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68138
Operator's Manual
40 pgs8.94 Mb0
Operator's Manual
64 pgs3.79 Mb0
Operator's Manual [es]
44 pgs3.09 Mb0
Operator's Manual [fr]
44 pgs3.1 Mb0
Parts Catalogue
36 pgs2.56 Mb0
Parts Catalogue
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Schematic Drawing
1 pgs638.09 Kb0
Schematic Drawing
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Setup Instructions
1 pgs378.35 Kb0
Table of contents
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Toro 68138, 68138G, 68138HD Operator's Manual

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Page 1
FormNo.3421-177RevB
MBTX2500TrackedMudBuggy
ModelNo.68138—SerialNo.402100000andUp ModelNo.68138G—SerialNo.402100000andUp ModelNo.68138HD—SerialNo.400000000andUp
Registeratwww.T oro.com. OriginalInstructions(EN)
*3421-177*B
Page 2
ItisaviolationofCaliforniaPublicResourceCode Section4442or4443touseoroperatetheengineon anyforest-covered,brush-covered,orgrass-covered landunlesstheengineisequippedwithaspark arrester,asdenedinSection4442,maintainedin effectiveworkingorderortheengineisconstructed, equipped,andmaintainedforthepreventionofre.
Becauseinsomeareastherearelocal,state,or federalregulationsrequiringthatasparkarresterbe usedontheengineofthismachine,asparkarresteris availableasanoption.Ifyourequireasparkarrester, contactyourAuthorizedServiceDealer.GenuineToro sparkarrestersareapprovedbytheUSDAForestry Service.
Theenclosedengineowner'smanualissupplied forinformationregardingtheUSEnvironmental ProtectionAgency(EPA)andtheCaliforniaEmission ControlRegulationofemissionsystems,maintenance, andwarranty.Replacementsmaybeorderedthrough theenginemanufacturer.
WARNING
CALIFORNIA
Proposition65Warning
Theengineexhaustfromthisproduct
containschemicalsknowntotheStateof
Californiatocausecancer,birthdefects,
orotherreproductiveharm.
Batteryposts,terminals,andrelated
accessoriescontainleadandlead
compounds,chemicalsknownto
theStateofCaliforniatocause
cancerandreproductiveharm.Wash
handsafterhandling.
Useofthisproductmaycauseexposure
tochemicalsknowntotheStateof
Californiatocausecancer,birthdefects,
orotherreproductiveharm.
Introduction
Thismachineisintendedtobeusedbyprofessional, hiredoperatorsincommercialapplications.This machineisastable,reliable,andproductivemachine forcarryingandmovingmaterialsforanyjobsite.Itis primarilydesignedtomoveconcrete,mortar,gravel, dirt,ordebrisaroundjobsites.
Readthisinformationcarefullytolearnhowtooperate andmaintainyourproductproperlyandtoavoid injuryandproductdamage.Youareresponsiblefor operatingtheproductproperlyandsafely .
YoumaycontactT orodirectlyatwww.T oro.com forproductsafetyandoperationtrainingmaterials, accessoryinformation,helpndingadealer,orto registeryourproduct.
Wheneveryouneedservice,genuineToroparts,or additionalinformation,contactanAuthorizedService DealerorToroCustomerServiceandhavethemodel andserialnumbersofyourproductready.Figure1 identiesthelocationofthemodelandserialnumbers ontheproduct.Writethenumbersinthespace provided.
Important:Withyourmobiledevice,youcan
scantheQRcodeontheserialnumberdecal(if equipped)toaccesswarranty,parts,andother productinformation.
©2018—TheToro®Company 8111LyndaleAvenueSouth Bloomington,MN55420
Figure1
1.Modelandserialnumberlocation
ModelNo.
SerialNo.
Thismanualidentiespotentialhazardsandhas safetymessagesidentiedbythesafety-alertsymbol (Figure2),whichsignalsahazardthatmaycause
Contactusatwww.Toro.com.
2
g241847
PrintedintheUSA
AllRightsReserved
Page 3
seriousinjuryordeathifyoudonotfollowthe recommendedprecautions.
Figure2
1.Safety-alertsymbol
Thismanualuses2wordstohighlightinformation. Importantcallsattentiontospecialmechanical informationandNoteemphasizesgeneralinformation worthyofspecialattention.
Contents
Safety.......................................................................4
SafeOperatingPractices....................................4
g000502
SafetyandInstructionalDecals..........................6
ProductOverview.....................................................9
Controls.............................................................9
Specications..................................................10
Attachments/Accessories.................................10
Operation................................................................10
AddingFuel......................................................10
PerformingDailyMaintenance..........................12
OperatingtheParkingBrake.............................12
OperatingtheThrottle.......................................13
OperatingtheChoke.........................................13
StartingtheEngine...........................................13
ShuttingOfftheEngine.....................................14
OperatingtheHopper.......................................14
RemovingDebrisfromtheMachine..................14
LoweringtheHopperwithoutPower..................15
TransportingtheMachine.................................15
LiftingtheMachine...........................................16
Maintenance...........................................................17
RecommendedMaintenanceSchedule(s)...........17
Pre-MaintenanceProcedures..............................18
ReleasingtheCushionforRearAccess............18
UsingtheCylinderLock....................................18
Lubrication..........................................................19
GreasingtheMachine.......................................19
EngineMaintenance...........................................19
ServicingtheAirCleaner..................................19
CheckingtheEngine-OilLevel..........................20
ChangingtheEngineOilandFilter....................21
ServicingtheSparkPlugs.................................22
CleaningtheBlowerHousing............................23
FuelSystemMaintenance...................................24
ReplacingtheFuelFilter...................................24
DrainingtheFuelT ank......................................24
RemovingtheFuelT ank...................................25
ElectricalSystemMaintenance...........................25
ServicingtheBattery.........................................25
ServicingtheFuses..........................................27
DriveSystemMaintenance..................................27
ServicingtheTracks.........................................27
ServicingtheDriveBelt.....................................29
ControlsSystemMaintenance.............................30
AdjustingtheMotion-ControlLevers.................30
BrakeMaintenance...........................................31
HydraulicSystemMaintenance...........................32
ServicingtheHydraulicDriveSystem...............32
ServicingtheHydraulicLiftSystem...................34
CheckingtheHydraulicLines...........................36
Cleaning..............................................................37
RemovingDebrisfromtheMachine..................37
Storage...................................................................38
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Safety
Improperuseormaintenanceofthemachinecan resultininjury .Toreducethepotentialforinjury, complywiththesesafetyinstructionsandalwayspay attentiontothesafety-alertsymbol(Figure2),which meansCaution,Warning,orDanger—personal safetyinstruction.Failuretocomplywiththe instructionmayresultinpersonalinjuryordeath.

SafeOperatingPractices

–Donotstorethemachineorfuelcontainer
wherethereisanopename,spark,orpilot light,suchasonawaterheaterorother appliance.
–Ifyouspillfuel,donotattempttostartthe
engine;avoidcreatinganysourceofignition untilthefuelvaporshavedissipated.
•Checkthattheoperator'spresencecontrols,safety
switches,andshieldsareattachedandfunctioning properly.Donotoperatethemachineunlessthey arefunctioningproperly.
WARNING
Engineexhaustcontainscarbonmonoxide, anodorlessgasthatislethalifinhaled.
Donotruntheengineindoorsorinan enclosedarea.

Training

•ReadtheOperator'sManualandothertraining
material.Iftheoperator(s)ormechanic(s)cannot readthismanual,itistheowner'sresponsibilityto explainthismaterialtothem.
•Becomefamiliarwiththesafeoperationofthe
equipment,operatorcontrols,andsafetysigns.
•Alloperatorsandmechanicsshouldbetrained.
Theownerisresponsiblefortrainingtheusers.
•Neverletchildrenoruntrainedpeopleoperateor
servicetheequipment.Localregulationsmay restricttheageoftheoperator.
•Theowner/usercanpreventandisresponsible
foraccidentsorinjuriesoccurringtohimselfor herself,otherpeopleorproperty .

Preparation

•Wearappropriateclothingincludinghardhat,eye
protection,longpants,substantial,slip-resistant footwear,andhearingprotection.Tiebacklong hair.Donotwearloosejewelry.
•Inspecttheareawheretheequipmentistobe
usedandensurethatallobjectsareremovedfrom themachinebeforeuse.
•Knowandmarkthelocationsofallutilitylines.
•Useextracarewhenhandlingfuels.Theyare
ammableandvaporsareexplosive.
–Extinguishallcigarettes,cigars,pipes,and
othersourcesofignition. –Useonlyanapprovedcontainer –Donotremovethefuelcaporllthefueltank
whiletheengineisrunningorhot. –Donotaddordrainfuelinanenclosedspace.

Operation

•Useyourfullattentionwhileoperatingthe
machine.Donotengageinanyactivitythat causesdistractions;otherwise,injuryorproperty damagemayoccur.
•Neverrunanengineinanenclosedorpoorly
ventilatedarea.
•Operatethemachineonlyingoodlight,keeping
awayfromholesandhiddenhazards.
•Ensurethatalldrivesareinneutralbefore
startingtheengine.Starttheengineonlyfromthe operator'sposition.
•Donotoperatethemachinewiththeguards
notsecurelyinplace.Besureallinterlocksare attached,adjustedproperly,andfunctioning properly.
•Donotchangetheenginegovernorsettingor
overspeedtheengine.
•Stopthemachineonlevelground,lowerthe
hopper,shutofftheengine,andremovethekey beforeleavingtheoperator'spositionforany reason.
•Nevercarrypassengersandkeeppetsand
bystandersaway.
•Slowdownandusecautionwhenmakingturns
andcrossingroadsandsidewalks.
•Donotoperatethemachinewhileill,tired,or
undertheinuenceofalcoholordrugs.
•Usecarewhenloadingorunloadingthemachine
intoatrailerortruck.
•Usecarewhenapproachingblindcorners,shrubs,
trees,orotherobjectsthatmayobscurevision.
•Ensurethattheareaisclearofotherpeoplebefore
operatingthemachine.Shutoffthemachineif anyoneentersthearea.
•Neverleavearunningmachineunattended.
•Donotexceedtheratedoperatingcapacity,asthe
machinemaybecomeunstablewhichmayresult inlossofcontrol.
•Neverjerkthecontrols;useasteadymotion.
4
Page 5
•Watchfortrafcwhenoperatingnearorcrossing
roadways.
•Donottouchpartsthatmaybehotfromoperation.
Allowthemtocoolbeforeattemptingtomaintain, adjust,orservice.
•Checkforoverheadclearances(i.e.,branches,
doorways,electricalwires)beforedrivingunder anyobjectsanddonotcontactthem.
•Ensurethatyouoperatethemachineinareas
wheretherearenoobstaclesclosetoyou.Failure tomaintainadequatedistancefromtrees,walls, andotherbarriersmayresultininjuryasthe machinebacksupduringoperationifyouare notattentivetothesurroundings.Operatethe machineonlyinareaswherethereissufcient clearancefortheoperatortosafelymaneuverthe product.
•Locatethepinchpointareasmarkedonthe
machineandkeephandsandfeetawayfrom theseareas.
•Operatethemachineonlyingoodvisibilityand
appropriateweatherconditions.Donotoperate themachinewhenthereistheriskoflighting.
•Donotoverloadthehopperandalwayskeepthe
loadlevelwhenoperatingthemachine.

SlopeOperation

•Slopesareamajorfactorrelatedtoloss-of-control
andtip-overaccidents,whichcanresultinsevere injuryordeath.Theoperatorisresponsiblefor safeslopeoperation.operatingthemachineon anysloperequiresextracaution.Beforeusingthe machineonaslope,youmust:
–Reviewandunderstandtheslopeinstructions
inthemanualandonthemachine.
–Evaluatethesiteconditionsofthedayto
determineiftheslopeissafeformachine
operation.Alwaysusecommonsense
andgoodjudgmentwhenperformingthis
evaluation.Changesintheterrain,suchas
moisture,canquicklyaffecttheoperationof
themachineonaslope.
•Raisingthehopperonaslopeaffectsthestability
ofthemachine.Keepthehopperinthelowered positionwhenonslopes.
•Whenoperatingonaslope,foldtheplatformup
andwalkbehindthemachineuntilitisonat ground.
•Operateupanddownslopeswiththeheavy
endofthemachineuphill.Weightdistribution changeswithafullhopper.Afullhoppermakes thefrontofthemachinetheheavyend,sowhen travelingupordownslopeswithafullhopper, walk-behindthemachinewiththefullhopperuphill.
•Identifyhazardsatthebaseoftheslope.Do
notoperatethemachineneardrop-offs,ditches, embankments,waterorotherhazards.The machinecouldsuddenlyrolloverifawheelortrack goesovertheedgeortheedgecollapses.Keep asafedistance(twicethewidthofthemachine) betweenthemachineandanyhazard.
•Avoidstarting,stopping,orturningthemachineon
aslope.Avoidmakingsuddenchangesinspeed ordirection;turnslowlyandgradually.
•Keepallmovementsonslopesslowandgradual.
Donotmakesuddenchangesinspeedor direction.
•Donotoperatethemachineunderanyconditions
wheretraction,steering,orstabilityisinquestion. Beawarethatoperatingthemachineonwetgrass, acrossslopesordownhillmaycausethemachine tolosetraction.Lossoftractiontothewheelsor tracksmayresultinslidingandalossofbraking andsteering.Themachinecanslideevenifthe wheelsortracksarestopped.
•Removeormarkobstaclessuchasditches,holes,
ruts,bumps,rocksorotherhiddenhazards.T all grasscanhideobstacles.Uneventerraincould overturnthemachine.
•Ifyoulosecontrolofthemachine,stepoffand
awayfromthedirectionoftravelofthemachine.

MaintenanceandStorage

•Lettheenginecoolbeforestoringanddonotstore
themachinenearanopename.
•Engagetheparkingbrake,shutofftheengine,
removethekey ,andwaitforallmovementto stopbeforeadjusting,cleaning,orrepairingthe machine.
•Cleandebrisfromdrives,mufers,andtheengine
tohelppreventres.Cleanupoilorfuelspills.
•Donotstorefuelnearamesordrainindoors.
•Parkthemachineonlevelground.Neverallow
untrainedpersonneltoservicethemachine.
•Usejackstandstosupportcomponentswhen
required.
•Carefullyreleasepressurefromcomponentswith
storedenergy.
•Disconnectthebattery,negativeterminalrstand
positiveterminallast,beforemakinganyrepairs. Connectthebatterypositiveterminalrstand negativeterminallast.
•Keepyourhandsandfeetawayfrommoving
parts.Ifpossible,donotmakeadjustmentswith theenginerunning.
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Page 6
•Chargebatteriesinanopen,well-ventilatedarea,
awayfromsparkandames.Unplugthecharger beforeconnectingordisconnectingitfromthe battery.Wearprotectiveclothinganduseinsulated tools.
•Keepallpartsingoodworkingconditionandall
hardwaretightened.Replaceallwornordamaged decals.
•Usethecylinderlocktosecurethehopperinthe
raisedposition.
•Keepnutsandboltstight.Keepequipmentin
goodcondition.
•Nevertamperwithsafetydevices.
•UseonlygenuineT ororeplacementpartsto
ensurethatoriginalstandardsaremaintained.
SafetyandInstructionalDecals
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyarea ofpotentialdanger.Replaceanydecalthatisdamagedormissing.
•Batteryacidispoisonousandcancauseburns.
Avoidcontactwithskin,eyes,andclothing.Protect yourface,eyes,andclothingwhenworkingwitha battery.
•Batterygasescanexplode.Keepcigarettes,
sparks,andamesawayfromthebattery.
•Keepyourbodyandhandsawayfrompinhole
leaksornozzlesthatejecthigh-pressurehydraulic uid.Usecardboardorpapertondhydraulic leaks;neveruseyourhands.Hydraulicuid escapingunderpressurecanpenetrateskinand causeinjuryrequiringsurgerywithinafewhours byaqualiedsurgeon;otherwise,gangrenemay result.
115-4212
1.Hydraulic-uidlevel
2.ReadtheOperator's Manual.
1.Crushinghazardofhandsorfeet—installthecylinderlock.
3.Warning—donottouchthe hotsurface.
115-4858
decal116-8775
decal115-4212
1.ReadtheOperator’s
Manual.
decal115-4858
116-8775
2.Filltobottomofllerneck; warning—donotoverll thetank.
decal133-5619
133-5619
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decal132-8961
132-8961
137-0575
decal137-0575
1.Batterychargingcondition4.Hopperislowering.
2.Hourmeter5.Hopperisdown.
3.Hopperisraising.6.Hopperislowering automatically.
132-9051
1.Tie-downpoint
132-9052
1.ReadtheOperator’s
3.Cold-llline
Manual.
2.Transmissionuid
decal132-9051
decal132-9052
1.Main(15A)3.Logic(7.5A)
2.Auxiliary(15A)
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decal137-3715
137-3715
1.Parking-brakerelease
7.Explosionhazard—shutofftheengine beforeaddingfuel;nore,open ames,orsmokingwhenaddingfuel.
2.Parkingbrake8.Machinetippinghazard—donotdrive forwardwiththehopperraised;do notdrivedownslopeswiththehopper raised;donotdriveacrossslopeswith thehopperraised;driveslowlywiththe hopperdown.
3.Warning—readtheOperator’sManual;
hearingprotectionmustbeworn.
9.Warning—keepbystandersasafe distanceawayfromthemachine;watch behindyouwhenmovinginreverse.
4.Warning—alloperatorsshouldbe trainedbeforeoperatingthemachine.
10.Warning—engagetheparkingbrake, shutofftheengine,andremovethekey beforeleavingtheoperator’sposition.
5.Warning-keepawayfrommovingparts;
11.Lefttractioncontrols
keepallguardsandcoversinplace.
6.Poisonousfumesortoxicgases,
12.Raisehopper
asphyxiationhazard—donotrunthe engineinanenclosedspace.
13.Lowerhopper
14.Movethehandlesintooperate.
15.Righttractioncontrols
16.Engine-speedcontrol
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ProductOverview
Figure3
1.Hopper4.Fuel-tankcap
2.Hood
3.Controlpanel
Controls
5.Operatorplatform
6.Track
ParkingBrakeLever
Toengagetheparkingbrake,pullbackthelever. (Figure4).
Todisengagetheparkingbrake,pushthelever forward.
HourMeter
Thehourmeterrecordsthenumberofhoursthe enginehasoperated.Itoperateswhentheengine isrunning.Usethesetimesforschedulingregular maintenance(Figure4).
ChokeControl
g038268
Usethechoketostartacoldengine.Pullthechoke knobuptoengageit.Pushthechokeknobdownto disengageit(Figure4).
KeySwitch
Usethekeyswitchtostarttheengine(Figure4).The switchhas3positions:OFF,RUN,andSTART.
Becomefamiliarwithallthecontrols(Figure4)before youstarttheengineandoperatethemachine.
Figure4
1.Parking-brakelever6.Throttlelever
2.Hydraulic-tankcap
3.Hourmeter8.Dumpswitch
4.Chokecontrol
5.Keyswitch
7.Leftmotion-controllever
9.Rightmotion-controllever
ThrottleLever
ThethrottleleverisvariablebetweentheFASTand SLOWpositions(Figure4).
Motion-ControlLevers
Usethemotion-controlleverstodrivethemachine forwardandreverseandtoturneitherdirection (Figure4).
DumpSwitch
Usethedumpswitchtodumpandlowerthehopper. Ifyouholdtheswitchdown0.2to1.3seconds,the hopperfullylowersautomatically.
g038269
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Specications
Note:Specicationsanddesignaresubjectto
changewithoutnotice.
Width
Length
Height
Weight
Hoppercapacity
Maximumload
DischargeHeight
90.2cm(35-1/2inches)
268.0cm(105-1/2inches)
121.2cm(47.7inches)
734kg(1,619lb)
0.45m
1,134kg(2,500lb)
38.1cm(15inches)
3
Operation
Note:Determinetheleftandrightsidesofthe
machinefromthenormaloperatingposition.
Important:Beforeoperating,checkthefueland
oillevel,andremovedebrisfromthemachine. Also,ensurethattheareaisclearofpeopleand debris.
(16ft3)

AddingFuel

•Forbestresults,useonlyclean,fresh(lessthan
30daysold),unleadedgasolinewithanoctane ratingof87orhigher((R+M)/2ratingmethod).

Attachments/Accessories

AselectionofT oroapprovedattachmentsand accessoriesisavailableforusewiththemachine toenhanceandexpanditscapabilities.Contact yourAuthorizedServiceDealerorauthorizedT oro distributororgotowww.Toro.comforalistofall approvedattachmentsandaccessories.
Toensureoptimumperformanceandcontinuedsafety certicationofthemachine,useonlygenuineT oro replacementpartsandaccessories.Replacement partsandaccessoriesmadebyothermanufacturers couldbedangerous,andsuchusecouldvoidthe productwarranty.
•ETHANOL:Gasolinewithupto10%ethanol
(gasohol)or15%MTBE(methyltertiarybutyl ether)byvolumeisacceptable.Ethanoland MTBEarenotthesame.Gasolinewith15% ethanol(E15)byvolumeisnotapprovedforuse. Neverusegasolinethatcontainsmorethan10% ethanolbyvolume,suchasE15(contains15% ethanol),E20(contains20%ethanol),orE85 (containsupto85%ethanol).Usingunapproved gasolinemaycauseperformanceproblemsand/or enginedamagewhichmaynotbecoveredunder warranty.
•Donotusegasolinecontainingmethanol.
•Donotstorefueleitherinthefueltankorfuel
containersoverthewinterunlessyouuseafuel stabilizer.
•Donotaddoiltogasoline.
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Page 11
DANGER
DANGER
Incertainconditions,fuelisextremely ammableandhighlyexplosive.Areor explosionfromfuelcanburnyouandothers andcandamageproperty.
•Fillthefueltankoutdoors,inanopenarea, whentheengineiscold.Wipeupanyfuel thatspills.
•Neverllthefueltankinsideanenclosed trailer.
•Donotllthefueltankcompletelyfull. Addfueltothefueltankuntilthelevelis6 to13mm(1/4to1/2inch)belowthebottom ofthellerneck.Thisemptyspaceinthe tankallowsfueltoexpand.
•Neversmokewhenhandlingfuelandstay awayfromanopenameorwherefuel fumesmaybeignitedbyaspark.
•Storefuelinanapprovedcontainerand keepitoutofthereachofchildren.Never buymorethana30-daysupplyoffuel.
•Donotoperatewithoutentireexhaust systeminplaceandinproperworking condition.
Incertainconditionsduringfueling,static electricitycanbereleasedcausingaspark, whichcanignitethefuelvapors.Areor explosionfromfuelcanburnyouandothers andcandamageproperty.
•Alwaysplacefuelcontainersontheground awayfromyourvehiclebeforelling.
•Donotllfuelcontainersinsideavehicle oronatruckortrailerbedbecauseinterior carpetsorplastictruckbedlinersmay insulatethecontainerandslowthelossof anystaticcharge.
•Whenpractical,removefuel-powered equipmentfromthetruckortrailerand refueltheequipmentwithitswheelsonthe ground.
•Ifthisisnotpossible,thenrefuelsuch equipmentonatruckortrailerfroma portablecontainerratherthanfroma fuel-dispensernozzle.
•Ifyoumustuseafuel-dispensernozzle, keepthenozzleincontactwiththerimof thefueltankorcontaineropeningatall timesuntilfuelingiscomplete.
WARNING
Fuelisharmfulorfatalifswallowed. Long-termexposuretovaporscancause seriousinjuryandillness.
•Avoidprolongedbreathingofvapors.
•Keepyourfaceawayfromnozzleandfuel tankorconditioneropening.
•Keepfuelawayfromeyesandskin.
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Page 12

UsingStabilizer/Conditioner

PerformingDaily
Usefuelstabilizer/conditionerinthemachinetokeep thefuelfreshlongerwhenusedasdirectedbythe fuel-stabilizermanufacturer.
Important:Donotusefueladditivescontaining
methanolorethanol.
Addtheamountoffuelstabilizer/conditionertofresh fuelasdirectedbythefuel-stabilizermanufacturer.

FillingtheFuelTank

Fuel-tankcapacity:40.1L(10.6USgallons)
1.Cleantheareaaroundthefuel-tankcap.
2.Removethecap.
3.Addfueluntilitisatthebottomofthellerneck.
Note:Donotllthefueltankcompletelyfull.
Theemptyspaceinthetankallowsthefuelto expand.
4.Installthecap.
Maintenance
Beforestartingtheengineeachday ,performthe followingprocedures:
•Checktheengine-oillevel—refertoCheckingthe
Engine-OilLevel(page20).
•Checkthehydraulic-uidlevelforthedrive
system—refertoCheckingtheHydraulic-Fluid
LevelfortheDriveSystem(page32)
•Checkthehydraulic-uidlevelforthelift
system—refertoCheckingtheHydraulic-Fluid
LevelfortheLiftSystem(page34).

OperatingtheParking Brake

Alwaysengagetheparkingbrakewhenyoustopthe machineorleaveitunattended.Beforeeachuse, checktheparkingbrakeforproperoperation.
CAUTION
Figure5
Childrenorbystandersmaybeinjuredifthey moveorattempttooperatethemachinewhile itisunattended.
Removetheignitionkeyandengagethe parkingbrakewheneveryouleavethe machineunattended.

EngagingtheParkingBrake

Pulltheparking-brakeleverrearwardintothe ENGAGEDposition(Figure6).
g038312
g009465
Figure6
1.Parkingbrake—ENGAGED position
2.Parkingbrake—RELEASED position

ReleasingtheParkingBrake

Pushtheparking-brakeleverforward(Figure6).
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Page 13

OperatingtheThrottle

StartingtheEngine

ThethrottlecontrolmovesbetweenFASTandSLOW positions(Figure7).
AlwaysusetheFASTpositionwhenmovingthe machine.
Figure7

OperatingtheChoke

Usethechoketostartacoldengine.
1.Pullupthechokeknobtoengagethechoke beforeusingthekeyswitch(Figure8).
1.Engagetheparkingbrake.
2.Engagethechoke.
Note:Awarmorhotenginemaynotrequire
choking.Youmayneedtorepeatthestarting cyclewhenyoustarttheengineforthersttime afteryouhavelledacompletelyemptyfuel systemwithfuel.
3.MovethethrottlebetweentheFASTandSLOW positions.
4.TurnthekeyswitchtotheSTARTposition.
g008946
5.Whentheenginestarts,disengagethechoke.
Important:Donotengagethestarterformore
than5secondsatatime.Iftheenginefailstostart, allowa15-secondcool-downperiodbetween attempts.Failuretofollowtheseinstructionscan burnoutthestarter.
Note:Ensurethatyoufullyengagethechoke.
Youmayneedtoholdtheknobupwhenyou usethekeyswitch.
2.Pushdownthechoketodisengagethechoke aftertheenginehasstarted(Figure8).
g038313
Figure9
Figure8
1.ONposition2.OFFposition
g008959
13
Page 14

ShuttingOfftheEngine

1.MovethethrottlebetweentheFASTandSLOW positions.
2.Engagetheparkingbrake.
3.TurnthekeyswitchtotheOFFpositionand removethekey.
Figure10

OperatingtheHopper

Hoppercapacity:1134kg(2,500lb)

RemovingDebrisfromthe Machine

1.Parkthemachineonalevelsurface,move themotion-controlleverstotheNEUTRAL-LOCK position,engagetheparkingbrake,andlower thehopper.
2.Shutofftheengineandremovethekey.Allow theenginetocool.
3.Cleantheinsideofthehopperusingahose.
Important:Donotuseahammertoremove
materialfromtheinsideofthehopper;this maycausedamagetothemachine.
4.Cleananydebrisfromunderthehopper.
5.Wipeawaydebrisfromtheaircleaner.
6.Cleananydebrisbuildupontheengineandin thetransmissionwithabrushorblower.
g038314
Important:Blowoutdirtratherthanwash
itout.Ifyouusewater,keepitawayfrom electricalpartsandhydraulicvalves.Donot useahigh-pressurewasher.High-pressure washingcandamagetheelectricalsystem andhydraulicvalvesordepletegrease.
Knowtheloadcapacityofthemachineandnever exceedit.Thismachinenormallyoperatesonuneven, unpaved,bumpy,and/orinclinedsurfaces—adjustthe loadaccordingly.
1.Positionthemachinewhereyouintendtodump theload.
2.Dumpthehopperbypushingthetopofthe dumpswitch(Figure11).
3.Lowerthehopperbypushingthebottomofthe dumpswitch(Figure11).
Note:Ifyouholdthebottomoftheswitch
0.2to1.3seconds,thehopperfullylowers automatically.
Figure11
1.Dumpthehopper .2.Lowerthehopper .
g038270
14
Page 15
LoweringtheHopper

TransportingtheMachine

withoutPower
1.Installthecylinderlock;refertoInstallingthe
CylinderLock(page18).
2.Ensurethatthetubisempty.
3.Placealargedrainpanunderthe hydraulic-manifoldblock(Figure12).
Figure12
1.Hydraulic-manifoldblock
4.Disconnectthehosettingsinthemanifold blockandallowtheuidtodrainintothepain.
Note:Disposeoftheuseduidatacertied
recyclingcenter.
Useaheavy-dutytrailerortruckwithfull-widthramps totransportthemachine.Ensurethatthetraileror truckhasallthenecessarybrakes,lighting,and markingasrequiredbylaw.Pleasecarefullyreadall thesafetyinstructions.Knowingthisinformationcould helpyou,yourfamily,petsorbystandersavoidinjury. Refertoyourlocalordinancesfortrailerandtie-down requirements.
Important:Donotoperateordrivethemachine
onroadways.
1.Lowerthehopper.
2.Ifusingatrailer,connectittothetowingvehicle andconnectthesafetychains.
3.Ifapplicable,connectthetrailerbrakes.
g186548
4.Carefullyloadthemachineontothetraileror truck.
5.Shutofftheengine,removethekey ,andset thebrake.
6.Usethemetaltie-downloopsonthemachineto securelyfastenthemachinetothetrailerortruck withstraps,chains,cable,orropes(Figure13).
5.Connectthehosettings.
6.Useahoistorhave2peopleholdupthehopper andremovethecylinderlock.
7.Carefullylowerthehoppertothemachineframe.
Figure13
1.Fronttie-downloops2.Reartie-downloops
15
g185890
Page 16

LiftingtheMachine

Hoistthemachineusing2liftpointsunderthehopper and2reartie-downloops.Tiltthehopperforwardto locatethe2liftloopsandattachachainorstrapsat eachoftheloopsasshowninFigure14.
Note:Takeuptheslackinthechainorstrapsto
properlybalancetheunit.
1.Liftpointsunderhopper
g194436
Figure14
2.Reartie-downloops
16
Page 17
Maintenance
Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.
RecommendedMaintenanceSchedule(s)
MaintenanceService
Interval
Aftertherst10hours
Beforeeachuseordaily
Every25hours
Every40hours
Every50hours
Every100hours
MaintenanceProcedure
•Checkandadjustthetracktension(every10hoursuntil50hours).
•Checktheengine-oillevel.
•Cleantheblowerhousing(moreoftenunderextremelydusty,dirtyconditions).
•Checktheconditionofthetrack.
•Checktheparkingbrakeoperation.
•Checkthehydraulic-uidlevelforthedrivesystem.
•Checkthehydraulic-uidlevelfortheliftsystem.
•Removedebrisfromthemachine.
•Checkforloosefasteners.
•Serviceorreplacetheair-cleanerfoamelement(moreoftenunderextremelydusty, dirtyconditions).
•Checkthehydrauliclinesforleaks,loosettings,kinkedlines,loosemounting supports,wear,anddeterioration.
•Greasethemachine(greaseimmediatelyaftereverywashing).
•Checkthebattery.
•Checkandadjustthetracktension.
•Replacetheair-cleanerpaperelement(moreoftenunderextremelydusty ,dirty conditions).
•Changetheengineoilandtheengine-oillter.
•Checkthesparkplug.
•Removethecoolingshroudsandcleanthecoolingareas(moreoftenunder extremelydusty,dirtyconditions).
•Replacethefuellter(moreoftenunderdusty ,dirtyconditions).
•Inspectthedrivebelt.
•Cleandirtbuildupinthechassis.
•Replacethesparkplug.
•Checktheroadwheels.
Every300hours
•Replacethedrivebelt.
•Changethehydraulicuidandlterforthedrivesystem.
•Changethehydraulicuidfortheliftsystem.
•Replacethehydrauliclterfortheliftsystem.
Important:Refertoyourengineowner'smanualforadditionalmaintenanceprocedures.
CAUTION
Ifyouleavethekeyintheswitch,someonecouldaccidentlystarttheengineandseriously injureyouorotherbystanders.
Removethekeyfromtheswitchbeforeyouperformanymaintenance.
17
Page 18
Pre-Maintenance Procedures

ReleasingtheCushionfor RearAccess

Youcanreleasethecushionforrearaccesstothe machineformaintenanceoradjustment.
1.Lowertheplatform.
2.Loosenthetwistknobsoneachsideofthe machine(Figure15).
Figure15
g185887
Figure16
1.Cylinderlock2.Lift-cylinderrod
4.Slowlylowerthehopperuntilthecylinderlock contactsthecylinderbodyandrodend.
g032556
RemovingandStoringthe
1.Twistknob
3.Removethecushionandlowerittotheplatform.
4.Performanymaintenanceoradjustmentonthe machine.
5.Raisethecushion,andslideitontothepinson bothsidesofthemachine.
6.Tightenthetwistknobs.
2.Cushion

UsingtheCylinderLock

InstallingtheCylinderLock
1.Parkthemachineonalevelsurface,move themotion-controlleverstotheNEUTRAL-LOCK position,engagetheparkingbrake,andfully raisethehopper.
2.Removethe2cotterlesspinssecuringthe cylinderlocktothemachine.
3.Slidethecylinderlockoverthelift-cylinderrod andsecurewiththecotterlesspins(Figure16).
CylinderLock
Important:Removethecylinderlockfromthe
lift-cylinderrodandfullysecureitinthestorage positionbeforeoperatingthemachine.
1.Startthemachine.
2.Fullyraisethehopper.
3.Shutofftheengine.
4.Removethecotterlesspinssecuringthecylinder lock.
5.Placethecylinderlockonthepostsinsidethe machineframeandsecurewiththecotterless pins.
6.Lowerthehopper.
18
Page 19
Lubrication
EngineMaintenance

GreasingtheMachine

ServiceInterval:Every50hours
Whenoperatingthemachineundernormalconditions, lubricateallgreasettingsforthebearingsand bushingswithNo.2lithiumgrease.Lubricatethe bearingsandbushingsimmediatelyafterevery washing,regardlessoftheintervallisted.Applyalight coatingofoilontothecontrolcables.
Cylinderpivots(2)—Figure17

ServicingtheAirCleaner

ServiceInterval:Every25hours—Serviceorreplace
theair-cleanerfoamelement(more oftenunderextremelydusty,dirty conditions).
Every100hours—Replacetheair-cleaner paperelement(moreoftenunderextremely dusty,dirtyconditions).
Note:Operatingtheenginewithlooseordamaged
air-cleanercomponentscouldallowunlteredairinto theengine,causingprematurewearandfailure.
Note:Servicetheaircleanermoreoftenunder
extremelydusty,dirtyconditions.
RemovingtheElements
1.Rotatethelatchesoutward.
2.Removethecovertoaccesstheair-cleaner elements(Figure18).
Figure17
g019608
g243624
Figure18
1.Air-cleanercover2.Air-cleanerlatch
3.Removethefoamandpaperelements(Figure
19).
4.Removethefoamelementfromthepaper element(Figure19).
19
Page 20
Figure19
1.Air-cleanercover3.Paperelement
2.Foamelement
ServicingtheFoamElement
1.Washthefoamelementinwarmwaterand detergent.
2.Rinseandallowittoairdry.
3.Lightlyoilthefoamelementwithnewoiland squeezeoutexcessoil.

CheckingtheEngine-Oil Level

ServiceInterval:Beforeeachuseordaily
Important:Remembertoadd80%oftheoil,
andthengraduallyllittotheFullmarkonthe dipstick.
Important:Donotruntheenginewiththeoil
g028106
levelabovetheFullmarkorbelowthelowmark. Otherwise,youmaydamagetheengine.
1.Parkthemachineonalevelsurface,move themotion-controlleverstotheNEUTRAL-LOCK position,engagetheparkingbrake,andlower thehopper.
2.Shutofftheengine,andremovethekey.Allow theenginetocool.
3.Openthecowl.
4.Checktheengine-oillevelasshowninFigure
20.
ServicingthePaperElement
1.Gentlytapthepaperelementtodislodgedirt.
Note:Donotwashthepaperelementoruse
pressurizedair,asthisdamagestheelement.
Note:Replaceadirty,bent,ordamaged
element.Handlethenewelementcarefully; donotuseifthesealingsurfacesarebentor damaged.
2.Cleantheair-cleanerbaseasrequired,and checkthecondition.
InstallingtheElements
1.Installthefoamelementontothepaperelement.
2.Installtheelementsontotheair-cleanerbase (Figure19).
3.Installthecover,andsecureitwiththelatches (Figure18).
g243578
Figure20
20
Page 21

ChangingtheEngineOil andFilter

ServiceInterval:Every100hours
OilType::Detergentoil(APIserviceSJorhigher)
EngineOilCapacity:1.9L(64oz)
Viscosity:Refertothetablebelow.
Figure21
Changetheengineoilwhiletheengineiswarm.
Note:Disposeoftheusedoilatarecyclingcenter.
1.Parkthemachineonalevelsurface,move themotion-controlleverstotheNEUTRAL-LOCK position,engagetheparkingbrake,raisethe hopper,andinstallthecylinderlock.
g185888
g031623
Figure22
g017552
B.Installthedrainplug(Figure22).T orquethe
plugto13.6N∙m(10ft-lb).
4.Changetheengine-oillterasshowninFigure
23.
2.Shutofftheengineandremovethekey.
3.Performthefollowingstepstochangethe engineoil:
A.Removethedrainplugandallowallofthe
existingoiltodrainoutoftheengine(Figure
22).
21
Page 22
Figure23
5.Slowlypourapproximately80%ofthespecied oilintothellertube(Figure24).
g243623
Figure24
g027477

ServicingtheSparkPlugs

ServiceInterval:Every100hours—Checkthespark
plug.
Every300hours—Replacethesparkplug.
ThesparkplugsareRFIcompliant.Equivalent alternatebrandplugscanalsobeused.
Type:ChampionXC12YC
AirGap:0.76mm(0.03inch)
22
Page 23
RemovingtheSparkPlug
1.Parkthemachineonalevelsurface,move themotion-controlleverstotheNEUTRAL-LOCK position,engagetheparkingbrake,andlower thehopper.
2.Shutofftheengineandremovethekey.Allow theenginetocool.
3.Beforeremovingthesparkplug(s),cleanthe areaaroundthebaseoftheplugtokeepdirt anddebrisoutoftheengine.
4.Removethesparkplug(Figure25).
g027478
Figure25
CheckingtheSparkPlug
Important:Donotcleanthesparkplug(s).
Alwaysreplacethesparkplug(s)whenithas:a blackcoating,wornelectrodes,anoilylm,or cracks.
Note:Ifyouseelightbrownorgrayontheinsulator,
theengineisoperatingproperly.Ablackcoatingon theinsulatorusuallymeanstheaircleanerisdirty.
Setthegapto0.76mm(0.03inch).
InstallingtheSparkPlug
g028109
Figure27
Important:Ensurethatthesparkplugis
tightenedtothecorrecttorquespecication.A loosesparkplugmaycausethecylinderheadto overheat,whileanovertightenedsparkplugmay causedamagetothethreadsinthecylinderhead.

CleaningtheBlower Housing

Every100hours/Yearly(whichevercomesrst)
Toensurepropercooling,ensurethatthegrass screen,coolingns,andotherexternalsurfacesofthe enginearekeptcleanatalltimes.
Figure26
Ensurethatthecoolingshroudsareinstalled.
Important:Operatingtheenginewithablocked
grassscreen,dirtyorpluggedcoolingns,and/or coolingshroudsremovedcausesenginedamage duetooverheating.
g027479
23
Page 24
FuelSystem

DrainingtheFuelTank

Maintenance

ReplacingtheFuelFilter

ServiceInterval:Every100hours/Yearly(whichever
comesrst)(moreoftenunder dusty,dirtyconditions).
1.Parkthemachineonalevelsurface,move themotion-controlleverstotheNEUTRAL-LOCK position,engagetheparkingbrake,andlower thehopper.
2.Shutofftheengine,andremovethekey.Allow theenginetocool.
3.ReplacethefuellterasshowninFigure28.
Youcandrainthefueltankbyremovingitandpouring thefueloutofthellneck;refertoRemovingtheFuel
Tank(page25).Youcanalsodrainthefueltankby
usingasiphoninthefollowingprocedure.
DANGER
Incertainconditions,fuelisextremely ammableandhighlyexplosive.Areor explosionfromfuelcanburnyouandothers andcandamageproperty.
•Drainfuelfromthefueltankwhenthe engineiscold.Dothisoutdoorsinanopen area.Wipeupanyfuelthatspills.
•Neversmokewhendrainingfuelandstay awayfromanopename,orwhereaspark mayignitethefuelfumes.
1.Parkthemachineonalevelsurface,move themotion-controlleverstotheNEUTRAL-LOCK position,engagetheparkingbrake,andlower thehopper.
g185888
2.Shutofftheengine,andremovethekey.Allow theenginetocool.
3.Cleanaroundthefuelcaptopreventdebrisfrom gettingintothefueltank(Figure29).
4.Removethefuelcap.
5.Insertasyphonpumpintothefueltank.
6.Usingthesyphonpump,drainthefuelintoa cleanfuelcan(Figure29).
7.Wipeupanyspilledfuel.
Figure29
1.Fuelcap
g186224
Figure28
g027753
24
Page 25

RemovingtheFuelTank

1.Lowertheplatform.
2.Releasethecushion;refertoReleasingthe
CushionforRearAccess(page18).
3.Removethecrossbracket(Figure30).
ElectricalSystem Maintenance

ServicingtheBattery

ServiceInterval:Every50hours
DANGER
Batteryelectrolytecontainssulfuricacid, whichisfatalifconsumedandcausessevere burns.
Donotdrinkelectrolyteandavoidcontact withskin,eyesorclothing.Wearsafety glassestoshieldyoureyesandrubbergloves toprotectyourhands.
Figure30
1.Fueltank
4.Removethefueltankandsetitontheoperator platform.
Note:Ifyouwanttomovethefueltankfurther
fromthemachine,removethefuelandvent linesfromthetopofthetank.
2.Crossbracket
g186223
RemovingtheBattery
WARNING
Batteryterminalsormetaltoolscouldshort againstmetalmachinecomponents,causing sparks.Sparkscancausethebatterygasses toexplode,resultinginpersonalinjury.
•Whenremovingorinstallingthebattery, donotallowthebatteryterminalstotouch anymetalpartsofthemachine.
•Donotallowmetaltoolstoshortbetween thebatteryterminalsandmetalpartsofthe machine.
WARNING
Incorrectbattery-cableroutingcoulddamage themachineandcables,causingsparks. Sparkscancausethebatterygassesto explode,resultinginpersonalinjury.
•Alwaysdisconnectthenegative(black) batterycablebeforedisconnectingthe positive(red)cable.
•Alwaysconnectthepositive(red)battery cablebeforeconnectingthenegative (black)cable.
1.Parkthemachineonalevelsurface,move themotion-controlleverstotheNEUTRAL-LOCK position,engagetheparkingbrake,andlower thehopper.
2.Shutofftheengine,andremovethekey.Allow theenginetocool.
3.Removethenegativebatterycablefromthe battery(Figure31).
25
Page 26
Figure31
1.Positivebatterycable
2.Securingrod
3.Wingnut(2)
4.Negativebatterycable
4.Removethepositivebatterycablefromthe battery(Figure31).
5.Removethe2wingnuts,securingrod,andthe battery(Figure31).
InstallingtheBattery
1.Placethebatteryontheplatformandsecure itusingthe2wingnutsandthesecuringrod (Figure31).
2.Installthepositivebatterycabletothebattery (Figure31).
3.Installthenegativebatterycabletothebattery (Figure31).
ChargingtheBattery
WARNING
Chargingthebatteryproducesgassesthat canexplode.
Neversmokenearthebatteryandkeepsparks andamesawayfrombattery .
Important:Alwayskeepthebatteryfullycharged
(1.265specicgravity)topreventbatterydamage
g185906
whenthetemperatureisbelow0°C(32°F).
1.Removethebatteryfromthechassis;referto
RemovingtheBattery(page25).
2.Performthefollowingstepstocheckthe electrolytelevel:
A.Ensurethatthecellcoversarefreefromdirt
anddebris.
Important:Dirtanddebristhatenters
thebatterycellscausesdamagetothe battery.
B.Removethecoversfromthetopofthecells.
C.Ensurethattheelectrolytesolutioncovers
theleadplates.Usedistilledwatertotopoff thesolutionlevel,ifneeded.
3.Ensurethatthellercapsareinstalledonthe battery.
4.Chargethebatteryfor1hourat25to30Aor6 hoursat4to6A.
5.Whenthebatteryisfullycharged,unplugthe chargerfromtheelectricaloutlet,anddisconnect thechargerleadsfromthebatteryposts(Figure
32).
6.Installthebatteryontothemachineandconnect thebatterycables;refertoInstallingtheBattery
(page26).
1.Positivebatterypost
2.Negativebatterypost
26
Note:Donotrunthemachinewiththebattery
disconnected;electricaldamagemayoccur.
g000538
Figure32
3.Red(+)chargerlead
4.Black(-)chargerlead
Page 27

ServicingtheFuses

DriveSystem
Theelectricalsystemisprotectedbyfusesand requiresnomaintenance.Ifafuseblows,checkthe componentorcircuitforamalfunctionorshort.
1.Releasethecushionfromtherearofthe machine.
2.Pulloutthefusetoremoveorreplaceit(Figure
33).
3.Installthecushiontotherearofthemachine.
Note:Ensurethatthecorrect-sizefuseis
installed(Figure33).
Maintenance

ServicingtheTracks

ServiceInterval:Beforeeachuseordaily—Check
theconditionofthetrack.
Aftertherst10hours—Checkandadjustthe tracktension(every10hoursuntil50hours).
Every50hours—Checkandadjustthetrack tension.
Every300hours—Checktheroadwheels.
CleaningtheTracks
1.Parkthemachineonalevelsurface,move themotion-controlleverstotheNEUTRAL-LOCK position,engagetheparkingbrake,andlower thehopper.
2.Shutofftheengine,andremovethekey.Allow theenginetocool.
3.Lift/supportthesideofthemachinetobeworked onsothatthetrackis3to4inches(7.6to10 cm)offtheground.
Figure33
1.Mainpowerfuse(15A)3.Logicfuse(7.5A)
2.Auxiliarypowerfuse(15 A)
g189366
4.Usingawaterhoseorpressurewasher,remove dirtfromeachtracksystem.
Important:Ensurethatyouusehigh-pressure
watertowashonlythetrackarea.Donotuse ahigh-pressurewashertocleantherestofthe machine.Donotusehigh-pressurewaterbetween thedrivesprocketandthemachineoryoumay damagethemotorseals.High-pressurewashing candamagetheelectricalsystemandhydraulic valvesordepletegrease.
Important:Ensurethatyoufullycleantheroad
wheels,thefrontwheel,andthedrivesprocket (Figure34).Theroadwheelsshouldrotatefreely whenclean.
g186007
Figure34
1.Frontwheel3.Roadwheel
2.Track4.Drivesprocket
27
Page 28
AdjustingtheTrackTension
Ifyouplacethetabofthetensioningtoolalongthe rearedgeofthetensionnut,theotherendofthe tensioningtoolshouldalignwiththeedgeofthe tensionarmasshowninFigure35.Ifthedistanceis notcorrect,adjustthetracktensionusingthefollowing procedure:
4.Raisethemachinesothatthetracksareoffthe ground.
5.Cleanthedrivesprocket,thefrontwheel,and theroadwheels.Theroadwheelsshouldspin freelywhenclean.
6.Removethebolt(1/4x1-5/8inch),spacer,and nut(Figure35).
Note:Ifthetensioningtoolisnotavailable,the
distancebetweenthenutandedgeofthetensionarm shouldbe7.1cm(2-13/16inch).
Figure35
LeftTrackShown
1.Tensionnut
2.Tensioningtool(equalto
7.1cmor2-13/16inch)
3.Tensioningbolt7.Tab
4.Bolt(1/4x1-5/8inch)
5.Spacer
6.Nut
8.Tensionarm
7.Turnthetensioningbolttoadjustthedistance betweenthetensionnutandtheendtangent ofthetensiontubeuntilthedistanceiscorrect, asshowninFigure35.
8.Aligntheclosestnotchinthetensioningbolt totheboltholeandsecurethetensioningbolt withthebolt(1/4x1-5/8inch),spacer,andnut (Figure35).
ReplacingtheTracks
Replacethetrackswhentheyarebadlyworn.
1.Parkthemachineonalevelsurface,move themotion-controlleverstotheNEUTRAL-LOCK position,engagetheparkingbrake,andlower thehopper.
2.Shutofftheengine,andremovethekey.Allow theenginetocool.
3.Lift/supportthesideofthemachinetobeworked
g202806
onsothatthetrackis3to4inches(7.6to10 cm)offtheground.
4.Removetheretainingboltforthetensioning screw.
5.Releasethedrivetensionbyturningthe tensioningscrewclockwise(Figure35and
Figure36).
1.Parkthemachineonalevelsurface,move themotion-controlleverstotheNEUTRAL-LOCK position,engagetheparkingbrake,andlower thehopper.
2.Shutofftheengine,andremovethekey.Allow theenginetocool.
3.Cleanthetrackswithhigh-pressurewater.
Important:Ensurethatyouuse
high-pressurewatertowashonlythetrack area.Donotuseahigh-pressurewasher tocleantherestofthemachine.Donot usehighpressurewaterbetweenthedrive sprocketandthemachineoryoumay damagethemotorseals.High-pressure washingcandamagetheelectricalsystem andhydraulicvalvesordepletegrease.
g186008
Figure36
1.Frontwheel4.Roadwheel
2.Track5.Drivesprocket
3.Tensioningscrewand retainingbolt
6.Removethetrackatthetopofthefrontwheel,
peelingitoffthewheelwhilerotatingthetrack forward.
7.Whenthetrackisoffthefrontwheel,removeit
fromthedrivesprocketandroadwheels(Figure
36).
28
Page 29
8.Inspecttheconditionofthewheels.Ifthewheels showsignsofwear,replacethematthistime.
9.Beginningatthedrivesprocket,coilthenew trackaroundthesprocket,ensuringthatthe lugsonthetracktbetweenthespacersonthe sprocket(Figure36).
10.Pushthetrackunderthelugsandbetweenthe roadwheels(Figure36).
11.Startingatthebottomofthefrontwheel,install thetrackaroundthewheelbyrotatingthetrack rearwardwhilepushingthelugsintothewheel.
12.T ensionthetrack;refertoAdjustingtheTrack
Tension(page28).
13.Lowerthemachinetotheground.
14.Repeatsteps3through13toreplacetheother track.

ServicingtheDriveBelt

InspectingtheDriveBelt
ReplacingtheDriveBelt
ServiceInterval:Every300hours
1.Parkthemachineonalevelsurface,move themotion-controlleverstotheNEUTRAL-LOCK position,engagetheparkingbrake,andlower thehopper.
2.Shutofftheengine,andremovethekey .Allow theenginetocool.
3.Releasethecushionandremovethefueltank; refertoRemovingtheFuelTank(page25).
4.Raisetherearofthemachineandsupportthe machineonjackstands.
5.Removetheskidplate(Figure35).
ServiceInterval:Every100hours
1.Parkthemachineonalevelsurface,move themotion-controlleverstotheNEUTRAL-LOCK position,engagetheparkingbrake,andlower thehopper.
2.Shutofftheengine,andremovethekey .Allow theenginetocool.
3.Releasethecushionandremovethefueltank; refertoReleasingtheCushionforRearAccess
(page18).
4.Inspectthebelt(Figure37).Replacethebelt ifitisworn;refertoReplacingtheDriveBelt
(page29).
Note:Thesignsofawornbeltinclude
squealingwhilethebeltisrotating,frayededges, burnmarks,andcracksonthebelt.
g203662
Figure38
1.Rearbolt(2)3.Sidebolt(4)
2.Skidplate
6.Removetheextensionspring(Figure37).
7.Removethe2boltsand2nutsandloosenthe 2setscrewsonthecoupler.Removethegear pumpfromthepumpmount(Figure39).
Note:Youdonotneedtoremovethettings
fromthepump.
Figure37
1.Extensionspring2.Belt
g189546
29
Page 30
Figure39
1.Bolt(2)3.Gearpump
2.Pumpmount
4.Nut(2)
ControlsSystem Maintenance

Adjustingthe Motion-ControlLevers

Ifthemotion-controlleversdonotalignhorizontally , adjusttherightsidemotion-controllever.
1.Parkthemachineonalevelsurface,lowerthe hopper,engagetheparkingbrake,shutoffthe engine,andremovethekey.
2.Pushthemotion-controlleversdownoutofthe NEUTRAL-LOCKposition(Figure41).
3.Checkiftherightmotion-controlleveraligns
g189559
horizontallywiththeleftmotion-controllever (Figure41).
8.Removethedrivebeltfromtheenginepulley and2transmissionpulleys.
Figure40
1.Enginepulley
2.Idlerpulley
3.Transmissionpulley(2)
4.Belt
9.Routethenewbeltaroundtheenginepulleyand 2transmissionpulleys(Figure40).
g009436
Figure41
1.Leftmotion-controllever3.Checkthehorizontal
2.Rightmotion-controllever intheNeutral-lockposition
alignmenthere
4.Rightmotion-controllever
4.T oadjustthemotion-controllevershorizontally,
youmustadjustthecam.
g189571
5.Releasethecushionfromtherearofthe
machine.
6.Loosenthenutholdingthecam(Figure42).
10.Installthegearpump(Figure39).
11.Installtheextensionspring(Figure37).
12.Installthefueltank;refertoRemovingtheFuel
Tank(page25).
13.Raisethecushion.
30
Page 31
4.Releasetheparkingbrake.
5.Movethemotion-controlleversforward.
Note:Themachineshouldmoveforward.
Note:Ifthemachinedoesnotmoveforward,
refertoAdjustingtheParkingBrake(page31).
6.Engagetheparkingbrakeandshutoffthe machine.
Figure42
1.Cam
7.Adjustthecamuntilitalignswiththeleft motion-controlleverandtightenthenutforthe cam.
2.Nut
Note:Movingthecamclockwise(inthevertical
position)lowersthehandle;movingthecam counterclockwise(intheverticalposition)raises thehandle.
Important:Ensurethattheatportionofthe
camdoesnotgoaboveaverticalposition (rightorleft);otherwiseyoumaydamagethe switch.
8.Repeatsteps2through7fortheleft motion-controllever.

BrakeMaintenance

WARNING
Ifthebrakesarenotproperlyadjusted, seriousinjury,ordeath,mayoccur.
Checkyourbrakesdaily .Ifyouencounterany problemswiththebrakeswhileoperatingthe machine,stopthemachineimmediatelyand bringittoanAuthorizedServiceDealerfor repair.
g189389
1.Removethefueltank;refertoReleasingthe
CushionforRearAccess(page18).
2.Insidetheleftsideofthecontroltower,adjust thenutsuntilthecablesaretaught(Figure43).
Figure43
1.Cable
3.Installthefueltank,crossbracket,andcushion.
2.Nuts
g186011
AdjustingtheParkingBrake
CheckingtheParkingBrake
ServiceInterval:Beforeeachuseordaily
1.Parkthemachineonalevelsurface,lowerthe hopper,andengagetheparkingbrake.
2.Starttheengineandmovethethrottleleverto theFASTposition.
3.Movethemotion-controlleversforward.
Note:Themachineshouldnotmoveforward.
Note:Ifthemachinemovesforward,referto
AdjustingtheParkingBrake(page31).
31
Page 32
HydraulicSystem Maintenance
WARNING
Hydraulicuidescapingunderpressurecan penetrateskinandcauseinjury.Fluidinjected intotheskinmustbesurgicallyremoved withinafewhoursbyadoctorfamiliarwith thisformofinjury;otherwisegangrenemay result.
•Keepyourbodyandhandsawayfrom pinholeleaksornozzlesthateject high-pressurehydraulicuid.
•Usecardboardorpapertondhydraulic leaks;neveruseyourhands.
ServicingtheHydraulic
Figure44
1.Expansion-tankcap
2.Sightwindow
5.Iftheoillevelislow,removethecaplockand capfromthetopoftheexpansiontank(Figure
45),andaddenoughofthespeciedhydraulic
uidtoraiseittotheproperlevel.
3.Fluidatllline
g203616
DriveSystem
Expansion-tankcapacity:1.4L(1.5USqt)
Hydraulic-uidtype:T oro®HYPR-OIL™500
Important:Alwaysusethecorrecthydraulic
uid.Unspecieduidswilldamagethehydraulic system.
Note:Manyhydraulicuidsarealmostcolorless,
makingitdifculttospotleaks.Areddyeadditivefor thehydraulicsystemoilisavailablein0.67oz(20 ml)bottles.Onebottleissufcientfor4to6gal(15to 22L)ofhydraulicuid.OrderPartNo.44-2500from yourauthorizedT orodistributor.
CheckingtheHydraulic-Fluid LevelfortheDriveSystem
ServiceInterval:Beforeeachuseordaily
1.Parkthemachineonalevelsurface,move themotion-controlleverstotheNEUTRAL-LOCK position,engagetheparkingbrake,andlower thehopper.
2.Shutofftheengine,andremovethekey .Allow theenginetocool.
3.Openthecowl.
4.Usethesightwindowtochecktheuidlevelin theexpansiontank(Figure44).
Note:Theuidlevelshouldbeatthellline
onthedecal.
Important:Ensurethattheexpansion-tank
uidlevelisattheproperlevel.Overlling thetankmaycauseuidtopurgeoutofthe breatherhole.
Figure45
1.Bolt
2.Caplock
6.Installthecapandcaplock.Wipeupanyspilled hydraulicuid.
3.Cap
ChangingtheHydraulicFluidand FilterfortheDriveSystem
ServiceInterval:Every300hours
1.Parkthemachineonalevelsurface,move themotion-controlleverstotheNEUTRAL-LOCK position,engagetheparkingbrake,andlower thehopper.
g186038
32
Page 33
2.Shutofftheengine,andremovethekey .Allow theenginetocool.
10.Loosentheventplugineachtransmissionuntil loose(Figure48).
3.Lowerthecushionandremovethefueltank; refertoRemovingtheFuelTank(page25).
4.Removethe6bolts(2rear,4side)fromtheskid plateandremovetheskidplate(Figure46).
Figure46
1.Rearbolt(2)3.Sidebolt(4)
2.Skidplate
5.Locatethedrainpluginthebottomofeach transmission,thenplaceadrainpanunderthe plugs(Figure47).
Note:Thisallowsairtoescapethehydraulic
systemasyouaddhydraulicuid.
g203662
Figure48
1.Ventplug
g203517
11.Slowlyaddapproximately6.2L(208oz)uid totheexpansiontankuntilitstartstocomeout oftheventplugs.
Important:Usetheuidspeciedin
ServicingtheHydraulicDriveSystem(page
32)orequivalent.Otheruidscouldcause
systemdamage.
Figure47
1.Hydrauliclter
2.Drainplug
6.Removethedrainplugsandallowthehydraulic uidtofullydrainfromthemachine.
7.Removethehydraulic-ltercapandhydraulic lterfromeachtransmission(Figure47).
8.Installanewhydrauliclterwiththespringside facingoutandthehydraulic-ltercapforeach transmission.Torqueto13to15N∙m(115to 135in-lb).
Important:Monitorthelevelofuidinthe
expansiontanksothatyoudonotoverllit.
12.Tightentheventplugs.
13.Addhydraulicuidtotheexpansiontankuntilit reachestheuidline(Figure44).
Important:Donotoverll.
14.Installtheexpansion-tankcap.
15.Installtheskidplate(Figure46).
g203515
16.Installthefueltank;refertoRemovingtheFuel
Tank(page25).
17.Starttheengineandletitrunforabout2minutes topurgeairfromthesystem.
18.Shutofftheengineandcheckforleaks.
9.Installthedrainplugs.
33
Page 34
BleedingtheHydraulicDrive System
Bleedthetractionhydraulicsystemwheneveryou performmaintenanceonthehydrostatictransmission oraddhydraulicuidtotheexpansiontank.
1.Parkthemachineonalevelsurface,move themotion-controlleverstotheNEUTRAL-LOCK position,engagetheparkingbrake,andlower thehopper.

ServicingtheHydraulicLift System

CheckingtheHydraulic-Fluid LevelfortheLiftSystem
ServiceInterval:Beforeeachuseordaily
Reservoir-tankcapacity:1.4L(1.5USquarts)
2.Shutofftheengine,andremovethekey .Allow theenginetocool.
3.Checkthehydraulicuidlevelandaddhydraulic uidasnecessary;refertoCheckingthe
Hydraulic-FluidLevelfortheDriveSystem(page
32).
4.Supportthemachineonjackstands,high enoughtoraisethetracksofftheground.
5.Startthemachine.Slowlymovethe motion-controlleversforwardandreverse5to 6times.
6.Checkthehydraulicuidlevelandaddhydraulic uidasnecessary.
7.Repeatsteps5and6asnecessaryuntilallthe airiscompletelypurgedfromthesystem.
Note:Purgingiscompletewhenyouobtain
normalforwardandreversespeed.
8.Lowerthemachineandrepeattheprocedure withthetracksontheground.
Hydraulic-uidtype:ToroPremiumAllSeason HydraulicFluidorMobil®424HydraulicFluid
Important:Alwaysusethecorrecthydraulic
uid.Unspecieduidswilldamagethehydraulic system.
Note:Manyhydraulicuidsarealmostcolorless,
makingitdifculttospotleaks.Areddyeadditivefor thehydraulicsystemoilisavailablein0.67oz(20 ml)bottles.Onebottleissufcientfor4to6gal(15to 22L)ofhydraulicuid.OrderPartNo.44-2500from yourauthorizedT orodistributor.
1.Parkthemachineonalevelsurface,move themotion-controlleverstotheNEUTRAL-LOCK position,engagetheparkingbrake,raisethe hopper,andinstallthecylinderlock.
2.Shutoffthemachineandremovethekey.Allow themachinetocoolcompletely.
3.Removethellercapfromthereservoirtank (Figure49).
CAUTION
Thehydraulicbreather/llercapis designedtopressurizethereservoirto 34kPa(5psi).
Loosenthecapslowlytoavoidinjury wheneveraddinguidorworkingonthe hydraulicsystem.Useawrenchonthe hexdirectlyunderthecap.
34
Page 35
Figure49
1.Hex2.Fillercap
4.Lookinsidethetanktochecktheuidlevel.
ChangingtheHydraulicFluidfor theLiftSystem
ServiceInterval:Every300hours
1.Parkthemachineonalevelsurface,move themotion-controlleverstotheNEUTRAL-LOCK
g185888
g019614
position,engagetheparkingbrake,raisethe hopper,andinstallthecylinderlock.
2.Shutoffthemachineandremovethekey.Allow themachinetocoolcompletely.
3.Removethellercapfromthereservoirtank (Figure49).
CAUTION
Thehydraulicbreather/llercapis designedtopressurizethereservoirto 34kPa(5psi).
Loosenthecapslowlytoavoidinjury wheneveraddingoilorworkingonthe hydraulicsystem.Useawrenchonthe hexdirectlyunderthecap.
Note:Ifthemachineiscool,theuidshouldbe
attheCOLDlevel;ifthemachineishot,theuid shouldbeattheHOTlevel.
Figure50
1.HOTlevel2.COLDlevel
5.Fillthetankwithhydraulicuidonlyuptothe COLDlevel.
4.Placealargedrainpanunderthettingsatthe bottomofthereservoirtank.
5.Disconnectahosettingandallowtheuidto drainintothepan.
6.Whennished,installandtightenthetting.
Note:Disposeoftheuseduidatacertied
recyclingcenter.
7.Fillthereservoirtankwithapproximately2.2L (74oz)andinstallthellercap.
8.Removethecylinderlock.
9.Starttheengine.Raiseandlowerthehopper3 timestollthecylinderandhoseswithuid.
10.Raisethehopperandinstallthecylinderlock.
11.Shutofftheengine.
12.Add0.60L(20oz)ofhydraulicuidandinstall thellercap.
Note:TheuidlevelshouldbeattheColdll
g189403
line.Donotllpastthisline.
13.Removethecylinderlock.
14.Starttheengine.Raiseandlowerthehopper severaltimestoremoveairfromthesystem.
6.Installthellcap.Wipeupanyspilledhydraulic uid.
7.Removethecylinderlockandlowerthehopper.
35
Page 36
ReplacingtheHydraulicFilterfor theLiftSystem
ServiceInterval:Every300hours
Important:Donotsubstituteanautomotiveoil
lterorseverehydraulicsystemdamagemay result.
1.Parkthemachineonalevelsurface,move themotion-controlleverstotheNEUTRAL-LOCK position,engagetheparkingbrake,raisethe hopper,andinstallthecylinderlock.
2.Shutofftheengine,andremovethekey .Allow theenginetocool.
3.ReplacethelterasshowninFigure51.
5.Shutofftheengineandcheckforleaks.
6.Checktheuidlevelinthereservoirtank,refer toCheckingtheHydraulic-FluidLevelfortheLift
System(page34).
Note:Donotoverllthereservoirtank.
7.Removethecylinderlockandlowerthehopper.

CheckingtheHydraulic Lines

ServiceInterval:Every40hours—Checkthe
hydrauliclinesforleaks,loose ttings,kinkedlines,loosemounting supports,wear,anddeterioration. (Makenecessaryrepairsbefore operating.)
WARNING
Hydraulicuidescapingunderpressurecan penetrateskinandcauseinjury.Fluidinjected
g186042
intotheskinmustbesurgicallyremoved withinafewhoursbyadoctorfamiliarwith thisformofinjury;otherwise,gangrenemay result.
Figure51
•Keepyourbodyandhandsawayfrom pinholeleaksornozzlesthateject high-pressurehydraulicuid.
•Usecardboardorpapertondhydraulic leaks;neveruseyourhands.
g027477
4.Starttheengineandletitrunforabout2minutes topurgeairfromthesystem.
36
Page 37
Cleaning

RemovingDebrisfromthe Machine

ServiceInterval:Beforeeachuseordaily
Every100hours
1.Parkthemachineonalevelsurface,move themotion-controlleverstotheNEUTRAL-LOCK position,engagetheparkingbrake,andlower thehopper.
2.Shutofftheengine,andremovethekey .Allow theenginetocool.
3.Cleantheinsideofthehopperusingahose.
4.Cleananydebrisfromunderthehopper.
5.Wipeawaydebrisfromtheaircleaner.
6.Cleananydebrisbuildupontheengineandin thetransmissionwithabrushorblower.
Important:Itispreferabletoblowdirt
out,ratherthanwashingitout.Ifyouuse water,keepitawayfromelectricalpartsand hydraulicvalves.Donotuseahigh-pressure washer.High-pressurewashingcandamage theelectricalsystemandhydraulicvalvesor depletegrease.
37
Page 38
Storage
9.Checkandtightenallbolts,nuts,andscrews. Repairorreplaceanypartthatisdamaged.
1.Engagetheparkingbrake,shutofftheengine, andremovethekey.
2.Removedirtandgrimefromtheexternalpartsof theentiremachine,especiallytheengine.Clean dirtandchafffromtheoutsideoftheengine cylinderheadnsandblowerhousing.
3.Servicetheaircleaner;refertoServicingtheAir
Cleaner(page19).
4.Greasethemachine;refertoGreasingthe
Machine(page19).
5.Changetheenginecrankcaseoil;referto
ChangingtheEngineOilandFilter(page21).
6.Forstorageover30days,preparethemachine asfollows:
A.Addapetroleum-basedfuel
stabilizer/conditionertothefuelinthe tank.Donotuseanalcohol-based
stabilizer(ethanolormethanol).
B.Runtheenginetodistributeconditionedfuel
throughthefuelsystemfor5minutes.
C.Shutofftheengine,allowittocool,and
drainthefueltankusingapump-type syphon.
10.Paintallscratchedorbaremetalsurfaces.Paint isavailablefromyourAuthorizedServiceDealer.
11.Storethemachineinaclean,drygarageor storagearea.
12.Coverthemachinetoprotectitandkeepitclean.
D.Starttheengineandrunituntilitshutsoff.
E.Choketheengine.
F.Startandruntheengineuntilitdoesnot
startagain.
G.Disposeoffuelproperly.Recycleasper
localcodes.
Important:Donotstorefuelcontaining
stabilizer/conditionerlongerthanthe durationrecommendedbythefuel-stabilizer manufacturer.
7.Removethesparkplugsandcheckthecondition ofthem;refertoCheckingtheSparkPlug(page
23).
8.Preparetheengineasfollows:
A.Withthesparkplugsremovedfromthe
engine,pour2tablespoonsofengineoil intothesparkplugholes.
B.Placearagoverthesparkplugholesto
catchanyoilspray,thenturnthekeyto cranktheengineanddistributetheoilinside thecylinder.
C.Installthesparkplugs.
Note:Donotinstallthewireonthespark
plugs.
38
Page 39
Notes:
Page 40
CaliforniaProposition65WarningInformation

Whatisthiswarning?

Youmayseeaproductforsalethathasawarninglabellikethefollowing:
WARNING:CancerandReproductiveHarm—www.p65Warnings.ca.gov.

WhatisProp65?

Prop65appliestoanycompanyoperatinginCalifornia,sellingproductsinCalifornia,ormanufacturingproductsthatmaybesoldinorbroughtinto California.ItmandatesthattheGovernorofCaliforniamaintainandpublishalistofchemicalsknowntocausecancer,birthdefects,and/orother reproductiveharm.Thelist,whichisupdatedannually,includeshundredsofchemicalsfoundinmanyeverydayitems.ThepurposeofProp65isto informthepublicaboutexposuretothesechemicals.
Prop65doesnotbanthesaleofproductscontainingthesechemicalsbutinsteadrequireswarningsonanyproduct,productpackaging,orliteraturewith theproduct.Moreover,aProp65warningdoesnotmeanthataproductisinviolationofanyproductsafetystandardsorrequirements.Infact,the CaliforniagovernmenthasclariedthataProp65warning“isnotthesameasaregulatorydecisionthataproductis‘safe’or‘unsafe.’”Manyofthese chemicalshavebeenusedineverydayproductsforyearswithoutdocumentedharm.Formoreinformation,gotohttps://oag.ca.gov/prop65/faqs-view-all
AProp65warningmeansthatacompanyhaseither(1)evaluatedtheexposureandhasconcludedthatitexceedsthe“nosignicantrisklevel”;or(2) haschosentoprovideawarningbasedonitsunderstandingaboutthepresenceofalistedchemicalwithoutattemptingtoevaluatetheexposure.

Doesthislawapplyeverywhere?

Prop65warningsarerequiredunderCalifornialawonly.ThesewarningsareseenthroughoutCaliforniainawiderangeofsettings,includingbutnot limitedtorestaurants,grocerystores,hotels,schools,andhospitals,andonawidevarietyofproducts.Additionally,someonlineandmailorder retailersprovideProp65warningsontheirwebsitesorincatalogs.
.

HowdotheCaliforniawarningscomparetofederallimits?

Prop65standardsareoftenmorestringentthanfederalandinternationalstandards.TherearevarioussubstancesthatrequireaProp65warning atlevelsthatarefarlowerthanfederalactionlimits.Forexample,theProp65standardforwarningsforleadis0.5μg/day,whichiswellbelow thefederalandinternationalstandards.

Whydon’tallsimilarproductscarrythewarning?

•ProductssoldinCaliforniarequireProp65labellingwhilesimilarproductssoldelsewheredonot.
•AcompanyinvolvedinaProp65lawsuitreachingasettlementmayberequiredtouseProp65warningsforitsproducts,butothercompanies
makingsimilarproductsmayhavenosuchrequirement.
•TheenforcementofProp65isinconsistent.
•CompaniesmayelectnottoprovidewarningsbecausetheyconcludethattheyarenotrequiredtodosounderProp65;alackofwarningsfora
productdoesnotmeanthattheproductisfreeoflistedchemicalsatsimilarlevels.

WhydoesToroincludethiswarning?

Torohaschosentoprovideconsumerswithasmuchinformationaspossiblesothattheycanmakeinformeddecisionsabouttheproductstheybuyand use.T oroprovideswarningsincertaincasesbasedonitsknowledgeofthepresenceofoneormorelistedchemicalswithoutevaluatingthelevelof exposure,asnotallthelistedchemicalsprovideexposurelimitrequirements.WhiletheexposurefromT oroproductsmaybenegligibleorwellwithinthe “nosignicantrisk”range,outofanabundanceofcaution,T orohaselectedtoprovidetheProp65warnings.Moreover,ifT orodoesnotprovidethese warnings,itcouldbesuedbytheStateofCaliforniaorbyprivatepartiesseekingtoenforceProp65andsubjecttosubstantialpenalties.
RevA
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