Form No. 3421-177 Rev C MB TX 2500 Tracked Mud Buggy Model No. 68138—Serial No. 402100000 and Up Model No. 68138G—Serial No. 402100000 and Up Model No. 68138HD—Serial No. 400000000 and Up Register at www.Toro.com.
Introduction It is a violation of California Public Resource Code Section 4442 or 4443 to use or operate the engine on any forest-covered, brush-covered, or grass-covered land unless the engine is equipped with a spark arrester, as defined in Section 4442, maintained in effective working order or the engine is constructed, equipped, and maintained for the prevention of fire. This machine is intended to be used by professional, hired operators in commercial applications.
Contents serious injury or death if you do not follow the recommended precautions. Safety ....................................................................... 4 Safe Operating Practices.................................... 4 Safety and Instructional Decals .......................... 6 Product Overview ..................................................... 9 Controls ............................................................. 9 Specifications ..................................................
Safety Improper use or maintenance of the 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.
• Identify hazards at the base of the slope. Do • Watch for traffic when operating near or crossing • • • • • • not operate the machine near drop-offs, ditches, embankments, water or other hazards. The machine could suddenly roll over if a wheel or track goes over the edge or the edge collapses. Keep a safe distance (twice the width of the machine) between the machine and any hazard. roadways. Do not touch parts that may be hot from operation.
• Charge batteries in an open, well-ventilated area, • Battery acid is poisonous and can cause burns. away from spark and flames. Unplug the charger before connecting or disconnecting it from the battery. Wear protective clothing and use insulated tools. Avoid contact with skin, eyes, and clothing. Protect your face, eyes, and clothing when working with a battery. • Battery gases can explode. Keep cigarettes, • Keep all parts in good working condition and all sparks, and flames away from the battery.
decal132-8961 decal137-0575 132-8961 137-0575 1. Battery charging condition 4. Hopper is lowering. 2. Hour meter 5. Hopper is down. 3. Hopper is raising. 6. Hopper is lowering automatically. 1. Read the Operator’s Manual. 2. Transmission fluid 3. Cold-fill line decal132-9051 132-9051 1. Tie-down point decal137-8899 137-8899 decal132-9052 132-9052 1. Read the Operator’s Manual. 1. Main (15 A) 3. Logic (7.5 A) 2.
decal137-3715 137-3715 1. Parking-brake release 7. Explosion hazard—shut off the engine 13. Lower hopper before adding fuel; no fire, open flames, or smoking when adding fuel. 2. Parking brake 8. Machine tipping hazard—do not drive 14. Move the handles in to operate. forward with the hopper raised; do not drive down slopes with the hopper raised; do not drive across slopes with the hopper raised; drive slowly with the hopper down. 3. Warning—read the Operator’s Manual; hearing protection must be worn.
Parking Brake Lever Product Overview To engage the parking brake, pull back the lever. (Figure 4). To disengage the parking brake, push the lever forward. Hour Meter The hour meter records the number of hours the engine has operated. It operates when the engine is running. Use these times for scheduling regular maintenance (Figure 4). Choke Control g038268 Use the choke to start a cold engine. Pull the choke knob up to engage it. Push the choke knob down to disengage it (Figure 4). Figure 3 1.
Specifications Operation Note: Specifications and design are subject to Note: Determine the left and right sides of the machine from the normal operating position. change without notice. Width 90.2 cm (35-1/2 inches) Length 268.0 cm (105-1/2 inches) Height 121.2 cm (47.7 inches) Weight 734 kg (1,619 lb) Hopper capacity Maximum load Discharge Height Important: Before operating, check the fuel and oil level, and remove debris from the machine.
DANGER DANGER In certain conditions, fuel is extremely flammable and highly explosive. A fire or explosion from fuel can burn you and others and can damage property. In certain conditions during fueling, static electricity can be released causing a spark, which can ignite the fuel vapors. A fire or explosion from fuel can burn you and others and can damage property. • Fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any fuel that spills.
Using Stabilizer/Conditioner Performing Daily Maintenance Use fuel stabilizer/conditioner in the machine to keep the fuel fresh longer when used as directed by the fuel-stabilizer manufacturer. Before starting the engine each day, perform the following procedures: Important: Do not use fuel additives containing • Check the engine-oil level—refer to Checking the methanol or ethanol. Engine-Oil Level (page 20).
Operating the Throttle Starting the Engine The throttle control moves between FAST and SLOW positions (Figure 7). 1. Engage the parking brake. 2. Engage the choke. Always use the FAST position when moving the machine. Note: A warm or hot engine may not require choking. You may need to repeat the starting cycle when you start the engine for the first time after you have filled a completely empty fuel system with fuel. g008946 Figure 7 3. Move the throttle between the FAST and SLOW positions. 4.
Shutting Off the Engine 1. Move the throttle between the FAST and SLOW positions. 2. Engage the parking brake. 3. Turn the key switch to the OFF position and remove the key. Removing Debris from the Machine 1. Park the machine on a level surface, move the motion-control levers to the NEUTRAL-LOCK position, engage the parking brake, and lower the hopper. 2. Shut off the engine and remove the key. Allow the engine to cool. 3. Clean the inside of the hopper using a hose.
Transporting the Machine Lowering the Hopper without Power 1. Install the cylinder lock; refer to Installing the Cylinder Lock (page 18). 2. Ensure that the tub is empty. 3. Place a large drain pan under the hydraulic-manifold block (Figure 12). Use a heavy-duty trailer or truck with full-width ramps to transport the machine. Ensure that the trailer or truck has all the necessary brakes, lighting, and marking as required by law. Please carefully read all the safety instructions.
Lifting the Machine Hoist the machine using 2 lift points under the hopper and 2 rear tie-down loops. Tilt the hopper forward to locate the 2 lift loops and attach a chain or straps at each of the loops as shown in Figure 14. Note: Take up the slack in the chain or straps to properly balance the unit. g194436 Figure 14 1. Lift points under hopper 2.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 10 hours • Check and adjust the track tension (every 10 hours until 50 hours). Before each use or daily • • • • • • • • Check the engine-oil level. Clean the blower housing (more often under extremely dusty, dirty conditions). Check the condition of the track. Check the parking brake operation.
Pre-Maintenance Procedures Releasing the Cushion for Rear Access You can release the cushion for rear access to the machine for maintenance or adjustment. 1. Lower the platform. 2. Loosen the twist knobs on each side of the machine (Figure 15). g185887 Figure 16 1. Cylinder lock 4. g032556 2. Cushion 3. Remove the cushion and lower it to the platform. 4. Perform any maintenance or adjustment on the machine. 5. Raise the cushion, and slide it onto the pins on both sides of the machine. 6.
Lubrication Engine Maintenance Greasing the Machine Servicing the Air Cleaner Service Interval: Every 50 hours Service Interval: Every 25 hours—Service or replace the air-cleaner foam element (more often under extremely dusty, dirty conditions). When operating the machine under normal conditions, lubricate all grease fittings for the bearings and bushings with No. 2 lithium grease. Lubricate the bearings and bushings immediately after every washing, regardless of the interval listed.
Checking the Engine-Oil Level Service Interval: Before each use or daily Important: Remember to add 80% of the oil, and then gradually fill it to the Full mark on the dipstick. Important: Do not run the engine with the oil level above the Full mark or below the low mark. Otherwise, you may damage the engine. g028106 Figure 19 1. Air-cleaner cover 3. Paper element 1.
Changing the Engine Oil and Filter Service Interval: Every 100 hours Oil Type:: Detergent oil (API service SJ or higher) Engine Oil Capacity: 1.9 L (64 fl oz) g185888 Viscosity: Refer to the table below. g031623 Figure 22 g017552 Figure 21 B. Change the engine oil while the engine is warm. 4. Note: Dispose of the used oil at a recycling center. 1.
g243623 Figure 24 g027477 Figure 23 5. Servicing the Spark Plugs Slowly pour approximately 80% of the specified oil into the filler tube (Figure 24). Service Interval: Every 100 hours—Check the spark plug. Every 300 hours—Replace the spark plug. The spark plugs are RFI compliant. Equivalent alternate brand plugs can also be used. Type: Champion XC12YC Air Gap: 0.76 mm (0.
Removing the Spark Plug Installing the Spark Plug 1. Park the machine on a level surface, move the motion-control levers to the NEUTRAL-LOCK position, engage the parking brake, and lower the hopper. 2. Shut off the engine and remove the key. Allow the engine to cool. 3. Before removing the spark plug(s), clean the area around the base of the plug to keep dirt and debris out of the engine. 4. Remove the spark plug (Figure 25).
Draining the Fuel Tank Fuel System Maintenance You can drain the fuel tank by removing it and pouring the fuel out of the fill neck; refer to Removing the Fuel Tank (page 25). You can also drain the fuel tank by using a siphon in the following procedure. Replacing the Fuel Filter Service Interval: Every 100 hours/Yearly (whichever comes first) (more often under dusty, dirty conditions). 1.
Removing the Fuel Tank 1. Lower the platform. 2. Release the cushion; refer to Releasing the Cushion for Rear Access (page 18). 3. Remove the cross bracket (Figure 30). Electrical System Maintenance Servicing the Battery Service Interval: Every 50 hours DANGER Battery electrolyte contains sulfuric acid, which is fatal if consumed and causes severe burns. Do not drink electrolyte and avoid contact with skin, eyes or clothing.
Charging the Battery WARNING Charging the battery produces gasses that can explode. Never smoke near the battery and keep sparks and flames away from battery. Important: Always keep the battery fully charged (1.265 specific gravity) to prevent battery damage when the temperature is below 0°C (32°F). 1. Remove the battery from the chassis; refer to Removing the Battery (page 25). 2. Perform the following steps to check the electrolyte level: A. Ensure that the cell covers are free from dirt and debris.
Servicing the Fuses Drive System Maintenance The electrical system is protected by fuses and requires no maintenance. If a fuse blows, check the component or circuit for a malfunction or short. Servicing the Tracks 1. Release the cushion from the rear of the machine. 2. Pull out the fuse to remove or replace it (Figure 33). 3. Install the cushion to the rear of the machine. Service Interval: Before each use or daily—Check the condition of the track.
Adjusting the Track Tension If you place the tab of the tensioning tool along the rear edge of the tension nut, the other end of the tensioning tool should align with the edge of the tension arm as shown in Figure 35. If the distance is not correct, adjust the track tension using the following procedure: Note: If the tensioning tool is not available, the 4. Raise the machine so that the tracks are off the ground. 5. Clean the drive sprocket, the front wheel, and the road wheels.
8. Inspect the condition of the wheels. If the wheels show signs of wear, replace them at this time. 9. Beginning at the drive sprocket, coil the new track around the sprocket, ensuring that the lugs on the track fit between the spacers on the sprocket (Figure 36). 10. Replacing the Drive Belt Service Interval: Every 300 hours 1. Push the track under the lugs and between the road wheels (Figure 36).
Controls System Maintenance Adjusting the Motion-Control Levers If the motion-control levers do not align horizontally, adjust the right side motion-control lever. 1. Park the machine on a level surface, lower the hopper, engage the parking brake, shut off the engine, and remove the key. 2. Push the motion-control levers down out of the NEUTRAL-LOCK position (Figure 41). 3. Check if the right motion-control lever aligns horizontally with the left motion-control lever (Figure 41). g189559 Figure 39 1.
4. Release the parking brake. 5. Move the motion-control levers forward. Note: The machine should move forward. Note: If the machine does not move forward, refer to Adjusting the Parking Brake (page 31). 6. Engage the parking brake and shut off the machine. Adjusting the Parking Brake g189389 Figure 42 1. Cam 7. 1. Remove the fuel tank; refer to Releasing the Cushion for Rear Access (page 18). 2. Inside the left side of the control tower, adjust the nuts until the cables are taught (Figure 43).
Hydraulic System Maintenance WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury. Fluid injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury; otherwise gangrene may result. g203616 Figure 44 • Keep your body and hands away from pinhole leaks or nozzles that eject high-pressure hydraulic fluid. 2. Sight window • Use cardboard or paper to find hydraulic leaks; never use your hands. 5. 1.
2. Shut off the engine, and remove the key. Allow the engine to cool. 3. Lower the cushion and remove the fuel tank; refer to Removing the Fuel Tank (page 25). 4. Remove the 6 bolts (2 rear, 4 side) from the skid plate and remove the skid plate (Figure 46). 10. Loosen the vent plug in each transmission until loose (Figure 48). Note: This allows air to escape the hydraulic system as you add hydraulic fluid. g203517 g203662 Figure 48 Figure 46 1. Rear bolt (2) 1. Vent plug 3. Side bolt (4) 2.
Bleeding the Hydraulic Drive System Servicing the Hydraulic Lift System Bleed the traction hydraulic system whenever you perform maintenance on the hydrostatic transmission or add hydraulic fluid to the expansion tank. 1. Checking the Hydraulic-Fluid Level for the Lift System Park the machine on a level surface, move the motion-control levers to the NEUTRAL-LOCK position, engage the parking brake, and lower the hopper. Service Interval: Before each use or daily Reservoir-tank capacity: 1.4 L (1.
Changing the Hydraulic Fluid for the Lift System Service Interval: Every 300 hours 1. Park the machine on a level surface, move the motion-control levers to the NEUTRAL-LOCK position, engage the parking brake, raise the hopper, and install the cylinder lock. 2. Shut off the machine and remove the key. Allow the machine to cool completely. 3. Remove the filler cap from the reservoir tank (Figure 49).
Replacing the Hydraulic Filter for the Lift System 5. Shut off the engine and check for leaks. 6. Check the fluid level in the reservoir tank, refer to Checking the Hydraulic-Fluid Level for the Lift System (page 34). Service Interval: Every 300 hours Important: Do not substitute an automotive oil Note: Do not overfill the reservoir tank. filter or severe hydraulic system damage may result. 1.
Cleaning Removing Debris from the Machine Service Interval: Before each use or daily Every 100 hours 1. Park the machine on a level surface, move the motion-control levers to the NEUTRAL-LOCK position, engage the parking brake, and lower the hopper. 2. Shut off the engine, and remove the key. Allow the engine to cool. 3. Clean the inside of the hopper using a hose. 4. Clean any debris from under the hopper. 5. Wipe away debris from the air cleaner. 6.
Storage 9. Check and tighten all bolts, nuts, and screws. Repair or replace any part that is damaged. 1. Engage the parking brake, shut off the engine, and remove the key. 10. Paint all scratched or bare metal surfaces. Paint is available from your Authorized Service Dealer. 2. Remove dirt and grime from the external parts of the entire machine, especially the engine. Clean dirt and chaff from the outside of the engine cylinder head fins and blower housing. 11.
Notes:
California Proposition 65 Warning Information What is this warning? You may see a product for sale that has a warning label like the following: WARNING: Cancer and Reproductive Harm—www.p65Warnings.ca.gov. What is Prop 65? Prop 65 applies to any company operating in California, selling products in California, or manufacturing products that may be sold in or brought into California.
