FORM NO.
Introduction Thank you for purchasing a Toro product. All of us at Toro want you to be completely satisfied with your new product, so feel free to contact your local Authorized Service Dealer for help with service, genuine replacement parts, or other information you may require. Whenever you contact your Authorized Service Dealer or the factory, always know the model and serial numbers of your product.
Contents Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safe Operating Practices . . . . . . . . . . . . . . Sound Pressure Level . . . . . . . . . . . . . . . . . Sound Power Level . . . . . . . . . . . . . . . . . . Vibration Level . . . . . . . . . . . . . . . . . . . . . Slope Chart . . . . . . . . . . . . . . . . . . . . . . . . . Safety and Instruction Decals . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loose Parts . . . . . . . . .
Safety Improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert symbol, which means CAUTION, WARNING, or DANGER—“personal safety instruction.” Failure to comply with the instruction may result in personal injury or death. • Ensure that the area is clear of other people before operating the traction unit. Stop the traction unit if anyone enters the area.
Safety • Watch for traffic when operating near or crossing roadways. • Use extra care when loading or unloading the traction unit onto a trailer or truck. • Slopes are a major factor related to loss-of-control and tip-over accidents, which can result in severe injury or death. All slopes require extra caution. • • • • • Follow the recommendations in the attachment manuals for the use of counterweights to improve stability. • Use only Toro approved attachments.
Safety • Keep children out of the work area and under the watchful care of another responsible adult. • Never refuel the traction unit indoors. • Never store the traction unit or fuel container inside where there is an open flame, such as near a water heater or furnace. • Be alert and turn the traction unit off if children enter the area. • Before and while backing, look behind and down for small children. • Never carry children.
Safety Sound Pressure Level This unit has a sound pressure at the operator’s ear of 92 dB(A) (i.e., LpA), based on measurements of identical machines per Directive 81/1051/EEC. Sound Power Level This unit has a sound power level of 103 LwA, based on measurements of identical machines per Directive 84/538/EEC. Vibration Level This unit has a hand-arm vibration level under 2.5 m/s2 and maximum whole-body vibration level of 0.7 m/s2 based on measurements of identical machines per EN 1033 and EN 1032.
Safety Slope Chart 6
Safety Safety and Instruction 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. 1 9 1 3 4 5 2 6 28 28 7 # 93–7275 # 100–1701 2 11 10 8 12 1 13 2 14 15 16 17 18 19 21 20 # 100–1704 26 23 22 24 2 # 100–1705 25 1 2 27 # 100–1702 # 93–6686 Figure 1 1. 2. 3. 4. 5. 6. 7.
Safety 1 5 4 16 3 1 # 100–1703 # 93–9367 2 8 7 3 6 # 98–8235 # 98–8219 10 # 93–6680 # 93–7272 9 13 14 15 11 12 # 99–3089 # 93–9084 # 99–3095 # 99–3095 # 99–3088 Figure 2 1. 2. 3. 4. 8 Fast Traction drive Slow Pinch point–crushing of fingers or hands 5. Keep hands away 6. Cutting and entanglement in fan 7. Stay away from moving parts 8. Use only diesel fuel 9. 10. 11. 12. Parking brake Lift Point Sound power decal Sound pressure decal 13. 14. 15. 16.
Assembly Loose Parts Note: Use the chart below to verify all parts have been shipped. DESCRIPTION QTY. Valve lever 1 Jam nut 1 Key 2 Installing the Valve Lever 1. Thread the lever into the pump selector valve (Fig. 3). Note: 2. The lever should be installed with the bend toward the operator. Tighten the jam nut on the lever to lock it in position. 1 m–3883 Figure 3 1.
Specifications Overall width 40.5 inches (103 cm) Overall length 60.0 inches (152 cm) Overall height 49.0 inches (125 cm) Weight/Mass 1680 lbs (762kg) Rated operating capacity 515 lbs (234 kg) (with 200 lb operator, counterweight, & standard bucket) Tipping capacity l030lbs (468 kg) (with 200 lb operator, counterweight, & standard bucket) Wheelbase 28.5 inches (72 cm) Dump height (with standard bucket) 48.75 inches (124 cm) Reach – fully raised (with standard bucket) 26.
Check Before Operating Stability Data The following table lists the maximum slope recommended for the traction unit in the positions listed in the table. Slopes over the listed degree may cause the traction unit to become unstable. The data in the table assumes that the loader arms are fully lowered and that the factory installed tires are on the traction unit, inflated to the recommended pressure; raised arms and other tire types or pressure may affect the stability.
Before Operating Before operating, check the fuel and oil level, remove debris from the traction unit, ensure that the water is drained from the fuel filter, and check the tire pressure. Also, ensure that the area is clear of people and debris. You should also know and have marked the locations of all utility lines. Adding Fuel The engine runs on clean, fresh diesel fuel with a minimum cetane rating of 40. Purchase fuel in quantities that can be used within 30 days to ensure fuel freshness.
Check Before Operating Draining Water from the Fuel Filter Checking the Oil Level 1. Inspect fuel filter bowl, daily, for water or other contaminants. If water or other contaminants are present, they must be removed before commencing operation. Park the traction unit on a level surface, lower the loader arms, and stop the engine. 2. Remove the key and allow the engine to cool. 3. Clean around the oil dipstick (Fig. 5 & 6). 1. Close the fuel shut-off valve by turning it clockwise (Fig. 4). 4.
Check Before Operating 4. If coolant level is low, replenish the system. IMPORTANT: Do not over fill the radiator. 1 Qt 5. Replace the radiator filler cap, ensuring that it is tightly sealed. m–3742 Figure 6 1. Filler Cap Checking the Cooling System The cooling system is filled with a 50/50 solution of water and permanent ethylene glycol anti–freeze. Check the level of coolant at the beginning of each day, before starting the engine. POTENTIAL HAZARD • Coolant is hot and pressurized. 1 Figure 7 1.
Check Before Operating IMPORTANT: Do not wash the traction unit with high pressure. High–pressure washing can damage the electrical system or deplete grease. 1 Check Hydraulic Fluid Check the hydraulic fluid level before the engine is first started and after every 25 operating hours. Hydraulic Tank Capacity: 15 gal.
Operation Controls Throttle Lever Become familiar with all the controls (Fig. 10) before you start the engine and operate the traction unit. 5 4 The throttle lever regulates the engine speed as measured in rpm (revolutions per minute). Move the throttle up to increase engine speed or down to decrease speed. Place the throttle lever in the fast (rabbit) position for best performance during operation. 1 Note: Throttle position can be utilized to operate at slower speeds. 2 3 m–3883 Figure 10 1.
Operation To raise the loader arms, slowly pull the loader arm lever rearward. Auxiliary Hydraulics Lever To operate a hydraulic attachment in forward direction, slowly pull the auxiliary hydraulics lever rearward. To operate a hydraulic attachment in reverse direction, slowly push the auxiliary hydraulics lever forward.
Operation Setting the Parking Brake 1 2 5 1. Lift up on the brake handle and turn it one quarter turn counter-clockwise (Fig. 12). 2. Release the handle so that the pin on the rod slides in to the locking slot (Fig. 12). 3 4 Figure 11 1. Flow divider control 2. Knob 3. 12 o’clock position • 4. 10 to 11 o’clock position 5. 9 o’clock position 1 2 Move the flow divider control to the twelve–o’clock position to provide maximum speed to the traction unit hydraulics.
Operation 5. After the engine starts, move the throttle lever to the desired setting. IMPORTANT: Do not use starting fluid or other chemicals to improve starting performance. Stopping the Traction Unit To stop the traction unit, move the traction control levers to neutral, lower loader arms to the ground, and stop the engine. Remove the key. Stopping the Engine 1. Move the throttle lever to the slow (turtle) position. 2. Lower the loader arms to the ground. 3.
Operation Using the Cylinder Locks 7. Slowly lower the loader arms until cylinder locks contact the cylinder body and rod end. 8. Stop the engine. POTENTIAL HAZARD • The loader arms may lower when in the raised position. Removing/Storing the Cylinder Locks 1. Start the engine. WHAT CAN HAPPEN • Anyone under the loader arms may be injured or crushed. 2. Raise the loader arms to the fully raised position. 3. Stop the engine.
Operation the traction unit. The warranty of the traction unit may be voided if used with unapproved attachments. 1 IMPORTANT: Before installing the attachment, ensure that the mount plates are free of any dirt or debris. m–4056 Figure 16 1. Position the attachment on a level surface with enough space behind it to accommodate the traction unit. 2. Move the pump selector lever to the slow (turtle) position. 3. Start the engine. 4.
Operation Securing the Traction Unit for Transport POTENTIAL HAZARD • Hydraulic fluid escaping under pressure can penetrate skin and cause injury. WHAT CAN HAPPEN • Fluid accidentally injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result. HOW TO AVOID THE HAZARD • Keep body and hands away from pin hole leaks or nozzles that eject high pressure hydraulic fluid.
Maintenance Service Interval Chart Service Operation Each Use Hydraulic Fluid–check level Initial 8 Hours 25 Hours 50 Hours 100 Hours 200 Hours 400 hours X Hydraulic Fluid–change X Hydraulic Filter–change Engine Oil—check level Engine Initial X X Oil—change1 Initial Engine Oil Filter–change (200 hours or every other oil change) X Initial Traction Drive Chain Tension–check Initial X X Traction Drive Chain–lubrication X Wheel Nuts–tighten Initial Chassis—grease2 Air Cleaner Pre–C
Maintenance POTENTIAL HAZARD • If you leave the key in the ignition switch, someone could start the engine. WHAT CAN HAPPEN • Accidental starting of the engine could seriously injure you or other bystanders. HOW TO AVOID THE HAZARD • Remove the key from the ignition switch and and disconnect negative battery cable from battery before you do any maintenance. Servicing the Air Cleaner Service Interval/Specification Empty and inspect the pre–cleaner bowl before each use.
Maintenance 2. 3. 4. Rinse the filter with clear water. Maximum water pressure must not exceed 40 psi (275.8 kPa) to prevent damage to the filter element. Dry the filter using warm, flowing air (160_F (70_C) maximum), or allow the element to air-dry. Do not use compressed air or a light bulb to dry the filter element. Inspect the element when it is dry; refer to Inspecting the Filter Element. Compressed Air Method: 1. Blow compressed air from the inside to the outside of the dry filter element.
Maintenance 4. Place a pan below the oil drain. Changing the Engine Oil Filter 5. Remove the drain plug from the drain hose and let the oil drain completely (Fig. 17). Replace the oil filter after the initial 50 hours of operation and then after every 200 hours. 1. Drain the oil from the engine; refer to Changing/Draining Oil, page 25. 2. Place a drip pan beneath the oil drip tray to receive oil from the oil filter and oil passages in the engine. 3. Turn the filter counterclockwise to remove it.
Maintenance 1. 2. Park the traction unit on a level surface, lower the loader arms, and stop the engine. Remove the key. Allow the engine and radiator to cool, then remove the radiator cap (Fig. 19). Greasing and Lubrication Grease all bearings, bushings, and pivot joints every 8 operating hours. Grease more frequently when operating conditions are extremely dusty or sandy and immediately after every washing. Grease Type: General-purpose grease. Greasing the Traction Unit 1.
Maintenance 1. Lower the loader arms and stop the engine. Remove the key. 2. Close fuel shut-off valve on the filter (Fig. 20). POTENTIAL HAZARD • Under certain conditions fuel is extremely flammable and highly explosive. 3 WHAT CAN HAPPEN • A fire or explosion from fuel can burn you, others, and cause property damage. HOW TO AVOID THE HAZARD • Use a funnel and fill the fuel tank outdoors, 2 1 in an open area, when the engine is cold. Wipe up any fuel that spills.
Maintenance • Initial start up of a new traction unit or a traction unit that has been stored. • The engine has ceased running due to lack of fuel. • Maintenance has been performed on the fuel system components. 1. Ensure that the fuel tank is at least half full. 2. Lower the loader arms and stop the engine. Remove the key. 4. Install the fuel line onto the fuel filter. Slide the hose clamp close to the fuel filter to secure the fuel line.
Maintenance 7. Start the engine and let it run for about two minutes to purge air from the system. 8. Stop the engine and check for leaks. 9. Check the level of the fluid and add enough to raise the level to the green mark on the dipstick. IMPORTANT: Do not overfill the tank with fluid. Overfilling will cause system damage. Changing the Hydraulic Fluid Change the hydraulic fluid every 800 operating hours or yearly. Note: 1.
Maintenance 1. With the bucket installed, lower it into the ground until the front tires are off of the ground. 2. Stop the engine and remove the key. 3. Turn the front wheel forward on one side of the traction unit until the top span of the drive chain is tight. 4. 3. Remove the chain guard (Fig. 22). 4. Loosen the jam nuts on the chain tensioning bolt and loosen the bolt (Fig. 23). 1 Measure the distance between the bottom of the chain guard and the lower chain span (Fig. 22).
Maintenance 10. Repeat steps 3 through 9 for the other drive chain. IMPORTANT: Do not allow the electrolyte to get below the plates. (Fig. 25). 11. Start the engine and raise the bucket to return the front wheels to the ground. 1 2 Adjusting the Fan Belt Check the fan belt tension every 100 hours. Ensure that the belt is properly tensioned to prevent the engine from overheating and to allow proper battery charging. Check the belt midway in the span. Also, check the belt for cracks and tears.
Maintenance 2. 3. Remove the filler caps from the battery and connect a 3 to 4 amp battery charger to the battery posts. Charge the battery at a rate of 4 amperes or less for 4 hours (12 volts). Do not overcharge the battery. 7. Check the tire pressure; refer to Tire Pressure, page 14. 8. Charge the battery; refer to Servicing the Battery page 32. Install the filler caps after the battery is fully charged. 9.
Troubleshooting PROBLEM The starter does not crank. The engine cranks, but will not start. 34 POSSIBLE CAUSES CORRECTIVE ACTION 1. The electrical connections are corroded or loose. 1. Check the electrical connections for good contact. 2. A fuse is blown or loose. 2. Correct or replace the fuse. 3. The relay or switch is defective. 3. Contact your Authorized Service Dealer. 4. The battery is discharged. 4. Charge the battery or replace it. 5. A faulty starter or starter solenoid. 5.
Troubleshooting PROBLEM The engine cranks, but will not start (continued). The engine starts, but does not eep running. u g keep The engine runs, but knocks or misses. POSSIBLE CAUSES CORRECTIVE ACTION 8. Slow cranking speed. 8. Check the battery, oil viscosity and starting motor (contact your Authorized Service Dealer). 9. The air cleaner element is dirty. 9. Clean or replace. 10. Low compression. 10. Contact your Authorized Service Dealer. 11. The injection nozzles are faulty. 11.
Troubleshooting PROBLEM The engine runs, but knocks or misses (continued). The engine will not idle. The engine g overheats. 36 POSSIBLE CAUSES CORRECTIVE ACTION 3. There is air in the fuel. 3. Bleed nozzles and check for air leaks at the fuel hose connections and fittings between the fuel tank and engine. 4. The injection nozzles are faulty. 4. Contact your Authorized Service Dealer. 5. Low compression 5. Contact your Authorized Service Dealer. 6. The injection pump timing is incorrect.
Troubleshooting PROBLEM The engine overheats (continued). The engine loses power. Excessive black smoke from exhaust. e aust POSSIBLE CAUSES CORRECTIVE ACTION 5. The thermostat is faulty. 5. Contact your Authorized Service Dealer. 6. The fan belt is loose or broken. 6. Contact your Authorized Service Dealer. 7. Incorrect fuel is in the fuel system. 7. Drain and flush the fuel system; add fresh fuel. 8. Injection timing is incorrect. 8. Contact your Authorized Service Dealer. 9.
Troubleshooting PROBLEM POSSIBLE CAUSES CORRECTIVE ACTION Excessive black smoke from exhaust (continued). 6. Excessive loading. 6. Reduce load; use lower ground speed. Excessive white smoke from exhaust. 1. The glow plugs were not activated prior to turning the key to the start position. 1. Turn the key to the glow position for 5 to 7 seconds before starting the engine. 2. The engine temperature is low. 2. Check the thermostat. 3. The glow plugs are inoperative. 3.
