TORO MBTX2500 Operators Manual

FormNo.3407-540RevB
MBTX2500TrackedMudBuggy
ModelNo.68138—SerialNo.400000000andUp ModelNo.68138G—SerialNo.400000000andUp
Registeratwww.T oro.com. OriginalInstructions(EN)
*3407-540*B
WARNING
CALIFORNIA
Proposition65Warning
Thisproductcontainsachemicalorchemicals
knowntotheStateofCaliforniatocausecancer,
birthdefects,orreproductiveharm.
Theengineexhaustfromthisproduct
containschemicalsknowntotheStateof
Californiatocausecancer,birthdefects,
orotherreproductiveharm.
Becauseinsomeareastherearelocal,state,orfederal regulationsrequiringthatasparkarresterbeusedonthe engineofthismachine,asparkarresterisavailableas anoption.Ifyourequireasparkarrester,contactyour AuthorizedToroServiceDealer.
GenuineT orosparkarrestersareapprovedbytheUSDA ForestryService.
CustomerServiceandhavethemodelandserialnumbersof yourproductready.Figure1identiesthelocationofthe modelandserialnumbersontheproduct.Writethenumbers inthespaceprovided.
g185889
Figure1
1.Modelandserialnumberlocation
ItisaviolationofCaliforniaPublicResourceCode Section4442or4443touseoroperatetheengineonany forest-covered,brush-covered,orgrass-coveredlandunless theengineisequippedwithasparkarrester,asdenedin Section4442,maintainedineffectiveworkingorderorthe engineisconstructed,equipped,andmaintainedforthe preventionofre.
ThissparkignitionsystemcomplieswithCanadianICES-002
Theenclosedengineowner'smanualissuppliedfor informationregardingtheUSEnvironmentalProtection Agency(EPA)andtheCaliforniaEmissionControl Regulationofemissionsystems,maintenance,and warranty.Replacementsmaybeorderedthroughtheengine manufacturer.
Introduction
Thismachineisintendedtobeusedbyprofessional,hired operatorsincommercialapplications.Thismachineisa stable,reliable,andproductivemachineforcarryingand movingmaterialsforanyjobsite.Itisprimarilydesignedto moveconcrete,mortar,gravel,dirt,ordebrisaroundjobsites.
ModelNo.
SerialNo.
Thismanualidentiespotentialhazardsandhassafety messagesidentiedbythesafety-alertsymbol(Figure2), whichsignalsahazardthatmaycauseseriousinjuryordeath ifyoudonotfollowtherecommendedprecautions.
g000502
Figure2
1.Safety-alertsymbol
Thismanualuses2wordstohighlightinformation. Importantcallsattentiontospecialmechanicalinformation andNoteemphasizesgeneralinformationworthyofspecial attention.
Readthisinformationcarefullytolearnhowtooperateand maintainyourproductproperlyandtoavoidinjuryand productdamage.Youareresponsibleforoperatingthe productproperlyandsafely.
YoumaycontactTorodirectlyatwww .Toro.comforproduct safetyandoperationtrainingmaterials,accessoryinformation, helpndingadealer,ortoregisteryourproduct.
Wheneveryouneedservice,genuineToroparts,oradditional information,contactanAuthorizedServiceDealerorToro
©2017—TheToro®Company 8111LyndaleAvenueSouth Bloomington,MN55420
Contactusatwww.Toro.com.
2
PrintedintheUSA
AllRightsReserved
Contents
Safety...........................................................................4
SafeOperatingPractices...........................................4
SafetyandInstructionalDecals.................................6
ProductOverview..........................................................9
Controls................................................................9
Specications.........................................................9
Operation....................................................................10
ThinkSafetyFirst...................................................10
AddingFuel...........................................................10
PerformingDailyMaintenance.................................11
OperatingtheParkingBrake....................................12
OperatingtheThrottle............................................12
OperatingtheChoke..............................................12
StartingtheEngine.................................................13
ShuttingOfftheEngine..........................................13
OperatingtheHopper.............................................13
RemovingDebrisfromtheMachine..........................14
LoweringtheHopperwithoutPower.........................14
TransportingtheMachine........................................14
LiftingtheMachine................................................15
Maintenance.................................................................16
RecommendedMaintenanceSchedule(s)......................16
Pre-MaintenanceProcedures......................................17
ReleasingtheCushionforRearAccess.......................17
UsingtheCylinderLock..........................................17
Lubrication...............................................................18
GreasingtheMachine.............................................18
EngineMaintenance..................................................18
ServicingtheAirCleaner.........................................18
CheckingtheEngine-OilLevel.................................19
ChangingtheEngineOilandFilter...........................20
ServicingtheSparkPlugs.........................................21
CleaningtheBlowerHousing...................................22
FuelSystemMaintenance...........................................22
ReplacingtheFuelFilter..........................................22
DrainingtheFuelTank...........................................23
RemovingtheFuelTank..........................................23
ElectricalSystemMaintenance....................................24
ServicingtheBattery...............................................24
ServicingtheFuses.................................................25
DriveSystemMaintenance.........................................26
ServicingtheTracks................................................26
ServicingtheDriveBelt...........................................27
ControlsSystemMaintenance.....................................28
AdjustingtheMotion-ControlLevers........................28
BrakeMaintenance.................................................29
HydraulicSystemMaintenance....................................30
ServicingtheHydraulicDriveSystem........................30
ServicingtheHydraulicLiftSystem...........................32
CheckingtheHydraulicLines...................................34
Cleaning...................................................................35
RemovingDebrisfromtheMachine..........................35
Storage........................................................................35
3
Safety
Improperuseormaintenanceofthemachinecanresult ininjury.T oreducethepotentialforinjury,complywith thesesafetyinstructionsandalwayspayattentiontothe safety-alertsymbol,whichmeans or
Danger
complywiththeinstructionmayresultinpersonalinjury ordeath.
—personalsafetyinstruction.Failureto

SafeOperatingPractices

WARNING
Engineexhaustcontainscarbonmonoxide,an odorless,deadlypoisonthatcankillyou.
Donotruntheengineindoorsorinanenclosed area.
Training
ReadtheOperator'sManualandothertrainingmaterial.If
theoperator(s)ormechanic(s)cannotreadEnglish,itis theowner'sresponsibilitytoexplainthismaterialtothem.
Becomefamiliarwiththesafeoperationoftheequipment,
operatorcontrols,andsafetysigns.
Alloperatorsandmechanicsshouldbetrained.The
ownerisresponsiblefortrainingtheusers.
Neverletchildrenoruntrainedpeopleoperateorservice
theequipment.Localregulationsmayrestricttheageof theoperator.
Theowner/usercanpreventandisresponsiblefor
accidentsorinjuriesoccurringtohimselforherself,other peopleorproperty.
Preparation
Wearappropriateclothingincludinghardhat,eye
protection,longpants,substantial,slip-resistantfootwear, andhearingprotection.Tiebacklonghair.Donotwear jewelry.
Inspecttheareawheretheequipmentistobeusedand
ensurethatallobjectsareremovedfromthemachine beforeuse.
Useextracarewhenhandlingfuels.Theyareammable
andvaporsareexplosive.
Useonlyanapprovedcontainer. –Neverremovethefuelcaporaddfuelwhilethe
engineisrunning.Allowtheenginetocoolbefore
refueling.Donotsmoke. –Neverfuelordrainthemachineindoors. –Neverstorethemachineorfuelcontainerinside
wherethereisanopename,suchasnearawater
heaterorfurnace. –Neverllacontainerwhileitisinsideavehicle,trunk,
pick-upbed,oranysurfaceotherthantheground.
Caution
,
W ar ning
Keepcontainernozzleincontactwiththetankduring
lling.
Checkthattheoperator'spresencecontrols,safety
switches,andshieldsareattachedandfunctioning properly.Donotoperateunlesstheyarefunctioning
,
properly.
Operation
Neverrunanengineinanenclosedarea.
Onlyoperateingoodlight,keepingawayfromholesand
hiddenhazards.
Besurealldrivesareinneutralbeforestartingtheengine.
Onlystarttheenginefromtheoperator'sposition.
Neveroperatewiththeguardsnotsecurelyinplace.Be
sureallinterlocksareattached,adjustedproperly,and functioningproperly.
Donotchangetheenginegovernorsettingoroverspeed
theengine.
Stopthemachineonlevelground,lowerthehopper,and
shutofftheenginebeforeleavingtheoperator'sposition foranyreason.
Nevercarrypassengersandkeeppetsandbystanders
away.
Slowdownandusecautionwhenmakingturnsand
crossingroadsandsidewalks.
Donotoperatethemachinewhileill,tired,orunderthe
inuenceofalcoholordrugs.
Usecarewhenloadingorunloadingthemachineintoa
trailerortruck.
Usecarewhenapproachingblindcorners,shrubs,trees,
orotherobjectsthatmayobscurevision.
Ensurethattheareaisclearofotherpeoplebefore
operatingthemachine.Shutoffthemachineifanyone entersthearea.
Neverleavearunningmachineunattended.
Donotexceedtheratedoperatingcapacity ,asthe
machinemaybecomeunstablewhichmayresultinloss ofcontrol.
Neverjerkthecontrols;useasteadymotion.
Watchfortrafcwhenoperatingnearorcrossing
roadways.
Donottouchpartswhichmaybehotfromoperation.
Allowthemtocoolbeforeattemptingtomaintain,adjust, orservice.
Checkforoverheadclearances(i.e.,branches,doorways,
electricalwires)beforedrivingunderanyobjectsanddo notcontactthem.
Ensurethatyouoperatethemachineinareaswhere
therearenoobstaclesincloseproximitytotheoperator. Failuretomaintainadequatedistancefromtrees,walls, andotherbarriersmayresultininjuryasthemachine backsupduringoperationiftheoperatorisnotattentive tothesurroundings.Onlyoperatetheunitinareaswhere
4
thereissufcientclearancefortheoperatortosafely maneuvertheproduct.
Locatethepinchpointareasmarkedonthemachineand
keephandsandfeetawayfromtheseareas.
Lightningcancausesevereinjuryordeath.Iflightning
isseenorthunderisheardinthearea,donotoperate themachine;seekshelter.
Donotoverloadthehopperandalwayskeeptheload
levelwhenoperatingthemachine.
SlopeOperation
MaintenanceandStorage
Lettheenginecoolbeforestoringanddonotstorethe
machinenearanopename.
Engagetheparkingbrake,shutofftheengine,andwait
forallmovementtostopbeforeadjusting,cleaning,or repairingthemachine.
Cleandebrisfromdrives,mufers,andtheenginetohelp
preventres.Cleanupoilorfuelspills.
Donotstorefuelnearamesordrainindoors.
Parkthemachineonlevelground.Neverallowuntrained
personneltoservicethemachine.
Slopesareamajorfactorrelatedtoloss-of-controland tip-overaccidents,whichcanresultinsevereinjuryordeath. Allslopesrequireextracaution.
Operateupanddownslopeswiththeheavyendof
themachineuphill.Weightdistributionchanges.An emptyhoppermakestherearofthemachinetheheavy end,andafullhoppermakesthefrontofthemachine theheavyend.
Raisingthehopperonaslopewillaffectthestabilityof
themachine.Keepthehopperintheloweredposition whenonslopes.
Removeobstaclessuchasrocks,treelimbs,etc.fromthe
workarea.Watchforholes,ruts,orbumps,asuneven terraincouldoverturnthemachine.Tallgrasscanhide obstacles.
Keepallmovementsonslopesslowandgradual.Donot
makesuddenchangesinspeedordirection.
Avoidstartingorstoppingonaslope.Ifthemachine
losestraction,proceedslowly,straightdowntheslope.
Avoidturningonslopes.Ifyoumustturn,turnslowly
andkeeptheheavyendofthemachineuphill.
Donotoperateneardrop-offs,ditches,orembankments.
Themachinecouldsuddenlyturnoverifatrackgoes overtheedgeofaclifforditch,orifanedgecavesin.
Usecautionwhenoperatingonwetsurfaces.Reduced
tractioncouldcausesliding.
Donotparkthemachineonahillsideorslopewithout
loweringtheattachmenttothegroundandengagingthe parkingbrake.
Usejackstandstosupportcomponentswhenrequired.
Carefullyreleasepressurefromcomponentswithstored
energy.
Disconnectthebattery,negativeterminalrstandpositive
terminallast,beforemakinganyrepairs.Connectthe batterypositiveterminalrstandnegativeterminallast.
Keephandsandfeetawayfrommovingparts.Ifpossible,
donotmakeadjustmentswiththeenginerunning.
Chargebatteriesinanopen,well-ventilatedarea,away
fromsparkandames.Unplugthechargerbefore connectingordisconnectingitfromthebattery.W ear protectiveclothinganduseinsulatedtools.
Keepallpartsingoodworkingconditionandallhardware
tightened.Replaceallwornordamageddecals.
Usethecylinderlocktosecurethehopperintheraised
position.
Keepnutsandboltstight.Keepequipmentingood
condition.
Nevertamperwithsafetydevices.
UseonlygenuineT ororeplacementpartstoensurethat
originalstandardsaremaintained.
Useextracarewhenhandlingfuels.Theyareammable
andvaporsareexplosive.
Useonlyanapprovedcontainer.
Neverremovethefuelcaporaddfuelwhenthe
engineisrunning.Allowtheenginetocoolbefore refueling.Donotsmoke.
Neverfuelthemachineindoors.
Neverstorethemachineorfuelcontainerinside
wherethereisanopename,suchasnearawater heaterorfurnace.
Neverllacontainerwhileitisinsideavehicle,trunk,
pick-upbed,oranysurfaceotherthantheground.
Keepcontainernozzleincontactwiththetankduring
lling.
Batteryacidispoisonousandcancauseburns.Avoid
contactwithskin,eyes,andclothing.Protectyourface, eyes,andclothingwhenworkingwithabattery.
5
Batterygasescanexplode.Keepcigarettes,sparksand
amesawayfromthebattery.
Keepyourbodyandhandsawayfrompinholeleaks
ornozzlesthatejecthigh-pressurehydraulicuid.Use
SafetyandInstructionalDecals
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaofpotential danger.Replaceanydecalthatisdamagedormissing.
115-4212
cardboardorpapertondhydraulicleaks;neveruse yourhands.Hydraulicuidescapingunderpressurecan penetrateskinandcauseinjuryrequiringsurgerywithina fewhoursbyaqualiedsurgeonorgangrenemayresult.
1.Hydraulic-uidlevel
2.ReadtheOperator's Manual.
3.Warning—donottouchthe hotsurface.
115-4858
1.Crushinghazardofhandsorfeet—installthecylinderlock.
116-8775
1.ReadtheOperator’s
Manual.
2.Filltobottomofllerneck; warning—donotoverll thetank.
132-8961
1.Batterychargingcondition4.Hopperislowering.
2.Hourmeter5.Hopperisdown.
3.Hopperisraising.6.Hopperislowering automatically.
decal132-9051
132-9051
1.Tie-downpoint
decal132-9052
132-9052
1.Main(15A)3.Logic(7.5A)
decal117-2718
2.Auxiliary(15A)
117-2718
6
decal137-0575
137-0575
1.ReadtheOperator’s Manual.
2.Transmissionuid
3.Cold-llline
7
decal136-4615
136-4615
1.Parking-brakerelease
7.Explosionhazard—shutofftheengine beforeaddingfuel;nore,open ames,orsmokingwhenaddingfuel.
2.Parkingbrake8.Machinetippinghazard—donotdrive forwardwiththehopperraised;do notdrivedownslopeswiththehopper raised;donotdriveacrossslopeswith thehopperraised;driveslowlywiththe hopperdown.
3.Warning—readtheOperator’sManual;
hearingprotectionmustbeworn.
9.Warning—keepbystandersasafe distancefromthemachine;watch behindyouwhenmovinginreverse.
4.Warning—alloperatorsshouldbe trainedbeforeoperatingthemachine.
10.Warning—engagetheparkingbrake, shutofftheengine,andremovethekey beforeleavingtheoperatorposition.
5.Warning-keepawayfrommovingparts;
11.Lefttractioncontrols
keepallguardsandcoversinplace.
6.Poisonousfumesortoxicgases,
12.Raisehopper
asphyxiationhazard—donotrunthe engineinanenclosedspace.
13.Lowerhopper
14.Movethehandlesintooperate.
15.Righttractioncontrols
16.Engine-speedcontrol
8
ProductOverview
Figure3
1.Hopper4.Fuel-tankcap
2.Hood
3.Controlpanel
5.Operatorplatform
6.Track
ParkingBrakeLever
Toengagetheparkingbrake,pullbackthelever.(Figure4).
Toreleasetheparkingbrake,pushtheleverforward.
HourMeter
Thehourmeterrecordsthenumberofhourstheenginehas operated.Itoperateswhentheengineisrunning.Usethese timesforschedulingregularmaintenance(Figure4).
ChokeControl
Usethechoketostartacoldengine.Pullthechokeknob uptoengageit.Pushthechokeknobdowntodisengage
g038268
it(Figure4).
KeySwitch
Usethekeyswitchtostarttheengine(Figure4).Theswitch has3positions:OFF,RUN,andSTART.
ThrottleLever
Controls
Becomefamiliarwithallthecontrols(Figure4)beforeyou starttheengineandoperatethemachine.
Figure4
ThethrottleleverisvariablebetweentheFASTandSLOW positions(Figure4).
Motion-ControlLevers
Usethemotion-controlleverstodrivethemachineforward andreverseandtoturneitherdirection(Figure4).
DumpSwitch
Usethedumpswitchtodumpandlowerthehopper.Ifyou holdtheswitchdown0.2to1.3seconds,thehopperfully lowersautomatically .
Specications
Note:Specicationsanddesignaresubjecttochange
withoutnotice.
Width
g038269
Length
Height
90.2cm(35-1/2inches)
268.0cm(105-1/2inches)
121.2cm(47.7inches)
1.Parking-brakelever6.Throttlelever
2.Hydraulic-tankcap
3.Hourmeter8.Dumpswitch
4.Chokecontrol
5.Keyswitch
7.Leftmotion-controllever
9.Rightmotion-controllever
Weight
Hoppercapacity
Maximumload
DischargeHeight
9
734kg(1619lb)
0.45m
1134kg(2,500lb)
38.1cm(15inches)
3
(16ft3)
Operation
G009027
1
2
Note:Determinetheleftandrightsidesofthemachine fromthenormaloperatingposition.
Important:Beforeoperating,checkthefuelandoil level,andremovedebrisfromthemachine.Also,ensure thattheareaisclearofpeopleanddebris.Youshould alsoknowandhavemarkedthelocationsofallutility lines.

ThinkSafetyFirst

Carefullyreadallsafetyinstructionsandsymbolsinthe safetysection.Knowingthisinformationcouldhelpyouor bystandersavoidinjury.
CAUTION
Thismachineproducessoundlevelsthatcancause hearinglossthroughextendedperiodsofexposure.
Wearhearingprotectionwhenoperatingthis machine.
Useprotectiveequipmentforyoureyes,ears,hands,feet, andhead.
DANGER
Incertainconditions,fuelisextremelyammable andhighlyexplosive.Areorexplosionfromfuel canburnyouandothersandcandamageproperty.
Fillthefueltankoutdoors,inanopenarea,when theengineiscold.Wipeupanyfuelthatspills.
Neverllthefueltankinsideanenclosedtrailer.
Donotllthefueltankcompletelyfull.Add fueltothefueltankuntilthelevelis6to13mm (1/4to1/2inch)belowthebottomoftheller neck.Thisemptyspaceinthetankallowsfuel toexpand.
Neversmokewhenhandlingfuelandstayaway fromanopenameorwherefuelfumesmaybe ignitedbyaspark.
Storefuelinanapprovedcontainerandkeepit outofthereachofchildren.Neverbuymore thana30-daysupplyoffuel.
Donotoperatewithoutentireexhaustsystemin placeandinproperworkingcondition.
DANGER
Incertainconditionsduringfueling,static electricitycanbereleasedcausingaspark,which canignitethefuelvapors.Areorexplosionfrom
g009027
Figure5
1.Weareyeprotection.2.Wearhearingprotection.

AddingFuel

Forbestresults,useonlyclean,fresh(lessthan30days
old),unleadedgasolinewithanoctaneratingof87or higher((R+M)/2ratingmethod).
ETHANOL:Gasolinewithupto10%ethanol(gasohol)
or15%MTBE(methyltertiarybutylether)byvolume isacceptable.EthanolandMTBEarenotthesame. Gasolinewith15%ethanol(E15)byvolumeisnot approvedforuse.Neverusegasolinethatcontainsmore than10%ethanolbyvolume,suchasE15(contains15% ethanol),E20(contains20%ethanol),orE85(contains upto85%ethanol).Usingunapprovedgasolinemay causeperformanceproblemsand/orenginedamage whichmaynotbecoveredunderwarranty.
Donotusegasolinecontainingmethanol.
Donotstorefueleitherinthefueltankorfuelcontainers
overthewinterunlessafuelstabilizerisused.
Donotaddoiltogasoline.
fuelcanburnyouandothersandcandamage property.
Alwaysplacefuelcontainersonthegroundaway fromyourvehiclebeforelling.
Donotllfuelcontainersinsideavehicleoron atruckortrailerbedbecauseinteriorcarpets orplastictruckbedlinersmayinsulatethe containerandslowthelossofanystaticcharge.
Whenpractical,removefuel-poweredequipment fromthetruckortrailerandrefueltheequipment withitswheelsontheground.
Ifthisisnotpossible,thenrefuelsuchequipment onatruckortrailerfromaportablecontainer, ratherthanfromafuel-dispensernozzle.
Ifyoumustuseafuel-dispensernozzle,keepthe nozzleincontactwiththerimofthefueltank orcontaineropeningatalltimesuntilfuelingis complete.
10
WARNING
Fuelisharmfulorfatalifswallowed. Long-termexposuretovaporscancause seriousinjuryandillness.
Avoidprolongedbreathingofvapors.
Keepyourfaceawayfromnozzleandfueltank orconditioneropening.
Keepfuelawayfromeyesandskin.
UsingStabilizer/Conditioner
Useafuelstabilizer/conditionerinthemachinetoprovide thefollowingbenets:
Keepsfuelfreshduringstorageof90daysorless.For
longerstorage,drainthefueltank.
Cleanstheenginewhileitruns
Eliminatesgum-likevarnishbuildupinthefuelsystem,
whichcauseshardstarting
Important:Donotusefueladditivescontaining methanolorethanol.
FillingtheFuelTank
Fuel-tankcapacity:40.1L(10.6USgallons)
1.Cleantheareaaroundthefuel-tankcap.
2.Removethecap.
3.Addfueluntilitisatthebottomofthellerneck.
Note:Donotllthefueltankcompletelyfull.The emptyspaceinthetankallowsthefueltoexpand.
4.Installthecap.
Addthecorrectamountofstabilizer/conditionertothe fuel.
Note:Afuelstabilizer/conditionerismosteffective whenmixedwithfreshfuel.Tominimizethechanceof varnishdepositsinthefuelsystem,usefuelstabilizerat alltimes.
g038312
Figure6

PerformingDailyMaintenance

Beforestartingtheengineeachday,performthefollowing procedures:
Checktheengine-oillevel—refertoCheckingthe
Engine-OilLevel(page19).
Checkthehydraulic-uidlevelforthedrivesystem—refer
toCheckingtheHydraulic-FluidLevelfortheDrive
System(page30)
Checkthehydraulic-uidlevelfortheliftsystem—refer
toCheckingtheHydraulic-FluidLevelfortheLiftSystem
(page32).
11

OperatingtheParkingBrake

G008946
G008959
1
2

OperatingtheChoke

Alwaysengagetheparkingbrakewhenyoustopthemachine orleaveitunattended.Beforeeachuse,checktheparking brakeforproperoperation.
CAUTION
Childrenorbystandersmaybeinjuredifthey moveorattempttooperatethemachinewhileitis unattended.
Alwaysremovetheignitionkeyandengage theparkingbrakewhenleavingthemachine unattended.
EngagingtheParkingBrake
Pulltheparking-brakeleverrearwardintotheENGAGED position(Figure7).
Usethechoketostartacoldengine.
1.Pullupthechokeknobtoengagethechokebefore usingtheignitionswitch(Figure9).
2.Pushdownthechokeknobtodisengagethechoke aftertheenginehasstarted(Figure9).
g008959
Figure9
Figure7
1.Parkingbrake—engaged2.Parkingbrake—released
g009465
1.Onposition2.Offposition
ReleasingtheParkingBrake
Pushtheparking-brakeleverforward(Figure7).

OperatingtheThrottle

ThethrottlecontrolmovesbetweenFASTandSLOWpositions (Figure8).
AlwaysusetheFASTpositionwhenmovingthemachine.
g008946
Figure8
12

StartingtheEngine

ShuttingOfftheEngine

1.Engagetheparkingbrake.
2.Engagethechoke.
Note:Awarmorhotenginemaynotrequirechoking. Youmayneedtorepeatthestartingcyclewhenyou starttheengineforthersttimeafteryouhavelleda completelyemptyfuelsystemwithfuel.
3.MovethethrottlebetweentheFASTandSLOW positions.
4.TurnthekeyswitchtotheSTARTposition.
5.Whentheenginestarts,disengagethechoke.
Important:Donotengagethestarterformorethan5 secondsatatime.Iftheenginefailstostart,allowa 15-secondcool-downperiodbetweenattempts.Failure tofollowtheseinstructionscanburnoutthestarter.
1.MovethethrottlebetweentheFASTandSLOW positions.
2.Engagetheparkingbrake.
3.TurnthekeyswitchtotheOFFpositionandremove thekey.
g038314
Figure11
Figure10

OperatingtheHopper

Hoppercapacity:1134kg(2,500lb)
Knowtheloadcapacityofthemachineandneverexceedit. Thismachinenormallyoperatesonuneven,unpaved,bumpy, and/orinclinedsurfaces—adjusttheloadaccordingly.
1.Positionthemachinewhereyouintendtodumpthe load.
2.Dumpthehopperbypushingthetopofthedump switch(Figure12).
3.Lowerthehopperbypushingthebottomofthedump switch(Figure12).
g038313
Note:Ifyouholdthebottomoftheswitch0.2to1.3 seconds,thehopperfullylowersautomatically.
Figure12
1.Dumpthehopper.2.Lowerthehopper.
13
g038270
RemovingDebrisfromthe

TransportingtheMachine

Machine
1.Parkthemachineonalevelsurface,movethe motion-controlleverstotheNEUTRAL-LOCKposition, engagetheparkingbrake,andlowerthehopper.
2.Shutofftheengine,andremovethekey .Allowthe enginetocool.
3.Cleantheinsideofthehopperusingahose.
4.Cleananydebrisfromunderthehopper.
5.Wipeawaydebrisfromtheaircleaner.
6.Cleananydebrisbuildupontheengineandinthe transmissionwithabrushorblower.
Important:Itispreferabletoblowdirtout,rather thanwashingitout.Ifyouusewater,keepitaway fromelectricalpartsandhydraulicvalves.Do notuseahigh-pressurewasher.High-pressure washingcandamagetheelectricalsystemand hydraulicvalvesordepletegrease.
LoweringtheHopperwithout
Useaheavy-dutytrailerortruckwithfull-widthrampsto transportthemachine.Ensurethatthetrailerortruckhasall thenecessarybrakes,lighting,andmarkingasrequiredbylaw . Pleasecarefullyreadallthesafetyinstructions.Knowingthis informationcouldhelpyou,yourfamily,petsorbystanders avoidinjury.Refertoyourlocalordinancesfortrailerand tie-downrequirements.
Important:Donotoperateordrivethemachineon roadways.
1.Lowerthehopper.
2.Ifusingatrailer,connectittothetowingvehicleand connectthesafetychains.
3.Ifapplicable,connectthetrailerbrakes.
4.Carefullyloadthemachineontothetrailerortruck.
5.Shutofftheengine,removethekey ,andsetthebrake.
6.Usethemetaltie-downloopsonthemachineto securelyfastenthemachinetothetrailerortruckwith straps,chains,cable,orropes(Figure14).
Power
1.Installthecylinderlock;refertoInstallingtheCylinder
Lock(page17).
2.Ensurethatthetubisempty.
3.Placealargedrainpanunderthehydraulic-manifold block(Figure13).
Figure13
1.Hydraulic-manifoldblock
4.Disconnectthehosettingsinthemanifoldblockand allowtheuidtodrainintothepain.
g186548
Note:Disposeoftheuseduidatacertiedrecycling center.
5.Connectthehosettings.
6.Useahoistorhave2peopleholdupthehopperand removethecylinderlock.
7.Carefullylowerthehoppertothemachineframe.
g185890
Figure14
1.Fronttie-downloops2.Reartie-downloops
14

LiftingtheMachine

Hoistthemachineusing2liftpointsunderthehopperand 2reartie-downloops.Tiltthehopperforwardtolocatethe 2liftloopsandattachachainorstrapsateachoftheloops asshowninFigure15.
Note:Takeuptheslackinthechainorstrapstoproperly balancetheunit.
1.Liftpointsunderhopper
g194436
Figure15
2.Reartie-downloops
15
Maintenance
Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.
RecommendedMaintenanceSchedule(s)
MaintenanceService
Interval
Aftertherst10hours
Beforeeachuseordaily
Every25hours
Every40hours
Every50hours
Every100hours
MaintenanceProcedure
•Checkandadjustthetracktension(every10hoursuntil50hours).
•Checktheengine-oillevel.
•Cleantheblowerhousing(moreoftenunderextremelydusty ,dirtyconditions).
•Checktheconditionofthetrack.
•Checktheparkingbrakeoperation.
•Checkthehydraulic-uidlevelforthedrivesystem.
•Checkthehydraulic-uidlevelfortheliftsystem.
•Removedebrisfromthemachine.
•Checkforloosefasteners.
•Serviceorreplacetheair-cleanerfoamelement(moreoftenunderextremelydusty , dirtyconditions).
•Checkthehydrauliclinesforleaks,loosettings,kinkedlines,loosemounting supports,wear,anddeterioration.
•Greasethemachine(greaseimmediatelyaftereverywashing).
•Checkthebattery.
•Checkandadjustthetracktension.
•Replacetheair-cleanerpaperelement(moreoftenunderextremelydusty,dirty conditions).
•Changetheengineoilandtheengine-oillter.
•Checkthesparkplug.
•Removethecoolingshroudsandcleanthecoolingareas(moreoftenunder extremelydusty,dirtyconditions).
•Replacethefuellter(moreoftenunderdusty ,dirtyconditions).
•Inspectthedrivebelt.
•Cleandirtbuildupinthechassis.
•Replacethesparkplug.
•Checktheroadwheels.
Every300hours
•Replacethedrivebelt.
•Changethehydraulicuidandlterforthedrivesystem.
•Changethehydraulicuidfortheliftsystem.
•Replacethehydrauliclterfortheliftsystem.
Important:Refertoyourengineowner'smanualforadditionalmaintenanceprocedures.
16
Pre-Maintenance Procedures

ReleasingtheCushionfor RearAccess

Youcanreleasethecushionforrearaccesstothemachinefor maintenanceoradjustment.
1.Lowertheplatform.
2.Loosenthetwistknobsoneachsideofthemachine (Figure16).
Figure16
1.Twistknob
2.Cushion
g185887
Figure17
1.Cylinderlock2.Lift-cylinderrod
4.Slowlylowerthehopperuntilthecylinderlockcontacts thecylinderbodyandrodend.
g032556
RemovingandStoringtheCylinder Lock
3.Removethecushionandlowerittotheplatform.
4.Performanymaintenanceoradjustmentonthe machine.
5.Raisethecushion,andslideitontothepinsonboth sidesofthemachine.
6.Tightenthetwistknobs.

UsingtheCylinderLock

InstallingtheCylinderLock
1.Parkthemachineonalevelsurface,movethe motion-controlleverstotheNEUTRAL-LOCKposition, engagetheparkingbrake,andfullyraisethehopper.
2.Removethe2cotterlesspinssecuringthecylinderlock tothemachine.
3.Slidethecylinderlockoverthelift-cylinderrodand securewiththecotterlesspins(Figure17).
Important:Removethecylinderlockfromthe lift-cylinderrodandfullysecureitinthestorageposition beforeoperatingthemachine.
1.Startthemachine.
2.Fullyraisethehopper.
3.Shutofftheengine.
4.Removethecotterlesspinssecuringthecylinderlock.
5.Placethecylinderlockonthepostsinsidethemachine frameandsecurewiththecotterlesspins.
6.Lowerthehopper.
17
Lubrication
g019608
EngineMaintenance

GreasingtheMachine

ServiceInterval:Every50hours
Whenoperatingthemachineundernormalconditions, lubricateallgreasettingsforthebearingsandbushingswith No.2lithiumgrease.Lubricatethebearingsandbushings immediatelyaftereverywashing,regardlessoftheinterval listed.Applyalightcoatingofoilontothecontrolcables.
Cylinderpivots(2)—Figure18

ServicingtheAirCleaner

ServiceInterval:Every25hours—Serviceorreplacethe
air-cleanerfoamelement(moreoften underextremelydusty,dirtyconditions).
Every100hours—Replacetheair-cleanerpaper element(moreoftenunderextremelydusty,dirty conditions).
Note:Operatingtheenginewithlooseordamaged air-cleanercomponentscouldallowunlteredairintothe engine,causingprematurewearandfailure.
Note:Servicetheaircleanermoreoftenunderextremely dusty,dirtyconditions.
RemovingtheElements
1.Rotatethelatchesoutward.
2.Removethecovertoaccesstheair-cleanerelements (Figure19).
Figure18
g019608
g028105
Figure19
1.Air-cleanercover2.Air-cleanerlatch
3.Removethefoamandpaperelements(Figure20).
4.Removethefoamelementfromthepaperelement (Figure20).
18
Figure20
B
A
C
D
E
g027515
F
G
H

CheckingtheEngine-OilLevel

ServiceInterval:Beforeeachuseordaily
Important:Remembertoadd80%oftheoil,andthen graduallyllittotheFullmarkonthedipstick.
Important:Donotruntheenginewiththeoillevel abovetheFullmarkorbelowthelowmark.Otherwise, doingsomaydamagetheengine.
1.Parkthemachineonalevelsurface,movethe
g028106
motion-controlleverstotheNEUTRAL-LOCKposition, engagetheparkingbrake,andlowerthehopper.
1.Air-cleanercover3.Paperelement
2.Foamelement
ServicingtheFoamElement
1.Washthefoamelementinwarmwateranddetergent.
2.Rinseandallowittoairdry.
3.Lightlyoilthefoamelementwithnewoilandsqueeze outexcessoil.
ServicingthePaperElement
1.Gentlytapthepaperelementtodislodgedirt.
Note:Donotwashthepaperelementoruse pressurizedair,asthisdamagestheelement.
Note:Replaceadirty,bent,ordamagedelement. Handlethenewelementcarefully;donotuseifthe sealingsurfacesarebentordamaged.
2.Cleantheair-cleanerbaseasrequired,andcheckthe condition.
InstallingtheElements
2.Shutofftheengine,andremovethekey .Allowthe enginetocool.
3.Openthecowl.
4.Checktheengine-oillevelasshowninFigure21.
1.Installthefoamelementontothepaperelement.
2.Installtheelementsontotheair-cleanerbase(Figure
20).
3.Installthecover,andsecureitwiththelatches(Figure
19).
g027515
Figure21
19
ChangingtheEngineOiland
g017552
0
0
50
SAE 30
B
A
C D
E
F
3/4
g027477
Filter
ServiceInterval:Every100hours
OilType::Detergentoil(APIserviceSJorhigher)
EngineOilCapacity:1.9L(2.0USquarts)
Viscosity:Refertothetablebelow .
Figure22
Note:Disposeoftheusedoilatarecyclingcenter.
1.Parkthemachineonalevelsurface,movethe motion-controlleverstotheNEUTRAL-LOCKposition, engagetheparkingbrake,raisethehopper,andinstall thecylinderlock.
g185888
g031623
Figure23
g017552
5.Torquetheplugto13.6N∙m(10ft-lb).
6.Changetheengine-oillterasshowninFigure24.
2.Shutofftheengine,andremovethekey .Allowthe enginetocool.
3.Startandrunengineforafewminutestowarmthe engineoil,thenshutofftheengine.
4.ChangetheengineoilasshowninFigure23.
g027477
Figure24
20
7.Slowlypourapproximately80%ofthespeciedoil
B
A
C
D
E
g027517
B
A
g027478
B
A
g027479
intothellertube(Figure25).

ServicingtheSparkPlugs

ServiceInterval:Every100hours—Checkthesparkplug.
Every300hours—Replacethesparkplug.
ThesparkplugsareRFIcompliant.Equivalentalternate brandplugscanalsobeused.
Type:ChampionXC12YC
AirGap:0.76mm(0.03inch)
RemovingtheSparkPlug
1.Parkthemachineonalevelsurface,movethe motion-controlleverstotheNEUTRAL-LOCKposition, engagetheparkingbrake,andlowerthehopper.
2.Shutofftheengine,andremovethekey .Allowthe enginetocool.
3.Beforeremovingthesparkplug(s),cleanthearea aroundthebaseoftheplugtokeepdirtanddebrisout oftheengine.
4.Removethesparkplug(Figure26).
g027517
Figure25
g027478
Figure26
CheckingtheSparkPlug
Important:Donotcleanthesparkplug(s).Always
replacethesparkplug(s)whenithas:ablackcoating, wornelectrodes,anoilylm,orcracks.
Note:Ifyouseelightbrownorgrayontheinsulator,the engineisoperatingproperly.Ablackcoatingontheinsulator usuallymeanstheaircleanerisdirty.
Setthegapto0.76mm(0.03inch).
g027479
Figure27
21
InstallingtheSparkPlug
B
A
20 ft-lb 27 N-m
g028109
C
D
B
A
C
D
g027753
FuelSystem Maintenance

ReplacingtheFuelFilter

ServiceInterval:Every100hours/Y early(whichevercomes
rst)(moreoftenunderdusty ,dirty conditions).
1.Parkthemachineonalevelsurface,movethe motion-controlleverstotheNEUTRAL-LOCKposition, engagetheparkingbrake,andlowerthehopper.
2.Shutofftheengine,andremovethekey .Allowthe enginetocool.
3.ReplacethefuellterasshowninFigure29.
g028109
Figure28

CleaningtheBlowerHousing

Every100hours/Y early(whichevercomesrst)
Toensurepropercooling,ensurethatthegrassscreen, coolingns,andotherexternalsurfacesoftheengineare keptcleanatalltimes.
Makesurethecoolingshroudsareinstalled.
Important:Operatingtheenginewithablocked grassscreen,dirtyorpluggedcoolingns,and/or coolingshroudsremovedcausesenginedamagedue tooverheating.
g185888
g027753
Figure29
22

DrainingtheFuelTank

RemovingtheFuelTank

Youcandrainthefueltankbyremovingitandpouringthe fueloutofthellneck;refertoRemovingtheFuelTank
(page23).Youcanalsodrainthefueltankbyusingasiphon
inthefollowingprocedure.
DANGER
Incertainconditions,fuelisextremelyammable andhighlyexplosive.Areorexplosionfrom gasolinecanburnyouandothersandcandamage property.
Drainfuelfromthefueltankwhentheengineis cold.Dothisoutdoorsinanopenarea.Wipe upanyfuelthatspills.
Neversmokewhendrainingfuelandstayaway fromanopename,orwhereasparkmayignite thefuelfumes.
1.Parkthemachineonalevelsurface,movethe motion-controlleverstotheNEUTRAL-LOCKposition, engagetheparkingbrake,andlowerthehopper.
2.Shutofftheengine,andremovethekey .Allowthe enginetocool.
3.Cleanaroundthefuelcaptopreventdebrisfrom gettingintothefueltank(Figure30).
4.Removethefuelcap.
1.Lowertheplatform.
2.Releasethecushion;refertoReleasingtheCushionfor
RearAccess(page17).
3.Removethecrossbracket(Figure31).
Figure31
1.Fueltank
4.Removethefueltankandsetitontheoperator platform.
Note:Ifyouwanttomovethefueltankfurtherfrom themachine,removethefuelandventlinesfromthe topofthetank.
2.Crossbracket
g186223
5.Insertasyphonpumpintothefueltank.
6.Usingthesyphonpump,drainthefuelintoacleangas can(Figure30).
7.Wipeupanyspilledfuel.
Figure30
1.Fuelcap
g186224
23
ElectricalSystem Maintenance

ServicingtheBattery

ServiceInterval:Every50hours
WARNING
CALIFORNIA
Proposition65Warning
Batteryposts,terminals,andrelated
accessoriescontainleadandleadcompounds,
chemicalsknowntotheStateofCalifornia
tocausecancerandreproductiveharm.
Washhandsafterhandling.
1.Parkthemachineonalevelsurface,movethe motion-controlleverstotheNEUTRAL-LOCKposition, engagetheparkingbrake,andlowerthehopper.
2.Shutofftheengine,andremovethekey .Allowthe enginetocool.
3.Removethenegativebatterycablefromthebattery (Figure32).
DANGER
Batteryelectrolytecontainssulfuricacidwhichisa deadlypoisonandcausessevereburns.
Donotdrinkelectrolyteandavoidcontactwith skin,eyesorclothing.Wearsafetyglassestoshield youreyesandrubberglovestoprotectyourhands.
RemovingtheBattery
WARNING
Batteryterminalsormetaltoolscouldshortagainst metalmachinecomponents,causingsparks.Sparks cancausethebatterygassestoexplode,resulting inpersonalinjury.
Whenremovingorinstallingthebattery,donot allowthebatteryterminalstotouchanymetal partsofthemachine.
Donotallowmetaltoolstoshortbetween thebatteryterminalsandmetalpartsofthe machine.
Figure32
1.Positivebatterycable
2.Securingrod
4.Removethepositivebatterycablefromthebattery (Figure32).
5.Removethe2wingnuts,securingrod,andthebattery (Figure32).
3.Wingnut(2)
4.Negativebatterycable
InstallingtheBattery
1.Placethebatteryontheplatformandsecureitusing the2wingnutsandthesecuringrod(Figure32).
2.Installthepositivebatterycabletothebattery(Figure
32).
3.Installthenegativebatterycabletothebattery(Figure
32).
g185906
WARNING
Incorrectbattery-cableroutingcoulddamagethe machineandcables,causingsparks.Sparkscan causethebatterygassestoexplode,resultingin personalinjury.
Alwaysdisconnectthenegative(black)battery cablebeforedisconnectingthepositive(red) cable.
Alwaysconnectthepositive(red)batterycable beforeconnectingthenegative(black)cable.
24
ChargingtheBattery

ServicingtheFuses

WARNING
Chargingthebatteryproducesgassesthatcan explode.
Neversmokenearthebatteryandkeepsparksand amesawayfrombattery.
Important:Alwayskeepthebatteryfullycharged (1.265specicgravity)topreventbatterydamagewhen thetemperatureisbelow0°C(32°F).
1.Removethebatteryfromthechassis;refertoRemoving
theBattery(page24).
2.Checktheelectrolytelevel.
3.Ensurethatthellercapsareinstalledonthebattery.
4.Chargethebatteryfor1hourat25to30Aor6hours at4to6A.
5.Whenthebatteryisfullycharged,unplugthecharger fromtheelectricaloutlet,anddisconnectthecharger leadsfromthebatteryposts(Figure33).
6.Installthebatteryontothemachineandconnectthe batterycables;refertoInstallingtheBattery(page24).
Theelectricalsystemisprotectedbyfusesandrequiresno maintenance.Ifafuseblows,checkthecomponentorcircuit foramalfunctionorshort.
1.Releasethecushionfromtherearofthemachine.
2.Pulloutthefusetoremoveorreplaceit(Figure34).
3.Installthecushiontotherearofthemachine.
Note:Ensurethatthecorrect-sizefuseisinstalled
Figure34.
Note:Donotrunthemachinewiththebattery disconnected;electricaldamagemayoccur.
Figure33
1.Positivebatterypost
2.Negativebatterypost
3.Red(+)chargerlead
4.Black(-)chargerlead
g189366
Figure34
1.Mainpowerfuse(15A)3.Logicfuse(7.5A)
2.Auxiliarypowerfuse(15 A)
g000538
25
DriveSystem Maintenance

ServicingtheTracks

AdjustingtheTrackTension
Ifyouplacethetabofthetensioningtoolalongtherearedge ofthetensionnut,theotherendofthetensioningtoolshould alignwiththeedgeofthetensionarmasshowninFigure36. Ifthedistanceisnotcorrect,adjustthetracktensionusing thefollowingprocedure:
ServiceInterval:Beforeeachuseordaily—Checkthe
conditionofthetrack.
Aftertherst10hours—Checkandadjustthetrack tension(every10hoursuntil50hours).
Every50hours—Checkandadjustthetracktension.
Every300hours—Checktheroadwheels.
CleaningtheTracks
1.Parkthemachineonalevelsurface,movethe motion-controlleverstotheNEUTRAL-LOCKposition, engagetheparkingbrake,andlowerthehopper.
2.Shutofftheengine,andremovethekey .Allowthe enginetocool.
3.Lift/supportthesideofthemachinetobeworkedon sothatthetrackis3to4inches(7.6to10cm)off theground.
4.Usingawaterhoseorpressurewasher,removedirt fromeachtracksystem.
Important:Ensurethatyouusehigh-pressurewaterto washonlythetrackarea.Donotuseahigh-pressure washertocleantherestofthemachine.Donotuse highpressurewaterbetweenthedrivesprocketand themachineoryoumaydamagethemotorseals. High-pressurewashingcandamagetheelectrical systemandhydraulicvalvesordepletegrease.
Important:Ensurethatyoufullycleantheroadwheels, thefrontwheel,andthedrivesprocket(Figure35).The roadwheelsshouldrotatefreelywhenclean.
Note:Ifthetensioningtoolisnotavailable,thedistance betweenthenutandedgeofthetensionarmshouldbe7.1 cm(2-13/16inch).
Figure36
LeftTrackShown
1.Tensionnut
2.Tensioningtool(equalto
7.1cmor2-13/16inch)
3.Tensioningbolt7.Tab
4.Bolt(1/4x1-5/8inch)
5.Spacer
6.Nut
8.Tensionarm
1.Parkthemachineonalevelsurface,movethe motion-controlleverstotheNEUTRAL-LOCKposition, engagetheparkingbrake,andlowerthehopper.
2.Shutofftheengine,andremovethekey .Allowthe enginetocool.
3.Cleanthetrackswithhigh-pressurewater.
g202806
Figure35
1.Frontwheel3.Roadwheel
2.Track4.Drivesprocket
Important:Ensurethatyouusehigh-pressure
g186007
watertowashonlythetrackarea.Donotuse ahigh-pressurewashertocleantherestofthe machine.Donotusehighpressurewaterbetween thedrivesprocketandthemachineoryoumay damagethemotorseals.High-pressurewashing candamagetheelectricalsystemandhydraulic valvesordepletegrease.
4.Cleanthedrivesprocket,thefrontwheel,andtheroad wheels.Theroadwheelsshouldspinfreelywhenclean.
5.Removethebolt(1/4x1-5/8inch),spacer,andnut (Figure36).
26
6.Turnthetensioningbolttoadjustthedistancebetween thetensionnutandtheendtangentofthetensiontube untilthedistanceiscorrect,asshowninFigure36)
7.Aligntheclosestnotchinthetensioningbolttothe boltholeandsecurethetensioningboltwiththebolt (1/4x1-5/8inch),spacer,andnut(Figure36).
ReplacingtheTracks

ServicingtheDriveBelt

InspectingtheDriveBelt
ServiceInterval:Every100hours
1.Parkthemachineonalevelsurface,movethe motion-controlleverstotheNEUTRAL-LOCKposition, engagetheparkingbrake,andlowerthehopper.
Replacethetrackswhentheyarebadlyworn.
1.Parkthemachineonalevelsurface,movethe motion-controlleverstotheNEUTRAL-LOCKposition, engagetheparkingbrake,andlowerthehopper.
2.Shutofftheengine,andremovethekey .Allowthe enginetocool.
3.Lift/supportthesideofthemachinetobeworkedon sothatthetrackis3to4inches(7.6to10cm)off theground.
4.Removetheretainingboltforthetensioningscrew .
5.Releasethedrivetensionbyturningthetensioning screwclockwise(Figure36andFigure37).
Figure37
1.Frontwheel4.Roadwheel
2.Track5.Drivesprocket
3.Tensioningscrewand retainingbolt
6.Removethetrackatthetopofthefrontwheel,peeling itoffthewheelwhilerotatingthetrackforwards.
7.Whenthetrackisoffthefrontwheel,removeitfrom thedrivesprocketandroadwheels(Figure37).
8.Beginningatthedrivesprocket,coilthenewtrack aroundthesprocket,ensuringthatthelugsonthetrack tbetweenthespacersonthesprocket(Figure37).
9.Pushthetrackunderthelugsandbetweentheroad wheels(Figure37).
10.Startingatthebottomofthefrontwheel,installthe trackaroundthewheelbyrotatingthetrackrearward whilepushingthelugsintothewheel.
11.Tensionthetrack;refertoAdjustingtheTrackTension
(page26).
12.Lowerthemachinetotheground.
2.Shutofftheengine,andremovethekey .Allowthe enginetocool.
3.Releasethecushionandremovethefueltank;referto
RemovingtheFuelTank(page23).
4.Inspectthebelt(Figure38).Replacethebeltifitis worn;refertoReplacingtheDriveBelt(page27).
Note:Thesignsofawornbeltincludesquealing whilethebeltisrotating,frayededges,burnmarks,and cracksonthebelt.
g189546
Figure38
1.Extensionspring2.Belt
ReplacingtheDriveBelt
ServiceInterval:Every300hours
1.Parkthemachineonalevelsurface,movethe motion-controlleverstotheNEUTRAL-LOCKposition, engagetheparkingbrake,andlowerthehopper.
2.Shutofftheengine,andremovethekey .Allowthe enginetocool.
3.Releasethecushionandremovethefueltank;referto
RemovingtheFuelTank(page23).
4.Raisetherearofthemachineandsupportthemachine onjackstands.
5.Removetheextensionspring(Figure38).
6.Removethe2bolts,2nuts,andgearpumpfromthe pumpmount(Figure39).
Note:Youdonotneedtoremovethettingsfrom thepump.
13.Repeatsteps3through12toreplacetheothertrack.
27
Figure39
1.Bolt(2)3.Gearpump
2.Pumpmount
4.Nut(2)
ControlsSystem Maintenance

AdjustingtheMotion-Control Levers

Ifthemotion-controlleversdonotalignhorizontally,adjust therightsidemotion-controllever.
1.Parkthemachineonalevelsurface,lowerthehopper, engagetheparkingbrake,shutofftheengine,and removethekey .
2.Pushthemotion-controlleversdownoutofthe NEUTRAL-LOCKposition(Figure41).
3.Checkiftherightmotion-controlleveraligns horizontallywiththeleftmotion-controllever(Figure
g189559
41).
7.Removethedrivebeltfromtheenginepulleyand2 transmissionpulleys
Figure40
1.Enginepulley
2.Idlerpulley4.Belt
3.Transmissionpulley(2)
8.Routethenewbeltaroundtheenginepulleyand2 transmissionpulleys(Figure40).
g009436
Figure41
1.Leftmotion-controllever3.Checkthehorizontal
2.Rightmotion-controllever intheNeutral-lockposition
alignmenthere
4.Rightmotion-controllever
4.Toadjustthemotion-controllevershorizontally,you mustadjustthecam.
5.Releasethecushionfromtherearofthemachine.
g189571
6.Loosenthenutholdingthecam(Figure42).
9.Installthegearpump(Figure39).
10.Installtheextensionspring(Figure38).
11.Installthefueltank;refertoRemovingtheFuelTank
(page23).
12.Raisethecushion.
g189389
Figure42
1.Cam
28
2.Nut
7.Adjustthecamuntilitalignswiththeleft motion-controlleverandtightenthenutforthecam.
Note:Movingthecamclockwise(inthevertical position)lowersthehandle;movingthecam counterclockwise(intheverticalposition)raisesthe handle.
Important:Ensurethattheatportionofthe camdoesnotgoaboveaverticalposition(rightor left);otherwiseyoumaydamagetheswitch.
8.Repeatsteps2through7fortheleftmotion-control lever.

BrakeMaintenance

WARNING
Ifthebrakesarenotproperlyadjusted,serious injury,ordeath,mayoccur.
Checkyourbrakesdaily.Ifyouencounterany problemswiththebrakeswhileoperatingthe machine,stopthemachineimmediatelyandbring ittoanAuthorizedToroServiceDealerforrepair.
AdjustingtheParkingBrake
1.Removethefueltank;refertoRemovingtheFuelTank
(page23).
2.Insidetheleftsideofthecontroltower,adjustthenuts untilthecablesaretaught(Figure43).
Figure43
1.Cable
2.Nuts
CheckingtheParkingBrake
ServiceInterval:Beforeeachuseordaily
1.Parkthemachineonalevelsurface,lowerthehopper, andengagetheparkingbrake.
2.Starttheengineandmovethethrottlelevertothe FASTposition.
3.Movethemotion-controlleversforward.
Note:Themachineshouldnotmoveforward.
Note:Ifthemachinemovesforward,referto
AdjustingtheParkingBrake(page29).
4.Releasetheparkingbrake.
5.Movethemotion-controlleversforward.
Note:Themachineshouldmoveforward.
Note:Ifthemachinedoesnotmoveforward,referto
AdjustingtheParkingBrake(page29).
6.Engagetheparkingbrakeandshutoffthemachine.
3.Installthefueltank,crossbracket,andcushion.
29
HydraulicSystem Maintenance
WARNING
Hydraulicuidescapingunderpressurecan penetrateskinandcauseinjury.Fluidinjectedinto theskinmustbesurgicallyremovedwithinafew hoursbyadoctorfamiliarwiththisformofinjury organgrenemayresult.
Keepyourbodyandhandsawayfrompin holeleaksornozzlesthatejecthighpressure hydraulicuid.
Usecardboardorpapertondhydraulicleaks; neveruseyourhands.

ServicingtheHydraulicDrive System

Expansion-tankcapacity:1.4L(1.5USquarts)
Figure44
1.Expansion-tankcap
2.Sightwindow
5.Iftheoillevelislow ,removethecaplockandcap fromthetopoftheexpansiontank(Figure45),and addenoughofthespeciedhydraulicuidtoraiseit totheproperlevel.
3.Fluidatllline
g203616
Hydraulic-uidtype:Toro®HYPR-OIL™500
Important:Alwaysusethecorrecthydraulicuid. Unspecieduidswilldamagethehydraulicsystem.
Note:Manyhydraulicuidsarealmostcolorless,makingit difculttospotleaks.Areddyeadditiveforthehydraulic systemoilisavailablein2/3oz.(20ml)bottles.Onebottle issufcientfor4-6gal(15-221)ofhydraulicoil.Orderpart number44-2500fromyourauthorizedT orodistributor.
CheckingtheHydraulic-FluidLevelfor theDriveSystem
ServiceInterval:Beforeeachuseordaily
1.Parkthemachineonalevelsurface,movethe motion-controlleverstotheNEUTRAL-LOCKposition, engagetheparkingbrake,andlowerthehopper.
2.Shutofftheengine,andremovethekey .Allowthe enginetocool.
3.Openthecowl.
4.Usethesightwindowtochecktheuidlevelinthe expansiontank(Figure44).
Note:Theuidlevelshouldbeatthelllineonthe decal.
Figure45
1.Bolt
2.Caplock
6.Installthecapandcaplock.Wipeupanyspilled hydraulicuid.
3.Cap
ChangingtheHydraulicFluidandFilter fortheDriveSystem
ServiceInterval:Every300hours
1.Parkthemachineonalevelsurface,movethe motion-controlleverstotheNEUTRAL-LOCKposition, engagetheparkingbrake,andlowerthehopper.
2.Shutofftheengine,andremovethekey .Allowthe enginetocool.
3.Lowerthecushionandremovethefueltank;referto
RemovingtheFuelTank(page23).
4.Removethe6bolts(2rear,4side)fromtheskidplate andremovetheskidplate(Figure46).
30
Figure46
1.Rearbolt(2)3.Sidebolt(4)
2.Skidplate
5.Locatethedrainpluginthebottomofeach transmission,thenplaceadrainpanundertheplugs (Figure47).
g203662
g203517
Figure48
1.Ventplug
11.Slowlyaddapproximately6.2L(208oz)uidtothe expansiontankuntilitstartstocomeoutofthevent plugs.
Important:UsetheuidspeciedinServicingthe
HydraulicDriveSystem(page30)orequivalent.
Otheruidscouldcausesystemdamage.
Important:Monitorthelevelofuidinthe expansiontanksothatyoudonotoverllit.
12.Tightentheventplugs.
13.Addhydraulicuidtotheexpansiontankuntilit reachestheuidline(Figure44).
Important:Donotoverll.
14.Installtheexpansion-tankcap.
Figure47
1.Hydrauliclter
2.Drainplug
6.Removethedrainplugsandallowthehydraulicuidto fullydrainfromthemachine.
7.Removethehydraulic-ltercapandhydrauliclter fromeachtransmission(Figure47).
8.Installanewhydrauliclterwiththespringsidefacing outandthehydraulic-ltercapforeachtransmission. Torqueto13to15N∙m(115to135in-lb).
9.Installthedrainplugs.
10.Loosentheventplugineachtransmissionuntilloose (Figure48).
Note:Thisallowsairtoescapethehydraulicsystem asyouaddhydraulicuid.
g203515
15.Installtheskidplate(Figure46).
16.Installthefueltank;refertoRemovingtheFuelTank
(page23).
17.Starttheengineandletitrunforabout2minutesto purgeairfromthesystem.
18.Shutofftheengineandcheckforleaks.
31
BleedingtheHydraulicDriveSystem
ServicingtheHydraulicLift
Bleedthetractionhydraulicsystemwheneveryouperform maintenanceonthehydrostatictransmissionoraddhydraulic uidtotheexpansiontank.
1.Parkthemachineonalevelsurface,movethe motion-controlleverstotheNEUTRAL-LOCKposition, engagetheparkingbrake,andlowerthehopper.
2.Shutofftheengine,andremovethekey .Allowthe enginetocool.
3.Checkthehydraulicuidlevelandaddhydraulicuid asnecessary;refertoCheckingtheHydraulic-Fluid
LevelfortheDriveSystem(page30).
4.Supportthemachineonjackstands,highenoughto raisethetracksofftheground.
5.Startthemachine.Slowlymovethemotion-control leversforwardandreverse5to6times.
6.Checkthehydraulicuidlevelandaddhydraulicuid asnecessary.
7.Repeatsteps5and6asnecessaryuntilalltheairis completelypurgedfromthesystem.
Note:Purgingiscompletewhenyouobtainnormal forwardandreversespeed.
8.Lowerthemachineandrepeattheprocedurewiththe tracksontheground.
System
CheckingtheHydraulic-FluidLevelfor theLiftSystem
ServiceInterval:Beforeeachuseordaily
Reservoir-tankcapacity:1.4L(1.5USquarts)
Hydraulic-uidtype:ToroPremiumAllSeasonHydraulic FluidorMobil®424HydraulicFluid
Important:Alwaysusethecorrecthydraulicuid. Unspecieduidswilldamagethehydraulicsystem.
Note:Manyhydraulicuidsarealmostcolorless,makingit difculttospotleaks.Areddyeadditiveforthehydraulic systemoilisavailablein2/3oz.(20ml)bottles.Onebottle issufcientfor4-6gal(15-221)ofhydraulicoil.Orderpart number44-2500fromyourauthorizedT orodistributor.
1.Parkthemachineonalevelsurface,movethe motion-controlleverstotheNEUTRAL-LOCKposition, engagetheparkingbrake,raisethehopper,andinstall thecylinderlock.
2.Shutoffthemachineandremovethekey.Allowthe machinetocoolcompletely.
3.Removethellercapfromthereservoirtank(Figure
49).
CAUTION
Thehydraulicbreather/llercapisdesigned topressurizethereservoirto34kPa(5psi).
Loosenthecapslowlytoavoidinjurywhenever addingoilorworkingonthehydraulicsystem. Useawrenchonthehexdirectlyunderthe cap.
32
g019614
1
2
Figure49
1.Hex2.Fillercap
4.Lookinsidethetanktochecktheuidlevel.
Note:Ifthemachineiscool,theuidshouldbeat theCOLDlevel;ifthemachineishot,theuidshould beattheHOTlevel.
ChangingtheHydraulicFluidforthe LiftSystem
ServiceInterval:Every300hours
1.Parkthemachineonalevelsurface,movethe motion-controlleverstotheNEUTRAL-LOCKposition, engagetheparkingbrake,raisethehopper,andinstall
g185888
thecylinderlock.
2.Shutoffthemachineandremovethekey.Allowthe machinetocoolcompletely.
3.Removethellercapfromthereservoirtank(Figure
49).
CAUTION
Thehydraulicbreather/llercapisdesigned topressurizethereservoirto34kPa(5psi).
Loosenthecapslowlytoavoidinjurywhenever
g019614
addingoilorworkingonthehydraulicsystem. Useawrenchonthehexdirectlyunderthe cap.
4.Placealargedrainpanunderthettingsatthebottom ofthereservoirtank.
5.Disconnectahosettingandallowtheuidtodrain intothepan.
6.Whennished,installandtightenthetting.
Note:Disposeoftheuseduidatacertiedrecycling center.
7.Fillthereservoirtankwithapproximately2.2L(2.3US quarts)andinstallthellercap.
8.Removethecylinderlock.
9.Starttheengine.Raiseandlowerthehopper3timesto llthecylinderandhoseswithuid.
10.Raisethehopperandinstallthecylinderlock.
11.Shutofftheengine.
12.Add0.60L(20oz)ofhydraulicuidandinstallthe llercap.
Figure50
1.HOTlevel2.COLDlevel
5.FillthetankwithhydraulicuidonlyuptotheCOLD level.
6.Installthellcap.Wipeupanyspilledhydraulicuid.
7.Removethecylinderlockandlowerthehopper.
Note:TheuidlevelshouldbeattheColdllline. Donotllpastthisline.
13.Removethecylinderlock.
14.Starttheengine.Raiseandlowerthehopperseveral
g189403
timestoremoveairfromthesystem.
ReplacingtheHydraulicFilterforthe LiftSystem
ServiceInterval:Every300hours
Important:Donotsubstituteanautomotiveoillteror severehydraulicsystemdamagemayresult.
1.Parkthemachineonalevelsurface,movethe motion-controlleverstotheNEUTRAL-LOCKposition,
33
engagetheparkingbrake,raisethehopper,andinstall
B
A
C D
E
F
3/4
g027477
thecylinderlock.
2.Shutofftheengine,andremovethekey .Allowthe enginetocool.
3.ReplacethelterasshowninFigure51.

CheckingtheHydraulicLines

ServiceInterval:Every40hours—Checkthehydrauliclines
forleaks,loosettings,kinkedlines, loosemountingsupports,wear,and deterioration.(Makenecessaryrepairs beforeoperating.)
WARNING
Hydraulicuidescapingunderpressurecan penetrateskinandcauseinjury.Fluidinjectedinto theskinmustbesurgicallyremovedwithinafew hoursbyadoctorfamiliarwiththisformofinjury; otherwise,gangrenemayresult.
g186042
Keepyourbodyandhandsawayfrompinhole leaksornozzlesthatejecthigh-pressure hydraulicuid.
Usecardboardorpapertondhydraulicleaks; neveruseyourhands.
4.Starttheengineandletitrunforabout2minutesto purgeairfromthesystem.
5.Shutofftheengineandcheckforleaks.
6.Checktheuidlevelinthereservoirtank,referto
CheckingtheHydraulic-FluidLevelfortheLiftSystem
7.Removethecylinderlockandlowerthehopper.
(page32).
Note:Donotoverllthereservoirtank.
Figure51
g027477
34
Cleaning

RemovingDebrisfromthe Machine

ServiceInterval:Beforeeachuseordaily
Every100hours
1.Parkthemachineonalevelsurface,movethe motion-controlleverstotheNEUTRAL-LOCKposition, engagetheparkingbrake,andlowerthehopper.
2.Shutofftheengine,andremovethekey .Allowthe enginetocool.
3.Cleantheinsideofthehopperusingahose.
4.Cleananydebrisfromunderthehopper.
5.Wipeawaydebrisfromtheaircleaner.
6.Cleananydebrisbuildupontheengineandinthe transmissionwithabrushorblower.
Important:Itispreferabletoblowdirtout,rather thanwashingitout.Ifyouusewater,keepitaway fromelectricalpartsandhydraulicvalves.Do notuseahigh-pressurewasher.High-pressure washingcandamagetheelectricalsystemand hydraulicvalvesordepletegrease.
Storage
1.Shutofftheengineandengagetheparkingbrake.
2.Removedirtandgrimefromtheexternalpartsofthe entiremachine,especiallytheengine.Cleandirtand chafffromtheoutsideoftheenginecylinderheadns andblowerhousing.
3.Servicetheaircleaner;refertoServicingtheAir
Cleaner(page18).
4.Greasethemachine;refertoGreasingtheMachine
(page18).
5.Changetheenginecrankcaseoil;refertoChangingthe
EngineOilandFilter(page20).
6.Forstorageover30days,preparethemachineas follows:
A.Addapetroleumbasedstabilizer/conditioner
tofuelinthetank.Followmixinginstructions fromstabilizermanufacturer.Donotuse
analcohol-basedstabilizer(ethanolor methanol).
Note:Fuelstabilizer/conditionerismost effectivewhenmixedwithfreshfuelandusedat alltimes.
B.Runtheenginetodistributeconditionedfuel
throughthefuelsystem(5minutes).
C.Shutofftheengine,allowittocool,anddrainthe
fueltankusingapump-typesyphon.
D.Starttheengineandrunituntilitstops.
E.Choketheengine.
F.Startandruntheengineuntilitdoesnotstart
again.
G.Disposeoffuelproperly .Recycleasperlocal
codes.
Important:Donotstorestabilizer/conditioned fuelover90days.
7.Removethesparkplugsandchecktheconditionof them;refertoServicingtheSparkPlugs(page21).
8.Preparetheengineasfollows:
A.Withthesparkplugsremovedfromtheengine,
pour2tablespoonsofengineoilintothespark plugholes.
B.Placearagoverthesparkplugholestocatchany
oilspray ,thenpullthestarterropetocrankthe engineanddistributetheoilinsidethecylinder.
C.Installthesparkplugs.
Note:Donotinstallthewireonthesparkplugs.
9.Checkandtightenallbolts,nuts,andscrews.Repairor replaceanypartthatisdamaged.
10.Paintallscratchedorbaremetalsurfaces.Paintis availablefromyourAuthorizedServiceDealer.
35
11.Storethemachineinaclean,drygarageorstoragearea.
12.Coverthemachinetoprotectitandkeepitclean.
36
Notes:
Notes:
Notes:
TheToroWarranty
Alimitedwarranty(seewarrantyperiodsbelow)
Concrete,Masonry , andCompaction Equipment
ConditionsandProductsCovered
TheT oroCompanyanditsafliate,T oroWarrantyCompany,pursuanttoanagreement betweenthem,jointlywarrantyourT oroConcrete,Masonry,andCompaction EquipmentProductslistedbelowtobefreefromdefectsinmaterialsorworkmanship.
Thiswarrantycoversthecostofpartsandlabor ,butyoumustpaytransportationcosts.
Thefollowingtimeperiodsapplyfromtheoriginaldateofpurchase:
ProductsWarrantyPeriod
ConcreteMixers
SpindleBearingsLifetime*
1
Engine MortarMixers1year
DrumBearingsandSealsLifetime*
1
Engine ForwardPlateCompactors
2
Engine ReversiblePlates1year
1
Engine RammerCompactors
1
Engine MudBuggy1year
1
Engine PowerT rowels1year
1
Engine
Whereawarrantableconditionexists,wewillrepairtheProductatnocosttoyouincludingdiagnosis, labor,andparts.
*
LifetimeWarranty-OriginalOwnerOnly-Ifthebearing(s)orseal(s)onyourmixerfail,itwillbe
replacedunderwarranty ,atnocostforpartsorlabor.
1
SomeenginesusedonToroProductsarewarrantedbytheenginemanufacturer.
1year
2years
2years 2years 2years
2years 2years 2years
2years
2years
InstructionsforObtainingWarrantyService
IfyouthinkthatyourT oroProductcontainsadefectinmaterialsorworkmanship, followthisprocedure
1.ContactanyAuthorizedServicingOutlettoarrangeserviceattheirdealership. Tolocateoneconvenienttoyou,accessourwebsiteatwww.Toro.com.Select “WheretoBuy”andselect“Contractor”underproducttype.Y oumayalsocall ourtollfreenumberbelow.
2.Bringtheproductandyourproofofpurchase(salesreceipt)tothem.
3.IfforanyreasonyouaredissatisedwiththeServiceOutlet’sanalysisorwith theassistanceprovided,contactusat:
ToroWarrantyCompany
SWSCustomerCareDepartment
811 1LyndaleAvenueSouth
Bloomington,MN55420-1 196
TollFree:800-888-9926
**
ToroAuthorizedRentalCustomerswhohavepurchasedproductsdirectlyfromToroandhave signedtheT oroRentalCustomerAgreementhavetheabilitytoperformtheirownwarrantywork. PleasevisitT oro’sRentalPortalforelectronicwarrantyclamlingproceduresorcallthetollfree numberabove.
**
:
OwnerResponsibilities
YoumustmaintainyourToroProductbyfollowingthemaintenanceprocedures describedintheOperator’sManual.Suchroutinemaintenance,whetherperformedby
adealerorbyyou,isatyourexpense.Partsscheduledforreplacementasrequired maintenance(“MaintenanceParts”),arewarrantedfortheperiodoftimeuptothe scheduledreplacementtimeforthatpart.Failuretoperformrequiredmaintenance andadjustmentscanbegroundsfordisallowingawarrantyclaim.
ItemsandConditionsNotCovered
Notallproductfailuresormalfunctionsthatoccurduringthewarrantyperiodare defectsinmaterialsorworkmanship.Thisexpresswarrantydoesnotcoverthe following:
Productfailureswhichresultfromtheuseofnon-T ororeplacementparts,orfrom
installationanduseofadd-on,modied,orunapprovedaccessories
Productfailureswhichresultfromfailuretoperformrequiredmaintenanceand/or
adjustments
Productfailureswhichresultfromoperatingtheproductinanabusive,negligent,
orrecklessmanner
Partssubjecttoconsumptionthroughuseunlessfoundtobedefective.
Examplesofpartswhichareconsumed,orusedup,duringnormalproduct operationinclude,butarenotlimitedto:belts,wipers,sparkplugs,tires,lters, gaskets,wearplates,seals,O-rings,drivechains,orclutches.
Failurescausedbyoutsideinuence.Itemsconsideredtobeoutsideinuence
include,butarenotlimitedto,weather,storagepractices,contamination,useof unapprovedcoolants,lubricants,additives,orchemicals,etc.
Normal“wearandtear”items.Normal“wearandtear”includes,butisnotlimited
to,wornpaintedsurfaces,scratcheddecals,etc.
Repairsnecessaryduetofailuretofollowrecommendedfuelprocedure(consult
Operator'sManualformoredetails)
Removingcontaminantsfromthefuelsystemisnotcovered
Useofoldfuel(morethanonemonthold)orfuelwhichcontainsmorethan
10%ethanolormorethat15%MTBE
Failuretodrainthefuelsystempriortoanyperiodofnon-useoverone
month
Anycomponentcoveredbyaseparatemanufacturer’swarranty
Pickupanddeliverycharges
GeneralConditions
RepairbyanAuthorizedServicingOutletorSelf-ServiceasanAuthorizedRental Customerisyoursoleremedyunderthewarranty .
NeitherTheToroCompanynorToroWarrantyCompanyisliableforindirect, incidentalorconsequentialdamagesinconnectionwiththeuseoftheToro Productscoveredbythiswarranty,includinganycostorexpenseofproviding substituteequipmentorserviceduringreasonableperiodsofmalfunction ornon-usependingcompletionofrepairsunderthiswarranty .Allimplied warrantiesofmerchantabilityandtnessforusearelimitedtothedurationof thisexpresswarranty .Somestatesdonotallowexclusionsofincidentalor consequentialdamages,orlimitationsonhowlonganimpliedwarrantylasts, sotheaboveexclusionsandlimitationsmaynotapplytoyou.
Thiswarrantygivesyouspeciclegalrights,andyoumayalsohaveotherrights whichvaryfromstatetostate.
ExceptfortheenginewarrantycoverageandtheEmissionswarrantyreferenced below,ifapplicable,thereisnootherexpresswarranty .TheEmissionsControlSystem onyourProductmaybecoveredbyaseparatewarrantymeetingrequirements establishedbytheU.S.EnvironmentalProtectionAgency(EPA)ortheCalifornia AirResourcesBoard(CARB).RefertotheCaliforniaEmissionControlWarranty StatementsuppliedwithyourProductorcontainedintheenginemanufacturer’s documentationfordetails.
CountriesOtherthantheUnitedStatesorCanada
CustomerswhohavepurchasedT oroproductsoutsidetheUnitedStatesorCanadashouldcontacttheirT oroDistributor(Dealer)toobtainguaranteepoliciesforyourcountry , province,orstate.IfforanyreasonyouaredissatisedwithyourDistributor'sserviceorhavedifcultyobtainingguaranteeinformation,contacttheToroimporter.Ifallother remediesfail,youmaycontactusatT oroWarrantyCompany.
AustralianConsumerLaw:AustraliancustomerswillnddetailsrelatingtotheAustralianConsumerLaweitherinsidetheboxoratyourlocalT oroDealer .
374-0288RevD
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