Service Manual

ManualsBrandsToro ManualsCompact LoaderToro 22334

TX525

Service Manual

Sitework Systems

Form No. 492-9195

Summary of content (554 pages)

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Sitework Systems TX525 Service Manual 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 . . . . . . . . . . . . . ii 8/01/10 Rev.
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TABLE OF CONTENTS SAFETY INFORMATION General Information.......................................................................................................................1-1 Think Safety First..........................................................................................................................1-1 SPECIFICATIONS General Specifications..................................................................................................................2-1 Dimensions........................
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TABLE OF CONTENTS ENGINE Radiator & Oil Cooler Replacement..............................................................................................4-1 Radiator & Oil Cooler Assembly Removal..............................................................................4-1 Oil Cooler Removal.................................................................................................................4-6 Oil Cooler Installation..............................................................................
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TABLE OF CONTENTS ENGINE cont. Starter Assembly Testing...........................................................................................................4-188 Brush Wear.........................................................................................................................4-188 Brush Holder.......................................................................................................................4-188 Armature Coil.........................................................
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TABLE OF CONTENTS ELECTRICAL cont. Oil Pressure Switch.....................................................................................................................5-10 Purpose.................................................................................................................................5-10 Location................................................................................................................................5-10 How It Works..........................................
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TABLE OF CONTENTS HYDRAULIC SYSTEM 2 Spool Loader Valve Replacement..............................................................................................6-1 2 Spool Loader Valve Removal...............................................................................................6-1 2 Spool Loader Valve Installation............................................................................................6-5 Auxiliary Valve Replacement................................................................
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TABLE OF CONTENTS DRIVE SYSTEM cont. Left Hydrostatic Pump Replacement...........................................................................................7-39 Left Hydrostatic Pump Removal...........................................................................................7-39 Left Hydrostatic Pump Installation........................................................................................7-48 Wheel Motor Replacement.......................................................................
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TABLE OF CONTENTS HYDRAULIC TESTING TX525............................................................................................................................................9-1 Introduction.............................................................................................................................9-1 Flow Testing............................................................................................................................9-1 Hydraulic Testing.............................
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TABLE OF CONTENTS THIS PAGE INTENTIONALLY LEFT BLANK. x Rev.
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SAFETY INFORMATION SAFETY INFORMATION General Information General Information Avoid fires and explosions... This Thissymbol symbolmeans meansWARNING WARNINGor or PERSONAL SAFETY PERSONAL SAFETYINSTRUCTION INSTRUCTIONread thethe instruction because it ithas - read instruction because hastotodo with your safety. Failure to comply with do with your safety. Failure to comply the instruction may result in personal with the instruction may result in injury or even death. personal injury or even death.
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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 Item Engine Specification Domestic: 22319 Ser #270000001 - 280999999 / D902E2B 22320 Ser #270000001 - 280999999 / D902E2B International: 22333 Ser #270000001 - 280999999 / D902E2B 22334 Ser #270000001 - 280999999 / D902E2B RPM Setting Domestic: No-load Speed – 3670 rpm +20/-50 rpm Low idle Speed – 1600 rpm ± 100 rpm International: No-load Speed – 3200 rpm +75/-50 rpm Low idle Speed – 1600 rpm ± 50 rpm Oil Capacity 3.84 quarts (3.
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SPECIFICATIONS Periodic Maintenance Items Item Specification Maintenance Interval Grease General purpose grease 8 hours Hydraulic Oil 10w-30 or 15w-40 API service CH4 or higher diesel engine oil 400 hours* Hydraulic Filter Toro OEM filter 8 hours initial, 200 hours thereafter Engine Oil Toro OEM filter 50 hours initial & 100 hours thereafter* Engine Primary Air Filter Toro OEM filter 200 hours* Engine Safety Air Filter Toro OEM filter 600 hours* Cooling System 50/50 solution of water a
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SPECIFICATIONS Hydraulic System Item Specification Gear Pump A two-section tandem gear pump powers the loader and auxiliary hydraulic systems. Section 1 (Auxiliary): 13.8 gpm @ 3600 rpm (52.2 liter/min) Section 2 (Loader): 6.0 gpm @ 3600 rpm (22.7 liter/min) Loader Valve A two-spool monoblock valve controls loader functions via a single lever joystick. Main Relief Setting: 2400 psi (165.5 bar) Loader Spool: A 4-position spool with closed, raise, lower, and float positions controls loader functions.
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SPECIFICATIONS Hydraulic System cont. Item Specification Tank The hydraulic tank is a fabricated weldment integrated into the main frame. The tank has a cleanout access, stainless screens at the fill and suction ports and a remote breather connected via hose. Capacity: 10.5 gallons (39.7 liters) Filter In addition to the in-tank screens, the loader circuit passes through a 10 micron spin-on filter prior to returning to tank.
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SPECIFICATIONS SPECIFICATIONS Torque 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.
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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 Other Torque Torque Specifications Specifications 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 Equivalents Equivalents and and Conversions Conversions Decimal and Millimeter Equivalents Fractions 1/64 1/32 3/64 1/16 5/64 3/32 1/8 9/64 5/32 11/64 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 29/64 15/32 31/64 1/2 Decimals mm 0.015625 0.397 0.03125 0.794 0.046875 1.191 0.0625 1.588 0.078125 1.984 0.9375 2.381 0.1250 3.175 0.140625 3.572 0.15625 3.969 0.171875 4.366 0.1875 4.762 0.203125 5.159 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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MAINTENANCE Recommended Maintenance Schedule Maintenance Service Interval After the first 8 hrs Daily 25 hrs After the first 50 hrs 100 hrs Maintenance Procedure Maintenance Service Interval • Change hydraulic filter • • • • Grease the traction unit Check engine oil level Check for loose fasteners Clean/inspect the tracks for damage or wear • Check the cooling system • Drain water and other contaminants from the fuel filter/water separator • Clean the radiator • Remove debris from the traction
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MAINTENANCE Greasing the Traction Unit (4) are located on the right side (Fig. 0002). Grease all pivot joints every 8 operating hours and immediately after every washing. Grease Type: Lithium based NLGI2 1. Lower the loader arm and stop the engine. Remove the key from the ignition switch. 2. Clean the grease fittings with a rag. 3. Connect grease gun to each fitting and pump grease into the fittings until grease begins to ooze out (approximately 3 pumps). 4. Wipe any excess grease.
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MAINTENANCE Maintaining the Road Wheels 4. Ensure that the road wheel turns smoothly on the bearing. If it does not turn smoothly or spin freely, replace the bearing; refer to “Road Wheel Rebuild” on page 7-79. 1. If the inner wheels or the complete tray of wheels needs maintenance, remove the tracks. Refer to “Wide Track Removal” on page 7-68 or “Narrow Track Removal” on page 7-72. 5. Check the grease under the cap and around the gasket.
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MAINTENANCE Hydraulic Reservoir Tank 6. Remove the cap from the filler neck and check the fluid level on the dipstick (Fig. 0008). Location The hydraulic reservoir tank is located in the front of the TX525 unit. Hydraulic Tank Capacity: 10.5 gallons (39.7 liters) Type of Oil to Use: 10w-30 or 15w-40 detergent, diesel engine oil (API Service CH-4 or higher). Checking the Hydraulic Fluid Check the hydraulic fluid level daily before the engine is first started and after every 25 operating hours.
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MAINTENANCE Replacing the Hydraulic Filter 6. Wipe the surface of the filter adapter gasket area clean. Change the hydraulic filter: • After the first 8 operating hours. • After every 200 operating hours. 7. Pre-fill the hydraulic oil filter with oil and apply a thin coat of oil to the rubber gasket on the replacement filter. 1. Position the traction unit on a level surface. 2. Lower the loader arm, stop the engine, and remove the key. 3. Remove the rear access cover. 8.
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MAINTENANCE Changing the Hydraulic Fluid 5. Remove the LH side grill. Change the hydraulic fluid every 400 operating hours or yearly. 6. Clean the area around the filler neck of the hydraulic tank. Remove the hydraulic tank cap and dipstick (Fig. 0011 and Fig. 0012). Note: The hydraulic filter should be replaced whenever the hydraulic oil is changed. 1. Position the traction unit on a level surface and open the hood. 2.
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MAINTENANCE 7. Remove the drain plug and allow the oil to drain into the pan. 8. When oil is finished draining, install and tighten the drain plug. Note: Dispose of the used oil at a certified recycling center. 9. Fill the hydraulic tank with approximately 10.5 gallons (39.7 liters) of 10w-30 or 15w-40 detergent, diesel engine oil (API Service CH-4 or higher).
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MAINTENANCE Engine Servicing B Oil Dipstick - check oil level daily (Fig. 0015). A C Fig 0017 A. Oil fill B. Oil dipstick Fig 0015 PICT-8744 C. Oil filter PICT-8741 • Change oil after the first 50 hrs then every 100 hrs1, 2 Oil Drain (Fig. 0016 and Fig. 0017) • Oil Filter 200 hrs1, 3 More often in dusty, dirty conditions. Change oil after the first 50 operating hours. 3 For severe duty or rental applications, change every 3 100 operating hours.
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MAINTENANCE Servicing the Cooling System ! Service Interval: • Before each use or daily - Clean the radiator. If the engine has been running, the pressurized, hot coolant can escape and cause severe burns. • Every 100 hours - Check the cooling system hoses. • Do not remove the radiator cap when the engine is hot. Always allow the engine to cool at least 15 minutes or until the radiator cap is cool enough to touch without burning your hand before removing the radiator cap.
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MAINTENANCE Changing Engine Coolant 4. Remove the breather from the breather tube (Fig. 0020). 1. Park the machine on a flat surface, open the hood and raise the loader arm. Lock the loader arm into position using the loader arm lock. 2. Turn the machine off and allow it to cool. 3. Remove the left and right hand side panels (Fig. 0019). Fig 0020 PICT-4946a 5. Remove the 4 bolts securing the grill assembly to the frame (Fig. 0021). Fig 0019 PICT-4945 Fig 0021 3-10 Rev.
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MAINTENANCE 6. Slide the grill assembly forward (Fig. 0022). Fig 0022 8. Remove the grill assembly taking care not to damage the hydraulic tank breather hose (Fig. 0024). PICT-4955 Fig 0024 7. Remove the 2 bolts and nuts securing the overflow tank bracket to the grill assembly (Fig. 0023). Fig 0023 9. Inspect the foam seals on the inside of the grill assembly. Replace if worn or damaged (Fig. 0025). PICT-4959 Fig 0025 TX525 Service Manual PICT-4961 Rev.
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MAINTENANCE 10. Place an absorbent towel under the oil cooler inlet fitting located on the lower left hand corner of the oil cooler. 14. Using a 1-1/16” and a 1-1/8” wrench, remove the oil cooler outlet line from the oil cooler outlet fitting (Fig. 0027). 11. Using a 1-1/16” and a 1-1/8” wrench, remove the oil cooler inlet line from the oil cooler inlet fitting (Fig. 0026). Fig 0027 Fig 0026 PICT-4965 12. Cap the hydraulic line and fitting so debris does not enter the system. PICT-4968a 15.
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MAINTENANCE 17. Remove the front radiator mount (Fig. 0029). Fig 0029 19. Slide a length of 5/16” hose onto the petcock drain. Place the other end of the hose into a drain pan. Open the petcock and remove the radiator cap to drain the anti-freeze (Fig. 0031). PICT-4971 18. Tilt the radiator/oil cooler assembly forward and lift it out of the frame so that the petcock drain is above the frame (Fig. 0030). Fig 0031 PICT-4974 20. Remove the drain hose and close the petcock. 21.
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MAINTENANCE Changing Engine Coolant Assembly 5. Using 1-1/16” and 1-1/8” wrenches, install the hydraulic outlet line to the oil cooler outlet fitting (Fig. 0035). 1. Clean any debris around and under the radiator. 2. Using a 17mm wrench install the engine block coolant drain plug (Fig. 0033). Fig 0035 Fig 0033 PICT-8910 PICT-5126 6. Position the radiator mount into the frame (Fig. 0036). 3. Remove the drain hose and close the petcock. 4.
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MAINTENANCE 7. Loosely install 3 screws that will secure the radiator mount to the frame (Fig. 0037). Fig 0037 9. Without moving the position of the radiator, slide the radiator mount against the radiator and tighten the 3 radiator mount screws (Fig. 0039). PICT-5131 Fig 0039 8. Center the radiator and oil cooler assembly side to side in the frame so there is approximately a 1/8” space between the fan shroud and the fan. Spin the cooling fan.
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MAINTENANCE 11. Slide grill onto the frame so the grill base sits under the loader stops and the top of the grill sits on top of the radiator. Leave the grill in a slightly forward position. The overflow tank mounting holes should be just beyond the right hand boss on top of the radiator assembly. This will allow the overflow bottle assembly to be installed (Fig. 0041). 13. Install 2 bolts and nuts securing the overflow bottle assembly to the grill assembly (Fig. 0043).
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MAINTENANCE 15. Using a 1/2” socket, tighten the 4 bolts securing the grill assembly to the frame (Fig. 0045). New style (use flange head bolts): Fig 0047 Fig 0045 PICT-5605 PICT-5150 16. Check the cooling fan and shroud clearance. Adjust the position of the radiator if necessary. 18. Position the breather tube under the grill and install the breather (Fig. 0048). 17. Using a 9/16” socket, tighten the 2 bolts securing the radiator to the grill assembly (Fig. 0046 and Fig. 0047).
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MAINTENANCE 19. Fill the radiator. Refer to “Checking, Adding & Bleed ing the Engine Coolant” on page 4-138. 20. Clean the area around the filler neck of the hydraulic tank. Fuel System Drain the fuel filter/water separator before each use or daily (Fig. 0050). 21. Remove the cap from the filler neck. 22. Fill the hydraulic tank with of 10W-30 or 15W-40 detergent, diesel engine oil (API service CH-4 or higher). B 23. Start the engine and let it run for a few minutes. 24. Stop the engine. 25.
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MAINTENANCE Fuel Tank Removal 4. Using a 3/8” socket, remove the 6 screws that secure the left and right rear cover support panels to the tower assembly (3 screws per panel). Remove the panels (Fig. 0052). 1. Park the machine so that the tracks are resting on 2x4s. 2. Open the hood. Raise the loader arms, install the cylinder lock, stop the engine and remove the key. 3. Apply the parking brake. 3. Remove the rear access panel (Fig. 0051). Fig 0052 Fig 0051 PICT-4505a 5.
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MAINTENANCE 6. Remove the fuel tank bracket (Fig. 0054). Fig 0054 8. Mark the suction fuel line and tank fitting with an “S” and the return fuel line and tank fitting with an “R” (Fig. 0056): S - Fuel suction line R - Fuel return line PICT-5625 7. Disconnect the two wires (black and orange) from the fuel sending unit located on the top of the fuel tank (Fig. 0055). Fig 0056 PICT-4263 9. Slide the 2 fuel hose clamps down the fuel line away from the fuel tank fittings (Fig. 0057).
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MAINTENANCE Fuel Tank Installation 10. Slide the 2 fuel lines off the fuel tank fittings. Remove the fuel tank (Fig. 0058). 1. Slide the 2 fuel lines onto the fuel tank fittings. Install the fuel tank (Fig. 0059). Fig 0058 PICT-4265 Fig 0059 11. Remove the fuel cap and tip the fuel tank to dump any remaining fuel from the tank into a proper drain pan. 12.
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MAINTENANCE 3. Connect the two wires (black and orange) to the fuel sending unit located on the top of the fuel tank (Fig. 0061). A 5. Install the fuel tank bracket nut and bolt (Fig. 0063). B Fig 0063 Fig 0061 A. Orange wire (center terminal) PICT-5625 PICT-4262a B. Black wire (outside terminal) 6. Install the left and right rear cover support panels. Using a 3/8” socket, install the 6 screws that secure the left and right rear cover support panels to the tower assembly (3 screws per panel) (Fig.
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MAINTENANCE 7. Install the rear access panel (Fig. 0065). 9. Change the fuel filter/water separator and the inline fuel filter (if applicable). 10. Install the right hand side panel. 11. Remove the loader lock and lower the loader arm. 12. Close the hood. 13. Add fuel to the tank and install cap. 14. Release the parking brake. 15. Drive the unit off the 2x4’s. Fig 0065 PICT-4505a 8. Remove the right hand side panel (Fig. 0066). Fig 0066 TX525 Service Manual PICT-4942 Rev.
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MAINTENANCE Air Filter Replacing the In-Line Fuel Filter (Serial numbers 280000500 & higher) Replace the in-line filter when damage, contamination or debris is present. 1. Locate the in-line fuel filter (Fig. 0067) and note the direction of flow arrow on the side of the in-line filter. Fig 0067 Service Interval: • Every 200 hours - replace the primary air filter • Every 600 hours - replace the secondary air filter * More often in dusty, dirty conditions PICT-8751 Fig 0068 PICT-8748 2.
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MAINTENANCE Fuse Block 6. Install the heat shield using the 4 screws removed previously. To access the fuses, you must remove the heat shield. 1. Stop the engine and remove the key. 7. Install the prop rod into the retaining brackets and prop rod tab and secure it with the hairpin cotter. 2. Raise the hood. 8. Close the hood. 3. Pull the hairpin cotter from the bottom end of the hood prop rod and slide the prop rod out of the retaining brackets and the prop rod tab. Hydrostatic Pump Belt 4.
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MAINTENANCE Alternator/Fan Belt 4. Replace fan belt if it is worn or damaged. Replace the pulley if the belt groove is worn excessively (Fig. 0072). Fan Belt Tension: Deflects 0.28 to 0.35” (7 to 9mm) when the belt is pressed in the middle of the span (Fig. 0071). A B A Fig 0072 Fig 0071 fig. 3EEABAB1P017B A. New belt fig. 3EEABAB1P018A B. Worn belt A. Deflection 1. Stop the engine and remove the key. 2. Apply moderate thumb pressure to belt between the alternator and crankshaft pulleys. 3.
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MAINTENANCE Track Inspection Track Tension Adjustment 2-3/4” (7cm) (Fig. 0075). Clean the track and drive assembly daily. 1. = 2-3/4 inches (7cm) Check the track surface daily for cracks and tears. Replace the track if it is torn or cut and/or the tread is worn (Fig. 0073). Track Tread (cracked/damaged/worn): A B Fig 0075 A. Tension nut Fig 0073 PICT-3377 track install #3 B.
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MAINTENANCE Battery Maintenance A maintenance type battery needs fluid level checks on a routine basis. Use distilled water to bring the battery cells to the correct level. Check and clean electrical connections and the charging system if the battery requires water frequently and corrosion becomes excessive; both are signs of over-charging. Service Interval: • Every 100 hours—Check the battery electrolyte level (batteries with inspection caps). • Every 100 hours—Check the battery cable connections.
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MAINTENANCE Battery Testing You must first have the battery fully charged prior to any test. The surface charge must be removed before testing. To remove surface charge the battery must experience a load of 20 amps for 3 plus minutes. Battery specific gravity can be measured by using a hydrometer or a refractometer. Load testing removes amps from a battery much like start-ing an engine would. The battery may have a label with the amp load for testing and/or a CCA Cold Cranking Amp rating.
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MAINTENANCE Special Tools Spring Removal Tool (Fig. 0079) - Toro P/N: 92-5771 For tool use example see page 7-6, step 10. Listed below are the special tools used in some of the procedures in this manual. To order these tools, contact the Toro Company. Track Alignment Tool (Fig. 0077) - Toro P/N: 110-0069 For tool use example see page 7-3. Fig 0079 Fig 0077 PICT-4131b PICT-4139a Puller Kit (Fig. 0078) - Toro P/N: 112-2557 For tool use example see page 7-28, step 37. Fig 0078 3-30 PICT-4143b Rev.
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ENGINE Radiator & Oil Cooler Replacement 4. Remove the left and right hand side panels (Fig. 0080). Radiator & Oil Cooler Assembly Removal Note: Cleanliness is a key factor for any service work involving the hydraulic system. Thor oughly clean all exposed surfaces prior to any type of maintenance. Cleaning all parts by using a solvent wash and air drying is usually adequate. As with any precision equipment, all parts must be kept free of foreign material and chemicals.
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ENGINE 6. Remove the 4 bolts securing the grill assembly to the frame (Fig. 0082). Fig 0082 8. Remove the 2 bolts and nuts securing the overflow tank bracket to the grill assembly (Fig. 0084). PICT-4953 7. Slide the grill assembly forward (Fig. 0083). Fig 0083 Fig 0084 9. Remove the grill assembly taking care not to damage the hydraulic tank breather hose (Fig. 0085). PICT-4955 Fig 0085 4-2 PICT-4959 Rev.
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ENGINE 14. Place an absorbent towel under the oil cooler outlet fitting located on the upper right hand corner of the oil cooler. 10. Inspect the foam seals on the inside of the grill assembly. Replace if worn or damaged (Fig. 0086). 15. Using a 1-1/16” and a 1-1/8” wrench, remove the oil cooler outlet line from the oil cooler outlet fitting (Fig. 0088). Fig 0086 PICT-5138a 11. Place an absorbent towel under the oil cooler inlet fitting located on the lower left hand corner of the oil cooler. 12.
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ENGINE 18. Remove the front radiator mount (Fig. 0090). Fig 0090 20. Slide a length of 5/16” hose onto the petcock drain. Place the other end of the hose into a drain pan. Open the petcock and remove the radiator cap to drain the coolant (Fig. 0092). PICT-4971 19. Tilt the radiator/oil cooler assembly forward and lift it out of the frame so that the petcock drain is above the frame (Fig. 0091). Fig 0092 PICT-4974 21. Remove the drain hose and close the petcock. 22.
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ENGINE 23. Slide the 2 radiator hoses off the left hand side of the radiator (Fig. 0094). Fig 0094 TX525 Service Manual Fig 0096 PICT-4978 24. Loosen the hose clamp securing the radiator hose to the right hand side of the radiator. Slide the radiator hose off the right hand side of the radiator (Fig. 0095). Fig 0095 25. Remove the radiator/oil cooler assembly from the frame (Fig. 0096). PICT-4980 26.
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ENGINE Oil Cooler Removal 3. Remove the fan shroud from the radiator/oil cooler assembly (Fig. 0099). 1. Remove the 4 bolts, 2 washers and 4 nuts securing the fan shroud to the radiator/oil cooler assembly (Fig. 0097). Fig 0099 Fig 0097 PICT-5058 PICT-5061 4. Using a 1/2” wrench, remove the 2 bolts, washers and lock washers securing the oil cooler to the top side of the radiator (Fig. 0100). 2. Remove the backing plate from the radiator/oil cooler assembly (Fig. 0098).
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ENGINE 5. Using a 1/2” wrench, loosen the other 2 bolts, washers and lock washers securing the oil cooler to the bottom side of the radiator (Fig. 0101). 7. Inspect the oil cooler. Repair or replace. 8. Inspect the foam strips on the radiator. If worn or damaged, replace. Oil Cooler Installation 1. Clean all dirt and debris from the radiator assembly. 2. Position the oil cooler onto the radiator by sliding the oil cooler mounting flange under the 2 flat washers on the bottom side of the radiator (Fig.
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ENGINE 3. Loosely install the 2 bolts, lockwashers and washers securing the opposite oil cooler mounting flange to the top side of the radiator (Fig. 0104). 5. Position the fan shroud onto the radiator/oil cooler assembly (Fig. 0106). Fig 0106 Fig 0104 6. Position the backing plate onto shroud (Fig. 0107). 4. Center the oil cooler onto the radiator (Fig. 0105) and progressively tighten each of the 4 bolts to evenly secure the oil cooler to the radiator.
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ENGINE 7. Loosely install 2 bolts and nuts securing the backing plate and fan shroud to the radiator/oil cooler assembly (Fig. 0108). Fig 0108 TX525 Service Manual Fig 0110 PICT-5086 PICT-5089a 10. Install the radiator/oil cooler assembly into the machine. Refer to “Radiator & Oil Cooler Assembly Installation” on page 4-15. 8. Loosely install 2 bolts, washers and nuts securing the fan shroud to the radiator/oil cooler assembly (Fig. 0109). Fig 0109 9.
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ENGINE Radiator Removal 3. Remove the fan shroud from the radiator/oil cooler assembly (Fig. 0113). 1. Remove the 4 bolts, 2 washers and 4 nuts securing the fan shroud to the radiator/oil cooler assembly (Fig. 0111). Fig 0113 Fig 0111 PICT-5081a PICT-5073 4. Using a 1/2” wrench, remove the 2 bolts, washers and lock washers securing the oil cooler to the top side of the radiator (Fig. 0114). 2. Remove the backing plate from the radiator/oil cooler assembly (Fig. 0112).
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ENGINE 5. Using a 1/2” wrench, loosen the 2 bolts securing the bottom side of the oil cooler to the radiator (Fig. 0115). Fig 0115 TX525 Service Manual Fig 0117 PICT-5066 6. Remove the oil cooler from the radiator (Fig. 0116). Fig 0116 7. Remove the 2 oil cooler mounting bolts, lock washers and washers that are remaining in the radiator (Fig. 0117). PICT-5090 8. Remove the radiator bracket (Fig. 0118). PICT-5065 Rev.
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ENGINE 9. Inspect the foam seals on the radiator bracket. Replace if worn or damaged (Fig. 0119 and Fig. 0120). Radiator Installation 1. Apply 2 foam seals onto the new radiator. Locate as shown (Fig. 0121 and Fig. 0122). Right side: Fig 0119 PICT-5093a Fig 0121 PICT-5095a Fig 0122 PICT-5096 Left side: Fig 0120 PICT-5094a 10. Inspect the radiator. Repair or replace. 4-12 Rev.
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ENGINE 2. Slide the radiator bracket onto the radiator so that the mounting holes in the flanges line up (Fig. 0123). Fig 0123 4. Position the oil cooler onto the radiator by sliding the mounting flange onto the 2 bolts so that the mounting flange is located between the radiator and the flat washers (Fig. 0125). PICT-5098a Fig 0125 3. Thread 2 bolts, lockwashers and washers into the holes located on the bottom mounting flange (Fig. 0124). Fig 0124 5.
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ENGINE 6. Center the oil cooler onto the radiator (Fig. 0127) and progressively tighten each of the 4 bolts to evenly secure the oil cooler to the radiator. 8. Position the backing plate onto the fan shroud (Fig. 0129). Fig 0129 Fig 0127 9. Loosely install 2 bolts and nuts securing the backing plate and fan shroud to the radiator/oil cooler assembly (Fig. 0130). 7. Position the fan shroud onto the radiator/oil cooler assembly (Fig. 0128). Fig 0128 4-14 PICT-5107 PICT-5105a PICT-5106 Rev.
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ENGINE 10. Loosely install 2 bolts, washers and nuts securing the fan shroud to the radiator/oil cooler assembly (Fig. 0131). 12. Install the radiator/oil cooler assembly into the ma chine. Refer to “Radiator and Oil Cooler Assembly Installation” following. Radiator & Oil Cooler Assembly Installation 1. Inspect the foam seals located inside the frame. Replace if worn or damaged (Fig. 0133). Fig 0131 PICT-5109 11. Tighten the 4 bolts securing the fan shroud to the radiator/oil cooler assembly (Fig.
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ENGINE 2. Position the radiator/oil cooler assembly into the frame so it is on top of the foam seals and behind the 3 radiator mount holes (Fig. 0134). 5. Slide the left radiator hoses (top hoses) onto the 2 radiator flanges (Fig. 0136). Fig 0136 Fig 0134 3. Remove the protective caps from the inlet and outlet flanges and fittings. 4. Using 1-1/16” and 1-1/8” wrenches, install the hydraulic oil inlet line to the oil cooler inlet fitting (Fig. 0135). 6.
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ENGINE 7. Using 1-1/16” and 1-1/8” wrenches, install the hydraulic outlet line to the oil cooler outlet fitting (Fig. 0138). Fig 0138 9. Slide the hose clamp into position with the tightening screw head facing outward as shown. This will allow access to the tightening screw through the grill assembly when it is in position. Tighten the hose clamp (Fig. 0140). PICT-5126 Fig 0140 8. Slide the radiator inlet hose (bottom hose) onto the radiator flange (Fig. 0139). Fig 0139 10.
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ENGINE 11. Loosely install 3 screws that will secure the radiator mount to the frame (Fig. 0142). Fig 0142 13. Without moving the position of the radiator, slide the radiator mount against the radiator and tighten the 3 radiator mount screws (Fig. 0144). PICT-5131 Fig 0144 12. Center the radiator and oil cooler assembly side to side in the frame so there is approximately a 1/8” (3.2mm) space between the fan shroud and the fan. Spin the cooling fan.
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ENGINE 15. Slide grill onto the frame so the grill base sits under the loader stops and the top of the grill sits on top of the radiator. Leave the grill in a slightly forward position. The overflow tank mounting holes should be just beyond the right hand boss on top of the radiator assembly. This will allow the overflow bottle assembly to be installed (Fig. 0146). 17. Install 2 bolts and nuts securing the overflow bottle assembly to the grill assembly (Fig. 0148).
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ENGINE 19. Using a 1/2” socket, tighten the 4 bolts securing the grill assembly to the frame (Fig. 0150). Fig 0150 TX525, serial #280000001 & higher, use flange head bolts: PICT-5150 20. Check the cooling fan and shroud clearance. Adjust the position of the radiator if necessary. Fig 0152 PICT-5605 22. Position the breather tube under the grill and install the breather (Fig. 0153). 21. Using a 9/16” socket, tighten the 2 bolts securing the radiator to the grill assembly (Fig. 0151 and Fig. 0152).
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ENGINE 23. Fill the radiator. Refer to “Checking, Adding & Bleeding the Engine Coolant” on page 4-138. 24. Check the hydraulic oil level. Refer to “Checking the Hydraulic Fluid” on page 3-4. 5. Using a 3/8” socket combination, loosen the engine intake hose clamp and slide the intake hose down off of the air filter assembly (Fig. 0154 and Fig. 0155). 25. Purge air from the hydraulic system. Refer to “Purging Air Procedure” on page 9-19.
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ENGINE 6. Using a 1/2” wrench and 1/2” socket combination, remove the bolt and nut securing the bottom of the muffler to the rear muffler bracket (Fig. 0156). Fig 0156 8. Using a 13mm socket combination, remove the 4 bolts and washers from the muffler and exhaust manifold flange (Fig. 0158). Fig 0158 PICT-3263 7. Using a 1/2” socket combination, remove the bolts securing the muffler to the front muffler bracket (Fig. 0157). 9. Remove the muffler assembly (Fig. 0159).
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ENGINE 10. Replace the exhaust gasket (Fig. 0160). 2. Move the air cleaner assembly out of the way of the #1 cylinder injector to allow for testing and/or service (Fig. 0162). Important: Keep the air cleaner assembly away from the exhaust manifold area. Fig 0160 PICT-3271 Air Cleaner Assembly Removal Fig 0162 1. Using a 13mm socket, remove the 2 bolts and washers securing the air cleaner bracket assembly to the engine block (Fig. 0161).
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ENGINE Air Cleaner Assembly & Muffler Assembly Installation For testing and service of the injectors, refer to the Kubota Service manual “Kubota D722/D902 Tier 2 Diesel Engine Service Manual” (Toro Form No. 4924796) (Fig. 0164). Air Cleaner Assembly Installation 1. Position the air cleaner so the mounting bracket holes align with the mounting holes in the engine block. Using a 13mm socket, install 2 new bolts and washers securing the air cleaner assembly to the engine block (Fig. 0165).
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ENGINE Muffler Installation 3. Position the muffler assembly and thread the previously inserted bolt and washer into the exhaust manifold (Fig. 0169). 1. Ensure the exhaust gasket is in place (Fig. 0167). Fig 0167 Fig 0169 PICT-3270 4. Loosely install the remaining 3 bolts and washers on the muffler and exhaust manifold flange (Fig. 0170). 2. To aid in the installation process, insert a bolt and washer into the right front position on the muffler flange (Fig. 0168).
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ENGINE 5. Loosely install the bolts on the front muffler bracket (Fig. 0171). 7. Tighten the bolts on both the rear and front muffler brackets. 8. Tighten and torque the exhaust manifold bolts to 28 ft-lbs. (38 Nm) (Fig. 0173). Fig 0171 PICT-3265 6. Using a 1/2” wrench and 1/2” socket combination, install and tighten the bolt and nut securing the bottom of the muffler to the rear muffler bracket (Fig. 0172). Fig 0172 Fig 0173 PICT-3274 9.
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ENGINE Alternator Replacement 6. Using a 1/2” wrench, disconnect the negative battery cable from the battery (Fig. 0176). Alternator Removal 1. Park the machine on a flat surface. 2. Raise the hood. 3. Raise the loader arm. Lock the loader arm into position using the loader arm lock. 4. Turn the machine off and remove the key. Allow the machine to cool. 5. Remove the rear access panel (Fig. 0175). Fig 0176 PICT-5158 7. Remove the left hand side panel (Fig. 0177).
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ENGINE Alternator Mounting Styles TX525 22319 #270000556 - 270000720 22320 #270000712 - 270000885 22333 #270000423 - 270000446 22334 #270000427 - 270000436 The engine gear case housing flange is threaded and fit with brackets (Fig. 0179). The three methods of attaching the alternator are illus trated and described below. TX525 22319 #270000001 - 270000555 22320 #270000001 - 270000711 22333 #270000001 - 270000422 22334 #270000001 - 270000426 The engine gear case housing flange is threaded (Fig. 0178).
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ENGINE 8. Remove the boot from the terminal. Using a 10mm socket, remove the nut securing the positive cable to the alternator terminal (Fig. 0180). 10. Remove the positive battery cable terminal from the alternator terminal (Fig. 0182). Fig 0182 Fig 0180 11. Unplug the harness connector from the alternator (Fig. 0183). 9. Remove the washer from the alternator terminal (Fig. 0181). Fig 0183 Fig 0181 TX525 Service Manual PICT-5164 PICT-5161 PICT-5165 PICT-5162 Rev.
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ENGINE 12. Using a 12mm socket, remove the flange nut securing the hex spacer to the dipstick (Fig. 0184). Fig 0184 14. Slide the threaded hex spacer out of the dipstick bracket (Fig. 0186). Fig 0186 PICT-5170 13. Using a 13mm socket and a 9/16” wrench on the hex spacer, loosen the alternator mounting bolt, lockwasher and flat washer securing the alternator to the engine block. Loosen the bolt enough to free the hex spacer (Fig. 0185). 15. Remove the mounting bolt, lock washer and washer (Fig. 0187).
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ENGINE 16. Using a 12mm socket, support the alternator and remove the alternator belt tensioning bolt and lockwasher (Fig. 0188). 18. Remove the belt from the alternator pulley (Fig. 0190). Fig 0190 Fig 0188 19. Remove the alternator from the engine (Fig. 0191). 17. Remove the alternator belt guard (Fig. 0189). Fig 0191 Fig 0189 TX525 Service Manual PICT-5178 PICT-5166 PICT-5179 PICT-5177 Rev.
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ENGINE Alternator Installation 20. Remove the collar from the alternator (Fig. 0192). 1. Slide the collar into the mounting flange on the alternator (Fig. 0194). Fig 0192 PICT-5180a Fig 0194 21. To service the alternator, refer to “Alternator Assembly Teardown” on page 4-153 (Fig. 0193). PICT-5180av 2. Position the alternator up to the engine block (Fig. 0195). Fig 0193 PICT-5181a Fig 0195 4-32 Rev.
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ENGINE 3. Route the alternator belt around the alternator pulley (Fig. 0196). Fig 0196 PICT-5178 4. Position the alternator belt guard up to the slotted bracket (Fig. 0197). Fig 0197 5. Using a 12mm socket, loosely install the alternator belt tensioning bolt and lockwasher (Fig. 0198). Fig 0198 6. Loosely install the alternator mounting bolt, lock washer and washer through the belt guard, alternator, coller and into the alternator mounting flange (Fig. 0199).
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ENGINE 7. Position the threaded hex spacer into the dipstick bracket and align it with the alternator mounting flange (Fig. 0200). Fig 0200 9. Using a 13mm socket and a 9/16” wrench, tighten the alternator mounting bolt, lockwasher and flat washer securing the alternator to the engine block and threaded hex spacer (Fig. 0202). PICT-5175 Fig 0202 8. Apply tension to the alternator belt and tighten the top alternator mounting bolt (Fig. 0201). Fig 0201 4-34 PICT-5188 10.
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ENGINE 11. Tension the alternator belt. Refer to “Alternator/Fan Belt” on page 3-26. 14. Slide a washer onto the alternator terminal (Fig. 0206). 12. Plug the harness connector into the alternator (Fig. 0204). Fig 0206 Fig 0204 PICT-5165 15. Using a 10mm socket, install a nut securing the positive battery cable to the alternator terminal (Fig. 0207). Slide the boot onto the terminal. 13. Slide the positive battery cable terminal onto the alternator terminal (Fig. 0205).
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ENGINE 18. Install the rear access panel (Fig. 0210). 16. Install the left hand side panel (Fig. 0208). Fig 0208 4-36 PICT-4505a 19. Lower the loader arm. 17. Using a 1/2” wrench, connect the negative battery cable to the battery (Fig. 0209). Fig 0209 Fig 0210 PICT-4945 20. Lower the hood. PICT-5158 Rev.
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ENGINE Cooling Fan Replacement Checking the Alternator Belt Tension Cooling Fan Removal 1. Remove the radiator and oil cooler assembly. Refer to “Radiator & Oil Cooler Assembly Removal on page 4-1. 2. Using a 7/16” socket, remove the 4 bolts and lockwashers securing the cooling fan to the fan mount spacer (Fig. 0212). A Fig 0211 fig. EEAB...17B A. .28 to 0.35” (7.0 to 9.0mm) 1.
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ENGINE 3. Slide the cooling fan off the fan mount spacer (Fig. 0213). 5. Remove the fan mount spacer (Fig. 0215). Fig 0215 Fig 0213 4. Secure the flywheel so that it can not turn. Use a 6mm Allen socket to remove the 3 bolts securing the fan mount spacer to the engine coupler (Fig. 0214). Fig 0214 4-38 PICT-5115 PICT-5113a Cooling Fan Installation 1. Apply thread locking compound to the fan mount spacer mounting bolts (Fig. 0216). PICT-5114 Rev.
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ENGINE 2. Position the fan mount spacer to the engine coupler (Fig. 0217). Fig 0217 4. Torque the 3 bolts to 19 + 2 ft-lbs. (25.7 + 2.7 Nm) (Fig. 0219). PICT-5115 3. Secure the flywheel so that it can not turn. Use a 6mm Allen socket to install the 3 bolts securing the fan mount spacer to the engine coupler (Fig. 0218). Fig 0219 5. Slide the cooling fan onto the fan mount spacer (Fig. 0220). Fig 0220 Fig 0218 TX525 Service Manual PICT-5117 PICT-5113a PICT-5114 Rev.
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ENGINE 6. Using a 7/16” socket, install 4 bolts and lockwashers securing the cooling fan to the fan mount spacer (Fig. 0221). Flywheel Replacement Flywheel Removal 1. Remove the tandem pump assembly from the pump mount. Refer to “Hydraulic Tandem Pump Removal” on page 6-30. 2. Using a 13mm socket, remove the 4 bolts securing the pump mount to the engine housing (Fig. 0223). Fig 0221 PICT-5112a 7. Torque the 4 bolts to 100 + 10 in-lbs. (11.3 + 1.1 Nm) (Fig. 0222). Fig 0223 PICT-4863 3.
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ENGINE 4. Remove the hairpin cotter from the hood prop rod (Fig. 0225). Fig 0225 6. Using a 1/2” wrench, remove the 2 lower heat shield screws (Fig. 0227). Belt 001 5. Support the hood and remove the prop rod (Fig. 0226). Fig 0226 TX525 Service Manual Fig 0227 Belt 002 7. Using a 3/16” Allen wrench, remove the 2 upper heat shield screws (Fig. 0228). Belt 003 Rev.
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ENGINE 8. Remove the heat shield (Fig. 0229). Fig 0229 10. Remove the belt from the right and left hydraulic traction pump pulleys (Fig. 0231). Belt 005 Fig 0231 9. Using a spring tool (Toro p/n 92-5771), remove the idler spring from its post (Fig. 0230). Fig 0230 4-42 Belt 008 11. Remove the left hand side grill (Fig. 0232). Belt 007 Rev.
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ENGINE 12. Remove the drive belt from around the engine pulley (Fig. 0233). 14. Using a 6mm Allen socket, remove the 5 bolts securing the engine pulley to the flywheel (Fig. 0235). Fig 0233 Fig 0235 PICT-4862 13. Secure the flywheel to keep it from turning. You can do this by sliding a length of 5/16” diameter rod stock in between the fan mount pulley and fan mount spacer. The rod stock should be inserted so it runs on top of the fan mount pulley screw. The rod stock should be at least 16” (40.
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ENGINE 16. Using 14mm socket, remove the 5 bolts securing the flywheel to the crankshaft (Fig. 0237). Fig 0237 18. Inspect the starter engagement teeth. Replace the flywheel if worn or damaged (Fig. 0239). PICT-4843 Fig 0239 PICT-4847 Flywheel Installation 17. Remove the flywheel (Fig. 0238). 1. Slide the flywheel onto the crankshaft (Fig. 0240). Fig 0238 PICT-4844 Fig 0240 4-44 Rev.
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ENGINE 2. Apply engine oil to the 5 flywheel mounting bolt threads (Fig. 0241). Fig 0241 4. Using 14mm socket, install the 5 oiled bolts to secure the flywheel to the crankshaft (Fig. 0243). Fig 0243 PICT-4850a 3. Secure the flywheel to keep it from turning. You can do this by sliding a length of 5/16” diameter rod stock in between the fan mount pulley and fan mount spacer. The rod stock should be inserted so it runs on top of the fan mount pulley screw. The rod stock should be at least 16” (40.
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ENGINE 6. Slide the engine pulley onto the crankshaft (Fig. 0245). Fig 0245 8. Torque the 5 engine pulley mounting bolts to 19 + 2 ft-lbs. (25.7 + 2.7 Nm) (Fig. 0247). 4-46 PICT-4858 9. With the belt drive idler spring unhooked, route the drive belt around the engine pulley (Fig. 0248). 7. Using a 6mm Allen socket, install 5 bolts securing the engine pulley to the flywheel (Fig. 0246). Fig 0246 Fig 0247 PICT-4857 PICT-4856 Rev.
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ENGINE 10. Position the pump mount to the engine (Fig. 0249). Fig 0249 12. Ensure the belt is routed around the engine pulley and install the belt onto the right and left hydraulic traction pump pulleys (Fig. 0251). PICT-4861 Fig 0251 PICT-8902 11. Using a 13mm socket, install 4 bolts securing the pump mount to the engine housing (Fig. 0250). 13. Maneuver the spring tool (Toro p/n 92-5771) between the drive belt and the tower.
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ENGINE 14. Position the heat shield (Fig. 0253). Fig 0253 16. Using a 1/2” wrench, install the 2 lower heat shield screws (Fig. 0255). Belt 005 Fig 0255 15. Using a 3/16” Allen wrench, install the 2 upper heat shield screws (Fig. 0254). Fig 0254 4-48 Belt 002 17. Support the hood and install the prop rod (Fig. 0256). Belt 004 Fig 0256 Rev.
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ENGINE Starter Replacement 18. Install the hairpin cotter (Fig. 0257). Starter Removal 1. Park the machine on a flat surface. 2. Raise the hood. 3. Raise the loader arm. Lock the loader arm into position using the loader arm lock. 4. Turn the machine off and remove the key. Allow the machine to cool. 5. Remove the rear access panel (Fig. 0258). Fig 0257 Belt 001 19. Install the tandem pump and coupler assembly. Refer to “Hydraulic Tandem Pump Installation” on page 6-37.
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ENGINE 6. Using a 1/2” wrench, disconnect the negative battery cable from the battery (Fig. 0259). Fig 0259 Fig 0261 PICT-5158 7. Remove the left hand side panel (Fig. 0260). Fig 0260 8. Using a 12mm socket, remove the nut retaining the positive battery cable to the starter (Fig. 0261). 9. Remove the washer from the starter terminal (Fig. 0262). PICT-4945 Fig 0262 4-50 PICT-5190 Rev.
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ENGINE 10. Remove the positive battery cable from the starter terminal (Fig. 0263). Fig 0263 12. Remove the blue spade terminal from the starter (Fig. 0265). Fig 0265 PICT-5192 13. Unplug the wire harness from the starter (Fig. 0266). 11. Remove the grey fusible link wire from the starter terminal (Fig. 0264). Fig 0266 Fig 0264 TX525 Service Manual PICT-5194 PICT-5196 PICT-5193 Rev.
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ENGINE 14. Remove the 2 starter mounting bolts and lockwashers securing the starter to the engine block (Fig. 0267). 16. To service the starter refer to “Starter Assembly Teardown” on page 4-171 (Fig. 0269). Fig 0269 Fig 0267 PICT-5203a PICT-5198 Starter Installation 15. Remove the starter assembly (Fig. 0268). 1. Position the starter assembly to the engine block (Fig. 0270). Fig 0268 PICT-5202 Fig 0270 4-52 Rev.
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ENGINE 2. Install the 2 starter mounting bolts and lockwashers securing the starter to the engine block. Torque the bolts to 17.4 to 20.3 ft-lbs. (23.5 to 27.5 Nm) (Fig. 0271). 4. Plug the blue harness spade terminal onto the starter (Fig. 0273). Fig 0273 Fig 0271 PICT-5198 3. Plug the wire harness into the starter wire plug (Fig. 0272). 5. Slide the grey fusible link wire terminal onto the starter terminal (Fig. 0274). Fig 0274 Fig 0272 TX525 Service Manual PICT-5194 PICT-5193 PICT-5196 Rev.
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ENGINE 6. Slide the positive battery cable onto the starter terminal (Fig. 0275). Fig 0275 8. Using a 12mm socket, install a nut retaining the positive battery cable, grey wire and washer to the starter (Fig. 0277). PICT-5192 Fig 0277 7. Slide a washer onto the starter terminal (Fig. 0276). Fig 0276 9. Install the left hand side panel (Fig. 0278). PICT-5191 Fig 0278 4-54 PICT-5190 Rev.
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ENGINE Starter Solenoid Replacement 10. Using a 1/2” wrench, connect the negative battery cable to the battery (Fig. 0279). Starter Solenoid Removal 1. Park the machine on a flat surface. 2. Raise the hood. 3. Raise the loader arm. Lock the loader arm into position using the loader arm lock. 4. Turn the machine off and remove the key. Allow the machine to cool. 5. Remove the rear access panel (Fig. 0281). Fig 0279 PICT-5158 11. Install the rear access panel (Fig. 0280).
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ENGINE 6. Using a 1/2” wrench, disconnect the negative battery cable from the battery (Fig. 0282). Fig 0282 Fig 0284 PICT-5158 PICT-4945 Fig 0285 4-56 PICT-5190 9. Remove the washer from the starter terminal (Fig. 0285). 7. Remove the left hand side panel (Fig. 0283). Fig 0283 8. Using a 12mm socket, remove the nut retaining the positive battery cable to the starter (Fig. 0284). Rev.
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ENGINE 10. Remove the positive battery cable from the starter terminal (Fig. 0286). Fig 0286 12. Remove the blue spade terminal from the starter (Fig. 0288). PICT-5192 11. Remove the grey fusible link wire from the starter terminal (Fig. 0287). Fig 0287 TX525 Service Manual Fig 0288 PICT-5194 13. Unplug the wire harness from the starter plug (Fig. 0289). PICT-5193 Rev.
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ENGINE 14. Remove the 2 starter mounting bolts and lockwashers securing the starter to the engine block (Fig. 0290). Fig 0290 16. Remove the nut securing the white connector lead and grounding wire to the starter solenoid (Fig. 0292). 15. Remove the starter assembly (Fig. 0291). Fig 0291 4-58 Fig 0292 PICT-5198 PICT-5214a 17. Remove the white connector lead (Fig. 0293). PICT-5202 Rev.
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ENGINE 18. Remove the grounding wire (Fig. 0294). Fig 0294 20. Remove the starter solenoid assembly (Fig. 0296). PICT-5216a Fig 0296 PICT-5218a Starter Solenoid Installation 19. Using a 10mm socket, remove the 2 flange nuts securing the solenoid to the starter assembly (Fig. 0295). 1. Position the starter solenoid assembly to the starter assembly. Ensure the joint of the solenoid switch is engaged into the drive lever (Fig. 0297). B A Fig 0295 PICT-5217a Fig 0297 A.
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ENGINE 2. Using a 10mm socket, install 2 flange nuts securing the solenoid to the starter assembly (Fig. 0298). Fig 0298 PICT-5217a 3. Slide the grounding wire onto the starter solenoid terminal (Fig. 0299). Fig 0299 4. Slide the white connector lead onto the solenoid terminal (Fig. 0300). Fig 0300 5. Using a 10mm socket, install the nut securing the white connector lead and grounding wire to the starter solenoid (Fig. 0301). PICT-5216a Fig 0301 4-60 PICT-5215a Rev.
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ENGINE 8. Plug the wire harness into the starter wire (Fig. 0304). 6. Position the starter assembly to the engine block (Fig. 0302). Fig 0302 Fig 0304 PICT-5202 7. Install the 2 starter mounting bolts and lockwashers securing the starter to the engine block. Torque the bolts to 17.4 to 20.3 ft-lbs. (23.5 to 27.5 Nm) (Fig. 0303). 9. Plug the blue harness terminal onto the starter (Fig. 0305). Fig 0305 Fig 0303 TX525 Service Manual PICT-5196 PICT-5194 PICT-5198 Rev.
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ENGINE 10. Slide the grey fusible link wire terminal onto the starter terminal (Fig. 0306). 12. Slide a washer onto the starter terminal (Fig. 0308). Fig 0308 Fig 0306 13. Using a 12mm socket, install a nut retaining the positive battery cable, grey fusible link wire and washer to the starter terminal (Fig. 0309). 11. Slide the positive battery cable onto the starter terminal (Fig. 0307). Fig 0307 4-62 PICT-5191 PICT-5193 PICT-5192 Rev.
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ENGINE 16. Install the rear access panel (Fig. 0312). 14. Install the left hand side panel (Fig. 0310). Fig 0310 Fig 0312 PICT-4945 PICT-4505a 17. Remove the loader arm lock and lower the loader arms. 15. Using a 1/2” wrench, connect the negative battery cable to the battery (Fig. 0311). 18. Lower the hood. Fig 0311 TX525 Service Manual PICT-5158 Rev.
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ENGINE Engine Removal 6. Remove the left and right hand side panels (Fig. 0313). Note: Cleanliness is a key factor for any service work involving the hydraulic system. Thor oughly clean all exposed surfaces prior to any type of maintenance. Cleaning all parts by using a solvent wash and air drying is usually adequate. As with any precision equipment, all parts must be kept free of foreign material and chemicals. Protect all exposed sealing areas and open cavities from damage and foreign material.
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ENGINE 8. Using a 3/8” socket, remove the 6 screws that secure the left and right rear cover support panels to the tower assembly (3 screws per panel). Remove the panels (Fig. 0315). 10. Remove the fuel tank bracket (Fig. 0317). Fig 0317 Fig 0315 PICT-4454 9. Using 3/4” and 1/2” sockets, remove the 7 bolts and nuts securing the rear frame cover to the frame and fuel tank bracket. Remove the rear frame cover (Fig. 0316). 11.
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ENGINE 12. Mark the suction fuel line and tank fitting with an “S” and the return fuel line and tank fitting with an “R” (Fig. 0319): S - Fuel suction line R - Fuel return line 14. Slide the 2 fuel lines off the fuel tank fittings. Remove the fuel tank (Fig. 0321). Fig 0321 Fig 0319 PICT-4263 13. Slide the 2 fuel hose clamps down the fuel line away from the fuel tank fittings (Fig. 0320). 15. Remove the bolt, washer and nut securing the battery clamp to the frame. Remove the battery clamp (Fig. 0322).
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ENGINE 16. Slide the battery partially out of the battery mount. Disconnect the negative battery cable from the battery. Slide the battery out of the battery mount farther to access the positive battery cable terminal. Disconnect the positive battery cable and remove the battery and battery guard from the battery mount (Fig. 0323). 18. Mark the tandem pump lines and fittings as follows: A. Pump pressure line to loader valve (Fig. 0325) Fig 0325 Fig 0323 PICT-5382 PICT-4765 B.
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ENGINE C. Suction line from the tank (smaller fitting) (Fig. 0327). 21. Using a 1-1/8” wrench, remove the hydraulic line from the pump fitting labeled B (Fig. 0329). D. Suction line from the tank (larger fitting) (Fig. 0327). Fig 0329 Fig 0327 PICT-4767 PICT-4770a 22. Loosen the hose clamps securing the suction lines to the pump fittings marked C and D (Fig. 0330). 19. Place a drain pan under the hydraulic tandem pump. 20.
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ENGINE 26. Remove the 4 bolts securing the grill assembly to the frame (Fig. 0333). 23. Slide the hoses off the suction fittings (Fig. 0331). Fig 0331 PICT-4775a Fig 0333 24. Cap all the hydraulic lines and fittings so that debris does not enter the system. PICT-4953 27. Slide the grill assembly forward (Fig. 0334). 25. Remove the breather from the hydraulic oil breather hose (Fig. 0332). Fig 0334 Fig 0332 TX525 Service Manual PICT-4955 PICT-4946a Rev.
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ENGINE 28. Remove the 2 bolts and nuts securing the overflow tank bracket to the grill assembly (Fig. 0335). Fig 0335 30. Inspect the foam seals on the inside of the grill assembly. Replace if worn or damaged (Fig. 0337). Fig 0337 PICT-4959 PICT-5138a 31. Place an absorbent towel under the oil cooler inlet line fitting located on the lower left hand corner of the oil cooler. 29. Remove the grill assembly taking care not to damage the hydraulic tank breather hose (Fig. 0336). 32.
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ENGINE 33. Cap the hydraulic line and fitting so debris does not enter the system. 36. Cap the hydraulic line and fitting so debris does not enter the system. 34. Place an absorbent towel under the oil cooler outlet line fitting located on the upper right hand corner of the oil cooler. 37. Using a 1/2” socket, remove the 3 bolts securing the front radiator mount to the frame (Fig. 0340). 35. Using 1-1/16” and 1-1/8” wrenches, remove the hydraulic oil outlet line from the oil cooler outlet fitting (Fig.
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ENGINE 39. Tilt the radiator/oil cooler assembly forward and lift it out of the frame so that the drain petcock is above the frame (Fig. 0342). Fig 0342 41. Remove the drain hose and close the petcock. Set the radiator back in place in the frame. 42. Using a 3/8” socket, loosen the hose clamps securing the radiator hoses to the radiator fill tube and thermostat housing (Fig. 0344). PICT-4973 Fig 0344 40. Slide a length of 5/16” hose onto the drain petcock.
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ENGINE 44. Using a 3/8” socket, loosen the hose clamp securing the radiator hose to the engine block (Fig. 0346). Fig 0346 46. Carefully remove the radiator and oil cooler assembly (Fig. 0348). PICT-5399 45. Slide the radiator hose off the engine block inlet (Fig. 0347). Fig 0348 PICT-5402 47. Cap the radiator hoses and flanges so that debris does not enter the system. 48. Using a 3/8” socket, loosen the hose clamp securing the air intake hose to the engine intake (Fig. 0349).
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ENGINE 49. Slide the intake hose off the engine intake (Fig. 0350). Fig 0350 51. Using a 13mm socket, remove the 2 bolts and washers securing the air cleaner mounting bracket to the engine block (Fig. 0352). PICT-5407 Fig 0352 50. Using a 1/2” socket, remove the 2 bolts securing the air cleaner assembly to the muffler shield (Fig. 0351). Fig 0351 4-74 PICT-5412 52. Remove the air cleaner and coolant overflow bottle assembly (Fig. 0353). PICT-5408 Rev.
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ENGINE 53. Using two 1/2” wrenches, remove the bolt, 2 washers and nut securing the muffler assembly to the engine bracket (Fig. 0354). 55. Remove the muffler assembly (Fig. 0356). Fig 0356 Fig 0354 PICT-5416 PICT-5245 56. Remove the manifold gasket (Fig. 0357). 54. Using a 13mm socket, remove the 4 bolts and washers securing the muffler to the engine manifold (Fig. 0355). Fig 0357 Fig 0355 TX525 Service Manual PICT-5250 PICT-5246 Rev.
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ENGINE 57. Remove the hairpin cotter from the hood rod (Fig. 0358). Fig 0358 59. Using a 3/16” Allen wrench, remove the top 2 screws. Using a 1/2” socket, remove the bottom 2 screws securing the heat shield to the tower (Fig. 0360). PICT-5417 Fig 0360 PICT-5419a 58. Remove the hood rod (Fig. 0359). 60. Remove the heat shield (Fig. 0361). Fig 0359 PICT-5418 Fig 0361 4-76 Rev.
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ENGINE 61. Using a spring tool (Toro p/n 92-5771), unhook the idler spring from the spring post on the tower (Fig. 0362). 63. Disconnect the harness terminal from the water temperature sensor (Fig. 0364). Fig 0364 Fig 0362 62. Remove the drive belt from around the pulleys (Fig. 0363). Fig 0363 TX525 Service Manual PICT-5429 PICT-5422 64. Using a Phillips screw driver, disconnect the harness terminal from the engine oil pressure sensor (Fig. 0365). PICT-5423 Rev.
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ENGINE 65. Slide the boot off the alternator connection. Using a 10mm socket, remove the nut and washer securing the harness terminal to the alternator (Fig. 0366). 67. Disconnect the harness connector from the alternator (Fig. 0368). Fig 0368 Fig 0366 68. Unplug the harness connector from the .08mm (blue) fusible link wire (Fig. 0369). 66. Remove the harness terminal from the alternator (Fig. 0367). Fig 0369 Fig 0367 4-78 PICT-5439 PICT-5436 PICT-5444 PICT-5437a Rev.
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ENGINE 69. Slide the red boot off the starter terminal. Using a 12mm socket, remove the nut from the starter terminal (Fig. 0370). Fig 0370 71. Remove the 2.0mm (grey) fusible link terminal from the starter terminal (Fig. 0372). Fig 0372 PICT-5446 72. Remove the blue spade connector from the starter terminal (Fig. 0373). 70. Remove the positive battery cable from the starter terminal (Fig. 0371). Fig 0373 Fig 0371 TX525 Service Manual PICT-5448 PICT-5449 PICT-5447 Rev.
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ENGINE 73. Using a 7mm socket, remove the nut securing the harness terminal to the glow plug (Fig. 0374). Fig 0374 75. Unplug the harness connector from the engine shutdown solenoid (Fig. 0376). PICT-5457 Fig 0377 4-80 PICT-5459 76. Using a 13mm socket, remove the bolt securing the star washer, negative battery cable and harness terminal to the fuel injection pump (Fig. 0377). 74. Remove the harness terminal from the glow plug terminal (Fig. 0375). Fig 0375 Fig 0376 PICT-5456 Rev.
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ENGINE 77. Loosen the swivel clamp securing the throttle cable to the throttle control bracket (Fig. 0378). Fig 0378 79. Using a 10mm socket, remove the 2 bolts securing the throttle bracket to the engine (Fig. 0380). PICT-5465 78. Move the throttle control to approximately 3/4 throttle until the throttle cable slides out of the swivel clamp (Fig. 0379). Fig 0380 80. Move the throttle bracket assembly away from the engine (Fig. 0381).
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ENGINE 81. Slide the hose clamp back from the fuel line where it connects to the fuel injection pump. Slide the fuel line off (Fig. 0382). Fig 0382 83. Using a 1/2” socket, remove the top bolt and nut and the nut from the bottom bolt that secures the fuel pump bracket to the tower frame (Fig. 0384). Fig 0384 PICT-5470 82. Slide the hose clamp back from the fuel line where it connects to the fuel injector. Slide the fuel line off (Fig. 0383). PICT-5473 84.
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ENGINE 85. Loosen the hose clamp securing the oil drain hose to the engine. Disconnect the oil drain hose from the engine oil drain flange (Fig. 0386). Fig 0386 Note: Both the left hand and right hand cable guide appearance and position slightly changed from 2007 models to 2008 and newer models (Fig. 0388 and Fig. 0389): 2007 cable guides: PICT-5478 Fig 0388 86.
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ENGINE 87. Position the cable guide and the routed harness cables away from the engine assembly (Fig. 0390). Fig 0390 89. Using a 9/16” socket and wrench, remove the bolt and nut securing the left hand side of the engine assembly mount and cable guide to the mainframe (Fig. 0392). PICT-5480 Fig 0392 88. Using a 9/16” socket and wrench, remove the remaining 2 bolts and nuts securing the right hand side of the engine assembly mount to the mainframe (Fig. 0391). Fig 0391 4-84 PICT-5482 90.
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ENGINE 91. Using a 9/16” socket and wrench, remove the remaining 2 bolts and nuts securing the left hand side of the engine assembly to the mainframe (Fig. 0394). Fig 0394 93. Lift engine out of the frame. 94. Using a 9/16” socket and wrench, remove the 2 screws securing the engine mount plate to the left hand engine mount (Fig. 0396). PICT-5484 Fig 0396 92. Position and center an engine hoist over the engine. Attach chain hooks into the engine lift brackets (Fig. 0395).
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ENGINE 96. Remove the rebound strap (Fig. 0398). Fig 0398 98. Using a 1/2” socket, remove the 2 screws securing the forward ISO engine mount to the left hand engine mount (Fig. 0400). PICT-5490 Fig 0400 PICT-5493 97. Remove the 2 rebound washers (Fig. 0399). 99. Fig 0399 Remove the ISO engine mount (Fig. 0401). PICT-5491 Fig 0401 4-86 Rev.
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ENGINE 102. Transfer the engine from the engine hoist to an engine stand (Fig. 0404). 100. Using a 17mm socket, remove the 5 screws securing the left hand engine mount to the engine (Fig. 0402). Fig 0404 Fig 0402 Engine Component Removal 101. Remove the left hand engine mount from the engine (Fig. 0403). Fig 0403 1. Using a 10mm socket, remove the screw securing the starter baffle plate to the exhaust manifold (Fig. 0405). PICT-5497 Fig 0405 TX525 Service Manual PICT-5498 PICT-5495 Rev.
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ENGINE 2. Using a 13mm socket, remove the 2 screws securing the starter baffle plate to the engine (Fig. 0406). Fig 0406 4-88 Fig 0408 PICT-5500a PICT-5504 5. Remove the starter assembly from the engine (Fig. 0409). 3. Remove the starter baffle plate (Fig. 0407). Fig 0407 4. Using a 12mm socket, remove the 2 bolts securing the starter assembly to the engine (Fig. 0408). PICT-5501a Rev.
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ENGINE 6. Loosen the 2 alternator mounting bolts (Fig. 0410). 9. Remove the alternator belt (Fig. 0412). A B Fig 0410 PICT-5507 A. 12mm socket (top bolt) B. 13mm socket (bottom bolt) Fig 0412 PICT-5514a 10. Remove the top mounting bolt, lockwasher, belt guard and alternator (Fig. 0413). 7. Pivot the alternator toward the engine to relieve belt tension. 8. Using a 13mm socket and a 9/16” wrench, secure the hex spacer and remove the bottom alternator mounting bolt, lockwasher and flat washer (Fig.
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ENGINE 11. Using a 12mm socket and a 9/16” wrench, remove the nut securing the hex spacer to the engine oil dipstick (Fig. 0414). 13. Using an 11mm socket, remove the 4 bolts securing the fan to the fan mount spacer (Fig. 0416). Fig 0416 Fig 0414 PICT-5557a PICT-5516 14. Slide the fan off the fan mount spacer (Fig. 0417). 12. Remove the hex spacer (Fig. 0415). Fig 0417 Fig 0415 4-90 PICT-5522a PICT-5518 Rev.
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ENGINE 15. Secure the fan mount spacer. Using a 1/4” Allen wrench, remove the 3 bolts securing the fan mount spacer to the engine coupler (Fig. 0418). 17. Using a 1-1/8” wrench, remove the oil drain fitting from the oil pan (Fig. 0420 and Fig. 0421). Note: There is a 90 degree angle oil drain fitting and a straight oil drain fitting. • 90 degree oil drain fitting: Fig 0418 PICT-5524 16. Remove the fan mount spacer (Fig. 0419).
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ENGINE 18. Using a 10mm socket, remove the 2 bolts securing the engine shutdown solenoid bracket to the engine (Fig. 0422). 20. Remove the engine shutdown solenoid from the engine (Fig. 0424). Fig 0424 Fig 0422 19. Using a 5mm Allen wrench, remove the 2 bolts and lockwashers securing the engine shutdown solenoid to the engine (Fig. 0423). 21. Using a 9/16” socket and wrench, remove the 2 bolts and nuts securing the engine mount plate to the right hand engine mount (Fig. 0425).
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ENGINE 22. Remove the engine mount plate (Fig. 0426). Fig 0426 24. Remove the 2 rebound washers (Fig. 0428). PICT-5538 Fig 0429 TX525 Service Manual PICT-5539 25. Using a 1/2” socket, remove the 2 bolts securing the forward ISO engine mount to the right hand engine mount (Fig. 0429). 23. Remove the rebound strap (Fig. 0427). Fig 0427 Fig 0428 PICT-5537 Rev.
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ENGINE 26. Remove the ISO engine mount (Fig. 0430). Fig 0430 28. Remove the right hand engine mount from the engine (Fig. 0432). PICT-5542 Fig 0432 27. Using a 17mm socket, remove the 5 bolts securing the right hand engine mount to the engine (Fig. 0431). Fig 0431 29. Using a 13mm socket, remove the 2 bolts and flat washers securing the muffler support to the engine block (Fig. 0433). PICT-5543 Fig 0433 4-94 PICT-5544 Rev.
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ENGINE 32. Remove the tandem pump/pump mount assembly and coupler from the engine (Fig. 0436). 30. Remove the muffler mount (Fig. 0434). Fig 0434 PICT-5546a Fig 0436 31. Using a 13mm socket, remove the 4 bolts securing the tandem pump/pump mount assembly to the engine (Fig. 0435). 33. Remove the drive belt from the engine (Fig. 0437). Fig 0437 Fig 0435 TX525 Service Manual PICT-5531-2 PICT-5533-2 PICT-5547a Rev.
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ENGINE 34. Using a 6mm Allen head socket, remove the 5 bolts securing the engine pulley to the engine (Fig. 0438). Engine Installation Engine Component Installation 1. Position the engine pulley to the engine (Fig. 0440). Fig 0438 PICT-5534-2 Fig 0440 35. Remove the engine pulley from the engine (Fig. 0439). PICT-5537-2 2. Using a 6mm Allen head socket, install 6 bolts securing the engine pulley to the engine flywheel (Fig. 0441). Fig 0439 PICT-5537-2 36.
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ENGINE 3. Torque the 6 bolts to 19 + 2 ft-lbs. (00 + 00 Nm) (Fig. 0442). Fig 0442 5. Position the tandem pump/pump mount assembly and coupler to the engine so that the coupler slides onto the engine gear (Fig. 0444). IMG_8085 Fig 0444 4. Route the drive belt around the engine pulley (Fig. 0443). Fig 0443 6. Using a 13mm socket, install 4 bolts securing the tandem pump/pump mount assembly to the engine (Fig. 0445). IMG_8086 Fig 0445 TX525 Service Manual IMG_8087 Rev.
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ENGINE 7. Position the muffler mount to the engine (Fig. 0446). Fig 0446 9. Position the right hand engine mount to the engine (Fig. 0448). PICT-5546a Fig 0448 8. Using a 13mm socket, loosely install 2 new bolts and flat washers to attach the muffler mount to the engine block (Fig. 0447). Fig 0447 4-98 PICT-5544 10. Using a 17mm socket, install 5 bolts securing the right hand engine mount to the engine (Fig. 0449). IMG_8091 Rev.
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ENGINE 11. Torque the 5 bolts to 38 + 4 ft-lbs. (51.5 + 5.4 Nm) (Fig. 0450). Fig 0450 13. Using a 1/2” socket, install 2 bolts securing the forward ISO engine mount to the right hand engine mount (Fig. 0452). IMG_8090 Fig 0452 12. Position the ISO engine mount to the right hand engine mount (Fig. 0451). Fig 0451 TX525 Service Manual IMG_8093 14. Torque the 2 bolts to 220 + 25 in-lbs. (24.8 + 2.8 Nm) (Fig. 0453). PICT-5542 Rev.
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ENGINE 15. Position 2 rebound washers onto the ISO engine mounts (Fig. 0454). Fig 0454 17. Position the engine mount plate so that the bolts are inserted through the ISO mounts, rebound washers and rebound strap (Fig. 0456). PICT-5539 Fig 0456 16. Position the rebound strap onto the rebound washers (Fig. 0455). Fig 0455 18. Using a 9/16” socket and wrench, install 2 nuts securing the engine mount plate to the right hand engine mount (Fig. 0457). IMG_8094 Fig 0457 4-100 PICT-5537 Rev.
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ENGINE Note: Install the solenoid rod into the guide hole of the cylinder block (Fig. 0460). 19. Torque the 2 bolts to 30 + 3 ft-lbs. (40.6 + 5.4 Nm) (Fig. 0458). Fig 0458 IMG_8095 20. With the sealing o-ring in place, insert the engine shutdown solenoid into the engine (Fig. 0459). Fig 0459 Fig 0460 21. Using a 5mm Allen wrench, install 2 bolts and lock washers securing the engine shutdown solenoid to the engine (Fig. 0461). PICT-5534 Fig 0461 TX525 Service Manual IMG_8097a Rev.
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ENGINE 22. Route the solenoid wire and position the engine shutdown solenoid bracket onto the engine block (Fig. 0462). Fig 0462 24. Oil drain fitting: There are 2 oil drain fittings. 25. TX525 (22319 and 22320 #270000001 through 270999999) has a 90 degree fitting (Fig. 0464): IMG_8098 23. Using a 10mm socket, install 2 bolts securing the engine shutdown solenoid bracket to the engine (Fig. 0463). Fig 0463 4-102 Fig 0464 PICT-5550 26.
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ENGINE 27. 90 degree oil drain fitting only: Use a new rubber sealing washer. Thread the locking nut up against the sealing washers as shown (Fig. 0466). Fig 0466 29. Straight oil drain fitting only: Use a new rubber sealing washer. Using a 1-1/8” wrench, install the oil drain fitting into the oil pan and tighten (Fig. 0468). Fig 0468 PICT-5554a 28. 90 degree oil drain fitting only: Thread the oil drain fitting into the oil pan until the washers rest against the oil pan.
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ENGINE 31. Position the fan mount spacer (Fig. 0470). Fig 0470 33. Using a 1/4” Allen wrench, torque the 3 bolts to 19 + 2 ft-lbs. (25.7 + 2.7 Nm) (Fig. 0472). PICT-5525 Fig 0472 32. Install 3 bolts securing the fan mount spacer to the engine coupler (Fig. 0471). Fig 0471 4-104 PICT-5556 34. Slide the fan onto the fan mount spacer (Fig. 0473). PICT-5523 Rev.
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ENGINE 35. Using an 7/16” socket, install 4 bolts securing the fan to the fan mount spacer (Fig. 0474). 37. Position the hex spacer through the dipstick. Loosely install a nut onto the hex spacer (Fig. 0476). Fig 0474 Fig 0476 PICT-5521a 36. Torque the 4 bolts to 100 + 10 in-lbs. (11.3 + 1.1 Nm) (Fig. 0475). Fig 0475 TX525 Service Manual PICT-5518 38. Slide the alternator collar into the alternator mounting flange (Fig. 0477). PICT-5558a Rev.
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ENGINE 39. Position the alternator and belt guard to the alternator mounting bracket. Loosely install a mounting bolt and lockwasher securing the top of the belt guard and alternator (Fig. 0478). 41. Using a 13mm socket and a 9/16” wrench, loosely install the bottom alternator mounting bolt, lockwasher and flat washer through the belt cover, gear case housing mounting flange, collar and into the hex spacer.
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ENGINE 42. Apply tension to the alternator belt and tighten the top alternator mounting bolt (Fig. 0482). TX525 22319 #270000556 - 270000720 22320 #270000712 - 270000885 22333 #270000423 - 270000446 22334 #270000427 - 270000436 The engine gear case housing flange is not threaded (Fig. 0481). Fig 0482 Fig 0481 PICT-9354 PICT-5565 43. With the alternator belt tensioned, tighten the bottom alternator mounting bolt (Fig. 0483).
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ENGINE 44. 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) (Fig. 0484). 47. Position the starter assembly into the engine (Fig. 0486). A Fig 0486 Fig 0484 PICT-5566 fig. 3EEAB...17B 48. Using a 12mm socket, install 2 bolts and lockwashers securing the starter assembly to the engine (Fig. 0487). A. .28 - .35” (7 – 9mm) 45.
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ENGINE 49. Torque the starter mounting bolts to 17.4 - 20.3 ftlbs. (23.5 - 27.5 Nm) (Fig. 0488). Fig 0488 51. Using a 13mm socket, install 2 bolts securing the starter baffle plate to the engine (Fig. 0490). 50. Position the starter baffle plate (Fig. 0489). Fig 0489 Fig 0490 PICT-5568 52. Torque the 2 bolts securing the starter baffle plate to the engine to 17.4 - 20.3 ft-lbs. (23.5 - 27.5 Nm) (Fig. 0491). PICT-5501a Fig 0491 TX525 Service Manual PICT-5500a Rev.
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ENGINE Engine Assembly Installation 53. Using a 10mm socket, install a bolt securing the starter baffle plate to the exhaust manifold (Fig. 0492). Fig 0492 1. Transfer the engine from the engine stand to the engine hoist (Fig. 0494). PICT-5499 Fig 0494 54. Torque the bolt securing the starter baffle plate to the exhaust manifold to 7.23 - 8.32 ft-lbs. (9.8 - 11.3 Nm) (Fig. 0493). Fig 0493 4-110 PICT-5573a 2. Position the left hand engine mount to the engine (Fig. 0495). PICT-5570 Rev.
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ENGINE 3. Using a 17mm socket, install 5 bolts securing the left hand engine mount to the engine (Fig. 0496). Fig 0496 Fig 0498 PICT-5495 PICT-5574 Fig 0499 TX525 Service Manual PICT-5494 6. Using a 1/2” socket, install 2 bolts securing the forward ISO engine mount to the left hand engine mount (Fig. 0499). 4. Torque the 5 bolts to 38 + 4 ft-lbs. (51.5 + 5.4 Nm) (Fig. 0497). Fig 0497 5. Position the ISO engine mount to the left hand engine mount (Fig. 0498). Rev.
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ENGINE 7. Torque the 2 bolts to 220 + 25 in-lbs. (24.8 + 2.8 Nm) (Fig. 0500). Fig 0500 9. Position the rebound strap onto the 2 rebound washers (Fig. 0502). PICT-5576 8. Position the 2 rebound washers onto the ISO engine mounts (Fig. 0501). Fig 0501 Fig 0502 10. Position the engine mount plate so that the bolts are inserted through the ISO mounts, rebound washers and rebound strap (Fig. 0503). PICT-5491 Fig 0503 4-112 PICT-5490 Rev.
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ENGINE 13. Position the engine into the mainframe aligning the mounting holes on the engine mount plates with the mounting holes in the mainframe. 11. Using a 9/16” socket and wrench, install 2 nuts securing the engine mount plate to the left hand engine mount (Fig. 0504). 14. Remove the engine hoist from the engine. 15. Using a 9/16” socket and wrench, loosely install the rear 2 bolts and nuts securing the left hand side of the engine assembly to the mainframe (Fig. 0506). Fig 0504 PICT-5487 12.
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ENGINE 17. Position the left hand cable guide and the routed harness cables aligning the cable guide mounting hole with the engine and mainframe mounting hole (Fig. 0508). 2008 cable guide: Fig 0510 Fig 0508 PICT-5483 Note: Both the left hand and right hand cable guide appearance and position slightly changed from 2007 models to 2008 models (Fig. 0509 and Fig. 0510): 2007 cable guides: 18.
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ENGINE 19. Position the right hand cable guide and the routed harness cables aligning the cable guide mounting hole with the engine and mainframe mounting hole (Fig. 0512). 21. Torque all 6 engine mounting bolts to 30 + 3 ft-lbs. (41 + 4 Nm) (Fig. 0514). Fig 0514 Fig 0512 PICT-5578 20. Using a 9/16” socket and wrench, loosely install a bolt and nut securing the right hand side of the engine assembly and cable guide to the mainframe (Fig. 0513). 22.
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ENGINE 23. Position the fuel pump and filter assembly to the engine. Slide the fuel pump mounting bracket (bottom mounting hole) onto the bolt that was left in the tower assemb-ly upon removal (Fig. 0516). 25. Route the fuel return line up in between the fuel pump lines to the fuel injector (Fig. 0518). Fig 0518 Fig 0516 PICT-5580 24. Using a 1/2” socket, install the top bolt and nut and the nut onto the bottom bolt securing the fuel pump and filter bracket to the tower frame (Fig. 0517). 26.
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ENGINE 27. Slide the hose clamp up the fuel return line and into position securing the fuel line to the fuel injector (Fig. 0520). Fig 0520 29. Slide the hose clamp up the fuel line and into position securing the fuel line to the fuel injector pump (Fig. 0522). PICT-5471 Fig 0522 PICT-5469 28. Slide the fuel line onto the fuel injector pump (Fig. 0521). Fig 0521 TX525 Service Manual PICT-5470 Rev.
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ENGINE 30. Route the throttle cable to the left of the heat shield mount and over the top of the fuel pump (Fig. 0523 and Fig. 0524). Fig 0523 Note: Some TX525 models have a rubberized R-clamp secured to the top fuel pump mount ing bolt. The throttle cable should be routed through that R-clamp (Fig. 0525). PICT-5588 Fig 0525 PICT-5583a 31. Position the throttle bracket assembly up to the mounting surface on the engine (Fig. 0526). Fig 0524 PICT-5589 Fig 0526 4-118 Rev.
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ENGINE 32. Using a 10mm socket, install 2 bolts securing the throttle bracket to the engine. Torque the 2 bolts to 7.23 to 8.32 ft-lbs. (9.8 to 11.3 Nm) (Fig. 0527). Fig 0527 34. Tighten the swivel clamp securing the throttle cable to the throttle control bracket (Fig. 0529). Adjust the throttle cable. Refer to “Throttle Cable Adjustment” on page 4-142. PICT-5467 Fig 0529 33. With the throttle control in the fast position, lift up the throttle bracket swivel clamp.
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ENGINE 38. Route the glow plug harness cable behind the fuel line, under the solenoid connector and under the fuel injector lines (Fig. 0533). 36. Using a 13mm socket, install the bolt securing the star washer, negative battery cable and harness terminal to the fuel injection pump (Fig. 0531). Fig 0531 4-120 PICT-5590 39. Slide the glow plug harness terminal onto the center glow plug terminal (Fig. 0534). 37. Plug the harness connector into the engine shutdown solenoid connector (Fig. 0532).
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ENGINE 40. Using a 7mm socket, install a nut securing the harness terminal to the glow plug (Fig. 0535). Fig 0535 42. Route the fuel tank harness wires back to the rear of the machine between the tower and the hydraulic filter to tank line (Fig. 0537). PICT-5456 Fig 0537 41. Position the fuel pump connector to the engine side of the fuel pump mounting bracket (Fig. 0536). Fig 0536 43. Install the blue spade connector onto the starter terminal (Fig. 0538).
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ENGINE 44. Slide the 2.0mm (grey) fusible link terminal onto the starter terminal (Fig. 0539). Fig 0539 46. Using a 12mm socket, install a nut securing the fusible link and positive battery cable to the starter terminal. Slide the red boot over the terminal (Fig. 0541). PICT-5448 Fig 0541 45. Slide the positive battery cable onto the starter terminal (Fig. 0540). Fig 0540 47. Plug the harness connector into the .08mm (blue) fusible link connector (Fig. 0542).
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ENGINE 48. Plug the harness connector into the alternator (Fig. 0543). Fig 0543 50. Using a 10mm socket, install a nut and washer securing the harness terminal to the alternator (Fig. 0545). Slide the boot onto the terminal. PICT-5439a Fig 0545 49. Slide the harness terminal onto the alternator terminal (Fig. 0544). Fig 0544 51. Using a Phillips screw driver, install a screw securing the harness terminal to the engine oil pressure sensor (Fig. 0546).
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ENGINE 52. Water temperature harness wire routing: TX525 (#270000001 - 270000400): up the left side of the engine, between the engine block and alternator, up to the temperature sensor (Fig. 0547). 53. Plug the harness terminal into the water temperature sensor (Fig. 0549). Fig 0549 Fig 0547 PICT-5596 PICT-5429 54. Route the drive belt around the pulleys (rear view) (Fig. 0550). TX525 (#270000401 & higher): up between the dipstick and alternator (Fig. 0548).
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ENGINE 55. Using a spring tool (Toro p/n: 92-5771), hook the idler spring to the spring post on the tower (Fig. 0551). Fig 0551 57. Using a 3/16” Allen wrench, install the top 2 screws. Using a 1/2” socket, install the bottom 2 screws securing the heat shield to the tower (Fig. 0553). PICT-5601 56. Position the heat shield (Fig. 0552). Fig 0552 TX525 Service Manual Fig 0553 PICT-5419a 58. Install the hood rod (Fig. 0554). PICT-5421 Rev.
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ENGINE 59. Install a hairpin cotter into the hood rod (Fig. 0555). Fig 0555 61. Position the muffler assembly onto the muffler bracket and manifold (Fig. 0557). PICT-5417 Fig 0557 60. Install a new manifold gasket (Fig. 0556). Fig 0556 62. Using a 13mm socket, install 4 bolts and washers securing the muffler to the engine manifold (Fig. 0558). PICT-5250 Fig 0558 4-126 PICT-5416 Rev.
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ENGINE 63. Torque the 4 bolts to 28 + 3 ft-lbs. (38 + 4 Nm) (Fig. 0559). Fig 0559 65. Tighten the 2 bolts (previously loosely installed) securing the muffler mounting bracket to the engine block. Tighten the bolt securing the muffler to the muffler mounting bracket (Fig. 0561). PICT-5602a Fig 0561 64. Using two 1/2” wrenches, snugly install the bolt, 2 washers and nut securing the muffler assembly to the muffler mounting bracket (Fig. 0560). Fig 0560 66.
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ENGINE 69. Using a 1/2” socket, loosely install 2 bolts securing the air cleaner assembly to the muffler shield (Fig. 0565). 67. Slide the intake hose onto the engine intake (Fig. 0563). Fig 0563 PICT-5407 Fig 0565 68. Position the hose clamp. Using a 3/8” socket, tighten the hose clamp securing the intake hose to the engine intake (Fig. 0564). Fig 0564 70. Using a 13mm socket, loosely install 2 new bolts and washers securing the air cleaner mounting bracket to the engine block (Fig. 0566).
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ENGINE 71. Tighten the 2 bolts securing the air cleaner assembly to the muffler shield and the 2 bolts and washers securing the air cleaner mounting bracket to the engine block (Fig. 0567). 73. Using a 1-1/16” and a 1-1/8” wrench, install the hydraulic oil outlet line to the oil cooler outlet fitting (Fig. 0569). Fig 0569 Fig 0567 72. Carefully place the radiator and oil cooler assembly into the frame (Fig. 0568). Fig 0568 TX525 Service Manual PICT-4968a PICT-5408 74.
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ENGINE 75. Slide the radiator hose onto the engine block outlet (Fig. 0571). Fig 0571 Fig 0573 PICT-5400 76. Position the hose clamp. Using a 3/8” socket, tighten the hose clamp securing the radiator hose to the engine block (Fig. 0572). Fig 0572 77. Slide the 2 radiator hoses onto the radiator fill tube and the thermostat housing (Fig. 0573). 78. Position the 2 hose clamps. Using a 3/8” socket, tighten the hose clamps securing the radiator hoses to the radiator fill tube and thermostat housing (Fig.
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ENGINE 79. Position the radiator mount into the frame (Fig. 0575). Fig 0575 81. Center the radiator and oil cooler assembly side to side in the frame so that there is approximately 1/8” (3.2mm) gap between the shroud and the fan. Spin the cooling fan. Ensure the fan does not come into contact with the shroud. Adjust the radiator side to side as necessary (Fig. 0577). PICT-4971 80. Using a 1/2” socket, loosely install 3 screws holding the radiator mount to the frame (Fig. 0576). Fig 0577 PICT-5135 82.
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ENGINE 83. Inspect the foam seals on the inside of the grill assembly. Replace if worn or damaged (Fig. 0579). Fig 0579 85. Slide the grill onto the frame so it sits under the loader stops and on top of the radiator. Leave the grill in a slightly forward position. The overflow tank mounting holes should be just beyond the right hand boss on top of the radiator assembly. This will allow the overflow bottle assembly to be installed (Fig. 0581). PICT-5138 84.
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ENGINE 87. Install 2 bolts and nuts securing the overflow bottle assembly to the grill assembly (Fig. 0583). Fig 0583 TX525 (#280000001 & higher): Have 2 flange head bolts, no washers (Fig. 0585). Fig 0585 PICT-5145 88. Slide the grill assembly back aligning the mounting holes with the holes in the frame. Loosely install the 4 bolts securing the grill assembly to the frame and the 2 bolts and washers securing the grill to the radiator (Fig. 0584).
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ENGINE 89. Using a 1/2” socket, tighten the 4 bolts securing the grill assembly to the frame (Fig. 0587). Fig 0587 92. Position the breather tube under the grill and install the breather (Fig. 0589). Fig 0589 PICT-5150 90. Check the cooling fan and shroud clearance. Adjust the position of the radiator if necessary. PICT-5157 93. Install the left and right hand side panels (Fig. 0590). 91.
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ENGINE 94. Slide the suction hoses onto the tandem pump suction fittings (Fig. 0591). C. Suction line from the tank (smaller fitting). D. Suction line from the tank (larger fitting). 96. Using a 1-1/8” wrench, install the hydraulic line to the pump fitting labeled B (Fig. 0593). Fig 0593 Fig 0591 PICT-4770a PICT-4775a 97. Using a 15/16” wrench, install the hydraulic line to the test port t-fitting labeled A (Fig. 0594). 95.
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ENGINE 98. Using a 1/4” hex wrench, install the engine oil drain plug located on the underside of the frame inside the right hand wheel and track assembly (Fig. 0595). Fig 0595 100. Position the battery clamp into the slot on the battery mount and line up the mounting hole with the hole in the frame. Install a bolt, washer and nut to secure the battery clamp to the frame (Fig. 0597). PICT-3283 Fig 0597 99. Slide the battery partially into the battery mount.
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ENGINE 102. Position the 2 fuel hose clamps to secure the fuel lines to the fuel tank fittings (Fig. 0599). Fig 0599 104. Position the rear frame cover to the rear of the frame. Using 3/4” and 1/2” sockets, install 7 bolts and nuts to secure the rear frame cover to the frame and fuel tank bracket (Fig. 0601). PICT-4264 Fig 0601 103. Position the fuel tank into the rear of the frame. Connect the two wires (black and orange) to the fuel sending unit located on the top of the fuel tank (Fig. 0600).
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ENGINE Checking, Adding & Bleeding the Engine Coolant 106. Install the rear access panel (Fig. 0603). 1. Check the level of coolant in the expansion tank. The coolant should be at or above the mark on the tank (Fig. 0604). Fig 0603 PICT-4505a 107. Fill the engine with oil per specifications. Fig 0604 108. Fill the radiator. Refer to “Checking, Adding & Bleeding the Engine Coolant” on page 4-138. 109. Disengage the park brake and start the unit.
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ENGINE 2. Remove the coolant fill cap (Fig. 0605). Fig 0607 Fig 0605 Coolant 002 Note: The cooling system is filled with a 50/50 mixture of water and permanent ethylene glycol antifreeze. 3. Open the front and top coolant bleed valves (Fig. 0606 and Fig. 0607). Fig 0606 4. Pour coolant mixture into the coolant filler neck until the coolant begins to come out of the front coolant bleed valve (Fig. 0608). Coolant 003 Fig 0608 TX525 Service Manual Coolant 005 Rev.
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ENGINE 5. Close the front coolant bleed valve (Fig. 0609). Fig 0611 Fig 0609 Coolant 006 Coolant 003 7. Close the top coolant bleed valve (Fig. 0612). 6. Pour coolant mixture into the coolant filler neck until the coolant begins to come out of the top coolant bleed valve (Fig. 0610 and Fig. 0611). Fig 0612 Fig 0610 4-140 Coolant 005 Coolant 004 Rev.
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ENGINE 8. Pour coolant mixture into the coolant filler neck until the coolant level comes into the filler neck (Fig. 0613). Fig 0613 TX525 Service Manual Fig 0615 Coolant 007 Coolant 009 11. Install the expansion tank cap (Fig. 0616). 9. Install the coolant fill cap (Fig. 0614). Fig 0614 10. Remove the expansion tank cap and add coolant mixture into the expansion tank until it reaches the full line on the side of the tank (Fig. 0615). Coolant 002 Rev.
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ENGINE Throttle Cable Adjustment 4. There should be approximately 3/16” to 1/4” (0.48 to 0.635cm) of cable through the swivel (Fig. 0619). 1. Raise the hood. 2. Remove the right hand side panel (Fig. 0617). Fig 0619 Fig 0617 PICT-8759 3. Move the air intake hose out of the way of the throttle plate. Using a 1/4” wrench, loosen the throttle cable swivel (Fig. 0618). Fig 0618 5. To adjust the amount of cable going through the swivel (Fig. 0620): a.
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ENGINE d. Using two 7/16” wrenches, tighten the two adjusting nuts securing the throttle cable to the throttle plate (Fig. 0621). Fig 0621 PICT-7143a 6. Hold the throttle lever over to the low idle stop. Using a 1/4” wrench, tighten the swivel clamp screw to hold the throttle cable wire (Fig. 0622). Fig 0622 TX525 Service Manual 7. Move the throttle lever to the fast position to ensure the engine throttle lever rests against the high idle stop (Fig. 0623).
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ENGINE 8. Move the air intake hose back into position. Throttle Cable Replacement 9. Install the right hand side panel (Fig. 0625). Throttle Cable Removal 1. Position the traction unit on a flat surface. 2. Remove the ignition key. 3. Apply the parking brake. 4. Raise the hood. 5. Remove the hairpin cotter from the hood prop rod (Fig. 0626). Fig 0625 PICT-8759 10. Lower the hood. Fig 0626 4-144 Rev.
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ENGINE 6. Support the hood and remove the prop rod (Fig. 0627). Fig 0627 8. Using a 3/16” Allen wrench, remove the 2 upper heat shield screws (Fig. 0629). PICT-7128 7. Using a 1/2” wrench, remove the 2 lower heat shield screws (Fig. 0628). Fig 0629 9. Remove the heat shield (Fig. 0630). Fig 0630 Fig 0628 TX525 Service Manual PICT-7132 PICT-7133 PICT-7129 Rev.
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ENGINE 10. Remove the right hand side panel (Fig. 0631). Fig 0631 12. Using two 7/16” wrenches, loosen the adjusting nuts securing the throttle cable to the throttle plate (Fig. 0633). PICT-7138 Fig 0633 11. Move the air intake hose out of the way of the throttle plate. Using a 1/4” wrench, loosen the throttle cable swivel (Fig. 0632). Fig 0632 13. Remove the throttle cable from the throttle plate and slide the cable out of the swivel (Fig. 0634). PICT-7140 Fig 0634 4-146 PICT-7143a Rev.
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ENGINE 16. Remove the throttle cable from the machine. 14. Remove the clip securing the throttle cable to the throttle handle linkage (Fig. 0635). Fig 0635 17. Remove the adjusting nuts from the throttle cable. Retain them for use on the new throttle cable (Fig. 0637). PICT-7151a Fig 0637 PICT-7158a 15. Unhook the throttle cable Z-bend from the throttle cable handle linkage (Fig. 0636). Throttle Cable Installation 1.
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ENGINE 2. Insert the throttle cable z-bend into the throttle control handle linkage (Fig. 0639). Fig 0639 4. Route the throttle cable down the tower to the right hand side of the shield support (Fig. 0641). 3. Install the throttle cable clip/retainer into the throttle control handle linkage to secure (Fig. 0640). Fig 0640 4-148 Fig 0641 PICT-7155 PICT-7162 5. Route the throttle cable between the tower and the idler arm pivot (Fig. 0642). PICT-7160 Rev.
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ENGINE 6. Route the throttle cable between the fuel pump and fuel pump bracket, under the top mounting bolt (Fig. 0643). Fig 0643 7. Insert the end of the throttle cable through the swivel (Fig. 0645). Fig 0645 PICT-7165 Note: Some TX525 models have a rubberized R-clamp secured to the top fuel pump mount ing bolt. The throttle cable is routed through this R-clamp (Fig. 0644). 8. Insert the throttle cable into the throttle bracket so the 2 nuts straddle the bracket (Fig. 0646).
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ENGINE 9. There should be approximately 3/16” to 1/4” (0.48 to 0.635cm) of wire through the swivel (Fig. 0647). Fig 0647 10. Using two 7/16” wrenches, tighten the two adjusting nuts securing the throttle cable to the throttle plate (Fig. 0649). PICT-7107 Fig 0649 Note: To adjust the amount of wire going through the swivel loosen the two adjusting nuts securing the cable to the throttle bracket. To shorten the cable, thread the nuts toward the cable end.
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ENGINE 12. Move the throttle cable to the fast position to assure the engine throttle lever rests against the high idle stop (Fig. 0651). Fig 0651 13. Move the air intake hose back into position. 14. Install the right hand side panel (Fig. 0653). PICT-7104 Note: When the throttle lever is in the fast position the engine throttle lever should not contact the throttle cable end (Fig. 0652). Fig 0653 15. Position the heat shield (Fig. 0654).
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ENGINE 16. Using a 3/16” Allen wrench, install the 2 upper heat shield screws (Fig. 0655). Fig 0655 Fig 0657 PICT-7132 PICT-7128 19. Install the hairpin cotter into the hood prop rod (Fig. 0658). 17. Using a 1/2” wrench, install the 2 lower heat shield screws (Fig. 0656). Fig 0656 18. Support the hood and install the prop rod (Fig. 0657). PICT-7129 Fig 0658 PICT-7126 20. Lower the hood. 4-152 Rev.
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ENGINE Alternator Assembly Teardown 4. Remove the collar from the alternator shaft (Fig. 0661). 1. Position the alternator assembly into a vise. 2. Using a 22mm socket, remove the nut from the alternator shaft (Fig. 0659). Fig 0661 Fig 0659 PICT-8169 PICT-8266 5. Using a 10mm socket, remove the battery post nut (Fig. 0662). 3. Remove the pulley from the alternator shaft (Fig. 0660). Fig 0662 Fig 0660 TX525 Service Manual PICT-8171 PICT-8170 Rev.
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ENGINE 6. Slide the insulation bushing off the battery post (Fig. 0663). Fig 0663 4-154 Fig 0665 PICT-8172a PICT-8176a 9. Remove the 2 screws securing the brush holder to the alternator assembly (Fig. 0666). 7. Using a 7mm socket, remove the 3 bolts securing the end cover to the alternator (Fig. 0664). Fig 0664 8. Remove the end cover from the alternator (Fig. 0665). PICT-8175a Rev.
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ENGINE 12. Remove the regulator assembly from the alternator (Fig. 0669). 10. Remove the brush holder from the alternator assembly (Fig. 0667). Fig 0667 PICT-8255 11. Remove the 3 screws securing the regulator assembly to the alternator (Fig. 0668). Fig 0668 TX525 Service Manual Fig 0669 PICT-8181 13. Remove the 4 screws securing the rectifier to the alternator assembly (Fig. 0670). PICT-8180 Rev.
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ENGINE 14. Straighten out the 4 coil wires that are threaded through the rectifier (Fig. 0671). 16. Using an 8mm socket, remove the 2 nuts and 2 bolts securing the rear end frame to the alternator assembly (Fig. 0673). A A B B Fig 0671 PICT-8186 Fig 0673 A. Nuts (2) PICT-8190 B. Bolts (2) 15. Remove the rectifier from the alternator assembly (Fig. 0672). 17. Remove the rear end frame and rotor assembly from the alternator assembly (Fig. 0674). Fig 0672 PICT-8187 Fig 0674 4-156 Rev.
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ENGINE 20. Using a straight screwdriver, remove the bearing cover from the bearing on the rotor shaft (Fig. 0677). 18. Remove the rotor from the end frame (Fig. 0675). Fig 0675 PICT-8198 19. Remove the wave washer from the rotor (Fig. 0676). Fig 0676 Fig 0677 21. Using a puller, remove the bearing from the rotor shaft (Fig. 0678). PICT-8203a Fig 0678 TX525 Service Manual PICT-8204a Rev.
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ENGINE 22. Remove the washer from the rotor shaft (Fig. 0679). Fig 0679 24. Remove the retainer plate from the drive end frame (Fig. 0681). PICT-8208 Fig 0681 23. Using a Phillips screwdriver, remove the 4 screws securing the retainer plate to the inside of the drive end frame (Fig. 0680). Fig 0680 PICT-8194 25. Press the bearing out of the drive end frame (Fig. 0682). PICT-8192 Fig 0682 PICT-8197a 26. Inspect the bearings, rotor shaft and brushes. Replace if worn or damaged. 27.
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ENGINE Alternator Testing 2. If the measurement is not less than 1 ohm, replace the stator. Stator 3. Check the continuity across each stator coil lead and the core with the resistance range on a circuit tester (Fig. 0685). Fig 0683 PICT-8218 Fig 0685 1. Measure the resistance across each lead of the stator coil with the resistance range on a circuit tester (Fig. 0684). Fig 0684 TX525 Service Manual PICT-8220 4. If infinity is not indicated, replace the stator. PICT-8219 Rev.
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ENGINE Rotor 2. If the resistance is not 2.9 ohms, replace the rotor. 3. Check the continuity across the slip ring and the core with the resistance range on a circuit tester (Fig. 0688). Fig 0686 PICT-8215a 1. Measure the resistance across the slip rings with the resistance range on a circuit tester (Fig. 0687). Fig 0688 PICT-8217a 4. If infinity is not indicated, replace the rotor. Fig 0687 4-160 PICT-8216a Rev.
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ENGINE Brush Wear Slip Ring A Fig 0689 Fig 0690 PICT-8224a PICT-8222 A. .331” (8.4mm) 1. Check the slip ring surface for scoring. 2. If scored, correct with an emery paper or on a lathe. 3. Measure the OD of the slip ring with vernier calipers. 4. If the measurement is less than .551” (14.0mm), replace the rotor. 1. Measure the brush length with vernier calipers (Fig. 0000). 2. If the measurement is less than .331” (8.4mm), replace the brush assembly. 3.
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ENGINE Rectifier IC Regulator Fig 0691 Fig 0693 PICT-8210 PICT-8213 1. Check the continuity across the B terminal and the F terminal of IC regulator with resistance range of circuit tester. 2. The IC regulator is normal if resistance is measured in one direction and an open circuit is measured in the reverse direction (Fig. 0694). Fig 0692 PICT-8211 A B 1. Check the continuity across each diode (8) of the rectifier with the resistance range setting on a circuit tester. 2.
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ENGINE Alternator Reassembly 2. Press a bearing (smaller OD than the drive end frame bearing) onto the slip ring end of the rotor shaft (Fig. 0696 and Fig. 0697). 1. Slide a washer onto the slip ring end of the rotor shaft (Fig. 0695). Fig 0695 TX525 Service Manual Fig 0696 PICT-8227 Fig 0697 PICT-8230a PICT-8225a Rev.
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ENGINE 3. Install a bearing cover onto the rotor shaft over the bearing (Fig. 0698 and Fig. 0699). Fig 0698 4. Slide a wave washer onto the slip ring end of the rotor shaft (Fig. 0700). Fig 0700 PICT-8229a PICT-8231a 5. Install the slip ring shaft end of the rotor assembly into the rear end frame (Fig. 0701). Fig 0699 PICT-8230a Fig 0701 4-164 Rev.
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ENGINE 6. Install the bearing into the drive end frame (Fig. 0702 and Fig. 0703). Fig 0702 7. Position the retainer plate into the drive end frame over the bearing with the retainer plate tabs facing toward the bearing (Fig. 0704). PICT-8233 Fig 0704 PICT-8236a 8. Using a Philips screwdriver, install 4 screws to secure the retainer plate to the inside of the drive end frame (Fig. 0705). Fig 0703 PICT-8234a Fig 0705 TX525 Service Manual Rev.
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ENGINE 9. Slide the rear end frame/rotor assembly into the drive end frame assembly (Fig. 0706 and Fig. 0707). Fig 0706 10. Using an 8mm socket, install 2 nuts and 2 bolts securing the rear end frame to the drive end frame assembly (Fig. 0708). A B B A PICT-8239 Fig 0708 A. Nuts (2) Fig 0707 4-166 PICT-8242 B. Bolts (2) PICT-8240 Rev.
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ENGINE 11. Position the rectifier onto the alternator assembly so the 4 stator leads feed through the 4 holes that are next to each of the screw holes in the rectifier (Fig. 0709 and Fig. 0710). 12. Coil each of the 4 stator leads that are threaded through the rectifier so that they each coil around the threaded screw holes (Fig. 0711). Fig 0711 Fig 0709 PICT-8247 PICT-8243 13. Install 4 screws securing the stator coil leads and rectifier to the alternator assembly (Fig. 0712).
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ENGINE 14. Position the regulator assembly to the alternator (Fig. 0713). Fig 0713 16. Position the brush holder onto the alternator assembly (Fig. 0715). Fig 0715 PICT-8250 15. Install 3 screws to secure the regulator assembly to the alternator (Fig. 0714). PICT-8255 17. Install 2 screws securing the brush holder to the alternator assembly (Fig. 0716). A B Fig 0714 PICT-8253 Fig 0716 A. Longer screw 4-168 Rev. 000 PICT-8178 B.
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ENGINE 18. Slide the end cover onto the alternator (Fig. 0717). Fig 0717 20. Slide the insulation bushing onto the battery post (Fig. 0719). PICT-8260a Fig 0719 19. Using a 7mm socket, install 3 bolts to secure the end cover to the alternator (Fig. 0718). Fig 0718 21. Using a 10mm socket, install the battery post nut (Fig. 0720). PICT-8261a Fig 0720 TX525 Service Manual PICT-8263a Rev.
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ENGINE 22. Slide a collar onto the alternator shaft (Fig. 0721). Fig 0721 24. Using a 22mm socket and a strap wrench, install a nut onto the alternator shaft to secure the pulley. Torque the nut to 43.0 to 58.2 ft-lbs. (58.3 to 78.9 Nm) (Fig. 0723). PICT-8267a 23. Slide the pulley onto the alternator shaft (Fig. 0722). Fig 0722 4-170 Fig 0723 PICT-8270a PICT-8268a Rev.
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ENGINE Starter Assembly Teardown 3. Remove the jumper wire ring terminal and the starter wire from the magnetic switch terminal (Fig. 0726 and Fig. 0727). 1. Secure the starter in a vise (Fig. 0724). Fig 0724 PICT-8018a Fig 0726 PICT-8022a Fig 0727 PICT-8024a 2. Using a 12mm socket, remove the nut from the magnetic switch terminal (Fig. 0725). Fig 0725 TX525 Service Manual PICT-8019a Rev.
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ENGINE 4. Using a 10mm socket, remove the nuts from the mounting bolts securing the magnetic switch assembly to the starter (Fig. 0728). Fig 0728 6. Using a Phillips screw driver, remove the 2 screws securing the frame assembly to the brush spring (Fig. 0730). Fig 0730 PICT-8027a 7. Using an 8mm socket, remove the 2 through bolts from the starter assembly (Fig. 0731). 5. Remove the magnetic switch assembly from the starter by sliding it out of the drive lever and away from the starter (Fig. 0729).
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ENGINE 8. Remove the cover from the frame assembly (Fig. 0732). 10. Pull the springs back and slide the 2 positive brushes out of the spring holder assembly (Fig. 0734). Note: The positive brushes have leads attached to the yoke. Fig 0732 PICT-8144 9. Remove the frame assembly from the starter assembly (Fig. 0733). Fig 0734 PICT-8040 11. Slide the brush holder off the yoke assembly (Fig. 0735). Fig 0733 PICT-8034a Fig 0735 TX525 Service Manual Rev.
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ENGINE 12. Slide the yoke assembly off of the armature (Fig. 0736). 14. Remove the plate from the starter (Fig. 0738). Fig 0738 Fig 0736 15. Remove the 3 gears from on top of the starter shaft assembly (Fig. 0739). 13. Remove the armature assembly (Fig. 0737). Fig 0737 4-174 PICT-8044a PICT-8042a PICT-8043a Rev.
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ENGINE 16. Draw out the shaft assembly with the drive lever and the overrunning clutch from the housing (Fig. 0740). Fig 0740 18. Using a 12mm socket, drive the collar off the circlip on the shaft assembly (Fig. 0742). Fig 0742 PICT-8045a 17. Remove the starter housing from the vise and clamp the shaft assembly into the vise with the clutch assembly facing up (Fig. 0741). 19. Remove the circlip from the shaft assembly (Fig. 0743).
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ENGINE 20. Remove the collar from the shaft (Fig. 0744). Fig 0744 22. While supporting the shaft, remove the snap ring (Fig. 0746). PICT-8107a Fig 0746 21. Remove the clutch assembly from the shaft (Fig. 0745). Fig 0745 23. While supporting the shaft, remove the washer from the shaft (Fig. 0747). PICT-8051a Fig 0747 4-176 PICT-8056a Rev.
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ENGINE 24. Remove the shaft from the gear/bearing assembly (Fig. 0748). Fig 0748 26. Inspect: Gears (3) (Fig. 0750): PICT-8058 25. Remove the gear from the bearing assembly (Fig. 0749). Fig 0749 TX525 Service Manual Fig 0750 PICT-8101a Fig 0751 PICT-8093a Shaft (Fig. 0751): PICT-8059a Rev.
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ENGINE Ring gear (Fig. 0752): Fig 0752 Fig 0754 PICT-8096a Fig 0755 PICT-8099a PICT-8098a Collar (Fig. 0755): Clutch assembly (Fig. 0753 and Fig. 0754): Fig 0753 4-178 PICT-8094a Rev.
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ENGINE Lever (Fig. 0756): a. Check the commutator bar for wear. Polish the commutator with very fine emery paper if it is slightly worn (mica undercut must be thoroughly cleaned of emery dust). b. Measure the commutator OD with an outside micrometer at several points. c. If the minimum OD is less that the allowable limit of 1.142” (29.0mm), replace the armature. d. If the difference of the ODs exceeds the allowable limit of .0020” (.
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ENGINE Starter Assembly Rebuild 4. While supporting the shaft, slide a washer onto the shaft (Fig. 0760). 1. Slide the shaft into the gear (Fig. 0758). Fig 0760 Fig 0758 PICT-8090a PICT-8085a 5. While supporting the shaft, install a snap ring (Fig. 0761). 2. Secure the bearing assembly in a vise. 3. Insert the shaft/gear assembly into the bearing assembly (Fig. 0759). Note: There is a tab on the gear and bearing for alignment. Fig 0761 Fig 0759 4-180 PICT-8092a PICT-8088 Rev.
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ENGINE 6. Slide the clutch assembly onto the shaft (Fig. 0762). Fig 0762 8. Install a circlip into the groove of the shaft assembly (Fig. 0764). PICT-8105a Fig 0764 7. Slide the collar onto the shaft (Fig. 0763). Fig 0763 9. Press the collar onto the installed circlip (Fig. 0765). PICT-8107a Fig 0765 TX525 Service Manual PICT-8108 Rev.
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ENGINE 10. Remove the shaft assembly from the vise and clamp the starter housing into the vise. 11. Slide the lever onto the shaft assembly between the washer and the clutch (Fig. 0766). Fig 0766 Note: There is a notch in the bottom of the bearing assembly (Fig. 0768) that fits into the groove inside the housing (Fig. 0769). The notch and groove must be lined up to fully seat the bearing assembly in the housing. PICT-8112a Fig 0768 PICT-8116 Fig 0769 PICT-8115 12.
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ENGINE 13. Apply lithium grease to the gear teeth and the 3 gear posts on the shaft assembly (Fig. 0770). Fig 0770 15. Apply a light coat of lithium grease to the 3 gears (Fig. 0772). Fig 0772 PICT-8117 14. Install 3 gears onto the shaft assembly gear posts (Fig. 0771). PICT-8121 16. Install the plate into the bearing assembly (Fig. 0773). Note: There is a tab on the plate that must align with the groove inside the bearing. Fig 0771 PICT-8119 Fig 0773 TX525 Service Manual Rev.
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ENGINE 17. Slide the armature assembly into the starter assembly (Fig. 0774). 19. Pull back on the brush holder springs. Slide the brushes outward so that the springs are holding the brushes out (Fig. 0776). A B Fig 0774 PICT-8125a Fig 0776 A. Spring PICT-8129a B. Brush 18. Slide the yoke assembly onto the armature (Fig. 0775). Note: There is a tab on the yoke that lines up with a groove in the armature. Fig 0775 4-184 20. Slide the brush holder onto the yoke assembly.
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ENGINE 21. Lift the springs back and slide the 2 positive brushes into the open slots on the spring holder assembly. Release the springs (Fig. 0778). Fig 0778 23. Slide the frame assembly onto the starter assembly aligning the notch in the frame with the grommet on the yoke (Fig. 0780). Fig 0780 PICT-8135 22. Lift the springs back and slide the 2 fixed brushes into the brush holder. Release the springs (Fig. 0779). 24. Insert the cover into the frame assembly (Fig. 0781).
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ENGINE 25. Using a Phillips screw driver, install 2 screws securing the frame assembly to the brush spring (Fig. 0782). 27. Position the magnetic switch onto the starter with the short terminal positioned closest to the starter. Magnetic Switch Terminals (Fig. 0784) A B C Fig 0782 PICT-9119a Fig 0784 A. Tall terminal C. Spade plug 26. Using an 8mm socket, install 2 through bolts securing the frame assembly to starter assembly (Fig. 0783). PICT-8149a B.
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ENGINE 28. Using a 10mm socket, install 2 nuts onto the magnetic switch mounting bolts securing it to the starter (Fig. 0786). 30. Slide the jumper wire ring terminal onto the short terminal on the magnetic switch (Fig. 0788). Fig 0788 Fig 0786 29. Slide the starter wire onto the short terminal on the magnetic switch (Fig. 0787). Fig 0787 TX525 Service Manual PICT-8163 PICT-8158a 31. Using a 12mm socket, install a nut onto the magnetic switch short terminal to secure the wires (Fig. 0789).
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ENGINE Starter Assembly Testing Brush Holder Brush Wear A Fig 0791 Fig 0790 PICT-8069a PICT-8063a 1. Check the continuity across the brush holder and the holder support with a circuit tester. A. .354” (9.0mm) 2. If it conducts, replace the brush holder. 1. If the connecting face of the brush is dirty or dusty, clean it with emery paper. 2. Measure the brush length (A) with vernier calipers. 3. If the length is less than the allowable limit of .354” (9.
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ENGINE Armature Coil Field Coil 1. Check the continuity across the commutator and armature coil core with a resistance range circuit tester (Fig. 0792). 1. Check the continuity across the lead and brush with a circuit tester (Fig. 0794). Fig 0792 Fig 0794 PICT-8070 2. If it does not conduct, replace the yoke assembly. 2. If it conducts, replace the armature. 3. Check the continuity across the brush and yoke with a circuit tester (Fig. 0795). 3.
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ENGINE THIS PAGE INTENTIONALLY LEFT BLANK. 4-190 Rev.
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ELECTRICAL Electrical 3. Remove the hood rod (Fig. 0797). Many of the electrical components are located inside the control panel. To access them, remove the heat shield. Heat Shield Removal 1. Raise the hood. 2. Remove the hairpin cotter from the hood rod (Fig. 0796). Fig 0797 PICT-5257a 4. Using a 3/16” Allen wrench, remove the top 2 screws securing the heat shield to the tower. Using a 1/2” socket, remove the bottom 2 screws securing the heat shield to the tower (Fig. 0798).
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ELECTRICAL Ignition Switch 5. Remove the heat shield (Fig. 0799). Purpose This component provides the proper switching for the starter, ignition, accessories, and safety circuits. Location The ignition switch is mounted on the left side of the control panel (Fig. 0800). Fig 0799 PICT-5259 Fig 0800 PICT-5260 How It Works Detents inside the ignition switch give it 3 positions: OFF, RUN, and START.
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ELECTRICAL Testing Hour Meter 1. Disconnect the switch from the wiring harness. Purpose 2. Verify that continuity exists between the terminals listed for the START and RUN switch positions. Verify that there is NO continuity between the terminals in the OFF switch position (Fig. 0801). The hour meter displays the number of hours of operation that have been logged on the traction unit.
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ELECTRICAL How It Works How It Works The digital hour meter is an electrical clock. It is not repairable and can not be reset. The meter moves in proportion to the amount of resistance provided by the fuel sender located in the fuel tank. The movement is dampened to compensate for movement of the fuel inside the tank. Testing The digital hour meter should be replaced if any of the functions do not work properly.
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ELECTRICAL Relay How It Works Purpose A relay is an electrically actuated switch. The TX525 uses three relays to direct current flow to different areas of the machine. The three relays are the kill relay, the start relay and 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 three relays are located inside the tower assembly (Fig. 0805). 2.
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ELECTRICAL Engine Oil Pressure and Battery Charge Indicator Light Cluster 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. 0807). Purpose The engine oil pressure indicator light notifies the oper ator that the engine oil pressure is too low.
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ELECTRICAL How It Works If the engine oil pressure gets too low, the engine oil pressure light illuminates and an audible alarm sounds. If the battery charge becomes too low, the battery charge indicator light illuminates. Water Temperature and Glow Plug Indicator Light Cluster Purpose The water temperature indicator light notifies the operator when the engine coolant gets too hot. An audible alarm will also sound. Testing - Oil Pressure Light Disconnect the wire harness plug from the light cluster.
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ELECTRICAL How It Works Glow Plug Switch If the engine coolant gets too hot, the water temperature light illuminates and an audible alarm sounds. Purpose If the glow plugs are receiving power, the indicator light illuminates. The glow plug switch activates the glow plug relay which powers the glow plugs in addition to turning the glow plug indicator light on. Testing - Water Temperature Light Location Disconnect the wire harness plug from the lights.
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ELECTRICAL How It Works Water Temperature Sender The glow pug switch is manually depressed and held in place for 10 seconds. This activates the relay that closes the circuit which sends current to the glow plug. Purpose Testing Only terminals 1 and 2 are used in this application. The switch can be tested with an ohmmeter. There should be no continuity between terminals 1 and 2 except when the switch is depressed (Fig. 0813). The water temperature sender is a temperaturedependent variable resistor.
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ELECTRICAL How It Works Location When the water temperature reaches an excessive operating temperature the switch closes and connects the high temperature audible alarm and indicator light to ground. The alarm sounds and the indicator light illuminates. The oil pressure switch is located on the left side of the engine under the alternator (Fig. 0815). Testing It is not practical to test the water temperature switch in a shop environment.
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ELECTRICAL Neutral Proximity (Magnetic) Switch Location Purpose The neutral proximity switch is located under the center panel of the control panel. The drive handle and the center panel must be removed to access the neutral switch (Fig. 0817). The neutral proximity switch ensures the traction control lever is in the neutral/stop position when starting the unit. It is a magnetic type switch and it must be in close proximity to the traction control lever bolt to close the contacts (Fig. 0816).
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ELECTRICAL Testing Fuel Sender 1. Before electrically testing the switch, check the location of the switch and bolt, to make sure they are meeting in the sense zone on the switch. Both the switch and the bolt are adjustable and the air gap between them should be 1/8” to 1/4” (3.2 to 6.4mm). Purpose This electrical component sends a varying voltage to the control panel gauge corresponding to the fuel level in the tank. 2. Disconnect the switch from the wiring harness and remove it from the unit.
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ELECTRICAL Testing How It Works Disconnect the two wires and remove the mounting screws. Remove the sender from the fuel tank. Place the VOM negative lead on the negative terminal and the positive lead on the center stud. Refer to the chart below for proper resistance depending on float position. There is +12VDC applied to the audio alarm when the key is in the ON or RUN positions. The Water Temper ature Light provides a ground for the light and the audio alarm.
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ELECTRICAL Fuses How It Works Purpose If the circuit the fuse is protecting draws too much current, the metal conductor in the fuse melts in two, opening the circuit. 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. A failed fuse is a sign of a problem in that circuit.
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ELECTRICAL Testing Start circuit (Fig. 0825) 2.0mm fusible link: 2.0mm fusible link: Check for a failure of the 30 amp fuse first. Check for 12 volts at the solenoid stud. Remove the heat shrink from the splice. Use a test light to check for power at the terminal end and of the splice. If power is present at one end and not the other, then the fusible link is bad. Testing the fusible link with an ohmmeter: Attach the ohmmeter leads to each side of the link.
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ELECTRICAL Glow Plug How It Works Purpose When the ignition key is in the ON position and the glow plug switch is pressed, 12VDC activates a relay which provides 12VDC to the common power rail (buss bar connecting the glow plugs. The glow plugs are threaded into the head which provides the ground to the glow plug. The glow plug center element heats to a glowing red temperature to pre-heat the air in the pre-combustion chamber.
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ELECTRICAL Battery Testing Purpose You must first have the battery fully charged prior to any test. The surface charge must be removed before testing. To remove surface charge the battery must experience a load of 20 amps for 3 plus minutes. A battery supplies the energy source required to activate the starter motor to spin the engine so it will start. It also supplies the energy required to power the various electrical circuits in addition to the alternator.
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ELECTRICAL Storage How It Works Batteries in equipment stored for some portion of the year will self-discharge. Sulfation between the battery plates can occur and shorten the life of the battery. It is important to periodically charge the battery during storage to prevent damage due to sulfation. The alternator is belt driven from the engine crankshaft pulley.
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ELECTRICAL Starter How It Works Purpose The starter motor and solenoid work together to crank the engine over. The solenoid works as an electric switch that connects the battery with the starter motor. When the ignition key is turned to the start position battery voltage activates the solenoid that energizes the starter motor and pushes the starter gear forward. The starter gear meshes with the engine flywheel to crank the engine.
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ELECTRICAL THIS PAGE INTENTIONALLY LEFT BLANK. 5-20 Rev.
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HYDRAULIC SYSTEM 2 Spool Loader Valve Replacement Note: Cleanliness is a key factor in a successful repair of any valve system. Thoroughly clean all exposed surfaces prior to any type of maintenance. Cleaning all parts by using a solvent wash and air drying is usually adequate. As with any precision equipment, all parts must be kept free of foreign material and chemicals. Protect all exposed sealing areas and open cavities from damage and foreign material. 2.
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HYDRAULIC SYSTEM 4. Remove the rear access panel (Fig. 0835). 6. Mark the 2 spool valve fittings and hydraulic line nuts with the letters A – F as follows (Fig. 0837): AB C D E F Fig 0835 PICT-4505a Fig 0837 5. Using a 3/8” socket, remove the 3 screws securing the right hand side support bracket to the tower. Remove the right hand side support bracket (Fig. 0836). A. Hydraulic oil inlet line B. Tilt cylinder line C. Lift cylinder line PICT-4876a D. Hydraulic oil return line E. Lift cylinder line F.
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HYDRAULIC SYSTEM 8. Using a 13/16” wrench, disconnect the hydraulic line marked E from the 2 spool loader valve (Fig. 0839). 10. Using a 13/16” wrench, disconnect the hydraulic line marked C from the 2 spool loader valve (Fig. 0841). Fig 0839 Fig 0841 PICT-4880a PICT-4882a 9. Using a 13/16” wrench, disconnect the hydraulic line marked D from the 2 spool loader valve (Fig. 0840). 11. Using a 13/16” wrench, disconnect the hydraulic line marked B from the 2 spool loader valve (Fig. 0842).
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HYDRAULIC SYSTEM 14. Remove the 2 spool loader valve from the control panel assembly (Fig. 0845). 12. Using a 15/16” offset wrench, disconnect the hydraulic line marked A from the 2 spool loader valve fitting (Fig. 0843). Fig 0843 Note: Cap all the hydraulic lines and fittings so that debris does not enter the system. PICT-4886 Fig 0845 13. Using a 1/2” wrench and socket, remove the 3 mounting bolts and lock washers that secure the 2 spool loader valve to the control panel (Fig. 0844).
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HYDRAULIC SYSTEM 15. Remove the handle from the valve and transfer it to the replacement valve (Fig. 0847). 2 Spool Loader Valve Installation 1. Remove the protective caps from the hydraulic lines and fittings. 2. Position the 2 spool loader valve into the control panel (Fig. 0848). Fig 0847 PICT-2584a 16. Transfer all fittings and the handle over to the replacement 2 spool loader valve. Fig 0848 PICT-4896 3.
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HYDRAULIC SYSTEM 4. Using a 15/16” offset wrench, connect the hydraulic line marked A to the 2 spool loader valve fitting marked A (Fig. 0850). Fig 0850 6-6 Fig 0852 PICT-4886 5. Using a 13/16” wrench, connect the hydraulic line marked B to the 2 spool loader valve fitting marked B (Fig. 0851). Fig 0851 6. Using a 13/16” wrench, connect the hydraulic line marked C to the 2 spool loader valve fitting marked C (Fig. 0852). PICT-4882a 7.
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HYDRAULIC SYSTEM 8. Using a 13/16” wrench, connect the hydraulic line marked E to the 2 spool loader valve fitting marked E (Fig. 0854). 10. Position the right panel onto the control panel assembly (Fig. 0856). Fig 0856 Fig 0854 PICT-4343 PICT-4880a 9. Using a 15/16” wrench, connect the hydraulic line marked F to the 2 spool loader valve fitting marked F (Fig. 0855). 11. Using a 3/8” socket, install 3 self-tapping screws that secure the right panel to the control panel assembly.
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HYDRAULIC SYSTEM 12. Apply thread locking compound (Loctite 416 or equivalent) to brake handle threads (Fig. 0858). 14. Purge air from the hydraulic system. Refer to “Purging Air Procedure”, on page 9-19. Check for any leaks in the hydraulic fittings and hydraulic hoses. 15. Position the right hand rear cover support panel to the tower. Using a 3/8” socket, install 3 screws to secure the right rear cover support panel to the tower assembly (Fig. 0860). Fig 0858 PICT-5526 13.
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HYDRAULIC SYSTEM Auxiliary Valve Replacement 3. Using a 3/8” socket remove the 3 screws from left side panel. Remove panel (Fig 0863). Note: Cleanliness is a key factor in a successful repair of any valve system. Thoroughly clean all exposed surfaces prior to any type of maintenance. Cleaning all parts by using a solvent wash and air drying is usually adequate. As with any precision equipment, all parts must be kept free of foreign material and chemicals.
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HYDRAULIC SYSTEM 5. Remove the top left panel (Fig. 0865). Fig 0865 7. Remove stop plate (Fig. 0867). Fig 0867 PICT-4601 6. Using a 7/16” socket and wrench remove the 2 bolts, washers and nuts from stop plate (Fig. 0866). PICT-4899 8. Mark each auxiliary valve hydraulic line and fitting (Fig. 0868): C B A Fig 0866 Fig 0868 PICT-4898a A. B. C. D. 6-10 D Rev.
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HYDRAULIC SYSTEM 9. Using a 1-1/8” wrench, remove the hydraulic line marked A from the auxiliary valve fitting (Fig. 0869). Fig 0869 11. Using a 15/16” wrench, remove the hydraulic line marked C from the auxiliary valve fitting (Fig. 0871). Fig 0871 PICT-4903a 10. Using a 15/16” wrench, remove the hydraulic line marked B from the auxiliary valve fitting (Fig. 0870). PICT-4906 12. Using a 1-1/8” wrench, remove the hydraulic line marked D from the auxiliary valve fitting (Fig. 0872).
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HYDRAULIC SYSTEM 13. Disconnect the safety switch from the wire harness (Fig. 0873). 15. Lift the valve out of the frame (Fig. 0875). Fig 0875 Fig 0873 14. Using a 1/2” socket and wrench, remove the 2 auxiliary valve mounting bolts and nuts (Fig. 0874). Fig 0874 6-12 PICT-4913a PICT-4910 16. Using two 7/16” wrenches, remove the top nut and washer securing the handle to the hiflo spacer (Fig. 0876). PICT-4912 Rev.
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HYDRAULIC SYSTEM 17. Remove the handle from the hiflo spacer (Fig. 0877). Fig 0877 19. Using a 7/16” wrench, remove the spacer from the valve cap screw (Fig. 0879). PICT-1774a Fig 0879 18. Rotate the spring and remove it from the hiflo spacer (Fig. 0878). Fig 0878 20. Using a 1/2” wrench, remove the screw from the valve cap (Fig. 0880). PICT-1775a Fig 0880 TX525 Service Manual PICT-1777a Rev.
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HYDRAULIC SYSTEM 21. Using a 7/8” wrench, remove the switch from valve (Fig. 0881). Auxiliary Valve Installation Note: Replace o-ring on the switch. 1. Using a 7/8” wrench, install the switch into the valve (Fig. 0883). Fig 0881 PICT-1780a 22. If the valve is to be rebuilt, refer to “Auxiliary Valve Rebuild” on page 6-57. Fig 0883 PICT-1780a 2. Use a 1/2” wrench, thread the spacer mounting bolt into the valve cap (Fig. 0884). 23.
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HYDRAULIC SYSTEM 5. Slide the spring over the hiflo spacer and hook the spring under valve cap screw (Fig. 0887). 3. Apply thread locking compound to the spacer mounting bolt (Fig. 0885). Fig 0885 4. Using a 7/16” wrench, install the hiflo spacer onto valve cap bolt (Fig. 0886). Fig 0886 TX525 Service Manual Fig 0887 PICT-4916a PICT-1775a 6. Install the handle onto the hiflo spacer and hook the spring onto the handle (Fig. 0888). PICT-1777a Rev.
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HYDRAULIC SYSTEM 7. Using two 7/16” wrenches, install the top washer and nut securing the handle to the hiflo spacer (Fig. 0889). Fig 0889 6-16 Fig 0891 PICT-1779a PICT-4912 10. Plug the safety switch into the wire harness (Fig. 0892). 8. Lower the valve into the frame (Fig. 0890). Fig 0890 9. Using a 1/2” socket and wrench, install 2 mounting bolts and nuts securing the valve to the control panel frame (Fig. 0891). PICT-4913a Rev.
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HYDRAULIC SYSTEM 11. Remove the protective caps from the hydraulic lines and fittings. 12. Using a 1-1/8” wrench, install the hydraulic line marked with a D to the valve fitting marked with a D (Fig. 0893). 14. Using a 15/16” wrench, install hydraulic line nut marked with a B onto the valve fitting marked with a B (Fig. 0895). Fig 0895 Fig 0893 PICT-4909 13. Using a 15/16” wrench, install the hydraulic line nut marked with a C onto the valve fitting marked with a C (Fig. 0894). 15.
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HYDRAULIC SYSTEM 16. Disengage the park brake and start the unit. Follow the procedures for “Purging Air Procedure” on page 9-19. Check for any leaks at the hydraulic fittings and in the hydraulic hoses. 20. Position the left side support panel. Using a 3/8” socket, install 3 screws securing the left side support panel to the tower assembly (Fig. 0899). 17. If a new valve has been installed, perform a pressure test. Refer to “Auxiliary Circuit Pressure Test” on page 9-4. 18.
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HYDRAULIC SYSTEM 22. Using a 3/8” socket, install 4 screws securing the top left panel to the control panel (Fig. 0901). Tandem Pump / Engine Coupling Assembly Replacement Coupling Removal 1. Remove the Hydraulic Tandem Pump. Refer to “Hydraulic Tandem Pump Removal” on page 6-30. 2. Raise the hood and remove the left side grill (Fig. 0903). Fig 0901 PICT-4600 23. Install the rear access panel (Fig. 0902). Fig 0903 Fig 0902 TX525 Service Manual PICT-6962a PICT-4505a Rev.
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HYDRAULIC SYSTEM 3. Secure the flywheel to keep it from turning. You can do this by sliding a length of 5/16” diameter rod stock in between the fan mount pulley and fan mount spacer. The rod stock should be inserted so it runs on top of the fan mount pulley screw. The rod stock should be at least 16” long so that it rests on the left hand loader arm lift cylinder (Fig. 0904). 5. Remove the hub sleeve (Fig. 0906). Fig 0906 PICT-4828a Coupling Installation Fig 0904 PICT-4840 1.
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HYDRAULIC SYSTEM 2. Secure the flywheel to keep it from turning. You can do this by sliding a length of 5/16” diameter rod stock in between the fan mount pulley and fan mount spacer. The rod stock should be inserted so it runs on top of the fan mount pulley screw. The rod stock should be at least 16” long so that it rests on the left hand loader arm lift cylinder (Fig. 0908). 4. Install 4 bolts securing the hub sleeve to the flywheel (Fig. 0910). Fig 0910 Fig 0908 PICT-4840 PICT-4863 5.
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HYDRAULIC SYSTEM Hydraulic Oil Filter Head Replacement Note: Cleanliness is a key factor in a successful repair of any hydraulic system. Thoroughly clean all exposed surfaces prior to any type of maintenance. Cleaning all parts by using a solvent wash and air drying is usually adequate. As with any precision equipment, all parts must be kept free of foreign material and chemicals. Protect all exposed sealing areas and open cavities from damage and foreign material. 4.
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HYDRAULIC SYSTEM 6. Using a 15/16” wrench, remove the hydrostatic pump return line from the T-fitting on the right hand pump (Fig. 0915). Fig 0915 8. Using a 3/8” socket, remove the 3 screws that secure the right rear cover support panel to the tower assembly. Remove the panel (Fig. 0917). PICT-4922 7. Remove the rear access panel (Fig. 0916). Fig 0917 PICT-4504 9. Place absorbent cloth over the battery area to soak up the hydraulic fluid that will drain from the filter and filter head. 10.
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HYDRAULIC SYSTEM 11. Using a 1-3/8” wrench, remove the hydraulic reservoir return line from the filter head T-fitting (Fig. 0919). Fig 0919 13. Using a 1/2” wrench, remove the 2 bolts and washers securing the filter head to the mounting bracket (Fig. 0921). Fig 0921 PICT-4919 14. Remove the filter head assembly (Fig. 0922). 12. Using a 15/16” wrench, remove the loader valve hydraulic return line from the filter head fitting (Fig. 0920). Fig 0922 Fig 0920 6-24 PICT-4924a PICT-4926a PICT-4923 Rev.
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HYDRAULIC SYSTEM 15. Place the filter head assembly in a vise to secure. 16. Using a 1-3/8” wrench, loosen the T-fitting nut from the filter head. Remove the T-fitting and hydraulic line (Fig. 0923). Fig 0923 18. Inspect the bypass, filter threads, and gasket sealing surface. The bypass should move freely in and out. The filter threads and sealing surface should be free of damage. Replace the filter head if damaged (Fig. 0925). PICT-4927a Fig 0925 PICT-4930a Hydraulic Oil Filter Head Installation 17.
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HYDRAULIC SYSTEM 3. Thread the T-fitting into the filter head – leave the fitting nut loose (Fig. 0927). Fig 0927 5. Install 2 bolts and washers securing the filter head assembly to the mounting bracket (Fig. 0929). 4. Position the filter head assembly into the machine so that the flow arrow points toward the front of the machine (Fig. 0928). Fig 0928 6-26 Fig 0929 PICT-4938a PICT-4924a 6. Using a 15/16” wrench, install the loader valve hydraulic return line to the filter head (Fig. 0930).
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HYDRAULIC SYSTEM 7. Using a 1-3/8” wrench, install the hydraulic reservoir return line to the filter head T-fitting (Fig. 0931). Fig 0931 9. Using a 1-3/8” wrench, tighten the T-fitting nut securing the T-fitting to the filter head assembly (Fig. 0933). PICT-4919 Fig 0933 8. Using a 15/16” wrench, install the hydrostatic pump return line to the T-fitting on the right hand pump (Fig. 0932). Fig 0932 TX525 Service Manual PICT-4941 10.
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HYDRAULIC SYSTEM 11. Install the new hydraulic oil filter onto the filter head: Turn the filter until the gasket contacts the filter head then tighten an additional 3/4 turn (Fig. 0935). 13. Using a 3/8” socket, install 3 self-tapping screws that secure the right panel to the control panel assembly. Using a 3/8” socket and a 7/16” socket, install a bolt and nut securing the lower left corner of the right panel to the control panel assembly (Fig. 0937). A A B Fig 0935 A PICT-4943a Fig 0937 A.
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HYDRAULIC SYSTEM 15. Install the knob onto the brake handle (Fig. 0939). Fig 0939 18. Install the rear access panel (Fig. 0941). PICT-4342 16. Purge air from the hydraulic system. Refer to “Purging Air Procedure”, page 9-19. Check for any leaks in the hydraulic fittings and hydraulic hoses. Fig 0941 PICT-4505 19. Lower the machine. 17. Position the right hand rear cover support panel to the tower.
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HYDRAULIC SYSTEM Hydraulic Tandem Pump Replacement 3. Using a 3/8” socket, remove the 6 screws that secure the left and right rear cover support panels to the tower assembly (3 screws per panel). Remove the panels (Fig. 0943). Hydraulic Tandem Pump Removal 1. Raise the machine and set it on jack stands. Refer to “Lifting the Machine for Service” on page 7-1. 2. Remove the rear access panel (Fig. 0942). Fig 0943 Fig 0942 PICT-4505 PICT-4256 4.
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HYDRAULIC SYSTEM 5. Disconnect the two wires (black and orange) from the fuel sending unit located on the top of the fuel tank (Fig. 0945). 7. Slide the 2 fuel hose clamps down the fuel line away from the fuel tank fittings (Fig. 0947). Fig 0947 Fig 0945 6. Mark the suction fuel line and tank fitting with an “S” and the return fuel line and tank fitting with an “R” (Fig. 0946): S - Fuel suction line R - Fuel return line 8. Slide the 2 fuel lines off the fuel tank fittings. Remove the fuel tank.
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HYDRAULIC SYSTEM 9. Mark the tandem pump lines and fittings as follows: A. Pump pressure line to loader valve (Fig. 0949) Fig 0949 C. Suction line from the tank (smaller fitting) D. Suction line from the tank (larger fitting) (Fig. 0951) PICT-4765 Fig 0951 B. Pump pressure line to auxiliary valve (Fig. 0950) Fig 0950 10. Using a 15/16” wrench, remove the pump pressure line marked with an A from the hydraulic tandem pump (Fig. 0952). PICT-4766a Fig 0952 6-32 PICT-4767 Rev.
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HYDRAULIC SYSTEM 11. Using a 1-1/8” wrench, remove the pump pressure line marked with a B from the hydraulic tandem pump (Fig. 0953). 13. Slide the suction hoses, marked C and D, off the suction fittings (Fig. 0955). Fig 0955 Fig 0953 14. Loosen the pump pressure line fittings: 12. Loosen the two suction hose clamps (Fig. 0954). Fig 0954 15. Pump pressure line fitting marked A using a 15/16” wrench (Fig. 0956). PICT-4773a Fig 0956 TX525 Service Manual PICT-4775a PICT-4770a Rev.
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HYDRAULIC SYSTEM 16. Pump pressure line fitting marked B using a 1-1/8” wrench (Fig. 0957). Fig 0957 18. Suction hose fitting marked D using a 1-1/4” wrench (Fig. 0959). Fig 0959 PICT-4783a 17. Suction hose fitting marked C using a 1” wrench (Fig. 0958). PICT-4785a 19. Using a 5/8” socket, remove the 2 bolts securing the pump mount plate to the pump mount (Fig. 0960). Note: Support the pump as the 2 bolts are being removed. Fig 0958 PICT-4784a Fig 0960 6-34 Rev.
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HYDRAULIC SYSTEM 20. Remove the pump assembly (Fig. 0961). Fig 0961 22. Using a 1/8” Allen wrench, loosen the set screw securing the coupler gear to the pump shaft (Fig. 0963). PICT-4779a Fig 0963 21. The coupler sleeve may come off with the pump, or stay on the engine side of the coupler. Remove the coupler sleeve (Fig. 0962). Fig 0962 23. Remove the key from the pump shaft keyway (Fig. 0964). PICT-4781a Fig 0964 TX525 Service Manual PICT-4786a Rev.
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HYDRAULIC SYSTEM 24. Using a 5/8” wrench and a 11/16” socket, remove the 2 bolts and nuts securing the pump mount plate to the pump (Fig. 0965). 26. Inspect the pump shaft coupler gear, the coupler sleeve and the crankshaft coupler gear. Replace if worn or damaged (Fig. 0967, Fig. 0968 and Fig. 0969). Pump shaft coupler gear: Fig 0965 PICT-4789a 25. Remove the pump mount plate (Fig. 0966). Fig 0967 PICT-4796a Fig 0968 PICT-4797a Coupler sleeve: Fig 0966 6-36 PICT-4792a Rev.
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HYDRAULIC SYSTEM Hydraulic Tandem Pump Installation Crankshaft coupler gear: 1. Slide the plate onto the tandem pump (Fig. 0971). Note: Shoulder on pump plate faces away from pump. Fig 0969 PICT-4798 27. If the engine side of the coupling is damaged, re move it and replace it. Refer to “Tandem Pump / Engine Coupling Assembly Replacement” on page 6-19. Fig 0971 28. For tandem pump rebuild procedures, see “Hydraulic Tandem Pump Rebuild” on page 6-42. 29.
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HYDRAULIC SYSTEM 3. Apply anti-seize compound to the pump shaft (Fig. 0973). Fig 0973 5. Slide the coupler gear onto the pump shaft so that it seats against the shoulder on the shaft (Fig. 0975). 4. Install the key into the pump shaft keyway (Fig. 0974). Fig 0974 Fig 0975 PICT-4806 6. Using a 1/8” Allen wrench, tighten the set screw securing the coupler gear to the pump shaft (Fig. 0976). PICT-4808 Fig 0976 6-38 PICT-4811 Rev.
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HYDRAULIC SYSTEM 7. Slide the coupler sleeve onto the engine side of the coupler gear (Fig. 0977). Fig 0977 9. Install the tandem pump hoses as follows: a. Slide the suction hoses onto the suction fittings (Fig. 0979). PICT-4870a Fig 0979 8. Position the tandem pump to the engine. Insert the coupler gear into the white coupler sleeve. Using a 5/8” socket, install 2 bolts to secure the pump plate to the pump mounting plate (Fig. 0978).
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HYDRAULIC SYSTEM c. Using a 1-1/8” wrench, install the pump pressure line (marked B) to the pump fitting marked B (Fig. 0981). 10. Slide the 2 fuel lines onto the fuel tank fittings. Note the location markings (Fig. 0983). S - Fuel suction line R - Fuel return line Note: Before installing the fuel tank in the unit, disengage the park brake and start the unit. Refer to “Purging Air Procedure” on page 9-19. Check for any leaks at the hydraulic fittings and hoses. Fig 0981 PICT-4770a d.
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HYDRAULIC SYSTEM 11. Position the 2 fuel hose clamps and tighten to secure the fuel lines to the fuel tank fittings (Fig. 0984). 13. Position the rear frame cover to the rear of the frame. Using 3/4” and 1/2” sockets, install 7 bolts and nuts to secure the rear frame cover to the frame and fuel tank bracket (Fig. 0986). Note: The rear of the machine may have to be lifted to reposition the jack stands so that the rear frame cover can be installed. Fig 0984 PICT-4264 12.
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HYDRAULIC SYSTEM Hydraulic Tandem Pump Rebuild 15. Install the rear access panel (Fig. 0988). Note: Cleanliness is a key factor in a successful repair of any hydraulic system. Thoroughly clean all exposed surfaces prior to any type of maintenance. Cleaning all parts by using a solvent wash and air drying is usually adequate. As with any precision equipment, all parts must be kept free of foreign material and chemicals. Protect all exposed sealing areas and open cavities from damage and foreign material.
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HYDRAULIC SYSTEM 2. Secure the pump in a vise. 3. Mark the casing of the pump with a “V” that crosses over all sections of the pump (Fig. 0990). 5. Remove the cover from the pump assembly (Fig. 0992). Fig 0992 Fig 0990 PICT-2824a 4. Using a 7mm Allen wrench, loosen and remove the 4 bolts and washers securing the pump sections (Fig. 0991). 6. Remove the cap gasket from the pump housing (Fig. 0993). Fig 0993 Fig 0991 TX525 Service Manual PICT-2826a PICT-2828 PICT-2825a Rev.
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HYDRAULIC SYSTEM 6 gpm Pump Disassembly 3. Remove the driven gear from the pump assembly (Fig. 0996). 1. Mark the bushing assembly with a single line that extends out onto the pump housing (Fig. 0994). Fig 0996 Fig 0994 PICT-2832a PICT-2829 4. Remove the drive gear from the pump assembly (Fig. 0997). 2. Using a needle nose pliers, grab the center of the small bushing and lift the bushing from the pump housing assembly (Fig. 0995). Fig 0997 Fig 0995 6-44 PICT-2833a PICT-2830a Rev.
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HYDRAULIC SYSTEM 5. Using a needle nose pliers grab the center of the inner small bushing and lift it partially out of the pump housing (Fig. 0998). 7. Lift the inner small bushing out of the pump housing (Fig. 1000). Fig 1000 Fig 0998 14 gpm Pump Disassembly 6. 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. 0999). Fig 0999 TX525 Service Manual PICT-2836 PICT-2834a 1.
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HYDRAULIC SYSTEM 2. Remove the o-ring from the housing (Fig. 1002). Fig 1002 4. Mark the large pump bushing assembly with a “V” all the way down onto the pump shaft cover (Fig. 1004). PICT-2882a Fig 1004 3. Remove the drive link from the drive gear (Fig. 1003). Fig 1003 5. Remove the large pump bushing assembly from the pump shaft cover (Fig. 1005). PICT-2839a Fig 1005 6-46 PICT-2840 Rev.
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HYDRAULIC SYSTEM 6. Using a snap ring pliers, remove the snap ring from the pump cover (Fig. 1006). Fig 1006 8. 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. 1008). PICT-2842a Fig 1008 7. 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. 1007). Fig 1007 TX525 Service Manual PICT-2844a 9.
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HYDRAULIC SYSTEM 10. Install the snap ring into the pump cover (Fig. 1010). Fig 1010 2. Remove the driven gear from the bushing (Fig. 1012). PICT-2848a Fig 1012 14 gpm Pump Assembly PICT-2850a 3. Remove the drive gear from the bushing (Fig. 1013). Note: Lubricate all surfaces on reassembly. 1. Remove the bushing from the drive gear and driven gear shafts (Fig. 1011). Fig 1013 Fig 1011 6-48 PICT-2851a PICT-2849a Rev.
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HYDRAULIC SYSTEM 4. Inspect the gear surface of both of the bushings for damage (Fig. 1014). Fig 1014 PICT-2853a 5. Inspect the drive gear and driven gear surfaces for damage (Fig. 1015). Fig 1015 TX525 Service Manual 6. Remove the back-up ring from the top and bottom bushings (Fig. 1016). Fig 1016 PICT-2855a 7. Remove the gear seal from the top and bottom bushings (Fig. 1017). PICT-2854a Rev.
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HYDRAULIC SYSTEM 8. Install the gear seal with the lip side of the gasket facing away from the groove of the bushing (Fig. 1018). Fig 1018 10. Repeat the previous 2 steps for the second bushing, gear seal and back-up ring. 11. Making note of the markings on the bushing assembly, install the drive gear into the bushing (Fig. 1020). PICT-2861 Fig 1020 9. Install the back-up ring into the bushing so that it rests in the lip of the gear seal (Fig. 1019). PICT-2863a 12.
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HYDRAULIC SYSTEM 13. Install the second bushing onto the 2 gears (Fig. 1022). Fig 1022 2. Remove the driven gear (Fig. 1024). Fig 1024 PICT-2865a PICT-2867a 3. Remove the drive gear (Fig. 1025). 6 gpm Pump Assembly Note: Lubricate all surfaces on reassembly. 1. Remove one of the bushings (Fig. 1023). Fig 1025 Fig 1023 TX525 Service Manual PICT-2868a PICT-2866a Rev.
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HYDRAULIC SYSTEM 4. Inspect the gear surfaces of both the bushings for damage (Fig. 1026). Fig 1026 6. Remove the back-up ring from both of the bushings (Fig. 1028). 5. Inspect the drive and driven gears for damage (Fig. 1027). Fig 1027 6-52 Fig 1028 PICT-2870a PICT-2874a 7. Remove the gear seal from the both of the bushings (Fig. 1029). PICT-2876a Rev.
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HYDRAULIC SYSTEM 8. Install the gear seal with the lip side of the gasket facing away from the groove of the bushing (Fig. 1030). Fig 1030 10. Repeat the above 2 steps for the second bushing, gear seal and back-up ring. 11. Making note of the markings on the bushing assembly, install the drive gear into the bushing (Fig. 1032). PICT-2877a Fig 1032 9. Install the back-up ring into the bushing so that it rests in the lip of the gear seal (Fig. 1031). PICT-2879a 12.
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HYDRAULIC SYSTEM Hydraulic Tandem Pump Assembly 13. Install the second bushing onto the 2 gears (Fig. 1034). 1. Making note of the marks on the 14 gpm pump, slide the drive gear shaft of the 14 gpm pump assembly onto the mounting flange (Fig. 1036). Fig 1034 PICT-2881a Fig 1036 14. Inspect the drive link for damage (Fig. 1035). PICT-2885a 2. Install the drive link onto the drive gear of the 14 gpm pump assembly (Fig. 1037). Fig 1035 PICT-2884a Fig 1037 6-54 Rev.
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HYDRAULIC SYSTEM 3. Install the mounting flange o-ring into the housing groove (Fig. 1038). 5. Making note of the markings on the 6 gpm pump assembly, slide the 6 gpm pump assembly into the housing (Fig. 1040). Note: The pump shaft may have to be rotated to seat the 6 gpm pump onto the drive link. Fig 1038 PICT-2882a 4. Making note of the markings on the housing and mounting flange, install the pump housing over the 14 gpm pump assembly and onto the mounting flange (Fig. 1039). Fig 1039 Fig 1040 6.
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HYDRAULIC SYSTEM 7. Install the housing cover onto the housing (Fig. 1042). Fig 1042 9. Install the key into the keyway on the pump shaft (Fig. 1044). PICT-2895a Fig 1044 PICT-2898a 8. Using a 7mm Allen wrench, install the 4 bolts that secure the housing cover to the housing (Fig. 1043). Torque to 19 - 23 ft-lbs. (25.8 - 31.2 Nm). Fig 1043 6-56 PICT-2896a Rev.
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HYDRAULIC SYSTEM Auxiliary Valve Rebuild 1. Using a 7/8” wrench, remove the safety switch from the valve (Fig. 1046). Note: Cleanliness is a key factor in a successful repair of any valve system. Thoroughly clean all exposed surfaces prior to any type of maintenance. Cleaning all parts by using a solvent wash and air drying is usually adequate. As with any precision equipment, all parts must be kept free of foreign material and chemicals.
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HYDRAULIC SYSTEM 3. Remove the return spring cap (Fig. 1048). Fig 1048 6. While compressing the steel ball, slowly slide the steel collar up off the detent spring assembly (Fig. 1050). PICT-2679a Fig 1050 4. Clamp the auxiliary valve in a vise to secure in place. 5. Using a punch, compress the steel ball in the detent assembly (Fig. 1049). 7. Using a magnet, remove the 4 small steel balls from the spring retainer (Fig. 1051). Fig 1051 Fig 1049 6-58 PICT-2681a PICT-2683a PICT-2680a Rev.
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HYDRAULIC SYSTEM 8. Using a magnet, remove the large ball from the spring retainer (Fig. 1052). Fig 1052 10. Remove the spring retainer block from the valve (Fig. 1054). PICT-2684a 9. Remove the spring from inside the spring retainer (Fig. 1053). Fig 1053 TX525 Service Manual Fig 1054 PICT-2686a 11. Using a 13mm wrench, loosen the spring retainer from the valve (Fig. 1055). PICT-2685a Rev.
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HYDRAULIC SYSTEM 12. Remove the spring retainer from the valve assembly (Fig. 1056). Fig 1056 PICT-2688a 13. Remove the spring and retainers from the valve (Fig. 1057). Fig 1057 6-60 14. Using a 4mm Allen wrench, remove 2 screws from the switch block assembly (Fig. 1058). Fig 1058 PICT-2690a 15. Remove the switch block from the valve assembly (Fig. 1059). PICT-2689a Rev.
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HYDRAULIC SYSTEM 16. Using a 19mm wrench, loosen the relief (Fig. 1060). Fig 1060 19. Remove the operator lever block from the valve assembly (Fig. 1062). PICT-2693a Fig 1062 17. Remove the valve from the vise. 18. Using a 4mm Allen wrench, remove the 2 screws retaining the operator lever spool cap from the valve (Fig. 1061). 20. Remove the gasket from the valve assembly (Fig. 1063). Fig 1063 Fig 1061 TX525 Service Manual PICT-2741a PICT-2740 PICT-2694 Rev.
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HYDRAULIC SYSTEM 21. Remove the spool from the valve assembly (Fig. 1064). 23. Using a 19mm wrench, continue loosening the relief (Fig. 1066). Note: Inspect the spool and valve body bore. Replace the auxiliary valve assembly if damaged or there are scratches deep enough to catch a fingernail. Fig 1066 Fig 1064 PICT-2696a PICT-2699a 24. Remove the relief from the valve (Fig. 1067). 22. Remove both spool o-rings from the valve body (Fig. 1065). Fig 1067 Fig 1065 6-62 PICT-2700a PICT-2697 Rev.
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HYDRAULIC SYSTEM 25. Remove the seat from the relief port (Fig. 1068). Fig 1068 27. Remove the adjusting screw from the relief barrel (Fig. 1070). PICT-2702a Fig 1070 26. Using a 4mm Allen wrench and a 13mm wrench, loosen the adjusting screw from the relief (Fig. 1069). PICT-2704a 28. Using a punch, push the plunger out of the relief barrel (Fig. 1071).
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HYDRAULIC SYSTEM Spool Assembly 29. Remove the plunger from the relief (Fig. 1072). AB D G H I J CE F PICT-2706a Relief Assembly B A C D Adjusting screw & nut Body Body O-ring Plunger E. F. G. H. Spring cap screws Spring cap Detent collar Detent balls Detent plunger Spring block Spring & retainers Switch block screws I. J. K. L. M. N. O. P. Switch block Spool O-ring Valve body Spool O-ring Spool Handle cap Handle cap screws Detent switch 1.
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HYDRAULIC SYSTEM 2. Lubricate the spool and o-rings with oil. Install the spool into the valve body. Turning the spool as it is being installed to prevent o-ring damage (Fig. 1076). 4. Install the two threaded screws into the switch block and tighten with 4mm Allen wrench (Fig. 1078). Fig 1078 Fig 1076 3. Place the valve into a vise. Install the switch block to the valve assembly. The thicker offset on the switch block is assembled toward the valve (Fig. 1077). 5.
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HYDRAULIC SYSTEM 6. Install and thread the spring retainer into the spool (Fig. 1080). 8. Position the spring block over the spring (Fig. 1082). Fig 1082 Fig 1080 7. Place a punch into the spool opening and tighten the spring retainer with a 13mm wrench (Fig. 1081). 9. Place the spring into the spring retainer (Fig. 1083). Fig 1083 Fig 1081 6-66 PICT-2729a PICT-2715a PICT-2732a PICT-2716a Rev.
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HYDRAULIC SYSTEM 10. Place a small amount of grease to the center opening of the spring retainer (Fig. 1084). Fig 1084 TX525 Service Manual Fig 1086 PICT-2730a 11. Place a small amount of grease at each of the outer openings of the spring retainer (Fig. 1085). Fig 1085 12. Place the steel collar over a punch with the shoulder of the collar downward (Fig. 1086). PICT-2726a 13. Install the steel ball into the center retainer opening and onto the spring (Fig. 1087). PICT-2731a Rev.
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HYDRAULIC SYSTEM 14. Hold the steel collar onto the punch and push down on the center ball with the punch until the center ball is below the four holes in the spring retainer (Fig. 1088). 16. Slide the steel collar over the spring retainer and slowly release the pressure from the center ball (Fig. 1090). Fig 1090 Fig 1088 17. Install the spring cap with the 2 screws by pushing down on the cap and evenly threading and tightening the two screws with a 4mm Allen wrench (Fig. 1091). 15.
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HYDRAULIC SYSTEM 18. Remove the valve from the vise. Grease the swivel ball in the handle cap (Fig. 1092). Fig 1092 20. Place the handle cap onto the spool gasket. Make sure the swivel ball in the cap is placed in the opening of the spool (Fig. 1094). PICT-2739 Fig 1094 19. Place the gasket onto the valve body (Fig. 1093). Fig 1093 21. Install the two bolts to secure the handle cap onto the valve. Tighten the bolts using a 4mm Allen wrench (Fig. 1095).
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HYDRAULIC SYSTEM 22. Lubricate the plunger and then slide the plunger into the relief body (Fig. 1096). Fig 1096 PICT-2744a 23. Slide the spring onto the plunger in the relief body (Fig. 1097). Fig 1097 6-70 24. Slide the steel plunger into the relief body (Fig. 1098). Fig 1098 PICT-2748a 25. Slide the steel plunger cap onto the plunger in the relief body (Fig. 1099). PICT-2745a Rev.
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HYDRAULIC SYSTEM 26. Thread the adjusting screw and nut into the top of the relief body (Fig. 1100). Fig 1100 28. Tighten the relief assembly using a 19mm wrench (Fig. 1102). PICT-2752 27. Thread the relief assembly into the valve body (Fig. 1101). Fig 1101 TX525 Service Manual Fig 1102 PICT-2756a 29. Thread the safety switch into the switch block. Tighten using a 7/8” wrench (Fig. 1103). PICT-2755a Rev.
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HYDRAULIC SYSTEM Loader Valve Rebuild 1. Remove the cable tie from around the rubber bellows (Fig. 1105). 1. Before disassembly of any hydraulic component, use a clean, dirt-free work surface and clean solvent to prevent system contamination (Fig. 1104). A B C D E Fig 1104 A. Rubber Bellows B. System relief C. Work port relief (2) Fig 1105 PICT-2583 D. Spring Cap E. Detent spring cap 2. Remove the rubber bellows from the valve assembly (Fig. 1106). Wipe the excess grease from the joystick.
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HYDRAULIC SYSTEM 3. Using a 6mm Allen wrench, loosen the 3 hex head screws and spring lock washers (Fig. 1107). 5. Pictured below are the joystick joints (Fig. 1109). B A C Fig 1109 Fig 1107 PICT-2591a 4. Remove the articulated holder, screws and washers from the valve assembly (Fig. 1108). PICT-2593a A. Tilt Cylinder operation B. Loader Lift Cylinder operation C. Pivot for Lift and Tilt operation 6. Slide the end rod off the pin of the joystick joint for the tilt cylinder (Fig. 1110).
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HYDRAULIC SYSTEM 7. Using a 13mm socket and wrench, remove the nut holding the joystick joint and then remove the pivot for the lift and tilt operation (Fig. 1111). 9. Remove the joystick pivot from the valve assembly (Fig. 1113). Fig 1113 Fig 1111 8. Turn the loader lift joystick joint. Using a 3mm Allen wrench, remove the 2 hex head screws securing the joystick pivot to the valve assembly (Fig. 1112). Fig 1112 Joystick Assembly Installation 1.
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HYDRAULIC SYSTEM 2. Position the joystick pivot on the valve assembly (Fig. 1115). Fig 1115 4. Position the lift and tilt joystick joint onto the pivot and install the nut (Fig. 1117). PICT-2598a 3. Using a 3mm Allen wrench, install the 2 hex head screws that secure the joystick pivot (Fig. 1116). Fig 1116 Fig 1117 5. Using a 13mm wrench and socket, tighten the nut securing the joystick joint to the pivot for the lift and tilt operation (Fig. 1118).
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HYDRAULIC SYSTEM 6. Slide the end of the joystick joint onto the pin for the tilt cylinder (Fig. 1119). 8. Torque the 3 bolts to 17.7 ft-lbs. (24 Nm) (Fig. 1121). Fig 1121 Fig 1119 9. Lubricate all of the articulated parts inside the mechanical joystick area with synthetic base grease grade NLGI2 (Fig. 1122). 7. Position the articulated holder with 3 hex head screws and lock washers onto the valve assembly and thread the 3 bolts onto the joystick joints (Fig. 1120).
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HYDRAULIC SYSTEM Spool Removal 10. Position the rubber bellows over the base plate and install the tie strap in the groove of the rubber bellows (Fig. 1123). Note: To disassemble and assemble the valve, it is best to hold the valve in a bench vise. Note: When installing the rubber bellows, there is an offset in the bellows. Ensure proper installation. Fig 1123 1. Remove the cable tie from around the rubber bellows (Fig. 1125). PICT-2605a 11. Install the lift/tilt handle (Fig. 1124).
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HYDRAULIC SYSTEM 3. Using a 6mm Allen wrench, loosen the 3 hex head screws and spring lock washers (Fig. 1127). 5. Pictured below are the joystick joints (Fig. 1129). B A C Fig 1129 Fig 1127 PICT-2591a PICT-2593a A. Tilt Cylinder operation B. Loader Lift Cylinder operation C. Pivot for Lift and Tilt operation 4. Remove the articulated holder, screws and washers from the valve assembly (Fig. 1128). 6. Slide the end rod off the pin of the joystick joint for the tilt cylinder (Fig. 1130).
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HYDRAULIC SYSTEM 7. Using a 13mm socket and wrench, remove the nut securing the joystick pin and then remove the pin (Fig. 1131). Fig 1131 9. Turn the lift pivot. Using a 13mm socket and wrench, remove the nut holding the joystick pivot joint and then remove the joint from the lift and tilt spool (Fig. 1133). PICT-2607a Fig 1133 8. Using a 13mm socket and wrench, remove the nut holding the joystick pivot joint and then remove the pivot for the lift and tilt operation (Fig. 1132). Fig 1132 10.
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HYDRAULIC SYSTEM 11. Using a 4mm Allen wrench, remove the 2 hex head bolts that secure the joystick base plate to the valve assembly (Fig. 1135). 13. Remove the gasket from the valve (Fig. 1137). Fig 1137 Fig 1135 PICT-2612 14. Turn the valve assembly over. Using a 4mm Allen wrench, remove the two hex head bolts that secure each spring cap to the valve assembly (Fig. 1138). 12. Remove the joystick base plate from the valve assembly (Fig. 1136).
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HYDRAULIC SYSTEM 15. Remove both caps from the valve assembly (Fig. 1139). Fig 1139 17. Remove the detent spring from the valve assembly (Fig. 1141). 16. Using a drift punch to hold the top end of the spool, use a 6mm wrench to remove the detent spring assembly from the bottom of the spool (Fig. 1140). Fig 1140 TX525 Service Manual Fig 1141 PICT-2616 PICT-2618a 18.
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HYDRAULIC SYSTEM Before replacing the spool, clean and inspect the inner bore for damage. Check the condition of the o-rings, particularly for metallic particles embedded in the o-ring surface. Damage to o-ring grooves, particularly on the sealing surface, is unacceptable. In the event that an unacceptable condition occurs, the valve needs to be replaced (Fig. 1145). 19. Turn the valve in the vise sideways. Remove the tilt spool by twisting and pulling the spool from the top of the valve (Fig. 1143).
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HYDRAULIC SYSTEM 22. Remove the two o-rings located at the bottom of the valve; a small dental pick works to help remove the o-rings (Fig. 1147). 1. Lubricate the two o-rings located at the bottom of the valve and install (Fig. 1149). Fig 1149 Fig 1147 2. Lubricate and install the spool valve seals in the top of the valve (Fig. 1150). Spool Assembly Replace all seals and o-rings with new parts. Lubricate the valve, o-rings, and spool with 10W-30 oil prior to installation (Fig. 1148).
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HYDRAULIC SYSTEM 3. Lubricate the tilt spool. Install the spool in the port furthest away from the relief; twist and push gently, so you do not damage the o-ring (Fig. 1151). 5. Install the spring valve assembly with a 5mm hex wrench and torque to 5 ft-lbs. (6.8 Nm) (Fig. 1153). Fig 1153 Fig 1151 4. Lubricate and install the lift spool in the port closest to the relief, twist and push gently, so you do not damage the o-ring (Fig. 1152). 6.
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HYDRAULIC SYSTEM 7. Install the detent spring assembly and torque to 5 ft-lbs. (6.8 Nm) (Fig. 1155). Fig 1155 9. Install the spool caps over the detent and spring valve (Fig. 1157). TX525 Service Manual PICT-2639 10. Tighten and torque the cap screws to 5 ft-lbs. (6.8 Nm) (Fig. 1158). 8. Lubricate the spring with synthetic base grease grade NLGI2 (Fig. 1156). Fig 1156 Fig 1157 PICT-2637 PICT-2638 Rev.
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HYDRAULIC SYSTEM 11. Rotate the valve in the bench vise. Install the gasket over the spools and onto the valve assembly (Fig. 1159). 13. Secure the base plate with 2 cap screws and tighten using a 4mm Allen wrench (Fig. 1161). Fig 1161 Fig 1159 PICT-2641a 12. Position the joystick base plate over the spools and onto the gasket (Fig. 1160). 14. Apply thread locking compound to the 2 screws that will secure the pivot to the valve (Fig. 1162).
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HYDRAULIC SYSTEM 15. Position the pivot onto the base plate and install the 2 screws, using a 3mm Allen wrench, to secure the pivot to the base plate. Torque the 2 screws to 7 ftlbs. (9.5 Nm) (Fig. 1163). 17. Position the loader lift joystick joint into the lift spool and install the nut. Torque the nut to 31 ft-lbs. (42 Nm) (Fig. 1165). Fig 1165 Fig 1163 16. Apply thread locking compound to the threads of the loader lift joystick joint (Fig. 1164). 18.
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HYDRAULIC SYSTEM 19. Position the pivot joystick joint into the pivot and install the nut. Torque the nut to 31 ft-lbs. (42 Nm) (Fig. 1167). 21. Position the joint pin into the tilt spool and install the nut. Torque the nut to 31 ft-lbs. (42 Nm) (Fig. 1169). Fig 1169 Fig 1167 20. Apply blue thread locking material to the threads of the joystick pin (Fig. 1168). 22. Install the end rod onto the joystick pin (Fig. 1170). Fig 1170 Fig 1168 6-88 PICT-2653a PICT-2651a PICT-2654 PICT-2652a Rev.
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HYDRAULIC SYSTEM 23. Position the articulated holder with 3 hex head screws and lock washers onto the valve assembly and thread the 3 bolts onto the joystick joints (Fig. 1171). 25. Lubricate all of the articulated parts inside the mechanical joystick area with synthetic base grease grade NLGI2 (Fig. 1173). Fig 1173 Fig 1171 PICT-2655 PICT-2602a 24. Torque the 3 bolts to 17.7 ft-lbs. (24 Nm) (Fig. 1172). 26.
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HYDRAULIC SYSTEM 27. Install the lift/tilt handle (Fig. 1175). Fig 1175 2. Using a 24mm wrench, remove the main relief valve from the valve assembly (Fig. 1177). PICT-2584a Fig 1177 Main Relief Valve Pressure relief is designed to prevent internal fluid pressure from rising above a pre-determined maximum pressure. PICT-2656 3. Remove the main relief valve assembly from the valve (Fig. 1178). 1.
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HYDRAULIC SYSTEM 4. Disconnect the body of the main relief valve from the main relief valve bonnet (Fig. 1179). 5. Connect the body of the main relief valve to the main relief valve bonnet (Fig. 1181). Fig 1179 Fig 1181 PICT-2661a The relief valve is used to adjust to the specified system pressure (2400 + 50 psi or 165.47 + 3.45 bar) by increasing or decreasing the load on the spring against the disc.
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HYDRAULIC SYSTEM 7. Using a 24mm socket and wrench, tighten the body of the main relief valve onto the main relief valve bonnet (Fig. 1183). Fig 1183 1. Using a 10mm Allen wrench, remove the 2 work port relief plugs (Fig. 1185 and Fig. 1186). Fig 1185 PICT-2663 Fig 1186 PICT-2668a PICT-2658 Work Port Relief The work relief ports relieve the fluid spikes when the Lift and Tilt Cylinders are being actuated. These ports are non-adjustable. Port relief setting is 2030 psi (140 bar) (Fig. 1184).
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HYDRAULIC SYSTEM 2. Install both seats and reliefs into the valve work ports (Fig. 1187). Fig 1187 4. Install both work port relief plugs. Tighten using a 10mm Allen wrench (Fig. 1189). PICT-2667 3. Install both springs into the valve work ports (tapered end of the spring goes in first) (Fig. 1188). Fig 1188 Fig 1189 PICT-2663 Note: There are 3 “blank” ports on the valve that have plugs with o-rings inserted into them (Fig. 1190).
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HYDRAULIC SYSTEM Lift Cylinder Assembly Rebuild 1. Extend the ram of the tilt cylinder out approximately 6” to 12” (15.24 to 30.48cm). 2. Clean all dirt and other foreign substance from the openings, particularly at the head of the hydraulic cylinder. Note: If excessive wear due to side-loads or binding is a possibility, mark or note the piston and head relationship to the rod and tube.
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HYDRAULIC SYSTEM 6. Continue to rotate the head counter-clockwise until the retaining ring is completely removed (Fig. 1194). Fig 1194 PICT-3037 7. Pull out on the rod to remove the piston and head assembly from the barrel (Fig. 1195). Fig 1195 TX525 Service Manual 8. Remove the barrel from the vise. INSPECT ROD: There should be no scratches or pits deep enough to catch the fingernail. Pits that go to the base metal are unacceptable.
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HYDRAULIC SYSTEM INSPECT TUBE 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” long (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 (Fig. 1196). A Lift Cylinder Disassembly 1.
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HYDRAULIC SYSTEM 3. Remove the back-up piston seal from the ram assembly (Fig. 1199). 5. Slide the piston off the end of the ram (Fig. 1201). Fig 1201 Fig 1199 4. Using a 1-1/8” socket, remove the nut from the ram assembly (Fig. 1200). 6. Remove the inner o-ring from the inside of the piston (Fig. 1202). Fig 1202 Fig 1200 TX525 Service Manual PICT-3045a PICT-3042a PICT-3046a PICT-3043a Rev.
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HYDRAULIC SYSTEM 7. Remove the o-ring from the head on the ram assembly (Fig. 1203). 9. Slide the head off the end of the ram (Fig. 1205). Fig 1205 Fig 1203 10. Remove the wiper seal from inside the head (Fig. 1206). 8. Remove the flat back-up ring from the head on the ram assembly (Fig. 1204). Fig 1206 Fig 1204 6-98 PICT-3049a PICT-3047a PICT-3050a PICT-3048a Rev.
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HYDRAULIC SYSTEM 11. Remove the wear seal from inside the head (Fig. 1207). Piston Assembly (Fig. 1209): A B C D E Fig 1209 Fig 1207 PICT-3051 12. Thoroughly rinse the inside of the head with a clean solvent. Rinse and clean all internal components of any foreign material with a lint-free rag. 13. Visually inspect for material defects and contamination. All seals and o-rings must be replaced with new parts. D C Fig 1208 A. Wiper B. Wear Seal C. Head TX525 Service Manual PICT-3056a D. Piston E.
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HYDRAULIC SYSTEM 15. Install the wiper seal so that the lip of the seal is installed in the groove inside the head (Fig. 1211). 17. Install the o-ring into the groove next to the flat backup ring. The o-ring is installed on the barrel side of the groove (Fig. 1213). Note: If possible, the head/seal assembly should sit for at least one hour to allow the seals to normalize. Fig 1211 PICT-3058 16. Install the flat back-up ring into the head.
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HYDRAULIC SYSTEM 19. Install the piston seal on top of the back-up ring (Fig. 1215). Lift Cylinder Assembly Note: Lubricate all parts during assembly. 1. Secure the cylinder ram into a vise. 2. Protect the threads of the ram and then slide the o-ring onto the ram shaft and into the groove (Fig. 1217). Fig 1215 PICT-3062a 20. Install the wear ring onto the piston (Fig. 1216). Fig 1217 PICT-3064a 3. Remove the thread protection material. 4. Slide the head onto the cylinder ram (Fig. 1218).
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HYDRAULIC SYSTEM 5. Slide the piston onto the cylinder ram (Fig. 1219). 7. Remove the ram from the vise and secure the cylinder barrel into the vise. 8. Install the ram assembly into the cylinder barrel by rotating the piston assembly while pushing the piston into the barrel (Fig. 1221). Fig 1219 PICT-3066a 6. Install the nut onto the end of the ram. Using a 1-1/8” socket, torque the nut to 100 - 120 ft-lbs. (135.6 - 162.7 Nm) (Fig. 1220). Fig 1221 PICT-3068a 9.
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HYDRAULIC SYSTEM 10. Insert the end of the ring through the notch in the barrel and into the hole in the groove. Place the spanner wrench onto the head assembly (Fig. 1223). Tilt Cylinder Assembly Rebuild 1. Extend the ram of the tilt cylinder out approximately 6” to 12” (15.24 to 30.48cm). 2. Clean away all dirt and foreign substance from openings, particularly at the head of the hydraulic cylinder. 3. Clamp the tilt cylinder in a vise so that the locking ring slot is facing up. 4.
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HYDRAULIC SYSTEM Note: If excessive wear due to side-loads or binding is a possibility, mark or note the piston and head relationship to the rod and tube. This condition will usually show up as a highly polished surface on the piston and head 90° to the pin rotation axis (Fig. 1226). 6. Continue to rotate the head counter-clockwise until the retaining ring is completely removed (Fig. 1228). Fig 1228 Fig 1226 PICT-2953 PICT-2957 7.
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HYDRAULIC SYSTEM 8. Remove the barrel from the vise. 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, less than 0.5 inch long (1.27cm) 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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HYDRAULIC SYSTEM Tilt Cylinder Disassembly 3. Remove the back-up piston seal from the ram assembly (Fig. 1233). 1. Remove the piston wear ring from the ram assembly (Fig. 1231). Fig 1233 Fig 1231 PICT-2963a PICT-2961 4. Using a 1-1/2” socket, remove the nut from the ram assembly (Fig. 1234). 2. Carefully remove the seal from the ram assembly (Fig. 1232). Fig 1234 Fig 1232 6-106 PICT-2964a PICT-2962 Rev.
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HYDRAULIC SYSTEM 5. Slide the piston off the end of the ram (Fig. 1235). Fig 1235 7. Remove the o-ring from the head on the ram assembly (Fig. 1237). PICT-2965a Fig 1237 6. Remove the o-ring from the ram (Fig. 1236). Fig 1236 8. Remove the flat back-up ring from the head on the ram assembly (Fig. 1238). PICT-2966a Fig 1238 TX525 Service Manual PICT-2967a Rev.
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HYDRAULIC SYSTEM 9. Slide the head off the end of the ram (Fig. 1239). Fig 1239 11. Remove the seal from inside the head (Fig. 1241). PICT-2969a 10. Remove the wiper seal from inside the head (Fig. 1240). Fig 1240 6-108 Fig 1241 PICT-2971 12. Turn the head over and remove the wear ring from inside of head. (Fig. 1242). PICT-2970 Rev.
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HYDRAULIC SYSTEM 13. Thoroughly rinse the inside of the tube with a clean solvent. Rinse and clean all internal components of foreign material with a lint-free rag. Piston Assembly (Fig. 1244): 14. Visually inspect for material defects and contamination. All seals and o-rings must be replaced with new parts. Head Assembly (Fig. 1243): A B C D Fig 1244 E Fig 1243 A. Wiper Seal B. Seal C. Wear Ring F 15. Lubricate the head and all seals with 10W-30 oil prior to installation. PICT-2973a 16.
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HYDRAULIC SYSTEM 17. Turn the head over and twist the wear seal into a “C” shape and allow it to snap into the groove (Fig. 1246). 19. Install the flat back-up ring into the deepest groove in the head. The flat back-up seal is installed up against the ram side of the groove (Fig. 1248). Note: The groove of the seal faces toward the barrel side of the head. Fig 1248 Fig 1246 PICT-2976 18. Install the wiper seal so that the lip of the seal is installed in the groove inside the head (Fig. 1247).
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HYDRAULIC SYSTEM 21. Install the wear ring into the widest groove on the piston (Fig. 1250). Fig 1250 23. Install the seal ring into the narrowest groove on the piston covering the back up ring. (Fig. 1252). PICT-2980a 22. Install the backup ring into the narrowest groove on the piston (Fig. 1251). Fig 1251 Fig 1252 24. Wrap a protector over the threads of the ram. Install the o-ring onto the ram. Remove the o-ring protector from the threads (Fig. 1253).
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HYDRAULIC SYSTEM Tilt Cylinder Assembly 4. Install the nut onto the end of the ram. Using a 1-1/2” socket, torque the nut to 110 - 120 ft-lbs. (149.1 162.7 Nm) (Fig. 1256). Note: Lubricate all parts during assembly. 1. Secure the cylinder ram into a vise. 2. Slide the head onto the cylinder ram (Fig. 1254). Fig 1256 Fig 1254 PICT-2984a 6-112 5. Remove the ram from the vise and secure the cylinder barrel into the vise. 6.
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HYDRAULIC SYSTEM 7. Rotate the head until the ring hole in the ring groove is within the slot on the barrel (Fig. 1258). Fig 1258 9. Begin rotating the spanner wrench so that the head pulls the ring inside the barrel. Continue rotating until the beveled edge of ring is completely installed inside the barrel on the head assembly (Fig. 1260). PICT-2988 Fig 1260 PICT-2994 8. Insert the bent end of the ring through the notch in the barrel and into the hole in the groove.
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HYDRAULIC SYSTEM THIS PAGE INTENTIONALLY LEFT BLANK. 6-114 Rev.
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DRIVE SYSTEM Lifting the Machine for Service 1. Place two pieces of approximately 2” (5.08cm) thick wood blocks directly behind both tracks (Fig. 1261). 4. Raise the rear of the machine, remove the two wood blocks and place a jack stand under each corner of the frame (Fig. 1263). Fig 1263 Fig 1261 PICT-4248 PICT-4245 5. Raise the hydraulic floor jack approximately 15” (38.10cm) and position it at the front of the machine (Fig. 1264). 2. Back the machine up onto the wood blocks. 3.
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DRIVE SYSTEM 6. Start the machine and raise the loader arm enough to clear the hydraulic floor jack. Place the floor jack directly below the mount plate and lower the loader arm onto the hydraulic floor jack. Continue lowering the loader arm to raise the tracks off the ground (Fig. 1265). 8. Lower the hydraulic floor jack so the machine rests on the jack stands. Lower the loader arms to the resting position (Fig. 1267). Fig 1267 Fig 1265 PICT-4250 PICT-4253 9.
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DRIVE SYSTEM Track Guide Alignment 3. Wide track models only: Slide a washer/tensioner wheel assembly onto the tensioner arm wheel shaft. Install a nut to secure (Fig. 1270). Alignment Tool (Toro p/n: 110-0069) (Fig. 1268): Fig 1268 Fig 1270 DSC-0624 PICT-4483 4. Insert the notched end of the alignment tool into the drive wheel spacer (Fig. 1271). 1. Remove the track. Refer to “Wide Track Removal” on page 7-68 or “Narrow Track Removal” on page 7-72. 2.
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DRIVE SYSTEM 5. Secure the notched end with the pin (Fig. 1272). Fig 1272 7. Torque the 4 track guide mounting bolts to 75 ft-lbs. (102 Nm) (Fig. 1274). PICT-4484 Fig 1274 6. Rotate the tool and move the track guide as necessary until the tool fits into the track guide channel. Secure the end of the alignment tool with a strap (Fig. 1273). Fig 1273 PICT-4493 8. Remove the alignment tool. 9.
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DRIVE SYSTEM Belt Replacement 6. Support the hood and remove the prop rod (Fig. 1277). Belt Removal 1. Position the traction unit on a flat surface. 2. Remove the ignition key. 3. Apply the parking brake. 4. Raise the hood. 5. Remove the hairpin cotter from the hood prop rod (Fig. 1276). Fig 1277 Belt 003 7. Using a 1/2” wrench, remove the 2 lower heat shield screws (Fig. 1278). Fig 1276 Belt 001 Fig 1278 TX525 Service Manual Rev.
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DRIVE SYSTEM 8. Using a 3/16” Allen wrench, remove the 2 upper heat shield screws (Fig. 1279). Fig 1279 Fig 1281 Belt 004 9. Remove the heat shield (Fig. 1280). Fig 1280 10. Using a spring tool, remove the idler spring from its post (Fig. 1281). 11. Remove the belt from the right and left hydraulic traction pump pulleys (Fig. 1282). Belt 005 Fig 1282 7-6 Belt 007 Rev.
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DRIVE SYSTEM 12. Remove the rear access cover (Fig. 1283). Fig 1283 14. Remove the gas tank hold down bracket (Fig. 1285). Fig 1285 Belt 006 13. Using a 1/2” wrench and 1/2” socket combination, remove the gas tank hold down bracket bolt and nut (Fig. 1284). 15. Using a 5/8” socket combination, remove the 2 hydraulic pump mount plate bolts (Fig. 1286). Fig 1286 Fig 1284 TX525 Service Manual Belt 010 Belt 013 Belt 009 Rev.
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DRIVE SYSTEM Belt Installation 16. Rotate the hydraulic pump clockwise and pull the hydraulic pump outward to separate the coupling sleeve and the hub sleeve. This will permit belt removal (Fig. 1287). Fig 1287 1. Pull the hydraulic pump outward to create enough clearance between the coupling sleeve and the hub sleeve to allow for belt installation (Fig. 1289). Belt 012 Fig 1289 Belt 015 17. Remove the belt (Fig. 1288). 2.
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DRIVE SYSTEM 3. Using a spring tool, install the idler spring onto its post (Fig. 1291). 4. Rotate and push the hydraulic pump by hand until the coupling sleeve properly meshes with the hub sleeve recessed in the engine pulley (Fig. 1293). Note: Do not use the hydraulic pump mount plate bolts to draw the coupling sleeve into the hub sleeve. Doing so could result in the snap ring sliding out of its groove on the hub coupling. This will result in the loss of hydraulics.
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DRIVE SYSTEM 5. Using a 5/8” socket, install and torque the 2 hydraulic pump mount plate bolts to 50 ft-lbs. (67.8 Nm) (Fig. 1294). 7. Install the rear access cover (Fig. 1296). Fig 1296 Fig 1294 Belt 006 Belt 018 8. Position the heat shield (Fig. 1297). 6. Using a 1/2” wrench and socket, install the gas tank hold down bracket (Fig. 1295). Fig 1297 Fig 1295 7-10 Belt 005 Belt 009 Rev.
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DRIVE SYSTEM 9. Using a 3/16” Allen wrench, install and tighten the 2 upper heat shield screws (Fig. 1298). Fig 1298 11. Support the hood and install the prop rod (Fig. 1300). Fig 1300 Belt 004 10. Using a 1/2” wrench, install and tighten the 2 lower heat shield screws (Fig. 1299). 12. Install the hairpin cotter (Fig. 1301). Fig 1301 Fig 1299 TX525 Service Manual Belt 003 Belt 001 Belt 002 Rev.
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DRIVE SYSTEM Idler Arm Replacement 5. Using a 3/16” Allen wrench, remove the top 2 screws. Using a 1/2” socket, remove the bottom 2 screws securing the heat shield to the tower (Fig. 1304). Idler Arm Removal 1. Shut engine off, apply parking brake, and remove ignition key. 2. Lift the engine hood assembly. 3. Remove the hairpin cotter from the prop rod (Fig. 1302). Fig 1304 PICT-5258 6. Remove the heat shield (Fig. 1305). Fig 1302 Belt 001 4. Remove the prop rod (Fig. 1303).
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DRIVE SYSTEM 7. Remove the rear access panel (Fig. 1306). Fig 1306 9. Using a spring tool, remove the idler spring from its post (Fig. 1308). PICT-4505a Fig 1308 8. Using a 3/8” socket, remove the 3 screws securing the right hand support panel to the tower assembly. Remove the right hand support panel (Fig. 1307). PICT-5360 10. Using a 1/2” socket and wrench, remove the nut securing the idler arm assembly to the tower (Fig. 1309).
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DRIVE SYSTEM 11. Remove the idler arm assembly from the unit (Fig. 1310). 13. Inspect the idler pulley bearing and the two flange bushings. Replace if worn or damaged (Fig. 1312). E F DSC-3321 (found in the TX420/425 F C manual – “Drive” section, pg 8-55) G H D I A B Fig 1310 12. Remove the spring and rubber spring retainer from the idler assembly and slide the rubber spring retainer off the spring (Fig. 1311). Fig 1311 7-14 Fig 1312 PICT-5371 A. B. C. D. E.
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DRIVE SYSTEM Idler Arm Assembly Installation 3. Slide a spring tool through the rubber spring retainer. Hook the idler spring to the spring tool (Fig. 1315). 1. Position the idler arm assembly in the unit so the drive belt is routed between the pulley and the idler arm spring post (Fig. 1313). Fig 1315 Fig 1313 PICT-5373 PICT-5376a 4. Pull the idler spring approximately half way into the rubber spring retainer (Fig. 1316). 2.
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DRIVE SYSTEM 5. Hook the idler spring to the idler arm spring post (Fig. 1317). Fig 1317 8. Position the right hand support panel to the tower. Using a 3/8” socket, install 3 screws to secure the right hand support panel to the tower assembly (Fig. 1319). PICT-5378 Fig 1319 PICT-4504 6. Align the belt with the idler pulley. 7. Using a spring tool, install the idler spring onto its post (Fig. 1318). 9. Install the rear access panel (Fig. 1320). Fig 1320 Fig 1318 7-16 PICT-4505a PICT-5379 Rev.
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DRIVE SYSTEM 10. Position the heat shield (Fig. 1321). Fig 1321 12. Install the prop rod (Fig. 1323). Belt 005 11. Using a 3/16” Allen wrench, install the top 2 screws. Using a 1/2” socket, install the bottom 2 screws securing the heat shield to the tower (Fig. 1322). Fig 1323 13. Install a hairpin cotter into the prop rod (Fig. 1324). Fig 1324 Fig 1322 TX525 Service Manual Belt 003 Belt 001 PICT-5258 Rev.
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DRIVE SYSTEM Right Hydrostatic Pump Replacement Right Hydrostatic Pump Removal 3. Using a 3/8” socket, remove the 6 screws that secure the left and right rear cover support panels to the tower assembly (3 screws per panel). Remove the panels (Fig. 1326). Note: Cleanliness is a key factor in a successful repair of any valve system. Thoroughly clean all exposed surfaces prior to any type of maintenance. Cleaning all parts by using a solvent wash and air drying is usually adequate.
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DRIVE SYSTEM 5. Remove the fuel tank bracket (Fig. 1328). Fig 1328 7. Mark the suction fuel line and tank fitting with an “S” and the return fuel line and tank fitting with an “R” (Fig. 1330): S - Fuel suction line R - Fuel return line PICT-5626 6. Disconnect the two wires (black and orange) from the fuel sending unit located on the top of the fuel tank (Fig. 1329). Fig 1330 PICT-4263 8. Slide the 2 fuel hose clamps down the fuel lines away from the fuel tank fittings (Fig. 1331).
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DRIVE SYSTEM 11. Remove the left hand panel from the control panel assembly (Fig. 1334). 9. Slide the 2 fuel lines off the fuel tank fittings. Remove the fuel tank (Fig. 1332). Fig 1332 PICT-4265 10. Using a 3/8” socket, remove the 4 self-tapping screws securing the left hand panel to the control panel assembly (Fig. 1333). Fig 1334 PICT-4601 12. Using a 3/8” socket, remove the 3 self-tapping screws that secure the right panel to the control panel assembly.
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DRIVE SYSTEM 13. Remove the right hand panel from the control panel assembly (Fig. 1336). C. Case drain line (Fig. 1338). Fig 1338 Fig 1336 PICT-4639a PICT-4269 D. Right hand wheel motor port (Fig. 1339). 14. Mark the hydrostatic pump fittings and lines as follows: A. Inlet line from the left hand hydrostatic pump (Fig. 0000). E. Left hand wheel motor port (Fig. 1339). B. Inlet line from the hydraulic oil filter (Fig. 1337). Fig 1339 Fig 1337 TX525 Service Manual PICT-4640 PICT-4637 Rev.
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DRIVE SYSTEM 17. Mark the tandem pump, T-fitting and hose with the letter “G” (Fig. 1342). 15. Mark the hydraulic pump wheel motor hoses and fittings with the letters D and E (Fig. 1340). Fig 1340 PICT-4747 16. Mark the tandem pump, hose and fitting running to the 2 spool valve with a letter “F” (Fig. 1341). Fig 1341 7-22 Fig 1342 PICT-4737 18. Mark the tandem pump test port fitting with the letter “H” (Fig. 1343). PICT-4736 Rev.
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DRIVE SYSTEM 19. Using a 15/16” wrench, disconnect the right hand hydrostatic pump lines (just marked) as follows: C. Case drain line (Fig. 1346). A. Inlet line from the hydraulic oil filter (Fig. 1344). Fig 1346 Fig 1344 PICT-4636 B. Inlet line to the left hand hydrostatic pump (Fig. 1345). D. Hydraulic hose running from the “D” port on the right hand hydrostatic pump to the upper fitting on the left wheel motor (Fig. 1347).
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DRIVE SYSTEM E. Hydraulic hose running from the “E” port on the hydrostatic pump to the lower fitting on the left wheel motor (Fig. 1348). Fig 1348 21. Using a 15/16” wrench, remove the wheel motor hose fittings marked “E” from the right hand hydraulic pump (Fig. 1350). Fig 1350 PICT-4645 20. Using a 15/16” wrench, remove the wheel motor hose fittings marked “D” from the right hand hydraulic pump (Fig. 1349). 22.
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DRIVE SYSTEM 23. Using a 15/16” wrench, remove the hose from the T-fitting marked “G” on the tandem pump (Fig. 1352). Fig 1352 25. Remove the T-fitting marked “G” from the tandem pump (Fig. 1354). Note: Cap all hydraulic lines and fittings to prevent debris from entering system. PICT-4738a Fig 1354 24. Using a 15/16” wrench, remove the test port fitting “H” from the T-fitting marked “G” (Fig. 1353). Fig 1353 26.
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DRIVE SYSTEM 30. Using a 1/2” wrench, remove the 2 lower heat shield screws (Fig. 1358). 27. Raise the hood. 28. Remove the hairpin cotter from the hood prop rod (Fig. 1356). Fig 1358 Fig 1356 Belt 001 31. Using a 3/16” Allen wrench, remove the 2 upper heat shield screws (Fig. 1359). 29. Support the hood and remove the prop rod (Fig. 1357). Fig 1359 Fig 1357 7-26 Belt 002 Belt 004 Belt 003 Rev.
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DRIVE SYSTEM 32. Remove the heat shield (Fig. 1360). Fig 1360 34. Remove the belt from the right and left hydraulic traction pump pulleys (Fig. 1362). Belt 005 Fig 1362 33. Using a spring tool, remove the idler spring from its post (Fig. 1361). Fig 1361 35. Secure the pulley. Using a 5/8” socket, remove the center nut and washer retaining the pulley to the right hand hydrostatic pump shaft (Fig. 1363). Belt 007 Fig 1363 TX525 Service Manual Belt 008 Rev.
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DRIVE SYSTEM 38. Remove the key from the hydrostatic pump shaft keyway (Fig. 1366). 36. Install a special pulley puller (Toro p/n: 112-2557) onto the right hand hydrostatic pulley (Fig. 1364). Fig 1364 37. Remove the right hand pulley from the hydrostatic pump shaft (Fig. 1365). Fig 1365 Fig 1366 PICT-4593a 39. Using a 3/4” socket and wrench, remove the top bolt and nut securing the right hand hydrostatic pump to the tower frame.
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DRIVE SYSTEM Right Hydrostatic Pump Installation 40. Remove the right hand hydrostatic pump from the tower frame (Fig. 1368). 1. With the lower pump mounting bolt and nut loosely installed in the tower frame, position the right hand hydrostatic pump so the pump shaft is inserted through the frame (Fig. 1370). Fig 1368 PICT-4753 41. If replacing the pump, transfer all markings and fittings to the new pump (Fig. 1369). Fig 1370 PICT-4753 Note: Do not install the fittings marked D and E. 2.
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DRIVE SYSTEM 3. Install a key into the hydrostatic pump shaft keyway (Fig. 1372). Fig 1372 4. Slide the pulley onto the right hand hydrostatic pump shaft with the thicker flange side facing toward the pump (Fig. 1374). PICT-4650 Fig 1374 Note: The pulley has a tapered through hole and a thicker flange on one side than the other (Fig. 1373). Fig 1373 7-30 PICT-4758 5. Slide a washer onto the pump shaft (Fig. 1375). PICT-4662a Rev.
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DRIVE SYSTEM 8. Route the belt around the engine pulley and the right and left hydrostatic pump pulleys (rear view) (Fig. 1378). 6. Install a nut to secure the pulley to the right hand hydrostatic pump shaft (Fig. 1376). A Fig 1376 B E PICT-4761 Fig 1378 7. Torque the nut to 260 + 40 in-lbs. (29.38 + 4.5 Nm) (Fig. 1377). A. LH pump pulley B. Drive belt C. RH pump pulley C D TX525 belt routing D. Idler pulley E. Engine pulley 9. Install the idler spring onto its post (Fig. 1379).
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DRIVE SYSTEM 10. Position the heat shield (Fig. 1380). Fig 1380 12. Using a 1/2” wrench, install the 2 lower heat shield screws (Fig. 1382). Belt 005 Fig 1382 11. Using a 3/16” Allen wrench, install the 2 upper heat shield screws (Fig. 1381). Fig 1381 7-32 Belt 002 13. Support the hood and install the prop rod (Fig. 1383). Belt 004 Rev.
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DRIVE SYSTEM 17. Install the T-fitting marked “G” into the tandem pump (Fig. 1386). 14. Install the hairpin cotter (Fig. 1384). Fig 1384 Belt 001 Fig 1386 15. Lower the hood. 16. Using a 1/2” socket and wrench, install the nut and bolt securing the steering linkage to the right hand pump control arm (Fig. 1385). 18. Using a 15/16” wrench, install the test port fitting “H” onto the T-fitting marked “G” (Fig. 1387). Fig 1387 Fig 1385 TX525 Service Manual PICT-4742a PICT-4741a PICT-4752 Rev.
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DRIVE SYSTEM 19. Using a 15/16” wrench, install the hose marked “G” onto the T-fitting marked “G” on the tandem pump (Fig. 1388). Fig 1388 21. Loosely install the wheel motor hose fittings marked “D” and “E” into the right hand hydraulic pump ports marked “D” and “E” so they are positioned at approximately 8:00 (D) and 9:00 (E) clock positions (Fig. 1390). PICT-4738a Fig 1390 20. Using a 1-1/8” wrench, install the hydraulic hose marked “F” onto the tandem pump fitting (Fig. 1389). Fig 1389 22.
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DRIVE SYSTEM B. Inlet line from the left hand hydrostatic pump marked “B” to the fitting marked “B” (Fig. 1394). D. Wheel motor hose marked “D” to the fitting marked “D” (Fig. 1392). Fig 1392 PICT-4644 C. Case drain line marked “C” to the fitting marked “C” (Fig. 1393). Fig 1393 TX525 Service Manual PICT-4643a Rev. 000 Fig 1394 PICT-4641 A. Inlet line from the hydraulic oil filter marked “A” to the fitting marked “A” (Fig. 1395).
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DRIVE SYSTEM 23. With the fitting secured, tighten the pump fitting nuts on the fittings marked “D” and “E” to the hydraulic pump (Fig. 1396). 25. Position the left hand panel onto the control panel assembly (Fig. 1398). Fig 1398 Fig 1396 PICT-4756 24. Using a 3/8” socket, install 3 self-tapping screws that secure the right panel to the control panel assembly.
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DRIVE SYSTEM 27. Slide the 2 fuel lines onto the fuel tank fittings. Note the location markings (Fig. 1400). S - Fuel suction line R - Fuel return line 29. Position the fuel tank into the rear end of the frame. Connect the two wires (black and orange) to the fuel sending unit located on the top of the fuel tank (Fig. 1402). Note: Before installing the fuel tank in the unit, disengage the park brake and start the unit.
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DRIVE SYSTEM 31. Position the rear frame cover to the rear end of the frame. Using 3/4” and 1/2” sockets, install 7 bolts and nuts to secure the rear frame cover to the frame and fuel tank bracket (Fig. 1404). Note: The rear of the machine may have to be lifted to reposition the jack stands so that the rear frame cover can be installed. 32. Position the left hand rear cover support panel to the tower. Using a 3/8” socket, install 3 screws to secure the left rear cover support panel to the tower assembly.
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DRIVE SYSTEM Left Hydrostatic Pump Replacement 4. Using 3/4” and 1/2” sockets, remove the 7 bolts and nuts securing the rear frame cover to the frame. Remove the rear frame cover (Fig. 1409). Left Hydrostatic Pump Removal 1. Raise the machine and set it on jack stands. Refer to “Lifting the Machine for Service” on page 7-1. Note: The rear of the machine may have to be lifted to reposition the jack stands so that the rear frame cover can be removed. 2. Remove the rear access panel (Fig. 1407).
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DRIVE SYSTEM 6. Disconnect the two wires (black and orange) from the fuel sending unit located on the top of the fuel tank (Fig. 1411). 8. Slide the 2 fuel hose clamps down the fuel lines away from the fuel tank fittings (Fig. 1413). Fig 1413 Fig 1411 7. Mark the suction fuel line and tank fitting with an “S” and the return fuel line and tank fitting with an “R” (Fig. 1412): S - Fuel suction line R - Fuel return line 9. Slide the 2 fuel lines off the fuel tank fittings. Remove the fuel tank (Fig. 1414).
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DRIVE SYSTEM 12. Mark the hydrostatic pump fittings and lines as follows: A. Hydraulic oil inlet from the filter (Fig. 1417). 10. Using a 3/8” socket, remove the 4 self-tapping screws securing the left hand panel to the control panel assembly (Fig. 1415). Fig 1415 PICT-4600 C. Case drain line returning to the hydraulic oil tank (Fig. 1418). PICT-4601 Fig 1418 TX525 Service Manual PICT-4603 B. Right pump case drain line and, 11. Remove the left hand panel from the control panel assembly (Fig. 1416).
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DRIVE SYSTEM D. Hydraulic hose running to the lower port on the right hand wheel motor and, E. Hydraulic hose running to the upper port on the right hand wheel motor (Fig. 1419). 13. Using a 15/16” wrench, disconnect the left hand hydraulic pump lines (just marked) as follows: A. Hydraulic oil inlet from the filter (Fig. 1421). Fig 1421 Fig 1419 PICT-4612 PICT-4608 B. Right pump case drain line (Fig. 1422). F.
PAGE 420
DRIVE SYSTEM C. Case drain line returning to the hydraulic oil tank (Fig. 1423). Fig 1423 E. Hydraulic hose running from the “E” port on the hydrostatic pump to the lower fitting on the right wheel motor (Fig. 1425). PICT-4614 Fig 1425 14. Using a 1-1/8” wrench, disconnect the remaining left hand hydrostatic pump lines (just marked) as follows: D. Hydraulic hose running from the “D” port on the pump to the upper fitting on the right wheel motor (Fig. 1424). F.
PAGE 421
DRIVE SYSTEM G. Hydraulic hose running to the upper port on the left hand wheel motor (Fig. 1427). Note: Cap all hydraulic lines and fittings to prevent debris from entering system. 16. Raise the hood. 17. Remove the hairpin cotter from the hood prop rod (Fig. 1429). Fig 1429 Fig 1427 15. Remove the nut and bolt securing the drive linkage to the left hand hydrostatic pump (Fig. 1428). Fig 1428 7-44 Belt 001 PICT-4623 18. Support the hood and remove the prop rod (Fig. 1430). PICT-4618 Rev.
PAGE 422
DRIVE SYSTEM 19. Using a 1/2” wrench, remove the 2 lower heat shield screws (Fig. 1431). 21. Remove the heat shield (Fig. 1433). Fig 1433 Fig 1431 20. Using a 3/16” Allen wrench, remove the 2 upper heat shield screws (Fig. 1432). 22. Using a spring tool, remove the idler spring from its post (Fig. 1434). Fig 1434 Fig 1432 TX525 Service Manual Belt 005 Belt 002 Belt 007 Belt 004 Rev.
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DRIVE SYSTEM 23. Remove the belt from the right and left hydraulic traction pump pulleys (Fig. 1435). Fig 1435 25. Install a pulley puller (Toro p/n: 112-2557) onto the left hand hydrostatic pump pulley (Fig. 1437). Fig 1437 Belt 008 24. Secure the pulley. Using a 5/8” socket, remove the center nut and washer retaining the pulley to the left hand hydrostatic pump shaft (Fig. 1436). 26. Remove the left hand pulley from the hydrostatic pump shaft (Fig. 1438).
PAGE 424
DRIVE SYSTEM 29. Remove the left hand hydrostatic pump from the tower frame (Fig. 1441). 27. Remove the key from the hydrostatic pump shaft keyway (Fig. 1439). Fig 1439 PICT-4598 28. Using a 3/4” socket and wrench, remove the top bolt and nut securing the left hand hydrostatic pump to the tower frame. Loosen the lower nut and bolt (Fig. 1440). Fig 1441 30. If replacing the pump, transfer all markings and fittings to the new pump (Fig. 1442). Fig 1442 Fig 1440 PICT-4627 PICT-4626a PICT-4619 31.
PAGE 425
DRIVE SYSTEM Left Hydrostatic Pump Installation 3. Install a key into the hydrostatic pump shaft keyway (Fig. 1445). 1. With the lower bolt and nut loosely installed in the tower frame, position the left hand hydrostatic pump so the pump shaft is inserted through the frame (Fig. 1443). Fig 1445 Fig 1443 PICT-4627 PICT-4598 4. The pulley has a tapered through hole and a thicker flange on one side (Fig. 1446). 2. Using a 3/4” socket and wrench, install the top bolt and nut.
PAGE 426
DRIVE SYSTEM 5. Slide the left hand pulley onto the hydrostatic pump shaft with the thicker flange side facing toward the pump (Fig. 1447). 7. Install a nut to secure the pulley to the left hand hydrostatic pump shaft (Fig. 1449). Fig 1449 Fig 1447 8. Torque the nut to 260 + 40 in-lbs. (29.38 + 4.5 Nm) (Fig. 1450). 6. Slide a washer onto the pump shaft (Fig. 1448). Fig 1448 TX525 Service Manual PICT-4634 PICT-4632 PICT-4633 Rev.
PAGE 427
DRIVE SYSTEM 9. Route the belt around the engine pulley and the right and left hydrostatic pump pulleys (rear view) (Fig. 1451). A B E Fig 1451 A. LH pump pulley B. Drive belt C. RH pump pulley 11. Position the heat shield (Fig. 1453). C D Fig 1453 Belt 005 TX525 belt routing D. Idler pulley E. Engine pulley 12. Using a 3/16” Allen wrench, install the 2 upper heat shield screws (Fig. 1454). 10. Using a spring tool, install the idler spring onto its post (Fig. 1452).
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DRIVE SYSTEM 15. Install the hairpin cotter (Fig. 1457). 13. Using a 1/2” wrench, install the 2 lower heat shield screws (Fig. 1455). Fig 1457 Fig 1455 16. Using a 1-1/8” wrench, install the left hand hydrostatic pump lines as follows: G. Hydraulic hose coming from the upper port on the left hand wheel motor (Fig. 1458). 14. Support the hood and install the prop rod (Fig. 1456). Fig 1456 Belt 003 Fig 1458 TX525 Service Manual Belt 001 Belt 002 Rev.
PAGE 429
DRIVE SYSTEM F. Hydraulic hose coming from the lower port on the left hand wheel motor (Fig. 1459). Fig 1459 D. Hydraulic hose coming from the lower port on the right hand wheel motor (Fig. 1461). E. Hydraulic hose coming from the upper port on the right hand wheel motor (Fig. 1460). Fig 1460 Fig 1461 PICT-4621 17. Using a 15/16” wrench, connect the left hand hydrostatic pump lines as follows: C. Case drain line returning to the hydraulic oil tank (Fig. 1462).
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DRIVE SYSTEM B. Right pump case drain line (Fig. 1463). Note: A 7/8” wrench may need to be used to hold the fitting while tightening the hydraulic line. 18. Position the right hand panel onto the control panel assembly (Fig. 1465). Fig 1465 Fig 1463 PICT-4269 PICT-4613 19. Using a 3/8” socket, install 3 self-tapping screws that secure the right panel to the control panel assembly.
PAGE 431
DRIVE SYSTEM 20. Position the left hand panel onto the control panel assembly (Fig. 1467). 22. Slide the 2 fuel lines onto the fuel tank fittings. Note the location markings (Fig. 1469). S - Fuel suction line R - Fuel return line Note: Before installing the fuel tank into the unit, disengage the park brake and start the unit. Refer to “Purging Air Procedure”, page 9-19, and check for any leaks in the hydraulic fittings and hydraulic hoses. Fig 1467 PICT-4601 21.
PAGE 432
DRIVE SYSTEM 25. Position the fuel tank bracket onto the fuel tank (Fig. 1472). 23. Position the 2 fuel hose clamps to secure the fuel lines to the fuel tank fittings (Fig. 1470). Fig 1470 Fig 1472 PICT-4264 24. Position the fuel tank into the rear end of the frame. Connect the two wires (black and orange) to the fuel sending unit located on the top of the fuel tank (Fig. 1471). PICT-5626 26. Position the rear frame cover to the rear end of the frame.
PAGE 433
DRIVE SYSTEM 27. Position the left hand rear cover support panel to the tower. Using a 3/8” socket, install 3 screws to secure the left rear cover support panel to the tower assembly. Repeat to install right hand rear cover support panel (Fig. 1474). Wheel Motor Replacement The following procedures can be followed for right or left wheel motor removal. When removing the right wheel motor, the battery has to be removed.
PAGE 434
DRIVE SYSTEM 7. Remove the drive sprocket from the wheel motor shaft (Fig. 1479). 5. Using a wheel puller, break the drive sprocket free from the wheel motor shaft (Fig. 1477). Fig 1477 TX525 Service Manual PICT-4452 8. Remove the key from the wheel motor shaft keyway (Fig. 1480). 6. Remove the patch lock nut from the wheel motor shaft (Fig. 1478). Fig 1478 Fig 1479 PICT-4450 PICT-4451 Rev.
PAGE 435
DRIVE SYSTEM 9. Remove the rear access panel (Fig. 1481). Fig 1481 11. Using 3/4” and 1/2” sockets, remove the 7 bolts and nuts securing the rear frame cover to the frame and fuel tank bracket (Fig. 1483). PICT-4505 Fig 1483 10. Using a 3/8” socket, remove the 6 screws that secure the left and right rear cover support panel to the tower assembly. Remove the panel (Fig. 1482). PICT-4456 12. Remove the rear frame cover (Fig. 1484).
PAGE 436
DRIVE SYSTEM 15. Mark the suction fuel line and tank fitting with an “S” and the return fuel line and tank fitting with an “R” (Fig. 1487): S - Fuel suction line R - Fuel return line 13. Remove the fuel tank bracket (Fig. 1485). Fig 1485 PICT-5626 14. Disconnect the two wires (black and orange) from the fuel sending unit located on the top of the fuel tank (Fig. 1486). Fig 1487 PICT-4263 16. Slide the 2 fuel hose clamps down the fuel line away from the fuel tank fittings (Fig. 1488).
PAGE 437
DRIVE SYSTEM 17. Slide the 2 fuel lines off the fuel tank fittings. Remove the fuel tank. (Fig. 1489). Fig 1489 19. For right hand wheel motor removal only: Slide the battery partially out of the battery mount. Disconnect the negative battery cable from the battery. Slide the battery out of the battery mount further to access the positive battery cable terminal. Disconnect the positive battery cable and remove the battery and battery guard from the battery mount (Fig. 1491). PICT-4265 18.
PAGE 438
DRIVE SYSTEM 21. Place a drain pan under the wheel motor that is being removed. Using a 1-1/8” 15°/60° offset open end wrench, disconnect the two hydraulic lines running to the wheel motor. Install protective caps on the hydraulic lines (Fig. 1493). 23. Remove the 4 bolts, and lock washers retaining the wheel motor to the frame (Fig. 1495). Fig 1495 Fig 1493 PICT-4461 PICT-4464 24. Remove the wheel motor mounting plate (Fig. 1496). 22.
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DRIVE SYSTEM 25. Rotate the wheel motor 90° so the ports are facing upward, this will allow the raised portion of the wheel motor to fit through the notch in the frame. Remove the wheel motor (Fig. 1497). Fig 1497 Wheel Motor Installation 1. Insert the wheel motor into the frame with the ports facing up. After the wheel motor is inside the frame, rotate the wheel motor 90° clockwise so the hydraulic ports are facing to the rear (Fig. 1498). PICT-4466 Fig 1498 PICT-4471 26.
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DRIVE SYSTEM 5. Install the 4 mounting bolts and lock washers through the wheel motor housing and frame. The top 2 mounting bolts will also thread into the mounting plate. Torque the 4 mounting bolts to 75 ± 8 ft-lbs. (102 ± 11 Nm) (Fig. 1502). 3. Position the wheel motor mounting plate on the inside of the frame with the wide side positioned toward the rear of the machine (Fig. 1500). Fig 1500 PICT-4477 Fig 1502 4. Apply a thread locking compound to the threads of the wheel motor mounting bolts (Fig.
PAGE 441
DRIVE SYSTEM 8. Install the two hydraulic lines to the wheel motor using a 1-1/8” 15°/60° offset open end wrench (Fig. 1504). Note: To ease installation, connect the bottom hydraulic line first. Fig 1504 9. For right hand wheel motor installation only: Slide the battery partially into the battery mount. Install the positive battery cable to the positive battery terminal. Slide the battery further into the battery mount. Install the negative battery cable to the negative battery terminal.
PAGE 442
DRIVE SYSTEM 11. Connect the fuel lines to the fuel tank fittings. Note the location markings. Secure the fuel lines with hose clamps (Fig. 1507). S - Fuel suction line R - Fuel return line 12. Position the fuel tank into the rear end of the frame. Connect the two wires (black and orange) to the fuel sending unit located on the top of the fuel tank (Fig. 1508). Note: Before installing the fuel tank in the unit, disengage the park brake and start the unit. Refer to “Purging Air Procedure” on page 9-19.
PAGE 443
DRIVE SYSTEM 14. Position the rear frame cover to the rear end of the frame. Using 3/4” and 1/2” sockets, install 7 bolts and nuts to secure the rear frame cover to the frame and fuel tank bracket (Fig. 1510). 16. Install the rear access panel (Fig. 1512). Note: The rear of the machine may have to be lifted to reposition the jack stands so that the rear frame cover can be installed. Fig 1512 PICT-4505 17. Insert the key into the wheel motor shaft keyway (Fig. 1513). Fig 1510 PICT-4456 15.
PAGE 444
DRIVE SYSTEM 18. Slide the drive sprocket onto the wheel motor shaft (Fig. 1514). Fig 1514 20. With the parking brake on, torque the patch lock nut to 300 + 100/-0 ft-lbs. (406.7 + 135.5 Nm) (Fig. 1516). PICT-4452 Fig 1516 19. Thread a new patch lock nut onto the wheel motor shaft (Fig. 1515). Fig 1515 TX525 Service Manual PICT-4481 21. Install the track. Refer to “Wide Track Installation” on page 7-70, or “Narrow Track Installation” on page 7-73. PICT-4451 Rev.
PAGE 445
DRIVE SYSTEM Track Replacement 5. Using a 1/2” drive ratchet, release the drive tension by turning the tensioner bolt clockwise until the tensioning nut contacts the tensioner bolt head. Push the tension wheel toward the rear of the unit (Fig. 1518). Wide Track Removal 1. Lift the machine. Refer to “Lifting the Machine for Service” on page 7-1. 2. Stop the engine, and remove the key. 3. Set the parking brake to the ON position. 4. Remove the locking bolt, spacer and nut (Fig. 1517).
PAGE 446
DRIVE SYSTEM 8. Remove the outer washer, tensioner wheel and inner washer (Fig. 1520). Fig 1520 10. Remove the track from the rear drive sprocket (Fig. 1522). PICT-4443 Fig 1522 PICT-4447 9. Remove the track from the front tensioner wheel (Fig. 1521). Fig 1521 TX525 Service Manual PICT-4446 Rev.
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DRIVE SYSTEM Wide Track Installation 3. Ensure old grease and dirt are cleaned out of the area between the two washers and the bearings on the outside tensioner wheel. Fill the area on one side of the wheel with grease (Fig. 1525). Important: Before installing the track, use the Alignment Tool, Toro P/N 110-0069, for proper alignment between the drive sprocket and the front tension wheel. Refer to “Track Guide Alignment” on page 7-3. 1.
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DRIVE SYSTEM 5. Slide the outer tensioner wheel onto the tensioner wheel shaft with the installed washer side going on first (Fig. 1527). 7. Slide the second washer over the tensioner wheel shaft and into the wheel over the grease (Fig. 1529). Fig 1529 Fig 1527 8. Using a 1-1/2” socket, install a nut securing the tensioner wheel. Torque the nut to 300 ft-lbs. (407 Nm) (Fig. 1530). 6. Apply grease to the bearing area on the outside of the tensioner wheel (Fig. 1528).
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DRIVE SYSTEM 9. Turn the tensioning screw counter-clockwise until the distance between the tension nut and the back of the tension arm is 2-3/4” (7cm) (Fig. 1531). Narrow Track Removal 1. Lift the machine. Refer to “Lifting the Machine for Service” on page 7-1. 2. Raise the loader arms approximately 12” (30.48cm). 3. Stop the engine and remove the key. 4. Using a 7/16” socket and wrench, remove the locking bolt and nut (Fig. 1533). A Fig 1531 fig. 33 m-4775 A. 2-3/4” (7cm) Fig 1533 10.
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DRIVE SYSTEM 6. Push the tension wheel toward the rear of the unit to move the tension arm against the frame (Fig. 1535). (If it does not touch the frame, continue turning the tensioning screw until it does.) 8. When the track is off of the tension wheel, remove it from the road wheel and drive sprocket (Fig. 1537). Fig 1537 Fig 1535 PICT-5346 PICT-5342 Narrow Track Installation 7.
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DRIVE SYSTEM 2. Push the track under and between the road wheels. Starting at the bottom of the tension wheel, install the track around the wheel by rotating the track rearward while pushing the lugs into the wheel (Fig. 1539). 4. Align the closest notch in the tension screw to the locking bolt hole and secure the screw with the locking bolt and nut (Fig. 1541). Fig 1541 Fig 1539 PICT-5340 PICT-5358 5. Lower the traction unit to the ground. 3.
PAGE 452
DRIVE SYSTEM Track Guide Replacement 5. Install a hydraulic floor jack and a suitable board under the track guide for support (Fig. 1543). Track Guide Removal 1. Lift the machine, refer to “Lifting the Machine for Service” on page 7-1. 2. Remove the track. Refer to “Wide Track Removal” on page 7-68, or “Narrow Track Removal” on page 7-72. 3. Raise the loader arm approximately 12” (30cm). Secure the loader arms. 4. Slide the tensioner arm out of the mainframe (Fig. 1542). Fig 1543 PICT-4521 6.
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DRIVE SYSTEM Note: The track guide end with the step, is mounted toward the drive sprocket (Fig. 1547). 7. Using the floor jack, lower the track guide from the frame (Fig. 1545). Fig 1545 PICT-4523 Track Guide Installation Fig 1547 PICT-4545 3. Using a 3/4” socket, loosely install 4 bolts and lock washers to secure the track guide to the mainframe (Fig. 1548). 1. Place a suitable board onto a hydraulic floor jack. Place the track guide on top of the floor jack. 2.
PAGE 454
DRIVE SYSTEM 4. Remove the hydraulic jack and board. Road Wheel Replacement 5. Raise the loader arm approximately 12” (30cm). Secure the loader arms. For inner road wheel replacement: To replace the inner road wheels, the track guide assembly must be removed from the machine. Refer to “Track Guide Removal” on page 7-75. 6. Slide the tensioner arm into the mainframe (Fig. 1549). For this procedure, the track guide has been removed from the machine for photo purposes. Road Wheel Removal 1.
PAGE 455
DRIVE SYSTEM 2. Remove the wheel bearing cap (Fig. 1551). Fig 1551 4. Remove the road wheel bolt (Fig. 1553). 3. Remove the bogie gasket (Fig. 1552). Fig 1552 7-78 Fig 1553 PICT-4525 PICT-4527 5. Slide the road wheel off the track guide (Fig. 1554). PICT-4526 Rev.
PAGE 456
DRIVE SYSTEM Road Wheel Rebuild 4. Clean the road wheel of all debris. Inspect and replace if damaged. 1. Secure the road wheel assembly in a vise. Road Wheel Assembly (Fig. 1557) 2. Drive the road wheel bearing out of the road wheel (Fig. 1555). A B C D E F G Fig 1557 Fig 1555 PICT-4530a A. B. C. D. Grease seal Road wheel Bearing Bolt PICT-4534a E. Bogie Gasket F. Cap G. Retaining ring 3. Turn the road wheel over in the vise and drive the grease seal out of the road wheel (Fig. 1556). 5.
PAGE 457
DRIVE SYSTEM 6. Press a new bearing into the road wheel so that the bearing shoulder is facing the grease seal (Fig. 1559). Road Wheel Installation 1. Clean the track guide of all debris. 2. Slide the road wheel onto the track guide (Fig. 1561). Fig 1559 PICT-4535a Fig 1561 7. Apply grease to the grease seal lip (Fig. 1560). Important: Take care that no grease gets on the inside diameter of the road wheel bearing. Fig 1560 3. Apply thread locking compound to the road wheel bolt (Fig. 1562).
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DRIVE SYSTEM 4. Install the road wheel bolt (Fig. 1563). Fig 1563 6. Install the bogie gasket over the bolt head, inside the outer cap ring of the road wheel (Fig. 1565). PICT-4527 Fig 1565 5. Torque the road wheel bolt to 150 + 15 ft-lbs. (203 + 20 Nm) (Fig. 1564). Fig 1564 7. Apply grease to the cavity in the road wheel bearing cap (Fig. 1566). PICT-4540a Fig 1566 TX525 Service Manual PICT-4526 Rev.
PAGE 459
DRIVE SYSTEM Tensioner Arm Replacement - Wide Track 8. Install the road wheel bearing cap (Fig. 1567). Tensioner Arm Removal - Wide Track 1. Lift the machine, refer to “Lifting the Machine for Service” on page 7-1. 2. Remove the Track. Refer to “Wide Track Removal” on page 7-68. 3. Raise the loader arms approximately 12” (7cm). 4. Slide the tensioner arm assembly out of the mainframe (Fig. 1569). Fig 1567 PICT-4525 9.
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DRIVE SYSTEM Tensioner Arm Rebuild - Wide Track 5. Remove the spring from the tensioner arm (Fig. 1570). 1. Rotate the tensioner arm so the bottom of the tensioner arm is facing up and slide it back into the mainframe so that the square portion of the tensioner arm is inserted into the mainframe (Fig. 1572). Fig 1570 PICT-4569 6. Remove the tensioner bolt and tensioner block from the mainframe (Fig. 1571). Fig 1572 PICT-4571 2.
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DRIVE SYSTEM 3. Remove the outer washer from the tensioner wheel (Fig. 1574). Fig 1574 7-84 Fig 1576 PICT-4574 4. Remove the tensioner wheel from the tensioner arm shaft (Fig. 1575). Fig 1575 5. Remove the inner washer from the tensioner wheel (Fig. 1576). PICT-4576 6. Slide the tensioner arm out of the mainframe (Fig. 1577). PICT-4575 Rev.
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DRIVE SYSTEM Tensioner Arm and Wheel Assembly (Fig. 1578 and Fig. 1579) Welded, non-replaceable style (serial #270000001 270999999): Fig 1578 7. Secure the tensioner arm into a vise with the bottom side facing up. 8. Drive the roll pin out of the shaft end of the tensioner arm (Fig. 1580). PICT-4566a Fig 1580 Cast, replaceable style (serial #280000001 & up): Fig 1579 9. Press the tensioner arm shaft out of the tensioner arm (Fig. 1581). PICT-4567a Fig 1581 TX525 Service Manual PICT-4549a Rev.
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DRIVE SYSTEM 10. Make an alignment marking on the tensioner arm through hole and tensioner arm shaft roll pin slot (Fig. 1582): A. Place a mark on the tensioner arm shaft dividing the roll pin slot in half B. Place a mark on the tensioner arm through-hole (non-shoulder side) dividing the through-hole in half. 12. Press the tensioner arm shaft into the tensioner arm ensuring the center of the shaft roll pin groove aligns with the center of the tensioner arm through-hole (Fig. 1584).
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DRIVE SYSTEM Tensioner Arm Installation - Wide Track 3. Place a washer into the greased wheel bore (Fig. 1588). 1. With the bottom side facing up, slide the tensioner arm far enough into the mainframe so that the squared portion of the tensioner arm is inserted into the mainframe (Fig. 1586). Fig 1588 Fig 1586 PICT-4578 PICT-4498 4. Slide the tensioner wheel, washer side facing in, onto the tensioner arm shaft (Fig. 1589). 2. Apply grease to the inside of the tensioner wheel bore (Fig. 1587).
PAGE 465
DRIVE SYSTEM 7. Using a 1-1/2” socket, install a nut securing the tensioner wheel to the tensioner arm shaft. Torque the nut to 300 ft-lbs. (407 Nm) (Fig. 1592). 5. Apply grease to the inside of the tensioner wheel bore (Fig. 1590). Fig 1590 PICT-4580 Fig 1592 6. Place a washer into the greased wheel bore (Fig. 1591). Fig 1591 8. Slide the tensioner arm assembly out of the mainframe (Fig. 1593). PICT-4581 Fig 1593 7-88 PICT-4583 Rev.
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DRIVE SYSTEM 9. Slide the tensioner spring into the tensioner arm (Fig. 1594). Fig 1594 11. Rotate the tensioner arm so the top is facing up for proper installation and slide it back into the mainframe (Fig. 1596). PICT-4585 Fig 1596 10. Slide the tensioner bolt and nut into the tensioner arm (Fig. 1595). PICT-4590 12. Install the track. Refer to “Wide Track Installation” on page 7-70. 13. Lower the loader arm. 14. Lower the machine to the ground. Fig 1595 TX525 Service Manual PICT-4587 Rev.
PAGE 467
DRIVE SYSTEM Tensioner Arm Wheel Bearing Replacement - Wide Track 4. Using a 1/2” drive ratchet, release the drive tension by turning the tensioner screw clockwise until the tensioning nut contacts the tensioner bolt head. Push the tension wheel toward the rear of the unit (Fig. 1598). Tensioner Arm Wheel Bearing Removal Wide Track 1. Lift the machine. Refer to “Lifting the Machine for Service” on page 7-1. 2. Set the parking brake to the ON position. 3. Remove the locking bolt, spacer and nut (Fig.
PAGE 468
DRIVE SYSTEM 6. Remove the outer washer, tensioner wheel and inner washer (Fig. 1600). Fig 1600 9. Turn the wheel over and drive the second bearing out using a punch and hammer (Fig. 1602). PICT-4443 Fig 1602 PICT-4513a 7. Secure the tensioner wheel in a vise. 8. Drive one of the bearings out using a punch and hammer (Fig. 1601). Fig 1601 TX525 Service Manual PICT-4510a Rev.
PAGE 469
DRIVE SYSTEM 10. Clean the tensioner arm wheel of all grease and debris. Replaced if damaged or worn. Inner tensioner wheel bearing removal: 11. Raise the loader arm approximately 12” (30.48cm). 14. Using a 1-1/2” socket, remove the nut securing the inner tensioner wheel to the tensioner arm shaft (Fig. 1604). 12. Remove the track. Refer to “Wide Track Removal” on page 7-68. 13.
PAGE 470
DRIVE SYSTEM 16. Remove the tensioner wheel from the tensioner arm shaft (Fig. 1606). Fig 1606 18. Position the tensioner wheel in a vise to secure. 19. Drive one of the bearings out using a punch and hammer (Fig. 1608). PICT-4575 Fig 1608 17. Remove the inner washer from the tensioner wheel or tensioner arm shaft (Fig. 1607). Fig 1607 PICT-4510a 20. Turn the wheel over and drive the second bearing out using a punch and hammer (Fig. 1609). PICT-4576 Fig 1609 PICT-4513a 21.
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DRIVE SYSTEM Tensioner Arm Wheel Bearing Installation Wide Track 3. Turn the wheel over in the vice. Drive a second bearing into the wheel bore with the longer flange of the bearing facing inward (Fig. 1612). Tension Arm Wheel and Bearings (Fig. 1610): Fig 1612 Fig 1610 PICT-4519 PICT-4517a 1. Install the tensioner arm wheel into a vise to secure. 2. Press a bearing into the wheel bore with the longer flange of the bearing facing inward (Fig. 1611). To install the inner tensioner wheel, continue on.
PAGE 472
DRIVE SYSTEM 6. Apply grease to the inside of the tensioner wheel bore (Fig. 1614). Fig 1614 8. Slide the tensioner wheel onto the tensioner arm shaft (Fig. 1616). TX525 Service Manual PICT-4579 9. Apply grease to the inside of the tensioner wheel bore (Fig. 1617). 7. Place a washer into the greased wheel bore (Fig. 1615). Fig 1615 Fig 1616 PICT-4497 PICT-4498 Rev.
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DRIVE SYSTEM 10. Place a washer into the greased wheel bore (Fig. 1618). Fig 1618 12. Slide the tensioner arm assembly out of the mainframe (Fig. 1620). Fig 1620 PICT-4581 11. Using a 1-1/2” socket, install a nut securing the tensioner wheel to the tensioner arm shaft. Torque the nut to 300 ft-lbs. (407 Nm) (Fig. 1619). 13. Slide the tensioner spring into the tensioner arm (Fig. 1621). Fig 1621 Fig 1619 7-96 PICT-4584 PICT-4585 PICT-4583 Rev.
PAGE 474
DRIVE SYSTEM Tensioner Wheel Bearing Replacement - Narrow Track 14. Slide the tensioner bolt and nut into the tensioner arm (Fig. 1622). Tensioner Wheel Bearing Removal - Narrow Track 1. Raise the machine. Refer to “Lifting the Machine for Service” on page 7-1. 2. Raise the loader arm. 3. Remove the track. Refer to “Narrow Track Removal” on page 7-72. Fig 1622 PICT-4587 4. Slide the tensioner arm out to access the bolt head on the inner side of the tensioner wheel.
PAGE 475
DRIVE SYSTEM 5. Remove the tensioner wheel from the tensioner arm (Fig. 1625). Fig 1625 6. Support the tensioner wheel so there is a space under it for bearing removal. Using a hammer, drive the upper bearing down to create a gap between spacer and bearing, then use a drift punch to hammer the lower bearing out. The spacer will fall out when the bearing is removed. Turn the tensioner wheel over and drive out the other bearing. Inspect the tensioner wheel housing and spacer (Fig. 1627).
PAGE 476
DRIVE SYSTEM Tensioner Wheel Bearing Installation Narrow Track 1. Press the first bearing in so the outer bearing race is flush with the center hub. 2. Turn the tensioner wheel over and install the spacer centered on the inner race (tensioner wheel bolt can be used to keep the spacer centered to the bearing inner race) and press the second bearing in until the spacer is captured between the bearings.
PAGE 477
DRIVE SYSTEM 3. Reassemble the tensioner wheel to the tension arm. Tensioner Wheel Assembly (Fig. 1630): 5. Position the tensioner wheel and slide the axle bolt partially through the wheel (Fig. 1632). A B C BD Fig 1632 Fig 1630 A. Bolt B. Washer (2) PICT-5350 PICT-5354a C. Tensioner wheel D. Nut 6. Position a greased washer between the tensioner wheel and the tension arm and continue sliding the axle bolt through (Fig. 1633). 4.
PAGE 478
DRIVE SYSTEM 7. Install a nut onto the tensioner wheel axle bolt. Torque to 150 + 15 ft-lbs. (203 + 20 Nm) (Fig. 1634). Fig 1634 PICT-5356 8. Install the track. Refer to “Narrow Track Installation” on page 7-73. 9. Lower the loader arm. TX525 Service Manual Rev.
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DRIVE SYSTEM THIS PAGE INTENTIONALLY LEFT BLANK. 7-102 Rev.
PAGE 480
BRAKES Parking Brake Assembly Replacement 4. Using a 3/8” socket, remove the 6 screws that secure the left and right rear cover support panels to the tower assembly (3 screws per panel). Remove the panels (Fig. 1636). Brake Assembly Removal 270000100 270000999 1. Raise the machine and set it on jack stands. Refer to “Lifting the Machine for Service” on page 7-1. 2. Place the brake handle in the “OFF” position. 3. Remove the rear access panel (Fig. 1635). Fig 1636 PICT-4504 5.
PAGE 481
BRAKES 8. Mark the suction fuel line and tank fitting with an “S” and the return fuel line and tank fitting with an “R” (Fig. 1640): S - Fuel suction line R - Fuel return line 6. Remove the fuel tank bracket (Fig. 1638). Fig 1638 PICT-5626 7. Disconnect the two wires (black and orange) from the fuel sending unit located on the top of the fuel tank (Fig. 1639). Fig 1640 PICT-4263 9. Slide the 2 fuel hose clamps down the fuel line away from the fuel tank fittings (Fig. 1641).
PAGE 482
BRAKES 10. Slide the 2 fuel lines off the fuel tank fittings. Remove the fuel tank. (Fig. 1642). Fig 1642 12. Slide the battery partially out of the battery mount. Disconnect the negative battery cable from the battery. Slide the battery out to access the positive battery cable terminal. Disconnect the positive battery cable and remove the battery and battery guard from the battery mount (Fig. 1644). PICT-4265 11.
PAGE 483
BRAKES 16. Position the brake handle in the ON position. 14. Using two 7/16” sockets, remove the 2 bolts and nuts holding the left hand brake plate to the brake mounting bracket (the socket/ratchet on the bolt head should be 1/4” drive to clear the oil pan) (Fig. 1646). Fig 1646 17. Using a 3/8” socket, remove the 4 bolts that secure the top right panel to the control panel assembly (Fig. 1648). Fig 1648 PICT-4325 15. Push the 2 brake plates outward toward the drive wheels (Fig. 1647). PICT-4268 18.
PAGE 484
BRAKES 19. Using a 1/2” wrench, loosen the bottom nut on the brake cable (Fig. 1650). Fig 1650 21. Using a 9/16” socket and wrench, remove the nut from the shoulder bolt securing the brake handle to the brake switch support bracket (Fig. 1652). PICT-4272 Fig 1652 20. Slide the rubber boot up the brake cable and unthread the top nut (Fig. 1651). Fig 1651 22. Remove the brake handle, shoulder bolt and 2 spring washers. (Fig. 1653). PICT-4283 Fig 1653 TX525 Service Manual PICT-4284 Rev.
PAGE 485
BRAKES 25. Pull down on the brake cable and slide the threaded portion of the brake cable assembly out of the slot (Fig. 1656). 23. Remove the cotter pin from the clevis pin that secures the brake cable to the brake handle (Fig. 1654). Fig 1654 Fig 1656 PICT-4286 PICT-4289 24. Support the brake handle and remove the clevis pin. Remove the brake handle (Fig. 1655). 26. Pull the brake cable down through the hydraulic lines (Fig. 1657). Fig 1655 Fig 1657 8-6 PICT-4288a Rev.
PAGE 486
BRAKES 27. Route the brake cable out of the frame and remove the brake assembly from the machine (Fig. 1658). Fig 1658 3. Slide the spring back to expose the tube guide and set screw. Hold the spring back by placing the spring in the slot on the tube guide (Fig. 1660). PICT-4328 Fig 1660 Brake Cable Replacement 270000100 270000999 PICT-1697a 4. Using a 3/32” hex wrench, loosen the set screw that secures the tube guide to the brake cable assembly (Fig. 1661). 1.
PAGE 487
BRAKES 7. Slide the spring off the brake cable (Fig. 1664). 5. Slide the tube guide away from the bracket (Fig. 1662). Fig 1664 Fig 1662 8. Using a 3/32” hex wrench, remove the set screw retaining the second tube guide to the brake cable (Fig. 1665). 6. Remove the bracket from the brake cable (Fig. 1663). Fig 1663 8-8 PICT-1702a PICT-1700a PICT-1701a Rev.
PAGE 488
BRAKES 9. Remove the second bracket from the brake cable (Fig. 1666). Fig 1666 11. Using a 3/32” hex wrench, tighten the tube guide set screw onto the brake cable so that the bracket is secure (Fig. 1668). PICT-1704a Fig 1668 10. Install a bracket and tube guide onto the new brake cable (Fig. 1667). Fig 1667 12. Slide the spring onto the brake cable and up to the bracket (Fig. 1669). PICT-1703a Fig 1669 TX525 Service Manual PICT-1705a Rev.
PAGE 489
BRAKES 13. Slide the second bracket onto the brake cable (Fig. 1670). Fig 1670 15. Using a 3/32” hex wrench, tighten the tube guide set screw onto the brake cable so that the bracket is secure (Fig. 1672). PICT-1707a Fig 1672 14. Pull the spring back and install the tube guide onto the brake cable (Fig. 1671). Fig 1671 16. Apply the convoluted tube to the brake cable and slide it up to the brake cable tube guide (Fig. 1673). PICT-1708a Fig 1673 8-10 PICT-1709a Rev.
PAGE 490
BRAKES Brake Assembly Installation 270000100 270000999 b. over the top of the negative battery cable c. 1. Route the brake cable as follows: d. between the hydraulic filter and the frame a. Through the frame brake bracket (Fig. 1674). Fig 1674 behind the hydraulic filter return line 2. Install the brake assembly into the frame so that the tabs on the two brake plate mounting brackets are pointing down (Fig. 1675). PICT-4295 Fig 1675 PICT-4300 3.
PAGE 491
BRAKES 6. Thread the upper nut onto the threaded portion of the brake cable down to the control panel slot (Fig. 1679). 4. Secure the brake cable to the brake handle with a clevis pin. Install the cotter pin into the clevis pin (Fig. 1677). Fig 1677 Note: A spring washer is installed on each side of the brake handle. PICT-4305 Fig 1680 8-12 PICT-4306 7. Install the shoulder bolt and 2 spring washers through the handle. (Fig. 1680). 5.
PAGE 492
BRAKES 8. Insert the shoulder bolt through the brake support bracket (Fig. 1681). Fig 1681 10. Position the right panel onto the control panel assembly (Fig. 1683). PICT-4308 9. Using a 9/16” socket and wrench, install the nut onto the shoulder bolt securing the brake handle to the brake support bracket (Fig. 1682). Fig 1683 11. Using a 3/8” socket, install 4 bolts securing the top right panel to the control panel assembly (Fig. 1684).
PAGE 493
BRAKES 14. Using two 7/16” sockets, install 2 bolts and nuts to secure the left hand brake plate to the brake mounting bracket (the socket/ratchet on the bolt head should be a 1/4” drive to clear the oil pan) (Fig. 1686). 12. Position the brake handle in the OFF position. Note: If the handle does not rest at the back of the OFF slot, the brake cable adjustment nuts should be threaded further onto the brake cable adjustment threads. 13.
PAGE 494
BRAKES 16. Check the placement of the brake plates. Each brake plate should be flush with the frame (Fig. 1688). Fig 1688 17. Tighten the two jam nuts. Slide the rubber boot over the end of the brake cable adjustment threads (Fig. 1690). PICT-4332 Note: If the brake plates extend out past the frame, the brake cable adjustment nuts should be adjusted upward on the brake cable adjustment threads (Fig. 1689). Fig 1689 Fig 1690 18. Slide the battery partially into the battery mount.
PAGE 495
BRAKES 19. Position the battery clamp into the slot on the battery mount and line up the mounting hole with the hole in the frame. Using a 1/2” socket and wrench, install a bolt, washer and nut to secure the battery clamp to the frame (Fig. 1692). 21. Position the 2 fuel hose clamps to secure the fuel lines to the fuel tank fittings (Fig. 1694). Fig 1694 Fig 1692 PICT-4310a 20. Slide the 2 fuel lines onto the fuel tank fittings. Note the location markings (Fig. 1693).
PAGE 496
BRAKES 23. Position the fuel tank bracket onto the fuel tank (Fig. 1696). Fig 1696 25. Position the left hand rear cover support panel to the tower. Using a 3/8” socket, install 3 screws to secure the left rear cover support panel to the tower assembly. Repeat to install right hand rear cover support panel (Fig. 1698). PICT-5626 24. Position the rear frame cover to the rear end of the frame.
PAGE 497
BRAKES Brake Assembly Removal 280000100 & higher 1. Raise the machine and set it on jack stands. Refer to “Lifting the Machine for Service” on page 7-1. 2. Place the brake handle in the “OFF” position. 5. Using 3/4” and 1/2” sockets, remove the 7 bolts and nuts securing the rear frame cover to the frame and fuel tank bracket. Remove the rear frame cover (Fig. 1702). Note: The rear of the machine may have to be lifted to reposition the jack stands so that the rear frame cover can be removed. 3.
PAGE 498
BRAKES 7. Disconnect the two wires (black and orange) from the fuel sending unit located on the top of the fuel tank (Fig. 1704). 9. Slide the 2 fuel hose clamps down the fuel line away from the fuel tank fittings (Fig. 1706). Fig 1706 Fig 1704 8. Mark the suction fuel line and tank fitting with an “S” and the return fuel line and tank fitting with an “R” (Fig. 1705): S - Fuel suction line R - Fuel return line 10. Slide the 2 fuel lines off the fuel tank fittings. Remove the fuel tank (Fig. 1707).
PAGE 499
BRAKES 11. Using a 1/2” socket and wrench, remove the bolt, washer and nut securing the battery clamp to the frame. Remove the battery clamp (Fig. 1708). 13. Remove the knob from the brake handle (Fig. 1710). Fig 1710 Fig 1708 PICT-4342 PICT-4310a 12. Slide the battery partially out of the battery mount. Disconnect the negative battery cable from the battery. Slide the battery out to access the positive battery cable terminal. Disconnect the positive battery cable.
PAGE 500
BRAKES 15. Remove the right panel from the control panel assembly (Fig. 1712). Fig 1712 17. Support the brake handle and remove the clevis pin that retains the brake cable to the brake handle (Fig. 1714). PICT-4343a Fig 1714 16. Remove the cotter pin from the clevis pin attaching the brake cable to the brake handle (Fig. 1713). Fig 1713 18. Using a 1/2” wrench, loosen the bottom nut on the brake cable (Fig. 1715). PICT-4345 Fig 1715 TX525 Service Manual PICT-4347 Rev.
PAGE 501
BRAKES 19. Slide the rubber boot up onto the brake cable and remove the top nut from the threaded portion of the brake cable (Fig. 1716). 21. Pull the brake cable down through the hydraulic lines (Fig. 1718). Fig 1718 Fig 1716 22. Using a 1/2” socket, remove the 2 bolts holding the right brake plate to the right brake mounting bracket (Fig. 1719). 20. Pull down on the cable and slide the threaded portion of the brake cable assembly out of the slot (Fig. 1717).
PAGE 502
BRAKES 23. Using a 1/2” socket, remove the 2 bolts holding the left brake plate to the left brake mounting bracket (Fig. 1720). 25. Using a 1/2” socket, remove the 2 bolts securing the brake bar support to the frame (Fig. 1722). Fig 1722 Fig 1720 PICT-4371 PICT-4365a 26. Remove the brake cable assembly from the machine (Fig. 1723). 24. Push the 2 brake plates outward toward the drive wheels (Fig. 1721). Note: The drive wheels may have to rotate to permit the brake plates to extend fully outward.
PAGE 503
BRAKES Brake Cable Replacement 280000100 & higher Brake Assembly (Fig. 1724) B C D A E 1. Remove the Brake Assembly from the machine. Refer to “Brake Assembly Removal 280000100 & higher” on page 8-18. 2. Remove the convoluted tube from the brake cable (Fig. 1725). F G Fig 1724 A. Brake plate assembly D. (2) (included for photo E. purposes only) F. B. Brake mounting bracket (2) G. C.
PAGE 504
BRAKES 3. Place the brake and cable assembly into a bench vise. 6. Place the new cable through the right hand brake support bracket and place a tube guide (tube guide set screw toward the bracket side) over the cable and tighten tube guide set screw with 3/32” Allen wrench (Fig. 1728). 4. Using a 3/32” Allen wrench, loosen the set screws on both tube guides (Fig. 1726). Fig 1726 Fig 1728 IMG_7508a 5. Support the spring and tube guides and remove the cable from the brake mounting bracket (Fig. 1727).
PAGE 505
BRAKES 8. Place the cable end into the opening in the left hand brake mounting bracket. Pull back on the spring enough to allow the tube guide to be installed. Install the tube guide onto the cable end and tighten the set screw with 3/32” Allen wrench (Fig. 1730). Brake Assembly Installation 280000100 & higher 1. Route the brake cable into the machine as follows: a. under the positive and negative battery cables b.
PAGE 506
BRAKES 3. Push the 2 brake plates inward so the brake plate brackets line up with the brake mounting brackets (Fig. 1733). Fig 1733 5. Using a 1/2” socket, install 2 bolts to secure the right brake plate bracket to the right brake mounting bracket (Fig. 1735). PICT-4367 4. Using a 1/2” socket, install 2 bolts to secure the left brake plate bracket to the left brake mounting bracket (Fig. 1734). Fig 1734 TX525 Service Manual Fig 1735 PICT-4355a 6.
PAGE 507
BRAKES 7. Pull down on the cable and slide the threaded portion of the brake cable assembly into the slot (Fig. 1737). 9. Slide the rubber boot down over the end of the threaded portion of the brake cable (Fig. 1739). Fig 1739 Fig 1737 10. Position the right panel onto the control panel assembly (Fig. 1740). 8. Thread the upper nut onto the threaded portion of the brake cable and tighten (Fig. 1738). Fig 1740 Fig 1738 8-28 PICT-4420 PICT-4414 PICT-4343a PICT-4419a Rev.
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BRAKES 11. Using a 3/8” socket, install 3 self-tapping screws that secure the right panel to the control panel assembly. Using a 3/8” socket and a 7/16” socket, install the bolt and nut securing the lower left corner of the right panel to the control panel assembly (Fig. 1741). 13. Install the knob onto the brake handle (Fig. 1743). A A B Fig 1743 A Fig 1741 A. Self-tapping screw (3) PICT-4341 B.
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BRAKES 14. Slide the battery partially into the battery mount. Install the positive battery cable to the positive battery terminal. Slide the battery farther into the battery mount. Install the negative battery cable to the negative battery terminal. Slide the battery guard in between the battery and the frame so that the hole in the guard lines up with the battery clamp mounting hole in the frame (Fig. 1745). 16. Slide the 2 fuel lines onto the fuel tank fittings. Note the location markings (Fig. 1747).
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BRAKES 18. Position the fuel tank into the rear end of the frame. Connect the two wires (black and orange) to the fuel sending unit located on the top of the fuel tank (Fig. 1749). 20. Position the rear frame cover to the rear end of the frame. Using 3/4” and 1/2” sockets, install 7 bolts and nuts to secure the rear frame cover to the frame and fuel tank bracket (Fig. 1751). Note: The rear of the machine may have to be lifted to reposition the jack stands so that the rear frame cover can be installed.
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BRAKES 21. Position the left hand rear cover support panel to the tower. Using a 3/8” socket, install 3 screws to secure the left rear cover support panel to the tower assembly. Repeat to install right hand rear cover support panel (Fig. 1752). Brake Plate Replacement 280000100 & higher The following procedures show removal and installation of the left hand brake plate assembly. The procedure is the same for removal and install of the right hand brake plate assembly. Brake Plate Removal 1.
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BRAKES 4. Using a 3/8” socket, remove the 6 screws that secure the left and right rear cover support panels to the tower assembly (3 screws per panel). Remove the panels (Fig. 1755). 6. Remove the fuel tank bracket (Fig. 1757). Fig 1757 Fig 1755 PICT-4504 5. Using 3/4” and 1/2” sockets, remove the 7 bolts and nuts securing the rear frame cover to the frame and fuel tank bracket. Remove the rear frame cover (Fig. 1756). PICT-5626 7.
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BRAKES 8. Mark the suction fuel line and tank fitting with an “S” and the return fuel line and tank fitting with an “R” (Fig. 1759): S - Fuel suction line R - Fuel return line 10. Slide the 2 fuel lines off the fuel tank fittings. Remove the fuel tank (Fig. 1761). Fig 1761 Fig 1759 PICT-4263 9. Slide the 2 fuel hose clamps down the fuel line away from the fuel tank fittings (Fig. 1760). 11. Using a 1/2” socket and wrench, remove the bolt, washer and nut securing the battery clamp to the frame.
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BRAKES 12. Slide the battery partially out of the battery mount. Disconnect the negative battery cable from the battery. Slide the battery out to access the positive battery cable terminal. Disconnect the positive battery cable. Remove the battery and battery guard from the battery mount (Fig. 1763). 14. Push the brake plate outward toward the drive wheel (Fig. 1765). Fig 1765 Fig 1763 PICT-4312a PICT-4367 15.
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BRAKES 16. Using a 7/16” socekt and wrench, remove the 2 bolts and nuts securing the brake plate to the brake link bar (Fig. 1767). Fig 1767 Brake Plate Installation 1. Align the brake plate with the brake link bar. Using a 7/16” socket and wrench, install 2 bolts and nuts securing the brake plate to the brake link bar (Fig. 1769). PICT-4379a Fig 1769 Brake Plate Assembly (Fig. 1768) A B PICT-4379a 2. With the brake handle in the Off position, slide the brake plate assembly into the frame (Fig.
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BRAKES 3. Push the brake plate inward aligning the brake link bar with the brake mounting bracket (Fig. 1771). Fig 1771 5. Slide the battery partially into the battery mount. Install the positive battery cable to the positive battery terminal. Slide the battery farther into the battery mount. Install the negative battery cable to the negative battery terminal.
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BRAKES 7. Slide the 2 fuel lines onto the fuel tank fittings. Note the location markings (Fig. 1775). S - Fuel suction line R - Fuel return line 9. Position the fuel tank into the rear end of the frame. Connect the two wires (black and orange) to the fuel sending unit located on the top of the fuel tank (Fig. 1777). B A Fig 1775 Fig 1777 PICT-4265 PICT-4262 A. Center terminal (orange wire) B. Outside terminal (black wire) 8.
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BRAKES 11. Position the rear frame cover to the rear end of the frame. Using 3/4” and 1/2” sockets, install 7 bolts and nuts to secure the rear frame cover to the frame and fuel tank bracket (Fig. 1779). Note: The rear of the machine may have to be lifted to reposition the jack stands so that the rear frame cover can be installed. 12. Position the left hand rear cover support panel to the tower. Using a 3/8” socket, install 3 screws to secure the left rear cover support panel to the tower assembly.
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BRAKES Brake Handle Spring Bracket Assembly Replacement 280000100 & higher 2. Remove the right hand side support panel (Fig. 1783). Note: 2007 models have a brake switch located in the brake handle support bracket inside the control panel. 2008 and later models do not have a brake switch located in the brake handle support bracket inside the control panel. The following procedure was performed on a 2008 model (no switch). Brake Handle Spring Bracket Assembly Removal 1. Remove the rear access panel (Fig.
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BRAKES 4. Using a 3/8” socket, remove the 3 self-tapping screws that secure the top right panel to the control panel assembly. Using a 3/8” socket and a 7/16” socket, remove the bolt and nut securing the lower left corner of the top right panel to the control panel assembly (Fig. 1785). 6. Remove the cotter pin from the clevis pin attaching the brake cable to the brake handle (Fig. 1787). A A B Fig 1787 A Fig 1785 A. Self-tapping screw (3) PICT-4341 B. Bolt and nut PICT-4345 7.
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BRAKES 8. Side the rubber boot up off the threaded end of the brake cable. Loosen the lower nut securing the brake cable to the spring bracket (Fig. 1789). Fig 1789 10. Using a 9/16” wrench and socket, remove the nut from the bolt securing the spring bracket assembly to the inside of the control panel (Fig. 1791). PICT-4390 9. Remove the top nut from the threaded portion of the brake cable and remove the brake cable from the spring bracket (Fig. 1790). Fig 1791 11.
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BRAKES Brake Handle Spring Bracket Assembly Installation 12. Remove the spacer from the spring bracket (Fig. 1793). Brake Handle Spring Bracket Assembly (Fig. 1795) A Fig 1793 B C D F E PICT-4395 Fig 1795 13. Remove the spring bracket (Fig. 1794). A. Bolt B. Washer C. Spring PICT-4398a D. Spacer E. Spring Bracket F. Nut 1. Position the spring bracket into the control panel (Fig. 1796). Fig 1794 PICT-4397 Fig 1796 TX525 Service Manual Rev.
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BRAKES 2. Position the spacer with the lower end placed inside the spring bracket slot (Fig. 1797). Fig 1797 4. With the washer on the bolt, install the bolt into the spacer and through the control panel bracket (Fig. 1799). PICT-4409 Fig 1799 3. Slide the spring down over the spacer (Fig. 1798). Fig 1798 5. Using a 9/16” wrench and socket, install a nut onto the bolt securing the spring bracket assembly to the inside of the control panel (Fig. 1800). PICT-4408 Fig 1800 8-44 PICT-4411 Rev.
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BRAKES Note: There should be approximately 3/4” (1.9cm) of exposed thread past the nut (Fig. 1801). Fig 1801 7. Slide the rubber boot onto the threaded portion of the brake cable (Fig. 1803). Fig 1803 PICT-4413 6. Slide the threaded portion of the brake cable into the slot of the spring bracket so that the bottom nut is on the underside of the bracket. Thread the top nut onto the brake cable and tighten (Fig. 1802). 8.
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BRAKES 9. Install a cotter pin into the clevis pin attaching the brake cable to the brake handle (Fig. 1805). 11. Using a 3/8” socket, install 3 self-tapping screws that secure the top right panel to the control panel assembly. Using a 3/8” socket and a 7/16” socket, Install the bolt and nut securing the lower left corner of the top right panel to the control panel assembly (Fig. 1807). A Fig 1805 10. Position the top right panel onto the control panel assembly (Fig. 1806).
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BRAKES 13. Install the knob onto the brake handle (Fig. 1809). Fig 1809 14. Position the right hand side support bracket. Using a 3/8” socket, install 3 self-tapping screws to secure (Fig. 1811). PICT-4342 Fig 1811 Note: If the brake plates extend out past the frame, the brake cable adjustment nuts should be adjusted upward on the brake cable adjustment threads (Fig. 1810). 15. Install the rear access panel (Fig. 1812). Fig 1812 Fig 1810 TX525 Service Manual PICT-4504 PICT-4505a PICT-4340 Rev.
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BRAKES Brake Handle Replacement 2. Remove the knob from the brake handle (Fig. 1814). Note: 2007 models have a brake switch located in the brake handle support bracket inside the control panel. 2008 and later models do not have a brake switch located in the brake handle support bracket inside the control panel. The following procedure was performed on a 2008 model (no switch). Brake Handle Removal 1. Remove the rear access panel (Fig. 1813). Fig 1814 PICT-4342 3.
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BRAKES 4. Remove the right panel from the control panel assembly (Fig. 1816). Fig 1816 6. Support the brake handle and remove the clevis pin that retains the brake cable to the brake handle (Fig. 1818). PICT-4343a Fig 1818 5. Remove the cotter pin from the clevis pin attaching the brake cable to the brake handle (Fig. 1817). Fig 1817 7. Using a 9/16” socket and wrench, remove the nut from the shoulder bolt securing the brake handle to the control panel bracket (Fig. 1819).
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BRAKES 8. Remove the bolt, bushing, brake handle and leaf spring (Fig. 1820). Fig 1820 d. Replace the leaf spring if there is an air gap between the center portion of the spring and the straight edge (Fig. 1822). PICT-4428a Fig 1822 9. Inspect the leaf spring and bushing: Leaf Spring a. Lay the leaf spring on a flat surface. b. Place a straight edge across the spring through the center of the bolt hole. c. Bushing Inspect the bushing OD and ID and the hole in the handle where the bushing mounts.
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BRAKES Brake Handle Installation 2. Slide the brake handle onto the bolt/leaf spring. Position the leaf spring onto the handle as shown (Fig. 1826): Brake Handle Assembly (Fig. 1824) D C A E B Fig 1824 A. Nut B. Bushing C. Handle F Fig 1826 PICT-4429a D. Knob E. Leaf spring F. Shoulder bolt PICT-4434a 3. Install the bushing over the bolt and into the handle (Fig. 1827). 1. Slide the leaf spring onto the shoulder bolt (Fig. 1825).
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BRAKES 4. Install the brake handle assembly into the control panel bracket (Fig. 1828). Fig 1828 6. Support the brake handle and install a clevis pin securing the brake cable to the brake handle (Fig. 1830). PICT-4428a Fig 1830 5. Using a 9/16” socket and wrench, install a nut onto the shoulder bolt (Fig. 1829). Fig 1829 8-52 PICT-4425 7. Install a cotter pin onto the clevis pin (Fig. 1831). PICT-4426a Rev.
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BRAKES 8. Position the right panel onto the control panel assembly (Fig. 1832). Fig 1832 10. Apply thread locking compound (Loctite 416 or equivalent) to brake handle threads (Fig. 1834). Fig 1834 PICT-4343a 9. Using a 3/8” socket, install 3 self-tapping screws securing the top right panel to the control panel assembly. Using a 3/8” socket and a 7/16” socket, install the bolt and nut securing the lower left corner of the top right panel to the control panel assembly (Fig. 1833). PICT-5526 11.
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BRAKES 12. Install the rear access panel (Fig. 1836). Fig 1836 8-54 PICT-4505a Rev.
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HYDRAULIC TESTING TX525 A. & B. 2-Spool Valve Hose Fitting and Coupler (Fig. 1838) Introduction Due to the many types and manufacturers of test equipment, the test hoses and fittings needed will vary. Refer to the connection information at each hydraulic test location.
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HYDRAULIC TESTING D. RH Drive Hydrostat Pump Test Gauge – 3/4”-16 – 37º Female (Fig. 1842) Pump Fitting – 13/16” - 16 ORFS – Straight Female (Fig. 1840) Fig 1842 Fig 1840 DSC-0579a DSC-0577a Test hoses: E. Couplers Diameter Length PSI Rated #8 3’ (91.4cm) 5000 Coupler End – 7/8” - 14 UNF-2B O-ring Seal (Fig. 1841) E. Flow Tester (Fig. 1843) A C B Fig 1841 DSC-0580a Fig 1843 A. Pressure gauge B. Flow gauge 9-2 Rev. 000 PICT-3520a C.
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HYDRAULIC TESTING Hydraulic Testing Hydraulic testing needs to be done in a systematic manner with a basic understanding of the hydraulic system and functions. It is recommended that you have the hydraulic schematic for the model and serial number being tested. Schematics can be obtained from this service manual or from the Toro Operator Manual or Parts Catalog provided with the unit. The TX525 hydraulic system utilizes a dual gear pump to push oil to all the hydraulic components of the unit.
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HYDRAULIC TESTING Auxiliary Circuit Pressure Test 1. Cycle the hydraulic oil until warm. Note: Make sure the engine RPM is checked and set properly prior to any hydraulic testing. 2. Park the unit on level ground. This test checks the auxiliary circuit system pressure. The components involved in this test are: gear pump, auxiliary valve, auxiliary couplers and hoses. 3. Set the park brake. 4. Shut the engine off. A pressure test can be done by using a flow type or a non-flow type tester.
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HYDRAULIC TESTING Removal of Pressure Gauge Prior to adjusting pressure relief, flow test should be done. If adjustment of the auxiliary pressure relief valve is required, continue on. If not, skip to step 8. 1. Let the engine and hydraulic oil cool. a. Unlatch and open the rear access panel (Fig. 1846). 2. Cycle the auxiliary valve to relieve any pressure in the circuit. 3. Push back on the female coupler locking collar to sparate the fittings (Fig. 1845). Fig 1846 Fig 1845 PICT-3402 4.
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HYDRAULIC TESTING c. Using a 4mm Allen wrench, adjust the pressure adjustment screw (Fig. 1848): • Turn the screw clockwise to increase the pressure. d. After achieving the recommended 3000 psi (206.89 bar), tighten the jam nut to lock the pressure adjustment screw in place (Fig. 1849). • Turn the screw counter-clockwise to decrease the pressure. Fig 1849 Fig 1848 9-6 PICT-4316a Rev. 000 PICT-4315a e.
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HYDRAULIC TESTING Auxiliary Circuit Flow Test 8. Start the engine and run at full rpm. This test checks the system flow of the auxiliary circuit. The components involved in this test are: gear pump, auxiliary valve, auxiliary couplers and hoses. When the traction unit tests to the recommendation the attachment may be at fault. 9. Activate the auxiliary valve handle and hold. View the flow (gpm) gauge, take reading. 10. Flow specification is 14 gpm (53 lpm). 11. Lower engine rpm. 12. Shut the engine off.
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HYDRAULIC TESTING Loader Circuit Flow Testing This test determines the flow output of the gear pump. The components involved in this test are: hydraulic line and pump. If the gear pump flow test meets specifications, then the loader valve or hydraulic line may be at fault. 8. Thread a flow meter hydraulic hose to the hydraulic pump fitting and tighten with a 15/16” wrench (Fig. 1853). 1. Cycle the hydraulic oil until warm. 2. Park the unit on level ground. 3. Set the park brake. 4.
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HYDRAULIC TESTING 10. Thread the hydraulic pump hose previously removed from the pump fitting onto the adaptor on the flow meter hose. Tighten the hose using a 15/16” wrench and 7/8” wrench on the adaptor fitting (Fig. 1855). 12. Start the engine and run at full rpm. 13. Take the flow reading from the gauge (Fig. 1857). Fig 1857 Fig 1855 PICT-3408 PICT-3406 11. Using a 7/8” wrench, tighten both hoses to the flow gauge (Fig. 1856). 14. With no restriction, the flow specification is 5.5 gpm (20.8 lpm).
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HYDRAULIC TESTING Flow Gauge Removal 1. Let the engine and hydraulic oil cool prior to loosen ing any hydraulic fittings. 5. Using a 1516” wrench on the hose and a 7/8” wrench on the adaptor, remove the adaptor from the flow meter hose (Fig. 1859). 2. Cycle the loader valve handle to relieve any pres sure in the system. 3. Place an oil drain pan under the flow meter hydraulic connections. 4.
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HYDRAULIC TESTING 7. Using a 15/16” wrench, connect the hydraulic hose to the hydraulic pump (Fig. 1861). Fig 1861 PICT-3403 8. Start the engine and cycle the loader valve. Inspect for leaks. 9. Release the park brake. 10. Properly discard all oily towels. TX525 Service Manual Rev.
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HYDRAULIC TESTING Loader Circuit Pressure Test Pressure Test This test determines if the loader valve relief is properly set or working correctly. The components involved in this test are: gear pump, hydraulic lines, loader valve and test port fitting. If the pressure can not be adjusted to meet specification then the loader valve or relief valve will need to be repaired or replaced. If the pressure meets specification the loader valve is not the problem. The lift or tilt cylinder could be at fault. 1.
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HYDRAULIC TESTING 2. Remove the rear access panel. 3. Place absorbent towel(s) below the hydraulic pump. 6. Thread the hydraulic hose (previously removed) onto the test port fitting and tighten using a 15/16” wrench (Fig. 1866). 4. Using a 15/16” wrench, remove the hydraulic hose from the pump fitting (Fig. 1864). Fig 1866 Fig 1864 PICT-3411 PICT-3403 7. Plug the test gauge into the test port (Fig. 1867). 5. Thread the test port fitting onto the hydraulic pump and tighten using a 15/16” wrench (Fig.
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HYDRAULIC TESTING 8. Start the engine and run at full rpm. 9. Move the loader arm handle so the tilt cylinder is retracted into the cylinder barrel. Hold the handle and take the pressure (psi) reading from the gauge (Fig. 1868). If adjustment is needed: a. Remove the RH control panel cover. b. Using a 19mm wrench and a 5mm Allen wrench, adjust the pressure adjustment screw (Fig. 1869 and Fig.
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HYDRAULIC TESTING c. If the recommended pressure specification can not be reached, replace or rebuild the valve. d. Install the RH control panel cover. 12. Check hydraulic fluid and add as needed. 13. Start unit and check for leaks. 14. Release park brake. 15. Shut engine off. TX525 Service Manual Rev.
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HYDRAULIC TESTING Test Gauge Removal 5. Using a 15/16” wrench, remove the test port fitting from the hydraulic pump (Fig. 1873). 1. Let the engine and hydraulic oil cool prior to loosening any hydraulic fittings. 2. Cycle the loader valve handle to relieve any pressure in the system. 3. Using a 15/16” wrench, disconnect the test gauge from the test port fitting (Fig. 1871). Fig 1873 PICT-3410 6. Connect the hydraulic hose to the hydraulic pump and tighten with a 15/16” wrench (Fig. 1874).
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HYDRAULIC TESTING Traction Control Tracking Adjustment, Full Forward Position 4. If the traction unit veers right, loosen the left jam nut and adjust the tracking set screw on front of the traction control (Fig. 1876). If the traction unit does not drive straight when you hold the traction control against the reference bar, complete the following procedure: Note: Whenever an adjustment is made, check to make sure the set screws contact stops in the full forward position. C 1.
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HYDRAULIC TESTING Traction Control Neutral Adjustment 5. Loosen the jam nuts on the traction rods, under the control panel (Fig. 1878). If the traction unit creeps forward or backward when the traction control is in neutral (and the unit is fully warmed up), make the neutral adjustment: A 1. Park the traction unit on a flat surface and lower the loader arm. 2. Stop the engine and remove the key. B 3. Lift/support the traction unit so that both tracks are off of the ground.
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HYDRAULIC TESTING Purging Air Procedure Due to the effects air has on efficiency in hydrostatic drive applications, it is critical that air is purged from the system. These purge procedures should be implemented anytime a hydrostatic system or hydraulic line has been opened to facilitate maintenance or any additional oil has been added to the system. Air creates inefficiency because it has compression and expansion rates that are higher than that of oil.
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HYDRAULIC TESTING THIS PAGE INTENTIONALLY LEFT BLANK. 9-20 Rev.
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TX525 Service Manual Form No.