park the traction unit on a level surface, lower the loader arms, and fully retract the tilt cylinder. 3. Stop the engine, remove the key, and allow the engine to cool. Figure 19 1. Filler neck 4. Open the hood. 5.
Checking, Adding, and Bleeding the Engine Coolant Service Interval: Before each use or daily Clean debris off of the screen, oil cooler, and front of the radiator daily and more often if conditions are extremely dusty and dirty The cooling system is filled with a 50/50 solution of water and permanent ethylene glycol antifreeze. Check the level of coolant in the expansion tank at the beginning of each day before starting the engine.
F. Close the top coolant bleed valve (Figure 21). G. Pour coolant into the coolant filler neck until the coolant level comes into the filler neck (Figure 21). H. Install the coolant fill cap (Figure 21). I. Add coolant into the expansion tank until it reaches the Full line on the side of the tank (Figure 21). 3. Install the expansion tank cap.
between attempts. Failure to follow these instructions can burn out the starter motor. 6. Move the throttle lever to desired setting. Important: If the engine is run at high speeds when the hydraulic system is cold (i.e., when the ambient air temperature is near 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).
operating characteristics of the traction unit. The warranty of the traction unit may be voided if used with unapproved attachments. 1 Important: Before installing the attachment, ensure that the mount plates are free of any dirt or debris and that the pins rotate freely. If the pins do not rotate freely, grease them. 3 1. Position the attachment on a level surface with enough space behind it to accommodate the traction unit. 2 2. Start the engine. G004182 3. Tilt the attachment mount plate forward.
Note: When you connect the attachment male connector first, you will relieve any pressure built up in the attachment. WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury. Fluid injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result. • Keep your body and hands away from pin hole leaks or nozzles that eject high pressure hydraulic fluid.
Securing the Traction Unit for Transport When transporting the traction unit on a trailer, always use the following procedure: Important: Do not operate or drive the traction unit on roadways. 1. Lower the loader arms. 2. Stop the engine. 3. Secure the traction unit to the trailer with chains or straps using the tie-down/lift loops (Figure 4) to secure the rear of the traction unit and the loader arms/mount plate to secure the front of the traction unit.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 8 hours • Replace the hydraulic filter. After the first 50 hours • Change the engine oil and filter. • Check and adjust the track tension. Before each use or daily • • • • • • • • • • Check the engine oil level. Check the cooling system. Grease the traction unit.
CAUTION If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the ignition before you do any maintenance. Premaintenance Procedures Closing the Hood 1. Lift up on the tab securing the prop-rod (Figure 28) Before opening any of the covers, stop the engine and remove the key. Allow the engine to cool before opening any covers Opening the Hood 1. Loosen the hood locking screw (Figure 27) Figure 28 1.
Opening the Rear Access Cover Removing the Side Screens 1. Unscrew the 2 hand knobs securing the rear access cover to the machine (Figure 29). 2. Slide the side screens (Figure 30) up and out of the slots in the front screen and frame. 1. Open the hood. Figure 29 1. Hand knob 2. Tilt the rear access cover down and remove to access the internal components (Figure 29). Figure 30 1. Side screen Closing the Rear Access Cover Installing the Side Screens 1.
Lubrication Engine Maintenance Greasing the Traction Unit Servicing the Air Cleaner Service Interval: Before each use or daily (Grease immediately after every washing.) Service Interval: Before each use or daily—Check the air filter service indicator. Every 25 hours—Remove air cleaner cover, clean out debris, and check the air filter service indicator. Every 600 hours—Replace the safety air filter. Grease Type: General-purpose grease. 1. Lower the loader arms and stop the engine. Remove the key. 2.
Servicing the Engine Oil • If the service indicator is clear, clean any debris from cover and install cover. Service Interval: After the first 50 hours—Change the engine oil and filter. Every 100 hours—Change the engine oil. Every 200 hours—Change the oil filter. Ensure that the cover is seated correctly and seals with the air cleaner body. • If the service indicator is red, replace the air filter as described in Replacing the Filters.
Figure 35 Figure 36 1. Oil drain plug 1. Oil filter 5. When the oil has drained completely, replace the plug. 4. Pour new oil of the proper type through the center hole of the filter. Stop pouring when the oil reaches the bottom of the threads. Note: Dispose of the used oil at a certified recycling center. 5. Allow a minute or two for the oil to be absorbed by filter material, then pour off the excess oil. 6.
Fuel System Maintenance DANGER Under certain conditions, diesel fuel and fuel vapors are highly flammable and explosive. A fire or explosion from fuel can burn you and others and can cause property damage. • Use a funnel and fill the fuel tank outdoors, in an open area, when the engine is off and is cold. Wipe up any fuel that spills. • Do not fill the fuel tank completely full. Add fuel to the fuel tank until the level is 1/4 to 1/2 in. (6 to 13 mm) below the bottom of the filler neck.
9. Secure the hoses with the hose clamps. Electrical System Maintenance Draining the Fuel Tank Servicing the Battery Service Interval: Every 2 years Service Interval: Every 100 hours—Check the battery electrolyte level (replacement battery only). pointing in the same direction as the one on the old filter. Have an Authorized Service Dealer drain and clean the fuel tank. Every 100 hours—Check the battery cable connections.
level is up to the Upper line (Figure 38) on the battery case. 6. Install the battery filler caps. 2 Charging the Battery 3 WARNING 1 Charging the battery produces gasses that can explode. G003794 Never smoke near the battery and keep sparks and flames away from battery. Figure 38 1. Filler caps 2. Upper line 3. Lower line 3. If the electrolyte is low, add the required amount of distilled water; refer to Adding Water to the Battery. Important: Always keep the battery fully charged (1.
Figure 40 illustrates the fuse block and identifies the fuse positions. Figure 41 1. Prop-rod tab 2. Retaining bracket—top 3. Prop-rod 4. Retaining bracket—bottom 5. Hairpin cotter Figure 40 1. 30 amp. fuse—main circuit 2. Empty 4. Remove the 4 screws securing the fuse panel and then pull the panel out and up to remove it (Figure 42). 3. 10 amp fuse—control panel/relay 4.
Drive System Maintenance Servicing the Tracks Service Interval: After the first 50 hours—Check and adjust the track tension. Before each use or daily—Clean the tracks. Before each use or daily—Check the tracks for excessive wear (If the tracks are worn, replace them.) Figure 43 1. Track 2. Drive sprocket Every 100 hours—Check and adjust the track tension. Every 250 hours/Yearly (whichever comes first)—Check and grease the road wheels. 3. Road wheels 4.
Figure 45 1. Locking bolt 2. Tensioning screw 3. Tension tube 4. Tension wheel Figure 46 4. Using a 1/2 inch drive socket (Figure 46), turn the tensioning screw counter-clockwise until the distance between the tension nut and the back of the tension tube (Figure 44) is 2-3/4 inches (7 cm). 1. 2. 3. 4. 5. Align the closest notch in the tension screw to the locking bolt hole and secure the screw with the locking bolt and nut (Figure 45). Track 1/2 inch socket Tension wheel Fork tube 5. 6. 7. 8.
Replacing the Tracks (Model 22324) 11. Install the large washers on the wheels over the grease. When the tracks are badly worn, replace them. 12. Install the inner tension wheel and secure it with the nut removed previously (Figure 47). 1. Lower the loader arms, stop the engine, and remove the key. 13. Torque the nut to 300 ft-lb (407 N-m). 2. Lift/support the side of the unit to be worked on so that the track is 3 to 4 inches (7.6 to 10 cm) off of the ground. 14.
Cooling System Maintenance Servicing the Cooling System Service Interval: Before each use or daily—Clean the radiator. Every 100 hours—Check the cooling system hoses. Yearly—Change the engine coolant (Authorized Service Dealer only). Figure 49 1. Road wheel 2. Gasket 3. Bolt 4. Road wheel cap 5. Snap ring 6. Add grease under the cap DANGER If the engine has been running, the pressurized, hot coolant can escape and cause severe burns. 4. Check the grease under the cap and around the gasket (Figure 49).
Belt Maintenance Changing the Engine Coolant Have an Authorized Service Dealer change the engine coolant yearly. Checking the Condition of the If you need to add engine coolant, refer to Hydraulic Pump Belt Checking, Adding, and Bleeding the Engine Coolant (page 20). Service Interval: Yearly Check the condition of the hydraulic pump belt (Figure 50) yearly. Have an Authorized Service Dealer replace it if it becomes damaged or worn. Figure 50 1.
Controls System Maintenance The factory adjusts the controls before shipping the traction unit. However, after many hours of use, you may need to adjust the traction control alignment, the neutral position of the traction control, and the tracking of the traction control in the full forward position. Figure 52 Important: To adjust the controls properly, complete each procedure in the order listed. 1. Traction control 2. Stem , bolt and nut 5.
Adjusting the Tracking of the Traction Control, Full Forward Position If the traction unit does not drive straight when you hold the traction control against the reference bar, complete the following procedure: 1. Drive the traction unit with the traction control against the reference bar, noting which direction the traction unit veers. 2. Release the traction control. 3.
Hydraulic System Maintenance WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury. Fluid injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result. • 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, never use your hands.
Checking the Hydraulic Lines 6. Place a large drain pain (capable of holding 15 US gallons) under the drain plug on the front of the traction unit (Figure 58). Service Interval: Every 100 hours—Check the hydraulic lines for leaks, loose fittings, kinked lines, loose mounting supports, wear, weather, and chemical deterioration. (Make necessary repairs before operating.) Every 1,500 hours/Every 2 years (whichever comes first)—Replace all moving hydraulic hoses.
Cleaning Storage Removing Debris from the Traction Unit 1. Lower the loader arms, stop the engine, and remove the key. 2. Remove dirt and grime from the entire traction unit. Service Interval: Before each use or daily Important: You can wash the traction unit with mild detergent and water. Do not pressure wash the traction unit. Avoid excessive use of water, especially near the control panel, engine, hydraulic pumps, and motors.
Troubleshooting Problem The starter does not crank Possible Cause 1. The electrical connections are corroded or loose. 1. Check the electrical connections for good contact. 2. A fuse is blown or loose. 3. The battery is discharged. 4. The relay or switch is damaged. 2. Correct or replace the fuse. 3. Charge the battery or replace it. 4. Contact your Authorized Service Dealer. 5. Contact your Authorized Service Dealer. 6. Contact your Authorized Service Dealer. 5. A damaged starter or starter solenoid.
Problem The engine runs, but knocks or misses. Possible Cause 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. 3. There is air in the fuel. 2. Refer to Engine Overheats. 3. Bleed nozzles and check for air leaks at the fuel hose connections and fittings between the fuel tank and engine. 4. Contact your Authorized Service Dealer. 5. Contact your Authorized Service Dealer. 6.
Problem Excessive white smoke from exhaust. Possible Cause 1. The key was turned to the start position before the glow plug light turned off. 1. Turn the key to the run position and allow the glow plug light to turn off before starting the engine. 2. The engine temperature is low. 3. The glow plugs are inoperative. 4. The injection pump timing is incorrect. 2. Check the thermostat. 3. Check the fuse, glow plugs and wiring. 4. Contact your Authorized Service Dealer. 5.
Schematics G007388 Electrical Schematic (Rev.
Hydraulic Schematic (Rev.
Notes: 51
Toro Compact Utility Equipment Warranty A One-Year Limited Warranty Conditions and Products Covered The Toro® Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly warrant your Toro Compact Utility Equipment (“Product”) to be free from defects in materials or workmanship.
