Form No. 3395-823 Rev A RT1200 Traction Unit Model No. Model No. Model No. Model No. Register at www.Toro.com. Original Instructions (EN) 25450—Serial No. 315000001 and Up 25450A—Serial No. 315000001 and Up 25450C—Serial No. 315000001 and Up 25450W—Serial No.
WARNING CALIFORNIA Proposition 65 Warning This product contains a chemical or chemicals known to the State of California to cause cancer, birth defects, or reproductive harm. Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Because in some areas there are local, state, or federal regulations requiring that a spark arrester be used on the engine of this machine, a spark arrester is available as an option.
Contents Safety ........................................................................... 4 Before Operating the Machine .................................. 5 Electrical Line Safety ............................................... 7 Gas Line Safety ....................................................... 7 Communication Line Safety...................................... 7 Water Line Safety .................................................... 7 Safety and Instructional Decals .................................
Safety Drive System Maintenance .........................................57 Servicing the Tires ..................................................57 Servicing the Axles .................................................59 Servicing the Transmission ......................................62 Cooling System Maintenance ......................................65 Servicing the Cooling System ...................................65 Belt Maintenance ......................................................
Utility Line Color Electric Red Telecommunication, alarm or signal, cables, or conduit Orange Natural gas, oil, steam, petroleum, or other gaseous or flammable material Yellow Sewer and drain Green Drinking water Blue Reclaimed water, irrigation, and slurry lines Purple Temporary survey markings Pink Proposed excavation limits White • Before operating the machine with an attachment, ensure that the attachment is properly installed. • Use extra care when handling fuels.
Maintenance and Storage • Locate the pinch point areas that are marked on the machine and attachments; keep hands and feet away from these areas. • Lower the attachment(s), stop the engine, wait for all • Lightning can cause severe injury or death. If lightning is seen or thunder is heard in the area, do not operate the machine; seek shelter. • Slope Operation • • Avoid operating this machine on slopes, if possible. • Keep all movements on slopes slow and gradual.
Gas Line Safety • Battery gases can explode. Keep cigarettes, sparks, and flames away from the battery. • Keep your body and hands away from pinhole leaks WARNING or nozzles that eject high-pressure hydraulic fluid. Use cardboard or paper to find hydraulic leaks; never use your hands. Hydraulic fluid escaping under pressure can penetrate skin and cause injury, requiring surgery within a few hours by a qualified surgeon; otherwise, gangrene may result.
Safety and Instructional Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost. Figure 4 1. Decal 125-6689 7. Decal 130-7541 (2 decals, 1 on each side) 2. Decal 125-4963 8. Decal 125-6694 (2 decals, 1 on each side) 3. 4. 5. 6. Decal Decal Decal Decal 125-8479 125-8480 125-8499 125-6135 9. 10. 11. 12.
Figure 5 1. Decal 125-8496 2. Decal 125-8473 (on the floor panel covering the battery) 7. Decal 125-4963 8. Decal 127-1829 3. Decal 125-8495 4. Decal 127-1828 9. Decal 125-8480 10. Decal 125-6157 (under the left-side cowl) 5. Decal 125-6139 6. Decal 130-7540 11. Decal 125-8483 12. Decal 125-6689 125-4963 Figure 6 1. Decal 131–0439 2. Decal 130-7539 1. Warning—do not touch hot surfaces. 3. Decal 125-8484 4.
0000 0000 125–6135 0000 125-6157 125–6139 1. Lift point; tie down point 1. Disconnect the battery power. 3. On/Start 2. Off/Stop 4. Read the Operator’s Manual. 125-6671 1. Explosion hazard; electric shock hazard—call local utilities before digging.
125-8479 125-6689 1. Burn hazard from contents under pressure—read the Operator’s Manual. 1. Warning—keep away from 2. Cutting/dismemberment hot surfaces. hazard, fan—keep away from moving parts; keep all guards and safety devices in place. 125-8480 1. Warning—do not climb on ROPS. 125-6694 1. Tie-down point 125-8481 1. Hydraulic supply 125–8473 1. Explosion hazard—wear eye protection. 3. Fire hazard—keep open flames away. 2.
5-8499 125-8482 1. Hydraulic return 1. Warning—read the Operator's Manual. 3. Forward 2. Reverse 4. Transmission—gear selection 125–8483 130-7541 1. Hydraulic fluid; read the Operator’s Manual. 1. Warning—keep bystanders away from the machine. 131-0439 1. Differential—lock 125-8484 1. 12-volt receptacle 12 2.
125-8495 1. Tilt the machine left 6. Sideshift—left (optional attachment) 11. Auxiliary hydraulic (optional 16. Trencher—fast rotation kit) (optional accessory) 2. Tilt the machine right 7. Lower the crumber/rotate the plow forward (optional attachment) 12. Vibratory plow depth—float 17. Trencher—slow rotation (optional accessory) on (optional accessory) 3. Auto frame leveling on (optional kit) 8. Raise the crumber/rotate 13. Vibratory plow depth—float 18. Warning—read the Operator's Manual.
127-1828 1. Hydraulic pressure 4. Raise the attachment. 2. Lower the attachment. 5. Hydraulic return 3. Case drain 127-1829 130-7539 1. Oil drain 131-0440 1. Parking brake—engage 2. Parking brake—disengage 14 1. Electrical power 3. Engine—run 2. Engine—stop 4.
130-7540 1. Warning—read the Operator's Manual. 4. Warning—keep bystanders away from the machine. 2. Warning—do not operate the machine unless you have received instruction. 5. Warning—keep away from moving parts; keep all guards and shields in place. 3. Warning—wear a seatbelt. 6. Warning—wear hearing protection. 15 7. Explosion hazard; electric shock hazard—before digging call the local utilities service. 8.
Product Overview Figure 7 1. Nose panel 5. Backfill blade 2. Left side panel 6. Fuel reservoir 3. Grab handles 7. Fuel cap 4. ROPS enclosure 8. Steps Figure 8 1. Grab handles 4. Steps 2. Right side panel 5. Hydraulic-fluid sight gauge 3. Nose panel 6.
Controls Throttle Button • Throttle-up Button—Press the throttle-up button Become familiar with all the controls (Figure 9 through Figure 16) before you start the engine and operate the machine. (button 7), located at the bottom-right corner of the command center, to increase the engine speed (Figure 9). Note: Press the button repeatedly to increase the engine speed up to the maximum engine speed (2,450 rpm).
Key Switch Use the key switch to power the electrical accessories, start the machine, and stop the machine (Figure 11). The 4 key-switch positions are as follows: • Accessory—Rotate the key switch to this position to energize the lamp switch circuits. • Stop—Rotate the key switch to this position to stop the engine and de-energize the electrical system. • • Note: When you release the key, it will automatically go to the Run position. Figure 11 1.
• Move the utility-traction joystick forward to move the • Move the joystick to the left to tilt the backfill blade to the machine forward (Figure 14). • Move the traction joystick rearward to move the machine • in reverse (Figure 14). • Move the traction joystick to the center (Neutral) position to stop the machine (Figure 14). • left, or move the joystick to the right to tilt the backfill blade to the right (Figure 15).
• Move the joystick rearward to start the vibration of the plow blade (Figure 15). • Move the joystick further rearward to increase the vibration (Figure 15). • Move the joystick toward the Neutral position to decrease and stop the vibration (Figure 15). Trencher • Move the joystick forward to start the digging chain in the forward direction (Figure 15). • Move the joystick further forward to increase the chain speed (Figure 15). Figure 16 • Move the joystick to the Neutral position to stop the 1.
Seat-Height and Seat-Slide Buttons – Rotate the lever for the weight compensator counterclockwise to reduce the support tension of the seat. Armrest-Height Control Rotate the armrest-height control to raise or lower the armrest (Figure 17). Seat-Lumbar Knob Rotate the seat-lumbar knob, found behind the seat, to adjust the back lumbar support for best comfort (Figure 17).
Operation Note: Determine the left and right sides of the machine from the normal operating position. Think Safety First Carefully read all safety instructions and symbols in the safety section. Knowing this information could help you or bystanders avoid injury. DANGER Operating on wet grass or a steep slopes can cause sliding and loss of control. Wheels dropping over an edge can cause a rollover, which may result in serious injury, drowning, or death. Figure 18 1. Battery On position 2.
Preparing for Work Using summer-grade fuel above 20° F (-7°C) contributes toward a longer fuel pump life and increased power compared to using winter-grade fuel. Before operating the machine on the job site, review the following items: WARNING • Gather all relevant information available about the job site before you begin working. Fuel is harmful or fatal if swallowed. Long-term exposure to fuel vapors can cause serious injury and illness. • Avoid prolonged breathing of vapors.
Using Biodiesel Fuel This machine can also use a biodiesel blended fuel of up to B20 (20% biodiesel, 80% petrodiesel). The petrodiesel portion should be low or ultra-low sulfur. Observe the following precautions: • The biodiesel portion of the fuel must meet specification ASTM D6751 or EN14214. • The blended fuel composition should meet ASTM D975 or EN590. • Biodiesel blends may damage painted surfaces. • Use B5 with a biodiesel content of 5% or less in cold weather.
Checking the Engine-Oil Level Service Interval: Before each use or daily Note: The engine is shipped with oil in the crankcase; however, check the oil level before and after you first start the engine. Oil specification: API classification of CJ-4 or higher Use only high-quality SAE 15W-40 heavy-duty engine oil with an API classification of CJ-4 or higher.
Checking the Coolant Level in the Reservoir Service Interval: Before each use or daily If the engine overheat warning is displayed on the control panel, check the coolant level in the reservoir and add coolant if it is low. Also inspect the engine compartment around the radiator and clear away any obstructions to air flow. 1. Park the machine on a level surface, stop the engine, and remove the ignition key. 2. Allow the engine to cool. 3.
Checking the Hydraulic-Fluid Level Checking the Restricted Air-Cleaner Indicator Service Interval: Before each use or daily Service Interval: Before each use or daily 1. Start the engine; refer to Operating the Engine (page 34). 2. Check to see if the restricted air-cleaner indicator is displayed in the home screen of the command center (Figure 28). Hydraulic fluid specification: Mobilfluid 424 Note: Many brands of hydraulic fluid are almost colorless, making it difficult to detect leaks.
• Check the machine for broken, damaged, loose, or missing parts. Replace, tighten, or adjust these parts before you operate the machine. • Repair or replace all damaged ROPS and seat belt parts. Operating the Command Center Software Messages The command center will display information about the controller version, display version, and installed optional attachments or kits that are operated through the command center.
Note: If the indicator goes into the red area, reduce the engine speed to idle for a few minutes to allow the engine to cool, then stop the engine. Check the coolant level, for debris on the radiator, or for a thermostat that does not operate correctly. Also check the drive belt, belt tensioner, or water-pump pulley. • Fuel-level indicator—This indicator shows the remaining level of fuel that is in the tank, and it is displayed in the lower right area of the command display (Figure 31).
Figure 34 Figure 33 1. Machine or engine error 4. Check alternator or battery 2. Low engine-oil pressure (flashes) 5. Engine overheated (flashes) 3. High hydraulic-oil temperature (flashes) 6. Low fuel quantity (flashes) 1. Wait-to-start-engine indicator Reading the Machine or Engine Error Indicators in the Command Display Note: When a warning indicator is shown in the command display, take corrective measures immediately.
Note: If this message is displayed, stop the engine and replace the hydraulic-return filter. Accessing the Engine Information Screen To access the engine-information screen, press button number 1 on the main-selection screen; refer to Accessing the Main-Selection Screen (page 31). • Hydraulic-charge filter restriction (traction motor)—This message is displayed if the charge filter for the traction motor is restricted (Figure 35).
Figure 39 Accessing the Engine Errors Information Screen Use the trencher diagnostic screen (Figure 40) view suspect part number—failure mode identifier (SPN-FMI) codes for the engine; contact an Authorized Service Dealer. Figure 38 1. Display brightness indicator 2. Decrease brightness 3. Increase brightness 4.
Using the PIN screen Note: This procedure requires that you have the PIN number, which you can obtain from an Authorized Service Dealer. Note: To access the trencher setup function for the machine, you must enter the unique 8-digit identification number assigned into the PIN screen. The trencher setup functions protected by the PIN screen include the following: • Pedal calibration • Steering setup • Auto-tilt setup 1.
Operating the Engine air is at the proper temperature for starting the engine, the wait-to-start indicator in the display turns off. 2. Turn the key switch to the Start position. Before Starting the Engine Note: If the engine starts and then stops, do not turn the key switch to the Start position again until the starter motor has stopped turning. 1. Check the oil level; refer to Checking the Engine-Oil Level (page 25). 2.
Operating the Machine in Extreme Conditions Both hot and cold weather place unusual demands upon the machine and the attachments. You can minimize temperature-related problems on the machine by performing the following steps: Operating the Machine in Hot Weather 1. Clean all dirt and debris from the radiator, heat exchanger, hydraulic-fluid cooler, and engine area to ensure that there is proper air flow to cool the engine. 2. Remove any debris from the air inlets in the nose and side panels. 3.
4. Check the coolant mixture before you operate the machine in cold weather. Use only a 50% ethylene glycol and 50% water mixture in the cooling system year round. Driving and Stopping the Machine 5. Before operating the machine, move it at low speed and actuate each hydraulic control several times to warm the oil. Using the Traction-Control Pedal The traction-control pedal controls the direction and the speed of the machine. The speed of the machine depends on the position of the gear-selector switch.
Steering the Machine Using the Front-wheel Steering Use the steering wheel to control the front-wheel steering (Figure 46). Note: The front-wheel steering and rear-wheel steering operate independently (unless the machine is equipped with the optional advanced steering control). Figure 47 1. Utility-traction joystick 3. Move the lever out of the Neutral detent position and to 1 of the following positions: • Move the lever forward (toward the front of the machine) to move the machine forward (Figure 47).
2. 3. 4. 5. 6. Important: If you must temporarily park the machine on a slope or an incline, position the machine at a right angle to the slope, with the front of the machine toward the bottom of the hill. Ensure that the machine is behind an object that will not move. Support or lower all attachments to the ground. Set the parking brake.
Installing the Tilt-lockout Pin 1. Use the tilt switch to align the hole in the chassis-lockout bracket with the holes in the axle-lockout bracket (Figure 49). 2. Remove the hairpin from the tilt-lockout pin (Figure 50). Note: The tilt-lockout pin should be stowed in the vertical hole in the axle-lockout bracket. Figure 51 1. Tilt the machine right 2. Tilt the machine left Note: Use the tilt gauge (Figure 52) to determine the degree of tilt at which the machine is operating. Figure 50 1.
Note: You must sit in the operator seat before you move the machine; otherwise, the machine will not move. Note: The utility-traction lever controls the speed of the machine. The farther that you move the lever from the Neutral position, the faster the machine moves. Important: Control the speed of the machine travel with the utility-traction lever, not the throttle. 5. Check the indicator display frequently. Figure 54 Using the Backfill Blade 1.
• To angle the backfill blade to the left: Press the left • 8. Stop the engine and remove the key. 9. Fasten the front and rear of the machine to the trailer using chains and a binder (Figure 58). half of the thumb control (Figure 57). To angle the backfill blade to the right: Press the right half of the thumb control (Figure 57). Figure 57 1. Angle—left Figure 58 2. Angle—right 1. Front tie-down point (each side) 2.
Completing the Work for the Day When you complete your work for the day, do the following: 1. Backfill the spoils in the part(s) of the trench in which you are finished working. 2. Move the machine to a safe and stable location. 3. Move all levers to the Neutral position. 4. Set the parking brake. 5. Lower all attachments to the ground. 6. Let the machine idle for a few moments to cool it down. 7. Stop the engine, wait for all moving part to stop, and remove the ignition key. 8.
Maintenance Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 100 hours • Check the oil level in the wheel hubs. • Check the oil level in the front and rear axles. After the first 200 hours • Change the oil in the wheel hubs. • Change the oil in the axles. Before each use or daily • • • • • • • • • • • Drain the water and sediment from the fuel-water separator. Check the engine-oil level. Check the coolant level in the reservoir.
Premaintenance Procedures Lubrication General Safety Grease Type: Lithium-based grease. Greasing the Machine Greasing the Front and Rear Axles WARNING Improperly servicing or repairing the machine can cause injury or death. Service Interval: Every 250 hours 1. Clean the grease fittings with a rag. If you do not understand the service procedures for this machine, contact an Authorized Toro Service Dealer or obtain the service manual for this machine. 2.
Greasing the Front and Rear Drive Shafts Service Interval: Every 500 hours 1. Clean the grease fittings with a rag. 2. Connect the grease gun to the grease fitting for the slide coupling at the forward end of the drive shaft, and apply 2 or 3 pumps of grease to the fitting (Figure 62). Figure 60 Rear axle 1. Grease fitting (upper pivot) 2. Grease fitting (lower pivot) 3.
Engine Maintenance Before maintaining the engine, perform the following steps: 1. Park the machine on level ground, lower all attachments, and stop the engine. 2. Remove the ignition key and allow the engine to cool for 2 or 3 minutes. Accessing the Engine Figure 63 Removing the Side Panels 1. Grease fitting 1. If the optional backhoe is installed, perform the following substeps to remove the left side panel; otherwise, skip to step 2: 3. Wipe up any excess grease. A.
Installing the Side Panels 1. Align the side panel with the machine frame. 2. Align the mounting bolt at the top of the side panel with the hole in the support flange of the hood panel (Figure 67). Figure 67 Figure 65 1. Latch lever 3. Side-panel latch 2. Latch button 1. Hole (support flange—hood panel) 3. Hood panel 2. Mounting bolt 4. Side panel 3. Apply light inward pressure against the panel at 1 of the latches. 4. Lift the panel up and then away from the machine (Figure 66). 4.
Servicing the Engine Oil and Filter Crankcase capacity: 15.0 L (15.9 US qt) with the filter. Use only high-quality SAE 15W-40 heavy-duty engine oil with an API classification of CH-4 or higher. While SAE 15W-40 oil with an API classification of CH-4 or higher is recommended for most climates, refer to Figure 68 for oil viscosity recommendations for extreme climates. °C -40 -30 -20 -10 0 10 20 30 40 50 °C -40 -22 -2 14 32 50 58 86 104 122 All Seasons 15W-40 Figure 69 Winter Conditions 10W-30 1.
Important: The oil pressure gauge must indicate engine oil pressure within 15 seconds after you start the engine. If there is no indication of engine oil pressure within 15 seconds, shut off the engine immediately to avoid damaging the engine and check that the engine oil level is correct. 5. Stop the engine and remove the key. 6. Wait 5 minutes and check the oil level; refer to steps 4 through 8 in Checking the Engine-Oil Level (page 25). 7.
Checking the Air-intake Piping Checking the Charge-air Piping Service Interval: Before each use or daily—Check the air-intake piping for wear, damage, and loose fasteners. Service Interval: Every 250 hours Every 250 hours—Check the air-intake piping for wear, damage, and loose fasteners. Inspect the charge-air piping and hoses (Figure 73) for leaks, holes, cracks, or loose connections, and tighten any loose connections. Inspect the air-intake piping for wear, damage, and loose clamps (Figure 74).
Fuel System Maintenance Servicing the Fuel System Draining Water from the Fuel Tank Service Interval: Before each use or daily 1. Stop the engine. 2. Place a drain pan under the drain plug in the fuel tank. Figure 75 1. Air pre-cleaner 2. Air-cleaner housing 3. Latch (4) 3. Unscrew the drain plug from the fuel tank and drain the water (Figure 76). 4. Secondary air-cleaner element 5. Primary air-cleaner element 6. Air-cleaner cover 3.
3. Install a new breather into the pipe coupling hand tight (Figure 78). 4. Install the right side panel; refer to Installing the Side Panels (page 47). Replacing the Fuel Filters Service Interval: Every 500 hours The engine on this machine uses a dual fuel-filter system, with a primary fuel filter and a secondary fuel filter. The primary fuel filter includes a fuel-water separator; it is not pressurized but operates under a vacuum.
a side block-off plug can allow debris to enter the fuel system and damage fuel system components. Important: If possible, pre-fill new primary- and secondary-fuel filters with clean fuel prior to assembly using the clean side block-off plug packed with the filter. Do not pour fuel directly into the center of the filter, because this will allow unfiltered fuel to enter the system and may damage the fuel system components. Note: You must prime the system after you install the fuel filters. 1.
Electrical System Maintenance 2. Rotate the battery-disconnect switch clockwise to the On position; refer to Battery-Disconnect Switch (page 21). 3. Clean the fuel-pump head and the priming pump using a quick-dry spray cleaner and compressed air (Figure 81). Maintaining the Battery Accessing the Battery Remove the battery cover as follows: 1. Ensure that the battery-disconnect switch is in the Off position; refer to Battery-Disconnect Switch (page 21). 2.
Connecting a Booster Battery Servicing the Battery WARNING WARNING Exposure to battery acid or a battery explosion can cause serious personal injury. Charging the battery produces gasses that can explode. Before you service a battery, always wear face protection, protective gloves, and protective clothing. Never smoke near the battery and keep sparks and flames away from battery. Note: This procedure requires 2 people to perform.
4. Connect the battery charger to the electrical source. 6. Connect the negative (-) jumper cable to a ground point, such as the nut at the pivot point for the alternator (Figure 83). Important: Do not overcharge the battery. Note: Charge the battery as shown in the following table: 7. Start the engine; refer to steps 1 through 4 in Starting the Engine (page 34). Note: If the engine starts and then stops, do not operate the starter motor until the starter motor stops turning.
Drive System Maintenance Servicing the Tires WARNING Exploding tires and/or rim parts can cause injury or death. Figure 86 1. Hex-flanged bolts (5/16 x 3/4 inch) 4. Fuse block 2. Cover 3. Console 5. Fuses Keep yourself and others out of the area of danger. Stand on the tread side of the tire. Always fill the tires to the correct air pressure, and follow the instructions in this manual for adding air or servicing the tires. 4.
Note: Before you add air, ensure that the tire is properly installed on the machine, or put the wheel in a restraining device, such as a tire inflation cage. 2. Remove the cap from the valve stem. 3. Attach the self-locking chuck of the air hose to the valve stem. 4. When inflating the tire while it is mounted to the machine, stand behind the tread of the tire. Note: Ensure that all persons are away from the side of the tire before you start to add air. 5.
Servicing the Axles Changing the Oil in the Wheel Hubs Hub-and-axle oil specification: Mobilfluid 424 Service Interval: After the first 200 hours Every 1,000 hours Checking the Oil Level in the Wheel Hubs Wheel hub oil capacity: approximately 1.5 L (1.6 US qt) Note: If possible, change the oil when it is warm. Service Interval: After the first 100 hours Every 250 hours 1. Move the machine forward or backward until the oil plug for the wheel hub is at the 6 o’clock position (Figure 90).
Checking the Oil Level in the Axles Service Interval: After the first 100 hours Every 250 hours 1. Place a drain pan under the pinion housing of the axle. 2. Remove the plugs from the sight port in the pinion housing of the axle (Figure 91 and Figure 92). Figure 92 Rear Axle 3. Plug 2. Forward 4. Site port 3. Look through the sight port and check that the oil level in the axle is level with the bottom of the threads of the port (Figure 91 and Figure 92). Figure 91 Front Axle 1. Front-axle housing 1.
Figure 93 Front Axle 1. Drain plug 3. Drain port 2. Drain pan 4. Front-axle housing Figure 95 Front Axle 1. Front-axle housing 4. Pinion housing 2. Oil-servicing equipment 5. Sight port 3. Fill plug Figure 94 Rear Axle 1. Drain plug 3. Drain port 2. Drain pan 4. Rear-axle housing 2. Remove the plugs from the sight port and the drain port of the pinion housings for the axles (Figure 93 and Figure 94). Note: Allow the oil to drain completely from the pinion housing and axle. 3.
Servicing the Transmission 6. Fill the axles with the specified oil through the sight port until the oil is level with the threads at the bottom of the port (Figure 95 and Figure 96). Transmission-oil specification: Mobilfluid 424 7. Wait a few minutes for the oil to settle, then add more oil as necessary. Checking the Oil Level in the Transmission Note: Continue to add oil until the oil level stabilizes and is at the bottom of the threads of the sight port. Service Interval: Every 100 hours 8.
Changing the Transmission Oil 3. Apply PTFE thread sealing tape to the threads of the plug. Service Interval: Every 1,000 hours 4. Fill the transmission with the specified oil through the fill port (Figure 101). Draining the Transmission Oil Important: When you fill the transmission with oil, slowly add the oil into the transmission to avoid entraining air with the oil. Note: If possible, drain the oil when it is warm. 1. Park the machine on a level surface, stop the engine, and remove the key. 2.
Changing the Transmission Filter 9. Check the transmission oil level; if the level is low, add the specified oil to the transmission; refer to Filling the Transmission with Oil (page 63). Service Interval: Every 500 hours Note: You can access the transmission filter from underneath the right side of the machine, inboard of the hydraulic tank. Important: When you fill the transmission with oil, slowly add the oil into the transmission to avoid entraining air with the oil. 1.
Cooling System Maintenance 3. Remove the left side panel; refer to Removing the Side Panels (page 46). Servicing the Cooling System 4. Check the coolant level by looking at the sight gauge in the side of the surge tank (Figure 103). 2. Allow the engine to cool. Note: You should see that the coolant level is above the midpoint of the sight gauge.
Checking the Condition of Cooling System Components Service Interval: Every 300 hours Check the condition of the cooling system for leaks, damage, dirt, and loose hoses, and clamps. Clean, repair, tighten, and replace the components as necessary. Checking the Concentration of the Coolant Service Interval: Every 1,000 hours Test the concentration of ethylene glycol based antifreeze in the coolant . Ensure that the coolant is a mixture of 50% ethylene glycol and 50% water.
Note: Dispose of the used coolant properly according to local codes. Figure 106 1. Drain valve 9. Close the drain valve (Figure 106). Figure 107 10. Remove the drain hose and clamp (Figure 104 and Figure 105). 1. Reservoir door 2. Filler neck (recovery tank) Flushing the Cooling System 3. Funnel 4. Coolant system cleaning solution Engine and radiator coolant capacity: 18.5 L (19.5 US qt) C. 1. Condition the cooling system as follows: A.
D. Open the drain valve and drain the cleaning solution into a drain pan (Figure 104 and Figure 106). cooling system properly can damage both the engine and the cooling system. 1. Remove the radiator cap from the recovery tank (Figure 103). E. Close the drain valve (Figure 106). 2. Flush the cooling system as follows: 2. Fill the cooling system with the specified coolant mixture (Figure 110) until the fluid level is up to the midpoint in the sight gauge (Figure 103). A.
Belt Maintenance Servicing the Engine Drive Belt WARNING Stop the engine and remove the key from the key switch before you begin to perform any maintenance or repair work. WARNING Figure 111 Contacting a rotating belt can cause serious injury or death. 1. Belt tensioner Always stop the engine and remove the key from the key switch before working near belts. 3. Remove the belt from the pulleys.
Hydraulic System Maintenance Changing the Hydraulic Fluid and Replacing the Breather Servicing the Hydraulic System The capacity of the hydraulic-fluid reservoir: 150 L (40 US gallons) Service Interval: Every 1,000 hours The capacity of the hydraulic-fluid system: 182 L (48 US gallons) Hydraulic-fluid specification: Toro Premium All-season Hydraulic Fluid Draining the Hydraulic Reservoir If Toro Premium All-season Hydraulic Fluid is not available, you may use Mobil DTE 15M Special (Mobil DTE 15M flu
Figure 113 1. Fill cap 3. Plug 2. Sight gauge (hydraulic reservoir) 4. Drain pan Figure 114 7. Remove the drain plug from the hydraulic reservoir (located underneath the reservoir), and drain the reservoir (Figure 113). 1. Fill level (midpoint) 3. Hydraulic fluid 2. Sight gauge 8. Examine the condition of the seal on the drain plug. Note: Replace the seal if it is worn or damaged. 2. Clean the fill cap with solvent. 9. Install the drain plug (Figure 113). 3. Install the fill cap (Figure 114).
Changing the Hydraulic Filters Removing the Traction-pedal Assembly Remove the traction-pedal assembly as follows: 1. Remove the 4 hex-flanged head bolts that secure that traction-pedal assembly to the chassis of the machine (Figure 115). Figure 116 1. Container suitable for hydraulic fluid Figure 115 1. Hex-flanged head bolts 3. 6-pin connector (traction-pedal sensor) 2. Traction-pedal assembly 4. 6-socket connector (machine harness) 3. Hydraulic-charge filter 2. Sharp object 3.
Note: Use a tapered-center punch or awl to puncture the filter case. 12. Install the traction-pedal assembly; refer to Removing the Traction-pedal Assembly (page 72). 3. Rotate the hydraulic-return filter counterclockwise and remove the filter (Figure 117). Installing the Traction-pedal Assembly 1. Connect the 6-socket connector of the machine harness to the 6-pin connector of the traction-pedal sensor (Figure 115). Note: Discard the filter properly. 4.
ROPS Maintenance Checking and Servicing the ROPS A ROPS certification label located on the support structure contains information about the maximum gross machine weight, the machine model number, and the ISO number. Replacing a Damaged ROPS System If the ROPS system has been damaged in an accident, such as a rollover or hitting an overhead object during transport, replace any damaged ROPS components to restore the ROPS system to its original level of protection.
Welding on the Machine 5. Using the finger pulls, lift the battery cover up to remove it from the ROPS platform (Figure 120). Important: Before you use an electric welder to repair or modify the machine, perform all the following: 6. Remove the lock-washer nut (3/8 inch) securing the negative-battery cable and ring terminal to the negative stud of the battery and remove the cables from the battery (Figure 121).
2. Disconnect the 50-socket connector (CPU 1) from the back of the computer module (Figure 124). Figure 122 1. Charge wire 3. 4-socket connector (voltage-sense wire) Figure 124 2. Boot 2. Remove the nut and washer that secures the terminal of the charge wire to the stud of the alternator, and remove the terminal. 1. Forward 3. Computer module 2. 50-socket connector (CPU 1) 4. 38-socket connector (CPU-2) 3.
Cleaning 5. Align the boot of the charge wire over the terminal and stud (Figure 122). Removing Dirt and Debris from the Machine Closing the Machine 1. Assemble the positive-battery cable into the positive stud of the battery (Figure 121) with the lock-washer nut (3/8 inch) that you removed in step 7 of Preparing to Disconnect the Components (page 75).
Storage 4. Stop the engine. Preparing for Seasonal Storage 6. Secure all the fuel system fittings. 5. Flush the fuel tank with fresh, clean diesel fuel. 7. Service the air cleaner; refer to Servicing the Air-cleaner System (page 50). For storage over 30 days, prepare the machine, the attachments, and the engine as follows: 8. Seal the air cleaner inlet and the exhaust outlet with plastic and weatherproof tape. 9.
Troubleshooting Problem The starter does not crank. Possible Cause 1. The electrical connections are corroded or loose. 1. Check the electrical connections for good contact. 2. 3. 4. 5. 2. 3. 4. 5. A fuse is blown. A fuse is loose. The battery is discharged. The relay or switch is damaged. 6. The starter or starter solenoid is damaged. 7. Internal engine components have seized up. 1. The engine cranks but will not start. Replace the fuse. Install the fuse. Charge the battery or replace it.
Problem The engine runs but knocks or misses. Possible Cause 1. There is dirt or water in the fuel system. 1. Drain and flush the fuel system; add fresh fuel. 2. The engine overheats. 2. Check the engine oil level and add oil as needed; also check and service the coolant system, if necessary. 3. Bleed the nozzle and check for air leaks at the fuel hose connections and the fittings between the fuel tank and the engine. 4. Contact your Authorized Service Dealer. 5. Contact your Authorized Service Dealer.
Problem The engine loses power. Possible Cause 1. The engine is under an excessive load. 1. Reduce the ground speed of the machine. 2. The engine oil level is either too low or too high. 3. The air cleaning system elements are dirty. 4. There is dirt or water in the fuel system. 2. Either add or drain the engine oil until the oil level is at the Full mark. 3. Service the air cleaning system elements. 4. Drain and flush the fuel system; add fresh fuel. 5.
Notes: 82
Notes: 83
Underground Equipment The Toro Underground Warranty A Limited Warranty Conditions and Products Covered The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly warrant your Toro Underground Equipment (“Product”) to be free from defects in materials or workmanship. Where a warrantable condition exists, we will repair the Product at no cost to you including diagnostics, labor, and parts.
