Toro 22302TE Operator's Manual

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FORM NO. 3322–630

Dingo

220-D

Traction Unit

Model Number 22302TE—990001 & Up

Operator’s Manual

International English (GB)

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. These numbers will help the Service Dealer or Service Representative provide exact information about your specific product. The two numbers are stamped into a plate mounted on left rear side of frame.

For your convenience, write the product model and serial numbers in the space below.

Model No:

Serial No.

Read this manual carefully to learn how to operate and maintain your product correctly. Reading this manual will help you and others avoid personal injury and damage to the product. Although we design, produce and market safe, state-of-the-art products, you are responsible for using the product properly and safely. You are also responsible for training persons, who you allow to use the product, about safe operation.

The warning system in this manual identifies potential hazards and has special safety messages that help you and others avoid personal injury, even death. DANGER, WARNING and CAUTION are signal words used to identify the level of hazard. However, regardless of the hazard, be extremely careful.

DANGER signals an extreme hazard that will cause serious injury or death if the recommended precautions are not followed.

WARNING signals a hazard that may cause serious injury or death if the recommended precautions are not followed.

CAUTION signals a hazard that may cause minor or moderate injury if the recommended precautions are not followed.

The Toro Company – 1999

8111 Lyndale Ave. South Bloomington, MN 55420–1196

Two other words are also used to highlight information. “Important” calls attention to special mechanical information and “Note” emphasizes general information worthy of special attention.

The left and right side of the machine is determined by standing on the platform in the normal operator’s position.

Printed in the USA

Contents

Page

Safety 2.

Assembly 9

Specifications 10

Before Operating 12

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Safe Operating Practices 2 Sound Pressure Level 5 Sound Power Level 5 Vibration Level 5 Slope Chart 6 Safety and Instruction Decals 7

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Loose Parts 9 Installing the Valve Lever 9

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Attachments 10 Stability Data 11

Adding Fuel 12 Draining Water from the Fuel Filter 13 Checking the Oil Level 13 Checking the Cooling System 14 Removing Debris from the Traction Unit 14 Check Hydraulic Fluid 15 Tire pressure 15

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Page

Operation 16

Maintenance 23

Troubleshooting 34

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Controls 16 Setting the Parking Brake 18 Starting and Stopping the Engine 18 Driving Forward or Backward 19 Stopping the Traction Unit 19 Moving a Non Functioning Traction Unit 19 Using the Cylinder Locks 20 Attachments 20 Securing the Traction Unit for Transport 22 Cold W

Service Interval Chart 23 Servicing the Air Cleaner 24 Servicing the Engine Oil 25 Changing the Engine Coolant 26 Greasing and Lubrication 27 Fuel Filter 27 Bleeding the Fuel System 28 Draining the Fuel Tank 29 Servicing the Hydraulics System 29 Traction Drive Chains 30 Adjusting the Fan Belt 32 Servicing the Battery 32 Cleaning and Storage 33

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eather (Below Freezing) Tips 22

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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.

Safe

This product is capable of amputating hands and feet. Always follow all safety instructions to avoid serious injury or death.

Operating Practices

POTENTIAL HAZARD

• Engine exhaust contains carbon monoxide,

which is an odorless, deadly poison.

WHAT CAN HAPPEN

• Carbon monoxide can kill you.

hearing protection, and a hard hat are advisable and may be required by some local ordinances and insurance regulations.

• Ensure that the area is clear of other people

before operating the traction unit. Stop the traction unit if anyone enters the area.

• Never carry passengers on attachments or on the

traction unit.

• Always look down and behind before and while

backing.

• Do not place your feet under the platform.

• Slow down before turning. Sharp turns on any

terrain may cause loss of control.

• Never leave a running traction unit unattended.

Always lower the loader arms, stop the engine, and remove the key before dismounting.

• Do not exceed the rated operating capacity, as

the traction unit may become unstable which may result in loss of control.

HOW TO AV

OID THE HAZARD

• Do not run engine indoors or in an enclosed

area.

General Operation

• Read, understand, and follow all instructions in

the operator’s manual, in the video, and on the traction unit before starting. Also, read all attachment manuals where supplied.

• Allow only responsible adults who are familiar

with the instructions to operate the traction unit.

• Do not operate the traction unit or attachments

while wearing sandals, tennis shoes, sneakers, or shorts. Always wear long pants and substantial shoes. W

earing safety glasses, safety shoes,

• Do not carry a load with the arms raised. Always

carry loads close to the ground. Do not step off of the platform with the load raised.

• Do not over-load the attachment and always

keep the load level when raising the loader arms. Logs, boards, and other items could roll down the loader arms, injuring you.

• Never jerk the control levers; use a steady

motion.

• Keep your hands, feet, hair, and loose clothing

away from any moving parts.

• Operate only in daylight or good artificial light.

• Do not operate the traction unit while under the

influence of alcohol or drugs.

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.

• Do not touch parts which may be hot from

operation. Allow them to cool before attempting to maintain, adjust, or service.

Slope Operation

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.

• Operate up and down slopes with the heavy

end of the traction unit uphill. Weight

distribution changes. An empty bucket will make the rear of the traction unit the heavy end, and a full bucket will make the front of the traction unit the heavy end. Most other attachments will make the front of traction unit the heavy end.

• Do not operate the traction unit on hillsides or

slopes exceeding the angles recommended in the Stability Data section, page 11, and those in the attachment operator’s manual. See also the slope chart on page 6.

• Follow the recommendations in the attachment

manuals for the use of counterweights to improve stability.

• Use only Toro approved attachments.

Attachments can change the stability and the operating characteristics of the traction unit. Warranty may be voided if used with unapproved attachments.

• Keep all movements on slopes slow and gradual.

Do not make sudden changes in speed or direction.

• Avoid starting or stopping on a slope. If tires

lose traction, proceed slowly, straight down the slope.

• Check for overhead clearances (i.e. branches,

doorways, electrical wires) before driving under any objects and do not contact them.

• Avoid turning on slopes. If you must turn, turn

slowly and keep the heavy end of the traction unit uphill.

• Do not operate near drop-offs, ditches, or

embankments. The traction unit could suddenly turn over if a wheel goes over the edge of a cliff or ditch, or if an edge caves in.

• Raising the loader arms on a slope will affect the

stability of the machine. Whenever possible, keep the loader arms in the lowered position when on slopes.

• Removing an attachment on a slope will make

the rear of the traction unit heavy. Refer to the Stability Data section, page 11, to determine whether the attachment can be safely removed on the slope.

• Remove obstacles such as rocks, tree limbs, etc.

from the work area. Watch for holes, ruts, or bumps, as uneven terrain could overturn the traction unit. T

• Use slow speed on slopes. Before starting the

engine, put the pump selector lever in the slow (turtle) position so that you will not have to stop or shift while on the slope.

all grass can hide obstacles.

• Do not operate on wet grass. Reduced traction

could cause sliding.

• Do not park the traction unit on a hillside or

slope without lowering the attachment to the ground, setting the parking brake, and chocking the wheels.

• Do not try to stabilize the traction unit by putting

your foot on the ground.

Children

Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the traction unit and the work activity. Never assume that children will remain where you last saw them.

Safety

• Keep children out of the work area and under the

watchful care of another responsible adult.

• 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. They may fall off and be

seriously injured or interfere with safe traction unit operation.

• Never allow children to operate the traction unit.

• Use extra care when approaching blind corners,

shrubs, trees, the end of a fence, or other objects that may obscure vision.

Service

• Stop the engine before performing any service,

repairs, maintenance, or adjustments.

• If any maintenance or repair requires the loader

arms to be in the raised position, secure the arms in the raised position with the hydraulic cylinder locks included with traction unit.

• Never run a traction unit inside a closed area.

• 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.

• Stop and inspect the equipment if you strike an

object. Make any necessary repairs before restarting.

• Use only genuine replacement parts to ensure

that original standards are maintained.

• 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.

• Battery gases can explode. Keep cigarettes,

sparks and flames away from the battery.

• Keep your body and hands away from pin hole

leaks or nozzles that eject high pressure hydraulic fluid. Use cardboard or paper to find hydraulic leaks. Hydraulic fluid escaping under pressure can penetrate skin and cause injury requiring surgery within a few hours by a qualified surgeon or gangrene may result.

• Keep nuts and bolts tight. Keep equipment in

good condition.

• Never tamper with safety devices. Check safety

systems for proper operation before each use.

• Keep the traction unit free of grass, leaves, or

other debris build-up. Clean up oil or fuel spillage. Allow the traction unit to cool before storing.

• Use extra care when handling diesel and other

fuels. They are flammable and vapors are explosive.

• Use only an approved container.

• Never remove the fuel cap or add fuel when

the engine is running. Allow the engine to cool before refueling. Do not smoke.

Safety

Sound

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

This unit has a sound power level of 103 LwA, based on measurements of identical machines per Directive 84/538/EEC.

Vibration

This unit has a hand-arm vibration level under

2.5 m/s

0.7 m/s machines per EN 1033 and EN 1032.

Pressure Level

Power Level

Level

and maximum whole-body vibration level of

based on measurements of identical

Safety

Slope

Chart

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.

Safety

# 100–1704

1 3 4 5

1514

# 100–1705

# 100–1701

# 93–7275

1. Safety

alert symbol Read the operator’s manual Entanglement hazard Crushing hazard Explosion hazard Electric shock hazard Do not dig in areas with

buried gas or power lines Shut of

f engine and remove key before leaving the operator’

s position

# 93–6686

9. W

ait for moving parts to stop

10. W

ear protective foot wear

11. W

ear a protective hard hat

12. W

ear eye protection

13.

Keep bystanders away from the work area

14.

Lower attachment

15.

Lever movement indicator

16. T

raction drive

17. T

ilt attachment down

Figure 1

18.

19.

20. T

21.

22.

23.

# 100–1702

Shift the auxiliary hydraulics lever into neutral

Start the engine

ipping hazard–exceeding rated load capacity can cause instability

Keep a full load uphill Keep an empty load downhill Do not step of

operator platform with a raised load

f of the

24.

Raise attachment

25. T

ilt attachment up

26.

Hydraulic oil only

27.

Maximum load capacity

28.

Don’t use starting fluid or other chemical to try to enhance starting performance

Safety

# 98–8219

# 99–3089

1. Fast

2. Traction

3. Slow

drive

Pinch point–crushing of fingers or hands

# 98–8235

# 93–9084

7. Stay

8. Use

# 99–3095

Figure 2

Keep hands away Cutting and entanglement in

fan

away

from moving parts

only diesel fuel

# 93–9367

# 93–7272

# 99–3095

Parking brake

10.

Lift Point

11.

Sound power decal

12.

Sound pressure decal

100–1703

# 93–6680

14 15

# 99–3088

13.

Safety alert symbol

14.

No riders

15.

Read the operator’s manual

16. Throttle

Assembly

Loose

Note: Use the chart below to verify all parts have been shipped.

DESCRIPTION QTY. USE

alve lever

Jam nut Key 2

Installing

1. Thread the lever into the pump selector valve

2. Tighten the jam nut on the lever to lock it in

Parts

the V

(Fig. 3). Note: The lever should be installed with the

bend toward the operator.

position.

alve Lever

Install valve lever

Start the engine

1. Pump

m–3883

Figure 3

selector lever

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 48.75 inches (124 cm)

(with standard bucket) Reach – fully raised 26.0

(with standard bucket) Height to hinge pin 66.0 inches (168 cm)

(standard bucket in highest position)

inches

(66 cm)

Attachments

Many attachments are available for use with the traction unit. These attachments allow you to perform many different functions with the traction unit such as hauling materials, digging holes, grading, and more. Contact your Toro dealer for a list of all approved SiteW accessories.

IMPORTANT: Use only Toro approved attachments.

orks Systems attachments and

Power 14.0 Kw All specifications are for the base unit without an

attachment, unless otherwise noted. Specifications and design subject to change without notice.

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.

Maximum Recommended Slope

when Operating with:

Front Uphill

Configuration

raction unit without attachment

raction unit with counterweight, without attachment

raction unit with an attachment rated with one of the following

stability ratings for each slope position:*

A 22° 22° 20° B 19° 19° 17°

9° 20° 17° 7° 20° 15°

Rear Uphill

Side Uphill

C 15° 15° 13° D 11° 11° 9° E 7° 5° 5°

* In each attachment manual is a set of three stability ratings, one for each hill position. To determine the maximum slope you can traverse with the attachment installed, find the degree of slope that corresponds to the stabilities ratings of the attachment. Unless otherwise specified in the attachment manual, assume that the listed ratings are for use without the counterweight.

Example: If the attachment installed on the traction unit has a Front Uphill rating of B, a Rear Uphill rating of D, and a Side Uphill rating of C, then you could drive forward up a 19

° slope, rearward up a 11° slope, or

sideways on a 13° slope, as listed in the above table.

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

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.

Use summer grade diesel fuel (No. 2–D) at temperatures above 20 F (–7 C) and winter grade diesel fuel (No. 1–D or No. 1–D/2–D blend) below 20 F (–7 C). Use of winter grade diesel fuel at lower temperatures provides lower flash point and pour point characteristics, allowing easier starts and lessening the chances of chemical separation of the fuel due to lower temperatures.

Use of summer grade diesel fuel above 20 F (–7 C) will contribute toward longer life of the fuel pump components.

IMPORTANT: Do not use ker gasoline in place of diesel fuel. Failure to observe this caution will damage the engine.

1. 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.

Fuel

osene or

Note: This space in the tank allows fuel to

expand. Do not fill the fuel tank completely full.

5. Install the fuel tank cap securely. Wipe up any

fuel that may have spilled.

If possible, fill the fuel tank after each use. This will minimize possible buildup of condensation inside the fuel tank.

POTENTIAL HAZARD

• Under certain conditions fuel is extremely

flammable and highly explosive.

WHAT CAN HAPPEN

• A fire or explosion from fuel can burn you,

others, and cause property damage.

HOW TO AV

OID THE HAZARD

• Use a funnel and fill the fuel tank outdoors,

in an open area, when the engine is cold. Wipe up any fuel that spills.

• Do not fill the fuel tank completely full.

Add fuel to the fuel tank until the level is 1/4” to 1/2” (6 mm to 13 mm) below the bottom of the filler neck. This empty space in the tank allows fuel to expand.

• Never smoke when handling fuel, and stay

away from an open flame or where fuel fumes may be ignited by a spark.

• Store fuel in an approved container and

keep it out of the reach of children. Never buy more than a 30-day supply.

3. Clean around the fuel tank cap and remove the

cap.

4. Use a funnel and add diesel fuel to the fuel tank,

until the level is 1/4 to 1/2 inch (6 mm to 13 mm) below the bottom of the filler neck.

Check Before Operating

Draining Water from the Fuel Filter

Inspect fuel filter bowl, daily, for water or other contaminants. If water or other contaminants are present, they must be removed before commencing operation.

1. Close the fuel shut-off valve by turning it

clockwise (Fig. 4).

2. Unscrew the nut securing bowl to filter head.

3. Remove the water or other contaminants from

the bowl.

Checking

the Oil Level

1. 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).

4. Pull out the dipstick and wipe the metal end

clean.

5. Slide the dipstick fully into the tube.

6. Pull the dipstick out and look at the metal end. If

oil level is low, remove the filler cap and slowly pour only enough oil into the filler opening to raise the level to the F (full) mark.

IMPORTANT: Do not overfill the crankcase with oil because the engine may be damaged.

7. Replace the dipstick and filler cap.

Fuel shut-of

f valve

1. Fuel

Bleed screws

filter

Figure 4

4. Nut

4. Inspect the fuel filter and replace it if it is dirty.

Refer to Replacing the Fuel Filter, page 28.

5. Install the bowl on the filter head. Ensure that

the O-ring is positioned properly between the bowl mounting nut and the filter head.

6. Open the fuel shut-off valve.

7. Open the bleed screws (Fig. 4), allowing the

bowl to fill with fuel.

Close the bleed screws.

Figure 5

1. Dipstick 2. Filler

Cap

Check Before Operating

4. If coolant level is low, replenish the system. IMPORTANT: Do not over fill the radiator.

1 Qt

m–3742

Figure

1. Filler

Checking

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.

Cap

the Cooling System

POTENTIAL HAZARD

• Coolant is hot and pressurized.

WHAT CAN HAPPEN

• Discharge of hot pressurized coolant can

cause sever

e burns.

5. Replace the radiator filler cap, ensuring that it is

tightly sealed.

Figure 7

1. Filler

Removing T

Cap

Debris from the

raction Unit

IMPORTANT: Operating the engine with a blocked or plugged radiator will result in engine damage from overheating.

HOW TO AV

OID THE HAZARD

• Do not remove the radiator cap when the

engine is hot. Always allow the engine to cool at least 15 minutes or until the radiator cap is cool enough to touch without burning your hand before removing it.

1. Park the traction unit on a level surface, lower

the loader arms, and stop the engine. Remove the key.

2. Allow the engine to cool.

3. Remove the radiator filler cap and check the

coolant level (Fig. 7). The coolant should be up to filler neck.

1. Park the traction unit on a level surface, lower the loader arms, and stop the engine. Remove the key.

2. Check for debris in the air filter pre–cleaner. Wipe away debris before each use and/or during use, if required.

3. Clean any debris from the engine with a brush or blower before each use.

4. From the front side of the radiator, either spray the radiator with a hose or blow with compressed air.

IMPORTANT: It is preferable to blow dirt out, rather than washing it out. If water is used, keep it away from electrical items.

Check Before Operating

IMPORTANT: Do not wash the traction unit with high pressure. High–pressure washing can damage the electrical system or deplete grease.

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. (56 l) Use only Group 1 ISO type 46/68 anti–wear

hydraulic fluids, recommended for ambient temperatures consistently below 100_F (38_C), such as Toro Hy–Pro, Mobil Fluid 424, or other equivalent fluid:

IMPORTANT: Use only the group 1 ISO type 46/68 anti–wear hydraulic fluids. Other fluids could cause system damage.

1. Position the traction unit on a level surface,

lower the loader arms, and stop the engine.

2. Clean the area around filler neck of the hydraulic

tank (Fig. 8).

3. Remove the cap from filler neck and check the

fluid level. The fluid level should be up to the green mark on the dipstick.

Figure 8

1. Filler

Tire

neck cap

pressure

Maintain the air pressure in the tires as specified. Check the tires when they are cold to get the most accurate pressure reading.

Pressure: 20–30 psi (138–207 kPa)

Note: Use lower tire pressure (20 psi) when

operating in sandy soil conditions to improve traction.

4. If the level is low, add enough fluid to raise it to

the proper level.

5. Install the cap on the filler neck.

Figure 9

1. Valve

m–1872

stem

Operation

Controls

Become familiar with all the controls (Fig. 10) before you start the engine and operate the traction unit.

Figure 10

1. Traction

POTENTIAL

control levers Attachment tilt lever Loader arm lever

HAZARD

Auxiliary hydraulics lever

Pump selector lever

• The operator could fall off of the platform.

WHAT CAN HAPPEN

• The operator could be seriously injured.

HOW TO AV

OID THE HAZARD

• Do not move any of the contr

unless standing with both feet on the platform and with hands holding the hand grips.

m–3883

ol levers

Throttle Lever

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.

Note: Throttle position can be utilized to

operate at slower speeds.

Traction Control Levers

To move forward, slowly push the traction control levers forward. To move rearward, slowly push the traction control levers rearward.

To go straight, apply equal pressure to both traction control levers.

To turn, decrease pressure on the traction control lever toward the direction you want to turn.

The farther you move the traction control levers in either direction, the faster the traction unit will move in that direction.

To slow or stop, move the traction control levers to neutral.

Attachment Tilt Lever

Key Switch

The key switch, used to start and stop the engine, has four positions: off, on, glow, and start. Rotate the key clockwise to the glow position and hold it for 5–7 seconds (longer when the temperature is below freezing), then to the start position to engage the starter motor. Release the key when the engine starts. The key will move automatically to the on position. To shut the engine off, rotate the key counterclockwise to the off position.

To tilt the attachment forward, slowly push the attachment tilt lever forward.

To tilt the attachment rearward, slowly pull the attachment tilt lever rearward.

Loader Arm Lever

To lower the loader arms, slowly push the loader arm lever forward.

To raise the loader arms, slowly pull the loader arm lever rearward.

Operation

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.

Pump Selector Lever

Move the pump selector lever to the fast (rabbit) position to set the traction drive, loader arms, and attachment tilt to high speed and the auxiliary hydraulics to low speed.

Move the pump selector lever to the slow (turtle) position to set the auxiliary hydraulics to high speed and the traction drive, loader arms, and attachment tilt to low speed.

POTENTIAL HAZARD

• If the pump selector lever is moved while

the traction unit is in motion, the traction unit will either stop suddenly or accelerate quickly.

• If the traction unit is operated with the

pump selector lever in an intermediate position, the traction unit will operate erratically and may be damaged.

WHAT CAN HAPPEN

• You could be thrown forward or

backwards, resulting in injury.

• If the traction unit accelerates quickly, you

could loose control of the traction unit and injure bystanders or yourself.

• You could loose control of the traction unit,

severely injuring yourself or others.

• The traction unit could be damaged.

HOW TO AV

OID THE HAZARD

• Do not move the pump selector lever when

the traction unit is in motion.

• Do not operate the traction unit when the

speed selector is in any intermediate position (i.e., any position other than fully forward or fully rearward).

Flow Divider Control

The traction unit hydraulics (i.e., the traction drive, loader arms, and attachment tilt) work on a separate hydraulic circuit from the auxiliary hydraulics for powering attachments; however, the two systems share the same hydraulic pumps. Using the flow divider control (Fig. 11), you can vary the speed of the traction unit hydraulics by diverting hydraulic flow to the auxiliary hydraulics circuit. The flow divider allows you to divide the flow of fluid in varying degrees to slow the traction unit. Thus, the more hydraulic flow you divert to the auxiliary hydraulics, the slower the traction unit hydraulics will move.

Operation

1. Flow

2. Knob

divider control

12 o’clock position

Figure 1

10 to 1

1 o’clock position

9 o’clock position

• Move the flow divider control to the

twelve–o’clock position to provide maximum speed to the traction unit hydraulics.

Use this setting for fast operation of the traction unit.

• Move the flow divider control between the

twelve–o’clock and nine–o’clock positions to slow the traction unit hydraulics and fine tune the speed.

Setting

the Parking Brake

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).

m–4457

Figure 12

1. Brake

handle

2. Pin

3. To release the brake, lift up on the handle and

turn it one quarter turn clockwise.

Use a setting in this range with attachments with hydraulics where you need to both run the attachment and move the traction unit hydraulics, such as the auger, boring unit, hydraulic blade, and tiller.

• Move the control to the nine–o’clock position to

transfer all hydraulic flow to the auxiliary hydraulics of the attachment.

In this setting, the traction unit hydraulics will not work. Use this setting with hydraulic attachments that do not required the traction unit hydraulics. There are currently no attachments that require the nine–o’clock position; however, the trencher does work best if you set it close to nine–o’clock so that the traction unit will creep slowly when trenching.

Note: The flow divider control can be fixed

in place by turning the knob on the control clockwise until it contacts the dial (Fig. 11).

Starting

and Stopping the

Engine

Starting the Engine

1. Stand on the platform.

2. Move the throttle lever midway between slow

and fast (rabbit and turtle) positions.

3. Rotate the key clockwise to the glow position

and hold for 10 seconds. Note: A warm or hot engine may require less

glow time.

4. Turn the ignition key to the start position. When

the engines starts, release the key.

IMPORTANT: Do not engage the starter for more than 10 seconds at a time. If the engine fails to start, allow a 30 second cool-down period between attempts. Failure to follow these instructions can burn out the starter motor.

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 Engine

1. Move the throttle lever to the slow (turtle)

position.

2. Lower the loader arms to the ground.

3. Turn the ignition key off. Note: If the engine has been working hard or

is hot, let it idle for a minute before stopping the engine. This helps cool the engine before it is stopped. In an emergency, the engine may be stopped immediately.

Stopping

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.

POTENTIAL HAZARD

the T

raction Unit

• Someone could move or attempt to operate

the traction unit while it is unattended.

WHAT CAN HAPPEN

• Children or bystanders may be injured if

they use the traction unit.

HOW TO AV

•

Always r leaving the traction unit, even if just for a few minutes.

OID THE HAZARD

emove the ignition key when

Driving

To drive the traction unit, complete the following actions as necessary:

• To move forward, slowly push the traction control levers forward.

• To move rearward, slowly pull the traction control levers rearward.

• To go straight, apply equal pressure to both traction control levers.

• To turn, decrease pressure on the traction control lever toward the direction you want to turn.

• To slow or stop, move the traction control levers to neutral.

Note: The farther you move the traction

Forward or Backward

control levers in either direction, the faster the traction unit will move in that direction.

Moving T

raction Unit

IMPORTANT: Never tow the traction unit without disconnecting the traction drive chains because hydraulic damage may occur.

a Non Functioning

To Tow the Traction Unit

1. Stop the engine.

2. Remove the traction drive chains secured to front

and rear wheels.

3. Lift the rear wheels off of the ground and then

tow or push the traction unit.

To Lift the Traction Unit

1. Stop the engine.

2. Lift entire traction unit off of the ground

(attaching the lift chains to the two holes in the frame located just above the attachment point of the loader arms) and move it.

Operation

Using

POTENTIAL

the Cylinder Locks

HAZARD

• The loader arms may lower when in the

raised position.

WHAT CAN HAPPEN

• Anyone under the loader arms may be

injured or crushed.

HOW TO AV

OID THE HAZARD

• Always install the cylinder locks when

doing maintenance that requir loader arms.

es raised

Installing the Cylinder Locks

1. Start the engine.

7. Slowly lower the loader arms until cylinder

locks contact the cylinder body and rod end.

8. Stop the engine.

Removing/Storing the Cylinder Locks

1. Start the engine.

2. Raise the loader arms to the fully raised position.

3. Stop the engine.

4. Remove the clevis pin and cotter pin securing

each cylinder lock.

5. Remove the cylinder locks.

6. Lower the loader arms.

7. Install the cylinder locks over the hydraulic

hoses and secure them with the clevis pins and cotter pins (Fig. 14).

2. Raise the loader arms to the fully raised position.

3. Stop the engine.

4. Position a loader arm cylinder lock over each lift

cylinder rod (Fig. 13).

5. Secure each loader arm cylinder lock with a

clevis pin and cotter pin (Fig. 13).

Clevis pin

Lift cylinder rod

m–4398

1. Cylinder

Lift cylinder

Hairpin cotter

Figure 13

lock

6. Start the engine.

Hairpin cotter

Clevis pin

1. Hydraulic

Cylinder locks

Figure 14

hoses

Attachments

Connecting an Attachment

IMPORTANT: Use only Toro approved attachments. Attachments can change the stability and the operating characteristics of

m–4397

Operation

the traction unit. The warranty of the traction unit may be voided if used with unapproved attachments.

IMPORTANT: Before installing the attachment, ensure that the mount plates are free of any dirt or debris.

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. Slowly push the attachment tilt lever forward to

tilt the attachment mount plate forward.

5. Position mount plate into the upper lip of the attachment receiver plate (Fig. 15).

m–4056

Figure 16

1. Quick

attach pins (shown in engaged position)

Connecting the Hydraulic Hoses

If the attachment requires hydraulics for operation, connect the hydraulic hoses as follows:

1. Stop the engine.

2. Move the auxiliary hydraulics lever forward,

backward, and back to neutral to relieve pressure at the hydraulic couplers.

IMPORTANT: Ensure that all foreign matter is cleaned from the hydraulic connections.

m–4055

Figure 15

1. Mount

plate

Receiver plate

6. Raise the loader arms while tilting back the mount plate at the same time.

IMPORTANT: The attachment should be raised enough to clear the ground and the mount plate tilted all the way back.

7. Stop the engine.

8. Engage the quick attach pins (Fig. 16).

3. Remove the protective covers from the hydraulic

couplers on the traction unit. Connect the covers together to prevent contamination during operation.

4. Slide the collar back on the hydraulic couplers

and connect the attachment couplers to the traction unit couplers.

Operation

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 AV

OID THE HAZARD

• Keep body and hands away from pin hole

leaks or nozzles that eject high pressure hydraulic fluid.

• Use cardboard or paper to find hydraulic

leaks, never use your hands.

5. Confirm that the connection is secure by pulling

on the hoses.

Removing an Attachment

1. Lower the attachment to the ground

2. Stop the engine.

3. Disengage the quick attach pins by turning them

to the outside.

4. If the attachment uses hydraulics, move the

auxiliary hydraulics lever forward, backward, and back to neutral to relieve pressure at the hydraulic couplers.

Securing

the T

raction Unit for

Transport

IMPORTANT: Do not operate or drive the traction unit on roadways.

IMPORTANT: When transporting the traction unit on a trailer, always use the following procedure:

1. Lower the loader arms.

2. Stop the engine.

3. Secure the traction unit to the trailer with chains

or straps using the operator platform support openings to secure the rear of the traction unit and the loader arms to secure the front of the

Cold Weather (Below Freezing) Tips

• Use a Kabota cylinder-head heater before

starting in cold weather. This heater can be obtained from the engine manufacturer.

• Warm up the traction unit with the throttle set in

the mid-range for at least 10 minutes.

• Refer to your engine operator’s manual for

further cold weather operating tips.

5. If the attachment uses hydraulics, slide the collar

back on the hydraulic couplers and disconnect them.

IMPORTANT: Connect the attachment hoses together to prevent hydraulic system contamination during storage.

6. Install the protective covers onto the hydraulic

couplers on the traction unit.

7. Start the engine, tilt the mount plate forward,

and back the traction unit away from the attachment.

Maintenance

Service

Hydraulic Fluid–check level Hydraulic Fluid–change Hydraulic Filter–change Engine Oil—check level Engine Oil—change Engine Oil Filter–change

(200 hours or every other oil change)

raction Drive Chain

Tension–check T

raction Drive

Chain–lubrication Wheel Nuts–tighten Chassis—grease Air Cleaner

Pre–Cleaner—empty Paper Air

Cleaner—service Paper Air

Cleaner—replace Fuel—drain Hydraulic lines5–check X Battery–check electrolyte Battery–charge,

Disconnect cables Fuel Filter—replace Fan Belt–check Radiator Coolant

Level—check Radiator–flush & change

coolant T

ires—check pressure Fasteners–check/tighten X Chipped Surfaces—paint

present, 5 Replace moving lines every 2 years or 1500 operating hours

Interval Chart

Operation

often in dusty

, dirty conditions, 2 Immediately after

Each

Use8Hours25Hours50Hours

Initial X

Initial

X X

every washing, 3 Storage Service, 4 Immediately if water is

100

Hours

200

Hours

400

hours

Yearly

X X

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 AV

OID 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.

Clean the air filter cartridge after every 100 operating hours. Service it more often if operating conditions are extremely dusty or sandy.

Replace the cartridge after every 400 operating hours or yearly.

Removing the Air Cleaner Cartridge

1. Park the traction unit on a level surface, lower

the loader arms, and stop the engine. Remove the key.

2. Unscrew and remove the air cleaner cover.

3. Unscrew the retaining nut and remove the

cartridge from the air cleaner body.

Servicing Dust Cup And Baffle

Inspect the dust cup and rubber baffle each day. Never allow dust to build up closer than one inch from the rubber baffle.

1. Dump dust out of the dust cup.

2. After cleaning the cup and baffle, assemble and

install both parts.

Cleaning the Air Filter Cartridge

Clean the air cleaner filter every 100 hours or more frequently in extreme dusty or dirty conditions by washing or using compressed air. Replace the element after every four cleanings (400 hours) or annually, whichever comes first.

Clean the element by washing it in a solution of filter cleaner (available from your Toro dealer) and water, or blow dirt out of filter by using compressed air.

Note: Compressed air is recommended when

element must be used immediately after servicing because a washed element must be dried before it is used. By comparison, washing the element cleans better than blowing dirt out with compressed air washed when exhaust soot is lodged in the filter pores.

IMPORTANT: Do not remove the plastic fin assembly before cleaning.

Washing Method:

. The filter must be

1. Prepare a solution of filter cleaner and water and

soak filter element about 15 minutes. Refer to directions on filter cleaner carton for complete information.

Maintenance

2. Rinse the filter with clear water. Maximum water

pressure must not exceed 40 psi (275.8 kPa) to prevent damage to the filter element.

3. 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.

4. 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. Do not exceed 100 psi (689.5 kPa) to prevent damage.

2. Keep the air hose nozzle at least one inch from

the pleated paper, and move the nozzle up and down while rotating the filter element.

3. Inspect the element when dust and dirt are

removed; refer to Inspecting the Filter Element.

Servicing

Change oil after the first 50 operating hours and then every 100 operating hours there after.

Oil Type: High–quality detergent oil classified “API Service CD” or higher for diesel engines. Use no special additives with recommended oils.

Crankcase Capacity: 4 quarts (3.8 liters) Viscosity: See the table below.

USE THESE SAE VISCOSITY OILS

the Engine Oil

Inspecting the Filter Element

1. Place a bright light inside the filter.

2. Rotate the filter slowly while checking for

cleanliness, ruptures, holes, and tears. Replace the filter if damage is evident.

Check the fin assembly damage. Replace the filter if damage is evident.

, gasket, and screen for

Installing the Air Filter Cartridge

1. Wipe the inside of the air cleaner body with a

damp cloth to remove excess dust.

2. Slide the filter into the air cleaner body and

secure it in place with the wing nut and gasket.

3. Install the dust cup and baffle.

4. Install the cover and tighten the retaining screw.

Changing/Draining the Engine Oil

1. Start the engine and let it run for five minutes.

This warms the oil so it drains better.

2. Park the traction unit so that the drain side is

slightly lower than the opposite side to ensure that the oil drains completely.

3. Lower the loader arms and stop the engine.

Remove the key.

POTENTIAL HAZARD

• Components will be hot if the traction unit

has been running.

WHAT CAN HAPPEN

• Touching hot components can cause burns.

HOW TO AV

OID THE HAZARD

• Allow the traction unit to cool before

performing maintenance or any touching components.

Maintenance

4. Place a pan below the oil drain.

5. Remove the drain plug from the drain hose and

let the oil drain completely (Fig. 17).

Figure 17

1. Drain

plug

6. Install the drain plug and tighten it. Note: Dispose of the used oil at a certified

recycling center.

7. Remove the oil filler cap (Fig. 18) and refill the engine with oil.

Changing the Engine Oil Filter

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. Note: Dispose of oil filter properly. Recycle

in accordance with local codes.

4. Before installing the filter, lightly oil the gasket on the filter with fresh, clean oil.

5. Screw the filter on by hand until the gasket contacts the oil filter adapter. Tighten 1/2 to 3/4 turn more.

6. Fill the crankcase with the proper type of new oil and replace the filler cap; refer to Changing the Oil, page 25.

IMPORTANT: Do not overfill the engine with oil. Overfilling will cause engine damage.

Figure 18

1. Oil

filler cap

8. Replace the filler cap.

9. Start the engine and let it run at idle for 5

minutes. Then stop the engine.

10. Wait 3 minutes and recheck the oil level. If

required, add oil to bring the level to the upper line on the dipstick.

Changing

the Engine Coolant

Change the engine coolant every 400 hours or 2 years.

POTENTIAL HAZARD

• Coolant is hot and pressurized.

WHAT CAN HAPPEN

• Discharge of hot pressurized coolant can

cause sever

HOW TO AV

e burns. OID THE HAZARD

• Do not remove the radiator cap when the

engine is hot. Always allow the engine to cool at least 15 minutes or until the radiator cap is cool enough to touch without burning your hand before removing the radiator cap.

Maintenance

1. Park the traction unit on a level surface, lower

the loader arms, and stop the engine. Remove the key.

2. Allow the engine and radiator to cool, then

remove the radiator cap (Fig. 19).

Figure 19

1. Radiator

3. Open both coolant drain valves at the bottom of

4. When the coolant stops flowing, close the drain

5. Slowly fill the radiator with 0.8 gal. (3.1 l) of a

6. Install the radiator cap.

7. Start the engine and operate it until it is warm.

cap

the radiator and allow coolant to flow into a drain pan.

Note: If you wish, you can attach a 3/8” ID

hose to each of the two drain valves.

valves.

50/50 mixture of water and permanent ethylene glycol anti–freeze.

Recheck the coolant level after the engine has cooled down and replenish if required; refer to Checking the Cooling System, page 14.

Greasing

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.

and Lubrication

Greasing the Traction Unit

1. Lower the loader arms and stop the engine.

Remove the key.

2. Clean the grease fittings with a rag. Make sure to

scrape any paint off the front of the fitting(s).

3. Connect a grease gun to each fitting. Pump

grease into the fittings until grease begins to ooze out of the bearings.

4. Wipe up any excess grease.

Lubricating Traction Drive Chain

1. Lower the loader arms and stop the engine.

Remove the key.

2. Apply a general purpose oil (10W30) onto upper

and lower chain spans.

3. Start the traction unit and slowly move it

forward to expose un-lubed upper and lower chain spans.

4. Stop the engine and remove the key.

5. Apply oil to newly exposed un-lubed chain

spans.

8. Dispose of engine coolant properly, according to

local laws and codes and keep it away from children and animals.

Fuel

Replace the fuel filter after every 400 operating hours or yearly, whichever occurs first.

Filter

Replacing the Fuel Filter

Never re–install a dirty filter.

Maintenance

1. Lower the loader arms and stop the engine.

Remove the key.

2. Close fuel shut-off valve on the filter (Fig. 20).

1. Filter

2. Fuel

shut–of

Figure 20

f valve

Bleed screws

3. Unscrew the nut securing the bowl to the filter

head.

4. Remove water or other contaminants from the

bowl.

POTENTIAL HAZARD

• Under certain conditions fuel is extremely

flammable and highly explosive.

WHAT CAN HAPPEN

• A fire or explosion from fuel can burn you,

others, and cause property damage.

HOW TO AV

OID THE HAZARD

• Use a funnel and fill the fuel tank outdoors,

in an open area, when the engine is cold. Wipe up any fuel that spills.

• Do not fill the fuel tank completely full.

Add fuel to the fuel tank until the level is 1/4” to 1/2” (6 mm to 13 mm) below the bottom of the filler neck. This empty space in the tank allows fuel to expand.

• Never smoke when handling fuel, and stay

away from an open flame or where fuel fumes may be ignited by a spark.

• Store fuel in an approved container and

keep it out of the reach of children. Never buy more than a 30-day supply.

5. Remove the fuel filter and replace it with a new

one.

6. Install the bowl to the filter head.

7. Ensure that the O-ring is positioned properly

between the bowl mounting nut and the filter head.

8. Open the fuel shut-off valve on on the filter.

9. Open the bleed screws on filter mounting head to

fill the bowl with fuel (Fig. 20).

10.

Close the bleed screws.

Bleeding

the Fuel System

Bleeding of the fuel system is required in any of the following conditions:

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.

3. Open the fuel shut-off on the fuel filter (Fig. 20).

4. Open the bleed screws on filter mounting head to

fill the bowl with fuel (Fig. 20).

5. Use the key switch to crank the engine until fuel

comes out of the bleed screws in a steady stream.

Close the bleed screws.

7. On right side of the engine, locate the air vent

plug on top of the fuel injection pump and open it.

8. Use the key switch to crank the engine until fuel

comes out of the vent plug in a steady stream.

9. Close the vent plug.

4. Install the fuel line onto the fuel filter. Slide the

hose clamp close to the fuel filter to secure the fuel line.

Servicing

the Hydraulics

System

Replacing the Hydraulic Filter

Change the hydraulic filter after the first eight operating hours and every 200 operating hours thereafter.

1. Position traction unit on a level surface, lower

the loader arms, and stop the engine. Remove the key.

IMPORTANT: Do not substitute an automotive oil filter or severe hydraulic system damage may result.

2. Place a drain pan under the filter and remove the

old filter.

3. Wipe the filter adapter gasket surface clean

(Fig. 21).

4. Apply a thin coat hydraulic fluid to the rubber

gasket on the replacement filter (Fig. 21).

Draining

1. Park the traction unit on a level surface, lower

the loader arms, and stop the engine. Remove the key.

2. Loosen the hose clamp and slide it up the fuel

line away from the fuel filter.

3. Pull the fuel line off of the fuel filter and allow

fuel to drain into a fuel can or drain pan. Note: Now is the best time to install a new

the Fuel T

fuel filter because the fuel tank is empty.

ank

Figure 21

1. Hydraulic

2. Gasket

5. Install the replacement hydraulic filter onto the

6. Clean up any spilled fluid.

filter

filter adapter. Tighten it clockwise until the rubber gasket contacts the filter adapter, then tighten the filter an additional 1/2 turn (Fig. 21).

3. Adapter

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: If fluid becomes contaminated, contact

your local Toro dealer because the system must be flushed. Contaminated fluid looks milky or black when compared to clean oil.

1. Position the traction unit on a level surface,

lower the loader arms and stop the engine. Remove the key.

2. Place a 15 gallon drain pan under the hydraulic

tank.

3. Remove the drain plug from the bottom rear of

the tank and let the hydraulic fluid flow into the drain pan.

4. Install and tighten the plug when finished

draining.

9. Check level of the fluid and add enough to raise level to the green mark on the dipstick.

IMPORTANT: Do not overfill the tank with fluid. Overfilling will cause system damage.

Check the Hydraulic Lines

After every 100 operating hours, check the hydraulic lines and hoses for leaks, loose fittings, kinked lines, loose mounting supports, wear, weather, and chemical deterioration. Replace all moving hydraulic hoses every 1500 hours or 2 years, which ever comes first. Make necessary repairs before operating.

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 AV

OID THE HAZARD

• Keep body and hands away from pin hole

leaks or nozzles that eject high pressure hydraulic fluid.

• Use cardboard or paper to find hydraulic

leaks, never use your hands.

5. Remove the filler cap and fill the tank with

approximately 15 gallons of hydraulic fluid. Refer to Checking Hydraulic Fluid.

IMPORTANT: Use only hydraulic fluids specified. Other fluids could cause system damage.

6. Install the filler cap.

7. Start the engine and use all hydraulic controls to

distribute hydraulic fluid throughout the system.

8. Stop the engine.

Traction

Drive Chains

Checking the Tension

Check the drive chain tension before using the traction unit for the first time and every 50 hours of use thereafter.

Drive chains should have about 1–1/2 to 2–1/2 inches of slack between the bottom of the chain guard and the bottom chain span when the top chain span is pulled tight. Use the following procedure to check the tension:

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. Measure the distance between the bottom of the

chain guard and the lower chain span (Fig. 22). If the slack in the chain is not within 1–1/2 to 2–1/2 inches, adjust the tension (refer to Adjusting the Tension).

3. Remove the chain guard (Fig. 22).

4. Loosen the jam nuts on the chain tensioning bolt

and loosen the bolt (Fig. 23).

m–3963

1. Chain

tensioning bolt

Figure 23

Jam nuts

5. Turn the front wheel backward on one side of the

traction unit until the lower span of the drive chain is tight.

6. Slide a 3 inch by 3 inch block of wood between

the top span and the mud guard (Fig. 24).

1. Chain

guard

Bottom span of the chain

Figure 22

1–1/2” to 2–1/2”

m–3962

IMPORTANT: Under sandy conditions, sand can build up on the sprockets. This enlar

ges the sprocket and the chain tightens. Under these conditions the chains should have 2–1/2 to 3–1/2 inches of slack between the bottom of the chain guard and the lower chain span.

5. Repeat steps 3 and 4 for the other drive chain.

6. Start the engine and raise the bucket to return the

front wheels to the ground.

Adjusting the Tension

IMPORTANT: In sandy conditions, an additional 1/2 inch of slack may improve chain performance.

Figure 24

1. Mud

guard

3” x 3” block of wood

3. T

op span of the chain

7. Tighten the chain tensioning bolt until the top

span tightens around the block of wood (Fig. 23 and 24).

8. Tighten the jam nuts on the bolt to secure it in

place (Fig. 23).

m–3961

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.

9. Remove the block of wood and replace the chain

guard.

Maintenance

10. Repeat steps 3 through 9 for the other drive

chain.

11. Start the engine and raise the bucket to return the

front wheels to the ground.

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.

The fan belt should have a maximum deflection of .28–.35 inch (7–9mm) with a 22 pound (10Kg) load applied.

1. Position traction unit on a level surface, lower

the loader arms, and stop the engine. Remove key from ignition switch.

2. Loosen the alternator mounting bolts.

3. Adjust the belt to the proper tension and tighten

the bolts.

IMPORTANT: Do not allow the electrolyte to get below the plates. (Fig. 25).

1. Filler

caps

Lower part of tube

Figure 25

3. Plates

1262

2. If the electrolyte is low, add the required amount

of distilled water; refer to Adding Water to the Battery, below.

Adding Water to the Battery

The best time to add distilled water to the battery is just before you operate the traction unit. This lets the water mix thoroughly with the electrolyte solution.

1. Clean the top of the battery with a paper towel.

Servicing

the Battery

Check the electrolyte level in the battery every 25 hours. Always keep the battery clean and fully charged. Use a paper towel to clean the battery case. If the battery terminals are corroded, clean them with a solution of four parts water and one part baking soda. Apply a light coating of grease to the battery terminals to reduce corrosion.

Voltage: 12 v, 340 to 380 Cold Cranking Amps

Checking the Electrolyte Level

1. Open covers to see into the cells. The electrolyte

must be up to the lower part of the tube (Fig. 25).

2. Lift off the filler caps (Fig. 25).

3. Slowly pour distilled water into each battery cell

until the level is up to the lower part of the tube (Fig. 25).

IMPORTANT: Do not overfill the battery because electr sever

e corr

olyte (sulfuric acid) can cause

osion and damage to the chassis.

4. Press the filler caps onto the battery.

Charging the Battery

IMPORTANT: Always keep the battery fully charged (1.260 specific gravity). This is especially important to prevent battery damage when the temperature is below 32°F (0°C).

1. Check the electrolyte level; refer to Checking

Electrolyte Level.

Maintenance

2. 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.

3. Install the filler caps after the battery is fully

charged.

POTENTIAL HAZARD

• Charging the battery pr

WHAT CAN HAPPEN

oduces gasses.

• Battery gasses can explode.

HOW TO AV

OID THE HAZARD

• Keep cigarettes, sparks, and flames away

from the battery.

Cleaning

and Storage

7. Check the tire pressure; refer to Tire Pressure,

page 14.

8. Charge the battery; refer to Servicing the Battery

page 32.

9. Flush the fuel tank with fresh, clean diesel fuel

10. Check and tighten all bolts, nuts, and screws.

Repair or replace any part that is damaged.

11. Check anti–freeze protection and fill the radiator

with a 50/50 solution of water and permanent ethylene glycol anti–freeze.

12. Paint all scratched or bare metal surfaces. Paint

is available from your Authorized Service Dealer.

13. Store the traction unit in a clean, dry garage or

storage area. Remove the key from the ignition switch and keep it in a memorable place.

14. Cover the traction unit to protect it and keep it

clean.

1. Lower the loader arms and stop the engine.

Remove the key.

2. Remove dirt and grime from the external parts of

the entire traction unit, especially the engine. Clean dirt and chaff from the outside of the engine.

IMPORTANT: You can wash the traction unit with mild detergent and water. Do not pressure wash the traction unit. Avoid excessive use of water control panel, engine, hydraulic pumps and motors.

3. Service the air cleaner; refer to Servicing the Air

Cleaner, page 24.

4. Grease the traction unit; refer to Greasing and

Lubrication, page 27.

5. Change the crankcase oil; refer to Servicing the

Engine Oil, page 25.

, especially near the

6. Change the hydraulic fluid; refer to Servicing the

Hydraulic System, page 29.

Troubleshooting

PROBLEM

The starter does not crank.

The engine cranks, but will not start.

POSSIBLE CAUSES

The electrical connections are corroded or loose.

A fuse is blown or loose.

The relay or switch is defective.

The battery is discharged.

A faulty starter or starter solenoid.

Seized internal engine components.

Incorrect starting procedure.

The fuel tank is empty

The fuel shut-of closed.

Dirt, water, stale fuel, or incorrect fuel is in the fuel system.

f valve is

. 2.

CORRECTIVE ACTION

Check the electrical connections for good contact.

Correct or replace the fuse. Contact your Authorized

Service Dealer Charge the battery or replace

it. Contact your Authorized

Service Dealer Contact your Authorized

Service Dealer Refer to Starting and

Stopping the Engine, page

18. Fill with fresh fuel. Open the fuel shut-of

Drain and flush the fuel system; add fresh fuel.

f valve.

Clogged fuel line.

There is air in the fuel

Inoperative glow plugs.

Clean or replace.

Bleed the nozzles and check for air leaks at the fuel hose connections and fittings between the fuel tank and engine.

Check the fuse, glow plugs and wiring.

Troubleshooting

eep u g

PROBLEM

The engine cranks, but will not start (continued).

POSSIBLE CAUSES

Slow cranking speed.

The air cleaner element is dirty.

10.

Low compression.

11.

The injection nozzles are faulty.

12.

The fuel filter is clogged.

13.

The injections pump timing is incorrect.

14.

The injection pump is faulty

15.

Improper fuel grade for cold weather use.

10.

11.

12.

13.

. 14.

15.

CORRECTIVE ACTION

Check the battery viscosity and starting motor (contact your Authorized Service Dealer).

Clean or replace.

Contact your Authorized Service Dealer

Replace the fuel filter Contact your Authorized

Service Dealer Contact your Authorized

Service Dealer Drain the fuel system and

replace the fuel filter fresh fuel of proper grade for ambient temperature conditions. Y warm the entire traction unit.

, oil

. Add

ou may need to

The engine starts, but does not keep running.

The engine runs, but knocks or misses.

The fuel tank vent is restricted.

Dirt or water is in the fuel system.

The fuel filter is clogged.

The fuel pump is faulty

There is air in the fuel.

Improper fuel grade for cold weather use.

Dirt, water, stale fuel, or incorrect fuel is in the fuel system.

Engine overheating.

. 4.

Contact your Authorized Service Dealer

Drain and flush the fuel system; add fresh fuel.

Replace the fuel filter Contact your Authorized

Service Dealer Bleed the nozzles and check

for air leaks at fuel hose connections and fittings between the fuel tank and engine.

Drain the fuel system and replace the fuel filter fresh fuel of proper grade for ambient temperature conditions.

Drain and flush the fuel system; add fresh fuel.

See ENGINE OVERHEA

. Add

TS.

Troubleshooting

PROBLEM

The engine runs, but knocks or misses (continued).

The engine will not idle.

POSSIBLE CAUSES

There is air in the fuel.

The injection nozzles are faulty.

Low compression

The injection pump timing is incorrect.

Excessive carbon build–up.

Internal wear or damage.

The fuel tank vent is restricted.

Dirt, water, stale fuel, or incorrect fuel is in the fuel system.

CORRECTIVE ACTION

Bleed nozzles and check for air leaks at the fuel hose connections and fittings between the fuel tank and engine.

Contact your Authorized Service Dealer

Drain and flush the fuel system; add fresh fuel.

The engine overheats.

The fuel pump is faulty

Low compression.

The air cleaner element is dirty.

The fuel filter is clogged.

There is air in the fuel.

More coolant is needed.

Restricted air flow to the radiator.

The crankcase oil level is incorrect.

Excessive loading.

. 3.

Contact your Authorized Service Dealer

Clean or replace.

Replace the fuel filter

Bleed the nozzles and check for air leaks at the fuel hose connections and fittings between the fuel tank and engine.

Check and add coolant.

Inspect and clean the radiator screen with every use.

Fill or drain to the full mark.

Reduce load; use lower ground speed.

Troubleshooting

e aust

PROBLEM

The engine overheats (continued).

The engine loses power

POSSIBLE CAUSES

The thermostat is faulty

The fan belt is loose or broken.

Incorrect fuel is in the fuel system.

Injection timing is incorrect.

Coolant pump is defective.

The crankcase oil level is incorrect.

The air cleaner element is dirty.

Dirt, water, stale fuel, or incorrect fuel is in the fuel system.

The engine is overheated.

Low compression.

. 5.

CORRECTIVE ACTION

Contact your Authorized Service Dealer

Drain and flush the fuel system; add fresh fuel.

Contact your Authorized Service Dealer

Fill or drain to the full mark.

Clean or replace.

Drain and flush the fuel system; add fresh fuel.

See ENGINE OVERHEA Contact your Authorized

Service Dealer

TS.

Excessive black smoke from exhaust.

The fuel tank vent is restricted.

The engine load is excessive.

There is air in the fuel.

The injection pump timing is incorrect.

10.

The injection pump is faulty

The air cleaner element is dirty.

The injection pump timing is incorrect.

Incorrect fuel is in the fuel system.

The injection nozzles are faulty.

. 10.

Contact your Authorized Service Dealer

Reduce ground speed. Bleed the nozzles and check

for air leaks at the fuel hose connections and fittings between the fuel tank and engine.

Contact your Authorized Service Dealer

Clean or replace.

Contact your Authorized Service Dealer

Drain the fuel system and refill with specified fuel.

Contact your Authorized Service Dealer

The injection pump is faulty

. 5.

Contact your Authorized Service Dealer

Troubleshooting

PROBLEM

Excessive black smoke from exhaust (continued).

Excessive white smoke from exhaust.

raction unit does not drive.

POSSIBLE CAUSES

Excessive loading.

The glow plugs were not activated prior to turning the key to the start position.

The engine temperature is low.

The glow plugs are inoperative.

The fuel injection nozzles are faulty.

The injection pump timing is incorrect.

Low compression.

1. T

raction pump drive coupler

is loose or broken.

Hydro fluid level low

Pump and/or wheel motor is defective or damaged.

CORRECTIVE ACTION

Reduce load; use lower ground speed.

1. T

urn the key to the glow position for 5 to 7 seconds before starting the engine.

Check the thermostat.

Check the fuse, glow plugs and wiring.

Contact your Authorized Service Dealer

Contact Authorized Service Dealer.

Add hydro fluid to reservoir

Contact your Authorized Service Dealer

Engine will not shut of

f 1.

Control valve is defective or damaged.

Relief valve is defective or damaged.

Flow divider valve lever is in 9 o’clock position.

Stop timer or solenoid failed.

Contact your Authorized Service Dealer

Move lever to 12 o’clock to 10 o’clock position.

Set the throttle as low as possible. With the auxiliary hydraulics hoses disconnected, engage the auxiliary hydraulics to overload and stop the engine. Contact your Authorized Service Dealer

Toro 22302TE Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual