Form No. 3395-883 Rev A RT1200 Traction Unit Model No. Model No. Model No. Model No. Register at www.Toro.com. Original Instructions (EN) 25500—Serial No. 315000001 and Up 25500A—Serial No. 315000001 and Up 25500C—Serial No. 315000001 and Up 25500W—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 ............................................................................ 5 Electrical Line Safety ............................................... 7 Gas Line Safety ....................................................... 7 Communication Line Safety...................................... 7 Water Line Safety .................................................... 7 Safety and Instructional Decals .....................
Safety Servicing the Tires ..................................................55 Servicing the Axles .................................................56 Servicing the Transmission ......................................60 Cooling System Maintenance ......................................63 Servicing the Cooling System ...................................63 Belt Maintenance ......................................................67 Servicing the Engine Drive Belt ................................
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 2. 3. 4. 5. 6. Decal Decal Decal Decal Decal 125-4963 125-8479 125-8480 125-8499 125-6135 Figure 5 7. Decal 125-6694 (2 decals, 1 on each side) 8. 9. 10. 11. Decal Decal Decal Decal 1. Decal 125-8496 2.
117-2718 0000 0000 0000 125-4963 1. Warning—do not touch hot surfaces. 125-6157 1. Disconnect the battery power. 3. On/Start 2. Off/Stop 4. Read the Operator’s Manual. 125–6135 125-6671 1. Explosion hazard; electric shock hazard—call local utilities before digging. 125–6139 1.
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—no riders 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. Caustic liquid/chemical burn hazard—rinse affected area and seek medical assistance.
125-8499 125-8482 1. Hydraulic return 1. Warning—read the Operator's Manual. 3. Forward 2. Reverse 4. Transmission—gear selection 125–8483 131-0439 1. Hydraulic fluid; read the Operator’s Manual. 1. Differential—lock 125-8484 2. Differential—unlock 127-1829 1. 12-volt receptacle 1.
131-0440 1. Parking brake—engage 2. Parking brake—disengage 130-7539 1. Electrical power 3. Engine—run 2. Engine—stop 4. Engine—start 125-8495 1. Tilt the machine right 6. Sideshift—left (optional attachment) 11. Auxiliary hydraulic (optional 16. Trencher—fast rotation kit) (optional accessory) 2. Tilt the machine left 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.
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. 14 7. Explosion hazard; electric shock hazard—before digging call the local utilities service. 8.
Product Overview Controls Become familiar with all the controls (Figure 9 through Figure 16) before you start the engine and operate the machine. Command Center Home Screen Controls Use the buttons on the command center to control the operation of machine functions, and to navigate to the machine setup and diagnostic screens (Figure 9). Figure 7 1. Nose panel 5. Fuel reservoir 2. Left side panel 6. Fuel cap 3. Grab handles 7. Steps 4. ROPS enclosure Figure 9 Home screen shown 1.
Throttle Button • Throttle-up Button—Press the throttle-up button (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). • Throttle-down Button—Press the throttle-down button (button 8), located at the bottom-right corner of the command center, to lower the engine speed (Figure 9).
• Move the utility-traction joystick forward to move the Key Switch machine forward (Figure 14). 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.
• Push the joystick forward to lower the backfill blade or Rear-Wheel-Steering Switch vibratory plow or pull the joystick rearward to raise the backfill blade or vibratory plow (Figure 15). The switch for the rear-wheel steering is used to control the steering direction (left or right) of the rear wheels. The switch for the rear-wheel steering is located behind the backfill blade/vibratory plow joystick. Note: The function of the joystick depends on the attachment selected in the command center.
Note: The neutral-indicator light turns on when you turn the key switch to the On position and both the utility-traction-control and attachment-control levers are in the Neutral position. Attachment-Elevation Switch The attachment-elevation switch raises and lowers an attachment mounted at the rear of the machine. • Press the switch on the left to lower the attachment boom (Figure 15). • Press the switch on the right to raise the attachment boom (Figure 15).
Seat-Rotation Lever and Seat-Weight Compensator • Seat-rotation lever—Use this lever to unlock the seat so that you can rotate the seat to the desired position. The seat will rotate 360° and lock into position at 10° increments (Figure 17). Note: Rotate the seat to the Front position before driving the machine. • Seat-weight compensator—Rotate this lever for the weight compensator to adjust the seat support tension for the weight of the operator (Figure 17).
Operation • Gather all relevant information available about the job Note: Determine the left and right sides of the machine from the normal operating position. • Review all blueprints and other plans, and identify all site before you begin working. existing or proposed structures, characteristics of the landscape, and other proposed jobs in the area scheduled at the same time as your job.
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. • Check seals, hoses, and gaskets that come in contact with the fuel, as they may degrade over time.
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. Install the fuel-tank cap and tighten it securely by hand. Draining Water from the Fuel-Water Separator Figure 22 Service Interval: Before each use or daily 1. Open the drain valve. 1. Remove the left side panel; refer to Removing the Side Panels (page 44). 3. Close the drain valve. 2.
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.
Checking the Restricted Air-Cleaner Indicator • Clean machine components that you use. • Remove any loose items from the machine. • Check the machine for broken, damaged, loose, or Service Interval: Before each use or daily missing parts. Replace, tighten, or adjust these parts before you operate the machine. 1. Start the engine; refer to Operating the Engine (page 33). • Repair or replace all damaged ROPS and seat belt parts. 2.
Using the Home Screen Use the previous screen, next screen, down screen, or up screen buttons to display either the rpm home screen (A of Figure 30), the % load home screen (B of Figure 30) or the main selection screen (C of Figure 30). Figure 31 1. Gear indicator 6. Check alternator or battery 2. Parking brake indicator 7. Hour meter 3. Tachometer 8. Hydraulic-fluid temperature 4. Machine or engine error 9. Coolant temperature 5. Low engine-oil pressure 10.
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).
Note: If this message is displayed, stop the engine and replace the hydraulic-return filter. • Hydraulic-charge filter restriction (traction motor)—This message is displayed if the charge filter for the traction motor is restricted (Figure 35). Note: If this message is displayed, stop the engine and replace the hydraulic-charge filter for the traction motor. • Air-filter restriction (engine)—This message is displayed when the air filter requires service (Figure 35).
Accessing the Main-Selection Screen To access the main-selection screen, press and release the up arrow and the down arrow buttons (Figure 36) at the same time. This screen allows the user to choose from the function screens shown in Figure 36. Figure 37 1. Return to the previous screen Accessing the Trencher Setup Function Screen Note: You need the PIN to access this screen; to obtain the PIN, contact an Authorized Toro Distributor. Figure 36 1. Engine information 2. Trencher (traction unit) setup 3.
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 intake air to warm up before starting. When the intake air is at the proper temperature for starting the engine, the wait-to-start indicator in the display turns off. Before Starting the Engine 2. Turn the key switch to the Start position. 1. Check the oil level; refer to Checking the Engine-Oil Level (page 24). 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. 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 53 Using the Power Port 1. Front tie-down point (each side) 2.
Moving a Non-functioning Machine Repair a non-functioning machine on the job site, if possible. Otherwise, you must lift the machine with a spreader bar and transport the machine to a repair facility. 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.
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 Removing the Side Panels 1. If the optional backhoe is installed, perform the following substeps to remove the left side panel; otherwise, skip to step 2: A.
Installing the Side Panels Servicing the Engine Oil and Filter 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 61). 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.
Figure 65 1. Oil-filter head Figure 63 1. Engine-oil drain fitting 2. Oil filter 3. Rotate the oil filter to the left and remove the oil filter (Figure 65). 5. Remove the cap from the drain fitting and allow the engine oil to drain completely (Figure 63). Note: Recycle the used oil filter according to local codes. Note: Removing the oil-fill cap from the valve cover helps to drain the engine oil (Figure 64). 4. Use a rag to wipe clean the surface of the oil-filter head, where the oil filter seats. 5.
Checking the Charge-air Piping 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. Service Interval: Every 250 hours Inspect the charge-air piping and hoses (Figure 67) for leaks, holes, cracks, or loose connections, and tighten any loose connections. 5.
Checking the Air-intake Piping Service Interval: Before each use or daily—Check the air-intake piping for wear, damage, and loose fasteners. Every 250 hours—Check the air-intake piping for wear, damage, and loose fasteners. Inspect the air-intake piping for wear, damage, and loose clamps (Figure 68). Figure 69 1. Air pre-cleaner 2. Air-cleaner housing 3. Latch (4) 4. Secondary air-cleaner element 5. Primary air-cleaner element 6. Air-cleaner cover 3.
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 71 3. Unscrew the drain plug from the fuel tank and drain the water (Figure 70). 1. Intake hose (bottom of the tank) 3. Siphoning equipment 2. Fuel cap 4. Drain pan 2.
3. Install a new breather into the pipe coupling hand tight (Figure 72). 4. Install the right side panel; refer to Installing the Side Panels (page 45). 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. 2. Rotate the battery-disconnect switch clockwise to the On position; refer to Battery-Disconnect Switch (page 20). 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.
Servicing the Battery Electrical System Maintenance WARNING Exposure to battery acid or a battery explosion can cause serious personal injury. Maintaining the Battery Before you service a battery, always wear face protection, protective gloves, and protective clothing. Accessing the Battery Remove the battery cover as follows: WARNING 1. Ensure that the battery-disconnect switch is in the Off position; refer to Battery-Disconnect Switch (page 20).
Connecting a Booster Battery 6. Connect the negative (-) jumper cable to a ground point, such as the nut at the pivot point for the alternator (Figure 77). WARNING 7. Start the engine; refer to steps 1 through 4 in Starting the Engine (page 33). Charging the battery produces gasses that can explode. Note: If the engine starts and then stops, do not operate the starter motor until the starter motor stops turning. Do not operate the starter motor for more than 30 seconds at one time.
4. Connect the battery charger to the electrical source. Important: Do not overcharge the battery. Note: Charge the battery as shown in the following table: Battery Charging Settings and Times Charger Setting Charging Time 4 to 6 amperes 30 minutes 25 to 30 amperes 10 to 15 minutes Figure 80 5. When the battery is fully charged, unplug the charger from the electrical source, then disconnect the charger leads from the battery posts (Figure 78). Replacing a Fuse 1.
Drive System Maintenance 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. Servicing the Tires 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. WARNING Exploding tires and/or rim parts can cause injury or death.
Servicing the Axles Hub-and-axle oil specification: Mobilfluid 424 Checking the Oil Level in the Wheel Hubs Service Interval: After the first 100 hours Every 250 hours Note: Have another person help you align the oil plugs in the axles when you service the axle oil. 1. Ensure that the machine is on a level surface and that all the attachments are in the transport position. 2. Move the machine forward or backward until the plug for the wheel hub is at either the 3 o’clock or 9 o’clock position (Figure 83).
Changing the Oil in the Wheel Hubs 7. Install the plug in the oil port of the wheel hub. Service Interval: After the first 200 hours 8. Repeat this procedure for the other wheel hubs. Every 1,000 hours Checking the Oil Level in the Axles Wheel hub oil capacity: approximately 1.5 L (1.6 US qt) Service Interval: After the first 100 hours Toro Premium Gear Oil is available from an Authorized Toro Service Dealer. See the parts catalog for part numbers. Every 250 hours 1.
Figure 87 Front Axle 1. Drain plug 3. Drain port 2. Drain pan 4. Front-axle housing Figure 86 Rear Axle 1. Rear-axle housing 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 85 and Figure 86). Figure 88 Rear Axle 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.
Figure 89 Front Axle Figure 90 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 89 and Figure 90). 7. Wait a few minutes for the oil to settle, then add more oil as necessary.
Cleaning the Axle Breathers Servicing the Transmission Service Interval: Every 1,000 hours Transmission-oil specification: Mobilfluid 424 1. Clean the area around the breathers with a cleaning solvent (Figure 91 and Figure 92). 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.
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 95). 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 61). 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 44). Servicing the Cooling System 4. Check the coolant level by looking at the sight gauge in the side of the surge tank (Figure 97). 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 100 1. Drain valve 9. Close the drain valve (Figure 100). Figure 101 10. Remove the drain hose and clamp (Figure 98 and Figure 99). 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 98 and Figure 100). cooling system properly can damage both the engine and the cooling system. 1. Remove the radiator cap from the recovery tank (Figure 97). E. Close the drain valve (Figure 100). 2. Flush the cooling system as follows: 2. Fill the cooling system with the specified coolant mixture (Figure 104) until the fluid level is up to the midpoint in the sight gauge (Figure 97). 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 105 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 107 1. Fill cap 3. Plug 2. Sight gauge (hydraulic reservoir) 4. Drain pan Figure 108 7. Remove the drain plug from the hydraulic reservoir (located underneath the reservoir), and drain the reservoir (Figure 107). 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 107). 3. Install the fill cap (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 109). Figure 110 1. Container suitable for hydraulic fluid Figure 109 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 70). 3. Rotate the hydraulic-return filter counterclockwise and remove the filter (Figure 111). 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 109). 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 114). 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 115).
Disconnecting the Alternator Wiring 1. At the alternator, slide the boot off the terminal and stud at the back of the alternator (Figure 116). Figure 117 1. Lower-console panel 2. Hex-flanged head bolts (6 x 20 mm) 2. Disconnect the 50-socket connector (CPU 1) from the back of the computer module (Figure 118). Figure 116 1. Charge wire 3. 4-socket connector (voltage-sense wire) 2. Boot 2.
Cleaning 3. Align the lower-console panel to the console (Figure 117). 4. Secure the panel to the console with the 4 hex-flanged head bolts (6 x 20 mm). Removing Dirt and Debris from the Machine Connecting the Alternator Wiring Important: Operating the engine with blocked screens, dirty or plugged cooling fins, and/or cooling shrouds removed, will result in engine damage from overheating. 1. Ensure that the battery-disconnect switch is in the Off position; refer to Battery-Disconnect Switch (page 20).
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 47). 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.
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.
