Toro 22334, 22319, 22320, Dingo TX 525, TX 525 Operator's Manual

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Page 1

Form No. 3357-573 Rev A

G004222

TX 525 Compact Utility Loader

Model No. 22333 —Serial No. 270000001 and Up Model No. 22334 —Serial No. 270000001 and Up

Page 2

Warning

CALIFORNIA

Pr oposition 65 W ar ning

Diesel engine exhaust and some of its constituents ar e kno wn to the State of Calif or nia to cause cancer , bir th defects, and other r epr oducti v e har m.

Because in some areas there are local, state , or federal regulations requiring that a spark ar rester be used on the engine of this mac hine , a spark ar rester is a v ailable as an option. If y ou require a spark ar restor , contact y our A uthorized Ser vice Dealer .

Gen uine T oro spark ar resters are appro v ed b y the USD A F orestr y Ser vice .

Important: It is a violation of Calif or nia Public R esource Code Section 4442 to use or operate the engine on an y f or est-co v er ed, br ush-co v er ed, or g rass-co v er ed land without a spar k ar r ester muf ﬂer maintained in w or king order , or the engine constricted, equipped, and maintained f or the pr ev ention of ﬁr e. Other states or federal ar eas may ha v e similar la ws.

into a plate mounted under the hood near the belt dri v e . W rite the n umbers in the space pro vided.

Model No.

Serial No.

T his man ual identiﬁes potential hazards and has safety messag es identiﬁed b y the safety aler t symbol ( Figure 1 ), whic h signals a hazard that ma y cause serious injur y or death if y ou do not follo w the recommended precautions .

Figure 1

1. Safety alert symbol

T his man ual uses 2 other w ords to highlight infor mation. Impor tant calls attention to special mec hanical infor mation and Note emphasizes g eneral infor mation w or th y of special attention.

T he enclosed Engine Owner’ s Man ual is supplied f or inf or mation r egarding the US En vir onmental Pr otection Agency (EP A) and the Calif or nia Emission Contr ol R egulation of emission systems, maintenance, and w ar ranty . R eplacements may be order ed thr ough the engine man uf actur er .

Introduction

R ead this infor mation carefully to lear n ho w to operate and maintain y our product properly and to a v oid injur y and product damag e . Y ou are responsible for operating the product properly and safely .

Y ou ma y contact T oro directly at www .T oro .com for product and accessor y infor mation, help ﬁnding a dealer , or to register y our product.

W henev er y ou need ser vice , g en uine T oro par ts , or additional infor mation, contact an A uthorized Ser vice Dealer or T oro Customer Ser vice and ha v e the model and serial n umbers of y our product ready . T he model and serial n umbers are stamped

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Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Safe Operating Practices . . . . . . . . . . . . . . . . . . . . . . 4

Sound Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Sound P o w er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Slope Char t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Safety and Instr uctional Decals . . . . . . . . . . . . 9

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1 Acti v ating the Batter y . . . . . . . . . . . . . . . . . . . . . . 12

2 Charging the Batter y . . . . . . . . . . . . . . . . . . . . . . . 13

3 Chec king Fluid Lev els . . . . . . . . . . . . . . . . . . . . . 14

Product Ov er view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Speciﬁcations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Filling the Fuel T ank . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Chec king the Engine Oil Lev el . . . . . . . . . . . 21

Chec king the Hy draulic Fluid

Lev el . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Chec king, Adding, and Bleeding

the Engine Coolant . . . . . . . . . . . . 23

Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . 24

Star ting and Stopping the

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Stopping the T raction Unit . . . . . . . . . . . . . . . . . 25

Mo ving a Non-functioning

T raction Unit . . . . . . . . . . . . . . . . . . . . . 26

Using the Cylinder Loc k . . . . . . . . . . . . . . . . . . . . . 26

Using Attac hments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Securing the T raction Unit for

T ranspor t . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Lifting the T raction Unit . . . . . . . . . . . . . . . . . . . . 28

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

R ecommended Maintenance

Sc hedule(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Premaintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . 30

Opening the Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Closing the Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Opening the R ear Access

Co v er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Closing the R ear Access Co v er . . . . . . . . . . . 31

R emo ving the Side Screens . . . . . . . . . . . . . . . . . 31

Installing the Side Screens . . . . . . . . . . . . . . . . . . 31

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Greasing the T raction Unit . . . . . . . . . . . . . . . . . 31

Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Ser vicing the Air Cleaner . . . . . . . . . . . . . . . . . . . 32

Ser vicing the Engine Oil . . . . . . . . . . . . . . . . . . . . 33

Fuel System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Chec king the Fuel Lines and

Connections . . . . . . . . . . . . . . . . . . . . . . 34

Draining the Fuel Filter/W ater

Se parator . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

R e placing the Fuel Filter

Canister . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Draining the Fuel T ank . . . . . . . . . . . . . . . . . . . . . . 35

Electrical System Maintenance . . . . . . . . . . . . . . . . . . . 35

Ser vicing the Batter y . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Dri v e System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 37

Ser vicing the T rac ks . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Cooling System Maintenance . . . . . . . . . . . . . . . . . . . . . 41

Ser vicing the Cooling System . . . . . . . . . . . . . 41

Belt Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Chec king the Condition of

the Hy draulic Pump

Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Chec king the Alter nator/F an Belt

T ension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Controls System Maintenance . . . . . . . . . . . . . . . . . . . . 42

Adjusting the T raction Control

Alignment . . . . . . . . . . . . . . . . . . . . . . . . . 42

Adjusting the T raction Control

Neutral P osition . . . . . . . . . . . . . . . . 43

Adjusting the T rac king of the

T raction Control, Full

F orw ard P osition . . . . . . . . . . . . . . . 43

Hy draulic System Maintenance . . . . . . . . . . . . . . . . . . 44

R e placing the Hy draulic Filter . . . . . . . . . . . . 44

Changing the Hy draulic Fluid . . . . . . . . . . . . . 45

Chec king the Hy draulic Lines . . . . . . . . . . . . . 45

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

R emo ving Debris from the

T raction Unit . . . . . . . . . . . . . . . . . . . . . 46

Cleaning the Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Storag e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

T roubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Sc hematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

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Safety

hearing protection. Long hair , loose clothing or jew elr y ma y g et tangled in mo ving par ts .

Impr oper use or maintenance by the operator or o wner can r esult in injur y . T o r educe the potential f or injur y , compl y with these safety instr uctions and al w ays pay attention to the safety aler t symbol , which means: Caution , W ar ning , or Danger —per sonal safety instr uction. F ailur e to compl y with the instr uction may r esult in per sonal injur y or death.

Safe Operating Practices

T his product is capable of amputating hands and feet. Alw a ys follo w all safety instr uctions to a v oid serious injur y or death.

Engine exhaust contains carbon mono xide, an odor less, deadl y poison that can kill y ou.

Do not r un the engine indoor s or in an enclosed ar ea.

Training

• R ead the Operator’ s Manual and other training material. If the operator(s) or mec hanic(s) can not read English, it is the o wner’ s responsibility to explain this material to them.

• Become familiar with the safe operation of the equipment, operator controls , and safety signs .

• All operators and mec hanics should be trained. T he o wner is responsible for training the users .

• Nev er let c hildren or untrained people operate or ser vice the equipment. Local regulations ma y restrict the ag e of the operator .

• T he o wner/user can prev ent and is responsible for accidents or injuries occur ring to himself or herself , other people or proper ty .

Preparation

• Ev aluate the ter rain to deter mine what accessories and attac hments are needed to properly and safely perfor m the job . Only use accessories and attac hments appro v ed b y the man ufacturer .

• Inspect the area where the equipment is to be used and remo v e all objects suc h as roc ks , to ys , and wire whic h can be thro wn b y the mac hine .

• Use extra care when handling fuels . T hey are ﬂammable and v apors are explosi v e .

– Use only an appro v ed container

– Nev er remo v e the fuel cap or add fuel with

the engine r unning . Allo w the engine to cool before refueling . Do not smok e .

– Nev er refuel or drain the mac hine indoors .

• Chec k that the operator’ s presence controls , safety switc hes , and shields are attac hed and functioning properly . Do not operate unless they are functioning properly .

Operation

• Nev er r un an engine in an enclosed area.

• Only operate in g ood light, k ee ping a w a y from

holes and hidden hazards .

• Be sure all dri v es are in neutral and parking brak e is eng ag ed before star ting the engine . Only star t the engine from the operator’ s position.

• Slo w do wn and use extra care on hillsides . Be sure to tra v el in the recommended direction on hillsides . T urf conditions can affect the mac hine’ s stability .

• Slo w do wn and use caution when making tur ns and when c hanging directions on slopes .

• Nev er operate with the guards not securely in place . Be sure all interloc ks are attac hed, adjusted properly , and functioning proper ty .

• Do not c hang e the engine g o v er nor setting or o v erspeed the engine .

• Stop on lev el g round, lo w er implements , diseng ag e the auxiliar y h y draulics , eng ag e parking brak e , shut off the engine before lea ving the operator’ s position for any reason.

• K ee p hands and feet a w a y from mo ving attac hments .

• Look behind and do wn before bac king up to be sure of a clear path.

• W ear appropriate clothing including hard hat, safety glasses , long pants , safety shoes , and

• Nev er car r y passeng ers and k ee p pets and b ystanders a w a y .

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• Slo w do wn and use caution when making tur ns and crossing roads and sidew alks .

• Do not operate the mac hine under the inﬂuence of alcohol or dr ugs .

• Use care when loading or unloading the mac hine into a trailer or tr uc k.

• Use care when approac hing blind cor ners , shr ubs , trees , or other objects that ma y obscure vision.

• R ead all attac hment man uals .

• Ensure that the area is clear of other people

before operating the traction unit. Stop the traction unit if any one enters the area.

• Nev er lea v e a r unning traction unit unattended. Alw a ys lo w er the loader ar ms , stop the engine , set the parking brak e , and remo v e the k ey before lea ving .

• Do not ex ceed the rated operating capacity , as the traction unit ma y become unstable whic h ma y result in loss of control.

• Do not car r y a load with the ar ms raised. Alw a ys car r y loads close to the g round.

• Do not o v er -load the attac hment and alw a ys k ee p the load lev el when raising the loader ar ms . Logs , boards , and other items could roll do wn the loader ar ms , injuring y ou.

• Nev er jerk the controls; use a steady motion.

• W atc h for trafﬁc when operating near or

crossing roadw a ys .

• Do not touc h par ts whic h ma y be hot from operation. Allo w them to cool before attempting to maintain, adjust, or ser vice .

• Chec k for o v erhead clearances (i.e . branc hes , doorw a ys , electrical wires) before dri ving under any objects and do not contact them.

• Ensure that y ou operate the traction unit in areas where there are no obstacles in close pro ximity to the operator . F ailure to maintain adequate distance from trees , w alls , and other bar riers ma y result in injur y as the traction unit bac ks up during operation if the operator is not attenti v e to the sur roundings . Only operate the unit in areas where there is sufﬁcient clearance for the operator to safely maneuv er the product.

• Before dig ging, ha v e the area mark ed for underg round utilities , and do not dig in mark ed areas .

• Locate the pinc h point areas mark ed on the traction unit and attac hments and k ee p hands and feet a w a y from these areas .

• Before operating the traction unit with an attac hment, ensure that the attac hment is properly installed.

Slope Operation

Slopes are a major factor related to loss-of-control and tip-o v er accidents , whic h can result in sev ere injur y or death. All slopes require extra caution.

• Do not operate the traction unit on hillsides or slopes ex ceeding the angles recommended in the Stability Data section in Speciﬁcations , pag e 19 , and those in the attac hment Operator’ s Manual . See also the Slope Char t , pag e 8 .

• Operate up and do wn slopes with the hea vy end of the traction unit uphill. W eight

distribution c hang es . An empty buc k et will mak e the rear of the traction unit the hea vy end, and a full buc k et will mak e the front of the traction unit the hea vy end. Most other attac hments will mak e the front of traction unit the hea vy end.

• Raising the loader ar ms on a slope will affect the stability of the mac hine . W henev er possible , k ee p the loader ar ms in the lo w ered position when on slopes .

• R emo ving an attac hment on a slope will mak e the rear of the traction unit hea vy . R efer to the Stability Data section in Speciﬁcations , pag e 19 , to deter mine whether the attac hment can be safely remo v ed on the slope .

• R emo v e obstacles suc h as roc ks , tree limbs , etc . from the w ork area. W atc h for holes , r uts , or bumps , as unev en ter rain could o v er tur n the traction unit. T all g rass can hide obstacles .

• Use only T oro-appro v ed attac hments . Attac hments can c hang e the stability and the operating c haracteristics of the traction unit. W ar ranty ma y be v oided if used with unappro v ed attac hments .

• K ee p all mo v ements on slopes slo w and g radual. Do not mak e sudden c hang es in speed or direction.

• A v oid star ting or stopping on a slope . If the traction unit loses traction, proceed slo wly , straight do wn the slope .

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• A v oid tur ning on slopes . If y ou m ust tur n, tur n slo wly and k ee p the hea vy end of the traction unit uphill.

• Do not operate near drop-offs , ditc hes , or embankments . T he traction unit could suddenly tur n o v er if a trac k g oes o v er the edg e of a cliff or ditc h, or if an edg e ca v es in.

• Do not operate on w et g rass . R educed traction could cause sliding .

• Do not park the traction unit on a hillside or slope without lo w ering the attac hment to the g round, setting the parking brak e , and c hoc king the trac ks .

Maintenance and Storage

• Diseng ag e the auxiliar y h y draulics , lo w er the attac hment, set the parking brak e , stop the engine , and remo v e the k ey . W ait for all mo v ement to stop before adjusting, cleaning, or re pairing .

• Clean debris from attac hments , dri v es , m ufﬂers , and engine to help prev ent ﬁres . Clean up oil or fuel spillag e .

• If any maintenance or re pair requires the loader ar ms to be in the raised position, secure the ar ms in the raised position with the h y draulic cylinder loc k.

• Secure the loader ar m v alv e with the loader v alv e loc k anytime y ou need to stop the mac hine with the loader ar ms raised.

• K ee p n uts and bolts tight. K ee p equipment in g ood condition.

• Nev er tamper with safety devices .

• K ee p the traction unit free of g rass , lea v es ,

or other debris build-up . Clean up oil or fuel spillag e . Allo w the traction unit to cool before storing .

• Use extra care when handling fuels . T hey are ﬂammable and v apors are explosi v e .

– Use only an appro v ed container .

– Nev er remo v e the fuel cap or add fuel when

the engine is r unning . Allo w the engine to cool before refueling . Do not smok e .

– Nev er refuel the traction unit indoors .

• Let the engine cool before storing and do not store near ﬂame .

• Do not store fuel near ﬂames or drain indoors .

• P ark the mac hine on lev el g round. Nev er allo w

untrained personnel to ser vice the mac hine .

• Use jac k stands to suppor t components when required.

• Carefully release pressure from components with stored energ y .

• Disconnect the batter y before making any re pairs . Disconnect the neg ati v e ter minal ﬁrst and the positi v e last. R econnect positi v e ﬁrst and neg ati v e last.

• K ee p hands and feet a w a y from mo ving par ts . If possible , do not mak e adjustments with the engine r unning .

• Charg e batteries in an open w ell v entilated area, a w a y from spark and ﬂames . Unplug the c harg er before connecting or disconnecting it from the batter y . W ear protecti v e clothing and use insulated tools .

– Nev er store the traction unit or fuel

container inside where there is an open ﬂame , suc h as near a w ater heater or fur nace .

– Nev er ﬁll a container while it is inside a

v ehicle , tr unk, pic k-up bed, or any surface other than the g round.

– K ee p container nozzle in contact with the

tank during ﬁlling .

• Stop and inspect the equipment if y ou strik e an object. Mak e any necessar y re pairs before restar ting .

• Use only g en uine T oro re placement par ts to ensure that original standards are maintained.

• K ee p all par ts in g ood w orking condition and all hardw are tightened. R e place all w or n or damag ed decals .

Page 7

• Batter y acid is poisonous and can cause bur ns . A v oid contact with skin, eyes , and clothing . Protect y our face , eyes , and clothing when w orking with a batter y .

• Batter y g ases can explode . K ee p cig arettes , sparks and ﬂames a w a y from the batter y .

• K ee p y our body and hands a w a y from pin hole leaks or nozzles that eject high pressure h y draulic ﬂuid. Use cardboard or paper to ﬁnd h y draulic leaks; nev er use y our hands . Hy draulic ﬂuid escaping under pressure can penetrate skin and cause injur y requiring surg er y within a few hours b y a qualiﬁed surg eon or g ang rene ma y result.

Sound Pressure

T his unit has a maxim um sound pressure lev el at the operator’ s ear of 88 dB A, based on measurements of identical mac hines per EN

11201.

Sound Power

T his unit has a guaranteed sound po w er lev el of 103 dB A, based on measurements of identical mac hines per EN 6395.

Vibration

T his unit does not ex ceed a hand/ar m vibration lev el of 1.5 m/s identical mac hines per EN 1033.

, based on measurements of

Page 8

Slope Chart

Page 9

Safety and Instructional Decals

Safety decals and instr uctions are easily visible to the operator and are located near any area of potential dang er . R e place any decal that is damag ed or lost.

1. Operator’s Manual location

2. Engine—stop

3. Engine—run

4. Engine—start

5. Hour meter

6. Fuel gauge—diesel 10. Glow plug 14. Warning—read the

7. Engine oil 11. Slow 15. Tipping hazard—move the

8. Battery

112-2540

9. Engine temperature

12. Continuous variable setting

13. Fast

Operator’s Manual.

traction unit with the heavy end up hill; do not travel with the loader arms raised.

104-9957

1. Warning—read the Operator’s Manual.

2. Warning—remove the ignition key and lower the loader arms before leaving the machine.

3. Crushing hazard—install the cylinder lock and read the instructions before servicing or performing maintenance.

4. Cutting hazard of hands or feet—wait for moving parts to stop; stay away from moving parts.

5. Crushing/dismemberment hazard of bystanders—keep bystanders a safe distance from the machine.

6. Explosion and electric shock hazard—do not dig in areas with buried gas or electrical lines.

104-9951

1. Hot surface/burn hazard—wear protective gloves when handling the hydraulic couplers and read the Operator’s Manual for information on handling hydraulic components.

1. Warning—read the Operator’s Manual ; maximum load rating of 500 lb. (228 Kg).

1. Crushing hazard of hands or feet—install the cylinder lock.

104-9950

104-9954

Page 10

100-8821

1. Crushing hazard and cutting hazard of hand—stay a safe distance from the front of the traction unit when the loader arms are raised.

108-4636

1. Auxiliary hydraulics 3. Forward

2. Locked reverse (detent) 4. Neutral (off)

93-6686

1. Hydraulic oil

2. Read the Operator’s Manual.

104-9953

1. Lower the loader arms. 4. Curl the bucket.

2. Dump the bucket. 5. Float the bucket on the ground.

3. Raise the loader arms.

104-9952

1. Traction Control

2. Forward 4. Turn right or left

3. Reverse

93-7814

1. Entanglement hazard, belt—stay away from moving parts.

106-6755

1. Engine coolant under

pressure.

2. Explosion hazard—read the

Operator’s Manual.

3. Warning—do not touch the

4. Warning—read the

93-6681

1. Cutting/dismemberment—hazard, fan-stay away from

moving parts.

hot surface.

Operator’s Manual.

Page 11

104-9958

1. Disengaged 3. Engaged

2. Parking brake

93-9084

1. Lift point 2. Tie-down point

100-8822

1. Warning—do not carry passengers.

Battery Symbols

Some or all of these symbols are on your battery

1. Explosion hazard 6. Keep bystanders a safe

2. No re, open ame, or smoking.

3. Caustic liquid/chemical burn hazard

4. Wear eye protection

5. Read the Operator’s

Manual.

distance from the battery.

7. Wear eye protection; explosive gases can cause blindness and other injuries

8. Battery acid can cause blindness or severe burns.

9. Flush eyes immediately with water and get medical help fast.

10. Contains lead; do not discard.

1. Engine coolant

93-9404

2. Read the Operator’s

Manual.

Page 12

Setup

Step

Activating the Battery

Parts needed for this step:

ounces

Procedure

Batter y posts, ter minals, and r elated accessories contain lead and lead compounds, chemicals kno wn to the State of Calif or nia to cause cancer and r epr oducti v e har m. W ash hands after handling .

Bulk electrolyte with 1.265 specic gravity (Purchase from a battery supply outlet.)

Warning

CALIFORNIA

Pr oposition 65 W ar ning

Figure 2

1. Battery access panel 4. Washer

2. Battery clamp

3. Bolt

3. Clean the top of the batter y and remo v e the v ent caps ( Figure 5 ).

5. Battery

Batter y electr ol yte contains sulfuric acid which is a deadl y poison and causes sev er e bur ns.

Do not drink electr ol yte and a v oid contact with skin, ey es or clothing . W ear safety g lasses to shield y our ey es and r ub ber g lo v es to pr otect y our hands.

Fill the batter y wher e clean w ater is al w ays a v aila ble f or ﬂushing the skin.

F ollo w all instr uctions and compl y with all safety messa ges on the electr ol yte container .

1. R emo v e the batter y access co v er ( Figure 2 ).

2. R emo v e the batter y from the mac hine ( Figure 2 ).

Important: Nev er ﬁll the batter y with electr ol yte while the batter y is installed on the machine. Electr ol yte can be spilled on other par ts and cause cor r osion.

Figure 3

4. Slo wly pour electrolyte into eac h batter y cell until the lev el is up to the upper line on the batter y case .

Important: Do not o v erﬁll the batter y because electr ol yte (sulfuric acid) can cause sev er e cor r osion and dama ge to the chassis.

Page 13

Figure 4

G003792

5. W ait ﬁv e to ten min utes after ﬁlling the batter y cells . Add electrolyte , if necessar y , until the electrolyte lev el is up to the upper line on the batter y case .

6. Install the batter y v ent caps ( Figure 5 ).

Figure 5

1. Fill caps 3. Lower line

2. Upper line

Figure 6

1. Positive post

2. Negative post

Charging the batter y pr oduces gasses that can explode.

Nev er smok e near the batter y and k eep spar ks and ﬂames a w ay fr om batter y .

2. W hen the batter y is fully c harg ed, unplug the c harg er from the electrical outlet, then disconnect the c harg er leads from the batter y posts ( Figure 6 ).

3. Install the batter y into the mac hine ( Figure 7 ).

4. Install the batter y access co v er ( Figure 7 ).

3. Charger red (+) wire

4. Charger black (—) wire

Step

Charging the Battery

No Parts Required

Procedure

1. Connect a c harg er to the batter y ( Figure 6 ) and c harg e it for a minim um of 1 hour at 6 to 10 amps . Do not o v erc harg e the batter y .

Page 14

Figure 7

1. Battery access panel 4. Washer

2. Battery clamp

3. Bolt

5. Battery

Step

Checking Fluid Levels

No Parts Required

Procedure

Before star ting the engine for the ﬁrst time , c hec k the engine oil and h y draulic ﬂuid lev els . R efer to Operation for more infor mation.

Page 15

Product Overview

Figure 8

1. Road wheels 4. Loader arms 7. Mount plate 10. Tie-down/lift loop

2. Track 5. Hood 8. Reverse safety plate

3. Lift cylinder 6. Auxiliary hydraulic couplers 9. Control panel

11. Rear access cover

Page 16

Controls

Traction Control

Become familiar with all the controls ( Figure 9 ) before y ou star t the engine and operate the traction unit.

Figure 9

1. Auxiliary hydraulics lever 7. Loader arm/attachment tilt

2. Key switch 8. Parking brake lever

3. Hour meter

4. Fuel gauge 10. Traction control

5. Indicator lights and glow plug switch

6. Throttle lever

lever

9. Reference bar

11. Loader valve lock

T o mo v e forw ard, mo v e the traction control forw ard. T o mo v e rearw ard, mo v e the traction control rearw ard ( Figure 10 ).

T o tur n, rotate the traction control in the desired direction ( Figure 10 ).

T he far ther y ou mo v e the traction control in any direction, the faster the traction unit will mo v e in that direction.

T o stop , release the traction control.

Figure 10

Key Switch

T he k ey switc h, used to star t and stop the engine , has three positions: off , r un, and star t.

T o star t the engine , rotate the k ey to the star t position. R elease the k ey when engine star ts and it will mo v e automatically to the r un position.

T o stop the engine , rotate the k ey to the off position.

Throttle Lever

Mo v e the control forw ard to increase the engine speed and rearw ard to decrease speed.

Reference Bar

W hen dri ving the traction unit, use the reference bar as a handle and a lev erag e point for controlling the traction control and the auxiliar y h y draulics lev er . T o ensure smooth, controlled operation, do not tak e both hands off of the reference bar while operating the traction unit.

Loader Arm/Attachment Tilt Lever

T o tilt the attac hment forw ard, slo wly mo v e the lev er to the right ( Figure 11 ).

T o tilt the attac hment rearw ard, slo wly mo v e the lev er to the left ( Figure 11 ).

T o lo w er the loader ar ms , slo wly mo v e the lev er forw ard ( Figure 11 ).

T o raise the loader ar ms , slo wly mo v e the lev er rearw ard ( Figure 11 ).

Y ou can also push the lev er fully forw ard into a detent position ( Figure 11 ) to release the loader ar ms so that the attac hment rests on the g round. T his allo ws attac hments suc h as the lev eler and the h y draulic blade to follo w the contours of the g round (i.e ., ﬂoat) when g rading .

Page 17

Figure 11

1. Lower the loader arms 4. Tilt the attachment forward

2. Raise the loader arms

3. Tilt the attachment rearward

5. Detent (Float) position

By mo ving the lev er to an inter mediate position (suc h as , forw ard and left), y ou can mo v e the loader ar ms and tilt the attac hment at the same time .

Auxiliary Hydraulics Lever

T o operate a h y draulic attac hment in the forw ard direction, rotate the auxiliar y h y draulics lev er rearw ard and pull it do wn to the reference bar ( Figure 13 , n umber 1).

T o operate a h y draulic attac hment in rev erse direction, rotate the h y draulics lev er rearw ard, then mo v e it left into the upper slot ( Figure 13 , n umber

2).

If y ou release the lev er while in the forw ard position, the lev er will automatically retur n to the neutral position ( Figure 13 , n umber 3). If it is in the rev erse position, it will remain there until y ou pull it out of the slot.

Loader Valve Lock

T he loader v alv e loc k secures the loader ar m/attac hment tilt lev er so that y ou cannot push it forw ard. T his helps to ensure that no one will accidentally lo w er the loader ar ms during maintenance . Secure the loader ar ms with the loc k anytime y ou need to stop the mac hine with the loader ar ms raised.

T o set the loc k, lift up on it so it clears the hole in the control panel and swing it to the left in front of the loader ar m lev er , pushing it do wn into the loc k ed position ( Figure 12 ).

Figure 13

1. Forward ow hydraulics 3. Neutral

2. Reverse ow hydraulics

Parking Brake Lever

T o set the parking brak e , push the brak e lev er forw ard and to the left and then pull it rearw ard ( Figure 14 ).

Note: T he traction unit ma y roll slightly before the brak es eng ag e in the dri v e sproc k et.

Figure 12

1. Loader valve lock 2. Loader arm/attachment tilt

lever

Page 18

Figure 14

T o release the brak e , push the lev er forw ard and then right, into the notc h.

Fuel Gauge

T his g aug e measures the amount of fuel in the fuel tank.

Figure 15

1. Engine oil pressure light 4. Battery charge indicator

2. Engine coolant temperature light

3. Glow plug switch

light

5. Glow plug light

Engine Oil Pressure Light

If the engine oil pressure g ets too lo w , this light illuminates and an audible alar m sounds . If this happens , stop the engine immediately and c hec k the oil. If lo w , add oil and/or look for possible leaks .

Battery Charge Indicator Light

If the batter y c harg e becomes too lo w , this light illuminates and an audible alar m sounds . If this happens , stop the engine and c harg e or re place the batter y . Chec k the tension of the alter nator belt; refer to y our Engine Operator’ s Manual .

Engine Coolant Temperature Light

If the engine coolant g ets too hot, this light illuminates and an audible alar m sounds . If this happens , stop the engine and allo w the traction unit to cool. Chec k the coolant lev el when the engine has fully cooled.

Glow Plug Light

Illuminates while the glo w plugs are c harg ed and w ar ming the engine .

Glow Plug Switch

Press and hold this switc h for 10 seconds to acti v ate the glo w plugs before star ting the engine .

Hour Meter

T he hour meter displa ys the n umber of hours of operation that ha v e been log g ed on the traction unit.

Page 19

Specications

Note: Speciﬁcations and design are subject to c hang e without notice .

Model 22333

Width Length Height Weight

34 inches (86 cm) 71 inches (180 cm) 43 inches (109 cm)

1950 lb (885 Kg)

Operating capacity

Tipping capacity

Wheelbase

Dump height (with narrow bucket) 47 inches (119 cm)

Reach—fully raised (with narrow bucket) 22 inches (55 cm)

Height to hinge pin (narrow bucket in highest position) 66 inches (168 cm)

Model 22334

Width Length Height Weight

Operating capacity

Tipping capacity

553 lb (251 Kg)

1580 lb (717 Kg)

31.2 inches (79 cm)

41 inches (104 cm) 71 inches (180 cm) 43 inches (109 cm)

2050 lb (885 Kg)

553 lb (251 Kg)

1580 lb (717 Kg)

Wheelbase

Dump height (with narrow bucket) 47 inches (119 cm)

Reach—fully raised (with narrow bucket) 22 inches (55 cm)

Height to hinge pin (narrow bucket in highest position) 66 inches (168 cm)

31.2 inches (79 cm)

Attachments/Accessories

A selection of T oro appro v ed attac hments and accessories are a v ailable for use with the mac hine to enhance and expand its capabilities . Contact y our A uthorized Ser vice Dealer or Distributor or g o to www .T oro .com for a list of all appro v ed attac hments and accessories .

Important: Use onl y T or o appr o v ed attachments. Other attachments may cr eate an unsafe operating en vir onment or dama ge the traction unit.

Page 20

Stability Data

T he follo wing tables list the maxim um slope recommended for the traction unit in the positions listed in the tables . Slopes o v er the listed deg ree ma y cause the traction unit to become unstable . T he data in the tables assume that the loader ar ms are fully lo w ered; raised ar ms ma y affect the stability .

In eac h attac hment man ual is a set of three stability ratings , one for eac h hill position. T o deter mine the maxim um slope y ou can tra v erse with the attac hment installed, ﬁnd the deg ree of slope that cor responds to the stability ratings of the attac hment. Example: If the attac hment installed on a TX model 22319 traction unit has a F ront Uphill rating of B , a R ear Uphill rating of D , and a Side Uphill rating of C , then y ou could dri v e forw ard up a 19° slope , rearw ard up a 12° slope , or sidew a ys on a 14° slope , as listed in the follo wing table .

Model 22333

Conguration

Traction unit without attachment Traction unit with an attachment rated with one of the following

stability ratings for each slope position:*

A B C D E

Maximum Recommended Slope when

Front Uphill Rear Uphill Side Uphill

11° 21° 19°

25° 25° 20° 19° 19° 18° 16° 15° 14° 10° 12° 9°

5° 5° 5°

Operating with:

Model 22334

Conguration

Traction unit without attachment Traction unit with an attachment rated with one of the following

stability ratings for each slope position:*

A B C D E

Maximum Recommended Slope when

Operating with:

Front Uphill Rear Uphill Side Uphill

12° 19° 21°

25° 25° 23° 22° 22° 20° 18° 16° 14° 10° 10° 10°

5° 5° 5°

Page 21

Operation

Note: Deter mine the left and right sides of the

mac hine from the nor mal operating position.

Important: Bef or e operating , check the fuel and oil lev el, and r emo v e de bris fr om the traction unit. Also, ensur e that the ar ea is clear of people and de bris. Y ou should also kno w and ha v e mar k ed the locations of all utility lines.

Filling the Fuel Tank

1. R emo v e the fuel tank cap ( Figure 16 ).

Under cer tain conditions, diesel fuel and fuel v apor s ar e highl y ﬂamma ble and explosi v e. A ﬁr e or explosion fr om fuel can bur n y ou and other s and can cause pr oper ty dama ge.

• Use a funnel and ﬁll the fuel tank outdoor s, in an open ar ea, when the engine is of f and is cold. W ipe up an y fuel that spills.

• Do not ﬁll the fuel tank completel y full. Add fuel to the fuel tank until the lev el is 1/4 to 1/2 inch (6 to 13 mm) belo w the bottom of the ﬁller neck. T his empty space in the tank allo ws the fuel to expand.

• Nev er smok e when handling fuel, and stay a w ay fr om an open ﬂame or wher e fuel fumes may be ignited by a spar k.

• Stor e fuel in a clean, safety-appr o v ed container and k eep the cap in place.

Figure 16

1. Fuel tank cap

2. Fill the tank to about one inc h belo w the top of the tank, not the ﬁller nec k, with No . 2 diesel fuel.

3. Install the fuel tank cap .

Checking the Engine Oil Level

1. P ark the traction unit on a lev el surface , lo w er the loader ar ms , and stop the engine .

2. R emo v e the k ey and allo w the engine to cool.

3. Open the hood.

4. Clean around the oil dipstic k ( Figure 17 ).

Page 22

Figure 17

1. Oil dipstick 2. Oil ller cap

5. Pull out the dipstic k and wipe the metal end clean ( Figure 17 ).

2. P ark the traction unit on a lev el surface , lo w er the loader ar ms , and fully retract the tilt cylinder .

3. Stop the engine , remo v e the k ey , and allo w the engine to cool.

4. Open the hood.

5. Clean the area around the ﬁller nec k of the h y draulic tank ( Figure 18 ).

6. Slide the dipstic k fully into the dipstic k tube ( Figure 17 ).

7. Pull the dipstic k out and look at the metal end.

8. If the oil lev el is lo w (belo w the bottom hole), clean around the oil ﬁller cap and remo v e the cap ( Figure 17 ).

9. Slo wly pour only enough oil into the v alv e co v er to raise the lev el to the top hole on the dipstic k.

Important: Do not o v erﬁll the crankcase with oil because the engine may be dama ged.

10. R e place the ﬁller cap and dipstic k.

11. Close the hood.

Checking the Hydraulic Fluid Level

Chec k the h y draulic ﬂuid lev el before the engine is ﬁrst star ted and after ev er y 25 operating hours .

Figure 18

1. Hydraulic ller neck cap

6. R emo v e the cap from the ﬁller nec k and c hec k the ﬂuid lev el on the dipstic k ( Figure 19 ).

T he ﬂuid lev el should be betw een the marks on the dipstic k.

Hy draulic T ank Capacity: 12 US g allons (45.4 l)

Use 10W -30 deterg ent, diesel engine oil (API ser vice CH-4 or higher).

1. R emo v e the attac hment, if one is installed; refer to R emo ving an Attac hment.

Page 23

If the engine has been r unning , the pr essuriz ed, hot coolant can escape and cause sev er e bur ns.

• Do not r emo v e the radiator cap when the engine is hot. Al w ays allo w the engine to cool at least 15 min utes or until the radiator cap is cool enough to touch without bur ning y our hand bef or e r emo ving the radiator cap .

• Do not touch radiator and sur r ounding par ts that ar e hot.

Figure 19

1. Filler neck 2. Dipstick

7. If the lev el is lo w , add enough ﬂuid to raise it to the proper lev el.

8. Install the cap on the ﬁller nec k.

9. Close the hood.

Checking, Adding, and Bleeding the Engine Coolant

Clean debris off of the screen, oil cooler , and front of the radiator daily and more often if conditions are extremely dusty and dir ty

T he cooling system is ﬁlled with a 50/50 solution of w ater and per manent eth ylene glycol antifreeze . Chec k the lev el of coolant in the expansion tank at the beginning of eac h da y before star ting the engine .

• Use a ra g when opening the radiator cap , and open the cap slo wl y to allo w steam to escape.

R otating shaft and f an can cause per sonal injur y .

• Do not operate the machine without the co v er s in place.

• K eep ﬁnger s, hands and clothing clear of r otating f an and dri v e shaft.

• Shut of f the engine and r emo v e the ignition k ey bef or e perf or ming maintenance.

Sw allo wing engine coolant can cause poisoning .

• Do not s w allo w engine coolant.

• K eep out of r each of childr en and pets.

1. Chec k the lev el of coolant in the expansion tank ( Figure 20 ).

T he coolant lev el should be at or abo v e the mark on the side of the tank.

Page 24

E. P our coolant into the coolant ﬁller nec k

until the coolant begins to come out of the top coolant bleed v alv e ( Figure 21 ).

F . Close the top coolant bleed v alv e

( Figure 21 ).

G . P our coolant into the coolant ﬁller nec k

until the coolant lev el comes into the ﬁller nec k ( Figure 21 ).

H. Install the coolant ﬁll cap ( Figure 21 ).

I. Add coolant into the expansion tank until

it reac hes the Full line on the side of the tank ( Figure 21 ).

3. Install the expansion tank cap .

Figure 20

1. Expansion tank

2. Full mark

2. If the coolant lev el is lo w , complete the follo wing procedure:

A. R emo v e the coolant ﬁll cap ( Figure 21 ).

Figure 21

1. Expansion tank 3. Top coolant bleed valve

2. Coolant ll cap and ller neck

4. Front coolant bleed valve

B . Open the front and top coolant bleed

v alv es ( Figure 21 ).

C . P our coolant into the coolant ﬁller nec k

until the coolant begins to come out of the front coolant bleed v alv e ( Figure 21 ).

D . Close the front coolant bleed v alv e

( Figure 21 ).

Bleeding the Fuel System

Y ou m ust bleed the fuel system before star ting the engine if any of the follo wing situations ha v e occur red:

• Initial star t up of a new mac hine .

• Engine has ceased r unning due to lac k of fuel.

• Maintenance has been perfor med upon fuel

system components (e .g ., ﬁlter re placed).

Under cer tain conditions, diesel fuel and fuel v apor s ar e highl y ﬂamma ble and explosi v e. A ﬁr e or explosion fr om fuel can bur n y ou and other s and can cause pr oper ty dama ge.

• Use a funnel and ﬁll the fuel tank outdoor s, in an open ar ea, when the engine is of f and is cold. W ipe up an y fuel that spills.

• Do not ﬁll the fuel tank completel y full. Add fuel to the fuel tank until the lev el is 1/4 to 1/2 in. (6 to 13 mm) belo w the bottom of the ﬁller neck. T his empty space in the tank allo ws the fuel to expand.

• Nev er smok e when handling fuel, and stay a w ay fr om an open ﬂame or wher e fuel fumes may be ignited by a spar k.

• Stor e fuel in a clean, safety-appr o v ed container and k eep the cap in place.

1. Ensure that the fuel tank is at least half full.

Page 25

2. Open the hood.

3. Open the air bleed screw on the fuel injection pump ( Figure 22 ).

5. T ur n the ignition k ey to the Star t position. W hen the engines star ts , release the k ey .

Important: Do not enga ge the star ter f or mor e than 10 seconds at a time. If the engine f ails to star t, allo w a 30 second cool-do wn period betw een attempts. F ailur e to f ollo w these instr uctions can bur n out the star ter motor .

6. Mo v e the throttle lev er to desired setting .

Important: If the engine is r un at high speeds when the h y draulic system is cold (i.e., when the ambient air temperatur e is near fr eezing or lo w er), h y draulic system dama ge could occur . W hen star ting the engine in cold conditions, allo w the engine to r un in the middle thr ottle position f or 2 to 5 min utes bef or e mo ving the thr ottle to f ast (ra b bit).

Figure 22

1. Fuel injection pump bleed screw

4. T ur n the k ey in the ignition switc h to the On position. T he electric fuel pump will begin operation, thereb y forcing air out around the air bleed screw . Lea v e the k ey in the On position until a solid stream of fuel ﬂo ws out around the screw .

5. Tighten the screw and tur n the k ey to the Off position.

Note: Nor mally , the engine should star t after the abo v e bleeding procedures are follo w ed. Ho w ev er , if engine does not star t, air ma y be trapped betw een injection pump and injectors; contact y our A uthorized Ser vice Dealer .

Starting and Stopping the Engine

Starting the Engine

Note: If outdoor temperature is belo w

freezing, store the traction unit in a g arag e to k ee p it w ar mer and aid in star ting .

Stopping the Engine

1. Mo v e the throttle lev er to the slo w (tur tle) position.

2. Lo w er the loader ar ms to the g round.

3. T ur n the ignition k ey off . Note: If the engine has been w orking hard or

is hot, let it idle for a min ute before tur ning the ignition k ey off . T his helps cool the engine before it is stopped. In an emerg ency , the engine ma y be stopped immediately .

Stopping the Traction Unit

T o stop the traction unit, release the traction control, mo v e the throttle lev er to slo w (tur tle), lo w er loader ar ms to the g round, and stop the engine . Set the parking brak e and remo v e the k ey .

1. Ensure that the auxiliar y h y draulics lev er is in neutral.

2. Mo v e the throttle lev er midw a y betw een slo w (tur tle) and fast (rabbit) positions .

3. T ur n the ignition k ey to the R un position.

4. Press the glo w plug switc h and hold it for 10 seconds .

A child or untrained bystander could attempt to operate the traction unit and be injur ed.

R emo v e the k ey fr om the s witch when lea ving the traction unit, ev en if just f or a few seconds.

Page 26

Moving a Non-functioning Traction Unit

Important: Do not to w or pull the traction

unit without ﬁr st opening the to w v alv es, or the h y draulic system will be dama ged.

1. Stop the engine .

2. Open the rear access co v er .

3. Using a wrenc h, tur n the to w v alv es on the h y draulic pumps twice counter -cloc kwise ( Figure 23 ).

2. Raise the loader ar ms to the fully raised position.

3. Stop the engine .

4. R emo v e the hair pin cotter and clevis pin securing the cylinder loc k to the loader ar m ( Figure 24 ).

Figure 24

1. Cylinder lock 3. Clevis pin

2. Lift cylinder

4. Hairpin cotter

Figure 23

1. Left tow valve (right track) 2. Right tow valve (left track)

4. T o w the traction unit as required.

5. W hen the traction unit has been re paired, close the to w v alv es before operating it.

Using the Cylinder Lock

T he loader ar ms may lo w er when in the raised position cr ushing an y one under them.

Install the cylinder lock bef or e perf or ming maintenance that r equir es raised loader ar ms.

5. Lo w er the cylinder loc k o v er the cylinder rod and secure it with the clevis pin and hair pin cotter ( Figure 24 ).

6. Slo wl y lo w er the loader ar ms until cylinder loc k contacts the cylinder body and rod end.

Removing/Storing the Cylinder Lock Important: Ensur e that the cylinder lock is

r emo v ed fr om the r od and full y secur ed in the stora ge position bef or e operating the traction unit.

1. Star t the engine .

2. Raise the loader ar ms to the fully raised position.

3. Stop the engine .

4. R emo v e the clevis pin and cotter pin securing the cylinder loc k.

5. R otate the cylinder loc k up to the loader ar m and secure it with the clevis pin and hair pin cotter .

Installing the Cylinder Lock

1. R emo v e the attac hment.

6. Lo w er the loader ar ms .

Page 27

Using Attachments

Important: If y ou ar e using an attachment

with a serial n umber of 200999999 or ear lier , the man ual f or the attachment may contain inf or mation speciﬁc to the use of the attachment with other compact utility loader models, such as settings f or the ﬂo w di vider contr ol and speed selector lev er and the use of a counterw eight on the traction unit. T hese systems ar e built into the TX, and y ou should ignor e an y r efer ences to them.

Installing an Attachment Important: Use onl y T or o-appr o v ed

attachments. Attachments can change the sta bility and the operating characteristics of the traction unit. T he w ar ranty of the traction unit may be v oided if used with unappr o v ed attachments.

Important: Bef or e installing the attachment, ensur e that the mount plates ar e fr ee of an y dir t or de bris and that the pins r otate fr eel y . If the pins do not r otate fr eel y , g r ease them.

Important: T he attachment should be raised enough to clear the g r ound, and the mount plate should be tilted all the w ay back.

6. Stop the engine .

7. Eng ag e the quic k attac h pins , ensuring that they are fully seated in the mount plate ( Figure 26 ).

Important: If the pins do not r otate to the enga ged position, the mount plate is not full y aligned with the holes in the attachment r ecei v er plate. Check the r ecei v er plate and clean it if necessar y .

1. P osition the attac hment on a lev el surface with enough space behind it to accommodate the traction unit.

2. Star t the engine .

3. Tilt the attac hment mount plate forw ard.

4. P osition mount plate into the upper lip of the attac hment recei v er plate ( Figure 25 ).

Figure 25

1. Mount plate 2. Receiver plate

5. Raise the loader ar ms while tilting bac k the mount plate at the same time .

Figure 26

1. Quick attach pins (shown in engaged position)

2. Disengaged position

3. Engaged position

If y ou do not full y seat the quick attach pins thr ough the attachment mount plate, the attachment could f all of f of the traction unit, cr ushing y ou or bystander s.

Ensur e that y our quick attach pins ar e full y seated in the attachment mount plate.

Page 28

Connecting the Hydraulic Hoses

If the attac hment requires h y draulics for operation, connect the h y draulic hoses as follo ws:

1. Stop the engine .

2. Mo v e the auxiliar y h y draulics lev er forw ard, bac kw ard, and bac k to neutral to reliev e pressure at the h y draulic couplers .

3. Mo v e the auxiliar y h y draulics lev er into the rev erse position.

4. R emo v e the protecti v e co v ers from the h y draulic couplers on the traction unit.

5. Ensure that all foreign matter is cleaned from the h y draulic connectors .

6. Push the attac hment male connector into the female connector on the traction unit.

Note: W hen y ou connect the attac hment male connector ﬁrst, y ou will reliev e any pressure built up in the attac hment.

8. Conﬁr m that the connection is secure b y pulling on the hoses .

9. Mo v e the auxiliar y h y draulics lev er to neutral.

Removing an Attachment

1. Lo w er the attac hment to the g round.

2. Stop the engine .

3. Diseng ag e the quic k attac h pins b y tur ning them to the outside .

4. If the attac hment uses h y draulics , mo v e the auxiliar y h y draulics lev er forw ard, bac kw ard, and bac k to neutral to reliev e pressure at the h y draulic couplers .

5. If the attac hment uses h y draulics , slide the collar bac k on the h y draulic couplers and disconnect them.

Important: Connect the attachment hoses to gether to pr ev ent h y draulic system contamination during stora ge.

Hy draulic ﬂuid escaping under pr essur e can penetrate skin and cause injur y . F luid injected into the skin must be surgicall y r emo v ed within a few hour s by a doctor f amiliar with this f or m of injur y or gang r ene may r esult.

• K eep y our body and hands a w ay fr om pin hole leaks or nozzles that eject high pr essur e h y draulic ﬂuid.

• Use cardboard or paper to ﬁnd h y draulic leaks, nev er use y our hands.

Hy draulic coupler s, h y draulic lines/v alv es, and h y draulic ﬂuid may be hot. If y ou contact hot components y ou may be bur ned.

• W ear g lo v es when operating the h y draulic coupler s.

• Allo w the traction unit to cool bef or e touching h y draulic components.

• Do not touch h y draulic ﬂuid spills.

7. Push the attac hment female connector into the male connector on the traction unit.

6. Install the protecti v e co v ers onto the h y draulic couplers on the traction unit.

7. Star t the engine , tilt the mount plate forw ard, and bac k the traction unit a w a y from the attac hment.

Securing the Traction Unit for Transport

W hen transpor ting the traction unit on a trailer , alw a ys use the follo wing procedure:

Important: Do not operate or dri v e the traction unit on r oad w ays.

1. Lo w er the loader ar ms .

2. Stop the engine .

3. Secure the traction unit to the trailer with c hains or straps using the tie-do wn/lift loops ( Figure 8 ) to secure the rear of the traction unit and the loader ar ms/mount plate to secure the front of the traction unit.

Lifting the Traction Unit

Y ou can lift the traction unit using the tie-do wn/lift loops as lift points ( Figure 8 ).

Page 29

Maintenance

Note: Deter mine the left and right sides of the mac hine from the nor mal operating position.

Recommended Maintenance Schedule(s)

Maintenance Service

Interval

After the rst 8 operating

hours

After the rst 50

operating hours

Before each use or daily

Every 25 hours

Every 100 hours

Maintenance Procedure

• Replace the hydraulic lter.

• Change the engine oil.

• Change the oil lter.

• Check and adjust the track tension.

• Check the engine oil level.

• Check the cooling system.

• Grease the traction unit.

• Drain water and other contaminants from the fuel lter/water separator.

• Check the condition of and clean the tracks.

• Clean the radiator.

• Remove debris from the traction unit.

• Check for loose fasteners.

• Check the hydraulic uid level.

• Change the engine oil (more frequently when operating conditions are extremely dusty or sandy).

• Check the battery electrolyte level (replacement battery only).

• Check the battery cable connections.

• Check and adjust the track tension.

• Check the cooling system hoses.

• Check the alternator/fan belt tension (refer to the Engine Operator’s Manual for instructions).

• Check the hydraulic lines for leaks, loose ttings, kinked lines, loose mounting supports, wear, weather, and chemical deterioration.

• Check for dirt build-up in the chassis.

Every 200 hours

Every 250 hours

Every 400 hours

Every 500 hours

Every 600 hours

Every 1,500 hours

• Replace the primary air lter.

• Change the oil lter (more frequently when operating conditions are extremely dusty or sandy).

• Replace the hydraulic lter.

• Check and grease the road wheels.

• Check the fuel lines and connections for deterioration, damage, or loose connections.

• Replace the fuel lter canister.

• Change the hydraulic uid.

• Replace the alternator/fan belt (refer to the Engine Operator’s Manual for instructions).

• Replace the safety air lter.

• Replace all moving hydraulic hoses.

Yearly

• Change the engine coolant (Authorized Service Dealer only).

• Check the condition of the hydraulic pump belt.

Page 30

Maintenance Service

Interval

Maintenance Procedure

Yearly or before storage

Every 2 years

Important: R efer to y our Engine Operator’ s Man ual f or additional maintenance pr ocedur es.

If y ou lea v e the k ey in the ignition s witch, someone could accidentl y star t the engine and seriousl y injur e y ou or other bystander s.

R emo v e the k ey fr om the ignition bef or e y ou do an y maintenance.

• Check and adjust the track tension.

• Touch up chipped paint

• Drain and clean the fuel tank (Authorized Service Dealer only).

Premaintenance Procedures

Before opening any of the co v ers , stop the engine and remo v e the k ey . Allo w the engine to cool before opening any co v ers

Opening the Hood

1. Push do wn on the hood while using a coin or screw dri v er to tur n the hood latc h cloc kwise ( Figure 27 ).

Figure 27

1. Hood, push down 2. Hood latch, turn clockwise

2. Swing the hood up ( Figure 28 ).

Figure 28

1. Hood, swing up

Closing the Hood

Lo w er the hood and secure it b y pushing do wn on the front of the hood until it loc ks in place .

Opening the Rear Access Cover

1. Unscrew the 2 hand knobs securing the rear access co v er to the mac hine ( Figure 29 ).

Page 31

Figure 29

1. Hand knob

2. Tilt the rear access co v er do wn and remo v e to access the inter nal components ( Figure 29 ).

Closing the Rear Access Cover

Figure 30

1. Side screen

1. Mo v e the rear access co v er in place o v er the bac k of the traction unit making sure the tabs line up in the slots .

2. Push the access co v er forw ard, lining up the hand knob screws with the threaded holes in the mac hine .

3. Screw the hand knobs tight to secure the rear access co v er in place .

Removing the Side Screens

1. Open the hood.

2. Slide the side screens ( Figure 30 ) up and out of the slots in the front screen and frame .

Installing the Side Screens

Slide the side screens into place in the slots in the front screen and frame .

Lubrication

Greasing the Traction Unit

Grease all pi v ot joints ev er y 8 operating hours and immediately after ev er y w ashing .

Grease T ype: General-pur pose g rease .

1. Lo w er the loader ar ms and stop the engine . R emo v e the k ey .

2. Clean the g rease ﬁttings with a rag .

3. Connect a g rease gun to eac h ﬁtting ( Figure 31 and Figure 32 ).

Page 32

Figure 31

Replacing the Filters

1. Lo w er the loader ar ms , stop the engine , and remo v e the k ey .

2. Open the hood.

3. R elease the latc hes on the air cleaner and pull the air cleaner co v er off of the air cleaner body ( Figure 33 ).

Figure 33

1. Air lter body 4. Air cleaner cover

2. Safety lter 5. Latches

3. Primary lter

6. Dust cap

Figure 32

4. Pump g rease into the ﬁttings until g rease begins to ooze out of the bearings (appro ximately 3 pumps).

5. Wipe up any ex cess g rease .

Engine Maintenance

Servicing the Air Cleaner

Primar y Filter : R e place after ev er y 200 operating hours or more often in dusty conditions .

Safety Filter : R e place after ev er y 600 operating hours .

Note: Ser vice the air cleaner more frequently if operating conditions are extremely dusty or sandy .

4. Squeeze the dust cap sides to open it and knoc k the dust out.

5. Clean the inside of the air cleaner co v er with compressed air .

6. Gently slide the primar y ﬁlter out of the air cleaner body ( Figure 33 ). A v oid knoc king the ﬁlter into the side of the body .

Important: Do not attempt to clean the primar y ﬁlter .

7. R emo v e the safety ﬁlter only if y ou intend to re place it.

Important: Nev er attempt to clean the safety ﬁlter . If the safety ﬁlter is dir ty , then the primar y ﬁlter is dama ged and y ou should r eplace both ﬁlter s.

8. Inspect the new ﬁlter(s) for damag e b y looking into the ﬁlter while shining a bright light on the outside of the ﬁlter . Holes in the ﬁlter will appear as bright spots . Inspect the element for tears , an oily ﬁlm, or damag e to the r ubber seal. If the ﬁlter is damag ed do not use it.

9. If y ou are re placing the safety ﬁlter , carefully slide the new ﬁlter into the ﬁlter body ( Figure 33 ).

Page 33

Important: T o pr ev ent engine dama ge, al w ays operate the engine with both air ﬁlter s and co v er installed.

10. Carefully slide the primar y ﬁlter o v er the safety ﬁlter ( Figure 33 ). Ensure that it is fully seated b y pushing on the outer rim of the ﬁlter while installing it.

Important: Do not pr ess on the soft inside ar ea of the ﬁlter .

11. Install the air cleaner co v er with the side indicated as UP facing up and secure the latc hes ( Figure 33 ).

12. Close the hood.

Servicing the Engine Oil

Chang e oil and the oil ﬁlter after the ﬁrst 50 operating hours . Chang e the oil ev er y 100 operating hours and the oil ﬁlter ev er 200 operating hours thereafter ..

Changing the Oil

1. Star t the engine and let it r un for ﬁv e min utes . T his w ar ms the oil so it drains better .

2. P ark the traction unit so that the drain side is slightly lo w er than the opposite side to ensure that the oil drains completely .

3. Lo w er the loader ar ms , set the parking brak e , stop the engine , and remo v e the k ey .

Components will be hot if the traction unit has been r unning . If y ou touch hot components y ou may be bur ned.

Allo w the traction unit to cool bef or e perf or ming maintenance or touching components under the hood.

4. R emo v e the drain plug ( Figure 35 ).

Note: Chang e oil and oil ﬁlter more frequently when operating conditions are extremely dusty or sandy .

Oil T ype: Deterg ent diesel engine oil (API ser vice CH-4 or higher)

Crankcase Capacity: w/ﬁlter , 0.98 US g allons (3.7 l)

Viscosity: See table belo w

Figure 35

1. Oil drain plug

5. W hen the oil has drained completely , re place the plug .

Note: Dispose of the used oil at a cer tiﬁed recycling center .

Figure 34

6. R emo v e the oil ﬁll cap and slo wly pour appro ximately 80% of the speciﬁed amount of oil in through the v alv e co v er .

7. Chec k the oil lev el; refer to Chec king the Engine Oil Lev el in Operation , pag e 21 .

Page 34

8. Slo wly add additional oil to bring the lev el to the upper hole on the dipstic k.

9. R e place the ﬁll cap .

Changing the Oil Filter

1. Drain the oil from the engine; refer to Changing the Oil.

2. Place a shallo w pan or rag under the ﬁlter to catc h oil.

3. R emo v e the old ﬁlter ( Figure 36 ) and wipe the surface of the ﬁlter adapter g ask et.

Fuel System Maintenance

Under cer tain conditions, diesel fuel and fuel v apor s ar e highl y ﬂamma ble and explosi v e. A ﬁr e or explosion fr om fuel can bur n y ou and other s and can cause pr oper ty dama ge.

• Use a funnel and ﬁll the fuel tank outdoor s, in an open ar ea, when the engine is of f and is cold. W ipe up an y fuel that spills.

• Nev er smok e when handling fuel, and stay a w ay fr om an open ﬂame or wher e fuel fumes may be ignited by a spar k.

Figure 36

1. Oil lter

4. P our new oil of the proper type through the center hole of the ﬁlter . Stop pouring when the oil reac hes the bottom of the threads .

5. Allo w a min ute or tw o for the oil to be absorbed b y ﬁlter material, then pour off the ex cess oil.

6. Apply a thin coat of new oil to the r ubber g ask et on the re placement ﬁlter .

7. Install the re placement oil ﬁlter to the ﬁlter adapter . T ur n the oil ﬁlter cloc kwise until the r ubber g ask et contacts the ﬁlter adapter , then tighten the ﬁlter an additional 1/2 tur n.

• Stor e fuel in a clean, safety-appr o v ed container and k eep the cap in place.

Checking the Fuel Lines and Connections

Chec k the fuel lines and connections ev er y 400 hours or yearly , whic hev er comes ﬁrst. Inspect them for deterioration, damag e , or loose connections . Tighten any loose connections and contact y our A uthorized Ser vice Dealer for assistance in ﬁxing damag ed fuel lines .

Draining the Fuel Filter/Water Separator

Drain w ater or other contaminants from the fuel ﬁlter/w ater se parator ( Figure 37 ) daily .

8. Fill the crankcase with the proper type of new oil; refer to Changing the Oil.

Page 35

Electrical System Maintenance

Servicing the Battery

Warning

CALIFORNIA

Pr oposition 65 W ar ning

Figure 37

1. Fuel lter canister/water separator

1. Locate the fuel ﬁlter on the right side of the engine( Figure 37 ) and place a clean container under it.

2. Loosen the drain plug on the bottom of the ﬁlter canister and allo w it to drain.

3. W hen ﬁnished, tighten the drain plug .

2. Drain plug

Replacing the Fuel Filter Canister

R e place the ﬁlter canister after ev er y 400 hours of operation.

1. Clean the area where the ﬁlter canister mounts ( Figure 37 ).

2. R emo v e the ﬁlter canister and clean the mounting surface ( Figure 37 ).

Important: T he f ollo wing pr ocedur es appl y when ser vicing a (dr y) batter y that has r eplaced the original batter y . T he original (w et) batter y does not r equir e ser vice.

Chec k the electrolyte lev el in the batter y ev er y 100 hours . Alw a ys k ee p the batter y clean and fully c harg ed. Use a paper to w el to clean the batter y case . If the batter y ter minals are cor roded, clean them with a solution of four par ts w ater and one par t baking soda. Apply a light coating of g rease to the batter y ter minals to reduce cor rosion.

V oltag e: 12 v , 450 Cold Cranking Amps

Checking the Electrolyte Level

1. Stop the engine and remo v e the k ey .

2. Look at the side of the batter y . T he electrolyte m ust be up to the Upper line ( Figure 38 ). Do not allo w the electrolyte to fall belo w the Lo w er line ( Figure 38 ).

3. Lubricate the g ask et on the new ﬁlter canister with clean oil.

4. Install the ﬁlter canister b y hand until the g ask et contacts the mounting surface , then rotate it an additional 1/2 tur n ( Figure 37 ).

Draining the Fuel Tank

Ha v e an A uthorized Ser vice Dealer drain and clean the fuel tank ev er y 2 years .

Page 36

G003794

Important: Do not o v erﬁll the batter y

G003792

because electr ol yte (sulfuric acid) can cause sev er e cor r osion and dama ge to the chassis.

5. W ait ﬁv e to ten min utes after ﬁlling the batter y cells . Add distilled w ater , if necessar y , until the electrolyte lev el is up to the Upper line ( Figure 38 ) on the batter y case .

6. Install the batter y ﬁller caps .

Figure 38

1. Filler caps 3. Lower line

2. Upper line

3. If the electrolyte is lo w , add the required amount of distilled w ater; refer to Adding W ater to the Batter y .

Adding Water to the Battery

T he best time to add distilled w ater to the batter y is just before y ou operate the traction unit. T his lets the w ater mix thoroughly with the electrolyte solution.

Batter y electr ol yte contains sulfuric acid which is a deadl y poison and causes sev er e bur ns.

• Do not drink electr ol yte and a v oid contact with skin, ey es or clothing . W ear safety g lasses to shield y our ey es and r ub ber g lo v es to pr otect y our hands.

Charging the Battery

Charging the batter y pr oduces gasses that can explode.

Nev er smok e near the batter y and k eep spar ks and ﬂames a w ay fr om batter y .

Important: Al w ays k eep the batter y full y charged (1.265 speciﬁc g ra vity). T his is especiall y impor tant to pr ev ent batter y dama ge when the temperatur e is belo w 32°F (0°C).

1. Chec k the electrolyte lev el; refer to Chec king Electrolyte Lev el.

2. Mak e sure the ﬁller caps are installed in the batter y .

3. Charg e the batter y for 10 to 15 min utes at 25 to 30 amps or 30 min utes at 4 to 6 amps ( Figure 39 ). Do not o v erc harg e the batter y .

• Fill the batter y wher e clean w ater is al w ays a v aila ble f or ﬂushing the skin.

1. R emo v e the batter y from the traction unit.

Important: Nev er ﬁll the batter y with distilled w ater while the batter y is installed in the traction unit. Electr ol yte could be spilled on other par ts and cause cor r osion.

2. Clean the top of the batter y with a paper to w el.

( Figure 38 ).

4. Slo wly pour distilled w ater into eac h batter y cell until the electrolyte lev el is up to the Upper

3. R emo v e the ﬁller caps from the batter y

line ( Figure 38 ) on the batter y case .

1. Positive battery post

2. Negative battery post

4. W hen the batter y is fully c harg ed, unplug the c harg er from the electrical outlet, then

Figure 39

3. Red (+) charger lead

4. Black (-) charger lead

Page 37

disconnect the c harg er leads from the batter y posts ( Figure 39 ).

5. R e place the batter y co v er .

Servicing the Fuses

T he electrical system is protected b y fuses . It requires no maintenance; ho w ev er , if a fuse blo ws , c hec k the component/circuit for a malfunction or a shor t. Figure 40 illustrates the fuse bloc k and identiﬁes the fuse positions .

Figure 41

1. Prop-rod

2. Hairpin cotter

4. R emo v e the 4 screws securing the fuse panel and then pull the panel out and up to remo v e it ( Figure 42 ).

Figure 40

1. 30 amp. fuse—main circuit 3. 10 amp fuse—control

2. Empty

panel/relay

4. Open position for optional accessories

Note: If the traction unit will not star t, either the main circuit or control panel/rela y fuse could be blo wn.

T o access the fuses , y ou m ust remo v e the fuse panel, as follo ws:

1. Stop the engine and remo v e the k ey .

2. Raise the hood.

3. Pull the hair pin cotter from the end of the hood prop-rod and slide the prop rod out of the retaining brac k ets ( Figure 41 ).

Figure 42

1. Fuse panel

2. Screw

5. Chec k the fuses .

6. Install the fuse panel using the 4 screws remo v ed previously .

7. Install the prop-rod into the retaining brac k ets and secure it with the hair pin cotter .

8. Close the hood.

Drive System Maintenance

Servicing the Tracks

Cleaning the Tracks

Chec k the trac ks for ex cessi v e w ear and clean them periodically . If the trac ks are w or n, re place them.

Page 38

1. With a buc k et on the loader ar ms , lo w er the buc k et to the g round so that the front of the traction unit lifts off of the g round a few inc hes .

2. Stop the engine , and remo v e the k ey .

3. Using a w ater hose or pressure w asher , remo v e dir t from eac h trac k system.

Important: Ensur e that y ou use high-pr essur e w ater to w ash onl y the track ar ea. Do not use a high-pr essur e w asher to clean the r est of the traction unit. Do not use high pr essur e w ater betw een the dri v e spr ock et and the traction unit or y ou may dama ge the motor seals. High-pr essur e w ashing can dama ge the electrical system and h y draulic v alv es or deplete g r ease.

Figure 44

1. 2-3/4 inches (7 cm)

Important: Ensur e that y ou full y clean the r oad wheels, the tension wheel, and the dri v e spr ock et ( Figur e 43 ). T he r oad wheels should r otate fr eel y when clean.

Figure 43

1. Track 3. Road wheels

2. Drive sprocket 4. Tension wheel

1. Lo w er the loader ar ms , stop the engine , and remo v e the k ey .

2. Lift/suppor t the side of the unit to be w ork ed on so that the trac k is off of the g round.

3. R emo v e the loc king bolt and n ut ( Figure 45 ).

Figure 45

1. Locking bolt 3. Tension tube

2. Tensioning screw

4. Tension wheel

Adjusting the Track Tension

Chec k and adjust the trac k tension after the ﬁrst 50 operating hours and ev er y 100 operating hours thereafter . T here should be 2-3/4 inc hes (7 cm) betw een the tension n ut and the bac k of the tension tube ( Figure 44 ). If not, adjust the trac k tension using the follo wing procedure:

4. Using a 1/2 inc h dri v e soc k et ( Figure 46 ), tur n the tensioning screw counter -cloc kwise until the distance betw een the tension n ut and the bac k of the tension tube ( Figure 44 ) is 2-3/4 inc hes (7 cm).

5. Align the closest notc h in the tension screw to the loc king bolt hole and secure the screw with the loc king bolt and n ut ( Figure 45 ).

6. Lo w er the traction unit to the g round.

Page 39

Replacing the Tracks (Model 22319)

W hen the trac ks are badly w or n, re place them.

1. Lo w er the loader ar ms , stop the engine , and remo v e the k ey .

2. Lift/suppor t the side of the unit to be w ork ed on so that the trac k is 3 to 4 inc hes (7.6 to 10 cm) off of the g round.

3. R emo v e the loc king bolt and n ut ( Figure 45 ).

4. Using a 1/2 inc h dri v e soc k et, release the dri v e tension b y tur ning the tensioning screw cloc kwise ( Figure 45 and Figure 46 ).

9. Push the trac k under and betw een the road wheels ( Figure 46 ).

10. Star ting at the bottom of the tension wheel, install the trac k around the wheel b y rotating the trac k rearw ard while pushing the lugs into the wheel.

11. T ur n the tensioning screw counter -cloc kwise until the distance betw een the tension n ut and the bac k of the fork tube ( Figure 44 ) is 2-3/4 inc hes (7 cm).

12. Align the closest notc h in the tension screw to the loc king bolt hole and secure the screw with the loc king bolt and n ut.

13. Lo w er the traction unit to the g round.

14. R e peat ste ps 2 through 13 to re place the other trac k.

Replacing the Tracks (Model 22320)

W hen the trac ks are badly w or n, re place them.

Figure 46

1. Track 5. Track lug

2. 1/2 inch socket 6. Drive sprocket

3. Tension wheel 7. Sprocket spacer

4. Fork tube 8. Road wheels

5. Push the tension wheel to w ard the rear of the unit to mo v e the fork tube ag ainst the frame ( Figure 46 ). (If it does not touc h the frame , contin ue tur ning the tensioning screw until it does .)

6. Begin remo ving the trac k at the top of the tension wheel, peeling it off of the wheel while rotating the trac k forw ards .

1. Lo w er the loader ar ms , stop the engine , and remo v e the k ey .

2. Lift/suppor t the side of the unit to be w ork ed on so that the trac k is 3 to 4 inc hes (7.6 to 10 cm) off of the g round.

3. R emo v e the loc king bolt and n ut ( Figure 45 ).

4. Using a 1/2 inc h dri v e soc k et, release the dri v e tension b y tur ning the tensioning screw cloc kwise ( Figure 45 and Figure 47 ).

7. W hen the trac k is off of the tension wheel, remo v e it from the dri v e sproc k et and road wheels ( Figure 46 ).

8. Beginning at the dri v e sproc k et, coil the new trac k around the sproc k et, ensuring that the lugs on the trac k ﬁt betw een the spacers on the sproc k et ( Figure 46 ).

Page 40

Figure 47

1. Track 6. Track lug

2. 1/2 inch socket 7. Drive sprocket

3. Tension wheel nut 8. Sprocket spacer

4. Outer tension wheel 9. Road wheels

5. Fork tube 10. Inner tension wheel

5. Push the tension wheel to w ard the rear of the unit to mo v e the tension tube ag ainst the frame ( Figure 47 ). (If it does not touc h the frame , contin ue tur ning the tensioning screw until it does .)

16. T or que the n ut to 300 ft-lb (407 N ⋅ m).

17. T ur n the tensioning screw counter -cloc kwise until the distance betw een the tension n ut and the bac k of the tension tube ( Figure 44 ) is 2-3/4 inc hes (7 cm).

18. Align the closest notc h in the tension screw to the loc king bolt hole and secure the screw with the loc king bolt and n ut.

19. R e peat ste ps 2 through 18 to re place the other trac k.

20. Lo w er the traction unit to the g round.

Maintaining the Road Wheels

Chec k and g rease the road wheels ev er y 250 operating hours or yearly .

1. R emo v e the trac ks; refer to R e placing the T rac ks .

2. R emo v e the 4 bolts securing eac h lo w er trac k guide whic h contains the road wheels , and remo v e them ( Figure 48 ).

6. R emo v e the n ut securing the outer tension wheel and remo v e the wheel ( Figure 47 ).

7. R emo v e the trac k ( Figure 47 ).

8. R emo v e the n ut securing the inner tension wheel and remo v e the wheel ( Figure 47 ).

9. Pull the 4 larg e w ashers out of the 2 wheels , 1 on eac h side of eac h wheel.

10. Clean the old g rease and dir t out of the area betw een where the w ashers w ere installed and the bearings inside the wheels , then ﬁll this area on eac h side of eac h wheel with g rease .

11. Install the larg e w ashers on the wheels o v er the g rease .

12. Install the inner tension wheel and secure it with the n ut remo v ed previously ( Figure 47 ).

13. T or que the n ut to 300 ft-lb (407 N ⋅ m).

14. Install the new trac k, ensuring that the lugs in the trac k ﬁt betw een the spacers in the middle of the dri v e sproc k et ( Figure 47 ).

15. Install the outer tension wheel and secure it with the n ut remo v ed previously ( Figure 47 ).

Figure 48

1. Road wheels

2. Lower track guide

3. Track guide bolts (only two shown)

3. R emo v e the snap ring and cap from a road wheel ( Figure 49 ).

Page 41

Figure 49

1. Road wheel 4. Road wheel cap

2. Gasket

3. Bolt 6. Add grease under the cap

5. Snap ring

4. Chec k the g rease under the cap and around the g ask et ( Figure 49 ). If it is dir ty , g ritty , or de pleted, clean out all of the g rease , re place the g ask et, and add new g rease .

Cooling System Maintenance

Servicing the Cooling System

If the engine has been r unning , the pr essuriz ed, hot coolant can escape and cause sev er e bur ns.

• Do not touch radiator and sur r ounding par ts that ar e hot.

5. Ensure that the road wheel tur ns smoothly on the bearing . If it is frozen, re place the road wheel as described in the Road W heel Kit Installation Instr uctions or contact y our A uthorized Ser vice Dealer for re pair .

6. Place the g reased road wheel cap o v er the bolt head ( Figure 49 ).

7. Secure the road wheel cap with the snap ring ( Figure 49 ).

8. R e peat ste ps 3 through 7 for the other road wheels .

9. Install eac h trac k guide to the traction unit frame using the fasteners y ou remo v ed previously . T or que the bolts to 67 to 83 ft-lb (91 to 112 N ⋅ m).

10. Install the trac ks; refer to R e placing the T rac ks .

• Use a ra g when opening the radiator cap , and open the cap slo wl y to allo w steam to escape.

R otating shaft and f an can cause per sonal injur y .

• Do not operate the machine without the co v er s in place.

• K eep ﬁnger s, hands and clothing clear of r otating f an and dri v e shaft.

• Shut of f the engine and r emo v e the ignition k ey bef or e perf or ming maintenance.

Sw allo wing engine coolant can cause poisoning .

• Do not s w allo w engine coolant.

• K eep out of r each fr om childr en and pets.

Cleaning Radiator Screen

Before eac h use , c hec k and clean the radiator screen, located behind the g rill at the front of the traction unit. R emo v e any build-up of g rass ,

Page 42

dir t or other debris from the radiator screen with compressed air .

Changing the Engine Coolant

Ha v e an A uthorized Ser vice Dealer c hang e the engine coolant yearly .

If y ou need to add engine coolant, refer to Chec king, Adding, and Bleeding the Engine Coolant in Operation , pag e 21 .

Belt Maintenance

Checking the Condition of the Hydraulic Pump Belt

Chec k the condition of the h y draulic pump belt ( Figure 50 ) yearly . Ha v e an A uthorized Ser vice Dealer re place it if it becomes damag ed or w or n.

Controls System Maintenance

T he factor y adjusts the controls before shipping the traction unit. Ho w ev er , after many hours of use , y ou ma y need to adjust the traction control alignment, the neutral position of the traction control, and the trac king of the traction control in the full forw ard position.

Important: T o adjust the contr ols pr oper l y , complete each pr ocedur e in the order listed.

Adjusting the Traction Control Alignment

If the traction control bar does not rest ﬂush and square with the reference bar when in the full bac kw ard position, immediately complete the follo wing procedure:

1. P ark the traction unit on a ﬂat surface and lo w er the loader ar m.

Figure 50

1. Hydraulic Pump Belt

Checking the Alternator/Fan Belt Tension

Chec k and adjust the tension of the alter nator/fan belt ev er y 100 operating hours . R e place it ev er y 500 operating hours . R efer to the Engine Operator’ s Manual for instr uctions .

2. Stop the engine and remo v e the k ey .

3. Pull straight bac k on the traction control so the front of the control contacts the reference bar ( Figure 51 ).

Figure 51

1. Front of the control, out of alignment

4. If the front of the traction control does not rest square and ﬂush with the reference bar , loosen the ﬂang e n ut and bolt in the stem of the traction control ( Figure 52 ).

2. Reference bar

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Figure 52

1. Traction control 2. Stem , bolt and nut

5. Adjust the traction control so that it rests ﬂush ag ainst the reference bar when it is pulled straight bac k ( Figure 52 and Figure 53 ).

Figure 53

6. Tighten the ﬂang e n ut and bolt in the traction control stem.

Adjusting the Traction Control Neutral Position

If the traction unit cree ps forw ard or bac kw ard when the traction control is in neutral and the unit is w ar m, immediately complete the follo wing procedure:

1. Lift/suppor t the traction unit so that both trac ks are off of the g round.

2. Open the rear access co v er .

3. Loosen the jam n uts on the traction rods , under the control panel ( Figure 54 ).

Figure 54

1. Traction rod

2. Jam nut

4. Star t the traction unit and set the throttle to about 1/3 open position.

W hen the traction unit is r unning , y ou could be caught and injur ed in mo ving par ts or bur ned on hot surf aces.

Stay a w ay fr om pinch points, mo ving par ts, and hot surf aces when adjusting the r unning traction unit.

5. If the left trac k mo v es , lengthen or shor ten the right traction rod until the trac k stops mo ving .

6. If the right trac k mo v es , lengthen or shor ten the left traction rod until the trac k stops mo ving .

7. Tighten the jam n uts .

8. Close the rear access co v er .

9. Stop the engine and lo w er the traction unit to the g round.

10. Dri v e the traction unit in full rev erse , c hec king to see if the unit trac ks straight. If it does not, note the direction the traction unit v eers . R e peat the adjustment previously described so that it trac ks straight in rev erse .

Adjusting the Tracking of the Traction Control, Full Forward Position

If the traction unit does not dri v e straight when y ou hold the traction control ag ainst the reference bar , complete the follo wing procedure:

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1. Dri v e the traction unit with the traction control ag ainst the reference bar , noting whic h direction the traction unit v eers .

2. R elease the traction control.

3. If the traction unit v eers to the left , loosen the right jam n ut and adjust the trac king set screw on the front of the traction control ( Figure 55 ).

4. If the traction unit v eers to the right , loosen the left jam n ut and adjust the trac king set screw on the front of the traction control ( Figure 55 ).

1. P osition traction unit on a lev el surface .

2. Lo w er the loader ar ms , stop the engine , and remo v e the k ey .

3. Open the rear access co v er .

4. Place a drain pan under the ﬁlter ( Figure 56 ).

Figure 56

1. Hydraulic lter

5. R emo v e the old ﬁlter ( Figure 56 ) and wipe the surface of the ﬁlter adapter g ask et clean.

Figure 55

1. Set screw 3. Stop

2. Jam nut

5. R e peat ste ps 1 through 4 until the traction unit dri v es straight in the full forw ard position.

Important: Ensur e the tracking set scr ews touch the stops in the full f orw ard position to a v oid o v er str oking the h y draulic pumps.

Hydraulic System Maintenance

Replacing the Hydraulic Filter

Important: Do not substitute an automoti v e

oil ﬁlter or sev er e h y draulic system dama ge may r esult.

Chang e the h y draulic ﬁlter :

6. Apply a thin coat h y draulic ﬂuid to the r ubber g ask et on the re placement ﬁlter .

7. Install the re placement h y draulic ﬁlter onto the ﬁlter adapter ( Figure 56 ). Tighten it cloc kwise until the r ubber g ask et contacts the ﬁlter adapter , then tighten the ﬁlter an additional 3/4 tur n.

8. Clean up any spilled ﬂuid.

9. Star t the engine and let it r un for about tw o min utes to purg e air from the system.

10. Stop the engine and c hec k for leaks .

• K eep y our body and hands a w ay fr om pin hole leaks or nozzles that eject high pr essur e h y draulic ﬂuid.

• After the ﬁrst 8 operating hours

• After ev er y 200 operating hours

• Use cardboard or paper to ﬁnd h y draulic leaks, nev er use y our hands.

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11. Chec k the ﬂuid lev el in the h y draulic tank (refer to Chec king the Hy draulic Fluid in Operation , pag e 21 ) and add ﬂuid to raise the lev el to mark on dipstic k. Do not o v er ﬁll the tank.

12. Close the rear access co v er .

Changing the Hydraulic Fluid

Chang e the h y draulic ﬂuid after ev er y 400 operating hours or yearly .

1. P osition the traction unit on a lev el surface .

2. Open the hood.

3. Install the cylinder loc k, stop the engine , and remo v e the k ey .

4. Allo w the traction unit to cool completely .

5. R emo v e the h y draulic tank cap and dipstic k ( Figure 57 ).

Note: T he ﬁller cap is behind the front screen. If y ou w ant to impro v e y our access to it, remo v e the screen.

Figure 58

1. Drain plug

7. R emo v e the drain plug and allo w the oil to drain into the pan ( Figure 58 ).

8. W hen ﬁnished, install and tighten the drain plug .

Note: Dispose of the used oil at a cer tiﬁed recycling center .

Figure 57

1. Filler neck 2. Dip stick

6. Place a larg e drain pain (capable of holding 15 US g allons) under the drain plug on the front of the traction unit ( Figure 58 ).

9. Fill the h y draulic tank with appro ximately 12 US g allons (45.4 l) of 10W -30 or 15W -40 deterg ent, diesel engine oil (API ser vice CH-4 or higher); refer to Chec king Hy draulic Fluid in Operation , pag e 21 .

10. Star t the engine and let it r un for a few min utes .

11. Stop the engine .

12. Chec k the h y draulic ﬂuid lev el and top it off if necessar y; refer to Chec king Hy draulic Fluid in Operation , pag e 21 .

13. Close the hood.

Checking the Hydraulic Lines

After ev er y 100 operating hours , c hec k the h y draulic lines and hoses for leaks , loose ﬁttings , kink ed lines , loose mounting suppor ts , w ear , w eather , and c hemical deterioration. R e place all mo ving h y draulic hoses ev er y 1500 hours or 2 years , whic h ev er comes ﬁrst. Mak e necessar y re pairs before operating .

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Cleaning the Chassis

• K eep y our body and hands a w ay fr om pin hole leaks or nozzles that eject high pr essur e h y draulic ﬂuid.

• Use cardboard or paper to ﬁnd h y draulic leaks, nev er use y our hands.

Cleaning

Removing Debris from the Traction Unit

Important: Operating the engine with

block ed scr eens and/or cooling shr ouds r emo v ed, will r esult in engine dama ge fr om o v erheating .

Ov er time , the c hassis under the engine collects dir t and debris that m ust be remo v ed. Using a ﬂashlight, open the hood and inspect the area under the engine on a regular basis . W hen the debris is 1 to 2 inc hes dee p , ha v e an A uthorized Ser vice Dealer remo v e the rear of the traction unit, fuel tank, and batter y and ﬂush the c hassis clean.

1. P ark the traction unit on a lev el surface , lo w er the loader ar ms , and stop the engine .

2. R emo v e the k ey and allo w the engine to cool.

3. Open the hood.

4. Clean any debris from the front and side screens .

5. Wipe a w a y debris from the air cleaner .

6. Clean any debris build-up on the engine and in the oil cooler ﬁns with a br ush or blo w er .

Important: It is pr efera ble to blo w dir t out, rather than w ashing it out. If w ater is used, k eep it a w ay fr om electrical items and h y draulic v alv es. Do not use a high-pr essur e w asher . High-pr essur e w ashing can dama ge the electrical system and h y draulic v alv es or deplete g r ease.

7. Clean debris from the hood opening, m ufﬂer , and heat shields .

8. Close the hood.

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Storage

1. Lo w er the loader ar ms , stop the engine , and remo v e the k ey .

2. R emo v e dir t and g rime from the entire traction unit.

Important: Y ou can w ash the traction unit with mild detergent and w ater . Do not pr essur e w ash the traction unit. A v oid ex cessi v e use of w ater , especiall y near the contr ol panel, engine, h y draulic pumps, and motor s.

3. Ser vice the air cleaner; refer to Ser vicing the Air Cleaner .

4. Grease the traction unit; refer to Greasing the T raction Unit.

5. Chang e the crankcase oil; refer to Ser vicing the Engine Oil.

6. Charg e the batter y; refer to Ser vicing the Batter y .

7. Chec k and adjust the trac k tension; refer to Adjusting the T rac k T ension.

8. Chec k and tighten all bolts , n uts , and screws . R e pair or re place any par t that is damag ed.

9. P aint all scratc hed or bare metal surfaces . P aint is a v ailable from y our A uthorized Ser vice Dealer .

10. Store the traction unit in a clean, dr y g arag e or storag e area. R emo v e the k ey from the ignition switc h and k ee p it in a memorable place .

11. Co v er the traction unit to protect it and k ee p it clean.

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Troubleshooting

Problem

The starter does not crank

Possible Cause Corrective Action

1. The electrical connections are corroded or loose.

2. A fuse is blown or loose. 2. Correct or replace the

3. The battery is discharged.

4. The relay or switch is damaged.

5. A damaged starter or starter solenoid.

6. Seized internal engine components.

1. Check the electrical connections for good contact.

fuse.

3. Charge the battery or replace it.

4. Contact your Authorized Service Dealer.

5. Contact your Authorized Service Dealer.

6. Contact your Authorized Service Dealer.

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Problem

Possible Cause Corrective Action

The engine cranks, but will not start.

1. Incorrect starting procedure.

1. Refer to Starting and Stopping the Engine

2. The fuel tank is empty. 2. Fill with fresh fuel.

3. The fuel shut-off valve is closed.

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

3. Open the fuel shut-off valve.

4. Drain and ush the fuel system; add fresh fuel.

fuel system.

5. Clogged fuel line. 5. Clean or replace.

6. There is air in the fuel. 6. Bleed the nozzles and check for air leaks at the fuel hose connections and ttings between the fuel tank and engine.

7. Inoperative glow plugs. 7. Check the fuse, glow plugs, and wiring.

8. Slow cranking speed. 8. Check the battery, oil viscosity, and starting motor (contact your Authorized Service Dealer).

9. The air cleaner lters are

9. Service the air lters.

dirty.

10. The fuel lter is clogged. 10. Replace the fuel lter.

11. Improper fuel grade for

cold weather use.

11. Drain the fuel system and replace the fuel lter. Add fresh fuel of proper grade for ambient temperature conditions. You may need to warm the entire traction unit.

12. Low compression.

12. Contact your Authorized Service Dealer.

13. The injection nozzles are damaged.

14. The injection pump timing is incorrect.

15. The injection pump is broken.

16. The ETR solenoid is broken.

13. Contact your Authorized Service Dealer.

14. Contact your Authorized Service Dealer.

15. Contact your Authorized Service Dealer.

16. Contact your Authorized Service Dealer.

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Problem

Possible Cause Corrective Action

The engine starts, but does not keep running.

1. The fuel tank vent is restricted.

1. Loosen the cap. If the engine runs with the cap loosened, replace the cap.

2. Dirt or water is in the fuel system.

2. Drain and ush the fuel system; add fresh fuel.

3. The fuel lter is clogged. 3. Replace the fuel lter.

4. There is air in the fuel. 4. Bleed the nozzles and check for air leaks at fuel hose connections and ttings between the fuel tank and engine.

5. Improper fuel grade for

cold weather use.

5. Drain the fuel system and replace the fuel lter. Add fresh fuel of proper grade for ambient temperature conditions.

6. The spark arrestor screen is clogged.

7. The fuel pump is damaged.

6. Clean or replace the spark arrestor screen.

7. Contact your Authorized Service Dealer.

The engine runs, but knocks or misses.

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

1. Drain and ush the fuel system; add fresh fuel.

fuel system.

2. Engine overheating. 2. Refer to Engine Overheats.

3. There is air in the fuel. 3. Bleed nozzles and check for air leaks at the fuel hose connections and ttings between the fuel tank and engine.

4. The injection nozzles are

damaged.

5. Low compression

4. Contact your Authorized Service Dealer.

5. Contact your Authorized Service Dealer.

6. The injection pump timing is incorrect.

7. Excessive carbon build-up.

6. Contact your Authorized Service Dealer.

7. Contact your Authorized Service Dealer.

8. Internal wear or damage. 8. Contact your Authorized Service Dealer.

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Problem

Possible Cause Corrective Action

The engine will not idle.

The engine overheats.

1. The fuel tank vent is restricted.

1. Loosen the cap. If the engine runs with the cap loosened, replace the cap.

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

2. Drain and ush the fuel system; add fresh fuel.

fuel system.

3. The air cleaner lters are

3. Service the air lters.

dirty.

4. The fuel lter is clogged. 4. Replace the fuel lter.

5. There is air in the fuel. 5. Bleed the nozzles and check for air leaks at fuel hose connections and ttings between the fuel tank and engine.

6. The fuel pump is

damaged.

7. Low compression

6. Contact your Authorized Service Dealer.

7. Contact your Authorized Service Dealer.

1. More coolant is needed. 1. Check and add coolant.

2. Restricted air ow to the radiator.

2. Inspect and clean the radiator screen with every use.

3. The crankcase oil level is incorrect.

3. Fill or drain to the full mark.

4. Excessive loading. 4. Reduce load; use lower ground speed.

5. Incorrect fuel is in the

fuel system.

6. The thermostat is

damaged.

7. The fan belt is loose or

broken.

8. Injection timing is

incorrect.

9. Coolant pump is

damaged.

5. Drain and ush the fuel system; add fresh fuel.

6. Contact your Authorized Service Dealer.

7. Contact your Authorized Service Dealer.

8. Contact your Authorized Service Dealer.

9. Contact your Authorized Service Dealer.

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Problem

Possible Cause Corrective Action

The engine loses power.

1. The engine load is

1. Reduce ground speed.

excessive.

2. The crankcase oil level is incorrect.

3. The air cleaner lters are

2. Fill or drain to the full mark.

3. Service the air lters.

dirty.

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

4. Drain and ush the fuel system; add fresh fuel.

fuel system.

5. Engine overheating. 5. Refer to Engine Overheats.

6. The spark arrestor screen

is clogged.

6. Clean or replace the spark arrestor screen.

7. There is air in the fuel. 7. Bleed the nozzles and check for air leaks at fuel hose connections and ttings between the fuel tank and engine.

8. Low compression

8. Contact your Authorized Service Dealer.

9. The fuel tank vent is restricted.

10. The injection pump timing is incorrect.

11. The injection pump is damaged.

9. Contact your Authorized Service Dealer.

10. Contact your Authorized Service Dealer.

11. Contact your Authorized Service Dealer.

Excessive black smoke from exhaust.

1. Excessive loading. 1. Reduce load; use lower ground speed.

2. The air cleaner lters are

2. Service the air lters.

dirty.

3. Incorrect fuel is in the

fuel system.

3. Drain the fuel system and rell with specied fuel.

4. The injection pump timing is incorrect.

5. The injection pump is damaged.

6. The injection nozzles are damaged.

4. Contact your Authorized Service Dealer.

5. Contact your Authorized Service Dealer.

6. Contact your Authorized Service Dealer.

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Problem

Possible Cause Corrective Action

Excessive white smoke from exhaust.

Traction unit does not drive.

1. The key was turned to the start position before the glow plug light turned off.

1. Turn the key to the run position and allow the glow plug light to turn off before starting the engine.

2. The engine temperature

2. Check the thermostat.

is low.

3. The glow plugs are inoperative.

4. The injection pump timing is incorrect.

5. The injection nozzles are damaged.

6. Low compression

3. Check the fuse, glow plugs and wiring.

4. Contact your Authorized Service Dealer.

5. Contact your Authorized Service Dealer.

6. Contact your Authorized Service Dealer.

1. The parking brake is on. 1. Release the parking brake.

2. Hydraulic uid level low. 2. Add hydraulic uid to the reservoir.

3. The tow valves are open. 3. Close the tow valves.

4. Flow divider valve lever

is in 9 o’clock position.

5. Traction pump drive

coupler is loose or

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

5. Contact your Authorized Service Dealer.

broken.

6. Pump and/or wheel motor is damaged.

7. Control valve is damaged.

6. Contact your Authorized Service Dealer.

7. Contact your Authorized Service Dealer.

8. Relief valve is damaged. 8. Contact your Authorized Service Dealer.

Page 54

Schematics

Electrical Schematic (Rev. A)

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Hydraulic Schematic (Rev. A)

Page 56