Form No. 3390-971 Rev A RT1200 Traction Unit Model No. 25450W—Serial No. 314000501 and Up Register at www.Toro.com.
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.
Contents Servicing the Tires ..................................................56 Servicing the Axles .................................................58 Servicing the Transmission ......................................62 Cooling System Maintenance ......................................65 Servicing the Cooling System ...................................65 Belt Maintenance ......................................................69 Servicing the Engine Drive Belt ................................
Safety Utility Line Color Electric Red Improperly using or maintaining this machine can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert symbol (Figure 2), which means Caution, Warning, or Danger—personal safety instruction. Failure to comply with the instruction may result in personal injury or death.
• Before operating the machine with an attachment, ensure • Locate the pinch point areas that are marked on the that the attachment is properly installed. machine and attachments; keep hands and feet away from these areas. • Use extra care when handling fuels. They are flammable • Lightning can cause severe injury or death. If lightning and vapors are explosive. is seen or thunder is heard in the area, do not operate the machine; seek shelter. – Use only an approved container.
Maintenance and Storage • Battery acid is poisonous and can cause burns. Avoid contact with skin, eyes, and clothing. Protect your face, eyes, and clothing when working with a battery. • Lower the attachment(s), stop the engine, wait for all moving parts to stop, and remove the key whenever you adjust, clean, or repair the machine. • Battery gases can explode. Keep cigarettes, sparks, and flames away from the battery. • Do not touch parts that may be hot from operation.
Gas Line Safety WARNING If you damage a gas line, an immediate explosion and fire hazard could occur. Leaking gas is both flammable and explosive and may cause serious injury or death. • Do not smoke while operating the machine. • Shut off the machine and remove the key. • Remove all individuals from the work area. • Immediately contact the proper emergency and utility authorities to secure the area.
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 1230–7541 (2 decals, 1 on each side) 2. Decal 125-8479 8. Decal 125-6694 (2 decals, 1 on each side) 3. 4. 5. 6. Decal Decal Decal Decal 125-4963 125-8480 125-6135 125-8499 9. 10. 11. 12.
Figure 5 1. Decal 125-8496 2. Decal 125-8473 (on the floor panel covering the battery) 7. Decal 127-1829 8. Decal 125-8480 3. Decal 125-8495 9. Decal 125-6157 (under the left-side cowl) 4. Decal 127-1828 5. Decal 125-6139 6. Decal 130-7540 10. Decal 125-8483 11. Decal 125-6689 Figure 6 1. Decal 131–0439 2. Decal 127-1830 3. Decal 130-7539 4. Decal 125-8484 5. Decal 131–0440 125–6135 125-4963 1. Warning—do not touch hot surfaces.
125-6671 1. Explosion hazard; electric shock hazard—call local utilities before digging. 125–6139 1. Lift point; tie down point 125-6689 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. 0000 0000 0000 125-6157 1. Disconnect the battery power. 3. On/Start 2. Off/Stop 4. Read the Operator’s Manual. 125-6694 1.
125–8473 1. Explosion hazard—wear eye protection. 3. Fire hazard—keep open flames away. 2. Caustic liquid/chemical burn hazard—rinse affected area and seek medical assistance. 4. Poison hazard—do not tamper with the battery. 125-8481 1. Hydraulic supply 125-8479 1. Burn hazard from contents under pressure—read the Operator’s Manual. 125-8482 1. Hydraulic return 125-8480 1. Warning—do not climb on ROPS. 125–8483 1. Hydraulic fluid; read the Operator’s Manual.
5-8484 1. 12-volt receptacle 125-8499 1. Warning—read the Operator's Manual. 3. Forward 2. Reverse 4. Transmission—gear selection 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.
125-8496 8. Rear wheel steering—turn the wheels right; machine will turn left 9. Rear wheel steering—auto center (optional kit) 1. Backfill blade/vibratory plow—tilt/swing left 2. Backfill blade/vibratory plow—tilt/swing right 3. Backfill blade/vibratory plow—lower 10. Lower the attachments 4. Backfill blade/vibratory plow—raise 11. Raise the attachments 5. Backfill blade/vibratory plow head—angle left 12. Rear attachment—forward speed 6. Backfill blade/vibratory plow head—angle right 13.
127-1829 130-7539 1. Oil drain 127-1830 3. Lower the attachment 1. Read the Operator's Manual. 2. Raise the attachment 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. Preparing for Work Before operating the machine on the job site, review the following items: • Gather all relevant information available about the job site before you begin working. • Review all blueprints and other plans, and identify all existing or proposed structures, characteristics of the landscape, and other proposed jobs in the area scheduled at the same time as your job. Figure 18 1.
trailer from a portable container rather than from a fuel dispenser nozzle. fuel at lower temperatures provides a lower flash point and cold flow characteristics, which aid in starting the engine and help prevent clogging the fuel filter. • If you must use a fuel dispenser nozzle, keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete.
Figure 20 1. Fuel-water separator 2. Drain valve 3. Rotate the drain valve counterclockwise approximately 3-1/2 turns until the valve drops down from the fuel-water separator (Figure 21). Figure 19 1. Filler neck Note: The valve should extend 25 mm (1 inch) from the separator. 2. Fuel-tank cap (off) Note: Remove the cap slowly to reduce the air pressure buildup. 2. Fill the fuel tank to the bottom of the neck to allow space for the fuel to expand. Note: The fuel tank capacity is 182 L (48 US gal). 3.
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 Checking the Hydraulic-Fluid Level Service Interval: Before each use or daily 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. Use Toro Premium All-season Hydraulic Fluid (available in 5-gallon pails or 55-gallon drums.
Figure 27 1. Restricted air-cleaner indicator 2. Command center 3. Replace the air-cleaner element(s) as follows: A. Replace the primary air-cleaner element; refer to Replacing the Air-cleaner Elements (page 49). Figure 26 1. Fill cap (off) 3. Hydraulic fluid level at the midpoint of the sight glass B. Repeat steps 1 and 2. C. If the restricted air-cleaner indicator is still displayed, replace the secondary air-cleaner element; refer to Replacing the Air-cleaner Elements (page 49). 2.
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. This information is displayed on the splash screen during start up of the machine, as shown in A of Figure 28 or when you access the main selection screen, as shown in B of Figure 28. Figure 29 1. Previous screen button 2.
• Coolant temperature indicator—This indicator shows the temperature of the coolant in the engine-cooling system. It is displayed in the lower center area of the instrument cluster (Figure 30). 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.
Important: Do not run the engine if this warning message is displayed. Note: If this message is displayed, stop the engine and replace the hydraulic-charge filter for the transmission. • Check alternator or battery—This message is displayed • Hydraulic-charge filter restriction if the alternator is not charging the battery (Figure 30 and Figure 31). (accessories)—This message is displayed if the charge filter for the hydraulic circuit for the accessories is restricted (Figure 33).
Figure 35 1. Return to the previous screen Figure 34 1. Engine information 2. Trencher (traction unit) setup 5. Trencher (traction unit) errors 6. Up arrow and down arrow buttons 3. Screen setup 7. Engine errors Accessing the Trencher Setup Function Screen You will need a PIN to access this screen; to obtain the PIN, contact an Authorized Toro Distributor. 4.
Setting the Front and Rear Steering Positions Note: This procedure requires that you have the PIN number, which you can obtain from an Authorized Service Dealer. 1. Press button number 2 [Trencher (traction unit) setup] on the main-selection screen; refer to Accessing the Main-Selection Screen (page 30). 2.
Operating the Engine 2. Turn the key switch to the Start position. 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. Before Starting the Engine WARNING Important: Do not operate the starter motor until it stops turning. Do not operate the starter motor for more than 30 seconds at one time. Allow the starter motor to cool for 30 seconds before you operate it again.
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 41). Note: The front-wheel steering and rear-wheel steering operate independently (unless the machine is equipped with the optional advanced steering control). Figure 42 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 42).
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 44). 2. Remove the hairpin from the tilt-lockout pin (Figure 45). Note: The tilt-lockout pin should be stowed in the vertical hole in the axle-lockout bracket. Figure 46 1. Tilt the machine right 2. Tilt the machine left Note: Use the tilt gauge (Figure 47) to determine the degree of tilt at which the machine is operating. Figure 45 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 49 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 53). half of the thumb control (Figure 52). To angle the backfill blade to the right: Press the right half of the thumb control (Figure 52). Figure 52 1. Angle—left Figure 53 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 57). Figure 55 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 58 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 62). Figure 62 Figure 60 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 61). 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 63 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 64 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 Every 250 hours Service Interval: Every 250 hours Inspect the air-intake piping for wear, damage, and loose clamps (Figure 69). Inspect the charge-air piping and hoses (Figure 68) for leaks, holes, cracks, or loose connections, and tighten any loose connections. Figure 69 1. Charge-air pipe (left) Figure 68 1.
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 70 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 71). 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 73). 4. Install the right side panel; refer to Installing the Side Panels (page 46). 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 76). 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 78). 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 33). 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 81 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 Use Toro Premium All-season Hydraulic Fluid (available in 5-gallon pails or 55-gallon drums. See the parts catalog or an Authorized Toro Service Dealer for part numbers). If Toro hydraulic fluid is not available, you may use an equivalent hydraulic fluid such as Mobilfluid 424, provided that it meets all the following material properties and industry specifications. Do not use a synthetic hydraulic fluid. Consult with your lubricant distributor to identify a satisfactory product.
Figure 85 1. Wheel hub 4. Oil port at the 3 o’clock position 2. Oil port at the 6 o’clock position 5. Plug 3. Drain pan 6. Oil-servicing equipment Figure 86 Front Axle 1. Front-axle housing 3. Sight port 2. Plug 2. Place a drain pan under the oil port of the wheel hub (Figure 85). 3. Remove the plug and drain the oil from the planetary (Figure 85). 4. Check the condition of the O-ring for the plug. Note: Replace the O-ring if it is worn or damaged. 5.
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 86 and Figure 87). Note: Use a flashlight and a mirror to help you see the oil level. • If the oil level is too high, allow the oil to drain from the sight port. • If the oil level is too low, add the specified oil to the axle housing sight port; refer to steps 6 and 7 in Changing the Oil in the Axles (page 60). 4. Clean the threads of the sight plug. Figure 89 Rear Axle 5.
Figure 90 Front Axle Figure 91 Rear Axle 1. Front-axle housing 4. Pinion housing 1. Rear-axle housing 4. Fill plug 2. Oil-servicing equipment 5. Sight port 2. Forward 5. Sight port 3. Fill plug 3. Oil-servicing equipment 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 90 and Figure 91). 7. Wait a few minutes for the oil to settle, then add more oil as necessary.
Checking the Oil Level in the Transmission Service Interval: Every 100 hours Important: If you operate the machine while the level of the transmission oil is below the recommended level, you may damage the transmission and the parking brake. 1. Park the machine on a level surface. 2. Start the engine and run it for 10 minutes. Figure 93 1. Breather fitting 3. Stop the engine and remove the ignition key. 2. Rear axle 4. After 5 minutes, check the transmission oil level in the sight gauge (Figure 94). 2.
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 96). 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 oil; refer to Checking the Oil Level in the Transmission (page 62). 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 45). Servicing the Cooling System 4. Check the coolant level by looking at the sight gauge in the side of the surge tank (Figure 98). 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.
Figure 101 1. Drain valve 9. Close the drain valve (Figure 101). 10. Remove the drain hose and clamp (Figure 99 and Figure 100). Figure 102 Flushing the Cooling System 1. Reservoir door 2. Filler neck (recovery tank) Engine and radiator coolant capacity: 18.5 L (19.5 US qt) 1. Condition the cooling system as follows: A. Ensure that the coolant is drained from the radiator and that the drain valve is closed (Figure 101). B. C.
D. Open the drain valve and drain the cleaning solution into a drain pan (Figure 99 and Figure 101). cooling system properly can damage both the engine and the cooling system. 1. Remove the radiator cap from the recovery tank (Figure 98). E. Close the drain valve (Figure 101). 2. Flush the cooling system as follows: 2. Fill the cooling system with the specified coolant mixture (Figure 105) until the fluid level is up to the midpoint in the sight gauge (Figure 98). 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 106 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) The machine comes from the factory with a full hydraulic fluid reservoir that contains approximately 182 L (48 US gal) of high-quality hydraulic fluid.
Figure 108 1. Fill cap 4. Plug 2. Sight gauge 5. Drain pan 3. Hydraulic reservoir Figure 109 7. Remove the drain plug from the hydraulic reservoir (located underneath the reservoir), and drain the reservoir (Figure 108). 1. Fill level (midpoint) 3. Hydraulic fluid 2. Sight gauge 8. Examine the condition of the seal on the drain plug. 2. Clean the fill cap with solvent. Note: Replace the seal if it is worn or damaged. 3. Install the fill cap (Figure 109). 9. Install the drain plug (Figure 108).
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 110). Figure 111 1. Container suitable for hydraulic fluid Figure 110 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 112). 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 110). 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 Disconnecting the Computer-module Connectors Important: Before you use an electric welder to repair or modify the machine, disconnect all the following components: • The wiring at the alternator. • The 2 connectors for the computer module. • The connector for the command-center display. 1. Remove the 4 hex-flanged head bolts (6 x 20 mm) that secure the lower-console panel to the console, and remove the panel (Figure 116).
Connecting the Computer-module Connectors Cleaning Removing Dirt and Debris from the Machine 1. Connect the 38-socket connector (CPU-2) to the back of the computer module (Figure 117). 2. Connect the 50-socket connector (CPU 1) to the back of the computer module (Figure 117). Important: Operating the engine with blocked screens, dirty or plugged cooling fins, and/or cooling shrouds removed, will result in engine damage from overheating. 3. Align the lower-console panel to the console (Figure 116). 1.
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 49). 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.
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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.
